Product category:
Special purpose presses and equipment
News Release from: Shell Lubricants | Subject: Internal hydroforming fluids
Edited by the Manufacturingtalk Editorial
Team on 03 December 2002
Successful IHF depends on careful oils
choice
Successful internal hydroforming (IHF) depends on careful oils choice that extends over corrosion protection oils, tube bending fluids, secondary hydraulic and the actual hydroforming lubricants.
Internal high pressure forming (IHF) is a relatively new and cost effective deformation process that allows the production of automotive components with low weight and high stability The great advantage of hydroforming is that it keeps the texture of formed metal
This article was originally published on Manufacturingtalk on 10 Sep 2007 at 8.00am (UK)
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Hydroforming is mainly used to manufacture exhaust systems, axles, frames and car bodies.
This process is also used in a number of other industries including plumbing, where a number of small parts are produced.
hydroforming allows parts of very complex geometry, that under conventional processing conditions need several production steps, to be manufactured in a single process.
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Weld joints are no longer necessary because the parts are produced in one piece.
Through the calibration method hydroforming parts reach a very high dimensional accuracy.
The advantage of this is that IHF parts show a high work hardening, therefore the wall thickness can be decreased and material can be saved.
The basic process of hydroforming consists of a tube that is pressed in a form, with aid of a pressure fluid.
The pressure for this process is more than 1500 bar.
The lubricant that is brought on the outside of the tube should separate the work piece and the tool and enable the material to flow into the form.
Further more, the process includes the pre-bending of the tubes and cleaning, as well as the corrosion protection of the finished work pieces.
Therefore, a machine that is constructed for the Hydroforming process is a very complex system.
In the whole process chain a number of lubricant systems with different types of tasks are included, and if possible should be compatible with each other.
This starts at the primary hydraulic and extends over corrosion protection oils, tube bending fluids, secondary hydraulic and the actual hydroforming lubricants.
The cleaning of the work pieces between bending process and the actual hydroforming should be avoided because of economical and ecological reasons.
Therefore the bending oil and the product for the outer lubrication should be compatible or, in an ideal situation, the same product.
An industrial scale application of hydroforming is mainly dependent on the tribological task, where the lubricants have a key function.
Aspects of HSE, as well as work-safety, will influence the development of all lubricants in the future, including those developed for hydroforming.
mineral oil is going to be replaced by good biodegradable esters.
Due to recent developments, Biodegradable esters, are no longer the expensive option.
Like other procedures in metalworking, it is only possible to work on optimal solutions in cooperation with the machine tool builder, lubricant developer and users.
For example, in the case of hydroforming: Schuler Hydroforming, Simpelkamp SPS, Shell Metalworking Europe, Benteler Maschinenbau and ACI Renault or BMW - as the end users of the whole concept.
As already mentioned a hydroforming work piece goes through several manufacturing steps: tube manufacturing, cut tubes to the right length, bending (performing), hydroforming, cleaning and corrosion protection.
For all these steps lubricants are used.
It is the aim of users as well as lubricant producers to reduce the products as far as possible.
The compatibility of lubricants will play a key role in achieving this.
At Shell Metalworking Europe modern concepts for the outer lubrication are understood.
The advantages of the new concepts, developed together during the prototyping phase with Press producers (Schuler Hydroforming, Simpelkamp SPS) are as follows: Outer lubricants based on mineral oil or synthetic esters (Fenella Oil HDL group of Products): * More or less insoluble and extremely good demulsifying tendency in the pressure fluid.
* High adhesive capacity on the work piece.
* Adaptation to the work piece (no discoloration or corrosion) * The viscosity should be adapted to the thickness of the material.
* Free from solid lubricants, that can result in build-ups in the tool.
Outer lubricants based on polymer film former (Fenella Fluid HDF group of products): * Stable, dry, tack-free and above all elastic film.
* Vehicle must dry as quick as possible.
* Solvent free.
* Evetually weldable.
Pressure media (Fenella Fluid HPF group of products): * Good pressure build up.
* Minimizing the wall thickness decreasing during deformation.
* Good filterability.
* Compatibility with other lubricants.
* Good corrosion protection.
* Lubrication of the hydraulic system.
* Lubrication of the pressure stamp.
* Good internal lubrication of the work piece.
* No foam tendancy.
* Stable towards yeast, fungus and bacteria.
A committed partner for metal working fluids, such as Shell Metalworking Europe, puts the whole portfolio of hydroforming lubricants at a customer's disposal.
This contains bending oils, lubricants for the outer lubrication (oils as well as polymers), pressure fluids for inner lubrication, cleaning and corrosion protection fluids, with all products involved in the process chain compatible to each other.
Clearance certification of well known system manufacturers exist.
Hydroforming system producers and Shell Metalworking Europe exchange their experience so that lubricants are already included in the prototyping of new work pieces.
(There are no restrictions concerning the materials.) That results in the following advantages for the Hydroforming user: * One single contact partner for all production fluids.
* Ultra modern fluid technology for longer life of instruments and tools.
* Well suited products for different demands in mass-production or prototyping.
* All products are offered world-wide.
* Development of the products takes place together with press and tool producer.
* Quick on-site service by a pool of specialists.
* Complete package of industrial fluids, conform to the customer demand.
* Health, safety and environment requirements are integrated in the development of products. Request a free brochure from Shell Lubricants ...
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