EP0849011B1 - Method of and installation for manufacturing hollow profiles with end cross-section extensions - Google Patents

Method of and installation for manufacturing hollow profiles with end cross-section extensions Download PDF

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Publication number
EP0849011B1
EP0849011B1 EP97119522A EP97119522A EP0849011B1 EP 0849011 B1 EP0849011 B1 EP 0849011B1 EP 97119522 A EP97119522 A EP 97119522A EP 97119522 A EP97119522 A EP 97119522A EP 0849011 B1 EP0849011 B1 EP 0849011B1
Authority
EP
European Patent Office
Prior art keywords
blank
tool
tool half
pressure
shaping
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.)
Expired - Lifetime
Application number
EP97119522A
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German (de)
French (fr)
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EP0849011A1 (en
Inventor
Helmut Augustin
Henning Blöcker
Kai-Uwe Dr. Dudziak
Uwe Hardtke
Carsten Rogowski
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.)
Mercedes Benz Group AG
Original Assignee
DaimlerChrysler AG
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Publication date
Application filed by DaimlerChrysler AG filed Critical DaimlerChrysler AG
Publication of EP0849011A1 publication Critical patent/EP0849011A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D17/00—Forming single grooves in sheet metal or tubular or hollow articles
    • B21D17/02—Forming single grooves in sheet metal or tubular or hollow articles by pressing
    • B21D17/025—Forming single grooves in sheet metal or tubular or hollow articles by pressing by pressing tubes axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/047—Mould construction

Definitions

  • the invention relates to a method for producing hollow profiles with end cross-sectional extensions after Preamble of claim 1 and a device for Implementation of the method according to the preamble of the claim 6.
  • a generic method or a generic device is known from DE 44 44 759 A1.
  • Process for the production of exhaust gas inlet connections for Automotive catalytic converters become a tubular blank in the engraving of a two-part hydroforming tool inserted, whereupon the forming tool is closed.
  • the engraving each tool part has a protruding, from the axial Wedge-shaped recess deviating in the longitudinal direction of the blank shape on, the recesses being formed uniformly, however mirror-inverted by a rotation angle of 180 ° vertical axis are offset from each other.
  • the blank and at the same time the engraving will be in the closed position of the forming tool axially on both sides by two with one connection for the introduction of high pressure fluid stamps sealed pressure-tight, which during the initiated by the high-pressure fluid expansion of the Blank into the recesses Wall material of the blank push towards the middle.
  • the fully formed blank is here according to the engraving shape in the expansion area asymmetrical. After removing the formed blank is this from a separator in the expansion area divided with a planar bevel cut such that two Hollow profiles of identical shape emerge, the other in a separating position facing ends in the manner relative to the rest hollow cylindrical course are expanded in cross-section that they have an oblique funnel shape.
  • the known method has a high rejection rate, because with the formation of small radii at the expansion edges, in this case even one-sided by 90 ° required very high pressures of over 1000 bar and the high Degrees of deformation, i.e. the ratio of insert blank diameter to the largest diameter of the formed component, from Over 60% cannot use enough wall material despite being pushed in delivered to the expansion area via the tracking stamp be so that due to the resulting material shortage in this area the wall of the blank is sometimes so thin that it can come to burst the blank.
  • the appropriate reflow of the wall material prevents the high friction of the Despite the stamped wall material on the engraving Introducing a lubricant between the engraving and the blank.
  • the invention has for its object a generic Method or a generic device for its implementation to develop further from a hollow Blank hollow profiles with the lowest possible reject rate and thus can be reliably produced with high degrees of deformation are expanded at the end.
  • the task is according to the invention by the features of the claim 1 regarding the procedure and the characteristics of claim 6 solved with regard to the device.
  • the simultaneous Expanding by means of a fluid pressure and axial, by the closing movement of the open one at the beginning of the forming process Forming tool causes high compression of the blank Forming degrees possible, one with regard to the forming the high fluid pressure required by pure expansion (> 1000 bar) comparatively low fluid pressure of about 200-300 is to be raised in cash. So that the fluid pressure generating system also simplified, since the necessary for very high pressures Pressure intensifiers are eliminated.
  • the adjustment of the fluid pressure and the upsetting movement is such that the risk of kinking the blank can be practically excluded.
  • the bulbous, rotationally symmetrical bulbs formed during the forming process Blanks are made easy by a simple cut to be separated into two hollow profiles perpendicular to their longitudinal extent. Because of their rotational symmetry, they are used as a connector for catalyst housings for the conventional trained housing optimally suitable, whereby by the straight cone of the one Such socket formed according to the invention hollow profile best possible flow conditions for the catalyst body are guaranteed.
  • the method according to the invention allows due to the lower demands on high formability the use of stainless ferritic in comparison to the previously used austenitic materials cheaper materials.
  • Ferritic materials can due to the lower thermal expansion Hollow profiles more compact than austenitic materials or assemblies consisting of or including them getting produced.
  • Fig. 1 as well as in Fig. 2 is an internal high pressure forming tool 1, which consists of two tool halves, one upper 2 and a lower 3.
  • the forming tool 1 is integrated in a forming press that a press ram 4 and includes a press table 5.
  • the upper tool half 2 is firmly connected to the press ram 4 via a head plate 6. It also has an end facing away from the press ram 7 a recess 8 into which an exchangeable upper Die insert 9 inserted and on the face 7 with the Tool half 2 is screwed.
  • the lower half of the tool 3 is hydraulic with the press table 5 via several anchored there working drive cylinder 10 connected, the circular distributed over the underside 42 of the lower tool half 3 are arranged and through which the lower tool half 3 is movable is drivable.
  • the die inserts 9, 13 each have hollow inserts 9.13 axially penetrating engraving parts 14 and 15, which at Create a common, rotationally symmetrical engraving 16 form.
  • the two engraving parts 14, 15 are horizontal with respect to the running parting plane 17 of the forming tool 1 arranged mirror-inverted to each other and point - starting from the parting plane 17 - first a first shorter hollow cylindrical one Section 18, then a second conical Section 19 tapering at an angle of approximately 45 ° and a third immediately following it longer hollow cylindrical extension 33. Sections 18 and 19 are different from the contour of the blank 28 radial recesses of the engraving 16 are formed.
  • On the engraving parts 14, 15 is followed by a guide bore 20 which push the tool halves 2, 3 coaxially to the engraving axis 21 and in each of which a stamp 22, 23 is slidably received is.
  • the punches 22, 23 have a central axially penetrating them Fluid channel 24 through which the engraving parts 14, 15 with a externally arranged high-pressure fluid production system connected are.
  • the stamps 22, 23 are on side 25 facing the engraving part formed as a conically tapered pin 26, wherein between the engraving part 14, 15 and the pin 26 an oblique Forms annular gap 27 in which the tubular to be formed Blank 28 can be jammed by the wedge effect is.
  • the receptacle for the blank 28 thus form the engraving part 14,15 and the pin 26, being due to the jamming of the blank 28 in the engraving 16 with respect to the external environment a high-pressure-tight seal is achieved.
  • the forming tool 1 is thus one end of an inserted blank 28 completely enclosed and pressure-tight held.
  • On side 29 of the stamp facing away from the engraving part 22, 23 is this with a stamp plate 30, 38 hydraulically operating drive cylinder 31, 35 connected by which the stamp 22,23 can be raised or lowered depending on use is.
  • the pressure of the finished formed Blank 28 in the engraved parts 15, 16 not so be large that a removal of the resulting from the blank 28 bulging hollow profile 47 due to lack high removal forces to be applied to a removal device is prevented.
  • the removal could, for example through a suitable lubrication between blank 28 and engraved part 15:16 to be relieved.
  • the blank becomes 28 with its lower end 48 in the reception of the lower Tool half 3 used by means of a production robot, the conical section 19 of the engraving part 14 for insertion of the blank 28 acts centering (Fig.3a).
  • the press ram 4 is located with the upper tool half 2 in an upper end position.
  • the upper tool half 2 After inserting the blank 28 into the receptacle of the lower one Tool half 3, the upper tool half 2 is driven lowered from the press ram 4 into a catching position (FIG. 3b), in which the press ram 4 simultaneously by means of the working cylinder 31 synchronously driven upper punch 22 in the upper end 32 of the blank 28 is inserted and in the upper Sealing jammed.
  • the snap position is defined by the height of a columnar spacer 34, which is firmly anchored on the press table 5 on the one hand and on the on the other hand, the press ram 4 taking a while of the further manufacturing process to be in a fixed position is coming.
  • the upper tool half 2 thus has in the catching position reaches its lowest lowered position, the press ram 4 applies the required closing force.
  • the encoder 37 is with the hydraulically operating drive cylinders 10 of the lower Tool half 3 coupled in such a way that the map control output target position values a measure of the Form the size and direction of the driving force.
  • the actual position the lower tool half 3 then becomes the target position by increasing or decreasing the driving force of the drive cylinders 10 aligned.
  • Tool half 3 As an alternative to the control of the lower one described above Tool half 3 is equally conceivable that this means preprogrammed drive values stored in said control unit is motion controlled. Then the one to be created Pressure of the fluid pressure generating system controlled, wherein this control also a map control with in the electronic control unit stored position-pressure-value pairs is.
  • the control is such that one of the the drive cylinders 10 of the lower tool half 3 coupled Displacement measuring device 36 as a function of an instantaneous one drive-specific value, preferably the drive force output, to the current position of the lower half of the tool 3 related sensor-acquired position value via the map a target pressure value of the fluid pressure generating system fluid pressure to be generated is metered, after which the Pressure generating system their previous actual pressure value Adjusted target pressure value.
  • the stamp 22.23 are for Tracking in the closed position of the forming tool 1 depending controlled by the calibration pressure according to a map, in which the pressure value of the current fluid pressure one Shift value for the stamp 22.23 is assigned, which by a measuring system, not shown here, on the stamp drive is transmitted.
  • a spacer cylinder 40 is arranged, whose piston 41 on the underside 42 of the lower half of the tool 3 is attached.
  • the piston 41 bounds with the cylinder base 43 a pressure chamber 44.
  • the interaction of the pressure force within the pressure chamber 44 and the driving force of the drive cylinder 35 define the position of the stamp 23 relatively to the lower half of the tool 3.
  • the pressure within the pressure space 44 is reduced as required, after which the piston 41 deeper into that of the drive cylinder 35 driven distance cylinder 40 immersed.
  • the stamp 23 is thus moved into the engraving part 14.
  • the Stamp 22 is synchronized with the stamp 23 by appropriate actuation of the drive cylinder 31 pushed into the engraving part 15.
  • the fluid pressure is released, whereupon the press ram 4 with the upper tool half 2 and the stamp 22 is raised to its upper end position and the forming tool 1 thus opens.
  • the pressure is still in the pressure chamber 44 further lowered, after which the piston 41 goes deeper into the spacer cylinder 40 immersed, driven by the drive cylinder 35 the stamp 23 further into the engraving part 14 is pushed into it.
  • a robotic one equipped with a pincer-shaped gripper 46 Removal device engages under the bulbous expansion of the Hollow profile 47 positively and is based on the End face 11 of the lower tool half 3. Subsequently the pressure in the pressure chamber 44 is increased and at the same time the driving force of the drive cylinder 35 reduced. The lower stamp plate 38 together with stamp 23 pulled back down, whereby the hollow profile 47 by means of the engagement of the gripper 46 is stripped from the punch 23 (FIG. 3f). Then the hollow profile 47 is from the lower tool half 3 completely detached so that the removal of the hollow profile 47th can be done (Fig. 3g). Instead of a gripper 46 is also removal with a robot arm equipped with a suction cup is conceivable. Finally, the lower tool half 3 is in its lower Starting position under hydraulic pressure release of the drive cylinder 10 retracted by their own weight.
  • the formed blank 28 is in the area its bulge in the middle by a transverse to its longitudinal extent running cut using a suitable separating device for example by means of a laser into two identical ones Hollow sections separated with a cross-sectional end.
  • a suitable separating device for example by means of a laser into two identical ones Hollow sections separated with a cross-sectional end.
  • the spacer cylinder 40 can be used during the forming process for a rigid connection between the lower stamp plate 38 and the lower tool half 3.
  • the cylinders 10 are by the movement of the serving as a forming cylinder Drive cylinder 35 of the punch 23 entrained.
  • the cylinders 10 are pressurized to the forming tool 1 closed during the subsequent calibration process hold.
  • the spacer cylinder 40 is depressurized, so that tracking of the stamp 23 during calibration to the pressure within the engraving 16 to be able to maintain.
  • a movable lower one Tool half 3 is also conceivable that the lower tool half 3 is fixed and that the upper, with the press ram 4 of a forming press firmly connected tool half 2 is movable and for reshaping the blank 28 to the lower Tool half 3 is movable.
  • this does not apply the spacer 34.
  • the control of the press ram 4 in coordination with the high-pressure fluid control applies above said. Otherwise, a control is also conceivable in which both tool halves 2, 3 are movable and can be moved into the contact position can be moved towards each other.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Forging (AREA)

