US1808731A - Method of forming shells - Google Patents

Description

June 2, 1931. 3, IRELAND 1,808,731

METHOD OF FORMING SHELLS Filed April 25, 1950 2 Sheets-Sheet 1 Patented June 2, 1931 UNITED-STATES.

PATENT OFFICE enemas E. lawn, or TOLEDO, one, assumes; TO THE CITY momma a root cou- 1 mm, or 10mm, 01110, A CORPORATION or OHIO METHOD OF FORMING SHELLS Application file'a April 25,

' 5 and straining of the material and without production of surface marks and imperfections as ordinarily result from drawing dies,

thus "leaying' .the surface smooth and unmarred and suitable for plating or other surface treatment with minimum preparation.

the metal shifts inwardly from its margins- I It has heretofore been the practice to draw such bodies from flat sheets ofmaterial into a pan-like form and then remove the central area to afford an open frame. In such method under a contractive tension reducing the marginal contour and necessitating an excess of material to be distributed within the die thus tending to form wrinkles and surface markin s, which imperfections are accentuated y the movement of the metal upon the die surface. V

In the present method the blank is formed as an endless flaring band of material, the,

2 margins of which are gripped and held under tension while pressure is applied to the intermediate portion of the blank in a direction perpendicular to the general planeof the flaring band and inclined to the flaring sides thereof whereby the band is expanded and stretched by internal pressure, so forming the material into shape over a ram or form without the use of a corresponding matrix by a pulling tension such as to increase the extent of the marginal line and prevent formation of wrinkles and surface markings.

One of the objects of my invention is to form a radiator shell from sheet metal parts that are so shaped that the parts ma be integrally connected to form a 'blan from which the shell may be produced and thereby enable the production of radiator shells at an exceedingly low cost. In the preferred form of construction and manufacture of the radiator shell the shell is formed from two sheet metal parts that are cut to shape, and portions of the edges of the parts are buttwelded. When they are thus integrally connected, they maintain each other in a substantially definite relation-and so that por- 1930. Serial No. 447,380.

tions thereof are located at desired angles relative to each other and will lie against, substantially, the entire surfaceof the die-blank holder. The sheet metal between the edges, which is engaged by the die-blank holder, is

shaped by the dies. Thus the shells may be formed to the required shape by the use of the least'ainount of metal and by producingthe minimum of the draw of the metal when it is being die-pressed. The blank, being formed of integrally connected parts, eliminates waste of the portion located within the inner edge of the metal'where a continuous ring, or oblong continuous part, is cut from sheetmetal. Also, by forming the band from two parts and butt-welding them, they may be so cut that when they are secured, they will roughly conform to the outlines of the edges of the completed radiator shell, and, consequently, when their edge portions are secured by the sheet metal holder, they may be shaped to produce the required configuration by the dies with the least amount of draw, and least amount of abrasive action, thus protecting the surface of the metal to greatly reduce the finishing cost.

If desired, shells may be formed by shaping portions thereof separately andjoining them after they have been shaped. A portion of the shell may be formed to cover theupper end and the sides of the radiator core, while the other portion may constitute a trim ex.- tending between the ends of the first named portion. The said portions maybe secured together or secured to parts of the automobile to complete the decorative features of the front of the automobile. Thus, the shell may be formed by cutting substantially U- shaped strips from sheet metal having relatively' spreading legs and bending the strip to roughly conform to the shape of the shell and securing the edges of the strip and shaping the central portions of the strip as may be'desire'd.

In the preferred method of formation of the radiator shells, a plurality of parts are formed substantially truncated V-shaped or, more accurately, U-shaped, with 1e portions of each part inclined to each ot er. The spread of the leg portions may be varied according-to the slope that it is desired to 've the portions of the parts to one of the e ges of t e blank when they are bent roughly to conform to the shape of the radiator shell.

-The inner edges of the U-shaped strips, that are thus cut from the sheet, substantially conform to the outer edges whereby substantially all of the sheet, from which the parts joined together may be varied according to the final shape that is to be formed.

"To illustrate a practical application of the method embodying my invention, I have selected a particular radiator shell as illustrative of a shell that may be produced by the use of my invention and shall describe the shell, together with the steps used, in. its production, it being understood that variations in the method may be followed within the .limitations of the claims and their equivalent operations. The shapes that are'formed by the use of my invention, in the formation of the particular radiator shell selected, is shown in the accompanying drawings.

Fig. 1 illustrates a sheet of metal from which a plurality of parts of one form, used in making a plurality of radiator shells, may be out and the figure indicates the use of practically all of the material of the sheet.

