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EP1626824A1 - Procede pour produire des pieces de vehicule individualisees, notamment des pieces d'enveloppe exterieure individualisees a partir de pieces de serie fabriquees en serie, et pieces d'enveloppe exterieure produites selon ce procede - Google Patents

Procede pour produire des pieces de vehicule individualisees, notamment des pieces d'enveloppe exterieure individualisees a partir de pieces de serie fabriquees en serie, et pieces d'enveloppe exterieure produites selon ce procede

Info

Publication number
EP1626824A1
EP1626824A1 EP04711311A EP04711311A EP1626824A1 EP 1626824 A1 EP1626824 A1 EP 1626824A1 EP 04711311 A EP04711311 A EP 04711311A EP 04711311 A EP04711311 A EP 04711311A EP 1626824 A1 EP1626824 A1 EP 1626824A1
Authority
EP
European Patent Office
Prior art keywords
mandrel
series
series part
forming tool
outer skin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP04711311A
Other languages
German (de)
English (en)
Other versions
EP1626824B1 (fr
Inventor
Stefan Bartscher
Gero Kempf
Maik Hammer
Tobias LÖBEL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bayerische Motoren Werke AG
Original Assignee
Bayerische Motoren Werke AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayerische Motoren Werke AG filed Critical Bayerische Motoren Werke AG
Publication of EP1626824A1 publication Critical patent/EP1626824A1/fr
Application granted granted Critical
Publication of EP1626824B1 publication Critical patent/EP1626824B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/14—Spinning
    • B21D22/18—Spinning using tools guided to produce the required profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards

Definitions

  • the present invention relates to a method for producing outer skin parts for vehicles according to the preamble of patent claim 1 and to an outer skin part made according to this method according to patent claim 31.
  • Vehicle body parts such as bonnets, roofs, fenders, side parts, trunk lids, etc. are usually produced by deep drawing from flat starting sheets.
  • the tools of deep-drawing presses are known to be very expensive and can therefore only be used profitably with relatively large quantities.
  • the sheet geometries that can be produced with conventional deep-drawing presses are limited in terms of their complexity.
  • vehicle designers are increasingly demanding more design freedom, which cannot always be met with conventional deep-drawing tools.
  • Modern vehicle designs are characterized, for example, by transitions between convex and concave component sections as well as by strongly accentuated character lines or edges with sometimes very narrow radii of curvature. Even here, conventional deep-drawing processes occasionally reach production limits.
  • the basic principle of Dieless Forming is that a flat sheet metal plate, i.e. a non-preformed sheet is formed into a three-dimensional component by means of the forming dome.
  • the forming mandrel is pressed against the sheet metal blank.
  • a three-dimensional sheet metal part can be produced from the flat sheet metal blank by an incremental feed of the forming dome.
  • a major disadvantage of the Dieless Forming process described in US Pat. No. 6,216,508 B1 is the very long production time. If you want to manufacture a large, complex sheet metal part, for example a body part for a vehicle, from a flat sheet metal board using the Dieless Forming process, this is extremely time-consuming.
  • the forming mandrel has to travel the entire sheet metal blank contour by contour in a meandering or spiral manner, which takes a very long time in comparison to conventional deep drawing.
  • the production of a body part of a vehicle for example an engine hood, takes a few seconds or fractions of seconds using conventional deep-drawing processes.
  • the object of the invention is to provide a method with which components, in particular outer skin parts for vehicles and in particular those for small or Small series vehicles, customer requirements can be manufactured individually and at the same time inexpensively or to create an outer skin part that meets these requirements.
  • the invention is not limited to workpieces made of sheet metal.
  • An application of the invention is basically for all types of components, such as Structural parts, possible.
  • the invention is also not limited to sheet metal components. Rather, an application of the invention is also possible for workpieces made of plastic, in particular for parts made of thermoplastic, or other materials.
  • the essence of the invention consists primarily in meeting individual customer requirements by using a “series outer skin part” produced in series production
  • Post-processing is "individualized” with a “forming tool” that is pressed against the series outer skin part and moved relative to the series outer skin part.
  • Semi-finished or finished body-in-white parts such as bonnets, tailgates, doors, side panels, fenders, roofs, etc. can be used to create character lines, lettering, etc. be impressed.
  • character lines or component edges already present in the series outer part can be traced or deepened and thus more pronounced than is possible or is the case with the series outer skin parts used for conventional series vehicles.
  • Such post-processing with a forming tool can be used to produce an infinite number of design modifications from conventional series outer skin parts, and so inexpensively as was previously not possible.
  • series-like vehicles in small series or as individual vehicles, it is easier to meet customers' wishes for customization, particularly in the case of high-priced vehicles.
  • vehicles acquire an individual "design note” and thus stand out visually from the other vehicles of the respective vehicle type.
  • the invention is expressly not limited to the production of outer skin parts for small series or individual vehicles. Vehicles are often subjected to a "model revision” - a so-called “facelift” - in the course of their product life cycle. As part of model revisions, the outer skin parts of the vehicles are occasionally revised to a certain extent or made more appealing. So far, it has been necessary to purchase new press tools or to adapt existing press tools according to the new design, which is regularly associated with very high tool costs. With the method explained in more detail below, it is now possible to rework or rework outer skin parts produced with the “old” pressing tools. In this way, additional character lines, beads, etc. can be embossed into the “old outer skin parts”, which means a “model revision "made possible at a much lower cost than was previously the case.
  • Another important advantage of the invention is that a corresponding "rework station" can be integrated into an existing production line without problems.
  • Series parts intended for individual vehicles or for individualized vehicles or for a model revision are reworked in the "rework station".
  • Series parts for conventional series vehicles pass through the rework station without being reworked.
  • Post-processing according to the invention is of course also possible outside the production line in separate processing stations.
  • the basic principle of the method according to the invention is to emboss a three-dimensional contour into a sheet metal part by means of a shaping tool, which can be designed like a mandrel, for example.
  • the forming tool is also referred to below as a “forming mandrel”, which, however, is not to be understood as restrictive in the sense of a specific tool shape.
  • the end of the "forming mandrel” is pressed against the component during the finishing of a component, which can be designed, for example, as a tip or as a rounded tip. At the same time, the component and the forming mandrel are displaced relative to one another. As a result, the geometry of the end of the Forming dome and depending on the contact pressure and the "clamping or support state" of the component to be machined an "indentation or bulge" or, generally speaking, a three-dimensional contour.
  • the contour to be produced can be, for example, the shape of a groove, a bead or have a different shape.
  • the invention encompasses both “one-curve post-processing” and to a certain extent “incremental post-processing”.
  • the forming tool used is attached to the component to be post-processed, pressed against the component, and then the forming tool is moved relative to the component with a single movement. Post-processing is thus carried out by the forming tool "in one go “is moved, whereby the desired geometry, eg a bead, a character line or the like is stamped into the component.
  • a geometry produced in a first post-processing step such as a bead
  • a geometry produced in a first reworking step can be moved relative to by a slight shift the component and essentially transversely to the direction of travel of the first reworking step can be “widened” and thus become more pronounced.
  • finished means that the body-in-white part would in itself be ready for painting, but had previously been reworked in one component area or in several component areas. In principle, however, it is also conceivable to finish already finished outer skin components by reworking according to the invention “ individualize "or differentiate. "Semi-finished” means that the body-in-white part is further processed after the post-processing according to the invention, for example by post-treating the surface, trimming or bending component edges, drilling holes, thread cutting or the like and only then painting.
  • the series outer skin or the body shell part is clamped in a holding device.
  • the holding device can be formed, for example, by a large number of individual “holding points” or “holding sections”. It is also possible to use suction cup-like holding elements. Suction cup-like holding elements have the advantage that the risk of damage to the outer skin sheet metal part, in particular the risk of damage to the component surface, is reduced during clamping and during machining, since the workpiece is not clamped between two holding elements but is fixed by negative pressure.
  • the workpiece, ie the serial outer skin part is preferably clamped in before the post-processing in such a way that its geometry in the edge region does not change as a result of the post-processing. In other words, the postprocessing should not change connection dimensions or gap dimensions, which arise when the outer skin part is later installed in a body, with respect to the “normal series vehicle”.
  • the series outer skin part can either be held exclusively by means of a holding device, for example in its edge area.
  • a holding device for example in its edge area.
  • one or more "counterholders” or support elements can be used. Such counterholders or support elements are pressed against the series outer skin part from the side opposite the forming mandrel, ie "from behind”. Edge-shaped or arched “support elements” can be used as counterholders. Alternatively, the counterholders can also have the shape of a
  • Adopt "die” which has a "negative shape” corresponding to the three-dimensional contour to be produced.
  • a counter-holder does not necessarily have to be used.
  • one counterholder is preferably arranged on the left in the travel direction of the forming tool and the other counterholder in the travel direction on the right next to the geometry to be produced.
  • the shape of the geometry to be produced can already be influenced by the choice or the change in the spacing of the counterholders from one another and by the lateral spacing of the counterholders, which will be explained in more detail later.
  • the forming mandrel can, for example, have a smooth, convexly curved tool tip. It can be symmetrical or asymmetrical.
  • the tool tip can also be formed by a rotatably mounted ball which rolls on the series outer skin part during the machining of the series outer skin part. which reduces the mechanical stress on the series outer skin part in the deformation area.
