Using Fixed Die Patents (Class 72/60)
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Patent number: 7003996Abstract: A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell formed from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank, placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.Type: GrantFiled: July 3, 2003Date of Patent: February 28, 2006Assignee: Hot Metal Gas Forming Intellectual Property, Inc.Inventors: William C. Dykstra, George D. Pfaffmann, Xin Wu
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Patent number: 6997025Abstract: A super-plastic forming tool for forming aluminum sheets is provided that includes a seal bead that is configured to facilitate removal of the aluminum sheet from the seal bead after a super-plastic forming operation. Contraction of the aluminum sheet at a faster rate than the super-plastic forming tool facilitates removal of the aluminum sheet due to the specific geometry of the seal bead. The seal bead has a more shallowly sloped outer surface than its inner surface and may be provided in different configurations including flat, convex, concave shapes.Type: GrantFiled: March 6, 2003Date of Patent: February 14, 2006Assignee: Ford Motor CompanyInventors: Peter A. Friedman, Warren Benjamin Copple, George Luckey, Jr.
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Patent number: 6966209Abstract: An internal high-pressure deformation method for the production of in particular bulging out closed hollow bodies and a corresponding device are disclosed. At least two workpiece parts (1,2) are employed, wherein at least one of the two workpiece parts (1,2) preformed of cup shape and exhibits a flange, and are pressure agent sealingly pressed in the region of the flanges (1.1,1.2) in the deformation tool according to the invention such that the two work tool pieces (1,2) are together deformed by the internal high-pressure deformation method and are further processed separately or jointly after the internal high-pressure deformation. The apparatus is subdivided in tool regions (E1, E2, E3, E4) corresponding to the work piece forms to be generated and corresponding to the number of the workpiece parts (1,2), wherein the tool regions (E1, E2, E3, E4) are disposed in different planes (FIG. 2).Type: GrantFiled: February 22, 2000Date of Patent: November 22, 2005Inventor: Bernd Schulze
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Patent number: 6938450Abstract: The tensioner assembly is provided for clamping at least two objects and comprises a tie rod member, a thrust ring positioned on the tie rod member against one of the objects, a first retaining member for removably engaging a distal end of the tie rod member, and a second retaining member for removably engaging the distal end of the tie rod member between the thrust ring and said first nut member and spaced apart therefrom. Each of the first and second retaining members is provided with a set of jackbolts adapted to engage complementary holes therein and to extend from the holes to compressively bias the thrust ring. The total load experienced by the tensioner assembly is shared by two retaining members so that load carried by the first retaining member remains substantially constant during operation, while the second retaining member is subject to stress variation.Type: GrantFiled: February 7, 2003Date of Patent: September 6, 2005Assignee: Dana CorporationInventors: Ouqi Zhang, James P. Larkin
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Patent number: 6935150Abstract: The mould (10) includes at least one part (20), intended to be in contact with the component (12) being moulded, made from sintered vitreous silica. According to the process, said component (12) is formed by the superplastic forming in the mould (10) of a plate (18) made of a material capable of undergoing superplastic deformation, for example titanium or titanium alloy, aluminium or aluminium alloy, or any material exhibiting superplastic properties. Preferably, a barrier is formed between at least a part of the contact surfaces of the mould (10) and the component (12) being moulded, for example by coating with boron nitride, at least partially, the contact surfaces of the mould (10) and the component (12) being moulded, before placing the plate (18) in the mould (10), and/or by injecting an inert gas, notably helium or argon, between the contact surfaces of the mould (10) and the component (12) being moulded.Type: GrantFiled: September 12, 2001Date of Patent: August 30, 2005Assignee: Vesuvius Crucible CompanyInventors: Daniel Merle, Frédéric Caillaud
