EP0770435B1 - Method for making an axle support - Google Patents

Method for making an axle support Download PDF

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Publication number
EP0770435B1
EP0770435B1 EP19950114847 EP95114847A EP0770435B1 EP 0770435 B1 EP0770435 B1 EP 0770435B1 EP 19950114847 EP19950114847 EP 19950114847 EP 95114847 A EP95114847 A EP 95114847A EP 0770435 B1 EP0770435 B1 EP 0770435B1
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EP
European Patent Office
Prior art keywords
hollow profile
bending
internal pressure
tube
axle
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP19950114847
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German (de)
French (fr)
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EP0770435A1 (en
Inventor
Egon Olszewski
Rainer Hansen
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Benteler Deustchland GmbH
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Benteler Deustchland GmbH
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Publication date
Application filed by Benteler Deustchland GmbH filed Critical Benteler Deustchland GmbH
Priority to EP19950114847 priority Critical patent/EP0770435B1/en
Priority to ES95114847T priority patent/ES2124949T3/en
Priority to DE59504498T priority patent/DE59504498D1/en
Publication of EP0770435A1 publication Critical patent/EP0770435A1/en
Application granted granted Critical
Publication of EP0770435B1 publication Critical patent/EP0770435B1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00Making other particular articles
    • B21D53/88Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033Deforming tubular bodies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033Deforming tubular bodies
    • B21D26/037Forming branched tubes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D9/00Bending tubes using mandrels or the like
    • B21D9/15Bending tubes using mandrels or the like using filling material of indefinite shape, e.g. sand, plastic material

