Archive for the Metal Fabrication Category

Where Would We Be Without High-Temperature Metal Gas Forming?

Where Would We Be Without High-Temperature Metal Gas Forming?

Although your average American probably has not heard of high metal gas forming, that does not mean they have not taken advantage of products made possible (or made better) through it. Those of us in the industry know better. We recognize that the vast majority of us would lead less comfortable and convenient lives without high-temperature metal gas forming. 

Higher Value Increases Use of Aluminum in Vehicles

Higher Value Increases Use of Aluminum in Vehicles

In 2015, Ford’s F-150 was the first high-volume vehicle produced with an aluminum frame, reducing the F-150’s weight by 700 pounds. Since then, the need for strong, lightweight material is driving a significant increase in the use of hydroformed aluminum to make automobiles that are both fuel and cost efficient while retaining key safety features.

A New Way of Doing: High-Temperature Metal Gas Forming

A New Way of Doing: High-Temperature Metal Gas Forming

The birth of hydroforming has brought with it many advantages. When compared to mainstream production techniques, hydroforming has proved itself to be effective, quick, reliable and capable of outperforming products manufactured with standard conventional processes. Nevertheless, the close counterpart of hydroforming, high-temperature metal gas forming, is on the rise and has shown itself to be just as powerful. 

American Hydroformers Employs Faro Edge Scan Arm HD

American Hydroformers Employs Faro Edge Scan Arm HD

At American Hydroformers we recently obtained and implemented a new Faro Edge Scan Arm HD that enables enhanced product development, inspection, and quality control. As a 3D scanning and probing device, the Faro Edge Scan Arm HD provides capabilities such as rapid prototyping, reverse engineering, 3D modeling and rapid point cloud collection and comparison. Ideal for scanning challenging materials, the Faro Edge Scan Arm HD also allows for contact and non-contact measurements.

  • Rapid Scanning Speed
  • High Definition Data
  • Up to 2,000 Points per Scan Line
  • Fast Frame Rates
  • Scan Challenging Materials
  • Highly Accurate and Repeatable
  • Contact & Non-Contact Measurements

Acquiring this new Faro Edge Scan Arm HD will allow American Hydroformers to probe virtually any part or tube and collect all of the data needed to reproduce it.  With up to 2,000 actual points per scan line, extreme resolution and high accuracy, we are able to reproduce even the most intricate parts and components. The actual setup of the scanning arm features an extra wide scan stripe as well as fast frame rates. This allows for increased productivity with the large coverage area and the reducing scanning times.

Autoform Hydro Simulation

In addition to the Faro Edge Scan Arm HD, our in-house capabilities also include the utilization of AutoForm Hydro simulation software as well as FEA simulations. Our team of engineers are trained and regularly updated on this software which provides a comprehensive understanding and analysis of the entire hydroforming process. By employing this software in-house and utilizing the simulation process, we supply our customers with rapid verification, shorter development time, and improved process reliability.

  • Easily Identify Forming Issues
  • Rapid Tool Design
  • Accurate Springback Simulation
  • Quality & Cost Improvements
  • Reduced Development Time
  • Improved Reliability
  • Lower Material & Production Costs

By enabling better price controls and reduced tooling expense, American Hydroformers provides a cost-effective source for part production. Unlike other metal forming techniques, hydroforming allows for increased part strength, lower part weight, and greater design flexibility, while also improving overall part quality. Contact American Hydroformers to see how you can reduce your tooling and part costs.

How Tube Hydroforming Can Help Cafe Standards?

How Tube Hydroforming Can Help Cafe Standards?

CAFE Standards:

The Corporate Average Fuel Economy standards (CAFE) standard enacted in 2014 imposes fuel efficiency and green house gas emission standards on the manufacturers of cars and medium and heavy-duty trucks. These standards get progressively stricter every year, with costly fines imposed for every car or truck model that fails to meet them. Cars must improve performance by 37% and trucks by 23% every year.

Generally speaking, automakers have been beating the CAFE standard every year. It’s in the interests of the manufacturers to build lighter and more efficient vehicles while maintaining high safety standards. How do the manufacturers manage to do that? The goals are achieved by improving engine and transmission technologies, body aerodynamics that reduce air resistance at high speeds, tires with lower rolling resistance, and very importantly parts that reduce weight.

Weight reducing manufacturing technologies:

  • Hydroforming technologies can shape aluminum, brass, steel and stainless steel into complex, hollow forms which are lightweight and structurally stiff and strong.
  • Hydroformed parts eliminate most of the heavy welding required in conventional parts assembly.
  • Using hydroforming technology in manufacture produces structures with fewer separate parts and fewer heavy welds and joints.
  • Hydroforming uses dies capable of high precision, able to meet the exacting tolerances of aircraft parts.
  • Replacing sheet metal bending and joining with hydroforming eliminates multiple welds and draw marks produced by the traditional method of pressing a male and female die together.

A typical example of the benefit of hydroforming is cited by Professor Muammer Ko, of the Virginia Commonwealth University.  Prof. Koe talked about an aluminum radiator support for a passenger car.

