Dana Corporation

Automatic Feed Company

Lasercoil Technologies, LLC

Richard A Marando

Eric M Schrack

Robert D Durand

Jason A Poirier

Joseph J Vasalani, Iii

Jeffrey P Dziki

John A Beckman

Daniel E Hunter

John L Kichline, Jr

Andrew R Simboli

Stephen M Lapic

Scott M McGill

Richard L Stuck

Kim Beck

James C Larkin

Thomas R Sanko

Edward Drost

George M Hetrick, Iii

Kurt McMurtrie

A laser blanking device for high speed cutting of a rapidly fed strip of coil stock is disclosed and includes a support frame extending along a first longitudinal axis and a conveyor supported by the support frame. A strip of coil stock material is fed onto the conveyor at a pinch roll located near a first end of the frame. Transverse, moveable gantries above the conveyor suspend lasers. A pinch roll located near a second end of the frame assists movement of the material. Multiple laser cutting operations are simultaneously performed on the material as it moves along the device, and a laser head suspended from a gantry situated after the second pinch roll completes a cut that separates a blank from the remainder of the stock material.

Progressive laser blanking device for high speed cutting

A method of manufacturing a node for joining a plurality of structural members together, such as in a vehicular body and frame assembly, is well suited for joining structural members that are formed from differing materials. An insert is provided having a node securing portion and a mounting portion that is adapted to have a structural member secured thereto. A node is formed about the node securing portion of the insert for joining a plurality of structural members together. The insert can be formed from a first material, while the node can be formed from a second material that is different from the first material. The insert can be provided with a node securing portion having at least one aperture or protrusion formed therein, and the node can be formed within or about the aperture or protrusion. A plurality of inserts can be provided, each having a node securing portion and a mounting portion, and the node can be formed about each of the node securing portions of the inserts. The structural members can be secured to the mounting portions of the inserts before the node is formed.

Method of manufacturing a node for connecting vehicle frame members

An apparatus and method of applying a lubricating material to an outer surface of a workpiece. Initially, a workpiece is provided that is preferably formed from a closed channel structural member having a circular or box-shaped cross sectional shape. Lubricating material is applied to an outer surface of the workpiece. In a second step of the method, the workpiece may be heat treated. The workpiece is then heated to elevate the temperature of the workpiece so as to cause the lubricating material to dry substantially immediately on the workpiece, thereby providing a coating of lubricating material having a substantially uniform thickness. In a fourth step of the method, a deforming process is performed on the workpiece during the period of time following the heat treatment process, and after applying the lubricating material, in which the workpiece retains the full or partial softening characteristics.

Method of lubricating a workpiece for hydroforming

A method for performing a hydroforming operation on a hollow workpiece includes the initial step of filling the interior of the workpiece with a hydroforming fluid. The pressure exerted by the hydroforming fluid against the interior of the workpiece is below the yield strength of the workpiece so as to not change the shape of the workpiece. Then, first and second die sections of the hydroforming apparatus are closed about the workpiece. The movement of the two die sections causes some mechanical deformation of the workpiece, but the presence of the hydroforming fluid within the workpiece prevents the amount of this mechanical deformation of the hollow workpiece from being undesirably large. Thereafter, the pressure exerted by the hydroforming fluid against the interior of the workpiece is increased to above the yield strength of the workpiece. As a result, the workpiece is deformed into engagement with the first and second die sections of the hydroforming die.

Method for performing a hydroforming operation

A hydroforming apparatus includes upper and lower platens that are connected together by tie rods extending through respective compression tubes. An upper die section is carried on the upper platen by a generally C-shaped suspension arm, while a lower die section is carried on the lower platen. The upper and lower die sections have recessed areas formed therein that define a die cavity. Lift assemblies are provided on the lateral ends of the hydroforming apparatus for selectively elevating the lower die section upwardly into engagement with the upper die section. When the lower die section is elevated by the lift assemblies, a workpiece is enclosed within the die cavity. A bolster is then moved between the hydroforming die and the lower platen. A cylinder array containing a plurality of pistons is next hydraulically actuated so as to securely clamp the hydroforming die between the cylinder array and the lower platen. While the cylinder array is actuated, pressurized fluid is supplied within the workpiece, deforming it into conformance with the die cavity.

