EP2762244A1 - Cup shaped body and method for manufacturing the same - Google Patents

Abstract

The method involves producing a hollow body (5) by deep-drawing process. A circumferential shoulder (7) which extends between two shell sections (8, 9) in a plane is inclined to a plane, which is perpendicular to a deep-drawing direction (R) of the deep-drawing process that is performed in a shell (6) of the hollow body. The hollow body is cut along the shoulder to obtain a cup-shaped body with the flange of the cup-shaped body formed from a part of the shoulder, where the hollow body is deep-drawn in one draught from a piece of sheet metal i.e. flat pre-cut sheet metal. The deep-drawing direction during the deep-drawing process is linear deep-drawing direction. Independent claims are also included for the following: (1) a cup-shaped body (2) a cup-shaped component (3) a deep-drawing device for producing a hollow body.

Description

The invention relates to a method for producing a cup-shaped body, the edge of which has a flange and lies in a plane which is inclined to a plane perpendicular to the direction of the axial extension of the cup-shaped body level. The invention also relates to a cup-shaped, one-piece thermoformed body, a component with a housing and a thermoforming device for producing a hollow body.

The DE 10 2005 045 727 B4 discloses a deep drawing process for producing a hollow part. The two mold halves of a thermoforming machine are moved during the deep drawing process in an odd relative movement to each other. In this case, a tool half is displaced by lifting cylinders. At the resulting sheet metal component no flange is provided. Such a deep drawing process is very complex due to the complex relative movement between the mold halves and requires an exact control of the movement sequence and a structurally complex suspension of a mold half.

The JP 3 090 234 A discloses a cylindrical metal housing with a bottom. The housing is cut through, creating a sloping edge. Subsequently, the hollow body is placed in a device in which its wall is brought by means of an arcuate molding tool in an arcuate shape. The resulting hollow body has no flange.

There is a need in the art for cup-shaped bodies whose rim is formed by a flange. Such bodies are used inter alia to form parts of a housing. With their flange they bear against the flange of an opposite housing part or pipe, so that a (sealed) closed housing can be formed. One application example is the production of silencers for vehicles, eg a turbocharger silencer. Here resonator chambers are formed by a housing which seals the silencer to the outside airtight. In the area of the adjacent flanges of two cup-shaped housing parts, a reliable and airtight connection can be made.

Due to the increasing requirement of space-saving design, it is often necessary to angled components or to build around the corner. Here is e.g. a change of direction of a flow channel is no longer accomplished exclusively by passing between the individual components pipes or pipes, but a change of direction is already effected by the component itself. For this purpose, it has proven to be advantageous to configure the housing parts such that a change of direction is achieved by the special geometric shape of housing parts and their composition.

Because of these more complex geometric shapes and their manufacturing process designed complicated and requires a variety of complex processing steps or makes it inevitable that such a housing part must be composed of several pieces or can not be made in one piece.

The object of the present invention is to provide a simple method for producing a cup or cup-shaped body, which can be used in particular in vehicle technology and there in particular for mufflers. In this case, the production costs are reduced and thus the price of a component comprising a cup-shaped body can be reduced. The method should be reliable and feasible with basically known methods. With the method, it should be possible to produce high quality and accurately dimensioned workpieces without great effort.

This object is achieved by a method of the type mentioned by the steps: producing a hollow body by a deep drawing process, is formed in the shell of the hollow body, a circumferential shoulder which extends between two shell sections and lies in a plane perpendicular to the Deep drawing direction of the deep-drawing process level inclined, and cutting the hollow body along the paragraph to obtain the cup-shaped body, wherein the flange of the cup-shaped body is formed by at least a portion of the paragraph.

A great advantage of the invention is that a geometrically complex body can be produced in a simple manner and above all in one piece. The challenge (flange is not orthogonal to the draw direction and cup height is usually too high to make it in one go) was to make a cup or cup-shaped body of which Edge forms a flange and lies in a plane which is inclined to a plane perpendicular to the direction of the axial extent of the cup-shaped body level.

According to the invention, only a deep-drawing process and a severing process are required for this purpose. With the deep-drawing process, the future flange of the cup-shaped body is shaped as a shoulder in the shell of a hollow body (intermediate product). The in the shell of the hollow body forming a step and obliquely extending paragraph separates a first shell portion of smaller diameter or cross-section of a second shell portion of larger diameter or cross-section. With the cutting of the hollow body along the shoulder of the paragraph or a part thereof becomes a flange which is inclined with respect to the axis of the cup-shaped body. That jacket section, which adjoins the bottom of the hollow body, forms the wall of the cup-shaped body after the process of severing. When cutting a jacket portion is completely separated from the other shell section.

