Abstract: A frame member of rectangular cross section with rounded corners is formed by expansion of a tubular blank within a die cavity having an inner portion of corresponding cross section and an outer transition portion which is of smoothly continuously curved cross sectional profile elongated substantially parallel to the larger dimension of the rectangular section. An outer portion of the tubular blank is deformed to correspond with the continuously curved cross sectional profile and is sealed by a resiliently compressible sealing element of corresponding profile through which fluid pressure is applied in order to expand the blank. By matching the profile of the transition portion to the rectangular inner portion, the transition portion can be made shorter and considerable savings of materials and resources can be achieved.

Abstract: An extrusion molding process including the steps of: i) extruding a material through an extruding die into a tubular molding, ii) driving two clamping devices to clamp the tubular molding at different elevations, causing an air-tight space to be formed within the tubular, iii) closing two symmetrical halves of a molding die on the molding between the clamping devices and simultaneously lowering one clamping device to stretch the molding downwards, causing the molding to be compressed in a die cavity between the two symmetrical halves of the molding die and molded into the desired finished product; and iv) opening the molding die from the finished product and returning the clamping devices to their former positions.

Abstract: Apparatus and method for hydroforming multiple components simultaneously with a smaller capacity press than would be possible using conventional hydroforming methods and apparatus. Die pairs are positioned with multiple die cavities in series so that the separating force transmitted to a press holding the dies equals the force developed in a single die cavity, even though multiple components are being formed in the die cavities.

Abstract: In a method and apparatus for fabricating a hollow body, preferably of sheet metal, such as for example automobile hoods and doors, at least two blanks are held sealingly together and the hollow body is then shaped by internal hydroforming.

Abstract: A large dimension hollow body such as a fuel tank is formed from cold deformable sheet metal by cutting a sheet metal blank of a conformation matching the hollow structure to be formed and which has a nonuniform cross section between its ends. The sheet metal blank is then formed into a three-dimensional shape closed at one end and subjected to hydrostatic forming, whereupon the other end is closed optionally after insertion of an object to be received in the tank such as a fuel pump. The welding of the edges of the blank together and the application of the caps can produce pressure-tight weld seams and can be effected by laser-beam welding or tungsten inert gas welding.

Abstract: Internal high pressure forming at present takes place by exerting a pressure between sheet metal blanks fixed by a marginal weld. It has already been proposed to deform under high internal pressure sheet metal blanks merely placed on one another in a combined clamping and sealing die. Problems arise with regards to the sealing and material flow. Thus, to overcome the aforementioned disadvantages, the invention proposes a method for forming at least one workpiece under high liquid or hydraulic pressure, in which the workpiece, during pressure build-up, is initially marginally clamped in per se known manner and in the final phase of forming to the desired final shape of the workpiece (sizing) the marginal area of the workpiece is freed.

Abstract: A backrest structure for a vehicle seat comprises two hydroformed, tubular, horizontal crosspieces and vertical uprights engaged without any clearance in orifices punched into these crosspieces during hydroforming.

Abstract: A method for the production of reinforced hollow sections with a continuous periphery. In order to provide in a simple manner, hollow sections with selective local reinforcement at points subject to high mechanical loads, an opening is formed in the periphery of the hollow section and a reinforcing plate is inserted into the opening, such that it at least projects into the hollow section. The reinforcing plate is then joined to the hollow section in the region of the edge of the opening.

Abstract: In a method of forming a hollow workpiece having open ends by inner pressure in a multi-part forming tool, the forming tool having a forming mold is heated and the workpiece is placed into the forming mold of the forming tool. Closing plugs are inserted into the open ends of the workpiece, wherein the closing plugs are components of closing cylinders, in order to seal off the open ends. The forming tool is closed. A heated pressure fluid is introduced into the hollow workpiece through at least one of the closing plugs, with the hollow workpiece having been heated and plasticized in the forming tool. The material of the hollow workpiece is pressed with the heated pressure fluid into the forming mold of the forming tool. The device for performing the method has a multi-part forming tool with a forming mold for the workpiece. Hydraulic closing cylinders with closing plugs are provided for sealing the open ends of the workpiece. The forming tool has a heating device for heating at least the forming mold.

Abstract: A lever, for example, for transferring force to another structural component of a mechanism, has a prefabricated connecting piece disposed on at least one of its ends. The lever is constructed as a hollow profile made of material that can be shaped without cutting. The hollow profile forms a receiving chamber on at least one end for the prefabricated connecting piece. The walls of the receiving chamber rest tightly against the circumference and the end faces of the connecting piece.

