U.S. patent application number 11/512692 was filed with the patent office on 2007-03-22 for deforming tool and process for manufacture.
This patent application is currently assigned to DaimlerChrysler AG. Invention is credited to Karl-Heinz Fuller, Michael Knuppel.
Application Number | 20070062245 11/512692 |
Document ID | / |
Family ID | 37715625 |
Filed Date | 2007-03-22 |
United States Patent
Application |
20070062245 |
Kind Code |
A1 |
Fuller; Karl-Heinz ; et
al. |
March 22, 2007 |
Deforming tool and process for manufacture
Abstract
In the deformation of geometrically similar components of a
component family, in which the characteristic which differs is in
particular thickness, there is according to conventional
construction techniques of deformation tools a separate deformation
tool necessary for each component. The inventive deformation tool
system, including the following tool active parts stamp, blank
holder and matrix, were in at least one work tool active part is
shaped in a mask technique, enable the deformation of various
components with this deformation tool system, in that for at least
one tool active part at least two exchangeable masks of different
characteristics are provided. Depending upon the component of a
component family to be produced an optimal mask is selected from
the pre-constituted supply of masks and used for deformation of the
component in the deformation tool.
Inventors: |
Fuller; Karl-Heinz;
(Neu-Ulm, DE) ; Knuppel; Michael; (Neu-Ulm,
DE) |
Correspondence
Address: |
AKERMAN SENTERFITT
P.O. BOX 3188
WEST PALM BEACH
FL
33402-3188
US
|
Assignee: |
DaimlerChrysler AG
Stuttgart
DE
|
Family ID: |
37715625 |
Appl. No.: |
11/512692 |
Filed: |
August 29, 2006 |
Current U.S.
Class: |
72/413 |
Current CPC
Class: |
B21D 22/20 20130101;
B21D 24/00 20130101; B21D 37/01 20130101; B21D 37/02 20130101 |
Class at
Publication: |
072/413 |
International
Class: |
B21D 37/02 20060101
B21D037/02 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 31, 2005 |
DE |
10 2005 041 460.5 |
Claims
1. A deformation tool system, including the following tool active
parts: stamp, blank holder and matrix, wherein at least one tool
active part is shaped by a mask technique, wherein, for at least
one work tool active part, at least two interchangeable masks of
different characteristics, in particular thickness, surface
texturing and/or thermal conductivity, are provided and/or wherein
for at least two tool active parts respectively at least one mask
of different characteristics, in particular thickness, surface
texturing and/or thermal conductivity, is provided.
2. The deformation tool system according to claim 1, wherein the
masks are preferably of cold rolled steel sheet in a thickness of
0.5 mm to 5 mm, in particular from 1 to 2.5 mm, and/or the surface
of one of the tool active parts and/or one of the masks has a
friction and wear reducing texture, which in particular is formed
by an electric discharge texturing (EDT) process, and/or the
thermal conductivity of a mask material at room temperature is
preferably in the range of less than 400 W/mK, in particular from
15 to 55 W/mK.
3. The deformation tool system according to claim 1, wherein the
masks are comprised of composite or sandwich materials, in
particular sandwich materials and/or metal sheets in combination
with cotton fiber composite materials.
4. The deformation tool system according to claim 1, wherein the
masks are comprised of different mask materials.
5. The deformation tool system according to claim 1, wherein one
mask is fixed on a tool active part using securing elements on a
surface different from the shape producing surface of the work tool
active part.
6. The deformation tool system according to claim 1, wherein one of
the tool active parts is provided, which is produced using the
rapid tooling technique known as metal laminated object
manufacturing (metal-LOM).
7. A process for production of a deformation tool, including the
following tool active parts: stamp, blank holder and matrix,
wherein at least one tool active part is shaped in a masking
technique, wherein at least one tool active part is joined to to
one mask, which is selected from a reservoir or a supply of at
least two interchangeable masks with different characteristics, in
particular with regard to their thickness, their surface texturing
and/or thermal conductivity, and/or wherein at least two tool
active parts are joined respectively to one mask, which exhibits
different characteristics, in particular thickness, surface
texturing and/or thermal conductivity.