The severing can be achieved by means of a cutting tool, e.g. a mechanical saw, a punching tool or a laser cutting device, be accomplished.

The severing process may be of the type that the entire heel of the (original) hollow body forms the flange of the cup-shaped body. Alternatively, it is also conceivable that only a part or a portion of the paragraph forms the flange.

The direction of the axial extension corresponds (as seen from the point of view of the cup-shaped body) of the deep drawing direction. The axial extent corresponds to the longitudinal axis of the cup-shaped body, which corresponds to the cylinder axis in the case of a cylindrical body. This axis is also referred to as a longitudinal axis, if the axial extent is smaller than the radial dimensions of the cup-shaped body, so if e.g. the height of the cylinder is less than its diameter. Instead of a circular cross section (cylinder), the hollow body or the cup-shaped body could also have an oval or elliptical cross section.

Preferably, the deep drawing direction during the deep drawing process is straight. It thus only requires a simple linear relative movement between the punch and die one

Deep-drawing device. The longitudinal axis of the hollow body and of the resulting cup-shaped body are therefore also rectilinear.

Preferably, the hollow body is deep drawn in a single pass. With appropriate design of thermoforming tools, the number of processing steps can be kept low.

Preferably, the hollow body of a sheet metal part, preferably from a flat sheet metal blank, deep-drawn. To produce the complex geometric shape of the cup-shaped body, only a single piece of sheet metal is required. The resulting bowl is pulled out of one piece. The floor, walls and flange thus hang together in one piece.

Preferably, the plane in which the heel extends, inclined to the plane oriented perpendicular to the deep drawing direction by an angle β of at least 10 °. In the case of a housing component to be produced from two cup-shaped bodies according to the invention, this can result in a change of direction or a construction around the corner of at least 20 °. For example, To achieve a change of direction of 45 °, therefore, is an angle β of about 22.5 °

Preferably, the cup-shaped body is cylindrical, wherein the axial extent of the cylinder axis corresponds. The cross section normal to the direction of the axial extent is thus circular, resulting in a particularly advantageous ratio of volume to surface. Cylindrical hollow bodies are easy to handle and also easy to deep draw. Alternatively, shapes with an elliptical or oval cross section would also be conceivable. Even at the corners rounded rectangular cross sections are possible.

Preferably, the bottom of the cup-shaped body lies in a plane which is inclined to the plane perpendicular to the direction of the axial extent of the cup-shaped body, wherein preferably the plane in which the bottom of the cup-shaped body lies, substantially parallel to the plane which runs the flange is. By this measure, alternative forms of bowl-shaped body can be realized, which can be geometrically optimized depending on the space required. The direction of the axial extent or the longitudinal axis is in this case orthogonal neither to the ground nor to the plane of the flange.

Preferably recesses are introduced in the bottom and / or in the wall of the cup-shaped body, in particular for supply or discharge lines or resonator chamber openings (in the case of a silencer). The cup-shaped body is further processed in this way to be available for specific applications. By removing the bottom of the cup-shaped body can also be converted into a piece of pipe.

Preferably, the hollow body is deep-drawn in at least two strokes, in particular, when the height of the hollow body is equal to or greater than its diameter. As described above, the method is particularly suitable even if the hollow body can not be produced in one go, but several moves are required. This is particularly advantageous if the ratio between the height of the hollow body and its diameter reaches a critical value for the deep-drawing process.

The severing of the hollow body preferably takes place along the shoulder by means of a stamping process. The advantage is that can be cut from the hollow body here by a single and simple movement of a punching tool, the napförmige body.

Preferably, the punching operation is carried out in the same apparatus in which the deep drawing operation takes place, and the punching tool is moved during the punching operation in a direction corresponding to the deep drawing direction. The severing of the hollow body thus takes place together with the deep-drawing process in one and the same process. Due to the fact that the punching process takes place by a movement of the punching tool in the deep drawing direction, the hollow body does not have to be substantially repositioned after the deep drawing process. He remains in the thermoforming device and is cut through in this, so that as a finished product, the cup-shaped body can be removed directly from the thermoforming device or falls out of this.

The object of the invention is also achieved with a cup-shaped, one-piece deep-drawn body, the edge of which is formed by a flange and lies in a plane which is inclined to a plane perpendicular to the direction of the axial extent of the cup-shaped body. The cup-shaped body integrally comprises bottom, wall and flange. It is sufficient a single piece of sheet metal, from which the cup-shaped body according to the invention is formed.

