US20150165507A1

US20150165507A1 - Forming Tool and Method for Enlarging an Opening by Means of an Enlarging Device

Info

Publication number: US20150165507A1
Application number: US14/404,062
Authority: US
Inventors: Eggert Reese
Original assignee: Airbus Defence and Space GmbH
Current assignee: Airbus Defence and Space GmbH
Priority date: 2012-06-01
Filing date: 2013-05-28
Publication date: 2015-06-18
Also published as: DE102012010793A1; EP2855042A1; ES2579729T3; WO2013178211A1; EP2855042B1; CN104797355A

Abstract

A forming tool for widening an opening includes an expanding device with several expansion elements. The expansion elements are each provided with a curved forming surface extending between two peripheral end edges. The expansion elements are moveable between a first position corresponding to a contracted state where the expansion elements in connection with one another by way of separating surfaces, and a second position corresponding to a widened state where the expansion elements are displaced in radial direction from a center of the expanding device such that the separating surfaces are spaced apart from one another. In the first position the peripheral end edges are spaced further apart from the center than a central region of the forming surfaces so that the fatigue strength of mounting bores can be increased, openings in thick-walled components can expanded more reliably, and/or the formation of cracks is avoided.

Description

BACKGROUND AND SUMMARY OF THE INVENTION

Exemplary embodiments of the invention relate to a forming tool for widening an opening using an expanding device, an expansion element for use in a forming tool according to the invention, and a method for widening an opening.
In aerospace engineering it is desirable to widen high-loaded mounting bores in metal components using a forming method, which typically involves cold forming. As a result of the plastic deformation of the material in the region of the bore, internal stresses are generated, which contribute to an improvement of the fatigue strength. The propagation of the strain field is thereby subject to the applied strain, and in the case of a widening of about 3% of the initial diameter, corresponds to about two times the initial diameter, for example.
A plurality of forming tool methods, which are also referred to as mandrel methods, are known from prior art. The object of all these methods known from prior art is a change of the diameter.
US patent document U.S. Pat. No. 2,672,175 discloses a forming tool used for widening thin-walled pipes, for example, automotive muffler pipes. The tool comprises a conical four-sided block, against which four individual elements slide on the principle of the inclined plane, thus leading to a diameter change. The disadvantage is that the tool is only suited for thin-walled components, and that the forming forces are not transmitted evenly. As a result thereof, there is the risk of component damages. Moreover, the degree of widening cannot be controlled accurately, and larger forces cannot be transmitted.
US patent document U.S. Pat. No. 3,077,916 discloses a forming tool used for widening thin-walled pipes. The tool is provided with a sleeve having several sleeve elements, which can be displaced in a radial direction. A screw is guided through an inner whole of the sleeve, wherein a conical mandrel is arranged on each end side protruding into the inner hole. By turning the screw, one of the two mandrels is moved toward the other mandrel, wherein the sleeve elements move in a radial direction. Thus, a widening of the thin-walled pipes takes place. A similar tool is also disclosed in US patent document U.S. Pat. No. 3,986,383. However, both forming tools have the disadvantage that they are only suited for thin-walled components, and larger forces cannot be transmitted. Furthermore, the expansion forces are only transmitted non-uniformly so that component damages can occur time and again. In addition, it is not possible to accurately control the expansion degree so that it is often difficult to release the tool again if forces that are too large are applied.
US patent document U.S. Pat. No. 5,138,863 discloses a forming tool for widening thin-walled pipes for producing pipe connections. The forming tool is provided with a mandrel that can be moved in an axial direction, which can be inserted in a sleeve provided with several sleeve elements, wherein the radial displacement of the sleeve elements is subject to the depth of insertion of the mandrel. The disadvantage hereby is that the forming tool is not suitable for flaring thick-walled structures.
European patent document EP 1 611 976 A1 discloses a method and a device for reducing internal stresses is disclosed.
German patent document DE 26 54 102 C2 discloses a forming tool used for widening pipes. The forming tool is provided with a mandrel and a sleeve formed of several sleeve elements that can be moved in a radial direction. The mandrel is displaceably mounted in an axial direction and can be inserted into the sleeve, wherein subject to the depth of insertion of the mandrel, a corresponding radial displacement of the sleeve elements takes place. However, the forming tool has the disadvantage that it cannot be used for widening bore holes of thick-walled structures, for example, thick plates.
