EP1657007B9 - Method for forming workpieces - Google Patents

Method for forming workpieces Download PDF

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Publication number
EP1657007B9
EP1657007B9 EP20050024456 EP05024456A EP1657007B9 EP 1657007 B9 EP1657007 B9 EP 1657007B9 EP 20050024456 EP20050024456 EP 20050024456 EP 05024456 A EP05024456 A EP 05024456A EP 1657007 B9 EP1657007 B9 EP 1657007B9
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EP
European Patent Office
Prior art keywords
workpiece
medium
die
punch
pressure
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Not-in-force
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EP20050024456
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German (de)
French (fr)
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EP1657007A1 (en
EP1657007B1 (en
Inventor
Joachim Hermann Schondelmaier
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Individual
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    • 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
    • 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
    • B21D26/043—Means for controlling the axial pusher
    • 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
    • B21D26/045—Closing or sealing means

Definitions

  • the present invention relates to a method for deforming workpieces according to the preamble of claim 1, with the general hollow body such as pipes can be expanded by applying an internal pressure or deformed into a desired contour.
  • workpieces which have, for example, a complex geometric shape can be adjusted.
  • the so-called hydroforming process has long been known.
  • the workpiece to be deformed is inserted into a tool mold which contains the contour of the workpiece to be produced as an engraving or negative mold.
  • the tool is closed and locked by a hydraulic press.
  • Sealing punches which are attached to hydraulic axial cylinders, close the front ends of the pipes.
  • an internal pressure in the front pipe is filled into a front pipe and built by a pressure pump, an internal pressure in the front pipe.
  • the pre-pipe is widened.
  • the sealing dies push the pipe ends, causing material to flow into the forming zone.
  • a targeted control of the internal pressure and the sealing punch movement causes the material to be applied to the tool contour and thus the finished part its final Form receives.
  • This hydroforming process is for example in the DE 195 30 055 A1 .
  • the forming pressure will be generated by hydraulic pumps.
  • these hydraulic pumps only reach forming pressures up to a limited value. Due to the limited forming pressure many geometrical shapes and wall thicknesses can not be produced with this method or only very time consuming. Workpieces with larger wall thicknesses, which may also consist of a more deformation-resistant material, can be produced with these known methods, if at all, only conditionally. Due to the limited pressures also only relatively small deformations can be achieved in workpieces with these known procedures.
  • the previous devices for the hydroforming process are very complex and complex to ensure the necessary tightness in the workpiece.
  • the system technology is expensive, on the other hand, long cycle times result from the complex change of workpieces.
  • the US 2,770,874 discloses a forming process in which two mutually movable punches are hydraulically or otherwise pressed against a plastic medium in the workpiece.
  • a medium here, however, a very special is used, namely molten aluminum.
  • molten aluminum solidifies again at the edge region, a seal against the punch and the tool is to be achieved. Due to the fact that this forming process known from it works only with molten aluminum which solidifies for sealing, it is not comparable with a forming process in which water, oil, plastic or a mixture thereof is used as the medium for producing a forming pressure.
  • the EP 0 760 264 A1 shows a device for the hydraulic deformation of tubular components, however, a very special design with a sealing mandrel and a stamp is described herein, which, however, is not suitable for directly applying a compressive force directly to the medium.
  • the sealing mandrel is arranged so that it opens at one end of the pipe section to be deformed and conducts there a seal on a conical surface.
  • the sealing mandrel is hollow and coupled via a channel with a stamp that builds up by moving by pressing pressure in the sealing mandrel and thus in the workpiece pressure.
  • the structure of the tool and the forming device is relatively complicated and expensive to manufacture.
  • the JP-A-0 712 42 69 shows a forming device consisting of several die parts. In these die parts, a cavity is formed, which has the desired outer contour of the workpiece to be deformed.
  • the hollow workpiece to be deformed is filled with oil, rubber or the like.
  • a plunger is inserted through an opening in the hollow workpiece and exerts pressure on the oil, rubber or the like contained therein so that the desired shaping takes place in the die.
  • the stamp exerts immediate pressure on the medium in the hollow body to be deformed, such as oil, rubber or the like.
  • the seal between the punch and the workpiece is neither obvious nor explained.
  • the interior of a hollow body to be formed is subjected to hydraulic pressure.
  • a hydraulic pressure is also exerted on its outer side, wherein the pressure in the interior of the hollow body is greater than the pressure on its outer side.
  • the external pressure is at least 500 bar.
  • a movable punch or piston is guided in an extra holding part. Only the holding part comes at all with the workpiece to be deformed in contact.
  • the JP-A-56 080 329 shows a completely different procedure for forming a workpiece.
  • a needle is immersed by impact from above into a liquid. Only with the sliver down the needle is a seal at the upper end of the workpiece to be deformed achieved by separate means. The needle itself is guided in a special holder.
  • the technical problem underlying the present invention is to provide a procedure that allows a better forming of workpieces.
  • the workpiece is placed in a die (cavity tool), which already has the desired workpiece contour in the interior as a negative mold.
  • the medium here water, oil, plastic or a mixture thereof, be introduced into the workpiece, for example via a feed device.
  • the workpiece or the cavity formed by this workpiece can be substantially filled with said medium. But it may also be sufficient that at least one or the portions of the workpiece to be deformed are covered by the medium.
  • the medium is first inserted or filled in the matrix and then the workpiece is inserted. Finally, the punch is moved and pressed against the medium, so that this deformed the workpiece according to the negative mold of the die. The punch is retracted to achieve a seal to the workpiece with a press fit into the workpiece.
  • the basic idea here is that the workpiece to be deformed and the punch define a closed cavity, which is now filled by the medium. By displacing the medium, an internal pressure is built up in the closed cavity, which leads to a deformation of the workpiece in the predetermined by the negative mold escape space. The pressure is thus determined by the force with which the punch is pressed and its end face, which faces the medium determined. This allows - as mentioned above - achieve a higher internal pressure than before, which can allow new applications, and also no pump for generating the internal pressure is necessary. It should be emphasized again here that the movable punch causes the forming pressure on the medium and not a pump as in the known method. Since the pressure is generated by a mechanical pressing device, forming pressures of up to 25,000 bar (or possibly even more) can be achieved.
  • the medium to which the stamp exerts the forming pressure can have a solid, semi-solid or liquid state of aggregation.
  • liquids water or oils are suitable, but it is also possible to use solid materials such as plastics. The latter are particularly suitable due to the low viscosity compared to liquid media, since thus the tightness of the device can be ensured easier.
  • solid materials such as plastics.
  • the latter are particularly suitable due to the low viscosity compared to liquid media, since thus the tightness of the device can be ensured easier.
  • all media can be used for the process according to the invention, which were also used in the previous known hydroforming process.
  • Another exemplary embodiment of the method provides for the use of an additional sealing system, which is attached, for example, to the punch or to the die.
  • the die or the tool can be immersed in a medium.
  • the punch which can be introduced into the workpiece with press-fitting, and optionally the separate sealing system, in order to thus deform it.
  • a further exemplary embodiment of the method provides that the illustrated method is carried out by means of cold forming.
  • a hot forming is conceivable and feasible.
  • at least one heating device for heating the workpiece, the die and / or the medium may be present on the device according to the invention mentioned above.