Preferably, the cup-shaped body is cylindrical, wherein the direction corresponds to the axial extent of the cylinder axis. The cross section normal to the direction of the axial extent is thus circular, resulting in a particularly advantageous ratio of volume to surface. Cylindrical hollow bodies are easy to handle and also easy to deep draw.

Preferably, the bottom of the cup-shaped body lies in a plane which is inclined to the plane perpendicular to the direction of the axial extent of the cup-shaped body, wherein preferably the plane in which the bottom of the cup-shaped body lies, substantially parallel to the plane which runs the flange is.

The cup-shaped body is preferably produced according to one of the embodiments described above for the manufacturing process.

The object is also achieved with a component, in particular a silencer, which has a housing, wherein the housing is formed by at least one cup-shaped body according to one of the embodiments described above.

Preferably, the housing comprises at least two cup-shaped bodies, which lie with their flanges against each other, wherein the directions of the axial extensions or longitudinal axes of the cup-shaped body are inclined to each other. As a result, a flanged connection mediated by the flanges can be used with simultaneous directional change, e.g. a flow channel (e.g., for compressed air or exhaust gases).

The object is also achieved with a deep-drawing device for producing a hollow body by a deep-drawing process along a deep drawing direction, with a punch and a die, wherein on the outer wall of the punch and on the outer wall of the die in each case a circumferential step is formed, which in a plane which is inclined to a direction perpendicular to the deep drawing direction of the deep-drawing process plane.

Preferably, the deep drawing of the thermoforming device is rectilinear, whereby a simple linear movement between the punch and die is sufficient.

Preferably, the deep-drawing device comprises a punching tool, which is movable in the deep drawing direction for performing a punching operation, whereby the method steps can be carried out in a single device.

For a better understanding of the invention, this will be explained in more detail with reference to the following figures.

Fig. 1

einen Hohlkörper, aus dem der napfförmige Körper geschnitten werden kann;

Fig. 2

die Herstellung eines Hohlkörpers in einer Tiefziehvorrichtung;

Fig. 3

die Tiefziehvorrichtung aus Fig. 2 mit in die Matrize geschobenem Stempel;

Fig. 4

das Durchtrennen des Hohlkörpers entlang des Absatzes mit einem Schneidwerkzeug;

Fig. 5

den Hohlkörper nach der Durchtrennung;

Fig. 6

den erfindungsgemäßen napfförmigen Körper;

Fig. 7

einen erfindungsgemäßen Bauteil, dessen Gehäuse aus zwei napfförmigen Körpern zusammengesetzt ist;

Fig. 8

eine Ausführungsform des erfindungsgemäßen Verfahrens;

Fig. 9

eine Ausführungsform eines erfindungsgemäßen napfförmigen Körpers;

Fig. 10

eine Tiefziehvorrichtung mit einem Stanzwerkzeug.

Each shows in a highly schematically simplified representation:

Fig. 1

a hollow body from which the cup-shaped body can be cut;

Fig. 2

the production of a hollow body in a thermoforming device;

Fig. 3

the thermoforming device Fig. 2 with stamp pushed into the die;

Fig. 4

the cutting of the hollow body along the shoulder with a cutting tool;

Fig. 5

the hollow body after transection;

Fig. 6

the cup-shaped body according to the invention;

Fig. 7

a component according to the invention, whose housing is composed of two cup-shaped bodies;

Fig. 8

an embodiment of the method according to the invention;

Fig. 9

an embodiment of a cup-shaped body according to the invention;

Fig. 10

a thermoforming device with a punching tool.

By way of introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component names, wherein the disclosures contained in the entire description can be mutatis mutandis to the same parts with the same reference numerals or component names. Also, the location information chosen in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and are to be transferred to the new situation mutatis mutandis when a change in position. Furthermore, individual features or combinations of features from the different exemplary embodiments shown and described can also represent independent, inventive or inventive solutions.

The embodiments show possible embodiments of the invention, it being noted at this point that the invention is not limited to the specifically illustrated embodiments thereof, but rather various combinations of the individual embodiments are possible with each other and this possibility of variation due to the teaching of technical action by representational Invention in the skill of those skilled in this technical field. So are all conceivable embodiments, which are possible by combinations of individual details of the illustrated and described embodiments, of the scope of protection.

Fig. 1 shows a hollow body 5 as an intermediate in the manufacture of a cup-shaped body 1 as in Fig. 5 and 6 is shown. The hollow body 5 is produced by a deep-drawing process in a deep-drawing device. In this case, a circumferential shoulder 7 is formed in the resulting shell 6 of the hollow body 5. This extends between a first casing section 8 and a second casing section 9 and lies substantially in a plane which is inclined to a plane F perpendicular to the deep-drawing direction R of the deep-drawing process ( Fig. 4 ).

