CN111167906A - Method and apparatus for forming materials with low ductility - Google Patents
Method and apparatus for forming materials with low ductility Download PDFInfo
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- CN111167906A CN111167906A CN201911094635.1A CN201911094635A CN111167906A CN 111167906 A CN111167906 A CN 111167906A CN 201911094635 A CN201911094635 A CN 201911094635A CN 111167906 A CN111167906 A CN 111167906A
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- 238000000034 method Methods 0.000 title claims abstract description 68
- 239000000463 material Substances 0.000 title claims abstract description 63
- 238000009957 hemming Methods 0.000 claims abstract description 138
- 230000003287 optical effect Effects 0.000 claims abstract description 32
- 238000005452 bending Methods 0.000 claims abstract description 17
- 230000002093 peripheral effect Effects 0.000 claims description 24
- 229910000838 Al alloy Inorganic materials 0.000 claims description 15
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 14
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 12
- 239000011777 magnesium Substances 0.000 claims description 12
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- 229910052749 magnesium Inorganic materials 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 description 23
- 239000002184 metal Substances 0.000 description 23
- 238000010438 heat treatment Methods 0.000 description 17
- 229910001092 metal group alloy Inorganic materials 0.000 description 16
- 238000007493 shaping process Methods 0.000 description 9
- 230000007547 defect Effects 0.000 description 8
- 238000005096 rolling process Methods 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 230000001678 irradiating effect Effects 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 230000001939 inductive effect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000005555 metalworking Methods 0.000 description 1
- 239000013307 optical fiber Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
-
- 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
- B21D19/00—Flanging or other edge treatment, e.g. of tubes
- B21D19/02—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge
- B21D19/04—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge shaped as rollers
- B21D19/043—Flanging or other edge treatment, e.g. of tubes by continuously-acting tools moving along the edge shaped as rollers for flanging edges of plates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
-
- 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
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/02—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
- B21D39/021—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder for panels, e.g. vehicle doors
- B21D39/023—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder for panels, e.g. vehicle doors using rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/50—Working by transmitting the laser beam through or within the workpiece
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
- Laser Beam Processing (AREA)
Abstract
The present invention relates to a method and apparatus for forming a material having low ductility. And more particularly, to a method of hemming a low ductility material, the method comprising: a first sheet of material made of a low ductility material is provided, and an integrated creasing device with at least one laser head and a roll-forming assembly comprising rollers is provided. Hemming the first sheet by moving a roll-forming assembly relative to the first sheet in a hemming direction, wherein the roll-forming assembly is arranged relative to the first sheet to form a fold region in front of the roll-forming assembly. The at least one laser head directs laser light along two optical paths to form two irradiation spots. One of the irradiation spots irradiates a local portion of the first sheet material at a substantially constant predetermined distance in front of the roll-forming assembly in the hemming direction and within the bending region, and the other of the irradiation spots irradiates a portion of the roller.
Description
Technical Field
The present invention relates generally to the field of forming materials having low ductility, and more particularly to methods and apparatus for forming materials having low ductility.
Background
Many industries aim to reduce the weight of the products they produce while still maintaining the structural integrity of the products. In this context, lighter weight metals and metal alloys, such as aluminum, magnesium and aluminum alloys, magnesium alloys, are gaining increasing attention due to their relatively lower density and relatively higher specific strength compared to more traditional metals or metal alloys, such as steel. However, these materials have relatively low ductility which may lead to the formation of cracks or other defects when the materials are bent or folded.
In material science, ductility is the ability of a solid material to deform under tensile stress. Ductility is particularly important in metal working because materials that crack or break under stress cannot be manipulated using metal forming processes such as hammering, bending, rolling, roller hemming, and/or drawing.
Accordingly, it is desirable to provide forming processes and apparatuses for forming materials having relatively low ductility.
It is also desirable to provide a roller hemming process and apparatus for forming a material having relatively low ductility.
Systems for folding the edges of two or more metal parts together to form one part are well known. Such systems are commonly used in the manufacture of various automotive body parts such as doors, liftgates, hoods, etc., as well as in the manufacture of various other manufactured products.
Hemmed joints are well known in the automotive industry and, in addition, are used to join together the inner and outer metal panels of a vehicle door with other closure members of a motor vehicle. The resulting hem joints each typically include a metal flange of one panel that is folded over the edge of the other panel. Typically, in motor vehicle construction, the peripheral flange or outer edge region of the outer panel is folded over the outer edge region of the inner panel. The resulting hemmed joint provides a finished edge and mechanical connection between the two panels, which increases the strength and rigidity of the member.
For example, when an automotive door is to be manufactured in a hemming machine of the prior art, a pre-stamped outer door panel is loaded onto a suitably shaped anvil and then a pre-stamped inner door member is placed atop the inside of the outer door panel with the edge of the outer door panel and the edge of the inner door member overlapping each other and held in place by a clamp or other suitable mechanism. The hemming machine is then activated to move the suitably shaped first hem beam onto the anvil portion through a complex motion to fold the edges of the outer door panel and the inner door member onto each other to a first range of values, typically about forty-five degrees.
