EP2871005B1 - Forming device for the plastic deformation of a component and method for forming a component - Google Patents

Description

The invention relates to a forming device for plastic deformation of a component, in particular a sheet metal component according to the preamble of claim 1. Furthermore, the invention relates to a method for forming a component, using the inventive unforming device. When forming components, in particular of metallic semi-finished products or sheet metal components, it is known to use, depending on the type of forming process, for example, swivel bending machines or pressing machines for the plastic deformation of the respective components. Depending on the material properties, such as the modulus of elasticity or the hardness of the respective component this can be subjected depending on the nature of the forming process of a pressure, tensile, shear, or bending, in particular, formed from a metal components for the same said forming process are particularly suitable. Depending on the application, for example, steel, aluminum, copper or alloys such as brass can be used as materials for the provided for the forming process component. In addition to the metallic materials and other materials, such as plastics can be transformed.

It often happens during bending, or when bending of components with relatively long bending or bending lines to angular deviations of the bending angle over the length of the bending line. As a result of high contact forces respective bending means, such as an upper part or a lower part of a forming bending bending machine forming device when bending a component itself are slightly bent when the component is deformed under a relative movement between the lower part and the upper part of the forming device. As a result of such bending, the bending angle along the longitudinal extension of the bent, or folded component is not constant. Depending on the manufacturing tolerance, this can lead to increased rejects being produced during component forming or at least the reshaped components have to be reworked at great expense. Such post-processing or production of rejects is particularly disadvantageous in industrial production in terms of additional time and expense. Accordingly, the production of formed or bent components with particularly high tolerance requirements is possible only with considerable effort or even technically unrealizable.

From the DE 10 2005 018 866 B3 is a generic device for bending or folding of an object, in particular a formed as a sheet metal part, known, which has means for clamping the object to be processed and a movable bending device. The local means comprise a trained as a top beam upper part, a lower part and a movable bending cheek of the bending device. The movable bending cheek is formed in two parts, wherein the two parts of the bending cheek are connected to each other by means of respective, designed as screws or bolts coupling elements and movable relative to each other. As a result of the relative movement of the two parts relative to one another, a warping of a bending rail designed as a crowning element can be set, wherein the bending rail is arranged on one of the two parts. The warping of the bending rail to compensate for any unwanted angular deviations on the component is now present in that due to the relative movement of the two parts to each other, the part on which the bending rail is arranged, is warped and thereby the bending rail is subjected to this warping. A component to be deformed is then inserted between the upper part and the bending rail of the lower part and deformed under a relative movement between the upper part and the lower part, or bent. As a result of the warping of the local bending rail due to the relative movement of the two parts of a possible angular deviation of the bending angle over the length of the bending line of the component to be formed can be counteracted particularly effective. In order to realize the most desired warping of the bending bar, the two parts of the bending cheek are made with high manufacturing costs particularly precise and matched exactly by means of the respective coupling elements.

From the EP 2 127 772 A2 a forming machine is known, which comprises a tool frame on both sides held and relatively movable tool carrier with a tool holder in a positionally variable recorded tool.

The tool carrier is equipped over its length with a plurality of actuating elements which act on the tool from a side facing away from the workpiece. Each actuating element in this case comprises a hydraulic cylinder, wherein the hydraulic cylinders are hydraulically connected to each other such that during a forming process, a substantially uniform contact pressure on a workpiece is set along the tool.

The EP 0 934 131 B1 discloses a bending machine for flat material, with a machine frame, on which a lower cheek with lower cheek tool and a top cheek with Oberwangenwerkzeug is arranged. The upper and lower cheeks are movable relative to each other for fixing and bending the sheet. The bending machine also includes a bending cheek having a be equipped with a bending beam tool Biegegewangenwerkzeugaufnahme and which is held about a rotation axis pivotally mounted on the machine frame. The bending cheek tool holder is provided with an adjustable crowning device which, viewed in the bending direction, supports one foot of the bending beam tool only in one subarea, so that the foot bears on a rear abutment surface of the bending cheek tool holder when bending forces occur.

