EP1848554B1 - Method and device for producing components - Google Patents

Method and device for producing components Download PDF

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Publication number
EP1848554B1
EP1848554B1 EP05794717A EP05794717A EP1848554B1 EP 1848554 B1 EP1848554 B1 EP 1848554B1 EP 05794717 A EP05794717 A EP 05794717A EP 05794717 A EP05794717 A EP 05794717A EP 1848554 B1 EP1848554 B1 EP 1848554B1
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EP
European Patent Office
Prior art keywords
forming
preform
tool
component
support plunger
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EP05794717A
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German (de)
French (fr)
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EP1848554A1 (en
Inventor
Bernd Schulze
Peter Juraschek
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Fischer Hydroforming Chemnitz & Co KG GmbH
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Tower Automotive Hydroforming & Co KG GmbH
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Publication of EP1848554A1 publication Critical patent/EP1848554A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C29/00—Cooling or heating work or parts of the extrusion press; Gas treatment of work
    • B21C29/006—Gas treatment of work, e.g. to prevent oxidation or to create surface effects
    • 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
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/025—Stamping using rigid devices or tools for tubular 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
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00

Definitions

  • the invention relates to a method for the production of components according to the preamble of the first claim, wherein a component is produced in several forming stages, wherein a forming stage is a hydroforming, (see, eg GB-A-1 206 072 ).
  • DE 102 41 028 B3 describes a method for producing arcuate (rounded) structural components from an extruded profile, which, after emerging from the die of the extruder for the purpose of molding as an arcuate (rounded) profile of guide tools is fed and hot in one or more processing stations, wherein before hot forming, the working temperature of the workpiece is adjusted by cooling.
  • the hot forming can also be done as hydroforming.
  • a disadvantage of the aforementioned solutions is that after completion of hydroforming no further reshaping processing in the direction of the cavity of the workpiece is more and the forming capacity is limited in hydroforming. In particular, tight radii during hydroforming can not be reproduced. Corresponding components must be produced by machining or can not be produced in one piece.
  • the method of manufacturing a component is by use of a voided starting workpiece having a wall with an inner surface and an outer surface, the starting workpiece being formed in an hydroforming (IHU) tool by the action of a pressure of a pressure medium acting on the inner surface thereof a first forming operation in a by the hydroforming (IHU) tool certain preform is formed and then the preform in a second forming process in a forming tool by acting on the outer surface in the direction of the cavity of the preform forming process in the required shape of the component, which also has narrow radii, is reshaped.
  • IHU hydroforming
  • the second forming operation may be either a hot forming operation or a cold forming operation.
  • the second forming process preferably takes place in a tool by means of at least one tool element having a first mold surface and acting on the outer surface, the mold surface having the contour which is to be produced on the outer wall of the component.
  • a support punch in the preform which has at least one second mold surface against which acts the first mold surface of the tool element, so that the lying between the two mold surfaces wall portion of the preform is formed by the second forming operation in the final shape.
  • a hot forming operation is required, the entire preform or only partial areas where the second forming operation is to take place are heated to the hot working temperature. This can be done inside or outside the device, for example by means of inductive heating or by radiant heat. To avoid scaling, hot forming can be carried out under a protective gas atmosphere.
  • the device for producing a component from a cavity-provided starting workpiece which has a wall with an inner surface and an outer surface, consists of an hydroforming (hydroforming) tool, in which by the action of a pressure of a pressure medium acting on the inner surface of the starting part the initial part is converted into a preform determined by the hydroforming (hydroforming) tool in a first forming operation, wherein a forming tool is used in a subsequent station, into which the preform can be inserted, wherein the forming tool moves at least one towards the cavity and on the outer surface of the preform acting, first tool element having a first mold surface corresponding to the generated contour of the component to be produced.
  • an hydroforming (hydroforming) tool in which by the action of a pressure of a pressure medium acting on the inner surface of the starting part the initial part is converted into a preform determined by the hydroforming (hydroforming) tool in a first forming operation, wherein a forming tool is used in a subsequent station, into which the preform can be inserted
  • the tool advantageously has a support punch, which engages through an opening of the preform in the cavity. At least one second mold surface is formed on the support punch, against which the first mold surface of the tool is movable, so that the wall of the preform is deformable between the two mold surfaces.
  • the support punch can be axially divided into a first part (20a) and a second part (20b), wherein the first part and / or the second part in each case one may contain second mold surface.
  • One or both parts of the support punch may be independently movable into / out of the preform. It is also possible to arrange the support punch or a part of the support punch fixed to the frame on the tool, so that the preform is then pushed over to the desired position.
  • the first part and / or the second part of the support punch may be movable perpendicular to the axis of the support punch in the direction of the tool element and away therefrom.
  • a third part of the support punch may extend between the first part and the second part of the support punch.
  • the tool can be heated and be in a protective gas atmosphere.
  • the hot forming subsequent to the hydroforming it is possible to reshape the component in the regions (for example, to produce a bead) in which a strong solidification has been recorded by the preceding forming stages.
  • ECM machining By a final electrochemical machining (ECM machining), it is possible to significantly improve the surface of the component. The roughness of the surface is reduced and any existing burr removed. This reduces the friction to the friction partner and increases the life of the component.
  • Fig. 1a shows the cross section of a tubular starting workpiece 1A.
  • This pipe section acc. Fig. 1b in a first region 1.1 its initial diameter. In the middle of 1.2 the diameter was reduced and the adjoining area 1.3 was widened at its open end by hydroforming. The area 1.3 forms a kind of pot, which is followed by the reduced area 1.2.
  • the section AA acc. Fig. 1b is in Fig. 1c shown.
  • This in Fig. 1b and 1c illustrated preform 1V is placed in a tool 10 with the area 1.3, which was preformed by IHU.
  • the tool 10 has a lower mold half 10.1.
  • a tool element 11 is arranged, which has a first mold surface 12 corresponding to the component shape to be produced with a wave-shaped portion 12.1.
  • a support punch 20 is provided which is divided axially into a first punch half 20a and a second punch half 20b.
  • the first punch half 20a lies in the direction of the tool element 11 and has a second mold surface 21, which lies opposite the first mold surface 12 of the tool element 11 and is adapted thereto.
  • Fig. 2 shows the opened tool 10 with the inserted in the area 1.3 preform 1V and located therein punch halves 20a, 20b of the support punch 20 before the second forming process.
  • Fig. 5 shows the three-dimensional view of the open tool 10 after the second forming process with the therein component 1 B, without tool element 11.
  • area 1.3 pot area of the embossed axially extending shaft portion 30 and the undercut 31 can be seen. The operation of the tool is explained in summary below:
  • the preform 1 V is inserted into the tool 10 and is located at the end located on the 1.3 side of a transverse plate 10.2.
  • the first half of the stamp (not visible here) is fixed to the frame.
  • the preform 1 V is thus pushed over the first punch half to the stop on the transverse plate 10.2.
  • the second punch half 20b in the preform 1V and the tool member 11 performs a lifting movement in the direction of the lower tool 10.1, whereby the wall of the preform 1 V between the tool element 11 and punch 20 is transformed.
  • the second punch half 20b moves out of the component 1B and the tool element 11 upwards. Now, the manufactured component 1B can be removed from the frame-fixed first punch half 20a.
  • Fig. 6 the three-dimensional view of the component 1 B produced according to the invention is shown.
  • the component 1B is in this case a Rastierhülse for securing adjustment positions of a shift linkage for motor vehicles.
  • These Rast istshülsen have a pot area 1.3, followed by a cylindrical reduced area 1.2 connects.
  • an extended area 1.1 follows.
  • an axially extending shaft portion 30 was generated.
  • This shaft portion 30 forms a latching recess into which a detent ball, not shown, a ball catch can engage.
  • the pot region 1.3 has an undercut 31 for determining the selection plane and a link 32 is cut out, via which the determination of the individual gears of the gearshift takes place.
  • the backdrop 32 is opposite a recess 33rd
  • the locking sleeve is first formed in one piece and was made from a pipe section.
  • the one-piece and extremely simple production has the advantage that higher accuracies can be achieved than in the production of shaving sleeves, which are composed of several individual parts. Furthermore, a near contour production is possible, which can be supplemented if necessary by a final mechanical processing.
  • the second forming operation is carried out by hot forming, it is possible to influence the structure in a targeted manner and thus to carry out a hardening to increase the strength.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Catalysts (AREA)
  • Nonmetallic Welding Materials (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Treatment Of Steel In Its Molten State (AREA)

