hydroforming presented by: byron erath duane ellsworth
Post on 15-Jan-2016
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TRANSCRIPT
HYDROFORMINGHYDROFORMING
Presented by:
Byron Erath
Duane Ellsworth
OUTLINE:OUTLINE:
What is Hydroforming How and where is Hydroforming used Materials used in Hydroforming processes Design Considerations Advantages/Disadvantages Economics of Hydroforming Websites and Links Conclusion
HYDROFORMINGHYDROFORMING
Hydroforming uses the force of water or hydraulic fluids to shape a single part.
There are two types of hydroforming:
1. Tube hydroforming
2. Sheet hydroforming
TUBE HYDROFORMINGTUBE HYDROFORMING
Used when a complex shape is needed
A section of cold-rolled steel tubing is placed in a closed die set
A pressurized fluid is introduced
into the ends of the tube
The tube is reshaped to the confine of the cavity
Outer tool part
Tube
Inner tool part
Section A - A
Upper tool partnot shown
SHEET HYDROFORMINGSHEET HYDROFORMING
2 METHODS:
Sheet steel is forced into a female cavity by water under pressure from a pump or by press action
Sheet steel is deformed by a male punch, which acts against the fluid under pressure.
Note: Sheet hydroforming provides a work-hardening effect as the steel is forced against the
blanks through fluid pressure.
APPLICATIONSAPPLICATIONS
Automotive industry
Sanitary use
Aerospace– Lighter, stiffer parts
Chevy SSR Frame
APPLICATIONS (CONT)APPLICATIONS (CONT)
1. Body shell
2. Driving shaft
3. Assembled camshaft
4. Exhaust systems
5. Engine cooling system
6. Radiator frame
7. Safety requirements
8. Engine bearer
9. Integral member
10. Cross member
11. Frame structure parts
12. Axle elements
MATERIALSMATERIALS
Steel (mild and harder steels)Stainless SteelAluminum alloysResearch continues to expand the
capabilities of the hydroforming process
DESIGN CONSIDERATIONSDESIGN CONSIDERATIONS
Hydroforming is generally defined as either low-pressure or high pressure.
The demarcation point is 83MPa Constant pressure volumetric expansion
< 5% required to shape the part = Low pressure
> 5% (but < 25%) = High Pressure
DESIGN CONSIDERATIONSDESIGN CONSIDERATIONS Product- Geometry, thickness
distribution
- Dimensional accuracy/tolerances
- Surface finish
- Microstructure, mechanical and metallurgical
properties, hardness
Tool/Dies
-Geometry of tools
- Material hardness
- Surface conditions
- Stiffness and accuracy
Equipment
- Press capacity
- Speed/production rate
- Force/energy capabilities
- Rigidity and accuracy
Work piece/Material
-Flow stress as a function of strain, strain rate and microstructure
-Workability as a function of strain, strain rate and microstructure
- Surface conditions
- Geometry of tubing ( outside diameter, tube wall thickness, roundness, properties of welding line, etc.)
Deformation zone - Deformation mechanics, model used for analysis - Metal flow, velocities, strain rates, strains (kinematics)
- Stresses (variation during
deformation)
ADVANTAGESADVANTAGES
Hydroforming draws material into the mold Part consolidation Weight reduction through more efficient
section design and tailoring of the wall thickness
Improved structural strength and stiffness Lower tooling cost due to fewer parts Fewer secondary operations (no welding of
sections required and holes may be punched during hydroforming)
Tight dimensional tolerances and low spring back
Reduced scrap
ADVANTAGES (CONT.)ADVANTAGES (CONT.) Results compared to conventional steel body structure:
50% less weight 45% less parts (less tools, less assembly) 45% less welding seams Tighter tolerances
Volvo Hydroformed Structure concept in Aluminum, (Schuler Hydroforming 1998)
DISADVANTAGESDISADVANTAGES
Slow cycle time
Expensive equipment and lack of extensive knowledge base for process and tool design
Requires new welding techniques for assembly.
ECONOMICSECONOMICS
INFORMATION ON THE WEBINFORMATION ON THE WEB
www.hydroforming.net www.vari-form.com www.hdt-gti.com www.revindustries.com www.autosteel.org www.schuler-hydroforming.de www.egr.msu.edu/~aenader nsmwww.eng.ohio-state.edu/html/tube_hydroforming.html
CONCLUSIONCONCLUSION
Hydroforming is an innovative forming process
Hydroforming is becoming more popular (ie.automotive and aerospace industries)
The advantages outweigh the limitations
Material selection is broad and continues to increase
Information can be found everywhere!
QUESTIONS???QUESTIONS???