EP2110189A1 - Method for dieless forming of sheet metal - Google Patents
Method for dieless forming of sheet metal Download PDFInfo
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- EP2110189A1 EP2110189A1 EP08007621A EP08007621A EP2110189A1 EP 2110189 A1 EP2110189 A1 EP 2110189A1 EP 08007621 A EP08007621 A EP 08007621A EP 08007621 A EP08007621 A EP 08007621A EP 2110189 A1 EP2110189 A1 EP 2110189A1
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- Prior art keywords
- sheet metal
- semi
- cavity
- finished product
- metal elements
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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
- B21D26/021—Deforming sheet bodies
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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
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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
- B21D26/053—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 characterised by the material of the blanks
- B21D26/059—Layered blanks
Definitions
- This invention relates to three-dimensional sheet metal structures and their semi-finished products, as well as methods for the production of three-dimensional sheet metal structures and their semi-finished products.
- Sheet metal is a very versatile material that, due to its plastic deformability, can be transformed from a simple planar basic shape into complex three-dimensional sheet metal structures.
- Such components can have a high rigidity and strength at a relatively low weight and are therefore often used when weight is an important factor, for example in vehicle construction and lightweight construction.
- the media pressure required for forming depends, inter alia, on the geometry of the component, the sheet thickness and the material used, and can range from 5 MPa (aluminum sheet) to 200 MPa (stainless steel sheet). Such pressures can only be generated hydraulically, and require expensive, expensive tools.
- the internal high-pressure method is used, a variant of high-pressure sheet metal forming, in which the pressurized medium is introduced into a pressure-tight closed interior of a tubular sheet metal blank, which is arranged in a mold forming an external die ,
- a method is described, for example, in WO 00/10748 A1 and WO 2006/018846 A1 .
- the necessary pressures are similar to conventional high-pressure sheet metal forming.
- a tubular sheet metal blank it is also possible to use two laminations laid one on top of the other in order to form a tank, for example.
- the known methods are the very high working pressures, which can be up to 200 MPa (2000 bar). At such pressures, the forming tools are heavily loaded. Their preparation and operation is also complicated and expensive, and limits the size of the manufacturable components.
- the object of the invention is to provide three-dimensional sheet metal structures and their semi-finished products, as well as methods for the production of three-dimensional sheet metal structures and their semi-finished products, which do not have the above-mentioned and other disadvantages.
- such processes should be time and cost efficient, and do without expensive tools.
- the invention will be described using the example of sheet metal. In addition to sheet metal, however, the invention can be applied to any other sheet-like starting material which has a certain degree of plasticity and ductility. If a material is suitable for conventional forming processes, it can also be used for the processes according to the invention.
- two or even more sheet metal elements cut to a specific contour are provided. These blanks can be cut directly before processing, which is advantageous for larger blanks, or have already been prepared in advance.
- the two or more sheet metal elements are joined together along their edges, so that forms a substantially pressure-tight closed cavity.
- this semi-finished product is reshaped by inflating the three-dimensional sheet structure, that is, it is generated within the cavity relative to the external environment, an overpressure, for example by introducing compressed air or filling with water or other hydraulic active medium.
- inflation is used synonymously with the term transformation.
- the sheet metal blanks are plastically deformed by the increased internal pressure and stretched elastically to a certain extent, the deformation is "free", that is not predetermined by a die or a stamp.
- the type of forming is determined by the choice of contouring and topological connection of the sheet metal elements, the specific properties of the sheet such as material, modulus of elasticity, sheet thickness, rolling direction, as well as the process parameters such as applied working pressure and forming time. It is not necessary, however, as already explained, to use a die or another shaping tool.
- one or more limiting elements are arranged on the sheet metal elements.
- the said limiting elements may, for example, be substantially one-dimensional, for example sheet metal strips or cables, which are arranged between the sheet metal elements and connected to the latter at suitable locations, so that when inflating Sheet metal structure, the spatial distance of the connected by the limiting element points of the sheet metal blanks is limited upwards.
- the distance of the corresponding points can also be fixed, for example with stiff rods.
- boundary elements that are two-dimensional Shaping, which defines a minimum inner contour at a certain point when inflating the sheet metal structure.
- webs or other structures can be attached as limiting elements on the sheet metal elements to locally modify the mechanical strength of the sheet surfaces, and so to influence the shaping during inflation / deformation of the sheet metal structure.
- the boundary elements can also take on other tasks after the completion of the three-dimensional sheet metal structure.
- limiting elements can be configured as perforated plates, which serve as slosh plates in later operation.
- the limiting elements of the mechanical stabilization serve, for example as internal struts.
- Inventive three-dimensional sheet structures can be used for a variety of uses, such as lightweight construction elements and vehicles, etc, as floats, tanks, ornaments, furniture, and more.
- FIG. 1 schematically shown with a cross section through (a) a semi-finished product before inflation, and (b) through the finished inflated sheet metal structure.
- Two flat sheet metal elements 11, 11 'or sheet metal blanks are cut to DIN 8588, 8589 with a certain contour of the raw sheet. This is done by a conventional method, for example by means of punching or laser cutting.
- the corresponding contoured sheet metal elements 11, 11 ' are arranged one above the other, and along their contours 16 according to DIN 8580 assembled to form a semi-finished product 1a, for example by welding, joining or gluing.
- the greatest flexibility in terms of shaping is achieved with laser welding.
- one or more ports 13 are provided for a supply of a pressure medium.
- the production of the semi-finished product 1a is preferably done in line, that is, the sheet metal elements are cut from roll plate and then welded directly along the contours. Appropriate systems are known to those skilled in the industrial practice. For smaller sheet metal elements 11. 11 'it may also be useful to produce them in a separate operation, and ready to provide contoured for the preparation of the semi-finished product.
- the semi-finished product can then be converted directly to the finished three-dimensional sheet metal structure and further processed, or later in a separate step.
