CN108528531B - 汽车结构部件及其制造方法 - Google Patents
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Abstract
一种汽车结构部件,包括网格结构。该网格结构限定多个单元。该多个单元包括大量至少部分填充的单元以及大量中空单元,每个至少部分填充的单元填充有填充物,中空单元分布在大量至少部分填充的单元之间,用于分配和定向负载。
Description
技术领域
本发明涉及汽车结构部件,更具体地涉及增材制造的汽车结构部件及其制造方法。
背景技术
汽车结构部件用于支撑车辆的各种元件,这些元件包括动力传动系、油箱、悬架、底盘主体、驾驶室以及其他元件。这些部件可以被设计为动态地承受由车辆在各种地形上运动而产生的各种力,并且在某些情况下为车辆的驾驶员提供一定的保护。通常,结构支撑力度越大,重量越大。此外,各种结构部件的设计定向和配置可能受到现有制造技术的限制。因此,我们希望提供与制造汽车结构部件相关的改进和设计方案。
发明内容
在本发明的一个示例性非限制性实施例中,汽车结构部件包括网格结构。该网格结构限定多个单元。该多个单元包括大量至少部分填充的单元以及大量中空单元,每个至少部分填充的单元填充有填充物,中空单元分布在大量至少部分填充的单元之间,用于分配和定向负载。
另外地,在前述实施例中,该大量中空单元是开放单元。
替代地或另外地,在前述实施例中,该网格结构和填充物是增材层制造的。
替代地或另外地,在前述实施例中,至少该网格结构是增材制造的。
替代地或另外地,在前述实施例中,该网格结构是金属的。
替代地或另外地,在前述实施例中,该网格结构和填充物是一个均质件。
替代地或另外地,在前述实施例中,该多个单元具有相同的尺寸。
替代地或另外地,在前述实施例中,该汽车结构部件包括包围网格结构的增材制造外蒙皮。
替代地或另外地,在前述实施例中,该网格结构、填充物和外蒙皮是一个整体件。
替代地或另外地,在前述实施例中,该大量至少部分填充的单元形成至少一个第一行,大量中空单元形成至少一个第二行,该至少一个第二行与该至少一个第一行相邻设置。
替代地或另外地,在前述实施例中,该至少一个第一行是V形的。
替代地或另外地,在前述实施例中,该至少一个第二行是V形的。
替代地或另外地,在前述实施例中,网格结构包括多个叠放的薄片,每个薄片包括多个单元。
在本发明的另一个非限制性实施例中,车架包括第一部件、第二部件和增材制造部件。该增材制造部件在第一部件与第二部件之间延伸,并与第一和第二部件啮合。该增材制造部件包括限定多个单元的网格结构。该多个单元包括大量至少部分填充的单元以及大量中空单元,中空单元分布在大量至少部分填充的单元之间,用于分配和定向负载。
另外地,在前述实施例中,该第一部件包括正面防撞护栏。
替代地或另外地,在前述实施例中,该第二部件包括架梁。
在本发明的另一个非限制性实施例中,一种形成汽车结构部件的方法包括增材制造网格结构的步骤。该网格结构限定具有大量至少部分填充的单元的多个单元以及大量空心单元。该大量空心单元分布在多个至少部分填充的单元中,用于分配和定向负载。
另外地,在前述实施例中,该方法包括在增材制造网格结构的同时,增材制造填充物,该填充物设置在大量至少部分填充的单元中的每一个中。
替代地或另外地,在前述实施例中,该增材制造是增材层制造。
替代地或另外地,在前述实施例中,该方法包括排空大量中空单元中未使用的粉末,该中空单元是开放单元。
从以下结合附图的详细描述中,本发明的以上特征和优点以及其他特征和优点将变得显而易见。
附图说明
仅通过示例的方式,在以下实施例的详细描述中呈现了其他特征、优点和细节,详细描述是参考附图进行的,附图中:
图1是作为本发明的一个非限制性示例性实施例的车架的局部透视图;
图2是示出了汽车结构部件并沿图1的线2-2截取的车架的横截面图;
图3是根据图2的圈3截取的汽车结构部件的网格结构的局部透视图;
图4是用于至少制造车架的汽车结构部件的网格结构的增材制造系统的示意图;
图5是沿图3的线5-5截取的汽车结构部件的网格结构的横截面图;
图6是网格结构的第二实施例的顶剖面的平面图;以及
