EP3590620B1 - Matrizensatz und verfahren zur formung einer geschlossenen vertiefung - Google Patents

Matrizensatz und verfahren zur formung einer geschlossenen vertiefung Download PDF

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Publication number
EP3590620B1
EP3590620B1 EP18190706.4A EP18190706A EP3590620B1 EP 3590620 B1 EP3590620 B1 EP 3590620B1 EP 18190706 A EP18190706 A EP 18190706A EP 3590620 B1 EP3590620 B1 EP 3590620B1
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EP
European Patent Office
Prior art keywords
punch
groove
sheet material
die set
die
Prior art date
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Active
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EP18190706.4A
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English (en)
French (fr)
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EP3590620A1 (de
Inventor
Yufeng Zheng
Tao Zhao
Shouzin WEI
Fuchuan Jiao
Songqiong ZHANG
Steve Arnold
Jianping Liu
Haoran Wang
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BMW Brilliance Automotive Ltd
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BMW Brilliance Automotive Ltd
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Publication of EP3590620A1 publication Critical patent/EP3590620A1/de
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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
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/10—Die sets; Pillar guides
    • 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
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/10—Stamping using yieldable or resilient pads
    • 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
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards

Definitions

  • the present invention relates to a die set for forming a closed recess in a metal sheet material. Furthermore, the present invention relates to a method for forming a closed recess in a metal sheet material.
  • the die set and method according to the present invention are especially suitable for forming a closed recess such as a recess of handle area on an exterior door panel of an automobile, a recess of badge area on an exterior panel of an engine cover and a fuel filling area on the exterior panel of side frame.
  • Such method for manufacturing a closed recess will be illustrated by exemplifying a recess of handle area on the exterior door panel below.
  • the forming of the recess of the handle area on an exterior door panel is an important forming feature on an entire vehicle, and such part of area is also an important concerning item in the surface evaluation of an entire vehicle.
  • the shape at the recess of the handle area is normally formed by a drawing die.
  • the shape of the recess of the handle area is mainly formed by an upper die of the die set.
  • the upper die of the drawing die set has a punch made of a casting, and the lower die has a punch including a groove.
  • the sheet material is pressed tightly by the material pressing pad on the upper die and the lower die, and as the press slider of the upper die continues to run downward, the portion of punch of the upper die starts to contact with the sheet material and gradually press the sheet material into the groove of the punch of the lower die to form a recess of the handle area.
  • the sheet material at the rounding corner of the recess of the handle area is in a free state, and the pressing force is only to tension such part of sheet material.
  • the force of the punch of the upper die acting on the sheet material is far greater than a tensile force transferred by the material pressing force to such part of area, so that the sheet material outside the rounding corner may flow over the rounding corner of the recess of the handle area into the recess of the handle area.
  • the rounding corner of the recess of the handle area sometimes has an irregular contour, thereby resulting in uneven inflow amount of the material, so that an uneven tangential compressive stress is produced in such area of rounding corner of the recess of the handle area, which accordingly results in the production of a product defect, for example the production of a depression.
  • the method of stamping a sheet material by an elastic material to form a sheet material is also known in the prior arts. However, the principles thereof are still the same as the draw forming.
  • the stamp forming of the groove is realized by rapidly deforming the elastic material so as to rapidly form the sheet material, so that it is still likely to cause the product defect.
  • the closed recess means that the circumferential contour of the recess formed in the sheet material is closed.
  • the edge portion of the first punch contacts with the sheet material, and presses the sheet material against the second punch, thereby producing a material pressing effect.
  • the deformation firstly begins at the portion of the first punch in contact with the sheet material, and the force of pressing the sheet material may be gradually enlarged.
  • the first punch may begin to be slowly compressed inwards from an edge of its first groove, and the edge region of the first groove may contact with the sheet material earlier than the inside of the first groove.
  • the sheet material above the second groove of the second punch has already lacked of support on the second punch, if there is a force applied on the sheet material, the sheet material may begin to be deformed along the edge of the second groove so as to form a rounding corner of the recess of handle area, and along with the gradual deformation of the first punch, the sheet material may be slowly attached against the inner wall of the second groove along the edge of the second groove under the action of the first punch.
