Next Generation Sheet Hydroforming Presses

Next Generation Sheet Hydroforming Presses
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Dynamic Forming Capability
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Low Cost Tooling
Powerful, Intuitive Controls
Manufactured by Beckwood Press Company
Forming Impressions
Our Triform is faster, more flexible and more productive than
our other sheet hydroforming presses.”
- Chris See, Piper Aircraft, Inc.
A major lighting manufacturer had a legacy product requiring an airtight, box-shaped
receptacle. By transferring production to a Triform Sheet Hydroforming Press they were
able to:
• Decrease forming operations from 8 to 1
• Eliminate welding
• Reduce tooling costs
• Reduce scrap
• Improve quality and appearance
• Reduce the cost per receptacle produced from $27 each to $2 each
With the success we have had with the Triform press on the A320
program, Aerosud is now working on the design for the Airbus A350 Slat Track
Cans using the Triform hydroform.”
- Dr. Deon Labuschagne, Aerosud
An aerospace parts manufacturer had been creating flanged components with a
traditional rubber pad press and were encountering excessive wrinkling, requiring
skilled craftsmen for finishing. Transferring production to a Triform Press allowed
them to:
• Eliminate wrinkling
• Eliminate the need for labor intensive hand finishing
• Eliminate spring-back
• Eliminate scrap
• Save 55 minutes per part produced
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What is Triform Sheet Hydroforming
Triform Sheet Hydroforming is a process which uses hydraulic fluid in a flexible bladder or diaphragm to shape sheet material against a
single tool. The process can create a wide range of geometric shapes from a variety of materials including sheet metals, high-strength
steels, titanium and even composites.
The Triform process:
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dramatically reduces tooling costs
minimizes the need for skilled labor
reduces part development time and
increases the ability to efficiently form complex geometries
Triform is a ‘Single Tool Technology,’ which means there is no need for expensive matched male/female die sets, as the diaphragm acts
as a universal female. This results in greatly decreased tooling costs and, therefore, lower overall per part costs. Tooling can be made
quickly, from a wide variety of materials including steel, aluminum, poured epoxies, 3D printed materials and even wood.
This ability to rapidly create (or modify) tooling, gives Triform users the ability to react quickly to their production needs, at a fraction of the
cost and time of processes which rely on traditional matched die sets. It is these unique tooling requirements that make Triform
hydroforming the go-to technology for short-run production and prototyping. Triform hydroforming is used in many industries, including:
A Triform press can replace many different metal forming processes, and can consolidate multiple steps into a single operation. Most
parts, including those which are deep drawn, are formed in one press cycle. Fluid Cell parts are often formed net shape and require no
additional finishing work.
There are two types of Triform processes: Fluid Cell & Deep Draw
Our Triform Press helped decrease part turnaround time by nearly
90%. We now have an unbeatable edge - Predictability through simulation
and Speed through stable production. We can now develop and produce
new parts for our customers in just a few days vs. a few weeks.
-Rob Bass, Cambridge Metals and Plastics
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Fluid Cell Sheet Hydroforming
In Fluid Cell sheet hydroforming, a part is formed over a single tool using the force of the diaphragm.
The sheet material is placed atop a stationary form block which rests on the lower press platen or working surface. The diaphragm is
pressurized with hydraulic fluid, expanding as it exerts equal pressure on every point inside the chamber. Multiple parts can be run in a
single Fluid Cell cycle, as long as the tools and blanks fit within the forming area of the press.
Fluid Cell vs. Rubber Pad (or Guerin) Presses
Fluid Cell presses can be thought of as high-performance
alternatives to traditional rubber pad presses (sometimes known as
Guerin presses), which use a confined block of rubber to shape
material against tooling, as opposed to the flexible diaphragm used
in the sheet hydroforming process.
While traditional rubber pad forming typically exerts a maximum
pressure of ~1,250 PSI on the part, Triform Fluid Cell presses yield
5,000 – 10,000 PSI, depending on the model.
