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WO2005077561A1 - Method and device for producing a peripherally closed hollow profile - Google Patents

Method and device for producing a peripherally closed hollow profile Download PDF

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Publication number
WO2005077561A1
WO2005077561A1 PCT/EP2005/001283 EP2005001283W WO2005077561A1 WO 2005077561 A1 WO2005077561 A1 WO 2005077561A1 EP 2005001283 W EP2005001283 W EP 2005001283W WO 2005077561 A1 WO2005077561 A1 WO 2005077561A1
Authority
WO
WIPO (PCT)
Prior art keywords
branch
hollow profile
counter
contour
stamp
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.)
Ceased
Application number
PCT/EP2005/001283
Other languages
German (de)
French (fr)
Inventor
Thomas Griskiewitz
Jörg KÖLLN
Jens Schult
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.)
Mercedes Benz Group AG
Original Assignee
DaimlerChrysler 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 DaimlerChrysler AG filed Critical DaimlerChrysler AG
Priority to CA002556070A priority Critical patent/CA2556070A1/en
Priority to US10/589,201 priority patent/US20080034824A1/en
Publication of WO2005077561A1 publication Critical patent/WO2005077561A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/28—Making tube fittings for connecting pipes, e.g. U-pieces
    • B21C37/29—Making branched pieces, e.g. T-pieces
    • B21C37/294—Forming collars by compressing a fluid or a yieldable or resilient mass in the tube
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/037—Forming branched tubes
    • 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
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/24—Perforating, i.e. punching holes
    • B21D28/28—Perforating, i.e. punching holes in tubes or other hollow bodies