All of the tools for widening of pipes known from prior art are not suited to transmit high forming forces of, for example, 50 kN. This is particularly necessary for high-strength metal components having large wall thickness as used in aerospace applications, in order to introduce internal stresses by means of plastic deformation in the vicinity of the bore. This concerns wall, plate, or stack thickness t, for example, which amount to a multiple of the hole diameter d to be widened, that is, t=0.5 to 5*d. In comparison thereto, the wall thickness of the thin-walled pipes merely corresponds to a fraction of the diameter to be expanded, namely, for example, t=0.05 to 0.3*d.
It is known to use conventional forming methods for thick-walled components, like the split-sleeve method as disclosed in US patent document U.S. Pat. No. 5,305,627, for example, or the split-mandrel method as disclosed in US patent document U.S. Pat. No. 4,423,619. The forming tool is provided with a sleeve and a mandrel, wherein locally, the mandrel has a diameter that is larger than the bore diameter. The mandrel is pulled through the bore hole, and the diameter of the bore is continuously enlarged over the thickness of the component. However, both expansion methods have the disadvantage that the generated internal stress field is inhomogeneous, and even insubstantial deviations from the production dimensions of the bores and/or the tool result in great fluctuations in the expansion degree. For example, a bore having a diameter of 6 mm, which nominally was widened by 4%, can ultimately have an actual expansion degree of between 2.5% and 4.9%. Furthermore, the methods also have the disadvantage of an inhomogeneous stress and strain distribution. Moreover, with these methods, high-performance materials having highly direction-dependent properties, for example, aluminum alloys as frequently used in aerospace technology, can only be widened to a very small degree, that is, significantly below 3%. Thus, an improvement of the fatigue strength is hardly achieved. In addition, the kind of material deformation and the stress condition in the material resulting therefrom, under which the desired internal stresses are to be generated, lead to early crack formation. Furthermore, the use of sleeves as is done in the split-sleeve method makes the method expensive and uneconomical. In addition, time and again problems occur with the split-mandrel method due to premature tool failure, in particular cold welds between the mandrel and the component.
International patent publication WO 2007/121932 A1 disclose a forming tool with which a bore can be continuously widened across the entire wall thickness, that is, plate or stack thickness. Due to its introduction of force, the forming tool ensures a favorable multi-axis stress state as compared to the conventional expansion methods. In this way, a homogenous strain field and significantly improved fatigue strength are achieved. The method is particularly advantageous for pronouncedly orthotropic materials, aluminum alloys, for example, in which bores can be widened free of cracks. The bores can hereby be widened up to 5% of their original diameter.
Exemplary embodiments of the invention are directed to a forming tool and a forming method, with which the fatigue strength of openings in components, for example, mounting bores, is increased, as well as openings in thicker-walled components can be more reliably widened, and/or the formation of cracks is avoided.
Furthermore, a beneficial expansion element for the tool and/or the method is disclosed.
The invention, according to an aspect thereof, provides a forming tool for widening an opening using an expanding device comprising several expansion elements, wherein the expansion elements are each provided with a curved forming surface extending between two peripheral end edges, wherein the expansion elements can be moved from the first position into a second position, wherein in the first position, which corresponds to a contracted state, the expansion elements are in connection with one another by way of separating surfaces, and wherein in a second position, which corresponds to an expanded state, the expansion elements are displaced in a radial direction from a center of the expanding device such that the separating surfaces are spaced apart from one another, wherein in the first position, the peripheral end edges are spaced further apart from the center than a central region of the forming surfaces.
Advantageously, internal stresses in the region of openings can be generated in a targeted manner without damaging the component in the process, for example.
With a forming tool according to an advantageous embodiment, in the area surrounding a mounting hole, internal compressive stresses, in particular in thick-walled metal components like high-strength aluminum alloys, for example, can be faultlessly introduced, that is, without cracks, so that the fatigue strength of the bore, and ultimately of the component is significantly improved.
Compared to traditional forming tools, an improvement of 10% to 15% is achieved, for example. The expansion of the bore diameter is hereby 3% to 5% of the initial bore diameter, for example.
Furthermore, an advantageous embodiment of the forming tool allows a uniform introduction of force into the component so that a markedly improved flow behavior of the material is realized. In particular, internal stresses are uniformly introduced across the component thickness so that the applied internal stresses do not vary across the component thickness but are homogeneous.
Preferably, with a forming tool according to an embodiment of the invention, no friction occurs on the inner wall of the opening.