It is an object of the invention to provide a forming device for plastic deformation of a component, in particular a sheet metal component, which is inexpensive to manufacture and safely prevents unwanted deviations during forming of the component. Furthermore, it is an object of the present invention to provide a corresponding method for forming a component.

This object is achieved by a forming device having the features of patent claim 1 and by a method for forming a component having the features of patent claim 8. Advantageous embodiments with expedient developments of the invention are specified in the dependent claims.

In the forming device according to the invention, the bending rail has a slot which spaces the first region from the second region over at least a substantial portion of a longitudinal extension of the bending rail and the bending rail comprises at least one recess between the first region and the second region in which the deformation component is arranged is.

Based on the deformation component, the bending rail is elastically deformable in itself, wherein at least the first region can be arched and additionally or alternatively, the second region is subjected to a curvature. By using a plurality of deformation components at different locations of the bending rail, a higher degree of freedom is created in the warping of the first region of the bending rail and thus its edge. Thereby also any angular deviations of a bending angle can be compensated, if e.g. the bending of the upper part of the forming device - for example, as a result of asymmetric stiffening struts or material accumulations or material inhomogeneities of the upper or lower part of the forming device or the component - takes place off-center during forming. By using a plurality of the deformation components, therefore, the edge of the first region of the bending rail could not only be concave or convex, but also, for example, wave-shaped elastically deformed in order to compensate for corresponding deviations.

Unlike the prior art, therefore, the bending rail, characterized in that it comprises at least one deformation component and thus in itself is partially elastically deformable, formed as a so-called barbed bending rail. If the component to be formed is designed, for example, as a metal sheet, a respective different springback behavior of the bent metal sheet over the entire working width of the shaping device or the length of the bending rail can be compensated by means of the bightable bending rail. Since it is a particularly inexpensive and easy to manufacture component of the forming device in the bending rail, a particularly economical way is also created to compensate for deviations along the bending line.

Through the slot in the bending bar an inhomogeneity with respect to their strength and rigidity is specifically created in this and implemented by means of the deformation components deformation of the bending rail particularly effective in the form of a warping of the edge. On the one hand, in this context, it is conceivable to widen the slot at least in regions by means of the deformation component and thereby to effect a deformation of the first region relative to the second region. On the other hand, it is also possible by means of the slot to use the second region only as a tensile force or compressive force transmitting element which is fixed to the lower part over its length such that the second region itself is not elastically bent, but only stretched or is compressed. The slot is then widened in some areas. Such a deformation of the bending rail or its edge can accordingly take place particularly effectively if the first region and the second region of the bending rail are connected together at their two ends corresponding to the longitudinal extension and thus the slot extends over a substantial region of the bending rail.

By arranging the deformation components in the recess, the bending rail can be made particularly compact. By such an arrangement, the bending rail can also be designed to save space. By a corresponding contouring of the recess, the elastic deformability of the bending rail can be influenced. If the recess is generously dimensioned and correspondingly much material is removed from the bending rail, the distance between the edge of the recess and the edge of the bending rail is reduced. Thus, a greater deformation of the bending rail can be made possible, or less force is required for a deformation of the bending rail. If, on the other hand, the recess is dimensioned to be particularly small, more material remains in the area between the edge and the recess on the bending rail, which makes it particularly stiff and resistant to a force acting on the component side when it is deformed. Thus, an efficient and economical way is created in a particularly simple manner to buckle the edge of the bending rail according to the respective requirements.

As a further advantage, it has been shown that the deformation component comprises a first component and a second component, which are movable relative to each other. By using the first component and the second components, any undesired plastic deformations on the bending rail can be prevented in a particularly effective manner, in particular if the first component and the second component are designed as pressure-distributing shell elements. The first component and the second component are moved apart by applying a pressure, thereby causing the deformation of the bending rail. The pressure exerted by the deformation component and the bending rail partially elastically deforming pressure is then distributed by the first component and the second component particularly evenly on the bending rail, whereby elastic deformation of the bending rail due to impermissibly high pressure peaks can be particularly effectively prevented.

