Abstract: The present invention relates to a heating and forming apparatus for sheet material and method for rapid heating and shaping of sheet material. The apparatus comprises a first and second respectively movable forming dies, with the first forming die having a forming surface and defining a cavity with the second forming die. The apparatus is adaptable to receive a sheet material positionable within the cavity. A heating mechanism is placed within the cavity to heat the sheet material. The forming surface of the first forming die is not substantially heated. A pressurization mechanism is in communication with the cavity to move the sheet material into conformity with the forming surface of the first die. An improvement in the process of stretch forming a sheet material into a product by using quick plastic forming (QPF) or superplastic forming (SPF) is provided.

Abstract: The forming tool is provided for sheet-metal components and embodied in particular as a forming gripper. The forming tool can be positioned and handled in an automated manner by an industrial robot system. The forming tool has a component-probing system, which contains a probing element that is displaceable upon contact with the component. The displacement of the probing element can be ascertained by a measuring system. Furthermore, a suitable method for positioning the forming tool is provided.

Abstract: A guided keeper assembly and method for metal forming dies includes a base having a mounting face, a connector portion and a central aperture. A guide pin has a cylindrical center portion closely received in the central aperture of the base for reciprocation, an enlarged first end with an alignment member, and an outwardly opening circumferential groove. A retainer ring is removably mounted in and protrudes radially outwardly of the groove to securely, yet detachably, retain the base on the guide pin between the enlarged head and the retainer ring in an assembled condition to facilitate transport and mounting of the guided keeper assembly.

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: The present invention provides a method and apparatus for forming a sheet of ductal material by superplastic forming. The gas pressure is varied to control the material flow during the forming process. Accordingly, the gas pressure can be increased or decreased to control the rate of deformation of the workpiece. Accordingly, the method and apparatus contemplates the use of predetermined pressure profiles to reduce the overall forming time.

Abstract: A hydroforming device includes a top die and a bottom die, set between which is a metal element to be formed and which are pressed against one another during a hydroforming process. A relative movement of the two dies between the open condition and the closed condition is controlled by a hydraulic cylinder. The opening of the two dies during the hydroforming process, when the forming cavity is filled with liquid at a high pressure, is prevented by applying on the two dies a force generated by means of two wedge-shaped members, which are horizontally mobile, controlled by respective actuator means and having inclined surfaces in contact with corresponding inclined surfaces of a vertically mobile member. The mobile member and the hydraulic cylinder are set operatively in series between one and the same die of the two dies and the base of the hydroforming cell.

Abstract: Disclosed is a method for producing a complex composite metal structure having a metallic foam substrate. A sheet metal structure is provided having a metallic foam precursor formed of metallic particles and foaming agents. The sheet metal structure is formed using quick plastic or superplastic formation processes. After or during the formation of the metal, the temperature of the metallic precursor is raised to a point that the foaming agent produces a metallic foam.

Abstract: The invention can be defined in its most general form as a device for sheet material corrugation by means of bending and can be used in production of light core for sandwich panels, and elements of heat-exchange apparatus. The device includes the pivotedly connected in-between shaping and auxiliary systems of dies (4) and the drive for their transformation including the system of vacuumization and the chamber (3) made of flexible gas-proof material where the latter of said systems is fixed. Used to set the system of shaping dies (4) into its initial plane state is the mechanism made in the form of rigid chamber with the perforated cap (2) providing the possibility to connect the chamber to the system of vacuumization. The device also includes the subsidiary flexible removable vacuum chamber (8) wherein the blank (6) from sheet material is placed in contact with the shaping system of dies (4).

Abstract: A method and apparatus for forming a sheet of ductile material by superplastic forming is disclosed. The method is directed to first creating a pre-form by mechanical forming in which the pre-form is created with a die and punch. Thereafter the pre-form is subjected to gas pressure in a forming cavity to complete formation of the part. A metallic gasket is provided to ensure that no pressurized gas escapes from the forming cavity.

Abstract: A press plant includes a press of pressure cell type, into which a tray device, which defines a space intended to receive a workpiece and, optionally, a forming tool, is insertable. The tray device comprises a tray plate and a tray frame. The tray frame is adapted to independently withstand, at least in certain portions, loads applied during the pressing operation. The tray device is divisible into at least an upper part and a lower part. The invention also relates to a method and use of a tray device in a press plant.

