WO2008028982A1 - Electromagnetic device and method for the geometric rectification of stamped metal parts - Google Patents
Electromagnetic device and method for the geometric rectification of stamped metal parts Download PDFInfo
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- WO2008028982A1 WO2008028982A1 PCT/ES2006/000511 ES2006000511W WO2008028982A1 WO 2008028982 A1 WO2008028982 A1 WO 2008028982A1 ES 2006000511 W ES2006000511 W ES 2006000511W WO 2008028982 A1 WO2008028982 A1 WO 2008028982A1
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- block
- electromagnetic coil
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- rectified
- electromagnetic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/14—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces applying magnetic forces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
Definitions
- the present invention relates to an electromagnetic device and a method for the geometric rectification of stamped metal parts that has application in the steel industry, allowing the rectification of the deformation produced by the elastic recovery as a consequence of the residual stresses that occur. generated in this type of sheet-shaped parts after the completion of a mechanical forming process, for example after a drawing process.
- the conventional stamping process of sheet metal requires the use of a press and at least two dies, one embutidor and another calibrator, each of which is in turn made up of a trampler, a matrix and a complete male that have all the geometry, shape and dimensions, which is required to obtain in the sheet to be shaped.
- Foucault in the piece or sheet to conform having said Foucault currents in the opposite direction to those that circulate through each electromagnetic coil, so that the coil and the metal part are repelled so that the piece is actuated against the wall of the dies, adopting the form that is required, that is to say They have the dies, which matches the final geometry of the complete piece that is intended to be obtained.
- the aforementioned electromagnetic forming devices comprise a conductor, also called an actuator, which is usually a copper solenium coil that is connected in series with a capacitor, or usually with a capacitor bank, and with a high circuit. Fast ignition voltage and media.
- a representation of the commonly used discharge current has a damped sinusoidal shape, with frequencies that are usually in a range between 10 kHz and 100 kHz.
- the current generated in the electromagnetic coil and the currents generated in the piece have the opposite direction, whereby coil and piece repel each other, so that the piece acquires a high repulsion speed, being actuated against a male or female element and taking its shape
- the electromagnetic pressure is it transforms into kinetic energy, being able to acquire the piece speeds of an order of magnitude that is between 200 m / s and 300 m / s.
- Japanese patents No. JP 2004-122177 and JP 2001-252788 describe processes with printing presses that incorporate a magnetic forming device that avoids the "springback" effect.
- Japanese Patent No. JP 2004-122177 describes a line of presses or equipment comprising a plurality of presses, commonly referred to as ⁇ transfer ', which contains at least one electromagnetic forming station in the press itself in order to obtain a piece of Aluminum without elastic recovery, with a certain final geometry.
- the electromagnetic forming operation is carried out simultaneously with the stamping operation, which requires the use of expensive equipment or the adaptation of existing equipment of stamping, combining electromagnetic means with the stamping process itself, which significantly increases the production costs of the pieces.
- the electromagnetic device and the method for the geometric rectification of stamped metal parts that the invention proposes allow to correct the deformation produced by the effect of the elastic recovery after a conventional forming process, in an independent equipment to the one of mechanical stamping by means of the application of Electromagnetic loads only in those areas or parts of the part that need to be rectified to obtain a piece with a required final geometry and in accordance with established dimensional tolerances.
- a first aspect of the present invention relates to an electromagnetic device for the geometric rectification of stamped metal parts that allows a rectification of the deformation produced by the elastic recovery as a result of the residual stresses that are generated in the pieces after the completion of a mechanical stamping process.
- the electromagnetic device proposed by the invention comprises at least one block configured to receive the impact and contact a face of a certain area to be rectified of a piece, that is, a sheet that has been previously mechanically stamped on a press.
- the geometry of a surface of said, at least one, block configured to contact the piece to be rectified corresponds exactly to a final geometry, that is, shape and dimensions, which is required to obtain on said face of the area to be rectified from the piece.
- an element that penetrates a plane defined by the sheet is usually called male, and a complementary element configured to accommodate the sheet deformed by the action of said male, in the description of the present
- the invention means a block as any element such as a male, a matrix or an insert that has the appropriate geometry and is configured to receive the impact and contact the part to be rectified.
- the device comprises an electromagnetic coil that is configured to be positioned on a face opposite to that of said at least one block of a certain area to be rectified from the part.
- the coil Complementary electromagnetic is located on a second face, opposite the first face, and vice versa, that is, in the case that a block is located on the second face of the piece, then the electromagnetic coil is located on the first face.
- Each, at least one, electromagnetic coil comprises at least one winding of a copper wire, which is embedded in a piece, preferably a synthetic body for example of fiberglass.
- Said electromagnetic coil has an outer surface facing a face of the piece to be rectified, which has a geometry approximate to the final geometry that is to be obtained in the piece, that is to say it has a geometry complementary to that of the at least one corresponding block.
- there is a gap or clearance between each, at least one, electromagnetic coil and each, at least one, block that is less than ten times the thickness of the piece, so that the action of the magnetic field drives the piece for its impact against the cue.
- At least one, electromagnetic coil comprises at least one winding that is connected to a power source, configured to generate a magnetic field.
- Each, at least one, electromagnetic coil is operatively located so that the magnetic field that it generates acts in a certain area to be rectified of the piece, acting on it and producing an impact of the piece against the corresponding block.
- Each, at least one, electromagnetic coil is configured to act in both the flat areas of the piece as in curved areas or folding lines, that is to say in areas where the sheet has a change of direction between planes.
- each, at least one, winding and electromagnetic coil have an approximate geometry to the final geometry to be obtained, including a curved geometry.
- At least one, winding is connected to a discharge circuit comprising a capacitor, preferably a capacitor bank, and a high voltage circuit comprising a power supply source and means of fast ignition, that is to say electrical switches, so that when the capacitors are charged and activated by means of rapid ignition, a transient current is created in each, at least one, winding generated by the transient magnetic field.
- Said magnetic field induces eddy currents in the piece to be rectified, because it is a sheet of an electrically conductive material, the current generated in each at least one winding and the eddy currents generated in the felt part. on the contrary, so that the piece is driven in a direction opposite to that of each, at least one, electromagnetic coil, being pushed against said, at least a, block, so that the face of the areas to be rectified of the piece in contact with said, at least one, block is formed by acquiring the geometry of said, at least one block.
- said at least one block and electromagnetic coil are linked to both a first base and a second base, in order to serve as a support. It also contemplates the possibility that said first base and said second base comprise means of mobile closure, being able to be arranged both horizontally and vertically.
- the device comprises at least one accelerator, commonly referred to in English as 'driver', located between said at least one electromagnetic coil and the part to be rectified, in order to reduce the energy requirements of the device to obtain a certain geometry in a piece to be rectified.
- 'driver' located between said at least one electromagnetic coil and the part to be rectified, in order to reduce the energy requirements of the device to obtain a certain geometry in a piece to be rectified.
- Said accelerator consists of a sheet of a material with a high copper content, which, due to its high electrical conductivity, allows the accelerator to generate induced currents of greater intensity than those generated in the part, which is a sheet of material with lower electrical conductivity. For this reason, the repulsive force between the accelerator and the electromagnetic coil is higher compared to the case of not having said accelerator, allowing the same results to be obtained with lower energy requirements.
- a second aspect of the invention relates to a method for geometric rectification of stamped metal parts, with a device Electromagnetic as described above.
- the method of the invention is carried out from a metal part to be rectified, that is, a sheet that has already been mechanically stamped, in a traditional press, in order to rectify the geometry of the piece in those areas where the It is outside established tolerances. Unlike the prior art methods, it is not a question of avoiding the negative effect of the elastic recovery of the piece when stamping the piece, but of correcting it afterwards.
- the method for the geometric rectification of stamped metal parts, object of the invention comprises the steps described below.
- a first stage comprising positioning a stamped part with each zone to be rectified operatively located between a block and an electromagnetic coil, said part being conveniently separated from the block, which is separated from the complementary electromagnetic coil a distance not exceeding ten times the thickness of the piece, in order that said piece may impact said block by the action of a magnetic field generated by said electromagnetic coil.
- the method comprises a second stage which comprises generating a magnetic field configured to act in the areas to be rectified of the piece so that they adopt a final geometry required when the piece is hit against each block.
- the method comprises a third stage which comprises extracting the already rectified piece.
- the method comprises an intermediate stage, which will be carried out prior to the second stage of the magnetic field generation, and which comprises placing at least one accelerator, that is to say a sheet of a material with a high content in copper, between said at least one, electromagnetic coil and the piece to be rectified, in order to reduce the energy requirements of the method.
