Method and apparatus for axially shaping a tube

Abstract

A method and an apparatus for axially shaping a tube use a mandrel guided in the tube and an annular die guided on the outside of the tube. The tube is clamped in a clamping device. The outer diameter of the tube is reduced by moving the annular die in a pushing direction. In order to form undercuts on the outside and inside of the tube the method uses the following steps: Reversing the direction of movement of the die and the mandrel upon reaching an end position from the pushing direction to an opposite pulling direction. In a first setting step, the die and the mandrel are then moved in relation to one another to a first preset annular-gap setting, and in a subsequent first shaping step, the die and the mandrel are moved in the pulling direction, while maintaining the preset annular gap.

Claims

1.-13. (canceled)

14. A method for axially shaping a tube (200) with a mandrel (110) guided in the tube (200) and an annular die (120) guided on an outside of the tube (200), an inside diameter of the annular die (120) being smaller than an original outside diameter of the tube (200), wherein the annular die (120) has at least one conical axially extending transition portion (120-I, 120-II) on its inside, wherein the mandrel (110) has at least one conical axially extending transition portion (110-I, 110-II) on its outside, and wherein the die and the mandrel in their juxtaposition span an annular gap (130) for passing through and shaping a wall of the tube (200), the method comprising: clamping the tube (200) with an original wall thickness in a clamping device (140) such that at least one free portion (210) of the tube (200) remains for shaping the tube (200); inserting the mandrel (110) into the tube (200); reducing the original outside diameter of the tube (200) by pushing the annular die (120) in a pushing direction (S) towards the clamping device (140) over the free portion (210) of the tube (200), wherein the mandrel (110) leads the die (120) in the pushing direction; upon reaching an end position (E), reversing the direction of movement of the die (120) and the mandrel (110) from the pushing direction (S) to an opposite pulling direction (Z); moving, in a first setting step, the die (120) and mandrel (110) in relation to one another to a first preset annular-gap setting; and moving, in a first shaping step, the die (120) and mandrel (110) in the pulling direction (Z) over a first partial portion (T1) of the free tube portion (210), while maintaining the first preset annular-gap setting.

15. The method according to claim 14, wherein, after the first shaping step, the setting step and subsequent shaping step are repeated at least once more, wherein, in each further setting step, the die (120) and the mandrel (110) are set to a new annular-gap setting, which differs from the previous annular-gap setting.

16. The method according to claim 15, wherein, in at least one of the setting steps, the die (120) and the mandrel (110) are moved in relation to one another to a negative annular-gap setting, with which the conical transition portions (110-I, 120-I) of the die (120) and the mandrel (110), which taper towards the free end of the tube (200), span the annular gap at a rear side of the die.

17. The method according to claim 15, wherein the mandrel (110) has a cylindrical portion (110-III) in addition to the at least one conical transition portion (110-I, 110-II) on its outside; and wherein in at least one of the setting steps the die (120) and the mandrel (110) are set in relation to one another to a minimum vertical annular distance between the narrowest point of the annular die and the opposite cylindrical portion (110-III) of the mandrel (110).

18. The method according to claim 17, wherein, in the subsequent shaping step, the axial stretching of the tube (200) in the pulling direction (Z) to a wall thickness, which corresponds to the minimum vertical annular distance, takes place.

19. The method according to claim 15, wherein in at least one of the setting steps, the die (120) and mandrel (110) are moved in relation to one another to a positive annular-gap setting, with which the conical transition portions (110-II, 120-II) of the die (120) and mandrel (110), which flare towards the free end of the tube (200), span the annular gap at a front side of the die.

20. The method according to claim 15, wherein in at least one of the setting steps, the die (120) is stopped and the mandrel (110) is moved relative to the die (120).

21. The method according to claim 15, wherein in at least one of the setting steps the movement of the die (120) and the mandrel (110) in relation to one another is performed by moving the mandrel (110) while the die (120) continues to move continuously in the pulling direction (Z).

22. The method according to claim 15, wherein in at least one of the shaping steps, the die (120) and the mandrel (110) are moved synchronously.

