Abstract: A production line for the manufacture of a product through hydroforming, having a decoiler (11) for unrolling a steel strip (12) from a coil (13), a roll-forming unit (14) for folding the steel strip into a tube (16), a welding unit (17) for welding together the edges of the steel strip, a hydroforming unit (18) having an openable mold (19, 20) to receive the completed tube as the tube is being formed and welded, a cutting arrangement (24, 25) for cutting off the completed product (23) that has been removed from the hydroforming unit, sealing arrangements (30, 33; 35-39) at two ends of the mold for sealing the tube, and a line (38) for the supply of pressure medium through one of the sealing arrangements for placing the tube under pressure. A method for manufacturing a product in such a line is also provided.

Abstract: A hydroforming apparatus includes a hydroforming die member and a hydroforming press. A fastener couples the press to the die member, the fastener having a shaft and a shoulder. A spacer positioned on the fastener spaces the die member from the press. The shaft is secured to the press housing. The shoulder is positioned within a slot in the die member configured to receive the shoulder as the shoulder is inserted into the slot in a direction transverse to a longitudinal axis of the fastener.

Abstract: A hydroform seal assembly includes a seal housing and an annular nozzle carried by the seal housing and sized to insert into a tube end. A first actuator moves the seal housing to insert the nozzle. A plurality of jaws are carried by the seal housing and are movable radially inward into clamping engagement with the tube to clamp the tube onto the annular nozzle. A cam bushing is movably mounted within the seal housing, surrounds the jaws, and has cam surfaces complimentary with cam surfaces provided on the jaws so that movement of the cam bushing relative the jaws will cam the jaws radially inward. A backup cam is movable within the seal housing. The cam bushing and backup cam have complimentary cam surfaces by which movement of the backup cam will forcibly move the cam bushing relative the seal housing. A second actuator moves the backup cam.

Abstract: An apparatus and method for locally expanding tubular member includes a pre-form die having a cavity with an expansion chamber therein to receive a portion of a tubular blank between ends thereof. The apparatus also includes a bladder apparatus for insertion in the tubular blank and cooperating with the pre-form die to locally expand the portion of the tubular blank in the expansion chamber to form a locally expanded tubular member.

Abstract: A method of making a variable thickness tubular member for a vehicle includes the steps of providing a tubular member and positioning a mandrel inside of the tubular member. The method also includes the steps of hydroforming the tubular member into a variable thickness tubular member having a variable wall thickness along its perimeter.

Abstract: An apparatus and method for hydroshearing and hydrotrimming for a hydroforming die includes a cutting insert fixed relative to the hydroforming die. The apparatus and method also includes a disposable insert fixed relative to the hydroforming die. The apparatus and method further includes a plunger movable relative to the hydroforming die to allow fluid within a tubular member to force a wall portion of the tubular member outward against the plunger and be sheared in the hydroforming die to trim the tubular member.

Abstract: Disclosed is a pipe expanding device for expanding a thin pipe with a small diameter using elasticity and compressing and bending characteristics of a spring. Steel wires whose opposite contact sections are processed with a slope to be engaged in parallel so that contact length of both ends thereof are extended are bent and wound to form a ring spring having a single circumference with its body being partially cut off. This ring spring is used as a mold so as to expand an outer diameter of a pipe as much as a circumferential length of both ends that are widened rather than a normal circumferential diameter due to elasticity of the spring while the ring spring presses the pipe. This pipe expanding device employing the ring spring is simple and economical and allows even an unskilled person to use it easily.

Abstract: A high-pressure system for hydroshaping a hollow workpiece has a lower die and an upper die vertically shiftable above the lower die and forming therewith a cavity shaped to hold the workpiece. An upper actuating element bears downward via a vertically compressible hydraulic operating cylinder on the upper die. A spring-loaded pressure-storing cylinder is connected by a hydraulic line to the operating cylinder and to the workpiece. Downward shifting of the actuating element first closes the dies together, then internally pressurizes the workpiece via the line from the operating cylinder such that the workpiece deforms and shapes itself to the cavity, and then fills the spring-loaded pressure-storing cylinder. Subsequent upward shifting of the actuating element at first allows the pressure-storing cylinder to empty, and then entrains the upper die upward off the workpiece by the actuating element.

