Hydroforming machine and a method of hydroforming

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the technology of a hydroforming machine. It is related with the technology of preventing any wrinkle of products after molding, by adjusting pressure of the fluid acting on the blank.

2. Description of Prior Art

By the environmental regulation against emission from a car becoming severe, it is requested to the cleaning efficiency of catalyst by reducing heat capacity of the exhaust manifold, which is one of members of constituting the exhaust gas passage of a car, made thinner, and rise the temperature of the exhaust passage easily, and activate the catalyst.

When molding a blank into a complex form like an exhaust manifold, which made from a thin metal board (thin board), usually the ironing has been chosen. However in the ironing, the wrinkle is mentioned as a poor fabrication. Wrinkle happens, when distortion of the shrinkage direction occurs in the blank molding, it is especially easy to generate in the case of the low face stiffness of a thin board.

Generally, there are three methods of preventing the wrinkle in ironing with die, (1) to prepare bead for removing wrinkle in the part of blank, having possibility of wrinkle, (2) to prepare bead on the part of mold, corresponding to wrinkle, (3) to mold a blank by two or more operation for dissolving the large distortion in shrinkage direction on the specific part of a blank. However, the method of (1) requires preparing a bead on the blank. It is no use in the case that the shape of the products has many limitations. Moreover, the method of (2) may induce another poor forming, such as stretching and cracking, for a product, some forms of products make it difficult to determine the forming conditions which generate neither wrinkle nor stretching and cracking. Furthermore, the method of (3) tends to make a dent, called a shock line, in the side of the product after molding. the method of (3) requites increase of number of processing steps and cost. When molding a complex shape, like a said exhaust manifold, it is difficult to prevent a wrinkle by using any method of (1), (2), and (3).

Hydroforming machine which forms a board-like blank using the pressure of liquid is known as forming equipment suitable for forming thin board in complicated form with preventing wrinkle in the process. Generally, Hydroforming machine applies pressure on one side of a board shape blank with liquids, such as water and oil, makes deformation at the blank along with the mold etc. of predetermined shape. Furthermore, Hydroforming machine applies pressure on internal surface of a tubular object, makes deformation at outer surface of the tubular object along with the mold etc. of predetermined shape.

In FIG. 8, typical and conventional hydroforming machine 101 comprises a die 102 with an opening only on the upper surface and a fluid tank 102a filled up with a liquid was formed, a holder 103 which can pinch the periphery part of thin board 111 between die 102 and itself, and a punch 104 which is movable in the direction extracted from the fluid tank 102a and inserted into the fluid tank 102a. In the state which filled up fluid tank 102a with the liquid, thin board 111 is pinched between a die 102 and a holder 103, a punch 104, which is installed in a hole 103a bored through the holder 103, is moved in the direction of insertion into the liquid tank 102a. Consequently, the pressure of liquid fluid in the tank 102a increases according to the position of the punch 104 (amount which the punch 104 is inserted into the fluid tank 102). Thin board 111 is deformed along with the shape of a tip part of punch 104.

Generally, hydroforming machine press a blank hard against a die with the liquid pressure, each part of the blank is pressed hard in right angle to the surface of the die contacted with the blank at almost same pressure. There is an advantage that it is possible to control the imbalance of a flow of the blank material (small flow at a portion of the blank with the strong restraint by the die, large flow at a portion of blank with the weak restraint). The advantage contributes to prevention of wrinkle.

Hydroforming machine given in the patent reference, Japanese Laid Open Gazette No. 2003-266132,A, is known as conventional one. In the patent reference 1, hydroforming machine comprises a upper die in which cavity was formed, and lower die which can pinch the periphery part of a board-like blank between upper die and it serf, feeds liquid between lower die and blank, and deforms the blank along with cavity of upper die.

SUMMARY OF THE INVENTION

However, in the case of above-mentioned hydroforming machine 101, the pressure of a liquid filling the fluid tank 102a and the position of punch 104 have an one-to-one correspondence. It is not possible to control the pressure of the fluid independently without changing the position of the punch 104. Therefore, by using hydroforming machine 101, it is difficult to prevent wrinkle at some shape of the formed products from thin board 111. Moreover, in hydroforming machine of the patent reference 1, at the start of processing, the blank is not in contact with cavity surface. For this reason, it is depending on the allowance of final shape of products, of the quality of blank to occur wrinkle on products.

