Hydroforming is a manufacturing process that uses fluid pressure to form hollow metal parts with complex geometries. There are two types: tube hydroforming uses pressurized fluid to reshape tubing inside a die, while sheet hydroforming forces sheet metal into a die cavity using fluid or press action. Hydroforming is used in automotive, sanitary, and aerospace applications to create parts with tight tolerances, fewer welds, and reduced weight. Design considerations include part geometry, material properties, die design, and pressure capabilities. Hydroforming allows for innovative part designs but has high equipment costs and slow cycle times.
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HydroForming
1. HYDROFORMING
Presented By, Seminar Guide:
Shruchet J B. G. Prashanth
Dept. of I.E. M.
1JS08IM045
JSSATE, Bangalore
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2. OUTLINE:
What is Hydroforming?
How and where is Hydroforming used?
Materials used in Hydroforming processes
Design Considerations
Effect of Temperature on HF
Advantages/Disadvantages
Economics of Hydroforming
The Hydroforming Process
Conclusion
Bibliography 2
3. HYDROFORMING
Hydroforming is the manufacturing of hollow
bodies with complex geometries by means of
fluid pressure.
There are two types of hydroforming:
1. Tube hydroforming
2. Sheet hydroforming
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4. TUBE HYDROFORMING
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
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5. SHEET HYDROFORMING
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.
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7. APPLICATIONS: Automotive Industry
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
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8. MATERIALS
Steel (mild and harder steels)
Stainless Steel
Aluminum alloys
Copper Tubes
Research continues to expand the capabilities of
the hydroforming process 8
9. DESIGN CONSIDERATIONS
Product •Tool/Dies •Equipment
• Geometry, thicknes
s distribution •Geometry of tools •Press capacity
• Dimensional •Material hardness •Speed /
accuracy/tolerance production rate
•Surface conditions
s •Force / Pressure
• Surface finish
•Stiffness and
capabilities
accuracy
• Microstructure, me
•Rigidity and
chanical and accuracy
metallurgical
properties, hardnes
s
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10. DESIGN CONSIDERATIONS
Work Deformation zone
piece/Material • Deformation mechanics,
model used for analysis
• Material Yield Strength
• Metal flow, velocities, strain
• Surface conditions
rates, strains (kinematics)
• Geometry of tubing ( outside
• Stresses (variation during
diameter, tube wall thickness, deformation)
roundness, properties of
welding line, etc.)
Pressure Consideration: The liquid pressure in the die cavity -
30 to 150 MPa
•Material Yield Strength
•Material Wall Thickness
•Inner radius of sharpest cross-sectional corner 10
11. Effect of Temperature on HF
Formability of the lightweight materials usually increases
at elevated temperature levels
Warm forming technology with selective heating enables
manufacturing of lightweight parts, and also reduces
number of manufacturing steps and part consolidation.
The internal stresses are released at high temperatures,
hence reduces defects and provides better finish of the
product.
It uses the tooling and hydraulic medium as means of 11
transporting heat as well as mechanical/hydraulic force
12. ADVANTAGES
Extraordinary Design Flexibility
Fewer Parts
Lower tooling cost due to fewer parts
Weight reduction through more efficient section
design and tailoring of the wall thickness
Improved structural strength and stiffness
Fewer secondary operations
Tight dimensional tolerances and low spring back
Reduced scrap
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13. ADVANTAGES (CONT.)
Compared to conventional steel body structure:
50% less weight
45% less parts (less tools, less assembly)
45% less welding seams
Tighter tolerances
Volvo Hydroformed Structure concept in
Aluminum, (Schuler Hydroforming 1998)
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14. DISADVANTAGES
Slow cycle time
Expensive equipment and lack of extensive
knowledge base for process and tool design
Requires new welding techniques for assembly.
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16. CONCLUSION
Hydroforming is an innovative forming
process
Hydroforming is becoming more popular (i.e.
automotive and aerospace industries)
The advantages outweigh the limitations
Material selection is broad and continues to
increase
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17. BIBLIOGRAPHY
www.hydroforming.net
www.vari-form.com
www.hdt-gti.com
www.revindustries.com
www.autosteel.org
www.schuler-hydroforming.de
www.kaupp.com/hydro.htm
www.egr.msu.edu/~aenader
nsmwww.eng.ohio-state.edu/html/tube_hydroforming.html
A Study on Warm Hydroforming of Al and Mg Sheet Materials:
Mechanism and Proper Temperature Conditions, by Ho Choi,
Muammer Koç, & Jun Ni.
Automotive component development by means of hydroforming,
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