  • the first groove of the first punch disappears along with deformation, and the material protruding from a material pressing surface of the first punch completely attaches the sheet material against the inner wall of the second groove of the second punch, and thus finally forms the shape of a closed recess on the sheet material.
  • the sheet material is only deformed along the edge of the second groove of the second punch. Similar to flanging, the force transferred by the first punch always presses the sheet material in the thickness direction of the material, without a radial tensile stress present. Thus, the material may not flow into the closed recess to be formed, so as to avoid the problem of producing a tangential compressive stress and a material flow around the closed recess.
  • the sheet material is also slowly attached against the second groove of the second punch along with the deformation of the first punch.
  • the sheet material that is not deformed is always in a stress state with a bidirectional tensile stress in a plane, and the forming of the closed recess is gradually realized in minor local deformations. Therefore, the die set according to the present invention may also be referred to as a forming die set with "multiple flanging".
  • the area after the deformation of the first punch becomes a material pressing area, in order to produce the material pressing action. Along with the continuous progress of the forming, the material pressing area is enlarged continuously.
  • the present invention solves the problem of producing a tangential compressive stress and a material flow outside the rounding corner of the closed recess, so that a defect may not be produced.
  • the first punch is made of polyurethane, which preferably has a Shore hardness of 80 to 95, and particularly preferably has a Shore hardness of about 90.
  • Polyurethane has a favorable deformability and restorability after deformation, and can withstand certain pressure, so that it has a proper hardness to stamp the sheet material.
  • polyurethane has a large friction coefficient, for example, about 0.4, while the metal sheet material usually has a friction coefficient of about 0.1.
  • the present invention exactly utilizes such large friction coefficient of polyurethane to effectuate reducing the flow of the material and slowly stamp forming the metal sheet material, thereby uniformly performing the deformation, so that it is not likely to produce the product defect.
  • the first punch has a thickness of at least 80 mm.
  • the first punch needs to have certain thickness. Based on such thickness selection, the first punch can stamp form the sheet material with sufficient strength.
  • the first groove has a radial dimension greater than that of the second groove by at least 10 mm, and gradually deepens in a circular arc shape.
  • the stamp forming time is favorably controlled by this technical feature. Further, since the first groove in the first punch gradually deepens, the edge region may contact with the sheet material earlier than the inside, which effectuates that the stamp forming is slowly and uniformly performed.
  • the first punch has a radial dimension greater than that of the second groove by at least 40mm. Accordingly, the closed recess of the sheet material can be effectively stamped out.
  • the second groove of the rigid second punch on the lower die has an air vent hole at its bottom, wherein the air vent hole preferably has a diameter of 4 mm to 6 mm.
  • the upper die has a material pressing pad having an installation space for the first punch to be embedded into, which installation space is constructed as a through hole having a stop shoulder, wherein the first punch rests against the stop shoulder after being embedded into the installation space.
  • the upper die has an upper shoe, in which the material pressing pad is held by a retainer screw, and the retainer screw is provided with a washer preferably made of polyurethane, which washer is disposed between a lower side of the material pressing pad and a head of the retainer screw, for absorbing an impact. Based on the washer for absorbing an impact force, the vibration in the stamping process is alleviated, thereby prolonging the service life of the entire press.
  • the upper shoe is provided with a fixing member preferably made of metal.
  • the first punch is fixed onto the fixing member by a screw bolt.
  • the first punch is fixed onto the fixing member by adhesion, or the first punch is directly fixed onto the material pressing pad by a lock in a form closed manner.
  • the second groove is a rounded groove without edges.
  • the contour of the first groove of the first punch and the overall contour of the first punch are determined according to the closed recess to be formed.
  • the first groove of the first punch has a depth that is greater than that of the second groove of the second punch.
  • the contact surface between the fixing member and the first punch may be planar or curved.
  • the present invention relates to a method for forming a closed recess in a metal sheet material, according to the appended claim 14.
  • the edge portion of the first punch contacts with the sheet material, and presses the sheet material on the second punch, thereby producing a material pressing effect.
