US 6,322,645 B1Granted

Method of forming a tubular blank into a structural component and die therefor

OwnerWilliam C. Dykstra, George D. Pfaffmann +1inventors

InventorsWilliam C. Dykstra, George D. Pfaffmann, Xin Wu

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Abstract

A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell formed from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank, placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.

A method of forming an elongated tubular metal blank with first and second ends, at least one of said ends being open, into a tubular structural component having a predetermined outer configuration, said method comprising:

(a) providing a shape imparting shell formed from a low permeability, rigid material, said shell being in the form of first and a second half shell, each of which includes an inner surface defining said predetermined shape, an outer support and mounting surface and spaced lateral edges which edges define a parting plane between said two half shells when said half shells are brought together to form said shell;
(b) providing a first die member with an upper side and a lower side and having a non-magnetic support framework for carrying said first half shell mounted in said framework by a cast compression force transmitting non-magnetic material with said laterally spaced edges of said first half shell facing outwardly from said lower side of said first die member, said cast material having a strength and hardness substantially less than said rigid material;
(c) providing a second die member with an upper side and a lower side and having a non-magnetic support framework for carrying said second half shell mounted in said framework by a cast compression force transmitting non-magnetic material with said laterally spaced edges of said second half shell facing outwardly from said upper side of said second die member, said cast material having a strength and hardness substantially less than said rigid material;
(d) plugging said open end or ends of said tubular metal blank;
(e) placing said plugged tubular metal blank into said second half shell in said second die member;
(f) moving said first die member relative to said first die member to capture said tubular metal blank in said shape imparting shell;
(g) forming said tubular metal blank into said component by inductively heating axial portions of said tubular metal blank by axially spaced conductors adjacent said shell while or before forcing gas at a high pressure into said plugged tubular metal blank until said tubular metal blank conforms to at least a portion of the inner surfaces of said first and second half shells to form said component.

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Abstract

Claims79