Unlike rubber pad forming presses, which apply uneven pressure,
Triform presses provide uniform pressure on every square inch of
the part’s surface, resulting in reduced material wrinkling, increased
definition and less manual hand-finishing.
Radiused bends can be formed
without material wrinkling
Parts can be formed over male
tools, or into female cavities
Traditional Rubber Pad forming
applies uneven pressure,
primarily to the top of the part
Stainless steel exhaust part for
automotive industry
Sheet Hydroforming applies
even pressure across every
square inch of the part.
Well-suited to structural
aerospace forming
Triform’s Fluid Cell process is ideal for forming shallow contours, bending flanges, forming lightening holes, joggles or stiffener beads.
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Deep Draw Sheet Hydroforming
In Deep Draw sheet hydroforming, parts are formed using the same diaphragm-principle associated with Fluid Cell forming. However, the
tooling used in Triform’s Deep Draw process is attached to a moveable hydraulic cylinder, called a punch, which extends up into the
diaphragm during the cycle.
During the Deep Draw process, the pressurized diaphragm primarily acts to hold the material, as the tool extends atop the hydraulic
cylinder. Parts which require a controlled flow of the material, such as cans, boxes or those with curved flanges which have a greater
tendency to wrinkle, benefit greatly from the deep drawing action.
Triform Deep Draw presses allow for the ability to form complex geometries which would be impossible, or extremely challenging and
expensive with the use of traditional male/female tooling. Parts are frequently formed in a single cycle, eliminating secondary processes
such as the welding of box corners.
Drawing parts to heights which are twice the diameter is common and, in general, forming tall parts within a Triform Deep Draw press will
require fewer operations when compared to traditional draw forming.
Typical deep drawn materials include Aluminum, Steel, Stainless, Inconel, Brass, Copper, some Titanium alloys and even Plastics &
Composites.
Small, deep drawn niobium cup
Triformed on a 25” press
Titanium part Triformed in a single
cycle with < $1,250 tooling
Slat-track can for Airbus A320
Triforms offer extreme draw ratios
Triforming produces curved
radius parts without wrinkling
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Advantages of Triform Sheet Hydroforming
Triform Sheet Hydroforming offers several advantages over traditional forming. Some of the most notable benefits are lower manufacturing
costs, increased forming capability and increased process efficiency.
Lower Costs
Tooling Costs
The diaphragm used in Triform Sheet Hydroforming acts as a universal die, conforming to any shape placed within the press chamber.
This eliminates the need for 1matched, male-female tooling. This process simplification can reduce tooling costs by 50% - 90% compared
with conventional press tooling. And because tool-makers are only focused on the single form block, the creation of new tooling and the
modification of existing tooling is significantly faster and less expensive. Materials frequently used for Triform hydroforming tooling include
steel, aluminum, 3D printed materials, poured epoxies and even wood.
3D-Printed tools facilitate rapid part development
Plywood as an inexpensive tooling option
Poured epoxy tools made from existing parts
Material Costs
Sheet hydroforming can result in less than 10% variation in blank to finished-part thickness, due to the uniform elongation of the material.
The forces applied during the cycle are multi-directional, drawing the material around the tool and reducing stretching or thinning
associated with traditional draw forming. This allows the starting material thickness to be reduced, thereby reducing overall material costs.
Uniform wall thickness
Maintains surface finishes
Finishing Costs
Thanks to the flexible diaphragm, parts are produced with smooth, scratch-free surfaces which typically require no secondary polishing. By
eliminating the need for secondary finishing – required due to the marring left by the direct-metal contact of male/female dies – labor costs
can be reduced. Some parts can even be painted prior to forming, without damage to the surface finish.
Development Costs
In traditional forming, high tooling costs and precision alignment requirements limit new part development due to increased tooling costs
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and lead time constraints. By contrast, the creation of new Triform tooling and subsequent modification to that tooling are less formidable.
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Increased Forming Capability
Complex Geometric Shapes
The uniform pressure exerted by the diaphragm allows for the production of complex geometric shapes which are difficult or
impossible using traditional forming methods. Parts which normally require multiple steps, via expensive progressive dies, can often
be formed in a single cycle. The expansion capabilities of the diaphragm even allow for the formation of negative angles.