Apparatus for performing a hydroforming operation

An apparatus and method for manufacturing a vehicle frame component allow a preliminary heat treatment process to be performed in a relatively quick and easy manner so as to facilitate the subsequent performance of a bending or other deforming process. Initially, a workpiece that is to be manufactured into the vehicle frame component is provided. The workpiece is preferably a closed channel structural member formed from an aluminum alloy and having a circular or box-shaped cross sectional shape. The workpiece is subjected to a scanning heat treatment process, wherein the workpiece is heat treated in a continuous and longitudinal manner from one end to the other. Preferably, the workpiece is supported vertically during the scanning heat treatment process to prevent the shape thereof from becoming distorted. The scanning heat treatment process is preferably a retrogression heat treatment process, wherein the workpiece is rapidly heated to a sufficient temperature that provides for full or partial softening thereof, followed by relatively rapid cooling. In a third step of the method, a deforming process is performed on the workpiece during the period of time following the retrogression heat treatment process in which the workpiece retains the full or partial softening characteristics. Any desired deforming process may be performed on the workpiece, including hydroforming, magnetic pulse welding, or both.

Apparatus and method of manufacturing a vehicle frame assembly

A vehicle frame assembly includes a first vehicle frame component that is formed by deforming a closed channel structural member to have a relatively small end portion and a relatively large end portion. A member is provided having first and second ends. The relatively large end portion of the closed channel structural member is secured to the first end portion of the member to form the first vehicle frame component. A plurality of second vehicle frame components are provided. The first vehicle frame component and the plurality of second vehicle frame components are secured together to form the vehicle frame assembly.

Method of manufacturing a vehicle body and frame assembly

A hydroforming apparatus includes an upper platen carrying an upper die section and a lower platen carrying a lower die section. The platens are connected together by tie rods extending through respective compression tubes. The upper and lower die sections have recessed areas formed therein that define a die cavity. When the lower die section is moved to a lowered position, a workpiece can be disposed in the recessed area formed therein. Then, the lower die section and the workpiece are elevated by cylinders such that the workpiece is enclosed within the die cavity and mechanically deformed by the cooperated upper and lower die sections. A support block is then moved between the hydroforming die and the lower platen. A cylinder array containing a plurality of pistons is next hydraulically actuated so as to securely clamp the hydroforming die between the cylinder array and the lower platen. While the cylinder array is actuated, pressurized fluid is supplied within the workpiece, deforming it into conformance with the die cavity.

Apparatus for performing hydroforming operation

A method for forming a closed channel structural member having a central portion that is enlarged relative to the end portions thereof is disclosed. Initially, first and second tubes are formed in respective hydroforming dies to have desired shapes that are preferably characterized by a relatively large diameter first end portions and relatively small diameter second end portions. Each of the two tubes is then oriented such that the relatively large diameter first end portions are disposed adjacent to one another. Lastly, the relatively large diameter first end portions are joined together in any conventional manner, such as by butt welding, to form a unitary member characterized by a relatively large diameter central portion extending between a pair of relatively small diameter end portions. The unitary member can be used as a component, such as a side rail, of a vehicle body and frame assembly.

A method of manufacturing a sleeve mechanism without the use of machines by using a hydroforming process. The method includes the steps of providing an inner sleeve, an intermediate sleeve, and an outer sleeve concentrically within one another. The concentric sleeves are then expanded by using a hydroforming process such that an external thread is formed on the inner sleeve and an internal thread is formed on the outer sleeve. After the hydroforming process, the intermediate sleeve is removed by using any desired manner, such as melting or chemical dissolution. The relatively small space remaining between the inner and outer sleeves allow them to freely rotate about each other to ensure smooth operation of the screw and sleeve mechanism. Alternatively, the inner and outer sleeves may be hydroformed in separate operations.

