Pre-crush die assembly and method

Abstract

A pre-crush die assembly is utilized for controlled deforming of at least a portion of one or more tubular members to be used in a subsequent hydroforming operation. The tubular member has a centerline extending therethrough. The die assembly comprises at least two dies that move interdependently towards each other to deform the tubular member on opposite sides thereof equally about the centerline of the tubular member where the tubular member is being pre-crushed.

1 . A pre-crush die assembly for controlled deforming of at least a portion of a tubular member to be used in a subsequent hydroforming operation, the tubular member having a centerline extending therethrough and the pre-crush die assembly comprising: 
 a support table for supporting the tubular member relative therewith; and,    a sub-assembly mounted to the support table for movement relative thereto, the sub-assembly comprising a first die and a second die both adapted to move relative to the support table and interdependently of each other between an open position and a closing position engaging and deforming the portion of the tubular member, in the open position, the first and second dies being positioned in spaced non-contacting relation to opposing sides of the tubular member, and the first and second dies moving interdependently in opposing directions towards each other into the closing position to continuously maintain the first and second dies equidistant from the centerline of the tubular member adjacent the portion of the tubular member being deformed.    
     
     
         2 . The pre-crush die assembly of  claim 1  wherein in the open position the first and second dies are spaced equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed.  
     
     
         3 . The pre-crush die assembly of  claim 2  further comprising at least one drive coupler mechanically coupling the first and second dies to further maintain the first and second dies equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies from the open position to the closing position.  
     
     
         4 . The pre-crush die assembly of  claim 2  wherein the sub-assembly further comprises a first carriage for supporting the first die and a second carriage for supporting the second die, the support table comprising a guide trackway along which the first and second carriages move.  
     
     
         5 . The pre-crush die assembly of  claim 4  further comprising at least one drive coupler mechanically coupling the first and second carriages whereby the first and second dies are further maintained equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies.  
     
     
         6 . The pre-crush die assembly of  claim 4  wherein the first and second carriages each comprises at least one elongate rail having an elongate groove extending along its length and the guide trackway comprises a guide member mounted to the support table having an edge surface portion extending into and along the elongate groove of the elongate rail.  
     
     
         7 . The pre-crush die assembly of  claim 6  further comprising at least one drive coupler mechanically coupling the elongate rails of the first and second carriages whereby the first and second dies are further maintained equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies.  
     
     
         8 . The pre-crush die assembly of  claim 5  wherein the at least one drive coupler comprises a first toothed rack mounted to the first carriage of the first die, a second toothed rack mounted to the second carriage of the second die, and a toothed pinion mounted to the support table for rotation therewith and the toothed pinion being mounted in meshing relation with the first and second toothed racks.  
     
     
         9 . The pre-crush die assembly of  claim 7  wherein the at least one drive coupler comprises a first toothed rack mounted to the elongate rail of the first carriage, a second toothed rack mounted to the elongate rail of the second carriage, and a toothed pinion mounted to the support table for rotation therewith and the toothed pinion being mounted in meshing relation with the first and second toothed racks.  
     
     
         10 . The pre-crush die assembly of  claim 4  further including stops mounted to the support table for engaging the first and second carriages to limit movement of the first and second carriages into the closing position.  
     
     
         11 . The pre-crush die assembly of  claim 8  further including stops mounted to the support table for engaging the elongate rails of the first and second carriages to limit movement of the first and second dies into the closing position.  
     
     
         12 . The pre-crush die assembly of  claim 2  further comprising a plurality of fastening devices carried by the support table for removably securing the tubular member between the first and second dies when in the open position.  
     
     
         13 . The pre-crush die assembly of  claim 2  wherein the sub-assembly comprises: 
 a first set of rails adapted to slide relative to the support table;    a second set of rails interspaced with the first set of rails adapted to slide relative to the support table in directions opposite to those of the first rails;    the first die mounted to the first set of rails; and,    the second die mounted to the second set of rails.    
     
     
         14 . The pre-crush die of  claim 13  wherein the sub-assembly further comprises: 
 a first mounting plate connected for movement with the second set of rails;    at least one first hydraulic cylinder mounted to the first mounting plate and coupled with the first die, and the at least one first hydraulic cylinder adapted to expand and contract causing during expansion the first and second dies to move interdependently, via the first mounting plate and the first and second rails into the closing position.    
     
