Apparatus and method for hydroshearing and hydrotrimming for hydroforming die

1. An apparatus for hydroshearing and hydrotrimming for a hydroforming die comprising:

a cutting insert fixed relative to the hydroforming die;

a disposable insert fixed relative to the hydroforming die;

a plunger movable relative to the hydroforming die to allow fluid within a tubular member to force a wall portion of the tubular member outward against said plunger and be sheared in the hydroforming die to trim the tubular member; and

a cutting blade having a cutting edge and being movable relative to the hydroforming die.

2. An apparatus as set forth in claim 1 wherein said cutting insert has an end surface that is generally planar to contact the tubular member.

3. An apparatus as set forth in claim 1 wherein said disposable insert has an end surface with at least a portion spaced from the tubular member.

4. An apparatus as set forth in claim 1 wherein said plunger has an end surface that is generally planar.

5. An apparatus as set forth in claim 1 wherein said cutting insert has a cutting edge.

6. An apparatus as set forth in claim 1 including a link mechanism to connect said cutting blade to said plunger.

7. An apparatus as set forth in claim 6 wherein said link mechanism comprises a plurality of first linkages having one end connected to said plunger and a plurality of second linkages having one end connected to said first linkages and another end connected to said cutting blade.

8. An apparatus as set forth in claim 7 including a plurality of pins to connect said linkages together at ends thereof.

9. An apparatus as forth in claim 1 wherein said cutting blade is disposed between said cutting insert and said plunger, and said plunger is disposed between said cutting blade and said disposable insert.

10. An apparatus for hydroshearing and hydrotrimming comprising: a hydroforming die having at least one die half having a die forming cavity for receiving the tubular member and a cavity extending axially therein and communicating with said die forming cavity;

a cutting insert disposed in said cavity and fixed relative to said die half, said cutting insert having an end surface that is generally planar to contact the tubular member;

a disposable insert disposed in said cavity and fixed relative to said die half, said disposable insert having an end surface with at least a portion spaced from the tubular member; and

a plunger disposed in said cavity and movable relative to said die half, said plunger being a cutting blade with a cutting edge to allow fluid within a tubular member to force a wall portion of the tubular member outward against said plunger and be sheared in said hydroforming die to trim the tubular member.

11. An apparatus for hydroshearing and hydrotrimming comprising:

a hydroforming die having at least one die half having a die forming cavity for receiving the tubular member and a cavity extending axially therein and communicating with said die forming cavity;

a cutting insert disposed in said cavity and fixed relative to said die half, said cutting insert having an end surface that is generally planar to contact the tubular member;

a disposable insert disposed in said cavity and fixed relative to said die half, said disposable insert having an end surface with at least a portion spaced from the tubular member;

a cutting blade movable relative to the hydroforming die;

a plunger disposed in said cavity and movable relative to said die half; and

a link mechanism to connect said cutting blade to said plunger to allow fluid within a tubular member to force a wall portion of the tubular member outward against said plunger and be sheared by said cutting blade in said hydroforming die to trim the tubular member.

12. An apparatus for hydroshearing and hydrotrimming a tubular member comprising:

a hydroforming die having at least one die half having a die forming cavity for receiving the tubular member and a cavity extending axially therein and communicating with said die forming cavity;

a first blade movable relative to said die forming cavity to cut a groove in the tubular member; and

a second blade movable relative to said die forming cavity in direction different from said first blade to shear the tubular member in said hydroforming die to trim the tubular member.

13. A method of hydroshearing and hydrotrimming a tubular member with a hydroforming die, said method comprising the steps of:

providing a hydroforming die having at least one die half having a die forming cavity and a cavity extending axially therein and communicating with the die forming cavity;

moving a first blade relative to the die forming cavity to cut a groove in the tubular member; and

moving a second blade relative to the die forming cavity in direction different from the first blade to shear the tubular member in the hydroforming die to trim the tubular member.