DE102017218997A1 - Apparatus and method for forming a fiber reinforced thermoplastic blank - Google Patents

Abstract

The present invention relates to a forming device (10) for a method for forming a flexible, rod-shaped blank (1) made of fiber-reinforced thermoplastic. The forming device (10) comprises:
- a die (14) for receiving and forming the blank (1), comprising a molding area (14.1, 14.2) comprising a mold bottom area (14.2) against which the blank (1) in a forward direction (20.3) is pressed, and a form lateral area ( 14.1), against which the blank (1) is pressed in a lateral direction (20.1) which is lateral to the forward direction (20.3),
- A lateral punch (16) which is displaceable in the first lateral direction (20.1), for pressing the blank (1) against the form lateral region (14.1) of the die (14), and
- A forward punch (12, 16.2) for pressing the blank (1) against the mold bottom portion (14.2) of the die (14), wherein the forward punch is formed i) in a separate execution as a in the forward direction (20.3) displaceable, from the lateral punch (16) separate element, or ii) in a unitary embodiment, as a projection (16.2) of the lateral punch (16) projecting in the first lateral direction (20.1).

Description

The present invention relates to a forming device for a method for forming a flexible, rod-shaped blank made of fiber-reinforced thermoplastic. Furthermore, the invention relates to a method for forming a flexible, rod-shaped blank made of fiber-reinforced thermoplastic.

With fibers, mechanical, thermal and dynamic properties of thermoplastic polymers can be greatly improved. For example, long-fiber reinforced thermoplastics are characterized by high rigidity with very good energy absorption capacity, which meets the requirements of lightweight construction in motor vehicles. The glass fiber reinforcement also causes a significant increase in the notched impact strength and heat resistance. Therefore, fiber reinforced thermoplastic rods are often used for load bearing structures in lightweight automotive components.

However, when 3D reshaping a fiber reinforced thermoplastic rod, there is often the problem that the blank, ie, the workpiece to be reshaped, is cut to an initial length before reshaping which changes to a final, greater or lesser final length due to reshaping than the desired final length, so that length waste or scrap arises. This misjudgment is a consequence of complex 3D forming processes which, in the case of the known forming devices, make it more difficult to correctly estimate a change in length of the blank occurring during forming.

The problems associated with the misjudgment of the real end length reduce the economic efficiency of the forming.

It is therefore an object of the present invention to remedy the disadvantages described above in forming a blank made of fiber-reinforced thermoplastic or at least partially correct. In particular, it is an object of the present invention to provide a method for forming a flexible, rod-shaped blank of fiber-reinforced thermoplastic and a forming device for a forming process, wherein the structure of the forming simplified and the economic efficiency of the forming process is improved.

The above object is solved by the independent claims. Accordingly, the object is achieved by a forming device having the features of claim 1 and by a forming method having the features of claim 4. Further features and details of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details that are described in connection with the forming device, also in connection with the forming process and in each case vice versa, so that with respect to the disclosure of the individual invention aspects always reciprocal reference is or may be.

According to one aspect, the object is achieved by a shaping device for a method for forming a flexurally soft, rod-shaped blank made of fiber-reinforced thermoplastic.

1. i) eine erste Lateralrichtung,
2. ii) eine zweite Lateralrichtung, entlang welcher eine Lateralkoordinate verläuft, und
3. iii) eine Vorwärtsrichtung, die vorzugsweise zur ersten Lateralrichtung und zur ersten Lateralrichtung senkrecht steht.

For a description of the forming device and the associated forming process, it is helpful to use a coordinate system. The coordinate system can be determined by three directions:

1. i) a first lateral direction,
2. ii) a second lateral direction along which a lateral coordinate passes, and
3. iii) a forward direction which is preferably perpendicular to the first lateral direction and the first lateral direction.

• - erste Lateralrichtung = x-Richtung, x-Achse,
• - zweite Lateralrichtung = y-Richtung, y-Achse,
• - Vorwärtsrichtung = z-Richtung, z-Achse.

This is a skewed coordinate system. Optionally, a Cartesian coordinate system can also be used in which preferably the following equivalents apply:

• first lateral direction = x-direction, x-axis,
• second lateral direction = y-direction, y-axis,
• - Forward direction = z-direction, z-axis.

• - eine erste Ebene, bestimmt durch die erste und zweite Lateralrichtung, beispielsweise xy-Ebene, und
• - eine zweite Ebene, bestimmt durch die zweite Lateralrichtung und die Vorwärtsrichtung, beispielsweise yz-Ebene.

Die erste Ebene und die zweite Ebene können windschief zueinander oder senkrecht aufeinander stehen.Two levels can be defined in the coordinate system:

• a first plane determined by the first and second lateral directions, for example xy plane, and
• a second plane determined by the second lateral direction and the forward direction, for example yz plane.

The first level and the second level can be skewed to each other or perpendicular to each other.

The blank may be a prefabricated workpiece or raw material, preferably a semi-finished product which has been brought into rod form and transferred by means of thermal or chemical treatment in a flexible state. This flexible means that the rod is deformable or deformable with little effort. The rod shape is characterized by a length of the rod which is considerably larger than its lateral extent, the rod i) may have a rectangular, square, round or oval cross-section and ii) may be straight or curved.

The forming may be considered as a manufacturing process in which the flexible blank is selectively brought from the original shape to another shape without material being removed from the blank or fed to the blank. During forming, the cross section of the blank may also be changed.