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Patent number: 6935151Abstract: A hot forming die (10) has forming surfaces (16,18) and the forming surfaces have a nickel oxide layer (20). A stop off material coating (22) builds up on the nickel oxide layer (20) in operation. A method of cleaning the forming surfaces (16,18) of the hot forming die (10) includes washing the forming surfaces (16,18) of the hot forming die (10) in water to remove the stop off material (22) without removing the nickel oxide layer (20) from the forming surfaces (16,18). The forming surfaces (16,18) may be soaked in water (26) and/or a jet (30) of pressurized water may be directed onto the forming surfaces (16,18). The stop off material is quickly removed without damaging the forming surfaces (16,18). The retention of the nickel oxide layer (20) improves the quality of the hot-formed articles and the interval between cleaning of the hot forming die (10) is increased.Type: GrantFiled: May 30, 2003Date of Patent: August 30, 2005Assignee: Rolls-Royce plcInventor: John Hewitt
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Patent number: 6907761Abstract: A method of superplastically forming a workpiece comprises placing the workpiece (16) in a die (14) and heating the workpiece (16) to a temperature at which the workpiece (16) is superplastically formable. Pressure is applied to the workpiece (16) to superplastically form the workpiece (16) to the shape of the die (14). The temperature of the workpiece (16) is measured and is analysed to determine the measured temperature distribution of the workpiece (16) at stages in the superplastic forming process. A database of desired temperature distributions of the workpiece (16) at different stages in the superplastic forming process is kept.Type: GrantFiled: June 17, 2002Date of Patent: June 21, 2005Assignee: Rolls-Royce plcInventors: Peter J Spence, Richard G Milburn
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Patent number: 6884976Abstract: An apparatus and a method for forming a localized joint in at least one structural member are provided. The apparatus includes a tool that corresponds to a joint portion of the structural member. An induction coil is disposed in the tool, and a power source is configured to energize the induction coil. A susceptor disposed between the tool and the structural member has a Curie temperature at which the susceptor becomes paramagnetic such that an electromagnetic field induced in the susceptor by the induction coil heats the susceptor to the Curie temperature for forming the joint.Type: GrantFiled: November 27, 2002Date of Patent: April 26, 2005Assignee: The Boeing CompanyInventors: Marc R. Matsen, Terry L. Smith
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Patent number: 6843089Abstract: The present invention provides a method of embossing or imprinting patterns in the surface of a sheet metal article using superplastic forming at suitable SPF temperatures. A template having a pattern is interposed between a forming tool and a sheet metal blank. Gas pressure is applied to the sheet metal blank. This pressure forces the sheet metal against the surface of the lower forming tool having the template there between. The sheet metal blank is stretch formed according to the contours of the surface of the lower forming press and the template. The embossed and shaped sheet metal part is then removed from the forming tool.Type: GrantFiled: October 23, 2002Date of Patent: January 18, 2005Assignee: General Motors CorporationInventors: Paul Edward Krajewski, George M. Barton, Gary A. Kruger
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Patent number: 6843088Abstract: Apparatus and method for hot blow-forming an article from a blank of sheet metal. Simultaneously, a surface of the blank of sheet metal is formed against a form tool body that partially defines a forming surface and against a form tool insert that also partially defines the forming surface and that is positioned within a recess of the form tool body such that a lateral gap is defined between the form tool insert and form tool body. Opposed projections are provided on upper surfaces of the form tool insert and the form tool body adjacent the gap. The projections create a raised portion on the sheet metal panel that corresponds to the gap. The raised portion is removed flush with respect to a visible surface of the article.Type: GrantFiled: February 13, 2004Date of Patent: January 18, 2005Assignee: General Motors CorporationInventors: Gary A. Kruger, Mark G. Konopnicki, Chongmin Kim
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Patent number: 6837087Abstract: A blank positioning and guide construction which includes guide pin slotting that effects the accurate positioning of the sheet on the forming die and guide pin thereof and which provides for the enlargement of the guide pin slot by the predetermined deformation of portion of the sheet at a predetermined bend line adjacent to the guide pin slot to eliminate adherence of the part to the pin so that the part can be ejected from the die without detrimental part distortion of the part.Type: GrantFiled: September 13, 2002Date of Patent: January 4, 2005Assignee: General Motors CorporationInventors: Richard Murray Kleber, Donald L. Kenyon, Verril J. Gamet
