DE102009031981B4 - Method for producing a motor vehicle component in the form of a torsion profile - Google Patents

Abstract

In this process, a rectangular metal plate is first provided with a U-shaped depression (11). The end sections of the board are deformed into an S-shape. Thereafter, the legs of the plate next to the trough (11) are bent over essentially parallel to one another and to the trough (11) and then, with their longitudinal edges in contact, are tubular in the end sections (2) and in the longitudinal section (3) with the trough (11) U- deformed. Then the longitudinal edges of the deformed legs are joined together, for example welded. The torsion profile (1) can then be twisted about its longitudinal axis or deformed in a wave-like manner. It can also have different wall thicknesses in certain areas.

Description

The invention relates to a method for producing a motor vehicle component in the form of a torsion profile from a blank according to the features in the preamble of claim 1.

To the extent of the procedure of DE 10 2007 061 198 B3 a rectangular blank is deformed by rolling either from a narrow side or from a long side in such a way that different thickness areas are created. Then the so contoured plate is bent into a slotted tube and then welded along the longitudinal edges. The welded pipe is then deformed with a U-shaped sword in such a way that torsionally rigid cylindrical end sections, a torsionally soft U-shaped middle length section and transition sections that change between the end sections and the middle length section from the cylindrical cross-section of the end sections to the U-shaped cross-section are formed. Since the embossing of the U-shaped trough takes place in the middle length section on a tube that is closed on the circumference, the material is highly stressed in many places during the shaping process, with the result that various mechanical parameters of the torsion profile (the expansion, stretching and limit shape changes associated with a forming process ) cannot be determined with the desired precision.

Similar problems also arise with a method in which the torsion profile is manufactured directly from a welded or drawn tube with a constant wall thickness.

From the U.S. 5,507,518 A it is known to initially provide a plate with a longitudinally directed U-shaped trough at a distance from its front ends in at least one production stage. The legs of the deformed plate next to the trough are then bent over essentially parallel to one another and to form the trough. Subsequently, the bent legs are deformed into a tubular shape with contact of their longitudinal edges in the areas adjacent to the front ends of the plate and in a U-shape in the longitudinal section with the trough to match the contour of the trough. The longitudinal edges of the deformed legs are now joined to one another.

In the DE 603 15 671 T2 describes a stabilizer and a manufacturing method of the same. The stabilizer comprises a tubular element with a central section and two end sections and is essentially U-shaped. The end portions of the stabilizer are bent / angled with respect to the central portion so that the stabilizer acquires its U-shape. In addition, the end sections are twisted with respect to the central section.

In the case of a torsion profile for a motor vehicle, it is important that it must meet very special conditions, with particular criteria being the installation space and the K&C requirements (Kinematic & Compliance).

Based on the prior art, the invention is based on the object of creating a method for producing a motor vehicle component in the form of a torsion profile from a metallic blank, in which the mechanical properties of the torsion profile are precisely determined, taking into account the most variable possible integration into a torsion beam rear axle can.

According to the invention, this object is achieved in the features of claim 1.

Another solution is seen in the features of claim 2.

A third solution to the problem posed is part of claim 3.

Advantageous further developments are the subject of claims 4 to 10.

In order to meet the installation space requirements in particular, a straight torsion profile often does not meet the requirements placed on its kinematic behavior and / or its stiffness behavior. This is where the invention comes into play in that the areas adjacent to the front ends of the plate are now rotated relative to the longitudinal section with the trough about the longitudinal axis of the torsion profile. The method according to claim 1 and claim 3 provides that the areas adjacent to the end faces of the patina are deformed out of round. The method according to claim 2 provides that the torsion profile is deformed in a wave-like manner in the longitudinal direction. It can also be advantageous to manufacture the torsion profile from a blank with wall thicknesses that differ in certain areas over its length. With a twisted or undulating torsion profile or with a torsion profile that has different wall thicknesses in some areas, it is now advantageously possible to bring the thrust center into the correct position and thereby compensate for the disadvantages of a straight torsion profile. The center of thrust can be brought into many positions due to the interplay of rotation and / or wave shape and / or variable wall thickness without the available installation space being impaired. Furthermore, a better adaptation to the longitudinal and transverse rigidity is possible. In addition, a blank with variable wall thicknesses (tailored rolled blank) are used when higher strengths are required in a torsion profile in the transitions from the central U-shaped length section to the transition sections and from the transition sections to the tubular end sections. Although this is associated with a slight increase in weight, a higher roll stiffness is achieved.

