EP1626824B1 - Method for the production of individualized vehicle parts, especially individualized shell parts made from serially produced standard parts - Google Patents

Description

The present invention relates to a method for the production of vehicle parts according to the preamble of claim 1.

• PATENT ABSTRACTS OF JAPAN Bd. 2003, Nr. 06, 3. Juni 2003 (2003-06-03) -&; JP 2003 053436 A (AMINO:KK), 26. Februar 2003 (2203-02-26)
• US 6 216 508 B1
• DE 40 34 625 A

Such a method is known from PATENT ABSTRACTS OF JAPAN vol. 2002, no. 08, 5 August 2002 (2002-08-05) - &; JP 2002 102944 A (HONDA MOTOR CO LTD), April 9, 2002 (2002-04-09). The technical background of the invention further includes

• PATENT ABSTRACTS OF JAPAN vol. 2003, no. 06, 3 June 2003 (2003-06-03) - &; JP 2003 053436 A (AMINO: KK), February 26, 2003 (2203-02-26)
• US 6 216 508 B1
• DE 40 34 625 A

Vehicle body parts, such as hoods, roofs, fenders, side panels, trunk lids, etc. are usually made by deep drawing from flat starting sheets. The tools of deep drawing presses are known to be very expensive and can therefore be used profitably only in relatively large quantities. In addition, the sheet metal geometries that can be produced with conventional deep-drawing presses are limited in their complexity. However, vehicle designers are demanding increasingly broad scope for design that can not always be met with conventional thermoforming tools. Modern vehicle designs are characterized, for example, by transitions between convex and concave component sections as well as by strongly accentuated character lines or edges, some of which are very narrow Radii of curvature. Already here one encounters with customary thermoforming processes occasionally to manufacturing limits.

A completely different way is the so-called "Dieless Forming Technology", for example, from the US 6,216,508 B1 is known. As the name suggests, the sheet metal forming takes place "Dieless", ie without a form in the traditional sense. When Dieless-forming, as in the US 6,216,508 B1 is described, a flat sheet metal plate is clamped in its edge region in a holding device. For the processing, a forming mandrel is used, which is arranged substantially perpendicular to the clamped sheet metal blank and which is movable in the X and Y directions. A feed movement in the Z direction is possible, either by moving the Zustelldorns or by vertical movement of the clamped in the fixture sheet metal blank.

The basic principle of Dieless Forming, as stated in the US 6,216,508 B1 is known, is that a flat sheet metal blank, ie a non-preformed sheet metal is formed by means of the forming mandrel in a three-dimensional component. For this purpose, the forming mandrel is pressed against the sheet metal blank. By meandering or spiraling down the entire sheet metal blank, a three-dimensional sheet metal part can be produced from the flat sheet metal blank by an incremental infeed of the forming mandrel. An advantage of the Dieless Forming process compared to conventional deep-drawing processes is that even very complex component geometries can be produced.

A major disadvantage of in the US 6,216,508 B1 However, the described Dieless forming process is the very long production time. If you want to produce a large, complex sheet metal part, such as a body part for a vehicle from a flat sheet metal plate in the Dieless Forming process, so this is extremely time consuming. In the in the US 6,216,508 B1 As described in the Dieless Forming method, the forming mandrel has to drive the entire sheet-metal blank contour in a meandering or helical contour, which takes a very long time in comparison to conventional deep drawing. The production of a body part of a vehicle, such as a hood, takes a few seconds or fractions of seconds with conventional deep-drawing process. Would you try one Such body part completely according to the Dieless Forming method, as in the US 6,216,508 B1 This would take many minutes, depending on the component, even up to several hours.

Another problem encountered in the fabrication of complete components by the use of the Dieless Forming method is that in incremental deformation of a sheet, i. During a transformation "track by track" very strong changes in the crystal structure of the sheet occur. Experiments have shown that in more complex body parts made of plane, i. not preformed starting sheets are completely produced by "Dieless Forming", often strong surface roughness arise. The roughness of the component surface is often so strong that the sheet metal part after its production usually can not be painted directly, but must be reworked consuming before painting, e.g. by trowelling and grinding the surface or by other "smoothing". All in all, Dieless Forming Technology has so far faced many unsolved problems. The Dieless Forming process could therefore not prevail in the automotive industry, in particular in the mass production of body parts, so far.

