U.S. patent application number 16/392872 was filed with the patent office on 2020-08-06 for tubular member deformation process.
The applicant listed for this patent is Tad V. Machrowicz. Invention is credited to Tad V. Machrowicz.
Application Number | 20200246855 16/392872 |
Document ID | / |
Family ID | 1000004071349 |
Filed Date | 2020-08-06 |
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United States Patent
Application |
20200246855 |
Kind Code |
A1 |
Machrowicz; Tad V. |
August 6, 2020 |
TUBULAR MEMBER DEFORMATION PROCESS
Abstract
A process to plastically deform a metallic tubular member
includes heating a portion of the tubular member to at least 350
degrees Celsius, performing a feeding operation on the tubular
member by applying axial force to one end of the tubular member to
plastically deform a primary deformed portion of the tubular
member, and subsequently creating one of a bent portion in the
tubular member and a secondary deformed portion in the tubular
member between the one end of the tubular member and the primary
deformed portion.
Inventors: |
Machrowicz; Tad V.;
(Ortonville, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Machrowicz; Tad V. |
Ortonville |
MI |
US |
|
|
Family ID: |
1000004071349 |
Appl. No.: |
16/392872 |
Filed: |
April 24, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62800741 |
Feb 4, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 15/02 20130101;
B21D 7/162 20130101 |
International
Class: |
B21D 15/02 20060101
B21D015/02; B21D 7/16 20060101 B21D007/16 |
Claims
1. A process to plastically deform a metallic tubular member,
comprising heating a portion of the tubular member to at least 350
degrees Celsius; performing a feeding operation on the tubular
member by applying axial force to one end of the tubular member to
plastically deform a primary deformed portion of the tubular
member; and subsequently creating one of a bent portion in the
tubular member and a secondary deformed portion in the tubular
member between the one end of the tubular member and the primary
deformed portion.
2. The process of claim 1, wherein performing the feeding operation
on the tubular member comprises creating an expanded portion in the
tubular member.
3. The process of claim 1, wherein performing the feeding operation
on the tubular member comprises creating a flattened portion in the
tubular member.
4. The process of claim 1, wherein performing the feeding operation
on the tubular member comprises creating a thickened portion in the
tubular member.
5. The process of claim 1, wherein performing the feeding operation
on the tubular member comprises applying axial force to two ends of
the tubular member.
6. The process of claim 1, wherein subsequently creating one of the
bent portion and the secondary deformed portion comprises:
achieving a minimum temperature in a secondary portion of the
tubular member of at least 350 degrees Celsius; and creating the
bent portion.
7. The process of claim 6, further comprising, after performing the
feeding operation, permitting the tubular member to cool; and
wherein achieving the minimum temperature comprises heating the
tubular member back to the minimum temperature.
8. The process of claim 1, wherein subsequently creating one of the
bent portion and the secondary deformed portion comprises:
achieving a minimum temperature in a portion of the tubular member
of at least 350 degrees Celsius; and creating the secondary
deformed portion.
9. The process of claim 8, further comprising, after performing the
feeding operation, permitting the tubular member to cool; and
wherein achieving the minimum temperature comprises heating the
tubular member back to the minimum temperature.
10. The process of claim 8, wherein creating the secondary deformed
portion comprises creating an expanded portion.
11. The process of claim 8, wherein creating the secondary deformed
portion comprises creating a flattened portion.
12. The process of claim 8, wherein creating the secondary deformed
portion comprises creating an thickened portion.
13. The process of claim 8, wherein creating the secondary deformed
portion comprises creating a twist in the tubular member.
14. A process to plastically deform a metallic tubular member,
comprising heating a portion of the tubular member to at least 350
degrees Celsius; performing a feeding operation on the tubular
member by applying axial force to a two ends of the tubular member
to plastically deform a primary deformed portion of the tubular
member; and subsequently deforming the tubular member between the
primary deformed portion and the first end of the tubular member
and deforming the tubular member between the primary deformed
portion and a second end of the tubular member, wherein deforming
the tubular member between the primary deformed portion and the
first end of the tubular member and deforming the tubular member
between the primary deformed portion and the second end of the
tubular member each comprise creating one of a bend in the tubular
member and creating an additional deformed portion in the tubular
member.
