EP2180964B1 - Process for deforming a hollow part - Google Patents

Process for deforming a hollow part Download PDF

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Publication number
EP2180964B1
EP2180964B1 EP08806905.9A EP08806905A EP2180964B1 EP 2180964 B1 EP2180964 B1 EP 2180964B1 EP 08806905 A EP08806905 A EP 08806905A EP 2180964 B1 EP2180964 B1 EP 2180964B1
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EP
European Patent Office
Prior art keywords
matrix
hollow part
die
segments
during
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP08806905.9A
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German (de)
French (fr)
Other versions
EP2180964A2 (en
Inventor
Eberhard Rauschnabel
Bernhard Adams
Karsten Juhr
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.)
Ifutec Ingenieurbuero fur Umformtechnik GmbH
Stiftung Fachhochschule Osnabrueck
Original Assignee
Ifutec Ingenieurbuero fur Umformtechnik GmbH
Stiftung Fachhochschule Osnabrueck
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.)
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Priority to EP08806905.9A priority Critical patent/EP2180964B1/en
Publication of EP2180964A2 publication Critical patent/EP2180964A2/en
Application granted granted Critical
Publication of EP2180964B1 publication Critical patent/EP2180964B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00—Making other articles
    • B21K23/04—Making other articles flanged articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/20—Making helical or similar guides in or on tubes without removing material, e.g. by drawing same over mandrels, by pushing same through dies ; Making tubes with angled walls, ribbed tubes and tubes with decorated walls
    • B21C37/205—Making helical or similar guides in or on tubes without removing material, e.g. by drawing same over mandrels, by pushing same through dies ; Making tubes with angled walls, ribbed tubes and tubes with decorated walls with annular guides
    • 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
    • B21D17/00—Forming single grooves in sheet metal or tubular or hollow articles
    • B21D17/02—Forming single grooves in sheet metal or tubular or hollow articles by pressing
    • B21D17/025—Forming single grooves in sheet metal or tubular or hollow articles by pressing by pressing tubes axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting

Definitions

  • the present invention relates to a method for forming a hollow molded part, in which in a first process step, a hollow molded part is inserted into a first die which annularly surrounds and supports the hollow molded part in a support region along its lateral surface, and in which in a second process step, the hollow molded part in Direction of its major axis is compressed such that the hollow molded part is plastically deformed in a not supported by the first die forming area.
  • the method according to the invention belongs to a category of methods in which, for example, according to the EP 1 611 973 A1 a multi-part die is provided for supporting the outside of a hollow molded part on which a flange is to be formed by means of plastic deformation.
  • the die is divided in the axial direction into two die parts, which are adjustable relative to each other during a plastic forming operation.
  • the reshaped hollow molded part is subjected to a Axialpressvorgang, which brings the basic problem of buckling with it, so that only comparatively thin flanges can be produced on the hollow molded part.
  • a method for locally expanding a hollow molded part in which a forming force is applied by means of a hydraulically active medium by high-pressure forming on the hollow molded part.
  • the hollow molded part In a non-reshaping region, the hollow molded part is firmly supported on the outside by means of a first die, while a multi-part, adjustable second die is provided in a forming region not described in detail.
  • the second die includes four segments positioned around the die, each having a spherical inner surface. The segments are controlled away via hydraulic piston-cylinder units so moved radially, that they rest against the hollow mold part, but cause a support of set to the yield point under internal pressure material of the hollow molded part.
  • the method according to the invention belongs to the category of transverse extrusion processes, by means of which wide, flange-like thickenings of hollow moldings can be produced.
  • a typical effect is that when axial compression of a hollow molded part, in particular a tubular element, the material largely moves outward.
  • the result for wider thickening or higher degrees of deformation is the problem that the wall of the hollow molded part bulges outward, wherein optionally results in an inner fold inside the hollow molded part.
  • Such a configuration causes a weakening of the (dynamic) strength of the hollow molded part, which is generally unacceptable and can not be easily compensated by increasing the wall thickness of the hollow molded part.
  • the object of the invention is therefore to provide a method, can be produced by plastic deformation of a hollow molded resilient as possible with the flanges.
  • the object of the invention is also to provide a method of the type mentioned in which to produce a hollow shaped part in a particularly simple manner by cross extrusion a load-bearing wall thickening without an inner fold.
  • An inventive forming tool for forming a particular metallic hollow molded part 1 with preferably circular cylindrical lateral surface comprises in a first embodiment according to the Fig. 1 and 2 a first die 2a, 2b, wherein the die 2a, 2b is divided transversely to a main axis 4 of the tool so as to give two independent die parts 2a, 2b.
  • the die parts 2a, 2b are in turn again divided in each case in the axial direction.
  • the die thus comprises, in particular, a first annular die part 2a and a second annular die part 2b, into which the hollow shaped part 1 is preferably inserted accurately and which are initially positioned at a distance from one another. Between the die parts a forming area U is formed which is not supported by the die parts 2a, 2b.
  • a second die 3 which is adjustable in its geometry and / or changeable is arranged, which preferably surrounds the hollow shaped part 1 in the forming region U initially with a certain distance.
  • the second Matrix 3 is subdivided into four segments 3a, 3b, 3c, 3d in the direction of one or more planes parallel to the main axis 4 of the hollow molded part 1 and / or in the direction of one or more planes E1, E2 containing the main axis 4 of the hollow molded part (cf. Fig. 2 ).
  • the segments are movable in a manner not shown on one or more carriers, in particular resiliently and / or adjustably mounted.
  • the segments together form a multi-part circular cylindrical ring.
  • at least one segment has a geometry deviating on the inside from the circular cylindrical shape.
  • the second die 3 is designed as elastically deformable, closed, the hollow mold part 1 enclosing ring, in particular as a spring band or as a hydraulic pressure hose.
  • the hollow molded part 1 is inserted into the die parts 2a, 2b.
  • Die 2a, 2b and mold part 1 are positioned such that the first die 2a, 2b, the hollow mold part 1 in a support region S along its lateral surface 1 'annular surrounds and supports (see. Fig. 1 ).
  • the hollow molded part can be supported via a mandrel, not shown.
  • the hollow mold part 1 in an upstream process step above room temperature (theoretically close to the solidus temperature of the material) are heated and subjected to the subsequent process steps in a warm state.
  • a second process step the hollow mold part 1 is compressed by means of a pressing device, not shown in the direction of its major axis 4 such that the hollow mold part 1 is plastically deformed in the non-supported by the first die 2a forming area U, wherein the hollow molded part in the forming area U is supported by the second die 3 on the outside at least after a certain forming movement.
  • material of the hollow molded part 1 can flow in the radial direction to the outside and / or to the inside, wherein the flow of material by means of the second die 3 and possibly by means of a dome is controllable.
  • the said forming movement is terminated in particular when the material of the hollow molded part has completely filled the space provided within the dies 2, 3 and optionally around the mandrel.
  • the second die 3 is moved in a direction transverse to the main axis of the hollow shaped part 1 (arrow 5); In particular, it is opened continuously and / or gradually in the radial direction.
  • the latter is in Fig. 1 by dashed lines and in Fig. 2 shown schematically by arrows 7.
  • a continuous and / or stepwise opening movement of the second die 3 can be superimposed on an oscillating movement of individual segments 3a, 3b, 3c, 3d of the second die.
  • the second die 3 is pressed against the hollow mold part 1 during the forming process or during a temporal part of the forming process with a predetermined force and / or a predetermined force curve.
  • the second die 3 is preferably moved in the radial direction during the forming process or a part of the forming process along a predetermined path and / or with a predetermined course of speed.
  • the second die 3 and / or the hollow molded part 1 and / or individual segments are rotated during the forming step about the main axis 4 of the hollow molded part; This is preferably done in a completely circular cylindrical and rotationally symmetrical workpiece design.
  • individual die parts can additionally be rotated about one (or several different) parallel to the main axis 4, but spaced from this axis (s). This makes it possible to achieve particularly small radial gaps between the segments in each working position.
  • first die part 2a and the second die part 2b of the first die 2 are moved toward one another in the direction of the arrows 6 during the forming process, thereby assisting a material flow to the outside.
  • first die part 2a and the second die part 2b of the first die 2 are moved apart in the opposite direction to the arrows 6 during the forming process, so that a material flow in the axial direction is made possible.
  • a (possibly oscillating) axial movement of the die parts and / or the hollow molded part 1 can be superimposed on a continuous movement of the first die part 2a and the second die part 2b.
  • the radial and / or axial movement of the die parts a (possibly oscillating) rotational movement or a movement in the circumferential direction superimposed.
  • a second embodiment according to the Fig. 3 and Fig. 4a, 4b corresponds essentially to that according to the Fig. 1 and 2 Therefore, reference can be made to the above description in its entirety and equivalent components are provided with the same reference numerals.
  • the forming tool comprises in the second embodiment, in turn, a first die 2a, 2b, which in turn a first annular die part 2a and a second annular die part 2b, in which the hollow mold part 1 is inserted.
  • a forming area U is formed which is not supported by the die parts 2a, 2b.
  • a second die 3 adjustable in its geometry is arranged, which surrounds the hollow shaped part 1 in the forming area U.
  • the second die 3 is subdivided in the direction of three planes E1, E2, E3 containing the main axis 4 of the hollow shaped part 1 into six segments 3a-3f (cf. Fig. 4a, 4b ).
  • the segments are resiliently supported by mechanical coil springs 10 on a support 9.
  • the segments 3a - 3f together form a multi-part approximately circular cylindrical ring, which in a first working position according to Fig. 4a the hollow mold part 1 completely, that encompasses without significant gaps.
  • the hollow molded part 1 is supported on the inside during a forming step or during a plurality of forming steps by a third die in the form of a cylindrical mandrel 8a, 8b engaging in the hollow shaped part.
  • the hollow molded part is subjected to a Axialpressvorgang in a forming step.
  • the hollow molded part 1 is compressed by means of a pressing device 11 in the direction of its main axis 4 such that the hollow molded part 1 is plastically deformed in the Umform Stud U not supported by the first die 2a, wherein the hollow molded part in the forming area U of the second die 3 on the outside with a force defined by the springs 10 is supported.
  • material of the hollow molded part 1 can flow in the radial direction to the outside, wherein the material flow by means of the second die 3 is preset controllable.
  • approximately 10% to 30% of the yield stress of the material of the hollow molded part is set as surface loads between the segments and the hollow molded part.
  • the spring characteristics can be chosen to be linear, but also progressive or degressive.
  • the segments 3a-3f of the second die 3 are moved in different directions transversely to the main axis of the hollow molded part 1 (arrows 5).
  • Each segment is assigned a separate movement path in the radial direction, the straight lines of the movement paths intersecting one another at a point M on the main axis 4.
  • the die 3 can in turn be opened continuously, stepwise or oscillating in the radial direction.
  • Fig. 4b a second working position of the segments 3a - 3f is shown, which is preferably taken after a (first) forming step and in which the second die is at least approximately opened.
  • an adjustable and / or elastically deformable mandrel 8a, 8b can be provided.
  • inner collars can be produced in an analogous manner or inner recesses can be produced.
  • Fig. 6a and 6b Possible results of the forming process according to the invention are the Fig. 6a and 6b refer to.
  • a formation of an inner fold is avoided so that dynamic loadable hollow parts (eg gear shafts for gearboxes and the like) with a small wall thickness and a wide flange can be produced from the formed hollow shaped part.
  • a machining operation is provided in a method following the described forming steps.
  • a possible end product in the form of a gear shaft is schematically shown in FIG Fig. 7 shown. Out Fig. 7 it can be seen that an (axial) width d of the flange is greater than three times the initial wall thickness t of the hollow molded part.
  • Fig. 5a and 5b is a third embodiment of a forming tool according to the invention shown in two different working positions.
  • the structure of the forming tool corresponds in principle to the previously described embodiments, so that in turn the same reference numerals are used for equivalent components and, moreover, to a possible embodiment of the apparatus and the forming method can be fully incorporated by reference to the previous embodiments.
  • the forming tool in the third embodiment in turn comprises a first die into which the hollow molded part 1 is inserted. Within the first die, a forming area is formed, which is not supported by the first die. In this forming area, in turn, a second die 3 adjustable in its geometry is arranged, which surrounds the hollow shaped part 1 in the forming area U.
  • the second die 3 comprises four segments 3a-3d, which are mounted linearly displaceably within a guide device 12 in the radial direction and are coupled to a gear 13.
  • the segments 3a-3d together with the guide means form a multi-part ring which, in a first working position according to FIG Fig. 5a surrounds the hollow molded part 1.
  • the thickness of the segments in the pressing direction preferably corresponds substantially to the width of the flange to be produced.
  • the segments 3a-3d adapt on the inner side in each case to the hollow molded part 1 by a concave cylindrical surface, wherein the radius of the concave cylindrical surfaces preferably corresponds to the outside radius of the finished molded hollow molded part.
  • the segments 3a-3d have lateral extensions in the region of their inner, concave cylindrical surfaces.
  • each lateral extension is preferably embodied in each case in one piece with the associated segment and preferably extend in the direction of at least one adjacent segment.
  • each lateral extension engages between the inner, concave cylindrical surface of the adjacent segment and the outer surface of the hollow molded part.
  • the hollow molded part 1 is preferably supported on the inside during a forming step by a third die in the form of a dome.
  • the transmission 13 essentially comprises four radially guided cap sections 3a ', 3b', 3c ', 3d', which are connected on the one hand to the segments 3a-3d and each have a convex cylindrical surface on the radially outer side.
  • the cap portions 3a '- 3d' are supported with their convex cylindrical surfaces in a ring 14 each on an associated cylindrical guide surface 14a, 14b, 14c, 14d.
  • the centers Ma, Mb, Mc Md of the convex cylindrical surfaces are preferably located on the radial displacement vectors of the segments 3a-3d.
  • the ring 14 is rotatably supported about the point of intersection M of the radial displacement vectors of the segments 3a-3d, wherein the point of intersection M of the displacement vectors is again preferably located on the main axis 4 of the hollow molded part.
  • the center points Xa, Xb, Xc, Xd of the cylindrical guide surfaces 14a-14d do not lie on the radial displacement vectors of the respective associated segments 3a-3d, but each with an identical distance thereto.
  • the cap portions 3a '- 3d' and the ring therefore contact each other offset by a distance Y in the region of a contact line N (in Fig. 5a exemplified for segment 3b, cap portion 3b 'and associated guide surface 14b).
  • a force-transmitting element 15 is assigned to the ring 14, which in the Fig. 5a and 5b is shown purely schematically.
  • the force-transmitting element 15 has a (passive) mechanical, pneumatic or hydraulic spring 19, which is connected via a lever arm 20 with the ring 14.
  • a controllable hydraulic cylinder may be provided which serves as a drive or brake unit for targeted adjustment of the ring.
  • an adjustment of the ring 14 via an adjustment of the force or the torque and / or via an adjustment of path or angle of rotation and / or speed or angular velocity and / or accelerations or angular accelerations take place.
  • a modified embodiment comes as a force-giving element 15 and instead of the spring 19, an electric servomotor used.
  • the friction coefficient between the cap portions 3a '- 3d' and the guide surfaces is chosen as low as possible, namely about 0.05 to 0.25 (but preferably below 0.15).
  • As tool materials of the transmission are Case hardening steels, ball bearing steels (type 100Cr6) and all types of cold and high speed steels.
  • the surface hardness of these construction elements is preferably above 60 HRC.
  • rollers are interposed between surfaces sliding against each other.
  • the transmission 13 sets the opening movement of the segments 3a - 3d in a rotational movement of the ring about the rotation axis M. This rotation acts now the power-giving element 15 against.
  • the force-transmitting element 15 controls the radial forces on the segments 3a - 3d preferably such that they press with 10% to 30% of the yield stress of the material to be formed against the hollow mold part. Buckling or buckling of the hollow molded part 1 is prevented.
  • FIG. 8 A fourth embodiment according to Fig. 8 corresponds to the principle according to the previous embodiments, which is why reference can be made to the above description in its entirety and equivalent components are provided with the same reference numerals.
  • the forming tool again comprises a first die 2a, 2b, which in turn has a first annular die part 2a and a second annular die part 2b into which the hollow shaped part 1 is inserted.
  • a forming area U is formed which is not supported by the die parts 2a, 2b.
  • a second adjustable die 3 is arranged, which surrounds the hollow molded part 1 in the forming area U.
  • the second die 3 is subdivided into a plurality of segments 3a, 3b, wherein the segments 3a, 3b are supported on a common ring 14 which is displaceable parallel to the main axis 4 and has a funnel-shaped sliding surface 14e.
  • the segments have corresponding cone-shaped outer surfaces.
  • a plurality of individual wedge elements are provided with planar wedge surfaces instead of the ring 14, which in turn are slidably mounted in the direction of the main axis 4.
  • a ring is provided with a plurality of inside planar sliding surfaces.
  • the ring 14 is optionally rotatably mounted about the main axis 4, it is also and especially in this case divided in the axial direction.
  • the ring 14 or an annular part thereof forms a more or less rigid unit with a plurality of hydraulic rams 16, which in turn are guided in hydraulic cylinders 17 (arrow 18).
  • the hydraulic plunger 16 together with the hydraulic cylinders 17 are components of a common support, actuation, and / or control unit, wherein a plurality of hydraulic cylinders are preferably arranged rotationally symmetrically about the main axis 4 of the system.
  • one or more hydraulic springs are provided in a modified embodiment (analogous to the force-transmitting element 15 in the third embodiment), which act in the direction of the arrow 18 on the ring 14
  • the hydraulic cylinders optionally an active drive in the form of a hydraulic pump with fluid circuit or a passive mechanical, pneumatic or hydraulic spring assigned.
  • the drive is used for targeted adjustment of the ring 14.
  • an adjustment of the ring 14 via an adjustment of the force and / or the path and / or the speed and / or the accelerations of the hydraulic ram done.
  • the friction coefficient between the segments 3 a, 3 b and the guide surfaces is chosen as low as possible, namely about 0.05 to 0.15.
  • Gear tools, ball bearing steels (type 100Cr6) and all types of cold and high-speed steels are provided as tool materials of the gear unit.
  • the surface hardness of these construction elements is preferably above 60 HRC.
  • an active or passive lubrication of the sliding surfaces between the segments 3a, 3b and the ring 14 may be provided with oil, grease or friction reducing surface coatings.
  • the hollow molded part 1 is supported on the inside during a forming step or during a plurality of forming steps by a third die in the form of a cylindrical mandrel 8a, 8b engaging in the hollow shaped part.
  • the hollow molded part is subjected to an axial compression process in a forming step.
  • the hollow molded part 1 is compressed by means of a pressing device 11 in the direction of its main axis 4 such that the hollow molded part 1 is plastically deformed in the Umform Scheme U not supported by the first die 2a, wherein the hollow molded part supported in the forming area U of the second die 3 on the outside becomes.
  • the segments 3a, 3b of the second die 3 are moved in different directions transversely to the main axis of the hollow molded part 1 (arrows 5).
  • Each segment is assigned a separate movement path in the radial direction, the straight lines of the movement paths intersecting one another at a point M on the main axis 4.
  • the die 3 can in turn be opened continuously, stepwise or oscillating in the radial direction.
  • the forming tool according to the invention allows the arrangement of a few (2 ⁇ n ⁇ 5), but also of many (n> 5) segments under uniform load in a small space, since the effect of a single force element mechanically transmitted via a cam gear to n segments and on the Geometry of the arrangement is reinforced.
  • the load amplification allows a very small dimensioning of the force-giving element 15, for example as a hydraulic cylinder, for a prototype transmission part after Fig. 6a, Fig. 6b had a force of 8 kN.
  • An upsetting process with segmented die requires a special uniformity of the support load, as with asymmetric load, a bending of the compression part to the side with little support effect and thus the Euler buckling is initiated.
  • the time response of a mechanically nearly rigid cam gear is essentially delay-free.
  • the time behavior of a hydraulic system with small amounts of oil (control force is small because of the mechanism) is almost ideal. Therefore, another advantage is the fact that by very rapid change of the force-time curve on the hydraulic side, the support behavior of n support segments can be influenced uniformly even with very small forming times simultaneously with the forming.
  • the system can be driven in advance as a passive oil displacement system with controlled backpressure or actively defined by a pump and thus the material flow.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Umformen eines Hohlformteils, bei dem in einem ersten Verfahrensschritt ein Hohlformteil in eine erste Matrize eingesetzt wird, die das Hohlformteil in einem Stützbereich entlang seiner Mantelfläche ringförmig umschließt und abstützt, und bei dem in einem zweiten Verfahrensschritt das Hohlformteil in Richtung seiner Hauptachse derart gestaucht wird, dass das Hohlformteil in einem von der ersten Matrize nicht abgestützten Umformbereich plastisch umgeformt wird.The present invention relates to a method for forming a hollow molded part, in which in a first process step, a hollow molded part is inserted into a first die which annularly surrounds and supports the hollow molded part in a support region along its lateral surface, and in which in a second process step, the hollow molded part in Direction of its major axis is compressed such that the hollow molded part is plastically deformed in a not supported by the first die forming area.

Das erfindungsgemäße Verfahren gehört zu einer Gattung von Verfahren, bei denen beispielsweise gemäß der EP 1 611 973 A1 eine mehrteilige Matrize zum außenseitigen Abstützen eines Hohlformteils vorgesehen ist, an dem mittels plastischer Umformung ein Flansch geformt werden soll. Dabei ist die Matrize in axialer Richtung in zwei Matrizenteile geteilt, die während eines plastischen Umformvorgangs relativ zueinander verstellbar sind. Dabei wird das umzuformende Hohlformteil einem Axialpressvorgang unterworfen, der das grundlegende Problem des Knickens mit sich bringt, so dass nur vergleichsweise dünne Flansche an dem Hohlformteil herstellbar sind.The method according to the invention belongs to a category of methods in which, for example, according to the EP 1 611 973 A1 a multi-part die is provided for supporting the outside of a hollow molded part on which a flange is to be formed by means of plastic deformation. In this case, the die is divided in the axial direction into two die parts, which are adjustable relative to each other during a plastic forming operation. In this case, the reshaped hollow molded part is subjected to a Axialpressvorgang, which brings the basic problem of buckling with it, so that only comparatively thin flanges can be produced on the hollow molded part.

