Patent Application
20250121423
The present invention relates to a press system, and more particularly to the press system and method of manufacturing hot stamped structural component from sheet blank under controlled atmosphere within the press system.
Due to raising global energy crisis, and environmental problems, automobile manufacturers are focusing on light weight technologies to improve the fuel efficiency of vehicles. The use of high-strength steels has become an inevitable trend for the sake of weight reduction and to improve safety. Press forming such as hot stamping is one of the manufacturing process being employed to manufacture such high strength steel components. In conventional hot stamping process, a workpiece (such as boron steel sheet blank) is heated in a conventional furnace to above the austenite transformation temperature and held for few minutes to achieve the austenite phase throughout its volume. Then the work-piece is quickly transferred within ˜10 seconds from the furnace to the stamping tool and quickly deformed into the required shape while being rapidly quenched to produce a final product predominately with a martensitic phase. In conventional electrical furnace, the workpiece is heated through radiation.
However, these conventional furnaces require more energy and consumes more time for heating of workpiece (boron steel) to its austenitic temperature. Apart from energy, furnaces require huge space for installation and reduces the productivity. Further, during heating time (˜3 min) in furnace and transfer time (˜10 seconds) from furnace to hot stamping press, steel sheet blanks such as uncoated boron steel reacts with atmosphere air and steel surface gets oxidized, and scales are generated on the surface of the steel sheet blanks. If scales exist on the steel sheets it may not be acceptable for automotive applications. Steel gets oxidized at high temperature when it reacts with atmosphere. Rate of oxidation is also dependent on the steel temperature and reaction time. Hence, it would be desirable to develop a press system having heating and stamping technique for workpieces which will reduce reaction time for surface oxidation.
It is an object of the invention to solve the problems of the prior art and to provide a press system comprising a new heating and stamping technique which increases productivity.
Another objective of the present invention is to develop a press system having a controlled atmosphere system which will reduce reaction time for surface oxidation and thereby reduces oxidation scale.
It is further another objective of the present invention to provide a press system which provides atmosphere control during forming phase to suppress generation of oxide scales.
This summary is provided to introduce concepts related to press system and method of manufacturing hot stamped structural component from sheet blank within press system. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
In one aspect of the present invention, a press system is provided. The press system comprises a controlled atmosphere system, and a press tool apparatus for manufacturing hot stamped structural component. The press tool apparatus comprises a lower body member, an upper body member corresponding to lower body member. The upper body member and the lower body member are configured to move with respect to one another. The press tool apparatus also comprises a press-tool chamber defined between the lower body member and the upper body member. The press tool apparatus further comprises an upper die member and a lower die member disposed within the press-tool chamber. The upper die member is coupled to the upper body member and the lower die member is coupled to the lower body member. The press tool apparatus comprises a heating device disposed within the press-tool chamber. The heating device is configured to heat a sheet blank. The upper die member and the lower die member are configured to perform hot blanking with stamping and in-die quenching on the heated sheet blank in the atmosphere controlled by the controlled atmosphere system to form the hot stamped structural component.
In an embodiment, controlling the atmosphere during formation of the hot stamped structural component suppresses generation of scales on the hot stamped structural component.
In an embodiment, the controlled atmosphere system encloses the press tool apparatus.
In an embodiment, the controlled atmosphere system is disposed between the lower body member and the upper body member.
In an embodiment, the controlled atmosphere system comprises an enclosure having at least one door, and an atmosphere control means.
In an embodiment, the enclosure encloses the press tool apparatus, and the atmosphere control means controls the atmosphere within the enclosure. In an embodiment, the enclosure is a room.
In an embodiment, the atmosphere control means is configured to control the atmosphere by controlling the air flow rate.
In an embodiment, the atmosphere control means is configured to control the atmosphere by filling with any medium which reduces oxygen content (reducing atmosphere), wherein the medium is any one of a solid medium, a liquid medium, or a gaseous medium.
In an embodiment, the atmosphere control means is configured to control the atmosphere by filling with an inert gas selected from any one of nitrogen gas, helium gas or argon gas.
In an embodiment, the enclosure and the at least one door are manufactured from material selected from any one of plastic, resin, wood, metal, alloy or composite material.
In an embodiment, the enclosure encloses the press-tool chamber and the atmosphere control means controls the atmosphere within the press tool chamber.
