EP2170538B1 - Shaping method and especially magnetorheological lubricant and device for use in said method - Google Patents

Shaping method and especially magnetorheological lubricant and device for use in said method Download PDF

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Publication number
EP2170538B1
EP2170538B1 EP08760527A EP08760527A EP2170538B1 EP 2170538 B1 EP2170538 B1 EP 2170538B1 EP 08760527 A EP08760527 A EP 08760527A EP 08760527 A EP08760527 A EP 08760527A EP 2170538 B1 EP2170538 B1 EP 2170538B1
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EP
European Patent Office
Prior art keywords
forming
field
lubricant
viscosity
tool
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Active
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EP08760527A
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German (de)
French (fr)
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EP2170538A1 (en
Inventor
Holger Böse
Piet WÖLCKEN
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Airbus Defence and Space GmbH
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EADS Deutschland GmbH
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Publication of EP2170538A1 publication Critical patent/EP2170538A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/201—Work-pieces; preparation of the work-pieces, e.g. lubricating, coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C9/00—Cooling, heating or lubricating drawing material
    • 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
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/18—Lubricating, e.g. lubricating tool and workpiece simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J3/00—Lubricating during forging or pressing
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M171/00—Lubricating compositions characterised by purely physical criteria, e.g. containing as base-material, thickener or additive, ingredients which are characterised exclusively by their numerically specified physical properties, i.e. containing ingredients which are physically well-defined but for which the chemical nature is either unspecified or only very vaguely indicated
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M171/00—Lubricating compositions characterised by purely physical criteria, e.g. containing as base-material, thickener or additive, ingredients which are characterised exclusively by their numerically specified physical properties, i.e. containing ingredients which are physically well-defined but for which the chemical nature is either unspecified or only very vaguely indicated
    • C10M171/001—Electrorheological fluids; smart fluids
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/44—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of magnetic liquids, e.g. ferrofluids
    • H01F1/447—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of magnetic liquids, e.g. ferrofluids characterised by magnetoviscosity, e.g. magnetorheological, magnetothixotropic, magnetodilatant liquids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S72/00—Metal deforming
    • Y10S72/707—Magnetism

