1

ADVANCES IN HYDROFORMING
TABLE OF CONTENTS
SeminarsTopics.com
LIST OF FIGURES
Fig.1 Hydro formed handle bar ..4
Fig.2 Hydro formed T-junction ............4
Fig.3 Sheet hydro forming 5
Fig.4 Tube hydro forming ............
Fig.5 Stre!!e! in Hydoformed com"onent ..#
Fig. $enefit! of Hydroforming .....11
Fig.# Forming %imit &iagram ....12
Fig.' Schematic &iagram of Tube Hydro forming ( )roce!! *ontrol 14
Fig.+ ,""lication! of Hydroforming .15
Fig.1- )art made u!ing .ariform )roce!! .1+
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ADVANCES IN HYDROFORMING
Fig.11 Setu" for Hammering ..21
Fig.12 Hammering *ycle .22
Fig.13 )art made by Hammering ....24
Fig.14 *on/entional 0ethod of Hydroforming ....2
Fig.15 )re-)re!!uri1ing 0ethod of Hydroforming ....2#
1. INTRODUCTION
Hydro forming i! a high-"re!!ure deformation "roce!! that !ha"e!
metal !heet! or tube! into a "redefined geometry by u!ing a fluid under
high "re!!ure. Hydro forming i! !imilar to the con/entional dee"-
dra2ing techni3ue 2ith a counter-mould. The !"ecific difference from
the con/entional method i! that a fluid i! u!ed in!tead of a die to forming
into final !ha"e. Thi! deformation "roce!! re3uire! a""lication of fluid
"re!!ure! u" to 4--- bar! de"ending on the !i1e of the com"onent.
,! the automobile indu!try !tri/e! to ma4e car lighter5 !tronger
and more fuel efficient5 it 2ill continue to dri/e hydro forming
a""lication!. Some automobile "art! !uch a! !tructural cha!!i!5
in!trument "anel beam5 engine cradle! and radiator clo!ure! are
becoming !tandard hydro formed "art!.
6ecently hydro forming 2a! u!ed for manufacturing of clad "i"e
u!ed in oil and chemical indu!try. The ca"ability of hydro forming can
be more fully u!ed to create com"licated "art!. 7!ing a !ingle hydro
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ADVANCES IN HYDROFORMING
formed item to re"lace !e/eral indi/idual "art! eliminate 2elding5 hole!5
"unching etc... Hydro forming !im"lifie! a!!embly and reduce in/entory.
The "roce!! i! 3uite !im"le - a blan4 2ith a clo!ed-form5 !uch a! a
cylinder5 i! internally "re!!uri1ed u!ing fluid. The fluid i! fre3uently
2ater. The a""lied "re!!ure i! u!ually in the range '--45- 0)a. 8t!
re!ultant "la!tic e9"an!ion i! confined in a die of the de!ired !ha"e.
2. HYDROFORMING
Hydroforming i! a co!t-effecti/e 2ay of !ha"ing malleable metal!
!uch a! aluminum or bra!! into !tructurally !tiff and !trong "iece!. :ne
of the large!t a""lication! of hydro forming i! the automoti/e indu!try5
2hich ma4e! u!e of the com"le9 !ha"e! "o!!ible by hydro forming to
"roduce !tronger5 lighter5 and more rigid body !tructure! for /ehicle!.
Thi! techni3ue i! "articularly "o"ular 2ith the high-end !"ort!
car indu!try and i! al!o fre3uently em"loyed in the !ha"ing of aluminum
tube! for bicycle frame!.
Hydro forming allo2! com"le9 !ha"e! 2ith conca/itie! to be
formed5 2hich 2ould be difficult !tandard !olid die !tam"ing. Hydro
formed "art! can often be made 2ith a higher !tiffne!! to 2eight ratio and
at a lo2er "er unit co!t.
Thi! "roce!! i! ba!ed on the 1+5-! "atent for hydra molding by Fred
%euthe!!er. 8t 2a! originally u!ed in "roducing 4itchen !"out!. Thi! 2a!
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ADVANCES IN HYDROFORMING
done becau!e in addition to the !trengthening of the metal5 hydramolding
al!o "roduced le!! ;grainy; "art!5 allo2ing for ea!ier metal fini!hing.

Fig 1 Hydro formed handle bar Fig 2 Hydro formed T-junction
3. CLASSIFICATION OF HYDOFORMING TECHNIQUES
Hydroforming i! broadly cla!!ified into !heet and tube hydroforming.
