Hydraulic forming New forming processes cut cycle times and production costs

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Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU

HASCO Hasenclever GmbH + Co KG

CUMSA

Renishaw plc

Hydraulic forming is a technology that uses high fluid pressure to shape sheet metal or tubes into the desired geometry. Instead of a second rigid tool, a fluid acts as the force-transmitting medium. Researchers in Chemnitz have now succeeded in significantly reducing production times in high-pressure sheet metal forming (HPSF) through intelligent process integration.

Cycle times in sheet hydroforming are typically longer than in conventional sheet metal forming processes such as deep drawing. Even when processing continuous strip material from coil stock, production rates of only six to eight strokes per minute are generally achievable. This is primarily because the process steps of “opening and closing the press,” “building up the clamping force,” and “forming” are performed sequentially.

Fraunhofer IWU has completely redesigned both the process sequence and the tool structure using its passive high-pressure sheet metal forming technology, enabling these steps to occur simultaneously. In passive HPSF, the forming pressure is generated directly within the tool through a hydraulic cylinder. As the press closes, the clamping force automatically generates the required fluid pressure. Standard presses can be used, eliminating the need for a separate high-pressure water-hydraulic system. Combined with coil-fed production, the technology enables manufacture of bipolar plates at rates of up to 60 cycles per minute for the first time.