DE102009031981A1 - Method for producing vehicle component in form of torsion profile from blank, involves providing blank with longitudinally aligned U-shaped trough at distance from its front end in production stage - Google Patents

Abstract

The method involves providing a blank with a longitudinally aligned U-shaped trough (11) at a distance from its front end in a production stage. The shanks of the deformed blanks are bent parallel to each other, where the deformed blanks are tubular at the adjacent areas. The blanks are deformed in U-shape in a longitudinal section (3).

Description

The The invention relates to a method for producing a motor vehicle component in the form of a Torsionsprofils from a board according to the Features in the preamble of claim 1.

Such a procedure counts to the extent of DE 10 2007 061 198 B3 to the state of the art. Here, a rectangular board by means of rolling either from a narrow side or from a longitudinal side starting deformed so that different thickness ranges arise. Subsequently, the thus contoured board is bent to the slot tube and then welded along the longitudinal edges. The welded tube is thereafter deformed with a U-shaped blade so that torsionally rigid cylindrical end portions, a torsionally soft U-shaped central longitudinal section and between the end portions and the central longitudinal section of the cylindrical cross section of the end portions in the U-shaped cross section changing transition sections are formed. Since the embossing of the U-shaped trough in the central longitudinal section takes place on a circumferentially closed tube, the material is subjected to high stress in many areas during the shaping, with the result that various mechanical characteristics of the Torsionsprofils (associated with a forming process strains, ironing and limit shape changes ) can not be determined with the desired precision.

Similar Problems also arise in a method in which the torsion profile directly from a welded or drawn pipe with is made constant wall thickness.

Of the Invention is - starting from the prior art - the Task is based on a method for producing a motor vehicle component in the form of a Torsionsprofils from a metallic board to create, in which the mechanical properties of the torsion profile considering as variable as possible Integration into a torsion beam rear axle can be accurately determined can.

The Solution to this problem according to the invention in the features of claim 1.

advantageous Further developments are subject matter of claims 2 to 11.

One first step of the method according to the invention is that the board in at least one manufacturing stage provided with a longitudinal U-shaped recess becomes. Here, the legs of the board next to the Mulde have the same or a different width. A such stamping of the hollow is associated with the advantage that the position of the joint seam on the closed torsion profile can be kept variable to when joining the longitudinal edges (Welding, soldering, gluing etc.) cheap To ensure production conditions. Depending on the material and material thickness, the trough when embossing directly into their final form will be brought. But also conceivable are two or more successive embossing operations with the aim of that specifically in the curved transition areas from the walls of the hollow to their bottom and to the side Legs next to the trough direct formations are possible. This allows a much improved determination of the mechanical Properties of the torsion profile ultimately produced.

The Board can be contoured rectangular or other contours exhibit. The variation in the design of a torsion profile is thereby considerably increased.

to Production of the trough is used for each work step Upper tool in the form of a forming the inner contour of the trough sword and as an abutment, a lower tool with an outer contour the trough determining sink used.

Now The legs of the deformed board are next to the trough over the entire length of the board is essentially parallel bent over each other and to the trough. In this way, at the later Ears of the torsion profile and in the transitional sections between the trough and the tubular end portions also a direct shaping with the resulting precise adjustment the mechanical properties are achieved.

To are largely U-shaped upper and lower tools used, which are tolerated except for the rounded end regions and the outer contour or the inner contour of the further deformed Determine board.

