Method for manufacturing a crash component and a crash management system

Abstract

Method for manufacturing a crash component (5) with: an extrusion step in which an extruded profile part (3) is produced by means of extrusion, wherein the extruded profile part (3) has a base profile (11) and a stiffening profile (13), and wherein the method includes a post-processing step in which the extruded profile part (3) is post-processed in the area of ​​the stiffening profile (13) to form a crash component (5), and wherein in the post-processing step the material of the stiffening profile (13) is removed along at least a first longitudinal section (L1) and / or a second longitudinal section (L2) of the base profile (11), so that after carrying out the post-processing step at least one stiffening profile segment (15) remains on the base profile (11), characterized by that in the post-processing step at least a first end section of the stiffening profile segment (15) is processed in such a way, that the first end section after completion of the post-processing step has the geometry of a first chamfer (21) or a first S-cut (35), and / or that in the post-processing step at least a second end section of the stiffening profile segment (15) is processed in such a way, that the second end section after completion of the post-processing step has the geometry of a second chamfer (23) or a second S-cut (37).

Description

[0001] The invention relates to a method for producing a crash component according to the preamble of claim 1 and to a crash management system according to claim 7.

[0002] In an exemplary method for producing a crash component, an extruded profile part is first produced by extrusion in an extrusion step. The extruded profile part is then locally reinforced with a reinforcing element to form the crash component. The reinforcing element is welded or screwed to the extruded profile part. When the reinforcing element is welded to the extruded profile part, a heat-affected zone is created on the extruded profile part and the reinforcing element. In the heat-affected zone, structural changes can occur that reduce the achievable strength of the crash component. If the reinforcing profile is screwed to the extruded profile part, bores must be provided on the extruded profile part, which reduce the achievable strength of the crash component due to notch effects.

[0003] A car body part is known from DE 10 2012 221 564 A1. A generic method for producing a crash component is known from WO 2009 077 313 A1. DE 10 2013 208 144 A1 discloses a motor vehicle body.

[0004] The object of the invention is to provide a method for producing a crash component, preferably for producing a crash management system of a motor vehicle, in which the crash component, preferably the crash management system, has increased strength compared to the prior art.

[0005] This object is achieved by the features of the independent claims. Preferred developments of the invention are disclosed in the subclaims.

[0006] According to the invention, a method for producing a crash component, preferably for producing a crash management system of a motor vehicle, is provided. The method comprises an extrusion step in which an extruded profile part is produced by extrusion. According to the invention, the extruded profile part comprises a base profile and a stiffening profile, and the method comprises a post-processing step in which the extruded profile part is post-processed in the region of the stiffening profile to form a crash component. In comparison to a crash component that is joined from an extruded profile part and a stiffening element, in the method according to the invention, no material and / or structural weakening due to heat-affected zones and / or notches or the resulting notch effect occurs between the base profile and the stiffening profile.The strength of the crash component is thus significantly increased in comparison - with the same choice of material and the same dimensions of the crash component.

[0007] In a specific example of the process, material from the stiffening profile and / or the base profile can be removed during the post-processing step. Local stiffening is thus achieved not by adding something to the extruded profile part, but by removing material from the extruded profile part. Heat-affected zones and notches, which negatively impact the strength of the crash component, can be avoided in this way.

[0008] Preferably, the material of the stiffening profile and / or the material of the base profile can be removed by cutting, preferably by a mechanical cutting process, particularly preferably by milling. Milling represents a cost-effective and precise cutting process, so that the crash component can be manufactured cost-effectively and while maintaining tight component tolerances.

[0009] According to the invention, during the post-processing step, the material of the stiffening profile is removed, preferably completely, along at least a first longitudinal section and / or a second longitudinal section of the base profile, so that after the post-processing step, preferably for local stiffening of the base profile, at least one stiffening profile segment remains on the base profile. Because the geometry of the stiffening element segment is obtained by removing material, for example, by milling, the geometry of the stiffening element segment can be freely selected within a very wide range. This allows even stiffening element segments with complex geometries to be manufactured cost-effectively.

[0010] Preferably, two or more stiffening profile segments can also remain attached to the base profile. The stiffening profile segments can all have the same geometry or different geometries. In principle, each of the stiffening profile segments can be manufactured according to the described process or according to the described crash components.

