EP1584382B1 - Method for hydroforming a steel tubular blank - Google Patents

Method for hydroforming a steel tubular blank Download PDF

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Publication number
EP1584382B1
EP1584382B1 EP05075830A EP05075830A EP1584382B1 EP 1584382 B1 EP1584382 B1 EP 1584382B1 EP 05075830 A EP05075830 A EP 05075830A EP 05075830 A EP05075830 A EP 05075830A EP 1584382 B1 EP1584382 B1 EP 1584382B1
Authority
EP
European Patent Office
Prior art keywords
blank
planar
tubular
friction
tubular blank
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.)
Not-in-force
Application number
EP05075830A
Other languages
German (de)
French (fr)
Other versions
EP1584382A1 (en
Inventor
Maarten Hendrik Kelder
Maria Gemma Othilde Klaassen
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.)
Tata Steel Ijmuiden BV
Original Assignee
Corus Staal BV
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 Corus Staal BV filed Critical Corus Staal BV
Priority to ES05075830T priority Critical patent/ES2305998T3/en
Priority to EP05075830A priority patent/EP1584382B1/en
Publication of EP1584382A1 publication Critical patent/EP1584382A1/en
Application granted granted Critical
Publication of EP1584382B1 publication Critical patent/EP1584382B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • 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

Definitions

  • the invention relates to a method for hydroforming a steel tubular blank into a product.
  • a method for hydroforming a tubular blank manufactured from a planar blank is e.g. known from JP-A-2002 035 854 .
  • a tubular blank is usually produced from a planar blank, which is cut from a metal sheet. This planar blank is formed into a tube which is then laser welded to form the tubular blank. In a typical hydroforming operation a tube, or a tubular blank, is bent into the overall shape desired for the final part, and then placed between a pair of dies.
  • the dies provide a cavity around the tube or tubular blank which has an interior shape matching the exterior shape desired for the part. Then, the ends of the tube or tubular blank are sealed and it is internally pressurised to expand it into the shape of the dies' cavity.
  • means to influence the friction between the tube or tubular blank and the forming tools are often used. These means may for instance comprise in-line lubrication stations in the hydroforming line. Friction influencing means may also be applied manually. These types of friction influencing means are complicated and/or expensive.
  • one or more of the objects are reached by a method for hydroforming a steel tubular blank into a product according to claim 1.
  • the planar blank is produced from a coil and the second layer with a friction influencing function is applied to the coil prior to producing the planar blank.
  • the second layer with a friction influencing function is applied to the coil immediately prior to forming of the planar blank, i.e. between decoiling and blanking.
  • the advantage of this method is that the second layer with a friction influencing function is applied to a large surface, thereby facilitating quality control and reproducible application of the layer or layers. This also enables to produce planar blanks and hence tubular blanks at a lower cost.
  • the tubular blank is already provided with a layer with a friction influencing function prior to entering the forming line. Consequently there is no need to apply means with a friction influencing function, such as a lubricant, in the forming line, making in-line stations or manual application of means with a friction influencing function obsolete.
  • the method according to the invention also enables to apply the means with a friction influencing function in a controlled manner thereby making the application of the means more reproducible, and thereby also making the behaviour of the tubular blank during forming more reproducible. This increases the stability and reproducibility of the forming process and results in a more reproducible formed product.
  • the layer with the friction influencing function to the planar blank is relatively straightforward and easily controlled, leading to an improved efficiency and quality of the friction behaviour of the tubular blank during forming.
  • a very controlled and reproducible application is obtained.
  • the tubular blank, manufactured as described hereinabove, is thereafter formed into a product at least partly by hydroforming.
  • the tailored friction on the outside provides a hydroformed product with the required surface, dimensions and properties.
  • the foil is a hydrocarbon such as polyethylene or a fluorocarbon such as polytetrafluorethylene.
  • This type of layer with a friction influencing function functions as a lubricant.
  • the foil enables easy application to the coil or the planar blank, for instance by known methods such as laminating or coextrusion of the foil, whereas it provides excellent adhesion to the planar blank prior to or during forming of the tubular blank and also during storage, handling and forming of the tubular blank.
  • the blank is essentially quadrangular, such as essentially rectangular or essentially tapered.
  • This type of lubricated blank will result in an essentially cylindrical tubular blank or an essentially conical tubular blank. The latter facilitates forming sloping shapes in the formed product.
  • the planar blank comprises at least a first blank portion and a second blank portion and wherein the first blank portion has different geometrical dimensions than the second blank portion and/or wherein the first blank portion is made from a different material than the second blank portion and/or wherein the material of the first blank portion has different properties than the material of the second blank portion.
  • planar blanks comprising a plurality of blank portions, i.e. at least two, can be produced by joining together a corresponding number of planar blank portions, each produced from metal sheet, by means of a joining technique such as welding for example laser-welding.
  • This embodiment enables to choose the geometry, for instance the thickness of the blank portion, or the type of material, or the properties of the material, independently of the geometry, the type of material, or the properties of the material of the second blank portion.
  • the strength of the first blank portion may be chosen differently from that of the second blank portion because of local strength requirements in the final formed product.
  • material for the first blank portion having different resistance to corrosion than the material of the second blank portion because of local requirements for corrosion resistance in the final formed product.
  • the invention also encompasses tubular blanks made from planar blanks having more than two blank portions, which blank portions may all have different characteristics.
  • the aim of the layer with a friction influencing function is to decrease the friction between the tubular blank and the forming tools which can be used to form the tubular blank into a product. Decreasing the friction facilitates forming the tubular blank into a product. It may also reduce the forces required to form the tubular blank into a product during the forming process.
  • the function of the second layer with a friction influencing factor is to decrease the friction between the tubular blank and the forming tools which can be used to form the tubular blank into a product.
  • the second layer being on the outer surface of the tubular blank, is likely to benefit from a reduced friction in terms of reducing the process forces during forming, but also in terms of a reduced wear of the outer surface and the forming tools.
  • a tubular blank may be produced from a planar blank, which is provided with a layer with a friction influencing function on the second side of the planar blank prior to forming the planar blank into a tubular blank.
  • the friction influencing function is chosen so as to reduce the friction on the second surface (i.e. the outside of the tubular blank) so as to influence the friction between the tubular blank and the hydroforming tools used to form the tubular blank into the hydroformed product.
  • the reduced friction on the outside of the tubular blank provides a smooth surface whilst also limiting the process forces.
  • a tubular blank may be produced from a planar blank, wherein the planar blank has a plurality of blank portions.
  • a planar blank may comprise three blank portions, such as a first blank portion of 2 mm aluminium with a proof stress of 150 MPa, a second blank portion comprising a 1 mm high strength low alloy steel with a tensile strength of above 600 MPa and a third blank portion comprising an 1.5 mm austenitic stainless steel with excellent corrosion resistance.
  • the tubular blank, and the final product which is made from it, is provided with a layer of friction influencing function which is applied to the second surface of the planar blank comprising a plurality of blank portions, and which function is chosen so as to reduce the friction.
  • a layer of friction influencing function which is applied to the second surface of the planar blank comprising a plurality of blank portions, and which function is chosen so as to reduce the friction.
  • a tubular blank may be produced from a planar blank, which is provided on its second surface with a first layer with a first friction influencing function on part of the first side and with another layer with a another friction influencing function on at least part of the second surface wherein the two layers each with their respective friction influencing function may at least partly overlap.
  • the layer or layers with the friction influencing function can be used to increase the friction in certain areas of the tubular blank, thus enabling a controlled material flow, which could be beneficial to reduce or increase strain levels in certain areas of the product.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Metal Extraction Processes (AREA)

