Compact Piercing Device for Hydro-Formed Members
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Solution Overview
Problem
Current piercing technologies for hydro-formed members face challenges with aperture formation due to limited space for piercing cylinders, resulting in restricted aperture density and suboptimal quality, and are complicated by the need for bulky hydraulic control systems in negative piercing methods.
Innovation Solution
A piercing device with a punch and guide bore, supported by a guide post and driven by a force-transferring member, allows for negative piercing during the hydro-forming process, reducing the required force and enabling a smaller hydraulic ram, while occupying minimal volume, thus enabling denser aperture formation without complex hydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional piercing cylinders are used to form apertures in hydro-formed members, then the piercing operation can be performed, but the large volume required for the cylinders restricts the number of apertures that can be formed in any region
Solution Approach 1:
The piercing device is segmented into multiple separate components: a punch element, a support member, and a drive member. This segmentation allows each component to be compact and enables multiple piercing devices to be arranged in close proximity within the hydro-forming die, thereby increasing the number of apertures that can be formed in a given region.
Solution Approach 2:
The punch is slidably received on the guide post, and the drive member extends through the support member, creating a nested arrangement where components are positioned within or through each other. This nesting minimizes the overall volume occupied by the piercing device while maintaining functionality.
2Manufacturing precision
If negative piercing is used to reduce piercing force and improve aperture quality, then better aperture quality and reduced force are achieved, but complex hydraulic control systems with stops and lines are required
Solution Approach 1:
The support member is pre-positioned within the hydro-forming die during the hydro-forming process itself. This preliminary positioning eliminates the need for complex hydraulic control systems with stops and lines, as the support member is already in place to guide the punch and enable the negative piercing action when needed.
Solution Approach 2:
The support member serves multiple functions: it guides the punch, positions the piercing device, and enables the negative piercing action. This self-service capability reduces the need for additional complex control systems, as the support member inherently provides the necessary functions without requiring external hydraulic control infrastructure.
3Manufacturing precision
If negative piercing is implemented with retraction and extension of the piercing die, then aperture quality improves, but the additional hydraulic infrastructure occupies more volume in the hydro-forming die
Solution Approach 1:
The piercing system is divided into separate compact components (punch, support member, drive member) that can be arranged in a space-efficient manner. This segmentation eliminates the need for bulky hydraulic infrastructure, as each component is independently positioned and does not require extensive hydraulic line routing or control stops.
Solution Approach 2:
The piercing device utilizes the vertical dimension by having the punch move along the guide post in a sliding arrangement. This dimensional approach allows the piercing action to occur in the vertical axis without requiring additional horizontal space for hydraulic infrastructure, thereby maximizing the use of available volume in the hydro-forming die.
Data Source
AI summary
A piercing device for hydro-formed members comprises a punch having a cutting surface and a guide bore, a support member having a guide post complementary in shape to the guide bore and drive passages, and a drive member having two arms forming U-shaped members. The arms of the drive member extend through the drive passages of the support member to transfer a force between a ram and the punch.