EP1933999B1 - Equipment for producing a closed-section cross-member, comprising an adaptable-length punch and/or matrix, and corresponding production method - Google Patents

Equipment for producing a closed-section cross-member, comprising an adaptable-length punch and/or matrix, and corresponding production method Download PDF

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Publication number
EP1933999B1
EP1933999B1 EP06820253A EP06820253A EP1933999B1 EP 1933999 B1 EP1933999 B1 EP 1933999B1 EP 06820253 A EP06820253 A EP 06820253A EP 06820253 A EP06820253 A EP 06820253A EP 1933999 B1 EP1933999 B1 EP 1933999B1
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EP
European Patent Office
Prior art keywords
closed
punch
length
section
cross
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EP06820253A
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German (de)
French (fr)
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EP1933999A1 (en
Inventor
Vincent Gillet
Julien Berson
Ludovic Ribay
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Auto Chassis International SNC
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Auto Chassis International SNC
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Priority to PL06820253T priority Critical patent/PL1933999T3/en
Publication of EP1933999A1 publication Critical patent/EP1933999A1/en
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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
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B21D53/90—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards axle-housings
    • 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
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/025—Stamping using rigid devices or tools for tubular articles
    • 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
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards

Definitions

  • the field of the invention is that of motor vehicles. More specifically, the invention relates to a tool for manufacturing a cross member with a closed section according to the preamble of claim 1, and a method of manufacturing such a cross member according to the preamble of claim 7 for the flexible axles for motor vehicles. Such tooling and such a method are known from the document EP 1 134 047 .
  • a flexible axle comprises two longitudinal arms each carrying a wheel mounting bracket and connected by a transverse connecting member called cross member or profile.
  • the principle of flexible axles reconciles a high stiffness in bending and a relative flexibility in torsion. In general, it is through the geometry of the section of the cross member, via its bending and torsional inertia, that the desired compromise between flexural stiffness and (relative) torsional flexibility is achieved.
  • the flexible axles are indeed tainted with a number of limitations among which a delicate compromise between longitudinal and transverse stiffness and durability conditioned by the endurance resistance of each of their components, subjected to significant elastic deformations.
  • the connecting element, or through is therefore one of the most difficult components to develop, especially in terms of endurance and behavior.
  • the crossbar connecting the longitudinal arms is made according to two different technologies.
  • the crossbar is made from a folded sheet metal element (or stamped) so as to provide a section having a shape of "U", "V” or “L".
  • These sleepers generally require to be associated with an anti-roll bar, providing torsional stiffness to the axle.
  • the second technology is to integrate the anti-roll stiffness function with the crossbar.
  • the cross is manufactured from a tube generally having a circular section, the tube being subjected at least in its central part to a deformation step (at the end of which a portion of the wall is crushed against another portion of the wall) to obtain the desired stiffness in torsion and flexion (examples: Ford 806 (registered trademarks) or Opel Zafira (registered trademarks)).
  • the diversity of anti-roll stiffness according to the needs is ensured by modification of the shape of the section of the cross-member and / or modification of the thickness of the tube.
  • the invention applies to sleepers made according to this second technology, these being commonly referred to as “closed-profile sleepers” or “closed-section sleepers”.
  • the cross tube is only deformed in a transverse portion to reduce torsional stiffness, and retains stronger torsion sections (eg circular) at the ends, to facilitate connection to the suspension arm by welding.
  • the crossbar of a flexible axle is characterized by a high stiffness in bending and a low torsion stiffness, the latter must be precisely calibrated (associated with the anti-roll stiffness of the axle.
  • One of the factors influencing the anti-roll stiffness is the dispersion over the thickness of the tube.
  • the problem is to decrease the sensitivity of the anti-roll stiffness of the axle to the dispersions on the thickness of the tube.
  • the order of magnitude is such that a dispersion of +/- 0.1 mm the thickness of the tube can generate of the order of three times the tolerance interval of the anti-roll stiffness of the axle of the specifications.
  • a first solution is to work with tube suppliers to control dispersions on the thickness of the tube (from a rolling process and welding), using a sorting method.
  • tubes from a rolling and welding process are used, to which a re-stretching is subsequently applied to improve the tolerance on the thickness.
  • a hot stamping process is used which makes it possible to better control the geometry of the sections formed.
  • the tube sheets are connected at each end of the cross-member by a "clinching" method (puncturing of one sheet in the other by punching).
  • the invention particularly aims to overcome the disadvantages of the prior art.
  • the object of the invention is to propose a tool for manufacturing a closed-section cross member for a flexible axle according to claim 1 which makes it possible to better control the dispersion of the torsion stiffness of the crossbar compared with the solutions of the prior art.
  • the invention also aims to provide such a tool that is simple in design and easy to implement.
  • the invention also aims to propose a method of manufacturing such a cross member, according to claim 7.
  • a tool for manufacturing a cross-section with a closed section intended to connect two longitudinal arms of a flexible axle of a motor vehicle said tooling comprising at least one die intended to cooperate with a punch to form on said closed section of said crosspiece a torsion zone length, and means for holding said crosspiece in position, characterized in that said matrix and / or said punch are adaptable in length to adapt said length of said torsion zone.
  • said matrix and said punch each comprise at least two parts that may be spaced apart / close to each other.
  • said two parts of said die and / or said punch may be actuated by at least one jack.
  • said two parts of said matrix and / or said punch are maintained in the extension of one another using screwing means.
  • the tooling preferably comprises a set of shims capable of being interposed between said two parts of said die and / or said punch.
  • the set of shims can then comprise a variety of shims of different thicknesses to cover a given amplitude, with the desired accuracy.
  • said means for holding in position comprise at least one variable-displacement mandrel.
  • Such mandrels contribute to the modularity of the tooling, allowing to adapt it according to both the thickness of the cross member and its length.
  • the invention also relates to a method of manufacturing a cross-section with a closed section intended to connect two longitudinal arms of a flexible axle of a motor vehicle, using a tool comprising at least one die intended to cooperate with a punch. to form on said closed section of said cross member a torsion zone length, and means for holding said crosspiece in position, characterized in that it comprises a step of adjusting the length of said matrix and / or said punch in order to adapting said length of said torsion zone.
  • the method comprises a preliminary step of calculating said length of said torsion zone as a function of the desired torsional stiffness for said cross-member and the wall thickness of said section.
  • the method comprises a step of adjusting the stroke of two mandrels forming said holding means in position.
  • the conventional tooling comprises a punch 2 and a die 3 actuated by a press and intended to cooperate to form the torsion zone, and mandrels 4 intended to bear against the ends of the tube 1.
  • the tube is placed in the press, and the mandrels are advanced against the tube so as to lock it; then we close the press.
  • the figure 2 illustrates the forming step of the torsion zone over a fixed and fixed length, the die 3 and the punch 2 crushing between them the tube.
  • the press is opened (the die 3 and the punch 2 are therefore spaced apart from one another) and the mandrels are moved away from the tube ( figure 3 ).
  • the torsion zone of a closed-section crosspiece denotes the zone L corresponding to the portion central of the cross.
  • the geometric profile of the section of the tube, the thickness of the tube and the length of the torsion zone are factors of order 1 for obtaining the torsional stiffness of the crossbar.
  • the variation of the length ⁇ L of the torsion zone varies the torsion stiffness R of the crossbar in the following way: if L increases, R decreases, and conversely .
  • the crossbar when the length of the torsion zone L is minimal, the crossbar has a maximum torsion stiffness ( figure 5 ). Conversely, when the length of the torsion zone L is maximum, the crossbar has a minimum torsional stiffness ( figure 6 ).
  • the principle of the invention illustrated by the figure 7 lies in the fact of making the punch 2 and the matrix 3 adaptable in length so that they allow variations in length ⁇ L corresponding to the length of the desired torsion zone.
  • the punch 2 and the die 3 each have two parts, respectively 2a, 2b and 3a, 3b may be moved closer or spaced apart from each other to obtain a variation ⁇ L.
  • the spacing between the parts 2a, 2b on the one hand, and the parts 3a, 3b on the other hand, is obtained by interposing between them one or more shims 6.
  • the number and the thickness of the shims are chosen according to the desired ⁇ L.
  • mandrel races 4 are controlled by hydraulic cylinders (not shown) ensuring the translation of the mandrels.
  • the adaptive adjustment of the tooling that has just been described is performed between each burst of production (a burst being defined by a batch of tubes characterized by an average thickness value of the tubes), in press, with or without partial dismantling. tooling.
  • the length of the torsion zone is calculated as a function of the thickness of the tube, this for a stiffness fixed by specifications.
  • the Figures 9 to 11 are graphs illustrating an example of a torsion stiffness tolerance range obtained by the invention as a function of a thickness dispersion and a given working length variation.
  • the graph of the figure 9 indicates a thickness dispersion (between 3.35 mm and 3.55 mm) on a batch of tubes.
  • the graph of the figure 10 indicates working length variations (corresponding to the length of the torsion zone).
  • the graph of the figure 11 indicates the output data for torsional stiffness.
  • the variation in working length (denoted L on the figure 4a ) between 618 and 700 mm makes it possible to respect a tolerance tolerance of stiffness of ⁇ 2 m.daN / ° for a tolerance on the thickness of the tube of ⁇ 0,1 mm.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Body Suspensions (AREA)
  • Body Structure For Vehicles (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)