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von Hohlprofilen mit endseitigen Querschnittserweiterungen nach dem Oberbegriff des Patentanspruches 1 und eine Einrichtung zur Durchführung des Verfahrens nach dem Oberbegriff des Patentanspruches 6.The invention relates to a method for producing hollow profiles with end cross-sectional extensions after Preamble of claim 1 and a device for Implementation of the method according to the preamble of the claim 6.

Ein gattungsgemäßes Verfahren bzw. eine gattungsgemäße Einrichtung ist aus der DE 44 44 759 A1 bekannt. Beim darin beschriebenen Verfahren zur Herstellung von Abgaseinlaßstutzen für Kraftfahrzeug-Katalysatoren wird ein rohrförmiger Rohling in die Gravur eines zweiteiligen Innenhochdruck-Umformwerkzeuges eingelegt, worauf das Umformwerkzeug geschlossen wird. Die Gravur jedes Werkzeugteils weist eine ausladende, von der axialen Längserstreckung der Rohlingsform abweichende keilförmige Ausnehmung auf, wobei die Ausnehmungen gleichförmig ausgebildet, jedoch spiegelverkehrt unter einem Drehwinkel von 180° um eine vertikale Achse versetzt zueinander angeordnet sind. Der Rohling und gleichzeitig die Gravur werden in der Schließstellung des Umformwerkzeuges beidseitig axial durch zwei mit einem Anschluß zur Einleitung von Hochdruckfluid versehene Stempel druckdicht verschlossen, welche während der durch das eingeleitete unter Hochdruck stehende Fluid erfolgende Aufweitung des Rohlinges in die Ausnehmungen hinein Wandungsmaterial des Rohlinges zur Mitte hin nachschieben. Der fertigumgeformte Rohling ist hierbei entsprechend der Gravurform im Aufweitungsbereich asymmetrisch ausgebildet. Nach Entnahme des umgeformten Rohlinges wird dieser von einer Trennvorrichtung im Aufweitungsbereich mit einem planaren Schrägschnitt derart geteilt, daß zwei Hohlprofile identischer Form entstehen, deren in Trennlage einander zugekehrten Enden in der Weise bezüglich des restlichen hohlzylindrischen Verlaufes querschnittserweitert sind, daß sie eine schräg verlaufenden Trichterform aufweisen. Die Herstellung von Hohlprofilen mit derartig großen Umformgraden mittels des bekannten Verfahrens ist mit einer hohen Ausschußrate behaftet, da bei der Ausbildung von kleinen Radien an den Aufweitungsrändern, in diesem Fall sogar einseitig von 90°, den dazu erforderlichen sehr hohen Drücken von über 1000 bar und den hohen Umformgraden, d.h. dem Verhältnis von Einlegerohlingsdurchmesser zum größten Durchmesser des umgeformten Bauteils, von über 60% kann nicht genügend Wandungsmaterial trotz Nachschiebens über die Nachführstempel in den Aufweitbereich geliefert werden, so daß durch die in diesem Bereich entstehende Materialarmut die Wandung des Rohlings teilweise so dünn wird, daß es zum Bersten des Rohlings kommen kann. Das geeignete Nachfließen des Wandungsmaterials verhindert die hohe Reibung des von den Stempel nachgeschobenen Wandungsmaterials an der Gravur trotz Einbringen eines Schmierstoffes zwischen Gravur und Rohling.A generic method or a generic device is known from DE 44 44 759 A1. With the described in it Process for the production of exhaust gas inlet connections for Automotive catalytic converters become a tubular blank in the engraving of a two-part hydroforming tool inserted, whereupon the forming tool is closed. The engraving each tool part has a protruding, from the axial Wedge-shaped recess deviating in the longitudinal direction of the blank shape on, the recesses being formed uniformly, however mirror-inverted by a rotation angle of 180 ° vertical axis are offset from each other. The blank and at the same time the engraving will be in the closed position of the forming tool axially on both sides by two with one connection for the introduction of high pressure fluid stamps sealed pressure-tight, which during the initiated by the high-pressure fluid expansion of the Blank into the recesses Wall material of the blank push towards the middle. The fully formed blank is here according to the engraving shape in the expansion area asymmetrical. After removing the formed blank is this from a separator in the expansion area divided with a planar bevel cut such that two Hollow profiles of identical shape emerge, the other in a separating position facing ends in the manner relative to the rest hollow cylindrical course are expanded in cross-section that they have an oblique funnel shape. The production of hollow profiles with such large degrees of deformation the known method has a high rejection rate, because with the formation of small radii at the expansion edges, in this case even one-sided by 90 ° required very high pressures of over 1000 bar and the high Degrees of deformation, i.e. the ratio of insert blank diameter to the largest diameter of the formed component, from Over 60% cannot use enough wall material despite being pushed in delivered to the expansion area via the tracking stamp be so that due to the resulting material shortage in this area the wall of the blank is sometimes so thin that it can come to burst the blank. The appropriate reflow of the wall material prevents the high friction of the Despite the stamped wall material on the engraving Introducing a lubricant between the engraving and the blank.