The first hem beam is then removed and a second, suitably shaped hem beam is moved onto the anvil with another complex motion to complete the portion by further folding the edges of the outer door panel and the inner door member onto each other to complete the hem.
As a result of the desire to reduce the weight of vehicles to improve, for example, fuel economy, there has been an increase in the use of aluminum and/or magnesium and aluminum and/or magnesium alloys in the manufacture of automotive bodies and components. Aluminum and/or magnesium and aluminum alloys and/or magnesium alloys have relatively low ductility, which may result in the formation of cracks or other defects in the bent or folded structure caused by the hemming process of the inner and outer panels.
Roller hemming is a relatively new development for joining inner and outer body panels by folding the outer flange over the edge of the inner panel. For a typical steel sheet panel, this process can produce a sharp hemmed appearance compared to conventional hemers. However, when hemming a metal or metal alloy panel having low ductility, the conventional hemmer must be modified to reduce the degree of bending of the metal or metal alloy sheet in order to prevent cracking along the hem line. It is difficult to produce sharp, flat hems with conventional hemers.
Disclosure of Invention
According to one aspect of at least one embodiment, there is provided a method of hemming a low ductility material, the method comprising: providing a first sheet of a low ductility material; providing an integrated hemming device comprising at least one laser head and a roll-forming assembly with rollers, wherein the at least one laser head is configured to direct laser light along two optical paths to form two irradiation spots that are at least partially non-overlapping one with the other; hemming the first sheet including moving a roll-forming assembly relative to the first sheet in a hemming direction, the roll-forming assembly being arranged relative to the first sheet to form a hem region prior to the roll-forming assembly to fold an edge portion of the first sheet back onto the first sheet itself during movement of the roll-forming assembly in the hemming direction to hem the first sheet; directing a laser along one of two optical paths using at least one laser head, irradiating a local portion of the first sheet material in the direction of the hem at a substantially constant predetermined distance in front of the roll-forming assembly and within the bending zone with one of two irradiation spots; and directing laser light along the other of the two optical paths using at least one laser head to irradiate a portion of the roller with the other of the two irradiation spots.
According to one aspect of at least one embodiment, there is provided a method of hemming a low ductility material, the method comprising: providing a first sheet of a low ductility material; providing an integrated hemming device comprising at least one laser head and a roll-forming assembly with rollers, wherein the at least one laser head is configured to direct laser light along two optical paths to form two irradiation spots that are at least partially non-overlapping one with the other; hemming the first sheet including moving a roll-forming assembly relative to the first sheet in a hemming direction, the roll-forming assembly being arranged relative to the first sheet to form a hem region prior to the roll-forming assembly to fold an edge portion of the first sheet back onto the first sheet itself during movement of the roll-forming assembly in the hemming direction to hem the first sheet; directing laser light along one of two optical paths using at least one laser head to irradiate a first localized portion of the first sheet material at a first substantially constant predetermined distance in front of the roll-forming assembly in the direction of the hem and within the bend region with one of two irradiation spots; and directing laser light along the other of the two optical paths using at least one laser head to irradiate a second partial portion of the first sheet material ahead of the roll forming assembly in the hemming direction at a second substantially constant predetermined distance with the other of the two irradiation spots, wherein one of the first partial portion and the second partial portion is at least partially non-overlapping with the other.
According to an aspect of at least one embodiment, there is provided a hemming apparatus for hemming a panel assembly including an outer panel and an inner panel, the apparatus comprising: a roll forming assembly having rollers for hemming the panel assembly; a retainer for positioning the panel assembly relative to the roll-forming assembly; and a laser source; wherein the laser source and the roll-on-roll assembly are configured to be movable as a whole, and wherein the laser source is configured during use to direct laser light along two optical paths to form two irradiation spots that are at least partially non-overlapping with each other.
According to one aspect of at least one embodiment, there is provided a method of forming a material having low ductility, the method comprising the steps of: providing a first sheet of a low ductility material, providing an integral forming device comprising a heat source and a forming element, and moving the forming element relative to the first sheet along a forming direction while heating a localized portion of the first sheet at a substantially constant predetermined distance in front of the forming element along the forming direction. The predetermined distance is selected to produce a predetermined temperature to achieve a predetermined ductility at the localized portion of the first sheet when the forming element reaches the localized portion of the first sheet.
According to one aspect of at least one embodiment, the step of heating comprises irradiating a localized portion of the first sheet with an energy beam. The energy beam may be a laser beam or an infrared beam. Thus, the heat source may be a laser source or an infrared light source. Alternatively, the heat source may also be an inductive heat source.