It is advantageous to deform the areas adjacent to the front ends of the board in the longitudinal direction of the board in an S-shape. This S-shaped embossing can be carried out on the plate, which is still flat, or at the same time as the embossing of the recess. Furthermore, an S-shaped embossing is conceivable after the trough has been produced. The S-shaped embossing of the areas adjacent to the front ends of the plate serves as a preparation for the formation of the tubular end sections of the torsion profile. Suitable upper and lower tools are used to stamp the S-shaped end areas.

According to claim 1 and claim 3, the end sections of the torsion profile are deformed out of round. In the procedure according to claim 2, the end sections of the torsion profile can be deformed to be circular or non-circular. A non-circular embossing can be carried out, for example, if the trailing arms to be connected to the torsion profile have corresponding connection areas of a torsion arm rear axle. The non-circular deformation can already take place in the course of the last work step before joining the longitudinal edges of the deformed legs.

The deformation of the areas adjacent to the front ends of the blank can be carried out using a mandrel. This increases the accuracy of the cross section of the end sections of the torsion profile with regard to the subsequent connection to the trailing arms of a twist beam rear axle.

The quality of the connection between the torsion profile and the trailing arms of a torsion beam rear axle is further improved in that the areas adjacent to the front ends of the plate are widened conically. In this way, a larger connection cross-section is achieved with an otherwise unchanged profile. Furthermore, modified trimmed edges are achieved with an unchanged height of the back of the torsion profile. This deformation can already be carried out during the deformation of the legs lying next to the trough. A correspondingly designed mandrel is used for this purpose.

Furthermore, it can be advantageous if a bead projecting in the direction of the longitudinal edges is formed from the bottom of the trough.

The metallic plate can in particular consist of steel or light metal, in particular aluminum.

It is also conceivable that the circuit board is made from a hybrid material.

The blank can also be shot-peened or treated in another suitable manner in advance of the forming.

• 1 in schematischer Perspektive ein Torsionsprofil für eine Verbundlenkerhinterachse;
• 2 in vergrößertem Maßstab einen vertikalen Querschnitt durch die Darstellung der 1 entlang der Linie II-II in Richtung der Pfeile IIa gesehen;
• 3 in schematischer Perspektive eine stählerne Platine in zwei Bearbeitungspositionen;
• 4 in der Perspektive ein Oberwerkzeug für einen 1. Arbeitsschritt;
• 5 in der Perspektive ein Unterwerkzeug für den 1. Arbeitsschritt;
• 6 in der Perspektive die Platine der 3 nach einer Verformung mit Hilfe der Werkzeuge gemäß den 4 und 5;
• 7 die Platine der 3 und 6 zusammen mit dem Oberwerkzeug und dem Unterwerkzeug gemäß den 4 und 5 im vertikalen Querschnitt;
• 8 im vertikalen Querschnitt ein weiteres Oberwerkzeug und ein weiteres Unterwerkzeug für einen 2. Arbeitsschritt gemäß 4 zusammen mit der dadurch weiter verformten Platine gemäß den 6 und 7;
• 9 in schematischer Perspektive die mittels des Oberwerkzeugs und des Unterwerkzeugs der 8 weiter verformte Platine;
• 10 in der Perspektive ein Oberwerkzeug für einen 3. Arbeitsschritt;
• 11 in der Perspektive die Platine der 9;
• 12 in der Perspektive ein Unterwerkzeug für den 3. Arbeitsschritt;
• 13 in der Perspektive die mit dem Ober- und Unterwerkzeug der 10 und 12 verformte Platine;
• 14 in der Perspektive ein Oberwerkzeug für einen 4. Arbeitsschritt;
• 15 in der Perspektive die Platine der 13 in 180° verdrehter Lage;
• 16 in der Perspektive ein Unterwerkzeug für den 4. Arbeitsschritt;
• 17 in der Perspektive ein fertig geformtes Torsionsprofil;
• 18 in der Perspektive ein Torsionsprofil gemäß einer weiteren Ausführungsform;
• 19 in der Perspektive ein Torsionsprofil gemäß einer dritten Ausführungsform;
• 20 in der Perspektive ein Torsionsprofil aus einer Platine mit bereichsweise unterschiedlichen Wanddicken und
• 21 einen vertikalen Querschnitt durch die Darstellung der 1 entlang der Linie II - II in Richtung der Pfeile IIa gesehen, gemäß einer weiteren Ausführungsform.

