Abstract: The present invention provides a method and device for inductively heating a first and second surface to form a closure assembly. A method contemplated by the present invention includes spacing an upper die from a lower die for receipt of the first surface and the second surface configured in an overlying orientation, securing one end of the first surface to an end of the second surface and compressing the first surface toward the second surface to form a compressed arrangement which is inductively heated into a closure assembly.

Abstract: A method is provided for setting up a tube bender having a bend die, a clamp die, a pressure die and a wiper die. The method includes providing a test-piece having an outer surface defined by a length and a substantially round cross-section. The method also includes arranging the pressure die, the clamp die, and the wiper die relative to each other in the tube bender, and arranging the test-piece relative to the pressure die, the clamp die, and the wiper die. The method further includes applying a force by the tube bender to clamp the test-piece, and determining whether the applied force is within a predetermined range of forces. Additionally, the method includes adjusting the arrangement of at least one of the pressure die, the clamp die, and the wiper die to apply a force to the test-piece that is within the predetermined range of forces.

Abstract: A tool adapted to form and method of forming a tapped hole within a workpiece in a single pass, includes a piercing section operable to punch a pilot hole in and produce a slug attached to the workpiece, and a tapping section operable to form a female thread along the periphery of the hole, and more preferably, an extruding section operable to push workpiece material away from the exterior surface defined thereby, an expanding section operable to expand the diameter of the hole, a sealing section operable to seal the hole during a hydroforming process, and a burnishing section operable to further expand and treat the periphery of the hole prior to tapping.

Abstract: A high pressure pump includes a pump housing. A piston rod located within the pump housing defines a plurality of pump cavities and a plurality of piston cavities. Movement of the piston within the piston cylinder pumps the fluid from the piston cavities out of the high pressure pump. The continuous pumping of HWBF from the pump housing provides fluid at a relatively constant flow and pressure. The HWBF pressure is also at a higher pressure than traditional single stage high pressure pumps can provide.

Abstract: A method is provided for joining tubes. An outer tube and an inner tube are provided. An end of the inner tube is inserted into an end of the outer tube to form an overlapped region of tube wall and form a pressure tight joint between the tubes. The overlapped region of the tubes is heated. The tubes are placed in pair of dies having a die cavity adjacent to the outer tube. Pressure is introduced into the tubes to expand the overlapped region of the tubes outwardly into the die cavity and thereby form an interlocking joint between the overlapped region of the outer tube and the inner tube.

Abstract: The invention provides a hydroforming apparatus for forming a length of tube. A hydroforming press includes an upper platen and a lower plate. A first die set is provided for forming a first lengthwise portion of the tube and a second die set provided adjacent the first die set which forms a second lengthwise portion of the tube. A first pivot acts between a first and second upper die so that the second upper die can be pivotally adjusted on the upper platen relative to the first upper die. A second pivot acts between a first and second lower die so that the second lower die can be pivotally adjusted on the lower platen relative to the first lower die. A die insert is provided having an upper die insert and a lower die insert that define upper and lower insert cavities that connect together the first and second cavity portions of the upper die set and the lower die set. This die insert is removably mounted as needed to accommodate the pivotal adjustment between the first and second die sets.

Abstract: A method is provided for setting up a tube bender having a bend die, a clamp die, a pressure die and a wiper die. The method includes providing a test-piece having an outer surface defined by a length and a substantially round cross-section. The method also includes arranging the pressure die, the clamp die, and the wiper die relative to each other in the tube bender, and arranging the test-piece relative to the pressure die, the clamp die, and the wiper die. The method further includes applying a force by the tube bender to clamp the test-piece, and determining whether the applied force is within a predetermined range of forces. Additionally, the method includes adjusting the arrangement of at least one of the pressure die, the clamp die, and the wiper die to apply a force to the test-piece that is within the predetermined range of forces.

Abstract: A hydroform die includes a plurality of seal units to provide fluid to die cavities. The plurality of seal units each define a piston cylinder. A piston is located within the cylinder and is selectively moveable between an open and a closed position. Additionally, the piston at least partially defines a valve chamber located on a first side of the piston and a piston chamber located on a second side of the piston. A piston fluid passage is defined by the piston to fluidly connect the valve chamber and the piston chamber.

Abstract: A system for hydroforming a workpiece containing fluid at elevated pressure includes a die in which the workpiece is formed, a source of control pressure, a tank at low pressure, and a valve that includes a displaceable control element that alternately moves between an open state and a closed state, opening and closing, respectively, a passage that hydraulically connects the fluid in the workpiece and the tank in response to the relative magnitudes of a first force applied to the control element by the control pressure source and a second force applied to the control element by pressure of the fluid in the workpiece acting on the control element in opposition to the first force.

Abstract: The present invention provides a method and device for inductively heating a first and second surface to form a closure assembly. A method contemplated by the present invention includes spacing an upper die from a lower die for receipt of the first surface and the second surface configured in an overlying orientation, securing one end of the first surface to an end of the second surface and compressing the first surface toward the second surface to form a compressed arrangement which is inductively heated into a closure assembly.