Definitions

  • the invention relates to a method for manufacturing an axle beam for motor vehicles by bending and Hydroforming a straight metallic hollow profile.
  • Construction workpieces such as axle beams of motor vehicles are consistently carried out today in lightweight construction. Such construction workpieces are usually around hollow molded parts made of a straight metallic mostly cylindrical tube are manufactured.
  • the hydroforming process offers for the forming processing of the pipe various possibilities.
  • a cylindrical tube is used as the initial profile under the pressure of a liquid with simultaneous axial Feed movement widened and shaped like a divided hollow tool pressed.
  • Hydroforming is described in "WT Workshop Technology" 79 (1989), pages 210 to 214. Because of its manufacturing technology Advantages is the hydroforming process, especially in the mass production of Construction workpieces, for example for the automotive industry, widespread.
  • axle support is off Contour finished.
  • add-on parts welded to the axle beam can be reinforcements, for example in the form of gusset plates, that of stabilization serve the axle carrier.
  • Such attachments are usually used however for fastening the axle carrier or Definition of other components on the axle support required.
  • JP-A-64053719 also applies a method for Production of a construction workpiece by bending and hydroforming a straight metallic hollow profile the state of the art.
  • a method for Production of a construction workpiece by bending and hydroforming a straight metallic hollow profile the state of the art.
  • the hollow profile is then used bent by inner mandrels.
  • inner Support arbors is only comparatively simple Component geometries possible.
  • the invention is based on the prior art Task based on the production of curved axle beams to make it more appropriate and economical and the number of subsequently on the construction workpiece to reduce attachments to be welded on.
  • the basic idea of the invention is First, enough material in on the straight starting profile to relocate the zones of forming, creating forming areas be preformed. The creation of the contour of the Subframe is then done by bending and hydroforming Final shaping.
  • fastening or reinforcement areas of the axle support can also be hydroformed before the bending process be shaped out of the initial profile.
  • the method according to the invention thus makes it possible in any case much of the otherwise after the final shaping parts to be welded on to be replaced.
  • the axial force is usually rigid on both sides Transfer tools to the pipe. Usually acts these are hydraulically moved pistons with corresponding shaped heads that hold the tube at both ends to lock. An increasing pressure is then built up in the pipe. As soon as this is so high that there is a deformation of the pipe in the area of the pre-deformed areas comes, the ends of the tube are in the axial direction pressed. This process is controlled depending on the internal pressure. Then there is a shift of profile material to the areas to be deformed. This is done area-specific preforming of bulges in the zones of the later bend or the later fastening or reinforcement areas.
  • the bulging takes place under the influence of a counter pressure, that works specifically in the area to be deformed. This is a precise control of the expansion process possible.
  • the size of the preformed areas is proportional for shortening the length of the hollow profile. To dilute the material or even bursting in the area of To avoid forming bulge, the forehead of the Bulging during the forming process due to the counter pressure supported.
  • the back pressure can basically be different Generated way.
  • a convenient way include counter cylinders in the manufacturing process which are coordinated with the press tool.
  • An advantage of the method is that with the first Production step first the zones of the forming are prefabricated on a straight pipe. Especially the zones the maximum deformation in which the subsequent The preformed hollow profile is bent, can be targeted to the subsequent plastic forming are prepared.
  • the bending process takes place under high internal pressure, so that the hydroformed contours remain. Wrinkling or the tube is prevented from being pressed in. By preforming the zones of maximum deformation also becomes the elastic that is otherwise typical for bending Springback avoided.
  • the subsequent one Final shaping is also done by hydraulic internal pressure performed.
  • the axle carrier receives its final one Shape. Pushing the ends of the curved construction workpiece not necessary. This is a significant procedural advantage.
  • the axle beam is used during or after the final shaping calibrated. Basically, it is possible that the final shaping only includes calibration. With the repressing the surface roughness is leveled and the Dimensional accuracy of the construction workpieces increased. In addition, the strength is increased during calibration.
  • axle beam is attached Mounting openings are provided.
  • the assembly openings can be used for the attachment of additional components as well as for the implementation of other components, such as a brake line be.
  • the assembly openings are made at effective internal pressure. In this way it is avoided that the construction workpiece at the cutting Production of the assembly openings, for example by cutting or punching, deformed.
  • the construction workpiece Before the hydraulic final shaping, the construction workpiece, depending on the design, also be flattened in areas.
  • the preformed Bulges and / or sections of the construction workpiece flattened. This process takes place in the hydroforming tool.
  • Control devices and hydraulic devices the production system can be used for preforming, used in the bending process as well as in the final shaping will.
  • the number of attachments to be welded reduced. Necessary fastening or reinforcement areas on the body of the construction workpiece can be made in one piece from the initial profile shape out. The extra effort for that The provision and definition of attachments is minimized or can even depend on the construction workpiece be completely saved.
  • the invention allows the production of a simple and more economical designed axle carrier for motor vehicles.
  • a curved axle beam is made from a tube in one piece with integrated fastening or Reinforcement areas made.
  • Hydroforming carried out with feeding on the straight tube.
  • the zones of maximum deformation preformed.
  • the preformed Areas are then created according to the respective requirements pressed flat. So fastening or Reinforcement areas are formed.
  • the axle support gets its final shape. If necessary, the axle beam is then attached Provide holes, the punching as described below Internal pressure takes place.
  • FIG. 1 shows the manufacture of an axle support 1 for a passenger car, based on an initial profile in the form of a straight, round in cross section Tube 2.
  • the axle support 1 (Figure 1E and Figure 1F) essentially comprises two tubular longitudinal sections 3, which over a middle section 4 are connected to each other. Of the Center section 4 transmits in particular torsion and Bending forces from the longitudinal sections 3 in the central section 4 be directed. In the transitions 5 from the longitudinal sections 3 to the central section 4 are on Axle beam 1 formed areas 6. these can for example also for attaching attachments.
  • the tube 2 is provided in a fixed initial length L A , which is matched to the dimensions of the axle support 1 or to the forming processes carried out during manufacture (FIG. 1A).
  • bulges 7 are preformed on the tube 2 ( Figure 1B).
  • the preforming is done by hydraulic Internal pressure, with an axial pushing at the same time the ends 8 is made.
  • the resultant is not mandatory, but advantageous preformed tube 2 'then a heat treatment subjected to medium annealing. This can result in the Preforming internal stress of the tube 2 'is reduced will.
  • the axis contour 2 '' is then created by bending ( Figure 1C).
  • the tube stands during the bending process 2 'under high internal pressure, so that the hydroformed contour preserved.
  • the bending process can also affect connect a heat treatment.
  • the hydroforming tool is then used in an intermediate step a flattening made (Figure 1D).
  • Figure 1D Here, the Areas 6 'flattened.
  • Figure 1E receives the axle beam 1 its final contour with the required dimensional accuracy (Calibration). With effective internal pressure further punched the mounting holes 9. So will prevents the contour of the axle beam 1 from being pressed in becomes.
  • the preforming is carried out in a press tool 11 (compare Figures 2 and 3).
  • the press tool 11 has two tool halves 12, 13 on. On the two end sides 14, 15 an axial punch 16, 17 is arranged in each case. Furthermore has the press tool 11 in the zones where the bulges are preformed, adapted to this Removal openings 18. Here are counter cylinders 19 arranged, the piston 20 of the contour of the bulges are trained accordingly.
  • the tool halves 12, 13 are moved together hydraulically.
  • the tube 2 is at both ends 8 by likewise hydraulically moved pistons 21 with correspondingly shaped Heads 22 closed.
  • the tube 2 is then with a Pressurized media.
  • the supply of the print medium takes place via a dashed line in FIG Internal high-pressure line 23, which runs through the pistons 21 is.
  • the preformed tube 2 ' is then bent. Of the Bending process is shown in Figures 4 and 5.
  • the preformed tube 2 ' is used by a bending tool 25 added.
  • the ends 8 are through the adapter 26 closed.
  • the Center section 4 fixed by the counter contour 29.
  • the pre-shaped axis contour 2 '' is after the bending process a hydroforming tool 30 in which the Final shaping is carried out (Figure 6).
  • the areas 6 ' are first flattened, whereby the forming areas 6 get their configuration.
  • the axis contour 2 '' is also in the areas 6 ' slightly flattened on the top (see also Figure 7).
  • the adapter 31 positively closed.
  • hydraulically Final shaping in which the axle support 1 with the required Dimensional accuracy is calibrated. After that become the assembly openings 9 when the internal pressure acts punched.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Achsträgers für Kraftfahrzeuge durch Biegen und Hydroformen eines geraden metallischen Hohlprofils.The invention relates to a method for manufacturing an axle beam for motor vehicles by bending and Hydroforming a straight metallic hollow profile.

Konstruktionswerkstücke wie Achsträger von Kraftfahrzeugen werden heute konsequent in Leichtbauweise ausgeführt. Bei solchen Konstruktionswerkstücken handelt es sich üblicherweise um Hohlformteile, die aus einem geraden metallischen, meist zylindrischen Rohr herstellt werden. Für die umformende Bearbeitung des Rohrs bietet das Innenhochdruck-Umformverfahren vielfältige Möglichkeiten. Hierbei wird ein zylindrisches Rohr als Ausgangsprofil unter dem Druck einer Flüssigkeit bei gleichzeitiger axialer Vorschubbewegung aufgeweitet und an die Form eines geteilten Hohlwerkzeugs angepreßt. Das Innenhochdruck-Umformen ist unter anderem beschrieben in "WT Werkstattstechnik" 79 (1989), Seiten 210 bis 214. Wegen seiner fertigungstechnischen Vorteile ist das Innenhochdruck-Umformverfahern, insbesondere bei der Massenproduktion von Konstruktionswerkstücken, beispielsweise für den Automobilbau, weit verbreitet.Construction workpieces such as axle beams of motor vehicles are consistently carried out today in lightweight construction. Such construction workpieces are usually around hollow molded parts made of a straight metallic mostly cylindrical tube are manufactured. The hydroforming process offers for the forming processing of the pipe various possibilities. Here, a cylindrical tube is used as the initial profile under the pressure of a liquid with simultaneous axial Feed movement widened and shaped like a divided hollow tool pressed. Hydroforming is described in "WT Workshop Technology" 79 (1989), pages 210 to 214. Because of its manufacturing technology Advantages is the hydroforming process, especially in the mass production of Construction workpieces, for example for the automotive industry, widespread.