- the semifinished product is inflated, that is, it is compared to the external environment in the interior 14 generates an overpressure, so that the unconnected surfaces of the sheet metal elements 11, 11 'are pushed apart, and the sheet metal elements 11, 11' free to a predetermined three-dimensional Transform sheet metal structure 1.
- compressed air or water or another hydraulic fluid pressurized is introduced into the cavity 14.
- the overpressure and the action time are determined by the contouring and the material parameters.
- the pressure is then lowered again, whereby due to the plastic deformation of the sheet, the shape remains stable.
- a certain amount of reversible elastic deformation must be taken into account when defining the process parameters and contouring. It may also be an increased internal pressure remain, for example, to mechanically stabilize the sheet metal structure 1.
- the pressure required in the interior is lower in a process according to the invention, and depending on the case is between 50 kPa (0.5 bar) and 1 MPa (10 bar).
- the shaping takes place without matrices or counter tools, very large sheet metal structures are also manufacturable.
- the semi-finished products are flat, they require much less space than the finished formed sheet metal structures. This results in the logistically advantageous possibility to transport larger sheet metal structures, for example, for use in buildings, as a semi-finished product to the installation site, and to finish there on site.
- An inventive sheet metal structure may also have openings, for example in the topological shape of a torus, as long as the interior is completed.
- the shaping of a sheet metal structure according to the invention results primarily from the choice of contours, the material properties and the process parameters.
- the by the increased internal pressure generated force acts basically perpendicular to the sheet surface. Due to the plastic deformation, there is a shift in the contours.
- When blowing out the semi-finished products they are therefore narrower in the plane of the contours, which must be considered in the choice of contouring, as in FIG. 2 is explained schematically.
- FIG. 2 (a) shown two long sheet metal elements 11 assembled with a width a and a length b to form a semi-finished product 1a, then the three-dimensional sheet metal structure 1 is waisted during forming (b).
- By a round contouring at the longitudinal ends (c) this effect can be reduced.
- An exact compliance with a constant width a over the entire length of the sheet metal structure can finally be achieved by broadening the sheet metal elements 11 in the middle (e), which then results in a unsupported sheet structure during inflation (f).
- FIG. 3 illustrates the use of sheets of different thicknesses.
- a first sheet metal element 11 is made of 2 mm thick sheet metal, while a second sheet metal element 11 'has a thickness of 0.8 mm.
- the sheets are stretched to varying degrees due to their resulting different mechanical stability, resulting in an asymmetric shaping of the sheet metal parts.
- the use of different sheet thicknesses thus also allows an influence on the deformation of the inventive three-dimensional sheet metal structure.
- FIG. 4 (a) shows three different examples of possible design forms of simple sheet metal structures according to the invention.
- the weld seam 12 does not necessarily have to match the contour 16 either.
- points the second sheet metal structure at the longitudinal ends of a weld 12 which can survive a certain part of the sheet metal elements, whereby a region is formed which is not inflated, and can serve for example for attaching a breakpoint.
- Another way to attach a breakpoint is in the first example of FIG. 4 (a) and in FIG. 4 (b) seen.
- the semi-finished product 1a has at its longitudinal end a dovetail-shaped contour 16, the tips of which move towards each other during inflation / reshaping. After forming, a correspondingly shaped connection point 16 is inserted between the two tips.
- pivoting movements can also be induced during the forming, with certain parts of the sheet metal structure being pivoted relative to others.
- Suitable for this purpose are, for example, constrictions in the contour. In this way, can produce three-dimensional sheet metal structures that would not be produced with conventional Blechumformungsclar.
- the possibility of determining the shape of the sheet metal structure may be restricted at a certain distance from the contour lines.
- This problem is solved by one or more limiting elements which are attached to one or more sheet metal elements, and limit the deformation of the sheet metal elements in one or the other of the inflation molding.
- FIG. 5 An exemplary example of an inventive sheet metal structure 1 with a delimiting element 2 is shown in FIG. 5 (a) before inflation / reshaping, (b) as detail I in the area of the boundary element 2 and (c) after inflation.
- the limiting element in the example shown is a folded sheet metal strip 2 which is arranged between two sheet-metal elements 11, 11 'and is connected to two connecting points 21, 21'. is positively and / or non-positively connected to the sheet metal elements at the points A and B, for example by gluing or welding.
- the limiting element 2 When inflating the semi-finished product, the limiting element 2 is now unfolded until it is stretched to its maximum length L.
- connection points 21, 21 'of the limiting element can be displaceable, possibly also with a latching mechanism.
- a rigid limiting element such as a distance rod, which would determine not only the maximum distance between points A and B, but also the minimum distance, and thus also the mechanical stabilization of the inventive sheet metal structure can serve.
- Such stabilization can also be achieved by crossing two or more limiting elements 2, 2 ', as in FIG FIG. 6 shown.
- a limiting element 2 can also limit only the deformation of a sheet metal element 11.
- FIG. 7 a possible embodiment (a) of an inventive semifinished product 1 a of a sheet metal structure 1 according to the invention, in which between two sheet metal elements 11, 11 'a web 2, for example in the form of a folded sheet metal strip is arranged, along its entire length with an 11 of the sheet metal elements connected is.
- the sheet metal structure 1 When inflating (b) the sheet metal structure 1 then prevents the limiting element 2 a bending of the surface of the sheet metal element 11 in the longitudinal direction, as in the longitudinal section in FIG. 7 (c) is apparent. This influences the overall forming, which is taken into account when determining the contouring, process parameters, etc.
- Such a web can of course be seconded on the outside of the sheet metal element.
- An inventive sheet structure 1 with a large volume can serve, for example, as a tank, for example for fuel, fuel oil or water.
- a tank is particularly suitable for installation in existing buildings, because it is usually no longer possible to bring a large-volume rigid tank later in the building interior.
- the tank will be welded together on site or replaced with a variety of smaller tanks.
