液壓機成形技術在行業應用優勢和優點

液壓機成形技術優勢

與傳統的沖壓工藝相比，液壓成形工藝在減輕重量、減少零件數量和模具數量、提高剛度與強度、降低生產成本等方面具有明顯的技術和經濟優勢，在工業領域尤其是汽車工業中得到了越來越多的應用。

在汽車工業及航空、航天等領域，減輕結構質量以節約運行中的能量是人們長期追求的目標，也是先進制造技術發展的趨勢之一。液壓成形（hydroforming）就是為實現結構輕量化的一種先進制造技術。

液壓成形也被稱為“內高壓成形”，它的基本原理是以管材作為坯料，在管材內部施加超高壓液體同時，對管坯的兩端施加軸向推力，進行補料。在兩種外力的共同作用下，管坯材料發生塑性變形，并最終與模具型腔內壁貼合，得到形狀與精度均符合技術要求的中空零件。

液壓機成形技術優點

對于空心變截面結構件，傳統的制造工藝是先沖壓成形兩個半片，然后再焊接成整體，而液壓成形則可以一次整體成形沿構件截面有變化的空心結構件。與沖壓焊接工藝相比，液壓成形技術和工藝有以下主要優點：

1. 減輕質量，節約材料。對于汽車發動機托架、散熱器支架等典型零件，液壓成形件比沖壓件減輕20%～40%；對于空心階梯軸類零件，可以減輕40%～50%的重量。

2．減少零件和模具數量，降低模具費用。液壓成形件通常只需要1套模具，而沖壓件大多需要多套模具。液壓成形的發動機托架零件由6個減少到1個，散熱器支架零件由17個減少到10個。

3. 可減少后續機械加工和組裝的焊接量。以散熱器支架為例，散熱面積增加43%，焊點由174個減少到20個，工序由13道減少到6道，生產率提高66%。

4. 提高強度與剛度，尤其是疲勞強度，如液壓成形的散熱器支架，其剛度在垂直方向可提高39%，水平方向可提高50%。

5. 降低生產成本。根據對已應用液壓成形零件的統計分析，液壓成形件的生產成本比沖壓件平均降低15%～20%,模具費用降低20%～30%。

Advantages of forming technology of hydraulic press

Compared with the traditional stamping process, hydroforming technology has obvious technical and economic advantages in reducing weight, reducing the number of parts and dies, improving stiffness and strength, reducing production costs and so on. It has been applied more and more in the industrial field, especially in the automobile industry.

In the automotive industry, aviation, aerospace and other fields, reducing structural mass to save energy in operation is a long-term goal pursued by people, and is also one of the development trends of advanced manufacturing technology. Hydroforming is an advanced manufacturing technology for lightweight structure.

Hydroforming is also known as "internal high pressure forming". Its basic principle is that the tube is used as the blank, and the ultra-high pressure liquid is applied inside the tube. At the same time, the axial thrust is applied to both ends of the tube blank to supplement the material. Under the joint action of the two external forces, the tube blank material plastic deformation, and finally fit with the inner wall of the mold cavity, so as to obtain the hollow parts whose shape and precision meet the technical requirements.

Advantages of hydraulic press forming technology

For the hollow variable cross-section structural parts, the traditional manufacturing process is to form two half pieces first, and then weld them into a whole, while hydroforming can form the hollow structural parts with changes along the cross-section of the components at one time. Compared with stamping welding process, hydroforming technology and process have the following main advantages:

1. Reduce weight and save materials. For typical parts such as engine bracket and radiator bracket, the weight of hydroforming parts is 20% - 40% less than that of stamping parts, and the weight of hollow stepped shaft parts can be reduced by 40% - 50%.

2. Reduce the number of parts and molds and reduce the cost of molds. Hydroforming parts usually only need one set of dies, while most stamping parts need more than one set of dies. The number of engine bracket parts reduced from 6 to 1, and the number of radiator bracket parts decreased from 17 to 10.

3. It can reduce the welding amount of subsequent machining and assembly. Taking the radiator bracket as an example, the heat dissipation area increased by 43%, the number of solder joints decreased from 174 to 20, the process decreased from 13 to 6, and the productivity increased by 66%.

4. Improve the strength and stiffness, especially the fatigue strength. For example, the stiffness of the hydroforming radiator bracket can be increased by 39% in the vertical direction and 50% in the horizontal direction.

5. Reduce production cost. According to the statistical analysis of applied hydroforming parts, the production cost of hydroforming parts is reduced by 15% ～ 20% and the die cost is reduced by 20% ～ 30%.