Patent Application
20180333761
The embodiments of the present invention relate to a method for machining and/or producing a component, which method is used in particular in the machining and/or production of a metallic sheet component or sandwich component or of a corresponding semifinished part.
The prior art has disclosed various mechanical severing methods with the aid of which a sheet-metal component can be trimmed or perforated. By way of example, DE 44 01 830 C1 describes a method in the case of which a sheet-metal part is fixed in a holder and then, during the working stroke of a cutting tool that is used, in the cutting gap between an upper blade and a lower blade, is initially plastically deformed and subsequently, after crack formation, fully severed. The disadvantage of this conventional method is that, if use is made of (functionally) surface-coated components, for example zinc-plated components, a non-coated surface, in the example a zinc-free surface, forms at the cutting edges, hole edges, hole walls, embrasures and the like as a result of the cutting process. This leads, in the example, to undesired damage of the component in the cut region, which can be at least partially eliminated only by cumbersome reworking or recoating. The non-coated cut regions and the like furthermore harbor the risk of disbonding of the surface coating still present on the surface of the component. This can cause additional component damage.
Taking this prior art as a starting point, it is an object of the embodiments of the present invention to specify a technically simple method, which is simple in terms of effort, for machining and/or producing a component, which method prevents or reduces secondary damage on the resulting component and thus ensures the high functionality and stability of the component.
According to the embodiments of the invention, this and other objects are achieved by means of a method for machining and/or producing a component in that, firstly, a component or a semifinished part is provided which has a main body with a first surface and with a first surface coating provided on the first surface, the component of semifinished part is subsequently notched on the first surface coated with the first surface coating, and then severing, perforation or trimming of the component or of the semifinished part is performed along the notch. Here, the notching is performed such that at least a part of the first surface coating which is notched in the process is maintained along the notch surfaces formed during the notching process. In other words, this means that the notching process is performed such that the first surface coating initially present on the first surface, which is to be notched, of the component or of the semifinished part is jointly recessed or pressed into the notch that is created, and said first surface coating remains present along the formed notch surfaces after the completion of the notching process.
The inventive method is applicable to all conceivable components/semifinished parts. The inventive method is suitable in particular for machining and/or producing metallic sheet components because, by means of the method according to the invention, it is furthermore possible for burr formation and flash formation to be reduced or prevented. The component to be used may furthermore be of single-layer or multi-layer construction, and may be provided for example in the form of a laminate. Furthermore, the inventive method is also usable in particular for sandwich components which comprise layers of plastic and steel, for example.
In the context of the invention, a surface coating is to be understood generally to mean a functional coating which is applied to the surface of the main body of the component/semifinished part for aesthetic reasons, for functionalization of the component/semifinished part, for protection or stability purposes, and in particular for the purposes of chemical and/or mechanical stability. The first surface coating may be of single-layer or multi-layer construction, and may be cohesively connected to the main body surface or may lie loosely on the latter. Furthermore, the first surface coating need not completely cover the first surface of the main body, but rather may be arranged in selected sections or in predefined regions.
The notching is performed at a location of the first surface of the component or of the semifinished part at which the first surface coating is present. As a result of the notching, so-called notch surfaces are formed, that is to say the surfaces that are formed as a result of the notching in the notching direction. According to the embodiments of the invention, said notch surfaces comprise at least a part of the notched first surface coating, which increases the functionality of the resulting component and the stability thereof with respect to environmental influences and chemical or mechanical action. This is the case in particular if the notch surfaces resulting from the notching are at least 40% covered, in particular at least 70% covered, by the first surface coating. It is preferable for the notch surfaces to be up to 100% covered with the first surface coating. The functionality introduced by the first surface coating is maintained in the resulting component even after the severing, perforation or trimming, specifically at least at the notched surfaces, the notch surfaces. It is rather possible, by means of the introduction of the first surface coating into the notch that is formed, and in a manner dependent on the surface coating that is used, for additional functionalities to be introduced, in one working step, into the notch and thus also into the component that is obtained after the perforation, severing or trimming. The inventive method is simple owing to a combination of standard processes, can be implemented without great technical effort, and permits the inexpensive machining and/or production of highly functional and highly stable components or semifinished parts with a short cycle time. It is furthermore possible to dispense with reworking for retroactive functionalization or sealing of the cut regions, whereby material costs and working effort can additionally be saved.
In one advantageous refinement of the inventive method, the severing, perforation or trimming of the component of the semifinished part is performed using a mechanical cutting process.
It is furthermore advantageous for the component or the semifinished part to have a second surface coating on a second surface situated opposite the first surface.
