EP2355942B1 - Method for forming hollow profiles - Google Patents

Method for forming hollow profiles Download PDF

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Publication number
EP2355942B1
EP2355942B1 EP09736120A EP09736120A EP2355942B1 EP 2355942 B1 EP2355942 B1 EP 2355942B1 EP 09736120 A EP09736120 A EP 09736120A EP 09736120 A EP09736120 A EP 09736120A EP 2355942 B1 EP2355942 B1 EP 2355942B1
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EP
European Patent Office
Prior art keywords
hollow profile
insert
forming
hollow
forming device
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP09736120A
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German (de)
French (fr)
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EP2355942A1 (en
Inventor
Hartmut RÜGGEBERG
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Modellbau Hartmut Rueggeberg
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Modellbau Hartmut Rueggeberg
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Publication of EP2355942A1 publication Critical patent/EP2355942A1/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
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/025—Stamping using rigid devices or tools for tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/10—Stamping using yieldable or resilient pads
    • B21D22/105—Stamping using yieldable or resilient pads of tubular products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting

Definitions

  • the invention relates to a method for forming hollow sections having at least one opening, wherein in the hollow profile, a fixed insert is placed and the hollow profile is applied externally by the action of a forming device with at least one forming force to achieve a hollow profile end shape and reshaped.
  • Hollow sections per se, ie structural elements with a closed, non-massive cross section, has long been known and generally well controlled, for example by extrusion. Hollow sections have - depending on the precise design - a very good ratio between the achieved stiffness of the hollow body, in particular bending and torsional stiffness, and the amount of material used.
  • hollow sections with a constant over the longitudinal extent of the profile cross-section are relatively easy to produce, however, often, for example, in the body structure, form requirements made that make a far-reaching transformation of the hollow section required.
  • Hollow profiles with constant cross-section, with single or multi-chamber cross-sections require over the deformation of solid bodies of a special, more complex treatment, since in the external action of a forming force on the hollow profile there is a risk of buckling and cracking.
  • the hollow profiles often do not accept the desired contour of the tools of the forming in the molding process, on the contrary, even significant deviations from the target contour remain, which is due to constriction and different compression and elongation of the hollow profile material.
  • Object of the present invention is to avoid the drawbacks in known methods for forming hollow sections - at least partially - to provide, in particular a method that allows deformation of hollow sections with high dimensional accuracy, in particular without deposits within the reshaped hollow profile remain.
  • the indicated object is achieved according to the invention first and essentially in the subject method in that the insert is transferred after and / or upon achievement of the hollow profile end shape at least partially in a liquid and / or gaseous state and substantially completely from the hollow profile Will get removed.
  • the insert liquefies after or during the transformation - which also includes a resolution - or is gasified, it is usually readily removable from the formed hollow section and can - depending on the material used - be reused or recycled. If it is mentioned that the insert located in the liquid and / or gaseous state "substantially completely" is removed from the hollow profile, then it is meant that at least a significant proportion of the deposit material is removed from the hollow profile, preferably more than 80%, more preferably more than 90%, most preferably more than 99% of the insert material originally used. Hollow sections frequently have openings at their ends even after a forming process, from which openings the fluid and / or gaseous state can flow out or flow out. If, after the forming of the hollow profile, such an opening is no longer present, in a preferred embodiment of the invention, an opening is introduced into the hollow profile to remove the transferred into a liquid and / or gaseous state deposit.
  • the insert is converted into a liquid and / or gaseous state by the insert is heated directly or indirectly via the hollow profile.
  • An immediate heating of the insert can for example be ensured by the fact that the insert also a heater - for example in the form of a heating wire - introduced into the hollow section and placed there, the heater is activated to liquefy the insert in retrospect.
  • the heating device can either be pulled out of the hollow profile or remain in the hollow profile if the hollow profile has been over-embossed for a distance.
  • the indirect heating of the insert over the hollow profile is possible, for example, by the use of thermal radiation or in that the hollow profile is exposed to a heat bath.
  • Materials with a lower melting temperature are advantageous in that less energy has to be expended in order to remove them from the hollow profile after the forming process, therefore it is also preferable to use material which a melting temperature more than 60 ° C, more preferably greater than or equal to 40 ° C. If the manufacturing environment allows it, a melting temperature of only greater than 30 ° C. may also be advantageous. Although, in principle, materials can be used whose melting temperatures are below the working temperature, but these are inevitably expensive to handle, since they are in other temperature ranges -. B. climate chamber - must be provided and processed quickly to prevent premature liquefaction.
  • wax or a wax-like substance is used as the material for the insert, "wax-like substance” referring in particular to the mechanical properties of wax (viscosity, hardness, toughness), not to the optical properties.
  • Waxes have the property that they are plastically deformable under normal conditions - ie under normal atmospheric pressure at about 20 ° C - without cracking or crumbling, but are still relatively dimensionally stable
  • most waxes are free of pollutants and therefore manageable even in direct contact with wax, which also has a very significant technical advantage, since it can be used to seal off Surfaces and thus used for corrosion protection Especially in the automotive industry, cavities, in particular cavities in hollow profiles, are sealed by wax for decades.
  • the opening of the hollow profile - or the openings - is sealed after introduction of the insert, in particular by embossing and / or by applying or introducing a stamp, for example a stamp of the forming device.
  • a stamp for example a stamp of the forming device.
  • the volume of the insert is such that it corresponds to the volume of the hollow profile upon reaching the hollow profile end shape.
  • the insert acts in the hollow profile not only as a counter-support based on a pure reaction force, but there are during forming areas of the hollow profile in which due to the hollow profile internal pressure exerted a resultant, outwardly directed force on the wall of the hollow profile becomes. Overall, this leads to a much better dimensional accuracy of the resulting formed hollow profile than is the case with hollow sections, which have been produced without such an insert - in particular wax-like insert.
  • Another advantage of the method according to the invention is therefore that even - assuming the choice of a suitable material for the deposit, such.
  • B. wax - a reshaping of the hollow profile from the inside to the outside with conventional forming devices is possible without having to resort to expensive devices, as used for example in the hydroforming.
  • a further advantageous embodiment of the method is that the insert is placed in the hollow profile by the material in the liquid state of the insert is filled in the hollow profile and the material of the insert is cooled to solidification in the insert.
  • FIG. 1 and 2 a method for forming hollow sections 1 is shown with at least one opening 2, the Fig. 3 and 4 show process products, hollow sections 1 "in hollow profile final form.
  • FIG. 1 shows in an overview, the time course of the actual process can not readily recognize the necessary for carrying out the process elements, namely a fixed insert 3, - present three fixed deposits 3, one insert for each of the three chambers - and a forming device 4a, 4b, wherein the hollow profile Outside by the action of the forming device 4a, 4b applied with a forming force to achieve a Hohlprofilendform and reshaped.
  • FIG. 1 the different deformation states of the hollow profile 1 are shown, wherein the unprocessed hollow profile 1 to the hollow profile 1 'closed by sealing points 5, from which finally the hollow profile 1 "in hollow profile final form 4b of the shaping device 4a, 4b are moved toward one another under the action of force and reshape the inserted hollow profile 1.
  • the upper tool 4a and the lower tool 4b accordingly have the negative form of the desired hollow profile shape, which should come as close as possible to the hollow profile end shape characterized in that the insert 3 is transferred after and / or upon reaching the Hohlprofilendform the hollow section 1 in a liquid and / or gaseous state and substantially completely removed from the hollow profile 1, which is not explicitly illustrated, but readily understandable ,
  • the insert 3 is converted into a liquid state by the insert 3 is indirectly heated via the hollow profile 1, namely, as in Fig. 2g indicated, is exposed to a stream of hot air.
  • the indirect heating of the insert 3 via the hollow profile 1 is particularly suitable when the hollow profile 1 consists of a good thermal conductivity material.
  • the hollow profile 1 consists of an aluminum alloy, which is highly thermally conductive. This is advantageous in this case, because automatically first the areas of the insert 3 are heated and liquefied, which are responsible for the fact that the insert 3 in the reshaped hollow section 1 "adheres.
  • the deformed metallic hollow profile 1 is inductively heated
  • the deformed hollow profile 1 is used for the heat treatment hung so that the insert automatically releases by gravity from the hollow profile, as soon as the edge areas have been liquefied enough.
  • 3 wax is used as the material for the insert, which has a melting point at about 40 ° C.
  • the working temperature at which the process described here is carried out is usually between 18 ° C and 25 ° C, a temperature range at which ordinary wax is readily plastically deformable without cracking or breaking.
  • Fig. 2 a nearly complete process flow is shown.
  • the insert 3 is placed in the hollow profile 1; the insert is already fixed during the placement.
  • the insert or the liquefied material of the insert is introduced into the reshaped hollow profile and cooled only in the hollow section so far that the material of the insert 3 solidifies into a solid insert 3.
  • Fig. 2b It is shown that the openings 2 of the hollow profile 1 are sealed after introduction of the insert 3, namely by embossing with stamping dies 6.
  • the sealing point 5 is located adjacent to the insert 3 in the hollow section 1 or the insert 3 is already through the Embossing compacted at the sealing points 5 in the hollow section 1.
  • the cavity of the hollow profile 1 is almost completely filled with the insert 3.
  • the volume of the insert 3 corresponds to the volume of the hollow profile 1 "upon reaching the hollow profile end shape., That means that at the completion of the forming process, the largest internal pressure is generated Volume of the hollow section 1 corresponds, the greatest possible conversion from the inside to the outside can be achieved, since practically at the beginning of the forming process, a considerable hollow profile internal pressure is generated Fig. 2g It can be seen that the end portions 7 of the deformed hollow profile 1 "are separated so that the subsequently liquefied insert 3 can flow out of the formed hollow profile 1". In other, not shown embodiments, smaller openings in the formed hollow section 1 "are introduced to remove the converted into a liquid state insert 3 can.
  • Fig. 3 and 4 are compared with the forming results which can be achieved with a conventional non-insert method ( Fig. 3 ) and which can be achieved with the method according to the invention - here with a wax-like insert 3.
  • Fig. 3 is good to realize that without the use of an insert no hollow profile internal pressure can be generated, which leads to an unsatisfactory shape, since only embossing contours can me poorly profiled transitions can be achieved; Bulges can not be generated at all, although the forming device provides the necessary space for it.

