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Tube Hydroforming: Part One :: Total Materia Article
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Tube Hydroforming: Part One
Tube hydroforming technology has been in existence for more than 30 years; but its use has been mostly limited to simple shapes and low-volume applications.
Te main benefits obtained from tube hydroforming technology include weight reduction due to improved part design, part consolidation where a single component replaces an assembly, reduced tooling cost as a result of part consolidation, and improved structural strength and stiffness of te hydroformed component.
Tube Hydroforming is a well-accepted production technology in te automotive industry while sheet hydroforming is used in selected cases for prototyping and low volume production. Research in advanced methods (warm sheet and tube hydroforming, double blank sheet hydroforming, combination of hydroforming and mechanical sizing, use of multi-point and elastic blank holders) is expanding te capabilities of hydroforming technologies to produce parts from Al and Mg alloys, as well as Ultra High Strength Steels.
In te development of advanced hydroforming methods, experience based knowledge is not readily available. Thus, robust process simulation is required, along with adequate material modeling and identification of friction coefficients as input to process simulation.
Tube hydroforming technology has been in existence for more than 30 years; but its use has been mostly limited to simple shapes and low-volume applications. Te process involves forming a straight or a pre-bent tube into a die cavity using internal hydraulic pressure, which may be coupled with controlled axial feeding of te tube.
Recent advances in forming machines and machine control systems have allowed for te introduction and te implementation of te process to produce several automotive components, which were originally produced by te stamping process. Components such as side rails, engine cradles, space frames, and several other key parts can be economically produced by tube hydroforming.
Te main benefits obtained from tube hydroforming technology include weight reduction due to improved part design, part consolidation where a single component replaces an assembly, reduced tooling cost as a result of part consolidation, and improved structural strength and stiffness of te hydroformed component. However, te drawbacks include incomplete knowledge base of te effects of processing parameters on te final product, expensive tooling requirement, and slower cycle times compared with metal stamping.
Te demand for lighter component solutions remains a primary driver in te automotive industry. Hydroforming is considered as one of te potential enabling technologies to deliver lightweight components. A new generation of hydroforming components; novel applications based on a better understanding of te process and te material application behind te products, designed with manufacture in mind, can deliver cost effective mass reduction in te race for lightweight solutions.
Te new generation of hydroformed components makes use of Advanced Steels and te characteristics of an advanced tubular product, in solutions based on materials, and application based hydroforming knowhow.
Te Tubular Hydroforming Technique
As mentioned above, tubular hydroforming is achieving increasing acceptance in te automotive industry for making a wide variety of components. Current applications include suspension frames, body structure, power-train components and exhaust pipes.
Te major advantages of tubular hydroforming that have initiated these applications are cost reduction and weight savings, improved dimensional stability, improved integrity and increased strength and stiffness of te components. Depending on te part design, pre-bending and pre-forming operations could be essential before te start of te tubular hydroforming process.
In te tubular hydroforming process, a tube is first placed in te closed cavity of a forming die. Once te ends of te tube are sealed, te tube is filled and pressurized with hydraulic fluid. Te internal pressure forces lead te tube to form into te shape of te tool cavity.
Most hydroforming processes also use axial force-feeding at te tube ends to feed material into te tool during forming. With te application of axial force-feeding, higher limits at te end of te part can be achieved.
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Tube Hydroforming: Part Two
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