Der Erfindung liegt die Aufgabe zugrunde, ein gattungsgemäßes Verfahren bzw. eine gattungsgemäße Einrichtung zu dessen Durchführung dahingehend weiterzuentwickeln, daß aus einem hohlen Rohling Hohlprofile mit geringstmöglicher Ausschußquote und damit prozeßsicher hergestellt werden können, die mit hohen Umformgraden endseitig querschnittserweitert sind.The invention has for its object a generic Method or a generic device for its implementation to develop further from a hollow Blank hollow profiles with the lowest possible reject rate and thus can be reliably produced with high degrees of deformation are expanded at the end.

Die Aufgabe ist erfindungsgemäß durch die Merkmale des Patentanspruches 1 hinsichtlich des Verfahrens und durch die Merkmale des Patentanspruches 6 hinsichtlich der Einrichtung gelöst.The task is according to the invention by the features of the claim 1 regarding the procedure and the characteristics of claim 6 solved with regard to the device.

Dank der Erfindung werden in einfacher Weise durch das gleichzeitige Aufweiten mittels eines Fluiddruckes und axiale, durch die Schließbewegung des anfangs des Umformvorgangs geöffneten Umformwerkzeuges bewirktes Zusammendrücken des Rohlinges hohe Umformgrade ermöglicht, wobei ein hinsichtlich dem beim Umformen durch reines Aufweiten erforderlichen hohen Fluiddruck (> 1000 bar) vergleichsweise geringer Fluiddruck von etwa 200-300 bar aufzubringen ist. Damit wird die Fluiddruckerzeugungsanlage gleichfalls vereinfacht, da die für sehr hohe Drücke notwendigen Druckübersetzer entfallen. Die Abstimmung des Fluiddruckes und der Stauchbewegung erfolgt derart, daß die Knickgefahr für den Rohling praktisch auszuschließen ist. Durch das Stauchen wird ausreichend Material in die Aufweitzone nachgeliefert, so daß sogar Umformgrade von über 90% möglich sind ohne daß eine Rißbildung oder gar eine Zerstörung des Rohlinges durch Aufplatzen auftritt. Da keine Relativbewegung beim Umformprozeß zwischen dem Rohling und der Gravur des Umformwerkzeuges stattfindet, ergibt sich auch keine Reibung, so daß auf die übliche Schmierung verzichtet werden kann. Dies hat zur Folge, daß keine Probleme beim Wiederaufbereiten der Fluiddruckflüssigkeit durch filterverstopfende Schmierstoffe auftreten können. Die beim Umformprozeß entstehenden bauchigen rotationssymmetrischen Rohlinge sind in einfacher Weise durch einen einfachen Schntt quer zu ihrer Längserstreckung in zwei Hohlprofile zu trennen. Aufgrund ihrer Rotationssymmetrie sind diese in der Verwendung als Anschlußstutzen für Katalysatorengehäuse für die herkömmlich ausgebildeten Gehäuse optimal geeignet, wobei durch den geradlinigen konischen Verlauf (straight cone) des zu einem derartigen Stutzen erfindungsgemäß umgeformten Hohlprofiles bestmögliche Anströmungsverhältnisse für den Katalysatorkörper gewährleistet sind. Weiterhin erlaubt das erfindungsgemäße Verfahren aufgrund der geringeren Ansprüche an ein hohes Umformvermögen den Einsatz von nichtrostenden ferritischen im Vergleich zu den bisher verwandten austenitischen Werkstoffen wesentlich preisgünstigeren Werkstoffen. Durch die Verwendung von ferritischen Werkstoffen können aufgrund der geringeren Wärmedehnung gegenüber austenitischen Werkstoffen kompaktere Hohlprofile bzw. aus diesen bestehende oder diese beinhaltende Zusammenbauten hergestellt werden.Thanks to the invention, the simultaneous Expanding by means of a fluid pressure and axial, by the closing movement of the open one at the beginning of the forming process Forming tool causes high compression of the blank Forming degrees possible, one with regard to the forming the high fluid pressure required by pure expansion (> 1000 bar) comparatively low fluid pressure of about 200-300 is to be raised in cash. So that the fluid pressure generating system also simplified, since the necessary for very high pressures Pressure intensifiers are eliminated. The adjustment of the fluid pressure and the upsetting movement is such that the risk of kinking the blank can be practically excluded. By upsetting if sufficient material is supplied to the expansion zone, so that even degrees of deformation of over 90% are possible without a Cracking or even destruction of the blank by bursting occurs. Because there is no relative movement in the forming process between the blank and the engraving of the forming tool, there is also no friction, so that the usual Lubrication can be dispensed with. As a result, none Problems with reprocessing the fluid pressure fluid can occur due to filter clogging lubricants. The bulbous, rotationally symmetrical bulbs formed during the forming process Blanks are made easy by a simple cut to be separated into two hollow profiles perpendicular to their longitudinal extent. Because of their rotational symmetry, they are used as a connector for catalyst housings for the conventional trained housing optimally suitable, whereby by the straight cone of the one Such socket formed according to the invention hollow profile best possible flow conditions for the catalyst body are guaranteed. Furthermore, the method according to the invention allows due to the lower demands on high formability the use of stainless ferritic in comparison to the previously used austenitic materials cheaper materials. By the use of Ferritic materials can due to the lower thermal expansion Hollow profiles more compact than austenitic materials or assemblies consisting of or including them getting produced.

Zweckmäßige Ausgestaltungen der Erfindung können den Unteransprüchen entnommen werden; im übrigen ist die Erfindung anhand eines in den Zeichnungen dargestellten Ausführungsbeispieles nachfolgend näher erläutert; dabei zeigt:

  • Fig. 1 in einem seitlichen Längsschnitt einen Abschnitt des Umformwerkzeuges der erfindungsgemäßen Einrichtung,
  • Fig. 2 das Umformwerkzeug aus Fig. 1 in perspektivischer Darstellung,
  • Fig. 3a-g in einem seitlichen Längsschnitt die Herstellungsabfolge des erfindungsgemäßen Verfahrens mit dem Umformwerkzeug aus Fig. 1 einschließlich der Entnahme des fertigumgeformten Rohlinges.
    • Expedient embodiments of the invention can be found in the subclaims; otherwise the invention is explained in more detail below with reference to an embodiment shown in the drawings; shows:
  • 1 in a lateral longitudinal section a section of the forming tool of the device according to the invention,
  • 2 is a perspective view of the forming tool from FIG. 1,
  • 3a-g in a lateral longitudinal section the production sequence of the method according to the invention with the forming tool from FIG. 1 including the removal of the finished formed blank.

