EP1299266A1 - Method of manufacturing structural members and the members provided by such method - Google Patents

Method of manufacturing structural members and the members provided by such method

Info

Publication number
EP1299266A1
EP1299266A1 EP01958645A EP01958645A EP1299266A1 EP 1299266 A1 EP1299266 A1 EP 1299266A1 EP 01958645 A EP01958645 A EP 01958645A EP 01958645 A EP01958645 A EP 01958645A EP 1299266 A1 EP1299266 A1 EP 1299266A1
Authority
EP
European Patent Office
Prior art keywords
energy absorbing
shape
members
parts
manufacturing
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Withdrawn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
EP01958645A
Other languages
German (de)
French (fr)
Inventor
Tor Arne Stjern
Egil Tromborg
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.)
Norsk Hydro ASA
Original Assignee
Norsk Hydro ASA
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 Norsk Hydro ASA filed Critical Norsk Hydro ASA
Publication of EP1299266A1 publication Critical patent/EP1299266A1/en
Withdrawn legal-status Critical Current

Links

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
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/14—Making other products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08—Making tubes with welded or soldered seams
    • B21C37/0803—Making tubes with welded or soldered seams the tubes having a special shape, e.g. polygonal tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/24—Arrangements for mounting bumpers on vehicles
    • B60R19/26—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means
    • B60R19/34—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means destroyed upon impact, e.g. one-shot type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
    • B62D21/15—Understructures, i.e. chassis frame on which a vehicle body may be mounted having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body
    • B62D21/152—Front or rear frames

Definitions

  • the present invention relates to a method of manufacturing energy absorbing structural members having closed cross-sectional configuration, and more particularly to manufacturing of crash boxes in (motor) vehicles, and also the members provided by such method.
  • a further object of the present invention is to provide novel energy absorbing structural members exhibiting variations in their wall thickness in the direction of their longitudinal extension comprising integrated additional parts.
  • Fig. 1 shows schematically in a perspective view an extruded open shape
  • Figs. 2-3 illustrate in a perspective view subsequent steps of material removing and reshaping/folding of the shape
  • Fig. 4 shows schematically the formed closed shape member being joined along abutted longitudinally extending folded walls.
  • Figure 1 is a perspective view of an open shape 1 being conventionally provided by extrusion process, or alternatively by drawing of aluminium alloy material.
  • the open shape is extruded with protruding ribs 11 ,12, representing a material buffer for consequent steps of reshaping and so does the thicker wall part 13 extending longitudinally in the extrusion direction as indicated in Figure 1.
  • Figure 2 illustrates schematically the second step of the manufacturing method - cutting of excess material from the protruding ribs 11 ,12, thus providing several vertically protruding parts 22,23.
  • Figure 3 schematically illustrates a first step in the process of bending/reshaping along the longitudinal extension of the energy absorbing member to be, showing formation of a side wall and top wall where the top wall at the same time provides a joining seam line 31 to be abutted to the corresponding seam line 32 after finishing the bending operation.
  • the buffer material from the thicker wall part 33, originally extruded in the longitudinal extrusion direction, is advantageously applied in providing thicker parts situated in front of the formed member and in plan normal to the extruding direction.
  • this novel method of manufacturing allows to provide the excess material in areas needed for formation of e.g. fastening flanges, reinforcing ribs etc. as illustrated in Figure 4.
  • Figure 4 illustrates schematically in a perspective view the ready folded hollow energy absorption member where the abutted opposing walls 41 ,42 are joined together along the joining line 43, preferentially by the new welding process so-called friction stir welding, resulting in no thermal distortion of the welded member.
  • the novel integral one-piece energy member in this particular case a crash box member, is provided with front part 44 exhibiting increased wall thickness. Furthermore, provision of the integrated flanges 45 simplifies construction and facilitates assembling, thus reducing both time and cost of the assembling operations. Additionally several protruding parts can be provided, e.g. the shown attachment flanges 46 integrated with the rear part of the crash box and reinforcing ribs 47 or means for e.g. fastening towing hooks (not shown in the Figure).
  • the actual energy absorbing structural member provided by the novel manufacturing method could be a (front/rear) side member in the space frame construction of vehicles.
  • the actual energy absorbing structural member provided by the novel manufacturing method could be a (front/rear) side member in the space frame construction of vehicles.
  • other cross-sectional configurations than the shown rectangular one can advantageously be provided by means of the novel manufacturing method.

Abstract

Energy absorbing structural member provided as an integral one-piece member exhibiting variation in wall thickness provided by a manufacturing method comprising steps of extruding an open shape, bending it along the major axis into a final cross-sectional configuration and finally closing the shape along abutted walls by welding operation.

