Hydroforming machine

Abstract

A hydroforming machine is disclosed which includes a plurality of dies with each die having an upper die plate hingedly connectable to and lockable with a lower die plate. Each upper die plate and lower die plate include an opening therethrough which are substantially alignable with each other. The hydroforming machine also includes a spacing device. The spacing device is disposed in mechanical cooperation with each of the dies and maintains a desired distance between each of the dies. The spacing device includes a plurality of hinges which hingedly connect each die with an adjacent die.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefits of and priority to U.S. Provisional Patent Application Ser. No. 60/683,658 entitled “BELLOWS HYDROFORMING TOOLS,” which was filed on May 23, 2005, the entire contents of which are hereby incorporated by reference herein.

BACKGROUND

The present disclosure relates to a hydroforming machine for forming a bellows and, more particularly relates to a hydroforming machine including a spacing device which allows for rapid changing of the spacing between adjacent dies.

Hydroforming is one of several processes that may be used for forming pieces of metal into bellows. During hydroforming, a plurality of dies are positioned parallel and adjacent to one another. A hollow tube is inserted into openings of the dies and is held in position. Pressurized water is forced through the hollow tube and the water pressure that is forced against the tube expands the walls of the tube outwardly. The dies apply pressure against the walls of the tube at desired locations along the length of the tube so that the wall of the tube is only expanded between adjacent dies. The dies are compressed together for forcing the expanded sections of the wall into a corrugated pattern for forming bellows.

The spacing between the dies determines the sizing of the bellows, thus it is typically desirable to be able to accurately and repeatably control and alter this spacing. It may also be desirable to change this spacing relatively quickly.

The dies generally include an upper die plate and a lower die plate. Further, a locking mechanism is generally included to lock the upper die plate with the lower die plate while the pressurized water (or another liquid or gas) is forced through the tube.

SUMMARY

The present disclosure relates to a hydroforming machine. The hydroforming machine includes a plurality of dies with each die having an upper die plate hingedly connectable to and lockable with a lower die plate. Each upper die plate and lower die plate includes an opening therethrough which are substantially alignable with each other. The hydroforming machine also includes a spacing device. The spacing device is disposed in mechanical cooperation with each of the dies and maintains a desired distance between each of the dies. The spacing device includes a plurality of hinges which hingedly connect each die with an adjacent die.

The present disclosure also relates to a hydroforming machine including a plurality of dies and a spacing device. Each die has an upper die plate hingedly moveable with respect to a lower die plate between an open position and a closed position. The distance between adjacent dies is adjustable while the upper die plates are in the open position, the closed position and any position therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described hereinbelow with reference to the figures wherein:

FIG. 1 is a perspective view of an embodiment of a hydroforming machine of the present disclosure;

FIG. 2 is a front view of the hydroforming machine of FIG. 1;

FIG. 3 is an enlarged perspective view of a hinge mechanism of the hydroforming machine of FIGS. 1 and 2;

FIG. 4 is an enlarged perspective view of a locking mechanism of the hydroforming machine of FIGS. 1-3 illustrated in an unlocked position;

FIG. 5 is a partial front view of the hydroforming machine of FIGS. 1-4 illustrated in a locked position;

FIG. 6 is an enlarged perspective view of a spacing device of an embodiment of the hydroforming machine;

FIG. 7 is a partial top view of the spacing device of FIG. 6;

FIG. 8 is a partial front view of the spacing device of FIGS. 6 and 7;

FIG. 9 is a partial top view of an embodiment of the spacing device of FIGS. 6-8;

FIG. 10 is several cross-sectional views a spacer bar as indicated by line 10-10 in FIG. 7; and

FIG. 11 is a partial top view of an alternate embodiment of the spacing device of FIGS. 6-9.

DETAILED DESCRIPTION

Embodiments of the presently disclosed hydroforming machine are described in detail with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, while the term “distal” refers to that part or component farther away from the user.

