EP3254777A1 - Method and device for producing sheet metal components - Google Patents

Abstract

The present invention relates to a molding tool for punching and / or forming a sheet metal blank into a sheet metal component, which comprises a shaped body which has at least two regions of different material hardness. The present invention also relates to a forming device for producing the sheet metal component from the sheet metal blank, which has such a molding tool, an arrangement of the forming device and the inserted into the forming sheet metal blank, and a method for producing a sheet metal component with the forming device.

Description

The present invention relates to a molding tool for punching and / or forming a sheet metal blank into a sheet metal component, which comprises a shaped body, a forming device for producing the sheet metal component from the sheet metal blank, which has such a mold, an arrangement of the forming device and inserted into the forming device Sheet metal blank, and a method for producing a sheet metal component with the forming device.

By deep drawing a one-piece metal forming production of a sheet metal component is possible. In this case, two rigid tools (die and punch) are used, between which a sheet metal blank is arranged. The sheet metal blank is pressed with the stamp in the form of elements of the die, so that it assumes its shape. However, the method is limited due to the workpiece properties of the blank and the forming conditions limits. By overstretching the sheet metal blanks cracks can form. In addition, the risk of wrinkling of the sheet metal blank on the flange is large. Deep drawing therefore requires relatively thick sheet metal blanks. In addition, a diameter of formed in the sheet metal blank moldings may not be too small, and their depth should not be too large.

For high-quality production, the die and punch must also be made to fit and moved in exact position to each other. Therefore, the manufacture of the tools is time-consuming and expensive and the set-up times are long. In this case, a design change usually requires the production of new tools. This type of deep drawing is therefore economically applicable only in large quantities.

In order to realize shorter set-up times and lower tooling costs, it is also known to deep-draw sheet metal blanks with elastic tools. In this case, a rigid and an elastic tool are used instead of two rigid tools. The elastic tool includes, for example, a rubber pad embedded in a case of a press ram or a press bottom table. During forming, the rubber pad is pressed into the contour of the hard tool. It takes with it the sheet metal blank arranged between the two tools, so that it is likewise pressed into the contour of the hard tool. The sheet metal blank approximates the contour of the hard tool.

The publication DE 10 2009 047 950 A1 discloses a device for shaping a plate of a thermoformable material, in particular a sheet. The device has a lower tool as a receptacle in which a mold element is formed. The receptacle has circumferentially closed sidewalls. The plate is placed above the mold element in the receptacle. It is pressed by means of a punch in the mold element. However, the device provides between the punch and the plate a pressure distribution layer of forming elements, which comprise a number of balls, which are cast in a plastic material, in particular of silicone or rubber. In addition, the prior art document discloses an embodiment in which the pressure distribution layer is formed of flowable bulk material. In this embodiment, an elastic intermediate layer is arranged between the bulk material and the plate in order to protect the surface of the plate from damage by the bulk material.

An alternative method for punching and / or forming sheet metal blanks and a device therefor are known from the documents US 2,055,077 . US 2,133,445 and US 2,190,659 known. In this method, a sheet metal blank is placed on a lower tool with form elements. On a stamp, an elastic molded body made of rubber or plastic is arranged on the die side. The shaped body is peripherally limited by side walls of the press ram or the press lower tool. Therefore, he presses the sheet metal blank when pressing the punch in the form elements. Depending on the shape of the mold elements, the sheet metal blank is reshaped or punched.

The object of the invention is to provide a method and an apparatus for punching and / or forming of sheet metal blanks, which allow the production of sheet metal components from the sheet metal blanks error-prone, accurately and inexpensively with low tooling costs and short makeready times.

The object is achieved with a mold having the features of independent claim 1, a forming apparatus having the features of independent claim 9, an arrangement having the features of independent claim 12, and a method having the features of independent claim 13. Advantageous embodiments are dependent Claims removable.

For this purpose, a forming tool for punching and / or forming a sheet metal blank into a sheet metal component is provided which comprises a shaped body which has at least two regions of different material hardness. The mold is used as an elastic tool of a forming device, which also has a tool die as a rigid tool. To reshape the sheet metal blank, it is arranged between the shaped body and the tool die.

As a result of the at least two regions of different material hardness, the forces acting on the sheet metal blank during forming can be set in a targeted manner.

For this purpose, it is preferred that a first region of high material hardness forms an edge of the molded article, and a second region of low material hardness forms an inner part of the molded article. Preferably, the edge surrounds the inner part on the outside completely or at least in a first section in full. In an embodiment in which the edge completely surrounds the inner part only in the first section, a larger press stroke is achievable.

