Accuracy in process chains using hydroforming

As the demands for lightweight construction and precision grow, there is an increasing interest on new processes, which are capable to manufacture parts having the desired mechanical, geometric and surface properties. The hydroforming process is one such process which can be used to fulfill these demands. It is based on forming a hollow piece into complex shaped parts in a few steps, which are often combined in one tool. The features of accuracy are analyzed. The typical precision of those parts, having geometrical measurements of about 500 mm, is in the range of about 0.5 mm. Examples for different process chains are given, including the accuracy. Process chains exist which deliver precise assemblies starting with parts of low accuracy. Process chains may be shortened by process integration using different subprocesses from the hydroforming technology.