Benefits
Fluid cell forming has proven to have a number of economic and processing advantages, particularly when compared to rubber pad pressing and mechanical or hydraulic stamping:
- Unlike the two- or three-piece tool sets used in stamping presses, Flexform requires only a single, shape-defining punch or die, cutting tool costs by 50 to 90 percent. The tools can be simple punches (blocks), punches with fixed blank holders, dies or expansion tools. Tool matching and alignment procedures are eliminated, and, with the uniformly applied pressure, stresses in the tool are almost purely compressional, permitting the use of inexpensive, lower-strength, easy-to-machine materials such as hardwood and plastic.
- Intricate shapes, including undercuts and holes, can be produced, often in one operation. Tools can incorporate cutting edges to eliminate downstream trimming.
- Multiple parts can be processed in a single cycle.
- With cycle times ranging from one to three minutes, lead times are dramatically shortened for both prototypes and production parts.
- Virtually any sheet metal from 0.1mm to more than 16 millimeters (.004 to .63 inches) can be formed. Different gauges can be formed on the same tool. The sheet metals most commonly formed on the fluid cell press are mild steel, high-strength steel and aluminum alloys, stainless steel, and titanium. Other materials can include nickel-based alloys such as Hastelloy®, Inconel®, and Nimonic 75.
- Surface finishes are free from scratches or gall marks.
- Complex parts can be designed and produced that would be prohibitively expensive with conventional presses. Large, intricate parts can be formed, allowing designers to combine smaller components into single, seamless units, saving downstream assembly time and the extra weight of welds and fasteners.