In accordance with one aspect of at least one embodiment, the forming element comprises a roll forming element. The roll-forming elements may have one or more rollers and the forming step may be performed in one or more roller channels.
In accordance with one aspect of at least one embodiment, the forming operation may be a bending, roller hemming, hammering, rolling and/or stretching operation.
According to one aspect of at least one embodiment, the laser beam has a large spot at the predetermined shaped area. The large spot laser beam may be selected to be a defocused beam or an enlarged beam produced by beam shaping optics. Alternatively, the large spot laser beam is the original beam generated directly by the laser source. Further, the laser beam may be selected to be a circular beam or a rectangular beam.
In accordance with one aspect of at least one embodiment, the low ductility material is made of aluminum, aluminum alloys, magnesium, and/or magnesium alloys.
In accordance with one aspect of at least one embodiment, the heating step is performed at a temperature in a range between about 150 ℃ to about 500 ℃.
According to one aspect of at least one embodiment, the heating step includes the step of varying an angle of incidence of the laser beam on the localized portion of the first sheet.
According to one aspect of at least one embodiment, the method further comprises the step of providing a programmable logic control for retrieving the predetermined forming temperature of the material having low ductility and the angle of incidence of the laser beam on the localized portion of the first sheet.
According to an aspect of at least one embodiment, there is provided a method comprising the further steps of: providing a second sheet adjacent the first sheet, securing the first sheet relative to the second sheet, the first sheet having a peripheral flange and the second sheet having a peripheral edge, moving the forming element relative to the first and second sheets along the peripheral flanges to fold the peripheral flange of the first sheet over the peripheral edge of the second sheet along the forming direction while heating a localized portion of the peripheral flange at a substantially constant predetermined distance in front of the forming element along the forming direction. The predetermined distance is selected to produce a predetermined temperature to achieve a predetermined ductility at the localized portion of the first sheet when the forming element reaches the localized portion of the first sheet.
According to one aspect of at least one embodiment, the present disclosure provides an apparatus for forming a material having low ductility, the apparatus comprising an integral forming device having a forming element and an energy source, wherein the forming element and the energy source are advanced simultaneously relative to the low ductility material. The forming apparatus may comprise a roll forming element. The energy source may be a laser source, an infrared light source, or an inductive heat source.
According to one aspect of at least one embodiment, there is provided a method of roller hemming a panel assembly comprising an outer panel and an inner panel, the method comprising the steps of: providing an outer panel having a peripheral flange, providing an inner panel adjacent the outer panel, the inner panel having a peripheral edge, securing the outer panel relative to the inner panel, and moving the roller elements along the peripheral flange relative to the outer and inner panels to fold the peripheral flange of the outer panel over the peripheral edge of the inner panel in a forming direction while heating a localized portion of the peripheral flange in the forming direction at a substantially constant predetermined distance in front of the roller elements. The predetermined distance is selected to produce a predetermined temperature to achieve a predetermined ductility at the localized portion of the peripheral flange when the roller elements reach the localized portion of the peripheral flange. The heating step includes the step of irradiating the localized portion with an energy beam. The energy beam may be a laser beam or an infrared beam. According to an embodiment of the invention, the roller element comprises at least one roller. Alternatively, two or more rollers may be employed. If desired, the hemming operation may be performed in one or more passes.
According to one aspect of at least one embodiment, the laser beam aiming angle may be varied with the folding angle of the roller element such that the incident spot of the laser beam on the surface of the peripheral flange is optimized.
According to one aspect of at least one embodiment, the method comprises a further step of determining the forming temperature at the local portion from the material before the forming step. The method may comprise a further step of determining the number of forming steps in dependence on the degree of bending.
According to one aspect of at least one embodiment, the method includes the further step of pre-flanging the peripheral flange of the outer panel.
According to one aspect of at least one embodiment, there is provided a roller hemming apparatus for hemming a panel assembly comprising an outer panel and an inner panel, the apparatus comprising a roller element for forming the panel assembly, a retaining device for positioning the panel assembly relative to the roller element, and a heat source moving in unison with the roller element; wherein the heat source is for emitting an energy beam onto a localized portion of the panel assembly in front of the roller element at a substantially constant predetermined distance. The predetermined distance is selected to produce a predetermined temperature to achieve a predetermined ductility at the localized portion of the panel assembly when the roller element reaches the localized portion of the panel assembly.
Drawings
Exemplary embodiments of the invention will now be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
fig. 1a and 1b show a flat sheet before undergoing a forming process and after undergoing a forming process according to the present invention;
fig. 2 to 6 are schematic representations illustrating a hemming process according to an embodiment of the present invention;
FIG. 7 shows a photographic image of a hemmed panel assembly made by conventional roller hemming;
figures 8 and 9 show a part of a roller hemming apparatus incorporating a laser head with a roller hemming device according to the invention;
FIGS. 10 to 12 show the panel assembly in the roller hemming apparatus of the present invention and how the laser beam is applied simultaneously in front of the hemming roller; and
figure 13 shows a photographic image of a crease line produced according to the present invention.
