Deep Draw Hydroforming

Deep Draw Hydroforming: The Ultimate Guide

Deep draw hydroforming is a popular and better metal fabrication technology. This guide will take you through all vital aspects of deep draw hydroforming.

What Is Sheet Metal Hydroforming?

It is an efficient, cost-effective, and quick technique of forming metal that produces component structures without wasting material. Intricate components are shaped from ductile metals.

Benefits Of Deep Draw Hydroforming

Rapid Cycle Time
Rapid Cycle Time

Deep drawing presses are cycled quickly hence high efficiency in producing large parts.

Recyclability
Recyclability

In the deep-drawn stamping, waste materials are recycled for later use in other applications.

Accurate Parts
Accurate Parts

It is simple to produce irregularly shaped products with maximum accuracy due to its ability to re-draw a part.

Faster Assembly
Faster Assembly

They create close-end shapes eliminating the need for fabrication and welding as a secondary process.

Deep-drawing Has Less Stretch
Deep-drawing Has Less Stretch

There is less material stretch and less friction during processing leading to better integrity, less blemishing, and less finishing work.

Versatility
Versatility

It manufactures copper, brass, steel, aluminum, and alloys to form without damaging or weakening the material. The products produced require less labor to execute hence less time.

Low Cost
Low Cost

Automation of the process reduces wear and tear on the machines leading to the production of thousands to millions of quantities hence reducing labor costs.

Strong And Lightweight
Strong And Lightweight

They use cold metals which retain strength and stability. Besides, are used in projects that require minimal labor, rapid cycle times, seamless elements, and complicated axisymmetric geometries.

Materials Suitable For Deep Draw Hydroforming

AluminumDue to their soft metal properties, they can conform to complex shapes and intricate molds.

Stainless steelThe metal is shaped by a hydroforming process and hydraulic fluid press against it from multiple directions forcing it to change form without stress or cracks.

BrassThe process creates a seamless and clean finish that works well with the decorative brass pieces.

CopperVarious tubes are formed to custom different specifications and different industries-standards dimensions.

InconelThey are the best materials for custom parts in high-temperature environments e.g. jet engine parts and aerospace components.

High nickel steelsHydroforming’s seamless forming process makes high nickel steel parts strong and reliable. They are used in high-pressure applications like turbine blades, liquefied gas storage, etc.

Materials Suitable For Deep Draw Hydroforming
Deep Draw Hydroforming Vs Metal Die Stamping.

Deep Draw Hydroforming Vs Metal Die Stamping.

Deep drawing creates sheet metal parts that are seamless and closed on one end with a depth greater than their radius. Their shapes are achieved by drawing metal into a cavity thus creating a uniform sheet thickness from start to finish unlike when they are stretched or thinned over a die. Simple parts require a single step to draw from their finished parts, while complex shapes and deep parts require multiple steps.

Hydroforming Vs Deep Drawing

Tooling 

You require a male die, a punch, and a blank holding ring tools for hydroforming.

Take a rubber diaphragm, and a pressurized forming chamber to act as the female die.

Compared with die tooling, hydroforming tooling is 50% less expensive.

Mount and align the hydroforming tools quickly to make a fast and efficient setup.

Development Costs 

Specifications like wall thickness and change in material type are accommodated in hydroforming without requiring new tooling.

Reduction In-Press Time 

A single hydroforming cycle draws complex parts, making it different from matched die operations requiring multiple press cycles. Hydroforming presses achieve a 60-70% reduction as compared to conventional matched die presses that reduce 35-45%

Finishing Costs

Hydroforming has an outstanding surface finishing compared to matched die metal forming that leaves scratch lines and stretch. Flexible diaphragm utilization in hydroforming process removes surface blemishes hence reducing the finishing cost.

Hydroforming Vs Deep Drawing

Deep Draw Hydroforming Process

Deep Draw Hydroforming Process
Deep Draw Hydroforming Process

Step 1: Calculate blank sizes

Step 2: Determine the number of draws needed

Process

1. Provide a design.

2. Review design to determine the part to be created with more than 30 400-ton presses Manor fleet. Consider the ideal shape, thickness, and radii of the finished part and determine what will work best based on customer specifications and expertise.

3. Create between 0.005 and 0.5 inches part with extremely tight tolerance, and make up to four feet wide and eight feet long dies.

4. Implement Finite Element Analysis to accurately simulate the entire manufacturing process and allow virtual creation of the parts using the final design.

5. Select the right flat metal sheet e.g. copper, aluminum, brass, and steel.

Note the parts’ depth and the degree of its’ radius and position well the die, and punch on the press.

6. Place the metal sheet, or blank on the die.

7. Apply the punch against the die with force to shape the workpiece.

8. Repeat the process to produce the correct depth and size.

Application Of Deep Draw Hydroforming

Aerospace Industry
Aerospace Industry

Aluminum and aluminum alloys are shaped into a wide range of parts by the hydroforming process. Stainless steel makes jet engine components, titanium for potable water tanks, and nickel alloys for nozzle system parts.

Automotive industry
Automotive Industry

They have complex shapes e.g. gas tanks, sensor covers, bell housings, etc. made by hydroforming.  Hydroforming produces lighter, stronger, and more rigid unibody structures for vehicles, making them weigh less and hence less fuel consumption.

Medical Industry
Medical Industry

They produce medical equipment like surgical trays, covers for operating room lights, and reflectors.

People Also Ask:

What Are The Two Types Of Hydroforming Process?

Sheet hydroforming; It is a method that improves the aluminum alloy sheets’ formability at room temperatures.

Tube hydroforming; It is a process that uses two die halves to expand metal tubes into a shape that contains the raw tube. They are used to stamp two part halves and then weld them together.

What Is Explosive Hydroforming?

A metal-forming technique used in a wide variety of applications e.g. automotive, aerospace, and maritime industries is called explosive hydroforming. It requires one-sided tooling die only hence saving cost on short-run parts.

Which Are The Critical Parameters In Hydroforming?

Bed Size

The footprint of the expected toolset must be able to be accommodated by the bed of the press. Orientation of the parts within the bed will be able to determine the overall bed dimensions of the rectangular or complex blank shapes.

Tonnages And Speeds

Manage punch speed for blank material to flow properly during the draw. To prevent material from thinning, tearing, or wrinkling, apply force to the blank holder, the punch, and the cushion to keep them within the blank’s acceptable range.

Stroke And Daylight

Enough daylight must be available between the fully retracted punch and the die face for flanged parts that require stripping. This translates to daylight double the press stroke to allow removal of the finished part from the press.

More Resources:

Hydroforming Process

Titanium Hydroforming

Hydroforming Stainless Steel

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