23. The method according to one claim 16, wherein, in one of the setting steps, the die (120) and the mandrel (110) are set in relation to one another to a minimum vertical annular distance between the narrowest point of the annular die and the opposite cylindrical portion (110-III) of the mandrel (110), wherein, in the subsequent shaping step, a stretching of the tube (200) is performed, and wherein, in the subsequent further setting step, a negative annular-gap setting is made, such that, in the subsequent further shaping step, an undercut (220) is formed on the outside of the tube (200); or wherein, in the subsequent further setting step, a positive annular-gap setting is made, such that, in the subsequent further shaping step, an undercut (240) is formed on the inside of the tube (200).

24. The method according to claim 23, wherein, after the undercut (220, 240) is formed, a setting step is again performed to set the minimum annular gap; and wherein, in a subsequent further shaping step, the stretching of the tube (200) takes place.

25. An apparatus for axially shaping a tube (200), comprising: a clamping device (140) for clamping the tube (200), such that a free portion (320) remains; a shaping device (150) axially aligned with the clamping device (140) and having an axially displaceable annular die (120) and a mandrel (110) coaxially guided within the annular die (120), wherein the die (120) and the mandrel each have a conical axially extending transition portion (110-I, 110-II, 120-I, 120-II), wherein the die (120) and the mandrel (110) in their juxtaposition span an annular gap for passing through and shaping the wall of the tube (200); and a control device (152) allocated to the shaping device (150) for moving the die (120) and the mandrel (110) independently of each other along the free portion of the tube (200) for shaping the tube (200) in a pushing direction (S) and a pulling direction (Z), wherein the control device (152) is configured to perform the method according to claim 14, wherein the control device (152) is further configured for setting the die (120) and the mandrel (110) to the minimum annular distance from each other by a mechanical forced coupling between the die (120) and the mandrel (110), wherein the shaping device (150) comprises a traversing carriage (153) for the die (120) and a mandrel bar (113) with the mandrel (110) firmly attached to the mandrel bar (113), wherein the traversing carriage (153) and the mandrel bar (113) are mechanically coupled to each other for synchronous traversing, wherein the die (120) is axially displaceably mounted in the traversing carriage (153) with a clearance (x), wherein the clearance (x) represents a travel path of the mandrel (110) coupled to the traversing carriage (153) between a left-side and a right-side stop (150-I; 150-II) relative to the die (120), and wherein the mandrel (110) in the right-side stop position is opposite the narrowest point of the die (120) with its cylindrical portion (110-III), such that the minimum annular gap (d.sub.min) is formed between the mandrel (110) and the die (120).

26. The apparatus according to claim 25, wherein the mandrel (110) is profiled in a longitudinal direction with a gearwheel-shaped cross-section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The description is accompanied by 18 figures.

[0030] FIG. 1 shows the apparatus for carrying out the method in an initial position;

[0031] FIG. 2 shows the mandrel and die in an initial position for reducing the outside diameter of the tube;

[0032] FIG. 3 shows the die and mandrel in an end position after reduction of the outside diameter of the tube;

[0033] FIG. 4 shows the beginning of a first stretching of the tube beginning from an end position;

[0034] FIG. 5 shows the end of stretching the tube over a first partial portion of the free end of the tube;

[0035] FIG. 6 shows the setting of a negative annular gap at the beginning of the formation of an undercut on the outside of the tube;

[0036] FIG. 7 shows the completion of the formation of the undercut on the outside and the beginning of a second stretching process;

[0037] FIG. 8 shows the end of the second stretching process;

[0038] FIG. 9 shows the change of the ring gap setting at the end of the second stretching;

[0039] FIG. 10 shows the setting of the annular gap with positive increase to initiate the formation of an undercut inside the tube;

[0040] FIG. 11 shows the end of the formation of the undercut inside the tube,

[0041] FIG. 12 shows another change in the setting of the annular gap to initiate a third axial stretching operation;

[0042] FIG. 13 shows the end of the entire tube shaping with the die removed from the tube and the mandrel largely extracted;

[0043] FIG. 14 shows the shaped tube after the shaping steps described above have been carried out;

[0044] FIG. 15 shows the formation of longitudinal grooves on the inside of the tube by using a mandrel with a gearwheel-shaped cross-section;

[0045] FIG. 16 shows the shaping device with the formation of a forced coupling or forced guidance, as the case may be, for the die at the beginning of a reduction of the outer diameter;

[0046] FIG. 17 shows the shaping device moved to an end position in the pushing direction with a left-side stop on a clamping device; and

[0047] FIG. 18 shows the shaping device after a reversal of its direction of movement in the pulling direction with the die now stopping on the left side.

