Hydroforming Press

Hydroforming Press
Hydroforming Press

We manufacture Hydroforming Press types. A Tee hydro forming press is used to manufacture T-formed parts from metal. High quality & Low Price & Free Consultation

A hydroforming press is a type of press used for shaping metal components through the application of hydraulic pressure. This process involves placing a sheet of metal over a die and then applying hydraulic pressure to form the metal into the desired shape.

The hydroforming press consists of a hydraulic system that supplies the pressure, a blank holder to hold the metal in place, and a die to shape the metal. The hydraulic system applies a force to a piston, which in turn applies the force to the blank holder. The pressure can be adjusted to control the speed and force of the forming process.

Hydroforming is commonly used in the production of complex shapes such as tubes, ducts, and other irregular shapes that cannot be easily formed using traditional stamping or forging methods. This process offers advantages such as improved part strength, reduced material waste, and increased design flexibility.

Hydroforming presses come in various sizes and capacities, and can be customized to meet the specific needs of different industries, including aerospace, automotive, and medical device manufacturing.

Hydroforming Press

A hydroforming press is a type of press that is used to shape ductile metals into complex shapes using a combination of fluid pressure and mechanical force. It is often used in the manufacturing of parts for the automotive and aerospace industries, where precision and strength are critical factors.

The hydroforming process begins with a blank piece of metal, typically made of aluminum or steel, that is placed into a die. The die is then closed and fluid is pumped into the chamber, which applies pressure to the metal from all directions. This pressure forces the metal to take on the shape of the die, resulting in a highly precise and complex part.

A hydroforming press is a specialized type of press that uses a high-pressure fluid to deform sheet metal into complex shapes. The process is similar to deep drawing, but it uses fluid pressure instead of mechanical force to form the material.

Advantages of Hydroforming

Hydroforming offers several advantages over traditional metal forming methods, including:

  • Reduced material waste: Hydroforming can produce complex shapes with minimal material waste, compared to other forming methods that may require trimming or scrap.
  • Improved surface finish: The fluid pressure used in hydroforming produces a smooth, even surface finish on the formed part, eliminating the need for secondary finishing operations.
  • Increased part strength: Hydroforming can produce parts with higher strength and fatigue resistance compared to other forming methods.
  • Versatility: Hydroforming can be used to form a wide range of shapes, including hollow and closed shapes that are difficult to produce with other methods.

Applications of Hydroforming

Hydroforming is commonly used in the automotive industry to produce a variety of components, such as:

  • Frame rails: Hydroformed frame rails are lighter and stronger than traditional frame rails, and they can be produced with complex shapes that improve vehicle performance.
  • Doors and body panels: Hydroformed doors and body panels are lighter and more dent-resistant than traditional panels, and they can be produced with intricate details.
  • Exhaust systems: Hydroformed exhaust systems are more durable and have fewer welds than traditional exhaust systems, making them less prone to leaks and corrosion.

Components of a Hydroforming Press

A hydroforming press consists of several key components:

  • Press frame: The press frame is a rigid structure that supports the other components of the press.
  • Platens: The platens are the heated surfaces that come into contact with the material being formed. They are typically made of steel or aluminum and can be heated electrically or with steam.
  • Hydraulic system: The hydraulic system generates the pressure that is used to deform the material. It consists of a pump, a reservoir, and a series of valves.
  • Die: The die is the mold that gives the formed part its shape. It is typically made of tool steel or high-strength aluminum.
  • Bladder: The bladder is a flexible membrane that is placed inside the die. It is filled with high-pressure fluid to deform the material against the die.

Hydroforming Process

The hydroforming process typically involves the following steps:

  1. Blank preparation: The material is cut to the desired size and shape.
  2. Preheating: The blank is preheated to a temperature that makes it more malleable.
  3. Die loading: The blank is placed inside the die.
  4. Bladder inflation: The bladder is inflated with high-pressure fluid, causing the blank to deform against the die.
  5. Hold and cooling: The pressure is held for a period of time to allow the material to cool and set in the desired shape.
  6. Unloading: The bladder is deflated, and the formed part is removed from the die.