The invention is explained in more detail below with reference to exemplary embodiments illustrated in the drawings. Show it:

• 1 a schematic perspective of a torsion profile for a twist beam rear axle;
• 2 on an enlarged scale a vertical cross-section through the illustration of 1 seen along the line II-II in the direction of the arrows IIa;
• 3 a schematic perspective of a steel blank in two processing positions;
• 4th in perspective, an upper tool for a 1st work step;
• 5 in perspective a lower tool for the 1st work step;
• 6th in perspective the circuit board of the 3 after a deformation with the help of the tools according to the 4th and 5 ;
• 7th the board of the 3 and 6th together with the upper tool and the lower tool according to the 4th and 5 in vertical cross section;
• 8th in vertical cross section a further upper tool and a further lower tool for a second work step according to FIG 4th together with the thus further deformed board according to the 6th and 7th ;
• 9 in a schematic perspective by means of the upper tool and the lower tool of 8th further deformed plate;
• 10 in perspective, an upper tool for a 3rd work step;
• 11 in perspective the circuit board of the 9 ;
• 12th in perspective a lower tool for the 3rd work step;
• 13th in perspective the one with the upper and lower tool of the 10 and 12th deformed board;
• 14th in perspective, an upper tool for a 4th work step;
• 15th in perspective the circuit board of the 13th in a 180 ° rotated position;
• 16 in perspective a lower tool for the 4th work step;
• 17th in perspective a fully formed torsion profile;
• 18th in perspective a torsion profile according to a further embodiment;
• 19th in perspective a torsion profile according to a third embodiment;
• 20th In perspective, a torsion profile made from a plate with wall thicknesses that differ in areas and areas
• 21 a vertical cross section through the illustration of the 1 along line II - II seen in the direction of arrows IIa, according to a further embodiment.

In the 1 and 2 1 denotes a torsion profile as part of an otherwise not illustrated twist beam rear axle of a motor vehicle. The torsion profile 1 has torsionally stiff, circular, tubular end sections 2 , a torsionally flexible U-shaped central length section 3 and between the middle length section 3 as well as the end sections 2 Transition sections changing from the U-shaped to the tubular cross-section 4th on. especially the 2 reveals that the torsion profile 1 in the middle length sections 3 in the area of the lateral thighs 5 as well as the arched back 6th is designed with two layers. The back 6th opposite longitudinal edges 7th are ear-shaped.

The torsion profile 1 is made from a rectangular steel plate 8th manufactured by the in 3 one half is shown. The other half is designed in mirror image, so that in the following (with the exception of the 18th ) only this half is illustrated and also described.

For manufacturing the torsion profile 1 are the forehead first 9 neighboring areas 10 the board 8th Deformed in an S-shape. The tools used for this are not shown in more detail.

Subsequently, the so deformed board 8a between the S-shaped areas 10 with a U-shaped trough 11 provided whose vertical central longitudinal plane VMLE next to the vertical central longitudinal plane VMLE1 the formed blank 8b runs (see 6th and 7th ). For making the trough 11 becomes the board 8a according to 3 between one from the 4th and 7th recognizable upper tool 12th and one from the 5 and 7th recognizable lower tool 13th placed. The upper tool 12th definitely with a bead 16 the inner contour of the trough 11 while the lower tool 13th with a gutter 17th serves as a counter bearing and determines the outer contour. The upper tool of the 4th can with side wings 46 be provided as they are from the 5 emerge to the board 8a to be able to deform properly. After the upper tool has moved together 12th and lower tool 13th has the board 8b those from the 6th recognizable contour with legs of different widths 14th and 15th .

For better shaping of the torsion profile 1 In a further step, the circuit board is made 8b the 6th and 7th by means of an upper tool 18th and a lower tool 19th (can be moved against each other) with regard to the trough 11 deliberately further deformed ( 8th ) that the different widths of the legs 14th , 15th adjacent wall sections 20th the trough 11 run largely parallel to each other. This is the top tool 18th with a correspondingly designed bead 21 and the lower tool 19th with one the outer contour of the trough 11 determining gutter 22nd Mistake. The board further deformed with this work step 8c is also from the 9 and 11 recognizable.

In a subsequent step, one of the 10 visible upper tool 23 and one from the 12th recognizable lower tool 24 the different widths of the legs 14th , 15th the board 8c next to the hollow 11 essentially parallel to each other and to the trough 11 bent over. The upper tool has for this purpose 23 between two legs that are inclined to one another 25th , 26th a bead 27 , which is located between end-side U-shaped areas 28 extends. The lower tool 24 as a counter bearing has next to a receiving channel 29 two support legs 30th on. The outer contour of the trough 11 determining receiving channel 29 ends in U-shaped support areas 31 above. The so far deformed board 8d is from the 13th and 15th evident. It points out the S-shaped areas 10 reshaped U-shaped ends 32 on.

