Hydroforming

Hydroforming isn't as mysterious as it seems. This technology area is full of articles, including case studies, on hydroforming sheet metal and tubular sections.

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Analyzing tubes, lubes, dies, and friction

October 10, 2002

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Comparing and correlating two tests, a common bench test (twist compression) and a straight-tube corner-fill test, simulate hydroforming to find the coefficient of friction.

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Designing a hydroforming press for research, production

September 12, 2002

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A new type of hydroforming press was recently developed for sheet applications. The new press incorporates data acquisition and control features for research purposes. Current press frame designs for tube and sheet forming are uneconomic for large forces. This press achieves a clamping force of 100 mN, which is absorbed by a single cast frame with a circumferential pretensioning system.

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Tube Hydroforming Design Flexibility—Part I

May 16, 2002

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Design flexibility is something that all automotive designers want, but too often they lack a thorough understanding of what that means—what aspects of design flexibility apply to a certain part and their effect on cost. A methodology often is adopted when (or even before) a part development...

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Predicting failure in hydroforming prevent aluminum tubes: Strain variables require sophisticated analysis

March 14, 2002

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This article discusses an approach to predicting failure in hydroforming prebent aluminum tubes. While strains are well researched for stamping sheet, this type of knowledge is lacking for hydroforming tubular components. Because the strains are different—prebent hydroformed tubular parts experience stress in the axial direction during bending, then in the circumferential direction during hydroforming—new methods for predicting failures are necessary. Researching these methods adds to the knowledge base of hydroforming, helping the technology gain further acceptance in manfacturing.

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Determining flow stress of tubes

March 14, 2002

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This article discusses tests that are used to evaluate flow stress in tube and why the uniaxial test is not suitable for this application. It discusses a bulge test, which stresses the tube biaxially, including tooling, software, and analysis tools for evaluating stresses.

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Hydroforming machine

Hydroforming gains ground in Germany

January 24, 2002

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This article examines hydroforming in Germany, focusing on the advancement of the technology. It specifically discusses growing automotive uses, a new type of hydroforming press, material quality requirements, cost factors, new testing methods, and simulation software.

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How material influences bending for hydroforming

January 10, 2002

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The bending characteristics of a tube depend on the material it is made of. Exceeding the allowable limits of this deformation results in unusable parts. The author relates his company's examination and comparison of the bending of two different seamless, extruded tubes: aluminum alloy and steel.

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Hydroforming provides Rx for medical pumps

January 10, 2002

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This article relates how a Florida-based company used hydroforming to produce titanium housings for implantable pumps for a Massachusetts-based manufacturer.

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Hydroforming Y-shaped stainless steel exhaust components

November 29, 2001

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T-shapes and Y-shapes are the most commonly hydroformed exhaust system components for automobiles. This article reports on the investigation into the metal flow in Y-shape hydroforming by the Engineering Research Center for Net Shape Manufacturing (ERC/NSM) at The Ohio State University, which conducted several experiments using the tooling available at the SPS research center in Aalen, Germany.

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Using hydroforming aluminum components versus steel stampings

November 15, 2001

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This article examines two transitions that are occurring in the automotive industry—the change from stamping to hydroforming, and the substitution of aluminum where steel was used previously.

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Hydroforming a new front automotive structure

October 25, 2001

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Hydroforming the parts in a vehicle structure can be of immense benefit on several counts, as a review of a recent project at the author's company can attest.

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Hydro bulge forming figure 1

Hydroforming with end feeding

August 16, 2001

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The list of applications for hydroforming with end feeding is growing all the time. Maybe you should check into how this technology could benefit your operation.

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Hydroforming on a budget

July 12, 2001

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You can use several strategies for starting a hydroforming operation on a limited budget. Review your alternatives for selecting a press, fluid intensification system, and developing the tooling necessary for your operation before you take the plunge.

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Hydroforming system

Successful tube hydroforming: Watching parameters, accurately simulating the process yield good results

June 15, 2001

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A typical tube hydroforming system is shown in Figure 1. Within this system, a host of factors must be taken into account, from starting tube geometry and material properties to the quality of the final part (such as thickness distribution and dimensional accuracy).

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Hydroforming of tubes, extrusions, and sheet

May 15, 2001

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Recent advances at the University of Stuttgart and acfross the industry have opened doors for hydroforming all kinds of materials and shapes.

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