EP1626824B1 - Method for the production of individualized vehicle parts, especially individualized shell parts made from serially produced standard parts - Google Patents
Method for the production of individualized vehicle parts, especially individualized shell parts made from serially produced standard parts Download PDFInfo
- Publication number
- EP1626824B1 EP1626824B1 EP04711311A EP04711311A EP1626824B1 EP 1626824 B1 EP1626824 B1 EP 1626824B1 EP 04711311 A EP04711311 A EP 04711311A EP 04711311 A EP04711311 A EP 04711311A EP 1626824 B1 EP1626824 B1 EP 1626824B1
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- EP
- European Patent Office
- Prior art keywords
- mandrel
- series part
- series
- shaping tool
- parts
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Images
Classifications
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- 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
- B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
-
- 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
- B21D22/14—Spinning
- B21D22/18—Spinning using tools guided to produce the required profile
-
- 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
Definitions
- the present invention relates to a method for the production of vehicle parts according to the preamble of claim 1.
- 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.
- the sheet metal geometries that can be produced with conventional deep-drawing presses are limited in their complexity.
- 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.
- customary thermoforming processes occasionally to manufacturing limits.
- 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.
- 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.
- 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 Rohkarosserie former such as bonnets, tailgates, doors, side panels, fenders, roofs, etc. can in this way character lines, logos or similar. be embossed.
- 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.
- the invention is expressly not limited to the production of exterior skin parts for small series or individual vehicles.
- vehicles are often subjected to a "model revision" - a so-called “facelift".
- facelift As part of model revisions, the outer skin parts of the vehicles are occasionally revised to a certain extent or made more appealing.
- 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.
- 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.
- a "one-curve post-processing" is performed.
- the forming tool used is attached to the nachzubeinde 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.
- 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.
- a geometry produced in a first rework, such as a bead by a slight displacement of the Umfomtechnikmaschines relative to the component and essentially transversely to the direction of travel of the first reworking "broadened” and are more pronounced in this way.
- 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.
- 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.
- the Serienau touchhaut- 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.
- 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.
- 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.
- 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.
- a holding device e.g. in its edge area.
- 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
- the counterholder does not necessarily have to be used.
- 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.
- 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.
- a forming mandrel can be used with a relatively sharp-edged tip.
- the tip may also be flat-leaved, wheel-shaped, plow-shaped or hull-shaped.
- 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.
- 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.
- a lubricating oil can be used as lubricating fluid.
- a forming mandrel can be used whose tool tip is adjustable during the machining process.
- 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.
- 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.
- 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.
- 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.
- a “processing station” further “tools” have, for example, a laser cutting device with which the outer skin sheet metal part can be additionally trimmed.
- FIGS. 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.
- 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.
- FIG. 10 shows an embodiment in which the counter-holder 8 is wider than the counter-holder 9.
- the support with respect to the tip of the forming mandrel 4 is only slightly asymmetrical.
- L1 is only slightly larger than L2 here.
- 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.
- 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.
- the forming tool is raised and reaches the point of space 11.
- 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.
- 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.
- 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. 14 U-shaped, ie open on one side. Alternatively, it may also be closed, comparable to a plate with a slot.
- the invention is by no means limited to a specific matrix form but covers all matrix forms. How out FIG.
- the inner edge of the die 14 in the "inlet region" of the forming tool 4 is obliquely inwardly flattened.
- 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 Serienau tohautteil and thereby support the forces exerted by the forming tool.
- 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.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Superstructure Of Vehicle (AREA)
- Body Structure For Vehicles (AREA)
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung von Fahrzeugteilen gemäß dem Oberbegriff des Patentanspruches 1.The present invention relates to a method for the production of vehicle parts according to the preamble of
Ein derartiges Verfahren ist aus PATENT ABSTRACTS OF JAPAN Bd. 2002, Nr. 08, 5. August 2002 (2002-08-05) -&;
- PATENT ABSTRACTS OF JAPAN Bd. 2003, Nr. 06, 3. Juni 2003 (2003-06-03) -&;
JP 2003 053436 A -
US 6 216 508 B1 -
DE 40 34 625 A
- PATENT ABSTRACTS OF JAPAN vol. 2003, no. 06, 3 June 2003 (2003-06-03) - &;
JP 2003 053436 A -
US 6 216 508 B1 -
DE 40 34 625 A
Fahrzeugkarosserieteile, wie Motorhauben, Dächer, Kotflügel, Seitenteile, Kofferraumdeckel etc. werden üblicherweise durch Tiefziehen aus ebenen Ausgangsblechen hergestellt. Die Werkzeuge von Tiefziehpressen sind bekanntermaßen sehr teuer und können daher nur bei relativ großen Stückzahlen rentabel eingesetzt werden. Außerdem sind die mit herkömmlichen Tiefziehpressen herstellbaren Blechgeometrien hinsichtlich ihrer Komplexität begrenzt. Fahrzeugdesigner fordern jedoch zunehmend breitere Gestaltungsspielräume, denen man mit herkömmlichen Tiefziehwerkzeugen nicht immer gerecht werden kann. Moderne Fahrzeugdesigns zeichnen sich beispielsweise durch Übergänge zwischen konvexen und konkaven Bauteilabschnitten sowie durch stark akzentuierte Charakterlinien bzw. Kanten mit zum Teil sehr engen Krümmungsradien aus. Bereits hier stößt man mit herkömmlichen Tiefziehverfahren gelegentlich an fertigungstechnische Grenzen.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.