Abstract: A hydroforming seal and method includes a nozzle having both a radially expandable O-ring seal and a conical tapered surface for separately sealing with the bore of the tube. The O-ring seal is expanded to seal the tube and pressurized fluid is added sufficient to support the interior of the tube while the dies are closed so that the tube is thereby bent and forced into the die cavity without collapse or injury to the tube. The O-ring seal is then contracted to a non-sealing position and the conical tapered surface provides metal-to-metal sealing while the higher hydroforming pressure is applied to expand the tube. The nozzle also has a radial shoulder that engages the end face of the tube so that advance of the nozzle feeds the tube into the die.

Abstract: A high pressure pump includes a pump housing. A piston rod located within the pump housing defines a plurality of pump cavities and a plurality of piston cavities. Movement of the piston within the piston cylinder pumps the fluid from the piston cavities out of the high pressure pump. The continuous pumping of HWBF from the pump housing provides fluid at a relatively constant flow and pressure. The HWBF pressure is also at a higher pressure than traditional single stage high pressure pumps can provide.

Abstract: A hydroform die includes a plurality of seal units to provide fluid to die cavities. The plurality of seal units each define a piston cylinder. A piston is located within the cylinder and is selectively moveable between an open and a closed position. Additionally, the piston at least partially defines a valve chamber located on a first side of the piston and a piston chamber located on a second side of the piston. A piston fluid passage is defined by the piston to fluidly connect the valve chamber and the piston chamber.

Abstract: A tool adapted to form and method of forming a tapped hole within a workpiece in a single pass, includes a piercing section operable to punch a pilot hole in and produce a slug attached to the workpiece, and a tapping section operable to form a female thread along the periphery of the hole, and more preferably, an extruding section operable to push workpiece material away from the exterior surface defined thereby, an expanding section operable to expand the diameter of the hole, a sealing section operable to seal the hole during a hydroforming process, and a burnishing section operable to further expand and treat the periphery of the hole prior to tapping.

Abstract: The invention provides a hydroforming apparatus for forming a length of tube. A hydroforming press includes an upper platen and a lower plate. A first die set is provided for forming a first lengthwise portion of the tube and a second die set provided adjacent the first die set which forms a second lengthwise portion of the tube. A first pivot acts between a first and second upper die so that the second upper die can be pivotally adjusted on the upper platen relative to the first upper die. A second pivot acts between a first and second lower die so that the second lower die can be pivotally adjusted on the lower platen relative to the first lower die. A die insert is provided having an upper die insert and a lower die insert that define upper and lower insert cavities that connect together the first and second cavity portions of the upper die set and the lower die set. This die insert is removably mounted as needed to accommodate the pivotal adjustment between the first and second die sets.

Abstract: In a rotary tube bender, a first set of pressure sensors is located between the normally disposed mating surfaces of a wiper die insert and its wiper die holder; and a second set of pressure sensors is located between the axially disposed surfaces of the wiper die insert and the wiper die holder. Signal outputs of the first and second sets of pressure sensors over the course of bending cycles are compared to previously determined nominal signal outputs for drift indicative of whether a realignment or replacement of the wiper die should be performed.

Abstract: A system for hydroforming a workpiece containing fluid at elevated pressure includes a die in which the workpiece is formed, a source of control pressure, a tank at low pressure, and a valve that includes a displaceable control element that alternately moves between an open state and a closed state, opening and closing, respectively, a passage that hydraulically connects the fluid in the workpiece and the tank in response to the relative magnitudes of a first force applied to the control element by the control pressure source and a second force applied to the control element by pressure of the fluid in the workpiece acting on the control element in opposition to the first force.

Abstract: A method of bending a metal object, such as a tube, is provided that uses real time, closed-loop feedback of the actual springback of the object in order to modify the applied bending force or preprogrammed bending coordinates so that the final desired bend geometry is achieved. The variability of springback from object to object is thus accounted for and the number of objects that must be scrapped due to incorrect bends (over bend or under bend) is reduced. The method is carried out using an apparatus such as a rotary draw bender with a measuring device operable to measure actual bend coordinates of metal objects bent by the bender. A controller is operatively connected to the bender and the measuring device and is configured to control the bender to bend the metal objects at least partly based on measured bend coordinates provided by the measuring device.

Abstract: A method of bending a metal object, such as a tube, is provided that uses real time, closed-loop feedback of the actual springback of the object in order to modify the applied bending force or preprogrammed bending coordinates so that the final desired bend geometry is achieved. The variability of springback from object to object is thus accounted for and the number of objects that must be scrapped due to incorrect bends (over bend or under bend) is reduced. The method is carried out using an apparatus such as a rotary draw bender with a measuring device operable to measure actual bend coordinates of metal objects bent by the bender. A controller is operatively connected to the bender and the measuring device and is configured to control the bender to bend the metal objects at least partly based on measured bend coordinates provided by the measuring device.

Abstract: Apparatus is provided for punching holes through the opposed first and second tube walls of a hydroformed tube while the tube is within the die cavity formed by a pair of hydroforming dies. A punch is mounted within a punch bore that intersects with the die cavity. A punch advances the punch to punch a first hole in the first tube wall and then travel across the die cavity and make a second hole in the second tube wall. A support mechanism for supporting the second wall of the tube against rupture by the hydroforming pressure includes spring biasing a support face of a support rod into engagement with the second wall and yielding during the punching of the second hole. A support rod actuator withdraws the support rod to carry the support face away from the second wall after the second hole is punched.