Manufacturing system for electro-hydraulic flanging and trimming a part

Abstract

A method of flange trimming a sheet metal panel to form a part including flanges for subsequent hemming or weld operation is disclosed. The method utilizes an electro-hydraulic forming (EHF) tool to form a channel within which a flange is cut out in a trimming operation. A combined flange/trim die may be provided in which both a channel forming operation and a flange trimming operation may be performed. A manufacturing system for fabricating a part by forming a channel in a peripheral portion and cutting the channel area to form a flange. The method also relates to a die for an EHF tool that defines a channel-shaped recess and has a trim edge for cutting a flange into the channel.

1 - 2 . (canceled) 
     
     
         3 . A method of flanging and trimming a sheet metal panel including a part shaped portion disposed inside a peripheral edge portion, comprising:
 forming a channel in the peripheral edge portion; and   trimming the panel within the channel in an electro-hydraulic forming (EHF) machine to cut-out a flange in the previously formed channel, wherein the steps of forming the channel and trimming the panel are both performed in a one-sided die that has a movable insert that provides a forming surface in a first location; and   moving the insert to a second location to provide a recess that is adjacent to a cutting edge and discharging the EHF machine to force the panel against the cutting edge to trim the panel.   
     
     
         4 . The method of  claim 3  wherein the insert is an elastomeric member and the step of forming a channel also includes compressing the elastomeric member. 
     
     
         5 . The method of claim  1  wherein the step of forming the channel includes forming a side wall that extends in a transverse direction relative to the peripheral edge portion. 
     
     
         6 . The method of  claim 5  wherein the side wall is cut in the trimming step to form a hem flange. 
     
     
         7 - 10 . (canceled) 
     
     
         11 . A manufacturing system comprising:
 forming a channel in a peripheral portion of a blank in a channel forming tool;   cutting a flange in the channel area in an electro-hydraulic forming tool provided with a one-sided trim die, wherein the peripheral portion of the blank is driven into engagement with the one-sided trim die to cut the flange in the channel area.   
     
     
         12 . The manufacturing system of  claim 11  wherein the channel forming tool is an EHF tool provided with a one-sided forming die, a vessel that contains a fluid, and at least two electrodes disposed in the fluid that are electrically connected to a capacitor circuit, wherein the capacitor circuit provides a high voltage pulse of electrical energy to the electrodes that creates a shockwave in the fluid that drives the peripheral portion of the blank into engagement with the one-sided forming die to form the channel area. 
     
     
         13 . The manufacturing system of  claim 11  wherein the channel forming tool is converted from a forming die arrangement in the forming step to a trim die arrangement in the cutting step to provide the one-sided trim die. 
     
     
         14 . The manufacturing system of  claim 13  wherein an insert in the one-sided trim die is moved from the forming die arrangement in which the die is used to form the channel to the trimming die arrangement to cut the offal from the flange. 
     
     
         15 . The manufacturing system of  claim 11  wherein the channel is formed with two side walls and a base wall extending between the side walls, and in the cutting step a weld flange is cut from the base wall. 
     
     
         16 . The manufacturing system of  claim 11  wherein the channel is formed with two side walls and a base wall extending between the side walls, and in the cutting step a hem flange is cut from one of the side walls. 
     
     
         17 . A one-sided die for an electro-hydraulic forming tool comprising:
 a die member that defines a recess for forming a channel around a shaped part in a sheet metal blank;   an insert assembled to the die member adjacent to the cutting edge that partially defines the channel-shaped recess, and wherein the insert is moved to a recessed position in the die member to expose the cutting edge to trim a flange from the channel.   
     
     
         18 . The one-sided die of  claim 17  wherein the insert is formed of an elastomeric material.