Abstract: The invention relates to a method of increasing the dynamic pressure resistance of a metal component with a tubular inner space, in which a hard metal ball is forced under high pressure through the interior of the tubular inner space, wherein the hard metal ball has a diameter that is greater than the inside diameter of the tubular inner space before the hard metal ball is forced through.

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 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 bulging apparatus has a heating station, a tube expanding station, a preforming station, and a main forming station. A straight tube as a workpiece is gripped by first holding mechanisms or second holding mechanisms, and delivered between the stations as the first holding mechanisms or second holding mechanisms are displaced. During a preforming process and a main holding process, both the first holding mechanisms and second holding mechanisms can be lifted and lowered vertically and can be moved horizontally.

Abstract: A member has a wave inhibitor adapted to control the effects of a wave of longitudinally displaced material positioned ahead of an expansion mandrel used to expand the member. The wave inhibitor has a decreasing transverse cross-sectional area to diminish the effects attributable to the wave, such as workpiece distortions, material upset of the workpiece, lengthening of the member, and excessively high strains in the workpiece. The wave inhibitor can also induce radially compressive stresses in the workpiece and produce an interference fit.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

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 hydro forming apparatus comprises a lower base; a lower mold mounted on the lower base and provided with an U-shaped lower cavity; an upper mold provided with a U-shaped upper cavity corresponding to the lower cavity and configured to be coupled with the lower mold; an upper base mounted on the upper mold and configured to be coupled with the lower base; and an adjusting unit for adjusting the shape of the U-shaped lower and upper cavities.

Abstract: The aim of the invention is to produce can bodies (24?) comprising a can shell (24) and a closing element (31b, 32, 31a) that is fixed to one face of the can shell (24). Said aim is achieved by producing a tube (11) from a metal strip (1), optionally from directly adjacent sections (112), by means of a shaping step, at least one optional cutting step, and a continuous welding step, sections of said tube (11) being used as closed convex surfaces for cans. The sections are shaped by a shell-shaping device in such a way that can shells (24) are provided into which a closing element (31b, 32, 31a), especially a can bottom (31b), can be inserted. The longitudinal seam (11a, 124) can be produced inexpensively and at great precision essentially as a continuous seam in the welding step by means of simple installations.

Abstract: The invention concerns a method whereby components are arranged in a mounting device, outside an internal high-pressure forming press, in accordance with their position and their function, such that they are linked to one another. The mounting device comprises an upper part and a lower part including cavities identical to the cavities of the internal high pressure tool. Once the components have been installed, the mounting device is introduced in the internal high-pressure press, then the upper part or the lower part of the mounting device is withdrawn, the part of the mounting device remaining in the internal high-pressure press being displaced against the upper tool or the lower tool. For the forming process, the components are maintained in a part of the tool by depression or by clamping, then the part of the mounting device is removed from the internal high-pressure press, thereby ensuring high precision positioning of components. Additionally, the production rate is substantially increased.

Abstract: A molding unit (20) for use in a can shaping process. Container preforms (F) are mounted on a table (16) which is rotated so a blank is moved from an initial loading station (P1) to a molding station (P4). The molding unit includes a two-part mold (20a, 20b) split vertically in half, and an inner surface (56) of each mold half is shaped to produce a desired can profile. Once the preform is in place, a pressurization unit (102) is lowered into place from above the mold onto an open, upper end of the preform. The mold is then closed and pressurized air is introduced into the preform and forces the sidewall of the preform outwardly against the inner surface of the mold to conform the preform into a desired container profile. The height of the preform tries to contract as its sidewall expands, but a force imparted to the preform by the pressurization unit controls the direction of any contraction so to prevent distortion of the container.

Abstract: The invention relates to a device for shaping a blank into a hollow profiled element comprising at least one base plate, onto which the blank that is to be shaped can be placed, at least one die core for the hollow profiled element and at least two die halves for shaping the blank into the hollow profiled element, as well as a method for producing a hollow profiled element with at least one molded-on stiffening and/or functional element made from a blank.