This applies in particular if, according to a further advantageous embodiment, the first component and the second component of the deformation component are movable relative to one another by means of an eccentric part. By rotating the eccentric part, which is arranged between the first component and the second component, the deformation component is infinitely adjustable and, accordingly, the elastic deformation of the bending rail can be adjusted particularly precisely. Depending on an eccentricity of the eccentric part, the first and second components can be moved relative to each other by exerting a particularly high deformation force or by traversing a particularly large deformation path.

It is furthermore advantageous if the first region and / or the second region of the bending rail is movable as a function of the relative movement between the first component and the second component of the deformation component. An elastic deformation of the bending bar is correspondingly particularly intuitive by the forming device operating personnel possible if associated with a relative movement of the first component to the second components of the deformation component and an elastic deformation of the bending bar. This applies in particular when, with an increase in the distance between the first component and the second component, a greater elastic deformation of the bending rail takes place, whereby ergonomically speaking, a particularly intuitive operation of the forming device is made possible.

In a further advantageous embodiment of the invention, the bending rail is integrally formed. Since the production costs, in particular of precision components increase with the number of individual components of which the respective component is composed, a one-piece design of the bending rail is particularly resource-friendly.

Preferably, the bending rail comprises respective cover plates for guided relative movement between the first and the second region. By means of such cover plates can be particularly efficient prevented any lateral bending of the first region relative to the second region or vice versa. In other words, by means of the cover plates, therefore, a particularly exact movement, which essentially extends in one plane, can be realized between the first region and the second region. A warping of the bending rail in an undesired spatial direction is accordingly particularly effectively prevented. Finally, it is advantageous if the forming device is designed as a folding machine. Swivel bending machines are particularly suitable for reshaping components which are designed as metal sheets with large thicknesses with great precision. The bending bar can be adapted to the rigidity of the pivoting bending machine with particularly little effort and, accordingly, can compensate deviations of a long bending line particularly effectively.

In the method according to the invention for forming a component by means of a forming device comprising a top part and a bottom part, in which the component is fixed between the upper part and a bending rail assigned to the lower part and deformed under a relative movement between the lower part and the upper part of the shaping device, an adjustment takes place respective predefined deformation parameters by means of at least one deformation component. By means of the deformation component at least one of the component facing and at least partially an edge forming first region of a first region and a second region having bending rail is elastically deformed at least partially. The forming of the component takes place under the relative movement between the lower part and the upper part of the shaping device by exerting a deformation force by the intermediary of the bending rail. Such a method ensures a particularly accurate and simple deformation of the component. Predefined, that is to say desired deformation parameters can therefore be set particularly precisely. For carrying out the method, a forming device according to the invention is used.

In an advantageous embodiment of the invention, the bending rail is elastically deformed in dependence of respective geometry sizes of the component by means of the deformation component. Such geometry sizes include, for example, the length, the width or the depth at the location of the component at which the transformation is to take place. The deformation of the component, or the suitability of the component for a slight or substantial deformation thus depends on such dimensions, for example, the depth, so the material thickness of the component influences the maximum possible bending radius or the bending angle. If the component to be formed extends only over a short region of the longitudinal extent of the bending rail, then the clamping means, ie the upper part and, additionally or alternatively, the lower part of the shaping device, are subjected to particularly high local stress locally and, if necessary, during the component deformation itself elastically deformed. This can be effectively compensated by the crowning, so the elastic deformation of the bending rail.

Finally, it is advantageous if the bending bar is elastically deformed by means of the deformation component as a function of respective parameters relating to the strength of the component. The strength of the component includes in particular material properties that influence the forming process. Such material properties include, for example, the modulus of elasticity or notched impact strength of the component. Further parameters which relate to the strength of the component are, for example, the concentration of alloy constituents or a possible hardening process to which the component has been subjected or a specific hardening depth which was previously selected in the corresponding hardening process of the component to be formed.

