ES2343814T3 - PROCEDURE AND TOOL FOR THE MANUFACTURING WITHOUT STARTING OF CHIPS OF PARTS WITH A WINDING AS WELL AS PART WITH A WRAP. - Google Patents

Abstract

The tool includes a punch (2) and a die. The die has a web (4) in the region of the groove field (6), and a recess (5a, 5b) in the region of the transition from the groove field to at least one side surface. The workpiece (1) produced by the too. has a groove extending at least from top to bottom. The groove should be to a depth of up to 50% of the thickness of the tool, the deeper the better.

Description

Procedure and tool for manufacturing without chip removal of parts with a notch as well as piece with a notch.

The invention relates to a piece with a face upper and with a lower face and with a notch manufactured without chip removal, which has lateral surfaces and a notch bottom, extending the notch at least from the upper face to the lower face of the piece, as well as a procedure for manufacturing a notch in a piece of metal.

The realization of notches in pieces form part of the known state of the art. Through this machining no chip removal of the pieces are notched in pieces or on the parts wall, usually by stamping or laminate. The pieces in question are in particular metal parts. In addition to flat products, typical parts are also tubes

In the known procedures for fabrication of notches generated by a no-start process Chip is removed, for example, material from the notch area by stamping or rolling to produce the contour wanted. Now the state of the art known to date it does not allow to form all the notches that the planners Mainly they cannot be manufactured with quality satisfactory deep notches and notches with a substantially U-shaped geometry. These profiles are produced at often by procedures with chip removal. In the case of notches in tubes whose depth is greater than the thickness of the tube wall exceeds the limits of the procedures of chip removal A specific part or procedure for the Production of a notch generated without chip removal is knows for example of document US 2005/016248 A1. The process of conforming is done however without taking into account the form of the underside of the notch wall.

The object of the invention is therefore propose a piece with such notches and describe a procedure for manufacturing such notches by a procedure without chip removal, in which the underside of the notch wall has a predetermined shape.

This objective is solved with a piece according to claim 1 and a method according to claim  7.

The part according to the invention has a upper face and a lower face as well as a notch made  without chip removal. This notch has surfaces laterals and a notch bottom; the notch extends from the top to the bottom of the tool and it crosses the entire thickness of the piece.

Therefore, part material moves at least in the area of the bottom of the notch but so general also in the area of the lateral surfaces, above of the underside of the piece. Notch depth, that is the difference from the top face of the piece in which the notch begins until the bottom of the notch can be greater than the thickness of the piece itself, that is the distance between the upper face and the lower face of the piece. The depth of the notch can be at least 10%, preferably as minimum 20%, preferably at least 40%, very preferably at least 50% more than the thickness of the piece. The depth of the notch that exceeds the thickness of the piece of wall is designated wall of the notch, which therefore follows the lateral surfaces and covers the bottom of the notch.

According to the invention, the part may be equipped with notches whose section, referring to the upper face of the piece is approximately U-shaped, that is, in which the lateral faces referred to the upper face of the piece are arranged approximately at right angles. It is therefore about notches with an essentially flat notch bottom, preferably smooth. The lateral surfaces of the notch can be arranged in relation to the upper face of the piece, before notching it, forming an angle α greater than 70 °, preferably greater than 80 °, most preferably greater than 85 °. According to the invention it is therefore possible to arrange the notch in one piece according to the invention with some lateral surfaces arranged at least by sections perpendicular to the upper face. The stretches noticeably perpendicular to the lateral surfaces extend to the upper face of the piece.

Notches with a section noticeably U-shaped are specified in the design of a piece often when they are part of blocking devices. It is obvious that in the lock sets plays a special role the appearance of the security, so it is necessary to keep the notch geometry. A typical application case for such notches is the specification to provide the tubes with headrests with deep U-shaped notches. latches arranged in the car seat fit into these notches so that a firm seat of the head restraints The notches described above may be made in all kinds of pieces, that is also in pieces of form tubular.

