Method for producing a formed component having a dimensionally accurate wall region

Abstract

A method for producing a formed component is disclosed. The method includes: preforming a workpiece to a preformed component having a base region, a wall region, and optionally a flange region, wherein a material quantity adaptation is set in the preformed component; and calibrating the preformed component to a finally formed component, at least in regions, having a base region, a wall region, and optionally a flange region, wherein compressing of the preformed component is performed at least in regions during the calibrating. The method provides a formed component wherein the dimensional accuracy is improved and, in particular, any spreading of the walls of U-shaped components or part-portions can be influenced in a targeted manner, so as to further improve the dimensional accuracy of the formed component. The material quantity adaptation is set by way of a base-specific material quantity adaptation, a wall-specific material quantity adaptation, a radii-specific material quantity adaptation, and/or optionally a flange-specific material quantity adaptation. A formed component made by the method is also disclosed.

Claims

1. A method for producing a formed component, the method comprising the steps of: preforming a workpiece into a preformed component having a base region, a wall region, and a flange region, wherein a material quantity adaptation is set in the preformed component; and calibrating the preformed component, at least in regions, to a finally formed component having the base region, the wall region, and the flange region, wherein compressing of the preformed component is performed at least in regions during the calibrating, wherein the material quantity adaptation is set by way of a material quantity adaptation of the base region, the wall region, a radius region, and/or the flange region, wherein an amount in percent of a material quantity adaptation of the base region is a percentage of a final material quantity of a base region of the component, an amount in percent of a material quantity adaptation of the wall region is a percentage of a final material quantity of a wall region of the component, an amount in percent of a material quantity adaptation of the radius region is a percentage of a final material quantity of a radius region of the component, and an amount in percent of a material quantity adaptation of the flange region is a percentage of a final material quantity of an flange region of the component, and at least two of the amounts selected from the amount of the material quantity adaptation of the base region, the amount of the material quantity adaptation of the wall region, the amount of the material quantity adaptation of the radius region, and the amount of the material quantity adaptation of the flange region differ from one another, wherein the amount of the material quantity adaptation of the base region and the amount of the material quantity adaptation of the wall region are set such that a material flow from the wall region in a direction of the base region and/or a material flow from the base region in a direction of the wall region is performed during the calibrating, and/or wherein the amount of the material quantity adaptation of the wall region and the amount of the material quantity adaptation of the flange region are set such that a material flow from the wall region in a direction of the flange region and/or a material flow from the flange region in a direction of the wall region is performed during the calibrating, and wherein the amounts of at least two material quantity adaptations selected from the group consisting of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region differ from one another by at least 0.2 percentage points.

2. The method as claimed in claim 1, wherein a material quantity adaptation of the base region, the wall region, the radius region, and/or the flange region is a material addition.

3. The method as claimed in claim 1, wherein at least two material quantity adaptations selected from the group consisting of the base-specific material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region are a material addition, and at least one material addition is larger than at least one other material addition.

4. The method as claimed in claim 1, wherein at least one selected from the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region is set in such a manner that a wall opening angle and/or a wall curvature radius of the finally formed component, at least in regions, is influenced in a targeted manner.

5. The method as claimed in claim 1, wherein a difference between the amounts of at least two material quantity adaptations selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region is set so as to be sufficiently large such that any spreading of the wall region of the finally formed component, at least in regions, is substantially avoided.

6. The method as claimed in claim 1, wherein a difference between the amounts of at least two material quantity adaptations selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region is set so as to be sufficiently minor such that any inward folding of the wall region of the finally formed component, at least in regions, is substantially avoided.

7. The method as claimed in claim 1, wherein at least one material quality adaptation selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region is a material addition and is set so as to be sufficiently large such that any spreading of the wall region of the finally formed component, at least in regions, is substantially avoided.

8. The method as claimed in claim 1, wherein the material quantity adaptation of the wall region is a material addition and is set so as to be sufficiently large that any excessive wall curvature of the wall region of the component at least in portions of the finally formed component is substantially avoided.

9. The method as claimed in claim 1, wherein the formed component has a cup-shaped cross section.

10. The method as claimed in claim 1, wherein the formed component is made from one of a steel material and an aluminum material.

11. A formed component having a base region, a wall region, and a flange region, produced by the method as claimed in claim 1.

12. The method as claimed in claim 1, wherein the amounts of at least two material quantity adaptations selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region differ by at least 0.5 percentage points.

13. The method as claimed in claim 1, wherein the amounts of at least two material quantity adaptations selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, the material quantity adaptation of the radius region, and the material quantity adaptation of the flange region differ by at least 2 percentage points.