[0011] According to the invention, during the post-processing step, at least a first end section of the stiffening profile segment is machined such that, after completion of the post-processing step, the first end section has the geometry of a first chamfer or a first S-bend. Alternatively or additionally, according to the invention, during the post-processing step, at least a second end section of the stiffening profile segment is machined such that, after completion of the post-processing step, the second end section has the geometry of a second chamfer or a second S-bend. The chamfers, radii, and S-bends all have the advantage of avoiding cross-sectional jumps in the crash component. In the region of the end sections of the stiffening profile segment, the cross-section of the crash component thus changes continuously, so that when the crash component is loaded, a homogeneous force distribution results in the region of the end sections of the stiffening profile segment.In addition, the notch effect is reduced in the area of ​​the end sections of the stiffening profile segment.

[0012] In a specific example of the method, at least one recess can be introduced into the stiffening profile and / or the stiffening profile segment during the post-processing step. Preferably, the at least one recess is formed by a bore or a perforation hole that is introduced, preferably drilled, into the stiffening profile and / or the stiffening profile segment during the post-processing step. The recesses can save material and reduce the weight of the crash component. Furthermore, additional components can be attached to the stiffening profile segment, for example, using the recesses.

[0013] In a preferred example of the method, the extruded profile part can be produced in the extrusion step such that the stiffening profile extends, preferably completely, over an entire length of the base profile.

[0014] In a particularly preferred example of the method, the extrusion step can be performed prior to the post-processing step. Preferably, the extrusion step can be completed, preferably completely, at the beginning of the post-processing step.

[0015] In a specific example of the method, the base profile can have the geometry of a hollow profile, preferably essentially the geometry of a rectangular or square tube. With such a geometry, the base profile has high rigidity and low weight. Alternatively or additionally, the stiffening profile can have the geometry of a flat profile, the geometry of a hollow profile, the geometry of an open profile, or the geometry of a rib. For example, the geometry of a flat profile can be manufactured particularly cost-effectively due to its geometric simplicity.

[0016] In a preferred example of the method, the crash component can form a cross member, preferably of the crash management system, and / or a joining step can be provided in which the crash component is joined to a first crash box and to a second crash box to form the crash management system. Alternatively or additionally, the crash component can form a first crash box, preferably of the crash management system, and / or a joining step can be provided in which the first crash box is joined to a second crash box and to a cross member to form the crash management system.

[0017] Preferably, the stiffening profile can form an axially continuous stiffener for the base profile, preferably with respect to a total length of the base profile.

[0018] Particularly preferably, the stiffening profile can be arranged on the outside of the base profile. Preferably, the stiffening profile can be arranged on a side wall of the base profile, wherein it can preferably be provided that the stiffening profile is arranged centrally on the side wall with respect to the side wall.

[0019] If the stiffening profile has the geometry of an open profile, the stiffening profile can, for example, have the geometry of a C-profile or an L-profile or a U-profile.

[0020] Preferably, the base profile can have a base profile longitudinal axis and / or the stiffening profile can have a stiffening profile longitudinal axis. Particularly preferably, the base profile longitudinal axis and the stiffening profile longitudinal axis can run parallel and / or spaced apart from one another. Alternatively or additionally, the stiffening profile can extend in an axial direction of the extruded profile part and / or in an axial direction of the base profile.

[0021] Particularly preferably, the stiffening profile can be made of the same material and / or connected in one piece to the base profile.

[0022] The material of the stiffening profile and / or the base profile can be removed by cutting using a cutting process according to the third main group of DIN 8580. For example, the material can be removed by cutting (see, for example, DIN 8588), machining with a geometrically defined cutting edge (see, for example, DIN 8589-0), machining with a geometrically undefined cutting edge (see, for example, DIN 8589-0), or removal (see, for example, DIN 8590). Preferably, the material can be removed by milling, laser cutting, eroding, etc.

[0023] Preferably, the extrusion step can be carried out in an extrusion press. Alternatively or additionally, the post-processing step can be carried out in a post-processing system, preferably for mechanical post-processing. Particularly preferably, the extrusion press and the post-processing system can be independent systems. Of course, it is also possible for the extrusion press and the post-processing system to be integrated into a common system, so that both the extrusion step and the post-processing step can be carried out, preferably equally, in the common system.