Abstract

Tooling for the fabrication of a crosspiece with a closed section for connecting two longitudinal arms of a motor vehicle axle comprises a die (3) cooperating with a punch (2) for forming on the closed section of the crosspiece a lengthwise zone of torsion (L) and a mechanism for retaining the crosspiece in position. The die and/or the punch are adaptable in length to enable the length of the zone of torsion to be adapted. An independent claim is also claimed for the fabrication of a crosspiece with a closed section.

Description

Le domaine de l'invention est celui des véhicules automobiles. Plus précisément, l'invention concerne un outillage de fabrication d'une traverse à section fermée selon le préambule de la revendication 1, ainsi qu'un procédé de fabrication d'une telle traverse selon le préambule de la revendication 7 pour les essieux souples pour les véhicules automobiles. Un tel outillage et un tel procédé sont connus du document EP 1 134 047 .The field of the invention is that of motor vehicles. More specifically, the invention relates to a tool for manufacturing a cross member with a closed section according to the preamble of claim 1, and a method of manufacturing such a cross member according to the preamble of claim 7 for the flexible axles for motor vehicles. Such tooling and such a method are known from the document EP 1 134 047 .

On rappelle qu'on désigne généralement par essieu souple un essieu conçu de façon à former un élément torsible entre deux roues.It is recalled that generally refers to a flexible axle axle designed to form a torsion element between two wheels.

Classiquement, un essieu souple comprend deux bras longitudinaux portant chacun un support de montage de roue et reliés par un élément de liaison transversale appelé traverse ou profil.Conventionally, a flexible axle comprises two longitudinal arms each carrying a wheel mounting bracket and connected by a transverse connecting member called cross member or profile.