Definitions

  • the invention relates to a method for producing a circumferentially closed hollow profile according to the preamble of patent claim 1 and a device therefor according to the preamble of patent claim 3.
  • a generic method or a generic device is known from DE 195 30 056 AI.
  • a branch is formed from a hollow profile blank by means of internal high pressure, which is supported by a receding counter-support during the molding of the cap of the branch.
  • the branch In the edge region of the cap, the branch has a large radius, so that it only rests with its central region on the end face of the counter-holder.
  • the support surface formed by the end face of the counter holder is enclosed by a collar-like, concave cutting edge. To a certain extent, the central area of the cap of the branch is thus in a depression in the counter-holder.
  • the forming pressure is increased considerably, as a result of which the radius in the edge region of the cap of the branch is reduced and this is pressed against the vertically protruding cutting edge.
  • the cutting edge cuts into a circumferential groove in the cap.
  • the counterhold is countered the shape of the branch is shifted towards the branch, whereby the cutting edge of the counter-holder completely cuts through the cap.
  • the counterholder is immersed in the opening of the branch thus created.
  • a calibration bead axially adjoining the cutting edge smoothes the inside wall of the branch. In order to produce this specially designed cutting edge, considerable effort is required.
  • this specially designed cutting edge is extremely heavily stressed by the increased internal pressure above the forming pressure, which leads to breakouts at the cutting edge relatively quickly during operation and thus results in a short service life of the counter-holder. Due to the described high susceptibility of the cutting edge to the high, fluidic and mechanical loads, a process-reliable separation of the cap of the branch is not possible in series production, since after the cutting edge has been damaged, the openings on the branch are punched only incompletely, and the component thus produced must be brought to the committee. The resulting costs are considerable, which in addition to the increased use of materials also include downtimes for retrofitting or repairing the counter holder.
  • the invention is based on the object of developing a generic method in such a way that the production of a hollow profile with secondary form elements and / or branches is made possible, in which a process-reliable separation of the cap of the secondary form element or the branch is achieved in a simple manner. Furthermore, an apparatus for performing the method is to be shown.
  • the object is according to the features of claim 1 with respect to the method and by the Features of claim 3 solved with respect to the device.
  • the invention is based on the surprising finding that the cap of the secondary form element and / or the branch can also be cleanly separated even with an internal high pressure which corresponds at most to the forming pressure for forming the hollow profile from the blank.
  • the caps are separated solely by a stroke of the counter-holding plunger which is opposite to the widening direction of the hollow profile.
  • the end face of the counter-holder stamp runs completely flat and therefore has no cutting or separating contours to be specially trained. This not only makes the counter-holder stamp much simpler, which considerably reduces the outlay on equipment; in addition, the end face and the separating contour of the counter-holder stamp become less susceptible to mechanical loads, which ensures a particularly long durability of the separating contour of the counter-holder stamp.
  • the internal high pressure does not have to exceed the forming pressure in order to separate the cap of the secondary form element and / or the branch, but the normal forming pressure or pressures below it is sufficient to cleanly separate the cap, what provides additional relief for the separating contour.
  • This also eliminates an excessive outlay on equipment, which is required at pressures that exceed the forming pressure, since the locking force for the hydroforming tool can only be applied by extremely powerful hydraulic cylinders and an extremely stable press frame.
  • the width of the annular gap between the wall of the bushing formed in the forming tool, in which the stamp is guided, and the circumference of the stamp should correspond approximately to the wall thickness of the secondary form element or the branch.
  • the secondary molding element and / or the branch after the separation process by means of a plunging movement of the counter-holder stamp into the opened secondary molding element and / or the branch means a calibration contour corresponding to the secondary form element or to the branch. This connects to the end of the stamp on the side facing away from the hollow profile.
  • the known circumferential bead is not required in order to calibrate the secondary form element or the branch. Rather, it can be omitted in a simple manner, which considerably simplifies the design of the counter-holder stamp.
  • the design of the counter-holder stamp is only to be adapted to the desired shape of the branch or the secondary form element.
  • a circumferential collar is formed on the counter-holder stamp, which immediately adjoins the calibration contour on the side facing away from the hollow profile. This ensures that the inhomogeneous material distribution that sometimes occurs due to calibration tion of the secondary form element or branch, which leads to an unevenly drawn-in edge of the branch or secondary form element, is made more uniform by axially pressing the collar onto the end edge of the secondary form element or branch obtained by the trimming.
  • the end edge Due to its flatness and due to the almost tolerance-free design, the end edge is of high quality and has a favorable effect on subsequent connection processes of the hollow profile on other components that have to be attached to the branch or the secondary form element, that the joining distance between the end edge and the component is even is large and thus a homogeneous and therefore particularly good long-term joint connection is achieved.
  • connection techniques such as welding, gluing or the like. can be used reliably.
  • the punch end which contains the separating contour, is frustoconical and has bevel surfaces facing the secondary form element or the branch.
  • the conical shape of the counter-holder plunger creates a radially circumferential sealing seat on the branch or counter-shaped element, as a result of which a pressure drop within the hollow profile is prevented in a highly advantageous manner. This means that several branches can be opened at the same time or one after the other with several punching counterholders arranged on the hollow profile, i.e. the cap can be separated from the branch without the internal high pressure in the hollow profile dropping and thus insufficient process reliability.
  • the end edge of the counter-holder stamp is rounded. Due to the rounding of the End edge, which forms the separating contour, additionally prevents the cap from being separated even while the branch or the secondary form element is being shaped. As a result, when the cap is later removed, the cap is not punched out sharply, but rather is torn out, which creates an undefined opening edge, which, however, is smoothed by the subsequent calibration and thus leads to the desired production result.
  • FIG. 1 is a side longitudinal section of a device according to the invention in the expansion phase of the hollow profile with a backing die
  • FIG. 3 is a side view in sections of a counter-holder stamp of a device according to the invention with a calibration contour adjoining the end of the stamp,
  • Fig. 4 in a side view in sections a counter-holder stamp of a device according to the invention with a circumferential collar.
  • FIG. 1 shows a device 1 which contains an internal high-pressure forming tool 2 and with which a circumferentially closed hollow profile 3, which is introduced into the internal high-pressure forming tool 2, with an auxiliary form element and / or a branch 4 serve.
  • the device 1 also contains a counter-holder stamp 5, which is integrated into the forming tool 2 so that it can be moved with little play.
  • a hollow profile blank 23 is placed within the internal high-pressure forming tool 2 under such a fluidic internal high-pressure Pi that it widens and conforms to the engraving 6 of the forming tool 2, in which the blank 23 is inserted.
  • hollow profile material is displaced in accordance with the internal high pressure Pi, which thereby forms a secondary molding element or the branch 4.
  • the branch 4 is supported during its formation by the end face 8 of the counter-holding plunger 5, the plunger 5 receding in the direction of the arrow as the length of the branch 4 increases.
  • two axial rams 9 of the device 1 are provided, which act on the hollow profile 3 in a sealing manner and push both ends 10 in the direction of the expansion area during the expansion in the direction of the arrow.
  • the drive of the counter-holding plunger 5 is reversed, so that it dips into the secondary form element or the branch 4 and thereby its cap 11 by means of a separating contour formed by the end edge 12 of the plunger 5 is separated out, forming a slug. This is done in the direction of the arrow with the force F. In the meantime, there is a pressure in the hollow profile 3 which corresponds to or is less than the forming pressure.
  • the end face 8 bordered by the end edge 12 of the stamp 5 runs continuously just gig.
  • the width of the annular gap 22 between the circumference 13 of the plunger 5 and the lead-through wall 14 is dimensioned such that it approximately corresponds to the wall thickness of the secondary molding element or the branch 4.
  • the cap 11 of the branch 4 is thus separated solely by a stroke of the counter-holding plunger 5 which is opposite to the widening direction of the hollow profile 3.
  • the counter-holder stamp 5 can, as can be seen from FIGS. 1 and 2, be of continuous cylindrical design. 3, the stamp end 15, which faces the branch 4 and contains the separating contour, can be frustoconical, with bevel surfaces 16 facing the secondary form element or the branch 4. The open branch 4 is sealed completely pressure-tight via these bevel surfaces 16. This avoids a drop in pressure within the hollow profile 3, so that branches 4 formed there at other points in the hollow profile 3 can be carried out sequentially and reliably by cap separation by means of a counter-holding plunger 5 arranged there.
  • a counter-holder stamp 17 additionally has a calibration contour 18, which adjoins the stamp end 19 on the side of the stamp 17 facing away from the hollow profile and is designed according to the contour of the secondary form element or the branch.
  • a circumferential collar 20 of the counter-holding punch 17 directly adjoins the calibration contour 18 on the side facing away from the hollow profile.
  • This collar 20 acts on the end face of the opening edge of the branch, whereby a uniform flatness of this end face is ensured.
  • the terminating edge 21 of the counter-holder stamp 17 can also be rounded in order to completely avoid that a circumferential predetermined breaking point is generated during the support function of the counter-holder stamp 17, which can burst open at least locally due to the prevailing internal high pressure, after which the further formation of the branch 4 no longer takes place can be done reliably.
  • the cap 11 can still be separated from the branch 4 with the rounded end edge 21 of the stamp end 19.

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

Abstract

The aim of the invention is to allow for the production of a hollow profile (3) using secondary forming elements and/or junctions (4), wherein the cover (11) of the secondary forming element and/or junction (4) can be removed in a simple and reliable manner. For this purpose, the cover (11) of the secondary forming element and/or the junction (4) is removed under internal high pressure that does not exceed the forming pressure for producing the hollow profile (3) from the blank, the removal being brought about by the sole lift of the counter-mold (5, 17) that acts in the direction opposite to the direction of expansion of the hollow profile (3). The face (8) of the counter-mold (5, 17) is a continuous even structure, and the end edge (12, 21) of the mold (5, 17) forms the contour of separation. The width of the annular gap (22) between the wall (14) of the passage (7) produced by the forming tool (2) in which the mold (5, 17) is displaceably guided and the mold circumference (13) corresponds approximately to the wall thickness of the secondary forming element or junction (4).