Sheet hydroforming i! further cla!!ified into !heet hydroforming 2ith a
"unch <SHF-)= and !heet hydroforming 2ith a die <SHF-&=5 de"ending
on 2hether a male <"unch= or a female <die= tool 2ill be u!ed to form the
"art. SHF-& i! further cla!!ified into hydroforming of !ingle blan4! and
double blan4!5 de"ending on the number of blan4! being u!ed in the
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ADVANCES IN HYDROFORMING
forming "roce!!
Fig.3 Sheet hydro forming <Source> ?@=
5

ADVANCES IN HYDROFORMING
8n tube hydroforming tube i! loaded into hydoroforming die! and
the "re!! clo!e!. The !ealing rod engage! the "art !ealing the end! and
fill! the tube 2ith 2ater. )re!!ure in!ide the tube increa!e!5 no2 the
!ealing rod i! "u!he! the tube into the die and the internal "re!!ure i!
ram"ed to ma9imum /alue. The hydroformed tube ta4e! the !ha"e of the
mould. Final "art i! remo/ed from the mould.
Fig.4 Tube hydro forming <Source> ?@=

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ADVANCES IN HYDROFORMING
4. BENEFITS OF HYDRO FORMING
4.1 Better degree ! de!r"#t$% ! t&e !r"ed '#rt
$y a""lying a uniform force to the metal !heet5 the fluid !ha"e! it
into the form of the tool. 8n thi! "roce!!5 a uniform di!tribution of !heet
thic4ne!!e! i! achie/ed5 2hich allo2! for ma9imum degree! of
deformation. ,bru"t change! in !tre!! are a/oided A a factor that en!ure!
high dimen!ional accuracy and reduce! the tendency of the material to
return to it! original !i1e and !ha"e 2hen the a""lied load i! remo/ed.
C%(e%t$%#) dee'*dr#+$%g H,dr!r"ed +$t& t&e FB2-
!trong local thinning of the
material
inhomogeneou! di!tribution of
material thic4ne!!e!
le!! internal !tre!! of the formed
"art
le!! internal !tre!! and le!! tendency
to return to it! original !ha"e
homogeneou! !trength and le!!
amount of 2a!te
high dimen!ional accuracy
Fig.5 Stre!!e! in Hydoformed com"onent
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ADVANCES IN HYDROFORMING
4.2 Gd S.r!#/e F$%$0&
Since the metal !heet i! deformed u!ing a "re!!uri1ed fluid in!tead of
a con/entional dee"-dra2ing die5 the !urface i! not in direct contact 2ith
any tool that may lead to !urface damage. 8n the hydroforming "roce!!5 the
metal !heet only come! into contact 2ith the tool 2hen the ma9imum
re3uired forming "re!!ure i! reached. Thi! re!ult! in e9cellent !urface
fini!h of the formed "art!.
4.3 U0e ! V#r$.0 E%g$%eer$%g M#ter$#)0
The hydroforming "roce!! allo2! you to u!e the com"lete !"ectrum
of all ductile and malleable material!. Bo matter if you are u!ing 0tee)
0&eet01 0t#$%)e00 0tee)1 !"ecial alloy!5 aluminum5 co""er5 bra!! or titan> for
all of them5 o"timum degree! of deformation can be achie/ed. 0etal !heet
thic4ne!!e! range from -.-5 to mm. S"ecifically for /ery thin metal
!heet!5 the "o!!ibilitie! of hydroforming are far !u"erior to tho!e of
con/entional forming techni3ue!
4.4 S#($%g0 $% t)$%g /0t0 .' t 234
%o2 tooling co!t! are a great ad/antage of the hydroforming "roce!!
u!ing the Form $alancer. Tooling co!t! are reduced to 5-C by the fact
alone that only the negati/e molding tool i! needed. Further !a/ing! are
generated by no longer needing hold-do2n de/ice! and guide 2ay !y!tem!.
&ue to the "o!!ibilitie! of forming com"le9 geometrie! 2ith only one tool5
u"!tream machining o"eration! can often be omitted5 2hich in mo!t ca!e!
reduce! tooling co!t! to only 2-C com"ared to tho!e of con/entional dee"-
dra2ing tool!.
