EP2640535B1 - Method and set of components for producing a tubular structural part, in particular a built-up camshaft - Google Patents

Method and set of components for producing a tubular structural part, in particular a built-up camshaft Download PDF

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Publication number
EP2640535B1
EP2640535B1 EP11782645.3A EP11782645A EP2640535B1 EP 2640535 B1 EP2640535 B1 EP 2640535B1 EP 11782645 A EP11782645 A EP 11782645A EP 2640535 B1 EP2640535 B1 EP 2640535B1
Authority
EP
European Patent Office
Prior art keywords
section
opening
carrier pipe
end piece
component set
Prior art date
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
Application number
EP11782645.3A
Other languages
German (de)
French (fr)
Other versions
EP2640535A1 (en
Inventor
Rico Demuth
Jens Gentzen
Jürgen MEUSEL
Alexander Paul
Daniel Paul
Robert Reichelt
Frank Schieck
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Thyssenkrupp Dynamic Components Teccenter AG
Original Assignee
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
ThyssenKrupp Presta TecCenter AG
Priority date (The priority date 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 date listed.)
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Publication date
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Publication of EP2640535A1 publication Critical patent/EP2640535A1/en
Application granted granted Critical
Publication of EP2640535B1 publication Critical patent/EP2640535B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
    • F01L1/02—Valve drive
    • F01L1/04—Valve drive by means of cams, camshafts, cam discs, eccentrics or the like
    • F01L1/047—Camshafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/045—Closing or sealing means
    • 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
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/06—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes in openings, e.g. rolling-in
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/84—Making other particular articles other parts for engines, e.g. connecting-rods
    • B21D53/845—Making camshafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
    • F01L1/02—Valve drive
    • F01L1/04—Valve drive by means of cams, camshafts, cam discs, eccentrics or the like
    • F01L1/047—Camshafts
    • F01L1/053—Camshafts overhead type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
    • F01L1/02—Valve drive
    • F01L1/04—Valve drive by means of cams, camshafts, cam discs, eccentrics or the like
    • F01L1/047—Camshafts
    • F01L2001/0471—Assembled camshafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2303/00—Manufacturing of components used in valve arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2303/00—Manufacturing of components used in valve arrangements
    • F01L2303/01—Tools for producing, mounting or adjusting, e.g. some part of the distribution
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49229—Prime mover or fluid pump making
    • Y10T29/49293—Camshaft making
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53996—Means to assemble or disassemble by deforming

