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DE102015203642A1 - Method for producing a component by forming a multilayer flat semi-finished product with a soft core layer and component produced therewith - Google Patents

Method for producing a component by forming a multilayer flat semi-finished product with a soft core layer and component produced therewith Download PDF

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Publication number
DE102015203642A1
DE102015203642A1 DE102015203642.1A DE102015203642A DE102015203642A1 DE 102015203642 A1 DE102015203642 A1 DE 102015203642A1 DE 102015203642 A DE102015203642 A DE 102015203642A DE 102015203642 A1 DE102015203642 A1 DE 102015203642A1
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DE
Germany
Prior art keywords
component
core layer
finished product
forming
soft core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
DE102015203642.1A
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German (de)
Inventor
Maik Hammer
Matthias Pernicka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bayerische Motoren Werke AG
Original Assignee
Bayerische Motoren Werke AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayerische Motoren Werke AG filed Critical Bayerische Motoren Werke AG
Priority to DE102015203642.1A priority Critical patent/DE102015203642A1/en
Publication of DE102015203642A1 publication Critical patent/DE102015203642A1/en
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • B29C2043/022—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having locally depressed lines, e.g. hinges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

Die Erfindung betrifft ein Verfahren zur Herstellung eines Bauteils (300), insbesondere eines Karosseriebauteils, durch Umformen eines mehrlagigen flächigen Halbzeugs (200), das wenigstens eine weiche Kernlage (210) und mindestens eine harte Decklage (220, 230) aufweist, wobei das Umformen mithilfe eines Matrize (110) und Patrize (120) aufweisenden Presswerkzeugs (100) erfolgt. Es ist vorgesehen, dass an bestimmten Stellen (A, B, C, D), an denen im herzustellenden Bauteil (300) markante Formelemente erzeugt werden sollen, zwischen Patrize (120) und Matrize (110) eine lokal verstärkte Komprimierung der weichen Kernlage (210) erfolgt, so dass in der weichen Kernlage (210) erhöhte Druckspannungen entstehen, durch die eine präzise Ausformung der harten Decklage (220, 230) erreicht wird. Die Erfindung betrifft ferner ein verfahrensgemäß hergestelltes Karosseriebauteil (300).The invention relates to a method for producing a component (300), in particular a body component, by forming a multilayer flat semi-finished product (200) comprising at least one soft core layer (210) and at least one hard cover layer (220, 230) by means of a die (100) having a matrix (110) and male (120). It is envisaged that at certain points (A, B, C, D) at which distinctive form elements are to be produced in the component (300) to be produced, a locally reinforced compression of the soft core layer () between male part (120) and female part (110) ( 210) takes place, so that in the soft core layer (210) increased compressive stresses arise, through which a precise shaping of the hard cover layer (220, 230) is achieved. The invention further relates to a method according to manufactured body component (300).

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Bauteils durch Umformen eines mehrlagigen flächigen Halbzeugs, welches wenigstens eine weiche Kernlage und mindestens eine harte Decklage aufweist, wobei das Umformen mithilfe eines Matrize und Patrize aufweisenden Presswerkzeugs erfolgt.The invention relates to a method for producing a component by forming a multilayer flat semi-finished product which has at least one soft core layer and at least one hard cover layer, wherein the forming takes place with the aid of a die having male and female parts.

Die Erfindung betrifft ferne ein verfahrensgemäß hergestelltes Bauteil, wobei es sich insbesondere um ein Karosseriebauteil für ein Kraftfahrzeug handelt.The invention relates remotely to a device produced according to the component, which is in particular a body component for a motor vehicle.

