Posts Tagged american hydroforming

Sheet Hydroforming: 4 Advantages

Sheet Hydroforming: 4 Advantages

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.

Want to know more? Just contact us and let’s talk.

 

Benefits of Tubular Hydroforming

Benefits of Tubular Hydroforming

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
  • Consistency
  • 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.

Tube Hydroforming White Paper

Tube Hydroforming White Paper

 

Tube hydroforming is at the heart of the process that enables modern-day life to proceed more efficiently. From the water piping systems of local utilities to the cars we drive and bikes we ride, tube hydroforming is the process that allows the efficient creation of complex shapes with minimal waste in modern life. So what exactly is tube hydroforming?

Hydroforming Explained

As technology advances, businesses, government agencies, and utility providers around the world seek out the most cost-effective way to obtain the materials needed for piping, rail systems, and car parts (to name a few industries) while ensuring the products received still meet stringent requirements for strength and structural integrity. This is where hydroforming comes into play.

Hydroforming is a process that takes ductile metals, such as aluminum, stainless steel, brass, and other low alloy steels, and transforms them into the shapes needed by various industries. The process is conducted by fitting these metals into preformed dies or molds and reshaping them with the help of high pressure hydraulics.

For instance, when a piece of copper piping needs to be molded to a particular shape and still maintain a high stiffness-to-weight ratio, hydroforming is used. The copper piping would be placed inside a forming die with the desired mold shape for the end product. The copper tube is then inflated with high pressure hydraulic fluids from the open ends that force it to conform to the new shape of the mold.

The hydraulic fluid forces the expansion or alteration of the tube until it fits into the desired mold. Hydroforming is done with all metals that can be reshaped at room temperature, and is capable of achieving complex yet strong molded shapes in a much more cost-effective manner than other stamping or welding processes.

Evolution of Tube Hydroforming

Hydroforming was born out of the deficiencies of older metal forming processes. The first patent for a modern version of hydroforming was filed with the U.S. Patent Office in July 1952 (and later issued in 1955) by Fred Leuthesser Jr. and John Fox of the Schaible Company in Cincinnati, Ohio.

To read the full article, down load our Tube Hydroforming White Paper here:

http://vptag.wufoo.com/forms/m7x4z5/

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.

Hydroforming for Performance in the Automotive Industry

Hydroforming for Performance in the Automotive Industry

Automakers face a number of challenges in providing consumers with vehicles that are safe, fuel efficient and reliable. One way they are achieving these goals is with the use of hydroformed automotive parts. Hydroforming is a metal fabrication process that uses high pressurized fluid and a specialized type of die molding that produces parts which are lightweight, cost-effective and although thinner, have increased strength and structural integrity.

BMW has been using hydroformed parts in their high performance vehicles for several years. The BMW M3 features hydroformed exhaust tubes, for instance. Ford utilized hydroformed steel tubes in the B-pillars and a hydroformed roof rail in the 2013 Ford Fusion. The structural superiority as well as the lighter weight and reduced costs are key reasons that automakers have begun to incorporate hydroformed parts into their newer models.

Weight is increasingly a concern for both consumers and automakers due to EPA regulations regarding fuel efficiency. A lighter vehicle enjoys improved MPG, in fact, according to the EPA, every 100 pounds of extra weight in a vehicle reduces the MPG by 2 percent.

But perhaps more important than weight and MPG, is safety. Hydroformed parts have a higher stiffness to weight ratio and increased strength. The absence of welding joints means these parts have a greater ability to absorb crash energy. This means vehicles have greater crash worthiness which translates into improved safety for the occupants of the vehicle in case of a crash.

For improved safety and structural strength as well as reduced weight and overall production costs, hydroforming is a perfect solution for the performance automotive industry.

We are American Hydroformers and we specialize in the manufacture of hydroformed parts. Contact us for information on hydroforming solutions for your automotive parts needs.

What Is Tube Hydroforming? All you need to know.

What Is Tube Hydroforming? All you need to know.

Whether you are well-informed or brand-new to the subject, here is a primer on the basics of tube hydroforming. Read on to discover more about the process, the materials, the products, and the benefits.

Process

Simply put, hydroforming is the process of shaping ductile metals into desired pieces using either high or low pressure from hydraulic fluid. A hollow tube is placed into a negative mold, and fluid is pumped into the mold until the pressure shapes the material into the desired form. The fluid is removed and the product is finished.

Materials

Tube hydroforming can be done on metals including aluminum, brass, stainless steel, and low alloy steel.

Products

Tube hydroforming is used to make car frames, particularly high-end sports models. Specifially, engine cradles, suspension, radiator supports, and instrument panel beams are manufactured in this manner. Aluminum bicycle frames use this technology. And additionally, the brass tubes of Yamaha saxophones are made with this process.

Benefits

Tube hydroforming is desirable because it results in lightweight and structurally stiff products. The process is also very cost-effective, requiring few tools and minimal maintenance. Tube hydroforming provides an easy process for creating complex shapes, reducing the need for welding operations. Compared to other methods, tube hydroforming leaves a smooth finish and an appealing appearance.

American Hydroformers is based in Fort Wayne, IN, and specializes in the hydroform tube forming process. Whether you work in appliances, automotive, or plumbing fields, we are here to help you! Visit our “What Is Hydroforming” page to learn more about the process we use and see before and after photos.

Contact us today to request a quote and get more information about our services!

AHI Adds 1800 Ton Hydroforming Press

AHI Adds 1800 Ton Hydroforming Press

American Hydroformers Inc. has been supplying parts to the automotive industry for nearly 10 years now. Hydroforming gives our customers the ability to specify lighter weight, stronger parts with the benefit of removing multiple manufacturing processes.  One thing we have learned over the years, if you are going to serve the major businesses in any industry they must have complete faith in your companies ability to supply their demand.  Most clients will not even give you the time of day if you do not have redundant press capabilities to continue supplying their production schedules and or production lines.  Currently we have 3 hydroforming presses and are in the process or adding to it.  We are constantly looking for ways to improve our processes to remain competitive and expand our product offerings. We have recently taken possession of an 1800 Ton Hydrap Pressen Hydroforming Press that is in the construction process at our Ft. Wayne, IN facility.  This press will gives us the ability to add another hydroforming operation to our manufacturing process or it can also serve a pre-forming function to one of our other hydroforming presses.

We also rely heavily on our in-house tool and die shops that give us the ability to customize dies and maintenance them accordingly.  We run many components and parts for other Tier 1 suppliers when they are overwhelmed, sure we help out our competitors at times, but we have come to find that building a relationship with everyone in the industry is much more beneficial for everyone.

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 us to see how you can reduce your tooling and part costs.