DETAILED DESCRIPTION

[0048] The invention is described in detail below with reference to the above figures in the form of exemplary embodiments. In all figures, the same technical elements are designated with the same reference signs.

[0049] FIG. 1 shows the apparatus in accordance with the invention. It includes a clamping device 140 for clamping a tube 200 to be shaped, such that a free portion 210, that is, a portion of the tube 200 that is not a clamped portion, remains for shaping. At the free end of the tube 200, a shaping device 150 can be seen, in which an annular die 120 and a mandrel 110 arranged coaxially thereto are displaceably mounted. In the exemplary embodiment shown herein, the die 120 includes two conical transition portions on the inside, a first transition portion 120-I of which tapers towards the free end of the tube 200 and a second transition portion 120-II of which flares towards the free end of the tube 200. The mandrel 110 has a first conical transition portion 110-I on its outside, which tapers towards the free end of the tube 200 and towards the shaping device 150, and a transition portion 110-II that flares towards the free end of the tube 200 and towards the shaping device 150. A cylindrical transition portion 110-III with a constant maximum outer diameter is formed in between. The pairing of annular die 120 and mandrel 110 is selected such that the minimum distance between the die at its narrowest point and the cylindrical portion 110-III of mandrel 110 having maximum outside diameter is less than or equal to the original wall thickness of the tube 200.

[0050] In order to carry out the method in accordance with the invention, it is not absolutely necessary that each of the die 120 and the mandrel 110 has two conical transition portions. To realize undercuts 220, 240 on the outside of the tube 200, only the conical transition portions on the die 120 and mandrel 110, which taper towards the free end of the tube 215, are required. To form undercuts 220, 240 only inside the tube 200, only the transition portions on the die 120 and mandrel 110, which flare towards the free end 215 of the tube and towards the shaping device 150, are required. If only a stretching of the tube 200 is desired, only the presence of the cylindrical portion 110-III at the mandrel 110 with a maximum outside diameter without conical transition portions is required. Depending on the desired shaping of the tube 200, the die 120 and the mandrel 110 must be selected in each case with the correspondingly necessary transition portions and minimum annular gap.

[0051] A control device 152 is allocated to the shaping device 150 for moving the die 120 and the mandrel 110 independently of each other along the free portion 210 of the tube 200 in a pushing direction S and a pulling direction Z. When the die 120 is moved in the pushing direction, the tube 200 is subjected to compression and there is a risk of bending and compression of the tube 200. When the die 120 and mandrel 110 are moved in the pulling direction, there is a risk of the tube 200 tearing, in particular if the annular gap is set too narrow.

[0052] FIG. 1 shows the initial position of mandrel 110 and die 120 for carrying out the method. The mandrel 110 and die 120 are located at the free end of the tube 200 and aligned coaxially with it. The mandrel 110 has already moved a short distance into the free end of the clamped tube 200.

[0053] FIG. 2 shows the beginning of a desired reduction of the outer diameter of the tube 200 by pushing the annular die 120 in the pushing direction S towards the clamping device 140. Given that the smallest clear inside diameter D.sub.M of the die 120 is smaller than the outside diameter D.sub.R of the tube 200, the desired reduction of the outside diameter occurs when the die 120 is moved in the pushing direction. Thereby, the wall of the tube 200 slides along the transition portion 120-I of the die 120. The mandrel 110 thereby precedes the die 120 in the pushing direction S; it is not involved in the shaping process itself in that its surface does not contribute to the shaping, that is, specifically to the reduction of the outer diameter. During this shaping process, it serves at most to guide and support the tube 200 against bending.