    • In Fig. 1 wie auch in Fig. 2 ist ein Innenhochdruck-Umformwerkzeug 1 dargestellt, welches aus zwei Werkzeughälften, einer oberen 2 und einer unteren 3 besteht. Das Umformwerkzeug 1 ist in einer Umformpresse integriert, die einen Pressenstößel 4 und einen Pressentisch 5 beinhaltet. Die obere Werkzeughälfte 2 ist über eine Kopfplatte 6 mit dem Pressenstößel 4 fest verbunden. Sie weist des weiteren eine auf pressenstößelabgewandter Stirnseite 7 eine Aussparung 8 auf, in die ein austauschbarer oberer Matrizeneinsatz 9 eingelassen und an der Stirnseite 7 mit der Werkzeughälfte 2 verschraubt ist. Die untere Werkzeughälfte 3 ist mit dem Pressentisch 5 über mehrere dort verankerte hydraulisch arbeitende Antriebszylinder 10 verbunden, die kreisförmig über die Unterseite 42 der unteren Werkzeughälfte 3 verteilt angeordnet sind und durch die die untere Werkzeughälfte 3 hubbeweglich antreibbar ist. In der der oberen Werkzeughälfte 2 zugewandten Stirnseite 11 der unteren Werkzeughälfte 3 ist eine hinsichtlich der Aussparung 8 gleichgestaltete Aussparung 12 ausgebildet, in welcher ein unterer Matrizeneinsatz 13 eingelassen und an der Stirnseite 11 mit der Werkzeughälfte 3 verschraubt ist.In Fig. 1 as well as in Fig. 2 is an internal high pressure forming tool 1, which consists of two tool halves, one upper 2 and a lower 3. The forming tool 1 is integrated in a forming press that a press ram 4 and includes a press table 5. The upper tool half 2 is firmly connected to the press ram 4 via a head plate 6. It also has an end facing away from the press ram 7 a recess 8 into which an exchangeable upper Die insert 9 inserted and on the face 7 with the Tool half 2 is screwed. The lower half of the tool 3 is hydraulic with the press table 5 via several anchored there working drive cylinder 10 connected, the circular distributed over the underside 42 of the lower tool half 3 are arranged and through which the lower tool half 3 is movable is drivable. In the upper half of the tool 2 facing end face 11 of the lower tool half 3 is a recess 12 of identical design with respect to recess 8 formed in which a lower die insert 13 is inserted and screwed to the tool half 3 on the end face 11 is.

    Die Matrizeneinsätze 9,13 weisen jeweils hohle, die Einsätze 9,13 axial durchsetzende Gravurteile 14 und 15 auf, die bei Anlage aneinander eine gemeinsame rotationssymmetrische Gravur 16 bilden. Die beiden Gravurteile 14, 15 sind bezüglich der horizontal verlaufenden Trennebene 17 des Umformwerkzeuges 1 spiegelverkehrt zueinander angeordnet und weisen - ausgehend von der Trennebene 17 - zuerst einen ersten kürzeren hohlzylindrischen Abschnitt 18, dann anschließend einen zweiten konisch unter einem Winkel von etwa 45° sich verjüngenden Abschnitt 19 und einen dritten sich unmittelbar an diesen anschließenden längeren hohlzylindrischen Fortsatz 33 auf. Die Abschnitte 18 und 19 werden durch von der Kontur des Rohlings 28 abweichenden radialen Ausnehmungen der Gravur 16 gebildet. An die Gravurteile 14,15 schließt sich jeweils eine Führungsbohrung 20 an, die die Werkzeughälften 2,3 koaxial zur Gravurachse 21 durchsetzen und in die jeweils ein Stempel 22,23 verschiebbar aufgenommen ist.The die inserts 9, 13 each have hollow inserts 9.13 axially penetrating engraving parts 14 and 15, which at Create a common, rotationally symmetrical engraving 16 form. The two engraving parts 14, 15 are horizontal with respect to the running parting plane 17 of the forming tool 1 arranged mirror-inverted to each other and point - starting from the parting plane 17 - first a first shorter hollow cylindrical one Section 18, then a second conical Section 19 tapering at an angle of approximately 45 ° and a third immediately following it longer hollow cylindrical extension 33. Sections 18 and 19 are different from the contour of the blank 28 radial recesses of the engraving 16 are formed. On the engraving parts 14, 15 is followed by a guide bore 20 which push the tool halves 2, 3 coaxially to the engraving axis 21 and in each of which a stamp 22, 23 is slidably received is.

    Die Stempel 22,23 weisen einen zentralen sie axial durchsetzenden Fluidkanal 24 auf, über den die Gravurteile 14,15 mit einer extern angeordneten Fluidhochdruckerzeugungsanlage verbunden sind. Die Stempel 22,23 sind auf gravurteilzugewandter Seite 25 als konisch sich verjüngender Zapfen 26 ausgebildet, wobei sich zwischen dem Gravurteil 14,15 und dem Zapfen 26 ein schräg verlaufender Ringspalt 27 ausbildet, in dem der umzuformende rohrförmige Rohling 28 durch die Keilwirkung verklemmend aufnehmbar ist. Die Aufnahme für den Rohling 28 bilden somit der Gravurteil 14,15 und der Zapfen 26 aus, wobei durch die Verklemmung des Rohlinges 28 in der Gravur 16 gegenüber der äußeren Umgebung eine fluidhochdruckdichte Abdichtung erreicht wird. In der Öffnungsstellung des Umformwerkzeuges 1 ist damit jeweils ein Ende eines eingebrachten Rohlings 28 gänzlich umschlossen und druckdicht gehalten. Auf gravurteilabgewandter Seite 29 des Stempels 22,23 ist dieser über eine Stempelplatte 30,38 mit einem hydraulisch arbeitenden Antriebszylinder 31,35 verbunden, durch welchen der Stempel 22,23 je nach Gebrauch anheb- oder absenkbar ist. The punches 22, 23 have a central axially penetrating them Fluid channel 24 through which the engraving parts 14, 15 with a externally arranged high-pressure fluid production system connected are. The stamps 22, 23 are on side 25 facing the engraving part formed as a conically tapered pin 26, wherein between the engraving part 14, 15 and the pin 26 an oblique Forms annular gap 27 in which the tubular to be formed Blank 28 can be jammed by the wedge effect is. The receptacle for the blank 28 thus form the engraving part 14,15 and the pin 26, being due to the jamming of the blank 28 in the engraving 16 with respect to the external environment a high-pressure-tight seal is achieved. In the open position the forming tool 1 is thus one end of an inserted blank 28 completely enclosed and pressure-tight held. On side 29 of the stamp facing away from the engraving part 22, 23 is this with a stamp plate 30, 38 hydraulically operating drive cylinder 31, 35 connected by which the stamp 22,23 can be raised or lowered depending on use is.

    Es ist natürlich denkbar, die Aufnahme des Rohlinges 28 im Umformwerkzeug 1 ohne Führungsbohrung 20 und Stempel 22,23 zu gestalten, so daß der sich an den zylindrischen Fortsatz 33 des Gravurteiles 14,15 anschließende Grund der Werkzeughälfte 2,3 und das Gravurteil 14,15 selbst die Aufnahme bilden. Gegebenenfalls kann am Grund entsprechend der Ausbildung des Stempels 22,23 ein Aufnahmezapfen angeformt sein. Diese werkzeugtechnisch einfache Alternative zu dem Vorsehen von verschiebbaren Stempeln 22,23 ist allerdings nur dann sinnvoll, wenn nach der eigentlichen Umformung des Rohlings 28 dieser nicht noch nachkalibriert werden muß, so daß auf eine Nachführung von Stempeln 22,23 zur Aufrechterhaltung einer ausreichenden Abdichtung verzichtet werden kann. Gleichfalls sollte die Anpressung des fertigumgeformten Rohlinges 28 in den Gravurteilen 15,16 nicht so groß sein, daß eine Entnahme des aus dem Rohling 28 entstandenen bauchig aufgeweiteten Hohlprofils 47 aufgrund mangelnder aufzubringender hoher Entnahmekräfte einer Entnahmevorrichtung verhindert wird. Die Entnahme könnte dahingehend beispielsweise durch eine geeignete Schmierung zwischen Rohling 28 und Gravurteil 15,16 erleichtert werden.It is of course conceivable for the blank 28 to be received in the forming tool 1 without guide bore 20 and punch 22, 23, so that the cylindrical extension 33 of the Engraving part 14, 15 subsequent base of the tool half 2, 3 and the engraving part 14, 15 itself form the receptacle. Possibly can at the bottom according to the design of the stamp 22,23 a receiving pin can be formed. This in terms of tools simple alternative to the provision of sliding Stamp 22.23 is only useful if after the actual forming of the blank 28, this is not yet recalibrated must be, so that a tracking of stamps 22,23 waived to maintain adequate sealing can be. Likewise, the pressure of the finished formed Blank 28 in the engraved parts 15, 16 not so be large that a removal of the resulting from the blank 28 bulging hollow profile 47 due to lack high removal forces to be applied to a removal device is prevented. The removal could, for example through a suitable lubrication between blank 28 and engraved part 15:16 to be relieved.