Aus derFrom the EP 0 497 438 A1EP 0 497 438 A1 ist ein Verfahren zum örtlichen Aufweiten eines Hohlformteils bekannt, bei dem eine Umformkraft mittels eines hydraulisch wirksamen Mediums durch Hochdruckumformen auf das Hohlformteils aufgebracht wird. In einem nicht umzuformenden Bereich wird das Hohlformteil mittels einer ersten Matrize außenseitig fest abgestützt, während in einem nicht näher beschriebenen Umformbereich eine mehrteilige, verstellbare zweite Matrize vorgesehen ist. Die zweite Matrize beinhaltet vier um das Hohlformteil herum positionierte Segmente, jeweils eine kugelige Innenoberfläche aufweisen. Die Segmente werden über hydraulische Kolben-Zylinder-Einheiten derart weg-gesteuert radial bewegt, dass sie an dem Hohlformteil anliegen, jedoch eine Abstützung des bis an die Fließgrenze unter Innendruck gesetzten Materials des Hohlformteils bewirken. Unter Hinnahme einer Abnahme der Wandstärke des Hohlformteils wird so ein abschnittsweise nach außen aufgeweitetes Hohlformteil erzeugt.a method for locally expanding a hollow molded part is known, in which a forming force is applied by means of a hydraulically active medium by high-pressure forming on the hollow molded part. In a non-reshaping region, the hollow molded part is firmly supported on the outside by means of a first die, while a multi-part, adjustable second die is provided in a forming region not described in detail. The second die includes four segments positioned around the die, each having a spherical inner surface. The segments are controlled away via hydraulic piston-cylinder units so moved radially, that they rest against the hollow mold part, but cause a support of set to the yield point under internal pressure material of the hollow molded part. Upon acceptance of a decrease in the wall thickness of the hollow molded part, a hollow shaped part which is widened in sections to the outside is produced.

Das erfindungsgemäße Verfahren, gehört zur Gattung der Querfließpressverfahren, mit deren Hilfe breite, flanschartige Verdickungen an Hohlformteilen herstellbar sind. Dabei besteht ein typischer Effekt darin, dass sich bei axialer Stauchung eines Hohlformteils, insbesondere eines Rohrelements, das Material größtenteils nach außen bewegt. Somit ergibt sich bei breiteren Verdickungen bzw. höheren Umformgraden das Problem, dass sich die Wandung des Hohlformteils nach außen wölbt, wobei sich im Inneren des Hohlformteils ggf. eine Innenfalte ergibt. Eine derartige Konfiguration verursacht eine Schwächung der (dynamischen) Festigkeit des Hohlformteils, die im Allgemeinen nicht hingenommen und auch nicht ohne weiteres durch eine Vergrößerung der Wandstärke des Hohlformteils kompensiert werden kann.The method according to the invention belongs to the category of transverse extrusion processes, by means of which wide, flange-like thickenings of hollow moldings can be produced. In this case, a typical effect is that when axial compression of a hollow molded part, in particular a tubular element, the material largely moves outward. Thus, the result for wider thickening or higher degrees of deformation is the problem that the wall of the hollow molded part bulges outward, wherein optionally results in an inner fold inside the hollow molded part. Such a configuration causes a weakening of the (dynamic) strength of the hollow molded part, which is generally unacceptable and can not be easily compensated by increasing the wall thickness of the hollow molded part.

Aufgabe der Erfindung ist es daher, ein Verfahren, bereitzustellen, mit dem durch plastische Umformung an einem Hohlformteil möglichst belastbare Flansche herstellbar sind. Aufgabe der Erfindung ist es ferner, ein Verfahren der eingangs genannten Art zur Verfügung zu stellen, bei dem an einem Hohlformteil auf besonders einfache Weise durch Querfließpressen eine möglichst belastbare Wandverdickung ohne eine Innenfalte herzustellen.The object of the invention is therefore to provide a method, can be produced by plastic deformation of a hollow molded resilient as possible with the flanges. The object of the invention is also to provide a method of the type mentioned in which to produce a hollow shaped part in a particularly simple manner by cross extrusion a load-bearing wall thickening without an inner fold.

Die Aufgabe wird durch ein Verfahren mit den Merkmalen des Anspruchs 1 gelöst Weitere vorteilhafte Ausgestaltungen des Verfahrens sind in den abhängigen Ansprüchen definiert.The object is achieved by a method having the features of claim 1. Further advantageous embodiments of the method are defined in the dependent claims.

Weitere Vorteile, Merkmale und vorteilhafte Weiterbildungen des Erfindungsgegenstandes ergeben sich aus der anschließenden Beschreibung, den Zeichnungen sowie den Ansprüchen.Further advantages, features and advantageous developments of the subject invention will become apparent from the ensuing description, the drawings and the claims.

Hierzu zeigen

Fig. 1
in einem schematischen Längsschnitt ein erstes Ausführungsbeispiel des erfindungsgemäßen Umformwerkzeugs,
Fig. 2
in einem schematischen Querschnitt in Richtung der Linie II-II das Umformwerkzeug nach Fig. 1,
Fig. 3
in einem schematischen Längsschnitt ein zweites Ausführungsbeispiel des erfindungsgemäßen Umformwerkzeugs mit einer zweiten Matrize,
Fig. 4a und 4b
in schematisierten Längsansichten die Segmente der zweiten Matrize gemäß Fig. 3 in zwei Arbeitspositionen,
Fig. 5a und 5b
in schematisierten Längsansichten ein drittes Ausführungsbeispiel des erfindungsgemäßen Umformwerkzeuges in zwei Arbeitspositionen,
Fig. 6a und 6b
jeweils in einer Längsansicht und einem teilweisen Längsschnitt ein erfindungsgemäß umgeformtes Hohlformteil,
Fig. 7
in einer Prinzipskizze eine Gegenüberstellung von erfindungsgemäß umgeformtem Hohlformteil und einer fertigen Getriebewelle sowie
Fig. 8
in einem schematischen Längsschnitt ein viertes Ausführungsbeispiel des erfindungsgemäßen Umformwerkzeuges.
Show this
Fig. 1
in a schematic longitudinal section a first embodiment of the forming tool according to the invention,
Fig. 2
in a schematic cross section in the direction of the line II-II, the forming tool after Fig. 1 .
Fig. 3
in a schematic longitudinal section, a second embodiment of the forming tool according to the invention with a second die,
Fig. 4a and 4b
in schematic longitudinal views of the segments of the second die according to Fig. 3 in two working positions,
Fig. 5a and 5b
in schematic longitudinal views, a third embodiment of the forming tool according to the invention in two working positions,
Fig. 6a and 6b
each in a longitudinal view and a partial longitudinal section of an inventively formed hollow molded part,
Fig. 7
in a schematic diagram of a comparison of inventively formed hollow molded part and a finished gear shaft and
Fig. 8
in a schematic longitudinal section, a fourth embodiment of the forming tool according to the invention.

Ein erfindungsgemäßes Umformwerkzeug zum Umformen eines insbesondere metallischen Hohlformteils 1 mit vorzugsweise kreiszylindrischer Mantelfläche umfasst in einem ersten Ausführungsbeispiel gemäß den Fig. 1 und 2 eine erste Matrize 2a, 2b, wobei die Matrize 2a, 2b quer zu einer Hauptachse 4 des Werkzeugs derart geteilt ist, dass sich zwei unabhängige Matrizenteile 2a, 2b ergeben. In einem bevorzugten Ausführungsbeispiel sind die Matrizenteile 2a, 2b ihrerseits nochmals jeweils in axialer Richtung geteilt ausgeführt. Die Matrize umfasst also insbesondere ein erstes ringförmiges Matrizenteil 2a und ein zweites ringförmiges Matrizenteil 2b, in die das Hohlformteil 1 vorzugsweise passgenau eingesetzt wird und die zunächst voneinander beabstandet positioniert sind. Zwischen den Matrizenteilen ist ein Umformbereich U gebildet, der von den Matrizenteilen 2a, 2b nicht abgestützt ist.An inventive forming tool for forming a particular metallic hollow molded part 1 with preferably circular cylindrical lateral surface comprises in a first embodiment according to the Fig. 1 and 2 a first die 2a, 2b, wherein the die 2a, 2b is divided transversely to a main axis 4 of the tool so as to give two independent die parts 2a, 2b. In a preferred embodiment, the die parts 2a, 2b are in turn again divided in each case in the axial direction. The die thus comprises, in particular, a first annular die part 2a and a second annular die part 2b, into which the hollow shaped part 1 is preferably inserted accurately and which are initially positioned at a distance from one another. Between the die parts a forming area U is formed which is not supported by the die parts 2a, 2b.

Zwischen dem ersten Matrizenteil 2a und dem zweiten Matrizenteil 2b ist eine zweite in ihrer Geometrie verstellbare bzw. veränderbare Matrize 3 angeordnet, die das Hohlformteil 1 in dem Umformbereich U bevorzugt anfänglich mit einem gewissen Abstand umgreift. Die zweite Matrize 3 ist in Richtung einer oder mehrerer parallel zur Hauptachse 4 des Hohlformteils 1 orientierter Ebenen und/oder in Richtung einer oder mehrerer die Hauptachse 4 des Hohlformteils enthaltender Ebenen E1, E2 in vier Segmente 3a, 3b, 3c, 3d unterteilt (vgl. Fig. 2). Die Segmente sind in nicht näher dargestellter Weise an einem oder mehreren Trägern beweglich, insbesondere federnd und/oder verstellbar gelagert. Die Segmente bilden gemeinsam einen mehrteiligen kreiszylindrischen Ring. In einem modifizierten Ausführungsbeispiel weist wenigstens ein Segment eine innenseitig von der Kreiszylinderform abweichende Geometrie auf.Between the first die part 2 a and the second die part 2 b, a second die 3 which is adjustable in its geometry and / or changeable is arranged, which preferably surrounds the hollow shaped part 1 in the forming region U initially with a certain distance. The second Matrix 3 is subdivided into four segments 3a, 3b, 3c, 3d in the direction of one or more planes parallel to the main axis 4 of the hollow molded part 1 and / or in the direction of one or more planes E1, E2 containing the main axis 4 of the hollow molded part (cf. Fig. 2 ). The segments are movable in a manner not shown on one or more carriers, in particular resiliently and / or adjustably mounted. The segments together form a multi-part circular cylindrical ring. In a modified embodiment, at least one segment has a geometry deviating on the inside from the circular cylindrical shape.

