Metal deforming – By application of fluent medium – or energy field – With actuated tool engaging work
Reexamination Certificate
2002-12-17
2004-05-25
Jones, David B. (Department: 3725)
Metal deforming
By application of fluent medium, or energy field
With actuated tool engaging work
C072S055000, C072S058000, C072S367100, C072S370060, C029S421100
Reexamination Certificate
active
06739166
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to forming a shaped tubular member and, more particularly, to a method of forming a tubular member with a flange of hydroformed metal tubing for assembling automotive structures.
BACKGROUND OF THE INVENTION
It is known to form a cross-sectional profile of a tubular member by a hydro-forming process in which a fluid filled tubular blank is placed within a die and then the die is closed so that the tubular blank is pinched within the die. Fluid pressure is then increased inside the tubular member to expand the blank outwardly against the die cavity to provide a tubular product having a die formed cross-sectional profile. The tubular product may also have different cross-sectional profiles along the length thereof.
It is also known to form a tubular member with a flange. An example of such a tubular member with a flange is disclosed in U.S. Pat. No. 5,070,717 to Boyd. In this patent, a method of forming a flanged-tubular member is accomplished by sizing the tubular blank to the largest cross-section circumferential measure of the desired end product. Then, a hydro-forming die and process is used to expand any excess circumferential measure into a flange defining portion of the die cavity to thereby enable the formation of a cross-section of lesser cross-sectional measure than the largest cross-section. The flange may be trimmed as desired to shorten the length of the flange, in which case, welding or other suitable attachment processes may be employed to join the flanges together to strengthen the tubular member.
However, the flange is created from the original tube diameter section. The tubular member is selected based on the biggest section. Thus, if a longer flange is needed, and/or larger section size is needed, it requires using a bigger diameter tube, thus adding mass and cost, which is undesired. In addition, the tubular member is pinched where sections required are smaller. Further, the flange has to be trimmed and welded to keep the section closed (if required).
As a result, it is desirable to provide a new method of forming a tubular member with a flange. It is also desirable to provide a method of forming a tubular member with a flange that allows smaller diameter tubes to be used. It is further desirable to provide a method of forming a tubular member with integral flanges where needed. Therefore, there is a need in the art to provide a method of forming a tubular member with a flange that meets these desires.
SUMMARY OF THE INVENTION
It is, therefore, one object of the present invention to provide a new method of forming a tubular member with a flange.
It is another object of the present invention to provide a method of forming a tubular member with integral flanges where needed.
To achieve the foregoing objects, the present invention is a method of forming a tubular member with at least one flange. The method includes the steps of providing a tubular member. The method also includes the steps of expanding at least one portion of the tubular member and positioning the tubular member between open die halves mating with one another to define a tubular cavity portion and a flange cavity portion. The method includes the steps of applying at least nominal internal hydraulic pressure to the tubular member. The method further includes the steps of progressively closing the die halves to progressively deform the tubular member within the tubular cavity portion and progressively expel the at least one portion of the tubular member into the flange cavity portion to define a flange comprised of wall portions of the tubular member engaging one another. The method includes the steps of increasing the hydraulic pressure to expand and conform the tubular member to the tubular cavity portion. The method also includes the steps of separating the die halves and removing the tubular member having a flange from the die.
One advantage of the present invention is that a method of forming a tubular member with an integral flange is provided for a vehicle, eliminating extra welding of stamped flanges. Another advantage of the present invention is that the method allows the use of smaller diameter tube, resulting in less cost and mass. Yet another advantage of the present invention is that the method allows easier assembly of tubular members. Still another advantage of the present invention is that the method provides multiple flanges on a single tubular member. A further advantage of the present invention is that the method creates flanges where the tubular member needs it.
Other objects, features, and advantages of the present invention will be readily appreciated, as the same becomes better understood, after reading the subsequent description taken in conjunction with the accompanying drawings.
REFERENCES:
patent: 5070717 (1991-12-01), Boyd et al.
patent: RE33990 (1992-07-01), Cudini
patent: 5458393 (1995-10-01), Benedyk
patent: 5720092 (1998-02-01), Ni et al.
patent: 6092865 (2000-07-01), Jackel et al.
patent: 6112567 (2000-09-01), Birkert
patent: 6247344 (2001-06-01), Eipper
patent: 6257035 (2001-07-01), Marks et al.
patent: 6263720 (2001-07-01), Valin
patent: 6302478 (2001-10-01), Jackel et al.
patent: 6394335 (2002-05-01), Meier et al.
patent: 2001/0042986 (2001-11-01), Patelczyk
General Motors Corporation
Hargitt Laura C.
Jones David B.
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