Classifications

• • 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
  • B21K25/00—Uniting components to form integral members, e.g. turbine wheels and shafts, caulks with inserts, with or without shaping of the components
• • 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
  • B21J5/002—Hybrid process, e.g. forging following casting
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21B—MANUFACTURE OF IRON OR STEEL
  • C21B3/00—General features in the manufacture of pig-iron
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B1/00—Preliminary treatment of ores or scrap

Definitions

• the present invention relates to a method of manufacturing a part made at least partially of a metal alloy.
• the invention also relates to a method for optimizing a part.
• the field of the invention is that of the manufacture of parts made entirely or partially of a metal alloy (ferrous or non-ferrous), said manufacture including two successive operations of foundry and forging.
• EP0586314 describes the positioning of inserts in a foundry preform, then the striking of the preform to obtain the final piece.
• the inserts are fixedly and permanently integrated by deformation of the material, thus defining local reinforcement zones.
• the inserts are formed separately and then attached to the body of the part constituted by the preform, which the present invention aims to avoid.
• the weight goals of the structures are constantly decreasing, with an increase in their demands and a cost objective compatible with the market. These constraints lead today in most cases to a compromise in terms of choice of materials, process, weight and costs. For example, if a particular area of the part is subjected to high stresses, the material of this piece overall will be driven by this area and induce high costs related to the choice of this material.
• the object of the present invention is to provide an improved manufacturing method.
• the subject of the invention is a method for manufacturing a part made at least partially of a metal alloy, the method comprising a metallurgical manufacturing step a1) consisting of manufacturing the body of the part, characterized in that the method then comprises a reinforcing step a2) of forming a local reinforcement on the body, in a stress zone of the workpiece.
• the invention makes it possible to locally improve the mechanical characteristics of the part, for example its resistance to fatigue or its hardness, while keeping the mass of the reinforced part as small as possible and without using an insert.
• the invention can reduce locally a section of the room, and thus gain space.
• the invention may make it possible to improve the overall performance of the part, for example its stiffness.
• the metallurgical manufacturing step a1) comprises a foundry operation a1 1) of making a foundry preform, then a forging operation a12) of forging the foundry preform to obtain the body of the room.
• This metallurgical manufacturing step a1) corresponds to the implementation of the COBAPRESS process.
• the metallurgical manufacturing step a1) comprises a foundry operation a1 1) of manufacturing the body of the part.
• This foundry operation a1 1) is not followed by a forging operation a12).
• the metallurgical manufacturing step a1) comprises a forging operation a12) of manufacturing the body of the part. This forging operation at 12) is not preceded by a foundry operation a1 1).
• the invention also relates to a method for optimizing the design of an existing part, comprising a metal alloy body, the optimization method comprising the following successive phases:
• the part is a structural part for automobile (including a pivot type ground connection piece, steering arm, suspension arm, a cradle-type structural part ”), aeronautic, industrial equipment or medical device.
• the local reinforcement has a surface at least 50% in contact with the body of the workpiece.
• the local reinforcement substantially marries the body of the room.
• the method comprises a step of surface preparation of the zone to be reinforced, between the metallurgical manufacturing step a1) and the reinforcing step a2).
• the method comprises a step of finishing the part in the reinforced zone, after the reinforcing step a2).
• the method comprises a surface treatment step, applied at least on one part of the body, between steps a1) and a2).
• the method comprises a surface treatment step, applied at least on part of the part, after step a2).
• the body and local reinforcement consist of different metal alloys.
• the body is made of a metal alloy, while the local reinforcement consists of a composite material.
