METHOD AND DEVICE FOR PRODUCING SHAPED SHEET-METAL COMPONENTS BY MEANS OF PREFORMED COMPONENTS

Abstract

A method for producing a component in which a workpiece is preformed to form a preformed component and a finally shaped component is produced from the preformed component. The preformed component is formed into a singly or multiply offset finally shaped component by a forming process. The invention furthermore relates to a device with a forming tool. The forming tool is designed as a multi-part forming tool in which each part of the multi-part forming tool includes at least one punch and one die. The forming tool is designed to produce a singly or multiply offset finally shaped component by shaping from the preformed component.

Claims

1. A method for producing a component, in particular a structural component of a vehicle, comprising the method steps: preforming a workpiece into a preformed component, and producing a finally shaped component from the preformed component, wherein the preformed component is converted into a singly or multiply offset finally shaped component or into a singly or multiply offset finally shaped, highly dimensionally accurate component by a forming, in particular in at least one method step.

2. The method according to claim 1, wherein a finally shaped component is first produced from the preformed component by shaping and then the finally shaped, highly dimensionally accurate component is produced from the finally shaped component by calibration.

3. The method according to claim 1, wherein the forming and calibration for producing the finally shaped, highly dimensionally accurate component are carried out in a common method step.

4. The method according to claim 1, wherein the preformed, the finally shaped and/or finally shaped, highly dimensionally accurate component is a substantially elongated component, in particular a component elongated in the longitudinal direction by a factor of >1, in particular at least by a factor of 3, preferably at least by a factor of 5, compared to the transverse direction.

5. The method according to claim 1, wherein the preformed, the finally shaped and/or the finally shaped, highly dimensionally accurate component is a half shell-shaped component, in particular a component U-shaped or hat-shaped in cross section.

6. The method according to claim 1, wherein the preformed component is formed into a Z-shaped or U-shaped finally formed or finally formed, highly dimensionally accurate component.

7. The method according to claim 1, wherein different regions of the preformed component are shaped and/or calibrated in a time-delayed manner into the finally shaped or finally shaped, highly dimensionally accurate component.

8. The method according to claim 6, wherein the finally shaped or finally shaped, highly dimensionally accurate component comprises at least one offset middle region with two adjacent edge regions, wherein preferably during the forming of the preformed component into the finally shaped or finally shaped, highly dimensionally accurate component the edge regions are aligned and / or remain substantially parallel and the longitudinal axis of the middle region is angled with respect to the longitudinal axis of the edge regions, in particular by 10 to 120, preferably 30 to 90.

9. The method according to claim 1, wherein a multi-part forming tool is used, wherein the middle region of the preformed component is formed into a final shape after at least one edge region of the preformed component has been formed into a final shape, or wherein the middle region of the preformed component is formed and calibrated into a finally shaped, highly dimensionally accurate shape after at least one edge region of the preformed component has been formed and calibrated into a finally shaped, highly dimensionally accurate shape.

10. The method according to claim 1, wherein the preformed component is placed in dies, which are arranged inclined to the direction of displacement of the punches or dies used for the forming.

11. The method according to claim 1, wherein the preformed component is first clamped between at least one edge die and the associated at least one edge punch, wherein the clamping force is so high that the preformed component essentially cannot slip.

12. A device, in particular for carrying out a method according to claim 1, comprising a forming tool, wherein the forming tool is designed as a multi-part forming tool, wherein each part of the multi-part forming tool comprises at least one punch and a die, wherein the forming tool is arranged to produce a singly or multiply offset finally shaped component by shaping from the preformed component, or is arranged to produce a singly or multiply offset finally shaped, highly dimensionally accurate component by forming and calibrating from the preformed component.

13. The device according to claim 12, wherein the forming tool has at least one middle tool part with two adjacent edge tool parts, wherein the at least one middle tool part comprises at least one central punch and at least one central die and at least one of the edge tool parts has an edge punch and an edge die.