A further advantageous refinement of the inventive method characterized in that the component or the semifinished part is notched both on the first surface coated with the first surface coating and on the second surface coated with the second surface coating. In other words, the first surface coating, the main body of the component/of the semifinished part and the second surface coating form a type of layered structure, in which the main body of the component/of the semifinished part is arranged between the two surface coatings. The first and the second surface coating may be of identical form or may differ in terms of type, form, design and/or functionality. By means of the notching process on both sides, a subsequent severing, perforation or trimming process with improved cut quality can be facilitated, and the first and/or second surface coating can be provided along a particularly large region of the notch surfaces and thus also in the immediate vicinity of the cut region or hole region that is formed, that is to say at hole margins, hole edges, embrasures, cut edges, cut surfaces and the like. The functionalization of the component produced is thus maximized.
The notching on the first surface coated with the first surface coating can be performed to the desired notch depth. If notching is performed only from the side of the first surface coating, then a notch depth in particular of up to 90% of the thickness of the main body, but in particular of at least 80% of the thickness of the main body, can be implemented. The thickness of the main body is in this case determined in the intended notching direction, that is to say in the direction in which the notching process is to be performed or has been performed.
To provide particularly good functionalization in the component produced, it is provided in a further advantageous refinement that the notching on the first surface coated with the first surface coating and/or on the second surface coated with the second surface coating is performed in each case to a depth of less than half of the thickness of the main body of the component/semifinished part, in particular to a depth of 10 to 40% of the thickness of the main body. The thickness of the main body is in this case determined in the intended notching direction, that is to say in the direction in which the notching process is to be performed. By contrast, notching on both sides to a depth of in each case 50% of the thickness of the main body has proven to be rather disadvantageous, because the notch tips of the oppositely formed notches thus coincide.
To further improve the cut quality, it is furthermore advantageously the case that the notching is performed symmetrically in the notching direction, for example in cylindrical, conical or V-shaped fashion. In other words, this means that the shape of the notch is of symmetrical form.
To further reduce the technical effort and/or cost outlay involved in the inventive method, the notching is advantageously performed by means of stamping, roll-stamping, rolling or knurling. The methods mentioned here are particularly highly suitable for configuring the notching process such that the first and/or second surface coating is formed, or remains situated, on the corresponding notch surfaces.
To promote burr-free severing, perforation or trimming, it is furthermore advantageously provided that the notching is performed symmetrically on the first surface coated with the first surface coating and on the second surface coated with the second surface coating. Here, symmetrical refers to a configuration with the same notch shape and also the same notch depth.
As already described, the surface coating, and thus both the first surface coating and the second surface coating, is not restricted in terms of detail. The surface coating(s) is or are advantageously selected from at least one zinc layer, at least one zinc-aluminum layer, at least one adhesive layer and/or at least one polymer layer.
Further advantageous coatings are for example CDC (cathodic tip coating) layers and paints, for example in the case of the method being used on already fully coated components/semifinished parts (white goods).
Here, layers composed of zinc are advantageous for improving the corrosion resistance of the component or of the semifinished part. Owing to the inventive method, this corrosion resistance then extends to the notch surfaces and, owing to the remote effect of the zinc, also to the cut surfaces, cut edges, hole edges, embrasures and the like which remain, after the severing, perforation or trimming of the component or of the semifinished part, on the useful component that is formed. Here, it has been found that at least 40%, in particular at least 70% coverage of the notch surfaces with zinc is sufficient, owing to the remote effect of the zinc, to ensure a high level of corrosion protection in the resulting component/semifinished part.
By contrast, adhesive layers are suitable for introducing a further functionality to the notch surfaces and thus also to the cut regions, that is to say the cut surfaces, cut edges, hole edges, hole margins, embrasures and the like. This is advantageous in particular if it is the intention for a further component/semifinished part to be connected by means of adhesive forces to the regions formed during the severing process, cutting process or perforation process. Here, the inventive method eliminates a complex additional step of the retroactive introduction of an adhesive into the notch and cut region.
Furthermore, the corresponding surface coating may also comprise at least one polymer layer. Examples here are paint layers, that is to say protective paints, colored paints, corrosion protection paints and the like. The respective functionality is, by means of the notching in the inventive method, extended to the notch surfaces and also to the cut regions. The component formed is distinguished by high stability and functionality.
A thickness of the main body of the component/of the semifinished part advantageously amounts to at most 3 mm and in particular 0.5 to 2.5 mm. In this way, good spreading of the surface coating(s) onto the corresponding notch(es) can be ensured.
