EP2351623B1 - Verfahren zur herstellung eines verformten querschnitts und formartikel mit vierseitigem querschnitt mit hervorragender punktschweissfähigkeit - Google Patents

Verfahren zur herstellung eines verformten querschnitts und formartikel mit vierseitigem querschnitt mit hervorragender punktschweissfähigkeit Download PDF

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EP2351623B1
EP2351623B1 EP09816295.1A EP09816295A EP2351623B1 EP 2351623 B1 EP2351623 B1 EP 2351623B1 EP 09816295 A EP09816295 A EP 09816295A EP 2351623 B1 EP2351623 B1 EP 2351623B1
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Prior art keywords
mpa
tubing material
loaded
internal pressure
girth
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French (fr)
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EP2351623A1 (de
EP2351623A4 (de
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Toyohisa Shinmiya
Koji Suzuki
Osamu Sonobe
Yuji Hashimoto
Rinsei Ikeda
Akio Sato
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JFE Steel Corp
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JFE Steel Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/041—Means for controlling fluid parameters, e.g. pressure or temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D51/00—Making hollow objects
    • B21D51/02—Making hollow objects characterised by the structure of the objects
    • B21D51/06—Making hollow objects characterised by the structure of the objects folded objects
    • 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
    • B21D51/00—Making hollow objects
    • B21D51/16—Making hollow objects characterised by the use of the objects