Abstract: A method is provided for forming a tube between a pair of dies. The tube is captured between a pair of dies having die surfaces constructed of an electrically non-conducting material defining a die cavity therein. The ends of the tube are sealed and electrical current is applied to the tube to induce electrical resistance heating of the tube. The interior of the tube is pressurized to expand the tube into the cavity to thereby form the heated tube.

Abstract: A method for shaping an aerosol container (10) to a desired body contour. A container body (12) is formed into a cylindrical shape and installed into a mold (30) whose inner surface defines the desired body contour. A bladder (74) is fitted onto a tool (50) insertable into an open end (M) of the container body. Once the tool is inserted, the bladder is inflated with a hydraulic fluid. Pressurizing the bladder forces the bladder against a sidewall of the body forcing the body outwardly and deforming it against the inside of the mold. After the container body is shaped, the bladder is de-pressurized and the tool withdrawn leaving the container with a defined body contour. The hydraulic fluid with which the bladder is pressurized is, at all times, contained within the bladder and does not contact the container sidewall so no subsequent drying of the container is required after the shaping process is complete.

Abstract: A method is provided for hydroforming a ring-shaped tubular structure such as a door opening for a vehicle body. The method includes providing a ring-shaped tubular blank having a hollow sealed interior, capturing the ring shaped tubular blank in a hydroforming die cavity, piercing the ring shaped tubular blank with a hollow punch, and introducing pressurized fluid through the hollow punch into the hollow sealed interior to expand the tubular structure to conform with the shape of the hydroforming die cavity and thereby hydroform the ring-shaped tubular structure.

Abstract: An apparatus and method for performing a hydroforming process cause either or both of the opposed end portions of the workpiece to be deformed to achieve desired shapes therein. Initially, a workpiece having a pair of end portions is disposed within a die cavity defined by first and second die sections have cooperating recesses. A pair of end feed assemblies engage the end portions of the workpiece and deform such end portions to a desired shape. Pressurized fluid is provided within the workpiece either before, during, or after the deformation of the end portions of the workpiece to deform the central portion thereof it into a desired shape as defined by the die cavity.

Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.

Abstract: A method and an apparatus for reshaping a tube having an initial outside diameter, an initial wall thickness, and an initial length to form a tube have a reshaped outside diameter, a reshaped length, and a reshaped wall thickness, wherein at least one of the reshaped outside diameter, the reshaped length, and the reshaped wall thickness is different than a respective one of the initial outside diameter, the initial wall thickness, and the initial length. The method includes mounting the tube between two axially displaceable pressure rams with the ends of the tube against respective rams; applying an internal hydraulic pressure to the tube; applying an axial mechanical pressure to the tube via the rams; and simultaneously and uniformly cold-working the tube over its entire length by adjusting the internal hydraulic pressure and the axial mechanical pressure as a function of the reshaped outside diameter, the reshaped wall thickness, and the reshaped length.

Abstract: A hydroforming apparatus for hydroforming a workpiece. The apparatus includes a die in which a die cavity is located, and an outer ring subassembly. The outer ring subassembly is movable relative to the die, and includes a ring and one or more first cam segments attached thereto. The outer ring subassembly also includes one or more second cam segments and one or more tapered wedges positioned between the first and second cam segments. The tapered wedge is movable between an extended position, in which the second cam segment is pushed to an open position in which the second cam segment is engageable with the outer surfaces when the subassembly is proximal to the die, and a retracted position, in which the second cam segment is moved to a closed position by a biasing means. The second cam segment includes a lower surface shaped to engage outer surfaces.