Abstract: An apparatus for forming two plates into a hollow workpiece has a pair of dies having edge regions adapted to be pressed together against outer peripheries of the plates. An outer element in the edge region of one of the dies is adapted to rotate therein about an axis generally parallel to the direction and an inner element set in the outer element is rotatable therein about an axis generally parallel to and offset from the outer-element axis. The inner element is formed offset from its axis with an axially throughgoing feed passage aligned with a feed hole in the plate engaging the one die. A fluid forced under pressure through the passage and hole into a space between the plates deforms the plates away from each other in the direction while displacing the hole perpendicular to the direction with movement of the passage perpendicular to the direction.

Abstract: In the present invention, in a method of fabricating a metal vessel formed by expanding in hydraulic bulge formation a cylinder having a bottom, wherein a flat plate material is formed into a cylinder, the edges welded, and a bottom member welded to one open part of the cylindrical shell member, the stationary point of the expanded part of the shell member is made the expanding part side from the shell member—bottom member weld of the cylinder with a bottom, and thereby by expanding the shell part on the opening side, a metal vessel is formed, and thus the time of the processing itself of a plurality of expanding process of press-working and ironing and transiting of moving from one step to the next can be completed by one step, decreasing the time and reducing the cost.

Abstract: The invention relates to a process for producing a region of greater wall thickness in a longitudinal hollow section (1) which, to this end, is subjected to a radial and axial pressure and plastically deformed thereby. The hollow section (1) is secured in a matrix (2) corresponding to the section dimensions which has an enlarged cross section corresponding to the intended final dimensions of the hollow section (1) in the deformation region. The essential embodiment consists in that the deformation to attain an increased wall thickness (14) takes place in a region between the ends of the section. In addition, the wall thickness (19) can be increased at at least one of the ends of the section.

Abstract: A method of manufacturing a vehicle frame assembly includes the initial steps of providing first and second side rails and providing first and second cross members. Each of the first and second cross members has first and second ends extending from a central portion. A desired torsional stiffness is determined for the first cross member. In response to this determination, the first and second ends of the first cross member are enlarged so as to achieve the desired torsional stiffness for the cross member. A similar process can be conducted for the second cross member. Then, the first ends of the first and second cross members are secured to the first side rail, and the second ends of the first and second cross members are secured to the second side rail to form a vehicle frame assembly.

Abstract: For shaping small radii in edge and corner regions of preformed workpieces or blanks, the invention provides for a postforming of exclusively said edge and corner regions by high liquid pressure. For performing the method an apparatus has a die part (forming insert) with expansion spaces constructed in its edge and corner regions.

Abstract: Superplastic forming equipment and processes featuring a rotatable, low-friction stuffing unit for engagement with a blank sheet of superplastic formable metal to optimize the quantity or amount of material that is drawn onto a forming die for improved part forming. The stuffer is rotatably mounted in a chambered upper tool of the forming equipment and is offset from the forming profile of the lower forming die. The rotatable stuffer physically contacts portions of a blank sheet of heated forming material as the upper tool is lowered and effectively pulls the sheet material into the working area and around portions of the profile of the forming die in an intermediate or preforming phase of forming operation. With increased material in operative position in the die, the wall of the formed part will be intact and meet design specifications.

Abstract: A forming device having a fluid source for providing a pressurized fluid, a strongback having a die cavity, a tubular workpiece having a hollow interior, a die and a mandrel assembly. The die is formed from a plurality of mated die components and includes an internal cavity which is configured to correspond to a predetermined tube profile. The die is at least partially disposed in the die cavity and surrounds at least a portion of the tubular workpiece. The mandrel assembly is disposed at least partially within the hollow interior of the tubular workpiece in an area proximate the die and is in sealing engagement with the hollow interior of the tubular workpiece. The mandrel assembly includes at least one feed aperture that is in fluid connection with the fluid source. The feed aperture directs the pressurized fluid against the hollow interior of the tubular workpiece to cause the tubular workpiece to expand into the internal cavity.