8. A process for production of a component of a component family of
similar geometry by deforming at least one deformation tool,
including the work tool active parts: stamp, blank holder and
matrix, wherein for at least one work tool active part a mask
optimized for this component is selected from a supply of at least
two interchangeable masks with different characteristics, in
particular thickness, surface texturing and thermal conductivity
and joined with the tool active part and/or wherein for at least
two tool active parts respectively one mask optimized for this
component is selected, which differ in their characteristics, in
particular their thickness, surface texturing and thermal
conductivity, and are joined with the work tool active part.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns a deformation tool system, a process
for manufacture of a deformation tool and a process for manufacture
of components of a component family.
[0003] 2. Description of Related Art
[0004] The fundamental sequence of events in the deformation of
workpieces comprises introducing the workpiece into a
shape-imparting deforming tool, which is comprised of a lower and
an upper tool, and applying an external force upon the deformation
tool and/or the work piece, which can bring about a flow of the
material of the workpiece and its plastic deformation into a shape
predetermined by the shape of the tools. Particularly in the
deformation of sheets, and depending upon whether a single- or
double-acting press is used, the lower or the upper tool is
comprised of a tool effective stamp and a blank holder, and the
complementary upper or lower tool is comprised of the work tool
effective matrix.
[0005] In the deformation of geometrically similar components
within a component family, which the characteristic difference
between family members is in particular the thickness, in
accordance with conventional manufacturing processes a separate
deformation tool is required for each component. Typical
applications can be found in the automobile industry with regard to
frame and/or structural parts of the car body manufacture.
[0006] Known from the state of the art (DE 25 48 815 A1, DE 16 27
738 A1) are deformation tools in the masking technique and
processes for their manufacture. Herein these deformation tools
comprise a lower and/or upper tool, which includes a shape
imparting shell, that is, a mask, and a support-providing backing
material. The shape imparting shell represents in this type of tool
construction the shape-determining functional surface of the
respective tool for the deformation of a components, while the
supporting backing material provides, as the base body, stability
of the respective tool. As a manufacturing process for a tool
construction of this type, it is described in DE 25 48 815 A1, that
the shape determining shells are generated on separate negative
models of the respective shape-determining surface, for example via
application processes such as hot thermal spraying, and the thus
obtained shape providing shells are back-filled thereafter, for
example by a casting processes. Disadvantageous in this type of
tool manufacturing process is however that the final geometry of
both the shape producing shell as well as the backfill is not
precisely defined, whereby the reproducibility of the individual
components, that is, the shape determining shell and the backfill,
is not possible. A further manufacturing process is described in DE
16 27 738 A1, in which the shape producing shell of sheet metal is
deformed on a negative model by means of explosion deformation and
subsequently backfilled with concrete or a plastic material. Both
mentioned processes have the disadvantage, that the production of
the backfill material and the presence of the shape producing shell
are bonded, and the possibility of a change-out of the shape
producing shell, as necessitated for example by a strong friction
wear of the shape producing shell, is not possible due to the type
of joining of shape producing shell and backfill.
[0007] Further it is known from DE 198 07 404 A1 a deforming tool
in the mask technique and a process for manufacture thereof,
wherein the mask and the backfill exhibit a defined geometry and
dimension. It is described therein that the final thickness of the
latter mask of the lower and/or upper tool must be taken into
consideration already at the front end in the production of the
base body of the active parts of the deforming tool. Accordingly a
tool of this type is suitable essentially for deformation of a
single component and a further, geometrically similar component,
which differs from the original component, would require an
additional, new deformation tool.
[0008] It is the task of the invention to solve the above-mentioned
problems, in particular with regard to the reproducibility and
exchangeability of masks and the applicability of tool parts to
more than one component, and to provide a deformation tool system
for the deformation of components, in particular the series
manufacture, which exhibits a greater flexibility and at the same
time an economical series production, as well as a process for
manufacturing a deformation tool and a process for manufacturing a
component from a component family of similar geometry.
