U.S. patent application number 11/157586 was filed with the patent office on 2005-12-22 for deforming tool and process for manufacturing thereof.
Invention is credited to Fueller, Karl-Heinz, Haug, Tilmann, Hortig, Dirk, Knueppel, Michael.
Application Number | 20050279152 11/157586 |
Document ID | / |
Family ID | 35479182 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050279152 |
Kind Code |
A1 |
Fueller, Karl-Heinz ; et
al. |
December 22, 2005 |
Deforming tool and process for manufacturing thereof
Abstract
Deforming tool and process for manufacturing thereof in the
deformation of work pieces the outer force acts on the deforming
tool and/or the work piece, which causes a flow of the work piece
material and its plastic deformation into a shape determined by the
tool shape. Therein the tool is subjected to high friction wear
forces. In the framework of the ever shorter production cycles it
is also necessary that deforming tools must be produced ever more
rapidly, wherein their friction wear resistance must be maintained
to the greatest extent possible. The inventive deforming tool
includes a lower and an upper tool, wherein lower and/or upper tool
include a shape determining shell and a backfill for supporting
thereof, wherein lower and/or upper tool are comprised at least in
part of laminated material layers or powder particles joined to
each other, wherein the deforming tool includes an elastic
intermediate layer between lower and/or upper tool (backfill) and
the shape determining shell. The elastic intermediate layer serves
for evenly distributing or minimizing tension or pressure peaks in
the pressure load in the deforming process, and thus to reduce the
friction wear of the tool.
Inventors: |
Fueller, Karl-Heinz;
(Neu-Ulm, DE) ; Haug, Tilmann; (Weissenhorn,
DE) ; Hortig, Dirk; (Hattenhofen, DE) ;
Knueppel, Michael; (Neu-Ulm, DE) |
Correspondence
Address: |
PENDORF & CUTLIFF
5111 MEMORIAL HIGHWAY
TAMPA
FL
33634-7356
US
|
Family ID: |
35479182 |
Appl. No.: |
11/157586 |
Filed: |
June 21, 2005 |
Current U.S.
Class: |
72/462 |
Current CPC
Class: |
B23P 15/246 20130101;
B21K 5/20 20130101 |
Class at
Publication: |
072/462 |
International
Class: |
B21J 013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 21, 2004 |
DE |
102004029973.0-14 |
Claims
1. A deforming tool, including lower and upper tool, wherein lower
and/or upper tool are comprised of a shape determining shell and a
backfill for supporting thereof; wherein lower and/or upper tool
are at least partially comprised of laminated material layers,
wherein the laminated material layers are oriented in such a
manner, that as many as possible step stages occur in the direction
towards the shape determining shell.
2. The deforming tool according to claim 1, wherein the deforming
tool includes an elastic intermediate layer between upper and/or
lower tool (backfill) and shape determining shell.
3. The deforming tool according to claim 2, wherein the elastic
intermediate layer has a thickness of 0.5 to 2 mm.
4. The deforming tool according to claim 2, wherein the elastic
intermediate layer is comprised of one single piece or of a
flowable material.
5. The deforming tool according to claim 1, wherein the shape
determining shell and/or the laminated material layers or the
powder particles are metal.
6. (canceled)
7. The deforming tool according to claim 1, wherein the shape
determining shell has a surface structure adapted for formation of
micro lubricant pockets into the surface of the work piece to be
deformed.
8. A process for manufacturing a deforming tool which includes
lower and upper tool, wherein, beginning with a three-dimensional
data set a volume model of the deforming tool, a Laminated Object
Manufacturing (LOM) rapid process is used to build up the deforming
tool or parts thereof in layers, wherein for the lower and/or upper
tool a shape determining shell and a backfill for supporting
thereof are produced, wherein a three-dimensional data set of the
volume model of the shape determining shell is created, and from
the three-dimensional data set, the volume model of the deforming
tool (shell) is extracted, so that a three dimensional model of the
supporting backfill results, which is then built up by the LOM
process, and that the material layer to be laminated are oriented
in such a manner that as many as possible steps occur in the
direction towards the shape determining shell.
