US20110067467A1 - Method and tool for contracting tubular members by electro-hydraulic forming before hydroforming - Google Patents
Method and tool for contracting tubular members by electro-hydraulic forming before hydroforming Download PDFInfo
- Publication number
- US20110067467A1 US20110067467A1 US12/563,184 US56318409A US2011067467A1 US 20110067467 A1 US20110067467 A1 US 20110067467A1 US 56318409 A US56318409 A US 56318409A US 2011067467 A1 US2011067467 A1 US 2011067467A1
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- US
- United States
- Prior art keywords
- tube
- chamber
- tool
- wire
- liquid
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/06—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves
- B21D26/12—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves initiated by spark discharge
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49803—Magnetically shaping
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49805—Shaping by direct application of fluent pressure
Definitions
- the present invention relates to electro-hydraulic forming to contract a tubular member in a die.
- EHF electro-hydraulic forming
- a capacitor bank or other source of stored charge, delivers a high current pulse across two electrodes that are submerged in a fluid, such as oil or water.
- the electric arc discharge vaporizes some of the surrounding fluid and creates shock waves in the fluid.
- a workpiece that is in contact with the fluid may be deformed by the shock waves to fill an evacuated die.
- Electro-hydraulic forming may be used, for example, to form a flat blank in a one-sided die.
- the use of EHF for a one-sided die may save tooling costs and may also facilitate forming parts into shapes that are difficult to form by conventional press forming or hydroforming techniques.
- Electro-hydraulic forming also facilitates forming high strength steel, aluminum and copper alloys.
- AHSS advanced high strength steel
- UHSS ultra high strength steel
- Lightweight materials, such as AHSS and UHSS and high-strength aluminum alloys are lightweight materials that are used to reduce the weight of vehicles.
- Tube hydroforming is well-known technology that is currently used in production.
- One problem with hydroforming tubes is that the tube tends to thin in areas that are formed to a greater extent.
- the method and tool disclosed and claimed in this application provide increased opportunities for hydroforming parts from ductile steel and also high strength materials that have reduced formability.
- larger diameter tubular preforms can be used to form parts having smaller diameter cross-sections in localized areas.
- the tube blank is selected to correspond to the average perimeter of the final part.
- the tube blank provides material that is worked in the hydroforming process.
- the hydroforming process is generally used to expand the tubular blank with pressure that is exerted from the inside of the tube. With expansion hydroforming, the size of the tube is limited to the minimum perimeter of the smallest cross-section of the finished part. This limits the quantity of material that is available for the hydroforming operation and, in turn, limits the extent to which the tube can be expanded.
- a tube or tubular preform is first formed to a reduced diameter in an electro-hydraulic forming process that applies an impact force to the outer surface of the tube.
- the partially contracted tube is then loaded into a hydroforming tool and formed by the application of fluid pressure to the inner side of the tube to expand the tube and form the tube against the hydroforming die.
- the tool that is illustrated to compress or contract the tubular preform includes two parts that together define a chamber. A portion of the tube is first encircled with a wire and then placed in the chamber. The chamber is filled with a fluid, such as water or oil, and sealed. The wire is selectively connected to a source of stored electrical energy, such as a capacitor circuit, to cause an electrical discharge in the fluid in the chamber that forms the portion of the tube radially inward to a reduced cross-sectional area. The balance of the tube may be maintained at full cross-sectional area size.
- the tubular preform is later formed by expanding in a hydroforming operation in the full cross-sectional area. The portion of the tube that was compressed may be expanded from the reduced cross-sectional area.
- FIG. 1 is a diagrammatic cross-sectional view of an electro-hydraulic forming tool that is used to contract the diameter of a tube prior to hydroforming.
- FIG. 2 is a cross-sectional view taken along the line 2 - 2 in FIG. 1 .