Aus dem Stand der Technik sind mehrlagige bzw. mehrschichtige flächige Halbzeuge bekannt, die mehrere Lagen bzw. Schichten aus Werkstoffen mit verschiedenen Eigenschaften aufweisen bzw. aus solchen verschiedenen Werkstoffen zusammengesetzt sind. Solche plattenartigen Mehrschichtverbunde werden auch als Mehrschichtmaterialien oder Sandwichmaterialien bezeichnet und können durch unterschiedliche Verfahren zu Bauteilen weiterverarbeitet werden. Ein gängiges Verfahren ist das Umformen eines anfänglich ebenen Halbzeugzuschnitts mithilfe eines Presswerkzeugs, welches eine Patrize (Stempel) und eine Matrize aufweist, wobei die Umformung zwischen korrespondierenden form- bzw. gestaltvorgebenden Werkzeugwirkflächen, die an der Patrize und an der Matrize ausgebildet sind, erfolgt. Diesbezüglich wird auf die DE 10 2009 016 215 A1 hingewiesen.Multilayer or multilayer flat semi-finished products are known from the prior art, which have a plurality of layers or layers of materials with different properties or are composed of such different materials. Such plate-like multilayer composites are also referred to as multilayer materials or sandwich materials and can be further processed by components into different components. A common method is the forming of an initially flat semifinished blank by means of a pressing tool, which has a male (punch) and a die, wherein the deformation between corresponding shape or shape-predetermined tool acting surfaces formed on the male and on the die, takes place. In this regard is on the DE 10 2009 016 215 A1 pointed.

Bei dieser umformenden Verarbeitung in einem Presswerkzeug erweist sich jedoch die Erzeugung bzw. Ausbildung markanter Formelemente am herzustellenden Bauteil als schwierig, insbesondere dann, wenn das verwendete mehrlagige Halbzeug eine weiche Kernlage und wenigstens eine harte Decklage aufweist. Für gewöhnlich verhindert die weiche Kernlage eine präzise Ausformung der harten Decklage bzw. Decklagen. Insbesondere kann es im Presswerkzeug aufgrund der Nachgiebigkeit der weichen Kernlage zu einer nur unvollständigen Geometrieabbildung markanter Formelemente in der Decklage kommen.In this forming processing in a pressing tool, however, the production or formation of distinctive features on the component to be produced proves to be difficult, especially when the multi-layer semifinished product used has a soft core layer and at least one hard cover layer. Usually, the soft core layer prevents precise shaping of the hard top layer or cover layers. In particular, it can come in the pressing tool due to the flexibility of the soft core layer to an incomplete geometry imaging distinctive features in the top layer.

Die Erfindung soll zumindest diesen mit dem Stand der Technik einhergehenden Nachteil beseitigen oder zumindest verringern.The invention is intended to eliminate or at least reduce at least this disadvantage associated with the prior art.

Dies gelingt mit einem erfindungsgemäßen Verfahren, welches die Merkmale des Patentanspruchs 1 aufweist. Mit einem nebengeordneten Patentanspruch erstreckt sich die Erfindung auch auf ein erfindungsgemäß hergestelltes Karosseriebauteil für ein Kraftfahrzeug, wobei es sich insbesondere um ein Karosserie-Außenhautbauteil handelt. Bevorzugte Weiterbildungen und Ausgestaltungen ergeben sich analog für beide Erfindungsgegenstände aus den abhängigen Patentansprüchen und aus den nachfolgenden Erläuterungen.This is achieved with a method according to the invention which has the features of patent claim 1. With a sibling claim, the invention also extends to an inventively manufactured body component for a motor vehicle, which is in particular a body shell component. Preferred developments and refinements emerge analogously for both subject matters of the invention from the dependent claims and from the following explanations.

Das erfindungsgemäße Verfahren sieht vor, dass an (bestimmten) Stellen, an denen im herzustellenden Bauteil markante Formelemente erzeugt werden sollen, zwischen Patrize und Matrize eine lokal verstärkte Komprimierung der weichen Kernlage erfolgt, so dass (dort) in der weichen Kernlage erhöhte Druckspannungen entstehen, durch die eine präzise (plastische) Ausformung der harten Decklage, zumindest auf einer Seite und bevorzugt auf beiden Seiten des Halbzeugs bzw. des daraus hergestellten Bauteils, erreicht wird.The method according to the invention provides that at (specific) points at which distinctive shape elements are to be produced in the component to be produced, a locally reinforced compression of the soft core layer takes place between male and female, so that (there) increased compressive stresses arise in the soft core layer, by a precise (plastic) shaping of the hard cover layer, at least on one side and preferably on both sides of the semifinished product or of the component produced therefrom, is achieved.

