JP2020535971A - Methods and devices for making molded sheet metal parts with preformed parts - Google Patents

Abstract

The present invention relates to a method for manufacturing parts, particularly structural parts of a vehicle. The method comprises a method step of preforming a workpiece to form a preformed part (1) and a final molded part (8) or final molding from the preformed part (1). Includes a method step of manufacturing the dimensionally accurate part (13). The preformed part (1) is offset to the final molded part (8) offset at one or more locations, or is offset at one or more locations and is dimensionally accurate. Is molded into the part (13) of the above by a molding step, particularly in at least one method step. The present invention further relates to devices with molding tools, in particular for carrying out the methods according to the invention. This forming tool is designed as a multi-part forming tool, and each part of the multi-part forming tool has at least one punch (2a, 2b, 2c) and one die (3a, 3b, 3c). And. The molding tool is designed or preformed to produce the final molded part (8) offset at one or more locations by molding from the preformed part (1). Molding and calibration from the part (1) is designed to produce the final molded dimensionally accurate part (13) offset in one or more places. The forming tool is designed as a multi-part forming tool. Each portion of the multi-part molding tool comprises at least one punch and one die. [Selection diagram] FIG. 2a

Description

The present invention is a method for manufacturing a part, particularly a structural part of a vehicle, from a method step of preforming a workpiece into a preformed part and a final preformed part. It relates to a method including a method step and a method of manufacturing a complete molded component (Germany: endgeformten Bauteils, English: finally shaped component). The present invention further relates to devices with molding tools, in particular for carrying out the methods according to the invention.

Parts made by sheet metal forming, such as deep drawn parts, usually require final edge trimming, for example cutting off excess areas of the deep drawn parts. For flanged portions, this can be done, for example, using one or more trimming tools that partially or completely cut the flange as desired from above or at an angle. On the other hand, for the flangeless part, trimming is already much more complicated. The reason is that it is necessary to cut from the side, for example, with a wedge sluice valve. However, this trimming work is disadvantageous. The reason is that trimming usually requires work, one or several individual, often requiring frequent maintenance. These tasks often also require specialized tool technology and their own logistics systems. In addition, the cut out increases the amount of scrap and brings additional costs.

Several different approaches have been adopted to at least shorten this processing chain. In these approaches, among other things, flange trimming was incorporated into the final forming operation, such as the deep drawing operation. While this can result in significant cost savings, there are still some drawbacks. For example, the generation of discarded sections, the fabrication of complex tools, extensive testing, undesired springback action, limited dimensional accuracy, and ease of process confusion.

For this reason, methods and devices, especially those with a U-shaped or hat-shaped (Germany: hutprofilartigen, English: hat-profile-like) cross section, to eliminate or significantly reduce the edge trimming of parts Multiple proposals have been made.

The proposed methods are characterized in that preformed parts very close to the final contour are produced by various forming methods. These preformed parts have predominantly flat material tolerances due to appropriate shape changes such as border and flange extensions, undulating floors, or modified draw radii. In a subsequent dedicated calibration step, this material addition is extruded. This results in thickening and readjustment of residual stresses in the direction of the sheet metal plane. Modifications of these methods are accompanied by shape changes, and there may be material shortages in some sections. Local trimming work before or after calibration is also possible. Its purpose is to reduce trimming in addition to minimizing springback. That is, a finished part with no edge trimming can be manufactured from a preformed part close to the final contour, and by extension, a molded blank having the minimum dimensions, a so-called minimum molded blank, can be manufactured using a minimum amount of material.

For example, from Patent Document 1, it is known that a dimensionally accurate half-shell is manufactured in a two-step process. For this purpose, a preformed half-shell very close to the final contour is first produced. Due to their respective geometry, these hemishells carry extra material over the entire cross section. These preformed hemishells are then compressed into their respective final shapes by a further pressing step. The half-shell produced in this way has particularly high dimensional accuracy. The reason is that the residual stress components that cause the half-shell springback are superimposed or reduced by the introduced compression.

However, one drawback of this manufacturing process is that the preformed hemishells usually need to be further trimmed so that they have the desired dimensions, especially with respect to the height of the border. .. It is known, for example, from Patent Document 2, that final trimming is incorporated into the deep drawing process in order to optimize the processing chain. To make flangeless drawn parts, according to this document, the flange region of the half-shell is trimmed in the region of the die contact surface. The preformed half-shell thus produced is then calibrated in the same tool by a compression shoulder placed on a drawing die. However, this method also has a drawback that excess blank material is generated as waste, and integration of the cutting edge into the deep drawing die causes extremely large tool wear. In addition, the dimensions of the half-shell are inaccurate because it is not fully guaranteed that the position of the blank will not change during deep drawing. Therefore, trimming of the flange or border area is required.

Patent Document 3 also describes a method for producing a dimensionally high-precision half-shell having a bottom region, a border region, and a flange region. In this case, first the preformed half-shell is molded from the blank and then molded and trimmed into the final molded half-shell.