Preferably, the radial displacement of the expansion elements can be controlled so that the proceeding deformation process can be monitored so that a homogeneous strain field is achieved, which is beneficial for an effective increase in fatigue strength. Thus, even high-performance materials can be widened in the area of an opening free of cracks.
Preferably, the forming tool can be used for widening openings of different diameters.
Preferably, a forming tool according to an embodiment of the invention facilitates an inspection of the widened opening, because cracks, provided they happen after all, extend from the center to both sides so that cracks can be detected from both sides of the opening.
Preferably, the forming tool is suited to test new materials with regard to their behavior during a cold forming. In this way, the number of tests of this kind can be reduced, and thus, test expenses associated therewith can be reduced.
Beneficially, a forming tool according to an embodiment of the invention compensates for dimensional changes as a result of its wear so that it can be used for a longer period of time.
Preferably, with a beneficial embodiment of the forming tool, no normal force affecting the workpiece surface occurs during the widening of an opening so that no bending moment damaging the workpiece is induced.
Advantageously, with a forming tool according to the present invention, no cold welding of the sleeve with the workpiece takes place during the widening. Thus, damage to the component by a cold welding is not possible. Moreover, the sleeve can be re-used.
Preferably, with a forming tool according to an embodiment of the invention, only negligible beads occur in the edge region of an expanded opening. In this way, production costs are reduced because an additional cost-intensive step for removing the bead is eliminated, and the widening process can be integrated into the production process more advantageously.
Preferably, with a beneficial embodiment of a forming tool, the sleeve can be re-used so that the production costs can be reduced. It is thus no longer necessary to use a new sleeve each time for widening an opening.
Advantageously, an elaborate and cost-intensive removal of a sleeve is eliminated with a forming tool according to a beneficial embodiment.
Advantageously, with a forming tool according to an embodiment of the invention, the need of an expensive clamping bushing for widening of an opening is dispensed with.
Further preferably, a forming tool according to the present invention can be used for widening openings in repair parts, wherein depending on the opening diameter and the desired widening of the opening, the forming behavior of the repair part and the distribution of internal stress in the area of the opening, and the fatigue strength resulting therefrom can beneficially be determined in advance by means of an FEM simulation.
In order to promote a uniform introduction of force into the component, and thus make a better flow process possible, it is further preferably provided that in the second position, the peripheral end edges and the forming surfaces are equidistantly spaced apart from the center.
It is further preferred that seen in cross section in radial direction, the forming surface of the expansion elements has the shape of a circular arc.
Preferably, in the first position, the end edges are located on a circumscribed circle, and a central region of the forming surfaces is at a distance from the circle, and in the second position, both the end edges and the forming surfaces are located on a circumscribed circle.
The expansion elements can be identical, for example, wherein in the first position, which is corresponding to a contracted state, an outer contour of a cross section, as seen from the expanding device in radial direction, can correspond approximately to a four-leaf clover.
For example, a diameter in the region of the end edges of the expansion elements can be similar to the initial diameter of the bore to be widened.
In the second position, which is corresponding to an expanded state, a cylindrical outer radius of the expansion elements can be corresponding to the radius of the opening in an expanded state, that is, the end diameter of the expanded opening.
In this way, an optimal internal stress distribution in the area of the mounting bore can be beneficially attained.
In a further advantageous embodiment, a radius of the forming surfaces is greater than a distance of the end edges from the center of the expanding device in the first position, wherein the radius of the forming surfaces is preferably between 2.5% and 10% greater, and in particular, about 5% greater.
As a result, a markedly homogenous internal stress zone develops during the expansion process, which in turn has a positive effect on the fatigue strength.
Furthermore, a drive element is preferably provided, by means of which the expanding device can be moved from the first position to a second position.
Preferably, the drive element is provided with a mandrel, which can be inserted into an inner hole of the expanding device.
For example, the mandrel is configured as a conical four-sided mandrel and is made of a high-strength metal or ceramic material having a high pressure and flexural strength as well as hardness.
For example, a hard metal with a strength of more than 4000 MPa and a hardness of more than 60 HRC can be used for the mandrel.