- at least one accelerator that is to say a sheet of a material with a high content in copper
- the deformation of the metal part to be rectified is achieved by discharging an electric current through said at least one winding that is close to the area to be rectified of the part. Due to the currents that are induced in the piece, rapid movement occurs in the area of the part near the coil. The kinetic energy associated with the movement causes the physical change in the piece.
- the electromagnetic device and method for the geometric rectification of stamped metal parts that the invention proposes constitute an advance in the forming devices and methods used up to now, and solve in a fully satisfactory and simple manner the problematic previously exposed, in the line of allowing its use in all types of sheets, whatever its forming process has been, allowing the use and habitual use of the available stamping equipment such as traditional presses in a certain factory, that is, without the need of having to make any modification on them, to later rectify the pieces in the device of the invention, external to the press line, only in cases where it is necessary.
- the user can manufacture a part by means of a conventional stamping process and, in view of the result, decide whether it is necessary to use the electromagnetic forming device of the invention for its rectification.
- the device proposed by the invention is different from the electromagnetic forming devices of the state of the art as it does not require an upper matrix and a lower matrix that accurately reproduce the final geometry, both the shape and dimensions, of the entire piece a obtained because the magnetic field acts only in those areas where the part is outside the permissible tolerances, with the consequent reduction of costs.
- the electromagnetic device proposed by the invention is extremely simple and inexpensive to manufacture, by using at least one block and at least one electromagnetic coil that allows its adaptation to each type of geometry.
- At least one, block and said, at least one, electromagnetic coil are interchangeable, adapting to each area to be rectified, so if your design is taken care of, the same pair consisting of a block and an electromagnetic coil can be used for rectification of different pieces, being located in areas that have the same final geometry to obtain.
- This device eliminates the need to make successive corrections in the geometry of conventional stamping dies to eliminate the effect called "springback" on the piece. These corrections are generally made through an iterative process of correction, trial and error, with the great increase in costs that this entails.
- the device of the invention replaces the mechanical caliper die, which can be dispensed with, with the consequent saving of space in a factory, reduction of initial costs by eliminating a die and possibility of using press lines with a less station.
- the device of the invention in comparison with the devices and procedures described in Japanese patents No. JP 2004-122177 and JP 2001-252788, allows, in addition to the above-mentioned advantages, the rectification of all types of parts, preferably sheets, of conductive metal materials, such as steels.
- Figure 1. Shows an electrical scheme of the discharge circuit comprising the device of the invention and which allows the generation of a magnetic field for the rectification of metal parts.
- Figure 2. It shows a section of a final geometry to be obtained for a piece and a geometry obtained after a conventional stamping process, the latter being appreciated the "springback" effect, in comparison with the final geometry to be obtained.
- Figure 3. Shows a section of an elevation view of a schematic representation of the electromagnetic device proposed by the invention, in which the situation of a piece to be rectified can be seen.
- Figure 4.- Shows a section according to a plan view of an embodiment of the device of the invention, in which three plugs and three electromagnetic coils can be seen in three areas to be rectified of the sheet, on a base design of a die of conventional printing, in which the simplicity of the device object of the invention can be checked against the complexity of a conventional printing die.
- Figure 5.- Shows an elevation view of the electromagnetic device of the invention according to the A-A direction of the previous figure.
- Figure 6.- Shows a section of an elevation view, according to the B-B cut line shown in the figure
- Figure 7- Shows another section of an elevation view like the one in the previous figure, according to the cut-off line CC shown in figure 4.
- Figure 8 shows a flow chart in which the main steps comprising the method for geometric rectification of stamped metal parts proposed by the invention can be seen.
- the electromagnetic device for the geometric rectification of stamped metal parts comprises at least one block (2) configured to receive the impact and contact a face of a certain area to rectify a piece (1).
- the geometry of a surface of said, at least one, block (2) configured to contact the part (1) to be rectified corresponds exactly to a final geometry (10) that is required to obtain on said face of the area to be rectified from the piece (1).
- the device comprises an electromagnetic coil
- the complementary electromagnetic coil (5) is located on a second face (11), opposite the first face ( 12 and vice versa, that is, in the case that a block (2) is located on the second face (11) of the part (1), then the electromagnetic coil (5) is located on the first face (12).
- Each, at least one, electromagnetic coil (5) comprises at least one winding (6) embedded in a piece, preferably a synthetic body for example of fiberglass. Said electromagnetic coil (5) has an outer surface facing a face of the piece
- each, at least one, electromagnetic coil (5) and each, at least one , block (2) which is less than ten times the thickness of the piece (1), so that the action of the magnetic field drives the piece (1) for its impact against the block (2).
- each, at least one, electromagnetic coil (5) comprises at least one winding (6) that is connected to an electrical power source (7), configured to generate a magnetic field .
- Each, at least one, electromagnetic coil (5) is operatively located so that the magnetic field that it generates acts in a certain area to be rectified of the piece (1), acting on it and producing an impact of the piece (1) against the corresponding block (2).
- Each, at least one, winding (6) is connected to a discharge circuit comprising a capacitor (8), preferably a capacitor bank (8), and a high voltage circuit comprising a power supply (7) Y rapid ignition means (9), so that when the capacitors (8) are charged and activated by means of rapid ignition (9), a transient current is created in each at least one winding (6) that generates the transient magnetic field.
- Said magnetic field induces eddy currents in the part (1) to be rectified, whereby the part (1) is actuated in a direction opposite to that of each, at least one, electromagnetic coil (5), being pushed against said , at least one, block (2), so that the face of the areas to be rectified of the piece (1) in contact with said, at least one, block (2) is formed by acquiring the geometry of said, at least one , cue (2).
- said at least one block (2) and electromagnetic coil (5) are linked to both a first base (3) and a second base ( 4), in order to serve as support.
- said first base (3) and said second base (4) comprise means of mobile closure to facilitate the extraction of the piece (1), being able to be arranged both horizontally and vertically.
- the device comprises a first block (2) located in a complementary manner to a first electromagnetic coil (5) comprising a first winding (6).
- the device comprises a second block (2 ') located in a complementary manner to a second electromagnetic coil (5') comprising a second winding (6 ').
- the device comprises a third block ⁇ 2 '') located so complementary to a third electromagnetic coil (5 '') comprising a third winding (6 '') arranged perpendicular to the first winding (6) and the second winding (6 ').
- the first winding (6) has a geometry that adapts to the curved area of the final geometry (10) to be obtained in the piece.
- first block (2), the third block (2 '') and the second electromagnetic coil (5 ') are linked to the first base (3) while the second block (2'), the first electromagnetic coil (5) and the third electromagnetic coil (5 '') are linked to the second base (4).
- the device comprises at least one accelerator (13), which consists of a sheet of a material with a high copper content, as can be seen in Figure 3, located between said, at least one, electromagnetic coil (5) and the part (1) to be rectified, in order to reduce the energy requirements of the device to obtain a certain geometry in a part (1) to be rectified.
- accelerator (13) which consists of a sheet of a material with a high copper content, as can be seen in Figure 3, located between said, at least one, electromagnetic coil (5) and the part (1) to be rectified, in order to reduce the energy requirements of the device to obtain a certain geometry in a part (1) to be rectified.
- a second aspect of the invention relates to a method for geometric rectification of stamped metal parts, with an electromagnetic device as described above.
- the method of the invention is carried out from a metal part to be rectified, that is, a sheet that has already been mechanically stamped, in a traditional press, in order to rectify the geometry of the piece in those areas where it is outside established tolerances.
- the method for geometric rectification of stamped metal parts, object of the invention comprises the following steps:
- a first stage (A) comprising positioning a stamped part (1) with each zone to be rectified operatively located between a block (2) and an electromagnetic coil (5), said part (1) being conveniently separated from the block (2), which is separated from the electromagnetic coil (5) complementary a distance not exceeding ten times the thickness of the piece (D -
- a second stage (B) comprising generating a magnetic field configured to act in the areas to be rectified of the piece (1) so that they adopt a final geometry (10) required when the piece (1) impacts against each block (2) .
- a third stage (C) comprising extracting the already rectified piece.
- the method comprises an intermediate stage, which will be carried out prior to the second stage (B), and which comprises placing at least one accelerator (13), that is to say a sheet of a material with a high content in copper, between said at least one, electromagnetic coil (5) and the part (1) to be rectified, in order to reduce the energy requirements of the method.