Patent Document 4 describes a method for manufacturing a half-shell part by a drawing punch and a drawing die. Machining by inserting a drawing punch into the die in a single working step and preforming the blank into a sheet metal blank with at least one bottom and at least one border and possibly a flange. Is reliable and cost-effective production is realized. In this case, during preforming, excess material is punched into the bottom and border of the sheet metal blank, or into additional flanges, and the sheet metal blank is molded and calibrated into a half-shell part with a final shape. ..

Each of the above approaches is common in that the premold is produced in the first method step. This premold is as close as possible to the final or finished shape of the part and may require additional edge trimming.

Reducing or eliminating edge trimming requires a strong, variable preforming method that results in parts that are as free of friction and batch and thickness variations as possible, with each process slightly different from each other. .. As mentioned above, this is done using a separate outer presser device, a compression inner presser device, and a larger aperture clearance and aperture radius.

Only where this approach fails due to the formation of significant folds or ridges requires the addition of edge contours, a dampened presser device, or a small aperture radius. These give rise to additional extra space.

It has been found in the process of realization of actual parts that currently known approaches to preformed design are not always sufficient to create challenging part shapes or reduce trimming as much as possible. Thus, trimming is required after conventional deep drawing to premold into, for example, relatively strongly offset premolded products for U-beams, such as those found in vehicles. This requires more material and reduces the saving effect.

German Patent Application Publication No. 10 2007 059 251 (A1) German Patent Application Publication No. 10 2011 050 001 (A1) German Patent Application Publication No. 10 2008 037 612 (A1) German Patent Application Publication No. 10 2009 059 197 (A1)

Against this background, the present invention is based on the object of providing methods and devices for the cost-effective fabrication of parts of complex shape.

As a break from traditional technological development, this goal is achieved in a versatile way. In this method, the preformed part, especially the part far from the final contour, is offset in one or more places (especially in the longitudinal direction), especially by the forming operation by at least one machining step. It can be transformed into a finally molded, dimensionally accurate part that is offset in one or more places. Therefore, in the pre-molding step in the first tool stage, or in some cases some tool stages, simple parts, especially far from the final contour, but easily manufacturable, are, first of all, less variable. Pre-molded by no manufacturing method. The edge contour of this part deviates slightly from the target contour. Then, in a further method step, the final molded part can be made by molding from the preformed part, at least in the second tool. The advantage of the method according to the invention is that for the production of parts, especially parts with complex shapes, a nearly flat blank or a minimally molded blank can be used and edge trimming can be significantly eliminated. Compared with known methods, the manufacturing process can be greatly simplified.

In this regard, the workpiece is, for example, a nearly flat blank or a minimally molded blank. The workpiece is preferably made of one or more steel materials. Alternatively, aluminum material or other metal can be used.

It should be understood that pre-molded parts, especially those far from the final contour, mean, in particular, pre-molded parts of parts that cannot be molded into finished parts by calibration alone. For example, a preformed part or a part far from the final contour is a nearly linear part. Of course, the preformed part or the part far from the final contour may already have a structured surface element. When the final molded part is, for example, an offset part, a preformed part or a part far from the final contour is, for example, a part with less offset or no offset. For example, a preformed part or a part that is far from the final contour in at least one direction, eg, in the longitudinal direction, has a substantially constant cross-sectional shape, unlike the final molded part. The manufacture of pre-molded parts, or parts that are far from the final contour because their final contour is so different from the final molded part, is embossing of the floor to be formed and raising of the border to be formed. By processing (embossing and raising), the processing can be performed in a more reliable, simple and material-saving manner. Alternatively, an effective continuous method such as roll molding can also be used. On the other hand, it should be understood that the finally molded, dimensionally accurate part specifically means the calibrated part.

Manufacture of preformed parts, especially parts far from the final contour, can include, for example, deep drawing-like molding steps. Deep drawing tools can be used in this forming step, for example, with an inner holding device, a distant outer holding device, and / or a large drawing radius and gap, and optional auxiliary equipment for loading and positioning. Is. In particular, molding can also be performed, including, for example, embossing the base and raising the border, or optionally arranging the flanges to be formed. Any combination of folding and / or bending and / or (perforation) embossing, or roll forming followed by splitting into multiple parts is conceivable.

According to another embodiment of the method according to the invention, molding and calibration for making the final molded dimensionally accurate part can be done in one coalescing method step. The advantage of this embodiment is that the final molded dimensionally accurate part can be obtained from the preformed part in a single machining step, especially using a single tool. ..

Alternatively, in another embodiment of the method according to the invention, the final molded part is first made by molding from the preformed part in a further molding step and then finally molded dimensionally high. Precision parts are calibrated from the final molded part. The advantage of this two-step variant is that the method can be economically incorporated into an existing machining chain, for example, because existing calibration tools can be used to calibrate the part.

Pre-molded parts, or especially final molded parts, where calibration is expected, are material additions and / or material shortages necessary for the production of particularly final molded dimensionally accurate parts. Includes parts.

