EP3296093B1 - Processing method, processing machine for performing the method, processing centre with a number of such processing machines and movement path of the tools of the processing machine - Google Patents
Processing method, processing machine for performing the method, processing centre with a number of such processing machines and movement path of the tools of the processing machine Download PDFInfo
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- EP3296093B1 EP3296093B1 EP17187980.2A EP17187980A EP3296093B1 EP 3296093 B1 EP3296093 B1 EP 3296093B1 EP 17187980 A EP17187980 A EP 17187980A EP 3296093 B1 EP3296093 B1 EP 3296093B1
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- 238000012545 processing Methods 0.000 title claims description 204
- 238000000034 method Methods 0.000 title claims description 80
- 238000003672 processing method Methods 0.000 title claims description 17
- 238000003754 machining Methods 0.000 claims description 294
- 238000005452 bending Methods 0.000 claims description 113
- 239000000463 material Substances 0.000 claims description 51
- 238000004080 punching Methods 0.000 claims description 48
- 230000008569 process Effects 0.000 claims description 40
- 238000004049 embossing Methods 0.000 description 45
- 238000005520 cutting process Methods 0.000 description 27
- 230000001360 synchronised effect Effects 0.000 description 18
- 238000010586 diagram Methods 0.000 description 8
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- 238000013461 design Methods 0.000 description 4
- 238000006073 displacement reaction Methods 0.000 description 4
- 238000005482 strain hardening Methods 0.000 description 4
- 239000011888 foil Substances 0.000 description 3
- 238000007373 indentation Methods 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000005336 cracking Methods 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000007779 soft material Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/20—Applications of drives for reducing noise or wear
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B1/00—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen
- B30B1/26—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by cams, eccentrics, or cranks
- B30B1/261—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by cams, eccentrics, or cranks by cams
Definitions
- the present invention relates to a processing method for processing a workpiece, a corresponding processing machine with first and second processing elements for performing the processing method, such as a punching, embossing, bending or drawing machine, a processing center with a plurality of such processing machines and a movement pattern of the first and second machining elements for machining the workpiece.
- the quality of the cut surface is defined, for example, by the parameters Edge indentation, smooth-cut surface, smooth-cut surface proportion, roughness of the smooth-cut surface, fracture surface angle, roughness of the fracture surface, width and height of the fracture surface, cut burr, shell-shaped tear, tear, edge zone that can be influenced, material hardness before / after cutting, etc.
- the focus is on the smooth-cut surface proportion, the roughness the smooth cut surface, the punch indentation and the punch burr.
- a smooth-cut surface proportion of 100% of the material thickness, without punch indentation and punch burr is aimed for. Since this ideal has not yet been possible with any progressive tool, such parts have to be reworked in a complex manner.
- a known method for achieving a high quality cut surface is the so-called fine blanking method.
- the workpiece is held in place along the cutting contour with the aid of a ring spike and a reduced cutting gap is used.
- cut surfaces can be obtained that are free of cracks and tears over the entire thickness of the material, and the tightest dimensional and flatness tolerances can also be achieved.
- the prerequisite for using the ring spike is a certain material thickness of the workpiece of more than 1 mm, since with thinner workpieces the transverse forces occurring in the cutting area can lead to unevenness due to the smaller material volume.
- the materials in which the fineblanking process can be used are limited in terms of hardness and brittleness and, moreover, a triple-acting press is required, which has a particularly high guide accuracy of the punch and a rigid press frame.
- counter-cutting Another known method for achieving an improved cut surface quality is what is known as counter-cutting, which is assigned to shear cutting and in which a distinction is made between three-stage counter-cutting and two-stage counter-cutting.
- the workpiece is machined in two or three stages, with a reversal of the cutting direction of the cutting punches used between the individual stages.
- the workpiece is at the three-stage Counter-cutting is first cut in the first stage, counter-cutting takes place in the second stage after reversing the cutting direction, and in the third stage, after another reversal of the cutting direction, the workpiece is finally cut through.
- the cut surface in three-step counter-cutting is characterized in particular by a complete absence of burrs, two smooth-cut surfaces and the fracture zone between these smooth-cut surfaces.
- the DE 42 07 165 A1 a method for punching a metal foil with a pair of punching tools and a pair of punches, which are respectively arranged above and below the metal foil to be processed and are driven by piezoelectric actuators.
- the punches are vibrated so that a half-punching operation and a punching-back operation are repeatedly carried out, the punches butt against the two sides of the workpiece clamped between the punches.
- the metal foil is separated along the shear surface without the formation of burrs due to the low cyclical material fatigue.
- the DE 10 2007 015 467 A1 shows a cam mechanism with a cam member and an engaging member, the engaging member having a rotatably mounted take-off roller for transmitting a drive force introduced into the cam member to the engaging member, the engaging member having at least two rotatably mounted take-off rollers. Furthermore, this document discloses a production method therefor, gives a program for carrying out at least some of the steps of Manufacturing process and discussed a punching and bending machine equipped with such a cam gear.
- FIG. 1 shows the DE 103 27 018 B3 a punching and bending machine with a floor-supported four-column frame in which a press ram and a drawing cushion are guided so that they can be moved vertically.
- the press ram and the drawing cushion can each be driven by a pair of cams arranged on an output shaft.
- the output shaft is driven by an associated drive shaft with an associated gear unit from a motor.
- the motor can be flanged to one or the other end of the respective drive shaft.
- the present invention provides a modular, cam-controlled, step, stamping and bending machining center. This is set up in a freely scalable manner using a number of punching-bending machines described above.
- the material structure of the workpiece can be significantly influenced or damaged by a workpiece machining process, such as a punching process, as a result of local deformations in the machining area and thus the remaining deformability of the material can be significantly reduced.
- a workpiece machining process such as a punching process
- one-step, continuous linear movements of the machining elements are generated during machining of the workpiece during the respective machining strokes.
- these single-stage movement strokes of the machining elements have a negative effect on the remaining deformability of the workpiece in the machining area via the lattice defects present or occurring in the workpiece material, which in turn can lead to undesired cracks in this area.
- one or more machining elements dynamically strike or strike the workpiece positioned in the machine. This can lead to wobbling or vibrations of the machining elements and the workpiece to lead.
- the cutting gap must also be selected to be relatively large in punching machines in order to prevent damage to the processing or active elements (punch, die) of the punching machine during processing.
- the aforementioned relative movements between the corresponding machining elements and the workpiece can negatively affect the quality of the cut surface, the material structure of the workpiece and also the realizable cutting gap in an undesirable manner.
- One object of the present invention is therefore to provide a processing method, a corresponding processing machine and a movement pattern of first and second processing elements that can be used with a large number of materials with different material qualities (from soft, HV 80, modulus of elasticity 100,000 N / m 2 , up to hard, HV 260, modulus of elasticity 185,000 N / m 2 ) also in the thin sheet area with material thicknesses of 0.03-1 [mm] provide an improved surface quality of workpiece processing surfaces and can also suppress a negative influence on the material structure in the workpiece processing area.
- the object is achieved according to the invention by a machining method according to claim 1.
- a workpiece is machined using at least one machine tool.
- the at least one processing machine has a first and a second processing element for processing the workpiece, which is positioned between them, first and second servomechanical drives with a servo actuator and a cam gear, each of which is assigned to the first and second machining elements and connected to them, in order to drive the first and second machining elements for machining the workpiece along at least one machining axis that is perpendicular to a longitudinal axis of the workpiece to be machined, at least one hold-down device for fixing of the workpiece during machining and guides for the machining elements.
- the cam gear of the servomechanical drives has a cam member designed as a cam disk and an engaging member with at least two rotatably mounted take-off rollers for transmitting a drive force introduced into the cam member by the servo actuator to the engaging member.
- the engaging member is designed as a linear slide connected to a corresponding processing element, which has a pivotably mounted pendulum lever which carries the at least two take-off rollers, which are rotatably mounted in such a way that the cam disc for transmitting the drive force introduced to the linear slide on the at least two the cam disc adjacent take-off rollers can be rolled, with the generation of a total active force consisting of two active force components.
- the workpiece to be machined is first positioned between the first and second machining elements of the machine tool.
- the workpiece is then fixed by the at least one hold-down device of the processing machine and the first and second processing elements are brought into contact with the workpiece without changing its shape.
- the workpiece is then processed by the first and second processing elements with a plastic deformation of the workpiece, with the first and second processing elements being at least temporarily equidistant from one another or synchronously by the first and second servomechanical drives of the processing machine in a multi-stage manner during the processing process are driven in opposite directions to each other.
- the invention thus provides for the first time a machining method in which first and second machining elements are first brought into contact with the workpiece before machining the workpiece without changing its shape. Furthermore, in the machining method according to the invention, a workpiece positioned between machining elements is machined for the first time by multi-stage driving of the machining elements at least temporarily with a synchronously equidistant or synchronously opposite movement of the machining elements to one another.
- the machining method according to the invention suppresses an undesired influencing of the intergranular structure of the workpiece in the workpiece machining area and thus, for example, the cut surface quality in stamped parts or the surface quality or surface quality of stamped parts can be improved.
- the synchronously equidistant movement sequence of the first and second processing elements can also ensure that the plastic deformation of the workpiece in the processing area is kept as low as possible.
- the equidistance of the machining elements during machining of the workpiece means that the workpiece section between the machining elements is not compressed or deformed, which in turn leads to a lower number of lattice defects or to a lower density of dislocations in the machining area of the workpiece. Due to the lower number of lattice defects in the workpiece material, undesired work hardening of the material and thus the generation of cracks in the workpiece processing area is also suppressed.
- the synchronously opposing movement sequence of the processing elements which can be used, for example, in stamping, bending or drawing processes, means that the flow behavior of the workpiece material can be influenced in a positive manner. In this way, for example, contours such as undercuts, cutting edges or the like can be formed in an advantageous manner. Furthermore, the workpiece material can relax during the machining process.
- the above processing method can be implemented, for example, as part of a punching, embossing, bending or drawing process.
- a step size of processing stages can be varied by the multi-stage drive of the first and second processing elements when processing the workpiece and / or a movement speed of the first and second processing elements can be varied during processing of the workpiece and / or the first and second processing elements are held in a rest position for a predetermined period of time between the processing stages.
- the step size in the multi-stage drive of the first and second machining elements that is, the gradation of machining by the first and second machining elements, and the moving speed of the first and second machining elements during machining of the workpiece can be appropriately varied according to the material properties of the workpiece or can be chosen.
- a predetermined period of time can be provided between the individual processing stages, in which the first and second processing elements are held in a rest position.
- the speed of movement of the first and second processing elements can advantageously be reduced.
- an increased speed of movement of the first and second processing elements can be selected.
- the cutting speed in the immersion area of the cutting punch can be selected up to a factor of 16 faster than in an eccentric press.
- the first and second machining elements can be held in contact with the workpiece for a predetermined period of time in a rest position of the first and second machining elements without changing the shape of the workpiece before machining the workpiece.
- the first and second machining elements are held in abutment with the first and second machining elements for a predetermined period of time without changing the shape of the workpiece.
- This predetermined period of time between bringing the processing elements into contact with or on the workpiece and the start of workpiece processing can prevent any vibrations of the first and second processing elements and the workpiece caused by the impact of the first and second processing elements the workpiece are caused, decay, whereby relative movements between the machining elements and the workpiece in a direction running transversely to the direction of movement of the machining elements can be suppressed even more reliably during machining.
- the surface quality of the workpiece machining surfaces obtained can be improved even more reliably, and an undesired influencing of the material structure in the machining area by machining can be suppressed even more reliably.
- the first and second machining elements can be driven during machining of the workpiece in a pulsating manner with a feed movement of the machining elements in the direction of the workpiece and with a return movement of the machining elements away from the workpiece that is opposite to the feed movement .
- the return movement of the processing elements in the context of the pulsating drive of the first and second processing elements leads to the fact that the material can relax, whereby the Can realign crystals or atoms in the material.
- This leads to less strain hardening due to the machining and thus to an improved deformation behavior during a subsequent feed movement of the machining elements in the direction of the workpiece, which ultimately leads to an improved surface quality of the machined workpieces with fewer cracks.
- the gentle processing avoids an increasing amount of material on the active elements by applying microparticles of the workpiece. This increases the service life while maintaining the same quality.
- a plurality of processing machines can be used for processing the workpiece in a plurality of successive processing steps, which are encompassed by a common housing structure, whereby a processing center is formed with the plurality of processing machines.
- the workpiece is guided as strip material to the machining center and, for machining in the successive machining steps, is conveyed to and through the machining machines in the machining center.
- a processing machine for carrying out the processing method according to the invention.
- the processing machine according to the invention has: at least a first and a second processing element for processing a workpiece, which is located between them is positioned, at least one hold-down device for fixing the workpiece during machining and guides for the machining elements.
- the first and second processing elements are each assigned servomechanical drives with a servo actuator and a cam gear and connected to them in order to drive the first and second processing elements for processing the workpiece along at least one processing axis that is perpendicular to a longitudinal axis of the workpiece to be processed Workpiece is aligned.
- the cam mechanism has a cam member designed as a cam disk and an engaging member with at least two rotatably mounted take-off rollers for transmitting a drive force introduced into the cam member by the servo actuator to the engaging member.
- the engaging member is designed as a linear slide connected to a corresponding processing element, which has a pivotably mounted pendulum lever which carries the at least two take-off rollers, which are rotatably mounted in such a way that the cam disc for transmitting the drive force introduced to the linear slide on the at least two the cam disc adjacent take-off rollers can be rolled, with the generation of a total active force consisting of two active force components.
- the processing machine according to the invention also has a control device which is designed in such a way that it controls the processing machine in accordance with the processing method according to the invention.
- the invention thus provides for the first time that servomechanical drives with a servo actuator and a cam gear are provided in each case for first and second processing elements of a processing machine.
- this also enables exact reproducibility of the desired movement sequences of the processing elements.
- This configuration also enables better decoupling of the machining elements from the drive with regard to interference. Due to the cam drive, temperature-related expansions in the drive do not have a negative effect on the process. Reactions from the process, such as pulse peaks, also do not have a negative effect on the drive.
- the first and second processing elements are arranged opposite one another along the at least one processing axis.
- punched parts with a very high cut surface quality can be obtained, since machining with two opposite machining elements means that no excessive deformation of the workpiece and thus no undesired cracks occur in the workpiece when machining the workpiece.
- first and second processing elements are arranged offset from one another in a direction running transversely to the at least one processing axis. This arrangement of the processing elements allows the flow behavior of the workpiece material in the processing area to be influenced in a targeted manner.
- a machining center with a plurality of machine tools according to the invention and a conveyor device for conveying the workpiece in the machining center to and through the plurality of machine tools is provided.
- the workpiece corresponds to a strip material and the processing machines are encompassed by a common housing structure.
- a movement pattern of first and second processing elements is for processing one positioned between them Workpiece provided.
- the first and second machining elements come into contact with the workpiece before machining the workpiece, initially without changing its shape, and they move during the machining process with a plastic deformation of the workpiece in a multi-stage manner, at least temporarily, equidistantly or synchronously opposite to each other.
- the first and second machining elements are in contact with the workpiece for a predetermined period of time in a rest position of the first and second machining elements without changing the shape of the workpiece.
- the first and second machining elements move in a pulsating manner with a feed movement of the machining elements in the direction of the workpiece and with a return movement of the machining elements away from the workpiece that is opposite to the feed movement.
- the movement of the first and second processing elements takes place during the processing of the workpiece as part of an embossing process with n steps and a feed amount due to the feed movement of the first and second processing elements in each of the n processing steps is in relation to an initial thickness s of the workpiece before the Machining along a direction perpendicular to a longitudinal axis of the workpiece is (1/2 ⁇ 1 / n ⁇ s) and a return amount by the returning movement of the first and second machining elements in each of the n machining stages is in proportion to the initial thickness s of the workpiece before machining along the direction perpendicular to the longitudinal axis of the workpiece (3/10 ⁇ 1 / n ⁇ s).
- a soft material such as CuSn6 can be given a spring property.
- the first processing element corresponds to a bending punch and the second processing element corresponds to a bending core and the movement of the bending punch and the bending core during the machining of the workpiece as part of a bending process takes place in n stages.
- a feed amount due to the feed movement of the bending punch in each of the n processing stages in relation to an initial thickness s of the workpiece before processing along a direction perpendicular to a longitudinal axis of the workpiece is (3 ⁇ 1 / n ⁇ s) and a return amount due to the return movement of the bending punch, a return amount due to the return movement of the bending core and a feed amount due to the feeding movement of the bending core in each of the n processing stages in relation to the initial thickness s of the workpiece before processing along the direction perpendicular to the longitudinal axis of the workpiece is (1 / n s).
- the first machining element corresponds to a drawing punch and the second machining element corresponds to a drawing die and the movement of the drawing punch and the drawing die during the machining of the workpiece as part of a drawing process takes place in n stages.
- a feed amount by the feed movement of the drawing punch in each of the n processing stages in relation to an initial thickness s of the workpiece before processing along a direction perpendicular to a longitudinal axis of the workpiece is (120 ⁇ 1 / n ⁇ s) and a return amount by the return movement of the drawing punch, a return amount by the returning movement of the drawing die and a feeding amount by the feeding movement of the drawing die in each of the n processing stages in relation to the initial thickness s of the workpiece before processing along the direction perpendicular to the longitudinal axis of the workpiece is (1/120 n ⁇ s).
- the number of processing stages n can be equal to 10 or 12.
- the above movement patterns can be used in the processing method according to the invention using the processing machine according to the invention.
