Hydroforming for Advanced Manufacturing

Contents......Page 6
Contributor contact details......Page 12
Preface......Page 16
1.1 Introduction......Page 18
1.2 Hydroforming systems, equipment, tooling and controls......Page 27
1.3 Materials, formability, forming limits and advantages......Page 32
1.4 Tribology in hydroforming – friction, wear, lubricants, coatings and testing methods......Page 34
1.5 Computer simulations for tube hydroforming......Page 38
1.6 Developments in hydroforming and concluding remarks......Page 41
1.7 References......Page 45
Part I: Principles of hydroforming......Page 48
2.2 Presses......Page 50
2.3 Pressure intensification systems......Page 56
2.4 Controls......Page 60
2.5 Tooling......Page 62
2.6 Future trends......Page 67
2.8 References......Page 68
3.1 Introduction......Page 69
3.2 Stress and strain relationships in tube hydroforming......Page 71
3.3 Determination of forming limits......Page 79
3.4 Forming loads and process control......Page 83
3.5 Preceding forming operations......Page 86
3.6 References......Page 92
4.1 Introduction......Page 94
4.2 Steel materials......Page 95
4.3 Aluminium and magnesium alloys......Page 98
4.4 Formability testing......Page 101
4.5 Future trends......Page 104
4.6 References......Page 107
5.1 Introduction......Page 110
5.2 Tube formability......Page 111
5.3 Measuring tube formability......Page 116
5.4 Tube-forming limits......Page 125
5.5 Formability analysis for numerical simulations......Page 131
5.6 Formability analysis in the plant......Page 132
5.7 Conclusions and future trends......Page 133
5.8 References......Page 134
6.1 Introduction to tube hydroforming design......Page 138
6.2 Technological classifications of tube hydroforming processes......Page 140
6.3 Hydroformability of tubular parts......Page 144
6.4 Guidelines for process design......Page 148
6.5 Finite element analysis strategies for process design......Page 153
6.6 Designing a new hydroforming process: a simple example......Page 156
6.7 References......Page 159
7.1 Introduction......Page 161
7.2 Parameters that influence friction, lubrication, and wear......Page 165
7.3 Lubrication mechanisms......Page 171
7.4 Development and evaluation of hydroforming lubricants......Page 180
7.5 Impact of numerical modelling in hydroforming tribology......Page 189
7.7 References......Page 194
Part II: Hydroforming techniques and their applications......Page 196
8.1 Introduction......Page 198
8.2 Concept of rotary draw bending process......Page 199
8.3 Material behavior in rotary draw bending process......Page 200
8.4 Pre-flattening/crushing......Page 210
8.5 Part design and tube formability......Page 214
8.7 References......Page 217
9.2 Hydropiercing......Page 219
9.3 End-cutting and saw-cutting......Page 226
9.4 Welding......Page 229
9.5 References......Page 232
10.2 Hydroforming processes......Page 233
10.3 Dies and presses for hydromechanical deep drawing......Page 251
10.4 References......Page 254
11.1 Introduction......Page 255
11.2 Aluminum and magnesium alloy tubes......Page 256
11.3 Aluminum tube bending and hydroforming......Page 265
11.4 Magnesium tube bending......Page 272
11.5 Forming at elevated temperatures......Page 274
11.6 Automotive applications and future trends......Page 277
11.8 References......Page 280
12.1 Introduction......Page 284
12.2 Low-pressure hydroforming......Page 285
12.3 Part characteristics......Page 288
12.4 Cross-section pre-forming......Page 294
12.5 Conclusions......Page 302
12.6 Reference......Page 303
13.1 Introduction......Page 304
13.2 So many options; how to choose?......Page 305
13.4 Stampings and assemblies......Page 306
13.5 Tube forming......Page 307
13.6 Commonly held misconceptions......Page 315
13.7 Low-pressure hydroforming......Page 316
13.8 High-pressure hydroforming......Page 319
13.9 Other comparative process factors......Page 325
13.10 Conclusions......Page 330
13.11 References......Page 331
14.2 Evolution of the technology......Page 332
14.3 How fluid cell pressing works......Page 334
14.4 Recent developments......Page 336
14.5 Essentials of ductile materials......Page 340
14.6 Suitable part applications......Page 342
14.7 Tools (form blocks)......Page 343
14.8 Part manufacture......Page 347
14.9 Conclusions......Page 350
15.1 Introduction......Page 352
15.2 What makes it so difficult to lose weight?......Page 353
15.3 How to lose weight......Page 354
15.4 How tube hydroforming can help you lose it......Page 355
15.5 Weight loss limitations and how to address them......Page 365
15.7 References......Page 368
16.2 Lightweight materials: advantages and disadvantages in manufacturing......Page 369
16.3 Forming technologies for lightweight materials......Page 370
16.4 Warm hydroforming: state-of-the-art review......Page 371
16.5 Comparison of warm and cold hydroforming: a numerical study......Page 380
16.6 Process design and control in warm hydroforming......Page 384
16.7 Characterization of materials for warm hydroforming conditions......Page 390
16.8 References......Page 397
Index......Page 401