September brought glad tidings in the world of deep draw hydroforming. Not only have power player Beckwood Press Company announced improvements in the area of low-volume, high-mix production, but it was also confirmed that they will be exhibiting and presenting educational sessions at the upcoming FABTECH 2014.
While working to solve a problem for one of their clients, they recently built and installed a Triform deep draw press that featured a 25″ diameter forming area, 10,000 PSI of pressure, and a 12″ draw capacity. The client is pleased, and Beckwood is proud of its work:
“We are proud to announce the installation, and successful training and ramp up of another Triform deep draw hydroforming application this year,” said Beckwood President, Jeffrey Debus. “Our engineering team provided a machine with advanced forming capability, faster forming time, and a reduced reliance on skilled labor; and our support team provided the training and assistance the client needed to get their operators up to speed and working with the press on an expert level within days of installation” (Today’s Medical Developments)
FABTECH 2014 Sessions
It was announced through the PR Web that Beckwood would bring their industry-leading designs and Triform expertise to FABTECH 2014 in Atlanta, Georgia. In addition to giving an hour-long session, Beckwood and Triform will be available in the exhibition hall, where they will display their new 30-ton custom deep draw hydroforming hydraulic press, featuring some of the latest control technologies that they have developed.
Parties interested in attending the event should seek more information directly from FABTECH here.
For more information about deep draw hydroforming or anything else hydroforming related, please feel free to contact us.
One of the questions we get asked a lot about our business is: what is tube hydroforming and how is it used?
In order to understand tube hydroforming, perhaps one should first understand hydroforming. Hydroforming is a fabricating process in which metals such as steel, stainless steel, copper, aluminum or brass is shaped. Tube hydroforming is one of the two types of hydroforming. This type of hydroforming uses two die halves in order to expand a metal tube into a shape. The process was first patented in the 1950s, but didn’t become widely used until the 1970s. It replaced the older process of stamping two part halves and welding them together.
Hydroforming is a more efficient process than stamping, as it eliminates the welding and allows for more intricate shapes to be formed. Tube hydroforming is readily used in the automotive sector as well as for use in the tubular parts of bicycles, motorcycles, musical instruments and other innovative designs such as stainless steel water bottles. In vehicles, tube hydroforming is most often seen in the manufacture of engine cradles. It is also found in suspension, radiator supports, and instrument panel support beams. The framing around the Harley Davidson motorcycle engine is made through the tube hydroforming process. Yamaha saxophones also use the process.
American Hydroformers is not restricted to the use of circular or round tube stock, but rather can use any tube profile. Hydroforming can be done on standard tube diameters of up to 5″ with a wall thickness of up to 5 mm. However, it is possible to meet customer specifications on dimensions with rounds and other shapes.
For more information about hydroforming and the other services that American Hydroformers offers, contact us.
Who We Are
American Hydroformers is a high pressure hydroforming company that began in 2003. Based in the heart of America, Ft. Wayne, Indiana, American Hydroformers specializes in the hydroform tube forming process. We conduct, oversee, and perform the tube forming process in all of its various stages from the beginning to the end. Resulting in a superior product unrivaled by others in the field.
We also provide metal fabricating solutions that utilize the most advanced techniques available today. Including hydraulic press work, laser cutting, deep draw hydroforming, sheet hydroforming, metal stamping, among many others.
Industries We Serve
Appliances: The handles for appliances that we fabricate are stronger and more ergonomic. They are often featured on new ovens and refrigerators because of their sleek, polished appearance, and can be molded into many different designs.
Automotive: The automobile industry benefits greatly from our hydroformed products because they are lighter, stronger, and stiffer than traditionally-designed parts.
Diesel Exhaust: Because of recent EPA regulations on how exhaust systems produce emissions, the trucking industry sought out hydroformed products because of their ability to be made smaller and stronger, while still meeting regulations.
Plumbing: Plumbing hydroformed products are catching on very quickly. This is because hydroformed plumbing products are more versatile than traditional fixtures, and are a designer’s dream.
The hydroforming equipment that we use is state-of-the art and modern. We are able to provide precision craftsmanship through our laser and plasma-cutting machines, and our stamping/hydraulic presses can fabricate all parts and pieces economically and with ease.