According to another embodiment preferred according to the invention a piece provided with a notch whose angle of incidence β reaches 10 °. The angle of incidence? Is measured between the upper face of the piece before notching it (horizontal) and the upper face of the piece after notching. Preferably the angle of incidence that is formed due to notching reaches up to 5º, more preferably up to 3rd, advantageously up to 1st. Is accurate frequently maintain a reduced incidence angle when lateral notch surfaces are arranged substantially perpendicular to the upper face of the piece. To the maintaining a reduced incidence angle maximizes the side surface section that is arranged substantially perpendicular to the upper face of the piece. The smaller the angle of incidence can be maintained the more appropriate is the notch as an element of a locking device. Be considered as a special advantage of the invention that were developed notched parts that have a U-shaped section especially deep and marked, that is an angle? chosen as large as possible and an angle? chosen as much reduced possible.

According to an advantageous embodiment of the invention, the notch wall presents in the area where the notch extends beyond the underside of the piece, in the area of the bottom of the notch, that is on the side of the notch wall facing the notch presents a different contour than on the underside of the wall of the notch In this case the notch is produced with a tool composed of punch and die. The section of the notch on the "inner face" is given by the contour of the punch. The punch is shaped according to the requirements relative to the geometry of the notch, for example according to requirements related to surface length and orientation lateral, the contour of the notch bottom or the angle of incidence. In contrast, the matrix is not generally subject to such rigorous requirements of form. According to the invention and depending on the material of the piece can have a relatively free. According to the invention it is advantageous if the inner face of the notch wall formed by the matrix has a contour other than the inside face of the notch wall formed by the punch.

It is also preferred that the wall of the notch and eventually also the bottom of the notch in the area where the notch extends beyond the face bottom of the piece, present sections of different thickness of wall.

It has been observed that both the forming different from the inside face and the bottom face of the wall of the notch as the forecast of sections of different thickness of wall have a very advantageous impact on the possibilities of Carving of the notch. In particular, the notches of U-shaped section that until now could not be produced by machining without chip removal, and especially U-shaped deep section in which the notch is extends from the upper face to the lower face of the piece or beyond this, they can be produced safely by machining without chip startup if the notch wall It presents sections of different contour and wall thickness.

For this reason it is reasonable for many embodiments if the wall thickness of the wall of the notch increases towards the lateral surfaces. A thickness of reduced wall of the upper face of the notch in the area between the lateral surfaces or separated from the surfaces Side can be accepted without problems for most embodiments. Precisely in the transition from lateral surfaces that are located in the area of the thickness of wall of the piece towards the wall of the notch that has been displaced outside the area of the wall thickness of the piece is advantageous to provide a greater wall thickness in order to allow the creep of the material of the piece to the wall of the notch. Precisely this design helps to be stamped especially deep notches.

A tool for stamping a notch It presents a punch that penetrates the piece and reproduces the contour of the notch in the piece, and a matrix that stamps the lower face of the notch or the bottom of the notch, by the fact that the punch compresses the piece against the die. The matrix presents a bridge in the area of the bottom of the notch. The matrix also has a recess in the area of the transition from the bottom of the notch to at least one of the lateral surfaces of the notch.

The realization of the matrix with bridge and recess is an essential condition for the formation of U-shaped notches, especially deep, in the pieces. The notches that extend throughout the thickness of the piece require a movement of material from the piece beyond the underside of the piece. The greater the angle? between the upper face and the lateral surface of the notch, both before it causes the shaping without chip removal of the piece a cut or shear of the material. Surprisingly it has been proven that this shear can be cut counteract very effectively if the cutout in the womb can accommodate enough piece material, which is displaced by punch penetration This material preferably flows to inside the recess and is then available to form the notch bottom.

