WO2010034298A1

WO2010034298A1 - Stamped patterned metal sheet, method and stamping apparatus for producing said metal sheet

Info

Publication number: WO2010034298A1
Application number: PCT/DE2009/001328
Authority: WO
Inventors: Wilfried Rupp
Original assignee: Lti - Metalltechnik Gmbh
Priority date: 2008-09-25
Filing date: 2009-09-25
Publication date: 2010-04-01
Also published as: DE202008017563U1; EP2365887A1; DE102008048991A1; DE102008048991B4

Abstract

The invention proposes a cold-rolled metal sheet (1) having stamped-in tear drop-shaped patterns (2), a method for producing said metal sheet (1), and a stamping apparatus for carrying out the method using a single-stroke tool (9).

Description

EMBOSSED PATTERNED METAL, METHOD AND PUNCHING DEVICE FOR PRODUCING THIS PANEL

State of the art

The invention relates to a tear plate made of metal with a large number of increased tear patterns to improve slip resistance and a method for producing the tear sheet according to the invention and the tool to do so.

In order to achieve a certain slip resistance for walk-in surfaces and to prevent slipping on these surfaces, these are covered with metal plates. These panels have embossed patterns and are used for example in factories, at entrances to machines, in house entrances, in buses, on deck of ships, at entrances and exits of escalators, etc.

From DE 2014467 a method for rolling and punching is known from objects with large-scale continuous Waffelmustern. Usually these metal plates are approximately between 1 - 4 mm thick. The patterns arranged thereon are usually formed in a hot rolling process with forming rolls.

Hot rolling must take place at very high temperatures before the metal plate to be processed has cooled down. This hot rolling is done in a rolling mill, the rolling machine is very expensive and the rolling process is complicated. The resulting sheets are often faulty, which leads to complaints and costly bug fixes.

In addition, a scale layer is produced in the hot rolling process, as a result of which the rolled tear sheets must subsequently be pickled, which additionally increases the costs. Therefore, it offers advantages not to produce the sheets by means of a hot rolling process, but to use standardized cold-rolled sheets (stock items).

Punching is a forming process with shape-related design. For this purpose, punching machines are used which have a punch head with a tool holder for a punch and an opposite tool holder for a die. The workpiece is moved via a controlled displacement device in the desired position under the punch. In such forming process is the final contour of the deformed area by the geometry of the tool pair, d. H. of stamp and die, set. The generation of the final contour takes place by a controlled movement between the workpiece and the tool.

In the production of machine linings and running plates made of rolled tear sheets according to DIN 59220 after the above As a rule, the tears are precisely defined in terms of their design, ie the start of tears beginning at the bottom, left or right must be observed exactly.

In order to produce a cold-punched tear plate with the requirements placed on this, in the production process according to the prior art, numerous process steps in succession are necessary. Also in the post-processing of these serially produced sheets are many individual operations in z.T. manual labor necessary to achieve the desired properties. In the workflows gem. the prior art, no individual embodiments of the sheets are possible.

The invention and its advantages

The invention according to the features of the main claim, however, has the advantage that by the manufacturing process of non-slip sheets with patterns by punching an individual design of the sheets is possible and numerous steps are saved. In this case, a standard sheet format, in particular a cold-rolled sheet, placed on a CNC sheet metal machine. Each pattern which is to be introduced into this standard sheet, ie, for example, every tear, is stamped by means of the single stroke tool according to the invention. This process is done by lowering the tool. If necessary, tears are omitted if, for example, instead of a hole is to be introduced at this point. On a tread for machines, where, for example, a thread for a hinge to be arranged, holes can be introduced instead of the tears pattern at this point. In contrast to Design of standard sheets can be omitted in the inventive production tears, for example in the bending region of the sheet. For this, the arrangement of the tears is calculated in advance, these are punched in the flat and then bent the sheet. Thus, a design example of a tread of a single sheet is possible as a complete piece in one piece. If, in addition, a panel is to be integrated in a step which has no tear, it is produced from a single sheet.

The bending process according to the prior art is problematic because it is difficult due to the different position of the tears and the bending dies are heavily worn by the existing tears and the different sheet thickness. Therefore, additional bending edges are often not possible with standard metal sheets with tears distributed uniformly throughout.

