1. Field of the Invention
The present invention relates to the field of machining workpieces made of metal, such as steel, and, more particularly, to an apparatus to form a workpiece.
2. Description of the Related Art
The machining of a workpiece can include any process such as cutting, pressing, drawing and shaping.
Pot-shaped components can include a bottom, a container wall and a drawn edge. Such a component is often used as a spring cup for accommodating the ends of a coil spring. They are used widely in the automotive industry in particular.
High-strength steels are problematic in the production of such spring cups. Although these have the advantage that they have extremely high tensile strengths, such steels are relatively brittle and prone to tearing. Therefore steels of lesser thickness and lower weight may be used. This occurs particularly during deformation at high stress transition zones. The tearing occurs in particular in the transition regions between the cup bottom and cup wall and between the cup wall and drawn edge.
DE 102 54 103 B3 describes a deep-drawing tool for deep drawing of formed parts. This includes an annular clamping device for clamping a blank. The clamping device encloses a space in which a bottom and a former body are movable in the drawing direction. These two may have different speeds, which should lead to higher forming precision.
DE 27 27 174 C2 describes a method and an apparatus for deep drawing of an aluminium container. In this case, two parts are mutually movable, namely a punch and a die. The speed of the upwardly moving punch can be greater than the speed of downwardly moving die. A high drawing ratio is achieved in this way.
DE 10 2007 050 581 A1 discloses a method for influencing the sheet thickness progression in deep drawing of hollow bodies. This involves multiple cambering (deformation) and back cambering (reforming) of a workpiece. During the reforming phase, the relative velocity between the punch and the die is increased relative to the increased rate during the deforming phase. The punch performs a movement against the deforming phase during the reforming phase. The speeds of the punch during the phases are unequal.
What is needed in the art is an apparatus and method so that high-strength steels can be formed without leading to any tearing in the edge regions and drawn to a greater depth than could be achieved before.
The present invention provides an apparatus, an installation and a method to machine high-strength metals into a workpiece by using a punch and a die in two parts, which together form a substantially cylindrical inner part and a ring surrounding it. All four components mentioned can be moved in the drawing direction for the purpose of forming.
At least two of the parts involved in the drawing process can have different speeds, at least during certain stages of forming. In particular, the inner die may have a higher speed than the outer die.
The following procedures are possible:
I. During the initial phase, both dies move in the same direction with the same speed.
II. During the middle phase, the two dies move in one and the same direction, but the inner die at a higher speed than the outer die.
III. In the final stage the inner die is stationary, while the outer die continues to move at constant speed.
Further variants are also possible. The outer die can move from the beginning at constant speed. In contrast, the trajectory of the inner die can equal to the inner curve of a controlled movement (e.g., a sine curve) starting from a lower speed than that of the outer die, then exceeding the initial speed and then decreasing again. The speed differences can be significant, for instance the speed of the inner die can be 1.5-2, 2.5 or 3 times greater than the speed of the outer die.
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate an embodiment of the invention and such exemplification is not to be construed as limiting the scope of the invention in any manner.
Referring now to the drawings, and more particularly to
An inner die 3 is situated above the punch 1, and surrounded by an outer die 4. The inner die 3 is substantially cylindrical. The inner die 3 is annular. In turn, the inner die 3 has a bottom forming area 3.1. The outer die 4 is also annular. The outer die 4 includes a wall forming area 4.1, and further includes a clamping surface 4.2 for tightly clamping the drawn edge 5.3 of a workpiece 5 on the supporting surface 2.1 of the blank holder 2.
The workpiece 5 is the result of a circular disk-shaped plate or a sheet metal blank (
The drawing apparatus 6 operates as follows: the drawing apparatus 6 is initially open to receive the workpiece 5 (i.e., a sheet metal blank or pre-shaped workpiece), which means the clamping surface 4.2 of the outer die 4 is located approximately at the height of the bottom forming area 3.1 of the inner die 3. The supporting surface 2.1 of the blank holder 2 is located at approximately the same height. In this phase, a workpiece 5 is inserted into the drawing apparatus 6 and clamped between the supporting surface 2.1 and the clamping surface 4.2. Now, the actual working phase of the drawing apparatus 6 begins. The inner die 3 and the outer die 4 move together with the workpiece 5, as well as the blank holder 2, downwardly in the drawing direction, illustrated by the arrow (
The drawing apparatus 6 is only one station of a series of drawing stations. In practice, they are connected in series in a workshop (not shown). In this case, only one drawing station needs to be designed according to the invention, i.e., it is provided with drives which can provide the inner die 3 on the one hand and the outer die 4 and the blank holder 2 on the other hand with different speeds during the drawing process.
A drive (not shown) is respectively associated with at least two parts including the punch 1, the blank holder 2, the inner die 3 and the outer die 4, all of which are involved in the drawing process. The drive moves these two parts simultaneously with different respective speeds during a specific phase of the forming process.
Referring now to
Further possibilities for realizing the invention are as follows:
The present invention is described in terms of producing a pot-shaped component. It is understood, however, that hollow bodies deviating from the pot shape or cup shape can also be produced with the present invention. The dies can also have shapes that deviate from the described shapes including a disk and a ring.
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
Number | Date | Country | Kind |
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10 2012 005 635.4 | Mar 2012 | DE | national |
This is a continuation of PCT application No. PCT/EP2013/055553, entitled “DEVICE AND METHOD FOR MACHINING A WORKPIECE CONSISTING OF METAL, PARTICULARLY FOR PRODUCING A CUP-SHAPED COMPONENT FOR THE AUTOMOBILE INDUSTRY, AS WELL AS SUCH A WORKPIECE” filed Mar. 18, 2013, which is incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/EP2013/055553 | Mar 2013 | US |
Child | 14463490 | US |