US20140020228A1 - Method for producing a tubular stabilizer for a motor vehicle - Google Patents
Method for producing a tubular stabilizer for a motor vehicle Download PDFInfo
- Publication number
- US20140020228A1 US20140020228A1 US13/935,936 US201313935936A US2014020228A1 US 20140020228 A1 US20140020228 A1 US 20140020228A1 US 201313935936 A US201313935936 A US 201313935936A US 2014020228 A1 US2014020228 A1 US 2014020228A1
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- United States
- Prior art keywords
- tube
- swaging
- stabilizer
- section
- tubular stabilizer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K21/00—Making hollow articles not covered by a single preceding sub-group
- B21K21/16—Remodelling hollow bodies with respect to the shape of the cross-section
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/04—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes with tubes; of tubes with rods
- B21D39/046—Connecting tubes to tube-like fittings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/06—Making machine elements axles or shafts
- B21K1/12—Making machine elements axles or shafts of specially-shaped cross-section
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60G—VEHICLE SUSPENSION ARRANGEMENTS
- B60G21/00—Interconnection systems for two or more resiliently-suspended wheels, e.g. for stabilising a vehicle body with respect to acceleration, deceleration or centrifugal forces
- B60G21/02—Interconnection systems for two or more resiliently-suspended wheels, e.g. for stabilising a vehicle body with respect to acceleration, deceleration or centrifugal forces permanently interconnected
- B60G21/04—Interconnection systems for two or more resiliently-suspended wheels, e.g. for stabilising a vehicle body with respect to acceleration, deceleration or centrifugal forces permanently interconnected mechanically
- B60G21/05—Interconnection systems for two or more resiliently-suspended wheels, e.g. for stabilising a vehicle body with respect to acceleration, deceleration or centrifugal forces permanently interconnected mechanically between wheels on the same axle but on different sides of the vehicle, i.e. the left and right wheel suspensions being interconnected
- B60G21/055—Stabiliser bars
- B60G21/0551—Mounting means therefor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- F16F1/00—Springs
- F16F1/02—Springs made of steel or other material having low internal friction; Wound, torsion, leaf, cup, ring or the like springs, the material of the spring not being relevant
- F16F1/14—Torsion springs consisting of bars or tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J7/00—Hammers; Forging machines with hammers or die jaws acting by impact
- B21J7/02—Special design or construction
- B21J7/14—Forging machines working with several hammers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/06—Making machine elements axles or shafts
- B21K1/063—Making machine elements axles or shafts hollow
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60G—VEHICLE SUSPENSION ARRANGEMENTS
- B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
- B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
- B60G2206/012—Hollow or tubular elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60G—VEHICLE SUSPENSION ARRANGEMENTS
- B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
- B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
- B60G2206/40—Constructional features of dampers and/or springs
- B60G2206/42—Springs
- B60G2206/427—Stabiliser bars or tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60G—VEHICLE SUSPENSION ARRANGEMENTS
- B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
- B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
- B60G2206/80—Manufacturing procedures
- B60G2206/81—Shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60G—VEHICLE SUSPENSION ARRANGEMENTS
- B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
- B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
- B60G2206/80—Manufacturing procedures
- B60G2206/81—Shaping
- B60G2206/8102—Shaping by stamping
- B60G2206/81022—Shaping by stamping by forging
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49908—Joining by deforming
- Y10T29/49925—Inward deformation of aperture or hollow body wall
Definitions
- the present invention relates to a method for producing a tubular stabilizer for a motor vehicle.
- semi-active or active stabilizers which by incorporating an actuator, for example an electric actuating motor, can be adjusted in their stiffness characteristics so as to have a high resistance moment against torsion for example when negotiating curves, and thus only allow a small rolling behavior of the motor vehicle, however when driving straight ahead only have a small resistance moment against torsion and thus ensure a corresponding driving comfort.
- an actuator for example an electric actuating motor
- Such a motor vehicle stabilizer is for example known from EP 1 814 748 B1.
- the stabilizer halves that are connected to the corresponding actuator are for example known as stabilizer rods or tubular stabilizers, i.e. as hollow components.
- the stabilizer halves are often bent multiple times three dimensionally due to the packaging inside the motor vehicle, in particular due to the surrounding axle components and the kinematic coupling for spring extension and compression of the wheel, so that lines, shock absorbers or other components do not come into contact with the stabilizer half during spring extension and compression of the wheel.
- stabilizer halves have to be produced cost effectively and with a low own weight in order to keep the proportion of the un-sprung wheel masses low and thus establish a high level of driving dynamics of the motor vehicle.
- the stabilizer halves are exposed to long-term high varying loads throughout the service life of a motor vehicle, often over more than ten years, and therefore have to be produced particular durable.
- the goal is to produce the components with a durability, which is as high as possible.
