WO2003000441A1 - Procede pour produire une piece structurelle d'un corps d'automobile et piece structurelle - Google Patents

Procede pour produire une piece structurelle d'un corps d'automobile et piece structurelle Download PDF

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Publication number
WO2003000441A1
WO2003000441A1 PCT/AT2002/000185 AT0200185W WO03000441A1 WO 2003000441 A1 WO2003000441 A1 WO 2003000441A1 AT 0200185 W AT0200185 W AT 0200185W WO 03000441 A1 WO03000441 A1 WO 03000441A1
Authority
WO
WIPO (PCT)
Prior art keywords
flange
structural part
extruded profile
deformation
section
Prior art date
Application number
PCT/AT2002/000185
Other languages
German (de)
English (en)
Inventor
Franz Trubert
Michael Seifert
Harry KÖDER
Original Assignee
Magna Ihv Gesellschaft Für
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Magna Ihv Gesellschaft Für filed Critical Magna Ihv Gesellschaft Für
Publication of WO2003000441A1 publication Critical patent/WO2003000441A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • 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
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • 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
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/047—Mould construction
    • 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
    • B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/01—Making rigid structural elements or units, e.g. honeycomb structures beams or pillars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D23/00—Combined superstructure and frame, i.e. monocoque constructions
    • B62D23/005—Combined superstructure and frame, i.e. monocoque constructions with integrated chassis in the whole shell, e.g. meshwork, tubes, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D27/00—Connections between superstructure or understructure sub-units
    • B62D27/02—Connections between superstructure or understructure sub-units rigid
    • B62D27/023—Assembly of structural joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/008—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of light alloys, e.g. extruded

