EP1579931A1 - Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung - Google Patents

Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung Download PDF

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Publication number
EP1579931A1
EP1579931A1 EP04425207A EP04425207A EP1579931A1 EP 1579931 A1 EP1579931 A1 EP 1579931A1 EP 04425207 A EP04425207 A EP 04425207A EP 04425207 A EP04425207 A EP 04425207A EP 1579931 A1 EP1579931 A1 EP 1579931A1
Authority
EP
European Patent Office
Prior art keywords
plunger
protrusion
hydroforming
punching member
hollow body
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.)
Granted
Application number
EP04425207A
Other languages
English (en)
French (fr)
Other versions
EP1579931B1 (de
Inventor
Rosanna c/o C.R.F. Brun
Marco c/o C.R.F. Colosseo
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.)
Centro Ricerche Fiat SCpA
Original Assignee
Centro Ricerche Fiat SCpA
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 Centro Ricerche Fiat SCpA filed Critical Centro Ricerche Fiat SCpA
Priority to DE602004006956T priority Critical patent/DE602004006956T2/de
Priority to AT04425207T priority patent/ATE364460T1/de
Priority to EP04425207A priority patent/EP1579931B1/de
Publication of EP1579931A1 publication Critical patent/EP1579931A1/de
Application granted granted Critical
Publication of EP1579931B1 publication Critical patent/EP1579931B1/de
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
    • B21D26/035—Deforming tubular bodies including an additional treatment performed by fluid pressure, e.g. perforating

