KR20190010574A - METHOD AND APPARATUS FOR MANUFACTURING PARTS CONTAINED, at least in part, of metal alloys - Google Patents

Abstract

The present invention relates to a method of manufacturing a component (20) consisting at least in part of a metal alloy, said method comprising a metallurgical manufacturing step a1) of manufacturing a body (21) of said component And the method then comprises an augmenting step a2) of forming local reinforcements 40, 50, 60 directly on the body 21 in regions Z4, Z5, Z6 under stress of the part 20, And a control unit. The present invention also relates to a method for optimizing a part.

Description

METHOD AND APPARATUS FOR MANUFACTURING PARTS CONTAINED, at least in part, of metal alloys

The present invention relates to a method of manufacturing a component at least partially composed of a metal alloy. The present invention also relates to a method of optimizing a part.

The field of the invention relates to the manufacture of components which make up all or part of a metal (iron or non-ferrous) alloy, which includes continuous foundry and forging processes.

Saint-Jean Industries developed the COBAPRESS (trademark) method for aluminum and its alloys 30 years ago. This technique consists in particular forging a foundry preform in a single forge process, as described in the documents EP0119365, EP0586314 and EP2877353.

The COBAPRESS method proved to be very effective for suspension applications in most automotive manufacturing industries. Particularly, compared with conventional foundries, a remarkable improvement in mechanical properties and in particular decrease assistance is possible in this way. This method is also competitive with forging in terms of cost and achievable geometric complexity.

EP 0586314 discloses a method of locating an insert in a foundry preform and then striking the preform to obtain a final part. The insert is fixed by the deformation of the material and permanently integrated to define the locally enhanced area. The insert is laterally formed and added to the body of the part comprising the preform; This is to be avoided by the present invention.

Reducing the weight of structures in the automotive, aerospace and industrial sectors today is associated with improvements in safety, the environment and other standards.

The weight goal for the structure is that the stress on the structure increases and permanently decreases with cost goals that are compatible with the market. In most cases today these constraints lead to compromises, including selection of materials, processing, weight and cost.

For example, if a large pressure is applied to a particular area of a part, the material of this part as a whole is guided by this area, resulting in higher costs associated with the selection of this material.

An object of the present invention is to propose an improved manufacturing method.

In this regard, the present invention relates to a method of manufacturing a component consisting at least in part of a metal alloy, said method comprising a metallurgical manufacturing step a1) of manufacturing the body of said part, The method then includes an enforcing step a2) to form a local reinforcement directly on the body in the area under stress of the part.

Thus, the mechanical properties of the part, such as fatigue resistance or hardness, can be improved locally with the present invention without using additional parts while keeping the mass of the reinforced part as low as possible. As a replacement or complement, the present invention, which results in space savings, can reduce the section of the part locally. In addition, the overall performance of the part, for example its stiffness, can be improved with the present invention.

According to the first embodiment, the metallurgical manufacturing step a1) comprises a foundry preform a11) for manufacturing a foundry preform, and then a forging of the foundry preform to obtain the body of the part, Forging step a12). This metallurgical manufacturing step a1) corresponds to the implementation of the COBAPRESS method.

According to the second embodiment, the metallurgical manufacturing step a1) comprises a foundry process a11) for manufacturing the body of the part. In this foundry process a11), the forging process a12) is not followed.

According to a third embodiment, the metallurgical manufacturing step a1) comprises a forging step a12) comprising a step of manufacturing the body of the part. The forging process a12) does not precede the foundry process a11).

The present invention relates to a method of optimizing the design of existing components comprising metal alloy bodies, said optimization method comprising the steps of:

b1) identifying an area under stress of said existing part by, for example, numerical simulation;

b2) defining an optimized part comprising the deformed body by providing at least one local reinforcement formed on the body of the area under stress;

b3) defining a manufacturing tool by metallurgy tailored to the body of the optimized part;

b4) using the tools to manufacture the body of the optimized part; And

b5) forming the local reinforcement directly in the body in the area under stress of the optimized part.

According to another advantageous feature of the invention, considered alone or in combination:

- These components are components for automotive structural components (especially pivot type suspensions, directional arms, suspension arms, underframe structural components, etc.), aviation, industrial equipment or medical devices.

The local reinforcement has a surface arranged to contact at least 50% of the body of the part.