In einem weiteren modifizierten Ausführungsbeispiel ist die zweite Matrize 3 als elastisch verformbarer, geschlossener, das Hohlformteil 1 umschließender Ring, insbesondere als Federband oder als hydraulischer Druckschlauch ausgeführt.In a further modified embodiment, the second die 3 is designed as elastically deformable, closed, the hollow mold part 1 enclosing ring, in particular as a spring band or as a hydraulic pressure hose.

In einem ersten Verfahrensschritt des erfindungsgemäßen Umformverfahrens wird das Hohlformteil 1 in die Matrizenteile 2a, 2b eingesetzt. Matrize 2a, 2b und Hohlformteil 1 werden derart positioniert, dass die erste Matrize 2a, 2b das Hohlformteil 1 in einem Stützbereich S entlang seiner Mantelfläche 1' ringförmig umschließt und abstützt (vgl. Fig. 1). Innenseitig kann das Hohlformteil über einen nicht näher dargestellten Dorn abgestützt sein. In einem modifizierten Ausführungsbeispiel kann das Hohlformteil 1 in einem vorgeschalteten Verfahrensschritt über Raumtemperatur hinaus (theoretisch bis nahe an die Solidustemperatur des Werkstoffs) erwärmt werden und in warmem Zustand den nachfolgenden Verfahrensschritten unterworfen werden.In a first method step of the forming process according to the invention, the hollow molded part 1 is inserted into the die parts 2a, 2b. Die 2a, 2b and mold part 1 are positioned such that the first die 2a, 2b, the hollow mold part 1 in a support region S along its lateral surface 1 'annular surrounds and supports (see. Fig. 1 ). On the inside, the hollow molded part can be supported via a mandrel, not shown. In a modified embodiment, the hollow mold part 1 in an upstream process step above room temperature (theoretically close to the solidus temperature of the material) are heated and subjected to the subsequent process steps in a warm state.

In einem zweiten Verfahrensschritt (Umformschritt) wird das Hohlformteil 1 mit Hilfe einer nicht näher dargestellten Pressvorrichtung in Richtung seiner Hauptachse 4 derart gestaucht, dass das Hohlformteil 1 in dem von der ersten Matrize 2a nicht abgestützten Umformbereich U plastisch deformiert wird, wobei das Hohlformteil im Umformbereich U von der zweiten Matrize 3 zumindest nach einer gewissen Umformbewegung außenseitig abgestützt wird. Dabei kann Material des Hohlformteils 1 in radialer Richtung nach außen und/oder nach innen fließen, wobei der Materialfluss mittels der zweiten Matrize 3 und ggf. mittels eines Domes steuerbar ist. Die genannte Umformbewegung ist insbesondere dann beendet, wenn das Material des Hohlformteils den zur Verfügung gestellten Freiraum innerhalb der Matrizen 2, 3 und ggf. um den Dorn vollständig ausgefüllt hat.In a second process step (forming step), the hollow mold part 1 is compressed by means of a pressing device, not shown in the direction of its major axis 4 such that the hollow mold part 1 is plastically deformed in the non-supported by the first die 2a forming area U, wherein the hollow molded part in the forming area U is supported by the second die 3 on the outside at least after a certain forming movement. In this case, material of the hollow molded part 1 can flow in the radial direction to the outside and / or to the inside, wherein the flow of material by means of the second die 3 and possibly by means of a dome is controllable. The said forming movement is terminated in particular when the material of the hollow molded part has completely filled the space provided within the dies 2, 3 and optionally around the mandrel.

Anschließend wird die zweite Matrize 3 während des Umformschritts in einer Richtung quer zur Hauptachse des Hohlformteils 1 bewegt (Pfeil 5); insbesondere wird sie kontinuierlich und/oder stufenweise in radialer Richtung geöffnet. Letzteres ist in Fig. 1 mittels gestrichelter Linien und in Fig. 2 mit Pfeilen 7 schematisch dargestellt.Subsequently, during the forming step, the second die 3 is moved in a direction transverse to the main axis of the hollow shaped part 1 (arrow 5); In particular, it is opened continuously and / or gradually in the radial direction. The latter is in Fig. 1 by dashed lines and in Fig. 2 shown schematically by arrows 7.

Während des Umformvorganges, in dem Material des Hohlformteils 1 weiter nach außen fließt, kann einer kontinuierlichen und/oder stufenweisen Öffnungsbewegung der zweiten Matrize 3 eine oszillierende Bewegung einzelner Segmente 3a, 3b, 3c, 3d der zweiten Matrize überlagert sein. Bevorzugt wird die zweite Matrize 3 während des Umformvorgangs oder während eines zeitlichen Teils des Umformvorgangs mit einer vorbestimmten Kraft und/oder einem vorbestimmten Kraftverlauf gegen das Hohlformteil 1 gedrückt. Alternativ oder ergänzend wird die zweite Matrize 3 während des Umformvorgangs oder eines Teils des Umformvorgangs entlang eines vorbestimmten Weges und/oder mit einem vorbestimmten Geschwindigkeitsverlauf bevorzugt in radialer Richtung bewegt. Damit lässt sich dem fließenden Material sukzessive mehr Raum zur Verfügung stellen, den dieses faltenfrei einnehmen kann. Optional werden die zweite Matrize 3 und/oder das Hohlformteil 1 und/oder einzelne Segmente während des Umformschritts um die Hauptachse 4 des Hohlformteils gedreht; dies erfolgt bevorzugt bei einer vollständig kreiszylindrischen und rotationssymmetrischen Werkstückgestaltung. In einem modifizierten Ausführungsbeispiel lassen sich einzelne Matrizenteile zusätzlich um eine (bzw. mehrere verschiedene) parallel zur Hauptachse 4, jedoch von dieser beabstandet angeordneten Achse(n) drehen. Damit lassen sich in jeder Arbeitsposition besonders kleine radiale Spalte zwischen den Segmenten erzielen.During the forming process, in which material of the hollow molded part 1 flows further outward, a continuous and / or stepwise opening movement of the second die 3 can be superimposed on an oscillating movement of individual segments 3a, 3b, 3c, 3d of the second die. Preferably, the second die 3 is pressed against the hollow mold part 1 during the forming process or during a temporal part of the forming process with a predetermined force and / or a predetermined force curve. Alternatively or additionally, the second die 3 is preferably moved in the radial direction during the forming process or a part of the forming process along a predetermined path and / or with a predetermined course of speed. This allows successively more space to be made available to the flowing material, which this fold-free can take up. Optionally, the second die 3 and / or the hollow molded part 1 and / or individual segments are rotated during the forming step about the main axis 4 of the hollow molded part; This is preferably done in a completely circular cylindrical and rotationally symmetrical workpiece design. In a modified embodiment, individual die parts can additionally be rotated about one (or several different) parallel to the main axis 4, but spaced from this axis (s). This makes it possible to achieve particularly small radial gaps between the segments in each working position.

In einer bevorzugten Variante werden das erste Matrizenteil 2a und das zweite Matrizenteil 2b der ersten Matrize 2 während des Umformvorganges in Richtung der Pfeile 6 aufeinander zu bewegt, wodurch ein Materialfluss nach außen unterstützt wird. In einem modifizierten Ausführungsbeispiel werden das erste Matrizenteil 2a und das zweite Matrizenteil 2b der ersten Matrize 2 während des Umformvorganges entgegen der Richtung der Pfeile 6 auseinander gefahren, so dass ein Materialfluss in axialer Richtung ermöglicht wird. In allen Fällen lässt sich einer kontinuierlichen Bewegung des ersten Matrizenteils 2a und des zweiten Matrizenteils 2b eine (ggf. oszillierende) Axialbewegung der Matrizenteile und/oder des Hohlformteils 1 überlagern. In einem weiteren modifizierten Ausführungsbeispiel wird der radialen und/oder axialen Bewegung der Matrizenteile eine (ggf. oszillierende) Rotationsbewegung bzw. eine Bewegung in Umfangsrichtung überlagert.In a preferred variant, the first die part 2a and the second die part 2b of the first die 2 are moved toward one another in the direction of the arrows 6 during the forming process, thereby assisting a material flow to the outside. In a modified embodiment, the first die part 2a and the second die part 2b of the first die 2 are moved apart in the opposite direction to the arrows 6 during the forming process, so that a material flow in the axial direction is made possible. In all cases, a (possibly oscillating) axial movement of the die parts and / or the hollow molded part 1 can be superimposed on a continuous movement of the first die part 2a and the second die part 2b. In a further modified embodiment, the radial and / or axial movement of the die parts a (possibly oscillating) rotational movement or a movement in the circumferential direction superimposed.

Ein zweites Ausführungsbeispiel gemäß den Fig. 3 und Fig. 4a, 4b entspricht im wesentlichen demjenigen gemäß den Fig. 1 und 2, weshalb auf die vorstehende Beschreibung vollumfänglich Bezug genommen werden kann und gleichwirkende Bauteile mit gleichen Bezugszeichen versehen sind.A second embodiment according to the Fig. 3 and Fig. 4a, 4b corresponds essentially to that according to the Fig. 1 and 2 Therefore, reference can be made to the above description in its entirety and equivalent components are provided with the same reference numerals.

Das Umformwerkzeug umfasst im zweiten Ausführungsbeispiel wiederum eine erste Matrize 2a, 2b, die wiederum ein erstes ringförmiges Matrizenteil 2a und ein zweites ringförmiges Matrizenteil 2b, in die das Hohlformteil 1 eingesetzt wird. Zwischen den Matrizenteilen ist ein Umformbereich U gebildet, der von den Matrizenteilen 2a, 2b nicht abgestützt ist. Zwischen dem ersten Matrizenteil 2a und dem zweiten Matrizenteil 2b ist eine zweite in ihrer Geometrie verstellbare Matrize 3 angeordnet, die das Hohlformteil 1 in dem Umformbereich U umgreift. Die zweite Matrize 3 ist in Richtung dreier die Hauptachse 4 des Hohlformteils 1 enthaltender Ebenen E1, E2, E3 in sechs Segmente 3a - 3f unterteilt (vgl. Fig. 4a, 4b). Die Segmente sind über mechanische Schraubenfedern 10 an einem Träger 9 federnd gelagert.The forming tool comprises in the second embodiment, in turn, a first die 2a, 2b, which in turn a first annular die part 2a and a second annular die part 2b, in which the hollow mold part 1 is inserted. Between the die parts a forming area U is formed which is not supported by the die parts 2a, 2b. Between the first die part 2 a and the second die part 2 b, a second die 3 adjustable in its geometry is arranged, which surrounds the hollow shaped part 1 in the forming area U. The second die 3 is subdivided in the direction of three planes E1, E2, E3 containing the main axis 4 of the hollow shaped part 1 into six segments 3a-3f (cf. Fig. 4a, 4b ). The segments are resiliently supported by mechanical coil springs 10 on a support 9.