Definitions

  • the present invention relates to a forming method of complex cross-section shape (or shape tube)and a quadrate cross-section forming article having high spot weldability, and more particularly, relates to a forming method of complex cross-section shape that forms a tubing material serving as a stock (or element tube)into a complex cross-section shape by a hydroform process, and to a quadrate cross-section forming article with high spot weldability which is formed from a tubing material by the forming method and which has one or two pairs of parallel sides.
  • a portion corresponding to a product portion having a width smaller than the pipe diameter of the bent article is subjected to crushing into a cross-section shape having a width smaller than the stock diameter (or diameter of element tube) by a pressing machine or a dedicated machine, as illustrated in Fig. 1(b) of Patent Document.
  • This crushed article is set in a cavity between upper and lower dies, as illustrated in Fig. 1(c) of Patent Document 1, and the upper and lower dies are closed, as illustrated in Fig. 1(d) of Patent Document 1. After that, liquid is injected into the crushed article, as illustrated in Fig.
  • Patent Document 1 so as to load an internal pressure of, for example, 22000 psi (151 MPa), whereby the article is plastically deformed to fit surfaces of the dies and is formed into a cross-section shape illustrated in Fig. 1(f) of Patent Document 1.
  • a pipe of circular cross section is bent into a required planar shape, for example, into a U-shape illustrated in Fig. 3(b) of Patent Document 1, and the bent article is also subjected to crushing into a cross-section shape having a reduced width by a pressing machine or a dedicated machine, as illustrated in Fig. 2(b) of Patent Document 1.
  • This crushed article is set in a cavity between upper and lower dies, as illustrated in Fig. 2(c) of Patent Document 1, and a low pressure of, for example, about 1000 psi (7MPa) is loaded in the crushed article for prepressurization before closing of dies, as illustrated in Fig. 2(d) of Patent Document 1. Subsequently, closing of dies is performed, as illustrated in Fig. 2(e) of Patent Document 1, and the internal pressure is increased to a high internal pressure of 6000 to 7000 psi (42 to 49 MPa), whereby the prepressurized article is plastically deformed into a cross-section shape illustrated in Fig. 2(f) of Patent Document 1 so as to fit surfaces of the dies.
  • Patent Document 1 Japanese Unexamined Patent Application Publication No. 2000-246361
  • Document EP1293415 describes a method according to the preamble of claim 1.
  • the first type forming method of the related art it is typical to adopt a high increasing rate of girth of 10% or more, and rupture is more likely to occur in a low-ductility tubing material, for example, a high-strength steel tube when a high internal pressure is loaded.
  • the second type deep hollows are formed in some portions of the complex cross-section forming article that should be flat (for example, portions serving as sides of a rectangular cross section) by crushing, and this makes spot welding, especially one-side spot welding quite difficult.
  • the curvature radius R of corners R (for example, portions serving as corners of the rectangular cross section) is much larger than that of corresponding corners of the dies. Hence, it is difficult to obtain a sharp cross-section shape, and the form accuracy of the product is insufficient.
  • the forming technique of complex cross-section shape of the related art using the hydroform process has difficulty in obtaining a complex cross-section forming article having high spot weldability and high dimensional accuracy.
  • the complex cross section refers to a cross section different from a circular form cross section, for example, a rectangular cross section.
  • the present inventors conceived a means that realized a complex cross-section forming article, which allowed easy spot welding, by the hydroform process, and made the present invention. That is, the present invention is as follows:
  • an internal pressure is continuously loaded in the tubing material by liquid, and the tubing material is formed so that the maximum internal pressure is within a proper range, preferably, so that an increasing rate of girth after forming is within a proper range.
  • This allows the tubing material to be formed into a complex cross-section shape having a small hollow depth on flat surface and corner curvature radius R that provides a sharp outline (with a small curvature radius). Since an obtained complex cross-section forming article has a small hollow depth on flat surface, it is excellent in one-side spot weldability to a metallic sheet. Moreover, springback deformation after removal of the pressure is suppressed, and the complex cross-section forming article has high dimensional accuracy.
  • FIG. 1 includes explanatory views schematically illustrating a method of the present invention.
  • a tubing material 10 is formed by a metallic tube, such as a steel tube, having a tensile strength (abbreviated as TS) of 590 MPa or more.
  • TS tensile strength
  • the tubing material 10 is set in a die having at least one flat surface, for example, a pair of upper and lower dies 1 and 1A having flat surfaces.
  • the cross-section shape of the dies 1 and 1A is different from that of the tubing material 10.
  • the tubing material 10 can or cannot be subjected to preforming.
  • the term preforming refers to bending the tubing material into a U-shape in the longitudinal direction, as illustrated in Fig. 3(b) of Patent Document 1, bending into an S-shape, bending at 90°, crushing a longitudinal part of the tubing material, or local tube expansion or contraction. Then, the tubing material is crushed by the upper and lower dies 1 and 1A in a state in which no internal pressure is loaded in the tubing material or a low internal pressure (50 MPa or less) is loaded therein by liquid.
  • the case in which no internal pressure is loaded in the tubing material includes two cases, that is, a case in which there is no liquid in the pipe and a case in which no internal pressure is produced even when there is liquid in the pipe.