Definitions

  • the present invention relates to methods for hydroforming hollow bodies. Such methods have been known and used since long. They provide hydroforming of hollow bodies, such as tubular elements of metal material, within a cavity of a hydroforming die, by applying a fluid (for example water) under pressure within the hollow body, in order to expand the body wall outwardly against the surface of the die cavity.
  • a fluid for example water
  • a typical application of hydroforming methods is that of the manufacture of metal tubular elements for exhaust pipes of motor-vehicle engines.
  • a metal tubular element having any desired configuration for instance a straight, curved or S-shape configuration
  • Structures of this type are for instance required to form the exhaust manifold of the engine of a motor-vehicle.
  • a method for hydroforming a hollow body with at least a branch portion wherein a hydroforming die is provided, having a forming cavity.
  • a hollow blank body, originally lacking of the branch portion, is placed within the die cavity and pressurized fluid is fed within the hollow blank body in order to cause formation of a blind bottomed protrusion on awall of the hollow body, which protrusion is expanding in a corresponding portion of the die cavity.
  • the hollow body is extracted from the hydroforming die and subjected to a separated shearing operation of the blind bottom in order to obtain an opening at the end of the protrusion.
  • the main purpose of the present invention is to propose a new method for forming a hollow body provided with a branch portion, which is simpler, easier to carry out and quicker than the methods proposed in the known art.
  • the object of the invention is a method for hydroforming a hollow body with at least one branch portion, wherein:
  • the shearing operation required for removing the blind bottom of the protrusion formed by hydroforming is carried out within the hydroforming die. For this reason, it is not necessary to remove the formed piece from the die to carry out the shearing operation in a different place and with a different tool. This makes the operations necessary to obtain the end piece simpler and easier, considerably reducing manufacturing times.
  • said plunger-punching member acts on the bottom wall of a protrusion extending outwardly of the body, the drawback found in the solution of US 6 305 201 B1 does not occur.
  • the circumferential edge of the opening which is thereby defined usually results radially deformed inwardly, whereby it requires an end operation for deformingit radially outwardly, in order to give the component the desired geometry, within the required manufacturing tolerances.
  • such end step for outwardly deforming the edge of the opening of the branch portion of the hollow body and for calibrating the opening dimension is carried out within the same hydroforming die.
  • said plunger/punching member once its shearing stroke towards the interior of the hollow body is completed, is moved in the opposite direction and used as a chuck for radially deforming the opening edge outwardly and press it against the wall of the die cavity.
  • the plunger/punching member has a radially extendable section and actuating means are provided to cause this expansion at the end of the shearing stroke of the plunger/punching member inwardly of the hollow body, and prior to the return stroke of the plunger/punching member, which causes expansion and calibration of the opening edge of the branch portion.
  • the portion of the plunger/punching member which causes the outwardly deformation of the opening edge is in a retracted, non operating condition during the shearing stroke and it moves into its operating expanded configuration just before the start of the return stroke. Thanks to such return stroke, the branch portion is calibrated in order to have a diameter precisely corresponding to that of the corresponding portion of the die cavity.
  • a further feature of the invention consists in that the above plunger/punching member has a magnetic or magnetizable front head, in order to retain on it the shearing operation scrap.
  • numeral 1 generally designates the apparatus used for carrying out the hydroforming method according to the invention.
  • Numeral 2 is a hydroforming die illustrated only diagrammatically in the drawings.
  • the die 2 includes a cavity 3 wherein a tubular steel element 4 is placed, originally having a cross-section of constant shape and size along the full-length of the tubular element 4.
  • the die 2 consists in at least two parts that can be opened among them to allow the introduction and the extraction of the tubular element within the die.
  • the cavity 3 of the hydroforming die 2 show a cylindrical main portion, which axis is indicated by 5, and an additional portion 6 constituted by a cylindrical cavity radially branching with respect to the axis 5 from the cylindrical main portion of the cavity 3.
  • the portion 6 of the hydroforming cavity 3 is for allowing a radial protrusion to form on the wall of the tubular element 4.
  • the drawings show a tubular element 4 in form of a straight cylinder by way of example, it would be equally possible to provide a tubular element 4 and correspondingly a cavity 3 having a complex form, for example a configuration with one or more curves.
  • plungers 7, 8 which are schematically illustrated in the drawings, are slidably mounted, whose stems 7a, 8a are driven through actuating means of any type (usually fluid actuator means) in order to subject the tubular element 4 to a mechanical compression in the direction of its main axis 5.
  • actuating means of any type usually fluid actuator means
  • plungers 7, 8 are in front contact with the end surfaces of the tubular element 4.
  • the two plungers 7,8 have axial passages 7b,8b which put in communication the space 4a inside the tubular element 4 respectively with an outlet pipe 9 for enabling the hydroforming liquid (for example water) to leave space 4a and an inlet pipe 10 (only diagrammatically illustrated) for feeding the pressurized fluid required for carrying out the hydroforming operation within the space 4a.
  • an outlet pipe 9 for enabling the hydroforming liquid (for example water) to leave space 4a
  • an inlet pipe 10 (only diagrammatically illustrated) for feeding the pressurized fluid required for carrying out the hydroforming operation within the space 4a.
  • a valve 11 is interposed in the outlet pipe 9 .
  • a third plunger 12 is further slidably mounted, which structure and function will be described in more detail in the following.
  • Plunger 12 is also subjected to actuator means of any known type (typically fluid means) which are able to drive it in any one of its two moving directions, by applying a predetermined force.
  • the actuating means of the two plungers 7, 8 and of the third plunger 12 are controlled by an electronic control circuit according to a predetermined program, in order to carry out the operation cycle that will be described in more detail in the following.
  • the third plunger body 12 consists in four angular sectors 13 defining at their ends two conical surfaces 14, 15 in contact with a conical surface 16 and a conical surface 17 respectively of two end elements 18, 19 of the plunger 12.
  • the end element 18 is rigidly connected with a stem 19 which axially passes through the four sectors 14 and has a threaded end on which the annular body of the end element 19 is screwed.
  • Actuator means of any type are contemplated to give a rotation motion to stem 20 with respect to the end element 19, in order to cause the two end elements 18, 19 to move towards each other. Due to the mutual engagement among the conical surfaces 14, 16 and 15, 17, this movement, causes an outward radial movement of the fours sectors 13, which determines an expansion of the plunger portion 12 interposed among the two end elements 18 and 19.
  • Figure 7 illustrates the assembly in the expanded condition.
  • spring means are further provided for pushing sectors 13 towards their radially inward position, corresponding to the minimum diameter configuration of the plunger 12.
  • These spring means may consist, for example, in one or more elastic rings 21 placed around the four sectors 13.
  • the plunger 12 is capable to assume a smaller diameter configuration or an expanded diameter configuration.
  • a further important feature of the plunger 12 resides in that the front circumferential edge 18a of the end element 18 is shaped like a cutting edge, in such a way that the plunger 12 may also function as a shearing punching member to make a circular opening in the metal body wall 4.
  • the tubular element 4 has, as already indicated, a tubular conformation with a section of constant shape and size along the full-length thereof.
  • the tubular element 4 is placed within the hydroforming die 2 in the condition illustrated in figure 1.
  • the plunger 12 is arranged with its front end surface in contact with the tubular element wall 4, as illustrated in figure 1.
  • the hydroforming method is started by feeding a high pressure fluid (water) within the space 4a.
  • a high pressure fluid water
  • an axial mechanical compression is also applied to the tubular element 4 by the two opposite plungers 7, 8 which are driven to move one towards the other.
  • the joined action of the two plungers 7, 8 and of the pressurized water within the space 4a upon the tubular element wall 4 causes the forming of a protrusion 22 (figure 2) on the tubular element wall 4 expanding outwardly in the portion 6 of the hydroforming cavity.
  • the third plunger 12 is progressively moved backwardly, that is e moved away from the main portion of the hydroforming cavity 3, to allow the formation of the protrusion 22.
  • the moving back of the plunger 12 is however performed by applying to such plunger a controlled pressure in order to provide a resistance to the growing of the protrusion 22 sufficient to form at last a desired configuration (illustrated in the figure 3) with a bottom wall 22a which is substantially planar.
  • the plunger 12 is used as a shearing punching member.
  • the wall portion 22a thus removed remains adherent to the front surface of the plunger/punching member 12, because the end portion of the plunger 12 comprises a permanent magnet or a portion magnetizable by a solenoid (not illustrated). Therefore, the scrap does not fall freely inside the tubular element, but remains adherent to the plunger 12.
  • the plunger 12 is brought in its expanded diameter configuration and then moved again in a radially outward direction.
  • a portion 23 (figures 6, 7) of the external surface of the plunger/punching member 12 comes into contact with the internal surface of the circumferential edge of the opening 22b by pressing it again against the portion 6 of the cavity 3, in order to obtain the forming of a tubular portion 34 branching from the tubular element 4, with a regular cylindrical configuration, with the desired size.
  • the element obtained is a finished hollow body, such as the tubular element of the illustrated example, with a branch tubular portion already having its end opening 22b and with a geometry corresponding to the requirements. It is not then necessary to subject the element coming out from the hydroforming die to further operations or processes.
  • the hollow body configuration may be of any type, and in particular may be a complex configuration other than the one of the cylindrical tubular element here illustrated by way of example.
  • the branch portion configuration may be different and may include, for instance, a curved portion.
  • the invention is also applicable when multiple branch portions have to be formed on a same hollow body, in which case it is necessary to provide a plunger/punching member for each of these portions within the hydroforming die.