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

Description

Die Erfindung betrifft ein Verfahren zur Umformung von Hohlprofilen mit wenigstens einer Öffnung, wobei in dem Hohlprofil eine feste Einlage plaziert wird und das Hohlprofil außenseitig durch Einwirken einer Umformvorrichtung mit wenigstens einer Umformkraft zur Erzielung einer Hohlprofil-Endform beaufschlagt und umgeformt wird.The invention relates to a method for forming hollow sections having at least one opening, wherein in the hollow profile, a fixed insert is placed and the hollow profile is applied externally by the action of a forming device with at least one forming force to achieve a hollow profile end shape and reshaped.

Die Herstellung von Hohlprofilen an sich, also von Strukturelementen mit einem geschlossenen, nicht massiven Querschnitt, ist seit langem bekannt und in der Regel gut beherrschbar, beispielsweise durch Strangpressen. Hohlprofile weisen - je nach genauer Ausgestaltung - ein ausgesprochen gutes Verhältnis auf zwischen der erzielten Steifigkeit des Hohlkörpers, insbesondere Biege- und Torsionssteifigkeit, und der eingesetzten Materialmenge.The production of hollow sections per se, ie structural elements with a closed, non-massive cross section, has long been known and generally well controlled, for example by extrusion. Hollow sections have - depending on the precise design - a very good ratio between the achieved stiffness of the hollow body, in particular bending and torsional stiffness, and the amount of material used.

Hohlprofile mit einem über die Längserstreckung des Profils gleichbleibenden Querschnitt sind zwar vergleichsweise einfach herstellbar, jedoch werden häufig, beispielsweise im Karosseriestrukturbau, Formanforderungen gestellt, die eine weitreichende Umformung des Hohlprofils erforderlich machen. Hohlprofile mit gleichbleibendem Querschnitt, mit Ein- oder Mehrkammerquerschnitten, bedürfen jedoch gegenüber der Umformung von massiven Körpern einer besonderen, aufwendigeren Behandlung, da bei der außenseitigen Einwirkung einer Umformkraft auf das Hohlprofil die Gefahr des Knickens und der Rißbildung besteht. Ferner ist bei einer solchen Umformung von Hohlprofilen problematisch, daß die Hohlprofile beim Unformprozeß häufig nicht die Sollkontur der Werkzeuge der Umformvorrichtung annehmen, ganz im Gegenteil sogar erhebliche Abweichungen von der Sollkontur bestehen bleiben, was bedingt ist durch Einschnürung und unterschiedliche Stauchung sowie Dehnung des Hohlprofil-Materials.Although hollow sections with a constant over the longitudinal extent of the profile cross-section are relatively easy to produce, however, often, for example, in the body structure, form requirements made that make a far-reaching transformation of the hollow section required. Hollow profiles with constant cross-section, with single or multi-chamber cross-sections, however, require over the deformation of solid bodies of a special, more complex treatment, since in the external action of a forming force on the hollow profile there is a risk of buckling and cracking. Furthermore, in such a deformation of hollow profiles is problematic that the hollow profiles often do not accept the desired contour of the tools of the forming in the molding process, on the contrary, even significant deviations from the target contour remain, which is due to constriction and different compression and elongation of the hollow profile material.

