Abstract
A method for producing a motor vehicle component from a light metal alloy includes: extruding an extruded profile with, in cross section, at least two mutually different wall thicknesses and at least one closed hollow chamber and with an extrusion width, at least partially flattening and/or widening the cross section to a processing width, wherein the processing width is greater than the extrusion width, before or after the flattening and/or widening, performing separation to form blanks, processing the blanks by deformation to form the motor vehicle component.
Claims
1. Method for producing a motor vehicle component, the method comprising: extruding a 5000 series, 6000 series, or 7000 series aluminum alloy as an extruded profile having, in cross section, at least two mutually different wall thicknesses and at least one closed hollow chamber and an extrusion width, at least partially flattening and/or widening the cross section to a processing width, wherein the processing width is at least 10% greater than the extrusion width, after the flattening and/or widening, performing separation of the extruded profile to obtain a blank, processing the blank by deformation of the blank to form the motor vehicle component.
2. Method according to claim 1, wherein the at least one closed hollow chamber is still maintained after the flattening and/or widening.
3. Method according to claim 1, further comprising cutting the at least one closed hollow chamber in an extrusion direction, such that, in the extrusion direction, the closed hollow chamber is formed in portions.
4. Method according to claim 1, wherein the extruded profile further has at least one flange projecting from one side of the at least one closed hollow chamber.
5. Method according to claim 1, wherein the at least one closed hollow chamber comprises at least two closed hollow chambers which are formed adjacent to one another, or are formed so as to be connected by a web.
6. Method according to claim 1, wherein the at least one closed hollow chamber is reduced in height and/or increased in width during the widening and/or flattening.
7. Method according to claim 1, further comprising, after the separation, cutting the flattened/widened blank at an angle of between 5 and 90 degrees with respect to an extrusion direction, wherein a component length of the motor vehicle component to be produced is greater than the processing width.
8. Method according to claim 1, wherein the extruded profile has a width of 30 mm to 500 mm and a wall thickness of 1 to 10 mm.
9. Method according to claim 1, wherein the processing width is between 300 mm and 1500 mm.
10. Method according to claim 1, wherein the deformation is performed in a progressive tool.
11. Method according to claim 10, wherein the progressive tool performs at least two of the following process steps: elongating the blank, edge cutting of the blank, deformation to form the motor vehicle component, hole punching, and/or hole forming.
12. Method according to claim 1, wherein the extruded profile further has flanges projecting from two opposite sides of the at least one closed hollow chamber.
13. Method according to claim 1, further comprising, after the separation, cutting the flattened/widened blank at an angle of between 5 and 85 degrees.
14. Method according to claim 1, wherein the processing width is between 400 mm and 1500 mm.
15. Method according to claim 1, wherein the processing width is between 500 mm and 1500 mm.
16. Method according to claim 1, wherein the processing width is at least 20% greater than the extrusion width.
17. Method according to claim 1, wherein the processing width is at least 30% greater than the extrusion width.
18. Method according to claim 1, wherein the deformation is performed in a 6-stage progressive tool.
19. Method according to claim 1, wherein the at least one closed hollow chamber is flattened during the flattening and/or widening.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For an understanding of embodiments of the disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:
(2) FIGS. 1a and 1b show an extruded profile extruded by way of the method according to the invention, after the extrusion and after the widening,
(3) FIGS. 2a and 2b show an extruded profile extruded by way of the method according to the invention, after the extrusion and after the widening,
(4) FIG. 3 shows a floor panel, produced by way of the method according to the invention, of a motor vehicle,
(5) FIGS. 4a to 4c show a production method according to the invention in the individual process steps,
(6) FIGS. 5a to 5d show a door impact beam produced by way of the method illustrated in FIGS. 4a to c,
(7) FIG. 6 shows a method sequence according to the invention for the production of a motor vehicle component in the form of a suspension cross-brace,
(8) FIGS. 7a to 7c show a method sequence for the production of a hollow chamber which is formed only in portions in a longitudinal direction,
(9) FIG. 8 shows a motor vehicle pillar,
(10) FIG. 9 shows a longitudinal beam lower shell,
(11) FIG. 10 shows a closure plate of a longitudinal beam,
(12) FIG. 11 shows a rear-window shelf,
(13) FIG. 12 shows a transmission tunnel,
(14) FIG. 13 shows a rear floor plate,
(15) FIG. 14 shows a front floor plate,
(16) FIG. 15 shows a seat crossbeam,
(17) FIG. 16 shows an alternative seat crossbeam,
(18) FIGS. 17a to 17f show a longitudinal beam,
(19) FIGS. 18a to 18f show a crossbeam, and
(20) FIGS. 19a to 19d show a roof rail.
