Daimler Chrysler Ag

Borgwarner Inc.

Daimler-benz Ag

Mercedes-benz Aktiengesellschaft

Thomas Huelsberg

Pierre Bonny

Ralf Puenjer

Uwe Hardtke

Eckhard Reese

Henning Bloecker

Thorsten Sternal

Holger Nuhn

Hildwin Kuzi

Thoralf Nehls

Ulrich Haag

Alfred Riggers

Dirk Riewert

Olav Reinhardt

Michael Halves

Wilfried Bien

Jan Peter Elfeldt

Ulrich Hagg

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 process and a device produces an assembly linkage on a hollow profile which is shaped for the installation of the assembly part by internal high-pressure remodeling. In order to achieve the shaping of an assembly linkage in a component space-saving, for a subsequent assembly correctly positioned, and with regard to its contour exactly fitted to the assembly part, in simple manner and even with high degrees of remodeling in a secure process, the hollow profile, under internal pressure, which is smaller than the remodeling pressure, is indented at the place of the to-be-produced assembly linkage by a die and by forming a rough contour. Afterward, while the die remains in this indenting position, a fluid high pressure is created in the hollow profile. Thereby, the hollow profile sides surrounding the die are molded to the external contour of the die, and that after releasing the fluid high pressure and the subsequent removal of the die, the finished trough-shaped assembly linkage is released.

Apparatus for producing an assembly linkage on a hollow profile

A process for manufacturing holes on the circumference of a hollow section situated in an internal high pressure forming tool uses the action of a punch integrated in the forming tool. A desired breaking point is formed on the hollow section, which follows the edge contour of the operating face of the punch; and after the withdrawal of the punch, the hollow section material surrounded by the desired breaking area, acted upon by internal high pressure, is extracted from the hollow section from the inside to the outside, forming a hole. In order to produce holes on the circumference of hollow sections, in which the shape of the outer circumference of the hollow section is maintained, the wall of the hollow section is weakened to form an unstable thin area. The punch penetrates into the wall of the hollow section at an internal high pressure which corresponds to the forming pressure for forming a hollow blank inserted in the forming tool. When the punch is withdrawn, the internal high pressure, tears the hollow section material surrounded by the thin area out of the hollow section in the withdrawal direction of the punch.

Process and device for manufacturing holes on the circumference of hollow sections

Process and apparatus for producing an assembly linkage on a hollow profile

A method for manufacturing an air-gap-insulated exhaust pipe having a branch stub, as well as an exhaust pipe produced according to such a method and a tool for forming such an exhaust pipe. Two tubes are inserted into one another to form a double tube. The double tube is placed in a first internal high-pressure shaping tool, and exposed to internal high pressure fluid such that it expands to match the contours of the engraving of the first shaping tool, and a double-walled branch stub is blown out of the double tube. The partially formed double tube is then placed in a second internal high-pressure shaping tool, with the double tube being surrounded, between the two ends including the branch stub, circumferentially and throughout by a corresponding design of the engraving, by an expansion chamber. The outer tube is expanded between the outer tube and inner tube under high pressure up to a precise fit with the engraving of the second shaping tool to form an insulating air gap, with the end of the branch stub being supported externally without yielding via a second counterpunch. The finished double tube is removed from the second shaping tool and a cap area of the branch stub, containing the end, is cut off to form a through opening between the interior of the inner tube and the ambient environment outside the air-gap-insulated exhaust pipe.

Air gap insulated exhaust pipe with branch pipe stub and method of manufacturing same

A process for manufacturing holes on the circumference of a hollow section situated in an internal high pressure forming tool uses the action of a punch integrated in the forming tool. A desired breaking point is formed on the hollow section, which follows the edge contour of the operating face of the punch; and after the withdrawal of the punch, the hollow section material surrounded by the desired breaking area, acted upon by internal high pressure, is extracted from the hollow section from the inside to the outside, forming a hole. In order to produce holes on the circumference of hollow sections, in which the shape of the outer circumference of the hollow section is maintained, the wall of the hollw section is weakened to form an unstable thin area. The punch penetrates into the wall of the hollow section at an internal high pressure which corresponds to the forming pressure for forming a hollow blank inserted in the forming tool. When the punch is withdrawn, the internal high pressure, tears the hollow section material surrounded by the thin area out of the hollow section in the withdrawal direction of the punch.

