Technical field of the invention

The invention relates to an automated tool and a method for shaping a preformed metal sheet workpiece to be used for different packaging purposes. More particularly, the invention relates to an automated tool with expandable sections and a method of shaping a preformed metal sheet workpiece e.g. used for containers, packages, cans etc.

Background of the invention

Known techniques for producing metal packages or cans with specific forms or contours include the use of matrices or other pre- ^' shaped tools which are thrusted into a sheet of metal (a blank) by pressure force in order to manufacture a desired object. Such a blank can be taken through several different shaping processes or stations in order to end up having a desired form. Whenever a blank enters a shaping station or point it may already be more or less preformed. The matrices or tools used in such processes are designed and manufactured to form the object into one specific shape, which means that if a detail needs to be changed or added in the manufactured object, it requires the designing and manufacturing of a whole new matrix or tool which of course is both time-consuming and expensive.

Since the shaping tools of the known techniques typically has a fixed predefined outer shape, the freedom of choice for the shape of a workpiece to be manufactured is limited as the final shape of the workpiece must allow the shaping tool to be removed or retracted from the shaped workpiece.

Another limitation of the known techniques is that the number of details in the object to be manufactured by matrices or similar tools typically must be kept relatively low. This is also due to the cost of designing and manufacturing such tools. The more details the more difficult and expensive tools. Hence, the configuration of an object to be manufactured by press shaping is therefore typically limited by the cost of the matrices or tools needed for shaping the object.

Another limitation of the known techniques are the need for the workpiece to be shifted between a number of different shaping/working stations if the final shape of the workpiece is just a little bit complicated. In such cases there is a need for different shaped manufacturing tools and a need for a system that can shift workpieces between

shaping/working stations. The more stations the more tools to be designed and also the more time is needed before the workpiece is shaped to its final, desired form.

Description of the invention

It is an object of the present invention to provide an automated tool for shaping of preformed metal sheet workpieces wherein a larger freedom of choice for the shaping (and thereby the final shape) of the preformed metal sheet workpieces is provided.

It is a further object of the present invention to provide a method for shaping preformed metal sheet workpieces used for e.g. containers, packages, cans and the like by using an expandable, automated tool.

It is a still further object of the present invention to provide a method of shaping a workpiece where the shaped workpiece may have any desired shape as well as a high degree of details.

In a first aspect of the present invention, the disadvantages of the known techniques described above are overcome by providing an automated tool for shaping a preformed metal sheet workpiece comprising:

• a vertically movable base part supporting an inner tool part comprising a plurality of first horizontally moveable tool sections for engagement with a first side of the metal sheet workpiece and further supporting an outer tool part comprising a plurality of second horizontally moveable tool sections for engagement with a second side of the metal sheet workpiece, and

• actuation means for moving said base part, and

• a guide plate guiding the first and second moveable tool sections.

The moveable tool sections of the inner and outer tool part can horizontally move between an expanded and a non-expanded state, respectively, for shaping the preformed workpiece into a final shape.

In an embodiment according to the first aspect of the invention the horizontal movement of the moveable tool sections is substantially perpendicular to the extension of the sides of the workpiece to be shaped.

In another embodiment the inner and outer tool parts are supported on the base part by at least one vertical rod.

In a still further embodiment the movable tool sections are demountably fixed to a block, the block being fixedly attached to a T-shaped element having an inclined guiding surface and being in sliding engagement with a guide on the vertical rod in order to obtain the horizontal movement of the tool sections upon the vertical movement of the base part.

In yet another embodiment the guide plate has slots in which the movable tool sections are guided.

In still another embodiment the tool is further provided with a curling tool having means for curling an edge of the metal sheet workpiece, and the curling tool is being supported by a plurality of pins engageable with or connected to the base part.

In yet another embodiment the curling tool is shaped identical to the final shape of the workpiece so as to facilitate curling of the entire edge of the workpiece.

In a further embodiment the movable tool sections further comprise means for providing the workpiece with a reinforcing structure.

Thus, an automated tool is provided which allows for a shaping process in which the shaping and curling is provided in the same machining step, which reduces the production costs and production time. An embodiment of the automated tool is shown and described more in detail with reference to figures lla-14.