Referring to FIG. 1, a hydroforming machine is shown and is generally referred to by reference numeral 100. This embodiment of hydroforming machine 100 includes a plurality of dies 110, a hinge mechanism 160, a locking mechanism 180 and a spacing device 200. Each die 110 includes an upper die plate 120 and a lower die plate 140, which are hingedly connected to each other via hinge mechanism 160. An upper opening 130a is disposed in each upper die plate 120 and a lower opening 130b is disposed in lower die plate 140. When upper die plates 120 and lower die plates 140 are approximated, upper opening 130a and lower opening 130b form a generally circular opening 130.

In use, a ram (not explicitly shown in this embodiment) retracts dies 110 as far as spacing device 200 allows. When upper die plates 120 are open (i.e., not approximated with lower dies plates 140), a hollow tube (not explicitly shown) is placed onto lower opening 130b of lower die plates 140. Upper die plates 120 are approximated towards lower die plates 120 via rotation about hinge mechanism 160. Once fully approximated, upper die plates 120 and lower die plates 140 are locked together via locking mechanism 180, thus locking hollow tube therebetween. The hollow tube, which may include a plug (not shown), is generally filled and pressurized with a liquid (e.g., water). Such pressurization causes the hollow tube to bulge into areas between dies 110. Dies 110 are then collapsed axially by compression exerted by the ram. Dies 110 are forced together so that each die 110 contacts an adjacent die 110. Locking mechanism 180 is then released, upper dies plates 120 are opened and the formed bellow or bellows can be removed. The ram is then retracted, causing dies 110 to be drawn apart from adjacent dies 110.

With reference to FIGS. 2 and 3, hinge mechanism 160 is illustrated (locking mechanism 180 and spacing device 200 are not illustrated in these figures). In this embodiment, hinge mechanism 160 includes an upper aperture 162 in each of upper die plates 120 and a lower aperture 164 in each of lower die plates 140. Upper apertures 162 and lower apertures 164 at least partially align to form hinge aperture 165. A hinge pin 166 (and/or keeper shaft 167) is insertable through hinge aperture 165. In the illustrated example, apertures 162 and 164 are disposed at an angle to their respective plates 120 and 140, thus allowing hinge pin 166 (and thus upper dies plates 120) to be removed in situ. Thus, if a die 110 is damaged or is in need of repair, it can be removed from hydroforming machine 100 and an additional die 110 or die plate 120, 140 can be inserted as a replacement. It is envisioned to machine die plates 120 and 140 at substantially half of their nominal thickness in the portions of upper die plates 120 and lower die plates 140 that overlap each other as part of (and possibly adjacent) hinge mechanism 160. It is also envisioned to machine a relief (not explicitly shown) to allow for leaves (not explicitly shown) of hinge pin 166.

Now referring to FIGS. 4 and 5, locking mechanism 180 is illustrated. Locking mechanism 180 includes a lock aperture 182 and a lock shuttle 184. Lock aperture is made up of upper lock apertures 182a disposed in each of upper die plates 120 and lower lock apertures 182b disposed in each of lower die plates 140. In its unlocked (or first) position (illustrated in FIG. 4), lock shuttle 184 is disposed substantially within lower lock apertures 182b. When upper die plates 120 are approximated with lower die plates 140, upper lock apertures 182a substantially align with lower lock apertures 182b. Here, lock shuttle 184 is then slidable into its locked (or second) position (illustrated in FIG. 5) where lock shuttle 184 engages both upper lock aperture 182a and lower lock aperture 182b, thus locking upper die plates 120 and lower die plates 140 together.

To unlock die plates 120 and 140, lock shuttle 184 is returned to its first position. It is envisioned that a lower surface 183 of upper lock aperture 182a is titled downward at an angle α towards lower lock aperture 182b (see FIG. 5) to help ensure die plates 120 and 140 can properly lock together and to help ensure die plates 120 and 140 do not separate during operation. It is envisioned that angle α is in the range of about 0.5 degrees to about 5 degrees and more particularly in the range of about 1 degree to about 2 degrees. It is also envisioned that upper die plates 120 and/or lower die plates 140 include at least one guide aperture 170 extending therethrough. Guide aperture(s) 170 may be provided for primary shaft(s) (not explicitly shown) to extend through. The ram axially pushes dies 110, which ride on the primary shaft(s).

