Patent Grant
8266939
This application is a national stage application of International Application No. PCT/JP2008/063469, filed 18 Jul. 2008, which claims priority to Japanese Application No. 2007-189235, filed 20 Jul. 2007, which is incorporated by reference in its entirety.
The present invention relates to a hydroforming method comprising placing a metal tube in a mold, closing the mold, then applying internal pressure inside the tube to form it to a predetermined shape and a hydroformed product formed by this.
The general processing steps in conventional hydroforming will be explained below using
First, a metal tube 1 shorter in length than the mold is placed inside a groove of the lower mold 2 so that the tube ends of the metal tube 1 are positioned inside from the end faces of the mold (same figure (a)).
The metal tube 1 of this example is an example of a straight tube. In the case of a bent tube, it is necessary to perform the bending in advance so as to become a shape matching the groove of the lower mold 2.
Next, the upper mold 3 is lowered to close the mold and clamp the metal tube 1 between the lower mold 2 and the upper mold 3 (same figure (b)).
After that, the seal punches 4 and 5 are made to advance. Water is inserted as a pressurizing fluid from the seal punch 4 having a water insertion port 6 while making the punches advance. Substantially simultaneously with the water 7 being filled inside the metal tube 1, the seal punches 4 and 5 are made to contact the end faces of the metal tube 1 to seal them to prevent the water 7 from leaking (same figure (c)).
After that, the pressure inside the metal tube 1 (below, referred to as the internal pressure) is raised to obtain the hydroformed product 8 (same figure (d)). To prevent the water 7 from leaking and secure a seal at this step, the cross-sectional shape of the tube ends 9 of the metal tube 1 and the tube end vicinities 9′ may be made the same circular shapes as before being worked.
However, when the end faces of the final product 10 are not the same shapes as the tube material, since the tube ends 9 and tube end vicinities 9′ and the transition parts 11 are unnecessary, they are cut off and discarded (same figure (e)). That is, the yield falls by that amount.
An example reducing this drop in yield is described in “Automobile Technology (vol. 57, no. 6 (2003), p. 23)”. In this example, the tube ends are not circular, but are rectangular in cross-section the same as the end face shapes of the final product shape. However, in this case, before placing the metal tube to the mold, pre-forming for forming the tube ends into rectangular cross-sections becomes necessary.
In the method described in Japanese Patent Publication (A) No. 2004-42077, a metal tube with a circular cross-section is placed as it is to the lower mold so that the tube ends of the metal tube become inside the end faces of the mold. Along with the descent of the upper mold, the tube ends are made to deform to rectangular cross-sections. The rectangular cross-section seal punches are made to abut against these as is, then the pressurizing fluid is supplied to the inside of the metal tube for axial pressing as necessary. However, while this method can be applied to elliptical, rectangular, oblong, and other relatively simple cross-sections, the front ends of the seal punches must be formed to the same shapes as the ends of the shaped article. Application to complicated cross-sections is considered difficult.
Further, to prevent wrinkles forming at the time of closing the hydroforming mold, the practice has been to close the mold while applying internal pressure. With the method, it is necessary to seal the tube ends after finishing closing the mold, so for example as described in Japanese Patent Publication (A) No. 2001-9529, the method is adopted of closing the mold at just the tube ends and pushing the seal punches to secure a seal, then closing the mold at the tube center. Accordingly, the tube ends in this case are limited to a circular, elliptical, or other simple cross-sectional shapes.
On the other hand, hydroforming has the defect of the difficulty of spot welding and bolting with other parts after shaping. Therefore, technology for forming a flange at the time of hydroforming is proposed in Japanese Patent Publication (A) No. 2001-259754 or Japanese Patent Publication (A) No. 2006-61944. However, with these methods, pluralities of hydroforming steps or separate punches able to move in the mold become necessary. Further, with the method, it is believed difficult to form a flange along the entire length while applying internal pressure.
In the present invention, the object is to raise the yield of the hydroformed product by forming even the tube ends to the product shape as much as possible. Further, the inventors propose a hydroformed product having a flange along its entire length in the longitudinal direction formed by a single step.