The automated tool according to the first aspect may be combined with any of the features of the automated tools mentioned below in connection with the other aspects.

In a second aspect of the present invention, the disadvantages of the known techniques described above are overcome by providing a method for shaping a preformed metal sheet workpiece with an automated tool according to the first aspect, comprising the steps of

• Loading the preformed metal sheet workpiece onto the tool;

• Actuating the actuation means to move the base part vertically thereby horizontally moving the movable sections of the inner and the outer tool part to simultaneously engage with the first and second sides of the workpiece, respectively, for the shaping thereof; and

• Retracting the actuation means and unloading the workpiece from the tool.

In an embodiment of the method according to the second aspect, the method further comprises the step of curling an edge of the workpiece by moving the base part further

vertically so as to provide engagement between the edge of the workpiece and the curling tool thereby curling the edge of the workpiece.

In a third aspect of the present invention, the disadvantages of the known techniques described above are overcome by providing a method for shaping a preformed metal sheet workpiece with an automated tool, comprising the steps of

• Loading a preformed metal sheet workpiece onto the tool;

• Actuating actuation means so as to move a base part of the tool vertically thereby horizontally moving a plurality of movable sections of the inner and the outer tool part to simultaneous engagement with first and second sides of the workpiece, respectively, for the shaping thereof; and

• Retracting the actuation means and unloading the workpiece from the tool.

In an embodiment of the method according to the third aspect of the invention, the method further comprises the step of curling an edge of the workpiece by moving the base part further vertically so as to provide engagement between an edge of the workpiece and a curling tool thereby curling the edge of the workpiece.

In a fourth aspect of the present invention, the disadvantages of the known techniques described above are overcome by providing an automated tool for shaping a preformed metal sheet workpiece comprising:

• An inner part with a plurality of movable sections with engaging surfaces together defining a forming tool for engagement with a first surface of the metal sheet workpiece, said sections being able to alternate between a first non-expanded state and a second expanded forming state in a direction substantially perpendicular to the extension of part of the workpiece to be formed by the sections,

• A second part with one or more sections for engagement with a second opposite surface of the metal sheet workpiece, and

• wherein engaging surfaces of the sections of the inner and outer tool parts are contoured so as to leave a specific shape in the metal sheet workpiece when actuated.

The inner part of the automated tool comprises a plurality of movable sections with engaging surfaces together defining a forming tool, which can be expanded in a direction substantially perpendicular to the extension of the part of the workpiece to be formed, i.e. in a radial direction with respect to the centre of the inner tool part. In this way, the inner tool part may have one cross sectional area in a first non-expanded state and a second

larger cross sectional area in a second expanded state, the larger cross sectional area being a result of the expansion of the inner tool part. The actuation of the movable sections can of course be reversed, thereby bringing the inner tool part back into the first non-expanded state. The inner tool part engages a first surface of a preformed metal sheet workpiece.

The forming of the metal sheet workpiece is typically made by conventional deep-drawing methods, but it may of course also be preformed in any other known way. Onwards in this application the single term "workpiece" will be used, but should be construed as meaning a "preformed metal sheet workpiece", unless otherwise indicated.

Furthermore, in this application, the term "a first surface" should be construed in a way meaning one of the two surfaces of a metal sheet workpiece, i.e. not excluding that the metal sheet workpiece may comprise bends, neck-ins, flanges, corrugations or the like before being shaped by the tool.

The second part of the automated tool comprises one or more sections for engagement with a second surface of the preformed metal sheet workpiece. In operation, when the movable sections of the inner tool part are actuated into the second expanded state and engage the first surface of the workpiece, the one or more sections of the outer tool part engage with the second surface of the workpiece.

In a specific embodiment according to the fourth aspect of the invention, one or more sections of the second part are movable between a first non-engaging state and a second engaging state wherein it engages said second opposite surface.

In another specific embodiment according to the fourth aspect of the invention, the sections of the outer tool part are movable in a direction towards the sections of the inner tool part and the sections of the inner tool part are movable in a direction towards the sections of the outer tool part. The sections of the outer tool part may therefore be actuated so as to engage the second surface of the workpiece simultaneously with the inner tool part engaging the first surface of the workpiece.

