EP2548670B1 - Outil de formage et procédé destiné à la fabrication de pièces de formage ä partir de platines en métal - Google Patents

Outil de formage et procédé destiné à la fabrication de pièces de formage ä partir de platines en métal Download PDF

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Publication number
EP2548670B1
EP2548670B1 EP12176670.3A EP12176670A EP2548670B1 EP 2548670 B1 EP2548670 B1 EP 2548670B1 EP 12176670 A EP12176670 A EP 12176670A EP 2548670 B1 EP2548670 B1 EP 2548670B1
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EP
European Patent Office
Prior art keywords
tool
forming
formed body
forming tool
tool part
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Application number
EP12176670.3A
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German (de)
English (en)
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EP2548670A1 (fr
Inventor
Jochen Dörr
Jochem Grewe
Hans-Jürgen Knaup
Gero Müllers
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Benteler Automobiltechnik GmbH
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Benteler Automobiltechnik GmbH
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Publication of EP2548670A1 publication Critical patent/EP2548670A1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/16—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/022—Stamping using rigid devices or tools by heating the blank or stamping associated with heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/208—Deep-drawing by heating the blank or deep-drawing associated with heat treatment

Definitions

  • the invention relates to a forming tool and a method for producing molded components made of metal plates, preferably of light metal.
  • Tempered forming processes increase the cut-off ratio in metal blanks, especially in light metal blanks, such as aluminum blanks.
  • a reduction in weight can be achieved by reducing the wall thicknesses and the assembly effort can be reduced by avoiding multi-part components.
  • the EP 1 601 478 B1 describes the deep drawing of heated aluminum blanks in an at least partially heated tool at 150 ° C to 350 ° C in the presence of a compatible with the subsequent operations lubricant.
  • the DE 10 2006 046 305 A1 discloses an apparatus for at least partially forming sheets beyond the forming limits.
  • the DE 101 62 437 A1 describes a forming tool with a shaping engraving for the production of workpieces made of metallic materials, especially aluminum.
  • the forming tool is divided into engraving segments with engraving surfaces for setting different temperature fields.
  • the CH 657 548 A5 includes a forming tool for isothermal forming of metals in the art.
  • This consists of an inner molded body, referred to there as a die body, an immediately surrounding, annularly arranged, electrically and thermally insulating ceramic body in which an inductive heating coil is embedded, a radial prestress generating pressing body and arranged between the ceramic body and the compact annular Component which serves the magnetic field control and can be designed as an annular electrical conductor for shielding or as a magnetic segment or magnetic ring for conducting the magnetic field.
  • the EP 1 645 345 A2 discloses a hot forming tool which is heatable by means of a plurality of electric heating cartridges.
  • the heating cartridges are arranged in the tool body or bodies such that the temperature of the molding surface or molding surfaces is kept within a predeterminable temperature range. The temperature at a location on or in the tool is detected and the heating cartridges simultaneously switched on and off depending on the measured temperature.
  • a heatable tool for drop forging of long, flat or disc-shaped workpieces in closed die emerges.
  • the tool comprises a press ram, an ejector punch and a floating insert, in the direction of movement of the ram movably biased die insert.
  • the moldings of hot or warm forging tools are exposed to high thermal and mechanical stresses during operation. This applies in particular for the contact surfaces of the shaped bodies coming into contact with the metal plates to be formed.
  • the invention aims at improving the efficiency and process reliability of component production with tempered tools.
  • the invention is therefore, starting from the prior art, based on the object to show a system engineering and application technology improved forming device and a method for the production of molded parts from metal blanks with improved efficiency and process reliability in component manufacturing.
  • the objective part of the object is achieved by a forming tool according to claim 1.
  • the forming tool for the production of molded components made of metal plates has a tool upper part and a lower tool part.
  • the upper tool part and the lower tool part comprise heatable molded bodies, between which the Metal blanks are reshaped.
  • At least one shaped body in the upper tool part and / or in the lower tool part is arranged in a bearing, wherein the bearing is designed such that thermal expansions of the shaped body during the heating phase are made possible.