Description

Verfahren und Vorrichtung zur Herstellung eines umfänglich geschlossenen Hohlprofils Method and device for producing a circumferentially closed hollow profile

Die Erfindung betrifft ein Verfahren zur Herstellung eines umfänglich geschlossenen Hohlprofils gemäß dem Oberbegriff des Patentanspruches 1 und eine Vorrichtung dazu gemäß dem Oberbegriff des Patentanspruches 3.The invention relates to a method for producing a circumferentially closed hollow profile according to the preamble of patent claim 1 and a device therefor according to the preamble of patent claim 3.

Ein gattungsgemäßes Verfahren bzw. eine gattungsgemäße Vorrichtung ist aus der DE 195 30 056 AI bekannt. Im dort be¬ schriebenen Verfahren wird aus einem Hohlprofilrohling mittels Innenhochdruck ein Abzweig ausgeformt, der von einem zurückweichenden Gegenhalter während des Ausformprozesses an der Kappe des Abzweiges abgestützt wird. Im Randbereich der Kappe weist der Abzweig jeweils einen großen Radius auf, so däss er nur mit seinem Mittenbereich an der Stirnseite des Gegenhalters anliegt. Die von der Stirnseite des Gegenhalters gebildete Stützfläche wird von einer kragenartigen, konkaven Schneidkante umschlossen. Gewissermaßen befindet sich der Mittenbereich der Kappe des Abzweiges damit in einer Mulde des Gegenhalters. Nach Erreichen der gewünschten Höhe des Abzweiges wird der Umformdruck erheblich erhöht, wodurch sich der Radius im Randbereich der Kappe des Abzweiges verringert und dieser gegen die vertikal abragende Schneidkante gepresst wird. Als Folge davon schneidet die Schneidkante in die Kappe eine umlaufende Rille ein. Nun wird der Gegenhalter entgegen der Ausformrichtung des Abzweiges zum Abzweig hin verschoben, wodurch die Schneidkante des Gegenhalters die Kappe gänzlich durchschneidet. Der Gegenhalter taucht dabei in die so erzeugte Öffnung des Abzweiges ein. Hierbei glättet ein sich axial an die Schneidkante anschließender Kalibrierwulst die Innenwandung des Abzweiges. Um diese speziell ausgebildete Schneidkante herzustellen, ist ein erheblicher Aufwand erforderlich. Des Weiteren ist diese speziell ausgebildete Schneidkante durch den über dem .Umformdruck liegenden erhöhten Innendruck extrem stark belastet, was im Betrieb relativ schnell zu Ausbrechungen an der Schneidkante führt und damit eine geringe Standzeit des Gegenhalters zur Folge hat. Aufgrund der geschilderten hohen Anfälligkeit der Schneidkante gegenüber den hohen, fluidischen und mechanischen Belastungen ist eine prozesssichere Abtrennung der Kappe des Abzweiges in der Serienproduktion nicht möglich, da nach einer Beschädigung der Schneidkante das Stanzen der Öffnungen am Abzweig nur unvollständig erfolgt und dadurch das so hergestellte Bauteil dem Ausschuss zugeführt werden muss. Die dabei entstehenden Kosten sind beträchtlich, die neben dem erhöhten Materialeinsatz auch die Ausfallzeiten zur Umrüstung bzw. Reparatur des Gegenhalters umfassen.A generic method or a generic device is known from DE 195 30 056 AI. In the BE there ¬ described methods, a branch is formed from a hollow profile blank by means of internal high pressure, which is supported by a receding counter-support during the molding of the cap of the branch. In the edge region of the cap, the branch has a large radius, so that it only rests with its central region on the end face of the counter-holder. The support surface formed by the end face of the counter holder is enclosed by a collar-like, concave cutting edge. To a certain extent, the central area of the cap of the branch is thus in a depression in the counter-holder. After the desired height of the branch is reached, the forming pressure is increased considerably, as a result of which the radius in the edge region of the cap of the branch is reduced and this is pressed against the vertically protruding cutting edge. As a result, the cutting edge cuts into a circumferential groove in the cap. Now the counterhold is countered the shape of the branch is shifted towards the branch, whereby the cutting edge of the counter-holder completely cuts through the cap. The counterholder is immersed in the opening of the branch thus created. Here, a calibration bead axially adjoining the cutting edge smoothes the inside wall of the branch. In order to produce this specially designed cutting edge, considerable effort is required. Furthermore, this specially designed cutting edge is extremely heavily stressed by the increased internal pressure above the forming pressure, which leads to breakouts at the cutting edge relatively quickly during operation and thus results in a short service life of the counter-holder. Due to the described high susceptibility of the cutting edge to the high, fluidic and mechanical loads, a process-reliable separation of the cap of the branch is not possible in series production, since after the cutting edge has been damaged, the openings on the branch are punched only incompletely, and the component thus produced must be brought to the committee. The resulting costs are considerable, which in addition to the increased use of materials also include downtimes for retrofitting or repairing the counter holder.

Der Erfindung liegt die Aufgabe zugrunde, ein gattungsgemäßes Verfahren dahingehend weiterzubilden, dass die Herstellung eines Hohlprofils mit Nebenformelementen und/oder Abzweigen ermöglicht wird, bei der in einfacher Weise eine prozesssichere Abtrennung der Kappe des Nebenformelements bzw. des Abzweiges erreicht wird. Des Weiteren soll eine Vorrichtung zur Durchführung des Verfahrens aufgezeigt werden.The invention is based on the object of developing a generic method in such a way that the production of a hollow profile with secondary form elements and / or branches is made possible, in which a process-reliable separation of the cap of the secondary form element or the branch is achieved in a simple manner. Furthermore, an apparatus for performing the method is to be shown.

Die Aufgabe ist erfindungsgemäß durch die Merkmale des Patentanspruches 1 hinsichtlich des Verfahrens und durch die Merkmale des Patentanspruches 3 hinsichtlich der Vorrichtung gelöst .The object is according to the features of claim 1 with respect to the method and by the Features of claim 3 solved with respect to the device.