14. The device according to claim 13, wherein the at least one edge die of at least one of the edge tool parts is a height-adjustable edge die and wherein the edge dies, in particular the non-height-adjustable edge dies, optionally comprise an inner hold-down device.

15. The device according to claim 13, wherein the at least one edge punch of at least one of the edge tool parts is movably mounted with respect to the other punches, and is preferably mounted in a force-acting manner by at least one hydraulic adjusting means.

16. The device according to claim 12, wherein the device and/or the forming tool is in an inclined position with respect to the direction of displacement.

17. The device according to claim 12, wherein the forming tool has a forming edge die with a calibration function, in particular a height-adjustable forming edge die with a calibration function, optionally with an inner hold-down device.

18. The device according to claim 12, wherein the forming tool has means for blocking the flow of material over the edge of the component, in particular lateral or frontal barrier walls, and/or optionally includes means for clamping individual bottom regions of the preformed component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The invention will be explained in more detail hereinafter with the aid of two exemplary embodiments in conjunction with the drawings, in which:

[0047] FIG. 1a-d show schematic representations of the shaping of the preformed component in the finally shaped component in the context of a first embodiment of a method according to the invention with an embodiment of a device according to the invention, wherein only the effective surfaces of the punches and dies are shown, and

[0048] FIG. 2a-f show schematic representations of the shaping of the preformed component into the finally shaped, highly dimensionally accurate component in a single step in the context of a second exemplary embodiment of the method according to the invention with an exemplary embodiment of a device according to the invention, wherein only the effective surfaces of the punches and dies are shown.

DETAILED DESCRIPTION

[0049] Exemplary embodiments of the method according to the invention and of the device according to the invention are explained in more detail hereinafter based on the production of a hat-profile-like, singly offset component. An analogous procedure is employed for flangeless and/or multiply offset parts.

[0050] The same reference numerals are used hereinafter for similar or corresponding features.

[0051] In a first step, not shown, a singly shaped preformed component 1 in the form of an offset, elongated and, in the longitudinal direction, predominantly straight hat profile with a predetermined edge contour is inexpensively produced by suitable means. The term simple refers to the extension of the longitudinal axis of the preformed component, which may otherwise have fully structured further surface elements or curvatures. Suitable measures for producing this singly shaped, preformed component 1 are for example embossing and raising/turning up or robust deep drawing with a distant outer hold-down device. The device for producing the singly shaped, preformed, in particular component 1 far from the final contour is thus, for example, a tool for embossing and raising or a deep-drawing tool with an inner hold-down device, distant outer hold-down device, large drawing radii and drawing gaps, and also aids for loading and positioning. Singly shaped, preformed components 1 can alternatively also be produced by roll shaping.

[0052] The further shaping takes place in the next step in a forming tool, shown schematically in FIG. 1, according to the device in accordance with the invention. The forming tool for the further shaping of the singly shaped preformed component 1 is constructed here in three parts and comprises a centre tool part and two edge tool parts, wherein the centre tool part has a central punch 2b and a centre die 3b and the first edge tool part has an edge punch 2a and a height-adjustable edge die 3a, wherein the edge die 3a is movably mounted in a height-adjustable manner via spindle sleeves 6. The non-height-adjustable die parts can also have an optional inner hold-down device (not shown), which when extended facilitates the positioning and loading. The second edge tool has a movable edge punch 2c and a rigid edge die 3c. The movable edge punch 2c associated with the rigid edge die 3c is movably mounted by for example hydraulic or other force-acting adjustment means, the direction of movement 5 of these force-acting adjustment means being shown relative to the other punches, namely the central punch 2b and the edge punch 2a of the first edge tool part. The forming tool is inclined with respect to the downward movement of a press represented by the arrow 4. The course of the further shaping is described below.