  • the invention aims at the core to an isothermal deformation under elevated temperature.
  • a uniform temperature of the tool and workpiece or metal plate is desired as a function of location and time for the entire deformation process.
  • isotherm is to be understood as meaning a temperature with the accuracy of +/- 25 ° C. This requires that the tool or the moldings are heated. Accordingly, a heating device is provided, by means of which the shaped bodies are heated to the required forming temperature. To ensure the isothermal deformation, the forming tool or the shaped body is heated homogeneously and kept at a preselected forming temperature during series production.
  • thermo expansions of the moldings and / or the metal blanks to be formed are made possible in or by the storage according to the invention.
  • both the expansion of the tool steel of the moldings and the metal plate to be formed are taken into account in the geometric design of the moldings.
  • the forming tool according to the invention and the method according to the invention increase the cost-effectiveness and process reliability of component production with tempered tools. In addition, only then the applicability and Durability ensured for series operation.
  • the invention enables isothermal hot or warm forging with short cycle times. Problems from the thermal expansion difference between tool steel of the moldings and the material of the metal plate to be formed are largely eliminated. In addition, the use of materials can be reduced by reducing the costs of further processing, even with demanding geometries.
  • the storage comprises three, in particular at least four staggered bearings.
  • the four bearings on a pitch circle are offset by 90 ° to each other.
  • the bearing or each bearing has a guided in an expansion groove sliding block.
  • On the upper mold body and on the lower mold body and / or on a hold-down guide segments are provided, via which the upper mold body and the lower mold body and / or the hold-down during the forming process are relative to each other position-oriented.
  • the moldings can be massive, so-called monobloc bodies.
  • the shaped bodies can also be advantageously segmented and composed of individual shaped body segments. This improves the assembly and also allows easy interchangeability of the moldings or individual molded body segments.
  • at least one shaped-body segment can also be arranged to be vertically displaceable relative to adjacent shaped-body segments.
  • a heating device For controlling the temperature of the molded body, a heating device is provided.
  • the tempering can be carried out preferably by an electrical resistance heating, for example via cartridge heaters, or inductively by means of an inductive heating coil.
  • the heating device may be in contact with a surface of the molded body as a separate tool component on the outside.
  • the heater or components thereof may also be integrated into the moldings.
  • thermoforming of steel blanks in particular of high-strength steels, is carried out in a temperature range of 900 ° C to 1250 ° C.
  • the hot forging of sheet steel plates takes place at 650 ° C to 900 ° C.
  • the warm forging of corrugated metal boards is carried out at a temperature between 150 ° C and 550 ° C depending on the material.
  • High-strength aluminum alloys of the 7xxx series or magnesium alloys only have a significant deformability at elevated temperatures, which requires tempered tools. It has been found that alloys of the 7xxx series are sufficiently ductile at higher temperatures so that they can be hot-formed in a forming tool.
  • the storage according to the invention contributes significantly to the economy and process reliability in the production of components made of high-strength aluminum alloys.
  • a temperature between 150 ° C. and 350 ° C. preferably a temperature between 200 ° C. and 300 ° C.
  • the forming tool has a heating device by means of which the temperature of the mold jaws to a temperature of 150 ° C to 350 ° C, preferably between 200 ° C and 300 ° C.
  • the metal plate is preferably made of light metal, in particular of aluminum or an aluminum alloy, preferably of a naturally hard aluminum alloy of the 5xxx series.
  • Such materials of the Al-Mg group (5xxxer) are, for example, natural-hard aluminum alloys Al-Mg3 (EN-AW 5754) or Al-Mg4.5Mn (EN-AW 5083).
  • light metal in particular aluminum or an aluminum alloy and magnesium or a magnesium alloy lightweight construction is taken into account.
  • the invention enables the production of molded parts with uninterrupted fiber flow and tight dimensional tolerances. There are high to very high degrees of deformation feasible.
  • the invention enables low forming times and avoidance of concatenated reforming reheat process steps.
  • the finished molded components have largely homogeneous mechanical properties with low residual stresses in the finished Molded component, which can lead to problems in subsequent process sections, such as a trimming. After the forming process, the mold component can be trimmed to remove excess material. It is advantageous to cool the mold component of the Endberough.