Conclusion

Hydroforming is a powerful and versatile metal forming process that is used to produce a wide variety of components for a variety of industries. It offers several advantages over traditional metal forming methods, including reduced material waste, improved surface finish, increased part strength, and greater versatility.

How does a Hydroforming Press function?

The process of hydroforming can be broken down into several key steps:

  1. Material selection: The first step in the hydroforming process is to select the appropriate material for the part being produced. Typically, this will be a ductile metal such as aluminum or steel.
  2. Blank preparation: The blank, or sheet of metal, is then cut to the appropriate size and shape for the part being produced. It may also be pre-formed to a certain degree to make it easier to shape during the hydroforming process.
  3. Die preparation: The die, which will be used to shape the metal, is then prepared. This involves heating and lubricating the die to ensure that the metal can be shaped smoothly and accurately.
  4. Loading: The blank is loaded into the die and the press is closed. The fluid pressure is then applied to the metal, forcing it to take on the shape of the die.
  5. Forming: As the fluid pressure is applied, the metal is shaped into the desired form. The pressure is carefully controlled to ensure that the metal is not overstretched or damaged during the process.
  6. Unloading: Once the forming process is complete, the fluid pressure is released and the part is removed from the die. It may then be trimmed or finished as necessary.

Hydroforming presses come in a variety of sizes and configurations, ranging from small tabletop models to large, industrial-scale machines capable of shaping parts several feet in diameter. They can be used to produce a wide range of parts, from simple tubes and cylinders to highly complex shapes with multiple curves and bends.

Overall, the hydroforming process offers a number of advantages over traditional stamping and forming methods. It allows for greater precision and accuracy in shaping metal parts, while also reducing the amount of material waste and minimizing the need for secondary operations such as welding and machining.

In the last decades, advanced forming processes such as sheet hydroforming have an increasing interest, particularly in the automotive and aerospace industries. This process has many advantages such as reduction of tool costs, enhanced formability, capability to form complex parts, reduced die wear, higher dimensional accuracy, and surface quality compared to the conventional sheet metal forming processes.

Material selection for the hydroforming press

The selection of materials for the hydroforming press is crucial for ensuring its durability, performance, and cost-effectiveness. Various factors influence the choice of materials, including the desired properties of the press, the type of components being formed, and the operating conditions.

Key Considerations for Material Selection

  1. Strength and Durability: The materials used for the press frame, platens, and dies must be strong enough to withstand the high pressures and forces involved in the hydroforming process. They should also be durable and resistant to wear and tear.
  2. Heat Resistance: The platens and dies must be able to withstand the high temperatures required to preheat the material being formed. They should also be able to maintain their shape and dimensions under these conditions.
  3. Dimensional Accuracy: The dies must be made from materials that can maintain precise dimensions over time. This is essential for producing high-quality components with the desired tolerances.
  4. Cost-effectiveness: The materials used for the press should be cost-effective without compromising on quality or performance. The balance between initial cost and long-term durability is crucial.

Common Materials Used in Hydroforming Presses

  1. Steel: Steel is a common choice for the press frame, platens, and dies due to its strength, durability, and heat resistance. Various grades of steel are used depending on the specific requirements of the press.
  2. Aluminum: Aluminum is sometimes used for the platens due to its lighter weight and faster heating and cooling rates. However, aluminum is generally not as strong or durable as steel.
  3. Tool Steel: Tool steel is a high-strength material that is often used for dies, especially for forming complex shapes. It is known for its wear resistance and ability to maintain dimensional accuracy.
  4. High-Strength Aluminum: High-strength aluminum alloys are sometimes used for dies, particularly for forming lighter components. They offer a balance between strength and weight.
  5. Rubber or Plastic Membranes: Rubber or plastic membranes are used for the bladder, the flexible component that applies pressure to the material being formed. These materials must be able to withstand high pressure and maintain their flexibility under these conditions.