Abstract

The method involves utilizing an output workpiece provided with a cavity (2) and a wall having inner (4) and outer (5) surfaces. Internal high pressure working takes place using the workpiece in a reforming process. A blank mold is produced, and reformed into the required form of a construction unit (1B) by a reforming tool (10) in another reforming process. A support die (20) engages with the mold in latter process. An independent claim is also included for a device for manufacturing a construction unit.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von Bauteilen nach dem Oberbegriff des ersten Patentanspruches, wobei ein Bauteil in mehreren Umformstufen hergestellt wird, wobei eine Umformstufe ein Innenhochdruckumformen ist, (siehe z.B. GB-A-1 206 072 ).The invention relates to a method for the production of components according to the preamble of the first claim, wherein a component is produced in several forming stages, wherein a forming stage is a hydroforming, (see, eg GB-A-1 206 072 ).

Bekannt ist nach DE 101 20 063 ein Verfahren zur Herstellung von metallischen Profilbauteilen für Kraftfahrzeuge, bei dem das Ausgangsmaterial bzw. Walzprofil mittels Induktion auf eine zum Härten erforderliche Temperatur erwärmt, abgeschreckt und gehärtet wird. Vor dem Innenhochdruckumformen ist jedoch das Härten des Bauteiles nicht erwünscht.It is known after DE 101 20 063 a method for producing metal profile components for motor vehicles, in which the starting material or roll profile is heated by induction to a temperature required for curing, quenched and cured. However, before hydroforming, curing of the component is undesirable.