  • the moldings are arranged incorporating insulation in the upper tool part and / or lower tool part.
  • the shaping tool components or the shaped bodies are also thermally decoupled from other system components and assemblies of the forming tool. In this way, an impairment of the system components and aggregates is avoided by an inadmissible temperature effect and ensures the reliability for the operating personnel.
  • the insulation can be supported by cooling.
  • the cooling is arranged in particular on the side of the insulation facing away from the tool between the base body of the upper or lower part of the tool.
  • the active surfaces of the moldings are provided with a coating.
  • the coating is carried out by nitriding or a chemical or physical vapor deposition from the gas phase (CVD or PVD).
  • a coating in the form of a DLC (diamond like carbon) layer has at least as good wear, friction and corrosion-reducing properties.
  • the moldings consist of a tool steel, in particular of a chromium-containing special steel with additions of molybdenum and vanadium.
  • a tool steel for the moldings is used, which, based on a warm forging, in the working temperature range of 150 ° C to 400 ° C shows the lowest possible starting effect.
  • the inventive method for producing a molded component from a metal plate provides that a metal plate heated to a forming temperature and in a forming tool between a heated moldings of a Tool shell and a heated moldings of a tool lower part is formed to form the mold component. During the forming process thermal expansion of the moldings are compensated.
  • the storage gives the moldings degrees of freedom in the two-dimensional plane of the moldings.
  • the moldings are secured by the bearing against rotation.
  • the storage thus captivates the molding (s) while providing thermal expansion.
  • the storage maintains a fictitious fixed point of the molding or bodies, without hindering the thermal expansion.
  • the fictitious fixed point of the storage is ideally located near the center of gravity of the moldings.
  • the invention relates to a mold component, in particular an automobile component, which is shaped by the method according to this invention.
  • a mold component in particular an automobile component, which is shaped by the method according to this invention.
  • it is a molded component selected from the group consisting of: bumpers, door impact beams, roof rails, side rails, instrument panel beams, A, B, C or D pillars, pillar reinforcement, transmission tunnels and sills or sill reinforcements.
  • FIGS. 1 to 4 are mutually corresponding components or component components provided with the same reference numerals.
  • each forming tool 1A, 1B, 1C has a tool lower part 2 and a tool upper part 3.
  • the lower tool part 2 and the upper tool part 3 are displaceable relative to each other.
  • a heated lower mold body 4 and in the upper mold part 3 a heated upper mold body 5 is integrated. Between the lower mold body 4 and the upper mold body 5, a mold space 6 is formed.
  • the lower tool part 2 and the upper tool part 3 each have a base body 7 and 8, in which the lower mold body 4 and the upper mold body 5 is received.
  • the heater 9 is integrated into the moldings 4 and 5, respectively.
  • the surfaces of the molded bodies 4, 5 or of the heating device 9 facing the main body 7, 8 are surrounded by an insulation 10.
  • the insulation 10 contributes to the support of an isothermal transformation.
  • the insulation 10 protects adjacent system components and units of the forming tools 1A, 1B, 1C against adverse effects of temperature.
  • a cooling 11 is integrated with cooling components, which ensure the dissipation of residual heat from the heated moldings 4, 5.
  • the shaped bodies 4, 5 are segmented and are formed from individual molded body segments 12, 13, 14, 15.
  • the active surfaces of the shaped bodies 4, 5 or of the shaped body segments 12, 13, 14, 15 are provided with a coating.
  • a coating may, for example, be nitrided or be designed as a DLC layer.
  • the coating is advantageous due to the high tendency to react between the moldings 4, 5, which consist of steel, and also ensures a high surface quality of the molded components in the series.
  • a hold-down 16 is further integrated, which is associated with the lower mold body 4 and encloses this.
  • the hold-down 16 is vertically displaceable separately to the lower tool part 2 and the lower mold body 4.
  • a piston-cylinder system 17 is provided for the linear displacement.
  • FIGS. 1 . 3 and 4 each show the forming tool 1A, 1B, 1C in the open position.
