EP2790850B1 - Method of manufacturing a steering knuckle - Google Patents

Method of manufacturing a steering knuckle Download PDF

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Publication number
EP2790850B1
EP2790850B1 EP12812572.1A EP12812572A EP2790850B1 EP 2790850 B1 EP2790850 B1 EP 2790850B1 EP 12812572 A EP12812572 A EP 12812572A EP 2790850 B1 EP2790850 B1 EP 2790850B1
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EP
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Prior art keywords
steering knuckle
die
forging
finished
contour
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EP12812572.1A
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German (de)
French (fr)
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EP2790850A1 (en
Inventor
Markus Bachmann
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CDP Bharat Forge GmbH
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CDP Bharat Forge GmbH
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    • 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
    • B21J5/008—Incremental forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • 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
    • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
    • B21J5/025—Closed die forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J9/00—Forging presses
    • B21J9/02—Special design or construction
    • B21J9/027—Special design or construction with punches moving along auxiliary lateral directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/06—Making machine elements axles or shafts
    • B21K1/12—Making machine elements axles or shafts of specially-shaped cross-section

Definitions

  • the present invention relates to a method for producing a steering knuckle of commercial vehicles.
  • the final contour is to be understood as meaning the shape of the surface of the finished forging (before a possible mechanical fine machining such as trimming or hot-straightening), ie it also includes indentations, indentations, undercuts and the like.
  • Under outer contour is the part of the surface of the forging to see, which is generally directed away from the forging to the outside, and thus, for example, no undercuts, indentations or the like.
  • the outer contour is determined by the shape of the inner surfaces of the forging die.
  • a semi-finished or almost finished forged part with a smaller outer contour than the final contour is preferably obtained during the pre-forging.
  • the pre-forging can consist of one, but also of two or more forging steps, by means of which the forging of the final contour is approximated.
  • the die is filled in an optimal way "from the inside", resulting in much lower Committee by incomplete Gesenk spallung.
  • the provision of the extra step of forming, compared to the prior art, has advantages both in terms of economy and process stability.
  • Another advantage is that is displaced by the forming and in particular the insertion of the / the tool material and thus the fiber flow of the material is held parallel to the surfaces (the final contour).
  • the finished forged part is given increased strength, in particular at edges and bends as well as other more complicated geometric features of the surface of the forged part, such as, for example, bearing receptacles.
  • the tool which is introduced during forming in the forging, a mandrel or hollow mandrel.
  • a mandrel or hollow mandrel high forming forces can be applied, which lead to an efficient material displacement during forming and a complete filling of the die.
  • a hollow mandrel also allows a particularly precise shaping of the forged part at the insertion point and can thus be used particularly effectively for determining the final contour.
  • secondary molding elements of the finished forging are formed by the tool (s).
  • Belleformemia in the sense of the present application are forming features of the forged part surface, which forging technology is difficult or impossible to produce by dies (against each other moving die halves), for example, the shots for bearings on truck steering knuckles.
  • the formation of secondary features required in the prior art material-removing machining operations which not only increased the use of materials but also extended the process times.
  • the forming is carried out substantially at the temperature of the previous step of pre-forging.
  • the advantage here is that due to the still high temperatures from the forging process, a much less power-consuming forming is possible and at the same time no additional energy for heating the forging for the transformation is needed.
  • the forming / shaping directions determined by the tool / s substantially perpendicular to the closing direction of the die is / are.
  • the material forced towards the sides of the tool can thus almost completely fill the mold cavity defined by the die.
  • This mold cavity preferably defines the outer contour of the predetermined final contour, in other words the die determines the position of the substantially outwardly directed surfaces of the finished forging, while depressions, indentations or similar ancillary features can be defined by the tools (eg hollow mandrels).
  • FIG. 1 schematically shows the sequence of a manufacturing process of a truck steering knuckle according to the prior art.
  • a blank 10 made of steel is first compressed, pre-pressed and subjected to a first pre-forging step ( FIGS. 1a to c ), wherein the essential outer geometry of the finished component is generated.
  • Figure 1d the subsequent second pre-forging step ( Figure 1d ) are produced by the die, the detailed outer contours of this intermediate product 10 '(but not greater than the predetermined final contour).
  • FIG. 2 is for comparison with the conventional method of FIG. 1 the sequence of an exemplary method for the production of forgings shown according to the invention, again using the example of the truck steering knuckle.
  • a blank 20 is first compressed, pre-pressed and forged in two steps ( FIGS. 2a to d ) to substantially approximate the outer contour of the finished forging.
  • the pre-forging ie in the present case after the second pre-forging step
  • the blank 20 ' is still substantially at forging temperature
  • a deformation of the forging in a die is performed, the mold cavity of which the outer contour of the predetermined Final contour of the component defined.
  • each a hollow mandrel of the front and rear stub axle side in the semi-finished forging 20 'introduced and thereby the inwardly recessed bearing receivers 21 a and 21 b formed ( FIG. 2e and 3b ).
  • the hollow mandrels have exactly the shape and dimensions of the trainees bearing to be formed. Only then is removed by burring / hot straightening located in the forge blacksmithing excess, but the burring or hot straightening is no longer necessary to produce the complete final contour and thus takes much less time than the burring or hot straightening in due to the substantially lower material removal State of the art (cf.
  • FIG. 3 is shown in perspective and in sectional view, a comparison between the finished forged and deburred components.
  • the finished forged blank 10 'produced by the conventional method does not yet include recesses for the Bearing support, the corresponding side sections 11a and 11b are solid. Accordingly, the weight of the conventionally manufactured stub axle is 32kg.
  • the truck steering knuckle according to the invention already has the recesses for the bearing shells, so they no longer need to be made by machining under material rejects.
  • the weight of the finished forged blank, which is 29kg, is correspondingly lower. It can not only save about 10% of material but also significantly shorter process times can be achieved.
  • FIG. 4 is a perspective view of a die used in the method according to the invention shown, with the sake of clarity, only the lower die half 30 is shown. This is done in the second step of forging ( Figure 2d ) produced intermediate product 20 ', which is still substantially at the forging temperature, inserted into the die 30 and this closed by lowering the upper die half (not shown) (see arrow: "closing direction" in FIG. 4 ).
  • hollow dowels 31a and 31b are pressed from two directions (see arrows "forming direction") into the sides of the half-finished forging 20 'which form the bearing receptacles in the finished forged truck knuckle 20 "' Due to the still high temperatures from the previous forging process, due to the material displaced by the hollow mandrels 31a and 31b, the entire die shape, ie the predetermined final contour, is completely filled in. This is illustrated by the shaded contours of the forging 20 " , In other words, during the forming according to the invention, the material flows into the initially free mold spaces on the inner surfaces of the dies until the die mold has been filled.
  • slightly more material is preferably present in the die at the beginning of the forming, as is required in terms of volume for the final forging. During the subsequent displacement of the material due to the insertion of the tool / tools this flows into the burrs on the Die edges and thus always ensures a reliable, complete Gesenk hypollung.
  • the savings achieved by the inventive method of raw material is particularly good from the sectional drawing of FIG. 5 refer to.
  • the reference numeral 22 indicates that after the second pre-forging ( Figure 2d ) designated forged contour
  • reference numeral 23 denotes the final contour after the forming process according to the invention, that is, after the introduction of the hollow mandrels.
  • the predetermined by the die 30 outer end contour 23 is filled starting from the forged contour 22.
  • the volume fraction of the introduced hollow mandrel fills the die starting from the forged smaller forging contour 22 up to the predetermined final contour 23.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)

