DE102016214929A1 - Method for producing a three-dimensional molded component and molded component - Google Patents

Abstract

The invention relates to a method for producing a three-dimensional molded component from a plate-shaped starting material, comprising the steps of: forming at least one groove-like depression along a predetermined line in the plate-shaped starting material, reforming the plate-shaped starting material at least along the groove-like depression (20), whereby a bending edge (30) is formed which delimits a first surface section (12A) and a second surface section (14A) at least in sections, - forming a weld (S) in the groove-like depression (20) mutually opposite side walls (22, 24) of the groove-like recess (20) at least partially cohesively connects to each other for fixing and stabilizing the three-dimensional mold component (10A) and a produced by the method three-dimensional mold component.

Description

The invention relates to a method for producing a three-dimensional molded component and a molded component produced by the method.

For the production of three-dimensional molded components, various forming processes are known in which a previously substantially flat starting material is formed in one or more steps, so that the resulting three-dimensional molded component has dimensions in all three dimensions that are well beyond the thickness of the starting material used. By way of example, the forming of a sheet metal blank in a body component of a vehicle by means of deep drawing may be mentioned. For this purpose, many sequential forming steps are necessary, with a separate shape-memory tool must be kept ready for each step that is shaped individually according to the forming step and the component shape to be produced. These tools are very expensive, which is why even small component changes are associated with high costs.

From the publication 100 65 142 A1 a method for producing a molded component is known, in which an individually adjustable forming tool is used with a plurality of supports. In a step preceding the reshaping, the desired free-form surface of the component is calculated by means of CAD methods, and adjustment values for each individual support are determined therefrom. The disadvantage of this is that the adjustment of the plurality of bearing points is subject to tolerances and consequently with this production method, no high quality level is achieved.

Accordingly, it is an object of the invention to show a way how three-dimensional moldings can be produced comparatively low on high quality level, in addition, a high degree of flexibility in terms of component changes is made possible.

This object is achieved by the method according to claim 1, as well as a molded component according to claim 9. Further preferred embodiments will become apparent from the dependent claims and the description below.

• – Ausbilden mindestens einer nutartigen Vertiefung entlang einer vorgegebenen Linie in dem plattenförmigen Ausgangsmaterial,
• – Umformen des plattenförmigen Ausgangsmaterials zumindest entlang der nutartigen Vertiefung, wobei sich eine Biegekante ausbildet, die einen ersten und zweiten Flächenabschnitt zumindest abschnittsweise voneinander abgrenzt,
• – Ausbilden einer Schweißnaht in der nutartigen Vertiefung, welche einander gegenüberliegende Seitenwände der nutartigen Vertiefung zumindest abschnittsweise stoffschlüssig miteinander verbindet zur Fixierung und Stabilisierung des dreidimensionalen Formbauteils.

The method according to the invention serves to produce a three-dimensional molded component from a plate-shaped starting material and comprises the steps:

• Forming at least one groove-like depression along a predetermined line in the plate-shaped starting material,
• - Forming the plate-shaped starting material at least along the groove-like depression, wherein a bending edge is formed, which delimits a first and second surface portion at least in sections,
• - Forming a weld in the groove-like depression, which mutually opposite side walls of the groove-like recess at least partially cohesively connects to each other for fixing and stabilizing the three-dimensional mold component.

In this case, it is preferable that more than one groove-like depression and consequently more than one bending edge is formed. Preferably, a bending edge is generated in the forming step along each groove-like depression.

In the area of the groove-like depression, the material thickness of the plate-shaped material is reduced, as a result of which it is purposefully weakened. The groove-like depression is bounded to the sides of each side surface. In the bottom region of the groove-like depression remains a material web. The groove-like recess is formed along a line at which the formation of a bending edge is intended. The length of the groove-like depression may in this case correspond to the length of the desired bending edge. The groove-like depression or groove can in principle have any desired cross-sections. By suitable choice of the width of the groove, the groove cross-section and in particular the width and thickness of the material web remaining in the bottom region, the deformation behavior of the plate-shaped material can be predetermined and controlled in a targeted manner. The groove-like depression can z. B. be produced by machining, abrading or forming material processing, preferably a method with high accuracy and reproducibility is selected.