The advantages and preferred embodiments described for the forming device according to the invention also apply to the method according to the invention and vice versa. For carrying out the method according to the invention, the device according to the invention can be used.

Further advantages, features and details of the invention will become apparent from the claims, the following description of preferred embodiments and from the drawings.

Fig. 1a

eine Vorderansicht einer als Schwenkbiegemaschine ausgebildeten Umformvorrichtung, welche ein Oberteil sowie ein eine bombierbare Biegeschiene umfassendes Unterteil umfasst;

Fig. 1b

eine Schnittansicht der in Fig. 1 a gezeigten Umformvorrichtung entsprechend einer in Fig. 1 a gekennzeichneten Schnittlinie F-F;

Fig. 2a

eine Draufsicht auf die Biegeschiene der Umformvorrichtung;

Fig. 2b

eine Vorderansicht auf die Biegeschiene der Umformvorrichtung;

Fig. 2c

eine Seitenansicht auf die Biegeschiene der Umformvorrichtung;

Fig. 2d

eine Detailansicht eines in Fig. 2 mit D gekennzeichneten Ausschnitts, welcher ein Abdeckblech zeigt, mittels welchem ein erster Bereich und ein zweiter Bereich der Biegeschiene geführt werden;

Fig. 2e

eine vergrößerte Vorderansicht einer Verformungskomponente der Biegeschiene, wobei die Verformungskomponente vorliegend ein als Exzenterwelle ausgebildetes Exzenterteil umfasst, mittels welchem eine ersten Komponente und eine zweiten Komponente der Verformungskomponente relativ zu einander verstellbar sind; und in

Fig. 2f

eine vergrößerte Vorderansicht auf die Verformungskomponente, deren erste Komponente und zweite Komponente in Folge einer Verdrehung des Exzenterteils voneinander beabstandet werden.

Show it:

Fig. 1a

a front view of a formed as a bending machine forming device comprising an upper part and a bombable bending rail comprehensive base;

Fig. 1b

a sectional view of in Fig. 1 a shown forming device according to a in Fig. 1 a marked section line FF;

Fig. 2a

a plan view of the bending rail of the forming device;

Fig. 2b

a front view of the bending rail of the forming device;

Fig. 2c

a side view of the bending rail of the forming device;

Fig. 2d

a detailed view of an in Fig. 2 D section marked D, which shows a cover plate, by means of which a first region and a second region of the bending rail are guided;

Fig. 2e

an enlarged front view of a deformation component of the bending rail, wherein the deformation component in the present case comprises an eccentric shaft designed as an eccentric shaft, by means of which a first component and a second component of the deformation component are adjustable relative to each other; and in

Fig. 2f

an enlarged front view of the deformation component, the first component and second component due to a rotation of the eccentric are spaced apart.

Fig. 1 a shows a front view of a forming device 1 designed as a folding machine, which comprises a top part 3 designed as a top beam and a bottom part 4. On the lower part 4, a bending rail 6 is arranged, wherein - as from a in Fig. 1b illustrated sectional view according to a section line FF Fig. 1 a - it can be seen that a reshaping component 2, which is presently designed as a metal sheet, between the upper part 3 and the bending rail 6 of the lower part 4 is fixed. In order to bend the component 2 as part of a plastic deformation, in the present case the lower part 4, as well as the bending rail 6 arranged on the lower part 4 are pivoted so far relative to the upper part 3 in accordance with a relative movement 5 marked with a double arrow, until the component has been bent in accordance with the desired bending angle or Bend radius bent and accordingly plastically deformed.

