EP0815985A1 - Procédé et dispositif pour le formage à chaud d'éléments tubulaires en forme de caisson de forme quelconque en alliage léger - Google Patents

Procédé et dispositif pour le formage à chaud d'éléments tubulaires en forme de caisson de forme quelconque en alliage léger Download PDF

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Publication number
EP0815985A1
EP0815985A1 EP97109605A EP97109605A EP0815985A1 EP 0815985 A1 EP0815985 A1 EP 0815985A1 EP 97109605 A EP97109605 A EP 97109605A EP 97109605 A EP97109605 A EP 97109605A EP 0815985 A1 EP0815985 A1 EP 0815985A1
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EP
European Patent Office
Prior art keywords
extrusion
phase
moulds
cavities
alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP97109605A
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German (de)
English (en)
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EP0815985B1 (fr
Inventor
Mario Da Re'
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fiat Auto SpA
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Fiat Auto SpA
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Filing date
Publication date
Application filed by Fiat Auto SpA filed Critical Fiat Auto SpA
Publication of EP0815985A1 publication Critical patent/EP0815985A1/fr
Application granted granted Critical
Publication of EP0815985B1 publication Critical patent/EP0815985B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/08—Making wire, bars, tubes
    • B21C23/085—Making tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/14—Making other products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C29/00—Cooling or heating work or parts of the extrusion press; Gas treatment of work
    • B21C29/006—Gas treatment of work, e.g. to prevent oxidation or to create surface effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/004—Thixotropic process, i.e. forging at semi-solid state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00—Making hollow articles not covered by a single preceding sub-group
    • B21K21/16—Remodelling hollow bodies with respect to the shape of the cross-section
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/12—Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase

Definitions

  • the invention relates to a method of carrying out the hot-forming of tubular box-type elements (simply called “boxes” below) made of a light alloy (based on aluminium and/or magnesium for example) having the most diverse and complex shapes, both in transverse section and in the longitudinal direction. Box-type elements of this kind are used in particular in the motor industry as structural elements of the body of vehicles.
  • the invention also relates to an apparatus suitable for implementing the method according to the invention.
  • box-type elements of complex shape have been obtained in sheet steel or another material which is easy to weld (in contrast to aluminium and light alloys in general) and produced precisely by longitudinal welding of several profiles of open transverse section.
  • the boxes have high weights, which mean higher costs, greater fuel consumption and increased pollution.
  • the object of the invention is to overcome the disadvantages described, by providing a method that is relatively simple, inexpensive and which does not require complex or cumbersome pieces of equipment, to form box-type elements made of any light alloy available on the market in any form or shape, with a high degree of accuracy and the minimum of waste.
  • a method for the hot-forming of a tubular box of any shape made from a light alloy comprising a first phase in which the alloy is hot-extruded through a die of suitable shape so as to be formed into a tube of pre-determined section and generally rectilinear, and a moulding phase, in which the extrusion is pressed, to obtain the box of desired shape, between at least two moulds provided with respective conjugated cavities capable of defining with their contour the final shape of the box; characterized in that during the said moulding phase, the said moulds are kept close to each other in a fluid-tight manner; the said moulds being heated so as to maintain the extrusion, during the entire moulding phase, substantially at the same temperature at which it left the first extrusion phase; the moulding phase being carried out by creating a vacuum between extrusion and cavities, inside the cavities, and conveying a pressurized gas inside the extrusion.
  • the method of the invention preferably also comprises a second phase in which the extruded tube, still hot, is fed between the said moulds provided with conjugated cavities, during this second phase the moulds being heated so as to maintain the extrusion substantially at the same temperature at which it left the first extrusion phase; during the second phase the moulds being kept close together at a certain distance apart from each other, so that the cavities define a guide channel for the extrusion, inside which the latter is caused to slide so as to obtain a pre-form of it.
  • the above-mentioned phases are carried out sequentially and in the shortest possible time.
  • an extrusion that is substantially rectilinear and of simple shape in transverse section may be pre-formed in the longitudinal direction into any desired shape (U, L, zigzag, etc., for example), obtaining the hot bending thereof without the risk of breaking the transverse section and without having to resort to suitable bending equipment, and can then be moulded into a shape of transverse section of any complex design (H, star, etc.), still without any risk of breaking its transverse section.
  • the invention also relates to an apparatus for the hot-forming of a tubular box of any shape made from a light alloy, comprising an extrusion station capable of providing a tubular extrusion of pre-determined section and generally rectilinear, and a moulding station comprising at least two moulds provided with respective conjugated cavities capable of defining with their contour the final shape of the box to be obtained; characterized in that the said moulding station is arranged immediately downstream of the extrusion station, to receive said extrusion leaving the extrusion station directly between said moulds; the said moulds being provided with heating means and the moulding station also comprising:
  • FIG. 1 shows an apparatus which can be used according to the invention to obtain the hot-forming of a tubular box 2 of any shape (in the non-exhaustive example shown the box 2 is U-shaped in longitudinal direction and rectangular transverse section) made of any light alloy.
  • the apparatus 1 comprises an extrusion station 3, of known type, capable of carrying out a first phase, that of extrusion, of the method of the invention to provide a tubular extrusion 4 of pre-determined section (circular in the non-exhaustive case shown) and generally rectilinear, and a moulding station 5 (capable, as will be seen, of carrying out a second and a third phase of the method of the invention) comprising at least two moulds 6, 7 (of which 7, the top one, is shown in Fig. 1 in a phantom view, so that the bottom mould 6 can be seen) provided with respective conjugated cavities 8, 9 (see also Fig. 3) capable of defining with their contour the final shape of the box 2 to be obtained (in this case the cavities 8, 9 are configured in a U on plan and have a rectangular transverse section).
  • an extrusion station 3 of known type, capable of carrying out a first phase, that of extrusion, of the method of the invention to provide a tubular extrusion 4 of pre-determined section
  • the moulding station 5 is arranged immediately downstream of the extrusion station 3, to receive the extrusion 4 leaving the extrusion station 3 directly between the moulds 6, 7, so that when the extrusion begins to be worked in the station 5 it is still substantially at the same temperature at which it left the station 3; for this purpose, for example, the two stations 3 and 5 are arranged adjacent to one another and are connected by conveying means, such as a motor-driven roller conveyor 10, which is known, and which is capable of taking the extrusion 4 when it leaves the station 3 and causing it to advance, with pre-determined force, towards and inside the station 5.