Subsequently, the bent legs are tubular under contact of their longitudinal edges in the areas adjacent to the front ends of the board and U-shaped in the longitudinal section with the trough. Here, the torsionally rigid tubular end portions, the torsionally soft U-shaped central longitudinal portion and the transition portions between the central longitudinal portion and the end portions are formed. This results in the middle length section except the end ears a double-layered workpiece on which important parameters of the cross-sectional shape, namely the spread angle between the two-ply walls of the trough, the radii of the two-ply back of the workpiece and the shape and size of the ears can be specifically determined. Due to the influence of the cross-sectional shape and the shear center of the later torsion profile can be accurately positioned.

to Production of the longitudinal edges not yet joined torsion profile, the workpiece is then For example, rotated 180 °, so that the trough down and show the thighs up. But it can be another Angle of rotation can be selected according to the final shaping. Now is using a the outer contour of the Torsionsprofils dominant hood-like upper tool and one with a longitudinal Projection into the trough holding counter-holder as a lower tool shaped the torsion profile. Do the thighs have a different one Width, are the touching longitudinal edges the bent leg in an area next to the back of the torsion profile.

To the shaping of the Torsionsprofils be final the longitudinal edges of the deformed legs are joined together, in particular welded. This is preferably done in strained state, the location of the joint seam position in a wide range is freely selectable, since the seam is not is strained by strains due to forming work.

It is beneficial to the front ends of the board adjacent areas in the longitudinal direction of the board S-shaped deform. This S-shaped embossment can be at the still level Board be carried out or at the same time with the Embossing the trough. Furthermore, an S-shaped Embossing after the completion of the trough conceivable. The S-shaped Embossing of the front ends of the board adjacent areas serves as preparation for the formation of the tubular End portions of the Torsionsprofils.

Also for embossing the S-shaped end portions are suitable Upper and lower tools used.

The End portions of the Torsionsprofils can be circular or also be deformed out of round. For example, a non-round imprinting then be made when connecting to the torsion profile Trailing arm of a torsion beam rear axle corresponding Have connection areas. The non-round deformation can already in the course of the last work step before joining the longitudinal edges the deformed leg done.

The Deformation of the front ends of the board adjacent areas can be done over a thorn. This increases the accuracy of the cross section of the end sections the Torsionsprofils with regard to the later connection to the trailing arm of a torsion beam trailing axle.

About that In addition, it is conceivable that the end portions relative to the longitudinal section twisted with the trough about the longitudinal axis of the Torsionsprofils become. Depending on the degree of twist can hereby each best connection to the trailing arm of a torsion beam trailing axle be achieved.

The Quality of the connection of the torsion profile with the trailing arms a torsion beam trailing axle is thereby further improved, that the areas adjacent the front ends of the board conical be widened. It becomes a bigger one in this way Connection cross section achieved with otherwise unchanged profile. Furthermore, modified trim edges are achieved at an unchanged height the back of the torsion profile. This deformation can already during the deformation of lying next to the trough Thighs are performed. For this purpose, a corresponding trained thorn used.

A another embodiment of the invention is seen therein, that the torsion profile in the longitudinal direction wavy is deformed. This type of deformation is also called S-punch profile designated. It serves to shift the center of the shear, the favorable for special space requirements. The middle area the Torsionsprofils is then opposite the tubular End portions offset in the central longitudinal plane of the trough arranged.

The to manufacture the Torsionsprofils provided board can over their entire extent a uniform thickness exhibit. It is also conceivable that the torsion profile of a Board with different wall thicknesses over its length is manufactured. A board with variable wall thicknesses (tailored rolled blank) can be used, if in a Torsionsprofil in the transitions from the middle U-shaped Length section on the transition sections and from the transitional sections to the terminal tubular ones End sections higher strengths are required. Herewith Although there is a slight increase in weight, it does achieved a higher roll stiffness.

The metallic board can be made in particular of steel or light metal, in particular aluminum.

Further It is conceivable that the board made of a hybrid material becomes.

Also the board can be shot peened in advance of forming or in be treated in another suitable way.