Im Stand der Technik ist bereits erkannt worden, daß viele dieser Probleme - jedenfalls auch - auf einen fehlenden Gegendruck im Inneren des Hohlprofils zurückgehen. Es ist daher bekannt, eine feste Einlage in dem umzuformenden Hohlprofil an geeigneter Stelle zu plazieren, die bei Umformung des Hohlprofils einen geeigneten Gegendruck aufbringt und das Hohlprofil von innen her abstützt, wodurch die Gefahr der Zerstörung des Hohlprofils durch - lokales - Knicken oder Einreißen gemildert wird. Die feste Einlage wird mit dem Hohlprofil - in unterschiedlichem Maße - umgeformt und muß häufig in dem umgeformten Hohlprofil verbleiben, was in der Regel jedoch zu vermeiden ist, da die Einlage ihren Zweck nach der Umformung erfüllt hat, die Einlage das Gewicht des Hohlprofils erhöht und üblicherweise nicht zur Verbesserung der Steifigkeit des Hohlprofils beiträgt.It has already been recognized in the prior art that many of these problems - at least also - are due to a lack of back pressure inside the hollow profile. It is therefore known to place a fixed insert in the reshaped hollow profile at a suitable location, which applies a suitable back pressure during deformation of the hollow profile and the hollow profile of supported inside, whereby the risk of destruction of the hollow profile by - local - kinking or tearing is mitigated. The fixed insert is with the hollow profile - to varying degrees - reshaped and must often remain in the formed hollow profile, which is to be avoided, however, as a rule, since the insert has fulfilled its purpose after forming, the insert increases the weight of the hollow profile and usually does not contribute to the improvement of the stiffness of the hollow profile.

Aus dem Stand der Technik ist auch das Verfahren der Innenhochdruckumformung (IHU) bekannt, bei dem ein Materialfluß von innen nach außen dadurch erzielt wird, daß das Hohlprofil mit einem flüssigen Medium gefüllt und das Medium unter hohen Druck gesetzt wird, der die Wandung des Hohlprofils nach außen in die Gegenhalter der Umformvorrichtung drückt. Mit dem Verfahren lassen sich zwar sehr gute Umformergebnisse erzielen, jedoch ist die Innenhochdruckumformung mit einem sehr großen gerätetechnischen Aufwand verbunden und daher kostspielig in der Anwendung.From the prior art, the method of hydroforming (IHU) is known in which a flow of material from the inside to the outside is achieved by filling the hollow section with a liquid medium and the medium is placed under high pressure, the wall of the hollow section pressed outwards into the counter-holder of the forming device. Although very good forming results can be achieved with the method, the hydroforming is associated with a very large expenditure on equipment and therefore costly to use.

Aufgabe der vorliegenden Erfindung ist es, die aufgezeigten Nachteile bei bekannten Verfahren zur Umformung von Hohlprofilen - zumindest teilweise - zu vermeiden, insbesondere ein Verfahren anzugeben, das eine Umformung von Hohlprofilen mit hoher Formtreue gestattet, insbesondere ohne daß Einlagen innerhalb des umgeformten Hohlprofils verbleiben.Object of the present invention is to avoid the drawbacks in known methods for forming hollow sections - at least partially - to provide, in particular a method that allows deformation of hollow sections with high dimensional accuracy, in particular without deposits within the reshaped hollow profile remain.

Die aufgezeigte Aufgabe ist erfindungsgemäß zunächst und im wesentlichen bei dem in Rede stehenden Verfahren dadurch gelöst, daß die Einlage nach und/oder bei Erzielen der Hohlprofil-Endform zumindest teilweise in einen flüssigen und/oder gasförmigen Zustand überführt wird und im wesentlichen vollständig aus dem Hohlprofil entfernt wird.The indicated object is achieved according to the invention first and essentially in the subject method in that the insert is transferred after and / or upon achievement of the hollow profile end shape at least partially in a liquid and / or gaseous state and substantially completely from the hollow profile Will get removed.

Dadurch, daß die Einlage nach oder auch während der Umformung verflüssigt - das umfaßt auch eine Auflösung - oder vergast wird, ist sie in der Regel ohne weiteres aus dem umgeformten Hohlprofil entfernbar und kann - je nach verwendetem Material - wieder verwendet oder recycelt werden. Wenn davon die Rede ist, daß die im flüssigen und/oder gasförmigen Zustand befindliche Einlage "im wesentlichen vollständig" aus dem Hohlprofil entfernt wird, dann ist damit gemeint, daß jedenfalls ein erheblicher Anteil des Einlagenmaterials aus dem Hohlprofil entfernt wird, vorzugsweise mehr als 80 %, besonders bevorzugt mehr als 90 %, ganz besonders bevorzugt mehr als 99 % des ursprünglich eingesetzten Einlagenmaterials. Hohlprofile weisen häufig auch nach einem Umformvorgang an ihren Enden Öffnungen auf, aus denen die im flüssigen und/oder gasförmigen Zustand befindliche Einlage ausfließen bzw. ausströmen kann. Wenn nach der Umformung des Hohlprofils eine solche Öffnung nicht mehr vorhanden ist, wird bei einer bevorzugten Ausgestaltung der Erfindung eine Öffnung in das Hohlprofil eingebracht zur Entfernung der in einen flüssigen und/oder gasförmigen Zustand überführten Einlage.The fact that the insert liquefies after or during the transformation - which also includes a resolution - or is gasified, it is usually readily removable from the formed hollow section and can - depending on the material used - be reused or recycled. If it is mentioned that the insert located in the liquid and / or gaseous state "substantially completely" is removed from the hollow profile, then it is meant that at least a significant proportion of the deposit material is removed from the hollow profile, preferably more than 80%, more preferably more than 90%, most preferably more than 99% of the insert material originally used. Hollow sections frequently have openings at their ends even after a forming process, from which openings the fluid and / or gaseous state can flow out or flow out. If, after the forming of the hollow profile, such an opening is no longer present, in a preferred embodiment of the invention, an opening is introduced into the hollow profile to remove the transferred into a liquid and / or gaseous state deposit.