The local reinforcements substantially combine with the body of the component.

A plurality of local strengthening parts are formed in the body in one or more areas under the stress of the parts.

- the method comprises the step of preparing the surface of the area to be strengthened between the metallurgical manufacturing step a1) and the strengthening step a2).

- the method comprises finishing the part in the reinforced area after the reinforcing step a2).

- the method comprises a surface treatment step applied to at least a part of the body between step a1) and step a2).

- the method comprises a surface treatment step applied to at least a part of the part after step a2).

- The body and local reinforcements consist of different metal alloys.

- The body is made of a metal alloy, while the local reinforcement is made of a composite material.

- The body is made of metal alloy, but the local reinforcements are made of ceramic material.

The local reinforcement is formed by cold spraying.

The local reinforcement is formed by micro-arc oxidation.

The local reinforcement is formed by attaching a composite assembly having the final shape onto the body of the part.

- The local reinforcement is formed by baking the resin.

- The local reinforcement is formed by lamination.

- The local reinforcement is replaced by the original part of the body of the existing part.

- The local reinforcement is fitted to the body of the existing part, replaced by an overmolded or pressed insert.

- Optimized parts are almost the same dimensions as existing parts.

- Optimized parts have locally reduced dimensions compared to existing parts.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be better understood when taken in conjunction with the following description, given purely by way of non-limiting example and with reference to the accompanying drawings, in which: FIG.
1 is a top view of a component according to the state of the art, including a metal alloy body made according to a foundry process and then a forging process.
Figure 2 is a side view of the part of Figure 1;
Figures 3 and 4 are views similar to Figures 1 and 2 illustrating an optimization method for component design.
Figs. 5 and 6 are views similar to Figs. 1 and 2 showing a part optimized according to the invention, including a local reinforcement formed on the body in the region under stress.
7 is a cross-sectional view taken along the line VII-VII in FIG. and
Figs. 8-12 are views similar to Figs. 3-7 showing a second embodiment of a part optimized according to the present invention. Fig.

A part 10 comprising a single piece body 11 and an annular insert 18 fitted to the body 11 is shown in Figs. For example, component 10 is an automotive suspension component.

The body 11 consists of a metal alloy, for example an aluminum alloy, according to two successive foundry processes and forging processes. The body 11 includes a main portion 12, an end portion 13 and a long portion 14 connecting the portions 12 and 13. Two through openings (15, 16) are arranged in the part (12). The opening 15 has a substantially rectangular cross section, and the opening 16 has a circular cross section.

The insert 18 is made of a metal alloy, for example steel, in an opening 16 formed in the body 11 and then fitted, overmolded or pressed (in particular by COBAPRESS). The insert 18 provides various functions between the body 11 and the unillustrated elements arranged through the opening 16: thermal coupling, frictional resistance, lubrication, and the like.

Areas under stress Z4, Z5 and Z6 of component 10, corresponding to elements 14, 15 and 16 respectively, are shown in Figs. 3 and 4. Fig.

In the context of the present invention, the area under stress of component 10 is defined as the area where large mechanical, thermal, friction and / or wear stresses are applied when component 10 is operating. These stresses are referred to as large as long as special care is required to maintain the operating integrity of the part due to the environment (mechanical systems integrated, external factors, etc.).

E.g:

Mechanical stresses can be caused by flexion, torsion, traction and / or compressive forces experienced by these areas.

- Thermal stresses can be caused by permanent or temporary local temperature increases experienced in this area.

- Frictional constraints caused by electrical cables that extend along the part and rub against the surface of the part in this area.

- Friction restrictions can occur by injecting material into this area from the ground on which the part-mounted vehicle is traveling.

In fact, regions Z4, Z5 and Z6 of the component 10 are not subjected to the same stresses during operation.

In the zone Z4, a reduced weight of the part 14 composed of the metal alloy is required without deteriorating the mechanical performance. For this purpose, the outer portion 140 of this portion 14 may be replaced by a composite material.