1/8” thick contoured steel
Multi-faceted lighting reflector
Triforms can form negative angles
Improved Efficiency
Tooling Setup & Changeover
Use of non-mated tooling allows for faster setup & changeover, particularly within the Fluid Cell process, wherein the form blocks can
be hand-placed, unsecured on the forming surface. Triform presses frequently reduce tool change time by 60%-70%, making the
process ideal for High-Mix / Low-Volume situations that require frequent tool changes.
Reliance on Skilled Labor
Triform hydroforming offers net shape part production, eliminating (or greatly minimizing) the need for manual hand finishing of
partially formed parts. Hand-finished parts are associated with inflated labor expenses, increased scrap rates, inferior part quality and
decreased productivity.
For example, parts formed with the use of traditional rubber pad presses often require multiple hits, with manual hammering in
between. This is due to the nature of the pressure applied in rubber pad forming, which is limited in terms of both the maximum
pressures applied to the part, and the uniformity of those applied pressures. A large percentage of parts which require this ‘human
touch’ between multiple pad press cycles, can be formed to net shape in a single Triform cycle.
Rubber Pad formed part requires manual
handwork
Triformed part eliminates need for
manual handwork
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Powerful, Intuitive Controls
Triform has achieved the perfect balance between advanced control capabilities, and an
easy-to-use interface. The result is a press system that doesn’t require an experienced
engineer for operation, yet offers more capability than was ever thought possible.
Accuracy & Repeatability
Operators are able to precisely control both Bladder Pressure & Punch Position (on
Deep Draw Models) for up to 30 individual recipe steps for each press cycle. Tears or
wrinkles can be quickly eliminated with simple program changes to the bladder pressure,
punch position (or both) at precise points in the cycle. These recipes can then be saved
for future use.
Triform’s recipe function: Bladder pressure &
punch position stored for up to 30 recipe steps
Development Tools
Triform’s ‘In-Sight’ feature allows part developers the opportunity to pause the cycle at any point in the forming process, and open the
press for a visual inspection of the forming results. Depending on those results, the operator then has the option of either continuing the
cycle, or aborting in order to modify the recipe, lubrication or other process variables per the visual feedback received. This ability to
look inside the chamber greatly expedites new part development, saving valuable time & material.
Diaphragm (Bladder) Technology
Fast, Inexpensive Bladder Changes
Triform systems facilitate fast, simple and inexpensive bladder changes that increase
up-time and minimize overall costs. Bladder changes take approximately 30 minutes
for smaller Triform presses, and only 3-4 hours on larger models. This is in stark
contrast to other systems, which require maintenance teams to devote several days, if
not weeks, to performing bladder changes.
High-Performance Bladder Materials
Triform’s high-performance neoprene and urethane bladders provide ultimate
durability and performance. Unlike natural rubber diaphragms, Triform diaphragms
are compatible with standard, petroleum-based hydraulic fluids & forming lubricants.
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Components & Design
Quality, Standard Components with Widespread Availability
The components used on all Triform presses are, wherever possible, standard
‘catalogued’ components, available world-wide from local suppliers. Triform customers
do not have to fear the extended down-time associated with custom-made components,
specific to their individual sheet hydroforming presses, only available through the press
manufacturer.
Component part numbers match those of the original component manufacturer, allowing
Triform customers the ability to source replacements either through Triform, or directly
from their local suppliers.
Elimination of Significant Foundation / Installation Requirements
Triform’s advanced engineering and unique pressure containment systems allow for
significantly reduced press size and weight, without sacrificing structural integrity or
machine durability. The majority of Triform models require no special ceiling heights,
nor do they require expensive pits or specially poured foundations. Small-medium
Triform presses have even been used in cellular environments, in which the Triform
presses themselves were moved in order to maximize efficiency. This portability is in
stark contrast to other hydroforming presses, which due to the size, weight and need for
expensive pits and foundations, have been termed ‘monuments.’