Abstract: A method of manipulating and forming material where the material is a metal blank. The blank is inserted into an electromagnetic field that keeps it in levitation and heats it up to the temperature between solid state and liquid state. Temperature is measured by infrared thermometer. After the blank reaches the required temperature it is formed to the desired shape by external force. The temperature changes during the forming phase and this change can be controlled or uncontrolled. Forming of levitated blank is done by changing position of levitation device by inserting the blank between forming tools or levitated blank stays in place and forming tools move towards it and then the forming takes place.

Abstract: The invention relates to a vacuum-assisted method and a device for forming an essentially flat blank (12) of metal into a thin-walled, shell-type body (14), especially for performing the method in accordance with one of the preceding claims, that has a supporting structure (16) forming a mold chamber (18) that holds the blank (12) during increasing deformation into the thin-walled, shell-body (14), a device (20) allocated to the supporting structure (16) for clamping the blank (12) about its circumference (22) to the supporting structure (16), that seals the reverse face (24) of the blank (12) facing towards the mold chamber (18) against the front face (26) of the blank (12) facing away from the mold chamber (18), and a device (28) allocated to the mold chamber (18) that also communicates with the mold chamber (18) for applying a vacuum and evacuating the mold chamber (18), and at least one forming tool (50) applied to the front face (26) of the blank (12) is/are allocated to the supporting structure (16), an

Abstract: A hydroforming device includes a top die and a bottom die, set between which is a metal element to be formed and which are pressed against one another during a hydroforming process. A relative movement of the two dies between the open condition and the closed condition is controlled by a hydraulic cylinder. The opening of the two dies during the hydroforming process, when the forming cavity is filled with liquid at a high pressure, is prevented by applying on the two dies a force generated by means of two wedge-shaped members, which are horizontally mobile, controlled by respective actuator means and having inclined surfaces in contact with corresponding inclined surfaces of a vertically mobile member. The mobile member and the hydraulic cylinder are set operatively in series between one and the same die of the two dies and the base of the hydroforming cell.

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 bi-material die apparatus for high temperature forming of metal parts has at least two opposing die segments having inner surfaces together forming a hollow mold chamber for receiving a mold blank between the die segments. The die segments are of a first material having a first coefficient of thermal expansion CTE1. At least one insert of a second material is associated with the inner surface of at least one of the die segments so as to project into the mold chamber, the second material having a second coefficient of thermal expansion CTE2 higher than CTE1 and higher than the coefficient of thermal expansion of the metal product to be formed in the cavity.

Abstract: A bi-material die apparatus for high temperature forming of metal parts has at least two opposing die segments having inner surfaces together forming a hollow mold chamber for receiving a mold blank between the die segments. The die segments are of a first material having a first coefficient of thermal expansion CTE1.

Abstract: A titanium sheet to be formed is heated in a sealingly closed tool by the radiation heat from the heating elements integrated into the tool to a forming temperature not exceeding 600° C., and is deformed towards a cold tool contour by the action of a non-oxidizing gaseous pressure medium introduced into the tool and heated to the hot-forming temperature, as well as by underpressure generated on the side of the workpiece facing away from the pressure medium.

Abstract: A method for superplastically forming a preform to manufacture a structural assembly with a contoured configuration is provided. The preform includes first and second structural members in a stacked configuration, with at least one additional peripheral member abutting the stack and joined thereto by a friction welded butt joint. In some cases, the preform defines dissimilar forming characteristics throughout, such as variations in material or thickness according to the amount of superplastic forming to be performed in each portion of the preform.

Abstract: The invention concerns a clamping device for a device for the production of metal parts by forming with a closed forming tool, the clamping device comprising at least several tension hoops (2), these tension hoops (2) each being provided with at least one tension frame (2.2) of a closed contour, the tension frame being provided with two segments (2.3) arranged opposite each other at some distance, between which a forming tool (12) can be arranged, each of these segments (2.3) being provided with at least either one bearing surface (2.1) or one bearing surface (2.4), and the tension hoops (2) being each linked by at least one articulated joint (8) in order to be pivoted, a bearing surface (3.1) which is located above or on the upper surface of the forming tool (12) and used as support for a bearing surface (2.1) of a tension hoop (2), and a device (5) which generates a clamping force of more than 3 MN and is composed of several power-generating elements.

Abstract: A sheet metal forming process and apparatus using both a mechanical forming step and a superplastic forming step. The mechanical forming step includes using a double-action draw die to create a preform. The preform is then transferred to a superplastic forming tool that uses a superplastic forming process to complete the forming process and create a finished workpiece. Using the mechanical forming step enables rapid creation of a preform having a geometry that reduces overall forming time and provides the ability to draw in additional material to reduce part thinning.