  • Another exemplary embodiment of the method provides that the forming pressure is not constant, but exerted on the medium. This may cause material defects that may arise during a sudden application of high pressure, be avoided. For example, the increase in the forming pressure can be increased steadily or in stages.
  • a workpiece to be deformed is placed in a die. Subsequently, the workpiece is filled with a medium on which a displaceable punch exerts a forming pressure by displacing the medium. As a result, the workpiece clings to the negative mold and receives the desired shape.
  • the stamp is driven for example by a press.
  • the present invention is based on the idea, instead of generating the forming pressure via a pump as in the case of the known method mentioned at the outset, for the first time to exert a high internal pressure by displacing the special, aforementioned medium.
  • a very large pressure can be exerted. This allows significantly higher forming pressures than before.
  • By generating the forming pressure by moving the movable punch ie generally by displacing a deformable, but substantially incompressible medium, much higher internal pressures in the workpiece to be deformed can be generated than previously.
  • no hydraulic pump longer necessary but it is now this used the previously used to hold the tool press.
  • a seal can be achieved by the press fit between the punch and the workpiece.
  • the plunger In the hydroforming process, care must be taken to ensure that the forming pressure builds up exclusively in the interior of the workpiece to be deformed, since an external pressure counteracts the deformation direction.
  • the plunger In order to build up the pressure exclusively in the interior, the plunger has an outer diameter which is oversized relative to the inner diameter of the hollow part of the workpiece into which the plunger is pressed. Leave it Depending on the component to be molded, it may be possible to produce desired wall thicknesses in addition to the sealing effect.
  • Another exemplary embodiment of the device according to the invention comprises a sealing system which surrounds the stamp on the circumferential side, so that no medium can escape laterally of the movable punch.
  • the sealing system for example, a sleeve in which the punch is axially retractable, and at least one seal between the sleeve and stamp includes.
  • the sleeve is positively on the workpiece and thus seals the medium from the die.
  • a sealing ring arranged, so that the medium is sealed from the environment.
  • the sleeve may be provided on the front side with at least one annular tooth or the like, which engages in the workpiece and ensures a better seal.
  • Another exemplary embodiment of the present invention provides that a plurality of cavities are provided in the tool, in each of which at least one punch is retractable. This can be formed with a tool in a press several workpieces simultaneously. For larger workpieces it may u.U. also be expedient to provide several punches on a cavity at different locations.
  • Fig. 1 the basic structure of an exemplary embodiment of a device 1 is shown.
  • the die 4 which is mounted on a subfloor 11 or pressed against the subfloor 11, has inside a cavity 14 with a negative mold 5 (here a depression or indentation) to which the workpiece 2 snuggles under pressure.
  • the forming device comprises a punch 3, which can be moved into the workpiece 2 with a press fit in order to exert a forming pressure P on a medium 7 which is located in the workpiece 2.
  • a negative mold 5 here a depression or indentation
  • the die 4 can be made of one piece, since the workpiece 2 in the present case, for example, has no complicated undercuts and thus can be seen easily from the die 4 after deformation. For this purpose, only the bottom 11 must be removed or the die 4 are lifted from the bottom 11. Then the deformed workpiece 2, which now also protrudes into the recess 5, can be removed downwards out of the die 4.
  • the workpiece 2 to be deformed is already inserted (for example, form-fitting) in the die 4.
  • the medium 7 is introduced into the workpiece 2 via a feed device 15 so that at least the points of the workpiece 2 to be deformed (in this case the workpiece section opposite the ornament 5 in the die 4) are covered.
  • the underbody 11 will serve as a base or counter-position for the workpiece 2.
  • the punch 3 By pressing the punch 3, the workpiece 2 is pressed into the recess 5 with the aid of the medium 7 and assumes the corresponding predetermined shape or shape.
  • the Fig. 2 shows an embodiment of the device of Fig. 1 with which even complex geometries such as undercuts can be formed.
  • One Workpiece 2 is inserted into a die 4 and held by an ejector 10 at a defined height. Since the final shape to be achieved has an undercut, the die 4 is formed in two parts (see Fig. 3 ) to allow the removal of the workpiece 2 after the forming process.
  • a reinforcing ring 6 used as a fastening means which surrounds the die 4 in a form-fitting manner.
  • the reinforcing ring 6 and the die 4 is conically oversized to produce by means of a press connection tangential compressive stress and thus to ensure the cohesion of the die 4.
  • a medium 7 is then filled until at least about the location to be deformed, for example, with a feeder 15 and exerted by the in the workpiece 2 with press fit retractable punch 3 forming pressure P.
  • P press fit retractable punch 3
  • the workpiece 2 deformed until the negative mold 5 'is reached.
  • the reinforcing ring 6 is removed from the die 4, so that the die 4 can be opened and the workpiece 2 can be removed.
  • Fig. 3 and 4 illustrate the possible embodiments of the die 4 and the reinforcing ring 6. It can also be seen that the matrix 4 can have any number of divisions in cross-section in complex geometric shapes of the workpiece 2.
  • the sealing system 8 comprises a sleeve 12 which is inserted in a form-fitting manner into the die 4 and, in the exemplary embodiment of the method according to the present invention shown, rests on the end face of the workpiece 2 facing the front side.
  • On the inner wall of the sleeve sits at least one O-ring 13 1 for sealing the punch 3.
  • On the die 4 facing the end face of the sleeve 12 is at least one sealing ring 13 2 is arranged, which seals the die 4 against the atmosphere.
  • the punch 3 in the inner bore or inner hole of the sleeve 12th slidably mounted.
  • the punch 3 is fitted in the inner bore or the inner hole of the sleeve 12 with a press fit.
  • the underbody 11 and the die are connected to each other here, for example by screws (not shown).
  • FIG. 6 another embodiment of a sealing system 8 is shown comprising a sleeve 12 with a ring point and a seal 13, which seals the sleeve 12 and the punch 3. Since the punch 3 can be moved into the workpiece 2 with a press fit, the sleeve 12 has the ring point (see detail B), which provides a seal between the sleeve 12 and the workpiece 2, and the further seal 13 2 forms the sleeve 12 with respect to the die 4 seals, the pressure build-up only in the interior of the workpiece 2, which is filled with the medium 7, ensured.
  • the Fig. 7 shows another possible embodiment of the forming device 1 with a conical reinforcing ring 6, which encloses a multi-part conical die 4 and a punch 3, which is controlled by a mechanical device 9 (for example, a press).
  • the die 4 which has the negative mold 5 inside, encloses the undeformed workpiece 2, which is filled by means of a feed device 15 with a medium 7 at least to over the surfaces to be deformed.
  • the mechanical device 9 controls the punch 3 in such a way that pressure is exerted on the medium 7.
  • the stamp 3 is retracted with a press fit into the workpiece 2, whereby the forming pressure P increases and thereby the workpiece 2 conforms to the negative mold 5.
  • the sealing system 8 prevents on the one hand the escape of the medium 7 and on the other hand, that the pressure builds up only in the interior of the workpiece 2.
  • FIG. 8 An exemplary sequence of the hydroforming process according to the invention shows the Fig. 8 , Initially, the female mold 4 formed with the female mold 5, which in the case of undercuts may consist of several parts, is provided with the reinforcing ring 6, which reinforces and / or holds the female mold together.
  • the reinforcing ring 6, which is conically formed on the inner peripheral side is plugged onto the one or multi-part die 4, which is conically shaped on the outer peripheral side.
  • the workpiece 2 to be deformed is inserted and filled in the next step with a medium 7 until at least the parts of the workpiece to be deformed are covered.
  • the punch 3 is displaced by the mechanical device 9 in the direction of the cavity 14 of the workpiece 2 and thereby a forming pressure P is built up via the medium 7 in the workpiece interior.
  • the sealing system 8 can be used to ensure that the pressure build-up takes place exclusively in the interior of the workpiece 2.
  • the punch 3, which is controlled by the mechanical device 9, exerts pressure on the medium 7 until the workpiece 2 has completely nestled against the negative mold 5.
  • the forming pressure P can be kept constant or variable.
  • the reinforcing ring 6 is removed, the die 4 is opened and the deformed workpiece 2 is removed.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Description