- Embodiments of the processing machine according to the invention for carrying out the processing method according to the invention, the processing center according to the invention and the movement pattern according to the invention of first and second movement elements in the context of processing methods according to the invention are described in detail with reference to the figures.
- FIG. 13 is a front view of the punching device 1 according to the invention for punching a workpiece W
- the FIG Figure 1A The arrow shown in the immediate vicinity of the workpiece W indicates a feed direction of the workpiece, which is present as strip material, along the longitudinal axis WL of the workpiece W.
- Figure 1B FIG. 3 is a side view of the FIG Figure 1A illustrated punching device 1 and according to the invention
- Figure 1C FIG. 3 is a cross-sectional view of the FIG Figure 1A punching device 1 shown along the in Figure 1A Line AA shown, the section AA being a stepped Section which does not run through servo actuators 14 of the punching device 1 shown in FIG Figure 1B and Figure 1C are shown.
- the longitudinal axis WL of the workpiece W to be machined extends along a Y direction and a machining axis B extends along a Z direction.
- the punching device 1 comprises first and second punches 2, 4, which in the case of FIG Figure 1C The illustration shown along the machining axis B are arranged opposite one another.
- the first and second punches 2, 4 are at the in Figure 1C
- the punching device 1 shown here is surrounded by first and second punch guides 3, 5, which enable the punch 2, 4 to be precisely linearly guided along the machining axis B.
- the punching device 1 also has a spring-loaded hold-down 7, two cutting dies 9, 9 'and first and second servomechanical drives for driving the first and second punches 2, 4, which are each assigned to the punches 2, 4 and are connected to them.
- the first and second servomechanical drives each include a servo actuator 14 and a cam gear 15 with a cam member 6, an engaging member 8, a pendulum lever 24 and two take-off rollers 12 'and 12 ", the engaging member 8 via a punch holder with a corresponding punch 2, 4 is coupled in order to transmit a movement of the engagement member 8 to a corresponding punch 2, 4.
- the movement of the punch 2, 4 is determined by the design of the cam member 6 provided in the cam mechanism 15.
- the sequence of movements the individual punch 2, 4 can be changed as desired by varying the design of the cam member 6.
- the punching device 1 shown is configured in such a way that the punches 2, 4 move synchronously equidistant from one another in a multi-stage manner during the punching of the workpiece W by means of the drive by means of the first and second servomechanical drives. This movement during the machining process results from the superposition of a mechanical cam and an electronic cam.
- the Figures 1A to 1E The punching device 1 shown also has a control device not shown in the figures which is designed in such a way that it controls the synchronous operation of the two servo actuators 14.
- FIGS 1D and 1E a part of the punching device 1 according to the invention is shown while a punching method according to the invention is being carried out.
- the Figures 1D and 1E show a processing state between two successive processing stages in the context of the punching method according to the invention by the multi-stage drive of the first and second punch 2, 4 before the punching process is completed.
- the workpiece W is not deformed during the processing shown here by the first and second punches 2, 4 between them and the first and second punches 2, 4 have a constant distance from one another during the punching of the workpiece in each of the several processing stages , that is, the punches 2, 4 are arranged equidistant from one another in each processing stage.
- a rotation of the servo actuator 14 is transmitted via an output shaft of the same to the cam element 6 of the cam gear 15 and the rotation of the cam element 6 is, as will be described in detail later, via a coupling with the pendulum lever 24 mounted in the engagement element 8 converted into a linear movement of the engaging member 8.
- the hold-down 7 of the in Figure 1C The punching device 1 shown is spring-loaded with respect to the punch guide 3 and designed to lead with respect to the punch 2, that is, the hold-down 7 is in an initial position before the workpiece W is fixed with the help of the hold-down 7 along the processing axis B in Figure 1C opposite the punch 2 and, when the punch 2 moves along the machining axis B in the direction of the workpiece, it therefore comes into contact with the workpiece W in front of the punch 2 in order to fix it.
- the hold-down device it can also be provided in any other suitable configuration in order to fix the workpiece during processing.
- the hold-down 7 can also have a contour provided for the workpiece so that it is held securely and with as little play as possible. Through the Fixing of the workpiece W with the hold-down 7 ensures that the workpiece W does not move during the machining, and thus the machining can be carried out with the required precision.
- FIG. 2A and 2B a partial cross-sectional view of an embossing device 1 'described as a second embodiment of the processing machine according to the invention, wherein in the Figures 2A and 2B only the area of the embossing device 1 'adjacent to the workpiece W is shown and the other components of the embossing device 1' are not shown, since these essentially correspond to the elements shown and described in detail in the first embodiment of the processing machine according to the invention.
- the figure shown extends the longitudinal axis WL of the workpiece W to be machined in the Figures 2A and 2B illustrated image along a Y direction and first and second machining axes B1, B2 extend along a Z direction.
- the embossing device 1 'shown serves, for example, for embossing a cutting edge on a smooth-cut surface of the workpiece W.
- the embossing device 1 ' according to the invention comprises first and second embossing dies 2', 4 ', which are linearly guided by first and second die guides 3', 5 'along the processing axes B1, B2, a spring-loaded hold-down device 7' and first and second servomechanical ones Drives (not shown).
- the servomechanical drives and the punch guides 3 ', 5' in this second embodiment essentially correspond to the elements shown and described in the first embodiment of the processing machine according to the invention and a detailed description of these elements is therefore dispensed with at this point.
- the first and second embossing dies 2 ', 4' of the embossing device 1 ' are in a direction running transversely to the processing axes B1, B2, that is, along the X-direction Figure 2B , arranged offset to one another.
- the embossing device 1 ′ is not limited to the first and second embossing punches 2 ', 4' along the X direction in Figure 2B are arranged offset to one another, and the dies 2 ', 4' can also be along the in Figure 2B Y-direction shown offset from one another or these can be arranged opposite one another along a common machining axis, as is described in the first embodiment of the machine tool according to the invention.
- the embossing device 1 'shown is configured in such a way that the embossing dies 2', 4 'move synchronously in opposite directions to one another in a multistage manner during the machining of the workpiece by the drive by means of the first and second servomechanical drives.
- the in Figures 2A and 2B The embossing device 1 ′ shown also has a control device not shown in the figures, described later, which is designed in such a way that it controls the synchronous operation of the two servo actuators 14.
- the hold-down device 7 'of the embossing device 1' according to the invention has a recess 7a on the side of the workpiece W, which is used to receive the material flowing during the embossing of the workpiece W and thus to form the cutting edge during the embossing process.
- the rest of the design of the hold-down 7 ' essentially corresponds to the design of the hold-down 7 described above in connection with the punching device 1 according to the invention the embossing processing can be influenced in an advantageous manner in a targeted manner.
- the workpiece material can flow better in the direction of the recess 7a during the machining of the workpiece W through the offset arrangement of the embossing dies 2 ', 4' in order to form the cutting edge of the workpiece.
- FIGS Figures 3A and 3B a partial cross-sectional view of a bending device 1 ′′ described as a third embodiment of the processing machine according to the invention, wherein in FIGS Figures 3A and 3B only the area of the bending device 1 ′′ adjoining the workpiece W is shown and on a Representation of the other components of the bending device 1 ′′ is omitted, since these essentially correspond to the elements shown and described in detail in the first embodiment of the processing machine according to the invention.
- the bending device 1 comprises "a bending punch 2" and a bending core 4 ", which are linearly guided by first and second guides 3", 5 "along the processing axes B1, B2, a spring-loaded hold-down 7" and first and second servomechanical Drives (not shown).
- the servomechanical drives and the spring-loaded hold-down 7 ′′ in this third embodiment essentially correspond to the elements shown and described in the first embodiment of the processing machine according to the invention and a detailed description of these elements is therefore dispensed with at this point Figure 3A
- the illustrated guide 5 "of the bending core 4" is designed in such a way that it guides the bending core 4 "linearly along the processing axis B2 and also has a recess which enables the bending punch 2" to penetrate the guide 5 "during the bending process the end Figures 3A and 3B
- the bending punch 2 ′′ and the bending core 4 ′′ are arranged offset from one another in a direction running transversely to the machining axes B1, B2, that is, along the X direction.
- Both the punch 2 ′′ and the bending core 4 ′′ have at one end thereof on the side of the workpiece W to be machined a convex elevation or a projection in the X direction, which is shaped as a function of the bending contour to be produced.
- the bending device 1 ′′ shown is configured in such a way that the punch 2 ′′ and the bending core 4 ′′ rotate at least temporarily synchronously in opposite directions during the machining of the workpiece W by the drive by means of the first and second servomechanical drives move towards each other.
- the bending device 1 ′′ shown also has a control device not shown in the figures, described later, which is designed such that it controls the synchronous operation of the two servo actuators 14 Figures 3A and 3B
- the bending process shown by the punch 2 ′′ and the bending core 4 ′′, the workpiece W is folded in the direction of the Z-axis.
- FIG. 4A and 4B a partial cross-sectional view of a pulling device 1 '''described as a fourth embodiment of the processing machine according to the invention, wherein in the Figures 4A and 4B only the area of the pulling device 1 '''' adjacent to the workpiece W is shown and the other components of the pulling device 1 '''are not shown, since these essentially correspond to the elements shown and described in detail in the first embodiment of the processing machine according to the invention.
- the longitudinal axis WL of the workpiece W to be processed extends into the Figures 4A and 4B along a Y direction and first and second machining axes B1, B2 extend along a Z direction.
- the inventive drawing device 1 "'comprises a drawing punch 2'" and a drawing die 4 "', which are linearly guided by first and second guides 3'", 5 "'along the machining axes B1, B2, a spring-loaded hold-down device 7"'and first and second servomechanical drives (not shown).
- the servomechanical drives, the first and second guides 3 "', 5'" and the spring-loaded hold-down device 7 '"in this fourth embodiment essentially correspond to the elements shown and described in the first embodiment of the processing machine according to the invention and a detailed description of these elements is therefore dispensed with at this point.
- the drawing die 4 '' ' has at one end thereof on the side of the workpiece W to be machined a recess for receiving the workpiece material deformed by the drawing punch 2' '', the contour of the recess of the drawing die 4 '' 'depending on the desired shape of the finished machined workpiece is formed.
- the drawing device 1 "'shown is configured in such a way that the drawing punch 2'" and the drawing die 4 "'move in a multi-stage manner, at least temporarily, synchronously in opposite directions during the machining of the workpiece W by the drive by means of the first and second servomechanical drives In this case, within the scope of the individual processing stages, there is a synchronous opposite return movement of the drawing punch 2 '"and the drawing die 4"' away from the workpiece W and a synchronous opposite feed movement of the drawing punch 2 "'and the drawing die 4"' towards the workpiece W.
- the drawing device 1 ′′ 'shown also has a control device not shown in the figures, described later, which is designed in such a way that it controls the synchronous operation of the two servo actuators 14.
- the cam 6 of the cam gear 15 is designed in the form shown here as a counterclockwise rotating cam 6 which is coupled to an output shaft of the servo actuator 14, and the engagement member 8 of the cam gear 15 is in the form shown here as a linear slide 8 educated.
- the linear slide 8 is guided so as to be longitudinally displaceable in a guide designed as a housing structure, so to speak, which resembles a web 22.
- the one used here Cam gear 15 has at least two take-off rollers 12 'and 12 ".
- the two take-off rollers 12' and 12" are carried by the pendulum lever 24, on which they are rotatably mounted is mounted in the end section of the linear slide 8 facing the cam 6.
- the drive force impressed by the cam 6 can be broken down into two drive-force components 28, 34 which each act on the take-off roller 12' and on the take-off roller 12".
- the first drive force component 28 (arrow F ') with the take-off roller 12' can be broken down into a first transverse force component 30 (arrow F transverse ') and a first active force component 32 (arrow F act').
- the second drive force component 34 can be broken down into a second transverse force component 36 (arrow F transverse ”) and a second active force component 38 (arrow F active”)
- the two transverse force components 30 and 36 compensate each other and lead to the transverse forces being able to be reduced to zero in the ideal case.
- FIGS. 6A to 6D show a machining center 20 with a plurality of machine tools according to the invention.
- the machining center 20 shown here are exemplarily four machine tools according to the invention from the machine machines described above according to the first to fourth embodiments arranged next to one another on a support frame and encompassed by a common housing structure or a common frame.
- a conveying device 21 is also provided in order to convey the workpiece W guided as strip material to the machining center 20 to the individual machining machines in the machining center 20 and through them.
- the workpiece W guided as strip material to the machining center can be punched in a first machining step using a punching device according to the invention, whereby a punched surface with a very high smooth cut portion is obtained, and then the workpiece can be processed further to a bending device according to the invention , an embossing device according to the invention and a drawing device according to the invention are conveyed in the machining center.
- the machining of the workpiece in the machining center can be completed without handling the workpiece between the respective machining steps.
- the combination according to the invention of several processing machines in a single processing center thus significantly reduces the handling effort when processing the workpiece and thus the processing costs.
- FIG. 7 a movement pattern according to the invention, first and second punch for processing a workpiece in the context of a punching method according to the invention using the in Figures 1A to 1E shown punching device 1 described.
- Fig. 7 the vertical axis represents a path corresponding to the stroke movement of the respective punch and the horizontal axis represents the time curve.
- the distance indicated by D1 corresponds to the thickness of the workpiece or the strip thickness.
- One line L1 in Fig. 5 represents a sequence of movements of the first punch 2 of the punching device 1 and a line L2 in Fig. 7 shows a sequence of movements of the second punch 4 of the punching device 1.
- the workpiece W to be processed is first positioned between the punches 2, 4 and the workpiece is fixed by the hold-down device 7 of the punching device 1 (in Fig. 7 not shown).
- the first and second punches 2, 4 are in a position of rest with the workpiece W for a predetermined period of time T2, which is defined between the times t1 and t2, after they strike the workpiece W in contact, that is, between the impact of the punches on the workpiece at time t1 and the start of workpiece machining at time t2, a predetermined time period T2 is provided in which the punches do not move or are not driven.
- vibrations of the punches 2, 4 and the workpiece W which can arise when the punches hit the workpiece, can be reduced and the quality of the cut surface of the punched surfaces obtained can be significantly improved as a result.
- the movement pattern according to the invention is not limited to the fact that the punches 2, 4 are in a rest position for a predetermined period of time after they hit the workpiece, and processing can be carried out immediately after the punches 2, 4 have hit or come into contact on or with the workpiece without a period of time with a rest position of the punches being provided between the impact of the punch on the workpiece and the start of workpiece machining.
- the first and second punches 2, 4 then move by means of the drive by means of the servomechanical ones Drives in a multistage manner in the same direction or synchronously equidistant from one another in order to punch the workpiece W.
- the first punch 2 moves in one direction towards the workpiece W and the second punch 4 moves concurrently or synchronously with the movement of the first punch 2 in a direction opposite to the direction of movement of the first punch 2.
- the punches 2, 4 of the punching device 1 move during the processing or the punching process of the workpiece W at a substantially constant distance from one another.
- the movement pattern shown as part of the punching process according to the invention is a predetermined time period T1 provided between the individual processing stages of the workpiece by the multi-stage movement of the punch, for example between the times t3 and t4, in which the punch are in a rest position and are not driven.
- This predetermined time period T1 can be appropriately varied depending on the material properties of the workpiece, such as the hardness of the workpiece. Due to the predetermined time period T1 provided in the movement pattern described here and the corresponding processing method, the lattice structure of the workpiece material can relax. In addition, the entire drive train is relaxed, right down to the respective punching punches. In connection with the multiple processing stages, this results in increased process capability.
- the step size of the processing stages can also be determined by the multi-stage drive of the first and second punches 2, 4 when processing the workpiece and a movement speed of the first and second punches 2, 4 during processing of the workpiece can be varied in order to obtain an improved cut surface quality of the stamped parts.
- the first and second punches 2, 4 move back to their starting positions before machining the workpiece in order to release or eject the punching slug, as indicated by the lines L1 and L2.
- the synchronous movement sequence of the punch with this movement pattern results from the superposition of a mechanical curve and an electronic curve.
- the synchronous operation of the two punches is ensured with the in Fig. 7
- the movement pattern shown is controlled using the control device provided in the control device 1 with the aid of a virtual master axis.
- the virtual master axis acts as a master in relation to the active axes (slaves) of the servo actuators.
- the position deviation of the axis should be in the order of magnitude less than 0.005 [mm].
- the virtual axis is supported by a control loop.
- sensors on the active elements continuously record force, displacement and structure-borne noise and transmit them as a correction value to the master axis at a speed of ⁇ 1/125 [sec].
- Fig. 8 is a further inventive movement pattern of first and second stamping dies for processing a workpiece in the context of an inventive stamping method using the in Figures 2A and 2B illustrated embossing device 1 'described.
- FIG Fig. 8 shows a distance indicated by D1 corresponds to the thickness of the workpiece or the strip thickness.
- a line L1 'in Fig. 8 shows a sequence of movements of the first stamping punch 2 'of the stamping device 1' and a line L2 'in FIG Fig. 8 shows a sequence of movements of the second stamping die 4 'of the stamping device 1'.
- the workpiece W to be processed is first positioned between the first and second embossing punches 2 ', 4' of the embossing device 1 'and then the workpiece is fixed by the hold-down 7' of the embossing device 1 ' (in Fig. 8 not shown). Then the Sequence of movements of the first and second dies 2 ', 4' for processing the workpiece.
- the dies 2 ', 4' move by the drive by means of the associated servomechanical drives initially linearly in the direction of the workpiece W until it comes into contact with the workpiece at a point in time t5 come.