[0053] As shown in FIG. 1a, the edge punches 2a, 2c and the central punch 2b are in the raised position at the start of the further shaping step. The height-variable edge die 3a is raised to the level of the rigid edge die 3c by the spindle sleeves of the press, as indicated by the arrow 6. The other two dies 3b, 3c are already located in their end position, are rigid and are not moved. In addition the inner hold-down device (not shown) of the one fixed edge die 3c can be extended.

[0054] Firstly, the singly preformed component 1 is inserted into the dies 3a, 3b, 3c inclined to the direction of displacement 4. In this connection the preformed component can be positioned by the positive connection to the two edge dies and/or by the raised inner hold-down device, not shown, of the rigid edge die.

[0055] As shown in FIG. 1b, the edge punches 2a, 2c and the central punch 2b are afterwards lowered by the movement of the press in the direction of displacement 4. In this case first of all the force-acting movable edge punch 2c and also the raised, height-adjustable edge die 3a clamp the singly shaped preformed component 1 between their respective counterpart 2a, 3c. The clamping force is chosen so large that the singly shaped preformed component 1 cannot slip, or only slightly, during its movement. The middle region 1b of the singly shaped preformed component 1 is initially freely exposed.

[0056] In the further downward movement the edge punch 2a opposite the height-adjustable edge die 3a forces the said edge die 3a downwards. In addition the movable edge punch 2c is blocked in its downward movement by the rigid edge die 3c. The relative movement between the individual edge punches 2a, 2c and edge dies 3a, 3c, in conjunction with the clamping and the inclined position ensures that the middle region 1b of the singly shaped preformed component 1 is increasingly lengthened with respect to the rigid side 1c and thereby deflected. Since the resulting offset requires more material than the straight shape, this results in the stretching and thus associated tensile loading up to plastic deformation in almost all the transition regions between the middle region 1b and the edge regions 1a, 1c of the singly shaped preformed component 1. The necessary material for this comes mainly from the stretching of the transition regions between the regions of the die division.

[0057] In the end position, as illustrated in FIG. 1c, all die and punch parts are in a block state, which leads to the final shaping of the final-shaped component 8 (cf. FIG. 1d), in particular leads to the displacement of the respectively opposite punch parts 2a, 2b, 2c and die parts 3a, 3b, 3c to a local Z shape. Depending on the type of offset, the displacement over the longitudinal axis of the component can also take place multiply and in opposite directions. This then results in U-shaped or multiply offset variants of the finally shaped component 8. In the further shaping, surface elements of the component 8 that have not yet been preformed can also be supplemented.

[0058] As shown in FIG. 1d, the tool parts finally move into their starting position, as indicated by arrow 7, wherein the return movement direction of the force-acting adjustment means to the starting position is indicated by the arrow 5, and the finally shaped component 8 can be removed and if necessary placed in a calibration tool, not shown, where a high degree of dimensional accuracy is established in the course of the calibration.

[0059] The optional calibration tool has in particular a solid or split calibration die and likewise one-part or multi-part calibration punches as well as auxiliary elements for loading, support, positioning and ejecting. After the calibration, the finally shaped, highly dimensionally accurate component 13 can be removed.

[0060] In a second exemplary embodiment of the method according to the invention the device according to the invention comprises only two tools, a first tool for producing the singly shaped preformed component and the forming tool for further shaping with combined calibration.

[0061] The tool for producing the singly shaped preformed component is for example the same tool as in the variant of the first exemplary embodiment, thus for example a tool for embossing and raising or for robust deep drawing with a distanced outer hold-down device or a roll forming with subsequent portioning.