  • a "rolling mandrel" can also be used, in which the tool tip is formed by a wheel or by a roller. Multiple mandrels or multi-armed forming mandrels can also be used.
  • the forming mandrel does not necessarily have to have a round or rounded tip Rather, a forming mandrel with a relatively sharp-edged tip can also be used.
  • the tip can also be flat, wheel-shaped, plow-shaped or similar to a ship's hull.
  • a forming mandrel with a faceted tool tip is also conceivable.
  • the forming mandrel does not necessarily have to be made of steel or tool steel. Forming mandrels made of plastic, wood, ice, sand, concrete or other materials are also conceivable.
  • the tool tip of the forming dome can be hardened, unhardened, coated or uncoated. It can e.g. be provided with a wear-resistant single or hybrid coating.
  • the forming mandrel can be guided in up to six axes relative to the component in order to achieve the desired “shape result”.
  • the shaping mandrel or the tool tip of the forming mandrel can also be rotated or oscillated about the longitudinal axis of the forming mandrel during post-processing.
  • a mandrel with or without lubrication can be used.
  • a lubrication system can be integrated in the forming mandrel.
  • the lubrication system can also be arranged on the outside of the forming mandrel.
  • the lubrication system ensures that the "processing point", i.e. the point at which the forming mandrel touches the series outer skin part, is constantly supplied with sufficient lubricant.
  • a lubricating oil can be used as the lubricant.
  • a forming mandrel can be used, the tool tip of which can be adjusted during the machining process.
  • the width of the tool tip can be changed transversely to the direction of travel of the tool mandrel during the machining process.
  • geometries with variable "width" can be produced in a single operation.
  • the travel speed with which the forming mandrel is moved relative to the series outer skin part during the reworking does not have to be constant. Rather, the travel speed can be varied as a function of the instantaneous “degree of deformation” of the series outer skin part. With smaller degrees of deformation, a higher travel speed can be selected, with larger degrees of deformation a lower travel speed.
  • Both the forming mandrel and the "workpiece” can be heated or cooled as required or have an ambient temperature during processing.
  • Heating the forming dome leads to heat input into the area of the workpiece to be formed, which increases its ductility, which facilitates the forming. Especially in the case of plastic parts
  • the series outer skin part can also be preheated or heated directly during the post-processing.
  • the standard outer skin part can be heated by hot air, radiant heaters, lasers or another heat source.
  • Series outer skin parts can be preheated to just below a material-specific "softening temperature" during post-processing and / or locally heated to a suitable "forming temperature” by means of a heated forming dome or selective additional heating at the point of engagement.
  • the workpiece can also be pretreated by other methods before post-processing. For example, it can be irradiated, coated, etched, hardened, roughened, smoothed, polished, sprayed with lubricating liquid or ground. It can also be pretreated by sandblasting before finishing. The finishing of the series outer skin part is preferably controlled fully automatically.
  • the forming mandrel can either be designed as a machining tool of a CNC machine tool, similar to that in US Pat. No. 6,216,608 B1, or it can be arranged on an arm of a correspondingly programmed machining robot.
  • a “processing station” can have further “tools”, for example a laser cutting device with which the outer skin sheet metal part can also be trimmed.
  • Fig. 1 an outer skin part with a molded bead, by a
  • Fig. 5 shows the basic principle of post-processing according to the invention
  • FIG. 13 shows an exemplary embodiment in which a front flap is reworked; and Fig. 14 a die-like counterholder.
  • Figure 1 shows a series outer skin sheet metal part 1 of a vehicle.
  • the series outer skin sheet metal part 1 of FIG. 1 is a “door outer skin”.
  • a molded bead 2 was “subsequently” incorporated into the series outer skin sheet metal part 1, which will be explained in more detail in connection with the following figures.
  • Figure 2 shows a section through the outer skin part 1 of Figure 1 along the section line A - A.
  • the molded bead 2 has a length I and a depth t.
  • the depth t of the shaped bead 2 has its maximum in the area of the z-axis of FIG. 2 and decreases towards the ends of the shaped bead 2.
  • FIG. 3 shows a cross section through the outer skin part 1 along the section line BB of FIG. 1. It can be seen that the shaped bead 2 is relatively sharp-edged. Such strongly accented character lines are difficult or impossible to produce with conventional deep-drawing processes.
  • FIG. 4 schematically describes the post-processing operation of the series outer skin part 1.
  • the series outer skin part 1 is clamped into a holding device 3 (not shown in more detail here) or fixed to a holding device 3.
  • the series outer skin part 1 is fastened to the holding device 1 only in its edge regions.
  • a forming dome 4 is brought up to the series outer skin part 1 and pressed against the series outer skin part 1 with a predetermined pressing force.
  • the forming mandrel 4 is moved in the direction of arrow 5 relative to the series outer skin part 1.
  • a "feed movement" of the forming dome 4 takes place relative to the series outer skin part 1, as a result of which the molding bead 2 is impressed into the series outer skin part 1 through the tip 6 of the forming dome 4.
  • FIG. 5 shows an exemplary embodiment in which a matrix-like counter-holder 7 is used to press against the side of the series outer skin part 1 opposite the forming mandrel 4.
  • the series outer skin part 1 is thus by supported matrix-like counter-holder 7, which enables the production of a sharp-edged contour, as shown in Figure 5, easily.
  • the die-like counterholder can be a component-specific tool or a "universal tool" that can also be used for the individualization of other series outer skin components.
  • FIGS. 6-8 show different cross sections A-A, B-B and C-C of a molded bead 2 subsequently embossed into a series outer skin part 1.
  • FIGS. 6a, 6b show an exemplary embodiment in which a strongly accented molded bead 2 was subsequently embossed into the series outer skin part 1, the “tip” of the molded bead 2 being softly rounded,
  • Figure 7b shows the cross section B-B. In this area the molded bead 2 is less accentuated.
  • the “tip” of the shaped bead 2 here has a larger radius of curvature than in FIG. 6b.
  • Figure 8b shows the cross section C-C.
  • the shaped bead 2 is again more strongly accentuated in this area. Similar to FIG. 6b, the “tip” of the shaped bead 2 has a relatively small radius of curvature.
  • FIG. 9 shows an embodiment in which the series outer skin part 1 is supported from the side opposite the forming mandrel 4 during the finishing by two counter-holders 8, 9 of essentially the same width.
  • the contour of the series outer skin part is indicated by 1 'before the post-processing.
  • the “tip” of the forming dome 4 is more strongly accentuated here than in the case of the forming mandrel 4 shown in FIG 9 at a distance L2.
  • the counterholders 8, 9 thus have a distance L3 which is equal to the sum of the distances L1 and L2.
  • L1 is smaller than L2 here.
  • the support is thus asymmetrical with respect to the position of the tip of the forming dome 4.
  • Figure 10 shows an embodiment in which the counter-holder 8 is wider than the counter-holder 9.
  • the support with respect to the tip of the forming dome 4 is only slightly asymmetrical.
  • L1 is only slightly larger than L2.
  • the tip of the forming dome 4 is blunt here, which results in a correspondingly less accentuated bulge.
  • Figure 1 1 shows an embodiment in which the counterholders 8, 9 are arranged at a relatively small distance L3 from each other. This enables relatively large degrees of deformation and, as can be seen from the drawing, the production of a relatively strongly accented molded bead.
  • Figure 12 shows the path of the forming tool using the example of a series outer skin part 1, such as a bonnet into which two character lines 2a, 2b are embossed.
  • the forming tool (not shown) is first lowered onto the serial outer skin part 1 from a point in space 10, which is referred to here as the “starting point” of the traversing movement
  • the forming tool is raised and reaches the space point 11. From there, the forming tool is moved to the space point 12.
  • the forming tool is lowered again onto the series outer skin part 1 and moved along the character line 2b to be produced 2b, the forming tool is raised and reaches space point 13.
  • FIG. 13 shows the “bonnet” 1 of FIG. 12 after the production of the character lines 2a and 2b.
  • a central bead 2c was embossed into the bonnet sheet by the same method, which protrudes upward from the bonnet, similar to that in FIG. 6 -8 is shown.
  • FIG. 14 shows a die 14 which can be used to produce a shaped bead, such as the shaped bead 2c in FIG. 13.
  • the die 14 is pressed against the series outer skin part (not shown here), namely from the side opposite the forming tool 4.
  • the die 14 is provided for the partial support of the forces exerted by the forming tool 4 on the series outer skin part.
  • the matrix 14 can be U-shaped, as in FIG. 14, that is to say open on one side.
  • the invention is by no means limited to a specific form of the die, but covers all the forms of the die.
  • the inner edge of the die 14 is flattened obliquely inwards in the “inlet area” of the forming tool 4.
  • the inner edge is essentially perpendicular to the support surfaces 17, 18 of the die 14, which press against the series outer skin part "from behind" during the finishing process and thereby support the forces exerted by the forming tool.
  • the travel path 19 of the forming tool should also be mentioned, which extends essentially centrally with respect to the two legs of the die 14.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Superstructure Of Vehicle (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