图7是图6的网格结构的透视图,示出了多个剖面。
具体实施方式
以下描述本质上仅是示例性的,并不旨在限制本发明及其应用或用途。应当理解的是,在整个附图中,相同的附图标记表示相同或相应的零件和特征。
根据本发明的一个示例性实施例,图1示出了例如车架20的一部分,车架20可以包括三个部件22、24和26。部件22可以在部件24、26之间延伸,并且可以与部件24、26啮合。在一个实施例中,部件22可以是汽车结构部件;部件26可以是副车架、车架附件或其他结构部件;并且部件24可以是护栏(例如正面防撞护栏)、副车架、车架附件或其他结构部件。在一个实施例中,结构部件22可以在正面防撞护栏24与车架附件26之间延伸,并与它们啮合。
在一个实施例中,部件或车架附件26可以是横梁、纵梁和/或摇杆面板。部件或正面防撞护栏24可以是前保险杠或前保险杠支架,汽车结构部件22可以是部件24、26之间的连接件。部件24、26可以由任何类型的结构材料制成,包括塑料、铝、钢和其他金属合金。此外,部件24、26可以通过传统方式制造(即,非增材制造方式),可以通过模制、机械加工和/或冲压方式制造。汽车结构部件22可以是增材制造的,由足以提供所需结构完整性的各种材料制作。在一个实施例中,汽车结构部件22可以直接增材制造到部件24、26中的一个或两个上。在另一个实施例中,汽车结构部件22可以与部件24、26分开进行增材制造,然后通过包括紧固件紧固、焊接、粘合等各种方式啮合到部件24、26上。
参照图2,汽车结构部件22可以包括网格结构28和外蒙皮或外壳30。网格结构28通常可以位于外壳30内部。在一个实施例中,网格结构28可以在外壳30的内表面32之间延伸并与内表面32啮合,外壳30的外表面34可以与部件24、26直接接触。网格结构28可以由与外壳30相同的材料制成,可以与外壳30一起形成一个整体均质件。在另一个实施例中,外壳30可以与网格结构28分开形成或制造,随后网格结构28插入外壳30内部。
参照图2和图3,汽车结构部件22的网格结构28可以限定多个单元33的边界。每个单元33通常可以具有相同的形状,可以具有重复定向或配置。该多个单元33可以包括大量中空单元36以及大量至少部分填充的单元38。在一个实施例中,每个至少部分填充的单元38可以填充有填充物40。在另一个实施例中,网格结构28的一段可以包括通常包围并限定相应单元38的壁,单元38可以包含衬在四周壁上的材料,有效地增加这段网格结构28的壁厚。衬在壁上的材料可以由与网格结构28相同的材料制成。
在一个实施例中,网格结构28和填充物40(或壁厚增加的壁)可以通过增材制造制成或形成为一个整体匀质件。另外地,填充物40可以由与网格结构28不同的材料制成,和/或可以是疏松粉体、液体或固体形式,其可以直接啮合或形成到四周的网格结构28上。虽然所示的每个单元33是菱形的,并且由网格结构28的四个侧面限定,但应当理解的是,每个单元33可以是任何形状的。例如,重复单元33可以是三角形、正方形、六边形或任何其他形状。
中空单元36和至少部分填充的单元38可以设置为特定图案,用于分配和/或重新定向施加在部件22上的力。例如,中空单元36和至少部分填充的单元38可以形成互换行42、44,该互换行可以是V形的,如图2所示。中空单元36和至少部分填充的单元38的设置可以进一步促进和/或控制部件22和/或相邻部件24、26在一般预定方向上的塑性变形(即,预定碰撞路径),这个方向可能与所施加的力的方向不同。可以设想并理解的是,多个单元33可以是开放单元或闭合单元,可以取决于所应用的增材制造工艺的类型。还可以设想的是,网格结构28可以包括叠放的单元33薄片段或层。在这种三维定向中,一层至少部分填充的单元38的V形形状通常可以,例如,形成三维锥形形状或任何其他形状。
