WO2005018845A1 - Procede de fabrication de composants metalliferes et installation de profilage permettant le profilage de composants metalliferes - Google Patents

Procede de fabrication de composants metalliferes et installation de profilage permettant le profilage de composants metalliferes Download PDF

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Publication number
WO2005018845A1
WO2005018845A1 PCT/EP2004/009213 EP2004009213W WO2005018845A1 WO 2005018845 A1 WO2005018845 A1 WO 2005018845A1 EP 2004009213 W EP2004009213 W EP 2004009213W WO 2005018845 A1 WO2005018845 A1 WO 2005018845A1
Authority
WO
WIPO (PCT)
Prior art keywords
roll
forming
metal
profiling
components
Prior art date
Application number
PCT/EP2004/009213
Other languages
German (de)
English (en)
Inventor
Thomas Adelmann
Alexander Egidi
Karl-Heinz FÜLLER
Günter Rostek
Original Assignee
Daimlerchrysler Ag
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
Priority claimed from DE10342540A external-priority patent/DE10342540A1/de
Application filed by Daimlerchrysler Ag filed Critical Daimlerchrysler Ag
Publication of WO2005018845A1 publication Critical patent/WO2005018845A1/fr

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Classifications

    • 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
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • 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
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • 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
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
    • B21D5/10—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles for making tubes
    • B21D5/12—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles for making tubes making use of forming-rollers
    • 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