In consideration of the above-mentioned problem, this invention offers hydroforming machine which effectively prevents wrinkles on the products formed complex.

Subjects which this invention is going to solve are mentioned above, means for solving this subject is explained below.

According to one aspect of the invention there is provided a hydroforming machine molding a board shape blank having; a lower die having an opening on the upper surface and a fluid tank filled with fluid, an upper die being able to hold a periphery part between the lower die and the upper die, a movable object being movable in a direction into or out for the fluid tank, and a fluid pressure controller controlling the fluid pressure in the fluid tank according to the position of the movable object. In order to the invention, it is possible to prevent generating wrinkle effectively when a board-like blank formed in complicated shape. The thinner the blank the lager an effect of preventing wrinkle becomes.

According to other aspect of the invention there is provided claim 2 is the hydroforming machine recited in claim 1, wherein said fluid pressure controller comprises, a passage connecting the fluid tank and an outside of the lower die, a valve arranged at a halfway of the passage, a fluid pressure detection means which detects pressure of fluid in the fluid tank; and a movable object position detection means which detects a position of the movable object. In order to the invention, the pressure of the water, filled in the fluid tank, can be adjusted with simple composition without using actuators, such as hydraulic cylinder, etc. Maintenance becomes easy and the manufacture cost of hydroforming machine can be reduced.

According to another aspect of the invention there is provided the hydroforming machine recited in claim 1 or 2, wherein said board shape blank has a dent approximately fitting with the tip of the movable object. In order to the invention, while the tip part of a movable object contacts blank, it mitigates distortion of the shrinkage direction generated to a contact part. And it suppresses generating of wrinkle more effectively.

According to another aspect of the invention there is provided a method for hydroforming a board shape blank by a hydroforming machine, wherein the hydroforming machine comprising; a lower die having an opening on the upper surface and a fluid tank filled with fluid, an upper die being able to hold a periphery part between the lower die and the upper die, and a movable object being movable in a direction into or out for the fluid tank, wherein the board shape blank has a dent approximately fitting with the tip of the movable object. In order to the invention, it prevents generating of wrinkle for board-like blank effectively also in the case of forming complicated shape. Especially, the thinner the blank the lager deterrence effect becomes about generating of wrinkle. Moreover, while the tip part of a movable object contacts the blank, it can mitigate distortion of the shrinkage direction generated to a contact part, and can suppress generating of wrinkle more effectively.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 The side sectional view showing one form of operation of hydroforming machine concerning this invention.

FIG. 2 The figure showing the relation of the pressure of the liquid with which amount of insertion and fluid tank to fluid tank of a punch are filled up.

FIG. 3 The side sectional view showing the punch at the time of (a) in FIG. 2, and the relation of thin board.

FIG. 4 The side sectional view showing the punch at the time of (b) in FIG. 2, and the relation of thin board.

FIG. 5 The side sectional view showing the punch at the time of (c) in FIG. 2, and the relation of thin board.

FIG. 6 The side sectional view showing the punch at the time of (d) in FIG. 2, and the relation of thin board.

FIG. 7 The side sectional view showing the punch at the time of (e) in FIG. 2, and the relation of thin board.

FIG. 8 The side sectional view showing one form of operation of conventional hydroforming machine.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Below, a hydroforming machine 1 which is an embodiment of the hydroforming machine of this invention is explained using FIG. 1. In addition, a hydroforming machine 1 of this embodiment is equipment which forming thin boards 11 to an exhaust manifold of a car as a product. This invention is widely applicable to what forms thin board in complicated shape. It is not limited to the use of a hydroforming machine 1.

A hydroforming machine 1 mainly comprises die 2, a holder 3, a punch 4, a pressure controller 5, and a control device 6, etc.