Calibration can be understood to mean, in particular, the final molding of the final molded part. Calibration can also be achieved by one or more stamping or upsetting procedures (Germany: Stauchvorgaenge, English: upsetting procedures). However, it is possible to subject the finally molded or finally molded dimensionally accurate parts to further machining steps. In this further machining step, partial modifications of the part are made, such as introduction of connecting holes, side embossing, flange placement, or (slightly) trimming. However, the purpose is to design the shape of the tool used for calibration so that other methods do not require additional forming steps.

In another embodiment of the method according to the invention, a preformed part, a final molded part, and / or a finally molded dimensionally accurate part are substantially elongated parts. It has been found that the method according to the present invention can be particularly advantageously used in the manufacture of elongated parts of complex shapes. It should be understood that an elongated part means a part in which one side is significantly longer than the other two sides, and in particular has a prominent border. This longer side naturally forms the preferred direction of the component, referred to below as the longitudinal direction. The other two sides represent the horizontal direction, respectively. In particular, particularly complex shaped parts can be manufactured in a particularly cost-effective manner from long parts whose longitudinal direction is at least 1 time, especially at least 3 times, preferably at least 5 times longer than their lateral direction. ..

According to another embodiment of the method according to the invention, preformed parts, final molded parts, and / or finally molded dimensionally accurate parts are semi-shell parts, in particular. A part having a U-shaped or hat-shaped cross section. The method according to the invention has been recognized to be particularly suitable for cost-saving fabrication of semi-shell parts, and its use is particularly advantageous for parts with a U-shaped or hat-shaped cross section. It has been proven to be.

According to another embodiment of the method according to the invention, the preformed part is a final molded part having a Z-shape (offset) or U-shape (double offset) in its longitudinal direction, or finally molded. It is molded into a dimensionally high-precision part. The methods according to the invention are particularly suitable for complex shapes such as offset parts, or significantly offset parts such as significantly offset U-shaped parts, especially if the parts are calibrated. It is the production of parts. The method according to the invention has been demonstrated to be particularly cost effective in the fabrication of parts that are offset at one location or multidimensionally offset at one location. Therefore, in the method according to the present invention, it is possible to manufacture a part having a complicated shape from a blank that is minimally formed, so that edge trimming can be largely omitted if necessary. These parts can be manufactured in a material-saving manner, especially when the parts have a Z-shape or a U-shape in the longitudinal direction. In this case, in any case, the Z-shape can be formed by the displacement of the shape portions facing each other with the intermediate region as the center, so that the region to be changed of the preformed part has a predetermined angle with respect to the displacement direction. Displaced. For example, if the longitudinal or longitudinal axis extends in the X direction, displacement in the Z and / or Y directions is possible (coordinate system). Depending on the nature of the offset, the displacement along the longitudinal axis of the part can be repeated and can occur in both directions. In this case, a U-shaped or multi-point offset variant of the final molded part, or the final molded dimensionally accurate part, is obtained.

According to another embodiment of the method according to the invention, a plurality of different regions of the preformed part are time-delayed to the finally molded or finally molded dimensionally accurate part. German: zeitversetzt, English: time-delayed) molded and / or calibrated.

Therefore, multiple different regions of the preformed part are not molded or calibrated at the same time, at least in part, into the final molded shape, or the final molded dimensionally accurate shape. In this case, it should be understood that the finally molded shape means the shape of the final molded part. It should be understood that the finally formed dimensionally accurate shape means the shape of the finally formed dimensionally accurate part. The plurality of different regions may be partially overlapped or completely different regions. Thus, multiple different regions of a preformed part are molded or calibrated, at least partially individually or individually. Molding or calibration of preformed parts specifically consists of partial molding or calibration steps. It is preferable that there is some overlap in time between the molding and / or calibration of these regions so that the molding and / or calibration of the different regions takes place partially simultaneously. However, it is also possible that the molding and / or calibration of one region be performed only after the molding and / or calibration of the previous region is complete. For example, at least a first region and a second region where molding and / or calibration are performed at different time points can be considered. However, more than two, eg, 3, 4, 5, or more different regions are also possible. This procedure provides additional cost savings in the manufacture of complex parts. Thus, in particular, cost-saving use of a single tool and / or use of low maintenance tools in additional forming steps and / or final forming can be realized. In particular, the scope of application can be expanded to include parts that could not be satisfactorily manufactured, for example, due to their respective complex shapes, especially using the boundary conditions of methods known from the prior art.

In another embodiment, the final molded part, or the final molded dimensionally accurate part, has at least three regions, particularly an offset intermediate region and two adjacent edge regions. In this case, when the preformed part is molded into the final molded part, or the final molded dimensionally accurate part, both edge regions are aligned approximately parallel and /. Alternatively, it preferably remains aligned in parallel and the longitudinal axis of the intermediate region is inclined with respect to the longitudinal axis of the edge region. Other orientations of both edge regions are also possible in the X, Y, and / or Z directions (coordinate system). In this regard, the term edge region refers to the fact that such regions are located adjacent to intermediate regions and do not depend on the absolute position of this region in the entire final part. The method according to the invention has been found to be particularly advantageous for the fabrication of parts of such complex shapes. The final molded part also has an angle of 10 ° to 120 °, particularly an angle of 20 ° to 100 °, preferably 25, between the longitudinal axis of at least one edge region and the longitudinal axis of at least one intermediate region. With an angle of ° to 90 °, the complexity and control of the forming and / or calibration tool can be kept as low as possible. To further reduce the complexity of the tool, the final-formed or finally-formed precision parts also have a longitudinal axis of at least one edge region and a longitudinal axis of at least one intermediate region. It is particularly preferable to have an angle of 30 ° to 60 ° with the axis.