Gemäß einer besonders bevorzugten Ausgestaltung der Erfindung wird die Einlage in einen flüssigen und/oder gasförmigen Zustand überführt, indem die Einlage unmittelbar oder mittelbar über das Hohlprofil erhitzt wird. Eine unmittelbare Erhitzung der Einlage kann beispielsweise dadurch gewährleistet werden, daß mit der Einlage auch eine Heizvorrichtung - beispielsweise in Form eines Heizdrahtes - in das Hohlprofil eingebracht und dort plaziert wird, wobei die Heizvorrichtung zur Verflüssigung der Einlage im Nachhinein aktiviert wird. Die Heizvorrichtung kann nach der Verflüssigung oder Vergasung der Einlage entweder aus dem Hohlprofil herausgezogen werden oder auch in dem Hohlprofil verbleiben, wenn das Hohlprofil für eine Entfernung zu stark verprägt worden ist. Die mittelbare Erwärmung der Einlage über das Hohlprofil ist beispielsweise durch Einsatz von Wärmestrahlung möglich oder dadurch, daß das Hohlprofil einem Wärmebad ausgesetzt wird.According to a particularly preferred embodiment of the invention, the insert is converted into a liquid and / or gaseous state by the insert is heated directly or indirectly via the hollow profile. An immediate heating of the insert can for example be ensured by the fact that the insert also a heater - for example in the form of a heating wire - introduced into the hollow section and placed there, the heater is activated to liquefy the insert in retrospect. After the liquefaction or gasification of the insert, the heating device can either be pulled out of the hollow profile or remain in the hollow profile if the hollow profile has been over-embossed for a distance. The indirect heating of the insert over the hollow profile is possible, for example, by the use of thermal radiation or in that the hollow profile is exposed to a heat bath.

Allgemein ist es vorteilhaft, für die Einlage ein Material zu verwenden, das unter den gegebenen Einsatzbedingungen - Arbeitstemperatur beim Umformvorgang - fest ist. Unter "normalen" Arbeitsbedingungen, also bei einem Luftdruck von etwa einem bar und bei einer Umgebungstemperatur von etwa 21° C, hat es sich gemäß einer bevorzugten Ausgestaltung des Verfahrens als vorteilhaft herausgestellt, wenn für die Einlage ein Material verwendet werden, das eine Schmelztemperatur von mehr als 80° C aufweist; ein solches Material ist auch bei vielen in Folge der Umformarbeit sich einstellenden Temperaturen noch fest und formstabil. Materialien mit einer geringeren Schmelztemperatur sind aber dahingehend vorteilhaft, daß weniger Energie aufgewendet werden muß, um sie nach dem Umformvorgang aus dem Hohlprofil zu entfernen, deshalb wird vorzugsweise auch Material verwendet, das eine Schmelztemperatur mehr als 60° C, besonders bevorzugt größer oder gleich 40° C aufweist. Wenn die Fertigungsumgebung es erlaubt, kann auch eine Schmelztemperatur von nur größer 30° C vorteilhaft sein. Zwar können grundsätzlich auch Materialien verwendet werden, deren Schmelztemperaturen unterhalb der Arbeitstemperatur liegen, jedoch sind diese zwangsläufig aufwendig in der Handhabung, da sie in anderen Temperaturbereichen - z. B. Klimakammer - bereitgestellt werden und schnell verarbeitet werden müssen, um vorzeitige Verflüssigung zu verhindern.In general, it is advantageous to use a material for the insert, which is fixed under the given conditions of use - working temperature during the forming process. Under "normal" working conditions, ie at an air pressure of about one bar and at an ambient temperature of about 21 ° C, it has been found according to a preferred embodiment of the method to be advantageous if the material used for the insert, which has a melting temperature of greater than 80 ° C; Such a material is still firm and dimensionally stable even in the case of many temperatures resulting from the forming work. Materials with a lower melting temperature, however, are advantageous in that less energy has to be expended in order to remove them from the hollow profile after the forming process, therefore it is also preferable to use material which a melting temperature more than 60 ° C, more preferably greater than or equal to 40 ° C. If the manufacturing environment allows it, a melting temperature of only greater than 30 ° C. may also be advantageous. Although, in principle, materials can be used whose melting temperatures are below the working temperature, but these are inevitably expensive to handle, since they are in other temperature ranges -. B. climate chamber - must be provided and processed quickly to prevent premature liquefaction.

In einer ganz besonders bevorzugten Ausgestaltung des erfindungsgemäßen Verfahrens wird als Material für die Einlage Wachs oder ein wachsähnlicher Stoff verwendet, wobei sich "wachsähnlicher Stoff' insbesondere auf die mechanischen Eigenschaften von Wachs bezieht (Viskosität, Härte, Zähigkeit), nicht auf die optischen Eigenschaften. Wachse haben die Eigenschaft, daß sie bei Normalbedingungen - also unter normalem atmosphärischen Druck bei etwa 20° C - plastisch verformbar sind, ohne zu reißen oder zu bröckeln, aber dennoch relativ formstabil sind. Vorteilhaft bei Wachsen ist darüber hinaus, daß sie bei Temperaturen von mehr als etwa 40° C schmelzen, üblicherweise ohne sich zu zersetzen. Darüber hinaus sind die meisten Wachse frei von Schadstoffen und daher von Menschen auch in direktem Kontakt gut handhabbar. Wachs hat zusätzlich auch einen ganz wesentlichen technischen Vorteil, denn es kann zur Versiegelung von Oberflächen und damit zum Korrosionsschutz eingesetzt werden. Gerade in der Automobilindustrie werden Hohlräume, insbesondere Hohlräume in Hohlprofilen, jahrzehntelang durch Wachs versiegelt.In a very particularly preferred embodiment of the method according to the invention, wax or a wax-like substance is used as the material for the insert, "wax-like substance" referring in particular to the mechanical properties of wax (viscosity, hardness, toughness), not to the optical properties. Waxes have the property that they are plastically deformable under normal conditions - ie under normal atmospheric pressure at about 20 ° C - without cracking or crumbling, but are still relatively dimensionally stable In addition, most waxes are free of pollutants and therefore manageable even in direct contact with wax, which also has a very significant technical advantage, since it can be used to seal off Surfaces and thus used for corrosion protection Especially in the automotive industry, cavities, in particular cavities in hollow profiles, are sealed by wax for decades.

Für bestimmte Anwendungen hat es sich als vorteilhaft herausgestellt, wenn die Öffnung des Hohlprofils - oder die Öffnungen - nach Einbringen der Einlage abgedichtet wird, insbesondere durch Verprägen und/oder durch An- oder Einbringen eines Stempels, beispielsweise eines Stempels der Umformvorrichtung. Eine besonders effektive Nutzung der Einlage ist dann gegeben, wenn die Dichtstelle benachbart zur Einlage gelegen ist, da das Material der Einlage beim Umformen dann nicht beliebig in Hohlräume ausweichen kann.For certain applications, it has proven to be advantageous if the opening of the hollow profile - or the openings - is sealed after introduction of the insert, in particular by embossing and / or by applying or introducing a stamp, for example a stamp of the forming device. A particularly effective use of the insert is given when the sealing point is located adjacent to the insert, since the material of the insert during forming then can not dodge into cavities.

