EP2065105A1 - Electromagnetic device and method for the geometric rectification of stamped metal parts - Google Patents

Electromagnetic device and method for the geometric rectification of stamped metal parts Download PDF

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Publication number
EP2065105A1
EP2065105A1 EP06807943A EP06807943A EP2065105A1 EP 2065105 A1 EP2065105 A1 EP 2065105A1 EP 06807943 A EP06807943 A EP 06807943A EP 06807943 A EP06807943 A EP 06807943A EP 2065105 A1 EP2065105 A1 EP 2065105A1
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EP
European Patent Office
Prior art keywords
block
electromagnetic coil
rectified
electromagnetic
metal 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.)
Withdrawn
Application number
EP06807943A
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German (de)
English (en)
French (fr)
Inventor
Edurne Iriondo Plaza
Beatriz Gonzalez Ciordia
Iñaki EGUIA IBARZABAL
Maria Angeles Gutierrez Garcia
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fundacion Tecnalia Research and Innovation
Original Assignee
Fundacion Labein
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fundacion Labein filed Critical Fundacion Labein
Publication of EP2065105A1 publication Critical patent/EP2065105A1/en
Withdrawn legal-status Critical Current

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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
    • 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
    • B21D26/14—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces applying magnetic forces
    • 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
    • B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts

Definitions

  • the present invention relates to an electromagnetic device and a method for the geometric rectification of stamped metal parts having application in the iron and steel industry, allowing to rectify the deformation produced by elastic recovery as a result of the residual stress generated in this type of parts in the form of sheets after carrying out a mechanical forming process, for example after a flanging process.
  • the conventional stamping process of metal sheets requires the use of a press and at least two dies, a drawing die and a calibrating die, each of which is in turn formed by a complete hold-down plate, female element and male element having all the geometry, shape and dimensions desired in the sheet to be formed.
  • These electromagnetic forming processes are based on generating a magnetic field by means of electromagnetic coils inducing Foucault currents in the part or sheets to be formed, said Foucalt currents having the opposite direction to the currents circulating in each electromagnetic coil, therefore, the coil and the metal part repel each other such that the part is driven against the wall of the dies, adopting the desired shape, i.e. the shape of the dies, which coincides with the final geometry of the complete part which is intended to be obtained.
  • the aforementioned electromagnetic forming devices currently comprise a conductor, also denominated actuator, which is usually a copper solenoid coil connected in series with a capacitor, or usually a capacitor bank, and with a high voltage circuit and trigger start means.
  • a conductor also denominated actuator, which is usually a copper solenoid coil connected in series with a capacitor, or usually a capacitor bank, and with a high voltage circuit and trigger start means.
  • a representation of the discharge current usually used has a damped sinusoidal shape, with frequencies that are usually in a range between 10 kHz and 100 kHz.
  • the current generated in the electromagnetic coil and the currents generated in the part have opposite directions, therefore, the coil and the part repel each other such that the part acquires a high repulsion velocity and is driven against a male or female part adopting its shape.
  • the electromagnetic pressure is converted into kinetic energy, the part being able to acquire velocities of an order of magnitude between 200 m/s and 300 m/s.
  • Japanese patents No. JP 2004-122177 and JP 2001-252788 describe processes with presses for forming by stamping, incorporating a magnetic forming device which allows avoiding the springback effect.
  • Japanese patent No. JP 2004-122177 describes a line of presses or equipment comprising a plurality of presses, commonly called "transfer”, containing at least an electromagnetic forming device in the press itself with the aim of obtaining an aluminium part without elastic recovery with a certain final geometry.
  • the electromagnetic forming process is carried out simultaneously with the stamping process, and this requires the use of expensive equipment or the adaptation of existing stamping equipment, combining the electromagnetic means with the stamping process itself, which significantly increases the production costs of the parts.
  • the electromagnetic device and the method for the geometric rectification of stamped metal parts proposed by the invention allows correcting the deformation produced by the springback effect after a conventional forming process in an equipment independent of the mechanical stamping equipment by means of applying electromagnetic charges only in those areas or parts of the part which require to be rectified to obtain a part with a desired final geometry and in accordance with established dimensional tolerances.
  • a first aspect of the invention relates to an electromagnetic device for the geometric rectification of stamped metal parts which allows rectifying the deformation produced by the elastic recovery as a result of the residual stress generated in the parts after carrying out a mechanical stamping process.
  • the electromagnetic device proposed by the invention comprises at least one block configured to receive the impact and contact a side of a certain area to be rectified of a part, i.e., a sheet which has been previously mechanically stamped in a press.
  • the geometry of a surface of said at least one block configured to contact the part to be rectified corresponds exactly to a final geometry, i.e., shape and dimensions, which is desired in said side of the area to be rectified of the part.
  • a block is considered to be any element such as a male element, a female element or an insert having the suitable geometry and being configured to receive the impact and contact the part to be rectified.
  • the device comprises an electromagnetic coil which is configured to be located on a side opposite to said at least one block of a certain area to be rectified of the part.
  • the complementary electromagnetic coil is located on a second side opposite to the first side, and vice versa, i.e., in the event that the block is located on the second side of the part, then the electromagnetic coil is located on the first side.
  • Each at least one electromagnetic coil comprises at least one winding of a copper wire embedded in a part, preferably a synthetic body of glass fiber for example.
  • Said electromagnetic coil has an outer surface opposite to a side of the part to be rectified having a geometry approximate to the desired final geometry in the part, i.e., it has a geometry complementary to that of the at least one corresponding block, there being a space or clearance between each at least one electromagnetic coil and each at least one block that is less than ten times the thickness of the part, with the aim that the action of the magnetic field drives the part for its impact against the block.
  • each at least one, electromagnetic coil comprises at least one winding connected to a power supply source configured to generate a magnetic field.
  • Each at least one electromagnetic coil is operatively located such that the magnetic field it generates acts in a certain area to be rectified of the part, acting thereupon and producing an impact of the part against the corresponding block.
  • Each at least one electromagnetic coil is configured to act both on the planar areas of the part and in the curved areas or folding lines, i.e., in the areas in which the sheet has a change in direction between planes.
  • each at least one winding and electromagnetic coil have a geometry approximate to the final geometry to be obtained, including a curved geometry.
  • each at least one winding is connected to a discharge circuit comprising a capacitor, preferably a capacitor bank, and to a high voltage circuit comprising a power supply source and trigger start means, i.e., electrical switches, such that when the capacitors are charged and are activated by means of the trigger start means, a transient current is created in each at least one winding generating the transient magnetic field.