• - eine Matrize zum Aufnehmen und Umformen des Rohlings, mit einem Formbereich umfassend einen Formbodenbereich gegen den der Rohling in einer Vorwärtsrichtung gepresst wird, und einen Formlateralbereich, gegen den der Rohling in einer zur Vorwärtsrichtung lateralen ersten Lateralrichtung gepresst wird,
• - einen Lateralstempel, der in der ersten Lateralrichtung verschiebbar ist, zum Pressen des Rohlings gegen den Formlateralbereich der Matrize, und
• - einen Vorwärtsstempel zum Pressen des Rohlings gegen den Formbodenbereich der Matrize, wobei der Vorwärtsstempel ausgebildet ist i) in einer Separatausführung als ein in der Vorwärtsrichtung verschiebbares, von dem Lateralstempel separates, Element, oder ii) in einer Einheitsausführung als ein in die erste Lateralrichtung ragender Vorsprung des Lateralstempels.

The forming device comprises:

• a die for receiving and reshaping the blank, having a molding area including a mold bottom area against which the blank is pressed in a forward direction, and a mold lateral area against which the blank is pressed in a first lateral direction lateral to the forward direction,
• a lateral punch displaceable in the first lateral direction for pressing the blank against the form lateral region of the die, and
• a forward punch for pressing the blank against the mold bottom region of the die, the forward punch being formed i) in a separate embodiment as a forwardly displaceable, separate from the lateral punch, or ii) in a unitary design as projecting in the first lateral direction Projection of the lateral punch.

The die may be formed as a rigid or stationary part of the forming device, wherein at least one movable part (lateral punch, forward punch) deforms the blank by means of displacement relative to the die and pressing against the molding area of the die.

The molding area of the die may comprise an elongated pressure plate having at least one contact surface with the blank, wherein the contact surface may press the blank against the lateral punch and / or forward punch and i) may be formed as a contact surface with a convexly shaped cross-sectional contour in the first plane, or ii) two each having one of the elongated shape of the blank to be formed following shape may comprise abutting contact surfaces.

In the separate version, the forming device comprises two mutually independently movable parts or punches, namely the lateral punches which are displaceable in the first lateral direction and the forward punches which are separately formed by the lateral punches and are movable separately. By sequentially or simultaneously shifting lateral punches and forward punches, the blank can be pressed between the punches and the die area of the die and thereby formed.

In the unitary embodiment, the forming device comprises a movable part, namely the lateral punch displaceable in the first lateral direction, which has a projection projecting in the first lateral direction. In a maximally extended or displaced state of the lateral punch, the projection of the lateral punch has a pressure surface facing the blank, which has a fixed distance from the mold bottom region of the die and thus forms a rod-shaped pressing space for the blank, between a lateral end face of the lateral punch, the pressure surface of the blank Lateral punch projection and the mold bottom area of the die.

In the unitary embodiment, the lateral punch, when displaced in the first lateral direction towards the mold area of the die or blank, may include the blank i) between the lateral end face of the lateral punch and the die lateral area of the die, and ii) between the pressure surface of the lateral punch Projection and the mold bottom area of the die, in which press space. During lateral displacement of the lateral punch, the blank can thus be pressed in the first lateral direction and in the forward direction.

Optionally, the molding area, if it comprises two abutting contact surfaces, can contribute to a press space formed between the end face of the forward punch, the end face of the lateral punch and the contact surfaces of the die forming area, into which the blank can be inserted and pressed by the punches.

• v1) Ermitteln einer, beim Umformen des Rohlings zu erwartenden, Längenänderung des Rohlings gegenüber einer festgelegten Anfangslänge, zum Reduzieren oder Vermeiden von Längenverschnitt,
• v2) Schneiden des Rohlings auf eine Endlänge = Anfangslänge + Längenänderung, und
• v3) Umformen des Rohlings mittels der Umformeinrichtung.

According to a further aspect, the object is achieved by a method for forming a flexurally soft, rod-shaped blank made of fiber-reinforced thermoplastic by means of the above-described forming device, the method comprising:

• v1) determining a change in the length of the blank to be expected during the forming of the blank compared to a specified initial length, in order to reduce or avoid longitudinal blending,
• v2) cutting the blank to an end length = initial length + length change, and
• v3) forming the blank by means of the forming device.

The initial length may correspond to a roughly estimated length which the blank could have after forming; it may, for example, correspond to an extent of the forming device into which the blank is placed for forming, or it may have a value based on experience of changes in length due to forming by means of the forming device.

The determination of the change in length in step v1) preferably means a computer-based calculation based on the structure of the forming plant and the dynamics of the forming. In this case, a CAD model of the forming machine can be used, with surfaces or elements which contact and / or guide the blank during forming, taking into account the geometry of the acting elements, enabling a realistic and precise simulation of the change in length.

In order to detect any deviations between real and simulated changes in length due to parameters such as temperature and / or humidity in an environment of the forming plant, first test runs can be performed. On the basis of the test runs, corrections of the simulated changes in length can be determined and quantified.

In order to determine the corrections, parameters involved in the test runs, such as the type and cumulative service life of the forming device, material parameters of the blank, temperature, humidity and, on the other hand, measured deviations, can be systematically recorded. The values of the parameters and the deviations can be supplied in the form of value series to an adaptive, self-learning system, for example a neural network, which learns the relationship between parameters and deviations, so that in real operation, with knowledge of the parameters, the length changes determined by means of simulation become reliable and be corrected in a realistic way.

1. i) in der ersten Ebene mittels Pressen des Rohlings zwischen Lateralstempel und Formlateralbereich der Matrize, und
2. ii) in der zweiten Ebene mittels Pressen des Rohlings zwischen Vorwärtsstempel und Formbodenbereich der Matrize.