Abstract: The forming time necessary to superplastically form an object from a metal sheet is estimated by empirical analysis. The required rate of gas mass flow into a forming cavity is then determined using either a nomograph composed of four interrelated graphs, or a single graph which requires the input of fewer variables than the nomograph. The present invention may also be used to form cells of multiple sheet panels from a stack of sheets. In the latter application, forming time necessary to complete forming of the cells from an interim point where the core sheet forming pressure and the die temperature are increased from interim levels to their final values is estimated by empirical analysis. A nomograph or single graph of the present invention then determines the gas mass flow rate necessary to safely and efficiently complete forming of the cells from the foregoing interim point.

Abstract: Methods and apparatus employing an ultra high-pressure fluid pulse to perform metal working operations, including joining and cold working. In one application, an ultra high-pressure fluid pulse is directed into a hollow rivet that is seated within an orifice formed in two metal sheets, causing the fastener to expand outwardly, in an interference fit with the orifice that joins the metal sheets together. The ultra high-pressure fluid pulse can alternatively be applied to the metal sheets to plastically deform them into a cavity to form a clinch fastener joint. Further, the ultra high-pressure fluid pulse is usable to plastically deform the interface between stacked metal sheets or other components into surface features that are provided on one of the sheets, to form a mechanical interlock.

Abstract: A method and a device for manufacturing a hollow body from two plates, which are placed against one another and inserted into an internal high pressure forming tool. After the forming tool is closed, a fluid is introduced under high pressure between the plates by way of an expansion lance inserted between the plates. The plates are expanded until they abut the interior surfaces of the forming tool that match the shape of the hollow body. To achieve a process-reliable manufacture of the hollow body, the plates, before any internal high pressure is developed, are pinched in the thickness direction along the circumference of the opening that surrounds the inserted expansion lance by cooperation between the dies of the forming tool and the circumferential contour of the expansion lance that is oversize relative to the location between the plates at which the expansion lance is introduced.

Abstract: A method and a device for manufacturing a hollow body from two plates, which are placed against one another and inserted into an internal high pressure forming tool. After the forming tool is closed, a fluid is introduced under high pressure between the plates by way of an expansion lance inserted between the plates. The plates are expanded until they abut the interior surfaces of the forming tool that match the shape of the hollow body. To achieve a process-reliable manufacture of the hollow body, the plates, before any internal high pressure is developed, are pinched in the thickness direction along the circumference of the opening that surrounds the inserted expansion lance by cooperation between the dies of the forming tool and the circumferential contour of the expansion lance that is oversize relative to the location between the plates at which the expansion lance is introduced.

Abstract: A mechanical press is adapted to perform a hydroforming operation. The press includes a stationary base supporting a bolster that carries a lower die section, a movable slide that carries an upper die section, and a drive mechanism for selectively raising and lowering the slide relative to the base. An inflatable bladder is disposed between the base and the bolster. Initially, the drive mechanism is operated to lower the slide to its bottom dead center position such that the die sections enclose a workpiece within a die cavity. Then, pressurized fluid is supplied within the workpiece to expand it outwardly into conformance with the die cavity. At the same time, pressurized fluid is also supplied to the interior of the inflatable bladder. The application of such pressurized fluid causes the inflatable bladder to be physically expanded, causing the bolster carrying the lower die section to be raised relative to the base.

Abstract: The invention relates to a process for fastening components on a hollow shaft (1), during which process the components (21, 22, 23), exhibiting an opening, are put into specified positions on the hollow shaft (1) and for the purpose of fastening components (21, 22, 23) the hollow shaft (1) is expanded by introducing a pressure medium. Support matrices (3) are arranged only between the components (21, 22, 23) for the purpose of bracing the regions of the hollow shaft (1) between the components (21, 22, 23) during the expansion operation.

Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.

Abstract: A cold forging forming method for forming a three-dimensional hollow article without rough edges, wherein, an alloy of low melting point is used instead of mercury as a filler with plasticity. When the alloy of low melting point is heated and molten, it can be poured, discharged and recollected at normal temperatures but can have good stiffness after being solidified, thereby, the solidified alloy of low melting point can support a seamless die cavity against forging pressure, thereby, a stiff wall of the seamless die cavity is formed. A shaped work piece in the die cavity can be released when the solidified alloy is heated to melt, and an inner die for a different die cavity can be substituted for the old one, and an effect of recovery for reusing the filler can be achieved, and cost of forming can be reduced. All these meet the requirement of environment protection.