- a sheet metal structure according to the invention can now be brought into the building as a space-saving semifinished product 1a, and then be inflated / reshaped into the finished tank. It is also possible to additionally roll or fold the flat semifinished product in a suitable manner prior to transport in order to make it even more compact.
- FIG. 9 (a) A simple example of a rolled semi-finished product 1a shows FIG. 9 (a) , By increasing the internal pressure, this rolls Semi-finished product automatically, in order then to be shaped into the final three-dimensional shape of the inventive sheet metal structure 1, as in FIG. 9 (b) shown.
- inventive sheet metal structures which are intended for use as vehicle tanks, it is possible to use two-dimensional boundary elements which, for example, can be configured as perforated plates and thus serve as slosh plates later in operation.
- inventive sheet metal structures can also be designed double-walled, which in turn is particularly advantageous for tanks. For this purpose, instead of two four sheet metal elements are welded.
- FIG. 8 shows two further embodiments of an inventive sheet metal structure 1.
- FIG. 8 (a) is mounted on a sheet metal element 11 in the longitudinal direction of a bead 2.
- Beading is often used in sheet metal technology to stabilize sheet metal structures.
- they serve as limiting element 2 because it influences the deformation of the sheet metal element 11 during the forming process.
- the shape of the beads is also variable to affect the shape of the three-dimensional sheet structure 1.
- FIG. 8 (b) was the semifinished product 1a bent before the forming process in the flat state, which also allows influencing the shape.
- FIG. 10 Other variants of inventive sheet metal structures 1 are in FIG. 10 shown. These are designed multi-chamber, wherein the boundary surfaces between two chambers each serve as a limiting element 2, which influences the shape of the overall structure 1. So shows Figure 10 (a) a variant in which in the two sheet metal elements 11, 11 'additional welds 2 are mounted within the contours 16, which lead to three separate chambers. When inflating / reshaping the Semifinished 1a, these welds form 2 interfaces between the chambers, and at the same time influence the deformation of the sheet metal structure 1 as delimiting elements. In a preferred variant, various internal pressures in the chambers can additionally be selected.
- FIG. 10 (f) shows a multi-chambered variant.
- the individual sheet metal elements 11, 11 'stacked in a brick shape, and so welded 12, that a single sheet metal element 11 each serves as the top of a chamber and as the bottom of the next chamber.
- FIGS. 10 (b) and (c) two or a smaller chambers are arranged within a third, larger chamber. During forming, they influence the deformation of the outer chamber due to their volume and shape, and therefore also function as a delimiting element 2
- FIG. 10 (d) again shows a multi-chambered variant in which folded sheet metal elements 11 are arranged inside each other and welded 12 are.
- individual sheet metal structures are arranged in a brick shape. In both of these variants, in each case a part of a sheet metal element 11 simultaneously serves as a limiting element 2.
- inventive sheet metal structures FIGS. 10 (a) and (b) are particularly suitable as lightweight carrier structures.
- the additional stiffening of the edges by the outer edges corresponds to a reinforcement of the upper and lower chords.
- inventive sheet metal structures FIG. 10 (d) to (f) in turn are suitable for larger-scale applications, for example, for facade and roof elements or flat support structures such as floors.
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Abstract
Description
Diese Erfindung betrifft dreidimensionale Blechstrukturen und deren Halbfabrikate, sowie Verfahren zur Herstellung von dreidimensionalen Blechstrukturen und deren Halbfabrikaten.This invention relates to three-dimensional sheet metal structures and their semi-finished products, as well as methods for the production of three-dimensional sheet metal structures and their semi-finished products.
Blech ist ein sehr vielseitig verwendbarer Werkstoff, der aufgrund seiner plastischen Verformbarkeit aus einer einfachen flächigen Grundform in komplexe dreidimensionale Blechstrukturen umgeformt werden kann. Solche Bauteile können bei relativ geringem Gewicht eine hohe Steifigkeit und Festigkeit aufweisen, und werden deshalb häufig eingesetzt, wenn das Gewicht ein wichtiger Faktor ist, beispielsweise im Fahrzeugbau und Leichtbau.Sheet metal is a very versatile material that, due to its plastic deformability, can be transformed from a simple planar basic shape into complex three-dimensional sheet metal structures. Such components can have a high rigidity and strength at a relatively low weight and are therefore often used when weight is an important factor, for example in vehicle construction and lightweight construction.
Für die Umformung von flächigen, plastisch verformbaren Werkstoffen wie Blech sind verschiedene Verfahren bekannt, wie beispielsweise das Tiefziehen mit Stempel und Matrize. Für speziellere Formgebungen können andere Verfahren eingesetzt werden, so zum Beispiel Hochdruck-Blechumformung, auch bekannt als Hydroforming, bei der im Vergleich zum herkömmlichen Tiefziehen der Stempel durch ein direkt auf das Werkstück wirkendes Druckmedium ersetzt wird, welches von einer Seite auf das Blech wirkt, und dieses gegen eine die Formgebung bestimmende Matrix drückt. Eine alternative Variante ist das hydromechanische Tiefziehen, bei dem die Matrize durch einen mit Druckmedium gefüllten, druckregulierten Hohlraum ersetzt wird. Das umzuformende Blech schliesst den Hohlraum druckdicht ab. Der von der anderen Seite auf das Blech wirkende Stempel verformt zum einen das Werkstück, und erzeugt zum anderen gleichzeitig aufgrund der Verdrängung des Druckmediums im Hohlraum den notwendigen hydraulischen Druck. Der für die Umformung benötigte Mediendruck hängt unter anderem von der Geometrie des Bauteils, der Blechdicke und dem verwendeten Werkstoff ab, und können von 5 MPa (Aluminiumblech) bis 200 MPa (Edelstahlblech) reichen. Solche Drücke können nur hydraulisch erzeugt werden, und erfordern aufwendige, teure Werkzeuge.For the forming of flat, plastically deformable materials such as sheet metal various methods are known, such as deep drawing with punch and die. Other methods may be used for more specific shapes, such as high pressure sheet metal forming, also known as hydroforming, where, in comparison to conventional deep drawing, the punch is replaced by a pressure medium acting directly on the workpiece and acting on the sheet from one side. and pushes it against a shaping matrix. An alternative variant is hydromechanical deep drawing, in which the die is replaced by a pressure-regulated cavity filled with pressure medium. The reshaping Sheet metal seals the cavity pressure-tight. The punch acting on the sheet from the other side, on the one hand deforms the workpiece, and on the other hand simultaneously generates the necessary hydraulic pressure due to the displacement of the pressure medium in the cavity. The media pressure required for forming depends, inter alia, on the geometry of the component, the sheet thickness and the material used, and can range from 5 MPa (aluminum sheet) to 200 MPa (stainless steel sheet). Such pressures can only be generated hydraulically, and require expensive, expensive tools.