Damit ist eine 3D Umformung durch zwei sequentielle 2D Umformungen ausführbar.The concept of forming device and forming method is compared to known concepts less complicated, faster executable and causes the technical effect that it allows a two-stage transformation of the blank in each case one plane:

1. i) in the first plane by pressing the blank between the lateral punch and the lateral form of the die, and
2. ii) in the second plane by means of pressing the blank between the forward punch and the mold bottom area of the die.

Thus, a 3D transformation by two sequential 2D transformations executable.

The mentioned effect has the advantage that with the present method a simulation of a 3D transformation and thus a determination of the deformation of the blank caused by the deformation is easier, less complicated and more precise. This is because two 2D simulations are less complex than a conventional 3D simulation, and thus the results of the 2D simulations are closer to reality and / or the overall simulations require less computational effort.

The present mold-forming and forming-based concept enables simplification of tools and processes used, reduction or elimination of blending and rejects, and thus, improvement in economy, cost-effectiveness and precision in 3D reshaping of fiber-reinforced thermoplastic rods.

In a preferred embodiment of the invention, the form lateral region of the die in the first plane can run along a lateral contour and is preferably strip-shaped. In particular, the lateral contour may have a functionally dependent on the Lateralkoordinate functional course and / or the lateral contour may extend in the first plane.

The described lateral contour has the technical effect that the lateral contour has a 2D profile. The mentioned effect has the advantage that a first of two 2D transformations can be implemented, which together form the 3D forming and simulatable compared to a conventional 3D forming simpler and with higher precision so that the determined, caused by the forming, change in length of the blank closer to reality is.

In a preferred embodiment of the invention, the lateral punch may have an end face facing the die lateral region of the die, which preferably extends in the first plane along the lateral contour and is in particular strip-shaped. Preferably, the form lateral region of the die and the end face of the lateral punch are adapted to each other and extend complementary to each other so as to laterally limit the rod-shaped pressing space of the blank and advantageously allow the lateral pressing and forming of the blank in the first plane.

In a preferred embodiment of the invention, the mold bottom region of the die in the second plane along a contour height run. The height contour may preferably have a functional course dependent on the lateral coordinate.

The contour contour described has the effect that it has a 2D profile, which has the advantage that it implements a second of two 2D transformations, which together form the 3D transformation, and corresponds to the already described advantage of the lateral contour.

In a preferred development of the invention, the forward punch can have an end face facing the mold bottom region of the die, which preferably extends in the second plane along the contour of the contour and is in particular strip-shaped. Preferably, the mold bottom region of the die and the end face of the forward punch are adapted to each other to thereby limit the rod-shaped pressing space of the blank in the forward direction on both sides and advantageously to allow the pressing in the forward direction and forming the blank in the second plane.

This has the effect that, upon displacement of the forward punch on the mold bottom portion of the die toward, between the end face of the forward punch, the end face of the lateral punch and the mold bottom portion of the die, the rod-shaped space formed as a gap is formed. The mentioned effect has the advantage that the blank, if it is located in the pressing space, in the forward direction and / or the first lateral direction is pressed, whereby the blank by means of a 2D deformation in the second plane and / or a 2D deformation in the first level is deformable.

In a preferred development of the invention, a lateral surface of the forward punch can run along the lateral contour. This has the effect that thereby the rod-shaped intermediate space or pressing space for receiving the blank can be formed, so that in the pressing space of the blank in the forward direction is pressed, preferably an escape of the blank material due to the press pressure, past the ram not allowed or . is prevented. The effect has the advantage that a loss of material during pressing of the blank in the press room is reduced or prevented.

In a preferred development of the invention, the projection of the lateral punch, in the unitary embodiment, can be funnel-shaped in the region facing the mold bottom region of the die in the first lateral direction. The funnel-shaped shape of the lateral punch has the effect that the projection of the lateral punch provides a still missing limit for the pressing space already delimited in lateral areas and in a floor area by displacing the lateral punch in the first lateral direction. The effect has the advantage that a complete delimitation of the pressing space (laterally and in the forward direction) is formed by displacement of a single element (lateral punch) and thereby the pressing and forming of the blank are made possible both in the first and in the second plane.

In a preferred development of the invention, the forming device in the separate embodiment may comprise a clamping slide designed as a rod, which protrudes from an opening of the form lateral region of the die, wherein preferably a longitudinal axis of the clamping slide is parallel to the first lateral direction. In addition to this, the forming device may preferably comprise an elastic element for resiliently supporting the clamping slide against a bottom of the opening.

The arrangement of clamping slide and elastic element causes the effect that the clamping slide can be guided displaceably in the opening of the die and supported by the elastic element such that the blank between the lateral punch and the clamping slide is resiliently clamped. An associated advantage is that the blank clamped between the clamping slide and the lateral punch can be precisely guided in the first lateral direction so as to be pressed and precisely shaped between the end face of the lateral punch and the lateral form portion of the die. A further advantage is that after completion of the forming and after the return of the stamp, the elastic element can relax, thereby pushing out the clamping slide, which pushes the blank away from the molding area and makes it possible to remove the blank from the die.

In a preferred embodiment of the invention, the forming device may comprise a gripping device, by means of which the blank is gripped at its ends, for moving the blank along the forward direction. Advantageously, thus, in an early phase of forming, when there is a length excess at the ends of the blank, the blank can be guided to the die and positioned in the forming area.