Markante Formelemente sind vorrangig Bauteilkanten mit kleinem Kantenaußenradius (an der Krümmungsaußenseite), der vorzugsweise kleiner ist als das 5-fache und insbesondere kleiner ist als das 2,5-fache der Ausgangsdicke des mehrlagigen flächigen Halbzeugs. Eine solche, insbesondere im sichtbaren Bauteilbereich verlaufende, Bauteilkante kann auch als scharfkantige Bauteilkante bezeichnet werden. Markante Formelemente können aber bspw. auch Sicken, Ecken und sonstige Formelemente (bspw. eingeprägte Schriftzüge und Logos) sein.Striking form elements are primarily component edges with a small edge outer radius (on the curvature outside), which is preferably smaller than 5 times and in particular smaller than 2.5 times the initial thickness of the multilayer flat semi-finished product. Such, in particular in the visible component area extending, component edge can also be referred to as a sharp-edged component edge. However, distinctive form elements can also be, for example, beads, corners and other form elements (for example impressed lettering and logos).

Die anforderungsgerechte Ausformung eines markanten Formelements, insbesondere vorausgehend beschriebener Art, gelingt erfindungsgemäß durch eine verstärkte bzw. erhöhte Komprimierung der weichen Kernlage an der betreffenden Stelle bzw. im betreffenden Bereich oder Abschnitt, wofür die Werkzeugwirkfläche an der Patrize und/oder an der Matrize entsprechend ausgebildet ist/sind. Durch die lokale Komprimierung bzw. Verdichtung entstehen im Inneren der Kernlage lokal höhere Druckspannungen, die, quasi von innen, auf die harte Decklage einwirken und eine präzise Geometrieabbildung des Formelements mit entsprechender Formgebung der Decklage begünstigen. Mit anderen Worten formuliert heißt dies, dass an kritischen Stellen, an denen Formelemente erzeugt werden sollen, über eine lokale Verpressung der relativ weichen Kernlage bzw. Kernschicht die Umformung der härten bzw. steiferen Decklage und damit die Abbildung von Formelementen unterstützt wird, so dass letztlich die zuverlässige und reproduzierbare Erzeugung einer gewünschten Bauteilform gelingt.The requirement-oriented shaping of a striking element element, in particular of the previously described type, is achieved according to the invention by increased or increased compression of the soft core layer at the relevant point or in the relevant area or section, for which purpose the tool acting surface on the male and / or on the female mold is designed accordingly is / are. The local compression or compression creates locally higher compressive stresses inside the core layer, which act on the hard top layer, as it were from the inside, and promote a precise geometric imaging of the shaped element with corresponding shaping of the top layer. In other words, this means that at critical points at which mold elements are to be produced, a local compression of the relatively soft core layer or core layer, the deformation of the hardened or rigid cover layer and thus the image of mold elements is supported, so that ultimately the reliable and reproducible production of a desired component shape succeeds.

Das für die Herstellung des Bauteils verwendete mehrlagige Halbzeug besteht aus wenigstens einer weichen Kernlage und mindestens einer auf dieser weichen Kernlage befindlichen harten Decklage. Bevorzugt ist beidseitig der weichen Kernlage wenigstens eine harte Decklage vorgesehen. Unter einer weichen Kernlage wird verstanden, dass der Kernlagenwerkstoff, insbesondere in Relation zum Decklagenwerkstoff, eine niedrige bzw. niedrigere Verformungsfestigkeit (bzw. Verformungswiderstand) aufweist. Bei dem Kernlagenwerkstoff handelt es sich bspw. um einen Kunststoff oder einen Kunststoffschaum, insbesondere eines thermoplastischen Kunststoffs, oder einen Metallschaum. Bei dem Kernlagenwerkstoff kann es sich auch um einen Verbundwerkstoff handeln. Unter einer harten Decklage wird verstanden, dass der Decklagenwerkstoff, insbesondere in Relation zum Kernlagenwerkstoff, eine hohe bzw. höhere Verformungsfestigkeit aufweist, also steif bzw. steifer ist. Bei dem Decklagenwerkstoff handelt es sich bspw. um ein Metall oder einen Faserkunststoffverbund. Bei einer metallischen Decklage handelt es sich insbesondere um ein Stahl- oder Aluminiumblech, das bspw. eine Blechdicke von 0,5 mm bis 2,0 mm aufweisen kann. Das mehrlagige flächige Halbzeug weist eine bevorzugte Ausgangsdicke von 3 mm bis 6 mm und insbesondere von 4 mm bis 5 mm auf.The multi-layer semifinished product used for the production of the component consists of at least one soft core layer and at least one hard cover layer located on this soft core layer. Preferably, at least one hard top layer is provided on both sides of the soft core layer. A soft core layer is understood to mean the core layer material, especially in relation to the cover layer material, a low or lower deformation resistance (or deformation resistance). The core layer material is, for example, a plastic or a plastic foam, in particular a thermoplastic, or a metal foam. The core layer material may also be a composite material. A hard cover layer is understood to mean that the cover layer material, in particular in relation to the core layer material, has a high or higher deformation resistance, ie is stiff or stiffer. The cover layer material is, for example, a metal or a fiber-plastic composite. A metallic cover layer is, in particular, a steel or aluminum sheet which, for example, may have a sheet thickness of 0.5 mm to 2.0 mm. The multilayer flat semi-finished product has a preferred starting thickness of 3 mm to 6 mm and in particular of 4 mm to 5 mm.

