Method for the series production and stacking of form-uniform sheet metal parts

Abstract

The invention relates to a method for the serial production of identical sheet metal parts (100), in particular body parts, wherein the sheet metal parts (100) are produced in a press or press line by forming a sheet metal material (M) and then arranged into a stack (200) of sheet metal parts. According to the invention, during the production of the sheet metal parts (100) in the press or press line, at least one cup-shaped spacer element (110) is formed into each sheet metal part (100), which functions as a spacer in the stack (200) of sheet metal parts.

Description

[0001] The invention relates to a method for the serial production of sheet metal parts of identical shape. The method provides that the sheet metal parts are produced in a press or press line by forming sheet metal material and then arranged into a stack of sheet metal parts.

[0002] In the serial production of sheet metal parts with identical or identical shapes, the parts can be temporarily stacked on top of each other after production and then transported and stored as a stacked unit. The individual parts can then be removed from the stack and fed into a further processing step.

[0003] DE 10 2016 201 237 A1 describes a method for manufacturing a sheet metal forming part, including hot forming and press hardening. The finished sheet metal forming parts are stacked in a so-called storage device, i.e., arranged to form a stack of sheet metal forming parts.

[0004] DE 10 2011 117 640 B4 describes a device for stacking sheet metal parts on presses and press lines.

[0005] When sheet metal parts of identical shape and geometry are stacked or arranged in a stack, they can become jammed due to their shape and geometry, making unstacking more difficult. Furthermore, the shape and geometry of the sheet metal parts can cause the stack to tilt or become unstacked as the stack height increases, making automated loading and unloading more difficult, increasing the stack volume, and potentially increasing the likelihood of jamming.

[0006] The invention is intended to avoid the disadvantages described above.

[0007] This is achieved with the inventive method of claim 1. Advantageous further developments and embodiments of the invention result from the dependent claims, the following description (this expressly includes optional and exemplary features) and the figures.

[0008] In the inventive method for the serial production of identical sheet metal parts, in particular body panels, the sheet metal parts are produced in a press or in a press line comprising several presses or the like by forming sheet metal material and then, typically in an exit area of ​​the press or press line, stacked, i.e., arranged into a stack of sheet metal parts, which can also be referred to as stacking the sheet metal parts. The stacking of the sheet metal parts can be carried out manually or automatically. Preferably, the sheet metal parts are stacked vertically on top of each other, thus forming a vertical stack of sheet metal parts. In principle, the sheet metal parts can also be arranged or stacked side by side or in a horizontal stack of sheet metal parts. Preferably, the sheet metal parts are stacked directly without intermediate layers or the like.

[0009] According to the invention, at least one cup-shaped spacer element is formed into each sheet metal part during its production in the press or press line. This spacer element then functions as a spacer in the stack of sheet metal parts, being virtually integrated into the sheet metal part or formed integrally with it. The cup-shaped spacers are particularly intended to prevent the sheet metal parts from jamming in the stack and / or from tilting or shifting, and to enable straight stacking, especially with substantially parallel sheet metal parts.

[0010] The at least one cup-shaped spacer element preferably has a cup height that is dimensioned such that jamming of the sheet metal parts in the stack of sheet metal parts and / or tilting or shifting of the stack of sheet metal parts is prevented.

[0011] Preferably, at least one cup-shaped spacer element is specifically designed as a spacer or distance element and is formed into the sheet metal material or sheet metal part for this purpose. In addition to this primary function, secondary functions can also be provided, as described below.

[0012] In principle, at least one cup-shaped spacer element is consistently located in the same position on every sheet metal part and always has the same or identical shape or geometry. However, varying positions and / or shapes or geometries (i.e., also with regard to dimensions) are conceivable and technically feasible. If several cup-shaped spacers are provided for each sheet metal part, they can be identical or different.

[0013] The sheet metal material used is preferably a metal sheet, e.g., an aluminum or steel sheet, which is available particularly as thin sheet metal, optionally also as tailored blank. The metal sheet may have a coating, e.g., a corrosion protection coating. The forming of the metal sheet can be cold forming and / or hot forming and may also include so-called press hardening. However, the invention is also fundamentally suitable for other non-metallic sheet-like semi-finished products. For example, the sheet metal material used may also be a so-called organosheet.

