METHOD FOR THE PRODUCTION OF SHEET METAL COMPONENTS AND DEVICE THEREFOR

Abstract

The disclosure relates to a method and a device for the production of dimensionally accurate sheet metal components.

Claims

1-16. (canceled)

17. A method of manufacturing a sheet metal component, the method comprising: preforming of a sheet to form a sheet preform in a preforming tool, the sheet preform having at least one flangeless section in its longitudinal extent and excess sheet material at least in some regions; and final forming of the sheet metal preform into a sheet metal component in a calibrating tool comprising at least one calibrating punch and at least one calibrating die, in which the excess sheet material in the sheet metal preform is compressed by relative movement between the calibrating punch and the calibrating die; wherein during the final forming process, an edge of the sheet metal preform present at least in the flangeless section comes into contact with a slide shoulder provided on a slide which can be moved essentially horizontally, is supported thereon and is subjected to pressure.

18. The method according to claim 17, wherein the sheet metal preform is inserted into the calibrating tool in such a way that its opening points downwards and is positioned on the calibrating die.

19. The method according to claim 17, wherein the slider (23) is moved in the direction of the calibrating punch during the relative movement between the calibrating die and the calibration punch to such an extent that a defined distance between the slider and the calibrating punch is selected at least in the region of the flangeless section of the sheet metal preform, which distance corresponds to the material thickness of the sheet metal used plus >0 to 0.35 mm.

20. The method according to claim 17, wherein the sheet metal preform is provided with a bottom, which is acted upon with an excess sheet metal material at least in the flangeless section in the course of preforming, such that a bottom region has been produced during preforming, so that the sheet metal preform is positioned on the calibrating punch at least via the precurved bottom region at least in the region of the flangeless section of the sheet metal preform in such a way that the edge of the sheet metal preform present at least in the flangeless section is arranged above the slider shoulder.

21. The method according to claim 17, wherein the sheet metal preform is provided with a bottom, in which embossments have been produced during preforming, so that the sheet metal preform is positioned at least via the embossments on the calibrating punch in such a way that the edge of the sheet metal preform present at least in the flangeless section is arranged above the slider shoulder.

22. The method according to claim 17, wherein the sheet metal preform is provided with a bottom, wherein at least a partial region of the bottom, when the sheet metal preform is inserted into the calibrating tool, comes into contact with at least one adjustable insert, which is spaced apart from the calibrating punch when the sheet metal preform is inserted into the calibrating tool, and the sheet metal preform is positioned on the insert at least via the partial region of the base at least in the region of the flangeless section of the sheet metal preform in such a way that the edge of the sheet metal preform present at least in the flangeless section is arranged above the slider shoulder.

23. The method according to claim 17, wherein the slider is controlled in such a way that it assumes an end position which is set between 10 and 80 mm before the bottom dead center of the calibrating tool is reached.

24. A device for manufacturing a sheet metal component, for carrying out the method according to claim 1, the device comprising: at least one preforming tool for preforming a sheet into a sheet preform, the sheet preform having at least one flangeless section in its longitudinal extension and excess sheet material at least in some regions; and at least one calibrating tool for final forming of the sheet metal preform into a sheet metal component, wherein the calibrating tool comprises at least one calibrating punch, at least one calibrating die and at least one substantially horizontally movable slide, wherein the excess sheet material in the sheet metal preform is compressed by the relative movement between the calibrating punch and the calibrating die; wherein the slider has a slider shoulder, which is provided at least in the flangeless section of the sheet metal preform, so that the edge of the sheet metal preform present at least in the flangeless section can be brought into contact with the slider shoulder of the slider by the relative movement, can be supported thereon and can be subjected to a pressure.

25. The device according to claim 24, wherein the slider is configured such that it covers less than 50% of a lateral height of the sheet metal component to be manufactured.

26. The device according to claim 24, wherein the slider shoulder is configured as a projection of the slider and the calibrating punch has a recess on one or both sides at least in the flangeless section of the sheet metal preform, in which recess the projection of the slider can be received during the final forming of the sheet metal preform.

27. The device according to claim 24, wherein the slider has on its upper side facing the calibrating die at least one projection or several projections and/or at least one recess or several recesses at least in the flangeless section of the sheet metal preform and also the calibrating die has on its lower side facing the slider at least one projection or several projections and/or at least one recess or several recesses at least in the flangeless section of the sheet metal preform, so that during the final forming of the sheet metal preform the projection on the underside of the calibrating die is configured to be accommodated in the recess on the upper side of the slider and, conversely, the projection on the upper side of the slider is configured to be accommodated in the recess on the underside of the calibration die.

28. The device according to claim 24, wherein the calibrating punch comprises at least one adjustable insert arranged in the calibrating punch, which insert can be spaced apart from the calibrating punch.

29. The device according to claim 24, wherein the slider is driven mechanically, hydraulically, pneumatically, electromagnetically.

30. The device according to claim 24 wherein the slider is fixed in an end position during the final forming of the sheet metal preform.