During forming, the molding is subject to the press stroke. The peripheral edge of high material hardness seals the inner part of small material hardness to the outside. He processes the press stroke by denting. Since it seals the inner part to the outside, it prevents buckling of the inner part to the outside. Crushing and thereby destroying the inner part is prevented by the edge. Such a mold must not be enclosed on the outside by side walls, at least in the section completely surrounded by the edge. The forming device used for punching and / or forming the sheet metal blank therefore requires, despite the use of the elastic molded body neither in the press ram still in the press bottom table a suitcase for receiving the molding.

The molded body is preferably made of plastics or rubber, in particular of elastomers. Particularly preferably, it is internally made of a synthetic rubber, in particular ethylene-propylene-diene rubber (EPDM), manufactured and has a shell made of polyurethane. The first region of high material hardness, in particular the edge of the molding, preferably has a Shore hardness of about 80-100, particularly preferably about 95. He is thus hard enough not to flow during forming as recesses or through holes formed mold elements of the tool die. In addition, it is used for jamming the sheet metal blank. Alternatively, the shell in the first region of high material hardness, in particular at the edge of the molding, also from fabric reinforced rubber, for example, Kevlar, steel mesh or the like. Further preferably, the second region of low material hardness, in particular the inner part of the molding, has a Shore hardness of about 20-70, particularly preferably about 50. As a result, the region of low material hardness during forming into the formed as recesses or through holes form elements is flowable. A determination of the Shore hardness can be found in DIN ISO 7619-1.

The shaped body preferably extends in a first extension direction. Preferably, the first extension direction corresponds to an actuating direction of the forming device used for punching and / or forming the sheet metal blank. Particularly preferably, the shaped body is formed substantially plate-shaped or cuboid. It is preferred that the first and the second region are arranged side by side in a second and / or third extension direction, which extend transversely to the first direction of extension. An actuating side and a fastening side opposite this are therefore not surrounded by the edge.

The molded body can be formed either in one piece or in several pieces. A one-piece embodiment can be produced for example by a multi-component injection molding. However, it is preferred that it is formed in several pieces, preferably of at least a first molding for the first region and a second molding for the second region. In addition, the first region can be formed from a plurality of first shaped pieces adjoining one another in the second and / or third extension direction. Furthermore, the second region may be formed from a plurality of second shaped pieces laminated in multiple layers in the first direction of extent. Such a multi-part design of the molding has the advantage that the fittings for moldings of different blanks are reusable.

In a preferred embodiment, the shaped body has at least one area, in particular another shaped area, of a different material hardness. In principle, both the edge and the inner part can be formed from areas of different material hardness. However, it is preferred that the further region forms the inner part together with the second region of second material hardness. Since the material hardness determines the flow properties of the shaped body, the strength with which the shaped body flows into the form elements, in particular recesses or through bores, of the tool die can be influenced thereby. Preferably, the wider range of other material hardness has a greater material hardness than the second region. This makes it less fluid than the second area. Through holes or Recesses in the sheet metal blank can be covered, without the inner part flows during forming in the through holes or recesses.

In order to specifically influence the flowability of the shaped body and / or the forces acting on the sheet metal blank during forming, it is also preferred that a thickness of the shaped body in the first direction of extent and / or the material hardness of the shaped body, in particular of the inner part, at least partially in stages or change continuously. Such a design of the shaped body allows, for example, a targeted approximately constant during forming pressure or a deliberately increasing or decreasing pressure on the sheet metal blank. In the formation of large cavities in the sheet metal blank can, in particular by a center of the cavity towards increasing material hardness, through which the pressure on the sheet metal blank decreases towards the middle, to ensure that it does not tear when forming.

In a preferred embodiment, the mold also has a hold-down frame, which is arranged on the actuation side of the molded body. During forming, the actuating side of the molded body, preferably over the entire surface, bears against the hold-down frame. It is preferred that it has cutouts for all cavities and folds to be formed in the sheet metal blank. Through the cutouts, the molded body can flow into the tool die and take along the sheet metal blank. It is preferred that the hold-down and the sheet metal blank flush with each other. The hold-down prevents the formation of wrinkles in the sheet. This embodiment of the mold allows the use of final trimmed sheet metal blanks. After reshaping the sheet metal blank into the sheet metal part, no reworking of the sheet metal part is therefore required any more.