To ensure despite this a conforming of notch bottom and surface accuracy lateral by means of the punch it is planned to arrange in the matrix a bridge. This bridge is preferably in the center from the bottom of the notch, equidistant from the surfaces lateral. The bridge ensures that the bottom of the notch is It can conform in a controlled way by the punch.

According to an embodiment advantageously, the matrix is made in such a way that the recess extends in the area of the lateral surfaces of the notch to beyond the bridge. The recess that preferably it is located in the transition zone between the bottom of the notch and the lateral surface of the notch, it therefore extends according to this preferred embodiment not only in the entire depth of the notch or the bottom of the notch, which is defined by the bridge. In this case the matrix is made in section similar to a "W" in which the recess extends above the upper edge from the bridge to the side surface area of the notch Especially where the notch extends beyond the thickness of the piece, it creates in the area of the surfaces  lateral space so that the material of the piece can flow. With this, an array of this class is especially suitable for obtaining deep U-shaped notches.

If in this embodiment the depth of the recess has at least the measurement of the wall of the notching effectively prevents shearing from occurring or cutting of the material of the piece when forming the notch.

If the cutout is provided with an outline rounded, this also contributes to favor the creep of the piece material. Especially a rounding in the transition from the lateral surfaces inside the recess and in the transition from the bridge to the interior of the recess preserves the rounded transitions in the contour of the recess.

In an advantageous embodiment of the tool it is planned that the punch and die act in such a way jointly that the bottom of the notch is located at or by under the underside of the piece. This way you can stamp especially deep notches.

The punch and die are preferably made in such a way that for a given pressure to introduce the punch are arranged at a distance predetermined with each other, thus specifying the thickness of notch wall. For this, the punch and the die can present different contours, so that the separation between punch and die is larger or smaller by sections.

Especially when stamping notches on tubes a matrix in two parts is preferably used. An array Bipartite allows you to enter and remove the matrix easily inside the tube.

The invention further comprises a method for the manufacture of notches in a piece without starting of chip In its basic conception this procedure presupposes the Next steps:

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Forming the piece by so least a first tool that moves inside the piece by sections in a first direction of tangential work or in the plane of the piece,

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Forming the piece by so minus a second tool that travels inside the piece in a second direction of tangential work or in the plane of the piece, being the second work direction opposite to the First work direction.

It is considered an essential advantage of this procedure that material is not transported outside the notch which is about creating but instead moves to its inside. In known procedures, eg when rolling the notches by means of a plurality of rollers acting in the same work direction material was laminated outside the area of the notch that is about creating. The excess material is then cut at one end of the notch.

When stamping the notch the material of the piece that had to move, ran in direction towards lateral surfaces.

The advantage of the procedure according to the invention according to claim 7 is especially manifested in notching tubes Deep notches and notches with an approximately U-shaped section can only be manufacture in a limited or expensive way with known procedures till the date. And this because usually there is not enough material available for the notch wall for notches so deep in tubes. In the notches they have a depth greater than the thickness of the tube wall, the bottom of the notch constitutes a weak point. This weak point is especially manifests p. ex. when in crash tests of vehicles the support of the head that is attached in a notch of this class, starts during the impact because the tube presents too little material at the bottom of the notch or on the wall of the notch to withstand the impact.

In the process according to the invention, the displaced material is carried towards the bottom of the notch or to the wall of the notch it is about to create. Is say that the material is transported precisely where Strength reasons are required to be able to create notches with a particularly large notch depth.

According to an embodiment the method according to the invention of such is applied preferably  so that the sections of the piece that are conformed by the first and by the second tool, overlap. This way you get input a deformation as uniform as possible This overlap of the sections of the tools are not necessarily necessary since which, as will be explained later, can also be applied other possibilities of shaping without chip removal in the procedure according to the invention. However it is advantageous especially if it is used to make the notch exclusively the first or the first and second tools.