Description

Technisches GebietTechnical area

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Achsschenkels von Nutzfahrzeugen.The present invention relates to a method for producing a steering knuckle of commercial vehicles.

Stand der TechnikState of the art

In der Fahrzeugindustrie sowie allgemein im Bereich der Transport- und Nutzfahrzeuge (das heißt zum Beispiel PKW, LKW, Baufahrzeuge, Züge) kommen zunehmend hochbelastete geschmiedete Bauteile mit komplexen Geometrien zum Einsatz. Gleichzeitig sind auch die Anforderungen an die Präzision der Bauteile gestiegen. Bei der Herstellung derartiger Schmiedeteile, wie zum Beispiel den eingangs genannten Achsschenkeln für Nutzfahrzeuge, wird im gegenwärtigen Stand der Technik zunächst durch Schmieden ein Rohteil erzeugt, welches nach dem Abgraten anschließend nochmals mechanisch, das heißt spanend nachbearbeitet wird, um gewünschte Merkmale wie Lageraufnahmen mit der erforderlichen Präzision auszubilden und so zum Fertigprodukt zu gelangen. Durch diese mechanische Nachbearbeitung verlängern sich zum Einen aber die Bearbeitungszeiten am geschmiedeten Teil, und andererseits wird auf Grund der Materialentfernung durch die spanende Nachbearbeitung der für das Endprodukt benötigte Rohmaterialanteil erhöht. Beide Gesichtspunkte führen zu einer nicht unwesentlichen Kostensteigerung sowie zu erhöhter Umweltbelastung. Während es aus Sicht der Materialersparnis denkbar wäre, derartige Bauteile zu gießen, so haben Gussprodukte jedoch in Hinblick auf die Materialfestigkeit und Belastbarkeit eindeutige Nachteile gegenüber Schmiedeprodukten, welche insbesondere bei hochbelasteten Bauteilen wie den genannten Achsschenkeln für Nutzfahrzeuge von großer Bedeutung sind.In the automotive industry and in general in the field of transport and commercial vehicles (ie, for example, cars, trucks, construction vehicles, trains) increasingly heavily loaded forged components with complex geometries are used. At the same time, the demands on the precision of the components have increased. In the production of such forgings, such as the aforementioned stub axles for commercial vehicles, a blank is first produced by forging in the current state of the art, which is then re-machined mechanically after the trimming, that is machined to desired features such as bearing mountings with the form the required precision and thus arrive at the finished product. On the one hand, however, the machining times on the forged part are lengthened by this mechanical reworking, and on the other hand, the raw material content required for the end product is increased due to the removal of material by the subsequent machining. Both aspects lead to a not insignificant cost increase and to increased environmental impact. While it would be conceivable from the point of view of material savings to cast such components, however cast products have clear disadvantages in terms of material strength and resilience compared to forged products, which are particularly important for heavy-duty components such as the stub axles for commercial vehicles of great importance.