For more on our equipment, click here.
A prominent leader in hydraulic press and automation sheet hydroforming systems named Beckwood Press Company, has produced a hydroforming press especially catered to aerospace industry parts supplier, Steelville Manufacturing Co, according to an article on digitaljournal.com which outlines the mutually beneficial deal between the two:
The bladder-forming press provides Steelville dramatically increased forming capability, and features a 24″ forming area and 5,000 PSI of forming pressure.
Steelville Manufacturing Co. (located in Steelville, Missouri and formed in 1959), is a parts supplier for many large US aerospace companies, including leaders in the industry like Boeing and Lockheed Martin, among others.
They collaborated with Beckwood Press Co. after the two decided that the speed in which their internal forming capability and overall parts production efficiency was functioning, could easily be increased through the addition of Triform Sheet Hydroforming press.
Triform Sheet Hydroforming equipment provides even and accurate pressure, which greatly reduces production time, and all but eliminates manual hand-work.
Not mention next to no maintenance requirements, which mainly consists of a bladder change process that takes roughly an hour to complete. And because of the size and design of the Triform Sheet Press, the space it occupies on the production floor is minimal.
Before Beckwood and Steeleville collaborated together, Steelville was mainly press brake forming their parts. But since March, when the Triform 24-5BD began operation at their facility, Steelville has already seen a positive impact on all manufacturing operations.
According to Joseph Dust, one of Steelville Manufacturing Co.’s chief engineers who was in charge of the Triform press integration, they had been manufacturing parts for a very long time, which they soon came to find out were almost tailor-made for the Triform press.
The addition of the [press] definitely makes forming parts much easier, [and] the overall time required to make our form tools has been cut in half.
Adding that, just over the first few weeks the Triform press was in operation, they had already produced well over 10 parts, all with reduced manual labor and costs. A timeframe that would have typically seen a part production count of next to 5, or even less.
For additional information on the Triform Sheet Hydroforming Press, click here.
For more details on the collaboration between the two companies, click here.
For more information on how American Hydroformers can help you, to request a free quote, or for related information on how the hydroforming process can revolutionize how you do business, please contact us any time.
As automotive and mountain-biking companies begin to roll out sneak peeks at their 2015 lineups, it is becoming increasingly apparent just how much new advancements in hydroforming aluminum have affected both industries overall. This is pleasing because since aluminum is lighter than carbon and stainless steel, the use of hydroformed aluminium in car parts has opened new vistas of possibilities for increased effectiveness and decreased weight.
Take for example the 2015 lineup from the German biking company Merida. According to a recent article, next year’s lineup boasts more aluminium than ever, including a new Reacto aero bike featuring a very special frame:
The frame in question is made from hydroformed triple-butted 6066 aluminium with a tapered head tube and an integrated seat clamp like you’ll find on the carbon models. It looks like a high-quality piece of work in a very good grade of alloy (road.cc).
Looking beyond the world of cycling to the automotive realm, we see that Ford has certainly taken advantage of new opportunities provided by aluminum hydroforming.
Proof of this can be easily witnessed in their new 2015 line, which includes an all-aluminum body for its new F-150. In fact, the new F-150 was a recent spotlight by Ford’s purchasing chief Hau Thai-Tang, citing that the vehicle is the the first pickup with an aluminum body. As a result, it is on average about sixty pounds lighter. The F-150 still incorporates a steel frame, however, for improved rigidity (Auto News).
With new advancements being made all the time in the area of aluminium hydroforming, we look forward to many more companies taking advantage of these techniques to provide vehicles and machinery that are not only lighter and more durable but are also more cost-effective.
For more information about this or anything else, please feel free to contact us.
Friction stir welding is used to create joints that are of the highest quality and of the highest strength. Friction stir welding was patented in 1991. The first applications that friction stir welding was used for was aluminium fabrications. With its low distortion, the solid-state joining process of friction stir welding is able to create lap joints or butt joints. The joints can also be created in a wide variety of the thickness and the length.
Since friction stir welding is a solid state process, you will not have to concern yourself with any of the errors that may occur when you are using fusion welding. The quality of welding is excellent, and it is friendly for the environment. There are not any kind of fumes that will be triggered into the air.