As tools are used according to the invention preferably rollers or pushers. The tools of rollers and pushers are not known per se for the notch manufacturing without chip removal. But I always know used in one direction and generally in a sequence of several tools for fabricating a depth notch desired. Within the framework of the present invention, it is preferred Use as few tools as possible. In spite of that it they can use various tools especially when it comes to deform large amount of material or obtain an outline complex, among these also tools that work on it sense of work but have a different outline. At The use of rollers should be considered advantageous without problems an angle of incidence? less than 5 °, preferably less than 3º, most preferably less than 1º, since that when the tool is rolled, no introduction of notch material as is typical eg for the print.

According to an embodiment advantageous of the method according to the invention, one or more first and second tools make up the piece in several phases of work. Preferably, a workpiece arranged in fixed position The first and second tools are mobile, eg arranged on rails or on a car and move with Relation to the piece. They do not deform the piece in a single phase of I work but in several steps, making first of all a shallow notch that then deepens other work phases until it has reached its contour definitive. In this way, notches can also be manufactured with more complex or more precise contours, and can be manufacture notches in which they have to deform large amounts of material

According to the procedure according to the invention, the piece that is about notching continues to deform after the first and second tool by stamping to get the notch. The printing is advantageous as second phase of work in particular to obtain the depth of definitive notch. Once the contour between the upper face of the piece and the lateral surfaces by a tangential or lateral attack of the force of the first and second tools, the radial force attack in a third Working direction by the stamping punch achieved with little expense the shaping of the notch bottom.

The invention is explained below. using an example of realization.

In the Figures you can see

Fig. 1 a sectional view of a piece before of a notching process, together with a tool composed of stamping punch and die,

Fig. 2 the embodiment according to Fig. 1, in a first phase of the notching process,

Fig. 3 the embodiment according to Fig. 1, in a second phase of the notching process,

Fig. 4 a sectional view of a piece machined after the notching process and

Fig. 5 an enlarged detail of the view of the Fig. 5, as well as

Fig. 6 a perspective representation of a piece manufactured according to the procedure conforms to the invention.

Fig. 1 shows a sectional view of the piece 1 together with the tool set consisting of the punch 2 and matrix 3. To simplify the representation you have shown only a partial detail of piece 1. Also the punch 2 is represented only partially, and at the end upper not shown the punch 2 is located a device suitable to exert a pressure adapted to the material of the piece 1, such as a pneumatically operated pressure punch. The punch 2 and the die 3 are made of tempered steel.

Matrix 3 has a bridge 4 in its extension longitudinal, on whose sides two recesses 5a are arranged, 5b Bridge 4 serves as a stop to determine a depth of controlled notch for the subsequent notching process.

The two recesses 5a and 5b serve to accommodate the material of part 1 displaced by the notching process. The recesses 5a, 5b extend in the direction of movement of punch 2 beyond bridge 4 and have a contour line round to avoid the effect of cutting during the process of fitted.

To notch a metal part 1 with a 1.5 mm thickness is exerted on the piece 1 a force of approx. 60 kN by means of punch 2 and die 3. Thus punch 2 shifts the material of part 1 in the direction of matrix 3 as depicted in Fig. 2. Due to the force exerted, the material of the piece 1 flows to the recesses 5a, 5b of matrix 3 that is made in such a way that those can fully accommodate the flowing material. The bridge 4 that protrudes and the pressure of tightening of punch 1 is what determine the depth of the notch. According to the strength of pressure exerted by the punch 1 is formed between the punch 1 and the bridge 4 a layer of displaced material of a defined thickness that forms a notch bottom 6 as shown in at Fig. 3. The two recesses 5a and 5b are now completely filled by displaced material. The realization of recesses 5a, 5b should be chosen so that they are large enough to accommodate displaced material from piece 1. Depending on the application and the desired geometry of the notch, the recesses 5a, 5b however can also be bigger.

