EP1326722B1 - Apparatus and method for hydroforming a tubular part - Google Patents

Apparatus and method for hydroforming a tubular part Download PDF

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Publication number
EP1326722B1
EP1326722B1 EP01974611A EP01974611A EP1326722B1 EP 1326722 B1 EP1326722 B1 EP 1326722B1 EP 01974611 A EP01974611 A EP 01974611A EP 01974611 A EP01974611 A EP 01974611A EP 1326722 B1 EP1326722 B1 EP 1326722B1
Authority
EP
European Patent Office
Prior art keywords
tube
tubular blank
engaging structures
blank
hydroforming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP01974611A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1326722A1 (en
Inventor
Mark Cobb
Erich Genseberger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Magna International Inc
Original Assignee
Cosma International Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cosma International Inc filed Critical Cosma International Inc
Publication of EP1326722A1 publication Critical patent/EP1326722A1/en
Application granted granted Critical
Publication of EP1326722B1 publication Critical patent/EP1326722B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/047—Mould construction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/045—Closing or sealing means

Definitions

  • the invention relates generally to an improved apparatus and method for more efficiently hydroforming a tubular part. More specifically, the invention relates to an apparatus and method that uses a punch to shape each end of the part into the desired configuration and hold the part during hydroforming.
  • a raw tube is positioned within a hydroforming tool and the tube is secured at its ends.
  • the middle portion of the raw tube is then subjected to hydroforming, leaving a transitional zone between the ends of the raw tube and the hydroformed middle portion.
  • the hydroformed part is then finished by having the two transition zones removed from the tube, leaving only the fully hydroformed middle portion.
  • the ends of the tube can be secured by tip portions being generally wedge-shaped as disclosed in EP 1022073A1.
  • Hydroforming is also disclosed in the U.S. Patent Nos. 5,987,950 to Horton and 6,014,950 to Jaekel et al.
  • One object of the present invention is to provide an improved apparatus and method for forming a hollow part.
  • Another object of the present invention is to provide an improved apparatus and method for efficiently and cost effectively shaping a hollow part by mechanically shaping at least one end of the part and by hydroforming a portion of the part.
  • Still another object of the invention is to provide an apparatus and method for forming a part that uses a punch to secure each end of the part while the punch shapes the end so that each end has the same configuration as a hydroformed, middle portion.
  • a hydroforming die assembly for hydroforming a part from a tubular blank, the part having a desired configuration different from a configuration of the blank and including a desired cross section at one end thereof, the die assembly comprising: a die structure having interior surfaces defining a die cavity, the die cavity having a cross sectional configuration conforming to the desired cross section of the part; and a pair of tube-end engaging structures disposed at opposite ends of the die cavity and constructed and arranged to engage opposite ends of the tubular blank, the tube-end engaging structures being constructed and arranged to seal the opposite ends of the tubular blank and to pressurize hydroforming fluid within the tubular blank for expanding the tubular blank into conformity with the interior surfaces of the die cavity, a first of the tube-end engaging structures having an outer cross-sectional configuration corresponding to the desired cross section at one end of the part, the first of the tube-engaging structures being movable into forced engagement with one end of the tubular blank to conform the one end of the tubular blank to the outer cross-section
  • a method of forming a hydroformed part comprising the steps of: providing a hydroforming die assembly for hydroforming a part from a tubular blank, the part having a desired configuration different from a configuration of the blank and including a desired cross section at one end of the part, the die assembly including a die structure having interior surfaces defining a die cavity, the die cavity having a cross sectional configuration conforming to the desired cross section of the part, and a pair of tube-end engaging structures disposed at opposite ends of the die cavity and constructed and arranged to engage opposite ends of the tubular blank, the tube-end engaging structures being constructed and arranged to seal the opposite ends of the tubular blank and to pressurize hydroforming fluid within the tubular blank for expanding the tubular blank into conformity with the interior surfaces of the die cavity, a first of the tube-end engaging structures having an outer cross-sectional configuration corresponding to the desired cross section at one end of the part; moving the first of the tube-engaging structures into forced engagement with one end of the tubular blank to