Factors Influencing Material Selection for Specific Components

  1. Press Frame: The press frame is subjected to the highest forces and pressures, so it requires strong and durable materials like high-grade steel.
  2. Platens: The platens must withstand high temperatures and maintain dimensional accuracy, so materials like steel or high-strength aluminum are often used.
  3. Dies: Dies must be strong, wear-resistant, and dimensionally accurate, so materials like tool steel or high-strength aluminum alloys are commonly used.
  4. Bladder: The bladder needs to be flexible and pressure-resistant, so rubber or plastic membranes are typically used.
  5. Other Components: Other components, such as hydraulic cylinders and valves, also require specific materials based on their function and operating conditions.

Conclusion

Careful material selection is essential for designing and manufacturing a high-performance hydroforming press that can operate efficiently and produce quality components. By considering the desired properties, operating conditions, and cost-effectiveness, engineers can choose appropriate materials for each component, ensuring the long-term durability and reliability of the press.

Blank preparation

Blank preparation is a crucial step in the hydroforming process, ensuring the material is properly shaped and conditioned for forming. It involves several key steps to achieve the desired dimensions, surface quality, and material properties for successful hydroforming.

  1. Cutting: The starting material, typically a sheet metal blank, is cut to the approximate size and shape required for the final formed part. Accurate cutting ensures minimal material waste and a good starting point for subsequent forming operations.
  2. Edge Preparation: The edges of the blank are trimmed and prepared to remove any imperfections, burrs, or sharp edges that could cause tears or disruptions during hydroforming. This ensures a smooth transition between the blank and the die, preventing material snagging or tearing.
  3. Cleaning: The blank is thoroughly cleaned to remove any surface contaminants, such as oils, greases, or dirt. These contaminants can interfere with the adhesion of the forming lubricant and affect the surface finish of the formed part.
  4. Degreasing: After cleaning, the blank may be degreased using a solvent or chemical solution to remove any remaining oils or residues that could hinder the forming process. Proper degreasing ensures a clean surface for lubricant application and prevents adhesion issues.
  5. Lubrication: A suitable lubricant is applied to the blank to reduce friction and prevent galling or tearing during the hydroforming process. The lubricant should be compatible with the material being formed and provide adequate protection against wear and tear.
  6. Preheating: Depending on the material and the complexity of the formed part, preheating may be necessary to increase the malleability of the material and facilitate the forming process. Preheating helps to reduce the forming force required and improves the flow characteristics of the material.
  7. Blank Inspection: The prepared blank is thoroughly inspected for any defects, imperfections, or inconsistencies in its dimensions, surface quality, or material properties. Detecting and correcting any issues at this stage prevents problems during the hydroforming process and ensures the production of high-quality formed parts.

In summary, blank preparation plays a critical role in the hydroforming process by ensuring the material is properly shaped, conditioned, and free from defects, enabling successful forming and achieving the desired part dimensions and surface finish.

Die preparation

Die preparation is an essential step in the hydroforming process, ensuring the proper configuration and condition of the die to produce high-quality formed parts. It involves several key steps to achieve the desired accuracy, surface finish, and wear resistance of the die.