According to another embodiment of the method according to the invention, a multi-part molding tool is used. In this case, the intermediate region of the preformed part is formed into the final shape after at least one edge region of the preformed part has been formed into the final shape. Alternatively, the intermediate region of the preformed part is molded and calibrated to the final molded dimensionally accurate shape when at least one edge region of the preformed part is finally formed. After being molded and calibrated into a dimensionally accurate shape.

In a preferred embodiment of the method according to the invention, the die on which the preformed part is placed is disposed obliquely to the displacement direction of the punch or die used for molding. It should be understood that the displacement direction specifically means the direction of movement of the punch and / or die during the molding process, and thus, for example, the vertical direction. It should be understood that a die arranged diagonally with respect to the vertical direction specifically means that the longitudinal axis of the inserted part is tilted with respect to the displacement direction. It is recognized that the ironing angle (Germany: Abstreckgrad, English: degree of ironing) can be advantageously adjusted by the angle between the displacement direction and the posture of the part. The smaller this angle, the larger the ironing process can be realized. Therefore, the desired squeezing angle can be adjusted cost-savingly using a single tool.

In another advantageous embodiment of the method according to the invention, the preformed part is pressed between at least one edge die and at least one edge punch associated thereto. This compression force is so high that the preformed part basically does not slip (ie, slips at all or only slightly). Therefore, by adjusting the compression force, it is possible to manufacture a part having a complicated shape with relatively little effort.

According to the second teaching of the present invention, this object is achieved in one general purpose device by designing the molding tool as a multi-part molding tool. In this case, each portion of the multi-part forming tool comprises at least one punch and one die. This molding tool produces a final molded part offset in one or more locations by molding from a preformed part, or a final molded dimensional offset in one or more locations. High precision parts are constructed from preformed parts by molding and calibration. The device is preferably used in transfer presses or in individual linked presses.

The use of such devices allows for the cost-effective production of complex parts. Thus, in particular, cost-saving use of a single molding tool and / or use of a low maintenance molding tool in additional molding steps and / or final molding can be achieved, for example. In particular, the scope of application is extended to parts that have not been properly manufactured or have been extremely difficult to realize, for example, due to each complicated shape under the boundary conditions of conventionally known methods. be able to.

The devices according to the invention are tools for making preformed parts, such as embossing and raising tools, or inner press devices, remote outer press devices, large draw radii and draw gaps, and / Or a deep drawing tool, which has auxiliary equipment for loading and positioning. It is also possible to use the roll forming process and then divide it into individual parts (preformed parts).

For the production of final molded dimensionally accurate parts, the devices according to the invention are integrated or split molding dies with calibration capabilities, especially with calibration capabilities, and / or calibration capabilities. A molding die, also with an integral or multi-part structure, and / or a molding tool with auxiliary elements for loading, supporting, positioning, and / or discharging may be provided.

Alternatively, or in addition, the devices according to the invention specifically include one-piece or split-type calibration dies and / or similarly part- or multi-part calibration punches and / or loading, support, positioning, and /. Alternatively, it may have a calibration tool with auxiliary elements for release.

In another embodiment of the device according to the invention, the forming tool has at least one central tool portion and two adjacent edge tool portions. In this case, at least one center tool portion comprises at least one center punch and at least one center die, and at least one edge tool portion comprises an edge punch and an edge die. This configuration guarantees a particularly reliable and cost-saving fabrication using the device according to the invention.

According to another embodiment of the device according to the invention, at least one edge die of at least one edge tool portion is a height adjustable edge die. Since at least one edge die is height adjustable, eg, mounted on a spindle sleeve, the order of molding and / or calibration of multiple different regions of the preformed part can be advantageously adjusted. For example, not only shaping and / or calibration of the edge region of a preformed part, but also compression can be performed as early as before or during molding and / or calibration of another part region (particularly the intermediate region). This further simplifies the fabrication of this part, with particularly high dimensional accuracy, without edge trimming. In some cases, edge dies, especially edge dies that are not height adjustable, i.e. edge dies that are already in the end position, are equipped with an inner retainer device or shape-retaining punch. The inner retainer device or shape-retaining punch basically supports most of the shape of the edge region so that the forming movement does not cause significant dimensional changes, so in addition to the indentation engagement with both edge tool parts, Preformed parts can be positioned particularly advantageously and thus a certain degree of dimensional accuracy can be achieved. With respect to edge dies, the term height-adjustable means that the edge dies so designated are height-adjustable compared to other die parts of the forming tool, while these other die parts are immovable with respect to each other. Please understand that it means that.