FIGS. 6-11 illustrate a spacing device 200. Spacing device 200 includes spacer hinges 300 and a spacer bar 310 (or spacers 312). Spacer hinges 300 include an inner hinge pin 302 and an outer hinge pin 304, which are linked together by linkage 306. Generally, spacer hinges 300 are affixed adjacent an edge (or both edges) of upper die plates 120 and/or lower die plates 140. (FIG. 8 illustrates hinges 300 affixed adjacent an edge of lower die plates 140.) More specifically, inner hinge pin 302 is affixed to die plates 120 or 140 and is connected to outer hinge pin 304 via hinge linkage 306. Spacer bar 310 is disposed between inner pin 302 and outer pin 304. More specifically, spacer bar 310 may be disposed between an edge (or shoulder) of die 110 and outer pin 304.

With continued reference to FIGS. 6-11, when dies 110 are compressed together, outer hinge pins 304 are moved outwardly with respect to inner pins 302 (i.e., outer hinge pins 304 are move away from die 110). Accordingly, when dies 110 are separated from each other, outer pins 304 move inwardly with respect to inner pins 302 (i.e., towards die 110). See FIG. 9. As can be appreciated by referencing FIGS. 6-9 and 11, spacer bar 310 (or spacers 312) limits the inward travel of outer pins 304 when dies 110 are separated from each other. Thus, altering the width “w” (FIG. 7) of spacer bar 310 changes the distances that dies 110 may move apart from an adjacent die 110.

Using spacing device 200 of FIGS. 6-11, a user is able to remove and replace spacer bar 310 (or spacers 312a, 312b, discussed below), either before or after upper die plates 120 are approximated with lower die plates 140, or at any time in between. Thus, to change the desired distance between dies 110, a user can easily and quickly remove spacer bar 310 and replace spacer bar 310 with a different sized spacer bar 310. Further, as can be appreciated, a user may perform such a replacement without the use of any tools.

With reference to FIG. 7, spacing device 200 is illustrated adjacent both edge of die plates 120 or 140. While not necessarily necessary, this embodiment may lead to more accurate spacing control. FIG. 7 also illustrates spacer bar 310 (two spacer bars 310 are illustrated) having a substantially constant width “w” along its length. This constant width “w” creates a uniform spacing between each adjacent die 110.

FIG. 9 illustrates spacing device 200 having a spacer bar 310 that has a varying width. More specifically, spacer bar 310 is illustrated being stepped with two different widths, w1 and w2. This stepped spacer bar 310 corresponds to different distances between adjacent dies 110, d1 and d2, respectively. Depending on the desired product, a spacer bar 310 having a constant width or a varied width may be used.

Now referring to FIG. 10, different cross-sections of spacer bar 310 indicated by line 10-10 in FIG. 7 are illustrated. While a circular (including oval) and rectangular cross-section are shown, the cross-section of spacer bar 310 may be any suitable regular or non-regular shape.

With reference to FIG. 11, spacing device 200 having a plurality of spacers 312 is illustrated. In this embodiment, spacers 312 having substantially the same or different shapes may be used to provide proper spacing for adjacent dies 110. Here, at least a portion of circular-shaped disc 312a is positioned between inner hinge pin 302 and outer hinge pin 304. Included in this embodiment, is a portion of spacer 312 positioned between outer hinge pin 304 and an edge of die 110. In addition to circular-shaped disc 312a, a rectangular spacer 312b is illustrated. Spacer 312 may have any suitable regular or irregular shape. It is also envisioned that spacer 312 is positioned between a head of outer (or inner) hinge pin 304 and a portion of linkage 306. It is further envisioned that spacer (e.g., 312a) will be vertically spaced apart from an adjacent spacer (e.g., 312b) to enable dies 110 to be compressed without adjacent spacers 312a, 312b contacting each other.