In the region Z5, an improved resistance of the part 10 in the region of the opening 15 is obtained without changing the material constituting the body 11. To this end, the portion 150 located around the aperture 15 can be replaced by a metal alloy that is stronger than the resistance of the body 11. [

In the region Z6, the reduced weight of the portion 12 is obtained without degrading the performance of the component 10 in the region of the opening 16. For this purpose the steel insert 18 is covered by a covering formed in the opening 16 by low temperature spraying of powder comprising metal particles (alloys of aluminum, copper, cobalt, nickel, molybdenum, aluminum quasi- Lt; / RTI >

You can, of course, choose a different solution based on the specification document that needs to be met.

The part 20 according to the invention is shown in Figs. The part 20 is an optimized version of the part 10 shown in Figs. The part 20 has similar functions and dimensions to the part 10.

Some of the components of component 20 can be compared to the components of component 10 described above and have the same reference numbers for simplicity. The other components of the component 20 are different from the component 10 and have a reference number increased by 10.

The component 20 includes a body 21 and various local reinforcements 40,50 and 60 which are formed directly in the body 21 separately in the regions Z4, Z5 and Z6 of the component 10.

As mentioned above, these regions Z4, Z5 and Z6 are not subjected to the same stress during operation. Under these conditions, the choice of materials that make up the body 21 and the local reinforcements 40, 50 and 60 is a compromise in terms of performance, weight and cost.

The body 21 consists of a metal alloy, for example an aluminum alloy, according to two successive foundry processes and forging processes. The body 21 includes a main portion 22, an end portion 13 and a long portion 24 connecting the portions 22 and 13. Two through openings 15 and 16 are arranged in the part 22. [

In the zone Z4, the body 21 comprises an elongate section 24 provided as a local reinforcement 40. The portion 24 is made of a metal alloy, and the reinforcement 40 is made of a composite material. For example, the reinforcement 40 may be formed by layers of a carbon, glass or thermoplastic resin (especially a poly (p-phenylene terephthalamide) known under the Kevlar brand name), which is precoated with a resin, . The reinforcement 40 is in the form of a composite element attached on the body 21 and taking its final shape directly on the body 21. [ The reinforcement 40 replaces the portion 140 of the body 11 such that substantially the portions 14 and 24 have substantially the same dimensions. By means of the reinforcement 40, the part 20 can be made lighter in the area Z4 without reducing the mechanical performance.

In the zone Z5, the reinforcement 50 is replaced by the portion 150 of the body 11. [ The opening 15 is formed through the reinforcing portion 50 at the portion 22. The opening 15 has the same dimensions as the parts 10 and 20. The reinforcement 50 is made of a metal alloy that is stronger than the body 11 by, for example, low-temperature injection. The strength of the part 20 is improved near the opening 15 compared to the part 10 without changing the material of the body 21 compared to the body 11. [

In the zone Z6, the insert 18 is replaced by a coating 60 formed by low-temperature spraying at the opening 16. The portion 22 of the component 20 can be lighter with the coating 60 without degrading its performance near the opening 16. [

The body 21 constitutes a majority of the volume of the component as compared to the reinforcements 40, 50 and 60.

Modifications of the component 10 of Figs. 3 and 4 are shown in Figs. 8 and 9. Fig. Areas under stress Z4 and Z6 of the component 10 corresponding individually to the elements 14 and 16 of the component 10 are shown in this variant. In the zone Z4, the two outer portions 141 and 142 of the portion 14 can be replaced by a composite material. In zone Z6, the steel insert 18 can be replaced with a coating formed by low-temperature spraying at the opening 16.

The part 30 according to the invention is shown in Figs. The part 30 is an optimized version of the part 10 shown in Figs. The part (30) has similar function and dimensions to the part (10).

Some of the components of component 30 may be compared to the components of component 10 described above and have the same reference numbers for simplicity. The other components of the component 30 are different from the component 10 and have a reference number increased by 10.

The component 30 includes a body 31 and various local reinforcements 41, 42, 60 formed directly on the body 31.

The body 31 is composed of a metal alloy, for example an aluminum alloy, according to two successive foundry processes and forging processes. The body 31 includes a main portion 12, an end portion 13 and a long portion 34 connecting the portions 32 and 13. Two through openings (15, 16) are arranged in the part (12).

In the region Z4, the body 31 comprises an elongate portion 34 provided with two local reinforcements 41,42. The part 34 is made of a metal alloy, and the reinforcing parts 41 and 42 are made of a composite material. The reinforcements 41 and 42 replace the respective portions 141 and 142 of the body 11 such that the portions 14 and 34 have substantially the same dimensions. With the reinforcements 41 and 42, the part 30 can be made lighter in the area Z4 without reducing its mechanical performance.