TECHNISCHES GEBIETTECHNICAL AREA

Die vorliegende Erfindung betrifft ein Verfahren zum Verformen von Werkstücken gemäß dem Oberbegriff des Anspruchs 1, mit dem allgemein Hohlkörper wie beispielsweise Rohre durch Aufbringen eines Innendruckes aufgeweitet bzw. in eine gewünschte Kontur verformt werden können. Mittels eines solchen Verfahrens können Werkstücke, die beispielsweise eine komplexe geometrische Form haben, vergestellt werden.The present invention relates to a method for deforming workpieces according to the preamble of claim 1, with the general hollow body such as pipes can be expanded by applying an internal pressure or deformed into a desired contour. By means of such a method, workpieces which have, for example, a complex geometric shape can be adjusted.

HINTERGRUND DER ERFINDUNGBACKGROUND OF THE INVENTION

Zur Herstellung von Werkstücken mit komplexeren Konturen wie beispielsweise Hohlkörper mit Ausbuchtungen oder Hinterschneidungen ist seit längeren das sogenannte Innenhochdruck-Umformverfahren bekannt. Dabei wird das zu verformende Werkstück in eine Werkzeugform eingelegt, die die Kontur des herzustellenden Werkstücks als Gravur bzw. Negativform enthält. Daraufhin wird das Werkzeug durch eine hydraulische Presse geschlossen und zugehalten. Dichtstempel, die an hydraulischen Axialzylindern angebracht sind, verschließen die Vorrohrenden. Durch einen der Dichtstempel hindurch wird Wasser in ein Vorrohr gefüllt und über eine Druckpumpe ein Innendruck in dem Vorrohr aufgebaut. Durch Erhöhen des Druckes über die Druckpumpe wird das Vorrohr aufgeweitet. Gleichzeitig schieben die Dichtstempel die Rohrenden nach, wodurch Werkstoff in die Umformzone fließt. Eine gezielte Regelung des Innendruckes und der Dichtstempelbewegung bewirkt, dass sich der Werkstoff an die Werkzeugkontur anlegt und damit das Fertigteil seine entgültige Form erhält. Dieses Innenhochdruck-Umformverfahren ist beispielsweise in der DE 195 30 055 A1 , EP 0 906 800A1 , DE 100 56 610 A1 und der DE 102 11 087 A1 beschrieben.For the production of workpieces with more complex contours such as hollow body with bulges or undercuts the so-called hydroforming process has long been known. In this case, the workpiece to be deformed is inserted into a tool mold which contains the contour of the workpiece to be produced as an engraving or negative mold. Then the tool is closed and locked by a hydraulic press. Sealing punches, which are attached to hydraulic axial cylinders, close the front ends of the pipes. Through one of the seal through water is filled into a front pipe and built by a pressure pump, an internal pressure in the front pipe. By increasing the pressure via the pressure pump, the pre-pipe is widened. At the same time, the sealing dies push the pipe ends, causing material to flow into the forming zone. A targeted control of the internal pressure and the sealing punch movement causes the material to be applied to the tool contour and thus the finished part its final Form receives. This hydroforming process is for example in the DE 195 30 055 A1 . EP 0 906 800 A1 . DE 100 56 610 A1 and the DE 102 11 087 A1 described.

Bei diesen üblichen Innenhochdruck-Umformverfahren wird der Umformdruck über hydraulische Pumpen erzeugt werden. Diese hydraulische Pumpen erreichen jedoch lediglich Umformdrücke bis zu einem begrenzten Wert. Durch den begrenzten Umformdruck können mit diesem Verfahren viele geometrische Formen und Wandstärken bisher nicht oder nur sehr zeitaufwendig erzeugt werden. Werkstücke mit größeren Wandstärken, die möglicherweise zudem aus einem verformungsfesteren Material bestehen, lassen sich mit diesen bekannten Verfahren, wenn überhaupt, nur bedingt herstellen. Aufgrund der begrenzten Drücke können mit diesen bekannten Verfahrensweisen zudem auch nur relativ geringe Umformungen in Werkstücken erreicht werden.In these conventional hydroforming process, the forming pressure will be generated by hydraulic pumps. However, these hydraulic pumps only reach forming pressures up to a limited value. Due to the limited forming pressure many geometrical shapes and wall thicknesses can not be produced with this method or only very time consuming. Workpieces with larger wall thicknesses, which may also consist of a more deformation-resistant material, can be produced with these known methods, if at all, only conditionally. Due to the limited pressures also only relatively small deformations can be achieved in workpieces with these known procedures.

Ferner sind die bisherigen Vorrichtungen für das Innenhochdruck-Umformverfahren sehr aufwändig und komplex ausgebildet, um die nötige Dichtigkeit in dem Werkstück zu gewährleisten. Dadurch ist zum einen die Anlagentechnik kostenintensiv, zum anderen entstehen lange Taktzeiten durch den aufwändigen Wechsel der Werkstücke.Furthermore, the previous devices for the hydroforming process are very complex and complex to ensure the necessary tightness in the workpiece. As a result, on the one hand, the system technology is expensive, on the other hand, long cycle times result from the complex change of workpieces.

Die US 2,770,874 offenbart ein Umformverfahren, bei dem zwei zueinander bewegliche Stempel hydraulisch oder auf andere Weise gegen ein im Werkstück befindliches plastisches Medium gedrückt werden. Als Medium kommt hier allerdings ein sehr spezielles zum Einsatz, nämlich geschmolzenes Aluminium. Dadurch, dass das geschmolzene Aluminium am Randbereich wieder erstarrt, soll eine Abdichtung gegenüber dem Stempel und dem Werkzeug erzielt werden. Aufgrund der Tatsache, dass dieses hieraus bekannte Umformverfahren nur mit geschmolzenem Aluminium, das zur Dichtung erstarrt, funktioniert, ist es mit einem Umformverfahren, bei dem als Medium zur Erzeugung eines Umformdruckes Wasser, Öl, Kunststoff oder eine Mischung hiervon verwendet wird, nicht vergleichbar.The US 2,770,874 discloses a forming process in which two mutually movable punches are hydraulically or otherwise pressed against a plastic medium in the workpiece. As a medium here, however, a very special is used, namely molten aluminum. The fact that the molten aluminum solidifies again at the edge region, a seal against the punch and the tool is to be achieved. Due to the fact that this forming process known from it works only with molten aluminum which solidifies for sealing, it is not comparable with a forming process in which water, oil, plastic or a mixture thereof is used as the medium for producing a forming pressure.

In der US 5,445, 001 ist ein Umformverfahren offenbart, bei dem ein Rohr durch Erhöhen des Innendrucks in einer Matrize verformt wird. Die Art, wie der Druck erzeugt wird, ist allerdings nicht näher erläutert. Es wird nur allgemein auf übliche Verfahren verwiesen, so dass offensichtlich ist, dass diese Druckschrift lediglich den zuvor erläuterten Stand der Technik widerspiegelt.In the US 5,445,001 For example, there is disclosed a forming method in which a tube is deformed by increasing the internal pressure in a die. However, the way in which the pressure is generated is not explained in detail. It is only generally referred to common methods, so that it is obvious that this document reflects only the prior art explained above.

Die EP 0 760 264 A1 zeigt eine Vorrichtung zur hydraulischen Umformung von rohrförmigen Bauteilen, jedoch ist hierin eine äußerst spezielle Ausgestaltung mit einem Abdichtdorn und einem Stempel beschrieben, die allerdings nicht zur unmittelbaren Aufbringung einer Druckkraft direkt auf das Medium geeignet ist. Wie aus der einzigen Figur und der zugehörigen Beschreibung entnommen werden kann, ist hier der Abdichtdorn so angeordnet, dass er an ein Ende des zu verformenden Rohrsstücks einmündet und dort an einer konischen Fläche eine Abdichtung leitet. Der Abdichtdorn ist allerdings hohl ausgebildet und über einen Kanal mit einem Stempel gekoppelt, der durch Verschieben mittels Pressendruck in dem Abdichtdorn und damit im Werkstück einen Druck aufbaut. Dadurch ist der Aufbau des Werkzeugs und der Umformvorrichtung relativ kompliziert und teuer zu fertigen.The EP 0 760 264 A1 shows a device for the hydraulic deformation of tubular components, however, a very special design with a sealing mandrel and a stamp is described herein, which, however, is not suitable for directly applying a compressive force directly to the medium. As can be seen from the single figure and the associated description, here the sealing mandrel is arranged so that it opens at one end of the pipe section to be deformed and conducts there a seal on a conical surface. However, the sealing mandrel is hollow and coupled via a channel with a stamp that builds up by moving by pressing pressure in the sealing mandrel and thus in the workpiece pressure. As a result, the structure of the tool and the forming device is relatively complicated and expensive to manufacture.

