CN118159370A

CN118159370A - Press system and method of manufacturing a hot stamped structural component

Info

Publication number: CN118159370A
Application number: CN202280071377.9A
Authority: CN
Inventors: M·季; D·V·拉朱; R·K·韦玛; A·拉吉
Original assignee: Tata Steel Ltd
Current assignee: Tata Steel Ltd
Priority date: 2021-09-01
Filing date: 2022-09-01
Publication date: 2024-06-07
Also published as: WO2023031838A1

Abstract

The present application relates to a press system and a method for producing a hot stamped structural component from a sheet material in a press system. The press system includes a controlled atmosphere system and a press tooling device. The press tooling device includes a lower body member, an upper die member, a lower die member, and a heating device configured to heat the plate blank. The upper and lower die members are arranged to perform hot blanking with stamping and in-mold quenching on a heated sheet blank in an atmosphere controlled by a controlled atmosphere system to form a hot stamped structural member. By controlling the atmosphere during the formation of the hot stamped structural component, the formation of scale will be inhibited.

Description

Press system and method of manufacturing a hot stamped structural component

Technical Field

The present invention relates to a press system and, more particularly, to a press system and method for manufacturing hot stamped structural components from sheet stock under a controlled atmosphere within the press system.

Background

Due to the exacerbation of global energy crisis and environmental concerns, automotive manufacturers are working on lightweight technologies in order to increase the fuel efficiency of vehicles. The use of high strength steels has been an unavoidable trend for the purpose of weight saving and safety improvement. Press forming (e.g., hot stamping) is one manufacturing process used to manufacture such high strength steel components. In a conventional hot stamping process, a workpiece (e.g., a boron steel sheet blank) is heated in a conventional furnace to above the austenite transformation temperature and held for a few minutes to achieve the austenite phase throughout its volume. The workpiece is then rapidly transferred from the furnace to the press tool in about 10 seconds and rapidly deformed into the desired shape while being rapidly quenched to produce a final product having a predominantly martensitic phase. In a conventional electric furnace, the workpiece is heated by radiation.

However, these conventional furnaces require more energy and consume more time for heating the workpiece (boron steel) to its austenitic temperature. In addition to energy, the furnace requires a huge installation space and reduces productivity. Moreover, in the heating time in the furnace (about 3 minutes) and the transfer time from the furnace to the hot stamping machine (about 10 seconds), the steel plate blank (e.g., uncoated boron steel) reacts with atmospheric air, the steel surface oxidizes, and an oxide scale develops on the surface of the steel plate blank. When scale is present on the steel sheet, this may be unacceptable for automotive applications. Steel oxidizes at high temperatures when reacted with the atmosphere. The oxidation rate also depends on the steel temperature and reaction time. It is therefore desirable to develop a press system that has heating and stamping techniques for the work pieces that will reduce the reaction time for surface oxidation.

Object of the Invention

The object of the present invention is to solve the problems of the prior art and to provide a press system comprising novel heating and stamping techniques with improved productivity.

It is another object of the present invention to develop a press system with a controlled atmosphere system that will reduce the reaction time of surface oxidation and thus reduce scale.

It is a further object of the present invention to provide a press system that provides atmospheric control during the forming stage to inhibit the formation of scale.

Disclosure of Invention

The present disclosure is provided to introduce concepts related to press systems and methods for manufacturing hot stamped structural components from a sheet blank within a press system. These concepts will be further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

In one aspect of the invention, a press system is provided. The press system includes a controlled atmosphere system and a press tooling apparatus for manufacturing a hot stamped structural member. The press tool device includes a lower body member and an upper body member corresponding to the lower body member. The upper body member and the lower body member are configured to move relative to one another. The press tool device also includes a press tool cavity defined between the lower body member and the upper body member. The press tool arrangement further comprises an upper and a lower mold part arranged within the press tool cavity. The upper mold member is connected to the upper body member and the lower mold member is connected to the lower body member. The press tool arrangement comprises a heating device which is arranged in the press tool chamber. The heating means are arranged to heat the plate blank. The upper and lower die members are arranged to perform hot blanking with stamping and in-mold quenching on a heated sheet blank in an atmosphere controlled by a controlled atmosphere system to form a hot stamped structural member.