  • FIG. 1 Shown generally in FIG. 1 is an exploded perspective view of a hydroforming die assembly generally indicated at 10 in accordance with the present invention.
  • the hydroforming die assembly 10 includes a movable upper die structure 12, a movable lower die structure 14, a fixed die structure 16, and a fixed base 18 on which the fixed die structure 16 is mounted.
  • a plurality of pneumatic or nitrogen spring cylinders 20 mount the lower die structure 14 for movement on the fixed base 18.
  • the upper die structure 12, lower die structure 14, and fixed die structure 16 cooperate to define a longitudinal die cavity therebetween, having a substantially boxed-shaped or multifaceted cross section as will be described herein.
  • the upper die structure 12, lower die structure 14, fixed die structure 16, and fixed base 18 are each made of an appropriate steel material such as P-20 steel and/or 2714 steel.
  • the upper die structure 12 defines a pair of cradle areas 22 at opposite longitudinal ends thereof.
  • the cradle areas 22 are shaped and arranged to receive and accommodate upper clamping structures 26, at opposite longitudinal ends of the upper die structure 12.
  • the clamping structures 26 are each connected to the upper die structure 12 at the respective cradle areas 22, by a plurality of pneumatic or nitrogen spring cylinders 24 which permit relative vertical movement between the clamping structures 26 and the upper die structure 12.
  • the lower die structure 14 has similar cradle areas 30 at opposite longitudinal ends thereof which are constructed and arranged to accommodate lower clamping structures 28 in a similar fashion. As shown, the longitudinal ends, indicated at 15, forming cradle area 30 of the lower die structure 14 have a generally U-shaped configuration.
  • the lower clamping structures 28 each have an upwardly facing surface 34 having a cross-sectional configuration that defines one-half of a multifaceted surface configuration.
  • multifaceted means square, rectangular, parallelepiped, polygonal, or any other closed, non-circular or oval configuration.
  • surface 34 defines one half of a rectangle.
  • each upper clamping structure 26 is substantially identical to the lower clamping structures 28 but are inverted with respect thereto. More particularly, each upper clamping structure 26, has a downwardly facing surface 36 having a cross-sectional configuration that defines a second half of the multifaceted (i.e., rectangular) surface configuration.
  • the surface 36, of each clamping structure 26, cooperates with surface 34, of the respective lower clamping structures 28, to form a multifaceted clamping surface that captures end portions of a tubular blank 40 when the upper die structure 12 is lowered.
  • the upper die structure 12 defines a longitudinal channel 38 having a substantially inverted U-shaped cross section.
  • the channel 38 is defined by a downwardly facing, generally horizontal longitudinally extending surface 44, and a pair of spaced, longitudinally extending vertical side surfaces 43, which extend parallel to one another from opposite sides of surface 44.
  • the lower die structure 14 has a central opening 42 extending vertically therethrough, between the U-shaped longitudinal ends 15.
  • the opening 42 receives fixed die structure 16.
  • Interior vertical surfaces 41 in the lower die structure 14 define the aforementioned central opening 42. More particularly, a pair of longitudinally extending side surfaces 41, define the lateral extremities of the opening 42. The surfaces are vertically disposed in parallel facing relationship with one another.
  • the U-shaped end portions 15 of the lower die structure 14 define the longitudinal extremities of the opening 42, and have interior surfaces (not shown) vertically disposed in parallel facing relation to one another.
  • the fixed base 18 is in the form of a substantially rectangular metal slab.
  • the fixed die structure 16 is affixed to an upper surface 46 of the fixed base 18.
  • the fixed die structure 16 is an elongate structure which extends along a major portion of the length of the upper surface 46 of the fixed base 18, generally along the center of the fixed base 18.
  • the fixed die structure 16 projects upwardly from the fixed base 18 and has substantially vertical side surfaces 48 on opposite longitudinal sides thereof
  • the fixed die structure 16 is constructed and arranged to extend within the opening 42 in the lower die structure 14, with minimal clearance between the generally vertical side surfaces 48 of the fixed die structure and vertical surfaces 41 of the lower die structure 16. Similarly, there is minimal clearance between the interior transverse side surfaces (not shown) of end portions 15 of the lower die structure 14 and the vertical end surfaces 49 of the fixed die structure 16.
  • the fixed die structure 16, further includes an upwardly facing, generally horizontal and longitudinally extending die surface 50, which is constructed and arranged to extend in spaced facing relation to the longitudinally extending, downwardly facing die surface 44 of the upper die structure