- a method for producing a tubular stabilizer for a motor vehicle in particular for producing a tubular stabilizer half for an active or semi-active motor vehicle stabilizer, includes swaging at least a section of a tube having a constant cross sectional geometry from outside the tube in a swaging device, thereby reducing an outer diameter of the tube and providing the tube with cross sectional geometries that vary along a longitudinal direction of the tube, wherein a connection flange or an actuator sleeve is formed on the tubular stabilizer by the swaging.
- a tube in particular a metallic tube having a constant cross sectional geometry, and in particular having a round outer cross sectional geometry is processed by a swaging device, in particular a rotary swaging device, so that the outer diameter is reduced.
- a rotary swaging method which represents a chipless forming process for reducing the cross section of rods, tubes or wires.
- the rotary swaging device itself contains multiple swaging tools arranged at an angle distance form one another, which carry out simultaneous radial oscillating movements in quick succession. At each inwardly oriented movement of the swaging tools, a portion of the tube to be formed is formed so as to reduce the outer diameter. The tube is moved through the swaging device with a forward movement, which occurs pulsed so as to be adjusted to the oscillating movements of the swaging tools.
- the rotary swaging process is advantageous in that micro cracks that occur during widening inside the material structure or on the outer sheath surface or inner sheath surface of the tube to be worked on, are avoided. As a result of the swaging process, the material is condensed which avoids the occurrence of micro cracks during widening.
- connection flange or an actuator sleeve is formed one-piece and from uniform material on the tubular stabilizer half by the swaging process.
- connection flange in particular the end of the tube to be worked on is initially either not or only to a minor degree, worked on or increased in its wall thickness.
- the longitudinal section of the tube adjoining the end is further preferably reduced in its cross sectional geometry in particular in its outer diameter so that it is configured smaller relative to the original tube.
- the connection flange can be formed with a profiling for connection to an actuator during or after the swaging process or the connection flange can be welded to the actuator.
- an actuator sleeve such a longitudinal section of the end of the tube is in particular not or only to a minor degree deformed by the swaging process so that an actuator sleeve or a sleeve shaped body is formed, wherein then the longitudinal section of the tubular stabilizer adjoining the sleeve-shaped body is reduced in its cross sectional geometry by the swaging process.
- the swaging process in particular allows introducing toothings inside the sleeve or in a transitional section of sleeve to tubular stabilizer half, so that for example an actuator which is introduced or inserted into the sleeve for example in the form of an electromotor can be form fittingly coupled with the tubular stabilizer half.
- the wall thickness can be increased during the swaging process.
- an inward shift occurs while the material remains constant over the length, whereby the wall thickness per longitudinal section increases while the outer diameter decreases.
- Corresponding counter holders or forming mandrels allow reducing the wall thickness with the method according to the invention, wherein the outer diameter remains essentially constant or is only slightly reduced.
- the at least partial reduction of the wall thickness allows selecting as initial material a tube with great diameter ratios and which has a high resistance moment against torsion at simultaneous small wall diameter and due to a small wall thickness has a low own weight to work on at least parts such that for a subsequent bending process a slight bending is enabled and a high resistance moment against torsion remains over the longitudinal sections which extend essentially straight.
- the tube is pushed through the swaging device in axial direction with a forward movement, wherein the speed of the forward feed is adjustable.
- the forward feed is in particular carried out pulsed however it can also be set within the framework of the invention as constant forward feed speed or as a continuous forward feed with adjustable speed can be set so that a respective outer diameter to be produced and a corresponding wall thickness results in the tube to be worked on.
- At least the section that is to be swaged before can be heated prior to the swaging process, wherein the heating is carried out in particular by an induction coil arranged upstream of the swaging device.
- the upstream located heating in particular enables providing a particularly homogenous structure within the component so that the workpiece is not weakening as a result of the heat treatment or the forming in the hot condition at local high deformation degrees.
- the swaging tool itself can be heated, wherein then a conductive heat conduction occurs at contact with the work piece. It is further possible within the scope of the invention to position a quenching sprinkler immediately downstream of the swaging device, which quenching sprinkler effects a hardening or alternatively to arrange a heating device downstream of the swaging tool so that an at least partial tempering occurs after the forming.
- the end section of the tube can be placed into the swaging device and passed through the swaging device and retained in its original state or starting condition, wherein the actual swaging process, i.e. the forming of the tube only occurs in a middle longitudinal section of the tube, i.e. after passing of the end section through the swaging device.
- the actual swaging process i.e. the forming of the tube only occurs in a middle longitudinal section of the tube, i.e. after passing of the end section through the swaging device.
- this allows working on longitudinal sections, which are not accessible during classical widening by mechanical forming. From the state of the art it is known at best to use high pressure forming processes, which however is only possible with significant production costs and limited degrees of freedom.
- the swaged tubular stabilizer can be further formed relative to its center longitudinal axis after finishing of at least a first swaging forming.
- a mandrel can be introduced into the tube during the forming process, wherein the mandrel in particular has an outer profile, which is embossed into the tube inner sheath surface during the swaging process. It is in particular possible to form an inner toothing with this inside the tubular stabilizer to be produced, preferably of the tubular stabilizer half to be produced.
