EP1383619A1 - Method and device for the production of varying elements - Google Patents
Method and device for the production of varying elementsInfo
- Publication number
- EP1383619A1 EP1383619A1 EP02727360A EP02727360A EP1383619A1 EP 1383619 A1 EP1383619 A1 EP 1383619A1 EP 02727360 A EP02727360 A EP 02727360A EP 02727360 A EP02727360 A EP 02727360A EP 1383619 A1 EP1383619 A1 EP 1383619A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- membrane
- pressure
- branch
- hollow profile
- expansion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 10
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 4
- 239000012528 membrane Substances 0.000 claims abstract description 45
- 230000000750 progressive effect Effects 0.000 claims abstract 2
- 239000011248 coating agent Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- 239000002783 friction material Substances 0.000 claims description 2
- 239000007788 liquid Substances 0.000 claims description 2
- 238000000465 moulding Methods 0.000 abstract description 4
- 230000015572 biosynthetic process Effects 0.000 abstract description 3
- 239000012530 fluid Substances 0.000 abstract 1
- 239000000463 material Substances 0.000 description 3
- 239000011324 bead Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000009172 bursting Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping 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
- B21D26/033—Deforming tubular bodies
- B21D26/037—Forming branched tubes
Definitions
- the invention relates to a method for producing secondary shaped elements according to the preamble of patent claim 1 and a device for carrying out the same according to the preamble of patent claim 3.
- a generic method or a generic device is known from US 4,840,053.
- a hollow profile is inserted into a divided internal high-pressure shaping tool, the upper part of which has a pot-shaped branch originating from the engraving. After an internal high pressure has been exerted within the hollow profile, it widens into the branch and lies against the contour of the branch, as a result of which the secondary shaped element corresponding to the branch is formed.
- a solid body is slidably arranged in the branch, which supports the end face of the secondary molding element that is formed.
- This form of support is implemented in the usual way by means of steel stamps that are actively operated from the outside.
- this is only possible in the case of branches or for secondary shaped elements, whose surface lines on the inside or outside run in a straight line and parallel to one another, so that the stamp can be guided freely in the branch.
- the invention has for its object to develop a generic method or a generic device such that in a simple manner and reliable from the Shape course almost any shaped secondary elements can be formed on the hollow profile.
- the flexible and large-area adaptation of the membrane to the structural conditions of the branch shape makes it easy quickly and at all times the supporting element that is being formed is provided with sufficient supporting force, through which the hollow profile material can nestle optimally against the wall contour of the branch without running the risk of exceeding the yield point, which would result in the hollow profile bursting, and on the other hand due to the elasticity of the membrane a - with respect to the wall contour of the branch - retreating true to shape is achieved and jamming between the end face of the secondary mold element being formed and the branch wall is avoided.
- FIG. 1 shows a device for producing secondary shaped elements on a circumferentially closed hollow profile, which includes an internal high-pressure forming tool 1.
- a hollow profile blank 3 is inserted along its longitudinal extent.
- a branch 4 radially extends from the engraving 2 and penetrates the tool 1.
- the branch 4 is rounded in the region 5 of the transition to the longitudinal extent of the engraving 2 with large radii.
- the branch wall 6 has a bead 7 locally approximately in the middle, so that the wall 6 has an undercut with the flank 8 of the bead 7 facing away from the hollow profile blank 3.
- the branch 4 is covered on its end 9 remote from the hollow profile by a resilient membrane 10 belonging to the device in a high-pressure-tight manner spans.
- the membrane 10 is attached with its edge 11 circumferentially between the rear side 12 of the forming tool 1 and a clamping plate 14 of the device provided with a recess 13 in the covering area.
- the membrane 10 can be easily replaced in the event of a wear state that is no longer tolerable.
- the membrane 10 is sealed at its edge 11 opposite the rear side 12 of the forming tool 1 with an annular seal 15 and the clamping plate 14 located on the rear side 12 of the forming tool 1 is sealed on the underside thereof with an annular seal 16.
- a pressure channel 18 runs in the support plate 17 of the device, which is connected on the one hand to a pressure generator and on the other hand opens out on the side 19 of the support plate 17 facing the membrane 10.
- the support plate 17 is also sealed for reasons of pressure tightness with an annular seal 20 against the clamping plate 14.
- a pressure medium which can be liquid or gaseous due to the ease of handling, is now fed into the pressure channel 18, after which the membrane 10 is pressurized on the back when it exits.
- the membrane 10 is stretched in such a way that it conforms to the branch wall 6 on the one hand and on the hollow profile blank 3 on the other hand (FIG. 2).
- an internal high pressure can already be present in the hollow profile blank 3.
- the support pressure and the expansion pressure are increased, the ratio of the expansion pressure to the support pressure during the expansion phase being such that on the one hand the expansion pressure is considerably greater than the support pressure so that the blank 3 expands.
- the support pressure relative to the expansion pressure must not be so low that the blank 3 ruptures.
- the pressure conditions must be designed in such a way that a certain state of stress is formed within the blank material, which permits process-reliable expansion.
- the expansion pressure is increased. 3
- the blank 3 is arched into the branch 4 at the location thereof, the membrane 10, which counteracts the expansion direction being pressurized, being pushed back by the arch 21.
- the membrane 10 advantageously consists of a low-friction material or is provided with a low-friction coating, so that the friction of the curvature 21 of the blank 3 on the membrane 10 is as small as possible and therefore no stretching of the blank 3 in the area of the supporting system the membrane 10 takes place. This contributes to the process security of the expansion.
