A state of the art review of hydroforming technology
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REVIEW
A state of the art review of hydroforming technology Its applications, research areas, history, and future in manufacturing Colin Bell 1
&
Jonathan Corney 1 & Nicola Zuelli 2 & David Savings 3
Received: 13 March 2019 / Accepted: 15 August 2019 # The Author(s) 2019
Abstract Hydroforming is a relatively new metal forming process with many advantages over traditional cold forming processes including the ability to create more complicated components with fewer operations. For certain geometries, hydroforming technology permits the creation of parts that are lighter weight, have stiffer properties, are cheaper to produce and can be manufactured from fewer blanks which produces less material waste. This paper provides a detailed survey of the hydroforming literature of both established and emerging processes in a single taxonomy. Recently reported innovations in hydroforming processes (which are incorporated in the taxonomy) are also detailed and classified in terms of Btechnology readiness level^. The paper concludes with a discussion on the future of hydroforming including the current state of the art techniques, the research directions, and the process advantages to make predictions about emerging hydroforming technologies. Keywords Hydroforming . Fluid forming . Cold forming . Sheet Near Net Shape Manufacturing . New manufacturing technologies . Aerospace
Introduction Hydroforming is a near net shape metal forming process whereby complicated shapes are created by the utilization of fluid pressure instead of (or in conjunction with) traditional mechanical forces. The hydroforming process has several advantages over other forming processes which has helped establish it in a range of specific applications. These are: the ability to create re-entrant features, reduced thinning [1], enhanced mechanical properties, better surface finish [2], fewer components required in an assembly [3], and less required rework due to the creation of geometries which are closer to the final shape, [4]. These advantages primarily stem from the ability of the working fluid to exert pressure evenly over the entire surface of a material and for the equipment to vary this
* Colin Bell [email protected] 1
Design, Manufacture and Engineering Management, University of Strathclyde, 75 Montrose St, Glasgow G11XJ, UK
2
Advanced Forming Research Centre (AFRC), University of Strathclyde, 85 Inchinnan Drive, Inchinnan PA49LJ, UK
3
Rolls-Royce plc, PO Box 31, Derby DE24 8BJ, UK
fluid pressure during the forming cycle based upon an optimized load path.
Hydroforming subcategories Hydroforming has been exploited in many manufacturing sectors including the automotive and aerospace industries to produce components which otherwise would be difficult or impossible to form. The fluid pressure allows for more even material expansion and for pressure generation in orientations other than the forming direction which enable creation of additional or more prominent features. Thus, hydroforming fills a manufacturing gap by allowing higher ma
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