According to another embodiment of the device according to the invention, at least one edge punch of at least one edge tool portion is movably attached to the other punch (part). Since the at least one edge punch is movably attached to act with a force, preferably by at least one hydraulic actuating means, the order of forming and / or calibrating multiple different regions of the preformed part. Can be adapted to your advantage. For example, not only molding and / or calibration of the edge region of the preformed part, but also compression can be performed before or during molding and / or calibration of another part region (particularly the intermediate region). This further simplifies the fabrication of these parts, with particularly high dimensional accuracy, without edge trimming. Thus, in combination with a height-adjustable die, simultaneous molding and / or calibration of both edge regions adjacent to the intermediate region of the preformed part can be achieved, for example, particularly advantageously. With respect to edge punches, the term movable means that the edge punches thus designated can be moved separately with respect to other punched portions of the forming tool according to the invention, especially with respect to height, while referring to. It should be understood that the other punched parts being made are immovable with respect to each other.

A particular advantage is when, according to another embodiment, the device and / or molding tool is tilted relative to the displacement direction. It was recognized that these measures could favorably adjust the ironing angle.

According to another embodiment of the device according to the invention, the molding tool is a calibrated molding edge die and / or a calibrated molding edge punch, in particular a calibrated, optionally inner presser device. Has a height-adjustable molding edge die, with. Therefore, the molding and calibration of the preformed part into the final molded part can be advantageously performed with a single tool.

A calibrated forming (edge) die and a calibrating forming (edge) punch basically already include the final shape of the final molded dimensionally accurate part (edge). ) Please understand that it means die or punch.

In another embodiment of the device according to the invention, the molding tool has means to prevent material flow across the edges of the part, such as side or end face blocking walls. This further improves the dimensional accuracy of the final molded part by blocking the material flow of the part during the stamping procedure, for example, at the additional flange edge of the semi-shell part, at least temporarily. , Especially in the additional flange area. This guarantees that the blank material will not be extruded from the stamped area and thus all excess blank material will be completely molded into the final molded part. Pre-molded and / or finally molded and / or finally molded dimensionally accurate blockage of material flow to the outside of the part is used for stamping procedures. This can be particularly preferably realized by the partition wall provided on the punch. On the one hand, this has the advantage that no additional moving parts need to be provided to block the material flow outwards. On the other hand, what is achieved by this is that during the stamping procedure that causes the material flow, the barrier that blocks the material flow moves precisely to the expected position for blocking. Alternatively, the movable side wall can provide a blocking effect. In addition, the device optionally has means of compressing individual base areas of preformed parts. This enables accurate positioning of the preformed parts. This is especially advantageous for dimensional accuracy.

The above and below description of method steps according to preferred embodiments of the method is also intended to disclose the corresponding means for implementing these method steps according to preferred embodiments of the device. Disclosure of means for carrying out one method step is also intended to disclose the corresponding method step.

In the following, the invention will be described in more detail with the help of two exemplary embodiments, in conjunction with the drawings.

A schematic representation of molding from a preformed part to a final molded part performed by one embodiment of a device according to the invention in the context of a first embodiment of the method according to the invention, wherein the punch and die are effective. A schematic diagram is shown in which only the faces are shown. A schematic representation of molding from a preformed part to a final molded part performed by one embodiment of a device according to the invention in the context of a first embodiment of the method according to the invention, wherein the punch and die are effective. A schematic diagram is shown in which only the faces are shown. A schematic representation of molding from a preformed part to a final molded part performed by one embodiment of a device according to the invention in the context of a first embodiment of the method according to the invention, wherein the punch and die are effective. A schematic diagram is shown in which only the faces are shown. A schematic representation of molding from a preformed part to a final molded part performed by one embodiment of a device according to the invention in the context of a first embodiment of the method according to the invention, wherein the punch and die are effective. A schematic diagram is shown in which only the faces are shown. In the context of a second exemplary embodiment of the method according to the invention, simply from a preformed part performed by one exemplary embodiment of a device according to the invention to a finally molded dimensionally accurate part. FIG. 6 shows a schematic view of molding in one step, showing only the effective surfaces of the punch and die. In the context of a second exemplary embodiment of the method according to the invention, simply from a preformed part performed by one exemplary embodiment of a device according to the invention to a finally molded dimensionally accurate part. FIG. 6 shows a schematic view of molding in one step, showing only the effective surfaces of the punch and die. In the context of a second exemplary embodiment of the method according to the invention, simply from a preformed part performed by one exemplary embodiment of a device according to the invention to a finally molded dimensionally accurate part. FIG. 6 shows a schematic view of molding in one step, showing only the effective surfaces of the punch and die. In the context of a second exemplary embodiment of the method according to the invention, simply from a preformed part performed by one exemplary embodiment of a device according to the invention to a finally molded dimensionally accurate part. FIG. 6 shows a schematic view of molding in one step, showing only the effective surfaces of the punch and die. In the context of a second exemplary embodiment of the method according to the invention, simply from a preformed part performed by one exemplary embodiment of a device according to the invention to a finally molded dimensionally accurate part. FIG. 6 shows a schematic view of molding in one step, showing only the effective surfaces of the punch and die. In the context of a second exemplary embodiment of the method according to the invention, simply from a preformed part performed by one exemplary embodiment of a device according to the invention to a finally molded dimensionally accurate part. FIG. 6 shows a schematic view of molding in one step, showing only the effective surfaces of the punch and die.