- FIG. 3 is a cross-sectional view similar to FIG. 2 , but showing an alternative embodiment wherein variable diameter coils are used to contract the tube to different extents along different portions of the tube.
- FIG. 4 is a diagrammatic cross-sectional view of an alternative embodiment of the electro-hydraulic forming tool wherein a single loop of wire is provided in the electro-hydraulic forming tool.
- FIG. 5 is a diagrammatic cross-sectional view of a tube showing the tube before contraction and after contraction.
- FIG. 6 is a flowchart illustrating the steps of the method of compressing a tubular preform in an electro-hydraulic forming tool prior to forming the tubular preform by expanding the tube in a hydroforming operation.
- an electro-hydraulic forming tool 10 is used to contract a tubular preform 12 prior to hydroforming the tubular preform is diagrammatically illustrated.
- a wire coil 14 is wrapped in a spaced relationship around the tubular preform 12 and submerged in a liquid 18 , such as water or oil.
- the liquid 18 is contained within a chamber 20 defined by a first tool part 22 and a second tool part 24 .
- the chamber 20 must be sealed, as shown by first seal 26 and second seal 28 .
- the chamber 20 is filled by an upper port 30 and a lower port 32 . It should be understood that a single fill/evacuation port could be provided instead of the two ports as illustrated.
- Tubular preform 12 and wire coil 14 are preassembled and then inserted into the chamber 20 defined by the first tool part 22 and the second tool part 24 .
- first seal 26 engages a second seal 28 .
- the chamber 20 is filled through the lower port until the liquid flows out of upper port 30 .
- the electro-hydraulic forming tool 10 is shown with the second tool part 24 (shown in FIG. 1 ) removed.
- the tubular preform 12 is encircled by the wire coils 14 and immersed in the liquid 18 .
- the first tool part 22 retains the first seal 26 to seal the chamber 20 as described with reference to FIG. 1 above.
- the seal 26 extends about the periphery of the forming chamber 20 and on one side of the tubular perform 12 . (The seal 26 is not visible behind the tubular perform 12 as viewed in FIGS. 2-5 .)
- a capacitor circuit 36 that comprises a stored power source is connected to opposite ends of the wire coil 14 by a positive electrode 38 and a negative electrode 40 .
- the stored power source may be an induction circuit that could be used instead of the capacitor circuit.
- FIG. 3 is a view similar to FIG. 2 that shows an alternative embodiment wherein reduced diameter wire loops 46 are provided as part of the wire coil 14 .
- the tubular preform 12 is shown wrapped by the wire coil 14 including the reduced diameter wire loops 46 and is submerged in the fluid 18 .
- the wire coil 14 is connected to a capacitor circuit, as previously described with reference to FIG. 2 .
- the capacitor circuit 36 When the capacitor circuit 36 is discharged, the more closely wrapped wire loops 46 are closer to the tubular preform 12 and, as a result, exert a greater contraction force on the tubular member 12 .
- This greater contraction force compresses that portion of the tube to a greater extent compared to the contraction force applied by the other loops of the wire coil 14 .
- FIG. 4 an alternative embodiment of the electro-hydraulic forming tool is shown in which a single loop wire 48 is provided.
- the single loop of wire 48 is wrapped in a spaced relationship around the tubular preform 12 and immersed within the liquid 18 in the chamber 20 . Only one part of the chamber 20 is shown in FIG. 4 which is that part defined first tool part 22 with its associated seal 26 .
- the second tool part 24 and the second seal 28 are also included in this embodiment, but are not illustrated to better illustrate the tool.
- FIG. 5 the embodiment of FIG. 4 is shown including the tubular preform 12 with a full diameter wall section illustrated by reference numeral 38 and a contracted wall section shown in phantom lines and identified by reference numeral 40 .
- the single loop wire 48 may be used to act on a smaller portion of the tubular member 12 than in the embodiment shown in FIGS. 1-3 .