  • a discharge circuit comprising a capacitor, preferably a capacitor bank
  • a high voltage circuit comprising a power supply source and trigger start means, i.e., electrical switches
  • Said magnetic field induces Foucault currents in the part to be rectified due to the fact that the part is a sheet of electrical conducting material, the current generated in each at least one winding and the Foucault currents generated in the part having opposite directions, therefore, the part is driven in the direction opposite to that of each at least one electromagnetic coil, being pushed against said at least one block such that the side of the areas to be rectified of the part in contact with said at least one block is formed acquiring the geometry of said at least one block.
  • said at least one block and electromagnetic coil are linked both at a first base and a second base, with the aim of serving as a support.
  • said first base and said second base comprise moveable closure means, the bases being able to be arranged in both a horizontal and a vertical position.
  • the device comprises at least one driver located between said at least one electromagnetic coil and the part to be rectified, with the aim of reducing the energy demands of the device to obtain a certain geometry in a part to be rectified.
  • Said driver consists of a sheet of material with a high copper content, so that, due to its high electrical conductivity, it makes it possible for the driver to generate induced currents of a greater intensity than those generated in the part, which is a sheet of material with a lower electrical conductivity. For this reason, the repulsion force between the driver and the electromagnetic coil is greater with respect to the case of not having said driver, allowing to obtain the same results with a lower energy demand.
  • a second aspect of the invention relates to a method for the geometric rectification of stamped metal parts with an electromagnetic device like the one described previously.
  • the method of the invention is carried out starting from a metal part to be rectified, i.e., a sheet which has already been mechanically stamped in a traditional press, with the aim of rectifying the geometry of the part on those areas in which the part is out of the established tolerances. Unlike the methods of the state of the art, it is not intended to avoid the negative spring back effect of the part when the part is stamped, but to correct it afterwards.
  • the method for the geometric rectification of stamped metal parts object of the invention comprises the steps described below.
  • a first step comprises to place a stamped part with each area to be rectified operatively located between a block and an electromagnetic coil, said part being conveniently separated from the block which is separated from the complementary electromagnetic coil by a distance not greater than ten times the thickness of the part, with the aim that the said part can impact against said block by the action of a magnetic field generated by said electromagnetic coil.
  • the method comprises a second step comprising to generate a magnetic field configured to act in the areas to be rectified of the part such that they adopt a required final geometry when the part impacts against each block.
  • the method comprises a third step comprising to remove the already rectified part.
  • the method comprises an intermediate step which would be carried out before the second step of generation a magnetic field and comprising to place at least one driver, i.e. a sheet of material with a high copper content between said at least one electromagnetic coil and the part to be rectified, with the aim of reducing the energy demands of the method.
  • at least one driver i.e. a sheet of material with a high copper content between said at least one electromagnetic coil and the part to be rectified
  • the deformation of the metal part to be rectified is achieved by means of the discharge of an electric current through said at least one winding which is near the area to be rectified of the part. Due to the currents induced in the part, a quick movement of the area of the part near the coil occurs. The kinetic energy associated with the movement originates the physical change in the part.
  • the electromagnetic device and method for the geometric rectification of stamped metal parts proposed by the invention constitute a breakthrough in the forming devices and methods used to date, and they fully and easily solve the aforementioned drawbacks in that they allow its use in any type of sheets, whichever their forming process has been, allowing the regular exploitation and use of available stamping equipment such as for example traditional presses in a certain factory, i.e., without the need of having to carry out any modification thereof, in order to later rectify the parts in the device of the invention outside the press line only in the cases in which it is necessary.
  • the user can manufacture a part by means of a conventional stamping process and in view of the result, can decide if it is necessary to use the electromagnetic forming device of the invention for its rectification.
  • the device proposed by the invention is different from the electromagnetic forming devices of the state of the art because it does not require an upper female element and a lower female element accurately reproducing the final geometry, both the shape and the dimensions, of the entire part to be obtained due to the fact that the magnetic field acts only in those areas in which the part is out of the admissible tolerances, with the subsequent cost reduction.
  • the electromagnetic device proposed by the invention uses at least one block and at least one electromagnetic coil as tools allowing its adaptation to each type of geometry.
  • Said at least one block and said at least one electromagnetic coil can be exchanged, being adapted to each area to be rectified, therefore, if their design is taken care of, a same pair formed by a block and an electromagnetic coil can serve to rectify different parts, being located in areas having the same final geometry to be obtained.
  • This device eliminates the need of having to carry out successive corrections in the geometry of conventional stamping dies in order to eliminate the springback effect in the part. These corrections are generally carried out by means of an iterative correction, trial and error process with the great cost increase that this entails.
  • the device of the invention substitutes the mechanical calibrating die which can be omitted, with the subsequent saving of space in a factory, the reduction of initial costs due to the removal of a die and the possibility of use in press lines with one less station.
  • the device of the invention allows rectifying any type of parts, preferably sheets, of conducting metallic materials such as steel, in addition to the aforementioned advantages.
  • the electromagnetic device for the geometric rectification of stamped metal parts comprises at least one block (2) configured to receive the impact and contact a side of a certain area to be rectified of a part (1).