Für die Herstellung von komplexen Hohlstrukturen aus Blech wird das Innen-Hochdruck-Verfahren angewandt, eine Variante der Hochdruck-Blechumformung, bei der das druckbeaufschlagte Medium in einen druckdicht abgeschlossenen Innenraum eines röhrenförmigen Blechrohlings eingebracht wird, das in einem eine äussere Matrize bildenden Werkzeug angeordnet ist. Ein solches Verfahren ist beispielsweise beschrieben in
Den bekannten Verfahren eigen sind die sehr hohen Arbeitsdrücke, welche bis 200 MPa (2000 bar) betragen können. Bei solchen Drücken werden die formgebenden Werkzeuge stark belastet. Deren Anfertigung und betrieb ist zudem aufwendig und teuer, und die Grösse der herstellbaren Bauteile begrenzt.The known methods are the very high working pressures, which can be up to 200 MPa (2000 bar). At such pressures, the forming tools are heavily loaded. Their preparation and operation is also complicated and expensive, and limits the size of the manufacturable components.
Aufgabe der Erfindung ist es, dreidimensionale Blechstrukturen und deren Halbfabrikate, sowie Verfahren zur Herstellung von dreidimensionalen Blechstrukturen und deren Halbfabrikaten zur Verfügung zu stellen, welche die oben erwähnten und andere Nachteile nicht aufweisen. Insbesondere sollen solche Verfahren zeit- und kosteneffizient sein, und ohne teure Werkzeuge auskommen.The object of the invention is to provide three-dimensional sheet metal structures and their semi-finished products, as well as methods for the production of three-dimensional sheet metal structures and their semi-finished products, which do not have the above-mentioned and other disadvantages. In particular, such processes should be time and cost efficient, and do without expensive tools.
Diese und andere Aufgaben werden gelöst durch die erfindungsgemässen Herstellungsverfahren, Halbfabrikate und Blechstrukturen gemäss den unabhängigen Patentansprüchen. Weitere bevorzugte Varianten und Ausführungsformen sind in den abhängigen Ansprüchen gegeben.These and other objects are achieved by the inventive manufacturing method, semi-finished products and sheet metal structures according to the independent claims. Further preferred variants and embodiments are given in the dependent claims.
Nachfolgend wird die Erfindung am Beispiel von Blech beschrieben. Neben Blech kann jedoch die Erfindung auf jedes andere flächige Ausgangsmaterial angewandt werden, welches ein gewisses Mass an Plastizität und Duktilität aufweist. Wenn ein Material für herkömmliche Umformungsverfahren geeignet ist, kann es auch für die erfindungsgemässen Verfahren verwendet werden.The invention will be described using the example of sheet metal. In addition to sheet metal, however, the invention can be applied to any other sheet-like starting material which has a certain degree of plasticity and ductility. If a material is suitable for conventional forming processes, it can also be used for the processes according to the invention.
Beim erfindungsgemässen Verfahren zur Herstellung von dreidimensionalen Blechstrukturen werden zwei oder auch mehr mit einer bestimmten Kontur zugeschnittene Blechelemente bereitgestellt. Diese Rohlinge können direkt vor der Verarbeitung zugeschnitten werden, was für grössere Rohlinge vorteilhaft ist, oder bereits vorab hergestellt worden sein. Die zwei oder mehr Blechelemente werden entlang ihrer Kanten zusammengefügt, so dass sich ein im wesentlichen druckdicht geschlossener Hohlraum bildet. Anschliessend wird dieses Halbfabrikat durch Aufblasen zur dreidimensionalen Blechstruktur umgeformt, das heisst, es wird innerhalb des Hohlraums gegenüber der äusseren Umgebung ein Überdruck erzeugt, beispielsweise durch Einleiten von Druckluft oder Befüllen mit Wasser oder einem anderen hydraulischen Wirkmedium. Im folgenden wird der Begriff Aufblasen jeweils synonym zum Begriff Umformen verwendet. Die Blechrohlinge werden durch den erhöhten Innendruck plastisch verformt und in einem gewissen Mass auch elastisch gedehnt, wobei die Umformung "frei" ist, also nicht durch eine Matrize oder einen Stempel vorgegeben ist. Die Art der Umformung ist durch die Wahl der Konturgebung und topologischen Verbindung der Blechelemente, die spezifischen Eigenschaften des Blechs wie Material, Elastizitätsmodul, Blechdicke, Walzrichtung, sowie die Prozessparameter wie angewandter Arbeitsdruck und Umformzeit bestimmt. Nicht notwendig ist hingegen wie bereits erläutert die Verwendung einer Matrize oder eines anderen formgebenden Werkzeugs.In the method according to the invention for the production of three-dimensional sheet metal structures, two or even more sheet metal elements cut to a specific contour are provided. These blanks can be cut directly before processing, which is advantageous for larger blanks, or have already been prepared in advance. The two or more sheet metal elements are joined together along their edges, so that forms a substantially pressure-tight closed cavity. Subsequently, this semi-finished product is reshaped by inflating the three-dimensional sheet structure, that is, it is generated within the cavity relative to the external environment, an overpressure, for example by introducing compressed air or filling with water or other hydraulic active medium. Hereinafter the term inflation is used synonymously with the term transformation. The sheet metal blanks are plastically deformed by the increased internal pressure and stretched elastically to a certain extent, the deformation is "free", that is not predetermined by a die or a stamp. The type of forming is determined by the choice of contouring and topological connection of the sheet metal elements, the specific properties of the sheet such as material, modulus of elasticity, sheet thickness, rolling direction, as well as the process parameters such as applied working pressure and forming time. It is not necessary, however, as already explained, to use a die or another shaping tool.