As mentioned above, there is the dilemma that can not be produced arbitrarily complex body designs with conventional deep drawing. A further problem is that deep-drawing processes, due to the expensive tools, are only possible in mass production, i. from certain minimum lot sizes are profitable.

Especially for premium vehicles, many customers have very special equipment requirements, which can not always be satisfied with the customarily offered special equipment program. Many vehicle manufacturers therefore already offer so-called "individual or small series vehicles" for individual types of vehicles. In the body area, these individual or small series vehicles but often not or only slightly different from the standard production vehicles. The reason for this is that an individual design of the body shell is not yet possible to cover costs. The "individualization" in such vehicles is limited Nowadays, in comparison to conventional production vehicles, it is often the case that unusual interior materials and unusual colors are offered.

The object of the invention is to provide a method by which components, in particular outer skin parts for vehicles and especially those for small or very small series vehicles, customer requirements are individually and at the same time inexpensive to produce or to meet these requirements expectant outer skin part.

This object is solved by the features of claim 1. Advantageous embodiments and further developments of the invention can be found in the dependent claims.

The basic principle of the Dieless-Forming process is, as already mentioned, known per se and, for example, in the aforementioned US 6,216,508 B1 described. It is expressly stated that the entire technical content of the US 6,216,508 B1 The subject of the present patent application should be, even if the invention does not focus on the in the US 6,216,508 B1 directed method is directed. In the examination process of the present patent application is therefore on demand in all in the US 6,216,508 B1 disclosed features alone or in combination with other features of US 6,216,508 B1 or the present text. Therefore, the Dieless Forming procedure itself need not be explicitly explained in detail in this text.

Although the following description of the invention relates primarily to standard sheet metal sheet metal parts, it is to be expressly understood that the invention is not limited to sheet metal workpieces. An application of the invention is basically in all types of components, such. Structural parts, possible. The invention is not limited to components made of sheet metal. Rather, an application of the invention is also possible with workpieces made of plastic, in particular with parts made of thermoplastic material, or other materials.

The essence of the invention is primarily to meet individual customer needs, by a mass-produced "serial skin part" by Post-processing is "individualized" with a "forming tool" pressed against the serial skin section and moved relative to the serial skin section.

An essential difference to the US 6,216,508 B1 is that the post-processing is done on a "preformed series part", which in its entirety just after the in the US 6,216,508 B1 described method, but by another manufacturing method, such as deep drawing. Only a subarea or several subsections of this preformed series part are reworked with the above-mentioned forming tool, but not the entire series part.

The preformed "series part", which can already represent a semi-finished or finished body part, is stamped before installation in a body shell by a "post-processing" additionally deviates from conventional production vehicles "geometry" or "contour". Semi-finished or finished Rohkarosserieteilen such as bonnets, tailgates, doors, side panels, fenders, roofs, etc. can in this way character lines, logos or similar. be embossed. Furthermore existing character lines or component edges can already be drawn or deepened and thus more pronounced in the series outer part than is possible or the case with the standard outer skin parts used for conventional production vehicles. From conventional serial outer skin parts can be prepared by such reworking with a forming tool an infinite variety of design modifications and indeed as cost-effective, as it has not been thought possible. By offering series-like vehicles in small batches or as individual vehicles, one can better meet customers' wishes for customization, especially for high-priced vehicles. Vehicles gain an individual "design touch" through such a differentiation and thus stand out optically clearly from the other vehicles of the respective vehicle type.

Experiments have shown that, in contrast to the production of complete sheet metal parts from flat starting sheets by Dieless Forming, as in the US 6,216,508 B1 is already described in a mere post-processing "preformed" sheet metal parts (Serienhauthautteile) the surface problems described above do not occur. In particular, in the case of a "minor" post-processing, eg in the production of character lines or in the accentuation of already existing component structures, only a relatively small change occurs in the crystal structure of the sheet. The surface finish in the range of such character lines produced by a post-processing according to the invention is so good that a complex surface post-treatment, as required in the prior art, is superfluous. The component can therefore be fed directly to a conventional painting process after the post-processing.