Einen ganz anderen Weg geht die sogenannte "Dieless-Forming-Technologie", die beispielsweise aus der
Das Grundprinzip des Dieless Forming, wie es aus der
Ein wesentlicher Nachteil des in der
Ein weiteres Problem, das bei der Herstellung kompletter Bauteile durch Anwendung des Dieless Forming Verfahrens auftritt, besteht darin, dass bei der inkrementellen Verformung eines Blechs, d.h. bei einer Umformung "Spur für Spur" sehr starke Veränderungen in der Kristallstruktur des Blechs auftreten. Versuche haben gezeigt, dass bei komplexeren Karosserieteilen, die aus ebenen, d.h. nicht vorgeformten Ausgangsblechen komplett durch "Dieless Forming" hergestellt werden, vielfach starke Oberflächenrauhigkeiten entstehen. Die Rauhigkeiten der Bauteiloberfläche sind häufig so stark, dass das Blechteil nach seiner Herstellung in der Regel nicht unmittelbar lackiert werden kann, sondern vor dem Lackieren aufwändig nachbearbeitet werden muss, z.B. durch Spachteln und Schleifen der Oberfläche oder durch andere "Glättungsbearbeitungen". Insgesamt sieht man sich bei der Dieless Forming Technologie bislang mit zahlreichen ungelösten Problemen konfrontiert. Das Dieless Forming Verfahren konnte sich daher im Kraftfahrzeugbau, insbesondere in der Serienfertigung von Karosserieteilen, bislang nicht durchsetzen.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.
Wie oben bereits erwähnt, besteht das Dilemma, dass sich mit herkömmlichen Tiefziehverfahren nicht beliebig komplexe Karosseriedesigns herstellen lassen. Ein weiteres Problem besteht darin, dass Tiefziehverfahren aufgrund der teueren Werkzeuge nur bei einer Großserienfertigung, d.h. ab bestimmten Mindestlosgrößen rentabel sind.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.
Insbesondere bei Premiumfahrzeugen haben viele Kunden ganz spezielle Ausstattungswünsche, die sich mit dem üblicherweise angebotenen Sonderausstattungsprogramm nicht immer befriedigen lassen. Viele Fahrzeughersteller bieten daher für einzelne Fahrzeugtypen bereits heute sogenannte "Individual- bzw. Kleinserienfahrzeuge" an. Im Karosseriebereich unterscheiden sich diese Individual- bzw. Kleinserienfahrzeuge aber häufig nicht oder nur wenig von den normalen Serienfahrzeugen. Der Grund hierfür ist, dass eine individuelle Gestaltung der Karosserieaußenhaut bisher kostendeckend nicht möglich ist. Die "Individualisierung" bei derartigen Fahrzeugen beschränkt sich heutzutage im Vergleich zu herkömmlichen Serienfahrzeugen häufig auf das Angebot ausgefallener Materialien für den Innenraum sowie auf ausgefallene Farben.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.
Aufgabe der Erfindung ist es, ein Verfahren anzugeben, mit dem Bauteile, insbesondere Außenhautteile für Fahrzeuge und insbesondere solche für Klein- bzw. Kleinstserienfahrzeuge, Kundenwünschen entsprechend individuell und gleichzeitig kostengünstig herstellbar sind bzw. ein diesen Anforderungen gerecht werdendes Außenhautteil zu schaffen.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.
Diese Aufgabe wird durch die Merkmale des Patentanspruches 1 gelöst. Vorteilhafte Ausgestaltungen und Weiterbildungen der Erfindung sind den Unteransprüchen zu entnehmen.This object is solved by the features of
Das Grundprinzip des Dieless-Forming Verfahrens ist, wie bereits erwähnt, an sich bekannt und z.B. in der eingangs erwähnten
Wenngleich sich die nachfolgende Beschreibung der Erfindung primär auf Serienaußenhautteile aus Blech bezieht, wird ausdrücklich darauf hingewiesen, dass die Erfindung nicht auf Werkstücke aus Blech beschränkt ist. Eine Anwendung der Erfindung ist grundsätzlich bei allen Arten von Bauteilen, wie z.B. Strukturteilen, möglich. Die Erfindung ist auch nicht auf Bauteile aus Blech beschränkt. Eine Anwendung der Erfindung ist vielmehr auch bei Werkstücken aus Kunststoff, insbesondere bei Teilen aus thermoplastischem Kunststoff, oder anderen Materialien möglich.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.
