Abstract: The present invention was made with the object of eliminating the short pipe member when attaching a bolting nut to a hydroformed part, preventing an increase in the difficulty of hydroforming for attaching the nut, extending the nut length so as to enable sufficient strength at the time of bolting, and enabling application even to thin wall hydroformed parts and comprises inserting a metal pipe into a split mold having a pierce punch able to be moved perpendicular to an axis of the inserted metal pipe or in a slanted direction, having a front part narrower than a center part, and having around the front part a nut having an inside diameter larger than an outside diameter of the front part and smaller than an outside diameter of the center part; hydroforming it; then making the pierce punch advance to pierce part of the hydroformed part and pushing the nut by a center part arranged behind the nut and embedding the nut in the metal pipe.

Abstract: A method of forming a bottle-shaped or other contoured metal container by providing a hollow metal preform having a closed end and a wall thickness that decreases progressively in a direction away from the closed end, and subjecting the preform to internal fluid pressure to cause the preform to expand against the wall of a die cavity defining the desired container shape. The method may be employed in pressure-ram-forming procedures wherein a punch is advanced by means of a backing ram into the die cavity to displace and deform the closed end of the preform.

Abstract: A hydroforming process forms a hydroformed automotive component as a multiple cell member having an integral internal rib separating the cells and reinforcing the hydroformed component to increase the strength of a hydroformed component with a given size and shape. The tubular blank can be manufactured through a roll-forming process or by welding two structural tubular members, to form a tubular blank that has multiple cells with an internal rib separating the cells. The hydroforming process injects fluid under pressure into each of the cells to expand the tubular blank into the shape defined by the die holding the blank. The internal web separating the cells of the blank becomes an integral internal reinforcement spanning the component to enhance the strength, rigidity and stiffness of the component. Providing differential pressure on the multiple cells can stretch and twist the internal rib for positioning internally as desired.

Abstract: A hydroforming apparatus and working method able to simply find a load path are proposed, which system and method use a mold in which contact sensors able to judge contact with a metal tube inside the mold are mounted at least at two different positions in the tube axial direction, perform a first step of axially pushing tube ends in a state with the internal pressure held at a constant value and stopping the progress of the axial pushing action when judging that among the contact sensors not yet in contact mounted at positions closest to the tube ends detect contact with the metal tube, next perform a second step of raising only the internal pressure while leaving the positions of the tube ends fixed and stopping the increase in the internal pressure when the contact sensor not yet in contact judges contact, next perform a third step of lowering the internal pressure to the value before raising it while leaving the positions of the tube ends fixed, and repeat said first step to third step until all of said c

Abstract: Disclosed is a method of manufacturing a multilayered tube, including: preparing an outer tube, an inner tube having an outer diameter of 95˜98% of an inner diameter of the outer tube, and dies with a shaping void having a diameter of 100.20˜100.

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: The present invention provides a method of manufacturing a fuel filler tube that significantly reduces the number of manufacturing steps. In the preferred embodiment, a tubular blank is pre-formed to an intermediate configuration approximating the form of the final fuel filler tube, and then through hydroforming the intermediate tubular preform is formed to final form. The preferred embodiment of the invention uses axial compression for controlling the axial length of the tube and its wall thickness. The method of the invention uses less material than conventional processes, and provides greater control over the parameters of the final product while eliminating many steps of the conventional process.

Abstract: A tubular preform is contracted in an electro-hydraulic forming operation. The tubular preform is wrapped with one or more coils of wire and placed in a chamber of an electro-hydraulic forming tool. The electro-hydraulic forming tool is discharged to form a compressed area on a portion of the tube. The tube is then placed in a hydroforming tool that expands the tubular preform to form a part.

Abstract: In a hot bulge forming apparatus 1, a preheated tubular material 10b is disposed in a cavity 33A defined by dies 21A, 31A, air is supplied into an interior of the tubular material 10b so that the tubular material 10b is pressed against cavity surfaces 211A, 311A by the pressure of the air to thereby form the tubular material 10b into a shape defined by the cavity 33A. Thereafter, the resulting tubular material 10c is disposed in a cavity 33B defined by dies 21B, 31B, and air is supplied into an interior of the tubular material 10c so that the tubular material 10c is pressed against cavity surfaces 211B, 311B by the pressure of the air to thereby form the tubular material 10c into a shape defined by the cavity 33B while the tubular material 10c is cooled by the cavity surfaces 211B, 311B. Projecting portions 331 each having an arc-shaped section are formed at portions of the cavity surfaces 211A, 311A against which lengthwise end sides of the tubular material 10b are pressed.

Abstract: The present invention relates to a device and a method for holding tool parts together during a hydroforming process. The device comprises a first portion comprising a first force transmitting surface and a second portion comprising a second force transmitting surface, which are connected by means of a pivot, and a length variable power member which, with a force, tends to turn the second portion in relation to the first portion around the pivot by means of a first lever which is longer than a second lever by means of which a resultant larger force is created which acts between said force transmitting surfaces for holding the tool parts together during a hydroforming process.

