Hydroforming: Presented By: Byron Erath Duane Ellsworth

HYDROFORMING
Presented by:
Byron Erath
Duane Ellsworth
OUTLINE:
What is Hydroforming
How and where is Hydroforming used
Materials used in Hydroforming processes
Design Considerations
Advantages/Disadvantages
Economics of Hydroforming
Websites and Links
Conclusion
HYDROFORMING
Hydroforming uses the force of water or hydraulic
fluids to shape a single part.
There are two types of hydroforming:

1. Tube hydroforming
2. Sheet hydroforming
TUBE HYDROFORMING
Used when a complex shape is Section A - A
Outer tool part
needed
Tube
A section of cold-rolled steel

tubing is placed in a closed die Inner tool part
Upper tool part
not shown
set
A pressurized fluid is
introduced into the ends of the
tube
The tube is reshaped to the

confine of the cavity
SHEET HYDROFORMING
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.
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
MATERIALS
Steel (mild and harder steels)
Stainless Steel
Aluminum alloys
Research continues to expand the
capabilities of the hydroforming process
DESIGN CONSIDERATIONS
Hydroforming is generally defined as either low-
pressure or high pressure.
The demarcation point is 83MPa
Constant pressure volumetric expansion
< 5% required to shape the part = Low pressure
> 5% (but < 25%) = High Pressure
DESIGN CONSIDERATIONS
Product Tool/Dies Equipment
- Geometry, thickness -Geometry of tools - Press capacity
distribution
- Dimensional - Material hardness - Speed/production rate
accuracy/tolerances - Surface conditions - Force/energy capabilities
- Surface finish - Stiffness and accuracy - Rigidity and accuracy
- Microstructure, mechanical
and metallurgical
properties, hardness
Work piece/Material Deformation zone

- Deformation mechanics, model used
-Flow stress as a function of strain, strain rate and for analysis
microstructure - Metal flow, velocities, strain rates,
-Workability as a function of strain, strain rate and strains (kinematics)
microstructure - Stresses (variation during
- Surface conditions deformation)
- Geometry of tubing ( outside diameter, tube wall
thickness, roundness, properties of welding line, etc.)
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.

ECONOMICS
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
nsmwww.eng.ohio-state.edu/html/tube_hydroforming.html
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!

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HYDROFORMING

There are two types of hydroforming:

A section of cold-rolled steel

The tube is reshaped to the

Sheet steel is forced into a female cavity by water

Work piece/Material Deformation zone

50% less weight

Volvo Hydroformed Structure concept in Aluminum,

Expensive equipment and lack of extensive knowledge

Requires new welding techniques for assembly.

Hydroforming is becoming more popular

The advantages outweigh the limitations

Material selection is broad and continues to

Information can be found everywhere!

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