Process for manufacturing holes on the circumference of hollow sections

A process and a device produces a linkage of a hollow cylindrical air/fuel ratio detector holder to an opening for the impingement of the air/fuel ratio detector, which is fastened into the holder, to an exhaust pipe equipped with exhaust gas. A desired finished shape is given through internal high-pressure remodeling of a blank pipe. During this process, internal high-pressure remodeling creates a contact surface on the exhaust pipe which is formed by a buckling. The contact surface is created to in the inverted shape of the contact contour of the casing surface of the holder so that a dimensionally stable linkage of an air/fuel ratio detector holder to an exhaust pipe is achieved simply.

Process and apparatus for producing a linkage of an air/fuel ratio detector holder to an exhaust pipe

A process for manufacturing an air-gap-insulated exhaust elbow of a motor vehicle exhaust system achieves in a simple manner a manufacturing of space-saving air-gap-insulating exhaust elbows which is reliable with respect to the process and can be precisely reproduced. The exhaust elbow is joined together from several air-gap-insulated exhaust pipes as well as the pertaining entry flanges and the exit flange, which, by way of an internal high-pressure metal forming process, are shaped in an air-gap-insulating manner from one double pipe respectively. The ends of the air-gap-insulated exhaust pipes which are to be connected with one another are first trimmed while opening the respective air insulating gap and are then fitted into one another. In such case, the ends are shaped such that the fitted connections of the outer pipes and of the inner pipes of the exhaust pipes to be connected are made with play. The mutually connected outer pipe ends of the exhaust pipes are welded together at the point of their fitted connection while forming a circular bead. The connection-free ends of the exhaust pipes to be connected to the cylinder head are fitted together with the respective pertaining entry flanges and are welded together and the connection-free end, which faces away from the cylinder head, of the last one of the branched exhaust pipes arranged in a row side-by-side, is fitted together with the exit flange and is welded to the latter.

Process of manufacturing an air-gap-insulating exhaust elbow of a vehicle exhaust system

A process and a device produces a linkage of a hollow cylindrical air/fuel ratio detector holder to an opening for the impingement of the air/fuel ratio detector, which is fastened into the holder, to an exhaust pipe equipped with exhaust gas. A desired finished shape is given through internal high-pressure remodeling of a blank pipe. During this process, internal high-pressure remodeling creates a contact surface on the exhaust pipe which is formed by a buckling. The contact surface is created in the inverted shape of the contact contour of the casing surface of the holder so that a dimensionally stable linkage of an air/fuel ratio detector holder to an exhaust pipe is achieved simply.

Process and apparatus for producing a linkage of an air/fuel ratio

An arrangement for the internal high-pressure forming of hollow profiles has an internal high-pressure forming tool, into whose die sinking the hollow profile can be inserted. At least one axial die has a sealing head which can be inserted with play by a section into the hollow profile. This sealing head has a support part which is provided with a pressure fluid duct and on which a sealing arrangement is held and which is rigidly connected with the axial die, and has a stop surface, which in the operative position of the sealing head rests on the face side against the end of the hollow profile. The sealing arrangement contains at least one sealing element which can be radially spread open for an allaround sealing contact on the interior side of the hollow profile. To achieve a reliable fluid high-pressure-tight sealing in a simple manner without deformation of the hollow profile, so that a forming is permitted which is secure with respect to the process relative to stable pressure conditions during internal high-pressure forming, the sealing arrangement has a supporting ring which supports the sealing element, can be axially displaceably guided on the support part relative thereto and dips into the hollow profile when the sealing head is coupled to the hollow profile. A stop body has the stop surface of the sealing ring on the hollow profile and which is fixedly connected with the supporting ring. The support part has an operating device which, when the stop body rests against the hollow profile, acts upon the sealing element in a spreading-open manner because of a further axial movement of the support part relative to the supporting ring in an interaction with the supporting ring.

Arrangement for the internal high-pressure forming of hollow profiles

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.

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Rosengarten, Germany

Thomas Huelsberg