  • conveying means such as a motor-driven roller conveyor 10, which is known, and which is capable of taking the extrusion 4 when it leaves the station 3 and causing it to advance, with pre-determined force, towards and inside the station 5.
  • stations 3 and 5 could also be adjacent or contiguous, and in this case the conveying means, particularly the roller conveyor 10, would be of dimensions which are reduced or actually absent, the feed force being conveyed to the extrusion directly by the action of the extruder.
  • the station 3 is preferably of the type that is capable of being fed with billets 11 of pre-determined dimensions and weight, obtained directly from the molten light alloy; these billets 11 are obtainable on the market and are fed to the station 3 in known manner, by means of handling devices 12, after having been pre-heated in a furnace to a pre-determined temperature which is suitable for rendering plastic (under suitable pressure) the alloy from which they are formed; in particular the station 3 includes an extrusion press 13, which is known, and illustrated solely in diagrammatic form, into which the red-hot billets (as is illustrated pictorially in Fig.
  • the billet 11 brought to the temperature of maximum plasticity specific to the alloy of which it is made, and once it has been introduced into the press 13 (which is preferably of the heated type), is subjected to an extremely high compression from a ram 15 of the press 13, which brings the alloy of which the billet 11 is composed into a fluid state, including if of high viscosity, which enables the alloy to flow through the die 14, receiving the desired shape from it and thus supplying, at the exit from the station 3, a solid pre-form (in the sense that it is capable of maintaining its own shape including under load and it can be handled mechanically), including if still red-hot, comprising the extrusion 4.
  • a matrix (or die) 14 which is known, and shaped in the shape which it is desired to impart to the transverse section of the extrusion 4 leaving the station: in practice, the billet 11, brought to the temperature of maximum plasticity specific to the alloy of which it is made, and once it has been introduced into the press 13 (which is preferably of the heated type), is subjected to an extremely high
  • the extrusion phase like every successive phase also, is carried out at the temperature of maximum plasticity of the alloy, and the extrusion 4 is formed as a tube which is substantially rectilinear and of substantially circular transverse section. More specifically, all the phases of the method of the invention are carried out whilst maintaining the alloy at a temperature at which it is in a semi-solid state, or it is within its solidification range and contains a liquid phase fraction lower than 50% by weight.
  • At least the extrusion phase could also be carried out at a higher temperature, starting, for example, directly from the melt as well as from billets 11, in which case a different press 13 will be used and the die 14 will be of the cooled type, so as to ensure, however, at the exit from the station 3, the supply of an extrusion 4 which is at the temperature of maximum plasticity of the alloy used.
  • the moulds 6, 7 of the station 5 are made of material that is a good conductor of heat and are provided with heating means, shown diagrammatically by 20 and capable of keeping them and, consequently, the blank 4 fed between them substantially at the same temperature at which it left the station 3, or at the above-mentioned temperature of maximum plasticity of the alloy used;
  • the means 20 may be electrical resistors or, preferably, coils in which an oil (or another diathermic fluid heated in a suitable boiler which is not shown) is made to circulate.
  • the moulding station 5 comprises actuating means 22 (comprising, for example, a hydraulic press with appropriate limit switches, shown solely in diagrammatic form with a block) capable of moving the moulds 6, 7 relatively in the direction of the arrow (Fig. 1) - generally speaking the mould 6 will be stationary and the mould 7 will be moved so that it is brought close to/moved away vertically from the mould 6 - to keep the moulds 6, 7 selectively arranged in two different operating positions.
  • actuating means 22 comprising, for example, a hydraulic press with appropriate limit switches, shown solely in diagrammatic form with a block
  • a first operating position is that shown in Figs. 1 and 3, in which the moulds 6, 7 are arranged exactly superimposed, but only semi-close together, i.e. close together at a certain distance D apart from each other (Fig. 3) so that the facing cavities 8, 9 define between them an open guide channel 23 (in this case U-shaped on plan) for the extrusion 4; the cavities 8, 9 are also produced in such a way that the channel 23 is provided with at least one through open end 24 (see also Fig.
  • the second operating position which the moulds 6, 7 can assume is not shown, insofar as it corresponds simply to the first, but in which the distance D is reduced to zero, so that the moulds 6, 7 are kept close together with a pre-determined pressure; in particular, according to the invention the moulds 6, 7 are configured (or equipped, as will be seen) in such a way that in this second operating position they are close together not only in contact but also in a perfectly fluid-tight, particularly gas-tight, manner.