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Patent number: 6837088Abstract: A flask and tool assembly includes a forming tool insert that is housed within an insulated flask having four vertical sides. An insulation enclosure surrounds the flask and the flask contains a heater plate for contacting the bottom of the forming tool insert. The tops of the sides of the flask provide surfaces for gripping bottom edges of a sheet metal blank to be formed. A cover for the tool-containing flask provides complementary gripping surfaces for top edges of the sheet metal blank and defines a chamber above the sheet metal blank for pressurized forming gas. A peripheral seal underlies the sheet metal blank and bridges a space between the outer side surfaces of the forming tool insert and the inner surfaces of the sides of the flask, thereby obviating the need to provide a precision fit between the flask and forming tool insert.Type: GrantFiled: March 10, 2004Date of Patent: January 4, 2005Assignee: General Motors CorporationInventors: Richard Murray Kleber, Edward W. Bennett, Richard Harry Hammar
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Patent number: 6832501Abstract: The invention is for a method to produce components from a blank made of deep-drawable material using a free-flowing action medium. The method consists in clamping the blank in a forming device in which the action medium applies a pressure to the blank, preforming the blank be elevating the pressure exercised by the action medium in restricted areas of the blank and finish forming the preformed blank with a forming tool.Type: GrantFiled: September 30, 2002Date of Patent: December 21, 2004Assignee: Thyssenkrupp Stahl AGInventors: Tino Gruszka, Franz-Josef Lenze
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Publication number: 20040250585Abstract: 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.Type: ApplicationFiled: June 12, 2003Publication date: December 16, 2004Inventors: Edward W. Bennett, Leonard L. Pollum, Gary A. Kruger
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Publication number: 20040172998Abstract: A super-plastic forming tool for forming aluminum sheets is provided that includes a seal bead that is configured to facilitate removal of the aluminum sheet from the seal bead after a super-plastic forming operation. Contraction of the aluminum sheet at a faster rate than the super-plastic forming tool facilitates removal of the aluminum sheet due to the specific geometry of the seal bead. The seal bead has a more shallowly sloped outer surface than its inner surface and may be provided in different configurations including flat, convex, concave shapes.Type: ApplicationFiled: March 6, 2003Publication date: September 9, 2004Applicant: FORD MOTOR COMPANYInventors: Peter A. Friedman, Warren Benjamin Copple, George Luckey
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Patent number: 6779374Abstract: In a system and method for bulge forming an article including a shaped portion from blank stock, the system includes a cage section adapted to enable the blank stock to be positioned and enclosed therein, and a die element, for enabling the shaped portions of the article to be formed thereagainst, adapted to be enclosed in the cage sections. The system further includes a flexible member, adapted to be enclosed in the cage sections, and to bulge therein upon the application of pressure to the flexible member. The flexible member is also adapted to push into and exert pressure on the blank, and to bend the blank relative to the die element to form the shaped portion of the article. The system also includes a flexible tube, for enabling expansion of the flexible member upon pumping a pressure exerting medium therethrough into the flexible member, to exert pressure on the blank and form the shaped portion of the article against the die element.Type: GrantFiled: September 13, 2000Date of Patent: August 24, 2004Assignee: Klune Industries, Inc.Inventor: Gerardo Roldan
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Patent number: 6745604Abstract: An apparatus for forming a metal piece at an elevated temperature comprises a part having a binding surface configured to hold the metal during forming, wherein the binding surface comprises a porcelain enamel coating. The apparatus may be a superplastic forming process, and the binding surface may have an enamel coated seal bead that cooperates with a second binding surface of a second binding surface to form a seal about a perimeter of a metal sheet that is formed into a desired shape.Type: GrantFiled: March 13, 2003Date of Patent: June 8, 2004Assignee: General Motors CorporationInventor: Arianna T. Morales
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Publication number: 20040103707Abstract: The invention relates to a hydroforming device and a hydroforming process and also to a hydroforming die arrangement.Type: ApplicationFiled: December 3, 2003Publication date: June 3, 2004Inventor: Andreas Winters
