Patent Grant
10413957
The present invention relates to machines for and methods of plastic deformation, advantageously at high velocity and at high pressure, of the wall of a workpiece by means of a technique of electro-hydraulic forming.
Certain materials have a limited ductility. That is particularly the case with metals such as titan alloys or types of steel having a high limit of elasticity.
In this context, shaping of certain workpieces, especially tubular pieces, may be done by means of hydroforming machines, such as described in documents U.S. Pat. Nos. 6,305,204 4,557,128. In those machines, the fluid under pressure transits to the forming chamber through a channel having a small diameter provided in a cylindrical tool penetrating into the tube to be deformed.
Those hydroforming techniques ensure a progressive deformation of the material through obtaining provision of fluid under pressure by specific means.
But the deformation of the material obtained by such hydro-forming techniques generates an elastic return at the end of the process, which may appear limiting as far as applications are concerned.
In a very different field, which needs rather specific knowledge, forming of those materials may be done by high-velocity and high-pressure forming techniques, especially by electro-hydraulic forming techniques, or electro-hydroforming techniques, such as described in document EP-1 488 868.
Those electro-hydraulic forming techniques are based on the rapid movement of a forming fluid applied to one of the faces of the wall of the workpiece to be deformed, together with a rapid increase of the pressure of that fluid (contrarily to the progressive increase of pressure of hydroforming machines).
The forming fluid is then used as a means for stamping the piece to be deformed.
The energy that is necessary for the forming action is available as a shock wave in the forming fluid.
However, present electric hydroforming machines are not entirely adapted to apply certain deformations to specific structures of workpieces, especially an expansion to cylindrical tubular pieces having small diameters.
In this context, the present invention proposes a new electro-hydraulic forming machine, and a new method, appropriate for generating dynamic deformation of a projectile part of the wall of a workpiece to be formed, and especially adapted to the shaping of cylindrical tubular pieces having small diameters.
The corresponding electro-hydraulic forming machine is thus intended to allow for plastic deformation of a projectile part of the wall of a workpiece to be formed, preferably a cylindrical tubular piece, by a forming fluid intended for being applied on an internal face of that projectile part.
That electro-hydraulic forming machine comprises:
According to a particularly interesting embodiment, the application tool is shaped as a cylindrical tubular element which delimits the chamber intended to be filled with said forming fluid, and which comprises two ends:
In that case, preferably, the downstream holes of the application tool end radially through said application tool and are distributed over the circumference of its downstream end.
The downstream end of the application tool comprises a cylindrical external surface in which a groove is formed into which the downstream holes end, said groove being intended for forming a reserve of liquid in front of the imprint of the target support.
According to an advantageous feature, the application tool comprises, at the level of the downstream hole or holes, means for ensuring tightness to the forming-fluid, in order to limit the work zone of the latter. In this case, the tightness means comprises preferably
According to a particularly interesting form of embodiment, the means for generating the shock wave comprises a piston adapted for ensuring a pressure multiplying effect, said piston being movable in translation/linear motion through an upstream hole of the application tool, in fluid communication with its chamber, said piston comprising two ends:
According to still another particularity, the chamber of the application tool is further connected to
The target support may be a matrix or a piece to be crimped on the workpiece to be deformed.
The present invention also relates to the tool for applying a shock wave to the forming fluid, for an electro-hydraulic forming machine as defined here-above.
The invention further relates to a method of plastic deformation of a projectile part of the wall of a workpiece by means of an electro-hydraulic forming machine as defined here-above, for example a cylindrical tubular piece for its expansion or for its shaping.
This method comprises the following steps:
The invention will be further illustrated, without being limited at all, by the following description of different embodiments represented on the enclosed drawings wherein
The electro-hydraulic forming machine 1, represented on
In a general manner, the terms “deformation”, “forming”, “shaping” are employed in an equivalent manner.
That electro-hydraulic forming machine 1 allows for implementing methods of high-velocity forming which are able to push the limits of forming material and to limit their elastic return.
The workpiece P to be deformed is made of a material chosen amongst metallic materials (such as titan alloys, steels with high elasticity limit) or non-metallic, ductile or non-ductile materials.
The workpiece P advantageously consists of a cylindrical tubular piece having a longitudinal axis P′ and comprising a wall P1 having an internal face P11 and an external face P12.
A “projectile” part P13 of the wall P1 of that workpiece P is intended to undergo a “plastic deformation”, i.e. a permanent deformation obtained by displacing matter, especially of the stamping or drawing type.
