CASE HISTORY #1 Interlaken develops system for hydroforming offset stainless steel fuel filler necks.
CASE HISTORY #2 Stainless steel fittings manufacturer uses Interlaken hydroforming system to improve quality and profits.
CASE HISTORY #3 Stainless steel fittings manufacturer purchases second Interlaken hydroforming system as a result of cost savings from first system.
CASE HISTORY #4 University gets two machines in one with their Interlaken System. It does both hydroforming and metal formability research.
CASE HISTORY #1 Interlaken develops system for hydroforming offset stainless steel fuel filler necks.
Problem
The automotive industry desires light- weight, high strength components that are easily recyclable. One component being considered for change is the fuel filler neck. Traditionally manufactured out of painted carbon steel, stainless steel has recently been chosen as the material of choice. This has caused problems with traditional manufacturing processes. The tooling used to create the expanded offset of the fuel filler neck galls the product and shortens tool life. A different manufacturing process is needed.
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Solution
Interlaken has developed a system for manufacturing the stainless steel offset fuel filler necks using hydroforming. The asymmetrical shape of the offset requires more than a simple expansion of a tube into a die cavity. Using UniPress, Interlaken’s sophisticated press control system, a precise feed and internal pressure profile was developed to allow the material to flow into the unique cavity shape.
Results
With the Interlaken hydroforming system, manufacturers can consistently produce stainless steel fuel filler necks to tight manufacturing tolerances without any galling or tool wear. Production systems are available to manufacture one or more fuel filler necks per cycle.
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CASE HISTORY #2 Stainless steel fittings manufacturer uses Interlaken hydroforming system to improve quality and profits.
Problem
A major mid-western manufacturer of stainless steel fittings for the sanitary, biopharmaceutical, semiconductor and petrochemical markets wanted to increase the quality of their product by incorporating some new technology. Cheap offshore fittings and competitive domestic producers were cutting into their profit margins. They were looking to increase the quality of the fittings they were producing to capture a larger share of the premium fittings market. This market consisted of buyers that were willing to pay more for a high quality product.
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Solution
The manufacturer had decided early on
in their investigation that hydroforming was the answer. They purchased an Interlaken Model 3360-HF-340 hydroforming system. This is a 170-ton servo hydraulic system with three 58,000 lb. sealing actuators and a 20,000 psi pressure intensification system. This system is designed to do 90’s, 45’s and T’s of up to 4" in diameter.
Results
With the Interlaken hydroforming system, the manufacturer can produce fittings with an excellent finish that have a diametrical accuracy to within .004 inches. Better diametrical control reduces polishing time and the need to mechanically resize the tube ends. With the improved quality, the manufacturer is in position to capture a larger share of the premium stainless steel fittings market.
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CASE HISTORY #3 Stainless steel fittings manufacturer purchases second Interlaken hydroforming system as a result of cost savings from first system.
Problem
A manufacturer of stainless steel fittings for the sanitary, biopharmaceutical, semiconductor and petrochemical markets purchased an Interlaken hydroforming press system to gain market share in the premium fittings market. The fittings were produced and sold for a very attractive price. The demand for the premium fittings increased. The first hydroforming press system did not have the capacity to produce the number of fittings that were now in demand.
Solution
The manufacturer decided to take a portion of the profits from the increase in business to invest in another Interlaken hydroforming press system.
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Hydroforming press system with a die for producing 4-inch diameter stainless steel elbows.
Results
With two Interlaken hydroforming systems, the manufacturer is meeting increased production demands. They again find themselves in a favorable position to capture a larger market share of the premium fittings market.
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Two-250 ton hydroforming press systems for manufacturing stainless steel fittings
| CASE HISTORY #4 University gets two machines in one with their Interlaken System. It does both hydroforming and metal formability research.
Problem
The University of Michigan was looking for a sophisticated research system that would allow them to do metals formability research, prove out hydroforming models, do basic hydroforming research and allow them to do contract work for their supporters like the Big Three and Tier One suppliers. They needed this machine to fit in a cramped laboratory and more importantly fit into their limited budget.
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Solution
They purchased an Interlaken Model 3360-SPHF-75 metal formability and hydroforming system. This is a servo hydraulic press with a 75,000 lb. clamp, a 58,000 lb. punch and two 37,000 lb. sealing actuators for hydroforming. The system also includes a 20,000 psi pressure intensification system. With the Interlaken system, the university can do metals formability, hydroforming and lubrication research. Simple die changes and the user friendly UniTest control system make switching between modes easy.
Results
The U of M now has a system that can do both metal formability and hydroforming research. The users of the system report ease of use, versatility and reliable data acquisition as key features. The TestBuilder function allows students to easily set up their own tests. They like the precision control and repeatability, giving them accurate results.
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