In an embodiment, controlling the atmosphere during formation of the hot stamped structural component will inhibit the creation of scale on the hot stamped structural component.

In an embodiment, the controlled atmosphere system surrounds the press tooling device.

In an embodiment, the controlled atmosphere system is arranged between the lower body part and the upper body part.

In an embodiment, a controlled atmosphere system includes an enclosure having at least one door and an atmosphere control device.

In an embodiment, the enclosure encloses the press tooling device, and the atmosphere control device controls the atmosphere within the enclosure. In an embodiment, the enclosure is a room.

In an embodiment, the atmosphere control means is arranged to control the atmosphere by controlling the air flow rate.

In an embodiment, the atmosphere control device is arranged to control the atmosphere (reduce or reduce the atmosphere) by filling any medium that reduces the oxygen content, wherein the medium is any one of a solid medium, a liquid medium or a gaseous medium.

In an embodiment, the atmosphere control means is arranged to control the atmosphere by filling with an inert gas selected from any one of nitrogen, helium or argon.

In an embodiment, the enclosure and the at least one door are made of a material selected from any one of plastic, resin, wood, metal, alloy, or composite material.

In an embodiment, the enclosure encloses a press tool cavity, and the atmosphere control device controls atmosphere within the press tool cavity.

In an embodiment, the controlled atmosphere system is arranged such that the press tool chamber is completely isolated from the surrounding atmosphere.

In an embodiment, the press system comprises a slab stock unit and a finished product collection unit.

In an embodiment, the controlled atmosphere system is equipped with a sheet stock material unit on one side and a finished product collection unit on the other side. The slab stock unit is configured to provide a slab stock to the press tooling device and the finished product collection unit is configured to receive the hot stamped structural component from the press tooling device.

In an embodiment, the heating device is a resistive heating device using the principle of joule heating.

In an embodiment, the heating device comprises a power source and a plurality of electrodes including a first electrode, a second electrode, a third electrode, and a fourth electrode.

In an embodiment, the press tool arrangement comprises at least one clamping arrangement arranged to selectively engage or disengage at least one of the plurality of electrodes.

In an embodiment, the press tool device comprises two clamping devices comprising a first pneumatic cylinder and a second pneumatic cylinder. The first pneumatic cylinder is configured to selectively engage or disengage the third electrode with the first electrode and the second pneumatic cylinder is configured to selectively engage or disengage the fourth electrode with the second electrode.

In an embodiment, the plurality of electrodes are copper electrodes. In an embodiment, the slab stock is an uncoated boron steel slab stock.

In an embodiment, the thickness of the plate blank ranges between 0.6mm and 2.0 mm.

In an embodiment, the upper and lower mold members are configured to operate at a predetermined temperature.

In an embodiment, the upper body member and the lower body member are moved relative to each other by any one of mechanical means or hydraulic means.

In an embodiment, the heating device is an induction heating device.

In an embodiment, the press system includes a control system and a closed loop feedback system. The closed loop feedback system is arranged to monitor information related to the controlled atmosphere system and the press tooling device and to communicate this information to a control system arranged to control the press system.