The Invention is illustrated below with reference to the drawings Embodiments explained in more detail. Show it:

1 a torsional profile for a torsion beam rear axle in a schematic perspective;

2 on a larger scale a vertical cross section through the representation of 1 seen along the line II-II in the direction of arrows IIa;

3 in schematic perspective, a steel circuit board in two processing positions;

4 in perspective, an upper tool for a 1st step;

5 in perspective, a lower tool for the 1st step;

6 in perspective the board of the 3 after deformation using the tools according to 4 and 5 ;

7 the board of the 3 and 6 together with the upper tool and the lower tool according to 4 and 5 in vertical section;

8th in vertical cross-section another upper tool and another lower tool for a 2nd step according to 4 together with the further deformed board according to the 6 and 7 ;

9 in a schematic perspective, the means of the upper tool and the lower tool of 8th further deformed board;

10 in perspective, an upper tool for a 3rd step;

11 in perspective the board of the 9 ;

12 in perspective a lower tool for the 3rd step;

13 in perspective, with the upper and lower tools of the 10 and 12 deformed board;

14 in perspective, an upper tool for a 4th step;

15 in perspective the board of the 13 in 180 ° twisted position;

16 in the perspective of a lower tool for the 4th step;

17 in perspective, a fully formed torsion profile;

18 in perspective, a torsion profile according to another embodiment;

19 in perspective, a torsion profile according to a third embodiment;

20 in perspective, a torsion profile of a board with partially different wall thicknesses and

21 a vertical cross section through the representation of 1 along the line II-II seen in the direction of arrows IIa, according to another embodiment.

In the 1 and 2 is with 1 a Torsionsprofil as part of an otherwise unspecified illustrated twist beam rear axle of a motor vehicle. The torsion profile 1 has torsionally rigid, circular, tubular end sections 2 , a torsionally soft U-shaped middle section 3 and between the middle length section 3 and the end sections 2 from the U-shaped in the tubular cross-section changing transition sections 4 on. especially the 2 lets recognize that the torsion profile 1 in the middle length sections 3 in the area of the lateral thighs 5 and the arched spine 6 is designed double-layered. The back 6 opposite longitudinal edges 7 are formed ear-shaped.

The torsion profile 1 is made of a rectangular steel circuit board 8th made by the in 3 a half is shown. The other half is mirror-inverted, so that below (with the exception of the 18 ) only this one half is illustrated and also described.

For the production of the torsion profile 1 First, the front ends 9 neighboring areas 10 the board 8th S-shaped deformed. The tools used for this purpose are not shown in detail.

Following this, the thus deformed board 8a between the S-shaped areas 10 with a U-shaped trough 11 whose vertical center longitudinal plane VMLE next to the vertical center longitudinal plane VMLE1 of the formed board 8b runs (see 6 and 7 ). For the production of the hollow 11 will the board 8a according to 3 between one out of the 4 and 7 recognizable upper tool 12 and one out of the 5 and 7 recognizable lower tool 13 placed. The upper tool 12 determined with a bead 16 the inner contour of the trough 11 while the lower tool 13 with a gutter 17 serves as an abutment and determines the outer contour. Also the upper tool of the 4 can with side wings 46 be provided as they are from the 5 come out to the circuit board 8a to deform properly. After the collapse of upper tool 12 and lower tool 13 has the board 8b the from the 6 recognizable contour with legs of different widths 14 and 15 ,

For better shaping of the torsion profile 1 In a further step, the board becomes 8b of the 6 and 7 by means of an upper tool 18 and a lower tool 19 (movable against each other) with regard to the trough 11 purposefully deformed further ( 8th ), that to the differently wide thighs 14 . 15 adjacent wall sections 20 the hollow 11 largely parallel to each other. This is the upper tool 18 with a correspondingly formed bead 21 and the lower tool 19 with a the outer contour of the trough 11 determining gutter 22 Mistake. The with this step further deformed board 8c is also from the 9 and 11 recognizable.