14. A method for producing a formed component, the method comprising the steps of: preforming a workpiece into a preformed component having a base region and a wall region, wherein a material quantity adaptation is set in the preformed component; and calibrating the preformed component, at least in regions, to a finally formed component having the base region and the wall region, wherein compressing of the preformed component is performed at least in regions during the calibrating, wherein the material quantity adaptation is set by way of a material quantity adaptation of the base region, the wall region, and/or a radius region, an amount in percent of a material quantity adaptation of the base region is a percentage of a final material quantity of a base region of the component, an amount in percent of a material quantity adaptation of the wall region is a percentage of a final material quantity of a wall region of the component, and an amount in percent of a material quantity adaptation of the radius region is a percentage of a final material quantity of a radius region of the component, and at least two of the amounts selected from the amount of the material quantity adaptation of the base region, the amount of the material quantity adaptation of the wall region, and the amount of the material quantity adaptation of the radius region differ from one another, the amount of the material quantity adaptation of the base region and the amount of the material quantity adaptation of the wall region are set such that a material flow from the wall region in a direction of the base region and/or from the base region in a direction of the wall region is performed during the calibrating, and the amounts of at least two material quantity adaptations selected from the group consisting of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, and the material quantity adaptation of the radius region differ from one another by at least 0.2 percentage points.

15. The method as claimed in claim 14, wherein a material quantity adaptation of the base region, the wall region, and/or the radius region is a material addition.

16. The method as claimed in claim 14, wherein at least two material quantity adaptations selected from the group consisting of the base-specific material quantity adaptation of the base region, the material quantity adaptation of the wall region, and the material quantity adaptation of the radius region are a material addition, wherein at least one material addition is larger than at least one other material addition.

17. The method as claimed in claim 14, wherein at least one selected from the material quantity adaptation of the base region, the material quantity adaptation of the wall region, and the material quantity adaptation of the radius region is set in such a manner that a wall opening angle and/or a wall curvature radius of the finally formed component, at least in regions, is influenced in a targeted manner.

18. The method as claimed in claim 14, wherein a difference between the amounts of at least two material quantity adaptations selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, and the material quantity adaptation of the radius region is set so as to be sufficiently large such that any spreading of the wall region of the finally formed component, at least in regions, is substantially avoided.

19. The method as claimed in claim 14, wherein a difference between the amounts of at least two material quantity adaptations selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, and the material quantity adaptation of the radius region is set so as to be sufficiently minor such that any inward folding of the wall region of the finally formed component, at least in regions, is substantially avoided.

20. The method as claimed in claim 14, wherein at least one material quality adaptation selected from the group of the material quantity adaptation of the base region, the material quantity adaptation of the wall region, and the material quantity adaptation of the radius region is set so as to be sufficiently large such that any spreading of the wall region of the finally formed component, at least in regions, is substantially avoided.

21. The method as claimed in claim 14, wherein the material quantity adaptation of the wall region is a material addition and is set so as to be sufficiently large that any excessive wall curvature of the wall region of the component at least in portions of the finally formed component is substantially avoided.

22. The method as claimed in claim 14, wherein the formed component has a cup-shaped cross section.

23. The method as claimed in claim 14, wherein the formed component is made from one of a steel material and an aluminum material.

24. A formed component having a base region and a wall region, produced by the method as claimed in claim 14.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is to be explained in more detail hereunder by means of exemplary embodiments in conjunction with the drawing. In the drawing

(2) FIGS. 1, 2 show in each case schematic cross-sectional illustrations of a wall region and of a base region of a component for visualizing the effects of an exemplary embodiment of the method on the component;

(3) FIG. 3 shows a schematic cross-sectional illustration of a component according to the prior art;

(4) FIG. 4 shows a schematic cross-sectional illustration of a component which has been produced according to an exemplary embodiment of the method according to the invention;

(5) FIG. 5 shows test results for the wall end distance and the wall curvature radius as a function of the base-specific material addition after the calibrating; and

(6) FIG. 6 shows test results for the wall end distance and the wall curvature radius as a function of the wall-specific material addition after the calibrating.

DESCRIPTION OF THE INVENTION

(7) FIGS. 1, 2 show in each case schematic cross-sectional illustrations of a wall region 2, 2′ and of a base region 4, 4′ of a component 1, 1′ for visualizing the effects of an exemplary embodiment of the method on the component 1, 1′.