In another aspect of the invention, a method of manufacturing a hot stamped structural component from a sheet stock in a press system is provided. The press system includes a controlled atmosphere system including an enclosure having at least one door and an atmosphere control device. The press system further includes a press tooling device. The press tool device includes a lower body member and an upper body member corresponding to the lower body member. The upper body member and the lower body member are configured for movement relative to one another. The press tool device also includes a press tool cavity defined between the lower body member and the upper body member. The press tool arrangement includes an upper die member and a lower die member disposed within the press tool cavity. The upper mold member is connected to the upper body member and the lower mold member is connected to the lower body member. The press tool arrangement comprises a heating device arranged in the press tool chamber. The heating device includes a plurality of electrodes connected to a power source. The method includes delivering a slab to a plurality of electrodes. The method further includes closing at least one door of the enclosure and controlling the atmosphere within the enclosure by an atmosphere control device. The method further comprises clamping the plate blank between the plurality of electrodes by at least one clamping device. The method includes heating the slab to a first predetermined temperature by supplying power from a power source to a plurality of electrodes. The method further comprises releasing the heated plate blank by retracting the at least one clamping device. The method further includes moving the upper body member relative to the lower body member. The method includes performing hot blanking with stamping and in-mold quenching on a heated sheet blank in a controlled atmosphere through an upper die part and a lower die part to form a hot stamped structural part.

In an embodiment, the first predetermined temperature ranges from about 350 ℃ to 950 ℃. In an embodiment, the first predetermined temperature ranges from about 750 ℃ to 950 ℃. In an embodiment, the first predetermined temperature is 900 ℃.

In an embodiment, the press system includes a non-contact pyrometer to detect the temperature of the sheet blank.

In an embodiment, the press system comprises a control system and a closed loop feedback system, wherein the closed loop feedback system is arranged to monitor information related to the controlled atmosphere system and the press tool arrangement and to communicate this information to the control system arranged to control the press system.

Other features and aspects of the present invention will become apparent from the following description and the accompanying drawings.

Drawings

FIG. 1 illustrates a schematic diagram of an example press system according to an embodiment of the invention;

FIG. 2 shows a schematic view of a press tool arrangement of a press system according to an embodiment of the invention;

Figures 3 and 4 show different views of a press tool arrangement according to an embodiment of the invention;

FIGS. 5 and 6 illustrate different views of a controlled atmosphere system of a press system according to an embodiment of the present invention;

FIG. 7 illustrates a flow chart of a method of manufacturing a hot stamped structural component from a blank in a press system according to an embodiment of the invention;

FIG. 8 illustrates an image of a prior art hot stamped structural component manufactured using conventional systems and methods;

FIG. 9 shows an image of a hot stamped structural component manufactured using the press system of the present invention; and

Fig. 10 shows a graph depicting stress-strain curves of a prior art hot stamped structural component and a hot stamped structural component manufactured using the press system of the present invention.

The drawings referred to in this description should not be understood as being drawn to scale, except if specifically indicated and are merely exemplary in nature.

Detailed Description

A detailed description of various exemplary embodiments of the invention is presented herein with reference to the drawings. It should be noted that the embodiments are described in such detail herein in order to clearly communicate the invention. However, the details provided herein are not intended to limit the intended variations of the embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

It will also be appreciated that various devices, although not explicitly illustrated and described herein, may be devised to carry out the principles of this invention. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass equivalents thereof.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed concurrently or the figures may sometimes be executed in the reverse order, depending upon the functionality/acts involved.

Unless defined otherwise, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Referring to fig. 1, an exemplary press system (200) is shown according to an embodiment of the present invention. The press system (200) is capable of forming a hot stamped structural component (111) from a sheet blank (110). The press system (200) includes a slab stock unit (202), a controlled atmosphere system (170), a press tooling device (100), and a finished product collection unit (204). The sheet stock material unit (202) is configured to store the sheet stock material (110). The finished product collection unit (204) is arranged to store the hot stamped structural component (111). The hot stamped structural component (111) may be a component such as a center pillar, roof rail, bumper, and/or impact beam.

In the illustrated embodiment, the sheet stock (110) is an uncoated boron steel sheet stock. Alternatively, the slab (110) may be any steel or alloy, such as an aluminum alloy, a titanium alloy, a magnesium alloy, and the like, without limitation. In the example shown, the thickness of the slab (110) ranges between 0.6mm and 2.0 mm. Alternatively, the slab (110) may have any thickness without limiting the scope of the invention.

