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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. |
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Hydroform tools normally cost at least 50% less than conventional press tooling. |
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Versatility in forming complex shapes and contours: Irregularly contoured shapes are easily formed using the hydroform process because matching dies are not required. |
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Minimal material thinout: Hydroforming flows the material rather than stretching it. Therefore, material thinout is minimal-usually less than 10%. |
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Fewer operations required: Many parts requiring two or three operations on conventional presses can be formed in one hydroform operation. |
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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. |
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Fast tool changes: Tools are quickly mounted and are self-centring and self aligning. Set-ups are quick and simple. |
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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. |
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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. |
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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. |
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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. |
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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. |
Hydro Forming Pads