Die Erfindung basiert auf der überraschenden Erkenntnis, dass die Kappe des Nebenformelementes und/oder des Abzweigs auch bei einem Innenhochdruck sauber herausgetrennt werden kann, der höchstens dem Umformdruck zur Ausbildung des Hohlprofils aus dem Rohling entspricht. Anders als im Stand der Technik erfolgt das Trennen der Kappen allein durch einen der Aufweitrichtung des Hohlprofils entgegengerichteten Hub des Gegenhalterstempels. Die Stirnseite des Gegenhalterstempels verläuft dabei durchgängig eben und weist damit keine speziell auszubildenden Schneid- bzw. Trennkonturen auf. Dadurch wird nicht nur der Gegenhalterstempel deutlich einfacher gestaltet, was den apparativen Aufwand erheblich reduziert; zudem wird die Stirnfläche und die Trennkontur des Gegenhalterstempels weniger anfällig gegenüber mechanischen Belastungen, was eine besonders lange Haltbarkeit der Trennkontur des Gegenhalterstempels gewährleistet. Darüber hinaus kommt noch dazu, dass der Innenhochdruck nicht noch den Umformdruck übersteigen muss, um die Kappe des Nebenformelements und/oder des Abzweigs abzutrennen, sondern es reicht der normal anstehende Umformdruck oder auch Drücke, die diesen unterschreiten, um die Kappe sauber herauszutrennen, was eine zusätzliche Entlastung der Trennkontur erbringt. Hierzu entfällt auch ein übermäßiger apparativer Aufwand, der bei Drücken erforderlich ist, die den Umformdruck übersteigen, da die Zuhaltekraft für das Innenhochdruckumformwerkzeug nur von außerordentlich leistungsfähigen Hydraulikzylindern und einem extrem stabilen Pressengerüst aufgebracht werden kann. Allerdings sollte die Breite des Ringspaltes zwischen der Wandung der im Umformwerkzeug ausgebildeten Durchführung, in der der Stempel verschiebbar geführt ist, und dem Stempelumfang in etwa der Wandstärke des Nebenformelementes bzw. des Abzweiges entspre- chen, da sonst beim Ausformen des Abzweiges bzw. des Nebenformelementes Hohlprofilmaterial mittels des Innenhochdrucks in den Ringspalt hineinverdrängt werden kann, was zu einer unerwünschten Form des Abzweiges bzw. des Nebenformelementes und auch einer vorzeitigen Abtrennung der Kappe aufgrund der Anlage des Hohlprofilmaterials an der Trennkontur des Gegenhalterstempels führen kann. Somit wird insgesamt in einfacher Weise eine prozesssichere Abtrennung der Kappe des Nebenformelements bzw. des Abzweiges durch die erfindungsgemäße Lösung erreicht .The invention is based on the surprising finding that the cap of the secondary form element and / or the branch can also be cleanly separated even with an internal high pressure which corresponds at most to the forming pressure for forming the hollow profile from the blank. In contrast to the prior art, the caps are separated solely by a stroke of the counter-holding plunger which is opposite to the widening direction of the hollow profile. The end face of the counter-holder stamp runs completely flat and therefore has no cutting or separating contours to be specially trained. This not only makes the counter-holder stamp much simpler, which considerably reduces the outlay on equipment; in addition, the end face and the separating contour of the counter-holder stamp become less susceptible to mechanical loads, which ensures a particularly long durability of the separating contour of the counter-holder stamp. In addition, there is also the fact that the internal high pressure does not have to exceed the forming pressure in order to separate the cap of the secondary form element and / or the branch, but the normal forming pressure or pressures below it is sufficient to cleanly separate the cap, what provides additional relief for the separating contour. This also eliminates an excessive outlay on equipment, which is required at pressures that exceed the forming pressure, since the locking force for the hydroforming tool can only be applied by extremely powerful hydraulic cylinders and an extremely stable press frame. However, the width of the annular gap between the wall of the bushing formed in the forming tool, in which the stamp is guided, and the circumference of the stamp should correspond approximately to the wall thickness of the secondary form element or the branch. Chen, otherwise hollow profile material can be displaced into the annular gap by means of the internal high pressure when the branch or the secondary form element is formed, which leads to an undesirable shape of the branch or the secondary form element and also to premature separation of the cap due to the contact of the hollow profile material with the separating contour of the Counterholder stamp can lead. Overall, a process-reliable separation of the cap of the secondary molding element or the branch is achieved in a simple manner by the solution according to the invention.

In einer besonders bevorzugten Weiterbildung der Erfindung nach Anspruch 2 bzw. in einer entsprechenden bevorzugten Weiterbildung der erfindungsgemäßen Vorrichtung nach Anspruch 5 wird das Nebenformelement und/oder der Abzweig nach dem Trennvorgang durch eine Eintauchbewegung des Gegenhalterstempels in das geöffnete Nebenformelement und/oder den Abzweig hinein mittels einer zum Nebenformelement bzw. zum Abzweig formentsprechenden Kalibrierkontur kalibriert. Dieser schließt sich auf hohlprofilabgewandter Seite an das Stempelende an. In mehreren praktischen Versuchen hat sich erwiesen, dass der bekannte umlaufende Wulst nicht erforderlich ist, um das Nebenformelement bzw. den Abzweig zu kalibrieren. Vielmehr kann er in einfacher Weise entfallen, was die Gestaltung des Gegenhalterstempels wesentlich vereinfacht. Die Gestaltung des Gegenhalterstempels ist lediglich an die gewünschte Form des Abzweiges bzw. des Nebenformelementes anzupassen.In a particularly preferred development of the invention according to claim 2 or in a corresponding preferred development of the device according to the invention according to claim 5, the secondary molding element and / or the branch after the separation process by means of a plunging movement of the counter-holder stamp into the opened secondary molding element and / or the branch means a calibration contour corresponding to the secondary form element or to the branch. This connects to the end of the stamp on the side facing away from the hollow profile. In several practical tests, it has been shown that the known circumferential bead is not required in order to calibrate the secondary form element or the branch. Rather, it can be omitted in a simple manner, which considerably simplifies the design of the counter-holder stamp. The design of the counter-holder stamp is only to be adapted to the desired shape of the branch or the secondary form element.