[0054] In contrast to the subsequent shaping step, with which the die 120 and the mandrel 110 are moved in the pulling direction, the annular gap between the die 120 and the mandrel 110 is not important when the outer diameter is reduced by moving the die 120 in the pushing direction; its size is irrelevant; in particular, the mandrel 110 can advance so far in front of the die 120 that a conical transition portion of the mandrel 110 facing the die 120 has no influence on the wall of the tube 200 if the latter is reduced by the movement of the die 120.

[0055] In accordance with FIG. 3, the reduction of the outer diameter D.sub.R of the tube 200 occurs over an essential part of the free portion 210, specifically in this case until the die 120 abuts the clamping device 140. Of course, the end of the reduced tube portion defined in this way is merely exemplary; in fact, the reduction of the tube 200 can end even before it reaches the clamping device 140.

[0056] In FIG. 3, it can be clearly seen that the material displaced during the reduction of the outer diameter results in an increase in the wall thickness of the tube 200 in the region of the reduced outer diameter.

[0057] In order to reverse this increase in wall thickness, at least in a first partial portion T1 of the free end of the tube 200, the die 120 and the mandrel 110 are moved to their minimum ring spacing d.sub.min in a first setting step, in accordance with FIG. 4. For this purpose, the direction of movement of the mandrel 110 is reversed from the pushing direction S to the opposite pulling direction Z, and the mandrel 110 is moved towards the die 120. To set the minimum annular gap d.sub.min, as already mentioned, the mandrel 110 is moved relative to the die 120 such that the cylindrical portion 110-III of the mandrel faces the location of the annular die with the smallest annular diameter.

[0058] Such setting of the minimum annular gap by changing the position of the die 120 and the mandrel 110 in relation to one another can be made, on the one hand, electronically or, on the other hand, as shown in FIGS. 16 to 18, with the aid of a mechanical forced coupling of the die 120 and the mandrel 110 within the shaping device 150. A traversing carriage 153 is provided within the shaping device 150 for the axial movement of the die 120 in the pushing and pulling directions. A mandrel bar 113 is arranged coaxially with the traversing carriage 153 for the axial movement of the mandrel 110 in the pushing and pulling direction. With electronic control, the traversing carriage 153 with the die 120 and the mandrel bar 113 with the mandrel 110 —electronically controlled—are moved independently of each other in the axial direction.

[0059] In the case of forced coupling, the die 120 is mounted in or on, as the case may be, the traversing carriage 153 so as to be displaceable with an axial clearance x in the axial direction. Their movement is limited by two stops 150-I and 150-II in the axial direction. In the initial position shown in FIG. 16 at the beginning of a movement in the pushing direction to reduce the outer diameter, the die 120 strikes the right-side stop 150-I within a traversing carriage 153. From this initial situation, the traversing carriage 153 is moved together with the die 120 and synchronously with the mandrel 110 in the pushing direction S towards the clamping device 140. FIG. 17 shows the stop of the traversing carriage 153 at the clamping device 140. During the specified movement in the pushing direction S, the die 120 always strikes the right-side stop 150-I. In the embodiment of the shaping device with the specified forced coupling, the traversing carriage 153 of the shaping device 150 is mechanically coupled to the mandrel 110 or to the mandrel bar 113, as the case may be. This means that a movement of the carriage 153 in the axial direction is carried out by the mandrel 110 with the mandrel bar 113 in the same way.

[0060] When the stop position of the carriage 153 on the clamping device 140 shown in FIG. 17 is reached, the die 120 remains at its right-side stop position 150-I, as already mentioned. At the same time, the mandrel 110 is offset or advanced, as the case may be, to the left relative to the die 120 due to the forced coupling with the traversing carriage 153—as was also the case during the entire previous pushing movement. In order to achieve a change in the setting of the annular gap to the minimum annular gap d.sub.min in this situation, the direction of movement of the carriage 153—and coupled with this also the direction of movement of the mandrel 110—is reversed from the pushing direction S to the pulling direction Z, and the traversing carriage 153 initially moves together with the mandrel 110 a short distance in the axial direction according to the axial clearance x. Until then, the position of the die 120 remains unchanged, but the mandrel 110 is moved towards the die 120 in the pulling direction. This changes the annular gap between the die 120 and the mandrel 110. The clearance x is dimensioned such that, in accordance with FIG. 18, the cylindrical portion 110-III of the mandrel 110 moves exactly below the smallest clear diameter of the die 120. In this way, in accordance with FIG. 18, the minimum annular gap d.sub.min is preset for the subsequent shaping step of axial stretching.

