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Hydroforming

Fluid Forming, Rubber Diaphragm Forming, Specialized Die Forming
Hydroformed Part Hydroformed Part Hydroformed Parts

Specific Advantages of Hydroforming Include:

  • INEXPENSIVE TOOLING
    A male die (punch) and a draw ring (blank holder) are generally the only tools required. The rubber diaphragm in the hydroform machine acts as a universal female die. Hydroform tools normally cost at least 50% less than conventional press tooling.
  • VERSATILITY IN FORMING COMPLEX SHAPES AND CONTOURS
    Irregularly contoured shapes are easily formed using the hydroform process because matching dies are not required.
Precision Hydroformed Parts
  • MINIMAL MATERIAL THINOUT
    Hydroforming flows the metal rather than stretching it. Therefore, material thinout is minimal - usually less than 10%. Wall thickness at the open end of the part is typically nominal or greater, (a big advantage for trimming, welding and assembly). This often results in material savings because thinner blanks can be used - a particularly important factor when expensive alloys or a large number of parts are ordered.
  • FEWER OPERATIONS REQUIRED
    Many parts requiring two or three operations on conventional presses can be formed in one hydroform operation. First draw operations frequently hydroformed with reductions of 60% to 70% - compared to only 35% to 45% using conventional dies.
  • SAVINGS IN TOOL MATERIALS
    Hardened tool steels are rarely required. Most punches and draw rings are made of meehanite (cast iron) - an inexpensive, easily machined material that provides an exceptionally long tool life. Kirksite and cast plastics may be used for very short runs.
Hydroforming Process
  • FAST TOOL CHANGES
    Tools are quickly mounted and are self-centering and self-aligning. Set-ups are quick and simple.
  • SAVINGS IN FINISHING COSTS
    Matched die methods of forming can cause scuff marks, shock and stretch lines. In the Hydroform method, the wrapping action of the flexible diaphragm virtually eliminates these faults. Savings of up to 90% in finishing costs have been realized.
  • MATERIALS VERSATILITY
    Practically all sheet metals capable of being cold formed - carbon steel, aluminum, stainless steel, copper, brass, precious metals, high strength alloys, and others can be hydroformed. Thickness of materials can vary within the limits of the machine without need for tool revisions.
  • PRECISION
    The hydroform method forms parts with extremely difficult configurations while at the same time working to precise tolerances. Unless the material being formed exhibits abnormal springback, inside measurements can be held to +/- .005" or +/- .002" in some instances, depending on material and shape.
  • EASE OF DESIGN CHANGE
    Development cost can be a large part of total tooling cost with conventional deep draw techniques. With hydroforming, material or metal thickness can be altered usually without any tooling changes being necessary. Hydroforming can also eliminate or minimize the number of multiple draw operations required with a corresponding reduction in tryout costs.
  • LOW WORK-HARDENING
    Hydroforming does not cause work-hardening of materials at the same rate as conventional drawing operations. Consequently, annealing between draw operations is rarely required. The need for multiple draw operations can often be eliminated too.

Hyrofroming provided by Charles Schillinger CompanyPalmer Associates proudly represents Charles Schillinger Company for hydroforming and metal spinning.

Hydroforming - Process and Equipment

Hydroforming presses use a unique fluid forming process which offers many advantages over conventional mechanical and hydraulic presses. An elastic die member (rubber diaphragm) acting as a seal across the bottom of a fluid-filled forming chamber serves as the upper blankholder and female die element - a universal die which accommodates any shape. The lower portion of the press holds a punch attached to a hydraulic piston and a blankholder ring surrounds the punch.

At the start of the Hydroform machine cycle, the top of the punch (which is inverted compared to a conventional press) is normally level with the top of the blankholder ring. The forming chamber is lowered and a hydraulic precharge is applied.

As the punch is raised into the forming chamber, the flexible diaphragm wraps the blank around the punch, controlling the material and forming it to the shape of the punch. At the end of the draw all of the material is supported on the inside either by the punch or the blank holding ring and the top by the flexible die member.

To complete the cycle, pressure is released, the forming chamber is raised and the punch is retracted form the drawn part.











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