    Zur Herstellung von endseitig querschnittserweiterten Hohlprofilen mit Erweiterungen hohen Umformgrades (>90%) wird der Rohling 28 mit seinem unteren Ende 48 in die Aufnahme der unteren Werkzeughälfte 3 mittels eines Produktionsroboters eingesetzt, wobei der konische Abschnitt 19 des Gravurteils 14 zur Einbringung des Rohlings 28 zentrierend wirkt (Fig.3a). Der Pressenstößel 4 befindet sich dabei mit der oberen Werkzeughälfte 2 in einer oberen Endposition. Wie Fig. 2 entnehmbar, sind in der unteren Werkzeughälfte 3 in kreisförmiger Anordnung zueinander sechs Matrizeneinsätze 13 eingelassen, die parallel zueiander verlaufen und mit sechs Matrizeneinsätzen 9 in der oberen Werkzeughälfte 2 korrespondieren. Dadurch können in einem einzigen Arbeitsgang verfahrensökonomisch mehrere Rohlinge 28 gleichzeitig und unter gleichen Arbeitsbedingungen umgeformt werden. For the production of hollow profiles with cross-sectional expansion at the end with extensions of high degree of forming (> 90%) the blank becomes 28 with its lower end 48 in the reception of the lower Tool half 3 used by means of a production robot, the conical section 19 of the engraving part 14 for insertion of the blank 28 acts centering (Fig.3a). The press ram 4 is located with the upper tool half 2 in an upper end position. As can be seen in FIG. 2, are in the lower tool half 3 in a circular arrangement to each other six die inserts 13 embedded in parallel to each other run and with six die inserts 9 in the upper half of the tool 2 correspond. This can be done in a single Process economically several blanks 28 at the same time and formed under the same working conditions.

    Nach dem Einsetzen des Rohlinges 28 in die Aufnahme der unteren Werkzeughälfte 3 wird die obere Werkzeughälfte 2 angetrieben vom Pressenstößel 4 in eine Fangposition abgesenkt (Fig. 3b), in der der gleichzeitig zum Pressenstößel 4 mittels des Arbeitszylinders 31 synchron angetriebene obere Stempel 22 in das obere Ende 32 des Rohlings 28 eingeschoben ist und in der oberen Aufnahme abdichtend verklemmt. Die Fangposition ist definiert durch die Höhe eines säulenförmigen Distanzkörpers 34, der einerseits am Pressentisch 5 fest verankert ist und auf dem andererseits der Pressenstößel 4 unter Einnahme einer während des weiteren Herstellungsprozesses ortfesten Lage zu liegen kommt. Somit hat die obere Werkzeughälfte 2 in der Fangposition ihre unterste Absenklage erreicht, wobei der Pressenstößel 4 die erforderliche Schließkraft aufbringt.After inserting the blank 28 into the receptacle of the lower one Tool half 3, the upper tool half 2 is driven lowered from the press ram 4 into a catching position (FIG. 3b), in which the press ram 4 simultaneously by means of the working cylinder 31 synchronously driven upper punch 22 in the upper end 32 of the blank 28 is inserted and in the upper Sealing jammed. The snap position is defined by the height of a columnar spacer 34, which is firmly anchored on the press table 5 on the one hand and on the on the other hand, the press ram 4 taking a while of the further manufacturing process to be in a fixed position is coming. The upper tool half 2 thus has in the catching position reaches its lowest lowered position, the press ram 4 applies the required closing force.

    Alsdann wird die untere Werkzeughälfte 3 von den Antriebszylindern 10 angehoben, wobei der untere Stempel 23 angetrieben durch den zugehörigen unteren Antriebszylinder 35 synchron zur Anhebung der unteren Werkzeughälfte 3 angehoben wird. Bei der Anhebung wird über den Fluidkanal 24 mittels der Fluidhochdruckerzeugungsanlage ein Hochdruck auf den Rohling 28 innenseitig ausgeübt, der diesen aufzuweiten beginnt. Durch das Anheben der unteren Werkzeughälfte 3 wird gleichzeitig der Rohling 28 axial gestaucht, wobei die Stauchbarkeit von der Aufweitwirkung des Fluiddruckes begünstigt wird. Der Prozeß des Aufweitstauchens endet bei Anlage der beiden Werkzeughälften 2,3 aneinander, d.h. bei Erreichen der Schließstellung des Umformwerkzeuges 1 (Fig. 1). Der umgeformte Rohling 28 liegt dann nahezu, wenn nicht gar vollständig an der Gravur 16 des Umformwerkzeuges 1 an.Then the lower tool half 3 of the drive cylinders 10 raised, the lower punch 23 driven through the associated lower drive cylinder 35 in synchronism with Raising the lower tool half 3 is raised. In the Raising is carried out via the fluid channel 24 by means of the high-pressure fluid generation system a high pressure on the blank 28 inside exercised, which begins to expand it. By lifting the lower tool half 3 becomes the blank 28 axially compressed, the compressibility of the expansion effect the fluid pressure is favored. The process of Expanding ends when the two tool halves are in contact 2.3 to each other, i.e. when the forming tool reaches the closed position 1 (Fig. 1). The formed blank 28 then lies almost, if not completely, on the engraving 16 of the forming tool 1 on.

    Um eine kontrollierte Umformung zu erhalten, ist die Abhängigkeit der Drucksteuerung der Anlage zur Fluiddruckerzeugung von der Bewegungssteuerung der unteren Werkzeughälfte 3 unerläßlich. Hierbei ist die Ausbildung der Bewegungssteuerung als Kennfeldsteuerung mit in einer elektronischen Steuereinheit gespeicherten Druck-Position-Wertepaaren sinnvoll, bei der der Druckwert eines momentan erzeugten Fluiddruckes einem Positionswert der einzunehmenden Stellung der unteren Werkzeughälfte 3 in vertikaler Richtung zugemessen wird, in die die untere Werkzeughälfte 3 je nach vorhergehender Lage dann angehoben oder abgesenkt wird. Zur Realisierung ist für die erfindungsgemäße Einrichtung eine Wegmeßvorrichtung 36 vorgesehen, deren Wegmeßgeber 37 an der hubbeweglichen unteren Werkzeughälfte 3 einenends und ortsfest am unbeweglichen Teil der Arbeitszylinder 10 anderenends angebracht ist. Der Wegmeßgeber 37 ist mit den hydraulisch arbeitenden Antriebszylindern 10 der unteren Werkzeughälfte 3 in der Weise gekoppelt, daß die von der Kennfeldsteuerung ausgegebenen Soll-Positionswerte ein Maß für die Größe und Richtung der Antriebskraft bilden. Die Ist-Position der unteren Werkzeughälfte 3 wird danach der Soll-Position durch Erhöhung bzw. Erniedrigung der Antriebskraft der Antriebszylinder 10 angeglichen.To get a controlled reshaping is the dependency the pressure control of the system for generating fluid pressure from the movement control of the lower tool half 3 is essential. Here is the formation of the motion control as Map control with stored in an electronic control unit Pressure-position-value pairs, where the Pressure value of a currently generated fluid pressure a position value the position to be assumed for the lower half of the tool 3 is measured in the vertical direction, in which the lower Tool half 3 then raised depending on the previous position or is lowered. To implement is for the invention Device provided a displacement measuring device 36, the Travel sensor 37 on the lower half of the tool 3 at one end and stationary on the immovable part of the working cylinder 10 is attached at the other end. The encoder 37 is with the hydraulically operating drive cylinders 10 of the lower Tool half 3 coupled in such a way that the map control output target position values a measure of the Form the size and direction of the driving force. The actual position the lower tool half 3 then becomes the target position by increasing or decreasing the driving force of the drive cylinders 10 aligned.

    Als Alternative zur oben beschriebenen Steuerung der unteren Werkzeughälfte 3 ist gleichermaßen denkbar, daß diese mittels in besagter Steuereinheit gespeicherter, vorprogrammierter Antriebswerte bewegungsgesteuert ist. Danach wird der zu erzeugende Druck der Fluiddruckerzeugungsanlage gesteuert, wobei diese Steuerung ebenfalls eine Kennfeldsteuerung mit in der elektronischen Steuereinheit gespeicherten Position-Druck-Wertepaaren ist. Die Steuerung erfolgt derart, daß ein von der mit den Antriebsylindern 10 der unteren Werkzeughälfte 3 gekoppelten Wegmeßvorrichtung 36 in Abhängigkeit von einem momentanen antriebsspezifischen Wert, vorzugsweise der Antriebskraft ausgegebener, auf die momentane Stellung der unteren Werkzeughälfte 3 bezogener sensorisch erfaßter Positionswert über das Kennfeld einem Soll-Druckwert des von der Fluiddruckerzeugungsanlage zu erzeugenden Fluiddruckes zugemessen ist, worauf die Druckerzeugungsanlage ihren vorhergehenden Ist-Druckwert dem Soll-Druckwert angleicht.As an alternative to the control of the lower one described above Tool half 3 is equally conceivable that this means preprogrammed drive values stored in said control unit is motion controlled. Then the one to be created Pressure of the fluid pressure generating system controlled, wherein this control also a map control with in the electronic control unit stored position-pressure-value pairs is. The control is such that one of the the drive cylinders 10 of the lower tool half 3 coupled Displacement measuring device 36 as a function of an instantaneous one drive-specific value, preferably the drive force output, to the current position of the lower half of the tool 3 related sensor-acquired position value via the map a target pressure value of the fluid pressure generating system fluid pressure to be generated is metered, after which the Pressure generating system their previous actual pressure value Adjusted target pressure value.