[0014] A cup-shaped spacer is a pot-shaped depression, particularly with a circular cross-section, formed into the sheet metal material. It has a circumferential wall (rim), particularly a closed circumferential wall, and a bottom (cup bottom), particularly a closed bottom. Preferably, the cup-shaped spacer is formed into the sheet metal in a single-stage process, particularly without generating waste (su). For the single-stage forming of a cup-shaped spacer, a punch (cup punch) and a counteracting die (cup die) are preferably used. These are arranged in a press tool specifically designed for forming at least one cup-shaped spacer or can be integrated into a press tool already used for manufacturing the sheet metal parts, particularly a forming and / or cutting tool.The forming of a cup-shaped spacer can also be carried out in a multi-stage process, using a corresponding number of punches and dies distributed across several press tools or stations. The latter allows for the forming of a cup-shaped spacer with a large cup depth and, if necessary, also with a stepped shape or geometry.

[0015] The cup-shaped spacer is preferably formed without any drilling or cutting operations, so that the sheet metal part has no opening at that location through which moisture or dirt could later penetrate. Furthermore, no cutting or drilling waste is generated. However, the forming of the cup-shaped spacer can be combined with a preceding, subsequent, or simultaneous drilling and / or cutting operation, for example, to achieve a greater cup depth in sheet metal that is difficult to form.

[0016] The spacing achieved by the cup-shaped spacer element is essentially determined by the cup height and is typically a multiple of the sheet thickness, i.e., at least twice the thickness of the sheet material. Thus, a very large spacing can be generated compared to the sheet thickness alone. Preferably, the cup height and / or the shape or geometry (i.e., also the dimensions) of the cup-shaped spacer element can be changed or adjusted to allow for flexible adaptation. This can be achieved by adjusting the punch or by replacing the punch and / or the die.

[0017] Preferably, the diameter (outer diameter) of the cup-shaped spacer element corresponds to four to ten times the sheet thickness of the sheet material. In particular, the cup-shaped spacer element is designed to have a diameter (outer diameter) of 8 mm to 12 mm. The sheet thickness of the sheet material, which refers specifically to the initial sheet thickness, is preferably 0.8 mm to 3.0 mm. The initial sheet material can also have different sheet thicknesses (as, for example, in a tailored rolled blank).

[0018] Preferably, the bottom edge of the cup-shaped spacer element, meaning the outer circumferential transition between the bottom (cup bottom) and the circumferential wall (rim), is formed with an undercut ring contour, in particular an undercut ring bead, which is preferably circumferential. This ring contour or ring bead is undercut, especially in the axial or vertical direction of the cup-shaped spacer element, which preferably also corresponds to the stacking direction of the sheet metal parts in the sheet metal stack. The forming of the undercut ring contour or ring bead can be carried out without a tool slide or the like, in particular by a local embossing process of the sheet metal material between the punch and die.In this local embossing process, in addition to deep drawing and stretch forming of the sheet metal, a local flow forming of the sheet metal at the bottom edge also takes place when forming the cup-shaped spacer element. This creates the undercut ring contour or ring bead. This process can also be described as embossing the bottom edge. The punch and die are designed appropriately for this purpose, as shown, for example, in [reference to relevant figure]. Fig. 3 As shown, the undercut ring contour or ring bead prevents the cup-shaped spacers from sliding into each other within the stack of sheet metal parts, or at least reduces this to a predetermined degree, thus ensuring the intended spacing. Furthermore, the ring contour or ring bead can also act as scratch protection.

[0019] Preferably, the cup-shaped spacer element is arranged or formed in a sheet metal component area that is not visible, or at least not directly visible, after the sheet metal component has been installed according to the process, particularly in a vehicle body. The cup-shaped spacer element is therefore not perceived as an obstruction.

[0020] As explained above, the primary function of at least one cup-shaped spacer element is to act as a spacer or spacer within a stack of sheet metal parts. Furthermore, such a cup-shaped spacer element, particularly when a sheet metal part manufactured according to this process is used as a body panel component, can also serve a secondary function (further use) as an alignment element for component alignment during installation of the sheet metal part, and / or as a fastening element for attaching another component (e.g., a cable duct) to the sheet metal part, preferably to the installed sheet metal part, in particular by means of a clip or snap connection with a corresponding clip or snap element.

[0021] Further advantages of the invention include the fact that a cup-shaped spacer element, functioning as a spacer, requires only a small area on the sheet metal part and can also be manufactured with very tight tolerances. In addition to the advantages already described, the invention, with its efficient use of space (due to its small packing volume), enables the relatively simple stacking of even complexly shaped sheet metal parts, thus eliminating the need for customized storage and transport racks or similar devices, which are currently still widely used.

[0022] The invention is explained in more detail below by way of example and in a non-limiting manner with reference to the schematic figures. The features shown in the figures and / or explained below can, even independently of specific combinations of features, be general features of the invention and further develop the invention accordingly. Fig. 1 shows a stack of sheet metal parts manufactured according to the invention. Fig. 2 shows a detailed sectional view of two sheet metal parts from the stack. Fig. 1 and illustrates the generation of distances using the molded-in cup-shaped spacer elements. Fig. 3 illustrates, in two sectional views, the molding of a Fig. 2 cup-shaped spacer element shown, using a cup tool.