9. (canceled)
10. The process for manufacturing a deforming tool according to
claim 8, wherein for the deforming tool to be produced, an elastic
intermediate layer is provided between lower and/or upper tool
(backfill) and the deforming shell, wherein the three-dimensional
set of a volume model of the elastic intermediate layer is created
and subtracted from the first three-dimensional set of the volume
model of the supporting backfill, so that a second
three-dimensional set of the volume model of the supporting
backfill results, which then can be built up in layers by the rapid
LOM process.
11. The process for manufacturing a deforming tool according to
claim 8, wherein a flat shell preform and a work piece to be
deformed are introduced in the lower or upper tool, optionally with
inlaying or introduction of an elastic intermediate layer, and with
action of the corresponding upper or lower tool, these are deformed
in such a manner that from the flat shell pre-form the
form-determining shell results.
12. The deforming tool according to claim 1, wherein at least one
of the upper and lower tools is made at least in part of joined
powder particles.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns a deforming tool and a process for
manufacturing thereof in according with the precharacterizing
portion of Patent Claims 1, 2 and 8. One such generic tool and one
such process are already known from DE 199 00 597 A1.
[0003] 2. Related Art of the Invention
[0004] The basic sequence in the process of deforming work pieces
is comprised therein, that the work piece is introduced into a form
determining tool, which is comprised of a lower tool and an upper
tool; that an external force is applied to the deforming tool
and/or the work piece which brings about a yielding of the work
piece material and a plastic deformation into a shape determined by
the tool shape.
[0005] In the framework of increasingly shorter production cycles
it is increasingly necessary to produce such deforming tools more
rapidly, wherein their quality must substantially be
maintained.
[0006] In DE 199 00 597 A1 it is proposed to rapidly produce the
tool by means of Laminated Object Manufacturing (LOM), building up
of paper or plastic sheets, or by means of laser sintering of
plastic powder. In one exemplary embodiment it is besides this
disclosed that the tool can comprise a shape determining shell and
a filler material supporting the shell.
[0007] This type of tool exhibits a limited friction-wear
resistance and is thus suitable only for a limited production
run.
SUMMARY OF THE INVENTION
[0008] It is the task of the invention to provide a deforming tool
with high friction wear. resistance as well as a process for
manufacturing thereof.
[0009] With regard to the deforming tool to be provided and the
process for manufacturing thereof, the invention is described by
the characteristics of Patent Claims 1, 2 and 8. The remaining
claims contain advantageous embodiments and further developments of
the inventive deforming tool (Patent Claims 3 through 7) and the
inventive process (Patent Claims 9 through 11).
[0010] The task with regard to the deforming tool to be provided is
inventively solved thereby, that it comprises a lower and an upper
tool, wherein the lower and/or upper tool includes a shape
determining shell and a backfill for supporting thereof, wherein
lower and/or upper tool are comprised at least partially of
laminated material layers, and wherein the laminated material
layers are arranged in such a manner, that there are as many as
possible, as small as possible, steps in the direction towards the
shape determining shell, such that the laminated material layers
support the shell as evenly as possible.
[0011] For example, in a conventional basin-shaped deep draw tool
the material layers are preferably oriented parallel to the
direction of closing of the tool. Thereby the characteristic
step-shape effect (that is, little, high steps) occurs essentially
in the narrow region of the basin wall, while in the essentially
longer area of the basin floor there occur very many, very small
step stages, which do not lead to a noticeable step effect and thus
support the shell very evenly.
[0012] An optimal orientation with as many as possible, as short as
possible, step stages in the direction towards the shape
determining shell can easily be determined by known optimization
programs.
[0013] In addition to the conventional joining by adhesive, the
joining of the individual laminated layers can be reinforced by
through-going reinforcement, in particular in the form of wires or
rods.
[0014] With regard to the deforming tool to be provided the task is
inventively solved in that this includes a lower and an upper tool,
wherein lower and/or upper tool comprise a shape determining shell
and a backfill supporting this, wherein lower and/or upper tool are
comprised at least in part of laminated material layers or powder
particles joined to each other, wherein the deforming tool includes
an elastic intermediate layer between lower and/or upper tool
(lower and/or upper backfill) and the shape determining shell.
[0015] The elastic intermediate layer serves to reduce pressure or
stress tips in the pressure load in the deforming process or to
evenly distribute this, and thus to reduce the friction wear of the
tool.
