Multi-Segment Hydroforming Tool for Undercut Tubular Parts
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Solution Overview
Problem
Existing hydroforming methods require preforming operations and cannot produce components with undercuts or avoid laborious parting line coordination, leading to potential quality issues and inefficiencies.
Innovation Solution
A hydroforming tool with at least three movable tool segments that form a closed cavity without parting lines in contact with the workpiece, allowing for the production of components with undercuts and eliminating the need for preforming steps by maintaining a fully enclosed shaping cavity during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional two-tool-half hydroforming is used, then the structure is simple, but preforming operations are required and undercuts cannot be produced
Solution Approach 1:
The tool is divided into multiple movable tool segments (at least three) that can independently move relative to each other. This segmentation allows the tool to form complex cavity shapes including undercuts without requiring preforming operations, while maintaining manageable structural complexity through modular design
2Ease of operation
If fixed molds are used, then the tool structure is stable, but workpieces must be pushed axially and preforming cannot always be avoided
Solution Approach 1:
The tool segments are designed to be movable rather than fixed, allowing them to move in directions other than purely axial. This dynamic configuration enables the tool to accommodate workpieces in various orientations and form complex shapes including undercuts without requiring preforming operations
3Manufacturing precision
If parting lines are coordinated between tool halves, then the tool can be closed, but laborious coordination is required and quality may be impaired
Solution Approach 1:
The design eliminates parting lines from contact with the workpiece by using movable tool segments that close without requiring parting line coordination. This extraction of the parting line function from the forming process eliminates the laborious coordination step and prevents quality impairment from offsets
4Shape
If preforming operations are performed, then complex shapes can be achieved, but the process time and complexity increase
Solution Approach 1:
The tool segments are pre-configured in an open state that allows easy workpiece loading, then move to a closed state that forms the final complex shape in a single operation. This preliminary positioning of the tool segments eliminates the need for separate preforming operations while maintaining the ability to produce complex shapes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables the production of high-quality components without preforming and undercuts, improving the efficiency and quality of the hydroforming process by eliminating direct contact with parting lines, thus reducing laborious coordination and potential offsets.
Implementation Method 1
a high internal pressure being applied... with the aid of a fluid, for example a water/oil emulsion, introduced into the interior, is widened essentially transversely to the longitudinal axis
Data Source
AI summary
A tool for the internal high-pressure shaping of a workpiece, in particular for producing a tubular structural component for a motor vehicle, is provided. The tool includes at least three movable tool segments, which bound a shaping cavity for accommodating and shaping the workpiece. The movable tool segments, at least in some sections, completely form the shaping cavity in a closed state of the tool. A method for shaping a workpiece by internal high-pressure shaping is also provided.