Explosion forming system

• US 8,443,641 B2
• Filed: 04/30/2009
• Issued: 05/21/2013
• Est. Priority Date: 02/14/2007
• Status: Active Grant

• Current Assignee: Magna International Incorporated
• Original Assignee: Cosma Engineering Europe AG
• Inventors: Zak, Alexander, Kotagiri, Seetarama S., Horton, Frank A.
• Primary Examiner(s): Tolan, Edward
• Assistant Examiner(s): KATCOFF, MATTHEW GORDON
• Application Number:
  US12/432,954
• Publication Number:
  US 20090205396A1
• Time in Patent Office: 1,482 Days
• Field of Search: 72/56, 72/61, 727/06, 294/212
• US Class Current: 72/56
• CPC Class Codes: B21D 26/08 generated by explosives, e.g. chemical explosives

Abstract

An explosion forming apparatus (10) that preferably utilizes a shock wave (42) directed along a work piece (12) to progressively conform the work piece to a contour die cavity (44).

Claims

1. An apparatus for modifying a work piece having a longitudinal length, the apparatus comprising:

an ignition chamber configured for generating a traveling shock wave that has a shock wave length that is less than the longitudinal length of the work piece;

a die, wherein the die includes a first die plate and a second die plate, wherein at least one of the first and second die plates is movable relative to the other between an open position and a closed position wherein the first and second die plates together define a die cavity in which the work piece can be positioned;

a transfer structure configured, in use, to convey the shock wave directly from the ignition chamber directly into the die cavity,

wherein, in operation, the shock wave applies a localized pressure to the work piece in a direction that is transverse to the direction of travel of the shock wave,

wherein the ignition chamber has at least one inlet for the ingress of oxygen and hydrogen combustibles, the apparatus further comprising an igniter and a controller for the transfer of a selected ratio and quantity of oxygen and hydrogen into the ignition chamber and for actuating the igniter to react the combustibles to generate an explosion that generates the shock wave,

wherein the controller serially executes explosions and the apparatus further comprising a cooling system for cooling the ignition chamber so as to reduce the pressure of water vapour created by reacting oxygen and hydrogen.

2. An apparatus as claimed in claim 1, wherein the ignition chamber and the transfer structure together define a pre-work piece shock wave flow conduit that has a cross-sectional size and a cross-sectional shape that are substantially constant and substantially free of reflection elements.

3. An apparatus as claimed in claim 2, wherein the cross-sectional shape is circular.

4. An apparatus as claimed in claim 1, wherein the ignition chamber has at least one inlet for the ingress of oxygen and hydrogen combustibles, the apparatus further comprising an igniter and a controller for the transfer of a selected ratio and quantity of oxygen and hydrogen into the ignition chamber and for actuating the igniter to react the combustibles to generate an explosion that generates the shock wave.

5. An apparatus as claimed in claim 4, wherein the controller serially executes explosions and the apparatus further comprises a cooling system for cooling the ignition chamber so as to reduce the pressure of water vapour created by reacting oxygen and hydrogen.

6. An apparatus as claimed in claim 1, wherein the ignition chamber is generally cylindrical and has an ignition chamber interior that has at least a selected ratio of length to diameter.

7. An apparatus as claimed in claim 1 further comprising an incompressible fluid inlet positioned to permit, in use, he passage of incompressible fluid from an incompressible fluid source into a work piece when the work piece is in the die cavity.

8. An apparatus as claimed in claim 7, further comprising a controller configured to permit, prior to the generation of the shock wave, a flow of incompressible fluid into the die cavity to a selected fill level such that the work piece is substantially filled with incompressible fluid, and wherein the ignition chamber and the transfer structure together define a pre-work piece shock wave flow conduit that is configured to transfer the shock wave into the incompressible fluid.

9. An apparatus as claimed in claim 8, wherein the selected fill level is such that the transfer structure is substantially filled with incompressible fluid.

10. An apparatus as claimed in claim 9, wherein the selected fill level is such that part of the ignition chamber is filled with incompressible fluid.

11. An apparatus as claimed in claim 1, wherein the transfer structure includes an isolation valve positionable in an open position wherein, in use, the ignition chamber is fluidly connected to the work piece, and a closed position wherein, in use, the ignition chamber is isolated from the work piece.

12. An apparatus as claimed in claim 1, wherein the die cavity is defined by a die cavity wall having at least one punch aperture therein so that, in use, the shock wave punches a hole through the work piece into the die cavity aperture.

13. An apparatus as claimed in claim 1, wherein the die cavity is defined by a die cavity wall having at least one trim aperture that extends all the way around the die cavity, and that is positioned so that, in use, the shock wave trims an end portion from the work piece at the trim aperture.

14. An apparatus as claimed in claim 1, further comprising a pressure reducer configured to reduce the pressure associated with the shock wave, wherein the pressure reducer is positioned downstream from the die.

15. An apparatus as claimed in claim 14, wherein the pressure reducer includes a plurality of shock wave reduction elements that are positioned to impinge on a shock wave traveling therepast.