Ein wichtiger Effekt des erfindungsgemäßen Verfahrens besteht gerade bei Einlagen, die sich bei der Umformung selbst stark verformen - wie z. B. Wachs -, darin, daß die Einlage einen entsprechenden Gegendruck - Innendruck im Hohlprofil - erzeugt und das auch in Bereichen, die von den Werkzeugen der Umformvorrichtungen noch überhaupt nicht kontaktiert sind. Durch das Abdichten der Öffnungen des Hohlprofils kann also insgesamt ein Wirkraum der Einlage definiert werden. Wenn davon die Rede ist, daß die Öffnung des Hohlprofils nach Einbringen der Einlage abgedichtet wird, dann wird darunter nicht nur verstanden, daß die Öffnung direkt verschlossen wird, also die Randkonturen der Öffnung verschlossen werden, sondern es soll darunter allgemein verstanden werden, daß das Hochprofil - an beliebiger Stelle - so beeinflußt wird, daß die Einlage nicht beliebig entweichen kann.An important effect of the method according to the invention is just for deposits that deform themselves during the forming itself - such. B. Wax -, in that the insert generates a corresponding back pressure - internal pressure in the hollow profile - and that also in areas that are not contacted by the tools of the forming devices at all. By sealing the openings of the hollow profile, it is thus possible to define a total effective area of the insert. If it is mentioned that the opening of the hollow profile is sealed after insertion of the insert, then this is not only understood that the opening is closed directly, so the edge contours of the opening are closed, but it should be understood that the general High profile - at any point - is influenced so that the insert can not escape arbitrarily.

Bevorzugt wird das Volumen der Einlage so bemessen, daß es dem Volumen des Hohlprofils bei Erreichen der Hohlprofil-Endform entspricht. Dies ist insbesondere dann sinnvoll, wenn gemäß einer besonders bevorzugten Weiterentwicklung des Verfahrens beim Umformen des Hohlprofils und der Einlage des Hohlprofils durch das Umformwerkzeug ein Hohlprofil-Innendruck erzeugt wird, mit dem das Hohlprofil zumindest bereichsweise von innen nach außen umgeformt wird, insbesondere das Wandmaterial des Hohlprofils in wenigstens eine noch nicht ausgefüllte Kavität des Umformwerkzeugs gepreßt wird. In diesem Fall wirkt die Einlage in dem Hohlprofil nicht nur als Gegenhalt, der auf einer reinen Reaktionskraft beruht, sondern es gibt beim Umformen Bereiche des Hohlprofils, in denen aufgrund des Hohlprofil-Innendrucks eine resultierende, nach außen gerichtete Kraft auf die Wandung des Hohlprofils ausgeübt wird. Insgesamt führt dies zu einer sehr viel besseren Formtreue des resultierenden umgeformten Hohlprofils als dies bei Hohlprofilen der Fall ist, die ohne eine derartige Einlage - insbesondere wachsartige Einlage - hergestellt worden sind.Preferably, the volume of the insert is such that it corresponds to the volume of the hollow profile upon reaching the hollow profile end shape. This is particularly useful if, according to a particularly preferred further development of the method during forming of the hollow profile and the insert of the hollow profile by the forming a hollow profile internal pressure is generated with which the hollow profile is at least partially reshaped from inside to outside, in particular the wall material of Hollow profile is pressed into at least one not yet completed cavity of the forming tool. In this case, the insert acts in the hollow profile not only as a counter-support based on a pure reaction force, but there are during forming areas of the hollow profile in which due to the hollow profile internal pressure exerted a resultant, outwardly directed force on the wall of the hollow profile becomes. Overall, this leads to a much better dimensional accuracy of the resulting formed hollow profile than is the case with hollow sections, which have been produced without such an insert - in particular wax-like insert.

Ein weiterer Vorteil des erfindungsgemäßen Verfahrens besteht folglich darin, daß auch - die Wahl eines geeigneten Materials für die Einlage vorausgesetzt, wie z. B. Wachs - eine Umformung des Hohlprofils von innen nach außen mit konventionellen Umformvorrichtungen möglich ist, ohne auf aufwendige Vorrichtungen zurückgreifen zu müssen, wie sie beispielsweise bei der Innenhochdruckumformung verwendet werden.Another advantage of the method according to the invention is therefore that even - assuming the choice of a suitable material for the deposit, such. B. wax - a reshaping of the hollow profile from the inside to the outside with conventional forming devices is possible without having to resort to expensive devices, as used for example in the hydroforming.

Eine weitere vorteilhafte Ausgestaltung des Verfahrens besteht darin, daß die Einlage in dem Hohlprofil plaziert wird, indem das im flüssigen Zustand befindliche Material der Einlage in das Hohlprofil gefüllt wird und das Material der Einlage bis zur Verfestigung in der Einlage abgekühlt wird. Diese Vorgehensweise hat mehrere Vorteile. Einerseits hat es den Vorteil, daß auch schlecht erreichbare Bereiche des Hohlprofils ohne weiteres erreicht werden können - beispielsweise bei einem schon in einem ersten Arbeitsschritt umgeformten Hohlprofil, und andererseits hat es den Vorteil, daß ein hoher Verfüllungsgrad des Hohlprofils erzielt werden kann.A further advantageous embodiment of the method is that the insert is placed in the hollow profile by the material in the liquid state of the insert is filled in the hollow profile and the material of the insert is cooled to solidification in the insert. This procedure has several advantages. On the one hand, it has the advantage that even poorly accessible areas of the hollow profile can be readily achieved - for example, in a already transformed in a first step hollow section, and on the other hand, it has the advantage that a high degree of filling of the hollow profile can be achieved.

