Forging processes, in particular lightweight alloy forging processes

Abstract

Forging process, wherein in at least one forging step (12, 14) a forged component (16) designed as a spring fork is formed in a forging tool designed as a die, wherein in at least one process step (22) after a forging process a bending process of the forged component (16) is carried out, wherein the bending process of the forged component (16) is carried out about a transverse axis which runs transversely to a longitudinal axis of the forged component (16), characterized in that in the forging step (12, 14) a bionic or a truss-like structure is introduced in a bearing area (38) of the forged component (16) and in a further bearing area (44) by means of a forging tool designed as a roughing die or as a finishing die.

Description

State of the art

[0001] The invention relates to a forging process, in particular a lightweight alloy forging process, according to the preamble of claim 1.

[0002] From DE 10 2012 005 863 A1, a forging process, in particular a lightweight alloy forging process, and at least one forged component produced by means of the forging process are already known, wherein in the already known forging process, in at least one process step, in particular in a forging forming step, the forged component is formed in a forging tool, in particular in a die.

[0003] Furthermore, forging processes and at least one forged component produced by means of the respective forging process are already known from US 2011 / 0 302 984 A1 and DE 10 2011 002 208 A1, wherein in at least one forging forming step the forged component is formed in a forging tool, in particular in a die, and in at least one process step a bending forming of the forged component takes place.

[0004] Furthermore, a swivel bearing with a damper clamp is already known from EP 3 409 401 A1, which is preferably manufactured by a casting process, although a forging process for manufacturing the swivel bearing is also conceivable. Bending the swivel bearing after forging is not known from EP 3 409 401 A1.

[0005] Furthermore, a forging process for manufacturing a wheel or wheel component is already known from DE 10 2016 005 646 A1, but a bending process of the wheel or wheel component after forging is not known from it.

[0006] The object of the invention is, in particular, to provide a generic method with improved properties regarding the production of complex component geometries in forged components, which are ready for use with minimal post-processing effort, and a generic forged component with improved properties regarding overall weight, high load-bearing capacity, and few areas requiring post-processing. This object is achieved according to the invention by the features of claim 1 and / or claim 8, while advantageous embodiments and further developments of the invention can be found in the dependent claims. Advantages of the invention

[0007] The invention relates to a forging process, in particular a lightweight alloy forging process, wherein in at least one process step, in particular a forging forming step, a forged component designed as a shock absorber fork is formed in a forging tool designed as a die, wherein in at least one process step after a forging forming a bending forming of the forged component takes place, wherein the bending forming of the forged component takes place about a transverse axis, which runs transversely, in particular at least substantially perpendicularly, to a longitudinal axis of the forged component.

[0008] It is proposed that, during the forging process, a bionic or truss-like structure be introduced into one load-bearing area and another load-bearing area of ​​the forged component using a forging tool designed as a roughing die or a finishing die. The forging process is preferably intended for the production of lightweight alloy components for the automotive, aerospace, and / or industrial sectors. "Intended" is understood to mean, in particular, specially designed and / or specially equipped. The fact that an element and / or unit is / are intended for a specific function is understood to mean, in particular, that the element and / or unit fulfills / fulfills and / or performs / performs this specific function in at least one application and / or operating condition. Preferably, the bending process differs from hot forming of the forged component carried out in a die.In particular, the bending of the forged component is carried out after hot forming of the forged component in a die. Preferably, the bending of the forged component takes place outside the die in which the forged component is hot formed, especially during the forging process. However, it is also conceivable that the die in which the forged component is hot formed is multi-part, in particular having several movably connected sections, and that movable sections of the die, especially after hot forming of the forged component in the die, are moved relative to each other, in particular about a bending axis, to perform the bending of the forged component.

[0009] Preferably, the bending of the forged component is carried out about a bending axis of the forged component. "Substantially parallel" here refers in particular to an alignment of a direction relative to a reference direction, especially in a plane, wherein the direction has a deviation from the reference direction of preferably less than 8°, advantageously less than 5°, and particularly advantageously less than 2°. Preferably, the bending axis runs at least substantially parallel to a longitudinal axis of a partial area of ​​the forged component designed as a damper tube receptacle. According to the invention, the forged component is bent about the transverse axis, which runs transversely, and in particular at least substantially perpendicularly, to the longitudinal axis of the forged component.The term "essentially perpendicular" here is intended to define, in particular, an orientation of a direction relative to a reference direction, wherein the direction and the reference direction, especially when viewed in a projection plane, enclose an angle of 90° and the angle has a maximum deviation of, in particular, less than 8°, advantageously less than 5°, and most advantageously less than 2°. Preferably, in at least one process step after the forging, a bending deformation is carried out, in particular by more than 90°, more preferably by more than 120°, and most preferably by more than 160°, on at least a partial region of the forged component, in particular about the bending axis of the forged component. Preferably, in at least one process step after the forging, a bending deformation of the forged component, in particular of at least a partial region of the forged component, is carried out by 180° about the bending axis of the forged component.Preferably, by means of bending, two ends of the forged component that are opposite each other before bending and / or support areas of the forged component that are arranged at least substantially in a common plane, in particular fork arms of the forged component designed as a suspension fork, are bent towards each other. Preferably, the support areas are bent by means of bending such that, after bending, they are aligned in planes that are at least substantially parallel to each other. Preferably, the support area and / or the further support area are designed as fork arm(s) of the forged component designed as a suspension fork.Preferably, the forged component is hot-formed in the forging step in such a way that the forged component has a small material thickness in the area of ​​the bending axis, such as a film hinge-like design in the area of ​​the bending axis, at least one opening in the area of ​​the bending axis, or has other designs in the area of ​​the bending axis that appear useful to a person skilled in the art, in particular to be able to carry out a bending forming with low force expenditure.It is also conceivable that in the forging process, fork arms of the forged component designed as a suspension fork, connected in particular by a thin connecting section, are forged, especially without a damper tube mount of the forged component designed as a suspension fork, a bending forming of the forged fork arms is carried out, and subsequently the damper tube mount of the forged component designed as a suspension fork is joined to the fork arms, in particular by welding. It is also conceivable that additional functional elements, such as chassis mounting areas of the forged component designed as a suspension fork, are forged on during a forging process or joined after forging or solution annealing, in particular by welding.

