EP3222369B1 - Hydroformpresse mit offener matrize und integriertem tiefziehen - Google Patents

Hydroformpresse mit offener matrize und integriertem tiefziehen Download PDF

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Publication number
EP3222369B1
EP3222369B1 EP16382134.1A EP16382134A EP3222369B1 EP 3222369 B1 EP3222369 B1 EP 3222369B1 EP 16382134 A EP16382134 A EP 16382134A EP 3222369 B1 EP3222369 B1 EP 3222369B1
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EP
European Patent Office
Prior art keywords
die
hydroforming
sheet metal
male
deep
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EP16382134.1A
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English (en)
French (fr)
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EP3222369A1 (de
Inventor
Jose Ortiz Cicuendez
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Priority to ES16382134T priority patent/ES2707796T3/es
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/021—Deforming sheet bodies
    • B21D26/027—Means for controlling fluid parameters, e.g. pressure or temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/021—Deforming sheet bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/021—Deforming sheet bodies
    • B21D26/031—Mould construction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/02—Die constructions enabling assembly of the die parts in different ways
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/0088—Lubricating means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B5/00—Presses characterised by the use of pressing means other than those mentioned in the preceding groups
    • B30B5/02—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure

Definitions

  • the hydraulic machine described herein is based on the principle of applying hydrostatic pressure for creating a permanent deformation on a sheet or sheet metal.
  • the hydroforming process for the described application is based on an open die that defines, in a plan view, the outer perimeter of the final part.
  • an open die that defines, in a plan view, the outer perimeter of the final part.
  • the contour of the part obtained varies by changing the die.
  • the machine of the invention has its own fastening system that enables one profile type to be quickly replaced with another.
  • This hydroforming process with an open die is indicated for any type of cover or bottom for tanks with a circular, elliptical or panoramic plan or any other profile.
  • the most relevant feature of the process is the high deformation capacity, plus the level of finish of the part, since there is a uniform distribution of tensile forces in the work process.
  • the invention falls within the field of machines tools for metal deformation; specifically those employed for sheet metal works using mechanical deformation means.
  • the equipment allows bottoms with a circular, elliptical or panoramic plan or any other profile made of different metals (aluminium, carbon steel, alloy steel, stainless steel, among others) to be obtained.
  • Said bottoms may be assembled in self-supported road cisterns, tank containers for intermodal transport, as well as the rest of mobile or stationary containers or deposits for which covers or bottoms with different profiles are required.
  • the described equipment makes it possible to combine a deep-drawing process with an open-die hydroforming process, for which there is a specific tool available that defines the plan profile of the bottom to be manufactured, along with other obvious dimensional features: radius of curvature, material and thickness of the sheet metal; it is therefore important to know the elongation itself since it can limit the deep-drawing depth and load.
  • the high hydraulic load of the described equipment, along with a high stiffness and dimensional accuracy of the work area enable these two processes to be combined in the same work cycle.
  • the hydroforming process consists of shaping a material through the action of a liquid under pressure (water or water and oil emulsions).
  • a liquid under pressure water or water and oil emulsions.
  • the process itself is usually divided into three basic steps:
  • the fluid mainly employed is water, to which some type of lubricant is usually added.
  • Steel is the material on which this process is nowadays employed, although all the metals that can be cold shaped are eligible for the hydroforming process.
  • simple sheet metal which is based on the use of a pressurised fluid to force the sheet metal to adopt the shape of the punch or mould.
  • the pressure increase is obtained by means of hydraulic systems (pumps or pressure boosters).
  • the hydroforming of a simple sheet metal may be carried out with an intermediate membrane between the work fluid and the part to be shaped, or directly without the membrane, whereby the fluid and the part are in contact.
  • the die hydroforming system uses a die, which acts as a negative of the final shape of the part on one of the faces, and a hydraulic mechanism that provides the pressurised fluid (it may be included in both the upper and lower die) for pushing the sheet metal against the die.
  • the material expands due to the pressure of the fluid inside a die shaped as a closed cavity. The material is deformed by the internal pressure. In general, this process involves the following steps:
  • the hydroforming process is a process in which the sheet metal is positioned on a die, which only seals the perimeter thereof. Next, the material is deformed with a conventional hydraulic press and liquid under pressure is introduced. Sometimes the starting material has a preform (pretensioning) in the direction opposite to the press impact by applying pressure prior to the punch activation. In this way, the material endures a hardening work, which is very difficult to achieve with other traditional deep-drawing methods.
  • the hydroforming technology enables large deformations in materials with an elongation ranging from moderate to high, since the stress distribution is clearly more perfect than that produced by a standard deep-drawing process. In order to correctly carry out the hydroforming process a great hydraulic load is necessary, as the machine has a high work section and therefore the lifting force of the piece is high as well.
  • the open-die simple hydroforming process is used; for larger thicknesses, the lifting load generated by the hydroforming fluid is so high that the hydraulic structure and pipeline have a complex and critical sizing.