The invention is expressly not limited to the production of exterior skin parts for small series or individual vehicles. In the course of their product life cycle, vehicles are often subjected to a "model revision" - a so-called "facelift". As part of model revisions, the outer skin parts of the vehicles are occasionally revised to a certain extent or made more appealing. Previously, it was necessary here to purchase new pressing tools or adapt existing pressing tools according to the new design, which is regularly associated with very high tooling costs. With the method explained in more detail below, it is now possible to revise or rework outer body parts produced with the "old" pressing tools. In this way, additional character lines, beads, etc. can be imprinted into the "old shell parts", which allows a "model revision" at a much lower cost than was previously the case.

Another important advantage of the invention is that a corresponding "rework station" can be integrated in an existing production line without problems. Series parts that are intended for individual vehicles or for individualized vehicles or for a model revision are reworked in the "rework station". Serial parts for conventional production vehicles pass through the rework station without being reworked. Of course, post-processing according to the invention is also possible outside the production line in separate processing stations.

As already mentioned, in the method according to the invention, a three-dimensional contour is embossed into a sheet metal part by means of a forming tool which is designed like a mandrel. The forming tool is also referred to below as "forming mandrel", but this is not meant to be limiting in the sense of a particular tool shape.

The "forming mandrel" is used in the post-processing of a component with its end, e.g. may be formed as a tip or a rounded tip pressed against the component. At the same time the component and the mandrel are moved relative to each other. In this way, according to the geometry of the end of the forming mandrel and in dependence on the contact pressure and the "clamping or support state" of the component to be machined, a "recess or bulge" or generally speaking a three-dimensional contour is produced. The contour to be produced may be e.g. have the shape of a groove, a bead or another shape.

According to the invention, a "one-curve post-processing" is performed.

In the "one-curve post-processing" the forming tool used is attached to the nachzubearbeitende component, pressed against the component and then the forming tool is moved with a single movement relative to the component. The post-processing is thus done by moving the forming tool "in one go", whereby the desired geometry, e.g. a bead, a character line or similar is impressed in the component.

In contrast, the forming tool is moved in an "incremental reworking" several times relative to the component to be machined and delivered incrementally. A geometry produced in a first reworking operation, such as a bead, can be deepened, ie more pronounced, by a corresponding feed movement-substantially perpendicular to the component to be reworked-in a further reworking operation. Alternatively or additionally, a geometry produced in a first rework, such as a bead, by a slight displacement of the Umfomwerkzeugs relative to the component and essentially transversely to the direction of travel of the first reworking "broadened" and are more pronounced in this way. By a meandering guidance of the forming mandrel or by repeated pulling close to each other next to each other "processing trajectories", it is also possible to produce larger three-dimensional bulges, such as pronounced intake ducts, the "power dome" of a bonnet or, in general, structural elevations.

As already explained, however, the essence of the invention does not exist as in the case of US 6,216,508 B1 in the manufacture of complete body parts by means of the Dieless Forming process; This would be too time consuming and unprofitable. Rather, the essence of the invention consists in the "subsequent" processing or individualization of individual areas of semi-finished or finished components, in particular of body shell parts.

In this context, "finished" means that the body shell part would in itself be ready for painting, but is previously finished in one component area or in several component areas. In principle, it is also conceivable to "individualize" or already differentiate already finished painted outer skin components by a post-processing according to the invention. "Semi-finished" means that the bodywork part is post-processed further according to the invention, e.g. by aftertreatment of the surface, trimming or bending of component edges, drilling of holes, thread cutting or the like and only then is painted.

Before the post-processing according to the invention, the Serienaußenhaut- or the Rohkarosserieteil is clamped in a holding device. The holding device can be formed, for example, by a multiplicity of individual "holding points" or "holding sections". It is also possible to use suction cup-like holding elements. Suction cup-like holding elements have the advantage that reduces the risk of damage to the outer skin sheet metal part, in particular the risk of damage to the component surface, during clamping and during processing, since the workpiece is not clamped between two holding elements, but is fixed by negative pressure.

