Hydroforming

Training Objective

After watching the video and reviewing this printed material, the viewer will
gain knowledge and understanding of the hydroforming process and its use in
manufacturing sheet metal parts.

• Both sheet metal hydroforming and tubular hydroforming are explained

• The specific requirements for each hydroforming type is featured
• The fundamental elements of a hydroforming system are discussed
• Metals used in hydroforming are explored

Hydroforming uses fluid pressure applied to a tubular or sheet metal blank to

form it into the desired component shape. The most commonly used materials in
hydroforming include the various grades of steel. These grades of steel are used
extensively because they exhibit good fatigue properties, high energy
absorption, and reasonable resistance to corrosion. Other metals used for
hydroforming include:

• Stainless Steels
• Aluminum
• Copper
• Copper Alloys

The Hydroforming System

All hydroforming systems include:

• Tooling and dies

• A hydraulic press
• A fluid-pressure intensification system

Hydroforming dies vary dramatically with regards to sheet metal hydroforming and
tubular hydroforming operations. Dies may be single or multi-cavity.

Hydroforming utilizes hydraulic, rather than mechanical, presses for many

reasons. Hydraulic presses are able to deliver full tonnage at any point in the
stroke, not just at the bottom as is the case with mechanical presses. The
hydraulic press can be adjusted to provide optimal part clearance. Also,
hydraulic presses can be stopped in mid-stroke which is advantageous to some
hydroforming operations.

The fluid-pressure intensification pressure system consists of a low-pressure,

high flow rate filling system, along with a high-pressure intensifier to raise
the fluid pressure to forming levels. The forming fluid is water-based and
contains additives such as lubricants, drying agents, rust preventatives, and
bactericides.

In a typical hydroforming operating cycle, a blank is placed on the lower die

tooling, and the press is closed. Fluid is then introduced to either one side of
the sheet metal blank, or within the tubular blank. As fluid pressure is
intensified the blank deforms, taking the shape of the tooling. Lubrication is
especially important in hydroforming. Lubricants assist in reducing the friction
and stresses as the metal flows into its final shape.

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Tubular Hydroforming

Tubular hydroforming begins with the placement of either straight tubes, or more
commonly preformed tubes, into the die. Sealing punches within the die close off
the tube ends as fluid pressurization begins. The three surfaces of a tube that
can act as sealing surfaces, include:

• The outside diameter of the tube

• The inside diameter of the tube
• The end surface of the tube

During forming, a combination of increasing internal fluid pressure and a

simultaneous axial pressing on the tube ends by the sealing punches cause the
tubular material to flow into the contours of the die.

Tubular hydroforming is generally divided into three operating techniques:

• Low-Pressure Hydroforming uses fluid pressures of 12,000 PSI/828 BAR or less.

Cycle time is less than with other hydroforming methods, but components must
be designed carefully to form properly using the lower fluid pressures.

• High-Pressure Hydroforming uses fluid pressures ranging from 20,000 to

100,000 PSI/1,379 to 6,895 BAR. The exact amount of pressure needed is
dependent upon several factors such as material yield strength, tube wall
thickness and the inside radius of the sharpest cross-sectional corner. When
the tube is expanded by high pressure within the die cavity, material
thickness may vary throughout the part. Additionally, larger presses are
needed for high-pressure hydroforming and the higher operating pressures can
result in longer cycle times.

• Pressure Sequence Hydroforming utilizes the closing action of the hydraulic

press to assist in the hydroforming of the blank. The blank is first placed
in the die cavity and the die is partially closed, partly deforming the tube.
Low-pressurized fluid is then pumped into the blank allowing it to resist
compression. The die starts to close again with the desired low-pressure
maintained while part cross section reduces. Once the die is fully closed,
high pressure is applied to the fluid, forcing the blank material into the
corner recesses of the die cavity with no wall thinning. Maximum pressure for
pressure sequence hydroforming is typically under 10,000 PSI/690 BAR.

Tubular hydroforming cycles also include 'hydro-piercing' to create holes and

slots in the part. The piercing tool is incorporated into the hydroforming die
and activated during the forming cycle by hydraulic cylinders. The piercing
action is usually inward against the pressurized fluid. Piercing can also be
performed outwardly by retracting a plunger, or backup punch. The fluid pressure
within the tube causes the surface material to fail, creating a hole in the
unreinforced portion of the tube wall.

