DE102024206217A1 - Method for machining a component which has at least one through-opening for receiving another component, and component producible by the method, and motor vehicle with such a component - Google Patents

Abstract

The invention relates to a method for processing a component (1) which has at least one through-opening (2) for receiving a further component (3). In a process step, at least one fracture joint is created in the component (2), so that at least two fracture surfaces (7a, 7b) are produced in the component (1).
The invention proposes that the fracture separation is carried out in such a way that the component (2) remains a single component even after the fracture separation.
The invention further relates to a component which can be manufactured by the method and to a motor vehicle with at least one such component.

Description

The invention relates to a method for machining a component which has at least one through-opening for receiving a further component with the features of the preamble of claim 1. The invention further relates to a component which can be manufactured by the method and to a motor vehicle with at least one such component.

The process of fracture separation has been known for many years in connecting rod manufacturing. This is how the DE 100 22 884 A1 A method applicable to the fracture separation of connecting rods for internal combustion engines. Specifically, it is proposed that, in one of the components to be subjected to fracture separation, embrittlement be induced only in the fracture zone by means of a localized heat treatment, compared to the untreated part. This should be achieved in such a way that the embrittlement zone extends over a large portion of the fracture topography necessary for the reliable joining of the fracture-separated components.

WO 2013/135652 A1 describes a method for fracture-separating a workpiece along a bearing eye. In this process, fracture-separation notches are formed in a circumferential wall, roughly defining the fracture plane. A cracking mandrel is used to apply a fracture-separation force to the bearing. A fracture guide notch is formed at a distance from the fracture-separation notches and lies in the fracture plane.

From the DE 10 2011 101 857 A1 A process for manufacturing metallic components with an opening or cavity is known, which includes selective laser sintering or melting. In this process, one- or multi-component metallic powder is melted layer by layer at corresponding cross-sectional areas using laser beams. After the laser sintering or melting process, the component undergoes a fracture separation process in which it is broken along a fracture line into at least two fragments. The fragments are then rejoined at their fracture points to form the component. The fracture line penetrates at least part of the opening or cavity.

The known methods carry an increased risk of damaging the fracture surfaces or of losing or accidentally rotating one of the individual components. Furthermore, two-part assembly leads to increased dimensional inaccuracies. Until now, these disadvantages have been mitigated through complex measures in fully automated manufacturing.

The present invention is based on the objective of proposing a method for machining a component which has at least one through-opening for receiving another component, which can be carried out reliably and with less effort. Furthermore, the method should result in a component with high accuracy. A further objective of the invention is to propose a component which can be manufactured using the method according to the invention.

These problems are solved by a method with the features of claim 1 and by a component with the features of claim 7. Advantageous embodiments or further developments of the invention can be found in the respective dependent claims.

The invention relates to a method for machining a component which has at least one through-opening for receiving another component. In a process step, at least one fracture surface is created in the component, so that at least two fracture surfaces are produced in the component. The component is preferably made of metal, in particular of cast aluminum.

According to the invention, it is proposed that the fracture separation be carried out in such a way that the component remains a single component even after the fracture separation. Thus, the fracture separation does not produce two components.

This approach lays the foundation for a more reliable and less complex process. Because the process doesn't create two separate components, but rather retains the original single component even after fracture separation, the effort required for intermediate storage, clamping, and machining is reduced. The risk of accidental twisting of the component halves or even loss is minimized.

According to a first advantageous embodiment, it is proposed that during the fracture separation process, a fracture path is generated which traverses a circumferential wall of the through-hole, wherein the circumferential wall has at least one through-hole traversing the fracture path for the realization of a bolted connection. Such an embodiment contributes to increasing the accuracy and process reliability of the method. The fracture can preferably be achieved by applying a metered spreading force by means of a spreading tool is inserted into the through-hole.

In a suitable further development, the fracture path is generated such that it extends perpendicular or approximately perpendicular to a longitudinal axis of the through-hole. This further development is intended to help ensure that the subsequent component can be reliably held within the component while applying only small clamping forces.

In another embodiment, a material weakening is introduced into the circumferential wall of the through-hole prior to fracture separation, in order to initiate the fracture in a controlled manner. This material weakening can preferably be introduced in the form of a notch originating from the through-hole and extending radially outward into a portion of the circumferential wall. The notch can preferably extend axially along the entire length of the through-hole. Instead of a notch, the introduction of a laser marking or a saw cut is also conceivable.