To solve the problem, the present invention has as its gist the following:
(1) A hydroforming method characterized by placing a metal tube in a lower mold in a state with tube ends sticking out from the mold, injecting pressurized fluid into the metal tube through an inside of a seal punch while pressing seal punches against the tube ends of the metal tube to apply a predetermined pressing force, filling the inside of the metal tube with a pressurized fluid to apply a predetermined internal pressure, then, while applying the internal pressure and pressing force, lowering the upper mold and closing the mold, deforming the tube along with the tube end and finishing the forming operation in the state with the tube ends sticking out from the mold.
(2) A hydroforming method as set forth in (1), characterized by, after closing the mold, further boosting the internal pressure in said metal tube and ending the forming operation.
(3) A hydroforming method as set forth in either (1) or (2), characterized in that when a sectional area of a metal part of said metal tube in a cross-section vertical to an axial direction of said metal tube is S1 [mm2], a sectional area of an inside of said metal tube is S2 [mm2], an yield stress of said metal tube is YS [MPa], and said predetermined internal pressure is P1 [MPa], a force F1 [N] pressed by said seal punches when closing the mold satisfies formula (1):
P1·S2+0.3YS·S1≦F1≦P1·S2+0.7YS·S1 (1)
(4) A hydroforming method as set forth in (3), characterized in that when a sectional area of a metal part of said metal tube in a cross-section vertical to an axial direction of said metal tube is S1 [mm2], a sectional area of a cavity of said mold is S3 [mm2], an yield stress of said metal tube is YS [MPa], and an internal pressure boosted to after closing the mold is P [MPa], a force F [N] pressed by said seal punches when boosting the internal pressure after closing the mold satisfies formula (2):
P·(S3−S1)+0.5YS·S1≦F≦P·(S3−S1)+1.5YS·S1 (2)
(5) A hydroforming method as set forth in any one of (1) to (4), characterized in that when the length by which the tube ends of the metal tube stick out from the mold in the state before the seal punches press against the tube ends of the metal tube is made the seal length, the seal length is 2 to 4 times the plate thickness of the metal tube.
(6) A hydroforming method as set forth in any one of (1) to (5), characterized in that a Rockwell hardness of a surface of the seal punches contacting tube ends of the metal tube is HRC50 or more and a surface roughness is Ra2.0 or less.
(7) A hydroformed product characterized by comprising an integral deformed product obtained by a single step of hydroforming by a method as set forth in any one of (1) to (6), the hydroformed product characterized by having a flange along the entire length in the longitudinal direction.
(8) A hydroformed product as set forth in (7) having a curvature factor in the longitudinal direction.
(a) state of placing metal tube 1 into groove of lower mold 2
(b) state of lowering upper mold 3 to close mold (closing mold)
(c) state of sealing tube ends 9 of metal tube 1 by seal punches 4 and 5
(d) state of raising internal pressure to end forming operation
(e) final product cutoff from the formed tube
(a) state of placing metal tube 1 into groove of lower mold 2
(b) state of using seal punches 12 and 13 to seal tube ends 9 of metal tube 1 and applying internal pressure
(c) state of pressing seal punches 12 and 13 against tube ends 9 to apply internal pressure and in that state lowering the upper mold 3 to close the mold
(d) state of raising the internal pressure after closing the mold so-as to end the forming operation
(a) state of placing metal tube 1 into groove of lower mold 2
(b) state of using seal punches 12 and 13 to seal, tube ends 9 of metal tube 1 and applying internal pressure
(c) state of pressing seal punches 12 and 13 against tube ends 9 to apply internal pressure and in that state lowering the upper mold 3 to close the mold
(d) state of raising the internal pressure after closing the mold so as to end the forming operation
(a) a hydroformed product having a straight flange along its entire length
(b) a hydroformed product having a flange having curvature in its longitudinal direction
First, as shown in the same figure (a), the metal tube 1 is placed on the lower mold 2. At that time, the length of the metal tube 1 is made larger than the length of the lower mold 2, so the tube is placed in a state with the tube ends 9 sticking out slightly from the ends of the mold.
