| Patent application number | Description | Published |
|---|
| 20080257007 | METHOD AND APPARATUS FOR FORMING A BLANK AS A PORTION OF THE BLANK RECEIVES PULSES OF DIRECT CURRENT - A method is provided for forming a sheet metal blank or tubular blank in a metal forming tool, such as a sheet metal press or a media forming tool. The sheet metal press has an upper die and a lower die that are moved by a press to form the metal blank. The forming tool has a plurality of electrodes that are connected in an electrical circuit to a source of direct current. The electrodes provide pulses of the electric current to at least a portion of the blank. The method comprises loading the blank into the forming tool and closing the upper die and the lower die. The electrical circuit is completed between multiple electrodes through one or more portions of the blank. Electrical current is pulsed intermittently through the blank in a plurality of pulses. | 10-23-2008 |
| 20090272165 | ELECTROHYDRAULIC TRIMMING, FLANGING, AND HEMMING OF BLANKS - A method of electrohydraulically trimming a blank involving positioning a blank on a trimming member having a cutting edge such that a portion to be trimmed extends over the cutting edge and is in fluid communication with a chamber. Immobilize the blank with respect to the trimming member. Position a pair of electrodes in the chamber proximate the portion of the blank to be trimmed such that the electrodes and the trimming member are on opposite sides of the blank. Electrically connect the electrodes to a capacitor. Charge the capacitor. Fill the chamber with fluid to submerge the electrodes and to contact the portion of the blank to be trimmed. Discharge the capacitor across the electrodes to generate a pressure pulse that pushes the portion of the blank to be trimmed against the cutting edge thus trimming it off the blank. | 11-05-2009 |
| 20090272166 | METHOD OF USING AN ELECTROMAGNETIC FORMING MACHINE TO HEM A PLURALITY OF PANELS TO FORM A PANEL ASSEMBLY - A method of using an electromagnetic forming machine to hem a panel assembly includes providing an inner panel and an outer panel. The outer panel has a plurality of flanges and a plurality of relief areas. An electric forming machine is provided having a coil for discharging electric energy to generate a magnetic field. The inner panel is positioned such that portions of the outer edge of the inner panel are aligned with the flanges of the outer panel to form a loose assembly of panels. The loose assembly of panels is positioned proximate the electromagnetic forming machine such that the coil surrounds the flanges and is disposed substantially coplanar with a plane formed by the relief areas. The electromagnetic forming machine is activated to generate a magnetic field causing the flanges to bend over. | 11-05-2009 |
| 20090272167 | PULSED ELECTRO-HYDRAULIC CALIBRATION OF STAMPED PANELS - A tooling method for calibrating a partially formed metal part in an electro-hydraulic forming tool. The method includes loading a partially formed metal part onto a forming surface of a die. The part is then clamped onto the forming surface and the part is pulsed with a high rate energy pulse to overcome a spring-back effect in the part. The EHF calibration tool includes a punch to which a part is held by clamps while a capacitive discharge circuit is discharged through electrodes provided in the tool. Upon discharge of the capacitive discharge circuit through the electrodes, a high rate energy pulse is applied through a liquid to calibrate the part. | 11-05-2009 |
| 20090272168 | ELECTROHYDRAULIC FORMING TOOL AND METHOD OF FORMING SHEET METAL BLANK WITH THE SAME - An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die. | 11-05-2009 |
| 20100175447 | ELECTRO-HYDRAULIC FLANGING AND TRIMMING - A method of flange trimming a sheet metal panel to form a part including flanges for subsequent hemming or weld operation is disclosed. The method utilizes an electro-hydraulic forming (EHF) tool to form a channel within which a flange is cut out in a trimming operation. A combined flange/trim die may be provided in which both a channel forming operation and a flange trimming operation may be performed. A manufacturing system for fabricating a part by forming a channel in a peripheral portion and cutting the channel area to form a flange. The method also relates to a die for an EHF tool that defines a channel-shaped recess and has a trim edge for cutting a flange into the channel. | 07-15-2010 |
| 20110067467 | METHOD AND TOOL FOR CONTRACTING TUBULAR MEMBERS BY ELECTRO-HYDRAULIC FORMING BEFORE HYDROFORMING - 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. | 03-24-2011 |
| 20110067468 | Seal for Fluid Forming Tools - An electro-hydraulic forming tool for forming a sheet metal blank in a one-sided die has first and second rigid rings that engage opposite sides of a sheet metal blank. The rigid rings are contained within slots on a die portion and a hydraulic force applicator portion of the forming tool. The seals are either resiliently biased by an elastomeric member or inherently resiliently biased into contact with the blank. | 03-24-2011 |