Description

"Method of manufacturing structural members and the members provided by such method"
The present invention relates to a method of manufacturing energy absorbing structural members having closed cross-sectional configuration, and more particularly to manufacturing of crash boxes in (motor) vehicles, and also the members provided by such method.
Presently such structural members are provided by a conventional extrusion process (particularly members made of Al or Al-alloys), extruding closed shapes of the required cross-sectional configuration and uniform wall thickness in their longitudinal extension in one production step.
However, there are several disadvantages connected to the present conventional manufacturing method of such members. First of all, due to the limitations inherent to the extrusion process a lower extruding speed and increased die wear are typical for providing (intricate) closed shapes compared to provision of open ones.
Furthermore, it is not possible to provide shapes exhibiting variation along their longitudinal extension, and there is a limit with regard to a maximum achievable diameter (cross-sectional area) of the provided shape (members). Consequently, in order to meet various requests to specific performance of the actual structural members and/or cope with the limited available space left for the member it is necessary to reshape the members and reinforce/strengthen them on predetermined locations. It is therefore an object of the present invention to provide a new method of manufacturing energy absorbing structural members offering more flexibility with regard to their cross-sectional configuration and no limitation of the maximum diameter of the resulting members.
A further object of the present invention is to provide novel energy absorbing structural members exhibiting variations in their wall thickness in the direction of their longitudinal extension comprising integrated additional parts.
These and other objects are achieved in accordance with the present invention by provision of a novel manufacturing method and the resulting structural members as it appears from the attached patent claims 4 and 1.
Specific novel features and advantages of the structural members provided by the manufacturing method according to the invention will be apparent from the following detailed description of preferred embodiment(s) of the structural member with reference to the accompanying drawings, Figs. 1-4, where
Fig. 1 shows schematically in a perspective view an extruded open shape,
Figs. 2-3 illustrate in a perspective view subsequent steps of material removing and reshaping/folding of the shape, and
Fig. 4 shows schematically the formed closed shape member being joined along abutted longitudinally extending folded walls.
Referring to Figures 1-4 illustrating by the way of example steps in the novel manufacturing process of a crash box according to the present invention, Figure 1 is a perspective view of an open shape 1 being conventionally provided by extrusion process, or alternatively by drawing of aluminium alloy material. The open shape is extruded with protruding ribs 11 ,12, representing a material buffer for consequent steps of reshaping and so does the thicker wall part 13 extending longitudinally in the extrusion direction as indicated in Figure 1.
Figure 2 illustrates schematically the second step of the manufacturing method - cutting of excess material from the protruding ribs 11 ,12, thus providing several vertically protruding parts 22,23.
Figure 3 schematically illustrates a first step in the process of bending/reshaping along the longitudinal extension of the energy absorbing member to be, showing formation of a side wall and top wall where the top wall at the same time provides a joining seam line 31 to be abutted to the corresponding seam line 32 after finishing the bending operation. The buffer material from the thicker wall part 33, originally extruded in the longitudinal extrusion direction, is advantageously applied in providing thicker parts situated in front of the formed member and in plan normal to the extruding direction. Thus this novel method of manufacturing allows to provide the excess material in areas needed for formation of e.g. fastening flanges, reinforcing ribs etc. as illustrated in Figure 4.
Figure 4 illustrates schematically in a perspective view the ready folded hollow energy absorption member where the abutted opposing walls 41 ,42 are joined together along the joining line 43, preferentially by the new welding process so-called friction stir welding, resulting in no thermal distortion of the welded member.
As it appears from Figure 4 the novel integral one-piece energy member, in this particular case a crash box member, is provided with front part 44 exhibiting increased wall thickness. Furthermore, provision of the integrated flanges 45 simplifies construction and facilitates assembling, thus reducing both time and cost of the assembling operations. Additionally several protruding parts can be provided, e.g. the shown attachment flanges 46 integrated with the rear part of the crash box and reinforcing ribs 47 or means for e.g. fastening towing hooks (not shown in the Figure).
Although the present invention has been described and illustrated with respect to the preferred features/embodiments and manner of manufacturing, it is to be understood that various changes and modifications may be made to the specifically described and illustrated arrangement without departing from the scope of the present invention.
Thus, e.g. the actual energy absorbing structural member provided by the novel manufacturing method could be a (front/rear) side member in the space frame construction of vehicles. Furthermore, other cross-sectional configurations than the shown rectangular one can advantageously be provided by means of the novel manufacturing method.

