EP2419547A1 - Method for producing a shaped part - Google Patents

Method for producing a shaped part

Info

Publication number
EP2419547A1
EP2419547A1 EP10718421A EP10718421A EP2419547A1 EP 2419547 A1 EP2419547 A1 EP 2419547A1 EP 10718421 A EP10718421 A EP 10718421A EP 10718421 A EP10718421 A EP 10718421A EP 2419547 A1 EP2419547 A1 EP 2419547A1
Authority
EP
European Patent Office
Prior art keywords
aluminum sheet
forming
cold
aluminum
heated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP10718421A
Other languages
German (de)
French (fr)
Other versions
EP2419547B1 (en
Inventor
Karl Michael Radlmayr
Wolfgang Stall
Claudio Canalini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Voestalpine Metal Forming GmbH
Original Assignee
Voestalpine Metal Forming GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Voestalpine Metal Forming GmbH filed Critical Voestalpine Metal Forming GmbH
Priority to EP10718421.0A priority Critical patent/EP2419547B1/en
Publication of EP2419547A1 publication Critical patent/EP2419547A1/en
Application granted granted Critical
Publication of EP2419547B1 publication Critical patent/EP2419547B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/208—Deep-drawing by heating the blank or deep-drawing associated with heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B21D35/005—Processes combined with methods covered by groups B21D1/00 - B21D31/00 characterized by the material of the blank or the workpiece
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent

Definitions

  • the invention relates to a method for producing a molded part from an aluminum sheet having an aluminum alloy, in particular from an aluminum alloy of the 5000 series, in which at least the aluminum sheet is introduced into a forming tool and cold formed by this and in a further step or in further steps the cold-formed aluminum sheet is heated at least once at least in some areas and at least once further formed.
  • the invention is therefore based on the object to improve a method of the type described above, that in spite of a high strength of the molded part, a fast cycle time in the production of the molding and a flexibly customizable production output of moldings can be made possible. In addition, this method should provide a cost-effective production of moldings.
  • the invention solves this problem by the fact that the heated aluminum sheet is subjected to further forming before reaching a temperature which has the aluminum sheet during its cold forming.
  • the heated aluminum sheet is subjected to further shaping before reaching a temperature which the aluminum sheet has during its cold forming, then not only can the time interval between the two forming steps be reduced, so that comparatively short Throughput times can be made possible, but it may also turn out that so that the strength of the molding is not significantly reduced compared to other methods.
  • the heating can be used advantageously or can certainly be used for the recovery of the microstructure of the aluminum alloy in order to be able to counteract unwanted strain hardening. This is readily possible for a person skilled in the art via the parameters of time and / or temperature level during heating and possibly also over the time of a subsequent cooling.
  • the parameters during heating and thereby not excluded cooling of the aluminum sheet can certainly be chosen or adjusted so that, for example, before cooling the heated and cold-formed aluminum sheet to room temperature, the aluminum sheet can be subjected to further forming.
  • this does not rule out that several times a heating and / or cooling of the aluminum sheet is carried out until further forming, it can only be crucial that the heated aluminum sheet before further reaching a temperature which has the aluminum sheet during its cold forming is subjected.
  • a method can now be provided which can combine the advantages of a short throughput time on the one side, which are contrary to the prior art, with a comparatively high degree of deformation and a comparatively high strength on the other side.
  • Such processes are also referred to as "in-line" processes, since in these, from the first process step to the finished molded part, no significant storage times have to be maintained
  • Reason may also be the inventive method in the production of a molded part with an aluminum alloy on relatively large production areas, which must exist, for example, by a storage during artificial aging, be dispensed with, so that thus a cost-effective production can be possible.
  • an oven for a cold aging can be avoided, which does not require a significant number of cold-formed aluminum sheets must be made so that a flexibly adaptable production output can be possible by the inventive method.
  • an aluminum sheet can be understood as a flat finished rolling mill made of an aluminum material or aluminum alloy.
  • the aluminum sheet is formed by the cold forming into a partial shape of the molded part and by the further forming in the final shape of the molded part, then increased deformation of the molded part can open, because the aluminum sheet is exposed to increased stresses by a heated further forming.
  • increased deformation of the molded part can open, because the aluminum sheet is exposed to increased stresses by a heated further forming.
  • the degree of deformation during cold forming can be set such that the heating carried out in a next step and, if appropriate, cooling is sufficient to reduce such strain hardening in the microstructure that no substantial change in strength must be expected.
  • An advantageous recovery of the structure after the cold forming may result if the cold-formed aluminum sheet is heated below the recrystallization temperature of the aluminum alloy, in particular between 150 and 350 degrees Celsius.
  • the inventive method allow the lubricant to be removed from the aluminum sheet only in one step after further forming.
  • the applied lubricant can thus remain on the aluminum sheet during the process, because its disintegration can be avoided by avoiding a thermal aging known from the prior art. Costly and time-consuming cleaning steps are reduced so advantageous because only in one step after further forming the lubricant is removed from the aluminum sheet.
  • Lubricants or lubricants with a temperature resistance up to 350 degrees Celsius are known from the prior art.
  • Advantageous properties for the production of the molded part result when the aluminum sheet is at least partially reshaped by deep drawing. Likewise, this can be applied to a combination of deep drawing and ironing to reshape the aluminum sheet.
  • the aluminum sheet is introduced during further forming in a forming tool, then advantageous process conditions for the production of the molded part can be created. It may also be possible to reuse the forming tool already used in cold forming, which may save costs. If the forming tool is heated, then a possible cooling of the aluminum sheet can be reduced.
  • the cold-formed aluminum sheet is at least partially trimmed before and / or after further forming, then a special accuracy of the molded part thus created can be made possible.