  • preparation is made by liquid injection (bubbles are removed while filling the pipe with liquid) while performing crushing.
  • hollows (referred to as flat-surface hollows) are formed in tube wall portions facing the flat surfaces of the dies, and gentle corners R are formed in tube wall portions facing the corners of the dies.
  • the coefficient of 0.045 on the right side is preferably replaced with 0.09, more preferably replaced with 0.12, because this further improves the shape of the article.
  • the maximum internal pressure is usually about 100 to 200 MPa for the following reason.
  • the performance of a pressure intensifier for applying the internal pressure is usually up to 200 MPa. If the projection area of the article in a horizontal plane (or the projection area of the die cavity) is excessively large, the performance is sometimes set to be less than 200 MPa, for example, 150 MPa because of the limit of the pressing force of the pressure intensifier. When the above limit is not made and a tube stock (or element tube) is thin and has a low strength, sufficient corrective forming is sometimes possible at 100 MPa.
  • axial feeding is preferably performed after a short time elapses from the loading of internal pressure, and axial feeding is not performed simultaneously with the loading of internal pressure.
  • the cylinder stroke of an axial feeding pressing machine is adjusted so that the axial feeding length (stroke) is about 0 to 2% of the forming portion length L of an end product after the hydroform process when the ratio L/D of the forming portion length L and the tube stock (or element tube)outer diameter D is higher than or equal to about 10, so that the axial feeding length is about 0 to 3.5% of the length L when L/D is higher than 7 and less than 10, and so that the axial feeding length is 0 to 5% of the length L when L/D is lower than or equal to 7.
  • the internal pressure is loaded, the axial feeding pressing machine tends to be pushed back by reactive force applied thereto. Hence, an axial feeding force exists even when the axial feeding length is 0%.
  • forming is preferably performed so that the increasing rate of girth after forming becomes higher than or equal to 2.0% and lower than or equal to 10.0%.
  • the ratio t/D of the thickness to the outer diameter of the steel tube used for the tubing material exceeds 0.05, the hollow depth on flat surface tends to increase as t/D increases.
  • a steel tube having a ratio t/D of 0.05 or less is preferably used as the tubing material.
  • the hollow depth on flat surface needs to be 0.5 mm or less (the definition of hollow depth on flat surface is shown in Fig. 2 , as a specific measurement method, the hollow depths on the flat surfaces of the complex cross-section forming article were measured with a laser distance meter, and the largest hollow depth was defined as the hollow depth on flat surface). If the hollow depth on flat surface of the product exceeds 0.5 mm, for example, when a steel sheet 12 is pressed against a product 11 by a spot welding electrode 3, as illustrated in Fig. 3 , a relatively large gap ⁇ is easily formed between the steel sheet 12 and the product 11 in an area just below the electrode 3. Hence, a stable current-carrying state cannot be obtained, and failure is likely to occur in spot welding.
  • the corner curvature radius R of the article is set to be 10 mm or less (the definition of the corner curvature radius R is shown in Fig. 2 , as a specific measurement method, the complex cross-section forming article was cut along a plane perpendicular to the longitudinal direction, cross-sectional photographs of all corners were taken into images, circles having various curvature radii were superimposed on the corners to find curvature radii R of all the corners, and the largest curvature radius R was set as the corner curvature radius R).
  • both the hollow depth on flat surface and the corner curvature radius R decreased as the maximum internal pressure increased and that the higher one of the maximum internal pressure for the hollow depth on flat surface of 0.5 mm and the maximum internal pressure for the corner curvature radius R of 10 mm was preferably set as the lower limit of the maximum internal pressure.
  • the relationship between this lower limit and TS of the tubing material is shown in Fig. 4 .
  • the lower limit P min of the maximum internal pressure is given by the above-described Expression (1) when TS is 590 MPa or more.
  • forming is preferably performed so that the increasing rate of girth after forming becomes 2.0 to 10.0% under the condition that the maximum internal pressure after crushing is P min [MPa] or more.
  • forming is performed by using a combination of dies and a tubing material such that an inner girth L K of the cross section of the dies during closing the dies and an outer girth L P of the tubing material before hydroforming satisfy the following relational expression.
  • the correspondence relationship between the maximum internal pressure and the increasing rate of girth is found beforehand by FEM (finite element method) analysis or by experiment, and the internal pressure for use in forming after crushing is set at the maximum internal pressure corresponding to the target increasing rate of girth in this correspondence relationship.
  • an internal pressure which satisfies the condition that the maximum internal pressure is higher than or equal to P min [MPa] specified by the above Expression (1) and is higher than 50 MPa, is loaded in the tubing material by the liquid while continuing closing of the dies, whereby hydroforming is performed so that the increasing rate of girth after forming is higher than or equal to the below-described A% and is lower than or equal to 11.0%.
  • the increasing rate of girth is given by the following expression.
  • the flat-surface hollows are further reduced, and the corners R have a more sharply rounded shape (having a smaller curvature radius) because the material (material of tubing material) expands thereat.