Der Kern der Erfindung besteht primär darin, individuellen Kundenwünschen gerecht zu werden, indem ein in Serienfertigung hergestelltes "Serienaußenhautteil" durch Nachbearbeitung mit einem "Umformwerkzeug", das gegen das Serienaußenhautteil gedrückt und relativ zu dem Serienaußenhautteil verfahren wird, "individualisiert" wird.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.
Ein wesentlicher Unterschied zu der
Dem vorgeformten "Serienteil", das an sich bereits ein halbfertiges oder fertiges Rohkarosserieteil darstellen kann, wird vor dem Einbau in eine Rohkarosserie durch eine "Nachbearbeitung" zusätzlich eine von herkömmlichen Serienfahrzeugen abweichende "Geometrie" bzw. "Kontur" eingeprägt. Halbfertigen oder fertigen Rohkarosserieteilen wie Fronthauben, Heckklappen, Türen, Seitenteilen, Kotflügeln, Dächern etc. können auf diese Weise Charakterlinien, Schriftzüge o.ä. eingeprägt werden. Ferner können bereits im Serienaußenteil vorhandene Charakterlinien oder Bauteilkanten nachgezogen oder vertieft und somit stärker ausgeprägt werden, als dies bei den für herkömmliche Serienfahrzeuge verwendeten Serienaußenhautteilen möglich bzw. der Fall ist. Aus herkömmlichen Serienaußenhautteilen können durch eine derartige Nachbearbeitung mit einem Umformwerkzeug eine unendliche Vielzahl von Designabwandlungen hergestellt werden und zwar so kostengünstig, wie man es bislang nicht für möglich gehalten hat. Indem man serienähnliche Fahrzeuge in Kleinserien oder als Individualfahrzeuge anbietet, kann man den insbesondere bei hochpreisigen Fahrzeugen bestehenden Wünschen der Kunden nach Individualisierung besser gerecht werden. Fahrzeuge erlangen durch eine derartige Differenzierung eine individuelle "Design-Note" und heben sich somit von den übrigen Fahrzeugen des jeweiligen Fahrzeugtyps optisch deutlich ab.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.
Versuche haben gezeigt, dass im Unterschied zur Herstellung kompletter Blechteile aus ebenen Ausgangsblechen durch Dieless Forming, wie dies in der
Die Erfindung ist ausdrücklich nicht auf die Herstellung von Außenhautteilen für Kleinserien- oder Individualfahrzeuge beschränkt. Fahrzeuge werden im Laufe ihres Produktlebenszyklus häufig einer "Modellüberarbeitung" - einem sogenannten "Facelift" - unterzogen. Im Rahmen von Modellüberarbeitungen werden gelegentlich auch die Außenhautteile der Fahrzeuge in gewissem Umfang überarbeitet bzw. ansprechender gestaltet. Bisher war es hierbei erforderlich, neue Presswerkzeuge anzuschaffen bzw. vorhandene Presswerkzeuge entsprechend dem neuen Design anzupassen, was regelmäßig mit sehr hohen Werkzeugkosten verbunden ist. Mit dem im folgenden noch näher erläuterten Verfahren ist es nun möglich, mit den "alten" Presswerkzeugen hergestellte Außenhautteile zu überarbeiten bzw. nachzubearbeiten. Auf diesem Weg können zusätzliche Charakterlinien, Sicken etc. in die "alten Außenhautteile" eingeprägt werden, was eine "Modellüberarbeitung" mit wesentlich geringeren Kosten ermöglicht als dies bisher der Fall war.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.
Ein weiterer wesentlicher Vorteil der Erfindung besteht darin, dass in eine bestehende Fertigungsstraße problemlos eine entsprechende "Nacharbeitsstation" integriert werden kann. Serienteile, die für Individualfahrzeuge oder für individualisierte Fahrzeuge oder für eine Modellüberarbeitung vorgesehen sind, werden in der "Nacharbeitsstation" nachbearbeitet. Serienteile für herkömmliche Serienfahrzeuge durchlaufen die Nacharbeitsstation ohne dass sie nachbearbeitet werden. Selbstverständlich ist eine Nachbearbeitung gemäß der Erfindung auch ausserhalb der Fertigungsstrasse in separaten Bearbeitungsstationen möglich.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.