- the membrane 10 elastically recedes.
- the finished hollow profile 22 now has a secondary shaped element 23 which bears almost completely on the entire contour of the branch 4 (FIG. 4).
- the membrane 10 now assumes its starting position and is supported on the back by the support plate 17 covering the branch 4 at the location of the end position of the end face 24 of the secondary form element 23. It can be a useful co ⁇ !
- ⁇ tr M ⁇ hj d d: ⁇ hj DJ tr: hj ⁇ DJ hj co LQ o CL P- 3 3 co CQ ÜJ hj Hi C P- rt rs rr hj DJ CO o rt CL a H P- rt Cfl Hi hj H ⁇ Hl rt rt PV ⁇ lQ ⁇ 3 N d ⁇ N 3 d O rt N ⁇ N P- o ⁇ 1 P- da tr o ⁇
- the membrane 10 springs back from a tensioned state in the starting position. This ensures that there is no adhesion of the membrane 10 to the end face 24 of the secondary form element 23 and no jamming between the latter and the branch wall 6.
- this variant is only useful in the case of secondary form elements 23, which do not involve special contouring of the end face 24.
- the support plate 17 can be omitted in a component-saving manner.
- the pressure medium can also be supplied to the membrane 10 in some other way. After the expansion has ended, the internal high pressure is first released and then the supporting pressure is released, so that the desired end position of the end face 24 can be maintained and no further forming takes place.
- the pressure ratio of the support pressure and the internal high pressure can also be such that the support pressure increases in the final phase of the expansion until it is almost equal to the internal high pressure in the end position of the end face 24. This causes the expansion to stop. Then both pressures have to be reduced to the same extent at the same time, so that further forming does not take place.
- the device includes a bypass line which connects the pressure line of the internal high pressure to the pressure line of the support pressure.
- a controllable valve is arranged in the bypass line, which keeps the bypass line closed during the expansion and opens the bypass line after the end position 24 of the end face element 23 has been reached.
- pressure equalization is created in a relatively simple manner, which enables the secondary form element 23 to be kept in shape.
- the pressure control described can be used in all device variants within the scope of the invention in the last phase of the expansion and then takes the place of the other pressure controls described.
Landscapes
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
The invention relates to a method and a device for the production of varying elements in a hollow profile, enclosed around the circumference thereof. The device comprises an internal high pressure moulding tool, into the die recess of which a hollow profile blank may be inserted. A branch leads radially off from the die recess, in which the hollow profile blank may be expanded by means of a fluid internal high pressure to form the varying element. According to the invention, varying elements of almost any shape may be formed in the hollow element in a simple and process-secure manner with regard to the moulding process, whereby the device further comprises a membrane and a pressure generator, by means of which the membrane may be pressurised by a pressure medium in such a way that the membrane lies supported against the expanding direction during the expansion of the varying element as said element is formed. The membrane yields elastically on progressive formation of the varying element until the end form is achieved. The membrane is mounted on the tool outside the longitudinal edge of the die recess and stretching across the branching.
Description
Verfahren und Vorrichtung zur Herstellung von Nebenformelementen Method and device for producing secondary shaped elements
Die Erfindung betrifft ein Verfahren zur Herstellung von Nebenformelementen gemäß dem Oberbegriff des Patentanspruches 1 und eine Vorrichtung zur Durchführung desselben gemäß dem 0- berbegriff des Patentanspruches 3.The invention relates to a method for producing secondary shaped elements according to the preamble of patent claim 1 and a device for carrying out the same according to the preamble of patent claim 3.
Ein gattungsgemäßes Verfahren bzw. eine gattungsgemäße Vorrichtung ist aus der US 4,840,053 bekannt. Dabei wird ein Hohlprofil in ein geteiltes Innenhochdruck-Umfor werkzeug eingelegt, dessen Oberteil einen von der Gravur abgehenden topfförmigen Abzweig aufweist. Nach Ausüben eines Innenhochdruckes innerhalb des Hohlprofiles weitet sich dieses in den Abzweig auf und legt sich an der Kontur des Abzweiges an, wodurch sich das dem Abzweig formentsprechende Nebenformelement ausbildet. Zur Erzielung einer kontrollierten und prozesssicheren Ausbildung des Nebenformelementes ist in dem Abzweig ein Festkörper verschiebbar angeordnet, der die Stirnseite des sich ausbildenden Nebenformelementes abstützt. Diese Form der Abstützung wird in inzwischen üblicher Weise durch aktiv von außen betätigte Stahlstempel realisiert. Dies ist jedoch nur bei Abzweigen bzw. für Nebenformelemente möglich, deren Mantellinien der Innenseite bzw. Außenseite geradlinig und parallel zueinander verlaufen, so dass der Stempel ungehindert im Abzweig geführt werden kann.A generic method or a generic device is known from US 4,840,053. In this case, a hollow profile is inserted into a divided internal high-pressure shaping tool, the upper part of which has a pot-shaped branch originating from the engraving. After an internal high pressure has been exerted within the hollow profile, it widens into the branch and lies against the contour of the branch, as a result of which the secondary shaped element corresponding to the branch is formed. In order to achieve a controlled and process-reliable design of the secondary molding element, a solid body is slidably arranged in the branch, which supports the end face of the secondary molding element that is formed. This form of support is implemented in the usual way by means of steel stamps that are actively operated from the outside. However, this is only possible in the case of branches or for secondary shaped elements, whose surface lines on the inside or outside run in a straight line and parallel to one another, so that the stamp can be guided freely in the branch.