[0024] Preferably, the extruded profile part is made of metal, such as steel, aluminum, magnesium, or alloys of the aforementioned metals. Alternatively, the extruded profile part can be made of plastic or a fiber-plastic composite.

[0025] The invention also relates to a crash management system comprising a first crash box, a second crash box, and a cross member, wherein the first crash box and / or the second crash box and / or the cross member is formed by a crash component manufactured using the method described above. Local reinforcements or stiffeners can be provided on the first crash box, the second crash box, or the cross member without heat-affected zones and / or notches reducing the strength of the crash management system. This results in high rigidity and / or strength while maintaining a low weight of the crash management system.

[0026] The invention also relates to a motor vehicle, preferably a passenger car, with at least one crash management system as described above.

[0027] In a preferred example of the motor vehicle, preferably the passenger car, a first crash management system can be installed in the front of the motor vehicle, preferably the passenger car. Alternatively or additionally, a second crash management system can be installed in the rear of the motor vehicle, preferably the passenger car.

[0028] Embodiments of the invention are explained in more detail below with reference to the attached schematic drawing.

[0029] They show: Fig. 1 in a perspective view of an extruded profile part produced by extrusion with a base profile and a stiffening profile; Fig. 2 in a perspective view the extruded profile part with the base profile and a stiffening profile segment; Fig. 3 shows a perspective view of a crash component of a crash management system; Fig. 4 in a view from above the crash component of the crash management system; Fig. 5 shows a top view of a crash component according to a further example; Fig. 6 in a view from above a crash component according to another example, and Fig. 7 shows the crash management system in a perspective view.

[0030] Based on the Fig. 1 to 4 and 7, a method for producing a crash component and for producing a crash management system 1 (hereinafter also referred to as CMS 1) of a motor vehicle, specifically a passenger car (hereinafter also referred to as a passenger car), is explained. In the method, an extruded profile part 3 is first produced by extrusion in an extrusion step. The extruded profile part 3 is converted into a crash component 5 in a subsequent post-processing step. The crash component 5 forms a cross member of the CMS 1, which is ready for assembly here only as an example, and is joined in a joining step to a first crash box 7 and a second crash box 9 to form the CMS 1. Based on the Fig. 5 and Fig. 6 shows further examples of a crash component.

[0031] In the Fig. 7 shows the crash management system 1. The first crash box 7 and the second crash box 9 are connected to each other by means of the crash component 5, wherein the crash component 5 forms a cross member of the CMS 1. In the specifically described example, the crash component 5 extends essentially parallel to the transverse axis of the vehicle when the CMS 1 is installed in the vehicle.

[0032] In the Fig. Figure 1 shows the extruded profile part 3, which is manufactured by extrusion in the extrusion step. The extruded profile part 3 has a base profile 11 and a stiffening profile 13, which are connected to each other in a single piece and made of the same material. The extruded profile part 3 is made of steel here only as an example.

[0033] In the specific example described, the base profile 11 has the geometry of a hollow profile, more precisely a square tube. After completion of the extrusion step and before the start of the post-processing step, the stiffening profile 13 has the geometry of a rectangular flat profile and extends, preferably without gaps, over the entire length L of the base profile 11 and along the base profile 13.

[0034] In the Fig. 2 shows the implementation of the post-processing step. During the post-processing step, material is removed from the extruded profile part 3, specifically in the area of ​​the stiffening profile 13. The removal of the material is carried out by milling, merely by way of example. The material is removed in such a way that the material of the stiffening profile 13, or the stiffening profile 13, is essentially completely removed after completion of the post-processing step along two longitudinal sections L1 and L2 of the base profile 11, merely by way of example. The material of the stiffening profile 13 removed in the post-processing step is shown in the Fig. 2 shown in dashed lines. As shown in the Fig. 2 and Fig. 3, after completion of the post-processing step, a stiffening profile segment 15 remains on the base profile 11.

[0035] As part of the post-processing step, according to the illustrations in the Fig. 3 and Fig. 4 Material is removed from a first end section of the stiffening profile segment 15 and from a second end section of the stiffening profile segment 15 in such a way that, after completion of the post-processing step, the first end section has the geometry of a first chamfer 21 and the second end section has the geometry of a second chamfer 23. In addition, recesses are introduced into the stiffening profile segment 15 during the post-processing step. The recesses are formed merely by way of example by bores 25, which are introduced into the stiffening profile segment 15 by drilling.