.Fig. 2 illustrates a strip from which parts a of another form may likewise be cut in the formation of a pluralit of radiator shells and, likewise, indicates t e utilization of subthe line 7-7 indicated in Fig. 6. Fig. 8 is astantially all of the metal of the strip. Fig.

3 illustrates the location of one of the parts,

cut from the sheet shown in Fig. 1, with reference to one of the parts out from the strip shown in Fig. 2, and shows the parts welded at portions of their edges to produce roughly the shape of the shell. Fig. 4 illustrates the shell when it has been die-pressed to shape.

Fig. 5 is an end view of the shell when formed as shown in Fig. 4. Fig. 6 illustrates the shell shown in Fig. 4 when it has been trimmed. Fig. 7 is a view of a section of the shell shown in Fig. 6, taken on the plane of view of the shell when 'it has been punched and pierced to form holes along'its edge to connect parts thereto, as, for example, cushion-members for parts of the hood of an automobile, and also for receiving a neck of 'arradiator. Fig: 9 is aview of a section taken on the plane of the line 99- indicated in ventionally the relation of the parts of the press and shows the relative positions of these-partsin advance ofsecuring and shaping the strips of sheet metal. Fig. 11 illustrates the positions of the partsof the press when the sheet metal has been secured-in position in advance 'of shaping the central areas of the strip. Fig. 12 mdicates the positions of-the parts of the press when the shell has been shaped.

When the parts 1 have been cut from the sheet of metal 2, as indicated by the dotted lines 3, and the parts 4 have been cut from the strip 5 and from the scrap from sheet 2, as indicated by the dotted lines 6, in Figs. 1 and 2, they may be joined together, as illustrated in Fig. 3, to form blanks. The end edge portions 8, formed by cutting along the dotted line 7, are joined to turned up end portions 9 of the parts 4. The edge portions 10 will then be substantially in line with the edge portions 11 that form the end edges of the parts 4. Preferably, the corner portions 12 of the parts are rolled inwardly to conform to the curvature of the upturned end portions 9 of the parts 4, substantially as indicated in Fig. 3. When the parts 1 and 4 are thus joined together, they form a continuous band, the portions of the part 1 being located inclined to the plane of the edge 13, while the surface of the body portion 4 will be slightly raised above the plane "of. the bottom edge, but will be located substantially parallel to the said plane. The band that is thus formed will conform substantially to the die-plate holder which will grip the edges of the band as formed.

The dies may then shape the portions located intermediate the edges of the connected parts, substantially as shown in Figs. 4 and 5. As shown in Fig. 9, the strip that makes up the body of-the shell is located. in position in the holding die so that its edges will be located in contact with the sheet metal blank holding parts 30 and 31, of the press 32 which are spaced apart by the intermediate open area 48 across which the material will be bridged. The sheet metal part- 1 is bent at its corners in the manner shown in Fig. 3, which roughly conforms to the shape of the shell and also which conforms to will nest in the holding members 30 and 31. e M

The movable holding members 35 and 36 descend to grip the edge portions of the blank as shown in Fig. 10. These members also have surfaces 37 and 38 that conform to the surfaces of the edge portions of the blank so that upon the descent of the members 35 and 36, the edge portions of the blank will be tions that are clamped between the said clamping members of the press. The engaging faces of the members 3337 are flat and g are disposedzsubstantially in the initial plane of the material whereas the engaging faces 34-38 are stepped and indented to effect a more secure hold upon the material. As a result the intake of material through the holding members 3438, if any, involves a contraction of the material beyond the useable contoured area, whereas, the take of material, if any, through the holding faces 33-37 occurs under an expanding or stretching tension which precludes the formation of Wrinkles. While there may be some take of material from the larger margin, i. e., through the holding members 3438,' the resulting die marks and wrinkles Will be disposed close to the edge of the produced form and in a position where they will not be highly objectionable. The ram or male shaping member 41 engages the unsupported portion of the flaring blank intermediate the holding members 3337 and 3438 in a direction substantially perpendicular to its general plane and in inclined relation to the surface of the blank. Since the blank originally conforms roughly to the shape of the shell, the configuration produced by the stretching operation departs from'that of the shell blank by a. definite expansion. This eliminates deformation that occurs by reason of sharply bending and subsequently stretching the bent portion and thus eliminates flaws and faults in the shell as finally formed, namely, creases that penetrate the metal, and wrinkles that are raised above the surface. It is exceed ingly diflicult to remove the faults and markings, that is, creases or wrinkles that occur by bendin and stretching, particularly sharply ben ing and stretching, and by localized stretching, that is, stretching more in' one portion of the sheet than in adjoining portions. By thus shaping the blanks'so that they roughly conform to the shape of the shell as finally produced and stretchin the metal without sharply bending, mar 'ngs of the metal will be entirely avoided. Furthermore, by so shaping the blank and sec'ur ing it at its edges, the central areas may be formed quite entirely by stretching. Thus, the shell is substantially entirely shaped without the use of a fixed die and by the use ing of the metal.