31. The device according to claim 24, wherein the slider is configured to be controlled in such a way that it assumes an end position which can be set between 10 and 80 mm before the bottom dead center of the calibrating tool is reached.

32. The device according to claim 24, wherein the slider ledge is designed perpendicular to the frame or inclined at an angle of +/30 to the vertical of the frame.

32. The device according to claim 24, wherein the device is integrated in one of a press line, a transfer press and a progressive press.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The invention is explained in more detail below with reference to the drawings. Identical parts are provided with identical reference signs. In detail:

[0036] FIG. 1 a sketched perspective view of the production of a sheet metal preform,

[0037] FIGS. 2 to 4a sequence of steps at different times for manufacturing a sheet metal component according to one embodiment of the method according to the invention and a device according to the invention in a schematic sectional view,

[0038] FIG. 5a perspective view of a calibrating tool according to an embodiment of the device according to the invention,

[0039] FIG. 6a perspective view of a calibrating tool according to a further embodiment of the device according to the invention, and

[0040] FIG. 7a perspective view of a final sheet metal component produced.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] FIG. 1 shows a perspective view of the production of a sheet metal preform (2) from a sheet (1) in a preforming tool (10) not shown in detail. The sheet metal preform (2) can be produced in one or more steps using any combination of shaping processes. With the reference sign (10), the preforming tool can thus be combined from one or more tools that are suitable for producing a sheet metal preform (2) from a sheet metal (1). The sheet metal (1) is, for example, unwound and cut to length as a defined blank or shaped blank from a metal coil not shown and made available for the further process. The sheet metal (1) is preferably made of a steel material, preferably a high-strength steel material, for example with a material thickness of between 0.5 and 4 mm. Alternatively, aluminum materials or other metals can also be used.

[0042] FIGS. 2 to 4 show schematically in a sectional view a sequence of an embodiment of a method according to the invention or a device according to the invention, which relates at least to the configuration of the calibrating tool (20). The method according to the invention for manufacturing a sheet metal component (3), see for example FIG. 7, comprises at least two steps. Firstly, the method comprises preforming a sheet metal (1) into a sheet metal preform (2) having, in cross-section, a bottom and two frames, each with a transition between the bottom and the frame.

[0043] The sheet metal preform (2) or the sheet metal component (3) can, for example, comprise at least one flanged section (L), shown here on the left-hand side of the downwardly open profile, and at least one flangeless section (2.1). If there is at least one section in the longitudinal extent (L) with a flange, which can for example be arranged on one side or both sides in different sections, there is also a transition between the frame and the flange in the area of the flange. The following explanations are based on an example that shows a section in cross-section in which both sides of the sheet metal preform (2) and, as a result, both sides of the sheet metal component are flangeless in at least one section. Of course, only one side can also be flangeless and the other side can be flanged in cross-section or completely flangeless (not shown).

[0044] The sheet metal preform (2) is created in such a way that excess sheet metal material (4) is provided, which is preferably arranged in the bottom and/or in the bottom and in the transition between the bottom and the frame(s) and/or in the frames, preferably evenly distributed in the sheet metal preform (2). Excess sheet material can be introduced into the sheet metal preform (2) in the bottom as a bottom area (2.2) that is pre-curved in the direction of the opening () of the sheet metal preform (2) in order to make the sheet metal preform (2) at least over the pre-curved bottom area (2.2) at least in the region of the flangeless section (2.1) of the sheet metal preform (2) on the calibrating punch (21) in such a way that the edge (2.11) of the sheet metal preform (2) present at least in the flangeless section (2.1) is arranged above the slider shoulder (23.1) of the slider (23). Alternatively or additionally, at least one adjustable insert (21.2) can be arranged in the calibrating punch (21), which can be spaced apart from the calibrating punch (21), so that at least a partial area of the bottom comes into contact with the insert (21.2) and the sheet metal preform (2) is positioned on the insert (21.2) at least via the partial region of the bottom at least in the region of the flangeless section (2.1) of the sheet metal preform (2) in such a way that the edge (2.11) of the sheet metal preform (2) present at least in the flangeless section (2.1) is arranged above the slider shoulder (23.1) of the slider (23). This ensures that the slider(s) (23) can be moved into their end position in the direction of the calibrating punch (21) without negatively influencing the edge (2.11), see FIG. 2. In particular, the slider shoulder (23.1) can be designed perpendicular to the frame or inclined at an angle of +/30 to the vertical of the frame.