Abstract: A process for forming a hydroformed automotive component with an integrally formed attachment bracket or weld flange begins with a tubular blank manufactured through a roll-forming process to convert sheet metal into a tubular body portion having excess parent sheet metal material extending past the tube weld joint to define an integrated flange. This integrated flange tubular blank is then placed into a forming die and subjected to a conventional hydroforming manufacturing process to form the automotive component into the desired shape and configuration. One side of the forming die is formed with a slot defining a gap in which the integrated flange material is received to create the weld flange or attachment bracket when the die is closed against the integrated flange material while the hydroforming process is undertaken. Alternatively, the integrated flange material could be welded onto the tubular blank during the formation of the tubular blank.

Abstract: A warm hydro-forming device comprises: an upper mold and a lower mold respectively mounted to an upper mold die and a lower mold die; a lifting die installed to the lower mold die through a guide unit, an upper portion of the lifting die being connected to the upper mold die through a lifting unit to cooperatively operate in an upward and downward direction with the upper mold die; a pair of hydraulic pressure cylinders for providing an axial compression force to the tube component and supplying a forming hydraulic fluid into the tube component; an ascending and descending unit for ascending or descending the upper mold die; and a heating unit associated with the lifting die such that the heating unit can move toward or away from the tube component. The heating unit heats the tube component and a forming hydraulic fluid through a high frequency induction heating.

Abstract: The invention concerns methods and devices for bending a cylindrical tube or the like (1) so as to obtain two consecutive sections (2, 3) of said tube forming between them a non-null angle alpha. The method is essentially characterised in that it consists in producing, in the wall (4) of the tube (1), a wave (20) defined between two flanks (22, 23) forming between them a non-null angle beta substantially centred on the separation plane (21) between the two sections, then in producing a permanent plastic deformation of the wave (20) until the value of the angle between the two sections (2, 3) is obtained. The device enables to implement said method. The invention is useful in particular but not exclusively, for producing pipes for transporting fluids in motor vehicles or the like.

Abstract: A reconfigurable tool and/or die geometry and methods of use generally comprise forming at least a portion of a shape defining surface with a shape memory material. In response to an activation signal, the shape memory material changes geometry of the shape defining surface to provide a means for forming parts with different geometries from the same tool and/or die. In an alternative embodiment, an insert for a tool and/or die can be used, wherein the insert has at least a portion of its shape defining surface formed of a shape memory material. Also disclosed are processes for forming a first part with a defined geometry and a second part with a defined geometry different from the first part defined geometry using a reconfigurable tool and/or die as well as a reconfigurable insert with a standard tool and/or die.

Abstract: A hydroform die tube holding assembly and method of using same includes at least one seal unit for sealing an end of a tube. The hydroformed die tube holding assembly also includes a seal unit elevator for attachment to a lower die half to operatively support the at least one seal unit. The hydroformed die tube holding assembly further includes at least one upper gas spring for attachment to an upper die half to engage, the seal unit elevator to drive the seal unit elevator downward prior to the upper die half engaging the tube.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: The invention relates to an expansion tool for expanding tube ends. The expansion tool has an expansion mandrel and a counter-support, said expansion mandrel consisting of a tow-bar and an elastic rubber expansion element surrounding it. The counter-support supports the expansion element on the base extremity and radially surrounds it at a distance. In order to improve an expansion tool of the above-described kind, the tow-bar is anchored in a bolt fastening element and the counter-support can be impinged upon via a pressure bar element that projects beyond the bolt fastening element in the longitudinal direction of the tow-bar.

Abstract: A method of forming a tubular member with thickened ends includes the steps of positioning a tubular member between open die halves and sealing ends of the tubular member. The method also includes the steps of applying at least nominal internal hydraulic pressure to the tubular member and progressively closing the die halves. The method includes the steps of raising the hydraulic pressure substantially within the tubular member to expand and conform the tubular member to the tubular cavity portion. The method further includes the steps of thickening a wall thickness of the axial ends of the tubular member, separating the die halves, and removing the tubular member having thickened axial ends from the die.