  • the described process provides a slow and progressive deformation, with a homogeneous distribution of the deformation force, the hydrostatic pressure being continuous since the gravitational effects are negligible due to the short deformation height, max. 500 mm.
  • the temper hardening experienced by the sheet metal is also homogeneous, continuous and without areas of stress concentration, unlike most deep-drawing processes.
  • the equipment of the present invention enables the hydroforming process to be carried out with great thicknesses (up to 8 mm), with materials having a high elastic limit (such as AISI 316L stainless steel), and with a great deformation height, of up to 500 mm, thus enabling the process to directly compete with the preceding deep-drawing processes conventionally used to manufacture bottoms with these thicknesses.
  • the two big technical problems to be solved are, on the one hand the high hydraulic capacity required to hold a sheet metal and, on the other hand, the integration of a tab providing a perpendicular wing to the manufactured bottom or cover.
  • the hydraulic load is closely related to the work pressure and the cross-section of the sheet metal; as well as the friction thereof with the base of the press and the open die (on the lower and upper portions of the sheet metal, respectively).
  • the relation implies the calculation of the lifting force of the work area together with an empirical value of the metal-rubber friction coefficient for the press base and metal-metal friction coefficient for the open die. Said relation links the work pressure, deformation height, thickness, elastic limit of the material and the effective cross-section to the hydraulic force (provided by a series of hydraulic cylinders).
  • the invention consists of the configuration of the subsystems making up the hydroforming press with an open die and integrated deep-drawing.
  • the structure of the press (5) is made up of a series of equidistant rings (51) that provide a modular structure, which may be expanded and reinforced, and which allow a simple assembly given that all the parts are previously cut and are provided with notches (52, 53) that force the welder to place them in a unequivocal position, while the design of the upper and lower beds (54) is optimised so the construction can be realised step by step, without it being necessary to resort to large-tonnage lifting cranes for this purpose.
  • the expandable feature enables the bottom of the press to be elongated by simply adding the aforementioned rings (51) along one direction of the press and the other, which enables the creation of sizes according to the specifications of the final user of the machine.
  • the structure enables the flexural stresses to be distributed, ring by ring (51), in an independent manner, given that an elongation does not change the stress distribution and therefore neither the thicknesses nor the geometry of the remaining rings is modified.
  • the feature of being reinforced is achieved by varying the thickness of the rings (51) for example from 10 mm downwards and upwards, thus enabling the manufacture of one single machine - with regards to external dimensions - that may operate, for example, with pressures ranging from 15 MN to 30 MN, without significantly changing any portion of the press.
  • This feature, along with that of being expandable, provides great design flexibility, saving time in the development of new models within the range.
  • the press comprises a hydraulic subsystem that, since the machine requires a high hydraulic load, is composed by a large number of hydraulic cylinders (6) (24 in this embodiment) with approximately a 500 mm stroke, employing a work pressure comprised between 20 MPa and 40 MPa, for which the wall and the material of the cylinders must be conveniently calculated.
  • the hydraulic load varies, according to versions, between 15 MN and 30 MN and with it the work capacity of the machine.
  • the hydraulic unit (8) provides the power and control of the cylinder network that makes the manufacture of bottoms possible; this operates sequentially with a redundant response system when faced with failures such as electric shortages, conduit breakages, or mechanical breakdowns:
  • the die (3) lowering/lifting is realised with the same hydraulic actuators that generate the hydraulic load, which is controlled through an electrovalve system that blocks the passage of hydraulic fluid to the remaining cylinders; for this process only two cylinders are employed, a front and a rear cylinder.
  • the control of the hydraulic pressure is carried out through proportional valves, which enables the relative slippage of the work sheet metal (1) relative to the open die (3) to be adjusted.
  • This "on the fly” pressure adjustment enables certain slippage of the metal sheet and thereby the calibration of the striction (thickness reduction) in the central portion thereof, which is the highest portion of the dome.
  • the high pressure pump of the hydraulic unit uses a frequency variator that provides the possibility of calibrating the deformation along a wide range of mm/s.
  • the hydraulic cylinders may be adjusted to the work profile by means of guides integrated in the structural design of the machine itself. The movement thereof is manual, performed through the operator.
  • the hydroforming process is carried out with drinkable water extracted from the standard water system of the factory where the equipment is installed.
  • the prior deep-drawing process followed by the hydroforming process makes the employment of a lubricant emulsion necessary.
  • the emulsion is sprayed - a water soluble dissolution of the lubricant - over the male and female portions of the die, after the deep-drawing, the hydroforming process starts using the same dissolved lubricant fluid.
  • the pump that pressurises the fluid and therefore, the one that enables the hydroforming is the same that finely sprays the fluid over the die to ensure the lubrication of the dies along with the work sheet metal.
  • the hydroforming cycle ends, a high amount of the fluid used both for the deep-drawing and for the hydroforming - it is the same - is recovered, the recovery percentage of which ranges between 97 and 98 %.
  • the die for the prior deep-drawing is made up of the following elements:
  • the control equipment (7) is based on an assembly of programmable automatons, which regulate the entire process, avoiding overlapping processes, optimising the cycle timing and providing the process with a high safety by taking the responsibility for the equipment work away from the operator, whose function is just that of supervising and not acting on the same.

