Understanding the Hydroform Process
Cold-Forming Methods
,Hydroforming
The hydroform process has been around for more than half a century and was developed to provide a method of producing low volume runs of asymmetrical parts in an efficient and cost-effective manner. Other cold-forming methods, such as deep draw stamping, can’t typically produce small batches of irregularly shaped parts as effectively as hydroforming. Conveniently, almost any metal can be hydroformed – brass, copper, high-strength alloys, stainless steel, aluminum and many more.
The first step of the hydroform process is to insert a metal blank over a blankholder ring that is placed over a punch to fit the shape of the part. Next, the press is closed and a pressurized fluid in the diaphragm pushes the blank down to form the metal in the shape of the punch. Finally, the pressure in the forming chamber is released and the punch is retracted, revealing the finished part.
There are many advantages associated with the hydroform process. First, it is the optimal cold-forming method for complex shapes with asymmetrical contours. There are fewer tooling costs – up to 50 percent fewer – than conventional cold-forming processes. Set-up is also easier and parts can be produced in a single cycle, making the process efficient and quick. Additionally, the hydroform process mitigates material thin out and allows operators to optimize materials and blank thicknesses to achieve the greatest cost savings. Finally, the hydroform process creates parts that are shiny and blemish-free without the need for additional finishing operations, which can be costly.
Hydroforming is a superior cold-forming process, but depending on the part’s specific application, it may not always be the right choice. Jones Metal is an expert in the hydroform process, but also has expertise in deep draw stamping. Engineers at Jones Metal Forming work with customers to help them determine which process will better suit their needs and save them the most money. In addition, Jones Metal’s staff understands the unique needs and challenges of manufacturers in a variety of industries – medical, defense, automotive, aerospace, commercial lighting, and more.
To learn more about the hydroform process, call Jones Metal at 740-545-6381!
Recommended Resources from the Hydroforming Experts
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a deep dive on hydroforming by Jones Metal Products.
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