EP1197273A1 - Dispositif et méthode pour la déformation mécanique, hydromécanique ou hydraulique - Google Patents

Dispositif et méthode pour la déformation mécanique, hydromécanique ou hydraulique Download PDF

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Publication number
EP1197273A1
EP1197273A1 EP00870228A EP00870228A EP1197273A1 EP 1197273 A1 EP1197273 A1 EP 1197273A1 EP 00870228 A EP00870228 A EP 00870228A EP 00870228 A EP00870228 A EP 00870228A EP 1197273 A1 EP1197273 A1 EP 1197273A1
Authority
EP
European Patent Office
Prior art keywords
die
porous
forming
fluid
hydroforming
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.)
Withdrawn
Application number
EP00870228A
Other languages
German (de)
English (en)
Inventor
Michel Vermeulen
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.)
Sidmar SA
Original Assignee
Sidmar SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Sidmar SA filed Critical Sidmar SA
Priority to EP00870228A priority Critical patent/EP1197273A1/fr
Publication of EP1197273A1 publication Critical patent/EP1197273A1/fr
Withdrawn legal-status Critical Current

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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
    • 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
    • B21D26/021—Deforming sheet bodies
    • B21D26/027—Means for controlling fluid parameters, e.g. pressure or temperature
    • 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
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/205—Hydro-mechanical deep-drawing
    • 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
    • B21D26/021—Deforming sheet bodies
    • B21D26/031—Mould construction
    • 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
    • B21D26/041—Means for controlling fluid parameters, e.g. pressure or temperature
    • 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 present invention is related essentially to devices used for forming objects, in particular from flat sheet material or tubes by a hydroforming (HF) process, a mechanical process or a hydro-mechanical forming process.
  • HF hydroforming
  • a sheet is pushed against a die by a punch, in order to take on the form of the punch and of the die's inside wall.
  • a hydraulic pressure is locally added to this mechanical force, in order to facilitate the deformation process.
  • hydroforming (HF) techniques exist, wherein a tube or a sheet of a given material, such as metal, composite or plastic is deformed solely by applying a hydraulic pressure inside a hollow die, pushing the tube or sheet against said die so that said tube or sheet takes on the form of said die's interior surface.
  • Any fluid can be used, e.g. a mixture of oil and water, suitably treated for high-pressure applications, i.e. anti-corrosion, lubricating additives for pumps, piping and drainage.
  • the outer surfaces of the component to be formed are lubricated in order to reduce friction and wear.
  • the use of special fluids can improve the situation to some extent.
  • the present invention aims to provide a device and a method, in particular for hydroforming, wherein friction is reduced in the zones where it is needed the most, i.e. where the actual deforming is taking place.
  • the present invention equally aims to use the device and method according to the invention in conventional mechanical forming techniques such as deep drawing techniques.
  • the present invention is related to a device used for forming an object, in particular from a sheet or tube, said device comprising at least one die, said die having at least one alcove in the inner wall of said die, said alcove being connected to a hydraulic supply system, said system supplying a fluid flow between said material and said die, characterised in that said alcove is partially filled by a porous zone, said porous zone representing a restrictor in said fluid flow, said porous zone being placed flush with the die wall, so that no interruption of said die wall occurs.
  • Said porous zone may be formed by a piece of porous material, said material may be metallic or non-metallic.
  • said porous zone consists of a plurality of slots.
  • said porous zone consists of a plurality of bores.
  • a device according to the present invention may be a device used for hydroforming of objects, or a device used for mechanical or hydro-mechanical forming of objects.
  • One embodiment of the invention is related to a device, wherein at least one separate hydraulic system is used for supplying fluid to said porous zones.
  • Another embodiment of the present invention is related to a device for hydroforming or hydro-mechanical forming, wherein the hydraulic system used for supplying the hydroforming pressure or the hydraulic pressure during hydro-mechanical forming is also used to supply the fluid to said porous zones.
  • the present invention is equally related to a method to perform hydroforming using a device according to the invention, said method being characterised in that a plurality of porous zones is activated by supplying them with fluid, said activating of said zones taking place in a sequence during the deformation process.
  • Fig. 1 represents a schematic view of an HF installation according to the prior art.
  • Fig. 2 illustrates the problem of acquiring a small radius by hydroforming.
  • Fig. 3a represents a schematic view of an HF installation according to the present invention.
  • Fig 3b represents a detailed view of a device according to the present invention.
