EP3210686A2 - Method and device for incrementally shaping of tubular or profile components - Google Patents

Abstract

The invention relates to a method for forming, in particular for expanding pipe or profile components (12), in which a blank (1) of the pipe or profile component (12) by means of a within the blank (1) arranged tool (2) is formed wherein the blank (1) of the pipe or profile component (12) of the at least one relative to the blank (1) movably arranged forming tool (2) is brought by local plastic deformation incrementally and successively in the formed finished mold. Also proposed is a device suitable for carrying out the method.

Description

The invention relates to a method for the incremental deformation of tubular or profile components according to the preamble of claim 1 and to a device suitable for carrying out the method according to the preamble of claim 12.

Various forming processes can be used for the production of complex pipe and profile components with cross-sectional geometries varying over the longitudinal axis and arbitrarily shaped. The shaping can basically take place in two ways. On the one hand, the semifinished product can be reshaped by externally acting active tools. Typical process examples are the swaging, sliding, pressing and the incremental pipe and profile forming. On the other hand, the shaping can be realized by acting from inside to outside tools. An essential difference between the two variants is that when forming from the inside to the outside, the area of the space to which it is formed is much larger (theoretically to infinity) and therefore a much larger change in shape can also be achieved. In comparison, the attacking tools in the transformation from outside to inside can only exploit the space inside the tube.

The most well-known process for internal tube forming is hydroforming (IHU). In the case of the hydroforming process, a semi-finished tube is inserted into a rigid die in the first step, which has the negative geometry of the profile geometry to be produced. In the second step, a kneading medium (e.g., fluid, steel balls, sand) serving as a tool is directed into the interior of the pipe and pressurized so that the pipe is expanded and pressed outwardly and against the die. An advantage of this method lies in the high achievable component complexity. The main disadvantage of this method is the very low process flexibility due to the high tooling costs, since a separate die must be provided for each profile geometry to be produced.

Further methods for internal tube forming include, for example, the expansion of hollow bodies (see DIN8585-3), in which the entire diameter of the tube is increased by pushing in or pulling through a rigid mandrel tool / wide body, which has a larger outer diameter compared to the tube inner diameter. The achievable geometries are always symmetrical or rotationally symmetric in tubes.

Another possibility for expanding hollow bodies lies in the use of internal segment-shaped spreading tools or rotating rolling tools such as in the DE 196 19 340 C2 , which are pressed for example by means of wedge or cone against the inner wall of the hollow body. The forming takes place simultaneously on the entire inner circumference of the tube. The disadvantages of the described method for expanding hollow bodies by means of internal mandrel, rolling or spreading tools lie, on the one hand, in the limited component complexity, that is to say a profile cross section change is possible with a tool, but this is limited to only one due to the shape of the tools Change in the cross-sectional size, ie circular pipe sections are increased, for example, from their initial diameter to a larger circular pipe diameter. The symmetries of the initial cross sections are thus preserved. Compared to hydroforming, the last-mentioned methods thus enable and provide considerably less design freedom.

For the three-dimensional forming of originally flat sheet metal parts, a manufacturing method has become known in which by means of so-called. Incremental forming the sheet metal component is locally plastically deformed and by systematic displacement of the forming zone over the relevant surface of the sheet metal component so successively produced the deformed configuration of the sheet metal component is produced. This incremental deformation offers, in particular for small quantities of the components to be produced, the advantage of being able to do largely without special forms to be made and still allows a far-reaching flexible shaping of the sheets to be deformed. As tools, for example, stylet-like tools are used, which are moved along predeterminable paths relative to the sheet metal component to be deformed and in this case reshape the sheet metal component only locally. Repeating the process often enough, so can be generated by the addition of these individual local and each relatively small transformations and larger transformations of the sheet metal component. For this purpose, only the movements of the forming tool to execute accordingly and, for example by means of numerical control to specify accordingly.

A method which allows a total deformation of pipe and profile components by located in the interior of the pipe and profile component tools and thus similarly high component complexities can be achieved as in the hydroforming process, is not currently known.

Object of the present invention is therefore to propose a method for forming, in particular for the expansion of tubular or profile components with varying over the longitudinal axis and arbitrarily shaped cross-sectional geometries, which is much more flexible than the conventional method and the production of correspondingly complex pipe or profile components as well as with the hydroforming made possible to produce.

The solution of the object of the invention results in terms of the method of the characterizing features of claim 1 and in terms of the device from the features of claim 12 each in cooperation with the features of the associated preamble. Further advantageous embodiments of the invention will become apparent from the dependent claims.

The invention relating to the method is based on a method for forming, in particular for expanding pipe or profile components with over Longitudinal axis varying and arbitrarily shaped cross-sectional geometries, in which a blank of the pipe or profile component is formed by means of a tool disposed within the blank. Such a generic method is further developed according to the invention that the blank of the pipe or profile component of the at least one relative to the blank movably arranged forming tool is brought by local plastic deformation incrementally and successively in the formed finished mold. The term expansion of tubular and profile components with varying over the longitudinal axis and arbitrarily shaped cross-sectional geometries will be understood in the following a locally acting change in shape of the pipe and profile component, starting from a suitably preformed blank, in which the cross-sectional shape, in particular the cross-sectional geometry and Cross-sectional dimensions, and / or the wall thicknesses of the pipe and profile component under the influence of inside and / or outside of the pipe and profile component attacking tools is changed. In this case, such machining both in the circumferential direction and in the longitudinal direction change the shape of the pipe and profile component and lead to corresponding local or global changes of the pipe and profile component. The respective processable cross-sectional shapes of the pipe and profile components include any conceivable closed or open profile cross sections, in particular of course also tubular cross sections. Such profile cross-sections are not limited to rotationally symmetrical cross-sections, but also allow only locally changed cross-sectional shapes with asymmetrical, especially non-rotationally symmetrical designs such as ribs, pockets, local bulges and indentations and protuberances. Such locally changed cross-sectional shapes can not be achieved with conventional expansion methods, since they are generally always likewise rotationally symmetrical on the pipe and profile component due to the relative rotation between the blank and the tool. Although the expansion under the action of each of the rolls only takes place locally during the widening by means of a conventional roll arrangement, this local forming in each case adds up to an overall rotationally symmetrical change in shape of the cross section of the blank due to the relative rotation between forming head and blank. By contrast, the local and incremental change in shape according to the present invention is to be understood as meaning that these local and incremental changes in shape primarily occur only on partial regions of the cross-section or circumferential shape of the blank or pipe and pipe Profile components acts and this shape changes only spatially limited, usually non-rotationally symmetrical formed portions of the pipe and profile component produced.