Bevorzugt umfasst das erfindungsgemäße Umformen eines insbesondere mit wenigstens einer metallischen Decklage ausgebildeten mehrlagigen flächigen Halbzeugs einen Tiefziehvorgang. Beim Tiefziehen handelt es sich um ein Zug-Druck-Umformen, wozu das verwendete Presswerkzeug ferner wenigstens einen Niederhalter aufweist, mit dem das umzuformende mehrlagige flächige Halbzeug in einem Flanschbereich gegen die Matrize gedrückt wird und unter Aufrechterhaltung der Druckeinwirkung im Flanschbereich in die Matrize einfließen kann. (Dies unterscheidet sich von einer reinen Umformung, die nur zwischen den Wirkflächen von Patrize und Matrize erfolgt.) Der Tiefziehvorgang dient insbesondere der Erzeugung einer vorgegebenen Bauteilkontur durch tiefziehende Formgebung der metallischen Decklage, bei der es sich insbesondere um ein Stahl- oder Aluminiumblech handelt, wobei die weiche Kernlage dieser tiefziehenden Formgebung folgt. Erst am Ende oder gegebenenfalls erst nach Abschluss des Tiefziehvorgangs erfolgt die Ausformung der markanten Formelemente zwischen den Werkzeugwirkflächen von Patrize und Matrize in der zuvor beschriebenen Weise. Demnach handelt es sich bei dieser Weiterbildung um eine (einstufige) Kombination aus einem Tiefziehvorgang zur Erzeugung der Bauteilkontur und einem sich unmittelbar daran anschließenden Prägevorgang zur Ausformung wenigstens eines Formelements.The forming according to the invention of a multilayer flat semi-finished product formed in particular with at least one metallic cover layer preferably comprises a deep-drawing process. When deep-drawing is a train-pressure-forming, including the press tool used further comprises at least one hold-down with which the reshaping multilayer sheet semi-finished is pressed in a flange against the die and can flow into the die while maintaining the pressure in the flange , (This differs from a pure deformation, which takes place only between the active surfaces of male and female mold.) The deep drawing process is used in particular to produce a predetermined component contour by deep-drawing of the metallic cover layer, which is in particular a steel or aluminum sheet, the soft core layer follows this deep-drawing shape. Only at the end or, if appropriate, only after the completion of the deep-drawing process, the shaping of the distinctive shape elements between the tool effective surfaces of male and female in the manner described above. Accordingly, this development is a (one-stage) combination of a deep-drawing process for producing the component contour and an immediately following embossing process for shaping at least one molding element.

Bevorzugt erfolgt die erfindungsgemäße Herstellung eines Bauteils durch einstufiges Umformen des mehrlagigen flächigen Halbzeugs. D. h., das Umformen erfolgt in einem Schritt bzw. in einer Pressenstufe. Nach der Entnahme aus dem Presswerkzeug weist das hergestellte Bauteil im Wesentlichen Endgeometrie auf. Weitere Umformschritte bzw. -stufen sind bevorzugt nicht vorgesehen. Allerdings kann noch eine Schneidoperation, insbesondere zur Abtrennung eines eventuell vorhandenen Flanschbereichs, vorgesehen sein.Preferably, the production of a component according to the invention is carried out by single-stage forming of the multilayer flat semifinished product. D. h., The forming takes place in one step or in a press stage. After removal from the pressing tool, the manufactured component essentially has final geometry. Further forming steps or stages are preferably not provided. However, a cutting operation, in particular for the separation of a possibly existing flange area, may be provided.

