ADVANCES IN HYDROFORMING 1

TABLE OF CONTENTS

LIST OF FIGURES

Fig.1 Hydro formed handle bar …………………………………………..4

Fig.2 Hydro formed T-junction …….………………………........…..….4

Fig.3 Sheet hydro forming ………………………………………………5

Fig.4 Tube hydro forming ……………………………………..........…..6

Fig.5 Stresses in Hydoformed component ……………………………..7

Fig.6 Benefits of Hydroforming …………………………………...…..11

Fig.7 Forming Limit Diagram ………………………………………....12

Fig.8 Schematic Diagram of Tube Hydro forming & Process Control 14

Fig.9 Applications of Hydroforming ………………………………….15

Fig.10 Part made using Variform Process …………………………….19

Fig.11 Setup for Hammering ……………………………………….….21

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Fig.12 Hammering Cycle ……………………………………….………22

Fig.13 Part made by Hammering ……………………………………....24

Fig.14 Conventional Method of Hydroforming …………………...….26

Fig.15 Pre-Pressurizing Method of Hydroforming …………………....27

1. INTRODUCTION

Hydro forming is a high-pressure deformation process that shapes

metal sheets or tubes into a predefined geometry by using a fluid under
high pressure. Hydro forming is similar to the conventional deep-
drawing technique with a counter-mould. The specific difference from
the conventional method is that a fluid is used instead of a die to forming
into final shape. This deformation process requires application of fluid
pressures up to 4000 bars depending on the size of the component.
As the automobile industry strives to make car lighter, stronger
and more fuel efficient, it will continue to drive hydro forming
applications. Some automobile parts such as structural chassis,
instrument panel beam, engine cradles and radiator closures are
becoming standard hydro formed parts.
Recently hydro forming was used for manufacturing of clad pipe
used in oil and chemical industry. The capability of hydro forming can
be more fully used to create complicated parts. Using a single hydro
formed item to replace several individual parts eliminate welding, holes,
punching etc... Hydro forming simplifies assembly and reduce inventory.
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The process is quite simple - a blank with a closed-form, such as a

cylinder, is internally pressurized using fluid. The fluid is frequently
water. The applied pressure is usually in the range 80-450 MPa. Its
resultant plastic expansion is confined in a die of the desired shape.

2. HYDROFORMING

Hydroforming is a cost-effective way of shaping malleable metals

such as aluminum or brass into structurally stiff and strong pieces. One
of the largest applications of hydro forming is the automotive industry,
which makes use of the complex shapes possible by hydro forming to
produce stronger, lighter, and more rigid body structures for vehicles.
This technique is particularly popular with the high-end sports
car industry and is also frequently employed in the shaping of aluminum
tubes for bicycle frames.

Hydro forming allows complex shapes with concavities to be

formed, which would be difficult standard solid die stamping. Hydro
formed parts can often be made with a higher stiffness to weight ratio and
at a lower per unit cost.

This process is based on the 1950s patent for hydra molding by Fred
Leuthesser. It was originally used in producing kitchen spouts. This was
done because in addition to the strengthening of the metal, hydramolding
also produced less "grainy" parts, allowing for easier metal finishing.
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Fig 1 Hydro formed handle bar Fig 2 Hydro formed T-junction

3. CLASSIFICATION OF HYDOFORMING TECHNIQUES

Hydroforming is broadly classified into sheet and tube hydroforming.

Sheet hydroforming is further classified into sheet hydroforming with a
punch (SHF-P) and sheet hydroforming with a die (SHF-D), depending
on whether a male (punch) or a female (die) tool will be used to form the
part. SHF-D is further classified into hydroforming of single blanks and
double blanks, depending on the number of blanks being used in the

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forming process

Fig.3 Sheet hydro forming (Source: [6])

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In tube hydroforming tube is loaded into hydoroforming dies and

the press closes. The sealing rod engages the part sealing the ends and
fills the tube with water. Pressure inside the tube increases, now the
sealing rod is pushes the tube into the die and the internal pressure is
ramped to maximum value. The hydroformed tube takes the shape of the
mould. Final part is removed from the mould.