Durch geeignete Wahl der Konturen können während der Umformung auch Knick- und Biegebewegungen innerhalb der dreidimensionalen Struktur erzeugt werden, so dass in einem einzigen Schritt Formgebungen der resultierenden Blechstrukturen möglich werden, die mit herkömmlichen Blechumformungsverfahren nicht in einem Arbeitsgang erreichbar sind.By suitable choice of the contours bending and bending movements can be generated within the three-dimensional structure during the forming, so that in a single step shapes of the resulting sheet metal structures are possible, which can not be achieved in a single operation with conventional Blechumformungsverfahren.
Bei grösseren Strukturen mit grossflächigen Bereichen, die nicht der Nähe einer Verbindungskontur liegen, ist in diesen Bereichen die Beeinflussung der Formgebung durch die Konturierung beschränkt. Um dieses Problem zu lösen, werden ein oder mehrere Begrenzungselemente an den Blechelementen angeordnet Die genannten Begrenzungselemente können beispielsweise im wesentlichen eindimensional sein, zum Beispiel Blechstreifen oder Kabel, die zwischen den Blechelementen angeordnet und an geeigneten Stellen mit diesen verbunden werden, so dass beim Aufblasen der Blechstruktur die räumliche Distanz der durch das Begrenzungselement verbundenen Punkte der Blechrohlinge nach oben begrenzt ist. Je nach Wahl des Begrenzungselements, kann die Distanz der entsprechenden Punkte auch fix festgelegt werden, beispielsweise mit steifen Stäben. Ebenso ist es möglich, Begrenzungselemente zu verwenden, die eine zweidimensionale Formgebung aufweisen, die beim Aufblasen der Blechstruktur an einer bestimmten Stelle eine minimale innere Kontur vorgibt. Auch Stege oder andere Strukturen können als Begrenzungselemente auf den Blechelementen angebracht werden, um lokal die mechanische Festigkeit der Blechflächen zu modifizieren, und so die Formgebung beim Aufblasen/Umformen der Blechstruktur zu beeinflussen.For larger structures with large areas, which are not close to a connecting contour, the influence on the shaping is limited by the contouring in these areas. In order to solve this problem, one or more limiting elements are arranged on the sheet metal elements. The said limiting elements may, for example, be substantially one-dimensional, for example sheet metal strips or cables, which are arranged between the sheet metal elements and connected to the latter at suitable locations, so that when inflating Sheet metal structure, the spatial distance of the connected by the limiting element points of the sheet metal blanks is limited upwards. Depending on the choice of the limiting element, the distance of the corresponding points can also be fixed, for example with stiff rods. It is also possible to use boundary elements that are two-dimensional Shaping, which defines a minimum inner contour at a certain point when inflating the sheet metal structure. Also webs or other structures can be attached as limiting elements on the sheet metal elements to locally modify the mechanical strength of the sheet surfaces, and so to influence the shaping during inflation / deformation of the sheet metal structure.
Die Begrenzungselemente können nach der Fertigstellung der dreidimensionalen Blechstruktur auch weitere Aufgaben übernehmen. Beispielsweise können bei erfindungsgemässen Blechstrukturen, die als Fahrzeugtanks dienen sollen, Begrenzungselemente als Lochbleche ausgestaltet werden, die im späteren Betrieb als Schwappbleche dienen. Ebenso können die Begrenzungselemente der mechanischen Stabilisierung dienen, beispielsweise als innere Verstrebungen.The boundary elements can also take on other tasks after the completion of the three-dimensional sheet metal structure. For example, in the case of sheet metal structures according to the invention, which are intended to serve as vehicle tanks, limiting elements can be configured as perforated plates, which serve as slosh plates in later operation. Likewise, the limiting elements of the mechanical stabilization serve, for example as internal struts.
Erfindungsgemässe dreidimensionale Bleckstrukturen können für eine Vielzahl von Verwendungszwecken eingesetzt werden, beispielsweise als Leichtbauelemente für Bauwerke und Fahrzeuge, etc, als Schwimmer, Tanks, Ziergegenstände, Möbel, und vieles mehr.Inventive three-dimensional sheet structures can be used for a variety of uses, such as lightweight construction elements and vehicles, etc, as floats, tanks, ornaments, furniture, and more.
Im folgenden wird die erfindungsgemässe Vorrichtung anhand von Zeichnungen erläutert.
Figur 1- zeigt in einem Querschnitt (a) durch ein Halbfabrikat vor dem Aufbla- sen/Umformen, und (b) die fertige umgeformte Blechstruktur.
Figur 2- zeigt drei Varianten einer Konturgebung für eine erfindungsgemässe Blech- struktur, vor und nach dem Aufblasen/Umformen.
- Figur 3
- zeigt eine Ausführungsform einer erfindungsgemässen Blechstruktur, bei der Blechelemente mit zwei verschiedenen Wanddicken verwendet wurden.
Figur 4- zeigt in (a) drei verschiedene mögliche Ausführungsformen einer erfin- dungsgemässen Blechstruktur, und in (b) ein Detail eines endseitigen Halte- punktes einer solchen Blechstruktur.