Referring to fig. 2,3 and 4, the press tool apparatus (100) includes a hot press configured to manufacture a hot stamped structural component (111). The press tool device (100) of the present invention heats a sheet blank (110) and then punches (trims) the sheet blank (110) while shaping and in-mold quenching the heated sheet blank (110).

The press tool device (100) comprises a heating device (102). The heating device (102) is arranged as a heating plate blank (110). In the example shown, the heating device (102) is a resistive heating device using the principle of joule heating. The heating device (102) uses the principle of joule heating to heat the slab (110). In another example, the heating device (102) is an induction heating device. The blank (110) can be heated by a heating device for a predetermined amount of time to a predetermined temperature.

The heating device (102) includes a power source (116) (shown in fig. 4) and a plurality of electrodes (114), the electrodes (114) including a first electrode (114 a), a second electrode (114 b), a third electrode (114 c), and a fourth electrode (114 d). In the example shown, the plurality of electrodes (114) are copper electrodes. Alternatively, the plurality of electrodes (114) may be fabricated from any electrically conductive material (e.g., stainless steel) without limitation. In the example shown, the power supply (116) is a low voltage, high current DC power supply. The press system (200) includes a non-contact pyrometer (253) to detect the temperature of the sheet blank (110).

The press tool arrangement (100) comprises at least one clamping device (130), which clamping device (130) is arranged to selectively engage or disengage at least one of the plurality of electrodes (114). The press tool device (100) comprises two clamping devices (130), the two clamping devices (130) comprising a first pneumatic cylinder (130 a) and a second pneumatic cylinder (130 b). In the example shown, the clamping device (130) is represented as a pneumatic cylinder. Alternatively, the clamping device (130) may be a mechanical or hydraulic clamping device without any limitation. The second electrode (114 b) is supported by the first pneumatic cylinder (130 a), and the fourth electrode (114 d) is supported by the second pneumatic cylinder (130 b). The first pneumatic cylinder (130 a) is configured to selectively engage or disengage the third electrode (114 c) from the first electrode (114 a), and the second pneumatic cylinder (130 b) is configured to selectively engage or disengage the fourth electrode (114 d) from the second electrode (114 b).

The press tool device (100) comprises a lower body part (106) and an upper body part (104) corresponding to the lower body part (106). The upper body member (104) and the lower body member (106) are configured to move relative to each other. The upper body member (104) and the lower body member (106) are moved relative to each other by any one of mechanical means or hydraulic means. In the example shown, the upper body part (104) is moved relative to the lower body part (106) by hydraulic means (not shown). In another example, the lower body member (104) may be movable relative to the upper body member (104) without any limitation. The lower body member (106) and the upper body member (104) define a press tool cavity (118) (shown in fig. 3). In the example shown, the heating device (102) is arranged within a press tool chamber (118). The first electrode (114 a) and the third electrode (114 c) are supported by a plurality of holder members (117) extending from the lower body member (106).

The press tool arrangement (100) comprises an upper die part (120) and a lower die part (122). In the example shown, the upper die part (120) and the lower die part (122) are arranged within a press tool chamber (118). The upper mold part (120) is connected to the upper body part (104) and the lower mold part (122) is connected to the lower body part (106). Additional base parts (not shown), not marked) and fastening parts (not shown) are used to connect the mould part with the body part.

In the example shown, the upper die part (120) and the lower die part (122) are provided with blanking tools (not shown) in order to blank/trim the plate blank (110). Different types of blanking tools known in the art may be used to perform different blanking operations on the sheet blank (110) without any limitation. In another example, only one of the upper die member (120) and the lower die member (122) is provided with a blanking tool, without any limitation. The upper (120) and lower (122) mold members are configured to operate at a predetermined temperature. A cooling unit (not shown) that circulates coolant, such as cooling water or dry ice coolant, through circulation members, such as pipes provided in the upper mold member (120) and the lower mold member (122), enables the upper mold member (120) and the lower mold member (122) to be operated at a predetermined temperature.