During the forming adjacent to the groove-like depression surface portions are bent and / or folded relative to each other, whereby it comes to a deformation at least in the region of the groove-like depression and a bending edge is formed. The course of the bending edge substantially corresponds to the course of the groove-like depression. Due to the material weakening, the bending edge preferably forms where the groove-like depression extends. Due to the material behavior and dependent z. B. of the material thickness, however, the bending edge may also be slightly offset from the course of the groove-like depression or z. B. leak into a material area in which no groove-like depression is formed more. The bending edge can z. B. be defined more precisely by their bending angle and bending radius.

The method is applicable to all plate-shaped and weldable materials, such as. Weldable metals or metal alloys, or weldable plastics and plastic composites. For example, the plate-shaped material may be in the form of a sheet metal blank or as a fiber-reinforced (eg CFK, GFRP or aramid fiber reinforced) plastic material with a thermoplastic matrix.

The invention is based on the consideration that can be predetermined by a targeted material weakening, at which points and to what extent the plate-shaped material is deformed upon application of force. The calculations required to determine the position and configuration of the component weakenings in the form of the groove-like depression (s) can, for. B. by CAD calculations. It can realize a largely independent of the forming tool used shaping. Component changes can be implemented quickly and inexpensively. During the forming, the material web remaining in the bottom region of the groove is of increasing importance, since this prevents an uncontrolled "deflection" or deformation of the plate-like material during the forming and ensures the formation of the desired surface shape. Due to the deformation, it can in particular in the bottom region of the groove-like depression to high material loads such. B. tensions come. The inventively provided welding process favors the degradation of material stresses due to the local heat input. In addition, only by the cohesive joining of the side walls, the component weakening is resolved, so that this method is suitable for the production of components with elevated strength requirements, as z. B. exist in the automotive industry.

In a preferred embodiment, the forming of the plate-shaped starting material takes place in a three-dimensional mold component by free-forming. When free-form is dispensed with a shape memory tool element. This eliminates the high costs of individually tailored to each mold component tools. Rather, the deformation of the starting material in the three-dimensional mold component z. B. done by punctual or small-scale force on individual surface sections. This can be achieved by universally applicable handling devices, such. B. appropriately programmed industrial robots, or implement handling devices with traversable punches. However, the possibility of making the forming without shape memory tool, does not exclude, in principle, to use a shape memory tool for forming.

The method according to the invention makes use of the fact that the course and the design of the groove-like depression (s) allow the shape in which the adjoining surface sections to be shaped to be defined. Advantageously, complex mold components can thus be produced in a simple manner. These are to be understood as meaning those shaped components which, owing to their external shape, can only be described in a complex manner. Complex mold components can, for. B. be composed of a plurality of different surface portions which are delimited from each other by a plurality of contour lines. Individual surface sections may in particular be designed as free-form surfaces, this being understood as a surface which can not be described by simple mathematical geometries such as planes, lateral surfaces of cones, cylinders, etc., or as a one-dimensionally curved surface. Free-form surfaces may in particular be multiply and / or dimensionally curved surfaces and in particular have complex concave and / or convex portions. In one embodiment, the course of the at least one groove-like depression is designed such that a complex molding component with at least one free-form surface is formed by the deformation. For this purpose, the at least one groove-like depression extend, for example, along a curved line or along a line bent in opposite directions, wherein z. B. also several or all groove-like depressions may have a curved or opposite curved course.

In one embodiment, the plate-shaped starting material is essentially an exact development of the three-dimensional molded component. In this embodiment, no compression or stretching of the starting material takes place during the forming, which would have to be taken into account during the unwinding. An exception form the areas of the bending edge (s), in which in particular a bending shortening can occur, which can be taken into account in the development of the mold component, which is indicated by the term "substantially". Due to the reduced material thickness of the plate-shaped starting material in the region of the bending edges, a bending shortening will occur to a reduced extent. The blank determination is preferably carried out by CAD system.

