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.
Posts Tagged high pressure hydroforming
Although the process of high-temperature metal gas forming may not be common knowledge, most people benefit from this process on a daily basis. They just don’t know that they do.
Every time you drive a motor vehicle, fly in an airplane or ride a bicycle, hydroforming was likely used as part of their manufacture. Hydroforming provides a number of advantages when compared to other alternative methods of metal shaping. By learning more about what is hydroforming, understanding the significance of this process in our daily life should be possible.
The Standard Concept
Aluminum is a malleable material that is often molded using hydroforming. Two processes can be used during the hydroforming process for manipulation. The first is using high pressure hydraulic fluid to produce a certain shape with the metal. The metal (typically a flat sheet) is placed inside a container with a mold. The container is sealed off and hydraulic fluid injected until a certain pressure is achieved. This pressure causes the metal to mold to the shape of the dye. A variation of this concept involves the manipulation of a hollow tube of metal. The hollow tube is placed inside of a negative mold and fluid is injected into the inside of the tube, causing it to expand into the shape of the mold.
Low Pressure Versus High Pressure Tube Hydroforming
In tube hydroforming, two methods are typically used. The only difference between the two are the pressures used and when they are applied. In high pressure hydroforming, the tube is exposed to high pressures (typically between 1500 and 2000 bars) only after being closed in the dye of the hydraulic press. In low pressure hydroforming, the tube is exposed to a low pressure of between 120-180 bars before being closed in the dye of the hydraulic press. According to Metal Working World Magazine, “The material does not collapse, taking the die shape, but simply it is uniformly stretched (thus avoiding the corrugations of the inner surface that are instead frequently present in the high pressure method), like in a pre-forming process.”
Be sure to contact us at American Hydroformers if you have any questions about what is hydroforming.
American Hydroformers is on the cutting edge of production technology. We offer many services, including metal fabrication solutions through the use of hydroforming, laser cutting, and several other forming techniques.
But perhaps the technique that garners the most interest is how our internal high pressure hydroforming press system works, and why it is so widely sought after.
Hydroforming (or internal high pressure forming) is a forming process by which an active solution (often a water and oil emulsion) forces a hollow part into a desired shape by applying a variable amount internal pressure that depends largely upon the density of the material (click here to watch a clip). And at its peak, the pressure can reach several thousand bars.
The advantages of this technique are many (especially compared to deep draw hydroforming), but most apparent are:
– Large design ratio
– Reduction of overall parts
– Lowered amount of weld-spots or connections
– Reduction of material weight
– Higher ductile and mechanical strength
– More durable
– Increased forming accuracy
Because of these positives, high pressure hydroforming has becoming a superior technique in many industrial sectors (most notably, automobile manufacturers). But has branched out to many others, including plumbing and heating, household appliances, furniture, bicycle frame manufacturing, machines and equipment, and even aerospace and aviation.
However, hydroforming stands out the most in the automobile industry, because of widely used parts for the chassis, motor, crossbeams, side beams, and roof frames, throughout the industry.
Additionally, hydroforming gives automakers the freedom of design, so that they can make lighter and faster cars that appeal to a broader group of people, while remaining relatively inexpensive in terms of production.
For more information on how we can help you, please contact us any time.