Abstract

This invention relates to a method for manufacturing a metal tubular blank suitable for forming into a product comprising the steps of providing an essentially planar blank, said planar blank having a first surface and a second surface; producing the tubular blank from the planar blank whereby the second surface of the planar blank becomes the outside of the tubular blank; wherein a first layer with a first friction influencing function is applied to at least part of the first side of the planar blank and/or a second layer with a second friction influencing function is applied to at least part of the second side of the planar blank prior to forming the planar blank into a tubular blank, so as to influence the friction between the tubular blank and forming tools which can be used to form the tubular blank into the product, and wherein the first and/or second layer are applied in the form of a foil, a dry lubricant, a wax or an oil. The invention further relates to a tubular blank and a product produced from such a tubular blank.

Description

  • The invention relates to a method for hydroforming a steel tubular blank into a product. A method for hydroforming a tubular blank manufactured from a planar blank is e.g. known from JP-A-2002 035 854 .
  • In the industry, and in particular in the automotive sector, forming is an important tool in manufacturing complex shapes with as main materials steel and aluminium. Suppliers are urged to improve the formability of their materials and to integrate their processes because of, amongst others, costs and environmental aspects. A part of this objective can be achieved using a relative novel forming technology such as hydroforming. A tubular blank is usually produced from a planar blank, which is cut from a metal sheet. This planar blank is formed into a tube which is then laser welded to form the tubular blank. In a typical hydroforming operation a tube, or a tubular blank, is bent into the overall shape desired for the final part, and then placed between a pair of dies. The dies provide a cavity around the tube or tubular blank which has an interior shape matching the exterior shape desired for the part. Then, the ends of the tube or tubular blank are sealed and it is internally pressurised to expand it into the shape of the dies' cavity. By means of hydroforming different forming steps can be integrated and much more complex shapes can be formed which in turn saves costs and efforts compared with conventionally made products. In order to obtain complex shapes, means to influence the friction between the tube or tubular blank and the forming tools are often used. These means may for instance comprise in-line lubrication stations in the hydroforming line. Friction influencing means may also be applied manually. These types of friction influencing means are complicated and/or expensive.
  • It is an object of the invention to influence the friction during forming which is economically attractive. It is also an object of the invention to reproducibly influence the friction during forming.
  • According to a first aspect of the invention, one or more of the objects are reached by a method for hydroforming a steel tubular blank into a product according to claim 1.
  • By the method according to the invention, the planar blank is produced from a coil and the second layer with a friction influencing function is applied to the coil prior to producing the planar blank. The second layer with a friction influencing function is applied to the coil immediately prior to forming of the planar blank, i.e. between decoiling and blanking.
  • The advantage of this method is that the second layer with a friction influencing function is applied to a large surface, thereby facilitating quality control and reproducible application of the layer or layers. This also enables to produce planar blanks and hence tubular blanks at a lower cost.
  • Thus, the tubular blank is already provided with a layer with a friction influencing function prior to entering the forming line. Consequently there is no need to apply means with a friction influencing function, such as a lubricant, in the forming line, making in-line stations or manual application of means with a friction influencing function obsolete. The method according to the invention also enables to apply the means with a friction influencing function in a controlled manner thereby making the application of the means more reproducible, and thereby also making the behaviour of the tubular blank during forming more reproducible. This increases the stability and reproducibility of the forming process and results in a more reproducible formed product. Application of the layer with the friction influencing function to the planar blank is relatively straightforward and easily controlled, leading to an improved efficiency and quality of the friction behaviour of the tubular blank during forming. By applying the second layer with a friction influencing function in the form of a foil, a dry lubricant, a wax or an oil, a very controlled and reproducible application is obtained. The tubular blank, manufactured as described hereinabove, is thereafter formed into a product at least partly by hydroforming. The tailored friction on the outside provides a hydroformed product with the required surface, dimensions and properties.
  • In an embodiment of the invention the foil is a hydrocarbon such as polyethylene or a fluorocarbon such as polytetrafluorethylene. This type of layer with a friction influencing function functions as a lubricant. The foil enables easy application to the coil or the planar blank, for instance by known methods such as laminating or coextrusion of the foil, whereas it provides excellent adhesion to the planar blank prior to or during forming of the tubular blank and also during storage, handling and forming of the tubular blank.
  • In an embodiment of the invention the blank is essentially quadrangular, such as essentially rectangular or essentially tapered. This type of lubricated blank will result in an essentially cylindrical tubular blank or an essentially conical tubular blank. The latter facilitates forming sloping shapes in the formed product.
