Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

Sheet hydroforming

High economic efficiency even in small series

Active media-based forming cannot only by applied in closed profiles. In sheet hydroforming (SHF) shaping also occurs by applying high pressure to an active medium. In particular, this process exhibits high economic potential in small series since manufacturing only requires a component-specific die; a punch is not necessary for shaping. By combining this method with further processes such as injection molding or press hardening and especially by integrating joining operations, complex components and assemblies can be manufactured more efficiently than ever before.

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  • Contoured basin floor outlet for a fish-friendly weir
  • Superplastic forming: OLED TV frame
  • Hydroforming and hydro-joining of lightweight camshafts
  • Hydroformed engine hood model of magnesium wrought alloy
  • Process combination of deep drawing, injection molding and forming with the melt

  • Manufacturing of small (component weight: 4 g) and large components (component weight: 40 kg)
  • Economic manufacturing of prototypes and small batch sizes
  • Realization of metal-plastic hybrid components by combining deep drawing, injection molding and forming with the melt
  • Manufacturing of highly complex component geometries using superplastic forming (SPU)

Development of process chains

  • Analyses of markets and trends, technology scouting
  • Development and optimization of existing and new processes
  • Technological and economic analyses of process chains
  • Development and realization of new manufacturing concepts
  • Planning and design of processes, tools and machines

Development and evaluation of forming strategies

  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Numerical simulation
  • Manufacturing of prototypes

Quality assurance

  • Process monitoring and control
  • “Intelligent” state-dependent process control

Machine technology

  • HF press DUNKES HS3-1500 (max. closing force: 15,000 kN; max. active media pressure: 120 MPa (gas) or 700 MPa (HFA fluid))
  • HF press Schuler SHP 50000 (max. closing force: 50,000 kN; max. active media pressure: 120 MPa (gas) or 400 MPa (HFA fluid))
  • Peripherals (system for induction heating, chamber furnaces, robots, 10 kW cooling unit and electrical die heating)

Software

  • CAD: Catia V5, PTC Creo, Inventor
  • FEM simulation: AutoForm, PamStamp, LS Dyna, Abaqus, Deform, Ansys

Testing technology

  • Coordinate measuring instrument PRISMO7S-ACC (ZEISS)
  • Various optical and contact measuring devices for roughness and profiles
  • White light interferometer, ITO Stuttgart University
  • Confocal microscope, ITO Stuttgart University
  • Scanning electron microscope, LEO Oberkochen; stereomicroscope
  • EDX system, Oxford Instruments
  • Optical measuring station UBM
  • Form measuring instrument F2002, HOMMEL
  • Ultrasonic wall thickness gauges
  • Profile projector PJ300