That plastic deformation consists advantageously in a radial expansion or beading, called “dudgeonnage” in French, of the projectile part P13 of the workpiece P to be deformed.
Therefore, the forming fluid F is intended to be applied, with high velocity and with high pressure, on the internal face P11 of the projectile part P13 of the wall P1 to be deformed. Thus, what is implemented is to obtain pressing the projectile part P13 of that wall P1 at high velocity onto the imprint of a target support by means of high hydraulic pressure.
The forming fluid F consists advantageously of a liquid, preferably of water.
The intended “high velocity” is, without being limiting at all, between 100 and 150 m/s; and the indicated “high pressure” is, here again without being limiting at all, several hundreds of bars, or even higher than thousand bars.
To this end, according to the invention, the electro-hydraulic forming machine 1 comprises mainly:
As will be specified hereafter, the application tool 4 allows for local application of a shock wave on the projectile part P13, by means of the forming fluid F, advantageously for causing the radial expansion of an annular band which is part of the cylindrical tubular piece.
In a general manner, the “internal face” of the projectile part P13 is to be understood as the face onto which the forming fluid F is applied; and the “external face” of the projectile part P13 is to be understood as the opposite face which is intended to get pushed into the target imprint and to fit the latter.
The target support 2 advantageously consists of a matrix that may be intended to receive a piece to be expanded radially (or a piece to be crimped).
The target support 2 comprises a cylindrical through-hole 21 comprising an annular imprint 22 intended to get in front of the external face P12 of the projectile part P13 of the wall P1 to be deformed.
The diameter of that cylindrical through-hole 21 corresponds advantageously, within a clearance, to the external diameter of the workpiece P to be deformed, as defined by the external face P12 of its wall P1.
The profile of the imprint 22 is adapted accordingly, especially as a function of the final shape as wanted for the projectile part P13 of the wall P1 to be deformed.
The application tool 4 consists of a cylindrical tubular element having a longitudinal axis 4′ intended to extend in a coaxial manner, or at least in an approximately coaxial manner, with respect to the longitudinal axis P′ of the piece P to be deformed and with respect to the longitudinal axis of the cylindrical through-hole 21.
The application tool 4 comprises two ends 41:
The application tool 4 further comprises two cylindrical surfaces 43:
The diameter of the cylindrical external face 43b of the application tool 4 corresponds advantageously, within a clearance, to the diameter of the internal face P11 of the wall P1 to be deformed.
The diameter of the cylindrical external face 43b is for example comprised between several millimeters (for example 2 through 20 mm) and several centimeters (for example 2 through 5 cm).
The downstream holes 42 of the application tool 4 are intended to end in front of the projectile part P13 of the wall P1 to be deformed and in front of the imprint 22 of the matrix 2.
The downstream holes 42 are adapted to allow for passing of the forming fluid F from said chamber 44, especially for ensuring optimal propagation of the shock wave generated in that forming fluid F towards the imprint 22 of the target support 2.
Therefore, the downstream holes 42 are open ended, i.e. on the one hand, they are in fluid communication with the chamber 44 at the inside and, on the other hand, open ended at the level of the peripheral external surface 43b of the application tool 4.
The downstream holes 42 are regularly distributed over the circumference of the application tool 4, and they are spaced at a constant angular sector. The downstream holes 42 are at least two; here, they are four, spaced two by two at an angular sector of about 90°.
Each downstream hole 42 extends radially, i.e. on a radial axis passing through the axis 4′ of the application tool 4.
Further, the downstream holes 42 are each shaped as elongate slot with a longitudinal axis extending in parallel to the longitudinal axis 4′ of the application tool 4.
The length of said holes 42, along the longitudinal axis 4′, corresponds at least approximately to the width of the projectile part P13 along the longitudinal axis P′ of the wall P1 or to the width of the imprint 22 of the target support 2.
The width of said holes 42 is adapted for occupying a maximum portion of the circumference of the downstream end 41b of the application tool 4, while maintaining a structure which is able to resist to the mechanical strain acting upon.
The external surface 43b of the application tool 4 further comprises, on the side of its downstream end 41b, a groove 46 into which the downstream holes 42 end.
That structure allows for a homogeneous distribution of the forming pressure over the whole internal circumference of the projectile part P13 to be deformed by radial expansion.
To this end, the groove 46 of generally annular shape extends over the whole circumference of the external surface 43b of the application tool 4 and ends into the periphery (at the opposite of its longitudinal axis 4′).