Preferably, the inner hole of the sleeve is provided with a geometry that is analogous to the geometry of the mandrel.
Moreover, the mandrel can be of conical shape, wherein the inner hole, that is, an inner side of the expansion elements can, analogous to the mandrel, also be of conical shape.
The sleeve can be made of a high-strength metal material with high ductility, wherein the sleeve can be made of a nickel-cobalt-based alloy with a tensile strength of over 2000 MPa.
The inner surfaces of the inner hole and/or the outer surfaces of the mandrel are preferably provided with a coating. The coating reduces the friction coefficient so that there is an improved sliding. Furthermore, the coating protects against abrasion or wear, and in damp surroundings, also against corrosion. Lubricating properties of the coating can be provided by way of intercalated graphite particles. The inner surface of the inner hole and the outer surface of the mandrel can be referred to as functional surfaces of the mandrel and of the expansion elements. The functional surfaces can hereby be coated with an extremely hard layer, for example, for improving the gliding properties, for protection against corrosion, and premature wear and tear.
Preferably, the coating can be an electrochemically applied nickel layer and/or a diamond-like carbon layer, in particular at a thickness of few nanometers and up to several micrometers.
The electrochemically applied nickel layer can be 10 μm, or the diamond-like carbon layer can have a hardness of up to 6000 kg/mm².
In a further advantageous embodiment, an angle between a central axis of the mandrel and an outer surface is between 0.3 degrees and 3 degrees. By way of the angle between the central axis and the outer surfaces, that is, the functional surfaces of the mandrel, the conicity thereof is formed. With the aid of the angle, the axial force is deflected to the radial force required for the expansion. The angle hereby significantly controls the ratio of axial to radial force, the friction losses, and the possible wear on the tool.
For example, at an angle of 0.3 degrees, for a bore hole of a diameter of 6 mm in an alloy 2000 at a ratio of workpiece thickness t to the bore diameter d of t/d=5, the force can be 20 kN. In comparison thereto, the radial force is 38 kN at an angle of 3 degrees and otherwise same ratio of t/d=5.
According to a further aspect, preferably an expansion element for use in such a forming tool is formed.
Preferably, the expansion element is provided with an approximately trapezoidal cross-sectional shape, wherein at least one side extending between the two legs is curved. Further preferably, the curved side has a radius that is corresponding to that of the opening in an expanded state.
According to a further aspect, the invention provides a method for widening an opening from a first diameter d1 to a second diameter d2, the method comprising the following steps:
a) Providing several expansion elements, each having a forming surface and two separating surfaces extending between two end edges, wherein in a first position that is corresponding to a diameter of d1 in a non-expanded state, the expansion elements can be moved into a second position that is corresponding to a diameter d2 in the desired expanded state, by displacing the expansion elements in a radial direction, wherein the separating surfaces and the forming surfaces are configured such that in the first position, a central region of the forming surfaces, when placed against the non-expanded opening, is further apart from the inner wall of the opening than the end edges, and that in the second position, the forming surfaces altogether correspond to the contour of the inner wall of the desired expanded opening;
b) assembling the expansion elements to form an expanding device and moving the expansion elements to their first position;
c) inserting the expanding device into the opening, and
d) continuously widening the opening by moving the expansion elements into the second position.
With a continuous widening of the opening, a uniform introduction of force into the component is made possible so that a markedly improved flow behavior of the material is achieved. Advantageously, a homogeneous strain field is attained so that thick-walled metal components, for example, made of high-strength aluminum alloys, can be widened without a formation of cracks. Thus, the fatigue strength of the opening is increased.
Preferably, the method for widening the opening can be applied from one side so that with two adjacent workpieces, only one of the two openings is widened. Thus, the expanding device can also be used for widening an opening of a metal and non-metal combination, like a hybrid combination with fiber composite materials, for example, where only the metal component is to be widened. The metal portion can hereby be widened without the non-metal part being touched and/or damaged. In this way, a method step referred to as one-step assembly becomes possible because after the drilling for expanding of the metal component, the parts do not need to be separated again but can remain in their already fixed position instead. This makes a saving of time possible.
Further preferably, the method is used for holding open an opening having a diameter d in workpieces having a plate or stack thickness t, wherein t>d, in particular t>2*d.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Exemplary embodiments of the invention are described in more detail below with reference to the attached drawings, wherein:

