Abstract: A bobbin tool is disclosed that includes a top shoulder, a bottom shoulder, and an axial pin that extends between the top and bottom shoulders. The bottom shoulder has an annular shoulder end surface, a back surface opposite the annular shoulder end surface, and a side surface that joins the annular shoulder end surface and the back surface. One or more and radially-extending blades may be disposed on the side surface of the bottom shoulder and/or one or more axially-extending blades may be disposed on the back surface. The one or more blades provide the bobbin tool with an ability to friction stir weld a variable thickness workpiece assembly, axially plunged through the workpiece assembly along an axis of rotation of the bobbin tool, and/or be extracted through the workpiece assembly along an axis of rotation of the bobbin tool.

Abstract: A bobbin tool is disclosed that includes a top shoulder, a bottom shoulder, and an axial pin that extends between the top and bottom shoulders. The bottom shoulder has an annular shoulder end surface, a back surface opposite the annular shoulder end surface, and a side surface that joins the annular shoulder end surface and the back surface. One or more and radially-extending blades may be disposed on the side surface of the bottom shoulder and/or one or more axially-extending blades may be disposed on the back surface. The one or more blades provide the bobbin tool with an ability to friction stir weld a variable thickness workpiece assembly, axially plunged through the workpiece assembly along an axis of rotation of the bobbin tool, and/or be extracted through the workpiece assembly along an axis of rotation of the bobbin tool.

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 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: 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 for scraping, grinding, smoothing, machining or otherwise finishing a weld joint between two wire electrodes, such as those used in gas metal arc welding (GMAW) systems. When two wire electrode ends are coaxially joined together by a process such as butt welding, it creates a weld joint that can jam a GMAW welding gun or other device with tight dimensional tolerances. The tool described herein may be used to finish such a weld joint so that a relatively uniform cross-sectional shape and/or size is produced across the weld joint, thus, making it less likely to jam the welding gun. According to an exemplary embodiment, the tool is designed to fit over two wire electrodes connected by a weld joint, and generally includes a housing assembly and a cutting device.

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 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: 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 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: A method is provided for forming a complexly-shaped tubular structure such as a tapered pillar or other structure for a vehicle body. A sheet metal blank having a longitudinal axis is rolled about the longitudinal axis to form a tubular shape and the side edges of the blank are then welded together to form a tube. The tube is then enclosed in a hydroforming die and pressurized to conform the tube to the shape of the die and thereby form the desired complex shape. The sheet metal blank may be formed by the end-to-end welding together of a plurality of separate sheet metal blanks that differ from one another in characteristic including material thickness, material alloy composition, and/or coating. One or more of the blanks can have side edges that are non-parallel so that the tube will taper in diameter along its length.

Abstract: A tool forms a threaded hole in a hydroformed part while the part remains in a hydroforming die cavity and under pressure. The tool has a hole-piercing end portion adapted on advancement of the tool to pierce and form a hole in the part and an extruding portion adapted on continued tool advancement to extrude an annular extrusion that extends into the tube interior. An adjacent sealing portion of the tool seals the hole during the ongoing advancement and extrusion of the annular extrusion so that hydroforming fluid remains under pressure. A thread-forming portion of the tool forms an internal thread within the annular extrusion upon the continued advancement and rotation of the tool.

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: A tool forms a threaded hole in a hydroformed part while the part remains in a hydroforming die cavity and under pressure. The tool has a hole-piercing end portion adapted on advancement of the tool to pierce and form a hole in the part and an extruding portion adapted on continued tool advancement to extrude an annular extrusion that extends into the tube interior. An adjacent sealing portion of the tool seals the hole during the ongoing advancement and extrusion of the annular extrusion so that hydroforming fluid remains under pressure. A thread-forming portion of the tool forms an internal thread within the annular extrusion upon the continued advancement and rotation of the tool.

Abstract: A hydrotapping power unit is disclosed that is operable to hold a hydrotapping tool in a home position adjacent a part while the latter is being hydroformed in a die cavity, to then advance the tool to pierce a hole in the hydroformed part while the part remains in the die cavity and under pressure and then continue to advance the tool to inwardly extrude the part about the hole, to then further advance while also rotating the tool at a feed rate equal to the thread pitch of the tool to thereby form a thread in the pierced hole, and finally retract while also rotating the tool but in the reverse direction and at the same feed rate to release the tool from the threaded hole.

Abstract: A hydrotapping power unit is disclosed that is operable to position and hold a hydrotapping tool in a home position adjacent a part while the part is being hydroformed in a die cavity, to then advance the tool to pierce a hole in the hydroformed part while the part remains in the die cavity and under pressure and then continue to advance the tool to inwardly extrude the part about the hole, to then further advance while also rotating the tool so that the tool is fed at a feed rate equal to the thread pitch of the tool to thereby form a thread in the pierced hole, and finally to retract while also rotating the tool but in the reverse direction and at the same feed rate to release the tool from the threaded hole.