Bekannt ist auch das Innenhochdruckumformverfahren zur Herstellung von Profilbauteilen, wobei ein Ausgangswerkstück in Form eines Hohlprofiles in ein Umformwerkzeug eingelegt und in diesem durch die Zuführung eines Druckmittels umgeformt wird. In DE 197 08 905 C2 wird ein gattungsgemäßes Verfahren zur Herstellung von profilierten Karosseriehohlträgern beschrieben, bei dem ein Stück eines längsnahtgeschweißten Stahlrohres als Rohling unter Verwendung eines teilbaren Formgebungswerkzeuges mittels Innenhochdruck in die durch das Werkzeug bestimmte Form umgeformt wird. Das Umformen des Stahlrohres erfolgt in mehreren Stufen. In der letzten Stufe vor dem Innenhochdruckumformen werden die teilgefertigten Werkstücke zwischengeglüht. Als Ausgangswerkstück wird Warmbandstahlblech, statt des bisher eingesetzten Kaltwalzbleches, verwendet, um die Duktilität des Werkstoffes zu erhöhen. Gem. DE 100 42 465 A1 wird ein Bauteil partiell mechanisch (auch mittels Hydroumformen) aufgeweitet und/oder reduziert und anschließend das gesamte Bauteil weichgeglüht.Also known is the hydroforming process for the production of profile components, wherein an initial workpiece is inserted in the form of a hollow profile in a forming tool and formed in this by the supply of a pressure medium. In DE 197 08 905 C2 a generic method for the production of profiled hollow body is described in which a piece of a longitudinally welded steel tube is shaped as a blank using a divisible forming tool by means of internal high pressure in the mold determined by the tool. The forming of the steel pipe takes place in several stages. In the final stage before hydroforming, the partially machined workpieces are annealed. Hot rolled steel sheet is used as the starting material instead of the previously used cold rolled sheet to increase the ductility of the material. Gem. DE 100 42 465 A1 If a component is partially expanded and / or reduced mechanically (also by means of hydro-forming) and then the entire component is annealed.

DE 102 41 028 B3 beschreibt ein Verfahren zur Herstellung von bogenförmigen (gerundeten) Strukturbauteilen aus einem Strangpressprofil, welches nach dem Austreten aus der Matrize der Strangpresse zum Zwecke der Ausformung als bogenförmiges (gerundetes) Profil von Führungswerkzeugen geführt wird und in heißem Zustand einer oder mehreren Bearbeitungsstationen zugeführt wird, wobei vor dem Warmumformen die Bearbeitungstemperatur des Werkstücks durch Kühlen eingestellt wird. Das Warmumformen kann auch als Innenhochdruckumformen erfolgen. Nachteilig bei den vorgenannten Lösungen ist, dass nach Abschluss des Innenhochdruckumformens keine weitere umformende Bearbeitung in Richtung zum Hohlraum des Werkstücks mehr erfolgt und das Umformvermögen bei Innenhochdruckumformen begrenzt ist. Insbesondere sind enge Radien beim Innenhochdruckumformen nicht abbildbar. Entsprechende Bauteile müssen spanend erzeugt werden oder sind nicht einteilig herstellbar. DE 102 41 028 B3 describes a method for producing arcuate (rounded) structural components from an extruded profile, which, after emerging from the die of the extruder for the purpose of molding as an arcuate (rounded) profile of guide tools is fed and hot in one or more processing stations, wherein before hot forming, the working temperature of the workpiece is adjusted by cooling. The hot forming can also be done as hydroforming. A disadvantage of the aforementioned solutions is that after completion of hydroforming no further reshaping processing in the direction of the cavity of the workpiece is more and the forming capacity is limited in hydroforming. In particular, tight radii during hydroforming can not be reproduced. Corresponding components must be produced by machining or can not be produced in one piece.

Es bestand daher die Aufgabe, ein effektives kostengünstiges Verfahren und eine Einrichtung zur Herstellung von Bauteilen zu entwickeln, mit welchen insbesondere einteilige rohrförmige Hohlteile herstellbar und enge Radien abbildbar sind.It was therefore the object to develop an effective cost-effective method and a device for the production of components, with which in particular one-piece tubular hollow parts can be produced and narrow radii can be represented.

Diese Aufgabe wird erfindungsgemäß mit den Merkmalen des ersten und 10.This object is achieved according to the invention with the features of the first and 10th

Patentanspruchs gelöst. Vorteilhafte Ausgestaltungen ergeben sich aus den Unteransprüchen.Patent claim solved. Advantageous embodiments emerge from the subclaims.

Das Verfahren zum Herstellen eines Bauteils erfolgt unter Verwendung eines mit einem Hohlraum versehenen Ausgangswerkstückes, welches eine Wandung mit einer Innenfläche und einer Außenfläche aufweist, wobei das Ausgangswerkstück in einem Innenhochdruckumform(IHU)-Werkzeug durch die Wirkung eines auf dessen Innenfläche wirkenden Druckes eines Druckmediums in einem ersten Umformvorgang in eine durch das Innenhochdruckumform(IHU)-Werkzeug bestimmte Vorform umgeformt wird und anschließend die Vorform in einem zweiten Umformvorgang in einem Umformwerkzeug durch ein auf die Außenfläche in Richtung zum Hohlraum der Vorform wirkendes Umformverfahren in die geforderte Form des Bauteils, welches auch enge Radien aufweisen kann, umgeformt wird.The method of manufacturing a component is by use of a voided starting workpiece having a wall with an inner surface and an outer surface, the starting workpiece being formed in an hydroforming (IHU) tool by the action of a pressure of a pressure medium acting on the inner surface thereof a first forming operation in a by the hydroforming (IHU) tool certain preform is formed and then the preform in a second forming process in a forming tool by acting on the outer surface in the direction of the cavity of the preform forming process in the required shape of the component, which also has narrow radii, is reshaped.