  • the station 5 comprises pneumatic means, shown diagrammatically by 26, which are arranged, for example, incorporated inside (or underneath or adjacent to) the stationary mould 6, can be actuated solely in the second operating position of the moulds 6, 7 and are capable both of creating the vacuum inside the cavities 8, 9 between the extrusion 4, previously introduced into the channel 23, and the cavities 8, 9 themselves, and of conveying a pressurized gas inside the extrusion 4 which is present between the moulds 6, 7.
  • this gas is preferably an inert gas, such as helium, argon or nitrogen.
  • a phase of pre-forming or blocking towards the definitive shape desired for the box 2 is then carried out on the extrusion 4.
  • the block or blank which the tubular extrusion 4 constitutes is taken from the die 4 and immediately fed continuously, still hot, between the two moulds 6, 7 arranged in the above-mentioned first operating position, inside the curved channel 23 defined by the cavities 8, 9.
  • the extrusion 4 is still at the temperature of maximum plasticity of the alloy which forms it (which is variable with the composition of the alloy and is therefore specific to each alloy used at any given time) and to the fact that it is maintained at this temperature by the means 20, the extrusion 4 is pre-formed by the effect of its sliding, with gradual introduction, in the channel 23 of which it will tend to assume the shape, in particular the extrusion 4 will be bent into a U (dashed section in Fig. 1) or into any other shape corresponding to the shape on plan of the cavities 8, 9.
  • a third phase of the method of the invention which comprises a moulding phase of the already pre-formed extrusion into the definitive dimensions and shape of the box 2 to be obtained.
  • a cutting phase (Fig. 2) is carried out in which the pre-formed extrusion 4 in the channel 23 is cut in correspondence with the through open end 24 of the channel 23, by means of a bulkhead with shears 30, for example, which is made to ascend from a seat (not shown) provided in the mould 6 to intercept and close the end 23.
  • This same bulkhead 30 is produced in such a way that it is also capable of sealing the end 23 in a fluid-tight manner immediately after having carried out the cutting phase; alternatively, this closing function may be performed by any other known mobile sealing means, such as another sliding bulkhead, an expanding sleeve etc.
  • this closing function may be performed by any other known mobile sealing means, such as another sliding bulkhead, an expanding sleeve etc.
  • the moulds 6, 7 are brought together into contact, gradually reducing the distance D between them, until they are pressed against each other in a fluid-tight manner; in this configuration (Fig.
  • the bulkhead 30 (or means equivalent to it) will not only close the open end of the moulds 8, 9 in a fluid-tight manner but also the internal volume of the pre-formed extrusion 4, whose corresponding open end, or that just cut, will be coupled in contact with the bulkhead 30 (or with the possible sealing means which will have taken the place of the bulkhead/shears 30 after the cutting phase).
  • the moulding phase is not, therefore, carried out in traditional manner, simply by bringing the moulds 6, 7 into contact, but, profiting from the fact that the latter are brought close together in a fluid-tight manner and that, also once the moulds 6, 7 are close together the extrusion 4 is kept by the heating means 20 at the temperature of maximum plasticity of the alloy being worked, so that it is highly deformable, the moulding phase is carried out by creating a vacuum between extrusion 4 and cavities 8, 9, inside the cavities 8, 9 themselves, and by conveying a pressurized gas inside the extrusion 4.
  • the pneumatic means 26 include a double pump 40 and two pipes 41 and 42; the pipe 42 has an outlet (or a series of outlets, consequent on a possible bifurcation of it, which is not shown for reasons of simplicity) inside the cavities 8 and/or 9, whereas the pipe 41 extends partly inside the bulkhead 30, or in such a way as to have an outlet 44 facing, with moulds 6, 7 close together in contact, the internal cavity of the extrusion 4, in correspondence with one of its two opposite terminal ends, in the case illustrated one end 50 (Fig. 2) corresponding to the open end 24 (now closed by the bulkhead 30) of the channel 23.
  • the pressurized gas inert gas such as argon, helium or nitrogen at 100 atmospheres, indicated by the small arrows in Fig. 3
  • the pressurized gas fed inside the extrusion 4 through the channel 41 will tend to "inflate” it, producing the deformation of its lateral wall (the alloy forming the extrusion 4 is in fact in a plastic state) which is squeezed to copy the profile of the cavities 8, 9, whilst a similar effect will be achieved by the extraction of the air present in the cavities 8, 9 (only shown in diagrammatic form in Fig. 3 by small arrows pointing towards the pipe 42), which enables the plastic walls of the extrusion 4 in deformation phase to copy the walls of the cavities 8, 9 without air bubbles being interposed to produce surface defects.
  • the heating means 20 are de-activated and the moulds 5, 6 moved apart to a distance greater than D and such as to enable the box 4 thus obtained to be extracted from them as soon as it has cooled down sufficiently.
  • the technology of the invention can therefore be used for any light alloy and in particular for the alloys of aluminium (Al) such as: Al/copper, Al/silicon, Al/magnesium, Al/zinc alloys; and for magnesium (Mg)-based alloys such as: Mg/aluminium, Mg/aluminium/zinc, Mg/zinc/rare earths.
  • Al aluminium
  • Mg magnesium-based alloys

