Patent Abstract:
A hydroforming machine is disclosed which includes a plurality of dies with each die having an upper die plate hingedly connectable to and lockable with a lower die plate. Each upper die plate and lower die plate include an opening therethrough which are substantially alignable with each other. The hydroforming machine also includes a spacing device. The spacing device is disposed in mechanical cooperation with each of the dies and maintains a desired distance between each of the dies. The spacing device includes a plurality of hinges which hingedly connect each die with an adjacent die.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims the benefits of and priority to U.S. Provisional Patent Application Ser. No. 60/683,658 entitled “BELLOWS HYDROFORMING TOOLS,” which was filed on May 23, 2005, the entire contents of which are hereby incorporated by reference herein. 
     
    
     BACKGROUND  
       [0002]     The present disclosure relates to a hydroforming machine for forming a bellows and, more particularly relates to a hydroforming machine including a spacing device which allows for rapid changing of the spacing between adjacent dies.  
         [0003]     Hydroforming is one of several processes that may be used for forming pieces of metal into bellows. During hydroforming, a plurality of dies are positioned parallel and adjacent to one another. A hollow tube is inserted into openings of the dies and is held in position. Pressurized water is forced through the hollow tube and the water pressure that is forced against the tube expands the walls of the tube outwardly. The dies apply pressure against the walls of the tube at desired locations along the length of the tube so that the wall of the tube is only expanded between adjacent dies. The dies are compressed together for forcing the expanded sections of the wall into a corrugated pattern for forming bellows.  
         [0004]     The spacing between the dies determines the sizing of the bellows, thus it is typically desirable to be able to accurately and repeatably control and alter this spacing. It may also be desirable to change this spacing relatively quickly.  
         [0005]     The dies generally include an upper die plate and a lower die plate. Further, a locking mechanism is generally included to lock the upper die plate with the lower die plate while the pressurized water (or another liquid or gas) is forced through the tube.  
       SUMMARY  
       [0006]     The present disclosure relates to a hydroforming machine. The hydroforming machine includes a plurality of dies with each die having an upper die plate hingedly connectable to and lockable with a lower die plate. Each upper die plate and lower die plate includes an opening therethrough which are substantially alignable with each other. The hydroforming machine also includes a spacing device. The spacing device is disposed in mechanical cooperation with each of the dies and maintains a desired distance between each of the dies. The spacing device includes a plurality of hinges which hingedly connect each die with an adjacent die.  
         [0007]     The present disclosure also relates to a hydroforming machine including a plurality of dies and a spacing device. Each die has an upper die plate hingedly moveable with respect to a lower die plate between an open position and a closed position. The distance between adjacent dies is adjustable while the upper die plates are in the open position, the closed position and any position therebetween.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     Embodiments of the present disclosure are described hereinbelow with reference to the figures wherein:  
         [0009]      FIG. 1  is a perspective view of an embodiment of a hydroforming machine of the present disclosure;  
         [0010]      FIG. 2  is a front view of the hydroforming machine of  FIG. 1 ;  
         [0011]      FIG. 3  is an enlarged perspective view of a hinge mechanism of the hydroforming machine of  FIGS. 1 and 2 ;  
         [0012]      FIG. 4  is an enlarged perspective view of a locking mechanism of the hydroforming machine of  FIGS. 1-3  illustrated in an unlocked position;  
         [0013]      FIG. 5  is a partial front view of the hydroforming machine of  FIGS. 1-4  illustrated in a locked position;  
         [0014]      FIG. 6  is an enlarged perspective view of a spacing device of an embodiment of the hydroforming machine;  
         [0015]      FIG. 7  is a partial top view of the spacing device of  FIG. 6 ;  
         [0016]      FIG. 8  is a partial front view of the spacing device of  FIGS. 6 and 7 ;  
         [0017]      FIG. 9  is a partial top view of an embodiment of the spacing device of  FIGS. 6-8 ;  
         [0018]      FIG. 10  is several cross-sectional views a spacer bar as indicated by line  10 - 10  in  FIG. 7 ; and  
         [0019]      FIG. 11  is a partial top view of an alternate embodiment of the spacing device of  FIGS. 6-9 . 
     
    
     DETAILED DESCRIPTION  
       [0020]     Embodiments of the presently disclosed hydroforming machine are described in detail with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, while the term “distal” refers to that part or component farther away from the user.  