Au cours de la conception d'un essieu, deux grandeurs sont, entre autres, considérées pour apprécier la qualité de l'essieu : la flexion et la torsion.During the design of an axle, two sizes are considered, among others, to assess the quality of the axle: bending and torsion.

Le principe des essieux souples permet de concilier une forte raideur en flexion et une relative souplesse en torsion. En général, c'est par la géométrie de la section de la traverse, via ses inerties de flexion et de torsion, qu'est obtenu le compromis souhaité entre raideur en flexion et souplesse (relative) de torsion.The principle of flexible axles reconciles a high stiffness in bending and a relative flexibility in torsion. In general, it is through the geometry of the section of the cross member, via its bending and torsional inertia, that the desired compromise between flexural stiffness and (relative) torsional flexibility is achieved.

Les dernières années ont vu un déploiement important de la technique des essieux souples sur les segments de gamme inférieure et moyenne de la construction automobile, grâce à de nombreux avantages, parmi lesquels un excellent compromis prestations/architecture, et une mise en oeuvre économique utilisant principalement des assemblages de type mécano soudé.Recent years have seen a significant roll-out of flexible axle technology in the lower and mid-range segments of the automotive industry, thanks to numerous advantages, including an excellent performance / architecture compromise, and economical implementation using mainly welded type assemblies.

Ces avantages conduisent les concepteurs de liaison au sol à continuellement pousser la technique dans ses derniers retranchements. Les essieux souples sont en effet entachés d'un certain nombre de limitations parmi lesquelles un compromis délicat entre raideurs longitudinale et transversale et une durabilité conditionnée par la tenue en endurance de chacun de leurs composants, soumis à d'importantes déformations élastiques.These advantages lead the ground designers to continually push the technique to its limits. The flexible axles are indeed tainted with a number of limitations among which a delicate compromise between longitudinal and transverse stiffness and durability conditioned by the endurance resistance of each of their components, subjected to significant elastic deformations.

L'élévation permanente des exigences de confort et d'agrément de conduite oriente notamment la conception des essieux souples vers des solutions consistant à introduire une raideur de torsion entre les deux bras tirés, communément appelée « barre anti-dévers » ou « BAD », dans le but de limiter le dévers du véhicule en virage tout en préservant une grande souplesse verticale du train, garante du filtrage des imperfections de la chaussée vers la caisse.The permanent rise in the requirements of comfort and driving pleasure, in particular, guides the design of flexible axles towards solutions. consisting in introducing a torsional stiffness between the two trailing arms, commonly called "anti-roll bar" or "ADB", in order to limit the tilt of the vehicle when cornering while preserving a great vertical flexibility of the train, guarantor of the filtering imperfections of the roadway to the cash register.

Mais l'élargissement permanent du périmètre d'application de la technique des essieux souples vers des véhicules de forte masse (grosse berline, monospace voire véhicule utilitaire) sans pour autant transiger sur la qualité de prestation, rapprochent continuellement les composants les plus sollicités de leurs limites absolues de fonctionnement, que ce soit la résistance statique à des efforts incidentels, ou la tenue en fatigue à un cycle de chargement représentatif de la vie du train.But the permanent widening of the scope of application of the soft-axle technology towards mass-produced vehicles (big sedan, minivan or commercial vehicle) without compromising on the quality of service, brings the most demanded components closer and closer to each other. absolute operating limits, be it the static resistance to incidental forces, or the fatigue resistance to a load cycle representative of the life of the train.

L'élément de liaison, ou traverse, fait donc partie des composants les plus délicats à mettre au point, notamment sur le plan de l'endurance et du comportement.The connecting element, or through, is therefore one of the most difficult components to develop, especially in terms of endurance and behavior.

Actuellement, sur les essieux souples, la traverse reliant les bras longitudinaux est réalisée suivant deux technologies différentes.Currently, on the flexible axles, the crossbar connecting the longitudinal arms is made according to two different technologies.

Selon une première technologie, la traverse est réalisée à partir d'un élément en tôle pliée (ou emboutie) de façon à lui procurer une section présentant une forme en « U », en « V » ou en « L ». Ces traverses nécessitent généralement d'être associées à une barre anti-dévers, apportant une raideur en torsion à l'essieu.According to a first technology, the crossbar is made from a folded sheet metal element (or stamped) so as to provide a section having a shape of "U", "V" or "L". These sleepers generally require to be associated with an anti-roll bar, providing torsional stiffness to the axle.

La deuxième technologie consiste à intégrer la fonction raideur anti-dévers à la traverse.The second technology is to integrate the anti-roll stiffness function with the crossbar.

Dans ce cas, la traverse est fabriquée à partir d'un tube présentant généralement une section circulaire, le tube étant soumis au moins dans sa partie centrale à une étape de déformation (à l'issue de laquelle une portion de la paroi est écrasée contre une autre portion de la paroi) afin d'obtenir les raideurs souhaitées en torsion et flexion (exemples : Peugeot 806 (marques déposées) ou Opel Zafira (marques déposées)).In this case, the cross is manufactured from a tube generally having a circular section, the tube being subjected at least in its central part to a deformation step (at the end of which a portion of the wall is crushed against another portion of the wall) to obtain the desired stiffness in torsion and flexion (examples: Peugeot 806 (registered trademarks) or Opel Zafira (registered trademarks)).