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

Claims (6)

  1. Hydroformpresse mit offener Matrize und integriertem Tiefziehen, umfassend:
    - eine modulare Struktur, gebildet durch eine Serie von Ringen (51), die vertikal und gleichmäßig angeordnet sind, bereitgestellt mit Kerben (52, 53), wobei Platten (55) gekoppelt sind, die sie von oben und von unten verbinden, wodurch eine feste und eindeutige Position bestimmt wird, bevor sie zusammengeschweißt werden, deren innerer Hohlraum, in dem die Matrize und die Betätigungszylinder positioniert sind, durch sowohl obere als auch untere Betten (54) begrenzt ist, wobei die Struktur nur nach vorne und nach hinten offen ist;
    - eine offene Matrize (2, 3), die sich auf einer horizontalen Ebene in einer Betriebsposition innerhalb der Presse befindet, deren Muttermatrizenbereich (3) einen zentralen Hohlraum (32) in Ausrichtung mit der Kontur hat, die in dem Blech (1) gebildet werden soll, auf dessen Matrize mehrere hydraulische Zylinder (6) betrieben werden, von denen mindestens zwei auch als Betätigungszylinder betrieben werden können, die dafür zuständig sind, die Matrize auf den zu formenden Teil zu senken, während sie alle in Betrieb genommen werden, indem sie den Muttermatrizenbereich (3) der Matrize gegen das Blech (1) bewegen und pressen, das auf dem Patrizenbereich (2) der Matrize platziert ist, bevor die hydraulische Hydroformpresse darauf angewendet wird, die in die entgegengesetzte Richtung betrieben wird;
    - eine Serie von hydraulischen Zylindern (6) mit einem Hub, der durch die Höhe der auszuführenden Verformung bestimmt wird, die dafür zuständig sind, das Blech (1) gegen den Patrizenbereich (2) oder gegen die tiefziehende Patrize (4) zu bewegen oder zu drücken, die sich auf dem Patrizenbereich (2) der Matrize befindet, wobei gegen das Blech ausreichender Druck für das vorherige Hydroformen und/oder Tiefziehen eines Randbereichs davon angewendet wird;
    - eine tiefziehende Patrize (4), auf der das zu verformende Blech (1) angeordnet werden kann, auf das bei Verwendung der Muttermatrizenbereich (3) der offenen Matrize und der Druck fällt, der gegen diese durch eine Serie von peripheren hydraulischen Zylinder (6) ausgeübt wird, die eine fluiddichte Dichtung an dem Rand des Patrizenbereichs (2) der Matrize erstellen, die mit mehreren Auslässen für Wasser unter Hochdruck bereitgestellt ist, die an dem Blech (1) ein Wölben nach oben bewirken, dessen äußeres Profil durch den inneren Hohlraum (32) des Muttermatrizenbereichs (3) der Matrize bestimmt ist und dessen Höhe durch die Zeit und den Druck des Hydroformens bestimmt ist, der durch Proportionalventile gesteuert wird, die das Gleiten des Blechs (1) durch den zentralen Hohlraum der offenen Matrize erleichtern.
  2. Hydroformpresse mit offener Matrize und integriertem Tiefziehen nach Anspruch 1, dadurch gekennzeichnet, dass die Bereiche der Patrize (2) und Muttermatrize (3) der Matrize anpassbar sind, wobei sie einen variablen Umfang haben, der eine Bewegung ihrer Bereiche in eine radiale Richtung durchführt, wodurch die Dicke des Werkstücks geändert werden kann, ohne dadurch Risse oder Spalten zu erzeugen.
