Plus, I'm thinking the die is in two pieces that begin to close around the rail as the water pressure increases in a very controlled manner.
Can someone explain how hydroforming works?
Thread Starter
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Joined: Apr 2008
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From: Columbia SC
Can someone explain how hydroforming works?
The C5 (and C6 too, I guess) use "hydroformed" frame rails to save weight and get away from having to weld up separate structures into one. I am having trouble visualizing how this works. I saw a photo once of the assembly line and in the foreground were long, straight box-section rails that were to become the frames. If water pressure "blows" these straight rails into the finished shape inside a die, how do the pieces get INTO this die in the first place? I mean, the die has to have the finished shape in its interior, but a straight channel wouldn't fit into it as I see it.
I know I'm missing something but can't figure it out. Anyone know?
Thanks, Ralph Boineau in central South Carolina
I know I'm missing something but can't figure it out. Anyone know?
Thanks, Ralph Boineau in central South Carolina
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St. Jude Donor '08-'09-'10-'11-'12-'13-'14-'15-'16
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The C5/C6 frames are rather convoluted by comparison and need to be formed from both sides simultaneously. It's possible the "die" may actually consist of more than two sections (or "halves") in order to accomplish the more complex shaping required.
Burning Brakes
Joined: Nov 2002
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From: Los Altos CA
This is from Digital Corvettes:
"In the hydroforming process, operators feed precut hollow, round steel tubes, called blanks, into a bender, where they are shaped into the general form of the final part. Robots place the bent tube into the lower half of a hydroforming die where the ends are sealed. A combination of water, mixed with a touch of oil and corrosion inhibitor, is fed through the seals into the blank and then highly pressurized to shape the steel into the desired configuration (conformed to the die walls). Depending on the part, the water pressure may range anywhere from 5000 psi to 30,000 psi - and in special cases, may even near 100,000 psi.At the same time, the machine compresses the ends of the blank, which eliminates thin spots on the outer wall of the blank, and prevents wrinkling on the inner wall, as well. Often, any required holes or slots can be pierced into the part while it is in the hydroforming die. The component is then removed from the hydroforming press, the ends are trimmed and mounting holes are pierced with lasers and cutting torches. The result is a finished part that may require only trimming before heading off to the assembly line. "
"In the hydroforming process, operators feed precut hollow, round steel tubes, called blanks, into a bender, where they are shaped into the general form of the final part. Robots place the bent tube into the lower half of a hydroforming die where the ends are sealed. A combination of water, mixed with a touch of oil and corrosion inhibitor, is fed through the seals into the blank and then highly pressurized to shape the steel into the desired configuration (conformed to the die walls). Depending on the part, the water pressure may range anywhere from 5000 psi to 30,000 psi - and in special cases, may even near 100,000 psi.At the same time, the machine compresses the ends of the blank, which eliminates thin spots on the outer wall of the blank, and prevents wrinkling on the inner wall, as well. Often, any required holes or slots can be pierced into the part while it is in the hydroforming die. The component is then removed from the hydroforming press, the ends are trimmed and mounting holes are pierced with lasers and cutting torches. The result is a finished part that may require only trimming before heading off to the assembly line. "
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