Fig.4 Tube hydro forming (Source: [6])

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4. BENEFITS OF HYDRO FORMING

4.1 Better degree of deformation of the formed part

By applying a uniform force to the metal sheet, the fluid shapes it

into the form of the tool. In this process, a uniform distribution of sheet
thicknesses is achieved, which allows for maximum degrees of
deformation. Abrupt changes in stress are avoided – a factor that ensures
high dimensional accuracy and reduces the tendency of the material to
return to its original size and shape when the applied load is removed.
Conventional deep-drawing Hydroformed with the FB25

strong local thinning of the

less internal stress and less tendency
material
to return to its original shape
inhomogeneous distribution of
homogeneous strength and less
material thicknesses
amount of waste
less internal stress of the formed
high dimensional accuracy
part

Fig.5 Stresses in Hydoformed component

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4.2 Good Surface Finish

Since the metal sheet is deformed using a pressurized fluid instead of
a conventional deep-drawing die, the surface is not in direct contact with
any tool that may lead to surface damage. In the hydroforming process, the
metal sheet only comes into contact with the tool when the maximum
required forming pressure is reached. This results in excellent surface
finish of the formed parts.

4.3 Use of Various Engineering Materials

The hydroforming process allows you to use the complete spectrum
of all ductile and malleable materials. No matter if you are using steel
sheets, stainless steel, special alloys, aluminum, copper, brass or titan: for
all of them, optimum degrees of deformation can be achieved. Metal sheet
thicknesses range from 0.05 to 6 mm. Specifically for very thin metal
sheets, the possibilities of hydroforming are far superior to those of
conventional forming techniques

4.4 Savings in tooling costs up to 80%

Low tooling costs are a great advantage of the hydroforming process
using the Form Balancer. Tooling costs are reduced to 50% by the fact
alone that only the negative molding tool is needed. Further savings are
generated by no longer needing hold-down devices and guide way systems.
Due to the possibilities of forming complex geometries with only one tool,
upstream machining operations can often be omitted, which in most cases
reduces tooling costs to only 20% compared to those of conventional deep-
drawing tools.

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4.5 Reduction in weight

Automakers continuously strive to reduce motor vehicle mass,
mainly for efficiency and environmental reasons such as improving fuel
efficiency and reducing emissions. However, as they reduce vehicle
weight, they must try to avoid compromising other important criteria, such
as strength and energy management. They look for technologies,
techniques, and processes that satisfy these various needs, to which
hydroforming is the answer. Also the process and functional characteristics
need to be maintained. If a design engineer changes a part, he has to think
about how will the manufacturing engineers make the new part? How will
the line workers join the various parts to make assemblies? When finished,
will everything work as intended? Answers to all this questions in
Hydroforming.

Hydoformed versus Stamped Components

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Much of a vehicle's weight is in the structural frame, and most frames are
made from steel. The exception is aluminum,which is used in some
automobiles.

Mass Weld LengthPerformance Fore/Aft

Concept
(kg) (mm) Loading
Red scale set to 1.0 x
Stamped 23.0 4,915
material strength
Red scale set to 1.0 x
Hydroformed 20.9 3,975
material strength
Change -2.1 -940
Compared to a traditional stamped automotive part, a similar
tubular component has less mass and requires less welding. In this
case, the reductions were more than 9 percent mass and 19
percent in weld length.

4.6 Nearly unlimited wall Thickness variations

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The wall thickness can be adjusted anywhere along the part between
some predetermined minimum and maximum thickness, allowing a nearly
infinite combination of thickness zones. This level of design freedom
enables design engineers to fine-tune the part to achieve a desired load
response. Variable-wall technology is not limited to round cross sections—
it can be used to manufacture most symmetric shapes without any
postforming operations. Heat treatment adds even more versatility to these
structures, imparting properties that range from those of strip to fully cold-
worked steel. Finally, it can be beneficial in many nonautomotive
applications as well.