Wie bereits erwähnt wird bei dem Verfahren gemäß der Erfindung , mittels eines Umformwerkzeugs, das dornartig gestaltet ist, eine dreidimensionale Kontur in ein Blechteil eingeprägt. Das Umformwerkzeug wird im folgenden auch als "Umformdorn" bezeichnet, was jedoch nicht einschränkend im Sinne einer bestimmten Werkzeugform zu verstehen ist.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.
Der "Umformdorn" wird bei der Nachbearbeitung eines Bauteils mit seinem Ende, das z.B. als Spitze oder als abgerundete Spitze ausgebildet sein kann, gegen das Bauteil gedrückt. Gleichzeitig werden das Bauteil und der Umformdorn relativ zueinander verschoben. Hierdurch wird entsprechend der Geometrie des Endes des Umformdorns und in Abhängigkeit von der Anpresskraft sowie dem "Einspann- bzw. Abstützzustand" des zu bearbeitenden Bauteils eine "Ein- bzw. Ausbuchtung" oder ganz allgemein gesprochen eine dreidimensionale Kontur hergestellt. Die herzustellende Kontur kann z.B. die Form einer Rille, eines Wulstes oder eine andere Form haben.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.
Nach der Erfindung wird eine "One-Curve-Nachbearbeitung" durchgeführt.According to the invention, a "one-curve post-processing" is performed.
Bei der "One-Curve-Nachbearbeitung" wird das verwendete Umformwerkzeug an das nachzubearbeitende Bauteil angesetzt, gegen das Bauteil gedrückt und anschließend wird das Umformwerkzeug mit einer einzigen Verfahrbewegung relativ zu dem Bauteil verfahren. Die Nachbearbeitung erfolgt also, indem das Umformwerkzeug "in einem Zug" verfahren wird, wodurch die gewünschte Geometrie, z.B. eine Sicke, eine Charakterlinie o.ä. in das Bauteil eingeprägt wird.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.
Demgegenüber wird das Umformwerkzeug bei einer "inkrementellen Nachbearbeitung" mehrmals relativ zu dem nachzubearbeitenden Bauteil verfahren und inkrementell zugestellt. Eine in einem ersten Nacharbeitsgang hergestellte Geometrie, wie z.B. eine Sicke, kann durch eine entsprechende Zustellbewegung - im wesentlichen senkrecht zu dem nachzubearbeitenden Bauteil - in einem weiteren Nacharbeitsgang vertieft, d.h. stärker ausgeprägt werden. Alternativ oder ergänzend dazu kann eine in einem ersten Nacharbeitsgang hergestellte Geometrie, wie z.B. eine Sicke, durch eine geringfügige Verschiebung des Umfomwerkzeugs relativ zu dem Bauteil und im wesentlichen quer zur Verfahrrichtung des ersten Nacharbeitsgangs "verbreitert" und auf diese Weise stärker ausgeprägt werden. Durch eine mäanderartige Führung des Umformdorns oder durch wiederholtes Abfahren nahe nebeneinanderlieger "Bearbeitungstrajektorien" können auch größere dreidimensionale Ausbuchtungen, wie z.B. ausgeprägte Ansaugkanäle, der "Powerdome" einer Motorhaube oder ganz allgemein strukturelle Erhöhungen hergestellt werden.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.
Wie bereits erläutert, besteht jedoch der Kern der Erfindung nicht wie bei der
"Fertig" bedeutet in diesem Zusammenhang, dass das Rohkarosserieteil an sich fertig für eine Lackierung wäre, zuvor aber noch in einem Bauteilbereich oder in mehreren Bauteilbereichen nachbearbeitet wird. Prinzipiell denkbar ist aber auch, bereits fertig lackierte Serienaußenhautbauteile durch eine Nachbearbeitung gemäß der Erfindung zu "individualisieren" bzw. zu differenzieren. "Halbfertig" bedeutet, dass das Rohkarosserieteil nach der Nachbearbeitung gemäß der Erfindung noch weiter nachbearbeitet wird, z.B. durch Nachbehandeln der Oberfläche, Beschneiden bzw. Abkanten von Bauteilrändem, Bohren von Löchern, Gewindeschneiden o.ä. und erst anschließend lackiert wird.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.
Vor der Nachbearbeitung gemäß der Erfindung wird das Serienaußenhaut- oder das Rohkarosserieteil in eine Halteeinrichtung eingespannt. Die Halteeinrichtung kann beispielsweise durch eine Vielzahl einzelner "Haltepunkte" bzw. "Halteabschnitte" gebildet sind. Es ist auch möglich, saugnapfartige Halteelemente einzusetzen. Saugnapfartige Halteelemente haben den Vorteil, dass sich die Gefahr einer Beschädigung des Außenhautblechteils, insbesondere die Gefahr einer Beschädigung der Bauteiloberfläche, beim Einspannen und während der Bearbeitung verringert, da das Werkstück nicht zwischen zwei Halteelemente eingeklemmt, sondern durch Unterdruck fixiert wird.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.
