02.07.2008

Hydroforming: flexible, fast and powerful

The Schuler Group’s new compact lines boast low investment and running costs as well as fast availability

Wherever high-performance machines and vehicles are developed, there is a growing need for complex metal parts which can not only meet the extreme requirements but also be produced economically. This trend in the automotive and engineering sector, as well as in the aerospace industry, has been accompanied by a similar increase in demand for hydroforming equipment. In this process, tubes and metal parts can be formed into almost any shape with the aid of a liquid medium and a pressure of up to 4,000 bar.

Schuler Hydroforming in Wilnsdorf, a subsidiary of the Schuler Group, has now developed a compact line which can be ready for production without much preparation or long waiting times. “We were able to draw on our combined expertise from the development and production of large presses and manufacturing lines to create a smaller, compact machine. The Compact Hydroformer allows serial production of a wide range of components in mid to high runs,” explains Thomas Schirmer, Head of Project Planning at Schuler Hydroforming. “Its compact design saves space and does away with the need for a special foundation. Assembly and production launch times have also been shortened,” adds Thomas Schirmer.

Hydroforming for various application fields

Among the biggest users of hydroforming technology are automotive companies, who produce large numbers of hydroformed parts – such as manifolds and exhaust systems, but also axle parts. Hydroformed parts are up to one third lighter than traditional, deep-drawn and welded parts. Despite significantly thinner walls, they are also just as rigid and thus also suitable for lightweight construction. With regard to ever stricter exhaust regulations, vehicle manufacturers can help save weight by using hydroformed parts in their designs – thus lowering both fuel consumption and CO2 emissions. In view of impending legislation changes, the latter is likely to become an increasingly important factor in the auto industry.

Growth in small part segment

Schuler Hydroforming recently supplied its first Compact Hydroformers. One of the customers is a supplier of exhaust system parts. “Our customers are impressed by our fast delivery and installation times,” says Thomas Schirmer. The Compact Hydroformer adapts well to a variety of space requirements and can be integrated into the existing manufacturing process at floor level. In the case of larger machines, on the other hand, there are preliminary costs for the foundation and supply lines. Thanks to its modular construction, the line can reduce both investment and operating costs by up to 30 percent. A further benefit is the fast availability of the lines: the machine was ready for production some three months earlier than a conventional solution.