 |
Inexpensive
tooling: A male die (punch) and a draw
ring (blank holder) are generally the only tools required.
The rubber or Urethane diaphragm in the hydroform machine
acts as a universal female die. |
|
Hydroform tools normally
cost at least 50% less
than conventional press tooling. |
|
Versatility
in forming complex shapes and contours:
Irregularly contoured shapes are easily formed using the
hydroform process because matching dies are not required. |
|
Minimal
material thinout: Hydroforming flows the
material rather than stretching it. Therefore, material
thinout is minimal-usually less than 10%. |
|
Fewer
operations required: Many parts requiring
two or three operations on conventional presses can be
formed in one hydroform operation. |
|
Savings
in Tool materials: Hardened tool steels
are rarely required. Most punches and draw rings are made
of meehanite(cast iron). Kirksite, Epoxy or hard grade
urethane castings can be used for short runs. |
|
Fast
tool changes: Tools are quickly mounted
and are self-centring and self aligning. Set-ups are quick
and simple. |
|
Savings
in finishing costs: Matched die methods
of forming can cause scuff marks, shock and stretch lines.
In the hydroform method, the wrapping action of the flexible
diaphragm virtually eliminates these faults. Savings of
up to 90% in finishing costs have been realized. |
|
Material
versatility: Practically all sheet metals
capable of being cold formed- carbon steel, aluminum,
stainless steel, copper, brass, precious metals, high
strength alloys, and others can be hydroformed. Thickness
of materials can vary within the limits of the machine
without need for tool revisions. |
|
Precision:
Hydroform method forms parts with extremely difficult
configurations while at the same time holding precise
tolerances. Unless the spring back on the material being
formed is abnormal, inside measurements can be held to
+.005" or +.002 in some instances , depending on
material and shape. |
|
Ease
of design change: Development cost can
be a large part of total tooling cost with conventional
deep draw techniques. With hydroforming, material or metal
thickness can be altered usually without any tooling change
being necessary. |
|
Low
work-hardening: Hydroforming does not
cause work-hardening of material at the same rate as conventional
drawing operations. Consequently, annealing between draw
operations is rarely required. This can often eliminate
the need for multiple draw operations. |
Die-Thane Tooling 