- FIG. 6 a flowchart is illustrated that shows the steps of the process used to initially contract portions of a tube prior to hydroforming to expand the tube into a desired part shape.
- the tube is preformed by bending to form the tube to a desired shape along its length.
- the first step in the process may follow the preform bending and comprises wrapping the coiled wire around the tube at 50 .
- the coil and tube are then inserted into the electro-hydraulic forming tool at 52 .
- the electro-hydraulic forming tool is discharged to compress a localized area of the tube at 54 .
- the wire is destroyed by the discharge and essentially vaporizes creating a shockwave in the electro-hydraulic forming tool chamber 20 that impacts the tubular preform to compress it in a localized area.
- the tube may then be removed from the electro-hydraulic forming tool at 56 .
- the tubular preform with the contracted localized area is then inserted into a hydroforming tool at 58 .
- the hydroforming tool forms the tubular preform at 60 expanding appropriate portions of the tube including portions of the tube that were not contracted.
- the portions of the tube that were contracted or compressed in the electro-hydraulic forming tool may also be expanded in the hydroforming operation at 60 .
- the tubular preform is compressed to the minimum diameter of the part to be formed.
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- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
Description
- 1. Technical Field
- The present invention relates to electro-hydraulic forming to contract a tubular member in a die.
- 2. Background Art
- In electro-hydraulic forming (“EHF”), an electric arc discharge is used to convert electrical energy to mechanical energy. A capacitor bank, or other source of stored charge, delivers a high current pulse across two electrodes that are submerged in a fluid, such as oil or water. The electric arc discharge vaporizes some of the surrounding fluid and creates shock waves in the fluid. A workpiece that is in contact with the fluid may be deformed by the shock waves to fill an evacuated die.
- Electro-hydraulic forming may be used, for example, to form a flat blank in a one-sided die. The use of EHF for a one-sided die may save tooling costs and may also facilitate forming parts into shapes that are difficult to form by conventional press forming or hydroforming techniques. Electro-hydraulic forming also facilitates forming high strength steel, aluminum and copper alloys. For example, advanced high strength steel (AHSS) and ultra high strength steel (UHSS) can be formed to a greater extent with electro-hydraulic forming techniques when compared to other conventional forming processes. Lightweight materials, such as AHSS and UHSS and high-strength aluminum alloys are lightweight materials that are used to reduce the weight of vehicles.
- The use of these high strength, lightweight materials is increasing and has been proposed for hydroforming tubes. Tube hydroforming is well-known technology that is currently used in production. One problem with hydroforming tubes is that the tube tends to thin in areas that are formed to a greater extent.
- The above problems are addressed by Applicant's invention as summarized below.
- The method and tool disclosed and claimed in this application provide increased opportunities for hydroforming parts from ductile steel and also high strength materials that have reduced formability. By applying the method, larger diameter tubular preforms can be used to form parts having smaller diameter cross-sections in localized areas. Generally, the tube blank is selected to correspond to the average perimeter of the final part. The tube blank provides material that is worked in the hydroforming process. The hydroforming process is generally used to expand the tubular blank with pressure that is exerted from the inside of the tube. With expansion hydroforming, the size of the tube is limited to the minimum perimeter of the smallest cross-section of the finished part. This limits the quantity of material that is available for the hydroforming operation and, in turn, limits the extent to which the tube can be expanded.
- According to the method, a tube or tubular preform is first formed to a reduced diameter in an electro-hydraulic forming process that applies an impact force to the outer surface of the tube. The partially contracted tube is then loaded into a hydroforming tool and formed by the application of fluid pressure to the inner side of the tube to expand the tube and form the tube against the hydroforming die.