The first jacket section 8 adjoining the bottom 10 of the hollow body 5 has a smaller diameter or cross section than the second jacket section 9 facing away from the bottom 10. The shoulder 7 forms an inclined step in the jacket 6.

FIGS. 2 and 3 show in schematic representations the deep drawing process, are moved in the punch 13 and die 14 of a thermoforming device 15 relative to each other from a flat sheet metal part 4 (in particular steel sheet, preferably stainless steel sheet) according to the hollow body 5 Fig. 1 to shape. To form the peripheral shoulder 7 in the shell of the hollow body 5, the punch 13 has an upper punch portion 13a with a larger diameter or cross section and a lower punch portion 13b with a smaller diameter or cross section. The stamp portions 13a, 13b are separated by a circumferential step 13c forming a step. Correspondingly, the die 14 has an upper die portion 14a with a larger diameter or cross section and a lower die portion 14b with a smaller diameter or cross section. The die sections 14a, 14b are separated from each other by a peripheral step 14c forming a step.

The circumferential paragraphs 13c, 14c extend substantially in a plane which is inclined to a direction perpendicular to the thermoforming direction R of the thermoforming device 15 oriented plane F (preferably at an angle of at least 10 ° and depending on the desired dimensioning of the cup to be produced). The preferred thermoforming direction R is rectilinear or linear.

It is preferred if the hollow body 5 (from a flat piece of sheet metal, in particular stainless steel sheet) is deep drawn in a single pass.

The hollow body 5, the cup-shaped body 1 and the corresponding thermoforming tools (punch 13 and die 14) are preferably cylindrical. In this case, the direction of the axial extent coincides with that of the cylinder axis or is parallel to it.

Fig. 4 now shows the subsequent step of severing the hollow body 5 along the paragraph 7 to obtain the cup-shaped body 1. Here, an inventive, one-piece deep-drawn cup-shaped body 1, the edge 2 has a flange 3 and extends substantially in a plane E, which leads to a perpendicular to the direction of the axial extent L of the cup-shaped body 1 standing plane F is inclined.

Such a body is in Fig. 5 and 6 shown, wherein now the first shell portion 8 of the hollow body 5, the wall 11 of the cup-shaped body 1 forms.

The plane E, in which the paragraph 7 is located, is inclined to the perpendicular to the deep drawing direction R aligned plane F by an angle β of at least 10 °. In the in Fig. 6 illustrated embodiment, this angle is about 22.5 °.

In further processing steps 1 recesses can be introduced in the bottom 10 and / or in the wall 11 of the cup-shaped body, in particular for supply or discharge lines or resonator chamber openings (in the case of a muffler). This can be similar to the severing of the hollow body 5 by means of a cutting tool 16 (FIG. Fig. 4 ), preferably by means of a laser processing tool.

Fig. 7 shows schematically and without inlets and outlets a component 12 according to the invention (for example in the form of a muffler) with a housing, which is composed of two cup-shaped bodies 1 according to the invention, which lie with their flanges 3 together. The directions of the axial extensions L and longitudinal axes of the cup-shaped body 1 are inclined to each other, whereby a running along the axis L flow channel undergoes a change of direction. In the present case, the flange 3 of a respective body 1 is inclined by 22.5 °, so that in the component 12, a kink of 45 ° results, ie two cups together result in a chamber with 45 ° -Knick.

The 8 and 9 show an embodiment of the invention, wherein the bottom 10 of the cup-shaped body 1 lies in a plane which is inclined to the plane F perpendicular to the direction of the axial extent L of the cup-shaped body 1. In this particular embodiment, the plane in which the bottom 10 of the cup-shaped body 1 is located, is substantially parallel to the plane E, in which the flange 2 extends. One from such bodies 1 analogous to Fig. 7 Composite component is highly compact and compact.

Fig. 10 Finally, as a preferred embodiment, the deep-drawing device 15 from the FIGS. 2 and 3 additionally with a punching tool 17 integrated in the deep-drawing device 15, which is movable in the deep-drawing direction R for carrying out a punching operation and on its oblique bottom has a circumferential cutting edge. The stamp 13 is now in a waiting position. The advantage of this embodiment is that deep-drawing process and cutting are carried out in one and the same device, whereby the manufacturing process can be streamlined in terms of time and in terms of the required effort and thus made less expensive.

