Hydroforming die assembly and method for deforming a tube

Abstract

A hydroforming die assembly for deforming a tube and a method for deforming the tube are provided.

We claim: 
     
         1 . A hydroforming die assembly for deforming a tube, comprising:
 a lower die having a first cavity formed therein;   a vertically movable upper die disposed above the lower die, the vertically movable upper die having a second cavity formed therein;   a first sealing assembly disposed proximate to a first end of the lower die, the first sealing assembly having a first subplate, a first feed insert, a first axial cylinder, and a first seal cone, the first seal cone coupled to the first axial cylinder, the first feed insert and the first axial cylinder coupled to the first subplate, the first subplate configured to move vertically;   a second sealing assembly disposed proximate to a second end of the lower die, the second sealing assembly having a second subplate, a second feed insert, a second axial cylinder, and a second seal cone, the second seal cone coupled to the second axial cylinder, the second feed insert and the second axial cylinder coupled to the second subplate, the second subplate configured to move vertically;   the first and second feed inserts configured to initially support the tube above the lower die;   the upper die being configured to move vertically downwardly to contact the tube when the tube is supported on the first and second feed inserts;   the first and second axial cylinders configured to move the first and second seal cones, respectively, toward first and second ends of the tube, respectively, to seal the first and second ends of the tube, respectively, the first and second seal cones configured to increase a pressure of a fluid disposed in the tube to obtain pressurized fluid therein; and   the upper die being further configured to move further vertically downwardly against the tube while the tube has the pressurized fluid therein such that the first and second sealing assemblies are moved vertically downwardly and the tube is at least partially deformed into the first and second cavities.   
     
     
         2 . The hydroforming die assembly of  claim 1 , further comprising:
 the first and second axial cylinders further configured to move the first and second seal cones, respectively, further inwardly into the first and second ends of the tube, respectively, the first and second seal cones further configured to further increase the pressure of the fluid in the tube to deform the tube into the first and second cavities.   
     
     
         3 . A method for deforming a tube utilizing a hydroforming die assembly, the hydroforming die assembly having a lower die with a first cavity formed therein, a vertically movable upper die with a second cavity formed therein, and first and second sealing assemblies, the first sealing assembly having a first subplate, a first feed insert, a first axial cylinder, and a first seal cone, the first feed insert and the first axial cylinder coupled to the first subplate, the first subplate configured to move vertically, the second sealing assembly having a second subplate, a second feed insert, a second axial cylinder, and a second seal cone, the second feed insert and the second axial cylinder coupled to the second subplate, the second subplate configured to move vertically, the method comprising:
 supporting the tube above the lower die utilizing the first and second feed inserts;   moving the upper die being vertically downwardly to contact the tube when the tube is supported on the first and second feed inserts;   moving the first and second seal cones, respectively, toward first and second ends of the tube, respectively, to seal the first and second ends of the tube, respectively, utilizing the first and second axial cylinders, respectively;   increasing a pressure of a fluid disposed in the tube to obtain pressurized fluid therein utilizing the first and second seal cones; and   moving the upper die further vertically downwardly against the tube while the tube has the pressurized fluid therein such that the first and second sealing assemblies are moved vertically downwardly and the tube is at least partially deformed into the first and second cavities.   
     
     
         4 . The method of  claim 3 , further comprising:
 moving the first and second seal cones, respectively, further inwardly into the first and second ends of the tube, respectively, utilizing the first and second axial cylinders, respectively; and   increasing the pressure of the fluid in the tube to deform the tube into the first and second cavities utilizing the first and second seal cones.