Posts Tagged what is tube hydroforming

Finite Element Analysis strengthens hydroformed parts and customer relationships

Finite Element Analysis strengthens hydroformed parts and customer relationships

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.

What Is Hydroforming: The Basics

What Is Hydroforming: The Basics

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.

Tube Hydroforming vs. Sheet Hydroforming: What is Hydroforming?

Tube Hydroforming vs. Sheet Hydroforming: What is Hydroforming?

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.

What is Hydroforming?

What is Hydroforming?

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.

Improving the World with Hydroforming

Improving the World with Hydroforming

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!

What is Hydroforming and Why Use It?

What is Hydroforming and Why Use It?

When many think about the manufacture of metal parts for cars, bicycles, and such,  they often think of  such processes as solid die stamping,  However, in the late 1940’s and 50’s a new process called hydroforming was developed to form metal parts, especially those with asymmetrical and irregular shapes that are difficult for stamping to form.

What is hydroforming?  Simply put, hydroforming uses a high pressure liquid to force a thin metal sheet or tube into a specialized die mold.  Almost all metals capable of being cold formed can also be hydroformed:  aluminum, brass, steel, stainless steel, and high strength alloys.   There are two types of hydroforming; sheet hydroforming and tube hydroforming.

For sheet hydroforming, a metal blank sheet is placed over the mold.  Then, in one type of sheet hydroforming, the mold is closed by a water filled bladder .Water pressure within the bladder is then increased, forcing the metal into the mold.

For tube hydroforming, a raw tube is placed between two dies.  The ends of the dies are then sealed off and water fills the tube.  The water pressure is increased until the tube takes the form of the mold.

The advantages of this process over traditional stamping are many.  It is ideal for forming complex shapes.  Hydroforming also produces parts that are more lightweight and have a higher stiffness to weight ration than stamped parts. Finally, its costs per unit are lower than stamping.

From hydroforming’s initial use in forming kitchen spouts its use has expanded to other plumbing fixtures, to widespread use in the auto and aircraft industry, to the manufacture of bicycles, and to the forming of the handles of appliances.   Hydroforming has even been used to manufacture the brass tube of the Yamaha saxophone.   It has proven itself to be an increasingly versatile tool.

Contact us if you would like to learn more about hydroforming and how it can meet your needs.

What Is Tube Hydroforming? All you need to know.

What Is Tube Hydroforming? All you need to know.

Whether you are well-informed or brand-new to the subject, here is a primer on the basics of tube hydroforming. Read on to discover more about the process, the materials, the products, and the benefits.

Process

Simply put, hydroforming is the process of shaping ductile metals into desired pieces using either high or low pressure from hydraulic fluid. A hollow tube is placed into a negative mold, and fluid is pumped into the mold until the pressure shapes the material into the desired form. The fluid is removed and the product is finished.

Materials

Tube hydroforming can be done on metals including aluminum, brass, stainless steel, and low alloy steel.

Products

Tube hydroforming is used to make car frames, particularly high-end sports models. Specifially, engine cradles, suspension, radiator supports, and instrument panel beams are manufactured in this manner. Aluminum bicycle frames use this technology. And additionally, the brass tubes of Yamaha saxophones are made with this process.

Benefits

Tube hydroforming is desirable because it results in lightweight and structurally stiff products. The process is also very cost-effective, requiring few tools and minimal maintenance. Tube hydroforming provides an easy process for creating complex shapes, reducing the need for welding operations. Compared to other methods, tube hydroforming leaves a smooth finish and an appealing appearance.

American Hydroformers is based in Fort Wayne, IN, and specializes in the hydroform tube forming process. Whether you work in appliances, automotive, or plumbing fields, we are here to help you! Visit our “What Is Hydroforming” page to learn more about the process we use and see before and after photos.

Contact us today to request a quote and get more information about our services!