| 20110067470 | Method and Tool for Expanding Tubular Members by Electro-Hydraulic Forming - An electro-hydraulic forming tool having one or more electrodes for forming parts with sharp corners. The electrodes may be moved and sequentially discharged several times to form various areas of the tube. Alternatively, a plurality of electrodes may be provided that are provided within an insulating tube that defines a charge area opening. The insulating tube is moved to locate the charge area opening adjacent one of the electrodes to form spaced locations on a preform. In other embodiments, a filament wire is provided in a cartridge or supported by an insulative support. | 03-24-2011 |
| 20110088442 | Hydromechanical Drawing Process and Machine - A hydromechanical forming tool is disclosed that may include electro-hydraulic forming chambers in which a stored charge circuit may be discharged through electrodes to improve the level of detail that may be formed in a blank. The hydromechanical forming tool may include a liquid chamber at the entrance to the draw chamber to reduce friction, as the blank is drawn into the draw chamber. The draw chamber may have a movable bottom wall that is moved in tandem with the punch to reduce the amount of liquid in the draw chamber and reduce the need to pump liquid into and out of the draw chamber during a hydromechanical forming tool cycle. | 04-21-2011 |
| 20110179846 | Method and Apparatus for Making a Part by First Forming an Intermediate Part that has Donor Pockets in Predicted Low Strain Areas Adjacent to Predicted High Strain Areas - A method of forming a part that has areas of high strain and predicted areas of low strain from a blank and method of designing a die for forming such a part. Predicted areas of low strain are identified that are adjacent to predicted areas of high strain. A pre-forming die is designed to form the blank to provide a donor pocket in an intermediate part in a predicted low strain area that is adjacent to the predicted high strain area. The donor pocket of the intermediate part is drawn into the predicted high strain area while forming the intermediate part into the part. | 07-28-2011 |
| 20120056445 | Body Panel and Reinforcement Assembly - A body panel assembly comprising an outer panel formed to a predetermined contour and a reinforcement assembly comprising a network or plurality of links that intersect to form a plurality of nodes. The network may be formed by a plurality of strips that are joined together at the nodes. The reinforcement assembly, or reinforcement panel, is attached with one surface flush to the outer body panel. One side of the reinforcement assembly is attached to the outer panel by brazing or bonding with an adhesive. | 03-08-2012 |
| 20120103045 | Electro-Hydraulic Forming Process with Electrodes that Advance within a Fluid Chamber Toward a Workpiece - A system for electro-hydraulically forming a sheet metal part in an electro-hydraulic forming (EHF) machine. The part in a first shape is placed in the EHF machine between a one-sided forming die and a chamber that is filled with a liquid. An electrode is discharged in the chamber to form the part toward the forming die. The electrode is advanced within the chamber toward the part and a subsequent discharge is provided in the chamber to form the part. A gap discharge EHF machine and a wire discharge EHF machine may be used in the system. | 05-03-2012 |
| 20120111080 | ELECTRODE ASSEMBLY FOR ELECTRO-HYDRAULIC FORMING PROCESS - An electrode assembly for electro-hydraulic forming tool in which the insulation sleeve is assembled over an electrode rod. The insulation sleeve has a deflection surface that is beveled or oriented at an angle relative to the axis of the electrode rod. The electrode assembly may include a replaceable conical receptacle that facilitates placement of an electrode tip an insulation sleeve tip. An electrode tip profile that is shaped to minimize erosion caused by discharge of the electro-hydraulic forming machine. | 05-10-2012 |
| 20120160004 | Method of Reducing Cycle Time in a Hydro-Mechanical Forming Process and a Tool for Hydro-Mechanically Forming a Part - A hydro-forming tool for use in a method of forming a blank into a liquid filled chamber. The chamber is formed by a container ring and a moveable wall that together define a variable volume chamber for containing the liquid. The wall is moveable relative to the container ring to provide a chamber in which the volume of liquid required to back up the blank is minimized. The liquid reduces friction at the chamber entry rim. Liquid may be ported through a counter punch to hydro-form the blank into the detail forming areas. | 06-28-2012 |
| 20120180542 | Method and Apparatus for Sharp Flanging and Trimming Sheet Metal Panels - A method and apparatus for forming flanges on a panel. The flanges may be weld flanges or hem flanges. The flanges stretch to reduce spring back and may be trimmed. The trimming operation is performed after the flange area is formed on the panel. | 07-19-2012 |