Der zweite Umformvorgang kann entweder ein Warmumformvorgang oder ein Kaltumformvorgang sein. Bevorzugt erfolgt der zweite Umformvorgang in einem Werkzeug mittels mindestens eines eine erste Formfläche aufweisenden und auf die Außenfläche wirkenden Werkzeugelementes, wobei die Formfläche die Kontur aufweist, die an der Außenwandung des Bauteils zu erzeugen ist. Dazu greift während des zweiten Umformvorganges ein Stützstempel in die Vorform ein, der mindestens eine zweite Formfläche aufweist, gegen welche die erste Formfläche des Werkzeugelementes wirkt, so dass der zwischen beiden Formflächen liegende Wandbereich der Vorform durch den zweiten Umformvorgang in die Endform umgeformt wird. Ist ein Warmumformvorgang erforderlich, wird die gesamte Vorform oder nur partielle Bereiche, in denen der zweite Umformvorgang erfolgen soll, auf die Warmumformtemperatur erwärmt. Dies kann innerhalb oder außerhalb der Einrichtung z.B. mittels induktiver Erwärmung oder durch Strahlungswärme erfolgen. Um Verzunderungen zu vermeiden, kann die Warmumformung unter Schutzgasatmosphäre durchgeführt werden.The second forming operation may be either a hot forming operation or a cold forming operation. The second forming process preferably takes place in a tool by means of at least one tool element having a first mold surface and acting on the outer surface, the mold surface having the contour which is to be produced on the outer wall of the component. To do this During the second forming process, a support punch in the preform, which has at least one second mold surface against which acts the first mold surface of the tool element, so that the lying between the two mold surfaces wall portion of the preform is formed by the second forming operation in the final shape. If a hot forming operation is required, the entire preform or only partial areas where the second forming operation is to take place are heated to the hot working temperature. This can be done inside or outside the device, for example by means of inductive heating or by radiant heat. To avoid scaling, hot forming can be carried out under a protective gas atmosphere.

Weiterhin ist es möglich, durch die Temperatur bei der Warmumformung und die Art und Geschwindigkeit der Abkühlung auf Raumtemperatur ein gezieltes Endgefüge herbeizuführen.Furthermore, it is possible to bring about a targeted final structure by the temperature during the hot forming and the type and speed of cooling to room temperature.

Die Einrichtung zum Herstellen eines Bauteils aus einem mit einem Hohlraum versehenen Ausgangswerkstück, welches eine Wandung mit einer Innenfläche und einer Außenfläche aufweist, besteht aus einem Innenhochdruckumform(IHU)-Werkzeug, in welchem durch die Wirkung eines auf die Innenfläche des Ausgangsteils wirkenden Druckes eines Druckmediums das Ausgangsteil in einem ersten Umformvorgang in eine durch das Innenhochdruckumform(IHU)-Werkzeug bestimmte Vorform umgeformt wird, wobei in einer nachfolgenden Station ein Umformwerkzeug Anwendung findet, in welches die Vorform einlegbar ist, wobei das Umformwerkzeug mindestens ein in Richtung zum Hohlraum bewegbares und auf die Außenfläche der Vorform wirkendes, erstes Werkzeugelement aufweist, welches eine erste Formfläche entsprechend der zu erzeugenden Kontur des herzustellenden Bauteils aufweist.The device for producing a component from a cavity-provided starting workpiece, which has a wall with an inner surface and an outer surface, consists of an hydroforming (hydroforming) tool, in which by the action of a pressure of a pressure medium acting on the inner surface of the starting part the initial part is converted into a preform determined by the hydroforming (hydroforming) tool in a first forming operation, wherein a forming tool is used in a subsequent station, into which the preform can be inserted, wherein the forming tool moves at least one towards the cavity and on the outer surface of the preform acting, first tool element having a first mold surface corresponding to the generated contour of the component to be produced.

Das Werkzeug weist vorteilhafter Weise einen Stützstempel auf, welcher durch eine Öffnung der Vorform in deren Hohlraum eingreift. Am Stützstempel ist mindestens eine zweite Formfläche ausgebildet, gegen welche die erste Formfläche des Werkzeuges bewegbar ist, so dass die Wandung der Vorform zwischen beiden Formflächen umformbar ist.The tool advantageously has a support punch, which engages through an opening of the preform in the cavity. At least one second mold surface is formed on the support punch, against which the first mold surface of the tool is movable, so that the wall of the preform is deformable between the two mold surfaces.

Dabei kann der Stützstempel axial in einen ersten Teil (20a) und einen zweiten Teil (20b) geteilt sein, wobei der erste Teil und/oder der zweite Teil jeweils eine zweite Formfläche enthalten kann. Ein oder beide Teile des Stützstempels können unabhängig voneinander in die/aus der Vorform bewegbar sein. Es ist auch möglich, den Stützstempel oder einen Teil des Stützstempels gestellfest am Werkzeug anzuordnen, so dass die Vorform dann bis zur gewünschten Lage darüber geschoben wird. Weiterhin kann der erste Teil und/oder der zweite Teil des Stützstempels senkrecht zur Achse des Stützstempels in Richtung zum Werkzeugelement und davon weg bewegbar sein.In this case, the support punch can be axially divided into a first part (20a) and a second part (20b), wherein the first part and / or the second part in each case one may contain second mold surface. One or both parts of the support punch may be independently movable into / out of the preform. It is also possible to arrange the support punch or a part of the support punch fixed to the frame on the tool, so that the preform is then pushed over to the desired position. Furthermore, the first part and / or the second part of the support punch may be movable perpendicular to the axis of the support punch in the direction of the tool element and away therefrom.