The individual calculation and inventive positioning of each tear their position can be adapted to the contours of the sheet to be punched, so their pointed ends are positioned, for example, flush with the bending edge. As a result, a particularly advantageous optical configuration is achieved and the bending process is facilitated since no tears are arranged in the bending area and no tears are likewise arranged on the edge of a tread, for example, but the edge is visually discontinuous. Alternatively, a tear can also be applied directly in parallel on the bending edge or any other deformation can be made in order to achieve greater safety against slipping on the tread. Usually, the cutting of the metal sheet according to the prior art with the cutting shear takes place longitudinally and transversely due to the restrictive specifications of the properties of the sheets. To machine the plate with a CNC punching or laser machine, the first line of tears must be determined and their position determined. The problem arises that the distances of the tears from batch to batch vary and the distance of the first tear to the long side has a high tolerance. This means that each sheet has to be measured separately. Thus, the machining with the CNC machine is from the outset errory.

According to the invention, this process of cutting is performed unmanned in the first operation, the above-mentioned source of error being determined by the positioning of the tears entered into the machining program. excreted in the manufacturing process according to the prior art.

Then holes are usually drilled or punched and often introduced counterbores on a drill press. According to the invention, these steps also take place unmanned in the first operation. The sinkings or holes and the tears are introduced simultaneously in one operation in the sheet. According to an advantageous embodiment of the invention, no tear is introduced in the region of the subsidence.

According to the state of the art, for blanks with corner radii, the blank must be inserted twice on eccentric presses in order to punch out the contour once and raise the corners once more. According to an advantageous embodiment of the invention, this process also takes place in the first Operation, which can be dispensed with the vertices, since no tears are desired in the Umkantungen and therefore they are not stamped in this area. This results in a high degree of design freedom and opens up numerous individual design options for arranging tears, flat countersinks, drill holes, punched holes, etc.

According to an advantageous embodiment of the invention also round warts or patterns of any other geometric design form can be introduced with forming tools in the sheet. The arrangement of the round warts, for example, take place directly on a tread to meet the high safety requirements to avoid slipping.

According to a further advantageous embodiment of the invention, the part number for the sheet is inserted with a number embossing tool already in the first step. Thus, no separate operation is necessary and the corresponding part number is already stored in the CNC program. This avoids faulty insertion of the number by manual attachment of the part number by means of welding or as a separate number plate on the underside of the tear plate according to the prior art.

According to the state of the art, cold-rolled flat iron, which are provided with threads, are separately processed and subsequently welded on many sheets. The flat iron is usually cut to size, deburred, drilled several times, lowered on both sides, the thread cut and welded to the footplate. These numerous Workflows are shortened according to an advantageous embodiment of the invention to a process step by the flat iron are integrated into the metal plate, so sheet and flat iron consist of a coherent piece, the sheet is pre-punched and lowered on the CNC machine and at the same time the thread is rolled. Subsequently, the bend is performed.

According to this advantageous embodiment of the invention, teardrop sheets according to the invention are not made of numerous individual parts, the gem in labor-intensive welding processes. The prior art must be connected to each other, but there are inventively additional bends planned in the base plate.

According to an additional embodiment of the invention, the material thickness of the sheets is reduced. In order not to have to accept losses with respect to the rigidity of the sheets, this is inventively achieved with additional Biegekantungen, through which the visual impression is improved and the part price is reduced. Due to the associated weight savings, the individual parts are lighter and therefore easier to handle. In addition, the transport costs are reduced.

An advantage of this manufacturing method described is that the sheets according to the invention can be designed in a few operations from commercially available sheet metal formats and therefore the supply chain can be greatly reduced or limited, while up to 24 blanks of the sheets were necessary. This also reduces the high production costs involved in the processing of the sheets. There are individual embodiments of the sheets according to the invention possible because it can be selected by program control, which position in which form is introduced. Sheets can can be easily redesigned, in which numerous forming tools can be used because the shape is easily interchangeable by minor use of tools. Therefore, the sheets according to the invention with the cold-punched anti-slip structure are far better suited for further processing. The individual arrangement or the omission of patterns, so for example tears, creates an optical steering function for the human eye. In all embodiments, it is possible to use standardized bearing plates and not rely on expensive special shapes that have long delivery times and their purchase prices are higher by a high percentage than the standard sheets.