Die JP-A-0 712 42 69 zeigt eine Umformvorrichtung, die aus mehreren Matrizenteilen besteht. In diesen Matrizenteilen ist ein Hohlraum ausgebildet, der die gewünschte Außenkontur des zu verformenden Werkstücks aufweist. Das hohle Werkstück, das zu verformen ist, wird mit Öl, Gummi oder dergleichen gefüllt. Ein Stempel wird durch eine Öffnung in dem hohlen Werkstück eingerührt und übt einen Druck auf das darin befindliche Öl, Gummi oder dergleichen aus, so dass die gewünschte Formgebung in der Matrize erfolgt. Der Stempel übt unmittelbar Druck auf das in dem zu verformenden Hohlkörper befindliche Medium wie Öl, Gummi oder dergleichen aus. Die Abdichtung zwischen Stempel und Werkstück ist weder ersichtlich noch erläutert.The JP-A-0 712 42 69 shows a forming device consisting of several die parts. In these die parts, a cavity is formed, which has the desired outer contour of the workpiece to be deformed. The hollow workpiece to be deformed is filled with oil, rubber or the like. A plunger is inserted through an opening in the hollow workpiece and exerts pressure on the oil, rubber or the like contained therein so that the desired shaping takes place in the die. The stamp exerts immediate pressure on the medium in the hollow body to be deformed, such as oil, rubber or the like. The seal between the punch and the workpiece is neither obvious nor explained.

Bei dem in der EP-A-0 740 969 offenbarten Verfahren wird das Innere eines umzuformenden Hohlkörpers hydraulischem Druck ausgesetzt. Während des Expandierens wird auch an seiner Außenseite ein hydraulischer Druck ausgeübt, wobei der Druck im Inneren des Hohlkörpers größer ist als der Druck an seiner Außenseite. Der äußere Druck beträgt mindestens 500 bar. Überdies ist ein beweglicher Stempel bzw. Kolben in einem extra Halteteil geführt. Nur das Halteteil kommt überhaupt mit dem zu verformenden Werkstück in Kontakt.In the in the EP-A-0 740 969 According to the disclosed method, the interior of a hollow body to be formed is subjected to hydraulic pressure. During the expansion, a hydraulic pressure is also exerted on its outer side, wherein the pressure in the interior of the hollow body is greater than the pressure on its outer side. The external pressure is at least 500 bar. Moreover, a movable punch or piston is guided in an extra holding part. Only the holding part comes at all with the workpiece to be deformed in contact.

Die JP-A-56 080 329 zeigt eine gänzlich andere Verfahrensweise zum Umformen eines Werkstücks. Hier wird eine Nadel mittels Schlag von oben in eine Flüssigkeit eingetaucht. Erst mit dem Nachuntenschlagen der Nadel wird über separate Einrichtungen eine Abdichtung am oberen Ende des zu verformenden Werkstücks erzielt. Die Nadel selbst wird in einer speziellen Halterung geführt.The JP-A-56 080 329 shows a completely different procedure for forming a workpiece. Here, a needle is immersed by impact from above into a liquid. Only with the sliver down the needle is a seal at the upper end of the workpiece to be deformed achieved by separate means. The needle itself is guided in a special holder.

DARSTELLUNG DER ERFINDUNGPRESENTATION OF THE INVENTION

Das der vorliegenden Erfindung zugrunde liegende technische Problem besteht darin, eine Verfahrensweise bereitzustellen, die eine bessere Umformung von Werkstücken ermöglichen.The technical problem underlying the present invention is to provide a procedure that allows a better forming of workpieces.

Dieses technische Problem wird durch ein Verfahren zum Umformen eines Werkstücks mittels eines Mediums, das einen Innendruck auf ein in einem Werkzeug eingelegtes Werkstück ausübt und dieses aufweitet bzw. verformt, mit den Merkmalen des Anspruchs 1, gelöst. In einem ersten Schritt wird das Werkstück in eine Matrize (Werkzeug mit Hohlraum) eingelegt, die im Inneren bereits die gewünschte Werkstückkontur als Negativform aufweist. Daraufhin wird das Medium, hier Wasser, Öl, Kunststoff oder eine Mischung hiervon, in das Werkstück, beispielsweise über eine Zuführeinrichtung eingebracht werden. Grundsätzlich kann das Werkstück bzw. der von diesem Werkstück gebildete Hohlraum im Wesentlichen mit dem genannten Medium gefüllt werden. Es kann aber auch ausreichen, dass zumindest der oder die zu verformenden Abschnitte des Werkstücks von dem Medium bedeckt sind. Anzumerken ist zudem, dass alternativ auch erst das Medium in die Matrize eingefügt bzw. gefüllt wird und anschließend das Werkstück eingelegt wird. Schließlich wird der Stempel verfahren und gegen das Medium gedrückt, so dass dieses das Werkstück entsprechend der Negativform der Matrize verformt. Der Stempel wird dabei zur Erzielung einer Dichtung zum Werkstück mit einer Presspassung in das Werkstück eingefahren.This technical problem is solved by a method for forming a workpiece by means of a medium, which exerts an internal pressure on a workpiece inserted in a tool and this expands or deformed, with the features of claim 1, solved. In a first step, the workpiece is placed in a die (cavity tool), which already has the desired workpiece contour in the interior as a negative mold. thereupon the medium, here water, oil, plastic or a mixture thereof, be introduced into the workpiece, for example via a feed device. In principle, the workpiece or the cavity formed by this workpiece can be substantially filled with said medium. But it may also be sufficient that at least one or the portions of the workpiece to be deformed are covered by the medium. It should also be noted that, alternatively, the medium is first inserted or filled in the matrix and then the workpiece is inserted. Finally, the punch is moved and pressed against the medium, so that this deformed the workpiece according to the negative mold of the die. The punch is retracted to achieve a seal to the workpiece with a press fit into the workpiece.

Der Grundgedanke hierbei ist, dass das zu verformende Werkstück und der Stempel einen abgeschlossenen Hohlraum definieren, der nun durch das Medium ausgefüllt wird. Durch Verdrängen des Mediums wird in dem abgeschlossenen Hohlraum ein Innendruck aufgebaut, der zu einem Verformen des Werkstücks in den durch die Negativform vorgegebenen Ausweichraum führt. Der Druck ist also dabei durch die Kraft, mit der der Stempel eingedrückt wird und dessen Stirnfläche, die dem Medium zugewandt ist, bestimmt. Dadurch lässt sich - wie oben erwähnt - ein höherer Innendruck als bisher erzielen, was neue Einsatzbereiche ermöglichen kann, und zudem ist keine Pumpe zum Erzeugen des Innendruckes notwendig. Es sei hier nochmals herausgestellt, dass der bewegliche Stempel den Umformdruck auf das Medium bewirkt und nicht eine Pumpe wie beim bekannten Verfahren. Da der Druck über eine mechanische Pressvorrichtung erzeugt wird, können hierbei Umformdrücke von bis zu 25.000 bar (oder u. U. sogar mehr) erreicht werden.The basic idea here is that the workpiece to be deformed and the punch define a closed cavity, which is now filled by the medium. By displacing the medium, an internal pressure is built up in the closed cavity, which leads to a deformation of the workpiece in the predetermined by the negative mold escape space. The pressure is thus determined by the force with which the punch is pressed and its end face, which faces the medium determined. This allows - as mentioned above - achieve a higher internal pressure than before, which can allow new applications, and also no pump for generating the internal pressure is necessary. It should be emphasized again here that the movable punch causes the forming pressure on the medium and not a pump as in the known method. Since the pressure is generated by a mechanical pressing device, forming pressures of up to 25,000 bar (or possibly even more) can be achieved.

Das Medium, auf das der Stempel den Umformdruck ausübt, kann einen festen, halbfesten oder flüssigen Aggregatzustand aufweisen. Für flüssige Stoffe eignen sich Wasser oder Öle, jedoch besteht auch die Möglichkeit, feste Stoffe wie z.B. Kunststoffe einzusetzen. Letztere eigenen sich besonders aufgrund der niedrigen Viskosität gegenüber flüssigen Medien, da somit die Dichtheit der Vorrichtung einfacher gewährleistet werden kann. Grundsätzlich ist aber festzuhalten, dass für das erfindungsgemäße Verfahren alle Medien verwendbar sind, die auch bei den bisherigen bekannten Innenhochdruck-Verfahren eingesetzt wurden.The medium to which the stamp exerts the forming pressure can have a solid, semi-solid or liquid state of aggregation. For liquids, water or oils are suitable, but it is also possible to use solid materials such as plastics. The latter are particularly suitable due to the low viscosity compared to liquid media, since thus the tightness of the device can be ensured easier. Basically, however, it should be noted that all media can be used for the process according to the invention, which were also used in the previous known hydroforming process.