L'invention concerne un procédé servant à produire des pièces de véhicule, notamment des pièces d'enveloppe extérieure pour des véhicules. Selon l'invention, on produit à partir d'un matériau de départ une pièce de série finie ou semi-finie préformée tridimensionnellement, notamment une pièce d'enveloppe extérieure de série, pour un type de véhicule fabriqué en série. On produit ensuite une pièce individualisée à partir de la pièce de série préformée (1) en estampant après-coup un contour tridimensionnel (2) dans la pièce de série à l'aide d'un outil de façonnage (4) de type mandrin qui est pressé d'un côté contre la pièce de série et est simultanément déplacé par rapport à la pièce de série.
EP04711311A 2003-05-28 2004-02-14 Procede pour produire des pieces de vehicule individualisees, notamment des pieces d'enveloppe exterieure individualisees a partir de pieces de serie fabriquees en serie Expired - Lifetime EP1626824B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10324244A DE10324244A1 (de) 2003-05-28 2003-05-28 Verfahren zur Herstellung individualisierter Außenhautblechteile aus in Serienfertigung hergestellten Serienaußenhautblechteilen für Fahrzeuge sowie nach diesem Verfahren hergestellte Außenhautblechteile
PCT/EP2004/001403 WO2004105976A1 (fr) 2003-05-28 2004-02-14 Procede pour produire des pieces de vehicule individualisees, notamment des pieces d'enveloppe exterieure individualisees a partir de pieces de serie fabriquees en serie, et pieces d'enveloppe exterieure produites selon ce procede

