FluidForming Sheet Metal Hydroforming Provides New Solution To An Old Problem
FluidForming is a sheet metal hydroforming process that achieves a 99.996% first-pass yield rate, providing the accuracy and repeatability that precision-driven industries need. A reinvention of conventional hydroforming, FluidForming uses extremely high forming pressures to form geometrically complex parts, like heat exchangers.
Problem: Significant Springback and Excessive Downstream Costs
High tooling costs, non-conforming part waste, springback, and time-consuming post-production work have long plagued manufacturers of heat exchangers.
Solution, Part I: Design Improvement
The FluidForming metal forming process virtually eliminates these costly issues.
FluidForming Americas is the only company in North America that forms parts using the FluidForming process. Before forming heat exchangers, engineers at the company use finite element analysis (FEA) and simulation software enables the product team to evaluate the part design prior to tool build.
This lowers tooling development costs and, because only one tool is needed, overall tooling costs are also reduced.
The company’s engineers begin with an evaluation of the customer's existing design. Using FEA, they identify areas where heat exchangers can be improved and optimized for the FluidForming process – prior to production. Ultimately, this step saves time, lowers costs, and helps ensure even material flow. Even material flow minimizes – or eliminates – stretching or tearing.
Solution, Part II: Higher Forming Pressures
Once the part design has been optimized and approved, FluidForming’s high forming pressures (up to 60,000 psi) yield parts with minimal springback or warping.
With a 99.996% first pass yield success rate, the FluidForming metal forming process can provide the quality, accuracy, and repeatability manufacturers of heat exchangers require. Additionally, because only one surface of the heat exchanger is subjected to the flexible and self-adjusting tool surface (recycled water), the resulting parts are free from scratches, dents, or burrs.
Furthermore, because of the negligible distance between the tool and metal surface, highly complex parts can be formed with greater accuracy and repeatability than legacy methods afford. Because completed heat exchangers experience virtually no warping or springback, expensive and time-consuming post-forming fixturing and clamping is minimized or eliminated.
The process can help manufacturers move from additive welding to the highly efficient, clamp-free stacked laser welding process to complete the unit.
“Part accuracy went from no-two-parts-are-alike to Six Sigma conformance and repeatability with 0% non-conforming product,” said the customer’s VP. (Due to an ongoing non-disclosure agreement, the company cannot be identified in this article.)
Sustainability Statement
Legacy hot-forming methods like stamping and casting are inherently wasteful and environmentally harmful. And parts formed with conventional methods rely on large blocks of metal or casting that must be extensively machined prior to use. Even then, the finished surfaces remain rough, making the part difficult to clean. The FluidForming process produces parts that are free from blemishes, making them more efficient and easier to clean and maintain.
As raw materials become harder to come by — and more costly — environmentally-conscious manufacturers are turning to sustainable sheet metal hydroforming practices to help them minimize waste and maximize value. The FluidForming metal forming process makes sustainable manufacturing possible:
- Zero harmful process emissions.
- Minimal material waste.
- Elimination of harmful consumables (hydroforming bladders, oils, hydraulic fluid, etc.).
- Elimination wasteful overproduction.
- Six Sigma (99.996%) first-pass yield rate.
- Recycled tap water is the forming force.
Results: Conventional Heat Exchanger Case Study
- 97% reduction in plate deflection and warping.some text
- 4/1000” vs. 1/10”
- .0043% failure rate.some text
- 15 failures out of 350,00 units vs. 17,500.
- 350,000 parts formed w/no tool maintenance.
- Downtime eliminated.
- Post-process fixturing costs eliminated.
- Uses recycled tap water, produces no emissions or harmful waste.
FluidForming Americas is the only company in North America that forms parts using the FluidForming process. They’ve produced heat exchangers for HVAC, power cell, and exhaust heat recovery manufacturers. FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS9100 Rev D, ISO 9001:2015 certified. ITAR Registered.
To learn more about the FluidForming Americas value-add JIT and product development services, contact FluidForming Americas at (800) 497-3545 or email us at info@ffamericas.com.
FluidForming Americas, Inc. is a member of the Precision Metal Forming Association and is AS9100 Rev D, ISO 9001:2015 certified. ITAR registered.