Post on 22-Jan-2023
Electropneumatics and Hydraulics
(I) Pvt. Ltd., Pune
Perspectives and Outlook on the Current
Trends in Metal Forming
Focus: Hydroforming
By: Abhijit ChakravartyBy: Abhijit ChakravartyBy: Abhijit ChakravartyBy: Abhijit Chakravarty
Plant head, Component division
* Some images in this presentation are from public domain.
1. Water Bulging and Hydroforming- a perspective
2. Hydroformed Exhaust Parts emerging as a viable option
3. Introducing Aluminium Hydroforming in 2 Wheelers
Handle Bar
4. PEM Fuel Cell Bipolar plate manufacturing- a
perspective
Presentation Overview
A cold forming process in which a round/preformed tube
is expanded from the inside into a complex shape using
pressurized waterpressurized waterpressurized waterpressurized water.
A cold forming process in which a round/preformed tube
is expanded from the inside into a complex shape using
pressurized waterpressurized waterpressurized waterpressurized water.
Water Bulging Water Bulging Water Bulging Water Bulging Water Bulging Water Bulging Water Bulging Water Bulging Hydroforming Hydroforming Hydroforming Hydroforming Hydroforming Hydroforming Hydroforming Hydroforming
• Automotive chassis parts
• Engine cradle support
• Heat exchanger Housings
• Bicycle frames
• Aerospace …
• Utensils
• Plumbing parts
• Decorative parts
• Musical instruments….
FORMING WITH WATERFORMING WITH WATERFORMING WITH WATERFORMING WITH WATER
Tube Hydroforming
High
pressure
water
intensifier
Axial cylinders with
position sensor
Tooling
CNC
controls
Hydraulic power pack
Hydraulic press
TUBE WATER BULGING TUBE HYDROFORMING
1 Process Pure expansion Expansion with axial compression/feed
2 Forming tonnage 5 to 500 T 1000 to 5000 T
3 Parts
Straight
Simple and symmetrical
Single piece
Straight/bent/preformed
Complex and any type
Single piece
4 Thinning Can be controlled No control, ~40-50%
5 EquipmentCost- lower
Space- less, vertical forming
Cost- higher
Space- more, horizontal forming
6 Tool Simpler More complicated
7 Process synchronisation Critical Relatively easy
8 Productivity Low High
9 Part cost Lower Higher
10 ApplicationsPlumbing, decorative, cookware,
architectural, musical sector
Automotive, aerospace, medicine,
electronics, heating & air conditioning,
agriculture
Comparison
Tubular Part Forming for
automotive applications
Tubular Part Forming for
automotive applications
Conventional
Stamping/Others
Conventional
Stamping/OthersWater FormingWater Forming
Water
Bulging
Water
BulgingHydroformingHydroforming
Evaluating & Continuous
improvements
Evaluating & Continuous
improvements
Under
development
Combined Water
Bulging + Hydroforming
Combined Water
Bulging + Hydroforming
Right part selection
Right volumes
Right size machine
Mostly unsuitable
Conventional Parts & Process
Bending
Stamping + Welding
Critical part geometries and custom
shapes (packaging, flow
requirements)
Drastic shape changes
Large expansions, up to 100%
Tight bend radii, down to 1D in thin-
walled tubes
Difficult to form materials- SS 400,
austenitic SS
Leakages from welds
Weld spatters/aesthetics
Large
sions
Large
expan
sions
Difficul
bends
Difficul
t
bends
CompleComple
x
profiles
Hydroformed Exhaust parts
Hydroforming process- a viable option?
Conventional Forming Challenges How Hydroforming Helps
Critical part geometries and custom
shapes (packaging, flow requirements)More easily possible to form in hydroforming
Drastic shape changes
Large expansions, up to 100%Multi-stage hydroforming with intermediate annealing
Tight bend radii, down to 1D in thin-
walled tubesSpecialised 1D compound bending capability
Difficult to form materials- SS 400,
austenitic SSAided by formability characteristics of hydroforming
Leakages from welds Consolidated, integral single piece part with no joints
Weld spatters/aesthetics Single piece part so almost no welding
Typical Parts: Cat cons, inlet/outlet pipes, silencers, exhaust manifold parts, EGR
housings, etc.
EP Development
completed in SS304,
SS 441
EP Development
completed in SS304,
SS 441
RM tube
Double hydroforming
with preforming
Bending
Preforming
Hydroforming
Annealing
Hydroforming
Post process
RM tube
Water bulging
Hydroforming
Post process
RM tube
Hydroforming with
preforming
Bending
Preforming
Hydroforming
Post process
RM tube
Single stage
Hydroforming
Hydroforming
Post process
Exhaust hydroforming routes
� Hydroforming crack• Feed optimisation
• Material selection
� Intermediate annealing• Managing the process logistics
� Orange peel effect• RM manufacturing process
control
• Buffing
� HF folds/wrinkles• Feed optimisation
• Intermediate annealing
• Multistage hydroforming
� Tool marks and parting line• Critical tool maintenance
• Part buffing
Challenges in exhaust hydroforming
Al 6082 frame for sport bikes
YZ450FX- Bilateral Beam Aluminium Frame_ Application : Bicycle
Aluminium hydroforming in 2-wheelers
Why hydroformed?