SUMMARY OF THE INVENTION
[0009] With regard to the deformation tool system to be provided,
the process for manufacture of a deformation tool and the process
for production of components of a component family are set forth in
the independent patent claims. The further claims contain
advantageous embodiments and further developments of the inventive
deformation tool system (Patent claims 2 through 6).
[0010] The task with regard to the deformation tool system to be
provided is inventively solved thereby, that it includes a lower
and an upper tool, where lower and/or upper tool are produced
according to the mask technique, and wherein multiple
interchangeable masks of different characteristics, in particular
with regard to thickness, surface texture and/or thermal
conductivity for at least one tool active or effective part of the
lower and/or upper tool are provided.
[0011] For example, a tool design of this type substantially raises
the flexibility of the deformation tool, since the deformation tool
enables manufacture of geometrically similar components, which
differ from the original component for example in the
characteristic of thickness, likewise, in that a certain bandwidth
of various component thicknesses is taken into consideration in the
manufacture of the base body of the corresponding active part and
the corresponding thickness of the new component is, in the end,
simply accommodated by means of the exchangeable masks.
[0012] A further advantage of the inventive deformation tool system
is that the base body of the tool active part can be described
precisely by computer controlled data models and therewith can be
produced reproducibly independently of the masks by conventional
milling processes or also by more modern rapid tooling processes,
in particular a rapid tooling technology layer building up process
known as laminated object manufacturing (LOM) in which metal layers
can be employed, whereby a sufficient stability of the tool is
achieved for series production and simultaneously expense and time
in the manufacture are saved.
[0013] Also advantageous in the inventive deformation tool system
is that masks with the same or different characteristics can be
produced reproducibly in that they are produced directly with the
geometrically exactly defined base body of the tool active part of
the deformation tool system in a deformation process or however by
separate deforming processes, such as incremental deformation or
however for example temperature control deformation processes for
non-metallic materials, such as for example carbon fiber composite
reinforced materials. Therewith masks of the same or different
characteristics can be pre-staged for the deformation tool system
in sufficient numbers, whereby the flexibility of the deformation
system to deform components of similar geometry of a component
family is realized, and beyond this laborious and costly repairs
and interruption of a conventional deformation tooling is
substantially reduced by a deformation tool system of the present
type thereby that the friction wear due to contact between
deformation tool and component occurs in the exchangeable masks and
that these masks, to the extent that they are worn, can be simply
exchanged against a corresponding mask from the pre-staged supply
of masks of the deformation tool system.
[0014] Alternatively or additionally the task of the deformation
system to be provided is inventively solved thereby, that it
includes a lower and upper tool, wherein lower and/or upper tool
are produced according to the masking technique and wherein for at
least two active parts of the lower and upper tool respectively at
least one mask of different characteristics, in particular in
regard to thickness, surface texture and/or thermal conductivity,
are provided.
[0015] For example, a work tool arrangement of this type
substantially increases the flexibility of the deformation tool,
since the deformation tool enables, in the case of a change of the
component material or the coating of the component material, for
example associated with a change in the tribologic relationship
between deformation tool and component and higher heat development
or input in the deformation process, by the selection of masks
which are suitable and differ in their characteristics for the
respective active parts, for example surface texturing and thermal
conductivity of the deformation tool, appropriate to the new
constraints or conditions.
DETAILED DESCRIPTION OF THE INVENTION
[0016] In a advantageous embodiment of the deformation system the
temperature development in the tool during the deformation process,
and therewith the heating of the deformation tool and the stability
of the deformation process, can be controlled thereby, that
materials are employed for the masks which, depending upon their
thermal conductivity, insulate the deformation tool or supply to it
a targeted heating from the deformation process. An increased heat
development in the deformation process is to be expected in
particular in the deformation of the materials with a tensile
strength of greater than 600/nm.sup.2. Advantageous herein are mask
materials, which exhibit at room temperature a thermal conductivity
in the range of less than 400 W/mK, preferably the thermal
conductivity of the mask materials lies in the range of 15W/mK to
55W/mK.
[0017] For reduction of friction and friction wear between
deformation tool and component, the surface of the respective mask
as the tool part which is in direct contact with the component is
to be provided advantageously with a texturing. This preferably
occurs by an electronic process, in particular electrical
discharged texturing (EDT).
