CONTENTS :

• Abstract
• References
• Introduction
• Methods of hydroforming
• Hydro joining
• Advantage and Disadvantages
• Application
• Conclusion
• ABSTRACT

1. The hydroforming technology has gained in importance

over the last few years. Today the lightweight
construction of automobiles is one of the main fields of
application.
2. Hydroforming is a cost-effective way of shaping
malleable metals such as aluminium into light weight,
structurally stiff and strong pieces.
3. This technique is particularly popular with the high-end
sports car industry and is also frequently employed in the
shaping of aluminium tubes for bicycle frames.
4. Hydroforming is a specialized type of die forming that
uses a high pressure hydraulic fluid to press room
temperature working material into a die.
• REFERENCES

1. Alessia Mentella, “Introduction to

hydroforming process” ,Universita dicassino.
2. John Godwin “Hydroforming techniques” .
3. Nader Asnafi, “Tube bending and
hydroforming”,Sapa technology, Sweden.
4. Taylan Altan, “Processes for hydroforming
sheet metal” Stamping journal, Feb 06 edition
and March 06 edition
• INTRODUCTION

1. Hydroforming is a relatively new process, which uses

water pressure to form complex shapes from sheet or
tube material.
2. Structural strength and stiffness can be improved and
the tooling costs reduced because several components
can be consolidate into one hydro formed part.
3. Some of automobile parts such as structural chassis,
instrument panel beam and radiator closures are
becoming standard hydro formed parts.
4. Using a single hydro formed item to replace several
individual parts eliminate welding, holes and punching.
5. The fluid frequently water. The applied pressure is
usually in the range 80-450MPA.
• What is HYDROFORMING ?

1.“Hydroforming is a cost-effective way of

shaping ductile metal such as aluminium, Brass,
low alloy steels, stainless steel into light
weight, structurally stiff and strong pieces”.
2.“Hydrofroming is a manufacturing process
where liquid pressure is used to form complex
shapes”.
3.“Hydrofroming is the manufacturing process of
hallow bodies with complex geometrics by
means of fluid pressure”.
• Methods of HYDROFORMING.

There are two types of hydroforming :-

1.Tube hydroforming :-
The tube hydroforming process is used to form
parts in materials such as
steel tubes and aluminium extrusions by applying
hydraulic pressure.
2. Sheet hydroforming :-
Sheet hydroforming converts the irregular shaped
material into a finished and uniform thickness
sheet.
1. Tube HYDROFORMING.

• Used when a complex

shape is needed.
• A section of cold-
rolled steel tubing is
placed in a closed die
set.
• A pressurized fluid is
introduced into the
ends of the tube.
• The tube is reshaped
to the confine of the
cavity.
• Steps in TUBE HYDROFORMING.
1. A computer-controlled machine cuts a length of straight ‘Metal
tubing’, also called a blank, to the proper size and feeds into a
machine.

2. The blank is inserted into the die, which is pumped full of highly
pressurized water. The water fills the blank, which conforms to the die
walls. The shapes the blanks into desired form.
3. At the same time, the machine compresses the ends of the
blank, which eliminates thin spots on the outer wall of the blank,
and prevents wrinkling on the inner wall, as well.The component
is then removed from the hydroforming press, the ends trimmed
and mounting holes are pierced with laser and cutting torches.
• Advantages of TUBE HYDROFORMING.

1. Increased strength to weight ratio.

Improved stiffness torsion and bending
rigidly.
2. Incorporation of hole punching and slot
making.
3. Reduction in production cost.
4. Reduced floor areas.
2. SHEET HYDROFORMING.

• Sheet hydroforming involves forming of sheet

with application of fluid pressure.
• During the sheet hydroforming process, the
hydraulic pressure varies in the range equal
to or less than 100 MPA.
• A sheet metal blank informed by hydraulic
counter pressure generated by punch
drawing sheet into pressurized water
chambers.
• The water pressure effectively punches the
sheet firmly against punch to form required
shape.
• Steps in SHEET HYDROFORMING.
1.The process take place in
two stages performed
during one press stroke.
2. The sheet is performed
by applying low fluid
pressure while it is
clamped firmly by a blank
holder pressure.
3. In next step fluid
pressure increased
gradually and blank
holder pressure is
controlled relative to
• DOUBLE SHEET HYDROFORMING.

1. This is the new concept in sheet

hydroforming.
2. In addition, hydroforming of sheet
metal can be more effective by
controlling the metal flow between
to the binders.
• Advantages of DOUBLE SHEET HYDROFORMING.

1. Integration of more parts, further reduction of

component and steps.
2. A complete component is made in one single
hydroforming step, with only top and bottom
die.
3. Stiffness increase and reduction in overall spring
back due to closed box section and continuous
weld section.
• HYDRO JOINING.

1. Usually after hydroforming, additional operations

are required to form assemblies.
2. To reduce manufacturing time and number of
process steps, joining operation are being
integrated into hydroforming process.
3. This is also reduces tool cost.
• MATERIALS.
1.Steel (Mild and Harder steels).
2.Stainless steel.
3.Aluminum alloys.
4.Brass.
5.Bronze.
6.Hastelloy (Ni-Cr-Mo).
7.Inconel (Ni-Cr).
8.Titanium & specialty metals.
9.Nickel.
10.Monel (Ni-Cu).
11.Best for materials having high Elastic madulus &
high strain hardening.
• DESIGN CONSIDERATIONS.

Product

-Geometry , thickness distribution.

-Dimensional accuracy/tolerances.
-Surface finish.
-Microstructure , Mechanical and Metallurgical
properties , Hardness.
• Advantages of HYDROFORMING.
1.There are numerous automotive components well
suited to hydroforming of sheets.
2. This is especially true in area of outer skin with
its extreme demand of surface quality and
dimensional accuracy.
3. Langer outer skin parts for passenger cars, utility
vehicles and truck such as goods and doors as well
as complex structural components can be formed.
4. Low capital cost, fewer and simpler dies.
5. Reduction in weight.
6. High process capability.
7. Reduction in cost of component.
• Disadvantage of HYDROFORMING.

1.Slow cycle time.

2. Expensive equipment and lack of
extensive knowledge base for process and
tool design.
3. Requires new welding techniques for
assembly.
• APPLICATION.
1.Automotive industry.
2. Aero space industry.
3. Medicine technology.
4. Electronic items.
5. Heating and air
conditioning.
6. Agriculture industry.
• CONCLUSION.

1.During the last 12 years, general awareness of

hydro forming has grown steadily.
2. Although interest in hydroforming is wide
ranging, the majority of application are in
automobile industry.
3. It cannot be applied to every components.
4.Hydroforming is an innovative forming process.
5.Hydroforming is becoming more popular (i.e
automotive and aerospace industries).
6.The advantage is to outweight the limitations.
7.Materials selection is broad and continuous to
increase.
• BIBLIOGRAPHY.

1.Www.hydroforming.net
2.Www.vari-form.com
3.www.hdt-gti.com
4.Www.revindustries.com
5.www.autosteel.org
6.Www.schuler-hydroforming.de
7.Www.kaupp.com/Hydrofromin.htm
8.Www.egr.msu.edu/~aenader
9.Nsmwwww.eng.ohio-
state.edu/html/Tube_hydroforming.html
10.Automotive components Development by means
of hydroforming, by
THANK YOU