Metal Forming

High velocity hydro forming

Hydro forming was developed in the late 1940and early 1950 to provide cost
effective mean to produce small quantities of drawn part with asymmetrical
contours that do not lend themselves to stamping.

Hydro forming uses the force of water or hydraulic fluids to shape a single
part.

Hydro forming uses fluid pressure applied to a tubular or sheet metal blank
to form it into the desired component shape.

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Metal Forming

High velocity hydro forming

Hydro forming System
Tooling and dies Vary dramatically, Dies may be single or multicavity
A hydraulic press -Hydraulic presses are able to deliver full tonnage
at any point in the stroke
A
fluid-pressure
intensification system
The forming fluid is water
based
and
contains
additives
such
as
lubricants, drying agents,
rust preventatives, and
bactericides.

Department of Mechanical Engineering ,BVOE & RI Nasik

Metal Forming

High velocity hydro forming

There are two types of hydro forming:
1. Tube hydro forming
2. Sheet hydro forming

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Metal Forming

High velocity hydro forming

Tubular Hydro forming
Tubular hydro forming 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

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Metal Forming

High velocity hydro forming

Tubular Hydro forming
Tube Hydro forming (THF) / Bulge forming of tubes / liquid bulge forming /
Hydraulic pressure forming (HPF)

Department of Mechanical Engineering ,BVOE & RI Nasik

Metal Forming

High velocity hydro forming

T shape tube hydro forming

Department of Mechanical Engineering ,BVOE & RI Nasik

Metal Forming

High velocity hydro forming

Department of Mechanical Engineering ,BVOE & RI Nasik

Metal Forming

High velocity hydro forming

Low-Pressure Hydro
forming

High-Pressure Hydro
forming

Pressure Sequence
Hydro forming

12,000 PSI/828 BAR or

less

20,000 to 100,000
PSI/1,379 to 6,895 BAR

10,000 PSI/690 BAR.

Material. Wall thickness

material yield
strength, tube wall
thickness and the inside
radius

die is partially closed

Low-pressurized fluid is
then pumped
die is fully closed, high
pressure is applied

material thickness may

not vary throughout the
part

material thickness may

vary throughout the part

die cavity with no wall

thinning.

Cycle time is less

longer cycle time

Moderate cycle time

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Metal Forming

High velocity hydro forming

Defects in tube hydro forming
The risk of bursting is a result of too high internal pressure and is
initiated by a local neck in the tube wall, whereby the onset of this local
necking significantly depends on the initial tube wall thickness.

Department of Mechanical Engineering ,BVOE & RI Nasik

Metal Forming

High velocity hydro forming

Defects in tube hydro forming
Buckling is posed at the start of the process by too high axial loads on the
initial tube, and it is also present for the entire starting phase.
Wrinkles are, as exhibited during free forming at the intake regions of
the expansion zone, if the pure-shear path is selected. These wrinkles
cause no problem and are straightened out during calibration.

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Metal Forming

High velocity hydro forming

Advantages of tube hydro forming

Very precise sizing and shaping of components,

Increase in strength due to work hardening,
Low weight with optimum strength
High rigidity,
High fatigue strength,
Fewer welding joints for complex components,
Low flow resistance (exhaust systems).

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Metal Forming

High velocity hydro forming

Sheet hydro forming

This process is based on the 1950s patent for hydra molding by Fred
Leuthesser, Jr. and John Fox of the Schaible Company of Cincinnati, Ohio
in the United States. It was originally used in producing kitchen spouts.
Active Hydro-Mechanical Drawing
Sheet steel is forced into a female cavity by water under pressure from a
pump or by press action

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Metal Forming

High velocity hydro forming

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Metal Forming

High velocity hydro forming

Rubber Diaphragm Forming
Sheet steel is deformed by a male punch, which acts against the fluid under
pressure.
Typical forming pressures
range from 5,000 to 15,000
PSI/345 to 1,034 BAR.

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Metal Forming

High velocity hydro forming

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Metal Forming

High velocity hydro forming

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Metal Forming

High velocity hydro forming

Design considerations
Hydro forming is generally defined as either low-pressure or high pressure
Constant pressure volumetric expansion
< 5% required to shape the part = Low pressure
> 5% (but < 25%) = High Pressure

Product

Tool/Dies

Equipment

- Geometry, thickness
distribution
- Dimensional
accuracy/tolerances
- Surface finish
- Microstructure,
mechanical and
metallurgical
properties, hardness

-Geometry of tools

- Press capacity

- Material hardness

- Speed/production rate

- Surface conditions

- Force/energy
capabilities

- Stiffness and accuracy

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- Rigidity and accuracy

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Metal Forming

High velocity hydro forming

Design considerations

Work piece/Material
-Flow stress as a function of strain, strain rate and
microstructure
-Workability as a function of strain, strain rate and
microstructure
- Surface conditions
- Geometry of tubing ( outside diameter, tube wall
thickness, roundness, properties of welding line,
etc.)