The engaging surfaces of the inner and outer tool parts are so contoured that their engagement with the workpiece will leave (press) a specific, desired shape in the workpiece when the tool is actuated. Thereby, the workpiece is shaped between the sections of the inner and the outer tool parts. The shaping of the workpiece is thus effectuated by movement of either the sections of the inner tool part alone towards a

stationary outer tool part or simultaneous movement of both the sections of the inner and outer tool parts toward each other.

The sections of the inner and the outer tool parts may engage the workpiece in corresponding relationship on each side of the workpiece, i.e. each individual section of a tool part may have a corresponding individual section on the other tool part in order to shape the workpiece. The tool parts may be configured in a way so that only a part of the workpiece is shaped by corresponding sections. These possibilities for configuring of the sections facilitate a number of improvements, e.g. a rapid readjustment or exchange of the shaping tool in case the requirements for the shape of the workpiece change, as well as a higher number or degree of shaping details in the final shape if the workpiece.

In another embodiment according to the fourth aspect of the invention, the outer tool part encircles/circumvents the inner tool part. If the outer tool part encircles or circumvents the inner tool part it may be either stationary or movable as previously mentioned. Such a configuration of the tool parts may be desirable if the tool is set up to produce e.g. circular or otherwise rounded objects. It also means an increase in production speed since the outer tool part does not need to move or shift at any time.

In an embodiment according to the fourth aspect of the invention, the tool has a base part for supporting the sections of the inner and outer tool parts, i.e. the tool parts are exchangeable on the base part so that if one of the parts should malfunction it is not necessary to exchange the whole tool. Also, the malfunctioning part may be quickly replaced be a spare or reserve part, thus assuring a minimising of stand still time of the production line. The base part of the tool may preferably hold or harbour the main portion of the technical installations needed for operating the tool according to the invention.

In yet another specific embodiment according to the fourth aspect of the invention, the base part of the tool has means for defining the movement directions of the movable sections of the tool parts when these are actuated. Such means may e.g. be milled grooves or channels or any other form of sliding means such as e.g. rails or slides.

In specific embodiments according to the fourth aspect of the invention, the tool parts include means for guiding a sliding movement of the movable sections. In this way the movable sections are guided in a straight linear motion without any risk of inaccuracy. Such means for guiding the sliding movement may e.g. comprise protruding tongues on the movable sections and corresponding grooves in the base part of the tool. The grooves may of course also be placed in the tool parts with the tongues being placed on the base part. In addition to the means for guiding the sliding movements of the tool parts the tool

may further have a plurality of stationary or fixed sections placed between the movable sections.

The sliding movements of the movable sections of the tool parts may be actuated by any kind of actuating means. Preferably, but not exclusively, such means may be hydraulic or pneumatic cylinders. Each movable section of the tool parts may be actuated by individual cylinders meaning that it will be possible to move the parts individually. The sections may on the other hand also be moved by a single actuating means. The number of actuation means may be fitted for the specific operation.

In another specific embodiment, the inner tool part comprises means for moving the inner tool part between the first non-expanded state and the second expanded state, the means moving substantially perpendicular to the moving direction of the one or more movable sections of the inner tool part.

The means for moving the inner tool part may be a piston or piston-like element placed in a centre portion of the inner tool part. A movement of the element will cause the movable sections of the inner tool part to move in the directions defined by the cooperating guiding means of the movable sections and the tool base part. The movement of some of the sections may also occur as a relative movement, i.e. the direct engagement of the movable element on a number of movable sections may cause a resulting movement of other sections. Preferably, but not exclusively, the upper part of the element is constituted by inclined surfaces, which slidingly interengage with corresponding surfaces of the movable sections of the inner tool part. These corresponding surfaces may be shaped in a way so that a movement of the element causes a substantially transverse movement of the movable sections of the inner tool part. This transverse movement of the movable sections may preferably take place in a direction substantially perpendicular to the extension of the part of the workpiece to be formed by the movable sections. However, the movement of the element may also cause a parallel movement of the movable sections.