Abstract: A method for making a bicycle frame part includes the steps of preparing a malleable tubular blank that has an outer surface and that is made from an alloy selected from the group consisting of Al—Mg—Sc alloy, Al—Mg—Zr alloy, and Al—Mg—Li—Zr alloy; placing the tubular blank in a mold such that the tubular blank is surrounded by an inner surface of the mold; heating the tubular blank to a working temperature ranging from 200 to 500° C; and injecting a high-pressure fluid into the tubular blank so as to permit expansion and permanent deformation of the tubular blank in the mold to an extent that the outer surface of the expanded tube abuts against and conforms to the inner surface of the mold.

Abstract: A method using high interior pressure to reshape structural section of continuously bounded overall cross-section, whereby the overall cross-section can be provided with extra walls or chambers and a stopper is forced radially against each end of the piece. The object is to reduce wear on the stopper while ensuring that any walls or chambers in addition to its overall crosssection will buckle or bulge only at their ends.

Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.

Abstract: A method for expanding tubular blanks includes pre-expanding or initially expanding a section of the tube by forcing a punch into an open end of the tube. The punching process may be repeated to achieve up to approximately 50% expansion from the original configuration of the blank. Then, the same pre-expanded section can be further expanded by hydroforming such that the blank is filled with pressurized fluid to achieve further expansion of the initially expanded section up to approximately 100% expansion from the original configuration of the blank. As a final step, the open end of the expanded tube may be cut to its ultimate shape.

Abstract: A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell formed from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank, placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.

Abstract: In an apparatus for quenching thin walled metal hollow casings (6) manufactured by blow molding, the apparatus has a molding tool (1) defining a slot or aperture (21) and a delivery system for applying a coolant to the slot or aperture (21) of the molding tool (1). In a method of applying a coolant to the external surface of a blow molded casing (6), the coolant is applied onto an external surface of the casing (6) after the casing (6) has been formed against a tool (1) which includes at least one slot or aperture (21).

Abstract: A mold clamping apparatus includes a frame including a holding portion for holding a mold and an open portion allowing the mold to be inserted into/taken out from the holding portion in a direction of the longer side of the mold, a mold moving device for moving the mold to insert/take out the mold into/from the holding portion through the open portion in the frame, and a mold opening/closing device for opening/closing the mold located outside the frame. This mold clamping apparatus is capable of holding the mold securely in a closed state resisting a pressure acting to open the mold and allows reduction of energy consumption, equipment maintenance cost, production cost, and the size thereof.

Abstract: The subject matter of the present invention is a method of manufacturing, in a tool mold provided with a final contour as desired, a hollow metal body the cross-sectional shape of which varies in the longitudinal direction, an internal pressure being applied to a tubular hollow body with approximately uniform initial wall thickness, the tubular hollow body having the highest temperature in the zones of greatest deformation, the temperature in these zones being reduced once the hollow body fits against the wall of the tool mold, the temperature being subsequently increased in zones with lower degrees of deformation.

Abstract: A device for forming a single or mutli-chamber workpiece by high internal pressure created by a medium capable of flow in the hollow interior of the workpiece. The device contains a forming tool with a cavity accommodating the workpiece and pressure generating equipment for generating the high internal pressure. The pressure generating equipment contains a displacement pump with a pressure converter having a longitudinally coupled displacement body with different working surface areas A1, A2, which operates with a stroke frequency f, whereby strokes of the pressure converter cause a pressure p1 created on the primary side to be raised until a higher secondary pressure p2 is reached on the secondary side.

Abstract: In a method of fabricating a bellows by bulge forming, an annealing step is carried out during the bulge forming process of the bellows so that the capability of the material to elongate is recovered, and the workability of the bellows is improved in effect. In particular, the ratio of the outer diameter to the inner diameter can be made greater than a value that can be achieved by a single forming step. Therefore, the deflection (stroke) of each annular bulge or pleat can be increased for a given stress or the number of annular bulges and the length of the bellows can be decreased for a given stroke of the bellows.