- at least one accelerator (13) that is to say a sheet of a material with a high content in copper
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- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Straightening Metal Sheet-Like Bodies (AREA)
Abstract
Description
DISPOSITIVO ELECTROMAGNÉTICO Y MÉTODO PARA LA RECTIFICACIÓN GEOMÉTRICA DE PIEZAS METÁLICAS ESTAMPADAS ELECTROMAGNETIC DEVICE AND METHOD FOR THE GEOMETRIC RECTIFICATION OF STAMPED METAL PARTS
D E S C R I P C I Ó ND E S C R I P C I Ó N
OBJETO DE LA INVENCIÓNOBJECT OF THE INVENTION
La presente invención se refiere a un dispositivo electromagnético y a un método para la rectificación geométrica de piezas metálicas estampadas que tiene aplicación en la industria siderúrgica, permitiendo rectificar la deformación producida por la recuperación elástica como consecuencia de las tensiones residuales que se . generan en este tipo de piezas en forma de chapa tras la realización de un proceso de conformado mecánico, por ejemplo tras un proceso de embutición.The present invention relates to an electromagnetic device and a method for the geometric rectification of stamped metal parts that has application in the steel industry, allowing the rectification of the deformation produced by the elastic recovery as a consequence of the residual stresses that occur. generated in this type of sheet-shaped parts after the completion of a mechanical forming process, for example after a drawing process.
ANTECEDENTES DE LA INVENCIÓNBACKGROUND OF THE INVENTION
El proceso de estampación convencional de chapas metálicas requiere la utilización de una prensa y al menos dos troqueles, uno embutidor y otro calibrador, cada uno de los cuales está compuesto a su vez por un pisador, una matriz y un macho completos que tienen toda la geometría, forma y dimensiones, que se requiere obtener en la chapa a conformar.The conventional stamping process of sheet metal requires the use of a press and at least two dies, one embutidor and another calibrator, each of which is in turn made up of a trampler, a matrix and a complete male that have all the geometry, shape and dimensions, which is required to obtain in the sheet to be shaped.
El problema que tienen los procesos de estampación mecánica, se manifiesta tras la extracción de las piezas de la prensa, debido a que experimentan una recuperación elástica que produce unas deformaciones, rizos de pared y torsiones como consecuencia de las tensiones residuales que se generan en las piezas tras el proceso de embutición, con lo que la geometría de la pieza es distinta a la que se requiere obtener.The problem of the processes of mechanical stamping, manifests itself after the extraction of the pieces of the press, because they experience an elastic recovery that produces deformations, wall curls and torsions as a result of the residual tensions that are generated in the pieces after the drawing process, with which the geometry of the piece is different from what is required to obtain.
El problema mencionado en el párrafo anterior es habitualmente conocido por su término en inglés como "springback", y tiene como consecuencia que las piezas obtenidas se encuentren fuera de unas tolerancias establecidas, las cuales, sobre todo en determinadas aplicaciones como por ejemplo en el sector de la automoción o en el sector aeronáutico, son muy estrictas, por lo que se plantea la necesidad de rectificar la geometría de las piezas obtenidas tras el proceso de embutición.The problem mentioned in the previous paragraph is usually known by its term in English as "springback", and has as a consequence that the pieces obtained are outside established tolerances, which, especially in certain applications such as in the sector of the automotive industry or in the aeronautical sector, they are very strict, so the need to rectify the geometry of the pieces obtained after the drawing process is raised.
Con el objeto de solucionar este inconveniente, tras la realización del proceso de embutición mecánica es necesario efectuar un reconformado de la pieza completa en un troquel calibrador, en el cual se consigue el rectificado de aquellas zonas de la pieza que quedan fuera de las tolerancias admisibles tras el proceso de embutición mecánica, lo cual encarece notablemente los costes de producción de las piezas.In order to solve this problem, after the mechanical drawing process has been carried out, it is necessary to carry out a reconform of the complete piece in a calibrating die, in which the grinding of those areas of the piece that are outside the permissible tolerances is achieved. after the mechanical drawing process, which significantly increases the production costs of the pieces.
Por otro lado, con el objeto de solucionar este mismo inconveniente, a partir de 1960 surgieron unos procesos de conformado alternativos que comprenden circuitos y medios electromagnéticos capaces de generar unas corrientes suficientes para producir una deformación en el material, en sustitución de las prensas tradicionales habitualmente utilizadas hasta el momento, tal y como se ha expuesto anteriormente.On the other hand, in order to solve this same problem, from 1960 onwards, alternative forming processes emerged that include circuits and electromagnetic means capable of generating enough currents to produce a deformation in the material, replacing the traditional presses usually used so far, as described above.
Estos procesos de conformado electromagnético se basan en la generación de un campo magnético mediante bobinas electromagnéticas que inducen unas corrientes deThese electromagnetic forming processes are based on the generation of a magnetic field by electromagnetic coils that induce currents of
Foucault en la pieza o chapa a conformar, teniendo dichas corrientes de Foucault sentido contrario a las que circulan por cada bobina electromagnética, por lo que la bobina y la pieza metálica se repelen de forma que la pieza es accionada contra la pared de los troqueles, adoptando la forma que se requiere, es decir la que tienen los troqueles, que coincide con la geometría final de la pieza completa que se pretende obtener.Foucault in the piece or sheet to conform, having said Foucault currents in the opposite direction to those that circulate through each electromagnetic coil, so that the coil and the metal part are repelled so that the piece is actuated against the wall of the dies, adopting the form that is required, that is to say They have the dies, which matches the final geometry of the complete piece that is intended to be obtained.
En la actualidad los dispositivos de conformado electromagnético anteriormente referidos comprenden un conductor, también denominado actuador, que habitualmente es una bobina soleniode de cobre que se encuentra conectada en serie con un condensador, o habitualmente con una batería de condensadores, y con un circuito de alto voltaje y medios de encendido rápido.At present, the aforementioned electromagnetic forming devices comprise a conductor, also called an actuator, which is usually a copper solenium coil that is connected in series with a capacitor, or usually with a capacitor bank, and with a high circuit. Fast ignition voltage and media.
El funcionamiento de estos dispositivos se explica a continuación. Cuando los condensadores se encuentran cargados y se encienden, es decir se cierra el interruptor del circuito que lo conecta a la bobina electromagnética, se crea una corriente transitoria en dicha bobina electromagnética, la cual genera un campo magnético transitorio que induce las corrientes de Foucault en el material conductor, que es la pieza metálica que se pretende deformar.The operation of these devices is explained below. When the capacitors are charged and turn on, that is to say the circuit breaker that connects it to the electromagnetic coil is closed, a transient current is created in said electromagnetic coil, which generates a transient magnetic field that induces Foucault currents in the conductive material, which is the metal piece that is intended to deform.
Una representación de la corriente de descarga habitualmente utilizada tiene una forma sinusoidal amortiguada, con frecuencias que habitualmente se encuentran en un rango entre 10 kHz y 100 kHz. La corriente generada en la bobina electromagnética y las corrientes generadas en la pieza tienen sentido contrario, por lo cual bobina y pieza se repelen entre si, de forma que la pieza adquiere una gran velocidad de repulsión, siendo accionada contra un elemento macho o hembra y tomando su forma. La presión electromagnética se transforma en energía cinética, pudiendo adquirir la pieza velocidades de un orden de magnitud que se encuentra entre 200 m/s y 300 m/s.A representation of the commonly used discharge current has a damped sinusoidal shape, with frequencies that are usually in a range between 10 kHz and 100 kHz. The current generated in the electromagnetic coil and the currents generated in the piece have the opposite direction, whereby coil and piece repel each other, so that the piece acquires a high repulsion speed, being actuated against a male or female element and taking its shape The electromagnetic pressure is it transforms into kinetic energy, being able to acquire the piece speeds of an order of magnitude that is between 200 m / s and 300 m / s.
Estos procesos de conformado electromagnético han sido objeto de numerosos estudios por parte de diversos autores, los cuales se recogen en diferentes documentos, como por ejemplo en los siguientes artículos:These electromagnetic forming processes have been the subject of numerous studies by various authors, which are collected in different documents, such as in the following articles:
- Golovashchenko, Sergey F. ^Springback calibration using pulsed electromagnetic field'; © 2005 American Institute of Physics.- Golovashchenko, Sergey F. ^ Springback calibration using pulsed electromagnetic field '; © 2005 American Institute of Physics.
Moon, F. C. ^Magneto solid mechanics' ; ASTME;Moon, F. C. ^ Magneto solid mechanics'; ASTME;
High Velocity Forming of Metals; 1968. - Plum, M. M. yElectromagnetic forming. Metals handbook' ; Maxwell Laboratorios Inc. PáginasHigh Velocity Forming of Metals; 1968. - Plum, MM and Electromagnetic forming. Metals handbook '; Maxwell Laboratories Inc. Pages
644-653.644-653.
Belyy, I. V., Fertik, S. M. y Khimenko, L. T.Belyy, I. V., Fertik, S. M. and Khimenko, L. T.
^Electromagnetic metal forming handbook Kharkov' ; URSS; 1977.^ Electromagnetic metal forming handbook Kharkov '; USSR; 1977.