La diversité de raideur anti-dévers en fonction des besoins est assurée par modification de la forme de la section de la traverse et/ou par modification de l'épaisseur du tube.The diversity of anti-roll stiffness according to the needs is ensured by modification of the shape of the section of the cross-member and / or modification of the thickness of the tube.

L'invention s'applique à des traverses réalisées selon cette deuxième technologie, celles-ci étant couramment désignés par les termes de « traverses à profil fermé » ou par « traverses à section fermée ».The invention applies to sleepers made according to this second technology, these being commonly referred to as "closed-profile sleepers" or "closed-section sleepers".

D'une façon générale, tous les essieux souples utilisant une traverse constituée d'un tube présentent dans leur région centrale une concavité ayant une section en forme de « U » ou de « V ».In general, all the flexible axles using a tube crossbar have in their central region a concavity having a section in the shape of "U" or "V".

Le tube de traverse est seulement déformé dans une portion transversale pour diminuer sa raideur en torsion, et conserve des sections à inertie de torsion plus forte (par exemple circulaires) aux extrémités, pour faciliter la connexion au bras de suspension par soudage.The cross tube is only deformed in a transverse portion to reduce torsional stiffness, and retains stronger torsion sections (eg circular) at the ends, to facilitate connection to the suspension arm by welding.

Selon l'une ou l'autre des technologies qui viennent d'être mentionnées, la traverse d'un essieu souple se caractérise par une raideur importante en flexion et par une raideur en torsion faible, cette dernière devant être précisément calibrée (associée à la raideur anti-dévers de l'essieu.According to one or the other of the technologies just mentioned, the crossbar of a flexible axle is characterized by a high stiffness in bending and a low torsion stiffness, the latter must be precisely calibrated (associated with the anti-roll stiffness of the axle.

Concernant les traverses à section fermée, l'ensemble de la raideur est assurée par la traverse, dont l'inertie de torsion a été soigneusement ajustée en fonction de la raideur anti-dévers demandée au cahier des charges. De ce fait, la tolérance sur la raideur anti-dévers de l'essieu est intégralement associée à celle de la traverse elle-même.In the case of closed section cross members, all the stiffness is ensured by the cross member, whose torsional inertia has been carefully adjusted according to the anti-roll stiffness required by the specifications. As a result, the tolerance on the anti-roll stiffness of the axle is integrally associated with that of the crossbar itself.

Lors de la fabrication de traverses d'essieu à section fermée (par déformation d'un tube), le fabricant est généralement confronté à la difficulté de respecter la tolérance sur la raideur anti-dévers exprimée par le constructeur automobile au travers d'un cahier des charges.When manufacturing closed-section axle crosspieces (by deformation of a tube), the manufacturer is generally faced with the difficulty of respecting the tolerance on the anti-roll stiffness expressed by the car manufacturer through a booklet charges.

Un des facteurs influents sur la raideur anti-dévers est la dispersion sur l'épaisseur du tube.One of the factors influencing the anti-roll stiffness is the dispersion over the thickness of the tube.

Le problème consiste à diminuer la sensibilité de la raideur anti-dévers de l'essieu aux dispersions sur l'épaisseur du tube.The problem is to decrease the sensitivity of the anti-roll stiffness of the axle to the dispersions on the thickness of the tube.

L'ordre de grandeur est tel qu'une dispersion de +/- 0,1 mm sur l'épaisseur du tube peut générer de l'ordre de trois fois l'intervalle de tolérance de la raideur anti-dévers de l'essieu du cahier des charges.The order of magnitude is such that a dispersion of +/- 0.1 mm the thickness of the tube can generate of the order of three times the tolerance interval of the anti-roll stiffness of the axle of the specifications.

Plusieurs solutions ont été apportées à ce problème de maîtrise de la raideur anti-dévers d'un essieu torsible à section fermée.Several solutions have been made to this problem of controlling the anti-roll stiffness of a torsion axle with a closed section.

Une première solution consiste à travailler avec les fournisseurs de tubes pour maîtriser les dispersions sur l'épaisseur du tube (issus d'un process roulage puis soudage), par recours à une méthode de tri.A first solution is to work with tube suppliers to control dispersions on the thickness of the tube (from a rolling process and welding), using a sorting method.

Le potentiel de cette solution s'avère en pratique relativement limité.The potential of this solution turns out to be relatively limited in practice.

Selon une deuxième solution, on utilise des tubes issus d'un process roulage puis soudage, sur lesquels on applique ensuite un ré-étirage pour améliorer la tolérance sur l'épaisseur.According to a second solution, tubes from a rolling and welding process are used, to which a re-stretching is subsequently applied to improve the tolerance on the thickness.

Cette solution s'avère efficace, mais le coût associé est important. On augmente donc le coût global de l'essieu, ce qui est le plus souvent incompatible avec les exigences des constructeurs de véhicules automobiles.This solution is effective, but the associated cost is important. This increases the overall cost of the axle, which is most often incompatible with the requirements of motor vehicle manufacturers.

Selon une autre solution, on a recours à un processus d'emboutissage à chaud, qui permet de maîtriser au mieux la géométrie des sections formées.According to another solution, a hot stamping process is used which makes it possible to better control the geometry of the sections formed.

Toutefois, la pratique montre que cette technique ne permet pas de diminuer la sensibilité aux dispersions sur l'épaisseur.However, practice shows that this technique does not reduce the sensitivity to dispersions on the thickness.

