US20040065394A1 - Warm hydro-forming method and apparatus for aluminum alloys - Google Patents
Warm hydro-forming method and apparatus for aluminum alloys Download PDFInfo
- Publication number
- US20040065394A1 US20040065394A1 US10/428,532 US42853203A US2004065394A1 US 20040065394 A1 US20040065394 A1 US 20040065394A1 US 42853203 A US42853203 A US 42853203A US 2004065394 A1 US2004065394 A1 US 2004065394A1
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- United States
- Prior art keywords
- tube component
- hydro
- forming
- die
- predetermined temperature
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Classifications
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- 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
- B21D26/041—Means for controlling fluid parameters, e.g. pressure or temperature
-
- 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
-
- 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
- a hydro-forming method is a tube-forming method using hydraulic pressure, and is generally performed at a normal temperature range of between 10 and 30 degrees Celsius.
- Tube hydro-forming technology is widely used in the automotive industry. For example, this technology is used for manufacturing various components of a vehicle such as body structure components, and is cost-effective.
- a conventional aluminum tube hydro-forming method includes a softening process for a high strength aluminum tube 100 in order to secure elongation for forming a component (S 110 ).
- the tube 100 is then, as shown in FIG. 9, loaded on a lower die 101 of a pressing machine (S 120 ). Subsequently, in a state in which an upper die 103 descends, as shown in FIG. 10, hydraulic cylinders 105 and 107 axially compress the tube 100 , and thereby creating a seal in the bore of the tube 100 (S 130 ).
- Hydraulic pressure is then supplied into the tube 100 , so that the tube 100 is expanded to forming surfaces 109 and 111 by the hydraulic pressure and axial force transmitted from the hydraulic cylinders 105 and 107 (S 140 ).
- the tube 100 is taken out from the upper and lower dies 101 and 103 .
- the fully formed tube component 100 then undergoes a hardening process to increase its strength (S 150 ).
- a warm hydro-forming method for forming a tube component of aluminum alloys that is disposed in a hydro-forming apparatus along a forming surface of a first die and a second die, by a compressing force of hydraulic cylinders disposed at both ends of the tube component and hydraulic pressure supplied to the tube component, wherein hydro-forming of the tube component is performed while it is in a heated state by supplying forming hydraulic pressure into the tube component, after increasing a temperature of the tube component to a predetermined temperature within a predetermined temperature range in a state such that the tube component is charged by hydraulic pressure just before hydro-forming.
- the hydraulic pressure is supplied into the tube component by one of water, a water-soluble liquid, and an oily liquid that can be used as pressure-transmitting medium in the predetermined temperature range.
- the tube component is made of an aluminum-based material.
- the hydro-forming method for aluminum alloys comprises: loading a tube component made of an aluminum alloy on a die of a hydro-forming apparatus; bringing a first die and a second die together in a state in which the tube component is loaded, and sealing and axially compressing the tube component by an operation of a hydraulic cylinder disposed on each side of the tube component; heating the tube component to a temperature within a predetermined temperature range; forming the tube component along forming surfaces formed on the first die and the second die by providing an axial compressing force of the hydraulic cylinder and supplying hydraulic pressure into the tube component, when the tube component is heated to the predetermined temperature; and taking the formed tube component out of the first and second dies, and cooling the tube component.
- the hydro-forming apparatus for an aluminum alloy comprises a first die, a second die, a pair of hydraulic cylinders, and a heating unit.
- the first die and the second die define forming surfaces for a tube component, and the tube component is compressed between the first and second dies.
- the hydraulic cylinders are configured to axially compress both sides of the tube component and to supply hydraulic pressure for tube forming.
- the heating unit is disposed in at least one of the first and second dies at positions corresponding to the forming surfaces of the first and second dies, and the heating unit heats the tube component.
- the heating unit is a heating coil that is operated in response to an electrical signal of a control unit, and the heating coil heats the tube component to a predetermined temperature.
- FIG. 1 is a flowchart for a warm tube hydro-forming method according to the preferred embodiment of the present invention
- FIGS. 2 to 6 show successive states of a hydro-forming apparatus according to the preferred embodiment of the present invention
- FIG. 7 shows relations between tensile strength and elongation according to temperatures of a high strength aluminum alloy (AL 7075);
- FIG. 8 is a flowchart for the tube hydro-forming method according to the prior art.