The method according to the invention uses the basic idea of the incremental sheet metal forming which is already known per se for plane sheet metal components and transfers this local forming to the shaping, in particular during the expansion of pipe or profile components. Thus, a complex, previously or only very costly manufacturable finished part geometry can also be produced on pipe or profile components with simple tools that one or more forming tools locally reshape the material of the blank locally and by correspondingly frequent execution of such transformations so successively the desired Prefabricated geometry of the pipe or profile component is created. Only by specifying corresponding trajectory data of the at least one forming tool, which is in itself simply shaped, are it possible to realize component geometries of different complexities, which up to now could only be produced considerably more costly by means of hydroforming. Based on the simple local forming geometries, the production of virtually any hollow profiles with varying cross-sections along the longitudinal axis is possible due to the great kinematic flexibility of the method according to the invention. Due to the low tooling costs and the very high flexibility, the process is of particular interest for components from prototype construction. In particular, a variation of highly complex profile cross-sections along the component longitudinal axis can be realized in one process step, which until now was only possible with hydroforming. The tool cost and the tool costs are much lower with the present invention compared to the hydroforming, which represents a further significant advantage over the previous method for internal forming. Similar to incremental sheet metal forming, the incremental approach of this invention achieves significantly higher shape changes compared to current methods, resulting in higher material utilization.

In a first advantageous embodiment, the at least one forming tool is movable in at least one spatial direction relative to the blank of the pipe or profile component and / or driven pivotably about at least one spatial axis. Depending on the forming geometry to be carried out, the forming tool can be moved relative to the blank in such a way that the forming geometry of the tube or profile component to be produced can be composed particularly simply from the respectively locally acting incremental deformations or can be generated kinematically simply. For this purpose, the six conceivable degrees of freedom of a spatial movement of the forming tool relative to the blank are available, namely three translational movements and three rotational movements. Of course, individual or all conceivable movements of the forming tool relative to the blank can be combined with each other in order to come as close as possible to one of the respective local finished part geometry of the pipe or profile component or to produce the corresponding shape as simply as possible. Also, derived movements of the forming tool or movements of the blank can be performed, which can be helpful here. It goes without saying that in addition to a movement of the forming tool relative to the fixed blank in kinematic reversal movement of the blank relative to the fixed forming tool can lead to the same results, therefore, in the following is always spoken only of relative movements between the forming tool and blank , Also, of course, simultaneous relative movements of forming tool and blank to each other are conceivable.

So it is conceivable, for example, in one embodiment that the at least one forming tool is moved in the forming relative to the blank of the pipe or profile component in at least one direction radially inwardly and / or outwardly. As a result, simple point transformations of the blank in the form of simple widening can be generated. The radial direction can be oriented in different spatial directions, for example, vertically radially outward and radially oriented radially horizontally to the outside or radially in another intermediate position. If, for example, movements of the forming tool in at least one axial direction of the blank then occur in a further embodiment, already line-like deformations can be produced, such as deformations of the outer contour of the blank which extend in the axial direction in the axial direction. If such a radial and axial movement of the forming tool is accompanied by a movement of the forming tool that is perpendicular thereto or at least partially perpendicular thereto, complex spatial deformations of the blank can be produced. So For example, an additional pocket-like or groove-like widening of the blank can be produced by an additional movement of the forming tool that is essentially in the tangential direction relative to the outer contour of the blank.

In general, it is therefore advantageous if the at least one forming tool can be moved simultaneously in the radial and / or in the axial and / or tangential direction of the blank in the forming with respect to the blank of the pipe or profile component, as this results in a large number of topographies can be generated in the outer contour of the blank to be formed. Instead of a substantially tangential movement of the forming tool, it is also possible to use a further radial movement of the forming tool that is perpendicular to the first radial adjustment. In this case, the tangential movement of the forming tool, especially in the case of circularly symmetrical cross sections of the blank, should be advantageous, whereas the further radial movement of the forming tool perpendicular to the first radial adjustment should be used in the case of non-circularly symmetrical cross sections, e.g. of profiles and in particular also profiles with corners or the like. To be preferred.

In addition to such linear relative movements of the forming tool, the at least one forming tool can be rotated or pivoted about the radial and / or about an axial and / or about the tangential axis of movement in the forming relative to the blank of the pipe or profile component. This allows the creation of further forming geometries, e.g. also of local undercuts or curved edged protuberances in the forming geometry of the pipe or profile component, which can not be generated with the basic movements alone or not sufficient.

In general, the at least one forming tool, depending on the locally produced forming geometry in the forming with respect to the blank of the pipe or profile component, a superimposed movement along the radial and / or along the axial and / or along the tangential axis of movement and / or Verschwenkungen to a or perform more of these axes of motion and is therefore adaptable to almost all possible Umformgeometrien the pipe or profile component.

Furthermore, it is of particular advantage that the at least one forming tool can perform the deformation along the entire longitudinal axis of the blank or of parts of the longitudinal axis of the blank in the forming relative to the blank of the pipe or profile component. In this way, a corresponding deformation can be made both on the face side of the blank and in the middle region of the blank. Also, such transformations do not have to be made uniform over the entire length of the pipe or profile component, but it may be e.g. in the middle region, a completely different transformation contour than at the end faces are present and in between, e.g. Even undeformed sections may be arranged.