Darstellung der ErfindungPresentation of the invention

Ausgehend von dieser Problemstellung ist es eine Aufgabe der Erfindung, ein Verfahren zur Herstellung von Schmiedeteilen bereit zu stellen, welches ohne Einbußen bei der Fertigungsgenauigkeit das Einsatzgewicht des Bauteils reduziert und das Rohteilgewicht insgesamt verringert, und dabei gleichzeitig die Fertigungszeiten verkürzt.Based on this problem, it is an object of the invention to provide a method for the production of forgings, which reduces the operating weight of the component without sacrificing the manufacturing accuracy and reduces the overall weight of the blank, while shortening the production times.

Gelöst wird diese Aufgabe durch ein Verfahren zur Herstellung eines Achsschenkels mit den Merkmalen des Anspruchs 1. Bevorzugte Ausführungsformen sind in den Unteransprüchen definiert.This object is achieved by a method for producing a steering knuckle with the features of claim 1. Preferred embodiments are defined in the subclaims.

Im Sinne der Erfindung ist unter Endkontur die Form der Oberfläche des fertigen Schmiedeteils (vor einer eventuellen mechanischen Feinbearbeitung wie Abgraten oder Warmrichten) zu verstehen, sie umfasst also auch Vertiefungen, Einbuchtungen, Hinterschnitte und dergleichen. Unter Außenkontur ist hingegen der Teil der Oberfläche des Schmiedeteils anzusehen, der allgemein vom Schmiedeteil nach Außen weg gerichtet ist, und somit beispielsweise keine Hinterschnitte, Einbuchtungen oder dergleichen umfasst. Bei herkömmlichem Schmieden wird die Außenkontur durch die Form der Innenflächen des Schmiedegesenks bestimmt. Im Falle der vorliegenden Erfindung wird beim Vorschmieden bevorzugt ein halb- bzw. nahezu fertiges Schmiedeteil mit im Vergleich zur Endkontur kleineren Außenkontur erhalten. Das Vorschmieden kann dabei aus einem, aber auch aus zwei oder mehreren Schmiedeschritten bestehen, mithilfe derer das Schmiedeteil der Endkontur angenähert wird.For the purposes of the invention, the final contour is to be understood as meaning the shape of the surface of the finished forging (before a possible mechanical fine machining such as trimming or hot-straightening), ie it also includes indentations, indentations, undercuts and the like. Under outer contour, however, is the part of the surface of the forging to see, which is generally directed away from the forging to the outside, and thus, for example, no undercuts, indentations or the like. In conventional forging, the outer contour is determined by the shape of the inner surfaces of the forging die. In the case of the present invention, a semi-finished or almost finished forged part with a smaller outer contour than the final contour is preferably obtained during the pre-forging. The pre-forging can consist of one, but also of two or more forging steps, by means of which the forging of the final contour is approximated.

Durch das erfindungsgemäße Umformen wird es möglich, den Rohling unter geringerem Materialeinsatz herzustellen, da zum Erreichen der Endkontur kein mechanisches beziehungsweise spanendes Fertigbearbeiten notwendig ist. Eine eventuelle Nachbearbeitung kann somit zeitsparend auf das präzise Erreichen der Dimensionen konzentriert werden, wozu lediglich geringfügiger Materialabtrag (beispielsweise in Form von Abgraten) notwendig ist, so dass einerseits der Anteil des Rohmaterials am fertigen Produkt sinkt und andererseits erhebliche Zeitersparnisse bei der Herstellung erzielt werden können. Weiter werden auf Grund des geringeren Rohteilgewichts sowie des geringeren Einsatzgewichts (Volumen) des Schmiedeteils Ersparnisse beim Transport sowohl innerhalb der Fabrik als auch nachfolgend bei der Auslieferung erzielt. All dies wirkt sich positiv nicht nur auf die Herstellungskosten aus, sondern trägt auch zu einer geringeren Umweltbelastung der Produktion bei. Durch das Einbringen des Werkzeugs oder der Werkzeuge in das Schmiedeteil und die dementsprechende Materialverdrängung wird auch auf optimale Weise das Gesenk "von innen" gefüllt, was zu wesentlich geringerem Ausschuß durch unvollständige Gesenkfüllung führt. In anderen Worten bringt das Vorsehen des, im Vergleich zum Stand der Technik zusätzlichen Schritts des Umformens Vorteile sowohl im Hinblick auf Wirtschaftlichkeit als auch auf Prozessstabilität.By forming the invention, it is possible to produce the blank with less material use, since no mechanical or machining finishing is necessary to achieve the final contour. A possible post-processing can thus be time-saving concentrated on the precise achievement of the dimensions, for which only minor material removal (for example in the form of burring) is necessary, so that on the one hand the proportion of raw material decreases on the finished product and on the other hand considerable time savings can be achieved in the production , Further, due to the lower stock weight and lower insert weight (volume) of the forging, savings are made in transportation both within the factory and subsequently upon delivery. All this has a positive effect not only on the manufacturing costs, but also contributes to a lower environmental impact of production. By introducing the tool or tools in the forging and the corresponding displacement of material, the die is filled in an optimal way "from the inside", resulting in much lower Committee by incomplete Gesenkfüllung. In other words, the provision of the extra step of forming, compared to the prior art, has advantages both in terms of economy and process stability.