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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)
EP04425207A 2004-03-24 2004-03-24 Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung Expired - Lifetime EP1579931B1 (de)

Priority Applications (3)

Application Number Priority Date Filing Date Title
DE602004006956T DE602004006956T2 (de) 2004-03-24 2004-03-24 Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung
AT04425207T ATE364460T1 (de) 2004-03-24 2004-03-24 Verfahren und vorrichtung zum innenhochdruckumformen eines hohlkörpers mit mindestens einer abzweigung
EP04425207A EP1579931B1 (de) 2004-03-24 2004-03-24 Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP04425207A EP1579931B1 (de) 2004-03-24 2004-03-24 Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung

Publications (2)

Publication Number Publication Date
EP1579931A1 true EP1579931A1 (de) 2005-09-28
EP1579931B1 EP1579931B1 (de) 2007-06-13

Family

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EP04425207A Expired - Lifetime EP1579931B1 (de) 2004-03-24 2004-03-24 Verfahren und Vorrichtung zum Innenhochdruckumformen eines Hohlkörpers mit mindestens einer Abzweigung

Country Status (3)

Country Link
EP (1) EP1579931B1 (de)
AT (1) ATE364460T1 (de)
DE (1) DE602004006956T2 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2745951A1 (de) 2012-12-20 2014-06-25 C.R.F. Società Consortile per Azioni Verfahren zur Herstellung einer Nockenwelle in einem Verbrennungsmotor

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB470485A (en) * 1935-04-02 1937-08-13 Edward Shelton Cornell Jr Method of producing integral metal pipe fittings
US5765420A (en) * 1995-08-16 1998-06-16 Wilhelm Schaefer Maschinenbau Gmbh & Co. Process and apparatus for producing hollow bodies having at least one branch
DE19751402A1 (de) * 1997-11-14 1999-06-02 Mannesmann Ag Verfahren und Vorrichtung zur Herstellung eines Abzweiges an einem Hohlprofil
EP1010480A1 (de) * 1998-12-18 2000-06-21 Tubes et Formes Verfahren und Vorrichtung zur Herstellung einer geneigten Zweigleitung in einem metallischen Rohr durch Hydroformung
DE19909928A1 (de) * 1999-01-20 2000-12-07 Audi Ag Vorrichtung zum teilweisen oder vollständigen Durchtrennen eines Werkstückes
JP2001286947A (ja) * 2000-03-31 2001-10-16 Kawasaki Hydromechanics Corp チューブハイドロフォーミングの膨出端部成形方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB470485A (en) * 1935-04-02 1937-08-13 Edward Shelton Cornell Jr Method of producing integral metal pipe fittings
US5765420A (en) * 1995-08-16 1998-06-16 Wilhelm Schaefer Maschinenbau Gmbh & Co. Process and apparatus for producing hollow bodies having at least one branch
DE19751402A1 (de) * 1997-11-14 1999-06-02 Mannesmann Ag Verfahren und Vorrichtung zur Herstellung eines Abzweiges an einem Hohlprofil
EP1010480A1 (de) * 1998-12-18 2000-06-21 Tubes et Formes Verfahren und Vorrichtung zur Herstellung einer geneigten Zweigleitung in einem metallischen Rohr durch Hydroformung
DE19909928A1 (de) * 1999-01-20 2000-12-07 Audi Ag Vorrichtung zum teilweisen oder vollständigen Durchtrennen eines Werkstückes
JP2001286947A (ja) * 2000-03-31 2001-10-16 Kawasaki Hydromechanics Corp チューブハイドロフォーミングの膨出端部成形方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 2002, no. 02 2 April 2002 (2002-04-02) *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2745951A1 (de) 2012-12-20 2014-06-25 C.R.F. Società Consortile per Azioni Verfahren zur Herstellung einer Nockenwelle in einem Verbrennungsmotor
WO2014096988A1 (en) 2012-12-20 2014-06-26 C.R.F. Società Consortile Per Azioni Method for producing a camshaft for an internal-combustion engine

Also Published As

Publication number Publication date
DE602004006956T2 (de) 2007-10-18
ATE364460T1 (de) 2007-07-15
EP1579931B1 (de) 2007-06-13
DE602004006956D1 (de) 2007-07-26

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