Particularly advantageous in terms of the main times and thus also with regard to the economic viability of a method according to the invention, it is when two or more forming tools in the forming relative to the blank of the pipe or profile component simultaneously in each case at different points of the blank, the blank incrementally. If the movements for the respective incremental forming can be carried out independently of each other, the necessary manufacturing time is drastically reduced due to the temporally parallel execution of the respective transformations. The number of incrementally executable incremental transformations depends in particular on the space available for the arrangement and movement of the forming tools within the blank and the complexity of the movements to be performed and possibly possible collisions between the forming tools. In a first embodiment, it is conceivable that the two or more simultaneously forming forming tools radially offset each other at different points of the same peripheral portion of the blank, the blank in each case incrementally. For example, radially offset from each other symmetrically deformed profile cross-sections such as fin-like shapes can be generated. In another embodiment, it is also conceivable that the two or more simultaneously forming forming tools axially offset each other at different cross-sectional portions along the longitudinal axis of the blank, the blank in each case incrementally. In this way, the same or different shapes can be generated in the outer periphery of the pipe or profile component, which are arranged axially offset from one another.

For the accuracy of the deformation of the blank, it may be advantageous if the blank of the pipe or profile component is at least partially, preferably in the region of the respective incremental deformation, supported by at least one externally arranged on the blank, locally acting counter tool, which forms the shape the incremental deformation influenced. As a result, the material to be reshaped locally of the blank is stabilized at least in the forming zone and the counter tool acts like a counter-holder known from other forming processes. Between forming tool and counter tool, the material to be reshaped of the blank is clamped tight and therefore can not buck due to the deformation or locally crack. Also, a corresponding clamping between the forming tool and counter-tool can be used specifically to influence the state of stress during the forming and, for. also bring about local cross-sectional reductions. In addition, changes in the state of stress caused thereby can be used specifically for minimizing the local springback of the material of the blank after the forming and the forming forces required for forming.

Furthermore, it is conceivable that the at least one counter tool and the respective associated forming tool perform mutually coordinated movements for the incremental deformation of the section of the blank to be formed between them, preferably the counter tool moves in a manner suitable or substantially synchronous with the movement of the forming tool or tools. This achieves, on the one hand, that the counter-tool can also be geometrically simple as well as the forming tool, since the same advantages as due to the mobility of the forming tool also apply to the counter-tool due to the mobility of the counter-tool. On the other hand, the forming tool and the counter-tool can at least temporarily also exchange their respective function, so that e.g. With a corresponding forming geometry, the counter-tool virtually assumes the function of the forming tool and the actual forming tool serves as a kind of counter-holder.

Of particular advantage is that the blank can be formed in the cold or in the heated state. For example, cold forming is often sufficient in the case of easily deformable materials, and in the case of poorly deformable materials however, be transformed at correspondingly higher forming temperatures and thus the poor forming behavior can be improved. Forming at higher temperatures can also be usefully used to extend the deformation limits, to reduce the deformation forces, to reduce the springback and to set a defined microstructure state (press hardening).

In a first embodiment it is e.g. conceivable that the blank of the pipe or profile component consists of a metallic material or has a metallic material. Thus, e.g. Pipe or profile components made of steel materials, light metals, but also difficult to deform metallic materials are formed incrementally in the manner according to the invention. In another embodiment, however, it is also conceivable that the blank of the pipe or profile component consists of a plastic-containing material, preferably a thermoplastic material.

Furthermore, the blank may have a circular-symmetrical or self-contained profiled cross-sectional shape. In addition to the classic deformation of circularly symmetrical or ovalized tubes, the method according to the invention can be used particularly well for profiles of almost any cross-section due to its high flexibility of geometry generation. Thus, due to the flexible mobility of the forming tools even angular or otherwise complex shaped profile cross-sections can be reshaped, which was previously only much more complex by hydroforming possible.

In a further embodiment, the at least one forming tool and the blank interact mechanically with each other at least locally. Thus, due to a mechanical contact between the blank and the forming tool, the material of the blank can be plastically deformed locally and thus permanently brought into a different topography.

In another embodiment, however, it is also conceivable that the at least one forming tool and the blank interact with each other at least locally without contact. Thus, for example, the magnetic interaction can be exploited to a deformation by at least selectively at least one forming tool has a tool for the electromagnetic deformation. Such tools for the electromagnetic deformation are known per se and allow due to high and abruptly generated magnetic fields a very rapid local deformation of particular sheets and tubes.

Furthermore, it is of particular advantage that in the method according to the invention more than one blank as a pipe or profile component can be deformed together in such a spatial arrangement that at least in the region of the deformed sections, the blanks, preferably positively or non-positively connected to each other become. If you order, for example, two each tubular or profile-shaped blanks with slightly varying cross-sectional dimensions coaxially to each other and the smaller blank inside within the larger blank, so due to the local deformation at least in individual formed sections of the inner blank so non-positively or positively applied to the outer blank, that these two blanks are permanently connected together.

The invention further relates to a device for forming, in particular for expanding pipe or profile components, wherein a tool arranged within a blank of the pipe or profile component transforms the blank, in particular for carrying out the method according to claim 1, wherein the at least one forming tool in such a way is designed to be movable relative to the blank that the at least one forming tool, the blank due to the executed movements by local plastic deformation incrementally and successively transforms into the formed finished mold. The method has already outlined the characteristics and features and the resulting advantages of the method, which are equally applicable to the present device and to which reference is expressly made to the device. Therefore, only additional aspects of the device that have not already been described above for the method will be explained in more detail below.

For the kinematic reversal of the relative movements or also to provide additional mobility, it may be advantageous in the device if the device in addition to the support of the pipe or profile component also provides the possibility that the blank is designed such held and movable that the blank during the forming relative to the at least one forming tool is rotatable and / or displaceable. This may alternatively relative to the movement of the forming tool relative movements between forming tool and blank are also generated by a movement of the blank itself. Thus, for example, it may be easier to carry out a tangential, ie, in the circumferential direction, relative movement between the blank and the forming tool by rotating the blank about its longitudinal axis.

Particularly stable with respect to the acting forming forces is an embodiment of the at least one forming tool, wherein the at least one forming tool is arranged on a adapted to the cross section of the blank of the pipe or profile component tool holder and is designed to be movable relative to this tool holder. In the case of a circular-symmetrical cross-section of the blank, the tool holder can also be designed with a circular symmetrical cross section and only slightly smaller than the inner diameter of the blank, so that it can absorb the radial forming forces particularly well and without undue deformation. Relative to this tool holder and arranged in the tool holder drives then the at least one forming tool can be moved relative to the tool holder and pressed for the forming of the blank. However, it is also conceivable that the respective locally acting forming forces in the interior of the pipe or profile component itself are compensated thereby and thereby not even applied to the tool holder by two opposing deformations simultaneously and e.g. offset by 180 ° be performed on the cross section of the pipe or profile component and thereby cancel each other in their force on the pipe or profile component. Also can be arranged opposite to the actual local forming exporting forming a passive and possibly no deformation exporting passive support tool, so that here the resulting force on the pipe or profile component is largely or completely compensated.