    Nach dem Schließen des Umformwerkzeuges 1 wird die Bewegungssteuerung der unteren Werkzeughälfte 3 von der Drucksteuerung abgekoppelt. Danach wird unter hohem Fluiddruck zwischen 800 und 1000 bar die vorläufige Form des umgeformten Rohlinges 28 in den Endzustand kalibriert, wonach dieser an die Gravurform angepreßt wird und wobei die kleinen Radien am Rohling 28 erzeugt werden (Fig. 3c). Da es sich hierbei nur um eine geringe Umformung handelt, muß nur wenig Wandungsmaterial nachfließen. Dieses fließt unter Einwirkung des Fluiddruckes von selbst zum Aufweitbereich mit geringfügiger Verkürzung des den zylindrischen Fortsätzen 33 der Gravur 16 entsprechenden zylindrischen Abschnittes des umgeformten Rohlinges 28. Es ist somit kein Nachführstempel bekannter Art notwendig, über den Wandungsmaterial mit großem Kraftaufwand nachgeliefert wird. Aufgrund der gleichermaßen geringen Relativbewegung des Rohlinges 28 zur Gravur 16 ist nur eine leichte Schmierung erforderlich. Natürlich ist es auch prinzipiell denkbar, mittels des Stempels 22,23 Wandungsmaterial nachzuschieben.After closing the forming tool 1, the motion control the lower tool half 3 from the pressure control uncoupled. Then under high fluid pressure between 800 and 1000 bar the preliminary shape of the formed blank 28 calibrated to the final state, after which it matches the engraving shape is pressed and the small radii are generated on the blank 28 are (Fig. 3c). Since this is only a minor one Forming is involved, only a little wall material has to flow in. This flows by itself under the influence of the fluid pressure Expanding area with a slight shortening of the cylindrical Extensions 33 of the engraving 16 corresponding cylindrical Section of the formed blank 28. It is therefore not Tracking stamp of a known type necessary over the wall material is delivered with great effort. Due to the equally small relative movement of the blank 28 to Engraving 16 requires only light lubrication. Naturally it is also conceivable in principle by means of the stamp 22.23 to add wall material.

    Um die Dichtigkeit des Rohlinges 28 und der Gravur 16 bei der axialen Verkürzung des Rohlinges 28 zu gewährleisten, ist allerdings ein Nachführen des jeweiligen Stempels 22,23 notwendig. Dabei bringen die Stempel 22,23 jedoch keine zusätzliche den Rohling 28 stauchende Kraft auf, sondern werden nur mit der Verkürzungsbewegung mitverschoben. Die Stempel 22,23 sind zur Nachführung in Schließstellung des Umformwerkzeuges 1 in Abhängigkeit vom Kalibrierdruck nach einem Kennfeld verschiebbar gesteuert, in dem der Druckwert des momentanen Fluiddruckes einem Verschiebewert für den Stempel 22,23 zugeordnet wird, der von einem hier nicht gezeigten Wegmeßsystem auf den Stempelantrieb übertragen wird. Zur Verschiebung des unteren Stempels 23 relativ zur unteren Werkzeughälfte 3 ist in der Oberseite 39 der unteren Stempelplatte 38 ein Distanzzylinder 40 angeordnet, dessen Kolben 41 an der Unterseite 42 der unteren Werkzeughälfte 3 befestigt ist. Der Kolben 41 begrenzt mit dem Zylindergrund 43 einen Druckraum 44. Die Wechselwirkung der Druckkraft innerhalb des Druckraumes 44 und die Antriebskraft des Antriebszylinders 35 definieren die Lage des Stempels 23 relativ zur unteren Werkzeughälfte 3. Zum Nachführen des Stempels 23 wird der Druck innerhalb des Druckraumes 44 bedarfsgerecht erniedrigt, wonach der Kolben 41 tiefer in den vom Antriebszylinder 35 getriebenen Distanzzylinder 40 eintaucht. Der Stempel 23 wird somit in den Gravurteil 14 hineinverschoben. Der Stempel 22 wird synchron zum Stempel 23 durch entsprechende Betätigung des Antriebszylinders 31 in den Gravurteil 15 hineinverschoben.To the tightness of the blank 28 and the engraving 16 in the To ensure axial shortening of the blank 28 is, however a tracking of the respective stamp 22, 23 necessary. However, the stamps 22, 23 do not bring any additional ones the blank 28 compressive force, but only with the Shortening movement also shifted. The stamp 22.23 are for Tracking in the closed position of the forming tool 1 depending controlled by the calibration pressure according to a map, in which the pressure value of the current fluid pressure one Shift value for the stamp 22.23 is assigned, which by a measuring system, not shown here, on the stamp drive is transmitted. To move the lower punch 23 relatively to the lower tool half 3 is in the top 39 a lower cylinder 40, a spacer cylinder 40 is arranged, whose piston 41 on the underside 42 of the lower half of the tool 3 is attached. The piston 41 bounds with the cylinder base 43 a pressure chamber 44. The interaction of the pressure force within the pressure chamber 44 and the driving force of the drive cylinder 35 define the position of the stamp 23 relatively to the lower half of the tool 3. For tracking the punch 23 the pressure within the pressure space 44 is reduced as required, after which the piston 41 deeper into that of the drive cylinder 35 driven distance cylinder 40 immersed. The stamp 23 is thus moved into the engraving part 14. The Stamp 22 is synchronized with the stamp 23 by appropriate actuation of the drive cylinder 31 pushed into the engraving part 15.

    Nach erfolgter Kalibrierung wird der Fluiddruck entspannt, worauf der Pressenstößel 4 mit der oberen Werkzeughälfte 2 und dem Stempel 22 in seine obere Endposition angehoben wird und das Umformwerkzeug 1 sich somit öffnet. Dabei wird der fertigumgeformte Rohling 28 bis zur Trennebene 17 freigegeben (Fig. 3d). Um das Hohlprofil 47 in einfacher Weise aus dem unteren Gravurteil 14 zu entnehmen, wird im Druckraum 44 der Druck noch weiter abgesenkt, wonach der Kolben 41 noch tiefer in den Distanzzylinder 40 eintaucht, wodurch angetrieben durch den Antriebszylinder 35 der Stempel 23 weiter in den Gravurteil 14 hineinverschoben wird. Dabei beaufschlagt er axial das Hohlprofil 47 und schiebt diesen gleichermaßen aus der Aufnahme heraus, bis die oberste Verschiebestellung des Stempels 23 erreicht ist, in der der untere Öffnungsrand 45 des Hohlprofiles 47 im Übergang hohlzylindrischen Fortsatzes 33 zum von diesem aus konisch erweiterten Abschnitt 19 des Gravurteils 14 der unteren Werkzeughälfte 3 angeordnet ist (Fig.3e). Denkbar sind jedoch auch Stellungen über diese hinaus. Um die Haftung der oberen Werkzeughälfte 2 am Hohlprofil 47 im Gegensatz zu der der unteren Werkzeughälfte 3 zu verringern, kann die Trennebene 17 der beiden Werkzeughälften 2,3 zu dem konischen Abschnitt 19 des oberen Gravurteils 15 hinversetzt sein, so daß der untere Gravurteil 14 axial länger ist als der obere. In diesem Fall bildet die Trennebene 17 nicht wie bisher die Spiegelebene zwischen den Gravurteilen 14,15.After calibration, the fluid pressure is released, whereupon the press ram 4 with the upper tool half 2 and the stamp 22 is raised to its upper end position and the forming tool 1 thus opens. This is the finished one Blank 28 released to the parting line 17 (Fig. 3d). To the hollow profile 47 in a simple manner from the lower To remove the engraving part 14, the pressure is still in the pressure chamber 44 further lowered, after which the piston 41 goes deeper into the spacer cylinder 40 immersed, driven by the drive cylinder 35 the stamp 23 further into the engraving part 14 is pushed into it. He axially acts on the hollow profile 47 and equally push it out of the recording, until the uppermost displacement position of the stamp 23 is reached is in the lower opening edge 45 of the hollow profile 47 in the transition from hollow cylindrical extension 33 to this from conically enlarged section 19 of the engraving part 14 of the lower one Tool half 3 is arranged (Fig.3e). Are conceivable but also positions beyond this. To the liability of upper tool half 2 on the hollow profile 47 in contrast to the the lower tool half 3 can reduce the parting plane 17 of the two tool halves 2, 3 to the conical section 19 of the upper engraving part 15, so that the lower one Engraving part 14 is axially longer than the upper one. In this case does not form the parting plane 17 as before between the mirror plane the engraving parts 14.15.