- the swaging step can include forming at least a section of the tube from a round starting geometry to an elliptic, polygonal and rectangular cross sectional geometry. This is to be selected in dependence on the loads to be expected and on the subsequently available mounting space for mounting the tubular stabilizer.
- the tube can be worked work on by introducing a mandrel into the tube and a counter holding mandrel so that the wall thickness is reduced by the swaging process at least in sections in longitudinal direction of the tube.
- FIGS. 1 a - d show ends of tubular stabilizer halves produced according to the method according to the invention
- FIG. 2 shows a first possible processing method of an end of a tubular stabilizer
- FIG. 3 shows a second possible processing method of an end of a tubular stabilizer
- FIG. 4 shows a further alternative embodiment for processing an end of a p[tubular stabilizer
- FIG. 5 shows a possible method step for processing a middle longitudinal section of a tubular stabilizer
- FIG. 6 shows a further possibility for processing a middle longitudinal section of a tubular stabilizer
- FIG. 7 shows a possibility for processing a tube section with upstream located heating device.
- FIGS. 1 a - d there are shown different ends 1 of tubular stabilizer halves 2 , which are produced with the method according to the invention.
- a sleeve 3 is formed on the end 1 , wherein the sleeve 3 serves for receiving a not further shown actuating system, which can be inserted into an inner space 4 of the sleeve 3 .
- a transitional section 5 whose outer diameter decreases extends in longitudinal direction 6 of the tubular stabilizer halve 2 .
- Adjoining the transitional section 5 itself is a longitudinal section 7 of the tubular stabilizer half 2 with constant outer diameter.
- Adjoining this longitudinal section 7 in longitudinal direction 6 of the tubular stabilizer half 2 is a second transitional section 8 again followed by a second longitudinal section 9 with constant outer diameter.
- All longitudinal sections 7 and the sleeve 3 in the embodiment of the tubular stabilizer half 2 shown in FIG. la have in common that they have the same wall thickness 10 .
- the transitional section 5 and the longitudinal section 7 are produced according to the invention with the rotary swaging method.
- the sleeve 3 has the original geometric dimensions of the starting tube or has been worked on in no significant degree with the rotary swaging method.
- FIG. 1 b shows a second embodiment of a tubular stabilizer half 2 , wherein this has a connection flange 11 at its end 1 , wherein the connection flange 11 is configured tapered in longitudinal direction of the tubular stabilizer half 2 and is adjoined by a longitudinal section 7 with a constant outer diameter, again followed by a second transition section 8 which is adjoined again by a second longitudinal section 9 with constant outer diameter.
- 1 b has an essentially constant wall thickness 10 wherein at its end 1 in the region of the connection flange 11 , the embodiment has an increased wall thickness 12 , wherein the increased wall thickness 12 in particular serves for connection of a further component for example a coupling member of a not further shown actuator and a thermal joining is possible via the increased wall thickness 12 .
- FIG. 1 c shows a further embodiment of tubular stabilizer half 2 produced according to the invention, wherein the latter essentially over its entire length has an essentially constant wall thickness 10 and is constructed analogous to the embodiment according to FIG. 1 a , with the difference that at its end 1 no sleeve but a connection sleeve 13 is formed.
- the connection sleeve 13 has the same wall thickness 10 of the tubular stabilizer half produced according to the invention.
- FIG. 1 d shows a fourth embodiment of a tubular stabilizer half 2 which was produced with the method according to the invention, wherein this embodiment analogous to FIG. 1 c also has a connection sleeve 13 , wherein the connection sleeve 13 has an increased wall thickness 12 relative to the longitudinal section 7 which adjoins the connection sleeve 13 in longitudinal direction 6 .
- FIG. 2 shows a first embodiment of the production method according to the invention for a tubular stabilizer half 2 , wherein in a swaging device 14 which has in this case exemplary shown two swaging tools 15 , which carry out a pulsed linear movement 16 , wherein the linear movement 16 is directed toward a center and the original outer diameter 17 of the tube is reduced to an outer diameter 19 after the swaging process.
- the original wall thickness 10 of the tube 18 is thickened to an increased wall thickness 12 .
- FIG. 3 shows a second embodiment of a swaging tool 15 for carrying out a swaging process according to the invention, wherein the swaging device 14 has again two swaging tools 15 which perform a linear movement 16 toward each other in pulsing steps.
- an inner mandrel 20 is inserted into the tube 18 , which inner mandrel 20 , in turn is form fittingly coupled with a counter holding mandrel 21 , so that the end 1 of the tube 18 comes to rest against the counter holder mandrel 21 .
- This enables, to reduce the wall thickness 12 , relative to an original wall thickness 10 of the tube 18 .
- the original outer diameter 17 of the tube 18 is also reduced by the swaging process to an outer diameter 19 .
- FIG. 4 shows a further embodiment of the production method according to the invention, wherein again in a swaging device 14 two swaging tools 15 are arranged so that they carry out a pulsing linear movement 16 toward each other.
