What is Heavy Metal Hydroforming?
Heavy metal hydroforming, also known as hydraulic press metal forming, not like sheet metal stamping, is a processing method that utilizes hydraulic technology to achieve plastic deformation of heavy metal materials. This technology is widely used in various industries such as automotive, aerospace, construction, and home appliances for producing complex parts and products.
A hydraulic forming machine applies pressure generated by a hydraulic system to shape materials. This pressure can be immense, sufficient to cause plastic deformation in metal or non-metal materials, forming the desired shape. Hydraulic forming employs specialized molds and integrates water and high-pressure fluid control systems to ensure the metal blanks conform to the mold’s shape and contours.
Our Capabilities
We are equipped with hydraulic presses with a maximum capacity of 2000T, suitable for various metal hydroforming processes like stamping, bending, flanging, and sheet metal drawing. These processes are applicable to a wide range of ductile materials, including stainless steel and aluminum alloys.
Our 2000T hydraulic press is mainly used for shallow drawing, extrusion forming, and embossing of metal materials. For example, it is ideal for forming high-precision components such as automotive panels, interior parts, gaskets, battery pack cooling plates for new energy vehicles, computer and server housings, home appliance shells, TV back panels, and plate radiators.
This press is also suitable for pressing graphite crucibles, automotive parts, refractory materials, powder products, composite materials, and plastic products. Our largest hydraulic press worktable measures 3×2 meters, perfect for pressing battery pack cooling plates for new energy vehicles, meeting the hydraulic forming manufacturing needs of most parts.
Advantages of Using Hydraulic Forming Techniques
- Form Complex Shapes: Hydraulic forming can produce parts with intricate shapes through various processes like forming, pressing, and stamping.
- High Surface Quality and Dense Internal Structure: The parts produced by hydraulic forming have excellent surface quality and a dense internal structure.
- Reduced Processing Steps and Simplified Mold Design: Hydraulic forming reduces the number of processing steps and simplifies mold design, lowering production costs.
- Reduced Part and Mold Quantity, Lower Mold Costs: Hydraulic forming generally requires only one set of molds, whereas stamping often needs multiple sets, reducing the number of parts and molds needed and cutting down mold costs.
- Increased Production Efficiency: Automation in hydraulic forming significantly boosts production efficiency, reducing the time and cost of manual operations.
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Industrial Application
Application in New Energy Battery Casings
We use a 500-ton four-column composite material compression molding hydraulic press with an operating table of 1800x1800mm for producing new energy battery casings. The material used is BMC (Bulk Molding Compound) resin. This process helps in precise forming of battery casings, ensuring dimensional accuracy and surface smoothness.
Metal Hydroforming in Automotive Body Parts
Hydraulic forming is capable of manufacturing car door parts with complex curves and reinforcing ribs. The process involves placing a metal sheet in a mold and applying high pressure via a hydraulic press to shape the sheet into the desired car door form. The formed part is then cooled and solidified in the mold to maintain its shape. The part is removed and undergoes necessary post-processing like trimming, cleaning, and painting. This method supports fast, continuous production, making it suitable for large-scale manufacturing needs. It is also applicable for structural parts such as frames and chassis components.
Industrial Fan Assembly Frame
Hydraulic forming is extensively used in the industrial sector for parts requiring drawn curves. For instance, industrial fan frames with curved and bent surfaces can only be achieved through hydraulic forming. Compared to the common welding method of joining circular rings and flat steel plates, hydraulic forming offers aesthetic curved visual appeal, simplifies the production process, and is favorable for mass production.
Metal Hydroforming in Other Industries
- Electrical Industry: Enclosures for high and low voltage switch cabinets, transformer and generator housings.
- Energy Industry: Towers and blades for wind turbines, solar panel brackets.
- Heavy Machinery: Frames and shields for heavy machinery, enclosures for hydraulic presses and other industrial equipment.
- Manufacturing and Industrial Equipment: Bed frames and worktables for machine tools, enclosures for industrial automation equipment.
FAQ on Metal Hydroforming Services
What is your maximum forming capability? Our metal hydroforming capabilities range from small precision parts to large complex components, with a maximum size of up to 3000*2000 millimeters.
What types of metal materials can you process? We have extensive experience processing a wide range of materials, including but not limited to carbon steel, stainless steel, aluminum alloys, copper alloys, special alloys, and composite materials.
How do you ensure the quality of your products? We implement strict quality control processes, including raw material inspection, process control, and final product inspection. Before shipment, we provide complete dimension reports and appearance reports to ensure accuracy and quality.
Can you provide custom services? Yes, we offer custom services, from design support and prototype creation to mass production. We can meet the personalized needs of our customers.
How long is the typical production cycle? The production cycle depends on the complexity of the parts and the order volume. Typically, it takes about six weeks from order confirmation to delivery, but we can offer expedited production services for urgent orders.
How do you control costs? We control costs by optimizing production processes, adjusting manufacturing techniques, and modifying designs to improve material utilization, ensuring competitive pricing for our customers.
Can you provide samples? Yes, we offer free sample production services to allow customers to confirm product quality and performance before placing an order.
Do you have experience handling large volume orders? Yes, we have extensive experience in large-scale production and can ensure high-quality orders are completed within strict delivery timelines.
How do you ensure timely delivery? We use a process control system and provide weekly progress reports based on the production schedule. Additionally, our proximity to international ports ensures efficient and timely transportation.
What kind of after-sales services do you provide? We offer comprehensive after-sales services, including technical consultations, quick responses to customer feedback, and resolution of any issues that may arise. For any quality issues after receipt, we actively respond and take corrective actions such as repairs or local rework, covering the associated costs.