[0023] The in Fig. 1The sheet metal parts 100 shown, which are identical in shape, are produced in a press or press line using the method according to the invention and stacked on top of each other to form a vertical stack 200. Each sheet metal part 100 has at least one molded cup-shaped spacer element 110, which acts as a spacer in the stack 200. The cup-shaped spacers 110 prevent the sheet metal parts 100 from jamming in the stack 200 and also prevent the stack 200 from tilting or becoming misaligned with increasing stack height. In the illustrated embodiment, the cup-shaped spacers 110 are shaped downwards. The cup-shaped spacers 110 can also be shaped upwards with the same effect.

[0024] A in Fig. 2The cup-shaped spacer element 110 shown has a circumferential wall (rim) 111 and a base (cup base) 112, preferably with a circular cross-section. Preferred ranges for the diameter D and the cup height H are given above. The base rim 113 of the cup-shaped spacer element 110 is formed circumferentially with an undercut ring contour 114, preferably in the form of a circumferential ring bead, such that the ring contour or ring bead 114 has an undercut U in the axial direction (height direction) of the cup-shaped spacer element 110. The undercut ring contour or ring bead 114 prevents the cup-shaped spacer elements 110 from sliding into one another or becoming wedged together when the sheet metal parts 100 are stacked.

[0025] The cup-shaped spacer elements 110 can be produced in a single-stage shaping process using the in Fig. 3The cup tool 300 shown is used to form the sheet metal material M of the sheet metal parts 100. The forming is achieved in particular by local deep drawing and / or stretch drawing of the sheet metal material M. The cup tool 300 is integrated, in particular, into a press tool of the press or press line. The cup tool 300 has a punch (cup punch) 310 and a counteracting die (cup die) 320. The forming of the undercut ring contour or ring bead 114 is carried out without a tool slide by a local embossing process of the sheet metal material M. To realize such a local embossing process, the cavity of the die 320 can, for example, be designed with an embossing protrusion 321, which leads to a radially outward material flow in the bottom area, indicated by arrows. Demolding is possible without special effort due to the absence of undercuts in the cup tool 300. Reference symbol list

[0026] 100Sheet metal part 110Cup-like spacer element 111Circular wall 112Base 113Base edge 114Ring contour 200Sheet metal part stack 300Cup tool 310Punch 320Die 321Embossed height ADetail DDiameter HCup height MSheet metal material UUndercut sSheet metal thickness

Claims

1. Method for the serial production of sheet metal parts (100) of identical shape, in particular body parts, wherein the sheet metal parts (100) are produced in a press or press line by forming a sheet metal material (M) and are then arranged to form a stack of sheet metal parts (200), characterized by the fact that When producing the sheet metal parts (100) in the press or press line, at least one cup-shaped spacer element (110) is formed into each sheet metal part (100), which acts as a spacer in the stack of sheet metal parts (200).

2. Method according to claim 1, characterized by the fact that the cup depth (H) of the cup-shaped spacer element (110) corresponds to at least twice the sheet thickness (s) of the sheet material (M).

3. Method according to any of the preceding claims characterized by the fact that The diameter (D) of the cup-shaped spacer element (110) corresponds to four to ten times the sheet thickness (s) of the sheet material (M).

4. Method according to any one of the preceding claims, characterized by the fact that The forming of the cup-shaped spacer element (110) is carried out in a single-stage process using a punch (310) and a counteracting die (320), which are integrated in particular into a press tool of the press or press line.

5. Method according to any one of the preceding claims, characterized by the fact that the bottom edge (113) of the cup-shaped spacer element (110) is formed with an undercut ring contour (114).

6. Method according to claims 4 and 5, characterized by the fact that The undercut ring contour (114) is produced by a local embossing process of the sheet material (M) between punch (310) and die (320).

7. Method according to any of the preceding claims, characterized by the fact that the cup-shaped spacer element (110) is arranged in a sheet metal forming area that is not visible after installation.

8. Use of a sheet metal forming part (110) produced by a method according to any one of the preceding claims 1 to 7 as a body component, wherein the cup-shaped spacer element (110) acts as an alignment element when installing the sheet metal forming part (110).

9. Use of a sheet metal forming part (110) produced by a method according to any one of the preceding claims 1 to 7 as a body component, wherein the cup-shaped spacer element (110) functions as a fastening element for fastening a further component to the sheet metal forming part (110).

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