In a first conceivable embodiment, the forming tool and / or the counter tool may be a punctiform formed, punctiform acting forming tool, which may have, for example, a rounded trained, preferably hemispherical trained end for mechanical deformation of the blank. As a result, a geometrically unique shape of the forming tool is given, which can produce a variety of Umformgeometrien. Depending on Diameter of the tapping-like forming tool and the radius of the action end are also almost square Umformgeometrien generated.

In another conceivable embodiment, the forming tool and / or the counter-tool can be a forming tool which acts linearly, e.g. have a roll-like or roller-shaped forming tool for mechanical deformation of the blank. As a result, the effective range of the forming tool is extended and it is possible, e.g. to reduce the frictional forces in the forming zone by roller bearing design of such roll-like or roller-like formed forming tools.

It is also conceivable in a further embodiment that the forming tool and / or the counter-tool has a shape which is adapted to the shape to be produced of the section of the pipe or profile component to be formed. In the case of complex forming geometries, a simplification of the forming can thereby be achieved by providing a part of the geometry information that otherwise would have to be produced by successive incremental forming through the shaping of the forming tool and / or counter-tool.

For the execution of the movements of the forming tool and / or the counter tool, it is advantageous if the at least one forming tool and / or the counter tool is formed mechanically and / or electrically and / or fluidically movable and controllable. As a result, conventional motion controls can be used on conventional machine tools or appropriate components can be provided for the production of special machines.

An advantage for increasing the complexity of recoverable transformations is when each of the forming tools has an independent drive for relative adjustment to other tools and / or the tool holder. This allows a maximum of flexibility, but also requires attention to the collision problem, especially when several forming tools are used in parallel at the same time.

In another conceivable embodiment, the at least one forming tool can be designed to be movable and controllable by means of magnetic action, preferably by means of electromagnetic forces. For example, electromagnets arranged inside or outside the blank may move the individual forming tools triggered and possibly also controlled, wherein in a further embodiment, the magnetic effect is generated on the forming tool within the tool holder or the forming tool is moved by means disposed outside of the blank magnetic devices.

A particularly preferred embodiment of the method according to the invention is shown in the drawing.

Figur 1a, 1b -

eine erste Ausgestaltung der erfindungsgemäßen Verfahrens mit einem kreissymmetrisch ausgebildeten Rohling des Rohr- oder Profilbauteils und einem radial nach oben und unten verfahrbaren stichelartigen Umformwerkzeug in einem Schnitt (Figur 1b) und die sich daraus ergebende Umformgeometrie des Rohr- oder Profilbauteils (Fig. 1 a),

Figur 2 -

eine andere Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem axial verfahrbaren stichelartigen Umformwerkzeug in einer geschnittenen räumlichen Ansicht,

Figur 3a, 3b -

eine weitere Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem tangential in Umfangsrichtung verstellbaren stichelartigen Umformwerkzeug und die sich daraus ergebende Umformgeometrie des Rohr- oder Profilbauteils,

Figur 4 -

eine weitere Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem radial, axial und tangential in Umfangsrichtung verstellbaren stichelartigen Umformwerkzeug und eine damit herstellbare Umformgeometrie des Rohr- oder Profilbauteils,

Figur 5 -

eine mit den Bewegungsmöglichkeiten des stichelartigen Umformwerkzeugs der Figur 4 erzielbare Umformgeometrie des Rohr- oder Profilbauteils bei schraubenartiger Überlagerung der axialen und radialen Umformung,

Figur 6 -

eine weitere Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem radial verstellbaren und um die radiale Verstellachse zusätzlich verschwenkbaren Umformwerkzeug, mit dem hinterschnittartige Formgebungen erzeugt werden können,

Figur 7 -

eine andere Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem radial verstellbaren und quer zu der radialen Verstellachse zusätzlich verschwenkbaren Umformwerkzeug, mit dem in axialer Richtung abgerundete Aufweitungen erzeugt werden können,

Figur 8 -

Beispiele für mehrere gleichzeitig an einem kreissymmetrisch ausgebildeten Rohling des Rohr- oder Profilbauteils radial verstellbare und inkrementell umformende Werkzeuge, die an unterschiedlichen Stellen des gleichen Querschnittsabschnitts des Rohlings im Eingriff sind,

Figur 9 -

ein Beispiel für eine erzielbare Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils, bei dem mehrere radial und axial verstellbare und inkrementell umformende Werkzeuge an unterschiedlichen Stellen des gleichen Querschnittsabschnitts und axial versetzt zueinander an unterschiedlichen Querschnittsabschnitten des Rohlings im Eingriff sind,

Figur 10a-10d -

Beispiele für die Formgebung unterschiedlicher Umformwerkzeuge bei radialer Umformung eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit stichelartig konvexer (Figur 10a), flach linienförmiger (Figur 10b) und konkav linienförmiger (Figur 10c) Formgebung des Umformwerkzeugs sowie einer Kombination eines flach linienförmigen mit einem stichelartig konvexen Umformwerkzeug (Figur 10d) am gleichen Querschnittsabschnitt des Rohlings,

Figur 11a-11d -

Beispiele für die Ausführung unterschiedlicher Umformwerkzeuge bei radialer Umformung eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem starren, stichelartig konvexen (Figur 11a), einem walzenartig wälzgelagerten linienförmigen (Figur 11 b), einem wälzgelagerten Rollenwerkzeug (Figur 11c) sowie einem kugeligen wälzgelagerten Umformwerkzeug (Figur 11d),

Figur 12 -

Beispiele für einfache nicht-kreissymmetrische Rohlinge des Rohr- oder Profilbauteils

Figur 13 -

eine weitere Umformgeometrie eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils mit einem außerhalb des Rohlings angeordneten und mit dem innenliegenden Umformwerkzeug zusammen wirkenden Gegenwerkzeug,

Figur 14 -

ein Beispiel für ein magnetisch betätigtes kugelförmiges und loses Umformwerkzeug, das zur radialen inkrementellen Umformung eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils eingesetzt werden kann,

Figur 15 -

ein Beispiel für ein magnetisch wirkendes Umformwerkzeug, das mittels elektromagnetischer Umformung zur radialen inkrementellen Umformung eines kreissymmetrisch ausgebildeten Rohlings des Rohr- oder Profilbauteils eingesetzt werden kann,

Figur 16 -

ein Beispiel für ein erfindungsgemäß längserstrecktes Rohr- oder Profilbauteilen, dem eine Krümmung mittels Umformwerkzeugin Längsrichtung aufgeprägt wurde.