Definitions

  • the invention relates to a molding method in which a material of a workpiece is formed by means of at least one molding tool, wherein between the material and the at least one molding tool, a lubricant is used, as in the JP 01293925 is disclosed, will be discussed in more detail below. Moreover, the invention relates to an apparatus for carrying out such a method.
  • JP 01293925 is disclosed a molding method in which the surface of a molding tool, which is provided for forming a workpiece, is coated with a magnetic fluid which is held by permanent magnets on the surface.
  • the DE 103 17 880 B3 discloses a molding method in which a material of a workpiece is formed by means of at least one molding tool. As a substrate under the material to be deformed a magnetorheological fluid is used, which can form a shape-variable counter-form by attaching a variable magnetic field.
  • EP 0 317 186 A discloses a cooling system for a motor in which two elements rotate against each other. In the space between the two elements, a liquid is introduced whose viscosity can be changed by a magnetic or electric field.
  • the US Pat. No. 6,106,380 describes a method for finishing a workpiece in which a magnetorheological fluid is influenced by a magnetic field so that it abrades the surface of the workpiece.
  • DE 102 48 329 A1 describes a method for forming a component blank by means of a pressurized active medium, wherein the active medium is a magnetorheological or electrorheological medium.
  • WO 03/013759 A1 discloses a method and an apparatus for producing a positive cold-joining, wherein for forming a clamping force, a hold-down is controlled by a liquid whose viscosity is actively influenced, so that the clamping force exerted by the hold-down clamping force can be selectively varied.
  • the object of the invention is to improve a molding method of the type mentioned in such a way that a larger variety of shapes with improved qualities can be achieved.
  • a material of a workpiece is formed by means of at least one molding tool.
  • a lubricant is inserted between the material and the at least one mold whose viscosity is variable by changing a field.
  • the lubricant has, for example, electrorheological and / or magnetorheological properties, i. its viscosity is e.g. changed by the application of an electric or magnetic field.
  • the molding process is a metal forming process wherein the material is a metal.
  • the invention is suitable for cross-platform methods in which the metal is transformed without the supply of additional heat.
  • a metal sheet (30) is reshaped.
  • the molding process is an incremental sheet molding or incremental molding process.
  • a magnetorheological fluid is particularly preferably used.
  • Magnetorheological fluids are known, for example, from “Magnetorheological fluids for adaptive engine mounts", Fraunhofer ISC Annual Report 2004, p. 24 is known for use in adjustable engine mounts for vibration damping of engine vibrations on vehicles.
  • the invention is concerned with a completely different technical field, namely molding methods.
  • the molding method according to the invention is in a preferred embodiment, for example, a sheet metal forming process.
  • the lubricant with field modifiable viscosity is used in a forming process.
  • a method with locally greatly varying coefficients of friction requirements such as, for example, Incremental Sheet Forming (IBF).
  • IBF Incremental Sheet Forming
  • Incremental sheet metal transformations which can be further developed according to the invention, are described, for example, in the publication "3 D-machining: Flexible Forming of Thin Sheet Without Counterform”; Fraunhofer Institute for Production Engineering and Automation - Robot Systems; R + R 05.04 / 10.05, October 2005 as well as in the publication "hammering into the bottomless” in "interactive Fraunhofer IPA", no.
  • variable viscosity can also be used for example for better removal of the lubricant after the molding process, wherein after the forming process, the viscosity is changed by applying or changing a field in order to remove the lubricant better.
  • a lubricant with a viscosity that can be influenced by a field, but especially during the forming process, offers particular advantages.
  • metal forming and in particular in incremental forming processes it is often desirable to locally influence the coefficient of friction in order to optimize the process.
  • a particularly preferred embodiment of the invention is characterized by applying and / or changing an influencing the viscosity of the lubricant electric or magnetic field to the lubricant for influencing the deformation.
  • Field (56) or one of several fields may be generated externally outside of the at least one molding tool (14, 44, 48, 50, 142).
  • the viscosity of the liquid used can now be varied with controllable by the field stiffness.
  • the field can be a single field, for example, a locally differently shaped field, or several locally defined and / or overlapping fields can be used.
  • the field or one of multiple fields may be external to the outside of the at least one Forming tool are generated.
  • one is not limited by the geometry of the molding tool. For example, so superconducting magnets can be used for particularly strong magnetic fields.
  • both electrical and magnetic fields are influenced by metal molds or other metal parts of a forming device.
  • the or at least one of several fields is generated in or on the molds. It is also possible to superimpose an external field with a field generated on the forming tools.
  • further procedures and combinations are conceivable. Also temporally and / or locally variable fields are conceivable.
  • the at least one field is passed in an advantageous embodiment by the at least one mold and / or the material to the lubricant. This is particularly advantageous in metal molds or metals to be formed because the electrical or magnetic properties of the metal materials are useful for the pipe.
  • the spatial distribution and / or the flux density of the field can be controlled by the shaping of the at least one molding tool.
  • the lubricant for use in a molding process for forming a workpiece by means of at least one molding tool is characterized in that it is a liquid having a viscosity variable by application of a field.
  • the viscosity targeted and controllable by applying or Changing a field can be adjusted, for example, locally to change the coefficient of friction in the molding process and / or adjust and / or to facilitate attachment, distribution or removal of the lubricant to or from material or mold.
  • the lubricant is preferably an electrorheological and / or magnetorheological fluid which contains polarizable particles dispersed in a carrier fluid.
  • a carrier fluid By selecting the carrier liquid and the particles, the properties of the lubricant can be adjusted. For example, by selecting carrier liquids of more or less high viscosity and by selecting the particle size or particle shape, the adjustable viscosity range can be selected.
  • the carrier liquid is, for example, a forming oil suitable for use in a metal forming process. Therein are then dispersed by the corresponding field polarizable particles.
  • oils or other lubricating fluids are used with compared to previously used in conventional metal molding process forming oils of lower viscosity as a base.
  • the device according to the invention suitable for carrying out an incremental sheet metal forming process, for forming a material of a workpiece with at least one molding tool using a lubricant is characterized by a field generating device for generating a field influencing the viscosity of an electrorheological and / or magnetorheological lubricant.
  • a magnetorheological fluid - hereinafter referred to as MRF - for forming metals
  • the device preferably has a magnetic field generating device for generating a magnetic field with which the viscosity of the MRF can be adjusted.
  • the apparatus is formed as a sheet metal forming apparatus for cold forming metal sheets, forming tools similar to known corresponding sheet metal forming apparatuses.
  • the molding device is designed for deep drawing a metal sheet.
  • this is a deep-drawing device or IBU device that is designed for forming a metal sheet.
  • IBU device that is designed for forming a metal sheet.
  • all other cold forming processes and at least some hot working processes can benefit from the application of the invention.
  • the invention is also applicable to, for example, extrusion molding and extrusion molding, wire drawing and wire drawing, rolling or pressing processes and devices, and / or forging processes and devices, such as tumble forging.
  • the at least one mold at least one permanent magnet or electromagnet.
  • a field can be designed, formed and / or generated that results in an optimum contact state between tool and workpiece at any given point in the contact zone.
  • a field-variable viscosity liquid is used in the forming method or apparatus in which a material of a workpiece is formed by at least one die.
  • Fig. 1 are possible frictional conditions in a metal forming process in which a metal material 10 of a workpiece 12 is formed by means of a molding tool 14, shown in a so-called Stribeck diagram.
  • the diagram is shown in the left half of the figure.
  • a contact zone 16 between the mold 14 and workpiece 12 shown in different areas of the diagram.
  • a first region A denotes a molding process without lubricant 18.
  • boundary layers 20 of the two friction partners 12, 14 are wetted with lubricant 18.
  • the lubricant 18 settles at low addition first on the friction surfaces and adheres to it. Boundary friction takes place, with friction surfaces rubbing against each other under the adhesion of lubricant.
  • the coefficient of friction ⁇ is slightly lower, ⁇ 1 ⁇ ⁇ ⁇ max , where ⁇ 1 represents a coefficient of friction at the boundary between boundary friction and mixed friction.
  • a third region C is lubricant 18 in spaces 21 between the friction partners 12, 14, but there are still more or fewer contact areas 22 at which the boundary layers 20 still touch.
  • the coefficient of friction ⁇ is again lower, ⁇ 2 ⁇ ⁇ ⁇ l, where ⁇ 2 represents the coefficient of friction at the boundary of the mixed friction to the purely hydrodynamic friction.
  • the film thickness d is so large that there are no more contact areas 22.
  • the coefficient of friction ⁇ can be optimized in the region C of the mixed friction and in particular in the region D of the purely hydrodynamic friction by a viscosity control.
  • MRF magnetorheological fluid
  • An MRF is an intelligent liquid material whose rheological properties can be noticeably, mostly dramatically, and in most cases reversibly controlled by a magnetic field.
  • An MRF is for example in a magnetic field and returns after switching off the magnetic field in the liquid state.
  • MRFs are analogous to electrorheological fluids - ERF - which are useful in an alternative embodiment where it is possible to effectively apply an electric field due to the materials.
  • An MRF is formed by a dispersion of magnetically polarizable particles in a carrier liquid.
  • Fig. 2 to 5 illustrates how a metal sheet 30 by means of one or more molds 14 by a forming process - in Fig. 2 eg a drawing process - is brought into the desired three-dimensional shape.
  • a molding device 40 for carrying out a deep drawing process is shown.
  • the molding device 40 has a punch 42 whose edge regions 44 serve as molding tools 14.
  • the punch 42 is movable between two restraints 46 relative thereto.
  • the restraints 46 have fixed jaws 48 and movable jaws 50, which can be pressed to clamp the metal sheet 30 with a defined force F on the stationary jaws 48.
  • the jaws 48, 50 serve as further molds 14.
  • edges 52 of the fixed jaws 48 are shaped according to the desired shape.
  • a forming oil 54 which should have a certain viscosity ⁇ .
  • the viscosity ⁇ of the forming oil 54 is adjusted via a magnetic field 56 to the requirement, in order to improve the forming process.
  • the magnetic field 56 is generated externally via a magnetic field generating device (not shown in detail), which for example has superconducting magnets, and / or in the forming tools 14, 44, 48, 50 and through the working surfaces of the forming tools 14, 44, 48, 50 and passed through the metal sheet 30.
  • a magnetic field generating device not shown in detail
  • the molding tools 14, 44, 48, 50 electronic magnets 58, for example, electronically controllable electromagnets on.
  • the magnetic field 56 may alter the stiffness of the MRF 60.
  • the magnetic field 56 is adjusted by a controller, not shown, that at clamping surfaces 62 of the jaws 48, 50 a variable over time viscosity and thus a variable over time friction coefficient ⁇ 62 is set to depending on the shape progress of the edge of the metal sheet 30th hold or allow material to follow.
  • a contact surface 64 the magnetic field and thus the viscosity of the MRF 60 are adjusted by the control so that a relatively low friction coefficient ⁇ 64 prevails at the contact surface 64.
  • the magnetic field 56 is adjusted so that a viscosity of the MRF 60 sets, which ensures a high friction coefficient ⁇ 44 .
  • the MRF 60 is tuned by its composition to a desired adjustable viscosity range. For this purpose, the size distribution of the magnetizable particles in the MRF 60 and the carrier liquid are optimized.
  • the carrier liquid the forming oil 54 is used, wherein for this task, in particular a particularly low-viscosity forming oil 54 is selected.
  • a liquid with field controllable viscosity is not so Blechzieh compiler limited, but also applicable to other metalworking methods. It can also be transferred to appropriate forming processes for forming other materials by means of molds that can be influenced by different viscosities of lubricants or release agents used.
  • FIG. 3 Figure 10 shows a molding apparatus 140 suitable for carrying out such an incremental sheet metal forming process and constructed of the basic construction as described in one of the aforementioned references.
  • a mold 142 of the molding apparatus 140 has the electronic magnet 58 similar to that in FIG Fig. 2 shown embodiment.
  • magnetorheological fluid Although the use of a magnetorheological fluid has been described in the aforementioned embodiments, the invention is not limited to the use of magnetorheological fluids.
  • an electrorheological fluid whose viscosity can be changed by applying an electric field.
  • a mold 14, 44, 48, 50, 142 of the described embodiments could be formed as an electrode for applying the electric field.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Power Engineering (AREA)
  • Lubricants (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Forging (AREA)

Abstract

The invention relates to a shaping method wherein a material (10) of a workpiece (12, 30) is shaped using at least one mold (14, 44, 48, 50, 142). In order to allow a wider variety of shapes while enhancing quality, a lubricant (18) is used between the material (10) and the at least one mold (14, 44, 48, 50, 142), the viscosity of said lubricant being variable by applying or varying a field (56).

Description

Die Erfindung betrifft ein Formverfahren, bei dem ein Material eines Werkstückes mittels wenigstens eines Formwerkzeuges umgeformt wird, wobei zwischen dem Material und dem wenigstens einen Formwerkzeug ein Schmiermittel verwendet wird, wie dies in der JP 01293925 offenbart ist, auf die nachfolgend noch näher eingegangen wird. Außerdem betrifft die Erfindung eine Vorrichtung zur Durchführung eines solchen Verfahrens.The invention relates to a molding method in which a material of a workpiece is formed by means of at least one molding tool, wherein between the material and the at least one molding tool, a lubricant is used, as in the JP 01293925 is disclosed, will be discussed in more detail below. Moreover, the invention relates to an apparatus for carrying out such a method.

Ein solches Verfahren, und eine zum Durchführen desselben verwendbare Formvorrichtung sind aus dem Buch "Die Schmierung in der Metallbearbeitung", Theo Mang, ISBN 3-8023-0682 bekannt. Demnach ist es bekannt, bei Metallumformverfahren, wie beispielsweise einem Tiefziehen von Metallblechen, Schmiermittel einzusetzen. Dadurch wird der Reibkoeffizient zwischen dem wenigstens einen Formwerkzeug und dem Material verändert, um das Formverfahren sowie dessen Ergebnis zu beeinflussen.Such a method, and a molding apparatus which can be used for carrying it out, are known from the book "Lubrication in Metal Working", Theo Mang, ISBN 3-8023-0682. Accordingly, it is known to use lubricants in metal forming processes, such as deep drawing metal sheets. Thereby, the friction coefficient between the at least one mold and the material is changed to influence the molding process and its result.