Eine weitere beispielhafte Ausführungsform des Verfahrens sieht den Einsatz eines zusätzlichen Dichtungssystems vor, das beispielsweise am Stempel oder an der Matrize angebracht ist.Another exemplary embodiment of the method provides for the use of an additional sealing system, which is attached, for example, to the punch or to the die.

Um die Befüllungsdauer des Werkstücks mit dem Medium zu verkürzen, kann in einer weiteren beispielhaften Ausführungsform der Erfindung die Matrize bzw. das Werkzeug in ein Medium eingetaucht werden. Über den in das Werkstück mit Presspassung einfahrbaren Stempel und optional dem separaten Dichtungssystem kann dennoch gewährleistet werden, dass der Druckaufbau ausschließlich im Inneren des Werkstücks erfolgt, um es somit zu verformen.In order to shorten the filling time of the workpiece with the medium, in another exemplary embodiment of the invention, the die or the tool can be immersed in a medium. However, it is still possible to ensure that the pressure build-up takes place exclusively in the interior of the workpiece via the punch, which can be introduced into the workpiece with press-fitting, and optionally the separate sealing system, in order to thus deform it.

Eine weitere beispielhafte Ausführungsform des Verfahrens sieht vor, dass das dargestellte Verfahren mittels Kaltumformung ausgeführt wird. Alternativ hierzu ist aber auch eine Warmumformung denkbar und durchführbar. Besonders bei spröden Materialien kann es von Vorteil sein, das Werkstück, die Matrize und/ oder das Medium zu erhitzen, um somit die Umformqualität zu erhöhen. Hierfür kann an der eingangs genannten, erfindungsgemäßen Vorrichtung zumindest eine Heizeinrichtung zum Erwärmen des Werkstücks, der Matrize und/ oder des Mediums vorhanden sein.A further exemplary embodiment of the method provides that the illustrated method is carried out by means of cold forming. Alternatively, however, a hot forming is conceivable and feasible. Especially with brittle materials, it may be advantageous to heat the workpiece, the die and / or the medium, thus increasing the forming quality. For this purpose, at least one heating device for heating the workpiece, the die and / or the medium may be present on the device according to the invention mentioned above.

Eine weitere beispielhafte Ausführungsform des Verfahrens sieht vor, das der Umformdruck nicht konstant, sondern ansteigend auf das Medium ausgeübt wird. Dadurch können Materialfehler, die während eines plötzlichen Ausüben von hohem Druck entstehen können, vermieden werden. Beispielsweise kann der Anstieg des Umformdrucks stetig oder in stufen erhöht werden.Another exemplary embodiment of the method provides that the forming pressure is not constant, but exerted on the medium. This may cause material defects that may arise during a sudden application of high pressure, be avoided. For example, the increase in the forming pressure can be increased steadily or in stages.

Mit dem erfindungsgemäßen Innenhochdruck-Umformverfahren können verschieden ausgeprägte Werkstücke verformt werden. Neben Hohlstücken sind beispielsweise auch Halbrohrschnitte, Bleche oder U-Profile verformbar, die entlang ihrer Längsachse auch in verschiedene Richtungen gebogen oder verformt sein können.With the hydroforming process according to the invention differently shaped workpieces can be deformed. In addition to hollow pieces, for example, half-pipe sections, sheets or U-profiles are deformable, which can be bent or deformed along its longitudinal axis in different directions.

Zusammengefasst wird erfindungsgemäß ein zu verformendes Werkstück in eine Matrize eingelegt. Anschließend wird das Werkstück mit einem Medium befüllt, auf das ein verschiebbarer Stempel durch Verdrängen des Mediums einen Umformdruck ausübt. Dadurch schmiegt sich das Werkstück an die Negativform und erhält die gewünschte Form. Der Stempel wird dabei beispielsweise von einer Presse angetrieben.In summary, according to the invention, a workpiece to be deformed is placed in a die. Subsequently, the workpiece is filled with a medium on which a displaceable punch exerts a forming pressure by displacing the medium. As a result, the workpiece clings to the negative mold and receives the desired shape. The stamp is driven for example by a press.

Der vorliegenden Erfindung liegt der Gedanke zugrunde, anstatt wie bei dem eingangs genannten bekannten Verfahren den Umformdruck über eine Pumpe zu erzeugen, erstmals einen hohen Innendruck durch Verdrängen des speziellen, zuvor genannten Mediums auszuüben. Beispielsweise kann mittels einer hydraulischen Presse und einen hierdurch zu verschiebenden Stempel auf ein vorgegebenes Mediumvolumen ein sehr großer Druck ausgeübt werden. Damit lassen sich deutlich höhere Umformdrücke erreichen als bisher. Durch das Erzeugen des Umformdrucks durch Verschieben des beweglichen Stempels, also allgemein durch Verdrängen eines verformbaren, aber im wesentlichen inkompressiblen Mediums, sind weitaus höhere Innendrücke in dem zu verformenden Werkstück erzeugbar als bisher. Zudem ist erstmals für die Durchführung des Innenhochdruck-Umformverfahrens keine hydraulische Pumpe mehr notwendig, sondern es wird nunmehr hierfür die bisher zum Zuhalten des Werkzeugs verwendete Presse eingesetzt. Auβerdem ist durch die Presspassung zwischen Stempel und Werkstück eine Dichtung zu erzielen.The present invention is based on the idea, instead of generating the forming pressure via a pump as in the case of the known method mentioned at the outset, for the first time to exert a high internal pressure by displacing the special, aforementioned medium. For example, by means of a hydraulic press and a punch to be displaced thereby to a predetermined volume of medium, a very large pressure can be exerted. This allows significantly higher forming pressures than before. By generating the forming pressure by moving the movable punch, ie generally by displacing a deformable, but substantially incompressible medium, much higher internal pressures in the workpiece to be deformed can be generated than previously. In addition, for the first time for carrying out the hydroforming process no hydraulic pump longer necessary, but it is now this used the previously used to hold the tool press. In addition, a seal can be achieved by the press fit between the punch and the workpiece.

Bei dem Innenhochdruck-Umformverfahren ist darauf zu achten, dass der Umformdruck sich ausschließlich im Inneren des zu verformenden Werkstücks aufbaut, da ein äußerer Druck der Umformrichtung entgegenwirkt. Der Stempel hat hierzu, um den Druck ausschließlich im Inneren aufzubauen, einem gegenüber dem Innendurchmesser des Hohlteils des Werkstücks, in den der Stempel eingedrückt wird, ein Übermaß aufweisenden Außendurchmesser. Damit lassen sich - je nach zu formendem Bauteil - möglicherweise zusätzlich zu dem Dichtungseffekt gewünschte Wanddicken herstellen.In the hydroforming process, care must be taken to ensure that the forming pressure builds up exclusively in the interior of the workpiece to be deformed, since an external pressure counteracts the deformation direction. For this purpose, in order to build up the pressure exclusively in the interior, the plunger has an outer diameter which is oversized relative to the inner diameter of the hollow part of the workpiece into which the plunger is pressed. Leave it Depending on the component to be molded, it may be possible to produce desired wall thicknesses in addition to the sealing effect.

Eine weitere beispielhafte Ausführungsform der erfindungsgemäßen Vorrichtung umfasst ein Dichtungssystem, das den Stempel umfangseitig umgibt, damit kein Medium seitlich des beweglichen Stempels austreten kann.Another exemplary embodiment of the device according to the invention comprises a sealing system which surrounds the stamp on the circumferential side, so that no medium can escape laterally of the movable punch.