Preferably, the workpiece, i. the serial outer skin part is clamped in such a way before the post-processing that its geometry does not change in the border area by the post-processing. In other words, the post-processing connection dimensions or gaps, resulting in the later installation of the outer skin part in a body, with respect to the "normal production vehicle" should not change.

Depending on the complexity of the component geometry to be produced "subsequently", the serial outer skin part during the post-processing can either be held exclusively by means of a holding device, e.g. in its edge area. In the case of more complex component geometries or in the case of three-dimensional contours which have a strong surface gradient, in particular with relatively "sharp" edges, one or more counterstains or support elements can be used Alternatively, the anvil can take on the form of a "die" which has a "negative mold" corresponding to the three-dimensional contour to be produced However, the counterholder does not necessarily have to be used.

If two counter holders are used, it is preferable to arrange one counter holder in the direction of travel of the forming tool to the left and the other counter holder in the direction of travel to the right of the geometry to be produced. Already by the choice or the change of the distance of the anvils from each other and by the lateral distance of the counter-holder of the geometry to be produced, the geometry to be produced can be influenced in shape, which will be explained later in more detail.

The forming mandrel may, for example, have a smooth, convexly curved tool tip. It can be symmetrical or asymmetrical. The tool tip can also be formed by a rotatably mounted ball which rolls on the serial outer skin part during the processing of the series outer skin part, whereby the mechanical stress of the serial outer skin part is reduced in the deformation region. Alternatively, a "rolling mandrel" can be used, in which the tool tip is formed by a wheel or by a roller. It is also possible to use multiple mandrels or multi-arm mandrels. The forming mandrel does not necessarily have to have a rounded or rounded tip. Rather, a forming mandrel can be used with a relatively sharp-edged tip. Alternatively, the tip may also be flat-leaved, wheel-shaped, plow-shaped or hull-shaped. Also, a forming mandrel with a faceted tool tip is conceivable.

The forming mandrel does not necessarily have to be made of steel or tool steel. Also conceivable are mandrels made of plastic, wood, ice, sand, concrete or other materials. The tool tip of the forming mandrel may be hardened, uncured, coated or uncoated. It can e.g. be provided with a wear-resistant single or hybrid coating. The forming mandrel can be guided in up to six axes relative to the component in order to achieve the desired "shape result". The forming mandrel or the tool tip of the forming mandrel can also be rotated or oscillated about the longitudinal axis of the forming mandrel during the post-processing.

A forming mandrel with or without lubrication can be used. For example, a lubrication system can be integrated in the forming mandrel. The lubrication system can also be arranged on the outside of the forming mandrel. The lubrication system ensures that the "processing point", i. the point at which the forming mandrel touches the serial skin part is constantly supplied with sufficient lubricating fluid. As lubricating fluid, a lubricating oil can be used.

Furthermore, a forming mandrel can be used whose tool tip is adjustable during the machining process. For example, it can be provided that the width of the tool tip can be changed transversely to the direction of travel of the tool mandrel during the machining process. In this way, variable-width geometries can be fabricated in a single operation.

The travel speed with which the forming mandrel is moved relative to the serial outer skin part during the post-processing does not have to be constant. Rather, the traversing speed can be varied as a function of the instantaneous "degree of deformation" of the serial outer skin part. For smaller degrees of deformation, a higher traversing speed can be selected; for larger degrees of deformation, a smaller traversing speed can be selected.

Both the mandrel and the "workpiece" can be heated or cooled during processing if necessary or have ambient temperature. In the case of serial skin parts made of sheet metal, but especially in the case of "workpieces" made of plastic, it may be advantageous to heat the forming mandrel or the tool tip of the forming mandrel during the processing of the serial outer skin part. A heating of the forming mandrel leads to a heat input into the area of the workpiece to be formed, whereby its ductility increases, which facilitates the forming. In particular plastic parts thereby a transformation is facilitated.