     
         15 . The pre-crush die of  claim 14  wherein the sub-assembly comprises a closed loop sub-assembly further comprising: 
 a second mounting plate connected for movement with the first set of rails spaced along the first and second rails from the first mounting plate; and    at least one second hydraulic cylinder mounted to the second mounting plate and coupled with the second die, and the at least one second hydraulic cylinder adapted to expand and contract in unison with the expansion and contraction of the at least one first hydraulic cylinder whereby expansion of the at least one second hydraulic cylinder causing the first and second dies to move interdependently, via the second mounting plate and the first and second rails into the closing position.    
     
     
         16 . The pre-crush die of  claim 15  wherein the at least one second hydraulic cylinder is indirectly coupled with the second die.  
     
     
         17 . The pre-crush die assembly of  claim 15  wherein the first and second rails each have an elongate groove extending along its length and the support table has fixedly mounted thereto guide members having edge surface portions slidingly extending into and along the elongate groove of each of the first and second rails.  
     
     
         18 . The pre-crush die assembly of  claim 16  wherein the first and second rails each have an elongate groove extending along its length and the support table has fixedly mounted thereto guide members having edge surface portions slidingly extending into and along the elongate groove of each of the first and second rails.  
     
     
         19 . The pre-crush die assembly of  claim 13  further comprising at least one drive coupler mechanically coupling the first and second rails whereby the first and second dies are further maintained equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies and first and second rails.  
     
     
         20 . The pre-crush die assembly of  claim 19  wherein the at least one drive coupler comprises a first toothed rack mounted to the first rail, a second toothed rack mounted to the second rail, and a toothed pinion mounted to the support table for rotation therewith and the toothed pinion being mounted in meshing relation with the first and second toothed racks.  
     
     
         21 . The pre-crush die assembly of  claim 19  further including stops mounted to the support table for engaging the first and second rails to limit movement of the first and second carriages into the closing position.  
     
     
         22 . The pre-crush die assembly of  claim 15  further comprising a plurality of fastening devices carried by the support table for removably securing the tubular member between the first and second dies when in the open position.  
     
     
         23 . The pre-crush die assembly of  claim 15  further comprising at least one drive coupler mechanically coupling the first and second rails whereby the first and second dies are further maintained equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies and first and second rails.  
     
     
         24 . The pre-crush die assembly of  claim 23  wherein the at least one drive coupler comprises a first toothed rack mounted to the first rail, a second toothed rack mounted to the second rail, and a toothed pinion mounted to the support table for rotation therewith and the toothed pinion being mounted in meshing relation with the first and second toothed racks.  
     
     
         25 . The pre-crush die assembly of  claim 16  further comprising a plurality of fastening devices carried by the support table for removably securing the tubular member between the first and second dies when in the open position.  
     
     
         26 . The pre-crush die assembly of  claim 16  further comprising at least one drive coupler mechanically coupling the first and second rails whereby the first and second dies are further maintained equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies and first and second rails.  
     
     
         27 . The pre-crush die assembly of  claim 26  wherein the at least one drive coupler comprises a first toothed rack mounted to the first rail, a second toothed rack mounted to the second rail, and a toothed pinion mounted to the support table for rotation therewith and the toothed pinion being mounted in meshing relation with the first and second toothed racks.  
     
     
         28 . A pre-crush die assembly for controlled deforming of at least a portion of a tubular member to be used in a subsequent hydroforming operation, the tubular member having a centerline extending therethrough and the pre-crush die assembly comprising: 
 a support table for supporting the tubular member relative therewith; and,    a closed loop sub-assembly mounted to the support table for movement relative thereto, the closed loop sub-assembly comprising:    a first set of rails adapted to slide relative to the support table;    a second set of rails interspaced with the first set of rails adapted to slide relative to the support table in directions opposite to those of the first rails;    a first mounting plate connected for movement with the second set of rails;    a second mounting plate connected for movement with the first set of rails spaced along the first and second rails from the first mounting plate;    at least one first hydraulic cylinder mounted to the first mounting plate;    at least one second hydraulic cylinder mounted to the second mounting plate;    at least one first die mounted to the first set of rails between the first and second mounting plates and coupled with the first hydraulic cylinder;    at least one second die mounted to the second set of rails between the first and second mounting plates and coupled with the second hydraulic cylinder, the at least one first die and the at least one second die being positioned on opposing sides of the tubular member in an open position spaced in non-contacting relation to the tubular member equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed; and    the first and second hydraulic cylinders adapted to expand and contract, and causing, during expansion, the first and second dies to move interdependently, via the first and second mounting plates and the first and second rails, in opposing directions towards each other into a closing position engaging and deforming the tubular member whereby the first and second dies remain equidistant from the centerline of the tubular member adjacent the portion of the tubular member being deformed as the first and second dies move from the open position to the closing position.    
     