In einer weiteren, besonders bevorzugten Weiterbildung der erfindungsgemäßen Vorrichtung nach Anspruch 6 ist am Gegenhalterstempel ein umlaufender Bund ausgebildet, der sich an die Kalibrierkontur auf hohlprofilabgewandter Seite unmittelbar anschließt. Hierdurch wird erreicht, dass die durch das Kalibrieren bisweilen auftretende inhomogene Materialvertei- lung des Nebenformelementes bzw. des Abzweiges, die zu einem ungleichmäßig eingezogenen Rand des Abzweiges bzw. Nebenformelementes führt, vergleichmäßigt wird, indem der Bund axial auf die durch die Beschneidung erhaltene Abschlusskante des Nebenformelements bzw. des Abzweiges aufgepresst wird. Die aufgrund ihrer Ebenheit und infolge der nahezu toleranzfreien Ausbildung qualitativ hochwertige Abschlusskante wirkt sich dahingehend günstig für nachfolgende Verbindungsverfahren des Hohlprofils an weiteren Bauteilen, die an dem Abzweig bzw. dem Nebenformelement befestigt werden müssen, aus, dass der Fügeabstand zwischen der Abschlusskante und dem Bauteil gleichmäßig groß ist und somit eine homogene und damit einen besonders guten Langzeithalt gebende Fügeverbindung erreicht wird. Hierbei sind derartige Verbindungstechniken, wie Schweißen, Kleben oder dgl . prozesssicher einsetzbar.In a further, particularly preferred development of the device according to the invention, a circumferential collar is formed on the counter-holder stamp, which immediately adjoins the calibration contour on the side facing away from the hollow profile. This ensures that the inhomogeneous material distribution that sometimes occurs due to calibration tion of the secondary form element or branch, which leads to an unevenly drawn-in edge of the branch or secondary form element, is made more uniform by axially pressing the collar onto the end edge of the secondary form element or branch obtained by the trimming. Due to its flatness and due to the almost tolerance-free design, the end edge is of high quality and has a favorable effect on subsequent connection processes of the hollow profile on other components that have to be attached to the branch or the secondary form element, that the joining distance between the end edge and the component is even is large and thus a homogeneous and therefore particularly good long-term joint connection is achieved. Here are such connection techniques, such as welding, gluing or the like. can be used reliably.

In einer weiteren, besonders bevorzugten Ausgestaltung der erfindungsgemäßen Vorrichtung nach Anspruch 4 ist das Stempelende, das die Trennkontur beinhaltet, kegelstumpfförmig ausgebildet und weist zum Nebenformelement bzw. zum Abzweig zugewandte Anschrägungsflachen auf. Durch die konische Form des Gegenhalterstempels wird ein radial umlaufender Dichtsitz an dem Abzweig bzw. Gegenformelement erzeugt, wodurch in höchst vorteilhafter Weise ein Druckabfall innerhalb des Hohlprofils verhindert wird. Damit können mit mehreren, am Hohlprofil angeordneten, stanzenden Gegenhalterstempeln mehrere Abzweige gleichzeitig oder nacheinander geöffnet werden, also die Kappe vom Abzweig abgetrennt werden, ohne dass der Innenhochdruck im Hohlprofil abfallen würde und dadurch keine ausreichende Prozesssicherheit gegeben sein würde.In a further, particularly preferred embodiment of the device according to the invention as claimed in claim 4, the punch end, which contains the separating contour, is frustoconical and has bevel surfaces facing the secondary form element or the branch. The conical shape of the counter-holder plunger creates a radially circumferential sealing seat on the branch or counter-shaped element, as a result of which a pressure drop within the hollow profile is prevented in a highly advantageous manner. This means that several branches can be opened at the same time or one after the other with several punching counterholders arranged on the hollow profile, i.e. the cap can be separated from the branch without the internal high pressure in the hollow profile dropping and thus insufficient process reliability.

In einer weiteren bevorzugten Weiterbildung der erfindungsgemäßen Vorrichtung nach Anspruch 7 ist die Abschlusskante des Gegenhalterstempels verrundet. Aufgrund der Verrundung der Abschlusskante, die die Trennkontur bildet, wird zusätzlich verhindert, dass schon während dem Ausformen des Abzweiges bzw. des Nebenformelementes ein Trennvorgang der Kappe erfolgt. Hierdurch wird beim späteren gewollten Abtrennen der Kappe dieselbe von dem Gegenhalterstempel nicht scharf herausgestanzt, sondern vielmehr herausgerissen, wodurch ein Undefinierter Öffnungsrand entsteht, der allerdings durch die nachfolgende Kalibrierung geglättet wird und somit zu dem gewünschten Herstellungsergebnis führt.In a further preferred development of the device according to the invention, the end edge of the counter-holder stamp is rounded. Due to the rounding of the End edge, which forms the separating contour, additionally prevents the cap from being separated even while the branch or the secondary form element is being shaped. As a result, when the cap is later removed, the cap is not punched out sharply, but rather is torn out, which creates an undefined opening edge, which, however, is smoothed by the subsequent calibration and thus leads to the desired production result.

Nachfolgend ist die Erfindung anhand zweier in den Zeichnungen dargestellter Ausführungsbeispiele näher erläutert.The invention is explained in more detail below with reference to two exemplary embodiments shown in the drawings.