[0061] The minimum ring spacing d.sub.min can be less than or equal to the original wall thickness of the tube 200. In any case, in accordance with FIG. 4, it is smaller than the increased wall thickness of the tube 200 due to the reduction of the outer diameter. In this respect, FIG. 4 shows the beginning of a subsequent first shaping step, with which the direction of movement of the die 120 is also reversed from the pushing direction S to the pulling direction Z. Within the framework of such first shaping step, the die 120 and the mandrel 110 are then moved in the pulling direction Z while maintaining the preset minimum ring distance d.sub.min. Thereby, the specified axial stretching of the tube takes place for the purpose of reducing the increased wall thickness to the size of the annular gap d.sub.min. Preferably, the die 120 and the mandrel 110 move synchronously. However, the synchronous method is not absolutely necessary during axial stretching; the only prerequisite would be that, when the die 120 and the mandrel 110 move in relation to one another, the region of the smallest inner diameter of the die 120 moves in the region of the cylindrical portion of the mandrel 110, such that the minimum annular gap d.sub.min is maintained constant during axial stretching.

[0062] FIG. 5 shows the end of axial stretching over the first partial portion T1 of the free tube portion.

[0063] At this point, in accordance with FIG. 6, after the first shaping step, a second setting step is performed, with which the annular gap between the die 120 and the mandrel is newly set. Specifically, the annular gap is set negatively here, that is, the setting is made such that the annular gap is spanned by the conical transition portions 110-I of the mandrel 110 and 120-I of the die 120, which taper or converge, as the case may be, towards the free end 215 of the tube 200. Viewed in the vertical direction, such transition portions face each other in regions. The newly set annular gap is located on the rear side of die 120 as viewed in the pulling direction Z. The change in the position of die 120 and mandrel 110 in relation to one another takes place in the region of a tube portion T.sub.E2 following the first partial portion T1.

[0064] The tool pair of die 120 and mandrel 110 is then moved further in the pulling direction Z with this new negative annular-gap setting, and an undercut 220 is formed in the second shaping portion T2 on the outside of the previously thickness-reduced tube.

[0065] FIG. 7 shows the end of the second shaping portion T2.

[0066] At the end of the desired length T2, the die 120 and the mandrel 110 are again set to the minimum ring distance d.sub.min, that is, moved in relation to one another. This is done via a further setting portion T.sub.E3; see FIG. 7.

[0067] In accordance with FIG. 8, the die 120 and mandrel 110 are then moved over a further partial portion T3 of the free tube portion 210 while maintaining the minimum annular gap d.sub.min. In such third partial portion T3, the tube 200 is again axially stretched to reduce the wall thickness to the minimum annular gap d.sub.min.

[0068] In accordance with FIGS. 9 and 10, the annular-gap setting is then changed again; this time to a positive annular gap. With such positive annular gap, the annular gap is spanned by the conical transition portions 120-II and 110-II of the die 120 and mandrel 120, which are flared towards the free end of the tube 215. With such positive annular-gap setting, the conical transition portions with flaring towards the tube end are generally opposite each other as seen in the vertical direction, at least in sections. The positive annular gap is formed on the front side of the die 120, as viewed in the pulling direction. In accordance with FIG. 9, the positive annular-gap setting is realized by the die 120 temporarily reversing its direction of movement in the pushing direction at the end of the third partial portion T3 and in this way changing its relative position to the stationary mandrel 110, in such a way that the specified positive annular gap is set. However, this way of changing the setting of the annular gap is only exemplary; of course, the relative position at the end of T3 could also be achieved by moving the mandrel 110 further in the pulling direction relative to the die 120, which is stationary, for example, albeit with the use of force. Of course, the movement of both the die 120 and the mandrel 110 in relation to one another would also be conceivable.