- no predetermined period of time with a rest position of the dies 2 ', 4' is provided between the impact of the dies 2 ', 4' on the workpiece W and the start of the actual embossing of the workpiece W.
- the embossing dies are held in contact with the workpiece for a predetermined period of time in a rest position of the embossing dies before the machining of the workpiece.
- the embossing of the workpiece does not begin until the predetermined period of time has elapsed, starting from the impact of the die on the workpiece, which causes vibrations of the die and the workpiece, that is, a relative movement of these components, which occurs when the die hits the workpiece can be caused, can fade away.
- the first and second dies 2 ', 4' move synchronously in opposite directions and also in a pulsating manner through the drive by means of the first and second servomechanical drives in a multi-stage manner to stamp the workpiece W.
- the first and second dies 2 ', 4' both move in a multi-stage pulsating manner towards the workpiece W, that is, the two, during the machining of the workpiece W by the drive by means of the respective servomechanical drives
- Embossing dies 2 ', 4' move along the processing axes B1, B2, which in Figures 2A and 2B are shown, one on top of the other to, whereby the pulsating movement of the dies 2 ', 4' provides a feed movement of the dies 2 ', 4' towards the workpiece W and a return movement of the dies 2 ', 4' away from the workpiece in the opposite direction to the feed movement are.
- the material of the workpiece W can relax during the machining, as a result of which an excessive increase in the dislocation density in the workpiece material is suppressed in the course of the machining.
- Fig. 8 For the sake of simplicity, only the first four processing stages of this embossing process are shown.
- the machining angle based on the rotation of the respective servo actuator is 40 ° and the punch movement of the respective embossing punches per machining stage is defined as follows. Stamp feed movement: +0.010 mm / 1.5 ° Stamp rest position: ⁇ 0.000 mm / 1 ° Stamp return movement: -0.006 mm / 1.5 °
- a positive sign relates to a movement of the die in the direction of the workpiece and a negative sign relates to a movement of the respective die away from the workpiece.
- a feed amount due to the feed movement of the first and second dies 2 ', 4' in each of the ten processing stages is thus approximately 5% of the initial thickness s of the workpiece before processing and a Return amount by the return movement of the first and second Embossing die 2 ', 4' in each of the ten processing stages is approximately 3% of the initial thickness s of the workpiece before processing.
- the synchronous operation of the servo actuators is controlled by a virtual master axis using the control device provided in the embossing device 1 'and the virtual master axis acts as a master with respect to the active axes of the servo actuators (slave ).
- the position deviation of the axis should be less than 0.005 [mm].
- the virtual axis is supported by a control loop in order to achieve this accuracy, taking into account the influencing variables, force, speed, acceleration and mass inertia acting in the process.
- sensors on the active elements continuously record force, displacement and structure-borne noise and transmit them as a correction value to the master axis at a speed of 1/125 [sec].
- the first and second embossing dies 2 ′, 4 ′ move back to their starting positions before the processing of the workpiece W in order to release the processed workpiece W.
- FIG. 9 is then a further movement pattern according to the invention of a bending punch and a bending core as machining elements according to the invention for machining a workpiece as part of a bending method according to the invention using the in Figures 3A and 3B illustrated bending device 1 "described.
- FIG. 9 a distance indicated by D1 corresponds to the thickness of the workpiece or the strip thickness.
- a line L1 "in Fig. 9 represents a movement sequence of the bending punch 2 ′′ of the bending device 1 ′′ and a line L2 ′′ in FIG Fig. 9 represents a movement sequence of the bending core 4 ′′ of the bending device 1 ′′.
- the workpiece W to be processed is first positioned between the bending punch 2 "and the bending core 4" of the bending device 1 "and then the workpiece is fixed by the hold-down 7" of the bending device 1 "(in Fig. 9 not shown). Then the sequence of movements of the bending punch 2 ′′ and the bending core 4 ′′ for machining the workpiece begins.
- the punch 2 "and the bending core 4" move linearly towards the workpiece through the drive by means of the associated servomechanical drives until they come into contact with the workpiece.
- the bending core 4 ′′ is initially held in contact with the workpiece in a rest position after it has hit the workpiece and exerts a predetermined clamping force on the workpiece Workpiece W and the start of the actual bending processing of the workpiece, no predetermined period of time with a rest position of the bending punch 2 ′′ is provided in a rest position of the bending punch is held in abutment with the workpiece or is in contact with it
- Changes in the bending punch and the workpiece that is, a relative movement of these components, which can be caused when the bending punch hits the workpiece, can subside.
- the bending punch 2 ′′ moves in a multi-stage pulsating manner through the drive by means of the associated servomechanical drive during the machining process in order to bend the workpiece W. More precisely, the bending punch 2 ′′ moves during the Machining process by the drive by means of the associated servomechanical drive in a multi-stage manner pulsating in the direction of the workpiece, with the pulsating movement of the punch 2 "a feed movement of the punch 2" in the direction of the workpiece W and one to the feed movement oppositely oriented return movement of the bending punch 2 ′′ away from the workpiece is provided, which is, for example, 20% of the feed movement.
- the bending core 4 ′′ is driven by a corresponding servomechanical drive and is brought closer to the workpiece until it comes into contact with the workpiece Line L2 "in Fig. 9 is shown, and this exerts a clamping force on the workpiece.
- the bending core 4 ′′ remains in the above-described contact position with the workpiece Time t6 also starts a return movement of the bending core 4 ′′ in the direction away from the workpiece and the bending core 4 ′′ separates from the workpiece, whereby a synchronous movement of the bending punch 2 ′′ and the bending core 4 ′′ begins.
- the return movement of the bending core is a maximum of 1/10 of the workpiece thickness.
- the bending punch and the bending core move through the drive by means of the associated servomechanical drives in the context of the next processing stage again temporarily synchronously in the direction of the workpiece, with the bending core being brought into contact or abutment with the workpiece again without deformation and the bending punch provides for further deformation of the workpiece when the bending punch hits the workpiece surface.
- the stroke of the bending punch in the context of this feed movement is greater than the stroke of the bending core in the direction of the workpiece.
- the bending core is thus also held in a contact position with the workpiece during the deforming machining of the workpiece by the bending punch in the context of this machining stage until the latter is
- This sequence of movements of the bending punch 2 "and the bending core 4" is then repeated in every further processing stage.
- the aforementioned return movements of the bending punch and the bending core during the machining process relaxes the lattice structure in the workpiece and this significantly reduces the risk of cracking or unwanted structural changes in hard materials and small bending radii.
- the in Fig. 9 illustrated exemplary movement pattern with a temporarily synchronous counter-rotating movement of the bending punch and the bending core, the workpiece W is bent with a thickness s of 0.1 mm by the bending punch 2 ′′ and the bending core 4 ′′ in 10 processing steps.
- the movements of the bending punch and the bending core in relation to the rotation of the respective servo actuator are defined as follows for each processing stage. Bending punch feed movement: +0.03 mm / 3 ° Bending punch return movement: -0.01 mm / 1 ° Flexural core return movement: -0.01 mm / 1 ° Flexural core feed movement: +0.01 mm / 1 °
- a positive sign relates to a movement of the machining elements in the direction of the workpiece and a negative sign relates to a movement of the respective machining elements away from the workpiece.
- the synchronous running of the servo actuators is controlled by a virtual master axis using the control device provided for the bending device 1 "and the virtual master axis acts as a master in relation to the active axes of the servo actuators (slave) Position of an active axis, the position deviation of the axis should be less than 0.005 [mm].
- the virtual axis is supported by a control loop. In this control loop, sensors on the active elements continuously record force, displacement and structure-borne noise and transmit them as a correction value to the master axis at a speed of 1/125 [sec].
- the bending punch and the bending core move back to their starting positions before the processing of the workpiece in order to release the processed workpiece.
- FIG. 10 is then a further movement pattern according to the invention of a drawing punch and a drawing die as machining elements according to the invention for machining a workpiece as part of a drawing method according to the invention using the in Figures 4A and 4B shown pulling device 1 "'described.
- Fig. 10 represents a path corresponding to the stroke movement of the respective machining elements and the horizontal axis represents the time course, where D0 in Fig. 10 represents a start of drawing with a view to the movement of the drawing punch and the drawing die, and D2 represents a drawing end.
- a line L1 "'in Fig. 10 shows a movement sequence of the drawing punch 2 "'of the drawing device 1'" and a line L2 '"in Fig. 10 shows a sequence of movements of the drawing die 4 '"of the drawing device 1"'.
- the workpiece W to be machined is first positioned between the drawing punch 2 "'and the drawing die 4'" of the drawing device 1 "'and then the workpiece is fixed by the hold-down device 7"' of the drawing device 1 "'(in Fig. 10 not shown). Then the sequence of movements of the drawing punch 2 '"and the drawing die 4'" for machining the workpiece begins.
- the drawing punch 2 "'and the drawing die 4"' move by the drive by means of the associated servomechanical drives first linearly towards the workpiece until they come into contact with the workpiece.
- the drawing die 4 '′′ is initially held in contact with the workpiece in a rest position after striking the workpiece and this exerts a predetermined clamping force on the workpiece.
- the drawing punch 2 "' moves during of the machining process by the drive by means of the associated servomechanical drive in a multi-stage manner, pulsating in the direction of the workpiece, with the pulsating movement of the drawing punch 2 '''a feed movement of the drawing punch 2''' in the direction of the workpiece W and a
- the return movement of the drawing punch 2 "'away from the workpiece, which is directed opposite to the feed movement, is provided, which is, for example, 20% of the forward movement.
- the drawing die 4 ''' is driven by a corresponding servomechanical drive and brought closer to the workpiece until it comes into contact with the workpiece with the line L2 '"in Fig. 10 is shown, and this exerts a clamping force on the workpiece.
- the drawing die 4 "'remains in the aforementioned contact position with the workpiece.
- a return movement of the drawing die 4''' in the direction away from the workpiece also starts and the drawing die 4 '''is released from the workpiece, as a result of which a synchronous movement of these elements begins in opposite directions.
- the return movement of the drawing die is a maximum of 1/10 of the workpiece thickness.
- the drawing die is thus also held in a contact position with the workpiece during the deforming machining of the workpiece by the drawing punch as part of this processing stage until it is released from the workpiece again with a further return movement of the drawing punch 2 "'.
- This sequence of movements of the drawing punch 2"' and the drawing die 4 '" is then repeated in every further processing stage.
- the aforementioned return movements of the drawing punch and the drawing die during the processing process relax the lattice structure in the workpiece and thereby reduce the risk of cracking or undesired structural changes Degree of deformation of a drawing stage and thus it is possible to form several drawing sequences in one drawing sequence.
- FIG. 10 illustrated exemplary movement pattern with a temporarily synchronous counter-rotating movement of the drawing punch and the drawing die the workpiece W with a thickness s of 0.1 mm is drawn through the drawing punch 2 '"and the drawing die 4"' in 12 processing steps.
- the movements of the drawing punch and the drawing die in relation to the rotation of the respective servo actuator are defined as follows for each processing stage. Drawing punch feed movement: +1.00 mm / 5 ° Drawing punch return movement: -0.01 mm / 1 ° Draw die return movement: -0.01 mm / 1 ° Draw die feed movement: +0.01 mm / 1 °
- a positive sign relates to a movement of the machining elements in the direction of the workpiece and a negative sign relates to a movement of the respective machining elements away from the workpiece.
- the synchronous operation of the servo actuators is controlled by a virtual master axis using the control device provided in the drawing device 1 '' 'and the virtual master axis acts as a master with respect to the active axes of the servo actuators (slave)
- the position deviation of the axis should be less than 0.005 [mm].
- the virtual axis is supported by a control loop.
- sensors on the active elements continuously record force, displacement and structure-borne noise and transmit them as a correction value to the master axis at a speed of 1/125 [sec].
- the drawing punch and the drawing die move back to their starting positions before the workpiece was processed in order to release the processed workpiece.
- the processing is divided into 10 or 12 processing stages or steps is described, the present invention is not limited thereto and the multi-stage machining of the workpiece can be divided into any number of machining stages.
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Description
Die vorliegende Erfindung betrifft ein Bearbeitungsverfahren zum Bearbeiten eines Werkstücks, eine entsprechende Bearbeitungsmaschine mit ersten und zweiten Bearbeitungselementen zum Ausführen des Bearbeitungsverfahrens, wie beispielsweise eine Stanz-, Präge-, Biege- oder Ziehmaschine, ein Bearbeitungszentrum mit einer Mehrzahl derartiger Bearbeitungsmaschinen sowie ein Bewegungsmuster der ersten und zweiten Bearbeitungselemente zum Bearbeiten des Werkstücks.The present invention relates to a processing method for processing a workpiece, a corresponding processing machine with first and second processing elements for performing the processing method, such as a punching, embossing, bending or drawing machine, a processing center with a plurality of such processing machines and a movement pattern of the first and second machining elements for machining the workpiece.
Durch Bearbeitungsverfahren erzeugte Oberflächen von Werkstücken, wie beispielsweise Schnittflächen von Stanzteilen, sollen zunehmend als Funktionsflächen dienen, ohne dass die Werkstücke nach der Bearbeitung einer Nachbearbeitung unterzogen werden müssen. Beim Bearbeiten von Werkstücken, wie insbesondere beim Trennen oder Umformen, können bei den Werkstückbearbeitungsflächen jedoch Mikrorisse entstehen, welche bei einer dynamischen Beanspruchung der aus den Werkstücken gefertigten Bauteile zu einer Kerbwirkung führen können. Dies kann wiederum die Standzeiten der jeweiligen Bauteile negativ beeinflussen. Aus diesem Grund bestehen sehr hohe Anforderungen an die durch Bearbeitungsverfahren erzeugten Oberflächen.Surfaces of workpieces produced by processing methods, such as, for example, cut surfaces of stamped parts, are to increasingly serve as functional surfaces without the workpieces having to be subjected to post-processing after processing. When machining workpieces, such as in particular when separating or reshaping, however, microcracks can arise in the workpiece machining surfaces, which can lead to a notch effect in the event of dynamic loading of the components made from the workpieces. This in turn can negatively affect the service life of the respective components. For this reason, there are very high demands on the surfaces produced by machining processes.
Im Zuge der Bestrebungen, eine verbesserte Oberflächenbeschaffenheit von Werkstückbearbeitungsflächen zu erreichen, wurden in der vergangenen Zeit verschiedene Vorrichtungen und Verfahren vorgeschlagen.In the course of efforts to achieve an improved surface quality of workpiece machining surfaces, various devices and methods have been proposed in recent times.
In diesem Zusammenhang wurden beispielsweise Verfahren entwickelt, um die Schnittflächenqualität von mittels Scherung hergestellten Präzisionsteilen zu verbessern. Die Schnittflächenqualität ist hierbei beispielsweise definiert durch die Kenngrößen Kanteneinzug, Glattschnittfläche, Glattschnittflächenanteil, Rauheit der Glattschnittfläche, Bruchflächenwinkel, Rauheit der Bruchfläche, Breite und Höhe der Bruchfläche, Schnittgrat, schalenförmiger Abriss, Einriss, beinflussbare Randzone, Werkstoffhärte vor/nach dem Schneiden usw. Im Vordergrund stehen dabei jedoch der Glattschnittflächenanteil, die Rauheit der Glattschnittfläche, der Stanzeinzug und der Stanzgrat. Als Ideal wird hier ein Glattschnittflächenanteil von 100 % der Materialdicke, ohne Stanzeinzug und Stanzgrat, angestrebt. Da dieses Ideal bisher mit keinem Folgeverbundwerkzeug realisiert werden kann, müssen derartige Teile aufwändig nachgearbeitet werden.In this context, for example, methods have been developed to improve the quality of the cut surface of precision parts produced by means of shear. The quality of the cut surface is defined, for example, by the parameters Edge indentation, smooth-cut surface, smooth-cut surface proportion, roughness of the smooth-cut surface, fracture surface angle, roughness of the fracture surface, width and height of the fracture surface, cut burr, shell-shaped tear, tear, edge zone that can be influenced, material hardness before / after cutting, etc. However, the focus is on the smooth-cut surface proportion, the roughness the smooth cut surface, the punch indentation and the punch burr. As an ideal, a smooth-cut surface proportion of 100% of the material thickness, without punch indentation and punch burr, is aimed for. Since this ideal has not yet been possible with any progressive tool, such parts have to be reworked in a complex manner.
Ein bekanntes Verfahren zum Erreichen einer hohen Schnittflächenqualität ist das sogenannte Feinschneidverfahren. Bei diesem Verfahren wird das Werkstück während der Bearbeitung entlang der Schnittkontur mit Hilfe einer Ringzacke festgehalten und es wird mit einem reduzierten Schneidpalt gearbeitet. Durch dieses Verfahren können im Gegensatz zum konventionellen Scherschneiden Schnittflächen erhalten werden, die über die gesamte Materialdicke einriss- und abrissfrei sind, und zudem können engste Maß- und Planheitstoleranzen realisiert werden. Voraussetzung für die Verwendung der Ringzacke ist jedoch eine gewisse Materialdicke des Werkstücks von mehr als 1 mm, da bei dünneren Werkstücken die auftretenden Querkräfte im Schnittbereich aufgrund des kleineren Materialvolumens zu Unebenheiten führen können. Zudem sind die Materialien, bei welchen das Feinschneidverfahren zum Einsatz gebracht werden kann, hinsichtlich Härte und Sprödigkeit eingeschränkt und darüber hinaus ist eine dreifach wirkende Presse erforderlich, welche eine besonders hohe Führungsgenauigkeit des Stempels und einen steifen Pressenrahmen aufweist.A known method for achieving a high quality cut surface is the so-called fine blanking method. In this process, the workpiece is held in place along the cutting contour with the aid of a ring spike and a reduced cutting gap is used. With this method, in contrast to conventional shear cutting, cut surfaces can be obtained that are free of cracks and tears over the entire thickness of the material, and the tightest dimensional and flatness tolerances can also be achieved. However, the prerequisite for using the ring spike is a certain material thickness of the workpiece of more than 1 mm, since with thinner workpieces the transverse forces occurring in the cutting area can lead to unevenness due to the smaller material volume. In addition, the materials in which the fineblanking process can be used are limited in terms of hardness and brittleness and, moreover, a triple-acting press is required, which has a particularly high guide accuracy of the punch and a rigid press frame.