The molding tool furthermore preferably has a fastening frame, which is arranged on a fastening side opposite the actuating side and is provided for fastening the molding tool to the press, in particular a press ram or a press bottom table. Preferably, the shaped body is arranged between the hold-down frame and the mounting frame. In a multi-part design of the molded body, it is preferred that both the hold-down frame and the mounting frame have a, in particular fully provided, beveled bar. The strip holds the molding outside. As a result, the fittings of the molding do not have to be fastened together.

In the embodiment in which the edge completely surrounds the inner part only in at least one first section, it is further preferred for the at least one first section of the edge to be arranged on a fastening side of the molding tool opposite the actuating side. This embodiment allows a larger press stroke and therefore the formation of larger cavities.

The object is further achieved with a forming device for producing a sheet metal component from a sheet metal blank. The forming device has such a mold. In addition, it has a tool die, which has at least one molding element, in particular a recess or an Anformung. Such a recess is provided for the formation of cavities or folds, the Anformung for expansion of the sheet metal blank.

The tool die is preferably produced as a lamella packet, in particular of a plurality of pinned or riveted metal sheets, in particular punched or lasered sheet metal blanks. It can also be cast. In addition, it can be made of a hard plastic or resin. In a likewise preferred embodiment, it is made of wood or concrete.

Furthermore, the forming device on the press ram, which is movable in and against the first direction of extension. By the process of the press ram, the mold is pressed onto the tool die. In addition, it is preferred that the forming device has the press bottom table.

Preferably, the press ram is movable relative to the tool die and / or the molding tool. In a preferred embodiment, the mold is arranged on the press ram. In this case, the tool die is preferably arranged on the press bottom table.

The hold-down frame is preferably provided in the forming device movable in and against the first extension direction. This may change a distance of the hold-down frame from the press ram during forming. Particularly preferred for a chain or a band is provided.

The forming device is designed to be fully open in a very particularly preferred embodiment. It can therefore be used conventional, especially old, presses.

It is preferred that the edge surrounds the inner part on the outside completely. The forming device then requires no receptacle for the molding in the press ram or press bottom table. As a result, no precise positioning of the press ram relative to the press bottom table is required. Nevertheless, a highly accurately manufactured sheet metal component can be produced with the forming device.

The object is further achieved with an arrangement with a forming device, in particular with such a forming device, for producing such a sheet metal component from a sheet metal blank, and with the sheet metal blank. The sheet metal blank is preferably arranged between the tool die and the molding tool. Preferably, it is arranged on the tool die so that it covers the mold element. In this case, the mold is arranged between the sheet metal blank and the press ram. It is particularly preferably attached to the press ram and is moved relative to the tool die during forming.

The object is further achieved with a method for producing a sheet metal component from a sheet metal blank with such a forming device. The forming device has the press ram and the tool die. The method provides that the press ram is moved relative to the tool die, which has mold elements, and on which the sheet metal blank, which covers the mold elements, is moved in the first extension direction. Between the sheet blank and the press ram while the mold is arranged. The molding tool has the shaped body. In the process of the press ram, the molded body is deformed.

The method is characterized in that the sheet metal blank is jammed with the edge of the molding on the tool die. In addition, it is deformed with the inner part of the molding, in particular punched and / or reshaped.

It has been shown that the hold-down frame is already pressed sufficiently at low press stroke on the sheet metal blank to jam the sheet blank and hold. If the holding-down frame is flush with the sheet-metal blank, an outer contour of the sheet-metal blank also remains during forming. A post-processing of the sheet metal component after forming is not required.

In this case, the edge of the molding is deformed spherically outwardly during forming by the press stroke, wherein it seals the inner part to the outside. As a result, the inner part is not crushed during forming or even destroyed.

In order to influence the depth of cavities formed in the sheet-metal component, to reduce the risk of soil tears, or to protect through-holes or recesses from deformation, it is also preferred that the punching and / or forming of the sheet-metal blank from the molded body, in particular in the first extension direction, acting on the sheet metal cutting forces are selectively adjusted by areas of different material hardness and / or different thickness of the molding.

