CHAPTER 1

INTRODUCTION

Hydro forming is a high-pressure deformation process that shapes metal sheets or tubes into a
predefined geometry by using a fluid under high pressure. Hydro forming is similar to the
conventional deep-drawing technique with a counter-mould. The specific difference from the
conventional method is that a fluid is used instead of a die to forming into final shape. This
deformation process requires application of fluid pressures up to 4000 bars depending on the
size of the component.

Recently hydro forming was used for manufacturing of clad pipe used in oil and
chemical industry. The capability of hydro forming can be more fully used to create
complicated parts. Using a single hydro formed item to replace several individual parts
eliminate welding, holes, punching etc... Hydro forming simplifies assembly and
reduce inventory.

The process is quite simple - a blank with a closed-form, such as a cylinder, is

internally pressurized using fluid. The fluid is frequently water. The applied pressure is
usually in the range 80-450 MPa. Its resultant plastic expansion is confined in a die of
the desired shape.

1.1 SUMMARY
As the automobile industry strives to make car lighter, stronger and more fuel efficient,
it will continue to drive hydro forming applications. Some automobile parts such as
structural chassis, instrument panel beam, engine cradles and radiator closures are
becoming standard hydro formed parts.

1
 CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
Numerous research studies have been conducted for conventional
sheet metal forming methods such as deep drawing and mechanical stretch
forming, where both methods requiring a male and a female die for the proper
forming of a finished part. Relatively much less literature is available on the
sheet and tube hydroforming process, which uses a punch and hydrostatic
fluid pressure to form a finished part. In this chapter a review of the literature
focusing on the most recent experimental and numerical studies conducted on
sheet and tube hydroforming processes is presented.

2.2 REVIEW OF LITERATURE ON SHEET HYDROFORMING

McClintock (1968) and Rice and Tracey (1969) conducted several

research works on sheet metals and demonstrated a rapid decrease in fracture
ductility when hydrostatic pressure, applied across the material, was
increased. Yossifon et al (1977, 1984), Yossifon and Tirosh (1985, 1985a,
1988) published a series of articles dealing with simple analysis of the
hydroforming deep drawing process as applied to the formation of cups from
metallic materials such as copper, aluminum, steel and stainless steel. The
goal of the studies was to establish a hydroforming fluid pressure path,
relative to the punch stroke, that would prevent part failure due to rupture or
wrinkling. Their earlier studies demonstrated that excessive and insufficient
fluid pressures cause failure of hydroformed parts. The goal of the later
investigations was to determine a predetermined path that can be followed to
produce parts that are free from these types of defects.

2.3 REVIEW OF LITERATURE ON TUBE HYDROFORMING

Woo (1973) reported experimental and analytical results for tubes

2
bulged under internal pressure and axial compressive loading. He carried out
a numerical study assuming that the entire length of bulged tube was in
tension, and thus, free bulging took place. Limb et al (1976) used oil as
pressurizing medium in their experiments to investigate the forming of
copper, aluminum, low carbon steel and brass Tee-shaped tubular parts.
Results of lubricant and material evaluations were reported in terms of
protrusion height attainable.

2.4 SUMMARY OF LITERATURE REVIEW

Hydroforming is a complex process that is combined with certain
other processes such as the pre-bending, hydraulic bulging, and stamping.
Therefore, the deformation behavior is significantly complicated. In
hydroforming, it is essential to understand the basic technology of each
element in order to take advantage of the latent formability. It is also
important to clarify the effect of process parameters, material properties, tool
parameters, and process limit on the process. Even though considerable
amount of research work has been done in the field of sheet and tube
hydroforming, these aspects were not completely defined and only limited
number of materials has been tested. However, the deformation behavior of
super alloy during sheet and tube hydroforming has not yet been sufficiently
clarified. The formability and characteristics of any material are different
from others, so further research is necessary.

3
 CHAPTER 3
HYDROFORMING

Hydroforming is a cost-effective way of shaping malleable metals such as aluminum or

brass into structurally stiff and strong pieces. One of the largest applications of hydro
forming is the automotive industry, which makes use of the complex shapes possible
by hydro forming to produce stronger, lighter, and more rigid body structures for
vehicles. This technique is particularly popular with the high-end sports car industry
and is also frequently employed in the shaping of aluminum tubes for bicycle frames.

Hydro forming allows complex shapes with concavities to be formed, which would be
difficult standard solid die stamping. Hydro formed parts can often be made with a higher
stiffness to weight ratio and at a lower per unit cost.

This process is based on the 1950s patent for hydra molding by Fred Leuthesser. It was
originally used in producing kitchen spouts. This was done because in addition to the
strengthening of the metal, hydramolding also produced less "grainy" parts, allowing for
easier metal finishing.

Fig 3.1 Hydro formed handle bar Fig 3.2 Hydro formed T-junction

4
3.1 CLASSIFICATION OF HYDROFORMING TECHNIQUES

3.1.1 Sheet Hydroforming

Sheet hydro forming involves forming of sheet with application of fluid pressure. A sheet
metal blank informed by hydraulic counter pressure generated by punch drawing sheet
into pressurized water chambers. The water pressure effectively punches the sheet firmly
against punch to form required shape.