  • the aforementioned side surfaces 41, the upwardly facing surface 50, the side surfaces 43 and downwardly facing surface 44 cooperate to define a die cavity 52, having a multifaceted cross sectional configuration substantially throughout its longitudinal extent.
  • the die cavity surfaces define the desired shape of a part to be hydroformed from a circular or oval blank tube.
  • FIG. 2 shows the upper die structure 12 in an opened or raised position. In this position the hydroforming die assembly 10 enables the tubular blank 40 to be placed within the lower die structure 14.
  • each punch 81 includes an initial beveled portion 82 which transitions into a multifaceted, here rectangular, portion 84.
  • a base 86 forming a lateral shoulder 88 is formed at one end of the multifaceted portion 84 opposite the initial beveled portion 82.
  • the punch 81 is secured to the end of the mounting structure 90 by means of mechanical fasteners 92, such as bolts, extending through counter-bored apertures 94 formed in the punch 81 and into the holder 92.
  • Base 86 preferably has a size and shape that is complementary to the size and shape of the mounting structure 90 so as to form a smooth, uniform transition between the punch 81 and the mounting structure 90.
  • the beveled portion 82 is preferably formed at an angle e (see Fig. 7) of between about 13-17°, and most preferably, about 15° with respect to the sides of the box-shaped portion 84.
  • the multifaceted portion 84 preferably has straight sides so as to have a perimeter that defines a multifaceted shape, such as a polygon, square rectangle, skewed parallelogram, etc.
  • the perimeter shape of the box-shaped portion 84 corresponds substantially to the shape of the clamping surface formed by the upwardly facing surface 34 of the lower clamping structure 28 and the downwardly facing surface 36 of the upper clamping structure 26.
  • the size of the multifaceted portion 84 is defined so as to provide a sealing interference fit with the wall of the tubular blank 40, with the clamping surfaces providing external support for blank 40.
  • the forward end 83 of the punch 81 at the free end of the beveled portion 82 has dimensions that are smaller than the multifaceted portion 84, thus permitting the forward end 83 to be inserted into the unexpanded end of the tubular blank 40 as shown in FIG. 2.
  • the hydroforming ram can be further advanced under the force of hydraulic pressure, thus forcing the punch 81 into the end of the tubular blank 40 after the upper die structure 12 is lowered, as shown in FIG. 3.
  • the beveled portion 82 of the punch 81 gradually forms the end of the blank 40 until the multifaceted portion 84 is fully inserted into the end of the blank 40.
  • the end portions of blank 40 may be stretched outwardly as they are conformed to the multifaceted portion 84 and hence, the adjacent clamping surfaces 34, 36, as best shown in FIGs. 3 and 8.
  • the width of the lateral shoulder 88 is preferably substantially the same as the thickness of the tubular blank 40 so that the outer surface of the tubular blank 40 transitions smoothly with the outer surfaces of the base 86 and the holder 90.
  • the tubular blank 40 may be round (circular cross section). Punches 81 have a similar height and width dimensions as the blank.
  • the blank may be oval for punches that are rectangular or otherwise elongated along a height or width dimension. Hydroforming processes using oval tubular blanks are disclosed in U. S. Patent No. 5,987,950.
  • Providing a tubular blank having an oval cross-section is advantageous in comparison with the conventional circular cross-section because it provides a circumference that conforms more closely to the final cross sectional perimeter of the generally box-shaped (not square) cross-sectional shaped die cavity 52.
  • less expansion of the blank 40 is required when expanding the blank into conformity with the surfaces forming cavity 52.
  • the closer conformity of blank 40 and cavity surfaces allows the blank to be more easily expanded into the corners of the cavity 52, where expansion becomes most difficult due to the increasing frictional surface contact between the exterior surface of the blank and cavity surfaces during expansion of the blank 40.
  • the hydraulic fluid is injected through a channel 87 formed in one or both punches 81 which communicates with a channel 97 formed in the corresponding mounting structure 90.
  • the pre-filling operation is preferred to reduce cycle times, and to achieve a more smoothly contoured part, for some applications the upper die structure 12, may be fully lowered before any fluid is provided internally to tubular blank 40.
  • End portions of the sealed die cavity 52 are generally rectangular in shape as defined by surface portions 54 having generally the same size and shape as the clamping surfaces 34, 36 of the clamping structures 28, 26, respectively.
  • the portions 54 define areas of the die cavity which have a cross-sectional area that is the same as or only slightly larger than the area defined by the cross-sectional shape of the end portions of the tubular member 40 after the punches 81 have been forced into the ends of the tubular member as illustrated in FIG. 6.