The upper die member (120) and the lower die member (122) are configured to perform hot blanking with stamping and in-mold quenching on a heated blank (110). The interaction of the upper die part (120) of the press tool arrangement (100) and the lower die part (122) of the press tool arrangement (100) results in the shaping of the sheet blank (110).

Referring to fig. 1, a press system (200) includes a control system (251) and a closed loop feedback system (252). The closed loop feedback system (252) is arranged to monitor information related to the slab stock unit (202), the finished product collection unit (204), the non-contact pyrometer (253), the controlled atmosphere system (170) and the press tooling device (100) and to communicate the information to a control system (251) arranged to control the press system (200).

Referring to fig. 1 and 5, the press system (200) includes a controlled atmosphere system (170) configured to control atmosphere. The controlled atmosphere system (170) includes an enclosure (172) having at least one door (174) and an atmosphere control device (176). In one example, an atmosphere control device (176) is configured to control atmosphere by controlling air flow rate. In another example, the atmosphere control device (176) is configured to control atmosphere by filling with any medium that reduces oxygen content, wherein the medium is any one of a solid medium (e.g., ferrous oxide spheres), a liquid medium (e.g., liquid nitrogen), or a gaseous medium. In yet another example, the atmosphere control device (176) is configured to control the atmosphere by filling with an inert gas selected from any one of nitrogen, helium, or argon, or any combination thereof.

The controlled atmosphere system (170) is equipped with a sheet stock material unit (202) on one side and a finished product collection unit (204) on the other side. The sheet stock material unit (202) is arranged to provide sheet stock material (110) to the press tool arrangement (100), and the finished product collection unit (204) is arranged to receive hot stamped structural components (111) from the press tool arrangement (100).

In the example shown, a controlled atmosphere system (170) surrounds the press tooling device (100). The enclosure (172) encloses the press tooling device (100), and the atmosphere control device (176) controls the atmosphere within the enclosure (172). A controlled atmosphere system (170) surrounding the press tooling device (100) substantially isolates the press tooling device (100) from the surrounding atmosphere. In another example, the enclosure (172) is a room.

In another example (not shown), a controlled atmosphere system (170) may be disposed between the lower body member (106) and the upper body member (104) surrounding the press tool cavity (118). The controlled atmosphere system (170) is configured to isolate the press tool chamber (118) from the surrounding atmosphere.

In both examples, the enclosure (172) and the at least one door (174) are fabricated from a material selected from any one of plastic, resin, wood, metal, alloy, or composite.

In the example shown, the controlled atmosphere system (170) includes an enclosure (172) having a door (174). Alternatively, the enclosure (172) of the controlled atmosphere system (170) may have a plurality of doors (174), without limitation. The enclosure (172) includes at least one slot (175). In the example shown, the enclosure (172) includes two slots (175), one slot (175) (shown in fig. 6) facilitating insertion of the sheet stock (110) and the other slot (175) (not shown) facilitating retrieval of the hot stamped structural component (111). The at least one slot (175) is provided with a closing element (not shown) which is controlled manually or automatically to close the slot once the sheet blank (110) is inserted or the hot stamped structural component (111) is retrieved. In the example shown, a non-contact pyrometer (253) is disposed within the controlled atmosphere system (170). More particularly, the non-contact pyrometer (253) is disposed anywhere within the enclosure (172) such that it is proximate to the plate blank (110).

During operation, the controlled atmosphere system (170) controls the atmosphere within the enclosure (172) as the upper die member (120) and the lower die member (122) perform hot blanking with stamping and in-mold quenching on the heated sheet blank (110). Controlling the atmosphere during the formation of the hot stamped structural member (111) will inhibit the formation of scale on the hot stamped structural member (111).

A plurality of manipulators (not shown) may be used to transfer the sheet stock material (110) from the sheet stock material unit (202) to the press tooling device (100) and to transfer the hot stamped structural components (111) from the press tooling device (100) to the finished product collection unit (204).