Fig.6 Benefits of Hydroforming

5. FORMING LIMIT DIAGRAM

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During hydro forming process failure occurs due to thinning, this

is due to the excessive deformation in a given region. A quick and
economical analysis of deformation in a forged part is analyzed from
forming limit diagram. The sheet is deformed, converting circles in to
ellipse, and the distorted pattern is then measured and evaluated.
Regions where the area has expanded are locations of sheet thinning
Regions where area has contracted have undergone sheet thickening.
Using the ellipse on the deformed grid, the major (Strains in the
direction of larger radius) and associated minor strains (Strains
perpendicular to the major) can be determined for variety of locations
and values can be plotted on the forming limit diagram. If both major
and minor strains are positive deformation is known as stretching, and
thinning will possible.

Fig.7 Forming Limit Diagram

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6. HYDROFORMING PROCESS CONTROL

A typical hydro forming system would include a press capable of

developing necessary forces to clamp the die valves together when
internal pressure acts on fluid; a high pressure water system to intensify
water pressure for forming component, looking including aerial cylinder
and punches, depending on component and a control system for process
monitoring.
Since the entire process of operation takes place inside a closed
die, one cannot see what actually happens during forming. Therefore the
controller plays a vital role in displaying, monitoring and controlling the
different parameters.

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Fig.8 Schematic Diagram of Tube Hydro forming and Process Control

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7. APPLICATIONS

Almost any industry can benefit from the advantages of the

hydroforming process. Again and again companies are faced with the
challenge of simultaneously achieving both lower operating costs and
innovative solutions for evolutionary advances of their products. Our high-
pressure forming technology offers attractive possibilities in terms of price-
performance ratio and manufacturing time. Hydroforming finds its
application in following industries:

• Automotive industry
• Aerospace industry
• Medicine technology
• Electronic appliances
• Heating & air conditioning
• Agriculture industry

(a) (b) (c)

Fig.9 Applications of Hydroforming

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8. ADVANCES IN HYDROFORMING

In recent years hydroforming has become a commonly used method

of tube expansion for many applications, such as automotive chassis
frames, exhaust manifold piping connectors, and air-conditioning system
components. Because hydroforming uses water under high pressure to
expand the tube or pipe from the inside, and water can take any shape, it’s
a versatile process and is suitable for forming complex, single-piece
components.

During the last decade, industry has seen dawn of hydroforming as

an alternative for stamping and various forming the reason for this are its
advantages and the unprecedented research work done in improving the
techniques of hydroforming. Some of the new techniques are:

• Variform process or Pressure sequencing

• Hammering

• Pre-Pressurizing

• Manufacturing of Clad Pipes

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8.1 Variform process or Pressure Sequencing

Pressure Sequence Hydroforming (PSH) is a patented tube

hydroforming process that utilizes low internal fluid pressure to support the
tube while the die closes. Once closed the majority of the part profile has
been formed. At this point the internal pressure is increased to lock in the
form and provide backup for punching holes.
Hole size can range from as small as 2 times material thickness to as
large as 50 mm X 200 mm. Holes can be extruded or clean pierced, and
practically any shape including round, slot, square, hexagon, or
rectangular. The resulting material slug is typically pushed back out of the
way and left attached inside the tube, though there are techniques available
to remove them when required.
Pressure Sequence Hydroforming (PSH) is compatible with most
metals, if it can be made into a tube PSH can form it. The process that
normally establishes the required material elongation is the prebending
operation. PSH has proven process compatibility with High Strength steel
up to 960 MPa UTS, Dual Phase, and TRIP steels. In addition to carbon
steel the PSH process has been used to form both 5000 and 6000 series
aluminum, and numerous grades of stainless steel.