Abstract: A method for manufacturing a hydroforming member includes the step of providing a blank (10). The blank (10) is defined by blank wall (16). The blank (10) is placed in a die assembly (14) having a die cavity (12) defined by a die surface (24). The blank (10) is expanded so that the blank wall (16) is forced against the die surface (24) to form the hydroformed member. A portion of the blank wall conforms against a wall-thinning element (26, 28) positioned along the die surface (24) to form a removable wall section (46, 50) in a portion of the blank wall (24). The removable wall section (46, 50) is then removed from the blank wall (16) to form an opening in the hydroformed member.

Abstract: A method allowing for the fabrication of tubular structures, such as structural members used in vehicle bodies, from two or more metals or other materials using a hydroforming process. Being able to use two or more metals or other materials, such as, for example, high-strength steel and low-weight aluminum alloy, in body structure design allows for achieving an optimum material solution which combines the desirable attributes of the different materials.

Abstract: The invention comprises a device for expanding tubular members to a controlled diameter and its method of fabrication. The device includes an expandable bladder held in a convoluted form. After the device is inserted into a cylindrical tube to be evenly expanded, the bladder is expanded by hydraulic pressure to a controlled maximum diameter. It is then deflated so the device can then be moved to another location and reused. The bladder is formed from a flexible impervious material having integral reinforcing fibers. It is initially formed in a fully expanded configuration over a convoluted mandrel and a removable cylindrical shell. When the shell is removed vacuum or external pressure draws the bladder against the mandrel. The bladder is overmolded with a resilient cover to hold it in reduced form until pressurized. The bladder cover prevents the bladder from kinking during the expansion.

Abstract: The present invention relates to a method and a device for expansion forming of an article. According to at least one aspect of the invention, an expansion forming tool is pressure-compensated from two sides, pressure differences on each side being equalized by means of a pressure transmitter, which is applicable to the tool.

Abstract: A method and apparatus for tubular expansion are disclosed. In an embodiment, an apparatus for radially expanding a tubular comprises at least two expansion swages. At least one expansion swage is axially movable relative to other expansion swages. In addition, the apparatus includes sealing means capable of providing fluid tight pressure chambers between the expansion swages and an expanded portion of the tubular.

Abstract: A profile mother pipe for hydraulic bulging of the present invention has a peripheral length whose outer diameter is gradually increased or decreased from one end to the other end in an axial direction. In the profile mother pipe, a holding portion whose peripheral length is increased toward a pipe end face on one end side can be formed on at least one end side and a parallel portion can be formed on the other end side where the holding portion is not formed. In a working apparatus and method in which the profile mother pipe is used, pressing working can be performed from the pipe end toward the axial direction, even in use of the profile mother pipe whose sectional shape is largely varied in the axial direction. Therefore, an expansion ratio larger than ever before can be obtained in a hydraulic bulged product to which hydraulic bulging is performed.

Abstract: A structural element includes: at least one hollow metallic body (4) with a closed cross-section, an external surface (24), and at least one adhesion lug (22) formed on the external surface (24); and at least one plastic body (6) which is moulded over the metallic body, covering the external surface (24) of the metallic body in such a way as to at least partially cover the adhesion lug (22) in order to connect the plastic body (6) to the metallic body (4). According to one aspect of the invention, the adhesion lug (22) protrudes over the external surface (24) of the metallic body (4), the adhesion lug (22) being closed, connected to the metallic body (4), and having an undercut (40) in relation to the external surface (24) of the metallic body (4). The inventive structural element can be applied to the front of motor vehicles.

Abstract: A bulging apparatus has a heating station, a tube expanding station, a preforming station, and a main forming station. A straight tube as a workpiece is gripped by first holding mechanisms or second holding mechanisms, and delivered between the stations as the first holding mechanisms or second holding mechanisms are displaced. During a preforming process and a main holding process, both the first holding mechanisms and second holding mechanisms can be lifted and lowered vertically and can be moved horizontally.