Bevorzugt weist das mehrlagige flächige Halbzeug wenigstens eine aus Kunststoff und insbesondere aus thermoplastischem Kunststoff gebildete Kernlage auf. Insbesondere in diesem Fall ist vorgesehen, dass das erfindungsgemäße Umformen des mehrlagigen flächigen Halbzeugs in einem erwärmten Zustand erfolgt. Die Erwärmung des umzuformenden Halbzeugs kann außerhalb des Presswerkzeugs, d. h. vor dem Einlegen in das Presswerkzeug, oder innerhalb des Presswerkzeugs erfolgen. Die erforderliche Erwärmungstemperatur ergibt sich abhängig vom Kunststoffmaterial.The multilayer flat semi-finished product preferably has at least one core layer formed from plastic and in particular from thermoplastic material. In particular, in this case, it is provided that the inventive forming of the multilayer flat semifinished product takes place in a heated state. The heating of the semifinished product to be formed can take place outside the pressing tool, i. H. before insertion into the pressing tool, or within the pressing tool. The required heating temperature depends on the plastic material.

Das erfindungsgemäße Verfahren eignet sich zur Herstellung diverserer Kraftfahrzeugbauteile. Die Verwendung eines mehrere Lagen bzw. Schichten aus Werkstoffen mit verschiedenen Eigenschaften aufweisenden Halbzeugs ermöglicht z. B. die Herstellung sehr leichter und dennoch hoch belastbarer Bauteile. Weitere vorteilhafte Eigenschaften solcher Bauteile können eine gute Wärme- und Geräuschdämmung sein, Bei den Bauteilen handelt es sich bspw. um Interieurbauteile. Bevorzugt handelt es sich um Karosseriebauteile und insbesondere um Karosserie-Außenhautbauteile, vorzugsweise für einen Personenkraftwagen (PKW). Bevorzugt umfassen diese Karosseriebauteile und insbesondere Außenhautbauteile wenigstens eine markante bzw. scharfkantige Bauteilkante (wie obenstehend erläutert), welche in einem sichtbaren Bauteilbereich verläuft.The inventive method is suitable for the production of various motor vehicle components. The use of a multiple layers or layers of materials with different properties having semifinished product allows z. B. the production of very light and yet highly resilient components. Further advantageous properties of such components can be good heat and noise insulation. The components are, for example, interior components. It is preferably body parts and in particular body shell components, preferably for a passenger car (PKW). Preferably, these body components and in particular outer skin components comprise at least one distinctive or sharp-edged component edge (as explained above), which runs in a visible component region.

Die Erfindung wird nachfolgend anhand einer Figur beispielhaft und in nicht einschränkender Weise näher erläutert.The invention will now be described by way of example by way of example and not by way of limitation.

1 zeigt in einer schematischen Schnittdarstellung die erfindungsgemäße Umformung eines mehrlagigen flächigen Halbzeugs in einem Presswerkzeug. 1 shows a schematic sectional view of the inventive transformation of a multilayer sheet semi-finished in a press tool.

1 zeigt ein Presswerkzeug 100 zur Umformung eines mehrlagigen flächigen Halbzeugs 200. Das Presswerkzeug 100 ist in einer nicht gezeigten Presse oder Schließvorrichtung eingebaut und weist eine Matrize 110, einen Stempel bzw. eine Patrize 120 und einen Niederhalter 130 auf. Durch Absenken und Anheben der Matrize 110 kann das Presswerkzeug 100 in an und für sich bekannter Weise geschlossen und geöffnet werden. Während des Schließhubs erfolgt die Umformung des mehrlagigen Halbzeugs 200. 1 shows a pressing tool 100 for forming a multilayer flat semifinished product 200 , The pressing tool 100 is installed in a press or locking device, not shown, and has a die 110 , a stamp or a patrix 120 and a hold-down 130 on. By lowering and raising the die 110 can the pressing tool 100 closed and opened in a manner known per se. During the closing stroke, the forming of the multi-layer semifinished product takes place 200 ,