of only a movable die. The blank being supported upon its longitudinal margins only is stretched transversely of the strip of material forming the flaring band .into conformity with the ram or shapingmember 41. The expanding or stretching of the material precludes the formation of wrinkles and there is no excess material to be distributed, and since the stretching is effected in space no surface markings or draw lines develop. In the particular form of press shown'in the drawing, the metal is carried past the portion 34 by a projecting ridge or end 42, of the part'41,

into the space 48 until the shape is formed. Y

A portion of the stretched sheet metal is finally compressed between the part 43 of the holding member 31, and theend 42 and the edge of the surface 44 of the former 41, giving to the completed form a final set. Thus, the shell is formed entirely by a stretchingoperation in advance of any sharp bending move ment of the blank and the entire shell is pro duced by a gradual expansion of the entire area, as distinct from local drawing or bend- There is a continuous camlike expansion movement of the shaping die, instead of a direct pressure exerted on the metal at right angles to the surface of the blank before the metal has been stretched. This eliminates kinks or wrinkles and What is termed as tool markings.

The shell may then be trimmed to remove the portions 19 that have been gripped by the die-holder, leaving those portions of the shell that conform to the required shape of the shell, as shown in Figs. 6 and 7. These parts may then befurther shaped tofit the members with which they are associated, or mounted, in the automobile when assembled as a part of the automobile, such as to form the holes -18, the recess 20, and the hole 21. The depressed flange 22 may also be formed to receive the forward edge of the rhood of the automobile.

X a The narrow portion 23, formed from the part 4, will constitute a trim covering the lower edge of the radiator, while the other parts 24 cover the forward and lateral edge portions of the radiator core or cooling section. I

for which it is particularly desirable, it is also applicable to production of other parts and articles such as automobile cowls, circuitous moldings and contoured frames, such as picture frames. Furthermore, while an endless or complete frame or'shell unithas been illustrated some present automobile constructions employ an open end radiator shell as illustrated in my copending application Serial No. 447,381 filed ofeven date-herewith,

and which is formed by the present method in thesame manner and by" the same steps,

. merely omitting the part 4 and utilizing the method, however, is that heretofore described pressure.

of joining the portions 1 andilinto an endless band before subjecting them to forming It is to be understood that both sequences of operation as well as the formation of an open side U-shaped' unit are contemplated within the legitimate and valid scope of the appended claims.

I claim:

1. The process of forminga radiator shell which consists in shaping sheet metal parts, welding edge portions of the parts to produce a continuous flaring band roughly conforming to the shape of the shell, gripping opposite edges of the flaring band and stretching the portions intermediate the opposite edges of the flaring band by projecting such portions into space.

.2. The process of forming a radiator shell which consists in forming sheet metal parts, bending the ends of one of the parts in directions inclined to the plane of the body of the said part into flaring arcuate formation and welding the terminal edge portions of the said part to end edge portions 'of the other of the said parts to produce a continuous band roughly conforming to the shape of the shell and applying pressure to the portions of the welded parts intermediate the opposite edges of the connected parts in a directionsubstantially perpendicular to the general plane of the band and inclined flaring sides thereof.

3. The process of forming a radiator shell from sheet metal which consists in forming a blank of flaring curvilinear form, securing its edge portions and stretching the portions of the blank intermediate its secured edges by application of pressure in a direction substantially perpendicular to the general plane of the flared curvilinear blank.

. 4. The method of forming open framelike articles from sheet metal consisting in forming an endless flaring band of material, gripping the lon 'tudinalmargins of the band in substantially fixed relation with each other and applying pressure thereto intermediate its margins in a direction substantially perpendicular tothe general plane of the band and inclined to theflaring surfaces thereof to transversely stretch the band into predetermined contoured form.

5. The herein describedmethod of forming sheet metal articles consisting in forming an endless flaring band of sheet material, gripping the marginal edges of the band and applying pressure to the band intermediate to the vthe marginal edges and projectingthe engaged portion into space over a contoured form.