This deformed board 8d according to the 13th and 15th is then using an upper tool 33 according to 14th and a lower tool 34 according to 16 reshaped so that the thighs 14th , 15th under contact of their long edges 35 , 36 in the ends 32 tubular and in the longitudinal section with the trough 11 Be deformed in a U-shape ( 17th ). It will be on the long edges 35 , 36 not yet welded torsion profile 1 educated.

To carry out this work step with the board rotated by 180 ° 8d ( 15th ) is the upper tool 33 with a shaped channel 37 and adjacent splayed thighs 38 Mistake. The lower tool 34 owns one in the hollow 11 engaging support bead 39 as well as adjacent troughed lengths 40 for the long edges 7th the circuit board 8d . Furthermore, the lower tool is 34 with recording areas 41 for the ends 32 Mistake.

The long edges 35 , 36 the deformed leg 14th , 15th as well as the end sections 2 are then welded together so that a weld seam that extends almost in a straight line 42 is formed ( 17th ).

The deformation of the board 8d according to the 13th and 15th to the torsion profile 1 according to 17th can be done with the help of thorns, not shown, over which the ends 32 being beaten around. These mandrels can be cylindrical or conical.

A non-circular deformation of the end sections is also conceivable 2 a torsion profile 1a , for example from the 19th emerges. Furthermore lets 19th realize that the end sections 2 relative to the length segment 3 with the trough 11 around the longitudinal axis of the torsion profile 1a are twisted.

From the 18th is an embodiment of a torsion profile 1b recognizable, which is deformed in a wave-shape in the longitudinal direction. The middle area 43 is opposite the end sections 2 in the vertical central longitudinal plane of the torsion profile 1b in the direction of the arrow PF postponed. Such a deformation is preferably carried out before the longitudinal edges are welded 35 , 36 on the torsion profile 1 completed.

The 20th shows an embodiment in which the blank for the production of a torsion profile 1c has different wall thicknesses in some areas over its length. These different wall thicknesses 44 , 45 are on the torsion profile 1c the 20th in the area between the central U-shaped length section 3 and the transition sections 4th as well as between the transition sections 4th and the tubular end sections 2 recognizable. The board can be manufactured as so-called tailored rolled blanks.

In the 21 is ultimately an embodiment of a torsion profile 1d shown, in which by means of a suitable, not shown tool from the ground 47 the trough 11 a bead 48 towards the ear-like longitudinal edges 7th has been shaped. In this way there is a free space 49 created, which when joining the longitudinal edges 35 and 36 a melting of the soil 47 and thus a weakening of the torsion profile 1d prevented. The weld 42 can, as shown, in the middle of the back 6th or also be provided laterally.

List of reference symbols

1 -

Torsion profile

1a

- torsion profile

1b

- torsion profile

1c

- torsion profile

1d

- torsion profile

2 -

End sections of 1

3 -

middle length section of 1

4 -

Transition sections

5 -

Thigh in 3

6 -

Back in 3

7 -

Longitudinal margins in 3

8th -

circuit board

8a

- Circuit board

8b

- Circuit board

8c

- Circuit board

8d

- Circuit board

9 -

Front ends from 8

10 -

S-shaped area of 8a, 8b, 8c

11 -

Well in 8b, 8c, 8d

12 -

Upper tool

13 -

Lower tool

14 -

Legs of 8b, 8c, 8d

15 -

Legs of 8b, 8c, 8d

16 -

Bead on 12

17 -

Gutter in 13

18 -

Upper tool

19 -

Lower tool

20 -

Wall sections from 11

21 -

Bead on 18

22 -

Channel in 19th

23 -

Upper tool

24 -

Lower tool

25 -

Leg on 23

26 -

Leg on 23

27 -

Bead on 23

28 -

U-shaped areas at 23

29 -

Admission channel on 24

30 -

Support leg on 24

31 -

Support areas at 24

32 -

Ends at 8d

33 -

Upper tool

34 -

Lower tool

35 -

Long edge of 14

36 -

Long edge of 15

37 -

Form channel at 33

38 -

Leg at 33

39 -

Support bead on 34

40 -

Length section at 34

41 -

Recording areas for 32

42 -

Weld seam on 1

43 -

Middle range of 1b

44 -

Wall areas from 1c

45 -

Wall areas from 1c

46 -

Wing next to 17

47 -

Floor v. 11

48 -

Bead on 47

49 -

free space

PF -

Direction arrow

VMLE -

vertical median longitudinal plane of 11

VMLE1 -

Vertical median longitudinal plane of 8b

Claims (10)