Definitions

  • the invention relates to a method for producing a tubular member, in particular a built camshaft, by means of hydroforming, wherein a support tube and an end piece are fed, wherein inserted into an opening of the tail an associated end of the support tube and subsequently expanded by the application of a pressurized fluid and is connected to the end piece in a press fit, and wherein the opening before the pressurization with the fluid having a first portion having an inner cross section which is greater than the outer cross section of the associated end of the support tube.
  • the invention also relates to a set of components for the production of a tubular component, which has a carrier tube, an end piece with an opening for the carrier tube and for the arrangement on the carrier tube provided functional elements, such as cams.
  • camshaft Under a built camshaft is understood a camshaft, which is not manufactured in one piece in a Ur- or forming process, but assembled by the combination of several prefabricated parts. Modern built camshafts in addition to cams have additional functional elements, such as tail, sprocket, pulleys, encoder wheels, pump drives, bearings, plain bearings or the like, which must be mounted on a support tube with a suitable joining technology, with very high angular accuracies must be observed.
  • additional functional elements such as tail, sprocket, pulleys, encoder wheels, pump drives, bearings, plain bearings or the like, which must be mounted on a support tube with a suitable joining technology, with very high angular accuracies must be observed.
  • cams and optionally provided further functional elements are first pushed onto their hubs with a game on the support tube and positioned, in which case the support tube is subjected to a high internal pressure, whereby the support tube expanded with an elastic and a plastic portion and to the Inner surface of the hubs is created.
  • the cams and optionally provided further functional elements are widened to a certain extent, but this expansion preferably takes place only elastically.
  • both the support tube and the elements arranged thereon resiliently spring back, wherein the materials of the joining partners are selected so that the cams and other functional elements are held with an elastic residual stress in a press fit on the support tube.
  • the hydroforming is usually carried out in a mold, which limits the radial expansion by the pressurization. If according to a preferred embodiment of the hydroforming process, the carrier tube is acted upon over its entire length with a pressurized fluid, a sufficient seal is to ensure. Furthermore, the reliable transmission of high torques should be made possible in the hydroforming with the least possible use of materials and with a lightweight design.
  • a pressure source is usually connected to one end of the support tube while the end of the support tube opposite the pressure source must be closed pressure-tight, to which end pieces can be used, which are mounted like a cap.
  • Another variant is the possibility of pressure medium filling through an axial bore in the tail. The tube is sealed pressure-tight on the opposite side. A reliable seal is necessary to avoid the uncontrolled discharge of pressure fluid and thus an impairment of the joining process.
  • a method for producing a built camshaft with the features described above is known from DE 36 16 901 A known.
  • the production of the tubular component in the form of a built camshaft takes place in a closed mold, wherein a source of the pressurized fluid is connected to one side of the support tube and on the other side an end piece is pressed onto the local end of the support tube during the hydroforming process.
  • various measures are proposed.
  • the arrangement of a sealing ring in a radial groove or at the bottom of the opening of the tail is expensive, which due to the very high acting pressures during hydroforming typically 2000 to 5000 bar leaks in the polymeric sealing material can not be excluded.
  • the opening in the form of a blind bore at its bottom with a frusto-conical bevel against which the support tube is pressed.
  • a linear contact is achieved around the circumference, which can not ensure a reliable seal with dimensional deviations, ovality and local damage.
  • the production of such conical surfaces at the bottom of the opening is expensive.
  • the invention has for its object to provide a method for producing a tubular component, in which by means of hydroforming an end piece can be attached in a simple manner with a high reliability and reproducibility. Furthermore, a set of components is to be specified, which is suitable for carrying out the manufacturing process.
  • the object is achieved in that, starting from the front edge of the opening to the first portion, a second portion having a second inner cross section, which is smaller than the outer cross section of the associated end of the support tube, under training a circumferential edge connects in steps, wherein the support tube is first inserted with its corresponding end in the first section and wherein in a further insertion movement, the edge is cut into the material of the support tube.
  • the usually approximately rectangular step defines a comparatively sharp cutting edge, which engages when inserting the associated end of the support tube in the region of the end face of the support tube and there cuts into the material. In this cutting both a material deformation and a certain Materialabscherung can be done.
  • the end piece is prefixed after insertion of the support tube by the cutting of the edge to a certain extent, so that the support tube with the attached end piece can be handled easily before finally the joining takes place by means of internal high pressure.
  • the comparatively sharp edge cuts along the edge End face of the support tube, wherein the introduction of force initially has a considerable axial portion, whereby reinforced material deformation or shearing and less bending of the support tube takes place.
  • the height of the step is selected such that the second internal cross-section provided from the step is greater than the internal cross-section of the associated end of the tube. This difference in diameter results in the joining play for the pre-assembly.
  • the dimensions are preferably also chosen so that despite the formation of the stage, the support tube to a bottom of the opening or at least to just before the bottom of the opening in the region of the second section under deformation and / or shearing of a portion of the tube material can be inserted.
  • the second section which is preferably between 1 mm and 8 mm, preferably about 4 mm, a sealing material contact is achieved, so that local unevenness, imperfections or the like even at a pressure of several 1000 bar not lead to a noticeable reduction of the seal.
  • An extension of the second portion may be useful to compensate for uneven shortening of the tube as a result of forming operations.
  • the fact that the support tube can preferably be inserted with its end to the bottom of the opening also results in terms of dimensional accuracy of a particular high accuracy and reproducibility, since the bottom of the opening as it serves as a stop for the associated end of the support tube.
  • the present invention generally relates to a method for manufacturing a tubular member, wherein the cross-sectional shape of the support tube is not initially determined.
  • the cross-sectional shape of the support tube is not initially determined.
  • square, rectangular, elliptical or other cross-sectional shapes are conceivable, wherein a peripheral edge is always provided at the transition of the first section to the second section within the opening of the end piece, wherein the inner contour of the opening is adapted to the outer contour of the support tube.
  • a circular cross-section is usually provided, so that the sections of the opening are preferably circular-cylindrical or substantially circular-cylindrical.
  • the details of the dimensions with respect to the inner and outer cross sections relate to a circular configuration according to the inner and outer diameter.
  • the quality of the seal on the one hand and the force required for insertion of the support tube in the associated end piece on the other hand depend on the determination of the dimensions, the second inner cross section, the length of this section and the outer cross section of the tube.
  • the first inner cross-section relative to the second inner cross-section in the radial direction has an excess between 0.1 mm and 1 mm, particularly preferably between 0.2 mm and 0.4 mm, which measure the height of the corresponds to a substantially right-angled step between the first section and the second section.
  • the game between the first inner cross section and the outer cross section of the associated end of the support tube is preferably small and usually just chosen so that a jam-free pushing can take place.
  • the first inner cross section with respect to the outer cross section of the associated end of the tube in the radial direction an excess of less than 0.2 mm, more preferably between 0.05 mm and 0.1 mm.
  • the opening has a longitudinally extending total length, which is at least 60%, preferably at least 80% of the inner diameter of the first section. Based on the finished component, the length along the longitudinal direction of the support tube is to be determined.
  • the outer joining partner has a greater elastic recovery than the inner support tube. Accordingly, a sufficient expansion of the outer joint partner must be carried out beforehand, for which it may have a not too large wall thickness. So is provided according to a preferred embodiment, that the end piece in the region of the first portion of the opening has a wall thickness between 2 mm and 4 mm and so can be expanded elastically in the hydroforming to a sufficient extent.
  • the opening of the end piece can be pretreated before insertion of the associated end of the support tube with a particle beam, such as a corundum, a shot blasting, sandblasting or the like. This increases the coefficient of friction between the joining parameters. In order to avoid damage to the invention as sharp as possible edge at the transition from the first portion to the second portion of the opening, this can be covered during the pretreatment by the particle beam.
  • a particle beam such as a corundum, a shot blasting, sandblasting or the like.
  • connection strength can be further increased. Training is understood to be the generation of an additional relative movement between the joining partners, for example a twisting or shifting in alternating directions.
  • the contouring may, for example, have the form of a spiral, a pocket, an inner knurling, a butted inner contour or the like. Contours in which the formations run transversely to the direction of the torque transmission are particularly advantageous.
  • the pipe material is molded into the corresponding contouring, whereby in addition to the adhesion and a positive connection is formed.
  • the formation of a contouring requires a correspondingly high wall thickness of the tail, which counteracts to some extent elastic extensibility.
  • the hydroforming takes place within the scope of the invention expediently within a mold.
  • functional elements such as cams, sensor wheels, bearing rings or the like are threaded onto the carrier tube in the desired sequence, wherein the end piece is also attached at one end of the carrier tube as described above.
  • the support tube and the functional elements threaded thereon are then inserted into a tool mold and thereby aligned with respect to their axial position and rotational angle alignment.
  • the carrier tube is at a given Pressure as far as required for shaping and fastening required.
  • the pressure source may, according to a preferred embodiment, be moved axially to keep the tube tight and to compensate for shortening of the tube due to the bulge.
  • hydroforming can also be used to form functional surfaces such as bearing points from the support tube itself. This results in the advantage that due to the plastic deformation up to the tool shape, certain dimensional deviations of the carrier tube originally used are compensated. For the dimensional accuracy, in essence, only the provision of the support tube after elimination of the internal high pressure is decisive.
  • bearings on sections of the support tube they may, for example, also be subjected to finish machining and / or coating before hydroforming.
  • the carrier tube or the end piece are not completely cleaned, if despite the good seal in the region of the tail at least at the beginning of hydroforming certain amounts of pressure fluid in the joint gap or in the lower mold emulsion residues of previous forming operations, there is a risk that in the joint gap, a liquid film is formed which, as a kind of counter cushion and spacer, counteracts the forces exerted by the internal high pressure. It can then not be ruled out that the interference fit between the joining partners is impaired and / or that certain production fluctuations occur. In order to avoid such an impairment, is provided according to a preferred embodiment of the invention that at the beginning of hydroforming liquid can be removed from the joint gap between the carrier tube and tail.
  • the end piece in the region of the first portion of the opening may have at least one radial discharge channel, for example in the form of a bore and / or at least one groove extending in the longitudinal direction.
  • the expanding support tube is damaged at the edge of the opening, there may be provided between the first portion and the edge of the opening, a radius and / or a conical widening. A cutting into the widening support tube can be avoided.
  • the formation of a radius or a conical extension at the edge of the opening also contributes to the fact that the tail can be even more easily placed or preassembled on the associated end of the support tube.
  • the invention also relates to a set of components for producing a tubular component by means of hydroforming, wherein the component set has at least the carrier tube and end piece described above.
  • Fig. 1 shows the general structure of a formed by hydroforming camshaft having a support tube 1, at one end of the support tube 1, an end piece 2 and a plurality of functional elements in the form of cam 3 and a thrust bearing 4.
  • the end piece 2 and the functional elements are fixed by hydroforming in a press fit on the support tube 1.
  • outer contours of the carrier tube 1 are formed, which serve as bearing points 6.
  • Screwdriver release 7 in the camshaft provide access to cylinder head bolts.
  • a plurality of screwdriver release 7 are introduced into the support tube 1 over the length of the support tube 1.
  • the functional elements are first pushed onto the carrier tube 1 and the end piece 2 is preassembled at one end of the carrier tube 1.
  • the pressing of the end piece 2 on the associated end of the support tube 1 causes a fluid-tight connection, so that the discharge of pressurized fluid in the subsequent hydroforming can be avoided or at least largely avoided.
  • a pressure source connected to the support tube 1, wherein the support tube 1 is located with the functional elements in a mold which holds the functional elements in the desired axial position and the angular orientation to each other and limits the extent.
  • an end element 8 can be used.
  • the invention provided for pressure-tight closure end piece 2 and the associated end of the support tube 1 are shown in detail in the Fig. 2 shown, wherein the Fig. 2 shows the two components before their connection and accordingly before forming by means of internal high pressure.
  • the end piece 2 has an opening 9, wherein said opening comprises a first circular cylindrical portion 10a with an inner diameter I a and a directly adjoining the second portion 10b with a smaller inner diameter I b.
  • the transition between the first portion 10a and the second portion 10b is step-shaped, wherein the bend defines an edge 11 by about 90 °.
  • the outer diameter A of the support tube 1 is between the first inner diameter I a and the second inner diameter I b , so that the support tube 1 can first be easily inserted into the first portion 10 a and then abuts with its end face 12 at the edge 11. In a further insertion movement, the edge 11 cuts into the material of the support tube 1 a.
  • the material of the end piece 2 is correspondingly stronger or harder than that of the support tube 1.
  • the height of the step between the first portion 10a and the second portion 10b is chosen so that the support tube 1 can be pushed under partial deformation and / or shearing of the material to the bottom 13 of the opening 9 under increased force. Over substantially the entire measured in the axial direction length x b of the second section is thus a direct material contact and, accordingly, achieved a tight connection. In addition, by cutting the edge 11 into the material of the carrier tube 1, the end piece 2 is already prefixed, so that the carrier tube 1 and the end piece 2 can be handled together.
  • the length x b of the second portion 10b is typically between 1 mm and 8 mm, preferably about 4 mm.
  • the first inner diameter I a by 0.2 mm to 1 mm, preferably between 0.4 mm to 0.8 mm greater than the second inner diameter I b of the second portion 10b.
  • the inner diameter I a of the first portion 10a relative to the outer diameter A of the carrier tube 1 may have an excess of as less than 0.2 mm, for example, an excess of between 0.05 mm and 0.1 mm.
  • a discharge channel 14 is provided in the form of a bore in the embodiment.
  • a groove extending in the longitudinal direction can also be introduced into the first section 10a for the removal of fluid.
  • a conical widening 15 is provided there at the transition to the first section 10a.
  • the end piece 2 is not only used for pressure-tight closure, but also has functional features.
  • a central portion of the closed end piece 2 is provided with a thread 16 for a central screw.
  • the total length x g of the entire opening 9 in the illustrated embodiment is at least 80% of the first inner diameter I a .
  • connection can, for example, by adhesive, galvanizing or at least partially contouring be achieved.
  • adhesive for example, by adhesive, galvanizing or at least partially contouring be achieved.

