What is Hydroforming?
Hydroforming is a metal forming process where complex and structurally sound parts with tight tolerances that can be made from various metals. A water-based fluid force, oil, gas, or a flexible elastic polymer membrane, is highly pressurized up to 10,000 PSi is applied onto a piece of metal, or blank, to change its shape.
How does the hydroforming process work?
The metal blank is placed in the ring inside of the hydroforming machine. The press closes, while lowering the chamber down on top of the blank. The forming chamber utilizes a combination of oil and high pressure while the punch, along with the blank, is raised through the ring and into the forming chamber. The blank is formed over a rubberized die, creating the specified shape once the pressure releases, and the chamber rises back up. Utilizing fluids within the forming process allows the metals to stretch uniformly. This process is ideal for both small and large production runs, making it an efficient option for any time.
The rubberized die and fluid pressure leaves the finished part with no scratches and a nice, smooth surface. This has the potential to eliminate the need of adding a product finish or polish to the finished part, saving time and money. Flaws are easily avoided because of the lack of friction the material faces. During this specific forming process, the material only comes into contact with one other surface, the rubberized die. The fluid is a replacement for the male or female die, similar to that used in a deep draw hydraulic press. This is a significant reduction of tooling costs. Read here for more on the elements affecting metal flow.
Benefits of Hydroforming include
- Tight dimensional tolerances
- Ability to form complex shapes
- Fewer secondary operations
- Efficient processing
- Reduced cost (as opposed to other processes)
- Part reduction from consolidation
- Can handle various sized production runs
- Could be utilized to eliminate weld flanges
- Extremely Durable Parts
- Little tooling cost
Hydroforming is used in many industries including automotive, aerospace, power and medical, defense, and electricity.
Hydroforming is a specialized Deep Drawing process that could also be known as Sheet Hydroforming or Fluid Cell Sheet Hydroforming. Sheet hydroforming allows various materials to become complicated, complex, and structurally sound parts. It allows for asymmetrical or irregular shaped geometries, This process cannot produce shapes with sharp edges or angles, and the shapes are not as deep as Deep Drawn parts.
How to decide whether hydroforming is the right process to use?
There are various metals that can be hydroformed which include aluminum, stainless steel, carbon steel, copper, titanium, brass, or high strength alloys. Hydroforming can form parts into complex shapes with various angles or radii. Unlike metal spinning or deep drawing, hydroforming allows for more versatility when it comes to designing the shape of the final part.