Seminar

On
HYDROFORMING

Submitted By:
SK.SAMIULLA(17KQ1A0389)
MECHANICAL ENGINEERING
CONTENTS

 INTRODUCTION
 WHAT IS HYDROFORMING
 TUBE HYDROFORMING
 SHEET HYDROFORMING
 APPLICATIONS
 DOUBLE SHEET HYDRO FORMING
 HYDRO JOINING
 ADVANTAGES
 DISADVANTAGES
 CONCLUSION
 REFERENCES
INTRODUCTION

 Hydro Forming uses water pressure to form complex

shapes from sheet or tube material.
 The pressure may go up about 60,000 psi depending on
the component.
WHAT IS HYDROFORMING
 Hydroforming is a cost-effective way of shaping
ductile metals such as aluminum, brass, low alloy ste
els, stainless steel into lightweight, structurally stiff
and strong pieces.
 TUBE HYDROFORMING
 Used when a complex shape is Outer tool part Section A - A

needed.
Tube

 A section of cold-rolled steel

tubing is placed in a closed die set. Inner tool part
Upper tool part
not shown

 A pressurized fluid is introduced

into the ends of the tube .

 The tube is reshaped to the confine

of the cavity .
SHEET HYDROFORMING
 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.
APPLICATIONS
 Automotive industry

 Sanitary use

 Aerospace
 Lighter, stiffer parts
Chevy SSR Frame
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
DOUBLE SHEET HYDRO
FORMING
 Integration of more parts, further reduction of
components & thus steps.
 Stiffness increase and reduction in overall spring back
due to closed box section & continuous weld section.
 A complete component is made in one single
hydroforming step, with only top and bottom die .
HYDRO JOINING

 Usually after hydro forming, additional joining

operations are required to form assemblies.
 To reduce manufacturing time and number of process
steps, joining operation are being integrated into hydro
forming process.
 This also reduces tool cost.
 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
 ADVANTAGES (CONT.)
Results 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)
DISADVANTAGES

 Slow cycle time.

 Expensive equipment and lack of extensive knowledge
base for process and tool design.
 Requires new welding techniques for assembly.
CONCLUSION

 During the last 12 years, general awareness of hydro

forming has grown steadily .
 Although interest in hydroforming is wide ranging ,
the vast majority of application are in automobile
industry .
 Hydro Forming is not panacea for manufacturing all
automotive parts.
REFERENCES

[1] Koc Muammer, Altan Taylan. An overall review of the tube

hydroforming (THF) technology. J Mater Process Technol
2001;108:384–93.
[2] Grey JE, Devereaux AP, Parker WN. Apparatus for making
wrought metal T’s. US Patent; 1939.
[3] Leitloff FU. Hydroforming – from feasibility analysis to series
production. In: Proc 2nd international conference on innovations
in hydroforming technology. Columbus, OH, September 17, 1997.
[4] Ahmed M, Hashmi MSJ. Estimation of machine parameters for
hydraulic bulge forming of tubular components. J Mater Process
Technol 1997;64:9–23.
[5] Breckner M. Hydraulic systems for hydroforming. In: Proc
international conference on hydroforming. Stuttgart, Germany,
October 12–13, 1999
THANKS