     
         29 . The pre-crush die of  claim 28  wherein the at least one first and second hydraulic cylinders each comprise a hydraulic cylinder and piston with the piston being coupled directly to a corresponding one of the first and second dies.  
     
     
         30 . A pre-crush die assembly for controlled deforming of at least a portion of each of first and second tubular members to be used in a subsequent hydroforming operation, the first and second tubular members each having a centerline extending therethrough and the pre-crush die assembly comprising: 
 a support table for supporting the first and second tubular members relative therewith; and,    a closed loop sub-assembly mounted to the support table for movement relative thereto, the closed loop sub-assembly comprising:    a first set of rails adapted to slide relative to the support table;    a second set of rails interspaced with the first set of rails adapted to slide relative to the support table in directions opposite to those of the first rails;    a first mounting plate connected for movement with the second set of rails;    a second mounting plate connected for movement with the first set of rails spaced along the first and second rails from the first mounting plate;    at least one first hydraulic cylinder mounted to the first mounting plate;    at least one second hydraulic cylinder mounted to the second mounting plate;    a first master die and a first slave die mounted to the first set of rails between the first and second mounting plates and the first master die being directly coupled with the first hydraulic cylinder;    a second master die and a second slave die mounted to the second set of rails between the first and second mounting plates and the second master die being directly coupled with the second hydraulic cylinder,    the first master die and the second slave die being positioned on opposing sides of the first tubular member in an open position spaced in non-contacting relation to the first tubular member equidistant from the centerline of the first tubular member adjacent the portion of the first tubular member to be deformed;    the second master die and the first slave die being positioned on opposing sides of the second tubular member in the open position spaced in non-contacting relation to the second tubular member equidistant from the centerline of the second tubular member adjacent the portion of the second tubular member to be deformed;    the first and second hydraulic cylinders adapted to expand and contract, and causing, during expansion:    the first master die and the second slave die to move interdependently, via the first and second mounting plates and the first and second sets of rails, in opposing directions towards each other into a closing position engaging and deforming the first tubular member whereby the first master die and second slave die remain equidistant from the centerline of the first tubular member adjacent the portion of the first tubular member being deformed as the first master die and second slave die move from the open position to the closing position, and    the second master die and the first slave die to move interdependently, via the first and second mounting plates and the first and second sets of rails, in opposing directions towards each other into the closing position engaging and deforming the second tubular member whereby the second master die and first slave die remain equidistant from the centerline of the second tubular member adjacent the portion of the second tubular member being deformed as the second master die and first slave die move from the open position to the closing position.    
     
     
         31 . The pre-crush die of  claim 30  wherein the at least one first and second hydraulic cylinders each comprise a hydraulic cylinder and piston with the piston being coupled directly to a corresponding one of the first and second master dies.  
     
     
         32 . The pre-crush die assembly of  claim 30  wherein the first and second rails each have an elongate groove extending along its length and the support table has fixedly mounted thereto guide members having edge surface portions slidingly extending into and along the elongate groove of each of the first and second rails.  
     
     
         33 . The pre-crush die assembly of  claim 30  further comprising at least one drive coupler mechanically coupling the first and second rails whereby the first and second dies are further maintained equidistant from the centerline of the tubular member adjacent the portion of the tubular member to be deformed during interdependent movement of the first and second dies and first and second rails.  
     
     
         34 . The pre-crush die assembly of  claim 33  wherein the at least one drive coupler comprises a first toothed rack mounted to the first rail, a second toothed rack mounted to the second rail, and a toothed pinion mounted to the support table for rotation therewith and the toothed pinion being mounted in meshing relation with the first and second toothed racks.  
     
     
         35 . The pre-crush die assembly of  claim 30  further including stops mounted to the support table for engaging the first and second rails to limit movement of the first and second carriages into the closing position.  
     
     
         36 . A method of controlled deformation of at least a portion of a tubular member to be used in a subsequent hydroforming operation by first and second dies, the method comprising the steps of: 
 positioning the tubular member between the first and second dies in spaced non-contacting relation therewith; and,    interdependently moving the first and second dies towards each other to engage and deform the tubular member while continuously maintaining the first and second dies equidistant from the centerline of the tubular member adjacent the portion of the tubular member being deformed.    
     
     
         37 . The method of  claim 36  wherein during the step of positioning the tubular member between the first and second dies the centerline of the tubular member adjacent the portion to be deformed is spaced equidistant from the first and second dies.