In der JP 01293925 ist ein Formverfahren offenbart, bei dem die Oberfläche eines Formwerkzeuges, dass zum Umformen eines Werkstückes vorgesehen ist, mit einem magnetischen Fluid beschichtet ist, das durch Permanentmagnete an der Oberfläche festgehalten wird.In the JP 01293925 is disclosed a molding method in which the surface of a molding tool, which is provided for forming a workpiece, is coated with a magnetic fluid which is held by permanent magnets on the surface.

Die DE 103 17 880 B3 offenbart ein Formverfahren, bei dem ein Material eines Werkstückes mittels wenigstens eines Formwerkzeuges umgeformt wird. Als Unterlagen unter dem zu verformenden Material wird eine magnetorheologische Flüssigkeit verwendet, die eine formvariable Gegenform durch Anlagen eines variablen magnetischen Feldes bilden kann.The DE 103 17 880 B3 discloses a molding method in which a material of a workpiece is formed by means of at least one molding tool. As a substrate under the material to be deformed a magnetorheological fluid is used, which can form a shape-variable counter-form by attaching a variable magnetic field.

In der EP 0 317 186 A ist ein Kühlsystem für einen Motor offenbart, bei dem zwei Elemente gegeneinander rotieren. In dem Raum zwischen den beiden Elementen ist eine Flüssigkeit eingebracht, deren Viskosität sich durch ein magnetisches oder elektrisches Feld verändern kann.In the EP 0 317 186 A discloses a cooling system for a motor in which two elements rotate against each other. In the space between the two elements, a liquid is introduced whose viscosity can be changed by a magnetic or electric field.

Die US 6 106 380 beschreibt ein Verfahren zum Fertigstellen eines Werkstückes, bei dem eine magnetorheologische Flüssigkeit durch ein Magnetfeld derart beeinflusst wird, dass sie die Oberfläche des Werkstücks abschleift.The US Pat. No. 6,106,380 describes a method for finishing a workpiece in which a magnetorheological fluid is influenced by a magnetic field so that it abrades the surface of the workpiece.

DE 102 48 329 A1 beschreibt ein Verfahren zum Umformen eines Bauteilrohlings mittels eines unter Druck stehenden Wirkmediums, wobei das Wirkmedium ein magnetorheologisches oder elektrorheologisches Medium ist. DE 102 48 329 A1 describes a method for forming a component blank by means of a pressurized active medium, wherein the active medium is a magnetorheological or electrorheological medium.

In WO 03/013759 A1 ist ein Verfahren sowie eine Vorrichtung zur Herstellung einer formschlüssigen Kaltfügeverbindung offenbart, wobei zur Ausbildung einer Klemmkraft ein Niederhalter mittels einer Flüssigkeit ansteuerbar ist, deren Viskosität aktiv beeinflussbar ist, so dass die durch den Niederhalter ausgeübte Klemmkraft gezielt variiert werden kann.In WO 03/013759 A1 discloses a method and an apparatus for producing a positive cold-joining, wherein for forming a clamping force, a hold-down is controlled by a liquid whose viscosity is actively influenced, so that the clamping force exerted by the hold-down clamping force can be selectively varied.

Aufgabe der Erfindung ist es, ein Formverfahren der eingangs genannten Art derart zu verbessern, dass eine größere Formenvielfalt mit verbesserten Qualitäten erreichbar ist.The object of the invention is to improve a molding method of the type mentioned in such a way that a larger variety of shapes with improved qualities can be achieved.

Diese Aufgabe wird durch ein Formverfahren nach Anspruch 1 gelöst.This object is achieved by a molding method according to claim 1.

Eine Vorrichtung zum Durchführen eines solchen Formverfahrens ist Gegenstand des Nebenanspruchs.An apparatus for carrying out such a molding process is the subject of the independent claim.

Vorteilhafte Ausgestaltungen der Erfindung sind Gegenstand der Unteransprüche.Advantageous embodiments of the invention are the subject of the dependent claims.

Bei dem erfindungsgemäßen Formverfahren wird demnach ein Material eines Werkstückes mittels wenigstens eines Formwerkzeuges umgeformt. Dabei wird zwischen dem Material und dem wenigstens einen Formwerkzeug ein Schmiermittel eingefügt, dessen Viskosität durch ein Verändern eines Feldes veränderbar ist.In the molding method according to the invention, therefore, a material of a workpiece is formed by means of at least one molding tool. In this case, a lubricant is inserted between the material and the at least one mold whose viscosity is variable by changing a field.

Das Schmiermittel hat beispielsweise elektrorheologische und/oder magnetorheologische Eigenschaften, d.h. seine Viskosität wird z.B. durch das Anlegen eines elektrischen oder magnetischen Feldes verändert.The lubricant has, for example, electrorheological and / or magnetorheological properties, i. its viscosity is e.g. changed by the application of an electric or magnetic field.

In bevorzugter Ausgestaltung ist das Formverfahren ein Metallumformverfahren, wobei das Material ein Metall ist. Insbesondere ist die Erfindung für Kattformverfahren geeignet, bei denen das Metall ohne Zufuhr von zusätzlicher Wärme umgeformt wird. Ein Metallblech (30) wird umgeformt. Das Formverfahren ist ein Incremental-Sheet-Forming-Verfahren oder Inkrementelles Umformverfahren.In a preferred embodiment, the molding process is a metal forming process wherein the material is a metal. In particular, the invention is suitable for cross-platform methods in which the metal is transformed without the supply of additional heat. A metal sheet (30) is reshaped. The molding process is an incremental sheet molding or incremental molding process.

Als Schmiermittel wird besonders bevorzugt eine magnetorheologische Flüssigkeit (MRF) verwendet.As a lubricant, a magnetorheological fluid (MRF) is particularly preferably used.

Magnetorheologische Flüssigkeiten sind beispielsweise aus "Magnetorheological fluids for adaptive engine mounts", Fraunhofer ISC Annual Report 2004, p. 24 für die Anwendung in anpassbaren Motorlagern zur Schwingungsdämpfung von Motorschwingungen an Fahrzeugen bekannt. Bei der Erfindung geht es aber um ein ganz anderes technisches Gebiet, nämlich um Formverfahren.Magnetorheological fluids are known, for example, from "Magnetorheological fluids for adaptive engine mounts", Fraunhofer ISC Annual Report 2004, p. 24 is known for use in adjustable engine mounts for vibration damping of engine vibrations on vehicles. However, the invention is concerned with a completely different technical field, namely molding methods.

Das erfindungsgemäße Formverfahren ist in einer bevorzugten Ausgestaltung beispielsweise ein Blechumformverfahren. Zum Beispiel wird das Schmiermittel mit durch ein Feld beeinflussbarer Viskosität bei einem Umformverfahren verwendet. Besonders bevorzugt ist ein Verfahren mit lokal stark variierenden Reibzahlanforderungen, wie zum Beispiel eine Inkrementelle Blechumformung (IBU; auch Incremental Sheet Forming, (ISF)). Inkrementelle Blechumformungen, die erfindungsgemäß weitergebildet werden können, werden beispielsweise in der Veröffentlichung "3 D-Bearbeiten: Flexibles Umformen von Feinblech ohne Gegenform"; Fraunhofer-Institut für Produktionstechnik und Automatisierung - Robotersysteme; R+R 05.04/10.05, Oktober 2005 sowie in der Veröffentlichung "Hämmern ins Bodenlose" in "interaktiv- Fraunhofer IPA", Nr. 1.2004, S. 14 und 15 sowie in der DE 102 31 430 A1 , der DE 103 17 880 B3 und der DE 10 2005 024 378 A1 beschrieben. Dabei wird ein Formwerkzeug entlang einer vorgegebenen Bahn über das zu bearbeitende Werkstück gefahren, um so schrittweise Bereiche des Werkstückes bis zur endgültigen Form desselben umzuformen.The molding method according to the invention is in a preferred embodiment, for example, a sheet metal forming process. For example, the lubricant with field modifiable viscosity is used in a forming process. Particular preference is given to a method with locally greatly varying coefficients of friction requirements, such as, for example, Incremental Sheet Forming (IBF). Incremental sheet metal transformations, which can be further developed according to the invention, are described, for example, in the publication "3 D-machining: Flexible Forming of Thin Sheet Without Counterform"; Fraunhofer Institute for Production Engineering and Automation - Robot Systems; R + R 05.04 / 10.05, October 2005 as well as in the publication "hammering into the bottomless" in "interactive Fraunhofer IPA", no. 1.2004, p. 14 and 15 as well as in the DE 102 31 430 A1 , of the DE 103 17 880 B3 and the DE 10 2005 024 378 A1 described. In this case, a mold is moved along a predetermined path over the workpiece to be machined, so as gradually reshape the same to the final shape of the workpiece.

