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Forming Impressions
With the success we have had with the Triform press on the A320
program, Aerosud is now working on the design for the Airbus A350 Slat Track
Cans using the Triform hydroform.
- Dr. Deon Labuschagne, Aerosud
Triform is a Single Tool Technology, which means there is no need for expensive matched male/female die sets, as the diaphragm acts
as a universal female. This results in greatly decreased tooling costs and, therefore, lower overall per part costs. Tooling can be made
quickly, from a wide variety of materials including steel, aluminum, poured epoxies, 3D printed materials and even wood.
This ability to rapidly create (or modify) tooling, gives Triform users the ability to react quickly to their production needs, at a fraction of the
cost and time of processes which rely on traditional matched die sets. It is these unique tooling requirements that make Triform
hydroforming the go-to technology for short-run production and prototyping. Triform hydroforming is used in many industries, including:
A Triform press can replace many different metal forming processes, and can consolidate multiple steps into a single operation. Most
parts, including those which are deep drawn, are formed in one press cycle. Fluid Cell parts are often formed net shape and require no
additional finishing work.
There are two types of Triform processes: Fluid Cell & Deep Draw
Well-suited to structural
aerospace forming
Triforms Fluid Cell process is ideal for forming shallow contours, bending flanges, forming lightening holes, joggles or stiffener beads.
Triform Deep Draw presses allow for the ability to form complex geometries which would be impossible, or extremely challenging and
expensive with the use of traditional male/female tooling. Parts are frequently formed in a single cycle, eliminating secondary processes
such as the welding of box corners.
Drawing parts to heights which are twice the diameter is common and, in general, forming tall parts within a Triform Deep Draw press will
require fewer operations when compared to traditional draw forming.
Typical deep drawn materials include Aluminum, Steel, Stainless, Inconel, Brass, Copper, some Titanium alloys and even Plastics &
Composites.
Lower Costs
Tooling Costs
The diaphragm used in Triform Sheet Hydroforming acts as a universal die, conforming to any shape placed within the press chamber.
This eliminates the need for 1matched, male-female tooling. This process simplification can reduce tooling costs by 50% - 90% compared
with conventional press tooling. And because tool-makers are only focused on the single form block, the creation of new tooling and the
modification of existing tooling is significantly faster and less expensive. Materials frequently used for Triform hydroforming tooling include
steel, aluminum, 3D printed materials, poured epoxies and even wood.
Material Costs
Sheet hydroforming can result in less than 10% variation in blank to finished-part thickness, due to the uniform elongation of the material.
The forces applied during the cycle are multi-directional, drawing the material around the tool and reducing stretching or thinning
associated with traditional draw forming. This allows the starting material thickness to be reduced, thereby reducing overall material costs.
Finishing Costs
Thanks to the flexible diaphragm, parts are produced with smooth, scratch-free surfaces which typically require no secondary polishing. By
eliminating the need for secondary finishing required due to the marring left by the direct-metal contact of male/female dies labor costs
can be reduced. Some parts can even be painted prior to forming, without damage to the surface finish.
Development Costs
In traditional forming, high tooling costs and precision alignment requirements limit new part development due to increased tooling costs
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and lead time constraints. By contrast, the creation of new Triform tooling and subsequent modification to that tooling are less formidable.
Improved Efficiency
Tooling Setup & Changeover
Use of non-mated tooling allows for faster setup & changeover, particularly within the Fluid Cell process, wherein the form blocks can
be hand-placed, unsecured on the forming surface. Triform presses frequently reduce tool change time by 60%-70%, making the
process ideal for High-Mix / Low-Volume situations that require frequent tool changes.
Reliance on Skilled Labor
Triform hydroforming offers net shape part production, eliminating (or greatly minimizing) the need for manual hand finishing of
partially formed parts. Hand-finished parts are associated with inflated labor expenses, increased scrap rates, inferior part quality and
decreased productivity.
For example, parts formed with the use of traditional rubber pad presses often require multiple hits, with manual hammering in
between. This is due to the nature of the pressure applied in rubber pad forming, which is limited in terms of both the maximum
pressures applied to the part, and the uniformity of those applied pressures. A large percentage of parts which require this human
touch between multiple pad press cycles, can be formed to net shape in a single Triform cycle.
Development Tools
Triforms In-Sight feature allows part developers the opportunity to pause the cycle at any point in the forming process, and open the
press for a visual inspection of the forming results. Depending on those results, the operator then has the option of either continuing the
cycle, or aborting in order to modify the recipe, lubrication or other process variables per the visual feedback received. This ability to
look inside the chamber greatly expedites new part development, saving valuable time & material.
Pam-Stamp simulation to
determine process variables
Stratasys 3D printer to
produce the simulated tooling
3D Printing
Triforms collaboration with Stratasys, a world-leader in 3D printing technology, has
provided Triform with valuable experience related to the use of 3D printing within the
manufacturing process.
3D printed tools can dramatically improve development time and lower costs. The
combination of Triform sheet hydroforming & 3D printed tools is a powerful, gamechanging combination for those looking for a competitive edge.