Bei der Herstellung von gebogenen Achsträgern wird bislang so vorgegangen, daß Rohre zunächst vorgebogen werden. Hierbei werden die Rohre in eine Form gebracht, welche dem späteren Konturverlauf des Achsträgers entspricht. Anschließend wird das gebogene Hohlprofil hydroformtechnisch in die endgültige Form gebracht. Diese Vorgehensweise, wie sie beispielsweise in der DE-PS 40 17 072 (Nächster Stand der Technik) beschrieben ist, hat sich grundsätzlich bewährt.So far, the production of curved axle beams proceeded in such a way that pipes are first pre-bent. Here, the pipes are brought into a shape, which corresponds to the later contour of the axle beam. The bent hollow profile is then hydroformed brought into the final form. This approach, as for example in DE-PS 40 17 072 (state of the art) has generally proven itself.

Nach dem Hydroformvorgang ist der Achsträger von seiner Kontur her fertiggestellt. Jetzt werden Anbauteile schweißtechnisch am Achsträger festgelegt. Bei solchen Anbauteilen kann es sich um Verstärkungen handeln, beispielsweise in der Form von Knotenblechen, die der Stabilisierung des Achsträgers dienen. Meist werden solche Anbauteile jedoch zur Befestigung des Achsträgers bzw. zur Festlegung anderer Bauteile am Achsträger benötigt.After the hydroforming process, the axle support is off Contour finished. Now add-on parts welded to the axle beam. In such Attachments can be reinforcements, for example in the form of gusset plates, that of stabilization serve the axle carrier. Such attachments are usually used however for fastening the axle carrier or Definition of other components on the axle support required.

Die nachträgliche Anbringung der Anbauteile ist kosten- und arbeitsintensiv. Neben der mengen- und termingerechten Bereitstellung der Anbauteile ist der Aufwand für die schweißtechnische Festlegung hoch. Dementsprechend ist eine Rationalisierung des Herstellungsverfahrens wünschenswert.The subsequent attachment of the attachments is cost and labor intensive. In addition to the quantity and on time Providing the attachments is the effort for the high welding specification. Is accordingly rationalization of the manufacturing process is desirable.

Durch die JP-A-64053719 gilt ferner ein Verfahren zur Herstellung eines Konstruktionswerkstücks durch Biegen und Hydroformen eines geraden metallischen Hohlprofils zum Stand der Technik. Hierbei werden zunächst mittels hydraulischem Innendruck Ausbauchungen im Biegebereich erstellt. Anschließend wird das Hohlprofil unter Einsatz von inneren Stützdornen gebogen. Der Einsatz von inneren Stützdornen ist jedoch nur bei vergleichsweise einfachen Bauteilgeometrien möglich.JP-A-64053719 also applies a method for Production of a construction workpiece by bending and hydroforming a straight metallic hollow profile the state of the art. Here, first of all, by hydraulic internal pressure bulges in the bending area created. The hollow profile is then used bent by inner mandrels. The use of inner Support arbors is only comparatively simple Component geometries possible.

Der Erfindung liegt ausgehend vom Stand der Technik die Aufgabe zugrunde, die Herstellung von gebogenen Achsträgern zweckmäßiger und wirtschaftlicher zu gestalten und die Anzahl der nachträglich am Konstruktionswerkstück anzuschweißenden Anbauteile zu verringern.The invention is based on the prior art Task based on the production of curved axle beams to make it more appropriate and economical and the number of subsequently on the construction workpiece to reduce attachments to be welded on.

Die Lösung dieser Aufgabe besteht in den im Anspruch 1 aufgeführten Merkmalen.The solution to this problem consists in the Claim 1 listed features.

Der grundsätzliche Erfindungsgedanke besteht darin, zunächst am geraden Ausgangsprofil genügend Material in die Zonen der Umformung zu verlagern, wodurch Umformbereiche vorgeformt werden. Die Herstellung der Kontur des Achsträgers erfolgt anschließend durch Biegen und hydroformtechnische Endformung.The basic idea of the invention is First, enough material in on the straight starting profile to relocate the zones of forming, creating forming areas be preformed. The creation of the contour of the Subframe is then done by bending and hydroforming Final shaping.

Insbesondere können so vor dem Biegevorgang auch Befestigungs- bzw. Verstärkungsbereiche des Achsträgers hydroformtechnisch aus dem Ausgangsprofil herausgeformt werden.In particular, fastening or reinforcement areas of the axle support can also be hydroformed before the bending process be shaped out of the initial profile.

Das erfindungsgemäße Verfahren ermöglicht es damit, jedenfalls einen großen Teil der ansonsten nach der Endformung anzuschweißenden Anbauteile zu ersetzen.The method according to the invention thus makes it possible in any case much of the otherwise after the final shaping parts to be welded on to be replaced.

Bei der Herstellung der Achsträger wird zunächst von einem geraden metallischen Hohlprofil in Form eines Rohrs ausgegangen. Dieses wird in ein mehrteiliges Pressenwerkzeug eingelegt. Das Pressenwerkzeug ist so gestaltet, daß es die gezielte Vorformung an den erforderlichen Bereichen zuläßt, ohne daß es zu einer nachteiligen Wandverdünnung in diesen Zonen kommt. Nach dem Schließen des Pressenwerkzeugs wird das Rohr mit einem hydraulischen Innendruck und einer an den Enden des Rohrs angreifenden Axialkraft belastet.In the manufacture of the axle beam, first of all a straight metallic hollow profile in the form of a tube went out. This is in a multi-part press tool inserted. The press tool is designed so that the targeted preforming on the required areas allows without causing an adverse wall thinning comes in these zones. After closing the The pipe press tool is hydraulic Internal pressure and one engaging at the ends of the tube Axial force loaded.