Die Segmente 3a - 3f bilden gemeinsam einen mehrteiligen näherungsweise kreiszylindrischen Ring, der in einer ersten Arbeitsposition gemäß Fig. 4a das Hohlformteil 1 vollständig, d.h. ohne wesentliche Zwischenräume umgreift. Das Hohlformteil 1 wird während eines Umformschritts bzw. während mehrerer Umformschritte von einer dritten Matrize in Form eines in das Hohlformteil eingreifenden, zylindrischen Doms 8a, 8b innenseitig abgestützt.The segments 3a - 3f together form a multi-part approximately circular cylindrical ring, which in a first working position according to Fig. 4a the hollow mold part 1 completely, that encompasses without significant gaps. The hollow molded part 1 is supported on the inside during a forming step or during a plurality of forming steps by a third die in the form of a cylindrical mandrel 8a, 8b engaging in the hollow shaped part.

Wie schon mit Bezug auf das erste Ausführungsbeispiel gemäß Fig. 1 und 2 beschrieben, wird das Hohlformteil in einem Umformschritt einem Axialpressvorgang unterworfen. Dabei wird das Hohlformteil 1 mit Hilfe einer Pressvorrichtung 11 in Richtung seiner Hauptachse 4 derart gestaucht, dass das Hohlformteil 1 in dem von der ersten Matrize 2a nicht abgestützten Umformbereich U plastisch deformiert wird, wobei das Hohlformteil im Umformbereich U von der zweiten Matrize 3 außenseitig mit einer durch die Federn 10 definierten Kraft abgestützt wird. Dabei kann Material des Hohlformteils 1 in radialer Richtung nach außen fließen, wobei der Materialfluss mittels der zweiten Matrize 3 voreingestellt steuerbar ist. In bevorzugter Weise wird mittels der Federn 10 eine Flächenbelastung von 10 N/mm2 bis 100 N/mm2 zwischen dem Hohlformteil und den das Hohlformteil berührenden Kontaktfläche der Segmente 3a - 3f eingestellt. In einem modifizierten Ausführungsbeispiel werden als Flächenbelastungen zwischen den Segmenten und dem Hohlformteil ca. 10 % bis 30 % der Fließspannung des Werkstoffs des Hohlformteils eingestellt. Die Federkennlinien können linear, aber auch progressiv oder degressiv gewählt werden.As already with reference to the first embodiment according to Fig. 1 and 2 described, the hollow molded part is subjected to a Axialpressvorgang in a forming step. In this case, the hollow molded part 1 is compressed by means of a pressing device 11 in the direction of its main axis 4 such that the hollow molded part 1 is plastically deformed in the Umformbereich U not supported by the first die 2a, wherein the hollow molded part in the forming area U of the second die 3 on the outside with a force defined by the springs 10 is supported. In this case, material of the hollow molded part 1 can flow in the radial direction to the outside, wherein the material flow by means of the second die 3 is preset controllable. Preferably, by means of the springs 10, a surface load of 10 N / mm 2 to 100 N / mm 2 between the Molded part and the mold part contacting the contact surface of the segments 3a - set 3f. In a modified embodiment, approximately 10% to 30% of the yield stress of the material of the hollow molded part is set as surface loads between the segments and the hollow molded part. The spring characteristics can be chosen to be linear, but also progressive or degressive.

Im Rahmen dieses Umformvorgangs werden die Segmente 3a - 3f der zweiten Matrize 3 in unterschiedlichen Richtungen quer zur Hauptachse des Hohlformteils 1 bewegt (Pfeile 5). Jedem Segment ist dabei ein eigener Bewegungsweg in radialer Richtung zugeordnet, wobei sich die Geraden der Bewegungswege in einem Punkt M auf der Hauptachse 4 schneiden. Somit kann die Matrize 3 wiederum kontinuierlich, stufenweise oder oszillierend in radialer Richtung geöffnet werden. In Fig. 4b ist eine zweite Arbeitsposition der Segmente 3a - 3f dargestellt, die bevorzugt nach einem (ersten) Umformschritt eingenommen wird und in der die zweite Matrize zumindest annähernd geöffnet ist.As part of this forming operation, the segments 3a-3f of the second die 3 are moved in different directions transversely to the main axis of the hollow molded part 1 (arrows 5). Each segment is assigned a separate movement path in the radial direction, the straight lines of the movement paths intersecting one another at a point M on the main axis 4. Thus, the die 3 can in turn be opened continuously, stepwise or oscillating in the radial direction. In Fig. 4b a second working position of the segments 3a - 3f is shown, which is preferably taken after a (first) forming step and in which the second die is at least approximately opened.

In einem modifizierten Ausführungsbeispiel lässt sich ein verstellbarer und/oder elastisch deformierbarer Dorn 8a, 8b vorsehen. Damit lassen sich unter Ausnutzung des oben geschilderten Prinzips auf analoge Weise Innenbunde herstellen oder innenseitige Ausnehmungen erzeugen.In a modified embodiment, an adjustable and / or elastically deformable mandrel 8a, 8b can be provided. Thus, using the above-described principle, inner collars can be produced in an analogous manner or inner recesses can be produced.

Die vorstehend beschriebenen Verfahrensschritte und -merkmale lassen sich nahezu beliebig kombinieren, wobei sich jeweils ein Fließpressverfahren ergibt, das eine Ausbildung eines besonders breiten, zugleich sehr festen und nachbearbeitbaren Flansches an einem metallischen Hohlformteil ermöglicht. Mögliche Ergebnisse des erfindungsgemäßen Umformverfahrens sind den Fig. 6a und 6b zu entnehmen. Eine Bildung einer Innenfalte wird vermieden, so dass dynamisch belastbare Hohlteile (z.B. Zahnradwellen für Getriebe und dergleichen) mit geringer Wandstärke und breitem Flansch aus dem erformten Hohlformteil herstellbar sind. Dazu ist in einem sich an die beschriebenen Umformschritte anschließenden Verfahren beispielsweise eine Spanabhebende Bearbeitung vorgesehen. Ein mögliches Endprodukt in Form einer Getriebewelle ist schematisch in Fig. 7 dargestellt. Aus Fig. 7 ist ersichtlich, dass eine (axiale) Breite d des Flansches größer ist als die dreifache Ausgangswandstärke t des Hohlformteils.The method steps and features described above can be combined almost arbitrarily, each resulting in an extrusion process that allows a particularly wide, at the same time very strong and reworkable flange to a metallic mold part. Possible results of the forming process according to the invention are the Fig. 6a and 6b refer to. A formation of an inner fold is avoided so that dynamic loadable hollow parts (eg gear shafts for gearboxes and the like) with a small wall thickness and a wide flange can be produced from the formed hollow shaped part. For this purpose, for example, a machining operation is provided in a method following the described forming steps. A possible end product in the form of a gear shaft is schematically shown in FIG Fig. 7 shown. Out Fig. 7 it can be seen that an (axial) width d of the flange is greater than three times the initial wall thickness t of the hollow molded part.

In den Fig. 5a und 5b ist ein drittes Ausführungsbeispiel eines erfindungsgemäßen Umformwerkzeugs in zwei unterschiedlichen Arbeitspositionen dargestellt. Der Aufbau des Umformwerkzeugs entspricht im Prinzip den zuvor beschriebenen Ausführungsbeispielen, so dass wiederum für gleichwirkende Bauteile gleiche Bezugszeichen verwendet werden und im übrigen zu einer möglichen Ausführung der Vorrichtung und des Umformverfahrens vollumfänglich auf die vorigen Ausführungsbeispiele Bezug genommen werden kann.In the Fig. 5a and 5b is a third embodiment of a forming tool according to the invention shown in two different working positions. The structure of the forming tool corresponds in principle to the previously described embodiments, so that in turn the same reference numerals are used for equivalent components and, moreover, to a possible embodiment of the apparatus and the forming method can be fully incorporated by reference to the previous embodiments.

Das Umformwerkzeug umfasst im dritten Ausführungsbeispiel wiederum eine erste Matrize, in die das Hohlformteil 1 eingesetzt wird. Innerhalb der ersten Matrize ist ein Umformbereich gebildet, der von der ersten Matrize nicht abgestützt ist. In diesem Umformbereich ist wiederum eine zweite in ihrer Geometrie verstellbare Matrize 3 angeordnet, die das Hohlformteil 1 in dem Umformbereich U umgreift. Die zweite Matrize 3 umfasst vier Segmente 3a - 3d, die innerhalb einer Führungseinrichtung 12 in radialer Richtung linear verschieblich gelagert und mit einem Getriebe 13 gekoppelt sind.The forming tool in the third embodiment in turn comprises a first die into which the hollow molded part 1 is inserted. Within the first die, a forming area is formed, which is not supported by the first die. In this forming area, in turn, a second die 3 adjustable in its geometry is arranged, which surrounds the hollow shaped part 1 in the forming area U. The second die 3 comprises four segments 3a-3d, which are mounted linearly displaceably within a guide device 12 in the radial direction and are coupled to a gear 13.

Die Segmente 3a - 3d bilden gemeinsam mit der Führungseinrichtung einen mehrteiligen Ring, der in einer ersten Arbeitsposition gemäß Fig. 5a das Hohlformteil 1 umgreift. Die Dicke der Segmente in Pressrichtung entspricht bevorzugt im wesentlichen der Breite des zu erzeugenden Flansches. Die Segmente 3a - 3d passen sich im übrigen auf der inneren Seite jeweils durch eine konkave Zylinderfläche an das Hohlformteil 1 an, wobei der Radius der konkaven Zylinderflächen bevorzugt dem außenseitigen Radius des fertig geformten Hohlformteils entspricht. In einem modifizierten Ausführungsbeispiel weisen die Segmente 3a - 3d im Bereich ihrer inneren, konkaven Zylinderflächen seitliche Fortsätze auf. Die seitlichen Fortsätze sind bevorzugt jeweils einstückig mit dem zugehörigen Segment ausgeführt und erstrecken sich bevorzugt in Richtung wenigstens eines benachbarten Segments. Bevorzugt greift jeder seitliche Fortsatz zwischen die innere, konkave Zylinderfläche des benachbarten Segments und die Außenoberfläche des Hohlformteils ein. Somit ergibt sich quasi eine Überlappung der das Hohlformteil berührenden Flächen der Segmente, so dass auch bei einem radialen Auseinanderfahren der Segmente die Spalte gemäß Fig. 4b im Bereich der inneren, konkaven Zylinderflächen vermieden bzw. überbrückt werden. Ähnliches kann auch mit ineinandergreifenden Segmenten mit tropfenförmigem Querschnitt erreicht werden, die in der Art einer Fotoblende betätigt werden.The segments 3a-3d together with the guide means form a multi-part ring which, in a first working position according to FIG Fig. 5a surrounds the hollow molded part 1. The thickness of the segments in the pressing direction preferably corresponds substantially to the width of the flange to be produced. Incidentally, the segments 3a-3d adapt on the inner side in each case to the hollow molded part 1 by a concave cylindrical surface, wherein the radius of the concave cylindrical surfaces preferably corresponds to the outside radius of the finished molded hollow molded part. In a modified embodiment, the segments 3a-3d have lateral extensions in the region of their inner, concave cylindrical surfaces. The lateral extensions are preferably embodied in each case in one piece with the associated segment and preferably extend in the direction of at least one adjacent segment. Preferably, each lateral extension engages between the inner, concave cylindrical surface of the adjacent segment and the outer surface of the hollow molded part. As a result, there is virtually an overlap of the surfaces of the segments which contact the hollow molded part, so that the gaps are formed in accordance with the invention even if the segments are moved apart radially Fig. 4b be avoided or bridged in the region of the inner, concave cylindrical surfaces. The same can also be achieved with intermeshing segments of drop-shaped cross-section which are actuated in the manner of a photo diaphragm.