  • 1 a spraying of an aluminum sheet with lubricant
  • 2 shows a step of cold forming the aluminum sheet with a forming tool
  • Fig. 6 is a final final cutting of the aluminum sheet with a tool
  • Fig. 7 the molded part produced by the method.
  • an aluminum sheet 2 comprising an aluminum alloy, for example the 5000, 6000 or 7000 series, according to FIG. 2 is subjected to a change in shape, in particular forming.
  • the 5000 series has been found to be preferred, since this alloy is relatively strong, deformable and easier to process further.
  • the aluminum sheet 2 is introduced for the purpose of forming in the forming tool 3 and is cold-formed therein at room temperature, in particular deep-drawn. Thereafter, the cold-formed aluminum sheet 2 is removed from the forming tool 3 and heated via a gas burner 4 shown schematically in FIG. 4a.
  • the cold-formed aluminum sheet 2 can thus be heated in whole or in part, in the latter case this can be in or in the surrounding area of the areas of the aluminum sheet 2 which are the most stressed by the forming.
  • temperature- temperatures in the range of 150 to 350 degrees Celsius are conceivable, but the heating should be below the recrystallization temperature of the aluminum alloy.
  • the aluminum sheet 2 is then subjected to further forming by means of a forming tool 5, wherein this forming tool 5 can optionally also constitute the forming tool 3 according to FIG. 2. Again, the aluminum sheet 2 is deep-drawn by means of the forming tool 5.
  • the aluminum sheet 2 in this further deformation according to FIG. 5 at least partially has a temperature which is increased in relation to the temperature during cold forming. This can be achieved by subjecting the aluminum sheet 2 to the further transformation according to FIG. 5 before cooling the heated cold-formed aluminum sheet 2 to its temperature during the cold forming according to FIG. 2. It can therefore be created an "in-line" process in manufacturing, because the well-known from the prior art artificial aging can not interrupt the inventive method.
  • the method according to the invention also makes it possible to provide a device with a reduced space requirement, because, for example, the comparatively large space requirement for hot aging can be avoided.
  • the aluminum sheet 2 is first brought into a partial mold 6 of the molded part 1 during cold forming. Subsequently, the aluminum sheet 2 or the partial mold 6 is brought into the final shape 7 of the molded part 1 by the further forming of FIG. 5.
  • the different deformation according to FIGS. 2 and 5 can be recognized, for example, at the height-different left parts of the molds 3 and 5.
  • the aluminum sheet 2 when further deformed is raised in relation to cold forming so as to obtain reduced work hardening during cold working.
  • the degree of deformation in the two steps for forming can also be reversed or the same, which has not been shown in detail.
  • a temperature-resistant lubricant 8 for this illustration of the method step, a spray nozzle 9 is shown in Fig. 1, via which the lubricant 8 can be applied to the aluminum sheet 2. Since the method according to the invention can avoid long process steps, such as those caused by artificial aging, and in contrast to the aluminum sheet 2 is formed into a molded part 1 in comparatively short time intervals, the lubricant 8 can on the assumption of a temperature resistance to the last step on the Aluminum sheet 2 remain without a decomposition of the lubricant 8 must be feared. Elaborate cleaning processes or a repeated application of lubricant 8 can be avoided. In contrast to the prior art is thus conceivable that lubricant 8 from the aluminum sheet 2 to remove only in one step after further forming of FIG. 5, which can be done for example in the step of FIG.
  • a particularly uniform and / or positionally accurate heating of the cold-formed aluminum sheet 2 can take place if this in the form of aluminum sheet 2 at least partially following counter-forms 10, 11 of a heating tool 12 is introduced, which heating tool 12 is shown in Fig. 4b.
  • heating tool 12 is shown in Fig. 4b.
  • heating means 13 are provided at the locations of the desired heating.
  • the cold-formed aluminum sheet 2 is introduced into a tool 14 in order to be able to cut it at least partially.
  • This tool 14 may already be provided with means for heating the cold-formed aluminum sheet 2, which however has not been shown in detail. However, this could avoid the method step according to FIG. 4a or 4b.
  • the final shape 7 can be further trimmed, for which purpose in FIG. 6 it is introduced into a tool 15.
  • This tool 15 may also represent the tool 14 of FIG. 3.
  • the final shape 7 can be shortened and / or possibly also perforated.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

The invention relates to a method for producing a shaped part (1) from an aluminum sheet (2) comprising an aluminum alloy, in particular an aluminum alloy of the 5000 series, wherein at least one aluminum sheet (2) is introduced in a forming tool (3) and cold-formed by the same, and in a further step, or in further steps, the cold-formed aluminum sheet (2) is heated at least once at least in some regions and at least once further formed. In order to create advantageous conditions for the method, it is proposed for the heated aluminum sheet (2) to be subjected to the further forming step even before a temperature has been reached which the aluminum sheet (2) has during the cold forming thereof.

Description

Verfahren zur Herstellung eines Formteils Process for producing a molded part
Technisches GebietTechnical area
Die Erfindung bezieht sich auf ein Verfahren zur Herstellung eines Formteils aus einem eine Aluminiumlegierung aufweisenden Aluminiumblech, insbesondere aus einer Aluminiumlegierung der 5000 Reihe, bei dem wenigstens das Aluminiumblech in ein Umformwerkzeug eingebracht und durch dieses kaltumgeformt wird und in einem weiteren Schritt bzw. in weiteren Schritten das kaltumgeformte Aluminiumblech mindestens einmal zumindest bereichsweise erwärmt sowie wenigstens einmal weiter umgeformt wird.The invention relates to a method for producing a molded part from an aluminum sheet having an aluminum alloy, in particular from an aluminum alloy of the 5000 series, in which at least the aluminum sheet is introduced into a forming tool and cold formed by this and in a further step or in further steps the cold-formed aluminum sheet is heated at least once at least in some areas and at least once further formed.