It is furthermore advantageous for a layer thickness of the first surface coating and/or of the second surface coating on the respective surface of the component/semifinished part to amount to at most 20 μm and in particular at most 15 μm. The layer thickness of the respective surface coating is determined perpendicular to the corresponding surface of the component/semifinished part, and can be determined on the basis of photomicrographs. If the layer thickness of the surface coating(s) lies in the stated range, sufficient surface coating is available for covering the notch, and furthermore, at most such a quantity of surface coating is available that the severing process, perforation process or trimming process can be performed in a particularly exact manner.
In a further advantageous refinement of the inventive method, the notching is performed such that a layer thickness of the first surface coating along the notch surfaces amounts to at least 20%, in particular at least 30%, of the layer thickness of the first surface coating on the first surface of the component/semifinished part. At the same time, or alternatively, the notching is performed such that a layer thickness of the second surface coating along the notch surfaces amounts to at least 20%, in particular at least 30%, of the layer thickness of the second surface coating on the second surface of the component/semifinished part. The layer thickness of the respective surface coating along the notch surfaces is determined perpendicular to the corresponding notch surface. In this way, it can be ensured in a particularly effective manner that the functionality introduced by the respective surface coating is also obtained to a particularly high degree on the notch surfaces and thus on the cut surfaces, cut edges, hole edges, embrasures and the like.
It is furthermore advantageously provided that the notching is performed such that the layer thickness of the first surface coating along the notch surfaces and/or the layer thickness of the second surface coating along the notch surfaces describe a gradient. In particular, the layer thickness of the surface coating of the surface of the component/semifinished part decreases in uniform stepped fashion along the notching direction, such that, with minimum outlay of surface coating material, maximum functionalization in the resulting component/semifinished part can be achieved.
A further advantageous refinement of the inventive method provides that the notching of the component or of the semifinished part on the first surface coated with the first surface coating and/or on the second surface coated with the second surface coating is performed in the same process step as the severing, perforation or trimming of the component or of the semifinished part along the notch. This reduces the number of process steps and thus simplifies the method according to the invention. In the case of components or semifinished parts composed of carbon-fiber composite (CFC) plastics, the notching may for example be performed already in the shaping step by means of corresponding design of the shaping tool. In the case of components or semifinished parts composed of metallic sheet, the notch may be stamped in for example in the drawing tool.
Likewise also described according to the embodiments of the invention is a component produced in accordance with the method disclosed above. The component is distinguished by high functionality and stability.
The component is advantageously distinguished by the fact that at least a part of the first surface coating and/or of the second surface coating is maintained along notch surfaces.
Also disclosed is a device for carrying out the method described above.
In particular, the device is formed such that the notching and the severing, perforation or trimming of the component or of the semifinished part can be performed in one working step. By way of example, a device in the form of a perforating tool is provided, which is designed such that the notching can be performed by a hold-down means and a cutting die, and the perforation itself can be performed by means of a perforating punch, in a single pressing stroke.
Other objects, advantages and novel features of the embodiments of the present invention will become apparent from the following detailed description of one or more preferred embodiments when considered in conjunction with the accompanying drawings, in which:
The embodiments of the present invention will be discussed in detail on the basis of exemplary embodiments. The figures illustrate only those aspects of the inventive method which are of interest here; all other aspects have been omitted for the sake of clarity. Furthermore, the same reference designations are used to denote identical elements.
A component 1 is firstly provided. The component 1 is not restricted in terms of detail, and may for example be a sheet-metal component or a sandwich component. The component 1 comprises a main body 2. The main body 2 may be of single-layer or multi-layer construction. As illustrated in
The main body 2 has a first surface 3 and a second surface 4 situated opposite the first surface 3. A first surface coating 5 is provided on the first surface 3 and a second surface coating 6 is provided on the second surface 4.
The surface coatings 5, 6 may be identical or different, that is to say may be of identical or different type and form, may lie loosely on the respective surface 3, 4, or may be cohesively connected to the corresponding surface 3, 4. Exemplary surface coatings comprise at least one zinc layer, at least one zinc-aluminum layer, at least one adhesive layer and/or at least one polymer layer.
In the present example, the first surface coating 5 and the second surface coating 6 fully cover the corresponding first surface 3 and second surface 4. It is however also possible for the surface coating 5, 6 to be provided only in particular partial sections of the respective surface 3, 4, that is to say where the notching is to be performed. The first surface coating 5 has a layer thickness denoted by DOb1 on the first surface 3 of the component 1. Said layer thickness is determined perpendicular to the first surface 3 of the component 1. The second surface coating 6 has a layer thickness denoted by DOb2 on the second surface 4 of the component 1. Said layer thickness is determined perpendicular to the second surface 4 of the component 1. The layer thickness may be determined on the basis of photomicrographs.