(8) The component 1 in FIG. 1a has a base-specific material quantity adaptation in the form of a material addition or a compression addition of +2%, and a wall-specific material quantity adaptation in the form of a material addition or compression addition of +3%. On account of the compressing during the calibrating, illustrated by the arrows 6, a material flow is performed from the wall region into the base region, as is visualized by the arrow 8. As has been ascertained by simulations and is illustrated in FIG. 1b, this leads to the wall opening angle, or the mutual distance of the wall ends, respectively, being able to be reduced (arrows 10, 12). On account thereof, CAD-true base radii can be achieved, and an outward spring-back of the wall regions 2 can be counteracted such that the dimensional accuracy can be improved.

(9) The component 1′ in FIG. 2a has a base-specific material quantity adaptation in the form of a material addition or compression addition of +2%, and a wall-specific material quantity adaptation in the form of a material reduction of −2%. On account of the compression during the calibrating, illustrated by the arrows 6′, a material flow is performed from the base region 4′ into the wall region 2′, as is visualized by the arrow 8′. As has been ascertained by simulations and is illustrated in FIG. 2b, this also in this case leads to the wall opening angle, or the mutual distance of the wall ends, respectively, being able to be reduced (arrows 10′, 12′). CAD-true base radii can thus also be achieved here, and an outward spring-back of the wall regions 2′ can be counteracted such that the dimensional accuracy can be improved.

(10) FIG. 3 shows a schematic cross-sectional illustration of a flanged component 30 according to the prior art. The component 30 is produced by conventional deep drawing. The component 30, by virtue of the transition from the base region 34 to the wall region 32, exhibits spreading of the walls. Moreover, the wall region 32 has a residual curvature.

(11) FIG. 4 shows a schematic cross-sectional illustration of a flanged component 40 which has been produced according to an exemplary embodiment of the method according to the invention. A base-specific material addition and a wall-specific material addition herein were distributed in a non-uniform manner. It can be seen that the component 40, as opposed to the component 30, by virtue of the transition from the base region 44 to the wall region 42 does not exhibit any spreading of the walls. Moreover, the wall region 42 does not have any residual curvature.

(12) FIG. 5 shows test results for the wall end distance, respectively the component end distance, and the wall curvature radius as a function of the base-specific material addition (“base addition”) after the calibrating.

(13) The base-specific material additions or compression additions have been implemented in the form of two uniform corrugations from segment arches of a circle having identical radii in the base region.

(14) In FIG. 5, on the left the distance of the wall ends in mm is plotted over the base addition in %. The dashed line herein represents the nominal width of the wall ends. By contrast, on the right the radius of the wall curvature in mm is plotted over the base addition in %. Base additions of 0.5%, 1.0%, 1.5%, and 2.0% were chosen herein. The wall-specific material addition was at all times 3.0%.

(15) FIG. 6 shows test results for the wall end distance and the wall curvature radius as a function of the wall-specific material addition (“wall addition”) after the calibrating.

(16) The wall-specific material additions or compression additions here have been implemented in the form of three uniform, or tangentially consistent, respectively, corrugations from segment arches of a circle having identical radii in the base region.

(17) On the left the distance of the wall ends in mm is plotted over the wall addition in %. The dashed line herein represents the nominal width of the wall ends. By contrast, on the right the radius of the wall curvature in mm is plotted over the wall addition in %. Wall additions of 0%, 0.5%, 1.0%, 1.5%, 2.0%, 2.5%, and 3.0% were chosen herein. The base-specific material addition was at all times 2.0%.

(18) It can be seen that by splitting a general material addition into a base-specific material addition and a wall-specific material addition the wall end distance (or the wall opening angle, respectively) and the wall curvature radius can be set. It can be seen that the wall curvature can be reduced, or the wall curvature radius can be increased, respectively, by increasing the wall-specific material addition, since said wall curvature radius is primarily influenced by the wall-specific material addition (FIG. 6 on the right, as compared to FIG. 5 on the right). The wall-specific material addition can thus be set so as to be sufficiently large such that any excessive wall curvature of the walls of the at least in regions finally formed component can be substantially avoided.

(19) It can moreover be seen that the base-specific and/or wall-specific material addition should be set so as to be sufficiently large such that any spreading of the walls of the at least in regions finally formed component is substantially avoided, however should also be configured so as to be sufficiently minor in order for any inward folding to be substantially avoided (cf. FIG. 5 on the left, FIG. 6 on the left).

(20) The exemplary method and the exemplary device here have been explained in more detail by means of a non-flanged component. Flanged components are subject to an analogous procedure.