Sheet Metal Hydroforming

In sheet metal hydroforming, controlled metal flow during the operation

minimizes localized stress concentrations that may cause workpiece buckling or
wrinkling. Sheet metal hydroforming is slower than traditional stamping, thus
its use is limited to short runs of more highly specialized parts.

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Hydroforming

The two most common methods of sheet metal hydroforming are:

• Rubber Diaphragm Forming

• Active Hydro-Mechanical Drawing

In Rubber Diaphragm Forming, a fluid forming chamber is attached to the slides

of a hydraulic press. Fluid is retained within the chamber by a flexible rubber
diaphragm, which serves as a universal die capable of accommodating any shape.
Attached to the rubber diaphragm is a wear-pad which acts as a blankholder and
protects the diaphragm. A single tool, typically a punch, but in some cases a
cavity die, is mounted to a hydraulic cylinder on the bed of the press. A blank
is placed on the lower blankholder of the rubber diaphragm forming press. The
forming chamber is then lowered and initial pressure is applied. The punch moves
upward and into the flexible die member, shaping the sheet metal material.
Typical forming pressures range from 5,000 to 15,000 PSI/345 to 1,034 BAR. After
forming is completed, pressure is released, the forming chamber is raised, and
the punch is stripped from the finished part.

Active Hydro-Mechanical Drawing is used in fabricating large sheet metal panels

and can improve the buckling strength of the finished part. The lower
blankholder is a reservoir containing an oil and water emulsion as a fluid
medium, while the top die holds the punch. As the press closes over the blank it
forms a water tight seal between the die halves. At this stage, a part-specific
gap exists between the clamped blank and the punch. As soon as the blank-holding
force has built, the fluid is brought to a defined pressure. This pressure
causes a controlled bulging of the blank over its entire surface, resulting in
work hardening of the workpiece and a substantial improvement in buckling
strength of the part. Bulging continues until the blank comes to rest against
the center of the punch surface. After this pre-stretching process, the punch is
lowered into the blank. The sheet metal flows rather than rubs against the punch
and female die by fluid pressure. Active Hydro-Mechanical Drawing is cost
effective since only one die half needs to be machined to achieve the required
part shape.

Post Hydroforming Operations

Although many secondary operations are performed during hydroforming, many post-
hydroforming operations are needed to finish tubular and sheet metal parts.
Common post-hydroforming processing includes:

• Additional holemaking using conventional drilling, laser drilling, punching,

or cutting.

• Trimming to remove surplus metal from the hydroformed part using cutting
lasers, trimming dies, machining, sawing, or shearing operations.

• Joining operations, such as the various welding processes and mechanical

fasteners, are used to assemble hydroform components to existing structural
assemblies.

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Review Questions

1. A specific advantage of using a hydraulic press in hydroforming is:

a. high speed operation
b. quick change dies
c. operator safety
d. full tonnage throughout the stroke

2. To raise fluid pressure to hydroforming levels:

a. large electric pumps are used
b. fluid conduits are restricted
c. higher viscosity fluids are used
d. a high pressure intensifier is used

3. In tubular hydroforming, most often:

a. straight tubes are used
b. preformed tubes are used
c. softer aluminum is used
d. pre-pierced tubing is used

4. In High Pressure Hydroforming, fluid pressure ranges from:

a. 8,000 to 12,000 PSI/550 to 822 BAR
b. 20,000 to 50,000 PSI/1,379 to 3,425 BAR
c. 20,000 to 100,000 PSI/1,379 to 6,850 BAR
d. 100,000 to 150,000 PSI/6,850 to 10,275 BAR

5. An advantage of Pressure Sequence Hydroforming is:

a. higher production rates
b. stronger alloys can be formed
c. there is no wall thinning of the tube
d. less expensive dies can be used

6. In Rubber Diaphragm Forming, the diaphragm:

a. acts as a universal die
b. is attached to the press bed
c. is mounted to a hydraulic cylinder
d. must be replaced after 6 to 12 cycles

7. Active Hydro-Mechanical Drawing:

a. allows very large panels to be formed
b. hardens the workpiece
c. needs only one die half to be machined
d. all of the above

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Answer Key

1. d
2. d
3. b
4. c
5. c
6. a
7. d

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