  1. Die Design and Manufacturing: The die is designed and manufactured according to the specifications of the desired formed part. This includes precise dimensions, surface contours, and internal features to accommodate the material flow and forming process.
  2. Heat Treatment: Depending on the material and the complexity of the die, heat treatment may be necessary to enhance its strength, hardness, and wear resistance. Heat treatment ensures the die can withstand the high pressures and forces involved in hydroforming without deformation or wear.
  3. Surface Preparation: The surface of the die is carefully prepared to achieve a smooth, uniform finish. This may involve grinding, polishing, or other surface finishing techniques. A smooth surface helps to prevent material tearing or galling during hydroforming and contributes to a good surface finish on the formed part.
  4. Lubrication: A suitable lubricant is applied to the die to reduce friction and prevent sticking between the die and the material during hydroforming. The lubricant should be compatible with the material being formed and provide adequate protection against wear and tear.
  5. Die Inspection: The prepared die is thoroughly inspected for any defects, imperfections, or discrepancies in its dimensions, surface quality, or material properties. Detecting and correcting any issues at this stage ensures the die is in optimal condition for hydroforming and prevents problems that could affect the quality of the formed parts.
  6. Die Installation: The die is carefully installed into the hydroforming press, ensuring proper alignment and positioning with the platens and other components. Accurate installation is crucial for achieving the desired part dimensions and preventing off-center forming or other defects.
  7. Die Maintenance: Regular maintenance of the die is essential to maintain its performance and extend its lifespan. This includes cleaning, lubrication, and inspection to detect and address any wear, damage, or material degradation that could affect the forming process.

In summary, die preparation plays a critical role in the hydroforming process by ensuring the die is properly designed, manufactured, and maintained to produce high-quality formed parts. A well-prepared die contributes to accurate dimensions, smooth surface finish, and consistent part quality throughout the hydroforming process.

Loading

Loading in hydroforming refers to the process of introducing the preheated blank material into the hydroforming die and positioning it correctly for forming. The loading method and sequence are crucial for ensuring proper material flow, preventing defects, and achieving the desired part shape.

Types of Loading Methods in Hydroforming

  1. Axial Loading: Axial loading involves placing the blank directly into the die cavity and applying axial force to push it into the desired shape. This method is suitable for forming simple shapes with symmetrical geometry.
  2. Radial Loading: Radial loading involves placing the blank over the die cavity and applying radial force to deform it into the desired shape. This method is often used for forming more complex shapes with asymmetrical geometry.
  3. Combined Loading: Combined loading utilizes a combination of axial and radial forces to form the blank into the desired shape. This method is particularly useful for forming complex shapes with multiple contours and bends.

Factors Influencing Loading Method Selection

  1. Part Geometry: The complexity of the part geometry determines the most appropriate loading method. Axial loading is suitable for simple shapes, while radial or combined loading is better suited for complex shapes.
  2. Material Properties: The material properties, such as ductility and flow characteristics, influence the loading method. Ductile materials may require more radial force, while less ductile materials may benefit from combined loading.
  3. Press Capacity: The press capacity, including the available force and stroke, determines the feasibility of certain loading methods. Complex shapes may require higher forces, necessitating specific loading techniques.

Loading Sequence in Hydroforming

  1. Blank Positioning: The blank is carefully positioned within the die cavity, ensuring proper alignment and orientation. This step ensures the material flows correctly during forming.
  2. Holding Mechanisms: Holding mechanisms, such as clamps or pins, are engaged to secure the blank in place and prevent movement during forming. This prevents misalignment or defects.
  3. Bladder Inflation: The bladder, the flexible membrane inside the die, is inflated with high-pressure fluid. The pressure gradually increases, forcing the blank to conform to the die shape.
  4. Pressure Control: The pressure is controlled and monitored throughout the forming process to achieve the desired part shape and prevent over-forming or material defects.
  5. Pressure Release: Once the forming process is complete, the pressure is gradually released, allowing the blank to cool and set in the desired shape.
  6. Part Removal: The formed part is carefully removed from the die, ensuring no damage or deformation occurs.

Conclusion

Loading in hydroforming is a critical step that directly impacts the quality and accuracy of the formed part. By selecting the appropriate loading method, following a structured loading sequence, and implementing precise control over the loading process, manufacturers can achieve consistent and high-quality hydroformed parts.

Forming

Forming in hydroforming is the stage where the pre-heated blank material is subjected to high-pressure fluid to deform it into the desired shape. It is a critical step in the hydroforming process, as it determines the accuracy, dimensions, and surface finish of the formed part.