Definitions

  • the invention relates to a method for producing a tubular and spatially curved structural part from an extruded profile with a projecting flange extending in the longitudinal direction, and also relates to a structural part of a motor vehicle body produced by this method.
  • the structural part is of a long, tubular and spatially curved shape with a flange for attaching add-on elements. It can be a longitudinal or cross member, a sill or longitudinal roof spar, or an A pillar, a B pillar, a C pillar, or a combination of these.
  • the pillars can extend over the entire height of the vehicle, or only over part of it.
  • DE 195 06 160 discloses a subassembly which is composed of a plurality of structural parts which are optimized for cross-section and are individually shaped by internal high-pressure deformation of aluminum tube profiles, which may be extruded. These parts are then put together, which is labor intensive and imprecise.
  • WO 97/30882 discloses a vehicle frame made of bent steel profiles of constant cross-section, in which the A-pillar, longitudinal roof spar and C-pillar are formed by a single tubular structural part. To save weight here simply shaped thin-walled, flangeless profiles made of hardenable steel. The possibility of using hydroforming is mentioned in the margin.
  • the structural part should be designed in such a way that the process is easier to carry out and all strength requirements can be met with a low weight.
  • the method consists in first bending the extruded profile so that its shape at least approximates the desired curvatures of the final shape of the structural part. This bending can be in the plane or already spatial. Then a deformation is carried out in which the cross section of the extruded pro flies (20; 40) is changed and the flange is straightened. Only by straightening the flange in the tool (which can include positioning, changing the standoff angle and eliminating shafts created during the previous bending) can the problem arising from the task be solved.
  • the deformation is preferably divided into two steps.
  • a pre-forming process the raw part is brought into a preform suitable for the following hydroforming process and the flange is straightened.
  • the positioning of the flange preferably in the parting plane between the upper and lower tool, is taken into account (claim 2).
  • the flange can be interrupted in places before bending (claim 3).
  • the basic steps of the method according to the invention can be supplemented by intermediate steps and the hydroforming process can also be carried out in several steps.
  • a further bending can also take place during the pre-deformation (claim 4), for example in the third dimension, if the previous bending process took place in the plane.
  • the flange can be clamped for straightening between an upper and a lower pre-forming tool by compressing them, the angle at which the flange protrudes being changed in places (claim 5).
  • the flange for straightening between an upper and a lower pre-forming tool can be positioned with regard to position and angle by an additional slide (claim 6).
  • the flange is inserted into a groove in the tool (claim 7).
  • the tool consists of at least an upper part and a lower part, which are closed before the hydraulic pressure is applied.
  • the groove will be provided in the lower tool. It can go inwards normally from a flat or non-flat separating surface or also at an angle, depending on the shape given during bending, the desired course of the flange and the geometric requirements when inserting.
  • the flange when the bent and preformed extruded profile is inserted into the mold for the deformation according to the internal high-pressure process, the flange is inserted into a recess in the separating surface of one of the two halves of the tool (claim 8), so that the flange when the tool is closed is squeezed.
  • the flange when the tool is closed, the flange can not only be positioned precisely, but also any undulating bulging during bending can be leveled out again. With certain materials and with sufficient mechanical pressure between the two mold halves, the flange can also be hardened. However, it is also possible to change the angular position of the flange at this stage. Depending on the cross-sectional course of the structural part, it can be advantageous if the flange in the groove of the tool (claim 9) or in the separating surface between the two tool halves (claim 10) has some play so that it can shift during the deformation; namely when the hydroforming completely fills the mold and the flange is pushed a little further into the groove.
  • the cross section of the extruded profile has an inwardly extending bladder and the flange has a root, and before bending, the root of the flange is inserted into the bladder (claim 11), preferably in the longitudinal direction of the structural part (claim 12 ). If necessary, the flange is first interrupted in places and only then is the raw part bent. In the subsequent deformation according to the internal high-pressure process, the bladder is compressed and the root of the flange is thus firmly connected to the bladder (claim 13).
  • the invention also relates to a structural part of a motor vehicle body of long, tubular and spatially curved shape with a flange for connection to other parts of the vehicle body, which consists of a closed extruded profile with a longitudinally extending projecting flange.
  • the structural part should meet all requirements in terms of shape, strength and accuracy.
  • the structural part has a cross-section which is variable over its length, thanks to the deformation in the internal high-pressure process, and the flange is in the course and direction of its protrusion over the length of the Structural part variable and dimensionally fixed (claim 14).
  • the flange is dimensionally stable and the protrusion angle can be used during assembly without rework. This saves a significant amount of time.
  • the flange also accompanies the profile along its length, it can be interrupted in places (claim 15), for example if the structural part is a longitudinal roof spar, for example in the middle for connecting a B-pillar by means of welding.
  • the flange can even be disengaged in zones of strong bending (claim 16).
  • the cross section of the extruded profile which is used in the manufacture, is approximately square, the flange protrudes in the synimetral of a square side, and the square side has inclined sides on both sides of the flange, so that it forms an obtuse angle with the flange ( Claim 17). It is therefore an extruded profile that is already manufactured with a flange.
  • the symmetry facilitates the subsequent insertion into the tool for internal hydroforming and three-dimensional bending.
  • the direction of the flange results in minimal deformation of the flange from its plane during bending, especially if it lies in the bending pressure zone.
  • the cross-section of the extruded profile which is used in the manufacture, is essentially circular (claim 18), so it can also be elliptical or drop-shaped. If it is in particular teardrop-shaped, the flange is arranged on the peripheral part with the smallest radius of curvature (claim 19). This again makes three-dimensional bending and insertion into the tool for hydroforming easier.
  • the flange is inserted into the extruded profile and is only defined in the internal high-pressure process when it is deformed (claim 20). Due to the later insertion of the flange, it does not hinder the bending, or it cannot be damaged in the process, and the protrusion angle can easily be varied over the length of the structural part according to requirements.
  • the extruded profile which is assumed during production, consists in cross-section of an outer wall and of a bladder which extends into the inside, the outer wall being interrupted and its spaced-apart interrupting edges being connected by the bladder, and that Flange consists of a flange part and a root part, the root part being in the bladder (claim 21).
  • the bladder complements the profile to a closed profile, even strengthening it without being a hindrance to bending.
  • the root part is either inserted in the transverse direction or inserted in the longitudinal direction of the profile. In both cases, the angular position of the 5 flange has not yet been finally determined, it will only be deformed when later
  • the thickened root part is pushed lengthways into the bladder and remains pivotable through a considerable angle. This makes it easier to insert it into the tool for hydroforming and has a very special effect: When molding with hydroforming, the bladder is compressed so that it adheres to the
  • the structural part according to the invention is not bound to a specific material as long as it has the required properties. If it consists of a light metal extruded profile, its advantages are particularly clear through the adaptation of the cross section to the load.
  • Fig. 1 an embodiment of an inventive
  • Fig. 2 the same part in front view
  • Fig. 3 a) to f) cross sections through the same at different 0 locations