In the zone Z6, the insert 18 is replaced with a coating 60 formed by low-temperature spraying at the opening 16. The portion 22 of the portion 20 can be lighter with the coating 60 without reducing the performance near the opening 16. [

In addition, parts 10/20/30 may be formed differently from those of Figs. 1 to 12 without departing from the scope of the present invention.

In the embodiment of Figures 5-7 and 10-12, each reinforcement 40/41/42/50/60 engages the body 21/31 of the component 20/30. That is, each reinforcement 40/41/42/50/60 has a surface arranged in complete contact with the body 21/31.

As a variant not shown, the surface of the reinforcement portion in contact with the body may be arranged to contact at least 50% (and up to 100%) of the body. Preferably, the surface of the reinforcement is arranged in contact with the body at least 90%.

Whatever the embodiment of the present invention, the component 20/30 is at least partially composed of a metal alloy,

- the metal alloy body 21/31 produced by the metallurgical manufacturing step a1); And

- at least one local reinforcement formed directly on the body 21/31 in the region under stress of the part 20/30 during the reinforcement step a2) subsequent to the production step a1) by metallurgy.

The body 21/31 constitutes a majority of the volume of the part 20/30 relative to the reinforcement. Although the body 21/31 can consist of only one function, the characteristics of this part can be locally improved by the reinforcement. Each reinforcement has a volume of less than 20%, preferably less than 10% of the volume of the body 21/31.

In the context of the present invention, the local reinforcement is formed by a combination of low temperature injection, micro-arc oxidation, lamination, baking of the resin in the mold, complex assembly (taking its final shape on the body of the component as the adhesive dries) Attachment, or any other suitable technique.

The present invention excludes reinforcement by parts added on the body, for example by welding, screwing or pressing.

The present invention also excludes reinforcing components that are integral with the body by overmolding.

An object of the present invention is a method for manufacturing a part (20/30) made at least partly of a metal alloy.

The method comprises the following successive steps a1) and a2):

a1) a manufacturing step by metallurgy for manufacturing the body 21/31 of the part 20/30; And

a2) a strengthening step of forming a local reinforcement directly on the body 21/31 in the region under stress of the component 20/30.

According to the first embodiment, step a1) comprises a foundry process and then a forging process according to the COBAPRESS method.

According to the second embodiment, step a1) includes only a foundry process.

According to the third embodiment, step a1) includes only a foundry process.

The method may comprise preparing the surface of the area to be strengthened between step a1) and step a2) according to the technique used in step a2). As a non-limiting example, such surface preparation steps may include brushing, degreasing, shot blasting, machining, or depositing. In the case of composite reinforcement, the deposition may consist of applying an adhesive to the body 21/31 of the component 20/30.

The method may also include finishing the part 20/30 in the reinforced area after the reinforcing step a2). As a non-limiting example, such a finishing step may include machining, polishing or surface treatment.

The method may also include a surface treatment step. The surface treatment may be applied at least on at least part of the body 21/31 between at least step a1) and step a2) or at least on at least part of the surface of the part after step a2).

The invention also relates to a method for optimizing the design of an existing part (10) comprising a metal alloy body (11). First, the body 11 is manufactured, for example, according to a foundry process and / or a forging process.

The optimization method comprises the following successive stages b1, b2, b3, b4 and b5.

b1) Identify one or more stressed areas (Z4 / Z5 / Z6) of the existing part (10) by numerical simulation, for example.

b2) by providing at least one local reinforcement 40/41/42/50/60 formed on the body 21/31 of the zone Z4 / Z5 / Z6 under stress, 31) that define the optimized part (20/30).

b3) a step of defining metallurgical manufacturing tools (generally foundry and / or forging) for manufacturing said body (21/31) of said optimized part (20/30). The body 21/31 of the part 20/30 is different from the production tool for the existing body 11 of the part 10. In some cases, a foundry mold and a forge mother mold to be used for the body 11 can be simply modified to be used for manufacturing the body 21/31.

b4) Use the tools to manufacture the body (21/31) of the optimized part (20/30). This stage may include a foundry process and then a forging process, depending on the implementation of the COBAPRESS method. Alternatively, this stage may include only a foundry process.

b5) applying the local reinforcements (40, 41, 42, 50, 60) directly to the body (21/31) in the region under stress (Z4 / Z5 / Z6) Lt; / RTI >

The various embodiments and technical features of the above-mentioned variations may be combined together as a whole or as part thereof. Thus, the components 20/30 can be adapted in terms of cost, functionality and performance.