Eine weitere beispielhafte Ausführungsform der erfindungsgemäßen Vorrichtung sieht vor, dass das Dichtungssystem beispielweise eine Hülse, in die der Stempel axial einfahrbar ist, und zumindest eine Dichtung zwischen Hülse und Stempel umfasst. Die Hülse liegt formschlüssig an dem Werkstück auf und dichtet somit das Medium gegenüber der Matrize ab. In der Hülse, in der sich der Stempel bewegen kann, kann außerdem ein Dichtring angeordnet, so dass das Medium gegenüber der Umgebung abgedichtet wird. Beispielsweise kann die Hülse stirnseitig noch mit zumindest einer Ringzacke oder dergleichen ausgestattet sein, die in das Werkstück eingreift und für eine bessere Abdichtung sorgt.Another exemplary embodiment of the device according to the invention provides that the sealing system, for example, a sleeve in which the punch is axially retractable, and at least one seal between the sleeve and stamp includes. The sleeve is positively on the workpiece and thus seals the medium from the die. In the sleeve, in which the punch can move, also a sealing ring arranged, so that the medium is sealed from the environment. For example, the sleeve may be provided on the front side with at least one annular tooth or the like, which engages in the workpiece and ensures a better seal.

Eine weitere beispielhafte Ausführungsform der vorliegenden Erfindung sieht vor, dass in dem Werkzeug mehrere Hohlräume vorgesehen sind, in die jeweils zumindest ein Stempel einfahrbar ist. Damit können mit einem Werkzeug in einer Presse gleichzeitig mehrere Werkstücke geformt werden. Bei größeren Werkstücken kann es u.U. auch zweckmäßig sein, an einem Hohlraum an verschiedenen Stellen mehrere Stempel vorzusehen.Another exemplary embodiment of the present invention provides that a plurality of cavities are provided in the tool, in each of which at least one punch is retractable. This can be formed with a tool in a press several workpieces simultaneously. For larger workpieces it may u.U. also be expedient to provide several punches on a cavity at different locations.

Je nach Produktionsbedingungen kann es auch vorteilhaft sein, mehrere Werkzeuge der zuvor erläuterten Art in einer Presse gleichzeitig einzusetzen, um mehrere Werkstücke zu verformen.Depending on the production conditions, it may also be advantageous to simultaneously use several tools of the type explained above in one press in order to deform a plurality of workpieces.

KURZE BESCHREIBUNG DER ZEICHNUNGENBRIEF DESCRIPTION OF THE DRAWINGS

Im Folgenden sind zum besseren Verständnis und zur weiteren Erläuterung mehrere Ausführungsbeispiele der vorliegenden Erfindung unter Bezugnahme auf die beigefügten Zeichnungen näher beschrieben. Es zeigen:

Fig. 1
den Grundaufbau einer beispielhaften Ausführungsform einer Vorrichtung zur Durchführung des erfindungsgemäßen Verfahrens,
Fig. 2
eine beispielhafte Ausführungsform einer erfindungsgemäßen Vorrichtung in zwei verschiedenen Verfahrenzuständen,
Fig. 3
eine zweiteilige, konische Matrize mit einer Negativform für die Vorrichtung gemäß der Fig. 2,
Fig. 4
einen Armierungsring und die in Fig. 3 gezeigte Matrize,
Fig. 5
eine weitere beispielhafte Ausführungsform einer Vorrichtung zum Durchführen des Verfahrens der Erfindung mit einem Dichtungssystem,
Fig. 6
ein vergrößerte Darstellung des in Fig. 5 gezeigten Dichtungssystems,
Fig. 7
eine weitere beispielhafte Ausführungsform einer Vorrichtung zum Durchführen des Verfahrens der Erfindung, die mit einer Pressvorrichtung betrieben und gesteuert wird, und
Fig. 8
den prinzipiellen Ablauf des erfindungsgemäßen Umformverfahrens.
In the following, for better understanding and further explanation, several embodiments of the present invention will be described in detail with reference to the accompanying drawings. Show it:
Fig. 1
the basic structure of an exemplary embodiment of an apparatus for carrying out the method according to the invention,
Fig. 2
an exemplary embodiment of a device according to the invention in two different process states,
Fig. 3
a two-part, conical die with a negative mold for the device according to the Fig. 2 .
Fig. 4
a reinforcing ring and the in Fig. 3 shown template,
Fig. 5
another exemplary embodiment of an apparatus for carrying out the method of the invention with a sealing system,
Fig. 6
an enlarged view of the in Fig. 5 shown sealing system,
Fig. 7
another exemplary embodiment of an apparatus for carrying out the method of the invention, which is operated and controlled by a pressing device, and
Fig. 8
the basic sequence of the forming process according to the invention.

In allen Figuren hinweg sind gleiche Teile mit übereinstimmenden Bezugszeichen gekennzeichnet.Throughout the figures, like parts are identified by corresponding reference numerals.

BESCHREIBUNG VON BEISPIELHAFTEN AUSFÜHRUNGSFORMEN DER ERFINDUNGDESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

In der Fig. 1 ist der grundsätzliche Aufbau einer beispielhaften Ausführungsform einer Vorrichtung 1 gezeigt. Mit dieser Vorrichtung sind beispielsweise Umformungen an Werkstücken in einfache geometrische Formen ohne Hinterschneidungen möglich. Die Matrize 4, die auf einem Unterboden 11 befestigt ist oder gegen den Unterboden 11 gepresst wird, besitzt im Inneren einen Hohlraum 14 mit einer Negativform 5 (hier eine Vertiefung oder Einbuchtung), an die sich das Werkstück 2 unter Druck anschmiegt. Weiterhin umfasst die Umformvorrichtung einen Stempel 3, der mit Presspassung in das Werkstück 2 einfahrbar ist, um einen Umformdruck P auf ein Medium 7 auszuüben, das sich in dem Werkstück 2 befindet. In der Ausführungsform, wie sie in der Fig. 1 dargestellt ist, kann die Matrize 4 aus einem Stück gefertigt sein, da das Werkstück 2 im vorliegenden Fall z.B. keine komplizierten Hinterschneidungen aufweist und somit einfach aus der Matrize 4 nach der Verformung zu entnehmen ist. Hierfür muss nur der Unterboden 11 abgenommen werden bzw. die Matrize 4 vom Unterboden 11 abgehoben werden. Dann kann das verformte Werkstück 2, das nun auch in die Vertiefung 5 hineinragt, nach unten aus der Matrize 4 herausgenommen werden.In the Fig. 1 the basic structure of an exemplary embodiment of a device 1 is shown. With this device, for example, transformations of workpieces in simple geometric shapes without undercuts are possible. The die 4, which is mounted on a subfloor 11 or pressed against the subfloor 11, has inside a cavity 14 with a negative mold 5 (here a depression or indentation) to which the workpiece 2 snuggles under pressure. Furthermore, the forming device comprises a punch 3, which can be moved into the workpiece 2 with a press fit in order to exert a forming pressure P on a medium 7 which is located in the workpiece 2. In the embodiment as shown in the Fig. 1 is shown, the die 4 can be made of one piece, since the workpiece 2 in the present case, for example, has no complicated undercuts and thus can be seen easily from the die 4 after deformation. For this purpose, only the bottom 11 must be removed or the die 4 are lifted from the bottom 11. Then the deformed workpiece 2, which now also protrudes into the recess 5, can be removed downwards out of the die 4.

Bei dem in der Fig. 1 gezeigten Zustand ist das zu verformende Werkstück 2 bereits (beispielsweise formschlüssig) in die Matrize 4 eingelegt. Das Medium 7 ist über eine Zuführeinrichtung 15 in das Werkstück 2 eingebracht, so dass mindestens die zu verformenden Stellen des Werkstücks 2 (hier der Werkstückabschnitt, der der Verzierung 5 in der Matrize 4 gegenüberliegt) bedeckt sind. Dann wird der Unterboden 11 als Unterlage bzw. Gegenlage für das Werkstück 2 dienen. Durch Einpressen des Stempels 3 wird mit Hilfe des Mediums 7 das Werkstück 2 in die Vertiefung 5 gedrückt und nimmt die entsprechend vorgegebene Form bzw. Gestalt an.In the in the Fig. 1 shown state, the workpiece 2 to be deformed is already inserted (for example, form-fitting) in the die 4. The medium 7 is introduced into the workpiece 2 via a feed device 15 so that at least the points of the workpiece 2 to be deformed (in this case the workpiece section opposite the ornament 5 in the die 4) are covered. Then, the underbody 11 will serve as a base or counter-position for the workpiece 2. By pressing the punch 3, the workpiece 2 is pressed into the recess 5 with the aid of the medium 7 and assumes the corresponding predetermined shape or shape.