Abstract: The invention relates to a method for manufacturing an axle component having the following steps: arranging a hollow semi-finished product such as a tube in a die for forming the axle component; introduction of fluid into the interior of the hollow semi-finished product; and loading of the fluid with high pressure, in order to deform the hollow semi-finished product in accordance with the die as a result.

Abstract: A manufacturing method includes a first step of performing swage autofrettage on an object; a second step of heat soaking the object; and a third step of performing hydraulic autofrettage on the object. The second and third steps may be repeated one or more times. A final step may be heat soaking the object. The object may be, for example, a pressure vessel or gun barrel.

Abstract: A centralizer for installing on a metal pipe. The centralizer includes a generally tubular body having a central opening sufficiently large to allow insertion therethrough of a pipe having an external diameter; a sidewall of substantially uniform thickness including an inner-facing surface directed to the central opening and an outer-facing surface onto which are formed a plurality of outwardly protruding ribs by hydroforming the sidewall.

Abstract: A method of forming a hollow body having a hollow flange may include performing a hydroforming process to a tubular blank. The tubular blank may be deformed and shaped to form the hollow body and the hollow flange. Subsequent processes may be performed to the hollow flange such as a flattening process whereby confronting internal surfaces of the hollow flange are brought together to abut each other and form a flat flange.

Abstract: An exhaust mixer for an engine is provided having multiple flow tubes arranged in an annular array. A cooling space is formed to allow the passage of cooling air between the flow tubes and within the annular array. In one form the exhaust mixer can be constructed from multiple, individual exhaust flow tubes. The flow tubes can be constructed to engage neighboring flow tubes to create the annular array of exhaust flow tubes. The flow tubes can be interchangeable with other flow tubes.

Abstract: A method of forming a space frame for a cab, including forming each of a pair of hydroformed, longitudinally extending inner side rails, a hydroformed connecting member, a hydroformed first upper cross member, each of a pair of hydroformed upper longitudinal members, and each of a pair of hydroformed A-pillar members. The method including, providing a tubular metallic blank having a tubular metallic wall. The method also including placing the tubular metallic blank into a die cavity of a die assembly, the die cavity having die surfaces, and providing a high pressure fluid into an interior of the blank to expand the metallic wall of the central portion of the blank outwardly into conformity with the surfaces of the die cavity to define the respective hydroformed member.

Abstract: Method wherein a) a container (1, 6) is placed in a two halves mould (2) having an internal shaped wall (21), b) an internal pressure P of a fluid is build up so as to shape the skirt (12), is characterized in that an external pressure P?of a fluid is applied in an upper space (101) contiguous to an external or upper surface (100) of the open top end (10) and/or in a lower space (141) contiguous to an external or lower surface (140) of the shaped bottom end (14), so as to have, during the span of time ?t, a pressure difference ?P|P?P?1 low enough to prevent any distortion of the shaped open top end (10) and/or the shaped bottom end (14), so as to form a shaped metallic container (1?, 6?). An apparatus for carring out the method is also disclosed.

Abstract: The present invention provides a hydroforming method able to increase the expansion ratio to obtain a complicated shape hydroformed product and able to reduce the number of steps of work, that is, a hydroforming method loading a metal pipe into a divided mold, clamping the mold, then applying an internal pressure and pushing force in the pipe axial direction to said metal pipe, comprising, in a first hydroforming step, expanding said metal pipe in one direction of said metal pipe cross-section to obtain an intermediate product having a circumferential length of 90% to 100% of the circumferential length of the product shape in all of the expanded part in the pipe axial direction and having a height greater than the height of the product in said one direction and at least part of the pipe axial direction, then, in a second hydroforming step, reducing the height in the one direction of said intermediate product in all or part of the pipe axial direction while shaping the product to the final product shape.

Abstract: A metal forming die includes a first die half and a second die half moveable relative to the first die half. The first and second die halves define a die cavity when the second die half is in a closed position. A transducer is operable to vibrate the first die half during metal forming.

Abstract: A reinforced member which is made from a steel product having a strain aging characteristic and has a closed section at a cross section perpendicular to an axis of the reinforced member. The reinforced member includes a reinforced area which is produced by press-forming the steel product so as to generate a compression strain in the press-formed steel product due to the application of a compression stress to the steel product along the direction from a surface of the steel product to an inside of the steel product, and by giving a strain aging treatment to the press-formed member.

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 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: Articles are often formed from a tubular workpiece in a process which does not usefully shape the ends of the tube. In an embodiment of the invention, tube ends may be mechanically reduced in cross section and then expanded against a secondary forming surface(s) using an electromagnetic force to obtain desired shapes for the tube ends and minimize scrapping of workpiece material.