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

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines rohrförmigen Bauteils, insbesondere einer gebauten Nockenwelle, mittels Innenhochdruckumformung, wobei ein Trägerrohr und ein Endstück zugeführt werden, wobei in eine Öffnung des Endstücks ein zugeordnetes Ende des Trägerrohres eingesetzt und nachfolgend durch die Beaufschlagung mit einem Druckfluid aufgeweitet und mit dem Endstück in einem Presssitz verbunden wird, und wobei die Öffnung vor der Beaufschlagung mit dem Druckfluid einen ersten Abschnitt mit einem Innenquerschnitt aufweist, der größer ist als der Außenquerschnitt des zugeordneten Endes des Trägerrohres. Gegenstand der Erfindung ist auch ein Komponentensatz zur Herstellung eines rohrförmigen Bauteils, der ein Trägerrohr, ein Endstück mit einer Öffnung für das Trägerrohr sowie zur Anordnung auf dem Trägerrohr vorgesehene Funktionselemente, beispielsweise Nocken, aufweist.The invention relates to a method for producing a tubular member, in particular a built camshaft, by means of hydroforming, wherein a support tube and an end piece are fed, wherein inserted into an opening of the tail an associated end of the support tube and subsequently expanded by the application of a pressurized fluid and is connected to the end piece in a press fit, and wherein the opening before the pressurization with the fluid having a first portion having an inner cross section which is greater than the outer cross section of the associated end of the support tube. The invention also relates to a set of components for the production of a tubular component, which has a carrier tube, an end piece with an opening for the carrier tube and for the arrangement on the carrier tube provided functional elements, such as cams.

Unter einer gebauten Nockenwelle wird eine Nockenwelle verstanden, die nicht einstückig in einem Ur- oder Umformprozess gefertigt, sondern durch die Verbindung mehrerer vorgefertigter Teile zusammengesetzt wird. Moderne gebaute Nockenwellen besitzen neben Nocken noch zusätzliche Funktionselemente, wie Endstücke, Kettenrad, Riemenscheiben, Geberräder, Pumpenantriebe, Wälzlager, Gleitlager oder dergleichen, die auf einem Trägerrohr mit einer geeigneten Fügetechnologie befestigt werden müssen, wobei auch sehr hohe Winkelgenauigkeiten einzuhalten sind.Under a built camshaft is understood a camshaft, which is not manufactured in one piece in a Ur- or forming process, but assembled by the combination of several prefabricated parts. Modern built camshafts in addition to cams have additional functional elements, such as tail, sprocket, pulleys, encoder wheels, pump drives, bearings, plain bearings or the like, which must be mounted on a support tube with a suitable joining technology, with very high angular accuracies must be observed.

In der Praxis hat sich für die Herstellung von gebauten Nockenwellen die Innenhochdruckumformung bewährt, bei der in einem Prozessschritt mehrere Nocken und/oder andere Funktionselemente gleichzeitig in einem Presssitz auf einem Trägerrohr befestigt werden. Bei der Innenhochdruckumformung werden die Nocken und die gegebenenfalls vorgesehenen weiteren Funktionselemente zunächst an ihren Naben mit einem Spiel auf das Trägerrohr aufgeschoben und positioniert, wobei dann das Trägerrohr mit einem Innenhochdruck beaufschlagt wird, wodurch das Trägerrohr mit einem elastischen und einem plastischen Anteil aufgeweitet und an die Innenfläche der Naben angelegt wird. Auch die Nocken und gegebenenfalls vorgesehenen weiteren Funktionselemente werden in einem gewissen Maße aufgeweitet, wobei diese Aufweitung bevorzugt jedoch nur elastisch erfolgt. Nach dem Wegfall der Druckbeaufschlagung federn sowohl das Trägerrohr als auch die darauf angeordneten Elemente elastisch zurück, wobei die Materialien der Fügepartner so ausgewählt werden, dass die Nocken und weiteren Funktionselemente mit einer elastischen Restspannung in einem Presssitz auf dem Trägerrohr gehalten sind.In practice, hydroforming has proved successful in the manufacture of assembled camshafts, with several cams in one process step and / or other functional elements are simultaneously mounted in a press fit on a support tube. In the hydroforming the cams and optionally provided further functional elements are first pushed onto their hubs with a game on the support tube and positioned, in which case the support tube is subjected to a high internal pressure, whereby the support tube expanded with an elastic and a plastic portion and to the Inner surface of the hubs is created. The cams and optionally provided further functional elements are widened to a certain extent, but this expansion preferably takes place only elastically. After the elimination of pressurization, both the support tube and the elements arranged thereon resiliently spring back, wherein the materials of the joining partners are selected so that the cams and other functional elements are held with an elastic residual stress in a press fit on the support tube.

Die Innenhochdruckumformung erfolgt üblicherweise in einer Werkzeugform, welche die radiale Ausdehnung durch die Druckbeaufschlagung begrenzt. Wenn gemäß einer bevorzugten Ausgestaltung des Innenhochdruckverfahrens das Trägerrohr über seine gesamte Länge mit einem Druckfluid beaufschlagt wird, ist eine ausreichende Abdichtung zu gewährleisten. Des Weiteren soll bei der Innenhochdruckumformung bei einem möglichst geringen Materialeinsatz und mit einer leichten Bauweise die zuverlässige Übertragung großer Drehmomente ermöglicht werden.The hydroforming is usually carried out in a mold, which limits the radial expansion by the pressurization. If according to a preferred embodiment of the hydroforming process, the carrier tube is acted upon over its entire length with a pressurized fluid, a sufficient seal is to ensure. Furthermore, the reliable transmission of high torques should be made possible in the hydroforming with the least possible use of materials and with a lightweight design.

Wenn die Innenhochdruckumformung in einer Werkzeugform erfolgt, wird üblicherweise eine Druckquelle an das eine Ende des Trägerrohres angeschlossen, während das der Druckquelle gegenüberliegende Ende des Trägerrohres druckdicht verschlossen werden muss, wozu Endstücke verwendet werden können, die kappenartig aufgesetzt werden. Eine weitere Variante ist die Möglichkeit der Druckmediumbefüllung durch eine axiale Bohrung im Endstück. Dabei wird das Rohr auf der gegenüberliegenden Seite druckdicht verschlossen. Eine zuverlässige Abdichtung ist notwendig, um den unkontrollierten Austritt von Druckfluid und damit eine Beeinträchtigung des Fügeprozesses zu vermeiden.When the hydroforming is carried out in a mold, a pressure source is usually connected to one end of the support tube while the end of the support tube opposite the pressure source must be closed pressure-tight, to which end pieces can be used, which are mounted like a cap. Another variant is the possibility of pressure medium filling through an axial bore in the tail. The tube is sealed pressure-tight on the opposite side. A reliable seal is necessary to avoid the uncontrolled discharge of pressure fluid and thus an impairment of the joining process.

Ein Verfahren zur Herstellung einer gebauten Nockenwelle mit den eingangs beschriebenen Merkmalen ist aus der DE 36 16 901 A bekannt. Die Herstellung des rohrförmigen Bauteils in Form einer gebauten Nockenwelle erfolgt in einer geschlossenen Werkzeugform, wobei eine Quelle für das Druckfluid an der einen Seite des Trägerrohres angeschlossen wird und wobei an der anderen Seite ein Endstück während des Innenhochdruckumformprozesses auf das dortige Ende des Trägerrohres gedrückt wird. Um dabei eine Abdichtung zu erreichen, werden verschiedene Maßnahmen vorgeschlagen. Die Anordnung eines Dichtringes in einer radialen Nut oder am Boden der Öffnung des Endstücks ist aufwendig, wobei aufgrund der sehr hohen wirkenden Drücke beim Innenhochdruckumformen von typischerweise 2000 bis 5000 bar Leckagen an dem polymeren Dichtungsmaterial nicht ausgeschlossen werden können. Alternativ wird auch vorgeschlagen, die Öffnung in Form einer Sackbohrung an ihrem Boden mit einer kegelstumpfförmigen Anschrägung zu versehen, gegen die das Trägerrohr gedrückt wird. Dabei wird um den Umfang ein lediglich linienförmiger Kontakt erreicht, der bei Maßabweichungen, Unrundheiten sowie lokalen Beschädigungen eine zuverlässige Abdichtung nicht gewährleisten kann. Des Weiteren ist die Erzeugung solcher kegelförmigen Flächen am Boden der Öffnung aufwendig.A method for producing a built camshaft with the features described above is known from DE 36 16 901 A known. The production of the tubular component in the form of a built camshaft takes place in a closed mold, wherein a source of the pressurized fluid is connected to one side of the support tube and on the other side an end piece is pressed onto the local end of the support tube during the hydroforming process. In order to achieve a seal, various measures are proposed. The arrangement of a sealing ring in a radial groove or at the bottom of the opening of the tail is expensive, which due to the very high acting pressures during hydroforming typically 2000 to 5000 bar leaks in the polymeric sealing material can not be excluded. Alternatively, it is also proposed to provide the opening in the form of a blind bore at its bottom with a frusto-conical bevel against which the support tube is pressed. In this case, only a linear contact is achieved around the circumference, which can not ensure a reliable seal with dimensional deviations, ovality and local damage. Furthermore, the production of such conical surfaces at the bottom of the opening is expensive.