• the body is made of a metal alloy, while the local reinforcement is made of a ceramic material.
• Local reinforcement is formed by cold spraying.
• Local reinforcement is formed by micro-arc oxidation.
• the local reinforcement is formed by bonding a composite assembly taking its final shape on the body of the room.
• Local reinforcement is formed by baking a resin.
• Local reinforcement is formed by additive manufacturing.
• the local reinforcement is substituted for an original portion of the body of the existing room.
• the local reinforcement is substituted for an insert fitted, overmolded or pressed on the body of the existing part.
• the optimized part has substantially the same dimensions as the existing part.
• the optimized part has locally reduced dimensions compared to the existing part.
• Figure 1 is a top view of a piece according to the state of the art, comprising a metal alloy body, manufactured in a foundry operation and a forging operation;
• Figure 2 is a side view of the part of Figure 1;
• Figures 3 and 4 are views similar to Figures 1 and 2, illustrating a method of optimizing the design of the part;
• Figures 5 and 6 are views similar to Figures 1 and 2, showing an optimized part according to the invention, comprising local reinforcements formed on the body in stressed areas;
• Figure 7 is a section along the line VII-VII in Figure 6;
• Figures 8 to 12 are views similar to Figures 3 to 7, showing a second embodiment of an optimized part according to the invention.
• Figures 1 to 4 is shown a part 10, comprising a one-piece body 1 1 and a tubular insert 18 fitted into the body January 1.
• the part 10 is a ground connection part of a motor vehicle.
• the body 1 1 is made of metal alloy, for example aluminum alloy, following two successive operations of foundry and forging.
• the body 1 1 comprises a main portion 12, an end portion 13, and an elongated portion 14 connecting the portions 12 and 13.
• Two openings 15 and 16 through are formed in the portion 12.
• the opening 15 has a section substantially rectangular, while the opening 16 has a circular section.
• the insert 18 is made of metal alloy, for example steel, then fitted, overmolded or pressed (in particular by COBAPRESS) in the opening 16 formed in the body January 1.
• the insert 18 provides different functions between the body 1 1 and a not shown element disposed through the opening 16: thermal bonding, friction resistance, lubrication, etc.
• FIGS. 3 and 4 are highlighted stress zones Z4, Z5 and Z6 of the part 10, respectively corresponding to elements 14, 15 and 16.
• a stress zone of the part 10 is defined as being an area subjected to significant mechanical, thermal, friction and / or abrasion stresses when the part 10 is in use. These constraints are said to be important, insofar as they require particular attention to preserve the integrity of the part in operation, because of its environment (mechanical system to which the part is integrated, external factors, etc.).
• the mechanical stresses can be caused by bending, torsion, traction and / or compression forces experienced by this zone;
• the thermal stresses can be caused by a local temperature increase, permanent or temporary, suffered by this zone;
• Frictional stresses can be caused by an electric cable that extends along the room and is likely to rub against the surface of the room in this area;
• the abrasion stresses may be caused by a projection of materials from the ground on which the car equipped with the workpiece travels in this area.
• zones Z4, Z5 and Z6 of the part 10 are not subjected to the same constraints in service.
• zone Z4 we try to lighten part 14, made of metal alloy, without reducing its mechanical performance.
• an outer portion 140 of this portion 14 may be replaced by a composite material.
• zone Z5 it is sought to improve the resistance of the part 10 at the opening 15, without modifying the material constituting the body 1 1.
• a portion 150 located around the opening 15 can be replaced by a metal alloy stronger than that of the body 1 1.
• the steel insert 18 can be replaced by a coating formed in the opening 16 , by cold spraying a powder comprising metal particles (alloys of aluminum, copper, cobalt, nickel, molybdenum, aluminum quasi-crystals AI-QC ).
• FIGS. 1 to 4 a part 20 according to the invention.
• the part 20 is an optimized version of the part 10 shown in FIGS. 1 to 4.
• the part 20 has a function and dimensions similar to the part 10.
• part 20 Some components of the part 20 are comparable to those of the part 10 described above and, for the sake of simplification, bear the same reference numerals. Other elements constituting the piece 20 have differences with the piece 10 and have numerical references increased by ten.