Fig. 1

in (a) eine Anordnung aus einer Umformvorrichtung, die einen Formkörper umfasst, und einem in die Umformvorrichtung eingelegten Blechzuschnitt in einer Ruhelage, und in (b) die Anordnung in einer Arbeitslage;

Fig. 2

in (a) und (b) den Formkörper der Anordnung aus Fig. 1 (a), und zwar in (a) einen Schnitt A-A durch (b), und in (b) eine Betätigungsseite des Formkörpers, sowie in (c) die Betätigungsseite einer weiteren Ausführungsform des Formkörpers;

Fig. 3

eine Ausführungsform des Niederhalterahmens eines Formwerkzeugs der Umformvorrichtung;

Fig. 4

beispielhaft einen Blechzuschnitt;

Fig.5

eine Ausführungsform einer Werkzeugmatrize der Umformvorrichtung;

Fig. 6

in (a) ein Formwerkzeug und eine Werkzeugmatrize in einer explosionsartigen Ansicht, in (b) das an einen Pressenstempel der Umformvorrichtung montierte Formwerkzeug, und in (c) die an einen Pressenuntertisch montierte Werkzeugmatrize;

Fig. 7

in (a) ein Schnittbild eines mit der Umformvorrichtung hergestellten Blechbauteils schematisch, und in (b) - (d) verschiedene mit der Umformvorrichtung hergestellte Blechbauteile; und

Fig. 8

eine Anordnung aus einer weiteren Ausführungsform einer Umformvorrichtung, die einen Formkörper in der Ruhelage umfasst, und einem in die Umformvorrichtung eingelegten Blechzuschnitt.

The invention will be explained below with reference to figures. The figures are exemplary and do not limit the general idea of the invention. Show it:

Fig. 1

in (a) an arrangement of a forming device comprising a shaped body, and a sheet metal blank placed in the forming device in a rest position, and in (b) the arrangement in a working position;

Fig. 2

in (a) and (b) the shaped body of the arrangement Fig. 1 (a) in (a) a section AA through (b), and in (b) an actuating side of the shaped body, and in (c) the actuating side of a further embodiment of the shaped body;

Fig. 3

an embodiment of the hold-down frame of a forming tool of the forming device;

Fig. 4

for example, a sheet metal blank;

Figure 5

an embodiment of a tool die of the forming device;

Fig. 6

in (a) a mold and tool die in an exploded view, in (b) the mold mounted on a press die of the forming apparatus, and in (c) the tool die mounted on a press bottom table;

Fig. 7

in (a) a sectional view of a sheet metal component produced with the forming device schematically, and in (b) - (d) different sheet metal components produced with the forming device; and

Fig. 8

an arrangement of a further embodiment of a forming device, which comprises a shaped body in the rest position, and an inserted into the forming device sheet metal blank.

Fig.1 shows in (a) an arrangement 1 of a forming device 10 and an inserted into the forming device 10 sheet metal blank 3rd

The forming apparatus 10 has a press die 11 and a press bottom table 13. At the press bottom table 13, a tool die 12 is arranged. A tool contour (not designated) of the tool die 12 is shape-defining for a sheet metal structure (not designated) of a sheet metal component 30 to be produced from the sheet metal blank 3 (see FIG. Fig. 1 (b) ).

For this purpose, the tool die 12 has mold elements 20, 21, in particular recesses 20 for producing bends and cavities 35 in the sheet metal component 30 and projections 21 for the expansion of the sheet metal component 30. The tool die 12 is made of laminated sheet metal blanks 2 and pinned.

In addition, the forming device 10 has a molding tool 14. The molding tool 14 consists here of a molded body 5 made of an elastic plastic or rubber (rubber pad), and from a hold-down frame 4. In this case, the molded body 5 is located on the hold-down frame 4.

The molded body 5 has two regions 51, 52 of different material hardness B1, B2. A first region 51 of high material hardness B1 forms an edge 51 of the shaped body 5. A second region 52 of small material hardness B2 forms an inner part 52 of the shaped body 5. The edge 51 surrounds the inner part 52 on the outside 503 in its entirety. It is made in several pieces from at least one first fitting 511 for the first area 51 and a second fitting 521 for the second area 52. In principle, however, it can also be produced in one piece, for example by means of multi-component injection molding.

The molded body 5 extends in a first extension direction 60, which corresponds to an actuating direction of the forming device 10. In the first extension direction 60, it has a thickness 50 of approximately 20-150 mm, in particular 60-100 mm.

In addition, it extends in a second and a third extension direction 61, 62 which extend transversely to the first extension direction 60 and transversely to each other. The first and second regions 51, 52 are arranged next to one another in the second and / or third extension direction 61, 62. The molded body 5 is here substantially plate-shaped, namely approximately cuboid.

Since the molded body 5 has the edge 51 of high material hardness B1, a press die 11 and a press bottom table 13 which are open to the sides can be used.

On an operating side 502 of the shaped body 5 of the hold-down frame 4 is arranged. Shaped body 5 and hold-down frame 4 are in particular to each other over the entire surface.

