In the 1940s, deep draw hydroforming became the forefront method for developing and manufacturing irregular shaped metal parts. Die style stamping became archaic, as it became inefficient in comparison to the hydroforming method.
The old style die stamping method used heat to draw metal and parts formed using this process took longer to make as the process of shaping the metal uniformly took more time and manpower to develop. Deep draw hydroforming allowed manufacturers to create irregular or asymmetrical parts using a cold forming process. Because hydroformed parts requires less finishing work, less time and manpower is needed to create perfect pieces.
One distinct advantage of deep draw hydroforming is it allows the manufacturer to create and manipulate a variety of metals including aluminum, brass, carbon steel, stainless steel, and alloy. This versatility has allowed manufacturers to meet the demands of a variety of industries including, but not limited to the aerospace industry, the automobile industry, and the HVAC industry.
Top Advantages of Deep Draw Hydroforming
- Many parts can be formed using a one step process
- Irregular shapes can be manufactured in less time due to less finishing work on the final product
- Material stability and durability is maintained during the forming process
- Less machines are used in the process resulting in quicker set up times
- Development costs are significantly reduced
- Abnormalities such as ripping, tearing, wrinkling, and marking associated with traditional die forming is eliminated
For more information about how deep draw hydroforming can save your firm time and money in the manufacturing process, contact us. The experts at American Hydroformers have proudly served the metal manufacturing industry for over 10 years and are dedicated to creating comprehensive metal manufacturing solutions for your firm.
Sheet hydroforming is a process that uses liquid as the medium of energy transfer to form the workpiece. Hydroforming is applied more and more in industry because it results in a better strain state in the workpiece. A deeper draw can be achieved and the friction between tools and blanks is reduced.
The advantages of hydroforming include reduction in weight, increase in stiffness, no damage to the surface of the sheet, and the capability to form complex shapes.
1. Reduction in weight: If strength is not compromised, a reduction in weight is always advantageous in the automobile, airline, and other such industries. The reduction in weight can contribute to an increase in speed. In addition, in building any structure a reduction in weight is advantageous.
2. Increase in stiffness and rigidity: While we might want speed, we also want safety. With the stiffness and rigidity, safety is enhanced.
3. Complex shaped: With sheet hydroforming, many complex shapes can be created without the use of welds which could compromise safety. The use of stamps and hydraulics allows various shapes include concave and convex curves.
4. Good surface finish: We want the reduction in weight with safety. But we also want the aesthetics. This process produces quality surface finishes without the blemishes of welding.
Sheet hydroforming is useful in reducing weight and cost simultaneously by improving structural integrity, strength, and rigidity. Cost reduction includes the elimination or decrease of welds and welding operations. Additionally, production steps are reduced which contributes to the cost reduction.
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Since the 1950s, tubular hydroforming has become a staple in the metal fabrication industry. Technological advancements in computer controlling and high-pressure hydraulic systems have allowed the process to become a more viable solution for mass metal production.
Modern machines allow for an increased metal shaping capabilities which far exceed traditional methods due to the employment of independent control of axial feeding, internal pressure, and counter pressure.
There are numerous applications for hydroforming including those within the automotive industry. Hydroforming has revolutionized the production of a multitude of parts from how exhaust manifolds are built to how axles are formed.
The typical hydroforming process follows a progression sequence in which fluid pressure within the tube is increased after the die closes to force the material into the deformation zone. During the formation process, axial feeding and internal pressure are regulated simultaneously to ensure the proper shaping of the material. Spring back is prevented and tight tolerances are maintained by stretching the tube’s cross section beyond its yield point.
Tubular hydroforming allows developers and engineers to optimize designs through cross section reshaping and expansion. Because of the structural integrity of hydroformed pieces, hydroforming has become a critical element in developing mass produced automotive components.
Several advantages of tubular hydroforming include:
- Part consolidation
- Reduced waste
- Fewer parts so lower tooling cost
- Reduced need for secondary operations
- Low spring-back and tight tolerances
- Improved structural strength and stiffness of product
- Weight reduction through highly efficient design and tailoring of wall thickness
From an economic and mechanical standpoint, hydroforming makes perfect sense for the manufacturing of mass produced metal products. Cycle times can be reduced to increase production proficiency even more, allowing for an improved bottom line.
For more information on how hydroforming can help your business, contact the professionals at American Hydroforming. The experts at American Hydroforming use only the most technologically advanced methods for shaping and fabricating metal products and have been trusted leaders in the hydroforming industry since 2003.