Im einzelnen gibt es nun verschiedene Möglichkeiten, das erfindungsgemäße Verfahren auszugestalten und weiterzubilden. Dazu wird verwiesen auf die dem Patentanspruch 1 nachgeordneten Patentansprüche und auf die Beschreibung bevorzugter Ausführungsbeispiele in Verbindung mit der Zeichnung. In der Zeichnung zeigen

Fig. 1
die gegenständlichen Komponenten, die zur Durchführung des Verfahrens notwendig sind, sowie ein Hohlprofil in verschiedenen Umformzuständen,
Fig. 2a-2g
die Durchführung des erfindungsgemäßen Verfahrens in sieben Verfahrensschritten,
Fig. 3a, 3b
ein ohne geeignete Einlage umgeformtes Hohlprofil und
Fig. 4a, 4b
ein mit dem gleichen Umformwerkzeug wie in Fig. 3 bearbeitetes Hohlprofil, das mit dem erfindungsgemäßen Verfahren bei Verwendung einer Einlage aus Wachs erzielt worden ist.
In particular, there are various possibilities for designing and developing the method according to the invention. Reference is made to the claims subordinate to claim 1 and to the description of preferred embodiments in conjunction with the drawings. In the drawing show
Fig. 1
the objective components which are necessary for carrying out the method, as well as a hollow profile in different forming states,
Fig. 2a-2g
the implementation of the method according to the invention in seven process steps,
Fig. 3a, 3b
a formed without suitable insert hollow profile and
Fig. 4a, 4b
one with the same forming tool as in Fig. 3 machined hollow profile, which has been achieved with the inventive method using a wax insert.

In den Fig. 1 und 2 wird ein Verfahren zur Umformung von Hohlprofilen 1 mit wenigstens einer Öffnung 2 dargestellt, die Fig. 3 und 4 zeigen Verfahrensprodukte, Hohlprofile 1" in Hohlprofil-Endform.In the Fig. 1 and 2 a method for forming hollow sections 1 is shown with at least one opening 2, the Fig. 3 and 4 show process products, hollow sections 1 "in hollow profile final form.

Das in den Fig. 1 bis 4 dargestellte Hohlprofil 1 hat einen Mehrkammerquerschnitt, weist nämlich, wie in Fig. 1 zu sehen ist, drei parallel zueinander verlaufende Kammern auf. Fig. 1 zeigt in einer Übersicht, die den zeitlichen Verlauf des eigentlichen Verfahrens nicht ohne weiteres erkennen läßt, die zur Durchführung des Verfahrens nötigen Elemente, nämlich eine feste Einlage 3, - vorliegend drei feste Einlagen 3, jeweils eine Einlage für eine der drei Kammern - und eine Umformvorrichtung 4a, 4b, wobei das Hohlprofil 1 außenseitige durch Einwirken der Umformvorrichtung 4a, 4b mit einer Umformkraft zur Erzielung einer Hohlprofilendform beaufschlagt und umgeformt wird.That in the Fig. 1 to 4 illustrated hollow section 1 has a multi-chamber cross-section, namely, has, as in Fig. 1 can be seen, three mutually parallel chambers on. Fig. 1 shows in an overview, the time course of the actual process can not readily recognize the necessary for carrying out the process elements, namely a fixed insert 3, - present three fixed deposits 3, one insert for each of the three chambers - and a forming device 4a, 4b, wherein the hollow profile Outside by the action of the forming device 4a, 4b applied with a forming force to achieve a Hohlprofilendform and reshaped.

Bereits in Fig. 1 sind die verschiedenen Umformzustände des Hohlprofils 1 gezeigt, wobei das unbearbeitete Hohlprofil 1 zu dem durch Dichtstellen 5 geschlossenen Hohlprofil 1' wird, woraus schließlich das Hohlprofil 1" in Hohlprofil-Endform wird. Die Umformkraft wird dadurch aufgebracht, daß das Oberwerkzeug 4a und das Unterwerkzeug 4b der Umformvorrichtung 4a, 4b unter Kraftwirkung aufeinander zu bewegt werden und das eingelegte Hohlprofil 1 umformen. Das Oberwerkzeug 4a und das Unterwerkzeug 4b weisen demzufolge die Negativform der Hohlprofil-Sollform auf, der die Hohlprofil-Endform möglichst nahe kommen soll. Das dargestellte Verfahren zeichnet sich dadurch aus, daß die Einlage 3 nach und/oder bei Erzielen der Hohlprofilendform des Hohlprofils 1 in einen flüssigen und/oder gasförmigen Zustand überführt wird und im wesentlichen vollständig aus dem Hohlprofil 1 entfernt wird, was nicht explizit dargestellt, aber ohne weiteres verständlich ist.Already in Fig. 1 the different deformation states of the hollow profile 1 are shown, wherein the unprocessed hollow profile 1 to the hollow profile 1 'closed by sealing points 5, from which finally the hollow profile 1 "in hollow profile final form 4b of the shaping device 4a, 4b are moved toward one another under the action of force and reshape the inserted hollow profile 1. The upper tool 4a and the lower tool 4b accordingly have the negative form of the desired hollow profile shape, which should come as close as possible to the hollow profile end shape characterized in that the insert 3 is transferred after and / or upon reaching the Hohlprofilendform the hollow section 1 in a liquid and / or gaseous state and substantially completely removed from the hollow profile 1, which is not explicitly illustrated, but readily understandable ,

In den dargestellten Ausführungsbeispielen wird die Einlage 3 in einen flüssigen Zustand überführt, indem die Einlage 3 mittelbar über das Hohlprofil 1 erhitzt wird, nämlich, wie in Fig. 2g angedeutet, einem Warmluftstrom ausgesetzt wird. Die indirekte Erwärmung der Einlage 3 über das Hohlprofil 1 eignet sich insbesondere dann, wenn das Hohlprofil 1 aus einem gut wärmeleitfähigen Material besteht. Vorliegend besteht das Hohlprofil 1 aus einer Aluminiumlegierung, die gut wärmeleitfähig ist. Dies ist in diesem Fall deshalb vorteilhaft, weil automatisch zunächst die Bereiche der Einlage 3 erwärmt und damit verflüssigt werden, die dafür verantwortlich sind, daß die Einlage 3 in dem umgeformten Hohlprofil 1" haftet.In the illustrated embodiments, the insert 3 is converted into a liquid state by the insert 3 is indirectly heated via the hollow profile 1, namely, as in Fig. 2g indicated, is exposed to a stream of hot air. The indirect heating of the insert 3 via the hollow profile 1 is particularly suitable when the hollow profile 1 consists of a good thermal conductivity material. In the present case, the hollow profile 1 consists of an aluminum alloy, which is highly thermally conductive. This is advantageous in this case, because automatically first the areas of the insert 3 are heated and liquefied, which are responsible for the fact that the insert 3 in the reshaped hollow section 1 "adheres.

Bei anderen Ausgestaltungen des Verfahrens, wird das umgeformte metallische Hohlprofil 1" induktiv erwärmt. In einer hier nicht dargestellten Ausgestaltung des Verfahrens wird das umgeformte Hohlprofil 1" zur Wärmebehandlung so aufgehängt, daß die Einlage sich durch Schwerkraftwirkung automatisch aus dem Hohlprofil löst, sobald die Randbereiche genügend verflüssigt worden sind.In other embodiments of the method, the deformed metallic hollow profile 1 "is inductively heated In an embodiment of the method which is not shown here, the deformed hollow profile 1" is used for the heat treatment hung so that the insert automatically releases by gravity from the hollow profile, as soon as the edge areas have been liquefied enough.