Selon encore une autre solution, on réalise la liaison des tôles du tube, à chaque extrémité de la traverse, par un procédé de « clinchage » (enfoncement ponctuel d'une tôle dans l'autre par poinçonnement).According to yet another solution, the tube sheets are connected at each end of the cross-member by a "clinching" method (puncturing of one sheet in the other by punching).

Cette solution permet de mieux maîtriser la dispersion sur la longueur effective de la section travaillante (section d'inertie de torsion la plus faible), mais ne compense pas pour autant les dispersions sur l'épaisseur du tube.This solution makes it possible to better control the dispersion over the effective length of the working section (the lowest torsion section of inertia), but does not compensate for the dispersions on the thickness of the tube.

L'invention a notamment pour objectif de pallier les inconvénients de l'art antérieur.The invention particularly aims to overcome the disadvantages of the prior art.

Plus précisément, l'invention a pour objectif de proposer un outillage de fabrication d'une traverse à section fermée pour un essieu souple selon la revendication 1 qui permettre de mieux maîtriser la dispersion de la raideur de torsion de la traverse comparée aux solutions de l'art antérieur.More specifically, the object of the invention is to propose a tool for manufacturing a closed-section cross member for a flexible axle according to claim 1 which makes it possible to better control the dispersion of the torsion stiffness of the crossbar compared with the solutions of the prior art.

L'invention a également pour objectif de fournir un tel outillage qui soit simple de conception et facile à mettre en oeuvre.The invention also aims to provide such a tool that is simple in design and easy to implement.

L'invention a aussi pour objectif de proposer un procédé de fabrication d'une telle traverse, selon la revendication 7.The invention also aims to propose a method of manufacturing such a cross member, according to claim 7.

Ces objectifs, ainsi que d'autres qui apparaîtront par la suite, sont atteints grâce à l'invention qui a pour objet un outillage de fabrication d'une traverse à section fermée destinée à relier deux bras longitudinaux d'un essieu souple de véhicule automobile, ledit outillage comprenant au moins une matrice destinée à coopérer avec un poinçon pour former sur ladite section fermée de ladite traverse une longueur de zone de torsion, et des moyens de maintien en position de ladite traverse, caractérisé en ce que ladite matrice et/ou ledit poinçon sont adaptables en longueur en vue d'adapter ladite longueur de ladite zone de torsion.These objectives, as well as others which will appear later, are achieved thanks to the invention which has for object a tool for manufacturing a cross-section with a closed section intended to connect two longitudinal arms of a flexible axle of a motor vehicle said tooling comprising at least one die intended to cooperate with a punch to form on said closed section of said crosspiece a torsion zone length, and means for holding said crosspiece in position, characterized in that said matrix and / or said punch are adaptable in length to adapt said length of said torsion zone.

On obtient ainsi un système adaptatif permettant de faire varier la longueur de la zone de torsion (aussi appelée « zone travaillante ») de la traverse et, par conséquent, sa raideur de torsion.An adaptive system is thus obtained which makes it possible to vary the length of the torsion zone (also called the "working zone") of the cross member and, consequently, its torsion stiffness.

Une telle variation de la longueur de la zone de torsion peut être obtenue par simple réglage des dimensions de la matrice et du poinçon de l'outillage de formage, ceci de façon intégrée à l'outillage comme cela va apparaître plus clairement par la suite.Such a variation in the length of the torsion zone can be obtained by simple adjustment of the dimensions of the die and the punch of the forming tool, this in an integrated way to the tooling as it will appear more clearly later.

Selon une solution préférée, ladite matrice et ledit poinçon comprennent chacun au moins deux parties susceptibles d'être écartées/rapprochées l'une de l'autre.According to a preferred solution, said matrix and said punch each comprise at least two parts that may be spaced apart / close to each other.

De cette façon, on obtient une solution particulièrement simple et efficace pour adapter l'outillage en fonction de la raideur de torsion recherchée pour la traverse.In this way, a particularly simple and effective solution is obtained for adapting the tooling according to the torsional stiffness sought for the crossmember.

Selon un premier mode de réalisation, lesdites deux parties de ladite matrice et/ou dudit poinçon sont susceptibles d'être actionnés par au moins un vérin.According to a first embodiment, said two parts of said die and / or said punch may be actuated by at least one jack.

Selon une deuxième mode de réalisation, lesdites deux parties de ladite matrice et/ou dudit poinçon sont maintenus dans le prolongement l'une de l'autre à l'aide de moyens de vissage.According to a second embodiment, said two parts of said matrix and / or said punch are maintained in the extension of one another using screwing means.

Dans ce cas, l'outillage comprend préférentiellement un jeu de cales susceptibles d'être intercalées entre lesdites deux parties de ladite matrice et/ou dudit poinçon.In this case, the tooling preferably comprises a set of shims capable of being interposed between said two parts of said die and / or said punch.

Le jeu de cales peut alors comprendre une variété de cales de différentes épaisseurs permettant de couvrir une amplitude donnée, avec la précision recherchée.The set of shims can then comprise a variety of shims of different thicknesses to cover a given amplitude, with the desired accuracy.

Selon une solution avantageuse, lesdits moyens de maintien en position comprennent au moins un mandrin à course variable.According to an advantageous solution, said means for holding in position comprise at least one variable-displacement mandrel.

De tels mandrins contribuent à la modularité de l'outillage, permettant d'adapter celui-ci tant en fonction de l'épaisseur de la traverse que de sa longueur.Such mandrels contribute to the modularity of the tooling, allowing to adapt it according to both the thickness of the cross member and its length.