In an embodiment, the controlled atmosphere system is configured to completely isolate the press-tool chamber from the surrounding atmosphere.
In an embodiment, the press system comprises a sheet blank raw material unit and a finished product collection unit.
In an embodiment, the controlled atmosphere system is equipped with the sheet blank raw material unit on one side and the finished product collection unit on the other side. The sheet blank raw material unit is configured to provide sheet blanks to the press tool apparatus and the finished product collection unit is configured to receive the hot stamped structural component from the press tool apparatus.
In an embodiment, the heating device is a resistance heating device using joules heating principle.
In an embodiment, the heating device comprises a power source, and a plurality of electrodes including a first electrode, a second electrode, a third electrode and a fourth electrode.
In an embodiment, the press tool apparatus comprises at least one clamping device configured to selectively engage or disengage at least one of the plurality of electrodes.
In an embodiment, the press tool apparatus comprises two clamping devices including a first pneumatic cylinder, and a second pneumatic cylinder. The first pneumatic cylinder is configured to selectively engage or disengage the third electrode with the first electrode and the second pneumatic cylinder is configured to selectively engage or disengage the fourth electrode with the second electrode.
In an embodiment, the plurality of electrodes are copper electrodes. In an embodiment, the sheet blank is uncoated boron steel sheet blank.
In an embodiment, the sheet blank is of thickness ranging between 0.6 mm to 2.0 mm.
In an embodiment, the upper die member and the lower die member are configured to operate at predetermined temperatures.
In an embodiment, the upper body member and the lower body member are moved relative to the one another via any one of a mechanical arrangement or a hydraulic arrangement.
In an embodiment, the heating device is an induction heating device.
In an embodiment, the press system comprises a control system, and a closed loop feedback system. The closed loop feedback system is configured to monitor and communicate the information relating to the controlled atmosphere system and the press-tool apparatus to the control system configured to control the press system.
In another aspect of the present invention, a method of manufacturing a hot stamped structural component from a sheet blank within a press system is provided. The press system comprises a controlled atmosphere system comprising an enclosure having at least one door, and an atmosphere control means. The press system also comprises a press tool apparatus. The press tool apparatus comprises a lower body member and an upper body member corresponding to lower body member. The upper body member and the lower body member are configured to moved relative to the one another. The press tool apparatus further comprises a press-tool chamber defined between the lower body member and the upper body member. The press tool apparatus comprises an upper die member and a lower die member disposed within the press-tool chamber. The upper die member is coupled to the upper body member and the lower die member is coupled to the lower body member. The press tool apparatus comprises a heating device disposed within the press-tool chamber. The heating device comprises a plurality of electrodes coupled to a power source. The method comprises transferring the sheet blank onto the plurality of electrodes. The method also comprises closing the at least one door of the enclosure and controlling the atmosphere within the enclosure via the atmosphere control means. The method further comprises clamping the sheet blank between the plurality of electrodes via at least one clamping device. The method comprises heating the sheet blank to a first predetermined temperature by supplying power to the plurality of electrodes from the power source. The method also comprises unclamping the heated sheet blank by retracting the at least one clamping device. The method further comprises moving the upper body member with respect to the lower body member. The method comprises performing hot blanking with stamping and in-die quenching on the heated sheet blank by the upper die member and the lower die member in controlled atmosphere to form the hot stamped structural component.
In an embodiment, the first predetermined temperature ranges from about 350° C. to 950° C. In an embodiment, the first predetermined temperature ranges from about 750° C. to 950° C. In an embodiment, the first predetermined temperature is 900° C.
In an embodiment, controlling the atmosphere during formation of the hot stamped structural component suppresses generation of scales on the hot stamped structural component.
In an embodiment, the press system comprises a non-contact pyrometer to detect the temperature of the sheet blank.
In an embodiment, the press system comprises a control system, and a closed loop feedback system, wherein the closed loop feedback system is configured to monitor and communicate the information relating to the controlled atmosphere system and the press-tool apparatus to the control system configured to control the press system.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
The drawings referred to in this description are not to be understood as being drawn to scale except if specifically noted, and such drawings are only exemplary in nature.