Here, flat type seal punches 12 and 13 will be explained. These punches differ in shape from the general hydroforming seal punches 4 and 5 such as in the above-mentioned
The above seal punches 12 and 13 are made to gradually advance while filling water 7 inside the metal tube 1 through the water insertion port 6 so as press against and seal the tube ends 9 of the metal tube 1 as shown in
Next, as shown in
In the process, the mold is closed while the cross-section in contact with the lower mold 2 and upper mold 3 of course and also the cross-section of the non-contacting sticking out parts 15 are deformed. Further, if closing the mold while maintaining the internal pressure, wrinkles etc, will not remain after closing the mold. If ending up closing the mold without internal pressure, the flat part at the top surface side of the cross-section B-B will not become flat, but will end up becoming a convex shape.
If forming the tube to the final part shape in the state of
Above, the hydroforming method according to the present invention was explained, but the desirable suitable conditions for reliably forming the seal will be explained below using
First, the desirable pressing force for securing a seal will be explained.
The pressing force F1 at the time of closing the mold (pressing force from (b) to (c) of
As explained in the later explained Example 1, the inventors ran tests using a hydroforming mold while changing the force F1 pressing against the seal punches when closing the mold. With each F1, the internal pressure was raised while keeping the other working conditions the same (internal pressure P1 during mold closure=10 MPa, pressing force F at time of boost of pressure=300 kN).
The internal pressure when the water 7 in the tube started leaking from the seal parts (limit seal pressure (MPa)) was measured. Note that for the tube material, in addition to a steel tube of a wall thickness of 2.5 mm used in Example 1, a steel tube of 3.2 mm was also used.
The results are shown in
P1·S2+0.3YS·S1≦F1≦P1·S2+0.7YS·S1 (invention of (3)).
Next, the suitable pressing force F of the step (d) for boosting the pressure after that will be explained.
In this step as well, force due to internal pressure acts on the seal punches 12 and 13, so the pressing force F also has to be changed for a change of the internal pressure P. In the same way as the above-mentioned study, a force of a value of at least the internal pressure P multiplied with the sectional area of the inner surface of the tube becomes necessary. The sectional area of the inner surface of the tube of this step also gradually changes, but, again considering the safe side, envisioning the case where the sectional area is the largest, the area S3 of the mold cavity of the final target shape in the cross-section vertical to the axial direction of the metal tube was employed. However, S3, speaking in terms of a metal tube after finishing the forming operation, becomes the sum of the area of the inside of the tube and the sectional area of the tube itself in the cross-section vertical to the axial direction, so the area inside the tube becomes S3−S1.
Accordingly, the effective force for sealing the tube ends 9 becomes F−P·(S3−S1). The suitable value of this force was also investigated by the inventors.
The inventors ran tests using a hydroforming mold similar to the above and steel tubes (wall thicknesses of 2.5 mm and 3.2 mm) while changing in various ways the force F pressing against the ends while increasing the pressure. With each F1, the internal pressure was raised while keeping the other working conditions the same (internal pressure P1 during mold closure=10 MPa, pressing force F1 during mold closure=75 kN). The pressure when the water in the tube leaked from the seal parts (limit seal pressure (MPa)) was measured.
The results are shown in
This is because the pressing force becomes too high, the end face buckles, and the seal easily leaks.
Accordingly, the upper limit of F−P·(S3−S1) is made 1.5YS·S1. On the other hand, regarding the lower limit, a pressure of at least about half of the maximum limit seal pressure at the respective steel tubes (with wall thickness of 2.5 mm, about 100 MPa, while with wall thickness of 3.2 mm, about 80 MPa) was made the sealable range and 0.5YS·S1 was made the lower limit.
From the above, the suitable range of F can be expressed as follows:
P·(S3−S1)+0.5YS·S1≦F≦P·(S3−S1)+1.5YS·S1 (invention of (4)).
Next, the length of the sticking out parts 15 of the tube ends of the metal tube from the ends of the mold when the metal tube is placed on the lower mold 2 (seal length LS) will be explained. The inventors ran tests changing the seal length LS in various ways. As a result, they learned that if the seal length LS is too long, the pressing forces of the seal punches 12 and 13 cause the tube ends to buckle and sealing becomes impossible.
Further, the internal pressure causes the metal tube 1 to expand in the circumferential direction, so the axial direction shrinks somewhat. Accordingly, it is also learned that if the seal length LS becomes too short, the metal tube 1 will enter into the mold cavity and sealing will become impossible.