Weiter von Vorteil ist, dass durch das Umformen und insbesondere das Einführen des/der Werkzeuge Material verdrängt wird und somit der Faserverlauf des Materials parallel zu den Oberflächen (der Endkontur) gehalten wird. Dadurch wird dem fertigen Schmiedeteil eine erhöhte Festigkeit insbesondere an Kanten und Abwinkelungen sowie anderen komplizierteren geometrischen Merkmalen der Oberfläche des Schmiedteils, wie zum Beispiel Lageraufnahmen verliehen.Another advantage is that is displaced by the forming and in particular the insertion of the / the tool material and thus the fiber flow of the material is held parallel to the surfaces (the final contour). As a result, the finished forged part is given increased strength, in particular at edges and bends as well as other more complicated geometric features of the surface of the forged part, such as, for example, bearing receptacles.

Hierbei ist es bevorzugt, dass zu Beginn des Umformens geringfügig mehr Material im Gesenk vorhanden ist, als volumenmäßig für das endgültige Schmiedeteil (welches durch die vorgegebene Endkontur definiert wird) vonnöten ist, und somit durch das Einführen des Werkzeugs/der Werkzeuge beim Umformen das Material auch in die Grate an den Gesenkrändern fließt. Dadurch wird zusätzliche Prozesssicherheit im Hinblick auf eine vollständige Gesenkfüllung geschaffen.It is preferred that at the beginning of forming slightly more material is present in the die than in volume for the final forging (which is defined by the predetermined final contour) is needed, and thus by the insertion of the tool / tools during forming the material also flows into the ridges at the die edges. This creates additional process reliability with regard to complete die filling.

Bevorzugt ist das Werkzeug, welches beim Umformen in das Schmiedeteil eingeführt wird, ein Dorn oder Hohldorn. Durch den Einsatz eines Dorns oder Hohldorns können hohe Umformkräfte aufgebracht werden, welche zu einer effizienten Materialverdrängung beim Umformen und einem vollständigen Ausfüllen des Gesenks führen. Ein Hohldorn ermöglicht zudem eine besonders präzise Formung des Schmiedeteils an der Einführstelle und kann somit besonders effektiv zur Bestimmung der Endkontur eingesetzt werden.Preferably, the tool, which is introduced during forming in the forging, a mandrel or hollow mandrel. Through the use of a mandrel or hollow mandrel high forming forces can be applied, which lead to an efficient material displacement during forming and a complete filling of the die. A hollow mandrel also allows a particularly precise shaping of the forged part at the insertion point and can thus be used particularly effectively for determining the final contour.

Gemäß einer bevorzugten Ausführungsform werden durch das beziehungsweise die Werkzeuge Nebenformelemente des fertigen Schmiedeteils ausgebildet. Nebenformelemente im Sinne der vorliegenden Anmeldung sind dabei Formmerkmale der Schmiedeteiloberfläche, welche schmiedetechnisch nicht oder nur schwer durch Gesenke (gegeneinander bewegte Gesenkhälften) herstellbar sind, beispielsweise die Aufnahmen für Lagerschalen an LKW-Achsschenkeln. Insbesondere die Ausbildung von Nebenformelementen erforderte im Stand der Technik Material abtragende maschinelle Bearbeitungsvorgänge, welche nicht nur den Materialeinsatz erhöhten sondern auch die Prozesszeiten verlängerten. Indem derartige Nebenformelemente mit Hilfe des/der Werkzeuge ausgebildet werden, kann somit besonders viel Material und entsprechend Zeit gespart werden.According to a preferred embodiment, secondary molding elements of the finished forging are formed by the tool (s). Nebenformelemente in the sense of the present application are forming features of the forged part surface, which forging technology is difficult or impossible to produce by dies (against each other moving die halves), for example, the shots for bearings on truck steering knuckles. In particular, the formation of secondary features required in the prior art material-removing machining operations, which not only increased the use of materials but also extended the process times. Thus, by forming such auxiliary features by means of the tool (s), it is possible to save a great deal of material and time.

In einer besonders bevorzugten Ausführungsform wird das Umformen im Wesentlichen bei der Temperatur des vorangegangenen Schritts des Vorschmiedens durchgeführt. Vorteilhaft ist hierbei, dass auf Grund der noch aus dem Schmiedevorgang hohen Temperaturen eine wesentlich kraftsparendere Umformung möglich ist und gleichzeitig keine zusätzliche Energie zur Erwärmung des Schmiedeteils für die Umformung vonnöten ist.In a particularly preferred embodiment, the forming is carried out substantially at the temperature of the previous step of pre-forging. The advantage here is that due to the still high temperatures from the forging process, a much less power-consuming forming is possible and at the same time no additional energy for heating the forging for the transformation is needed.