- a tube 18 is reduced in the swaging device 14 in its outer diameter 17 and also in its wall thickness 10 , wherein an inner mandrel with profiled outer surface is introduced into the tube 18 and the outer profile of the inner mandrel 23 is swaged or embossed into an inner sheath surface 24 of the tube 18 by the swaging process.
- this inner mandrel it is possible for this inner mandrel to form a corresponding profile onto the inner sheath surface of the actuator sleeve or the connection flange, so that an inner toothing with an actuator can be produced by means of form fitting connection. Also, a corresponding profiling can be worked onto the front surface of the connection flange or the actuator sleeve, so that the profiling can also be form fittingly coupled with an actuator.
- FIG. 5 shows a further embodiment of the present invention, wherein here in a center section 25 of the tube 18 the wall thickness 26 is configured greater than the wall thickness 10 a the end of the tube 18 or the wall thickness 10 in the longitudinal section 7 that which follows the center section 25 in longitudinal direction of the tube 18 .
- an inner mandrel 20 is inserted into the tube 18 and at the end 1 , a counter holding mandrel 21 comes to rest formfitting against the tube 18 .
- the inner mandrel has a headpiece 20 a wherein headpiece 20 a and inner mandrel 20 are separated via a separation point 29 .
- FIG. 6 shows a further embodiment, wherein here an induction coil 27 is arranged upstream of the swaging device 14 and the tube 18 carries out a pushing in movement 28 so that it passes the induction coil 27 and is heated.
- an inner mandrel 20 which is arranged in the tube 18 and a counter holding mandrel 21 , which comes to rest form fittingly with an end 1 of the tube 18 .
- the swaging tools used according to FIG. 6 allow thickening of a wall thickness of a middle section 25 of the tube 18 . As a result, this middle section 25 attains a greater wall thickness 26 than the remaining section of the tube 18 in longitudinal direction 6 .
- the induction coil 27 can however be used in any other widening or compression method. For removal, the turned tube is removed with the tool halves 15 .
- FIG. 7 shows a further embodiment of the production method according to the invention, wherein here a middle section 25 is configured reduced in its outer diameter 19 relative to the outer diameter 17 of the remaining tube 18 .
- the turned tube is removed with the tool halves 15 .
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- Forging (AREA)
- Vehicle Body Suspensions (AREA)
Abstract
In a method for producing a tubular stabilizer, an original outer diameter of a tube is reduced in a swaging process thereby producing one-piece tubular stabilizer halves of uniform material.
Description
- This application claims the priority of German Patent Application, Ser. No. 10 2012 106 423.7, filed Jul. 17, 2012, pursuant to 35 U.S.C. 119(a)-(d), the disclosure of which is incorporated herein by reference.
- The present invention relates to a method for producing a tubular stabilizer for a motor vehicle.
- The following discussion of related art is provided to assist the reader in understanding the advantages of the invention, and is not to be construed as an admission that this related art is prior art to this invention.
- It is known from the state of the art to use stabilizers on motor vehicle axes in order to optimize the driving properties, in particular the rolling behavior of the motor vehicle. By way of the stabilizer, the wheel loads of the left and right vehicle side are distributed as a result of force distribution and the rolling behavior of a superstructure, which is also coupled with the stabilizer, is reduced. The stabilizer itself is known in particular as torsion stabilizer, which builds up a torsional moment as a result of rotating a tube section and transfers a corresponding occurring wheel load from one wheel to the other wheel.
- Regarding the stabilizer itself, there is a conflict of goals between driving dynamic and driving comfort. In particular in off-road vehicles or small transporters, high rolling behavior is to be expected, which would require a torsion stiff stabilizer, which however diminishes the driving comfort during straight ahead drive.
- From the state of the art, semi-active or active stabilizers are known which by incorporating an actuator, for example an electric actuating motor, can be adjusted in their stiffness characteristics so as to have a high resistance moment against torsion for example when negotiating curves, and thus only allow a small rolling behavior of the motor vehicle, however when driving straight ahead only have a small resistance moment against torsion and thus ensure a corresponding driving comfort.
- Such a motor vehicle stabilizer is for example known from
EP 1 814 748 B1. - The stabilizer halves that are connected to the corresponding actuator are for example known as stabilizer rods or tubular stabilizers, i.e. as hollow components.
- The stabilizer halves are often bent multiple times three dimensionally due to the packaging inside the motor vehicle, in particular due to the surrounding axle components and the kinematic coupling for spring extension and compression of the wheel, so that lines, shock absorbers or other components do not come into contact with the stabilizer half during spring extension and compression of the wheel.
- At the same time, stabilizer halves have to be produced cost effectively and with a low own weight in order to keep the proportion of the un-sprung wheel masses low and thus establish a high level of driving dynamics of the motor vehicle.
- However, as a result of the torsion, the stabilizer halves are exposed to long-term high varying loads throughout the service life of a motor vehicle, often over more than ten years, and therefore have to be produced particular durable. Thus, the goal is to produce the components with a durability, which is as high as possible.
