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Comparison between high, multi step high and (low) multi pressure
hydroforming of engine cradle in high strength steel
forming issues
part quality /
performance
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part
changes
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Wilen b. Wollerau
+91 40 4068 9999
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tool cost
www.autoform.com
© 2014 AutoForm Engineering GmbH, Switzerland.
„AutoForm" and other trademarks listed under www.autoform.com or trade names contained in this documentation or the Software are
trademarks or registered trademarks of AutoForm Engineering GmbH. Third party trademarks, trade names, product names and logos may
be the trademarks or registered trademarks of their respective owners. AutoForm Engineering GmbH owns and practices various patents and
patent applicatio ns that are listed on its website www.autoform.com. Software and specifications may be subject to change without notice.
Publication HY-1-E
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assembly
redesign
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Connecting and weighing up these decision drivers
allows the engineer to focus on the most
production
important criteria relevant for the quality of
robustness
the hydroformed parts as well as easily
adjust the process parameters in order to
achieve a better hydroforming process design.
production
cost
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High Pressure Hydroforming
Multi Step High Pressure Hydroforming
(Low) Multi Pressure Hydroforming
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AutoForm's hydroforming solution combines all of
the important aspects of Comprehensive Digital
Process Planning, enabling the assessment of the
hydroforming process in terms of function, quality,
lead time and cost related criteria.
Source: Schulergroup
product
weight
Rapid tool and process design for hydroformed parts
material cost
Rapid verification of multiple alternative concepts for
quality and cost improvements
Comprehensive in-depth understanding and validation
of entire hydroforming process
Shorter development time and reduced tooling,
material and production costs
Improved process reliability
Software Solution for Rapid
Tool Design and Simulation of
Tube Hydroforming Processes
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Trimming, Piercing
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Hydroforming
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Bending
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Calibration
(Low) Multi Pressure Hydroforming
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Trimming, Piercing
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Second Hydroforming
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First Hydroforming
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Bending
Trimming, Piercing
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Multi Step High Pressure Hydroforming
Hydroforming
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Preforming
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Bending
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High Pressure Hydroforming
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development time, reduced tooling, material and production costs as well as improved process reliability.
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AutoForm Hydro enables users to quickly generate and evaluate alternative tool designs and process layouts as well as
to find the best forming process for hydroformed parts. With AutoForm Hydro, companies can benefit from shorter
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Rapid and Effective Evaluation of Alternative Hydroforming Processes
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AutoForm
Hydro
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AutoForm Hydro
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AutoForm Hydro – Easy-to-use and Highly Intuitive Software Solution
well as to simulate and evaluate the complete forming process of hydroformed parts. The software solution provides a
springback. This software solution is used by part designers, process engineers as well as tool and die makers to
comprehensive in-depth understanding of hydroforming processes and allows the rapid identification of tool design and
evaluate hydroforming tool designs and process layouts.
process improvement potentials.
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Cutting
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Cutting
AutoForm Hydro supports the cutting process steps. The
complete forming process is thereby covered, including
the forming of tube ends as well as the piercing and
flanging of holes. As a result, tube length and related
material costs can be optimized.
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Springback
With the increasing usage of challenging materials, such
as high strength steels, the analysis of springback issues
when hydroforming parts is becoming more and more
important. AutoForm Hydro enables the accurate
springback simulation and evaluation of springback after
any forming process step.
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With AutoForm Hydro, users are equipped to meet
the increasing demands regarding part complexity,
ever higher part quality requirements,
implementation of new materials as well as
increased process complexity.
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Second
Hydroforming
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Annealing
Annealing
Additional process steps, such as annealing, are required
for certain complex hydroformed parts. Through the
annealing process, strains which result from prior
operations can be eliminated. AutoForm Hydro simulates
annealing by resetting the stresses and strains of prior
forming operations to zero, while maintaining the
calculated wall thickness. With AutoForm Hydro,
annealing can be carried out after any forming process
step and results can be evaluated accordingly.
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Preforming
Complex part geometries may require additional forming
operations which occur after the bending and before the
hydroforming operations. AutoForm Hydro enables rapid
generation of tool designs for preforming operations. The
preforming process step can be specified with or without
inner pressure and process layout alternatives can be
evaluated regarding formability issues.
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First
Hydroforming
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Preforming
Hydroforming
This operation enables the generation of tool geometry
for the final as well as the intermediate hydroforming
steps. The process setup allows the user to control the
hydroforming process, either by volume, displacement or
pressure. The high flexibility of the process setup enables
alternative process validations such as high, multi step
high and (low) multi pressure hydroforming. Based on
the simulation results, the user can gain valuable insights
regarding the entire tube hydroforming process.
Bending
AutoForm Hydro enables the user to automatically
determine the bending line of the tube. The software
offers the number of necessary bending operations and
bending radii, which can be adjusted according to
company specifications. AutoForm Hydro simulates the
bending operations taking into account all necessary
bending tool geometries (such as bend die, clamp die,
mandrel, etc.) and process steps. Forming issues such as
splits, excessive thinning, wrinkles and distortions can be
easily identified and countermeasures can be initiated
immediately.
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Bending
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Starting from the initial part geometry, AutoForm Hydro allows users to rapidly generate all necessary tool geometries as
process involving all process steps, such as bending, preforming, hydroforming, annealing, calibration, cutting and
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With the AutoForm Hydro software solution, the user can carry out a complete virtual tryout of the hydroforming
Springback