Vorteilhaft ist ferner, dass die durch das/die Werkzeuge bestimmte Umformrichtung/Umformrichtungen im Wesentlichen senkrecht zur Schließrichtung des Gesenks ist/sind. Beim Umformen wird nämlich der vorgeschmiedete Rohling in das Gesenk eingelegt und dieses geschlossen. Durch Einbringen der Werkzeuge in der genannten Umformrichtung im Wesentlichen senkrecht zur Schließrichtung des Gesenks kann somit das zu den Seiten des Werkzeugs weg gedrängte Material in nahezu idealer Weise den durch das Gesenk bestimmen Formhohlraum ausfüllen. Dieser Formhohlraum definiert bevorzugt die Außenkontur der vorgegebenen Endkontur, in anderen Worten bestimmt das Gesenk die Lage der im Wesentlichen nach außen gerichteten Oberflächen des fertigen Schmiedeteils, während durch die Werkzeuge (beispielsweise Hohldorne) Vertiefungen, Einbuchtungen oder ähnliche Nebenformelemente definiert werden können. Dies trägt ebenfalls zur effizienten Füllung des Gesenks bei und vermeidet dadurch übermäßigen Materialeinsatz.
Schließlich ist es besonders vorteilhaft, das Schmiedeteil nach dem Umformen einem Schritt des Abgratens beziehungsweise Warmrichtens zu unterziehen. Dadurch kann das durch das Hohldornen entstehende Verzugsverhalten des Schmiedeteils effizient kompensiert werden, ohne dass es eines großen Materialabtrags beziehungsweise Warmrichtaufwands bedarf, mit konsequenter Verbesserung der Präzision der Fertigung unter gleichbleibend geringem Materialeinsatz und mit kurzen Prozesszeiten.It is also advantageous that the forming / shaping directions determined by the tool / s substantially perpendicular to the closing direction of the die is / are. When forming namely the pre-forged blank is inserted into the die and this closed. By introducing the tools in said forming direction substantially perpendicular to the closing direction of the die, the material forced towards the sides of the tool can thus almost completely fill the mold cavity defined by the die. This mold cavity preferably defines the outer contour of the predetermined final contour, in other words the die determines the position of the substantially outwardly directed surfaces of the finished forging, while depressions, indentations or similar ancillary features can be defined by the tools (eg hollow mandrels). This also contributes to the efficient filling of the die and thereby avoids excessive use of material.
Finally, it is particularly advantageous to subject the forging after forming a step of trimming or hot straightening. As a result, the distorting behavior of the forging part resulting from the hollow mandrel can be compensated efficiently, without the need for a large material removal or heat straightening effort, with consequent improvement in the precision of production with consistently low material usage and with short processing times.

Kurze Beschreibung der ZeichnungenBrief description of the drawings

Nachfolgend wird eine bevorzugte Ausführungsform des erfindungsgemäßen Verfahrens anhand der beigefügten Zeichnungen beispielhaft erläutert.

  • Figur 1 zeigt am Beispiel eines Achsschenkels schematisch ein Herstellungsverfahren gemäß dem Stand der Technik;
  • Figur 2 zeigt schematisch ein Beispiel des erfindungsgemäßen Verfahrens zur Herstellung von Schmiedeteilen mit einer vorgegebenen Endkontur, ebenfalls am Beispiel des Achsschenkels;
  • Figur 3 zeigt eine Gegenüberstellung eines herkömmlich hergestellten Achsschenkels und eines erfindungsgemäß hergestellten Achsschenkels, sowohl in perspektivischer Ansicht als auch als radialen Schnitt durch die Lageraufnahmen;
  • Figur 4 zeigt eine perspektivische Ansicht einer unteren Gesenkhälfte mit eingelegtem Rohling zur Verdeutlichung der Umformrichtung und der Endkonturfüllung während des Umformvorgangs; und
  • Figur 5 zeigt einen radialen Schnitt durch einen erfindungsgemäß hergestellten Achsschenkel, wobei die Darstellung des Achsschenkels nach dem Schmieden und die Darstellung des Achsschenkels nach dem Umformen zur Verdeutlichung der Konturauffüllung übereinander gelegt sind.
Hereinafter, a preferred embodiment of the method according to the invention is explained by way of example with reference to the accompanying drawings.
  • FIG. 1 shows the example of a steering knuckle schematically a manufacturing method according to the prior art;
  • FIG. 2 shows schematically an example of the inventive method for the production of forgings with a predetermined final contour, also using the example of the steering knuckle;
  • FIG. 3 shows a comparison of a conventionally produced stub axle and a steering knuckle according to the invention, both in a perspective view and as a radial section through the bearing receivers;
  • FIG. 4 shows a perspective view of a lower die half with inserted blank to illustrate the Umformrichtung and the final contour filling during the forming process; and
  • FIG. 5 shows a radial section through a steering knuckle according to the invention, wherein the representation of the steering knuckle after forging and the representation of the steering knuckle after forming are superimposed to illustrate the contour filling.