The length of said groove 46 is equal to, or at least approximately equal to, the length of the downstream holes 42. The length of said groove 46, along the longitudinal axis 4′, corresponds at least approximatively to the width of the projectile part P13 along the longitudinal P′ of the wall P1 or to the width of the imprint 22 of the target support 2.
Its depth is some tenths of millimeters, for example comprised between 0.3 mm and 0.7 mm.
Said groove 46 is thus intended to form, together with the internal surface P11 of the projectile part P13 of the wall P1 to be deformed, a reserve of liquid R in front of the imprint 22 of the matrix 2.
The application tool 4 further comprises, at the level of its downstream holes 42, means 47 for ensuring tightness to the forming fluid F at its peripheral surface 43b.
Said tightness means 47 contribute to limit the work zone of the forming fluid F on either side of the downstream holes 42 and of the groove 46.
Here, said tightness means 47 comprises two O-rings 47a which are situated on either side of the downstream holes 42 and of the groove 46, around the external surface 43b of the application tool 4.
Said O-rings 47a are thus situated respectively upstream, as to the one, and downstream, as to the other, with respect to said downstream holes 42 and said groove 46.
Said O-rings 47a are adapted for getting in between the external surface 43b of the application tool 4 and the internal surface P11 of the wall P1 to be deformed, in order to participate in defining the upstream/downstream limits of the reserve of liquid R.
The chamber 44 of the application tool 4 extends over a downstream portion of the application tool 4, at the side of its downstream end 41b.
Said chamber 44 has a generally cylindrical shape with a diameter d defined by the internal surface 43a of the application tool 4.
For example, said chamber 44 has a diameter comprised between several millimeters and several centimeters and a volume sufficiently big for obtaining the deformation as wanted.
At the downstream end, the chamber 44 radially ends by the afore-mentioned downstream holes 42.
At an upstream end, said chamber 44 ends up by an upstream hole 48 located coaxially with respect to the longitudinal axis 4′ of the application tool 4.
Said upstream hole 48 is in fluid communication with the chamber 44; it is connected to the means 3 for generating the shock wave in the forming fluid F contained in the chamber 44.
By “shock wave”, one understands particularly, without being limited by any theory, a wave associated to an abrupt transition; it particularly has the shape of a high-pressure wave.
By “shock wave”, one further understands a shock-type movement (moving, pressure or any other variable), associated to the propagation of the shock through the forming fluid F.
Said shock wave is advantageously characterized by a wave front in which the pressure increases abruptly up to a relatively important value.
Here, means 3 for generating the shock wave in the forming fluid F comprises a piston 31 which is movable in linear motion through the upstream hole 48 of the chamber 44, and this in a direction oriented coaxially to its longitudinal axis 4′.
The piston 31 extends over an upstream portion of the application tool 4, at the side of its upstream end 41a.
Said piston 31 is provided with two opposite ends:
For example, the stroke of piston 31 is superior to the volume of liquid to be moved for allowing for the deformation; and its projection velocity is comprised between 100 and 150 m/s.
Said piston 31 is advantageously of the type of having a pressure multiplying effect.
By “pressure multiplying effect”, one understands a pressure inside the chamber 44 of the application tool 4 which is equal to at least twice the pressure generated at the upstream end 31b of the piston 31.
By “pressure multiplying effect”, one advantageously understands a multiple of the order of 5 through 15 (for example in the order of 10) between the pressure acting upon the upstream end 31b of the piston 31 and the pressure acting upon its downstream end 31a.
To this end, the downstream end 31a of the piston 31 has a front surface which is of the order of 5 through 15 (for example in the order of 10) times less than the front surface of the upstream end 31b of the piston 31. The cross-section relationship of the piston 31 allows performing multiplying of pressure.
For example, the diameter of the front surface of the downstream end 31a of the piston 31 is comprised between 10 mm and 20 mm and the diameter of the front surface of the upstream end 31b of the piston 31 is comprised between 50 and 70 mm.
The pressure is advantageously multiplied by a factor in the order of 5 through 15 (for example in the order of 10) from the upstream side to the downstream side.
Said piston thus applies a principle of “intensifying” the pressure of the fluid.
In the present case, the upstream end 31b of the piston 31 forms a head of a piston and its downstream end 31a forms a shaft extending inside the chamber 44.
The diameter of said downstream end 31a of the piston 31, forming a shaft, is advantageously identical, within a clearance, to the diameter of the chamber 44.
Practically, the workpiece P to be formed is lodged appropriately in the matrix 2 by positioning inside the through-hole 21.
Particularly, the projectile part P13 of its wall P1 is lodged appropriately, axially, in front of the imprint 22 of said matrix 2.