Stand der TechnikState of the art
Um einen hohen Umformungsgrad bei vergleichsweise hoher Festigkeit eines Formteils erreichen zu können, ist es aus dem Stand der Technik bekannt (DE 10 2008 032 911 A1), ein Aluminiumblech zuerst einer Kaltumformung bei Raumtemperatur, dann einer Erwärmung bzw. einer Warmauslagerung und abschließend nochmals einer Kaltumformung bei Raumtemperatur zu unterwerfen. Der Zwischenschritt des Warmauslagems soll Kaltverfestigungen, die durch das Kaltumformen entstehen, reduzieren, um so einen erhöhten Umformungsgrad garantieren zu können. Von Nachteil bei diesem bekannten Verfahren ist dessen vergleichsweise lange Verfahrensdauer, weil insbesondere das Warmauslagern mit seinem Erwärmen und anschließenden Abkühlen zeitintensiv ist. Schnelle Durchlaufzeiten bzw. eine flexible Anpassung in der Anzahl der Produktion von Formteilen können mit solch einem Verfahren nicht ermöglicht werden. Hinzu kommt, dass ein Warmauslagern in einem Ofen ver- gleichsweise kostenintensiv und auch einen großen Platzbedarf fordert, so dass damit eine kostengünstige Herstellung von Formteilen nicht durchgeführt werden kann.In order to be able to achieve a high degree of deformation with a comparatively high strength of a molded part, it is known from the prior art (DE 10 2008 032 911 A1), an aluminum sheet first a cold forming at room temperature, then a heating or a heat aging and finally another Cold forming at room temperature. The intermediate step of the hot aging process is to reduce work hardening caused by cold forming in order to guarantee an increased degree of deformation. A disadvantage of this known method is its comparatively long process time, because in particular the hot aging with its heating and subsequent cooling is time-consuming. Fast turnaround times or a flexible adaptation in the number of production of molded parts can not be made possible with such a method. In addition, hot aging in an oven comparatively expensive and also requires a lot of space, so that therefore a cost-effective production of moldings can not be performed.
Außerdem ist aus dem Stand der Technik bekannt (EP 0 726 106 A1), ein Werkstück nach einem Kaltumformschritt in einen Autoklaven zum Warmauslagern einzubringen. Während dieses Warmauslagerns wird Werkstück durch ein Presswerkzeug zum Kriechen gebracht, um damit das Werkstück einerseits formstabil zu halten und andererseits am Werkstück eventuell noch verbliebene Konturungenauigkeiten sowie zur Rückfederung führende Eigenspannungen ausgleichen zu können. Vergleichsweise kurze Durchlaufzeiten in der Herstellung eines Formteils sowie hohe Umformgrade am Formteil können mit diesem Verfahren nicht ermöglicht werden, insbesondere weil es für ein Umformen eines Fließens über der Fließgrenze des Formteils bedarf.In addition, it is known from the prior art (EP 0 726 106 A1) to introduce a workpiece after a cold forming step in an autoclave for hot aging. During this aging process, the workpiece is caused to creep by a pressing tool in order to keep the workpiece dimensionally stable on the one hand and to compensate for any contour inaccuracies remaining on the workpiece and for residual stresses leading to springback, on the other hand. Comparable short throughput times in the production of a molded part and high degrees of deformation of the molded part can not be made possible with this method, especially because it requires a reshaping of a flow above the yield point of the molding.
Darstellung der ErfindungPresentation of the invention
Die Erfindung hat sich daher die Aufgabe gestellt, ein Verfahren der eingangs geschilderten Art derart zu verbessern, dass trotz einer hohen Festigkeit des Formteils eine schnelle Durchlaufzeit in der Herstellung des Formteils und ein flexibel anpassbarer Produktionsausstoß an Formteilen ermöglicht werden kann. Außerdem soll dieses Verfahren eine kostengünstige Herstellung von Formteilen schaffen.The invention is therefore based on the object to improve a method of the type described above, that in spite of a high strength of the molded part, a fast cycle time in the production of the molding and a flexibly customizable production output of moldings can be made possible. In addition, this method should provide a cost-effective production of moldings.
Die Erfindung löst die gestellte Aufgabe dadurch, dass das erwärmte Aluminiumblech noch vor einem Erreichen einer Temperatur, die das Aluminiumblech bei seiner Kaltumformung aufweist, der weiteren Umformung unterworfen wird.The invention solves this problem by the fact that the heated aluminum sheet is subjected to further forming before reaching a temperature which has the aluminum sheet during its cold forming.