In the illustrated forming apparatus 10, the holding-down frame 4 of the forming tool 14 are arranged directly on the sheet metal blank 3 and the sheet metal blank 3 directly on the tool die 12. The sheet metal blank 3 is therefore arranged between the two tools 12, 14 of the forming device 10. In this case, the hold-down frame 4 is flush with the sheet metal blank 3, to prevent wrinkling in the sheet metal blank 3 during forming.

As the workpiece, a final trimmed sheet metal blank 3 is used, which may have a thickness (not designated) of up to 10 mm.

The press die 11 is arranged here spaced from the mold 14. The molding tool 14 may also be attached to the press ram 11. In principle, it is also conceivable to arrange the molding tool 14 on the press bottom table 13, and the tool die 12 on the press die 11 facing upper side 301 of the sheet metal blank 3 or on the press die 11th

Fig. 1a shows the forming device 10 in a rest position R. For forming or punching the sheet metal blank 3 in the sheet metal component 30 of the press ram 11 is moved in the first direction of extension 60. He puts on the molded body 5 and then pushes it in the first direction of extension 60. The molded body 5 is deformed.

The edge 51 of the molding 5 presses the hold-down frame 4 with a press stroke d7 (s. Fig. 1 (b) ) corresponding force 8 to the sheet metal blank 3, and this to the Werkzeugmatrize 12. The sheet metal blank 3 is thereby jammed between the hold-down frame 4 and the Werkzeugmatrize 12.

In addition, the edge 51 of the molded body 5 deforms outward. Since he the inner part 52 on the outside 503 (s. Fig. 2 ) surrounds it completely, sealing it to the outside. As a result, the inner part 52 is pressed onto the sheet-metal blank 3 with the force 8 corresponding to the press stroke d7. Due to the pressure of the inner part 52, the sheet metal blank 3 is pressed into or onto the shaped elements 20, 21, in particular into the recesses 20, of the tool die 12. The sheet metal blank 3 is formed essentially free according to the tool contour of the tool die 12. The risk of overstretching due to the self-organization of the sheet metal structure and a cold work hardening during forming is low. The tool contour of the tool die 12 therefore defines the final sheet metal structure of the sheet metal component 30.

Fig. 1 (b) shows the arrangement 1 with the forming device 10 in the working position A and the formed sheet metal component 30. The molded body 5 is deformed according to the press stroke d7. The inner part 52 has flowed into the recesses 20 of the tool die 12 and has taken the sheet metal blank 3 with it, so that this has deformed to the sheet metal component 30.

Fig. 2 shows in (a) and (b) the shaped body 5 of the arrangement 1 from Fig. 1 (a) , in (a) a section AA through (b), and in (b) an actuating side 502 of the molding 5.

The molded body 5 is of cuboid shape and has an edge 51 of high material hardness B1 surrounding it in its entirety on an outer side 503, and an inner part 52 of a material hardness B2 which is smaller relative to the edge 51. The inner part 52 and the edge 51 are each made of a molded piece 521, 522. On the operating side 502 and one of these opposite mounting side 501 are in the embodiments of Fig. 2 (a) and (b) No further regions 53, 54 of greater material hardness B3, B4 are provided.

However, the molded body 5 of the embodiment of the Fig. 2 (c) a plurality of further regions 53, 54 of another, in particular larger, material hardness B3, B4. These further areas 53, 54 are for covering in the sheet metal blank 3 (s. Fig. 4 ) arranged through holes 32 and slots 33 are provided. Through them, the inner part 51 smaller material hardness B1 can not flow into the through holes 32 and slots 33

Fig. 3 shows by way of example a hold-down frame 4 for producing a sheet metal component 30 with an approximately cuboidal cavity 35. The hold-down frame 4 has a bottom 42 in which a cutout 43 is provided in the region of a cavity 35 to be produced in the sheet metal component 3. Through the cutout 43, the inner part 52 of the molded body 5 can create the sheet metal blank 3 and press it into the recess 20 of the tool die 12.

In addition, it has bevelled strips 41, which extends at an angle (not labeled) to the bottom 42. The strips 41 hold the molded body 5 in its position.

Fig. 4 shows by way of example a top side 301 of the sheet metal blank 3. The sheet metal blank 3 has a final trimmed outer contour 31, so that it no longer has to be post-processed after forming in the sheet metal component 30.

In the illustrated embodiment, some through holes 32 and a slot 33 in the sheet metal blank 3 are provided. So that they do not deform during forming, they are covered by a shaped piece or a region 53, 54 of great material hardness B3, B4. The second region 52 smaller, second material hardness B2 can then not flow into the through-holes 32 or the slot 33 and deform the sheet metal blank 3 there unintentionally.

