 Hydroforming 

is a cost-effective way of shaping

ductile metals such as aluminium, brass , low
alloy steel, and stainless steel into lightweight,
structurally stiff and strong pieces.
 A special type of die forming using a high
pressure Hydraulic fluid to press room
temperature working material into a die

HISTORY
Discovered by HOLMSTROEM, MARTIN
There are three types of hydroforming:

1. Tube hydroforming

2. Sheet hydroforming

3. Explosive 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

1. Outer skin with its extreme demand of surface quality and
dimensional accuracy.

2. Longer outer skin parts for passenger cars, utility vehicles

3. Low capital cost. Fewer and simpler dies.

4. Better NHV (noise, vibration and harshness )factors.

5. Reduction in weight.

7. High process capability.

8. Reduction in cost of component.

 Steel (mild and harder steels)
 Stainless Steel
 Aluminum alloys
 Research continues to expand the
capabilities of the hydroforming process
 Extraordinary Design Flexibility.
 Fewer Parts
 Less Assembly
 Less Weight.
 Lower Tooling Costs.
 Less Post-Processing
 Greater Integrity (pressure flows the metal
into corners for greater precision rather than
streching)
 Results compared to conventional steel body
structure:

 50% less weight

 45% less parts (less tools, less assembly)
 45% less welding seams
 Tighter tolerances
 Slow cycle time

 Expensive equipment and lack of extensive

knowledge base for process and tool design

 Requires new welding techniques for assembly.

 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!