REFERENCE NUMBERS

1

Cup-shaped body

2

edge

3

flange

4

sheet metal part

5

hollow body

6

coat

7

paragraph

8th

First coat section

9

Second jacket section

10

ground

11

wall

12

component

13

stamp

13a

upper stamp section

13b

lower stamp section

13c

paragraph

14

die

14a

upper die section

14b

lower die section

14c

paragraph

15

Deep-drawing device

16

cutting tool

17

punching tool

L

axial extent

R

Thermoforming direction

e

level

F

level

β

angle

Claims (19)

Method for producing a cup-shaped body (1), the edge (2) of which has a flange (3) and extends in a plane (E) perpendicular to the direction of the axial extent (L) of the cup-shaped body (1) (F) is inclined, characterized by the steps: - Producing a hollow body (5) by a deep-drawing process, through which in the shell (6) of the hollow body (5) a circumferential shoulder (7) is formed, which extends between two shell sections (8, 9) substantially in a plane which a perpendicular to the deep drawing direction (R) of the deep-drawing process plane (F) is inclined, and - Cutting the hollow body (5) along the shoulder (7) to obtain the cup-shaped body (1), wherein the flange (2) of the cup-shaped body (1) by at least a portion of the shoulder (7) is formed. A method according to claim 1, characterized in that the deep drawing direction (R) during the deep drawing process is rectilinear. A method according to claim 1 or 2, characterized in that the hollow body (5) is deep-drawn in a single pass. Method according to one of claims 1 to 3, characterized in that the hollow body (5) from a sheet metal part (4), preferably from a flat sheet metal blank, is deep-drawn. Method according to one of claims 1 to 4, characterized in that the plane (E) in which the shoulder (7) lies, to the perpendicular to the deep drawing direction (R) aligned plane (F) by an angle (β) of at least 10th ° is inclined. Method according to one of claims 1 to 5, characterized in that the cup-shaped body (1) is cylindrical, wherein the axial extent (L) corresponds to the cylinder axis. Method according to one of claims 1 to 6, characterized in that the bottom (10) of the cup-shaped body (1) lies in a plane which is perpendicular to the direction of the axial extent (L) of the cup-shaped body (1) plane ( F), wherein preferably the plane in which the bottom (10) of the cup-shaped body (1) lies is substantially parallel to the plane (E) in which the flange (2) extends. Method according to one of claims 1 to 7, characterized in that in the bottom (10) and / or in the wall (11) of the cup-shaped body (1) recesses are introduced, in particular for supply or discharge lines or resonator chamber openings. Method according to one of claims 1 to 8, characterized in that the hollow body (5) is deep-drawn in at least two strokes, in particular, when the height of the hollow body (5) is equal to or greater than its diameter. Method according to one of claims 1 to 9, characterized in that the severing of the hollow body (5) along the shoulder (7) by a punching operation. A method according to claim 10, characterized in that the punching operation is carried out in the same device in which the deep drawing operation takes place, and that the punching tool (17) is moved during the punching process in a direction corresponding to the deep drawing direction (R). Cup-shaped, one piece, in particular a piece of sheet metal deep drawn body (1), the edge (2) by a flange (3) is formed and in a plane (E) which is perpendicular to the direction of the axial extent (L) of the cup-shaped body (1) is inclined plane (F). Cup-shaped body according to claim 12, characterized in that the cup-shaped body (1) is cylindrical, wherein the axial extent (L) corresponds to the cylinder axis. Cup-shaped body according to claim 12 or 13, characterized in that the bottom (10) of the cup-shaped body (1) lies in a plane which is perpendicular to the direction of the axial extent (L) of the cup-shaped body (1) plane (F ), wherein preferably the plane in which the bottom (10) of the cup-shaped body (1) lies is substantially parallel to the plane (E) in which the flange (2) extends. Component with a housing, in particular silencer, characterized in that the housing is formed by at least one cup-shaped body (1) according to one of claims 12 to 14. Component according to claim 15, characterized in that the housing comprises at least two cup-shaped body (1) which lie with their flanges (3) to each other, wherein the directions of the axial extensions (L) of the cup-shaped body (1) are inclined to each other. Deep-drawing device (15) for producing a hollow body (5) by a deep drawing process along a deep drawing direction (R), with a punch (13) and a die (14), characterized in that on the outer wall of the punch (13) and on the outer wall the die (14) is formed in each case a circumferential shoulder (13c, 14c) which lies in a plane which is inclined to a plane (F) oriented perpendicular to the deep-drawing direction (R) of the deep-drawing process. Deep-drawing device according to claim 17, characterized in that the deep-drawing direction (R) of the deep-drawing device (15) is rectilinear. Deep-drawing device according to claim 17 or 18, characterized in that the deep-drawing device (15) comprises a punching tool (17) which is movable to carry out a punching operation in a direction corresponding to the deep-drawing direction (R).

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