[0010] Preferably, the forging process is designed as a die forging process, in particular according to DIN 8583. Preferably, the forging process is designed as a die forging process with a fully enclosed workpiece, in particular as a die forging process with a fully enclosed workpiece and flash. Preferably, the forging process comprises several process steps in which the forged component is formed until a final forging dimension is achieved. Preferably, the forging process is designed in a manner known to those skilled in the art such that in at least one process step, at least substantially the entire cross-section of the forged component is plastically degraded. Preferably, the forging process results in a three-dimensional stress distribution in the forged component during the forming of a semi-finished product into a forged component.Preferably, a semi-finished product in the form of a continuously cast or extruded material is used to manufacture the forged component by means of a forging process. The forging process is preferably designed such that a temperature distribution within the forged component can be achieved as homogeneous as possible, for example, by means of a forging tool known to those skilled in the art, which is preferably designed as a roughing die or a finishing die, in particular to selectively influence local degrees of deformation in the forged component in a manner known to those skilled in the art. Preferably, in at least one process step, in particular before bending the forged component in the forging tool, a hot forming of the forged component takes place in the forging tool. The forging tool is preferably designed as a die, such as a roughing die, a finishing die, or another die that appears suitable to those skilled in the art.Preferably, one forging step of the forging process is carried out in one or more roughing dies and at least one further forging step of the forging process is carried out in one or more finishing dies.

[0011] Preferably, the forged component is formed in the forging tool, which is particularly designed as a die, at a forming temperature of more than 300 °C, preferably more than 400 °C, particularly preferably more than 490 °C, and most preferably less than 700 °C. Preferably, the forged component is formed in the forging tool, which is particularly designed as a die, at a forming temperature in the range of 500 °C to 560 °C, particularly when the forged component is made from an aluminum alloy of the 6000 series (EN AW 6xxx).When manufacturing the forged component from a different material that a person skilled in the art would consider suitable, in particular from an aluminum alloy from the 2000 series (EN AW 2xxx) or from the 7000 series (EN AW 7xxx), other forming temperature ranges are also possible, such as a forming temperature with a value from 420 °C to 560 °C or the like. A person skilled in the art will preferably select a suitable forming temperature range depending on the material chosen for the forged component.Preferably, in at least one step of the forging process, particularly before the bending of the forged component and / or before a hot forming step of the forging process, at least one semi-finished product used for forging the forged component is preheated, particularly to a temperature of more than 300 °C, preferably more than 400 °C, particularly preferably more than 490 °C, and most preferably less than 700 °C. Preferably, the forged component is preheated using a device already known to a person skilled in the art, such as a furnace or the like.

[0012] Preferably, in at least one process step, particularly before the bending of the forged component in the forging die and especially after preheating the semi-finished product, the semi-finished product is transferred, in particular at least partially automatically, to a forging device. The forging device preferably comprises at least the forging die in which the forged component is hot-formed. Additionally, the forging device may include further forging tools for processing the semi-finished product and / or the forged component, such as a forging tool for pre-forming the semi-finished product, a forging tool for deburring and / or trimming the forged component, a forging tool for calibrating the forged component, and / or other forging tools that a person skilled in the art would consider useful.However, it is also conceivable that the semi-finished product or the forged component is transferred during the forging process to different forging devices with different forging tools for pre-processing, processing and / or post-processing, such as pre-forming, hot forming, cutting, cooling, calibration or the like.

[0013] Preferably, at least one step of the forging process involves the forging component undergoing a heat aging process, particularly after cooling in a forging die, specifically to achieve a T1 to T10 condition according to DIN EN 515, and more preferably a T4, T5, T6, or T7 condition according to DIN EN 515. Heat aging of the forged component is preferably carried out at a temperature of less than 280 °C, more preferably less than 250 °C, and most preferably less than 220 °C. Most preferably, heat aging of the forged component is carried out at a temperature within the range of 120 °C to 250 °C.Preferably, in at least one step of the forging process, the forged component is transferred, in particular at least partially automatically, from the forging device to a heat aging device known to those skilled in the art, especially after bending of the forged component in a forging tool. Preferably, the forged component is transferred from the forging device to a heat aging device known to those skilled in the art at a temperature that is above, below, or corresponding to the heat aging temperature of the forged component.