[0069] Moving the die 120 and mandrel 110 while maintaining the now set positive annular gap results in the formation of an undercut 240 on the inside of the tube 200, as shown in FIG. 11. The formation of the undercut 220, 240 extends over a partial portion T4 of any desired length. At the end of the fourth partial region T4, the ring gap can again be changed, for example again to the minimum ring gap d.sub.min. Then, after a further setting portion TE5, a fifth partial portion T5 results again with the axially stretched tube; see FIGS. 12 and 13.

[0070] FIG. 14 shows the finished tube 200 after all the individual steps described above have been carried out.

[0071] It is important to mention that the sequence of steps explained here and the final result shown in FIG. 14 are merely exemplary with regard to the machining steps performed. Thus, after the one-time reduction of the outer diameter of the tube 200, any sequences of axial stretching, formation of undercuts 220, 240 on the outside of the tube 200 and formation of undercuts on the inside of the tube 200 are possible. In particular, the sequence of portions with axial stretching and the formation of undercuts 220, 240 proposed here is not mandatory. Rather, formed undercuts 220, 240 on the outside may also be immediately followed by formed undercuts 220, 240 on the inside of the tube 200 in the pulling direction; and vice versa. The partial portions over which the shaping of the tube 200 takes place in each case can in principle be of any length; they are limited only by the length of the free portion 210 of the tube 200. Thus, axial stretching, the formation of an undercut 220, 240 on the outside or the formation of an undercut 220, 240 on the inside of the tube 200 can also take place continuously over the entire free portion 210.

[0072] The wall thickness of the tube 200 in the region of an undercut 220, 240 depends on the actual set positive or negative annular distance, that is, the actual distance between the conical transition portions. Due to the electronic setting of the die 120 and the mandrel 110 in relation to one another, this distance and thus the wall thickness in the region of an undercut 220, 240 can be set highly precisely to any desired dimension.

[0073] FIG. 15 shows an example of the shaped tube 200 when a profiled mandrel 110 is used, specifically when a mandrel 110 with a gearwheel-shaped cross-section is used. In this way, it is then possible to realize, for example, an internal toothings 260 of the tube 200 over a long length in the case of very thin-walled tubes 200. The production of external toothings is also possible when using appropriately profiled ring dies. The forces required, in particular tensile forces, to realize such toothings are significantly lower than using dies 120 and mandrels 110 without any corresponding toothing.

LIST OF REFERENCE SIGNS

[0074] 110 Mandrel [0075] 110-I Axially extending conical transition portion of the mandrel, which is tapered towards the free end of the tube; [0076] 110-II Axially extending conical transition portion of the mandrel, which is flared towards the free tube end; [0077] 113 Mandrel bar [0078] 120 Die [0079] 120-I Axially extending conical transition portion of the die, which is tapered towards the free end of the tube [0080] 120-II Axially extending conical transition portion of the die, which is flared towards the free tube end [0081] 130 Annular gap [0082] 140 Clamping device [0083] 150 Shaping device [0084] 150-I Right-side stop for die [0085] 150-II Left-side stop for die [0086] 152 Control device [0087] 153 Traversing carriage [0088] 200 Tube [0089] 210 Free portion of the tube [0090] 215 Free end of the tube [0091] 220 Undercuts on the outside of the tube [0092] 240 Undercuts on the inside of the tube [0093] 260 Internal toothing of the tube [0094] S Pushing direction [0095] Z Pulling direction [0096] E End position [0097] T1, T2, T3 Partial portions of the free tube portion with shaping [0098] T.sub.E1, T.sub.E2, T.sub.E3 Transition portions of the free tube portion for changing the annular-gap setting [0099] D.sub.R Original outer diameter of the tube [0100] D.sub.M Minimum clear inner diameter of the annular die [0101] d.sub.min Minimum annular gap