3 Fundamentals of press design

430 Hydroforming
Photo Schmitz und Brill
Fig. 5.7.1
Hydroforming exhaust
manifold:
series production
Figure 5.7.1 and Table 5.7.2 compare a conventional with a hydroforming
construction of an exhaust manifold.
Further processing of parts
Further processing of hydroformed parts includes any production
processes which are executed directly on the component following the
hydroforming sequence or which are used to join hydroformed parts
together. If the geometry of the parts or specific requirements prevent
them from being pressed to their final dimension, finish processingis necessary.
The required final form is achieved using, for example, cutting,
stamping or milling processes.
Table 5.7.2: Comparison of conventional and hydroforming production for the exhaust manifold illustrated
in Fig. 5.7.1
Conventional production Hydroforming production
number of individual parts 17 9
service life 700 – 1,000 h > 1,500 h
manufacturing costs 100 % 85 %
development time 100 % 33 %
flange type varies same
weight 100 % 100 %
scrap < 0.5 %
Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998