In a following method step, notching of the component 1 is performed on the first surface 3, coated with the first surface coating 5, so as to obtain a notch 8. The notching may be performed by means of a suitable tool, in particular by means of a stamping tool. Stamping tools are particularly highly suitable for maintaining, during the notching process, at least a part of the first surface coating 5, which is notched in the process, along the notch surfaces 7 that form. In other words, not only a region of the main body 1 but likewise the first surface coating 5 situated thereon is recessed during the notching process. The first surface coating 5 may in particular also be pressed into the notch 8. It is possible here that, as a result of the notching, the layer thickness of the first surface coating DOb1, which is determined perpendicular to the first surface 3 of the component 1, is compressed. This has the result that a layer thickness of the first surface coating along the notch surfaces B is smaller than the layer thickness of the surface coating DOb1 on the first surface 3 of the component 1. The layer thickness of the first surface coating along the notch surfaces B is determined perpendicular to the corresponding notch surfaces.
The layer thickness of the first surface coating DOb1 on the first surface 3 of the component 1 advantageously amounts to at most 20 μm, and is in particular at most 15 μm. In particular, the notching is performed such that the layer thickness of the first surface coating along the notch surfaces B amounts to at least 20% and in particular at least 30% of the layer thickness of the first surface coating on the first surface of the component DOb1. This is shown in the present example. It is furthermore possible for the layer thickness of the first surface coating along the notch surfaces B to describe a gradient, and for example to decrease in the notching direction K.
As shown by way of example in
If the notching is performed from one side of the component 1, as shown here, then it is preferable for the notch depth to be as great as possible. The notch depth, which is determined in the notching direction, may extend to a depth of less than half of the thickness of the main body DG, but may in particular extend to a depth of 90% of the thickness of the main body 1 DG.
In a subsequent step, severing, perforation or trimming of the component is performed, for example by means of a mechanical cutting tool 10, along the notch 8 and for example in the notching direction K in
By contrast to the method illustrated in
The notching on the first surface 3 coated with the first surface coating 5 and on the second surface 4 coated with the second surface coating 6 is performed to a depth of in each case less than half of the thickness of the main body DG, in particular to a depth of 10 to 40% of the thickness of the main body DG. The notch tips that are formed are thus prevented from coinciding. The greater the depth to which the notch 8, 12 is formed, the larger the regions of the notch surfaces 7 that are covered with the respective surface coating 5, 6.
The notching on the first surface 3 coated with the first surface coating 5 and on the second surface 4 coated with the second surface coating 6 is performed symmetrically. Thus, the notches 8 and 12 are of identical form in terms of shape and notch depth. In this way, the first surface coating 5 and the second surface coating 6 are introduced into the notch surfaces 7 of the respective notches 8, 12 and thus functionalize the notch surfaces 7 proceeding from both surfaces 3, 4 of the component 1. It is thus made more easily possible to functionalize as large a notch surface region as possible.
In turn, during the notching process, not only a region of the main body 1 but likewise the first surface coating 5 and the second surface coating 6 situated thereon are recessed. It is furthermore possible here that, as a result of the notching, the layer thickness of the first surface coating DOb1, which is determined perpendicular to the first surface 3 of the component 1, and the layer thickness of the second surface coating DOb2, which is determined perpendicular to the second surface 4 of the component 1, are compressed. This has the result that a layer thickness of the first surface coating along the notch surfaces B is smaller than the layer thickness of the first surface coating DOb1 on the first surface 3 of the component 1. Likewise, a layer thickness of the second surface coating along the notch surfaces C is smaller than the layer thickness of the second surface coating DOb2 on the second surface 4 of the component 1. The layer thicknesses of the first and second surface coatings along the notch surfaces B, C are determined perpendicular to the notch surfaces 7.
It is also the case in the method illustrated in
The above description of the embodiments of the present invention serves merely for illustrative purposes and not for the purposes of restricting the invention. Various alterations and modifications are possible in the context of the invention without departing from the scope of the invention and of its equivalents.
The foregoing disclosure has been set forth merely to illustrate the embodiments of the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2016 201 433.1 | Feb 2016 | DE | national |
This application is a continuation of PCT International Application No. PCT/EP2017/051872, filed Jan. 30, 2017, which claims priority under 35 U.S.C. § 119 from German Patent Application No. 10 2016 201 433.1, filed Feb. 1, 2016, the entire disclosures of which are herein expressly incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2017/051872 | Jan 2017 | US |
| Child | 16050723 | US |