Stages of Forming in Hydroforming

  1. Pressure Application: The bladder, a flexible membrane inside the die, is inflated with high-pressure fluid, gradually increasing the pressure to deform the blank into the desired shape.
  2. Material Flow: The high-pressure fluid forces the blank to conform to the shape of the die, causing the material to flow and stretch along the contours of the die cavity.
  3. Material Strengthening: As the material undergoes deformation, it experiences strain hardening, increasing its strength and resistance to further deformation.
  4. Shape Retention: Once the desired shape is achieved, the pressure is maintained for a period of time to allow the material to cool and set in the desired form.

Factors Influencing Forming Success

  1. Blank Preparation: Proper blank preparation, including trimming, cleaning, lubrication, and preheating, ensures optimal material flow and prevents defects.
  2. Die Design: The die design, including its dimensions, surface finish, and internal features, plays a crucial role in achieving the desired part shape and surface quality.
  3. Pressure Control: Precise control of the hydraulic pressure is essential to prevent over-forming, under-forming, and material tearing or rupture.
  4. Temperature Control: Maintaining the appropriate temperature throughout the forming process ensures the material has the necessary ductility and flow characteristics for proper deformation.
  5. Process Monitoring: Continuous monitoring of the forming process, including pressure, temperature, and material flow, allows for adjustments and interventions to prevent defects.

Conclusion

Forming in hydroforming is a complex and dynamic process that requires careful consideration of material properties, die design, pressure control, and temperature management. By optimizing these factors and implementing precise process control, manufacturers can achieve consistent and high-quality hydroformed parts.

Unloading

Unloading in hydroforming is the final step in the process, where the formed part is carefully removed from the die. This stage is crucial for preventing damage to the formed part and ensuring its smooth release from the die.

Steps in Unloading

  1. Pressure Release: The pressure in the bladder is gradually released, allowing the material to relax and the formed part to shrink slightly as it cools.
  2. Bladder Deflation: The bladder is completely deflated, allowing access to the formed part within the die cavity.
  3. Part Removal: The formed part is carefully removed from the die, using appropriate tools and techniques to prevent damage or deformation. This may involve using ejectors, lifting mechanisms, or manual extraction.
  4. Inspection: The formed part is thoroughly inspected for any defects, imperfections, or inconsistencies in its dimensions, surface finish, or material properties. Early detection of defects allows for corrective actions or part replacement.

Factors Influencing Unloading Success

  1. Die Design: The die design should incorporate features that facilitate easy part removal, such as draft angles, clearances, and release mechanisms.
  2. Surface Lubrication: Proper lubrication of the die and the formed part reduces friction and prevents sticking or tearing during unloading.
  3. Part Handling: Careful handling of the formed part during unloading prevents damage from scratching, dropping, or excessive force.
  4. Inspection Procedure: A structured inspection procedure ensures that any defects or inconsistencies are identified and addressed promptly.

Conclusion

Unloading in hydroforming is an essential step for ensuring the successful completion of the forming process and the production of high-quality parts. By following proper unloading procedures, manufacturers can prevent damage to the formed part, maintain die integrity, and achieve consistent production of high-quality hydroformed components.

Characteristics of a Hydroforming Press

We specified that there are many different types of sheet hydroforming such as hydrostatic deep drawing, hydrodynamic deep drawing, hydromechanical deep drawing, and deep drawing assisted by radial pressure the hydromechanical deep drawing (HDD) is a special drawing process in which pressurized fluid medium is used instead of one of the die compared to the conventional deep drawing process.

HDD process is a kind of soft tool technology which was originated from hydroforming. In HDD, a pressurized fluid is taken as the female die, and the punch is a rigid body. As the punch forms the sheet, pressurized fluid assists the sheet against the punch and wraps it on the punch.