Process for the production of a motor vehicle component in the form of a torsion profile (1, 1a, 1b, 1c, 1d) from a blank (8), the torsionally rigid tubular end sections (2), a torsionally flexible U-shaped central longitudinal section (3) and between the central longitudinal section (3) and the end sections (2) from the U-shaped to the tubular cross-section changing transition sections (4), in which the following work steps are carried out: a) The board (8) is at a distance from its front ends (9) in at least one Production stage provided with a longitudinally directed U-shaped trough (11); b) the legs (14, 15) of the deformed plate (8b, 8c) next to the trough (11) are bent over essentially parallel to one another and to form the trough (11); c) the bent legs (14, 15) are tubular with contact of their longitudinal edges (35, 36) in the areas (10) adjacent to the front ends (9) of the plate (8a, 8b, 8c) and in the longitudinal section (3) with the Trough (11) deformed in a U-shape to match the contour of the trough (11); d) the longitudinal edges (35, 36) of the deformed legs (14, 15) are joined to one another; characterized in that the front ends (9) of the plate (8a, 8b, 8c) adjacent areas (10) are rotated relative to the longitudinal section (3) with the trough (11) around the longitudinal axis of the torsion profile (1) and the Front ends (9) of the board (8a, 8b, 8c) adjacent areas (10) are deformed out of round. Process for the production of a motor vehicle component in the form of a torsion profile (1, 1a, 1b, 1c, 1d) from a blank (8), the torsionally rigid tubular end sections (2), a torsionally flexible U-shaped central longitudinal section (3) and between the central longitudinal section (3) and the end sections (2) from the U-shaped to the tubular cross-section changing transition sections (4), in which the following work steps are carried out: a) The board (8) is at a distance from its front ends (9) in at least one Production stage provided with a longitudinally directed U-shaped trough (11); b) the legs (14, 15) of the deformed plate (8b, 8c) next to the trough (11) are bent over essentially parallel to one another and to form the trough (11); c) the bent legs (14, 15) are tubular with contact of their longitudinal edges (35, 36) in the areas (10) adjacent to the front ends (9) of the plate (8a, 8b, 8c) and in the longitudinal section (3) with the Trough (11) deformed in a U-shape to match the contour of the trough (11); d) the longitudinal edges (35, 36) of the deformed legs (14, 15) are joined to one another; characterized in that the torsion profile (1) is deformed in a wave-like manner in the longitudinal direction. Process for the production of a motor vehicle component in the form of a torsion profile (1, 1a, 1b, 1c, 1d) from a blank (8), the torsionally rigid tubular end sections (2), a torsionally flexible U-shaped central longitudinal section (3) and between the central longitudinal section (3) and the end sections (2) from the U-shaped to the tubular cross-section changing transition sections (4), in which the following work steps are carried out: a) The board (8) is at a distance from its front ends (9) in at least one Production stage provided with a longitudinally directed U-shaped trough (11); b) the legs (14, 15) of the deformed plate (8b, 8c) next to the trough (11) are bent over essentially parallel to one another and to form the trough (11); c) the bent legs (14, 15) are tubular with contact of their longitudinal edges (35, 36) in the areas (10) adjacent to the front ends (9) of the plate (8a, 8b, 8c) and in the longitudinal section (3) with the Trough (11) deformed in a U-shape to match the contour of the trough (11); d) the longitudinal edges (35, 36) of the deformed legs (14, 15) are joined to one another; characterized in that the torsion profile (1) is made from a plate with wall areas (44, 45) of different thicknesses in sections over its length and that the front ends (9) of the plate (8a, 8b, 8c) adjacent areas (10) are deformed out of round. Method according to one of the Claims 1 to 3 , characterized in that the areas (10) of the plate (8a, 8b, 8c) adjacent to the front ends (9) of the plate (8a, 8b, 8c) are deformed in an S-shape. Procedure according to Claim 2 , characterized in that the areas (10) adjacent to the front ends (9) of the plate (8a, 8b, 8c) are deformed out of round. Method according to one of the Claims 1 to 5 , characterized in that the areas (10) adjacent to the front ends (9) of the plate (8a, 8b, 8c) are deformed via a mandrel. Procedure according to Claim 2 , characterized in that the areas (10) adjacent to the front ends (9) of the plate (8a, 8b, 8c) are widened conically. Method according to one of the Claims 1 to 7th , characterized in that a bead (48) projecting in the direction of the longitudinal edges (7) is formed from the bottom (47) of the trough (11). Method according to one of the Claims 1 to 8th , characterized in that the torsion profile (1) is made from a plate made of a hybrid material. Method according to one of the Claims 1 to 9 , characterized in that the blank (8a, 8b, 8c) is shot-peened before it is deformed.

Images