At Helander, our metal spinning and sheet hydroforming processes produce a range of durable 
and high-quality metal parts. Tank heads especially are a perfect fit for our metal forming processes. We produce our tank heads in a number of dimensions and shapes, depending on each client’s specific needs. This blog will discuss how Helander makes tank heads and the advantages of using custom-made options instead of choosing stock tank heads.
Hydroforming is frequently and advantageously applied within the aerospace industry. The typically high complexity of aerospace components necessitates a fabrication technique that can
effectively produce the desired shapes and forms. Metal sheet hydroforming provides an economical manufacturing solution for parts with asymmetrical or complex geometries and irregular contours as the process requires fewer passes to produce the desired part than a comparable matched die stamping process.
At the heart of Helander’s hydroforming services is our cutting edge 20″ hydroforming press. Sheet hydroforming is an ideal process for manufacturing parts with complex or asymmetrical geometries that would require multiple punch cycles in a matched die stamping process. By replacing one of the rigid dies with highly pressurized hydraulic fluid contained in a flexible diaphragm, its dynamics allow it to take on the form of any conceivable geometry. We use it to create an almost unlimited range of geometric shapes, either shallow or deep drawn, from a wide variety of metals and metal alloys.
Designed by engineering and manufacturing professionals with decades of experience in the machine tool industry, this hydroforming press sets the industry standard in hydroforming technology. Their pioneering pressure containment system offers a significantly reduced press size and operates with outstanding integrity and durability. Modern design software, state-of-the-art hydraulics, and computer-driven controls provide us with the capability to produce seamless parts that are extremely lightweight, strong, and durable.
This flexiblepress is fully programmable can be used interchangeably in the deep draw or fluid cell process mode. For deep drawn parts or those with curved geometries, the downward-acting bladder holds the material during pressurization as the tool is extended upward by a hydraulic punch cylinder. This draws the material into the bladder and allows it to flow as needed. By contrast, the fluid cell process allows the downward pressure of the bladder to form the material around the tool, allowing multiple parts to be run in a single cycle.
Operating at up to 10,000 psi, this hydroform features and advanced control and hydraulic systems that allows us to precisely manage the forming pressure of punch travel, which facilitates the production of net-shaped parts. Its “open” feature enables our operators to visually inspect parts mid-cycle, after which they can either continue the cycle or abort in order to modify the recipe – a significant time saver in new part development projects.
Maximum punch tool diameter is 15″, while draw depth capacity is 10″. Outfitted with components from well-known names in industrial automation, it gives us the capability to for an extensive PM program.
If you are in the ultra-competitive manufacturing world, you are always looking for an advantage. This is especially true when it comes to die molding specialty products like magnetic rotary pumps.
When considering the numerous options available for working with metal, many companies choose the beneficial and cost effective process hydroforming. Originally developed around 1950, hydroforming is ideal for shaping many types of ductile metals, including brass, aluminum, stainless and low alloy steels. It holds a number of benefits when compared to similar work processes, especially when considering cost, precision, and efficient operation. One area where hydroforming especially excels is its role in minimizing secondary finishing operations.
Metal Spinning is a process by which a disc or tube of ductile metal is rotated on a spindle and formed into an axially symmetric part. Through the use of heavy forces and high speeds, the metal will deform and “flow” to form the desired shape around a mandrel, a kind of mold that is shaped to the interior geometry of the planned part. This process allows metal to deform evenly, without any wrinkling or warping, to create a smooth, even, and seamless surface. The processes’ heavy forces also realign and strengthen the grain structure, significantly increasing the tensile properties and fatigue resistance of the base material.
This blog has showcased our custom tank heads before, exhibiting our dedication to quality above all else in fulfilling your custom product orders. Today we’re going to be talking about them again, as a lens through which to look at one of our other manufacturing processes: hydroforming. While metal spinning is our core business and the process we use whenever we determine it to be the best match, hydroforming is ideal for custom tank head manufacturing thanks to its ability to combine product strength, concave form, and light weight.
At Helander, nothing makes us happier than doing great work that saves our customers money. Recently we’ve discovered a new production niche that has been bringing us tons of new and repeat customers. It seems that metal stamping facilities often face a dilemma. One of their clients might come to them requesting a short run or prototype of a new project. For the metal stamper this can be a giant headache, because it is often cost-prohibitive for them set all their machinery up to do small jobs. If they take the risk and don’t get the big project, they are out time and a lot of money. The solution? Going to Helander for metal spinning and hydroforming services that you can’t get elsewhere.
Lots of different types of machining methods are familiar to manufacturers. Even if you don’t deal with all of them or maintain a factory full of every machine that’s out there, you can probably rattle off quite a few different types: CNC machines, EDM, waterjet cutting, and so on. Of course, for us at Helander, one type invariably comes to mind first: metal hydroforming.