Die Axialkraft wird in der Regel beidseitig mit starren Werkzeugen auf das Rohr übertragen. Üblicherweise handelt es sich hierbei um hydraulisch bewegte Kolben mit entsprechend geformten Köpfen, die das Rohr an beiden Enden abschließen. Im Rohr wird dann ein steigender Druck aufgebaut. Sobald dieser so hoch ist, daß es zu einer Verformung des Rohrs im Bereich der vorzuverformenden Bereiche kommt, werden die Enden des Rohrs in axialer Richtung gedrückt. Dieser Vorgang ist innendruckabhängig gesteuert. Es kommt dann zu einer Verlagerung von Profilmaterial an die zu verformenden Bereiche. Hierdurch erfolgt eine bereichsweise gezielte Vorformung von Ausbauchungen in den Zonen der späteren Biegung oder der späteren Befestigungs- bzw. Verstärkungsbereiche.The axial force is usually rigid on both sides Transfer tools to the pipe. Usually acts these are hydraulically moved pistons with corresponding shaped heads that hold the tube at both ends to lock. An increasing pressure is then built up in the pipe. As soon as this is so high that there is a deformation of the pipe in the area of the pre-deformed areas comes, the ends of the tube are in the axial direction pressed. This process is controlled depending on the internal pressure. Then there is a shift of profile material to the areas to be deformed. This is done area-specific preforming of bulges in the zones of the later bend or the later fastening or reinforcement areas.

Das Ausbauchen erfolgt unter dem Einfluß eines Gegendrucks, der gezielt in dem zu verformenden Bereich wirkt. Damit ist eine präzise Steuerung des Ausbauchvorgangs möglich. Die Größe der vorgeformten Bereiche ist proportional zur Längenkürzung des Hohlprofils. Um eine Materialverdünnung oder gar ein Bersten im Bereich der sich bildenden Ausbauchung zu vermeiden, wird die Stirn der Ausbauchung während des Umformens durch den Gegendruck gestützt.The bulging takes place under the influence of a counter pressure, that works specifically in the area to be deformed. This is a precise control of the expansion process possible. The size of the preformed areas is proportional for shortening the length of the hollow profile. To dilute the material or even bursting in the area of To avoid forming bulge, the forehead of the Bulging during the forming process due to the counter pressure supported.

Der Gegendruck kann grundsätzlich auf unterschiedliche Weise erzeugt werden. In zweckmäßiger Weise lassen sich Gegenhaltezylinder in den Fertigungsprozeß einbinden, welche mit dem Pressenwerkzeug wirkungskoordiniert sind. The back pressure can basically be different Generated way. In a convenient way Include counter cylinders in the manufacturing process which are coordinated with the press tool.

Ein Vorteil des Verfahrens liegt darin, daß mit dem ersten Fertigungsschritt zunächst die Zonen der Umformung am geraden Rohr vorgefertigt werden. Insbesondere die Zonen der maximalen Umformung, in denen die anschließende Biegung des vorgeformten Hohlprofils vorgenommen wird, können so gezielt entsprechend auf die sich anschließende plastische Umformung vorbereitet werden.An advantage of the method is that with the first Production step first the zones of the forming are prefabricated on a straight pipe. Especially the zones the maximum deformation in which the subsequent The preformed hollow profile is bent, can be targeted to the subsequent plastic forming are prepared.

Der Biegevorgang erfolgt unter hohem Innendruck, so daß die hydrogeformten Konturen bestehen bleiben. Eine Faltenbildung oder ein Eindrücken des Rohrs wird unterbunden. Durch die Vorformung der Zonen der maximalen Umformung wird auch die ansonsten für das Biegen typische elastische Rückfederung vermieden. Die sich anschließende Endformung wird ebenfalls durch hydraulischen Innendruck vorgenommen. Hierbei erhält der Achsträger seine endgültige Form. Ein Nachschieben der Enden des gebogenen Konstruktionswerkstücks ist nicht erforderlich. Dies ist ein wesentlicher verfahrenstechnischer Vorteil.The bending process takes place under high internal pressure, so that the hydroformed contours remain. Wrinkling or the tube is prevented from being pressed in. By preforming the zones of maximum deformation also becomes the elastic that is otherwise typical for bending Springback avoided. The subsequent one Final shaping is also done by hydraulic internal pressure performed. Here the axle carrier receives its final one Shape. Pushing the ends of the curved construction workpiece not necessary. This is a significant procedural advantage.

Der Achsträger wird während oder nach der Endformung kalibriert. Grundsätzlich ist es möglich, daß die Endformung nur noch die Kalibrierung umfaßt. Mit der Nachpressung wird die Oberflächenrauhigkeit eingeebnet und die Maßgenauigkeit der Konstruktionswerkstücke gesteigert. Darüberhinaus wird beim Kalibrieren die Festigkeit erhöht.The axle beam is used during or after the final shaping calibrated. Basically, it is possible that the final shaping only includes calibration. With the repressing the surface roughness is leveled and the Dimensional accuracy of the construction workpieces increased. In addition, the strength is increased during calibration.

In einem weiteren Arbeitsgang wird der Achsträger mit Montageöffnungen versehen werden. Die Montageöffnungen können sowohl für die Befestigung von zusätzlichen Bauteilen als auch für die Durchführung von anderen Bauteilen, wie beispielsweise einer Bremsleitung, erforderlich sein. Die Herstellung der Montageöffnungen erfolgt bei wirkendem Innendruck. Auf diese Weise wird vermieden, daß sich das Konstruktionswerkstück bei der schneidtechnischen Herstellung der Montageöffnungen, beispielsweise durch Ausschneiden oder Lochen, verformt.In a further step, the axle beam is attached Mounting openings are provided. The assembly openings can be used for the attachment of additional components as well as for the implementation of other components, such as a brake line be. The assembly openings are made at effective internal pressure. In this way it is avoided that the construction workpiece at the cutting Production of the assembly openings, for example by cutting or punching, deformed.