Vorzugsweise wird das Werkstück, d.h. das Serienaußenhautteil vor der Nachbearbeitung so eingespannt, dass sich seine Geometrie im Randbereich durch die Nachbearbeitung nicht verändert. Anders ausgedrückt sollen sich durch die Nachbearbeitung Anschlussmaße bzw. Spaltmaße, die sich beim späteren Einbau des Außenhautteils in eine Karosserie ergeben, in Bezug auf das "normale Serienfahrzeug" nicht verändern.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.
Je nach Komplexität der "nachträglich" herzustellenden Bauteilgeometrie kann das Serienaußenhautteil während der Nachbearbeitung entweder ausschließlich mittels einer Halteeinrichtung gehalten werden, z.B. in seinem Randbereich. Bei komplexeren Bauteilgeometrien bzw. bei dreidimensionalen Konturen, die einen starken Flächengradienten aufweisen, insbesondere bei relativ "scharfen" Kanten, können ein oder mehrere Gegenhalter" bzw. Abstützelemente eingesetzt werden. Solche Gegenhalter bzw. Abstützelemente werden von der dem Umformdorn gegenüberliegenden Seite her, d.h. "von hinten her" gegen das Serienaußenhautteil gedrückt. Als Gegenhalter können kantenförmige oder gewölbte "Abstützelemente" verwendet werden. Alternativ dazu kann der Gegenhalter auch die Form einer "Matrize" übernehmen, welche eine der herzustellenden dreidimensionalen Kontur entsprechende "Negativform" aufweist. Ein solcher Gegenhalter muss aber nicht notwendigerweise verwendet werden.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.
Werden zwei Gegenhalter verwendet, so ist vorzugsweise der eine Gegenhalter in Verfahrrichtung des Umformwerkzeugs links und der andere Gegenhalter in Verfahrrichtung rechts neben der herzustellenden Geometrie angeordnet. Bereits durch die Wahl bzw. die Veränderung des Abstands der Gegenhalter voneinander und durch den seitlichen Abstand der Gegenhalter von der herzustellenden Geometrie kann die herzustellende Geometrie in ihrer Form beeinflusst werden, was später noch näher erläutert wird.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.
Der Umformdorn kann beispielsweise eine glatte, konvex gekrümmte Werkzeugspitze aufweisen. Er kann symmetrisch oder asymmetrisch sein. Die Werkzeugspitze kann auch durch eine drehbar gelagerte Kugel gebildet sein, die bei der Bearbeitung des Serienaußenhautteils auf dem Serienaußenhautteil abrollt, wodurch sich die mechanische Beanspruchung des Serienaußenhautteils im Verformungsbereich verringert. Alternativ dazu kann auch ein "Rolldorn" verwendet werden, bei dem die Werkzeugspitze durch ein Rad bzw. durch eine Rolle gebildet ist. Es können auch Mehrfachdorne bzw. mehrarmige Umformdorne verwendet werden. Der Umformdorn muss aber nicht unbedingt eine runde bzw. gerundete Spitze aufweisen. Vielmehr kann auch ein Umformdorn mit einer relativ scharfkantig ausgebildeten Spitze verwendet werden. Alternativ dazu kann die Spitze auch flach auslaufend, radförmig, pflugförmig oder schiffsrumpfähnlich sein. Auch ein Umformdorn mit einer facettierten Werkzeugspitze ist denkbar.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.
Der Umformdorn muss auch nicht notwendigerweise aus Stahl bzw. Werkzeugstahl bestehen. Denkbar sind auch Umformdorne aus Kunststoff, Holz, Eis, Sand, Beton oder anderen Materialien. Die Werkzeugspitze des Umformdorns kann gehärtet, ungehärtet, beschichtet oder unbeschichtet sein. Sie kann z.B. mit einer verschleißfesten Einfach- oder Hybridbeschichtung versehen sein. Der Umformdorn kann dabei in bis zu sechs Achsen relativ zum Bauteil geführt werden, um das gewünschte "Formergebnis" zu erzielen. Der Umformdorn bzw. die Werkzeugspitze des Umformdorns können während der Nachbearbeitung auch um die Längsachse des Umformdorns rotiert bzw. oszilliert werden.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.
Es kann ein Umformdorn mit oder ohne Schmierung verwendet werden. Beispielsweise kann in den Umformdorn ein Schmiersystem integriert sein. Das Schmiersystem kann auch außen am Umformdorn angeordnet sein. Das Schmiersystem sorgt dafür, das die "Bearbeitungsstelle", d.h. die Stelle, an welcher der Umformdorn das Serienaußenhautteil berührt, ständig mit ausreichend Schmierflüssigkeit versorgt wird. Als Schmierflüssigkeit kann ein Schmieröl verwendet werden.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.