Vor diesem Hintergrund liegt der Erfindung die Aufgabe zugrunde, ein Verfahren zur Herstellung eines rohrförmigen Bauteils anzugeben, bei dem mittels Innenhochdruckumformung ein Endstück auf einfache Weise mit einer hohen Zuverlässigkeit und Reproduzierbarkeit befestigt werden kann. Des Weiteren soll ein Komponentensatz angegeben werden, der zur Durchführung des Herstellungsverfahrens geeignet ist.Against this background, the invention has for its object to provide a method for producing a tubular component, in which by means of hydroforming an end piece can be attached in a simple manner with a high reliability and reproducibility. Furthermore, a set of components is to be specified, which is suitable for carrying out the manufacturing process.

Ausgehend von einem Verfahren mit den eingangs beschriebenen Merkmalen wird die Aufgabe erfindungsgemäß dadurch gelöst, dass ausgehend von dem vorderen Rand der Öffnung an den ersten Abschnitt ein zweiter Abschnitt mit einem zweiten Innenquerschnitt, der kleiner ist als der Außenquerschnitt des zugeordneten Endes des Trägerrohres, unter Ausbildung einer umlaufenden Kante stufenförmig anschließt, wobei das Trägerrohr mit seinem entsprechenden Ende zunächst in den ersten Abschnitt eingesetzt wird und wobei bei einer weiteren Einschubbewegung die Kante sich in das Material des Trägerrohres schneidet. Die üblicherweise in etwa rechtwinklige Stufe definiert eine vergleichsweise scharfe Schneidkante, welche beim Einschieben des zugeordneten Endes des Trägerrohres im Bereich der Stirnfläche des Trägerrohres angreift und dort in das Material einschneidet. Bei diesem Einschneiden können sowohl eine Materialumformung als auch eine gewisse Materialabscherung erfolgen. Durch die beschriebene Verfahrensführung wird erreicht, dass um den Umfang ein breiterer Dichtbereich erzeugt wird, wodurch eine besonders zuverlässige Abdichtung gewährleistet wird. Zusätzlich ist das Endstück nach dem Einschieben des Trägerrohres durch das Einschneiden der Kante in einem gewissen Maße vorfixiert, so dass das Trägerrohr mit dem daran befestigten Endstück ohne weiteres gehandhabt werden kann, bevor letztendlich das Fügen mittels Innenhochdruck erfolgt.Based on a method with the features described above, the object is achieved in that, starting from the front edge of the opening to the first portion, a second portion having a second inner cross section, which is smaller than the outer cross section of the associated end of the support tube, under training a circumferential edge connects in steps, wherein the support tube is first inserted with its corresponding end in the first section and wherein in a further insertion movement, the edge is cut into the material of the support tube. The usually approximately rectangular step defines a comparatively sharp cutting edge, which engages when inserting the associated end of the support tube in the region of the end face of the support tube and there cuts into the material. In this cutting both a material deformation and a certain Materialabscherung can be done. By the method described process is achieved that a wider sealing area is generated around the circumference, whereby a particularly reliable sealing is ensured. In addition, the end piece is prefixed after insertion of the support tube by the cutting of the edge to a certain extent, so that the support tube with the attached end piece can be handled easily before finally the joining takes place by means of internal high pressure.

Während bei den aus dem Stand der Technik bekannten kegelförmigen Anlageflächen bei einer großen Krafteinwirkung durch die schräge Krafteinleitung im Wesentlichen nur eine Verbiegung des vergleichsweise dünnwandigen Rohres erfolgt, schneidet gemäß der vorliegenden Erfindung die vergleichsweise scharfe, üblicherweise in etwa durch einen rechten Winkel gebildete Kante an der Stirnfläche des Trägerrohres ein, wobei die Krafteinleitung zunächst einen erheblichen axialen Anteil aufweist, wodurch verstärkt eine Materialumformung bzw. Abscherung und weniger eine Verbiegung des Trägerrohres erfolgt.While essentially only a bending of the comparatively thin-walled tube takes place in the case of the conical abutment surfaces known from the state of the art due to the oblique introduction of force, according to the present invention, the comparatively sharp edge, usually formed approximately by a right angle, cuts along the edge End face of the support tube, wherein the introduction of force initially has a considerable axial portion, whereby reinforced material deformation or shearing and less bending of the support tube takes place.

Die Höhe der Stufe ist so gewählt, dass der ausgehend von der Stufe vorgesehene zweite Innenquerschnitt größer ist als der Innenquerschnitt des zugeordneten Endes des Rohres. Diese Differenz der Durchmesser ergibt das Fügespiel für die Vormontage. Des Weiteren sind die Maße bevorzugt auch so gewählt, dass trotz der Ausbildung der Stufe das Trägerrohr bis zu einem Boden der Öffnung oder zumindest bis kurz vor dem Boden der Öffnung auch in den Bereich des zweiten Abschnittes unter Verformung und/oder Abscherung eines Teils des Rohrmaterials eingeschoben werden kann. Dabei wird dann im Wesentlichen über die gesamte Länge des zweiten Abschnittes, die bevorzugt zwischen 1 mm und 8 mm, vorzugsweise etwa 4 mm beträgt, ein abdichtender Materialkontakt erreicht, so dass lokale Unebenheiten, Fehlstellen oder dergleichen auch bei einer Druckeinwirkung von mehreren 1000 bar nicht zu einer merklichen Reduzierung der Abdichtung führen. Eine Verlängerung des zweiten Abschnitts kann zweckmäßig sein, um ungleichmäßige Verkürzung des Rohres in Folge von Umformvorgängen zu kompensieren. Dadurch, dass das Trägerrohr mit seinem Ende bevorzugt bis zu dem Boden der Öffnung eingeschoben werden kann, ergibt sich auch in Bezug auf die Maßhaltigkeit eine besonders hohe Genauigkeit und Reproduzierbarkeit, da der Boden der Öffnung gleichsam als Anschlag für das zugeordnete Ende des Trägerrohres dient.The height of the step is selected such that the second internal cross-section provided from the step is greater than the internal cross-section of the associated end of the tube. This difference in diameter results in the joining play for the pre-assembly. Furthermore, the dimensions are preferably also chosen so that despite the formation of the stage, the support tube to a bottom of the opening or at least to just before the bottom of the opening in the region of the second section under deformation and / or shearing of a portion of the tube material can be inserted. In this case, then over the entire length of the second section, which is preferably between 1 mm and 8 mm, preferably about 4 mm, a sealing material contact is achieved, so that local unevenness, imperfections or the like even at a pressure of several 1000 bar not lead to a noticeable reduction of the seal. An extension of the second portion may be useful to compensate for uneven shortening of the tube as a result of forming operations. The fact that the support tube can preferably be inserted with its end to the bottom of the opening, also results in terms of dimensional accuracy of a particular high accuracy and reproducibility, since the bottom of the opening as it serves as a stop for the associated end of the support tube.

Die vorliegende Erfindung bezieht sich allgemein auf ein Verfahren zur Herstellung eines rohrförmigen Bauteils, wobei die Querschnittsform des Trägerrohres zunächst nicht festgelegt ist. Grundsätzlich sind quadratische, rechteckige, elliptische oder andere Querschnittsformen denkbar, wobei stets an dem Übergang des ersten Abschnitts zu dem zweiten Abschnitt innerhalb der Öffnung des Endstücks eine umlaufende Kante vorzusehen ist, wobei die Innenkontur der Öffnung an die Außenkontur des Trägerrohrs angepasst ist.The present invention generally relates to a method for manufacturing a tubular member, wherein the cross-sectional shape of the support tube is not initially determined. In principle, square, rectangular, elliptical or other cross-sectional shapes are conceivable, wherein a peripheral edge is always provided at the transition of the first section to the second section within the opening of the end piece, wherein the inner contour of the opening is adapted to the outer contour of the support tube.

Insbesondere im Hinblick auf gebaute Nockenwellen ist aber üblicherweise ein kreisrunder Querschnitt vorgesehen, so dass die Abschnitte der Öffnung bevorzugt kreiszylindrisch oder im Wesentlichen kreiszylindrisch ausgebildet sind. Die Angaben der Maße bezüglich der Innen- und Außenquerschnitte beziehen sich bei einer kreisförmigen Ausgestaltung entsprechend auf die Innen- und Außendurchmesser.However, in particular with regard to built camshafts, a circular cross-section is usually provided, so that the sections of the opening are preferably circular-cylindrical or substantially circular-cylindrical. The details of the dimensions with respect to the inner and outer cross sections relate to a circular configuration according to the inner and outer diameter.