Das Hohlformteil 1 wird während eines Umformschritts bevorzugt von einer dritten Matrize in Form eines Doms innenseitig abgestützt.The hollow molded part 1 is preferably supported on the inside during a forming step by a third die in the form of a dome.

Das Getriebe 13 umfasst im wesentlichen vier radial geführte Kappenabschnitte 3a', 3b', 3c', 3d', die einerseits mit den Segmenten 3a - 3d verbunden sind und an der radial äußeren Seite jeweils eine konvexe Zylinderfläche aufweisen. Die Kappenabschnitte 3a' - 3d' stützen sich mit ihren konvexen Zylinderflächen in einem Ring 14 jeweils auf einer zugeordneten zylindrischen Führungsfläche 14a, 14b, 14c, 14d ab. Die Mittelpunkte Ma, Mb, Mc Md der konvexen Zylinderflächen liegen dabei bevorzugt auf den radialen Verschiebevektoren der Segmente 3a - 3d.The transmission 13 essentially comprises four radially guided cap sections 3a ', 3b', 3c ', 3d', which are connected on the one hand to the segments 3a-3d and each have a convex cylindrical surface on the radially outer side. The cap portions 3a '- 3d' are supported with their convex cylindrical surfaces in a ring 14 each on an associated cylindrical guide surface 14a, 14b, 14c, 14d. The centers Ma, Mb, Mc Md of the convex cylindrical surfaces are preferably located on the radial displacement vectors of the segments 3a-3d.

Der Ring 14 ist drehbar gelagert um den Schnittpunkt M der radialen Verschiebevektoren der Segmente 3a - 3d, wobei der Schnittpunkt M der Verschiebevektoren wiederum bevorzugt auf der Hauptachse 4 des Hohlformteils liegt. Die Mittelpunkte Xa, Xb, Xc, Xd der zylindrischen Führungsflächen 14a - 14d liegen nicht auf den radialen Verschiebevektoren der jeweils zugeordneten Segmente 3a - 3d, sondern mit jeweils identischem Abstand dazu. Die Kappenabschnitte 3a' - 3d' und der Ring kontaktieren einander deshalb jeweils versetzt um eine Distanz Y im Bereich einer Kontaktlinie N (in Fig. 5a beispielhaft eingezeichnet für Segment 3b, Kappenabschnitt 3b' und zugeordneter Führungsfläche 14b).The ring 14 is rotatably supported about the point of intersection M of the radial displacement vectors of the segments 3a-3d, wherein the point of intersection M of the displacement vectors is again preferably located on the main axis 4 of the hollow molded part. The center points Xa, Xb, Xc, Xd of the cylindrical guide surfaces 14a-14d do not lie on the radial displacement vectors of the respective associated segments 3a-3d, but each with an identical distance thereto. The cap portions 3a '- 3d' and the ring therefore contact each other offset by a distance Y in the region of a contact line N (in Fig. 5a exemplified for segment 3b, cap portion 3b 'and associated guide surface 14b).

Schließlich ist an dem Ring 14 ein Kraftgebendes Element 15 zugeordnet, das in den Fig. 5a und 5b rein schematisch dargestellt ist. Das Kraftgebende Element 15 weist eine (passive) mechanische, pneumatische oder hydraulische Feder 19 auf, die über einen Hebelarm 20 mit dem Ring 14 verbunden ist. Anstelle der passiven Feder 19 kann jedoch auch ein ansteuerbarer Hydraulikzylinder vorgesehen sein, der als Antriebs- bzw. Bremsaggregat dient zur gezielten Verstellung des Rings. Dabei kann eine Verstellung des Rings 14 über eine Einstellung der Kraft bzw. des Drehmoments und/oder über eine Einstellung von Weg bzw. Drehwinkel und/oder Geschwindigkeit bzw. Winkelgeschwindigkeit und/oder Beschleunigungen bzw. Winkelbeschleunigungen erfolgen. In einem modifizierten Ausführungsbeispiel kommt als Kraftgebendes Element 15 bzw. anstelle der Feder 19 ein elektrischer Servomotor zum Einsatz.Finally, a force-transmitting element 15 is assigned to the ring 14, which in the Fig. 5a and 5b is shown purely schematically. The force-transmitting element 15 has a (passive) mechanical, pneumatic or hydraulic spring 19, which is connected via a lever arm 20 with the ring 14. Instead of the passive spring 19 but also a controllable hydraulic cylinder may be provided which serves as a drive or brake unit for targeted adjustment of the ring. In this case, an adjustment of the ring 14 via an adjustment of the force or the torque and / or via an adjustment of path or angle of rotation and / or speed or angular velocity and / or accelerations or angular accelerations take place. In a modified embodiment comes as a force-giving element 15 and instead of the spring 19, an electric servomotor used.

Um möglichst geringe Getriebebelastungen zu erhalten, ist der Reibbeiwert zwischen den Kappenabschnitten 3a' - 3d' und den Führungsflächen möglichst niedrig gewählt, nämlich ca. 0,05 bis 0,25 (bevorzugt jedoch unter 0,15). Als Werkzeugwerkstoffe des Getriebes sind Einsatzstähle, Kugellagerstähle (Typ 100Cr6) und alle Arten von Kalt- und Schnellarbeitsstählen vorgesehen. Die Oberflächen-Härte dieser Konstruktionselemente liegt bevorzugt oberhalb von 60 HRC. In einem modifizierten Ausführungsbeispiel sind zwischen gegeneinander gleitenden Flächen Rollen zwischengeschaltet.In order to obtain the lowest possible transmission loads, the friction coefficient between the cap portions 3a '- 3d' and the guide surfaces is chosen as low as possible, namely about 0.05 to 0.25 (but preferably below 0.15). As tool materials of the transmission are Case hardening steels, ball bearing steels (type 100Cr6) and all types of cold and high speed steels. The surface hardness of these construction elements is preferably above 60 HRC. In a modified embodiment, rollers are interposed between surfaces sliding against each other.

Durch ein Plastifizieren des Hohlformteils 1, welches im Zuge des erfindungsgemäßen Umformverfahrens eine lokale radiale Ausdehnung des Hohlformteils 1 im Umformbereich bewirkt, ergibt sich nun eine Radialkraft F auf die konkaven Innenflächen der Segmente 3a - 3d. Bei einer resultierenden radialen Verschiebung der Segmente 3a - 3d ergibt sich ein auf den Ring wirkendes Drehmoment. Dieses ergibt sich aufgrund des Abstands Y zwischen der jeweiligen Kontaktlinie N und dem Bewegungsweg des jeweiligen Segments (z.B. hier Segment 3b).By plastifying the hollow molded part 1, which causes a local radial expansion of the hollow molded part 1 in the forming area in the course of the forming process according to the invention, now results in a radial force F on the concave inner surfaces of the segments 3a - 3d. A resulting radial displacement of the segments 3a-3d results in a torque acting on the ring. This is due to the distance Y between the respective contact line N and the path of movement of the respective segment (for example, segment 3b here).

Wenn der Abstand Y ausreichend groß und/oder die Reibung zwischen Kappenabschnitten 3a' - 3d' und den Führungsflächen 14a - 14d ausreichend klein ist, wird eine Selbsthemmung des Getriebes 13 vermieden. In diesem Fall ergibt sich während des Stauchprozesses ohne Zufuhr weiterer Antriebsenergie eine radiale Öffnungsbewegung der Segmente infolge der Formänderung des Hohlformteils 1. Das Getriebe 13 setzt die Öffnungsbewegung der Segmente 3a - 3d um in eine Drehbewegung des Ringes um die Rotationsachse M. Dieser Drehung wirkt nun das Kraftgebende Element 15 entgegen.If the distance Y is sufficiently large and / or the friction between the cap portions 3a '- 3d' and the guide surfaces 14a - 14d is sufficiently small, self-locking of the transmission 13 is avoided. In this case, results during the compression process without supply of further drive energy radial opening movement of the segments due to the change in shape of the hollow mold part 1. The transmission 13 sets the opening movement of the segments 3a - 3d in a rotational movement of the ring about the rotation axis M. This rotation acts now the power-giving element 15 against.

Somit steuert das Kraftgebende Element 15 die Radialkräfte auf die Segmente 3a - 3d bevorzugt derart, dass diese mit 10% bis 30% der Fließspannung des umzuformenden Werkstoffs gegen das Hohlformteil drücken. Knicken oder Beulen des Hohlformteils 1 wird so verhindert.Thus, the force-transmitting element 15 controls the radial forces on the segments 3a - 3d preferably such that they press with 10% to 30% of the yield stress of the material to be formed against the hollow mold part. Buckling or buckling of the hollow molded part 1 is prevented.

Ein viertes Ausführungsbeispiel gemäß Fig. 8 entspricht dem Prinzip nach den vorherigen Ausführungsbeispielen, weshalb auf die vorstehende Beschreibung vollumfänglich Bezug genommen werden kann und gleichwirkende Bauteile mit gleichen Bezugszeichen versehen sind.A fourth embodiment according to Fig. 8 corresponds to the principle according to the previous embodiments, which is why reference can be made to the above description in its entirety and equivalent components are provided with the same reference numerals.

Das Umformwerkzeug umfasst im vierten Ausführungsbeispiel wiederum eine erste Matrize 2a, 2b, die wiederum ein erstes ringförmiges Matrizenteil 2a und ein zweites ringförmiges Matrizenteil 2b, in die das Hohlformteil 1 eingesetzt wird. Zwischen den Matrizenteilen ist ein Umformbereich U gebildet, der von den Matrizenteilen 2a, 2b nicht abgestützt ist. Zwischen dem ersten Matrizenteil 2a und dem zweiten Matrizenteil 2b ist eine zweite verstellbare Matrize 3 angeordnet, die das Hohlformteil 1 in dem Umformbereich U umgreift. Die zweite Matrize 3 ist in mehrere Segmente 3a, 3b unterteilt, wobei die Segmente 3a, 3b an einem gemeinsamen, parallel zur Hauptachse 4 verschieblichen Ring 14 mit einer trichterförmigen Gleitfläche 14e abgestützt sind. Dazu weisen die Segmente korrespondierende kegelabschnittsförmige Außenflächen auf. In einem modifizierten Ausführungsbeispiel sind anstelle des Rings 14 mehrere einzelne Keilelemente mit ebenen Keilflächen vorgesehen, die wiederum in Richtung der Hauptachse 4 verschieblich gelagert sind. In einem weiteren modifizierten Ausführungsbeispiel ist ein Ring mit mehreren innenseitigen ebenen Gleitflächen vorgesehen.In the fourth exemplary embodiment, the forming tool again comprises a first die 2a, 2b, which in turn has a first annular die part 2a and a second annular die part 2b into which the hollow shaped part 1 is inserted. Between the die parts a forming area U is formed which is not supported by the die parts 2a, 2b. Between the first die part 2a and the second die part 2b, a second adjustable die 3 is arranged, which surrounds the hollow molded part 1 in the forming area U. The second die 3 is subdivided into a plurality of segments 3a, 3b, wherein the segments 3a, 3b are supported on a common ring 14 which is displaceable parallel to the main axis 4 and has a funnel-shaped sliding surface 14e. For this purpose, the segments have corresponding cone-shaped outer surfaces. In a modified embodiment, a plurality of individual wedge elements are provided with planar wedge surfaces instead of the ring 14, which in turn are slidably mounted in the direction of the main axis 4. In a further modified embodiment, a ring is provided with a plurality of inside planar sliding surfaces.