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Publication number: 20040079129Abstract: The present invention provides a method of embossing or imprinting patterns in the surface of a sheet metal article using superplastic forming at suitable SPF temperatures. A template having a pattern is interposed between a forming tool and a sheet metal blank. Gas pressure is applied to the sheet metal blank. This pressure forces the sheet metal against the surface of the lower forming tool having the template there between. The sheet metal blank is stretch formed according to the contours of the surface of the lower forming press and the template. The embossed and shaped sheet metal part is then removed from the forming tool.Type: ApplicationFiled: October 23, 2002Publication date: April 29, 2004Inventors: Paul Edward Krajewski, Georg M. Barton, Gary A. Kruger
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Patent number: 6725519Abstract: A method of making a gas tank includes hydroforming two halves and welding the halves together. Two types of welds are used in welding the two halves together, tack welds for holding the two halves together, and stitch welds to complete the welding of the two halves. Additional steps are taken prior to the finishing stitch welds. Reinforcement is added where necessary. Double tanks, for both gasoline and oil, are also fabricated by essentially the same method steps.Type: GrantFiled: March 14, 2002Date of Patent: April 27, 2004Inventor: Kyle P. Krejci
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Publication number: 20040074274Abstract: 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).Type: ApplicationFiled: September 2, 2003Publication date: April 22, 2004Inventors: Christian Donhauser, Wolfgang Rauh
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Publication number: 20040050128Abstract: A blank positioning and guide construction which includes guide pin slotting that effects the accurate positioning of the sheet on the forming die and guide pin thereof and which provides for the enlargement of the guide pin slot by the predetermined deformation of portion of the sheet at a predetermined bend line adjacent to the guide pin slot to eliminate adherence of the part to the pin so that the part can be ejected from the die without detrimental part distortion of the part.Type: ApplicationFiled: September 13, 2002Publication date: March 18, 2004Inventors: Richard Murray Kleber, Donald L. Kenyon, Verril J. Gamet
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Publication number: 20040035168Abstract: The lower part of a material to be molded forms a lower, seal with a die. A punch applying a molding force to the material forms an upper seal with the perimeter of the die. The space between the upper and lower, seals forms a pressure chamber that is filled with a fluid. As the punch descends into the die, the fluid is pressurized. The lower seal is a complete seal to prevent leakage of fluid into the die. The upper seal is given a clearance with the die that permits controlled leakage of fluid therepast at a rate that limits the maximum pressure in the pressure chamber while permitting the development of an adequate pressure on the material being molded.Type: ApplicationFiled: May 6, 2003Publication date: February 26, 2004Applicant: AIDA ENGINEERING CO., LTD.Inventors: Hisanobu Kanamaru, Kazuto Kobayashi
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Publication number: 20040035167Abstract: 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.Type: ApplicationFiled: July 29, 2003Publication date: February 26, 2004Inventors: Victor Lugovskoy, Vladimir Magaziner, Vitaly Chertkov, Guy Danieli
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Patent number: 6694790Abstract: Superplastic forming of sheet metal blanks is advanced both is quantity and quality with the utilization of a part separating and pressure distributing mid plate sandwiched between a pair of blanks. This arrangement is loaded between upper and lower die halves operatively mounted in a heated press which closes to effect the piercing of one of the blanks by a nozzle which subsequently delivers pressurized air or other inert gas to an intermediate chamber formed by the mid plate between the blanks to effect the simlayaneously forming of separate parts in both forming dies.Type: GrantFiled: April 17, 2002Date of Patent: February 24, 2004Assignee: General Motors CorporationInventors: Edward Frank Ryntz, Richard Murray Kleber
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Patent number: 6684475Abstract: 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.Type: GrantFiled: March 26, 2001Date of Patent: February 3, 2004Assignee: HDE Solutions GmbHInventors: Stefan Geissler, Karl Norbert Lohmann, Theodor Ostermann, Matthias Adolph
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Patent number: 6675621Abstract: Superplastic forming tools and method in which pairs of stacked metal blanks are serially loaded between heated forming dies that are moved to a closed position on each of the pair of blanks so that a partial perimeter gas seal is established therebetween. A pressure wedge is then introduced between the two blanks along one edge of the pair to act as a stopper or air seal to complete perimeter sealing thereof. The pressure wedge also establishes the operative position of a gas injection port, which directs pressurized air interiorly of the completed perimeter seal of the pair of blanks to force the blanks in opposite direction for the superplastic forming of a pair of discrete parts. The wedge and forming dies are then opened for the removal of a pair of formed parts and for the subsequent loading of additional pairs of stacked sheets for their simultaneous superplastic forming into pairs of parts.Type: GrantFiled: September 10, 2001Date of Patent: January 13, 2004Assignee: General Motors CorporationInventor: Richard Murray Kleber