Der Erfindung liegt die Aufgabe zugrunde, ein gattungsgemäßes Verfahren bzw. eine gattungsgemäße Vorrichtung dahingehend weiterzubilden, dass in einfacher Weise und prozesssicher vom
Formverlauf her nahezu beliebig gestaltete Nebenformelemente am Hohlprofil ausgebildet werden können.The invention has for its object to develop a generic method or a generic device such that in a simple manner and reliable from the Shape course almost any shaped secondary elements can be formed on the hollow profile.
Die Aufgabe ist erfindungsgemäß durch die Merkmale des Patentanspruches 1 hinsichtlich des Verfahrens und durch die Merkmale des Patentanspruches 3 hinsichtlich der Vorrichtung gelöst .The object is achieved by the features of claim 1 with regard to the method and by the features of claim 3 with regard to the device.
Aufgrund der den Abzweig abdeckenden elastischen Membran, die in Gebrauchslage jeweils unter einem Stützdruck steht, der während der Aufweitung des Hohlprofiles immer etwas unterhalb des aufweitenden Innenhochdruckes liegt, wird in einfacher Weise einerseits durch die flexible und großflächige Anpassung der Membran an die konstruktiven Gegebenheiten der Abzweigform schnell und jederzeit dem sich ausbildenden Nebenformelement eine ausreichende Stützkraft geboten, durch den sich das Hohlprofilmaterial optimal an die Wandungskontur des Abzweiges schmiegen kann ohne Gefahr zu laufen die Streckgrenze zu überschreiten, was zu einem Bersten des Hohlprofiles führen würde, und andererseits durch die Elastizität der Membran ein - bezüglich der Wandungskontur des Abzweiges - formgetreues Zurückweichen erreicht und dabei ein Verklemmen zwischen der Stirnseite des sich ausbildenden Nebenformelementes und der Abzweigwandung vermieden. Durch die erfindungsgemäße Lösung sind an Hohlprofilen Nebenformelemente prozesssicher herstellbar, die nahezu beliebige Querschnittsänderungen aufweisen können. Somit ist die Ausbildung von Hinterschnitten ohne weiteres möglich und eine Abstützung des Nebenformelementes auch bei großen Übergangsradien von der Längserstreckung der Werkzeuggravur zum Abzweig hin vom Umformbeginn an realisierbar. Letzteres ist gerade bei der Verwendung von Werkstoffen mit geringer Duktilität wie beispielsweise Leichtmetalllegierungen für die Gewährleistung der Prozesssicherheit von erheblichem Vorteil. Die Anordnung einer Membran ist apparativ von sehr geringem Aufwand und ist auch in einfacher Weise bei bestehenden Umformwerkzeugen nachrüstbar .
Zweckmäßige Ausgestaltungen der Erfindung können den Unteransprüchen entnommen werden; im übrigen ist die Erfindung anhand eines in den Zeichnungen dargestellten Ausführungsbeispieles nachfolgend näher erläutert; dabei zeigt:Due to the elastic membrane covering the branch, which in the position of use is under a support pressure that is always slightly below the expanding internal high pressure during the expansion of the hollow profile, the flexible and large-area adaptation of the membrane to the structural conditions of the branch shape makes it easy quickly and at all times the supporting element that is being formed is provided with sufficient supporting force, through which the hollow profile material can nestle optimally against the wall contour of the branch without running the risk of exceeding the yield point, which would result in the hollow profile bursting, and on the other hand due to the elasticity of the membrane a - with respect to the wall contour of the branch - retreating true to shape is achieved and jamming between the end face of the secondary mold element being formed and the branch wall is avoided. By means of the solution according to the invention, secondary shaped elements can be reliably produced on hollow profiles and can have almost any cross-sectional changes. Thus, the formation of undercuts is easily possible and support of the secondary form element can be realized even with large transition radii from the longitudinal extent of the tool engraving to the branch from the beginning of the forming. The latter is of particular advantage when using materials with low ductility, such as light metal alloys, to ensure process reliability. The arrangement of a membrane is very simple in terms of equipment and can also be easily retrofitted to existing forming tools. Expedient embodiments of the invention can be found in the subclaims; otherwise the invention is explained in more detail below with reference to an embodiment shown in the drawings; shows:
Fig. 1 in einem seitlichen Längsschnitt ein Abschnitt einer erfindungsgemäßen Vorrichtung in unverformtem Zustand des Hohlprofiles bei druckentlasteter Membran,1 in a lateral longitudinal section, a section of a device according to the invention in the undeformed state of the hollow profile with a pressure-relieved membrane,
Fig. 2 in einem seitlichen Längsschnitt ein Abschnitt der Vorrichtung aus Fig. 1 in unverformtem Zustand des Hohlprofiles bei abstützender Membran,2 in a lateral longitudinal section a section of the device from FIG. 1 in the undeformed state of the hollow profile with a supporting membrane,
Fig. 3 in einem seitlichen Längsschnitt ein Abschnitt der Vorrichtung aus Fig. 1 während der AufWeitung des Hohlprofiles in einen Abzweig des Umformwerkzeuges der Vorrichtung bei abstützender Membran,3 in a lateral longitudinal section, a section of the device from FIG. 1 during the expansion of the hollow profile into a branch of the forming tool of the device with a supporting membrane,
Fig. 4 in einem seitlichen Längsschnitt ein Abschnitt derFig. 4 in a lateral longitudinal section a section of
Vorrichtung aus Fig. 1 in Endzustand des Hohlprofiles mit Nebenformelement und in Ausgangslage befindlicher Membran.1 in the final state of the hollow profile with secondary form element and membrane in the starting position.