FIG. 14 shows a partial roller hemming apparatus incorporating a laser head projecting a plurality of laser beams with a roller hemming device according to an embodiment of the invention;
FIG. 15 illustrates a partial roller hemming apparatus combining a plurality of laser heads with a roller hemming device according to an embodiment of the present invention;
FIG. 16 illustrates a hemming process according to an embodiment of the invention;
FIG. 17 illustrates another hemming process according to an embodiment of the invention;
FIG. 18 illustrates another hemming process according to an embodiment of the invention wherein a divergent laser beam is used.
Detailed Description
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments disclosed, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
In accordance with at least one embodiment, a process and apparatus for forming a material having relatively low ductility is provided. According to another aspect of the present invention, a roller hemming process and apparatus for hemming a material having relatively low ductility is provided. The process and apparatus are particularly advantageous for roller hemming inner and outer panels comprising a metal or metal alloy having low ductility. Examples of such metals or metal alloys are magnesium and aluminum and magnesium alloys and aluminum alloys.
In the context of this application, the term "low ductility material" refers to any material having ductility such that a forming operation will introduce cracks or other defects in the formed material.
In the context of this application, the term "laser head" refers to an assembly from which a laser beam is emitted towards a workpiece. The laser head may not include a laser source. The laser head includes at least focusing optics and may include shielding glass and/or additional facilities, for example to direct a gas stream to the irradiation zone. The laser may enter the laser head through a high power optical fiber cable.
Referring to fig. 1a and 1b, a flat sheet 10 is shown before undergoing a forming process (fig. 1a) and after undergoing a forming process according to the present invention along an edge 12 (fig. 1 b). In accordance with the present invention, sheet 10 is made of a relatively low ductility material such as aluminum, magnesium, aluminum alloys, and magnesium alloys, and the process and apparatus in accordance with the present invention forms a bend along edge 12. Exemplary forming processes include hammering, bending, rolling, roller hemming, and/or stretching.
In accordance with the present invention, a method and apparatus for forming a material having relatively low ductility is provided. An integrated forming device is provided that combines a heat source, such as a laser source, infrared light source, or induction heat source, with the forming device. The heat source heats the metal or metal alloy to a predetermined temperature in accordance with a low ductility material to be formed at a predetermined location where the material is to be formed to increase ductility of the metal or metal alloy at the predetermined location. The forming device simultaneously performs the forming operation at the predetermined location while the heat source applies heat to the predetermined location. The heat source emits an energy beam that leads the forming device as the integrated forming device is advanced along the predetermined location of the material to be formed. The metal or metal alloy of the sheet to be formed is heated to an optimum temperature to achieve a predetermined ductility that allows the sheet to be formed without surface cracks or any other defects in the formed sheet. The process and apparatus according to the invention thus provide heat to a localized area of the sheet to be formed and thus allow the material to be formed at a desired optimum temperature and allow the introduction of a minimum heat input to avoid unnecessary thermal deformations in the formed sheet. Furthermore, the process and the apparatus according to the invention allow a reduction of the cycle time.
According to another aspect of the invention, the process and apparatus of the present invention are particularly advantageous for roller hemming applications where extreme bends are formed in low ductility materials.
Thus, according to one aspect of the invention, a roller hemming apparatus is provided with an energy source, such as a laser source. Examples of laser sources that can be used according to the invention are carbon dioxide lasers, Nd: YAG laser and laser diode. The laser head emits a laser beam ahead of the hemming roller. The laser beam heats the metal or metal alloy around the predetermined break line to increase the ductility of the metal or metal alloy. The hemming rollers follow the laser beam such that the heating operation and the hemming operation, i.e. the hot forming process, are performed simultaneously on the metal or metal alloy while the metal or metal alloy is still hot. The metal or metal alloy of the panel to be hemmed is heated to an optimum temperature to obtain a predetermined ductility that allows the hems to be formed without surface cracking or any other defects. The use of a laser is advantageous because the use of a laser provides both a brief heating and a localized heating around the intended location of the hem or around the hem line. Thus, the laser assisted hemming process according to the invention provides heat to a localized area of a metal or metal alloy panel and thus allows for a minimum of heat input, thereby reducing deformation of the panel to be hemmed and allowing the laser assisted hemming process to be performed in a relatively short period of time. In contrast, some prior art methods disclose pre-annealing processes to increase the ductility of some panels in order to obtain a flat crease line, which would significantly increase cycle time. According to the present invention, a cycle time for hemming a material having low ductility may be reduced by simultaneously heating and hemming at a predetermined hemming position or hemming line.
According to yet another aspect of the invention, the laser beam has a large spot at the location of irradiation that covers the entire bend radius or curvature area to allow more material to participate in the stretching. Examples of an amplified laser beam are a defocused beam or an amplified beam produced by beam shaping optics. Alternatively, a suitably sized primary beam directly from the laser may be used. According to yet another embodiment of the invention, the geometry of the laser beam may be selected according to the particular application. For example, the laser beam may be a circular beam or a rectangular beam.