FIG. 1 is a perspective view of an embodiment of a forming tool;

FIG. 2 is a perspective view of a mandrel;

FIG. 3 is a perspective view of an expansion element;

FIG. 4 is a perspective view of the forming tool inserted into an opening of a workpiece to be widened;

FIG. 5 is a longitudinal section of the forming tool and the workpiece during a deformation process;

FIG. 6 is a section of a radial cross section of a forming tool inserted in an opening prior to the widening of the opening;

FIG. 7 is a schematic illustration of the geometrical ratios of forming tool to opening prior to the widening of the opening;

FIG. 8 is a schematic illustration of the internal stress distribution in the workpiece after the opening has been widened using a conventional forming tool;

FIG. 9 is a schematic illustration of the internal stress distribution in the workpiece after the opening has been widened using a forming tool according to an embodiment of the invention;

FIG. 10 is a longitudinal section of the forming tool according to the invention and a hybrid compound during a deforming process; and

FIG. 11 is a diagram showing the life span of a workpiece at different load states, wherein openings were not, or were widened using different widening methods.

DETAILED DESCRIPTION

In FIG. 1, an embodiment of a forming tool 10 is illustrated. The forming tool 10 is provided with an expanding device 12 and a drive element 14, which can be inserted into an inner hole 16 of the expanding device 12.
As shown in FIGS. 1 and 2, the drive element 14 is configured as a mandrel 18, comprising a first section 20 and a second section 22. Viewed from a radial direction R, the first section 20 has a polygonal cross section. The first section 20 is of conical design in an axial direction A toward a first end 24 of the mandrel 18.
In the present embodiment, the mandrel 18 is configured as a four-sided mandrel, wherein other polygonal embodiments are also feasible. The outer surfaces of the mandrel 18 are configured as functional surfaces 26, wherein an angle α between the central axis M and the functional surfaces 26 brings about the conicity of the mandrel 18.
Ideally, the angle α is between 0.3 degrees and 3 degrees. Via the angle α, the axial force F_α is deflected to the radial force Fr required for the reaming. Thus, the angle α decisively controls the ratio of axial to radial force.
The mandrel 18 is made of a high-strength metal or ceramic material with high pressure and flexural strength as well as hardness, for example, a hard metal with a strength of more than 4000 MPa and a hardness of more than 60 HRC.
The functional surfaces 26 of the mandrel 18 can be coated with an extremely hard layer to improve the sliding properties, to protect against corrosion and against premature wear and tear, for example, with an electrochemically applied nickel layer having a thickness of several micrometers, or a diamond-like carbon layer having an extreme hardness of up to 6000 kg/mm², for example.
The second section 22 is configured as a holding section, by means of which the mandrel 18 can be accommodated in a tool or a receiving device such that the mandrel 18 can be moved in an axial direction and can be inserted into the inner hole 16 of the expanding device 12.
According to FIGS. 1 and 3, the expanding device 12 comprises several, for example, four expansion elements 28, which in an assembled state form a sleeve 30.
The expansion elements 28 are provided with a first section 32 and a second section 34. The first section 32 has a larger diameter than the second section 32 and is configured as a flange 36, which is provided with a bearing surface 38 for positioning on a workpiece 54. Additionally, a receiving device 40 in the form of a recess is placed into the second section 34, which in the peripheral direction extends about an outer surface 44 of the first section 32.