Abstract: According to the hydroforming method by the invention, when slots with the aspect ratio of 3 or more are pierced onto the bulge-formed portion made by the hydroforming, even the piercing can be carried out within a series of processing steps in the hydroforming, thereby eliminating the piercing operation by means of the cumbersome machining process such as milling and ensuring an excellent slot configuration. Thus, the hydroformed parts by the invention are best suited for the automobile parts etc. where various piercing operations are required, and the mold used for the hydroforming method by the invention can be widely employed for processing the automobile parts etc., whereby the invention can be applied for processing the parts in automobiles and industrial machineries as well.

Abstract: A process for forming a tubular member is provided which includes a pre-forming process for tube-expanding (bulge) forming and bending forming a tubular material using first and second molds and a final forming process for crush forming a preformed tube using a third mold so as to give its cross section a desired shape, the pre-forming step being carried out using the first and second molds heated at temperatures equal to or higher than the recrystallization temperature of the tubular material and the final forming step being carried out using the third mold heated at temperatures equal to or lower than the recrystallization temperature of the tubular material. The process enables a tubular material of aluminum alloy to be formed into a tubular member of high precision and high quality which has expanded portions as well as bent portions and whose cross section varies across its length.

Abstract: A production line for the manufacture of a product through hydroforming, having a decoiler (11) for unrolling a steel strip (12) from a coil (13), a roll-forming unit (14) for folding the steel strip into a tube (16), a welding unit (17) for welding together the edges of the steel strip, a hydroforming unit (18) having an openable mold (19, 20) to receive the completed tube as the tube is being formed and welded, a cutting arrangement (24, 25) for cutting off the completed product (23) that has been removed from the hydroforming unit, sealing arrangements (30, 33; 35-39) at two ends of the mold for sealing the tube, and a line (38) for the supply of pressure medium through one of the sealing arrangements for placing the tube under pressure. A method for manufacturing a product in such a line is also provided.

Abstract: A hydroforming method and apparatus.

Abstract: A hydroforming apparatus includes a hydroforming die member and a hydroforming press. A fastener couples the press to the die member, the fastener having a shaft and a shoulder. A spacer positioned on the fastener spaces the die member from the press. The shaft is secured to the press housing. The shoulder is positioned within a slot in the die member configured to receive the shoulder as the shoulder is inserted into the slot in a direction transverse to a longitudinal axis of the fastener.

Abstract: Apparatus and methods are provided for reducing drilling vibration during drilling with casing. In one embodiment, an apparatus for reducing vibration of a rotating casing includes a tubular body disposed concentrically around the casing, wherein tubular body is movable relative to the casing. Preferably, a portion of the tubular body comprises a friction reducing material. In operation, the tubular body comes into contact with the existing casing or the wellbore instead of the rotating casing. Because the tubular body is freely movable relative to the rotating casing, the rotating casing may continuously rotate even though the tubular body is frictionally in contact with the existing casing.

Abstract: An apparatus for expanding a tubular member comprising a support member, an expansion device for radially expanding the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, at least one pressure chamber defined by and positioned between the support member and expansion device, and one or more releasable supports coupled to the support member adapted to support the tubular member, wherein the releasable supports are positioned above the expansion device.

Abstract: A hydroform seal assembly includes a seal housing and an annular nozzle carried by the seal housing and sized to insert into a tube end. A first actuator moves the seal housing to insert the nozzle. A plurality of jaws are carried by the seal housing and are movable radially inward into clamping engagement with the tube to clamp the tube onto the annular nozzle. A cam bushing is movably mounted within the seal housing, surrounds the jaws, and has cam surfaces complimentary with cam surfaces provided on the jaws so that movement of the cam bushing relative the jaws will cam the jaws radially inward. A backup cam is movable within the seal housing. The cam bushing and backup cam have complimentary cam surfaces by which movement of the backup cam will forcibly move the cam bushing relative the seal housing. A second actuator moves the backup cam.