Show it:

FIG. 1a, 1b

a first embodiment of the method according to the invention with a circularly symmetrical blank of the tubular or profile component and a radially upwardly and downwardly movable tine-like forming tool in a section ( FIG. 1b ) and the resulting forming geometry of the pipe or profile component ( Fig. 1 a) .

FIG. 2 -

another forming geometry of a circularly symmetrical blank of the pipe or profile component with an axially movable tambourine forming tool in a sectional spatial view,

FIG. 3a, 3b -

a further forming geometry of a circularly symmetrical blank of the pipe or profile component with a tangentially circumferentially adjustable tine-like forming tool and the resulting forming geometry of the pipe or profile component,

FIG. 4 -

a further forming geometry of a circularly symmetrical blank of the pipe or profile component with a radially, axially and tangentially adjustable in the circumferential direction tachelike forming tool and thus produced Umformgeometrie the pipe or profile component,

FIG. 5 -

one with the possibilities of movement of the tapping-like forming tool FIG. 4 achievable forming geometry of Pipe or profile component with helical superimposition of the axial and radial deformation,

FIG. 6 -

a further forming geometry of a circularly symmetrical blank of the pipe or profile component with a radially adjustable and additionally pivotable about the radial adjustment axis forming tool can be generated with the undercut-like shapes,

FIG. 7 -

another forming geometry of a circularly symmetrical blank of the pipe or profile component with a radially adjustable and transverse to the radial adjustment axis additionally pivotable forming tool can be generated with the rounded in the axial direction widenings,

FIG. 8 -

Examples of a plurality of simultaneously radially adjustable and incremental forming tools on a circularly symmetrical blank of the pipe or profile component, which are engaged at different points of the same cross-sectional portion of the blank,

FIG. 9

an example of an achievable forming geometry of a circularly symmetrical blank of the pipe or profile component, in which a plurality of radially and axially adjustable and incrementally reshaping tools at different points of the same cross-section and axially offset from each other at different cross-sectional portions of the blank are engaged,

FIGS. 10a-10d

Examples of the shaping of different forming tools in the radial deformation of a circularly symmetrical blank of the pipe or profile component with spiky convex ( FIG. 10a ), flat line ( FIG. 10b ) and concave line ( FIG. 10c ) Forming the forming tool and a combination of a flat line with a Tongue-like Convex Forming Tool ( FIG. 10d ) at the same cross-sectional portion of the blank,

FIGS. 11a-11d

Examples of the execution of different forming tools in radial deformation of a circularly symmetrical shaped blank of the pipe or profile component with a rigid, like a spike-like convex ( FIG. 11a ), a roller-like roller-bearing linear ( FIG. 11b) , a roller bearing roller tool ( FIG. 11c ) and a spherical roller bearing forming tool ( FIG. 11d )

FIG. 12 -

Examples of simple non-circularly symmetrical blanks of the pipe or profile component

FIG. 13

Another forming geometry of a circularly symmetrical blank of the pipe or profile component with a arranged outside of the blank and cooperating with the inner forming tool counter tool,

FIG. 14 -

an example of a magnetically actuated spherical and loose forming tool, which can be used for the radial incremental deformation of a circularly symmetrical blank of the pipe or profile component,

FIG. 15 -

an example of a magnetically acting forming tool, which can be used by means of electromagnetic forming for the radial incremental deformation of a circularly symmetrical shaped blank of the pipe or profile component,

FIG. 16

an example of a longitudinally extended pipe or profile components according to the invention, to which a curvature has been impressed by means of a forming tool in the longitudinal direction.

In the FIG. 1 is a first embodiment of the method according to the invention with a circularly symmetrical blank 1 of the tube or profile component 12 and a radially upwardly and downwardly movable tine-like forming tool 2 in a section ( FIG. 1 b) and the resulting Umformgeometrie 4 of Pipe or profile component 12 ( Fig. 1a ). The circularly symmetrical blank 1, also referred to as a tube, is used in the forming according to FIG. 1 expanded selectively by the forming tools 2, so that in the simplest case, a wart-like protuberance 4 as a result of the incremental deformation in the outer contour of the blank 1 is formed. For this purpose, the mandrel-like formed and arranged inside the blank 1 forming tool 2 is pressed slowly in the radial direction 3 to the outside and the wall material of the blank 1 characterized in the in the FIG. 1a recognizable wart-like protuberance 4 brought. The forming tool 2 is in this case movably and drivably mounted on a tool holder 13, for example, similar to an internal turning tool rod-like axially protrudes into the interior of the blank 1 and the force between the blank 1 and forming tool 2 is supported and discharged. Here, the drives and bearings of the forming tool can be arranged on the tool holder 13 and operable from the outside. Such an incremental deformation is basically known from the field of simple planar sheet-metal parts and should therefore be explained in more detail here only insofar as this is of importance for the understanding of the present invention. This radial point-shaped incremental deformation represents the simplest case of the incremental deformation of tubular and profile components 12 and can be extended by the kinematics of the movement and arrangement of the forming tools 2, which can be seen in more detail in the following figures.