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ADVANCES IN HYDROFORMING
4.- Red./t$% $% +e$g&t
,utoma4er! continuou!ly !tri/e to reduce motor /ehicle ma!!5
mainly for efficiency and en/ironmental rea!on! !uch a! im"ro/ing fuel
efficiency and reducing emi!!ion!. Ho2e/er5 a! they reduce /ehicle
2eight5 they mu!t try to a/oid com"romi!ing other im"ortant criteria5 !uch
a! !trength and energy management. They loo4 for technologie!5
techni3ue!5 and "roce!!e! that !ati!fy the!e /ariou! need!5 to 2hich
hydroforming i! the an!2er. ,l!o the "roce!! and functional characteri!tic!
need to be maintained. 8f a de!ign engineer change! a "art5 he ha! to thin4
about ho2 2ill the manufacturing engineer! ma4e the ne2 "artD Ho2 2ill
the line 2or4er! join the /ariou! "art! to ma4e a!!emblie!D Ehen fini!hed5
2ill e/erything 2or4 a! intendedD ,n!2er! to all thi! 3ue!tion! in
Hydroforming.
H,d!r"ed (er0.0 St#"'ed C"'%e%t0
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ADVANCES IN HYDROFORMING
0uch of a /ehicleF! 2eight i! in the !tructural frame5 and mo!t frame! are
made from !teel. The e9ce"tion i! aluminum52hich i! u!ed in !ome
automobile!.
C%/e't
M#00
56g7
8e)d Le%gt&
5""7
9er!r"#%/e Fre:A!t
L#d$%g
Stam"ed 23.- 45+15
6ed !cale !et to 1.- 9
material !trength
Hydroformed 2-.+ 35+#5
6ed !cale !et to 1.- 9
material !trength
*hange -2.1 -+4-
*om"ared to a traditional !tam"ed automoti/e "art5 a !imilar
tubular com"onent ha! le!! ma!! and re3uire! le!! 2elding. 8n thi!
ca!e5 the reduction! 2ere more than + "ercent ma!! and 1+
"ercent in 2eld length.
4.; Ne#r), .%)$"$ted +#)) T&$/6%e00 (#r$#t$%0
1-
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ADVANCES IN HYDROFORMING
The 2all thic4ne!! can be adju!ted any2here along the "art bet2een
!ome "redetermined minimum and ma9imum thic4ne!!5 allo2ing a nearly
infinite combination of thic4ne!! 1one!. Thi! le/el of de!ign freedom
enable! de!ign engineer! to fine-tune the "art to achie/e a de!ired load
re!"on!e. .ariable-2all technology i! not limited to round cro!! !ection!G
it can be u!ed to manufacture mo!t !ymmetric !ha"e! 2ithout any
"o!tforming o"eration!. Heat treatment add! e/en more /er!atility to the!e
!tructure!5 im"arting "ro"ertie! that range from tho!e of !tri" to fully cold-
2or4ed !teel. Finally5 it can be beneficial in many nonautomoti/e
a""lication! a! 2ell.
Fig. $enefit! of Hydroforming
-. FORMING LIMIT DIAGRAM
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ADVANCES IN HYDROFORMING
&uring hydro forming "roce!! failure occur! due to thinning5 thi!
i! due to the e9ce!!i/e deformation in a gi/en region. , 3uic4 and
economical analy!i! of deformation in a forged "art i! analy1ed from
forming limit diagram. The !heet i! deformed5 con/erting circle! in to
elli"!e5 and the di!torted "attern i! then mea!ured and e/aluated.
6egion! 2here the area ha! e9"anded are location! of !heet thinning
6egion! 2here area ha! contracted ha/e undergone !heet thic4ening.
7!ing the elli"!e on the deformed grid5 the major <Strain! in the
direction of larger radiu!= and a!!ociated minor !train! <Strain!
"er"endicular to the major= can be determined for /ariety of location!
and /alue! can be "lotted on the forming limit diagram. 8f both major
and minor !train! are "o!iti/e deformation i! 4no2n a! !tretching5 and
thinning 2ill "o!!ible.
Fig.# Forming %imit &iagram
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ADVANCES IN HYDROFORMING
;. HYDROFORMING 9ROCESS CONTROL
, ty"ical hydro forming !y!tem 2ould include a "re!! ca"able of
de/elo"ing nece!!ary force! to clam" the die /al/e! together 2hen
internal "re!!ure act! on fluidH a high "re!!ure 2ater !y!tem to inten!ify
2ater "re!!ure for forming com"onent5 loo4ing including aerial cylinder
and "unche!5 de"ending on com"onent and a control !y!tem for "roce!!
monitoring.