Alternatively or additionally, the serial outer skin part can also be preheated or heated directly during post-processing. The series skin panel may be heated by hot air, radiant heaters, lasers, or another heat source. Series outer skin parts can be preheated to just below a material-specific "softening temperature" during post-processing and / or locally heated to a suitable "forming temperature" at the point of contact by means of a heated mandrel or selective additional heating.

The workpiece can also be pretreated by other methods before the post-processing. For example, it can be irradiated, coated, etched, hardened, roughened, smoothed, polished, sprayed with lubricating fluid or ground. It can also be pre-treated by sandblasting before reworking.

Preferably, the post-processing of the serial outer skin part is fully automatically controlled. The forming mandrel can either be designed as a machining tool of a CNC machine tool, similar to the US 6,216,608 B1 , or be arranged on an arm of a correspondingly programmed processing robot. Of course, such a "processing station" further "tools" have, for example, a laser cutting device with which the outer skin sheet metal part can be additionally trimmed.

Fig. 1

Ein Außenhautteil mit einer Formwulst, die durch eine Nachbearbeitung gemäß der Erfindung hergestellt wurde;

Fig. 2, 3

Schnitte durch das Außenhautteil der Figur 1;

Fig. 4

das Grundprinzip der Nachbearbeitung eines Serienaußenhautteils gemäß der Erfindung;

Fig. 5

das Grundprinzip der Nachbearbeitung gemäß der Erfindung bei Verwendung eines matrizenartigen Gegenhalters;

Fig. 6-8

Verschiedene Querschnitte eines nachträglich in ein vorgefertigtes Bauteil eingeprägten Formwulstes;

Fig. 9-11

Ausführungsbeispiele, bei denen das nachzubearbeitende Bauteil durch Gegenhalter abgestützt wird;

Fig. 12

eine schematische Darstellung einer möglichen Verfahrbewegung des Umformwerkzeugs;

Fig. 13

ein Ausführungsbeispiel, bei dem eine Frontklappe nachbearbeitet wird; und

Fig. 14

einen matrizenartigen Gegenhalter.

• Figur 1 zeigt ein Serienaußenhautblechteil 1 eines Fahrzeugs. Bei dem Serienaußenhautblechteil 1 der Figur 1 handelt es sich um eine "Türaußenhaut". In das Serienaußenhautblechteil 1 wurde "nachträglich" ein Formwulst 2 eingearbeitet, was im Zusammenhang mit den nachfolgenden Figuren noch näher erläutert wird.
• Figur 2 zeigt einen Schnitt durch das Außenhautteil 1 der Figur 1 entlang der Schnittlinie A - A. Der Formwulst 2 hat eine Länge 1 und eine Tiefe t. Die Tiefe t des Formwulstes 2 hat im Bereich der z-Achse der Figur 2 ihr Maximum und nimmt zu den Enden der Formwulst 2 hin ab.
• Figur 3 zeigt einen Querschnitt durch das Außenhautteil 1 entlang der Schnittlinie B - B der Figur 1. Es ist ersichtlich, dass der Formwulst 2 relativ scharfkantig ist. Derartige stark akzenturierte Charakterlinien sind mit herkömmlichen Tiefziehverfahren schwer bzw. gar nicht herstellbar.
• Figur 4 beschreibt schematisch den Nachbearbeitungsvorgang des Serienaußenhautteils 1. Das Serienaußenhautteil 1 wird in eine hier nicht näher dargestellte Halteeinrichtung 3 eingespannt bzw. an einer Halteeinrichtung 3 fixiert. Bei dem hier gezeigten Ausführungsbeispiel ist das Serienaußenhautteil 1 lediglich in seinen Randbereichen an der Halteeinrichtung 1 befestigt. Anschließend wird ein Umformdorn 4 an das Serienaußenhautteil 1 herangeführt und gegen das Serienaußenhautteil 1 mit einer vorgegebenen Andrückkraft gedrückt. In einem nächsten Schritt wird der Umformdorn 4 relativ zu dem Serienaußenhautteil 1 in Richtung des Pfeils 5 verfahren. Gleichzeitig erfolgt eine "Zustellbewegung" des Umformdorns 4 relativ zu dem Serienaußenhautteil 1, wodurch der Formwulst 2 durch die Spitze 6 des Umformdorns 4 in das Serienaußenhautteil 1 eingeprägt wird.
• Figur 5 zeigt ein Ausführungsbeispiel, bei dem mittels eines matrizenartigen Gegenhalters 7 von der dem Umformdorn 4 gegenüberliegenden Seite des Serienaußenhautteils 1 gegengedrückt wird. Das Serienaußenhautteil 1 wird also durch den matrizenartigen Gegenhalter 7 abgestützt, was problemlos die Herstellung einer scharfkantigen Kontur, wie in Figur 5 dargestellt, ermöglicht. Bei dem matrizenartigen Gegenhalter kann es sich um ein bauteilspezifisches Werkzeug oder um ein "Universalwerkzeug" handeln, das auch bei der Individualisierung anderer Serienaußenhautbauteile zum Einsatz kommen kann.