[0036] As can be seen from the Fig. 5, in another example, material in the region of the stiffening profile 13 can also be removed during the post-processing step in such a way that a first end section of a stiffening profile segment 27 has the geometry of a first radius 29 after completion of the post-processing step and a second end section of the stiffening profile segment 27 has the geometry of a second radius 31 after completion of the post-processing step.

[0037] As can be seen from the Fig.6, in another example, material in the region of the stiffening profile 13 can also be removed during the post-processing step in such a way that a first end section of a stiffening profile segment 33 has the geometry of a first S-bend 35 after completion of the post-processing step and a second end section of the stiffening profile segment 33 has the geometry of a second S-bend 37 after completion of the post-processing step. LIST OF REFERENCE SYMBOLS: 1 crash management system 3 Extruded profile part 5 Crash component 7 first crash box 9 second crash box 11 Basic profile 13 Stiffening profile 15 Stiffening profile segment 21 first phase 23 second phase 25 bore 27 Stiffening profile segment 29 first radius 31 second radius 33 Stiffening profile segment 35 first S-beat 37 second S-beat L total length L1 longitudinal section L2 longitudinal section

Claims

[1] Method for producing a crash component (5) comprising: an extrusion step in which an extruded profile part (3) is produced by extrusion, wherein the extruded profile part (3) has a base profile (11) and a stiffening profile (13), and wherein the method comprises a post-processing step in which the extruded profile part (3) is post-processed in the region of the stiffening profile (13) to form a crash component (5), and wherein, in the post-processing step, the material of the stiffening profile (13) is removed along at least a first longitudinal section (L1) and / or a second longitudinal section (L2) of the base profile (11), so that after carrying out the post-processing step, at least one stiffening profile segment (15) remains on the base profile (11), characterized by , that in the post-processing step at least a first end section of the stiffening profile segment (15) is processed in such a way, that the first end section has the geometry of a first chamfer (21) or a first S-bevel (35) after completion of the post-processing step, and / or that in the post-processing step at least a second end section of the stiffening profile segment (15) is processed in such a way, that the second end section has the geometry of a second chamfer (23) or a second S-bevel (37) after completion of the post-processing step. [2] Method according to claim 1, characterized bythat in the post-processing step, material of the stiffening profile (13) and / or material of the base profile (11) is removed, wherein it is preferably provided that the material of the stiffening profile (13) and / or the material of the base profile (11) is removed by means of separating, preferably by means of a mechanical separating process, particularly preferably by means of milling. [3] Method according to claim 1 or 2, characterized by that during the post-processing step at least one recess is introduced into the stiffening profile (13) and / or into the stiffening profile segment (15), wherein it is preferably provided that the at least one recess is formed by a bore (25) or a perforation hole which is drilled into the stiffening profile (13) and / or into the stiffening profile segment (15) during the post-processing step. [4] Method according to one of the preceding claims, characterized bythat in the extrusion step the extruded profile part (3) is produced in such a way that the stiffening profile (13) extends, preferably completely, over an entire length (L) of the base profile (11). [5] Method according to one of the preceding claims, characterized by , that the base profile (11) has the geometry of a hollow profile, preferably substantially the geometry of a rectangular or square tube, and / or, the stiffening profile (13) has the geometry of a flat profile, the geometry of a hollow profile, the geometry of an open profile or the geometry of a rib. [6] Method according to one of the preceding claims, characterized by , that the crash component (5) forms a cross member, and that a joining step is provided in which the crash component (5) is joined to form a crash management system (1) with a first crash box (7) and with a second crash box (9), and / or, the crash component (5) forms a first crash box, and that a joining step is provided in which the crash component (5) is joined to a second crash box (9) and to a cross member to form a crash management system (1). [7] Crash management system with a first crash box (7), a second crash box (9) and a cross member, wherein the first crash box (7) and / or the second crash box (9) and / or the cross member is formed by a crash component which is produced by a method according to one of the preceding claims. [8] Motor vehicle, preferably a passenger car, with at least one crash management system according to claim 7.

Images