Vor der hydraulischen Endformung kann das Konstruktionswerkstück, je nach konstruktiver Ausgestaltung, auch noch bereichsweise geplättet werden. Hierbei werden die vorgeformten Ausbauchungen und/oder Abschnitte des Konstruktionswerkstücks abgeflacht. Dieser Vorgang erfolgt im Hydroformwerkzeug.Before the hydraulic final shaping, the construction workpiece, depending on the design, also be flattened in areas. Here, the preformed Bulges and / or sections of the construction workpiece flattened. This process takes place in the hydroforming tool.

Die Steuereinrichtungen und die hydraulischen Einrichtungen der Fertigungsanlage können sowohl bei der Vorformung, beim Biegevorgang als auch bei der Endformung verwendet werden.Control devices and hydraulic devices the production system can be used for preforming, used in the bending process as well as in the final shaping will.

Durch das erfindungsgemäße Verfahrens wird die Anzahl der anzuschweißenden Anbauteile verringert. Notwendige Befestigungs- oder Verstärkungsbereiche am Körper des Konstruktionswerkstücks lassen sich einstückig aus dem Ausgangsprofil herausformen. Der zusätzliche Aufwand für die Bereitstellung und Festlegung von Anbauteilen wird minimiert oder kann sogar je nach Konstruktionswerkstück vollkommen eingespart werden.The number of attachments to be welded reduced. Necessary fastening or reinforcement areas on the body of the construction workpiece can be made in one piece from the initial profile shape out. The extra effort for that The provision and definition of attachments is minimized or can even depend on the construction workpiece be completely saved.

Vorteilhafte Weiterbildungen des erfindungsgemäßen Verfahrens sind in den Ansprüchen 2 und 3 zu sehen. Danach kann das Konstruktionswerkstück sowohl vor dem Biegevorgang als auch nach dem Biegevorgang einer Wärmebehandlung durch Glühen unterzogen werden. Hierbei werden die durch den Verformungsvorgang entstandenen Eigenspannungen reduziert. Auch Verzerrungen des Gefüges infolge der Verformung können so zurückgeführt werden. Der Werkstoff des Konstruktionswerkstücks erhält dementsprechend die für die Weiterverarbeitung erwünschten Eigenschaften. Advantageous further developments of the method according to the invention can be seen in claims 2 and 3. After that can the construction workpiece both before the bending process as well as after the bending process of a heat treatment undergo by annealing. Here, the through the internal stresses created during the deformation process are reduced. Distortion of the structure due to the deformation can be traced back. The material of the Construction workpiece receives accordingly for the further processing desired properties.

Die Erfindung erlaubt die Herstellung eines einfacher und ökonomischer gestalteten Achsträgers für Kraftfahrzeuge. Ein solcher gebogener Achsträger ist aus einem Rohr einstückig mit integrierten Befestigungs- bzw. Verstärkungsbereichen hergestellt. Dazu wird zunächst das Hydroformen mit Nachschieben am geraden Rohr vorgenommen. Hierbei werden die Zonen der maximalen Umformung vorgeformt. Anschließend erfolgt das Biegen des hydrogeformten Rohrs unter Innendruck. Die vorgeformten Bereiche werden dann entsprechend den jeweiligen Erfordernissen flach eingedrückt. So können Befestigungs- bzw. Verstärkungsbereiche ausgebildet werden. Durch Hydroformen bzw. Kalibrieren erhält der Achsträger seine Endform. Falls erforderlich, wird der Achsträger anschließend mit Löchern versehen, wobei das Lochen wie beschrieben unter Innendruck erfolgt.The invention allows the production of a simple and more economical designed axle carrier for motor vehicles. Such a curved axle beam is made from a tube in one piece with integrated fastening or Reinforcement areas made. To do this, first of all Hydroforming carried out with feeding on the straight tube. Here, the zones of maximum deformation preformed. Then the bending of the hydroformed pipe under internal pressure. The preformed Areas are then created according to the respective requirements pressed flat. So fastening or Reinforcement areas are formed. Through hydroforming or calibration, the axle support gets its final shape. If necessary, the axle beam is then attached Provide holes, the punching as described below Internal pressure takes place.

Bei dem Achsträger ist die Anzahl der anzuschweißenden Anbauteile reduziert. Infolge dessen ist seine Herstellung wirtschaftlicher. Durch die Einsparung an nachträglich anzuschweißenden Anbauteilen ergibt sich auch eine Gewichtseinsparung. Dies wirkt sich wiederum positiv auf den Kraftstoffverbrauch und den Schadstoffausstoß eines mit dem erfindungsgemäßen Achsträger ausgerüsteten Kraftfahrzeugs aus.In the case of the axle beam, the number of those to be welded on Add-on parts reduced. As a result, is his Manufacturing more economical. By saving on add-on parts to be welded on subsequently also a weight saving. This in turn affects positive on fuel consumption and pollutant emissions one equipped with the axle carrier according to the invention Motor vehicle from.