| 20120234070 | Method of Drawing a Blank by Preforming a Channel in a Preform that is Subsequently Drawn into a Die Cavity - A method of forming a blank into a part shape is provided in which the blank is drawn into one or more channels sequentially to form at least one pocket of material that is available to be drawn into the die cavity. Each pocket is formed by applying liquid pressure or mechanical pressure to form the blank into the channels. The channels may be filled with a liquid to reduce friction. Alternatively, portions of the blank may be drawn into a channel to form a first stage preform that includes a pocket. The pocket of the first stage preform is then drawn into the die cavity in a first partial drawing stage. The steps of drawing material into the channel and then into the die cavity may be repeated one or more times until the part is fully drawn into the desired shape. | 09-20-2012 |
| 20120247222 | Screening Test for Stretch Flanging a Trimmed Metal Surface - A method of testing metal samples is provided to simulate stretch flanging of trimmed surfaces. A sample having planar sides and a sidewall extending between the planar sides is placed in a fixture so that the planar sides are confined. The sidewall of the sample is bent about a curved surface while restricting buckling out of a planar area. One testing machine is disclosed in which a test specimen is clamped in a die with a nesting slot while a punch bends a sample against a forming surface that has a radius. In another testing machine, a mandrel and clamping element engage the planar sides of the sample while first and second bending members engage first and second end portions to bend one of the sidewalls of the sample about the mandrel. | 10-04-2012 |
| 20120285213 | Method and Apparatus for Hydro-Forming An Elongated Tubular Member - A method of hydro-forming an elongated tubular member that has areas of predicted high strain and areas of predicted low strain. The tubular member is initially deformed into a preliminary preform shape by compression in a preform die. Metal in the areas of predicted low strain is stretched during the preforming process by radially deforming the tube between two halves of the preform die. The preliminary preform is then expanded with internal hydro-forming pressure to form a preformed tube. The preformed tube is then hydro-formed into a final die to form the final shape for the part. The extra metal in the areas of low strain is stretched into the areas of high strain in the final hydro-forming operation. | 11-15-2012 |
| 20120312060 | Method and Apparatus for Pulsed Forming, Punching and Trimming of Tubular Members - A hydro-forming tool is disclosed in which first and second electrohydraulic forming (EHF) electrodes are used to provide a pressure pulse in opposite ends of a tubular pre-form. Alternatively, an accumulator with a rupturable membrane may be provided in opposite ends of a tubular pre-form for hydro-forming the tubular pre-form. A multiple discharge hydro-forming tool is also disclosed in which several pairs of accumulators are provided with selectively rupturable membranes that are ruptured to provide a pressure pulse in opposite ends of a tubular pre-form. The accumulators or EHF electrodes may be sequenced to provide separate pressure pulses that may be coordinated with retraction of a filler plug or shifting of a split ring into their respective retracted positions. A plurality of pressure pulses may be used to form, pierce and trim the tubular pre-form. | 12-13-2012 |
| 20120315109 | Metal Members and Assemblies that have Reinforced Punched Holes and Method of Forming the Holes - A metal member defining a hole in which the hole is reinforced by forming a flange and turning the flange back upon itself so that the rolled outer surface of the flange defines the perimeter of the hole. The sheared edge is spaced from the perimeter of the hole. The shaft of the fastener inserted in the hole contacts a non-sheared surface. A reinforcement ring may be assembled around the flange. | 12-13-2012 |
| 20130025343 | Method and Apparatus for Forming Sharp Styling Lines on Metal Panels - An apparatus and method for forming a style line with a sharp radius in a metal with lower formability than that of mild steel is disclosed. The apparatus and method use a die set with a means to back a portion of the metal having the style line formed with a material that moves with the surface of the style line as it is formed. In one embodiment an elastic member backs the metal panel, and in another embodiment a fluid medium backs the metal panel where the style line is formed. The apparatus and method achieve sharper radius style lines in metals like aluminum, advanced high strength steel, and ultra-high strength steel than a traditional hard surface die set can achieve. | 01-31-2013 |