[0018] In a further advantageous embodiment of the inventive
deformation tool system, the masks are provided as
shape-determining shells of cold rolled steel sheet with a
thickness of 0.5 mm to 5 mm. Preferably, the thickness of the
material to be employed lies in the range of between 1 mm to 2.5
mm, since this material thickness range covers the range of changes
occurring in the component thickness of geometrically similar
components or components of a component family. Cold-rolled steel
sheets as mask materials offer a very good deformability and good
friction wear resistance for series production. However, the
deformation tool system is not limited to the use of cold rolled
steel sheets as mask material, but rather includes all ferrous and
non-ferrous metals as well as non-metallic materials and composites
and sandwich materials, in particular in conjunction with carbon
fiber reinforced composite materials.
[0019] In a further preferred embodiment of the deformation tool
system, the fixing or bonding of the mask onto a tool active part
occurs with use of securing elements on a surface of the work tool
active part other than the shape imparting surface. This has the
advantage, that it is ensured, that the movement of the component
material during deformation does not extend beyond the location of
the fixation of the mask to the corresponding backfill material. An
influencing of the quality of the component by, for example,
scratching or imprinting by the fixing element of the mask is
therewith precluded.
[0020] The task with regard to the process to be provided for
production of a deformation tool, including a tool active dye or
punch or punching tool or stamp, a blank holder and a matrix with
at least one tool active part according to the masking technique,
is inventively solved by that at least one tool active part is
joined to a mask which is selected from a supply of at least two
exchangeable masks with different characteristics, in particular
their thickness, their surface texture and their thermal
conductivity.
[0021] The advantage of the inventive process for production of a
deformation tool lies therein, that in contrast to the previously
known state of the art according to DE 25 48 815 A1 and DE 16 27
738 A1, both the backfill material as well as the mask as shape
imparting shell are provided precisely as a three-dimensional data
set and therewith are reproducible, and that in contrast to DE 198
07 404 A1 the deformation tool cannot be used for only a single
component, but rather multiple components of a component family of
similar geometry.
[0022] The flexibility of the inventive process for production of a
deformation tool with regard to the deformation of components of a
component family is achieved thereby, that the thickness of
multiple components of a component family is already taken into
consideration in the construction of the deformation tool and
therewith is maintained in the deformation tool. Accordingly not
only the thickness of one single component is taken into
consideration in the description of backfill material and mask as
three dimensional data set, but rather as starting point the
maximum thickness of a component is used, and the 3D-data set of
the backfill material is constructed based thereupon. By the
pre-staging of masks of different characteristics, in particular
their thickness, their surface texture and their thermal
conductivity, the flexibility of the tool is ensured and, by an
employment of suitable masks in the deformation tool, components of
a component family can be produced with the deformation tool.
[0023] In one advantageous embodiment of the inventive process the
backfill material of at least one active part of the deformation
tool is produced by the layer building up rapid tooling technology
known as laminated object manufacturing (LOM) in conjunction with
metal layers. This embodiment is suited to save time and costs in
the manufacture of backfill.
[0024] Alternatively or additionally the task with regard to the
process for manufacture of a deformation tool, including work tool
active punch, blank holder and matrix with at least one tool active
part in accordance with the mask technique, is inventively solved
thereby, that for at least two active parts respectively one mask
is employed, which differs in at least one characteristic, in
particular thickness, surface texturing and thermal conductivity,
from at least the other masks employed in the deformation tool
system.
[0025] An advantageous embodiment of this type of a process for
manufacture of a deformation tool for production of components of a
component family of similar geometry ensures that by the
manufacturing and pre-staging of masks of different characteristic
for at least two active parts of the deformation tool the
flexibility of a deformation tool is further substantially
increased. Thereby, it is enabled to targetedly influence for
example different friction and wear protective characteristics of
the upper and lower tool, by for example an change of the component
material or a coating of the component material and/or to influence
for example heat introduction into the lower and/or upper tool as
advantageous for the process control.