Pressure Sequence Hydroforming (PSH) reshapes the tube cross

section into the required profile without stretching the material. The tube
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material thickness distribution found after hydroforming is the same as that

present in the bent tube. Pressure Sequence Hydroforming (PSH) reshapes
the tube while the die closes. Once the die is completely closed the tube
has been forced to take the shape of the die cavity without requiring the
material to expand. High Pressure Hydroforming first closes the die on an
undersized tube and then utilizes high internal fluid pressure to expand the
tube to fill the die cavity. The part to part or floor to floor cycle time for
Pressure Sequence Hydroforming is in the range of 17 seconds for a small
part such as an Instrument Panel Beam to 24 seconds for a large part such
as a roof rail or structural member.
The Pressure Sequence Hydroform (PSH) process uses a completely
different mechanism than HPH to form the corners. In the PSH process, the
tool stops before it is completely closed on the tube, this is referred to as
the prefill height. The tool dwells at this point as the tube is then filled with
fluid and lightly pressurized. The die is then fully closed while the tube is
supported by the prepressure. Using this support PSH forms the cross
section corners while the die is closing under prepressure.
Pressure Sequence Hydroforming is a dimensionally stable and
robust process. Product features that are produced in the hydroform tool are
typically very stable as the entire part profile and all piercing is completed
in a single cavity.

Sequencing the pressure prevents pinching the material in the die. As

part complexity continues to increase, in order to minimize part, containing

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the tubular blank inside the die cavity becomes more difficult. An
improperly contained blank can easily become pinched between the die
halves, leading to an improper fill and perhaps rupture. It also eliminates
the need for posthydroforming processes such as annealing and washing.
Using the PSH process, tube corner radii are formed in the bending mode
beyond the yield limit of the base material, rather than in the tensile mode
reached during conventional high-pressure hydroforming.

Fig.10 Part made using Variform Process

8.2 Hammering

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Hammering uses two alternating pressures. It reduces the drag force,

which is the friction that develops between the work piece and the die. As
the internal pressure increases, the work expansion force increases the drag
force, or friction, between the work piece and the die. Also, the internal
pressure becomes a force that pushes back against the hydraulic system.
The combination of work expansion force and internal pressure is the
reaction force.

As the reaction force increases, it becomes difficult to force the

material to flow into all of the contours and recesses of the die. The
hammering method cycles between a high and low pressure. The repeated
pressure drops reduce the drag force, allowing the material to flow further
in the die. It also prevents thinning at the expansion areas and improves the
process capability.

The hammering process is driven by a pump that varies the pressure

it develops, such as a direct drive volume (DDV) control pump, a high-
pressure generator that uses a hydraulic servo pump. The DDV is a hybrid
of an AC servomotor and reversible-piston pump. The pulsations are
generated by controlling the forward and reverse rotation of the AC
servomotor at high speed.

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The time from start-up time to shutdown time (including hold time)
is one cycle. The frequency is the number of cycles that elapse in one
second and is measured in hertz (Hz). Results from hydroforming trials
have shown that the optimal hammering frequency range is between 1 and
3 Hz. Frequencies higher than 3 Hz make it physically impossible for the
pressure to reach the intended high and low points.
In other words, reversing the pressure more than 3 times per second
doesn’t give the hydraulic system enough time to achieve the programmed
pressures. The optimal pressure range is between 725 and 4,350 pounds per
square inch (PSI), or 5 to 30 MPa.

Fig.11 Setup for Hammering (Source: [7])

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Above figure shows the actual setup used for Hammering. The
complete system uses three DDV pumps. One generates the pulsating
pressure that forms the tube; the others are multipurpose pumps used to
raise and lower the press’s upper die at high speed. When the upper die is
completely closed, the DDV seals and presses in both ends of the tube
work piece. The DDV’s AC servomotor is regulated by a CNC. This
controls the hammering frequency and pressure increase rate.

The pulse frequency and pressure on the secondary side is controlled

by the reversible AC servomotor of the DDV pump and pulsing the
primary side of the oil and water boosting cylinder at a ratio of 1-to-10.
The shape that can be formed in one cycle of tube expansion is determined
by the maximum water capacity in the high-pressure cylinder.