In summary, although the use of the Einzelhubwerkzeugs more time is needed, but advantageously this is again saved by numerous work steps take place in a single operation at the same time for punching the pattern and no longer have to be done one behind the other. In addition, the sheets can be better edited by eliminating tears in the bending area, so bend, are individually customizable and it arises, for example, in the execution of the metal sheet as a staircase optical paragraph. By means of standardized universal tools is in the cold-rolled

Standard sheet format the desired contour, thread, flat countersinks, countersinks, holes, punching, marking the part number, labels and the desired teardrop design introduced.

Further advantages and advantageous embodiments of the invention are the following description, the drawings and claims removed. drawings

Fig. Ia shows a tear plate according to the prior art in the plan view obliquely from above.

Fig. Ib shows a tear plate according to the invention obliquely from above.

Fig. Ic shows a tear plate gem. the prior art with a welded thread flat iron from the side

Fig. Id shows a tear sheet metal bent according to the invention with a portion formed from this sheet metal and provided with a thread.

In Fig. 2a, a schematic drawing of a Einzelhubwerkzeugs for forming the tear is shown by means of the punching machine.

In Fig. 2b, a sheet metal according to the prior art is shown.

FIG. 2c shows the tear pattern produced by means of the single stroke tool.

Fig. 3a shows a flattening tool with a punch.

FIG. 3b shows the sheet processed with the countersink tool with the counterbores.

FIG. 4 shows a sheet metal processed according to the invention with tear patterns and flat depressions In Fig. 5 the thread forming tool for use in cold rolled sheets is shown in detail.

Fig. 6 shows the vote of the individual to be introduced by the thread forming diameter for a threaded hole.

Fig. 7a shows a stamp with different symbols for punching part numbers and labels for the Einzelhubwerkzeug.

Fig. 7b shows the sheet with the applied labels.

Description of the embodiments

Fig. Ia shows the hot-rolled sheet 101 according to the prior art with the trough applied by hot rolling tears 102. In this case, holes are usually introduced manually with a countersink, which can hit by the standardized arrangement of tears directly on a tear or cut these. Thus, this reduction is feasible with the hand drill. In bending processes, the tears hurt each other, for example, in the edge or corner area when cutting out the contour.

1 b shows the cold-rolled sheet 1 according to the invention, which is provided with patterns 2, which are designed here as teardrop-shaped patterns, to increase slip resistance, as well as an edge 3 with a bending region 4, in which no patterns are introduced. Some positions on the plate 1 are not with the provided teardrop-shaped patterns 2, but instead there are flat depressions 5 are arranged with through holes 6.

In Fig. Ic is a hot-rolled sheet 101 gem. the prior art with a welded in a separate operation flat iron 7a with threads 8 shown.

Fig. Id shows the arrangement of a mounting bracket 7b with threads 8 on the plate 1 with the bending region 4 and the edge 3, which were integrated according to the invention in the metal plate, so were formed from a single sheet metal plate, pre-punched and lowered on CNC machines, a Thread was rolled and then bent and the area with a stiffened angle. In the dashed area no tear patterns are introduced.

In Fig. 2a, a Einzelhubwerkzeug 9 is shown with a punch 10 with the negative mold 11. In this case, the punch top view 12, the sheet 1 to be processed and the die 13 with the positive mold 14 are shown. The stamping die 11, 14 can be configured as tear, round wart or in any conceivable geometric shape.

In Fig. 2b is a sheet 101 gem. the prior art with teardrop patterns 102 shown. It becomes clear that the tears generated by hot rolling can be cut by standardized arrangement everywhere.

Fig. 2c shows a section of a sheet 1 according to the invention with the means of the tool 9 of Fig. 2a individually positioned tears 2, which can be arranged adapted by individual positioning of the edge shape of the sheet or certain positions for the introduction of, for example, bends, countersinks, holes or threads can be omitted.

Fig. 3a shows the punch 15 of a flat-lowering tool 16 from below and from the side, and the sheet 1 with the sinking depth 17 and the die 18th

In Fig. 3b, the sheet 1 with flat depressions 19 and the through hole 20 is shown.

4 shows a sheet 1 with the tear patterns 2 applied according to the invention by means of the tool from FIG. 2 a and the flat counterbores 19 applied by means of the tool from FIG. 3 a.