  • the coefficient on the right side of Expression (4) from 4.167 ⁇ 10 -3 to 4.8 ⁇ 10 -3 , because this improves the shape of the article (the flat-surface hollows and the corners R).
  • the maximum internal pressure at closing of the dies is preferably higher than 50 MPa so as to satisfy the condition that the maximum internal pressure is higher than both P min and 50 MPa.
  • P min is higher than 50 MPa for the maximum internal pressure.
  • the maximum internal pressure at closing of the dies is preferably higher than or equal to P min .
  • the thicknesses of portions near the corners R excessively decrease because of expansion of the material.
  • the decrease in thickness can be suppressed by applying compression force in the tube axis direction to the tube end so as to push the tube end toward the center in the tube axis direction (this is referred to as "axial feeding"), in addition to the loading of internal pressure after crushing.
  • axial feeding the cylinder stroke of the axial feeding pressing machine is adjusted so that the axial feeding length (stroke) is about 0 to 10% of the forming portion length of the end product subjected to the hydroform process.
  • the ratio t/D of the thickness to outer diameter of the steel tube used as the tubing material exceeds 0.05, the hollow depth on flat surface tends to increase as t/D increases.
  • a steel tube having a value t/D of 0.05 or less is preferably used as the tubing material.
  • the increasing rate of girth is preferably 11.0% or less when TS is 690 MPa or more. Further, the increasing rate of girth is preferably 10.0% or less when TS is 780 MPa or more.
  • forming is preferably performed so that the increasing rate of girth after forming becomes A to 11.0%. Further, when TS of the tubing material is 780 MPa or more, forming is preferably performed so that the increasing rate of girth after forming becomes A to 10.0%.
  • Tubing materials to which the forming method of this application is applicable are electric resistance welded steel tubes that are formed from a hot-rolled steel sheet or a cold-rolled steel sheet having a value TS of 590 MPa or more, and include an electric resistance welded steel tube formed from a hot-rolled steel sheet or a cold-rolled steel sheet subjected to heat treatment such as hardening and tempering.
  • the steel type of the above-described hot-rolled steel sheet and cold-rolled steel sheet may be common steel, low-alloy steel, ferritic stainless steel, austenitic stainless steel, or martensitic stainless steel. The steel type is not limited to these steels.
  • Tubing materials having values TS and sizes shown in Table 1 were formed into a complex cross-section shape with the dies 1 and 1A of rectangular cross section illustrated in Fig. 1 through the following procedure. All of the used tubing materials are electric resistance welded steel tubes. Table 2 shows compositions and production methods of steel sheets serving as the stocks (or element tube) of the electric resistance welded steel tubes No. 1 to No. 32. The length of the tubing materials used in the example was 300 mm. Procedure: insert in the dies ⁇ crush by closing the dies in a state in which there is no internal pressure or a state in which internal pressures of 50 MPa or less (10 MPa and 13 MPa for No. 10 and No.
  • a steel sheet 12 is placed on an upper flat surface of a product 11 and an electrode 3 is pressed against the steel sheet 12 from above with a fixed pressing force (50 to 200 Kgf), whereby one-side spot welding is performed at three points (welding conditions: current-carrying time 10 to 20 cycles (50 Hz), welding current 5 to 10 KA).
  • Spot weldability is evaluated on the basis of the presence or absence of nugget formation and the tensile shear load in a tensile shear test (JIS Z 3136), and is evaluated on a scale of two grades, that is, ⁇ G:Good and ⁇ P:Poor.
  • TSS of the tensile shear load of a joint is based on the following expression, and a joint that meets the reference value is judged sufficient (acceptable).
  • TSS N 1.85 xt ⁇ TS ⁇ 1 + 0.0059 EL ⁇ ND + 2.09
  • Table 1 shows the results of the above measurement and test. Table 1 shows that complex cross-section forming articles having high spot weldability and high dimensional accuracy were obtained from tubing materials having values TS of 590 MPa or more. In the examples of Table 1, the hollow depths on flat surface of the tubing materials having values t/D ⁇ 0.05 are smaller than those of the tubing materials having values t/D > 0.05.
  • tubing materials having values TS and sizes shown in Table 3 were formed into complex cross-section shapes with the dies 1 and 1A of rectangular cross section illustrated in Fig. 1 .
  • All of the used tubing materials are electric resistance welded steel tubes.
  • Table 4 shows the compositions and production methods of steel sheets serving as the stocks of the electric resistance welded steel tubes No. 1 to No. 30.
  • the length of the steel tubes used in the example was 300 mm.
  • Table 3 shows the results of the above measurement and test. Table 3 shows that complex cross-section forming articles having high spot weldability and high dimensional accuracy were obtained from tubing materials having values TS of 690 MPa or more in the example of the present invention. In the example of the present invention, the hollow depths on flat surface of the tubing materials having values t/D ⁇ 0.05 are smaller than those of the tubing materials having values t/D > 0.05.
  • forming is performed by continuously loading internal pressure by the liquid in a tubing material so that the maximum internal pressure is within a proper range, more preferably, so that the increasing rate of girth after forming is within a proper range, whereby the tubing material can be formed into a complex cross-section shape having a small hollow depth on flat surface and a corner curvature radius R for a sharp outline (small curvature radius). Since the obtained complex cross-section forming article has a small hollow depth on flat surface, it is excellent in one-side spot weldability to a metallic sheet. Moreover, springback deformation after removal of the pressure is suppressed, and the complex cross-section forming article has high dimensional accuracy.