Claims (18)

A method of manufacturing a part (20; 30) consisting at least in part of a metal alloy, the method comprising a metallurgical manufacturing step a1) of manufacturing the body (21; 31) of the part (20; 30)
The method then includes the steps of applying localized reinforcements 40, 41, 42, 50, 60 directly on the body 21, 31 in the regions Z4, Z5, Z6 under stress of the part 20, Gt; a2) < / RTI > to form a reinforcing layer (2). Process according to claim 1, characterized in that said metallurgical manufacturing step a1) comprises: a) a foundry process a11) for producing a foundry preform, and then the body (21; 31) of the part (20; 30) And a forging step (a12) for forging the foundry preform. Process according to claim 1, characterized in that said metallurgical manufacturing step a1) comprises a foundry process a11) or a forging process a12) for manufacturing said body (21; 31) of said part (20; 30) . The device according to any one of claims 1 to 3, wherein the local reinforcements (40, 41, 42, 50, 60) are in contact with the body (21; 31) of the part And a surface to be arrayed. 5. A device according to any one of claims 1 to 4, characterized in that the local reinforcements (40, 41, 42, 50, 60) are substantially joined to the body (21; 31) ). ≪ / RTI > 6. A device according to any one of claims 1 to 5, characterized in that a plurality of local reinforcements (40,41,42,50,60) are arranged in one or more areas (Z4, Z5, Z6) under stress of the part (20; 30) Is formed on the body (21; 31). The method according to any one of claims 1 to 6, characterized by comprising the step of preparing the surface of the zone (Z4, Z5, Z6) to be strengthened between the metallurgical manufacturing step a1) and the strengthening step a2) . The method according to any one of claims 1 to 7, characterized in that after the strengthening step a2), the step of finishing the part (20; 30) in the reinforced area (Z4, Z5, Z6) Way. The method according to any one of claims 1 to 8, characterized in that the body (21; 31) and the local reinforcement (50, 60) are made of different metal alloys. 10. A method according to any one of claims 1 to 8, characterized in that the body (21; 31) is made of a metal alloy, while the local reinforcement (40, 41, 42) Way. The method of claim 9, wherein the localized reinforcement (40, 41, 42, 50, 60) is formed by cold spraying. 10. The method of claim 9, wherein the local enhancements (40, 41, 42, 50, 60) are formed by micro-arc oxidation. 11. The method of claim 10, wherein the local reinforcement is formed by attaching a composite assembly having a final shape onto the body (21; 31) of the component (20; 30) ≪ / RTI > The method according to claim 10 or 13, characterized in that the local reinforcement (40, 41, 42, 50, 60) is formed by baking the resin. The method according to any one of claims 1 to 10, characterized in that the local reinforcements (40, 41, 42, 50, 60) are formed by additive manufacturing. A method of optimizing the design of an existing component (10) comprising a metal alloy body (11), said optimization method comprising the steps of:
b1) identifying areas under stress (Z4, Z5, Z6) of the existing part (10) by numerical simulation, for example;
b2) by providing at least one local reinforcement (40, 41, 42, 50, 60) formed on the body (21; 31) of the area under stress (Z4, Z5, Z6) 31) of the component (20; 30);
b3) defining a manufacturing tool by metallurgy aligned with the body (21; 31) of the optimized part (20; 30);
b4) fabricating the body (21; 31) of the optimized part (20; 30) using the metallurgical production tools; And
b5) applying the local reinforcements (40, 41, 42, 50, 60) directly to the body (21; 31) in the region of stress (Z4, Z5, Z6) The method comprising the steps of: 17. The method of claim 16, wherein the local reinforcement (40, 41, 42, 50) replaces the original portion (140, 150) of the body (11) of the existing part (10). 16. The method of claim 16, wherein the local reinforcement (60) is applied to the body (11) of the existing part (10) by replacing the overmolded or overmolded insert A feature optimization method.

Images