L'invention concerne également un procédé de fabrication d'une traverse à section fermée destinée à relier deux bras longitudinaux d'un essieu souple de véhicule automobile, à l'aide d'un outillage comprenant au moins une matrice destinée à coopérer avec un poinçon pour former sur ladite section fermée de ladite traverse une longueur de zone de torsion, et des moyens de maintien en position de ladite traverse, caractérisé en ce qu'il comprend une étape de réglage en longueur de ladite matrice et/ou dudit poinçon en vue d'adapter ladite longueur de ladite zone de torsion.The invention also relates to a method of manufacturing a cross-section with a closed section intended to connect two longitudinal arms of a flexible axle of a motor vehicle, using a tool comprising at least one die intended to cooperate with a punch. to form on said closed section of said cross member a torsion zone length, and means for holding said crosspiece in position, characterized in that it comprises a step of adjusting the length of said matrix and / or said punch in order to adapting said length of said torsion zone.

Préférentiellement, le procédé comprend une étape préalable de calcul de ladite longueur de ladite zone de torsion en fonction de la raideur de torsion souhaitée pour ladite traverse et de l'épaisseur de paroi de ladite section.Preferably, the method comprises a preliminary step of calculating said length of said torsion zone as a function of the desired torsional stiffness for said cross-member and the wall thickness of said section.

Selon une solution avantageuse, le procédé comprend une étape de réglage de la course de deux mandrins formant lesdits moyens de maintien en position.According to an advantageous solution, the method comprises a step of adjusting the stroke of two mandrels forming said holding means in position.

D'autres caractéristiques et avantages de l'invention apparaîtront plus clairement à la lecture de la description suivante d'un mode de réalisation préférentiel de l'invention donné à titre d'exemple illustratif et non limitatif, et des dessins annexés parmi lesquels :

  • les figures 1 à 3 sont chacune une vue d'une étape de fabrication d'une traverse à section fermée selon l'art antérieur ;
  • les figures 4a, 4b, 5 et 6 sont des vues permettant d'illustrer l'influence de la zone de torsion d'une traverse sur la raideur de torsion de celle-ci ;
  • la figure 7 est une vue schématique du principe général de l'invention ;
  • la figure 8 est une vue schématique d'un mode de réalisation préférentiel de l'invention ;
  • les figures 9 à 11 sont des graphes illustrant un exemple d'intervalle de tolérance de raideur de torsion obtenu grâce à l'invention en fonction d'une dispersion d'épaisseur et d'une variation de longueur travaillante données.
Other characteristics and advantages of the invention will emerge more clearly on reading the following description of a preferred embodiment of the invention given by way of illustrative and nonlimiting example, and the appended drawings in which:
  • the Figures 1 to 3 are each a view of a manufacturing step of a cross section closed according to the prior art;
  • the Figures 4a, 4b, 5 and 6 are views for illustrating the influence of the torsion zone of a cross member on the torsion stiffness thereof;
  • the figure 7 is a schematic view of the general principle of the invention;
  • the figure 8 is a schematic view of a preferred embodiment of the invention;
  • the Figures 9 to 11 are graphs illustrating an example of a torsion stiffness tolerance range obtained by the invention as a function of a thickness dispersion and a given working length variation.

En référence aux figures 1 à 3, on rappelle qu'une traverse à section fermée est fabriquée selon l'art antérieur à partir d'un tube 1 sur lequel on agit, par l'intermédiaire d'une presse, par déformation de sa section pour réaliser une zone de torsion.With reference to Figures 1 to 3 it will be recalled that a cross-section with a closed section is manufactured according to the prior art from a tube 1 on which, by means of a press, it acts by deforming its section to produce a torsion zone.

L'outillage classique comprend un poinçon 2 et une matrice 3 actionnés par une presse et destinés à coopérer pour former la zone de torsion, et des mandrins 4 destinés à venir en appui aux extrémités du tube 1.The conventional tooling comprises a punch 2 and a die 3 actuated by a press and intended to cooperate to form the torsion zone, and mandrels 4 intended to bear against the ends of the tube 1.

Selon une phase initiale, le tube est placé dans la presse, et les mandrins sont avancés contre le tube de façon à bloquer celui-ci ; puis on procède à la fermeture de la presse.In an initial phase, the tube is placed in the press, and the mandrels are advanced against the tube so as to lock it; then we close the press.

La figure 2 illustre l'étape de formage de la zone de torsion sur une longueur donnée et fixe, la matrice 3 et le poinçon 2 écrasant entre eux le tube.The figure 2 illustrates the forming step of the torsion zone over a fixed and fixed length, the die 3 and the punch 2 crushing between them the tube.

A l'issue de l'étape de formage, la presse est ouverte (la matrice 3 et le poinçon 2 étant par conséquent écartés l'un de l'autre) et les mandrins sont reculés du tube (figure 3).At the end of the forming step, the press is opened (the die 3 and the punch 2 are therefore spaced apart from one another) and the mandrels are moved away from the tube ( figure 3 ).

En référence aux figures 4a et 4b, on rappelle qu'on désigne par zone de torsion d'une traverse à section fermée la zone L correspondant à la partie centrale de la traverse.With reference to Figures 4a and 4b , it is recalled that the torsion zone of a closed-section crosspiece denotes the zone L corresponding to the portion central of the cross.

Pour une telle traverse, le profil géométrique de la section du tube, l'épaisseur du tube et la longueur de la zone de torsion sont des facteurs d'ordre 1 pour l'obtention de la raideur de torsion de la traverse.For such a cross, the geometric profile of the section of the tube, the thickness of the tube and the length of the torsion zone are factors of order 1 for obtaining the torsional stiffness of the crossbar.