Dabei zeigt:It shows:

Fig. 1 in einem seitlichen Längsschnitt eine erfindungsgemäße Vorrichtung in der Aufweitphase des Hohlprofils mit zurückreichendem Gegenhalterstempel,1 is a side longitudinal section of a device according to the invention in the expansion phase of the hollow profile with a backing die,

Fig. 2 in einem seitlichen Längsschnitt die Vorrichtung aus Figur 1 nach Abschluss der Hohlprofilaufweitung mit einem die Kappe des ausgeformten Nebenformelementes heraustrennenden Gegenhalterstempel,2 in a lateral longitudinal section, the device from FIG. 1 after completion of the hollow profile widening with a counter-holder punch separating the cap of the shaped secondary mold element,

Fig. 3 in einer seitlichen Ansicht abschnittsweise einen Gegenhalterstempel einer erfindungsgemäßen Vorrichtung mit einer sich rückwärtig an das Stempelende anschließenden Kalibrierkontur,3 is a side view in sections of a counter-holder stamp of a device according to the invention with a calibration contour adjoining the end of the stamp,

Fig. 4 in einer seitlichen Ansicht abschnittsweise einen Gegenhalterstempel einer erfindungsgemäßen Vorrichtung mit einem umlaufenden Bund.Fig. 4 in a side view in sections a counter-holder stamp of a device according to the invention with a circumferential collar.

In Figur 1 ist eine Vorrichtung 1 dargestellt, die ein Innen- hochdruckumformwerkzeug 2 beinhaltet und mit der ein umfänglich geschlossenes Hohlprofil 3, das in das Innenhochdruckum- formwerkzeug 2 eingebracht wird, mit einem Nebenformelement und/oder einem Abzweig 4 dien . Die Vorrichtung 1 enthält des Weiteren einen Gegenhalterstempel 5, der in das Umformwerkzeug 2 mit geringem Spiel verschiebbar integriert ist.FIG. 1 shows a device 1 which contains an internal high-pressure forming tool 2 and with which a circumferentially closed hollow profile 3, which is introduced into the internal high-pressure forming tool 2, with an auxiliary form element and / or a branch 4 serve. The device 1 also contains a counter-holder stamp 5, which is integrated into the forming tool 2 so that it can be moved with little play.

Zur Ausbildung des besagten Hohlprofils 3 wird ein Hohlprofilrohling 23 innerhalb des Innenhochdruckumformwerkzeuges 2 unter einen derartigen fluidischen Innenhochdruck Pi gesetzt, dass dieser sich aufweitet und konturtreu an die Gravur 6 des Umformwerkzeuges 2, in der der Rohling 23 eingebracht ist, anlegt. Im Bereich einer in dem Umformwerkzeug 2 ausgebildeten Durchführung 7, in der der Gegenhalterstempel 5 verschiebbar aufgenommen ist, wird Hohlprofilmaterial dem Innenhochdruck Pi zufolge hineinverdrängt, welches dabei ein Nebenformelement bzw. den Abzweig 4 ausformt. Zur prozesssicheren Ausformung des Abzweiges 4 wird dieser während seiner Entstehung von der Stirnseite 8 des Gegenhalterstempels 5 abgestützt, wobei der Stempel 5 mit zunehmender Ausformungslänge des Abzweiges 4 in Pfeilrichtung zurückweicht. Um genügend Hohlprofilmaterial in den Aufweitbereich des Abzweiges 4 zu liefern, sind zwei Axialstempel 9 der Vorrichtung 1 vorgesehen, die das Hohlprofil 3 beiderends dichtend beaufschlagen und beide Enden 10 in Richtung des Aufweitbereiches während der Aufweitung in Pfeilrichtung nachschieben.To form said hollow profile 3, a hollow profile blank 23 is placed within the internal high-pressure forming tool 2 under such a fluidic internal high-pressure Pi that it widens and conforms to the engraving 6 of the forming tool 2, in which the blank 23 is inserted. In the area of a bushing 7 formed in the forming tool 2, in which the counter-holding die 5 is slidably received, hollow profile material is displaced in accordance with the internal high pressure Pi, which thereby forms a secondary molding element or the branch 4. For the process-reliable shaping of the branch 4, the branch 4 is supported during its formation by the end face 8 of the counter-holding plunger 5, the plunger 5 receding in the direction of the arrow as the length of the branch 4 increases. In order to supply enough hollow profile material in the expansion area of the branch 4, two axial rams 9 of the device 1 are provided, which act on the hollow profile 3 in a sealing manner and push both ends 10 in the direction of the expansion area during the expansion in the direction of the arrow.

Nach Erreichen der gewünschten Abzweiglänge wird, wie in Figur 2 dargestellt, der Antrieb des Gegenhalterstempels 5 umgekehrt, so dass dieser in das Nebenformelement bzw. den Abzweig 4 eintaucht und dabei dessen Kappe 11 mittels einer Trennkontur, die von der Abschlusskante 12 des Stempels 5 gebildet wird, unter Bildung eines Lochbutzens heraustrennt. Dies geschieht gemäß Pfeilrichtung mit der Kraft F. Im Hohl- profil 3 herrscht währenddessen ein Druck, der dem Umformdruck entspricht oder kleiner ist. Die von der Abschlusskante 12 des Stempels 5 eingefasste Stirnseite 8 verläuft durchgän- gig eben. Um ein problemfreies Eintauchen in den Abzweig 4 zu ermöglichen, ist die Breite des Ringspaltes 22 zwischen dem Umfang 13 des Stempels 5 und der Durchführungswandung 14 so bemessen, dass sie in etwa der Wandstärke des Nebenformelementes bzw. des Abzweiges 4 entspricht. Das Trennen der Kappe 11 des Abzweiges 4 erfolgt somit allein durch einen der Aufweitrichtung des Hohlprofils 3 entgegengerichteten Hub des Gegenhalterstempels 5. Nach Entspannen des Druckes wird das Innenhochdruckumformwerkzeug 2 geöffnet und das fertig geformte und bearbeitete Hohlprofil 3 entnommen.After reaching the desired branch length, as shown in FIG. 2, the drive of the counter-holding plunger 5 is reversed, so that it dips into the secondary form element or the branch 4 and thereby its cap 11 by means of a separating contour formed by the end edge 12 of the plunger 5 is separated out, forming a slug. This is done in the direction of the arrow with the force F. In the meantime, there is a pressure in the hollow profile 3 which corresponds to or is less than the forming pressure. The end face 8 bordered by the end edge 12 of the stamp 5 runs continuously just gig. In order to enable problem-free immersion in the branch 4, the width of the annular gap 22 between the circumference 13 of the plunger 5 and the lead-through wall 14 is dimensioned such that it approximately corresponds to the wall thickness of the secondary molding element or the branch 4. The cap 11 of the branch 4 is thus separated solely by a stroke of the counter-holding plunger 5 which is opposite to the widening direction of the hollow profile 3. After the pressure has been released, the internal high-pressure forming tool 2 is opened and the completely shaped and machined hollow profile 3 is removed.