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  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Claims (4)

  1. Verfahren zur Formgebung eines Gegenstandes von komplexer Querschnittsgestalt, wobei ein Rohrmaterial mittels eines Formwerkzeugs von komplexer Querschnittsgestalt, das mindestens eine Fläche mit einem flachen Abschnitt aufweist, in einem Zustand gequetscht wird, in dem kein Innendruck beaufschlagt ist oder ein Innendruck von 50 MPa oder weniger in dem Rohrmaterial durch Flüssigkeit beaufschlagt ist, und durch kontinuierliches Beaufschlagen des Rohrmaterials durch die Flüssigkeit mit einem Innendruck zu einer komplexen Querschnittsgestalt geformt wird; dadurch gekennzeichnet, dass:
    das Rohrmaterial eine Zugfestigkeit von 690 MPa oder mehr aufweist, der maximale Innendruck durch das kontinuierliche Beaufschlagen höher als 50 MPa ist und dass das Rohrmaterial derart geformt wird, dass eine Zuwachsrate an Umfang nach dem Formgeben höher als oder gleich dem folgenden A % und kleiner als oder gleich 11,0 % ist: A = 4 , 167 × 10 − 3 × TS − 590
    Figure imgb0013
     wobei Zuwachsrate an Umfang = Außenumfang des Gegenstandes / Außenumfang des Rohrmaterials vor dem Formgeben − 1 × 100 % ,
    Figure imgb0014
    A: untere Grenze der Zuwachsrate des Umfangs (%),
    TS: Zugfestigkeit des Rohrmaterials (MPa).
  2. Verfahren zur Formgebung eines Gegenstandes von komplexer Querschnittsgestalt nach Anspruch 1, dadurch gekennzeichnet, dass ein Rohrende gegen eine Mitte in eine Rohrachsenrichtung eingedrückt wird, indem zusätzlich zu dem Beaufschlagen mit dem Innendruck nach dem Quetschen eine Kompressionskraft in der Rohrachsenrichtung auf das Rohrende angewandt wird.
  3. Verfahren zur Formgebung eines Gegenstandes von komplexer Querschnittsgestalt nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass ein Stahlrohr mit einer Zugfestigkeit von 780 MPa oder mehr als das Rohrmaterial benutzt wird und das Rohrmaterial derart geformt wird, dass die Zuwachsrate des Umfangs nach dem Formgeben höher als oder gleich dem folgenden A % und kleiner als oder gleich 10,0 % ist: A = 4 , 167 × 10 − 3 × TS − 590
    Figure imgb0015
     wobei A: untere Grenze der Zuwachsrate des Umfangs (%), TS: Zugfestigkeit des Rohrmaterials (MPa).
  4. Verfahren zur Formgebung eines Gegenstandes von komplexer Querschnittsgestalt nach einem von Anspruch bis 3, dadurch gekennzeichnet, dass ein Stahlrohr, dessen Verhältnis t/D von einer Dicke zu einem Außendurchmesser 0,05 oder weniger beträgt, als das Rohrmaterial benutzt wird.
EP09816295.1A 2008-09-25 2009-09-24 Verfahren zur herstellung eines verformten querschnitts und formartikel mit vierseitigem querschnitt mit hervorragender punktschweissfähigkeit Active EP2351623B1 (de)

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JP2008246268 2008-09-25
JP2008246271 2008-09-25
PCT/JP2009/067123 WO2010035883A1 (ja) 2008-09-25 2009-09-24 異形断面への成形方法およびスポット溶接性に優れた四辺形断面成形品

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JP6670543B2 (ja) * 2014-12-11 2020-03-25 住友重機械工業株式会社 成形装置及び成形方法
CN106311857B (zh) * 2015-12-21 2017-11-07 青岛世冠装备科技有限公司 一种复杂截面中空构件低压镦胀成形方法
CN105562516B (zh) * 2016-03-15 2018-03-30 哈尔滨工业大学 一种变截面异形管件充液压制成形方法
CN107243538A (zh) * 2017-08-08 2017-10-13 天津天锻航空科技有限公司 一种由小周长圆管成形大周长矩形的方法
CN111957804B (zh) * 2020-07-20 2021-06-29 燕山大学 用于薄壁管材充液弯曲成形的装置及其成形方法

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KR20110046557A (ko) 2011-05-04
KR101322229B1 (ko) 2013-10-28
WO2010035883A1 (ja) 2010-04-01
KR20130083492A (ko) 2013-07-22
EP2351623A4 (de) 2012-10-31
CN102164690A (zh) 2011-08-24

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