Detaillierte BeschreibungDetailed description

Figur 1 zeigt schematisch den Ablauf eines Herstellungsverfahrens eines LKW-Achsschenkels gemäß dem Stand der Technik. Ein Rohling 10 aus Stahl wird zunächst gestaucht, vorgepresst und einem ersten Vorschmiedeschritt unterzogen (Figur 1a bis c), wobei die wesentliche Außengeometrie des zu fertigen Bauteils erzeugt wird. Beim nachfolgenden zweiten Vorschmiedeschritt (Figur 1d) werden durch das Gesenk die detaillierten Außenkonturen dieses Zwischenprodukts 10' erzeugt (aber nicht größer als die vorgegebene Endkontur). Im abschließenden Schritt des Abgratens beziehungsweise Warmrichtens (Figur 1e) wird dann das überschüssige Schmiedematerial entfernt, sodass das geschmiedete Fertigprodukt 10" erhalten wird. Da durch den Schmiedevorgang jedoch keine komplizierten dreidimensionalen Konturen wie zum Beispiel seitliche Einbuchtungen für Lagerschalen ausgebildet werden können, muss das fertig geschmiedete Teil 10" noch mechanisch, das heißt spanend nachbearbeitet werden. Das bei der Nachbearbeitung anfallende überschüssige Material erhöht somit den Rohmaterialanteil am fertigen Produkt, was neben den hierfür notwendigen Bearbeitungszeiten die Herstellungskosten erhöht und zudem eine höhere Umweltbelastung bedingt. FIG. 1 schematically shows the sequence of a manufacturing process of a truck steering knuckle according to the prior art. A blank 10 made of steel is first compressed, pre-pressed and subjected to a first pre-forging step ( FIGS. 1a to c ), wherein the essential outer geometry of the finished component is generated. In the subsequent second pre-forging step ( Figure 1d ) are produced by the die, the detailed outer contours of this intermediate product 10 '(but not greater than the predetermined final contour). In the final step of trimming or hot honing ( Figure 1e Then, because the forging process can not form complicated three-dimensional contours such as side indentations for bearing shells, the finished forged part 10 "still needs to be machined, ie, machined be reworked. The resulting in the post-processing excess material thus increases the raw material content of the finished product, which in addition to the necessary processing times increases the cost and also causes a higher environmental impact.

In Figur 2 ist zum Vergleich mit dem herkömmlichen Verfahren der Figur 1 der Ablauf eines beispielhaften Verfahrens zur Herstellung von Schmiedeteilen gemäß der Erfindung dargestellt, wieder am Beispiel des LKW-Achsschenkels. Wie im Stand der Technik wird ein Rohling 20 zunächst gestaucht, vorgepresst und in zwei Schritten vorgeschmiedet (Figur 2a bis d), um im Wesentlichen die Außenkontur des fertigen Schmiedeteiles anzunähern. Anders als im Stand der Technik wird allerdings nach dem Vorschmieden (d.h. im vorliegenden Fall nach dem zweiten Vorschmiedeschritt), während sich der Rohling 20' noch im Wesentlichen auf Schmiedetemperatur befindet, eine Umformung des Schmiedeteils in einem Gesenk durchgeführt, dessen Formhohlraum die Außenkontur der vorgegebenen Endkontur des Bauteils definiert. Dabei werden im vorliegenden Fall des Achsschenkels während des Umformvorgangs, das heißt des Schließens des Gesenks, jeweils ein Hohldorn von der vorderen und hinteren Achsschenkelseite in das halb fertige Schmiedeteil 20' eingeführt und dadurch die nach Innen vertieften Lageraufnahmen 21a und 21b ausgebildet (Figur 2e und 3b). Die Hohldorne haben dabei exakt die Form und die Dimensionen der auszubildenden Lageraufnahme. Erst daraufhin wird durch Abgraten/Warmrichten der in der Schmiedeebene gelegene Schmiedeüberschuss entfernt, wobei allerdings das Abgraten beziehungsweise Warmrichten nicht mehr zur Erzeugung der vollständigen Endkontur notwendig ist und somit auf Grund des wesentlichen geringeren Materialabtrags viel weniger Zeit in Anspruch nimmt als das Abgraten oder Warmrichten im Stand der Technik (vgl. Figur 1e). Dieser Zeitgewinn wird auch nicht durch den im Vergleich zum Stand der Technik zusätzlichen Schritt des Umformens ("Hohldornens") Figur 2e) zunichte gemacht. Im Gegenteil erspart der zusätzliche Umformschritt des "Hohldornens" eine zusätzliche spanende Bearbeitung zur Ausbildung der Lageraufnahmen.In FIG. 2 is for comparison with the conventional method of FIG. 1 the sequence of an exemplary method for the production of forgings shown according to the invention, again using the example of the truck steering knuckle. As in the prior art, a blank 20 is first compressed, pre-pressed and forged in two steps ( FIGS. 2a to d ) to substantially approximate the outer contour of the finished forging. Unlike in the prior art, however, after the pre-forging (ie in the present case after the second pre-forging step), while the blank 20 'is still substantially at forging temperature, a deformation of the forging in a die is performed, the mold cavity of which the outer contour of the predetermined Final contour of the component defined. In this case, in the present case of the steering knuckle during the forming process, that is, the closing of the die, each a hollow mandrel of the front and rear stub axle side in the semi-finished forging 20 'introduced and thereby the inwardly recessed bearing receivers 21 a and 21 b formed ( FIG. 2e and 3b ). The hollow mandrels have exactly the shape and dimensions of the trainees bearing to be formed. Only then is removed by burring / hot straightening located in the forge blacksmithing excess, but the burring or hot straightening is no longer necessary to produce the complete final contour and thus takes much less time than the burring or hot straightening in due to the substantially lower material removal State of the art (cf. Figure 1e ). This time gain is also not due to the additional step of forming ("hollow thorns") compared to the prior art. FIG. 2e ). On the contrary, the additional forming step of the "hollow mandrel" saves an additional machining to form the bearing receptacles.

