Common Process Steps
Tube hydroforming normally begins with a straight round tube. Other shapes can be used, but round provides the greatest number of part design options. Preforming commonly includes bending to make the tube follow the general layout of the desired final part. Also required in many cases is cross-sectional performing.
Hydroforming is next, often coupled with in-die hole punching. This usually is followed by removing end scrap and welding additional components to the newly formed tube.
Some part designs and process requirements make it necessary to use special material, tube quality standards, lubrication (and cleaning), additional hole cutting outside the hydroforming die, and other processes. These factors will add cost, which can be worth it for the "value" they provide. However, they should be implemented only after considering alternate design approaches and processes that may render these steps unnecessary