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Process for manufacturing large area sheet metal parts, in particular a body component for a vehicle
Patent number: 6675620Abstract: A process for the manufacture of a large area sheet metal part, in particular a body component for a vehicle, from a flat blank, provides that one sided pressurization with an active medium in a forming tool gives the flat blank a prestretched preform, and that then the preform, removed from the forming tool, is formed into the final shape in a separate deep drawing tool.Type: GrantFiled: November 6, 2000Date of Patent: January 13, 2004Assignee: Dr. Ing. H.C.F. Porsche AGInventors: Rolf Heyll, Robert Koehr -
Patent number: 6672121Abstract: A method is disclosed for forming a hem flange in an aluminum alloy sheet during the forming of the sheet into a panel that is intended to be attached to a second panel by hemming. The hem flange is formed by fluid pressure over a small radius tool portion to bend the flange from the sheet material and stretch the flange material below the bend to form a thinned hemline valley in the material. The original bend and thinned valley cooperate during the folding of the flange around the second panel to form a flat pinched hem without cracking or fracturing the flange material.Type: GrantFiled: April 15, 2002Date of Patent: January 6, 2004Assignee: General Motors CorporationInventors: John E. Carsley, Chongmin Kim, John Robert Bradley, George K. Nurminen
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Patent number: 6672125Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.Type: GrantFiled: January 21, 2003Date of Patent: January 6, 2004Assignee: The Boeing CompanyInventors: Phillip E. Kenney, Jeffrey D. Fletcher, Dennis R. Malone, Lawrence B. Wilson
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Patent number: 6655181Abstract: A coating for superplastic forming (SPF) and quick plastic forming (QPF) tooling and an SPF/QPF process made possible with the coating. The coating defines the forming surface of an SPF/QPF tool, and consists essentially of either a tungsten carbide cermet or a chromium carbide cermet. The coating preferably comprises a metal matrix containing tungsten carbide or chromium carbide particles having a particle size of not more than 0.1 micrometer, and is preferably prepared to have a surface finish of not rougher than 0.3 micrometer Ra. An SPF/QPF process that makes use of a tool whose forming surface is provided with the coating can be performed without depositing any lubricant on the forming surface or workpiece.Type: GrantFiled: October 15, 2001Date of Patent: December 2, 2003Assignee: General Motors CorporationInventor: Arianna T. Morales
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Patent number: 6651327Abstract: A fuel rail formed by hydroforming. The hydroforming process includes applying a seal onto a fuel tube, and installing fuel injector blocks, including fuel injector ports, onto the tube in desired positions. The fuel tube assembly is placed in a die assembly, and pressurized fluid is supplied to the interior of the tube. The pressurized fluid causes the tube to expand outwardly into engagement with the blocks, and to pierce holes through the tube within each of the blocks to provide fluid communication with the associated fuel injector and other ports.Type: GrantFiled: December 10, 2001Date of Patent: November 25, 2003Assignee: Dana CorporationInventors: Randall F. Alder, Nicholas O. Kaltsounis, Donald B. Ford
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Publication number: 20030196466Abstract: Superplastic forming of sheet metal blanks is advanced both is quantity and quality with the utilization of a part separating and pressure distributing mid plate sandwiched between a pair of blanks. This arrangement is loaded between upper and lower die halves operatively mounted in a heated press which closes to effect the piercing of one of the blanks by a nozzle which subsequently delivers pressurized air or other inert gas to an intermediate chamber formed by the mid plate between the blanks to effect the simlayaneously forming of separate parts in both forming dies.Type: ApplicationFiled: April 17, 2002Publication date: October 23, 2003Inventors: Edward Frank Ryntz, Richard Murray Kleber