15. A process to plastically deform a metallic tubular member,
comprising heating a portion of the tubular member to at least 350
degrees Celsius; performing a feeding operation on the tubular
member by applying axial force to one end of the tubular member to
plastically deform a primary deformed portion of the tubular
member; subsequently creating a bent portion in the tubular member
between the one end of the tubular member and the primary deformed
portion, comprising: cooling the tubular member; and bending the
tubular member; and subsequently reheating the tubular member to at
least 350 degrees Celsius and creating a secondary deformed portion
on the tubular member. .
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This disclosure claims the benefit of U.S. Provisional
Patent Application No. 62/800,741 filed on Feb. 4, 2019, which is
hereby incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure is related to a process for forming a
complex metal part, and, in particular, to a process for
plastically deforming and subsequently bending a tubular
member.
BACKGROUND
[0003] The statements in this section merely provide background
information related to the present disclosure. Accordingly, such
statements are not intended to constitute an admission of prior
art.
[0004] Processes of creating metallic parts are known and varied.
According to one exemplary known process, a metal tubular member
can be heated and an axial force applied to one or more ends of the
member can be applied. Based upon the force and the temperature, a
thickened area in the tube can be created for this purpose or the
purpose of allowing subsequent enhanced elongation; or the force
and temperature can be used solely to enhance elongation beyond
that which the elevated temperatures can provide; or a combination
of both. This can be termed a feeding operation. Feeding operations
are useful in straight parts. However, in complex parts, such as
parts with bends and twists, areas of a part can be "landlocked",
wherein providing an axial force at one end of the part cannot
thicken a portion of the part around a bend or a twist.
SUMMARY
[0005] A process to plastically deform a metallic tubular member
includes heating a portion of the tubular member to at least 350
degrees Celsius, performing a feeding operation on the tubular
member by applying axial force to one end of the tubular member to
plastically deform a primary deformed portion of the tubular
member, and subsequently creating one of a bent portion in the
tubular member and a secondary deformed portion in the tubular
member between the one end of the tubular member and the primary
deformed portion.
[0006] According to one exemplary embodiment, a process to
plastically deform a metallic tubular member can include heating a
portion of the tubular member to at least 350 degrees Celsius,
performing a feeding operation on the tubular member by applying
axial force to a two ends of the tubular member to plastically
deform a primary deformed portion of the tubular member, and
subsequently deforming the tubular member between the primary
deformed portion and the first end of the tubular member and
deforming the tubular member between the primary deformed portion
and a second end of the tubular member, wherein deforming the
tubular member between the primary deformed portion and the first
end of the tubular member and deforming the tubular member between
the primary deformed portion and the second end of the tubular
member each comprise creating one of a bend in the tubular member
and creating an additional deformed portion in the tubular
member.
