Hydroforming Tube Punching with Spring-Loaded Support Rod
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Solution Overview
Problem
Current methods for punching holes through the opposed walls of a tube in a hydroforming die cavity are inefficient as they require separate tools and lack effective support mechanisms to prevent wall rupture under pressure.
Innovation Solution
A single punch apparatus with a support mechanism using a spring-loaded support rod to prevent tube wall rupture, allowing the punch to travel across the die cavity and punch holes in both tube walls while maintaining internal pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single punch is used to punch holes in both tube walls, then device complexity is reduced and productivity is improved, but the risk of tube wall rupture increases due to hydroforming pressure
Solution Approach 1:
A support rod is introduced as an intermediary element between the punch and the tube wall during the punching operation. The support rod provides temporary support to the tube wall being punched, distributing the stress and preventing rupture caused by hydroforming pressure. After punching is complete, the support rod is removed. This mediator allows the single punch to safely create holes in both walls without compromising tube integrity.
2Reliability
If the support rod remains in contact with the tube wall during punching, then tube wall rupture is prevented, but the punch cannot effectively travel across the die cavity
Solution Approach 1:
The support rod is designed with dynamic characteristics - it can be positioned to contact the tube wall when needed for support during punching, and withdrawn when the punch needs to travel across the die cavity. The support rod actuator controls the positioning and withdrawal of the support rod, allowing it to provide support during the punching operation and then clear the path for punch travel to the second wall.
3Reliability
If separate tools are used for punching each tube wall, then tube wall rupture is minimized, but manufacturing efficiency decreases
Solution Approach 1:
The invention merges the punching function into a single tool that can punch holes in both tube walls sequentially. The punch is designed to penetrate the first wall, travel across the interior of the tube, and then punch the second wall. Combined with the support rod mechanism that provides temporary support during each punching operation, this unified tool achieves both high reliability and improved manufacturing efficiency compared to using separate tools for each wall.
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
Enables efficient punching of holes in both tube walls without rupture, utilizing a single punch and support mechanism to manage hydroforming pressure, enhancing manufacturing efficiency.
Implementation Method 1
A support mechanism for supporting the second wall of the tube against rupture by the hydroforming pressure includes a spring that biases a support face of a support rod into engagement with the second wall and yields during the punching of the second hole
Implementation Method 2
introducing pressurized fluid to expand the tube into a shape defined by the die cavity
Data Source
AI summary
Apparatus is provided for punching holes through the opposed first and second tube walls of a hydroformed tube while the tube is within the die cavity formed by a pair of hydroforming dies. A punch is mounted within a punch bore that intersects with the die cavity. A punch advances the punch to punch a first hole in the first tube wall and then travel across the die cavity and make a second hole in the second tube wall. A support mechanism for supporting the second wall of the tube against rupture by the hydroforming pressure includes spring biasing a support face of a support rod into engagement with the second wall and yielding during the punching of the second hole. A support rod actuator withdraws the support rod to carry the support face away from the second wall after the second hole is punched.