Fig.12 Hammering Cycle

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The Hammering method cycles between a high and low pressure, so

Hammering has more variables than in conventional hydroforming. Instead
of one pressure, hammering uses two alternating pressures. Also, in this
case, the last two cycles as can be seen in above figure have a brief hold
time of 0.2 second at the points of minimum and maximum pressure.
Hammering allows the user to vary the difference between the high and
low pressure (10MPa in this case), the cycle time and also the hold time.

The two main problems faced while forming are rupturing and
buckling. Rupturing is usually the result of setting the internal pressure too
high or the expansion force too low. This causes the material to stretch and
become too thin in the expansion area, ultimately causing a rupture. This is
why it is critical to balance the internal pressure and initial expansion
force. Using an initial pressure that is too high also can cause the pipe to
expand too quickly, causing the material at the axis sealing area to pull
away. This, in turn, causes the fluid to leak, so the pressure does not rise to
the set value and the processing can’t start.

Buckling usually is caused by setting the internal pressure too low or

the expansion force too high. Using a processing time that is too fast also
may contribute to buckling.

Hammering eliminates these problems as it uses two alternating

pressures which balances initial pressure & expansion force. As we can see
the part made by conventional hydroforming process shown in the diagram
below is ruptured, whereas the part at the bottom made by Hammering did
not get ruptured.

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Fig.13 Part made by Hammering

8.3 Pre-pressurizing
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In pre-pressurizing method a metal tube is placed in lower mold

with the ends sticking out from it and injects a pressurizing fluid into the
metal tube through the inside of a seal punch and gradually presses the
seal punches against the tube ends, in the state with internal pressure and
pressing force applied the upper mold is lowered so as to deform the
tube and end the processing with the tube ends sticking out from the
mold and further boosting the internal pressure in metal tube after
closing the mold and ending the forming operation and a hydroformed
product having a flange across the entire length in longitudinal section is
formed.

As shown in Fig.14 the conventional hydroforming method relates

to placing a metal tube shorter in length than the mold in a mold so that
the tube ends of the metal tube are positioned inside the end faces of
mold, then upper mold is lowered to close the mold and clamp the tube
between upper and lower molds. After that seal punches advance and
water is inserted as a pressurizing fluid from one of the seals, the
pressure inside the tube is raised to obtain predetermined shape.

In this new technique of pre-pressurization a metal tube is placed

in the lower mold with its tube ends sticking out of the mold, injecting
pressurized fluid into the metal tube through an inside of a seal punch
while pressing seal punches against the tube ends, filling the inside of
metal tube with a pressurized fluid to apply internal pressure, then the
upper mold is lowered so as to close the mold, deforming the tube to the
predetermined shape with the tube ends sticking out of the mold. The
process is shown in Fig.15.

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Fig.14 Conventional Method of Hydroforming

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Fig.15 Pre-Pressurizing Method of Hydroforming (Source: [3])

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8.4 Manufacturing of Clad pipes

The energy sector is hot right now, and so is pipe production. Pipe
for transporting crude oil and crude gas must meet several criteria. The
material must have sufficient durability, corrosion resistance, and
strength, and the size must be large enough to transport the desired
volume. Corrosion resistance is necessary to prevent erosion damage
from pollutants in the oil or gas, which include hydrogen sulfide,
chlorides, and water. Finding the optimum material for making pipe for
this industry is tricky. Low-alloy carbon steels tend to be strong, but lack
corrosion resistance. Stainless steels resist corrosion but lack strength.
Cladding low-alloy carbon steel with a thin layer of a corrosion-resistant
alloy is a suitable process.

An alternative is to produce clad pipe that makes the best use of

corrosion-resistant alloys and low-alloy steels. Such pipe typically is
made from strong, low-alloy carbon steel and lined with a sleeve made
from a corrosion-resistant material approximately 0.19 inch thick. The
simplest mechanically clad pipe consists of a corrosion-resistant liner
inserted into a low-alloy external carbon steel pipe. A more sophisticated
mechanically clad pipe is produced by shrinking the external pipe or
rolling one pipe inside the other. The nature of the mechanical bond
depends on the process. Regardless of the method, the bond is purely
mechanical. The two distinct materials remain two distinct materials
they do not fuse together to become a single mass as metallurgically
bonded pipes do.