  • the portions 54 of the die cavity 52 define areas of the die cavity which are used to expand the tubular blank 40 during the hydroforming process only to the extent required to convert the shape of the blank from a round or oval cross section to a multifaceted (here rectangular) cross sectional configuration.
  • each unexpanded surface portion 54 of the die structure defines a shape consistent with the shape of the portions 84 and 86 of the punch 81.
  • the cavity 52 may also include an enlarged portion 56 towards the longitudinally central portions thereof
  • the fluid F can be pressurized to expand the tubular blank 40 into conformity with the surfaces defining die cavity 52 (see FIGS. 5 and 9).
  • the tubular blank 40 is expanded into the non-round, multifaceted (e.g., rectangular) of the die cavity 52. If the hydroforming assembly includes a die cavity with an enlarged portion 56, the blank 40 will be enlarged in that area.
  • the hydroformed member has a consistent shape out to its ends, and it is not necessary to cut the end portions off. If a portion of the blank is to be significantly enlarged in its cross-sectional perimeter (e.g., greater than 5% relative to the original blank perimeter), it may be preferred that the longitudinal ends of the blank be pushed inwardly toward one another to replenish wall thickness as the blank is expanded. If the blank is not to be enlarged, but is only expanded into conformity with a multifaceted die cavity, longitudinal movement of the ends during expansion of the blank may not be necessary. More particulars on the preferred hydroforming process are disclosed in U.S. Patent No. 6,014,879 to Jaekel et al..
  • a circular or oval punch as opposed to a multifaceted punch. This is because material flows more effectively and evenly toward the enlargement area from a rounded end than from a box-shaped end.
  • FIG. 11 Such a hydroforming configuration is shown in FIG. 11, in which the surrounding die structures are not shown for clarity of the illustration.
  • the arrangement shown includes one hydroforming ram 80 having a beveled, rectangular-shaped punch 81 and a rectangular-shaped mounting structure 90, as shown and described previously.
  • the arrangement also includes a second hydroforming ram 100 that includes a cylindrical base portion 112 and a smaller cylindrical portion 102 with an insertion bevel 116 formed at the end.
  • a circular, annular sealing shoulder 114 that engages the end of the tubular blank 40' is defined between base portion 112 and cylindrical portion 102.
  • the die structure presents a surface configuration that forms the blank 40' such that the cross sectional configuration at portion 110 of the blank is expanded only to the extent that the rounded cross section of the blank is converted to a multifaceted cross section.
  • the portion 110 is joined by a gradually tapered segment 108 which extends to an enlarged rectangular-shaped cross sectional portion 106.
  • the die structure presents a surface configuration that forms a relatively short, non-enlarged cylindrical portion 105 of the blank. The blank then transitions from the rounded perimeter shape at 105 to the rectangular cross section at area 106.
  • the cylindrical punch 100 allows for the relatively large expansion of enlarged area 106 and the abrupt transition region 104 because longitudinal pushing at the end of the tubular member 40' is more effective for replenishing wall thickness if the punch is round.
  • the cylindrical end portion of the formed member shaped by the cylindrical punch 100 would typically be cut off during a subsequent finishing operation.
  • the box-shaped end formed by the rectangular-shaped punch 81 can be tailored to the desired final member shape so the end need not be cut off.
  • one or more ram extenders 120 can be installed between the punch 81 and the holder 90.
  • the extenders 120 have a rectangular-shaped cross sectional configuration that conforms with the rectangular-shaped cross sections of the mounting structure 90 and the base 86 of the punch 81.
  • the hydroforming rams 80' can extend further into the relatively unenlarged portions 54 of the die cavity 52 to accommodate hydroforming of shorter tubular blanks 40' within the same die cavity 52.
  • the extended hydroforming blanks 80' cannot extend to an enlarged area 56 of the hydroforming cavity 52 or the seal between the end of the tubular blank 40' and the shoulder 88 of the punch 81 will be lost as the tubular blank expands into the enlarged area 56.
  • the present invention includes a hydroforming die assembly for hydroforming a part from a tubular blank comprising a die structure having interior surfaces defining a die cavity, the die cavity having a cross sectional configuration conforming to the predetermined cross section of the part, the part having a predetermined configuration different from a configuration of the blank and including a predetermined cross section at one end thereof.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
EP01974611A 2000-10-19 2001-10-17 Apparatus and method for hydroforming a tubular part Expired - Lifetime EP1326722B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US24133700P 2000-10-19 2000-10-19
US241337P 2000-10-19
PCT/IB2001/001946 WO2002032596A1 (en) 2000-10-19 2001-10-17 Apparatus and method for hydroforming a tubular part