  • the first punch presents certain deformability, as the pressure increases, the deformation firstly begins at the portion of the first punch in contact with the sheet material, and the force of pressing the sheet material may be gradually enlarged.
  • the pressing force is so large so as to deform the first punch, the first punch may begin to be slowly compressed inwards from an edge of its first groove, and the edge region of the first punch may contact with the sheet material earlier than the inside.
  • the sheet material above the second groove of the second punch has already lacked of support on the second punch, if there is a force applied on the sheet material, the sheet material may begin to be deformed along the edge of the second groove so as to form a rounding corner of the recess, and along with the gradual deformation of the first punch, the sheet material may be slowly attached against the inner wall of the second groove along the edge of the second groove under the effect of the first punch.
  • the first groove of the first punch disappears along with deformation, and the material protruding from a material pressing surface of the first punch completely attaches the sheet material against the inner wall of the second groove of the second punch, and thus finally forms the shape of a closed recess on the sheet material.
  • the sheet material is only deformed along the edge of the second groove of the second punch. Similar to flanging, the force transferred by the first punch presses the sheet material in the thickness direction of the material, without a radial tensile force present. Thus, the material may not flow into the closed recess to be formed, so as to avoid the problem of producing a tangential compressive stress and a material flow around the closed recess.
  • the sheet material is also slowly attached against the second groove of the second punch along with the deformation of the first punch.
  • the sheet material that is not deformed is always in a stress state with a bidirectional tensile stress in a plane, and the forming of the closed recess is gradually realized in minor local deformations. Therefore, the method according to the present invention may also be referred to as a forming method with "multiple flanging".
  • the forming time when the closed recess on the sheet material is stamp formed is controlled by design of a first groove in the first punch.
  • the forming of the closed recess can be realized in one process. Further, restricted by the shape of the recess of the product and the property of the material of the first punch, the forming of the closed recess may be realized in two processes, which may reduce the amount of deformation of the first punch and improve the service life of the material of the first punch.
  • the die set and method for forming a closed recess of the present invention will be introduced in detail by taking the forming of the recess of handle area on the exterior door panel as an example.
  • the shape of the product is firstly changed to form the shape of the exterior door panel of the automobile, which pertains to a conventional draw forming.
  • the shape of the recess of handle area is pressed out by the upper die and lower die, the present invention is mainly embodied in the die set and method used in this forming step.
  • FIG. 1 shows a sectional view of a die set for forming a closed recess in accordance with the present invention.
  • the die set according to the present invention has an upper die and a lower die.
  • the upper die includes an upper shoe 2 which is made of metal.
  • the upper shoe 2 is provided with a safety side pin 1 which is embedded into the upper shoe in a form closed manner and serves to prevent the material pressing pad 4 from falling off.
  • the number of the safety side pins may be one or more.
  • the upper shoe is provided with a material pressing pad 4 which is made of metal.
  • the material pressing pad 4 is connected with the upper shoe 2 by means of a retainer screw 9 on which a washer 8 made of polyurethane is mounted.
  • the washer is disposed below the material pressing pad 4 and supports the material pressing pad, so that the washer produces the effect of absorbing an impact force when the material pressing pad presses a blank material.
  • the upper side of the material pressing pad 4 is fixed with an upper pin-like member 5 by means of a screw bolt, which upper pin-like member 5 is fixed on the material pressing pad by its lower end and passes through a through hole in the upper shoe by its upper end.
  • the upper pin-like member 5 during die set closing is in contact with the upper air cushion of the stamping device by its upper end, for providing a material pressing force.
  • the material pressing pad 4 has a opening at a middle portion thereof, which opening forms an installation space for embedding the first punch.
  • a stop shoulder is formed in the opening, the first punch 7 is inserted into the installation space and is stopped against the stop shoulder.
  • the first punch 7 which is made of polyurethane, is attached against the fixing member 6 on the upper side and fastened onto the fixing member 6 by a screw bolt.
  • the fixing member 6 in turn is fixed onto the upper shoe 2 by a screw bolt.
  • the fixing member is made of metal.