Wird das erwärmte Aluminiumblech noch vor einem Erreichen einer Temperatur, die das Aluminiumblech bei seiner Kaltumformung aufweist, der weiteren Umformung unterworfen, dann kann nicht nur die Zeitspanne zwischen den beiden Umformschritten vermindert werden, so dass vergleichsweise kurze Durchlaufzeiten ermöglicht werden können, sondern es kann sich auch herausstellen, dass damit die Festigkeit des Formteils nicht wesentlich gegenüber anderen Verfahren vermindert ist. Die Erwärmung kann nämlich vorteilhaft genutzt werden bzw. durchaus für die Erholung des Gefüges der Aluminiumlegierung herangezogen werden, um unerwünschten Kaltverfestigungen entgegenwirken zu können. Dies ist einem Fachmann durchaus über die Parameter Zeit und/oder Temperaturhöhe beim Erwärmen und gegebenenfalls auch über die Zeit eines anschließenden Abkühlens ohne weiteres möglich. Die Parameter beim Erwärmen und beim dadurch nicht ausgeschlossenen Abkühlen des Aluminiumblechs können durchaus derart gewählt bzw. eingestellt werden, dass beispielsweise noch vor einem Abkühlen des erwärmten und kaltumgeformten Aluminiumblechs auf Raumtemperatur das Aluminiumblech der weiteren Umformung unterworfen werden kann. Dies schließt jedoch nicht aus, dass mehrmals ein Erwärmen und/oder Abkühlen des Aluminiumblechs bis zum weiteren Umformen durchgeführt wird, entscheidend kann nur sein, dass das erwärmte Aluminiumblech noch vor einem Erreichen einer Temperatur, die das Aluminiumblech bei seiner Kaltumformung aufweist, der weiteren Umformung unterworfen wird. Erfindungsgemäß kann nun ein Verfahren geschaffen werden, dass die aus dem Stand der Technik gegenläufigen Vorteile einer kurzen Durchlaufzeit auf der einen Seite mit einem vergleichsweise hohen Umformungsgrad und einer vergleichsweise hohen Festigkeit auf der anderen Seite verbinden kann. Vorstellbar zur Erhöhung des Umformungsgrads ist weiter, dass das kaltumgeformte und in einem weiteren Schritt erwärmte Aluminiumblech ohne wesentliche Abkühlung direkt der weiteren Umformung zugeführt wird und dann das Aluminiumblech einer Halbwarmumformung unter der Rekristallisationstemperatur oder einer Warmumformung über der Rekristallisationstemperatur der Aluminiumlegierung unterworfen wird. Auf jeden Fall kann mit einer Vermeidung einer Warmauslagerung ein Verfahren geschaffen werden, mit dem eine vergleichsweise durchgehende Bearbeitung des Aluminiumblechs erfolgen kann. Solche Verfahren werden auch als „In-Line" Verfahren bezeichnet, da bei diesen vom ersten Verfahrensschritt bis zum fertigen Formteil keine erheblichen Lagerzeiten eingehalten werden müssen. Aus diesem Grund kann auch das erfindungsgemäße Verfahren bei der Herstellung eines Formteils mit einer Aluminiumlegierung auf vergleichsweise große Produktionsflächen, die beispielsweise durch eine Lagerung beim Warmauslagern bestehen müssen, verzichtet werden, so dass damit auch eine kostengünstige Herstellung möglich werden kann. Hinzu kann kommen, dass damit ein Ofen für ein Warmauslagern vermeidbar sein kann, wodurch dafür nicht eine erhebliche Anzahl an kaltumgeformten Aluminiumblechen hergestellt werden müssen, so dass durch das erfindungsgemäße Verfahren ein flexibel anpassbarer Produktionsausstoß möglich werden kann. Außerdem wird noch festgehalten, dass ein Aluminiumblech als ein flaches Walzwerkfertigprodukt aus einem Aluminiumwerkstoff bzw. einer Aluminiumlegierung verstanden werden kann.If the heated aluminum sheet is subjected to further shaping before reaching a temperature which the aluminum sheet has during its cold forming, then not only can the time interval between the two forming steps be reduced, so that comparatively short Throughput times can be made possible, but it may also turn out that so that the strength of the molding is not significantly reduced compared to other methods. Namely, the heating can be used advantageously or can certainly be used for the recovery of the microstructure of the aluminum alloy in order to be able to counteract unwanted strain hardening. This is readily possible for a person skilled in the art via the parameters of time and / or temperature level during heating and possibly also over the time of a subsequent cooling. The parameters during heating and thereby not excluded cooling of the aluminum sheet can certainly be chosen or adjusted so that, for example, before cooling the heated and cold-formed aluminum sheet to room temperature, the aluminum sheet can be subjected to further forming. However, this does not rule out that several times a heating and / or cooling of the aluminum sheet is carried out until further forming, it can only be crucial that the heated aluminum sheet before further reaching a temperature which has the aluminum sheet during its cold forming is subjected. According to the invention, a method can now be provided which can combine the advantages of a short throughput time on the one side, which are contrary to the prior art, with a comparatively high degree of deformation and a comparatively high strength on the other side. It is further conceivable to increase the degree of deformation that the cold-formed and further heated in a further step aluminum sheet is fed directly to further forming without substantial cooling and then the aluminum sheet is subjected to a warm forging below the recrystallization or hot deformation above the recrystallization temperature of the aluminum alloy. In any case, a method can be created with the avoidance of thermal aging, with which a comparatively continuous processing of the aluminum sheet can take place. Such processes are also referred to as "in-line" processes, since in these, from the first process step to the finished molded part, no significant storage times have to be maintained Reason may also be the inventive method in the production of a molded part with an aluminum alloy on relatively large production areas, which must exist, for example, by a storage during artificial aging, be dispensed with, so that thus a cost-effective production can be possible. In addition, it may be that an oven for a cold aging can be avoided, which does not require a significant number of cold-formed aluminum sheets must be made so that a flexibly adaptable production output can be possible by the inventive method. It should also be noted that an aluminum sheet can be understood as a flat finished rolling mill made of an aluminum material or aluminum alloy.