In a subsequent step, using one of the 10 apparent upper tool 23 and one from the 12 recognizable lower tool 24 the legs of different widths 14 . 15 the board 8c next to the hollow 11 essentially parallel to each other and to the trough 11 bent. The upper tool has this 23 between two diagonally placed legs 25 . 26 a bead 27 that extends between terminal U-shaped areas 28 extends. The lower tool 24 as an abutment points next to a receiving channel 29 two support legs 30 on. The outer contour of the trough 11 determining receptacle 29 goes to the end in U-shaped support areas 31 above. The extent deformed board 8d is from the 13 and 15 seen. It points out the S-shaped areas 10 deformed U-shaped ends 32 on.

This deformed board 8d according to the 13 and 15 is then using an upper tool 33 according to 14 and a lower tool 34 according to 16 so transformed that the thighs 14 . 15 under contact of their longitudinal edges 35 . 36 in the ends 32 tubular and in the longitudinal section with the trough 11 Be deformed in a U-shape ( 17 ). It will be the long edges 35 . 36 not yet welded torsion profile 1 educated.

To perform this operation in 180 ° twisted board 8d ( 15 ) is the upper tool 33 with a trough 37 and adjacent splayed thighs 38 Mistake. The lower tool 34 owns one in the hollow 11 engaging support bead 39 as well as adjacent domed lengths 40 for the longitudinal edges 7 the board 8d , Furthermore, the lower tool 34 with recording areas 41 for the ends 32 Mistake.

The long edges 35 . 36 the deformed thigh 14 . 15 as well as the end sections 2 are then welded together, so that an almost straight extending weld 42 is formed ( 17 ).

The deformation of the board 8d according to the 13 and 15 to the torsion profile 1 according to 17 can be done with the help of not shown thorns, over which the ends 32 to be beaten around. These domes can be cylindrical or conical.

Also conceivable is a non-circular deformation of the end sections 2 a torsion profile 1a , as for example from the 19 evident. Furthermore, lets 19 recognize that the end sections 2 relative to the longitudinal section 3 with the hollow 11 around the longitudinal axis of the torsion profile 1a are twisted.

From the 18 is an embodiment of a torsion profile 1b recognizable, which is wavy deformed in the longitudinal direction. The middle area 43 is opposite the end sections 2 in the vertical central longitudinal plane of the torsion profile 1b moved in the direction of the arrow PF. Such deformation is preferably prior to welding of the longitudinal edges 35 . 36 on the torsion profile 1 completed.

The 20 shows an embodiment in which the board for producing a Torsionsprofils 1c Has over its length partially different wall thicknesses. These different wall thicknesses 44 . 45 are on the torsion profile 1c of the 20 in the area between the middle U-shaped longitudinal section 3 and the transitional sections 4 and between the transitional sections 4 and the tubular end portions 2 recognizable. The board can be manufactured as so-called tailored rolled blanks.

In the 21 is ultimately an embodiment of a Torsionsprofils 1d represented in which by means of a suitable, not shown tool from the ground 47 the hollow 11 a bead 48 towards the ear-shaped longitudinal edges 7 has been shaped. In this way, a free space 49 created, which when joining the longitudinal edges 35 and 36 a melting of the soil 47 and thus a weakening of the torsion profile 1d prevented. The weld 42 can, as shown, in the middle of the back 6 or also be provided laterally.