Gemäß einer Ausgestaltung der Erfindung kann sich zwischen dem ersten Teil und dem zweiten Teil des Stützstempels ein dritter Teil des Stützstempels erstrecken.According to one embodiment of the invention, a third part of the support punch may extend between the first part and the second part of the support punch.

Soll eine Warmumformung durchgeführt werden, kann das Werkzeug beheizbar sein und sich in Schutzgasatmosphäre befinden.If hot forming is to be carried out, the tool can be heated and be in a protective gas atmosphere.

Insbesondere durch die sich an das IHU anschließende Warmumformung ist es möglich, das Bauteil in den Bereichen umzuformen (z.B. eine Sicke herzustellen), in welchen durch die vorangegangenen Umformstufen eine starke Verfestigung zu verzeichnen ist.In particular, by the hot forming subsequent to the hydroforming, it is possible to reshape the component in the regions (for example, to produce a bead) in which a strong solidification has been recorded by the preceding forming stages.

Durch eine abschließende elektrochemische Bearbeitung (ECM-Bearbeitung) ist es möglich, die Oberfläche des Bauteils wesentlich zu verbessern. Die Rauheit der Oberfläche wird reduziert und eventuell vorhandener Grat abgetragen. Dadurch wird die Reibung zum Reibungspartner verringert und die Lebensdauer des Bauteils erhöht.By a final electrochemical machining (ECM machining), it is possible to significantly improve the surface of the component. The roughness of the surface is reduced and any existing burr removed. This reduces the friction to the friction partner and increases the life of the component.

Die Erfindung wird nachfolgend anhand eines Ausführungsbeispiels näher erläutert. Es zeigen:

Fig. 1a:
Ausgangswerkstück 1A im Querschnitt,
Fig. 1b:
Ansicht der Vorform 1V,
Fig. 1c:
Schnitt A-A gem. Fig. 1b,
Fig. 2:
Im offenen Werkzeug 10 befindliche Vorform 1V mit darin befindlichem Stützstempel 20 im Querschnitt,
Fig. 3:
Werkzeug 10 mit Bauteil 1B nach Abschluss des zweiten Umformvorganges im Querschnitt,
Fig. 4:
Längsschnitt gem. Fig. 3.
Fig. 5:
dreidimensionale Ansicht des geöffneten Werkzeuges nach dem zweiten Umformvorgang mit darin befindlichem Bauteil 1B,
Fig. 6:
dreidimensionale Ansicht des erfindungsgemäß hergestellten Bauteils 1 B.
The invention will be explained in more detail with reference to an embodiment. Show it:
Fig. 1a:
Starting workpiece 1A in cross-section,
Fig. 1b:
View of preform 1V,
Fig. 1c:
Section AA acc. Fig. 1b .
Fig. 2:
In the open tool 10 located preform 1V with therein support stamp 20 in cross section,
3:
Tool 10 with component 1B after completion of the second forming operation in cross section,
4:
Longitudinal section acc. Fig. 3 ,
Fig. 5:
three-dimensional view of the opened tool after the second forming operation with component 1B located therein,
Fig. 6:
three-dimensional view of the component 1 B produced according to the invention.