From the above, it was learned that the seal length LS shouldn't be too long or too short, specifically, a value of about three times the plate thickness t is suitable. Accordingly, the seal length LS is desirably set to a range of 2 to 4 times the plate thickness if considering the variations in materials or forming conditions (invention according to (5)).
Further, the seal surfaces 14 of the seal punches 12 and 13 should be as flat as possible to enable sliding while the tube ends are pressed against in the state of
Further, to greatly reduce the wear at the time of mass production, the seal surfaces 14 should be high in strength. Specifically, a Rockwell hardness of HRC50 or more is preferable (invention according to (6)).
If hydroforming by the above procedure, an integral hydroformed product as formed by a single step of hydroforming having a flange part over its entire length as shown in
Further, if bending the tube in advance and placing it in a hydroforming mold having a cavity matching that bent shape for hydroforming by a similar procedure, as shown in the same figure (b), a hydroformed product having curvature along the entire length at the inside and outside of the bend is obtained (invention according to (8)).
In
Below, examples of the present invention will be shown.
For the tube material, a steel tube having an outside diameter of 60.5 mm, a wall thickness of 2.5 mm, and a total length of 370 mm was used. For the steel type, STKM13B of a steel tube made of carbon steel for machine structures was employed. The hydroforming mold had a cross-sectional shape across the entire length as shown in
As the hydroforming conditions, the internal pressure P1 at the time of closing the mold was made 10 MPa and the pressing force F1 was made 100,000 N. Due to the size of the steel tube, the steel tube sectional area S1 was 456 mm2, the sectional area S2 inside the tube was 2419 mm2, and YS was 382 MPa. From the above, the following were calculated:
P1·S2+0.3YS·S1=10×2419+0.3×382×456=76,448
P1·S2+0.7YS·S1=10×2419+0.7×382×456=146,124
so 76,448≦F1(=100,000)≦146,124. Accordingly, during mold closure, the internal pressure did not fall much at all.
The mold could be closed in the state with internal pressure applied.
Next, after closing the mold, the internal pressure P was raised and the pressing force F was changed.
Specifically, the inventors ran tests by the load path of (1)→(2)→(3).
(1) Internal pressure of 10 MPa and axial pressing force of 110,000 N
(2) Internal pressure of 20 MPa and axial pressing force of 250,000 N
(3) Internal pressure of 80 MPa and axial pressing force of 250,000 N
The values of P·(S3−S1)+0.5YS·S1 and P·(S3−S1)+1.5YS·S1 in the cases of the above (1) to (3) are calculated by the cases of (1) to (3). Note that the mold sectional area S3 is 1880 mm2.
P·(S3−S1)+0.5YS·S1=(1)101,336,(2)115,576,(3)201,016
P·(S3−S1)+1.5YS·S1=(1),275,528,(2),289,768,(3)375,208
The above values resulted. In all of (1), (2), and (3), the results are in the preferable range of the pressing force. Accordingly, when working the tube after mold closure by the load path explained above, the part could be formed without seal leakage.
As a result of the above hydroforming, it was possible to obtain a hydroformed product formed with a flange along its entire length.
First, the center of the tube material was bent by ram bending to a radius of curvature of 484 mm (=8 times the outside diameter of the tube material). This bent tube was placed to the groove of the lower mold 17 of
After that, a seal punch of the same shape as Example 1 was used to apply a pressing force while applying internal pressure. The conditions of the internal pressure and pressing force were set the same as in Example 1. In that state, the upper mold (not shown) was made to descend to close the mold. Note that the cross-sectional shape of the upper mold was the same shape as the cross-section of the upper mold shown in
By the above step, it was possible to obtain a hydroformed product with a flange along its entire length even in the case of a bent shape.
As explained above, according to the present invention, the range of application of hydroformed products is broadened, so parts can be combined and the weight can be reduced. In particular, application to auto parts results in greater reduction of vehicle weight and therefore improved fuel economy and as a result can contribute to suppression of global warming. Further, application to industrial fields where no progress had been made in application up to now, for example, consumer electric products, furniture, construction machinery parts, motorcycle parts, and building parts can be expected.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-189235 | Jul 2007 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/063469 | 7/18/2008 | WO | 00 | 1/13/2010 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2009/014233 | 1/29/2009 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20100186473 A1 | Jul 2010 | US |