Definitions

  • the invention relates to a method for producing metal-containing components according to the preamble of patent claim 1 and to a roll profiling system for profiling metal-containing components according to the preamble of patent claim 8.
  • a method for partial roll profiling with an upstream or integrated cutting device for separating, in particular punching, elongated starting materials and producing a change in cross section of the hollow component profile by trimming is known from the publication DE 197 49 902 AI.
  • the hollow component profile has an interrupted component surface with reduced torsional and bending rigidity. Because of the reduced stiffness of the component produced by means of this separation process, this process proves to be unsuitable for structural and safety components. Furthermore, the processing by punching high-strength steels leads to increased wear of the punching tool, which leads to increased tool costs and set-up times and makes the machining process uneconomical.
  • the processing of the rolled profile by means of cutting, in particular laser cutting proves to be disadvantageous for safety components, since inevitable structural changes occur in the highly stressed edge region of the profile during laser cutting, which have a negative effect on the component strength under vibrating stress.
  • the present invention is based on the object of specifying a method for creating dimensionally stable components and of providing a device for profiling particularly stable components.
  • the solution according to the invention is provided by a method for producing metal-containing components, in particular of vehicle support structures, in which a metal-containing starting material is fed to a roll profiling system and roll profiled to a roll profile, wherein during roll profiling, forming takes place in such a way that the roll profile cross section is changed by means of the forming.
  • a major advantage of the method according to the invention is the production of components with a rolled profile cross section that changes over the length, height and / or width by means of continuous or discontinuous roll profiling and by means of integrated forming.
  • a cross-sectional change is introduced by reshaping, so that a reduction in the torsional and bending rigidity compared to a component produced by cutting is avoided.
  • the method according to the invention enables the production of components with very good structural properties in the highly stressed edge area of the component cross section, which have a positive effect on the component strength under vibrating stress.
  • the structural and safety components are thin-walled column structures made of sheet steel, longitudinal and cross profiles, such as side impact beams, bumpers, column reinforcements, longitudinal and cross beams, floor assembly and roof frame. These are characterized by a high degree of dimensional accuracy and lower tolerances, which ensure better integration by joining, in particular by laser welding, such as welding a floor assembly to a side member.
  • body structures for example support structures
  • support structures often have to be installed, in particular to adapt to the welded joint, be adjusted in cross-section so that they do not have a constant cross-section over their longitudinal course.
  • support structures are produced in such a way that the rolled profile cross section is changed.
  • An essential advantage of the method according to the invention in comparison to the components made from elongated profiles, in particular by means of conventional deep drawing, is essentially the better dimensional accuracy during the production of elongated components.
  • the process steps of roll profiling, forming and roll profiling are carried out in succession.
  • Roll forming is the conventional cold forming process such as Die or swivel bending, clearly superior due to the short production times.
  • the production times are significantly reduced both by the high output quantity per time and by the low tool costs compared to deep drawing. For this reason, the process is highly economical in the area of medium to large batch sizes.
  • the metal-containing starting material is preferably first straightened and then marked before it is then fed to the roll forming process and then deformed by a shaping process and then roll profiled again, means that roll forming with the integrated shaping means that a component with above it Longitudinal profile changed rolled profile cross-section can be produced, which is precisely adapted to the later use.
  • the production of the rolled profile and the production of the modified rolled profile cross section takes place in one working step. time-saving process without intermediate storage and the associated logistics costs.
  • a major advantage of the method according to the invention is that the successive method steps can be carried out in a compact device which has proven to be particularly economical.
  • the roll forming system with the forming device is controlled in discontinuous operation.
  • One advantage of this embodiment is the attachment of complex rolled profile cross-section variations to the component areas provided for this purpose with different component lengths.
  • the roll forming system is controlled in such a way that the component area to be modified is formed in the forming device.
  • the roll profiling system is preferably stopped for one to two seconds, the rolled profile is formed and the further roll profiling then takes place.
  • the integration of the forming process into the roll forming process has proven to be advantageous, the roll forming process being carried out conventionally or as a flexible roll profiling process.
  • the rolled profile is cold formed in order to change the cross section.
  • Such an embodiment of the method according to the invention has the essential advantage over conventional hot forming, in particular over tempering with subsequent roll profiling, that on the one hand lower process costs are caused and on the other hand there is an increased residual plastic strain due to a more ductile material condition.
  • Component manufactured according to the method compared to the components produced by means of conventional hot forming, a higher dimensional accuracy, whereby a calibration of the components to be carried out in the cold state is not necessary.
  • supports or A-, B-, C- or D-pillar structures in motor vehicle construction have to be manufactured with high quality and thus high dimensional accuracy in large numbers.
  • beads are formed during forming and / or formed under tension and / or pressure, in particular deep-drawn and / or stretch-drawn.
  • the method according to the invention proves to be particularly advantageous in that, after the first roll profiling and before the further roll profiler, metal-containing starting materials, in particular high-strength steels, can be deep-drawn without negative effects on the mechanical properties of the component to be formed.
  • the method according to the invention thus ensures that it is formed into complex, particularly dimensionally stable components.
  • components with changed final dimensions can be produced by stretch drawing, which have complex cross-sectional changes in the desired component areas and additionally reduced wall thicknesses over a constant profile cross section.
  • stretch drawing which have complex cross-sectional changes in the desired component areas and additionally reduced wall thicknesses over a constant profile cross section.
  • the combination of stretch drawing with deep drawing allows large-area, asymmetrical components to be produced.
  • components are produced by means of beads which are preferably integrated in the roll forming process and which have both variable cross-sectional changes and geometrically shaped stiffeners (beads) in the desired component areas.
  • Such an embodiment of the method according to the invention has the further advantage that the component areas processed by means of deep drawing and / or stretch drawing and / or beads cannot be reshaped in a single step, but in steps, in order to set a deformable structural state over the cross section of the component.
  • the rolled profile is limited locally and thus spatially by means of a shaping device, i.e. not formed over the entire length of the component.
  • the method is based on the fact that, for example, the locally limited reshaping enables elongated components with a reduced sheet thickness to be produced in zones with lower loads and with a possibly slightly increased sheet thickness in zones with high loads.
  • the method according to the invention makes it possible, depending on the requirements of the installation location, to provide a functional cross section for desired components.
  • the local forming of the rolled profile takes place exactly in the desired component area, so that "tailor-made components" can be produced.
  • the advantage of the method according to the invention is also that by means of the local, locally limited forming
  • Components such as side member, cross member and column structures, that are similar to each other, but have different lengths, are easier to manufacture.
  • high-strength steels and / or deep-drawing steels and / or Ti alloys and / or Ni alloys and / or metal-containing composite materials are used as the starting material.
  • An advantage of the method according to the invention is the use of high-strength and / or high-strength steels as the starting material, which can be roll-profiled, then formed into a rolled section with a variable cross-section and then further rolled-profiled.
  • these materials have the advantage that less installation space is required and, on the other hand, the increasing safety requirements in motor vehicle construction in the area of structural and safety components can be met.
  • a major advantage of the method according to the invention is the production of support structures from material which cannot be formed by means of conventional deep drawing.
  • high-strength steels preferably from the group of multi-phase steels, such as dual-phase steels (DP steels), complex phase steels (CP steels), martensite phase steels (MS-W steels) or residual austenite steels (transformation induced plasticity-TRIP- Steels), which cannot be formed by conventional deep drawing, are ideal for roll forming with integrated deep drawing.
  • These steels show particularly favorable hardening properties in relation to the formability-strength ratio. The increase in strength of these steels is achieved by introducing hard phases in a ductile material matrix.
  • Characteristic of these steels is the "bake hardening" potential superimposed on the hardening, which increases with the increasing forming.
  • the very high level of Cleaning these steels with a high initial strength is particularly advantageous for the crash behavior.
  • the method according to the invention thus allows the strength in the desired component areas to be increased even by the choice of a suitable material, without, for example, requiring expensive heat treatment.