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Patent number: 6631630Abstract: The present invention provides an apparatus and a method which use hydroforming to shape complex structures from materials such as sheet metal or composites. In particular, an apparatus and a method for shaping complex structures using composites such as continuous-fiber or woven fiber composites with limited wrinkling or rupture of the composite during the shaping process.Type: GrantFiled: September 22, 2000Date of Patent: October 14, 2003Assignee: Board of Trustees of Michigan State UniversityInventors: Farhang Pourboghrat, Michael A. Zampaloni, Andre Benard
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Publication number: 20030177801Abstract: An apparatus of superplastic forming for massive production is able to install a plurality of forming sheets and plates in one apparatus using dies of multi-layer structure and to form the sheets and plates with compressed gas, and therefore, a plurality of products can be fabricated rapidly and massively with a cheap facility investment. If preforms are used instead of flat blank sheets, the productivity can be improved greatly and the products of uniform thickness can be formed massively.Type: ApplicationFiled: March 20, 2003Publication date: September 25, 2003Applicant: Korea Institute of Science and TechnologyInventor: Jong-Woo Park
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Patent number: 6615631Abstract: Equipment and method for the rapid and easy extraction of formed metal parts from forming dies while in a press and operating at elevated temperatures. The invention features the controlled supply of streams of air or other inert gas to the interface of the hot surface of the forming die and the formed panel to augment removal so that flaws from removal equipment are minimized for optimized production of high quality parts. High velocity air is discharged through nozzles onto the forming surfaces of hot forming dies to cool the forming die and the part that contract at different rates and pop the part from the surface.Type: GrantFiled: April 19, 2001Date of Patent: September 9, 2003Assignee: General Motors CorporationInventors: Richard Murray Kleber, Nelson T. Brinas, Dana W. Moore, Donald L. Kenyon, Joseph B. Harris
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Patent number: 6581428Abstract: The present invention provides a method and apparatus for forming a sheet of ductile material by superplastic forming. Excessive wrinkling is prevented in the present invention by providing a method and apparatus which controls the amount of material flow during the forming process.Type: GrantFiled: January 24, 2002Date of Patent: June 24, 2003Assignee: Ford Motor CompanyInventor: Peter A. Friedman
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Patent number: 6571450Abstract: In the process for the monolithic molding of superplastic material, generation of wrinkles on the molded product can be prevented by avoiding local expansion generated in the no-bonding regions of both of three or more metal plates when the metal plates are monolithically molded by means of superplastic molding. The process is characterized in that auxiliary plates for molding are placed on both sides of the superposed plates through the no-bonding regions, these plates are set in the molding die, and a pressure lower than applied to the non-bonding regions is applied to spaces between inner wall of the molding die and the auxiliary plates to control movement of the top and bottom.Type: GrantFiled: July 3, 2001Date of Patent: June 3, 2003Assignee: Fuji Jukogyo Kabushiki KaishaInventor: Shinichi Yajima
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Patent number: 6553804Abstract: The hooking system of the lid (4) to the sliding plate comprises grooves (27) provided in the heating ceramic plate (11), to accommodate rails made of refractory steel. These rails (26) enable on the one hand to fix the ceramic plate (11) below the metal plate (10), via tension rods (14) and, on the other hand, to hook the lid (4), using H-section parts (22) that nest into T-shaped grooves (25) of the said rails and in identical T-shaped grooves provided opposite to one another in the upper section of the lid (4).Type: GrantFiled: March 22, 2001Date of Patent: April 29, 2003Assignee: ACB Pressure SystemsInventor: Bruno Convert
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Publication number: 20030070464Abstract: A coating for superplastic forming (SPF) and quick plastic forming (QPF) tooling and an SPF/QPF process made possible with the coating. The coating defines the forming surface of an SPF/QPF tool, and consists essentially of either a tungsten carbide cermet or a chromium carbide cermet. The coating preferably comprises a metal matrix containing tungsten carbide or chromium carbide particles having a particle size of not more than 0.1 micrometer, and is preferably prepared to have a surface finish of not rougher than 0.3 micrometer Ra. An SPF/QPF process that makes use of a tool whose forming surface is provided with the coating can be performed without depositing any lubricant on the forming surface or workpiece.Type: ApplicationFiled: October 15, 2001Publication date: April 17, 2003Inventor: Arianna T. Morales