Alternatively to a use of the molded body 5 of Fig. 1 (c) can also be a molded body 5 of the Fig. 2 (a), (b) (Without areas 53, 54 of greater material hardness B3, B4 in the inner part 51) are used. The through holes 32 and the slot 33 are then covered before forming, for example, with a piece of sheet metal (not shown).

Fig. 5 shows an example of an embodiment of a tool die 12. The tool die 12 is produced as a disk set of a plurality of sheet metal blanks 2. These are fastened to each other by means of pins 23. The tool die 12 has as a form of elements a recess 20 in which a plurality of projections 21 are arranged to expand as further form elements.

The recess 20 is completely surrounded by a retaining edge 22. The sheet metal blank 3 is clamped during forming between the retaining edge 22 and the hold-down 4.

Fig. 6 (a) shows the components of a mold 14 and a tool die 12 for producing an engine cover in an exploded view.

The tool die 12 is produced as a lamellae set of two laser-cut sheet metal blanks 2 made of a flat strip material, in particular black sheet metal.

The molding tool 14 includes the hold-down frame 4 and a mounting frame 15. These are made of stamped sheets of a flat strip material. They each have a circumferential strip 41, 151 to hold the multi-piece molded body 5.

The molded body 5 is arranged between the hold-down frame 4 and the mounting frame 15. It has an edge 51 of high material hardness B1 and two internal parts 52 of small material hardness B2. The edge 51 is formed from a plurality of edge-shaped shaped pieces 511, which are arranged side by side in the second and / or third extension direction 61, 62. The inner parts 52 are each formed from a plurality of shaped pieces 521 stacked one above the other in the first extension direction 60.

To produce the engine cover, the final trimmed sheet metal blank 3 is arranged between the tool die 12 and the molding tool 14. This is in Fig. 6 (a) schematically shown by a dashed line for the sheet metal blank 3 schematically.

In the areas in which the sheet metal component 30, here the engine cover, should identify cavities 35, the hold-down 4 and the sheet metal blanks 2 of the tool die 12 have cutouts 20.

Fig. 6 (b) shows the press ram 11 of the forming device 10 with arranged on the press ram 11 mold 14. The mounting frame 15 is fixed to the press ram 11. Between mounting frame 15 and hold-down frame 4, the molded body 5 is arranged. The hold-down frame 4 is attached by means of chains 16 on the mounting frame 15. As a result, it is movable in and against the first extension direction 60. The chains 16 yield during forming and thus allow the deformation of the molded body. 5

Fig. 6 (c) shows the attached to the press base table 13 tool die 12. The disk set of the sheet metal blanks 2 is attached to a support plate 121 which is fixed to the press base table 13.

By using sawn, stamped or laser cut sheet metal blanks 2 for the tool die 12, this is very inexpensive to produce. The production of a tool die 12 is possible in a very short time frame of a few weeks or even days. As a result, design changes in the tool die 12 can be implemented very quickly and inexpensively.

Fig. 7 (a) schematically shows a section through an approximately circular formed with the forming device 10 formed cavity 35th

As a result of a material hardness B1-B4 increasing toward the center M of the cavity 35, the pressure or the force 8 acting on the forming takes on the sheet metal blank 3 towards the center M. The sheet metal blank 3 forms freely. Due to the self-organization of the sheet metal structure and a work hardening during forming can be ensured even with deep cavities 35 that the sheet metal blank 3 does not tear in the process.

With the forming device so cavities 35 with a depth T of up to 200 mm can be produced.

In Fig. 7 (b) - (d) By way of example, a plurality of sheet-metal components 30 are shown, which are produced with the shaping device 10. Fig. 7 (b) shows by way of example an approximately circular cavity 35, Fig. 7 (c) shows an arcuate cavity 35, which is useful for example as part of a hydraulic tank, and Fig. 7 (d) shows a further embodiment of an engine cover with a plurality of flat cavities 35th

Depending on the press stroke d7, the material hardness B1-B4 of the regions 51-54 of the molded body 5, in particular of the inner part 52, and the tool contour of the tool die 12, the sheet metal blank 3 is pressed more or less into or onto the mold elements 20, 21 of the tool die 12 , As a result, sharp or flowing edges 34 of the sheet metal component 30 can be produced. The forming device 10 thus also enables punching.