Das mehrlagige Halbzeug 200 weist eine weiche, bspw. aus Kunststoff gebildete Kernlage 210 und zwei harte Decklagen 220 und 230 auf. Bei der Decklage 220 handelt es sich bspw. um eine metallische Decklage (Stahl- oder Aluminiumblech). Bei der Decklage 230 handelt es sich bspw. um eine metallische Decklage oder um eine Decklage aus Faserkunststoffverbund (bspw. CFK oder GFK). Das mehrlagige Halbzeug 200 weist eine gleichmäßige Ausgangsdicke im Bereich mehrerer Millimeter auf.The multi-layer semi-finished product 200 has a soft, eg. Made of plastic core layer 210 and two hard top layers 220 and 230 on. At the top layer 220 is, for example, a metallic cover layer (steel or aluminum sheet). In the topsheet 230 is, for example, a metallic cover layer or a cover layer of fiber-reinforced plastic composite (eg. CFK or GRP). The multi-layer semi-finished product 200 has a uniform initial thickness in the range of several millimeters.

Die Darstellung der 1 zeigt das Ende eines einstufigen Umformvorgangs, bei dem ein anfänglich ebener Halbzeugzuschnitt zu einem Endgeometrie aufweisenden Bauteil 300 umgeformt wurde. Bei dem Bauteil 300 handelt es sich insbesondere um ein Karosseriebauteil. Der Umformvorgang umfasst einen weitgehend konventionellen Tiefziehvorgang zur Erzeugung der Bauteilkontur und einen sich direkt daran anschließenden Prägevorgang zur Ausformung von markanten Formelementen im Bauteil 300.The presentation of the 1 shows the end of a single-stage forming operation, in which an initially flat semi-finished blank to a final geometry having component 300 was reshaped. In the component 300 it is in particular a body component. The forming process comprises a largely conventional deep-drawing process for producing the component contour and a directly subsequent embossing process for shaping distinctive shape elements in the component 300 ,

An den mit A, B, C und D gekennzeichneten Stellen erfolgt die Ausformung markanter Formelemente, wobei es sich insbesondere um Baueilkanten handelt, erfindungsgemäß durch eine lokal verstärkte Komprimierung der weichen Kernlage 210, so dass lokal in der weichen Kernlage 210 erhöhte Druckspannungen entstehen, durch die eine präzise Ausformung der metallischen Decklage 220 auf der späteren Sichtseite V des Bauteils 300 erreicht wird. Dies gelingt durch eine entsprechende Gestaltung der korrespondierenden Werkzeugwirkflächen an der Patrize 120 und an der Matrize 110.At the points marked with A, B, C and D, the shaping of distinctive shape elements takes place, which are in particular structural edges, according to the invention by a locally reinforced compression of the soft core layer 210 , so that locally in the soft core layer 210 increased compressive stresses caused by the precise shaping of the metallic cover layer 220 on the later visible side V of the component 300 is reached. This is achieved by a corresponding design of the corresponding tool effective surfaces on the male 120 and at the die 110 ,

