Post on 22-Dec-2015
Hydroforming - TubesMEE 3024
Hydroforming
Hydroforming Concept
BenefitsIncreased strength to weight ratiosMultiple cross – section reshaping or section modules increaseImproved stiffness torsion and bending rigidlyImprovement in noise, harshness, vibration (NHV) FactorIncorporation of hole punching, slot making, embosses during hydro forming process.Reduction in number of manufacturing stages, hence reduced tooling costsReduction in welding, hence distortion and subsequent heat treatmentGreatly reduced springback due to stretching
Hole Piercing Accuracy
Springback Reduction
No springback, only slight change in length
Maximum springback due to tension and compression
Minimal springback due to tension and no compression
NP NPTake MomentsAround NP
Hydroforming – Process Defects
Hydroforming System
Hydroforming Tooling
Tube Bending Made Preform
Hydroforming Process – High Pressure
• Tube Perimeter and diameter < Die Perimeter and width
• Die Closes completely under no pressure
• Tube is pressurized to fill remaining open cavities in the die
• Friction from die/tube contact prevents sliding and leads to localized thinning in corners
• More complicated geometry possible
Hydroforming Process – Low Pressure
• Tube Perimeter and Dia. ~ Die Perimeter and Width
• Die Closes partially under no pressure
• Tube is pressurized to and die completes travel
• Pressure completes “fill” with no localized thinning in corners as perimeters approximately same
• Less complicated cross-sectional geometry can be formed