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Hydroforming

Stainless steel and aluminium tube and sheet metal forming

Hydroforming is a process that uses water at very high pressure to mould stainless steel and aluminium with precision. It allows complex shapes that are difficult to achieve with other techniques.

The steel, which can be either sheet or tube, is placed inside a specially designed mould. The sheet metal is processed by means of uniform pressure exerted by water, used as a real punch, which guarantees a precise and detailed shape. In the case of pipes, the process differs slightly: high-pressure water is injected into the pipe, causing it to expand until it adheres to the inside walls of the mould.

This method allows complex shapes with curves and details that would be difficult to achieve with other traditional techniques. Both processes, for sheet and tube, ensure a high-quality product with precise geometries and high structural strength. Hydroforming therefore stands out as a versatile and innovative solution, ideal for various industrial applications.

The Advantages of Hydroforming
Metal parts can be produced very efficiently, even with special and complex shapes, including cavities or undercuts Greater creative freedom for designers due to process flexibility Reduction in the overall number of components required for the product Improved mechanical precision of the final component Homogenous stretching of the material, with reduced springback Superior surface quality obtained Possibility of significantly reducing product weight without compromising strength Reduction of post-forming interventions, such as cutting holes Overall savings due to reduced costs for tools and auxiliary equipment
INNOVATIONS

Our commitment to excellence

Since 2009, Inoxveneta has successfully introduced and developed hydroforming to create sheets and tubes with complex geometries and high performance. Our goal is to offer state-of-the-art solutions, transforming stainless steel and other metals into high value-added components for our customers. Thanks to our experience and technology, we guarantee an efficient processing of absolute excellence.

Hydroforming is never an isolated process, but part of a complete production cycle. Therefore, we make sure that each step, upstream and downstream, is perfectly integrated. Our flexible structure allows us to work with large international groups as well as small and medium-sized companies, adapting quickly to the needs of each customer and providing tailor-made solutions.

Our distinguishing features include:
Specialised engineering: targeted technical support for each project
In-house design and manufacture of moulds and tooling
4 hydroforming presses with a clamping force of up to 7,000 tonnes
Large working range, up to 2000 x 1300 mm
Water pressure up to 3600 bar for flawless results

We work closely with designers to optimise each step of the process:

Use of CAD-CAE tools for a detailed and concrete feasibility study Design for Hydroforming, to successfully address process-specific constraints Integrated product and process development to maximise efficiency
Hydroforming Sheet metal
Hydroformed stainless-steel components
Hydroforming is to date the most economical process for obtaining moulded components from sheet metal. The mould is not only easy to construct, but also very economical.

Thanks to this technology, it is possible to mould different types of materials and different thicknesses without having to modify the mould, because it is the water that adapts to the thickness of the sheet metal inserted. In addition, the sheet metal is deformed uniformly, and when the hydraulic pressure ceases, springback is minimised as well as uniform over the entire surface of the part, thus achieving maximum stability and the absence of geometric distortions.


Sheet metal hydroforming operation

Inoxveneta uses the water-punch hydroforming technique, which involves several steps:

01.
POSITIONING OF METAL SHEET

The sheet metal is placed on a work surface

02.
FLUID ENTERS

The press is closed

03.
FORMING METAL SHEET

Through a nozzle, a fluid is conveyed at very high pressure so as to ‘force’ the sheet metal to adhere to the mould surface, until the desired shape is achieved

04.
EXTRACTION OF METAL PART

When the mould is complete, the mould is opened and the finished part is removed

Water-punch hydroforming is ideal for:

 

  • Panels and planes
  • Inclined and conical surfaces
  • Geometries with complex and articulated details

 

The constraint of hydroforming sheet metal lies in the need to use presses with a considerable force, much greater than that required by traditional hydraulic stamping. Inoxveneta has met this challenge by equipping itself with two 6,000-ton and two 7,000-ton hydroforming presses, all designed with an innovative concept that allows costs to be contained without compromising operational efficiency.

Hydroforming of pipes
Stainless-steel and aluminium tubes without limits
Thanks to hydroforming technology, designers can push the limits of creativity. This technique makes it possible to achieve complex shapes that in the past would have required much more expensive and complex processes.

In the field of stainless steel and aluminium tube processing, hydroforming has established itself as a revolutionary process. Using hydrostatic pressure, the tubes are uniformly shaped, ensuring an even distribution of force over the entire surface. This process not only eliminates springback, but also increases the rigidity of the final component, making it aesthetically impeccable and structurally high-performing. The result is a product that excels in both aesthetics and reliability, with clear advantages in terms of production time and overall cost.

Tube hydroforming operation

Inoxveneta uses the water punch hydroforming technique, which involves several stages:

01.
POSITIONING OF TUBE

The tube is inserted into a specially designed mould

02.
CLOSING OF MOULD

Closing of the mould

03.
FILLING

High-pressure fluid is fed into the pipe

04.
AXIAL FEEDING

When necessary, the action of mechanical actuators helps to position the tube and improve its shaping

05.
FORMING FLUID UNDER PRESSURE

Under the action of the fluid pressure, the tube is deformed until it adheres perfectly to the shape of the mould

06.
EXTRACTION OF METAL PART

Once forming is complete, the hydroformed tube is removed from the mould

With Hydroforming you can process tubes:
Stainless steel and aluminium shaped tubes
Conical, for applications requiring special shapes.
Variable diameter or radius, ideal for complex designs
With variable profile
With multiple branches, such as T or Y configurations
The benefits of hydroforming for tubes
Simplification and reduction of completion operations, improving process efficiency Possibility of drilling directly on the tube during the forming process Elimination of joining operations, reducing production complexity Reduction in the number of specific tools required for processing Significant reduction in overall costs when processing stainless steel and aluminium tubes
Elastoforming
Sheet metal stamping with elastic die
Elastoforming is an advanced technology, widely used in the aeronautical industry and in all applications where safety dictates that neither the punch nor the die is metallic.

This elasto-plastic moulding technique produces moulded parts using an elastic matrix, such as rubber or polymers, which deforms the sheet under pressure. Thanks to our 6,000- and 7,000-tonne presses, we are able to elastoform sheet metal with precision. This process reduces the stress on the metal, which is typical of traditional stamping, allowing precise reproduction of parts and significant savings on tooling costs of up to 50%. In addition, it guarantees superior surface and dimensional quality, making it an ideal solution for efficient, high-quality production.

Elastoforming offers a more efficient alternative to traditional product development processes. Where several steps such as cutting, bending and welding are required, this technology enables the same result to be achieved with just one mould pressure. As well as significantly reducing processing times, it lowers costs by using less complex and cheaper moulds than conventional methods.   Elastoforming Operation
Positioning the sheet between the mould and the elastic matrix
Thrust of the sheet against the elastic die
The sheet is pushed further against the rubber half-mould, which gives it the desired shape
The advantages of elastoplastic pressing on the product and the process
Absence of stresses typical of traditional moulding, due to points of concentration of stretching (in the edges, radii of curvature)
High precision in terms of consistency of sheet thicknesses
Excellent repeatability of parts produced
Simple and low-cost tooling
Low production costs
Applications
Application sectors hydroforming and elastoforming
The sheet metal assemblies and components we produce are characterised by high technical standards, tight tolerances, and aesthetic finishes that must be impeccable to optimally enhance the equipment for which they are intended.

Application sectors

Sheet metal components made through hydroforming and elastoforming processes find application in many sectors:

 

  • Components for large kitchens and catering, food service
  • Automotive industry
  • Machine construction
  • Design furniture for home and office
  • Oil & Gas, power generation
  • Medical

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