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HYDROFORMING:

Technological & Economical Aspects Page 4:

Dr.-Ing. Alfons Böhm, Siempelkamp Pressen Systeme, Krefeld
Anthony Abbey,
Siempelkamp Pahnke Engineering, Springfield

Contents

1.) Part design determines production costs: Example engine cradle
2.) How to reduce the number of production steps: Examples
3.)
Hydroforming processes and die design for high volume production
4.)
Cost studies for various part
5.)
ALLFORM Double Ram Press Systems (DRS) for high volume production
6.)
Achievable reliability and quality: Some selected aspects

4. Cost studies for various part

The following cost studies /5/ give some general hints about the economy of hydroforming: The details will be discussed during the lecture in some details.

  • The results for the shown examples can be summarised:

  • Hydroforming reduces the number of components for engine cradles and cross members.

  • Hydroforming reduces the component weight when using steel material by about 10 .. 20 %

  • The tool costs of hydroforming in comparison to conventional stamping are 20 .. 30 % less.

  • The production costs of normal hydroforming (1) are about 15% less than conventional stamping.

  • Using aluminium as a tube material means a reduction of weight by more than 30% but an increase of production costs by nearly the same amount.

Type Number of Parts Weight
(kg)
Tool Costs
(DM)
(US-$)
Part Cost
(DM)
(US-$)
Conventional manufactured 34 24,56 8.842.500 DM
5.359.090 US-$
84,15 DM
51,00 US-$
Hydroforming:
Steel Engine Cradle
30 20,50 6.125.850 DM
3.712.636 US-$
70,67 DM
42,83 US-$
Hydroforming:
Aluminium Engine Cradle
30 14,41 6.421.350 DM
3.891.727 US-$
120,72 DM
73,17 US-$
Sequence-Pressure
Hydroforming
30 22,77 5.795.456 DM
3.512.398 US-$
75,17 DM
45,55 US-$

Fig. 5.1: cost study engine cradles /5/

DESCRIPTION PART
CONTENT
NET
WEIGHT
TOOL
COST
PIECE
COST
Stamped
Steel Assembly
34 54.031 lbs. $ 5.895.000 $ 56,10
Hydroforming
Aluminium
Assembly
N/A N/A N/A N/A
Hydroforming Steel Assembly (IHV) 30 45.095 lbs. $ 4.083.900 $ 47,11
Hydroforming (IHV)
Aluminium Assembly
30 31.710 lbs. $ 4.280.900 $ 80,48
Traditional
Hydroform
Assembly
30 50.100 lbs. $ 3.863.637 $ 50,11

Fig. 5.2: Cost Study: Engine Cradle /5/

DESCRIPTION PART
CONTENT
DEFLECTION
PER MM
NET
WEIGHT
TOOL
COST
PIECE
COST
Stamped Steel Assembly 8 0.2658 28.9 lbs. $ 3.666.600 $ 28.36
Hydroforming Steel
Assembly
5 0.2382 21.72 lbs. $ 2.007.350 $ 23.67
Hydroforming Aluminium Assembly 5 0.2583 14.72 lbs. $ 2.007.350 $ 39.71

Fig. 5.3: cost study cross member /5/

Note (1)
"Normal hydroforming" is here used in sense of "high pressure forming". Most european engineers do not divide hydroforming into high- or low-pressure forming because the height of any physical size is relative. Most important is the necessary internal pressure which can be calculated by different methods depending on the boundary conditions of the hydroform process. One method to calculate the necessary pressure is explained in detail in /2/.

Select your page: (1) (2) (3) (4) (5)

With permission of Siempelkamp Pressen Systeme / Germany.
All rights are reserved.

   

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Last update: Januar 12, 2000
Letzte Änderung: 12 Januar 2000

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