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Patent number: 6536250Abstract: A dent removal system is provided having a portable vacuum chamber head and a shaper vacuum roller coupled to a vacuum source. The vacuum chamber head has a center see-through window for aligning the head over a dented work surface, a template of desired surface shape and a matrix of closely-spaced standoff pins to communicate the template shape to the work surface while allowing passage of vacuum to the dent. A method is provided for removing dents in sheet metal surfaces using the dent removal system. The vacuum chamber head is positioned over the dented work surface and sealed. The work surface is excited with vibrational energy. Within the vacuum chamber head, force is applied to the template face to hold the template in fixed relation to the work surface. The template shape is transmitted to the work surface via the matrix of standoff pins.Type: GrantFiled: November 6, 2000Date of Patent: March 25, 2003Assignee: Dent Defyer, Inc.Inventor: Donald Paul Borchert
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Publication number: 20030046966Abstract: Superplastic forming tools and method in which pairs of stacked metal blanks are serially loaded between heated forming dies that are moved to a closed position on each of the pair of blanks so that a partial perimeter gas seal is established therebetween. A pressure wedge is then introduced between the two blanks along one edge of the pair to act as a stopper or air seal to complete perimeter sealing thereof. The pressure wedge also establishes the operative position of a gas injection port, which directs pressurized air interiorly of the completed perimeter seal of the pair of blanks to force the blanks in opposite direction for the superplastic forming of a pair of discrete parts. The wedge and forming dies are then opened for the removal of a pair of formed parts and for the subsequent loading of additional pairs of stacked sheets for their simultaneous superplastic forming into pairs of parts.Type: ApplicationFiled: September 10, 2001Publication date: March 13, 2003Inventor: Richard Murray Kleber
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Patent number: 6519992Abstract: A method of operating a metal forming press in which in a rigid press frame a workpiece is preloaded against a tool by means of a hold-down force, with at least one ram tool applying a ram force in parallel with the hold-down force, and closing cylinder forces being applied opposite to the ram force and the hold-down force, and a water chamber die being formed in the tool, whereby water chamber die forces can act on the workpiece, characterized in that the disturbing force resulting from the application of the ram force is determined and compensated by a change in the closing cylinder forces.Type: GrantFiled: March 23, 2001Date of Patent: February 18, 2003Inventor: Konrad Schnupp
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Patent number: 6516645Abstract: Equipment and methods for the rapid and easy cleaning of metal forming dies while in a press and operating at elevated temperatures. The invention features the physical removal of excess lubricant collecting on the hot surface of the forming dies under operating conditions so that no lubricant-induced flaws occur on the show surface of the formed part for optimized production of high quality parts. Special and effector tooling is supplied with high velocity air which draws in solid CO2 which sublimes into pressurize streams of gaseous CO2 that is discharged through nozzles onto the forming surfaces of hot forming dies after a number of lubricated parts have been formed therewith to physically sweep foreign matter including lubricants from the die surfaces. A robot is employed to move the activated end effector in predetermined paths across the dies for fully sweeping and cleaning the forming surfaces. The gas then dissipates.Type: GrantFiled: December 27, 2000Date of Patent: February 11, 2003Assignee: General Motors CorporationInventors: Arianna T. Morales, Edward Frank Ryntz, Nelson T. Brinas
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Patent number: 6497128Abstract: A method of manufacturing a fuel rail for use in a fuel delivery system, such as for an engine in a vehicle, includes the initial hydroforming step to deform a central portion of a workpiece to have one or more outwardly extending node portions, followed by a subsequent hydroforming step to deform one or more end portions of the workpiece to have additional outwardly extending node portions. To do this, a pair of pressure feed pistons are disposed within the interior of the workpiece and have head portions that sealingly engage the inner surface of the workpiece so as to define a pressure chamber therein. Pressurized fluid is introduced into the pressure chamber so as to deform a portion thereof into conformance with the portion of the die cavity located within the pressure chamber. Then, the pressure feed pistons are moved to re-define the pressure chamber within the workpiece. Pressurized fluid is again introduced into the enlarged pressure chamber so as to deform other portions of the workpiece.Type: GrantFiled: March 16, 2001Date of Patent: December 24, 2002Assignee: Dana CorporationInventors: James C. Canfield, Randall F. Alder, Gail M. Cunningham, David R. Fish, Harjinder Singh