[0007] According to another exemplary embodiment, a process to
plastically deform a metallic tubular member can include heating a
portion of the tubular member to at least 350 degrees Celsius,
performing a feeding operation on the tubular member by applying
axial force to one end of the tubular member to plastically deform
a primary deformed portion of the tubular member, and subsequently
creating a bent portion in the tubular member between the one end
of the tubular member and the primary deformed portion. Creating
the bent portion includes cooling the tubular member and bending
the tubular member. The process further includes subsequently
reheating the tubular member to at least 350 degrees Celsius and
creating a secondary deformed portion on the tubular member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] One or more embodiments will now be described, by way of
example, with reference to the accompanying drawings, in which:
[0009] FIGS. 1A-1C illustrate a known prior art process for
creating a thickened wall section in a tubular member;
[0010] FIG. 1D illustrates a tubular member with an expanded
central section formed with known processes without any feeding
operation, in accordance with the present disclosure;
[0011] FIG. 1E illustrates a tubular member with an expanded
central section formed with known processes including a feeding
operation to limit thinning of expanded wall sections, in
accordance with the present disclosure;
[0012] FIG. 1F illustrates a tubular member with an expanded
central section formed with known processes including a feeding
operation to maintain constant thickness of expanded wall sections,
in accordance with the present disclosure;
[0013] FIG. 2 illustrates an exemplary embodiment of a process for
deforming a tubular member, in accordance with the present
disclosure;
[0014] FIGS. 3A-3C illustrate another exemplary embodiment of a
process for deforming a tubular member, in accordance with the
present disclosure; and
[0015] FIGS. 4A, 4B, and 5-7 illustrate exemplary end product
configurations that can be created by the disclosed processes, in
accordance with the present disclosure;
[0016] FIG. 4A illustrates an exemplary structure including a
thickened central portion with bends between the thickened central
portion and ends of the structure;
[0017] FIG. 4B illustrates an exemplary structure including an
expanded central portion with bends between the expanded central
portion and ends of the structure; and
[0018] FIGS. 5-7 illustrate illustrates an exemplary structure
including a flattened deformed central portion differently oriented
flattened deformed portions between the deformed central portion
and ends of the structure.
DETAILED DESCRIPTION
[0019] According to known prior art processes, a feeding operation
can be used to control wall section thickness in metallic tubular
parts. Such metallic tubular parts formed through processes
including feeding can include either thickening or enhancing
elongation of the tubular parts. Such parts, once constructed, can
be used for a wide variety of purposes. It is known that feeding
operations require a linear column load to best thicken a wall
without buckling, however, off angle feeding can be used with
degrading efficiency. A more difficult balance between pressure,
force and resultant outward bubbling or inward folding is required
as angularity increases. In one embodiment, a feeding operation
through a part with a 90 degree or more bend can be said to be
exceedingly difficult or impossible. In another embodiment, a
feeding operation through a part with a 45 degree or more bend can
present significant balance problems and can be said to be
problematic or impractical. A non uniform distribution of material
occurs with more material forced to be added on the inside wall of
the angle versus the outside wall of the angle. Changes in feed
effectiveness and magnitude of wall thickness bias are continuous,
non linear, and depend heavily on the part geometry being formed.
The disclosed process can include either thickening or enhancing
elongation. With regard to thickening, material is fed into a
particular area for the purpose of aggregating metallic material in
that area. With regard to enhanced elongation, one may or may not
thicken first, then the expansion is continued to the enhanced
large length of line of the section and the resulting wall may be
finally thickened, an initial cross section can be maintained or
restored, or may be thinner than the initial wall thickness. In one
embodiment, the disclosed process can include a feeding operation
at a rate whereby the wall is never thickening, and the process is
just following the bubble growth to maintain wall or sometimes
allow thinning.
[0020] Referring now to the drawings, wherein the showings are for
the purpose of illustrating certain exemplary embodiments only and
not for the purpose of limiting the same, FIGS. 1A-1C illustrate a
known prior art process for creating a thickened wall section in a
tubular member. FIG. 1A illustrates an essentially straight
metallic tubular member 10. Tubular member 10 includes an exemplary
circular cross section, although it will be appreciated that the
cross section can be square, rectangular, rectangular with rounded
corners, triangular, or any similar cross section. Tubular member
10 includes a first end 12 and a second end 14. Similar processes
can be performed upon tubular members with more than two ends, for
example, with three tubes being joined by a middle portion or four
tubes being joined by a middle portion. Tubular member 10 includes
essentially straight side walls.
[0021] FIG. 1B illustrates the tubular member of FIG. 1A situated
within an exemplary feeding operation fixture. Tubular member 10 is
illustrated in cross section including first end 12, second end 14,
and wall sections to be thickened 16 and 18. A first fixed end 30
of exemplary feeding operation fixture 21 is illustrated which
first provides a fixed surface against which tubular member 10 can
be pressed. Second, fixed end 30 can seal an interior of tubular
member 10 such that air or another gas can be optionally
pressurized within tubular member 10. Second moving end 20 of
fixture 21 is illustrated, with an axial force 22 being applied to
moving end 20. Moving end 20 can seal the interior of tubular
member 10 such that air or another gas can be optionally
pressurized within tubular member 10. Tubular member 10 is heated
to at least 350.degree. C., either across the entire member or
locally at wall sections to be thickened 16 and 18. By pressing and
heating member 10, wall material can be fed into wall sections to
be thickened 16 and 18, thereby causing the walls to increase in
thickness.