Die Güte der Abdichtung einerseits sowie die zum Einschieben des Trägerrohrs in das zugeordnete Endstück erforderliche Kraft andererseits sind von der Festlegung der Maße, des zweiten Innenquerschnittes, der Länge dieses Abschnittes sowie des Außenquerschnittes des Rohres abhängig. In diesem Zusammenhang ist es bevorzugt, wenn der erste Innenquerschnitt gegenüber dem zweiten Innenquerschnitt in radialer Richtung ein Übermaß zwischen 0,1 mm und 1 mm, besonders bevorzugt zwischen 0,2 mm und 0,4 mm, aufweist, wobei dieses Maß der Höhe der im Wesentlichen rechtwinkligen Stufe zwischen dem ersten Abschnitt und dem zweiten Abschnitt entspricht. Das Spiel zwischen dem ersten Innenquerschnitt und dem Außenquerschnitt des zugeordneten Endes des Trägerrohres ist bevorzugt klein und üblicherweise gerade so gewählt, dass ein klemmfreies Aufschieben erfolgen kann. Gemäß einer bevorzugten Ausgestaltung der Erfindung weist der erste Innenquerschnitt gegenüber dem Außenquerschnitt des zugeordneten Endes des Rohres in radialer Richtung ein Übermaß von weniger als 0,2 mm, besonders bevorzugt zwischen 0,05 mm und 0,1 mm auf.The quality of the seal on the one hand and the force required for insertion of the support tube in the associated end piece on the other hand depend on the determination of the dimensions, the second inner cross section, the length of this section and the outer cross section of the tube. In this context, it is preferred if the first inner cross-section relative to the second inner cross-section in the radial direction has an excess between 0.1 mm and 1 mm, particularly preferably between 0.2 mm and 0.4 mm, which measure the height of the corresponds to a substantially right-angled step between the first section and the second section. The game between the first inner cross section and the outer cross section of the associated end of the support tube is preferably small and usually just chosen so that a jam-free pushing can take place. According to a preferred embodiment of the invention, the first inner cross section with respect to the outer cross section of the associated end of the tube in the radial direction an excess of less than 0.2 mm, more preferably between 0.05 mm and 0.1 mm.

Um an dem Endstück eine sichere Verbindung mit dem Trägerrohr zu gewährleisten und bevorzugt auch die Übertragung erheblicher Drehmomente zu ermöglichen, sind verschiedene Maßnahmen in Kombination oder alternativ zueinander vorzusehen.In order to ensure a secure connection to the support tube on the end piece and preferably also to allow the transmission of significant torques, various measures in combination or alternatively to each other are provided.

Zunächst ist die Festigkeit der Verbindung und damit das zu übertragende Drehmoment von der Überdeckung zwischen dem Trägerrohr und dem rohrförmigen Bauteil abhängig. Bei einer Ausgestaltung mit kreisförmigen Querschnitten ist deshalb gemäß einer bevorzugten Ausgestaltung der Erfindung vorgesehen, dass die Öffnung eine sich in Längsrichtung erstreckende Gesamtlänge aufweist, die zumindest 60 %, vorzugsweise zumindest 80 % des Innendurchmessers des ersten Abschnittes beträgt. Bezogen auf das fertige Bauteil ist die Länge entlang der Längsrichtung des Trägerrohres zu bestimmen.First, the strength of the connection and thus the torque to be transmitted by the overlap between the support tube and the tubular member dependent. In an embodiment with circular cross-sections, it is therefore provided according to a preferred embodiment of the invention that the opening has a longitudinally extending total length, which is at least 60%, preferably at least 80% of the inner diameter of the first section. Based on the finished component, the length along the longitudinal direction of the support tube is to be determined.

Um bei dem Innenhochdruckumformen eine hohe Fügefestigkeit zu erreichen, ist ausschlaggebend, dass der äußere Fügepartner eine größere elastische Rückstellung aufweist als das innenliegende Trägerrohr. Entsprechend muss zuvor auch eine ausreichende Aufweitung des außenliegenden Fügepartners erfolgen, wozu dieser eine nicht zu große Wandstärke aufweisen darf. So ist gemäß einer bevorzugten Ausgestaltung vorgesehen, dass das Endstück im Bereich des ersten Abschnittes der Öffnung eine Wandstärke zwischen 2 mm und 4 mm aufweist und so bei dem Innenhochdruckumformen im ausreichenden Maße elastisch aufgeweitet werden kann.In order to achieve a high joint strength in hydroforming, it is crucial that the outer joining partner has a greater elastic recovery than the inner support tube. Accordingly, a sufficient expansion of the outer joint partner must be carried out beforehand, for which it may have a not too large wall thickness. So is provided according to a preferred embodiment, that the end piece in the region of the first portion of the opening has a wall thickness between 2 mm and 4 mm and so can be expanded elastically in the hydroforming to a sufficient extent.

Um die kraftschlüssige Verbindung des Endstücks auf dem Trägerrohr im Presssitz zu verbessern, kann die Öffnung des Endstücks vor dem Einsetzen des zugeordneten Endes des Trägerrohres mit einem Partikelstrahl, beispielsweise einem Korundstrahl, einem Kugelstrahl, einem Sandstrahl oder dergleichen vorbehandelt werden. Dadurch erhöht sich der Reibwert zwischen den Fügeparametern. Um dabei eine Beschädigung der erfindungsgemäß möglichst scharfen Kante an dem Übergang von dem ersten Abschnitt zu dem zweiten Abschnitt der Öffnung zu vermeiden, kann diese während der Vorbehandlung durch den Partikelstrahl abgedeckt werden.In order to improve the frictional connection of the end piece on the support tube in an interference fit, the opening of the end piece can be pretreated before insertion of the associated end of the support tube with a particle beam, such as a corundum, a shot blasting, sandblasting or the like. This increases the coefficient of friction between the joining parameters. In order to avoid damage to the invention as sharp as possible edge at the transition from the first portion to the second portion of the opening, this can be covered during the pretreatment by the particle beam.

Auch ein gewisser Stoffschluss kann zu einer erhöhten Festigkeit der Verbindung beitragen. So ist es möglich vor dem Einsetzen des zugeordneten Endes des Trägerrohres in das Endstück Klebstoff auf die Außenfläche des Endes und/oder die Innenfläche der Öffnung aufzubringen oder auch die Oberfläche der Öffnung und/oder die Außenfläche des zugeordneten Endes des Rohres mit einer Verzinkung zu versehen, wobei durch die Beaufschlagung mit dem Druckfluid während des Innenhochdruckumformens die Zinkschicht zwischen beide Fügepartner verdichtet wird und ein Kraft-Stoffschluss mit Presslöten im Querpressverband erzeugt wird. Durch ein dynamisches Trainieren kann die Verbindungsfestigkeit noch weiter erhöht werden. Unter Trainieren versteht man die Erzeugung einer zusätzlichen Relativbewegung zwischen den Fügepartnern, beispielsweise ein Verdrehen oder Verschieben in wechselnde Richtungen.Even a certain adhesion can contribute to an increased strength of the connection. Thus, prior to insertion of the associated end of the carrier tube into the tail, it is possible to apply adhesive to the outer surface of the end and / or the inner surface of the opening, or to provide the surface of the opening and / or the outer surface of the associated end of the tube with galvanizing , In which the zinc layer is compressed between the two joining partners by the application of pressure to the pressurized fluid during hydroforming, and a force connection is produced by means of press soldering in the transverse compression bandage. Through a dynamic training, the connection strength can be further increased. Training is understood to be the generation of an additional relative movement between the joining partners, for example a twisting or shifting in alternating directions.

Um die Verbindung zwischen Endstück und dem zugeordneten Ende des Trägerrohres noch weiter zu verbessern, kann neben dem zuvor beschriebenen Kraftschluss durch einen Presssitz auch ein gewisser Formschluss durch eine zumindest abschnittsweise Konturierung der Öffnung des Endstücks erreicht werden. Die Konturierung kann beispielsweise die Form einer Spirale, einer Tasche, einer Innenrändelung, einer gestoßenen Innenkontur oder dergleichen aufweisen. Besonders vorteilhaft sind dabei Konturen, bei denen die Ausformungen quer zur Richtung der Drehmomentübertragung verlaufen. Durch die Beaufschlagung mit Innenhochdruck wird das Rohrmaterial in die entsprechende Konturierung eingeformt, wodurch sich zusätzlich zu dem Kraftschluss auch ein Formschluss ausbildet. Die Ausbildung einer Konturierung erfordert allerdings eine entsprechend hohe Wandstärke des Endstücks, was im gewissen Maße einer elastischen Dehnbarkeit entgegensteht.In order to further improve the connection between the end piece and the associated end of the support tube, in addition to the previously described frictional connection by a press fit and a certain positive fit can be achieved by at least partially contouring the opening of the tail. The contouring may, for example, have the form of a spiral, a pocket, an inner knurling, a butted inner contour or the like. Contours in which the formations run transversely to the direction of the torque transmission are particularly advantageous. By applying internal high pressure, the pipe material is molded into the corresponding contouring, whereby in addition to the adhesion and a positive connection is formed. However, the formation of a contouring requires a correspondingly high wall thickness of the tail, which counteracts to some extent elastic extensibility.