Since the entire "roce!! of o"eration ta4e! "lace in!ide a clo!ed
die5 one cannot !ee 2hat actually ha""en! during forming. Therefore the
controller "lay! a /ital role in di!"laying5 monitoring and controlling the
different "arameter!.
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ADVANCES IN HYDROFORMING
Fig.' Schematic &iagram of Tube Hydro forming and )roce!! *ontrol
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ADVANCES IN HYDROFORMING
<. A99LICATIONS
,lmo!t any indu!try can benefit from the ad/antage! of the
hydroforming "roce!!. ,gain and again com"anie! are faced 2ith the
challenge of !imultaneou!ly achie/ing both lo2er o"erating co!t! and
inno/ati/e !olution! for e/olutionary ad/ance! of their "roduct!. :ur high-
"re!!ure forming technology offer! attracti/e "o!!ibilitie! in term! of "rice-
"erformance ratio and manufacturing time. Hydroforming find! it!
a""lication in follo2ing indu!trie!>
,utomoti/e indu!try
,ero!"ace indu!try
0edicine technology
Ilectronic a""liance!
Heating ( air conditioning
,griculture indu!try

<a= <b= <c=
Fig.+ ,""lication! of Hydroforming
15
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ADVANCES IN HYDROFORMING
2. ADVANCES IN HYDROFORMING
8n recent year! hydroforming ha! become a commonly u!ed method
of tube e9"an!ion for many a""lication!5 !uch a! automoti/e cha!!i!
frame!5 e9hau!t manifold "i"ing connector!5 and air-conditioning !y!tem
com"onent!. $ecau!e hydroforming u!e! 2ater under high "re!!ure to
e9"and the tube or "i"e from the in!ide5 and 2ater can ta4e any !ha"e5 itJ!
a /er!atile "roce!! and i! !uitable for forming com"le95 !ingle-"iece
com"onent!.
&uring the la!t decade5 indu!try ha! !een da2n of hydroforming a!
an alternati/e for !tam"ing and /ariou! forming the rea!on for thi! are it!
ad/antage! and the un"recedented re!earch 2or4 done in im"ro/ing the
techni3ue! of hydroforming. Some of the ne2 techni3ue! are>
.ariform "roce!! or )re!!ure !e3uencing
Hammering
)re-)re!!uri1ing
0anufacturing of *lad )i"e!
1
1#
ADVANCES IN HYDROFORMING
2.1 V#r$!r" 'r/e00 r 9re00.re Se=.e%/$%g
)re!!ure Se3uence Hydroforming <)SH= i! a "atented tube
hydroforming "roce!! that utili1e! lo2 internal fluid "re!!ure to !u""ort the
tube 2hile the die clo!e!. :nce clo!ed the majority of the "art "rofile ha!
been formed. ,t thi! "oint the internal "re!!ure i! increa!ed to loc4 in the
form and "ro/ide bac4u" for "unching hole!.
Hole !i1e can range from a! !mall a! 2 time! material thic4ne!! to a!
large a! 5- mm K 2-- mm. Hole! can be e9truded or clean "ierced5 and
"ractically any !ha"e including round5 !lot5 !3uare5 he9agon5 or
rectangular. The re!ulting material !lug i! ty"ically "u!hed bac4 out of the
2ay and left attached in!ide the tube5 though there are techni3ue! a/ailable
to remo/e them 2hen re3uired.
)re!!ure Se3uence Hydroforming <)SH= i! com"atible 2ith mo!t
metal!5 if it can be made into a tube )SH can form it. The "roce!! that
normally e!tabli!he! the re3uired material elongation i! the "rebending
o"eration. )SH ha! "ro/en "roce!! com"atibility 2ith High Strength !teel
u" to +- 0)a 7TS5 &ual )ha!e5 and T68) !teel!. 8n addition to carbon
!teel the )SH "roce!! ha! been u!ed to form both 5--- and --- !erie!
aluminum5 and numerou! grade! of !tainle!! !teel.
1#
1'
ADVANCES IN HYDROFORMING
)re!!ure Se3uence Hydroforming <)SH= re!ha"e! the tube cro!!