Ein weiteres bekanntes Verfahren zum Erreichen einer verbesserten Schnittflächenqualität ist ferner das sogenannte Konterschneiden, welches dem Scherschneiden zuzuordnen ist und bei welchem zwischen einem dreistufigen Konterschneiden und einem zweistufigen Konterschneiden unterschieden wird. Die Bearbeitung des Werkstücks erfolgt bei diesen Verfahren in zwei bzw. drei Stufen, wobei zwischen den einzelnen Stufen eine Umkehr der Schneidrichtung der verwendeten Schneidstempel vorgesehen ist. Somit wird das Werkstück beim dreistufigen Konterschneiden in der ersten Stufe zunächst angeschnitten, in der zweiten Stufe erfolgt nach einer Umkehr der Schneidrichtung ein Gegenschneiden und in der dritten Stufe erfolgt nach einer abermaligen Umkehr der Schneidrichtung schließlich ein Durchschneiden des Werkstücks. Die Schnittfläche beim dreistufigen Konterschneiden ist insbesondere durch eine völlige Gratfreiheit, zwei Glattschnittflächen und die Bruchzone zwischen diesen Glattschnittflächen charakterisiert. Mit Blick auf den mit diesem Verfahren erreichbaren Glattschnittanteil von ca. 50 % und insbesondere mit Blick auf die verbleibende Bruchzone zwischen den beiden Glattschnittflächen besteht jedoch auch bei diesem Verfahren Raum für Verbesserungen.Another known method for achieving an improved cut surface quality is what is known as counter-cutting, which is assigned to shear cutting and in which a distinction is made between three-stage counter-cutting and two-stage counter-cutting. In this method, the workpiece is machined in two or three stages, with a reversal of the cutting direction of the cutting punches used between the individual stages. Thus, the workpiece is at the three-stage Counter-cutting is first cut in the first stage, counter-cutting takes place in the second stage after reversing the cutting direction, and in the third stage, after another reversal of the cutting direction, the workpiece is finally cut through. The cut surface in three-step counter-cutting is characterized in particular by a complete absence of burrs, two smooth-cut surfaces and the fracture zone between these smooth-cut surfaces. With a view to the smooth cut proportion of approx. 50% that can be achieved with this method and in particular with a view to the remaining fracture zone between the two smooth cut surfaces, there is, however, room for improvement in this method as well.
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Die
Weiter zeigt die
Grundsätzlich ist festzustellen, dass das Werkstoffgefüge des Werkstücks durch einen Werkstückbearbeitungsvorgang, wie beispielsweise einen Stanzvorgang, im Bearbeitungsbereich als Folge von lokalen Umformungen erheblich beeinflusst bzw. geschädigt werden kann und somit das verbleibende Umformvermögen des Materials deutlich reduziert sein kann. Bei bislang bekannten Bearbeitungsverfahren, wie insbesondere bei bekannten Scherschneidverfahren, werden während der Bearbeitung des Werkstücks bei den jeweiligen Bearbeitungshüben der Bearbeitungselemente einstufige, kontinuierliche Linearbewegungen derselben erzeugt. Diese einstufigen Bewegungshübe der Bearbeitungselemente wirken sich über die im Werkstückwerkstoff vorhandenen bzw. entstehenden Gitterfehler jedoch negativ auf das verbleibende Umformvermögen des Werkstücks im Bearbeitungsbereich aus, was wiederum zu nicht erwünschten Rissen in diesem Bereich führen kann.Basically, it should be noted that the material structure of the workpiece can be significantly influenced or damaged by a workpiece machining process, such as a punching process, as a result of local deformations in the machining area and thus the remaining deformability of the material can be significantly reduced. In previously known machining methods, such as in particular in known shear cutting methods, one-step, continuous linear movements of the machining elements are generated during machining of the workpiece during the respective machining strokes. However, these single-stage movement strokes of the machining elements have a negative effect on the remaining deformability of the workpiece in the machining area via the lattice defects present or occurring in the workpiece material, which in turn can lead to undesired cracks in this area.
Ferner erfolgt zu Beginn eines Bearbeitungsablaufs bei bislang bekannten Bearbeitungsverfahren, wie beispielsweise bei bekannten Scherschneidverfahren, ein dynamisches Auftreffen bzw. Aufschlagen von einem oder mehreren Bearbeitungselementen auf das in der Maschine positionierte Werkstück. Dies kann zu einem Taumeln bzw. zu Schwingungen der Bearbeitungselemente und des Werkstücks führen. Somit können zu Beginn der Werkstückbearbeitung Relativbewegungen zwischen den jeweiligen Bearbeitungselementen und dem zu bearbeitenden Werkstück in einer quer zu der Bewegungsrichtung der Bearbeitungselemente verlaufenden Richtung vorliegen. Diese Relativbewegungen können zu einer weiteren nicht erwünschten Verformung des Werkstücks im Bearbeitungsbereich und somit zu nicht erwünschten lokalen Gefügeveränderungen des Werkstücks im Bearbeitungsbereich führen. Durch diese Relativbewegungen muss bei Stanzmaschinen darüber hinaus der Schneidspalt verhältnismäßig groß gewählt werden, um Schäden an den Bearbeitungs- bzw. Aktivelementen (Stempel, Matrize) der Stanzmaschine während der Bearbeitung zu verhindern. Somit können die vorgenannten Relativbewegungen zwischen den entsprechenden Bearbeitungselementen und dem Werkstück die Schnittflächenqualität, das Werkstoffgefüge des Werkstücks und auch den realisierbaren Schneidspalt in unerwünschter Art und Weise negativ beeinflussen.Furthermore, at the beginning of a machining sequence in previously known machining methods, such as, for example, in known shear-cutting methods, one or more machining elements dynamically strike or strike the workpiece positioned in the machine. This can lead to wobbling or vibrations of the machining elements and the workpiece to lead. Thus, at the beginning of the workpiece machining, there can be relative movements between the respective machining elements and the workpiece to be machined in a direction running transversely to the direction of movement of the machining elements. These relative movements can lead to a further undesired deformation of the workpiece in the machining area and thus to undesired local structural changes of the workpiece in the machining area. As a result of these relative movements, the cutting gap must also be selected to be relatively large in punching machines in order to prevent damage to the processing or active elements (punch, die) of the punching machine during processing. Thus, the aforementioned relative movements between the corresponding machining elements and the workpiece can negatively affect the quality of the cut surface, the material structure of the workpiece and also the realizable cutting gap in an undesirable manner.
Eine Aufgabe der vorliegenden Erfindung besteht demnach darin, ein Bearbeitungsverfahren, eine entsprechende Bearbeitungsmaschine sowie ein Bewegungsmuster erster und zweiter Bearbeitungselemente bereit zu stellen, welche bei einer Vielzahl von Werkstoffen mit unterschiedlichen Materialqualitäten (von weich, HV 80, E-Modul 100.000 N/m2, bis hart, HV 260, E-Modul 185.000 N/m2) auch im Dünnblechbereich bei Materialdicken von 0,03 -1 [mm] eine verbesserte Oberflächenbeschaffenheit von Werkstückbearbeitungsflächen vorsehen und darüber hinaus eine negative Beeinflussung des Werkstoffgefüges im Werkstückbearbeitungsbereich unterdrücken können.One object of the present invention is therefore to provide a processing method, a corresponding processing machine and a movement pattern of first and second processing elements that can be used with a large number of materials with different material qualities (from soft, HV 80, modulus of elasticity 100,000 N / m 2 , up to hard, HV 260, modulus of elasticity 185,000 N / m 2 ) also in the thin sheet area with material thicknesses of 0.03-1 [mm] provide an improved surface quality of workpiece processing surfaces and can also suppress a negative influence on the material structure in the workpiece processing area.
Die Aufgabe wird erfindungsgemäß durch ein Bearbeitungsverfahren nach dem Anspruch 1 gelöst.The object is achieved according to the invention by a machining method according to
Bei dem erfindungsgemäßen Bearbeitungsverfahren wird gemäß einem Aspekt der Erfindung ein Werkstück unter Verwendung zumindest einer Bearbeitungsmaschine bearbeitet. Die zumindest eine Bearbeitungsmaschine weist ein erstes und ein zweites Bearbeitungselement zum Bearbeiten des Werkstücks, welches zwischen diesen positioniert ist, erste und zweite servomechanische Antriebe mit einem Servoaktuator und einem Kurvengetriebe, welche jeweils den ersten und zweiten Bearbeitungselementen zugeordnet und mit diesen verbunden sind, um die ersten und zweiten Bearbeitungselemente zum Bearbeiten des Werkstücks entlang zumindest einer Bearbeitungsachse anzutreiben, die senkrecht zu einer Längsachse des zu bearbeitenden Werkstücks ausgerichtet ist, wenigstens einen Niederhalter zum Fixieren des Werkstücks während der Bearbeitung und Führungen für die Bearbeitungselemente auf.In the machining method according to the invention, according to one aspect of the invention, a workpiece is machined using at least one machine tool. The at least one processing machine has a first and a second processing element for processing the workpiece, which is positioned between them, first and second servomechanical drives with a servo actuator and a cam gear, each of which is assigned to the first and second machining elements and connected to them, in order to drive the first and second machining elements for machining the workpiece along at least one machining axis that is perpendicular to a longitudinal axis of the workpiece to be machined, at least one hold-down device for fixing of the workpiece during machining and guides for the machining elements.
Das Kurvengetriebe der servomechanischen Antriebe weist ein als eine Kurvenscheibe ausgebildetes Kurvenglied und ein Eingriffsglied mit wenigstens zwei drehbar gelagerten Abnahmerollen zur Übertragung einer durch den Servoaktuator in das Kurvenglied eingeleiteten Antriebskraft auf das Eingriffsglied auf. Ferner ist das Eingriffsglied als ein mit einem entsprechenden Bearbeitungselement verbundener Linearschlitten ausgebildet, welcher einen schwenkbar gelagerten Pendelhebel aufweist, der die wenigstens zwei Abnahmerollen trägt, welche derart drehbar gelagert sind, dass die Kurvenscheibe zur Übertragung der eingeleiteten Antriebskraft auf den Linearschlitten auf den wenigstens zwei an die Kurvenscheibe anliegenden Abnahmerollen abwälzbar ist, unter Erzeugung einer aus zwei Wirkkraftkomponenten bestehenden Gesamtwirkungskraft.The cam gear of the servomechanical drives has a cam member designed as a cam disk and an engaging member with at least two rotatably mounted take-off rollers for transmitting a drive force introduced into the cam member by the servo actuator to the engaging member. Furthermore, the engaging member is designed as a linear slide connected to a corresponding processing element, which has a pivotably mounted pendulum lever which carries the at least two take-off rollers, which are rotatably mounted in such a way that the cam disc for transmitting the drive force introduced to the linear slide on the at least two the cam disc adjacent take-off rollers can be rolled, with the generation of a total active force consisting of two active force components.
Bei dem erfindungsgemäßen Bearbeitungsverfahren wird das zu bearbeitende Werkstück zunächst zwischen den ersten und zweiten Bearbeitungselementen der Bearbeitungsmaschine positioniert. Dann wird das Werkstück durch den wenigstens einen Niederhalter der Bearbeitungsmaschine fixiert und die ersten und zweiten Bearbeitungselemente werden ohne Formänderung des Werkstücks mit diesem in Anlage gebracht. Anschließend erfolgt die Bearbeitung des Werkstücks durch die ersten und zweiten Bearbeitungselemente mit einer plastischen Verformung des Werkstücks, wobei die ersten und zweiten Bearbeitungselemente während des Bearbeitungsvorgangs durch die ersten und zweiten servomechanischen Antriebe der Bearbeitungsmaschine in einer mehrstufigen Art und Weise zumindest zeitweilig synchron äquidistant zueinander oder synchron gegenläufig zueinander angetrieben werden.In the machining method according to the invention, the workpiece to be machined is first positioned between the first and second machining elements of the machine tool. The workpiece is then fixed by the at least one hold-down device of the processing machine and the first and second processing elements are brought into contact with the workpiece without changing its shape. The workpiece is then processed by the first and second processing elements with a plastic deformation of the workpiece, with the first and second processing elements being at least temporarily equidistant from one another or synchronously by the first and second servomechanical drives of the processing machine in a multi-stage manner during the processing process are driven in opposite directions to each other.
Die Erfindung sieht somit erstmals ein Bearbeitungsverfahren vor, bei welchem erste und zweite Bearbeitungselemente vor der Bearbeitung des Werkstücks ohne Formänderung desselben zunächst mit diesem in Anlage gebracht werden. Ferner wird bei dem erfindungsgemäßen Bearbeitungsverfahren ein zwischen Bearbeitungselementen positioniertes Werkstück erstmals durch ein mehrstufiges Antreiben der Bearbeitungselemente zumindest zeitweilig mit einer synchron äquidistanten oder synchron gegenläufigen Bewegung der Bearbeitungselemente zueinander bearbeitet.The invention thus provides for the first time a machining method in which first and second machining elements are first brought into contact with the workpiece before machining the workpiece without changing its shape. Furthermore, in the machining method according to the invention, a workpiece positioned between machining elements is machined for the first time by multi-stage driving of the machining elements at least temporarily with a synchronously equidistant or synchronously opposite movement of the machining elements to one another.
Durch das erfindungsgemäße in Anlage Bringen der ersten und zweiten Bearbeitungselemente mit dem Werkstück vor der eigentlichen Bearbeitung des Werkstücks ohne eine Formänderung desselben können Schwingungen der Bearbeitungselemente und/oder des Werkstücks beim Auftreffen bzw. Aufschlagen der Bearbeitungselemente auf das Werkstück unterdrückt werden, da die Bearbeitungselemente mit reduzierter Geschwindigkeit mit dem Werkstück in Anlage gebracht werden. Somit können durch Schwingungen hervorgerufene Relativbewegungen zwischen den Bearbeitungselementen und dem Werkstück in einer quer zu der Bewegungsrichtung der Bearbeitungselemente verlaufenden Richtung unterdrückt werden. Dadurch kann eine nicht gewünschte Umformung des Werkstücks im Bearbeitungsbereich, welche durch auftretende Relativbewegungen zwischen den Bearbeitungselementen und dem Werkstück hervorgerufen werden kann, unterdrückt werden, und somit kann die Oberflächenbeschaffenheit im Werkstückbearbeitungsbereich verbessert werden. Zudem kann eine nicht erwünschte Beeinflussung der interkristallinen Struktur bzw. des Werkstoffgefüges des Werkstücks im Bearbeitungsbereich durch die Relativbewegungen bzw. die dadurch hervorgerufene Umformung des Werkstücks unterdrückt werden.By bringing the first and second machining elements into contact with the workpiece prior to the actual machining of the workpiece without changing its shape, vibrations of the machining elements and / or the workpiece when the machining elements strike the workpiece can be suppressed, since the machining elements with be brought into contact with the workpiece at a reduced speed. Thus, relative movements caused by vibrations between the machining elements and the workpiece in a direction running transversely to the direction of movement of the machining elements can be suppressed. As a result, undesired deformation of the workpiece in the machining area, which can be caused by relative movements occurring between the machining elements and the workpiece, can be suppressed, and the surface quality in the workpiece machining area can thus be improved. In addition, undesired influencing of the intergranular structure or the material structure of the workpiece in the machining area by the relative movements or the deformation of the workpiece caused thereby can be suppressed.