In the following, exemplary embodiments of the method according to the invention and the device according to the invention will be described in more detail based on the fabrication of a hat-shaped component offset at one location. Similar procedures are used for parts without flanges and / or offsets at multiple points.

In the following, the same reference numerals are used for similar or corresponding features.

In the first step (not shown), it is offset, elongated, and mostly straight in the longitudinal direction, and has a predetermined edge contour. The preformed and preformed part 1 is inexpensively manufactured by appropriate means. The term simple (Germany: einfach, English: simple) refers to the extension of the longitudinal axis of a preformed part, which could otherwise have additional fully structured surface elements or bends. Suitable measures for making this one-point molded and preformed part 1 are, for example, embossing and raising / folding, or strong deep drawing using a distant outer presser device. Therefore, a device for making a part molded and preformed in one place, particularly a part 1 far from the final contour, is, for example, a tool for embossing and raising, or an inner presser device, a remote outer side. A presser device, a large aperture radius and clearance, and a deep drawing tool with auxiliary equipment for loading and positioning. Alternatively, it is also possible to manufacture the preformed part 1 which is molded at one place by roll molding.

According to the device according to the invention, further molding is performed in the next step in the molding tool schematically shown in FIG. The molding tool for further molding of the part 1 molded and preformed at one location is composed of three parts here, and includes a central tool part and two edge tool parts. The center tool portion has a center punch 2b and a center die 3b, and the first edge tool portion has an edge punch 2a and a height-adjustable edge die 3a. The edge die 3a is height-adjustably and movably attached via the spindle sleeve 6. The non-height adjustable die portion may also have an optional inner press device (not shown). This facilitates positioning and loading during expansion. The second edge tool has a movable edge punch 2c and an immovable edge die 3c. The movable edge punch 2c associated with the immovable edge die 3c is movably attached, for example, by adjusting means on which hydraulic pressure or other force acts. The moving direction 5 of the adjusting means on which these forces act with respect to the other punches, that is, the central punch 2b and the edge punch 2a of the first edge tool portion, is shown. The forming tool is tilted with respect to the downward movement of the press indicated by arrow 4. The process of further molding will be described below.

As shown in FIG. 1a, the edge punches 2a and 2c and the center punch 2b are in the raised position at the start of the further forming step. The variable height edge die 3a is raised to the level of the immobile edge die 3c by the spindle sleeve of the press, as indicated by the arrow 6. The other two dies 3b and 3c are already located at their respective end positions, are immobile and are not moved. In addition, the inner holding device (not shown) of one fixed edge die 3c is expandable.

First, the part 1 preformed at one location is inserted into dies 3a, 3b, 3c inclined with respect to the displacement direction 4. In this regard, the positioning of the preformed part can be done by indentation connections to the two edge dies and / or by an immovable edge die, not shown, raised inner retainer device.

As shown in FIG. 1b, the edge punches 2a and 2c and the center punch 2b are then lowered in the displacement direction 4 by the movement of the press. In this case, first of all, the movable edge punch 2c on which the force acts, and further, the raised height-adjustable edge die 3a, the parts 1 that are molded at one place and preformed are the respective counterparts 2a and 3c. Tighten between. This compression force is selected so that the part 1 molded and preformed at one location does not slip or slips slightly during its movement. The intermediate region 1b of the part 1 that is molded and preformed at one location is initially exposed.

In the further downward movement, the edge punch 2a facing the height-adjustable edge die 3a pushes down the edge die 3a. In addition, the movable edge punch 2c is prevented from moving downward by the immovable edge die 3c. The relative movement between the individual edge punches 2a and 2c and the edge dies 3a and 3c is such that the intermediate region 1b of the part 1 that is molded and preformed at one location is on the immovable side 1c in combination with the pressing and tilting positions. On the other hand, it guarantees that it is further extended and thus deflected. The resulting offset requires more material than the linear shape. This results in stretching and thus the accompanying tensile load, which causes plastic deformation over almost the entire transition region between the intermediate region 1b and the edge regions 1a and 1c of the part 1 that is molded and preformed at one location. cause. The material required for this is mainly provided by stretching the transition region between the regions of the die division.

At the end position, all dies and punches are blocked, as shown in FIG. 1c. This results in the final molding of the final molded part 8 (see FIG. 1d), in particular the opposing punch portions 2a, 2b, 2c and die parts 3a, 3b, 3c are localized. It is displaced into a Z shape. Depending on the type of offset, displacements across the longitudinal axis of the component can be made at multiple locations and in both directions. In this case, a U-shaped or multi-point offset variant of the final molded part 8 is provided. In further molding, the surface elements of the part 8 that have not yet been preformed can be supplemented.