Then, the application tool 4 is introduced into said piece P, so that its downstream holes 42 is lodged in front of said same imprint 22 of the matrix 2.
To this end, the application tool 4 is introduced, the one coaxially with respect to the other, by linear motion through the free end of the workpiece P.
The tightness between the downstream end 41b of the application tool 4 and the wall P1 to be deformed is ensured by tightness means 47 which get in between said external surface 43b of the application tool 4 and the internal surface P11 of said wall P1.
Then, the application tool 4 is appropriately filled with the forming fluid F, in order that the latter entirely fills the chamber 44 by extending inside the downstream holes 42 and that it fills its groove 46 for forming the reserve of liquid R.
Then, the means 32 for the operation of linear motion of the piston 31 are actuated in order to cause its projection from a retracted upstream position (upper half of
The downstream end 31a of the piston 31 is thus moved at high velocity in the direction of the downstream holes 42 of the application tool 4, said movement generating a shock wave in the forming fluid F inside the chamber 44 of the application tool 4.
Said shock wave propagates in the forming fluid F up to the reserve of liquid R.
The forming fluid F thus applies a dynamic radial pressure to the internal face P11 of the projectile part P13 to be deformed, said application causing its radial expansion at high velocity until fitting the imprint 22 of the matrix 2 (cf. lower half of
Once the deformation finished, the application tool 4 is withdrawn from the deformed workpiece P which is in turn withdrawn from the matrix 2.
For forming a new workpiece P, it is sufficient to set the piston 31 to its retracted upstream position (upper half of
The electro-hydraulic forming machine 1, illustrated by
It comprises the target support (not shown), the means 3 for generating the shock wave in the forming fluid F, and the tool 4 for the application of the forming fluid F to the projectile part of the wall to be deformed (not shown).
Here again, the application tool 4 has the shape of a cylindrical elongate tubular element having two ends:
Said application tool 4 further comprises said two cylindrical surfaces:
The chamber 44 of the application tool 4 ends, downstream, by the downstream holes 42 extending at the bottom of the groove 46 intended to define a reserve of liquid R and, upstream, by an upstream hole 48 at the level of which the piston 31 extends.
Here, the chamber 44 of the application tool 4 is provided with two open ended conduits 6, an upper one 6a and a lower one 6b (
Said two open-ended conduits 6a, 6b are situated coaxially to one another and perpendicularly and on either side of the longitudinal axis 4′ of the application tool 4.
The open-ended upper conduit 6a is intended to be connected to the means for generating a primary air vacuum inside the chamber 44, i.e. for example between 1 and 1000 Pa. And the open-ended lower conduit 6b is intended to be connected to the means for filling and evacuating said chamber 44, with the forming fluid F.
The function of said means is to avoid generation of a mattress of compressible air in said chamber 44 during the generation of the shock wave by said dedicated means 3.
Means 3 for generating the shock wave comprises the piston 31, the means for operation 32 of which consists here in “hydroelectric” means for operation.
In a general manner, by “hydro-electric means for operation”, one understands a device ensuring a projection of the piston by means of a propulsion force generated by a shock wave produced in a conducting fluid by an appropriate electric discharge.
Here, said means for operation 32 consists of a space 32a delimiting a chamber 32b inside which a pair of electrodes 32c and the upstream end 31b of the piston 31 extend.
Both electrodes 32c are intended for conducting the electric discharge inside a conducting fluid C filling the afore-mentioned chamber 32b.
Both electrodes 32c are lodged on either sides of the space 32a; they are spaced and situated in front of one another, and this, here, along a vertical or approximately vertical axis
Said two electrodes 32c may be connected by a fusible conducting wire (not shown), in order to control the initiating time of the shock wave (especially as a function of its time to fuse).
The space 32c is advantageously provided with sucking and vacuum conduits (not shown) the function of which is to avoid generation of a mattress of compressible air during the electric discharge.
Here again, said piston 31 is adapted to ensure a pressure multiplying effect.
By “pressure multiplying effect”, one advantageously understands a multiple of the order of 5 through 15 (for example in the order of 10) between the pressure acting by the conducting fluid C upon the upstream end 31b of the piston 31 and the pressure acting in the forming fluid F by its downstream end 31a.
Practically, for causing the motion of the piston 31, a strong electric discharge (several tenths of kV and kA) is set free in an extremely short time (between some microseconds and several hundreds of microseconds) between both electrodes 32c.
The strong electric current passes through the conductive liquid C situated inside the space 32b, generating a primary shock wave which dynamically raises the pressure of said conductive liquid C.