In Fig. 1 ist eine Vorrichtung zur Herstellung von Nebenformelementen an einem umfänglich geschlossenen Hohlprofil dargestellt, welche ein Innenhochdruckumformwerkzeug 1 beinhaltet. In dessen Gravur 2 ist entlang deren Längserstreckung ein Hohlprofilrohling 3 eingelegt. Von der Gravur 2 geht radial ein Abzweig 4 ab, der das Werkzeug 1 durchdringt. Der Abzweig 4 ist im Bereich 5 des Übergangs zur Längserstreckung der Gravur 2 mit großen Radien verrundet. Die Abzweigwandung 6 weist etwa mittig lokal einen Wulst 7 auf, so dass die Wandung 6 mit der dem Hohlprofilrohling 3 abgewandten Flanke 8 des Wulstes 7 eine Hinterschneidung besitzt. Der Abzweig 4 wird an seinem hohlprofilfernen Ende 9 von einer elastischen zur Vorrichtung gehörigen Membran 10 hochdruckdicht abdeckend
überspannt. Die Membran 10 ist zu diesem Zwecke mit ihrem Rand 11 umlaufend zwischen der Rückseite 12 des Umformwerk- zeuges 1 und einer mit einer Aussparung 13 im Abdeckbereich versehenen Klemmplatte 14 der Vorrichtung klemmend befestigt. Dadurch ist ein Austausch der Membran 10 im Falle eines nicht mehr tolerierbaren Verschleißzustandes leicht ausführbar. Zur Gewährleistung der Druckdichtigkeit ist die Membran 10 an ihrem Rand 11 gegenüber der Rückseite 12 des Umformwerkzeuges 1 mit einer Ringdichtung 15 und die auf der Rückseite 12 des Umformwerkzeuges 1 liegende Klemmplatte 14 unterseitig gegenüber diesem mit einer Ringdichtung 16 abgedichtet. Auf der Klemmplatte 14 liegt eine Stützplatte 17, an der die Membran 10 gemäß Fig. 1 in entspanntem druckentlasteten Zustand anliegt. In der Stützplatte 17 der Vorrichtung verläuft ein Druckkanal 18, der einerseits mit einem Druckerzeuger verbunden ist und andererseits auf der der Membran 10 zugewandten Seite 19 der Stützplatte 17 ausmündet. Die Stützplatte 17 ist ebenfalls aus Gründen der Druckdichtigkeit mit einer Ringdichtung 20 gegenüber der Klemmplatte 14 abgedichtet.1 shows a device for producing secondary shaped elements on a circumferentially closed hollow profile, which includes an internal high-pressure forming tool 1. In its engraving 2, a hollow profile blank 3 is inserted along its longitudinal extent. A branch 4 radially extends from the engraving 2 and penetrates the tool 1. The branch 4 is rounded in the region 5 of the transition to the longitudinal extent of the engraving 2 with large radii. The branch wall 6 has a bead 7 locally approximately in the middle, so that the wall 6 has an undercut with the flank 8 of the bead 7 facing away from the hollow profile blank 3. The branch 4 is covered on its end 9 remote from the hollow profile by a resilient membrane 10 belonging to the device in a high-pressure-tight manner spans. For this purpose, the membrane 10 is attached with its edge 11 circumferentially between the rear side 12 of the forming tool 1 and a clamping plate 14 of the device provided with a recess 13 in the covering area. As a result, the membrane 10 can be easily replaced in the event of a wear state that is no longer tolerable. To ensure pressure tightness, the membrane 10 is sealed at its edge 11 opposite the rear side 12 of the forming tool 1 with an annular seal 15 and the clamping plate 14 located on the rear side 12 of the forming tool 1 is sealed on the underside thereof with an annular seal 16. On the clamping plate 14 there is a support plate 17 on which the membrane 10 according to FIG. 1 rests in a relaxed, pressure-relieved state. A pressure channel 18 runs in the support plate 17 of the device, which is connected on the one hand to a pressure generator and on the other hand opens out on the side 19 of the support plate 17 facing the membrane 10. The support plate 17 is also sealed for reasons of pressure tightness with an annular seal 20 against the clamping plate 14.
Mittels des Druckerzeugers wird nun ein Druckmedium, das aufgrund der einfachen Handhabbarkeit flüssig oder gasförmig sein kann, in den Druckkanal 18 geleitet, wonach bei Austritt aus diesem die Membran 10 rückseitig druckbeaufschlagt wird. Dadurch und infolge der Elastizität bei noch fehlendem Gegendruck wird die Membran 10 derart gedehnt, dass sie sich einerseits konturgetreu an der Abzweigwandung 6 und andererseits am Hohlprofilrohling 3 anlegt (Fig. 2) . Hierbei kann im Hohlprofilrohling 3 schon ein Innenhochdruck anliegen. Dieser ist in dieser Phase entweder noch nicht so hoch, dass er aufweitend wirksam ist, oder entspricht zwar einem Aufweitdruck, jedoch ist dann der die Membran 10 dehnende Stützdruck gleich hoch, so dass noch keine Verformung des Hohlprofilrohlings 3 in den Abzweig 4 hinein stattfinden kann. Alternativ zu den genannten Druckmedien sind noch mechanische Spreizvorrichtungen denkbar, bei denen beispielsweise ein elastisch verformbarer Körper aus Vollgummi durch ein Stempel verformt wird,
wodurch die dabei verdrängte Gummimasse die Membran 10 an die Kontur der Abzweigwandung 6 presst.By means of the pressure generator, a pressure medium, which can be liquid or gaseous due to the ease of handling, is now fed into the pressure channel 18, after which the membrane 10 is pressurized on the back when it exits. As a result and due to the elasticity in the absence of back pressure, the membrane 10 is stretched in such a way that it conforms to the branch wall 6 on the one hand and on the hollow profile blank 3 on the other hand (FIG. 2). Here, an internal high pressure can already be present in the hollow profile blank 3. In this phase, this is either not yet so high that it has a widening effect, or indeed corresponds to an expansion pressure, but then the support pressure stretching the membrane 10 is the same, so that no deformation of the hollow profile blank 3 can take place into the branch 4 , As an alternative to the printing media mentioned, mechanical expansion devices are also conceivable in which, for example, an elastically deformable body made of solid rubber is deformed by a stamp, whereby the rubber mass displaced thereby presses the membrane 10 against the contour of the branch wall 6.