Fig. 5 shows in detail the thread forming tool 21 with the die 22, the spindle nut 23, the thread former 24, the lead screw 25 and the tool housing 26 with screwed anti-rotation. This thread forming tool 21 is used from above for machining the not yet bent sheets 1. This allows a direct thread forming, without having to edit other parts, which are then welded to the plate 1 or attached in some other way

The thread forming takes place in the sequence: pre-punching - sinking - re-punching - thread forming. Different thread sizes are possible. These depend on the sheet thickness 30 and the thread former used.

In Fig. 6, the sheet 1 with the threaded outer diameter 27, the pre-punch diameter 28, the core diameter 29 and the Material thickness 30 of the sheet 1 and the arrangement of the lead screw 25 shown for a threaded hole.

In Fig. 7a, an embossing head 31 is shown for embossing of labels and part numbers by means of this embossing tool, which consists of a rotatable member 32 with individual stamped with symbols 33 stamps. The embossing head 31 is like the thread forming tool 21 from above for introducing the desired numbers or letters used with the advantage that the sheet 1 is processed directly with it and not separate parts, which must then be welded to the plate.

Fig. 7b shows a sheet 1 with the number and letter set 34, which was impressed by means of the embossing head 31. All letters of the Latin alphabet and Arabic numerals can be imprinted.

All in the description, the following claims and the drawings illustrated features may be essential to the invention both individually and in any combination.

LIST OF REFERENCE NUMBERS

1 cold-rolled sheet

2 patterns

3 edge

4 bending area

5 flat sinking

6 through hole

7a flat iron

7b mounting bracket

7 threads

8 single stroke tool

9 stamps

10 negative form

1 1 stamping top view

12 matrix

13 positive form

14 punches

15 Flat countersinking tool

16 lowering depth

17 matrix

18 Flat lowering

19 through hole

20 thread forming tool

21 matrix

22 spindle nut

23 taps

24 leadscrew

25 tool housing

26 thread outside diameter

27 Punch diameter core diameter

material thickness

Embossing head rotatable part

stamp

Set of letters

hot rolled sheet hot rolled tear

Claims

claims

A sheet metal (1) for increasing the skid resistance with patterns (2), which are arranged following an arrangement instruction inputted into a CNC sheet metal working machine, each by means of a punching operation with a single stroke tool (9).

2. Sheet (1) according to claim 1, characterized in that by means of standardized universal tools (16, 21, 31) at least one point instead of the pattern (2) has a thread (8), a countersink (19), a countersink, a Bore and / or part numbers are arranged.

3. sheet (1) according to any one of the preceding claims, characterized in that in the bending region (4) of the sheet (1) no pattern (2) are arranged.

4. sheet (1) according to any one of the preceding claims, characterized in that the pattern (2) teardrop, in particular according to DIN 59220, are configured.

5. sheet (1) according to claim 4, characterized in that instead of the teardrop-shaped pattern (2) round warts, square warts and / or polygonal shapes by means of a forming tool on the plate (1) are arranged.

6. Sheet (1) according to one of the preceding claims, characterized in that a mounting bracket (7b) is integrated in the metal plate.

7. Sheet (1) according to one of the preceding claims, characterized in that a stiffening angle is integrated into the metal plate.

8. A method for producing sheets (1) according to claim 1, wherein a cold-rolled standard sheet format is placed on a CNC sheet metal working machine, the pattern (2) by means of at least one Einzelhubwerkzeugs (9) is stamped and simultaneously in place of the pattern (2) a controlled by the program control of the CNC sheet metal machine position other patterns, thread (8), flat countersinks (5), countersinks, punches, labels or part numbers are arranged and the sheet is then cut to the exact board dimension.

9. The method according to claim 8, characterized in that in the sheet metal mounting bracket (7a) are integrated without pattern, the sheet (1) on the CNC sheet metal working machine is pre-punched and lowered and at the same time the thread (8) is cut.

10. The method according to claim 9, characterized in that subsequently the bending of the sheet (1).

11. Einzelhubwerkzeug (9) for performing the method according to claim 8 with a punch (10) having a negative mold (11), in particular teardrop isr, with a die (13) on which a positive mold (14) is in particular teardrop-shaped, is arranged.

12. Einzelhubwerkzeug (9) for performing the method according to claim 8, according to claim 11, as a thread forming tool (21) having a die (22), a spindle nut (23), a thread former (24), a lead screw (25) and a tool housing (26) with screwed-on anti-twist device.

13. Einzelhubwerkzeug (9) according to claim 11 or 12, characterized in that instead of the punch (10) for the teardrop pattern (2) a punch (15) is arranged.