To further increase strength and corrosion protection reasons, the groove-like depression of the weld can be completely filled in a further embodiment.

The reproducibility and accuracy of the forming can be increased advantageously if, in one embodiment, the cross section of the groove-like depression is designed so that mutually opposite side walls through the deformation be moved towards each other and at least partially come into contact. This refinement has the further advantage that welding filler material can be dispensed with or the required amount can be reduced.

Advantageously, a laser welding method is used as the welding method in one embodiment. The laser welding process can be carried out with continuous laser radiation or pulsed laser radiation. However, the weld can also be carried out with further suitable welding methods known to the person skilled in the art. The weld can be formed with or without the use of additional material. The weld can z. B. be executed as a line seam or stitching.

The use of a laser welding process to form the weld is advantageous due to the narrow heat affected zone and the option for pulsed welding. Additional benefits may be obtained, although the groove-like depressions by laser, z. As laser ablation, are formed. So z. B. for both process steps the same welding device can be used.

The formable with the method mold components have a high quality and dimensional accuracy with high component stiffness, which is why in one embodiment preferably a vehicle component such. B. a structural component or an outer skin component is produced by the method.

A three-dimensional molded component according to the invention is produced by the process according to the invention and achieves the same technical effects and advantages as were described for the process.

The three-dimensional, produced by forming from a single plate-shaped starting workpiece shaped component has at least two surface portions, which are delimited by at least one bending edge at least in sections from each other. In one embodiment, the mold component has a groove-like depression substantially corresponding to the course of the bending edge and having two opposite side walls, which are connected to one another in a materially joined manner by at least one weld seam. In an alternative embodiment, the shaped component has a weld seam, which substantially corresponds in its course to the course of the bending edge.

Advantageously, the method according to the invention is particularly flexible. If freely programmable tools are used to produce the groove-like depressions and to reshape the plate-shaped starting material, it is sufficient to reprogram them in order to implement component changes quickly, simply and inexpensively.

The above-described characteristics, features, and advantages of this invention, as well as the manner in which they are achieved, will become clearer and more clearly understood in connection with the following description of the embodiments. If the term "can" is used in this application, it is both the technical possibility and the actual technical implementation.

Embodiments will be explained below with reference to the accompanying drawings. Show:

1 to 3 a schematic representation of individual process steps based on an exemplary component

4 and 5 exemplary three-dimensional components that can be produced by the method.

This in 1 shown substantially flat and plate-shaped starting material 10 in the form of a sheet is to be transformed into a predetermined three-dimensional shape. In a first step, the plate-shaped starting material 10 weakened along a predetermined line at which a targeted transformation and formation of a bending edge is intended. The material weakening takes place by forming a groove-like depression 20 which z. B. can be milled into the starting material. The groove-like depression extends in the example shown over the entire length of the starting material 10 , The groove-like depression 20 is to the sides of one sidewall each 22 and 24 limited. In the floor area remains a material web 26 ,

The transformation takes place by force K (represented by the arrows in 1 ) on the plate-shaped material 10 , making this into a three-dimensional shaped body 10A is transformed. The use of shape memory tools is not necessary, but rather specifies the material weakening where the forming takes place. In the example shown move by the force of the side walls 22 and 24 the groove-like depression 20 towards and in contact with each other. The groove-like depression shown in the figures 20 has a reverse curved course. When forming this requires that the adjacent faces 12 and 14 also transform and assume a complex form, only hinted at in the figures, s. transformed partial surfaces 12A and 14A in 2 ,

2 shows the plate-shaped starting material 10 as reshaped three-dimensional molded component 10A , wherein the molded component 10A in 2 shown so that the groove-like depression 20 facing the paper plane.

To the mold component 10A in its shape to fix and stabilize is along the groove-like depression 20 formed a weld S. In 3 By way of example, a continuous weld S is shown, which the side walls 22 . 24 the groove-like depression 20 connects cohesively over the entire length. If the requirements for stability allow, the weld S can also be formed as a line seam with a plurality of spaced-apart line or punctiform single seams, wherein the side walls 22 and 24 in this case are only partially joined together materially. In the 3 illustrated weld S is from the open side of the groove-like depression 20 shrink wrapped. It is equally conceivable to carry out the welding from the opposite side, ie to weld it from the side at which the material web limits the groove-like depression in the depth.