  • the fixing member 6 functions to fix the first punch 7, and transfers the pressure of the device onto the first punch 7 in the closing process of the die set.
  • the lower die includes a lower shoe 10 which is made of metal.
  • the second punch 11 is supported on the upper side of the lower shoe 10.
  • the second punch 11 is rigid and made of metal.
  • the upper side of the lower shoe is formed with a flange 19 at an edge side, and a positioning key 14 is provided between the flange 19 and the second punch 11.
  • the second punch 11 is fixed on the lower shoe 10 after being positioned by the positioning key 14.
  • the lower side of the material pressing pad is provided with an upper balance member which is preferably an upper conical balance block 5 having a conical recess.
  • the lower balance member which is preferably a lower conical balance block 15 includes an upper conical section and a lower cylindrical section.
  • the upper side of a flange of the lower shoe is provided with a cylindrical concave 20, and the lower conical balance block is embedded into the concave by its lower cylindrical section and forms a connection with the flange 19 in a form closed manner.
  • the lower conical balance block is embedded into a conical recess of the upper conical balance block by its upper conical section, such as to be adapted to the conical recess of the upper conical balance block.
  • the upper conical balance block 3 and the lower conical balance block 15 produce the guiding and pressure balancing effect during the closing of the die set.
  • the lateral surface of the flange 19 of the lower shoe 10 is provided with a projecting step 21, which is supported with a guiding member that is preferably a guiding plate 16.
  • the upper shoe 2, the lower shoe 10 and the guiding plate 16 form a die frame of the entire die set, and the guiding plate produces the guiding function for the upper die 2 during the closing of the die.
  • the first punch 7 has a first groove 17 on the side facing the sheet material, for guiding the first punch 7 to be deformed during the material pressing.
  • the second punch 11 has a second groove 18 on its side facing the first punch 7.
  • the first groove 17 has a radial dimension at least 10 mm greater than that of the second groove 18, and the first groove gradually deepens in a circular arc shape.
  • the first punch 7 has a radial dimension at least 40 mm greater than that of the second groove.
  • the upper end surface of the first punch away from the first groove 17 is planar, and the fixing member 6 is attached against the upper end surface.
  • the first punch has a Shore hardness of about 90, and the first punch 7 has a thickness of at least 80 mm.
  • the first punch is pressed against the sheet material 13 by its lower side having a first groove, and the sheet material 13 is made by draw forming in the previous step.
  • the contact area between the sheet material 13 and the first punch 7 is a forming surface after draw forming in the first step.
  • the first punch 7 is made of polyurethane by injection forming, wherein a fastening screw bolt is built-in when polyurethane is injected, and afterwards the deformable first punch is fastened onto the fixing member made of metal by the fastening screw bolt 6.
  • the bottom of the second groove 18 of the second punch 11 is provided with an air vent hole 12, which has a diameter of 4 mm to 6 mm, and produces the exhausting effect in the forming process.
  • the sheet material 13 is firstly placed on the second punch 11. Afterwards, the upper die moves downward, and the upper pin-like member 5 is gradually exposed out of the upper shoe 2 and comes in contact with the upper air cushion of the press, thereby starting to transfer a material pressing force.
  • the material pressing force is applied to the sheet material 13 by the material pressing pad 4, and the sheet material 13 is pressed against the second punch 11.
  • the upper die continues to move downward, and the pressure of the press device is transferred onto the first punch 7 through the upper shoe 2 and the fixing member 6.
  • the first punch begins to press the sheet material 13 tightly and begins to be deformed under the effect of a gradually increased pressure.
  • the material of the sheet material 13 on the edge of the second groove 18 begins to be deformed and gradually attached against the groove inner wall of the second groove 18 from the outside to the inside until being finally completely attached to the groove inner wall of the second groove 18 tightly.
  • the upper die moves upward, and the first punch 7 slowly restores an initial state under the driving of the screw bolt, and starts to move upward along with the fixing member 6.
  • the material pressing pad 4 leaves the sheet material 13 under the pulling of the washer 8 and the retainer screw 9, so that the entire forming process is finished.
