The Overview of Development of Hydroforming
Posted: 07/14/2022 09:48:11 Hits: 11
Hydroforming is a plastic forming process in which a certain force-transmitting medium fills the cavity of the tube blank and forms the tube from the inside out. Hydroforming is currently used as a precision forming technology for manufacturing some thin-walled tube parts with complex shapes, and it is also the parts manufacturing technology which saves the most materials in various equipment manufacturing industries. It is conducive to the development of lightweight, high precision and integration of various equipment. It is extremely important in the national economy and national defense technology industry.
Va-ri-Form first produced instrument panel beams for Chrysler in 1990 using the hydroforming process for commercial use; three years later, Daimler-Benz established its first production line using the hydroforming of pipe fittings. In 1994, SPS Company put fully automatic hydroforming technology into use in BMW Motor Company, and produced a special production line. In 2018, Ford used hydroformed engine mounts on two vehicles; GM used hydroformed technology to form the instrument panel beams on both vehicles. In Asia, hydroforming started relatively late. Japan established its hydroforming production line in 1997 and South Korea in 2003. In China, companies such as Wuxi Newplan and Shanghai Baosteel also established hydroforming production lines in the following years and engaged in their research and production.
In the field of domestic research, Shijian Yuan, Zhubin He and others from the Harbin Institute of Technology conducted in-depth research on the basic theory, using the plane stress yield ellipse to describe the change trend and stress state of the wall thickness in the internal high-pressure forming process. The distribution law of the wall thickness change of the formed parts in the high-pressure forming process and distribution characteristics of the wall thickness of the polygonal cross section of the reducer was found. Bing Du and others from Yanshan University determined the deformation mode of the long and short tube blanks, divided the expressions for the boundaries of the geometric dimensions, and gave the corresponding forming internal pressure model. Mohamed-Saïd Chebbaha, Nacer Hebbira and others from Bisquera University in Algeria proposed an inverse finite element method for the hydroforming simulation of anisotropic pipe fittings by using the positional relationship of the nodes before and after forming. The experimentally obtained flow stress data through the hydroforming of T-shaped and Y-shaped pipes verified that the method increases the efficiency compared to the classical explicit dynamic incremental method.
For the current stage of high-pressure forming or pipe hydroforming, the main development trends in the future are: as follows
Va-ri-Form first produced instrument panel beams for Chrysler in 1990 using the hydroforming process for commercial use; three years later, Daimler-Benz established its first production line using the hydroforming of pipe fittings. In 1994, SPS Company put fully automatic hydroforming technology into use in BMW Motor Company, and produced a special production line. In 2018, Ford used hydroformed engine mounts on two vehicles; GM used hydroformed technology to form the instrument panel beams on both vehicles. In Asia, hydroforming started relatively late. Japan established its hydroforming production line in 1997 and South Korea in 2003. In China, companies such as Wuxi Newplan and Shanghai Baosteel also established hydroforming production lines in the following years and engaged in their research and production.
In the field of domestic research, Shijian Yuan, Zhubin He and others from the Harbin Institute of Technology conducted in-depth research on the basic theory, using the plane stress yield ellipse to describe the change trend and stress state of the wall thickness in the internal high-pressure forming process. The distribution law of the wall thickness change of the formed parts in the high-pressure forming process and distribution characteristics of the wall thickness of the polygonal cross section of the reducer was found. Bing Du and others from Yanshan University determined the deformation mode of the long and short tube blanks, divided the expressions for the boundaries of the geometric dimensions, and gave the corresponding forming internal pressure model. Mohamed-Saïd Chebbaha, Nacer Hebbira and others from Bisquera University in Algeria proposed an inverse finite element method for the hydroforming simulation of anisotropic pipe fittings by using the positional relationship of the nodes before and after forming. The experimentally obtained flow stress data through the hydroforming of T-shaped and Y-shaped pipes verified that the method increases the efficiency compared to the classical explicit dynamic incremental method.
For the current stage of high-pressure forming or pipe hydroforming, the main development trends in the future are: as follows
(1) Ultra-high pressure
When high-impact materials are used to form complex structural parts, in order to ensure forming accuracy, ultra-high-pressure forming is required.
(2) Hot forming
The forming medium needs to be heated for light alloy materials with low plasticity at room temperatures to increase the plasticity of the material to achieve forming efficiency.
(3) Making a breakthrough in the critical dimension
In order to meet the requirements of lightweight structure, the diameter-thickness ratio of forming is getting bigger and bigger. How to make a breakthrough in the critical dimension of part forming is a major difficulty at present.
(4) The new forming process
Use internal high-pressure forming and joining processes to combine, and use the new forming process to form a variety of pipes or preforms into one part, reducing the amount of welding, the number of parts, and improving the integrity of components is conducive to the continuous development of internal high-pressure forming.
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