Electromagnetic (em) metal forming techniques for...

B - Operations – Transporting – 21 – D

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B21D 26/14 (2006.01) B21D 28/20 (2006.01) B21D 28/34 (2006.01) B21D 53/88 (2006.01) B23P 11/00 (2006.01) B23P 15/00 (2006.01) B23P 19/00 (2006.01) B21D 26/02 (2006.01)

Patent

CA 2612998

An apparatus and a method of forming a metal blank into a structural member of a predetermined shape are provided by placing a metal blank into a hydroforming mold. The hydroforming mold comprises an electromagnetic trimming/piercing assembly. The metal blank is hydroformed into a hydroformed member. An electric discharge circuit is energized to create an electromagnetic force sufficient to drive an electromagnetic driver. The electric discharge circuit is discharged to drive the electromagnetic driver toward the hydroformed member. The electromagnetic driver comprises a trimming/piercing tool for trimming/piercing the hydroformed member at a predetermined location to yield the predetermined shape. Structural members formed by the method and apparatus of the instant invention can be used, for example, in automotive applications. Furthermore, a method of making a camshaft assembly is provided. A plurality of cam and journal elements are provided, wherein each element includes an axial opening. The plurality of cam and journal elements are secured in a predetermined fixed orientation and spacing with their axial openings aligned on a common axis. A hollow shaft is inserted through the axial openings along the common axis in close-fitting relation with the openings of the plurality of cam and journal elements. Electromagnetic energy is provided to at least a portion of the hollow shaft along an axial extent of the hollow shaft to expand the hollow shaft into a mechanical locking relationship with the openings of the plurality of cam elements and journal and diametrically outwards adjacent the elements to secure the elements permanently on the hollow shaft in the predetermined fixed orientation and spacing.

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