Ferner kann ein Umformdorn verwendet werden, dessen Werkzeugspitze während des Bearbeitungsvorganges verstellbar ist. Beispielsweise kann vorgesehen sein, dass die Breite der Werkzeugspitze quer zur Verfahrrichtung des Werkzeugdorns während des Bearbeitungsvorgangs verändert werden kann. Auf diese Weise können in einem einzigen Arbeitsgang Geometrien mit veränderlicher "Breite" hergestellt werden.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.
Die Verfahrgeschwindigkeit, mit welcher der Umformdorn während der Nachbearbeitung relativ zum Serienaußenhautteil bewegt wird, muss nicht konstant sein. Vielmehr kann die Verfahrgeschwindigkeit in Abhängigkeit von dem momentanen "Umformgrad" des Serienaußenhautteils variiert werden. Bei kleineren Verformungsgraden kann eine höhere Verfahrgeschwindigkeit, bei größeren Verformungsgraden eine kleinere Verfahrgeschwindigkeit gewählt werden.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.
Sowohl der Umformdorn als auch das "Werkstück" können während der Bearbeitung bei Bedarf beheizt oder gekühlt werden oder Umgebungstemperatur haben. Bei Serienaußenhautteilen aus Blech, vor allem aber bei "Werkstücken" aus Kunststoff kann es von Vorteil sein, den Umformdorn bzw. die Werkzeugspitze des Umformdorns während der Bearbeitung des Serienaußenhautteils zu beheizen. Eine Beheizung des Umformdorns führt zu einem Wärmeeintrag in den umzuformenden Bereich des Werkstücks, wodurch sich dessen Duktilität erhöht, was die Umformung erleichtert. Insbesondere bei Kunststoffteilen wird dadurch eine Umformung erleichtert.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.
Alternativ oder ergänzend dazu kann auch unmittelbar das Serienaußenhautteil während der Nachbearbeitung vorgewärmt bzw. erhitzt werden. Das Serienaußenhautteil kann durch Heißluft, Heizstrahler, Laser oder durch eine andere Heizquelle erwärmt werden. Serienaußenhautteile können während der Nachbearbeitung bis knapp unter eine materialspezifische "Erweichungstemperatur" vorgewärmt und/oder mittels eines beheizten Umformdorns oder punktueller Zusatzerwärmung am Eingriffspunkt lokal auf eine geeignete "Umformtemperatur" erwärmt werden.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.
Das Werkstück kann vor der Nachbearbeitung auch durch andere Verfahren vorbehandelt werden. Es kann beispielsweise bestrahlt, beschichtet, geätzt, gehärtet, aufgeraut, geglättet, poliert, mit Schmierflüssigkeit besprüht oder geschliffen werden. Es kann vor der Nachbearbeitung auch durch Sandstrahlen vorbehandelt werden.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.
Vorzugsweise erfolgt die Nachbearbeitung des Serienaußenhautteils vollautomatisch gesteuert. Der Umformdorn kann entweder als Bearbeitungswerkzeug einer CNC-Werkzeugmaschine ausgebildet sein, ähnlich wie bei der
Im Folgenden wird die Erfindung im Zusammenhang mit der Zeichnung näher erläutert. Es zeigen:
- 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.
-
zeigtFigur 1ein Serienaußenhautblechteil 1 eines Fahrzeugs.Bei dem Serienaußenhautblechteil 1der Figur 1 handelt es sich um eine "Türaußenhaut". Indas Serienaußenhautblechteil 1 wurde "nachträglich"ein Formwulst 2 eingearbeitet, was im Zusammenhang mit den nachfolgenden Figuren noch näher erläutert wird. -
zeigt einen SchnittFigur 2durch das Außenhautteil 1der Figur 1 entlang der Schnittlinie A -A. Der Formwulst 2hat 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 denEnden der Formwulst 2 hin ab. -
zeigt einen Querschnitt durchFigur 3das 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. -
beschreibt schematisch denFigur 4Nachbearbeitungsvorgang des Serienaußenhautteils 1.Das Serienaußenhautteil 1 wird in eine hier nicht näher dargestellte Halteeinrichtung 3 eingespannt bzw. aneiner Halteeinrichtung 3 fixiert. Bei dem hier gezeigten Ausführungsbeispielist das Serienaußenhautteil 1 lediglich in seinen Randbereichen ander Halteeinrichtung 1 befestigt. Anschließendwird ein Umformdorn 4 andas Serienaußenhautteil 1 herangeführt und gegendas Serienaußenhautteil 1 mit einer vorgegebenen Andrückkraft gedrückt. In einem nächsten Schritt wird der Umformdorn 4 relativ zudem Serienaußenhautteil 1 inRichtung des Pfeils 5 verfahren. Gleichzeitig erfolgt eine "Zustellbewegung"des Umformdorns 4 relativ zudem Serienaußenhautteil 1, wodurch der Formwulst 2 durch dieSpitze 6 desUmformdorns 4 indas Serienaußenhautteil 1 eingeprägt wird. -
zeigt ein Ausführungsbeispiel, bei dem mittels eines matrizenartigen Gegenhalters 7 vonFigur 5der dem Umformdorn 4 gegenüberliegenden Seite desSerienaußenhautteils 1 gegengedrückt wird.Das Serienaußenhautteil 1 wird also durch den matrizenartigen Gegenhalter 7 abgestützt, was problemlos die Herstellung einer scharfkantigen Kontur, wie in 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.Figur 5