As shown in FIG. 1d, each tool portion finally moves to its respective starting position, as indicated by arrow 7. The direction of return movement of the adjusting means on which the force acts is indicated by an arrow 5'. The final molded part 8 can be removed and, if necessary, placed on a calibration tool (not shown). There, high dimensional accuracy is established during the calibration process.

Optional use calibration tools have, among other things, integrated or split calibration dies, as well as partial or multi-part calibration punches, and auxiliary elements for loading, supporting, positioning, and discharging. .. After calibration, the finally molded dimensionally accurate component 13 can be taken out.

In a second exemplary embodiment of the method according to the invention, the device according to the invention comprises only two tools. A molding tool that combines calibration with a first tool for making preformed parts that are molded in one location and for further molding.

The tool for manufacturing the preformed part that is molded in one place is, for example, the same tool as the modified version of the first exemplary embodiment. Thus, for example, tools for embossing and raising, for strong deep drawing with distant outer press devices, or for roll forming and subsequent splitting.

As shown in FIG. 2a, the final forming and calibration tool for a one-point molded and preformed part comprises a combination of a central tool portion and two edge tool portions. This central tool portion has a central punch 2b and a central die 3b. The first edge tool portion has an edge punch 2a and a height adjustable edge die 3a. The second edge tool portion has a movable edge punch 2c and an immovable edge die 3c. The height-adjustable edge die 3a and the immovable edge die 3c each have an inner holding device 10 in some cases. The movable edge punch 2c associated with the immovable edge die 3c is provided with respect to other punches, i.e., the center punch 2b and the edge punch 2a of the first edge tool portion, by hydraulic or other force acting adjusting means. Can be attached so that it can be moved. The forming tool is in a desired tilt position with respect to the downward movement 4 of the press. Unlike the modified version from the first exemplary embodiment, the dies 3a, 3b, 3c and the punches 2a, 2b, 2c have a calibration function, so that they are a molding die with a calibration function or a calibration function. It is a punch for molding. Further, the molding tool for the calibration process is a means in the form of a side barrier 9 and, in some cases, a front barrier (not shown) for blocking material flow across the edges of the part, and if necessary. Has the potential to compress the individual base regions of the preformed part 1 via the raised presser device 10.

As in the first exemplary embodiment, the forming punches 2a, 2b, 2c are initially in the raised position. The height-adjustable forming edge die 3a is raised, for example, by a press spindle sleeve, and in some cases by a hydraulic or other force-acting adjusting means. The direction 5 of movement of the adjusting means on which these forces act to the level of the immovable forming edge die is indicated by the arrow 6. The other two dies 3b and 3c are at their respective end positions, are immobile and are not moved. In addition, the optional inner holding device of both edge dies 3a and 3c has been expanded.

As shown in FIG. 2b, the preformed part 1 at one location is inserted into the die. In this regard, the positioning of component 1 can be performed by indentation connections to the two edge dies 3a and 3c and / or by the immovable edge die 3c, optionally raised, inner holding device 10.

Further, the movement of the press punch indicated by the arrow 4 lowers the three forming punches 2a, 2b, and 2c. First, the edge punch 2c mounted to act on the force and the raised height adjustable edge die 3a are the respective counterparties 2a, 3c, i.e. the bottom of the die, or in some cases the raised holding device 10. The preformed part 1 that has been molded at one location is pressed together. Since the cross section of the preformed part 1 deviates from the final shape, compression is initially possible only over some areas of the inner retainer device 10. This is combined with a small spacing 12 of each bottom region between the dies 3a, 3b, 3c and the punches 2a, 2b, 2c, or between the die portion and the punch portion. As can be seen from FIG. 2c, the intermediate region of the preformed part 1 molded at one location is initially freely exposed.

In the further downward movement, the edge punch 2a facing the movable edge die 3a displaces the edge die 3a downward together with the raised pressing device 10. In addition, the movable edge punch 2c is prevented from moving downward by the immovable edge die 3c.

Again, the relative movement between the individual edge tool portions guarantees further extension and thus deflection of the intermediate region of the preformed part 1 molded at one location. The resulting offset requires more material than the linear shape, and the firm compression 11 to the raised presser device 10 ensures that the material flow from the compressed region into the intermediate region is small. Therefore, there is also a stretching and thus a tensile load associated with it, and as shown in FIG. 2d, the plastic deformation of the preformed part 1 molded in one place is carried out in almost all the areas between the die division regions. Cause in the transition area.

Shortly before reaching the end position, the raised presser device 10 is also pushed down, as shown in FIG. 2e. After that, the upset process is finally started. In this step, especially by contact with the blocking means 9, all the extra surface portions of the final molded part 13 are further compressed in between.

At the end position, all dies and punches are blocked. As a result, the final forming of the end contour of the part is performed with high dimensional accuracy and without trimming.

Finally, as shown in FIG. 2f, each tool portion moves to its respective starting position, as indicated by arrow 7. The direction of return movement of the force-actuated adjusting means back to the starting position is indicated separately by the arrow 5'. The finally formed dimensionally high precision part 13 can be taken out and transferred to a further processing chain.