También existen documentos de patente que describen estos procedimientos de conformado electromagnético desde el inicio de su desarrollo, como por ejemplo la patente estadounidense No US 2,976,907 por "Dispositivo y método de conformado metálico" correspondiente al año 1961, hasta documentos más recientes en los que se recogen los últimos medios y aplicaciones, como por ejemplo en la patente estadounidense No US 6,050,121 por "Métodos híbridos de conformado metálico mediante conformado electromagnético" a favor de la Universidad de Ohio, en la patente estadounidense No US 5,730,016 por "Método y aparato para el conformado electromagnético de láminas metálicas" a favor de la firma Elmag, Inc., en la solicitud de patente estadounidense No US 2005/0097934 por "Aparato para el conformado electromagnético", en la solicitud de patente estadounidense No US 2005/0229376 por "Aparato y método electromagnético para el recorte, embutición y plegado" a favor de la firma General Motors, en la solicitud de patente estadounidense No US 2003/0182005 por "Método para la obtención de un troquel para el conformado de piezas metálicas con un forma requerida y métodos relacionados" a favor de Chu, E., Makosey, S. J. y Shoup, J. M. o en la patente estadounidense No US 5,860,306 por "Método de utilización de un actuador electromagnético y artículo fabricado con el mismo" a favor de Daehn, por citar algunos ejemplos.There are also patent documents that describe these electromagnetic forming procedures from the beginning of their development, such as US Patent No. 2,976,907 for "Device and method of metal forming" corresponding to the year 1961, to more recent documents in which they include the latest media and applications, such as in US Patent No. US 6,050,121 for "Hybrid methods of metal forming by electromagnetic forming" in favor of the University of Ohio, in US Patent No. US 5,730,016 for "Method and apparatus for formed by electromagnetic sheet metal "in favor of the firm Elmag, Inc., in US patent application No. US 2005/0097934 for" Apparatus for Electromagnetic forming ", in US patent application No. US 2005/0229376 for" Electromagnetic apparatus and method for cutting, drawing and folding "in favor of General Motors, in US patent application No. US 2003/0182005 by" Method for obtaining a die for forming metal parts with a required shape and related methods "in favor of Chu, E., Makosey, SJ and Shoup, JM or in US Patent No. US 5,860,306 for" Method of use of an electromagnetic actuator and article manufactured with it "in favor of Daehn, to name a few examples.
Adicionalmente en las patentes japonesas No JP 2004-122177 y JP 2001-252788 se describen unos procedimientos con prensas de conformado por estampación, que incorporan un dispositivo de conformado magnético que permite evitar el efecto "springback". La patente japonesa No JP 2004-122177 describe una linea de prensas o un equipo que comprende una pluralidad de prensas, comúnmente denominado λtransfer' , que contiene al menos una estación de conformado electromagnético en la propia prensa con el objeto de obtener una pieza de aluminio sin recuperación elástica, con una determinada geometría final.Additionally, Japanese patents No. JP 2004-122177 and JP 2001-252788 describe processes with printing presses that incorporate a magnetic forming device that avoids the "springback" effect. Japanese Patent No. JP 2004-122177 describes a line of presses or equipment comprising a plurality of presses, commonly referred to as λ transfer ', which contains at least one electromagnetic forming station in the press itself in order to obtain a piece of Aluminum without elastic recovery, with a certain final geometry.
El principal inconveniente que este tipo de equipos presenta es que resultan sumamente complejos y costosos debido a la necesidad de incorporar los medios de conformado electromagnético en los propios equipos para estampación, es decir en las propias prensas.The main drawback that this type of equipment presents is that they are extremely complex and expensive due to the need to incorporate the means of electromagnetic forming in the equipment for stamping itself, that is to say in the presses themselves.
La operación de conformado electromagnético se realiza de manera simultánea a la operación de estampación, lo que requiere la utilización de equipos costosos o bien la adaptación de los equipos existentes de estampación, combinando los medios electromagnéticos con el propio proceso de estampación, lo cual incrementa notablemente los costes de producción de las piezas .The electromagnetic forming operation is carried out simultaneously with the stamping operation, which requires the use of expensive equipment or the adaptation of existing equipment of stamping, combining electromagnetic means with the stamping process itself, which significantly increases the production costs of the pieces.
Además, si bien las chapas conformadas mediante los procesos electromagnéticos anteriormente referidos no presentan el indeseado efecto de la recuperación elástica, o efecto "springback", estos procesos presentan otra serie de inconvenientes, entre otras causas como consecuencia de la elevada temperatura que el campo magnético generado produce en la bobina electromagnética, necesitando incorporar medios de refrigeración con el objeto de que la temperatura de la bobina electromagnética durante el proceso no sea excesiva y asi alargar su vida útil, lo cual no es necesario en las prensas de estampación mecánica.In addition, although the sheets formed by the aforementioned electromagnetic processes do not have the unwanted effect of elastic recovery, or "springback" effect, these processes have other problems, among other causes as a result of the high temperature of the magnetic field. generated produces in the electromagnetic coil, needing to incorporate cooling means in order that the temperature of the electromagnetic coil during the process is not excessive and thus extend its useful life, which is not necessary in the presses of mechanical stamping.
DESCRIPCIÓN DE LA INVENCIÓNDESCRIPTION OF THE INVENTION
El dispositivo electromagnético y el método para la rectificación geométrica de piezas metálicas estampadas que la invención propone permiten corregir la deformación producida por el efecto de la recuperación elástica después de un proceso convencional de conformado, en un equipo independiente al de estampación mecánica mediante la aplicación de cargas electromagnéticas únicamente en aquellas zonas o partes de la pieza que se requiera rectificar para la obtención de una pieza con una geometría final requerida y de acuerdo con unas tolerancias dimensionales establecidas.The electromagnetic device and the method for the geometric rectification of stamped metal parts that the invention proposes allow to correct the deformation produced by the effect of the elastic recovery after a conventional forming process, in an independent equipment to the one of mechanical stamping by means of the application of Electromagnetic loads only in those areas or parts of the part that need to be rectified to obtain a piece with a required final geometry and in accordance with established dimensional tolerances.
Un primer aspecto de la presente invención se refiere a un dispositivo electromagnético para la rectificación geométrica de piezas metálicas estampadas que permite una rectificación de la deformación producida por la recuperación elástica como consecuencia de las tensiones residuales que se generan en las piezas tras la realización de un proceso de estampación mecánica.A first aspect of the present invention relates to an electromagnetic device for the geometric rectification of stamped metal parts that allows a rectification of the deformation produced by the elastic recovery as a result of the residual stresses that are generated in the pieces after the completion of a mechanical stamping process.
El dispositivo electromagnético que la invención propone comprende al menos un taco configurado para recibir el impacto y contactar con una cara de una determinada zona a rectificar de una pieza, es decir, una chapa que ha sido previamente estampada mecánicamente en una prensa.The electromagnetic device proposed by the invention comprises at least one block configured to receive the impact and contact a face of a certain area to be rectified of a piece, that is, a sheet that has been previously mechanically stamped on a press.
La geometria de una superficie de dicho, al menos un, taco configurada para contactar con la pieza a rectificar se corresponde exactamente con una geometria final, es decir, forma y dimensiones, que se requiere obtener en dicha cara de la zona a rectificar de la pieza .The geometry of a surface of said, at least one, block configured to contact the piece to be rectified corresponds exactly to a final geometry, that is, shape and dimensions, which is required to obtain on said face of the area to be rectified from the piece.
Si bien en el ámbito de la estampación se suele denominar macho a un elemento que penetra en un plano definido por la chapa, y matriz a un elemento complementario configurado para alojar la chapa deformada por la acción de dicho macho, en la descripción de la presente invención se entiende por taco cualquier elemento como un macho, una matriz o un inserto que tiene la geometria adecuada y que está configurado para recibir el impacto y contactar con la pieza a rectificar.Although in the field of stamping, an element that penetrates a plane defined by the sheet is usually called male, and a complementary element configured to accommodate the sheet deformed by the action of said male, in the description of the present The invention means a block as any element such as a male, a matrix or an insert that has the appropriate geometry and is configured to receive the impact and contact the part to be rectified.
Complementariamente a cada, al menos un, taco, el dispositivo comprende una bobina electromagnética que está configurada para situarse por una cara opuesta a la de dicho, al menos un, taco de una determinada zona a rectificar de la pieza.In addition to each, at least one, block, the device comprises an electromagnetic coil that is configured to be positioned on a face opposite to that of said at least one block of a certain area to be rectified from the part.
