Hydroforming, or utilizing the hydro-mechanical-press 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. Hydroforming is a great way to form complex, and custom fabrications.Â
How does the hydroforming process work?Â
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.Â
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 includeÂ
Hydroforming is used in many industries including automotive, aerospace, power and medical, defense, and electricity.Â
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.Â
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.
Deep Draw Metal Stamping for Strength and Efficiency The deep drawing sheet metal forming process is a cold-forming metal fabrication process that is conducted in a room-temperature environment. A metal blank is stretched around a die cavity, eventually conforming to the shape of the plug, shape of the die, and the depth of the draw.
Benefits of Forming Deep Drawn Metal Stamped Parts The deep drawing sheet metal forming process is a cold-forming process performed in an environment at or near room temperature, where the metal is permanently deformed into the desired geometry. In this process, the flat metal blank is formed and stretched around a die cavity with a
What is the Trimming Process and How is it Performed? Trimming is a process used to remove excess material to achieve a desired shape, size, and finish, while removing burrs and smooths out sharp edges. To trim a part, it is put on a lathe and processed by a highly skilled metal spinner, or a
The Metal Finishing and Polishing Process The polishing process is a secondary metal fabrication process that is done to create a smooth and shiny surface by utilizing abrasives or chemical treatment, and can be done by hand or robotic automation. The purpose of adding a finish or polish is to improve the appearance by creating
Metal Fabrication: What is the Beading and Edge Rolling Process? Beading and edge rolling are the metal forming processes of adding a radius, raised edge, or indented ridge along the edge of a piece. This process is done to increase stability and durability of the part, and can also increase its functionality by allowing for
Secondary Metal Fabrication Processes At TMS, our secondary metal forming processes consist of: Beading and Edge Rolling Trimming Welding Metal Finishing and Polishing Each process can be done manually or automated, depending on the part. Beading and Edge Rolling Beading is very similar to edge rolling. During the beading process, a radius is added to
The Benefits of One-piece Constructions At Toledo Metal Spnning Company, we have been forming metals since 1929. With nearly a century of experience, we have mastered a wide range of processes including laser cutting, metal spinning, deep drawing, machining, rolling and seam welding, to build strong and durable high-performance parts. But what truly sets us
Laser Cutting 101 What is laser cutting and how does it work? The laser beam is a heat source which can melt metals rather quickly. When the concentrated beam comes into contact with the material, in this case, metal, the beam’s energy is absorbed into the metal, causing it to melt. However, the laser beam