  • FIG. 4 detail IV in FIG. 1, enlarged, 5 shows a cross section to a first procedure according to the method according to the invention through the starting prof 6: the first step of a second procedure, FIG. 7: the second step of a second procedure, FIG. 8: the third step of a second procedure, FIG. 9: a variant of FIG. 6,
  • FIG. 10 a cross section through another initial profile for FIG. 1
  • FIG. 11 a cross section for FIG. 6 after processing.
  • FIG. 1 and 2 show, for example, a structural part of a motor vehicle body, denoted overall by 1, consisting of the upper part of an A-pillar 2, a longitudinal roof beam 3 and an upper part of a C-pillar 4, which are made from a continuous closed profile.
  • A-pillar 2 At the transition from the A-pillar 2 to the longitudinal roof spar 3 there is a point 7 of greater curvature.
  • the structural part 1 is also bent into the third dimension, in particular the C-pillar 4 ends in a foot 5 which is strongly S-shaped bent inwards.
  • the structural part 1 has a flange 6 essentially over its entire length.
  • the flange 6 is interrupted at 8 in order later to facilitate the welding on of a B-pillar 9, indicated by dashed lines in FIG.
  • FIG. 3 shows various cross sections through the structural part 1 at locations which are designated with the lower case letters a to f in FIG. 1.
  • section a the cross section of the profile is still approximately symmetrical and the flange 6 protrudes at the angle of the synimetral 23.
  • section b the cross section has already changed considerably and the flange 6 'is inclined at an angle 11 with respect to its direction in section a.
  • section c is the Flange 6 "is inclined in the opposite direction by an angle 12.
  • the section d shows the cross section where, because of the B-pillar 9, the flange 6 is interrupted, for example cut out.
  • the sections e and f show that the Location and direction of the flange 6 '", 6""each is different.
  • FIG. 4 the curved zone 7 of FIG. 1 can be seen in more detail.
  • the flange 6 is here provided with notches 14 so that trapezoidal tabs 15 remain between them. This notching is done before bending the still undeformed profile of constant cross-section because it enables small bending radii.
  • FIG. 5 shows a diagram of a first procedure for a first embodiment with an extruded profile of approximately square cross-section as the starting material.
  • the profile has three straight square sides 21 which merge into one another via fillets 22 and a flange 6 on an additional square side as an integral part of the profile. It lies in the symmetry 23 and projects outwards.
  • roof-like inclined sides 24 are provided, each enclosing an obtuse angle 25 with the flange 6. They facilitate insertion into the tool.
  • This profile is first cut to length and, if necessary, unlatched at points of great curvature or the flange is removed at certain points, then it is bent and already lies in a tool that can be a tool for both pre-forming and internal high-pressure forming , With simple form of the Pre-deformation is not necessary for the structural part.
  • the illustrated tool consists of a lower tool 30, which has an engraving 31 starting from a separating surface 32.
  • the separating surface 32 is the surface that comes into contact either with the workpiece or with the upper tool 33 during the internal high-pressure deformation.
  • the engraving is the part of the form on which the profile is brought into contact by the effect of the internal high pressure. This also applies to the upper tool 33 with the engraving 34 and the separating surface 35.
  • the separating surface 32 of the lower tool 30 has a recess 36 in which the flange 6 of the profile can be accommodated. This depression is somewhat shallower than the thickness of the flange 6.
  • the closing pressure of the upper tool 33 is applied to the flange 6 when the tool is closed.
  • any unevenness in the flange 6 is first straightened, the flange is further clamped firmly in the tool and, if desired, and if the profile is made of light metal, the flange 6 can even be hardened by cold working.
  • the clamping of the flange 6 has the purpose of preventing its displacement during the hydroforming.
  • the approximately square cross-section facilitates three-dimensional bending, simplifies welding butts if necessary and gives full contact surfaces for the later attachment of plate-shaped parts of the structure.
  • the inclination makes it easier to insert it into the tool for internal high pressure forming.
  • a second procedure for a first embodiment with an extruded profile of approximately circular cross-section as the starting material will now be described with reference to FIGS. 6, 7, 8. It consists of two work steps, a pre-deformation and a final deformation using high pressure.
  • the starting point is an extruded profile 40, which consists of a circular part 41 and a flange 46, which lies on average on a beam from the center 43. It is already bent and inserted into the preforming tool, which consists of a lower tool 50 and an upper tool 51 and moves downwards according to the directional arrow 55. Furthermore, a slide 52 can be present, which is moved in the horizontal direction to the profile 40 when the upper tool 51 is completely lowered in accordance with the arrow 56. The upper tool is drawn in two positions. First, before it is completely closed, see the contour 53, it grips the edge of the flange 46 and bends it further downwards into the Direction 46 *.
  • the profile 40 is inserted in such a way that the flange 46 already lies flat on the lower tool 50. Then, when the upper tool 51 is completely lowered, the flange 46 is only directed in order to level waves that have arisen when lying down. The slide 52 is then moved to the left in the image and the intermediate stage shown in FIG. 6 occurs, in which the flange is directed and the profile is in an optimal shape for the later internal high pressure deformation.
  • the intermediate profile is designated 40 *. It consists of the already deformed closed part 41 * and the directed or brought into position flange 46 *. Fig. 7 is only a section at one point of the entire structural part, the profile of which varies over its length.
  • the tool for internal high pressure deformation is designated 60 (lower tool) and 61 (upper tool).
  • the intermediate product from the preliminary deformation profile 41 * with flange 46 *
  • the workpiece is now inserted rotated by 180 ° in order to ensure the correct support and filling of the shape during the deformation.
  • the upper tool 61 is now lowered, the recess 62 for the flange 46 * in the upper tool being somewhat higher than the flange 46 * thick.
  • the workpiece is sealed and a very high pressure liquid is applied from the inside.
  • the closed part of the profile 41 * is pressed outwards into the engraving of the two tools 60, 61, which is indicated by dashed lines and is designated by 41 **. Because the closed part of the If the profile at the connection of the flange 46 * is also deformed outwards, the flange 46 * can shift outwards into the recess 62.
  • FIG. 9 shows an additional possibility for deforming the flange 46 of the profile 40.
  • the profile is located between a lower tool 70 and an upper tool 71, which can be both a preform and an internal high-pressure deformation tool.
  • a slide 73 is provided which is moved in the direction of arrow 74, presses the flange 46 into a recess 72 and thus deforms it.
  • 10 and 11 show another embodiment of a structural part according to the invention.
  • 10 shows this after bending, but before the internal high pressure deformation.
  • It is also an extruded profile 140, which consists of an essentially or approximately circular outer wall 141 with a part 142 having a smaller radius of curvature and an inwardly directed bladder 145.
  • the profile is thus approximately teardrop-shaped and has a symmetry, designated 143, in which a flange could also connect as an integrating part of the profile.
  • the outer wall 141 is cut open at the point 142 with the smallest curvature, so that on both sides of the symmetrical break edges 144 and 144 'are formed, which are spaced apart from one another.
  • the flange 146 with its root part 147 is now inserted into this bladder 145.
  • the root part 147 is polygonal in cross-section, in the exemplary embodiment shown it has three edges 148.
  • the flange 146 itself projects with considerable play between the interrupting edges 144, 144 ', so that it can be pivoted in both directions by an angle 149 to the symmetry.
  • the flange 146 with its root part 147 is inserted into the bladder 145 in the longitudinal direction of the profile, normal to the image plane in FIG. 6, which can take place before or after the profile is bent, depending on the circumstances and the choice of material.
  • the lower tool 150 of a tool for internal high pressure deformation is already drawn. It has a separating surface 152 and an engraving 151.
  • a groove 153 is machined into the engraving 151, into which the flange 146, which is not yet fixed in its direction, is inserted when the workpiece is inserted.
  • the groove 153 can thus have an arbitrary course and angle 149 over the length of the engraving 151.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Manufacturing & Machinery (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