In a preferred development of the invention, the shaping device may comprise two pressing jaws displaceable relative to one another and in the second lateral direction for pressing the blank in the second lateral direction. Should the blank have a length or material excess at its ends after forming, For example, due to a deviation of the determined or simulated from the real change in length, then advantageously by means of axial pressing of the blank at its ends, the surplus material can be pressed into the press room, so there is no length excess to be circumcised.

Preferably, the forming means may comprise extendable ejector pins from the forming area for removing product from the die obtained from the blank by forming. The Auswerfstifte advantageously allow a rapid removal of the blank from the forming device after forming.

1. a) Umformen des Rohlings in der ersten Ebene, und
2. b) Umformen des Rohlings in der zweiten Ebene.

In a preferred development of the invention, the 3D reshaping of the blank by means of the described shaping device can comprise the following steps:

1. a) forming the blank in the first plane, and
2. b) forming the blank in the second plane.

Forming the blank in a forming plane (first or second plane) means that a curve shape or contour which the blank takes on forming in the forming plane concerned lies in the forming plane and thus is a 2D curve shape or 2D contour. The reshaping in steps a), b) has the effect that a 3D transformation is implemented by means of two sequentially or simultaneously executed 2D deformations in each case a forming plane. The mentioned effect has the advantage that 2D transformations, which together simulate the 3D deformation, and their simulations compared to conventional transformations and 3D simulations easier and the thus determined, caused by the forming, change in length of the blank closer to reality.

• a.1) Einbringen des Rohlings in den Formbereich der Matrize,
• a.2) Verschieben des Lateralstempels in die erste Lateralrichtung zum Pressen des Rohlings gegen den Formlateralbereich der Matrize, sodass der Rohling in der ersten Lateralrichtung umgeformt wird, und
• b.1) Verschieben des Vorwärtsstempels in die Vorwärtsrichtung zum Pressen des Rohlings gegen den Formbodenbereich der Matrize, sodass der Rohling in der Vorwärtsrichtung umgeformt wird.

In a preferred embodiment of the invention, the forming of the blank in the first plane by means of a forming device with a forward punch in the separate embodiment may comprise the steps:

• a.1) introducing the blank into the molding area of the die,
• a.2) shifting the lateral punch in the first lateral direction to press the blank against the die lateral area of the die so that the blank is reshaped in the first lateral direction, and
• b.1) shifting the forward punch in the forward direction to press the blank against the mold bottom portion of the die so that the blank is deformed in the forward direction.

The said steps have the advantageous effect of making a 3D transformation of two separate 2D transformations, which is simpler than a conventional 3D forming and allows a more precise simulation, whereby the determination of the deformation of the blank caused by the reshaping is more realistic.

The steps a.1) -a.3) can advantageously be carried out quickly and allow a precise handling or treatment of the blank.

• - Einbringen des Rohlings in den Formbereich der Matrize, und
• - Verschieben des Lateralstempels in die erste Lateralrichtung zum Pressen des Rohlings gegen den Formlateralbereich der Matrize und gegen den Formbodenbereich der Matrize.

In a preferred embodiment of the invention, forming the blank with a forward punch in the unitary embodiment may include:

• - Introducing the blank in the molding area of the die, and
• - Moving the Lateralstempels in the first lateral direction for pressing the blank against the Formlateralbereich the die and against the mold bottom portion of the die.

Thus, the effect is achieved laterally limiting the rod-shaped pressing space of the blank, and advantageously increasing the lateral pressing and forming of the blank in the first and second planes by means of a single movement (displacement in the first lateral direction) and a single forming tool (lateral puncture) enable.

When forming the blank in the first plane, the blank may preferably assume the 2D lateral contour and in particular a 2D strip shape corresponding to the strip-shaped 2D profile of the lateral punch end face and the die form lateral area. In addition, during forming in the second plane, the blank can assume the 2D contour contour, preferably during pressing of the blank between the mold bottom region of the die and the end face of the forward punch.

Advantageously, thereby the respective 2D shapes in the first and second plane can be designed or defined.

Preferably, the introduction of the blank into the molding area of the die can be carried out by means of the gripping device or a gravitational force. This has the advantage of an uncomplicated Handling and / or exact guidance and positioning of the blank to the desired location in the molding area.

Preferably, after the blank has been pressed between the end face of the forward punch and the pressing surface of the mold bottom region, the blank can be pressed in the second lateral direction by moving the pressing jaws toward one another, preferably until the pressing jaws reach the die, in particular lateral lateral surfaces of the die. This advantageously causes the reduction or avoidance of length blending.

• v4) Abhärten des Rohlings. Das Abhärten kann durch Abkühlen der Formmasse im temperierten Werkzeug bzw. der temperierten Vorrichtung ausgeführt werden. Die formgebenden Bestandteile der Vorrichtung (Matrize, Lateralstempel, und Vorwärtsstempel) können mit einem Temperiermedium (Wasser oder Öl) durchflossen werden. Damit kann vorteilhafterweise das mittels Umformen erhaltene Produkt fertiggestellt werden.

Preferably, after step v3), the step may be carried out:

• v4) curing the blank. The hardening can be carried out by cooling the molding compound in the tempered tool or the tempered device. The shaping components of the device (matrix, lateral punches, and forward punches) can be flowed through with a tempering medium (water or oil). Thus, advantageously, the product obtained by forming can be completed.

Preferably, after the blank has hardened, the punches (lateral punches, forward punches) can be moved back and the product removed from the mold area of the die, either i) by means of the clamp, which is released when the punches are returned, and the blank is removed from the blank by relaxing the elastic element Or ii) by means of the Auswerfstiften which are extended from the mold bottom portion to eject the blank from the molding area.