Abstract: A method and apparatus for sealing the net shape of the end of a final product tube to eliminate or minimize scrap for a wide range of shapes of the end of the product. A sealing tool has a neck, and a coining portion comprising a shoulder extending outwardly from the neck. The sealing tool is inserted into the deformed end of the tube while the end is being laterally engaged by a clamp pressing inwardly against the outer surface of the tube. The end is then sealed by coining a surface of the tube by axially pressing the sealing tool into the end while laterally inwardly pressing the end with the clamp.

Abstract: A method of securing two or more components together is disclosed in which one of the members is made from a thin wall tubular material that can be expanded by a hydroforming technique to cause deformation which is used to secure one or more components (11, 12, 13, 14; 111, 122, 123 and 114) to the tubular member (9, 109).

Abstract: An aluminum-thermoplastic composite surface structure. A sheet of aluminum is formed to a single-sided mold by heating the sheet and applying a ramp of gas pressure. A thermoplastic resin is heated and microballons are added to the resin to lower the viscosity of the resin, which is applied through a nozzle in a hexagonal pattern on the formed aluminum sheet. Upon cooling, the composite resin forms a honeycomb pattern. The hexagonal pattern transitions to a columnar pattern and a backing layer of aluminum sheet is gas pressure formed to the resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that bonds to the applied resin.

Abstract: A method is disclosed for stretching magnesium-containing aluminum alloy sheet stock into intricate shapes such as are required in automotive body panels. The sheet stock, at a temperature in the range of about 400° C. to about 510° C., is stretched under the pressure of a working gas into conformance with the surface of a forming tool. The sheet forming pressure is increased continually in a controlled manner from ambient pressure to a final forming level in the range of about 250 psi to about 500 psi or higher. A portion of the sheet can experience strain rates substantially higher than 10−3 sec−1 and the forming of the sheet can be completed within 12 minutes.

Abstract: A method and apparatus for reshaping a container body (e.g., a metal, drawn and ironed container body) utilizing a floating mechanism for imparting an axial load is disclosed. In one embodiment, a container may have a substantially cylindrical sidewall with an inner surface and outer surface, where a shape defining means has a contoured surface positionable with respect to a container sidewall. When a floating mechanism imparts an axial load, a fluid seal is maintained allowing sidewall deformation by means of a directed pressurized fluid.

Abstract: A method for hydroforming a metallic tube comprising primary hydroforming and secondary hydroforming, wherein in the primary hydroforming step, the metallic tube is formed such that a circumferential length of an expanded portion of the primary-hydroformed tube as measured at a wall center region of the expanded portion becomes substantially equal to or slightly shorter than a circumferential length of an expanded portion of a product as measured at a wall center region of the expanded portion, and in the secondary hydroforming step, movable forming plates incorporated in the dies press the expanded portion formed through primary hydroforming so as to finish the cross-sectional profile of the expanded portion into that of the expanded portion of the product, and said primary hydroforming and secondary hydroforming are continuously performed within the dies. Also disclosed is an apparatus for performing the hydroformation method.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A hydroformed member having internal reinforcements and method of manufacturing the same. The method includes the steps of providing a die having a tooling cavity and a pair of opposing rams disposed in the tooling cavity. A tubular member is enclosed within the tooling cavity. The pair of opposing rams are then driven against opposing sides of the tubular member to form a pair of opposing indentations therein. While the rams remain in place, hydraulic fluid pressure is then applied within the tubular member causing the walls of the tubular member to closely conform to the shape of the tooling cavity and the pair of opposing rams.

Abstract: The present invention provides a process and apparatus for manufacturing an electromagnetic interference shielding metallic foil cladded plastic product.

Abstract: The present invention provides a process for manufacturing an electromagnetic interference shielding metallic foil cladded plastic outer shell product. A first side of a superplastic alloy foil is coated with an adhesive and then the foil is placed foil in a first half mold to allow the foil to be initially superplastically formed. A second half mold attached to a nozzle of an injection machine is covered onto the first half mold, and the two half molds are closed to further deform superplastic alloy foil. Softened plastic is introduced from the injection machine to a mold cavity between the foil and the second half mold, such that the superplastic alloy foil covered on the first half mold is completely formed and the softened plastic adheres on the adhesive-coated side of the superplastic alloy foil to form an electromagnetic interference shielding metallic foil cladded plastic outer shell product.