Publications (2)

Publication Number Publication Date
EP1326722A1 EP1326722A1 (en) 2003-07-16
EP1326722B1 true EP1326722B1 (en) 2005-10-12

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EP01974611A Expired - Lifetime EP1326722B1 (en) 2000-10-19 2001-10-17 Apparatus and method for hydroforming a tubular part

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US (1) US20050126243A1 (ja)
EP (1) EP1326722B1 (ja)
JP (1) JP2004511349A (ja)
KR (1) KR100789014B1 (ja)
CN (1) CN1227079C (ja)
AT (1) ATE306337T1 (ja)
AU (2) AU9412401A (ja)
BR (1) BR0114789A (ja)
CA (1) CA2426029C (ja)
CZ (1) CZ20031109A3 (ja)
DE (1) DE60114038T2 (ja)
MX (1) MXPA03003379A (ja)
NZ (1) NZ525377A (ja)
WO (1) WO2002032596A1 (ja)

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CN101322995B (zh) * 2008-06-27 2010-10-06 哈尔滨工业大学 大直径管件内高压成形模具
CN101927291B (zh) * 2009-06-22 2012-11-14 宝山钢铁股份有限公司 一种管件液压成形预成形方法及其装置
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KR101178920B1 (ko) * 2010-05-07 2012-08-31 잘만테크 주식회사 히트파이프 제조방법, 그 제조방법에 의해 제조된 히트파이프 및 그 히트파이프를 포함하는 냉각장치
CN102756033B (zh) * 2011-04-27 2015-09-30 上海汇众汽车制造有限公司 多层管快速充液成形方法和系统
US8534107B2 (en) * 2011-06-10 2013-09-17 Ford Global Technologies, Llc Method and apparatus for pulsed forming, punching and trimming of tubular members
US20150040399A1 (en) * 2012-03-14 2015-02-12 Endless Solar Corporation Ltd Method of fabricating a component of a solar energy system
CN102836909A (zh) * 2012-06-01 2012-12-26 北京理工大学 内高压端头组合密封技术
US8910500B2 (en) 2012-09-10 2014-12-16 National Research Council Of Canada Low friction end feeding in tube hydroforming
TR201505451T1 (tr) 2012-11-08 2015-07-21 Dana Automotive Systems Group İki̇nci̇l şekle sahi̇p, hi̇droli̇k preste bi̇çi̇mlendi̇ri̇lmi̇ş tahri̇k mi̇li̇ tüpü.
CN104785603B (zh) * 2015-05-13 2018-07-27 宁波钜智自动化装备有限公司 一种用于内高压成形管件加工的分体式堵头
TWI609727B (zh) * 2016-06-17 2018-01-01 國立中山大學 液壓成形方法及其裝置
CN107350330A (zh) * 2017-07-24 2017-11-17 柳州科瑞科技有限公司 一种左右不对称式管材内高压成形设备
CN107262585A (zh) * 2017-07-24 2017-10-20 柳州科瑞科技有限公司 一种左右对称式管材内高压成形设备
CN108787847A (zh) * 2018-06-18 2018-11-13 苏州渼富临信息科技有限公司 一种压力成型设备的夹紧式模具
CN114762872A (zh) * 2021-01-13 2022-07-19 宝山钢铁股份有限公司 一种管件内压支撑合模装置、方法以及管件的制造方法
CN114918308B (zh) * 2022-06-17 2023-08-29 昆山精诚得精密五金模具有限公司 一种金属管加工用液压胀形机

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Also Published As

Publication number Publication date
KR20030087614A (ko) 2003-11-14
KR100789014B1 (ko) 2007-12-26
CZ20031109A3 (cs) 2004-01-14
MXPA03003379A (es) 2004-05-04
WO2002032596A1 (en) 2002-04-25
EP1326722A1 (en) 2003-07-16
AU2001294124A1 (en) 2002-04-29
US20050126243A1 (en) 2005-06-16
AU9412401A (en) 2002-04-29
CA2426029A1 (en) 2002-04-25
CN1471444A (zh) 2004-01-28
NZ525377A (en) 2003-09-26
ATE306337T1 (de) 2005-10-15
DE60114038T2 (de) 2006-06-22
WO2002032596A9 (en) 2003-08-28
BR0114789A (pt) 2003-08-12
JP2004511349A (ja) 2004-04-15
CN1227079C (zh) 2005-11-16
WO2002032596A8 (en) 2002-10-24
DE60114038D1 (de) 2005-11-17
CA2426029C (en) 2009-11-24

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