Preferably, the ejection pins can serve not only for ejecting, but also for providing deformed bars for picking up with a gripper by defined and repeatable positioning in space. In order for the rods to remain on the ejectors, they can penetrate the rods during the forming process. These may be tapered so that they can penetrate between the fibers of the blank.

Thus, the product obtained by forming can advantageously be provided, for example for storage, for transport or for installation in a motor vehicle or in a component for a motor vehicle.

• 1 in einer Draufsicht eine erste Ausführungsform einer erfindungsgemäßen Umformeinrichtung, mit einem Vorwärtsstempel in Separatausführung,
• 2 in einer Seitenansicht eine erste Variante der ersten Ausführungsform der Umformeinrichtung,
• 3 in einer Seitenansicht eine zweite Variante der ersten Ausführungsform der Umformeinrichtung,
• 4 in einer Seitenansicht eine erste Variante der zweiten Ausführungsform der Umformeinrichtung, mit einem Vorwärtsstempel in der Einheitsausführung, und
• 5 in einer Seitenansicht eine zweite Variante der zweiten Ausführungsform der Umformeinrichtung, mit einem Vorwärtsstempel in der Einheitsausführung.

A forming device according to the invention will be explained in more detail with reference to drawings. Each show schematically:

• 1 in a plan view of a first embodiment of a forming device according to the invention, with a forward punch in separate execution,
• 2 in a side view a first variant of the first embodiment of the forming device,
• 3 in a side view a second variant of the first embodiment of the forming device,
• 4 in a side view of a first variant of the second embodiment of the forming device, with a forward punch in the unit embodiment, and
• 5 in a side view of a second variant of the second embodiment of the forming device, with a forward punch in the unit design.

Elements with the same function and mode of action are shown in the figures 1 to 5 each provided with the same reference numerals.

• - x-Richtung 20.1, x-Achse (erste Lateralrichtung 20.1),
• - y-Richtung 20.2, y-Achse, (zweite Lateralrichtung 20.2),
• - z-Richtung 20.3, z-Achse (Vorwärtsrichtung),

in welchem zwei Ebenen definiert sind:

• - eine xy-Ebene, bestimmt durch die x-Richtung 20.1 und y-Richtung 20.2 (erste Ebene), und
• - eine yz-Ebene, bestimmt durch die y-Richtung 20.2 und z-Richtung 20.3 (zweite Ebene).

In connection with the figures shown, a Cartesian coordinate system is used, which is determined by three directions:

• - x -Direction 20.1 . x Axis (first lateral direction 20.1 )
• - y -Direction 20.2 . y Axis, (second lateral direction 20.2 )
• - z -Direction 20.3 . z Axis (forward direction),

in which two levels are defined:

• - one xy Level, determined by the x -Direction 20.1 and y -Direction 20.2 (first level), and
• - one Y Z Level, determined by the y -Direction 20.2 and z -Direction 20.3 (second level).

• - eine Matrize 14 zum Aufnehmen und Umformen des Rohlings 1, mit einem Formbereich umfassend einen Formbodenbereich 14.2 gegen den der Rohling 1 in z-Richtung gepresst wird, und einen Formlateralbereich 14.1, gegen den der Rohling 1 in einer zur z-Richtung lateralen x-Richtung 20.1 gepresst wird,
• - einen Lateralstempel 16, der in der ersten Lateralrichtung 20.1 verschiebbar ist, zum Pressen des Rohlings 1 gegen den Formlateralbereich 14.1 der Matrize 14, und
• - einen Vorwärtsstempel 12 zum Pressen des Rohlings 1 gegen den Formbodenbereich 14.2 der Matrize 14, wobei der Vorwärtsstempel 12 ausgebildet ist als ein in der z-Richtung verschiebbares, von dem Lateralstempel 16 separates, Element.

1 and 2 show a first embodiment of a forming device according to the invention 10 , with a forward stamp 12 in separate version. The forming device 10 includes:

• - a die 14 for picking up and forming the blank 1 , with a molding area comprising a mold bottom area 14.2 against the blank 1 in z Direction is pressed, and a form lateral area 14.1 against which the blank 1 in a to z Direction lateral x -Direction 20.1 is pressed,
• - a lateral stamp 16 in the first lateral direction 20.1 is displaceable, for pressing the blank 1 against the form lateral area 14.1 the matrix 14 , and
• - a forward stamp 12 for pressing the blank 1 against the mold floor area 14.2 the matrix 14 , where the forward punch 12 is formed as a displaceable in the z-direction, from the lateral punch 16 separate, element.

In addition to the in the 1 and 2 shown variant of the first embodiment, is in 3 a variant shown with a flat face.

In the in 4 shown second embodiment of the forming device 10 with a forward stamp in unitary execution this is considered a in x -Direction 20.1 protruding projection 16.2 of the lateral stamp 16 educated.

In addition to the in 4 shown variant of the second embodiment, is in 5 a variant with a dipping edge shown.

• - in der in 1, 2 dargestellten Separatausführung zwei bewegliche Teile (Lateralstempel 16, Vorwärtsstempel 12), und
• - in der in 4 dargestellten Einheitsausführung ein bewegliches Teil (Lateralstempel 16),

den Rohling 1 mittels Verschieben relativ zur Matrize 14 und Pressen gegen den Formbereich 14.1, 14.2 der Matrize 14 umformt.The matrix 14 is as a rigid or immovable part of the forming device 10 trained, being

• - in the 1 . 2 Separate design shown two moving parts (lateral punches 16 , Forward stamp 12 ), and
• - in the 4 unit shown a movable part (lateral punches 16 )

the blank 1 by moving relative to the die 14 and pressing against the molding area 14.1 . 14.2 the matrix 14 reshapes.