Claims (18)

It is a method for manufacturing parts, especially structural parts of vehicles.
− The method step of preforming the workpiece into the preformed part (1), and
-A method step of manufacturing a final molded part (8, 13) from the preformed part (1), and
In the method including
-The preformed part (1) is the final molded part (8) offset at one or more locations, or the final offset at one or more locations, especially in at least one method step. A method characterized in that it is converted into a dimensionally high-precision part (13) formed by molding. The final molded part (8) is first manufactured by molding from the preformed part (1), and then the finally molded dimensionally accurate part (13) is the final The method of claim 1, characterized in that it is manufactured from a molded part (8) by calibration. The method according to claim 1, wherein the molding and calibration for manufacturing the finally molded dimensionally accurate part (13) is performed in a common one-method step. The preformed part (1), the final molded part (8), and / or the finally molded dimensionally accurate part (13) are approximately elongated parts (1, 8, 13). ), In particular, any of claims 1 to 3, wherein the longitudinal direction thereof is 1 time, particularly at least 3 times, preferably at least 5 times, long elongated parts (1, 8, 13) as compared with the lateral direction. The method described in item 1. The preformed part (1), the final molded part (8), and / or the finally molded dimensionally accurate part (13) are semi-shell parts (1, 8). 13, 13), particularly the method according to any one of claims 1 to 4, wherein the parts (1, 8, 13) having a U-shaped cross section or a hat-shaped cross section. The preformed part (1) is molded into a Z-shaped or U-shaped final molded part (8) or a finally molded dimensionally accurate part (13). Item 5. The method according to any one of Items 1 to 5. The plurality of different regions (1a, 1b, 1c) of the preformed part (1) are formed into the final molded part (8) or the finally molded dimensionally accurate part (13). The method of any one of claims 1-6, which is molded and / or calibrated with a time delay. The final molded part (8) or the finally molded dimensionally accurate part (13) has at least one offset intermediate region (1b) and two adjacent edge regions (1a, 1c). The edge during the molding of the preformed part (1), preferably into the final molded part (8) or the finally molded dimensionally accurate part (13). The regions (1a, 1c) remain aligned and / or substantially parallel, and the longitudinal axis of the intermediate region (1b) is relative to the longitudinal axis of the edge region (1a, 1c). The method of claim 6, wherein the method is tilted, particularly 10 ° to 120 °, preferably 30 ° to 90 °. A multi-part molding tool is used, and the intermediate region (1b) of the preformed part (1) has at least one edge region (1a, 1c) of the preformed part (1). After being molded into the final shape, the intermediate region of the preformed part (1) that is molded into the final shape is the at least one edge region (1a, 1c) of the preformed part (1). ) Is molded and calibrated into the finally molded dimensionally accurate shape, and then molded and calibrated into the finally molded dimensionally accurate shape, according to any of claims 1-8. The method described in item 1. The preformed part (1) is placed in a die (3a, 3b, 3c), and the die (3a, 3b, 3c) is a punch (2a, 2b, used for the molding). 2. The method according to any one of claims 1 to 9, wherein the die (3a, 3b, 3c) is arranged obliquely with respect to the displacement direction (4). The preformed part (1) is first pressed between at least one edge die (3a, 3c) and at least one edge punch (2a, 2c) associated thereto, and the pressing force is applied. The method according to any one of claims 1 to 10, wherein the preformed part (1) is basically large enough not to slip. In particular, in a device for carrying out the method according to any one of claims 1 to 11 with a molding tool.
The forming tool is designed as a multi-part forming tool, and each part of the multi-part forming tool has at least one punch (2a, 2b, 2c) and a die (3a, 3b, 3c). The forming tool is arranged to produce a final molded part (8) offset at one or more locations by molding from the preformed part (1), or said. Placed to produce a finally molded dimensionally accurate part (13) offset in one or more places by molding and calibration from a preformed part (1). The featured device. The forming tool has at least one intermediate tool portion and two adjacent edge tool portions, the at least one intermediate tool portion having at least one center punch (2b) and at least one center die (3b). 12. The device of claim 12, wherein at least one of the edge tool portions has an edge punch (2a, 2c) and an edge die (3a, 3b). The at least one edge die (3a, 3c) of the edge tool portion is a height-adjustable edge die (3a), and the edge die (3a, 3c), particularly a height-unadjustable edge die (3c),. The device according to claim 13, further comprising an inner pressing device (10) in some cases. The at least one edge punch (2c) of at least one of the edge tool portions is movably attached to the other punches (2a, 2b), preferably the force of at least one hydraulic adjusting means (5). The device according to claim 13 or 14, wherein the device is attached so as to act. The device according to any one of claims 12 to 15, wherein the device and / or the molding tool is in an inclined position with respect to the displacement direction (4). The forming tool has a forming edge die (3a) with a calibrating function, particularly a height-adjustable forming edge die (3a) having a calibrating function, and in some cases an inner pressing device (10). The device according to any one of claims 12 to 16. The molding tool has means for blocking the material flow across the edges of the part, particularly the side or front barrier wall (9), and / or, in some cases, the preformed part. The device according to any one of claims 12 to 17, comprising means for compressing the individual bottom regions of (1).

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