According to one aspect of the invention, a defocused laser beam is used to provide a relatively small amount of power. For panels made of aluminium, magnesium and/or aluminium alloys, magnesium alloys, the panels to be flanged are generally heated to a temperature of between about 150 ℃ and 500 ℃. However, the specific temperature depends on the material the panel comprises in order to locally increase the ductility of the panel around the predetermined bending area or crease line.
According to another aspect of the invention, the type of low ductility material determines the optimum temperature at which the metal or metal alloy is heated and the angle of incidence of the laser beam.
According to yet another aspect of the invention, a Programmable Logic Control (PLC) can be used to retrieve the optimum shaping temperature and the angle of incidence of the laser beam.
According to another aspect of the invention, the shaping operation may be performed in a single roll shaping step or in two or more roll shaping steps when the energy beams are simultaneously applied to the shaping positions.
According to another aspect of the invention, the forming temperature and the number of forming steps are selected according to the degree of bending, or in other words, the complexity of the formed shape of the product being formed. For example, a 5K aluminum alloy may be formed in a single rolling step if the forming temperature generated by the laser beam during forming is between about 250 ℃ and 260 ℃, or a 5K aluminum alloy may be formed in two rolling steps if the forming temperature generated by the laser beam during forming is between 180 ℃ and 220 ℃.
Turning now to fig. 2-6, an exterior panel 100 and an interior panel 104 are provided. The outer and inner panels may be prepared by various metal forming processes such as roll forming, drawing or stamping, and cutting. For example, motor vehicle body panels, doors, hoods, fenders, tailgates, trunks, and trunk lids can be constructed by stamping an outer sheet metal panel and separately stamping an inner sheet metal reinforcement panel and then joining the two panels together by flanging a flange of the outer periphery of the outer panel over an adjacent edge of the inner panel to secure the panels together. Advantageously, the outer panel is slightly larger than the inner panel to provide a boundary flange portion along the periphery of the outer panel which may be folded over the peripheral edge of the inner panel to define a hem flange connecting the two panels. The exterior panel 100 and the interior panel 104 may include various types of steel, aluminum alloys, magnesium, and/or magnesium alloys. However, aluminum, magnesium, and aluminum and magnesium alloys have relatively low ductility at room temperature, and if aluminum, magnesium, and aluminum and magnesium alloys are hemmed at this temperature, some surface defects, such as cracks, typically occur around the hemmed line when processed at this temperature. For example, fig. 7 shows a photographic image of a panel assembly made from conventional roller hemming, and wherein the outer panels of the panel assembly are made from a low ductility material. The panel assembly was hemmed at room temperature and from the photographic image it can be seen that the hemmed assembly had cracks around the hemmed line.
According to an embodiment of the present invention, the exterior panel 100 is pre-hemmed around a flange 102 along the periphery of the exterior panel 100. Figure 2 shows the flange pre-hemmed at about 90 degrees. Alternatively, the pre-crimping may be performed at various angles. According to another embodiment of the invention as discussed hereinbefore, the flanging operation can be done in a single rolling step, in which case the pre-flanging step is omitted.
Fig. 4 shows the inner panel 104 positioned adjacent to the flange 102 of the outer panel 100. The two panels are assembled and the panel assembly is secured by a suitable retainer such as a clamping device (not shown) for holding the panel assembly in place during the hemming operation. Alternatively, the inner and outer panels may be fixed by means of an adhesive.
Fig. 5 shows a schematic cross-sectional view of a hemmed panel assembly, wherein the flange 102 of the outer panel 100 is bent from a 90 degree pre-hemmed corner to a 180 degree hemmed corner, i.e. the flange 102 is folded over the peripheral edge 105 of the inner panel 104 to define a hemmed flange joining the two panels. Figure 6 shows an isometric view of a hemmed panel assembly.
Figures 8 and 9 show a part of the apparatus according to the invention, illustrating two configurations formed with two different folding angles. Laser head 702 is combined with a roller hemming apparatus represented by a hemming roller 704 and a hemming roller 706. A panel assembly (not shown) comprising an outer panel and an inner panel is held in a holding device (not shown) and is disposed between hemming roller 704 and hemming roller 706. Laser head 702 emits a laser beam 708, which laser beam 708 is a defocused beam 710 that is projected onto the panel assembly disposed between hemming roller 704 and hemming roller 706. The laser beam is projected onto the panel assembly and advanced with respect to the hemming roller. The laser beam is used to apply heat directly to the bending region to improve its elongation while the roller hemming apparatus and the rest of the panel assembly are kept at room temperature. Heat is introduced into the bending zone in real time while the roller is hemming. The laser beam is applied immediately in front of the hemming roller. Thus, the locally heated bending zone moves dynamically with the roller hemming apparatus of the present invention. Furthermore, the laser beam aiming angle may be varied with the folding angle of the roller such that the incident spot of the laser beam on the surface of the flange is optimized.