What Can You Expect From Friction Stir Welding?
- There will be no limit on the length and width of your panel. Friction stir welding can successfully meet the needs of your application, no matter what size the parts are.
- Since friction stir welding is one of the most cutting edge technologies and developments, there will be new developments and solutions for all of the customers using the process.
- Protecting the environment is a serious issue and concern. If you want to do your duty of protecting the environment, you can feel comfortable with using friction stir welding. It is a relatively green process. There will be no triggers of gases or fumes. You will be creating something amazing, while protecting the environment with this environmentally friendly process.
- Friction stir welding can be operated in every position.
- You can expect to be able to make hybrid components. This can be done by joining different products. Aluminum and magnesium alloys are two examples of different materials that can create those components.
- A low energy input compared to other types of processes.
In this day and age, and the different industries available, there is a certainty that the industry will find numerous uses for friction stir welding. This process is not expensive, and you have the great ability to weld or fuse different materials.
For more information about friction stir welding and how it can be beneficial to you, contact us.
Hydroforming is the process of using high pressured water to create custom metal structures to fit the needs of our clients. Centered in the Midwest since 2003, we have catered to a number of clients’ needs including:
- Tube forming
- Industrial laser cutting
- Stencil work
We use an internal high-pressure hydroforming press system which is quintessential in creating parts with complex geometries and extensive secondary operations. Our system is also the most efficient, saving our clients time and money. The newest addition to our press equipment, an 1800 Ton Hydrap Pressen Hydroforming Press, has allowed us to add to our manufacturing processes and serves as a pre-forming function for our existing hydroforming presses.
Hydroforming is the most efficient and cost-effective way of shaping amenable metals into pieces that are not only lightweight but also structurally sound. Uses include:
- Unibody structures in the automotive industry
- Bicycle frames
- Metal-based instruments
Traditional manufacturing methods, such as stamping and welding, are not only more expensive but also create structurally weaker products. They are unable to create fluid pieces that fit perfectly into their spaces.
Tube hydroforming is a similar process, most commonly used in the automotive industry. It is a very favorable process, as we can produce tubular formations with many geometric options, reducing the need for welding operations.
Contact us in Fort Wayne, IN for more information on how we can create your custom pieces. Be sure to catch our documentary on the Discovery Channel in 2014, and read up on our business in The Tube and Pipe Journal.
While most people are only vaguely aware of the concept of hydroforming and its many benefits, even fewer are well-versed in the specifics of tube hydroforming aluminum. The unfortunate truth is that although they often benefit from the results, most people are unaware of how this process actually influences their daily lives.
Three Applications for Aluminum Hydroforming:
- Mountain Bikes. We list this one first because it is probably one of the better known applications. Thanks to recent developments in aluminum hydroforming, mountain bike frames are now more sleek and lightweight than ever.
- Automotive Body Panels. Within the last few years, the overall emphasis on energy consumption and the desire on the part of auto makers to produce cars that are fuel-efficient have together led manufacturers to desire more lightweight designs in order to minimize fuel consumption. As early as 2012, it was suggested that sheet hydroforming techniques could be used to produce aluminum body panels, which would significantly lighten vehicle weight. We look forward to seeing how these ideas take shape in the days to come.
- Medical Device Manufacturing. Thanks to hydroforming technology, medical devices made from aluminium, titanium, stainless steel, and other composites can now be produced with lower cost and higher product quality than ever before. According to a recent article in Today’s Medical Developments, “Sheet hydroforming and the accompanying technologies are helping medical device manufactures prepare for the future. With these technologies, device manufacturers can stay ahead of government regulations, implement a leaner manufacturing environment, and bring products to market faster while delivering higher profit margins.”
Although hydroforming techniques mostly center on carbon steel and stainless steel, we look forward to seeing more applications of tube hydroforming aluminum in the days to come. For more information on this, or anything else, please feel free to contact us.
American Hydroformers provides metal fabricating solutions using the most advanced hydroforming processes available. Our manufacturing expertise includes hydroforming, hydraulic press work, laser cutting and various other metal forming techniques.