- The tool that is illustrated to compress or contract the tubular preform includes two parts that together define a chamber. A portion of the tube is first encircled with a wire and then placed in the chamber. The chamber is filled with a fluid, such as water or oil, and sealed. The wire is selectively connected to a source of stored electrical energy, such as a capacitor circuit, to cause an electrical discharge in the fluid in the chamber that forms the portion of the tube radially inward to a reduced cross-sectional area. The balance of the tube may be maintained at full cross-sectional area size. The tubular preform is later formed by expanding in a hydroforming operation in the full cross-sectional area. The portion of the tube that was compressed may be expanded from the reduced cross-sectional area.
- Other aspects of Applicant's concept will be better understood in view of the attached drawings and detailed description of the illustrated embodiments.
-
FIG. 1 is a diagrammatic cross-sectional view of an electro-hydraulic forming tool that is used to contract the diameter of a tube prior to hydroforming. -
FIG. 2 is a cross-sectional view taken along the line 2-2 inFIG. 1 . -
FIG. 3 is a cross-sectional view similar toFIG. 2 , but showing an alternative embodiment wherein variable diameter coils are used to contract the tube to different extents along different portions of the tube. -
FIG. 4 is a diagrammatic cross-sectional view of an alternative embodiment of the electro-hydraulic forming tool wherein a single loop of wire is provided in the electro-hydraulic forming tool. -
FIG. 5 is a diagrammatic cross-sectional view of a tube showing the tube before contraction and after contraction. -
FIG. 6 is a flowchart illustrating the steps of the method of compressing a tubular preform in an electro-hydraulic forming tool prior to forming the tubular preform by expanding the tube in a hydroforming operation. - Referring to
FIG. 1 , an electro-hydraulic formingtool 10 is used to contract atubular preform 12 prior to hydroforming the tubular preform is diagrammatically illustrated. Awire coil 14 is wrapped in a spaced relationship around thetubular preform 12 and submerged in aliquid 18, such as water or oil. Theliquid 18 is contained within achamber 20 defined by afirst tool part 22 and asecond tool part 24. Thechamber 20 must be sealed, as shown byfirst seal 26 and second seal 28. Thechamber 20 is filled by anupper port 30 and alower port 32. It should be understood that a single fill/evacuation port could be provided instead of the two ports as illustrated. -
Tubular preform 12 andwire coil 14 are preassembled and then inserted into thechamber 20 defined by thefirst tool part 22 and thesecond tool part 24. When assembled, thefirst seal 26 engages a second seal 28. Thechamber 20 is filled through the lower port until the liquid flows out ofupper port 30. - Referring to
FIG. 2 , the electro-hydraulic formingtool 10 is shown with the second tool part 24 (shown inFIG. 1 ) removed. Thetubular preform 12 is encircled by thewire coils 14 and immersed in theliquid 18. Thefirst tool part 22 retains thefirst seal 26 to seal thechamber 20 as described with reference toFIG. 1 above. Theseal 26 extends about the periphery of the formingchamber 20 and on one side of the tubular perform 12. (Theseal 26 is not visible behind thetubular perform 12 as viewed inFIGS. 2-5 .) - A
capacitor circuit 36 that comprises a stored power source is connected to opposite ends of thewire coil 14 by apositive electrode 38 and anegative electrode 40. Alternatively, the stored power source may be an induction circuit that could be used instead of the capacitor circuit. When thecapacitor circuit 36 is actuated, thewire coil 14 is energized to create a shockwave within thefluid 18 that is imparted to thetubular member 12. The tubular member in the area where thewire coil 14 encircles the tubular member is compressed from aninitial tube section 42 shown in solid line to a contractedtube section 44 shown in phantom lines. -
FIG. 3 is a view similar toFIG. 2 that shows an alternative embodiment wherein reduceddiameter wire loops 46 are provided as part of thewire coil 14. Thetubular preform 12 is shown wrapped by thewire coil 14 including the reduceddiameter wire loops 46 and is submerged in thefluid 18. Thewire coil 14 is connected to a capacitor circuit, as previously described with reference toFIG. 2 . When thecapacitor circuit 36 is discharged, the more closely wrappedwire loops 46 are closer to thetubular preform 12 and, as a result, exert a greater contraction force on thetubular member 12. This greater contraction force compresses that portion of the tube to a greater extent compared to the contraction force applied by the other loops of thewire coil 14. - Referring to