Fig. 10 shows a schematic cross-sectional side view of a panel assembly comprising an outer panel 902 having a pre-hemmed flange 904 and an inner panel 906, the outer panel 902 and the inner panel 906 being positioned in a holding device 908 between a hemming roller 910 and a hemming roller 912. Fig. 11 shows a schematic top view of a partially hemmed panel assembly. Arrow a indicates the direction in which the hemming rollers 910, 912 advance during the roller hemming process. As can be seen from fig. 11, the hemming rollers 910, 912 are advanced by a laser beam 914 which, while the roller hemming apparatus moves onto the panel assembly, the laser beam 914 simultaneously applies heat directly to the fold area to fold the flange of the outer panel over the peripheral edge of the inner panel. According to an embodiment of the present invention, the roller hemming apparatus of the present invention combines a laser head with a roller hemming apparatus, wherein the laser head and the hemming roller move in pairs, and wherein a laser beam is advanced with respect to the hemming roller. Region H in fig. 11 shows the hemmed region of the panel assembly after the roller hemming apparatus according to the present invention has moved over region H and approached the unbanded region U.
Fig. 12 shows another embodiment of the present invention, in which a single roller is used in the roller hemming apparatus of the present invention. Laser beam 1102 is applied to the bend region before roller 1104 moves across the bend region. The direction of roller movement is indicated by arrow a in fig. 12 and proceeds from the hemmed area "H" to the unhemmed area "U".
Alternatively, as discussed hereinbefore, other energy beam sources such as infrared light sources or induction heat sources may be employed in place of the laser heads in accordance with the present invention. However, the use of a laser is advantageous in that the use of a laser can be easily adapted to any application, i.e. the beam size and shape, the angle of incidence and the intensity of the laser beam can be easily adapted to any material to be shaped. Furthermore, the use of beam shaping optics enables a predetermined laser beam to be provided such that the incident energy beam affects the ductility of the material to be shaped in a predetermined manner to produce a shaped product without any cracks or other defects.
Figure 13 shows a photographic image of a hemmed panel according to an embodiment of the invention. As can be observed from this image, the formed panel assembly is free of cracks and other defects.
Furthermore, according to another aspect of the present invention, three-dimensional straight hemming may be achieved with a roller hemming apparatus, i.e. a roller hemming apparatus of the present invention may be used to produce a non-straight hem line such as, for example, a rounded hem line moving around a corner of a motor vehicle hood.
Advantageously, the process and apparatus of the present invention, which employs an energy beam such as a laser beam, applies heat directly to the bend region to improve its elongation. Heat is introduced into the bending zone in real time, i.e. simultaneously with a forming step such as roller hemming. The energy beam is applied directly in front of the shaping device. The energy beam aiming angle may be varied with the folding angle of the roller so that the incident spot of the energy beam on the surface of the flange is optimized.
Referring now to FIG. 14, a portion of an apparatus according to another embodiment of the present invention is shown. According to this embodiment, multiple heating spots are created on the panel assembly and/or the roller to improve the quality of the formed hem. Laser head 702 is combined with a roller hemming apparatus represented by a hemming roller 704 and a hemming roller 706. A panel assembly (not shown) comprising an outer panel and an inner panel is held in a holding device (not shown) and fed between hemming roller 704 and hemming roller 706. In at least some embodiments, creasing roller 706 is merely optional. The laser head 702 emits a laser beam that is divided, i.e., using laser optics 1402 to form a plurality of individual laser beams. In the particular example shown in fig. 14, one of the beams 708a is directed to hemming roller 704 and forms an irradiation spot 710a on hemming roller 704. The other beam 708b is directed to a panel assembly not shown and forms an irradiation spot 710b on the panel assembly not shown. As shown in more detail in fig. 16, laser beam 708b forms a spot 710b on the unflanged region "U" of the panel assembly in front of the hemming roller along hemming direction "a" to apply heat directly into the fold region, while laser beam 708a forms a spot 710a and applies heat directly to hemming roller 704. In this embodiment, heat is applied to the panel assembly bending area and to the hemming roller 704 while the roller is hemming. By heating creasing roller 704, less heat may be applied directly to the crease area at spot 710 a. In addition, the heated rollers 704 extend the length of time that the material of the panel assembly is maintained at the desired elevated temperature, which would otherwise tend to cool quickly after being irradiated by the laser, particularly when the panel assembly is pressed between unheated rollers. Alternatively, the laser beam aiming angle may be varied with the folding angle of the roller so that the incident spot of the laser beam on the surface of the flange is optimized.