In Figur 3 ist in perspektivischer sowie in Schnittansicht ein Vergleich zwischen den fertig geschmiedeten und abgegrateten Bauteilen dargestellt. Wie aus Figur 3a ersichtlich ist, umfasst das mit dem herkömmlichen Verfahren hergestellte fertig geschmiedete Rohteil 10' noch keine Ausnehmungen für die Lageraufnahme, die entsprechenden Seitenabschnitte 11a und 11b sind massiv. Dementsprechend beträgt das Gewicht des herkömmlich hergestellten Achsschenkels 32kg. Im Gegensatz dazu weist der erfindungsgemäß hergestellte LKW-Achsschenkel bereits die Ausnehmungen für die Lagerschalen auf, sie müssen also nicht mehr durch spanendes Bearbeiten unter Materialausschuss hergestellt werden. Entsprechend niedriger ist auch das Gewicht des fertig geschmiedeten Rohteils, das 29kg beträgt. Es können somit nicht nur etwa 10% an Material gespart sondern auch wesentlich kürzere Prozesszeiten erzielt werden.In FIG. 3 is shown in perspective and in sectional view, a comparison between the finished forged and deburred components. How out FIG. 3a can be seen, the finished forged blank 10 'produced by the conventional method does not yet include recesses for the Bearing support, the corresponding side sections 11a and 11b are solid. Accordingly, the weight of the conventionally manufactured stub axle is 32kg. In contrast, the truck steering knuckle according to the invention already has the recesses for the bearing shells, so they no longer need to be made by machining under material rejects. The weight of the finished forged blank, which is 29kg, is correspondingly lower. It can not only save about 10% of material but also significantly shorter process times can be achieved.

In Figur 4 ist eine perspektivische Ansicht eines beim erfindungsgemäßen Verfahren eingesetzten Gesenks dargestellt, wobei der besseren Verständlichkeit halber nur die untere Gesenkhälfte 30 dargestellt ist. Hierbei wird das im zweiten Schritt des Vorschmiedens (Figur 2d) erzeugte Zwischenprodukt 20', das sich noch im Wesentlichen auf Schmiedetemperatur befindet, in das Gesenk 30 eingelegt und dieses durch Absenken der oberen Gesenkhälfte (nicht gezeigt) geschlossen (siehe Pfeil: "Schließrichtung" in Figur 4). Gleichzeitig werden von zwei Richtungen aus (siehe Pfeile "Umformrichtung") Hohldorne 31a und 31b in die Seiten des halbfertigen Schmiedeteils 20' eingedrückt, welche die Lageraufnahmen im fertig geschmiedeten LKW-Achsschenkel 20"' ausbilden. Hierbei liegen die beiden, hier entgegen gesetzten Umformrichtungen senkrecht zur Schließrichtung des Gesenks. Wegen der noch hohen Temperaturen aus dem vorangegangenen Schmiedevorgang wird auf Grund des durch die Hohldornen 31a und 31b verdrängten Materials die gesamte Gesenkform, das heißt die vorgegebene Endkontur vollständig ausgefüllt. Dies ist durch die schattierten Umrisse des Schmiedeteils 20" dargestellt. In anderen Worten fließt beim erfindungsgemäßen Umformen das Material in die anfangs noch freien Formräume an den Gesenkinnenflächen bis die Gesenkform ausgefüllt ist. Hierzu ist vorzugsweise zu Beginn des Umformens geringfügig mehr Material im Gesenk vorhanden, als volumenmäßig für das endgültige Schmiedeteil vonnöten ist. Beim nachfolgenden Verdrängen des Materials aufgrund des Einführens des Werkzeugs/der Werkzeuge fließt dieses auch in die Grate an den Gesenkrändern und sichert dadurch stets eine zuverlässige, vollständige Gesenkfüllung.In FIG. 4 is a perspective view of a die used in the method according to the invention shown, with the sake of clarity, only the lower die half 30 is shown. This is done in the second step of forging ( Figure 2d ) produced intermediate product 20 ', which is still substantially at the forging temperature, inserted into the die 30 and this closed by lowering the upper die half (not shown) (see arrow: "closing direction" in FIG. 4 ). At the same time hollow dowels 31a and 31b are pressed from two directions (see arrows "forming direction") into the sides of the half-finished forging 20 'which form the bearing receptacles in the finished forged truck knuckle 20 "' Due to the still high temperatures from the previous forging process, due to the material displaced by the hollow mandrels 31a and 31b, the entire die shape, ie the predetermined final contour, is completely filled in. This is illustrated by the shaded contours of the forging 20 " , In other words, during the forming according to the invention, the material flows into the initially free mold spaces on the inner surfaces of the dies until the die mold has been filled. For this purpose, slightly more material is preferably present in the die at the beginning of the forming, as is required in terms of volume for the final forging. During the subsequent displacement of the material due to the insertion of the tool / tools this flows into the burrs on the Die edges and thus always ensures a reliable, complete Gesenkfüllung.