         [0021]     Referring to  FIG. 1 , a hydroforming machine is shown and is generally referred to by reference numeral  100 . This embodiment of hydroforming machine  100  includes a plurality of dies  110 , a hinge mechanism  160 , a locking mechanism  180  and a spacing device  200 . Each die  110  includes an upper die plate  120  and a lower die plate  140 , which are hingedly connected to each other via hinge mechanism  160 . An upper opening  130   a  is disposed in each upper die plate  120  and a lower opening  130   b  is disposed in lower die plate  140 . When upper die plates  120  and lower die plates  140  are approximated, upper opening  130   a  and lower opening  130   b  form a generally circular opening  130 .  
         [0022]     In use, a ram (not explicitly shown in this embodiment) retracts dies  110  as far as spacing device  200  allows. When upper die plates  120  are open (i.e., not approximated with lower dies plates  140 ), a hollow tube (not explicitly shown) is placed onto lower opening  130   b  of lower die plates  140 . Upper die plates  120  are approximated towards lower die plates  120  via rotation about hinge mechanism  160 . Once fully approximated, upper die plates  120  and lower die plates  140  are locked together via locking mechanism  180 , thus locking hollow tube therebetween. The hollow tube, which may include a plug (not shown), is generally filled and pressurized with a liquid (e.g., water). Such pressurization causes the hollow tube to bulge into areas between dies  110 . Dies  110  are then collapsed axially by compression exerted by the ram. Dies  110  are forced together so that each die  110  contacts an adjacent die  110 . Locking mechanism  180  is then released, upper dies plates  120  are opened and the formed bellow or bellows can be removed. The ram is then retracted, causing dies  110  to be drawn apart from adjacent dies  110 .  
         [0023]     With reference to  FIGS. 2 and 3 , hinge mechanism  160  is illustrated (locking mechanism  180  and spacing device  200  are not illustrated in these figures). In this embodiment, hinge mechanism  160  includes an upper aperture  162  in each of upper die plates  120  and a lower aperture  164  in each of lower die plates  140 . Upper apertures  162  and lower apertures  164  at least partially align to form hinge aperture  165 . A hinge pin  166  (and/or keeper shaft  167 ) is insertable through hinge aperture  165 . In the illustrated example, apertures  162  and  164  are disposed at an angle to their respective plates  120  and  140 , thus allowing hinge pin  166  (and thus upper dies plates  120 ) to be removed in situ. Thus, if a die  110  is damaged or is in need of repair, it can be removed from hydroforming machine  100  and an additional die  110  or die plate  120 ,  140  can be inserted as a replacement. It is envisioned to machine die plates  120  and  140  at substantially half of their nominal thickness in the portions of upper die plates  120  and lower die plates  140  that overlap each other as part of (and possibly adjacent) hinge mechanism  160 . It is also envisioned to machine a relief (not explicitly shown) to allow for leaves (not explicitly shown) of hinge pin  166 .  
         [0024]     Now referring to  FIGS. 4 and 5 , locking mechanism  180  is illustrated. Locking mechanism  180  includes a lock aperture  182  and a lock shuttle  184 . Lock aperture is made up of upper lock apertures  182   a  disposed in each of upper die plates  120  and lower lock apertures  182   b  disposed in each of lower die plates  140 . In its unlocked (or first) position (illustrated in  FIG. 4 ), lock shuttle  184  is disposed substantially within lower lock apertures  182   b . When upper die plates  120  are approximated with lower die plates  140 , upper lock apertures  182   a  substantially align with lower lock apertures  182   b . Here, lock shuttle  184  is then slidable into its locked (or second) position (illustrated in  FIG. 5 ) where lock shuttle  184  engages both upper lock aperture  182   a  and lower lock aperture  182   b , thus locking upper die plates  120  and lower die plates  140  together.  
         [0025]     To unlock die plates  120  and  140 , lock shuttle  184  is returned to its first position. It is envisioned that a lower surface  183  of upper lock aperture  182   a  is titled downward at an angle α towards lower lock aperture  182   b  (see  FIG. 5 ) to help ensure die plates  120  and  140  can properly lock together and to help ensure die plates  120  and  140  do not separate during operation. It is envisioned that angle α is in the range of about 0.5 degrees to about 5 degrees and more particularly in the range of about 1 degree to about 2 degrees. It is also envisioned that upper die plates  120  and/or lower die plates  140  include at least one guide aperture  170  extending therethrough. Guide aperture(s)  170  may be provided for primary shaft(s) (not explicitly shown) to extend through. The ram axially pushes dies  110 , which ride on the primary shaft(s).  