  • the upper tool part 3 and the lower tool part 2 are moved relative to each other and closed.
  • guide elements 18, 19 are provided which ensure a linear movement of the upper tool part 3 and lower tool part 2 to each other.
  • the guide elements 18, 19 are formed by a rod body on the main body 7 of the tool lower part 2 and a corresponding receptacle in the main body 8 of the upper tool part 3.
  • guide elements 20, 21 are provided on the upper mold body 5 and on the lower mold body 4 or the hold-down 16, which is assigned to the lower mold body 4, via which the upper mold body 5 and the lower mold body 4 or the hold-down 16 are positionally oriented relative to each other during the forming process.
  • the guide elements 20 on the upper mold body 5 are formed by slightly conical pins which engage in the closing operation of the forming tool 1B, 1C in the guide elements 21 formed by recordings on the lower mold body 4.
  • the receptacles 21 are provided in the outer molded body segment 15, which forms part of the blank holder 16.
  • the forming tool 1A, 1B, 1C is located in the in the FIGS. 1 . 3 and 4 shown open position.
  • the hold-down 16 is located in the standby position shown, which is displaced upward in the image plane with respect to the lower mold body 4.
  • the tool upper part 3 is displaced downwards.
  • the guide elements 18, 19 come between the upper die 3 and the lower tool part 2 for engagement.
  • the guide elements 20 in the form of the pins on the upper mold body 5 move into the guide elements 21 in the form of the receptacles on the hold-down 16.
  • the hold-down 16 is fixed.
  • the inserted metal plate first comes into contact with the upper mold body 5 and is clamped between the upper mold body 5 and the hold-down 16.
  • a shaped component is formed from the metal plate in the mold space 6 between the lower mold body 4 and the upper mold body 5.
  • the moldings 4, 5 By heating the moldings 4, 5 to forming temperature, there is a thermal expansion of the moldings 4, 5.
  • the metal plate is heated to forming temperature and thereby expands.
  • At least one shaped body 4, 5 in the upper tool part 3 and / or in the lower tool part 2 is arranged in a bearing 22.
  • the bearing 22 is designed such that thermal expansions of the molded body 4 or 5 are compensated during the forming process.
  • the bearing 22 comprises, as in the FIG. 2 to recognize four bearings 23 - 26 in a cross arrangement, which are arranged offset on a pitch circle of 90 ° to each other.
  • Each bearing 23 - 26 has an expansion groove 27 and a sliding block 28.
  • the sliding block 28 is guided in the expansion groove 27.
  • the expansion groove allows the unimpeded expansion of the molding during the heating or cooling phase of the tool.
  • the sliding block 28 is fixed to the lower heat plate 29 of the heater 9, whereas the expansion groove 27 is part of a groove body 30 which is fixed to the lower cooling plate 31 of the cooling 11.
  • the sliding block 28 is set directly on the lower mold body 4.
  • the groove body 30 is disposed on the cooling plate 31 of the cooling 11 and joined.
  • the groove body can also be fixed directly to the base body 7, 8. In this case, then the cooling 11 in the main body 7, 8 is integrated.
  • thermal expansion of the moldings 4, 5 are compensated defined.
  • the movements resulting from a force introduction as a consequence of a thermal expansion of the metal plate to be formed are also compensated by the bearing 22.
  • the bearing 22 ties the shaped body 4 in the plane (x - y).
  • a rotation of the moldings 4, 5 is prevented.
  • the bearing 22 ensures that a fictitious fixed point FP of the molded body or bodies 4, 5 is maintained without the thermal expansion of the molded bodies 4, 5 being hindered.