[0062] As shown in FIG. 2a, the tool for the final shaping and calibration of the singly shaped preformed component comprises in combination a centre tool part and two edge tool parts, wherein the centre tool part has a central punch 2b and a centre die 3b, and the first edge tool part has an edge punch 2a and a height-adjustable edge die 3a. The second edge tool part has a movable edge punch 2c and a rigid edge die 3c. The height-adjustable edge die 3a and the rigid edge die 3c each optionally has an inner hold-down device 10. The movable edge punch 2c associated with the rigid edge die 3c is movably mounted by hydraulic or other force-acting adjustment means relative to the other punches, namely the central punch 2b and the edge punch 2a of the first edge tool part. The forming tool is in a desired inclined position with respect to the downward movement 4 of the press. In contrast to the variant from the first exemplar embodiment, the dies 3a, 3b, 3c and punches 2a, 2b, 2c have a calibration function, so that they are forming dies with a calibration function or forming punches with a calibration function. Furthermore, the forming tool for the calibration process has means for blocking the flow of material beyond the edge of the component, in the form of the side shut-off walls 9 and optionally front-face shut-off walls, not shown, as well as the possibility of clamping individual base regions of the preformed component 1 via the raised hold-down device 10 if required.

[0063] As in the first exemplary embodiment, the forming punches 2a, 2b, 2c are initially in the raised position. The height-adjustable forming edge die 3a is raised for example by means of the spindle sleeves of the press and optionally hydraulic or other force-acting adjusting means, the direction of movement 5 of these force-acting adjusting means being illustrated, to the level of the rigid forming edge die, indicated by the arrow 6. The other two dies 3b, 3c are in their end position, and are rigid and are not moved. In addition the optional inner hold-down device of both edge dies 3a, 3c is extended.

[0064] As shown in FIG. 2b, the singly preformed component 1 is inserted into the die. In this connection the positioning of the component 1 can be effected through the positive connection to the two edge dies 3a, 3c and/or through the optionally raised inner hold-down device 10 of the rigid edge die 3c.

[0065] Furthermore, the three forming punches 2a, 2b, 2c are lowered by the movement of the press punch, indicated by the arrow 4. Firstly, the force-acting mounted edge punch 2c and also the raised, height-adjustable edge die 3a clamp the singly shaped preformed component 1 between their respective counterpart 2a, 3c, i.e. parts of the die bottom or the optionally raised hold-down device 10. Since the cross section of the preformed component 1 deviates from the final shape, the clamping is initially possible only over some regions of the inner hold-down device 10. This is associated with a small spacing 12 of the bottom regions between the dies 3a, 3b, 3c and punches 2a, 2b, 2c, or die parts and punch parts. As can be seen in FIG. 2c, the middle region of the singly shaped preformed component 1 is initially freely exposed.

[0066] In the further downward movement the edge punch 2a opposite the movable edge die 3a displaces the said edge die 3a with the raised hold-down device 10 downwards. In addition, the movably mounted edge punch 2c is blocked in its downward movement by the rigid edge die 3c.

[0067] Here too the relative movement between the individual edge tool parts ensures that the middle region of the singly preformed component 1 is increasingly lengthened and thereby deflected. Since the resulting offset requires more material than the straight shape and the firm clamping 11 to the raised hold-down devices 10 ensures that only a small amount of material flows from the clamped regions into the middle region, there is also stretching and thus associated tensile loading up to plastic deformation in almost all transition regions of the singly preformed component 1 between the regions of the die division, as illustrated in FIG. 2d.

[0068] Shortly before reaching the end position, the raised hold-down devices 10 are also forced downward, as shown in FIG. 2e. The upsetting process then finally starts, in which in particular through contact with the shut-off means 9 all excess surface portions of the component 13 finally formed in the meantime are increasingly compressed.

[0069] In the end position all die and punch parts are in a block state, which leads to the final shaping of the component end contour with a high degree of dimensional accuracy and freedom from trimming.

[0070] Finally, as shown in FIG. 2f, the tool parts move into their starting position, as indicated by the arrow 7, wherein the return movement direction of the force-actuating adjusting means to the starting position is indicated separately by arrow the 5. The finally shaped, highly dimensionally accurate component 13 can be removed and transferred to the further processing chain.

[0071] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0072] The use of the terms a and an and the and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms comprising, having, including, and containing are to be construed as open-ended terms (i.e., meaning including, but not limited to,) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., such as) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0073] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.