In Fig. 1 bis 6 wird die Herstellung eines Bauteils in Form einer Rastierhülse beschrieben. Fig. 1a zeigt den Querschnitt eines rohrförmigen Ausgangswerkstückes 1A. Dieser Rohrabschnitt behält gem. Fig. 1b in einem ersten Bereich 1.1 seinen Ausgangsdurchmesser. In der Mitte 1.2 wurde der Durchmesser reduziert und der sich anschließende Bereich 1.3 wurde an seinem offenen Ende durch Innenhochdruckumformen aufgeweitet. Der Bereich 1.3 bildet eine Art Topf, an den sich der reduzierte Bereich 1.2 anschließt. Der Schnitt A-A gem. Fig. 1b wird in Fig. 1c gezeigt. Diese in Fig. 1b und 1c dargestellte Vorform 1V wird mit dem Bereich 1.3, welcher durch IHU vorgeformt wurde, in ein Werkzeug 10 eingelegt. Das Werkzeug 10 weist eine untere Werkzeughälfte 10.1 auf. Dazu axialbeweglich ist ein Werkzeugelement 11 angeordnet, welches eine erste Formfläche 12 entsprechend der zu erzeugenden Bauteilform mit einem wellenförmigen Abschnitt 12.1 aufweist. Weiterhin ist ein Stützstempel 20 vorgesehen, der axial in eine erste Stempelhälfte 20a und eine zweite Stempelhälfte 20b geteilt ist. Die erste Stempelhälfte 20a liegt in Richtung zum Werkzeugelement 11 und weist eine zweite Formfläche 21 auf, die der ersten Formfläche 12 des Werkzeugelementes 11 gegenüberliegt und dieser angepasst ist. Fig. 2 zeigt das geöffnete Werkzeug 10 mit der im Bereich 1.3 eingelegten Vorform 1V und darin befindlichen Stempelhälften 20a, 20b des Stützstempels 20 vor dem zweiten Umformvorgang. Durch eine Bewegung des Werkzeugelementes 11 in Richtung zum Unterwerkzeug wirkt dieses mit der ersten Formfläche 12 auf die Außenseite 5 der Vorform 1V und formt somit diesen Wandbereich der Vorform in Richtung zum Hohlraum 2 um, bis sich dieser an die zweite Formfläche 21 der ersten Stempelhälfte 20a angelegt hat. Die Wandung der Vorform 1V wird somit zwischen beiden Formflächen entsprechend deren Gestaltung umgeformt, der Stützstempel 20 bildet dabei das "Gegenwerkzeug". Das geschlossene Werkzeug 10 nach dem Umformvorgang ist in Fig. 3 im Querschnitt und in Fig. 4 im Längsschnitt dargestellt. Die Innenfläche 4 liegt an der Formfläche 21 der ersten Stempelhälfte 20a und die Außenfläche 5 an der Formfläche 12 des Werkzeugelementes 11 an. Es wird aus Fig. 4 ersichtlich, dass im "Topfbereich" 1.3 neben einem hier nicht erkennbaren sich in Axialrichtung erstreckenden Wellenabschnitt auch ein Hinterschnitt 31 erzeugt wurde.In Fig. 1 to 6 the production of a component in the form of a Rastierhülse will be described. Fig. 1a shows the cross section of a tubular starting workpiece 1A. This pipe section acc. Fig. 1b in a first region 1.1 its initial diameter. In the middle of 1.2 the diameter was reduced and the adjoining area 1.3 was widened at its open end by hydroforming. The area 1.3 forms a kind of pot, which is followed by the reduced area 1.2. The section AA acc. Fig. 1b is in Fig. 1c shown. This in Fig. 1b and 1c illustrated preform 1V is placed in a tool 10 with the area 1.3, which was preformed by IHU. The tool 10 has a lower mold half 10.1. For this purpose, axially movable, a tool element 11 is arranged, which has a first mold surface 12 corresponding to the component shape to be produced with a wave-shaped portion 12.1. Furthermore, a support punch 20 is provided which is divided axially into a first punch half 20a and a second punch half 20b. The first punch half 20a lies in the direction of the tool element 11 and has a second mold surface 21, which lies opposite the first mold surface 12 of the tool element 11 and is adapted thereto. Fig. 2 shows the opened tool 10 with the inserted in the area 1.3 preform 1V and located therein punch halves 20a, 20b of the support punch 20 before the second forming process. By a movement of the tool element 11 in the direction of the lower tool, this acts with the first mold surface 12 on the outer side 5 of the preform 1 V and thus shapes this wall portion of the preform in the direction of the cavity 2, until this on the second mold surface 21 of the first punch half 20 a has created. The wall of the preform 1V is thus deformed between the two molding surfaces according to their design, the support punch 20 forms the "counter tool". The closed tool 10 after the forming process is in Fig. 3 in cross section and in Fig. 4 shown in longitudinal section. The inner surface 4 is located on the molding surface 21 of first punch half 20a and the outer surface 5 on the forming surface 12 of the tool element 11 at. It is going out Fig. 4 it can be seen that an undercut 31 has been produced in the "pot region" 1.3 in addition to a shaft section which can not be seen here in the axial direction.

Fig. 5 zeigt die dreidimensionale Ansicht des geöffneten Werkzeuges 10 nach dem zweiten Umformvorgang mit dem darin befindlichen Bauteil 1 B, ohne Werkzeugelement 11. Im Bereich 1.3 (Topfbereich) ist der eingeprägte sich axial erstreckende Wellenabschnitt 30 sowie der Hinterschnitt 31 ersichtlich. Nachfolgend wird die Wirkungsweise des Werkzeuges zusammenfassend erläutert: Fig. 5 shows the three-dimensional view of the open tool 10 after the second forming process with the therein component 1 B, without tool element 11. In area 1.3 (pot area) of the embossed axially extending shaft portion 30 and the undercut 31 can be seen. The operation of the tool is explained in summary below:

Die Vorform 1 V wird in das Werkzeug 10 eingelegt und liegt mit dem auf der Seite 1.3 befindlichem Ende an einer Querplatte 10.2 an. An dieser Querplatte 10.2 ist gestellfest die erste Stempelhälfte (hier nicht sichtbar) angeordnet. Die Vorform 1V wird somit über die erste Stempelhälfte bis zum Anschlag an die Querplatte 10.2 geschoben. Nun fährt die zweite Stempelhälfte 20b in die Vorform 1V ein und das Werkzeugelement 11 vollführt eine Hubbewegung in Richtung zum Unterwerkzeug 10.1, wodurch die Wandung der Vorform 1 V zwischen Werkzeugelement 11 und Stempel 20 umgeformt wird. Nach diesem zweiten Umformvorgang fährt die zweite Stempelhälfte 20b aus dem Bauteil 1B heraus und das Werkzeugelement 11 nach oben. Nun kann das hergestellte Bauteil 1B von der gestellfesten ersten Stempelhälfte 20a entnommen werden.The preform 1 V is inserted into the tool 10 and is located at the end located on the 1.3 side of a transverse plate 10.2. At this transverse plate 10.2 the first half of the stamp (not visible here) is fixed to the frame. The preform 1 V is thus pushed over the first punch half to the stop on the transverse plate 10.2. Now moves the second punch half 20b in the preform 1V and the tool member 11 performs a lifting movement in the direction of the lower tool 10.1, whereby the wall of the preform 1 V between the tool element 11 and punch 20 is transformed. After this second forming operation, the second punch half 20b moves out of the component 1B and the tool element 11 upwards. Now, the manufactured component 1B can be removed from the frame-fixed first punch half 20a.