In the FIG. 2 is another deformation geometry of a circularly symmetrical blank 1 of the pipe or profile component 12 with an axially movable tambourine forming tool 2 to recognize in a cut-away spatial view, in which the blank 1 by the axial (and possibly previous radial) adjustment of the forming tool 2 a finned radially projecting Umformgeometrie 4 has received. For this purpose, for example, the mandrel-like forming tool 2 can be delivered radially beforehand so that it protrudes beyond the inner periphery of the blank 1 and is then successively pressed in the direction of the longitudinal axis 5 of the blank 1 through the entire blank 1, pulled or moved generally therethrough. The forming tool deforms successively and incrementally the wall of the blank 1 in the region of the mechanical contact with the blank 1 and pushes this wall section gradually into the desired forming geometry 4. This deformation can be done in a stroke or successively by several strokes less delivery, which depends primarily on the degree of deformation and the Umformeignung the material of the blank 1.

In the FIGS. 3a and 3b is a further forming geometry of a circularly symmetrical blank 1 of the tube or profile member 12 to recognize, is used in the work with a tangentially adjustable in the circumferential direction stylet-like forming tool 2. Likewise, an exemplary resulting forming geometry 4 of the pipe or profile component 12 can be seen. The forming tool 2 can in an upstream processing step, for example, as in Figure 1 b be adjusted radially outward and is according to FIG. 3b then be converted by a tangential or in the circumferential direction of the circularly symmetrical blank 12 extending pivoting movement 3, then the forming tool 2 takes the position according to Item number 2 'a. This results in accordance with the width of the forming tool 2, an annular protuberance 4 on the outer wall of the blank 1. Repeats such tangential forming movements 3 of the forming tool 2 and displaced therebetween the forming tool 2 a little in the axial direction 5 of the blank 1, it follows and according to the wide annular protuberance 4 according to FIG. 3a , Again, the protuberance 4 again by means of many incremental forming movements of the forming tool 2 with little delivery in the direction of the wall of the blank 1 done.

In the FIG. 4 is another example of a forming geometry 4, 4 'of a circularly symmetrical blank 1 of the tube or profile component 12 with a radial, axial and tangential circumferentially adjustable stylet-like forming tool 2 and thus producible Umformgeometrie 4, 4' of the pipe or profile component 12th shown. This can be done either by a successive execution of axial transformations according to FIG. 2 under each tangential feed 3 of the forming tool 2 or by successive execution of tangential transformations according to FIG. 3b under each axial feed 3 of the forming tool 2, the groove-shaped bulged Umformgeometrie 4 are generated. It is also possible in an analogous manner to produce in this everted Umformgeometrie 4 another protuberance 4 ', which is further from the blank. To produce these forming geometries 4, 4 'is only the forming tool 2 and a appropriate motion specification for the forming tool 2 necessary, which is easy to ensure by means of numerical control. If, combined with the transformations described above, an adapted radial movement 3 of the forming tool 2 is added, flat wall regions can also be produced on the pipe or profile component 12.

In the FIG. 5 is a modification of the Umformgeometrie 4 according to FIG. 4 to recognize, in which with the possibilities of movement of the tapping-like forming tool 2, a helical superposition of the axial and radial deformation is carried out. Thus, the forming geometry 4 on the outer wall of the blank 1 once wound half around the outer circumference of the blank 1 around. For example, such shapes are often required for fluidic media in order to specifically influence these fluidic media. With the method according to the invention, such shapes 4 can easily be produced on tubes 12

The FIG. 6 shows a further forming geometry 4 of a circularly symmetrical blank 1 of the tube or profile component 12 with a radially (3) adjustable and about the radial adjustment axis (3) additionally pivotable forming tool 2, with the undercut-like shapes 4 "can be generated a spatial direction cross-like forming tool 2 (can be seen in the right part of the image FIG. 6 ) according to Figure 1 b used to expand the forming geometry 4 of the circular symmetrical blank 1 and then this cross-shaped forming tool 2 then rotated by 90 ° around the radial adjustment direction and the blank in this position of the forming tool 2 then deformed in the axial direction 5. As a result, the horizontally lying arms of the cross-shaped forming tool 2 form the undercut-like shapes 4 "in the protuberance 4, into which insertable and guide-like guided rod elements or the like can be inserted, for example in the longitudinal direction of the axis 5 of the blank 1.

In the FIG. 7 is another forming geometry 4 of a circularly symmetrical blank 1 of the pipe or profile member 12 with a radially adjustable and transverse to the radial adjustment axis additionally pivotable forming tool 2 to recognize the rounded in the axial direction 5 widenings 4 can be generated. This is done after an initial expansion according to FIG. 1 b the forming tool 2 about a radial transverse axis 3 around in the position according to Part number 2 'pivots and forms a rounded pocket 4 in the outer wall of the blank 1. In such a pocket 4 sensors could be introduced with a corresponding width, which can detect 12 prevailing environmental conditions in the interior of the pipe or profile component. Also, such pockets could serve as lubricant pockets or serve as a mechanical driver.

The FIG. 8 shows examples of several simultaneously on a circularly symmetrical shaped blank 1 of the tube or profile member 12 radially adjustable and incrementally reshaping forming tools 2, which are at different points of the same cross-sectional portion of the blank 1 in engagement. Such a plurality of tools 2 can be arranged, for example, on the outer circumference of a tool holder 13, not shown, and in each case offset by the corresponding pitch angle. By each radial expansion with these forming tools 2, the forming geometries 4 according to FIG. 8 generate with eg 2 or 4 protuberances 4. It goes without saying that individual or all of these forming tools 2 can basically be moved synchronously or independently of one another in all directions of movement.

In an embodiment according to FIG. 9 It is also conceivable to reshape not only on the same cross-sectional section of the blank 1 with a plurality of forming tools 2, but to use the forming tools 2 offset in the axial direction 5 within the blank 1 for incremental forming. The FIG. 9 shows an example of an achievable forming geometry 4 of a circularly symmetrical blank 1 of the tube or profile component 12, in which a plurality of radially and axially adjustable and incrementally reshaping forming tools 2 each fins like out standing protuberances 4 in the outer wall of the blank 1 produce. For this purpose, the respective forming tools 2 are first according to eg FIG. 1b moved radially outward and then moved in the axial direction 5 of the blank. If the forming tools 2 are arranged to fit, for example, on a common tool holder 13, many or all protuberances 4 can be produced in one stroke or with a few strokes of the forming tools 2. Of course, it is also conceivable, the protuberances with only one forming tool or less forming tools than in FIG. 9 to recognize one after the other.