1

torsion

1a

torsion

1b

torsion

1c

torsion

1d

torsion

2

End sections of 1

3

middle section of 1

4

Transition sections

5

Thighs in 3

6

Back in 3

7

Longitudinal edges in 3

8th

circuit board

8a

circuit board

8b

circuit board

8c

circuit board

8d

circuit board

9

Front ends of 8th

10

S-shaped area of 8a . 8b . 8c

11

Hollow in 8b . 8c . 8d

12

upper tool

13

lower tool

14

Thighs of 8b . 8c . 8d

15

Thighs of 8b . 8c . 8d

16

Bead on 12

17

Gutter in 13

18

upper tool

19

lower tool

20

Wall sections of 11

21

Bead on 18

22

Gutter in 19

23

upper tool

24

lower tool

25

Thighs on 23

26

Thighs on 23

27

Bead on 23

28

U-shaped areas 23

29

Recording mouth 24

30

Support leg on 24

31

Support areas 24

32

Ends 8d

33

upper tool

34

lower tool

35

Longitudinal edge of 14

36

Longitudinal edge of 15

37

Forming trough 33

38

Thighs on 33

39

Support bead on 34

40

Length section on 34

41

Recording areas for 32

42

Weld on 1

43

Mid-range of 1b

44

Wall areas of 1c

45

Wall areas of 1c

46

Wings beside 17

47

Soil v. 11

48

Bead on 47

49

free space

PF

arrow

VMLE

vertical center longitudinal plane of 11

VMLE1

Vertical center longitudinal plane of 8b

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• DE 102007061198 B3 [0002]

Claims (11)

Method for producing a motor vehicle component in the form of a torsion profile ( 1 . 1a . 1b . 1c . 1d ) from a board ( 8th ), the torsionally rigid tubular end sections ( 2 ), a torsionally soft U-shaped central longitudinal section ( 3 ) and between the middle section ( 3 ) as well as the end sections ( 2 ) transition from the U-shaped in the tubular cross-section transitional sections ( 4 ), characterized by the following steps: a) the circuit board ( 8th ) is at a distance from their front ends ( 9 ) in at least one manufacturing stage with a longitudinal U-shaped trough ( 11 ) Mistake; b) the thighs ( 14 . 15 ) of the deformed board ( 8b . 8c ) next to the hollow ( 11 ) are essentially parallel to each other and to the trough ( 11 ) bent over; c) the bent legs ( 14 . 15 ) are under contact of their longitudinal edges ( 35 . 36 ) in the front ends ( 9 ) of the board ( 8a . 8b . 8c ) adjacent areas ( 10 ) tubular and in the longitudinal section ( 3 ) with the trough ( 11 ) in adaptation to the contour of the trough ( 11 ) U-shaped deformed; d) the longitudinal edges ( 35 . 36 ) of the deformed limb ( 14 . 15 ) are joined together. Method according to claim 1, characterized in that the ends ( 9 ) of the board ( 8a . 8b . 8c ) adjacent areas ( 10 ) of the board ( 8a . 8b . 8c ) Are deformed in an S-shape. Method according to claim 1 or 2, characterized in that the ends ( 9 ) of the board ( 8a . 8b . 8c ) adjacent areas ( 10 ) are deformed out of round. Method according to one of claims 1 to 3, characterized in that the front ends ( 9 ) of the board ( 8a . 8b . 8c ) adjacent areas ( 10 ) are deformed over a mandrel. Method according to one of claims 1 to 4, characterized in that the front ends ( 9 ) of the board ( 8a . 8b . 8c ) adjacent areas ( 10 ) relative to the longitudinal section ( 3 ) with the trough ( 11 ) about the longitudinal axis of the Torsionsprofils ( 1 ) are twisted. Method according to one of claims 1 to 5, characterized in that the front ends ( 9 ) of the board ( 8a . 8b . 8c ) adjacent areas ( 10 ) are widened conically. Method according to one of claims 1 to 6, characterized in that the torsion profile ( 1 ) is deformed wave-shaped in the longitudinal direction. Method according to one of claims 1 to 7, characterized in that from the ground ( 47 ) of the trough ( 11 ) one towards the longitudinal edges ( 7 ) projecting bead ( 48 ) is formed. Method according to one of claims 1 to 8, characterized in that the torsion profile ( 1 ) from a board with sections of different thickness over its length ( 44 . 45 ) is manufactured. Method according to one of claims 1 to 9, characterized in that the torsion profile ( 1 ) is made of a board made of a hybrid material. Method according to one of claims 1 to 10, characterized in that the board ( 8a . 8b . 8c ) is shot peened before its transformation.