Through a targeted design of areas 51-54 of different material hardness B1-B4 in the molded body 5, the sheet-metal structure of the sheet-metal component 30 can therefore be specifically influenced. In the sheet metal blank 3 through holes 32 can be introduced before forming and the sheet metal component 30 are finally trimmed before forming. The variation of the material hardness B1 - B4 and / or the thickness 50 of the shaped body 5 also enables simultaneous shaping and punching of the sheet metal blank 3.

Fig. 8 shows an arrangement of a further embodiment of a forming device 10 and an inserted into the forming device 10 sheet metal blank 3. At the press ram 11 of the forming device 10, the molding tool 14 is attached. The tool die 12 is arranged on the press bottom table 13 of the forming device. The sheet metal blank 3 is arranged between the tool die 12 and the molding tool 14.

The molding tool 14 includes the hold-down frame 4 and instead of the mounting frame 15 here an actuating plate 112, which is spaced by spacers 111 from the press ram 11. With the actuating plate 112, the molded body 2 is deformed during forming. For this purpose, the actuating plate 112 preferably rests against the molded body 5 over its entire surface.

The molded body 5 is disposed between the hold-down frame 4 and the operation plate 112. It is here in the rest position R. It has the edge 51 of high material hardness B1 and an inner part 52 of small material hardness B2. The edge 51 of the molded body 5 completely surrounds the inner part 52 here only in a first section A1. As a result, a second section A2 of small material hardness B2 is provided below the edge 51.

In order to attach the molded body 5 to the hold-down frame 4, the mold 14 has side walls 17, which are made of a sheet, for example. On the side walls stops 113 are provided for the actuator plate 112.

The hold-down frame 4 can also here by means of chains 16 on the press ram 11, in particular on an additional mounting frame (s. Fig. 6b ), be attached. As a result, it is movable in and against the first extension direction 60. The chains 16 yield during forming and thus allow the deformation of the molded body. 5

The side walls 17 are attached to the hold-down frame 4. They can surround the molded body 5 and then have the advantage that the inner part 52 does not bulge outward even in the second section A2, which is not surrounded by the edge 51.

The molded body 5 extends in the first extension direction 60, which corresponds to the actuating direction of the forming device 10. In the first extension direction 60, the edge 51 has a first thickness 508 in the first section A1 and the inner part 52 has a second thickness 509 in the second section 2. The first and second sections A1, A2 here each have approximately half the thickness 50 of the shaped body 5. Because of the larger ones Flowability of the inner part 52 small material hardness B2 allows the molded body 5 of this embodiment, a larger press stroke. Thereby, the inner part 52 in recesses 20, which are formed deeper in particular in the direction of actuation 60, flow. Compared to the embodiment of the forming device 10 of Fig. 1 can be formed with this forming device 10 in the sheet metal component 30 larger cavities 35.

In order to reshape the sheet metal blank 3 into the sheet metal component 30, the press die 11, and with it the actuating plate 112, are moved in the actuating direction 60 relative to the press bottom table 13. The edge 51 of the molded body 5 presses the hold-down frame 4 to the sheet metal blank 3, and this to the tool die 12. The sheet metal blank 3 is thereby jammed between the hold-down frame 4 and the tool die 12.

During further movement of the press ram 11 in the actuating direction 60, the actuating plate 112 is pressed onto the molded body 5.

As a result, the inner part 52 is pressed onto the sheet metal blank 3. As a result of the pressure of the inner part 52, it is pressed into or onto the mold elements 20, 21, in particular into the recesses 20, of the tool die 12. The sheet metal blank 3 is formed, analogous to the embodiment of Fig. 1 , substantially according to the tool contour of the tool die 12 free.

LIST OF REFERENCE NUMBERS

1

arrangement

10

reshaping

11

press ram

111

spacer

112

operating plate

113

attack

12

tool die

13

Press undercounter

14

mold

15

mounting frame

151

mounting strip

16

Fasteners, chain

17

Side wall

2

sheet metal blank

201

top

202

bottom

20

Form element, recess

21

Form element, extension

22

retaining edge

23

pen

B1 - B4

First - fourth material hardness (Shore hardness)

3

sheet metal blank

30

sheet metal component

301

top

302

bottom

31

outer contour

32

Through Hole

33

Long hole

34

edge

35

cavity

4

Hold down frame

401

top

402

bottom

41

frame strip

42

ground

43

neckline

5

Shaped body, elastomer body, rubber pad

50

Thickness of the molding

501

mounting side

502

actuating side

503

outside

508

Strength of the first area

509

Strength of the second area

51

First area, edge

511

First fitting

52

Second area, inner part

521

Second fitting

53, 54

Third, fourth area, hole cover

60

First extension direction, actuating direction

61

Second extension direction

62

Third extension direction

d7

Work path / stroke of the press stamp

8th

force

R

Resting position of the mold

A

Working position of the mold

M

center

T

depth

A1

first section

A2

second part

Claims (15)