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Referring to
In the illustrated example, the sheet blank (110) is uncoated boron steel sheet blank. Alternatively, the sheet blank (110) may be any steel or alloys such as aluminium alloys, titanium alloys, magnesium alloys etc., without any limitations. In the illustrated example, the sheet blank (110) is of thickness ranging between 0.6 mm to 2.0 mm. Alternatively, the sheet blank (110) may be of any thickness, without limiting the scope of the invention.
Referring to
The press tool apparatus (100) comprises a heating device (102). The heating device (102) is configured to heat the sheet blank (110). In the illustrated example, the heating device (102) is a resistance heating device using joules heating principle. The heating device (102) heats the sheet blank (110) using joules heating principle. In another example, the heating device (102) is an induction heating device. The sheet blank (110) can be heated for a predetermined amount of time to a predetermined temperature by the heating device.
The heating device (102) comprises a power source (116) (shown in
The press tool apparatus (100) comprises at least one clamping device (130) configured to selectively engage or disengage at least one of the plurality of electrodes (114). The press tool apparatus (100) comprises two clamping devices (130) including a first pneumatic cylinder (130a), and a second pneumatic cylinder (130b). In the illustrated example, the clamping devices (130) are illustrated to be pneumatic cylinders. Alternatively, the clamping devices (130) may be mechanical or hydraulic clamping devices, without any limitations. The second electrode (114b) is supported by the first pneumatic cylinder (130a) and the fourth electrode (114d) is supported by the second pneumatic cylinder (130b). The first pneumatic cylinder (130a) is configured to selectively engage or disengage the third electrode (114c) with the first electrode (114a) and the second pneumatic cylinder (130b) is configured to selectively engage or disengage the fourth electrode (114d) with the second electrode (114b).
The press tool apparatus (100) comprises a lower body member (106) and an upper body member (104) corresponding to lower body member (106). The upper body member (104) and the lower body member (106) are configured to move with respect one another. The upper body member (104) and the lower body member (106) are moved relative to the one another via any one of a mechanical arrangement or a hydraulic arrangement. In the illustrated example, the upper body member (104) is moved relative to the lower body member (106) via hydraulic arrangement (not shown). In another example, the lower body member (104) may be moved relative to the upper body member (104), without any limitations. The lower body member (106) and the upper body member (104) define a press-tool chamber (118) (shown in
The press tool apparatus (100) comprises an upper die member (120) and a lower die member (122). In the illustrated example, the upper die member (120) and the lower die member (122) are disposed within the press-tool chamber (118).
The upper die member (120) is coupled to the upper body member (104) and the lower die member (122) is coupled to the lower body member (106). Additional base members (shown not numbered) and fastening members (not shown) may be used to couple the die members to the body members.
In the illustrated example, the upper die member (120) and the lower die member (122) are provided with blanking tools (not shown) to blank/trim the sheet blank (110). Different types of blanking tools known in the art may be used to perform different blanking operations on the sheet blank (110), without any limitations. In another example, only one of the upper die member (120), and the lower die member (122) are provided with the blanking tool, without any limitations. The upper die member (120) and the lower die member (122) are configured to operate at predetermined temperatures. A cooling unit (not shown) circulating coolant such as cooling water or a dry ice coolant through circulating members such as pipelines provided within the upper die member (120) and the lower die member (122) makes it possible to operate the upper die member (120) and the lower die member (122) at predetermined temperatures.
The upper die member (120) and the lower die member (122) are configured to perform hot blanking with stamping and in-die quenching on the heated sheet blank (110). The interaction of the upper die member (120) of the press tool apparatus (100) and the lower die member (122) of the press tool apparatus (100) results in a profiling of the sheet blank (110).
Referring to
Referring to
The controlled atmosphere system (170) is equipped with the sheet blank raw material unit (202) on one side and the finished product collection unit (204) on the other side. The sheet blank raw material unit (202) is configured to provide sheet blanks (110) to the press tool apparatus (100) and the finished product collection unit (204) is configured to receive the hot stamped structural components (111) from the press tool apparatus (100).
In the illustrated example, the controlled atmosphere system (170) encloses the press tool apparatus (100). The enclosure (172) encloses the press tool apparatus (100), and the atmosphere control means (176) controls the atmosphere within the enclosure (172). The controlled atmosphere system (170) enclosing the press tool apparatus (100) substantially isolates the press tool apparatus (100) from the surrounding atmosphere. In another example, the enclosure (172) is a room.