- Figur 5
- zeigt im Querschnitt eine mögliche Ausführungsform einer erfindungsge- mässen Bleckstruktur mit einem Begrenzungselement, (a) vor dem Aufbla- sen, (b) im Detail im Bereich des Begrenzungselements, und (c) nach dem Aufblasen.
- Figur 6
- zeigt eine weitere Variante einer erfindungsgemässen Blechstruktur, mit zwei gekreuzten Begrenzungselementen.
- Figur 7
- zeigt im Querschnitt noch eine weitere Variante einer erfindungsgemässen Blechstruktur, (a) vor und (b), (c) nach dem Aufblasen, mit einem Begren- zungselement in der Form eines auf einem der Blechelemente angebrachten Steges.
- Figur 8
- zeigt zwei weitere Ausführungsformen einer erfindungsgemässen Blech- struktur, bei welchen (a) Sicken bzw. (b) Sicken und Knicke in den Blech- elementen als Begrenzungselemente funktionieren.
- Figur 9
- zeigt (a) ein aufgerolltes erfindungsgemässes Halbfabrikat einer Blechstruk- tur, welches (b) durch das Erhöhen des Innendrucks sich selbsttätig ausrollt, um anschliessend in die endgültige dreidimensionale Form der erfindungs- gemässen Blechstruktur ungeformt zu werden.
- Figur 10
- verschiedene Varianten von mehrkammerig ausgestalteten erfindungsge- mässen Blechstrukturen, bei denen Grenzflächen zwischen zwei Kammern auch als Begrenzungselemente dienen, welche die Formgebung der Gesamt- struktur beeinflussen.
- FIG. 1
- shows in a cross section (a) through a semifinished product before inflation / forming, and (b) the finished formed sheet metal structure.
- FIG. 2
- shows three variants of a contouring for an inventive sheet metal structure, before and after inflation / forming.
- FIG. 3
- shows an embodiment of an inventive sheet metal structure, were used in the sheet metal elements with two different wall thicknesses.
- FIG. 4
- shows in (a) three different possible embodiments of a sheet metal structure according to the invention, and in (b) a detail of an end-side holding point of such a sheet metal structure.
- FIG. 5
- shows in cross-section a possible embodiment of a inventive Bleckstruktur with a limiting element, (a) before blowing, (b) in detail in the region of the limiting element, and (c) after inflation.
- FIG. 6
- shows a further variant of an inventive sheet metal structure, with two crossed boundary elements.
- FIG. 7
- shows in cross-section yet another variant of a sheet metal structure according to the invention, (a) before and (b), (c) after inflation, with a boundary element in the form of a web attached to one of the sheet metal elements.
- FIG. 8
- shows two further embodiments of an inventive sheet metal structure, in which (a) beads or (b) beads and kinks in the sheet metal elements function as delimiting elements.
- FIG. 9
- shows (a) a rolled semi-finished product according to the invention of a sheet metal structure, which (b) automatically unrolls by increasing the internal pressure, in order subsequently to be shaped into the final three-dimensional shape of the sheet metal structure according to the invention.
- FIG. 10
- various variants of multi-chamber designed according to the invention sheet metal structures, in which interfaces between two chambers also serve as limiting elements that influence the shape of the overall structure.
Das Grundprinzip der erfindungsgemässen Verfahren sind in
Die Fertigung des Halbfabrikats 1a geschieht vorzugsweise in Linie, dass heisst, die Blechelemente werden aus Rollenblech zugeschnitten und anschliessend direkt entlang den Konturen verschweisst. Entsprechende Anlagen sind dem Fachmann aus der industriellen Praxis bekannt. Bei kleineren Blechelementen 11. 11'kann es auch sinnvoll sein, diese in einem separaten Arbeitsgang herzustellen, und fertig konturiert zur Herstellung des Halbfabrikats bereitzustellen.The production of the
Das Halbfabrikat kann dann direkt zur fertigen dreidimensionalen Blechstruktur umgeformt und weiterverarbeitet werden, oder erst später in einem separaten Schritt. Dazu wird das Halbfabrikat aufgeblasen, das heisst, es wird gegenüber der äusseren Umgebung im Innenraum 14 ein Überdruck erzeugt, so dass die unverbundenen Flächen der Blechelemente 11, 11' auseinander gedrückt werden, und sich die Blechelemente 11, 11' frei zu einer vorbestimmten dreidimensionalen Blechstruktur 1 umformen. Zu diesem Zweck wird Druckluft oder Wasser oder eine andere hydraulische Flüssigkeit druckbeaufschlagt in den Hohlraum 14 eingebracht. Der Überdruck und die Wirkzeit bestimmen sich nach der Konturgebung und der Materialparametern. Nach dem Erreichen des Sollzustands der Form der dreidimensionalen Blechstruktur wird dann der Druck wieder abgesenkt, wobei aufgrund der plastischen Verformung des Blechs die Formgebung stabil bleibt. Eine gewisse reversible elastische Verformung muss dabei bei der Festlegung der Prozessparameter und der Konturgebung berücksichtigt werden. Es kann auch ein erhöhter Innendruck verbleiben, um beispielsweise die Blechstruktur 1 mechanisch zu stabilisieren.The semi-finished product can then be converted directly to the finished three-dimensional sheet metal structure and further processed, or later in a separate step. For this purpose, the semifinished product is inflated, that is, it is compared to the external environment in the interior 14 generates an overpressure, so that the unconnected surfaces of the
Im Gegensatz zu den herkömmlichen Umformungsverfahren ist bei einem erfindungsgemässen Verfahren der notwendige Druck im Innenraum geringer, und beträgt je nach Fall zwischen 50 kPa (0.5 bar) und 1 MPa (10 bar). Dies stellt wesentlich geringere Anforderungen an die technische Infrastruktur. Da die Formgebung ohne Matrizen oder Gegenwerkzeug erfolgt, sind zudem sehr grosse Blechstrukturen fertigbar. Da die Halbfabrikate flach sind, benötigen sie wesentlich weniger Platz als die fertig umgeformten Blechstrukturen. Dies ergibt die logistisch vorteilhafte Möglichkeit, grössere Blechstrukturen, beispielsweise für die Verwendung an Bauwerken, als Halbfabrikat zum Montageort zu transportieren, und dort vor Ort fertig zu stellen. Eine erfindungsgemässe Blechstruktur kann auch Öffnungen aufweisen, beispielsweise in der topologischen Form eines Torus, solange der Innenraum abgeschlossen ist.In contrast to the conventional forming process, the pressure required in the interior is lower in a process according to the invention, and depending on the case is between 50 kPa (0.5 bar) and 1 MPa (10 bar). This places significantly lower demands on the technical infrastructure. Since the shaping takes place without matrices or counter tools, very large sheet metal structures are also manufacturable. Since the semi-finished products are flat, they require much less space than the finished formed sheet metal structures. This results in the logistically advantageous possibility to transport larger sheet metal structures, for example, for use in buildings, as a semi-finished product to the installation site, and to finish there on site. An inventive sheet metal structure may also have openings, for example in the topological shape of a torus, as long as the interior is completed.