En el caso de que un taco esté situado por una primera cara de la pieza, entonces la bobina electromagnética complementaria está situada por una segunda cara, opuesta a la primera cara, y viceversa, es decir, en el caso de que un taco esté situado por la segunda cara de la pieza, entonces la bobina electromagnética está situada por la primera cara.In the event that a block is located on the first side of the piece, then the coil Complementary electromagnetic is located on a second face, opposite the first face, and vice versa, that is, in the case that a block is located on the second face of the piece, then the electromagnetic coil is located on the first face.
Cada, al menos una, bobina electromagnética comprende al menos un arrollamiento de un cable de cobre, que está embebido en una pieza, preferentemente un cuerpo sintético por ejemplo de fibra de vidrio. Dicha bobina electromagnética tiene una superficie exterior enfrentada a una cara de la pieza a rectificar, que tiene una geometría aproximada a la geometría final que se quiere obtener en la pieza, es decir tiene una geometría complementaria a la del, al menos un, taco correspondiente, existiendo un espacio u holgura entre cada, al menos una, bobina electromagnética y cada, al menos un, taco que es menor que diez veces el espesor de la pieza, con el objeto de que la acción del campo magnético impulse la pieza para su impacto contra el taco.Each, at least one, electromagnetic coil comprises at least one winding of a copper wire, which is embedded in a piece, preferably a synthetic body for example of fiberglass. Said electromagnetic coil has an outer surface facing a face of the piece to be rectified, which has a geometry approximate to the final geometry that is to be obtained in the piece, that is to say it has a geometry complementary to that of the at least one corresponding block. , there is a gap or clearance between each, at least one, electromagnetic coil and each, at least one, block that is less than ten times the thickness of the piece, so that the action of the magnetic field drives the piece for its impact against the cue.
Tal y como se ha mencionado anteriormente cada, al menos una, bobina electromagnética comprende al menos un arrollamiento que está conectado a una fuente de alimentación eléctrica, configurada para generar un campo magnético .As mentioned above each, at least one, electromagnetic coil comprises at least one winding that is connected to a power source, configured to generate a magnetic field.
Cada, al menos una, bobina electromagnética está operativamente situada de forma que el campo magnético que genera actúa en una determinada zona a rectificar de la pieza, actuando sobre la misma y produciendo un impacto de la pieza contra el taco correspondiente.Each, at least one, electromagnetic coil is operatively located so that the magnetic field that it generates acts in a certain area to be rectified of the piece, acting on it and producing an impact of the piece against the corresponding block.
Cada, al menos una, bobina electromagnética está configurada para actuar tanto en las zonas planas de la pieza como en las zonas curvas o lineas de plegado, es decir en las zonas en las que la chapa tiene un cambio de dirección entre planos.Each, at least one, electromagnetic coil is configured to act in both the flat areas of the piece as in curved areas or folding lines, that is to say in areas where the sheet has a change of direction between planes.
En una pieza estampada las uniones entre dos lados de la misma que están contenidos en diferentes planos tienen un determinado radio, siendo preferentemente en estas zonas, por las que la pieza está plegada, en las que se tiene el indeseado efecto de recuperación elástica, apreciándose una deformación no deseada. Con el objeto de eliminar esta deformación cada, al menos un, arrollamiento y bobina electromagnética tienen una geometría aproximada a la geometría final a obtener, incluyendo una geometría curva.In a stamped piece the joints between two sides of the same that are contained in different planes have a certain radius, preferably in these areas, where the piece is folded, in which there is the unwanted effect of elastic recovery, appreciating an unwanted deformation. In order to eliminate this deformation each, at least one, winding and electromagnetic coil have an approximate geometry to the final geometry to be obtained, including a curved geometry.
Con el objeto de poder generar el campo electromagnético cada, al menos un, arrollamiento está conectado a un circuito de descarga que comprende un condensador, preferentemente una batería de condensadores, y a un circuito de alto voltaje que comprende una fuente de alimentación eléctrica y medios de encendido rápido, es decir unos interruptores eléctricos, de forma que cuando los condensadores se encuentran cargados y son activados mediante los medios de encendido rápido, se crea una corriente transitoria en cada, al menos un, arrollamiento que genera el campo magnético transitorio.In order to be able to generate the electromagnetic field every, at least one, winding is connected to a discharge circuit comprising a capacitor, preferably a capacitor bank, and a high voltage circuit comprising a power supply source and means of fast ignition, that is to say electrical switches, so that when the capacitors are charged and activated by means of rapid ignition, a transient current is created in each, at least one, winding generated by the transient magnetic field.
Dicho campo magnético induce unas corrientes de Foucault en la pieza a rectificar, debido a que la misma es una chapa de un material conductor eléctrico, teniendo la corriente generada en cada, al menos un, arrollamiento y las corrientes de Foucault generadas en la pieza sentido contrario, por lo que la pieza es accionada en una dirección opuesta a la de cada, al menos una, bobina electromagnética, siendo empujada contra dicho, al menos un, taco, de manera que la cara de las zonas a rectificar de la pieza en contacto con dicho, al menos un, taco es conformada adquiriendo la geometría de dicho, al menos un, taco.Said magnetic field induces eddy currents in the piece to be rectified, because it is a sheet of an electrically conductive material, the current generated in each at least one winding and the eddy currents generated in the felt part. on the contrary, so that the piece is driven in a direction opposite to that of each, at least one, electromagnetic coil, being pushed against said, at least a, block, so that the face of the areas to be rectified of the piece in contact with said, at least one, block is formed by acquiring the geometry of said, at least one block.
Se contempla la posibilidad de que dichos, al menos un, taco y bobina electromagnética estén vinculados tanto a una primera base como a una segunda base, con el objeto de que sirvan como soporte. Asimismo se contempla la posibilidad de que dicha primera base y dicha segunda base comprendan medios de cierre móvil, pudiendo estar dispuestas en posición tanto horizontal como vertical.The possibility is contemplated that said at least one block and electromagnetic coil are linked to both a first base and a second base, in order to serve as a support. It also contemplates the possibility that said first base and said second base comprise means of mobile closure, being able to be arranged both horizontally and vertically.
Por último, se contempla la posibilidad de que el dispositivo comprenda al menos un acelerador, comúnmente denominado en inglés como 'driver', situado entre dicha, al menos una, bobina electromagnética y la pieza a rectificar, con el objeto de reducir las exigencias energéticas del dispositivo para la obtención de una determinada geometría en una pieza a rectificar.Finally, the possibility is contemplated that the device comprises at least one accelerator, commonly referred to in English as 'driver', located between said at least one electromagnetic coil and the part to be rectified, in order to reduce the energy requirements of the device to obtain a certain geometry in a piece to be rectified.
Dicho acelerador consiste en una chapa de un material con un contenido elevado en cobre, con lo que debido a su elevada conductividad eléctrica posibilita que en el acelerador se generen unas corrientes inducidas de mayor intensidad que las que se generan en la pieza, que es una chapa de material con menor conductividad eléctrica. Por este motivo la fuerza de repulsión entre el acelerador y la bobina electromagnética es superior respecto al caso de no disponer dicho acelerador, permitiendo la obtención de los mismos resultados con menor exigencia energética.Said accelerator consists of a sheet of a material with a high copper content, which, due to its high electrical conductivity, allows the accelerator to generate induced currents of greater intensity than those generated in the part, which is a sheet of material with lower electrical conductivity. For this reason, the repulsive force between the accelerator and the electromagnetic coil is higher compared to the case of not having said accelerator, allowing the same results to be obtained with lower energy requirements.
Por otro lado un segundo aspecto de la invención se refiere a un método para la rectificación geométrica de piezas metálicas estampadas, con un dispositivo electromagnético como el anteriormente descrito.On the other hand, a second aspect of the invention relates to a method for geometric rectification of stamped metal parts, with a device Electromagnetic as described above.
El método de la invención se realiza a partir de una pieza metálica a rectificar, es decir, una chapa que ya ha sido estampada mecánicamente, en una prensa tradicional, con el objeto de rectificar la geometría de la pieza en aquellas zonas en las que la misma se encuentra fuera de unas tolerancias establecidas. A diferencia de los métodos del estado de la técnica, no se trata de evitar el efecto negativo de la recuperación elástica de la pieza al estampar la pieza, sino de corregirlo a posteriori.The method of the invention is carried out from a metal part to be rectified, that is, a sheet that has already been mechanically stamped, in a traditional press, in order to rectify the geometry of the piece in those areas where the It is outside established tolerances. Unlike the prior art methods, it is not a question of avoiding the negative effect of the elastic recovery of the piece when stamping the piece, but of correcting it afterwards.
Asi pues, el método para la rectificación geométrica de piezas metálicas estampadas, objeto de la invención comprende las etapas que se describen a continuación .Thus, the method for the geometric rectification of stamped metal parts, object of the invention comprises the steps described below.