- FIGS. 9 to 12 show successive states of the hydro-forming apparatus according to the prior art.
- the warm hydro-forming method according to the preferred embodiment of the present invention uses the variation of elongation characteristics of aluminum alloys according to temperature, such that if the temperature of aluminum alloys increases to a high range (approximately between 50 and 300 degrees Celsius), its strength decreases and elongation rapidly increases, and if its temperature decreases back to a normal range (approximately between 10 and 30 degrees Celsius), its strength increases and elongation decreases to the initial values. Therefore, the warm hydro-forming method according to the preferred embodiment of the present invention is performed at a high temperature range (approximately between 50 and 300 degrees Celsius) without performing a softening process through thermal treatment, so that forming characteristics and desired strength can simultaneously be obtained.
- a warm hydro-forming apparatus includes a lower die 1 disposed in a lower portion of a pressing device (not shown) and an upper die 5 disposed above the lower die 1 .
- the upper die 5 moves down toward the lower die 1 , and a tube component 3 is compressed between the lower and upper dies 1 and 5 .
- a left hydraulic cylinder 7 and a right hydraulic cylinder 9 are respectively disposed on both sides of the lower die 1 , and they are configured to be inserted into both ends of the tube component 3 , so that they may axially compress the tube component 3 and create a seal in a bore thereof.
- the left and right hydraulic cylinders 7 and 9 supply a pressure transmitting medium into the tube component 3 , thereby supplying hydraulic pressure into the tube component 3 .
- An upper forming surface 11 is provided at a bottom surface of the upper die 5
- a lower forming surface 13 is provided at an upper surface of the lower die 1 .
- a heating unit is disposed in the lower and upper dies 1 and 5 behind the forming surfaces 11 and 13 , that is, at positions corresponding to the forming surfaces 11 and 13 .
- the heating unit may be a heating coil 21 that operates in response to an electrical signal of a control unit 20 .
- the heating coil 21 is designed to emit heat to a predetermined temperature. In this manner, heat emitted form the heating coil 21 heats the tube component 3 and the pressure transmitting medium to the predetermined temperature.
- the heating coil 21 is provided in order to heat the tube component 3 to a desired temperature.
- the tube component 3 can be heated by supplying a hot pressure transmitting medium that is heated by a separate heating apparatus, into the tube component 3 , without the heating coil 21 disposed inside the upper and lower dies 1 and 5 .
- the warm hydro-forming method according to the preferred embodiment of the present invention can, as shown FIGS. 2 to 6 , be applied to the above stated hydro-forming apparatus, as follows.
- a temperature of the tube component 3 is raised to a predetermined temperature within a predetermined temperature range by the heating coil 21 just before the expansion of the tube component 3 , in a state such that the hydraulic pressure is provided into the tube component 3 , and the hydraulic pressure is then finally provided into the tube component 3 so that the tube component 3 is formed in a heated state.
- the warm hydro-forming method according to the preferred embodiment of the present invention uses a temperature-dependant elongation characteristic of the high strength aluminum alloy.
- the strength of the tube component 3 drops slightly, but elongation thereof drastically increases, so that a sufficient shape change can be secured in that temperature range.
- the predetermined temperature range in which elongation of the tube component 3 drastically increases may preferably be in a range of between 50 and 300 degrees Celsius.
- FIG. 7 shows relations between tensile strength and elongation of the tube component 3 (made of aluminum alloy material (AL 7075 )) according to temperature.
- the tensile strength is between 570 MPa and 525 MPa (Mega Pascal), and elongation is between 11% and 14%.
- the tensile strength drastically decreases to a range of between 285 MPa and 40 MPa, but elongation drastically increases to a range of between 23% and 70%.
- a hydraulic fluid that has stability at the high temperature range (for example, 50 to 300 degrees Celsius) must be used as the hydraulic pressure-transmitting medium.
- Water, a water-soluble liquid, or an oily liquid that can be used as a pressure-transmitting medium in the predetermined temperature range (between 50 and 300 degrees Celsius) can be used as a pressure-transmitting medium of the hydraulic cylinders 7 and 9 . More specifically, in the present embodiment of the present invention, silicon oil can be used as the hydraulic fluid.
- the aluminum alloy tube component 3 is first loaded between the lower and upper dies 1 and 5 (S 10 ).
- the formed tube component 3 is taken from the lower and upper dies 1 and 5 , and it is then cooled.