[0016] Besides this, the elastic intermediate layer evens out the
step effect in the built-up of the tool of laminated material
layers, or the graininess of sintered powder surfaces, which
otherwise would imprint in the inner side of the shell and,
following longer employment, could leave an impression extending
through the shell and thus increase on the one hand the friction
wear of the shell, respectively the tool, and which would on the
other hand reduce the quality of the produced piece surface.
[0017] This type of effect can also be reduced by a suitable
selection of material for the shape determining shell. The shape
materials for the shell are thus, on the one hand, metallic, in
particular steel sheets, however may be non-metallic and in
particular reinforced plastics, for example carbon fiber reinforced
plastic composites (CFC).
[0018] The shape determining shell as well as the backfill, as well
as both, could be produced by the same or different rapid
prototyping processes. For example, the shape determining shell can
be laminated sheet metal or carbon-fiber reinforced webs, and the
backfill can be of sintered plastic powder. On the basis of the
comparatively small load on the backfill, this can also be produced
by other rapid processes, for example with 3D-printing or stereo
lithography.
[0019] In a preferred embodiment the elastic intermediate layer
exhibits a thickness of 0.5 to 2 mm. In a thickness of this type
the generally available, that is, easily and cost effectively
commercially available elastic materials, are capable of reducing
in sufficient manner most pressure tips in the pressure load in the
conventional deforming process, in order to significantly reduce
friction wear.
[0020] Suitable elastic materials are, for example plastics,
preferably polyolefin or polyurethane.
[0021] Therein the elastic intermediate layer can be in the form of
a single unitary piece, as well as of a flowable material, for
example plastic powder, or also a mass of polyurethane. Depending
upon deforming process and shape of the shell, the one or the other
may be preferred. An intermediate layer of one single piece would
be more easily produced, introduced and either be completely
removed or, as the case may be, exchanged or replaced. Flowable
material, in particular powder, can more easily conform to
complicated geometries of the shell.
[0022] With regard to friction wear, it is also advantageous when
the shape determining shell and/or the laminated material layers or
the powder particles are comprised of metal, in particular
steel.
[0023] Besides this, it is advantageous when the laminate material
layers are oriented in the manner such that as many as possible, as
thin or shallow step stages, are oriented in the direction toward
the shape determining shell, and support this thereby as evenly as
possible. The determining of the optimal orientation and an
advantageous supplemental interconnection of the laminate are
already described above.
[0024] In a preferred embodiment the shape determining shell
exhibits a particular surface treatment. For such a surface
treatment the shell is, in comparison to its backfill, a
comparatively small component and easier and more economical to
access. Suitable surface treatments include for example a surface
structuring by micro abrasion, which is suitable for forming micro
lubricant pockets in the surface of the workpiece to be deformed.
Also possible is a hardening of the shape determining shell by
suitable selection of material and temperature during its
manufacture.
[0025] The task, with regard to the process to be provided for
production of a deforming tool, which includes a lower and upper
tool, is inventively solved thereby, that beginning with a three
dimensional set of data of a volumetric model of the forming tool,
the deforming tool or parts thereof are build up in layers by rapid
processes, wherein for the lower and/or upper tool a shape
determining shell and a backfill for supporting thereof are
produced, and wherein the three dimensional data set of a volume
model for the shape determining shell is determined and is deduced
from the three dimensional data set of the volume model the
deforming tool, so that a three dimensional volume model of the
supporting backfill results, which is then built up in layers by
rapid processes.
[0026] According to DE 199 00 597 A1, in contrast, the backfill is
produced by back spraying and this must then harden or cure for at
least one day.
[0027] In contrast thereto the inventive process offers the
advantage of a rapid manufacturing and an independence from the
prior existence/non-existence of the shape-determining shell--its
data set is sufficient for the manufacture of the backfill. The
data set can be drawn from repeatedly for manufacturing of new
backfills, in comparison to which an actual shape shell is needed
in the case of back spraying, and is rigidly connected with the
backfill, and thus is only available for a single use.
[0028] In a preferred embodiment, as layer building rapid process,
Laminate Object Manufacturing is employed, wherein the material
layers to be laminated are oriented in such a manner, that as many
as possible, and as shallow as possible, step stages facing the
direction towards the shape determining shell occur and supports
this thereby as evenly as possible.