Fig. 2a shows a plan view and Fig. 2b a front view of the bending rail 6. The bending rail 6 has a longitudinal extent 12 of length L and, as in a side view of the bending rail 6 in Fig. 2c is recognizable, a width B and a depth T on. The bending rail 6 has an at least partially an edge 7 forming first region 8 and a second region 9, wherein the bending rail 6 is arranged in the forming device 1 such that the first region 8 faces the component to be formed 2, and accordingly the edge 7th rests against the component 2. The bending rail 6 further comprises in the present case a plurality of deformation components 10, by means of which the first region 8 is at least partially elastically deformable. The bending rail 6 likewise has a slot 11 which spaces the first area 8 from the second area 9 at least over a substantial area of the longitudinal extension 12 of the bending rail 6. In other words, therefore, the slot 11 of the bending rail 6 extends over a large part of the length L of the bending rail 6. The deformation components 10 are arranged in respective recesses 13 of the bending rail, wherein the recesses 13 are surrounded by the first region 8 and the second region 9 , In the present case, the recesses 13 are thus arranged between the first region 8 and the second region 9.

Fig. 2d shows an enlarged view of an in Fig. 2b with D marked section, it being understood that the bending rail 6 includes respective cover plates 19. The Cover plates 19 serve to stabilize the bending rail 6 and allow elastic deformation by means of the respective deformation components 10 such that, although the width B (FIG. Fig. 2c ) of the bending rail 6 along its longitudinal extension 12 and thus along its length L can change, but a lateral warping between the first region 8 and the second region 9 is effectively prevented. In other words, allow the respective cover plates 19 which are distributed along the bending rail 6, although a change in the width B over the length L of the bending rail 6, but prevent a change in the depth T and thus a lateral curvature between the first region 8 and second area 9 in the elastic deformation of the bending rail 6 by means of the deformation components 10. In order to allow a guided relative movement between the first region 8 and the second region 9, cover the respective cover plates 19, both the first region 8, and the second region 9 at least regionally. Since this also the slot 11 is covered by the respective cover plates 19, a secure guide is also in the at least partially elastic deformation of the bending rail 6, in which it can also come to a region-wise enlargement of the slot 11 allows. In order to fix the cover plates 19 particularly securely on the bending rail 6, they are presently screwed to the bending rail 6 by means of respective screws 20, which are designed as countersunk screws. The screws 20 are presently extending parallel to the longitudinal extent 12 and arranged on opposite sides of the respective cover plate 19.

As in particular from Fig. 2b It can be seen, the bending rail 6 is present in one piece and accordingly made particularly resource-friendly.

Fig. 2e and Fig. 2f each show an enlarged front view of the deformation component 10, wherein Fig. 2e shows a position of the deformation component 10, in which no deformation of the bending rail 6 takes place and Fig. 2f a position in which at least partially an elastic deformation of the bending rail 6 takes place. In the Fig. 2e and Fig. 2f It is shown that the deformation component 10 comprises a first component 14 and a second component 15, wherein the first component 14 and the second component 15 are formed as respective eccentric bearing shells and movable relative to each other. Between the first component 14 and the second component 15, an eccentric part 16 designed as an eccentric shaft is arranged, which has an eccentricity 17. In Fig. 2e In the present case, the eccentricity 17 runs parallel to the longitudinal extension 12 or to the slot 11 of the bending rail 6, whereby a gap 18, which is formed between the first component 14 and the second component 15, has a minimum value and, accordingly, a height of the respective deformation component 10, which by the first component 14, the second component 15 and the eccentric 16 is formed having the value h. The extension of the height with the value h in Fig. 2e extends in the same direction as the width B of the bending bar 6 and thus substantially perpendicular to the longitudinal extent 12. The eccentric 16 is rotatably mounted by means of tool engagement in an eccentric to a rotational axis 23 of the eccentric 16 and in the present case designed as a hexagon fixation opening 22 about the rotation axis 23. Will now, as in Fig. 2f As shown, the eccentric member 16 between the first component 14 and the second component 15 corresponding to a rotation indicated by an arrow 21 about the rotation axis 23 and thus relative to the first component 14 and the second component 15 is rotated, a deformation force on the first component 14 and on the second component 15, whereby the gap 18 and, accordingly, the height increases from the value h to h '. In other words, therefore, the first component 14 and the second component 15 of the deformation component 10 by means of the eccentric member 16 relative to each other movable. Since the respective deformation components 10 are arranged along the longitudinal extension 12 of the bending rail 6, the deformation force and thus also the height change of the deformation component 10 is transferred from the value h to the value h 'on the bending rail 6. As a result, the bending rail 6 is deformed elastically at least in some areas, specifically at those regions of the bending rail 6 in which a change in the height of the deformation component 10 takes place. In other words, the first region 8 and, additionally or alternatively, the second region 9 of the bending rail 6 as a function of the relative movement between the first component 14 and the second component 15 of the deformation component 10 movable.

