Abstract: A method of forming a hole in a hollow blank during a hydroforming process is provided. The method includes placing a blank in a cavity of a hydroforming die, the hydroforming die being configured to permit a punch to engage the blank. An interior of the blank is pressurized with a fluid. Further, a cutting end of a punch is applied through a wall portion of the blank and into the interior of the blank to form a hole. Furthermore, the cutting end of the punch is removed from the interior of the blank such that the cutting end of the punch is configured to allow material of the blank surrounding the formed hole to move away from the interior of the blank.

Abstract: A method of forming a hole in a hollow blank during a hydroforming process is provided. The method includes placing a blank in a cavity of a hydroforming die, the hydroforming die being configured to permit a punch to engage the blank. An interior of the blank is pressurized with a fluid. Further, a cutting end of a punch is applied through a wall portion of the blank and into the interior of the blank to form a hole. Furthermore, the cutting end of the punch is removed from the interior of the blank such that the cutting end of the punch is configured to allow material of the blank surrounding the formed hole to move away from the interior of the blank.

Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.

Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.

Abstract: In the present invention a tubular blank and an article such as a bushing to be assembled are loaded into a die. The tube is hydroformed using typical methods and, while the blank is still pressurized, a punch pierces a hole in the tube. The punch also has an article loaded onto it and, as the punch advances, the article is pushed into the tube through the pierced hole. The punch continues to advance such that it pierces a hole in the opposite side of the tube. The punch then retracts leaving the bushing in the tube. The article may alternately be inserted by means separate from the punch.

Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.

Abstract: A frame member of rectangular cross section with rounded corners is formed by expansion of a tubular blank within a die cavity having an inner portion of corresponding cross section and an outer transition portion which is of smoothly continuously curved cross sectional profile elongated substantially parallel to the larger dimension of the rectangular section. An outer portion of the tubular blank is deformed to correspond with the continuously curved cross sectional profile and is sealed by a resiliently compressible sealing element of corresponding profile through which fluid pressure is applied in order to expand the blank. By matching the profile of the transition portion to the rectangular inner portion, the transition portion can be made shorter and considerable savings of materials and resources can be achieved.

Abstract: A frame member of rectangular cross section with rounded corners is formed by expansion of a tubular blank within a die cavity having an inner portion of corresponding cross section and an outer transition portion which is of smoothly continuously curved cross sectional profile elongated substantially parallel to the larger dimension of the rectangular section. An outer portion of the tubular blank is deformed to correspond with the continuously curved cross sectional profile and is sealed by a resiliently compressible sealing element of corresponding profile through which fluid pressure is applied in order to expand the blank. By matching the profile of the transition portion to the rectangular inner portion, the transition portion can be made shorter and considerable savings of materials and resources can be achieved.

Abstract: A frame member of rectangular cross section with rounded corners is formed by expansion of a tubular blank within a die cavity having an inner portion of corresponding cross section and an outer transition portion which is of smoothly continuously curved cross sectional profile elongated substantially parallel to the larger dimension of the rectangular section. An outer portion of the tubular blank is deformed to correspond with the continuously curved cross sectional profile and is sealed by a resiliently compressible sealing element of corresponding profile through which fluid pressure is applied in order to expand the blank. By matching the profile of the transition portion to the rectangular inner portion, the transition portion can be made shorter and considerable savings of materials and resources can be achieved.

Abstract: A frame member of rectangular cross section with rounded corners is formed by expansion of a tubular blank within a die cavity having an inner portion of corresponding cross section and an outer transition portion which is of smoothly continuously curved cross sectional profile elongated substantially parallel to the larger dimension of the rectangular section. An outer portion of the tubular blank is deformed to correspond with the continuously curved cross sectional profile and is sealed by a resiliently compressible sealing element of corresponding profile through which fluid pressure is applied in order to expand the blank. By matching the profile of the transition portion to the rectangular inner portion, the transition portion can be made shorter and considerable savings of materials and resources can be achieved.