• • die Bruchflächen werden nach der Bruchtrennung durch die wenigstens eine Schraubenverbindung zusammengepresst
• • nach dem Zusammenpressen der Bruchflächen wird die Durchgangsöffnung auf eine gewünschte Größe und eine gewünschte Oberflächengüte hin bearbeitet
• • nach der Bearbeitung der Durchgangsöffnung wird die Schraubenverbindung wieder gelöst
• • die Durchgangsöffnung wird danach aufgespreizt
• • das weitere Bauteil wird in die Öffnung eingefügt
• • die Aufspreizung der Durchgangsöffnung wird aufgehoben
• • die Schraubenverbindung wird erneut festgezogen

Following a further development of the invention, the following additional process steps are proposed:

• • After the fracture separation, the fracture surfaces are pressed together by at least one screw connection
• • After pressing the fracture surfaces together, the through-hole is machined to a desired size and surface finish.
• • After machining the through-hole, the screw connection is loosened again.
• • The opening is then spread open
• • The next component is inserted into the opening.
• • The widening of the passage opening is lifted.
• • The screw connection is tightened again

The aforementioned process steps contribute to making the connection between the component and the other component to be received in the through-opening even more precise and reliable.

Thus, after the fracture surfaces are pressed together by the screw connection, the through-hole can be more easily machined to a desired size and surface finish that corresponds to the properties of the through-hole in the later use of the component.

Furthermore, the dimensions of the component to be inserted into the through-hole can be precisely matched to the dimensions of the finished through-hole within its tolerance range, and thus to the later application.

If the screw connection is loosened again after the through-hole has been machined, the through-hole can be slightly enlarged by carefully controlled spreading with a suitable spreading tool to facilitate axial insertion of a component to be received in the through-hole.

Removing the spread then results in a firm fit of the component to be received in the through-opening, which is sufficient to prevent unwanted position changes of the assembled component.

By tightening the screw connection again, a connection between the components is finally achieved that can withstand even high forces.

It is also worth mentioning that after tightening the bolted connection, a standard-compliant clamping force is generated within the component, resulting in little to no (harmful) tensile forces acting on the circumferential wall, while the bolted connection exerts only (harmless) compressive forces on the circumferential wall in the area of the bolted connection and in the area of the fracture. This allows for a very precise, prior design of the bolted connection according to current technical standards.

As already mentioned, the invention also proposes a component that can be manufactured using the inventive method.

The component has at least one fracture path formed by at least two fracture surfaces. The fracture path completely traverses a circumferential wall of a through-opening for receiving another component. The circumferential wall has at least one through-hole traversing the fracture path for the purpose of creating a bolted connection.

Such a component can be manufactured very efficiently using the inventive method. Furthermore, such a component provides the fundamental prerequisite for the safe and reliable manufacture of another component. can be reliably held in the through-opening.

Following further training, it is advantageous if the component has a material weakening that is radially limited to one side of the circumferential wall by the through-hole. This further training contributes to a more reliable and gentle manufacturing process for the component.

In another embodiment of the invention, it is proposed that the size of each fracture surface be at least as large as the bearing surface of the screw connection for a screw or nut. This contributes to a stable clamping of the components by the screw connection.

It is preferred that the size of each fracture surface is only as large as the bearing surface of the bolted joint for a screw or nut. This helps to prevent the component from being subjected to excessive material stress during the fracture process. In particular, this reduces the forces required for fracture separation.

Finally, the present invention is also intended to provide protection for a motor vehicle which is equipped with a component according to the invention.

The motor vehicle can be further developed by incorporating the component as part of a wheel suspension, with the through-opening in the component being cylindrical. This through-opening can serve to accommodate a cylindrical reservoir tube of a shock absorber. In this way, a reliable wheel suspension can be achieved that is space-saving and cost-effective to manufacture.

A preferred embodiment of the invention is illustrated in the figures and is explained in more detail in the following description with reference to the figures. This will also clarify further features and advantages of the invention. Identical reference numerals, even in different figures, refer to identical, comparable, or functionally equivalent components. Corresponding or comparable properties and advantages are achieved even if no repeated description or reference is made to them. The figures are not, or at least not always, to scale. In some figures, proportions or distances may be exaggerated to more clearly emphasize features of an embodiment.

• 1 ein Bauteil, welches durch das erfindungsgemäße Verfahren herstellbar ist, in einer Ansicht von der Seite, wobei ein weiteres Bauteil zur Bildung eines Bauteileverbundes in das Bauteil eingefügt ist,
• 2 eine Teilansicht auf den Bauteileverbund gemäß Ansicht II aus 1,
• 3 eine Vorderansicht auf ein Kraftfahrzeug, welches an seinen Vorderrädern mit dem Bauteileverbund aus dem Bauteil und dem weiteren Bauteil ausgestattet ist,
• 4a bis 4f ein Teildarstellung des Bauteils und auch des weiteren Bauteils zur Erläuterung der Herstellung des Bauteils sowie des Bauteileverbundes und
• 5 eine Teildarstellung des Bauteils gemäß Ansicht V aus 4f.