6. The herein described method of forming articles from sheet material consisting in forming a strip of material into a flaring curvilinearly bent blank, gripping the marginal edges of the strip and applying pressure to the strip intermediate its gripped edges in a direction substantially perpendlcular to the general plane of the flaring blank and thereby stretching the strip of material transversely over a contoured form.

7. The herein described method of forming articles from sheet material consisting in forming a strip of material into a flaring curvilinearly bent form, gripping the longitudinal marginal edges of the strip and simultaneously projecting into space in different directions different portions of the strip by pressure applied substantially perpendicular to the plane of the longitudinal margins of the bent strip intermediate its ing 'forma'tion, cutting a second flat blank section, marginally uniting the blank sections whereby the second section interconnects the terminals of the first section into endless formation, and subjecting such endless flaring composite-blank to radially expansive formin pressure.

10. The hereln described method of formingarticles from sheet material including cutting from a stock sheet a flat strip of material of substantially truncated V shape,

bending the strip to curvilinear flaring form and subjecting the bent strip to forming pressure in a direction substantially perpendicular to the general plane of the curvilinear flaring formation.

11. .The herein described method of forming articles from sheet material including forming a strip of material into a curvedly bent flaring formation, subjecting the bent strip to transversely expanding pressure throughout substantially its entire extent and effecting a take of material from the inner and shorter marginal edge under expansive tension and from the outer and longer margin under contractive tension.

12. The method which consists in bending a blank strip to locate one of the side edges thereof approximately in a plane and to flare the bent strip gripping the sides and end portion of the bent sheet metal blank at its respective edges and forming and stretchingthe unsecured area thereof into the required shape by pressure applied in a direction substantially perpendicular to the said plane of one of its gripped edges to one side only thereof.

l3. The process of forming a concavo-convex sheet metal unit, which consists in cutting from a sheet of material a truncated V-shaped part having its inner and outer edges substantially parallel to each other, and cutting from a sheet of material a second part, welding the ends of the first named part to portions of the edge of the last named part for forming a circuitous flaring band roughly conforming to the shape of the finished unit and transversely stretching the band intermediate its opposite edges into the desired shape.

14: The method of forming a structure embodying two transversely contoured portions integrally united into an open frame like unit, including bending a blank portion into a flaring U-shaped formation to form the end and sides of the unit, and disposing across the open end of the U-shaped formation a second blank portion to form the other end of the unit and simultaneously subjecting both portions to forming pressure.

15. The process of forming radiator shell which includes cutting froma sheet of mate- I rial a plurality of substantially truncated V-shaped parts having the inner edge of one part and outer edge of the adjacent part substantially conforming to each other with the convex margin of one part extending within the reentrant side of the adjacent part, bending each such part intosubstantially U-.

shaped flaring formation and subsequently contouring the flaring sides thereof transversely by subjecting the bent parts to pressure applied in the same direction simultw neously tothe substantially parallel sides and transverse portion of such U-shaped flaring formation. i

16. The process of forming a radiator shell from a strip of sheet metal, including bending the strip into a substantially U-'- shaped'flaring formation to conform roughly to the shape of the shell to be formed, and distending portions thereof intermediate its edge portions by'application of pressure'in' the same direction simultaneously to the. respective side and transverse portions of the U-shaped formation.

17. The herein described method of forming articles from ,sheet material consisting in forming a strip of material into a flaring curvilinearly bent blank, bringing the edges into planes yieldingly securing the marginal edges of the strip by gri ping the inner and outer marginal edges o the flaring blank,

and applying expanding pressure to the strip intermediate the secured margins and substantially perpendicular to the planes thereof, therebv distorting the flared blank into 18. The herein described method of form ing articles from sheet material including forming a strip of material into a flaring curvilinear formation, grippingthe marginal edges thereof, and shaping the article by simultaneously expanding the strip in difli'erj ent directions by pressure applied in one direction to the curved strip intermediate its gripped edges.

19. The method of forming an open frame like unit from sheet material, including providing two blank portions, disposing said portions in inclined relation one to the other in a forming apparatus in the approximate relation to each other which the parts occupy in the completed unit, gripping the opposite marginal edges of the respective portions and subjecting the areas of the relatively disposed blank portions intermediate their gripped margins to simultaneous forming pressure by action ofa forming member common to both blank portions.

20. The method of forming an open frame like unit from sheet material, including providing two blank portions interconnected in the final structure into an integral unit, disposing the portions in inclined relation to each other in the approximate positions they occupy in. the completed unit, holding the tion by application of forming pressure thereto.

In Witness whereof I have hereunto my name to this specification. v

- GEORGE E. IRELAND.

signed iao

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