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Monthly archive for September 2013

Benefits of Sheet Metal Hydroforming

Benefits of Sheet Metal Hydroforming

Sheet Metal Hydroforming is similar to the conventional deep-drawing technique, but has significant advantages for the formed part and keeps the tooling costs and production costs low.

Below is the list of t benefits of sheet metal hydroforming, as opposed to the conventional deep-drawing technique.

  • Inexpensive:
    Hydroforming tooling can cost less than half the price of standard press tooling. Tooling generally required is a male die and a draw ring.  The rubber diaphragm typically acts as a universal female die in the sheet metal hydroform machine.
  • Functional:
    Irregularly contoured shapes are easily formed using hydroforming, it also makes it easy to form irregular shapes and contours because matching dies are not generally needed.
  • No Need to Waste Time Thinning Material Out:
    No need to waste time stretching. Hydroforming flows the metal rather than stretching it as a result you will have less wall thinning.
  • Less Work:
    Usually parts require multiple operations with a typical press, with hydroforming most of the operations can be condensed into one operation.
  • Save Money:
    Since almost all punches and draw rings are made of inexpensive cast iron, hardened tool steels are therefore not often needed. These type of tools carry a longer life span. Sheet metal hydroforming offers a wrapping action of diaphragm which does not cause scuff marks, shock, and stretch lines.
  • Quick Set Up:
    Tools are able to be mounted easily and quickly they are also self-centering and self aligning. Set-up times are much quicker and  very efficient.
  • Durability of Materials:
    Almost  all sheet metals can be hydroformed such as stainless steel, carbon steel, aluminum, copper, brass, precious metals, high strength alloys. The material’s thickness varies within the restrictions of the machine. Usually tool modifications are not required.

As you can see sheet hydroforming as its many benefits. If you would like more information please contact us with any question you may have.

Understanding Metal Stamping and Its Many Uses

Understanding Metal Stamping and Its Many Uses

Metal stamping is a process which includes the stamping or pressing of sheet metal into different forms. Some of the different types of metal stamping include punching, deep drawing, pressing, embossing, bending, flanging, and coining to name a few. The most common medium for metal stamping is sheet metal but it can be performed on other types of materials such as polystyrene. The process of stamping can produce an specified object repeatedly normally within a few steps which makes stamping economically favorable.

In many cases the initial process of stamping involves a simulation process. A metal working firm can take specs, measurements, and blueprints in order to perform a test run on the product being stamped. Once the test pieces are made, they can be tested for durability. These tests can include the analysis of possible defects such as wrinkling, splits, and thinning. This simulation saves the hiring manufacturing company time and money since the analysis performed produces a minute batch of product for testing.

Because of its versatility, metal stamping can benefit a wide range of industries. The automotive industry uses metal stamping often in order to produce a large amount of parts with minimal man power and resources. The marine industry, mediacal industry, construction industry, and aerospace technology industry all use metal stamping to manufacture their parts and products.

American Hydroformers has been a metal working industry leader since 2003. They have produced exceptional quality products for a variety of industries; coupling their expert metal forming capabilities with a strong focus on customer satisfaction. American Hydroformers uses cutting-edge technology in order to ensure your final product exceeds your expectations.

While American Hydroformers technology revolves around hydroforming, we may have an alternative application different from stamping that could be economically more feasible.

Please, contact us for more information.

Hydroforming Advantages for Automotive

Hydroforming Advantages for Automotive

Hydroforming metal is one of the most cost effective ways of creating asymmetrical parts for the automotive industry. Many parts used on cars today have irregular shapes making traditional methods of manufacturing more cumbersome and expensive. The strength and weight of hydroformed parts also lends to better produced products which are easier to work while maintaining an overall better structural integrity. Here are some other hydroforming advantages that make it one of the best choices for fabricating parts for the automotive industry:

  • Reduced tooling costs: When manufacturing parts the traditional way, jigs and other forms must be manufactured before the process of fabrication begins. If a company only needs a small quantity of the manufactured parts, the increase in cost for tooling greatly affects the bottom line.
  • Increased quality and precision: Hydroforming uses a technique which employs a press, pressurized fluid, and a punch. This process is not only quicker than traditional types of fabrication, it also ensures greater accuracy because their are less steps in the process of hydroforming than traditional manufacturing.
  • Deep-drawing with less stretch: Hydroforming uses less friction in the manufacturing process. Deep draws can be performed with less material stretch. This means the product will have a better integrity as well as less blemishing; in turn requiring less finishing work.
  • The versatility of hydroforming: Steel, copper, brass, aluminum, alloys, etc can be manufactured into parts using the hydroform process. When dealing with these types of materials, many additional efforts must be put into place with traditional fabrication processes as to not damage or weaken the material.

In the automotive industry material strength is essential for safety. The race industry has especially seen benefits from the light weight and structurally sound parts developed as a result of hydroforming. As hybrid vehicle become more and more popular, hydroforming has played an integral part in keeping cars efficient through bettering the manufacturing process. When looking for hydroformed parts you can depend on for strength and lasting durability, please contact  the experts at American Hydroforming.

Midwest Hydroforming Boosting Alternative Energy

Midwest Hydroforming Boosting Alternative Energy

In 2009, the New York Times predicted that more and more states would look to harvest clean energy along highways and interstates by installing rows of turbines. Anyone who’s recently driven down Interstate 65 in Indiana or I-155 in Illinois can attest to that fact. Soon Kansas will join their ranks, having passed a bill in the state legislature to boost Kansas’s wind industry.

As more and more states take advantage of the benefits of wind energy, they’re only keeping pace with what’s happening on an international level. Around the world, groups are coming together to boost global consumption of clean alternative energy sources. Take Brazil, for example, which in 2012 saw two international companies coming together to build and operate two large-scale wind farms in Brazil’s northeast.

[We’ve] been seeking options to meet this demand, on a sustainable way, using renewable sources such as hydro, wind and biomass. The option to develop wind projects also helps diversify our energy matrix, reduce our emissions and ensure cost competiveness in the long term. (Vânia Somavilla)

With a global boost in wind energy production, there is, of course, a global increase in the need for components necessary to the Alternative Energy sector.

The midwest hydroforming industry aids by producing components for solar, wind, and nuclear power mechanisms.

As the Midwest sees and uptick in alternative energy consumption, it also sees an increased necessity of hydroforming in the Midwest.

If you have questions regarding how you can take advantage of our hydroforming expertise, please feel free to contact us. We look forward to doing our part to create a brighter, cleaner, more energy-efficient future.