In den in den Figuren dargestellten Ausführungsbeispielen wird als Material für die Einlage 3 Wachs verwendet, das einen Schmelzpunkt bei etwa 40° C aufweist. Die Arbeitstemperatur, bei der das hier dargestellte Verfahren durchgeführt wird, liegt im Regelfall zwischen 18° C und 25°C, ein Temperaturbereich, bei dem gewöhnliches Wachs gut plastisch verformbar ist ohne zu reißen oder zu brechen.In the embodiments illustrated in the figures, 3 wax is used as the material for the insert, which has a melting point at about 40 ° C. The working temperature at which the process described here is carried out is usually between 18 ° C and 25 ° C, a temperature range at which ordinary wax is readily plastically deformable without cracking or breaking.

In Fig. 2 ist ein nahezu vollständiger Verfahrensdurchlauf dargestellt. In Fig.2a wird die Einlage 3 in dem Hohlprofil 1 plaziert; die Einlage ist hier bereits während des Plazierens fest. Bei anderen - hier nicht dargestellten - Ausführungsbeispielen wird die Einlage bzw. das verflüssigte Material der Einlage in das umzuformende Hohlprofil eingebracht und erst in dem Hohlprofil soweit abgekühlt, daß sich das Material der Einlage 3 zu einer festen Einlage 3 verfestigt.In Fig. 2 a nearly complete process flow is shown. In 2a the insert 3 is placed in the hollow profile 1; the insert is already fixed during the placement. In other - not shown here - embodiments, the insert or the liquefied material of the insert is introduced into the reshaped hollow profile and cooled only in the hollow section so far that the material of the insert 3 solidifies into a solid insert 3.

In Fig. 2b ist dargestellt, daß die Öffnungen 2 des Hohlprofils 1 nach Einbringen der Einlage 3 abgedichtet werden, nämlich durch Verprägen mit Prägestempeln 6. Im vorliegenden Fall ist die Dichtstelle 5 benachbart zur Einlage 3 in dem Hohlprofil 1 gelegen bzw. wird die Einlage 3 bereits durch das Verprägen an den Dichtstellen 5 in dem Hohlprofil 1 verdichtet. In dem dargestellten Ausführungsbeispiel ist der Hohlraum des Hohlprofils 1 praktisch vollständig mit der Einlage 3 ausgefüllt. Nach dem Abdichten der Öffnungen 2 des Hohlprofils 1 in Fig. 2c wird das abgedichtete Hohlprofil 1' in das Prägewerkzeug 4a, 4b eingelegt (Fig. 2d). Durch Aufeinanderpressen des Oberwerkzeugs 4a und des Unterwerkzeugs 4b wird eine Umformkraft auf das Hohlprofil 1' ausgeübt.In Fig. 2b It is shown that the openings 2 of the hollow profile 1 are sealed after introduction of the insert 3, namely by embossing with stamping dies 6. In the present case, the sealing point 5 is located adjacent to the insert 3 in the hollow section 1 or the insert 3 is already through the Embossing compacted at the sealing points 5 in the hollow section 1. In the illustrated embodiment, the cavity of the hollow profile 1 is almost completely filled with the insert 3. After sealing the openings 2 of the hollow profile 1 in Fig. 2c is the sealed hollow profile 1 'in the embossing tool 4a, 4b inserted ( Fig. 2d ). By pressing together the upper tool 4a and the lower tool 4b, a forming force is exerted on the hollow profile 1 '.

Von besonderem Vorteil ist hier, daß beim Umformen des Hohlprofils 1' durch die Umformvorrichtung 4a, 4b und die Einlage 3 ein Hohlprofil-Innendruck erzeugt wird, mit dem das Hohlprofil 1' bereichsweise von innen nach außen umgeformt wird, nämlich das Wandmaterial des Hohlprofils 1' in die noch nicht ausgefüllten Kavitäten der Umformvorrichtung 4a, 4b gepreßt wird, wie dies in Fig. 2e dargestellt ist. Im Ergebnis wird ein umgeformtes Hohlprofil 1" erhalten, das eine hohe Formtreue aufweist, die mit konventionellen Umformverfahren - ohne Verwendung eines plastischen Einlegers 3 aus Wachs - nicht möglich wäre (Fig. 2f).Of particular advantage here is that when forming the hollow profile 1 'by the forming device 4a, 4b and the insert 3, a hollow profile internal pressure is generated, with which the hollow section 1' in regions from inside to outside is formed, namely the wall material of the hollow section. 1 'pressed into the not yet completed cavities of the forming device 4a, 4b will, as in Fig. 2e is shown. As a result, a reshaped hollow profile 1 "is obtained, which has a high dimensional accuracy, which would not be possible with conventional forming methods-without the use of a plastic insert 3 made of wax ( Fig. 2f ).

In dem dargestellten Ausführungsbeispiel entspricht das Volumen der Einlage 3 dem Volumen des Hohlprofils 1" bei Erreichen der Hohlprofil-Endform. Das bedeutet, daß bei Abschluß des Umformvorgangs der größte Innendruck erzeugt wird. Wenn das Volumen der Einlage 3 schon im Ausgangszustand des Hohlprofils 1 dem Volumen des Hohlprofils 1 entspricht, ist die größtmögliche Umformung von innen nach außen erzielbar, da praktisch gleich zu Beginn des Umformvorgangs ein erheblicher Hohlprofil-Innendruck erzeugt wird. In Fig. 2g ist zu erkennen, daß die Endbereiche 7 des umgeformten Hohlprofils 1" abgetrennt werden, so daß die danach verflüssigte Einlage 3 aus dem umgeformten Hohlprofil 1" ausfließen kann. In anderen, hier nicht dargestellten Ausführungsbeispielen, werden kleinere Öffnungen in das umgeformte Hohlprofil 1" eingebracht, um die in einen flüssigen Zustand überführte Einlage 3 entfernen zu können.In the illustrated embodiment, the volume of the insert 3 corresponds to the volume of the hollow profile 1 "upon reaching the hollow profile end shape., That means that at the completion of the forming process, the largest internal pressure is generated Volume of the hollow section 1 corresponds, the greatest possible conversion from the inside to the outside can be achieved, since practically at the beginning of the forming process, a considerable hollow profile internal pressure is generated Fig. 2g It can be seen that the end portions 7 of the deformed hollow profile 1 "are separated so that the subsequently liquefied insert 3 can flow out of the formed hollow profile 1". In other, not shown embodiments, smaller openings in the formed hollow section 1 "are introduced to remove the converted into a liquid state insert 3 can.

