Manufacturing cosine die profile for tubes

Hydroforming test (Bulging)

Asst. Prof. Dr.Hani Aziz Ameen




















5-1 Steps ofmanufacturingof die
1-select a suitable block with dimension (150 x 90 x 50)mm as shown in (fig.5-1)

Fig.5-1
2- facing and drilling by miller and drill machine with dimension (143 x 81 x41)(8.5 ,
15,6) as shown in fig.(5-2) (5-3) (5-4) (5-5)

fig.(5-2)



fig.(5-3)

fig.(5-4)

fig.(5-5)

3-join the two blocks together by bolts as shown in fig (5-6),(5-7)

Fig.(5-6)

Fig.(5-7)

4- use the marker to make the w.p in the center of machine as shown in fig.(5-8)


Fig .(5-8)
5- draw a circle in the center of w.p as shown in fig.(5-9)

Fig .(5-9)

6- To grantee the accurate position of w.p by righted angle ruler as shown in fig.(5-10)
, (5-11)


Fig .(5-10)

Fig .(5-11)

7- make a primary hole by using turning tool (carbide) as shown in fig.(5-12)


Fig .(5-12)
8- drill the w.p to a depth of 10 mm as shown in fig.(5-13)

Fig .(5-13)
9- drill the w.p through all with 10 than 14,16 and 18.5 as shown in fig.(5-14)
,(5-15)

Fig .(5-14)


Fig .(5-15)

Fig .(5-16)
10- separate the blocks to check the hole as shown in fig.(5-17) ,(5-18)

Fig .(5-17)


Fig .(5-18)
11- use the marker to make the cosine profile using the upper and lower slide of lathe
machine as shown in fig.(5-19) ,(5-20)

Fig .(5-19)

Fig .(5-20)
12- re-join the two blocks by bolts as shown in fig.(5-21)


Fig .(5-21)
13- use a paper model as a guide for the internal turning operation as shown in fig.(5-22)

Fig .(5-22)


14- re-separate the blocks to ensure the gained profiles accuracy as shown in fig.(5-23)
,(5-24) ,(5-25)


Fig .(5-23)

Fig .(5-24)

Fig .(5-25)


15- use the grinder to get the finished surfaces as shown in fig.(5-26)


Fig .(5-26)
16- manufacturing of plungers as shown in fig.(5-27) ,(5-28), (5-29), (5-30), (5-31)

Fig .(5-27)

Fig .(5-29)




Fig .(5-30)

Fig .(5-31)

Fig .(5-32)

17- the final shape of plunger as shown in fig. (5-33), (5-34), (5-35), (5-36)


Fig .(5-33)

Fig .(5-34)

Fig .(5-35)



Fig .(5-36)
18- The final shape for die parts as shown in fig.(5-37),(5-38),(5-39),(5-40), (5-41)

Fig.(5-37) upper and lower of die

Fig.(5-38) lower with plunger


Fig.(5-39) lower with plunger and tube

Fig.(5-40)

Fig.(5-41) close the die


5-2 Sealing
Seals are an important part of in the hydraulic system in situations where the
following condition apply[ 15].
1. Contaminants must be excluded from critical areas of a machine .
2. lubricants must be contained within a space .
3. pressurized fluids must be contained within a component such as a valve or a
hydraulic cylinder .
Some of the parameters affecting the choice of the type of sealing system, the
materials used, and the details of its design are follows :
1. the nature of the fluids to be contained or excluded .
2. Pressures on both sides of the seal.
3. The nature of any relative motion between the seal and the mating components .
4. Temperature on all parts of the sealing system .
Fig. (5-42), shows the two lips seal, that is using in our hydraulic system




Fig.(5-42) Two lips seal
5-3 Tube Hydroforming System
Because of high cost of hydraulic pump ,
so we redesigning and remanufacturing a
car jack and reversing its operation,
it can achieve high internal pressure by
squeezing the hydraulic inside tube.
Fig.(5-43) show the hydraulic jack.


Fig.(5-43) hydraulic jack


5-4 Test
1- close the die than apply pressure (300bar ) as shown in fig.(5-42)

Fig.(5-42)

2-open the die as shown in fig.(5-43)

Fig.(5-43)

3-The product as shown in fig. (5-44),(5-45)


Fig.(5-44)


Fig.(5-45)