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05-11-2009, 02:21 PM

Hydroforming (or hydramolding) is a cost-effective way of shaping malleable metals such as aluminum or brass into lightweight, structurally stiff and strong pieces. One of the largest applications of hydroforming is the automotive industry, which makes use of the complex shapes possible by hydroforming to produce stronger, lighter, and more rigid unibody structures for vehicles. This technique is particularly popular with the high-end sports car industry and is also frequently employed in the shaping of aluminium tubes for bicycle frames, 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. 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. 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 or hole punching, simplifies assembly and reduce inventory. Taking Advantage of Hydro Forming When considering hydro forming, companies need to ask whether this technology will make a part cheaper to produce. The real question is whether you can refine the entire manufacturing process to take advantage of hydro forming that is when it really makes. Instead of looking at a single competent to determine whether it can be hydro formed , companied need to look at a product through whole process, from material to assembly , to determine what savings can be achieved . For e.g. Hydro forming often reduces number of pieces or the amount of floor space used or eliminates the need for welding stations. Methods Of Hydro Forming Tube Hydro forming Straight, pre bent and or performed tubes are formed by internal water pressure with additional application of compressive mechanical forces. In this method the tube in placed in die and as press clamps the die valves, low pressure fluid in introduced into tube to pre form it. One the maximum clamping pressure in achieved, the fluid pressure inside the tube in increased so that tube bulges to take internal shape of the die. Simultaneously additional cylinders axially compress the tube to prevent thinning and brushing swing expansion.
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12-11-2010, 04:01 AM

I want more information on the mathematical analysis of various parameters governing the sheet hyroforming process in relation to the stress analysis, tearing pressue, maximum vblank holding force, anisostropy effects ,etc
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16-11-2010, 09:42 AM

please go through the following thread for more details on 'Hydroforming'


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