Referring now to FIG. 15, a portion of an apparatus according to another embodiment of the present invention is shown. A plurality of laser heads 702a and 702b are combined with a roller hemming apparatus represented by a hemming roller 704 and a hemming roller 706. In at least some embodiments, creasing roller 706 is merely optional. A panel assembly (not shown) comprising an outer panel and an inner panel is held in a holding device (not shown) and fed between hemming roller 704 and hemming roller 706. In the configuration shown in fig. 15, laser head 702a generates a first laser beam 708a and laser head 702b generates a second laser beam 708 b. One of the beams 708a is directed to the hemming roller 704 and forms an irradiation spot 710a on the hemming roller 704, and the other beam 708b is directed to a panel assembly, not shown, and forms an irradiation spot 710b on the panel assembly, not shown. As shown in more detail in fig. 16, laser beam 708b forms a spot 710b on the unflanged region "U" of the panel assembly in front of the hemming roller along hemming direction "a" to apply heat directly to the fold region, while laser beam 708a forms a spot 710a and applies heat directly to hemming roller 704. In this embodiment, heat is applied to the panel assembly bending area and to the hemming roller 704 while the roller is hemming. By heating creasing roller 704, less heat may be applied directly to the crease area at spot 710 a. In addition, the heated rollers 704 extend the length of time that the material of the panel assembly remains at an elevated temperature, which would otherwise tend to cool quickly after being irradiated by the laser, particularly as the panel assembly is squeezed between unheated rollers. Alternatively, the laser beam aiming angle may be varied with the folding angle of the roller so that the incident spot of the laser beam on the surface of the flange is optimized.
In an alternative embodiment shown in fig. 17, both laser beams 708a and 708b from a single laser source or from multiple individual laser sources are directed to the panel assembly, forming multiple laser beam spots 710a and 710b on the panel assembly. The size and/or shape and/or fluence and/or number of laser beam spots may be adjusted to adjust the heating of the desired width of the panel assembly in front of hemming roller 704 and hemming roller 706 along hemming direction "a". Optionally, the laser beam spot 710a and the laser beam spot 710b are at least partially superimposed on each other and/or the laser beam 708a and the laser beam 708b are of different powers or the like to control the heating and thus the temperature distribution in the bending region of the panel. In this way, different portions of the sheet may be heated to different depths, for example. Still alternatively, another heat source, such as, for example, an induction heating element, is used to heat hemming roller 704. The heated roller 704 prevents the panel assembly from cooling at strategic points during hemming.
FIG. 18 is a simplified side view of another embodiment showing a divergent laser beam 1802 being delivered from the end of a laser fiber 1804 and impinging on a panel assembly 1806. The divergent laser beam 1802 is less focused than the laser beams 708, 708a, 708b in the embodiments described above. The divergent laser beam irradiates and heats a relatively large area of the panel assembly 1806 in front of the roller 1808 in the hemming direction "a". Furthermore, the divergent laser beam may extend very close to the point where the roller 1808 contacts the panel assembly 1806 without a large angle of incidence, which allows the roller hemming device to be made more compact. Advantageously, since no laser focusing optics are required, the end of the laser fiber 1804 can reach directly to the area to be heated, which makes this configuration more cost effective.
It will be understood that the foregoing description is illustrative in nature and that the invention is intended to cover modifications, variations and equivalent arrangements included within the scope of the invention.
Claims (18)
1. A method of hemming a low ductility material, the method comprising:
providing a first sheet made of the low ductility material;
providing an integrated hemming device comprising:
at least one laser head; and
a roll-forming assembly comprising a roll of material,
wherein the at least one laser head is configured to direct laser light along two optical paths to form two irradiation spots that are at least partially non-overlapping one with the other;
hemming the first sheet comprising: moving the roll-forming assembly relative to the first sheet in a hemming direction, the roll-forming assembly being arranged relative to the first sheet to form a fold region before the roll-forming assembly to fold an edge portion of the first sheet back onto the first sheet itself during movement of the roll-forming assembly in the hemming direction;
directing laser light along one of the two optical paths using at least one laser head to irradiate a localized portion of the first sheet material in the direction of the hem at a substantially constant predetermined distance in front of the roll-forming assembly and within the bend region via one of the two irradiation spots; and
directing laser light along the other of the two optical paths using the at least one laser head to irradiate a portion of the roller through the other of the two irradiation spots.
2. The method of claim 1 in which the at least one laser head comprises a single laser head and the method comprises: using an optical element to direct a first portion of the laser light produced by the single laser head along the one of the two optical paths and using the optical element to direct a second portion of the laser light produced by the single laser head along the other of the two optical paths.
3. The method of claim 1 wherein the at least one laser head includes a first laser head and a second laser head, and the method includes: using the first laser head to direct the laser along the one of the two optical paths and using the second laser head to direct the laser along the other of the two optical paths.
4. The method of claim 1, wherein the low-ductility material is one of aluminum, an aluminum alloy, magnesium, and a magnesium alloy.