Nachdem sich die Membran 10 an den Rohling 3 angelegt hat, werden der Stützdruck und der Aufweitdruck erhöht, wobei das Verhältnis des Aufweitdruckes zum Stützdruck während der Aufweitphase derart sein muss, dass einerseits der Aufweitdruck erheblich größer als der Stützdruck ist, damit sich der Rohling 3 aufweitet. Andererseits darf der Stützdruck relativ zum Aufweitdruck nicht so niedrig sein, dass es zu einem Bersten des Rohlings 3 kommt. Die Druckverhältnisse müssen vor allen Dingen so gestaltet sein, dass ein bestimmter Spannungszustand innerhalb des Rohlingmaterials gebildet wird, der eine prozesssichere Aufweitung gestattet. Mit Fortgang der AufWeitung wird dabei der Aufweitdruck erhöht. Dadurch wird nach Fig. 3 der Rohling 3 an der Stelle des Abzweiges 4 in diesen hinein ausgewölbt, wobei die Membran 10, die der Aufweitrichtung druckbeaufschlagt entgegenwirkt, durch die Wölbung 21 zurückgedrängt wird.After the membrane 10 has applied to the blank 3, the support pressure and the expansion pressure are increased, the ratio of the expansion pressure to the support pressure during the expansion phase being such that on the one hand the expansion pressure is considerably greater than the support pressure so that the blank 3 expands. On the other hand, the support pressure relative to the expansion pressure must not be so low that the blank 3 ruptures. Above all, the pressure conditions must be designed in such a way that a certain state of stress is formed within the blank material, which permits process-reliable expansion. As the expansion continues, the expansion pressure is increased. 3, the blank 3 is arched into the branch 4 at the location thereof, the membrane 10, which counteracts the expansion direction being pressurized, being pushed back by the arch 21.
Die Membran 10 besteht vorteilhafter Weise aus einem reibarmen Werkstoff oder ist mit einer reibarmen Beschichtung versehen, so dass die Reibung der Wölbung 21 des Rohlings 3 an der Membran 10 möglichst gering ist und damit keine Abstre- ckung des Rohlings 3 in dem Bereich der stützenden Anlage der Membran 10 erfolgt. Dies trägt zur Prozesssicherheit der Aufweitung bei.The membrane 10 advantageously consists of a low-friction material or is provided with a low-friction coating, so that the friction of the curvature 21 of the blank 3 on the membrane 10 is as small as possible and therefore no stretching of the blank 3 in the area of the supporting system the membrane 10 takes place. This contributes to the process security of the expansion.
Mit Fortschritt der Ausbildung des Nebenformelementes 23 bis zum Erreichen der Endform weicht die Membran 10 elastisch zurück. Zum Abschluss der Aufweitung weist das fertiggestellte Hohlprofil 22 nun ein Nebenformelement 23 auf, das nahezu vollständig an der gesamten Kontur des Abzweiges 4 anliegt (Fig. 4) . Die Membran 10 nimmt nun ihre Ausgangsposition ein und wird rückseitig von der den Abzweig 4 an der Stelle der Endlage der Stirnseite 24 des Nebenformelementes 23 abdeckenden Stützplatte 17 abgestützt. Hierbei kann es sich als sinn-
co <! α ιQ ιQ tr r+ "3 (-1 rr CΛ DJ ω co d σ co DJ Hi rt s: CL Φ S φ N ω tr Φ Ω <j φ O P- Φ Φ tr Φ Φ DJ o Φ rt P- d Ω φ a P- flj: tr O: Φ Φ Φ hj P- a d Φ Φ ^-• tr oAs the formation of the secondary mold element 23 progresses until the final shape is reached, the membrane 10 elastically recedes. At the end of the expansion, the finished hollow profile 22 now has a secondary shaped element 23 which bears almost completely on the entire contour of the branch 4 (FIG. 4). The membrane 10 now assumes its starting position and is supported on the back by the support plate 17 covering the branch 4 at the location of the end position of the end face 24 of the secondary form element 23. It can be a useful co <! α ιQ ιQ tr r + "3 (- 1 rr CΛ DJ ω co d σ co DJ Hi rt s: CL Φ S φ N ω tr Φ Ω <j φ O P- Φ Φ tr Φ Φ DJ o Φ rt P- d Ω φ a P- flj: tr O: Φ Φ Φ hj P- ad Φ Φ ^ - • tr o
P- a φ cn a N H a d: Ω co P- Φ rt N H hj a hj O φ rt hj hj H- Φ ΦP- a φ cn a N H a d: Ω co P- Φ rt N H hj a hj O φ rt hj hj H- Φ Φ
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weitvorganges und Druckentlastung die Membran 10 aus einem gespannten Zustand heraus in die Ausgangslage zurückfedert. Dabei wird gesichert, dass es kein Anhaften der Membran 10 an der Stirnseite 24 des Nebenformelementes 23 und kein Verklemmen zwischen diesem und der Abzweigwandung 6 gibt. Diese Variante ist allerdings nur bei Nebenformelementen 23 sinnvoll, bei denen es nicht um eine besondere Konturierung der Stirnseite 24 geht. Des weiteren kann bauteilsparend die Stützplatte 17 entfallen. Hierzu kann das Druckmedium auch anderweitig der Membran 10 zugeführt werden. Nach Ende der AufWeitung wird zuerst der Innenhochdruck und dann der Stützdruck entspannt, so dass die gewünschte Endlage der Stirnseite 24 gehalten werden kann und