d u rin g t h e p ro cess. As a resu lt o f t h e axial m at erial flo w, h igh er d egrees o f d efo rm at io n are p o ssible t h an wh en fo rm in g o n ly by ch an gin g t h e
wall t h ickn ess. In so m e cases, lo cal m at erial co m p ressio n resu lt s. Th ese com ponents are ch aract erized by a n u m ber o f lo cally d ist ribu t ed
bu lges o ver t h e co m p o n en t len gt h wit h o r wit h o u t in t erm ed iat e ben d s Fig. 5.2.6
. Axial m at erial flo w as a resu lt o f co m p ressio n h as an effect o n ly at t h e co m p o n en t en d s. In t h e case o f sh ap ed elem en t s fo llo win g
ben d s o r a m arked bu lge, p o sit io n ed clo se t o t h e h o rizo n t al cylin d ers, o n ly exp an sio n an d calibrat io n t ake p lace, bu t h ard ly an y axial co m -
p ressio n . In t h e case o f su ch com ponents, axial co m p ressio n is n o t p o ssible fo r
vario u s reaso n s Fig. 5.2.7
. A calibrat io n p ro cess is ap p lied h ere, wh ere- by fo rm in g o n ly t akes p lace m ain ly by ch an gin g t h e wall t h ickn ess.
5.2.3 Fields of application
Th e d esign an d st ru ct u ral p o ssibilit ies o ffered by h yd ro fo rm in g are u sed su ccessfu lly in a n u m ber o f ap p licat io n s fo r t h e m an u fact u re o f h igh -
st ren gt h co m p o n en t s an d assem blies wit h o p t im ized service life an d weigh t ch aract erist ics.
410
Hydroforming
Fig. 5.2.6 Expansion
compression and local calibrating
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
411
Process technology and example applications
Fig. 5.2.7 Pure calibration
Fig. 5.2.8
Blank shapes single-w alled tubes
extruded sections w elded or unw elded
sheet metal blanks double-w alled tubes
sheet metal blanks conically rolled
and w elded
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
O n t h e basis o f t h e vario u s sem i-fin ish ed p ro d u ct sh ap es Fig. 5.2.8
, h yd ro fo rm in g can be ap p lied t o a wid e variet y o f field s. Th ree m ain
u ser gro u p s h ave em erged as t h e m o st sign ifican t o ver recen t years Table 5.2.1
: – t h e au t o m o t ive en gin eerin g an d su p p ly in d u st ry,
– san it ary an d d o m est ic in st allat io n in d u st ry, – p ip e an d p ip e co m p o n en t m an u fact u rers.
412
Hydroforming
Sector
automotive industry vehicles
– road – w ater
– air – rail
chemical, gas, oil industry, pow er station construction
domestic appliance industry bicycle industry
processing of sections
pumps and fittings heating, ventilation,
air conditioning furniture industry
lighting industry optics
Assembly
chassis, exhaust and intake systems, add-on parts,
drive system, seats, framesbodyw ork,
steering piping and tank components,
pipe fittings fittings, machines
pipe fittings frame construction, semi-
finished pipes, rail-bound vehicles, utility vehicles
housings fittings
frames, moulded elements street lighting
telescopes, torches
Component examples
cross members, side members, manifolds, roof rails, spoilers,
gear shafts, seat frame com- ponents, ABC pillars,
roof frame profiles, steering column w ith compensation
T-fittings, reducers, housings, panelling
tube bends, T-fittings, reducers, cross pieces,
bends pedal bearings, joints, frames
joints, girders, calibrated tubes, sections,
roof arches, frames, structural members
intake pipes tube bends, reducers,
T-fittings, manifolds legs, structural members,
joints, shells, shelves light masts, lamp shells
housings Table 5.2.1: Fields of application for the hydroforming technique
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
5 Hydroforming
5.3 Component development 5.3.1 User-oriented project management