With the method can be defined by forming the groove-like depressions on the flat starting material, where and how the plate-shaped material is deformed into a three-dimensional component, so that can be dispensed form memory forming tools. In combination with the at least partial closing of the groove-like recesses complex components can be made with the necessary in particular for vehicle construction strength. The 4 and 5 show exemplary exemplary three-dimensional mold components, which can be produced by the method. By arranging z. B. three groove-shaped recesses 20C and forming can be a molding component 10B in the form of a channel. The groove-shaped recesses 20B lie in the interior of the channel, on the outside form corresponding bending edges 30B ,

4 shows the channel in unfinished form. The channel profile is already fixed by a weld S1 along the abutting end faces, whereas the groove-shaped recesses 20B to be welded for stabilization. This can be z. B. done with a laser welding device in which the laser radiation is deflected by means of a guided into the channel mirror.

Likewise, complex moldings with z. B. one or more free-form surfaces are formed. 5 shows an example of a cut plate-shaped starting material 10C , which can be transformed by the method according to the invention to a motor cover with molded side panels and wheel arches. The starting material 10C is here as a substantially exact processing of the finished mold component before. The dashed lines 20C indicate at which points the groove-shaped recesses must extend, so that the desired complex shaped component can be formed by free-forming.

The embodiments are not to scale and are not restrictive. Modifications in the context of expert action are possible.

LIST OF REFERENCE NUMBERS

10, 100

plate-shaped starting material

10A, 10B

three-dimensional mold component

12, 12A, 14, 14A

surface sections

16

material web

20, 20B, 20C

groove-like depression

22, 24

side walls

30, 30B

bending edges

K

force

S, S1

Weld

Claims (10)

Method for producing a three-dimensional molded component from a plate-shaped starting material, comprising the steps of: - forming at least one groove-like depression ( 20 ) along a predetermined line in the plate-shaped starting material ( 10 ), - forming the plate-shaped starting material ( 10 ) at least along the groove-like depression ( 20 ), whereby a bending edge ( 30 ) forming a first area section ( 12A ) and a second surface section ( 14A ) is delimited from each other at least in sections, - forming a weld (S) in the groove-like depression ( 20 ), which opposing side walls ( 22 . 24 ) of the groove-like depression ( 20 ) at least partially cohesively connects to each other for fixing and stabilizing the three-dimensional molded component ( 10A ). Method according to claim 1, wherein the forming into the three-dimensional molded component ( 10A ) is done by free-form. Method according to one of the preceding claims, wherein the course of the at least one groove-like depression ( 20 ) Is designed such that the forming of a complex Molded part is formed with at least one free-form surface. Method according to one of the preceding claims, in which the plate-shaped starting material ( 10C ) is essentially an exact development of the three-dimensional mold component. Method according to one of the preceding claims, wherein the at least one groove-like depression ( 20 ) is completely filled by the weld (S). Method according to one of the preceding claims, wherein the cross section of the at least one groove-like depression ( 20 ) is designed so that the opposing side walls ( 22 . 24 ) are moved toward each other by the deformation and at least partially come into contact. Method according to one of the preceding claims, in which the welding method is a laser welding method. Method according to one of the preceding claims, in which the three-dimensional molded component ( 10A ) is a vehicle component. Three-dimensional mold component according to claim 8 produced by a method according to one of the claims 1 to 8. A three-dimensional molded component according to claim 9, which by forming from a single plate-shaped starting material ( 10 ) is formed with at least two surface sections ( 12A . 14A ) by at least one bending edge ( 30 ) are at least partially separated from each other, wherein - the mold component ( 10A ) a groove-like depression substantially corresponding to the course of the bending edge ( 20 ) having two opposite side walls, which are connected by at least one weld seam (S) at least partially cohesively with each other or - the mold component ( 10A ) one the course of the bending edge ( 30 ) has substantially corresponding weld seam (S).

Images