!ection into the re3uired "rofile 2ithout !tretching the material. The tube
material thic4ne!! di!tribution found after hydroforming i! the !ame a! that
"re!ent in the bent tube. )re!!ure Se3uence Hydroforming <)SH= re!ha"e!
the tube 2hile the die clo!e!. :nce the die i! com"letely clo!ed the tube
ha! been forced to ta4e the !ha"e of the die ca/ity 2ithout re3uiring the
material to e9"and. High )re!!ure Hydroforming fir!t clo!e! the die on an
under!i1ed tube and then utili1e! high internal fluid "re!!ure to e9"and the
tube to fill the die ca/ity. The "art to "art or floor to floor cycle time for
)re!!ure Se3uence Hydroforming i! in the range of 1# !econd! for a !mall
"art !uch a! an 8n!trument )anel $eam to 24 !econd! for a large "art !uch
a! a roof rail or !tructural member.
The )re!!ure Se3uence Hydroform <)SH= "roce!! u!e! a com"letely
different mechani!m than H)H to form the corner!. 8n the )SH "roce!!5 the
tool !to"! before it i! com"letely clo!ed on the tube5 thi! i! referred to a!
the "refill height. The tool d2ell! at thi! "oint a! the tube i! then filled 2ith
fluid and lightly "re!!uri1ed. The die i! then fully clo!ed 2hile the tube i!
!u""orted by the "re"re!!ure. 7!ing thi! !u""ort )SH form! the cro!!
!ection corner! 2hile the die i! clo!ing under "re"re!!ure.
)re!!ure Se3uence Hydroforming i! a dimen!ionally !table and
robu!t "roce!!. )roduct feature! that are "roduced in the hydroform tool are
ty"ically /ery !table a! the entire "art "rofile and all "iercing i! com"leted
in a !ingle ca/ity.
1'
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ADVANCES IN HYDROFORMING
Se3uencing the "re!!ure "re/ent! "inching the material in the die. ,!
"art com"le9ity continue! to increa!e5 in order to minimi1e "art5 containing
the tubular blan4 in!ide the die ca/ity become! more difficult. ,n
im"ro"erly contained blan4 can ea!ily become "inched bet2een the die
hal/e!5 leading to an im"ro"er fill and "erha"! ru"ture. 8t al!o eliminate!
the need for "o!thydroforming "roce!!e! !uch a! annealing and 2a!hing.
7!ing the )SH "roce!!5 tube corner radii are formed in the bending mode
beyond the yield limit of the ba!e material5 rather than in the ten!ile mode
reached during con/entional high-"re!!ure hydroforming.
Fig.1- )art made u!ing .ariform )roce!!
1+
2-
ADVANCES IN HYDROFORMING
2.2 H#""er$%g
Hammering u!e! t2o alternating "re!!ure!. 8t reduce! the drag force5
2hich i! the friction that de/elo"! bet2een the 2or4 "iece and the die. ,!
the internal "re!!ure increa!e!5 the 2or4 e9"an!ion force increa!e! the drag
force5 or friction5 bet2een the 2or4 "iece and the die. ,l!o5 the internal
"re!!ure become! a force that "u!he! bac4 again!t the hydraulic !y!tem.
The combination of 2or4 e9"an!ion force and internal "re!!ure i! the
reaction force.
,! the reaction force increa!e!5 it become! difficult to force the
material to flo2 into all of the contour! and rece!!e! of the die. The
hammering method cycle! bet2een a high and lo2 "re!!ure. The re"eated
"re!!ure dro"! reduce the drag force5 allo2ing the material to flo2 further
in the die. 8t al!o "re/ent! thinning at the e9"an!ion area! and im"ro/e! the
"roce!! ca"ability.
The hammering "roce!! i! dri/en by a "um" that /arie! the "re!!ure
it de/elo"!5 !uch a! a direct dri/e /olume <&&.= control "um"5 a high-
"re!!ure generator that u!e! a hydraulic !er/o "um". The &&. i! a hybrid
of an ,* !er/omotor and re/er!ible-"i!ton "um". The "ul!ation! are
generated by controlling the for2ard and re/er!e rotation of the ,*
!er/omotor at high !"eed.
2-
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ADVANCES IN HYDROFORMING
The time from !tart-u" time to !hutdo2n time <including hold time=
i! one cycle. The fre3uency i! the number of cycle! that ela"!e in one
!econd and i! mea!ured in hert1 <H1=. 6e!ult! from hydroforming trial!
ha/e !ho2n that the o"timal hammering fre3uency range i! bet2een 1 and
3 H1. Fre3uencie! higher than 3 H1 ma4e it "hy!ically im"o!!ible for the
"re!!ure to reach the intended high and lo2 "oint!.