(21) In the figures, the same reference designations are used for identical or similar components, even if a repeated description is omitted for reasons of simplicity.
DETAILED DESCRIPTION
(22) FIG. 1a shows an extruded profile 1 produced by way of the method according to the invention. The extruded profile 1 has a total of three hollow chambers 2, 3, 4 and has two flanges 5 which project laterally from the outer hollow chambers 2, 4. Altogether, the extruded profile 1 has an extrusion width 6, and has wall thicknesses W which differ from one another in cross section, wherein the wall thickness may be selected as desired on the basis of the extrusion process. In a subsequent processing step as per FIG. 1b, the extruded profile 1 is flattened, such that, as illustrated here, the lateral flanges 5 are substantially bent downward. Following this, the flattened or widened extruded profile 1 has a processing width 7 which is greater than the extrusion width 6. Thereafter, further processing by deformation can be performed. It is also possible, during the flattening, for the hollow chambers 2, 3, 4 to be flattened, though this is not shown.
(23) FIG. 2 shows an alternative design variant. Firstly, as per FIG. 2a, an extrusion profile 1 is produced which, altogether, has an undulating cross section. Said extrusion profile in turn has three directly adjacent hollow chambers 2, 3, 4 and has flanges 5 projecting laterally therefrom. The wall thickness W is selected so as to facilitate the following pressing forming step.
(24) FIG. 2b shows the extrusion profile between the hollow chambers 2, 3, 4 after the widening or flattening and, in this case, a further pressing deformation step. For this purpose, the extrusion profile has a component width 8 which is likewise greater than the extrusion width 6. The right-hand flange 5 in relation to the plane of the drawing and the left-hand flange 5 in relation to the plane of the drawing have each, by way of the pressing deformation, been altered so as to stand at an angle relative to the hollow chambers 2, 3, 4 arranged in the middle. Grooves 9 are formed between the hollow chambers, which grooves promote the widening. The hollow chambers 2, 3, 4 are connected to one another by webs 10. For example, it is in particular possible for a floor panel 11 shown in FIG. 3 to be produced in accordance with the design variant of FIGS. 2a and b.
(25) Here, the longitudinal direction 27 is oriented in the extrusion direction 14 of the blank. Consequently, in the longitudinal direction 27, there are formed thick regions 28 and, arranged in between these, thin regions 29.
(26) FIGS. 4a to c show a method according to the invention for producing an extruded profile 1, from the flattening or widening to the separation and/or cutting of the blanks 13 thus produced. In FIG. 4a, an extruded profile 1 with an undulating cross section is produced. Here, a wall thickness W2 arranged in the middle is greater than a wall thickness W3 arranged at the outer sides, and in between, a transition with the varying wall thickness W1 which decreases from the wall thickness W2 to the wall thickness W3. A thickness transition from wall thickness W1 to wall thickness W3 in the form of a thickness step change 12 can thus be easily produced owing to the extrusion. Said extruded profile 1 in turn has an extrusion width 6. In the region of the thickness step change 12, it is thus possible for a transition region which is very narrow in cross section to be realized, by contrast to a rolling process.
(27) The extrusion is followed by a flattening or widening, illustrated in FIG. 4b. The flattening or widening may, in the context of the invention, be performed by way of a pressing deformation tool, such that, owing to a pressing force F which acts on the component from above and/or below, said component can be widened, though additionally or alternatively by way of tensile deformation, such that the component is widened owing to a tensile force Z acting on the end. As a result, by way of separation of the extruded profile 1, blanks 13 are produced which have a processing width 7 greater than the extrusion width 6. Said blanks 13 can then initially be stored and/or processed further, in particular on the basis of a blank outline. The blank 13 is preferably cut at an angle with respect to the extrusion direction 14, such that in this way, a component width 8 or component length 15 can be realized which is greater than the processing width. For this purpose, the angle is particularly preferably between 70 and 90 relative to the extrusion direction 14. It is however also possible for a component cut to be produced which is formed transversely with respect to the extrusion direction 14. In this case, the component length substantially corresponds to the processing width 7.
(28) For example, by way of the method sequence illustrated in FIG. 4, a door impact beam 16 produced in FIGS. 5a to d can be formed. Instead of the separation by blank outline before the deformation, it may also be provided that the components are separated only in one of the final steps.