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Extrusion Of Metal (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
EP97109605A 1996-06-21 1997-06-12 Procédé et dispositif pour le formage à chaud d'éléments tubulaires en forme de caisson de forme quelconque en alliage léger Expired - Lifetime EP0815985B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT96TO000536A IT1286118B1 (it) 1996-06-21 1996-06-21 Metodo ed apparecchiatura per la formatura a caldo di elementi scatolati tubolari di forma qualsiasi realizzati in una lega leggera.
ITTO960536 1996-06-21

Publications (2)

Publication Number Publication Date
EP0815985A1 true EP0815985A1 (fr) 1998-01-07
EP0815985B1 EP0815985B1 (fr) 2001-09-05

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EP97109605A Expired - Lifetime EP0815985B1 (fr) 1996-06-21 1997-06-12 Procédé et dispositif pour le formage à chaud d'éléments tubulaires en forme de caisson de forme quelconque en alliage léger

Country Status (4)

Country Link
EP (1) EP0815985B1 (fr)
DE (1) DE69706482T2 (fr)
ES (1) ES2163068T3 (fr)
IT (1) IT1286118B1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005084845A1 (fr) * 2004-03-02 2005-09-15 Magtech-Magnesium Technologies Ltd. Article compose d'un tube en alliage de magnesium

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10241028B3 (de) * 2002-09-05 2004-07-29 Erbslöh Ag Verfahren zur Herstellung von bogenförmigen (gerundeten) Strukturbauteilen aus einem Strangpreßprofil

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6149735A (ja) * 1984-08-15 1986-03-11 Ryoda Sato 金属パイプに凸部を形成する方法
JPS63224857A (ja) * 1987-03-14 1988-09-19 Kawasaki Heavy Ind Ltd 半溶融金属加工方法
EP0294034A2 (fr) * 1987-05-06 1988-12-07 TI Corporate Services Limited Procédé de façonnage d'éléments en forme de boîtes
JPH04262819A (ja) * 1991-02-15 1992-09-18 Showa Alum Corp 金属押出管の膨出成形方法
JPH0732076A (ja) * 1993-07-19 1995-02-03 Mitsubishi Alum Co Ltd 車体構造用筒状部材の製造方法
EP0727343A1 (fr) * 1995-02-17 1996-08-21 General Motors Corporation Carrosserie et procédé de fabrication

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6149735A (ja) * 1984-08-15 1986-03-11 Ryoda Sato 金属パイプに凸部を形成する方法
JPS63224857A (ja) * 1987-03-14 1988-09-19 Kawasaki Heavy Ind Ltd 半溶融金属加工方法
EP0294034A2 (fr) * 1987-05-06 1988-12-07 TI Corporate Services Limited Procédé de façonnage d'éléments en forme de boîtes
JPH04262819A (ja) * 1991-02-15 1992-09-18 Showa Alum Corp 金属押出管の膨出成形方法
JPH0732076A (ja) * 1993-07-19 1995-02-03 Mitsubishi Alum Co Ltd 車体構造用筒状部材の製造方法
EP0727343A1 (fr) * 1995-02-17 1996-08-21 General Motors Corporation Carrosserie et procédé de fabrication

Non-Patent Citations (4)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 010, no. 207 (M - 500) 19 July 1986 (1986-07-19) *
PATENT ABSTRACTS OF JAPAN vol. 013, no. 013 (M - 783) 12 January 1989 (1989-01-12) *
PATENT ABSTRACTS OF JAPAN vol. 017, no. 043 (M - 1360) 27 January 1993 (1993-01-27) *
PATENT ABSTRACTS OF JAPAN vol. 95, no. 002 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005084845A1 (fr) * 2004-03-02 2005-09-15 Magtech-Magnesium Technologies Ltd. Article compose d'un tube en alliage de magnesium

Also Published As

Publication number Publication date
ES2163068T3 (es) 2002-01-16
ITTO960536A1 (it) 1997-12-21
EP0815985B1 (fr) 2001-09-05
DE69706482D1 (de) 2001-10-11
IT1286118B1 (it) 1998-07-07
DE69706482T2 (de) 2002-05-16
ITTO960536A0 (fr) 1996-06-21

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