The generated primary shock wave produces a thrust onto the upstream end 31b of the piston 31 which is projected by linear motion towards the downstream side.
Said motion generates a final shock wave inside the forming fluid F of the chamber 44 of the application tool 4.
As explained further up, said final shock wave propagates in the forming fluid F up to the groove 46 for causing expansion of the workpiece P at high velocity, and this until it fits the imprint of the matrix (not shown here).
In this case, said projectile part P13 gets pushed against the imprint 22 of said matrix 2 under the effect of the shock wave generated in the forming fluid F (as illustrated on the lower half of
The ring 7, forming here the target support, consists for example of a metallic piece, for example of the ferrule type. It is maintained in the imprint 22 of the matrix 2.
Said ring 7 comprises an internal surface 71 forming the imprint against which the projectile part P13 of the workpiece P is intended to fit when it is being shaped.
Practically, the projectile part P13 of the piece P to be formed gets pushed against the imprint 71 of the added ring 7, under the effect of the shock wave generated in the forming fluid F (such as illustrated on the lower half of
Said ring 7 is thus sandwiched between the projectile part P13 of the workpiece P to be formed and the imprint 22 of the matrix 2. It is thus crimped on the workpiece P by radial expansion of its projectile part P13.
Here, the flexible envelope 47b, which is hermetic to fluids, consists of some type of sleeve made of a material such as polyurethane.
Said flexible envelope 47b covers a downstream portion of the external surface 43b of the application tool 4.
Especially, said flexible envelope 47b extends in front of the downstream holes 42 of the application tool 4, closing the peripheral opening of the groove 46 for radially delimiting the reserve R.
Said flexible envelope 47b is advantageously fixed to the application tool 4 by means of two collars 47c on either sides of the downstream holes 42 and the groove 46.
That embodiment is interesting as it delimits the reserve R and as it thus avoids any leakage of forming fluid F. Due to this, the operations of creating a vacuum and filling are not repeated at each forming operation.
Such a tool 4, together with said flexible envelope 47b, is implemented in a way which is identical to the one described further up with reference to
It comprises the target support (not shown), the means 3 for generating the shock wave inside the forming fluid F, and the tool 4 for applying forming fluid F to the projectile part of the wall to be deformed (not shown).
Means 3 for generating the shock wave comprises the piston 31, the means for operation 32 of which consists here in “magnetic” means for operation.
The “magnetic” means for operation 32 comprises a magnetic space 32m provided with a coil 32s with or without concentrating means for the magnetic field.
The upstream end 31b of the piston 31 is situated in the magnetic space 32m.
Here, said upstream end 31b comprises a piece 31c, which is electrically conductive, forming a propulsion device that is able to resist to magnetic thrust intended to ensure the high-velocity acceleration of the piston 31.
Here, the propulsion piece 31c constitutes a massive core which allows to adjust the angle of the concentrating means of the magnetic field, without changing the coil 32s.
Machining of the peripheral surface of the propulsion piece 31c allows to obtain a tapered piece diverging from the upstream side to the downstream side.
Said propulsion piece 31c has a defined angle α (with respect to the longitudinal axis of said propulsion piece 31c) which is intended to make move the piston 31.
The axial force as generated is a function of the angle α of the field-concentrating device.
The increase of that angle α allows for an increase of the propulsion thrust as generated on the propulsion device 31c and its associated piston 31.
Any other form of the “magnetic” means for the operation 32 is possible.
It is for example possible to use a coil without a field-concentrating device (for example with a tapered coil); then, the angle α is fixed and thus definite.
The coil also can consist of a flat coil machined in a spiral form, the axis of which extends at least approximatively coaxially to the axis of the piston; the piston in front of the coil directly receives the thrust generated by the discharge of the capacitors.
The present invention thus provides an interesting technical solution for the dynamic radial expansion of a workpiece, advantageously of a workpiece of tubular radial shape.
The high-velocity deformation of that piece allows to limit the elastic return, thus favoring its plastic deformation.
The machine according to the invention provides different advantages, especially:
| Number | Date | Country | Kind |
|---|---|---|---|
| 13 57632 | Aug 2013 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/FR2014/051964 | 7/29/2014 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2015/015114 | 2/5/2015 | WO | A |
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| Number | Date | Country |
|---|---|---|
| 1488868 | Dec 2004 | EP |
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| Entry |
|---|
| International Search Report PCT/FR2014/051964 dated Nov. 3, 2014. |
| Number | Date | Country | |
|---|---|---|---|
| 20160175912 A1 | Jun 2016 | US |