Wird das Aluminiumblech durch das Kaltumformen in eine Teilform des Formteils und durch das weitere Umformen in die Endform des Formteils umgeformt, dann können sich erhöhte Umformungsgrade beim Formteil eröffnen, weil das Aluminiumblech durch ein erwärmtes weiteres Umformen erhöhten Belastungen aussetzbar ist. Außerdem bzw. alternativ dazu kann beim Kaltumformen mit einer verminderten Umformung des Aluminiumblechs zu einer Teilform begonnen werden, so dass auch mit einer verminderten Gefahr des Entstehens von Kaltverfestigungen gerechnet werden muss. Insbesondere kann der Umformungsgrad beim Kaltumformen derart eingestellt werden, dass das in einem nächsten Schritt durchgeführte Erwärmen und gegebenenfalls das Abkühlen ausreicht, derart Kaltverfestigungen im Gefüge zu vermindern, dass mit keiner wesentlichen Festigkeitsänderung gerechnet werden muss.If the aluminum sheet is formed by the cold forming into a partial shape of the molded part and by the further forming in the final shape of the molded part, then increased deformation of the molded part can open, because the aluminum sheet is exposed to increased stresses by a heated further forming. In addition, or alternatively, can be started during cold forming with a reduced deformation of the aluminum sheet into a part mold, so that even with a reduced risk of the formation of work hardening must be expected. In particular, the degree of deformation during cold forming can be set such that the heating carried out in a next step and, if appropriate, cooling is sufficient to reduce such strain hardening in the microstructure that no substantial change in strength must be expected.
Eine vorteilhafte Erholung des Gefüges nach der Kaltumformung kann sich ergeben, wenn das kaltumgeformte Aluminiumblech unterhalb der Rekristallisationstemperatur der Aluminiumlegierung, insbesondere zwischen 150 und 350 Grad Celsius, erwärmt wird.An advantageous recovery of the structure after the cold forming may result if the cold-formed aluminum sheet is heated below the recrystallization temperature of the aluminum alloy, in particular between 150 and 350 degrees Celsius.
Wird vor dem Kaltumformen das Aluminiumblech mit einem temperaturbeständigen Schmiermittel versehen, dann kann das erfindungsgemäße Verfahren erlauben, vom Aluminiumblech das Schmiermittel erst in einem Schritt nach dem weiteren Umformen zu entfernen. Das aufgetragene Schmiermittel kann so während des Verfahrens am Aluminiumblech verbleiben, weil dessen Zerfall durch eine Vermeidung einer aus dem Stand der Technik bekannten Warmauslagerung vermeidbar ist. Kosten- und zeitintensive Reinigungsschritte sind so vorteilhaft vermindert, weil erst in einem Schritt nach dem weiteren Umformen das Schmiermittel vom Aluminiumblech entfernt wird. Schmiermittel bzw. Schmierstoffe mit einer Temperaturbeständigkeit bis zu 350 Grad Celsius sind aus dem Stand der Technik bekannt.If the aluminum sheet is provided with a temperature-resistant lubricant before the cold forming, then the inventive method allow the lubricant to be removed from the aluminum sheet only in one step after further forming. The applied lubricant can thus remain on the aluminum sheet during the process, because its disintegration can be avoided by avoiding a thermal aging known from the prior art. Costly and time-consuming cleaning steps are reduced so advantageous because only in one step after further forming the lubricant is removed from the aluminum sheet. Lubricants or lubricants with a temperature resistance up to 350 degrees Celsius are known from the prior art.
Vorteilhafte Eigenschaften zur Herstellung des Formteils ergeben sich, wenn das Aluminiumblech durch Tiefziehen wenigstens teilweise umgeformt wird. Ebenso kann dadurch eine Kombination an Tiefziehen und Streckziehen zum Umformen des Aluminiumblechs angewandt werden.Advantageous properties for the production of the molded part result when the aluminum sheet is at least partially reshaped by deep drawing. Likewise, this can be applied to a combination of deep drawing and ironing to reshape the aluminum sheet.
Wird das Aluminiumblech beim weiteren Umformen in ein Umformwerkzeug eingebracht, dann können vorteilhafte Verfahrensbedingungen zur Herstellung des Formteils geschaffen werden. Außerdem kann möglich werden, dass das bereits beim Kaltumformen benutze Umformwerkzeug nochmals verwendet wird, was Kosten sparen kann. Ist das Umformwerkzeug erwärmt, dann kann ein eventuelles Abkühlen des Aluminiumblechs vermindert werden.If the aluminum sheet is introduced during further forming in a forming tool, then advantageous process conditions for the production of the molded part can be created. It may also be possible to reuse the forming tool already used in cold forming, which may save costs. If the forming tool is heated, then a possible cooling of the aluminum sheet can be reduced.
Wird das kaltumgeformte Aluminiumblech vor und/oder nach dem weiteren Umformen zumindest teilweise beschnitten, dann kann eine besondere Genauigkeit des damit geschaffenen Formteils ermöglicht werden.If the cold-formed aluminum sheet is at least partially trimmed before and / or after further forming, then a special accuracy of the molded part thus created can be made possible.
Kurze Beschreibung der ZeichnungShort description of the drawing
In den Figuren ist beispielsweise ein Ablaufbeispiel des Verfahrens gemäß dem Erfindungsgegenstand dargestellt. Es zeigenIn the figures, for example, a flow example of the method according to the subject invention is shown. Show it
Fig. 1 ein Besprühen eines Aluminiumblechs mit Schmiermittel, Fig. 2 einen Schritt des Kaltumformens des Aluminiumblechs mit einem Umformwerkzeug,1 a spraying of an aluminum sheet with lubricant, 2 shows a step of cold forming the aluminum sheet with a forming tool,
Fig. 3 ein Beschneiden des kaltumgeformten Aluminiumblechs mit einem weiteren Werkzeug,3 shows a trimming of the cold-formed aluminum sheet with another tool,
Fig. 4a und 4b alternative Möglichkeiten zum Erwärmen des kaltumgeformten Aluminiumblechs,4a and 4b alternative ways of heating the cold-formed aluminum sheet,
Fig. 5 ein weiteres Umformen des erwärmten Aluminiumblechs in einem Umformwerkzeug,5 shows a further forming of the heated aluminum sheet in a forming tool,
Fig. 6 ein abschließendes Endbeschneiden des Aluminiumblechs mit einem Werkzeug undFig. 6 is a final final cutting of the aluminum sheet with a tool and
Fig. 7 das durch das Verfahren hergestellte Formteil.Fig. 7, the molded part produced by the method.