(29) FIG. 5a shows a plan view, FIG. 5b shows a perspective view and FIGS. 5c and 5d show a cross-sectional view as per the section lines C-C and D-D from FIG. 5a. The door impact beam 16 may in this case have in each case an outer attachment region 17 and a component region extending in between. Here, the wall thicknesses W2, W3 and the transition W1 exist in the component. Here, the component length 15 has been produced on the basis of an oblique cut performed at an angle with respect to the extrusion direction 14, and said component length is thus greater than the processing width 7 as per FIG. 4. In FIG. 5b, it can be clearly seen that, after the cutting of the blank, a three-dimensional deformation is produced, for example by way of pressing deformation. The outer edges 20 are preferably oriented obliquely relative to a longitudinal direction 27 owing to an oblique cut. This is shown by the angle .
(30) FIG. 6 shows the method sequence according to the invention. Firstly, an extruded profile 1 is produced which has a hollow chamber 2 and mutually different wall thicknesses W1, W2, W3 and an extrusion width 6. The wall thickness W1 is smaller than the wall thickness W2 and also smaller than the wall thickness W3. The wall thickness W3 is smaller than the wall thickness W2. The extruded profile 1 thus produced may preferably, after the extrusion, be separated into individual blanks 13, wherein the blanks 13 are then supplied to a progressive tool 18, illustrated in this case in the form of a six-stage progressive tool 18. In the progressive tool 18, it is then possible, if this has not been performed already, for the blanks 13 to be widened and/or flattened and to be produced so as to form the motor vehicle component 19 by way of various cutting and deformation and extending operations. Said motor vehicle component is for example in the form of a suspension cross-brace and has the above-described hollow chamber 2 over the full extent in a longitudinal direction. Instead of the progressive tool 18, a transfer press may also be used.
(31) FIG. 7 shows an extruded profile 1 according to the invention with an uneven cross section and with a hollow chamber 2. Said extruded profile is flattened from an extrusion width 6 as per FIG. 7a to a processing width 7 illustrated in FIG. 7b, and in a further processing step as per FIG. 7c, the hollow chamber 2 is, in the longitudinal direction of the blank 13 thus produced, processed by cutting in the longitudinal direction 27 in length portions, such that the hollow chamber 2 is formed only in portions in the longitudinal direction of the blank 13. In this example, the same hollow chamber 2 is of unchanged form in cross section, but is also formed so as to be removed in parts over length portions.
(32) FIG. 8 shows a motor vehicle component 19 produced according to the invention in the form of a motor vehicle pillar, in this case in particular an A pillar. In the cross-sectional views A-A, B-B and C-C, there is provided in each case a wall thickness which is of homogeneous cross section, wherein a longitudinal section 20 shows that mutually different wall thicknesses W1, W2, W3, W4 are produced in the longitudinal direction. Said mutually different wall thicknesses W1, W2, W3, W4 may be produced by way of the method according to the invention, such that the extrusion direction 14 is depicted on the plane of the drawing in relation to the longitudinal section 20. The processing width that can be achieved here is, owing to the following three-dimensional pressing deformation, slightly greater than the component length 15 with which the component can be produced.
(33) FIG. 9 shows a further motor vehicle component 19 produced in accordance with the invention, based on the example of a longitudinal beam and, in this case, in particular, a longitudinal beam lower shell or internal reinforcement. In this case, in turn, two cross sections are illustrated as per the section lines A-A and B-B. The blank 13 initially to be processed has a processing width 7 and, in cross section, mutually different wall thicknesses W1, W2, W3, W4, W5, W6. Proceeding from the illustrated blank 13, the component is processed by deformation such that the component longitudinal direction 21 extends in the direction of the processing width 7. Furthermore, the processing width 7 substantially corresponds to the component length 15. A change in length, for example owing to three-dimensional processing by pressing deformation, is allowed for here.
(34) FIG. 10 shows a further produced motor vehicle component 19 for a longitudinal beam, for example an upper shell or a closing plate. In this case, too, it can be clearly seen that the component has been processed by pressing deformation three-dimensionally, wherein, in this case, too, it is in turn the case that the component longitudinal direction 21 extends transversely with respect to the extrusion direction 14, and thus the component length 15 substantially corresponds to the processing width 7 of the blank 13. In this case, too, the blank 13 in turn has mutually different wall thicknesses W1, W2, W3, W4, W5, W6 in cross section.
(35) FIG. 11 shows a motor vehicle component 19 in the form of a rear-window shelf in a sectional view with mutually different wall thicknesses W1, W2, W3, W4, W5, W6. The component longitudinal direction 21 is in this case itself oriented in the extrusion direction 14. The component itself has recesses 22 that can be produced by processing by cutting.