[0026] The task with regard to the process to be provided for
production of components of a component family of similar geometry
by deformation by means of a deformation tool, including a tool
active part stamp, blank holder and matrix, is inventively solved
thereby, that for at least one tool active part a mask optimized
for this component is selected from a supply including at least two
exchangeable masks with different characteristics, in particular
their thickness, their surface texture and their thermal
conductivity, and that these are joined with the tool active
part.
[0027] The advantage of the inventive process for manufacture of
components of a component family of similar geometry lies therein,
that the process of the deformation of multiple components of a
component family of similar geometry is made possible with only one
deformation tool.
[0028] The flexibility of the inventive process for manufacture of
a component of a component family of similar geometry is achieved
thereby, that the thickness of multiple components of a component
family are already taken into consideration in the construction of
the deformation tool and thus included in the deformation tool.
Thus not only the thickness of one component is taken into
consideration in the description of back feed and mask as three
dimensional data set, but rather the maximal thickness of a
component of a component family of similar geometry is used as
starting point and the 3D-dataset of the backfill is constructed
with reference thereto. By the pre-staging of masks of different
characteristics, in particular the thickness, their surface
texturing and their thermal conductivity, the flexibility of the
tool is then ensured, and by the employment of corresponding masks
in the deformation tool the varied components of a component family
can be produced with the deformation tool.
[0029] In an advantageous embodiment of the inventive process for
manufacture of a component of a component family of similar
geometry, the backfill of at least one active part of the
deformation tool a layer is formed using building-up rapid tooling
technology known as laminated object manufacturing (LOM) in
conjunction with metal layers. This embodiment is suited to save
time and expense in the manufacturing of the backfill.
[0030] Alternatively or additionally, the task of providing a
process for manufacture of a component of a component family of
similar geometry by deformation by means of a deformation tool
including a tool active stamp, blank holder and matrix, is
inventively solved thereby, that for at least two tool active parts
respectively one mask optimal for this component is selected, which
differs in its characteristics, in particular its thickness, its
surface texturing and the thermal conductivity, and is joined to
the tool active part.
[0031] One such advantageous embodiment of the inventive process
ensures that by the production and supply of masks differing in
their characteristics for at least two tool active parts of the
deformation tool the flexibility of a deformation tool is further
substantially increased. Thereby it is made possible to influence
in a targeted manner for example different friction and wear
conditions of the upper and lower tool, brought about for example
by a change of the component material or a coating of the component
material, and/or for example a thermal input into the lower and/or
upper tool advantageous for process control.
[0032] In the following the inventive deformation system and the
inventive process for manufacture of a deformation tool and for
production of components of a component family of similar geometry
is described in greater detail on the basis of an illustrative
example:
[0033] Beginning with the data set of the component construction,
which exists as a rule in the form of a surface data set, a
3D-volumetric model of the deformation tool is constructed. For
this the surface data set from the component construction is
defined as reference surface in the deformation tool as shape
producing surface of the upper tool, in this case the form
producing surface of the mask of the tool active part matrix.
Beginning therewith, by offset generation both in the one as well
as the other normal direction of the reference surface, the 3D
outer surface of the tool active part of the deformation tool, that
is the stamp, the blank holder and the matrix, is formed. Since
components of a component family of similar geometry with component
thicknesses of 1 mm, 1.5 mm and 2 mm and with various materials
such as DC05 and DP800 are deformed, in the direction of the upper
tool an offset of 1 mm of the 3D surface of the tool active part
matrix is computed. In the direction of the deformation tool, in
order to cover the maximal component thickness, an offset of 3 mm
of the 3D-surface of the tool active part stamp and blank holder is
arrived at. This manner of preceding enables, by use of a 1 mm
thick mask for the tool active part matrix in the upper part and by
use of a respectively 1 mm thick mask for the tool active part
stamp and blank holder in the lower tool, the production of a
component with 2 mm thickness. Analogously thereto, by use of
respectively 1.5 mm or 2 mm thick mask for the tool active part
stamp and blank holder in the lower tool, the production of 1.5 mm
or 1 mm thick component can be made possible. Since the reference
surface in the deformation tool with the 3D-surface of the 1 mm
thick mask of the tool active part matrix in the upper tool remains
unchanged in all cases, the exact component geometry remains,
according to the construction data set of the component, the same
for all components to be produced of the component family.