Die Eigenschaften der veränderbaren Viskosität können zum Beispiel auch bereits zum besseren Entfernen des Schmiermittels nach dem Formprozess verwendet werden, wobei nach dem Umformprozess die Viskosität durch Anlegen oder Verändern eines Feldes verändert wird, um das Schmiermittel besser entfernen zu können.The properties of the variable viscosity can also be used for example for better removal of the lubricant after the molding process, wherein after the forming process, the viscosity is changed by applying or changing a field in order to remove the lubricant better.

Ganz besondere Vorteile bietet die Anwendung eines Schmiermittels mit einer durch ein Feld beeinflussbaren Viskosität aber insbesondere während des Umformprozesses. Bei der Metallformung und insbesondere bei inkrementellen Umformprozessen ist es vielfach wünschenswert, lokal den Reibkoeffizienten zu beeinflussen, um den Prozess zu optimieren. In vorteilhafter Ausgestaltung der Erfindung kann nun durch Veränderung der Viskosität des Schmiermittels der Reibkoeffizient zwischen Werkstück und Formwerkzeug gezielt und insbesondere auch lokal verändert werden. Demnach ist eine besonders bevorzugte Ausgestaltung der Erfindung gekennzeichnet durch Anlegen und/oder Verändern eines die Viskosität des Schmiermittels beeinflussenden elektrischen oder magnetischen Feldes auf das Schmiermittel zum Beeinflussen der Umformung. Das Feld (56) oder eines von mehreren Feldern kann extern außerhalb des wenigstens einen Formwerkzeuges (14, 44, 48, 50, 142) erzeugt werden.The use of a lubricant with a viscosity that can be influenced by a field, but especially during the forming process, offers particular advantages. In metal forming and in particular in incremental forming processes, it is often desirable to locally influence the coefficient of friction in order to optimize the process. In an advantageous embodiment of the invention can now by changing the viscosity of the lubricant, the friction coefficient between the workpiece and the mold specifically and in particular locally changed. Accordingly, a particularly preferred embodiment of the invention is characterized by applying and / or changing an influencing the viscosity of the lubricant electric or magnetic field to the lubricant for influencing the deformation. Field (56) or one of several fields may be generated externally outside of the at least one molding tool (14, 44, 48, 50, 142).

Durch Anlegen eines Feldes, wie beispielsweise eines magnetischen Feldes bei Verwendung einer magnetorheologischen Flüssigkeit, kann nun die Viskosität der verwendeten Flüssigkeit mit durch das Feld beeinflussbarer Steifheit verändert werden. Das Feld kann ein einzelnes Feld, beispielsweise ein lokal unterschiedlich ausgeprägtes Feld, sein oder es können mehrere lokal definierte und/oder sich überlagernde Felder eingesetzt werden. Das Feld oder eines von mehreren Feldern können zum Beispiel extern außerhalb des wenigstens einen Formwerkzeuges erzeugt werden. Dadurch ist man nicht durch die Geometrie des Formwerkzeuges beschränkt. Beispielsweise können so auch supraleitende Magnete für besonders starke Magnetfelder eingesetzt werden.By applying a field, such as a magnetic field using a magnetorheological fluid, the viscosity of the liquid used can now be varied with controllable by the field stiffness. The field can be a single field, for example, a locally differently shaped field, or several locally defined and / or overlapping fields can be used. For example, the field or one of multiple fields may be external to the outside of the at least one Forming tool are generated. As a result, one is not limited by the geometry of the molding tool. For example, so superconducting magnets can be used for particularly strong magnetic fields.

Andererseits kann es bei extern erzeugten Feldern schwierig werden, die Feldstärke und Feldorientierung passend auf das Formwerkzeug zu übertragen. Beispielsweise werden sowohl elektrische als auch magnetische Felder durch metallene Formwerkzeuge oder andere Metallteile einer Umformvorrichtung beeinflusst. Bei einer vorteilhaften Ausgestaltung der Erfindung ist daher vorgesehen, dass das oder wenigstens eines von mehreren Feldern in oder an den Formwerkzeugen erzeugt wird. Es kann auch ein externes Feld mit einem an den Formwerkzeugen erzeugten Feld überlagert werden. Selbstverständlich sind weitere Verfahrensweisen und Kombinationen denkbar. Auch zeitlich und/oder örtlich variable Felder sind denkbar.On the other hand, with externally generated fields, it may be difficult to properly match the field strength and field orientation to the mold. For example, both electrical and magnetic fields are influenced by metal molds or other metal parts of a forming device. In an advantageous embodiment of the invention it is therefore provided that the or at least one of several fields is generated in or on the molds. It is also possible to superimpose an external field with a field generated on the forming tools. Of course, further procedures and combinations are conceivable. Also temporally and / or locally variable fields are conceivable.

Das wenigstens eine Feld wird bei einer vorteilhaften Ausgestaltung durch das wenigstens eine Formwerkzeug und/oder das Material zu dem Schmiermittel geleitet. Dies ist besonders bei metallenen Formwerkzeugen oder bei umzuformenden Metallen vorteilhaft, da die elektrischen oder magnetischen Eigenschaften der Metallmaterialien für die Leitung verwendbar sind.The at least one field is passed in an advantageous embodiment by the at least one mold and / or the material to the lubricant. This is particularly advantageous in metal molds or metals to be formed because the electrical or magnetic properties of the metal materials are useful for the pipe.

Zur gezielten Prozesssteuerung ist bevorzugt, dass an unterschiedlichen Orten und/oder zu unterschiedlichen Zeiten unterschiedliche Felder und/oder unterschiedliche Feldstärken und/oder Feldorientierungen angelegt werden.For targeted process control, it is preferred that different fields and / or different field strengths and / or field orientations are applied at different locations and / or at different times.

Die räumliche Verteilung und/oder die Flussdichte des Feldes kann durch die Formgebung des wenigstens einen Formwerkzeuges gesteuert werden.The spatial distribution and / or the flux density of the field can be controlled by the shaping of the at least one molding tool.

Das Schmiermittel zur Verwendung in einem Formverfahren zum Umformen eines Werkstückes mittels wenigstens eines Formwerkzeuges zeichnet sich dadurch aus, dass es eine Flüssigkeit mit einer durch Anlegen eines Feldes veränderbaren Viskosität ist. Dadurch kann während, vor oder nach dem Formprozess die Viskosität gezielt und steuerbar, durch Anlegen oder Verändern eines Feldes, eingestellt werden, beispielsweise um lokal den Reibwert im Formprozess zu verändern und/oder einzustellen und/oder um ein Anbringen, eine Verteilung oder eine Entfernung des Schmiermittels auf bzw. von Material oder Formwerkzeug zu erleichtern.The lubricant for use in a molding process for forming a workpiece by means of at least one molding tool is characterized in that it is a liquid having a viscosity variable by application of a field. Thus, during, before or after the molding process, the viscosity targeted and controllable, by applying or Changing a field can be adjusted, for example, locally to change the coefficient of friction in the molding process and / or adjust and / or to facilitate attachment, distribution or removal of the lubricant to or from material or mold.

Das Schmiermittel ist vorzugsweise eine elektrorheologische und/oder magnetorheologische Flüssigkeit, welche in einer Trägerflüssigkeit dispergierte polarisierbare Partikel enthält. Über die Auswahl der Trägerflüssigkeit und der Partikel können die Eigenschaften des Schmiermittels eingestellt werden. Beispielsweise lässt sich durch Auswahl von Trägerflüssigkeiten mehr oder weniger hoher Viskosität und durch Auswahl der Partikelgröße oder Partikelform der einstellbare Viskositätsbereich auswählen. Die Trägerflüssigkeit ist beispielsweise ein zur Verwendung in einem Metallumformprozess geeignetes Umformöl. Darin werden dann durch das entsprechende Feld polarisierbare Partikel dispergiert. Insbesondere werden hierzu Öle oder sonstige Schmierflüssigkeiten mit im Vergleich zu bisher in herkömmlichen Metallformverfahren verwendeten Umformölen geringerer Viskosität als Basis verwendet.The lubricant is preferably an electrorheological and / or magnetorheological fluid which contains polarizable particles dispersed in a carrier fluid. By selecting the carrier liquid and the particles, the properties of the lubricant can be adjusted. For example, by selecting carrier liquids of more or less high viscosity and by selecting the particle size or particle shape, the adjustable viscosity range can be selected. The carrier liquid is, for example, a forming oil suitable for use in a metal forming process. Therein are then dispersed by the corresponding field polarizable particles. In particular, for this purpose, oils or other lubricating fluids are used with compared to previously used in conventional metal molding process forming oils of lower viscosity as a base.