The major advantage of fluid forming is increased drawing ratio. The process take
place in two stages performed during one press stroke. The sheet is preformed by
applying low fluid pressure while it is in clamped firmly by a blank holder pressure.
Preforming achieves on evenly distributed strengthening in the component center. In
next step fluid pressure in gradually increased and blank holder pressure in controlled
relative to sheet reformation.

Fig.2.3 Sheet hydro forming

5
3.1.2 Tube Hydroforming
In tube hydroforming tube is loaded into hydoroforming dies and the press closes. The
sealing rod engages the part sealing the ends and fills the tube with water. Pressure inside
the tube increases, now the sealing rod is pushes the tube into the die and the internal
pressure is ramped to maximum value. The hydroformed tube takes the shape of the
mould. Final part is removed from the mould.

Fig.3.4 Tube hydro forming

6
3.2 SUMMARY
Based on the application, these methods of hydroforming are widely employed in
industries for better product and finishing. For newer applications. Sheet hydroforming is
widely used in automobile industry for the production of lighter body parts with good
strength. Tube hydroforming is widely used in sanitary industries as well as for the
production of complicated pipe parts.

7
 CHAPTER 4
WARM HYDROFORMING

In Warm Hydroforming process, the flange area of the blank has to be heated up to the
recrystallization temperature levels of the sheet metal for increased drawability as reported in
previous studies. It was reported that warm hydroforming temperature is in the range of 0.3
0.5 times of the melting temperature of the material.

In a typical Warm Hydroforming system, modular dies with heating systems were used and
cooling channels were designed in to keep the punch at low temperature levels to increase the
drawability of the work and to ensure a high temperature gradient between the heated flange areas
and the die radius region. In this system heating pipes were embedded into dies to actively control
the temperature levels. Temperature difference between the flange and the middle sections of die
during deep drawing usually occur between 40 C and 50 C. In addition, insulation plates are
also provided to prevent the loss of temperature from dies to the environment. In this new process
a new tool design that allows setting up a sheet metal hydroforming process on single action
presses without using special hydroforming equipment is utilized.

The Warm system can be summarized as follows:

Controlled in-die heating and/or cooling of the blank to achieve and maintain the desired
temperature distribution (i.e., selective heating and temperature gradient).
High precision automatic control of heating and cooling systems.

Tight sealing of the system at elevated pressures and temperatures so as to achieve

controlled deformation rate on the blank between BH and die.

The force that the sealing member carries should be low enough not to affect the
strength or should be defined to find the BHF exactly.

8
4.1 DESIGN OF WARM HYDROFORMING SYSTEM

4.1.1 Heating and Cooling Systems Design

In this system, the sheet material is heated from the flange region to achieve the desired
temperature distribution using in-die heating. Induction heating system was chosen over
cartridge heaters also band heaters and tubular heating elements are used in some systems
due to their easy and responsive control, nondestructive implementation on the dies and
capability to attain high temperatures in a short period of time (i.e. 10 min to 180 C).

Temperatures of the lower die and upper die are measured by four thermocouples having
different radial and circumferential positions. Term tool temperature is meant the value
set by temperature controller, and this value is the average temperature measured from
the innermost thermocouples of the lower and the upper die. Furthermore, in order to heat
the dies uniformly, the temperature differences measured from the innermost and the
outermost thermocouples die can be adjusted.

A mini-chiller cooling system is used for cooling the punch. The punch was designed to
achieve the necessary uniform cooling all around the punch. Temperature setting is
accomplished by recirculating the chilled water in the helical channels. Temperature
setting of the punch is also accomplished by a feedback signal received from two
thermocouples placed on the punch and going into the PLC control unit, and by
controlling the water from the chiller with an open/close solenoid valve. The open/close
PID control of the solenoid valve is again performed with the PLC control unit.

Fig 4.1 Schematic of the heating and cooling systems

9
4.1.2 Sealing Design
Sealing must be designed into a warm hydroforming system for successful and repeatable
forming at elevated pressures and temperatures. While the sealing between blank and
upper and lower dies is obtained through deformation of blank between the BH (lower
die) and upper die, the blank should be allowed to flow between BH and die. Hence,
control of BHF in coordination with punch position and fluid pressure is a delicate issue
of system and process design.

4.1.3 Insulation Design

After dies are heated up to the target temperature, they must be insulated from the body
of the press and environment with an insulation material that can withstand high
temperatures and compressive stress in order to maintain the desired temperature with
minimal variation during the process. The required properties of insulating materials are;
besides a low heat transfer coefficient that is not affected by the hydraulic fluid leakage
from the system, resistance to high temperatures up to 400 C, and compressive strength
of at least 25 MPa.

4.2 SUMMARY
The new warm hydroforming system is systematically engineered and designed. Due to
heating effect the work piece becomes more workable and more intricate designs can be
achieved. Also, it decreases the defects and increases surface finish.