Abstract: A superplastic forming apparatus and method for forming a sheet of material at an elevated temperatures into a workpiece having a complex geometry. The process takes advantage of a mechanical forming step, which draws material along a major axis to form a first preform. Upon completion of the first mechanical forming step, a second, initial superplastic forming step ask on the first preform to create a second preform having a plurality of channels or grooves located thereon. The grooves or channels function to draw additional material prior to the second or final gas forming step, which completes the forming process by driving the material against a forming surface. Accordingly, the method and apparatus function to reduce forming time and eliminate thinning and wrinkling of the sheet material during the forming process.

Abstract: Method of preforming and forming a sheet metal article from a preheated blank of sheet metal uses opposing dies including a punch having a punch surface defining a final configuration for the article and a cavity die having a cavity surface defining a preform configuration. The blank is placed between the dies and has a first side surface facing the cavity die and a second side surface facing the punch. A vacuum is applied to the first side of the blank to draw and shape the blank into the cavity die to a preform configuration conforming to the cavity surface. The punch and the cavity die are then closed toward one another and gas pressure is then applied to the first side surface of the blank to press the second side surface against the punch surface to the finish configuration.

Abstract: The invention relates to a forming die having a cavity which forms a shaping space and into which a workpiece can be introduced. A passage, which connects the shaping space to the area surrounding the die, runs within the forming die. To achieve a contour during the shaping of the workpiece which is unaffected by the arrangement of passages connecting the shaping space to the area surrounding the die in a simple way, it is proposed that the die contains a liquid-permeable and gas-permeable insert body, which is held in a recess of the die near to the shaping space and by means of a peripheral region facing the shaping space forms a section of the cavity, and that the passage opens out at the insert body outside this peripheral region.

Abstract: An apparatus for forming blanks having two thicknesses separated by a blank step includes a forming tool defining a binder surface that is characterized by a tool step, a first region on a first side of the tool step, a second region on a second side of the tool step, and a bead segment having a surface contiguous with the second region. The bead segment is configured to pinch material from a blank into any gap created between the tool step and the blank step caused by misalignment of the blank in the tool, thereby ensuring an effective seal to form the blank against a forming surface.

Abstract: The invention relates to a press of pressure cell type, which comprises a press chamber in which a diaphragm device is arranged. The diaphragm device includes a diaphragm which together with a press plate forms a pressure cell and is adapted to exert a forming pressure on a workpiece in the press chamber. The edge area of the diaphragm is placed in an annular diaphragm support. The press of pressure cell type also comprises actuating means which are adapted to actively exert a force on the diaphragm support in the direction of the press plate, the diaphragm support pressing the edge area of the diaphragm against the press plate so that an initial seal is provided between the diaphragm at its edge area and the press plate, which seal is built up when supplying pressure medium to the pressure cell by expansion of the diaphragm. The invention also relates to a diaphragm device, a method for applying a pressing power and a method for exchanging a diaphragm in a press of pressure cell type.

Abstract: A superplastic forming tool for forming a workpiece to make a part. The forming tool includes a forming die having first and second die members. At least one of the die members having a cavity including a forming surface and a plenum. A plurality of passageways extend between the plenum and the cavity. The passageways allow passage of fluid between the cavity and the plenum.

Abstract: A hydroforming machine characterized by a die 2 having an opening on the upper surface and a fluid tank 2a filled with fluid, a holder 3 being able to hold a periphery part between the die 2 and itself, a punch 4 being movable in a direction into or out for the fluid tank 2a, and a pressure controller 5 controlling the fluid pressure in the fluid tank 2a according to the position of the punch 4.

Abstract: A high-pressure press includes a pressure vessel surrounded by a force-absorbing press frame. The high-pressure press also includes a detection structure for detecting changes in length of at least one column comprised in the press frame, the changes in length depending on the pressure inside the pressure vessel. The detection structure includes a limit switch, which is adapted to detect if the change in length of the column has reached a threshold value and, in that case, interrupt a pressing operation in progress and reduce the pressure inside the pressure vessel.

Abstract: A system and method for superplastic forming a workpiece. The system includes a superplastic forming cell formed of a plurality of individual stations or modules, each one performing a specific manufacturing step or process on the workpiece. Individual stations include a preheat station, a forming station, a cooling station, a cleaning station and a trimming station. These stations work in conjunction with one another to reduce superplastic forming cycle times and correspondingly increased production times when manufacturing a workpiece using a superplastic forming process.

Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.