Die erfindungsgemäße, zum Durchführen eines inkrementellen Blechumformverfahrens geeignete, Vorrichtung zum Umformen eines Materials eines Werkstückes mit wenigstens einem Formwerkzeug unter Verwendung eines Schmiermittels zeichnet sich durch eine Felderzeugungseinrichtung zum Erzeugen eines die Viskosität eines elektrorheologischen und/oder magnetorheologischen Schmiermittels beeinflussenden Feldes aus. Bei der bevorzugten Verwendung einer magnetorheologischen Flüssigkeit - im folgenden kurz MRF genannt - zum Umformen von Metallen hat die Vorrichtung vorzugsweise eine Magnetfelderzeugungseinrichtung zum Erzeugen eines Magnetfeldes, mit dem die Viskosität der MRF eingestellt werden kann.The device according to the invention, suitable for carrying out an incremental sheet metal forming process, for forming a material of a workpiece with at least one molding tool using a lubricant is characterized by a field generating device for generating a field influencing the viscosity of an electrorheological and / or magnetorheological lubricant. In the preferred use of a magnetorheological fluid - hereinafter referred to as MRF - for forming metals, the device preferably has a magnetic field generating device for generating a magnetic field with which the viscosity of the MRF can be adjusted.

Die Vorrichtung ist als Metallblechumformvorrichtung zum Kaltformen von Metallblechen ausgebildet, wobei Formwerkzeuge ähnlich zu bekannten entsprechenden Metallblechumformvorrichtungen ausgebildet sind. Die Formvorrichtung ist zum Tiefziehen eines Metallbleches ausgebildet.The apparatus is formed as a sheet metal forming apparatus for cold forming metal sheets, forming tools similar to known corresponding sheet metal forming apparatuses. The molding device is designed for deep drawing a metal sheet.

Beispielsweise handelt es sich dabei um eine Tiefziehvorrichtung oder IBU-Vorrichtung, die zum Umformen eines Metallbleches ausgebildet ist. Aber auch alle anderen Kaltumformprozesse und zumindest einige Warmumformprozesse können von der Anwendung der Erfindung profitieren. So ist die Erfindung gemäß anderen Ausgestaltungen zum Beispiel auch auf Strangpressverfahren und Strangpressvorrichtungen, Drahtziehverfahren und Drahtziehvorrichtungen, Walz- oder Drückverfahren und -vorrichtungen und/oder auf Schmiedeverfahren und Vorrichtungen, wie zum Beispiel zum Taumelschmieden anwendbar.For example, this is a deep-drawing device or IBU device that is designed for forming a metal sheet. But also all other cold forming processes and at least some hot working processes can benefit from the application of the invention. Thus, according to other embodiments, the invention is also applicable to, for example, extrusion molding and extrusion molding, wire drawing and wire drawing, rolling or pressing processes and devices, and / or forging processes and devices, such as tumble forging.

Anders als bekannte entsprechende Metallbearbeitungsvorrichtungen weist bei einer bevorzugten Ausgestaltung der Erfindung das wenigstens eine Formwerkzeug wenigstens einen Permanentmagnet oder Elektromagnet auf.Unlike known corresponding metalworking devices, in a preferred embodiment of the invention, the at least one mold at least one permanent magnet or electromagnet.

Durch Inkorporieren von elektronischen Magneten in Formwerkzeuge kann ein Feld entworfen, ausgebildet und/oder erzeugt werden, das zu einem optimalen Kontaktzustand zwischen Werkzeug und Werkstück an irgendeinem vorgegebenen Punkt in der Kontaktzone führt.By incorporating electronic magnets into molds, a field can be designed, formed and / or generated that results in an optimum contact state between tool and workpiece at any given point in the contact zone.

Eine Flüssigkeit mit durch ein Feld veränderbarer Viskosität wird in dem Umformverfahren oder der Formvorrichtung, bei welchem bzw. in welcher ein Material eines Werkstücks durch wenigstens ein Formwerkzeug umgeformt wird, verwendet.A field-variable viscosity liquid is used in the forming method or apparatus in which a material of a workpiece is formed by at least one die.

Vorteile der Erfindung und/oder von deren vorteilhaften Ausgestaltungen sind insbesondere:

  • bisher bestehende Grenzen und Limits für das Umformen können signifikant überschritten werden; dies gilt insbesondere für Prozesskräfte (Anpressdruck), Grenzformänderung und Oberflächenqualität;
  • bisher nicht formbare Bauteile können nun geformt werden;
  • gegebenenfalls erleichtertes Entfernen von Schmiermittel;
  • verbesserte Prozesssteuerung oder Prozesskontrolle sowie
  • eine bessere Qualitätssicherung.
Advantages of the invention and / or its advantageous embodiments are in particular:
  • existing limits and limits for forming can be significantly exceeded; this applies in particular to process forces (contact pressure), limit shape change and surface quality;
  • previously immiscible components can now be shaped;
  • possibly facilitated removal of lubricant;
  • improved process control or process control as well
  • a better quality assurance.

Ein Ausführungsbeispiel der Erfindung wird nachfolgend anhand der beigefügten Zeichnung näher erläutert. Darin zeigt:

Fig. 1
ein zu Erläuterungszwecken wiedergegebenes schematisches Diagramm zur Darstellung des Einflusses eines Schmiermittels und insbesondere dessen Viskosität auf Metallblechumformverfahren;
Fig. 2
eine schematische Darstellung einer ersten Ausführungsform einer Formvorrichtung zur Metallbearbeitung am Beispiel einer Tiefziehvorrichtung zum Tiefziehen eines Bleches;
Fig. 3
eine schematische Darstellung einer zweiten Ausführungsform einer Formvorrichtung zur Metallbearbeitung am Beispiel einer Vorrichtung zum inkrementellen Blechumformen;
Fig. 4
ein Detail der Vorrichtung von Fig. 3; und
Fig. 5
eine vergrößerte Darstellung eines mit der Vorrichtung von Fig. 3 gerade zu bearbeitenden Bereichs eines Werkstückes.
An embodiment of the invention will be explained in more detail with reference to the accompanying drawings. It shows:
Fig. 1
an explanatory schematic diagram showing the influence of a lubricant and in particular its viscosity on sheet metal forming process;
Fig. 2
a schematic representation of a first embodiment of a molding apparatus for metalworking on the example of a thermoforming device for deep drawing a sheet;
Fig. 3
a schematic representation of a second embodiment of a shaping device for metal working on the example of an apparatus for incremental sheet metal forming;
Fig. 4
a detail of the device of Fig. 3 ; and
Fig. 5
an enlarged view of one with the device of Fig. 3 straight to be machined area of a workpiece.

In Fig. 1 sind mögliche Reibzustände bei einem Metallumformverfahren, bei dem ein Metallmaterial 10 eines Werkstückes 12 mittels eines Formwerkzeuges 14 umgeformt wird, in einem sogenannten Stribeck-Diagramm dargestellt. Das Diagramm ist in der linken Hälfte der Figur wiedergegeben. In der rechten Hälfte der Fig. 1 ist eine Kontaktzone 16 zwischen Formwerkzeug 14 und Werkstück 12 in verschiedenen Bereichen des Diagramms dargestellt.In Fig. 1 are possible frictional conditions in a metal forming process in which a metal material 10 of a workpiece 12 is formed by means of a molding tool 14, shown in a so-called Stribeck diagram. The diagram is shown in the left half of the figure. In the right half of the Fig. 1 is a contact zone 16 between the mold 14 and workpiece 12 shown in different areas of the diagram.

