Hydroforming

The input material - a straight or bended tube - is inserted into a tool, which consists of an upper and a lower die. After closing the die, two axial cylinders seal the tube ends. The cylinders have got a bore hole through which the tube is filled with a water-oil-emulsion. Afterwards an internal pressure (up to 4000 bar) is applied and hence the material begins to flow. During the plastic deformation the two axial cylinders are pressed against the tube ends and thus support the forming process. After all hydroforming can be used to manufacture precise geometries with an excellent repeating accuracy. Furthermore, significant weight reductions can be achieved due to stress - appropriate design and strain hardening. Compared to other manufacturing methods it is possible to produce complex geometries which results in a reduction of component numbers and process steps.