[0022] Moving end 12 can be described as an end from which material
is fed to thicken wall sections of member 10. An axial force
applied to the tubular member under threshold heat causes the
heated metal to aggregate in the desired area. A straight wall 17
exists between moving end 12 and wall sections to be thickened 16
and 18. According to known feeding operation processes, a straight
wall must exist between an end from which material is fed and a
wall section to be thickened. If a bend or a twist exists between
the end from which material is fed and the wall section to be
thickened, the material being fed accumulates at the bend or twist,
for example, causing a kink, wall buckle, or undesirable bend in
the part.
[0023] FIG. 1C illustrates the tubular member of FIG. 1A after the
feeding operation is complete. Tubular member 10 is illustrated in
cross section with thickened section 26 and thickened section
28.
[0024] In alternative embodiments, feeding can be used to augment
wall thickness during bending or wall manipulation processes, for
example, to permit a wall to be reformed or expanded past normal
limits without failing. For example, under normal bending or
expansion processes, a steel member expanded to 70% or more past
its original size would experience significant thinning or
undesirable necking of walls of the member. FIG. 1D illustrates a
tubular member with an expanded central section formed with known
processes without any feeding operation. Tubular member 10' is
illustrated in cross section with expanded section 26' and expanded
section 28', which can but need not represent an expanded ring in
the middle of member 10'. Expanded section 26' and expanded section
28' illustrate sections of tubular member 10' expanded to an
increased diameter of more than 70% greater than the original
diameter of the central section, for example, as illustrated at
unexpanded point 29'. Tubular member 10' is formed through heating
and expansion of an originally cylindrical member without any
feeding operation. As a result, expanded sections 26' and 28'
include only the material that was included in the original
cylindrical form, with that material being stretched into thinner
and thinner wall sections as the degree of expansion increases. One
having skill in the art will appreciate that such drastic expansion
of the material would result in impracticability and failure of
tubular member 10', for example, with a rupture, crack, or other
failure at thinnest point 27'.
[0025] FIG. 1E illustrates a tubular member with an expanded
central section formed with known processes including a feeding
operation to limit thinning of expanded wall sections. Tubular
member 10'' is illustrated in cross section with expanded section
26'' and expanded section 28'', which can but need not represent an
expanded ring in the middle of member 10''. Expanded section 26''
and expanded section 28'' illustrate sections of tubular member
10'' expanded to an increased diameter of more than 70% greater
than the original diameter of the central section. Tubular member
10'' is formed through heating and expansion of an originally
cylindrical member while material is fed from ends of tubular
member 10''. As a result of the feeding operation, thinning of
expanded sections 26'' and 28'' is limited and can be controlled to
a desired amount.
[0026] FIG. 1F illustrates a tubular member with an expanded
central section formed with known processes including a feeding
operation to maintain constant thickness of expanded wall sections.
Tubular member 10''' is illustrated in cross section with expanded
section 26''' and expanded section 28''', which can but need not
represent an expanded ring in the middle of member 10'''. Expanded
section 26''' and expanded section 28''' illustrate sections of
tubular member 10''' expanded to an increased diameter of more than
70% greater than the original diameter of the central section.
Tubular member 10''' is formed through heating and expansion of an
originally cylindrical member while material is fed from ends of
tubular member 10'''. As a result of the feeding operation,
thinning of expanded sections 26''' and 28''' is prevented and the
thickness of the wall sections is maintained.
[0027] In a number of particular desired end product
configurations, known processes to deform and shape tubular members
such as the process illustrated in FIGS. 1A-1C. FIGS. 4A, 4B, and
5-7 illustrate exemplary end product configurations that cannot be
created by simply feeding material from the two ends of the parts.