- It would therefore be desirable and advantageous to provide an improved method for producing a tubular stabilizer with which a tubular stabilizer for a motor vehicle in particular a tubular stabilizer half for a semi-active or active stabilizer for motor a motor vehicle can be produced particularly cost effectively and durably.
- According to one aspect of the present invention, a method for producing a tubular stabilizer for a motor vehicle, in particular for producing a tubular stabilizer half for an active or semi-active motor vehicle stabilizer, includes swaging at least a section of a tube having a constant cross sectional geometry from outside the tube in a swaging device, thereby reducing an outer diameter of the tube and providing the tube with cross sectional geometries that vary along a longitudinal direction of the tube, wherein a connection flange or an actuator sleeve is formed on the tubular stabilizer by the swaging.
- For this, a tube in particular a metallic tube having a constant cross sectional geometry, and in particular having a round outer cross sectional geometry, is processed by a swaging device, in particular a rotary swaging device, so that the outer diameter is reduced. This is in particular a rotary swaging method, which represents a chipless forming process for reducing the cross section of rods, tubes or wires.
- The rotary swaging device itself contains multiple swaging tools arranged at an angle distance form one another, which carry out simultaneous radial oscillating movements in quick succession. At each inwardly oriented movement of the swaging tools, a portion of the tube to be formed is formed so as to reduce the outer diameter. The tube is moved through the swaging device with a forward movement, which occurs pulsed so as to be adjusted to the oscillating movements of the swaging tools.
- This allows to producing a one-piece tubular stabilizer from uniform material, in particular a one-piece tubular stabilizer half from one material, which has a connection sleeve or a connection flange as well as cross sectional geometries which differ from one another over the length of the tubular stabilizer half, and is thus optimized with regard to the load characteristics and its specific own weight. In contrast to a widening process known from the state of the art, the rotary swaging process is advantageous in that micro cracks that occur during widening inside the material structure or on the outer sheath surface or inner sheath surface of the tube to be worked on, are avoided. As a result of the swaging process, the material is condensed which avoids the occurrence of micro cracks during widening.
- Within the scope of the invention, it is thus possible to also produce inner profiles or outer profiles that enable a form fitting engagement with further components, for example a toothing with an actuator. As an alternative, it is also conceivable to configure at least sub sections of the longitudinal section angled, which can be advantageous in particular with regard to a three dimensional deformation of the stabilizer half following the swaging process depending on the geometry to be produced.
- According to the invention, a connection flange or an actuator sleeve is formed one-piece and from uniform material on the tubular stabilizer half by the swaging process. By this, in particular a one-piece tubular stabilizer made of uniform material, in particular a tubular stabilizer half is produced, which has a high service life with regard to an ongoing, alternating bending loads.
- In the case of a connection flange, in particular the end of the tube to be worked on is initially either not or only to a minor degree, worked on or increased in its wall thickness. The longitudinal section of the tube adjoining the end is further preferably reduced in its cross sectional geometry in particular in its outer diameter so that it is configured smaller relative to the original tube. The connection flange can be formed with a profiling for connection to an actuator during or after the swaging process or the connection flange can be welded to the actuator.
- In the case of an actuator sleeve, such a longitudinal section of the end of the tube is in particular not or only to a minor degree deformed by the swaging process so that an actuator sleeve or a sleeve shaped body is formed, wherein then the longitudinal section of the tubular stabilizer adjoining the sleeve-shaped body is reduced in its cross sectional geometry by the swaging process. Within the framework of the invention, the swaging process in particular allows introducing toothings inside the sleeve or in a transitional section of sleeve to tubular stabilizer half, so that for example an actuator which is introduced or inserted into the sleeve for example in the form of an electromotor can be form fittingly coupled with the tubular stabilizer half.
- According to another advantageous feature of the present invention, the wall thickness can be increased during the swaging process. As a result of the reduction of the outer diameter an inward shift occurs while the material remains constant over the length, whereby the wall thickness per longitudinal section increases while the outer diameter decreases. Corresponding counter holders or forming mandrels allow reducing the wall thickness with the method according to the invention, wherein the outer diameter remains essentially constant or is only slightly reduced. The at least partial reduction of the wall thickness allows selecting as initial material a tube with great diameter ratios and which has a high resistance moment against torsion at simultaneous small wall diameter and due to a small wall thickness has a low own weight to work on at least parts such that for a subsequent bending process a slight bending is enabled and a high resistance moment against torsion remains over the longitudinal sections which extend essentially straight.
- According to another advantageous feature of the present invention, the tube is pushed through the swaging device in axial direction with a forward movement, wherein the speed of the forward feed is adjustable. The forward feed is in particular carried out pulsed however it can also be set within the framework of the invention as constant forward feed speed or as a continuous forward feed with adjustable speed can be set so that a respective outer diameter to be produced and a corresponding wall thickness results in the tube to be worked on.