Referring to fig. 6, a method (300) of manufacturing a hot stamped structural component (111) from a sheet blank (110) is shown. In step (301), the sheet stock material (110) from the sheet stock material unit (202) is transferred to a plurality of electrodes (114) within the press tool device (100) through slots (175) provided in the envelope (172).

In step (302), at least one door (174) of the controlled atmosphere system (170) is closed and the atmosphere within the enclosure (172) is controlled by an atmosphere control device (176).

In step (303), a blank (110) disposed between the plurality of electrodes (114) is clamped by at least one clamping device (130). A first pneumatic cylinder (130 a) engages the third electrode (114 c) with the first electrode (114 a), and a second pneumatic cylinder (130 b) engages the fourth electrode (114 d) with the second electrode (114 b) so as to sandwich the sheet blank (110) between the plurality of electrodes (114).

In step (304), the slab (110) is heated to a first predetermined temperature by supplying power from a power source (116) to the plurality of electrodes (114). The first predetermined temperature ranges from about 350 ℃ to 950 ℃ based on the material of the selected plate blank (110). In the example shown, the first predetermined temperature ranges from about 750 ℃ to 950 ℃. More particularly, the first predetermined temperature is within a temperature range of austenite formation. In the example shown, the first predetermined temperature is 900 ℃. The non-contact pyrometer is configured to detect/monitor the surface temperature of the sheet stock (110) and to send information to the control system (251) via a closed loop feedback system (252).

In step (305), the heated slab (110) is released by retracting the at least one clamping device (130). The first pneumatic cylinder (130 a) disconnects the third electrode (114 c) from the first electrode (114 a), and the second pneumatic cylinder (130 b) disconnects the fourth electrode (114 d) from the second electrode (114 b). The heated slab (110) rests on the lower mold part (122).

In step (306), the upper body member (104) of the press tool device (100) is moved relative to the lower body member (106). In step (307), hot blanking with stamping and in-mold quenching is performed on the heated sheet blank (110) in a controlled atmosphere by the upper die part (120) and the lower die part (122) to form a hot stamped structural part (111).

In fig. 8, a prior art hot stamped structural component manufactured using conventional methods (and systems) is shown, in fig. 9, a hot stamped structural component (111) manufactured using the disclosed press system (200), it can be seen from both figures that scale has been minimized/eliminated on the hot stamped structural component (111) manufactured using the press system (200) including the controlled atmosphere system (170).

Table 1: comparison between a prior art part (fig. 8) manufactured using conventional methods and a hot stamped structural part (fig. 9) manufactured using the disclosed press system

Stress-strain curves for different portions of prior art hot stamped structural components and hot stamped structural components (111) are shown in fig. 10, from which it can be inferred that the hot stamped structural components (111) formed within the disclosed press system (200) have the same or better mechanical and microstructural characteristics as the hot stamped structural components formed by conventional methods.

The present invention relates to a press system (200) that utilizes less space and investment and is energy efficient. The disclosed press system (200) includes a heating device (102), the heating device (102) providing rapid heating of the sheet blank (110). A press system (200) including a controlled atmosphere system (170) controls the atmosphere surrounding the press tooling device (200) to significantly reduce scale compared to conventional methods. Rapid heating within the press tool chamber (118) and hot stamping within a controlled atmosphere reduces/eliminates scale. Reduction of scale will reduce tool contamination and, as tool contamination is minimized and/or eliminated, reduce the need to clean the tool after each stroke, thereby improving productivity. Moreover, the hot stamped structural component (111) formed within the disclosed press system (200) has the same or better mechanical and microstructural characteristics as the component formed by conventional methods. Since the scale is reduced or eliminated, additional treatments such as shot blasting and the like required for removing the scale in the conventional method can be eliminated.

Moreover, the terminology used herein is for the purpose of describing embodiments only and is not intended to be limiting of the invention. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art without departing from the scope of the invention which is encompassed by the following claims.

The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

While the foregoing is directed to various embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is to be determined by the following claims. The invention is not limited to the embodiments, versions or examples described, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge that is available to the person having ordinary skill in the art.

