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Manufacturing cosine die profile for tubes

Hydroforming test (Bulging)

Asst. Prof. Dr.Hani Aziz Ameen

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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)

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fig.(5-3)

fig.(5-4)

fig.(5-5)

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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)

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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)

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Fig .(5-10)

Fig .(5-11)

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

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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)

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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)

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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)

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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)

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Fig .(5-23)

Fig .(5-24)

Fig .(5-25)

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

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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)

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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)

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Fig .(5-33)

Fig .(5-34)

Fig .(5-35)

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

Fig.(5-40)

Fig.(5-41) close the die

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Fig.(5-44)

Fig.(5-45)