keine weitere Umformung stattfindet. Das Druckverhältnis von Stützdruck und Innenhochdruck kann auch so sein, dass in der Endphase der Aufweitung der Stützdruck ansteigt, bis er in der Endlage der Stirnseite 24 nahezu gleich dem Innenhochdruck ist. Hierdurch kommt die Aufweitung zum Stillstand. Anschließend müssen beide Drücke gleichzeitig in gleichem Maße verringert werden, so dass eine weiterführende Umformung unterbleibt.Weitgangses and pressure relief the membrane 10 springs back from a tensioned state in the starting position. This ensures that there is no adhesion of the membrane 10 to the end face 24 of the secondary form element 23 and no jamming between the latter and the branch wall 6. However, this variant is only useful in the case of secondary form elements 23, which do not involve special contouring of the end face 24. Furthermore, the support plate 17 can be omitted in a component-saving manner. For this purpose, the pressure medium can also be supplied to the membrane 10 in some other way. After the expansion has ended, the internal high pressure is first released and then the supporting pressure is released, so that the desired end position of the end face 24 can be maintained and no further forming takes place. The pressure ratio of the support pressure and the internal high pressure can also be such that the support pressure increases in the final phase of the expansion until it is almost equal to the internal high pressure in the end position of the end face 24. This causes the expansion to stop. Then both pressures have to be reduced to the same extent at the same time, so that further forming does not take place.
Diese Gegebenheit kann dadurch bewerkstelligt werden, dass die Vorrichtung eine Bypassleitung beinhaltet, die die Druckleitung des Innenhochdruckes mit der Druckleitung des Stützdruckes verbindet. In der Bypassleitung ist dazu ein steuerbares Ventil angeordnet, das während der Aufweitung die Bypassleitung geschlossen hält und nach Erreichen der Endlage der Stirnseite 24 des Nebenformelementes 23 die Bypassleitung öffnet. Hierbei wird in relativ einfacher Weise ein Druckausgleich geschaffen, der eine Formwahrung des Nebenformelementes 23 ermöglicht. Die beschriebene Drucksteuerung kann bei allen Vorrichtungsvarianten im Rahmen der Erfindung in der letzten Phase der Aufweitung verwandt werden und tritt dann an die Stelle der beschriebenen anderen Drucksteuerungen.
This fact can be brought about in that the device includes a bypass line which connects the pressure line of the internal high pressure to the pressure line of the support pressure. For this purpose, a controllable valve is arranged in the bypass line, which keeps the bypass line closed during the expansion and opens the bypass line after the end position 24 of the end face element 23 has been reached. In this case, pressure equalization is created in a relatively simple manner, which enables the secondary form element 23 to be kept in shape. The pressure control described can be used in all device variants within the scope of the invention in the last phase of the expansion and then takes the place of the other pressure controls described.
Claims
1. Verfahren zur Herstellung von Nebenformelementen an einem umfänglich geschlossenen Hohlprofil, wobei ein Hohlprofilrohling mittels eines fluidischen Innenhochdruckes in einen von einer Gravur des Innenhochdruck-Umformwerkzeuges abgehenden Abzweig hinein unter Bildung des Nebenformelementes aufgeweitet wird, d a d u r c h g e k e n n z e i c h n e t , dass das sich bildende Nebenformelement (23) mittels einer von einem äußeren Druck beaufschlagten Membran (10) während der Aufweitung entgegen der Aufweitrichtung abgestützt wird, derart, dass die Membran (10) mit Fortschritt der Ausbildung des Nebenformelementes (23) bis zum Erreichen der Endform e- lastisch zurückweicht.1. A method for producing secondary shaped elements on a circumferentially closed hollow profile, wherein a hollow profile blank is expanded by means of a fluidic internal high pressure into a branch originating from an engraving of the internal high pressure forming tool to form the secondary molded element, characterized in that the secondary molded element (23) which is formed by means of a diaphragm (10) acted upon by an external pressure is supported against the widening direction during the expansion, such that the diaphragm (10) resiliently withdraws as the secondary mold element (23) progresses until the final shape is reached.
2. Verfahren nach Anspruch 1, d a d u r c h g e k e n n z e i c h n e t , dass die Abstützung des Nebenformelementes (23) unter sich mit dem Fortschritt der Aufweitung erhöhendem Stützdruck erfolgt.2. The method according to claim 1, so that the supporting of the secondary form element (23) takes place with the progressive expansion of the increasing support pressure.