  3. Hydroformpresse mit offener Matrize und integriertem Tiefziehen nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die Matrize eine Serie von festen hinteren Zentriervorrichtungen (23, 33), die eine minimale Variation in der relativen Position der Bereiche der Patrize (2) und Muttermatrize (3) während der erfolgreichen Arbeitszyklen der Einrichtung sichern, und vorderen einfahrbaren Zentriervorrichtungen hat, die das Erzeugen eines breiten Hohlraums ermöglichen, durch den das fertige Teil ausgefahren werden kann und das Arbeitsblech geladen werden kann.
  4. Hydroformpresse mit offener Matrize und integriertem Tiefziehen nach dem vorhergehenden Anspruch, dadurch gekennzeichnet, dass die vorderen Zentriervorrichtungen aus einer gleichen Anzahl von unteren (24) und oberen (34) Buchsen bestehen, durch die eine Patrize (35) der Zentriervorrichtung angetrieben von einem pneumatischen Zylinder (36) läuft.
  5. Hydroformpresse mit offener Matrize und integriertem Tiefziehen nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass der Muttermatrizenbereich (3) der Matrize auf seiner Oberseite so viele konische Zentriervorrichtungen (37) wie hydraulische Zylinder (6) hat, die in Ausrichtung mit ihnen sind, die jeden der Zylinder dazu zwingen, auf seinem Weg nach unten seine Position beizubehalten, wenn er an dem oberen Bereich der Matrize anliegt.
  6. Hydroformpresse mit offener Matrize und integriertem Tiefziehen nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die Patrizen-/Muttermatrizenbereiche der Matrize eine Struktur haben, die durch eine Anordnung von überlagerten Platten gebildet ist, die mit Bolzen angeordnet sind.
EP16382134.1A 2016-03-23 2016-03-23 Hydroformpresse mit offener matrize und integriertem tiefziehen Active EP3222369B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP16382134.1A EP3222369B1 (de) 2016-03-23 2016-03-23 Hydroformpresse mit offener matrize und integriertem tiefziehen
ES16382134T ES2707796T3 (es) 2016-03-23 2016-03-23 Prensa de hidroconformado de matriz abierta con embutición integrada

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP16382134.1A EP3222369B1 (de) 2016-03-23 2016-03-23 Hydroformpresse mit offener matrize und integriertem tiefziehen

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EP3222369A1 EP3222369A1 (de) 2017-09-27
EP3222369B1 true EP3222369B1 (de) 2018-10-24

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ES (1) ES2707796T3 (de)

Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
CN117483533B (zh) * 2024-01-03 2024-06-18 天津天锻航空科技有限公司 一种飞机输油半管类零件的成形方法

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Publication number Priority date Publication date Assignee Title
DE1240801B (de) * 1961-07-07 1967-05-24 Siemens Elektrogeraete Gmbh Vorrichtung zum hydraulischen Tiefziehen
US3668914A (en) * 1969-12-31 1972-06-13 Bogdan Vyacheslavovich Voitsek Method of stamping metal convex articles from sheets
JP3663413B2 (ja) * 2000-03-23 2005-06-22 トヨタ車体株式会社 表面に多数の凸部を有する薄肉金属板の製造方法
CN202779356U (zh) * 2012-07-15 2013-03-13 哈尔滨工业大学空间钢结构幕墙有限公司 多点无模液压胀形设备
CN103861927B (zh) * 2014-03-18 2016-01-20 哈尔滨工业大学 一种板材多点凸模充液拉深成形装置及方法

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ES2707796T3 (es) 2019-04-05

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