In dem gezeigten Beispiel ist die stempel- bzw. patrizenseitige Werkzeugwirkfläche in den Bereichen bzw. an den Stellen A, B, C und D mit Überhöhungen ausgebildet, so dass dort der Werkzeugspalt (dies ist gemäß Darstellung der Abstand zwischen den korrespondierenden Werkzeugwirkflächen bei vollständig geschlossenem Presswerkzeug 100) verringert ist. Der Werkzeugspalt ergibt sich also nicht, wie im Stand der Technik üblich, durch einen gleichmäßigen Flächen-Offset. Durch die Überhöhungen an der patrizenseitigen Werkzeugwirkfläche wird an den Stellen A, B, C und D eine lokal verstärkte Komprimierung der Kernschicht 210 hervorgerufen, sobald sich das Presswerkzeug 100 während des Schließhubs dem vollständig geschlossenen Zustand nähert (d. h. die Matrize 110 erreicht UT). In dem gezeigten Beispiel erfolgt die lokal verstärkte Komprimierung der weichen Kernschicht 210 also über die spätere Bauteilrückseite R. In der Folge wird das Deckblech 220 an den Stellen A, B, C und D von innen verstärkt gegen die matrizenseitige Werkzeugwirkfläche gepresst, wodurch an diesen Stellen eine präzise plastische Ausformung der harten Decklage 220 erreicht wird und somit die Geometrieabbildung der zu erzeugenden Formelemente gelingt.In the example shown, the punch-side or patrick-side tool acting surface is formed in the regions or at the points A, B, C and D with elevations, so that there the tool gap (this is shown as the distance between the corresponding tool effective surfaces at fully closed press tool 100 ) is reduced. The tool gap does not result, as is customary in the prior art, by a uniform surface offset. Due to the elevations on the patrick-side tool effective surface is at the points A, B, C and D, a locally enhanced compression of the core layer 210 caused as soon as the pressing tool 100 during the closing stroke approaches the fully closed state (ie the die 110 reaches UT). In the example shown, the locally enhanced compression of the soft core layer takes place 210 So on the later component back side R. As a result, the cover plate 220 reinforced at the points A, B, C and D from the inside pressed against the die-side tool acting surface, whereby at these points a precise plastic shaping of the hard top layer 220 is achieved and thus succeeds the geometry mapping of the molded elements to be generated.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

100100
Presswerkzeugpress tool
110110
Matrizedie
120120
Patrize (Stempel)Male (stamp)
130130
NiederhalterStripper plate
200200
mehrlagiges flächiges Halbzeugmultilayer flat semi-finished product
210210
Kernlagecore layer
220220
Decklage (außen)Cover layer (outside)
230230
Decklage (innen)Cover layer (inside)
300300
Bauteilcomponent
AA
Stelle, BereichPlace, area
BB
Stelle, BereichPlace, area
CC
Stelle, BereichPlace, area
DD
Stelle, BereichPlace, area
RR
Rückseiteback
VV
Vorderseite, SichtseiteFront side, visible side

ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION

Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Zitierte PatentliteraturCited patent literature

  • DE 102009016215 A1 [0003] DE 102009016215 A1 [0003]

Claims (9)