La présente invention concerne une pièce structurelle d'un corps d'automobile de configuration allongée, tubulaire et spatialement incurvée. Cette pièce structurelle comprend un rebord permettant d'appliquer des éléments rapportés. L'objectif de la présente invention est d'obtenir un faible poids et un minimum de coûts et de main d'oeuvre lors de la production et de l'assemblage du véhicule complet. A cette fin, la pièce structurelle (1) est constituée d'un profilé extrudé (20) clos et continu, qui est soumis à une prédéformation, puis à une déformation selon le procédé de formage sous haute pression interne (Innenhochdruckverfahren : IHU). La pièce est d'abord mise dans un moule intermédiaire et dirigée vers le rebord, la forme définitive est obtenue lors du formage sous haute pression interne et le rebord (6) est fixé aux dimensions exactes par rapport à l'allure et à la direction (38), sur la longueur de la pièce structurelle (1). La présente invention concerne également une pièce structurelle produite selon ledit procédé.
PCT/AT2002/000185 2001-06-26 2002-06-26 Procede pour produire une piece structurelle d'un corps d'automobile et piece structurelle WO2003000441A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10130794.2 2001-06-26
DE2001130794 DE10130794A1 (de) 2001-06-26 2001-06-26 Strukturteil eines Kraftfahrzeugkörpers und Verfahren zu dessen Herstellung