Weg zur Ausführung der ErfindungWay to carry out the invention
Gemäß den Figuren 1 bis 6 wird beispielsweise das erfindungsgemäße Verfahren zur Herstellung eines Formteils 1 nach Fig. 7 näher beschrieben. So ist gemäß Fig. 1 zu erkennen, dass ein Aluminiumblech 2, das eine Aluminiumlegierung, beispielsweise der 5000, 6000 oder 7000 Reihe, aufweist, nach Fig. 2 einer Formveränderung insbesondere Umformung unterworfen wird. Insbesondere die 5000 Reihe hat sich als bevorzugt herausgestellt, da diese Legierung vergleichsweise fest, umformbar und leichter weiter verarbeitbar ist. Das Aluminiumblech 2 wird zum Zweck der Umformung in das Umformwerkzeug 3 eingebracht und wird in diesem bei Raumtemperatur kaltumgeformt, insbesondere tiefgezogen. Danach wird das kaltumgeformte Aluminiumblech 2 dem Umformwerkzeug 3 entnommen und über einen gemäß Fig. 4a schematisch dargestellten Gasbrenner 4 erwärmt. Andere Arten zum Erwärmen des Aluminiumblechs 2 sind vorstellbar und einem Fachmann geläufig, beispielsweise kann dies über Waffeleisen, Infrarot, Laser, Induktion, Ultraschall und/oder auch über konduktive Verfahren erfolgen. Im Allgemeinen kann damit das kaltumgeformte Aluminiumblech 2 gesamt oder auch teilweise erwärmt werden, im letzteren Fall kann dies im oder im umliegenden Bereich der durch das Umformen am meisten beanspruchten Bereiche des Aluminiumblechs 2 liegen. Tem- peraturen in der Höhe von 150 bis 350 Grad Celsius sind vorstellbar, das Erwärmen soll jedoch unterhalb der Rekristallisationstemperatur der Aluminiumlegierung liegen. In einem weiteren Schritt nach Fig. 5 wird nun das Aluminiumblech 2 einer weiteren Umformung mit einem Umformwerkzeug 5 unterworfen, wobei dieses Umformwerkzeug 5 auch gegebenenfalls das Umformwerkzeug 3 nach Fig. 2 darstellen kann. Auch hier wird das Aluminiumblech 2 mit Hilfe des Umformwerkzeugs 5 tiefgezogen. Um besondere Voraussetzungen bei der Herstellung des Formteils 1 zu schaffen, weist das Aluminiumblech 2 bei dieser weiteren Umformung nach Fig. 5 zumindest teilweise eine gegenüber der Temperatur bei der Kaltumformung erhöhte Temperatur auf. Dies kann dadurch erreicht werden, dass noch vor einem Abkühlen des erwärmten kaltumgeformten Aluminiumblechs 2 auf seine Temperatur bei der Kaltumformung nach Fig. 2 das Aluminiumblech 2 der weiteren Umformung nach Fig. 5 unterworfen wird. Es kann daher ein "In-Line" Verfahren in der Fertigung geschaffen werden, weil das aus dem Stand der Technik bekannte Warmauslagern das erfindungsgemäße Verfahren nicht unterbrechen kann. Sohin kann schneller auf Kundenanforderungen in der Stückzahl reagiert werden, was unter anderem auch eine aufwendige Lagerhalterung vermeiden kann. Hinzu kommt, dass das erfindungsgemäße Verfahren auch ermöglicht, eine Vorrichtung mit einem verminderten Platzbedarf zur Verfügung zu stellen, weil beispielsweise der vergleichsweise große Platzbedarf beim Warmauslagern vermieden werden kann.According to FIGS. 1 to 6, for example, the method according to the invention for producing a molded part 1 according to FIG. 7 is described in greater detail. Thus, it can be seen from FIG. 1 that an aluminum sheet 2 comprising an aluminum alloy, for example the 5000, 6000 or 7000 series, according to FIG. 2 is subjected to a change in shape, in particular forming. In particular, the 5000 series has been found to be preferred, since this alloy is relatively strong, deformable and easier to process further. The aluminum sheet 2 is introduced for the purpose of forming in the forming tool 3 and is cold-formed therein at room temperature, in particular deep-drawn. Thereafter, the cold-formed aluminum sheet 2 is removed from the forming tool 3 and heated via a gas burner 4 shown schematically in FIG. 4a. Other ways of heating the aluminum sheet 2 are conceivable and familiar to a person skilled in the art, for example, this can be done via waffle irons, infrared, laser, induction, ultrasound and / or via conductive methods. In general, the cold-formed aluminum sheet 2 can thus be heated in whole or in part, in the latter case this can be in or in the surrounding area of the areas of the aluminum sheet 2 which are the most stressed by the forming. temperature- temperatures in the range of 150 to 350 degrees Celsius are conceivable, but the heating should be below the recrystallization temperature of the aluminum alloy. In a further step according to FIG. 5, the aluminum sheet 2 is then subjected to further forming by means of a forming tool 5, wherein this forming tool 5 can optionally also constitute the forming tool 3 according to FIG. 2. Again, the aluminum sheet 2 is deep-drawn by means of the forming tool 5. In order to create special conditions in the production of the molded part 1, the aluminum sheet 2 in this further deformation according to FIG. 5 at least partially has a temperature which is increased in relation to the temperature during cold forming. This can be achieved by subjecting the aluminum sheet 2 to the further transformation according to FIG. 5 before cooling the heated cold-formed aluminum sheet 2 to its temperature during the cold forming according to FIG. 2. It can therefore be created an "in-line" process in manufacturing, because the well-known from the prior art artificial aging can not interrupt the inventive method. So can react faster to customer requirements in the number of units, which among other things, a complex storage support can avoid. In addition, the method according to the invention also makes it possible to provide a device with a reduced space requirement, because, for example, the comparatively large space requirement for hot aging can be avoided.