参照图3并且在一个实施例中,网格结构28可以包括细长的多个第一壁(即,如图46A、46B和46C所示的三个)以及多个第二相交壁(即,如图48A、48B和48C所示的三个)。第一壁46A、46B和46C可以基本上彼此平行,第二相交壁48A、48B和48C可以基本上彼此平行,每个壁48A、48B和48C都与多个第一壁46A、46B和46C相交。每个第一壁46A、46B和46C都可以包括相对的面50、52,每个相交壁48A、48B和48C都可以包括相对的面54、56。在一个实施例中,多个单元33中的中空单元36可以由相应的相邻壁46A、46B的相对面52、50以及相应的相邻相交壁48A、48B的相对面56、54限定。中空单元36通常可以由四个相邻单元33(即,中空单元36和/或至少部分填充的单元38)包围,并且通过其中一个壁分隔开。例如,多个单元33中的填充单元38可以与中空单元36相邻,并且通过壁46B与中空单元36分隔开。多个单元33中的填充单元38可以由相应的相邻壁46B、46C的相对面52、50以及相应的相邻相交壁48A、48B的相对面56、54限定。
参照图4,汽车结构部件22可以在增材制造系统60中形成为制造产品或工件。增材制造系统60可以是增材层制造(ALM)装置(即,粉末床熔合)。ALM装置类型的示例可以包括直接金属激光烧结(DMLS)、选择性激光熔化(SLM)、激光束熔化(LBM)、电子束熔化(EBM)等。ALM装置可以通过工件的由成形逐层构建促进复合金属、聚合物、陶瓷和复合结构的制造。如增材制造领域的技术人员通常所知的那样,增材制造工艺背后的原理涉及使用定向能量源对雾化前体粉末床进行选择性熔化,该定向能量源可以形成工件的光刻构建。粉末的熔融可能发生在能量束的较小局部区域中,产生小体积的熔融,被称为熔池,其后通常进行快速固化,从而在工件的逐层制造过程中非常精确地控制固化过程。ALM装置可以通过计算机辅助设计(CAD)软件系统中的三维几何实体模型进行定向。还可以设想并理解的是,可以利用其他增材制造工艺来形成汽车结构部件22。其他工艺的示例可以包括VAT光聚合、材料喷射、粘合剂喷吹、材料挤出成型(即,熔融沉积建模)、利用超声焊接的片材层压,定向能量沉积等。
在一个实施例中,ALM装置或系统作为能够制造汽车结构部件22的增材制造系统的一个示例,如图1示意性示出。ALM装置60可以包括构建台62、颗粒分布器或刮器66、能量枪70、粉末供应料斗72以及剩余粉末料斗74,构建台62用于容纳粉末床64,颗粒分布器或刮器66用于将粉末床64分布到构建台62上(见箭头68),能量枪70用于选择性地熔化粉末床64的连续层84的区域,粉末供应料斗72用于向分布器66提供粉末。ALM装置60可以被构造为以逐层方式构建汽车结构部件22或其任何部分。粉末床64可以由与增材制造的部件或工件相同的材料组合物构成。
参照图4和图5,ALM装置60可以包括控制器或计算机78,其包含软件,用于根据汽车结构部件22的输入三维计算机辅助设计(CAD)模型输入数据并对自动化功能进行编程。该模型可以包括将部件22分解为多个薄片80,这些薄片沿垂直或Z坐标方向(参见图4中的箭头82)彼此附加构建在另一个的顶部。每个固化的薄片80在固化之前对应于粉末床64的各个层84,并且每个层84放置在先前固化的薄片80的构建表面86的顶部上。
控制器78通常可以通过向各种设备元件发送一系列电气和/或数字信号88来操作整个ALM装置60。例如,控制器78可以向供应料斗72的机械活塞90发送信号88,以便向上推送供料粉末92(见箭头94),并由分布器66接收。分布器66可以是刮器、辊筒或其他装置,以预定厚度将供料粉末92推送(见箭头68)或者放置在工件的构建表面86上,该预定厚度通过构建台62在控制器78控制下向下运动(见箭头82)而形成。任何多余的粉末96可以由分布器66推送入剩余料斗74中。
一旦在构建表面86上形成基本上水平的粉末层84,则控制器78可以向能量枪70发送信号88,以便发射激光或电子束(见箭头100)。电子束100可以通过定向机构98操纵或定向,该定向机构98通常可以位于能量枪70的输出处。定向机构98可以包括聚焦透镜,其使能量枪70发出的光束100聚集起来。然后,机构98的电磁扫描器或旋转镜子可以可控地定向能量束100。
受控能量束100撞击在粉末床64的顶层84的选定区域上。能量束100可以沿层84移动,以受控的速率和功率使该层的各个区域逐个熔化,从而将每个区域熔化成池。然后熔融池可以固化,最终形成薄片80。然后,当另一粉末层84铺在最后形成的固化薄片80上时,可以重复这个过程,能量枪70使该层的至少一部分与先前固化的薄片80的回熔区一起熔化,形成汽车结构部件22。
