EP2845662B1

EP2845662B1 - Press and method for the manufacture of a profile

Info

Publication number: EP2845662B1
Application number: EP13182920.2A
Authority: EP
Inventors: Gökhan Dogan; Yavuz Kapsiz; Fatih Önhon; Emrah Bayrak
Original assignee: Ford Otomotiv Sanayi AS; Ford Motor Co
Current assignee: Ford Otomotiv Sanayi AS; Ford Motor Co
Priority date: 2013-09-04
Filing date: 2013-09-04
Publication date: 2018-11-14
Anticipated expiration: 2033-09-04
Also published as: EP2845662A1

Description

The present invention relates to a press and a method for pressing a profile, as well as a method of manufacturing a vehicle. It is known and widely used to generate a profile from a sheet metal by using a press comprising an upper die and a lower die. The dies transfer their contours to the workpiece while closing the press.
US 4926676 A shows a forming process for producing sharp corners in sheet metal, and a press brake useful in carrying out such process. The press brake involves a male forming die incorporating a nipple for extruding the sheet metal stock material into the adjacent region defined by the female coining die for forming a sharp corner in the workpiece.
JP S59220227 , on which the preamble of the independent claims 1 and 3 is based, shows a forming method of a thin plate. In the method grooves are formed at specified positions of four faces of a hole of a forming die, and pressing tools that fit to the grooves are provided. Recessed parts are formed at specified positions on four faces of a punch, and the periphery of the thin plate to be formed is pressed between a flat part of the die and a wrinkle presser. Then, it is drawn by the punch and a formed product is obtained. A straight side of the formed product is bent to the inside by the pressing tool and a pressure ram. The pressing tool is returned to the groove and the presser is raised and the formed product is removed. The straight side of the formed product is returned to a specified shape by spring back.
EP 1752984 A2 relates to a clamping plate, a cartridge case, an information medium, a mold, and a method of manufacturing the clamping plate. The clamping plate includes a main body comprising: a recess circular in plan view formed in a central portion thereof, the recess having an inner peripheral wall inclined such that the recess is gradually reduced in diameter from an opening toward a bottom thereof; and an outer peripheral portion formed by an annular plate body such that the outer peripheral portion surrounds the opening, wherein the main body has a groove formed at an imaginary intersecting portion between an imaginary extended surface of a rear surface of the outer peripheral portion and an imaginary extended surface of a rear surface of the inner peripheral wall, along an imaginary line of intersection of the two imaginary extended surfaces the groove being recessed from the two imaginary extended surfaces.
It is an objective of the present invention to provide an improved press for generating a profile with smaller tolerances.
According to the present invention, this objective is achieved by a press as claimed in claim 1 and by a method as claimed in claim 3. The depending claims contain further developments of the invention.
According to a first aspect of the present invention a press according to claim 1 is provided. The press includes an upper die and a lower die. The upper die comprises at least one bulge at a front section. The bulge protrudes from an intermediate portion and is convexly formed with a bulge radius. The bulge merges into a transition radius at the intermediate portion, wherein the bulge radius and the transition radius have a ratio in a range of 2/3 to 1/2. By this measure, the workpiece to be treated can be fixed in a certain position before bending. The workpiece is prevented from a spring-back. The press allows generating a profile with smaller tolerances. Additional processes are not necessary for achieving the desired shape. The convex contour of the bulge prevents from increasing tensions inside the profile and from the formation of cracks. By the bulge an impression can be generated. Thus, the bulge has two functions. Additional means for fixing the workpiece are not necessary. Costs can be reduced.
In a still further development of the inventive press the at least one bulge is arranged at an edge of the upper die. By this measure, an impression can be generated in a junction portion of the profile. The impression at the junction portion increases the hardness of the junction portion. Thus, the junction portion is less elastic.
According to a second aspect of the present invention a method of manufacturing a profile according to claim 3 is provided.
The profile obtained includes at least one web and at least one flange, wherein the flange is substantially arranged transversal to the web. The profile comprises at least one impression accommodated at a junction portion. In particular the profile is U-shaped. By this measure, the profile obtained is dimensionally very accurate. Thus, a subsequent processing is greatly simplified. Products made from the profile show a higher quality. In particular the production of trucks is simplified by using such profiles.
According to a further development of the present invention a method of manufacturing a vehicle is provided. The vehicle obtained includes at least one such profile, in particular as a side member. Thus, the benefits of the profile will benefit the vehicle.
Further features, properties and advantages of the present invention will become clear from the following description of embodiments in conjunction with the accompanying drawings.

Figure 1: shows an inventive press and method.
Figure 2: shows a detail of an upper die of the press.
Figure 3: shows an inventive profile.
Figure 4: shows an inventive vehicle.