         [0026]      FIGS. 6-11  illustrate a spacing device  200 . Spacing device  200  includes spacer hinges  300  and a spacer bar  310  (or spacers  312 ). Spacer hinges  300  include an inner hinge pin  302  and an outer hinge pin  304 , which are linked together by linkage  306 . Generally, spacer hinges  300  are affixed adjacent an edge (or both edges) of upper die plates  120  and/or lower die plates  140 . ( FIG. 8  illustrates hinges  300  affixed adjacent an edge of lower die plates  140 .) More specifically, inner hinge pin  302  is affixed to die plates  120  or  140  and is connected to outer hinge pin  304  via hinge linkage  306 . Spacer bar  310  is disposed between inner pin  302  and outer pin  304 . More specifically, spacer bar  310  may be disposed between an edge (or shoulder) of die  110  and outer pin  304 .  
         [0027]     With continued reference to  FIGS. 6-11 , when dies  110  are compressed together, outer hinge pins  304  are moved outwardly with respect to inner pins  302  (i.e., outer hinge pins  304  are move away from die  110 ). Accordingly, when dies  110  are separated from each other, outer pins  304  move inwardly with respect to inner pins  302  (i.e., towards die  110 ). See  FIG. 9 . As can be appreciated by referencing  FIGS. 6-9  and  11 , spacer bar  310  (or spacers  312 ) limits the inward travel of outer pins  304  when dies  110  are separated from each other. Thus, altering the width “w” ( FIG. 7 ) of spacer bar  310  changes the distances that dies  110  may move apart from an adjacent die  110 .  
         [0028]     Using spacing device  200  of  FIGS. 6-11 , a user is able to remove and replace spacer bar  310  (or spacers  312   a ,  312   b , discussed below), either before or after upper die plates  120  are approximated with lower die plates  140 , or at any time in between. Thus, to change the desired distance between dies  110 , a user can easily and quickly remove spacer bar  310  and replace spacer bar  310  with a different sized spacer bar  310 . Further, as can be appreciated, a user may perform such a replacement without the use of any tools.  
         [0029]     With reference to  FIG. 7 , spacing device  200  is illustrated adjacent both edge of die plates  120  or  140 . While not necessarily necessary, this embodiment may lead to more accurate spacing control.  FIG. 7  also illustrates spacer bar  310  (two spacer bars  310  are illustrated) having a substantially constant width “w” along its length. This constant width “w” creates a uniform spacing between each adjacent die  110 .  
         [0030]      FIG. 9  illustrates spacing device  200  having a spacer bar  310  that has a varying width. More specifically, spacer bar  310  is illustrated being stepped with two different widths, w 1  and w 2 . This stepped spacer bar  310  corresponds to different distances between adjacent dies  110 , d 1  and d 2 , respectively. Depending on the desired product, a spacer bar  310  having a constant width or a varied width may be used.  
         [0031]     Now referring to  FIG. 10 , different cross-sections of spacer bar  310  indicated by line  10 - 10  in  FIG. 7  are illustrated. While a circular (including oval) and rectangular cross-section are shown, the cross-section of spacer bar  310  may be any suitable regular or non-regular shape.  
         [0032]     With reference to  FIG. 11 , spacing device  200  having a plurality of spacers  312  is illustrated. In this embodiment, spacers  312  having substantially the same or different shapes may be used to provide proper spacing for adjacent dies  110 . Here, at least a portion of circular-shaped disc  312   a  is positioned between inner hinge pin  302  and outer hinge pin  304 . Included in this embodiment, is a portion of spacer  312  positioned between outer hinge pin  304  and an edge of die  110 . In addition to circular-shaped disc  312   a , a rectangular spacer  312   b  is illustrated. Spacer  312  may have any suitable regular or irregular shape. It is also envisioned that spacer  312  is positioned between a head of outer (or inner) hinge pin  304  and a portion of linkage  306 . It is further envisioned that spacer (e.g.,  312   a ) will be vertically spaced apart from an adjacent spacer (e.g.,  312   b ) to enable dies  110  to be compressed without adjacent spacers  312   a ,  312   b  contacting each other.  
         [0033]     While several embodiments of the disclosure have been shown in the figures, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. For example, it is envisioned that objects other than bellows may be created from such a hydroforming machine. Those skilled in the art will envision other modifications within the scope and spirit the claims appended hereto.

Technology Classification (CPC): 1