3. Vorrichtung zur Herstellung von Nebenformelementen an einem umfänglich geschlossenen Hohlprofil, mit einem Innenhochdruckumformwerkzeug, in dessen Gravur ein Hohlprofilrohling einlegbar ist, wobei von der Gravur ein Abzweig radial abgeht, in den der Hohlprofilrohling mittels eines fluidischen Innenhochdruckes unter Bildung des Nebenformelementes aufweitbar ist, d a d u r c h g e k e n n z e i c h n e t , dass die Vorrichtung eine Membran (10) und einen Druckerzeuger beinhaltet, mittels dessen die Membran (10) über ein Druckmedium druckbeaufschlagbar ist, derart, dass die Membran (10) während der Auf eitung an dem sich bildenden Nebenformelement (23) entgegen der Aufweitrichtung abstützend anliegt, wobei die Membran (10) mit Fortschritt der Ausbildung des Nebenformelementes (23) bis zum Erreichen der Endform elastisch zurückweicht, und dass die Membran (10) den Abzweig (4) überspannend außerhalb der Längserstreckung der Gravur (2) am Werkzeug (1) angebracht ist.3.Device for producing secondary form elements on a circumferentially closed hollow profile, with an internal high-pressure forming tool, in the engraving of which a hollow profile blank can be inserted, a branch branching off radially from the engraving, into which the hollow profile blank can be expanded by means of a fluidic internal high pressure to form the secondary shaped element . that the device includes a membrane (10) and a pressure generator, by means of which the membrane (10) can be pressurized via a pressure medium, such that the membrane (10) is supported against the expansion direction during processing on the secondary mold element (23) that is being formed abuts, the membrane (10) elastically receding as the secondary mold element (23) progresses until the final shape is reached, and that the membrane (10) spans the branch (4) outside the longitudinal extent of the engraving (2) on the tool (1 ) is attached.
4. Vorrichtung nach Anspruch 3, d a d u r c h g e k e n n z e i c h n e t , dass die Membran (10) in einer ringförmigen Aussparung innerhalb des Abzweiges (4) befestigt ist.4. The device according to claim 3, so that the membrane (10) is fastened in an annular recess within the branch (4).
5. Vorrichtung nach Anspruch 3, d a d u r c h g e k e n n z e i c h n e t , dass die Membran (10) an der Rückseite (12) des gravurtragenden Umformwerkzeuges (1) am Ende (9) des Abzweiges (4) befestigt ist.5. The device according to claim 3, so that the membrane (10) is attached to the rear (12) of the engraving-forming tool (1) at the end (9) of the branch (4).
6. Vorrichtung nach einem der Ansprüche 3 bis 5, d a d u r c h g e k e n n z e i c h n e t , dass die Vorrichtung eine Stützplatte (17) enthält, die den Abzweig (4) an der Stelle der Endlage der Stirnseite (24) des Nebenformelementes (23) rückseitig der Membran (10) abdeckt.6. Device according to one of claims 3 to 5, characterized in that the device contains a support plate (17) which the branch (4) at the location of the end position of the end face (24) of the secondary form element (23) on the rear side of the membrane (10) covers.
7. Vorrichtung nach Anspruch 6, d a d u r c h g e k e n n z e i c h n e t , dass die Stützplatte (17) von der hinsichtlich eines Stütz- und/oder Innenhochdruckes unbelasteten Membran (10) beabstandet ist .7. The device as claimed in claim 6, so that the support plate (17) is spaced from the membrane (10) which is unloaded with respect to a support and / or high internal pressure.
8. Vorrichtung nach einem der Ansprüche 6 oder 7, d a d u r c h g e k e n n z e i c h n e t , dass in der Stützplatte (17) ein Druckkanal (18) verläuft, der einerseits mit dem Druckerzeuger verbunden ist und andererseits auf Seiten der Membran (10) ausmündet.8. Device according to one of claims 6 or 7, characterized in that a pressure channel (18) runs in the support plate (17), which is connected on the one hand to the pressure generator and on the other hand opens out on the side of the membrane (10).
9. Vorrichtung nach einem der Ansprüche 3 bis 8, d a d u r c h g e k e n n z e i c h n e t , dass die Endlage der Stirnseite (24) des Nebenformelementes (23) von der druckentlasteten Lage der Membran (10) beabstandet ist.9. Device according to one of claims 3 to 8, so that the end position of the end face (24) of the secondary form element (23) is spaced from the pressure-relieved position of the membrane (10).
10. Vorrichtung nach einem der Ansprüche 3 bis 9, d a d u r c h g e k e n n z e i c h n e t , dass das den Stützdruck übermittelnde Druckmedium flüssig o- der gasförmig ist.10. Device according to one of claims 3 to 9, that the pressure medium transmitting the support pressure is liquid or gaseous.
11. Vorrichtung nach einem der Ansprüche 3 bis 10, d a d u r c h g e k e n n z e i c h n e t , dass die Membran (10) aus einem reibarmen Werkstoff besteht oder mit einer reibarmen Beschichtung versehen ist.11. The device according to any one of claims 3 to 10, that the membrane (10) consists of a low-friction material or is provided with a low-friction coating.