The present invention will now be described, by way of example, with reference to the accompanying drawings, in which Fig. 1 shows an inventive press 10 while performing a pressing method 40.
The inventive press 10 includes an upper die 11 and a lower die 12. Between the upper die 11 and the lower die 12 a workpiece 13 is provided for performing the inventive pressing method 40. In particular the workpiece 13 is a thick sheet metal. For closing the press 10 the upper die 11 is moved in a pressing direction 41. For treating the workpiece 13 the upper die 11 is moved in the pressing direction 41. Thus, the upper die 11 moves into the space enclosed by the lower die 12. The workpiece 13 is forced to change its shape according to the shape of the upper die 11 and the lower die 12. After the pressing method 40 performed by the press 10 the workpiece 13 becomes an inventive profile 20.
In the shown embodiment the press 10 is designed so as to form a U-profile 20. However, it is also conceivable that the press 10 is designed for forming an I-profile or a T-profile etc. The profile 20 obtained by the present invention includes at least one web 21 and at least one flange 22, wherein the web 21 is substantially accommodated transversal to the flange 21.
The upper die 11 of the inventive press 10 comprises a front section 19. An exemplary embodiment of the front section 19 is shown in Fig. 2. According to the present invention the upper die 11 comprises at least one bulge 16. In particular the at least one bulge 16 is accommodated at an edge of the front section 19.
The bulge 16 has a height 15. The bulge 16 protrudes from an intermediate portion 26 of the upper die 11 with the height 15. The upper die 11 comprises a sidewall 27. In particular the sidewall 27 is inclined in a wall angle 14 as compared to the pressing direction.
The bulge 16 is convexly formed with a bulge radius 17. The bulge 16 merges into a transition radius 18 at the intermediate portion 26 of the upper die 11. The bulge radius 17 and the transition radius 18 have a ratio in a range of 2/3 to 1/2. The bulge radius 17 may be 9 mm, for example. The transition radius 18 may be 15 mm, for example. The height 15 of the bulge 16 may be 7.5 mm, for example. The wall angle 14 may be 2°, for example.
In the pressing method 40 the upper die 11 is moved toward the workpiece 13 while the workpiece 13 is arranged on the lower die 12. The front section 19 of the upper die 11 shows in the pressing direction 41. When the upper die 11 is moved the at least one bulge 16 of the upper die 11 contacts the workpiece 13 first. The bulge 16 fixes the workpiece 13 before the bending process starts by continuing the movement of the upper die 11 in pressing direction 41. The bulge 16 strains the workpiece 13. Thus, the workpiece 13 is held in position and prevented from a springback. The bulge 16 touches and squeezes the workpiece 13 slightly. By continuing the closing of the press 10 the workpiece 13 is completely formed by the upper die 11. The height 15 of the bulge 16 projects into the inside contour of the workpiece 13. Thereby, an impression 25 is generated in the workpiece 13 while closing the press 10.
Fig. 3 shows an embodiment of the obtained profile 20 in a cross-sectional view. Said profile 20 comprises at least one web 21 and one flange 22. The web 21 is substantially accommodated transversal to the flange 21. In particular the profile 20 has a U-shape as shown in Fig. 3.
The area where the web 11 and the flange 22 merge is defined as a junction portion 28. Said profile 20 comprises at least one impression 25 at the junction portion 28. In particular the at least one impression 25 is accommodated at an inner side 23 of the profile 20. The inner side 23 is defined as the side enclosed by the flange 22. The outer side 24 is defined as the side, which is not enclosed by a flange 22. Thus, a double T-profile comprises two inner sides 23 and no outer side 24. In particular the profile 20 includes one web 21, two flanges 22, two junction portions 25 and two impressions 25 as shown in Fig. 3.
Fig. 4 shows an exemplary embodiment of the obtained vehicle 30. Said vehicle 30 includes at least one said profile 20. The profile 20 may be arranged in a frame 32 of the vehicle. In particular the profile 20 is a side member of the frame 32.
In particular the vehicle 30 is a lorry respectively a truck. The present vehicle 30 according to Fig. 4 is a truck including a lead frame 32 and a passenger cabin 31. The shown vehicle 30 comprises also wheel guards 33 fixed to the lead frame 32.

List of reference numerals

10: Press
11: Upper Die
12: Lower Die
13: Workpiece
14: Wall Angle
15: Height
16: Bulge
17: Bulge Radius
18: Transition Radius
19: Front Section
20: Profile
21: Web
22: Flange
23: Inner Side
24: Outer Side
25: Impression
26: Intermediate Portion
27: Sidewall
28: Junction Portion
30: Vehicle
31: Passenger Cabin
32: Frame
33: Wheel Guard
40: Pressing Method
41: Pressing Direction

Claims

A press (10) including an upper die (11) and a lower die (12), wherein the upper die (11) comprises at least one bulge (16) at a front section (19), wherein the bulge (16) protrudes from an intermediate portion (26) and is convexly formed with a bulge radius (17), characterised in that the bulge (16) merges into a transition radius (18) at the intermediate portion (26), wherein the bulge radius (17) and the transition radius (18) have a ratio in a range of 2/3 to 1/2.
The press (10) as claimed in claim 1, characterised in that the at least one bulge (16) is arranged at an edge of the upper die (11).
A method of manufacturing a profile (20), the profile (20) including at least one web (21) and at least one flange (22) substantially arranged transversal to the web (21), the profile (20) further comprising at least one impression (25) accommodated at a junction portion (28) thereof, characterised by generating said profile (20) by means of a press as claimed in claim 1 or 2.
A method of manufacturing a vehicle (30) characterised in that it comprises the manufacture of at least one profile (20) according to the method of claim 3.
The method of manufacturing a vehicle (30) as claimed in claim 4, characterised in that the at least one profile (20) is a side member.