Claims

1.A press system (200), comprising:

A controlled atmosphere system (170); and

Press tool device (100) for manufacturing a hot stamped structural component (111), the press tool device (100) comprising:

a lower body member (106);

An upper body member (104) corresponding to the lower body member (106), wherein the upper body member (104) and the lower body member (106) are arranged to move relative to each other;

a press tool chamber (118) defined between the lower body member (106) and the upper body member (104);

An upper die part (120) and a lower die part (122) arranged within the press tool chamber (118), wherein the upper die part (120) is connected to the upper body part (104) and the lower die part (122) is connected to the lower body part (106);

-a heating device (102) arranged within the press tool chamber (118), wherein the heating device (102) is arranged to heat the plate blank (110); and

Wherein the upper die part (120) and the lower die part (122) are arranged to perform hot blanking with stamping and in-mold quenching on a heated plate blank (110) in an atmosphere controlled by a controlled atmosphere system (170) in order to form a hot stamped structural part (111).

2. The press system (200) of claim 1, wherein: controlling the atmosphere during formation of the hot stamped structural member (111) will inhibit the formation of scale on the hot stamped structural member (111).

3. The press system (200) of claim 1, wherein: a controlled atmosphere system (170) encloses the press tooling device (100).

4. The press system (200) of claim 1, wherein: a controlled atmosphere system (170) is disposed between the lower body member (106) and the upper body member (104).

5. The press system (200) of claims 1 to 4, wherein: the controlled atmosphere system (170) includes an enclosure (172) having at least one door (174) and an atmosphere control device (176).

6. The press system (200) according to claims 3 and 5, wherein: the enclosure (172) encloses the press tooling device (100), and the atmosphere control device (176) controls the atmosphere within the enclosure (172).

7. The press system (200) of claim 6, wherein: the enclosure (172) is a room.

8. The press system (200) of claims 5 to 7, wherein: an atmosphere control device (176) is arranged to control the atmosphere by controlling the air flow rate.

9. The press system (200) of claims 5 to 7, wherein: the atmosphere control device (176) is arranged to control the atmosphere by filling with any medium that reduces the oxygen content, wherein the medium is any one of a solid medium, a liquid medium or a gaseous medium.

10. The press system (200) of claims 5 to 7, wherein: an atmosphere control device (176) is provided to control the atmosphere by filling with an inert gas selected from any one of nitrogen, helium or argon.

11. The press system (200) of claim 1, wherein: the upper body member (104) and the lower body member (106) are moved relative to each other by any one of mechanical means or hydraulic means.

12. The press system (200) according to claims 4 and 5, wherein: an enclosure (172) encloses the press tool chamber (118), and an atmosphere control device (176) controls atmosphere within the press tool chamber (118).

13. The press system (200) of claim 12, wherein: the controlled atmosphere system (170) is configured to isolate the press tool chamber (118) from the surrounding atmosphere.

14. The press system (200) according to claims 3 to 13, wherein: the press system (200) includes a slab stock unit (202) and a finished product collection unit (204).

15. The press system (200) according to claims 3, 4 and 14, wherein: the controlled atmosphere system (170) is equipped with a sheet stock material unit (202) on one side and a finished product collecting unit (204) on the other side, wherein the sheet stock material unit (202) is arranged to provide sheet stock material (110) to the press tool device (100), and the finished product collecting unit (204) is arranged to receive the hot stamped structural component (111) from the press tool device (100).

16. The press system (200) of claim 1, wherein: the heating device (102) is a resistive heating device using the joule heating principle.

17. The press system (200) of claim 16, wherein: the heating device (102) includes a power source (116) and a plurality of electrodes (114) including a first electrode (114 a), a second electrode (114 b), a third electrode (114 c), and a fourth electrode (114 d).

18. The press system (200) according to claims 1 and 17, wherein: the press tool arrangement (100) comprises at least one clamping device (130) arranged to selectively engage or disengage at least one of the plurality of electrodes (114).