In dem Stribeck-Diagramm sind verschiedene Filmdicken d eines Schmiermittels 18 sowie die Reibzahl µ in Abhängigkeit von dem Faktor η v/p wiedergegeben, wobei η die Viskosität des Schmiermittels 18, v die Relativgeschwindigkeit der Reibpartner 12, 14 und p der Normaldruck in der Kontaktzone 16 ist.In the Stribeck diagram, different film thickness d of a lubricant 18 and the coefficient of friction μ are represented as a function of the factor η v / p, where η is the viscosity of the lubricant 18, v is the relative velocity of the friction partners 12, 14 and p is the normal pressure in the contact zone 16 is.

Ein erster Bereich A kennzeichnet ein Formverfahren ohne Schmiermittel 18. Es liegt reine Festkörperreibung vor. Die Reibzahl µ ist maximal, µ=µmax· In einem zweiten Bereich B sind Grenzschichten 20 der beiden Reibpartner 12, 14 mit Schmiermittel 18 benetzt. Das Schmiermittel 18 setzt sich bei geringer Zugabe zunächst an den Reiboberflächen an und haftet dort an. Es findet eine Grenzreibung statt, wobei Reiboberflächen unter Adhäsion von Schmiermittel aneinander reiben. Die Reibzahl µ ist etwas geringer, µ1 ≤ µ < µmax, wobei µ1 einen Reibwert an der Grenze zwischen Grenzreibung und Mischreibung darstellt. In einem dritten Bereich C befindet sich Schmiermittel 18 in Räumen 21 zwischen den Reibpartnern 12, 14, wobei es aber noch mehr oder weniger Kontaktbereiche 22 gibt, an denen sich die Grenzschichten 20 noch berühren. Die Reibzahl µ ist wiederum geringer, µ2 ≤ µ < µl, wobei µ2 den Reibwert an der Grenze von der Mischreibung zur rein hydrodynamischen Reibung darstellt. In einem vierten Bereich D ist die Filmdicke d so groß, dass es keine Kontaktbereiche 22 mehr gibt. Überall zwischen den Grenzschichten 20 befindet sich Schmiermittel 18. Es liegt reine hydrodynamische Reibung vor.A first region A denotes a molding process without lubricant 18. There is pure solid state friction. The coefficient of friction μ is maximum, μ = μ max . In a second region B, boundary layers 20 of the two friction partners 12, 14 are wetted with lubricant 18. The lubricant 18 settles at low addition first on the friction surfaces and adheres to it. Boundary friction takes place, with friction surfaces rubbing against each other under the adhesion of lubricant. The coefficient of friction μ is slightly lower, μ 1 ≦ μ <μ max , where μ 1 represents a coefficient of friction at the boundary between boundary friction and mixed friction. In a third region C is lubricant 18 in spaces 21 between the friction partners 12, 14, but there are still more or fewer contact areas 22 at which the boundary layers 20 still touch. The coefficient of friction μ is again lower, μ 2 ≦ μ <μl, where μ 2 represents the coefficient of friction at the boundary of the mixed friction to the purely hydrodynamic friction. In a fourth area D, the film thickness d is so large that there are no more contact areas 22. There is lubricant 18 everywhere between the boundary layers 20. There is pure hydrodynamic friction.

Die Reibzahl µ lässt sich im Bereich C der Mischreibung und insbesondere im Bereich D der rein hydrodynamischen Reibung durch eine Viskositätskontrolle optimieren. Über die Viskosität lässt sich auch die Schubspannung τ in der Kontaktzone 16 einstellen, dabei gilt τ = ηdv/dt, wobei dv/dt die Ableitung von v nach der Zeit ist.The coefficient of friction μ can be optimized in the region C of the mixed friction and in particular in the region D of the purely hydrodynamic friction by a viscosity control. The viscosity can also be used to set the shear stress τ in the contact zone 16, where τ = ηdv / dt, where dv / dt is the derivative of v with respect to time.

Bei der Metallumformung und insbesondere bei inkrementellen UmformProzessen ist es für eine Optimierung des Prozesses erwünscht, die Reibzahl lokal zu beeinflussen, um gezielt das Formgebungsverfahren an einer Stelle zu beeinflussen. Dies kann, wie voranstehend verdeutlicht, durch eine Beeinflussung der Viskosität eines bei der Metallformung eingesetzten Schmiermittels 18 geschehen. Hierzu wird bei den im folgenden näher erläuterten Formverfahren eine Flüssigkeit verwendet, deren Viskosität sich bei Anlegen oder Verändern eines Feldes verändert. In den Ausführungsbeispielen handelt es sich dabei um eine magnetorheologische Flüssigkeit, im folgenden kurz MRF genannt.In metal forming, and especially in incremental forming processes, it is desirable to optimize the process to locally influence the coefficient of friction in order to specifically influence the molding process at one point. As has been clarified above, this can be done by influencing the viscosity of a lubricant 18 used in metal forming. For this purpose, a liquid whose viscosity changes when a field is applied or changed is used in the molding method explained in more detail below. In the exemplary embodiments, this is a magnetorheological fluid, hereinafter referred to as MRF for short.

Eine MRF ist ein intelligentes flüssiges Material, dessen rheologische Eigenschaften merkbar, meist drastisch, und in den meisten Fällen reversibel durch ein Magnetfeld gesteuert werden können. Eine MRF wird zum Beispiel in einem Magnetfeld gelartig und kehrt nach Ausschalten des Magnetfeldes in den flüssigen Zustand zurück. MRF sind analog zu elektrorheologischen Flüssigkeiten - ERF -, die in einer alternativen Ausgestaltung, wo es aufgrund der Materialien möglich ist, wirksam ein elektrisches Feld anzulegen, verwendbar sind. Eine MRF wird durch eine Dispersion von magnetisch polarisierbaren Partikeln in einer Trägerflüssigkeit gebildet.An MRF is an intelligent liquid material whose rheological properties can be noticeably, mostly dramatically, and in most cases reversibly controlled by a magnetic field. An MRF is for example in a magnetic field and returns after switching off the magnetic field in the liquid state. MRFs are analogous to electrorheological fluids - ERF - which are useful in an alternative embodiment where it is possible to effectively apply an electric field due to the materials. An MRF is formed by a dispersion of magnetically polarizable particles in a carrier liquid.

Im folgenden wird anhand der Darstellung in Fig. 2 ein erstes Ausführungsbeispiel für eine Verbesserung einer Blechumformung durch den Einsatz von magnetorheologischen Flüssigkeiten am Beispiel eines Tiefziehverfahrens näher erläutert.The following is based on the illustration in Fig. 2 a first embodiment of an improvement of sheet metal forming by the use of magnetorheological fluids using the example of a deep-drawing process explained in more detail.

In den Fig. 2 bis 5 ist verdeutlicht, wie ein Metallblech 30 mit Hilfe von einem oder mehreren Formwerkzeugen 14 durch einen Umformprozess - in Fig. 2 z.B. ein Ziehprozess - in die gewünschte dreidimensionale Form gebracht wird.In the Fig. 2 to 5 illustrates how a metal sheet 30 by means of one or more molds 14 by a forming process - in Fig. 2 eg a drawing process - is brought into the desired three-dimensional shape.

In der Fig. 2 ist hierzu eine Formvorrichtung 40 zur Durchführung eines Tiefziehverfahrens dargestellt. Die Formvorrichtung 40 weist in dem Beispiel einen Stempel 42 auf, dessen Kantenbereiche 44 als Formwerkzeuge 14 dienen. Hierzu ist der Stempel 42 zwischen zwei Einspannungen 46 relativ zu diesen beweglich. Die Einspannungen 46 weisen feststehende Backen 48 und bewegliche Backen 50 auf, die zum Einspannen des Metallbleches 30 mit definierter Kraft F auf die feststehenden Backen 48 zu pressbar sind. Die Backen 48, 50 dienen als weitere Formwerkzeuge 14. Hierzu sind Kanten 52 der feststehenden Backen 48 entsprechend der gewünschten Formgebung geformt.In the Fig. 2 For this purpose, a molding device 40 for carrying out a deep drawing process is shown. In the example, the molding device 40 has a punch 42 whose edge regions 44 serve as molding tools 14. For this purpose, the punch 42 is movable between two restraints 46 relative thereto. The restraints 46 have fixed jaws 48 and movable jaws 50, which can be pressed to clamp the metal sheet 30 with a defined force F on the stationary jaws 48. The jaws 48, 50 serve as further molds 14. For this purpose, edges 52 of the fixed jaws 48 are shaped according to the desired shape.

