Impact absorber mount and method for manufacturing an impact absorber mount designed as a hybrid forged component

Abstract

Impact absorber mount (100) for a motor vehicle, which is manufactured as a hybrid forged component, comprising a metallic base component (110) and a metallic attachment component (120) which is connected to the base component (110), characterized in that the base component (110) is a forged part which is designed as an impact plate, and that the attachment component (120) is a tab-like sheet metal part which functions as a fixing tab, wherein the tab-like sheet metal part (120) has a connecting section (125) with which it is forged into the base component (110) designed as an impact plate in a form-fit and / or material-fit manner.

Description

[0001] According to the preamble of claim 1, the invention relates to an impact absorber mount for a motor vehicle, which is manufactured as a hybrid forged component, comprising a metallic base component and a metallic attachment connected to the base component. The invention further relates to a method for producing an impact absorber mount designed as a hybrid forged component.

[0002] DE 10 2009 049 872 B4 describes an impact absorber mount consisting of several sheet metal parts, namely a baffle plate and at least one adapter part, for attachment to a hollow-profile longitudinal member of a body structure. Among other things, a one-piece design is described in which an adapter part is molded onto the baffle plate (cf. Fig. 4). A two-part design is also described, in which the impact plate and an adapter part (4) are connected after their manufacture (cf. Fig. 6).

[0003] DE 10 2010 037 123 A1 describes a hybrid component produced by forging and a method for its production. The method can be used in cases where, due to the material selection and mechanical stresses, a hybrid combination of materials appears necessary, so that a hybrid forging process creates a new material combination and thus a component with new mechanical properties. The method provides for the first step of producing a preform of a first component by forming a raw material consisting of a wrought aluminum alloy.In a subsequent processing step, a hybrid component is created by forging a further component made of a stiffer material onto the preform of the first component while simultaneously further forming the first component, which has the property of providing a tensile-loadable connection between the first and the further component.

[0004] Regarding the state of the art, reference is also made to DE 10 2012 007 733 A1 and DE 10 2017 120 278 A1.

[0005] The invention is intended to demonstrate a possibility of achieving a high level of functional integration (which means combining as many requirements and subtasks as possible) in an impact absorber mount and at the same time meeting high safety requirements.

[0006] This is achieved with the inventive impact absorber mount of patent claim 1. The independent patent claim also extends the invention to a manufacturing method according to the invention. Further developments and refinements of the invention are evident for both subject matters from the dependent patent claims, the following description of the invention, and the drawings.

[0007] The impact absorber mount according to the invention is a formed component, which is understood to mean a component produced essentially by forming. The impact absorber mount according to the invention has a metallic base component (base body) and a metallic attachment which is connected to the base component. According to the invention, the base component is a forged component and the attachment has (at least) one connecting section with which it is forged into the base component in a form-fitting and / or material-fitting manner, which is understood to mean that the connecting section is embedded in the base component in a form-fitting and / or material-fitting manner, in particular in a form-fitting and material-fitting manner, wherein the form-fitting and / or material-fitting connection is achieved by forming the base component during its forging process.The impact absorber mount according to the invention is a formed component consisting of several individual parts joined together by forging, which can also be referred to as a hybrid forged component.

[0008] Forging refers to the pressure forming of a solid (metallic), especially heated, workpiece (blank). Within the scope of the invention, drop forging in a forming forging die is particularly envisaged.

[0009] The base component formed as a forged part has better strength properties than a sheet metal part or cast part. However, the limited shaping during forging makes functional integration difficult, which is why, according to the invention, this is achieved by an add-on part. The add-on part thus has at least one intended function (fixing function), so that functional integration is successful with the add-on part. Such an add-on part can therefore also be referred to as a functional component. Forging creates a very resilient connection between the base component and the add-on part. In particular, forging can create a (material-locking) cold weld, even with different metals. The forged connecting section can also function as reinforcement, in particular as load path reinforcement, of the forged part. The invention also enables new lightweight construction concepts.

[0010] The attachment part is a sheet metal part, i.e., a component made of sheet metal that forms a fixing tab or similar. In particular, this is a sheet steel or aluminum part.

[0011] The forged base component can be made from an aluminum, magnesium, or zinc alloy (which particularly means a wrought alloy). The add-on part can be made from almost any metal alloy, with the add-on part preferably being made from an aluminum or steel alloy. This results in numerous possible material combinations, with it being preferably provided that the base component is made from aluminum (i.e., an aluminum alloy) and the add-on part is made from steel (i.e., a steel alloy) or from aluminum (i.e., an aluminum alloy). The impact absorber mount according to the invention can have a plurality of add-on parts, which can also be made from different metals.

[0012] According to the invention, it is provided that the base component forms a baffle plate and that the attachment part forms a fixing part, namely a fixing tab.

[0013] The manufacturing method according to the invention for producing the impact absorber mount designed as a hybrid forged component comprises at least the following steps, which are to be carried out in this order: - Providing a solid blank, in particular a solid aluminum blank, for the base component and providing the attachment, wherein the attachment is a sheet metal part; - inserting the blank and the attachment into a forging die or the like, which is installed in particular in a forging press, wherein the blank is formed with a recess into which the connecting section of the attachment is inserted; - carrying out a forging process, in particular by closing the forging die by means of the forging press, whereby the blank is formed or forged into the base component and the connecting section of the attachment is also forged into the base component in a form-fitting and / or material-fitting manner; - Opening the forging die and removing or demoulding the produced impact absorber holder.

[0014] Advantageously, the method according to the invention enables the economical production of a respective impact absorber holder (see above), virtually in only one operation without subsequent joining operations.

[0015] The connecting section of the attachment can be designed with additional form-locking elements, such as holes or recesses, which lead to an improved form-locking with the base component when forged.

[0016] Preferably, the blank is preheated to a suitable forging temperature (e.g., 460°C to 500°C for an aluminum blank) and then inserted into the forging die in the heated state. The attachment, however, is preferably inserted into the forging die in a cold state (e.g., at room temperature) to promote cold welding during forging. However, the attachment can also be preheated to a specific temperature and then inserted into the forging die in the heated state.

[0017] The blank can have (at least) one recess into which the connecting section of the attachment is inserted. Insertion takes place before the forging process, i.e., at the latest, when it is inserted into the forging die. The recess is designed, for example, as a slot. This allows the blank and the connecting section of the attachment to be arranged in such a way that a favorable starting position for forging in the subsequent forging process is created.

[0018] Preferably, the attachment (sheet metal part) made of sheet metal is formed into a desired final shape in the forging die. This forming process preferably takes place before the forging process begins, in particular when the forging die is closed. The forging die is suitably designed.

[0019] The invention is explained in more detail below with reference to the drawing. Fig. 1 shows a perspective view of an impact absorber mount according to the invention. Fig. 2 illustrates in a sectional view the production of the impact absorber holder from Fig. 1 in a forging die.

[0020] The Fig. 1, the impact absorber mount 100, shown only schematically, is attached to the front side of a body longitudinal member. The impact absorber mount 100 is a formed component and has a forged base component or base module 110, which is designed as a so-called impact plate, and an attachment 120, which is designed as a tab-like sheet metal part. The attachment 120 functions here as a fixing tab, which was previously attached to the longitudinal member as a separate component. The attachment 120 has an indicated connecting section 125, which is forged into the base component or impact plate 110 in a form-fitting and / or material-fitting manner. Preferably, both the solid base component 110 and the attachment 120 made of sheet metal material are made of aluminum.

[0021] The Fig. 2, the forging die 200 shown only schematically comprises a lower die 210 and an upper die 220 which enclose a cavity 230. For the production of the Fig. 1, a heated solid blank (forging blank) R and the attachment 120 are placed together in the lower die 210 (with the forging die 200 open). As described above, the blank R can have a recess, in particular a slot-like recess, into which the connecting portion 125 of the attachment 120 is inserted. The lower die 210 has a fixing recess 215 for the attachment 120. A forging process is then carried out, as illustrated by the arrows F, wherein the blank R is formed into the intended final shape of the impact plate 110. In this process, the connecting portion 125 of the attachment 120 is also forged into the base component or the impact plate 110 in a form-fitting and / or material-fitting manner, creating a permanent connection.

[0022] As in Fig.As indicated in Figure 2, the connecting section 125 of the attachment 120 can be formed with bores or other additional form-locking elements, which lead to an improved undercut form-locking with the base component or the impact plate 110. The recesses or openings 115 in the impact plate 110 can be created in a manner known per se by punching the blank R.

Claims

[1] Impact absorber mount (100) for a motor vehicle, which is manufactured as a hybrid forged component, with a metallic base component (110) and a metallic attachment part (120) which is connected to the base component (110), characterized by that the base component (110) is a forged part which is designed as an impact plate, and that the attachment part (120) is a tab-like sheet metal part which functions as a fixing tab, wherein the tab-like sheet metal part (120) has a connecting section (125) with which it is forged in a form-fitting and / or material-fitting manner into the base component (110) designed as an impact plate. [2] Impact absorber holder (100) according to claim 1, characterized by that the attachment part (120) designed as a tab-like sheet metal part is a steel sheet or an aluminum sheet part. [3] Impact absorber holder (100) according to claim 1, characterized bythat both the base component (110) designed as a baffle plate and the attachment part (120) designed as a tab-like sheet metal part are made of aluminum. [4] Method for producing an impact absorber mount (100) designed as a hybrid forged component, with a metallic base component (110) and a metallic attachment part (120) which is connected to the base component (110), wherein the base component (110) is a forged part and the attachment (120) has a connecting section (125) with which it is forged into the base component (110) in a form-fitting and / or material-fitting manner, and wherein the base component (110) is designed as a baffle plate and the attachment part (120) is designed as a tab-like sheet metal part which functions as a fixing tab, comprehensively the following steps: - Providing a solid blank (R) for the base component (110) and providing the attachment (120), wherein the attachment (120) is a sheet metal part; - inserting the blank (R) and the attachment (120) into a forging die (200), wherein the blank (R) is formed with a recess into which the connecting section (125) of the attachment (120) is inserted; - carrying out a forging process, wherein the blank (R) is formed into the base component (110) and the connecting section (125) of the attachment (120) is forged into the base component (110) in a form-fitting and / or material-fitting manner; - Opening the forging die (200) and removing the manufactured impact absorber holder (100). [5] Method according to claim 4, characterized by that the recess in the blank (R) is a slot into which the connecting section (125) of the attachment part (120) designed as a sheet metal part is inserted. [6] Method according to claim 4 or 5, characterized by that the connecting section (125) of the attachment (120) is formed with additional form-locking elements. [7] Method according to one of the preceding claims 4 to 6, characterized by that the blank (R) is inserted into the forging die (200) in the heated state and the attachment (120) in the cold state. [8] Method according to one of the preceding claims 4 to 7, characterized by that the attachment (120) is formed in the forging die (200) before the forging process begins.

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