12. Vorrichtung nach einem der Ansprüche 3 bis 11, d a d u r c h g e k e n n z e i c h n e t , dass die Vorrichtung eine Bypassleitung beinhaltet, die die Druckleitung des Innenhochdruckes mit der Druckleitung des Stützdruckes verbindet und ein steuerbares Ventil enthält, das während der Aufweitung die Bypassleitung geschlossen hält und nach Erreichen der Endlage der Stirnseite (24) des Nebenformelementes (23) die Bypassleitung öffnet. 12. Device according to one of claims 3 to 11, characterized in that the device includes a bypass line which connects the pressure line of the internal high pressure with the pressure line of the support pressure and contains a controllable valve which keeps the bypass line closed during expansion and after reaching the end position the end face (24) of the secondary form element (23) opens the bypass line.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10121787A DE10121787C1 (en) | 2001-05-04 | 2001-05-04 | Method, for shaping additional element at a closed hollow profile, uses high inner fluid pressure within it to force the mantle into a shaped branch cavity while supported externally by an elastic membrane under pressure |
| DE10121787 | 2001-05-04 | ||
| PCT/EP2002/002418 WO2002090014A1 (en) | 2001-05-04 | 2002-03-06 | Method and device for the production of varying elements |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1383619A1 true EP1383619A1 (en) | 2004-01-28 |
| EP1383619B1 EP1383619B1 (en) | 2009-02-18 |
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ID=7683667
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP02727360A Expired - Lifetime EP1383619B1 (en) | 2001-05-04 | 2002-03-06 | Method and device for the production of accessory form elements |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US20040172999A1 (en) |
| EP (1) | EP1383619B1 (en) |
| CA (1) | CA2445406A1 (en) |
| DE (2) | DE10121787C1 (en) |
| WO (1) | WO2002090014A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10065033C1 (en) * | 2000-12-23 | 2002-07-11 | Daimler Chrysler Ag | Method for producing a circumferentially closed hollow profile and a device for carrying it out |
| DE10309625B4 (en) * | 2003-03-04 | 2006-04-13 | Audi Ag | Method for introducing a side mold into a cavity having a molded part |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19927064A1 (en) | 1999-06-15 | 2000-12-28 | Binder Technologie Ag Gams | Method of pressing sheet metal blanks has edge of blank clamped to die which is filled with pressure fluid to support it during deformation |
| DE19951850C1 (en) | 1999-10-28 | 2001-01-25 | Metallwarenfabrik Reichertshof | Production of molded parts comprises arranging a sheet steel between a molding tool and a membrane, molding the steel sheet against the molding tool, and releasing the pressure after complete deformation of the steel sheet |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1048482A (en) * | 1950-09-18 | 1953-12-22 | Ici Ltd | Manufacture of branch pipe fittings |
| US3350905A (en) * | 1963-12-21 | 1967-11-07 | Agency Ind Science Techn | Liquid pressure bulge forming apparatus |
| US4840053A (en) * | 1987-07-29 | 1989-06-20 | Mitsui & Co., Ltd. | Method for manufacturing a pipe with projections |
| DE19530056B4 (en) * | 1995-08-16 | 2004-09-09 | Schuler Hydroforming Gmbh & Co. Kg | Method and device for producing T-shaped or at least one dome-like hollow body |
| WO1998046381A1 (en) * | 1997-04-11 | 1998-10-22 | Rolf Haberstock | Fluid forming press |
| DE19752772C2 (en) * | 1997-11-28 | 1999-09-02 | Daimler Chrysler Ag | Process for producing an air-gap-insulated exhaust pipe provided with a branch connection |
| US6029487A (en) * | 1998-08-24 | 2000-02-29 | Avmat Kydroforming Ltd. | System and method for manufacturing tubular products from tubular workpieces |
| FR2787357B1 (en) * | 1998-12-18 | 2001-03-16 | Tubes Et Formes | METHOD AND APPARATUS FOR HYDROFORMING AN INCLINED PIPE FROM A METAL TUBE |
| DE10065033C1 (en) * | 2000-12-23 | 2002-07-11 | Daimler Chrysler Ag | Method for producing a circumferentially closed hollow profile and a device for carrying it out |
-
2001
- 2001-05-04 DE DE10121787A patent/DE10121787C1/en not_active Revoked
-
2002
- 2002-03-06 EP EP02727360A patent/EP1383619B1/en not_active Expired - Lifetime
- 2002-03-06 WO PCT/EP2002/002418 patent/WO2002090014A1/en active Application Filing
- 2002-03-06 DE DE50213291T patent/DE50213291D1/en not_active Expired - Lifetime
- 2002-03-06 US US10/476,532 patent/US20040172999A1/en not_active Abandoned
- 2002-03-06 CA CA002445406A patent/CA2445406A1/en not_active Abandoned
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19927064A1 (en) | 1999-06-15 | 2000-12-28 | Binder Technologie Ag Gams | Method of pressing sheet metal blanks has edge of blank clamped to die which is filled with pressure fluid to support it during deformation |
| DE19951850C1 (en) | 1999-10-28 | 2001-01-25 | Metallwarenfabrik Reichertshof | Production of molded parts comprises arranging a sheet steel between a molding tool and a membrane, molding the steel sheet against the molding tool, and releasing the pressure after complete deformation of the steel sheet |
Non-Patent Citations (2)
| Title |
|---|
| ALTAN T. PR.: "Metal forming handbook", 1998, SPRINGER, GERMANY, ISBN: 3-540-61185-1, pages: 407, 431, XP002989210 |
| See also references of WO02090014A1 |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2002090014A1 (en) | 2002-11-14 |
| DE10121787C1 (en) | 2002-07-11 |
| US20040172999A1 (en) | 2004-09-09 |
| CA2445406A1 (en) | 2002-11-14 |
| DE50213291D1 (en) | 2009-04-02 |
| EP1383619B1 (en) | 2009-02-18 |
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