Borgwarner Inc.

Daimler Chrysler Ag

Mercedes-benz Aktiengesellschaft

Ralf Puenjer

Thomas Huelsberg

Pierre Bonny

Eckhard Reese

Thorsten Sternal

Henning Bloecker

Holger Nuhn

Hildwin Kuzi

Wilfried Bien

Michael Halves

Olav Reinhardt

Dirk Riewert

Alfred Riggers

Thoralf Nehls

Jan Peter Elfeldt

Heinz-Ruediger Otte

In the method according to the invention for connecting a sheet metal component () to a component () consisting of cast metal, the sheet metal component () and the component () are welded to one another by means of a pulse-welding method. In particular, a sheet metal pipe () can thereby be welded to the port () of a housing () consisting of cast metal. This advantage may be utilized for an exhaust system with an exhaust manifold () and an exhaust assembly, such as a turbocharger ().

Method for connecting a sheet metal component, such as a pipe, to a cast metal component, such as a housing port, in particular for an exhaust system

A method and a device for removal of a slug separated from a hollow profile by means of a fluidic internal pressure from a hydroforming tool. The slug is separated from the hollow profile from the inside to the outside by the retraction of a plunger integrated into the hydroforming tool and clearing a slug channel when retracted, and is forced out of the die cavity of the hydroforming tool into the slug channel. Then, with the hollow profile in a zero-pressure state, the slug, which after it is pressed in abuts the end of the plunger, is removed by a removal tool from the hydroforming tool. In order to remove slugs from the hydroforming tool in any desired position of the slug channel that leads into the die of the hydroforming tool, in which the slug is initially received after perforation, in simple fashion, the slug is held at the end of the plunger during its stay in the slug channel by an adhesion means connected with the plunger. Then, after the hydroforming tool is opened and the finished hollow profile is removed, the slug, while continuing to adhere to the end of the plunger, is guided by means of the plunger and of the removal tool designed with adhesion means into the open die cavity. The slug and the area of the removal tool on which the adhesion means acts assume a relative position opposite one another, after which the slug is separated from the plunger and then adheres to the removal tool, by means of which the adhering slug is then removed from the hydroforming tool.

Method and device for removing a slug from a hydroforming tool

The invention relates to a method and a device for manufacturing T-pieces from an unbranched starting piece of pipe by means of internal high-pressure forming (IHF). For this purpose, the starting piece of pipe is placed in a two-part forming tool which gives the shape, can be opened and closed, surrounds the starting piece of pipe, and has a cutout corresponding to the desired shape of the T-shaped pipe branch. Placed in a sealing manner against the two open end faces of the inserted starting piece of pipe in each case is a plunger which is movable in the forming tool and can be pushed axially into the forming took in each case by a pressure cylinder. The interior of the starting piece of pipe is filled with pressure fluid by means of an opening in at least one of the plungers, prior to being placed on the plungers in a sealing manner. A fluid high-pressure is built up by pushing the plungers axially into the forming tool with high force and, thus initiated, by pushing pipe wall material axially towards the forming point, the pipe wall material is pressed into the cutout in the forming tool and the T-shaped branch is thus shaped. In order to be able to manufacture T-pieces with a curved branch, the end face of the T-shaped cutout for the pipe branch is supported with controllable force by means of a flexible mandrel.

Method of manufacturing a branched pipe by internal high-pressure forming

Growing community of inventors

Hamburg, Germany

Ralf Puenjer