8n other 2ord!5 re/er!ing the "re!!ure more than 3 time! "er !econd
doe!nJt gi/e the hydraulic !y!tem enough time to achie/e the "rogrammed
"re!!ure!. The o"timal "re!!ure range i! bet2een #25 and 4535- "ound! "er
!3uare inch <)S8=5 or 5 to 3- 0)a.
Fig.11 Setu" for Hammering <Source> ?#@=
21
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ADVANCES IN HYDROFORMING
,bo/e figure !ho2! the actual !etu" u!ed for Hammering. The
com"lete !y!tem u!e! three &&. "um"!. :ne generate! the "ul!ating
"re!!ure that form! the tubeH the other! are multi"ur"o!e "um"! u!ed to
rai!e and lo2er the "re!!J! u""er die at high !"eed. Ehen the u""er die i!
com"letely clo!ed5 the &&. !eal! and "re!!e! in both end! of the tube
2or4 "iece. The &&.J! ,* !er/omotor i! regulated by a *B*. Thi!
control! the hammering fre3uency and "re!!ure increa!e rate.
The "ul!e fre3uency and "re!!ure on the !econdary !ide i! controlled
by the re/er!ible ,* !er/omotor of the &&. "um" and "ul!ing the
"rimary !ide of the oil and 2ater boo!ting cylinder at a ratio of 1-to-1-.
The !ha"e that can be formed in one cycle of tube e9"an!ion i! determined
by the ma9imum 2ater ca"acity in the high-"re!!ure cylinder.
Fig.12 Hammering *ycle
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ADVANCES IN HYDROFORMING
The Hammering method cycle! bet2een a high and lo2 "re!!ure5 !o
Hammering ha! more /ariable! than in con/entional hydroforming. 8n!tead
of one "re!!ure5 hammering u!e! t2o alternating "re!!ure!. ,l!o5 in thi!
ca!e5 the la!t t2o cycle! a! can be !een in abo/e figure ha/e a brief hold
time of -.2 !econd at the "oint! of minimum and ma9imum "re!!ure.
Hammering allo2! the u!er to /ary the difference bet2een the high and
lo2 "re!!ure <1-0)a in thi! ca!e=5 the cycle time and al!o the hold time.
The t2o main "roblem! faced 2hile forming are ru"turing and
buc4ling. 6u"turing i! u!ually the re!ult of !etting the internal "re!!ure too
high or the e9"an!ion force too lo2. Thi! cau!e! the material to !tretch and
become too thin in the e9"an!ion area5 ultimately cau!ing a ru"ture. Thi! i!
2hy it i! critical to balance the internal "re!!ure and initial e9"an!ion
force. 7!ing an initial "re!!ure that i! too high al!o can cau!e the "i"e to
e9"and too 3uic4ly5 cau!ing the material at the a9i! !ealing area to "ull
a2ay. Thi!5 in turn5 cau!e! the fluid to lea45 !o the "re!!ure doe! not ri!e to
the !et /alue and the "roce!!ing canJt !tart.
$uc4ling u!ually i! cau!ed by !etting the internal "re!!ure too lo2 or
the e9"an!ion force too high. 7!ing a "roce!!ing time that i! too fa!t al!o
may contribute to buc4ling.
Hammering eliminate! the!e "roblem! a! it u!e! t2o alternating
"re!!ure! 2hich balance! initial "re!!ure ( e9"an!ion force. ,! 2e can !ee
the "art made by con/entional hydroforming "roce!! !ho2n in the diagram
belo2 i! ru"tured5 2herea! the "art at the bottom made by Hammering did
not get ru"tured.
23
24
ADVANCES IN HYDROFORMING
Fig.13 )art made by Hammering
2.3 9re*'re00.r$>$%g
24
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ADVANCES IN HYDROFORMING
8n "re-"re!!uri1ing method a metal tube i! "laced in lo2er mold
2ith the end! !tic4ing out from it and inject! a "re!!uri1ing fluid into the
metal tube through the in!ide of a !eal "unch and gradually "re!!e! the
!eal "unche! again!t the tube end!5 in the !tate 2ith internal "re!!ure and
"re!!ing force a""lied the u""er mold i! lo2ered !o a! to deform the
tube and end the "roce!!ing 2ith the tube end! !tic4ing out from the
mold and further boo!ting the internal "re!!ure in metal tube after
clo!ing the mold and ending the forming o"eration and a hydroformed
"roduct ha/ing a flange acro!! the entire length in longitudinal !ection i!
formed.