Una primera etapa que comprende posicionar una pieza estampada con cada zona a rectificar operativamente situada entre un taco y una bobina electromagnética, estando dicha pieza convenientemente separada del taco, que está separado de la bobina electromagnética complementaria una distancia no superior a diez veces el espesor de la pieza, con el objeto de que dicha pieza pueda impactar contra dicho taco por la acción de un campo magnético generado por dicha bobina electromagnética .A first stage comprising positioning a stamped part with each zone to be rectified operatively located between a block and an electromagnetic coil, said part being conveniently separated from the block, which is separated from the complementary electromagnetic coil a distance not exceeding ten times the thickness of the piece, in order that said piece may impact said block by the action of a magnetic field generated by said electromagnetic coil.
A continuación el método comprende una segunda etapa que comprende generar un campo magnético configurado para actuar en las zonas a rectificar de la pieza de manera que adopten una geometría final requerida al impactar la pieza contra cada taco.Next, the method comprises a second stage which comprises generating a magnetic field configured to act in the areas to be rectified of the piece so that they adopt a final geometry required when the piece is hit against each block.
Por último el método comprende una tercera etapa que comprende extraer la pieza ya rectificada.Finally the method comprises a third stage which comprises extracting the already rectified piece.
Se contempla la posibilidad de que el método comprenda una etapa intermedia, que se realizarla de manera previa a la segunda etapa de generación del campo magnético, y que comprende colocar al menos un acelerador, es decir una chapa de un material con un contenido elevado en cobre, entre dicha, al menos una, bobina electromagnética y la pieza a rectificar, con el objeto de reducir las exigencias energéticas del método.The possibility is contemplated that the method comprises an intermediate stage, which will be carried out prior to the second stage of the magnetic field generation, and which comprises placing at least one accelerator, that is to say a sheet of a material with a high content in copper, between said at least one, electromagnetic coil and the piece to be rectified, in order to reduce the energy requirements of the method.
La deformación de la pieza metálica a rectificar se consigue mediante la descarga de una corriente eléctrica a través de dicho, al menos un, arrollamiento que se encuentra próximo a la zona a rectificar de la pieza. Debido a las corrientes que se inducen en la pieza, se produce un movimiento rápido en la zona de la pieza cercana a la bobina. La energía cinética asociada con el movimiento origina el cambio fisico en la pieza.The deformation of the metal part to be rectified is achieved by discharging an electric current through said at least one winding that is close to the area to be rectified of the part. Due to the currents that are induced in the piece, rapid movement occurs in the area of the part near the coil. The kinetic energy associated with the movement causes the physical change in the piece.
Asi pues, de acuerdo con la invención descrita, el dispositivo electromagnético y método para la rectificación geométrica de piezas metálicas estampadas que la invención propone constituyen un avance en los dispositivos y métodos de conformado hasta ahora utilizados, y resuelven de manera plenamente satisfactoria y sencilla la problemática anteriormente expuesta, en la linea de permitir su utilización en todo tipo de chapas, cualquiera que haya sido su proceso de conformado, permitiendo el aprovechamiento y la utilización habitual de los equipos de estampación disponibles como por ejemplo las prensas tradicionales en una determinada fábrica, es decir, sin la necesidad de tener que realizar modificación alguna sobre los mismos, para posteriormente rectificar las piezas en el dispositivo de la invención, externo a la linea de prensas, únicamente en los casos en los que sea necesario .Thus, in accordance with the described invention, the electromagnetic device and method for the geometric rectification of stamped metal parts that the invention proposes constitute an advance in the forming devices and methods used up to now, and solve in a fully satisfactory and simple manner the problematic previously exposed, in the line of allowing its use in all types of sheets, whatever its forming process has been, allowing the use and habitual use of the available stamping equipment such as traditional presses in a certain factory, that is, without the need of having to make any modification on them, to later rectify the pieces in the device of the invention, external to the press line, only in cases where it is necessary.
Por lo tanto el usuario puede fabricar una pieza mediante un proceso de estampación convencional y a la vista del resultado decidir si es necesario utilizar el dispositivo electromagnético de conformado de la invención para su rectificación.Therefore, the user can manufacture a part by means of a conventional stamping process and, in view of the result, decide whether it is necessary to use the electromagnetic forming device of the invention for its rectification.
El dispositivo que la invención propone es diferente a los dispositivos de conformado electromagnético del estado de la técnica al no requerir una matriz superior y una matriz inferior que reproduzcan de manera exacta la geometría final, tanto la forma como las dimensiones, de toda la pieza a obtener debido a que el campo magnético actúa únicamente en aquellas zonas en las que la pieza se encuentra fuera de las tolerancias admisibles, con la consiguiente reducción de costes.The device proposed by the invention is different from the electromagnetic forming devices of the state of the art as it does not require an upper matrix and a lower matrix that accurately reproduce the final geometry, both the shape and dimensions, of the entire piece a obtained because the magnetic field acts only in those areas where the part is outside the permissible tolerances, with the consequent reduction of costs.
El dispositivo electromagnético que la invención propone resulta sumamente sencillo y barato de fabricar, al utilizar como utillaje al menos un taco y al menos una bobina electromagnética que permiten su adaptación a cada tipo de geometría.The electromagnetic device proposed by the invention is extremely simple and inexpensive to manufacture, by using at least one block and at least one electromagnetic coil that allows its adaptation to each type of geometry.
Dicho, al menos un, taco y dicha, al menos una, bobina electromagnética son intercambiables, adaptándose a cada zona a rectificar, por lo que si se cuida su diseño, una misma pareja constituida por un taco y una bobina electromagnética puede servir para la rectificación de piezas diferentes, situándose en zonas que tienen una misma geometría final a obtener.Said, at least one, block and said, at least one, electromagnetic coil are interchangeable, adapting to each area to be rectified, so if your design is taken care of, the same pair consisting of a block and an electromagnetic coil can be used for rectification of different pieces, being located in areas that have the same final geometry to obtain.
Por lo tanto el coste resulta mucho menor que en el caso de tener que disponer de un pisador, una matriz y un macho completos, que tengan exactamente la geometría final completa de toda la chapa a obtener.Therefore the cost is much lower than in the case of having to have a trampler, a matrix and a complete male, having exactly the complete final geometry of the entire sheet to obtain.
Este dispositivo elimina la necesidad de tener que realizar sucesivas correcciones en la geometria de los troqueles de estampación convencional para eliminar el efecto denominado "springback" en la pieza. Estas correcciones se realizan generalmente mediante un proceso iterativo de corrección, ensayo y error, con el gran incremento de costes que ello conlleva.This device eliminates the need to make successive corrections in the geometry of conventional stamping dies to eliminate the effect called "springback" on the piece. These corrections are generally made through an iterative process of correction, trial and error, with the great increase in costs that this entails.
El dispositivo de la invención sustituye al troquel calibrador mecánico, del cual se puede prescindir, con el consiguiente ahorro de espacio en una fabrica, reducción de costes iniciales por eliminación de un troquel y posibilidad de utilización de lineas de prensa con una estación menos.The device of the invention replaces the mechanical caliper die, which can be dispensed with, with the consequent saving of space in a factory, reduction of initial costs by eliminating a die and possibility of using press lines with a less station.
Además, el dispositivo de la invención, en comparación con los dispositivos y los procedimientos descritos en las patentes japonesas No JP 2004-122177 y JP 2001-252788, permite, además de las ventajas anteriormente señaladas, la rectificación de todo tipo de piezas, preferentemente chapas, de materiales metálicos conductores, tales como aceros.In addition, the device of the invention, in comparison with the devices and procedures described in Japanese patents No. JP 2004-122177 and JP 2001-252788, allows, in addition to the above-mentioned advantages, the rectification of all types of parts, preferably sheets, of conductive metal materials, such as steels.
DESCRIPCIÓN DE LOS DIBUJOSDESCRIPTION OF THE DRAWINGS
Para complementar la descripción que se está realizando y con objeto de ayudar a una mejor comprensión de las caracteristicas del invento, de acuerdo con un ejemplo preferente de realización práctica del mismo, se acompaña como parte integrante de dicha descripción un juego de dibujos en donde con carácter ilustrativo y no limitativo, se ha representado lo siguiente: La figura 1.- Muestra un esquema eléctrico del circuito de descarga que comprende el dispositivo de la invención y que permite la generación de un campo magnético para la rectificación de piezas las metálicas.To complement the description that is being made and in order to help a better understanding of the features of the invention, according to a preferred example of practical realization thereof, a set of drawings is attached as an integral part of said description where Illustrative and non-limiting, the following has been represented: Figure 1.- Shows an electrical scheme of the discharge circuit comprising the device of the invention and which allows the generation of a magnetic field for the rectification of metal parts.
