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Posts Tagged bicycle frames

What is tube hydroforming?

What is tube hydroforming?

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.

Tube Hydroforming

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.

Improving Bicycles with Tube Hydroforming

Improving Bicycles with Tube Hydroforming

What is tube hydroforming? It is a metal shaping method that is replacing stamping and pressing because of its quality products and cost-effectiveness. Tube hydroforming is used to create countless products: automotive exhaust components, sink faucets, hand rails, rifle scopes, sporting goods, and bicycle frame components. More bicycles than cars are sold in the USA every year. Last year, approximately 19 million bikes were purchased. When looking for a bike, people pay close attention to the weight and stability of the bike’s frame, because all these factors make the difference between a heavy, awkward bike and one that is light and easy to maneuver.

The tube hydroforming process offers the best features of an aluminum bicycle frame. Often when a manufacturer makes a bike frame, they press or stamp the components for the frame, but the problem is that this creates weak points that the eye cannot see. Tube hydroforming, however, creates a sturdy frame, because the hydraulic fluid is pumped into the frame at high pressure, creating evenly molded aluminum without any weak spots. The process produces interesting shapes and a thickness in the material, leaving a stronger and lighter tube to be used in the frame system.

Not only are manufacturers improving bicycles with tube hydroforming, but it also saves the manufacturers money, thus reducing bike costs for consumers. The manufacturer saves a lot of funds on tools that would have been needed for stamping and pressing techniques. Hydroforming is also done at room temperature, and the die used to cast material can be used over again, saving a lot of money on energy and material costs.

Hydroforming is a reliable and trusted process. Consumers have started specifically looking for hydro-formed bicycle frames because of the frames’ sturdiness, light weight, and pleasing appearance.

For more information about tube hydroforming, our services, and experience, please contact us.

Hydroformed Bicycle Frames

Hydroformed Bicycle Frames

You may think that if you’ve seen one bike, you’ve seen them all. Yes, they come in different colors and wheel sizes with different kinds of brakes; but they’re basically all the same. After all, they’ve all got two wheels, pedals, and a seat. How different can they be? As any cycling enthusiast can tell you, the answer to that question is very! Differences in the materials and manufacturing processes that are used can make one bike feel and ride very differently from another.

One of those different manufacturing processes involves hydroforming – a process that uses fluid and high pressure to form the tube. In bicycles, this results in a frame that’s not only stronger but also sways less under pressure, allowing it to accelerate faster. A new hydroforming process (triple hydroformed) that’s being used in some bikes goes a step further and reshapes the tubes after they’ve been welded together. The resuting frame contains less material and therefore weighs less. It also provides a more comfortable ride by minimizing vibrations to the seatpost. When all is said and done, hydroforming helps create a bike that accelerates faster, climbs hills easier, and corners easier than others – qualities any cycling enthusiast would die for.

But bikes for the cycling enthusiast aren’t the only kind of bikes hydroforming is helping to improve. Electric bikes are another. Electric bikes combine human power with the power of electricity. The two working together make for a ride that’s much less strenous. Older people find them easier to ride, and commuters can arrive at work and not have to shower immediately. Sales for electric bikes have been improving in the last few years – especially amongst those looking for alternative methods of transportation. Costing between three and five cents per battery charge, it’s not hard to see why. In addition to those looking for a cheaper way to get around town, they’re also proving popular for use in businesses like deliver y services, resorts and bike rentals. Some police departments and security firms are beginning to use them as well.

Bottom line? No matter which kind of bike you’re looking for – regular or electric – you’ll probably want to look for hydroformed bicycle frames. With better handling and less weight, they make riding a breeze.

To find out how we can help you with your hydroforming needs, contact us. We’re here to serve you.

Hydroforming into the Next Generation

Hydroforming into the Next Generation

Technology born in the 1940s has evolved through the decades to become the most desired manufacturing method for widely varied industries. From the shape of a saxophone, the tubes in bicycle frames, high strength automobile components, and even the new stainless steel sink installed your kitchen, hydroforming is a cost effective way to shape aluminum, brass, stainless steel, copper, alloys, and even carbon, into high strength structural components with tight tolerances.

When hydroforming, a large press is used with a punch similar to male die element in matched die forming. What would be the female element is actually a bladder full of hydraulic fluid at extreme pressures, and between the two is a metal blank. The punch presses into the bladder, shaping the metal into the desired form while leaving the surface smooth. Once pressed, the pressure is released from the bladder and the finished part is removed.

Here are some of the advantages to hydroforming:

  • Tooling costs are lower with hydroforming because the female side is a reusable bladder, only the male die and a holding ring are unique to each job.
  • Faster prototyping is possible. Various materials and material thicknesses can be used with the same tooling setup. This brings in your total project time thereby reducing development costs.
  • Complex shapes can be achieved with a single press cycle where traditional matched die forming would require multiple press cycles.
  • Hydroforming achieves outstanding surface finishes. The soft bladder leaves no lines, scratches, or surface blemishes, which would otherwise require extra time to polish out of the finished product.

At American Hydroformers, we have the expertise and the equipment to provide you with the next generation of formed metal components. From the automotive industry to the appliance business, contact our experts for more information.