  • the geometry of a surface of said at least one block (2) configured to contact the part (1) to be rectified exactly corresponds to a desired final geometry (10) in said side of the area to be rectified of the part (1).
  • the device comprises an electromagnetic coil (5) which is configured to be located on a side opposite to said at least one block (2) of a certain area to be rectified of the part (1).
  • the complementary electromagnetic coil (5) is located on a second side (11) opposite to the first side (12), and vice versa, i.e., in the event that a block (2) is located on the second side (11) of the part (1), then the electromagnetic coil (5) is located on the first side (12).
  • Each at least one electromagnetic coil (5) comprises at least one winding (6) embedded in a part, preferably a synthetic body of fiberglass for example.
  • Said electromagnetic coil (5) has an outer surface opposite to a side of the part (1), having a geometry approximate to the desired final geometry (10) in the part (1), there being a space or clearance between each at least one electromagnetic coil (5) and each at least one block (2) that is less than ten times the thickness of the part (1), with the aim that the action of the magnetic field drives the part (1) for its impact against the block (2).
  • each at least one electromagnetic coil (5) comprises at least one winding (6) connected to a power supply source (7) configured to generate a magnetic field.
  • Each at least one electromagnetic coil (5) is operatively located such that the magnetic field it generates acts in a certain area to be rectified of the part (1), acting thereupon and producing an impact of the part (1) against the corresponding block (2).
  • Each at least one winding (6) is connected to a discharge circuit comprising a capacitor (8), preferably a capacitor bank and a high voltage circuit comprising a power supply source (7) and trigger start means (9), such that when the capacitors (8) are charged and are activated by means of the trigger start means (9), a transient current is created in each at least one winding (6) generating the transient magnetic field.
  • Said magnetic field induces Foucault currents in the part (1) to be rectified, therefore the part (1) is driven in a direction opposite to that of each at least one electromagnetic coil (5), being pushed against said at least one block (2) such that the side of the areas to be rectified of the part (1) in contact with said at least one block (2) is formed acquiring the geometry of said at least one block (2).
  • said at least one block (2) and electromagnetic coil (5) are linked both at a first base (3) and a second base (4), with the aim of serving as a support.
  • said first base (3) and said second base (4) comprise moveable closure means to facilitate the removal of the part (1), the bases being able to be arranged in both a horizontal and a vertical position.
  • the device comprises a first block (2) located in a complementary manner to a first electromagnetic coil (5) comprising a first winding (6).
  • the device comprises a second block (2') located in a complementary manner to a second electromagnetic coil (5') comprising a second winding (6').
  • the device comprises a third block (2'') located in a complementary manner to a third electromagnetic coil (5'') comprising a third winding (6'') arranged perpendicular to the first winding (6) and to the second winding (6').
  • the first winding (6) has a geometry adapted to the curved area of the final geometry (10) to be obtained in the part.
  • the first block (2), the third block (2'') and the second electromagnetic coil (5') are linked to the first base (3) whereas the second block (2'), the first electromagnetic coil (5) and the third electromagnetic coil (5'') are linked to the second base (4).
  • the device comprises at least one driver (13) consisting of a sheet of material with a high copper content, as can be seen in figure 3 , located between said at least one electromagnetic coil (5) and the part (1) to be rectified, with the aim of reducing the energy demands of the device to obtain a certain geometry in a part (1) to be rectified.
  • at least one driver (13) consisting of a sheet of material with a high copper content, as can be seen in figure 3 , located between said at least one electromagnetic coil (5) and the part (1) to be rectified, with the aim of reducing the energy demands of the device to obtain a certain geometry in a part (1) to be rectified.
  • a second aspect of the invention relates to a method for the geometric rectification of stamped metal parts with an electromagnetic device like the one previously described.
  • the method of the invention is carried out starting from the metal part to be rectified, i.e., a sheet which has already been mechanically stamped in a traditional press, with the aim of rectifying the geometry of the part in those areas in which the part is out of the established tolerances.
  • the metal part to be rectified i.e., a sheet which has already been mechanically stamped in a traditional press
  • the method for the geometric rectification of stamped metal parts object of the invention comprises the following steps:
  • the method comprises an intermediate step which would be carried out before the second step (B) and comprising to place at least one driver (13), i.e. a sheet of material with a high copper content, between said at least one electromagnetic coil (5) and the part (1) to be rectified, with the aim of reducing the energy demands of the method.
  • at least one driver (13) i.e. a sheet of material with a high copper content

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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)
  • Straightening Metal Sheet-Like Bodies (AREA)
EP06807943A 2006-09-08 2006-09-08 Electromagnetic device and method for the geometric rectification of stamped metal parts Withdrawn EP2065105A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/ES2006/000511 WO2008028982A1 (es) 2006-09-08 2006-09-08 Dispositivo electromagnético y método para la rectificación geométrica de piezas metálicas estampadas

Publications (1)

Publication Number Publication Date
EP2065105A1 true EP2065105A1 (en) 2009-06-03

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EP06807943A Withdrawn EP2065105A1 (en) 2006-09-08 2006-09-08 Electromagnetic device and method for the geometric rectification of stamped metal parts

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US (1) US20090229332A1 (ja)
EP (1) EP2065105A1 (ja)
JP (1) JP2010502448A (ja)
WO (1) WO2008028982A1 (ja)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102248059B (zh) * 2011-06-16 2013-07-24 华中科技大学 多级多向电磁成形方法及装置
CN104353718B (zh) * 2014-10-17 2016-03-02 华中科技大学 一种板材包拉成形装置及成形的方法

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Publication number Publication date
WO2008028982A1 (es) 2008-03-13
JP2010502448A (ja) 2010-01-28
US20090229332A1 (en) 2009-09-17

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