Advantages of Hydroforming Pipe Fittings
Posted: 06/15/2022 11:40:06 Hits: 9
With the improvement of science, technology and productivity, the development and progress of the manufacturing industry to the intelligent manufacturing industry, various industries are undergoing rapid changes, showing the power of China to the world and making intelligent manufacturing go global, which makes the entire industry developed in the direction of green cleaning, low costs, high efficiency, and various forming methods. Good quality, light weights, and multi-disciplinary compounding have become the primary requirements of all manufacturing industries. Hydroforming refers to the use of a liquid medium to provide internal pressure, relying on it for internal conduction instead of rigid molds. It is an advanced flexible manufacturing process that makes the material fit the mold under the pressure of the liquid medium. Because its stress state in all directions has good performance, it can produce variable-section tubular products with complex shapes, such as front and rear subframes, anti-collision beams, and other products. Compared with cold stamping, hydroforming technology has the advantages of reducing processing steps and costs of processing molds, improving the precision of parts, and shortening the overall production time.
The hydroforming pipe fitting is an attractive precision net-shape manufacturing technology that can produce parts with lighter weights, higher strength and more uniform wall thickness, eliminating the complex multi-step operations for traditional stamping and welding. Hydroforming pipe fittings have the following 4 main advantages compared with traditional welding processes:
(1) The weight of the pipe fitting is reduced and the material of the tube blank is saved. Hydroforming technology can be used to form pipe fittings once, which can reduce the number of processes for pipe fittings with complex shapes. The part manufactured is not welded from multiple parts. There are no welding seams; the weight of the welding material is reduced, and less material is used. Weights of pipe fittings formed by hydroforming technology are 20% to 30% lighter than those of traditional welded parts, and the weight reduction effect is very good. Compared with some turning or boring parts, the weight can be reduced up to 75%.
(2) The quality of the parts is improved. In the hydroforming process, the pipe will undergo work hardening, which will increase the overall strength and rigidity of the forming area of the tee, especially the fatigue strength, and also make the wall thickness of the formed parts more even, the dimensional accuracy improved, and the overall quality greatly improved. Taking the radiator bracket as an example, the horizontal accuracy is improved by 50% compared with the traditional forming parts, and the vertical direction accuracy 39%, which also greatly improves the shape accuracy of the hydroformed parts.
(3) Machining and engineering volume can be reduced and can be formed in one step, which can reduce the number of parts. For complex-shaped components composed of several simple-shaped components by welding, the welding process and the number of machining processes can be reduced, and the number of assembly and post-processing engineering can be reduced.
(4) The manufacturing cost is reduced. The traditional stamping parts require different mold processing for different parts, so the whole process requires several sets of molds. Then, multiple parts are welded according to the requirement by welding. The cost of producing parts by hydroforming is usually about 20% lower than that of traditional stamping and welding parts, and the cost of producing molds is about 25% lower, including welding costs and other costs in the production process.
The hydroforming pipe fitting is an attractive precision net-shape manufacturing technology that can produce parts with lighter weights, higher strength and more uniform wall thickness, eliminating the complex multi-step operations for traditional stamping and welding. Hydroforming pipe fittings have the following 4 main advantages compared with traditional welding processes:
(1) The weight of the pipe fitting is reduced and the material of the tube blank is saved. Hydroforming technology can be used to form pipe fittings once, which can reduce the number of processes for pipe fittings with complex shapes. The part manufactured is not welded from multiple parts. There are no welding seams; the weight of the welding material is reduced, and less material is used. Weights of pipe fittings formed by hydroforming technology are 20% to 30% lighter than those of traditional welded parts, and the weight reduction effect is very good. Compared with some turning or boring parts, the weight can be reduced up to 75%.
(2) The quality of the parts is improved. In the hydroforming process, the pipe will undergo work hardening, which will increase the overall strength and rigidity of the forming area of the tee, especially the fatigue strength, and also make the wall thickness of the formed parts more even, the dimensional accuracy improved, and the overall quality greatly improved. Taking the radiator bracket as an example, the horizontal accuracy is improved by 50% compared with the traditional forming parts, and the vertical direction accuracy 39%, which also greatly improves the shape accuracy of the hydroformed parts.
(3) Machining and engineering volume can be reduced and can be formed in one step, which can reduce the number of parts. For complex-shaped components composed of several simple-shaped components by welding, the welding process and the number of machining processes can be reduced, and the number of assembly and post-processing engineering can be reduced.
(4) The manufacturing cost is reduced. The traditional stamping parts require different mold processing for different parts, so the whole process requires several sets of molds. Then, multiple parts are welded according to the requirement by welding. The cost of producing parts by hydroforming is usually about 20% lower than that of traditional stamping and welding parts, and the cost of producing molds is about 25% lower, including welding costs and other costs in the production process.
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