FIG. 4A illustrates hollow metallic structure 300 including a first
tubular end 310, a second tubular end 320, and thickened central
portion 330. Thickened central portion 330 includes thickened wall
sections 332 and 334 and can but need not include a thickened ring
around structure 300 at thickened central portion 330. Thickened
central portion 330, upon a straight tubular member, can be formed
by the feeding process described in FIGS. 1A-1C. However, bend 340
separates thickened central portion 330 from first end 310, and
bend 350 separates thickened central portion 330 from second end
320. A feeding operation from a direction of arrow 312 upon first
end 310 cannot create thickened central portion 330. Such an
attempted feeding operation would distort either bend 340 or
thickened central portion 330, for example, creating a kink or tear
on inner elbow of the bend. Similarly, a feeding operation from a
direction of arrow 322 upon second end 320 cannot create thickened
central portion 330. Such an attempted feeding operation would
distort either bend 350 or thickened central portion 330. However,
structure 300 including thickened central portion 330 can be formed
from a straight tubular member according to the processes disclosed
herein.
[0028] FIG. 4B illustrates hollow metallic structure 352 including
a first tubular end 360, a second tubular end 360, and expanded
central portion 380, with central portion 380 including an
exemplary expanded diameter of roughly double the diameter of the
rest of structure 352.
[0029] A tubular member can be deformed to create an expanded
central portion without a feeding operation similar to the process
illustrated in FIGS. 1A-1C. For example, the tube material can be
heated, the part can be pressurized from within to expand the
heated material, and die material outside the part can cause the
expanding tube material to fit a desired expanded profile. However,
the material of the tubular member is thinned by the expanding
process, and as a result, the resulting expanded section includes
thinner walls than the rest of the tubular member. By utilizing a
feeding operation in combination with expanding material of a
tubular member, material can be fed to the expanding section during
the expanding process, and the expanded section can be maintained
to include walls of a same thickness as a rest of the tubular
member.
[0030] Expanded central portion 380 includes walls that are
substantially a same thickness as the rest of structure 352 and
includes expanded wall sections 382 and 384 and can but need not
include an expanded ring around structure 352 at expanded central
portion 380. Expanded central portion 380, upon a straight tubular
member, can be formed by a feeding process similar to the process
described in FIGS. 1A-1C. However, bend 390 separates expanded
central portion 380 from first end 360, and bend 398 separates
expanded central portion 380 from second end 370. A feeding
operation from a direction of arrow 362 upon first end 360 cannot
create expanded central portion 380. Such an attempted feeding
operation would distort either bend 390 or expanded central portion
380. Similarly, a feeding operation from a direction of arrow 372
upon second end 370 cannot create expanded central portion 380.
Such an attempted feeding operation would distort either bend 398
or expanded central portion 380. However, structure 352 including
expanded central portion 380 can be formed from a straight tubular
member according to the processes disclosed herein. Whether or not
a desired angle or desired structure in a tubular member prevents a
desired feeding/deformation process in a center of the tubular
member can be described as an issue of a wall bias from the inner
to outer parts of the included angle. In some cases, one can apply
brute force according to known methods to achieve minimum wall
thicknesses in a central portion, but such a brute force
application of feeding past an unacceptable angle or geometry can
carry waste on the outboard wall, be inconsistent in the
manufacturing process, or create structural defects in the part
such as kinking. If this bias is out of an acceptable range,
straightening the feed angle to create the desired deformation in
the central portion and then applying the secondary operation
between the desired deformation and the end of the part can
overcome the cited problems.