A piece fitted according to the The procedure described above is represented in Fig. 4. Fig.  clearly shows that the bottom of the notch 6 is located below the original underside of part 1. The procedure allows to obtain recesses extraordinarily deep with an advantageous use of thin-walled parts such such as tubes. The formation of the recesses 5a, 5b of the Matrix 3 generates sections of notches in the walls Different wall thickness. Especially in the areas of the transition of the bottom area of the notch 6 with the walls sides it is advantageous to have a greater wall thickness for the mechanical stability of the notch. However the recesses 5a and 5b of the matrix 3 may be adapted to the geometry desired for notching.

Fig. 5 shows the definition of the angle of incidence? and angle a in an enlarged partial view of the upper face of the piece in Fig. 4. The angle of incidence it is measured between the original surface of the piece and the inclination of the surface of the piece next to the notch, produced at cause of the notch. The angle a is measured between the side wall of the notch and the original surface.

Fig. 6 shows a perspective view of a section of pipe 7 that has been fitted. The pipe section 7 It has a wall thickness W. The tube wall is crossed by a notch whose depth T is greater than the wall thickness W. This notch was prepared by passing a tool laminar itself known in a first sense of work A tangential to tube section 7 to beyond the ridge of the section of the tube, but not in the entire length of the notch. TO a second laminar tool was then passed in a second sense of work B opposite to the sense of work A, is also say tangential to tube section 7, beyond the crest of the tube section, but not the entire length of the notch The known laminar tools are not They have represented here for reasons of clarity.

The first and second laminating tools they alternately pass each one five times along the section of tube. In the depth of the notch then it has the same depth than wall thickness. The material from the tube wall has been largely displaced towards the bottom of the notch The stamping punch (which is not shown) that now performs a radial deformation from the third direction of work C, increases the depth of the notch T until the full measure, which is more than 50% above the thickness of wall W. By applying the procedure according to the invention there is much more material available for the manufacture of the notch wall, which in the known procedures. In consequently the notch manufactured in this way presents between other things a greater resistance than manufactured notches in accordance with known procedures.

Claims (8)

1. Piece with an upper face and with a lower face and with a notch manufactured by a procedure without chip removal, which has lateral surfaces and a notch bottom (6), the notch extending at least from the upper face to the lower face of the piece (1), characterized in that the notch has, in the area that extends beyond the lower face of the piece (1), a notch wall in which the contour of the notch bottom (6 ) and the underside of the notch wall formed by a die (3) have different shapes. 2. Part according to claim 1, characterized in that the depth of the notch is at least 10%, preferably at least 20%, preferably at least 40%, most preferably at least 50% deeper than the thickness of the piece (1). 3. Part according to claim 1 or 2, characterized in that at least one lateral surface of the notch is disposed relative to the upper face of the part (1) with an angle α greater than 70 °, preferably greater than 80 °, very preferably greater than 85º. 4. Part according to at least one of the preceding claims, characterized in that the angle of incidence β reaches up to 10 °, preferably up to 5 °, most preferably up to 3 °, advantageously up to 1 °. 5. Part according to at least one of the preceding claims, characterized in that the notch wall has sections of different wall thickness. 6. Part according to at least one of the preceding claims, characterized in that the wall thickness of the notch wall increases from the bottom of the notch (6) towards the lateral surfaces. 7. Procedure for the manufacture of a notch in a piece (1) of metal with the steps:

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Forming the part (1) by at least a first tool that moves penetrating the piece (1) in a first direction of tangential work or in the plan of the piece (1), by sections,

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Forming the part (1) by at least a second tool that moves penetrating through sections in part (1) in a second work direction tangential or in the plane of the piece (1), the second being work address opposite to the first address of job,

characterized in that after forming the part (1) by the first and the second tool, the part (1) is still formed by stamping between a stamping punch (2) and a die (3) that acts together with the stamping punch (2), to make the notch. Method according to claim 7, characterized in that as a first and / or second tool there is a slide or a roller that deforms the metal.