Abstract: A workpiece accumulator system for a stamping machine includes linear actuators, nesting blocks, exit rails, and a first controller. The nesting blocks are disposed on moveable members of the linear actuators and arranged to vertically stack workpieces being fabricated by the stamping machine. The first controller communicates with a second controller that controls the stamping machine. The first controller controls the linear positions of the linear actuators to retract the nesting blocks from an initial position to accommodate placement of the one of the plurality of workpieces in a stack on the nesting blocks. The linear actuators are controlled to retract the nesting blocks to fully retracted positions to place the plurality of workpieces in the stack onto the exit rails when a quantity of the plurality of workpieces in the stack is equal to a desired quantity.

Abstract: A workpiece accumulator system for a stamping machine includes linear actuators, nesting blocks, exit rails, and a first controller. The nesting blocks are disposed on moveable members of the linear actuators and arranged to vertically stack workpieces being fabricated by the stamping machine. The first controller communicates with a second controller that controls the stamping machine. The first controller controls the linear positions of the linear actuators to retract the nesting blocks from an initial position to accommodate placement of the one of the plurality of workpieces in a stack on the nesting blocks. The linear actuators are controlled to retract the nesting blocks to fully retracted positions to place the plurality of workpieces in the stack onto the exit rails when a quantity of the plurality of workpieces in the stack is equal to a desired quantity.

Abstract: A pair of self-aligning non-pinching hydroforming dies have fingers and slots which are operable during closure of the dies on a tubular part to effect precise alignment of the dies as they are pressed together to form a hydroforming cavity about the part so that the part is not pinched between mating surfaces of the dies during their closure on the part. The fingers are further capable of mechanically straightening and/or bending the part, if need be, to prevent pinching of the part during die closure. The fingers are also capable of mechanically forming a round tubular part to a non-round cross-section region of the die cavity as the dies close to help form the part as well as prevent pinching of this section. With all such mechanical forming operations by the action of the fingers on the part performed prior to the hydroforming of the part in the die cavity.

Abstract: Method and apparatus for forming unobstructed holes in a hydroformed metal part employs a punch having a peripheral side conforming to the desired hole shape and an end face having a central cutting edge with a high point that contacts on closure of a hydroforming die with an unsupported wall section of the part initiating a stress riser therein. During forming of the part, the hydraulic pressure forces the above wall section outward against this high point increasing the magnitude of the stress riser. The punch is advanced while maintaining the hydraulic pressure causing the above high point to fracture this wall section at the stress riser and the above cutting edge to then split and cut this wall section to form oppositely facing cut edges in this section. Simultaneously, oppositely angled cutting edges at opposite ends of the central cutting edge and at the punch end face periphery then cut this wall section in directions away from the oppositely facing cut edges to form oppositely extending slugs.