Der Ring 14 ist optional um die Hauptachse 4 drehbar gelagert, er ist auch und gerade in diesem Fall in axialer Richtung unterteilt. Der Ring 14 oder ein ringförmiger Teil desselben bildet eine mehr oder weniger steife Einheit mit mehreren Hydraulik-Stößeln 16, die wiederum in Hydraulikzylindern 17 geführt sind (Pfeil 18). Die Hydraulik-Stößel 16 sind samt den Hydraulikzylindern 17 Bestandteile einer gemeinsamen Abstütz-, Betätigungs-, und/oder Ansteuerungseinheit, wobei mehrere Hydraulikzylinder bevorzugt rotationssymmetrisch um die Hauptachse 4 des Systems herum angeordnet sind. Ergänzend oder anstelle einer hydraulischen Antriebseinheit sind in einem modifizierten Ausführungsbeispiel eine oder mehrere Hydraulikfedern vorgesehen (analog zum Kraftgebenden Element 15 im dritten Ausführungsbeispiel), die in Richtung des Pfeils 18 auf den Ring 14 wirkenThe ring 14 is optionally rotatably mounted about the main axis 4, it is also and especially in this case divided in the axial direction. The ring 14 or an annular part thereof forms a more or less rigid unit with a plurality of hydraulic rams 16, which in turn are guided in hydraulic cylinders 17 (arrow 18). The hydraulic plunger 16 together with the hydraulic cylinders 17 are components of a common support, actuation, and / or control unit, wherein a plurality of hydraulic cylinders are preferably arranged rotationally symmetrically about the main axis 4 of the system. In addition or instead of a hydraulic drive unit, one or more hydraulic springs are provided in a modified embodiment (analogous to the force-transmitting element 15 in the third embodiment), which act in the direction of the arrow 18 on the ring 14

Schließlich ist den Hydraulikzylindern optional ein aktiver Antrieb in Form einer Hydraulikpumpe samt Flüssigkeitskreislauf oder eine passive mechanische, pneumatische oder hydraulische Feder zugeordnet. Insbesondere der Antrieb dient zur gezielten Verstellung des Rings 14. Dabei kann eine Verstellung des Rings 14 über eine Einstellung der Kraft und/oder des Wegs und/oder der Geschwindigkeit und/oder der Beschleunigungen der Hydraulik-Stößel erfolgen.Finally, the hydraulic cylinders optionally an active drive in the form of a hydraulic pump with fluid circuit or a passive mechanical, pneumatic or hydraulic spring assigned. In particular, the drive is used for targeted adjustment of the ring 14. In this case, an adjustment of the ring 14 via an adjustment of the force and / or the path and / or the speed and / or the accelerations of the hydraulic ram done.

Um möglichst geringe Getriebebelastungen zu erhalten, ist der Reibbeiwert zwischen den Segmenten 3a, 3b und den Führungsflächen möglichst gering gewählt, nämlich ca. 0,05 bis 0,15. Als Werkzeugwerkstoffe des Getriebes sind Einsatzstähle, Kugellagerstähle (Typ 100Cr6) und alle Arten von Kalt- und Schnellarbeitsstählen vorgesehen. Die Oberflächen-Härte dieser Konstruktionselemente liegt bevorzugt oberhalb von 60 HRC. Optional kann auch eine aktive oder passive Schmierung der Gleitflächen zwischen den Segmenten 3a, 3b und dem Ring 14 mit Öl, Fett oder Reibungsvermindernden Oberflächenbeschichtungen vorgesehen sein.In order to obtain the lowest possible transmission loads, the friction coefficient between the segments 3 a, 3 b and the guide surfaces is chosen as low as possible, namely about 0.05 to 0.15. Gear tools, ball bearing steels (type 100Cr6) and all types of cold and high-speed steels are provided as tool materials of the gear unit. The surface hardness of these construction elements is preferably above 60 HRC. Optionally, an active or passive lubrication of the sliding surfaces between the segments 3a, 3b and the ring 14 may be provided with oil, grease or friction reducing surface coatings.

Das Hohlformteil 1 wird während eines Umformschritts bzw. während mehrerer Umformschritte von einer dritten Matrize in Form eines in das Hohlformteil eingreifenden, zylindrischen Dorns 8a, 8b innenseitig abgestützt.The hollow molded part 1 is supported on the inside during a forming step or during a plurality of forming steps by a third die in the form of a cylindrical mandrel 8a, 8b engaging in the hollow shaped part.

Wie schon mit Bezug auf die vorher geschilderten Ausführungsbeispiele beschrieben, wird das Hohlformteil in einem Umformschritt einem Axialpressvorgang unterworfen. Dabei wird das Hohlformteil 1 mit Hilfe einer Pressvorrichtung 11 in Richtung seiner Hauptachse 4 derart gestaucht, dass das Hohlformteil 1 in dem von der ersten Matrize 2a nicht abgestützten Umformbereich U plastisch deformiert wird, wobei das Hohlformteil im Umformbereich U von der zweiten Matrize 3 außenseitig abgestützt wird.As already described with reference to the previously described exemplary embodiments, the hollow molded part is subjected to an axial compression process in a forming step. In this case, the hollow molded part 1 is compressed by means of a pressing device 11 in the direction of its main axis 4 such that the hollow molded part 1 is plastically deformed in the Umformbereich U not supported by the first die 2a, wherein the hollow molded part supported in the forming area U of the second die 3 on the outside becomes.

Im Rahmen dieses Umformvorgangs werden die Segmente 3a, 3b der zweiten Matrize 3 in unterschiedlichen Richtungen quer zur Hauptachse des Hohlformteils 1 bewegt (Pfeile 5). Jedem Segment ist dabei ein eigener Bewegungsweg in radialer Richtung zugeordnet, wobei sich die Geraden der Bewegungswege in einem Punkt M auf der Hauptachse 4 schneiden. Somit kann die Matrize 3 wiederum kontinuierlich, stufenweise oder oszillierend in radialer Richtung geöffnet werden.As part of this forming operation, the segments 3a, 3b of the second die 3 are moved in different directions transversely to the main axis of the hollow molded part 1 (arrows 5). Each segment is assigned a separate movement path in the radial direction, the straight lines of the movement paths intersecting one another at a point M on the main axis 4. Thus, the die 3 can in turn be opened continuously, stepwise or oscillating in the radial direction.

Das erfindungsgemäße Umformwerkzeug erlaubt die Anordnung von wenigen (2 < n < 5), aber auch von vielen (n > 5) Segmenten bei gleichmäßiger Belastung auf kleinstem Raum, da die Wirkung eines einzigen Kraftelementes mechanisch über ein Kurvengetriebe auf n Segmente übertragen und über die Geometrie der Anordnung verstärkt wird. Die Lastverstärkung ermöglicht eine sehr kleine Dimensionierung des Kraftgebenden Elements 15 z.B. als Hydraulikzylinder, der für ein Prototyp-Getriebeteil nach Fig. 6a, Fig. 6b eine Kraft von 8 kN aufwies. Je mehr Segmente, umso geringer sind bei radialem Öffnen die Spalte, in die beim Stauchen Werkstoff einfließt und die als einen axial symmetrischen, unrunden Stauchbund bewirken (Fig. 6a, Fig. 6b). Ein Stauchverfahren mit segmentierter Matrize erfordert eine besondere Gleichmäßigkeit der Stützlast, da bei asymmetrischer Last ein Biegen des Stauchteiles zu der Seite mit geringer Stützwirkung und damit die Eulersche Knickung eingeleitet wird.The forming tool according to the invention allows the arrangement of a few (2 <n <5), but also of many (n> 5) segments under uniform load in a small space, since the effect of a single force element mechanically transmitted via a cam gear to n segments and on the Geometry of the arrangement is reinforced. The load amplification allows a very small dimensioning of the force-giving element 15, for example as a hydraulic cylinder, for a prototype transmission part after Fig. 6a, Fig. 6b had a force of 8 kN. The more segments, the smaller are the gaps in the case of radial opening, into which material flows during compression and which act as an axially symmetrical, non-circular compression collar ( Fig. 6a, Fig. 6b ). An upsetting process with segmented die requires a special uniformity of the support load, as with asymmetric load, a bending of the compression part to the side with little support effect and thus the Euler buckling is initiated.

Das Zeitverhalten eines mechanisch nahezu starren Kurvengetriebes ist im wesentlichen verzögerungsfrei. Das Zeitverhalten eines Hydrauliksystems mit kleinen Ölmengen (Steuerkraft ist wegen des Mechanismus klein) ist quasi ideal. Daher ist ein weiterer Vorteil darin zusehen, dass durch sehr schnelles Verändern des Kraft-Zeitverlaufes auf der Hydraulikseite das Abstützverhalten von n Stützsegmenten gleichmäßig auch bei sehr kleinen Umformzeiten simultan mit der Umformung zu beeinflussen ist. Das System kann als passives Ölverdrängersystem mit kontrolliertem Gegendruck oder auch aktiv über eine Pumpe und damit dem Stoff-Fluss definiert voreilend angetrieben werden.The time response of a mechanically nearly rigid cam gear is essentially delay-free. The time behavior of a hydraulic system with small amounts of oil (control force is small because of the mechanism) is almost ideal. Therefore, another advantage is the fact that by very rapid change of the force-time curve on the hydraulic side, the support behavior of n support segments can be influenced uniformly even with very small forming times simultaneously with the forming. The system can be driven in advance as a passive oil displacement system with controlled backpressure or actively defined by a pump and thus the material flow.