While several embodiments of the disclosure have been shown in the figures, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. For example, it is envisioned that objects other than bellows may be created from such a hydroforming machine. Those skilled in the art will envision other modifications within the scope and spirit the claims appended hereto.

Claims

1. A hydroforming machine, comprising:

a plurality of dies, each die including an upper die plate hingedly connectable to a lower die plate via a hinge mechanism and lockable with the lower die plate via a locking mechanism, each upper die plate and each lower die plate including an opening therethrough which are substantially alignable with respect to each other; and

a spacing device disposed in mechanical cooperation with each of the dies for maintaining a desired distance therebetween, the spacing device including a plurality of hinges which hingedly connect each die with an adjacent die.

2. The hydroforming machine according to claim 1, wherein the spacing device further includes a spacer bar.

3. The hydroforming machine according to claim 1, wherein each of the plurality of hinges comprises an inner hinge pin, an outer hinge pin and a linkage including a first opening for receiving the inner hinge pin and a second opening for receiving the outer hinge pin.

4. The hydroforming machine according to claim 3, wherein the inner hinge pin extends through at least a portion of a die.

5. The hydroforming machine according to claim 3, further comprising a spacer bar being positionable between the inner hinge pin and the outer hinge pin.

6. The hydroforming machine according to claim 1, further comprising another spacing device, one spacing device being positioned adjacent one edge of dies and another spacing device being positioned adjacent another edge of dies.

7. The hydroforming machine according to claim 2, wherein the spacer bar has a substantially constant width along its length.

8. The hydroforming machine according to claim 2, wherein the spacer bar has more than one size width along its length.

9. The hydroforming machine according to claim 2, wherein the spacer bar is stepped.

10. The hydroforming machine according to claim 2, wherein a cross section of the spacer bar at least one of circular and rectangular.

11. The hydroforming machine according to claim 3, wherein the spacing device further includes a plurality of spacers, each spacer being positionable adjacent an outer hinge pin.

12. The hydroforming machine according to claim 3, wherein the spacing device further includes a plurality of spacers, at least a portion of each spacer being positionable between an outer hinge pin and an inner hinge pin.

13. The hydroforming machine according to claim 11, wherein the spacers are discs.

14. The hydroforming machine according to claim 1, wherein the locking mechanism includes a lock shuttle being slidable between a first position where the lock shuttle engages an upper lock aperture disposed in at least an upper die plate or a lower lock aperture disposed in at least a lower die plate and a second position where the lock shuttle engages the upper lock aperture and the lower lock aperture.

15. The hydroforming machine according to claim 14, wherein the upper lock aperture includes a lower surface which is titled downward towards the lower lock aperture at an angle α, wherein α is in the range of about 0.5 degrees to about 5 degrees.

16. The hydroforming machine according to claim 14, wherein the lock shuttle is removable.

17. A hydroforming machine, comprising:

a plurality of dies, each die including an upper die plate hingedly moveable with respect to a lower die plate between an open position where upper die plate is in a spaced relation with lower die plate and a closed position where upper die plate is approximated with lower die plate;

a spacing device disposed in mechanical cooperation with the plurality of dies for maintaining a desired distance between adjacent dies; and

wherein the distance between adjacent dies is adjustable while the upper die plates are in the open position, the closed position and any position therebetween.

18. The hydroforming machine according to claim 17, wherein the spacing device includes a plurality of hinges which hingedly connect each die with an adjacent die

19. The hydroforming machine according to claim 18, wherein each of the plurality of hinges comprises an inner hinge pin, an outer hinge pin and a linkage including a first opening for receiving the inner hinge pin and a second opening for receiving the outer hinge pin.

20. The hydroforming machine according to claim 19, wherein the spacing device includes a spacer bar which is positionable between at least one inner hinge pin and at least one outer hinge pin.