[0014] By means of the forging process according to the invention, forged components with complex geometries can be advantageously produced, wherein the forged component has at least substantially a final component geometry. Forged components can be advantageously produced by the forging process requiring minimal post-processing to achieve the final component geometry. An advantageously economical forging process can be realized, by means of which complex components that were previously difficult or required extensive post-processing to forge can be produced.

[0015] Furthermore, it is proposed that in at least one process step prior to bending, preferably in the forging step, a surface of the forged component, at least in a partial area located on the inner side of a damper tube receptacle of the forged component designed as a suspension fork, be provided with a specific surface structure. It is conceivable that the forging process for solving the aforementioned problem could be implemented independently of the bending step in an alternative embodiment.Preferably, in the alternative embodiment, particularly in the embodiment carried out independently of the bending process step, the forging process is configured such that in at least one process step, particularly a forging step, a forged component is formed in a forging tool, particularly a die, and in at least one process step, particularly the forging step, a surface of the forged component, at least in a partial area of ​​the forged component, particularly on the inner side of a damper tube receptacle of the forged component designed as a suspension fork, is provided with a specific surface structure. "A specific surface structure" is understood to mean, in particular, a surface structure that has, in particular, macroscopic depressions, protrusions, and / or recesses.The specific surface structure can be, for example, a surface ribbing, transverse ribs, longitudinal ribs, a honeycomb-like indentation, or any other specific surface structure that would appear useful to a person skilled in the art. Preferably, during the forging process, a surface of the forged component, at least in a partial area, particularly on the inside of the damper tube receptacle of the forged component designed as a suspension fork, is provided with a specific surface structure, wherein the specific surface structure is a surface ribbing, ribs, a honeycomb structure, or the like. Preferably, the die, by means of which the forged component is hot-formed during the forging process, has a negative mold of the specific surface structure to be introduced, at least in a partial area.It is also conceivable that the specific surface structure is introduced into the forged component, particularly in a specific area, using a further die after hot forming of the forged component. Other methods of introducing the specific surface structure during the forging process that would appear useful to a person skilled in the art are also conceivable. Using the inventive design of the forging process, it is advantageously possible to introduce a functionally relevant surface structure into an area of ​​the forged component that is difficult or impossible to access, particularly with conventional forging processes, even during the forging process itself. This can advantageously avoid or minimize the need for additional post-processing of the area.

[0016] Furthermore, it is proposed that the bending of the forged component is carried out about a bending axis extending transversely, and in particular at least substantially perpendicularly, to a main forging force axis. Preferably, the main forging force axis extends, in particular in a manner already known to those skilled in the art, at least substantially perpendicularly to a surface of the forged component. Preferably, the main forging force axis is defined, in particular in a manner already known to those skilled in the art, by an arrangement of the forged component in the die and a direction of action of a working element of a forging device, in particular a hydraulic cylinder of a forging press, a spindle axis of a forging press by means of which the forging process can be carried out / is carried out, or other main drive direction of action of a forging device that appears useful to those skilled in the art.Preferably, during the hot forming of the forged component in the die, a main forming force of the forging device acts, particularly in a manner already known to those skilled in the art, along the main forging force axis. Preferably, the bending axis around which the forged component is bent by means of the bending forming process runs at least substantially parallel to the surface of the forged component, or at least a partial area of ​​the forged component that is provided with a specific surface structure during the forging forming process. More preferably, the bending axis around which the forged component is bent by means of the bending forming process runs at least substantially parallel to the surface of the inner side of the damper tube receptacle of the forged component designed as a suspension fork. Using the forging process according to the invention, forging components with complex geometries can advantageously be achieved.In particular, it can be advantageous to incorporate complex component structures into parts of the forged component that are difficult to access in a conventional forging process without subsequent bending.

[0017] Furthermore, it is proposed that in the forging step, at least one opening and / or at least one recess is introduced into a load-bearing area of ​​the forged component and at least one opening and / or at least one recess is introduced into a further load-bearing area of ​​the forged component, wherein the opening and / or the recess introduced in the load-bearing area is arranged opposite the opening and / or the recess introduced in the further load-bearing area after the bending of the forged component. According to the invention, a bionic or a truss-like structure is introduced in the load-bearing area and in the further load-bearing area during the forging step. In this context, a "bionic structure" is understood to mean, in particular, a structure based on bionics, especially structural bionics, and in particular a load-bearing structure.The bionic structure, in particular the bionic support structure, is specifically modeled on or based on a structure found in nature. Specifically, one form of the bionic structure, especially the bionic support structure, is based on a naturally occurring structure. Various configurations of the bionic structure are conceivable that would appear sensible to a person skilled in the art, such as a lattice structure, a honeycomb structure, a net structure, or the like.It is conceivable that in the forging step, fork arms of the forged component designed as a suspension fork, particularly those with a bionic structure, are forged, especially without a damper tube mount, and that the forged fork arms are then joined to a tube, an extruded profile, or the like, particularly by welding, especially to accommodate the damper tube mount of the forged component designed as a suspension fork on the fork arms. Using the forging process according to the invention, a complex geometry can advantageously be incorporated into the forged component. In particular, it is advantageous to incorporate complex component structures into sub-areas of the forged component that are difficult to access in a conventional forging process without subsequent bending.

[0018] Furthermore, it is proposed that the forging process include at least one punching and / or deburring step in which the forged component is punched and / or deburred after the forging step, with the punching and / or deburring step taking place before the bending of the forged component. Preferably, the punching and / or deburring in the punching and / or deburring step can be carried out according to one of the methods specified in DIN 8587 to DIN 8590. However, it is also conceivable that the punching and / or deburring step is carried out using a water jet or laser beam-based cutting process. Other methods for carrying out the punching and / or deburring step that appear sensible to a person skilled in the art are also conceivable.Preferably, the punching and / or deburring step is carried out by means of the forging device, in particular by means of a hydraulic spindle press, a mechanical spindle press, an electro-mechanical spindle press, an electro-hydraulic spindle press, a servo press or another forging device that appears useful to a person skilled in the art, and a punching and / or deburring tool of the forging device.It is conceivable that the forged component is perforated, slotted, or otherwise weakened in the area of ​​the bending axis of the forged component, around which the forged component is bent during the bending process, during the punching and / or deburring step or a subsequent process step, particularly before bending, especially in order to enable the forged component to be bent around the bending axis with minimal force. The inventive design of the forging process advantageously allows for a structurally simple preparation of the forged component for bending. It also advantageously enables reliable deburring and / or punching in areas of the forged component that are difficult to deburr and / or punch, particularly after bending.

[0019] Furthermore, it is proposed that the forging process comprises at least one heat treatment of the forged component, wherein the bending of the forged component takes place during the heat treatment, in particular after solution annealing and / or after quenching, preferably before hot aging. Preferably, the heat treatment of the forged component takes place after hot forming in the forging step. Preferably, the heat treatment, particularly when considered independently of the bending, takes place in three steps, wherein a first step is solution annealing, a further step is quenching, and an additional step is hot aging. Preferably, bending of the forged component takes place after solution annealing and / or after quenching. Preferably, bending of the forged component takes place before hot aging.Preferably, the forged component is solution annealed at temperatures of, in particular, more than 400 °C, more preferably more than 450 °C, and most preferably at a temperature within the range of 470 °C to 560 °C. In particular, the temperature range in which the solution annealing takes place depends, in a manner known to those skilled in the art, on the material chosen for the forged component, so that those skilled in the art will select a suitable temperature range for the solution annealing depending on the material chosen for the forged component. Preferably, after solution annealing, the forged component is quenched to a temperature of, in particular, less than 200 °C, more preferably less than 100 °C, and most preferably to a temperature within the range of 20 °C to 75 °C.Preferably, after quenching, the forged component is heated to a temperature of, in particular, more than 100 °C, preferably less than 200 °C, and most preferably to a temperature between 120 °C and 180 °C. In particular, the forged component is bent after heating to a temperature between 120 °C and 180 °C, preferably before aging. However, it is also conceivable that bending is carried out at room temperature or at a temperature between 20 °C and 75 °C, particularly directly after quenching. Preferably, aging is carried out after bending, and in particular immediately following the bending. Other heat treatment steps and temperatures that would be considered appropriate by a person skilled in the art are also conceivable, particularly depending on the material used for the forged component.The forged component is preferably made of aluminum or an aluminum alloy. Using the forging process according to the invention, an advantageous process chain can be realized, which can be designed to be particularly resource-optimized. It is advantageous to use a temperature suitable for heat treatment, especially for hot aging, in order to enable the forged component to be deformable during bending with minimal force.

[0020] Furthermore, it is proposed that in at least one process step prior to the forging step, a pre-bending of a forging blank, in particular a semi-finished product, from which the forged component is forged, especially in the forging step, is carried out. However, it is also conceivable alternatively that the forging process is carried out independently of a pre-bending of a forging blank. Preferably, the forging blank is designed as an aluminum bar. Preferably, the forging blank has a round cross-section. However, it is also conceivable that the forging blank has a polygonal cross-section. Preferably, the forging blank is heated in at least one process step, in particular before a pre-bending, to a temperature within a range of, in particular, 300 °C to 600 °C and more preferably 350 °C to 560 °C.Preferably, the forging blank is bent, particularly after heating, during pre-bending, especially into a U-shape. Preferably, the forging blank is pre-forged into the forged part in a blanking die. Preferably, the forged part is finished forged in a finishing die, particularly during the forging step. Preferably, after the forging step, the punching and / or deburring step, heat treatment, and bending of the forged part take place. Preferably, the forging blank and / or the forged part is made of an aluminum alloy, a titanium alloy, or another lightweight alloy that would be considered suitable by a person skilled in the art.Preferably, the forging blank and / or the forged component are made of an alloy, in particular an aluminum alloy, from the 2000 series (EN AW 2xxx), the 3000 series (EN AW 3XXX), the 4000 series (EN AW 4XXX), the 5000 series (EN AW 5xxx), the 6000 series (EN AW 6xxx), the 7000 series (EN AW 7xxx), or the 8000 series (EN AW 8xxx). Preferably, the forging blank and / or the forged component are made of a technically usable aluminum alloy whose alloy composition corresponds to values ​​of at least one series from the EN AW 1XXX to 8XXX series. The embodiment according to the invention allows for particularly advantageous adaptation of the forging blank to a final contour of the forged component. An optimized forging process can advantageously be implemented.

[0021] Furthermore, the invention relates to a forged component designed as a suspension fork, in particular a lightweight alloy forged component, with a load-bearing area and a further load-bearing area, which is produced by means of a forging process according to the invention. It is proposed that the load-bearing area and the further load-bearing area have a bionic or truss-like structure introduced by the forging process using a forging tool designed as a roughing die or a finishing die. By means of the embodiment according to the invention, a forged component with a complex component geometry with improved properties regarding overall weight, high load-bearing capacity, and with few areas requiring post-processing can advantageously be provided. It is particularly advantageous to realize a forged component optimized for a specific application with a low weight.

[0022] According to the invention, it is proposed that the forged component comprises at least one bionically designed sub-section, in particular at least one bionically designed fork arm. Preferably, the forged component comprises the bionically designed fork arm and a further bionically designed fork arm. Preferably, the forged component, designed as a shock absorber fork, has at least one damper tube receptacle on which the fork arm and the further fork arm are arranged. Preferably, the fork arm and the further fork arm are connected to each other via the damper tube receptacle. A clamping unit is preferably arranged or can be arranged on the damper tube receptacle. The clamping unit can be designed as a screw connection, a snap-fit ​​connection, a clamp connection, or the like. By means of the embodiment according to the invention, a weight- and function-optimized component geometry of the forged component can advantageously be realized.

[0023] The forging process and / or the forged component according to the invention are not to be limited to the application and embodiment described above. In particular, the forging process and / or the forged component according to the invention may, to achieve a functionality described herein, have a different number of individual elements, components, units, and process steps than those specified herein. Furthermore, values ​​within the specified limits of the value ranges stated in this disclosure are also to be considered disclosed and freely usable. Drawings

[0024] Further advantages become apparent from the following description of the drawings. The drawings illustrate an embodiment of a method according to the invention and possible embodiments of forged components according to the invention. The drawings, the description, and the claims contain numerous features in combination. A person skilled in the art will expediently consider the features individually and combine them into meaningful further combinations.

[0025] They show: Fig. 1 a flowchart of a forging process according to the invention in a schematic representation, Fig. 2. A schematic representation of an embodiment of a forged component before bending of the forged component. Fig. 3 Another embodiment of a forged component before bending of the forged component in a schematic representation, Fig. 4a a bending forming of a forged component to illustrate the forging process according to the invention in a schematic representation, Fig. 4b a detailed view of a specific surface introduced into a forged component by means of the forging process according to the invention in a schematic representation and Fig. 5 A forged component designed as a shock absorber fork in a schematic representation. Description of the exemplary embodiment

[0026] Fig. Figure 1 schematically shows a flowchart of a forging process 10, in particular a lightweight alloy forging process, for the production of lightweight alloy components for the automotive, aerospace, and / or industrial sectors. The forging process 10 is especially suitable for producing forged components 16 with complex geometries from a lightweight alloy, such as a wrought aluminum alloy. However, the forging process 10 is not limited to the production of forged components 16 from lightweight alloys. It is also conceivable that other components, which would appear useful to a person skilled in the art, could be produced using the forging process 10.

[0027] For the production of the exemplary forged component 16 using the forging process 10, a forging blank 52 is produced from a semi-finished product, in particular an aluminum semi-finished product, in at least one process step (not described in detail here) of the forging process 10 in a manner already known to a person skilled in the art, in a manner known to a person skilled in the art. This forging blank is produced in particular in the form of a bar or a disc. However, it is also conceivable that the at least one process step for producing the forging blank 52 is omitted in the forging process 10, since, for example, the forging blank 52 is purchased as bar stock and, for example, only cutting the bar stock to the desired length of the forging blank 52, or exclusively feeding the forging blank 52, in particular in the form of a forging blank 52 already cut to length and purchased, is part of the forging process 10.The forging blank 52 can be pre-processed in a process step of the forging process 10, in particular before a forging forming step 12, 14 of the forging process 10, in particular in the form of a pre-forming, or fed directly to a forging tool, in particular a roughing die or a finishing die, in particular depending on a final geometry of the forged component 16 to be produced.

[0028] The forging process 10 described below is preferably intended for the production of the forged component 16 designed as a shock absorber fork. The forging blank 52 is preferably pre-machined, in particular to enable an advantageous forming process. In at least process step 50 of the forging process 10, in particular before the forging forming steps 12 and 14 of the forging process 10, the forging blank 52 is pre-bent, from which the forged component 16 is forged, in particular in the forging forming steps 12 and 14. The forging blank 52 is preferably pre-bent in process step 50 of the forging process 10, in particular bent into a U-shape. The forging blank 52 is placed, in particular after the pre-bent, into a forging die designed as a pre-die (not shown in detail here).In at least one process step, in particular a first forging step 12, of the forging process 10, the forged component 16 is formed in the forging tool, which is designed in particular as a roughing die. The forged component 16 is fed, in particular after machining in the forging tool designed as a roughing die, to a further forging tool, in particular as a finishing die (not shown in detail here), and in particular inserted into the further forging tool, which is designed in particular as a finishing die. In at least one process step, in particular in a second forging step 14, of the forging process 10, the forged component 16 is formed in the further forging tool, which is designed in particular as a finishing die.However, it is also conceivable that the forged component 16 only undergoes one forging forming step 12, 14 and in this forging forming step 12, 14 is finished forged from the forging blank 52 to the forged component 16.

[0029] In at least one process step 22 of the forging process 10, in particular after a forging operation in the first forging operation 12 and / or in the second forging operation 14, the forged component 16 is bent, in particular by more than 60° of at least a partial region of the forged component 16. Preferably, the bending of at least a partial region of the forged component 16 is performed about a bending axis 32 of the forged component 16, in particular by more than 90°, preferably by more than 120°, and most preferably by more than 160°. Preferably, the bending of the forged component 16, in particular of at least a partial region of the forged component 16, is performed by 180° about the bending axis 32 of the forged component 16.Preferably, by means of bending, two ends of the forged component 16 facing away from each other prior to bending and / or support areas 38, 44 of the forged component 16, in particular fork arms 18, 20 of the forged component 16 designed as a suspension fork, which are arranged at least substantially in a common plane, are bent towards each other. Preferably, the support areas 38, 44 are bent by means of bending such that, after bending, they are aligned in planes that are at least substantially parallel to each other. Preferably, the support area 38 and / or the further support area 44 are designed as fork arms 18, 20 of the forged component 16 designed as a suspension fork.

[0030] The bending forming of the forged component 16 takes place about the bending axis 32 which runs transversely, in particular at least substantially perpendicularly, to a main forging force axis 30 (cf. Fig. 4a) Preferably, the bending of the forged component 16 takes place outside the die in which the forged component 16 is hot-formed, particularly during the forging process. However, it is also conceivable that the die in which the forged component 16 is hot-formed is multi-part, in particular comprising several movably connected sections, and that movable sections of the die, particularly after hot-forming of the forged component 16 in the die, are moved relative to each other, in particular about the bending axis 32, to perform the bending of the forged component 16.

[0031] The bending axis 32 of the exemplary forged component 16 preferably runs at least substantially parallel to a longitudinal axis of the forged component 16, in particular to longitudinal axes of the fork arms 18, 20 of the forged component 16 designed as a suspension fork. Preferably, the bending axis 32 runs at least substantially parallel to a longitudinal axis of a partial area of ​​the forged component 16 designed as a suspension fork, which is designed as a damper tube receptacle 26. In the forging process 10 according to the invention, the forged component 16 is bent about a transverse axis that runs transversely, in particular at least substantially perpendicularly, to the longitudinal axis of the forged component 16.

[0032] In at least one process step of the forging process 10, in particular before the bending forming, preferably in the first forging step 12 and / or in the second forging step 14, a surface 24 of the forged component 16 is given a specific surface structure 28 (see figure) at least in a partial area of ​​the forged component 16, in particular on an inside of the damper tube receptacle 26 of the forged component 16 designed as a suspension fork. Fig. 4b) provided. The specific surface structure 28 can, for example, be designed as a ribbing of the surface 24, as transverse ribs, as longitudinal ribs, as a honeycomb-like indentation, or as another specific surface structure 28 that appears useful to a person skilled in the art. Preferably, in the first forging step 12 and / or in the second forging step 14, the surface 24 of the forged component 16 is provided with the specific surface structure 28 at least in a partial area of ​​the forged component 16, in particular on the inside of the damper tube receptacle 26 of the forged component 16 designed as a suspension fork, wherein the specific surface structure 28 is designed as a ribbing of the surface 24, as ribs, as a honeycomb structure, or the like.Preferably, the roughing die and / or the finishing die has, at least in a partial area of ​​the roughing die and / or the finishing die by means of which the forged component 16 is hot-formed during the forging process, a negative form of the specific surface structure 28 to be introduced. It is also conceivable that the specific surface structure 28 is introduced into the forged component 16, particularly in the partial area of ​​the forged component 16, after hot forming of the forged component 16 by means of a further die or by means of a subtractive process. It is also conceivable that, in addition to subtractive processes such as machining (milling / turning) or beam-based processes (laser), other forming processes, such as embossing, are also used to introduce the specific surface structure 28.Alternatively or additionally, it is conceivable that the specific surface structure 28 is introduced during the bending process of the forged component 16. For example, a bending tool used to bend the forged component 16 could have a negative shape relative to the specific surface structure 28, by means of which the specific surface structure 28 is introduced into the forged component 16 during the bending process.

[0033] In the first forging step 12 and / or in the second forging step 14, at least one opening 34 and / or at least one recess 36 are made in the bearing area 38 of the forged component 16 and at least one opening 40 and / or at least one recess 42 are made in the further bearing area 44 of the forged component 16 (see also Fig. 2, Fig. 3 and Fig. 5), wherein the opening 34 and / or the recess 36 provided in the support area 38 are arranged opposite the opening 40 and / or the recess 42 provided in the further support area 44 after the bending of the forged component 16 on the forged component 16 (see Fig. 5).

[0034] According to the invention, a bionic or truss-like structure is introduced in the first forging step 12 and / or in the second forging step 14 in the support area 38 and in the further support area 44. The bionic structure, in particular the bionic support structure, is specifically modeled on or based on a structure found in nature. In particular, one form of the bionic structure, especially the bionic support structure, is based on a naturally occurring structure. Various embodiments of the bionic structure that would appear sensible to a person skilled in the art are conceivable, such as a lattice structure, a honeycomb structure, a net structure, or the like.Preferably, the bionic structure is generated by means of a computer simulation depending on a load case occurring in the use of the forged component 16 and is introduced by means of the roughing die and / or the finishing die during the first forging step 12 and / or the second forging step 14 in the bearing area 38 and in the further bearing area 44, in particular as a result of the introduction of the openings 34, 40 and / or recesses 36, 42 in the bearing area 38 and in the further bearing area 44.

[0035] The forging process 10 comprises at least one punching and / or deburring step 46, in which the forged component 16 is punched and / or deburred, in particular after the first forging step 12 and / or after the second forging step 14, wherein the punching and / or deburring step 46 takes place before the bending of the forged component 16. Preferably, the punching and / or deburring step 46 is carried out using a punching tool.It is conceivable that the forged component 16 is perforated, slotted, or otherwise weakened in the area of ​​the bending axis 32 of the forged component 16, around which the forged component 16 is bent during the bending process, in the punching and / or deburring step 46 or a subsequent process step, particularly before bending, especially in the area of ​​the bending axis 32, particularly to enable the forged component 16 to be bent around the bending axis 32 with minimal force. It is also conceivable that, particularly before bending, a defined area of ​​the forged component 16 is pre-bent by means of die bending, roll bending, or a swing bending process.It is also conceivable that, in particular by a fork arm 18, 20, partial sections of the forged component 16 are bent successively or simultaneously, especially during partial steps of the bending process. A maximum height h of the forged component 16 in the region of the bending axis 32 is preferred (see Figure 1). Fig. 4a) smaller than a maximum material thickness M of the forged component 16, in particular of the fork arms 18, 20 of the forged component 16 (see Fig. 4a) The maximum height h of the forged component 16 preferably extends at least substantially perpendicular to the bending axis 32 and at least substantially parallel to the main forging force axis 30. The maximum material thickness M preferably extends in a plane extending at least substantially perpendicular to the bending axis 32.

[0036] The forging process 10 comprises at least one heat treatment 48 of the forged component 16, wherein the bending of the forged component 16 takes place during the heat treatment 48, in particular after solution annealing and / or after quenching, preferably before aging. Preferably, the heat treatment 48 of the forged component 16 takes place after hot forming in the first forging step 12 and / or in the second forging step 14. Preferably, the heat treatment 48, particularly when considered independently of the bending, takes place in three steps, wherein a first step is solution annealing, a further step is quenching, and an additional step is aging. Preferably, the bending of the forged component 16 takes place after solution annealing and / or after quenching. Preferably, the bending of the forged component 16 takes place before aging.Preferably, the forged component 16 is solution annealed at temperatures of, in particular, more than 400 °C, more preferably more than 450 °C, and most preferably at a temperature within the range of 470 °C to 560 °C. Preferably, after solution annealing, the forged component 16 is quenched to a temperature of, in particular, less than 200 °C, more preferably less than 100 °C, and most preferably to a temperature within the range of 20 °C to 75 °C. Preferably, after quenching, the forged component 16 is heated to a temperature of, in particular, more than 100 °C, more preferably less than 200 °C, and most preferably to a temperature within the range of 120 °C to 180 °C. In particular, the forged component 16 is bent after being heated to a temperature between 120 °C and 180 °C, preferably before being warm-aged.Preferably, after the bending process, and especially following the bending process, the forged component 16 is subjected to a warm aging process.

[0037] In a further process step (not shown in detail here), the forged component 16 undergoes final machining. In particular, the final machining takes place after the heat treatment 48 of the forged component 16. Preferably, the final machining involves machining areas of the forged component 16, especially chassis connection areas 54 or clamping unit connection areas 56 of the forged component 16. However, it is also conceivable that, depending on component requirements and / or manufacturer specifications, final machining may be omitted and the forged component 16, especially after the heat treatment 48, is ready for use.