In den Fig. 3 und 4 sind die Umformergebnisse gegenübergestellt, die mit einem herkömmlichen Verfahren ohne Einlage erzielt werden können (Fig. 3) und die mit dem erfindungsgemäßen Verfahren - hier mit einer wachsähnlichen Einlage 3 - erzielt werden können.In the Fig. 3 and 4 are compared with the forming results which can be achieved with a conventional non-insert method ( Fig. 3 ) and which can be achieved with the method according to the invention - here with a wax-like insert 3.

In Fig. 3 ist gut zu erkennen, daß ohne Verwendung einer Einlage kein Hohlprofil-Innendruck erzeugt werden kann, was zu einer unbefriedigenden Formgebung führt, da nur Prägekonturen mich schwach profilierten Übergängen erzielt werden können; Auswölbungen könne überhaupt nicht erzeugt werden, wenngleich die Umformvorrichtung den nötigen Freiraum dafür vorsieht.In Fig. 3 is good to realize that without the use of an insert no hollow profile internal pressure can be generated, which leads to an unsatisfactory shape, since only embossing contours can me poorly profiled transitions can be achieved; Bulges can not be generated at all, although the forming device provides the necessary space for it.

Bei dem in Fig. 4 dargestellten Ergebnis des mit der gleichen Umformvorrichtung umgeformten Hohlprofils 1" unter Verwendung einer Wachseinlage ist nicht nur auffällig, daß auch eine Materialbewegung nach außen stattgefunden hat, sondern es sind auch deutlich prägnantere Konturen erzielt worden, die das Sollprofil, nämlich die Vorgabe - Negativform - der Umformvorrichtung, mit hoher Formtreue nachvollziehen.At the in Fig. 4 shown result of the reshaped with the same forming hollow section 1 "using a wax insert is not only striking that also a material movement has taken place to the outside, but there are also significantly more concise contours have been achieved, the target profile, namely the default - negative form - the Forming device, with high form faithfulness.

Claims (11)

  1. Method of forming hollow profiles (1) having at least one opening (2), wherein a solid insert (3) is positioned in the hollow profile (1) and the hollow profile (1), by the action of a forming device (4a, 4b), is on the outside acted upon and formed by at least one forming force to produce a final shape of the hollow profile,
    characterised in that
    after and/or during production of the final shape of the hollow profile the insert (3) is converted at least partly into a liquid and/or gaseous state and is removed substantially completely from the hollow profile (1).
  2. Method according to claim 1, characterised in that the insert (3) is converted into a liquid and/or gaseous state by heating the insert (3) directly or indirectly by way of the hollow profile (1).
  3. Method according to claim 1 or 2, characterised in that there is used for the insert (3) a material which at a pressure of one bar (101.3 kPa) has a melting temperature greater than 80°C, preferably greater than 60°C, especially greater than or equal to 40°C, more especially greater than or equal to 30°C.
  4. Method according to any one of claims 1 to 3, characterised in that there is used as material for the insert (3) wax or a wax-like substance - especially in terms of mechanical properties.
  5. Method according to any one of claims 1 to 4, characterised in that the opening (2) in the hollow profile (1) is sealed after introduction of the insert (3), especially by stamping and/or by application or introduction of a die, the sealing site (5) especially being located next to the insert (3).
  6. Method according to any one of claims 1 to 5, characterised in that the insert (3) is at least partly liquefied and/or vaporised by the forming work performed by the forming device (4a, 4b).
  7. Method according to any one of claims 1 to 6, characterised in that the volume of the insert (3) corresponds to the volume of the hollow profile (1) when the final shape of the hollow profile is achieved.
  8. Method according to any one of claims 1 to 7, characterised in that as forming device (4) there is used a stamping tool (4a, 4b) that substantially surrounds the hollow profile (1), especially a stamping tool (4a, 4b) having an upper tool (4a) and a lower tool (4b).
  9. Method according to any one of claims 1 to 8, characterised in that during the forming of the hollow profile (1) and the insert (3) by means of the forming device (4a, 4b) a hollow profile internal pressure is generated with which the shaping of the hollow profile (1), at least in some regions, is effected from the inside to the outside, the wall material of the hollow profile (1) especially being pressed into at least one as yet unfilled cavity of the forming device (4a, 4b).
  10. Method according to any one of claims 1 to 9, characterised in that an opening (8) is made in the hollow profile (1) for removing the insert (3) that has been converted into a liquid and/or gaseous state.
  11. Method according to any one of claims 1 to 10, characterised in that the insert (3) is positioned in the hollow profile (1) by introducing the material of the insert (3) in liquid state into the hollow profile (1) and cooling the material of the insert (3) until it solidifies in the hollow profile (1).
EP09736120A 2008-09-26 2009-09-10 Method for forming hollow profiles Not-in-force EP2355942B1 (en)

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DE200810049245 DE102008049245A1 (en) 2008-09-26 2008-09-26 Method for forming hollow profiles
PCT/EP2009/006555 WO2010034406A1 (en) 2008-09-26 2009-09-10 Method for forming hollow profiles

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JP4045568B2 (en) * 2001-11-14 2008-02-13 株式会社コーリツ Method for forming a recess in the outer surface of a hollow material and a core bar used in this method
DE102005007997B3 (en) * 2005-02-19 2005-12-08 Tower Automotive Hydroforming Gmbh & Co. Kg Construction unit manufacturing method, involves producing blank mold, which is then reformed into required form of construction unit by reforming tool in one of two reforming processes

Cited By (5)

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Publication number Priority date Publication date Assignee Title
WO2014202271A1 (en) * 2013-06-17 2014-12-24 Thyssenkrupp Steel Europe Ag Device for producing at least one undercut in a slotted or closed profiled sheet section
KR20160020481A (en) * 2013-06-17 2016-02-23 티센크루프 스틸 유럽 악티엔게젤샤프트 Device for producing at least one undercut in a slotted or closed profiled sheet section
US9895734B2 (en) 2013-06-17 2018-02-20 Thyssenkrupp Steel Europe Ag Device for producing at least one undercut in a slotted or closed profiled sheet section
KR102148556B1 (en) 2013-06-17 2020-08-26 티센크루프 스틸 유럽 악티엔게젤샤프트 Device for producing at least one undercut in a slotted or closed profiled sheet section
US10981206B2 (en) 2015-06-08 2021-04-20 Constellium-Singen Gmbh Precision forming of metallic hollow extrusions

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EP2355942A1 (en) 2011-08-17
DE102008049245A1 (en) 2010-04-01
WO2010034406A1 (en) 2010-04-01
ES2403115T3 (en) 2013-05-14

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