,! !ho2n in Fig.14 the con/entional hydroforming method relate!
to "lacing a metal tube !horter in length than the mold in a mold !o that
the tube end! of the metal tube are "o!itioned in!ide the end face! of
mold5 then u""er mold i! lo2ered to clo!e the mold and clam" the tube
bet2een u""er and lo2er mold!. ,fter that !eal "unche! ad/ance and
2ater i! in!erted a! a "re!!uri1ing fluid from one of the !eal!5 the
"re!!ure in!ide the tube i! rai!ed to obtain "redetermined !ha"e.
8n thi! ne2 techni3ue of "re-"re!!uri1ation a metal tube i! "laced
in the lo2er mold 2ith it! tube end! !tic4ing out of the mold5 injecting
"re!!uri1ed fluid into the metal tube through an in!ide of a !eal "unch
2hile "re!!ing !eal "unche! again!t the tube end!5 filling the in!ide of
metal tube 2ith a "re!!uri1ed fluid to a""ly internal "re!!ure5 then the
u""er mold i! lo2ered !o a! to clo!e the mold5 deforming the tube to the
"redetermined !ha"e 2ith the tube end! !tic4ing out of the mold. The
"roce!! i! !ho2n in Fig.15.
25
2
ADVANCES IN HYDROFORMING
Fig.14 *on/entional 0ethod of Hydroforming
2
2#
ADVANCES IN HYDROFORMING
Fig.15 )re-)re!!uri1ing 0ethod of Hydroforming <Source> ?3@=
2#
2'
ADVANCES IN HYDROFORMING
2.4 M#%.!#/t.r$%g ! C)#d '$'e0
The energy !ector i! hot right no25 and !o i! "i"e "roduction. )i"e
for tran!"orting crude oil and crude ga! mu!t meet !e/eral criteria. The
material mu!t ha/e !ufficient durability5 corro!ion re!i!tance5 and
!trength5 and the !i1e mu!t be large enough to tran!"ort the de!ired
/olume. *orro!ion re!i!tance i! nece!!ary to "re/ent ero!ion damage
from "ollutant! in the oil or ga!5 2hich include hydrogen !ulfide5
chloride!5 and 2ater. Finding the o"timum material for ma4ing "i"e for
thi! indu!try i! tric4y. %o2-alloy carbon !teel! tend to be !trong5 but lac4
corro!ion re!i!tance. Stainle!! !teel! re!i!t corro!ion but lac4 !trength.
*ladding lo2-alloy carbon !teel 2ith a thin layer of a corro!ion-re!i!tant
alloy i! a !uitable "roce!!.
,n alternati/e i! to "roduce clad "i"e that ma4e! the be!t u!e of
corro!ion-re!i!tant alloy! and lo2-alloy !teel!. Such "i"e ty"ically i!
made from !trong5 lo2-alloy carbon !teel and lined 2ith a !lee/e made
from a corro!ion-re!i!tant material a""ro9imately -.1+ inch thic4. The
!im"le!t mechanically clad "i"e con!i!t! of a corro!ion-re!i!tant liner
in!erted into a lo2-alloy e9ternal carbon !teel "i"e. , more !o"hi!ticated
mechanically clad "i"e i! "roduced by !hrin4ing the e9ternal "i"e or
rolling one "i"e in!ide the other. The nature of the mechanical bond
de"end! on the "roce!!. 6egardle!! of the method5 the bond i! "urely
mechanical. The t2o di!tinct material! remain t2o di!tinct material!
they do not fu!e together to become a !ingle ma!! a! metallurgically
bonded "i"e! do.
2'
2+
ADVANCES IN HYDROFORMING
, "roce!! 2a! de/i!ed 2hich u!ed hydraulic "re!!ure on the inner
"i"e and induction heating on the outer "i"e. The hydraulic "re!!ure cau!ed
the inner "i"e to e9"andH remo/ing the heat cau!ed the outer "i"e to !hrin4
a! it cooled.
, modern im"ro/ement to thi! "roce!! u!e! a hydraulic "i"e
calibration and lining machine e3ui""ed 2ith an additional 2ater !y!tem a!