Die Fig. 2 zeigt eine Ausführungsform der Vorrichtung der Fig. 1, mit der auch komplexe Geometrien wie beispielsweise Hinterschneidungen geformt werden können. Ein Werkstück 2 wird in eine Matrize 4 eingefügt und durch einen Auswerfer 10 in einer definierten Höhe gehalten. Da die zu erreichende Endform eine Hinterschneidung aufweist, wird die Matrize 4 zweiteilig ausgebildet (siehe Fig. 3), um nach dem Umformvorgang die Entnahme des Werkstücks 2 zu ermöglichen. Um die Matrize 4 selbst bei hohem Umformdruck zusammenzuhalten, wird in Fig. 2 ein Armierungsring 6 als Befestigungsmittel verwendet, der formschlüssig die Matrize 4 umgibt. Um die Dichtheit der Matrize sicherzustellen, ist der Armierungsring 6 sowie die Matrize 4 konisch mit Übermaß ausgeführt, um mittels einer Pressverbindung tangentiale Druckspannung zu erzeugen und somit den Zusammenhalt der Matrize 4 zu gewähren.The Fig. 2 shows an embodiment of the device of Fig. 1 with which even complex geometries such as undercuts can be formed. One Workpiece 2 is inserted into a die 4 and held by an ejector 10 at a defined height. Since the final shape to be achieved has an undercut, the die 4 is formed in two parts (see Fig. 3 ) to allow the removal of the workpiece 2 after the forming process. In order to keep the die 4 together even at high forming pressure, in Fig. 2 a reinforcing ring 6 used as a fastening means which surrounds the die 4 in a form-fitting manner. To ensure the tightness of the die, the reinforcing ring 6 and the die 4 is conically oversized to produce by means of a press connection tangential compressive stress and thus to ensure the cohesion of the die 4.

In das Werkstück 2 wird anschließend bis mindestens über die zu verformende Stelle beispielsweise mit einer Zuführeinrichtung 15 ein Medium 7 eingefüllt und durch den in das Werkstück 2 mit Presspassung einfahrbaren Stempel 3 Umformdruck P ausgeübt. Durch diesen Umformdruck P verformt sich das Werkstück 2 so lange, bis die Negativform 5' erreicht ist. Um das verformte Werkstück 2 zu entnehmen, wird der Armierungsring 6 von der Matrize 4 entfernt, so dass die Matrize 4 geöffnet und das Werkstück 2 entnommen werden kann. Fig. 3 und 4 veranschaulichen die möglichen Ausführungsformen der Matrize 4 und des Armierungsrings 6. Daraus ist auch ersichtlich, dass die Matrize 4 bei komplexen geometrischen Formen des Werkstücks 2 im Querschnitt beliebig viele Teilungen aufweisen kann.In the workpiece 2, a medium 7 is then filled until at least about the location to be deformed, for example, with a feeder 15 and exerted by the in the workpiece 2 with press fit retractable punch 3 forming pressure P. By this forming pressure P, the workpiece 2 deformed until the negative mold 5 'is reached. To remove the deformed workpiece 2, the reinforcing ring 6 is removed from the die 4, so that the die 4 can be opened and the workpiece 2 can be removed. Fig. 3 and 4 illustrate the possible embodiments of the die 4 and the reinforcing ring 6. It can also be seen that the matrix 4 can have any number of divisions in cross-section in complex geometric shapes of the workpiece 2.

Wie bereits eingangs erwähnt, ist es bei dem Innenhochdruck-Umformverfahren erforderlich, dass der Umformdruck P ausschließlich im Inneren des zu verformenden Werkstücks 2 aufgebaut wird. Deswegen ist in Fig. 5 beispielhaft eine Umformvorrichtung 1 mit einem Dichtungssystem 8 dargestellt. Das Dichtungssystem 8 umfasst eine Hülse 12, die formschlüssig in die Matrize 4 eingesetzt ist und in der gezeigten beispielhaften Ausführungsfom des Verfahrens gemäß der vorliegenden Erfindung stirnseitig auf der zugewandten Stirnseite des Werkstücks 2 aufliegt. Auf der Innenwandung der Hülse sitzt zumindest ein O-ring 131 zur Abdichtung des Stempels 3. Auf der der Matrize 4 zugewandten Stirnseite der Hülse 12 ist zumindest ein Dichtring 132 angeordnet, der die Matrize 4 gegenüber der Atmosphäre abdichtet. Außerdem ist der Stempel 3 in der Innenbohrung bzw. Innenloch der Hülse 12 verschiebbar gelagert. Der Stempel 3 ist in die Innenbohrung bzw. das Innenloch der Hülse 12 mit einer Presspassung eingepasst. Im Übrigen sind hier der Unterboden 11 und die Matrize miteinander verbunden, beispielsweise durch Schrauben (nicht gezeigt).As already mentioned, it is necessary in the hydroforming process that the forming pressure P is built exclusively in the interior of the workpiece 2 to be deformed. That is why in Fig. 5 exemplified a forming device 1 with a sealing system 8. The sealing system 8 comprises a sleeve 12 which is inserted in a form-fitting manner into the die 4 and, in the exemplary embodiment of the method according to the present invention shown, rests on the end face of the workpiece 2 facing the front side. On the inner wall of the sleeve sits at least one O-ring 13 1 for sealing the punch 3. On the die 4 facing the end face of the sleeve 12 is at least one sealing ring 13 2 is arranged, which seals the die 4 against the atmosphere. In addition, the punch 3 in the inner bore or inner hole of the sleeve 12th slidably mounted. The punch 3 is fitted in the inner bore or the inner hole of the sleeve 12 with a press fit. Incidentally, the underbody 11 and the die are connected to each other here, for example by screws (not shown).

Bei Erhöhung des Umformdrucks durch den Stempel 3, der in der Hülse 12 gleitet, ist somit ausschließlich eine Druckerhöhung auf das sich in dem Werkstück 2 befindende Medium 7 sichergestellt, so dass das Werkstück 2 verformt (aufgeweitet) wird und an die Negativform 5 der Matrize 4 ohne Druckverlust angepresst wird.When increasing the forming pressure by the punch 3, which slides in the sleeve 12, thus only an increase in pressure on the located in the workpiece 2 medium 7 is ensured, so that the workpiece 2 is deformed (expanded) and the negative mold 5 of the die 4 is pressed without pressure loss.

In der Fig. 6 wird eine weitere Ausführungsform eines Dichtungssystems 8 gezeigt, das eine Hülse 12 mit Ringzacke und eine Dichtung 13, umfasst, die die Hülse 12 und den Stempel 3 abdichtet. Da der Stempel 3 mit Presspassung in das Werkstück 2 einfahrbar ist, die Hülse 12 die Ringzacke hat (siehe Detail B), die eine Abdichtung zwischen der Hülse 12 und dem Werkstück 2 leistet, und die weitere Dichtung 132 die Hülse 12 gegenüber der Matrize 4 abdichtet, ist der Druckaufbau ausschließlich im Inneren des Werkstücks 2, das mit dem Medium 7 gefüllt ist, sichergestellt.In the Fig. 6 another embodiment of a sealing system 8 is shown comprising a sleeve 12 with a ring point and a seal 13, which seals the sleeve 12 and the punch 3. Since the punch 3 can be moved into the workpiece 2 with a press fit, the sleeve 12 has the ring point (see detail B), which provides a seal between the sleeve 12 and the workpiece 2, and the further seal 13 2 forms the sleeve 12 with respect to the die 4 seals, the pressure build-up only in the interior of the workpiece 2, which is filled with the medium 7, ensured.

