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Pryer Technology Group
2230 N. Sheridan
Tulsa, OK 74115
918.740.0111
info@pryertechgroup.com
Benefits of Hydroforming
Low Tooling Costs with Single Tool Technology
Hydroform tooling generally costs 50% less than tooling in traditional presses. This is primarily due to the punch (male die) and blank holder (draw ring) being the only tools needed. The flexible female die is emulated by the rubber diaphragm located in the machine.
Better Process Control
Hydroforming improves part quality, efficiency and reduces rejection
rates. Broken parts, due to applying too much pressure, and wrinkling
(not enough pressure) are easily eliminated with simple pressure adjustment
to the hydraulic chamber.
The flexible female diaphragm applies less forming pressure at the beginning
of the cycle, with incremental pressure increases during the stroke. This
reduces the stress during the critical phase of the process.
Reduced Material Costs
Hydroforming has less than 10% variation in blank to finished part thickness. This feature is due to uniform elongation of the metal. During the cycle, the applied force is multidirectional and the process draws the metal around the punch, which protects and greatly reduces stretching or thinning of the formed areas.
Hydroformers can utilize 40%-50% thinner materials over traditional methods, due to its ability to flow the metal instead of stretching it. This saves money, especially with processes that utilize expensive materials or a large number of parts.
Minimize Operations and Fewer Cycles
Consolidation of processes to one machine allows for reduced operation requirements. Parts requiring multiple operations on conventional presses can often be performed by a hydroform press in one cycle.
Versatility in Forming Complex Geometric Shapes and Contours
For conventional systems to produce high quality parts, tool alignment must remain extremely accurate with little variation. During the hydroforming process, matching dies are not required. A single operation can form stepped, irregular shaped parts that would require multiple steps with traditional press operations.
Reduces Reliance on Skilled Labor
Hydroforming can minimize the requirements of expensive and hard to find skilled labor. Many complex shapes are unable to be performed on a traditional system and must be hand reworked to achieve tight tolerances. This process can take time and may result in excess scrap. Irregular contoured shapes are easily achieved with a hydroform press due to the flexibility of the female diaphragm.
Minimal Setup and Changeover Time
Hydroforming can increase production with a reduction in setup and handling
times. With only minor equipment adjustments, hydroforming replacements
have been known to save 60%-70% tool change time through the diaphragm
replacement of the female die.
This feature is perfect for applications with short to medium run parts
or multiple configurations. Tools can be quickly changed and mounted with
a self aligning punch adapter for simple changeover.
Tool & Die Savings
Hydroform tooling is easily manufactured and inexpensive. The male die and blank holder have and excellent tool life, and bladders can last thousands of cycles. Tooling is most often made from inexpensive material, and hardened steel tooling is uncommon.
Versatility with Materials
A wide range of sheet metal material can be formed with a hydroform press, each with varying degrees of thickness. These materials include (but are not limited to): high strength alloys, carbon steel, aluminum, stainless steel, precious metals, copper and brass.
Precision Forming
Precise tolerances can be achieved to form parts with extremely difficult configurations. Hydroforming can even complete airtight fits on mating parts and has enhanced dimensional precision through a reduction in spring back.
Reduced Work-Hardening
Material tensile strength is maintained for a longer period of time on a hydroform application when comparing to conventional drawing applications.
Finishing Cost Savings
Hydroforming applications have a smooth, scratch free surface with a
uniform appearance due to the flexible diaphragm. Matched dies can cause
scuff marks and marring of the material, increasing secondary buffing
and polishing requirements. Many hydroformed part can be painted before
the process, without damage to the surface finish.
On many applications, secondary finishing can risk product variation and
can produce inefficient parts. Other applications have precise clean room,
sanitation or aesthetic requirements. Eliminating surface faults are essential
in many popular applications within the aerospace, medical, food and lighting
industries (among many others).
Low Development Costs
Tooling and material changes are simple and inexpensive with hydroforming applications, producing better parts. Hydroforming gives you the ability to eliminate multiple step processes, reduce tryout costs, and realize more process efficiency. Traditional deep draw systems have difficulty making minor changes to prototype production due to the high tooling costs and precision alignment.
Ask the Expert
Dr. Taylan Altan
The
Ohio State University
Professor and Director
ERC for Net Shape Manufacturing
Research Areas:
Major research capabilities include:
a) simulation and optimization of forging, sheet
forming, hydroforming and metal cutting processes,
b) cold precision forging using multiple action tooling,
c) blank holder force control in stamping,
d) die and mold manufacturing including high speed
milling, and
e) rapid tool manufacturing and prototyping of products
and processes.