Zwischen den Formwerkzeugen 14, 44, 48, 50 und dem Metallblech 30 befindet sich ein Umformöl 54, welches eine bestimmte Viskosität η aufweisen soll.Between the molds 14, 44, 48, 50 and the metal sheet 30 is a forming oil 54, which should have a certain viscosity η.

Durch den Einsatz einer magnetorheologischen Flüssigkeit - MRF - 60 wird die Viskosität η des Umformöls 54 über ein Magnetfeld 56 auf den Bedarfsfall eingestellt, um den Umformprozess zu verbessern.Through the use of a magnetorheological fluid - MRF - 60, the viscosity η of the forming oil 54 is adjusted via a magnetic field 56 to the requirement, in order to improve the forming process.

In dem hier vorgestellten Formverfahren wird das Magnetfeld 56 extern über eine nicht näher dargestellte Magnetfelderzeugungseinrichtung, die zum Beispiel supraleitende Magnete aufweist, und/oder in den Formwerkzeugen 14, 44, 48, 50 erzeugt und durch die Bearbeitungsflächen der Formwerkzeuge 14, 44, 48, 50 und durch das Metallblech 30 geleitet.In the molding method presented here, the magnetic field 56 is generated externally via a magnetic field generating device (not shown in detail), which for example has superconducting magnets, and / or in the forming tools 14, 44, 48, 50 and through the working surfaces of the forming tools 14, 44, 48, 50 and passed through the metal sheet 30.

Hierzu weisen die Formwerkzeuge 14, 44, 48, 50 elektronische Magnete 58, beispielsweise elektronisch steuerbare Elektromagnete, auf. Das Magnetfeld 56 kann die Steifheit der MRF 60 verändern. Durch die Form des entsprechenden Formwerkzeuges 14, 44, 48, 50 kann die räumliche Verteilung und die magnetische Flussdichte des Magnetfeldes 56 vorgegeben werden.For this purpose, the molding tools 14, 44, 48, 50 electronic magnets 58, for example, electronically controllable electromagnets on. The magnetic field 56 may alter the stiffness of the MRF 60. By the shape of the corresponding molding tool 14, 44, 48, 50, the spatial distribution and the magnetic flux density of the magnetic field 56 can be specified.

Das Magnetfeld 56 wird durch eine nicht näher dargestellte Steuerung so eingestellt, dass an Spannflächen 62 der Backen 48, 50 eine über die Zeit variable Viskosität und somit eine über die Zeit variable Reibzahl µ62 eingestellt wird, um je nach Formfortschritt den Rand des Metallbleches 30 festzuhalten oder einen Nachfluss von Material zu ermöglichen. An einer Kontaktfläche 64 wird durch die Steuerung das Magnetfeld und damit die Viskosität der MRF 60 so eingestellt, dass an der Kontaktfläche 64 eine relativ niedrige Reibzahl µ64 herrscht. An den Kantenbereichen 44 des Stempels 42 wird das Magnetfeld 56 so eingestellt, dass sich eine Viskosität der MRF 60 einstellt, die für eine hohe Reibzahl µ44 sorgt.The magnetic field 56 is adjusted by a controller, not shown, that at clamping surfaces 62 of the jaws 48, 50 a variable over time viscosity and thus a variable over time friction coefficient μ 62 is set to depending on the shape progress of the edge of the metal sheet 30th hold or allow material to follow. At a contact surface 64, the magnetic field and thus the viscosity of the MRF 60 are adjusted by the control so that a relatively low friction coefficient μ 64 prevails at the contact surface 64. At the edge regions 44 of the punch 42, the magnetic field 56 is adjusted so that a viscosity of the MRF 60 sets, which ensures a high friction coefficient μ 44 .

Die MRF 60 wird durch ihre Zusammensetzung auf einen gewünschten einstellbaren Viskositätsbereich abgestimmt. Hierfür werden die Größenverteilung der magnetisierbaren Partikel in der MRF 60 sowie die Trägerflüssigkeit optimiert. Als Trägerflüssigkeit wird das Umformöl 54 verwendet, wobei für diese Aufgabe insbesondere ein besonders niederviskoses Umformöl 54 ausgewählt wird.The MRF 60 is tuned by its composition to a desired adjustable viscosity range. For this purpose, the size distribution of the magnetizable particles in the MRF 60 and the carrier liquid are optimized. As the carrier liquid, the forming oil 54 is used, wherein for this task, in particular a particularly low-viscosity forming oil 54 is selected.

Wenngleich das Umformverfahren anhand eines Beispiels eines Blechziehverfahrens dargestellt worden ist, so ist die Anwendung einer Flüssigkeit mit einer durch ein Feld steuerbaren Viskosität nicht auf solche Blechziehverfahren beschränkt, sondern auch auf andere Metallbearbeitungsverfahren anwendbar. Es kann auch auf entsprechende Umformverfahren zum Umformen anderer Werkstoffe mittels Formwerkzeugen übertragen werden, die durch verschiedene Viskositäten von eingesetzten Schmier- oder Trennmitteln beeinflussbar sind.Although the forming process has been illustrated by way of example of a sheet metal drawing process, the use of a liquid with field controllable viscosity is not so Blechziehverfahren limited, but also applicable to other metalworking methods. It can also be transferred to appropriate forming processes for forming other materials by means of molds that can be influenced by different viscosities of lubricants or release agents used.

Besondere Vorteile bietet die Anwendung einer Flüssigkeit mit einer durch ein Feld steuerbaren Viskosität bei einem inkrementellen Umformverfahren, insbesondere bei einem inkrementellen Blechumformverfahren (IBU), wie es beispielsweise in der Veröffentlichung "3 D-Bearbeiten: Flexibles Umformen von Feinblech ohne Gegenform"; Fraunhofer-Institut für Produktionstechnik und Automatisierung - Robotersysteme; R+R 05.04/10.05, Oktober 2005 sowie in der Veröffentlichung "Hämmern ins Bodenlose" in "Interaktiv - Fraunhofer IPA", Nr. 1.2004, S. 14 und 15 oder in der DE 102 31 430 A1 , der DE 103 17 880 B3 oder der DE 10 2005 024 378 A1 beschrieben oder beansprucht wird.Particular advantages are the use of a liquid with a controllable by a field viscosity in an incremental forming process, especially in an incremental Blechumformverfahren (IBU), as described for example in the publication "3 D-editing: Flexible forming of sheet without counter-shape"; Fraunhofer Institute for Production Engineering and Automation - Robot Systems; R + R 05.04 / 10.05, October 2005 as well as in the publication "Hammering into the Bottomless" in "Interaktiv - Fraunhofer IPA", no. 1.2004, p. 14 and 15 or in the DE 102 31 430 A1 , of the DE 103 17 880 B3 or the DE 10 2005 024 378 A1 is described or claimed.

Fig. 3 zeigt eine Formvorrichtung 140, die zum Durchführen eines solchen inkrementellen Blechumformverfahren geeignet ist und vom Grundaufbau wie in einer der zuvor erwähnten Druckschriften beschrieben aufgebaut ist. Für den näheren Aufbau sowie die Funktion solcher Formvorrichtungen 140 wird daher ausdrücklich auf die zuvor erwähnten Druckschriften verwiesen. Anders als bei den bekannten Formvorrichtungen weist jedoch ein Formwerkzeug 142 der Formvorrichtung 140 den elektronischen Magneten 58 ähnlich wie bei dem in Fig. 2 gezeigten Ausführungsbeispiel auf. Fig. 3 Figure 10 shows a molding apparatus 140 suitable for carrying out such an incremental sheet metal forming process and constructed of the basic construction as described in one of the aforementioned references. For the closer structure and the function of such molding devices 140, reference is therefore expressly made to the aforementioned publications. Unlike the known molding apparatus, however, a mold 142 of the molding apparatus 140 has the electronic magnet 58 similar to that in FIG Fig. 2 shown embodiment.