The second section 34 is provided with a curved forming surface 46, which if seen in cross section in a radial direction, has the shape of a circular arc. The forming surface is defined between two peripheral end edges 48. Adjoining each of the end edges 48 is a separating surface 50, which serves as contact surface for a further expansion element 28.
On a side opposite of the forming surface 46, the expansion element is further provided with a functional surface 52, which analogous to the functional surface 26 of the mandrel 18 is also of conical design.
As can be seen in FIG. 1, in an assembled state of the expanding device 12, one expansion element each, by means of its separating surface 50, abuts a further separating surface 50 of a further expansion element 28 so that the expanding device 12 approximately forms a sleeve 30.
In order to fix the expansion elements 28 in their assembled state, an elastic means (not illustrated), for example, in the form of a rubber ring, can be inserted into the recesses 42.
As can be particularly seen in FIG. 6, in a starting position, only the end edges 48 rest on an inner wall 58, wherein a central region 60 of the forming surfaces 46 are spaced apart from the inner wall 58 of the opening 56. In order to achieve this, the separating surfaces 50 in the embodiment are configured such that in the starting position of the expanding device 12, only the end edges 48 abut the inner wall 58 of the opening 56, and the central region 60 of the forming surfaces 46 is spaced apart from the inner wall 58. Thus, in a starting position, the maximal diameter of the expanding device 12 corresponds to the diameter of the opening 56 in a non-expanded state.
The previously described embodiments are explained in more detail with the aid of an example illustrated in FIG. 7 for the configuration of the radius r_Fof the forming surfaces 46. For an opening 56, which in a non-expanded state has a diameter d₁of 6 mm, and the diameter d₂thereof is to be widened to 6.3 mm, the radius r_Fof the forming surface 46 has a length of 3.15 mm. The inner hole 16 of the expanding device 12 has a polygonal (square) cross section with an inner surface of 3.25 mm lateral length in a non-expanded state, and an inner surface of 4.12 mm lateral length in an expanded state.
A possible method for widening an opening 56 in a workpiece 54 will now be described in more detail with reference to FIGS. 4 and 5. As previously described, the expansion elements 28 are assembled to form an expanding device 12, and are fixed using an elastic means. Subsequently, the expanding device 12 is inserted into the opening 56.
As illustrated in FIGS. 4 and 5, for widening the opening 56, the mandrel 18, in particular the first section 20 of the mandrel 18, is introduced into the inner hole 16 of the expanding device 12. Because the respective functional surfaces 26, 52, are designed to complement each other, a movement of the expansion elements 28 in the radial direction R occurs upon introduction of the mandrel 18 into the inner hole 16, wherein a displacement of the expansion elements 28 in the radial direction R is subject to the insertion depth of the mandrel 18. By way of the angle α between the functional surface 26 and the central axis M of the mandrel 18, the axial force Fa is deflected to the radial force Fr required for the expansion. Thus, angle α decisively controls the ratio of axial to radial force, the friction losses, and the possible wear on the tool.
As can be seen in FIG. 5, a radial displacement of the expansion elements 28 is generated by an axial displacement of the mandrel 18, whereby a radial force Fr is applied, which widens the opening 56 of the workpiece 54. In this way, the material in the immediate vicinity of the opening 56 is plastically deformed. This results in the formation of internal stresses in the workpiece, which can occur in the material up to two times the distance of the diameter of the opening. In this way, the fatigue strength of the opening 56 is improved.