In the HDD process firstly the sheet is compressed at a definite blank holder force in such a manner that there is not any fluid leakage and there is not any wrinkling on the sheet as the sheet deforms. Then the sheet is bulged by a given pre-bulging pressure towards the punch while the punch is fixed at a definite position below the sheet. Thereafter the punch progresses and forms the sheet at a given forming pressure.

Prebulging has two actions in the process. The first is building pressure at the beginning of the forming stage and the second is hardening the material near the punch radius and increasing its strength against fracture. The process parameters that can affect obtaining a successfully formed cup are fluid pressure, blank holder force, friction between the sheet and the punch; the sheet and the blank holder, the radius of the punch, the gap between the punch and the die, the pre-bulging pressure, and height.

Hydromechanical Deep Drawing with a Hydroforming Press

Since the HDD is a complicated process, it needs to use Finite Element Method (FEM) to determine the correct parameter values. Therefore, many failures in the sheet such as fracture, thinning, and wrinkling can be analyzed and predicted without any expensive experimental repetitions

In this study, a hydromechanical deep drawing press, which is necessary for the production of the industrial teapot product, was designed. First, the dimensions of the body of the press were determined according to the specifications of the industrial product group to be produced. The press is designed to be axially symmetrical and able to use dies approximately 400 mm in diameter, which is necessary for the production of the teapot.

It was found from the preliminary analyses that at least a fluid pressure of 1150 bar and a blank holder force of 1100 tons were required for the production of the desired teapot. As a result of the required fluid pressure, the maximum force that the punch should have was obtained as 2310 kN (23 tons) from the finite element analyses (FEA) as can be seen in Fig. 2.

Consequently, the capacity of the press was determined as:

  • 1200 bar for the fluid pressure
  • 1250 tons for the blank holder force
  • 300 tons for the punch force

Dimensions

The minimum table dimensions were determined as 1100 x 1600 mm considering the connection of the main and auxiliary hydraulic cylinders that will apply the closing force of 1250 tons. To facilitate the analysis, parts of the solid model that will not affect the simulation are excluded from the analysis. In the analysis first, St 37 was assigned to the body materials. The loads on the press elements were defined as in Fig. 3.

Sectional views were given to show the forces exerted on the press body. On account of the punch, 300 tons of force will be exerted on the flange of the punch cylinder (blue arrows) and the blank holder; on account of the blank holder, 1250 tons of force will be exerted on the flange of the blank holder cylinder and blank holder.

Therefore, a total force of 1250 tons (yellow arrows) will be exerted upwards on the top of the press body, 1250 + 300 = 1550 tons of force (red arrows) will be exerted downwards on the bottom of the press body, and a total force of 1250 + 300 = 1550 tons of force (green arrows) will be exerted both downwards and upwards on the blank holder.

After defining the forces and the areas on which the forces were exerted, the material and the necessary boundary conditions were identified and the mesh structure of the model was constructed and then analyzed. Since the blank holder was not rigidly attached to the body and the forces acting on the top and bottom of the blank holder were equal, the modeling was done both with and without the blank holder To test the suitability of the designed and manufactured press body, the closing force and the deformation tests on the press body were applied.

In order to test the suitability of the designed and manufactured press body, the closing force test was applied to the press body. The pressing process could be carried out with the full capacity of the blank holder with a closing force of 1200 tons. As a result, it was observed that there was no compression or backlash in the slides. According to the results of the analyzes carried out later, strain gauges were bonded to the four critical regions of the press body (Fig. 4).

After bonding the strain gauges, data were collected from the four different regions of the press by using data acquisition software for specific pressure values between 50 bar and 230 bar, which is the capacity of the press. The measurements were made at 50, 100, 150, 200, and 230 bar by sets of increasing and decreasing pressures with five repetitions.

EMS Metalworking Machinery

We design, manufacture and assembly metalworking machinery such as:

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as a complete line as well as an individual machine such as:

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Applications:

  • Beading and ribbing
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