Idroformatura

Process

In hydroforming process sheet is plastically formed thanks to the action of a fluid (water or oil) distributing an hydrostatic pressure on such sheet. The final shape of the hydroformed piece outcomes from the contact with the fluid, from one side, with a male or female die, from the other side.

Hydroforming, in case of sheets is the most economic process to get components by sheet drawing.

The die, thus conceived results to be very easily feasible and at the same time to be very cheap. It is possible to draw typologies of different materials and thickness; even steel sandwiches and plastic materials of various kind, without modifying the die at all, as a matter of fact water adapts to the thickness of the sheet inserted. The superficial quality of the sheet in contact with water is absolutely unaffordable by the other drawing systems.

The hydroformed component results to be not sensitive to the phenomenon of the elastic return as far as the after-drawing dimensional stability is concerned. As a matter of fact, taken into account the central figure, the sheet deforms uniformly and by the stopping of the hydroforming hydraulic pressure, the elastic return is uniform on the whole surface of the sheet and let this one to keep stable not distorting the geometry of the component.

Thanks to this process therefore the numerous steps of setting the component and polishing the whole manufactured lots are eliminated.

In case of pipes forming the process is a complete revolution for the designers all over the world.

Starting from normal pipes round section welded one can get geometries which earlier could be get only by other processes such as plastic injection or melting. It is possible to push the material, by the suitable pushers (which have also the task to ensure the hydraulic hold), in order to feed the plastic deformation of the component and at the same time to assure the uniformity of thickness by the end of the drawing operation.

Brochure

The machine

Advantages

Compared to the traditional drawing technology foreseeing the auxilium of a punch, a blankholder and a matrix, the hydroforming process needs only using one part of the traditional die.

The economic advantage arising from this technology permits to low the investments cost for the equipment of about 60÷70% if compared to the traditional drawing system.

The die consists of the matrix (female) of the geometry of the piece to be drawed. Once such shape has been obtained by using a CNC machine it is possible to mount it directly into the hydroforming plant and to draw immediately the pieces required. Therefore every die adjustment activity is eliminated as well as the following optimization tests.

The series SLC can be equipped with a particular die hooking system which allows for its being equipped in a few minutes. This system solves the problem of the frequent production shifts and permits to the user to be very flexible and competitor in shifting from one manufacturing lot to the other, taking into account that a lot consists sometimes only of five/ten units.

Die hooking is carried out by electro-permanent magnets having a lifting capacity of up to 100 ton.

It is enough to position the die on the front machine feeding shuttle and the automatic system can then set the die in the proper site without it being necessary any further adjustment and therefore the proper alignment with the machine get assured.

Quality

The hydroformed product reaches quality levels quite superior than those ones which can be get by the product drawed by the traditional system.

Hydrostatic pressure which forms the sheet permits the drawed piece to be stretched uniformly in every direction and therefore assures a bigger rigidity. The part being in contact with the fluid does not present any scratch, therefore results to be very suitable for every part requiring to be painted or which however must comply with some very strict quality standards.

In traditional drawing the products generally speaking, after their deep-drawing undergo some other adjustment phases, in order to compensate annoying elastic returns of the material.

The hydroformed product on the contrary, thanks to the starting uniform stretching, results to be not sensitive to the phenomenon of the elastic returns. Thence any further working is avoided and a huge manufacturing cycle saving is obtained.

Drilling of the components

Hydroforming is not only a process suitable for sheet and pipes forming, as a matter of fact it permits a series of drillings to be carried out at the same time during the drawing cycle and in an absolutely controlled manner.

Holes are not carried out by mechanic punches, thence the corresponding saving as far as maintenance and warrantee are concerned together with an absolute repetitiveness of the drilling itself.

SLC plants

Since hydroforming requires uniform pressure across the whole piece, the corresponding necessary clamping force results to be elevated.

It was clear then that in order to exploit at the best every benefit from the hydroforming process it was necessary to study a new plant typology which would assure: a higher compactness, an elevated force-weight ratio and which would be very convenient from an economical point of view. The strict specifications imposed to our technical dept. did require also a machine practically without any elastic movement, which would have entailed a notable waste of energy, and whose light must be the most possible reduced in order to increase its rigidity.

Following to this careful and deep study the SLC series machines were born, they are characterised by a max height of about 4 meters and do require foundations not deeper than 1 meter. It was possible thanks to the particular cylindrical shape characterising their building philosophy. To get the maximum speed of drawing process a pressure intensifier has been conceived for the series SLC which allows to get to elevated pressures, several thousand bar and to feed the process by elevated quantities of fluid.

By this system the process time periods result to be absolutely comparable to the traditional drawing technique and in certain instances even quicker.

Self-learning, indispensable in hydroforming, which can be get by the most sophisticated hardware and software systems installed in command panels and command pulpits designed and realized by us permits to vary at the same time and in a controlled manner the pressure of the fluid as well as the clamping force of the machine.

Sheet, as a matter of fact, must slip in a controlled manner, as in traditional process, into the die in order to feed the material deformations during the drawing cycle. This control is carried out in traditional technology by the blankholder. In Hydroforming the blankholder's function is managed, without the blankholder, by the software foreseen in the SLC series. The program modules the clamping force of the machine, thus assuring that the sheet will be sliding at the proper speed during the drawing cycle. Thanks to this device it is possible to simplify drastically the construction of the dies.As a matter of fact the Hydroforming die consists only of a single element.

The software mentioned above is installed in the PC of the machine in complete Windows © operative system. In addition to that, every data of the machine is managed by a relational Database, Microsoft SQL ©, which interfaces easily with the management part of the company.

SLC series foresees the possibility to activate the failure a/o alarm teleservice, directly from the site of Muraro.

Technical specifications

 

 

 

 

SLC 6000

SLC 8000

SLC 12000

 

Max. clamping force

 

kN

 

60.000

 

80.000

 

120.000

 

Vertical light between open tables

 

mm

 

500

 

500

 

500

 

 

Vertical stroke of the table

 

mm

 

400

 

400

 

400

 

Upper and lower tables dimensions

 

mm

 

2200 x 1350

 

2500 x 1600

 

3000 x 1350

 

Lower shuttle dimensions

 

mm

 

2200 x 1350

 

2500 x 1600

 

3000 x 1350

 

Lower shuttle stroke

mm

2500

2800

3300

 

 

Upper principal table quick clamping and opening

 

Mm/s

 

200

 

200

 

 

200

 

 

Pressing speed

 

Mm/s

 

8 ÷ 3

 

 

11 ÷ 4

 

 

8 ÷ 3

 

 

Adjustable shuttle sliding speed

 

Mm/s

 

10 ÷ 400 ÷ 10

 

 

10 ÷ 400 ÷ 10

 

 

10 ÷ 400 ÷ 10

 

 

Low pressure water          delivery, 25 bar

 

Litri/s

 

14

 

14

 

14

 

High pressure water delivery

 

Litri/s

 

22

 

22

 

22

 

Overall mass of the machine

 

kg

 

240.000

 

290.000

 

330.000

 

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