De plus, pour un profil de section et une épaisseur de tube constants, la variation de la longueur ΔL de la zone de torsion fait varier la raideur de torsion R de la traverse de la façon suivante : si L augmente, R diminue, et inversement.Moreover, for a constant section profile and tube thickness, the variation of the length ΔL of the torsion zone varies the torsion stiffness R of the crossbar in the following way: if L increases, R decreases, and conversely .

Ainsi, lorsque la longueur de la zone de torsion L est minimale, la traverse présente une raideur de torsion maximale (figure 5). Inversement, lorsque la longueur de la zone de torsion L est maximale, la traverse présente une raideur de torsion minimale (figure 6).Thus, when the length of the torsion zone L is minimal, the crossbar has a maximum torsion stiffness ( figure 5 ). Conversely, when the length of the torsion zone L is maximum, the crossbar has a minimum torsional stiffness ( figure 6 ).

Tel que mentionné précédemment, le principe de l'invention illustré par la figure 7 réside dans le fait de rendre le poinçon 2 et la matrice 3 adaptables en longueur de façon qu'ils permettent des variations de longueur ΔL correspondantes à la longueur de la zone de torsion recherchée.As mentioned above, the principle of the invention illustrated by the figure 7 lies in the fact of making the punch 2 and the matrix 3 adaptable in length so that they allow variations in length ΔL corresponding to the length of the desired torsion zone.

Pour ce faire, selon le mode de réalisation illustré par la figure 8, le poinçon 2 et la matrice 3 présente chacune deux parties, respectivement 2a, 2b et 3a, 3b susceptibles d'être rapprochées ou écartées l'un de l'autre en vue d'obtenir une variation ΔL.To do this, according to the embodiment illustrated by the figure 8 , the punch 2 and the die 3 each have two parts, respectively 2a, 2b and 3a, 3b may be moved closer or spaced apart from each other to obtain a variation ΔL.

L'écartement entre les parties 2a, 2b d'une part, et les parties 3a, 3b d'autre part, est obtenu en intercalant entre elles une ou plusieurs cales 6.The spacing between the parts 2a, 2b on the one hand, and the parts 3a, 3b on the other hand, is obtained by interposing between them one or more shims 6.

Bien entendu, le nombre et l'épaisseur des cales sont choisis en fonction du ΔL recherché.Of course, the number and the thickness of the shims are chosen according to the desired ΔL.

Les parties 2a, 2b du poinçon sont maintenus avec les cales 6 à l'aide de tiges filetées 5. Il en va de même pour les parties 3a, 3b de la matrice avec les cales 6.The parts 2a, 2b of the punch are held together with the wedges 6 by means of threaded rods 5. The same goes for the parts 3a, 3b of the die with the wedges 6.

Par ailleurs, les courses des mandrins 4 sont pilotées par des vérins hydrauliques (non représentés) assurant la translation des mandrins.Furthermore, the mandrel races 4 are controlled by hydraulic cylinders (not shown) ensuring the translation of the mandrels.

On note que l'adaptation des longueurs du poinçon et de la matrice peut être obtenue de façon hydraulique, par exemple à l'aide de vérins embarqués, selon un autre mode de réalisation envisageable.It is noted that the adaptation of the lengths of the punch and the die can be obtained hydraulically, for example using embedded cylinders, according to another conceivable embodiment.

Le réglage adaptatif de l'outillage qui vient d'être décrit est réalisé entre chaque rafale de production (une rafale étant définie par un lot de tubes caractérisés par une valeur d'épaisseur moyenne des tubes), sous presse, avec ou sans démontage partiel de l'outillage.The adaptive adjustment of the tooling that has just been described is performed between each burst of production (a burst being defined by a batch of tubes characterized by an average thickness value of the tubes), in press, with or without partial dismantling. tooling.

Préalablement au réglage de l'outillage, on procède au calcul de la longueur de la zone de torsion en fonction de l'épaisseur du tube, ceci pour une raideur fixée par cahier des charges.Prior to the adjustment of the tooling, the length of the torsion zone is calculated as a function of the thickness of the tube, this for a stiffness fixed by specifications.

Un tel outillage permet donc, en termes de production, de former des pièces par rafales.Such tooling therefore allows, in terms of production, to form parts in bursts.

Les figures 9 à 11 sont des graphes illustrant un exemple d'intervalle de tolérance de raideur de torsion obtenu grâce à l'invention en fonction d'une dispersion d'épaisseur et d'une variation de longueur travaillante données.The Figures 9 to 11 are graphs illustrating an example of a torsion stiffness tolerance range obtained by the invention as a function of a thickness dispersion and a given working length variation.

Le graphe de la figure 9 indique une dispersion d'épaisseur (entre 3,35 mm et 3,55 mm) sur un lot de tubes.The graph of the figure 9 indicates a thickness dispersion (between 3.35 mm and 3.55 mm) on a batch of tubes.

Le graphe de la figure 10 indique des variations de longueur travaillante (correspondante à la longueur de la zone de torsion).The graph of the figure 10 indicates working length variations (corresponding to the length of the torsion zone).

Le graphe de la figure 11 indique les données de sortie relatives à la raideur de torsion.The graph of the figure 11 indicates the output data for torsional stiffness.