| 20130067976 | Apparatus and Method Using Reduced Volume Electro-Hydraulic Chambers for Trimming and Joining Panels - A tool for modifying a workpiece by either trimming or joining the workpiece. The tool is an electro-hydraulic tool that uses a pulse transmitted through a liquid to trim a workpiece or to join two thicknesses of metal together. A method of trimming the workpiece includes the steps of providing a high voltage discharge in a liquid that drives a workpiece into engagement with a cutting edge of a tool steel insert. A method of joining two or more thicknesses of metal together includes the step of creating a high voltage discharge through an electrode that accelerates one panel or thickness of metal into a second panel that is held stationary by a backing plate while the first thickness of metal is accelerated into the second thickness of metal. | 03-21-2013 |
| 20130098129 | PROCESS FOR PRE-FORMING CYLINDRICAL TUBES INTO TUBULAR MEMBERS HAVING SHARP CORNERS - A method of forming a tubular member with portions having finished corners formed in a hydroforming operation by initially forming a pre-form that includes sharp corners. The pre-form includes bulges of the tube material between the sharp corners that flow toward the intended corner locations as the tubular member is hydroformed. The bulges may be external ribs or internal recesses. | 04-25-2013 |
| 20130098135 | Hemming a Flange With Compression to Form a Sharp Edge - A tool and method of hemming a panel wherein the tool engages a flange to apply a compressive force with a stop initially preventing a distal end of the flange from moving inwardly. The hemming tool bends the intermediate portion of the flange between the flange bend and the distal end toward the panel. The stop is withdrawn to allow the flange to be progressively formed toward the panel until the distal end is aligned with the intermediate portion. | 04-25-2013 |
| 20130186873 | Electro-Hydraulic Rivet and Method of Riveting and Welding Parts - A method of riveting two metal parts through a hole with an electro-hydraulic riveting tool. The electro-hydraulic riveting tool includes a tube that is inserted in the hole and an electrode that is inserted within the tube. A liquid is contained within the tube and the electrode is immersed in the liquid. A stored charge is discharged through the electrode to create a shockwave within the fluid that forms the tube into a rivet structure and creates solid state weld between the rivet flanges and the parts that are joined. | 07-25-2013 |
| 20130333435 | Draw Die Set with Rolling Elements on Punch and Draw Die Cavity - A draw die set defines a die cavity. A die entry area is provided at the location where a blank is drawn into the die cavity. A plurality of rolling elements such as cylindrical rollers or spherical balls are retained in pockets formed at the die entry area. A punch may be provided with rolling elements that engage a blank on the opposite side from the rollers in the die entry area. The rollers in the die entry area and on the punch may be arranged in rows that form a tangent surface that engages the sheet metal blank as it is drawn into the die cavity. | 12-19-2013 |
| 20140020441 | Method and Tool for Expanding Tubular Members by Electro-Hydraulic Forming - An electro-hydraulic forming tool having one or more electrodes for forming parts with sharp corners. The electrodes may be moved and sequentially discharged several times to form various areas of the tube. Alternatively, a plurality of electrodes may be provided that are provided within an insulating tube that defines a charge area opening. The insulating tube is moved to locate the charge area opening adjacent one of the electrodes to form spaced locations on a preform. In other embodiments, a filament wire is provided in a cartridge or supported by an insulative support. | 01-23-2014 |
| 20140026630 | Hydromechanical Drawing Process and Machine - A hydromechanical forming tool is disclosed that may include electro-hydraulic forming chambers in which a stored charge circuit may be discharged through electrodes to improve the level of detail that may be formed in a blank. The hydromechanical forming tool may include a liquid chamber at the entrance to the draw chamber to reduce friction, as the blank is drawn into the draw chamber. The draw chamber may have a movable bottom wall that is moved in tandem with the punch to reduce the amount of liquid in the draw chamber and reduce the need to pump liquid into and out of the draw chamber during a hydromechanical forming tool cycle. | 01-30-2014 |
| 20140044899 | Assembly Including Parts Made of Dissimilar Metals and the Method of Manufacturing the Assembly - A method of joining parts with an electromagnetic joining process and an assembly made according to the process. Seals are assembled to a first part and a second part is assembled over the first part and the seals. A lubricant is applied to the first part between the seals to preoccupy or partially fill the area within the joint to prevent moisture from penetrating into the joint and causing corrosion. A portion of the second part is deformed into recesses formed in the first part to join the first and second parts. | 02-13-2014 |