Shaping tool (14) for punching and / or forming a sheet metal blank (3) into a sheet metal component (30) comprising a shaped body (5) having at least two regions (51-54) of different material hardness (B1-B5). Shaping tool (14) according to claim 1, characterized in that a first region of high material hardness (B1) has an edge (51) of the shaped body (5), and a second region (52) of low material hardness (B2) has an inner part (52) of the shaped body (5), wherein the edge (51) surrounds the inner part (52) on the outside (503) completely in at least a first section (A1). Mold (14) according to one of the preceding claims, characterized in that the shaped body (5) is formed from elastomers, wherein the first region (51) of high material hardness has a Shore hardness of about 80-100, in particular about 95, and the second region (52) of low material hardness has a Shore hardness of about 20-70, in particular of about 50 has. Mold (14) according to one of the preceding claims, characterized in that the shaped body (5) in a first extension direction (60) extends, and the first and the second region (51, 52) in a second and / or third extension direction ( 61, 62) are arranged side by side transversely to the first extension direction (60). Molding tool (14) according to one of the preceding claims, characterized in that the shaped body (5) • either in one piece, Or is made in several pieces from at least one first shaped piece (511) for the first area (51) and a second shaped piece (521) for the second area (52). Mold (14) according to claim 5, characterized in that the first region of a plurality of, in the second and / or third extension direction (61, 62) adjacent to each other first moldings (511), and / or that the second region (52) a plurality of second shaped pieces (521) layered in multiple layers in the first extension direction (60). Mold (14) according to one of the preceding claims, characterized in that it is internally made of a synthetic rubber, in particular ethylene-propylene-diene rubber, and that it has a polyurethane sheath, or at least in the first region of high material hardness, in particular at the edge of the molding, an envelope of fabric-reinforced rubber, in particular Kevlar, steel fabric or the like. Mold (14) according to one of the preceding claims, characterized in that it comprises a hold-down frame (4) which is arranged on an actuating side (502) of the shaped body (5). Molding tool (14) according to one of the preceding claims, characterized in that the at least one section (A1), in which the edge (51) surrounds the inner part (52) completely, on a mounting side (501) opposite the actuating side (502). of the mold (14) is arranged. Forming device (10) for producing a sheet-metal component (30) from a sheet-metal blank (3) comprising a molding tool (14) according to one of the preceding claims, a tool die (12) with at least one molding element (20, 21), and a press ram (11 ), which is movable in and against the first extension direction (60) relative to the tool die (12) has. Forming device (10) according to claim 10, characterized in that the molding tool (14) on the press ram (11) is fixed, wherein the hold-down frame (4) in and against the first extension direction (60) is movable. Arrangement (1) with a forming device (10) for producing a sheet metal component (30) from a sheet metal blank (3) according to any one of claims 10 to 11 and the sheet metal blank (3), which covers the forming element (21, 22) on the Tool mold (12) is arranged, wherein the molding tool (14) between the sheet metal blank (3) and the press ram (11) is arranged. Method for producing a sheet metal component (30) from a sheet metal blank (3), in which a press ram (11) of a forming device (10) relative to a tool die (12) of the forming device (10), the mold elements (20, 21), and at the sheet metal blank (3), the form elements (20, 21) covering, is arranged, in a first Extending direction (60) is moved, wherein between the sheet metal blank (3) and the press ram (11) a mold (14) according to one of claims 1 - 9 is arranged, which has a shaped body (5), which thereby, in particular free, deformed,
characterized in that
the sheet metal blank (3) is clamped to the edge (51) of the shaped body (5) on the workpiece die (12), and that it is deformed with the inner part (52) of the shaped body (5), in particular punched and / or formed. Method according to Claim 13, characterized in that the forces (8) acting on the sheet metal blank (3) during stamping and / or forming of the sheet metal blank (3) from the shaped body (5), in particular in the first direction of extent (60), are defined by areas (8). 51-54) of different material hardness (B1-B4) and / or a thickness (50) of the shaped body (5) can be adjusted in a targeted manner. Method according to one of claims 13-14, characterized in that the edge (51) of the shaped body (5) is deformed spherically outwards during forming by the press stroke, and the inner part (52) seals to the outside.

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