- the tube component 3 recovers its strength at the initial normal temperature, and elongation of the tube component 3 substantially decreases. Therefore, the tube component 3 recovers its mechanical characteristics of the normal temperature (S 50 ).
- the warm hydro-forming method and apparatus use elongation characteristics of the high strength aluminum alloy according to its temperature, and tube hydro-forming is performed in a state in which forming characteristics are secured in a predetermined temperature range. Therefore, in the warm hydro-forming method according to the present invention, softening and hardening processes of the conventional hydro-forming method can be eliminated, so forming quality and productivity can be improved.
Abstract
Description
- The present invention relates to a hydro-forming method for an aluminum alloys and an apparatus thereof, and more particularly, to a warm hydro-forming method and an apparatus thereof which are capable of securing forming characteristics in the range of warm forming temperatures using elongation characteristics of a high strength aluminum tube component that are dependant on its temperature, and which thereby successively preform a tube hydro-forming process.
- A hydro-forming method is a tube-forming method using hydraulic pressure, and is generally performed at a normal temperature range of between 10 and 30 degrees Celsius. Tube hydro-forming technology is widely used in the automotive industry. For example, this technology is used for manufacturing various components of a vehicle such as body structure components, and is cost-effective.
- Recently, instead of iron group materials, high strength aluminum alloys have become widely used in hydro-forming processes. Such high strength aluminum alloys have poorer forming characteristics at room temperature than does steel. Therefore, a softening process is used to secure forming characteristics, and then hydro-forming processes are successively performed. The softening process increases elongation (%) while decreasing the strength of aluminum materials, and an annealing process is most widely used as such a softening process.
- In order to secure the forming characteristics of the high strength aluminum materials, sufficient elongation for the most severely deformed portion of a fully formed component must be secured. For example, in order to secure elongation of greater than 20%, the softening process must be performed.
- A conventional aluminum tube hydro-forming method, as shown in FIGS.8 to 12, includes a softening process for a high
strength aluminum tube 100 in order to secure elongation for forming a component (S110). - The
tube 100 is then, as shown in FIG. 9, loaded on alower die 101 of a pressing machine (S120). Subsequently, in a state in which anupper die 103 descends, as shown in FIG. 10,hydraulic cylinders tube 100, and thereby creating a seal in the bore of the tube 100 (S130). - Hydraulic pressure is then supplied into the
tube 100, so that thetube 100 is expanded to formingsurfaces hydraulic cylinders 105 and 107 (S140). - After the hydro-forming process, the
tube 100 is taken out from the upper andlower dies tube component 100 then undergoes a hardening process to increase its strength (S150). - In such conventional tube hydro-forming method, a softening process prior to hydro-forming is inevitable. However, such a softening process may drastically decrease the strength of the material, and this damages the quality of the formed products. Also, a separate hardening process after the hydro-forming process is needed. Such a hardening process may also negatively affect the product quality, as well as the manufacturing costs.
- The information disclosed in this Background of the Invention section is only for enhancement of understanding of the background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art that is already known to a person skilled in the art.
- Therefore, a motivation of the present invention is to provide a warm hydro-forming method for aluminum alloys and an apparatus thereof which successively perform tube hydro-forming processes after securing forming characteristics within a predetermined temperature range, using an elongation characteristic of high strength aluminum tube component.
- In a preferred embodiment of the present invention, a warm hydro-forming method for forming a tube component of aluminum alloys that is disposed in a hydro-forming apparatus along a forming surface of a first die and a second die, by a compressing force of hydraulic cylinders disposed at both ends of the tube component and hydraulic pressure supplied to the tube component, wherein hydro-forming of the tube component is performed while it is in a heated state by supplying forming hydraulic pressure into the tube component, after increasing a temperature of the tube component to a predetermined temperature within a predetermined temperature range in a state such that the tube component is charged by hydraulic pressure just before hydro-forming.
- It is preferable that the predetermined temperature range is a range of between 50 and 300 degrees Celsius.
- Preferably, the hydraulic pressure is supplied into the tube component by one of water, a water-soluble liquid, and an oily liquid that can be used as pressure-transmitting medium in the predetermined temperature range.
- It is further preferable that the tube component is made of an aluminum-based material.
- In another preferred embodiment of the present invention, the hydro-forming method for aluminum alloys comprises: loading a tube component made of an aluminum alloy on a die of a hydro-forming apparatus; bringing a first die and a second die together in a state in which the tube component is loaded, and sealing and axially compressing the tube component by an operation of a hydraulic cylinder disposed on each side of the tube component; heating the tube component to a temperature within a predetermined temperature range; forming the tube component along forming surfaces formed on the first die and the second die by providing an axial compressing force of the hydraulic cylinder and supplying hydraulic pressure into the tube component, when the tube component is heated to the predetermined temperature; and taking the formed tube component out of the first and second dies, and cooling the tube component.
- In yet another preferred embodiment of the present invention, the hydro-forming apparatus for an aluminum alloy comprises a first die, a second die, a pair of hydraulic cylinders, and a heating unit. The first die and the second die define forming surfaces for a tube component, and the tube component is compressed between the first and second dies. The hydraulic cylinders are configured to axially compress both sides of the tube component and to supply hydraulic pressure for tube forming. The heating unit is disposed in at least one of the first and second dies at positions corresponding to the forming surfaces of the first and second dies, and the heating unit heats the tube component.
- It is preferable that the heating unit is a heating coil that is operated in response to an electrical signal of a control unit, and the heating coil heats the tube component to a predetermined temperature.
- The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, serve to explain the principles of the invention, where:
- FIG. 1 is a flowchart for a warm tube hydro-forming method according to the preferred embodiment of the present invention;
- FIGS.2 to 6 show successive states of a hydro-forming apparatus according to the preferred embodiment of the present invention;
- FIG. 7 shows relations between tensile strength and elongation according to temperatures of a high strength aluminum alloy (AL 7075);
- FIG. 8 is a flowchart for the tube hydro-forming method according to the prior art; and
- FIGS.9 to 12 show successive states of the hydro-forming apparatus according to the prior art.
- Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.
- The warm hydro-forming method according to the preferred embodiment of the present invention uses the variation of elongation characteristics of aluminum alloys according to temperature, such that if the temperature of aluminum alloys increases to a high range (approximately between 50 and 300 degrees Celsius), its strength decreases and elongation rapidly increases, and if its temperature decreases back to a normal range (approximately between 10 and 30 degrees Celsius), its strength increases and elongation decreases to the initial values. Therefore, the warm hydro-forming method according to the preferred embodiment of the present invention is performed at a high temperature range (approximately between 50 and 300 degrees Celsius) without performing a softening process through thermal treatment, so that forming characteristics and desired strength can simultaneously be obtained.
- A warm hydro-forming apparatus according to the preferred embodiment of the present invention, as shown in FIG. 2, includes a
lower die 1 disposed in a lower portion of a pressing device (not shown) and anupper die 5 disposed above thelower die 1. Theupper die 5 moves down toward thelower die 1, and atube component 3 is compressed between the lower andupper dies - A left
hydraulic cylinder 7 and a righthydraulic cylinder 9 are respectively disposed on both sides of thelower die 1, and they are configured to be inserted into both ends of thetube component 3, so that they may axially compress thetube component 3 and create a seal in a bore thereof. - The left and right
hydraulic cylinders tube component 3, thereby supplying hydraulic pressure into thetube component 3. - An upper forming
surface 11 is provided at a bottom surface of theupper die 5, and a lower formingsurface 13 is provided at an upper surface of thelower die 1. - A heating unit is disposed in the lower and
upper dies surfaces surfaces heating coil 21 that operates in response to an electrical signal of acontrol unit 20. Theheating coil 21 is designed to emit heat to a predetermined temperature. In this manner, heat emitted form theheating coil 21 heats thetube component 3 and the pressure transmitting medium to the predetermined temperature. - In this embodiment of the present invention, the
heating coil 21 is provided in order to heat thetube component 3 to a desired temperature. However, a person skilled in the art can easily know that thetube component 3 can be heated by supplying a hot pressure transmitting medium that is heated by a separate heating apparatus, into thetube component 3, without theheating coil 21 disposed inside the upper andlower dies - The warm hydro-forming method according to the preferred embodiment of the present invention can, as shown FIGS.2 to 6, be applied to the above stated hydro-forming apparatus, as follows.
- At first, the
tube component 3 that is disposed between the lower andupper dies surfaces hydraulic cylinders tube component 3. - During this process, a temperature of the
tube component 3 is raised to a predetermined temperature within a predetermined temperature range by theheating coil 21 just before the expansion of thetube component 3, in a state such that the hydraulic pressure is provided into thetube component 3, and the hydraulic pressure is then finally provided into thetube component 3 so that thetube component 3 is formed in a heated state. - That is, the warm hydro-forming method according to the preferred embodiment of the present invention uses a temperature-dependant elongation characteristic of the high strength aluminum alloy.
- In the predetermined temperature range, the strength of the
tube component 3 drops slightly, but elongation thereof drastically increases, so that a sufficient shape change can be secured in that temperature range. The predetermined temperature range in which elongation of thetube component 3 drastically increases may preferably be in a range of between 50 and 300 degrees Celsius. - FIG. 7 shows relations between tensile strength and elongation of the tube component3 (made of aluminum alloy material (AL 7075)) according to temperature. Referring to FIG. 7, in a normal temperature range of 25 and 100 degrees Celsius, the tensile strength is between 570 MPa and 525 MPa (Mega Pascal), and elongation is between 11% and 14%. However, in a high temperature range (between 150 and 300 degrees Celsius), the tensile strength drastically decreases to a range of between 285 MPa and 40 MPa, but elongation drastically increases to a range of between 23% and 70%.
- Because the warm hydro-forming method according to the preferred embodiment of the present invention is performed at a high temperature, a hydraulic fluid (pressure-transmitting medium) that has stability at the high temperature range (for example, 50 to 300 degrees Celsius) must be used as the hydraulic pressure-transmitting medium.
- Water, a water-soluble liquid, or an oily liquid that can be used as a pressure-transmitting medium in the predetermined temperature range (between 50 and 300 degrees Celsius) can be used as a pressure-transmitting medium of the
hydraulic cylinders - In the hydro-forming method according to the preferred embodiment of the present invention, the aluminum
alloy tube component 3 is first loaded between the lower and upper dies 1 and 5 (S10). - The lower and upper dies1 and 5 are then brought together, and the
hydraulic cylinders tube component 3, thereby sealing thetube component 3 and axially compressing the tube component 3 (S20). - Under this condition, hydraulic fluid at a high temperature within a predetermined temperature range is supplied into the
tube component 3, and thetube component 3 is simultaneously heated to the predetermined temperature by heat emitted from the heating coil 21 (S30). - When the
tube component 3 is heated to the predetermined temperature, the strength of thetube component 3 slightly decreases and elongation thereof drastically increases, so that thetube component 3 is formed along the formingsurfaces hydraulic cylinders - Finally, after the warm hydro-forming, the formed
tube component 3 is taken from the lower and upper dies 1 and 5, and it is then cooled. Thetube component 3 recovers its strength at the initial normal temperature, and elongation of thetube component 3 substantially decreases. Therefore, thetube component 3 recovers its mechanical characteristics of the normal temperature (S50). - As stated in the above, the warm hydro-forming method and apparatus according to the preferred embodiment of the present invention use elongation characteristics of the high strength aluminum alloy according to its temperature, and tube hydro-forming is performed in a state in which forming characteristics are secured in a predetermined temperature range. Therefore, in the warm hydro-forming method according to the present invention, softening and hardening processes of the conventional hydro-forming method can be eliminated, so forming quality and productivity can be improved.
- Although preferred embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concepts herein taught which may appear to those skilled in the present art will still fall within the sprit and scope of the present invention, as defined in the appended claims.
- Throughout this specification and the claims which follow, unless explicitly described to the contrary, the word “comprise” or variations such as “comprises” or “comprising” will be understood to imply the inclusion of stated elements but not the exclusion of any other elements.
Claims (10)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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KR1020020060550A KR20040031175A (en) | 2002-10-04 | 2002-10-04 | A method for warm hydro-forming of aluminium alloy and device thereof |
KR10-2002-0060550 | 2002-10-04 |
Publications (1)
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US20040065394A1 true US20040065394A1 (en) | 2004-04-08 |
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ID=32040966
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/428,532 Abandoned US20040065394A1 (en) | 2002-10-04 | 2003-05-02 | Warm hydro-forming method and apparatus for aluminum alloys |
Country Status (3)
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US (1) | US20040065394A1 (en) |
KR (1) | KR20040031175A (en) |
DE (1) | DE10317873A1 (en) |
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- 2003-05-02 US US10/428,532 patent/US20040065394A1/en not_active Abandoned
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