Die Innenhochdruckumformung erfolgt im Rahmen der Erfindung zweckmäßigerweise innerhalb einer Werkzeugform. Bevorzugt werden Funktionselemente wie Nocken, Sensorräder, Lagerringe oder dergleichen in der gewünschten Reihenfolge auf das Trägerrohr aufgefädelt, wobei auch an einem Ende des Trägerrohres das Endstück wie zuvor beschrieben aufgesteckt wird. Das Trägerrohr und die darauf aufgefädelten Funktionselemente werden dann in eine Werkzeugform eingelegt und dadurch hinsichtlich ihrer axialen Position und Drehwinkelausrichtung zueinander ausgerichtet. Nach dem Schließen der Werkzeugform wird eine Druckquelle an dem noch offenen Ende des Trägerrohres unter Anwendung einer axialen Kraft, die auch die Dichtfunktion gewährleistet, angeordnet, bevor durch die Druckquelle, beispielsweise einem Druckstempel die Beaufschlagung mit einem Druckfluid zur Durchführung des Innenhochdruckumformprozesses erfolgt. Dabei wird das Trägerrohr bei einem vorgegebenen Druck so weit ausgedehnt wie zur Ausformung und Befestigung erforderlich.The hydroforming takes place within the scope of the invention expediently within a mold. Preferably, functional elements such as cams, sensor wheels, bearing rings or the like are threaded onto the carrier tube in the desired sequence, wherein the end piece is also attached at one end of the carrier tube as described above. The support tube and the functional elements threaded thereon are then inserted into a tool mold and thereby aligned with respect to their axial position and rotational angle alignment. After closing the tool mold, a pressure source at the still open end of the support tube using an axial force, which also ensures the sealing function, arranged before the pressure source, such as a plunger is pressurized with a pressurized fluid to perform the hydroforming process. The carrier tube is at a given Pressure as far as required for shaping and fastening required.

Während des Innenhochdruckumformens kann die Druckquelle gemäß einer bevorzugten Ausgestaltung axial verfahren werden, um das Rohr dicht zu halten und eine Verkürzung des Rohres infolge der Ausbauchung auszugleichen. Neben der Fixierung der Funktionselemente in einem Presssitz kann das Innenhochdruckumformen auch dazu genutzt werden aus dem Trägerrohr selbst Funktionsflächen wie Lagerstellen zu bilden. Dabei ergibt sich der Vorteil, dass durch die plastische Verformung bis an die Werkzeugform heran gewisse Maßabweichungen des ursprünglich eingesetzten Trägerrohres ausgeglichen werden. Für die Maßhaltigkeit ist nämlich im Wesentlichen nur die Rückstellung des Trägerrohres nach dem Wegfall des Innenhochdrucks ausschlaggebend. Um an Abschnitten des Trägerrohres Lagerstellen zu bilden, können diese beispielsweise auch vor dem Innenhochdruckumformen einer Finish-Bearbeitung und/oder einer Beschichtung unterzogen werden.During hydroforming, the pressure source may, according to a preferred embodiment, be moved axially to keep the tube tight and to compensate for shortening of the tube due to the bulge. In addition to the fixation of the functional elements in a press fit, hydroforming can also be used to form functional surfaces such as bearing points from the support tube itself. This results in the advantage that due to the plastic deformation up to the tool shape, certain dimensional deviations of the carrier tube originally used are compensated. For the dimensional accuracy, in essence, only the provision of the support tube after elimination of the internal high pressure is decisive. In order to form bearings on sections of the support tube, they may, for example, also be subjected to finish machining and / or coating before hydroforming.

Wenn das Trägerrohr oder das Endstück nicht vollständig gereinigt sind, wenn trotz der erfindungsgemäß guten Abdichtung im Bereich des Endstücks zumindest zu Beginn der Innenhochdruckumformung noch gewisse Mengen an Druckfluid in den Fügespalt gelangen oder auch im Unterwerkzeug Emulsionsrückständen von vorherigen Umformvorgängen vorliegen, besteht die Gefahr, dass in dem Fügespalt ein Flüssigkeitsfilm entsteht, der als eine Art Gegenpolster und Abstandhalter den durch den Innenhochdruck ausgeübten Kräften entgegenwirkt. Es kann dann nicht ausgeschlossen werden, dass der Presssitz zwischen den Fügepartnern beeinträchtigt wird und/oder dass gewisse Produktionsschwankungen auftreten. Um eine solche Beeinträchtigung zu vermeiden, ist gemäß einer bevorzugten Ausgestaltung der Erfindung vorgesehen, dass zu Beginn des Innenhochdruckumformens Flüssigkeit aus dem Fügespalt zwischen Trägerrohr und Endstück abgeführt werden kann. Hierzu kann das Endstück im Bereich des ersten Abschnittes der Öffnung zumindest einen radialen Abführkanal, beispielsweise in Form einer Bohrung und/oder zumindest eine in Längsrichtung verlaufende Nut aufweisen.If the carrier tube or the end piece are not completely cleaned, if despite the good seal in the region of the tail at least at the beginning of hydroforming certain amounts of pressure fluid in the joint gap or in the lower mold emulsion residues of previous forming operations, there is a risk that in the joint gap, a liquid film is formed which, as a kind of counter cushion and spacer, counteracts the forces exerted by the internal high pressure. It can then not be ruled out that the interference fit between the joining partners is impaired and / or that certain production fluctuations occur. In order to avoid such an impairment, is provided according to a preferred embodiment of the invention that at the beginning of hydroforming liquid can be removed from the joint gap between the carrier tube and tail. For this purpose, the end piece in the region of the first portion of the opening may have at least one radial discharge channel, for example in the form of a bore and / or at least one groove extending in the longitudinal direction.

Um bei dem Innenhochdruckumformen zu vermeiden, dass das sich aufweitende Trägerrohr an dem Rand der Öffnung beschädigt wird, kann dort zwischen dem ersten Abschnitt und dem Rand der Öffnung ein Radius und/oder eine konische Aufweitung vorgesehen sein. Ein Einschneiden in das sich aufweitende Trägerrohr kann so vermieden werden. Die Ausbildung eines Radius oder einer konischen Erweiterung an dem Rand der Öffnung trägt auch dazu bei, dass das Endstück noch leichter auf das zugeordnete Ende des Trägerrohres aufgesetzt bzw. vormontiert werden kann.In order to avoid hydroforming in the hydroforming, the expanding support tube is damaged at the edge of the opening, there may be provided between the first portion and the edge of the opening, a radius and / or a conical widening. A cutting into the widening support tube can be avoided. The formation of a radius or a conical extension at the edge of the opening also contributes to the fact that the tail can be even more easily placed or preassembled on the associated end of the support tube.

Gegenstand der Erfindung ist auch ein Komponentensatz zur Herstellung eines rohrförmigen Bauteils mittels Innenhochdruckumformung, wobei der Komponentensatz zumindest das zuvor beschriebene Trägerrohr und Endstück aufweist.The invention also relates to a set of components for producing a tubular component by means of hydroforming, wherein the component set has at least the carrier tube and end piece described above.

Die Erfindung wird im Folgenden anhand lediglich ein Ausführungsbeispiel darstellenden Zeichnungen erläutert.The invention will be explained below with reference to only one embodiment illustrative drawings.

Es zeigen:

Fig. 1
den Längsschnitt einer gebauten Nockenwelle, die durch Innenhochdruckumformung aus einem Trägerrohr, Funktionselementen und einem Endstück gebildet ist,
Fig. 2
eine Detailansicht des in der Fig. 1 dargestellten Endstücks mit dem zugeordneten Ende des Trägerrohres vor der Innenhochdruckumformung.
Show it:
Fig. 1
the longitudinal section of a built camshaft, which is formed by hydroforming of a support tube, functional elements and an end piece,
Fig. 2
a detailed view of the in the Fig. 1 illustrated end piece with the associated end of the support tube before the hydroforming.

