Tool for forming threaded hole in a hydroformed part

A tool adapted to form a threaded hole in a hydroformed part while the part remains in a hydroforming die cavity, comprising;

• a hole-piercing end portion having a blunt end and a cylindrical surface adapted on advancement of the tool to pierce and form a hole in the part;
• an extruding portion having a concave-convex annular surface that progresses from the cylindrical surface of the hole-piercing end portion and is adapted on continued tool advancement to extrude an annular region and form an annular extrusion extending inward into the part;
• a sealing portion directly adjacent the extruding portion and having a cylindrical surface that progresses from the concave-convex surface and is of a diameter that is greater than the diameter of the cylindrical surface of the hole-piercing end portion and is adapted on continued tool advancement to seal the hole and the annular extrusion during the ongoing advancement of the extruding portion so that hydroforming fluid remains under pressure without leakage and loss of pressure;
• and
• a thread-forming portion directly adjacent the sealing portion and having controlled root diameter tapping threads adapted upon simultaneous rotation and continued advancement of the tool to form internal threads within the annular extrusion with tightly toleranced control of the major diameter, the thread flank and the minor diameter of the formed thread, whereby the thread forming portion tightly fits the formed internal threads to prevent the leakage and loss of pressure of the hydroforming fluid during the simultaneous rotation and continued advancement, and the subsequent rotation and extraction of the thread-forming potion of the tool from the hydroformed part.

A tool adapted to form a threaded hole in the wall of a hydroformed part while the part remains in a hydroforming die cavity and subject to pressurized fluid, comprising;

• a blunt end for engaging with the wall to support the wall against the pressurized fluid;
• a first cylindrical surface adjacent to the blunt end and a flat chamfer intersecting the blunt end and the cylindrical surface so that upon advancement of the tool a hole is pierced in the wall;
• a concave-convex annular surface that progresses from the cylindrical surface adjacent the blunt end and is adapted upon continued tool advancement to extrude an annular region surrounding the hole and form an annular extrusion that extends inward into the part;
• a second cylindrical surface directly adjacent the concave-convex annular surface and that progresses from the concave-convex surface and has a diameter that is greater than the diameter of the first cylindrical surface to seal the hole and the annular extrusion during the ongoing advancement of the tool so that pressurized fluid remains under pressure;
• and
• a thread-forming tapping thread directly adjacent the second cylindrical surface and adapted upon simultaneous rotation and continued advancement of the tool to form an internal thread within the annular extrusion, said thread-forming tapping thread having controlled root diameter tapping threads creating tightly toleranced control of the major diameter, the thread flank and the minor diameter of the formed thread, whereby the thread-forming tapping thread tightly fits the formed internal threads to prevent the leakage and loss of pressure of the hydroforming fluid during the simultaneous rotation and continued advancement, and the subsequent rotation and extraction of the thread-forming portion of the tool from the hydroformed part.