  • Fig. 4 represents a schematic view of the flow through the device according to the present invention.
  • Fig. 5 represents an alternative restrictor in the fluid flow according to the invention.
  • Fig. 6 represents a restrictor consisting of a plurality of slot inserts.
  • Fig. 7 represents a restrictor consisting of a plurality of bores with small diameter.
  • Fig. 8 represents an installation according to another embodiment of the invention.
  • Fig. 9 represents an exemplary case of a device according to the present invention.
  • Figure 1 shows a schematic view of a hydroforming device, comprising a die 1.
  • the internal pressure p i is exerted on the die's interior, said pressure being provided by a hydraulic supply system 2.
  • the pressure p i causes a sheet of material 3 to take on the form of the die's interior wall.
  • the sheet is clamped between die and blankholder 4. A problem occurs when it comes to pushing the material into the corners of the die and acquiring a sharp radius there.
  • Figure 2 shows an enlarged view of one of the corners of the die shown in figure 1.
  • a high pressure is needed to give the sheet such a sharp radius.
  • the friction forces between the sheet and the die are so high that sliding of the sheet along the die wall is no longer possible, so that the material can only be pushed into the corner by stretching the available material between the contact points 5 and 6. This may easily lead to cracking of the material. Otherwise, insufficient component radii can be obtained.
  • existing methods of supplying fluids between the material and the die show some clear disadvantages.
  • Figure 3a shows the same device, with means 7 for lubricating and maintaining the gap between the sheet and the die, according to a preferred embodiment of the present invention.
  • Figure 3b shows a detailed view of said means 7.
  • At least one alcove 11 is produced in the die wall.
  • a porous insert 12 which is placed flush with the inner die wall 13 in such a way that no discontinuity appears in said wall 13.
  • Above the insert a portion of the alcove 11 is left unoccupied, forming a cavity 14.
  • the alcove 11 is then connected through a channel 15 with a fluid supply system 16. A flow of fluid is maintained through the pores of the porous insert and into the gap 17 between the die 1 and the sheet 3, thereby maintaining a small lubricating gap between said die and sheet. This results in very low friction.
  • the die wall is now smooth and uninterrupted by the alcove 11, so that no material can be pushed into the alcove.
  • this kind of tool offers the added advantage of making optimal use of the hydrostatic bearing principle. This is explained in more detail on the basis of figure 4.
  • This figure 4 represents a porous insert 12 according to the invention and an equivalent hydraulic circuit corresponding to the fluid flow through said insert and the gap 17 between the die 1 and the material 3 to be formed.
  • the cavity 14 is equivalent to a hydraulic capacitance C C , with a given resistance R C in parallel. After this cavity 14, the fluid flow is restricted by two resistances in series: R r , defined by the porous insert 12, and R g , defined by the gap 17.
  • the porous insert can be made of any porous material, metallic (e.g. bronze, iron, etc.) or non-metallic (e.g. ceramic).
  • the bearing material should have suitable compression and tensile strength and appropriate roughness properties: R a should be sufficiently low and the skewness R sk should be negative.
  • the insert can have any form suitable for its location: square, round disc, annular cylindrical rings,...
  • a porous insert Besides a porous insert, other means are possible to create a restrictor close to the sheet, without creating a discontinuity in the die wall.
  • One of these options consists of a number of so-called 'slot entries'.
  • This type of restrictor consists of a number of narrow slots, with given dimensions such as length 1, width w and slot thickness d. From these dimensions, the hydraulic resistance can be easily calculated.
  • Figure 5 shows an embodiment whereby a number of these slots 18 have been made in the die wall.
  • Figure 6 shows the cross section along the line AA' with the slots 18.
  • a separate insert, containing these slots may be placed in the alcove, analogous to the porous insert 12.
  • the thickness d of the slot entries must be sufficiently lower than the sheet thickness t, in order to avoid deformation of the sheet into the slot itself and consequently to avoid sliding obstruction of the sheet along the die wall.
  • FIG. 7 shows the section along AA' for this type of restrictor.
  • the number of bores may be much larger than shown on this drawing.
  • the bores may be placed at non-equal distances from each other. It is however essential that they result in a homogenous flow resistance over the entire surface.
  • a restrictor of this type may equally be obtained by placing a separate insert, containing these bores. The diameter a of the bores must once again be sufficiently lower than the sheet thickness t to avoid the sheet being 'pushed' into the bores, which would cause an obstruction to the sliding of said sheet along the die wall.
  • the present invention is related to a forming device, comprising one or more porous zones through which fluid is supplied and which are flush with the die wall.