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A process was devised which used hydraulic pressure on the inner

pipe and induction heating on the outer pipe. The hydraulic pressure caused
the inner pipe to expand; removing the heat caused the outer pipe to shrink
as it cooled.

A modern improvement to this process uses a hydraulic pipe

calibration and lining machine equipped with an additional water system as
well as sophisticated controls. It uses a process similar to automotive parts
hydroforming machines to attain a high degree of compressive contact
between the two pipes. The corrosion-resistant pipe is inserted into the
outer low-alloy carbon steel pipe in a semi automated operation and is then
placed into the calibration machine's open tool form. The tool closes and
axial cylinders seal each of the pipe ends. Hydraulic fluid under high
pressure expands the inner tube. A firm compressive contact is achieved by
the elastic and plastic behaviors of the outer pipe and the inner pipe. The
elastic spring back of the outer pipe is greater than the plastic expansion of
the inner pipe; the resulting residual pressure stress of the inner pipe is in
the region of 7,250 to 14,500 pounds per square inch (PSI).

This provides a homogenous contact along the pipe's entire length.

One of the chief advantages of using a hydroforming process to

manufacture mechanically clad pipe is simple economics. Compared to
producing a non-clad or a metallurgically clad pipe, manufacturing clad
pipe with this method represents a significant cost reduction. Potential cost
reduction is in welding, because clad pipe has thinner walls than
homogenous pipe, and so requires less welding time. In this scenario, the
clad pipes are 0.39 in. thick, whereas the homogenous pipe is 0.59 in.
thick, a 13 percent difference.

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9. CONCLUSION

In this seminar report recent developments in hydroforming are

discussed systematically. After discussing these we conclude that:

1. Hydroforming has wide application in many industries like

automobile, aerospace, electronic goods, sanitary fittings, etc.

Many benefits offered – Good surface finish, Use of almost all
ductile and malleable material, Better deformation, High
dimensional accuracy, Savings up to 80% in post forming
processes (Refer page 8). Because of so many benefits offered
Hydroforming is considered as an effective method to meet the
demands of ever evolving manufacturing sector.

2. Due to introduction of hydroforming it is now possible to use light

weight aluminum structural frame instead of the conventional
heavy weight steel frame in automobiles. Resulting in reduction of
weight by more than 9 percent and weld length by 19%
(Refer page 10).

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3. Hydroforming facilitates manufacturing of a single large complex

component instead of many small components, reducing the

tooling costs by 50%. For example: operations like piercing can be
done during hydroforming itself. There is no need of finishing the
surface after hydroforming as hydrofomred component has a high
grade of surface finish.

4. Of the above discussed recent techniques Pressure sequencing and

Hammering are the most useful methods. Using these methods we

can hydroform any malleable metal ranging from copper to high
grade stainless steel. By reducing the drag force Hammering
eliminates the two major problems faced in forming namely
rupturing and buckling.

Thus adopting these new techniques there is better utilization

of material. The day will not be far away when hydroforming will
completely replace the conventional stamping and forming
processes.

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10. REFERENCES

1) Research paper: “Developments in Hydroforming” – S.H.Zang

2) U.S. Patent 2,713,314

3) U.S. Patent 2010-0186473

4) Book: “Hydroforming for advanced manufacturing”, By M, Koç,

2009 Woodhead Publishing Limited.

5) Book: “Hydroforming technology: Advanced Materials & Processes”

(Refereed): May, 1997: ASM International.

6) Book: “Fundamentals of Hydroforming” by Harjinder Singh.

7) http://www.thefabricator.com/techcell/hydroforming
8) http://www.americanhydroformers.com
9) http://www.sciencedirect.com

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