  • In a further embodiment of the invention the planar blank comprises at least a first blank portion and a second blank portion and wherein the first blank portion has different geometrical dimensions than the second blank portion and/or wherein the first blank portion is made from a different material than the second blank portion and/or wherein the material of the first blank portion has different properties than the material of the second blank portion. After producing a tubular blank from this planar blank, this tubular blank enables combining portions having different characteristics in terms of response to the forming and/or the properties of the formed product. It will be clear that the invention also encompasses tubular blanks made from planar blanks having more than two blank portions, which blank portions may all have different characteristics. In principle, there is no limit to the number of blank portions in a planar blank for a tailored tubular blank. The planar blanks comprising a plurality of blank portions, i.e. at least two, can be produced by joining together a corresponding number of planar blank portions, each produced from metal sheet, by means of a joining technique such as welding for example laser-welding.
  • This embodiment enables to choose the geometry, for instance the thickness of the blank portion, or the type of material, or the properties of the material, independently of the geometry, the type of material, or the properties of the material of the second blank portion. As an example, the strength of the first blank portion may be chosen differently from that of the second blank portion because of local strength requirements in the final formed product. Also it may be desired to use material for the first blank portion having different resistance to corrosion than the material of the second blank portion because of local requirements for corrosion resistance in the final formed product. Again it will be clear that the invention also encompasses tubular blanks made from planar blanks having more than two blank portions, which blank portions may all have different characteristics.
  • In an embodiment of the invention, the aim of the layer with a friction influencing function is to decrease the friction between the tubular blank and the forming tools which can be used to form the tubular blank into a product. Decreasing the friction facilitates forming the tubular blank into a product. It may also reduce the forces required to form the tubular blank into a product during the forming process.
  • The function of the second layer with a friction influencing factor is to decrease the friction between the tubular blank and the forming tools which can be used to form the tubular blank into a product. The second layer, being on the outer surface of the tubular blank, is likely to benefit from a reduced friction in terms of reducing the process forces during forming, but also in terms of a reduced wear of the outer surface and the forming tools.
  • Specific embodiments of the present invention will now be explained by the following non-limitative examples.
  • In the forming process of a hydroformed product, a tubular blank may be produced from a planar blank, which is provided with a layer with a friction influencing function on the second side of the planar blank prior to forming the planar blank into a tubular blank. The friction influencing function is chosen so as to reduce the friction on the second surface (i.e. the outside of the tubular blank) so as to influence the friction between the tubular blank and the hydroforming tools used to form the tubular blank into the hydroformed product. The reduced friction on the outside of the tubular blank provides a smooth surface whilst also limiting the process forces.
  • In the forming process of a hydroformed product, a tubular blank may be produced from a planar blank, wherein the planar blank has a plurality of blank portions. In a specific example, a planar blank may comprise three blank portions, such as a first blank portion of 2 mm aluminium with a proof stress of 150 MPa, a second blank portion comprising a 1 mm high strength low alloy steel with a tensile strength of above 600 MPa and a third blank portion comprising an 1.5 mm austenitic stainless steel with excellent corrosion resistance. The tubular blank, and the final product which is made from it, is provided with a layer of friction influencing function which is applied to the second surface of the planar blank comprising a plurality of blank portions, and which function is chosen so as to reduce the friction. When forming the tubular blank into a product by hydroforming, the choice of the layer with the friction influencing function, enables perfect process control and yields a product with the required surface properties, dimensions and properties.
  • It will be clear to the skilled person that the number and characteristics of the blank portions is to be tailored to the needs of the final product and the forming process.
  • In the forming process of a hydroformed product, a tubular blank may be produced from a planar blank, which is provided on its second surface with a first layer with a first friction influencing function on part of the first side and with another layer with a another friction influencing function on at least part of the second surface wherein the two layers each with their respective friction influencing function may at least partly overlap. This way a combination of friction influencing functions may be obtained on the same surface, thereby further extending the possibilities for improvement of process control and quality of the hydroformed product as to the required surface properties, dimensions and properties.
  • It will be clear that similar or different combination of friction influencing functions may be obtained on the first surface as well. It is even possible to obtain similar or different combination of friction influencing functions on both surfaces of the tubular blank. This combination of friction influencing functions on the same surface may also be combined with tubular blanks made from planar blanks comprising a plurality, for instance two, or three or four, or even more, blank portions. It may be beneficial to choose a friction influencing function of a layer depending on the properties or material of the respective blank portion. It should be noted that it is also part of the invention to provide one or more layers with a friction influencing function on the second side of the planar blank only. This enables a reduction in the use of the layer with a friction influencing function such as a lubricant, thereby also reducing costs.
  • It should be noted that the layer or layers with the friction influencing function can be used to increase the friction in certain areas of the tubular blank, thus enabling a controlled material flow, which could be beneficial to reduce or increase strain levels in certain areas of the product.
  • It is of course to be understood that the present invention encompasses any and all embodiments within the scope of the following claims.