  • Said porous zones can be either separate inserts made of porous material, inserts containing slots or bores, or simply slots or bores in the die wall.
  • the porosity must be such that the die wall is smooth on all locations, and that no deformation of the material into the pores, slots or bores can occur.
  • one insert or restrictor zone may be supplied with fluid from several supply lines, so that this one insert may serve to lubricate several locations (see references 47 and 48 or 49 and 50 in fig. 9).
  • a drain channel must be present in the die, so that the fluid can be evacuated from the space between the material and the die. This drain is not shown in figures 3a and 8. It is however shown in figure 9 (see number 60).
  • a forming device can be a hydroforming device such as shown in figure 3a, or a device used for mechanical forming (such as a deep drawing device) or hydro-mechanical forming,
  • a device used for mechanical forming such as a deep drawing device
  • hydro-mechanical forming the porous zones and their hydraulic supply systems are equally applicable in these latter types of devices.
  • the pressure control of the fluid flow into the hydrostatic inserts according to the invention can be realised separately, as in figure 3a, by applying a different hydraulic supply system 16 for each insert 12.
  • the pressure control can alternatively be integrated in the hydraulic system of the hydroforming or hydromechanical forming process, as shown in figure 8.
  • a simple shut-off valve 20 in the path to the inserts has to be used to stop the flow when the material is not yet present at the location of the insert. It is advised to open this valve during a stepping down or a low-pressure period of the internal HF pressure.
  • simultaneous or sequential action of the appropriate valve(s) has to be realised depending on the specific application. Said sequential action forms the basis of the method according to the present invention, described hereafter.
  • the present invention is equally related to a method to perform a forming technique on a sheet or a tube, such as hydroforming.
  • the method is characterised by the fact that the inserts 12 or more generally 'porous zones' (thereby including the slot entry and bore-type inserts), are activated in a given sequence during the deformation process, so that fluid is supplied to the area's where the friction forces are the highest.
  • the porous zones are activated by turning on the independent supply systems 16 in the embodiment of figure 3a, e.g. by using active control valves to control said supply systems. In the embodiment of figure 8, the porous zones are activated by operating the valves 20.
  • the sequence will depend on the object to be formed, and may be controlled on the basis of different principles of which three are mentioned here:
  • the cavity pressure (inside alcoves 11) must be higher than the internal hydroforming pressure (in the case of HF) in order to guarantee a positive flow of fluid through the insert in the direction of the gap.
  • said internal pressure may be lowered at regular intervals, so that a lubrication at the insert locations may be effectuated at the same regular intervals.
  • the capacitor action of the alcove 11 (and its connecting lines), along with an efficient design of the porous insert system can cause a periodic lubrication of the gap between sheet and die wall during each stepping down cycle of the (internal) pressure loop.
  • Figure 9 illustrates an example of a hydroforming device and method according to the present invention.
  • the device shown exhibits cylindrical symmetry around the axis 30.
  • a sheet 31 is being formed by way of an internal pressure p i inside the die 40.
  • One flat porous insert 41 is present on the top surface, and one cylindrical ring insert 42 is present around the curved surface.
  • Several cavities 43, 44, 45, 46 are present close to the porous inserts, said cavities being connected via supply lines 47, 48, 49, 50 respectively to the hydraulic supply system (not shown).
  • the cavity 44 is ring shaped and supplied with fluid through the supply line 48.
  • a drain tube 60 is present to allow the fluid to be evacuated from the space between the die and the object to be formed.
  • a proximity sensor 61 is present.
  • the deformation process is subdivided into different phases, each phase being characterised by the lubrication action of a different supply line.
  • Three states of the object during deformation are labelled 31, 32 and 33.
  • different supply lines of fluid can be activated in a given sequence, in order to acquire an optimal flow of the sheet material into the sharp corners of the die.
  • the sheet is deformed into state 31 by applying an internal pressure while activating the central supply line 47 in order to let the sheet material slide easily along the flat top surface of the die cavity.
  • the material is further deformed with the additional help of the supply line 50, making the sheet slide more easily along the die's side wall.
  • the supply lines 48 and 49 are simultaneously activated, allowing the sheet to slide into the sharp corner of the die cavity and to acquire the final state 33.
EP00870228A 2000-10-10 2000-10-10 Dispositif et méthode pour la déformation mécanique, hydromécanique ou hydraulique Withdrawn EP1197273A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP00870228A EP1197273A1 (fr) 2000-10-10 2000-10-10 Dispositif et méthode pour la déformation mécanique, hydromécanique ou hydraulique