A thin board 11 in this embodiment is a blank of SUS, whose thickness is 0.4 mm. The kind of the material blank is not limited. Various metal materials, such as titanium, copper, and aluminum, can be used for. Moreover, the thickness of a blank is not limited. Hydroforming machine 1 of the embodiment has larger effect of the prevention of generating wrinkle as compared with conventional hydroforming machine.

The die 2 is an example of the embodiment of a lower die of hydroforming machine of this invention. On an upper surface of the die 2, a fluid tank 2a with an opening at the upper surface is formed, it is filled up with water. In this embodiment, water is used for filling up the fluid tank 2a. Furthermore, the liquid of other kinds, like oil, etc., should be useful for filling the fluid tank 2a. A slot, which is ring-like shape in top view, is formed on the upper surface around the fluid tank 2a. The O ring 12 is fitted in this slot.

A holder 3 is an example of an upper die in a hydroforming machine of this invention. The holder 3 is arranged above the die 2. The holder 3, which actuated by an actuator not illustrated, can move between the position distant from the die 2 and the position in which pinching the periphery part of the thin board 11 with the die 2.

Punch 4 is an example of hydroforming machine of this invention, the punch 4 is installed with ability to slid vertically in a through hole 3a, the through hole 3a is formed at the position corresponding to the fluid tank 2a of the die 2 on the holder 3. The tip part of the punch 4 is a portion which counters the fluid tank 2a. The shape of the tip is equivalent to the shape of the exhaust manifold of a car, and has the complicated curved surface. The exhaust manifold is a product obtained by forming the thin board 11. The punch 4 moves in the vertical direction to a holder 3 by the hydraulic cylinder 13. In addition, the actuator which moves punch 4 in the vertical direction to a holder 3 may not be limited to hydraulic cylinder 13, also other actuators are sufficient as it.

Pressure controller 5 adjusts the pressure of the liquid with which fluid tank 2a was filled up according to the position of punch 4, amount of insertion to fluid tank 2a of punch 4 at the forming of the thin board 11. The pressure controller 5 of the embodiment mainly possesses a through hole 51, a valve 52, a pressure sensor 53, and position sensor 54, and so on.

Through hole 51 is a passage which opens fluid tank 2a and the exterior of die 2 for free passage at the portion of die 2 except the opening of the fluid tank 2a formed on the upper surface of die 2. The through hole 51 of this embodiment possesses a communicating passage 51a, a piping 51b, a piping 51c, etc.

The communicating passage 51a is a passage drilled in the inside of the die 2, one of the ends is connected with the side surface of the fluid tank 2a, and the other end is connected with the external surface of die 2.

The piping 51b is connected to one port of the other ends of the communicating passage 51a, and the valve 52. The piping 51c has one end connected to the port of another side of the valve 52, and the other end opened to outside.

The valve 52 is a valve arranged at the halfway part (in this embodiment, between piping 51b and piping 51c) of through hole 51.

By closing the valve 52, piping 51b and piping 51c are intercepted, and piping 51b and piping 51c are opened for free passage by opening a valve 52.

The pressure sensor 53 is an example of the liquid pressure detection means in the hydroforming machine of this invention.

In this embodiment, the pressure sensor 53 is connected to a valve 52, exactly through the communicating passage 51a from fluid tank 2a, and the piping 51b , and the valve 52, and the pressure of the water, filled in the fluid tank 2a, is detected.

The position sensor 54 is an example of the position detection means for movable object of a hydroforming machine of the invention.

The position sensor 54 detects the position of the punch 4, or amount of insertion to the fluid tank 2a of punch 4.

Thus, the pressure controller 5 of this embodiment is able to controls the pressure of the water filled in the fluid tank 2a simply, without using actuators, such as hydraulic cylinder. Thereby maintenance becomes easier and the manufacture cost becomes smaller.

A control device 6 opens and closes a valve 52 based on the pressure of the water filled in the fluid tank 2a detected by the pressure sensor 53, and the position of the punch 4 detected by the position sensor 54.

The controller 6 of the embodiment connected with the hydraulic cylinder 13 of an actuator not illustrated, and controls them according to the program.