Verfahren zur Herstellung eines Bauteils (300), insbesondere eines Karosseriebauteils, durch Umformen eines mehrlagigen flächigen Halbzeugs (200), das wenigstens eine weiche Kernlage (210) und mindestens eine harte Decklage (220, 230) aufweist, wobei das Umformen mithilfe eines Matrize (110) und Patrize (120) aufweisenden Presswerkzeugs (100) erfolgt, dadurch gekennzeichnet, dass an Stellen (A, B, C, D), an denen im herzustellenden Bauteil (300) markante Formelemente erzeugt werden sollen, zwischen Patrize (120) und Matrize (110) eine lokal verstärkte Komprimierung der weichen Kernlage (210) erfolgt, so dass in der weichen Kernlage (210) erhöhte Druckspannungen entstehen, durch die eine präzise Ausformung der harten Decklage (220, 230) erreicht wird.Method for producing a component ( 300 ), in particular a body component, by forming a multilayer flat semi-finished product ( 200 ), which has at least one soft core layer ( 210 ) and at least one hard top layer ( 220 . 230 ), wherein the forming by means of a die ( 110 ) and patrix ( 120 ) having pressing tool ( 100 ), characterized in that at locations (A, B, C, D) at which in the component to be produced ( 300 ) distinctive features are to be created between patrix ( 120 ) and die ( 110 ) a locally enhanced compression of the soft core layer ( 210 ), so that in the soft core layer ( 210 ) increased compressive stresses arise through the precise shaping of the hard cover layer ( 220 . 230 ) is achieved. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das mehrlagige flächige Halbzeug (200) wenigstens eine metallische Decklage (220, 230) aufweist.Method according to claim 1, characterized in that the multilayer flat semi-finished product ( 200 ) at least one metallic cover layer ( 220 . 230 ) having. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass das Umformen einen Tiefziehvorgang umfasst.A method according to claim 2, characterized in that the forming comprises a deep-drawing process. Verfahren nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, dass das Umformen in einem Schritt erfolgt.Method according to one of the preceding claims, characterized in that the forming takes place in one step. Verfahren nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, dass das mehrlagige flächige Halbzeug (200) eine Ausgangsdicke von 3 mm bis 6 mm und insbesondere von 4 mm bis 5 mm aufweist.Method according to one of the preceding claims, characterized in that the multilayer flat semi-finished product ( 200 ) has an initial thickness of 3 mm to 6 mm and in particular from 4 mm to 5 mm. Verfahren nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, dass es sich bei wenigstens einem markanten Formelement um eine im sichtbaren Bauteilbereich verlaufende Bauteilkante handelt, wobei deren Kantenaußenradius vorzugsweise kleiner ist als das 5-fache und insbesondere kleiner ist als das 2,5-fache der Ausgangsdicke des mehrlagigen flächigen Halbzeugs (200).Method according to one of the preceding claims, characterized in that at least one distinctive shaped element is a component edge extending in the visible component region, the edge outer radius of which is preferably less than 5 times and in particular less than 2.5 times that Starting thickness of the multilayer flat semi-finished product ( 200 ). Verfahren nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, dass das mehrlagige flächige Halbzeug (200) wenigstens eine aus Kunststoff und insbesondere aus thermoplastischem Kunststoff gebildete Kernlage (210) aufweist.Method according to one of the preceding claims, characterized in that the multilayer flat semi-finished product ( 200 ) at least one core layer formed of plastic and in particular of thermoplastic material ( 210 ) having. Verfahren nach einem der vorausgehenden Ansprüche und insbesondere nach Anspruch 7, dadurch gekennzeichnet, dass das Umformen des mehrlagigen flächigen Halbzeugs (200) in einem erwärmten Zustand erfolgt.Method according to one of the preceding claims and in particular according to claim 7, characterized in that the forming of the multilayer flat semifinished product ( 200 ) takes place in a heated state. Karosseriebauteil (300), insbesondere Außenhautbauteil, welches mit einem Verfahren gemäß einem der vorausgehenden Ansprüche aus einem mehrlagigen flächigen Halbzeug (200), das wenigstens eine weiche Kernlage (210) und mindestens eine harte Decklage (220, 230) aufweist, hergestellt ist.Body component ( 300 ), in particular outer skin component, which is produced by a method according to one of the preceding claims from a multilayer flat semi-finished product ( 200 ), which has at least one soft core layer ( 210 ) and at least one hard top layer ( 220 . 230 ) is made.
DE102015203642.1A 2015-03-02 2015-03-02 Method for producing a component by forming a multilayer flat semi-finished product with a soft core layer and component produced therewith Withdrawn DE102015203642A1 (en)

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CN108380741A (en) * 2017-02-03 2018-08-10 本特勒尔汽车技术有限公司 Shaping dies for manufacturing hollow unit and the method for running shaping dies
CN108527894A (en) * 2017-03-02 2018-09-14 大众汽车有限公司 Method for reinforcing a metal component by means of a robot-guided application head
CN111299453A (en) * 2018-12-11 2020-06-19 宝马股份公司 Method for manufacturing spare part of vehicle
EP4101616A1 (en) * 2021-06-10 2022-12-14 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Mold, apparatus, and method for producing metal-resin composite

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Publication number Priority date Publication date Assignee Title
CN108380741A (en) * 2017-02-03 2018-08-10 本特勒尔汽车技术有限公司 Shaping dies for manufacturing hollow unit and the method for running shaping dies
CN108380741B (en) * 2017-02-03 2019-11-15 本特勒尔汽车技术有限公司 Method for manufacturing the shaping dies of hollow unit and for running shaping dies
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CN108527894B (en) * 2017-03-02 2021-05-07 大众汽车有限公司 Method for reinforcing metal components by means of a robot-guided applicator head
CN111299453A (en) * 2018-12-11 2020-06-19 宝马股份公司 Method for manufacturing spare part of vehicle
CN111299453B (en) * 2018-12-11 2024-05-24 宝马股份公司 Method for manufacturing spare parts of vehicle
EP4101616A1 (en) * 2021-06-10 2022-12-14 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Mold, apparatus, and method for producing metal-resin composite
US12447700B2 (en) 2021-06-10 2025-10-21 Kobe Steel, Ltd. Mold, apparatus, and method for producing metal-resin composite

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