METHOD FOR INCREASING THE RIGIDITY OF SHEET METAL COMPONENTS AND SHEET METAL COMPONENT OBTAINED THEREFROM

Abstract

The present invention relates to the design, optimization and application of a reinforcement or reinforcements produced by additive manufacturing to increase the bending, torsional and load-bearing stiffness of sheet metal components.

Description

Technical field of the invention

[0001] The present invention relates to the design, optimization and application of a reinforcement or reinforcements produced by additive manufacturing to increase the bending, torsional and load-bearing stiffness of sheet metal components. Background of the invention

[0002] Sheet metal is a material widely used in the production of various components in many different sectors, from automobiles to household appliances. Compression molding and similar processes are often used in sheet metal forming. However, when changes to the final product are required, molds and similar elements must be modified. Today, standardization of product types plays a key role in reducing production costs, and it is of great importance to produce in as high a volume as possible without making changes to the system. However, as explained above, products that require modification, and especially those that must be produced in small quantities, pose a problem in terms of production costs.

[0003] Particularly in the automotive sector, sports and similar niche models of production vehicles are common, and these vehicles, especially high-performance ones, require more rigid versions of components than standard models due to their increased engine power and performance. Considering that niche models are produced in much smaller numbers compared to standard models, it can be seen that (in general) the drivetrain layout is more robust and advanced. These higher-rigidity components are usually produced according to a completely new design. Since production volumes are also low, the fixed costs for development and commissioning incur significant additional costs per unit.It is of great importance for the automotive industry to produce specific components for niche models with minimal fixed costs, minimal personnel expenditure and in the shortest possible time.

[0004] Some manufacturers tend to produce standard components for niche models from different materials. However, in this case, the price of the more stable material is a concern, and some materials may require different manufacturing techniques than sheet metal.

[0005] The Chinese patent document with publication number CN110341812A is specifically designed to improve vehicle bodies. The target area is determined by creating an algorithm for the body, not for any specific vehicle component.

[0006] The Turkish patent document with application number TR 2020 / 08028 discloses an optimization system that allows creating a digital model of a component, and the process of lightening the structure of the part to be produced is carried out by removing the regions where the desired threshold values ​​are not met from the digital model.

[0007] As a result, all of the above-mentioned problems have made innovation in the relevant field necessary. Objectives of the invention

[0008] The main objective of the invention is to provide the structure of a reinforcement method, particularly for adapting standardized sheet metal components to specific conditions.

[0009] Another object of the invention is to increase the rigidity of sheet metal components without compromising the standardized production process.

[0010] Another object of the invention is to increase the stiffness of a component without changing the geometry and material of the component used in standard models.

[0011] Yet another object of the invention is to increase the stiffness of a component without changing the properties of the part and the connection points. Brief description of the invention

[0012] In the method according to the invention, a final product consisting of a standard sheet metal is analyzed using computer-aided analysis methods. Based on this analysis, weak / insufficiently stiff regions of said final product are identified. The necessary reinforcements, such as ribs, are then designed for the identified areas using computer-aided design methods. The required number, thickness, and geometry of the reinforcements are also taken into account. After the said design has been created, this design is analyzed again using computer-aided analysis methods. In this method, the design process is repeated until the targeted stiffness values ​​are achieved.After obtaining the appropriate design, reinforcements are created on a standard component using an additive manufacturing process and the resulting reinforced standard product is subjected to a stiffness analysis using visual scanning techniques.

[0013] This achieves an increase in the stiffness value without changing the main characteristics of the standard component or the production process in any way. Definitions of the figures to explain the invention

[0014] The figures and the associated descriptions used to further explain the device developed by the present invention are as follows. Fig. Figure 1 is a representative schematic diagram of a sheet metal component. Fig. 1a is a sectional view of the Fig. 1. Fig. 2 is a schematic view of the Fig. 1, which is reinforced by additive manufacturing. Fig. 2a is a sectional view of the Fig. 2. Definitions of the elements / parts / components that make up the invention

[0015] The figures and the associated explanations used to better explain the device developed by the present invention are numbered and the correspondence of each number is given below: 10 components 11 Deepening 20 Reinforcing element Detailed description of the invention

[0016] The subject matter of the present invention relates to the design, optimization and application of a reinforcement or reinforcements produced by additive manufacturing to increase the bending, torsional and load-bearing stiffness of sheet metal components.

[0017] In the Fig. 1 and Fig. 1a shows a component (10) made of any sheet metal. This component (10) can be a part for household appliances or for motor vehicles. Examples of said component can be fixed or movable hinge brackets, clutch covers, radiator supports, wishbones, suspension towers, etc.

[0018] The component mentioned is a final product that has already been produced for a standard process.

[0019] First, said component (10) is analyzed for stiffness using computer-aided design (CAE) software. Preferably, a computer-aided graphical design of said component is used for this analysis. This can, for example, be a CAD model of said component.

[0020] Preferably, computer-aided design programs such as ANSYS, Fusion 360, LS-Dyna, SolidWorks or Siemens NX or similar programs can be used.

[0021] In a preferred embodiment, separate analyses are performed using multiple computer-aided design programs. The primary purpose of this is to verify the consistency of the stiffness value obtained as a result of the analysis. Thus, by applying the reinforcement element (20), it is possible to obtain an idea of ​​the stiffness value difference that may occur between the computer-generated prototype and the actual prototype.

[0022] In addition, the consistency of the stiffness value is optionally checked again by comparing the results of the above analysis with the known field values ​​of the component under investigation (10).