The inclined engaging surfaces of the upper part of the piston or piston-like element may be pyramid shaped and correspondingly the engaging surfaces of the movable sections may be wedge-shaped or tapered or otherwise shaped to fit on to the surfaces of the upper part of the piston-like element. The pyramid shape of the element may have a frustum if preferred. Alternatively, the upper part of the piston or piston-like element may be cone shaped or otherwise truncated and the corresponding engaging surfaces of the movable sections may therefore also be truncated in order to fit the upper part of the element. The upper part may also be in the form of a frustocone if preferred.

In an embodiment according to the fourth aspect of the present invention, the sections of the inner tool part are interconnected so as to move simultaneously upon actuating. With such interconnection it is assured that the plurality of movable sections are all moved simultaneously in their respective directions when expanding the tool by actuation of the piston or piston-like element. Hence, in this embodiment it is much less likely for the inner tool part to shape the workpiece in a wrong way or angle once the workpiece is loaded correctly onto the tool. The interconnection may be made by any suitable means, e.g. a slidable groove and tongue connection.

In a further embodiment according to the fourth aspect, the inner tool part comprises means for causing retraction of the movable sections from the second expanded state into the first non-expanded state. In order to be able to bring the expanded tool back into its non-expanded state and thereby facilitating the easy retraction of the inner tool part from the workpiece to be formed, the inner tool part may be equipped with a retraction connection. The connection may preferably, but not exclusively, be placed between the movable sections of the inner tool part and the upper part of the piston or piston-like element causing the movement of the sections.

In a specific embodiment according to the fourth aspect of the invention, the retraction connection may be a tongue and groove connection with the tongue parts being placed in the upper part of the piston or piston-like element, and the groove parts situated in the movable sections of the inner tool part. However, any suitable means may be used for connecting the parts such as a hinge, a screw, a pin etc. The means may e.g. be telescopic. The means for retraction may alternatively be electromagnetic means such that the retraction of the inner tool part can be done without the need for any physical connection between the parts.

The tool according to the fourth aspect of the invention may comprise means for cooling of the tool parts when in operation. Such means may be small channels milled or otherwise shaped into the tool parts facilitating cooling by a cooling fluid such as e.g. oil or water.

In a fifth aspect of the present invention, the disadvantages of the known techniques described above are overcome by providing a method for shaping a preformed metal sheet workpiece with a tool according to the fourth aspect of the invention, comprising the steps of

• Loading the preformed metal sheet workpiece onto the inner tool part being in the first non-expanded state;

• Actuating of the movable sections of the inner tool part into the second expanded forming state thus engaging a first surface of the workpiece with the sections while simultaneously engaging an opposite second surface of the workpiece with the sections of the outer tool part, thereby shaping the workpiece between said sections of the tool parts;

• Actuating of the movable sections of the inner tool part back into the first non- expanded state and

• Unloading the workpiece from the tool.

By carrying out the method according to the fifth aspect of the invention, the workpiece is loaded onto the inner tool part by way of loading means, which may be any kind of standard loading equipment or robot.

The movable sections of the inner tool part are then actuated and brought into engagement with a first surface of the workpiece. The actuation may be effected e.g. by moving the piston or piston-like element of the inner tool part as mentioned above. The sections of the outer tool part are simultaneously engaged. However, the engagement of the sections of the outer tool part may in this particular embodiment of the fifth aspect of the invention be said to be "passive", as they do not move.

In the instant that the workpiece is engaged on both the first and second surface by the sections of the inner and outer tool parts, the shaping of the workpiece is performed. Immediately thereafter the inner tool part is retracted or actuated into its first non- expanded state. This is done by reversing the movement of the piston or piston-like element of the inner tool part, which in turn causes the retraction means of the inner tool part to "pull" the movable sections of the inner tool part back into their initial position, i.e. the first non-expanded state.

To end the shaping cycle, the workpiece may be unloaded from inner tool part by the same equipment that loaded the workpiece onto the tool. Upon removal of the shaped workpiece, the tool is ready again and a new workpiece may be loaded onto the inner tool part.

By carrying out the method according to the fifth aspect of the invention, it is possible to shape a workpiece from one surface of the workpiece using the expandable sections of the inner tool part according to the fourth aspect of the invention, while correspondingly using the sections of the outer tool part as the necessary abutting surface. However, the sections of the outer tool part may be more than just an abutment surface as these sections may also be contoured in order to shape the workpiece from both sides at the same time. As

the workpiece is engaged on both sides simultaneously, the shaping is made much more efficient and in fact all the needed contours may be shaped into the workpiece in one single step.