FIG. 4 , an alternative embodiment of the electro-hydraulic forming tool is shown in which asingle loop wire 48 is provided. In the embodiment shown inFIG. 4 , the same reference numerals are used as previously described with reference toFIGS. 1-3 . The single loop ofwire 48 is wrapped in a spaced relationship around thetubular preform 12 and immersed within the liquid 18 in thechamber 20. Only one part of thechamber 20 is shown inFIG. 4 which is that part definedfirst tool part 22 with its associatedseal 26. Thesecond tool part 24 and the second seal 28 are also included in this embodiment, but are not illustrated to better illustrate the tool. - Referring to
FIG. 5 , the embodiment ofFIG. 4 is shown including thetubular preform 12 with a full diameter wall section illustrated byreference numeral 38 and a contracted wall section shown in phantom lines and identified byreference numeral 40. Thesingle loop wire 48 may be used to act on a smaller portion of thetubular member 12 than in the embodiment shown inFIGS. 1-3 . - Referring to
FIG. 6 , a flowchart is illustrated that shows the steps of the process used to initially contract portions of a tube prior to hydroforming to expand the tube into a desired part shape. In many instances, the tube is preformed by bending to form the tube to a desired shape along its length. The first step in the process may follow the preform bending and comprises wrapping the coiled wire around the tube at 50. The coil and tube are then inserted into the electro-hydraulic forming tool at 52. The electro-hydraulic forming tool is discharged to compress a localized area of the tube at 54. The wire is destroyed by the discharge and essentially vaporizes creating a shockwave in the electro-hydraulic formingtool chamber 20 that impacts the tubular preform to compress it in a localized area. The tube may then be removed from the electro-hydraulic forming tool at 56. The tubular preform with the contracted localized area is then inserted into a hydroforming tool at 58. The hydroforming tool forms the tubular preform at 60 expanding appropriate portions of the tube including portions of the tube that were not contracted. The portions of the tube that were contracted or compressed in the electro-hydraulic forming tool may also be expanded in the hydroforming operation at 60. The tubular preform is compressed to the minimum diameter of the part to be formed. - While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
Claims (16)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US12/563,184 US7905129B1 (en) | 2009-09-21 | 2009-09-21 | Method and tool for contracting tubular members by electro-hydraulic forming before hydroforming |
CN201020536411XU CN201815583U (en) | 2009-09-21 | 2010-09-20 | Processing equipment for forming pipes |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/563,184 US7905129B1 (en) | 2009-09-21 | 2009-09-21 | Method and tool for contracting tubular members by electro-hydraulic forming before hydroforming |
Publications (2)
Publication Number | Publication Date |
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US7905129B1 US7905129B1 (en) | 2011-03-15 |
US20110067467A1 true US20110067467A1 (en) | 2011-03-24 |
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US12/563,184 Expired - Fee Related US7905129B1 (en) | 2009-09-21 | 2009-09-21 | Method and tool for contracting tubular members by electro-hydraulic forming before hydroforming |
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US (1) | US7905129B1 (en) |
CN (1) | CN201815583U (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102814380A (en) * | 2011-06-10 | 2012-12-12 | 福特环球技术公司 | Method and Apparatus for Pulsed Forming, Punching and Trimming of Tubular Members |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN111922175B (en) * | 2020-08-24 | 2021-11-19 | 华中科技大学 | Electro-hydraulic explosion forming device and method |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102814380A (en) * | 2011-06-10 | 2012-12-12 | 福特环球技术公司 | Method and Apparatus for Pulsed Forming, Punching and Trimming of Tubular Members |
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CN201815583U (en) | 2011-05-04 |
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