- 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 skinsheet metal part 1 of a vehicle. In the series outer skinsheet metal part 1 ofFIG. 1 it is an "outer door skin". In the series outer skin sheet metal part 1 aFormwulst 2 was incorporated "subsequently", which will be explained in more detail in connection with the following figures. -
FIG. 2 shows a section through theouter skin part 1 ofFIG. 1 along the section line A - A. TheFormwulst 2 has alength 1 and a depth t. The depth t of theFormwulstes 2 has in the z-axis of theFIG. 2 their maximum and decreases towards the ends of theFormwulst 2 out. -
FIG. 3 shows a cross section through theouter skin part 1 along the section line B - B ofFIG. 1 , It can be seen that theFormwulst 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 serialouter skin part 1. The serialouter skin part 1 is clamped in aholding device 3 not shown here or fixed to aholding device 3. In the embodiment shown here, the seriesouter skin part 1 is attached to theholding device 1 only in its edge regions. Subsequently, a formingmandrel 4 is brought to the seriesouter skin part 1 and pressed against the seriesouter skin part 1 with a predetermined pressing force. In a next step, the formingmandrel 4 is moved in the direction of thearrow 5 relative to the serialouter skin part 1. At the same time, a "feed movement" of the formingmandrel 4 takes place relative to the serialouter skin part 1, whereby the shapedbead 2 is impressed into the seriesouter skin part 1 by thetip 6 of the formingmandrel 4. -
FIG. 5 shows an embodiment in which is pressed by means of a die-like counter-holder 7 of the formingmandrel 4 opposite side of the serialouter skin part 1. The seriesouter skin part 1 is thus by the supported die-like counter-holder 7, which easily produce a sharp-edged contour, as inFIG. 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.
Die
Claims (24)
- 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. - 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.
- 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.
- A method according to claim 1 or 3, wherein the starting material is a thermoplastics material.
- 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.
- A method according to claim 5, wherein the retaining device has a number of retaining stations.
- 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.
- 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.
- 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).
- 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.
- A method according to any of claims 1 to 10, wherein the mandrel-like shaping tool (4) has a smooth, convex tip.
- 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).
- 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).
- 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.
- 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.
- 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.
- 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.
- 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).
- 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).
- 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.
- 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.
- A method according to any of claims 1 to 21, wherein the mandrel-like shaping tool is part of a CNC machine tool.
- 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.
- 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.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10324244A DE10324244A1 (en) | 2003-05-28 | 2003-05-28 | Process for the production of individualized outer skin sheet metal parts from series production of outer skin sheet metal parts for vehicles as well as outer skin sheet metal parts manufactured according to this process |
PCT/EP2004/001403 WO2004105976A1 (en) | 2003-05-28 | 2004-02-14 | Method for the production of individualized vehicle parts, especially individualized shell parts made from serially produced standard parts, and shell parts produced according to said method |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1626824A1 EP1626824A1 (en) | 2006-02-22 |
EP1626824B1 true EP1626824B1 (en) | 2008-08-13 |
Family
ID=33482249
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP04711311A Expired - Lifetime EP1626824B1 (en) | 2003-05-28 | 2004-02-14 | Method for the production of individualized vehicle parts, especially individualized shell parts made from serially produced standard parts |
Country Status (8)
Country | Link |
---|---|
US (1) | US20060090530A1 (en) |
EP (1) | EP1626824B1 (en) |
JP (1) | JP2007512960A (en) |
KR (1) | KR20060014060A (en) |
CN (1) | CN100382910C (en) |
DE (2) | DE10324244A1 (en) |