Abstract: Method and apparatus for the production of a plurality of uniform expansions of a tube in a plurality of tube supports simultaneously. A plurality of tubes are expanded in apertures of tube supports in a repetitive manner, each tube being expanded into the plurality of tube supports simultaneously. The tube expander assembly, when positioned such that each bladder is centered on each land of the tube support surrounding the tube, will precisely control the degree (magnitude) of expansion of each tube against the tube support aperture by controlling the amount of applied hydraulic pressure applied to expandable bladders. The method and apparatus can also be used to expand a tube into the apertures of the tube sheet. This operation can be accomplished without removing the tube expander assembly from the tube. Ideally, the operation is accomplished simultaneously, but may be accomplished in sequential pressurizations.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: The invention relates to a process and apparatus for the forming of a hollow body. The process includes providing a forming mold comprising an upper mold and a lower mold which form a mold cavity having a cross-sectional contour in a closed state of the forming mold. The upper mold includes a roller. The hollow body is placed between the upper mold and the lower mold in an area of the mold cavity. The hollow body is preprofiled by moving at least one of the upper mold and the lower mold into the closed state at which time the roller comes into frictional contact with a surface of the hollow body running at an acute angle with respect to a direction of the movement of the at least one upper mold and lower mold. The preprofiled hollow body is then formed into a final shape corresponding to the cross-sectional contour of the forming mold by applying a hydraulic internal pressure into the preprofiled hollow body and expanding the hollow body while the upper mild and the lower mold are in the closed state.

Abstract: The invention relates to an expansion tool (1) for expanding tube ends (7). Said expansion tool has an expansion mandrel (8) and a counter-support (9), said expansion mandrel (8) consisting of a tow-bar (10) and an elastic rubber expansion element (11) surrounding it. The counter-support (9) supports the expansion element on the base extremity and radially surrounds it at a distance. In order to improve an expansion tool of the above-described kind, the tow-bar (10) is anchored in a bolt fastening element (20) and the counter-support (9) can be impinged upon via a pressure bar element (25) that projects beyond the bolt fastening element (20) in the longitudinal direction of the tow-bar (10).

Abstract: Hydroforming apparatus is provided with retractable part locators that are adapted when extended to receive and hold end portions of a tubular part to be hydroformed and thereby support and hold the part between the hydroforming dies when the dies are open. Seal units mounted on separate elevators have a retractable seal carrier and the seal carriers are adapted when the seal units are elevated to advance and initially engage the respective tubular part end portions while the part is being so held. The part locators are adapted to release the end portions of the part and retract out of the way of the seal carriers to permit the seal carriers to then further advance on the respective end potions of the part to a position closely adjacent the end faces of the dies while also centering the part lengthwise with respective to the dies prior to die closure.

Abstract: A method of making a tube having an expanded region which includes the steps of providing an elongated metal tube, preparing the tube to be expanded, and, exerting a generally uniform outwardly radial force to create the expanded region. During the preparation step, a region of the tube is annealed by applying heat. The outward radial force may be created by pressurizing the tube, by freezing water within the tube or by axially rotating the tube.

Abstract: A system and method for hydroforming hose fittings for use with hose assemblies.

Abstract: The seal units that form part of a hydroforming apparatus that further includes dies for hydroforming parts are each provided with a tubular part locator for locating and clamping a tubular part in alignment with the seal unit. The part locator basically comprises a locator member, a pair of pivot arms and a backup member wherein the locator member and the pivot arms together with the seal unit are supported by an elevator that aligns the seal unit and the locator member with the hydroforming dies when the latter close on the tubular part. The locator member has a concave surface and guide surfaces wherein the concave surface has a shape conforming to the outer surface of the part and the guide surfaces are adapted to guide an end portion of the tubular part onto the concave surface of the locator member and thereby into alignment with the seal unit.

Abstract: A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell formed from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank, placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.

Abstract: An approach to restoring the cross-section of a bent tube to circularity. The tube is placed into a fixture, so that pressurization does not remove the bend. Liquid is placed into the tube, and pressurized. Pressure is increased until the wall of the tube undergoes plastic deformation, and becomes circular.