[0031] FIGS. 5-7 illustrate an additional exemplary end product
configuration that cannot be created by simply feeding material
from the two ends of the part. FIG. 5 illustrates hollow metallic
structure 400 including a first tubular end 410, a second tubular
end 420, and deformed portions 430, 440, and 450. Deformed central
portion 430 includes a crimped deformation, flattening the cross
section of structure 400 in one orientation, making the structure
400 wider in two radial directions and narrower in two radial
directions. A deformed portion similar to deformed central portion
430 can be created upon a straight tubular member by heating the
straight tubular member and squeezing the material of the tubular
member in a die without feeding material to deformed portion during
the deforming process. However, without feeding, the walls of the
tubular member in the area of deformed portion would be thinned by
the deforming process as compared to the rest of the straight
tubular member. A deformed portion such as deformed central portion
430 can be formed with a feeding process similar to the feeding
processes of FIGS. 1A-1C, 1D, and 1E, and walls of the deformed
section can be maintained to include walls of a same thickness as a
rest of the tubular member.
[0032] Deformed portions 440 and 450 are similar to deformed
central portion 430, except that, deformed portions 440 and 450 are
rotated about a longitudinal axis of structure 400 by some angle as
compared to deformed central portion 430. FIG. 6 illustrates
structure 400 of FIG. 5 from an end view. One can see deformed
portions 430 and 440 rotated in relation to each other about a
central longitudinal axis of structure 400. FIG. 7 illustrates the
structure of FIGS. 5 and 6 through a cross section defined by
section line AA of FIG. 6. Wall sections of structure 400 are
illustrated to include substantially constant thickness throughout
the structure.
[0033] Deformed central portion 430, upon a straight tubular
member, can be formed by a feeding process similar to the feeding
process described in FIGS. 1A-1C. However, deformed portion 440
separates deformed central portion 430 from first end 410, and
deformed portion 450 separates deformed central portion 430 from
second end 420. A feeding operation from first end 410 cannot
create deformed central portion 430. Such an attempted feeding
operation would distort deformed portion 440. Similarly, a feeding
operation from second end 420 cannot create deformed central
portion 430. Such an attempted feeding operation would distort
deformed portion 450. However, structure 400 including deformed
central portion 430 can be formed from a straight tubular member
according to the processes disclosed herein.
[0034] Structures 300, 352, and 400 are exemplary end product
configurations that can be achieved by the disclosed process. It
will be appreciated that a vast variety of different end products
can be made according to processed disclosed herein, and the
disclosure is not intended to be limited to the particular examples
provided.
[0035] In one exemplary embodiment of the present disclosure,
rotation can needed to create a desired end product geometry. One
may want the original feed stock to have the length of line
maximized, but to feed it through an initial chokepoint it requires
an axis rotation. For example, a small tubular member through the
chokepoint may not be able to make a desired geometry in a middle
of the tubular member due to lack of length of line present in the
part, but a horizontal oval can be created through expansion of the
tubular member to create more length of line in the part. The
modified tubular member now has enough additional length of line to
do the job, and it can be fed through a chokepoint which is narrow
vertical but wide. However, without the presently disclosed
processes, a problem exists including the outer segments are tall
in vertical but narrow horizontal. The part still needs this larger
tube starting length of line, but the part cannot be present in the
original die shape or they would have conflicted with the tube in
the horizontal direction and prevented feeding. According to the
present process, one may feed through the narrow but wide
chokepoints, and subsequently one can create the desired bubble to
increase length of line. Finally, one may twist the ends to create
the desired end product geometry.
[0036] A process for deforming a tubular member is disclosed. The
process includes at least two steps. According to one embodiment of
the process, a tubular member first is plastically deformed. The
plastic deformation can include a deforming process to plastically
deform at least one wall portion of the tubular member to create a
deformed wall member portion. The deformed wall member portion can
include a thickened wall member portion, an expanded wall member
portion, or a flattened wall member portion, or an otherwise
deformed wall member portion. The process of creating the deformed
wall member portion can include a feeding process, for example,
providing wall material to either thicken or maintain a wall
thickness in the area being deformed. Second, the tubular member is
bent or deformed, such that one of a bent member portion and a
deformed member portion is created between the deformed wall member
portion and an end of the member portion. The tubular member can
then be further manipulated, for example, being placed within a die
to create a final part.
[0037] According to a second embodiment of the process, a tubular
member first is plastically deformed. The plastic deformation can
include a feeding process to deform at least one wall portion of
the tubular member to create a deformed wall member portion.