  • FIGS. 2a ) to 2e) show a comparison of stress states of a closed recess in a drawing method, and a bulging forming method, as well as a multiple flanging method of the present invention for manufacturing a closed recess.
  • a point is taken from different parts of the closed recess of the sheet material to be formed respectively, and on such points stress analysis is performed in cells.
  • FIG. 2a is a drawing method, in which the first punch is formed by a casting in FIG. 2a );
  • FIG. 2b is a bulging forming method, in which the first punch is formed from a liquid;
  • FIG. 2c is a multiple flanging method, in which the first punch is formed of a deformable material, such as polyurethane.
  • a deformable material such as polyurethane.
  • Points 1, 1', 1" at the rounding corner of the recess.
  • the cell at the point 1 is subjected to radial tensile stress, and such part of force is produced when the bottom of the punch contacts with the sheet material; the cell is subjected to compressive stress in the tangential direction, because the sheet material is to enter the groove under the driving of the punch. Compressive stress is produced upon shrinkage of the sheet material; the cell at the point 1 is close to the rounding corner of the recess, and thus is subjected to compressive stress in the material thickness direction.
  • the cell at the point 1' is also subjected to stress in three directions, but is subjected to tensile stress in the tangential direction, because the sheet material is subjected to compressive stress in the material thickness direction, thereby forcing the sheet material to be close to the second groove.
  • the cell at the point 1" is only subjected to compressive stress in the material thickness direction, because the deformation of the sheet material in such area has ended, and the sheet material is completely attached to the groove, so that it is not subjected to stress both in the radial direction and the tangential direction.
  • Points 2, 2', 2" for the drawing method, the cell at the point 2 does not contact with the die, and thus is not subjected to a stress in the material thickness direction, but is subjected to a tensile stress in the radial direction and still subjected to a compressive stress in the tangential direction.
  • the point 2' since the sheet material contacts with the punch, the point 2' is still subjected to a stress effect in three directions, and coincides with the state at the position of the point 1'.
  • the sheet material has been deformed at the point 2", so that there is no stress in the tangential direction.
  • the sheet material is still subjected to a slight tensile stress in the radial direction, and subjected to a compressive stress in the material thickness direction.
  • Points 3, 3', 3" for the drawing method, the stress state is consistent with the point 2, but is changed from compressive stress to tensile stress in the tangential direction; for the bulging forming method, the state at the point 3' is the same as the previous point 2'; for the multiple flanging method, the cell at the point 3" is at the moment of deformation, and the sheet material is gradually being attached against the second groove of the second punch under the effect of the first punch, so that the cell is subjected to a tensile stress both in the tangential direction and the radial direction, and subjected to a compressive stress in the material thickness direction.
  • Points 4, 4', 4" for the drawing method, the bottom of the first punch contacts with the sheet material, and the cell is subjected to a tensile stress both in the radial direction and the tangential direction; for the bulging forming method, the stress state at the point 4' is the same as the previous point 3'; for the multiple flanging method, since the second groove exists on the second punch, the cell at the point 4" does not contact with the die, so that it is not subjected to stress in the material thickness direction, but subjected to a tensile stress both in the tangential direction and the radial direction.
  • the multiple flanging method according to the present invention is substantively different from the conventional drawing and bulging forming methods in the forming process, and there is a very great radial tensile stress at the rounding corner of the recess to be formed in the drawing method.
  • the bulging forming method during the forming process, the sheet material is always uniformly subjected to a compressive stress in the material thickness direction, and there is a very great material pressing force so that the material may not flow into the rounding corner.
  • the bulging forming method is relatively hard to be realized in highspeed automatic production.
  • the first punch has a contour greater than the recess to be formed, and thus the first punch completely covers the second groove of the second punch.
  • the first punch produces the material pressing effect.
  • the upper die continuously runs downward, the first punch is deformed, thereby gradually pressing the sheet material on the edge of the second groove of the second punch, so as to form the rounding corner of the closed recess.
  • the forming at the rounding corner is similar to flanging based on simple material pressing. At this time, there may be probably flow of a small amount of materials, but the flow has a very small distance and is uniform.