- According to another advantageous feature of the present invention, at least the section that is to be swaged before can be heated prior to the swaging process, wherein the heating is carried out in particular by an induction coil arranged upstream of the swaging device. The upstream located heating in particular enables providing a particularly homogenous structure within the component so that the workpiece is not weakening as a result of the heat treatment or the forming in the hot condition at local high deformation degrees.
- According to another advantageous feature of the present invention, the swaging tool itself can be heated, wherein then a conductive heat conduction occurs at contact with the work piece. It is further possible within the scope of the invention to position a quenching sprinkler immediately downstream of the swaging device, which quenching sprinkler effects a hardening or alternatively to arrange a heating device downstream of the swaging tool so that an at least partial tempering occurs after the forming.
- According to another advantageous feature of the present invention, the end section of the tube can be placed into the swaging device and passed through the swaging device and retained in its original state or starting condition, wherein the actual swaging process, i.e. the forming of the tube only occurs in a middle longitudinal section of the tube, i.e. after passing of the end section through the swaging device. In contrast to a widening known from the state of the art, this allows working on longitudinal sections, which are not accessible during classical widening by mechanical forming. From the state of the art it is known at best to use high pressure forming processes, which however is only possible with significant production costs and limited degrees of freedom.
- According to another advantageous feature of the present invention, the swaged tubular stabilizer can be further formed relative to its center longitudinal axis after finishing of at least a first swaging forming. Within the context of the invention, this means a three dimensional forming, for example a bending or bending around of at least the end regions, but also a multiple three dimensional bending of the tubular stabilizer which is pre processed by the swaging.
- According to another advantageous feature of the present invention, a mandrel can be introduced into the tube during the forming process, wherein the mandrel in particular has an outer profile, which is embossed into the tube inner sheath surface during the swaging process. It is in particular possible to form an inner toothing with this inside the tubular stabilizer to be produced, preferably of the tubular stabilizer half to be produced.
- According to another advantageous feature of the present invention, the swaging step can include forming at least a section of the tube from a round starting geometry to an elliptic, polygonal and rectangular cross sectional geometry. This is to be selected in dependence on the loads to be expected and on the subsequently available mounting space for mounting the tubular stabilizer.
- According to another advantageous feature of the present invention, the tube can be worked work on by introducing a mandrel into the tube and a counter holding mandrel so that the wall thickness is reduced by the swaging process at least in sections in longitudinal direction of the tube.
- The previously mentioned steps and embodiments of the method according to the invention can be combined with each other at in any combination within the scope of the invention with the respectively associated advantages.
- Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
-
FIGS. 1 a-d show ends of tubular stabilizer halves produced according to the method according to the invention; -
FIG. 2 shows a first possible processing method of an end of a tubular stabilizer; -
FIG. 3 shows a second possible processing method of an end of a tubular stabilizer; -
FIG. 4 shows a further alternative embodiment for processing an end of a p[tubular stabilizer; -
FIG. 5 shows a possible method step for processing a middle longitudinal section of a tubular stabilizer; -
FIG. 6 shows a further possibility for processing a middle longitudinal section of a tubular stabilizer and -
FIG. 7 shows a possibility for processing a tube section with upstream located heating device. - Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
- Turning now to the drawing, and in particular to
FIGS. 1 a-d, there are showndifferent ends 1 oftubular stabilizer halves 2, which are produced with the method according to the invention. - In
FIG. 1 a, asleeve 3 is formed on theend 1, wherein thesleeve 3 serves for receiving a not further shown actuating system, which can be inserted into aninner space 4 of thesleeve 3. From thesleeve 3, atransitional section 5 whose outer diameter decreases extends inlongitudinal direction 6 of thetubular stabilizer halve 2. Adjoining thetransitional section 5 itself is alongitudinal section 7 of thetubular stabilizer half 2 with constant outer diameter. Adjoining thislongitudinal section 7 inlongitudinal direction 6 of thetubular stabilizer half 2 is a secondtransitional section 8 again followed by a secondlongitudinal section 9 with constant outer diameter. Alllongitudinal sections 7 and thesleeve 3 in the embodiment of thetubular stabilizer half 2 shown in FIG. la have in common that they have thesame wall thickness 10. Thetransitional section 5 and thelongitudinal section 7 are produced according to the invention with the rotary swaging method. Thesleeve 3 has the original geometric dimensions of the starting tube or has been worked on in no significant degree with the rotary swaging method. -