(36) FIG. 12 shows a motor vehicle component 19 in the form of a tunnel, in particular transmission tunnel. In the sectional view B-B, mutually different wall thicknesses W1, W2, W3 are realized in the cross section. The component longitudinal direction 21 corresponds in this case to the extrusion direction 14.
(37) FIG. 13 shows a motor vehicle component 19 in the form of a rear floor plate. In the longitudinal sectional view A-A, the component has mutually different wall thicknesses W1, W2. Here, the component width 8 substantially corresponds to the processing width 7 of a blank.
(38) FIG. 14 shows a motor vehicle component 19 in the form of a front floor plate. The floor plate is in turn formed with its component longitudinal direction 21 in the extrusion direction 14, wherein the cross section as per section line B-B has mutually different wall thicknesses W1, W2, W3, W4, W5.
(39) FIG. 15 shows a motor vehicle component 19 in the form of a seat crossbeam, to which a vehicle seat (not illustrated in any more detail) or seat rails are fastened. Here, the seat crossbeam is also formed with its component longitudinal direction 21 in the extrusion direction 14. The cross section consequently has mutually different wall thicknesses W1, W2, W3, W4, W5, W6.
(40) FIG. 16 likewise shows a motor vehicle component 19 in the form of a seat crossbeam. In this case, however, the component longitudinal direction 21 is formed transversely with respect to the extrusion direction 14. In the sectional illustration, the wall thicknesses W1, W2 differ from one another in the longitudinal section, wherein the wall thickness of a cross section resulting here in each case has a homogeneous profile, or as per section line A-A.
(41) FIG. 17 shows a motor vehicle component 19 in the form of a longitudinal beam. Said longitudinal beam has a base component 23, and a hollow profile component 24 coupled to the base component 23, in sections in the component longitudinal direction 21. In FIGS. 17a and b, the base component 23 is produced firstly from a flattened extruded profile 1 with mutually different wall thicknesses W1, W2, W3, W4, W5. Said extruded profile is subsequently, as can be seen from FIGS. 17c, 17d, 17e and 17f, processed by cutting and by deformation, such that the base component 23 is produced and is coupled to the hollow profile component 24. The coupling may be produced for example by welding. A hollow profile 25 exists.
(42) FIGS. 18a to f show a motor vehicle component 19 according to the invention in the form of a crossbeam with crash boxes 26 coupled to the crossbeam. The crossbeam itself is in this case, as per FIGS. 18a to c, firstly produced from an extruded profile 1, which in cross section has an uneven cross section, in particular an undulating or W-shaped cross section. The latter is, as per FIG. 18b, flattened and has two mutually different wall thicknesses W1, W2 with a respective wall thickness transition situated in between. Here, the wall thickness W1 increases to the wall thickness W2. Situated in a middle region is the wall thickness W2, which is constant over a middle section. From this, the crossbeam is then produced by processing by deformation, which crossbeam in turn has a greater wall thickness W2 as per the section line C-C than as per the section D-D, in which a relatively small wall thickness W1 prevails. In the cross section, however, the wall thickness is distributed homogeneously in each case over the entire cross section.
(43) FIGS. 19a to d show a motor vehicle component 19 produced as a roof rail. The roof rail is in turn produced from a base component 23, which is produced by way of the extrusion method according to the invention and which consequently has mutually different wall thicknesses W1, W2, W3, W4. The component longitudinal direction 21 in this case runs variably at an angle with respect to the extrusion direction 14. Consequently, it is possible for mutually different wall thickness regions in the component longitudinal direction 21 to be formed each case homogeneously over the cross section. Altogether, a component length 15 is realized which is longer than the processing width 7 of the blank 13.
REFERENCE DESIGNATIONS
(44) 1Extruded profile 2Hollow chamber 3Hollow chamber 4Hollow chamber 5Flange 6Extrusion width 7Processing width 8Component width 9Groove 10Web 11Floor panel 12Thickness step change 13Blank 14Extrusion direction 15Component length 16Door impact beam 17Attachment region 18Progressive tool 19Motor vehicle component 20Longitudinal section 21Component longitudinal direction 22Recess 23Base component 24Hollow profile component 25Hollow profile 26Crash box 27Longitudinal direction 28Thick region 29Thin region FPressing force WWall thickness W1Wall thickness W2Wall thickness W3Wall thickness W4Wall thickness W5Wall thickness W6Wall thickness ZTensile force Angle