  • the deformation is realized by continuous accumulation of minor local deformations rather than sudden change, and the area after deformation becomes a material pressing area at once.
  • the sheet material that is not deformed at a middle part of the recess to be formed is always subjected to bi-directional tensile stresses in the plane, and the entire forming process is similar to a flanging process having the material pressing function. Since the middle part of the recess is always subjected to bi-directional tensile stresses in the plane, the deformation of the material is more adequate.
  • the material is continuously attached against the groove from the outside to the inside. At the same time, the material pressing area of the first punch is continuously enlarged.
  • the sheet material beyond the rounding corner of the closed recess also stops flowing soon under the effect of the material pressing force and the rounding corner resistance. That is, the material that accomplishes the deformation does not take part in the following deformation, so that the deformation is more stable and thus a defect may not be produced. It is particularly to be noted that, restricted by the shape of the closed recess to be formed and the property of the material of the first punch, the forming of the closed recess probably needs to be realized in two processes, so that it is possible to reduce the amount of deformation of the first punch and improve the service life of the material of the first punch.
  • the side wall portion produces the effect of transferring and supporting a force of the first punch in the deformation process
  • the side wall portion is a force conduction area of the sheet material that is draw formed.
  • the bearing capacity of the sheet material at the position of the side wall determines a maximum deformation degree of the drawing member.
  • the place where the sheet material becomes the thinnest is at the side wall portion, which is a vulnerable portion for fracture, so that most of the fracture by drawing the sheet material occurs here.
  • various positions of the sheet material are always subjected to stresses in consistent states, so that the thickness of the part of the sheet material to be formed may always be uniform and consistent.
  • the deformation of the sheet material at the closed recess to be formed is performed from the outside to the inside, and the material beyond the recess basically does not take part in the deformation.
  • the sheet material at the middle position of the recess is always subjected to bi-directional tensile stresses in the plane with the same magnitude in the deformation process, and the middle position of the recess is the final forming area, at which a position with a maximum thinning rate also occurs.
  • the sheet material that takes part in the deformation is adequately deformed, and the thinning rate is gradually reduced from the inside to the outside, thereby improving the forming property of the material. Therefore, under the same conditions, the sheet material is less prone to fracture when the forming method with multiple flanging is used.
  • FIGS. 3a) to 3e present the deformation conditions of the sheet material when the die set has different closed heights, before the final forming is accomplished.
  • FIG. 3a shows a deformation condition of the sheet material when there is a play of 20mm between the upper die and the lower die before the die set is completely closed
  • FIG. 3b shows a deformation condition of the sheet material when there is a play of 14mm between the upper die and the lower die before the die set is completely closed
  • FIG. 3c shows a deformation condition of the sheet material when there is a play of 8mm between the upper die and the lower die before the die set is completely closed
  • FIG. 3a shows a deformation condition of the sheet material when there is a play of 20mm between the upper die and the lower die before the die set is completely closed
  • FIG. 3b shows a deformation condition of the sheet material when there is a play of 14mm between the upper die and the lower die before the die set is completely closed
  • FIG. 3c shows a deformation condition of the sheet material when there
  • FIG. 3d shows a deformation condition of the sheet material when there is a play of 3mm between the upper die and the lower die before the die set is completely closed
  • FIG. 3e shows a deformation condition of the sheet material when the die set is completely closed.
  • the sheet material A that has been formed already is stacked together with the sheet material B which is in the forming process. It can be seen in the figures that the formation of the closed recess is also realized by gradual deepening from the outside to the inside.
  • FIG. 4a shows the thinning rates of the closed recess of the sheet material formed by the draw forming method at different positions.
  • FIG. 4b shows the thinning rates of the closed recess of the sheet material formed by the multiple flanging method according to the present invention at different positions.
  • the thinning rate which is obtained by dividing the difference between the thickness before deformation and the thickness after deformation by the thickness before deformation, reflects the degree of deformation.
  • FIG. 5 is a comparison of the thinning rates of the sheet material at the closed recess to be formed when it is formed by the drawing method and the multiple flanging method.