Fig. 1 zeigt den allgemeinen Aufbau einer durch Innenhochdruckumformung gebildeten Nockenwelle, die ein Trägerrohr 1, an einem Ende des Trägerrohres 1 ein Endstück 2 sowie eine Vielzahl von Funktionselementen in Form von Nocken 3 und einem Axiallager 4 aufweist. Das Endstück 2 und die Funktionselemente sind durch Innenhochdruckumformung in einem Presssitz auf dem Trägerrohr 1 befestigt. Durch die Innenhochdruckumformung sind des Weiteren Außenkonturen des Trägerrohres 1 ausgeformt, die als Lagerstellen 6 dienen. Schrauberfreigänge 7 in der Nockenwelle ermöglichen den Zugang zu Zylinderkopfschrauben. Um eine einfache Montage der aus Nockenwelle und Zylinderkopf gebildeten Baueinheit zu ermöglichen, sind über die Länge des Trägerrohres 1 mehrere Schrauberfreigänge 7 in das Trägerrohr 1 eingebracht. Fig. 1 shows the general structure of a formed by hydroforming camshaft having a support tube 1, at one end of the support tube 1, an end piece 2 and a plurality of functional elements in the form of cam 3 and a thrust bearing 4. The end piece 2 and the functional elements are fixed by hydroforming in a press fit on the support tube 1. As a result of the hydroforming, furthermore, outer contours of the carrier tube 1 are formed, which serve as bearing points 6. Screwdriver release 7 in the camshaft provide access to cylinder head bolts. In order to enable a simple assembly of the assembly formed from the camshaft and cylinder head, a plurality of screwdriver release 7 are introduced into the support tube 1 over the length of the support tube 1.

Bei der Herstellung der Nockenwelle werden zunächst die Funktionselemente auf das Trägerrohr 1 aufgeschoben und das Endstück 2 an einem Ende des Trägerrohres 1 vormontiert wird. Wie nachfolgend im Detail beschrieben, bewirkt das Aufpressen des Endstücks 2 auf das zugeordnete Ende des Trägerrohres 1 eine fluiddichte Verbindung, so dass der Austritt von Druckfluid bei der nachfolgenden Innenhochdruckumformung vermieden oder zumindest weitgehend vermieden werden kann. Zur Innenhochdruckumformung wird gegenüberliegend des Endstücks 2 eine Druckquelle an das Trägerrohr 1 angeschlossen, wobei sich das Trägerrohr 1 mit den Funktionselementen in einer Werkzeugform befindet, welche die Funktionselemente in der gewünschten axialen Position und der winkligen Ausrichtung zueinander hält sowie die Ausdehnung begrenzt. Dort, wo die Druckquelle angeschlossen wird, kann nach Wegfall des Innenhochdruckes nachträglich ein Endelement 8 eingesetzt werden.In the production of the camshaft, the functional elements are first pushed onto the carrier tube 1 and the end piece 2 is preassembled at one end of the carrier tube 1. As described in detail below, the pressing of the end piece 2 on the associated end of the support tube 1 causes a fluid-tight connection, so that the discharge of pressurized fluid in the subsequent hydroforming can be avoided or at least largely avoided. For hydroforming is opposite the end piece 2 a pressure source connected to the support tube 1, wherein the support tube 1 is located with the functional elements in a mold which holds the functional elements in the desired axial position and the angular orientation to each other and limits the extent. There, where the pressure source is connected, after the elimination of the internal high pressure subsequently an end element 8 can be used.

Das erfindungsgemäß zum druckdichten Verschluss vorgesehene Endstück 2 sowie das zugeordnete Ende des Trägerrohres 1 sind im Detail in der Fig. 2 dargestellt, wobei die Fig. 2 die beiden Komponenten vor ihrer Verbindung und entsprechend vor dem Umformen mittels Innenhochdruck zeigt. In der Fig. 2 ist zu erkennen, dass das Endstück 2 eine Öffnung 9 aufweist, wobei die Öffnung einen ersten kreiszylindrischen Abschnitt 10a mit einem Innendurchmesser Ia und einen daran unmittelbar anschließenden zweiten Abschnitt 10b mit einem geringeren Innendurchmesser Ib umfasst. Der Übergang zwischen dem ersten Abschnitt 10a und dem zweiten Abschnitt 10b ist stufenförmig ausgebildet, wobei die Abwinklung um etwa 90° eine Kante 11 definiert. Der Außendurchmesser A des Trägerrohres 1 liegt zwischen dem ersten Innendurchmesser Ia und dem zweiten Innendurchmesser Ib, so dass das Trägerrohr 1 zunächst leicht in den ersten Abschnitt 10a eingeschoben werden kann und sodann mit seiner Stirnfläche 12 an der Kante 11 anschlägt. Bei einer weiteren Einschubbewegung schneidet die Kante 11 in das Material des Trägerrohres 1 ein. Hierzu ist es wichtig, dass der Werkstoff des Endstücks 2 entsprechend fester bzw. härter ist, als der des Trägerrohres 1.The invention provided for pressure-tight closure end piece 2 and the associated end of the support tube 1 are shown in detail in the Fig. 2 shown, wherein the Fig. 2 shows the two components before their connection and accordingly before forming by means of internal high pressure. In the Fig. 2 It can be seen that the end piece 2 has an opening 9, wherein said opening comprises a first circular cylindrical portion 10a with an inner diameter I a and a directly adjoining the second portion 10b with a smaller inner diameter I b. The transition between the first portion 10a and the second portion 10b is step-shaped, wherein the bend defines an edge 11 by about 90 °. The outer diameter A of the support tube 1 is between the first inner diameter I a and the second inner diameter I b , so that the support tube 1 can first be easily inserted into the first portion 10 a and then abuts with its end face 12 at the edge 11. In a further insertion movement, the edge 11 cuts into the material of the support tube 1 a. For this purpose, it is important that the material of the end piece 2 is correspondingly stronger or harder than that of the support tube 1.

Die Höhe der Stufe zwischen dem ersten Abschnitt 10a und dem zweiten Abschnitt 10b ist dabei so gewählt, dass das Trägerrohr 1 unter teilweiser Umformung und/oder Abscherung des Materials bis an den Boden 13 der Öffnung 9 unter erhöhter Krafteinwirkung geschoben werden kann. Über im Wesentlichen die gesamte in axialer Richtung gemessene Länge xb des zweiten Abschnittes wird damit ein direkter Materialkontakt und entsprechend eine dichte Verbindung erreicht. Zusätzlich ist durch das Einschneiden der Kante 11 in das Material des Trägerrohres 1 das Endstück 2 auch bereits vorfixiert, so dass das Trägerrohr 1 und das Endstück 2 gemeinsam gehandhabt werden können. Die Länge xb des zweiten Abschnittes 10b beträgt typischerweise zwischen 1 mm und 8 mm, vorzugsweise etwa 4 mm.The height of the step between the first portion 10a and the second portion 10b is chosen so that the support tube 1 can be pushed under partial deformation and / or shearing of the material to the bottom 13 of the opening 9 under increased force. Over substantially the entire measured in the axial direction length x b of the second section is thus a direct material contact and, accordingly, achieved a tight connection. In addition, by cutting the edge 11 into the material of the carrier tube 1, the end piece 2 is already prefixed, so that the carrier tube 1 and the end piece 2 can be handled together. The length x b of the second portion 10b is typically between 1 mm and 8 mm, preferably about 4 mm.

Um wie beschrieben einerseits eine gute Dichtwirkung zu erreichen und andererseits das Trägerrohr 1 mit seiner Stirnfläche 12 bis zu dem Boden 13 der Öffnung 9 schieben zu können, sind geeignete Maße für die Innendurchmesser Ia, Ib und den Außendurchmesser A des zugeordneten Endes des Trägerrohres 1 festzulegen. So kann beispielsweise der erste Innendurchmesser Ia um 0,2 mm bis 1 mm, vorzugsweise zwischen 0,4 mm bis 0,8 mm größer sein als der zweite Innendurchmesser Ib des zweiten Abschnittes 10b.To achieve a good sealing effect as described on the one hand and on the other hand to push the support tube 1 with its end face 12 to the bottom 13 of the opening 9, suitable dimensions for the inner diameter I a , I b and the outer diameter A of the associated end of the support tube 1 set. Thus, for example, the first inner diameter I a by 0.2 mm to 1 mm, preferably between 0.4 mm to 0.8 mm greater than the second inner diameter I b of the second portion 10b.