ES (1) | ES2309499T3 (en) |
WO (1) | WO2004105976A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102005048220C5 (en) * | 2005-09-29 | 2018-01-18 | Magna Exteriors (Germany) Gmbh | Method for producing a trim part variant for a motor vehicle and trim part |
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DE102005024378B4 (en) * | 2005-05-27 | 2016-02-18 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Method for incremental forming of thin-walled workpieces and device |
DE102006016460A1 (en) * | 2006-04-07 | 2007-10-11 | Bayerische Motoren Werke Ag | Device for processing sheet metal in the manufacture of outer skin parts for vehicles comprises a drive unit which rotates a tool holder and a deforming tool having a middle longitudinal axis which is offset from the axis of rotation |
DE102007009705B3 (en) * | 2007-02-28 | 2007-10-31 | Audi Ag | Press tool assembly for automotive body panels has standard base frame for clamp and standard base frame for press tool |
DE102008004051A1 (en) | 2008-01-11 | 2009-07-16 | Bayerische Motoren Werke Aktiengesellschaft | A method of forming a sheet metal part and apparatus for carrying out the method |
DE102008016999A1 (en) * | 2008-04-03 | 2009-10-08 | Bayerische Motoren Werke Aktiengesellschaft | Tool for postforming deep-drawn sheet metal part for body of motor vehicle, has embossing die supported in press base or pressure pad and moved from withdrawn position to plunged position in sheet metal part |
CN102000722A (en) * | 2009-08-31 | 2011-04-06 | 扬州恒德模具有限公司 | Upper rolling-rib die for rotating station of numerically-controlled turret punch |
US8783078B2 (en) | 2010-07-27 | 2014-07-22 | Ford Global Technologies, Llc | Method to improve geometrical accuracy of an incrementally formed workpiece |
JP5696682B2 (en) | 2012-04-05 | 2015-04-08 | トヨタ自動車株式会社 | Metal plate forming method |
JP6072433B2 (en) * | 2012-05-23 | 2017-02-01 | 株式会社アミノ | Sequential molding method and apparatus |
DE102014006683A1 (en) | 2014-05-08 | 2015-11-12 | GM Global Technology Operations LLC (n. d. Gesetzen des Staates Delaware) | Production line for processing at least one surface component and method for processing the at least one surface component in the production line |
DE102014219021A1 (en) * | 2014-09-22 | 2016-03-24 | Volkswagen Aktiengesellschaft | press tool |
DE102014221878A1 (en) | 2014-10-28 | 2016-04-28 | Bayerische Motoren Werke Aktiengesellschaft | Press tool for producing a sheet metal part having at least one sharp-edged sheet metal part edge and sheet metal part produced therewith |
US20180214927A1 (en) * | 2017-01-31 | 2018-08-02 | Ford Motor Company | Method for production of sheet metal components |
WO2019007555A1 (en) | 2017-07-06 | 2019-01-10 | Bobst Mex Sa | A method of creasing sheets |
CA3135330C (en) * | 2019-03-28 | 2023-06-27 | Honda Motor Co., Ltd. | Press forming method |
CN111114649B (en) * | 2019-11-28 | 2023-10-20 | 无锡曙光模具有限公司 | Automobile engine cabin covering shell part and processing technology thereof |
SE545199C2 (en) * | 2021-08-30 | 2023-05-16 | Stilride AB | Processing of a two dimensional sheet material |
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JP3475551B2 (en) * | 1995-02-27 | 2003-12-08 | 松下電器産業株式会社 | Shaft forming method from metal plate |
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-
2003
- 2003-05-28 DE DE10324244A patent/DE10324244A1/en not_active Ceased
-
2004
- 2004-02-14 JP JP2006529659A patent/JP2007512960A/en active Pending
- 2004-02-14 KR KR1020057022445A patent/KR20060014060A/en not_active Application Discontinuation
- 2004-02-14 EP EP04711311A patent/EP1626824B1/en not_active Expired - Lifetime
- 2004-02-14 WO PCT/EP2004/001403 patent/WO2004105976A1/en active IP Right Grant
- 2004-02-14 DE DE502004007843T patent/DE502004007843D1/en not_active Expired - Lifetime
- 2004-02-14 CN CNB2004800144869A patent/CN100382910C/en not_active Expired - Lifetime
- 2004-02-14 ES ES04711311T patent/ES2309499T3/en not_active Expired - Lifetime
-
2005
- 2005-11-28 US US11/287,203 patent/US20060090530A1/en not_active Abandoned
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102005048220C5 (en) * | 2005-09-29 | 2018-01-18 | Magna Exteriors (Germany) Gmbh | Method for producing a trim part variant for a motor vehicle and trim part |
Also Published As
Publication number | Publication date |
---|---|
JP2007512960A (en) | 2007-05-24 |
CN1795066A (en) | 2006-06-28 |
DE502004007843D1 (en) | 2008-09-25 |
DE10324244A1 (en) | 2004-12-30 |
US20060090530A1 (en) | 2006-05-04 |
ES2309499T3 (en) | 2008-12-16 |
CN100382910C (en) | 2008-04-23 |
KR20060014060A (en) | 2006-02-14 |
WO2004105976A1 (en) | 2004-12-09 |
EP1626824A1 (en) | 2006-02-22 |
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