In the FIGS. 10a to 10d are examples of the shaping of different forming tools 2 in the case of radial deformation of a blank 1 of the pipe or profile component 12, which is here only by way of example circularly symmetrical, once with a convexly convex ( FIG. 10a ), flat line ( FIG. 10b ) and concave line ( FIG. 10c ) Shaping of the forming tool 2 and in a combination of a flat-line with a spiky-convex forming tool ( FIG. 10d ) can be seen on the same cross-sectional portion of the blank 1. Similar to the incremental forming flat sheet metal components can be simplified by the shaping of the forming tool adaptation of the deformation of the desired Umformgeometrie 4. Of course, the forming tools 4 may also have concave or convex shapes in the longitudinal direction of the pipe or profile component 12.

In the FIGS. 11a to 11d Examples of the execution of different forming tools 2 in radial deformation of a circularly symmetrical blank 1 of the pipe or profile member 12 with a rigid, like a spike-like convex ( FIG. 11a ), a roller-like roller-bearing linear ( FIG. 11b) , a roller bearing roller tool 2 ( FIG. 11c ) and a spherical roller bearing forming tool 2 ( FIG. 11d ) to recognize. Thus, by rolling-mounted forming tools 2, which are also adapted to the shape of the produced Umformgeometrie 4, a substantial improvement of the Umformverhaltens of the blank can be achieved, as this affects the friction conditions between forming tool 2 and material of the blank in the forming zone. Of course, the forming tools 4 may also have concave or convex shapes in the longitudinal direction of the pipe or profile component 12.

In the FIG. 12 can be seen by way of example only examples, that the inventive method not as previously in the FIGS. 1 to 11 can be performed on circular symmetric cross-sections, but also for non-circular symmetrical blanks 1 of the tube or profile member 12 can be used in general, especially in non-circular symmetrical blanks 1 with corner regions 7 or very small radii.

The FIG. 13 shows a further forming geometry 4 of a circularly symmetrical blank 1 of the pipe or profile component 12, in which the forming with an arranged outside of the blank 1 and cooperating with the inner forming tool 2 counter-tool 8 is worked. In the simplest embodiment, the counter-tool 8 is arranged stationarily in the region of the forming zone and supports the material of the wall of the blank 1 successively pressed out by the internal forming tool 2 against the force effect of the forming tool 2. As a result, the accuracy of the shaping of the forming geometry 4 produced by the forming tool 2 can be improved. But it is also conceivable that the counter tool 8 is itself movable and, for example, matched to the movement of the forming tool 2 itself performs appropriate movements. Also, the shape of the counter tool 8 itself differently than in the FIG. 13 be formed, for example, the counter-tool 8 itself could also be shaped like a spike.

The FIG. 14 shows an example only schematically indicated example of a magnetically actuated spherical and loose forming tool 2, which can be used here for the radial incremental deformation of a circularly symmetrical blank 1 of the pipe or profile component 12. Thus, for example, a loose, electromagnetic forming tool 2 could be introduced into the interior of the blank 1 and then attracted by the magnetic effect of the magnet 10, which is placed outside the blank 1 in a suitable manner. If the magnetic action of the magnet 10 is then increased, for example by forming the magnet 10 as an electromagnet, the forming tool 2 is pulled radially outward in the case shown and deforms the wall of the blank 1 as in FIG FIG. 14 to recognize similar wart-like as the mechanically acting stylet-like forming tool 2 of the FIG. 1 b. Of course, the magnetic effect can also be spatially aligned differently, so that the deformation by the forming tool 2 can cause other geometries.

In the FIG. 15 a further example of an electromagnetically acting forming tool 2 is given, which can be used by means of electromagnetic deformation for the radial incremental deformation of a blank 1 of the pipe or profile member 12, which is hereby only circularly symmetrical. The electromagnetic transformation is basically known and can be used to spatially limited, but very effective local transformation of electromagnetic materials. Such an electromagnetically acting forming tool 2 is placed close to the wall in the region of the forming zone of the blank 1 and is at a sudden release of magnetic energy 12 a mechanically also abrupt impulse to the corresponding wall sections of the blank 1, whereby these wall sections deform mechanically and occupy the deformed Umformgeometrie 4.

The fields of application for the incremental forming of tubular or profile components 12 according to the invention are, on the one hand, structural lightweight construction, e.g. as load-adapted profiles for the automotive industry. Furthermore, the economic application of the method in the field of furniture industry or design is to be seen, since the production of individual free-form surfaces without great use of tools is possible. The use of the helical structures is conceivable in the field of heat engineering in heat exchangers (swirl tubes) and in conveyor technology (for example screw conveyors).

The FIG. 16 shows a way, the inventively elongated tube or profile members 12 impart a curvature in the longitudinal direction, for example, to produce cross-sectionally changed and bent in the longitudinal direction pipe or profile components 12. This is in the FIG. 16 used the possibility to deform in the longitudinal direction wall portions 14 of the cross section so that locally reduces the wall thickness of the blank 1 and this local change in wall thickness lead to a one-sided elongation of the pipe or profile component 12 bending the pipe or profile component 12. This can be generated by the same forming tool 2 that is used for the change in cross section and the bending or curvature of the pipe or profile member 12. It is also possible to produce such bends by bending tools acting on the outside of the blank 1, for example a three-roll bending tool or rolls or the like.