Abstract: Apparatus for fluid filling and pressurizing a tube having a high pressure-low flow fluid circuit in the form of a shaft having a longitudinal bore communicating with a high pressure fluid source, a tube seal device adjacent the forward end of the shaft for sealing the tube when the shaft is engaged with the tube and high pressure fluid flows into the tube, and a device for reciprocating the shaft to advance and retract the shaft toward and away from the tube. A high flow low pressure circuit has a shroud for housing the forward end of the shaft when retracted and a rearward opening slidably and sealably engaging the shaft rearward of the tube seal device. The interior of the shroud communicates with a high flow-low pressure fluid source for sealing an external surface adjacent an end of the tube.

Abstract: Fill and pressurization apparatus having a sectional fluid conductor having a first section fixed relative to the surroundings, and a second section which moves toward the first section to form an enclosure through which a high volume flow rate--low pressure flow may be passed to fill an adjacent open end of a tube with liquid. Said fluid is passed through an inlet conduit, which may be a rigid conduit, to the fixed first section. A seal head insertable into the end of the filled tube has an elastomeric seal member and a rod and a sleeve relatively axially displaceable to compress the seal member and deform it into sealing engagement with a surface of the tube. A stop member on one of the rod and sleeve and a stop surface on the other of the rod and sleeve limit the axial displacement and hence also the compressive force applied to the seal member. The relative displacement is achieved by retracting one of the rod and the sleeve and blocking the retraction of the other.

Abstract: An apparatus is provided for filling a tube with fluid and for pressurizing the tube, in order to expand and form it within a die for example. The apparatus provides a high flow-low pressure fluid circuit for quickly filling and draining the tube, together with a separate high pressure-low flow fluid circuit for pressurizing and depressurizing the tube. The high pressure circuit of the apparatus comprises a shaft having a longitudinal bore communicating with a high pressure fluid source and control means; tube sealing means adjacent the forward end of the shaft for sealing the tube when the shaft is engaged with the tube and high pressure fluid flows into the tube; and shaft reciprocating means for advancing and retracting the shaft.

Abstract: A method of and apparatus for punching a hole in sheet material is provided using pressurized fluid as the female die together with a modified male punch. The slug of material to be sheared from the material is during and after shearing continuously held against the face of the punch by the difference in pressure between the fluid and the punch face. In addition the area adjacent the perimeter of the hole may be deformed and drawn away from the die block face as the punch advances through the material. As the punch is withdrawn, the slug remains held against the punch face. The mechanical force withdrawing the punch together with the fluid pressure bearing on the slug and deformed area forces the slug and deformed area of material toward the die block face, inelastically retracting the deformed area. The deformed area may be fully retracted to a substantially flat form or partially retracted to a countersunk form.

Abstract: A two speed drive comprising: a driving member; a rotatable driven member coaxially positioned relative to the driving member; a planetary gear system rotatable with the driving member and with the driven member for providing in one condition a non-reducing speed drive and for providing in a second condition a speed reducing drive therebetween, the gear system including a sun gear drivingly engaging the driving member, a ring gear mounted for rotation about said driving member, and a plurality of planetary gears interconnecting the sun gear and the ring gear, the driven member attached to and carried with the planetary gears; and a electromagnetic clutch, operable in a first mode for simultaneously driving the sun gear and the ring gear in the one condition to establish a non-reducing speed drive and operable in a second mode to rotationally lock the ring gear for driving the driven member through the sun gear and the planetary gears at a speed less than the speed of the driving member.

Abstract: A differential drive mechanism (10) includes a driving member (12) and a driven member (16). A planetary gearset (64) drivingly connects the driving member (12) and driven member (16) to drive the driven member (16) at a speed lower than that of the driven member (12) when the electromagnetic actuator (46) is energized. When the electromagnetic actuator (46) is not energized, a clutching member (22) engages the driven member (16) to cause the latter to be driven at the same speed as that of the driving member (12).

Abstract: A double acting drive mechanism (10) includes a driving member (12) and a pair of driven members (16) and (18) which carry a small diameter pulley face (24) and a larger diameter pulley face (26) respectively. A clutch mechanism (34) normally couples one of the driven members (16) for rotation with the driving member (12) and the driven member (18) freewheels. Upon energization of the electromagnetic actuator (48), the armature (56), which rotates with the other driven member (18), engages the clutch mechanism (34) to couple the other driven member (18) for rotation with the driving member (12). Engagement of the armature (56) with the clutch mechanism (34) disengages the clutch mechanism (34) from the one driven member (16).