Abstract: The invention relates to a device for the internal high-pressure forming of components from tubular workpieces, in particular microcomponents, comprising an at least two-part mould, in which a workpiece can be placed, and means for sealing and/or applying pressure to the workpiece at the ends of the workpiece, in which device at least one guide (11) is arranged on the mould (2a, 2b), on which guide a carriage (12) is displaceable, which carriage carries means (4, 5) for sealing and/or filling/applying pressure to a workpiece end (1a), wherein a carriage (12) is displaceable by means of a drive (13, 15) which is arranged separately from the at least one guide (11) and is coupled to the carriage (12) at least essentially such that it is free from transverse forces.

Abstract: A frame assembly is manufacturing by initially providing first and second brackets. The brackets are provided by initially providing a closed channel structural member and deforming the closed channel structural member, such as by hydroforming, to have a central body portion having a pair of arm portions extending therefrom. The central portion is then divided, such as by cutting, to provide first and second brackets, each including one of the arm portions. A frame assembly is provided including a component having first and second openings formed therethrough. The arm portions of the first and second brackets are disposed respectively in the first and second openings and secured thereto by magnetic pulse welding.

Abstract: A preform with edges overlapped and jointed each other and first and second outer members for forming outer surfaces of a hydroformed product, and reinforcement members that are jointed to the first and second outer members to form reinforcement ribs that divide a hollow cross section of the outer surfaces, the reinforcement members having dimensions capable of suppressing elongation in a tensile direction due to a tensile force that develops during hydroforming.

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 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: 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: Blocks and inner rings of rolling bearings are arranged on the outer surface of a hollow shaft at predetermined intervals in the axial direction thereof. The outer surface of the hollow shaft is plastically deformed in its diameter enlarging direction so as to be press-fit to the inner surface of the blocks and inner surface of the inner rings of the rolling bearings. In this state, the blocks and inner rings of the rolling bearings are fixed to the outer surface of the hollow shaft.

Abstract: An inventive process is provided for creating residual compressive stress at a surface of a structure without resort to custom mandrels and dangerous high-pressure fluids. The inventive process yields autofrettage of a structure such as a tube, gun barrel and the like, the structure having an outer surface and an inner surface.

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: The invention relates to a tool for shaping hollow parts or metal sheets with the aid of a pressurized gas or fluid. Said shaping tool comprises at least two contour blocks which form a cavity. At least one of the contour blocks can be heated. The contour blocks (20, 25; 120, 125) are disposed in a two-piece tool housing (1) which is provided with insulation (10) for the contour blocks (20, 25; 120, 125). The load distribution plate (8,9) is connected to the tool housing (1).

Abstract: A preform with edges overlapped and jointed each other and first and second outer members for forming outer surfaces of a hydroformed product, and reinforcement members that are jointed to the first and second outer members to form reinforcement ribs that divide a hollow cross section of the outer surfaces, the reinforcement members having dimensions capable of suppressing elongation in a tensile direction due to a tensile force that develops during hydroforming.

Abstract: The invention relates to a method for manufacturing an axle component having the following steps: arranging a hollow semi-finished product such as a tube in a die for forming the axle component; introduction of fluid into the interior of the hollow semi-finished product; and loading of the fluid with high pressure, in order to deform the hollow semi-finished product in accordance with the die as a result.

Abstract: A can shaping process in which container preforms (F) are mounted on a table (16) which is rotated so a preform is moved from an initial loading station (P1) to a molding station (P4). A molding unit (20) includes a two-part mold (20a, 20b) split vertically in half, with inner surfaces (56) of the respective mold halves shaped to produce a desired container 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. The air pressure forces the sidewall of the preform outwardly against the inner surface of the mold to conform the shape of the container to a desired profile. After the shaping operation is complete, the pressurized air is withdrawn from the container, the mold halves are moved apart from each other, opening the mold.

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: A preform with edges overlapped and jointed each other and first and second outer members for forming outer surfaces of a hydroformed product, and reinforcement members that are jointed to the first and second outer members to form reinforcement ribs that divide a hollow cross section of the outer surfaces, the reinforcement members having dimensions capable of suppressing elongation in a tensile direction due to a tensile force that develops during hydroforming.

Abstract: According to a bulging device and a bulging method using a profile element pipe, for example, even when a profile steel pipe having a cross sectional shape varying in the axial direction as in a tapered pipe is hydraulically bulged, a bulging in which an internal pressure loading and an axial pressing are combined with each other can be performed to provide a larger expansion ratio than a conventional case and a joining and socket connection thereof to the other part can also be easily performed.

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 method of making a variable thickness tubular member for a vehicle includes the steps of providing a tubular member and positioning a mandrel inside of the tubular member. The method also includes the steps of hydroforming the tubular member into a variable thickness tubular member having a variable wall thickness along its perimeter.

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: 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: 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 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 method is provided for forming a tube between a pair of dies. The tube is captured between a pair of dies having die surfaces constructed of an electrically non-conducting material defining a die cavity therein. The ends of the tube are sealed and electrical current is applied to the tube to induce electrical resistance heating of the tube. The interior of the tube is pressurized to expand the tube into the cavity to thereby form the heated tube.

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.