Part number list

1

- blank

2

- Forming tool

3

- Adjustment direction forming tool

4, 4 ', 4 "

- Forming geometry

5

- Middle axis blank

6

- Storage forming tool

7

- corner area

8th

- Counter tool

9

- loose ball as forming tool

10

- magnet

11

- Magnet for electromagnetic transformation

12

- pipe or profile component

13

- Tool holder

14

- Section of lesser wall thickness

Claims (20)

Method for forming, in particular for expanding pipe or profile components (12), in which a blank (1) of the pipe or profile component (12) is formed by means of a tool (2) arranged inside the blank (1),
characterized in that
the blank (1) of the pipe or profile component (12) of the at least one relative to the blank (1) movably arranged forming tool (2) by local force successively incrementally plastically reshaped and brought into its final finished shape, wherein the local, incremental produced deformation comprises only portions of the cross section and / or the outer shape of the blank. Process for forming according to claim 1, characterized in that the change in shape is non-rotationally symmetrical to the shape of the pipe and profile component. Method for forming according to one of claims 1 or 2, characterized in that the at least one forming tool (2) in at least one spatial direction (3) relative to the blank of the pipe or profile component (12) movable and / or at least one spatial axis ( 3) pivotally driven is moved, wherein the at least one forming tool (2) in the forming relative to the blank (1) of the pipe or profile component (12) in the radial and / or axial and / or tangential direction (3) of the blank (1) is rotated and / or about the radial and / or about the axial and / or about the tangential axis of movement (3) or pivoted. Method for forming according to one of the preceding claims, characterized in that the at least one forming tool (2) in the forming with respect to the blank (1) of the pipe or profile component (12) the deformation along the entire longitudinal axis (5) of the blank (5) 1) or parts of the longitudinal axis (5) of the blank (1) performs. Process for forming according to one of the preceding claims, characterized in that two or more forming tools (2) at the same time, independently of one another or synchronously, at different locations of the blank in relation to the blank (1) of the pipe or profile component (12) (1) each incrementally transform the blank (1), wherein the two or more simultaneously forming forming tools (2) radially offset from each other at different locations of the same peripheral portion of the blank (1) each incrementally deform the blank (1) and / or axially offset to each other at different cross-sectional portions along the longitudinal axis (5) of the blank (1), the blank (1) each incrementally can transform. Process for forming according to one of the preceding claims, characterized in that the blank (1) during the deformation relative to the at least one forming tool (2) is rotated and / or moved. Process for forming according to one of the preceding claims, characterized in that the blank (1) of the pipe or profile component (12) at least in sections, preferably in the region of the respective incremental deformation, of at least one externally arranged on the blank (1), locally acting counter-tool (8) is supported, which influences the shape of the incremental forming, preferably the at least one counter-tool (8) and the respective associated forming tool (2) perform mutually coordinated movements for the incremental deformation of the section of the blank (1) to be formed between them, preferably the counter-tool (8) matches or substantially synchronously with the movement of the or the forming tools (2) moved. Forming process according to one of the preceding claims, characterized in that the blank (1) of the pipe or profile component (12) comprises a metallic material and / or a plastic-containing material, preferably a thermoplastic material. Forming method according to one of the preceding claims, characterized in that the blank (1) has a circularly symmetrical or self-contained or open, preferably slotted profiled cross-sectional shape, preferably the profiled cross-sectional shape angularly formed portions (7). Method for forming according to one of the preceding claims, characterized in that the at least one forming tool (2) and the blank (1) at least locally interact mechanically or at least locally interact without contact, preferably the at least one forming tool (2) a tool (11 ) for the electromagnetic transformation. Method for forming according to one of the preceding claims, characterized in that more than one blank (1) as a pipe or profile component (12) are simultaneously deformed together in a spatial arrangement such that at least in the region of the deformed portions (4) the blanks (1), preferably positively or non-positively connected to each other. Device for forming, in particular for expanding pipe or profile components (12), wherein a within a blank (1) of the pipe or profile component (12) arranged tool (2) the blank (1), in particular for carrying out the method according to claim 1,
characterized in that
the at least one forming tool (2) is designed so as to be movable relative to the blank (2) such that the at least one forming tool (2) moves the blank (1) incrementally and successively into the formed final shape by local plastic deformation due to the executed movements (3) (4) reshaped. Apparatus according to claim 12, characterized in that the at least one forming tool (2) in the forming relative to the blank (1) of the pipe or profile component (12) in the radial and / or axial and / or tangential direction (3) the blank (1) is movable and / or is rotatable or pivotable about the radial and / or about the axial and / or about the tangential movement axis (3). Device according to one of claims 12 or 13, characterized in that two or more forming tools (2) are movable and controllable such that in the forming relative to the blank (1) of the pipe or profile component (12) at the same time in different places Blank (1) is in each case incrementally formed, wherein the two or more simultaneously forming forming tools (2) arranged radially offset from each other at different locations of the same peripheral portion of the blank (1) and such, independently or synchronously, are movable, that they the blank (1) in each case incrementally reshape and / or the two or more simultaneously forming forming tools (2) axially offset from one another at different cross-sectional portions along the longitudinal axis (5) of the blank (1) and are movable so that they each blank transform incrementally. Device according to one of claims 12 to 14, characterized in that the at least one forming tool (2) on a to the cross section of the blank (1) of the pipe or profile component (12) adapted tool holder (13) arranged and is designed to be movable relative to this tool holder (13). Device according to one of claims 12 to 15, characterized in that the forming tool (2) and / or the counter tool (8) are a punctiform formed, punctiform acting forming tool (2), preferably the tuck-like formed forming tool (2) and / or Counter-tool (8) has a rounded trained, preferably hemispherical trained action end for mechanical deformation of the blank (1). Device according to one of claims 12 to 15, characterized in that the forming tool (2) and / or the counter tool (8) has a linear acting forming tool (2) for mechanical deformation of the blank (1), preferably a roll-like or roller-like formed forming tool (2) or has a shape which is adapted to the shape to be formed of the section (4) of the pipe or profile component (12) to be formed. Device according to one of claims 12 to 17, characterized in that the blank (1) of the pipe or profile component (12) at least in sections, preferably in the region (4) of the respective incremental deformation of at least one outside of the blank (1). arranged, locally acting counter-tool (8) is supported, which influences the shape of the incremental forming, wherein preferably the at least one counter-tool (8) along the outer contour of the incrementally deforming blank (1) of the pipe or profile component (12) relatively movable and / or is arranged pivotably. Device according to one of claims 12 to 18, characterized in that each of the forming tools (2) has an independent drive for relative displacement to other forming tools (2) and / or to the tool holder (13). Device according to one of claims 12 to 19, characterized in that the at least one forming tool (2) by means of magnetic effect (10), preferably by means of electromagnetic forces, is movable and controllable, preferably the magnetic effect (10) on the forming tool (2) within the tool holder (13) is generated or the forming tool (2) arranged outside of the blank (1) Magnetic devices (10) is moved.

Images