Publications (1)

Publication Number Publication Date
WO2003000441A1 true WO2003000441A1 (fr) 2003-01-03

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PCT/AT2002/000185 WO2003000441A1 (fr) 2001-06-26 2002-06-26 Procede pour produire une piece structurelle d'un corps d'automobile et piece structurelle

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DE (1) DE10130794A1 (fr)
WO (1) WO2003000441A1 (fr)

Cited By (4)

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WO2005051746A1 (fr) * 2003-10-27 2005-06-09 Behr Gmbh & Co. Kg Composant de support et procede de production associe
EP1712452A2 (fr) 2005-04-13 2006-10-18 GM Global Technology Operations, Inc. Compartiment passager pour voiture
EP1790553A1 (fr) * 2005-11-28 2007-05-30 Renault s.a.s. Elément de structure de véhicule autombile
WO2020051814A1 (fr) * 2018-09-13 2020-03-19 大连理工大学 Procédé pour mettre en forme un raccord de tuyau spécial ayant un bord de raccordement

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DE10309955A1 (de) * 2003-03-07 2004-09-23 Wilhelm Karmann Gmbh Kraftfahrzeug
DE10350145B4 (de) * 2003-10-28 2006-04-13 Daimlerchrysler Ag Erzeugen von IHU-Bauteilen mit Flansch
DE102006041110A1 (de) * 2006-09-01 2007-10-18 Audi Ag Verfahren zum Herstellen und Werkzeug zum Umformen eines Karosseriebauteils
FR3023247B1 (fr) * 2014-07-01 2017-12-22 Peugeot Citroen Automobiles Sa Cote d'habitacle d'un vehicule automobile comprenant un arceau superieur constitue par un profile
JP6745253B2 (ja) * 2017-03-28 2020-08-26 株式会社神戸製鋼所 車両用構造部材及びその製造方法

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005051746A1 (fr) * 2003-10-27 2005-06-09 Behr Gmbh & Co. Kg Composant de support et procede de production associe
EP1712452A2 (fr) 2005-04-13 2006-10-18 GM Global Technology Operations, Inc. Compartiment passager pour voiture
EP1712452B1 (fr) * 2005-04-13 2009-03-25 GM Global Technology Operations, Inc. Compartiment passager pour voiture
EP1790553A1 (fr) * 2005-11-28 2007-05-30 Renault s.a.s. Elément de structure de véhicule autombile
FR2893901A1 (fr) * 2005-11-28 2007-06-01 Renault Sas Element de structure de vehicule automobile
WO2020051814A1 (fr) * 2018-09-13 2020-03-19 大连理工大学 Procédé pour mettre en forme un raccord de tuyau spécial ayant un bord de raccordement

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