Abstract: An apparatus (10, 110) and method to form a workpiece (32, 132) into a useful product (28, 128) using a pressurized fluid (14), also termed as “hydroforming”. The workpiece may be a tube or may be one or a plurality of sheets of a material. The apparatus has a chamber (12) adapted to contain a quantity of a fluid, a hydroforming means positioned within the chamber, and means for substantially immersing the workpiece in the fluid before, during and after the hydroforming operation. Dies (16, 18) enclose the workpiece and provide a cavity of desired shape against which the workpiece is expanded by the pressurized fluid. The chamber may be open or closed to the atmosphere during operation and the fluid temperature and/or level may be controlled.

Abstract: A method for hot hydrostatic pressing by means of working liquid which tends to become unstable within a transition time when in contact with a blank heated to a high working temperature and at a pressure lower than the liquid's stabilization pressure. The pressing of the blank heated to the high working temperature is carried out by raising the pressure of the working fluid to said stabilization pressure for a time shorter than the transition time. This is achieved by surrounding the heated blank by a cover adapted to delay the contact between the heated blank and the working liquid until the pressure in the working chamber is raised.

Abstract: An apparatus and method of applying a lubricating material to an outer surface of a workpiece. Initially, a workpiece is provided that is preferably formed from a closed channel structural member having a circular or box-shaped cross sectional shape. Lubricating material is applied to an outer surface of the workpiece. In a second step of the method, the workpiece may be heat treated. The workpiece is then heated to elevate the temperature of the workpiece so as to cause the lubricating material to dry substantially immediately on the workpiece, thereby providing a coating of lubricating material having a substantially uniform thickness. In a fourth step of the method, a deforming process is performed on the workpiece during the period of time following the heat treatment process, and after applying the lubricating material, in which the workpiece retains the full or partial softening characteristics.

Abstract: A press and tooling apparatus for forming a preheated blank includes a heated upper tool and an opposing heated lower tool mounted within the press for relative closing movement to press the preheated blank there between. A binder ring assembly surrounds the lower tool and is mounted on the press for movement relative to the lower tool so at to bind the preheated blank to the upper tool in air tight sealing relationship in readiness for closure of the tools and application of pressurized gas to force the blank into contact with the upper tools. The binder ring assembly includes an upper ring that is heated so as to prevent the cooling of the preheated blank, and a lower ring that supports the upper ring and is fixedly connected to the upper ring by spaced apart connectors so as to minimize the heat transfer path from the heated upper ring to the lower ring.

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: A hybrid metal forming system includes a die cavity defined by a first die and a second die and a press adapted to apply a static pressure over the first die to deform a workpiece against the second die. The hybrid forming system also includes a dynamic loading system coupled to and positioned between, the press and the die cavity.

Abstract: Apparatus for hot gas blow-forming including opposed heated and insulated tool containers, each including a tool heater plate that is adapted for attachment to a platen of a press with one or more load bearing spacers interposed between the tool heater plate and the platen. Each tool container also includes an insulation enclosure having a base portion that is interposed between the tool heater plate and the platen and further having perimeter wall portion that surrounds the tool heater plate. A perimeter seal is preferably attached to at least one of the heated and insulated tool containers and is adapted for sealing engagement with the other of the heated and insulated tool containers.

Abstract: The present invention relates to a method in a press of pressure cell type comprising a forming tool and, separated therefrom, a diaphragm, which define a forming space in which a blank is inserted for forming thereof against the forming tool by pressing the diaphragm against the blank. A blank portion projecting from the forming space is gripped by means of at least one gripping device and the connection between the blank and the gripping device is shielded from the diaphragm at least when the diaphragm is pressed against the blank. The invention further relates to a press of pressure cell type and a tray device.

Abstract: The present invention relates to a press of pressure cell type, a tray for use in a press of pressure cell type and a method. The tray comprises a tray frame, which defines a space for arranging a forming tool and/or a work-piece. Prestressing means are arranged on the external surface of the tray frame and induce a compressing prestress which acts in planes parallel to the plane of the tray. The tray frame presents a curvature along its entire circumference.

Abstract: An apparatus for hydraulic high-pressure forming of a sheet, the apparatus having a top tool and a bottom tool as well as at least one pressure generating unit arranged between the press ram of a mechanical press and the top tool and uses a pressurized medium from the pressure generating unit as a working fluid for hydraulic preforming of the sheet. Contact faces of the tools directly engage with the sheet surface along the clamping area thereof and act to seal off the forming area that are subjected to the working fluid solely by contact sealing.

