Hydro forming

HYDRO FORMINGHYDRO FORMING
Presented by:
Nishal Jose
Reg. No: 89020695

OUTLINE
 What is Hydro Forming
 How and where is Hydro Forming used
 Materials used in Hydro Forming processes
 Design Considerations
 Advantages/Disadvantages
 Economics of Hydro Forming
 Websites and Links
 Conclusion

INTRODUCTION
Hydro Forming
High Pressure Water As a Punch
Widely Used In Automobile Industry

HYDRO FORMED
COMPONENTS
Automobile Component &
Bellows
Handle Bar T- Junction

METHODS OF HYDROFORMING
There are two types :
Tube Hydro Forming
Sheet Hydro Forming

TUBE HYDRO FORMING
 Used when a complex shape
is needed
 A section of cold-rolled steel
tubing is placed in a closed
die set
 A pressurized fluid is
introduced into the ends of
the tube
 The tube is reshaped to the
confine of the cavity
Outer tool part
Tube
Inner tool part
SectionA - A
Uppertoolpart
not shown

BENEFITS OF TUBE HYDRO
FORMING
Increased Strength To Weight Ratio’s
Reduction In Weight
Reduction In Production Cost
Reduction In Number Of Manufacturing
Stages
Improved Stiffness, Torsion And Bending
Rigidity
Less Floor Area

Step 2
Step 3
Step 1
Fig. Final Product

SHEET HYDRO FORMING
2 METHODS:
Sheet steel is forced into a female cavity by
water under pressure from a pump or by
press action.
Sheet steel is deformed by a male punch,
which acts against the fluid under pressure.
Note: Sheet hydroforming provides a work-hardening effect as the steel is forced against the
blanks through fluid pressure.

DOUBLE SHEET HYDRO
FORMING
Structurally Closed Components Are
Formed By This Process
High Pressure Process

HYDRO FORMING PROCESS
CONTROL
 Controller Plays A Virtual Role In Displaying,
Monitoring And Controlling

APPLICATION SPECTRUM
Automotive Components Well Suited To
Hydro Forming Of Sheets.
Outer Skin With It’s Extreme Demand Of
Surface Quality And Dimensional
Accuracy.
Longer Outer Skin Parts For Passenger
Cars, Utility Vehicles And Truck Such As
Goods.

APPLICATIONS (CONT)
1. Body shell
2. Driving shaft
3. Assembled camshaft
4. Exhaust systems
5. Engine cooling system
6. Radiator frame
7. Safety requirements
8. Engine bearer
9. Integral member
10. Cross member
11. Frame structure parts
12. Axle elements

MATERIALS
Steel (mild and harder steels)
Stainless Steel
Aluminum alloys
Research continues to expand the
capabilities of the hydroforming process

ADVANTAGES
 Hydroforming draws material into the mold
 Part consolidation
 Weight reduction through more efficient
section design and tailoring of the wall
thickness
 Improved structural strength and stiffness
 Lower tooling cost due to fewer parts
 Fewer secondary operations (no welding of
sections required and holes may be punched
during hydroforming)
 Tight dimensional tolerances and low spring
back
 Reduced scrap

DISADVANTAGES
Slow cycle time
Expensive equipment and lack of
extensive knowledge base for process and
tool design.
Requires new welding techniques for
assembly.

CONCLUSION
 Hydroforming is an innovative forming process
 Hydroforming is becoming more popular
(ie.automotive and aerospace industries)
 The advantages outweigh the limitations
 Material selection is broad and continues to
increase
 Information can be found everywhere!

INFORMATION ON THE WEB
www.hydroforming.net
www.vari-form.com
www.hdt-gti.com
www.revindustries.com
www.autosteel.org
www.schuler-hydroforming.de
www.egr.msu.edu/~aenader

Hydro forming

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Hydro forming