Claims

Claims
Energy absorbing structural member, particularly a crash box or side member in a vehicle frame structure comprising a closed shape (1) of any suitable cross-sectional configuration characterized in that the member is an integral one-piece member exhibiting variation in wall thickness being further provided with integrated protruding parts
(45,46,47), said parts having additional performance functions.
Energy absorbing member according to claim 1 , characterized in that the members are extruded and where the integrated parts are laterally extending attachment flenses (45,46).
Energy absorbing member according to claim 1 or 2, characterized in that the (extruded) member is made of aluminium alloy.
Method of manufacturing the energy absorbing member according to claim
1 , the method comprising steps of extruding an open shape exhibiting varied wall thickness across its lateral extension, removing of excess material/cutting bending of the shape along the major axis into a final configuration of the energy absorbing member including additional functional parts, and finally closing the shape by bending and abutting of opposing walls and joining of the thus abutted walls by any joining technique known per se. Method according to claim 4, characterized in that the joining is done by a welding operation.
Method according to claim 5, characterized in that the welding operation is friction stir welding.
EP01958645A 2000-07-10 2001-07-10 Method of manufacturing structural members and the members provided by such method Withdrawn EP1299266A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
NO20003555 2000-07-10
NO20003555A NO20003555L (en) 2000-07-10 2000-07-10 Process for the preparation of structural elements and the resulting elements
PCT/NO2001/000295 WO2002004253A1 (en) 2000-07-10 2001-07-10 Method of manufacturing structural members and the members provided by such method

Publications (1)

Publication Number Publication Date
EP1299266A1 true EP1299266A1 (en) 2003-04-09

Family

ID=19911365

Family Applications (1)

Application Number Title Priority Date Filing Date
EP01958645A Withdrawn EP1299266A1 (en) 2000-07-10 2001-07-10 Method of manufacturing structural members and the members provided by such method

Country Status (4)

Country Link
EP (1) EP1299266A1 (en)
AU (1) AU2001280270A1 (en)
NO (1) NO20003555L (en)
WO (1) WO2002004253A1 (en)

Families Citing this family (14)

* Cited by examiner, † Cited by third party
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DE10214473A1 (en) * 2002-03-30 2003-10-23 Bayerische Motoren Werke Ag Cross member between two lateral edge areas of a vehicle door
DE10335666A1 (en) * 2003-08-04 2005-04-14 Bayerische Motoren Werke Ag Compression/tension strut for vehicle body is in one piece and consists of at least two sections with different wall thicknesses in axial direction with continuous transition region between sections
EP1654149B1 (en) * 2003-08-06 2008-09-10 Dofasco Tubular Products Inc. Vehicle frame having energy management system and method for making same
DE102005057429B4 (en) * 2005-11-30 2009-06-25 Benteler Automobiltechnik Gmbh crash box
DE102013211794A1 (en) * 2013-06-21 2014-12-24 Magna International Inc. Receptacle for a towing vehicle and method of manufacture
CN104690496A (en) * 2013-12-04 2015-06-10 青岛润鑫伟业科贸有限公司 Cold processing technological method for refining metal grains
CN103878554B (en) * 2014-04-01 2016-02-10 湖南大学 The processing method of the thin-shell absorption structure that a kind of gradient distribution distributes
CN104384842A (en) * 2014-09-28 2015-03-04 常州捷佳创精密机械有限公司 Manufacturing method of tank
KR20160060271A (en) 2014-11-20 2016-05-30 현대자동차주식회사 Crash box of vehicle and assembly method thereof
CN104691464A (en) * 2015-03-10 2015-06-10 东北大学 Vehicular longitudinal metal energy absorbing box with variable wall thickness and preparation method thereof
DE102016101150A1 (en) 2016-01-22 2017-07-27 Benteler Automobiltechnik Gmbh Impact beam and method for producing an impact beam
KR101903481B1 (en) * 2016-12-20 2018-10-02 주식회사 성우하이텍 Crash box for vehicle and manufacturing method thereof
CN109623274A (en) * 2018-12-17 2019-04-16 马鞍山市新马精密铝业股份有限公司 A kind of machine-tooled method of aluminum alloy material energy-absorption box
CN113385896B (en) * 2021-06-10 2023-03-17 深圳金鑫绿建股份有限公司 Process for welding cranked box type

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DE19533366C2 (en) * 1995-09-09 1998-03-19 Ymos Ag Ind Produkte Impact beams for motor vehicles
JP3403290B2 (en) * 1996-03-22 2003-05-06 古河電気工業株式会社 Aluminum alloy extruded square tube for front side member with excellent axial compression characteristics
NO964154L (en) * 1996-10-01 1998-04-02 Hydro Raufoss Automotive As Process for manufacturing a structural part
DE19715308C2 (en) * 1997-04-11 2001-06-13 Benteler Werke Ag Method for producing a shock-absorbing impact carrier element for converting impact energy in motor vehicles
DE19829566B4 (en) * 1997-08-08 2005-06-23 Wagon Automotive Gmbh Impact absorbers for motor vehicles
NO985846L (en) * 1998-12-14 2000-06-15 Norsk Hydro As Procedure for producing elements

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Title
See references of WO0204253A1 *

Also Published As

Publication number Publication date
AU2001280270A1 (en) 2002-01-21
NO20003555D0 (en) 2000-07-10
NO20003555L (en) 2002-01-11
WO2002004253A1 (en) 2002-01-17

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