Durch die gestufte Bewegungsabfolge der Bearbeitungselemente während der Werkstückbearbeitung wirken im Vergleich zu einer einstufigen Werkstückbearbeitung geringere Prozesskräfte. Die von den Bearbeitungselementen auf das Werkstück übertragene Kraft wird durch die gestufte Bewegungsabfolge in mehrere Kräfte entsprechend den mehreren Bearbeitungsstufen aufgeteilt und durch eine Entspannung des Werkstückwerkstoffes zwischen den einzelnen Bearbeitungsstufen ergibt sich im Vergleich zu einer einstufigen Werkstückbearbeitung insgesamt eine verringerte in das Werkstück eingebrachte Bearbeitungskraft. Die Reduzierung der Bearbeitungskraft erfolgt dabei durch die Aufteilung der Bearbeitung in n Einzelschritte bzw. Bearbeitungsstufen. Dabei kann für jede Bearbeitungsstufe der Weg und die Geschwindigkeit der Bearbeitungselemente variiert werden und somit kann für jede Bearbeitungsstufe eine für den jeweiligen Prozess optimale Umformgeschwindigkeit definiert werden. Während der Bearbeitung des Werkstücks entstehen somit weniger Gitterfehler bzw. eine geringere Versetzungsdichte im Werkstoff und somit kann eine nicht erwünschte Kaltverfestigung des Werkstoffes im Bearbeitungsbereich unterdrückt werden. Somit wird durch das erfindungsgemäße Bearbeitungsverfahren eine nicht erwünschte Beeinflussung der interkristallinen Struktur des Werkstücks im Werkstückbearbeitungsbereich unterdrückt und somit kann beispielsweise die Schnittflächenqualität bei Stanzteilen oder die Oberflächengüte bzw. Oberflächenbeschaffenheit von Prägeteilen verbessert werden.Due to the stepped sequence of movements of the machining elements during workpiece machining, lower process forces act in comparison to single-step workpiece machining. The force transmitted from the processing elements to the workpiece is divided into several forces corresponding to the several processing stages through the stepped sequence of movements and the relaxation of the workpiece material between the individual processing stages results in Compared to a single-stage workpiece machining, an overall reduced machining force introduced into the workpiece. The processing force is reduced by dividing the processing into n individual steps or processing stages. The path and the speed of the processing elements can be varied for each processing stage and thus an optimal forming speed for the respective process can be defined for each processing stage. During the machining of the workpiece, fewer lattice defects or a lower density of dislocations occur in the material, and undesired work hardening of the material in the machining area can thus be suppressed. Thus, the machining method according to the invention suppresses an undesired influencing of the intergranular structure of the workpiece in the workpiece machining area and thus, for example, the cut surface quality in stamped parts or the surface quality or surface quality of stamped parts can be improved.
Durch die synchron äquidistante Bewegungsabfolge der ersten und zweiten Bearbeitungselemente kann zudem erreicht werden, dass die plastische Verformung des Werkstücks im Bearbeitungsbereich möglichst gering gehalten wird. Die Äquidistanz der Bearbeitungselemente während der Bearbeitung des Werkstücks führt dazu, dass der Werkstückabschnitt zwischen den Bearbeitungselementen nicht zusammengepresst bzw. verformt wird, was wiederum zu einer geringeren Anzahl von Gitterfehlern bzw. zu einer geringeren Versetzungsdichte im Bearbeitungsbereich des Werkstücks führt. Aufgrund der geringeren Anzahl von Gitterfehlern im Werkstückwerkstoff wird auch dadurch eine nicht erwünschte Kaltverfestigung des Materials und somit die Erzeugung von Rissen im Werkstückbearbeitungsbereich unterdrückt.The synchronously equidistant movement sequence of the first and second processing elements can also ensure that the plastic deformation of the workpiece in the processing area is kept as low as possible. The equidistance of the machining elements during machining of the workpiece means that the workpiece section between the machining elements is not compressed or deformed, which in turn leads to a lower number of lattice defects or to a lower density of dislocations in the machining area of the workpiece. Due to the lower number of lattice defects in the workpiece material, undesired work hardening of the material and thus the generation of cracks in the workpiece processing area is also suppressed.
Die synchron gegenläufige Bewegungsabfolge der Bearbeitungselemente, welche beispielsweise bei Präge-, Biege oder Ziehverfahren eingesetzt werden kann, führt dazu, dass das Fließverhalten des Werkstückwerkstoffes in positiver Art und Weise beeinflusst werden kann. Dadurch können beispielsweise Konturen, wie Hinterschnitte, Schneiden o.Ä., in vorteilhafter Art und Weise ausgebildet werden. Ferner kann sich der Werkstückwerkstoff während des Bearbeitungsvorgangs entspannen.The synchronously opposing movement sequence of the processing elements, which can be used, for example, in stamping, bending or drawing processes, means that the flow behavior of the workpiece material can be influenced in a positive manner. In this way, for example, contours such as undercuts, cutting edges or the like can be formed in an advantageous manner. Furthermore, the workpiece material can relax during the machining process.
Vorteilhafte Weiterbildungen des erfindungsgemäßen Bearbeitungsverfahrens sind Gegenstand der abhängigen Ansprüche.Advantageous developments of the machining method according to the invention are the subject of the dependent claims.
Das vorstehende Bearbeitungsverfahren kann beispielsweise im Rahmen einer Stanz-, Präge-, Biege- oder Ziehbearbeitung realisiert werden.The above processing method can be implemented, for example, as part of a punching, embossing, bending or drawing process.
In einer bevorzugten Ausführungsform können in Abhängigkeit der Materialeigenschaften des Werkstücks eine Schrittweite von Bearbeitungsstufen durch den mehrstufigen Antrieb der ersten und zweiten Bearbeitungselemente beim Bearbeiten des Werkstücks variiert werden und/oder eine Bewegungsgeschwindigkeit der ersten und zweiten Bearbeitungselemente während der Bearbeitung des Werkstücks variiert werden und/oder die ersten und zweiten Bearbeitungselemente zwischen den Bearbeitungsstufen für eine vorbestimmte Zeitspanne in einer Ruhestellung gehalten werden.In a preferred embodiment, depending on the material properties of the workpiece, a step size of processing stages can be varied by the multi-stage drive of the first and second processing elements when processing the workpiece and / or a movement speed of the first and second processing elements can be varied during processing of the workpiece and / or the first and second processing elements are held in a rest position for a predetermined period of time between the processing stages.
Gemäß diesem Bearbeitungsverfahren können die Schrittweite bei dem mehrstufigen Antrieb der ersten und zweiten Bearbeitungselemente, das heißt, die Abstufung der Bearbeitung durch die ersten und zweiten Bearbeitungselemente, und die Bewegungsgeschwindigkeit der ersten und zweiten Bearbeitungselemente während der Bearbeitung des Werkstücks gemäß den Materialeigenschaften des Werkstücks geeignet variiert bzw. gewählt werden. Zudem kann in Abhängigkeit der Materialeigenschaften des Werkstücks zwischen den einzelnen Bearbeitungsstufen eine vorbestimmte Zeitspanne vorgesehen sein, in welcher die ersten und zweiten Bearbeitungselemente in einer Ruhestellung gehalten werden. So kann beispielsweise bei weichen Werkstoffen die Bewegungsgeschwindigkeit der ersten und zweiten Bearbeitungselemente in vorteilhafter Weise reduziert werden. Bei harten Werkstoffen hingegen kann eine erhöhte Bewegungsgeschwindigkeit der ersten und zweiten Bearbeitungselemente gewählt werden. So kann beispielsweise bei harten Werkstoffen die Schneidgeschwindigkeit im Eintauchbereich des Schneidstempels im Vergleich zu einer Exzenterpresse bis um Faktor 16 schneller gewählt werden.According to this machining method, the step size in the multi-stage drive of the first and second machining elements, that is, the gradation of machining by the first and second machining elements, and the moving speed of the first and second machining elements during machining of the workpiece can be appropriately varied according to the material properties of the workpiece or can be chosen. In addition, depending on the material properties of the workpiece, a predetermined period of time can be provided between the individual processing stages, in which the first and second processing elements are held in a rest position. For example, in the case of soft materials, the speed of movement of the first and second processing elements can advantageously be reduced. In the case of hard materials, on the other hand, an increased speed of movement of the first and second processing elements can be selected. In the case of hard materials, for example, the cutting speed in the immersion area of the cutting punch can be selected up to a factor of 16 faster than in an eccentric press.
In einer bevorzugten Ausführungsform können die ersten und zweiten Bearbeitungselemente vor dem Bearbeiten des Werkstücks für eine vorbestimmte Zeitspanne in einer Ruhestellung der ersten und zweiten Bearbeitungselemente ohne Formänderung des Werkstücks mit diesem in Anlage gehalten werden.In a preferred embodiment, the first and second machining elements can be held in contact with the workpiece for a predetermined period of time in a rest position of the first and second machining elements without changing the shape of the workpiece before machining the workpiece.
Gemäß dieser bevorzugten Ausführungsform werden die ersten und zweiten Bearbeitungselemente vor der eigentlichen Bearbeitung des Werkstücks für eine vorbestimmte Zeitspanne in einer Ruhestellung der ersten und zweiten Bearbeitungselemente ohne Formänderung des Werkstücks mit diesem in Anlage gehalten. Durch diese vorbestimmte Zeitspanne zwischen dem in Anlage Bringen bzw. dem Auftreffen der Bearbeitungselemente mit bzw. auf das Werkstück und dem Beginn der Werkstückbearbeitung können evtl. auftretende Schwingungen der ersten und zweiten Bearbeitungselemente und des Werkstücks, welche durch das Auftreffen der ersten und zweiten Bearbeitungselemente auf das Werkstück hervorgerufen werden, abklingen, wodurch Relativbewegungen zwischen den Bearbeitungselementen und dem Werkstück in einer quer zur Bewegungsrichtung der Bearbeitungselemente verlaufenden Richtung während der Bearbeitung noch zuverlässiger unterdrückt werden können. Dadurch kann die erhaltene Oberflächenbeschaffenheit der Werkstückbearbeitungsflächen noch zuverlässiger verbessert werden und eine nicht erwünschte Beeinflussung des Werkstoffgefüges im Bearbeitungsbereich durch die Bearbeitung kann noch zuverlässiger unterdrückt werden.According to this preferred embodiment, before the actual machining of the workpiece, the first and second machining elements are held in abutment with the first and second machining elements for a predetermined period of time without changing the shape of the workpiece. This predetermined period of time between bringing the processing elements into contact with or on the workpiece and the start of workpiece processing can prevent any vibrations of the first and second processing elements and the workpiece caused by the impact of the first and second processing elements the workpiece are caused, decay, whereby relative movements between the machining elements and the workpiece in a direction running transversely to the direction of movement of the machining elements can be suppressed even more reliably during machining. As a result, the surface quality of the workpiece machining surfaces obtained can be improved even more reliably, and an undesired influencing of the material structure in the machining area by machining can be suppressed even more reliably.
In einer bevorzugten Ausführungsform können die die ersten und zweiten Bearbeitungselemente während der Bearbeitung des Werkstücks in einer pulsierenden Art und Weise mit einer Vorschubbewegung der Bearbeitungselemente in Richtung hin zu dem Werkstück und mit einer zu der Vorschubbewegung entgegengesetzt ausgerichteten Rückführbewegung der Bearbeitungselemente von dem Werkstück weg angetrieben werden.In a preferred embodiment, the first and second machining elements can be driven during machining of the workpiece in a pulsating manner with a feed movement of the machining elements in the direction of the workpiece and with a return movement of the machining elements away from the workpiece that is opposite to the feed movement .
Bei dieser bevorzugten Ausführungsform führt die Rückführbewegung der Bearbeitungselemente im Rahmen des pulsierenden Antriebs der ersten und zweiten Bearbeitungselemente dazu, dass sich der Werkstoff entspannen kann, wodurch sich die Kristalle bzw. Atome im Werkstoff neu ausrichten können. Dies führt wiederum zu einer geringeren Kaltverfestigung durch die Bearbeitung und somit zu einem verbesserten Verformungsverhalten bei einer darauffolgenden Vorschubbewegung der Bearbeitungselemente in Richtung hin zu dem Werkstück, was letztlich zu einer verbesserten Oberflächenbeschaffenheit der bearbeiteten Werkstücke mit weniger Rissen führt. Zudem vermeidet die schonende Bearbeitung einen mit fortlaufenden Stückzahlen steigenden Materialauftrag an den Aktivelementen durch einen Auftrag von Mikropartikeln des Werkstücks. Damit erhöht sich bei gleichbleibender Qualität die Standzeit.In this preferred embodiment, the return movement of the processing elements in the context of the pulsating drive of the first and second processing elements leads to the fact that the material can relax, whereby the Can realign crystals or atoms in the material. This in turn leads to less strain hardening due to the machining and thus to an improved deformation behavior during a subsequent feed movement of the machining elements in the direction of the workpiece, which ultimately leads to an improved surface quality of the machined workpieces with fewer cracks. In addition, the gentle processing avoids an increasing amount of material on the active elements by applying microparticles of the workpiece. This increases the service life while maintaining the same quality.
In einer bevorzugten Ausführungsform können eine Mehrzahl von Bearbeitungsmaschinen zum Bearbeiten des Werkstücks in mehreren aufeinanderfolgenden Bearbeitungsschritten verwendet werden, welche von einer gemeinsamen Gehäusestruktur umfasst sind, wodurch ein Bearbeitungszentrum mit den mehreren Bearbeitungsmaschinen ausgebildet ist. Dabei wird das Werkstück als Bandmaterial hin zu dem Bearbeitungszentrum geführt und für die Bearbeitung in den aufeinanderfolgenden Bearbeitungsschritten hin zu den Bearbeitungsmaschinen in dem Bearbeitungszentrum und durch selbige hindurch befördert.In a preferred embodiment, a plurality of processing machines can be used for processing the workpiece in a plurality of successive processing steps, which are encompassed by a common housing structure, whereby a processing center is formed with the plurality of processing machines. In this case, the workpiece is guided as strip material to the machining center and, for machining in the successive machining steps, is conveyed to and through the machining machines in the machining center.
Die Verwendung mehrerer Bearbeitungsmaschinen zum Durchführen aufeinanderfolgender Bearbeitungsschritte, welche als ein Bearbeitungszentrum von einer gemeinsamen Gehäusestruktur umfasst sind, führt zu einem deutlich reduzierten Handhabungsaufwand während der Werkstückbearbeitung und somit zu geringeren Bearbeitungskosten. Auf einer derartigen Anlage können Bauteile mit komplexen Strukturen unter Verwendung unterschiedlicher Bearbeitungsverfahren (Stanzen, Prägen, Biegen, Ziehen oder jedwede Kombination daraus) mit einer jeweils optimalen Bewegungsabfolge der entsprechenden Bearbeitungselemente produziert werden.The use of several processing machines to carry out successive processing steps, which are encompassed as a processing center by a common housing structure, leads to a significantly reduced handling effort during workpiece processing and thus to lower processing costs. On such a system, components with complex structures can be produced using different processing methods (punching, embossing, bending, drawing or any combination thereof) with an optimal sequence of movements for the corresponding processing elements.
Gemäß einem weiteren Aspekt der Erfindung ist eine Bearbeitungsmaschine zum Ausführen des erfindungsgemäßen Bearbeitungsverfahrens vorgesehen. Die erfindungsgemäße Bearbeitungsmaschine weist auf: zumindest ein erstes und ein zweites Bearbeitungselement zum Bearbeiten eines Werkstücks, welches zwischen diesen positioniert ist, wenigstens einen Niederhalter zum Fixieren des Werkstücks während der Bearbeitung und Führungen für die Bearbeitungselemente.According to a further aspect of the invention, a processing machine is provided for carrying out the processing method according to the invention. The processing machine according to the invention has: at least a first and a second processing element for processing a workpiece, which is located between them is positioned, at least one hold-down device for fixing the workpiece during machining and guides for the machining elements.
Bei der erfindungsgemäßen Bearbeitungsmaschine sind den ersten und zweiten Bearbeitungselementen ferner jeweils servomechanische Antriebe mit einem Servoaktuator und einem Kurvengetriebe zugeordnet und mit diesen verbunden, um die ersten und zweiten Bearbeitungselemente zum Bearbeiten des Werkstücks entlang zumindest einer Bearbeitungsachse anzutreiben, die senkrecht zu einer Längsachse des zu bearbeitenden Werkstücks ausgerichtet ist. Das Kurvengetriebe weist ein als eine Kurvenscheibe ausgebildetes Kurvenglied und ein Eingriffsglied mit wenigstens zwei drehbar gelagerten Abnahmerollen zur Übertragung einer durch den Servoaktuator in das Kurvenglied eingeleiteten Antriebskraft auf das Eingriffsglied auf. Ferner ist das Eingriffsglied als ein mit einem entsprechenden Bearbeitungselement verbundener Linearschlitten ausgebildet, welcher einen schwenkbar gelagerten Pendelhebel aufweist, der die wenigstens zwei Abnahmerollen trägt, welche derart drehbar gelagert sind, dass die Kurvenscheibe zur Übertragung der eingeleiteten Antriebskraft auf den Linearschlitten auf den wenigstens zwei an die Kurvenscheibe anliegenden Abnahmerollen abwälzbar ist, unter Erzeugung einer aus zwei Wirkkraftkomponenten bestehenden Gesamtwirkungskraft. Die erfindungsgemäße Bearbeitungsmaschine weist ferner eine Steuerungsvorrichtung auf, welche derart ausgestaltet ist, dass diese die Bearbeitungsmaschine gemäß dem erfindungsgemäßen Bearbeitungsverfahren steuert.In the processing machine according to the invention, the first and second processing elements are each assigned servomechanical drives with a servo actuator and a cam gear and connected to them in order to drive the first and second processing elements for processing the workpiece along at least one processing axis that is perpendicular to a longitudinal axis of the workpiece to be processed Workpiece is aligned. The cam mechanism has a cam member designed as a cam disk and an engaging member with at least two rotatably mounted take-off rollers for transmitting a drive force introduced into the cam member by the servo actuator to the engaging member. Furthermore, the engaging member is designed as a linear slide connected to a corresponding processing element, which has a pivotably mounted pendulum lever which carries the at least two take-off rollers, which are rotatably mounted in such a way that the cam disc for transmitting the drive force introduced to the linear slide on the at least two the cam disc adjacent take-off rollers can be rolled, with the generation of a total active force consisting of two active force components. The processing machine according to the invention also has a control device which is designed in such a way that it controls the processing machine in accordance with the processing method according to the invention.