The shape area 14.1 . 14.2 the matrix 14 includes an elongated pressure plate with two contact surfaces to the blank 1 , each one of the elongated shape of the blank 1 have the following shape, wherein the contact surfaces of the blank 1 opposite lateral stamp 16 and / or forward stamp 12 press down.

In the in 1 . 2 shown separate execution includes the forming device 10 two mutually independently movable parts or stamp, namely in the first lateral direction 20.1 movable lateral stamp 16 and that of the lateral stamp 16 separately formed and separately displaceable forward punch 12 , By separate, sequential or simultaneous, shifting of lateral punches 16 and forward stamp 12 can the blank 1 between the punches and the molding area of the die 14 pressed and thereby transformed.

The lateral stamp 16 has one, the form lateral area 14.1 the matrix 14 facing, face 16.1 in the xy Plane runs along the lateral contour and is strip-shaped. The form lateral area 14.1 the matrix 14 and the frontal area 16.1 of the lateral stamp 16 are matched to each other and are complementary to each other, so as to the strip-shaped pressing space of the blank 1 laterally limit, thereby enabling the lateral pressing and forming of the blank 1 in the xy -Level.

The forward stamp 12 includes a stamp handle 12.2 on which the forward stamp 12 can be touched to guide the forward punch 12 in z Direction, and a conically in z Direction tapered, funnel-shaped punch projection with a, the mold bottom area 14.2 the matrix 14 facing, face 12.1 in the Y Z Plane along a contour of the contour and is strip-shaped. The stamp handle 12.2 represents opposite the punch projection a roof edge-shaped widening, which is a lock on the die 14 causes when moving the forward punch 12 to the matrix 14 out.

dipping edge

Plane face

The mold floor area 14.2 the matrix 14 and the frontal area 12.1 of the forward stamp 12 are adapted to each other, so that the strip-shaped pressing space of the blank 1 in z Limit direction on both sides. As a result, the pressing in the z-direction and the forming of the blank 1 in the Y Z Level allows.

The lead 16.2 of the lateral stamp 16 has, in the in 4 shown unit type, in a mold bottom area 14.2 the matrix 14 facing area, in the first lateral direction 20.1 one to the opposite surface of the mold bottom area 14.2 parallel contact surface to the blank. When moving the Lateralstempels 16 in x Direction along the mold bottom area 14.2 is ensured that the blank 1 before pressing in the first lateral direction 20.1 , Has cross-sectional dimensions that are smaller than the distance between the lateral punch projection 16.2 and the mold bottom area 14.2 is so the lateral stamp projection 16.2 when moving not on the blank 1 gets stuck or gets caught.

Only after the pressing space forms a closed space towards both pressing directions, and the blank 1 in the first lateral direction 20.1 was pressed, so that the material of the blank 1 opposite z Direction expands or tries to evade unfolds the Lateralstempel-projection 16.2 a pressing force on the blank 1 in z-direction, so the blank 1 by means of Moving a single forming tool (lateral punch 16 ) in two directions ( x -Direction 20.1 . z -Direction 20.3 ) is pressed.

The forming device 10 includes in the 1 Separate execution shown one designed as a rod clamp 14.3 that results from an opening of the form lateral area 14.1 the matrix 14 protrudes, wherein a longitudinal axis of the clamping slide 14.3 parallel to the first lateral direction 20.1 , In addition to this includes the forming device 10 an elastic element 14.4 for resilient support of the clamping slide 14.3 against a bottom of the opening. This will cause the clamp slide 14.3 in the opening of the die 14 slidably guided and by the elastic element 14.4 supported so that the blank 1 between the lateral stamp 16 and the clamping slide 14.3 is resiliently clamped, for guiding the blank 1 to the form lateral area 14.1 the matrix 14 against which he by the lateral stamp 16 is pressed laterally. In particular, by the central clamping of the blank by means of the clamping slide a displacement during the forming in y Direction can be prevented. Due to the spring-mounted clamping slide, the clamping can be limited by a mechanical stop system to an adjustable maximum dimension.

The forming device 10 further comprises a gripping device 17 that the blank 1 at its ends along the second lateral direction 20.2 engages, to move the blank 1 along the z -Direction. This will, at an early stage of forming, if at the ends of the blank 1 a length excess exists, the blank 1 to the matrix 14 guided and positioned in the molding area.

1. a) Umformen des Rohlings 1 in der xy-Ebene, und
2. b) Umformen des Rohlings 1 in der yz-Ebene.

The 3D Forming the blank 1 by means of the described forming device 10 includes the following steps:

1. a) forming the blank 1 in the xy Level, and
2. b) forming the blank 1 in the Y Z -Level.

• a.1) Einbringen des Rohlings 1 in den Formbereich der Matrize 14,
• a.2) Verschieben des Lateralstempels 16 in die erste Lateralrichtung 20.1 zum Pressen des Rohlings 1 gegen den Formlateralbereich 14.1 der Matrize 14, sodass der Rohling 1 in der ersten Lateralrichtung 20.1 umgeformt wird, und
• b.2) Verschieben des Vorwärtsstempels 12 in z-Richtung zum Pressen des Rohlings 1 gegen den Formbodenbereich 14.2 der Matrize 14, sodass der Rohling 1 in z-Richtung umgeformt wird.