La figura 2. - Muestra una sección de una geometría final a obtener para una pieza y una geometría obtenida tras un proceso de estampación convencional, apreciándose en esta última el efecto "springback", en comparación con la geometría final a obtener.Figure 2. - It shows a section of a final geometry to be obtained for a piece and a geometry obtained after a conventional stamping process, the latter being appreciated the "springback" effect, in comparison with the final geometry to be obtained.
La figura 3.- Muestra una sección de una vista en alzado de una representación esquemática del dispositivo electromagnético que la invención propone, en la que puede apreciarse la situación de una pieza a rectificar.Figure 3.- Shows a section of an elevation view of a schematic representation of the electromagnetic device proposed by the invention, in which the situation of a piece to be rectified can be seen.
La figura 4.- Muestra una sección según una vista en planta de una realización del dispositivo de la invención, en la que pueden apreciarse tres tacos y tres bobinas electromagnéticas en tres zonas a rectificar de la chapa, sobre un diseño de base de un troquel de estampado convencional, en el que puede comprobarse la sencillez del dispositivo objeto de la invención frente a la complejidad de un troquel de estampado convencional.Figure 4.- Shows a section according to a plan view of an embodiment of the device of the invention, in which three plugs and three electromagnetic coils can be seen in three areas to be rectified of the sheet, on a base design of a die of conventional printing, in which the simplicity of the device object of the invention can be checked against the complexity of a conventional printing die.
La figura 5.- Muestra una vista en alzado del dispositivo electromagnético de la invención según la dirección A-A de la figura anterior.Figure 5.- Shows an elevation view of the electromagnetic device of the invention according to the A-A direction of the previous figure.
La figura 6.- Muestra una sección de una vista en alzado, según la línea de corte B-B mostrada en la figuraFigure 6.- Shows a section of an elevation view, according to the B-B cut line shown in the figure
4, en la que pueden apreciarse un taco y una bobina electromagnética situados en correspondencia, entre los cuales se encuentra una pieza a rectificar. La figura 7- Muestra otra sección de una vista en alzado como la de la figura anterior, según la linea de corte C-C mostrada en la figura 4.4, in which a block and an electromagnetic coil located in correspondence can be seen, among which is a piece to be rectified. Figure 7- Shows another section of an elevation view like the one in the previous figure, according to the cut-off line CC shown in figure 4.
La figura 8.- Muestra un diagrama de flujo en el que pueden apreciarse las principales etapas que comprende el método para la rectificación geométrica de piezas metálicas estampadas que la invención propone.Figure 8 shows a flow chart in which the main steps comprising the method for geometric rectification of stamped metal parts proposed by the invention can be seen.
REALIZACIÓN PREFERENTE DE LA INVENCIÓNPREFERRED EMBODIMENT OF THE INVENTION
A la vista de las figuras reseñadas puede observarse cómo en una de las posibles realizaciones de la invención, el dispositivo electromagnético para la rectificación geométrica de piezas metálicas estampadas comprende al menos un taco (2) configurado para recibir el impacto y contactar con una cara de una determinada zona a rectificar de una pieza (1) .In view of the aforementioned figures, it can be seen that in one of the possible embodiments of the invention, the electromagnetic device for the geometric rectification of stamped metal parts comprises at least one block (2) configured to receive the impact and contact a face of a certain area to rectify a piece (1).
La geometría de una superficie de dicho, al menos un, taco (2) configurada para contactar con la pieza (1) a rectificar se corresponde exactamente con una geometría final (10) que se requiere obtener en dicha cara de la zona a rectificar de la pieza (1) .The geometry of a surface of said, at least one, block (2) configured to contact the part (1) to be rectified corresponds exactly to a final geometry (10) that is required to obtain on said face of the area to be rectified from the piece (1).
Complementariamente a cada, al menos un, tacoIn addition to each, at least one, taco
(2), el dispositivo comprende una bobina electromagnética(2), the device comprises an electromagnetic coil
(5) que está configurada para situarse por una cara opuesta a la de dicho, al menos un, taco (2) de una determinada zona a rectificar de la pieza (1) .(5) which is configured to be located on a face opposite to said face, at least one, block (2) of a certain area to be rectified of the piece (1).
En el caso de que un taco (2) esté situado por una primera cara (12) de la pieza (1), entonces la bobina electromagnética (5) complementaria está situada por una segunda cara (11), opuesta a la primera cara (12), y viceversa, es decir, en el caso de que un taco (2) esté situado por la segunda cara (11) de la pieza (1), entonces la bobina electromagnética (5) está situada por la primera cara (12) .In the event that a block (2) is located on a first face (12) of the part (1), then the complementary electromagnetic coil (5) is located on a second face (11), opposite the first face ( 12 and vice versa, that is, in the case that a block (2) is located on the second face (11) of the part (1), then the electromagnetic coil (5) is located on the first face (12).
Cada, al menos una, bobina electromagnética (5) comprende al menos un arrollamiento (6) embebido en una pieza, preferentemente un cuerpo sintético por ejemplo de fibra de vidrio. Dicha bobina electromagnética (5) tiene una superficie exterior enfrentada a un cara de la piezaEach, at least one, electromagnetic coil (5) comprises at least one winding (6) embedded in a piece, preferably a synthetic body for example of fiberglass. Said electromagnetic coil (5) has an outer surface facing a face of the piece
(1), que tiene una geometría aproximada a la geometría final (10) que se quiere obtener en la pieza (1), existiendo un espacio u holgura entre cada, al menos una, bobina electromagnética (5) y cada, al menos un, taco (2) que es menor que diez veces el espesor de la pieza (1), con el objeto de que la acción del campo magnético impulse la pieza (1) para su impactó contra el taco (2) .(1), which has an approximate geometry to the final geometry (10) that is to be obtained in the piece (1), there is a gap or clearance between each, at least one, electromagnetic coil (5) and each, at least one , block (2) which is less than ten times the thickness of the piece (1), so that the action of the magnetic field drives the piece (1) for its impact against the block (2).
Tal y como se refleja en las figuras 1 y 3, cada, al menos una, bobina electromagnética (5) comprende al menos un arrollamiento (6) que está conectado a una fuente de alimentación eléctrica (7), configurada para generar un campo magnético.As reflected in Figures 1 and 3, each, at least one, electromagnetic coil (5) comprises at least one winding (6) that is connected to an electrical power source (7), configured to generate a magnetic field .
Cada, al menos una, bobina electromagnética (5) está operativamente situada de forma que el campo magnético que genera actúa en una determinada zona a rectificar de la pieza (1) , actuando sobre la misma y produciendo un impacto de la pieza (1) contra el taco (2) correspondiente.Each, at least one, electromagnetic coil (5) is operatively located so that the magnetic field that it generates acts in a certain area to be rectified of the piece (1), acting on it and producing an impact of the piece (1) against the corresponding block (2).
Cada, al menos un, arrollamiento (6) está conectado a un circuito de descarga que comprende un condensador (8) , preferentemente una batería de condensadores (8), y a un circuito de alto voltaje que comprende una fuente de alimentación eléctrica (7) y medios de encendido rápido (9), de forma que cuando los condensadores (8) se encuentran cargados y son activados mediante los medios de encendido rápido (9), se crea una corriente transitoria en cada, al menos un, arrollamiento (6) que genera el campo magnético transitorio.Each, at least one, winding (6) is connected to a discharge circuit comprising a capacitor (8), preferably a capacitor bank (8), and a high voltage circuit comprising a power supply (7) Y rapid ignition means (9), so that when the capacitors (8) are charged and activated by means of rapid ignition (9), a transient current is created in each at least one winding (6) that generates the transient magnetic field.
Dicho campo magnético induce unas corrientes de Foucault en la pieza (1) a rectificar, por lo que la pieza (1) es accionada en una dirección opuesta a la de cada, al menos una, bobina electromagnética (5), siendo empujada contra dicho, al menos un, taco (2), de manera que la cara de las zonas a rectificar de la pieza (1) en contacto con dicho, al menos un, taco (2) es conformada adquiriendo la geometría de dicho, al menos un, taco (2) .Said magnetic field induces eddy currents in the part (1) to be rectified, whereby the part (1) is actuated in a direction opposite to that of each, at least one, electromagnetic coil (5), being pushed against said , at least one, block (2), so that the face of the areas to be rectified of the piece (1) in contact with said, at least one, block (2) is formed by acquiring the geometry of said, at least one , cue (2).
