|Type of Press||Triform Deep Draw 16-10-7DD|
|Max Chamber Pressure||10,000 PSI|
|Forming Area||16" Diameter|
|Lower Punch Stroke||7"|
|Max Punch Tool Diameter||12"|
|Challenge||Eliminate annealing from the forming process to have better weld quality in final assembly.|
|Solution||Thanks to Triform's ability to tightly control the flow of the material as the downward acting bladder holds the material while the tool extends atop a punch cylinder, Aerosud was able to completely eliminate all 6 annealing steps. Now the part can be formed without using any heat in the process allowing for a better weld quality during final assembly.|
|Challenge||Reduce expense associated with scrap and part thinning.|
|Solution||Because the Triform press is able to form the cannister in a single step with controlled flow of the material, thinning of the part has been reduced significantly. Aerosud is now able to buy blanks that are 10% thinner. Additionally, because of the process repeatability inherent in a Triform, scrap parts are a thing of the past.|
|Results||Aerosud was able to eliminate 100% of their annealing process. They can now procure thinner starting materials, and scrap rates are less than 1%. The finished parts also offer a better weld quality in final assembly and the overall appearance is greatly improved. The reduction in forming steps also means parts can be produced faster with less skilled labor.|
Aerosud Holdings, a manufacturer of wing components for commercial airliners located in Pretoria, South Africa, was experiencing a bottleneck in the production of aluminum canisters for the Airbus A320. The company’s traditional forming operations required six annealing steps to draw a 4.5-in. diameter canister 6.5-in. deep. Excessive thinning in the process — which resulted in high scrap rates — required a starting sheet thickness of .080-in. In addition, the high number of anneals affected the quality of the welding in the final assembly and made it difficult to meet demanding delivery schedules.
By moving production to a Triform deep draw sheet hydroforming press, Aerosud is now able to draw the canisters consistently without needing a single annealing process. Additionally, the steady, uniform pressure of the Triform press reduced material thinning greatly, allowing the blank thickness to be reduced from a .080-in. sheet to a .063-in. sheet, offering significant material cost savings.
Thanks to Aerosud’s new 16-10-7DD Triform press, annealing has been completely eliminated from the forming process, part production costs have been lowered by 25%, scrap rates have been reduced to less than 1%, weld quality has been greatly improved, and the overall appearance of the final parts has been enhanced.