30 W. Silverdome Industrial Park
Pontiac, MI
48342
Ph
+248.332.5108 FAX +248.332.3619
Process
Overview
Making
it happen. Hydroforming is the use of
internal fluid pressure to expand, form, and bend a blank
or tube, which can allow formation of many cross-sectional
changes throughout the length of the part. Because of
this unique process, in most cases, a single hydroformed
part can be used to replace several stampings. Additionally,
our hydroforming process can hydropierce holes and slots
with minimal deformation on the part surface, effectively
combining what might have been an additional step in the
manufacturing process. This all adds up to dollars saved
from your manufacturing budget.
How
does Multi-Pressure Hydroforming work?
Tube
hydroforming.
In the tube hydroforming process, a tubular blank
is filled with an initial low-pressure fluid (1) prior
to closing the hydroform tool. This is used as a liquid
mandrel to prevent the tube from collapsing and to avoid
excessive surface deformation and wrinkling. It is also
used to bend the tube to the contour of the die during
the initial closing stage.
Next, the upper ram of the press lowers in place (2).
At this time, a higher-pressure intensifier boosts
the fluid, expanding the tube outward to the exact
shape of the die.
1.
Fill Pressure
2.
Low Pressure
3.
High Pressure
Sometimes,
axial feeding is used during the tube hydroforming
process to improve part formation. Axial feeding
means that the end of the tube is pushed into
the die during the hydroforming operation. This
is done to achieve three major effects:
1. To obtain higher expansion ratios near the
ends of parts;
2. To draw out sections such as T or Y Joints;
and
3. To minimize the wall thin out.
By
expanding parts using this method, there is
minimal reduction in material thickness as shown
in the T-Joint formation simulation to the right.
Sheet
hydroforming. Sheet hydroforming is similar
to the tube hydroforming process. A blank is loaded into
the hydroforming tool. The press upper ram lowers into
place and the high-pressure intensifier boosts the fluid,
pressing the blank into the die shape. Intricate design
details are formed as pressure builds, resulting in clear
design lines and well-formed radii.
