Here on the blog, we enjoy bringing you regular posts about the benefits of hydroforming. Today we’d like to take a step back and present a lesson on hydroforming for beginners: what the process entails and why it matters.
Posts Tagged what is tube hydroforming
In 2015, Ford’s F-150 was the first high-volume vehicle produced with an aluminum frame, reducing the F-150’s weight by 700 pounds. Since then, the need for strong, lightweight material is driving a significant increase in the use of hydroformed aluminum to make automobiles that are both fuel and cost efficient while retaining key safety features.
Tube Hydroforming is a type of die forming that is used to shape certain metals, including aluminum and stainless steel, into strong but lightweight pieces. This method is often used in the automotive industry, especially for sports cars, and is also used to create the tubes used in bicycle frames.
When your product represents a structural component of your customer’s purchase it sure better be structurally sound. Who can afford a costly recall or, even worse, be responsible for a personal accident? To help ensure against part failure American Hydroformers employs exacting Finite Element Analysis (FEA) procedures.
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.
What is hydroforming? Hydroforming is when the force of water, hydraulic fluids, or oils is used to shape a single part. There are two types of hydroforming and each has uses when creating products from steel, aluminum, etc. Hydroforming, used in industries, creates parts without using welds. This makes a stronger part and sometimes a product is created from a single piece of metal. So, what are the two types of hydroforming? They are Tube Hydroforming and Sheet Hydroforming.
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.
What is hydroforming? Hydroforming is an innovative method of pressing metal into the desired shape. It produces results similar to cold forming, but instead of simply pressing the metal with a mold, it is pressed by liquid pressure. Let’s be more specific about how it works.
Cold forming presses room temperature metal between a solid mold. Hydroforming also presses metal at room temperature, but only the bottom half of the mold is present, underneath the raw metal. The unit closes, creating a water tight seal around the metal and the mold, and then forces liquid into the unit through a hydraulic pump. This forces the metal down into the mold. The liquid is then released, and the newly formed metal reclaimed.
Many common metals can successfully undergo this process, including copper, brass, stainless steel, and aluminum. This list is very similar to the metals that can be used with the traditional cold forming method. Hydroforming is used to make all sorts of metal products, including satellite antennas, a tube for saxophones, bicycle frames, automobiles, and residential lighting materials.
The hydroforming method is particularly attractive because it can often be completed at a lower cost per unit than many other methods, including stamping or even wielding. It can also produce a higher stiffness-to-weight ratio than many other methods. Hydroforming is also beneficial because only half of the die is required. Since the fluid acts as the other half, it’s only necessary to fabricate the bottom in most cases. This also makes it much easier to change the thickness of the metal because there is no need to change the die.
Interested in learning more about Hydroforming and how it works? Contact us. We have all the answers, and we can help you with anything you need.
Hydroforming is a cost-effective way of shaping ductile metals into stiff, strong and lightweight pieces. Practically all metals that can be cold formed are suitable for hydroforming, and without being limited by geometric complexity, the applications are becoming endless. Here are a few industries which utilize hydroforming:
Aerospace: The precision and reliability of hydroformed parts is crucial to ensure success and safety in areas such as turbine construction, array antennas and construction of exterior structures.
Alternative Energies: Much like in aerospace, the components of alternative energy machines demand a lot in form and function. Be it solar, wind or waves, the flexibility of hydroforming production allows a wide array of metals to be utilized towards producing advanced components for the energy of the future.
Medical: Due to not being limited by traditional manufacturing methods, hydroforming finds a good niche in producing intricate parts for medical appliances such as pace-makers and advanced prosthetics. Being as it is so cost-effective, hydroforming has the ability to make much needed medical procedures more affordable to people who truly need them.
Home Appliances: Hydroforming makes very asthetically pleasing products; because of the unique manufacturing process, pieces come out smooth and free from dents and blemishes. In the appliance industry, hydroformed parts are moving into the eye’s view as they gain acceptance and use as handles and more due to these unique qualities.
Automotive: Faster, lighter, stronger seems to always be on the minds of motor enthusiasts, and hydroformed parts fit into this category perfectly. One of the most recognized uses for hydroforming, components made for vehicles gain durability from eliminating weak points made by traditional shaping and welding techniques. From retrofitting late-model cars to creating tech-forward alternative fuel vehicles, you can find an application for hydroforming.
Plumbing: Because the unique array of shapes able to be produced by hydroforming, not only is it excellent for creating strong and dependable fittings for under the sink, but hydroformed faucets and fixtures are gaining emerging acceptance as well. Limitless arrangements are possible, giving designers unprecidented freedom to create new and beautiful products.
At American Hydroformers, we offer complete assembly level fabrication of automotive structures, as well as industrial laser cutting and stencil work in addition to our quality hydroformed and tube hydroformed products. Contact us to see how we can improve your products today!