Zwischen dem Trägerrohr 1 und dem ersten Abschnitt 10a ist bevorzugt nur ein kleiner radialer Spalt vorgesehen. So kann beispielsweise der Innendurchmesser Ia des ersten Abschnittes 10a gegenüber dem Außendurchmesser A des Trägerrohres 1 ein Übermaß von möglichst weniger als 0,2 mm, beispielsweise ein Übermaß zwischen 0,05 mm und 0,1 mm aufweisen.Between the support tube 1 and the first portion 10 a, only a small radial gap is preferably provided. For example, the inner diameter I a of the first portion 10a relative to the outer diameter A of the carrier tube 1 may have an excess of as less than 0.2 mm, for example, an excess of between 0.05 mm and 0.1 mm.

In dem Fügespalt zwischen dem Trägerrohr 1 und dem Endstück 2 kann die Ansammlung von Flüssigkeit, beispielsweise aus Restflüssigkeit im Werkzeug oder einem geringen Anteil an austretendem Druckfluid, nicht in allen Fällen völlig ausgeschlossen werden. Um solche Flüssigkeit zu Beginn der Innenhochdruckumformung abführen zu können, ist in dem Ausführungsbeispiel ein Abführkanal 14 in Form einer Bohrung vorgesehen. Zusätzlich oder alternativ kann zur Abfuhr von Flüssigkeit auch eine in Längsrichtung verlaufende Nut in den ersten Abschnitt 10a eingebracht sein.In the joint gap between the support tube 1 and the end piece 2, the accumulation of liquid, for example, residual liquid in the tool or a small amount of leaking pressurized fluid, can not be completely excluded in all cases. In order to discharge such liquid at the beginning of the hydroforming, a discharge channel 14 is provided in the form of a bore in the embodiment. In addition or as an alternative, a groove extending in the longitudinal direction can also be introduced into the first section 10a for the removal of fluid.

Um bei dem Aufweiten des Trägerrohres 1 ein Einschneiden an dem vorderen Rand der Öffnung 9 zu vermeiden, ist dort an den Übergang zum ersten Abschnitt 10a eine konische Aufweitung 15 vorgesehen.In order to avoid incision at the front edge of the opening 9 when expanding the support tube 1, a conical widening 15 is provided there at the transition to the first section 10a.

Besonders bevorzugt ist eine Ausgestaltung, bei der das Endstück 2 nicht nur zum druckdichten Verschluss dient, sondern auch funktionelle Merkmale aufweist. So ist in dem Ausführungsbeispiel ein mittlerer Abschnitt des geschlossenen Endstücks 2 mit einem Gewinde 16 für eine Zentralschraube versehen.Particularly preferred is an embodiment in which the end piece 2 is not only used for pressure-tight closure, but also has functional features. Thus, in the embodiment, a central portion of the closed end piece 2 is provided with a thread 16 for a central screw.

Um zwischen dem Trägerrohr 1 und dem Endstück 2 eine ausreichende Fügespannung zu erzeugen, beträgt die Gesamtlänge xg der gesamten Öffnung 9 in dem dargestellten Ausführungsbeispiel zumindest 80 % des ersten Innendurchmessers Ia.In order to produce a sufficient joining stress between the support tube 1 and the end piece 2, the total length x g of the entire opening 9 in the illustrated embodiment is at least 80% of the first inner diameter I a .

Eine noch weitere Erhöhung der Festigkeit der Verbindung kann beispielweise durch Klebstoff, eine Verzinkung oder eine zumindest abschnittsweise Konturierung erreicht werden. Zum Zwecke der Übersichtlichkeit sind diese optionalen Maßnahmen in den Figuren nicht dargestellt.An even further increase in the strength of the connection can, for example, by adhesive, galvanizing or at least partially contouring be achieved. For the sake of clarity, these optional measures are not shown in the figures.

Claims (16)

  1. A method for manufacturing a pipe-shaped component, in particular an assembled camshaft, by means of internal high-pressure forming, wherein a carrier pipe (1) and an end piece (2) are supplied, wherein an associated end of the carrier pipe (1) is inserted into an opening (9) of the end piece (2) and is then widened through the application of a hydraulic fluid and connected with the end piece (2) by means of a press fit, and wherein the opening (9), prior to the application of the hydraulic fluid, comprises a first portion (10a) with an inner cross-section which is larger than the outer cross-section of the associated end of the carrier pipe (1), characterised in that, starting from the front rim of the opening (9), a second portion (10b) with a second inner cross-section smaller than that of the outer cross-section of the associated end of the carrier pipe (1) adjoins the first portion (10a) in a stepped manner, wherein the carrier pipe (1) with its corresponding end is initially inserted into the first portion (10a) and wherein, when a further insertion movement takes place, the edge (11) cuts into the material of the carrier pipe (1).
  2. The method according to claim 1, characterised in that the opening (9) of the end piece (2), prior to inserting the associated end of the carrier pipe (1), is pre-treated with a particle jet.
  3. The method according to claim 2, characterised in that the edge (11) is masked by the particle jet during the pre-treatment.
  4. The method according to one of claims 1 to 3, characterised in that prior to inserting the associated end of the carrier pipe (1) into the end piece (2), adhesive is applied to the external surface of the end and/or the internal surface of the opening (9).
  5. The method according to one of claims 1 to 4, characterised in that the carrier pipe (1), the end piece (2) and further functional elements comprising a hub, respectively, are placed into a tool mould, wherein the hydraulic fluid is applied once the tool mould has been closed.
  6. A component set for manufacturing a pipe-shaped component by means of internal high-pressure forming, in particular according to a method as specified in claims 1 to 5, comprising a carrier pipe (1), functional elements provided for arrangement on the carrier pipe (1), as well as an end piece (2) with an opening (9) for the carrier pipe (1),
    wherein the opening (9) comprises a first portion (10a) with a first inner cross-section larger than the outer cross-section of the associated end of the carrier pipe (1) and a second portion (10b) with a second inner cross-section smaller than the outer cross-section of the associated end of the carrier pipe (1),
    wherein, starting from the front rim of the opening (9), the second portion (10b) adjoins the first portion (10a) in a stepped manner, by forming a circumferential edge (11), and
    wherein the second inner cross-section is larger the inner cross-section of the associated end of the carrier pipe (1).
  7. The component set according to claim 6, characterised in that the first and the second inner cross-sections as well as the outer cross-section of the associated end of the pipe are circular in shape.
  8. The component set according to claim 7, characterised in that the opening (9) comprises an overall length (xg), which is at least 40%, preferably at least 80% of the inner diameter (Ia) of the first portion (10a).
  9. The component set according to one of claims 6 to 8, wherein the second portion (10b) extends over a length (xb) of between 1mm and 8mm, preferably of approx. 4mm.
  10. The component set according to one of claims 6 to 9, wherein the first inner cross-section compared to the second inner cross-section, in radial direction, is oversized by between 0.2 and 1mm, preferably by between 0.4mm and 0.8mm.
  11. The component set according to one of claims 6 to 10, wherein the first inner cross-section compared to the outer cross-section of the associated end of the carrier pipe (1), in radial direction, is oversized by less than 0.2mm, preferably by between 0.05mm and 0.1 mm.
  12. The component set according to one of claims 6 to 11, wherein provision is made for a radius and/or conical widening between the first portion (10a) and the rim of the opening (9), in order to avoid cutting into the widening carrier pipe (1), while the press fit is being formed through the application of a hydraulic fluid.
  13. The component set according to one of claims 6 to 12, characterised in that the surface of the opening (9) and/or the outer surface of the associated end of the carrier pipe (1) is zinc-plated.
  14. The component set according to one of claims 6 to 13, wherein the end piece (2), in the area of the first portion (10a) of the opening (9), comprises at least one radial discharge channel (14) and/or a groove extending in longitudinal direction.
  15. The component set according to one of claims 6 to 14, wherein the end piece (2), in the area of the first portion (10a) of the opening (9), comprises a wall thickness between 2mm and 4mm.
  16. The component set according to one of claims 6 to 15, wherein the end piece (2) comprises functional features.
EP11782645.3A 2010-11-19 2011-11-17 Method and set of components for producing a tubular structural part, in particular a built-up camshaft Not-in-force EP2640535B1 (en)

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DE102010060686.3A DE102010060686B4 (en) 2010-11-19 2010-11-19 Method and component set for producing a tubular component, in particular a built-up camshaft
PCT/EP2011/070397 WO2012066099A1 (en) 2010-11-19 2011-11-17 Method and set of components for producing a tubular structural part, in particular a built-up camshaft

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US9284858B2 (en) 2016-03-15
WO2012066099A1 (en) 2012-05-24
CN103442822A (en) 2013-12-11
DE102010060686B4 (en) 2015-02-26
US20130305532A1 (en) 2013-11-21
DE102010060686A1 (en) 2012-05-24
EP2640535A1 (en) 2013-09-25
CN103442822B (en) 2016-01-13

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