When you are working with metal, you will find that there are a variety of options and tools available for you to use. Although there are so many options for you to choose from, many companies decide to use hydroforming. Hydroforming is perfect for creating shapes using different types of metals. Hydroforming gives you several benefits when it comes to work operations, efficiency, productivity, and the cost.
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The process of friction stir welding is a relatively new way to join metal components together. It is a metal joining method that has applications in industrial fabrications and manufacturing such as aerospace, automotive manufacturing, and industrial engineering, anywhere that metal components need welds that meet the most demanding specifications.
Hydroforming is a unique process used to form metal. As a unique process, it also solves unique problems. Hydroforming makes a number of products possible that wouldn’t be possible through mainstream methods. Although it is not the most common method of forming metal, it is very useful, and a necessity to our society today. Let’s talk a little about how hydroforming works and what it does.
It does not matter where you look, you will always find information on how various companies and organizations have used an engineering simulation as part of their strategy when it comes to development. One of the best examples of engineering simulation is FEA or Finite Element Analysis.
As deep draw hydroforming continues to become a reliable and viable source of production, people who rely on hydroformed parts can only benefit from its persistent innovation.
Information about new and high-tech hydroforming presses in use around the country is part of the daily news cycle.
Corporate Average Fuel Economy (CAFE) standards regulate the fuel economy of vehicles sold in the United States. Rather than requiring minimum fuel efficiency standards for each vehicle, CAFE requires that each manufacturer’s average fuel economy meet certain requirements.
When you can control your manufacturing process, you will have a better chance of increasing your production, improving your quality, and reducing the overall costs. You need to have the right indicators when it comes to using a control system for your manufacturing needs because these indicators will have to be measured.
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.
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.
The rise of hydroforming as a viable manufacturing process which reduces the weight of resulting items is driving two distinct transitions in the industry. One of these is the switching from stamping to hydroforming, and the other is from steel to aluminum.
It is the desire to reduce item weight which is pushing forward the hydroforming of aluminum. Steel has long been the go-to metal for bike, automotive, marine, and aerospace components. However, the need for a more lightweight material arose when the industries began to feel a need for lighter components.
This is where aluminum came in. It is more lightweight than steel, resulting in the component having a 25%-50% reduction in overall weight as compared to the same component made from stamped steel. Once aluminum was able to easily be hydroformed, the transition began. Many manufacturers favor hydroforming over older means of metal forming such as stamping because hydroforming can deliver complex shapes and sizes, as well as requiring less finishing work. This is due to the fact that imperfections which would be present in the surface of the pressed metal when stamping are not present in components which were hydroformed.
The only downside manufacturers must take into consideration is the cost difference. Because aluminum is in such high demand across a wide range of industries, manufacturers could be looking at a cost anywhere from three to five times more than the same quantity of steel.
However, this is a small price to pay for the excellent product which comes from hydroforming aluminum. These superior components are ideal in industries where individual component weight is a variable.
If you would like to know more about hydroforming or friction stir welding, we invite you to visit us at our website. Additionally, you may contact us with any questions or comments about this article and more.