2ell a! !o"hi!ticated control!. 8t u!e! a "roce!! !imilar to automoti/e "art!
hydroforming machine! to attain a high degree of com"re!!i/e contact
bet2een the t2o "i"e!. The corro!ion-re!i!tant "i"e i! in!erted into the
outer lo2-alloy carbon !teel "i"e in a !emi automated o"eration and i! then
"laced into the calibration machineF! o"en tool form. The tool clo!e! and
a9ial cylinder! !eal each of the "i"e end!. Hydraulic fluid under high
"re!!ure e9"and! the inner tube. , firm com"re!!i/e contact i! achie/ed by
the ela!tic and "la!tic beha/ior! of the outer "i"e and the inner "i"e. The
ela!tic !"ring bac4 of the outer "i"e i! greater than the "la!tic e9"an!ion of
the inner "i"eH the re!ulting re!idual "re!!ure !tre!! of the inner "i"e i! in
the region of #525- to 1455-- "ound! "er !3uare inch <)S8=.
Thi! "ro/ide! a homogenou! contact along the "i"eF! entire length.
:ne of the chief ad/antage! of u!ing a hydroforming "roce!! to
manufacture mechanically clad "i"e i! !im"le economic!. *om"ared to
"roducing a non-clad or a metallurgically clad "i"e5 manufacturing clad
"i"e 2ith thi! method re"re!ent! a !ignificant co!t reduction. )otential co!t
reduction i! in 2elding5 becau!e clad "i"e ha! thinner 2all! than
homogenou! "i"e5 and !o re3uire! le!! 2elding time. 8n thi! !cenario5 the
clad "i"e! are -.3+ in. thic45 2herea! the homogenou! "i"e i! -.5+ in.
thic45 a 13 "ercent difference.
2+
3-
ADVANCES IN HYDROFORMING
?. CONCLUSION
8n thi! !eminar re"ort recent de/elo"ment! in hydroforming are
di!cu!!ed !y!tematically. ,fter di!cu!!ing the!e 2e conclude that>
1. Hydroforming ha! 2ide a""lication in many indu!trie! li4e
automobile5 aero!"ace5 electronic good!5 !anitary fitting!5 etc.
0any benefit! offered A Lood !urface fini!h5 7!e of almo!t all
ductile and malleable material5 $etter deformation5 High
dimen!ional accuracy5 Sa/ing! u" to '-C in "o!t forming
"roce!!e! <6efer "age '=. $ecau!e of !o many benefit! offered
Hydroforming i! con!idered a! an effecti/e method to meet the
demand! of e/er e/ol/ing manufacturing !ector.
2. &ue to introduction of hydroforming it i! no2 "o!!ible to u!e light
2eight aluminum !tructural frame in!tead of the con/entional
hea/y 2eight !teel frame in automobile!. 6e!ulting in reduction of
2eight by more than + "ercent and 2eld length by 1+C
<6efer "age 1-=.
3-
31
ADVANCES IN HYDROFORMING
3. Hydroforming facilitate! manufacturing of a !ingle large com"le9
com"onent in!tead of many !mall com"onent!5 reducing the
tooling co!t! by 5-C. For e9am"le> o"eration! li4e "iercing can be
done during hydroforming it!elf. There i! no need of fini!hing the
!urface after hydroforming a! hydrofomred com"onent ha! a high
grade of !urface fini!h.
4. :f the abo/e di!cu!!ed recent techni3ue! )re!!ure !e3uencing and
Hammering are the mo!t u!eful method!. 7!ing the!e method! 2e
can hydroform any malleable metal ranging from co""er to high
grade !tainle!! !teel. $y reducing the drag force Hammering
eliminate! the t2o major "roblem! faced in forming namely
ru"turing and buc4ling.
Thu! ado"ting the!e ne2 techni3ue! there i! better utili1ation
of material. The day 2ill not be far a2ay 2hen hydroforming 2ill
com"letely re"lace the con/entional !tam"ing and forming
"roce!!e!.

31
32
ADVANCES IN HYDROFORMING
13. REFERENCES
1= 6e!earch "a"er> M&e/elo"ment! in HydroformingN A S.H.Oang
2= 7.S. )atent 25#135314
3= 7.S. )atent 2-1---1'4#3
4= $oo4> MHydroforming for ad/anced manufacturingN5 $y 05 PoQ5
2--+ Eoodhead )ubli!hing %imited.
5= $oo4> MHydroforming technology> ,d/anced 0aterial! ( )roce!!e!N
<6efereed=> 0ay5 1++#> ,S0 8nternational.
= $oo4> MFundamental! of HydroformingN by Harjinder Singh.
#= htt">RR222.thefabricator.comRtechcellRhydroforming
'= htt">RR222.americanhydroformer!.com
+= htt">RR222.!ciencedirect.com
32