Second, the tubular member is twisted, such that a twisted member
portion is created between the thickened wall member portion and an
end of the member portion. The tubular member can then be further
manipulated, for example, being placed within a die to create a
final part.
[0038] FIG. 2 illustrates an exemplary embodiment of a process for
deforming a tubular member. Process 100 starts at step 102. At step
104, the process is initialized with a hollow metallic structure
with one or more open ends. At step 106, the metallic structure is
heated, or at least a portion of the structure is heated, to a
temperature above 350.degree. C. At step 108, an optional step, the
structure can be enclosed within a die after (or before) the part
is heated. At step 110, ends of the metallic structure are clamped
and sealed either before or after the structure is heated. If the
structure is enclosed in a die, the clamping and sealing can be
accomplished before or after the structure is placed into the die.
At step 112, the structure undergoes a feeding operation and the
part is internally pressurized, such that a portion of the
structure is plastically deformed, for example, to shape the walls,
to thin the walls in a desired way, to maintain a thickness of at
least one wall section or wall portion in the structure, or to
thicken at least one wall section or wall portion in the structure.
At step 114, the structure is bent. The bending can occur after the
structure is permitted to cool after the plastic deformation, after
re-heating the structure after the structure is cooled, or while
the structure is still hot from the plastic deformation step. The
bending is performed between an end of the structure that was a
feed axis for the feeding operation of step 112 and the portion of
the structure that was plastically deformed. In one embodiment, the
bend can be in excess of 15 degrees. In step 116, the structure is
heated or heat is retained in the structure to keep the structure
above at least 350.degree. C. In step 116, the structure is
enclosed in a die and the structure is put through a final shaping
operation including plastic deformation within the die according to
known die processes. The die can but need not be heated for this
step. At step 120, the process ends. Process 100 is provided as one
exemplary embodiment of a deformation process. Other embodiments
are envisioned, and the disclosure is not intended to be limited to
the particular examples provided herein.
[0039] The structure of FIG. 2 can be a tube or fabricated
multi-leg structure. At least one open end is required. Heating the
structure can be performed by any known means, including by
conducting current through the structure. Pressurizing a structure
or tubular member is useful to prevent the part from buckling or
caving in during the deformation of the part.
[0040] In the process of FIG. 2, one creates a plastically deformed
segment of a metallic structure through a feeding operation. The
structure then is subsequently bent, twisted, or otherwise
manipulated in such a way that a feeding operation would not have
been able to create the plastically deformed segment after the
bending or manipulation was performed.
[0041] FIGS. 3A-3C illustrate another exemplary embodiment of a
process for deforming a tubular member. Process 200 starts at step
202. A structure as described in FIG. 2 can be described in one
embodiment as a tubular member. At step 204, a tubular member is
pre-fabricated based upon a desired finalized shape. The member can
include any number of ends, including two ends, three ends, and
four ends. At step 206, a determination is made whether the tubular
member needs to be sealed on one or more ends. If no seal is
required, the process proceeds to step 212. If one seal is
required, the member is sealed on the required side at step 210. If
more than one seal is required, at step 208, the tubular member is
sealed on every required side. At step 212, the tubular member is
clamped, sealed, and pressurized. At step 214, a material feeding
operation is initiated. At step 216, a determination is made
whether the feeding operation should occur within a die. If the
feeding operation is to be performed outside of a die, the process
proceeds to step 218, where the tubular member is heated, and the
process proceeds to step 232. If the feeding operation is to be
performed within a die, the process advances to step 220, where a
determination is made whether the member is to be heated within the
die or outside of the die. If the member is to be heated outside of
the die, the process advances to step 222, where the member is
heated prior to being placed into the die in step 224; after which
the process subsequently advances to step 232. If the member is to
be heated within the die, the process advances to step 226, wherein
a determination is made whether the member should be actively
heated by a heating device or if the member should be passively
heated by heating the die. If the member is to be actively heated,
the process advances to step 228 where a heating device is used to
heat the member and the process advances to step 232. If the member
is to be passively heated, the process advances to step 230 where
the die is heated and the process advances to step 232. At step
232, an axial force is applied to at least one side of the tubular
member. At step 234, material is fed and the part is pressurized to
create desired plastic deformation in the tubular member. Plastic
deformation through such a feeding operation can include shaping a
section of the walls, thinning a section of the walls, or
thickening a section of the walls.