  • the curve a and the curve b are measurement results of two measurements performed at symmetrical positions on both sides of the closed recess formed by the draw forming method. It can be seen that the peak of the thinning rate is in the middle position, that is, the maximum thinning rate of the sheet material at the closed recess to be formed appears on the side wall.
  • the curve c and the curve d are measurement results of two measurements performed at symmetrical positions on both sides of the closed recess formed by the multiple flanging forming method.
  • the thinning rate of the sheet material at the closed recess to be formed is gradually reduced from the inside to the outside, and the maximum thinning rate appears at the center point.
  • the point with a minimum thinning rate is in the vicinity of the point 6 or 7, and thus the fracture of the side wall is likely to occur.
  • there is still material deformation at the points 10, 11, 12 of the sheet material located outside the closed recess thus, it is possible to obtain that there is still material flow at these points, so that a product defect is likely to be produced.
  • the multiple flanging forming there is basically a minor material deformation at the corresponding points 10, 11, 12.
  • the multiple flanging forming is more favorable for adequate deformation of the material.

Claims (14)

  1. Gesenksatz zum Formen einer geschlossenen Vertiefung in einem Metallblechmaterial, wobei der Gesenksatz ein Obergesenk und ein Untergesenk aufweist, wobei das Obergesenk mit einem verformbaren ersten Stempel (7) versehen ist, der auf der dem zu formenden Blechmaterial zugewandten Seite eine erste Aussparung (17) zum Führen der Verformung einschließt, und das Untergesenk einen starren zweiten Stempel (11) aufweist, der auf der dem zu formenden Blechmaterial zugewandten Seite eine zweite Aussparung (18) aufweist, die der geschlossenen Vertiefung, die geformt werden soll, entspricht, und die erste Aussparung (17) eine Außenkontur aufweist, die größer ist als die der zweiten Aussparung (18), sodass die erste Aussparung (17) die zweite Aussparung (18) überdeckt, dadurch gekennzeichnet, dass das Obergesenk ein Materialpresskissen (4) aufweist, um ein Blechmaterial (13) gegen den zweiten Stempel (11) zu pressen, wenn der erste Stempel (7) das Blechmaterial (13) fest gegen den zweiten Stempel presst und verformt, wobei die erste Aussparung eine Tiefe aufweist, die größer ist als die der zweiten Aussparung.
  2. Gesenksatz nach Anspruch 1, dadurch gekennzeichnet, dass der erste Stempel (7) aus Polyurethan besteht, das vorzugsweise eine Shore-Härte von 80 bis 95, und insbesondere eine Shore-Härte von 90 aufweist.
  3. Gesenksatz nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass der erste Stempel (7) eine Dicke von mindestens 80 mm aufweist.
  4. Gesenksatz nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die erste Aussparung (17) eine radiale Abmessung aufweist, die um mindestens 10 mm größer ist als die der zweiten Aussparung (18), und sich die erste Aussparung (17) allmählich in einer Kreisbogenform vertieft.
  5. Gesenksatz nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der erste Stempel eine radiale Abmessung aufweist, die um mindestens 40 mm größer ist als die der zweiten Aussparung (18).
  6. Gesenksatz nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die zweite Aussparung (18) an ihrem Boden ein Entlüftungsloch (12) aufweist, wobei das Entlüftungsloch vorzugsweise einen Durchmesser von 4 mm bis 6 mm aufweist.
  7. Gesenksatz nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Materialpresskissen (4) einen Einbauraum für den ersten Stempel (7) aufweist, der darin eingebettet werden soll, wobei der Einbauraum als ein Durchgangsloch konstruiert ist, das eine Anschlagschulter umfasst, wobei der erste Stempel (7), nachdem er in den Einbauraum eingebettet wurde, auf der Anschlagschulter ruht.
  8. Gesenksatz nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Obergesenk einen Oberschuh (2) aufweist, in dem das Materialpresskissen (4) von einer Halteschraube (9) gehalten wird, und die Halteschraube (9) mit einer Unterlegscheibe (8) versehen ist, die vorzugsweise aus Polyurethan besteht, wobei die Unterlegscheibe zwischen einer Unterseite des Materialpresskissens (4) und einem Kopf der Halteschraube angeordnet ist, um einen Stoß zu absorbieren.