In Fig. 6 ist die dreidimensionale Ansicht des erfindungsgemäß hergestellten Bauteils 1 B dargestellt. Das Bauteil 1B ist in diesem Fall eine Rastierhülse für die Sicherung von Verstellpositionen eines Schaltgestänges für Kraftfahrzeuge. Diese Rastierungshülsen weisen einen Topfbereich 1.3 auf, an den sich ein zylindrischer reduzierter Bereich 1.2 anschließt. In diesem Beispiel schließt sich ein erweiterter Bereich 1.1 an. Durch den zweiten Umformvorgang wurde ein sich axial erstreckender Wellenabschnitt 30 erzeugt. Dieser Wellenabschnitt 30 bildet eine Rastausnehmung, in welche eine nicht dargestellte Rastkugel einer Kugelraste eingreifen kann. Weiterhin weist der Topfbereich 1.3 eine Hinterschneidung 31 zur Festlegung der Wählebene auf und es ist eine Kulisse 32 ausgeschnitten, über welche die Festlegung der einzelnen Gänge der Gangschaltung erfolgt. Der Kulisse 32 gegenüberliegend befindet sich eine Ausnehmung 33.In Fig. 6 the three-dimensional view of the component 1 B produced according to the invention is shown. The component 1B is in this case a Rastierhülse for securing adjustment positions of a shift linkage for motor vehicles. These Rastierungshülsen have a pot area 1.3, followed by a cylindrical reduced area 1.2 connects. In this example, an extended area 1.1 follows. By the second forming operation, an axially extending shaft portion 30 was generated. This shaft portion 30 forms a latching recess into which a detent ball, not shown, a ball catch can engage. Furthermore, the pot region 1.3 has an undercut 31 for determining the selection plane and a link 32 is cut out, via which the determination of the individual gears of the gearshift takes place. The backdrop 32 is opposite a recess 33rd

Die Rastierhülse ist erstmalig einteilig ausgebildet und wurde aus einem Rohrabschnitt gefertigt. Die einteilige und äußerst einfache Fertigung bietet den Vorteil, dass höhere Genauigkeiten erzielbar sind, als bei der Herstellung von Rasierhülsen, die aus mehreren Einzelteilen zusammengesetzt sind. Weiterhin ist eine konturnahe Fertigung möglich, die ggf. durch eine abschließende mechanische Bearbeitung ergänzt werden kann.The locking sleeve is first formed in one piece and was made from a pipe section. The one-piece and extremely simple production has the advantage that higher accuracies can be achieved than in the production of shaving sleeves, which are composed of several individual parts. Furthermore, a near contour production is possible, which can be supplemented if necessary by a final mechanical processing.

Erfolgt der zweite Umformvorgang durch Warmumformung ist es möglich, das Gefüge gezielt zu beeinflussen und somit ein Härten zur Erhöhung der Festigkeit durchzuführen.If the second forming operation is carried out by hot forming, it is possible to influence the structure in a targeted manner and thus to carry out a hardening to increase the strength.

Claims (16)

  1. A method for producing a component (1B), using a starting workpiece (1A), provided with a cavity (2), which has a wall (3) having an inner surface (4) and an outer surface (5), the starting workpiece (1A) being formed in a hydroforming (IHU) tool in a first forming procedure into a preform (1V) and subsequently the preform (1V) being formed in a second forming procedure in a forming tool (10) by a forming method, which acts on the outer surface (5) in the direction toward the hollow cavity (2) of the preform (1V), into the required shape of the component (1 B), characterized in that a support plunger (20) engages in the preform (1V) during the second forming procedure.
  2. The method according to Claim 1, characterized in that the starting workpiece (1A) or the preform (1V) is regionally reduced in diameter/cross-section before or after the hydroforming.
  3. The method according to Claim 1 or 2, characterized in that the second forming procedure is a hot forming procedure or a cold forming procedure.
  4. The method according to one of Claims 1 through 3, characterized in that the second forming procedure is performed in a tool (10) using a tool element (11), which has at least one first forming surface (12) and acts on the outer surface (5).
  5. The method according to Claim 3 or 4, characterized in that, for the hot forming, the entire preform (1V) is heated, or only partial areas, in which the second forming procedure is to be performed, are heated to the hot forming temperature.
  6. The method according to one of Claims 3 through 5, characterized in that the heating to the hot forming temperature is performed by inductive heating or by radiant heat.
  7. The method according to one of Claims 3 through 6, characterized in that the hot forming is performed under protective gas atmosphere.
  8. The method according to one of Claims 3 through 7, characterized in that a targeted final microstructure may be generated by the temperature during the hot forming and the type and speed of the cooling to room temperature.
  9. The method according to one of Claims 1 through 8, characterized in that the surface of the component (1 B) is terminally processed using electrochemical processing.
  10. A device for producing a component (1B) according to Claim 1, made of a starting workpiece (1A), provided with the cavity (2), which has a wall (3) having an inner surface (4) and an outer surface (5), which is formed into a preform (1V) in a hydroforming tool, a forming tool being used in a downstream station in which the preform (1V) may be laid, the forming tool (10) having at least one first tool element (11), which is movable in the direction toward the cavity and acts on the outer surface (5) of the preform (1V), and which has a first forming surface (12) corresponding to the contour to be generated of the component (1 B) to be produced, characterized in that the tool (10) has a support plunger (20), which may be engaged through an opening (6) of the preform (1V) in its cavity (2) and which has at least one second forming surface (21), toward which the first forming surface (11) is movable such that the wall (2) of the preform (1V) may be formed between the two forming surfaces (11, 21).
  11. The device according to Claim 10, characterized in that the support plunger (20) is axially divided into at least a first part (20a) and a second part (20b), and the first part (20a) and/or the second part (20b) contains a second forming surface (21).
  12. The device according to Claim 11, characterized in that book parts (20a, 20b) of the support plunger (20) are movable independently of one another into/out of the preform (1V).
  13. The device according to Claim 12, characterized in that the first part (20a) and/or the second part (20b) of the support plunger (20) is movable perpendicular to the axis (A) of the support plunger (20) in the direction toward the tool element (11) and away therefrom.
  14. The device according to one of Claims 10 through 13, characterized in that a third part (20c) of the support plunger (20) extends between the first part (20a) and the second part (20b) of the support plunger (20).
  15. The device according to one of Claims 10 through 14, characterized in that the tool (10) is heatable.
  16. The device according to one of Claims 10 through 15, characterized in that a station for the electrochemical processing of the surface of the component is situated terminally.
EP05794717A 2005-02-19 2005-09-22 Method and device for producing components Active EP1848554B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102005007997A DE102005007997B3 (en) 2005-02-19 2005-02-19 Construction unit manufacturing method, involves producing blank mold, which is then reformed into required form of construction unit by reforming tool in one of two reforming processes
PCT/DE2005/001670 WO2006086935A1 (en) 2005-02-19 2005-09-22 Method and device for producing components