They show, each schematically

• 1 a component which can be manufactured by the method according to the invention, in a side view, wherein a further component is inserted into the component to form a component assembly,
• 2 a partial view of the component assembly according to view II from 1 ,
• 3 a front view of a motor vehicle which is equipped on its front wheels with the component assembly consisting of the component and the further component,
• 4a to 4f a partial representation of the component and also of the further component to explain the manufacturing of the component as well as the component assembly and
• 5 a partial representation of the component according to view V from 4f .

First, attention will be drawn to the 1 and 2 Reference is made to the following. It shows a component assembly ZSB consisting of a component 1 and another component 3. The side view of component 1 shows ( 1 ) has an approximately L-shaped appearance, in which the illustration shows an upper, horizontally extending L-leg 1a, which transitions into a vertically downwardly extending L-leg 1b.

Furthermore, a through-opening 2 is provided in the horizontally extending L-leg 1a, which serves to accommodate the additional component 3. In particular, the additional component 3 is held in the through-opening 2 by a clamping connection.

To create the clamping connection, a fracture line 7 was previously introduced into component 1, with the fracture line 7 forming two separation zones T1 and T2 at the free end of the horizontally extending L-shaped leg 1a. Furthermore, a material weakening 6 is evident. This is introduced in the form of a notch, which originates from the through-hole 2 and extends radially outwards into a portion of the circumferential wall of the through-hole 2. The material weakening 6 transitions into the fracture line 7. Its significance will be explained in more detail later.

The clamping connection for the further component 3 is achieved by tightening a screw connection 4, consisting of a screw 4a and a nut 4b, wherein the screw 4a is guided through a through-hole 5 which runs through the two separation areas T1, T2, i.e., traversing the fracture line 7. When the screw connection 4 is tightened, the separation areas T1, T2 with the associated fracture surfaces 7a and 7b are (see also) 4b and 4e) pressed tightly together. A longitudinal axis A1 of the through-opening 2 runs perpendicular to a longitudinal axis A2 of the through-bore 5.

In the illustrated embodiment, the component assembly ZSB is a component assembly that can be used as part of a motor vehicle's wheel suspension. Component 1 serves to mount a wheel carrier (not shown) and a brake caliper (not shown). The further component 3, clamped in component 1, is the hollow cylinder of a shock absorber. 1 The component assembly ZSB is shown in a position approximately corresponding to its mounting position on a motor vehicle. The outer surface A, facing outwards from the motor vehicle, and the inner surface I, facing inwards towards the longitudinal center surface of the motor vehicle, are numbered.

This shows 3 A motor vehicle K, on which the component assembly ZSB is arranged in the area of the front wheels 8. Other necessary components of the wheel suspension are not shown.

Now, based on the 4a to 4f The procedure for processing component 1 and for manufacturing the component assembly ZSB will be explained in more detail.

In this exemplary embodiment, component 1 is made of metal, specifically aluminum. It was previously manufactured in an aluminum casting and has a cylindrical through-opening 2' which does not yet meet the desired finished properties (diameter, surface finish). Furthermore, the through-bore 5 has already been created.

In a process step, a breaking force F1 is then generated using a suitable tool (e.g. wedge), which acts on the through-opening 2' (cf. 4a) .

Upon exceeding a certain breaking force F1, component 1 fractures, starting at the material weakening 6, which in this case serves as the controlled fracture initiation point. A fracture path 7 is formed, which originates at the material weakening 6 and continues radially outwards to the free end of component 1, thus creating the fracture zone T1 with fracture surface 7a and the fracture zone T2 with fracture surface 7b (see figure). 4b) .

It is essential that during the fracture separation process, component 1 is not separated into two components, but remains a single component even after the fracture separation. This enables more precise and faster further processing of component 1 and a more accurate and reliable manufacturing of the component assembly ZSB.

After the fracture separation, the separation areas T1, T2 and thus their fracture surfaces 7a, 7b are pressed together by the screw connection 4 in such a way that no separation gap remains and from the outside only the fracture path 7 is visible as a line (cf. 4c ).

The through-hole 2' is then brought to the desired properties using a suitable tool (e.g., a drill bit), corresponding to a desired finished dimension and surface finish. (Indicated by arrows, see figure.) 4d ).

A spreading force F3 is then applied to the through-opening 2 using a suitable spreading tool (not shown). This results in the separation areas T1 and T2 being slightly separated again. This allows the component 3 to be easily inserted into the enlarged through-opening 2 with the desired tolerance (see figure). 4e) .