10
 CHAPTER 5

BENEFITS OF HYDROFORMING

5.1 Better Degree of Deformation of The Formed Part

By applying a uniform force to the metal sheet, the fluid shapes it into the form of the
tool. In this process, a uniform distribution of sheet thicknesses is achieved, which allows
for maximum degrees of deformation. Abrupt changes in stress are avoided a factor that
ensures high dimensional accuracy and reduces the tendency of the material to return to
its original size and shape when the applied load is removed.

Fig 5.1 Conventional deep-drawing Fig 5.2 Hydroformed part

5.2 Good Surface Finish

Since the metal sheet is deformed using a pressurized fluid instead of a conventional
deep-drawing die, the surface is not in direct contact with any tool that may lead to
surface damage. In the hydroforming process, the metal sheet only comes into contact
with the tool when the maximum required forming pressure is reached. This results in
excellent surface finish of the formed parts.

5.3 Use of Various Engineering Materials

The hydroforming process allows you to use the complete spectrum of all ductile and
malleable materials. No matter if you are using steel sheets, stainless steel, special
alloys, aluminum, copper, brass or titan: for all of them, optimum degrees of deformation
can be achieved. Metal sheet thicknesses range from 0.05 to 6 mm. Specifically for very
thin metal sheets, the possibilities of hydroforming are far superior to those of
conventional forming techniques

11
5.4 Savings in tooling costs up to 80%

Low tooling costs are a great advantage of the hydroforming process using the Form
Balancer. Tooling costs are reduced to 50% by the fact alone that only the negative
molding tool is needed. Further savings are generated by no longer needing hold-down
devices and guide way systems. Due to the possibilities of forming complex geometries
with only one tool, upstream machining operations can often be omitted, which in most
cases reduces tooling costs to only 20% compared to those of conventional deep-drawing
tools.

5.5 Reduction in weight

Automakers continuously strive to reduce motor vehicle mass, mainly for efficiency and
environmental reasons such as improving fuel efficiency and reducing emissions.
However, as they reduce vehicle weight, they must try to avoid compromising other
important criteria, such as strength and energy management. They look for technologies,
techniques, and processes that satisfy these various needs, to which hydroforming is the
answer. Also, the process and functional characteristics need to be maintained. If a design
engineer changes a part, he has to think about how will the manufacturing engineers
make the new part? How will the line workers join the various parts to make assemblies?
When finished, will everything work as intended? Answers to all this questions in
Hydroforming.

5.6 SUMMARY

As the benefits of hydroforming are more compared to conventional stamping process, it

is gaining wider applications. The product cost can be greatly reduced due to material
saving. Inspite of the high material saving hydroformed products have high strength and
durability.

12
 CHAPTER 6
CONCLUSION

In this seminar report recent developments in hydroforming are discussed

systematically. After discussing these we conclude that:

Hydroforming has wide application in many industries like automobile,

aerospace, electronic goods, sanitary fittings, etc. Many benefits offered Good
surface finish, use of almost all ductile and malleable material, Better
deformation, High dimensional accuracy, Savings up to 80% in post forming
processes. Because of so many benefits offered Hydroforming is considered as an
effective method to meet the demands of ever evolving manufacturing sector.

Due to introduction of hydroforming it is now possible to use lightweight

aluminum structural frame instead of the conventional heavy weight steel frame
in automobiles. Resulting in reduction of weight by more than 9 percent and weld
length by 19%

Hydroforming facilitates manufacturing of a single large complex component

instead of many small components, reducing the tooling costs by 50%. For
example: operations like piercing can be done during hydroforming itself. There
is no need of finishing the surface after hydroforming as hydroformed component
has a high grade of surface finish.

Of the above discussed recent techniques, Pressure sequencing and Hammering

are the most useful methods. Using these methods, we can hydroform any
malleable metal ranging from copper to high grade stainless steel. By reducing the
drag force Hammering eliminates the two major problems faced in forming
namely rupturing and buckling.

Thus, adopting these new techniques there is better utilization of material. The day will
not be far away when hydroforming will completely replace the conventional stamping
and forming processes.

13
 REFERENCE

[1] Trkz, M., Halkac, H.S., Halkac, M., Dilme, M., Avc, S. and Ko, M., 2016.
Design, Fabrication, and Experimental Validation of a Warm Hydroforming Test System.
Journal of Manufacturing Science and Engineering, 138(4), p.045001.

[2] Ngaile, G. and Lowrie, J., 2014. New micro tube hydroforming system based on floating die
assembly concept. Journal of Micro and Nano-Manufacturing, 2(4), p.041004.

[3] Sato, H., Manabe, K.I., Wei, D., Jiang, Z. and Alexandrov, S., 2016. Tribological
behavior in microsheet hydroforming. Tribology International, 97, pp.302-312.

[4]Xu, Z., Peng, L., Yi, P. and Lai, X., 2012. Modeling of microchannel hydroforming process
with thin metallic sheets. Journal of Engineering Materials and Technology, 134(2), p.021017.

[5] Mc Clintock, F.A., 1968. A criterion for ductile fracture by growth of holes. J. Appl. Mech.
(35), 363379.

[6] Rice, J.R., Tracey, D.M., 1969. On the ductile enlargement of voids in triaxial stress fields.
J. Mech. Phys. Solids 17, 201217.

14