  • deep-drawing steels can be used according to the invention in structural and safety components, since they have a low carbon content, a fine-grained structure which is as low in texture as possible and have an elastic limit without a flow area.
  • Ti alloys or Ni alloys are only moderately suitable for forming with conventional forming processes. Nevertheless, these can be processed using the method according to the invention. This process can also be used to form Mg or Al alloys.
  • Cross beams made of Mg alloys are lighter than corresponding steel beams, despite the lower modulus of elasticity and strength values of the Mg alloys.
  • metal-containing composite materials for structural and safety components.
  • the advantage of these materials is that they can be used "tailor-made" for the components, so that reinforcements can only be introduced in the desired component areas.
  • high-strength steels is advantageous in the method according to the invention. Typically, however, these are more brittle and their ductility decreases as their strength increases.
  • the method according to the invention allows such steels to be shaped with suitable ductility / strength behavior. Due to the higher strength, components with the same stability - and thus safety - can also be manufactured with less material. The In addition, increased deformability enables complex components, such as support structures, to be manufactured more easily.
  • a central concern of the automotive industry is the reduction of fuel consumption by lowering the weight of the vehicle with unchanged safety, in particular crash safety - this can be achieved through the construction of lighter vehicles. Saving potential offers high-strength steels, since the increased strength means that less material can be used with the same dimensional stability.
  • High-strength steels can be deformed by the roll forming process according to the invention with integrated forming.
  • the shaping of the steels is designed according to the invention in which all process steps can be carried out on one system. This reduces the manufacturing times of the components.
  • Another object of the present invention relates to a roll profiling system for profiling metal-containing components with at least one integrated device for shaping, this device being suitable for changing the roll profile cross section, in particular locally.
  • An advantage of the roll profiling system according to the invention is that all process steps can be carried out on a single system, which can result in an increase in output (increase in product quantity) and in a time saving.
  • a high application rate per time results in a high economic efficiency of the roll profiling system according to the invention, the roll profiling system being conventionally designed or can be designed as a flexible roll profiling system.
  • the cost-effectiveness is limited by the high set-up and adjustment effort for the tool sets. This applies in particular especially for small lot sizes.
  • the reason for the high set-up and setting effort is due to the conventional system technology, which when changing to the production of a different profile usually requires a tool change for all stands and cause long setting times, which in turn adversely affect the productivity of the process.
  • the object of the invention shows the essential advantage that components with greatly differing cross-sectional changes can be locally reshaped in a single roll forming system with an integrated reshaping device. There is no need to transport the roll-formed components to a separate forming line.
  • the known logistics problem associated with conventional roll forming systems is eliminated according to this invention.
  • Another advantage of the invention compared ⁇ roll forming in particular to a bending device for bending elongated profile components is to be roll formed by the roll forming according to the invention with an integrated reforming device rolled profiles with complex profile cross-sections such.
  • the integrated device for shaping is designed to be displaceable parallel to the transport direction of the component to be profiled.
  • An advantage of this embodiment is the application of complex cross-sectional variations in component areas provided for this purpose, the components having different component lengths can have.
  • the roll forming system according to the invention can be controlled in such a way that the component area to be changed in cross section can be deformed in the forming device, preferably in a deep-drawing device.
  • the roll profiling system is preferably stopped for one to two seconds, the component is deformed and the further roll profiling then takes place.
  • the integration of the forming device in the roll profiling system has proven to be advantageous, the roll profiling process in the roll profiling system being carried out conventionally or else as a flexible roll profiling process.
  • the forming device can be moved in the transport direction of the component to be profiled in such a way that multiple changes in cross-section can be introduced on the same rolled profile. Furthermore, the distance between the cross-sectional changes to one another can be made variable such that components of the same length in different component areas have cross-sectional changes.
  • the displaceable design of the device for shaping enables cost-effective production due to the flexibility of the system, which makes the system economical.
  • the shaping device can also be arranged spatially separately in front of a first part of the roll profiling system, such that a roll profiling process is carried out first and then the forming process takes place separately, the subsequent roll profiling process then taking place in a further part of the roll profiling system.
  • the roll profiling system enables the production of modular components with different roll profile cross sections on a roll profiling system without the use of an additional tool.
  • Components can only be manufactured in a modular fashion by using the roll forming process step. So sine Similar components, which differ, for example, only in their position, can be produced without set-up processes and separate tool sets by cutting to length at the end of the rolling profile system.
  • the modular production leads to a reduction in production costs and to an increase compared to production with a conventional deep-drawing system! economic efficiency.
  • this embodiment is particularly useful for integrated forming devices with smaller forming tools.
  • the integrated device for shaping is laterally displaceably mounted parallel to one another in the plane of the horizontal in a vertical angle relative to the transport direction of the profiling component.
  • the rolling profiling system with integrated forming device it can be controlled in such a way that discontinuous operation is possible.
  • a major advantage of the roll forming plant according to the invention is the discontinuous operation, with which cross-sectional changes in various component areas can be introduced in the elongated, roll-formed components during the profiling process without a change of system.
  • the times of the control depending on the desired component change can be varied and freely selected.
  • a further advantageous embodiment of the roll profiling system according to the invention relates to the fact that the device for forming is a device for beading and / or a device for tensile and / or pressure forming, in particular deep-drawing forming.
  • An advantage of a roll forming system with one or more: integrated devices for beading is that with the device stiffening beads only in the areas de; Rolled profile can be introduced, in which a high rigidity is required.
  • the integrated shaping device has a punch and a hold-down device, and in particular an inner punch.
  • the roll forming system according to the invention with at least one integrated deep-drawing device has proven particularly useful in that, despite the deep-drawing process in the steel material, a material flow which is characteristic of high degrees of deformation during deep-drawing can only be observed to a lesser extent in the component.
  • An advantage of the deep-drawing device is the design of the stamp, which is to be designed in several parts such that the stamps can be quickly moved relative to one another. As a result, impressions with variable geometries can be introduced into the rolled profile.
  • This design of the stamp proves to be particularly economical since it eliminates the set-up times when changing the tool. This increases the output of the plant.
  • the punch is lowered and a hold-down device that prevents creasing creates the desired cross-section in the rolled profile, the rolled profile being positioned on an inner punch.
  • the inner punch has the negative shape of the desired component profile cross section.
  • FIG. 1 Schematic representation of the roll forming process according to the invention.
  • Fig. 2 Schematic representation of a deep-drawing device
  • Fig. 1 shows schematically an exemplary embodiment of the roll forming process according to the invention for rolling profiling 4 and 6 of a starting material.
  • starting material TRIP steels are used as coil 1.
  • the TRIP steels are very strong with increased ductility and are easily deformable by the method according to the invention.
  • the starting material is straightened 2, then marked in a second step 3.
  • the starting material is rolled-profiled in the first part of the roll-forming system 17. It is a uniform, constant over its length rolling profile 14, such as a U-profile, he testifies.
  • the rolling profiling system 17 is preferably stopped for one to two seconds in order to locally deform the rolled profile 14 by deforming the rolled profile 14 in a deep-drawing device 16.
  • the rolled profile 14 is cold-formed by means of deep-drawing that there are local changes in the cross section.
  • the deep-drawing device 16 in Fig. 2 comprises a Ste pe 11, a hold-down 12 and an inner punch 13. Dabe the deep-drawing device 16 is preferably arranged in parallel in the roll forming system 17 along the transport direction 15 ver mobile. The deep-drawing device 16 is shifted in the transport direction 15 of the component to be profiled such that multiple changes in cross-section can be introduced on the same rolled profile 14 with the one deep-drawing device 16.
  • a next process step the further rolling 6 takes place. Then perforate 7 and then trim 8. When trimming 8, unevenness in the component is removed.
  • joining 9 takes place. Spot welds, for example, are possible on the lower surface of the component.
  • cutting is carried out. The component is cut to the desired length.
  • TWIP steels that are highly deformable with increased strength, or BTR steels, or the other thin but very hard sheet metal alloys, such as Usibor steel, or BOR steel, or BORON steel or, for example, ZSTE steel or, for example, stainless steel, such as, for example, stainless steel alloyed with chromium or manganese.
  • a major advantage of the method according to the invention is the reduction of non-productive times, for example the set-up times.
  • the system restart times are shortened, particularly for deep-drawing operations.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Abstract