In the following the invention will be explained in connection with the drawing. Show it:

Fig. 1

An outer skin part with a molding bead, which was produced by a post-processing according to the invention;

Fig. 2, 3rd

Cuts through the outer skin part of the FIG. 1 ;

Fig. 4

the basic principle of the post-processing of a Serienshauthautteils according to the invention;

Fig. 5

the basic principle of post-processing according to the invention when using a die-like counter-holder;

Fig. 6-8

Various cross sections of a subsequently molded into a prefabricated component Formwulstes;

Fig. 9-11

Embodiments in which the nachzubearbeitende component is supported by counter-holder;

Fig. 12

a schematic representation of a possible movement of the forming tool;

Fig. 13

an embodiment in which a front door is reworked; and

Fig. 14

a female counterpart.

• FIG. 1 shows a series outer skin sheet metal part 1 of a vehicle. In the series outer skin sheet metal part 1 of FIG. 1 it is an "outer door skin". In the series outer skin sheet metal part 1 a Formwulst 2 was incorporated "subsequently", which will be explained in more detail in connection with the following figures.
• FIG. 2 shows a section through the outer skin part 1 of FIG. 1 along the section line A - A. The Formwulst 2 has a length 1 and a depth t. The depth t of the Formwulstes 2 has in the z-axis of the FIG. 2 their maximum and decreases towards the ends of the Formwulst 2 out.
• FIG. 3 shows a cross section through the outer skin part 1 along the section line B - B of FIG. 1 , It can be seen that the Formwulst 2 is relatively sharp. Such strongly accentuated character lines are difficult or impossible to produce with conventional deep drawing methods.
• FIG. 4 schematically describes the post-processing operation of the serial outer skin part 1. The serial outer skin part 1 is clamped in a holding device 3 not shown here or fixed to a holding device 3. In the embodiment shown here, the series outer skin part 1 is attached to the holding device 1 only in its edge regions. Subsequently, a forming mandrel 4 is brought to the series outer skin part 1 and pressed against the series outer skin part 1 with a predetermined pressing force. In a next step, the forming mandrel 4 is moved in the direction of the arrow 5 relative to the serial outer skin part 1. At the same time, a "feed movement" of the forming mandrel 4 takes place relative to the serial outer skin part 1, whereby the shaped bead 2 is impressed into the series outer skin part 1 by the tip 6 of the forming mandrel 4.
• FIG. 5 shows an embodiment in which is pressed by means of a die-like counter-holder 7 of the forming mandrel 4 opposite side of the serial outer skin part 1. The series outer skin part 1 is thus by the supported die-like counter-holder 7, which easily produce a sharp-edged contour, as in FIG. 5 represented, enabled. The matrix-like counterholder can be a component-specific tool or a "universal tool", which can also be used in the customization of other serial outer skin components.

The Figures 6-8 show different cross sections AA, BB and CC of a subsequently impressed in a series outer skin part 1 Formwulstes second

FIG. 6b shows a cross section along the section line AA. The FIGS. 6a, 6b show an embodiment in which in the series outer skin part 1 subsequently a strongly accentuated Formwulst 2 was impressed, wherein the "tip" of the Formwulstes 2 is soft rounded.

FIG. 7b shows the cross section BB. In this area, the Formwulst 2 is less strongly accentuated. The "tip" of Formwulstes 2 has here in comparison to FIG. 6b a larger radius of curvature.

FIG. 8b shows the cross section CC. In this area, the Formwulst 2 is again accentuated. Similar to FIG. 6b the "tip" of the Formwulstes 2 has a relatively small radius of curvature.

FIG. 9 shows an embodiment in which the serial outer skin part 1 during post-processing by two substantially equal width counter-holder 8, 9 from the side opposite to the forming mandrel 4 is supported. With 1 ', the contour of the Serienhauthautteils is indicated before post-processing. The "tip" of the forming mandrel 4 is here more accentuated than in the Fig. 10 The forming mandrel 8 is arranged at a distance L1 from the "center" of the shaped bead to be produced or from the tip of the forming mandrel 4, the counter-holder 9 at a distance L2. The counter-holders 8, 9 thus have a distance L3 which is equal to the sum of the distances L1 and L2. L1 is smaller than L2 here. The support is thus asymmetric with respect to the position of the tip of the forming mandrel 4. By changing the distances L1, L2 and L3 of the Supporting or clamping state of the serial outer skin part 1 and, as a result, also the shape of the shaped bead to be produced are changed.

FIG. 10 shows an embodiment in which the counter-holder 8 is wider than the counter-holder 9. Here, the support with respect to the tip of the forming mandrel 4 is only slightly asymmetrical. L1 is only slightly larger than L2 here. Compared to FIG. 9 Here is the tip of the forming mandrel 4 blunt, resulting in a correspondingly less accentuated Formwulst.

FIG. 11 shows an embodiment in which the counter-holders 8, 9 are arranged at a relatively small distance L3 from each other. This allows relatively large degrees of deformation and, as can be seen from the drawing, the production of a relatively strongly accentuated Formwulsts.

FIG. 12 shows the travel of the forming tool on the example of a series outer skin part 1, such as a hood, in the two character lines 2a, 2b are impressed. From a point in space 10, which is referred to here as the "starting point" of the movement, the forming tool (not shown) is first lowered onto the series outer skin part 1. The forming tool is then moved while applying a suitable pressing force against the serial outer skin part 1 pressed along the character line to be produced 2a. After the production of the character line 2a, the forming tool is raised and reaches the point of space 11. From there, the forming tool is moved to the point in space 12. Subsequently, it is lowered again onto the serial outer skin part 1 and moved along the character line 2b to be produced. After the production of the character line 2b, the forming tool is raised and reaches the point of space 13th

FIG. 13 shows the "hood" 1 of the FIG. 12 after making the character lines 2a and 2b. In addition, according to the same method, a central bead 2c was embossed in the engine cover sheet, which protruded upward from the engine hood, similar to that in Figs Figures 6-8 is shown.

FIG. 14 shows a die 14, which is used to produce a Formwulstes, such as the Formwulst 2c of FIG. 13 , can be used. The female mold 14 is pressed against the series outer skin part (not shown here) from the opposite side of the forming tool 4. The die 14 is provided for partially supporting the forces exerted by the forming tool 4 on the series outer skin part forces. The template 14 may be similar to that in FIG FIG. 14 U-shaped, ie open on one side. Alternatively, it may also be closed, comparable to a plate with a slot. However, the invention is by no means limited to a specific matrix form but covers all matrix forms. How out FIG. 14 can be seen, the inner edge of the die 14 in the "inlet region" of the forming tool 4 is obliquely inwardly flattened. In the lateral areas 16 of the die 14, however, the inner edge is substantially perpendicular to the support surfaces 17, 18 of the die 14, which press during the post-processing operation "from the back" against the Serienaußenhautteil and thereby support the forces exerted by the forming tool. For completeness, the travel path 19 of the forming tool is still mentioned, which extends substantially centrally with respect to the two legs of the die 14.