The forming of the blank 1 in the xy plane by means of an in 1 . 2 shown forming device 10 in separate execution includes the steps:

• a.1) Introduction of the blank 1 in the molding area of the die 14 .
• a.2) Moving the lateral punch 16 in the first lateral direction 20.1 for pressing the blank 1 against the form lateral area 14.1 the matrix 14 so the blank 1 in the first lateral direction 20.1 is transformed, and
• b.2) Moving the forward punch 12 in z Direction for pressing the blank 1 against the mold floor area 14.2 the matrix 14 so the blank 1 in z Direction is transformed.

• - Einbringen des Rohlings 1 in den Formbereich der Matrize 14, und
• - Verschieben des Lateralstempels 16 in die erste Lateralrichtung 20.1 zum Pressen des Rohlings 1 gegen den Formlateralbereich 14.1 der Matrize 14 und gegen den Formbodenbereich 14.2 der Matrize 14.

The forming of the blank 1 with a forward stamp 16.2 in the in 3 shown unit type includes:

• - Introduction of the blank 1 in the molding area of the die 14 , and
• - Move the Lateralstempels 16 in the first lateral direction 20.1 for pressing the blank 1 against the form lateral area 14.1 the matrix 14 and against the mold floor area 14.2 the matrix 14 ,

This is, according to both embodiments, the strip-shaped pressing space of the blank 1 laterally limited and allows the lateral pressing and forming of the blank 1 in the first and the Y Z -Level.

In other words, the forming process can be summarized as follows:

An already finished to the final measure, shaped as a straight rod blank 1 , is heated so that the thermoplastic matrix material softens and becomes malleable. The flexible rod 1 gets on the mold 14 stored. The die surface has a crown around the x Axis of the rod to be reshaped 1 on.

By moving the designed as a main slide Lateralstempels 16 becomes the staff 1 against the in x Direction sliding clamp slide 14.3 pressed and between main and clamping slide 14.3 clamped. The clamping force is over the elastic element 14.4 , which the clamping slide 14.3 supports, adjustable. By clamping the rod becomes 1 centrally fixed and a uniform indentation of the rod 1 secured on both sides in the form of a gap press room. The lateral contact surfaces of the main slide 16 and the matrix 14 with the wand 1 have the crown around the z Axis of the rod to be reshaped 1 on. By further shifting the main slide 16 and clamping slide 14.3 becomes the staff 1 to the z -Axis deformed.

The pressing of the rod 1 either via the forward stamp 12 from the top of the main slider 16 and the matrix 14 is put on. Alternatively, after placing the rod 1 on the mold 14 first the forward stamp 12 be attached and then the main and clamping slide 14.3 be moved.

A variant without forward punch for pressing the rod 1 is in 3 shown. In this case, the main slide 16 a footbridge 16.2 or lateral projection 16.2 on which a pressing out of the limp rod 1 prevented from the mold gap. The occurring forming forces in the z-direction are positively between the main slide 16 and die 14 added.

In general, the end cross-section of the rod changes during forming 1 opposite to its starting cross-section. In other words, the output cross section of the rod 1 does not have to correspond to its final cross section.

LIST OF REFERENCE NUMBERS

1

Blank, rod

10

reshaping

12

Forward punch in separate execution

12.1

Face of the forward punch

12.2

stamp handle

14

die

14.1

Form lateral area of the die

14.2

Mold bottom area of the die

14.3

clamping slide

14.4

elastic element

16

Lateral stamp, main pusher

16.1

Face of the lateral punch

16.2

Projection of the lateral punch, forward punch in unitary execution

17

gripping device

20.1

first lateral direction, x -Direction

20.2

second lateral direction, y -Direction

20.3

Forward direction z -Direction

Claims (8)