Lors de la fabrication de composants métallifères par emboutissage profond, la géométrie des composants est limitée en raison du procédé. La présente invention concerne donc un procédé de fabrication de composants métallifères et une installation de profilage (17) permettant le profilage de composants métallifères, en particulier de structures porteuses de véhicules, procédé selon lequel un matériau de base métallifère est acheminé à une installation de profilage (17) puis profilé en un profilé (14) et une déformation plastique (5) a lieu pendant le profilage (4, 6). Selon ladite invention, la modification de la section transversale du profilé par cette déformation plastique (5) est assurée. Une modification de la section transversale est particulièrement importante pour des composants de sécurité et de structure ainsi que pour des structures de montant, des profilés longitudinaux et transversaux, tels que des barres latérales de protection, des pare-chocs, des renforts de montant, des longerons et traverses, des dessous de caisse et des cadres de toit.
PCT/EP2004/009213 2003-08-19 2004-08-13 Procede de fabrication de composants metalliferes et installation de profilage permettant le profilage de composants metalliferes WO2005018845A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE10338014 2003-08-19
DE10338014.0 2003-08-19
DE10342540.3 2003-09-15
DE10342540A DE10342540A1 (de) 2003-08-19 2003-09-15 Verfahren zur Herstellung von metallhaltigen Bauteilen und Walzprofilierungsanlage zum Profilieren von metallhaltigen Bauteilen