    Eine mit einem zangenförmigen Greifer 46 bestückte robotische Entnahmevorrichtung untergreift die bauchige Aufweitung des Hohlprofiles 47 formschlüssig und stützt sich dabei an der Stirnseite 11 der unteren Werkzeughälfte 3 ab. Anschließend wird der Druck im Druckraum 44 erhöht und gleichzeitig die Antriebskraft des Antriebszylinders 35 verringert. Dabei wird die untere Stempelplatte 38 samt Stempel 23 nach unten zurückgezogen, wobei das Hohlprofil 47 durch die.Hintergreifung mittels des Greifers 46 vom Stempel 23 abgestreift wird (Fig. 3f). Hierauf ist das Hohlprofil 47 von der unteren Werkzeughälfte 3 vollständig losgelöst, so daß die Entnahme des Hohlprofiles 47 erfolgen kann (Fig. 3g). Anstelle eines Greifers 46 ist auch eine Entnahme mit einem saugnapfbestückten Roboterarm denkbar. Schließlich wird die untere Werkzeughälfte 3 in ihre untere Ausgangsposition unter Hydraulikdruckentspannung der Antriebszylinder 10 mittels ihres Eigengewichtes zurückgefahren.A robotic one equipped with a pincer-shaped gripper 46 Removal device engages under the bulbous expansion of the Hollow profile 47 positively and is based on the End face 11 of the lower tool half 3. Subsequently the pressure in the pressure chamber 44 is increased and at the same time the driving force of the drive cylinder 35 reduced. The lower stamp plate 38 together with stamp 23 pulled back down, whereby the hollow profile 47 by means of the engagement of the gripper 46 is stripped from the punch 23 (FIG. 3f). Then the hollow profile 47 is from the lower tool half 3 completely detached so that the removal of the hollow profile 47th can be done (Fig. 3g). Instead of a gripper 46 is also removal with a robot arm equipped with a suction cup is conceivable. Finally, the lower tool half 3 is in its lower Starting position under hydraulic pressure release of the drive cylinder 10 retracted by their own weight.

    Angemerkt sei an dieser Stelle, daß der Stempel 22,23 in werkzeugtechnisch einfacher und bezüglich des Arbeitsablaufes einfacher Weise sowohl die Funktion des Abdichtens der Gravur 16 und des Rohlinges 28 als auch der Bildung der Aufnahme für den Rohling 28 sowie des Auswerfens des fertigumgeformten Rohlinges 28 in sich trägt.It should be noted at this point that the stamp 22, 23 in tool technology easier and simpler in terms of the workflow Way both the function of sealing the engraving 16 and the blank 28 and the formation of the recording for the Blank 28 and the ejection of the fully formed blank 28 carries within.

    Nach der Entnahme wird der umgeformte Rohling 28 im Bereich seiner Ausbauchung mittig durch einen quer zu seiner Längserstreckung verlaufenden Schnitt mittels einer geeigneten Trennvorrichtung beispielsweise mittels eines Lasers in zwei identische Hohlprofile mit querschnittserweitertem Ende getrennt. Die Herstellung von einem Doppelteil pro Gravur 16 in einem Arbeitsgang erbringt damit für den Umformvorgang eine sehr hohe Effektivität und Produktivität. Die beschriebene Form der Gravur 16 und der Hohlprofile dienen in besonderer Anwendung als Anschlußstutzen für Katalysatorengehäuse, die mit diesen verschweißt werden.After removal, the formed blank 28 is in the area its bulge in the middle by a transverse to its longitudinal extent running cut using a suitable separating device for example by means of a laser into two identical ones Hollow sections separated with a cross-sectional end. The Production of one double part per engraving 16 in one operation thus provides a very high level for the forming process Effectiveness and productivity. The form of engraving described 16 and the hollow profiles serve as a special application Connection piece for catalytic converter housing, which is welded to them become.

    Alternativ kann der Distanzzylinder 40 während des Umformvorganges für eine starre Verbindung zwischen der unteren Stempelplatte 38 und der unteren Werkzeughälfte 3 sorgen. Die Zylinder 10 werden durch die Bewegung des als Umformzylinder dienenden Antriebszylinder 35 des Stempels 23 mitgeschleppt. Bei Erreichen der Anlagestellung der beiden Werkzeughälften 2,3 werden die Zylinder 10 mit hohem Druck beaufschlagt, um das Umformwerkzeug 1 beim nachfolgenden Kalibriervorgang geschlossen zu halten. Der Distanzzylinder 40 wird dagegen drucklos geschaltet, so daß ein Nachführen des Stempels 23 während des Kalibrierens möglich wird, um den Druck innerhalb der Gravur 16 aufrechterhalten zu können.Alternatively, the spacer cylinder 40 can be used during the forming process for a rigid connection between the lower stamp plate 38 and the lower tool half 3. The cylinders 10 are by the movement of the serving as a forming cylinder Drive cylinder 35 of the punch 23 entrained. When reached the contact position of the two tool halves 2, 3 the cylinders 10 are pressurized to the forming tool 1 closed during the subsequent calibration process hold. The spacer cylinder 40, on the other hand, is depressurized, so that tracking of the stamp 23 during calibration to the pressure within the engraving 16 to be able to maintain.

    Alternativ zur Umformung durch eine einerseits ortsfeste obere Werkzeughälfte 2 und eine andererseits hubbewegliche untere Werkzeughälfte 3 ist auch denkbar, daß die untere Werkzeughälfte 3 ortsfest angeordnet ist und daß die obere, mit dem Pressenstößel 4 einer Umformpresse fest verbundene Werkzeughälfte 2 hubbeweglich ist und zur Umformung des Rohlings 28 auf die untere Werkzeughälfte 3 verfahrbar ist. Hierzu entfällt natürlich der Distanzkörper 34. Bezüglich der Steuerung des Pressenstößels 4 in Abstimmung mit der Fluidhochdrucksteuerung gilt oben gesagtes. Im übrigen ist auch eine Steuerung denkbar, bei der beide Werkzeughälften 2,3 hubbeweglich sind und bis in die Anlagestellung aneinander aufeinanderzu verfahren werden können.As an alternative to reshaping by a stationary upper one Tool half 2 and on the other hand a movable lower one Tool half 3 is also conceivable that the lower tool half 3 is fixed and that the upper, with the press ram 4 of a forming press firmly connected tool half 2 is movable and for reshaping the blank 28 to the lower Tool half 3 is movable. Of course, this does not apply the spacer 34. Regarding the control of the press ram 4 in coordination with the high-pressure fluid control applies above said. Otherwise, a control is also conceivable in which both tool halves 2, 3 are movable and can be moved into the contact position can be moved towards each other.