Abstract: A process for fastening at least one part, such as a cam, gear wheel, disc, etc., onto a shaft in a torsionally resistant manner. The process includes a combination of features, including threading the part with a mating play onto the shaft, the part seating on the shaft with a seating surface which has a profile of a plurality of curved spline surfaces which are preferably offset by the same angles around the circumference and gradually rise up inwards over a cylindrical reference surface and fall back down again onto the reference surface. The process also includes the feature of eliminating the mating play between the shaft and the part and the feature of turning the part relative to the shaft into an intended position for fastening after eliminating the mating play. The torque required for turning the part into an intended angular position can be measured and can serve as a check to determine if a desired frictional engagement has been achieved.

Abstract: A shaft assembly including an inner hub having a centrally-disposed bore therethrough and an outer surface for carrying a first member concentrically thereon for rotation therewith, an outer hub having a centrally-disposed bore therethrough and an outer surface for carrying a second member thereon for rotation therewith. The bore of the outer hub is adapted for receiving the inner hub concentrically therein for rotation therewith. An outer pressure-expansible sleeve is provided for being concentrically-mounted within the bore of said outer hub and pressurized for locking the outer hub onto the inner hub. An inner pressure-expansible sleeve is concentrically-positioned in the bore of the inner hub and pressurized for locking the inner hub onto a rotatable spindle, whereby the inner hub and outer hub and the respective members mounted thereon are locked in fixed, concentric relation relative to each other and to the rotatable spindle.

Abstract: Lightweight flexure-resistant thin metal sheet is produced by passing flexible thin metal sheet between rolls having defined teeth, the teeth having radiused corners so that rows of projections are formed on both faces of the sheet without damage to the surface material or the rolls.

Abstract: In the present invention, in a method of fabricating a metal vessel formed by expanding in hydraulic bulge formation a cylinder having a bottom, wherein a flat plate material is formed into a cylinder, the edges welded, and a bottom member welded to one open part of the cylindrical shell member, the stationary point of the expanded part of the shell member is made the expanding part side from the shell member—bottom member weld of the cylinder with a bottom, and thereby by expanding the shell part on the opening side, a metal vessel is formed, and thus the time of the processing itself of a plurality of expanding process of press-working and ironing and transiting of moving from one step to the next can be completed by one step, decreasing the time and reducing the cost.

Abstract: The present invention provides a superplastic alloy-containing conductive plastic article for shielding electromagnetic interference. The conductive plastic article is a three-layer structure, in which the outer layers are plastic material, and the inner layer is a superplastic alloy. The requirements for the raw materials are that the melting point of the superplastic alloy is higher than the softening point of the plastic, and the superplastic alloy has superplasticity at a temperature higher than the softening point of the plastic. The conductive plastic article can be manufactured in one processing stage, has the same shielding effectiveness as that of a conventional metal plate article, and can take a delicate and complicated form as that of a conventional plastic article. Moreover, the superplastic alloy contained therein has a uniform thickness and good adherence to plastic.

Abstract: A tube member is placed in a die having a plurality of nodules formed in the cavity thereof. A chamber is formed between a mandrel and end piece within the tube. The mandrel is positioned adjacent a first of the nodules and the chamber is pressurized during a hydroforming cycle to form a node on the tube by simultaneously expanding a portion of the tube outward and feeding the tube linearly into the die cavity. A mechanism for feeding the tube linearly is external to the die cavity and has a member in abutment with one end of the tube. During a positioning cycle, the pressure in the chamber is reduced and the mandrel is moved longitudinally within the tube to a position adjacent the next sequential nodule to permit a repeat of the hydroforming cycle. In one embodiment of the hydroforming process, a mandrel is positioned into the tube from each tube end and a feed mechanism is disposed adjacent each tube end. This permits the sequential simultaneous hydroforming of pairs of nodes on the tube.

Abstract: A hydroforming apparatus for simultaneously performing two or more hydroforming operations includes a frame that is sized to support a plurality of hydroforming dies in a stacked relationship. Each of the dies includes a pair of cooperating die sections having respective recesses formed therein that define a die cavity. Initially, the first die section of the first die is positioned in an uppermost spaced apart position relative to the second die section of the second die, while the second die section of the first die and the first die section of the second die are positioned in an intermediate spaced apart position relative to both the first die sect of the first die and the second die section of the second die. Then, hollow tubular blanks are inserted between the spaced apart die sections of the first and second die Next, the ram and the support mechanism are moved downwardly relative to the be such that the pairs of cooperating die sections of the first and second dies engage one another.