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Tube hydroforming for expanded design options

June 13, 2006 | By Paul Tauzer

Hydroforming has become a favored technology for automotive parts because it allows manufacturers to increase a component's strength, reduce its weight, and reduce the number of parts in an assembly. Another important benefit, one that is often overlooked, is the increase in design freedom this technology allows. Engineers and designers must be aware of the factors that restrict design freedom, such as material characteristics and press limitations, and alternatives such as annealing and axial feeding that help work around these limitations.

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Introduction to Tube Hydroforming

June 13, 2006 | By Gary Morphy

Under the right circumstances, hydroforming can be a viable, cost-effective manufacturing process. Tube hydroforming often produces stronger structural components than can be achieved with more conventional methods. This article explains tube hydroforming, describes its evolution, and discusses the factors that should be considered when deciding whether to use the process.

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A new use for hydraulic presses

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.

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Schuler, HEATform form agreement

April 11, 2006

Schuler Hydroforming GmbH & Co. KG, Wilnsdorf, Germany, and HEATform GmbH, Wiesbaden, Germany, have entered into a strategic agreement concerning cooperation on HEATforming (hot expansion air technology forming).This technology uses inner pressure to form prewarmed hollow shapes. Schuler now offers...

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Processes for hydroforming sheet metal

April 11, 2006

Part three of a three-part series on sheet hydroforming, this article reviews the SHF-P and SHF-D processes.

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The heat is off

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.

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Tube Hydroforming Design Flexibility—Part IX:

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.

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Hydroforming software upgraded

November 8, 2005

AutoForm Engineering GmbH has released its Hydroforming software version 4.0 that provides analysis and simulation of the entire hydroforming process.New features include automatic generation of tooling and process definition for the bending operation before hydroforming. It also includes new...

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Tube Hydroforming Design Flexibility—Part VIII: Dimensional Stability

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.

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Tube Hydroforming Design Flexibility—Part VII: Holes

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.

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Forming advanced metals

December 7, 2004 | By Maarten Kelder, Kevin Edgar

The demand for lightweight components continues to be a primary driver in the automotive industry.

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Tube Hydroforming Design Flexibility—Part VI

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...

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Hydroforming tapered engineered tubes

June 8, 2004 | By Chuck Smith, Taylan Altan, Ph.D., Prashant Soman, Serhat Kaya, Yingyot Aue-u-lan

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.

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Part feature developments in hydroforming products

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.

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Developments in hydroforming

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.

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