如前所述,网格结构28的多个中空单元36可以是开放单元。由于单元36是开放的,所以在ALM的各个阶段或在制造之后,可以从每个中空单元排空留在单元中的未使用或未熔化粉末。
参照图6和图7,示出了结构部件的第二实施例,其中除了添加主要符号后缀之外,与第一实施例相同的元件具有相同的附图标记。网格结构28'可以用叠放在彼此顶部上的多个薄片80'(即,薄片或分层部分)增材制造为一个均质件。如图所示,网格结构28'的每个薄片80'通常可以沿x-y坐标平面平放,可以在z坐标方向上叠放。每个薄片80'可以包括多个单元33',其通常可以是,例如,六边形形状。由每个薄片80'限定的每个多个单元33'可以包括多个中空单元36'以及多个至少部分填充的单元38'。每个薄片80'中的单元36'、38'可以形成致密图案102。一个薄片80'中的致密图案102可以与相邻薄片中的致密图案不同。在多个薄片之间结合在一起的致密图案102可以形成三维致密图案。
在本示例中,图6和7所示的部分填充的单元38'是包含一层材料的单元,该材料粘附到或均匀地形成到网格结构28'的相邻限定壁上,该网格结构28'限定单元38'。还可以设想并理解的是,每个单元38'可以填充有与网格结构28'不同的材料。另外地,每个单元38'可以完全填充有与网格结构28'相同的材料,但还可以具有与网格结构密度不同的均匀密度。
本发明的优点和益处包括多单元汽车结构部件,其能够在撞击负载、外部施加力和/或服务负载的情况下限定可调碰撞路径。另一个优点是利用增材制造工艺设计和实现复杂蜂窝结构的能力。
虽然以上参照示例性实施例描述了本发明,但是本领域技术人员将会理解的是,在不脱离本发明范围的情况下,可以进行各种修改并且可以用等同物替换其元件。此外,在不脱离本发明实质范围的情况下,可以进行各种修改,使特定情况或材料也适用于本发明的教导。因此,本发明并非局限于所公开的特定实施例,而是将包括落入其范围内的所有实施例。
Claims (8)
1.一种汽车结构部件,包括:
限定多个单元的网格结构,所述多个单元具有大量至少部分填充的单元以及大量中空单元,每个至少部分填充的单元填充有填充物,所述中空单元分布在所述大量至少部分填充的单元之间,用于分配和定向负载,其中所述大量至少部分填充的单元形成至少一个第一行,所述大量中空单元形成至少一个第二行,所述至少一个第二行与所述至少一个第一行相邻设置,其中所述至少一个第一行是V形的,所述至少一个第二行是V形的。
2.如权利要求1所述的汽车结构部件,其中所述大量中空单元是开放单元。
3.如权利要求1所述的汽车结构部件,其中至少所述网格结构是增材制造的。
4.如权利要求3所述的汽车结构部件,其中所述网格结构是金属的。
5.如权利要求4所述的汽车结构部件,其中所述网格结构和所述填充物是一个均质件。
6.如权利要求1所述的汽车结构部件,其中所述多个单元具有相同的尺寸。
7.如权利要求3所述的汽车结构部件,还包括:
包围所述网格结构的增材制造外蒙皮。
8.如权利要求7所述的汽车结构部件,其中所述网格结构、所述填充物和所述外蒙皮是一个整体件。
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2017
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2018
- 2018-02-28 CN CN201810167086.5A patent/CN108528531B/zh active Active
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CN108528531A (zh) | 2018-09-14 |
DE102018104723B4 (de) | 2022-05-19 |
DE102018104723A1 (de) | 2018-09-06 |
US10343725B2 (en) | 2019-07-09 |
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