Due to its optimized geometry, the expanding device 12 according to the invention promotes a uniform force introduction into the component, thus making a markedly improved flow behavior of the material possible. As can be seen in FIGS. 8 and 9, this results in a significantly more homogenous internal stress distribution after the widening process, which in turn has a positive effect on the fatigue strength.
In FIG. 8, the internal stress distribution after the widening process with an expanding device known from the prior art is illustrated. With this expanding device, the forming surfaces have a radius corresponding to that of the opening in a non-expanded state. As can be seen in FIG. 8, an inhomogeneous internal stress distribution is thus achieved, wherein the biggest stress occurs in the central region of the forming surfaces. In the region of the end edges, the internal stresses introduced into the workpiece have barely noticeably penetrated the workpiece. In comparison thereto, with the expanding device 12 according to the embodiment of the invention, a homogenous internal stress distribution is achieved. As shown in FIG. 9, an even distribution of the internal stress, that is, an equally long distance of the internal stresses introduced into the workpiece, into the workpiece 54 is attained.
As can be seen in FIG. 10, the expanding device 12 has the advantage of one-sided access to the opening 56 so that the forming tool 10 can also be used for metal-non-metal combinations, like, for example, hybrid compounds with fiber composite materials, where only the metal component is to be flared. The metal workpiece alone can hereby be flared, without the non-metal part being touched or damaged. Thus, a method step referred to as one-step assembly becomes possible because after the drilling for the widening of the opening 56 of the metal component, the parts do not need to be separated again but can remain in their already fixed position. This results in savings in time and costs.
In FIG. 11, the service life of a workpiece for differently introduced stresses is illustrated. The first curve K1 and the second curve K2 show the service life curve for a workpiece made of an aluminum alloy, wherein the openings have not been widened.
The third curve K3 shows the service life of the same material, wherein the openings were widened by means of a conventional widening method. In this instance, the openings were expanded by 3%. As can be seen, the fatigue strength, and therefore the service life, increased due to the introduced internal compressive stresses. For example, with a non-expanded workpiece, with stress introduced into the workpiece, the number of load cycles is 100000, and with a workpiece, the openings of which have been widened by means of a conventional method, it is 1000000. Accordingly, the material strength was markedly increased.
By using the expanding device 12 according to the embodiment, the service life can be prolonged once more. The expanding device 12 according to the embodiment allows a greater widening of the opening so that higher internal compressive stresses can be introduced into the workpiece. In the present example, the opening was widened by 4%. As can be seen in the fourth curve K4, the service life of the workpiece further increases compared to the service life of a workpiece machined using a conventional widening method. Thus, the forming tool 10 of the present invention makes it possible to further increase the material strength with otherwise like material properties and dimensions.
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.

