Steam cushion forming

Patent metadata

Field	Value
Publication number	US-10427209-B2
Application number	US-201715584506-A
Country	US
Kind code	B2
Filing date	May 2, 2017
Priority date	May 2, 2017
Publication date	Oct 1, 2019
Grant date	Oct 1, 2019

Abstract

A method of forming a part from a blank includes positioning the blank within a forming die. Water is introduced between the blank and the forming die. The water is heated to form steam between the blank and the forming die. The blank is reshaped within the forming die to form the part while the steam is disposed between the blank and the forming die. The steam forms a cushion between the blank and the forming die to reduce friction therebetween. A lubricant is not applied to the blank prior to being positioned in the forming die. Therefore, the formed part does not require a washing step after being formed.

First claim

What is claimed is:

1. A method of forming a part from a blank, the method comprising:
positioning the blank within a forming die, wherein:
the forming die includes a first half and a second half;
the second half includes an exterior surface and a cavity;
the cavity has a shape, an inside wall and defines an opening through the exterior surface to receive the first half; and
the blank is positioned against the exterior surface and covers the opening;

introducing water between the blank and the forming die through the inside wall of the cavity, wherein the water is introduced at:
a first location on the inside wall adjacent the exterior surface; and
a second location on the inside wall distant from the exterior surface;

heating the water to form steam between the blank and the forming die; and
shaping the blank into the shape of the cavity within the second half of the forming die to form the part while the steam is disposed between the blank and the forming die, such that the steam forms a cushion between the blank and the forming die to reduce friction therebetween.

2. The method set forth in claim 1 , wherein the forming die includes a plurality of nozzles integrated into the second half of the forming die for dispensing the water, and wherein the water is further introduced between the blank and the forming die through the exterior surface of the second half of the forming die at a third location adjacent the cavity after the blank is positioned in the forming die.

3. The method set forth in claim 1 , wherein the first location and the second location are each defined as a localized high friction area between the forming die and the blank.

4. The method set forth in claim 1 , wherein heating the water to form the steam includes heating the water prior to introducing the water between the blank and the forming die.

5. The method set forth in claim 1 , wherein heating the water to form the steam includes heating the forming die to a pre-determined temperature prior to positioning the blank within the forming die.

6. The method set forth in claim 1 , wherein heating the water includes heating the blank prior to positioning the blank in the forming die, and wherein the shaping begins before the water is vaporized into the steam.

7. The method set forth in claim 1 , characterized by the blank not having a lubricant applied thereto prior to being positioned in the forming die.

8. The method set forth in claim 1 , further comprising mixing the water with a water soluble lubricant prior to introducing the water between the blank and the forming die.

9. The method set forth in claim 1 , wherein the blank is one of a plastic material or a metal material.

10. The method set forth in claim 1 , wherein the blank is a metal material including one of aluminum, magnesium, or steel.

11. The method set forth in claim 1 , further comprising removing the formed part from the forming die.

12. The method set forth in claim 11 , further comprising drying the formed part after being removed from the forming die to eliminate any condensate remaining on the formed part from the steam, whereby no lubricant exists on the formed part.

13. A forming process comprising:
positioning a blank within a forming die, wherein:
the blank does not include a lubricant applied thereto prior to being positioned in the forming die;
the forming die includes a first half and a second half;
the second half includes an exterior surface and a cavity;
the cavity has a shape, an inside wall and defines an opening through the exterior surface to receive the first half; and
the blank is positioned against the exterior surface and covers the opening;

introducing water between the blank and the forming die through the inside wall of the cavity, wherein the water is introduced at:
a first location on the inside wall adjacent the exterior surface; and
a second location on the inside wall distant from the exterior surface;

heating the water to form steam between the blank and the forming die;
shaping the blank into the shape of the cavity within the second half of the forming die to form a part while the steam is disposed between the blank and the forming die, whereby the steam forms a cushion between the blank and the forming die to reduce friction therebetween;
removing the formed part from the forming die; and
drying the formed part after being removed from the forming die to eliminate any condensate remaining on the formed part from the steam, whereby no lubricant remains on the formed part.

14. The method set forth in claim 13 , wherein the first location and the second location are each defined as a localized high friction area between the forming die and the blank.

15. The method set forth in claim 13 , wherein heating the water to form the steam includes heating the water prior to introducing the water between the blank and the forming die.

16. The method set forth in claim 13 , wherein heating the water to form the steam includes heating the forming die to a pre-determined temperature prior to positioning the blank within the forming die.

17. The method set forth in claim 13 , wherein heating the water includes heating the blank prior to positioning the blank in the forming die, and wherein the shaping begins before the water is vaporized into the steam.

18. The method set forth in claim 13 , wherein the steam is compressed within the second half of the forming die during the shaping of the blank.

19. The method set forth in claim 1 , wherein the steam is compressed within the second half of the forming die during the shaping of the blank.

20. The method set forth in claim 13 , wherein the forming die includes a plurality of nozzles integrated into the second half of the forming die for dispensing the water, and wherein the water is further introduced between the blank and the forming die through the exterior surface of the second half of the forming die at a third location adjacent the cavity after the blank is positioned in the forming die.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Morales Arianna T
• Mishra Raja K

Classifications

• C10N2040/24

  without essential removal of material {, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding}; Punching metal · CPC title

• B29C2037/92

  Lubricating · CPC title

• C03B40/02

  by lubrication; Use of materials as release or lubricating compositions · CPC title

• B21J3/00 Primary

  Lubricating during forging or pressing (lubricating in general F16N) · CPC title

• B29C51/082

  by shaping between complementary mould parts · CPC title