[0023] For example, if it is found as a result of the analysis carried out for the above-mentioned sheet metal component (10) that a recess (11) provided on the surface of the component (10) adversely affects the rigidity, it is concluded that a reinforcing element (20), a rib, should be formed on said recess (11), as shown in the Fig. 2 and Fig. 2a shown.

[0024] To reinforce said component (10), the reinforcing element is designed using computer-aided design methods / programs. Said design is also realized in the form of a computer-aided graphic model, for example a CAD model.

[0025] At this point, the geometric structure, pattern (triangular, square, zigzag pattern, etc.), thickness, density, number, and dimensions of the designed reinforcing element (20) play an important role. For example, on the component (10) in the Fig. 2 and Fig. 2a the reinforcing elements (20) with triangular cross-sections arranged at radial intervals of 45°, designed to be formed in the above-mentioned recess (11).

[0026] After the design phase, the analysis is carried out again using computer-aided analysis programs to decide whether the stiffness target determined on the visual model of the component (10) with reinforcement element (20) has been achieved or not.

[0027] The analysis is repeated after determining whether the stiffness target set at the end of the analysis has been achieved or not, and if not, the analysis is repeated by making the necessary changes.

[0028] When the stiffness value reaches the target level set by the user, a visual prototype is obtained, and after this phase, production of the physical prototype proceeds.

[0029] At this point, the reinforcement element (20) or reinforcement elements (20) that provide suitable stiffness results on the component (10), which is an already manufactured end product for a standard process, are provided by additive manufacturing.

[0030] The type of additive manufacturing process used herein should not be considered limiting, and any additive manufacturing process may be used in the process of the invention.

[0031] Accordingly, in its most basic form, said reinforcement method comprises the steps of providing a component (10) made of sheet metal and arranged as a final product and a solid model suitable for computer-aided graphic design programs; performing at least one stiffness analysis of said solid model by means of a computer-aided analysis program; adding at least one reinforcement element (20) to the solid model in at least one region that adversely affects the stiffness determined based on the stiffness analysis; re-performing at least one stiffness analysis of the newly obtained solid model by means of a computer-aided analysis program; physically adding said reinforcement element (20) to the sheet metal component (10) by means of an additive manufacturing process according to the solid model if said solid model achieves the desired stiffness value.Preferably, at least the stiffness analysis of the new volume model is carried out again using a computer-aided analysis program.

[0032] By subjecting the component (10) with the reinforcement element (20) or reinforcement elements (20) obtained by additive manufacturing to a computer-aided visual scan, a solid model suitable for computer-aided graphic design programs is obtained. Preferably, said solid model, referred to herein, is created as a CAD file.

[0033] The aforementioned computer-aided visual scanning process is preferably performed by scanning or by a coordinate measuring machine, also known as a CMM. The coordinate measuring machine can measure with minimal error, especially on components (10) with many irregular surfaces, such as the clutch cover.

[0034] The solid model, suitable for computer-aided graphical design programs, is subjected to a stiffness analysis again, at least using computer-aided analysis programs. Comparing the results of the analysis with previous ones and calculating how much the stiffness of the part can be improved ensures that it is determined whether the predicted strengthening target can be achieved on the physical part.

[0035] If, after analysis, the design fails to achieve the desired stiffness target, the design is modified. This modification is achieved by reviewing the stress zones and improving the design or creating a completely new design. In addition to stiffness, the appropriate structure of the reinforcing element (20) is decided in accordance with the difficulties that may arise during the manufacturing process. For example, with the invention, to achieve a stiffness value of a clutch cover with a thickness of 5 mm, a reinforcing element (20) can be formed on the clutch cover, which is made of the same material with a thickness of 4.5 mm, using additive manufacturing processes. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] CN 110341812A

[0005] TR 2020 / 08028

[0006]

Claims

[1] Reinforcing process for increasing the stiffness of sheet metal components (10); characterized by that it includes the steps Providing a component (10) made of sheet metal and arranged as a final product and a volume model suitable for computer-aided graphic design programs; Performing at least one stiffness analysis of said volume model using a computer-aided analysis program; adding at least one reinforcing element (20) to the volume model in at least one region that adversely affects the stiffness determined based on the stiffness analysis; physically adding said reinforcing element (20) to the sheet metal component (10) which is the region adversely affecting stiffness, by means of an additive manufacturing process. [2] Reinforcement method according to claim 1; characterized bythat at least the stiffness analysis of the new volume model obtained is carried out again using a computer-aided analysis program. [3] Reinforcing method according to claim 1 or 2; characterized by that the reinforcement element (20) added to the solid model is recreated if said reinforcement element (20) does not reach the desired stiffness value of the added solid model. [4] Reinforcement method according to claim 1; characterized by that a volume model is obtained by performing a computer-aided visual scanning process of the component (10) physically added with the reinforcing element (20), and wherein at least the stiffness analysis of the obtained volume model is performed again by means of a computer-aided analysis program. [5] Reinforcement method according to claim 4; characterized bythat the said computer-aided visual scanning process is carried out by a coordinate measuring device. [6] Reinforcement method according to claim 1; characterized by that the volume model of the component (10) to which no reinforcement element (20) is added is compared with the physical component (10). [7] Component (10) obtained by a process suitable for any one of the preceding claims. [8] Clutch cover according to claim 7. [9] Hinge bracket according to claim 7. [10] Radiator support according to claim 7. [11] Wishbone according to claim 7. [12] Suspension tower according to claim 7.

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