Der Vorteil bei der Verwendung von Druckluft als Druckmedium ist die leichte Handhabbarkeit. Hingegen sind Gase bei höheren Drücken aufgrund ihrer Kompressibilität weniger effizient, dass heisst, der notwendige Druck wird weniger schnell erreicht, und es tritt eine Temperaturerhöhung auf, die wiederum wegen der Materialausdehnung einen Einfluss auf die Blechstruktur hat Bei der Verwendung von hydraulischen Flüssigkeiten (Wasser, Öl, Wasser-Öl-Emulsionen) tritt dieses Problem nicht auf, und die Temperatur der Blechstruktur ist über das Druckmedium einstellbar. Hingegen stellt sich hier das Problem, die hydraulische Flüssigkeit anschliessend wieder aus der Blechstruktur zu entfernen, was aufwendiger ist als bei gasförmigen Druckmedien.The advantage of using compressed air as the pressure medium is the ease of handling. On the other hand, gases are less efficient at higher pressures due to their compressibility, that is, the necessary pressure is reached less quickly, and there is a temperature increase, which in turn has an influence on the sheet structure due to the material expansion When using hydraulic fluids (water, Oil, water-oil emulsions) this problem does not occur, and the temperature of the sheet structure is adjustable over the pressure medium. On the other hand, the problem here is to subsequently remove the hydraulic fluid from the sheet metal structure, which is more complicated than with gaseous pressure media.
Anstatt der Verwendung von Druckluft oder pneumatischen Flüssigkeiten können auch andere Methoden verwendet werden, um den Innendruck zu erhöhen. Beispielsweise können chemische Reaktionen angewandt werden, die ein bestimmtes Volumen an Gas produzieren. Auf diese Weise lässt sich zum Beispiel ein vollständig geschlossenes Halbfabrikat realisieren, in dass eine bestimmte Menge an geeigneten chemischen Edukten eingebracht wird. Nach Auslösen der Reaktion, beispielsweise durch eine lokale Erhöhung der Temperatur über einen bestimmten Schwellwert, tritt die Reaktion in Gang, das Gas wird produziert, und bläst die Blechstruktur wie gewünscht auf. Ebenso ist es möglich, für die Innendruckerhöhung ausschäumende Materialien zu verwenden, wie bspw. Polyurethanschaum, Schaumbeton oder Aluminiumschaum, die anschliessend im Hohlraum der Blechstruktur verbleiben.Instead of using compressed air or pneumatic fluids, other methods can be used to increase the internal pressure. For example, chemical reactions can be used that produce a certain volume of gas. In this way, for example, a completely closed semi-finished product can be realized, in which a certain amount of suitable chemical starting materials is introduced. Upon initiation of the reaction, for example by a local increase in temperature above a certain threshold, the reaction starts, the gas is produced, and the sheet structure blows as desired. It is also possible to use foaming materials for the internal pressure increase, such as, for example, polyurethane foam, foam concrete or aluminum foam, which subsequently remain in the cavity of the sheet-metal structure.
Die Formgebung einer erfindungsgemässen Blechstruktur ergibt sich primär aus der Wahl der Konturen, der Materialeigenschaften und der Prozessparameter. Die durch den erhöhten Innendruck erzeugte Kraft wirkt grundsätzlich senkrecht zur Blechoberfläche. Aufgrund der plastischen Verformung kommt es dabei zu einer Verschiebung der Konturen. Beim Ausblasen der Halbfabrikate werden diese also in der Ebene der Konturen schmaler, was bei der Wahl der Konturierung berücksichtigt werden muss, wie in
In
Die für eine bestimmte Form einer dreidimensionalen Blechstruktur benötigten Konturen der Blechelemente und Prozessparameter lassen sich unter Einbezug der Materialparameter rechnerisch bestimmen.
Durch eine geeignete Konturgebung können während der Umformung auch Schwenkbewegungen induziert werden, wobei gewisse Teile der Blechstruktur gegenüber anderen verschwenkt werden. Dazu geeignet sind beispielsweise Einschnürungen in der Kontur. Auf diese Weise lassen sich dreidimensionale Blechstrukturen fertigen, die mit herkömmlichen Blechumformungsverfahren gar nicht herstellbar wären.By means of a suitable contouring, pivoting movements can also be induced during the forming, with certain parts of the sheet metal structure being pivoted relative to others. Suitable for this purpose are, for example, constrictions in the contour. In this way, can produce three-dimensional sheet metal structures that would not be produced with conventional Blechumformungsverfahren.