The method according to the fifth aspect of the invention thereby facilitates the production of workpieces with "neck-ins" in one or more surfaces of the workpiece without the need for the metal material to be drawn by the tool. When producing neck-ins with conventional methods and tools, the metal material is drawn (and therefore "moved") between contoured inner and outer tool parts when engaged by the tool surfaces. With these conventional methods, this has only been done successfully by use of high quality and highly exact tools, which of course are very costly and time-consuming to manufacture. Even then, it is not always possible to control the movement of the metal material.

However, when using the method according to the invention there is no longer a need for the metal material to be drawn and "move" between the tool parts since the needed movements are performed by the expandable tools according to the invention. The movable surfaces of the tool parts engage the surfaces of the workpiece in the exact positions where the shaping is needed and the metal workpiece therefore do not move when drawn by the engagement of the tool parts. This also renders the need for a typical relatively large tolerance or margin between the inner and outer tool parts abundant.

This method of shaping a workpiece is only possible due to fact that the inner tool part is capable of being retracted back into its initial first non-expanded state after the shaping of the workpiece. Also, the shaped workpiece may therefore easily be removed, i.e. lifted off from the tool. If the inner tool part were not retractable, it would not be possible to lift the workpiece off the tool once the shaping of the workpiece is carried out since the shaped contours of the workpiece would still be in engagement with the contoured surfaces of the inner tool part.

The method according to the fifth aspect of the invention therefore also provides the possibility of manufacturing a metal workpiece such as a can or container with different sized cross sectional areas by use of a tool according to the fourth aspect. Normally, when using matrices or tools with a diameter larger than the object to be manufactured, it is not possible to retract the tool from the object once the shaping operation has been performed. Shaping of a preformed object having an initial large diameter or circumference to a smaller diameter or circumference is therefore possible by the method according to the fifth aspect of the invention. Furthermore, it allows the shaping to be performed in a single step since the object does not need to be moved to another shaping tool for further

processing or be manually treated in order to end up in the desired shape. This also means that any choice of shape of the object to be manufactured is possible.

In a specific embodiment according to the fifth aspect of the invention, the sections of the outer tool part are movable between a first non-engaging state and a second engaging state wherein it engages the second opposite surface, and further comprising, simultaneously with the step of actuating the one or more movable sections of the inner tool part, the step of;

• actuating the movable sections of the outer tool part into a second engaging state thus engaging the second surface of the workpiece, and thereby forming the workpiece between said sections of the tool parts.

The method of shaping the workpiece according to this embodiment of the invention is identical to the above described except for the sections of the outer tool part being movable.

This means, that when the movable sections of the inner tool part are actuated and brought into engagement with a first surface of the workpiece as described above, the sections of the outer tool part are simultaneously engaged. In this particular embodiment however, the sections of the outer tool part may be said to be "active", as they are moved into engagement with the second surface of the workpiece at the same time as the sections of the inner tool part engages the first surface of the workpiece.

In the instant that the workpiece is engaged on both the first and second surface by the sections of the first and outer tool parts, the shaping of the workpiece is performed. Immediately thereafter the inner tool part is retracted or actuated into its first non- expanded state and the outer tool part is simultaneously actuated into its non-engaging state. This is done by use of the retraction means according to the fourth aspect of the invention.

The workpieces may preferably be loaded onto the inner tool part from one or more loading points. Such loading points may have conveying arrangements for bringing the workpieces forward from a stock to the point of loading. Similarly there may also be one or more unloading points having conveying arrangements for sending on the shaped workpieces upon unloading. The loading and unloading of workpieces may preferably be handled by a computer-controlled robot.

In a sixth aspect of the invention, the disadvantages of the known techniques described above are overcome by providing a method for shaping a preformed metal sheet workpiece, comprising the steps of

• loading (a first side of) a preformed metal workpiece onto an expandable tool having a plurality of interconnected sections together defining a forming tool;

• providing an abutting surface engaging at least a part of or the whole (outer) circumference (of the second side) of the preformed metal sheet workpiece;

• expanding the expandable tool to engage the preformed metal sheet workpiece; • retracting the expandable tool, and

• unloading said workpiece from the expandable tool.