Um den Grad der Kaltverfestigungen beim ersten Umformen des Aluminiumblechs 2 nach Fig. 2 zu vermindern, wird das Aluminiumblech 2 beim Kaltumformen zunächst in eine Teilform 6 des Formteils 1 gebracht. Anschließend wird dann durch das weitere Umformen nach Fig. 5 das Aluminiumblech 2 bzw. die Teilform 6 in die Endform 7 des Formteils 1 gebracht. Die nach Fig. 2 und Fig. 5 verschiedene Umformung kann beispielsweise an den in der Höhe unterschiedlichen linken Teilen der Formwerkzeuge 3 und 5 erkannt werden. Sohin kann den Figuren 2 und 4 entnommen werden, dass das Aluminiumblech 2 beim weiteren Umformen gegenüber dem Kaltumformen erhöht umgeformt wird, um so verminderte Kaltverfestigungen beim Kaltumformen zu erhalten. Der Umformgrad bei den beiden Schritten zur Umformung kann jedoch auch umgekehrt oder gleich sein, was nicht näher dargestellt worden ist.In order to reduce the degree of work hardening during the first forming of the aluminum sheet 2 according to FIG. 2, the aluminum sheet 2 is first brought into a partial mold 6 of the molded part 1 during cold forming. Subsequently, the aluminum sheet 2 or the partial mold 6 is brought into the final shape 7 of the molded part 1 by the further forming of FIG. 5. The different deformation according to FIGS. 2 and 5 can be recognized, for example, at the height-different left parts of the molds 3 and 5. Thus, it can be seen from FIGS. 2 and 4 that the aluminum sheet 2, when further deformed, is raised in relation to cold forming so as to obtain reduced work hardening during cold working. However, the degree of deformation in the two steps for forming can also be reversed or the same, which has not been shown in detail.
Vor dem Kaltumformen des Aluminiumblechs 2 wird dieses mit einem temperaturbeständigen Schmiermittel 8 versehen. Zu dieser Darstellung des Verfahrensschritts ist in Fig. 1 eine Sprühdüse 9 dargestellt, über die das Schmiermittel 8 auf das Aluminiumblech 2 aufgebracht werden kann. Da das erfindungsgemäße Verfahren lange Verfahrensschritte, wie diese beispielsweise ein Warmauslagern bedingt, vermeiden kann, und im Gegensatz dazu in vergleichsweise kurzen Zeitabständen das Aluminiumblech 2 zu einem Formteil 1 geformt wird, kann das Schmiermittel 8 unter der Voraussetzung einer Temperaturbeständigkeit bis zum letzten Verfahrensschritt auf dem Aluminiumblech 2 bleiben, ohne dass eine Zersetzung des Schmiermittels 8 befürchtet werden muss. Aufwendige Reinigungsprozesse oder auch ein mehrmaliges Auftragen von Schmiermittel 8 kann so vermieden werden. Im Gegensatz zum Stand der Technik ist sohin vorstellbar, dass Schmiermittel 8 vom Aluminiumblech 2 erst in einem Schritt nach dem weiteren Umformen nach Fig. 5 zu entfernen, was beispielsweise im Schritt nach Fig. 7 erfolgen kann.Before the cold forming of the aluminum sheet 2, this is provided with a temperature-resistant lubricant 8. For this illustration of the method step, a spray nozzle 9 is shown in Fig. 1, via which the lubricant 8 can be applied to the aluminum sheet 2. Since the method according to the invention can avoid long process steps, such as those caused by artificial aging, and in contrast to the aluminum sheet 2 is formed into a molded part 1 in comparatively short time intervals, the lubricant 8 can on the assumption of a temperature resistance to the last step on the Aluminum sheet 2 remain without a decomposition of the lubricant 8 must be feared. Elaborate cleaning processes or a repeated application of lubricant 8 can be avoided. In contrast to the prior art is thus conceivable that lubricant 8 from the aluminum sheet 2 to remove only in one step after further forming of FIG. 5, which can be done for example in the step of FIG.
Eine besonders gleichmäßige und/oder positionsgenaue Erwärmung des kaltumgeformten Aluminiumblechs 2 kann erfolgen, wenn dieses in der Form des Aluminiumblechs 2 zumindest teilweise folgende Gegenformen 10, 11 eines Heizwerkzeugs 12 eingebracht wird, welches Heizwerkzeug 12 in Fig. 4b dargestellt ist. Entlang der Kontur der Gegenformen 10, 11 sind an den Stellen der gewünschten Erwärmung Heizmittel 13 vorgesehen.A particularly uniform and / or positionally accurate heating of the cold-formed aluminum sheet 2 can take place if this in the form of aluminum sheet 2 at least partially following counter-forms 10, 11 of a heating tool 12 is introduced, which heating tool 12 is shown in Fig. 4b. Along the contour of the countershapes 10, 11 heating means 13 are provided at the locations of the desired heating.
