Method of forming an integral grid reinforcement in a part using an electro-hydraulic forming process
A method of reinforcing a part formed from a sheet metal panel that has a predetermined area that requires reinforcement by forming a grid pattern of V-shaped channels in the predetermined area. The grid pattern may be formed by wire electrodes in an electro-hydraulic forming tool having a one-sided die. Alternatively, the grid pattern may be formed by a plurality of electrodes that are arranged in an array that is aligned in at least two directions on the opposite side of the part from the one-sided die.
1. A method of reinforcing a part comprising:
forming a metal panel into a three dimensional shape that includes a predetermined area requiring reinforcement;
placing the predetermined area between a one-sided die and an electro-hydraulic chamber that includes a first plurality of wire electrodes that extend in a first direction;
discharging a stored electrical charge through the sires to form a first set of grooves into a V-shaped cross-section having an internal radius of less than one-half the thickness of the panel in the one-sided die;
placing the predetermined area between the one-sided die and the electro-hydraulic chamber that includes a second plurality of wire electrodes that extend in a second direction that is different than the first direction; and
discharging a stored electrical charge through the wires to form a second set of grooves into a V-shaped cross-section having an internal radius of less than one-half the thickness of the panel, wherein the first and second sets of grooves intersect at a predetermined angle.
2. The method of claim 1 wherein the step of forming a grid pattern further comprises discharging a forming pulse against the area requiring reinforcement and forming the grid pattern into a one-sided die.
3. The method of claim 1 wherein the step of forming a grid pattern further comprises forming a grid of V-shaped cross-section grooves into a one-sided die that includes a first set of parallel grooves extending in a first direction and a second set of parallel grooves extending in a second direction, and wherein the first and second sets of grooves intersect at a predetermined angle.
4. The method of claim 3 wherein the predetermined angle is approximately a right angle.
5. A method of reinforcing a part comprising:
forming a panel that includes a predetermined area requiring reinforcement;
placing the predetermined area between a one-sided die and an array of electrodes that are aligned in a first direction and in a second direction, that intersect; and
discharging the plurality of electrodes to form a first plurality of channels in the first direction and a second plurality of channels in a second direction.
6. The method of claim 5 wherein the channels formed by the electrical discharge are formed into a V-shaped cross-section.
7. The method of claim 5 wherein the electrodes are connected to a source of stored electrical power having a first polarity, and wherein the panel is connected to the source of stored electrical power having a second polarity that is opposite the first polarity.