Get the Facts About Tube Hydroforming
There are two common types of hydroforming, tube hydroforming, and sheet hydroforming. But first, what is ‘hydroforming?’ It’s the process by which metals like steel, copper, aluminum, and brass are manipulated into a specific form or shape. Hydroforming is an efficient way of die molding that uses high-pressure fluid to fabricate metal.
Mountain bikers have been making lots of noise lately about the 2021 Chisel Comp, produced by the U.S.-based company Specialized. Lightweight and stiff, the new Chisel Comp perfectly balanced, designed to handle rough terrain with ease. This might explain why the model sold out more or less immediately.
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.
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.
May 1, 2013 will always be a day that the Ford Motor Company and the design team for the Ford Fusion can look back on with pride. That was the day the Steel Market Development Institue (SMDI) of the American Iron and Steel Institue awarded them the Automotive Excellence Award for 2013. Why? Because of their “innovative use of advanced high-strength steel throughout the [car’s] body structure and closures.”
So what was this innovative use? After all, high-strength steel has been used in cars for years. Turns out the Ford Fusion is the first car to make use of hydroformed steel tubes in its B-pillars – a design decision Ron Krupitzer (VP of automotive market, SMDI) believes “contributes to the vehicle’s improved side impact performance, mass reduction and roof strength.” All of which are important to the industry and consumers.
So what is tube hydroforming? Basically, it’s a process that uses a mold and hydraulic fluid to form a tube. Aluminum is placed inside a mold followed by the injection of hydraulic fluid under high-pressure. As the hydraulic fluid enters, the aluminum fills the mold evenly creating a tube that’s stronger and lighter than those created by other processes.
The automotive industry isn’t the only industry that’s discovered the advantages of tube hydroforming. The bicycle industry has as well. In traditional bicycle making, the tubes for the frame are stamped out of the material, a process which can cause weak points at the corners and rounded surfaces since the pressure used in the process is not distributed evenly. Hydroformed tubes avoid that uneven pressure and are stronger for it. In addition to their greater strength and lighter weight, hydroformed tubes also provide bicycle makers with reduced production costs, safer working conditions, and a better surface for painting and finishing.
Since it’s creation in the 1950s, the hydroforming has been used in the production of many products – from cars to bicycles to brass instruments and many other things. It’s a process whose future is bright and is sure to include many more awards and inventions.
If we can help you with your production needs, contact us. Helping you create your dream is part of our job.