Tal y como se muestra en las figuras 3 a 7, se contempla la posibilidad de que dichos, al menos un, taco (2) y bobina electromagnética (5) estén vinculados tanto a una primera base (3) como a una segunda base (4), con el objeto de que sirvan como soporte.As shown in Figures 3 to 7, the possibility is contemplated that said at least one block (2) and electromagnetic coil (5) are linked to both a first base (3) and a second base ( 4), in order to serve as support.
Asimismo se contempla la posibilidad de que dicha primera base (3) y dicha segunda base (4) comprendan medios de cierre móvil para facilitar la extracción de la pieza (1), pudiendo estar dispuestas en posición tanto horizontal como vertical.It also contemplates the possibility that said first base (3) and said second base (4) comprise means of mobile closure to facilitate the extraction of the piece (1), being able to be arranged both horizontally and vertically.
En la realización mostrada en las figuras 4 a 7, el dispositivo comprende un primer taco (2) situado de manera complementaria a una primera bobina electromagnética (5) que comprende un primer arrollamiento (6). Por otro lado el dispositivo comprende un segundo taco (2' ) situado de manera complementaria a una segunda bobina electromagnética (5' ) que comprende un segundo arrollamiento (6'). Finalmente el dispositivo comprende un tercer taco {2'') situado de manera complementaria a una tercera bobina electromagnética (5'') que comprende un tercer arrollamiento (6'') dispuesto de manera perpendicular al primer arrollamiento (6) y al segundo arrollamiento (6') .In the embodiment shown in Figures 4 to 7, the device comprises a first block (2) located in a complementary manner to a first electromagnetic coil (5) comprising a first winding (6). On the other hand, the device comprises a second block (2 ') located in a complementary manner to a second electromagnetic coil (5') comprising a second winding (6 '). Finally, the device comprises a third block {2 '') located so complementary to a third electromagnetic coil (5 '') comprising a third winding (6 '') arranged perpendicular to the first winding (6) and the second winding (6 ').
Tal y como se puede comprobar en la figura 6 el primer arrollamiento (6) tiene una geometría que se adapta a la zona curva de la geometría final (10) a obtener en la pieza.As can be seen in Figure 6, the first winding (6) has a geometry that adapts to the curved area of the final geometry (10) to be obtained in the piece.
En esta realización el primer taco (2), el tercertaco (2'') y la segunda bobina- electromagnética (5') están vinculados a la primera base (3) mientras que el segundo taco (2'), la primera bobina electromagnética (5) y la tercera bobina electromagnética (5' ' ) están vinculados a la segunda- base (4) .In this embodiment the first block (2), the third block (2 '') and the second electromagnetic coil (5 ') are linked to the first base (3) while the second block (2'), the first electromagnetic coil (5) and the third electromagnetic coil (5 '') are linked to the second base (4).
Por último, se contempla la posibilidad de que el dispositivo comprenda al menos un acelerador (13), que consiste en una chapa de un material con un contenido elevado en cobre, tal y como se puede apreciar en la figura 3, situado entre dicha, al menos una, bobina electromagnética (5) y la pieza (1) a rectificar, con el objeto de reducir las exigencias energéticas del dispositivo para la obtención de una determinada geometría en una pieza (1) a rectificar.Finally, the possibility is contemplated that the device comprises at least one accelerator (13), which consists of a sheet of a material with a high copper content, as can be seen in Figure 3, located between said, at least one, electromagnetic coil (5) and the part (1) to be rectified, in order to reduce the energy requirements of the device to obtain a certain geometry in a part (1) to be rectified.
Un segundo aspecto de la invención se refiere a un método para la rectificación geométrica de piezas metálicas estampadas, con un dispositivo electromagnético como el anteriormente descrito.A second aspect of the invention relates to a method for geometric rectification of stamped metal parts, with an electromagnetic device as described above.
El método de la invención se realiza a partir de una pieza metálica a rectificar, es decir, una chapa que ya ha sido estampada mecánicamente, en una prensa tradicional, con el objeto de rectificar la geometría de la pieza en aquellas zonas en las que la misma se encuentra fuera de unas tolerancias establecidas.The method of the invention is carried out from a metal part to be rectified, that is, a sheet that has already been mechanically stamped, in a traditional press, in order to rectify the geometry of the piece in those areas where it is outside established tolerances.
Tal y como puede apreciarse en la figura 8, el método para la rectificación geométrica de piezas metálicas estampadas, objeto de la invención comprende las siguientes etapas:As can be seen in Figure 8, the method for geometric rectification of stamped metal parts, object of the invention comprises the following steps:
Una primera etapa (A) que comprende posicionar una pieza (1) estampada con cada zona a rectificar operativamente situada entre un taco (2) y una bobina electromagnética (5), estando dicha pieza (1) convenientemente separada del taco (2) , que está separado de la bobina electromagnética (5) complementaria una distancia no superior a diez veces el espesor de la pieza (D -A first stage (A) comprising positioning a stamped part (1) with each zone to be rectified operatively located between a block (2) and an electromagnetic coil (5), said part (1) being conveniently separated from the block (2), which is separated from the electromagnetic coil (5) complementary a distance not exceeding ten times the thickness of the piece (D -
Una segunda etapa (B) que comprende generar un campo magnético configurado para actuar en las zonas a rectificar de la pieza (1) de manera que adopten una geometría final (10) requerida al impactar la pieza (1) contra cada taco (2) .A second stage (B) comprising generating a magnetic field configured to act in the areas to be rectified of the piece (1) so that they adopt a final geometry (10) required when the piece (1) impacts against each block (2) .
Una tercera etapa (C) que comprende extraer la pieza ya rectificada.A third stage (C) comprising extracting the already rectified piece.
Se contempla la posibilidad de que el método comprenda una etapa intermedia, que se realizarla de manera previa a la segunda etapa (B) , y que comprende colocar al menos un acelerador (13), es decir una chapa de un material con un contenido elevado en cobre, entre dicha, al menos una, bobina electromagnética (5) y la pieza (1) a rectificar, con el objeto de reducir las exigencias energéticas del método.The possibility is contemplated that the method comprises an intermediate stage, which will be carried out prior to the second stage (B), and which comprises placing at least one accelerator (13), that is to say a sheet of a material with a high content in copper, between said at least one, electromagnetic coil (5) and the part (1) to be rectified, in order to reduce the energy requirements of the method.
A la vista de esta descripción y j uego de figuras , el experto en la materia podrá entender que las realizaciones de la invención que se han descrito pueden ser combinadas de múltiples maneras dentro del objeto de la invención. La invención ha sido descrita según algunas realizaciones preferentes de la misma, pero para el experto en la materia resultará evidente que múltiples variaciones pueden ser introducidas en dichas realizaciones preferentes sin exceder el objeto de la invención reivindicada. In view of this description and game of figures, the person skilled in the art will be able to understand that the embodiments of the invention that have been described can be combined in multiple ways within the object of the invention. The invention has been described according to some preferred embodiments thereof, but it will be apparent to the person skilled in the art that multiple variations can be introduced in said preferred embodiments without exceeding the object of the claimed invention.
Claims
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2009527162A JP2010502448A (en) | 2006-09-08 | 2006-09-08 | Electromagnetic device and method for correcting the shape of stamped metal parts |
| PCT/ES2006/000511 WO2008028982A1 (en) | 2006-09-08 | 2006-09-08 | Electromagnetic device and method for the geometric rectification of stamped metal parts |
| US12/440,386 US20090229332A1 (en) | 2006-09-08 | 2006-09-08 | Electromagnetic device and method for the geometric rectification of stamped metal parts |
| EP06807943A EP2065105A1 (en) | 2006-09-08 | 2006-09-08 | Electromagnetic device and method for the geometric rectification of stamped metal parts |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/ES2006/000511 WO2008028982A1 (en) | 2006-09-08 | 2006-09-08 | Electromagnetic device and method for the geometric rectification of stamped metal parts |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2008028982A1 true WO2008028982A1 (en) | 2008-03-13 |
Family
ID=37907046
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/ES2006/000511 Ceased WO2008028982A1 (en) | 2006-09-08 | 2006-09-08 | Electromagnetic device and method for the geometric rectification of stamped metal parts |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US20090229332A1 (en) |
| EP (1) | EP2065105A1 (en) |
| JP (1) | JP2010502448A (en) |
| WO (1) | WO2008028982A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104353718A (en) * | 2014-10-17 | 2015-02-18 | 华中科技大学 | Plate packaging and drawing forming device and forming method |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102248059B (en) * | 2011-06-16 | 2013-07-24 | 华中科技大学 | Multistage and multidirectional electromagnetic forming method and device |
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Also Published As
| Publication number | Publication date |
|---|---|
| JP2010502448A (en) | 2010-01-28 |
| US20090229332A1 (en) | 2009-09-17 |
| EP2065105A1 (en) | 2009-06-03 |
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