Die Erfindung sieht somit erstmals vor, servomechanische Antriebe mit einem Servoaktuator und einem Kurvengetriebe jeweils bei ersten und zweiten Bearbeitungselementen einer Bearbeitungsmaschine vorgesehenen. Dies ermöglicht neben höheren Prozesskräften (bis zu 200 kN) und größeren realisierbaren Hüben (bis zu 100 [mm]) der Bearbeitungselemente ferner eine exakte Reproduzierbarkeit von gewünschten Bewegungsabläufen der Bearbeitungselemente. Diese Ausgestaltung ermöglicht ferner eine bessere Entkopplung der Bearbeitungselemente vom Antrieb hinsichtlich Störeinflüssen. Durch das Kurventriebe wirken sich temperaturbedinge Ausdehnungen im Antrieb nicht negativ auf den Prozess aus. Ebenso wirken sich Reaktionen aus dem Prozess, wie Impulsspitzen, nicht negativ auf den Antrieb aus.The invention thus provides for the first time that servomechanical drives with a servo actuator and a cam gear are provided in each case for first and second processing elements of a processing machine. In addition to higher process forces (up to 200 kN) and larger achievable strokes (up to 100 [mm]) of the processing elements, this also enables exact reproducibility of the desired movement sequences of the processing elements. This configuration also enables better decoupling of the machining elements from the drive with regard to interference. Due to the cam drive, temperature-related expansions in the drive do not have a negative effect on the process. Reactions from the process, such as pulse peaks, also do not have a negative effect on the drive.
Vorteilhafte Weiterbildungen der erfindungsgemäßen Bearbeitungsmaschine sind Gegenstand der abhängigen Ansprüche.Advantageous further developments of the machine tool according to the invention are the subject of the dependent claims.
In einer bevorzugten Ausführungsform sind die ersten und zweiten Bearbeitungselemente entlang der zumindest einen Bearbeitungsachse gegenüberliegend zueinander angeordnet. Durch diese Anordnung können beispielsweise Stanzteile mit sehr hoher Schnittflächenqualität erhalten werden, da die Bearbeitung mit zwei gegenüberliegenden Bearbeitungselementen dazu führt, dass bei der Bearbeitung des Werkstücks keine übermäßige Verformung des Werkstücks und somit keine unerwünschten Risse im Werkstück entstehen.In a preferred embodiment, the first and second processing elements are arranged opposite one another along the at least one processing axis. With this arrangement, for example, punched parts with a very high cut surface quality can be obtained, since machining with two opposite machining elements means that no excessive deformation of the workpiece and thus no undesired cracks occur in the workpiece when machining the workpiece.
Bei einer weiteren bevorzugten Ausführungsform sind die ersten und zweiten Bearbeitungselemente in einer quer zu der zumindest einen Bearbeitungsachse verlaufenden Richtung zueinander versetzt angeordnet. Durch diese Anordnung der Bearbeitungselemente kann das Fließverhalten des Werkstückmaterials im Bearbeitungsbereich gezielt beeinflusst werden.In a further preferred embodiment, the first and second processing elements are arranged offset from one another in a direction running transversely to the at least one processing axis. This arrangement of the processing elements allows the flow behavior of the workpiece material in the processing area to be influenced in a targeted manner.
Gemäß einem weiteren Aspekt der Erfindung ist ein Bearbeitungszentrum mit einer Mehrzahl von erfindungsgemäßen Bearbeitungsmaschinen und einer Fördereinrichtung zum Befördern des Werkstücks in dem Bearbeitungszentrum hin zu den mehreren Bearbeitungsmaschinen und durch diese hindurch vorgesehen. Hierbei entspricht das Werkstück einem Bandmaterial und die Bearbeitungsmaschinen sind von einer gemeinsamen Gehäusestruktur umfasst. Durch das Anordnen mehrerer erfindungsgemäßer Bearbeitungsmaschinen in einem Bearbeitungszentrum können verschiedene Bearbeitungsprozesse, wie beispielsweise Stanz-, Präge-, Biege- und Ziehvorgänge, in vorteilhafter Art und Weise in einer Bearbeitungseinheit zusammengefasst werden. Dies reduziert den Handhabungsaufwand des Werkstücks während der Bearbeitung und somit die Bearbeitungskosten wesentlich.According to a further aspect of the invention, a machining center with a plurality of machine tools according to the invention and a conveyor device for conveying the workpiece in the machining center to and through the plurality of machine tools is provided. Here, the workpiece corresponds to a strip material and the processing machines are encompassed by a common housing structure. By arranging several processing machines according to the invention in a processing center, various processing processes, such as, for example, punching, embossing, bending and drawing processes, can advantageously be combined in one processing unit. This significantly reduces the work involved in handling the workpiece during machining and thus the machining costs.
Gemäß einem weiteren Aspekt der Erfindung ist ein Bewegungsmuster erster und zweiter Bearbeitungselemente zum Bearbeiten eines zwischen diesen positionierten Werkstücks vorgesehen. Bei dem erfindungsgemäßen Bewegungsmuster kommen die ersten und zweiten Bearbeitungselemente vor der Bearbeitung des Werkstücks zunächst ohne Formänderung desselben mit dem Werkstück in Kontakt und diese bewegen sich während des Bearbeitungsvorgangs mit einer plastischen Verformung des Werkstücks in einer mehrstufigen Art und Weise zumindest zeitweilig synchron äquidistant zueinander oder synchron gegenläufig zueinander.According to a further aspect of the invention, a movement pattern of first and second processing elements is for processing one positioned between them Workpiece provided. In the movement pattern according to the invention, the first and second machining elements come into contact with the workpiece before machining the workpiece, initially without changing its shape, and they move during the machining process with a plastic deformation of the workpiece in a multi-stage manner, at least temporarily, equidistantly or synchronously opposite to each other.
Die ersten und zweiten Bearbeitungselemente stehen vor der Bearbeitung des Werkstücks für eine vorbestimmte Zeitspanne in einer Ruhestellung der ersten und zweiten Bearbeitungselemente ohne Formänderung des Werkstücks mit diesem in Kontakt.Before the workpiece is machined, the first and second machining elements are in contact with the workpiece for a predetermined period of time in a rest position of the first and second machining elements without changing the shape of the workpiece.
Die ersten und zweiten Bearbeitungselemente bewegen sich während der Bearbeitung des Werkstücks in einer pulsierenden Art und Weise mit einer Vorschubbewegung der Bearbeitungselemente in Richtung hin zu dem Werkstück und mit einer zu der Vorschubbewegung entgegengesetzt ausgerichteten Rückführbewegung der Bearbeitungselemente von dem Werkstück weg.During the machining of the workpiece, the first and second machining elements move in a pulsating manner with a feed movement of the machining elements in the direction of the workpiece and with a return movement of the machining elements away from the workpiece that is opposite to the feed movement.
In einer Ausführungsform erfolgt die Bewegung der ersten und zweiten Bearbeitungselemente während der Bearbeitung des Werkstücks im Rahmen eines Prägevorgangs mit n Stufen und ein Vorschubbetrag durch die Vorschubbewegung der ersten und zweiten Bearbeitungselemente in jeder der n Bearbeitungsstufen beträgt im Verhältnis zu einer Ausgangsdicke s des Werkstücks vor der Bearbeitung entlang einer senkrecht zu einer Längsachse des Werkstücks verlaufenden Richtung (1/2 · 1/n · s) und ein Rückführbetrag durch die Rückführbewegung der ersten und zweiten Bearbeitungselemente in jeder der n Bearbeitungsstufen beträgt im Verhältnis zu der Ausgangsdicke s des Werkstücks vor der Bearbeitung entlang der senkrecht zu der Längsachse des Werkstücks verlaufenden Richtung (3/10 · 1/n · s).In one embodiment, the movement of the first and second processing elements takes place during the processing of the workpiece as part of an embossing process with n steps and a feed amount due to the feed movement of the first and second processing elements in each of the n processing steps is in relation to an initial thickness s of the workpiece before the Machining along a direction perpendicular to a longitudinal axis of the workpiece is (1/2 · 1 / n · s) and a return amount by the returning movement of the first and second machining elements in each of the n machining stages is in proportion to the initial thickness s of the workpiece before machining along the direction perpendicular to the longitudinal axis of the workpiece (3/10 · 1 / n · s).
Damit kann der Umformgrad mit reduzierter Prozesskraft vergrößert werden und Materialeigenschaften in vorteilhafter Weise verändert werden. Beispielsweise kann dadurch einem weichen Werkstoff, wie CuSn6, eine Federeigenschaft vermittelt werden.In this way, the degree of deformation can be increased with reduced process force and material properties can be changed in an advantageous manner. For example, a soft material such as CuSn6 can be given a spring property.
In einer weiteren Ausführungsform entspricht das erste Bearbeitungselement einem Biegestempel und das zweite Bearbeitungselement entspricht einem Biegekern und die Bewegung des Biegestempels und des Biegekerns während der Bearbeitung des Werkstücks im Rahmen eines Biegeverfahrens erfolgt mit n Stufen. Hierbei beträgt ein Vorschubbetrag durch die Vorschubbewegung des Biegestempels in jeder der n Bearbeitungsstufen im Verhältnis zu einer Ausgangsdicke s des Werkstücks vor der Bearbeitung entlang einer senkrecht zu einer Längsachse des Werkstücks verlaufenden Richtung (3 · 1/n · s) und ein Rückführbetrag durch die Rückführbewegung des Biegestempels, ein Rückführbetrag durch die Rückführbewegung des Biegekerns sowie ein Vorschubbetrag durch die Vorschubbewegung des Biegekerns in jeder der n Bearbeitungsstufen im Verhältnis zu der Ausgangsdicke s des Werkstücks vor der Bearbeitung entlang der senkrecht zu der Längsachse des Werkstücks verlaufenden Richtung beträgt (1/n · s).In a further embodiment, the first processing element corresponds to a bending punch and the second processing element corresponds to a bending core and the movement of the bending punch and the bending core during the machining of the workpiece as part of a bending process takes place in n stages. Here, a feed amount due to the feed movement of the bending punch in each of the n processing stages in relation to an initial thickness s of the workpiece before processing along a direction perpendicular to a longitudinal axis of the workpiece is (3 · 1 / n · s) and a return amount due to the return movement of the bending punch, a return amount due to the return movement of the bending core and a feed amount due to the feeding movement of the bending core in each of the n processing stages in relation to the initial thickness s of the workpiece before processing along the direction perpendicular to the longitudinal axis of the workpiece is (1 / n s).
In einer weiteren Ausführungsform entspricht das erste Bearbeitungselement einem Ziehstempel und das zweite Bearbeitungselement entspricht einer Ziehmatrize und die Bewegung des Ziehstempels und der Ziehmatrize während der Bearbeitung des Werkstücks im Rahmen eines Ziehverfahrens erfolgt mit n Stufen. Hierbei beträgt ein Vorschubbetrag durch die Vorschubbewegung des Ziehstempels in jeder der n Bearbeitungsstufen im Verhältnis zu einer Ausgangsdicke s des Werkstücks vor der Bearbeitung entlang einer senkrecht zu einer Längsachse des Werkstücks verlaufenden Richtung (120 · 1/n · s) und ein Rückführbetrag durch die Rückführbewegung des Ziehstempels, ein Rückführbetrag durch die Rückführbewegung der Ziehmatrize sowie ein Vorschubbetrag durch die Vorschubbewegung der Ziehmatrize in jeder der n Bearbeitungsstufen im Verhältnis zu der Ausgangsdicke s des Werkstücks vor der Bearbeitung entlang der senkrecht zu der Längsachse des Werkstücks verlaufenden Richtung beträgt (1/120 · n · s).In a further embodiment, the first machining element corresponds to a drawing punch and the second machining element corresponds to a drawing die and the movement of the drawing punch and the drawing die during the machining of the workpiece as part of a drawing process takes place in n stages. Here, a feed amount by the feed movement of the drawing punch in each of the n processing stages in relation to an initial thickness s of the workpiece before processing along a direction perpendicular to a longitudinal axis of the workpiece is (120 · 1 / n · s) and a return amount by the return movement of the drawing punch, a return amount by the returning movement of the drawing die and a feeding amount by the feeding movement of the drawing die in each of the n processing stages in relation to the initial thickness s of the workpiece before processing along the direction perpendicular to the longitudinal axis of the workpiece is (1/120 n · s).
In einer weiteren bevorzugten Ausführungsform kann die Anzahl der Bearbeitungsstufen n gleich 10 oder 12 sein.In a further preferred embodiment, the number of processing stages n can be equal to 10 or 12.
Die vorstehenden Bewegungsmuster können bei dem erfindungsgemäßen Bearbeitungsverfahren unter Verwendung der erfindungsgemäßen Bearbeitungsmaschine eingesetzt werden.The above movement patterns can be used in the processing method according to the invention using the processing machine according to the invention.
Durch die vorstehenden Bewegungsmuster können die gleichen vorteilhaften Effekte erhalten werden, welche vorstehend in Zusammenhang mit dem erfindungsgemäßen Bearbeitungsverfahren beschrieben sind.The same advantageous effects as described above in connection with the machining method according to the invention can be obtained by the above movement patterns.
Weitere Merkmale, Aspekte und Vorteile der Erfindung werden anhand der nachfolgenden detaillierten Beschreibung bevorzugter Ausführungsformen unter Bezugnahme auf die beigefügten Abbildungen deutlicher ersichtlich.Further features, aspects and advantages of the invention will become more clearly apparent from the following detailed description of preferred embodiments with reference to the accompanying drawings.
Dabei zeigen:
- Fig. 1A
- eine Vorderansicht einer erfindungsgemäßen Bearbeitungsmaschine;
- Fig. 1B
- eine Seitenansicht der in
Fig. 1A dargestellten erfindungsgemäßen Bearbeitungsmaschine; - Fig. 1C
- eine Querschnittsansicht der in
Fig. 1A dargestellten erfindungsgemäßen Bearbeitungsmaschine entlang der inFig. 1A dargestellten Linie A-A; - Fig. 1D
- eine vergrößerte Teil-Querschnittsansicht der in
Fig. 1A dargestellten erfindungsgemäßen Bearbeitungsmaschine entlang der inFig. 1A dargestellten Linie A-A während der Durchführung eines erfindungsgemäßen Bearbeitungsverfahrens; - Fig. 1E
- eine Detailansicht, welche den in
Fig. 1D gezeigten Bereich A vergrößert darstellt; - Fig. 2A
- eine Teil-Querschnittsansicht einer weiteren erfindungsgemäßen Bearbeitungsmaschine während der Durchführung eines weiteren erfindungsgemäßen Bearbeitungsverfahrens;
- Fig. 2B
- eine Detailansicht, welche den in
Fig. 2A gezeigten Bereich B vergrößert darstellt; - Fig. 3A
- eine Teil-Querschnittsansicht einer weiteren erfindungsgemäßen Bearbeitungsmaschine während der Durchführung eines weiteren erfindungsgemäßen Bearbeitungsverfahrens;
- Fig. 3B
- eine Detailansicht, welche den in
Fig. 3A gezeigten Bereich C vergrößert darstellt; - Fig. 4A
- eine Teil-Querschnittsansicht einer weiteren erfindungsgemäßen Bearbeitungsmaschine während der Durchführung eines weiteren erfindungsgemäßen Bearbeitungsverfahrens;
- Fig. 4B
- eine Detailansicht, welche den in
Fig. 4A gezeigten Bereich D vergrößert darstellt; - Fig. 5
- eine schematische Darstellung eines in der erfindungsgemäßen Bearbeitungsmaschine verwendeten Kurvengetriebes;
- Fig. 6A
- eine schematische Darstellung eines erfindungsgemäßen Bearbeitungszentrums mit einer Mehrzahl erfindungsgemäßer Bearbeitungsmaschinen;
- Fig. 6B
- eine Detailansicht, welche den in
Fig. 6A gezeigten Bereich E vergrößert darstellt; - Fig. 6C
- eine Seitenansicht des in
Fig. 6A gezeigten Bearbeitungszentrums; - Fig. 6D
- eine Draufsicht des in
Fig. 6A gezeigten Bearbeitungszentrums; - Fig. 7
- ein Diagramm, welches ein erfindungsgemäßes Bewegungsmuster im Rahmen eines Stanzvorgangs darstellt;
- Fig.8
- ein Diagramm, welches ein weiteres erfindungsgemäßes Bewegungsmuster im Rahmen eines Prägevorgangs darstellt;
- Fig. 9
- ein Diagramm, welches ein weiteres erfindungsgemäßes Bewegungsmuster im Rahmen eines Biegevorgangs darstellt; und
- Fig. 10
- ein Diagramm, welches ein weiteres erfindungsgemäßes Bewegungsmuster im Rahmen eines Ziehvorgangs darstellt.