• the part 20 comprises a body 21, as well as various local reinforcements 40,
• these zones Z4, Z5 and Z6 are not subjected to the same constraints in service. Under these conditions, the choice of the constituent materials of the body 21 and local reinforcements 40, 50 and 60 is a compromise in terms of performance, weight and costs.
• the body 21 is made of metal alloy, for example aluminum alloy, following two successive operations of foundry and forging.
• the body 21 comprises a main portion 22, an end portion 13, and an elongated portion 24 connecting the portions 22 and 13. Two openings 15 and 16 through are formed in the portion 22.
• the body 21 comprises an elongated portion 24 provided with a local reinforcement 40.
• the portion 24 is made of metal alloy, while the reinforcement 40 is made of composite material.
• the reinforcement 40 is formed by sheets of carbon, glass or thermoplastic fibers (in particular poly (p-phenyleneterephthalamide, known under the trademark Kevlar), pre-coated with resin, having a quasi-finished state. is in the form of an element composite bonded to the body 21 and taking its final form directly on the body 21.
• the reinforcement 40 is substituted for the portion 140 of the body January 1, so that the parts 14 and 24 have substantially the same dimensions.
• the reinforcement 40 makes it possible to lighten the piece 20 in zone Z4, without reducing its mechanical performance.
• zone Z5 a reinforcement 50 is substituted for the portion 150 of the body 11.
• the opening 15 is formed through this reinforcement 50, in the part 22.
• the opening 15 has the same dimensions for the parts 10 and 20.
• the reinforcement 50 is made of metal alloy stronger than that of the body 1 1, by example by cold spraying.
• the resistance of the part 20 is improved at the opening 15 relative to the part 10, without modifying the material of the body 21 relative to the body January 1.
• the insert 18 is replaced by a coating 60 formed by cold spraying in the opening 16.
• the coating 60 makes it possible to lighten the part 22 of the part 20, without diminishing its performances at the level of the opening 16.
• the body 21 constitutes the bulk of the volume of the part, in comparison with the reinforcements 40, 50 and 60.
• FIGS. 8 and 9 show a variant of the part 10 of FIGS. 3 and 4.
• the stressed zones Z4 and Z6 of the part 10, respectively corresponding to the elements 14 and 16, are highlighted.
• Z4 two portions 141 and 142 external part 14 may be replaced by a composite material.
• zone Z6 the steel insert 18 can be replaced by a cold-spray coating in the opening 16.
• FIGS. 8 and 9 a part 30 according to the invention.
• the part 30 is an optimized version of the part 10 shown in FIGS. 8 and 9.
• the part 30 has a function and dimensions similar to the part 10.
• part 30 Some components of the part 30 are comparable to those of the part 10 described above and, for the sake of simplification, bear the same reference numerals. Other elements constituting the piece 30 differ from the piece 10 and have numerical references increased by ten.
• the part 30 comprises a body 31, as well as various local reinforcements 41, 42 and 60 formed directly on the body 31.
• the body 31 is made of metal alloy, for example aluminum alloy, following two successive operations of foundry and forging.
• the body 31 comprises a main portion 12, an end portion 13, and an elongated portion 34 connecting the portions 32 and 13. Two openings 15 and 16 through are formed in the portion 12.
• the body 31 comprises an elongated portion 34 provided with two local reinforcements 41 and 42.
• the portion 34 is made of metal alloy, while the reinforcements 41 and 42 are made of composite material.
• the reinforcements 41 and 42 are respectively substituted for the portions 141 and 142 of the body January 1, so that the parts 14 and 34 have substantially the same dimensions.
• the reinforcements 41 and 42 make it possible to lighten the piece 30 in zone Z4, without reducing its mechanical performance.
• the insert 18 is replaced by the coating 60 formed by cold spraying in the opening 16.
• the coating 60 makes it possible to lighten the part 22 of the part 20, without diminishing its performances at the level of the opening 16.
• each of the reinforcements 40/41/42/50/60 has a surface entirely disposed in contact with the body 21/31.
• the surface of the reinforcement in contact with the body can be disposed at least 50% in contact with the body (and up to 100%).
• the surface of the reinforcement is disposed at least 90% in contact with the body.
• the part 20/30 consists at least partially of a metal alloy and comprises:
• the body 21/31 constitutes the bulk of the volume of the part 20/30, in comparison with the reinforcements.
• the body 21/31 is likely to constitute a functional piece alone, while the reinforcements can locally improve the characteristics of this piece.
• Each reinforcement has a volume less than 20% of the volume of the body 21/31, preferably less than 10%.
• the local reinforcement can be formed by cold spraying, micro-arc oxidation, additive manufacturing, baking of a resin in a mold, bonding of a composite assembly (which takes its final form on the body of the piece when the glue dries), or any other suitable technique.
• the invention excludes the reinforcing parts attached to the body, for example by welding, screwing or pressing.
• the invention also excludes reinforcement pieces incorporated into the body by overmolding.
• the invention also relates to a method of manufacturing a part 20/30 made at least partially of a metal alloy.
• the method comprises the following successive steps a1) and a2):
• the step a1) comprises a foundry operation then a forging operation, in accordance with the COBAPRESS process.
• step a1) comprises only a foundry operation.
• step a1) comprises only a foundry operation.
• the method may comprise a step of surface preparation of the area to be reinforced, between steps a1) and a2), depending on the technique used in step a2).
• this surface preparation step can comprise a brushing, a degreasing, a shot blasting, a machining or a deposit.
• the deposit may consist in applying an adhesive to the body 21/31 of the part 20/30.
• the method may also include a step of finishing the workpiece 20/30 in the reinforced zone, after step a2).
• this finishing step may include machining, polishing or surface treatment.
• the method may also include a surface treatment step. This surface treatment may be applied at least on a part of the body 21/31 between steps a1) and a2), or at least part of the part after step a2).
• the invention also relates to a method of optimizing the design of an existing part 10, comprising a body 1 1 metal alloy. Initially, this body 1 1 is for example manufactured according to a foundry operation and / or a forging operation.
• the optimization method comprises the following successive phases b1, b2, b3, b4 and b5:
• an optimized part 20/30 comprising a body 21/31 modified, providing at least one local reinforcement 40, 41, 42, 50 and / or 60 formed on the body
• b3) Define tools of metallurgical manufacture (generally foundry and / or forging) to manufacture the body 21/31 of the optimized part 20 / 30.
• the manufacturing tools of the body 21/31 of the part 20/31 are different from the tools manufacturing body 1 1 of the original part 10.
• the foundry shells and forging dies used to fabricate the body 11 may simply be modified to allow the body to be made 21/31.
• b4) Fabricate the body 21/31 of the optimized part 20/30 with the tools.
• This phase may include a foundry operation and then a forging operation, in accordance with the implementation of the COBAPRESS process. Alternatively, this phase may only include a foundry operation.
• the part 20/30 can be adapted in terms of costs, features and performance.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Manufacturing & Machinery (AREA)
• Life Sciences & Earth Sciences (AREA)
• Environmental & Geological Engineering (AREA)
• General Life Sciences & Earth Sciences (AREA)
• Geochemistry & Mineralogy (AREA)
• Geology (AREA)
• Forging (AREA)
• Other Surface Treatments For Metallic Materials (AREA)
• Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Priority Applications (9)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Cited By (1)

Citations (7)

Family Cites Families (18)

• 2016
  • 2016-05-27 FR FR1654775A patent/FR3051697B1/fr active Active
• 2017
  • 2017-05-29 US US16/303,029 patent/US20190283115A1/en not_active Abandoned
  • 2017-05-29 RU RU2018141203A patent/RU2737367C2/ru active
  • 2017-05-29 KR KR1020187034212A patent/KR20190010574A/ko not_active Application Discontinuation
  • 2017-05-29 MA MA045156A patent/MA45156A/fr unknown
  • 2017-05-29 WO PCT/FR2017/051319 patent/WO2017203190A1/fr unknown
  • 2017-05-29 EP EP17731620.5A patent/EP3463713A1/fr not_active Withdrawn
  • 2017-05-29 CA CA3025976A patent/CA3025976A1/fr not_active Abandoned
  • 2017-05-29 MX MX2018014564A patent/MX2018014564A/es unknown
  • 2017-05-29 JP JP2018561969A patent/JP2019517389A/ja active Pending
  • 2017-05-29 BR BR112018074327-5A patent/BR112018074327A2/pt not_active Application Discontinuation
  • 2017-05-29 CN CN201780032248.8A patent/CN109311078B/zh not_active Expired - Fee Related

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