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Patent number: 6493913Abstract: In a device for hydraulic forming of a tubular component under high inner pressure compressive conditions in a lower die and an upper die of a forming tool, the upper die can be coupled for relative limited movement by at least one piston-cylinder unit containing a hydraulic fluid with the press plunger of a travel-limited mechanical press and the cylinder interior of the piston-cylinder unit can be coupled for providing fluid communication with the interior of the component. Alternatively, in the device for hydraulic forming of a blank under high pressure compressive conditions in a forming tool comprising a lower die and an upper die, the upper die can be coupled for relative limited movement by at least one piston-cylinder unit containing a hydraulic fluid with the press plunger of a travel-limited mechanical press and the cylinder chamber of the piston-cylinder unit can be coupled for establishing fluid communication with the forming space of the forming tool.Type: GrantFiled: November 30, 2000Date of Patent: December 17, 2002Assignee: Benteler AGInventors: Wolfgang Streubel, Thomas Harbarth
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Patent number: 6481256Abstract: A forming press for external high-pressure forming is proposed, in which the fluid box (10) is arranged stationarily. Working cylinders (6) are integrated in the ram (2) so as to achieve a compact design, and the sheetholding and closing force is applied by short-stroke cylinders (7).Type: GrantFiled: June 13, 2000Date of Patent: November 19, 2002Assignee: Muller Weingarten AGInventors: Joachim Beyer, Ulrich Hermann
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Publication number: 20020166222Abstract: A sheet hydroforming method is disclosed wherein two stacked metallic sheets are clamped between a pair of upper and lower dies 10, 11 and a fluid is introduced and pressurized between mating surfaces of the metallic sheets, causing the metallic sheets to bulge into a space defined by die cavities 10b and 11b. A thru-hole 11d for introducing the fluid is formed in one of the dies so as to lead to a holding surface of the die, while a pierced hole for introducing the fluid is formed in one of the metallic sheets in a portion of the one metallic sheet which portion is in contact with a holding surface 10a (10b) of one of the dies, the pierced hole being positioned with the thru-hole 11d, then the fluid is introduced in a pressurized state between mating surfaces of the metallic sheets from the thru-hole through the pierced hole, thereby causing the metallic sheets to bulge. According to this method, a pressurized fluid can be introduced between the mating surfaces of blanks easily without leakage of the fluid.Type: ApplicationFiled: May 9, 2002Publication date: November 14, 2002Inventors: Masayasu Kojima, Mitsutoshi Uchida
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Publication number: 20020152783Abstract: Equipment and method for the rapid and easy extraction of formed metal parts from forming dies while in a press and operating at elevated temperatures. The invention features the controlled supply of streams of air or other inert gas to the interface of the hot surface of the forming die and the formed panel to augment removal so that flaws from removal equipment are minimized for optimized production of high quality parts. High velocity air is discharged through nozzles onto the forming surfaces of hot forming dies to cool the forming die and the part that contract at different rates and pop the part from the surface.Type: ApplicationFiled: April 19, 2001Publication date: October 24, 2002Inventors: Richard Murray Kleber, Nelson T. Brinas, Dana W. Moore, Donald L. Kenyon, Joseph B. Harris
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Publication number: 20020129634Abstract: Mold insert apparatus and a method is provided for high pressure solid phase forming of relatively thin web or sheet material. The apparatus includes a die set assembly provided with a forming die set unit having a die forming cavity which receives a forming die and an opposed high pressure chamber die set unit wherein the die set units receive material to be formed therebetween when in spaced relationship and functional to clamp the material therebetween when the die set units are in closed forming positions for solid phase forming of the material against the forming die upon introduction of high pressure fluid into the high pressure chamber die set unit. A material preheating station is provided outside but generally proximal to the die forming cavity of the forming die set unit.Type: ApplicationFiled: September 28, 2001Publication date: September 19, 2002Applicant: Preco Industries, Inc.Inventors: John T. Pierson, James Gramling