US 7,028,519 B2 · High throughput quick-plastic-forming

Abstract

A method of quick-plastic-forming a component from a sheet metal blank in multiple forming stages of single-action tooling along a transfer line. The blank is transferred from a prebending station to a preforming station along the transfer line, wherein the blank is preformed by a single-action forming tool into a preform blank. The preform blank is then transferred from the preforming station to a finish-forming station along the transfer line, wherein the blank is finish-formed by a single-action forming tool into the component. The component is transferred from the finish-forming station to a cooling station along the transfer line. The transfer steps are carried out by a reciprocating transfer mechanism that simultaneously transfers the blanks and component from station to station along the transfer line.

Claims11

Dependent claims

A method of hot blow-forming a substantially three-dimensional component from a substantially two-dimensional blank using hot blow-forming tooling, said method comprising:

moving said blank to a first stage forming tool of a first stage forming station;
forming said blank into a first stage form by pressing one side of said blank so that an opposite side of said blank is brought into conformance with a forming surface of said first stage forming tool;
moving said first stage form from said first stage forming tool of said first stage forming station to a second stage forming tool of a second stage forming station;
and
forming said first stage form into a second stage form by applying a pressurized working gas against one side of said first stage form so that an opposite side of said first stage form is brought into conformance with a forming surface of said second stage forming tool that is internally heated to a second stage forming temperature, and by increasing the pressure of said working gas from ambient pressure to a second stage forming pressure;
said moving steps being carried out by a transfer apparatus that simultaneously transfers said blank and said first stage form.

3 more elements

A method of quick-plastic-forming a substantially three-dimensional component from a substantially two-dimensional blank in multiple forming stages having electrically heated single-action tooling, said method comprising:

preheating said blank to a preheat temperature to create a preheated blank for stretch elongation thereof under the pressure of a working gas;
loading said preheated blank to a prebending station;
prebending said prebent preheated blank along at least one axis thereof to create a prebent preheated blank;
moving said prebent preheated blank to a preforming tool of a preforming station;
preforming said preheated blank into a preform by applying a pressurized working gas to one side of said prebent preheated blank so that an opposite side of said prebent preheated blank is brought into conformance with a forming surface of said preforming tool that is internally heated to a preforming temperature, and by increasing the pressure of said working gas from ambient pressure to a preforming pressure;
moving said preform from said preforming tool of said preforming station to a finish-forming tool of a finish-forming station;
finish-forming said preform into said component by applying a pressurized working gas against one side of said preform so that an opposite side of said preform is brought into conformance with a finish-form surface of said finish-form tool that is internally heated to a finish-forming temperature that is lower than said preforming temperature, and by increasing the pressure of said working gas from ambient pressure to a finish-forming pressure that is higher than said preforming pressure;
moving said component to a cooling station;
allowing said component to cool;
and
unloading said component from said cooling station;
said moving steps being carried out by a reciprocating transfer mechanism.

9 more elements

A method of quick-plastic-forming a substantially three-dimensional component from a substantially two-dimensional aluminum alloy blank in multiple forming stages having electrically heated single-action tooling, said method comprising:

preheating said blank to between about 475° C. and about 550° C. to create a preheated blank for stretch elongation thereof under the pressure of a working gas;
loading said preheated blank to a prebending station;
prebending said preheated blank along at least one axis thereof to create a prebent preheated blank;
moving said prebent preheated blank to a preforming tool of a preforming station;
preforming said prebent preheated blank into a preform by applying a pressurized working gas to one side of said prebent preheated blank so that an opposite side of said prebent preheated blank is brought into conformance with a forming surface of said preforming tool that is internally heated to between about 475° C. and about 550° C., and by increasing the pressure of said working gas from ambient pressure to a preforming pressure;
moving said preform from said preforming tool of said preforming station to a finish-forming tool of a finish-forming station;
finish-forming said preform into said component by applying a pressurized working gas against one side of said preform so that an opposite side of said preform is brought into conformance with a finish-form surface of said finish-form tool that is internally heated to between about 400° C. and about 460° C., and by increasing the pressure of said working gas from ambient pressure to a finish-forming pressure that is higher than said preforming pressure;
moving said component to a cooling station;
allowing said component to cool;
and
unloading said component from said cooling station;
said moving steps being carried out by a reciprocating transfer mechanism.

9 more elements

Dependencies are inferred from the claim text.

High throughput quick-plastic-forming

Life of this patent

High throughput quick-plastic-forming

Life of this patent

Abstract

Claims11