FIG. 1 b shows a second embodiment of atubular stabilizer half 2, wherein this has aconnection flange 11 at itsend 1, wherein theconnection flange 11 is configured tapered in longitudinal direction of thetubular stabilizer half 2 and is adjoined by alongitudinal section 7 with a constant outer diameter, again followed by asecond transition section 8 which is adjoined again by a secondlongitudinal section 9 with constant outer diameter. The embodiment according toFIG. 1 b has an essentiallyconstant wall thickness 10 wherein at itsend 1 in the region of theconnection flange 11, the embodiment has an increasedwall thickness 12, wherein the increasedwall thickness 12 in particular serves for connection of a further component for example a coupling member of a not further shown actuator and a thermal joining is possible via the increasedwall thickness 12. -
FIG. 1 c shows a further embodiment oftubular stabilizer half 2 produced according to the invention, wherein the latter essentially over its entire length has an essentiallyconstant wall thickness 10 and is constructed analogous to the embodiment according toFIG. 1 a, with the difference that at itsend 1 no sleeve but aconnection sleeve 13 is formed. Theconnection sleeve 13 has thesame wall thickness 10 of the tubular stabilizer half produced according to the invention. -
FIG. 1 d shows a fourth embodiment of atubular stabilizer half 2 which was produced with the method according to the invention, wherein this embodiment analogous toFIG. 1 c also has aconnection sleeve 13, wherein theconnection sleeve 13 has an increasedwall thickness 12 relative to thelongitudinal section 7 which adjoins theconnection sleeve 13 inlongitudinal direction 6. -
FIG. 2 shows a first embodiment of the production method according to the invention for atubular stabilizer half 2, wherein in aswaging device 14 which has in this case exemplary shown twoswaging tools 15, which carry out a pulsedlinear movement 16, wherein thelinear movement 16 is directed toward a center and the originalouter diameter 17 of the tube is reduced to anouter diameter 19 after the swaging process. At the same time, as shown here, theoriginal wall thickness 10 of thetube 18 is thickened to an increasedwall thickness 12. -
FIG. 3 shows a second embodiment of aswaging tool 15 for carrying out a swaging process according to the invention, wherein theswaging device 14 has again twoswaging tools 15 which perform alinear movement 16 toward each other in pulsing steps. Into theswaging device 14, and end 1 of atube 18 is inserted, wherein aninner mandrel 20 is inserted into thetube 18, whichinner mandrel 20, in turn is form fittingly coupled with acounter holding mandrel 21, so that theend 1 of thetube 18 comes to rest against thecounter holder mandrel 21. This enables, to reduce thewall thickness 12, relative to anoriginal wall thickness 10 of thetube 18. The originalouter diameter 17 of thetube 18 is also reduced by the swaging process to anouter diameter 19. -
FIG. 4 shows a further embodiment of the production method according to the invention, wherein again in aswaging device 14 twoswaging tools 15 are arranged so that they carry out a pulsinglinear movement 16 toward each other. For this, atube 18 is reduced in theswaging device 14 in itsouter diameter 17 and also in itswall thickness 10, wherein an inner mandrel with profiled outer surface is introduced into thetube 18 and the outer profile of theinner mandrel 23 is swaged or embossed into aninner sheath surface 24 of thetube 18 by the swaging process. It is possible for this inner mandrel to form a corresponding profile onto the inner sheath surface of the actuator sleeve or the connection flange, so that an inner toothing with an actuator can be produced by means of form fitting connection. Also, a corresponding profiling can be worked onto the front surface of the connection flange or the actuator sleeve, so that the profiling can also be form fittingly coupled with an actuator. -
FIG. 5 shows a further embodiment of the present invention, wherein here in acenter section 25 of thetube 18 thewall thickness 26 is configured greater than the wall thickness 10 a the end of thetube 18 or thewall thickness 10 in thelongitudinal section 7 that which follows thecenter section 25 in longitudinal direction of thetube 18. For this, aninner mandrel 20 is inserted into thetube 18 and at theend 1, acounter holding mandrel 21 comes to rest formfitting against thetube 18. The inner mandrel has aheadpiece 20 a whereinheadpiece 20 a andinner mandrel 20 are separated via aseparation point 29. -
FIG. 6 shows a further embodiment, wherein here aninduction coil 27 is arranged upstream of theswaging device 14 and thetube 18 carries out a pushing inmovement 28 so that it passes theinduction coil 27 and is heated. Again shown is aninner mandrel 20, which is arranged in thetube 18 and acounter holding mandrel 21, which comes to rest form fittingly with anend 1 of thetube 18. The swaging tools used according toFIG. 6 allow thickening of a wall thickness of amiddle section 25 of thetube 18. As a result, thismiddle section 25 attains agreater wall thickness 26 than the remaining section of thetube 18 inlongitudinal direction 6. Within the scope of the invention, theinduction coil 27 can however be used in any other widening or compression method. For removal, the turned tube is removed with the tool halves 15. -
FIG. 7 shows a further embodiment of the production method according to the invention, wherein here amiddle section 25 is configured reduced in itsouter diameter 19 relative to theouter diameter 17 of the remainingtube 18. In this case as well, the turned tube is removed with the tool halves 15. - While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
- What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein:
Claims (14)
1. A method for producing a tubular stabilizer for a motor vehicle, comprising:
swaging at least a section of a tube having a constant cross sectional geometry from outside the tube in a swaging device, thereby reducing an outer diameter of the tube and providing the tube with cross sectional geometries that vary along a longitudinal direction of the tube, wherein a connection flange or an actuator sleeve is formed on the tubular stabilizer by the swaging.