Publications (2)

Publication Number Publication Date
EP1848554A1 EP1848554A1 (en) 2007-10-31
EP1848554B1 true EP1848554B1 (en) 2009-06-17

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Application Number Title Priority Date Filing Date
EP05794717A Active EP1848554B1 (en) 2005-02-19 2005-09-22 Method and device for producing components

Country Status (5)

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EP (1) EP1848554B1 (en)
AT (1) ATE433810T1 (en)
DE (2) DE102005007997B3 (en)
ES (1) ES2328834T3 (en)
WO (1) WO2006086935A1 (en)

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DE102016107950A1 (en) * 2016-04-28 2017-11-02 Schuler Pressen Gmbh Method for manufacturing a hollow component, component and press for manufacturing a hollow component

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DE102007034938A1 (en) * 2007-07-24 2009-01-29 Hebö Maschinenfabrik GmbH Tubular hollow profile producing method for use in automobile industry, involves compressing profile for enlarging or pulling of profile and for reducting wall thickness of profile, and extracting hollow section
DE102007039662B4 (en) 2007-08-22 2014-12-04 Rheinmetall Waffe Munition Gmbh charge igniter
EP2151651B1 (en) * 2008-08-07 2011-01-19 Giannoni S.p.a. Bi-thermal heat exchanger, method and plant for its manufacture
DE102008049245A1 (en) * 2008-09-26 2010-04-01 F.W. Brökelmann Aluminiumwerk GmbH & Co. KG Method for forming hollow profiles
DE102014210357B4 (en) 2014-06-02 2020-12-17 Schaeffler Technologies AG & Co. KG Locking sleeve for a switching shaft and switching arrangement with the switching shaft and the locking sleeve

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JPS6270030A (en) * 1985-09-24 1987-03-31 Orimupitsuku:Kk Molding of pole
DE19708905C2 (en) * 1997-03-05 2002-06-27 Daimler Chrysler Ag Process for the production of body panels
US5992197A (en) * 1997-03-28 1999-11-30 The Budd Company Forming technique using discrete heating zones
DE10042465C2 (en) * 2000-08-29 2002-08-01 Vaw Ver Aluminium Werke Ag Process for deforming tubular hollow bodies made of metal
JP4748861B2 (en) * 2001-01-19 2011-08-17 本田技研工業株式会社 Bulge forming method
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JP2003126923A (en) * 2001-10-24 2003-05-08 Honda Motor Co Ltd Method of forming tubular member
DE10241028B3 (en) * 2002-09-05 2004-07-29 Erbslöh Ag Process for the production of curved (rounded) structural components from an extruded profile

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Publication number Priority date Publication date Assignee Title
DE102016107950A1 (en) * 2016-04-28 2017-11-02 Schuler Pressen Gmbh Method for manufacturing a hollow component, component and press for manufacturing a hollow component
WO2017186219A1 (en) 2016-04-28 2017-11-02 Schuler Pressen Gmbh Method for producing a hollow component, component and press for producing a hollow component
DE102016107950B4 (en) * 2016-04-28 2018-02-01 Schuler Pressen Gmbh Method for manufacturing a hollow component and component

Also Published As

Publication number Publication date
EP1848554A1 (en) 2007-10-31
DE502005007540D1 (en) 2009-07-30
ATE433810T1 (en) 2009-07-15
ES2328834T3 (en) 2009-11-18
WO2006086935A1 (en) 2006-08-24
DE102005007997B3 (en) 2005-12-08

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