Abstract: An apparatus and method for locally expanding tubular member includes a pre-form die having a cavity with an expansion chamber therein to receive a portion of a tubular blank between ends thereof. The apparatus also includes a bladder apparatus for insertion in the tubular blank and cooperating with the pre-form die to locally expand the portion of the tubular blank in the expansion chamber to form a locally expanded tubular member.

Abstract: A hydroforming unit comprises a mould (19,20) that can be opened and sealing arrangements (30-33; 35-39) for sealing the ends of a tube-formed blank (16) placed in the mould, each one of the sealing arrangements (30-33; 35-39) comprises a ring (30, 35) with a thin wall that fits into the inner surface of the tube (16), and a plug (33, 36) that can be displaced in an axial direction mounted axially inside of the ring, and an arrangement (32,37) for initially drawing the plug (33, 36) outwards to put the ring under elastic tension against the inside of the tube-formed blank so that the plug and the ring together form a seal.

Abstract: A mono-diameter wellbore casing. The mono-diameter wellbore casing is formed by plastically deforming and radially expanding a first tubular member within a wellbore. A second tubular member is then plastically deformed and radially expanded in overlapping relation to the first tubular member. The second tubular member and the overlapping portion of the first tubular member are then radially expanded again.

Abstract: An apparatus and method for hydroshearing and hydrotrimming for a hydroforming die includes a cutting insert fixed relative to the hydroforming die. The apparatus and method also includes a disposable insert fixed relative to the hydroforming die. The apparatus and method further includes a plunger movable relative to the hydroforming die to allow fluid within a tubular member to force a wall portion of the tubular member outward against the plunger and be sheared in the hydroforming die to trim the tubular member.

Abstract: A hydroformed tubular member and method of hydroforming the hydroformed tubular member for a vehicle includes the steps of providing a tubular blank and positioning the tubular blank within a die. The method also includes the steps of hydroforming the tubular blank in the die into a tubular member having a generally “T” shape with a sidewall having a straight length of the sidewall increased from its originally expanded length.

Abstract: Disclosed is a pipe expanding device for expanding a thin pipe with a small diameter using elasticity and compressing and bending characteristics of a spring. Steel wires whose opposite contact sections are processed with a slope to be engaged in parallel so that contact length of both ends thereof are extended are bent and wound to form a ring spring having a single circumference with its body being partially cut off. This ring spring is used as a mold so as to expand an outer diameter of a pipe as much as a circumferential length of both ends that are widened rather than a normal circumferential diameter due to elasticity of the spring while the ring spring presses the pipe. This pipe expanding device employing the ring spring is simple and economical and allows even an unskilled person to use it easily.

Abstract: A hollow blade is shaped by superplastic inflation of a blank made up of welded-together sheets. A die comprising two hollow shapes clamping the outline of the blank is placed inside an autoclave-forming enclosure in order to subject the blank to superplastic inflation, and the two hollow shapes are united by U-shaped clamps made of a material having a coefficient of thermal expansion that is smaller than that of the material constituting said shapes.

Abstract: A high-pressure system for hydroshaping a hollow workpiece has a lower die and an upper die vertically shiftable above the lower die and forming therewith a cavity shaped to hold the workpiece. An upper actuating element bears downward via a vertically compressible hydraulic operating cylinder on the upper die. A spring-loaded pressure-storing cylinder is connected by a hydraulic line to the operating cylinder and to the workpiece. Downward shifting of the actuating element first closes the dies together, then internally pressurizes the workpiece via the line from the operating cylinder such that the workpiece deforms and shapes itself to the cavity, and then fills the spring-loaded pressure-storing cylinder. Subsequent upward shifting of the actuating element at first allows the pressure-storing cylinder to empty, and then entrains the upper die upward off the workpiece by the actuating element.

Abstract: A method for shaping an aerosol container (10) to a desired body contour. A container body (12) is formed into a cylindrical shape and installed into a mold (30) whose inner surface defines the desired body contour. A bladder (74) is fitted onto a tool (50) insertable into an open end (M) of the container body. Once the tool is inserted, the bladder is inflated with a hydraulic fluid. Pressurizing the bladder forces the bladder against a sidewall of the body forcing the body outwardly and deforming it against the inside of the mold. After the container body is shaped, the bladder is de-pressurized and the tool withdrawn leaving the container with a defined body contour. The hydraulic fluid with which the bladder is pressurized is, at all times, contained within the bladder and does not contact the container sidewall so no subsequent drying of the container is required after the shaping process is complete.

Abstract: A method is provided for hydroforming a ring-shaped tubular structure such as a door opening for a vehicle body. The method includes providing a ring-shaped tubular blank having a hollow sealed interior, capturing the ring shaped tubular blank in a hydroforming die cavity, piercing the ring shaped tubular blank with a hollow punch, and introducing pressurized fluid through the hollow punch into the hollow sealed interior to expand the tubular structure to conform with the shape of the hydroforming die cavity and thereby hydroform the ring-shaped tubular structure.

Abstract: An apparatus and method including a die assembly and tooling, which includes a draw bolt and coaxially disposed expandable element. When control of the apparatus is initiated the die assembly and draw bolt retract or move down over the work piece until the die assembly is seated in the die holder. The draw bolt continues to move down which causes the elastomer insert to expand and push the work piece outwardly forcing the work piece to conform to the contour of the die assembly creating the desired transition diameter.

Abstract: An apparatus and method for performing a hydroforming process cause either or both of the opposed end portions of the workpiece to be deformed to achieve desired shapes therein. Initially, a workpiece having a pair of end portions is disposed within a die cavity defined by first and second die sections have cooperating recesses. A pair of end feed assemblies engage the end portions of the workpiece and deform such end portions to a desired shape. Pressurized fluid is provided within the workpiece either before, during, or after the deformation of the end portions of the workpiece to deform the central portion thereof it into a desired shape as defined by the die cavity.

Abstract: A hydroforming apparatus for hydroforming a workpiece. The apparatus includes a die in which a die cavity is located, and an outer ring subassembly. The outer ring subassembly is movable relative to the die, and includes a ring and one or more first cam segments attached thereto. The outer ring subassembly also includes one or more second cam segments and one or more tapered wedges positioned between the first and second cam segments. The tapered wedge is movable between an extended position, in which the second cam segment is pushed to an open position in which the second cam segment is engageable with the outer surfaces when the subassembly is proximal to the die, and a retracted position, in which the second cam segment is moved to a closed position by a biasing means. The second cam segment includes a lower surface shaped to engage outer surfaces.

Abstract: A method and an apparatus for reshaping a tube having an initial outside diameter, an initial wall thickness, and an initial length to form a tube have a reshaped outside diameter, a reshaped length, and a reshaped wall thickness, wherein at least one of the reshaped outside diameter, the reshaped length, and the reshaped wall thickness is different than a respective one of the initial outside diameter, the initial wall thickness, and the initial length. The method includes mounting the tube between two axially displaceable pressure rams with the ends of the tube against respective rams; applying an internal hydraulic pressure to the tube; applying an axial mechanical pressure to the tube via the rams; and simultaneously and uniformly cold-working the tube over its entire length by adjusting the internal hydraulic pressure and the axial mechanical pressure as a function of the reshaped outside diameter, the reshaped wall thickness, and the reshaped length.

Abstract: A process for forming a hydroformed automotive component with an integrally formed attachment bracket or weld flange begins with a tubular blank manufactured through a roll-forming process to convert sheet metal into a tubular body portion having excess parent sheet metal material extending past the tube weld joint to define an integrated flange. This integrated flange tubular blank is then placed into a forming die and subjected to a conventional hydroforming manufacturing process to form the automotive component into the desired shape and configuration. One side of the forming die is formed with a slot defining a gap in which the integrated flange material is received to create the weld flange or attachment bracket when the die is closed against the integrated flange material while the hydroforming process is undertaken. Alternatively, the integrated flange material could be welded onto the tubular blank during the formation of the tubular blank.

Abstract: A punch for a hydroforming die includes a body, a neck extending axially from the body, a head extending axially from the neck and having a diameter less than a diameter of the body and a thumbnail slot extending axially and radially into the head to allow fluid within a tubular member to force a wall portion of the tubular member outward into the slot of the punch and be sheared by the punch to produce an opening in the tubular member.

Abstract: The hydroforming tool of the present invention comprises a pair of upper and lower tool inserts having open axial ends and defining an elongated cavity there between when the tool inserts are forced together. The upper and/or lower tool inserts are composed of segments that are attached to the upper and a lower base plates, by bolts. Retaining elements, such as pins, are introduced into holes in the base plates and continues into cavities formed in the segmented inserts. This prevents the insert segments from moving during the forming operation. In this way the use of base blocks may be omitted. Sometimes the friction force acting between the base plate and segmented inserts, caused by the high pressure applied to the tool surfaces, is sufficient to prevent the separation of the segments, whereby the segments are kept in place without the use of retaining elements.

Abstract: In hydroforming of hollow metal articles in a die, such as pressure-ram-forming procedures, a method of decreasing cycle time of the forming process, while ensuring acceptable product properties and avoiding failures, by modeling the process using finite element analysis to establish a pressure-time history that optimizes the forming operation and applies failure limits to selected variables such as minimum wall thickness or maximum strain rate, and transferring this pressure-time history to a computer controlling the forming process. Thermocouple and/or continuity sensors are incorporated into the die wall and connected to the computer so as to provide active feedback from the die to the control of the process.

Abstract: This invention relates to a method for molding a bicycle tube and the method comprises the following steps: first, providing a tube and then controlling thickness of the tube by a drawing and extruding process for forming a molding portion. Second, plasticize other portions of the tube into particular diameters and shapes by plasticizing processes. Third, hydroform the molding portion of the tube by a mold and a hydroforming device for forming particular three-dimensional shapes. By applying to the above-mentioned method, the tube could be molded into a three-dimensional, unique and delicate shape.

Abstract: A double action punch assembly for a hydroforming die includes a first punch segment having an aperture extending therethrough. The double action punch assembly also includes a movable mounting block disposed in the aperture of the first punch segment. The double action punch assembly further includes a plurality of second punch segments connected to the mounting block. The first punch segment is moved in a first action to pierce a tubular member in a first direction and the second punch segments are moved in a second action to pierce the tubular member in a second direction to produce an opening in the tubular member.

Abstract: A method of forming a bottle-shaped or other contoured metal container by subjecting a hollow metal preform having a closed end to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired shape, and advancing a punch by means of a backing ram into the die cavity to displace and deform the closed end of the preform either before or after expansion begins but before it is complete. The pressure-subjecting step is performed by simultaneously subjecting the preform in the die cavity to independently controllable internal and external positive fluid pressures and varying the difference between them to control strain rate. Apparatus for performing the method includes a split die with plural split inserts disposed in tandem to define the die cavity wall and heaters respectively inserted within the preform and arranged to heat the backing ram.

Abstract: In an embodiment of the invention, there is disclosed a tubing expansion tool (300) comprising a body (302) adapted for rotation within tubing to be expanded, and three expansion member modules (306) each comprising an expansion member (310) rotatably mounted with respect to the body (302), each expansion member module (306) being releasably coupled to the body (302) as a unit.