In another example (not shown), the controlled atmosphere system (170) may be disposed between the lower body member (106) and the upper body member (104) enclosing the press-tool chamber (118). The controlled atmosphere system (170) is configured to isolate the press-tool chamber (118) from the surrounding atmosphere.
The enclosure (172) and the at least one door (174) in both the examples are manufactured from material selected from any one of plastic, resin, wood, metal, alloy or composite material.
In the illustrated example, the controlled atmosphere system (170) comprises the enclosure (172) having one door (174). Alternatively, the enclosure (172) of the controlled atmosphere system (170) may have more than one door (174), without limitations. The enclosure (172) comprises at least one slot (175). In the illustrated example, the enclosure (172) comprises two slots (175), one of the slot (175) (as shown in
During operation, the controlled atmosphere system (170) controls the atmosphere within the enclosure (172), as the upper die member (120) and the lower die member (122) performs hot blanking with stamping and in-die quenching on the heated sheet blank (110). Controlling the atmosphere during formation of the hot stamped structural component (111) suppresses generation of scales on the hot stamped structural component (111).
A plurality of manipulators (not shown) may be used to transfer the sheet blank (110) from the sheet blank raw material unit (202) to the press tool apparatus (100) and to transfer the hot stamped structural component (111) to the finished product collection unit (204) from the press tool apparatus (100).
Referring to
At step (302), the at least one door (174) of the controlled atmosphere system (170) is closed and the atmosphere within the enclosure (172) is controlled by the atmosphere control means (176).
At step (303), the sheet blank (110) disposed between the plurality of electrodes (114) is clamped by the at least one clamping device (130). The first pneumatic cylinder (130a) engages the third electrode (114c) with the first electrode (114a) and the second pneumatic cylinder (130b) engages the fourth electrode (114d) with the second electrode (114b) to clamp the sheet blank (110) between the plurality of electrodes (114).
At step (304), the sheet blank (110) is heated to a first predetermined temperature by supplying power to the plurality of electrodes (114) from the power source (116). The first predetermined temperature ranges from about 350° C. to 950° C. based on the material of sheet blank (110) selected. In the illustrated example, the first predetermined temperature ranges from about 750° C. to 950° C. More particularly, the first predetermined temperature is in a temperature range of austenite formation. In the illustrated example, the first predetermined temperature is 900° C. The non-contact pyrometer is configured to detect/monitor the surface temperature of the sheet blank (110) and send the information to the control system (251) via the closed loop feedback system (252).
At step (305), the heated sheet blank (110) is unclamped by retracting the at least one clamping device (130). The first pneumatic cylinder (130a) disengages the third electrode (114c) with the first electrode (114a) and the second pneumatic cylinder (130b) disengages the fourth electrode (114d) with the second electrode (114b). The heated sheet blank (110) rest on the lower die member (122).
At step (306), the upper body member (104) of the press tool apparatus (100) is moved with respect to the lower body member (106). At step (307), hot blanking with stamping and in-die quenching on the heated sheet blank (110) is performed by the upper die member (120) and the lower die member (122) in controlled atmosphere to form the hot stamped structural component (111).
A prior art hot stamped structural component manufactured using conventional process (and system) is shown in
Stress strain curves of different portions of the prior art hot stamped structural component and the hot stamped structural component (111) are shown in
The present invention relates to the press system (200) utilizes less space, investment and is energy efficient. The disclosed press system (200) comprises heating device (102) which provides fast heating of the sheet blank (110). The press system (200) comprising the controlled atmosphere system (170) controls the atmosphere surrounding the press tool apparatus (200), thereby reducing the oxide scale significantly as compared to conventional processes. The fast heating within press tool chamber (118) and hot stamping within controlled atmosphere reduces/eliminates oxide scale. Reduction in oxide scale reduces the tool pollution and requirement of cleaning the tool after each stroke is reduced as tool pollution is minimized and/or eliminated, thereby increasing productivity. Further the hot stamped structural component (111) formed within the disclosed press system (200) have equal or better mechanical and microstructural properties than components formed from conventional processes. As, oxide scales are reduced or eliminated, additional process such as shot blasting etc., which were required to remove scale in the conventional processes may be eliminated.
Furthermore, the terminology used herein is for describing embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202131039596 | Sep 2021 | IN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2022/058201 | 9/1/2022 | WO |