19. The press system (200) of claim 18, wherein: the press tool device (100) comprises two clamping devices (130) comprising a first pneumatic cylinder (130 a) and a second pneumatic cylinder (130 b), wherein the first pneumatic cylinder (130 a) is arranged to selectively engage or disengage the third electrode (114 c) with the first electrode (114 a), and the second pneumatic cylinder (130 b) is arranged to selectively engage or disengage the fourth electrode (114 d) with the second electrode (114 b).

20. The press system (200) of claim 19, wherein: the plurality of electrodes (114) are copper electrodes.

21. The press system (200) according to claims 1 to 20, wherein: the sheet stock (110) is an uncoated boron steel sheet stock.

22. The press system (200) according to claims 1 to 21, wherein: the thickness of the blank (110) ranges between 0.6mm and 3.0 mm.

23. The press system (200) of claim 1, wherein: the upper (120) and lower (122) mold members are configured to operate at a predetermined temperature.

24. The stamping system (200) of claim 11, wherein: the upper body part (104) and the lower body part (106) are moved relative to each other by hydraulic means.

25. The press system (200) of claim 1, wherein: the heating device (102) is an induction heating device.

26. The press system (200) according to claims 1 to 25, wherein: the press system (200) comprises a control system (251) and a closed loop feedback system (252), the closed loop feedback system (252) being arranged to monitor information related to the controlled atmosphere system (170) and the press tool arrangement (100) and to communicate said information to the control system (251) arranged to control the press system (200).

27. A method (300) of manufacturing a hot stamped structural component (111) from a sheet blank (110) within a press system (200), the press system comprising:

a controlled atmosphere system (170) comprising an enclosure (172) having at least one door (174) and an atmosphere control device (176); and

Press tool arrangement (100), comprising:

a lower body member (106);

An upper die part (120) and a lower die part (122) arranged within the press tool chamber (118), wherein the upper die part (120) is connected to the upper body part (104) and the lower die part (122) is connected to the lower body part (106); and

A heating device (102) arranged within the press tool chamber (118), wherein the heating device (102) comprises a plurality of electrodes (114) connected to a power source (116);

wherein the method (300) comprises:

transferring a sheet blank (110) onto the plurality of electrodes (114);

closing the at least one door (174) of the enclosure (172) and controlling the atmosphere within the enclosure (172) by an atmosphere control device (176);

Clamping the sheet blank (110) between the plurality of electrodes (114) by at least one clamping device (130);

Heating the sheet blank (110) to a first predetermined temperature by supplying power from a power source (116) to the plurality of electrodes (114);

loosening the heated slab (110) by retracting the at least one gripping means (130);

Moving the upper body member (104) relative to the lower body member (106); and

Hot blanking with stamping and in-mold quenching is performed on a heated sheet blank (110) in a controlled atmosphere by an upper die part (120) and a lower die part (122) to form a hot stamped structural part (111).

28. The method (300) of claim 27, wherein: the first predetermined temperature ranges from about 350 ℃ to 950 ℃.

29. The method (300) of claim 28, wherein: the first predetermined temperature ranges from about 750 ℃ to 950 ℃.

30. The method (300) of claim 29, wherein: the first predetermined temperature is 900 ℃.

31. The method (300) of claim 27, wherein: controlling the atmosphere during formation of the hot stamped structural component (111) will inhibit the creation of scale on the hot stamped structural component (111), wherein inhibition of scale reduces tool contamination and tool wear.

32. The method (300) of claim 27, wherein: the press system (200) includes a non-contact pyrometer (253) to detect the temperature of the sheet blank (110).

33. The method (300) of claims 27 and 32, wherein: the press system (200) comprises a control system (251) and a closed loop feedback system (252), the closed loop feedback system (252) being arranged to monitor information related to the controlled atmosphere system (170) and the press tool arrangement (100) and to communicate said information to the control system (251) arranged to control the press system (200).