Die Erfindung wird nachstehend unter Bezugnahme auf die beigefügten Zeichnungen beschrieben. In allen Zeichnungen tragen einander entsprechende Bauteile die gleichen Bezugszeichen. Es zeigen:

Figur 1
in einer schematisierten Ablaufdarstellung den Fertigungsprozeß für einen Achsträger;
Figur 2
in der Ansicht, teilweise im vertikalen Längsschnitt ein Pressenwerkzeug bei der Vorformung;
Figur 3
in der Seitenansicht die Darstellung der Figur 2 entlang der Linie III-III;
Figur 4
einen Teilschritt des Biegevorgangs;
Figur 5
eine weitere Darstellung des Biegevorgangs;
Figur 6
die Darstellung eines Achsträgers bei der Endformung in der Draufsicht;
Figur 7
einen Schnitt durch die Darstellung der Figur 6 entlang der Linie VII-VII.
The invention is described below with reference to the accompanying drawings. In all drawings, corresponding components have the same reference numerals. Show it:
Figure 1
in a schematic flow diagram the manufacturing process for an axle beam;
Figure 2
in the view, partially in vertical longitudinal section, a press tool during preforming;
Figure 3
in the side view the representation of Figure 2 along the line III-III;
Figure 4
a sub-step of the bending process;
Figure 5
another illustration of the bending process;
Figure 6
the representation of an axle beam in the final shaping in plan view;
Figure 7
a section through the representation of Figure 6 along the line VII-VII.

Die Figur 1 zeigt die Fertigung eines Achsträgers 1 für einen Personenkraftwagen, ausgehend von einem Ausgangsprofil in Form eines geraden, im Querschnitt runden Rohrs 2.FIG. 1 shows the manufacture of an axle support 1 for a passenger car, based on an initial profile in the form of a straight, round in cross section Tube 2.

Der Achsträger 1 (Figur 1E und Figur 1F) umfaßt im wesentlichen zwei rohrförmige Längsabschnitte 3, die über einen Mittenabschnitt 4 miteinander verbunden sind. Der Mittenabschnitt 4 überträgt insbesondere Torsions- und Biegekräfte, die von den Längsabschnitten 3 in den Mittenabschnitt 4 geleitet werden. In den Übergängen 5 von den Längsabschnitten 3 zum Mittenabschnitt 4 sind am Achsträger 1 Umformbereiche 6 ausgebildet. Diese können beispielsweise auch zur Befestigung von Anbauteilen dienen.The axle support 1 (Figure 1E and Figure 1F) essentially comprises two tubular longitudinal sections 3, which over a middle section 4 are connected to each other. Of the Center section 4 transmits in particular torsion and Bending forces from the longitudinal sections 3 in the central section 4 be directed. In the transitions 5 from the longitudinal sections 3 to the central section 4 are on Axle beam 1 formed areas 6. these can for example also for attaching attachments.

Zur Fertigung des Achsträgers 1 wird das Rohr 2 in einer fixen Ausgangslänge LA bereitgestellt, welche abgestimmt ist auf die Dimensionen des Achsträgers 1 bzw. auf die bei der Fertigung vorgenommenen Umformvorgänge (Figur 1A). For the manufacture of the axle support 1, the tube 2 is provided in a fixed initial length L A , which is matched to the dimensions of the axle support 1 or to the forming processes carried out during manufacture (FIG. 1A).

Zunächst werden am Rohr 2 Ausbauchungen 7 vorgeformt (Figur 1B). Die Vorformung erfolgt durch hydraulischen Innendruck, wobei gleichzeitig ein axiales Nachschieben der Enden 8 vorgenommen wird. Auf diese Weise wird Profilmaterial an die vorzuformenden Bereiche 6' verlagert. Dies sind in dem dargestellten Beispiel die Zonen 7', in denen auch die maximale Umformung beim späteren Biegevorgang erfolgt.First, bulges 7 are preformed on the tube 2 (Figure 1B). The preforming is done by hydraulic Internal pressure, with an axial pushing at the same time the ends 8 is made. In this way, profile material shifted to the areas 6 'to be preformed. In the example shown, these are zones 7 ', in which also the maximum deformation during the later bending process he follows.

Nicht zwingend, aber vorteilhaft wird das so entstandene vorgeformte Rohr 2' anschließend einer Wärmebehandlung mittes Glühen unterzogen. Hierdurch kann die infolge der Vorformung entstandene Eigenspannung des Rohrs 2' reduziert werden.The resultant is not mandatory, but advantageous preformed tube 2 'then a heat treatment subjected to medium annealing. This can result in the Preforming internal stress of the tube 2 'is reduced will.

Die Erstellung der Achskontur 2'' erfolgt anschließend durch Biegen (Figur 1C). Beim Biegevorgang steht das Rohr 2' unter hohem Innendruck, so daß die hydrogeformte Kontur erhalten bleibt. Auch an den Biegevorgang kann sich eine Wärmebehandlung anschließen.The axis contour 2 '' is then created by bending (Figure 1C). The tube stands during the bending process 2 'under high internal pressure, so that the hydroformed contour preserved. The bending process can also affect connect a heat treatment.

Im Hydroformwerkzeug wird dann in einem Zwischenschritt ein Plätten vorgenommen (Figur 1D). Hierbei werden die Bereiche 6' abgeflacht. In der sich anschließenden hydraulischen Endformung (Figur 1E) erhält der Achsträger 1 seine abschließende Kontur mit der erforderlichen Maßgenauigkeit (Kalibrierung). Bei wirkendem Innendruck werden weiterhin die Montageöffnungen 9 gestanzt. So wird verhindert, daß die Kontur des Achsträgers 1 eingedrückt wird.The hydroforming tool is then used in an intermediate step a flattening made (Figure 1D). Here, the Areas 6 'flattened. In the subsequent Hydraulic final shaping (Figure 1E) receives the axle beam 1 its final contour with the required dimensional accuracy (Calibration). With effective internal pressure further punched the mounting holes 9. So will prevents the contour of the axle beam 1 from being pressed in becomes.

In einem abschließenden Fertigungsschritt (Figur 1F) wird ein Beschneiden der Eckbereiche 10 des Achsträgers 1 vorgenommen. In a final manufacturing step (Figure 1F) a trimming of the corner regions 10 of the axle beam 1 is carried out.