  9. Gesenksatz nach Anspruch 8, dadurch gekennzeichnet, dass der Oberschuh (2) mit einem Befestigungselement (6) versehen ist, das vorzugsweise aus Metall besteht.
  10. Gesenksatz nach Anspruch 9, dadurch gekennzeichnet, dass der erste Stempel (7) mit einem Schraubbolzen am Befestigungselement (6) befestigt ist.
  11. Gesenksatz nach Anspruch 9, dadurch gekennzeichnet, dass der erste Stempel (7) durch Adhäsion am Befestigungselement (6) befestigt ist, oder der erste Stempel (7) über eine formschlüssige Verriegelung direkt am Materialpresskissen (4) befestigt ist.
  12. Gesenksatz nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass es sich bei der zweiten Aussparung (18) um eine abgerundete Aussparung ohne Kanten handelt.
  13. Gesenksatz nach Anspruch 9, dadurch gekennzeichnet, dass die Kontaktfläche zwischen dem Befestigungselement (6) und dem ersten Stempel (7) eben oder gekrümmt ist.
  14. Verfahren zum Formen einer geschlossenen Vertiefung in einem Metallblechmaterial mittels des Gesenksatzes nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Verfahren wie folgt ausgeführt wird:
    Platzieren eines durch Ziehformen geformten Blechmaterials auf einem starren zweiten Stempel (11) des Untergesenks des Gesenksatzes, während sich der Gesenksatz in einem geöffneten Zustand befindet, wobei der erste Stempel (7), der am Obergesenk angeordnet ist, auf dem Blechmaterial ruht und eine erste Aussparung (17) des ersten Stempels zum Führen der Verformung eine zweite Aussparung (18), die am zweiten Stempel (11) des Untergesenks bereitgestellt ist, überdeckt, wobei die zweite Aussparung (18) der geschlossenen Vertiefung, die geformt werden soll, entspricht, wobei die erste Aussparung (17) eine Tiefe aufweist, die größer ist als die der zweiten Aussparung, wobei das Obergesenk ein Materialpresskissen (4) aufweist;
    Bewegen des Obergesenks nach unten, sodass das Materialpresskissen (4) ein Blechmaterial (13) gegen den zweiten Stempel (11) presst;
    festes Pressen des Blechmaterials (13) durch den ersten Stempel (7) gegen den zweiten Stempel (11), wobei in dem Vorgang, in dem das Obergesenk weiter nach unten läuft, wenn der auf den ersten Stempel wirkende Druck steigt, das Material an der Kante der ersten Aussparung des ersten Stempels (7) allmählich in Richtung der Innenseite der ersten Aussparung verformt wird, sodass der erste Stempel mit zunehmender Verformung desselben ein Blechmaterial, das sich über der zweiten Aussparung (18) des zweiten Stempels befindet, allmählich in Richtung einer Innenwand der zweiten Aussparung presst;
    wobei die erste Aussparung (17) des ersten Stempels (7) mit zunehmender Verformung verschwindet, und das Material, das allmählich aus einer Materialpressfläche des ersten Stempels (7) herausragt, das Blechmaterial allmählich von der Außenseite zur Innenseite gegen die Innenwand der zweiten Aussparung (18) des zweiten Stempels (11) presst, um die geschlossene Vertiefung zu formen.
EP18190706.4A 2018-07-02 2018-08-24 Matrizensatz und verfahren zur formung einer geschlossenen vertiefung Active EP3590620B1 (de)

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CN112775255B (zh) * 2020-12-24 2022-12-06 南京京力汽车零部件有限公司 一种冲压拉延模内压边成型装置及其使用方法

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GB2208619A (en) * 1987-08-15 1989-04-12 Austin Rover Group A sheet metal forming tool and methods of making and using same
US20160158974A1 (en) * 2013-06-19 2016-06-09 Zhongjin WANG Device and Method for Flexible Die Forming Plate Based on Magnetorheological Elastomer

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