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Application Number Priority Date Filing Date Title
EP00870228A EP1197273A1 (fr) 2000-10-10 2000-10-10 Dispositif et méthode pour la déformation mécanique, hydromécanique ou hydraulique

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EP1197273A1 true EP1197273A1 (fr) 2002-04-17

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8701453B2 (en) 2010-12-23 2014-04-22 Ford Global Technologies, Llc Method of reducing cycle time in a hydro-mechanical forming process and a tool for hydro-mechanically forming a part

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2821156A (en) * 1951-12-05 1958-01-28 Lyon George Albert Die
JPH04371323A (ja) * 1991-06-20 1992-12-24 Honda Motor Co Ltd プレスドロー金型におけるパンチ部材表面への自動塗油装置
EP0771598A1 (fr) * 1995-11-09 1997-05-07 Benteler Ag Procédé pour diminuer le frottement lors du formage hydraulique par haute pression interne et dispositif pour le formage hydraulique
DE19751413A1 (de) * 1997-11-14 1999-06-02 Mannesmann Ag Verfahren und Vorrichtung zur Verminderung der Wandreibung beim Innenhochdruck-Umformungsprozess

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2821156A (en) * 1951-12-05 1958-01-28 Lyon George Albert Die
JPH04371323A (ja) * 1991-06-20 1992-12-24 Honda Motor Co Ltd プレスドロー金型におけるパンチ部材表面への自動塗油装置
EP0771598A1 (fr) * 1995-11-09 1997-05-07 Benteler Ag Procédé pour diminuer le frottement lors du formage hydraulique par haute pression interne et dispositif pour le formage hydraulique
DE19751413A1 (de) * 1997-11-14 1999-06-02 Mannesmann Ag Verfahren und Vorrichtung zur Verminderung der Wandreibung beim Innenhochdruck-Umformungsprozess

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8701453B2 (en) 2010-12-23 2014-04-22 Ford Global Technologies, Llc Method of reducing cycle time in a hydro-mechanical forming process and a tool for hydro-mechanically forming a part

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