The loading and unloading of the workpieces is preferably carried out in a similar manner as described above in connection with the fifth aspect of the invention.

It will be apparent from the teachings of this application that the many features according to the different aspects of the invention may of course be interchanged and combined with some or all of the other aspects, so as to provide a custom made solution for any task in question covered by the scope of the invention.

Description of the figures

Embodiments of the invention will now be described in details with reference to the accompanying drawings, in which:

Fig. Ia is a partial, perspective view of an inner tool part in an expanded state,

Fig. Ib is a top plan view of an inner tool part in an expanded state,

Fig. Ic is a sectional view of an inner tool part in an expanded state taken along the line A- A in fig. Ib,

Fig. 2a is a partial, perspective view of an inner tool part in a non-expanded state,

Fig. 2b is a top plan view of an inner tool part in a non-expanded state,

Fig. 2c is a sectional view of an inner tool part in a non-expanded state taken along the line A-A in fig. 2b _r

Fig. 3 is a partial perspective view of an inner tool part in an expanded state placed in a base part of the tool,

Fig. 4a is a partial, perspective view of an outer tool part,

Fig. 4b is a top plan view of an outer tool part,

Fig. 4c is a sectional view of an outer tool part taken along the line A-A in fig. 4b,

Fig. 5 is a perspective view displaying the underside of an inner tool part,

Fig. 6 is a more detailed and partly exploded perspective view of an inner tool part,

Fig. 7a is a perspective view of one example of a workpiece being manufactured according to the invention,

Fig. 7b is a perspective view of another example of a workpiece being processed according to the invention,

Fig. 8a is a perspective view of another example of a workpiece before being processed according to the invention,

Fig. 8b is a perspective view of the workpiece of fig. 8a after having been processed according to the invention,

Fig. 9 is a perspective view of the tool parts, similar to fig. 3 but further showing a workpiece positioned above the tool parts before insertion and processing,

Fig. 10 is a cross-sectional view showing a workpiece positioned above the tool parts and indicating the step of inserting the workpiece into the tool for processing in the direction of the arrow,

Fig. 11a shows another embodiment of an automated tool according to the invention,

Fig. lib is a top view of the tool shown in figure 11a,

Fig. lie is a sectional view of the tool of figure lib taken along the line A-A,

Fig. Hd is an enlarged sectional view of a part of the tool of figure Hb,

Fig, 12 is a perspective view of parts of the tool of fig. 11a,

Fig. 13 is a perspective view of the base part of the tool of figure 11a,

Fig. 14 is a perspective view of parts of the tool of figure 11a, and

Fig. 15 is a perspective view of a tool almost similar to the tool of figure 11a, but for shaping metal sheets with another final shape.

Fig. Ia shows a perspective view of an inner tool part (1) according to the invention in an expanded state. The tool part has a number of movable sections (2) and (2b) that can move in a direction substantially perpendicular to the extension of the part of the workpiece (not shown) to be formed. The movement of the sections (2) and (2b) in order to expand the tool part is done by actuation of the piston-like element (3) in an upward, direction indicated by arrow P. The sections (2) move as a consequence of direct engagement with the element (3) whereas the sections (2b) move relatively due to their engagement with sections (2). Fig. Ia also shows means for retraction of the sections (4) and means for directing or guiding the movement of the movable sections (5).

Fig. Ib also shows the tool part of fig. Ia in a top plan view. As can be seen from the figure the retraction means (4) are connected to the piston-like element (3). When the inner tool part (1) is expanded by upward movement of element (3), the sections (2) and (2b) will move in a direction away from the element (3), indicated by arrows W. The sections (2) and (2b) are interconnected so as to move simultaneously and relatively to the other sections upon actuation of the element (3).

Fig. Ic is a sectional view of an inner tool part in an expanded state taken along line A-A in fig. Ib. The figure shows an example of how the retraction means (4) are connected to the piston or piston-like element (3). It is also possible to see how part of the surfaces (7) of the movable sections (2) are contoured in order to manufacture a workpiece with a neck-in feature.