Deformation zone
- Deformation
mechanics, model used for analysis
Metal flow, velocities, strain rates,
strains (kinematics)
- Stresses (variation during
deformation)

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Metal Forming

High velocity hydro forming

ADVANTAGES

Hydro forming is similar to conventional deep drawing techniques but has

significant advantages for formed part and keeps the tooling costs and hence
component production cost low
Hydro forming draws material into the mold
Part consolidation
Weight reduction through more efficient section design and tailoring of the wall
thickness
Improved structural strength and stiffness
Lower tooling cost due to fewer parts
Fewer secondary operations.
Tight dimensional tolerances and low spring back
Reduced scrap .
Hydro formed parts can often be made with a higher stiffness-to-weight ratio and
at a lower per unit cost than traditional stamped or stamped and welded parts.

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Metal Forming

High velocity hydro forming

Comparison of conventional deep drawing & hydro forming

Conventional deep drawing

strong local thinning of the material.

In-homogenous distribution of
material thickness
Less internal stress of the formed part

Hydro forming

Less internal stress & less tendency

to return to its original shape.
Homogenous strength and less
amount of waste
High dimensional accuracy

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Metal Forming

High velocity hydro forming

LIMITATIONS

Slow cycle time

Expensive equipment and lack of extensive knowledge base for process
and tool design
Requires new welding techniques for assembly

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Metal Forming

High velocity hydro forming

Post Hydro forming Operations
Although many secondary operations are performed during hydro forming,
many post-hydro forming operations are needed to finish tubular and sheet
metal parts. Common post-hydro forming processing includes:
Additional hole making using conventional drilling, laser drilling, punching,
or cutting.
Trimming to remove surplus metal from the hydro formed 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 hydro form components to
existing structural assemblies.

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Metal Forming

High velocity hydro forming

MATERIAL THAT CAN HYDRO FORM

The most commonly used materials in hydro forming 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 hydro forming include:
Stainless Steels
Aluminum
Copper & Alloys
Brass
Bronze
Inconel (Ni- Cr)
Monel (Ni- Cu)
Nickel
Titanium
Hastelloy (Ni- cr- Mo)

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Metal Forming

High velocity hydro forming

Applications

Hydro formed Side Rails on a Truck

Chassis (THF)

Hydro formed Exhaust Parts (THF)

Automotive industry Sanitary use

Aerospace Lighter, stiffer parts
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Metal Forming

High velocity hydro forming

Applications

Hydro formed Cam Shafts have Lower

Rotational Inertia and Require Less
Machining
Satellite antennas up to 6 meters in
diameter, such as those used in the
Allen Telescope Array
(
Radio Astronomy Laboratory
AT
University of California, Berkeley)
Lighting fixture housing and reflector
The Allen Telescope Array
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Metal Forming

High velocity hydro forming

Applications

The brass tube of

Yamaha saxophones

The process has become popular for the manufacture of aluminum

bicycle frames. The earliest commercially manufactured one being that
of the Giant Manufacturing Revive bicycle first marketed in 2003

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Metal Forming

High velocity hydro forming

Applications

1. Body shell
2. Driving shaft
3. Assembled camshaft
4. Exhaust systems
5. Engine cooling system
6. Radiator frame
7. Safety requirements
8. Engine bearer
9. Integral member
10. Cross member
11. Frame structure parts
12. Axle elements

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Metal Forming

High velocity hydro forming

Review Questions

A specific advantage of using a hydraulic press in hydro forming is:

a. high speed operation
b. quick change dies
c. operator safety
d. full tonnage throughout the stroke
To raise fluid pressure to hydro forming 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

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Metal Forming

High velocity hydro forming

Review Questions

In tubular hydro forming, most often:

a. straight tubes are used
b. preformed tubes are used
c. softer aluminum is used
d. pre-pierced tubing is used
In High Pressure Hydro forming, 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

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Metal Forming

High velocity hydro forming

Review Questions

Active Hydro-Mechanical Drawing:

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

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Metal Forming

High velocity hydro forming

Review Questions

An advantage of Pressure Sequence Hydro forming 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

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Metal Forming

High velocity hydro forming

parameters

Tube hydro forming

Sheet hydro forming

Name
Die
Punch
pressure
area
applications

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