LIST OF REFERENCE NUMERALS

10 forming tool
12 expanding device
14 drive element
16 inner hole
18 mandrel
20 first section
22 second section
24 first end (of mandrel)
26 functional surfaces
28 expansion elements
30 sleeve
32 first section
34 second section
36 flange
38 bearing surface
40 receiving device
42 recess
44 outer surface
46 forming surface
48 end edge
50 separating surfaces
52 functional surface
54 workpiece
56 opening
58 inner wall
60 central region
R radial direction
A axial direction
M central axis
α angle
Fα axial force
Fr radial force
rF radius of the functional surface
d1 diameter of the opening in a non-expanded state
d2 diameter of the opening in an expanded state
K1 first curve
K2 second curve
K3 third curve
K4 fourth curve

Claims

1-15. (canceled)

16. A forming tool for widening an opening, the forming tool comprising:

an expanding device comprising several expansion elements,

wherein the expansion elements each have a curved forming surface extending between two peripheral end edges,

wherein the expansion elements are moveable from a first position to a second position,

wherein in the first position, which corresponds to a contracted state, the expansion elements are connected with one another by way of separating surfaces,

wherein in the second position, which corresponds to an expanded state, the expansion elements are displaced in a radial direction from a center of the expanding device such that the separating surfaces are spaced apart from one another,

wherein in the first position, the peripheral end edges are spaced further apart from the center than a central region of the forming surfaces.

17. The forming tool of claim 16, wherein the peripheral end edges and the forming surfaces are equidistantly spaced apart from the center in the second position.

18. The forming tool of claim 16, wherein the forming surface of the expansion elements, seen in cross section in the radial direction, have a shape of a circular arc.

19. The forming tool of claim 18, wherein

in the first position the peripheral end edges are located on a circumscribed circle and the central region of the forming surface is at a distance from the circle, and

the second position, both the peripheral end edges and the forming surfaces are located on a circumscribed circle.

20. The forming tool of claim 18, wherein in the first position, a radius of the forming surfaces is greater than a distance of the end edges from the center of the expanding device.

21. The forming tool of claim 18, wherein in the first position, a radius of the forming surfaces is between 2.5% and 10% greater than a distance of the end edges from the center of the expanding device.

22. The forming tool of claim 18, wherein in the first position, a radius of the forming surfaces is 5% greater than a distance of the end edges from the center of the expanding device.

23. The forming tool of claim 16, further comprising:

a drive element configured to move the expanding device from the first position to a second position.

24. The forming tool of claim 23, wherein the drive element includes a mandrel configured for insertion into an inner hole of the expanding device.

25. The forming tool of claim 24, wherein at least inner surface of the inner hole or at least one outer surface of the mandrel has a coating.

26. The forming tool of claim 25, wherein the coating is formed of an electrochemically applied nickel layer and/or a diamond-like carbon layer having a thickness of few nanometers and up to several micrometers.

27. The forming tool of claim 23, wherein an angle between a central axis M of the mandrel and an outer surface is between 0.3 degrees and 3 degrees.

28. An expansion element for use in a forming tool the expansion element comprising:

several expansion elements,

29. The expansion element of claim 28, wherein the expansion element has a trapezoidal cross-sectional shape, wherein at least one side extending between the two legs is curved.

30. A method for widening an opening from a first diameter to a second diameter, the method comprising the following steps:

a) providing several expansion elements, each having a forming surface and two separating surfaces extending between two end edges, wherein the expansion elements are moveable from a first position, which in an unexpanded state corresponds to the first diameter, to a second position, which corresponds to the second diameter in the desired expanded state, by displacing the expansion elements in a radial direction, wherein the separating surfaces and the forming surfaces are configured such that in the first position, a central region of the forming surfaces, when placed against the non-widened opening, is further apart from the inner wall of the opening than the end edges, and that in the second position, the forming surfaces altogether correspond to the contour of the inner wall of the desired expanded opening;

b) assembling the expansion elements to form an expanding device and moving the expansion elements to the first position;

c) inserting the expanding device into the opening; and

d) continuously expanding the opening by moving the expansion elements into the second position.

31. The method of claim 30, further comprising:

widening the opening from one side so that with two adjacent workpieces, only one of the two openings is widened.

32. The method of claim 30, wherein the expanded opening has a diameter d in a workpiece having a plate or stack thickness t, wherein t>d.