Die Vorformung, wie in Figur 1B schematisch dargestellt, wird in einem Pressenwerkzeug 11 vorgenommen (vergleiche Figuren 2 und 3). Das Pressenwerkzeug 11 weist zwei Werkzeughälften 12, 13 auf. An den beiden Endseiten 14, 15 ist jeweils ein Axialstempel 16, 17 angeordnet. Desweiteren verfügt das Pressenwerkzeug 11 in den Zonen, in denen die Ausbauchungen vorgeformt werden, über diesen angepaßte Ausbauchöffnungen 18. Hier sind Gegenhaltezylinder 19 angeordnet, deren Kolben 20 der Kontur der Ausbauchungen entsprechend ausgebildet sind.The preforming, as shown schematically in FIG. 1B, is carried out in a press tool 11 (compare Figures 2 and 3). The press tool 11 has two tool halves 12, 13 on. On the two end sides 14, 15 an axial punch 16, 17 is arranged in each case. Furthermore has the press tool 11 in the zones where the bulges are preformed, adapted to this Removal openings 18. Here are counter cylinders 19 arranged, the piston 20 of the contour of the bulges are trained accordingly.

Nach dem Einlegen des Rohrs 2 in das Pressenwerkzeug 11 werden die Werkzeughälften 12, 13 hydraulisch zusammengefahren. Das Rohr 2 wird an beiden Enden 8 durch ebenfalls hydraulisch bewegte Kolben 21 mit entsprechend geformten Köpfen 22 verschlossen. Das Rohr 2 wird dann mit einem Druckmedium beaufschlagt. Die Zuführung des Druckmediums erfolgt über eine in der Figur 2 gestrichelt angedeutete Innenhochdruckleitung 23, welche durch die Kolben 21 geführt ist.After inserting the tube 2 into the press tool 11 the tool halves 12, 13 are moved together hydraulically. The tube 2 is at both ends 8 by likewise hydraulically moved pistons 21 with correspondingly shaped Heads 22 closed. The tube 2 is then with a Pressurized media. The supply of the print medium takes place via a dashed line in FIG Internal high-pressure line 23, which runs through the pistons 21 is.

In der nächsten Phase wird auf das Rohr 2 eine axiale Kraft ausgeübt, der durch die beiden gegeneinander wirkenden Axialstempel 16, 17 entsteht. Durch die Axialkräfte werden die Köpfe 22 in die Rohrenden 8 hineingedrückt und dichten so formschlüssig den Innenraum 24 ab. Gleichzeitig wächst innerhalb des Rohrs 2 der Flüssigkeitsdruck. Durch den Innendruck bei gleichzeitiger axialer Belastung gelangt das Rohr 2 in einen plastischen Zustand und beginnt, sich auszubauchen. Innendruckabhängig gesteuert werden nun die Kolben 20 der Gegenhaltezylinder 19 zurückgefahren. Damit kommt es zu einer gezielten Materialverlagerung in die Ausbauchöffnungen 18 unter gleichzeitigem axialen Nachschieben der Rohrenden 8, wodurch das gewünschte vorgeformte Rohr 2' entsteht. In the next phase, an axial on the tube 2 Force exerted by the two acting against each other Axial punch 16, 17 is formed. By the axial forces the heads 22 are pressed into the pipe ends 8 and form-fittingly seal the interior 24. At the same time, the liquid pressure increases within the tube 2. Due to the internal pressure with simultaneous axial Tube 2 gets into a plastic load Condition and begins to bulge. Depends on the internal pressure the pistons 20 of the counter-cylinders are now controlled 19 retracted. This leads to a targeted Material transfer into the expansion openings 18 below simultaneous axial feeding of the pipe ends 8, whereby the desired preformed tube 2 'is formed.

Das vorgeformte Rohr 2' wird anschließend gebogen. Der Biegevorgang ist in den Figuren 4 und 5 dargestellt. Hierzu wird das vorgeformte Rohr 2' von einem Biegewerkzeug 25 aufgenommen. Die Enden 8 werden durch die Adapter 26 verschlossen. Anschließend wird das Rohr 2' mit Innendruck beaufschlagt. An den Längsabschnitten 3 greifen schwenkbar ausgebildete Werkzeugteile 27 an und biegen diese über die Formkontur 28. Beim Biegevorgang wird der Mittenabschnitt 4 durch die Gegenkontur 29 fixiert.The preformed tube 2 'is then bent. Of the Bending process is shown in Figures 4 and 5. For this purpose, the preformed tube 2 'is used by a bending tool 25 added. The ends 8 are through the adapter 26 closed. Then the tube 2 'with internal pressure acted upon. Grip on the longitudinal sections 3 pivotable tool parts 27 and bend this over the shape contour 28. During the bending process, the Center section 4 fixed by the counter contour 29.

Die so vorgeformte Achskontur 2'' wird nach dem Biegevorgang einem Hydroformwerkzeug 30 zugeführt, in dem die Endformung vorgenommen wird (Figur 6). Im Hydroformwerkzeug wird zunächst ein Plätten der Bereiche 6' vorgenommen, wodurch die Umformbereiche 6 ihre Konfiguration erhalten. Auch die Achskontur 2'' ist in den Bereichen 6' oberseitig leicht abgeflacht (siehe auch Figur 7). Anschließend wird die Achskontur 2'' durch die Adapter 31 formschlüssig verschlossen. Hydraulisch erfolgt dann die Endformung, bei der der Achsträger 1 mit der erforderlichen Maßgenauigkeit kalibriert wird. Im Anschluß daran werden die Montageöffnungen 9 bei wirkendem Innendruck gestanzt. The pre-shaped axis contour 2 '' is after the bending process a hydroforming tool 30 in which the Final shaping is carried out (Figure 6). In the hydroforming tool the areas 6 'are first flattened, whereby the forming areas 6 get their configuration. The axis contour 2 '' is also in the areas 6 ' slightly flattened on the top (see also Figure 7). Subsequently is the axis contour 2 '' by the adapter 31 positively closed. Then hydraulically Final shaping, in which the axle support 1 with the required Dimensional accuracy is calibrated. After that become the assembly openings 9 when the internal pressure acts punched.