A control device 61 provides a storing means to store programs, an expansion means to expand a program, an operation means to perform predetermined operation according to a program, an input means for inputting the data for performing predetermined operation etc. from the outside, and a display means to display the data inputted by the result of the operation by the operation means, or the input means etc.

In addition, the control device 61 may be an exclusive thing, a personal computer, or a workstation.

Hereafter, the forming method of thin board 11 by the hydroforming machine 1 is explained using FIG. 1.

First, the fluid tank 2a is filled up with water and the thin board 11 is arranged in the predetermined position of the upper surface of the die 2. In this embodiment, the form of the upper surface of die 2 is not a plane, leans to one side a little. The thin board 11 is also beforehand crooked according to the inclination of the die 2. Moreover, when the tip part of the punch 4 and the portion which contacts with are flat and smooth in thin board 11, the punch 4 contacts the thin board 11, and the distortion of the shrinkage direction occurs in the contacted part. With some magnitude of distortion, it becomes the cause of generating a wrinkle. Therefore, the portion which contacts with the tip part of punch 4 in the thin board 11, should be made a cavity being roughly same shape with the tip portion of the punch 4. In addition, the method is not limited to make a cavity, roughly same shape with the tip portion of the punch 4, at the portion which contacts the tip part of the punch 4 in the thin board 11. It is also sufficient to use the usual stamping forming.

Next, the holder 3 is moved from the position distant from die 2 to the position which holds the periphery part of thin board 11 between die 2 and itself. At this time, the holder 3 is pushed against die 2 by predetermined power by the actuator which is not illustrated. Consequently, the periphery part of thin board 11 is restrained with die 2 and a holder 3. Moreover, the O ring 12 arranged at the periphery part of the fluid tank 2a is stuck on the undersurface of thin board 11. Thereby, the water fluid in the tank 2a does not leak from between thin board 11 and die 2

Then, the punch 4 is moved in the direction inserted in the fluid tank 2a. When the punch 4 is moved in the insert direction in the fluid tank 2a, the tip part of the punch 4 contacts the upper surface of thin board 11. In the thin board 11, the portion which has countered with the fluid tank 2a is deformed, and is pushed into the inside of the fluid tank 2a along with the shape of the tip part of the punch 4.

When the punch 4 is made to insert in fluid tank 2a, the sum of the volume of the space becomes small, the pressure of the water with which fluid tank 2a was filled up rises. In here the space is from the fluid tank 2a by which the opening on the upper surface of die 2 was blockaded by thin board 11 through the communicating passage 51a and piping 51b, to the valve 52. Moreover, the control device 6 discharges outside some water fluid in the tank 2a by opening the valve 52, the pressure of the water fluid in the tank 2a is reduced. In the process which moves the punch 4 in the direction inserted in fluid tank 2a, the hydroforming machine 1 is able to control the pressure of water filled in the fluid tank 2a can be adjusted according to the position of the punch 4 by opening and closing a valve 52 suitably.

After the punch 4 is inserted in fluid tank 2a until it becomes a predetermined position, the valve 52 is opened and the pressure of the water filled in the fluid tank 2a is lowered to normal pressure. And the punch 4 is moved in the direction evacuated from fluid tank 2a, the holder 3 is moved to the position distant from the die 2. The formed thin board 11, i.e., exhaust manifold, is taken out.

About the modification action of the thin board 11 is explained, in FIG. 3 to the FIG. 7, on the two conditions, the conditions of (A) shown with a thick dashed line in FIG. 2 below, and the conditions of (B) shown as a thick solid line.

The conditions of (A) are not concerned with change of amount of insertion (position of the punch 4) to fluid tank 2a of punch 4, and the pressure controller 5 is not operated (the state where the valve 52 was always closed). The pressure of the water filled in the fluid tank 2a increases, according to the increase of amount of insertion to fluid tank 2a of punch 4. The condition of (A) is roughly same with the conditions using conventional hydroforming machine 101 in FIG. 8.