Method of manufacturing a lead screw and sleeve mechanism using a hydroforming process

An apparatus and method are provided for initially performing a heat treatment process on a closed channel structural member to facilitate the subsequent performance of a magnetic pulse welding process so as to manufacture a vehicle frame component or a portion of a vehicle frame assembly. Initially, a workpiece is provided that is preferably formed from a closed channel structural member having a circular or box-shaped cross sectional shape. The workpiece is subjected to a scanning heat treatment process, wherein the workpiece is heat treated in a continuous and longitudinal manner from one end to the other. Preferably, the workpiece is supported vertically during the scanning heat treatment process to prevent the shape thereof from becoming distorted. The scanning heat treatment process is preferably a retrogression heat treatment process, wherein the workpiece is rapidly heated to a sufficient temperature that provides for full or partial softening thereof, followed by relatively rapid cooling. In a third step of the method, a deforming process is performed on the workpiece during the period of time following the retrogression heat treatment process in which the workpiece retains the full or partial softening characteristics. In a fourth step of the method, a magnetic pulse welding operation is performed to secure two workpieces together so as to manufacture a vehicle frame component or a portion of a vehicle frame assembly. At least one of the two workpieces is subjected to the scanning heat treatment process to facilitate the magnetic pulse welding process.

Method of manufacturing a vehicle frame assembly

A ladder type of vehicular body and frame assembly includes a pair of side rails, each of which is formed from three separate members, namely, a front closed channel structural member, a center open channel structural member, and a rear closed channel structural member. The closed channel structural members may be formed having a generally rectangular cross sectional shape, while the open channel structural members may be formed having a generally C-shaped cross sectional shape. The rear ends of the front closed channel structural members are connected to the front ends of the center open channel structural members at respective joints, such as by welding, riveting, bolting, adhesives, magnetic pulse welding, and the like. Similarly, the rear ends of the center open channel structural members are connected to the front ends of the rear closed channel structural members at respective joints, such as by welding, riveting, bolting, adhesives, magnetic pulse welding, and the like. The closed channel structural members are preferably formed to the desired shape by hydroforming. The open channel structural members may be formed to the desired shape by any conventional metal forming process, such as by pressing or roll forming.

Vehicle body and frame assembly and method of manufacturing same

A mechanical press is adapted to perform a hydroforming operation. The press includes a stationary base supporting a bolster that carries a lower die section, a movable slide that carries an upper die section, and a drive mechanism for selectively raising and lowering the slide relative to the base. An inflatable bladder is disposed between the base and the bolster. Initially, the drive mechanism is operated to lower the slide to its bottom dead center position such that the die sections enclose a workpiece within a die cavity. Then, pressurized fluid is supplied within the workpiece to expand it outwardly into conformance with the die cavity. At the same time, pressurized fluid is also supplied to the interior of the inflatable bladder. The application of such pressurized fluid causes the inflatable bladder to be physically expanded, causing the bolster carrying the lower die section to be raised relative to the base. The magnitude of this force is preferably selected to be approximately equal to the magnitude of the outwardly directed force exerted by the workpiece against the lower die section and, thus, the bolster. As a result, the lower die section is urged upwardly to remain in position relative to the upper die section during the hydroforming operation. In effect, the inflatable bladder pre-stresses the frame of the press and fills any extra space created by the deflections of the various components of the frame, thereby retaining the die sections and in position during the hydroforming operation. As a result, the press can be adapted to hydroform relatively large and thick-walled workpieces, such as vehicle frame components.

Mechanical press structure adapted to perform hydroforming operations

A hydroforming apparatus for simultaneously performing two or more hydroforming operations includes a frame that is sized to support a plurality of hydroforming dies in a stacked relationship. Each of the dies includes a pair of cooperating die sections having respective recesses formed therein that define a die cavity. Initially, the first die section of the first die is positioned in an uppermost spaced apart position relative to the second die section of the second die, while the second die section of the first die and the first die section of the second die are positioned in an intermediate spaced apart position relative to both the first die sect of the first die and the second die section of the second die. Then, hollow tubular blanks are inserted between the spaced apart die sections of the first and second die Next, the ram and the support mechanism are moved downwardly relative to the be such that the pairs of cooperating die sections of the first and second dies engage one another. End feed cylinders are then moved laterally into engagement with the end the tubular blanks to facilitate the filling thereof with a hydroforming fluid. The pressure of the fluid within the tubular blanks is then increased to such a magnitude that the tubular blanks are expanded outwardly into conformance with the respective die cavities. Thus, the hydroforming apparatus is capable of performing two or mo hydroforming operations simultaneously to decrease the overall amount of operational cycle time and, therefore, increase overall productivity.

Growing community of inventors

Mohrsville, PA, United States of America

Richard A Marando