Process Options > Low Pressure Hydroforming (LPH)
This method of preventing pinching is less intuitive
for most people than HPH. It is avoided by forming the tube filled
with low pressure water as the die closes on it. At any cross section
its periphery is essentially equal to the die cavity.
As seen in Figure LPH2, the die halves contact the round tube in
view (a). The normally round starting shape is forced toward the
intended shape as the die closes in LPH2(b). The tube is filled
with water (signified by shading) in 6(c) and low pressure is applied
while the die continues to close.
What distinguishes this process is that the periphery or circumference
of the starting tube is essentially equal to the desired periphery
of the finished part. Coupling this with low pressure water to keep
the tube wall in contact, with the die cavity wall (but still able
to slide) effectively harnesses the large mechanical force caused
by the closing press and die. This force resolves into compressive
components that act parallel to the tube wall as shown in Figure
LPH1. The water resists unwanted deformation inward (ie crushing
or ripples in the metal), the die outward, which facilitates a controlled
reshaping of the cross section throughout the length of the part.
This combination of hydraulic and mechanical forces used during
the cycle facilitates complex part forming. Using low pressure water
when the die is closing allows material to slide on the cavity surface
and get pushed into place using the power of the press.
As the die comes closed, forming is almost complete. Pressure is
increased to a higher level (normally <60 MPa) to produce the
final form of the part as shown in LPH2(d). Holes are punched at
this stage since the backing force provided by the water is greatest.
The other reason for this higher pressure is to flatten the planar
areas, not to finish forming the corners. It takes much less pressure
for the former than the latter.
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