Sur l'exemple ci-dessus, la variation de la longueur travaillante (notée L sur la figure 4a) entre 618 et 700 mm permet de respecter un intervalle de tolérance de raideur de ±2 m.daN/° pour une tolérance sur l'épaisseur du tube de ±0,1 mm.In the example above, the variation in working length (denoted L on the figure 4a ) between 618 and 700 mm makes it possible to respect a tolerance tolerance of stiffness of ± 2 m.daN / ° for a tolerance on the thickness of the tube of ± 0,1 mm.

Sans l'adaptation de longueur de la zone travaillante (c'est à dire avec les techniques de l'art antérieur), la dispersion de l'épaisseur du tube entraîne une dispersion de raideur de torsion de ± 7,25 m.daN/° (± 8%).Without the length adaptation of the working zone (that is to say with the techniques of the prior art), the dispersion of the thickness of the tube results in a torsional stiffness dispersion of ± 7.25 m.daN / ° (± 8%).

Claims (9)

  1. Tooling for manufacturing a closed-section cross-member intended to connect two longitudinal arms of a motor vehicle non-rigid axle, said tooling comprising at least one die (3) intended to collaborate with a punch (2) to form, on said closed section of said cross-member, a length (L) of torsion zone, and means for holding said cross-member in position, characterized in that said die (3) and/or said punch (2) are length-adjustable so that said length of said torsion zone (L) can be adapted.
  2. Tooling for manufacturing a closed-section cross-member according to Claim 1, characterized in that said die (3) and said punch (2) each comprise at least two parts (3a), (3b), (2a), (2b) that can be moved away from/toward each other.
  3. Tooling for manufacturing a closed-section cross-member according to Claim 2, characterized in that said two parts (3a), (3b), (2a), (2b) of said die (3) and/or of said punch (2) can be actuated by at least one actuating cylinder.
  4. Tooling for manufacturing a closed-section cross-member according to Claim 2, characterized in that said two parts (3a), (3b), (2a), (2b) of said die (3) and/or of said punch (2) are held in the continuation of one another using screwing means (5).
  5. Tooling for manufacturing a closed-section cross-member according to Claim 4, characterized in that it comprises a set of shims (6) which can be interposed between said two parts (3a), (3b), (2a), (2b) of said die (3) and/or of said punch (2).
  6. Tooling for manufacturing a closed-section cross-member according to any one of Claims 1 to 5, characterized in that said holding means comprise at least one variable-travel clamp (4).
  7. Method for manufacturing a closed-section cross-member intended to connect two longitudinal arms of a motor vehicle non-rigid axle, using tooling comprising at least one die (3) intended to collaborate with a punch (2) to form, on said closed section of said cross-member, a length (L) of torsion zone, and means for holding said cross-member in position, characterized in that it comprises a step of adjusting the length of said die (3) and/or of said punch (2) so as to adapt said length of said torsion zone (L).
  8. Method of manufacturing a closed-section cross-member according to Claim 7, characterized in that it comprises a prior step of calculating said length of said torsion zone (L) according to the desired torsional stiffness of said cross-member and according to the wall thickness of said section.
  9. Method of manufacturing a closed-section cross-member according to either of Claims 7 and 8, characterized in that it comprises a step of adjusting the travel of two clamps (4) that form said holding means.
EP06820253A 2005-10-04 2006-10-04 Equipment for producing a closed-section cross-member, comprising an adaptable-length punch and/or matrix, and corresponding production method Not-in-force EP1933999B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL06820253T PL1933999T3 (en) 2005-10-04 2006-10-04 Equipment for producing a closed-section cross-member, comprising an adaptable-length punch and/or matrix, and corresponding production method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0510131A FR2891480B1 (en) 2005-10-04 2005-10-04 TOOLING FOR MANUFACTURING A CLOSED SECTION FRAGMENT COMPRISING A MATRIX AND / OR A PUNCH OF ADAPTABLE LENGTH AND CORRESPONDING FABRICATION METHOD.
PCT/FR2006/050990 WO2007039703A1 (en) 2005-10-04 2006-10-04 Equipment for producing a closed-section cross-member, comprising an adaptable-length punch and/or matrix, and corresponding production method

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EP1933999A1 EP1933999A1 (en) 2008-06-25
EP1933999B1 true EP1933999B1 (en) 2009-09-30

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JP (1) JP2009509774A (en)
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NL2002482C2 (en) * 2009-02-03 2010-08-04 Weweler Nv Manufacturing of a vehicle axle.
JP4858624B2 (en) * 2009-04-01 2012-01-18 Ｊｆｅスチール株式会社 Torsion beam manufacturing method and torsion beam
KR101009494B1 (en) 2010-05-20 2011-01-19 이형광 Manufacturing method of cup used in cross member for vehicle
US9527120B2 (en) * 2012-02-01 2016-12-27 Magna International Inc. Transverse strut and method of forming a transverse strut
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DE102014109453A1 (en) * 2014-07-07 2016-01-07 Benteler Automobiltechnik Gmbh Method for producing a torsion profile from a tubular hollow profile and torsion profile
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JP6213705B1 (en) * 2016-05-10 2017-10-18 新日鐵住金株式会社 Torsion beam manufacturing method, torsion beam manufacturing apparatus, and torsion beam
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ATE444129T1 (en) 2009-10-15
JP2009509774A (en) 2009-03-12
EP1933999A1 (en) 2008-06-25
US20090071220A1 (en) 2009-03-19
WO2007039703A1 (en) 2007-04-12
DE602006009531D1 (en) 2009-11-12
FR2891480A1 (en) 2007-04-06
FR2891480B1 (en) 2008-04-04
PL1933999T3 (en) 2010-07-30

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