2. The method of claim 1 , used for producing a tubular stabilizer half for an active or semi-active motor vehicle stabilizer.
3. The method of claim 1 , wherein a wall thickness of the tube is increased in the swaging process.
4. The method of claim 1 , wherein the tube is pushed in an axial direction through the swaging device with a forward movement.
5. The method of claim 4 , wherein a speed of the forward movement is adjustable.
6. The method of claim 1 , further comprising before the swaging step, heating the section of the tube.
7. The method of claim 6 , wherein the section of the tube is heated by an induction coil arranged immediately upstream of the swaging device.
8. The method of claim 1 , further comprising inserting an end section of the tube into the swaging device, passing the end section through the swaging device while retaining the end section in an original state, and initiating the swaging at an inner section of the tube.
9. The method of claim 1 , further comprising forming the swaged tubular stabilizer relative to a longitudinal center axis of the tube stabilizer.
10. The method of claim 9 , further comprising inserting an inner mandrel into the tube during the forming process.
11. The method of claim 10 , wherein the inner mandrel has an outer profile, which is embossed by the swaging process into an inner sheath surface of the tube.
12. The method of claim 1 , wherein the swaging step includes forming at least a section of the tube from a round starting geometry to at least one cross sectional geometry selected from the group consisting of an elliptic, polygonal and rectangular cross sectional geometry.
13. The method of claim 1 , wherein a wall thickness of the tube is reduced by the swaging step by using an inner mandrel and a counter holding mandrel.
14. The method of claim 1 , further comprising after the swaging step, hardening and/or tempering at least a portion of the tubular stabilizer.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102012106423.7 | 2012-07-17 | ||
DE102012106423.7A DE102012106423A1 (en) | 2012-07-17 | 2012-07-17 | Method for producing a pipe stabilizer for a motor vehicle |
Publications (1)
Publication Number | Publication Date |
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US20140020228A1 true US20140020228A1 (en) | 2014-01-23 |
Family
ID=48747977
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/935,936 Abandoned US20140020228A1 (en) | 2012-07-17 | 2013-07-05 | Method for producing a tubular stabilizer for a motor vehicle |
Country Status (5)
Country | Link |
---|---|
US (1) | US20140020228A1 (en) |
EP (1) | EP2687392B1 (en) |
JP (1) | JP5669891B2 (en) |
CN (1) | CN103538438B (en) |
DE (1) | DE102012106423A1 (en) |
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US10486487B2 (en) | 2016-07-26 | 2019-11-26 | Toyota Jidosha Kabushiki Kaisha | Stabilizer and method of manufacturing the same |
US11193511B2 (en) * | 2016-06-21 | 2021-12-07 | Liebherr-Components Kirchdorf GmbH | Method for manufacturing a piston rod unit and a hollow shaft |
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DE102014214638A1 (en) * | 2014-07-25 | 2016-01-28 | Zf Friedrichshafen Ag | Process for the preparation of stabilizer halves for a roll stabilization system, and method for producing a roll stabilization system |
DE102014216674A1 (en) | 2014-08-21 | 2016-02-25 | Schaeffler Technologies AG & Co. KG | Tubular component and method for its production |
DE102014216717A1 (en) * | 2014-08-22 | 2016-02-25 | Zf Friedrichshafen Ag | Active roll stabilization system for a motor vehicle |
DE102015005522B4 (en) | 2015-04-30 | 2021-09-30 | Schomäcker Federnwerk GmbH | Method for producing a metallic hollow body |
DE102018110065A1 (en) * | 2018-04-26 | 2019-10-31 | Schaeffler Technologies AG & Co. KG | Process for the preparation of a first and second stabilizer half for a roll stabilizer |
JP7156196B2 (en) * | 2019-07-24 | 2022-10-19 | Jfeスチール株式会社 | Chain crimping device and crimping method |
CN112045124B (en) * | 2020-08-28 | 2022-06-21 | 江阴南工锻造有限公司 | Special core rod for cylinder barrel inner hole concave step and forming method |
CN117816882B (en) * | 2024-03-06 | 2024-05-03 | 江苏圣贤锻造有限责任公司 | Petrochemical pressure vessel tube plate forging equipment and process |
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Also Published As
Publication number | Publication date |
---|---|
EP2687392A1 (en) | 2014-01-22 |
EP2687392B1 (en) | 2015-04-01 |
CN103538438B (en) | 2016-05-25 |
CN103538438A (en) | 2014-01-29 |
JP5669891B2 (en) | 2015-02-18 |
JP2014018863A (en) | 2014-02-03 |
DE102012106423A1 (en) | 2014-01-23 |
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Owner name: BENTELER AUTOMOBILTECHNIK GMBH, GERMANY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:JANZEN, ANDREAS;BERHEIDE, FRISO;REEL/FRAME:030743/0683 Effective date: 20130705 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |