Abstract: The disclosure relates to punch die apparatus, related thermoforming press apparatus, and methods for thermohydroforming die-punched parts formed therefrom, in particular from sheet blank substrates such as polymer composite materials and metals. The disclosure further relates to thermohydroforming blanks incorporating a vacuum-sealed outer film, in particular polymer composite blanks which can be used in combination with the disclosed apparatus. The apparatus and methods are particularly suitable for thermohydroforming parts with complex deep drawn geometries yet which retain relatively smooth outer surfaces and internal material structure. The apparatus and methods provide a fast and efficient means for composite part manufacturing.

Abstract: The disclosure relates to punch die apparatus, related thermoforming press apparatus, and methods for thermohydroforming die-punched parts formed therefrom, in particular from sheet blank substrates such as polymer composite materials and metals. The disclosure further relates to thermohydroforming blanks incorporating a vacuum-sealed outer film, in particular polymer composite blanks which can be used in combination with the disclosed apparatus. The apparatus and methods are particularly suitable for thermohydroforming parts with complex deep drawn geometries yet which retain relatively smooth outer surfaces and internal material structure. The apparatus and methods provide a fast and efficient means for composite part manufacturing.

Abstract: A cylinder head (10) for an internal combustion engine has hydroformed port liners (18) positioned within selected ports, either exhaust and/or intake ports (14, 16). The hydroformed port liner (18) includes an air gap (24) for an insulation layer within the selected port (14, 16) between an outer surface (19) of the hydroformed port liner (18) and the wall of the port (14, 16). A cylinder head (12) with a predetermined port configuration has selected ports (14, 16) cast with protrusions (22). The selected ports (14,16) have a larger diameter than a standard size port diameter for that cylinder head to provide a predetermined port configuration by a preset amount based on the thickness of the hydroformed port liner (18) and a desired air gap (22). Protrusions (22) in the wall of the selected ports (14, 16) or on the insert sleeves (17) facilitate formation of the air gap during the hydroforming process.

Abstract: A cylinder head (10) for an internal combustion engine has hydroformed port liners (18) positioned within selected ports, either exhaust and/or intake ports (14, 16). The hydroformed port liner (18) includes an air gap (24) for an insulation layer within the selected port (14, 16) between an outer surface (19) of the hydroformed port liner (18) and the wall of the port (14, 16). A cylinder head (12) with a predetermined port configuration has selected ports (14, 16) cast with protrusions (22). The selected ports (14,16) have a larger diameter than a standard size port diameter for that cylinder head to provide a predetermined port configuration by a preset amount based on the thickness of the hydroformed port liner (18) and a desired air gap (22). Protrusions (22) in the wall of the selected ports (14, 16) or on the insert sleeves (17) facilitate formation of the air gap during the hydroforming process.

Abstract: The present invention provides an apparatus and a method which use hydroforming to shape complex structures from materials such as sheet metal or composites. In particular, an apparatus and a method for shaping complex structures using composites such as continuous-fiber or woven fiber composites with limited wrinkling or rupture of the composite during the shaping process.

Abstract: A method for determining a bending die radius of a bending machine for bending a part and an associated apparatus. The method involves entering into a computer data concerning the part to be bent and an initial estimate of the radius of the bending die. Based on the data related to the part and the initial estimate, a final value for the die radius is determined. An improved bending machine and an associated method are also disclosed.

Abstract: A method for determining a bending die radius of a bending machine for bending a part and an associated apparatus. The method involves entering into a computer data concerning the part to be bent and an initial estimate of the radius of the bending die. Based on the data related to the part and the initial estimate, a final value for the die radius is determined. An improved bending machine and an associated method are also disclosed.