| 20140047889 | Method and Apparatus for Sharp Bending High Strength Panels - A method and apparatus for forming a flange on a panel. The flange is formed under compression to provide a reduced outside radius on the finished flange. The flange may be formed about an outside corner with a distal edge of the flange being restricted by a limiting edge formed on a die. Alternatively, the flange may be formed into an inside corner of a die with a compressive force being exerted on a distal edge of the flange by a compressing tool while a forming tool forms the flange with a reduced final outside radius. | 02-20-2014 |
| 20140053622 | METHOD AND APPARATUS FOR ELECTRO-HYDRAULIC FORMING - One or more electro-hydraulic forming tools are operated by a press and provide formed parts to a trimming operation. A locking mechanism holds the die against the chamber during the electro-hydraulic forming (EHF) discharge. The lock may be a pin or clamp. One method of manufacturing an article includes providing three EHF tools that feed a single trimming press on a line. An alternative embodiment discloses a single EHF tool that supplies parts on a production line to an electro-hydraulic (EH) trimming tool. An electro-hydraulic pulse generator may be used to provide a stored charge to the EHF tool and the EH trimming tool. | 02-27-2014 |
| 20140083151 | ELECTRODE ASSEMBLY FOR ELECTRO-HYDRAULIC FORMING PROCESS - An electrode assembly for electro-hydraulic forming tool in which the insulation sleeve is assembled over an electrode rod. The insulation sleeve has a deflection surface that is beveled or oriented at an angle relative to the axis of the electrode rod. The electrode assembly may include a replaceable conical receptacle that facilitates placement of an electrode tip an insulation sleeve tip. An electrode tip profile that is shaped to minimize erosion caused by discharge of the electro-hydraulic forming machine. | 03-27-2014 |
| 20140238096 | MANUFACTURING SYSTEM FOR ELECTRO-HYDRAULIC FLANGING AND TRIMMING A PART - A method of flange trimming a sheet metal panel to form a part including flanges for subsequent hemming or weld operation is disclosed. The method utilizes an electro-hydraulic forming (EHF) tool to form a channel within which a flange is cut out in a trimming operation. A combined flange/trim die may be provided in which both a channel forming operation and a flange trimming operation may be performed. A manufacturing system for fabricating a part by forming a channel in a peripheral portion and cutting the channel area to form a flange. The method also relates to a die for an EHF tool that defines a channel-shaped recess and has a trim edge for cutting a flange into the channel. | 08-28-2014 |
| 20150024229 | METHOD OF FORMING AN INTEGRAL GRID REINFORCEMENT IN A PART USING AN ELECTRO-HYDRAULIC FORMING PROCESS - A method of reinforcing a part formed from a sheet metal panel that has a predetermined area that requires reinforcement by forming a grid pattern of V-shaped channels in the predetermined area. The grid pattern may be formed by wire electrodes in an electro-hydraulic forming tool having a one-sided die. Alternatively, the grid pattern may be formed by a plurality of electrodes that are arranged in an array that is aligned in at least two directions on the opposite side of the part from the one-sided die. | 01-22-2015 |
| 20150047178 | Method of Hemming Sheet Metal Panels with Friction Element Applying a Counteraction Force to Prevent Hem Creep - A hemming tool for forming a hem securing an outer panel to an inner panel. The hemming tool includes a hemming die that has a first portion of a forming surface with a first coefficient of friction and a second portion that has a second coefficient of friction that is greater than the first portion. A flange on the outer panel is initially engaged by the first surface to begin forming the hem flange toward the inner panel. The flange is engaged by the second hemming surface to continue forming the flange toward the inner panel. A method of hemming a sheet metal assembly including an inner and an outer panel is also disclosed that utilizes the hemming die that has a forming surface with a second coefficient of friction that is greater than the first portion to reduce flange creep and roll-in during a hemming operation. | 02-19-2015 |
| 20150047409 | Hemming a Flange with Compression to Form a Sharp Edge - A tool and method of hemming a panel wherein the tool engages a flange to apply a compressive force with a stop initially preventing a distal end of the flange from moving inwardly. The hemming tool bends the intermediate portion of the flange between the flange bend and the distal end toward the panel. The stop is withdrawn to allow the flange to be progressively formed toward the panel until the distal end is aligned with the intermediate portion. | 02-19-2015 |