1. Improved handling
2. Better suspension and vibration
absorption, especially in higher cc bikes
3. Aesthetics
4. Weight reduction without strength
compromise
Simulation result
% thinning – 19 % is a peak point, Majority of thinning is between 5.67% to 12.7%.
OD 22.2 mm
0% Expansion OD 22.2 mm
0% Expansion
OD 26 mm
17.11% Expansion
3D model
Actual thinning
8.75%
FLD
RM tube
Manufacturing Process
Sequence
Bending
Hydroforming
Annealing
Post processes
Aluminium handle bar- lower thickness
� Hydroforming crack• Low formability
• High spring back
• Process optimisation
� Orange peel effect• Material selection (suitable grain
sizes)
� Distortion after
hydroforming• Process optimisation for
temperature settings
• Fixturing
Challenges in aluminium hydroforming
Ministry Of New & Renewable Energy Govt. of India 2016Ministry Of New & Renewable Energy Govt. of India 2016Transportation
Heat & Power
Defence & Space
Alternate fuel- The hydrogen fuel cell
Main Characteristics:
Technology barriers?
Commercial Viability?
Infrastructure Viability?
Institutional support?
Indigenous Manufacturing?
Acceptability……………
Material Handling
Hydrogen fuel cellAdvantages:
• Clean energy
• High efficiency
compared to most
other renewable
energy sources
• Simple to install and
use
Disadvantages:
• Hydrogen supply chain
• Hydrogen logistics
• Lifetime of
components, especially
bipolar plate
• Cost
Proton Exchange Member (PEM) bipolar plate
• Very thin sheets, t= 0.075 to 0.1
mm
• Challenging and complex designs
with delicate channel structures
• High degrees of forming
• Maximum dimensional stability
• Low residual stress resulting in very
flat plates
Materials
High density graphiteↆMetallic
Stainless Steel
Aluminium Alloys
Titanium Alloys
Nickel Alloys
Metal based CompositesↆPre-coated
Most expensive
element of the
fuel stack
Main Characteristics :-
• Materials (Pre-coated / Un
coated)
• Micro Dimensional Precision
• Surface Finish
Bipolar plate manufacturing routes
Flow field design
Sheet or coil_(Coated/Uncoated)
FormingLaser
Welding (joining)
Coating Assembly
Progressive Press
Forming
Progressive Press
Forming
High Velocity
Forming
High Velocity
Forming
Sheet
Hydroforming
Sheet
Hydroforming
Typical process
Challenges
• Availability of pre-
coated sheet material
• Tool manufacturing
precision
• Material flow and
thinning
• Controlling surface
roughness
• Flatness of profile
• Dimension precision
• Avoid Micro-cracks
• Profile measurement
• Productivity and cost
About
Electropneumatics
Manufacturing Unit
Chakan-Talegaon Road, Opposite Hotel Matrix Inn,
Kharabe Wadi, Chakan, Pune 410 501, India.
For communications, please contact:
abhijitchakravarty@electropneumatics.com
cmddesign@electropneumatics.com
� Head office and plant at Chakan,
Pune
� Sales and service centers in
major cities in India
� 5000+ worldwide installations
� Team of 650 permanent +
additional contract
� Land: 62,000 sq. m.
Built-up area: 15,000 sq. m.
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Supplied to over 25 countries
Electropneumatics
Technology Leadership Innovative, Futuristic100% Indigenous
� Hydraulic Forming Presses
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� Hydraulic Molding
Machines
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Compacting Presses
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Transmission Tower
Equipment
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MACHINESMACHINESMACHINESMACHINES
[MMD][MMD][MMD][MMD]
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FLUID POWERFLUID POWERFLUID POWERFLUID POWER
[FPD][FPD][FPD][FPD]
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� AC Servo Motors
� PLC and CNC Systems
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Packages
DRIVES AND DRIVES AND DRIVES AND DRIVES AND
CONTROLSCONTROLSCONTROLSCONTROLS
[DCD][DCD][DCD][DCD]
� Customized mass
produced
hydroformed parts
COMPONENTSCOMPONENTSCOMPONENTSCOMPONENTS
[CMD][CMD][CMD][CMD]
STRATEGIC STRATEGIC STRATEGIC STRATEGIC
PROJECTSPROJECTSPROJECTSPROJECTS
[SPD][SPD][SPD][SPD]
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drives, controllers, AC
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Vehicles
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