Die Fig. 7 zeigt eine weitere mögliche Ausführungsform der Umformvorrichtung 1 mit einem konischen Armierungsring 6, der eine mehrteilige konische Matrize 4 umschließt und einen Stempel 3, der durch eine mechanische Vorrichtung 9 (beispielsweise eine Presse) gesteuert wird. Die Matrize 4, die im Inneren die Negativform 5 aufweist, umschließt das unverformte Werkstück 2, das mittels einer Zuführeinrichtung 15 mit einem Medium 7 mindestens bis über die zu verformenden Flächen gefüllt wird. Die mechanische Vorrichtung 9 steuert den Stempel 3 derart, dass Druck auf das Medium 7 ausgeübt wird. Dabei wird der Stempel 3 mit Presspassung in das Werkstück 2 eingefahren, wodurch sich der Umformdruck P erhöht und sich dadurch das Werkstück 2 an die Negativform 5 anschmiegt. Das Dichtungssystem 8 verhindert dabei zum einen den Austritt des Mediums 7 und zum anderen, dass sich der Druck nur im Inneren des Werkstücks 2 aufbaut.The Fig. 7 shows another possible embodiment of the forming device 1 with a conical reinforcing ring 6, which encloses a multi-part conical die 4 and a punch 3, which is controlled by a mechanical device 9 (for example, a press). The die 4, which has the negative mold 5 inside, encloses the undeformed workpiece 2, which is filled by means of a feed device 15 with a medium 7 at least to over the surfaces to be deformed. The mechanical device 9 controls the punch 3 in such a way that pressure is exerted on the medium 7. In this case, the stamp 3 is retracted with a press fit into the workpiece 2, whereby the forming pressure P increases and thereby the workpiece 2 conforms to the negative mold 5. The sealing system 8 prevents on the one hand the escape of the medium 7 and on the other hand, that the pressure builds up only in the interior of the workpiece 2.

Einen beispielhaften Ablauf des erfindungsgemäßen Innenhochdruck-Umformverfahrens zeigt die Fig. 8. Zu Beginn wird die mit der Negativform 5 ausgebildete Matrize 4, die im Falle von Hinterschneidungen aus mehreren Teilen bestehen kann, mit dem Armierungsring 6 versehen, der die Matrize verstärkt und/oder zusammenhält. Dazu wird der auf der Innenumfangsseite konisch ausgebildete Armierungsring 6 auf die auf der Außenumfangsseite konisch geformte ein- oder mehrteilige Matrize 4 gesteckt. Anschließend wird das zu verformende Werkstück 2 eingelegt und im nächsten Schritt mit einem Medium 7 befüllt, bis mindestens die zu verformenden Stellen des Werkstücks bedeckt sind. Zu Pressbeginn wird der Stempel 3 durch die mechanische Vorrichtung 9 in Richtung des Hohlraums 14 des Werkstücks 2 verschoben und dadurch ein Umformdruck P über das Medium 7 im Werkstückinnern aufgebaut. Dabei kann das Dichtungssystem 8 eingesetzt werden, um sicherzustellen, dass der Druckaufbau ausschließlich im Inneren des Werkstücks 2 erfolgt. Während des Pressens übt der Stempel 3, der von der mechanischen Vorrichtung 9 gesteuert wird, so lange Druck auf das Medium 7 aus, bis sich das Werkstück 2 vollständig an die Negativform 5 angeschmiegt hat. Während des Umformvorgangs kann der Umformdruck P konstant oder variabel gehalten werden. Im letzten Schritt des Verfahrens wird der Armierungsring 6 entfernt, die Matrize 4 geöffnet und das verformte Werkstück 2 entnommen.An exemplary sequence of the hydroforming process according to the invention shows the Fig. 8 , Initially, the female mold 4 formed with the female mold 5, which in the case of undercuts may consist of several parts, is provided with the reinforcing ring 6, which reinforces and / or holds the female mold together. For this purpose, the reinforcing ring 6, which is conically formed on the inner peripheral side, is plugged onto the one or multi-part die 4, which is conically shaped on the outer peripheral side. Subsequently, the workpiece 2 to be deformed is inserted and filled in the next step with a medium 7 until at least the parts of the workpiece to be deformed are covered. At the beginning of the press, the punch 3 is displaced by the mechanical device 9 in the direction of the cavity 14 of the workpiece 2 and thereby a forming pressure P is built up via the medium 7 in the workpiece interior. In this case, the sealing system 8 can be used to ensure that the pressure build-up takes place exclusively in the interior of the workpiece 2. During the pressing, the punch 3, which is controlled by the mechanical device 9, exerts pressure on the medium 7 until the workpiece 2 has completely nestled against the negative mold 5. During the forming process, the forming pressure P can be kept constant or variable. In the last step of the method, the reinforcing ring 6 is removed, the die 4 is opened and the deformed workpiece 2 is removed.

Bei der in der Fig.7 gezeigten Vorrichtung kann zum Entnehmen beispielsweise die mehrteilige Matrize 4 etwas radial nach außen gezogen werden, so dass das verformte Werkstück 2 über einen Auswerfer 10 aus der Matrize ausgeworfen werden kann.When in the Figure 7 For example, to remove the multi-part die 4, it can be pulled somewhat radially outward so that the deformed workpiece 2 can be ejected out of the die via an ejector 10.

Claims (9)

  1. A method for deforming workpieces (2) with at least the following method steps:
    a) positioning the workpiece (2) into a cavity (14) of a die (4), the cavity having the negative form (5) of the desired outer shape of a deformed workpiece (2),
    b) introducing a medium (7) including water, oil, plastics, or a mixture thereof into the workpiece (2), and
    c) pressing a punch (3) against the medium (7), such that the medium deforms the workpiece (2) according to the negative form (5) of the die (4), characterized in that the punch (3) is inserted into the workpiece (2) for achieving a sealing to the workpiece (2) by press fit and thereby pressing the punch (3) against the medium (7), such that the medium deforms the workpiece (2) according to the negative form (5) of the die (4).
  2. The method according to claim 1, wherein in step c), the punch (3) is pressed and displaced by a mechanical device (9), such as a press.
  3. The method according to claim 1 or 2, wherein the medium (7) is solid, semisolid, or liquid.
  4. The method according to any one of the claims 1 to 3, wherein the medium (7) is filled into a cavity (14) of the workpiece (2) at least until the single or a plurality of workpiece portions to be deformed are covered by the medium (7).
  5. The method according to any one of claims 1 to 4, wherein in step c), the compression force on the punch (3) is varied.
  6. The method according to any one of claims 1 to 5, wherein in step a), the workpiece (2) is positioned into a negative form (5) of a one-piece or multi-part die (4) assembled by a retainer (6).
  7. The method according to claim 6, wherein an armouring assembly (6) is form-fitted placed around the die (4) to hold the one-piece or multi-part die (4) together.
  8. The method according to claim 7, wherein in step a), the die (4) and the armouring assembly (6) are conically shaped and/or with oversize, and the one-piece or multi-part die (4) is form-fitted pressed into the armouring assembly (6).
  9. Method according to any one of the claims 1 to 8, wherein in step b), the medium (7) is inserted into the workpiece (2) via a feeder system (15).
EP20050024456 2004-11-10 2005-11-09 Method for forming workpieces Not-in-force EP1657007B9 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE200410054324 DE102004054324A1 (en) 2004-11-10 2004-11-10 Method and device for deforming workpieces

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EP1657007A1 EP1657007A1 (en) 2006-05-17
EP1657007B1 EP1657007B1 (en) 2012-08-29
EP1657007B9 true EP1657007B9 (en) 2013-01-23

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Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102601206A (en) * 2012-03-02 2012-07-25 张家港合瑞车桥有限公司 Hydraulic bulging pipe end sealing device
DE102017200917A1 (en) * 2017-01-20 2018-07-26 Thyssenkrupp Ag Device and method for autofretting a workpiece

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2770874A (en) 1953-04-27 1956-11-20 Cleveland Pneumatic Tool Co Method of locally expanding tubing
JPS5680329A (en) 1979-12-04 1981-07-01 Kaoru Abe Hydraulic forging device
JPH07124269A (en) 1993-10-21 1995-05-16 Shiyoukasen Kiko Kk Manufacture of water supply port head for fire fighting
US5445001A (en) 1994-08-10 1995-08-29 General Motors Corporation Method and apparatus for forming and cutting tubing
DE19516064C2 (en) 1995-05-04 1998-01-29 Rasselstein Ag Process for producing a sheet metal container with a substantially bulbous shape
EP0760264B1 (en) * 1995-08-24 1998-06-17 Benteler Ag Hydraulic forming device for tubular parts
DE19743863A1 (en) * 1997-10-04 1999-04-15 Schaefer Hydroforming Gmbh Method and device for producing a hollow shaft with external radial elevations by hydroforming

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EP1657007B1 (en) 2012-08-29
DE102004054324A1 (en) 2006-05-24

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