Bei Blechelementen mit grösseren Flächen kann in einem gewissen Abstand zu den Konturlinien die Möglichkeit der Formbestimmung der Blechstruktur eingeschränkt sein. Dieses Problem wird gelöst durch ein oder mehrere Begrenzungselemente, welche an einem oder mehreren Blechelementen angebracht werden, und die Verformung der Blechelemente bei der Aufblas-Umformung auf die eine oder andere Art begrenzen.For sheet metal elements with larger areas, the possibility of determining the shape of the sheet metal structure may be restricted at a certain distance from the contour lines. This problem is solved by one or more limiting elements which are attached to one or more sheet metal elements, and limit the deformation of the sheet metal elements in one or the other of the inflation molding.
Ein exemplarisches Beispiel für eine erfindungsgemässe Bleckstruktur 1 mit einem Begrenzungselement 2 ist in
Anstatt eines Blechstreifens können für das gezeigte Beispiel eines Begrenzungselements 2 auch Kabel, Ketten oder ähnliches verwendet werden. Ebenso ist es möglich, einen oder beide Anschlusspunkte 21, 21' des Begrenzungselements verschiebbar auszugestalten, eventuell auch mit einem Einrastmechanismus. Dies würde es dann erlauben, ein steifes Begrenzungselement einzusetzen, wie zum Beispiel einen Distanz-Stab, der so nicht nur die maximale Distanz zwischen den Punkten A und B bestimmen würde sondern auch die minimale Distanz, und der so auch zur mechanischen Stabilisierung der erfindungsgemässen Blechstruktur dienen kann. Eine solche Stabilisierung lässt sichauch durch Kreuzen von zwei oder mehr Begrenzungselementen 2, 2' erreichen, wie beispielsweise in
Ein Begrenzungselement 2 kann auch nur die Verformung eines Blechelements 11 begrenzen. So zeigt beispielsweise
Selbstverständlich können auch verschiedene Begrenzungselemente, also beispielsweise Kabel und Stege, miteinander kombiniert werden, um die gewünschte Form der dreidimensionalen Blechstruktur zu erreichen.Of course, various limiting elements, so for example cables and webs, can be combined with each other to achieve the desired shape of the three-dimensional sheet metal structure.
Eine erfindungsgemässe Blechstruktur 1 mit grossem Volumen kann beispielsweise als Tank dienen, beispielsweise für Treibstoff, Heizöl oder Wasser. Ein solcher Tank eignet sich besonders für den Einbau in bestehenden Gebäuden, weil es dort normalerweise nicht mehr möglich ist, einen grossvolumigen starren Tank nachträglich in das Gebäudeinnere zu bringen. Beim Einbau von Wärmepumpen und solarthermischen Anlagen, für die ein Wärmespeichertank benötigt wird, wird darum der Tank vor Ort zusammengeschweisst, oder durch eine Vielzahl kleinerer Tanks ersetzt. Eine erfindungsgemässe Blechstruktur kann nun aber als platzsparendes Halbfabrikat 1a in das Gebäude gebracht, und anschliessend zum fertigen Tank aufgeblasen/umgeformt werden. Es ist auch möglich, das flache Halbfabrikat vor dem Transport noch zusätzlich in geeigneter Weise zusammen zu rollen oder zu falten, um es noch kompakter zu machen. Beim Aufblasen entfaltet sich das Halbfabrikat direkt zur dreidimensionalen Blechstruktur. Da die relativ dünnwandige Blechstruktur sich bei der Verwendung als Tank im befüllten Zustand eventuell verformen könnte, kann die Struktur des Tankes stabilisiert werden, indem beispielsweise nach dem Aufblasen Gurte horizontal oder vertikal um den Umfang der Blechstruktur angelegt werden. Ein einfaches Beispiel eines zusammengerollten Halbfabrikats 1a zeigt
Bei erfindungsgemässen Blechstrukturen, die zur Verwendung als Fahrzeugstanks vorgesehen sind, können zweidimensionale Begrenzungselemente eingesetzt werden, die beispielsweise als Lochbleche ausgestaltet werden können, und so später im Betrieb als Schwappbleche zu dienen. In einer anderen Ausgestaltungsform können erfindungsgemässe Blechstrukturen auch doppelwandig ausgeführt werden, was wiederum für Tanks besonders vorteilhaft ist. Zu diesem Zweck wird werden anstatt zwei vier Blechelemente verschweisst.In the case of sheet metal structures according to the invention, which are intended for use as vehicle tanks, it is possible to use two-dimensional boundary elements which, for example, can be configured as perforated plates and thus serve as slosh plates later in operation. In another embodiment, inventive sheet metal structures can also be designed double-walled, which in turn is particularly advantageous for tanks. For this purpose, instead of two four sheet metal elements are welded.
Weitere Varianten von erfindungsgemässen Blechstrukturen 1 sind in
In zwei anderen Varianten in den
Die erfindungsgemässen Blechstrukturen aus
- 11
- dreidimensionale Blechstrukturthree-dimensional sheet metal structure
- 1a1a
- Halbfabrikatsemi-finished product
- 11-11'''11-11 '' '
- Blechrohling, BlechelementSheet metal blank, sheet metal element
- 1212
- Fügekante, VerbindungsnahtJoining edge, connecting seam
- 1313
- Anschluss für DruckmediumzuleitungConnection for pressure medium supply line
- 1414
- Hohlraumcavity
- 1515
- Zwischenraumgap
- 1616
- Konturcontour
- 2, 2'2, 2 '
- Begrenzungselementlimiting element
- 21,21'21.21 '
- Anschlusspunktconnection point
- 33
- Druckmediumprint media
- A, B, C, DA, B, C, D
- Punkt auf BlechelementPoint on sheet metal element
- L, L'L, L '
- Länge des BlechelementsLength of the sheet metal element
- aa
- Breitewidth
- bb
- Längelength
- II
- Detaildetail
Claims (15)
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EP08007621A EP2110189A1 (en) | 2008-04-18 | 2008-04-18 | Method for dieless forming of sheet metal |
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