[0029] An optimal orientation with as many as possible, as shallow
as possible, step stages in the direction towards the shape
determining shell can be easily determined by known optimization
programs.
[0030] In a further preferred embodiment an elastic intermediate
layer is provided for the deforming tool to be produced between the
upper and/or lower tool (backfill) and the shape determining shell,
wherein the three-dimensional data set of a volumetric module of an
elastic intermediate layer is determined and extracted or
subtracted from the first three-dimensional data set of the volume
model of the supporting backfill, so that a second
three-dimensional data set of the volumetric model of the
supporting back fill results, which then is built up in layers by
rapid processes.
[0031] By means of this process the individual parts of the lower
and/or upper tool are easily and economically produced and the
above described advantages of the elastic intermediate layer are
obtained.
[0032] In a further preferred embodiment of the inventive process,
a flat shell pre-form and a work piece to be deformed in the
supporting backfill of the upper or lower tool, optionally with an
introduced elastic intermediate layer, are introduced and under the
action of the corresponding upper or lower tool are deformed in
such a manner that from the flat shell pre-form the shape-providing
shell results.
[0033] This is a particularly simple, rapid and economical
possibility for the manufacturing of the shape determining shell,
which makes possible the reproduction or replenishment as often as
desired. This is in particular advantageous in cooperation with a
backfill which can be produced as often desired and without any
pre-existing shell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] In the following the inventive deforming tool and the
inventive process for its manufacture are described in greater
detail on the basis of an illustrative embodiment and the
figure:
[0035] First, a 3D-volumetric model of the deforming tool is
directly produced, or indirectly via a modeling of the deforming
tool to be produced.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The creation of the 3D-model can occur completely virtually
by means of a suitable CAD-program, or by plastic modeling and
subsequent optical or tactile measurement of the model, so called
reverse-engineering.
[0037] On the basis of the 3D-model a three dimensional data set of
the deforming tool is constructed. This shape determining side is
computationally reduced by the thickness of the shape determining
shell and the intermediate layer. The resulting data set is input
into a commercial type rapid prototyping system for laminated
object manufacturing. This is filled with rolled up, self-adhesive
metal foil. The metal foil is built up into a massive backfill by
the known LOM-process according to an input data set. Therein the
metal foils to be joined are oriented in such a manner that as many
as possible, as shallow as possible, steps result in the direction
towards the deforming shell. The optimal orientation is determined
in advance by an optimization program. In this embodiment the
optimal orientation runs--as can be seen from the figure--parallel
to the closing direction of the deforming tool.
[0038] Laid into this backfill are an elastic intermediate layer in
the shape of a 1 mm thick polyethylene web and a flat shell
pre-form. The flat shell pre-form is comprised of multiple layers
or carbon fiber composite webs adhered to each other, however not
fully cured. Subsequently the deform piece is introduced and then
the deform tool is closed under pressure. Thereby the flat shell
pre-form is deformed into a shape determining shell. This is
subsequently hardened by a suitable tempering.
[0039] The inventive deforming tool and the inventive process for
manufacture thereof in the embodiment of the above described
example have proven themselves as particularly suited for sheet
metal work in the automobile industry, in particular deep drawing.
In particular therewith substantial advantages with regard to the
time of manufacture of the tools and their wear resistance can be
achieved.
[0040] The invention is not limited to the above described
illustrative embodiment, but rather can be broadly applied.
[0041] The shape providing shell can also be directly built by
means of rapid processes, or also be milled from a blank, or can be
produced from a flat preform by first roughly deforming into a
pre-shell and a follow-up processing under force into the final
shape determining shell.
[0042] A backfill comprised of adhesive laminated thin metal sheets
may supplementally be reinforced by pull anchors, which run in the
direction of the layers of the individual lamellas and are clamped
on the sides of the deforming tool with suitable closing
mechanisms, for example threaded fasteners. At the same time one or
more pull anchors may serve as positioning elements for an
exactness of individual lamella as well as for the backfill and
form-determining shell.
[0043] In less demanding tools the intermediate layer can be
dispensed with, since the optimal orientation of the lamella
layers, and the therefore resulting more even supporting of the
shell, sufficiently minimizes friction wear.
* * * * *