  • The stamped manufacture process requires 17 unique parts weighing a total of 16.5 kilograms.
  • The hydroformed part is comprised of 10 parts and weighs 11.5 kilograms (a 30% weight savings).

The hydroforming process can produce structurally stiff and stable parts out of materials that are lighter in weight but able to replace stamped parts made with heavier materials.

  • When an aluminum part replaces a steel or cast-iron part, it means a weight reduction of 40% to 60%.
  • Warm hydroforming greatly increases the formability of lightweight materials like aluminum and magnesium, greatly increasing the possible range of hydroformed parts manufacturing.

Although stamping and welding have not gone away, increasing proportions of the automotive production has gone to hydroforming.

American Hydroformers engineers and manufactures tube hydroformed parts for the automotive industry out of Midwestern facility. Please contact us for more information.

Though Struggles Exist, Hydroforming and Metal Stamping Thrive

Though Struggles Exist, Hydroforming and Metal Stamping Thrive

U.S. manufacturing in the new tech age has brought with it many advances for those involved in the industries of metal stamping and hydroforming.

However, at the same time, it has continued to hinder growth across many industries, even though the dollar is strong, and the cost of oil per barrel is low.

For example, in states where manufacturing is intrinsically linked to automotive industry (like Ohio), there has been a strong showing, perhaps because of the industries tendency to diversify.

In Cleveland, according to a recent news article related to Cleveland manufacturing, companies like TimkinSteel Corp. and City Plating have been steady on the rise over the last few years.

As TimkinSteel Corp. spokesman, Joe Milicia, said in an email:

“We are feeling the effects of a strong dollar and a U.S. rig count that’s down more than 50-percent.”

So while many industries (in every state — not just Ohio) can pinpoint successes and failures throughout the year, the truth is that not every company sees a strong dollar as a bounty for growth.

Is hydroforming different?

Yes. Absolutely, in fact.

For those in the metal stamping and hydroforming industries, opportunities are abound. From things like LED and solar manufacturing in Ohio to automotive and aerospace in the Midwest, metal stamping and hydroforming adapt and advance.

Which, as the numbers will attest, prove that business is booming, and growth this year will lend to additional growth in the following years.

By continuing to focus on high-growth markets, hydroforming and metal stamping thrive in spite of negative factors that pervade other industries.

One could say that, growth is a slow-grind, but as long as there is formidable planning and need, manufacturers in the hydroforming sectors are verging on recession-proof.

For more information on how we can help you, please contact us any time.

How High-Speed Metal Stamping May Change the Industry

How High-Speed Metal Stamping May Change the Industry

Many aspects about manufacturing remain the same for decades. So many regular processes designed solely to fabricate are rarely altered because change costs money, and so often those in charge don’t levy for deviation because “if it ain’t broke, don’t fix it.”

The evidence of this type of thinking on our industry, however, is usually scant and lacking. In the world of hydroforming, innovation is part of our reality. We have spent many years designing and scheming for the future; we welcome forward-thought and progress.

For instance, take a look at metal stamping and how it has changed. To most untrained people, the process is simply a few lines of work, pushing materials, and stamping forms. It seems simple, though it really isn’t.

A great example of metal stamping innovation comes from a company on the East Coast called Intricate. They have, among other things, perfected the art of high-speed metal stamping.

From this write-up, it proves that with some extra effort and willingness to exceed previous expectations, hydroforming and metal stamping can go very far with a measured amount of success.

Company innovations include manufacturing speeds up to 1,500 strokes per minute, modular and carbide tooling, and multiple-out manufacturing.

With these types of progressions in the metal stamping field, the positives for consumers reaches new heights. By increasing the strokes per minute, Intricate has shown that metal stamping continues to be a viable source of production.

Add to that state-of-the-art machines, and a core group of people who care incredibly about what they do, and you have a recipe for success and a future full of solid enterprise and progression.

For more information on how we can help you, please contact us any time.

Tubular Hydroforming And Other Innovative Techniques

Tubular Hydroforming And Other Innovative Techniques

Whenever you are working on a project, no matter how big or how small, you should always look for the best possible way to make the project successful. When you want the project done correctly, it does not mean you can take the easy way or the quickest way to get it done.

If you are looking for a design for a tubular metal part, you may be scratching your head while you look for the best possible way to manufacture it. Well, whether you know it or not, you have a significant amount of options and solutions.

One of those options is hydroforming. As with any other options or solutions, hydroforming will have its advantages, disadvantages, and limitations. With disadvantages, you may have to change things, in regards to your design and the production process.

One of the newer forming technologies is known as tube stamping. Tube stamping opens a box of endless possibilities. With tube stamping, you will not find yourself jeopardizing your production time, your costs, or the weight of the product. If you anticipate a high-volume production, tube stamping will be a great solution because it is incredibly quick. Tube stamping is similar to tubular hydroforming because both processes can create those difficult and confusing parts.

Each tubular metal project that you take on will have its own requirements, whether it is related to the time or the cost. In order to choose the right process, you will need to evaluate all of the requirements and circumstances surrounding the process. You will certainly need to find the right fit, so it is important that you take your time to research all of the possible techniques.

If you are interested in more information about tube stamping, tubular hydroforming, or any other technique, contact us today.