  • the fixed point FP is close to the center of gravity of the moldings 4, 5.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Claims (10)

  1. Outil de façonnage pour fabriquer des composants moulés à partir de platines en métal, de préférence en métal léger, lequel présente une partie supérieure d'outil (3) et une partie inférieure d'outil (2), dans lequel la partie supérieure d'outil (3) et la partie inférieure d'outil (2) comprennent des corps moulés (4, 5) pouvant être chauffés et au moins un corps moulé (4, 5) est disposé dans la partie supérieure d'outil (3) et/ou dans la partie inférieure d'outil (2) dans un support (22), caractérisé en ce que le support (22) est réalisé de telle manière que des allongements thermiques du corps moulé (4, 5) sont permis lors de l'opération de chauffage, et que sont prévus, au niveau du corps moulé supérieur (5) et au niveau du corps moulé inférieur (4) et/ou au niveau d'un serre-flan (16), des éléments de guidage (20, 21), par l'intermédiaire desquels le corps moulé supérieur (5) et le corps moulé inférieur (4) et/ou le serre-flan (16) peuvent être orientés en position les uns par rapport aux autres lors de l'opération de façonnage.
  2. Outil de façonnage selon la revendication 1, caractérisé en ce que le support (24) comprend au moins trois, de préférence au moins quatre, paliers (23 - 26) décalés les uns par rapport aux autres.
  3. Outil de façonnage selon la revendication 1 ou 2, caractérisé en ce que le support (22) présente une clavette rainurée (28) guidée dans une rainure d'extension (27).
  4. Outil de façonnage selon au moins l'une quelconque des revendications 1 à 3, caractérisé en ce que le ou les corps moulés (4, 5) est/sont segmenté(s).
  5. Outil de façonnage selon au moins l'une quelconque des revendications 1 à 4, caractérisé en ce qu'est prévu un dispositif de chauffage (9) pour thermoréguler les corps moulés (4, 5) sur une température de 150 °C à 350 °C, de préférence sur une température de 200 °C à 300°C.
  6. Outil de façonnage selon au moins l'une quelconque des revendications 1 à 5, caractérisé en ce que les corps moulés (4, 5) sont disposés en intégrant une isolation (10) dans la partie supérieure d'outil (3) et/ou dans la partie inférieure d'outil (2).
  7. Outil de façonnage selon au moins l'une quelconque des revendications 1 à 6, caractérisé en ce que les surfaces actives des corps moulés (4, 5) présentent un revêtement.
  8. Outil de façonnage selon au moins l'une quelconque des revendications 1 à 7, caractérisé en ce qu'est prévu un système de refroidissement (11).
  9. Outil de façonnage selon au moins l'une quelconque des revendications 1 à 8, caractérisé en ce que les corps moulés (4, 5) sont constitués d'un acier d'outil, en particulier d'un acier spécial contenant du chrome avec des additifs de molybdène et de vanadium.
  10. Procédé pour fabriquer des composants moulés à partir d'une platine en métal, de préférence à partir d'une platine en métal léger, où la platine en métal est chauffée à une température de façonnage et est façonnée en le composant moulé dans un outil de façonnage entre un corps moulé (4, 5) chauffé d'une partie supérieure d'outil (3) et un corps moulé (4, 5) chauffé d'une partie inférieure d'outil (2), caractérisé en ce qu'un allongement thermique des corps moulés (4, 5) est permis lors de l'opération de chauffage, dans lequel des modifications de dimension des corps moulés (4, 5) sont permises à la suite de l'allongement thermique dans le cas d'une position définie des corps moulés (4, 5) dans la partie supérieure d'outil (3) et/ou la partie inférieure d'outil (2) et des éléments de guidage (20, 21) sont prévus au niveau du corps moulé supérieur (5) et au niveau du corps moulé inférieur (4) et/ou au niveau du serre-flan (16), par l'intermédiaire desquels le corps moulé supérieur (5) et le corps moulé inférieur (4) et/ou le serre-flan (16) peuvent être orientés en position les uns par rapport aux autres lors de l'opération de façonnage.
EP12176670.3A 2011-07-19 2012-07-17 Outil de formage et procédé destiné à la fabrication de pièces de formage ä partir de platines en métal Active EP2548670B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102011051943A DE102011051943A1 (de) 2011-07-19 2011-07-19 Umformwerkzeug und Verfahren zur Herstellung von Formbauteilen aus Metallplatinen

Publications (2)

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EP2548670A1 EP2548670A1 (fr) 2013-01-23
EP2548670B1 true EP2548670B1 (fr) 2018-11-07

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