Der Gegenhalterstempel 5 kann, wie aus Figur 1 und 2 ersichtlich ist, durchgängig .zylindrisch ausgebildet sein. Abweichend hiervon kann nach Fig. 3 das Stempelende 15, das dem Abzweig 4 zugewandt ist und die Trennkontur beinhaltet, kegelstumpfförmig ausgebildet sein, wobei es zum Nebenformelement bzw. zum Abzweig 4 zugewandte Anschrägungsflachen 16 aufweist. Über diese Anschrägungsflachen 16 wird der geöffnete Abzweig 4 völlig druckdicht abgedichtet. Dadurch wird ein Druckabfall innerhalb des Hohlprofiles 3 vermieden, so dass an anderen Stellen des Hohlprofils 3 dort ausgebildete Abzweige 4 durch Kappentrennung mittels eines jeweils dort angeordneten Gegenhalterstempels 5 prozesssicher sequentiell erfolgen kann.The counter-holder stamp 5 can, as can be seen from FIGS. 1 and 2, be of continuous cylindrical design. 3, the stamp end 15, which faces the branch 4 and contains the separating contour, can be frustoconical, with bevel surfaces 16 facing the secondary form element or the branch 4. The open branch 4 is sealed completely pressure-tight via these bevel surfaces 16. This avoids a drop in pressure within the hollow profile 3, so that branches 4 formed there at other points in the hollow profile 3 can be carried out sequentially and reliably by cap separation by means of a counter-holding plunger 5 arranged there.

In Abweichung zum vorangegangenen Ausführungsbeispiel der Gestaltung des Gegenhalterstempels 5, wie er aus Figur 3 zu ersehen ist, besitzt gemäß Figur 4 in einem anderen Ausführungsbeispiel ein Gegenhalterstempel 17 zusätzlich eine Kalibrierkontur 18, die sich auf hohlprofilabgewandter Seite des Stempels 17 an das Stempelende 19 anschließt und entsprechend der Kontur des Nebenformelementes bzw. des Abzweiges ausgebildet ist. Hierdurch wird bei tieferem Eintauchen des Gegenhalterstempels 17 in den Abzweig 4 der Bereich der durch den Kappenbeschnitt ausgebildeten Öffnung am Abzweig entspre¬ chend der gewünschten Form ausreichend gut geglättet . Hierbei wird eine optimale Anbindung an weitere Bauteile geschaffen, die in oder auf den Abzweig des Hohlprofils 3 gesteckt werden müssen. An die Kalibrierkontur 18 schließt sich des Weiteren auf hohlprofilabgewandter Seite unmittelbar ein umlaufender Bund 20 des Gegenhalterstempels 17 an. Dieser Bund 20 beaufschlagt die Stirnfläche des Öffnungsrandes des Abzweiges, wodurch eine gleichmäßige Ebenheit dieser Stirnfläche gewährleistet ist. Gegebenenfalls kann die Abschlusskante 21 des Gegenhalterstempels 17 auch noch verrundet sein, um gänzlich zu vermeiden, dass während der Abstützfunktion des Gegenhalterstempels 17 eine umlaufende Sollbruchstelle erzeugt wird, die aufgrund des herrschenden Innenhochdrucks zumindest lokal aufplatzen kann, wonach die weitere Ausbildung des Abzweiges 4 nicht mehr prozesssicher erfolgen kann. Nach Aufgabe der Stützfunktion des Gegenhalterstempels 17 kann trotzdem mit der verrundeten Abschlusskante 21 des Stempelendes 19 die Kappe 11 aus dem Abzweig 4 getrennt werden. In a departure from the previous embodiment of the design of the counter-holder stamp 5, as can be seen from FIG. 3, according to FIG. 4, in another embodiment, a counter-holder stamp 17 additionally has a calibration contour 18, which adjoins the stamp end 19 on the side of the stamp 17 facing away from the hollow profile and is designed according to the contour of the secondary form element or the branch. As a result, when the counter-holding plunger 17 is immersed deeper into the branch 4, the area of the Kappenbeschnitt the opening formed at the branch entspre ¬ accordingly sufficiently well smoothed to the desired shape. Here, an optimal connection to other components is created, which must be inserted in or on the branch of the hollow profile 3. Furthermore, a circumferential collar 20 of the counter-holding punch 17 directly adjoins the calibration contour 18 on the side facing away from the hollow profile. This collar 20 acts on the end face of the opening edge of the branch, whereby a uniform flatness of this end face is ensured. If necessary, the terminating edge 21 of the counter-holder stamp 17 can also be rounded in order to completely avoid that a circumferential predetermined breaking point is generated during the support function of the counter-holder stamp 17, which can burst open at least locally due to the prevailing internal high pressure, after which the further formation of the branch 4 no longer takes place can be done reliably. After the support function of the counter-holder stamp 17 has ended, the cap 11 can still be separated from the branch 4 with the rounded end edge 21 of the stamp end 19.