Knowledge & Support
Industry-Leading After-Sale Service and Support
Triform takes great pride in our Service and Support offerings, including a
complete team of experienced support technicians.
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WebPort Connectivity – standard on every Triform press – allows Beckwood
engineers and service technicians the ability to remotely access the press for
diagnostic support and program updates.
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Triform’s on-board diagnostic tools facilitate troubleshooting and can include
on-board system health monitoring capability for notifying maintenance crews
if/when certain performance parameters fall outside acceptable levels.
Process / Application Knowledge
The Triform Team has a deep reservoir of knowledge regarding not only the sheet
hydroforming process, but manufacturing in general. This knowledge, gained
through hard work over many decades, can accelerate your path to success.
Triform’s knowledge of quoting, product and project management, part
development and secondary operations and equipment gives our customers a
major competitive edge.
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Technology Partners of Triform Sheet Hydroforming
Triform strategically situates itself on the leading edge of technology, partnering with suppliers of the latest manufacturing innovations in
order to better help our customers gain a competitive advantage. These key partnerships make Triform an authority on several cuttingedge technologies.
Advanced 3D Forming Simulation Software
Triform is an official distributor of ESI’s Pam-Stamp 2G Forming Simulation Software,
which allows for extremely accurate 3D forming simulations for Sheet Hydroforming,
Stamping, Drawing, Bending and Tube Hydroforming.
Tool design, blank design and the part recipe can all be determined before a tool is made,
blanks are cut or the press even turned ‘On.’
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Simplified and Shortened New Part Development
Lower Costs via Labor & Material Savings
Forming Experience ‘In A Box’
Indispensable Quoting and Sales Tool
Ability to Try the Impossible
From concept to finished part in less than two days.
Pam-Stamp simulation to
determine process variables
Stratasys 3D printer to
produce the simulated tooling
Triform press to form the
part using the 3D tooling
3D Printing
Triform’s collaboration with Stratasys, a world-leader in 3D printing technology, has
provided Triform with valuable experience related to the use of 3D printing within the
manufacturing process.
3D printed tools can dramatically improve development time and lower costs. The
combination of Triform sheet hydroforming & 3D printed tools is a powerful, gamechanging combination for those looking for a competitive edge.
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Finished part, simulated and
formed in less than 2 days
889 Horan Drive l Saint Louis l Missouri l 63026
www.triformpress.com l www.beckwoodpress.com l [email protected]
855-864-4670 l 636-680-2356
Made for you. Made to last. Made in the USA.
Triform presses are engineered, manufactured, sold, serviced and supported by
Beckwood Press Company, from their company headquarters in St. Louis, Missouri USA.
Beckwood is a leading hydraulic press and automation systems manufacturer with nearly
40 years of experience engineering custom presses for a variety of industries and
applications. Beckwood and Triform systems are tackling challenging applications in a
variety of industries, including aerospace and defense, medical devices, energy / oil and
gas, automotive, construction, agricultural and more.
Triform presses are engineered by Beckwood’s in-house team of structural, hydraulic and
electrical / controls engineers. In-house manufacturing capabilities, such as machining,
welding and assembly allow Beckwood to maintain tight control over the manufacturing
and quality control processes.
The Triform Story
Beckwood Press Company developed the Triform Sheet Hydroforming line of presses in
direct response to an unmet need in the marketplace for modern sheet hydroforming
equipment, manufactured in the USA.
Prior to Triform’s release, companies searching for sheet hydroforming presses were
faced with limited options. Manufacturers of new sheet hydroforming equipment were
extremely scarce, especially in the US, and new machine prices corresponded to the lack
of competition. Used equipment was often a half a century old and presented several
potential hazards including outdated hydraulic and control systems, a lack of available
service, support and replacement parts, and high transportation and installation costs.
Triform presses were designed to specifically counter these challenges.
Learn more about Beckwood Press Company at www.beckwoodpress.com
View the full line of Triform Sheet Hydroforming presses at www.triforpmress.com
View video of the presses in action at www.triformpress.com/demo_video.php
Manufactured by Beckwood Press Company