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Hydroforming: Presentation by Paras Ajay Rahul Arora Prashant Kumar

The document discusses the process of hydroforming, which uses pressurized fluid to deform sheet or tube materials into desired shapes. It describes the main types as sheet hydroforming and tube hydroforming. The key systems and equipment are also summarized, including presses, dies, pressure systems, hydraulic cylinders and control systems. Some advantages are inexpensive tooling, versatility in complex shapes, and fewer operations. Applications mentioned include automotive, sanitary, and aerospace parts.

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paras19ajay3507
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48 views21 pages

Hydroforming: Presentation by Paras Ajay Rahul Arora Prashant Kumar

The document discusses the process of hydroforming, which uses pressurized fluid to deform sheet or tube materials into desired shapes. It describes the main types as sheet hydroforming and tube hydroforming. The key systems and equipment are also summarized, including presses, dies, pressure systems, hydraulic cylinders and control systems. Some advantages are inexpensive tooling, versatility in complex shapes, and fewer operations. Applications mentioned include automotive, sanitary, and aerospace parts.

Uploaded by

paras19ajay3507
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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HYDROFORMING

PRESENTATION BY
PARAS AJAY
RAHUL ARORA
PRASHANT KUMAR
CONTENTS

 INTRODUCTION
 TYPES OF HYDROFORMING
 SYSTEMS, TOOLING AND EQUIPMENT
 ADVANTAGES AND DISADVANTAGES
 APPLICATIONS
INTRODUCTION

Hydroforming is a material-forming process


that uses a pressurized fluid (liquid or gas) in
place of hard tooling (punch, die, mold,
inserts, etc.) either to plastically deform or to
aid in deforming a given blank material
(sheet or tube) into a desired shape.
TYPES OF HYDROFORMING
Sheet Hydroforming

 sheet blank is formed by hydraulic pressure


inside the die cavity
 classified into two parts: hydro mechanical
deep drawing and high-pressure sheet
hydroforming
Hydromechanical forming(HMD)
 Similar to conventional deep drawing except
the application of the counter pressure on the
other side of punch.
High-pressure sheet hydroforming

 combination of deep drawing and


hydroforming
 controlled metal flow into the cavity
Tube hydroforming

 simultaneous application of internal pressure


and axial compressive forces from both or
either ends
SYSTEMS,TOOLING AND EQUIPMENT

 Clamping devices for closing and holding the dies:


presses (hydraulic)
 Tooling: dies
 Pressure system; pumps, intensifier, valves,
sensors/transducers, controls,
 Hydraulic cylinders and punches: for sealing the tube
and move the material
 Process control systems; computers, data
acquisition, transducers, etc.
 Hydraulic conditioners: coolers, filters, additives, etc.
Press and Clamping Devices

 Must provide enough clamping load during


the forming period to prevent elastic
deflections and die separation
 Necessary tonnage of the press is a function
of the maximum internal pressure used
during forming, part size, material
Tooling

Hydroforming tooling consists of die holders,


dies, inserts, punches, sealing systems and,
sometimes, counter punches or movable
inserts.
Tooling

 High strength against stresses due to large


internal pressure and axial loading,
 Good surface finish to minimize friction and
increase formability,
 Flexibility by interchangeable inserts
 Good guiding systems,
 Balanced design to minimize the closing
force requirements.
Pressure system

 Pump, intensifier and control and relief


valves, coolers
 The applied pressure should have a range
from 2000 bar (30 ksi/200 MPa) up to 10 000
bar (150 ksi/1000 MPa)
Hydraulic cylinders and punches

 The axial punches are necessary


(a) to seal the end of the tube to avoid pressure
losses
(b) to feed material into expansion regions
Materials

 High and uniform elongation,


 Close mechanical and surface properties of
weld line to the base material (in case of
tubular materials),
 Good surface quality, free of scratches,
 Close dimensional tolerances (thickness,
diameter and shape),
 Tube edges perpendicular to the longitudinal
axis.
ADVANTAGE

 Inexpensive Tooling
 Versatility in Forming Complex Shapes and
Contours
 Minimal Material Thinout
 Fewer Operations Required
 Savings in Tool Materials
 Fast Tool Changes
 Savings in Finishing Costs
 Materials Versatility
DISADVANTAGES

 More Difficult to weld


 Slow cycle time
 Due to high pressure involved, trials cannot
be made using soft tooling.
 Once the dies are made, required
modifications are costly.
APPLICATIONS

 Automotive Industry
 Sanitary Use
 Aerospace-lighter and stiffer parts

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