5. The method of claim 1 wherein the laser heads heat the low ductility material within the bend region to a temperature between about 150 ℃ and about 500 ℃.
6. The method of claim 1, comprising:
performing the following steps before hemming the first sheet:
providing a second sheet adjacent to the first sheet; and
securing the first sheet relative to the second sheet; the second sheet has a peripheral edge;
wherein creasing the first sheet comprises moving the roll-forming assembly relative to the first sheet and the second sheet to fold the edge portion of the first sheet over the peripheral edge of the second sheet.
7. A method of hemming a low ductility material: the method comprises the following steps
Providing a first sheet made of the low ductility material;
providing an integrated hemming device comprising:
at least one laser head; and
a roll-forming assembly comprising a roll of material,
wherein the at least one laser head is configured to direct laser light along two optical paths to form two irradiation spots that are at least partially non-overlapping one with the other;
hemming the first sheet comprising: moving the roll-forming assembly relative to the first sheet in a hemming direction, the roll-forming assembly being arranged relative to the first sheet to form a fold region before the roll-forming assembly to fold an edge portion of the first sheet back onto the first sheet itself during movement of the roll-forming assembly in the hemming direction;
directing laser light along one of the two optical paths using the at least one laser head to irradiate a first localized portion of the first sheet material at a first substantially constant predetermined distance in front of the roll-forming assembly in the hemming direction and within the bending zone by one of the two irradiation spots; and
directing laser light along the other of the two optical paths using the at least one laser head to irradiate a second localized portion of the first sheet material ahead of the roll-forming assembly in the hem direction at a second substantially constant predetermined distance through the other of the two irradiation spots,
wherein one of the first partial portion and the second partial portion is at least partially non-overlapping with the other.
8. The method of claim 7, wherein the second localized portion is also within the inflection region.
9. The method of claim 7 in which the at least one laser head comprises a single laser head and the method comprises: using an optical element to direct a first portion of the laser light produced by the single laser head along the one of the two optical paths and using an optical element to direct a second portion of the laser light produced by the single laser head along the other of the two optical paths.
10. The method of claim 7 wherein the at least one laser head includes a first laser head and a second laser head, and the method includes: using the first laser head to direct the laser along the one of the two optical paths and using the second laser head to direct the laser along the other of the two optical paths.
11. The method of claim 7, wherein the low-ductility material is one of aluminum, an aluminum alloy, magnesium, and a magnesium alloy.
12. The method of claim 7 wherein the laser heads heat the low ductility material within the bend region to a temperature between about 150 ℃ and about 500 ℃.
13. The method of claim 7, comprising:
performing the following steps before hemming the first sheet:
providing a second sheet adjacent to the first sheet; and
securing the first sheet relative to the second sheet, the second sheet having a peripheral edge;
wherein creasing the first sheet comprises moving the roll-forming assembly relative to the first sheet and the second sheet to fold the edge portion of the first sheet over the peripheral edge of the second sheet.
14. A hemming apparatus for hemming a panel assembly comprising an outer panel and an inner panel, the apparatus comprising:
a roll forming assembly including a roller for flanging the panel assembly;
a retainer for positioning the panel assembly relative to the roll-forming assembly; and
a laser source;
wherein the laser source and the roll-forming assembly are configured to be movable as a unit, and
wherein the laser source is configured to direct laser light along two optical paths during use to form two irradiation spots that are at least partially non-overlapping with each other.
15. The apparatus of claim 14 wherein the laser source comprises a first laser head configured to direct laser light along a first of the two optical paths and a second laser head configured to direct laser light along a second of the two optical paths.
16. The apparatus of claim 14 wherein the laser source comprises a single laser head and optical elements to direct a first portion of the laser light produced by the single laser head along a first of the two optical paths and a second portion of the laser light produced by the single laser head along a second of the two optical paths.
17. The hemming apparatus of claim 14 wherein the laser source is configured to form the two irradiation spots, in use, on respective at least partially non-overlapping portions of the panel assembly and in front of the roller along the hemming direction at respective substantially constant predetermined distances.
18. The hemming apparatus of claim 14 wherein the laser source is configured to form, during use, one of the two irradiation spots on a portion of the panel assembly and in front of the roller at a respective substantially constant predetermined distance in the hemming direction, and the other of the two irradiation spots on a portion of the roller.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US16/189,760 US20190076908A1 (en) | 2010-05-17 | 2018-11-13 | Method and Apparatus for Forming Materials with Low Ductility |
| US16/189,760 | 2018-11-13 |
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| CN111167906A true CN111167906A (en) | 2020-05-19 |
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| CN201911094635.1A Pending CN111167906A (en) | 2018-11-13 | 2019-11-11 | Method and apparatus for forming materials with low ductility |
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| DE (1) | DE102018132090A1 (en) |
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| DE102018132090A1 (en) | 2020-05-14 |
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Application publication date: 20200519 |