Hydro forming
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Transcript of Hydro forming
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A Seminar Report
On
HYDROFORMING
Prepared by :-Patel Mehul.APatel Jay
Guided By ;-
D.H.Patel
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OUTLINE:
• What is Hydroforming• Types of hydroforming• Application• Design Considerations• Advantages/Disadvantages• Economics of Hydroforming• Reference Websites and Links• Conclusion
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HYDROFORMING
Hydroforming is a manufacturing process where liquid pressure is used to form complex shapes.
There are two types of hydroforming:
1) Tube hydroforming 2) Sheet hydroforming
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TUBE HYDROFORMING
Outer tool part
Tube
Inner tool part
Section A - A
Upper tool partnot shown
• 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.
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Tube Hydroforminga b
c d
FaxialFaxial
P
e f
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SHEET HYDROFORMING
• 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.
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APPLICATIONS
• Automotive industry
• Sanitary use
• Aerospace– Lighter, stiffer parts
Chevy SSR Frame
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APPLICATIONS (CONT)1. Body shell2. Driving shaft3. Assembled camshaft4. Exhaust systems5. Engine cooling system6. Radiator frame7. Safety requirements8. Engine bearer9. Integral member10. Cross member11. Frame structure parts12. Axle elements
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MATERIALS
• Steel (mild and harder steels)
• Stainless Steel
• Aluminum alloys
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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
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DESIGN CONSIDERATIONS
Product
- Geometry, thickness distribution- Dimensional accuracy/tolerances- Surface finish- Microstructure, mechanical and
metallurgical properties, hardness
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Tool/Dies
-Geometry of tools
- Material hardness
- Surface conditions
- Stiffness and accuracy
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Equipment
- Press capacity
- Speed/production rate
- Force/energy capabilities
- Rigidity and accuracy
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Work piece/Material
-Flow stress as a function of strain, strain rate and microstructure
-Workability as a function of strain, strain rate and microstructure
- Surface conditions
- Geometry of tubing ( outside diameter, tube wall thickness, roundness, properties of welding line, etc.)
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Deformation zone
-Deformation mechanics, model used for analysis
- Metal flow, velocities, strain rates, strains (kinematics)
- Stresses (variation during deformation)
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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
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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)
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DISADVANTAGES
• Slow cycle time
• Expensive equipment and lack of extensive knowledge base for process and tool design
• Requires new welding techniques for assembly.
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ECONOMICS
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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
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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!