On the conditions of (B), the pressure controller 5 is operated (the state where the valve 52 was opened suitably) to keep the pressure of the water filled in the fluid tank 2a is held to abbreviation regularity (pressure P2), when amount of insertion to the fluid tank 2a of the punch 4 is more than S2, In addition, amount of insertion to the fluid tank 2a of the punch 4 which is the horizontal axis of FIG. 2. It makes zero point which is the position contacted thin board 11 with the tip part of punch 4 first, when the punch 4 is moved in the direction inserted in the fluid tank 2a.

With the following in FIGS. 3, 4, and 5, the details of the modification action of thin board 11 are explained, when forming of the thin board 11 is performed on condition that (A).

FIG. 3 is a side sectional view showing the relation between punch 4 and thin board 11 on the conditions of (A) (or conditions of (B)), when forming of thin board 11 is performed and amount of insertion to fluid tank 2a of punch 4 is S1 (it corresponds to (a) in FIG. 2). With the point of amount of insertion into the fluid tank 2a of punch 4 being S1, the pressure (P1) of the water filled in the fluid tank 2a is not raised so much. Only the portion of the thin board 11 in contact with punch 4 is deformed accordance with the shape of the punch 4.

FIG. 4 is a side sectional view showing the relation between the punch 4 and the thin board 11 on the conditions of (A) when forming of thin board 11 is performed, and amount of insertion to fluid tank 2a of punch 4 is S3 (it corresponds to (b) in FIG. 2). One of the advantages of forming by this hydroforming machine is being able to prevent generating wrinkle. The thin board 11 deformed with pulling force by the pressure of the water filled in the fluid tank 2a, because of deformation of the thin board along with the cavity 4a, when the cavity 4a, which is a dent, is formed on the tip part of punch 4. However, the shape of the punch 4, there is a case generated the dent 20 similar to cavity 4a temporarily in the crevice between the through hole 3a, for installing the punch 4 on the holder 3, and the punch 4. The high pressure of the water in the fluid tank 2a (P3) makes the thin board 11 deforms along such a dent 20.

FIG. 5 is a side sectional view showing the relation between punch 4 and thin board 11 when forming of the thin board 11 is performed and amount of insertion to the fluid tank 2a of the punch 4 is S4 (it corresponds to (c) in FIG. 2) on the condition of (A). The amount of insertion to fluid tank 2a of the punch 4 becomes larger, and a dent 20 is lost, the portion which became depressed in thin board 11 and was changed along with 20 will shrink and be deformed, and wrinkled part 21 occurs.

Mentioned above, on the conditions of (A), the water pressure increase along with the amount of the insertion to fluid tank 2a of punch 4, and it becomes the cause of generating of wrinkle for Generating of a temporary dent 20 in the process of devotion to fluid tank 2a of punch 4. That is, when forming the thin board 111 using conventional hydroforming machine 101 shown in FIG. 8, it is difficult to prevent generating of such wrinkle.

Below, the details of the modification action of the thin board 11 are explained in FIGS. 3, 6, and 7, when forming of the thin board 11 is performed on condition that (B).

FIG. 3 is a side sectional view showing the relation between punch 4 and thin board 11, amount of insertion to fluid tank 2a of punch 4 is S1 (it corresponds to (a) in FIG. 2), when forming of thin board 11 is performed on condition that (B) (or conditions of (A)).

The pressure (P1) of the water with which fluid tank 2a was filled up is not raising so much, only the portion in contact with punch 4 of thin board 11 is deformed in accordance with the form of punch 4.

FIG. 6 is a side sectional view showing the relation between the punch 4 and the thin board 11, on the conditions of (B), when forming of thin board 11 is performed and amount of insertion to fluid tank 2a of punch 4 is S3 (it corresponds to (d) in FIG. 2).

On the conditions of (B), pressure controller 5 being operated, even if amount of insertion to fluid tank 2a of punch 4 increases, the pressure of the water with which fluid tank 2a was filled up is held to abbreviation regularity

After the point the pressure of the water with which fluid tank 2a was filled up is lower than the pressure P2 which the thin board 11 deformed along with a dent 20 (the point of amount of insertion to fluid tank 2a of punch 4 being set to S2).

Therefore, the pressure of the water with which fluid tank 2a at the time of being shown in FIG. 6 was P2 and the thin board 11 is not deformed along with 20.