- Figure 1A
- a front view of a processing machine according to the invention;
- Figure 1B
- a side view of the in
Figure 1A illustrated processing machine according to the invention; - Figure 1C
- a cross-sectional view of the in
Figure 1A illustrated processing machine according to the invention along the inFigure 1A shown line AA; - Figure 1D
- an enlarged partial cross-sectional view of the FIG
Figure 1A illustrated processing machine according to the invention along the inFigure 1A line AA shown while a machining method according to the invention is being carried out; - Figure 1E
- a detailed view showing the in
Figure 1D shows area A enlarged; - Figure 2A
- a partial cross-sectional view of a further processing machine according to the invention while a further processing method according to the invention is being carried out;
- Figure 2B
- a detailed view showing the in
Figure 2A shows area B enlarged; - Figure 3A
- a partial cross-sectional view of a further processing machine according to the invention while a further processing method according to the invention is being carried out;
- Figure 3B
- a detailed view showing the in
Figure 3A shows area C enlarged; - Figure 4A
- a partial cross-sectional view of a further processing machine according to the invention while a further processing method according to the invention is being carried out;
- Figure 4B
- a detailed view showing the in
Figure 4A shows area D shown enlarged; - Fig. 5
- a schematic representation of a cam gear used in the machine tool according to the invention;
- Figure 6A
- a schematic representation of a machining center according to the invention with a plurality of machine tools according to the invention;
- Figure 6B
- a detailed view showing the in
Figure 6A shows area E shown enlarged; - Figure 6C
- a side view of the in
Figure 6A shown machining center; - Figure 6D
- a top view of the in
Figure 6A shown machining center; - Fig. 7
- a diagram showing a movement pattern according to the invention in the context of a punching process;
- Fig. 8
- a diagram showing a further inventive movement pattern in the context of an embossing process;
- Fig. 9
- a diagram showing a further movement pattern according to the invention in the context of a bending process; and
- Fig. 10
- a diagram showing a further movement pattern according to the invention in the context of a drawing process.
Nachfolgend sind Ausführungsformen der erfindungsgemäßen Bearbeitungsmaschine zum Ausführen des erfindungsgemäßen Bearbeitungsverfahrens, des erfindungsgemäßen Bearbeitungszentrums sowie des erfindungsgemäßen Bewegungsmusters erster und zweiter Bewegungselemente im Rahmen erfindungsgemäßer Bearbeitungsverfahren mit Bezug auf die Abbildungen detailliert beschrieben.Embodiments of the processing machine according to the invention for carrying out the processing method according to the invention, the processing center according to the invention and the movement pattern according to the invention of first and second movement elements in the context of processing methods according to the invention are described in detail with reference to the figures.
Nachstehend ist mit Bezug auf die
Die Stanzvorrichtung 1 umfasst erste und zweite Stanzstempel 2, 4, welche bei der in
Die in
In den
Bei einem Betrieb der Stanzvorrichtung 1 wird eine Rotation des Servoaktuators 14 über eine Abtriebswelle desselben auf das Kurvenglied 6 des Kurvengetriebes 15 übertragen und die Rotation des Kurvenglieds 6 wird, wie später detailliert beschrieben ist, über eine Kopplung mit dem in dem Eingriffsglied 8 gelagerten Pendelhebel 24 in eine Linearbewegung des Eingriffsglieds 8 umgewandelt.During operation of the
Der Niederhalter 7 der in
Weiter ist mit Bezug auf die
Ebenso wie bei der in
Wie in
Die in
Der Niederhalter 7' der erfindungsgemäßen Prägevorrichtung 1' weist auf der Seite des Werkstücks W eine Ausnehmung 7a auf, welche zum Aufnehmen des beim Prägen des Werkstücks W fließenden Materials und somit zum Ausbilden der Schneide bei der Prägebearbeitung dient. Die übrige Gestaltung des Niederhalter 7' entspricht im Wesentlichen der vorstehend in Zusammenhang mit der erfindungsgemäßen Stanzvorrichtung 1 beschriebenen Ausgestaltung des Niederhalters 7. Durch die vorstehend erwähnte versetzte Anordnung der Prägestempel in der quer zu den Bearbeitungsachsen B1, B2 verlaufenden Richtung kann das Fließen des Materials bei der Prägebearbeitung in vorteilhafter Art und Weise gezielt beeinflusst werden. Bei der in
Weiter ist mit Bezug auf die
Ebenso wie bei der in
Wie in
Die in
Weiter ist mit Bezug auf die
Ebenso wie bei den vorstehend beschriebenen Bearbeitungsmaschinen gemäß den ersten bis dritten Ausführungsformen erstreckt sich die Längsachse WL des zu bearbeitenden Werkstücks W in den
Wie in
Die Ziehmatrize 4"' weist an einem Ende davon auf der Seite des zu bearbeitenden Werkstücks W eine Ausnehmung zur Aufnahme des durch den Ziehstempel 2"' verformten Werkstückmaterial auf, wobei die Kontur der Vertiefung der Ziehmatrize 4"' in Abhängigkeit der gewünschten Gestalt des fertig bearbeiteten Werkstücks ausgebildet ist.The drawing die 4 '' 'has at one end thereof on the side of the workpiece W to be machined a recess for receiving the workpiece material deformed by the drawing punch 2' '', the contour of the recess of the drawing die 4 '' 'depending on the desired shape of the finished machined workpiece is formed.
Die in
Nachstehend ist mit Bezug auf
Wie in
Über die beiden Abnahmerollen 12' bzw. 12" kann die von der Kurvenscheibe 6 aufgeprägte Antriebskraft in zwei Antriebskraftkomponenten 28, 34 zerlegt werden, die jeweils auf die Abnahmerolle 12' und auf die Abnahmerolle 12" einwirken. Dabei kann die erste Antriebskraftkomponente 28 (Pfeil F') mit der Abnahmerolle 12' in eine erste Querkraftkomponente 30 (Pfeil Fquer') und eine erste Wirkkraftkomponente 32 (Pfeil Fwirk') zerlegt werden. Mittels der Abnahmerolle 12" kann die zweite Antriebskraftkomponente 34 in eine zweite Querkraftkomponente 36 (Pfeil Fquer") und eine zweite Wirkkraftkomponente 38 (Pfeil Fwirk") zerlegt werden. Die beiden Wirkkraftkomponenten 32 und 38 addieren sich zur letztendlichen auf den Linearschlitten 8 einwirkenden Gesamtwirkkraft. Die beiden Querkraftkomponenten 30 und 36 kompensieren sich gegenseitig und führen dazu, das Querkräfte im Idealfall gegen Null reduziert werden können.Via the two take-off
Die
Bei dem in den
Durch diese Ausgestaltung können in einer einzigen Bearbeitungseinheit bzw. dem Bearbeitungszentrum somit verschiedene aufeinanderfolgende Bearbeitungsschritte durchgeführt werden. So kann das als Bandmaterial hin zu dem Bearbeitungszentrum geführte Werkstück W beispielsweise in einem ersten Bearbeitungsschritt zunächst unter Verwendung einer erfindungsgemäßen Stanzvorrichtung gestanzt werden, wodurch eine Stanzfläche mit einem sehr hohen Glattschnittanteil erhalten wird, und anschließend kann das Werkstück zur weiteren Bearbeitung hin zu einer erfindungsgemäßen Biegevorrichtung, einer erfindungsgemäßen Prägevorrichtung und einer erfindungsgemäßen Ziehvorrichtung in dem Bearbeitungszentrum befördert werden. Durch diese Ausgestaltung kann die Bearbeitung des Werkstücks in dem Bearbeitungszentrum ohne eine Handhabung des Werkstücks zwischen den jeweiligen Bearbeitungsschritten abgeschlossen werden. Das erfindungsgemäße Zusammenfassen mehrerer Bearbeitungsmaschinen in einem einzelnen Bearbeitungszentrum reduziert somit den Handhabungsaufwand bei der Bearbeitung des Werkstücks und somit die Bearbeitungskosten wesentlich.As a result of this configuration, various successive processing steps can thus be carried out in a single processing unit or the processing center. For example, the workpiece W guided as strip material to the machining center can be punched in a first machining step using a punching device according to the invention, whereby a punched surface with a very high smooth cut portion is obtained, and then the workpiece can be processed further to a bending device according to the invention , an embossing device according to the invention and a drawing device according to the invention are conveyed in the machining center. With this configuration, the machining of the workpiece in the machining center can be completed without handling the workpiece between the respective machining steps. The combination according to the invention of several processing machines in a single processing center thus significantly reduces the handling effort when processing the workpiece and thus the processing costs.
Zu beachten ist, dass die Erfindung nicht auf die in den
Nachstehend ist mit Bezug auf
In dem Diagramm von
Vor Beginn des in
Wie in
Bei dem in
Die synchrone Bewegungsabfolge der Stanzstempel bei diesem Bewegungsmuster ergibt sich aus der Überlagerung einer mechanischen Kurve und einer elektronischen Kurve. Der Synchronlauf der beiden Stanzstempel wird bei dem in
Mit Bezug auf
In gleicher Art und Weise wie in
Vor Beginn des erfindungsgemäßen Bewegungsmusters bzw. zu Beginn des erfindungsgemäßen Prägeverfahrens wird zunächst das zu bearbeitende Werkstück W zwischen den ersten und zweiten Prägestempeln 2', 4' der Prägevorrichtung 1' positioniert und anschließend wird das Werkstück durch den Niederhalter 7' der Prägevorrichtung 1' fixiert (in
Wie in dem Diagramm von
Bei dem hier beschriebenen Bewegungsmuster der Prägestempel zur Bearbeitung des Werkstücks im Rahmen des erfindungsgemäßen Prägeverfahrens bewegen sich die ersten und zweiten Prägestempel 2', 4' durch den Antrieb vermittels der ersten und zweiten servomechanischen Antriebe in einer mehrstufigen Art und Weise synchron gegenläufig zueinander und zudem pulsierend, um das Werkstück W zu prägen. Genauer gesagt, die ersten und zweiten Prägestempel 2', 4' bewegen sich während der Bearbeitung des Werkstücks W durch den Antrieb vermittels der jeweiligen servomechanischen Antriebe beide in einer mehrstufigen Art und Weise pulsierend in Richtung hin zu dem Werkstück W, das heißt, die beiden Prägestempel 2', 4' bewegen sich entlang den Bearbeitungsachsen B1, B2, welche in
Bei dem in
Bei den vorstehend angegebenen Vorschub- und Rückführbewegungen bezieht sich ein positives Vorzeichen auf eine Bewegung der Prägestempel in Richtung hin zu dem Werkstück und ein negatives Vorzeichen bezieht sich auf eine Bewegung der jeweiligen Prägestempel von dem Werkstück weg. Bei diesem beispielhaften erfindungsgemäßen Bewegungsmuster der ersten und zweiten Prägestempel 2', 4' beträgt ein Vorschubbetrag durch die Vorschubbewegung der ersten und zweiten Prägestempel 2', 4' in jeder der zehn Bearbeitungsstufen somit etwa 5 % der Ausgangsdicke s des Werkstücks vor der Bearbeitung und ein Rückführbetrag durch die Rückführbewegung der ersten und zweiten Prägestempel 2', 4' in jeder der zehn Bearbeitungsstufen beträgt etwa 3 % der Ausgangsdicke s des Werkstücks vor der Bearbeitung.In the case of the feed and return movements specified above, a positive sign relates to a movement of the die in the direction of the workpiece and a negative sign relates to a movement of the respective die away from the workpiece. In this exemplary movement pattern according to the invention of the first and second dies 2 ', 4', a feed amount due to the feed movement of the first and second dies 2 ', 4' in each of the ten processing stages is thus approximately 5% of the initial thickness s of the workpiece before processing and a Return amount by the return movement of the first and second Embossing die 2 ', 4' in each of the ten processing stages is approximately 3% of the initial thickness s of the workpiece before processing.
Auch bei diesem gegenläufigen Bewegungsmuster der ersten und zweiten Prägestempel 2', 4' wird der Synchronlauf der Servoaktuatoren unter Verwendung der bei der Prägevorrichtung 1' vorgesehenen Steuerungsvorrichtung von einer virtuellen Leitachse gesteuert und die virtuelle Leitachse wirkt als Master gegenüber den aktiven Achsen der Servoaktuatoren (Slave). Bei jeder beliebigen Position einer aktiven Achse soll dabei die Positionsabweichung der Achse kleiner als 0,005 [mm] sein. Um diese Genauigkeit unter Berücksichtigung der im Prozess wirkenden Einflussgrößen, Kraft, Geschwindigkeit, Beschleunigung und Massenträgheit zu realisieren, wird die virtuelle Achse von einem Regelkreis unterstützt. In diesem Regelkreis werden durch Sensoren an den Aktivelementen Kraft, Weg und Körperschall fortlaufend erfasst und mit einer Geschwindigkeit von 1/125 [sec] als Korrekturwert an die Leitachse übermittelt.Even with this opposing movement pattern of the first and second embossing dies 2 ', 4', the synchronous operation of the servo actuators is controlled by a virtual master axis using the control device provided in the embossing device 1 'and the virtual master axis acts as a master with respect to the active axes of the servo actuators (slave ). For any position of an active axis, the position deviation of the axis should be less than 0.005 [mm]. The virtual axis is supported by a control loop in order to achieve this accuracy, taking into account the influencing variables, force, speed, acceleration and mass inertia acting in the process. In this control loop, sensors on the active elements continuously record force, displacement and structure-borne noise and transmit them as a correction value to the master axis at a speed of 1/125 [sec].
Nach Abschluss der Prägebearbeitung des Werkstücks W bewegen sich die ersten und zweiten Prägestempel 2', 4' wieder hin zu deren Ausgangspositionen vor der Bearbeitung des Werkstücks W zurück, um das bearbeitete Werkstück W freizugeben.After the end of the embossing processing of the workpiece W, the first and second embossing dies 2 ′, 4 ′ move back to their starting positions before the processing of the workpiece W in order to release the processed workpiece W.
Mit Bezug auf
In gleicher Art und Weise wie in
Zu Beginn des erfindungsgemäßen Biegeverfahrens wird zunächst das zu bearbeitende Werkstück W zwischen dem Biegestempel 2" und dem Biegekern 4" der Biegevorrichtung 1" positioniert und anschließend wird das Werkstück durch den Niederhalter 7" der Biegevorrichtung 1" fixiert (in
Wie in dem Diagramm von
Bei dem hier beschriebenen Bewegungsmuster bewegt sich der Biegestempel 2" durch den Antrieb vermittels des zugehörigen servomechanischen Antriebs während des Bearbeitungsvorgangs in einer mehrstufigen Art und Weise pulsierend, um das Werkstück W zu biegen. Genauer gesagt, der Biegestempel 2" bewegt sich während des Bearbeitungsvorgangs durch den Antrieb vermittels des zugehörigen servomechanischen Antriebs in einer mehrstufigen Art und Weise pulsierend in Richtung hin zu dem Werkstück, wobei durch die pulsierende Bewegung des Biegestempels 2" eine Vorschubbewegung des Biegestempels 2" in Richtung hin zu dem Werkstück W und eine zu der Vorschubbewegung entgegengesetzt ausgerichtete Rückführbewegung des Biegestempels 2" von dem Werkstück weg vorgesehen ist, welche beispielsweise 20 % der Vorschubbewegung beträgt.In the movement pattern described here, the bending
Wie bereits vorstehend beschrieben ist, wird der Biegekern 4" durch einen entsprechenden servomechanischen Antrieb angetrieben und an das Werkstück angenähert, bis dieser mit dem Werkstück in Kontakt kommt. Vor Beginn der Werkstückbearbeitung liegt der Biegekern 4" somit an dem Werkstück an, wie mit der Linie L2" in
Bei dem in
Bei den vorstehend angegebenen Vorschub- und Rückführbewegungen bezieht sich ein positives Vorzeichen auf eine Bewegung der Bearbeitungselemente in Richtung hin zu dem Werkstück und ein negatives Vorzeichen bezieht sich auf eine Bewegung der jeweiligen Bearbeitungselemente von dem Werkstück weg. Auch bei diesem gegenläufigen Bewegungsmuster des Biegestempels und des Biegekerns wird der Synchronlauf der Servoaktuatoren unter Verwendung der bei der Biegevorrichtung 1" vorgesehenen Steuerungsvorrichtung von einer virtuellen Leitachse gesteuert und die virtuelle Leitachse wirkt als Master gegenüber den aktiven Achsen der Servoaktuatoren (Slave). Bei jeder beliebigen Position einer aktiven Achse soll dabei die Positionsabweichung der Achse kleiner als 0,005 [mm] sein. Um diese Genauigkeit unter Berücksichtigung der im Prozess wirkenden Einflussgrößen, Kraft, Geschwindigkeit, Beschleunigung und Massenträgheit zu realisieren, wird die virtuelle Achse von einem Regelkreis unterstützt. In diesem Regelkreis werden durch Sensoren an den Aktivelementen Kraft, Weg und Körperschall fortlaufend erfasst und mit einer Geschwindigkeit von 1/125 [sec] als Korrekturwert an die Leitachse übermittelt.In the case of the feed and return movements specified above, a positive sign relates to a movement of the machining elements in the direction of the workpiece and a negative sign relates to a movement of the respective machining elements away from the workpiece. Even with this opposing movement pattern of the bending punch and the bending core, the synchronous running of the servo actuators is controlled by a virtual master axis using the control device provided for the
Nach Abschluss der Biegebearbeitung des Werkstücks W bewegen sich der Biegestempel und der Biegekern wieder hin zu deren Ausgangspositionen vor der Bearbeitung des Werkstücks zurück, um das bearbeitete Werkstück freizugeben.After the bending processing of the workpiece W has been completed, the bending punch and the bending core move back to their starting positions before the processing of the workpiece in order to release the processed workpiece.