Nach dem Kaltumformen nach Fig. 2 wird das kaltumgeformte Aluminiumblech 2 in ein Werkzeug 14 eingebracht, um dieses zumindest auf Teilmaß beschneiden zu können. Dieses Werkzeug 14 kann bereits mit Mitteln zum Erwärmen des kaltumgeformten Aluminiumblechs 2 versehen sein, was jedoch nicht näher dargestellt worden ist. Damit könnte jedoch der Verfahrensschritt nach Fig. 4a oder 4b vermieden werden.After the cold forming according to FIG. 2, the cold-formed aluminum sheet 2 is introduced into a tool 14 in order to be able to cut it at least partially. This tool 14 may already be provided with means for heating the cold-formed aluminum sheet 2, which however has not been shown in detail. However, this could avoid the method step according to FIG. 4a or 4b.
Nach dem weiteren Umformen nach Fig. 5 kann die Endform 7 weiter beschnitten werden, wozu in Fig. 6 dieses in ein Werkzeug 15 eingebracht wird. Dieses Werkzeug 15 kann auch das Werkzeug 14 nach Fig. 3 darstellen. Ebenso kann in diesem Verfahrensschritt nach Fig. 6 oder in weiteren nicht dargestellten Verfahrensschritten die Endform 7 abgekanntet und/oder eventuell auch gelocht werden. After the further forming according to FIG. 5, the final shape 7 can be further trimmed, for which purpose in FIG. 6 it is introduced into a tool 15. This tool 15 may also represent the tool 14 of FIG. 3. Likewise, in this process step according to FIG. 6 or in further process steps, not shown, the final shape 7 can be shortened and / or possibly also perforated.

Claims

P a t e n t a n s p r ü c h e Patent claims
1. Verfahren zur Herstellung eines Formteils (1) aus einem eine Aluminiumlegierung aufweisenden Aluminiumblech (2), insbesondere aus einer Aluminiumlegierung der 5000 Reihe, bei dem wenigstens das Aluminiumblech (2) in ein Umformwerkzeug (3) eingebracht und durch dieses kaltumgeformt wird und in einem weiteren Schritt bzw. in weiteren Schritten das kaltumgeformte Aluminiumblech (2) mindestens einmal zumindest bereichsweise erwärmt sowie wenigstens einmal weiter umgeformt wird, dadurch gekennzeichnet, dass das erwärmte Aluminiumblech (2) noch vor einem Erreichen einer Temperatur, die das Aluminiumblech (2) bei seiner Kaltumformung aufweist, der weiteren Umformung unterworfen wird.Anspruch [en] A process for producing a molded article (1) from an aluminum sheet (2) comprising an aluminum alloy, in particular from an aluminum alloy of the 5000 series, in which at least the aluminum sheet (2) is introduced into a forming tool (3) and cold formed by the latter a further step or in further steps, the cold-formed aluminum sheet (2) at least once at least partially heated and at least once further formed, characterized in that the heated aluminum sheet (2) before reaching a temperature, the aluminum sheet (2) at its cold forming, which is subjected to further forming.
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass das Aluminiumblech (2) durch das Kaltumformen in eine Teilform (6) des Formteils (1 ) und durch das weitere Umformen in die Endform (7) des Formteils (1) umgeformt wird.2. The method according to claim 1, characterized in that the aluminum sheet (2) by the cold forming into a part mold (6) of the molded part (1) and by further forming in the final shape (7) of the molded part (1) is formed.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das kaltumgeformte Aluminiumblech (2) unterhalb der Rekristallisationstemperatur der Aluminiumlegierung, insbesondere zwischen 150 und 350 Grad Celsius, erwärmt wird.3. The method according to claim 1 or 2, characterized in that the cold-formed aluminum sheet (2) below the recrystallization temperature of the aluminum alloy, in particular between 150 and 350 degrees Celsius, is heated.
4. Verfahren nach Anspruch 1 , 2 oder 3, dadurch gekennzeichnet, dass vor dem Kaltumformen das Aluminiumblech (2) mit einem temperaturbeständigen Schmiermittel (8) versehen wird, wobei erst in einem Schritt nach dem weiteren Umformen das Schmiermittel (8) vom Aluminiumblech (2) entfernt wird. 4. The method of claim 1, 2 or 3, characterized in that prior to cold forming the aluminum sheet (2) is provided with a temperature-resistant lubricant (8), wherein only in one step after further forming the lubricant (8) from the aluminum sheet ( 2) is removed.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass das Aluminiumblech (2) beim weiteren Umformen in ein, insbesondere erwärmtes Umformwerkzeug (5) eingebracht wird.5. The method according to any one of claims 1 to 4, characterized in that the aluminum sheet (2) during further forming in a, in particular heated forming tool (5) is introduced.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass das Aluminiumblech (2) durch Tiefziehen wenigstens teilweise umgeformt wird.6. The method according to any one of claims 1 to 5, characterized in that the aluminum sheet (2) is formed by deep drawing at least partially.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass zum Erwärmen des kaltumgeformten Aluminiumblechs (2) dieses in eine der Form des Aluminiumblechs zumindest teilweise folgende Gegenform (10, 11) eines Heizwerkzeugs (12) eingebracht wird.7. The method according to any one of claims 1 to 6, characterized in that for heating the cold-formed aluminum sheet (2) of this in one of the shape of the aluminum sheet at least partially following counter-mold (10, 11) of a heating tool (12) is introduced.
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das kaltumgeformte Aluminiumblech (2) vor und/oder nach dem weiteren Umformen zumindest teilweise beschnitten wird. 8. The method according to any one of claims 1 to 7, characterized in that the cold-formed aluminum sheet (2) is trimmed before and / or after further forming at least partially.
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