FIG. 7 is a side sectional view showing the relation between punch 4 and thin board 11, when amount of insertion to the fluid tank 2a of the punch 4 is S4 (it corresponds to (e) in FIG. 2) and forming of the thin board 11 is performed on condition that (B).

On condition (B), the thin board 11 is not deformed along with the dent 20 while the dent 20 has occurred, amount of insertion to the fluid tank 2a of the punch 4 becomes larger, and wrinkle does not occur in absence of a dent 20.

Above mentioned, on the conditions of (B), even when it became depressed temporarily and dent 20 occurs between punch 4 and holders 3, pressure of the water filled in the fluid tank 2a while the dent 20 has occurred, holding to the pressure P2 lower than the pressure which the thin board 11 deformed along with 20, so it is possible to prevent generating of wrinkle.

In addition, the method of the above (B) is one of the examples to control the liquid pressure according to the position of the punch 4 by pressure controller 5. Moreover, it is also possible to apply methods other than the method of (B) applying to the forming of the thin board 11, according to the thickness, or the quality of the material, etc.

As other methods, there is a method possessing the step which increases the pressure of the water filling the fluid the tank 2a according to amount of insertion to the fluid tank 2a of punch 4, the step which holds the pressure of the water with which fluid tank 2a was filled up to abbreviation regularity even if amount of insertion to fluid tank 2a of punch 4 increases, and the step which increases the pressure of the water with which fluid tank 2a was again filled up with increase of amount of insertion to fluid tank 2a of punch 4, etc. is mentioned.

Like the above, the hydroforming machine 1 which is an embodiment of this invention is a hydroforming machine molding a board shape blank 11 provides the die 2 having a opening on the upper surface and the fluid tank 2a filled with fluid, the holder 3 being able to hold a periphery part between the die 2 and the holder 3, the punch 4 being movable in a direction into or out for the fluid tank 2a, and a fluid pressure controller 5 controlling the fluid pressure in the fluid tank 2a according to the position of the punch 4.

Thus, by constituting, it is possible to prevent generating of wrinkle for thin board 11 effectively also in the case the form complicated shape.

Moreover, the pressure controller 5 of hydroforming machine 1 which is an embodiment of this invention provides the through hole 51 which connects the outer side of die 2 to the fluid tank 2a, the valve 52 arranged at the halfway part of the through hole 51, the pressure sensor 53 which detects the pressure of the liquid filed in fluid tank 2a, the position sensor 54 which detects the position of punch 4.

It is simple composition, without using actuators, such as hydraulic cylinder, etc., and it is possible to adjust the pressure of the water of fluid tank 2a, and it make easy to maintenance and reduce the manufacture cost of hydroforming machine 1.

Moreover, the hydroforming machine 1 which is an embodiment of this invention make a dent in the portion which contacts the tip part of punch 4 in thin board 11, wherein the shape of the dent is roughly same shape with the tip of the punch 4.

Thus, by constituting, it is possible to mitigate distortion of the shrinkage direction generated to the contact part concerned, in case the tip part of punch 4 contacts thin board 11, and to prevent generating of wrinkle more effectively.

The method for liquid pressure forming which is an embodiment of this invention uses a hydroforming machine provides the die 2 in which fluid tank 2a with which an opening is carried out to the upper surface and a liquid is filled up was formed, the holder 3 which can pinch the periphery part of thin board 11 between die 2, The punch 4 which can move in the direction evacuated from the direction and fluid tank 2a inserted in fluid tank 2a, and make a dent roughly same shape with the tip of the punch 4 on the portion which contacts the tip part of punch 4 of thin board 11 before forming.

Thus, by constituting like that, it is possible to prevent generating of wrinkle for thin board 11 effectively also in case of forming a complicated shape.

Moreover, it is possible to mitigate distortion of the shrinkage direction generated to the contact part concerned, in case the tip part of punch 4 contacts the thin board 11, and to prevent generating of wrinkle more effectively.

Hydroforming machine and a method of hydroforming

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CPC

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Priority Claims (1)