1. Cost Savings
Hydroforming vastly reduces the tooling required for pressing and forming, even when working on
the most complex parts. The hydroforming process only requires two primary components—a draw
ring to act as a blank holder, and a male die or punch. The hydroforming machine set-up contains a
diaphragm crafted rubber, which serves as a flexible and ubiquitous female die. As a result of these
minimal internal requirements, hydroforming tooling usually costs less than half of the tooling
required by traditional presses.
As such, the overall cost of tool materials is greatly reduced. Hardened steel tools are rarely utilized
in the process. The majority of draw rings and punches are composed of inexpensive, easily machined
low carbon steel which provides exceptionally long tool life. Kirksite and casted plastics can also be
used for very short runs.
2. Simple Tool Installation & Maintenance
The process of installing and maintaining traditional press tools can be both lengthy and costly.
Hydroforming tools, however, are designed to mount quickly without the need for complex manual
adjustments. Hydroforming tools automatically align and center upon installation, saving time, cost,
and preventing wear and more frequent maintenance.
Matched die methods used for forming can cause scuff marks, shock, and stretch lines. In the
hydroforming method, however, the wrapping action of the flexible rubber diaphragm virtually
eliminates or reduces these faults, saving operators up to 90% in finishing costs.
3. Form Versatility
Hydroforming has the ability to form unusual non-symmetrical or uniquely curved shapes with ease
due to the fact that the process does not require matching dies. For specialty parts manufacturers,
this is an absolute must, as it has the potential to cut labor by as much as two-thirds.
4. Minimal Material Thinout
Instead of stretching, hydroforming flows the metal. This produces minimal material thinout at a rate generally lower than 10% overall. Depending on the initial thickness of the metal, the open end of the part may contain a slightly higher wall thickness, which provides a superior advantage for a wide range of secondary processes (welding, for example).
The minimal amount of thinout involved in the hydroforming process also adds to the cost saved in materials, as it allows thinner blanks to be used and produces less waste. This factor is particularly important when expensive alloys or a large number of parts are ordered.
5. Reduced Operations
The hydroforming process also reduces the number of operations and secondary finishing processes
required with traditional pressing and forming. This greatly reduces maintenance costs and saves
valuable time and labor. Many parts that would require several operations on a conventional press
can be accomplished in a single hydroforming operation.
6. Material Versatility
Virtually every sheet metal that can be cold formed has the ability to be hydroformed, including:
- Aluminum
- Brass
- Carbon Steel
- Copper
- Haynes 188 & 230
- Inconel 718 & 625
- Precious metals
- Stainless steel
- Titanium (CP grades primarily)
Hydroforming is also suitable for a range of material thicknesses between 0.01 inches to 0.5 inches.
This is important because it means varying thicknesses of metal can be formed within the machine without fabricating additional tooling, again saving significant cost and labor.