It is clear that, alternatively, the first component 14 and the second component 15 could be dispensed with and the eccentric part 16 could abut directly on the first region 8 and additionally or alternatively on the second region 9. In other words, the eccentric part 16 would then be in direct contact with the first region 8 and the second region 9 of the bending rail 6. By turning the eccentric part 16, the slot 11 and, consequently, the first area 8 of the bending bar 6 or its edge 7 would then buckle directly due to its eccentricity 17.

Claims (10)

1. Forming device (1) for plastically deforming a structural element (2), in particular a sheet metal structural element, which is fixable between a top part (3) and a bottom part (4) comprising a bending rail (6) of the forming device (1) and is deformable by a relative movement (5) between the bottom part (4) and the top part (3) of the forming device (1), wherein the bending rail (6) includes at least a first area (8) facing the structural element (2) and forming an edge (7) at least in certain areas as well as a second area (9) and in addition at least one deforming component (10), by means of which at least the first area (8) is elastically deformable at least in certain areas,
   characterized in that
   the bending rail (6) has a slit (11), which spaces the first area (8) from the second area (9) at least over a substantial area of a longitudinal extension (12) of the bending rail (6), and the bending rail (6) includes at least one recess (13) between the first area (8) and the second area (9), in which the deforming component (10) is disposed.
2. Forming device (1) according to claim 1,
   characterized in that
   the deforming component (10) includes a first component (14) and a second component (15), which are movable relatively to each other.
3. Forming device (1) according to claim 2,
   characterized in that
   the first component (14) and the second component (15) of the deforming component (10) are movable relatively to each other by means of an eccentric part (16).
4. Forming device (1) according to any one of claims 2 or 3,
   characterized in that
   the first area (8) and/or the second area (9) of the bending rail (6) are movable depending on the relative movement between the first component (14) and the second component (15) of the deforming component (10).
5. Forming device (1) according to any one of the preceding claims,
   characterized in that
   the bending rail (6) is integrally formed.
6. Forming device (1) according to any one of the preceding claims,
   characterized in that
   the bending rail (6) includes respective cover sheets (19) for guided relative movement between the first area (8) and the second area (9).
7. Forming device (1) according to any one of the preceding claims,
   characterized in that
   the forming device (1) is formed as a swing-bending machine.
8. Method for forming a structural element (2) by means of a forming device (1) comprising a top part (3) and a bottom part (4), in which the structural element (2) is fixed between the top part (3) and a bending rail (6) associated with the bottom part (4) and is deformed by a relative movement (5) between the bottom part (4) and the top part (3) of the forming device (1),
   characterized by the following steps:

   - adjusting respective predefined deforming parameters by means of at least one deforming component (10), by means of which at least a first area (8) facing the structural element (2) and forming an edge (7) at least in certain areas of a bending rail (6) having the first area (8) as well as a second area (9) is elastically deformed at least in certain areas; and

   - forming the structural element (2) by the relative movement (5) between the bottom part (4) and the top part (3) of the forming device (1) by exerting a deforming force with intervention of the bending rail (6), wherein

   - for performing the method, a forming device (1) according to any one of claims 1 to 7 is used.
9. Method according to claim 8,
   characterized in that
   the bending rail (6) is elastically deformed by means of the deforming component (10) depending on respective geometric variables of the structural element (2).
10. Method according to claim 8,
    characterized in that
    the bending rail (6) is elastically deformed by means of the deforming component (10) depending on respective parameters relating to the strength of the structural element (2).

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