[0045] According to an alternative or additional embossments (2.3) pointing locally or in sections in the direction of the opening (), see right-hand representation of the sheet metal preform (2) in FIG. 1, may have been produced in the bottom of the sheet metal preform during preforming, so that the sheet metal preform (2) can be positioned at least via the embossments (2.3) on the calibrating punch (21) in such a way that the edge (2.11) of the sheet metal preform (2), which is present at least in the flangeless section (2.1), can be arranged above the slider shoulder (23.1). The embossing (2.3) introduced into the bottom of the preform locally or in sections during preforming can be distributed along the bottom in the longitudinal direction (L) or can also be introduced only as local or sectional embossing (2.3) at the two ends of the sheet metal preform (2) as viewed in the longitudinal direction (L). These also do not necessarily have to be introduced in the area of the flangeless section (2.1) of the sheet metal preform (2) if a sheet metal component with flanges at least in sections is to be produced. The introduced embossings (2.3) therefore not only serve as spacers, but can also provide additional sheet material over the transverse extension of the sheet metal preform (2), at least in the regions locally or in regions.

[0046] The final forming of the sheet metal preform (2) into a sheet metal component (3) takes place in a calibrating tool (20) comprising at least one calibrating punch (21), at least one calibrating die (22) and at least one slide (23) which can be moved essentially horizontally, for example essentially horizontally to the calibrating punch (21), in which the excess sheet material (4) in the sheet metal preform (2) is compressed by relative movement between the calibrating punch (21) and the calibrating die (22). It has been found to be advantageous that during the final forming process, the edge (2.11) of the sheet metal preform (2) present at least in the flangeless section (2.1) comes into contact with a slide shoulder (23.1) provided on a slide (23) which can be moved essentially horizontally, is supported thereon and is subjected to a pressure in order to be compressed in particular.

[0047] The slide or slides (23) move in the direction of the calibrating punch (21) after the sheet metal preform (2) has been positioned on the calibrating punch. The slider (23) comprises a projection (23.2), at least in the flangeless section (2.1) of the sheet metal preform (2), which extends in the direction of the calibrating punch (21) and has the slider shoulder (23.1) on the upper section. The calibrating punch (21) comprises a recess (21.1) on one or both sides at least in the flangeless section (2.1) of the sheet metal preform (2), in which the projection (23.2) of the slider (23) can be accommodated during the final forming of the sheet metal preform (2). The projection (23.2) thus plunges into the recess (21.1), see FIGS. 3 and 4. The calibrating die (22) is also moved relative to the direction of the calibrating punch (21) at the same time or in succession. The slider (23) can be controlled in such a way that it assumes an end position that can be set between 10 and 80 mm before the bottom dead center of the calibrating tool (20) is reached. The slider (23) can also have an infeed slope, which can be used to reliably prevent the sheet metal preform (2) from jamming. Once the slider (23) has reached its end position, the lower part of the frame(s) and the edge (2.11) is enclosed on all sides, at least in the flangeless section (2.1), and the final forming can be completed by further lowering the calibrating die (22) until the bottom dead centre of the calibrating tool (20) is reached, see FIG. 5. In this way, a dimensionally stable sheet metal component (3) can be produced which is flangeless, at least in sections, and in particular has a frame opening angle of equal to or greater than 0. The slider(s) (23) are designed in particular in such a way that they preferably cover less than 50% of a lateral height (H) of the sheet metal component (3) to be manufactured.

[0048] The embodiment according to the invention can ensure that the sheet metal preform (2) can be positioned on the calibrating punch (21) without jamming before final forming or before closing the calibrating tool (20) and that flangeless sections (2.1) can also be final formed in a dimensionally accurate manner alongside flanged sections in a sheet metal component (3). For the final forming of the flanged sections, further sliders, in particular those not shown, are provided for blocking the flange edges of the sheet metal preform in the calibrating tool, so that these sections can also undergo compressive stress superimposition in the same way as the flangeless sections (2.1).

[0049] FIG. 5 shows a perspective view of a calibrating tool (20) according to one embodiment of the device according to the invention, which comprises at least one calibrating punch (21), at least one calibrating die (22) and at least one substantially horizontally movable slide (23), wherein the excess sheet material (4) in the sheet preform (2) is compressed by the relative movement between the calibrating punch (21) and the calibrating die (22)

[0050] FIG. 6 shows a perspective view of a calibrating tool (20) according to a further embodiment of the device according to the invention. On its upper side facing the calibrating die (22), the slider (23) has at least one projection or a plurality of projections (23.4) and/or at least one recess or a plurality of recesses (23.3) at least in the flangeless section (2.1) of the sheet metal preform (2). The calibrating die (22) also has at least one projection or several projections (22.2) and/or at least one recess or several recesses (22.1) on its underside facing the slider (23), at least in the flangeless section (2.1) of the sheet metal preform (2). When the sheet metal preform (2) is finished, the projection (22.2) on the underside of the calibrating die (22) can be accommodated in the recess (23.3) on the upper side of the slider (23) and vice versa, the projection (23.4) on the upper side of the slider (23) can be accommodated in the recess (22.1) on the underside of the calibrating die (22). In this example, the projection/recess principle is implemented completely along the longitudinal extension of the calibrating tool (20) on both sides.

[0051] The invention is not limited to the designs shown. Other sheet metal part shapes are also possible and require correspondingly adapted tool contours. In particular, the tools (10, 20) can be designed as interchangeable tools and can be used in a production line, in particular in a press line, transfer press or progressive press.