Publications (1)

Publication Number Publication Date
WO2005018845A1 true WO2005018845A1 (fr) 2005-03-03

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PCT/EP2004/009213 WO2005018845A1 (fr) 2003-08-19 2004-08-13 Procede de fabrication de composants metalliferes et installation de profilage permettant le profilage de composants metalliferes

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WO (1) WO2005018845A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2047924A3 (fr) * 2007-10-09 2010-11-03 Outimex AG Procédé et dispositif destinés à la fabrication d'une glissière de sécurité
WO2021180854A1 (fr) * 2020-03-13 2021-09-16 Cisma Solutions Aps Solution pour fournir une paroi d'extrémité sur un profilé de garniture métallique

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59101222A (ja) * 1982-11-30 1984-06-11 Matsushita Electric Works Ltd 金属角パイプの製造方法
DE19749902A1 (de) * 1997-11-12 1999-05-20 Schade Gmbh & Co Kg Verfahren zur Herstellung eines Profilstabes aus Metall
DE10120063A1 (de) * 2001-04-24 2002-11-14 Benteler Automobiltechnik Gmbh Verfahren zur Herstellung von metallischen Profilbauteilen für Kraftfahrzeuge
US20030024289A1 (en) * 2001-07-31 2003-02-06 Liu Lausan Chung-Hsin Method of manufacturing loading plane border frame tubes for chairs

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59101222A (ja) * 1982-11-30 1984-06-11 Matsushita Electric Works Ltd 金属角パイプの製造方法
DE19749902A1 (de) * 1997-11-12 1999-05-20 Schade Gmbh & Co Kg Verfahren zur Herstellung eines Profilstabes aus Metall
DE10120063A1 (de) * 2001-04-24 2002-11-14 Benteler Automobiltechnik Gmbh Verfahren zur Herstellung von metallischen Profilbauteilen für Kraftfahrzeuge
US20030024289A1 (en) * 2001-07-31 2003-02-06 Liu Lausan Chung-Hsin Method of manufacturing loading plane border frame tubes for chairs

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 0082, no. 16 (M - 329) 3 October 1984 (1984-10-03) *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2047924A3 (fr) * 2007-10-09 2010-11-03 Outimex AG Procédé et dispositif destinés à la fabrication d'une glissière de sécurité
WO2021180854A1 (fr) * 2020-03-13 2021-09-16 Cisma Solutions Aps Solution pour fournir une paroi d'extrémité sur un profilé de garniture métallique

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