Abstract: A press of pressure cell type, which comprises a press chamber in which a diaphragm device is arranged. The diaphragm device comprises a diaphragm which together with a press plate forms a pressure cell and is adapted to exert a forming pressure on a workpiece in the press chamber. The edge area of the diaphragm is placed in an annular diaphragm support. The press of pressure cell type also comprises actuating means which are adapted to actively exert a force on the diaphragm support in the direction of the press plate, the diaphragm support pressing the edge area of the diaphragm against the press plate so that an initial seal is provided between the diaphragm at its edge area and the press plate, which seal is built up when supplying pressure medium to the pressure cell by expansion of the diaphragm. The invention also relates to a diaphragm device, a method for applying a pressing power and a method for exchanging a diaphragm in a press of pressure cell type.

Abstract: A clamp assembly for a hydroforming die includes a stationary lower bed to support a lower die half of the hydroforming die, a stationary upper bed spaced above the lower bed, at least one guide post extending between the lower bed and the upper bed, a movable slide disposed between the upper bed and the lower bed and movable along the at least one guide post to support an upper die half of the hydroforming die, a lifting cylinder operatively connected to the movable slide to move the movable slide and upper die half toward and away relative to the lower die half, at least one link mechanism connected to the upper bed and the movable slide to equalize a force on the hydroforming die, and at least one linkage cylinder operatively connected to the at least one link mechanism to activate the at least one link mechanism to prevent the movable slide and upper die half from moving away from the lower die half to keep the hydroforming die closed during a hydroforming process.

Abstract: Disclosed is a method of forming metallic composite structures The method utilizes superplastic and quickplastic formation methodologies in conjunction with the use of appended engineered metallic foams to provide energy absorbing materials.

Abstract: An apparatus and method for removing a part from a forming tool and supporting the part. The apparatus includes a support member having a surface contoured to conform to a formed shape of the part and an aperture disposed in the surface. A manipulator moves the support member near the part while the part contacts the forming tool. Pressurized gas is directed toward the part to cause the release of the part from the forming tool and to cool the part. The surface supports the part to inhibit distortion as the part cools.

Abstract: A hot blow-forming apparatus includes opposed and complementary forming tools adapted for hot blow forming a surface of a heated sheet-metal workpiece against a forming surface of one of the tools. The tools are also adapted to close upon and grip a peripheral edge of the workpiece and perform work on a central portion of the workpiece to produce a formed panel. The tools incorporate an improved extraction apparatus, which includes a plurality of opposed and complementary spring-loaded extractor pads. Opposed extractor pads are spring-loaded to different levels so as to apply spring-load differentials therebetween and thereby apply different extraction forces in different locations of the resultant formed panel for distortion-free removal of the formed panel from the working surfaces of the tooling.

Abstract: A device for manufacturing formed parts by internal high pressure deformation. The device includes a housing composed of two tubular members which are placed one into the other and are connected by shrinkage, wherein the tool support unit is mounted in the concentric bore of the inner tubular member.

Abstract: A method of quick-plastic-forming a component from a sheet metal blank in multiple forming stages of single-action tooling along a transfer line. The blank is transferred from a prebending station to a preforming station along the transfer line, wherein the blank is preformed by a single-action forming tool into a preform blank. The preform blank is then transferred from the preforming station to a finish-forming station along the transfer line, wherein the blank is finish-formed by a single-action forming tool into the component. The component is transferred from the finish-forming station to a cooling station along the transfer line. The transfer steps are carried out by a reciprocating transfer mechanism that simultaneously transfers the blanks and component from station to station along the transfer line.

Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.

Abstract: The distortion-free removal of a heat softened sheet metal part from a heated forming surface is enabled by the elevation of lift pads in the forming surface. Strategically located and sized pads are recessed in the forming surface of the hot forming tool and the pads are part of the forming surface. At the completion of the stretch forming, or other hot forming, of a sheet metal blank on the forming surface, the pads are lifted in unison, without rotating them, on lift posts by a suitable lift mechanism to carefully and uniformly strip the flexible part from the hot forming surface.

Abstract: A forming tool (1) for hydromechanically deep-drawing workpieces from sheet metal blanks (2), the tool comprising a water tank (3), which acts as a lower tool and can be filled with a liquid active medium (8), thus forming the drawing die. The tool is also provided with a drawing ring (10), which is located in the upper section of the water tank (3) and is sealed against a volume of the active medium lying below. The boundary of the ring aperture (11) of the drawing ring (10) forms a drawing edge for the workpiece (2). The forming tool also comprises a drawing punch (9), which can be displaced with the sheet metal blank (2) interposed, through the ring aperture (11) of the drawing ring (10) into the section containing the active medium (8), whereby the sheet metal blank is pressed onto the drawing punch (9) using a reaction pressure as the application pressure, by means of a targeted displacement of the active medium (8).