Publications (2)

Publication Number Publication Date
EP1626824A1 true EP1626824A1 (fr) 2006-02-22
EP1626824B1 EP1626824B1 (fr) 2008-08-13

Family

ID=33482249

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04711311A Expired - Lifetime EP1626824B1 (fr) 2003-05-28 2004-02-14 Procede pour produire des pieces de vehicule individualisees, notamment des pieces d'enveloppe exterieure individualisees a partir de pieces de serie fabriquees en serie

Country Status (8)

Country Link
US (1) US20060090530A1 (fr)
EP (1) EP1626824B1 (fr)
JP (1) JP2007512960A (fr)
KR (1) KR20060014060A (fr)
CN (1) CN100382910C (fr)
DE (2) DE10324244A1 (fr)
ES (1) ES2309499T3 (fr)
WO (1) WO2004105976A1 (fr)

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KR20060014060A (ko) 2006-02-14
EP1626824B1 (fr) 2008-08-13
US20060090530A1 (en) 2006-05-04
JP2007512960A (ja) 2007-05-24
WO2004105976A1 (fr) 2004-12-09
DE10324244A1 (de) 2004-12-30
CN1795066A (zh) 2006-06-28
ES2309499T3 (es) 2008-12-16
CN100382910C (zh) 2008-04-23
DE502004007843D1 (de) 2008-09-25

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