    Claims (20)

    1. Method for manufacturing hollow profiles with end side cross-section extensions, wherein a hollow blank is expanded and calibrated through inner high pressure shaping by means of a shaping tool receiving the blank and consisting of two halves and after the calibration is cut through in the area of the expansion with the formation of two hollow profiles with cross-sectionally extended ends turned towards each other in the separating position,
      characterised in that
      the blank (28) is expanded in a continuous process when the shaping tool (1) is open and at the same time is compressed through a compressive force oriented axially from the outside onto at least one of the two blank ends (32, 48) to a rotation symmetrical, bulbous, preliminary shape which is approximated to the desired final form of the hollow profile, wherein the bulbous area is formed in a mirror symmetrical way to the middle transverse axis of the hollow profile (47), and that subsequently in the closed position of the shaping tool (1) the provisional form of the shaped blank (28) obtained through the expansion / compression process is calibrated by means of an increased inner pressure relative to the inner pressure during expansion / compression into a final form of the hollow profile (47) completely pressed on the engraved area (16).
    2. Method according to Claim 1,
      characterised in that
      the hollow profile (47) produced after the inner high pressure shaping, after its removal from the shaping tool (1), is separated in the area of its bulbous part, concentrically in transverse direction to the longitudinal extension of the hollow profile (47).
    3. Method according to Claim 1,
      characterised in that
      during calibration wall material of the blank (28) is axially pushed to its bulbous area.
    4. Method according to Claim 1,
      characterised in that
      a conically expanded bulbous area is formed on the blank (28) through the shaping process.
    5. Method according to Claim 4,
      characterised in that
      through the separation of the hollow profile (47) in the bulbous area individual hollow profiles in the same form are produced as connections for catalytic housing.
    6. Device for manufacturing hollow profiles with end side cross-section extensions, with an inner high pressure shaping tool consisting of two tool halves which can be displaced relative to each other in vertical direction and which lie on top of each other in the closed position, wherein this inner high pressure shaping tool has an engraved area formed from the two front sides of the tool halves turned towards each other for the purpose of applying a hollow longitudinal blank which is to be processed, wherein this engraved area has radial recesses deviating from the contour of the blank, with a fluid pressure producing installation, by means of which after the introduction of a pressure fluid into the blank a high pressure expanding the blank can be applied, with a device for axial fluid high pressure-tight sealing of the engraved area and with an externally arranged separating device, by means of which in the area of the expansion of the blank the latter can be separated into two hollow profiles with cross-sectionally extended ends, for the purpose of implementing the method according to Claim 1,
      characterised in that
      the separating plane (17) of the tool halves (2, 3) runs at right angles to the longitudinal extension of the rotation symmetrically formed engraved area (16) and is displaced at a distance from the mirror plane to the upper tool half (2) running centrally through the radial recesses of the engraved area (16) consisting of two hollow engraved area parts (14, 15) forming the expansion area in such a way that it forms the transition from a hollow cylindrical section (18) of the engraved area part (15) coming from the separating plane (17) to a tapering section (19) attaching thereto,
      the tool halves (2, 3) have a receiving point, in which in an open position of the shaping tool (1) an end (32, 48) of an inserted blank (28) is held in a completely enclosed and pressure-tight way, wherein the receiving points are formed from linear running hollow cylindrical extensions (33) of the engraved area (16) and from conically formed ends of a punch (22, 23), which is guided in a displaceable way in a guide bore (20) carrying through the respective tool half (23) and opening in the engraved area part (16) of the tool half (2, 3) with a separate drive with regard to the movable tool half,
      and that the device contains a control unit for controlling the relative movement of the tool halves (2, 3) to each other, wherein this control is correlated with the pressure control of the fluid pressure producing installation in such a way that the tool halves (2, 3) - starting from the open shaping tool (1) - approach each other in a resulting axial compression effect upon the blank (28) expanding at the same time through inner high pressure in a continuous movement until the two tool halves (2, 3) are lying against each other, wherein this position forms the closed position of the shaping tool (1), in which the movement control is de-coupled from the pressure control, after which the fluid pressure producing installation for the calibration process of the expanded / compressed hollow profile (47) produces a considerably higher fluid pressure in relation to the fluid pressure during expansion / compression.
    7. Device according to Claim 6,
      characterised in that
      the upper tool half (2) is secured on a pressing ram (4) of a shaping press, which can be displaced on a distance body (34) anchored to the pressing table (5), wherein the upper tool half (2) assumes a steadying position, in which the inserted blank (28) is held in the receiving point there.
    8. Device according to Claim 6,
      characterised in that
      the lower tool half (3) is equipped with a separate drive with regard to the upper tool half (2), by means of which it can be displaced in a lifting way.
    9. Device according to Claim 6,
      characterised in that the punch (23) of the lower tool half (3) is driven in such a way that during the approaching process of the two tool halves (2, 3) until they are lying against one another it constantly has the same relative position to the lower tool half (3) and can be displaced, when the tool halves (2, 3) are lying against one another, relative to the position of the lower tool half (3).
    10. Device according to Claim 6,
      characterised in that
      the form of an engraved area part (14, 15) is formed according to a conical connection for a catalytic converter.
    11. Device according to Claim 6,
      characterised in that
      the punch (23) of the lower tool half (3), after the release of the upper end (32) of the finished shaped blank (28) brought about by a lifting movement of the upper tool half (2), can be displaced so far into the engraved area part (14) of the lower tool half (3) that the blank (28) displaced along with it can be sensed by a removal device of the manufacturing device.
    12. Device according to Claim 11,
      characterised in that
      in the sensing position of the removal device the punch (23) assumes a withdrawal position in the guide bore (20), in which it is de-coupled from an impact of the finished shaped blank (28) forming the hollow profile (47).
    13. Device according to Claim 11,
      characterised in that
      the upper displacement position of the punch (23) is that in which the lower opening edge (45) of the hollow profile (47) formed from the shaped blank (28) is arranged in the transition of the receiving point to the recess of the engraved area part (14) of the lower tool half (3).
    14. Device according to Claim 6,
      characterised in that
      the shaping tool (1) has several engraved areas (16) with associated receiving points for the blank (28) to be inserted, wherein these engraved areas (16) are arranged parallel to each other.
    15. Device according to Claim 6,
      characterised in that
      the movement control is associated with the lower tool half (3), wherein the control is characterisation field control with pressure / position value pairs stored in the electronic control unit, wherein the pressure value of a momentarily produced fluid pressure is associated with a position value of the position of the lower tool half (3) to be assumed, into which the lower tool half (3) can be raised or lowered depending upon position.
    16. Device according to Claim 15,
      characterised in that
      the device contains a displacement measuring device (36), whose displacement measurement indicator (37) is arranged at one end on the lower tool half (3) which can be moved in a lifting way and on the other end in a fixed way and which is coupled with the drive of the lower tool half (3) in such a way that the position values given by the characterisation field control form a measure for the size and direction of the driving force.
    17. Device according to Claim 6,
      characterised in that
      the lower tool half (3) is movement-controlled by means of pre-programmed drive values stored in the control unit.
    18. Device according to Claim 17,
      characterised in that
      the pressure control of the fluid pressure producing installation is characterisation field control with position / pressure value pairs stored in the electronic control unit, wherein a position value relating to the momentary position of the tool half (3) given by a displacement measuring device (36) coupled with the drive of the lower tool half (3) depending upon the momentary drive value is attributed to a reference pressure value of the fluid pressure to be produced by the fluid pressure producing installation, with which the pressure producing installation aligns its afore-mentioned actual value.
    19. Device according to Claim 6,
      characterised in that
      the lower tool half (3) is arranged in a fixed way and the upper tool half (2), which can be moved in a lifting way and which is securely fixed with a pressing ram (4) of a shaping press, can be displaced for the purpose of shaping the blank (28) onto the lower tool half (3).
    20. Device according to Claim 6,
      characterised in that
      the punches (22, 23) are controlled, when the shaping tool (1) is in closed position, in a displaceable way depending upon the calibration pressure in such a way that they can be subsequently guided according to the shortening of the blank (28) conditioned by the expansion.
    EP97119522A 1996-11-20 1997-11-07 Method of and installation for manufacturing hollow profiles with end cross-section extensions Expired - Lifetime EP0849011B1 (en)

    Applications Claiming Priority (2)

    Application Number Priority Date Filing Date Title
    DE19648091 1996-11-20
    DE19648091A DE19648091C2 (en) 1996-11-20 1996-11-20 Method and device for producing hollow profiles with end cross-sectional enlargements

    Publications (2)

    Publication Number Publication Date
    EP0849011A1 EP0849011A1 (en) 1998-06-24
    EP0849011B1 true EP0849011B1 (en) 2001-09-12

    Family

    ID=7812278

    Family Applications (1)

    Application Number Title Priority Date Filing Date
    EP97119522A Expired - Lifetime EP0849011B1 (en) 1996-11-20 1997-11-07 Method of and installation for manufacturing hollow profiles with end cross-section extensions

    Country Status (4)

    Country Link
    US (1) US6009734A (en)
    EP (1) EP0849011B1 (en)
    DE (1) DE19648091C2 (en)
    ES (1) ES2163701T3 (en)

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    CN104128421A (en) * 2014-07-31 2014-11-05 上海永太汽车零部件厂 Internal high-pressure forming equipment
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    Also Published As

    Publication number Publication date
    ES2163701T3 (en) 2002-02-01
    DE19648091A1 (en) 1998-05-28
    EP0849011A1 (en) 1998-06-24
    DE19648091C2 (en) 1999-10-28
    US6009734A (en) 2000-01-04

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