Hydroforming tool and method to augment a ram forming machine

Abstract

A system comprises a ram tool subassembly and a master die subassembly. The ram tool subassembly further comprises a tool stick, a back body, a piston assembly, a piston housing, and a pusher holder. The master die subassembly further comprises a bottom tooling plate, a bottom master jaw, a nose block, a top master jaw, and a top tooling plate.

Claims

1. A system, comprising: a ram tool subassembly, wherein the ram tool subassembly further comprises: a tool stick; a back body; a piston assembly; a piston housing; and a pusher holder; a master die subassembly, wherein the master die subassembly further comprises: a bottom tooling plate; a bottom master jaw; a nose block to receive an unformed tube; a top master jaw; and a top tooling plate; and a compressible fluid source coupled to the ram tool subassembly, wherein: the compressible fluid source fills the unformed tube with a compressible fluid; and the ram tool subassembly moves forward to compress the fluid such that the compressible fluid is placed under pressure to form a formed tube from the unformed tube.

2. The system of claim 1, wherein the piston assembly further comprises a piston back plate.

3. The system of claim 1, wherein the piston housing further comprises: a check valve; a pressure transducer; and a pressure safety head.

4. The system of claim 3, wherein the pressure safety head further comprises a rupture disk.

5. The system of claim 3, wherein the pressure transducer is coupled to an electrical source such that the pressure transducer produces an electrical output signal when the pressure transducer is exposed to a pressure source.

6. The system of claim 3, wherein the check valve is a one-way flow valve.

7. The system of claim 1, wherein the pusher holder further comprises a plurality of opposing pusher blocks.

8. The system of claim 1, wherein the master die subassembly further comprises: a first pusher block for the bottom master jaw; and a second pusher block for the top master jaw.

9. The system of claim 1, wherein the master die subassembly further comprises a pressure gauge.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of the main assembly of the hydroforming tool constructed in accordance with the present disclosure.

(2) FIG. 2 is an exploded perspective view of the ram tool subassembly for the tool shown in FIG. 1.

(3) FIG. 3 is an exploded perspective view of the master die subassembly for the tool shown in FIG. 1.

DETAILED DESCRIPTION

(4) Referring now to the drawings in detail, wherein like-numbered elements refer to like elements throughout, FIG. 1 illustrates a preferred embodiment of the main assembly of the hydroforming tool (the tool). The tool comprises a ram tool subassembly 100 and a master die subassembly 200.

(5) FIG. 2 illustrates an exploded view of the elements of the ram tool subassembly 100. Moving away from the tool stick 10, the subassembly includes a back body 12, a piston assembly 14, a piston housing 16, and a pusher holder 18. The back body 12, the piston assembly 14, and the piston housing 16 may be substantially square in shape. The square shape aids the ram tool subassembly 100 in maintaining its structural integrity under the pressures used in hydroforming. However, examples are not so limited, and other shapes may be used for the back body 12, the piston assembly 14, and/or the piston housing 16. The back body 12, piston assembly 14, and piston housing 16 may be manufactured from a high-strength, fracture-resistant alloy, such as Hardox400. Examples are not so limited, however, and any high-strength and fracture resistant alloy or metal may be used to manufacture the back body 12, the piston assembly 14, and/or the piston housing 16.

(6) The piston assembly further comprises a piston back plate 15. The piston housing 16 further comprises a check valve 20, a pressure transducer 22, and a pressure safety head 24. The pressure safety head 24 comprises a rupture disk 26 that allows for pressure relief in a situation where system pressure is exceeded, or is beyond the pressure targeted for proper hydroforming of a particular tube application. The pressure transducer 22 converts fluid pressure to an electrical signal for monitoring and controlling pressure in the ram tool subassembly 100, and in the piston housing 16 in particular. When connected to an electrical source and exposed to a pressure source, the pressure transducer 22 produces an electrical output signal that is proportional to the pressure applied. The check valve 20 allow for a one-way flow of a fluid into the ram tool subassembly 100. The pusher holder 18 further comprises opposing pusher blocks 28. A plurality of shafts and fasteners are also shown.

(7) Referring now to FIG. 3, an exploded view of the master die subassembly 200 that complements the ram tool subassembly 100 is shown. As shown, moving from bottom to top, the master die subassembly 200 comprises a bottom tooling plate 30, a bottom master jaw 32, a nose block 34, a top master jaw 36, and a top tooling plate 38. Pusher blocks 42 and 46 are provided for the bottom master jaw 32 and the top master jaw 36, respectively. A pressure gauge 40 is also provided.

(8) In the present invention, an unformed tube (not shown) is loaded into a lower cavity of a sliding die, over the edge of a stationary sealing nose. The die is then clamped shut. The single ram nose is fed forward to seal the opposite end of the unformed tube. A lower pressure, but higher volume, pump then begins to fill the unformed tube. When the tube has been filled, the single ram cylinder, via the piston assembly 14, moves forward to compress the fluid. At the same time, the single ram cylinder is feeding in the material to form the raw tube to the desired shape. The pressure is created by filling the unformed tube with compressible liquid and using the ram cylinder, via the piston assembly 14, to generate the pressure necessary to form the tube in the shape desired.