Abstract: A process for producing a component for reducing the effect of an external mechanical impact, of the type which comprises an essentially tubular metal element which has a jump in its cross section which is such that under the influence of an axial load it can be turned at least partially inside-out as a result of plastic deformation, by means of which process the tubular element is formed by hydroforming from a piece of tube which has a cross section which is constant along its length, during which process part of the length of the cross section is increased in size, and the transitions in the cross section cover a short distance, and during the hydroforming an axial pressure on the piece of tube which is being deformed is set to be such that the transitions in cross section adapt to an S-shape.

Abstract: A high-pressure bulge-forming apparatus has a multipart die having a cavity adapted to receive a hollow workpiece and having ends oppositely open along an axis. Respective actuators aligned with the cavity ends have stems extending axially toward the cavity. Respective heads on the ends are engageable in the cavity with ends of the workpiece. One of the stems and the respective head is formed with a passage opening axially into the workpiece engaged by the respective head. Fasteners releasable secure the heads on the stems. Each head comprises an end part with an inwardly tapered outer surface and a base part fixed to the respective stem and carrying the respective head. In addition each head has a normally annular mounting plate between the respective base part and end part.

Abstract: A method and an apparatus are provided for internal high-pressure forming of a workpiece in a closed internal high-pressure forming die. The workpiece is expanded owing to the internal high fluid pressure exerted by a pressure generator and coming to rest on the cavity of the forming die. The workpiece and the forming die form friction partners in the areas of contact. In order to improve process reliability during the internal high-pressure forming of workpieces and to expand the scope of the method, vibration is imparted directly to at least one of the friction partners by a vibration generator during forming.

Abstract: A method for manufacturing an air-gap-insulated exhaust pipe having a branch stub, as well as an exhaust pipe produced according to such a method and a tool for forming such an exhaust pipe. Two tubes are inserted into one another to form a double tube. The double tube is placed in a first internal high-pressure shaping tool, and exposed to internal high pressure fluid such that it expands to match the contours of the engraving of the first shaping tool, and a double-walled branch stub is blown out of the double tube. The partially formed double tube is then placed in a second internal high-pressure shaping tool, with the double tube being surrounded, between the two ends including the branch stub, circumferentially and throughout by a corresponding design of the engraving, by an expansion chamber.

Abstract: A hydraulic expansion mandrel for expanding tubes in a heat exchanger tube bundle into a tubesheet is formed from a non-metallic material, such a carbon fiber-reinforced material. The mandrel includes an elongated cylinder having a tip, a fluid supply end and a reduced diameter section. A pair of O-rings separates the reduced diameter section from the tip and fluid supply end of the elongated cylinder. An adjustment shim, located between a threaded collar and a locking stop collar, adjusts the length of the mandrel inserted into a tube.

Abstract: Method and apparatus are disclosed wherein seal units sealingly connect a hydroforming fluid pressure source with the ends of a part to be hydroformed while the part is outside an intended die cavity and wherein the seal units are then conditioned with a relatively low sealing pressure capacity. The part is prefilled through the seal units with hydroforming fluid at a relatively low pressure sufficient to prevent later pinching, buckling, splitting and cracking of the part in the die cavity during hydroforming. The prefilled part, with the seal units remaining sealingly connected, is then enclosed in the die cavity and the seal units are conditioned with a relatively high pressure sealing capacity sufficient for the continued supply of hydroforming fluid to the part through the seal units at the considerably higher pressures required for hydroforming the part.

Abstract: The present invention provides a hydroforming system and method eliminating the need for a solid steel die (or mold) set operated by a conventional high tonnage hydraulic press. The invention utilizes a fabricated or bar-stock die set integrated to a series of adjustably placed hydraulic cylinders to create a self-contained operating unit. The system can include a die set, a plurality of activation and clamping hydraulic cylinders, a computer control system and reinforcement and support structures. The die set can be a mounted lower die half and an adjacent movable upper die half, each constructed of individual pieces of plate or bar stock. The computer control system interprets incoming linear position data from all of the activation hydraulic cylinders and monitors and controls hydraulic fluid flow into and out of each cylinder. The system can also have a plurality of support pillars affixed to the lower die half.