BezugszeichenaufstellungList of reference symbols

11
- Achsträger- axle beam
22nd
- Rohr
2' - vorgeformtes Rohr
2''- Achskontur
- Pipe
2 '- preformed tube
2 '' axis contour
33rd
- Längsabschnitt- longitudinal section
44th
- Mittenabschnitt- middle section
55
- Übergang- Crossing
66
- Umformbereich
6' - Bereich v. 6
- forming area
6 'area of 6
77
- Ausbauchung
7' - Zone der max. Umformung
- bulge
7 'zone of the max. Reshaping
88th
- Ende v. 2- end of 2nd
99
- Montageöffnung- assembly opening
1010th
- Eckbereich- corner area
1111
- Pressenwerkzeug- press tool
1212th
- Werkzeughälfte- Tool half
1313
- Werkzeughälfte- Tool half
1414
- Endseite v. 11- end of v. 11
1515
- Endseite v. 11- end of v. 11
1616
- Axialstempel- Axial punch
1717th
- Axialstempel- Axial punch
1818th
- Ausbauchöffnung- Removal opening
1919th
- Gegenhaltezylinder- counter cylinder
2020th
- Kolben v. 19- piston from 19th
2121
- Kolben v. 16 u. 17- piston from 16 u. 17th
2222
- Kopf v. 21- head of 21
2323
- Innenhochdruckleitung- Internal high pressure line
2424th
- Innenraum v. 2- interior v. 2nd
2525th
- Biegewerkzeug- bending tool
2626
- Adapter - adapter
2727
- Werkzeugteile- tool parts
2828
- Formkontur- shape contour
2929
- Gegenkontur- counter contour
3030th
- Hydroformwerkzeug- hydroforming tool
3131
- Adapter- adapter
LA L A
- Ausgangslänge - initial length

Claims (3)

  1. A method of making an axle bearer (1) for motor vehicles by bending and hydroforming of a straight metal hollow profile (2), characterised by the following steps:
    a) the hollow profile (2) is subjected to a hydraulic internal pressure and to an axial force acting at the ends (8) of the hollow profile (2), with zone-wise controlled preforming of bulges (7) out of the material of the hollow profile (2) and shifting of profile material to the zones (6', 7') required to be deformed, the bulging being effected under the influence of counter-pressure acting in the zone required to be deformed,
    b) bending of the preformed hollow profile (2') under hydraulic internal pressure,
    c) end forming by hydraulic internal pressure, the axle bearer (1) being calibrated during or after the end forming,
    d) production of assembly openings (9) with the internal pressure operative.
  2. A method according to claim 1, characterised in that the preformed hollow profile is annealed before bending.
  3. A method according to claim 1 or 2, characterised in that the hollow profile is annealed after bending.
EP19950114847 1995-09-21 1995-09-21 Method for making an axle support Expired - Lifetime EP0770435B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP19950114847 EP0770435B1 (en) 1995-09-21 1995-09-21 Method for making an axle support
ES95114847T ES2124949T3 (en) 1995-09-21 1995-09-21 PROCEDURE TO MANUFACTURE A SHAFT SUPPORT.
DE59504498T DE59504498D1 (en) 1995-09-21 1995-09-21 Method of manufacturing an axle beam

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP19950114847 EP0770435B1 (en) 1995-09-21 1995-09-21 Method for making an axle support

Publications (2)

Publication Number Publication Date
EP0770435A1 EP0770435A1 (en) 1997-05-02
EP0770435B1 true EP0770435B1 (en) 1998-12-09

Family

ID=8219640

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19950114847 Expired - Lifetime EP0770435B1 (en) 1995-09-21 1995-09-21 Method for making an axle support

Country Status (3)

Country Link
EP (1) EP0770435B1 (en)
DE (1) DE59504498D1 (en)
ES (1) ES2124949T3 (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6098437A (en) * 1998-03-20 2000-08-08 The Budd Company Hydroformed control arm
DE19829577B4 (en) * 1998-07-02 2005-06-16 Carsten Dipl.-Ing. Binder Method and device for producing parts by means of internal high-pressure forming technology
JP2000301251A (en) * 1998-12-31 2000-10-31 Dana Corp Production of front wheel axle beam by hydroforming
NL1011330C2 (en) * 1999-02-17 2000-08-18 Corus Staal Bv Method for deforming a thin-walled metal pipe section.
DE19955694A1 (en) 1999-11-18 2001-05-23 Alusuisse Tech & Man Ag Process for forming an initial profile or the like workpiece and profile therefor
FR2828120B1 (en) 2001-08-06 2003-10-10 Brigitte Dossmann METHOD AND DEVICE FOR BENDING A CYLINDRICAL TUBE OR THE LIKE

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6453719A (en) * 1987-08-20 1989-03-01 Agency Ind Science Techn Production of bend pipe
US4991293A (en) * 1989-08-02 1991-02-12 Proprietary Technology, Inc. Means for providing very small bend radii in the tube-like structures
US5890387A (en) * 1989-08-24 1999-04-06 Aquaform Inc. Apparatus and method for forming and hydropiercing a tubular frame member
DE4017072A1 (en) 1990-05-26 1991-11-28 Benteler Werke Ag METHOD FOR HYDRAULIC FORMING A TUBULAR HOLLOW BODY AND DEVICE FOR CARRYING OUT THE METHOD
DE4201819A1 (en) * 1991-01-28 1992-07-30 Mannesmann Ag METHOD AND DEVICE FOR THE HYDRAULIC EXPANSION OF TUBULAR HOLLOW PROFILES

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Publication number Publication date
ES2124949T3 (en) 1999-02-16
DE59504498D1 (en) 1999-01-21
EP0770435A1 (en) 1997-05-02

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