Claims (5)

  1. Method for hydroforming a steel tubular blank into a product comprising the steps of
    ● providing an essentially planar steel blank, said planar blank having a first surface and a second surface;
    ● producing the tubular blank from the planar blank whereby the second surface of the planar blank becomes the outside of the tubular blank;
    wherein a second layer with a second friction influencing function is applied to at least part of the second surface of the planar blank prior to forming the planar blank into a tubular blank, and wherein the blank is produced from a coil and the second layer is applied to the coil prior to producing the blank, so as to influence the friction between the tubular blank and hydroforming tools which can be used to hydroform the tubular blank into the product, and wherein the second layer is applied in the form of a foil, a dry lubricant, a wax or an oil, and
    ● a final step of hydroforming the tubular blank into the product.
  2. Method according to claim 1, wherein the second layer is applied in the form of a foil, the foil being a hydrocarbon such as polyethylene or a fluorocarbon such as polytetrafluorethylene.
  3. Method according to any of the claims 1 to 2, wherein the planar blank is essentially quadrangular such as essentially rectangular or essentially tapered.
  4. Method according to any of the claims 1 to 3, wherein the planar blank comprises at least a first blank portion and a second blank portion and wherein the first blank portion has different geometrical dimensions than the second blank portion and/or wherein the first blank portion is made from a different material than the second blank portion and/or wherein the material of the first blank portion has different properties than the material of the second blank portion.
  5. Method according to any one of the claims 1 to 4, wherein the second layer with a friction influencing factor decreases the friction between the tubular blank and the hydroforming tools which can be used to form the tubular blank into a product.
EP05075830A 2004-04-09 2005-04-08 Method for hydroforming a steel tubular blank Not-in-force EP1584382B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
ES05075830T ES2305998T3 (en) 2004-04-09 2005-04-08 METHOD FOR HYDRO-CONFORMATION OF A PIECE IN GROSS STEEL TUBULAR.
EP05075830A EP1584382B1 (en) 2004-04-09 2005-04-08 Method for hydroforming a steel tubular blank

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP04076086 2004-04-09
EP04076086 2004-04-09
EP05075830A EP1584382B1 (en) 2004-04-09 2005-04-08 Method for hydroforming a steel tubular blank

Publications (2)

Publication Number Publication Date
EP1584382A1 EP1584382A1 (en) 2005-10-12
EP1584382B1 true EP1584382B1 (en) 2008-07-02

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP05075830A Not-in-force EP1584382B1 (en) 2004-04-09 2005-04-08 Method for hydroforming a steel tubular blank

Country Status (5)

Country Link
US (1) US20050223768A1 (en)
EP (1) EP1584382B1 (en)
AT (1) ATE399606T1 (en)
DE (1) DE602005007790D1 (en)
ES (1) ES2305998T3 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2630084A1 (en) * 2007-04-30 2008-10-30 Mark Andreychuk Coiled tubing with retainer for conduit
US9194512B2 (en) 2007-04-30 2015-11-24 Mark Andreychuk Coiled tubing with heat resistant conduit
US8210544B2 (en) * 2008-05-16 2012-07-03 Honeywell International Inc. Apparatus for preventing incorrect installation of machinery components together

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Publication number Priority date Publication date Assignee Title
DE560341C (en) * 1929-05-23 1932-10-01 Youngstown Sheet And Tube Co Process for the production of pipes by bending sheet metal strips
SU431934A1 (en) * 1958-03-13 1974-06-15
GB1529061A (en) * 1976-06-23 1978-10-18 British Petroleum Co Forming process
US4269053A (en) * 1979-07-25 1981-05-26 Rockwell International Corporation Method of superplastic forming using release coatings with different coefficients of friction
JPH07178460A (en) * 1993-12-22 1995-07-18 Nippon Steel Corp Method for bending high strength galvanized steel sheet excellent in shape freezability
US5686194A (en) * 1994-02-07 1997-11-11 Toyo Kohan Co., Ltd. Resin film laminated steel for can by dry forming
US5431326A (en) * 1994-09-07 1995-07-11 General Motors Corporation Method of forming a tubular member with separate flange
US5941110A (en) * 1997-05-12 1999-08-24 Northern University Adaptive method and apparatus for forming tailor welded blanks
US6224992B1 (en) * 1998-02-12 2001-05-01 Alcoa Inc. Composite body panel and vehicle incorporating same
US6182487B1 (en) * 1998-02-18 2001-02-06 Nippon Sanso Corporation Metal vessel and a fabrication method for the same
US6265492B1 (en) * 1998-06-15 2001-07-24 E. I. Du Pont De Nemours And Company Melt-fabricable polytetrafluoroethylene
WO2000069004A1 (en) * 1999-05-07 2000-11-16 Matsushita Electric Industrial Co., Ltd. Square cell container and method of manufacturing the cell container
JP2002035854A (en) * 2000-07-27 2002-02-05 Nippon Steel Corp Steel pipe excellent in hydroform workability and manufacturing method therefor
EP1401596B1 (en) * 2001-07-05 2007-04-11 Magna Structural Systems Inc. Method for expanding a tubular blank
DE10210156A1 (en) * 2002-03-07 2003-09-25 Bayerische Motoren Werke Ag Method of producing tubular body in sections with differing thickness involves bending the tube and welding it

Also Published As

Publication number Publication date
ATE399606T1 (en) 2008-07-15
ES2305998T3 (en) 2008-11-01
EP1584382A1 (en) 2005-10-12
DE602005007790D1 (en) 2008-08-14
US20050223768A1 (en) 2005-10-13

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