Claims (24)

1. A method of producing vehicle parts, especially skin parts, wherein a semifinished or finished series part (1), especially a skin part for a type of vehicle in series production, is made from a starting material and preformed in three dimensions and an individualised part is produced from the preformed series part by subsequently impressing a three-dimensional contour (2) into the series part (1), using a mandrel-like shaping tool (4) which is pressed against the series part (1) from one side and simultaneously moved relative to the series part (1),
   characterised in that

   . the series part (1) is produced from the starting material by deep drawing and

   . the three-dimensional contour (2) is produced by a single movement of the shaping tool (4) in a single pass.
2. A method according to claim 1, wherein the starting material is a metal sheet and the series part (1) and the skin part for producing therefrom are both metal parts.
3. A method according to claim 1, wherein the starting material is a plastics material and the series part and the skin part made therefrom are both plastics material parts.
4. A method according to claim 1 or 3, wherein the starting material is a thermoplastics material.
5. A method according to claim 1, wherein the series part (1) is held at edge regions by the mandrel-like shaping tool (4) while being shaped.
6. A method according to claim 5, wherein the retaining device has a number of retaining stations.
7. A method according to claim 6, wherein retaining stations are provided, each formed by a retaining element similar to a suction cup and retaining the series part by negative pressure.
8. A method according to any of claims 5 to 7, wherein the series part (1), while being shaped by the mandrel-like shaping tool (4), is retained by the retaining device at edge regions only and is neither supported nor otherwise held in the intermediate regions of the component.
9. A method according to any of claims 5 to 7, wherein the series part (1), while being shaped by the mandrel-like shaping tool (4), is held by the retaining device and is supported in the intermediate region at at least one place by a clamp or pressure pad (7) disposed on the side of the series part (1) opposite the mandrel-like shaping tool (4).
10. A method according to claim 9, wherein the clamp or the like (7) is a component such as a female mould which serves as the negative mould relative to the three-dimensional contour in course of production.
11. A method according to any of claims 1 to 10, wherein the mandrel-like shaping tool (4) has a smooth, convex tip.
12. A method according to any of claims 1 to 11, wherein the tip of the mandrel-like shaping tool (4) is formed by a rotatably mounted ball which rolls on the series part (1) during machining of the series part (1).
13. A method according to any of claims 1 to 12, wherein the mandrel-like shaping tool (4) has an adjustable tip, the width of which is varied during the machining process relative to the series part (1), transversely of the direction of travel of the mandrel-like shaping tool (4).
14. A method according to any of claims 1 to 13, wherein the mandrel-like shaping tool is heated at least at the tip region while the series part (1) is being shaped.
15. A method according to any of claims 1 to 14, wherein the series part (1) is warmed or heated by a heating source while being shaped.
16. A method according to any of claims 1 to 15, wherein the shaping tool is rotated around a longitudinal axis thereof while the series part (1) is being shaped.
17. A method according to any of claims 1 to 15, wherein the mandrel is swung in oscillation around a longitudinal axis thereof while the series part (1) is being shaped.
18. A method according to any of claims 1 to 17, wherein design-relevant linear character contours are impressed in the series part (1) by the mandrel-like shaping tool (4).
19. A method according to any of claims 1 to 18, wherein a contour already present in the series part is retraced or deepened by additional machining by the mandrel-like shaping tool (4).
20. A method according to any of claim 1 to 19, wherein the series part (1) is a bonnet, tailgate, door, side part, mudguard or roof.
21. A method according to any of claims 1 to 20, wherein the mandrel-like shaping tool (4) is disposed on one arm of a robot.
22. A method according to any of claims 1 to 21, wherein the mandrel-like shaping tool is part of a CNC machine tool.
23. A method according to any of claims 1 to 22, wherein the mandrel-like shaping tool is rotated around its longitudinal axis while the series part (1) is being produced, resulting in frictional or drilling contact between the series part (1) and the tips of the shaping mandrel.
24. A method according to any of claims 1 to 23, wherein the series parts (1) while being shaped is held so that its geometry in its end regions is not altered relative to its starting state, especially so that fitting dimensions or gap dimensions applicable during subsequent incorporation in a carcase are not changed relative to the series part in its initial state.

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