Forming device (10) for a method for forming a flexurally soft, rod-shaped blank (1) made of fiber-reinforced thermoplastic, wherein the shaping device (10) comprises: - a die (14) for receiving and forming the blank (1), comprising a molding area (14.1, 14.2) comprising a mold bottom area (14.2) against which the blank (1) in a forward direction (20.3) is pressed, and a form lateral area ( 14.1), against which the blank (1) is pressed in a lateral direction (20.1) which is lateral to the forward direction (20.3), - A lateral punch (16) which is displaceable in the first lateral direction (20.1), for pressing the blank (1) against the form lateral region (14.1) of the die (14), and - A forward punch (12, 16.2) for pressing the blank (1) against the mold bottom portion (14.2) of the die (14), wherein the forward punch is formed i) in a separate execution as a in the forward direction (20.3) displaceable, from the lateral punch (16) separate element, or ii) in a unitary embodiment, as a projection (16.2) of the lateral punch (16) projecting in the first lateral direction (20.1). Forming device (10) after Claim 1 comprising at least one of the following components: - a clamp slide (14.3) formed as a rod and projecting from an opening of the form lateral area (14.1) of the die (14); - An elastic element (14.3) for resiliently supporting the clamping slide (14.3) against a bottom of the opening; - A gripping device (17) for gripping the blank (1) at its ends; - Two press jaws for pressing the blank (1) at its ends; - Auswerfstifte extendable from the mold bottom portion (14.2) of the die (14) for ejecting a product obtained from the blank (1) by means of forming. Forming device (10) according to any one of the preceding claims, - wherein a coordinate system is determined by three directions: i) the first lateral direction (20.1), ii) a second lateral direction (20.2), the forward direction (20.3) and the first lateral direction (20.1 iii) the forward direction (20.3), - wherein a first plane is determined by the first and second lateral direction (20.1, 20.1), and a second plane is determined by the second lateral direction (20.2 ) and the forward direction (20.3), the forming device (10) comprising at least one of the following features: - the form lateral region (14.1) of the die (14) extends in the first plane along a lateral contour and is preferably strip-shaped; the lateral punch (16) has an end face (16.1) facing the form lateral region (14.1) of the matrix (14), which preferably extends in the first plane along the lateral contour and is in particular strip-shaped, wherein preferably the lateral form region (14.1) of the matrix (14) and the end face (16.1) of the Lateralstempels (16) are adapted to each other; - The mold bottom portion (14.2) of the die (14) extends in the second plane along a contour of height and is preferably strip-shaped; - The forward punch (12, 16.2) has one, the mold bottom portion (14.2) facing the die (14), End face (12.1), which preferably extends in the second plane along the contour of the contour and is in particular strip-shaped, wherein preferably the mold bottom portion (14.2) of the die (14) and the end face (12.1) of the forward punch (12, 16.2) are adapted to each other; - The projection (16.2) of the Lateralstempels (16), in the unitary embodiment, in a the mold bottom region (14.2) of the die (14) facing region, in the first lateral direction (20.1), funnel-shaped; - The clamping slide (14.3) is slidably guided in the opening of the die (14) and supported by the elastic element (14.4) such that the blank (1) between the lateral punch (16) and the clamping slide (14.3) is resiliently clamped; - The gripping device (17) is designed to grip the blank (1) at its ends, whereby the blank (1) with respect to the molding area (14.1, 14.2) of the die (14) is displaceable; - The pressing jaws are along the second lateral direction (20.2) to each other displaceable, for pressing the blank (1) in the second lateral direction (20.2). Method for forming a flexible, rod-shaped blank (1) made of fiber-reinforced thermoplastic by means of a shaping device (10) according to at least one of the preceding claims, the method comprising: v1) determining a, during the forming of the blank (1) to be expected, change in length of the blank (1) compared to a predetermined initial length, to reduce or avoid length blending, v2) cutting the blank (1) to an end length = initial length + length change, and v3) forming the blank (1) by means of the forming device (10). Method according to the preceding claim, wherein the forming of the blank (1) in step v3) comprises: a) forming the blank (1) in the first plane, and b) forming the blank (1) in the second plane. Method according to Claim 5 in which the forming of the blank (1) by means of a forming device (10) with a separate punch (12) comprises the steps of: a.1) introducing the blank (1) into the forming area (14.1, 14.2) of the die (14 ), a.2) displacing the lateral punch (16) in the first lateral direction (20.1) for pressing the blank (1) against the form lateral region (14.1) of the matrix (14), so that the blank (1) in the first lateral direction (20.1 ) and b.1) moving the forward punch (12) in the forward direction (20.3) to press the blank (1) against the mold bottom portion (14.2) of the die (14) so that the blank (1) in the forward direction ( 20.3) is transformed. Method according to Claim 5 wherein the forming of the blank (1) by means of a forming device (10) with a forward punch (16.2) in the unitary embodiment comprises the steps of: - introducing the blank (1) into the forming area (14.1, 14.2) of the die (14), and - Moving the Lateralstempels (16) in the first lateral direction (20.1) for pressing the blank (1) against the Formlateralbereich (14.1) of the die (14) and against the mold bottom portion (14.2) of the die (14). Method according to at least one of the preceding method claims, comprising at least one of the following features: - when forming the blank (1) in the first plane, the blank (1) assumes the lateral contour, wherein preferably the blank (1) has a strip-like course Lateral punch face (16.1) and the die form lateral area (14.1) corresponding strip shape; - When forming the blank (1) in the second level of the blank (1) assumes the contour of height, preferably during pressing of the blank (1) between the forward punch (12, 16.2) and the mold bottom portion (14.2) of the die (14); - The introduction of the blank (1) in the molding area (14.1, 14.2) of the die (14) is carried out by means of the gripping device (17) or a gravitational force; - When moving the Lateralstempels (16) in the first lateral direction (20.1) for pressing the blank (1) against the Formlateralbereich (14.1) of the die (14) of the blank (1) between the lateral punch (16) and clamping slide (14.3) is clamped to guide the blank (1) so that it rests as completely as possible on the mold bottom area (14.2) of the die (14) and is brought as completely as possible to the form lateral area (14.1) of the die (14) and rests against it; - When moving the Lateralstempels (16) in the first lateral direction (20.1), the projection (16.2) of the Lateralstempels (16) over the blank (1) is performed in the unitary version, one of the blank (1) facing in the first lateral direction (20.1) funnel-shaped side surface of the projection (16.2), with increasing displacement of the Lateralstempels (16) in the first lateral direction (20.1) an increasing pressure in the forward direction (20.3) on the blank (1) exercises for pressing the blank (1) against the mold bottom area (14.2) of the die (14); - After the forming of the blank (1) in the first lateral direction (20.1) and in the forward direction (20.3) of the blank (1) by means of moving the pressing jaws in the second lateral direction (20.2) is pressed, preferably until the Pressing jaws to the die (14), in particular to lateral side surfaces of the die (14), passes; after step v3), the step is carried out: v4) curing the blank (1); after curing of the blank (1) lateral punch (16) and forward punch (12, 16.2) are moved back and the product is removed from the mold area (14.1, 14.2) of the die (14), in particular ejected against the forward direction (20.3), preferably by extending the Auswerfstifte from the mold bottom area.

Images