[0042] At step 235, a determination is made whether the tubular
member was put in a first die in steps 224, 228, or 230. If the
member was not put in a first die, the process advances to step
236. At step 236, it is determined whether an intermediate bending
operation is required. If the intermediate bending operation is
required the process advances to step 248. If the bending operation
is not required, the process advances to step 254.
[0043] If, at step 235, it is determined that the member was put in
a first die, the process advances to step 238. If the bending
operation is not required, the process advances to step 252. If the
bending operation is required the process advances to step 240. At
step 240, a determination is made whether the intermediate bending
operation can be performed within the die. If the intermediate
bending operation cannot be performed within the die, the process
advances to step 242, where the member is removed from the die, and
the process advances to step 248. If the intermediate bending
operation can be performed within the die, the process advances to
step 244, where the member is heated to a desired temperature, and
the member is bent within the die at step 246. The process then
advances to step 252.
[0044] At step 248, the member is heated to a desired temperature,
and the member is bent at step 250. The process then advances to
step 254.
[0045] At step 254, the tubular member is heated to a desired
temperature for a final shaping operation, and the process advances
to step 256 where the tubular member is placed in a die capable of
performing the final shaping operation. The process subsequently
advances to step 266.
[0046] At step 252, a determination is made whether the final
shaping operation can be performed within the first die, or whether
a second die is required. If the final shaping operation can be
performed within the first die, the process advances to step 264
where the member is heated within the first die to a desired
temperature required for the final shaping operation. The process
subsequently advances to step 266.
[0047] If, at step 252, it is determinate that the final shaping
operation cannot be performed within the first die, the process
advances to step 258, where the tubular member is removed from the
first die. At step 260, the member is heated to a desired
temperature required for the final shaping operation. At step 262,
the part is placed in a second die configured to perform the final
shaping operation. The process subsequently advances to step
266.
[0048] At step 266, a determination is made whether the die used
for the final shaping operation needs to be heated. If not, the
process advances to step 270. If the die does need to be heated,
then the process advances to step 268, where the die is heated, and
the process advances to step 270. At step 270, the final shaping
operation begins including die processes known in the art. At step
272, a determination is made whether any of the walls of the
tubular member need to be plastically deformed through a second
feeding operation. If not, the process advances to step 278. If one
or more sections or portions of the walls of the member do need to
be plastically deformed, the process advances to step 274, where an
axial force is applied to at least one side of the tubular member.
At step 276, material is fed and the member is internally
pressurized to plastically deform the member. At step 278, the die
process is completed upon the tubular member to create the final
part. At step 280, the final part is removed from the die. At step
282, the process ends. Process 200 is provided as one exemplary
embodiment of a deformation process. Other embodiments are
envisioned, and the disclosure is not intended to be limited to the
particular examples provided herein.
[0049] In various embodiments and descriptions, tubular members are
illustrated and described as being expanded more than 70% past an
original diameter or size. In some embodiments and materials, 70%
can describe a natural limit past which a metallic tube cannot be
expanded without a feeding operation as described herein. However,
70% expansion is not provided herein as any limiting value, the
process steps as disclosed herein can be utilized to create various
shapes and geometries in the parts being formed, including
expansion, wall augmentation, or large length of line expansion,
and the disclosed images and descriptions are meant to be
non-limiting examples of capabilities of the disclosed process.
[0050] The disclosure has described certain preferred embodiments
and modifications of those embodiments. Further modifications and
alterations may occur to others upon reading and understanding the
specification. Therefore, it is intended that the disclosure not be
limited to the particular embodiment(s) disclosed as the best mode
contemplated for carrying out this disclosure, but that the
disclosure will include all embodiments falling within the scope of
the appended claims.
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