Figs. 2a-2c are similar to figs. Ia-Ic except for the inner tool part being in its non- expanded state. As can be seen from figs. Ia-Ib and 2a- 2b, the expansion of the inner tool part causes the sections (2) and (2b) to move in an outward, radial direction in relation to the element (3). This is best seen in figs. Ic and 2c.

In fig. 3 is shown a partial perspective view of an inner tool part (1) in an expanded state placed in a base part (10) of the tool, where the inner tool part (1) is encircled/circumvented by a section (15) of an outer tool part. In this configuration, it is only the inner tool part (1), which is provided with movable sections. The shaping of the workpieces are performed by loading a workpiece (not shown) onto a position on top of the inner tool part (1) and the surfaces of the workpieces that are to be shaped by the tool are fitted into the space between the first (1) and second (15) tool parts. When the inner tool part is expanded the workpiece is shaped without the need for any drawing of the metal material in the process.

In fig. 4a the outer tool part in shown in a partial perspective view indicating a possible configuration of some of the movable sections (20) of the outer tool part as well as some stationary or fixed sections (22). The actual contoured forming surfaces (23) of the movable sections (20) are positioned just below the sections (20), which are best seen in fig. 4c. It is also possible to see hydraulic or pneumatic cylinders (21) for moving the movable sections (20). The base part (10) of the tool (1) is shown in a position supporting the sections of the outer tool part. The inner tool part (1) with the piston or piston-like element (3) of the inner tool part is also indicated and supported in the base part (10).

Fig. 4b is a top view of the tool in fig. 4a and shows the positions of the movable (20) and stationary (22) sections of the tool. It is also possible to see some of the movable sections (2) of the inner tool part (1), indicating that no workpiece is loaded.

Fig. 4c is a sectional view of taken along line A-A in fig. 4b. The figure shows the cylinders (21) for moving the sections (20) and also the contoured forming surfaces (23) of the tool sections (20).

Fig. 5 is a perspective view of the inner tool part (1) seen from below with the piston or piston-like element (3) pointing upwards. In the figure channels (6) for transporting a cooling fluid can be seen as well as milled grooves or channels (5) for guiding the movement of the sections (2b.) .

In fig. 6 it is possible to get a view of one example of how the sections (2) and (2b) of a inner tool part (1) are interconnected. Means for guiding the movable sections (2) and (2b) are shown as protruding T-shaped tongues (25) and grooves or channels (26) in the base part (10). The means for interconnecting the movable sections (2) and (2b) are shown as cooperating channels and flanges and are designated as (24). Examples of the contours (7) for shaping a workpiece with the inner tool part (1) can also be seen in more detail. The figure further provides a view of the inclined surfaces (27) of the piston or

piston-like element (3) and corresponding inclined surfaces (28) of the movable sections (2). As can be understood from the figure the movement of element (3) will cause a direct engagement between element (3) and sections (2) and also a simultaneous, relative movement of sections (2b).

Figs. 7a and 7b show two differently shaped workpieces (30) and (35) after having been processed according to the invention. Workpiece (30) is manufactured as a rectangular shape whereas workpiece (35) is shown with concave side parts (37). Both examples of workpieces have been shaped with flanges having neck-inns (31 and 36 respectively) in the parts being processed with the tool.

Fig. 8a shows another example of a workpiece (40) before being processed by the tool. The workpiece (40) is preformed with flanges or sides (41) to be processed by the tool according to the invention.

In Fig. 8b the workpiece has been processed and is now indicated by (45). The tool has shaped the flanges or sides and the figure shows that the workpiece can be bended as well as having a neck-inn performed in the same operation by the tool. A bended flange portion is indicated by (46) and a neck-inn by (47). Combinations of different shaping operations can of course be combined depending on the contours (7) of the tool, as it is also indicated at (47).

Fig. 9 shows the tool parts and a workpiece (50) before it is inserted on top of inner tool part (1) and subsequently processed. The view is schematic and illustrates how the workpiece is to be inserted. In operation, the workpiece is placed in the tool by means of a computer controlled robot or the like.

Fig. 10 is a cross-sectional view showing the workpiece (50) and the same situation as in fig. 9. The workpiece (50) is placed between the tool parts.