Claims

Patentansprüche claims Verfahren zur Herstellung eines umfänglich geschlossenen Hohlprofils mit einem Nebenformelement und/oder einem Abzweig, das bzw. der mittels Innenhochdruck aus einem Hohlprofilrohling. ausgeformt wird, wonach die Kappe des Nebenformelementes und/oder des Abzweigs mittels eines das Nebenformelement bzw. den Abzweig während des Ausformungsprozesses abstützenden Gegenhalterstempels herausgetrennt wird, dadurch gekennzeichnet, dass die Kappe (11) des Nebenformelementes und/oder des Abzweigs (4) bei einem Innenhochdruck herausgetrennt wird, der höchstens dem Umformdruck zur Ausbildung des Hohlprofils (3) aus dem Rohling entspricht, wobei das Trennen allein durch einen der Aufweitrichtung des Hohl- profils (3) entgegengerichteten Hub des Gegenhalterstempels (5,17) erfolgt.Method for producing a circumferentially closed hollow profile with a secondary shaped element and / or a branch which is produced from a hollow profile blank by means of internal high pressure. is molded, after which the cap of the secondary molding element and / or the branch is separated out by means of a counter-holder stamp supporting the secondary molding element or the branch during the molding process, characterized in that the cap (11) of the secondary molding element and / or the branch (4) is in one Internal high pressure is separated out, which corresponds at most to the forming pressure for forming the hollow profile (3) from the blank, the separation taking place solely by means of a stroke of the counter-holding die (5, 17) countering the expansion direction of the hollow profile (3). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Nebenformelement und/oder der Abzweig (4) nach dem Trennvorgang durch eine Eintauchbewegung des Gegen- halterstempels (5,17) in das geöffnete Nebenformelement und/oder den Abzweig (4) hinein mittels einer zum Nebenformelement bzw. zum Abzweig (4) formentsprechenden Kalibrierkontur (18) kalibriert wird. A method according to claim 1, characterized in that the secondary form element and / or the branch (4) after the separation process by immersing the counter-plunger (5,17) into the opened secondary form element and / or the branch (4) by means of a Secondary shaped element or calibration contour (18) corresponding to the branch (4) is calibrated. Vorrichtung zur Herstellung eines umfänglich geschlosse¬ nen Hohlprofils mit einem Nebenformelement und/oder einem Abzweig, mit einem Innenhochdruckumformwerkzeug zur Aus- formung des Hohlprofils und mit einem Gegenhalterstempel, der in das Umformwerkzeug verschiebbar integriert ist und das Nebenformelement bzw. den Abzweig während des Ausformungsprozesses abstützt, wobei der Gegenhalterstempel so angetrieben ist, dass er nach der Äusformung des Neben¬ formelementes und/oder des Abzweigs in dieses bzw. in diesen eintaucht und dabei die Kappe des Nebenformelemen¬ tes und/oder des Abzweigs mittels einer Trennkontur heraustrennt, dadurch gekennzeichnet, dass die Stirnseite (8) des Gegenhalterstempels (5,17) durchgängig eben verläuft, dass die Abschlusskante (12,21) des Stempels (5,17) die Trennkontur bildet und dass die Breite des Ringspaltes (22) zwischen der Wandung (14) der im Umformwerkzeug (2) ausgebildeten Durchführung (7), in der der Stempel (5,17) verschiebbar geführt ist, und dem Stempelumfang (13) in etwa der Wandstärke des Nebenformelementes bzw. des Abzweiges (4) entspricht. Apparatus for producing a peripherally geschlosse ¬ NEN hollow profile with a secondary shaped element and / or a branch, with an internal high for education shaping of the hollow profile and with a countermatrix, which is integrated displaceably in the forming tool and the side mold member or the feeder in the molding supported wherein the countermatrix is driven so that he or in these dips after Äusformung the sub ¬ mold element and / or of the feeder in this and thereby separates out the cap of the Nebenformelemen ¬ tes and / or of the feeder means of a separating contour, characterized in that that the end face (8) of the counter-holding punch (5, 17) runs continuously flat, that the end edge (12, 21) of the punch (5, 17) forms the separating contour and that the width of the annular gap (22) between the wall (14) the bushing (7) formed in the forming tool (2), in which the punch (5, 17) is guided t, and the punch circumference (13) corresponds approximately to the wall thickness of the secondary form element or the branch (4). Vorrichtung nach Anspruch 3, dadurch gekennzeichnet, dass das Stempelende (15,19), das die Trennkontur beinhaltet, kegelstumpfförmig ausgebildet ist und zum Nebenformelement bzw. zum Abzweig (4) zugewandte Anschrägungs- flachen (16) aufweist. Apparatus according to claim 3, characterized in that the punch end (15, 19), which contains the separating contour, is frustoconical and has bevel faces (16) facing the secondary form element or the branch (4). 5. Vorrichtung nach einem der Ansprüche 3 oder 4, dadurch gekennzeichnet, dass der Gegenhalterstempel (5,17) eine Kalibrierkontur (18) aufweist, die sich auf hohlprofilabgewandter Seite an das Stempelende (15,19) anschließt und entsprechend der Kontur des Nebenformelementes bzw. Abzweiges (4) aus¬ gebildet ist.5. Device according to one of claims 3 or 4, characterized in that the counter-holder stamp (5, 17) has a calibration contour (18) which adjoins the end of the stamp (15, 19) on the side facing away from the hollow profile and corresponds to the contour of the secondary molding element or Branch (4) is formed from ¬ . 6. Vorrichtung nach Anspruch 5, dadurch gekennzeichnet, dass am Gegenhalterstempel (17) ein umlaufender Bund (20) ausgebildet ist, der sich an die Kalibrierkontur (18) auf hohlprofilabgewandter Seite unmittelbar anschließt.6. The device according to claim 5, characterized in that a circumferential collar (20) is formed on the counter-holder stamp (17), which directly adjoins the calibration contour (18) on the side facing away from the hollow profile. 7. Vorrichtung nach einem der Ansprüche 3 bis 6, dadurch gekennzeichnet, dass die Abschlusskante (12,21) des Gegenhalterstempeis (5,17) verrundet ist. 7. Device according to one of claims 3 to 6, characterized in that the end edge (12,21) of the counter-holder stem (5,17) is rounded.
PCT/EP2005/001283 2004-02-13 2005-02-09 Method and device for producing a peripherally closed hollow profile Ceased WO2005077561A1 (en)

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