[0034] Beginning with the thus produced 3D-surface data sets of the
tool active parts, the 3D-volumetric models of the backfill to be
produced for the respective tool active parts is constructed. The
resulting data are processed in a commercially available rapid
tooling unit for laminated object manufacturing and, with
employment of metal layers, a backfill for individual tool active
parts is built up. For increasing the stability of the layer
joining and for improved positioning of the individual mechanical
layers the stacking of the individual layers occurs by pull anchors
and positioning rods. These are subsequently secured with securing
elements such as, for example, threaded screws.
[0035] The production of the masks occurs according to the
processes known according to the state of the art, in particular
according DE 198 07 474 A1. The manufacturing process of masks for
individual tool active parts, which is in part very labor
intensive, is here optimized for the deformation tool system in the
manner, that all required masks can be produced in a single work
process with differing characteristics, in particular the
thickness, the surface texturing and the thermal conductivity. From
this there results, in comparison to the multiple conventional
tools, advantages with regard to the manufacturing time and the
expense of the masks.
[0036] In this manner the masks required for the production of
components of a component family in thicknesses of 1 mm, 1.5 mm and
2 mm for the tool active part of the deforming tool, are produced
directly with the aid of the backfill already produced by the
metal-LOM-process of the work tool active part in one deformation
process. In this manner then individually all of the masks
necessary for the deformation of all components of a component
family in all thicknesses, in different materials or in different
materials with different surface texturing, are deformed.
Subsequently there occurs in certain cases also a final processing
of individual masks and the masks are prepared for receiving fixing
elements, which ensure the fixing of a mask upon an appropriate
backfill, for example they are provided with through-holes for
receiving a counter-sunk screw head and for this a flange area is
recessed. In the present case the produced masks are fixed outside
of the form producing surface on the side surfaces of the backfill
with hexagonal screws.
[0037] Finally, other masks with different characteristics, in
particular surface texturing, are produced. These are produced in
separate manufacturing processes parallel to the manufacturing of
the backfill and the previously described process of mask
production. This is possible because a 3D-data set exists from the
tool construction describing precisely the individual masks. For
example, carbon-fiber composite masks are produced in different
thicknesses and with different surface characteristics. Their
manufacture occurs in a conventional manufacturing process for
carbon-fiber composite components. Therewith geometric distinct
individual carbon-fiber masks are available as soon as the
deformation tool is ready for series production.
[0038] The thus produced supply of masks of different
characteristics, in particular thickness, material and surface
texturing, enables the manufacture of all components of the
component family of similar geometry with one deformation tool
system and with optimal process conditions with respect to friction
and wear or for example the thermal input in individual work tool
active parts.
[0039] Supplementally, by the deformation tool system the repair
and maintenance of a deformation tool is kept to a minimum in that,
in the case of wear, essentially one mask needs to be changed out.
This substantially reduces the required extensive time and
associated costs for maintenance, servicing and repair of
deformation tools.
[0040] The inventive deformation tool system, the inventive process
for its manufacture and the inventive process for production of
components of a component family of similar geometry has
demonstrated itself in the illustrative embodiment of the above
described example as particularly suited for sheet metal processing
in the automobile industry, in particular deep drawing. Beyond
this, it is advantageous that the invention is applicable to both
prototype manufacture as well as in the series production. In
particular, substantial advantages can be achieved therewith with
regard to the flexibility of the deformation tool for deforming of
more than only one component, for reduction of costs and time of
manufacturing of deformation tools.
[0041] The invention is not limited to the above described
illustrative embodiment, but rather can be broadly applied.
[0042] So it can be useful, for example, in consideration of the
extreme friction and wear conditions in the deformation process, to
harden or temper the individual masks by a thermal treatment
process or to apply in a separate process additional friction and
wear reducing surface layers such as, for example, a
TiC/TiN-layer.
[0043] In another embodiment it may be necessary that backfill
materials of individual tool active parts must be produced of a
solid material such as for example cast steel materials, by milling
processes, for reasons of, for example, the tool geometry or the
loads in the deformation process.
* * * * *