Hieraus resultieren zahlreiche weitere Neuerungen, die das neue Werkzeugsystem zumindest optional bietet:

  1. 1. Die Ausbildung der Wandstärke bei Rohrstauchprozessen kann über die Höhe und den Zeitverlauf der Stützkraft gesteuert werden. Das System ermöglicht damit das Führen eines flexiblen Stauchprozesses, bei dem über ein Steuerungsprogramm und nicht über Werkzeughardware die Durchmessergeometrie eines Stauchteiles in weitem Rahmen verändert werden kann (Fig. 6b)
  2. 2. Der Prozess kann bei sich ändernden knickrelevanten Parametern wie Zunahme der Wand-Stärke und abnehmender Werkstofftemperatur im Verlauf der Stauchung durch Veränderung der Stützkraft geregelt werden beispielsweise bzgl. des Faserverlaufes im Bund
  3. 3. Auf den bauteilseitigen Segmentflächen können Vertiefungen eingearbeitet sein, die während des Stauchens zu Hinterschnitten führen. Damit wird das Bauteil beim Öffnen der Presse immer formschlüssig und reproduzierbar auf der Maschinenseite festgehalten, auf der die Segmentmatrize aufgebaut ist. Vor dem Auswerfen aus dieser Seite kann durch aktives Öffnen der Segmente über Pumpenantrieb der Hinterschnitt freigegeben werden.
  4. 4. Wegen der sehr schnellen Zeitcharakteristik ist das System auch auf schnell laufenden mechanisch angetriebenen Maschinen einsetzbar, was für den wirtschaftlichen Einsatz bei der Warmumformung von sehr großem Vorteil ist (Wärmeübergang und damit Aufheizung der Werkzeuge nimmt mit der Druckberührzeit extrem ab)
  5. 5. Das System baut sehr Platz sparend, wenn bevorzugt nur ein Kraftelement integriert und angesteuert wird. Damit ist es als Zusatzsystem in den heute vorhandenen Maschinen, die stets mit sehr geringem Platzangebot im Arbeitsraum gekennzeichnet sind, nachrüstbar.
  6. 6. Wegen des geringen System-Platzbedarfes kann das System als schwimmende Matrize betrieben werden, mit dem auf einer einfachwirkenden Presse eine beidseitige Stauchbewegung entsprechend dem Prinzip in Fig 3 auf das Pressteil bewirkt werden kann.
This results in numerous other innovations that the new tool system offers, at least as an option:
  1. 1. The formation of the wall thickness in Rohrstauchprozessen can be controlled by the height and the time course of the supporting force. The system thus makes it possible to carry out a flexible upsetting process in which the diameter geometry of an upsetting part can be varied over a wide range by means of a control program and not by means of tool hardware ( Fig. 6b )
  2. 2. The process can be controlled with changing kink relevant parameters such as increase in wall thickness and decreasing material temperature in the course of compression by changing the support force, for example. With respect to the fiber flow in the federal government
  3. 3. Recesses can be incorporated on the component-side segment surfaces, which lead to undercuts during the upsetting. Thus, the component is always held form-locking and reproducible on opening the press on the machine side on which the segment matrix is constructed. Before ejecting from this side, the undercut can be released by actively opening the segments via the pump drive.
  4. 4. Because of the very fast time characteristic, the system can also be used on high-speed mechanically driven machines, which is very advantageous for economic use in hot forming (heat transfer and thus heating of the tools decreases extremely with the pressure contact time)
  5. 5. The system is very space-saving, if preferably only one force element is integrated and controlled. Thus, it can be retrofitted as an additional system in today's existing machines, which are always characterized by very little space in the work space.
  6. 6. Because of the small system space requirement, the system can be operated as a floating die, with a double-sided compression movement on a single-acting press according to the principle in Fig. 3 can be effected on the pressing part.

Claims (9)

  1. A method for deforming a hollow part, in which
    - in a first method step a hollow part (1) is inserted into a first matrix (2), which encloses and supports the hollow part annularly in a support area along its lateral surface, and in which
    - in a second process step, namely a forming step, in which the hollow part is subjected to an axial pressing, the hollow part is compressed along its main axis in such a manner that
    - the hollow part (1) is plastically formed in a forming area (U) that is not supported by the first matrix (2), wherein
    - the hollow part is supported on the external side in the forming area by a second matrix (3), the geometry of which is adjustable resp. variable, wherein
    - in the direction of one or more planes oriented parallel to the main axis (4) of the hollow part (1) and/or in the direction of one or more planes containing the main axis (4) of the hollow part the second matrix (3) is subdivided in segments (3a, 3b, 3c, 3d), which
    - support the hollow part (1) to be formed in radial direction during the plastic forming process of the same on several sides, and which
    - are adjustable in radial direction during the plastic forming of the hollow part, wherein
    - several segments (3a, 3b, 3c, 3d) are translationally slidably mounted, each along an assigned straight line, namely it shifting direction, wherein during the forming process the segments of the second matrix (3) are moved in different directions transversely with respect to the main axis of the hollow part (1), wherein the matrix is opened continuously, gradually or oscillatory in the radial direction, wherein each segment in this process is assigned to its own motion path in the radial direction, wherein the straight lines of the motion paths intersect in a point M on the main axis (4), wherein
    - the respectively assigned straight lines of several segments are arranged in a common plane, in particular perpendicular to a main axis of the hollow part to be formed, wherein
    - several, in particular all segments (3a, 3b, 3c, 3d) of the second matrix (3) have an equal thickness transversely with respect to its shifting direction, which
    - corresponds to the two- to twenty-fold value of the initial wall thickness (t) of the hollow part (1) to be formed.
  2. The method according to claim 1, characterized in that, during the forming step
    the second matrix (3) is moved in a direction transverse with respect to the main axis (4) of the hollow part, in particular is opened continuously and/or gradually in the radial direction and wherein an oscillatory movement of the second matrix (3) is superposed to a continuous and/or gradual opening movement of the second matrix (3).
  3. The method according to any vne of the claims 1 to 2, characterized in that the second matrix (3) is moved during the forming step
    - with a predetermined force and/or
    - is pressed with a predetermined force course against the hollow part (1) and/or
    the second matrix (3) is moved during the forming step
    - along a predetermined path and/or
    - with a predetermined speed course.
  4. The method according to any one of the claims 1 to 3, characterized in that the second matrix (3) and/or the hollow part (1) is rotated during the forming step about the main axis (4) of the hollow part.
  5. The method according to any one of the claims 1 to 4, characterized in that several segments (3a, 3b, 3c, 3d) of the second matrix (3) during the forming step are impinged via a joint gear box element with essentially equal forces.
  6. The method according to any one of the claims 1 to 5, characterized in that the first matrix (2) is carried out multipart, wherein in the first method step a first matrix part (2a) and a second matrix part (2b) are positioned spaced apart from one another and wherein during the forming step the first matrix part (2a) and the second matrix part (2b) are moved towards one another, in particular driven continuously towards one another.
  7. The method according to any one of the claims 1 to 6, characterized in that the first matrix (2) is carried out multipart, wherein in the first method step a first matrix part (2a) and a second matrix part (2b) are positioned spaced apart from one another and wherein during the forming step the first matrix part (2a) and the second matrix part (2b) are moved away from one another, in particular driven continuously away from one another.
  8. The method according to any one of the claims 6 to 7, characterized in that an oscillatory movement of the matrix parts and/or of the hollow part (1) is superposed to a continuous movement of the first matrix part (2a) and of the second matrix part (2b).
  9. The method according to any one of the claims 1 to 8, characterized in that the hollow part (1) is supported on the inside during the forming step by a third matrix in the form of a pin, in particular an adjustable and/or elastically deformable pin, engaging into the hollow part.
EP08806905.9A 2007-08-25 2008-08-24 Process for deforming a hollow part Not-in-force EP2180964B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP08806905.9A EP2180964B1 (en) 2007-08-25 2008-08-24 Process for deforming a hollow part

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP07016691A EP2030701A1 (en) 2007-08-25 2007-08-25 Tool and method for producing a hollow body
EP08806905.9A EP2180964B1 (en) 2007-08-25 2008-08-24 Process for deforming a hollow part
PCT/IB2008/002189 WO2009027789A2 (en) 2007-08-25 2008-08-24 Tool and process for producing a hollow part

Publications (2)

Publication Number Publication Date
EP2180964A2 EP2180964A2 (en) 2010-05-05
EP2180964B1 true EP2180964B1 (en) 2014-07-30

Family

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Family Applications (2)

Application Number Title Priority Date Filing Date
EP07016691A Withdrawn EP2030701A1 (en) 2007-08-25 2007-08-25 Tool and method for producing a hollow body
EP08806905.9A Not-in-force EP2180964B1 (en) 2007-08-25 2008-08-24 Process for deforming a hollow part

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP07016691A Withdrawn EP2030701A1 (en) 2007-08-25 2007-08-25 Tool and method for producing a hollow body

Country Status (2)

Country Link
EP (2) EP2030701A1 (en)
WO (1) WO2009027789A2 (en)

Cited By (1)

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RU2753073C1 (en) * 2020-12-08 2021-08-11 Федеральное государственное бюджетное образовательной учреждение высшего образования "Тульский государственный университет" (ТулГУ) Method for producing riffles on outer surface of shell

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DE102012003174B4 (en) * 2012-02-17 2017-06-01 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Method and device for producing a hollow profile with sections of different wall thickness
EP2711106A3 (en) * 2012-09-19 2014-12-03 IFUTEC Ingenieurbüro für Umformtechnik GmbH Method for producing wide, flange-like thickenings on hollow bodies
TWI494179B (en) * 2012-09-28 2015-08-01 Twdt Prec Co Ltd Mandrel manufacturing method
DE102013209948A1 (en) * 2013-05-28 2014-12-18 Brose Fahrzeugteile Gmbh & Co. Kommanditgesellschaft, Coburg Method for processing or forming heavy-duty components in motor vehicles

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WO1987001062A1 (en) * 1985-08-14 1987-02-26 Gesenkschmiede Schneider Gmbh Process for the production of flanges or collars on hollow parts by lateral extrusion
DE4201819A1 (en) * 1991-01-28 1992-07-30 Mannesmann Ag METHOD AND DEVICE FOR THE HYDRAULIC EXPANSION OF TUBULAR HOLLOW PROFILES
JP3554273B2 (en) * 1997-10-20 2004-08-18 ボーリンガー，ヨーゼフ Method for manufacturing a shaft from a single tube, apparatus for manufacturing a shaft from a single tube, and a camshaft manufactured from a single tube
US6572358B1 (en) * 2001-11-15 2003-06-03 Pilot Industries, Inc. Die assembly for forming a bead on a cylindrical tube
DE10204107B4 (en) * 2002-02-01 2018-12-13 Mahle International Gmbh Exhaust gas heat exchanger
DE102004032122A1 (en) * 2004-07-01 2006-01-19 IFUTEC Ingenieurbüro für Umformtechnik GmbH Method for forming tubular elements and method for producing hollow shafts

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2753073C1 (en) * 2020-12-08 2021-08-11 Федеральное государственное бюджетное образовательной учреждение высшего образования "Тульский государственный университет" (ТулГУ) Method for producing riffles on outer surface of shell

Also Published As

Publication number Publication date
EP2030701A1 (en) 2009-03-04
EP2180964A2 (en) 2010-05-05
WO2009027789A3 (en) 2009-07-02
WO2009027789A2 (en) 2009-03-05

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