Wie näher in Fig. 4 dargestellt ist, ist zwischen dem Metallblech 30 und dem Formwerkzeug 142 wie bei dem in Fig. 2 erläuterten Beispiel die magnetorheologische Flüssigkeit 60 eingesetzt, deren Viskosität η durch das mittels des Magneten 58 erzeugte Magnetfeld 56 veränderbar ist.How closer in Fig. 4 is between the metal sheet 30 and the mold 142 as in the Fig. 2 explained example, the magnetorheological fluid 60 used whose viscosity η is variable by the magnetic field generated by the magnet 58 56.

Dadurch lassen sich zum Beispiel an verschiedenen Bereichen der Kontaktfläche 64 zwischen Formwerkzeug 142 und Metallblech 30 unterschiedliche Anpressdrücke p1, p2, p3 erzeugen, wie dies in Fig. 5 dargestellt ist. Auf diese Weise erhält man weitere Einflussmöglichkeiten auf die Gestaltung des Metallblechs während den einzelnen Formschritten des sich entlang einer vorgegebenen Bewegungsbahn zum schrittweisen Umformen bewegenden Formwerkzeugs 142.As a result, different contact pressures p 1 , p 2 , p 3 can be generated, for example, at different areas of the contact surface 64 between the mold 142 and the metal sheet 30, as shown in FIG Fig. 5 is shown. To this In this way, further possibilities of influencing the design of the metal sheet during the individual forming steps of the shaping tool 142 moving along a predetermined path of movement for stepwise forming are obtained.

Wenngleich in den zuvor erwähnten Ausführungsbeispielen der Einsatz einer magnetorheologischen Flüssigkeit beschrieben worden ist, so ist die Erfindung nicht auf den Einsatz magnetorheologischer Flüssigkeiten begrenzt. Es könnte beispielsweise auch eine elektrorheologische Flüssigkeit verwendet werden, deren Viskosität durch das Anlegen eines elektrischen Feldes veränderbar ist. Beispielsweise könnte hierzu ein Formwerkzeug 14, 44, 48, 50, 142 der beschriebenen Ausführungsbeispiele als Elektrode zum Anlegen des elektrischen Feldes ausgebildet sein.Although the use of a magnetorheological fluid has been described in the aforementioned embodiments, the invention is not limited to the use of magnetorheological fluids. For example, it would also be possible to use an electrorheological fluid whose viscosity can be changed by applying an electric field. For example, for this purpose, a mold 14, 44, 48, 50, 142 of the described embodiments could be formed as an electrode for applying the electric field.

Bezugzeichenliste:LIST OF REFERENCE NUMBERS

1010
Metallmaterialmetal material
1212
Werkstückworkpiece
1414
Formwerkzeugmold
1616
Kontaktzonecontact zone
1818
Schmiermittellubricant
2020
Grenzschichtenboundary layers
2121
Räume zwischen ReibpartnernSpaces between friction partners
2222
Kontaktbereichcontact area
3030
Metallblech (Werkstück)Sheet metal (workpiece)
4040
Formvorrichtungmolding machine
4242
Stempelstamp
4444
Kantenbereiche (Formwerkzeug)Edge areas (molding tool)
4646
Einspannungclamping
4848
feststehende Backe (Formwerkzeug)fixed jaw (molding tool)
5050
bewegliche Backe (Formwerkzeug)movable jaw (mold)
5252
Kanteedge
5454
Umformölforming oil
5656
Magnetfeldmagnetic field
5858
elektronische Magneteelectronic magnets
6060
magnetorheologische Flüssigkeitmagnetorheological fluid
6262
Spannflächeclamping surface
6464
Kontaktflächecontact area
140140
Formvorrichtungmolding machine
142142
Formwerkzeugmold
µμ
Reibzahlcoefficient of friction
µ62 μ 62
variable Reibzahl an den Spannflächen 62variable friction coefficient on the clamping surfaces 62
µ64 μ 64
niedrige Reibzahl an der Kontaktfläche 64low friction at the contact surface 64th
µ44 μ 44
hohe Reibzahl an den Kantenbereichen 44high friction coefficient at the edge regions 44
ηη
Viskosität des SchmiermittelsViscosity of the lubricant
vv
Relativgeschwindigkeit der ReibpartnerRelative speed of the friction partners
pp
Normaldruck in der KontaktzoneNormal pressure in the contact zone
dd
Filmdicke des SchmiermittelsFilm thickness of the lubricant
AA
erster Bereich - Festkörperreibungfirst area - solid state friction
BB
zweiter Bereich - Grenzreibungsecond area - boundary friction
CC
dritter Bereich - Mischreibungthird range - mixed friction
DD
vierter Bereich - hydrodynamische Reibungfourth range - hydrodynamic friction

Claims (10)

  1. Forming method in which a material (10) of a workpiece (12, 30) is formed using at least one forming tool (14, 44, 48, 50, 142), with
    - the use of a lubricant (18), the viscosity of which can be modified by the variation of a field (56), between the material and the at least one forming tool;
    - the movement of the forming tool (14, 44, 48, 50, 142) for step-by-step forming of the material (10), characterised by
    - the variation of a field (56) during the steps of the forming process by the forming tool (14, 44, 48, 50, 142).
  2. Forming method according to claim 1
    characterised in that
    the material (10) is a metal that is preferably formed without the supply of additional heat.
  3. Forming method according to claim 2
    characterised in that
    it is a deep-drawing, extrusion, wire-drawing, rolling, pressing, forging, or tumble-forging process.
  4. Forming method according to any one of preceding claims characterised by the variation of at least one of the fields (56) that influences the viscosity of the lubricant of at least one part of the lubricant in order to influence the forming or to make the removal of the lubricant after the forming process easier, wherein by varying the field (56) the coefficient of friction of the material (10) is influenced generally and / or locally on the at least one forming tool (14, 44, 48, 50, 142).
  5. Forming method according to claim 4
    characterised in that
    the at least one field (56) is conducted to the lubricant (18) through the at least one forming tool (14, 44, 48, 50, 142) and / or the material (10).
  6. Forming method according to one of the claims 4 or 5
    characterised in that
    at different locations and / or at different times different fields and / or different field strengths can be applied
    wherein
    the spatial distribution and / or the flux density of the field (56) is predetermined by the shape of the at least one forming tool (14, 44, 48, 50, 142).
  7. Forming method according to any one of the preceding claims
    characterised in that
    an electrorheological flux and /or a magnetorheological flux is used.
  8. Forming method according to claim 7 and according to one of the claims 4 to 6
    characterised in that
    an electrical and/or magnetic field (56) is applied.
  9. Forming apparatus (142), suitable for performing an incremental sheet-metal-forming method, for forming a material (10) of a workpiece (12, 30) with at least one forming tool (14) for the step-by-step forming of the material (10), wherein the forming tool (14) is constructed to move along a pre-specified path of movement during the individual steps of the forming process to achieve gradual forming, wherein the forming apparatus (142) is configured as a sheet metal forming device for cold forming of sheet metal,
    characterised by a field generating means (58) to create a variable field which influences the viscosity of an electrorheological and/or magnetorheological lubricant (18, 60), wherein the field generating means (58) is configured to vary the field during the steps of the formation process performed by the forming tool (14) .
  10. Forming apparatus according to claim 9
    characterised in that
    the at least one forming tool (14) is provided with at least one permanent magnet or electro-magnet (58) and / or that the at least one forming tool (14) has at least one electrode device for generating an electric field.
EP08760527A 2007-06-08 2008-06-04 Shaping method and especially magnetorheological lubricant and device for use in said method Active EP2170538B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102007026592A DE102007026592B4 (en) 2007-06-08 2007-06-08 Forming method and in particular magnetorheological lubricant and apparatus therefor
PCT/EP2008/056948 WO2008148826A1 (en) 2007-06-08 2008-06-04 Shaping method and especially magnetorheological lubricant and device for use in said method

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EP2170538A1 EP2170538A1 (en) 2010-04-07
EP2170538B1 true EP2170538B1 (en) 2012-08-15

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KR20220144861A (en) * 2020-03-23 2022-10-27 노벨리스 인크. Devices and methods configured to manipulate friction between a workpiece and a deep drawing tool in a deep drawing process

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US8959968B2 (en) 2015-02-24
DE102007026592B4 (en) 2009-06-04
EP2170538A1 (en) 2010-04-07
US20110113845A1 (en) 2011-05-19
DE102007026592A1 (en) 2008-12-11
US20150183016A1 (en) 2015-07-02
WO2008148826A1 (en) 2008-12-11

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