Mit Bezug auf
In gleicher Art und Weise wie in
Zu Beginn des erfindungsgemäßen Ziehverfahrens wird zunächst das zu bearbeitende Werkstück W zwischen dem Ziehstempel 2"' und der Ziehmatrize 4'" der Ziehvorrichtung 1 "' positioniert und anschließend wird das Werkstück durch den Niederhalter 7"' der Ziehvorrichtung 1"' fixiert (in
Wie in dem Diagramm von
Bei dem hier beschriebenen Bewegungsmuster bewegt sich der Ziehstempel 2"' während des Bearbeitungsvorgangs durch den Antrieb vermittels des zugehörigen servomechanischen Antriebs während des Bearbeitungsvorgangs in einer mehrstufigen Art und Weise pulsierend, um das Werkstück umzuformen. Genauer gesagt, der Ziehstempel 2"' bewegt sich während des Bearbeitungsvorgangs durch den Antrieb vermittels des zugehörigen servomechanischen Antriebs in einer mehrstufigen Art und Weise pulsierend in Richtung hin zu dem Werkstück, wobei durch die pulsierende Bewegung des Ziehstempel 2"' eine Vorschubbewegung des Ziehstempels 2"' in Richtung hin zu dem Werkstück W und eine zu der Vorschubbewegung entgegengesetzt ausgerichtete Rückführbewegung des Ziehstempels 2"' von dem Werkstück weg vorgesehen ist, welche beispielsweise 20 % der Vorwärtsbewegung beträgt.In the movement pattern described here, the drawing punch 2 '''moves during the machining process through the drive by means of the associated servomechanical drive during the machining process in a pulsating manner in a multi-stage manner in order to reshape the workpiece. More precisely, the
Wie bereits vorstehend beschrieben ist, wird die Ziehmatrize 4"' durch einen entsprechenden servomechanischen Antrieb angetrieben und an das Werkstück angenähert, bis diese mit dem Werkstück in Kontakt kommt. Vor Beginn der Werkstückbearbeitung liegt die Ziehmatrize 4"' somit an dem Werkstück an, wie mit der Linie L2'" in
Bei dem in
Auch bei den vorstehend angegebenen Vorschub- und Rückführbewegungen bezieht sich ein positives Vorzeichen auf eine Bewegung der Bearbeitungselemente in Richtung hin zu dem Werkstück und ein negatives Vorzeichen bezieht sich auf eine Bewegung der jeweiligen Bearbeitungselemente von dem Werkstück weg. Ferner wird auch bei diesem gegenläufigen Bewegungsmuster des Ziehstempels und der Ziehmatrize der Synchronlauf der Servoaktuatoren unter Verwendung der bei der Ziehvorrichtung 1"' vorgesehenen Steuerungsvorrichtung von einer virtuellen Leitachse gesteuert und die virtuelle Leitachse wirkt als Master gegenüber den aktiven Achsen der Servoaktuatoren (Slave). Bei jeder beliebigen Position einer aktiven Achse soll dabei die Positionsabweichung der Achse kleiner als 0,005 [mm] sein. Um diese Genauigkeit unter Berücksichtigung der im Prozess wirkenden Einflussgrößen, Kraft, Geschwindigkeit, Beschleunigung und Massenträgheit zu realisieren, wird die virtuelle Achse von einem Regelkreis unterstützt. In diesem Regelkreis werden durch Sensoren an den Aktivelementen Kraft, Weg und Körperschall fortlaufend erfasst und mit einer Geschwindigkeit von 1/125 [sec] als Korrekturwert an die Leitachse übermittelt.Also in the case of the feed and return movements specified above, a positive sign relates to a movement of the machining elements in the direction of the workpiece and a negative sign relates to a movement of the respective machining elements away from the workpiece. Furthermore, even with this opposing movement pattern of the drawing punch and the drawing die, the synchronous operation of the servo actuators is controlled by a virtual master axis using the control device provided in the drawing device 1 '' 'and the virtual master axis acts as a master with respect to the active axes of the servo actuators (slave) For any position of an active axis, the position deviation of the axis should be less than 0.005 [mm]. In order to achieve this accuracy, taking into account the influencing variables, force, speed, acceleration and inertia, the virtual axis is supported by a control loop. In this control loop, sensors on the active elements continuously record force, displacement and structure-borne noise and transmit them as a correction value to the master axis at a speed of 1/125 [sec].
Nach Abschluss der Ziehbearbeitung des Werkstücks bewegen sich der Ziehstempel und die Ziehmatrize wieder hin zu deren Ausgangspositionen vor der Bearbeitung des Werkstücks zurück, um das bearbeitete Werkstück freizugeben.After the drawing process of the workpiece has been completed, the drawing punch and the drawing die move back to their starting positions before the workpiece was processed in order to release the processed workpiece.
Obwohl im Rahmen der vorstehend detailliert erläuterten erfindungsgemäßen Bewegungsmuster eine Aufteilung der Bearbeitung in 10 bzw. 12 Bearbeitungsstufen bzw. -schritte beschrieben ist, ist die vorliegenden Erfindung nicht darauf beschränkt und die mehrstufige Bearbeitung des Werkstücks kann in eine beliebige Anzahl von Bearbeitungsstufen aufgeteilt sein.Although within the scope of the movement pattern according to the invention explained in detail above, the processing is divided into 10 or 12 processing stages or steps is described, the present invention is not limited thereto and the multi-stage machining of the workpiece can be divided into any number of machining stages.
Claims (13)
- Machining method for machining a workpiece (W) using at least one processing machine (1; 1'; 1"; 1'") with a first and a second machining element (2, 4; 2', 4'; 2", 4"; 2"', 4"') for machining the workpiece (W) positioned between these elements, first and second servo-mechanical drives with a servo-actuator (14) and a cam gear (15) associated with the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') respectively and connected thereto in order to drive the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') for machining the workpiece (W) along at least one machining axis (B; B1, B2) oriented perpendicular to a longitudinal axis (WL) of the workpiece (W) to be machined, at least one hold-down device (7; 7'; 7"; 7"') for fixing the workpiece (W) during machining, and guides (3, 5; 3', 5'; 3", 5"; 3"', 5"') for the machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"'),the cam gear (15) having a cam member formed as a cam plate (6) and an engaging member with at least two rotatably supported take-off rollers (12', 12") for transmitting a driving force introduced into the cam member by the servo-actuator onto the engaging member;the engaging member being formed as a linear slide (8) connected to a corresponding machining element and having a pivotably mounted pendulum lever (24) which carries the at least two take-off rollers (12', 12") which are rotatably mounted in such a way that the cam plate (6) for transmitting the introduced driving force (28, 34) to the linear slide (8) is rollable on the at least two take-off rollers (12', 12") lying against the cam plate (6), generating a total effective force consisting of two active force components (32, 38),wherein the machining method comprises the following steps:positioning the workpiece (W) to be machined between the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') of the processing machine (1; 1'; 1"; 1'");fixing the workpiece (W) by the at least one hold-down device (7; 7'; 7"; 7"') of the processing machine (1; 1'; 1"; 1"');bringing the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') to lie against the workpiece (W) without deformation of the workpiece (W); andmachining the workpiece (W) by the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') with a plastic deformation of the workpiece (W),wherein the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') are driven during the machining operation by the first and second servo-mechanical drives of the processing machine (1; 1'; 1"; 1'") in a multistage fashion at least temporarily synchronously equidistant from one another or synchronously in opposite directions to one another.
- Machining method according to claim 1, comprising one of the following machining processes:
Punching, stamping, bending or drawing. - Machining method according to claim 1 or 2, wherein, depending on the material properties of the workpiece (W), a step size of machining stages is varied by the multi-stage drive of the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') during the machining of the workpiece (W) and/or a speed of movement of the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4"') is varied during machining of the workpiece (W) and/or the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') are held in a rest position for a predetermined period of time (T1) between the machining stages.
- Machining method according to any one of claims 1 to 3, wherein, before machining the workpiece (W), the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') are brought to lie against the workpiece (W) for a predetermined period of time (T2) in a rest position of the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') without deformation of the workpiece (W), and/or
wherein the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') are driven in a pulsating fashion during machining operation with a feed movement of the machining elements (2, 4; 2', 4'; 2", 4"; 2"', 4''') in the direction of the workpiece (W) and with a return movement of the machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') opposite to the feed movement away from the workpiece (W). - Machining method according to any one of claims 1 to 4, wherein a plurality of processing machines are used for machining the workpiece (W) in a plurality of successive machining steps enclosed in a common housing structure, thereby forming a machining centre (20) with the plurality of processing machines, wherein the workpiece (W) is fed as a strip material to the machining centre (20) and conveyed to and through the processing machines in the machining centre (20) for machining in successive machining steps.
- Processing machine (1; 1'; 1"; 1''') for machining a workpiece (W), comprising a first and a second machining element (2, 4; 2', 4'; 2", 4"; 2''', 4''') for machining the workpiece (W) positioned between these elements, at least one hold-down device (7; 7'; 7"; 7''') for fixing the workpiece (W) during machining and guides (3, 5; 3', 5'; 3", 5"; 3''', 5''') for the machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4'''), whereinthe first and second machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') are each assigned servo-mechanical drives with a servo-actuator (14) and a cam gear (15) and are connected to these in order to drive the first and second machining elements (2, 4; 2', 4'; 2", 4"; 2''', 4''') for machining the workpiece (W) along at least one machining axis (B; B1, B2) which is oriented perpendicular to a longitudinal axis (WL) of the workpiece (W) to be machined,the cam gear (15) having a cam member formed as a cam plate (6) and an engaging member having at least two rotatably supported take-off rollers (12', 12") for transmitting a driving force introduced into the cam member by the servo-actuator (14) onto the engaging member;the engaging member being formed as a linear slide (8) connected to a corresponding machining element (2, 4; 2', 4') and having a pivotably mounted pendulum lever (24) which carries the at least two take-off rollers (12', 12") which are rotatably mounted in such a way that the cam plate (6) for transmitting the introduced driving force (28, 34) to the linear slide (8) is rollable on the at least two take-off rollers (12', 12") lying against the cam plate (6), generating a total effective force consisting of two active force components (32, 38),wherein the processing machine (1; 1'; 1"; 1''') further comprises a control apparatus configured to control the processing machine (1; 1'; 1"; 1''') according to the processing method of any one of claims 1 to 5.
- Processing machine (1; 1'; 1''') according to claim 6, wherein the first and second processing elements (2, 4; 2', 4'; 2''', 4''') are disposed opposite each other along the at least one machining axis (B; B1, B2), or
wherein the first and second machining elements (2', 4'; 2", 4"; 2''', 4''') are offset relative to one another in a direction running transversely to the at least one machining axis (B; B1, B2). - Machining centre (20) comprising a plurality of processing machines (1; 1'; 1"; 1''') having the features according to claim 6 or 7 and a delivery device (21) for conveying the workpiece (W) in the machining centre (20) to and through the plurality of processing machines (1; 1'; 1"; 1'''), wherein the workpiece (W) corresponds to a strip material and the processing machines (1; 1'; 1"; 1''') are enclosed by a common housing structure.
- Movement pattern of first and second machining elements (2', 4') for machining a workpiece (W) positioned between the first and second machining elements (2', 4'), wherein the first and second machining elements (2', 4') initially come into contact with the workpiece (W) before the workpiece (W) is machined without any deformation of the workpiece (W) and, during the machining operation, move synchronously equidistantly to one another or synchronously in opposite directions to one another in a multi-stage fashion at least temporarily with a plastic deformation of the workpiece (W),wherein the first and second machining elements (2', 4'), prior to the machining of the workpiece (W), are in contact with the workpiece (W) for a predetermined period of time (T2) in a rest position of the first and second machining elements (2', 4') without any deformation of the workpiece (W), and/or wherein the first and second machining elements (2', 4') move in a pulsating fashion during the machining process with a feed movement of the machining elements (2', 4') in the direction of the workpiece (W) and with a return movement of the machining elements (2', 4') away from the workpiece in the opposite direction to the feed movement,wherein the movement of the first and second machining elements (2', 4') during the machining of the workpiece (W) takes place as part of a stamping operation with n stages, and a feed amount due to the feed movement of the first and second machining elements (2', 4') in each of the n machining stages relative to an initial thickness s of the workpiece (W) before machining along a direction perpendicular to a longitudinal axis (WL) of the workpiece (W) is (1/2 • 1/n • s), and a return amount due to the return movement of the first and second machining elements (2', 4') in each of the n machining stages relative to the initial thickness s of the workpiece (W) before machining along the direction perpendicular to the longitudinal axis (WL) of the workpiece (W) is (3/10 • 1/n • s).
- Movement pattern of first and second machining elements (2", 4") for machining a workpiece (W) positioned between the first and second machining elements (2", 4"), wherein the first and second machining elements (2", 4") initially come into contact with the workpiece (W) before the workpiece (W) is machined without any deformation of the workpiece (W) and, during the machining operation, move synchronously equidistantly to one another or synchronously in opposite directions to one another in a multi-stage fashion at least temporarily with a plastic deformation of the workpiece (W),wherein the first and second machining elements (2", 4"), prior to the machining of the workpiece (W), are in contact with the workpiece (W) for a predetermined period of time (T2) in a rest position of the first and second machining elements (2", 4") without any deformation of the workpiece (W), and/or wherein the first and second machining elements (2", 4") move in a pulsating fashion during the machining process with a feed movement of the machining elements (2", 4") in the direction of the workpiece (W) and with a return movement of the machining elements (2", 4") away from the workpiece in the opposite direction to the feed movement,wherein the first machining element corresponds to a bending punch (2") and the second machining element corresponds to a bending core (4") and wherein the movement of the bending punch (2") and of the bending core (4") during the machining of the workpiece (W) takes place as part of a bending process with n stages, and a feed amount due to the feed movement of the bending punch (2") in each of the n machining stages relative to an initial thickness s of the workpiece (W) before machining along a direction perpendicular to a longitudinal axis (WL) of the workpiece (W) is (3 • 1/n • s), and a return amount due to the return movement of the bending punch (2"), a return amount due to the return movement of the bending core (4") and a feed amount due to the feed movement of the bending core (4") in each of the n machining stages relative to the initial thickness s of the workpiece (W) before machining along the direction perpendicular to the longitudinal axis (WL) of the workpiece (W) is (1/n • s).
- Movement pattern of first and second machining elements (2"', 4''') for machining a workpiece (W) positioned between the first and second machining elements (2"', 4"'), wherein the first and second machining elements (2"', 4''') initially come into contact with the workpiece (W) before the workpiece (W) is machined without any deformation of the workpiece (W) and, during the machining operation, move synchronously equidistantly to one another or synchronously in opposite directions to one another in a multi-stage fashion at least temporarily with a plastic deformation of the workpiece (W),wherein the first and second machining elements (2''', 4'''), prior to the machining of the workpiece (W), are in contact with the workpiece (W) for a predetermined period of time (T2) in a rest position of the first and second machining elements (2"', 4''') without any deformation of the workpiece (W), and/or wherein the first and second machining elements (2"', 4''') move in a pulsating fashion during the machining process with a feed movement of the machining elements (2''', 4''') in the direction of the workpiece (W) and with a return movement of the machining elements (2"', 4''') away from the workpiece in the opposite direction to the feed movement,wherein the first machining element corresponds to a drawing punch (2''') and the second machining element corresponds to a drawing die (4''') and wherein the movement of the drawing punch (2''') and of the drawing die (4''') during the machining of the workpiece (W) takes place as part of a drawing process with n stages, and a feed amount due to the feed movement of the drawing punch (2''') in each of the n machining stages relative to an initial thickness s of the workpiece (W) before machining along a direction perpendicular to a longitudinal axis (WL) of the workpiece (W) is (120 • 1/n • s), and a return amount due to the return movement of the drawing punch (2'''), a return amount due to the return movement of the drawing die (4''') and a feed amount due to the feed movement of the drawing die (4''') in each of the n machining stages relative to the initial thickness s of the workpiece (W) before machining along the direction perpendicular to the longitudinal axis (WL) of the workpiece (W) is (1/120 • n • s).
- Movement pattern according to any one of claims 9 to 11, wherein the number of processing stages n is equal to 10 or 12.
- Movement pattern according to any one of claims 9 to 12 for performing the machining process according to at least one of claims 1 to 5 and/or using the processing machine (1; 1'; 1"; 1''') according to claim 6 or 7.
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DE102016117527.7A DE102016117527B4 (en) | 2016-09-16 | 2016-09-16 | Processing method, processing machine for carrying out the processing method, processing center with a plurality of such processing machines and movement patterns |
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EP3296093A1 EP3296093A1 (en) | 2018-03-21 |
EP3296093B1 true EP3296093B1 (en) | 2021-09-15 |
EP3296093B8 EP3296093B8 (en) | 2021-11-17 |
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JP2571959B2 (en) | 1988-12-05 | 1997-01-16 | 株式会社不二越 | Metal material shearing method |
DE4207165A1 (en) | 1992-03-06 | 1993-09-09 | Fuji Electric Co Ltd | Stamping of metallic foil in piezoelectrically operated press - is performed with vertical oscillation of stamping punches held flat against both sides of foil and moved through less than half of its thickness |
DE10327018B3 (en) | 2003-06-16 | 2004-10-28 | Wilhelm Settele | Stamping/bending machine with a cam-controlled staged action, for bodywork parts and the like, is in a modular structure with a press ram under the paired cams and paired cams for the draw cushions |
DE102007015467B4 (en) | 2007-03-30 | 2015-02-05 | Wilhelm Settele | Cam mechanism with two take-off rollers, method for producing such a cam gear, program for performing the steps of the method, and punch-bending machine with such a cam mechanism |
DE102009052250A1 (en) | 2009-11-06 | 2011-05-12 | Zetka Stanz- Und Biegetechnik Gmbh & Co. Kg | Drive unit for punching and bending machine, has motor, cam gear and linear section, at which receiver for tool is arranged |
DE102013105596B4 (en) | 2013-05-31 | 2015-10-29 | Schuler Pressen Gmbh | Press and method for operating the press |
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DE102016117527B4 (en) | 2018-10-31 |
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