[0038] Fig. Figure 2 shows an exemplary embodiment of the forged component 16, which is produced by means of the forging process 10, before a bending forming of the forged component 16. The in Fig. The forged component 16 shown in Figure 2 has a substantially constant radius over the entire extent of the damper tube receptacle 26, particularly before bending and after hot forming in the first forging step 12 and / or in the second forging step 14.

[0039] Fig. Figure 3 shows an exemplary further embodiment of the forged component 16, which is produced by means of the forging process 10, before a bending forming of the forged component 16. The in Fig. The forged component 16 shown in Figure 3 has different radii over its entire extent, particularly before bending and after hot forming in the first forging step 12 and / or in the second forging step 14, in the area of ​​the damper tube receptacle 26. Preferably, the damper tube receptacle 26 has a wave-like shape before bending. More preferably, the damper tube receptacle 26 has a convex curvature in the area of ​​the bending axis 32, particularly in a central region, before bending, with two adjoining side regions having a concave curvature. Further embodiments of the damper tube receptacle 26 before bending, particularly in the area of ​​the bending axis 32, which would appear advantageous to a person skilled in the art, are also conceivable, especially to enable a more advantageous forming process.

[0040] Fig.Figure 5 shows the forged component 16, which is manufactured using the forging process 10. The forged component 16 is designed as a shock absorber fork. The forged component 16 comprises at least one bionically designed section, in particular at least the bionically designed fork arm 18, 20. Preferably, the forged component 16 comprises the bionically designed fork arm 18 and a further bionically designed fork arm 20. Preferably, the forged component 16, designed as a shock absorber fork, has at least the damper tube receptacle 26, on which the fork arm 18 and the further fork arm 20 are arranged. Preferably, the fork arm 18 and the further fork arm 20 are connected to each other via the damper tube receptacle 26. The damper tube receptacle 26 preferably comprises the specific surface structure 28 on its inner surface. A clamping unit (not shown in detail here) is preferably arranged or can be arranged on the damper tube receptacle 26.The clamping unit can be designed as a screw connection, a snap-fit ​​connection, a clamp connection, or as any other clamping unit that a specialist would consider appropriate. Reference sign 10 forging processes 12 Forging step 14 Forging step 16 forged components 18 Fork arm 20 Fork arm 22nd process step 24 surface 26 Damper tube mount 28 Surface structure 30 Main forging force axis 32 Bending axis 34 Breakthrough 36 In-depth study 38 Carrying area 40 Breakthrough 42 In-depth study 44 Carrying area 46. ​​Hole punching and / or deburring step 48 Heat treatment 50th process step 52 Forging blank h maximum height M maximum material thickness 54 Chassis connection area 56 Clamping unit connection area

Claims

[1] Forging process, wherein in at least one forging step (12, 14) a forged component (16) designed as a shock absorber fork is formed in a forging tool designed as a die, wherein in at least one process step (22) after a forging process a bending process of the forged component (16) is carried out, wherein the bending process of the forged component (16) is carried out about a transverse axis which is transverse to a longitudinal axis of the forged component (16), characterized by , that in the forging process (12, 14) a bionic or truss-like structure is introduced in a bearing area (38) of the forged component (16) and in a further bearing area (44) by means of a forging tool designed as a roughing die or as a finishing die. [2] Forging process according to claim 1, characterized by, that in at least one process step prior to the bending forming, a surface (24) of the forged component (16) is provided with a specific surface structure (28) at least in a partial area of ​​the forged component (16), which is arranged on an inside of a damper tube receptacle (26) of the forged component (16) designed as a suspension fork. [3] Forging process according to claim 1 or 2, characterized by , that the bending of the forged component (16) takes place about a bending axis (32) running transversely to a main forging force axis (30). [4] Forging process according to any one of the preceding claims, characterized by, that in the forging step (12, 14) at least one opening (34) and / or at least one recess (36) is made in a support area (38) of the forged component (16) and at least one opening (40) and / or at least one recess (42) is made in a further support area (44) of the forged component (16), wherein the opening (34) and / or the recess (36) made in the support area (38) are arranged opposite the opening (40) and / or the recess (42) made in the further support area (44) after the bending of the forged component (16) on the forged component (16). [5] Forging process according to any one of the preceding claims, characterized byat least one punching and / or deburring step (46) in which the forged component (16) is punched and / or deburred after the forging step (12, 14), wherein the punching and / or deburring step (46) takes place before the bending of the forged component (16). [6] Forging process according to any one of the preceding claims, characterized by at least one heat treatment (48) of the forged component (16), wherein the bending of the forged component (16) takes place during the heat treatment (48). [7] Forging process according to any one of the preceding claims, characterized by , that in at least one process step (50) before the forging step (12, 14) a pre-bending forming of a forging blank (52) from which the forged component (16) is forged takes place. [8] Forged component (16) designed as a shock absorber fork, which is manufactured by means of a forging process according to one of claims 1 to 7, with a bearing area (38) and with a further bearing area (44), characterized by , that the load-bearing area (38) and the further load-bearing area (44) have a bionic or truss-like structure introduced by means of the forging process using a forging tool designed as a pre-die or as a finishing die.

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