Die durch das erfindungsgemäße Verfahren erreichte Ersparnis an Rohmaterial ist besonders gut aus der Schnittzeichnung der Figur 5 zu entnehmen. Mit der Bezugsziffer 22 ist die nach dem zweiten Vorschmieden (Figur 2d) erzeugte geschmiedete Kontur bezeichnet, während mit Bezugsziffer 23 die Endkontur nach dem erfindungsgemäßen Umformvorgang, das heißt nach dem Einbringen der Hohldorne bezeichnet ist. Durch das Einbringen beziehungsweise Eindrücken der Hohldorne wird also die von dem Gesenk 30 vorgegebene äußere Endkontur 23 ausgehend von der geschmiedeten Kontur 22 aufgefüllt. In anderen Worten füllt der Volumenanteil des eingebrachten Hohldorns das Gesenk ausgehend von der vorgeschmiedeten kleineren Schmiedekontur 22 bis zur vorgegeben Endkontur 23 auf.The savings achieved by the inventive method of raw material is particularly good from the sectional drawing of FIG. 5 refer to. The reference numeral 22 indicates that after the second pre-forging ( Figure 2d ) designated forged contour, while reference numeral 23 denotes the final contour after the forming process according to the invention, that is, after the introduction of the hollow mandrels. By introducing or impressing the hollow mandrels, therefore, the predetermined by the die 30 outer end contour 23 is filled starting from the forged contour 22. In other words, the volume fraction of the introduced hollow mandrel fills the die starting from the forged smaller forging contour 22 up to the predetermined final contour 23.

Claims (6)

  1. Method of manufacturing a steering knuckle (20"') of a commercial vehicle with a given end contour (23), comprising the following steps:
    preforging a blank (20) to obtain a semi-finished or almost-finished steering knuckle (20') of a commercial vehicle, wherein an outer contour (22) of the preforged steering knuckle (20') is smaller than an end contour (23) of the steering knuckle (20", 20'"), and
    then shaping the steering knuckle (20') in a die (30),
    wherein shaping is carried out essentially while still at the forging temperature of the preceding step of preforging,
    wherein during shaping the die (30) is closed and one or more tools (31a, 31b) are introduced into the steering knuckle (20') and in the process the material of the steering knuckle (20') is displaced and the die (30) is filled from the inside in such a way that the given end contour (23) is achieved.
  2. Method according to claim 1, wherein at the beginning of shaping there is more material in the die (30) than is necessary by volume for the final steering knuckle (20"').
  3. Method according to claim 1 or 2, wherein auxiliary shaped elements of the finished steering knuckle (20"'), namely bearing receptacles (21a, 21b), are formed by the tool or tools (31a, 31b).
  4. Method according to any of the preceding claims, wherein the shaping device(s) defined by the tool or tools (31 a, 31b) is/are substantially perpendicular to the direction of closing the die (30).
  5. Method according to any of the preceding claims, wherein the die (30) defines the outer contour of the given end contour (23).
  6. Method according to any of the preceding claims, wherein after additional shaping the steering knuckle (20") is subjected to a step of deburring or hot straightening.
EP12812572.1A 2011-12-16 2012-12-17 Method of manufacturing a steering knuckle Active EP2790850B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011088862A DE102011088862A1 (en) 2011-12-16 2011-12-16 Method for forming forgings
PCT/EP2012/075757 WO2013087924A1 (en) 2011-12-16 2012-12-17 Method for reshaping forged parts

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EP2790850A1 EP2790850A1 (en) 2014-10-22
EP2790850B1 true EP2790850B1 (en) 2016-06-01

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US (1) US9375778B2 (en)
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JP (1) JP6087372B2 (en)
KR (1) KR102031596B1 (en)
BR (1) BR112014014742B1 (en)
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DE (1) DE102011088862A1 (en)
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WO (1) WO2013087924A1 (en)

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CN107792173A (en) * 2017-09-27 2018-03-13 湖北三环锻造有限公司 With the spindle of tie rod arm integral forming

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CN104607544B (en) * 2015-01-16 2016-06-22 芜湖三联锻造有限公司 A kind of major axis novel Correction Die of class knuckle
CN108044019A (en) * 2017-11-30 2018-05-18 枣庄远东实业开发总公司 A kind of spindle vertical forging device and technique based on the pre- base of pneumatic hammer
CN109622845B (en) * 2019-02-18 2021-07-13 湖北三环锻造有限公司 Closed near-net forming process and die for drum type knuckle pre-forging piece
CN112756530B (en) * 2020-12-25 2022-07-22 章丘市普锐锻压有限公司 Forging process and forging production line

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BR112014014742B1 (en) 2020-10-13
DE102011088862A1 (en) 2013-06-20
US9375778B2 (en) 2016-06-28
JP6087372B2 (en) 2017-03-01
WO2013087924A1 (en) 2013-06-20
EP2790850A1 (en) 2014-10-22
KR102031596B1 (en) 2019-11-08
US20150013408A1 (en) 2015-01-15
CA2859332A1 (en) 2013-06-20
MX2014007088A (en) 2014-08-01
CA2859332C (en) 2020-01-21
JP2015500744A (en) 2015-01-08
KR20140103154A (en) 2014-08-25
BR112014014742A2 (en) 2017-06-13
MX344480B (en) 2016-12-16

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