May 9, 2006 | By Andreas Kinzyk
The use of high-strength steels (HSS) and ultrahigh-strength steels (UHSS) has made stamping complex structural automotive components increasingly difficult and capital-intensive. Changing from traditional stamping (at room temperature on a mechanical press) to hot stamping (at elevated temperatures on a hydraulic press, with a water-cooled die for quenching) provides a suitable alternative for OEMs that produce these challenging parts.
April 11, 2006
Part three of a three-part series on sheet hydroforming, this article reviews the SHF-P and SHF-D processes.
March 7, 2006 | By Tom Driggers
To make a complex heat exchanger shell, a company produces a prototype model using the hydroforming process, analyzing fatigue, thinning, and cycle times to decide if the process will prove to be cost-effective.
February 7, 2006 | By Gary Morphy
In this article Gary Morphy reviews high-pressure and pressure sequence hydroforming and discusses factors to consider when deciding which process is best for a particular application. The decision should be based in part on anticipating future needs.
June 14, 2005 | By Gary Morphy
Whether they are producing automobiles or hydroforming press parts, designers, manufacturers, and assembly personnel are very concerned about dimensional stability. Surfaces and holes must be located in a specified range and smaller is better. Concern escalates as the drive to improve quality and reduce build tolerances and problems increases.
February 8, 2005 | By Gary Morphy
When making holes in hydroformed parts, fabricators have many choices—milling, drilling, laser cutting, plasma cutting, flow drilling, post-piercing, and hydropiercing.
The demand for lightweight components continues to be a primary driver in the automotive industry.
September 14, 2004 | By Gary Morphy
Tube hydroforming reshapes a tube from a normally round cross section to a desired shape. The final shape, usually rectangular, develops along the part length. The cross-sectional periphery may be consistent throughout the part and equal to the original tube, or it can be expanded in localized...
Hydroforming often results in localized thinning. Using engineered tubes—tubes that have a thicker wall where the tube is most prone to thinning—can result in a stronger finished component.
March 25, 2004 | By Gary Morphy
Tube hydroforming technology continues to develop in ways that improve part utility, economy, or process robustness. Auto parts that have recently been produced by hydroforming include roof rails, radiator enclosures, a front-end structural module, and roof rails.
March 25, 2004 | By Dr. Stefan Wagner
Commentary from the people interviewed at the International Conference on Hydroforming (Oct. 2003) indicate that trends include an increasing interest in forming aluminum and other lightweight materials; more use of tailored tubes; and that sheet hydroforming is expected to grow faster than tube hydroforming.
February 26, 2004 | By Gary Morphy
Combined with the information in Part III of this series that focused on cross-section expansion before hydroforming, this article discusses the most common options used in preparing tube for hydroforming and achieving the designer-intended part. Properly executing bending and cross-section...
January 13, 2004 | By Eric Lundin
Hydroforming was one of the fastest-growing metal forming technologies during the 1990s. Most of U.S. industry cooled down during and after the recession of 2001, but things have been heating up lately, and the world of hydroforming is no exception. The North American Hydroforming Conference and Exhibition (Sept. 29 – Oct. 1 in Dayton, Ohio), which was sponsored by the Tube & Pipe Association, International® (TPA), and the Society of Manufacturing Engineers (SME), showcased new techniques, equipment, and applications that are moving the industry forward.
October 23, 2003 | By Gary Morphy
Material selection is a very important aspect of design flexibility when striving to fulfill part functionality requirements. Choosing the correct material is fundamental to making the part effectively and efficiently. The way a material is formed and the conditions it needs to withstand for...
The most common way to establish tube length after hydroforming is by cutting or shearing the tube to a specified dimension; however, cutting out this step can reduce scrap. A new method designed to eliminate this step combines forming the end of a tube to resemble its final form with using a hydroform die to correct end position variations off the bender. While this approach eliminates the final shear trim operation, it also presents new challenges.