Finally, the separating areas T1 and T2 are pressed together again by tightening the screw connection 4 with a screw force F2. It should be noted that due to the prior machining of the through-opening 2' to the desired final state (through-opening 2) and the accompanying tightening of the screw connection 4 (see figure), the following applies: 4d ) even in the assembled state of the component assembly ZSB the separation areas T1, T2, can be firmly pressed together and a gap-free fracture path 7 is present.

In the 5 Is the component assembly ZSB shown in a view V from 4f As can be seen, the fracture surface T2 has broken away. Thus, the fracture surface 7a is visible. A rear, annular bearing surface 4c of the screw 4a is shown with a dashed line. Similarly, an annular bearing surface of the nut 4b is not shown here. To ensure the stability of the screw connection 4, it is preferably desired that the fracture surface 7a is not smaller than the selected bearing surface 4c. A fracture surface 7a that is only as large as, or only slightly larger than, the bearing surface 4c is particularly preferred. In this way, the component 1 can be protected during the fracture separation process to create the fracture surfaces 7a, 7b by reducing the fracture separation force.

Ultimately, the described procedure creates a clamping connection between component 1 and the further component 3, where where there are hardly any or no tensile forces acting on the circumferential wall of the through-hole 2, while the bolted connection 4 only exerts compressive forces on the circumferential wall in the area of the bolted connection 4. In this way, a very precise, prior design of the bolted connection according to DIN is possible. The parameters of the bolted connection (bolt and nut bearing surface, bolt diameter, tightening torque and tightening angle) can already be determined during the manufacturing process ( 4c to 4f) the component assembly ZSB is adjusted as it will be in later use on the motor vehicle ( 3 ) come into play.

Reference symbol list

1

component

1a

first L-leg

1b

second L-leg

2

Passage opening finished

2'

Passage opening

3

further component

4

screw connection

4a

screw

4b

Mother

4c

Contact surface

5

through hole

6

Material weakening, notch

7

Fracture pattern

7a

Fracture surface

7b

Fracture surface

7c

Contact surface

8

front wheels

A

Outside

I

inside

A1

Longitudinal axis

A2

Longitudinal axis

F1

Breaking force

F2

Screw force

F3

Spreading force

ZSB

Component assembly

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• DE 100 22 884 A1 [0002]
• DE 10 2011 101 857 A1 [0004]

Claims (11)

Method for processing a component (1) which has at least one through-opening (2, 2') for receiving another component (3), wherein at least one fracture separation joint is produced in the component (1) in a process step, so that at least two fracture surfaces (7a, 7b) are produced in the component (1), characterized in that the fracture separation is carried out in such a way that the component (1) is still a single component even after the fracture separation. Procedure according to Claim 1 , characterized in that during the fracture separation a fracture path (7) is produced which crosses a circumferential wall of the through opening (2, 2'), wherein the circumferential wall has at least one through bore (5) crossing the fracture path (7) for the realization of a screw connection (4). Procedure according to Claim 2 , characterized in that the fracture profile (7) is generated in such a way that it extends perpendicular to a longitudinal axis (A1) of the through-opening (2). Procedure according to Claim 2 or 3 , characterized in that a material weakening (6) is introduced into the circumferential wall of the through-opening (2') prior to the fracture separation. Procedure according to Claim 4 , characterized in that the material weakening (6) is introduced in the form of a notch which originates from the through-opening (2') and extends radially outwards into a part of the circumferential wall. A method according to one of the preceding claims, characterized by the following further method steps: • the fracture surfaces (7a, 7b) are pressed together by the at least one screw connection (4) after the fracture separation. • after pressing the fracture surfaces (7a, 7b) together, the through-opening (2') is machined to a desired size and surface finish. • after machining the through-opening (2'), the screw connection (4) is loosened again. • the through-opening (2) is then spread open. • the further component (3) is inserted into the through-opening (2). • the spreading of the through-opening (2) is reversed. • the screw connection (4) is tightened again. Component (1) producible by a method according to one of the preceding claims, wherein the component (1) has at least one fracture profile (7) formed by at least two fracture surfaces (7a, 7b), wherein the fracture profile (7) completely traverses a circumferential wall of a through-opening (2) for receiving a further component (3) and the circumferential wall has at least one through-bore (5) traversing the fracture profile (7) for realizing a screw connection (4). Component (1) according to Claim 7 , characterized in that the component (1) has a material weakening (6) which is limited radially to one side of the circumferential wall by the through opening (2). Component (1) according to Claim 7 or 8 , characterized in that the size of each fracture surface (7a, 7b) is at least as large as a bearing surface (7) of the screw connection (4) for a screw (4a) or nut (4b). Motor vehicle (K), characterized by at least one component (1) according to one of the Claims 7 until 9 . motor vehicle (K) according to Claim 10 , characterized in that the component (1) is part of a wheel suspension and the through-opening (2) in the component (1) accommodates a cylindrical container tube (3) of a shock absorber.