Method and system for producing open or closed annular structural components made of light metal and alloys thereof

Abstract

A method and to a system for producing open or closed annular structural components made of light metal and alloys thereof, preferably of magnesium or magnesium alloys, having a two-dimensional or three-dimensional structure by means of extrusion, wherein the extruded profile exiting the die of the extrusion press is formed into a helical shape by way of one or more guide tools, and more particularly such that the ends of the helical shape are separated from the extruded strand in the region of the overlap and formed into a two-dimensional or three-dimensional structural component in a shaping device.

Claims

1. A method for producing a structural component, comprising: extruding a metal through a die of an extrusion press to provide an extruded profile in a form of a continuous strip; shaping the continuous strip as it exits the die into a nonplanar configuration having a polygonal shape with corner regions, the continuous strip in the nonplanar configuration having two overlapping ends arranged in separate planes; separating a predetermined length of the extruded profile from the continuous strip, the length being predetermined such that the two ends overlap sufficiently to provide a site for inseparably connecting the two ends; and forming the nonplanar configuration into an endless configuration constituting the structural component.

2. The method according to claim 1, wherein the metal is magnesium.

3. The method according to claim 1, further comprising inseparably connecting the two ends at the overlap to form the nonplanar configuration into the endless configuration constituting the structural component.

4. The method according to claim 1, wherein shaping the extruded profile into the nonplanar configuration as it exits the die is carried out while the profile is in a heated, formable state.

5. The method according to claim 1, wherein the structural component is part of an automotive space frame.

6. The method according to claim 1, wherein shaping the continuous strip as it exits the die into the nonplanar configuration is effected by a guide tool which comprises at least two parts which are displaceable relative to each other.

7. The method according to claim 6, wherein the guide tool comprises a pressing cylinder which selectively applies pressure to at least one of the at least two parts.

8. The method according to claim 1, wherein the extruded profile is hollow.

9. A system for producing a structural component, the system comprising a production line comprising, in the following sequence: a site for storage of ingots of a metal; a furnace configured to receive and heat the ingots; an extrusion press having a die, the extrusion press being configured to receive the heated ingots from the furnace and extrude a profile in form of a continuous strip; a guide tool configured to shape the continuous strip as it exits the die into a nonplanar configuration in which the continuous strip has two overlapping ends arranged in separate planes, the guide tool comprising at least two parts which are displaceable relative to each other; a separating device configured to separate a predetermined length of the profile from the continuous strip; and a device for inseparable connecting the two overlapping ends of the separated profile at the overlap to provide the structural component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The drawing shows the system for producing a closed annular structural component.

DETAILED DESCRIPTION OF THE INVENTION

(2) The system according to FIG. 1 comprises an ingot storage 1 for storing the extrusion billet 4, the heating furnace 2, in which the extrusion billets 4 are heated to the extrusion temperature, and the extrusion press 3 comprising the guide tools 5 for generating a helical shape 9. Downstream thereof is a shaping device 7 and a joining device 8, in which the shaped ends of the helical shape 9 are joined to yield a closed annular structural component 10.

(3) The extrusion billets 4 heated to the press temperature are inserted into the container of the extrusion press 3 and formed into an extruded profile. The extruded profile exiting the die of the extrusion press 3 is then formed into a helical shape 9 by way of the guide tools 5, and more particularly such that the ends of the helical shape 9 overlap slightly.

(4) Thereafter, the extrusion press 3 is stopped, and the helical shape 9 is separated from the exiting extruded profile at the location of the overlapping ends by way of a separating device 6, which is designed as a flying saw. Subsequent to the separating process, the severed helical shape 9 is transferred to a shaping device 7, in which this is shaped, for example into an annular structural component 10. The shaping device 7 creates a structural component 10 having a high dimensional accuracy and contour accuracy, and more particularly in the form of a ready-to-install component.

(5) Subsequent to the shaping operation, the ends are connected by a non-detachable connection in the connecting device 8, for example by way of welding. The ready-to-install component leaves the systems in this way.