Metal Tube Processing Equipment

4000 Ton CNC Tube Hydroforming Press

Automatic high-pressure hydraulic hydroforming equipment for the production of automotive components and other industrial metal tubular parts

These 4000-ton CNC tube hydroforming presses are used for manufacturing lightweight, high-strength tubular structural parts, mainly for automotive and industrial applications. Their design focuses on meeting current production demands for weight reduction, improved part quality, and higher efficiency. As tube hydroforming moves toward larger, more flexible, and more automated production lines, precise ultra-high-pressure control and servo-hydraulic systems play a key role in overall performance. The main features of CNC tube hydroforming presses include the following:

4000 Ton CNC Tube Hydroforming Press
  • 4000 Ton CNC Tube Hydroforming Press
  • 4000 Ton CNC Tube Hydroforming Press
    • Ultra-high-pressure capability
      Each hydroforming press is equipped with two intensifier cylinders, which allows internal pressure to reach up to 400 MPa. This pressure level allows tube hydroforming presses to handle complex parts with large deformation and high yield strength.
    • Accurate pressure control
      Pressure control at the intensifier cylinders is maintained within ±0.5 MPa, meeting the precision requirements for tube hydroforming processes.
    • Micron-level displacement control
      The cylinder displacement sensors can detect movement with a resolution down to 0.001 mm. During operation, the actual positioning accuracy of the side cylinders is controlled within ±0.1 mm, supporting precise material feeding during forming.
    • Efficient servo-hydraulic control
      Each hydraulic cylinder is driven by an independent servo control system, with speeds reaching up to 110 mm/s. Compared with conventional servo-valve control, servo-hydraulic control reacts faster and delivers better efficiency while keeping costs at a similar level.
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    Technical Parameters
    Item Unit Value / Spec Remarks
    Nominal force KN 40000
    Return force KN ≥1600
    Hydraulic system pressure MPa 25
    Side cylinder force KN 2500×4 Two cylinders per side (left & right)
    Main cylinder stroke mm 600
    Side cylinder stroke mm 180
    Max. daylight opening mm 1350
    Main cylinder pressing & side cylinder slow-feed control accuracy mm ±0.05 Displacement resolution: 0.01 mm; accuracy ensured by the user control program
    Side cylinder center distance mm 830
    Main motor power KW 2×75 / 4×63.5 Dual gear pumps; servo motors
    Effective working table size Left to right mm 2700 Distance between left and right side cylinder faces: 2700
    Front to back mm 1800
    Die closing speed Fast approach mm/s approx. 300 No load
    Slow approach mm/s 28 No load; 15 mm stroke
    Pressing speed mm/s 14 During die closing
    Return speed mm/s approx. 220
    Side cylinder speed Fast approach mm/s 100 No load
    Slow approach mm/s 29 Under load: 25 MPa; 80 mm stroke
    Return speed mm/s 90 No load
    Intensifier cylinder speed Fast approach mm/s 49 No load
    Slow approach mm/s 30 Under load: 25 MPa; 400 mm stroke
    Features
    Energy Consumption

    Energy Consumption
    Servo motor drives are used across the CNC hydroforming press, resulting in lower power consumption and reduced operating noise

    Cost Efficiency

    Cost Efficiency
    Unmanned production with integrated processing steps improves material utilization and helps control overall production costs

    Production Efficiency

    Production Efficiency
    The hydroforming press uses a dual-die setup, producing two parts per cycle to increase output efficiency

    Intelligent Control

    Intelligent Control
    A servo control system based on the Beckhoff EtherCAT bus is used, providing fast communication and efficient data processing throughout the production process

    Precision Control

    Precision Control
    A high-precision servo-hydraulic system is applied, with control accuracy maintained within ±0.1 mm to support stable and consistent forming results

    Hydroforming Technology
    • Material feeding accuracy
      Feeding displacement accuracy: 0.01 mm
      Forming stroke accuracy: 0.02 mm
    • Internal pressure control accuracy
      Synchronization time difference between internal pressure and material feeding: 0.002 s
    • In-die punching accuracy
      Response time between punching, pressure, and feeding axes: 0.002 s
      Hole diameter accuracy: ≤ 0.2 mm
      Hole position accuracy: ≤ 0.4 mm
    • Forming accuracy of finished parts
      Profile tolerance: ≤ 0.4 mm
      Wall thinning rate: < 15%
    Metal Tube Processing Equipment

    Compared with traditional stamping, the hydroforming process generally uses less energy because complex parts can be formed in a single step, instead of going through multiple operations and using various tools. Thanks to this, the whole process more efficient, allowing hydraulic system efficiency to increase from about 60% to around 85%, with energy savings of up to 25% per year. Since the pressure comes from inside the tube and is applied evenly, the material bends in a much more controlled way. This makes springback smaller and more predictable, usually around 0.1–0.3 mm. This level of control is especially useful when forming lightweight, high-strength tubes that require precise dimensions.

    In oval or rectangular tubes, uneven thickness usually comes from poor pressure or feeding control. Managing these two factors properly helps the material flow more naturally and keeps the wall thickness more consistent. CNC hydroforming equipment allows pressure to be controlled within ±0.5 MPa and cylinder movement within ±0.1 mm, so material flow can be adjusted accurately. During the tube forming process, sensors track the cylinder movement with a resolution of 0.001 mm, which allows the feeding process to be adjusted in real time as the material flows. Combined with proper process design and pressure distribution, this approach allows the wall thickness to remain close to uniform across the entire tube section.