Figs, lla-e show another embodiment of an automated tool 60 for shaping metal sheets. The tool (60) comprises a frame part 61 surrounding the movable parts of the tool. The tool is shown in an expanded state. The inner tool part has a number of movable sections (62) that can move in a direction substantially perpendicular to the extension of the part of the workpiece (63) to be formed. The sections (62) are demountable fixed on blocks (64) that are fixed to T-shaped elements (66) having an inclined guiding surface. The T-shaped elements (66) are in sliding engagement with guiders (67) that are fixed mounted to vertical rods (65).

The vertical rods (65) are fixed mounted to a base part (68), and the movement of the sections (62) in order to expand the tool part is done by actuation of the piston-like element (69) (shown in figure lie) in an upward direction indicated by arrow P, whereby the base part (68) is pushed upwards. As the base part (67) moves upwards, the rods (65) move upwards and the sections (62) move outwards as a consequence of inclined surface of the T-shaped elements (66) and result in an expansion of the inner tool.

The inner tool is retracted in the opposite way, by retracting the piston-like element (69) downward.

The second outer tool part is actuated simultaneously with the inner tool part as described above and in a similar manner. The outer tool comprises movable sections (70) that are mounted to blocks (71) being guided in guiders (72). The blocks (71) are in sliding engagement with vertical rods (73) that are fixed mounted to the base part (68) like the vertical rods (65).

As the base part (68) moves upwards by actuating the piston-like element (69), the vertical rods (73) moves upwards whereby the blocks (71) together with the tool sections (70) move inwards due to the inclined surface of the upper part of the vertical rods (73), and the outer tool is pushed towards the inner tool part.

The movable sections of the inner and outer tool are fixed to a guide plate 74 having guides in which the sections can slide.

Thus, the metal sheet is shaped in between the inner and outer tool part resulting in a workpiece (63) having the shape defined by the form of the tool parts.

The movable sections of the inner and outer tool can easily be changed, which means that the production easily can be changed from one the shape-form to another, and the number of different shapes that can be produced is high.

Fig. Hd is an enlarged sectional view of a part of the tool showing the curling tool comprised in the automated tool. The base part (68) holds a curling tool (76) that is supported on pins (75), the pins being supported on the base part (68). As the base part (68) moves upwards for moving the movable sections of the inner and outer tool, as described above, the curling tool (76) moves simultaneously upwards. When the workpiece (73) has been shaped between the tool parts (62, 70), the edge (77) of the workpiece need to be curled in order to avoid a sharp edge. This curling is provided by moving the base part (68) further upwards so that the edge (77) enters into the curling tool (76). The

movable sections of the inner and outer tool will not move when the base part moves further upwards, but are kept in the shaping position, as the extension of the above mentioned inclined surfaces are adjusted for this purpose.

Thus, the automated tool of figures lla-d provides a shaping process in which the shaping and curling is provided in the same machining step, which reduces the production costs and production time.

As shown in figure Hd, the tool parts (65, 70) also provide corrugation(s) (78) in the sidewall of the workpiece.

Fig. 12 is a perspective view of parts of the tool of fig. Ha, wherein the curling tool (76) is shown more in detail. The curling tool has the shape of the final workpiece in order allow curling of the entire edge of the workpiece (63). Only two sections (62, 70) of the inner and outer tool, respectively, are shown.

Fig. 13 is a perspective view of the base part (68) of the tool of figure Ha. The base part (68) comprises recesses (79, 80) in which the vertical rods (65, 73) are to be mounted, respectively.

Fig. 14 is a perspective view of parts of the tool of figure Ha. The tool is shown in a closed shaping condition, but one section of each of the inner and outer tool are left out.

Fig. 15 is a top view of a tool almost similar to the tool of figure Ha, but for shaping metal sheets with another final shape ("foot-shape"). The inner tool part has eleven movable sections (62), and the outer tool part has five movable sections (70) in order to provide the foot-shaped workpiece. The structure of this automated tool is identical to the automated tool of figures lla-15.

The number of moveable sections for the inner and/or outer tool part and the shape of these sections can easily be changed by the construction of the automated tool according to the invention, which gives a high freedom of choice for the shaping (and thereby the final shape) and allows for a high degree of details.