Stamped metal part and manufacturing process for such a part

Abstract

The invention relates to a part (1) for a motor vehicle, the part (1) being manufactured by stamping along a stamping axis Z, the part (1) being metallic and comprising a base (3) and a peripheral rim (5) connected to each other by a draft wall (7) with respect to the stamping axis Z, the draft wall (7) having at least one undercut (9a, 9b, 9c, 9d), an external surface of the at least one undercut (9a, 9b, 9c, 9d) being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°. The invention also relates to a vehicle comprising such a part (1), as well as a method for manufacturing such a part (1). Figure for the abstract: Figure 1

Description

Title of the invention: Stamped metal part and method for manufacturing such a part

[0001] The invention relates to the field of stamped metal parts for motor vehicles. The invention also relates to a method for manufacturing such a part.

[0002] In a known manner, metal parts for motor vehicles are obtained by stamping. For example, a metal strip is placed locally in a stamping press, and the press then deforms the metal strip in one or more passes to obtain a stamped metal part. The stamped metal part is then removed from the stamping press, for example by moving the metal strip, and a new stamped metal part is manufactured from the portion of the metal strip newly introduced into the stamping press. Subsequently, each metal part is separated from the metal strip, for example for transport or storage for later use.

[0003] Due to their stamped shape, these metal parts are easily stackable, which facilitates their transport and storage. However, the metal parts may jam together when stacked, preventing easy removal. Indeed, when the metal parts are stacked, there is a risk of jamming due to the large contact surface between two adjacent metal parts.

[0004] In order to allow the stacking of several stamped metal parts and to facilitate the subsequent extraction of each of these parts from the stack, it is known to place spacers between the metal parts when stacking them on top of each other. However, the arrangement of such spacers is complex and time-consuming.

[0005] The present invention aims to overcome one or more drawbacks of the prior art by allowing identical metal parts manufactured by stamping to be stacked while avoiding in a simple way the jamming of these metal parts between each other.

[0006] For this purpose, the invention relates to a part for a motor vehicle, the part being manufactured by stamping along a stamping axis Z, the part being metallic and comprising a base and a peripheral rim connected to each other by a wall in relief with respect to the stamping axis Z.

[0007] According to the invention, said part is such that the wall in relief with respect to the stamping axis Z has at least one undercut recess, a surface external of at least one indentation being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

[0008] Such a piece is therefore easily stackable, and the presence of at least one indentation simply limits the risk of jamming.

[0009] Furthermore, the range of inclination angles relative to the Z-axis of the stamping allows for at least one undercut dent without breakage or material rupture. Beyond 10°, the material's reconsolidation effect is lost, and the material undergoes deformation leading to fracture. Between 5° and 8°, the reconsolidation effect is significant and is optimal for an inclination angle of 5°. An inclination angle of less than 4° does not prevent the risk of jamming. Moreover, with an inclination angle of less than 3°, during the creation of at least one indentation, the material undergoes deformation leading to fracture. An optimal compromise is achieved for an inclination angle of 5°.

[0010] The said part may further comprise one or more of the following characteristics described below, taken separately or in combination.

[0011] The said part is such that at least one recess is continuous, such that there is continuity of material at every point in the at least one recess and in the area where the drafted wall and the at least one recess meet. The at least one recess thus created maintains the continuity of material in the drafted wall. This makes it possible, for example, to maintain the seal of the internal space delimited by the bottom and the drafted wall when the part is attached to a motor vehicle via the peripheral rim, since no discontinuity in material, such as a notch or a hole, is present.

[0012] Said part is for example made of aluminium. The use of aluminium is advantageous because of its lightness, malleability, corrosion resistance and its recyclability.

[0013] The said part is obtained, for example, by stamping a metal plate, preferably aluminum-based, with a thickness between 0.6 and 1.5 mm, preferably also 0.6 mm. This optimizes the manufacturing process. Indeed, a thinner plate leads to defects during stamping, and a thicker plate makes manufacturing too difficult.

[0014] The said part is for example such that the bottom and the peripheral rim are at least partially parallel to each other and orthogonal to the stamping axis Z. Thus, manufacturing by stamping is facilitated.

[0015] Said part is, for example, such that the wall in relief with respect to the stamping axis Z has at least four undercut recesses, an external surface of each recess being flat and inclined with respect to the axis Z-shaped stamping, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°. Thus, several parts can be stacked optimally, greatly reducing the risk of jamming.

[0016] Said part is for example such that the draft wall is inclined with respect to the stamping axis Z by a draft angle between 3° and 25°, preferably between 3° and 10°.

[0017] The invention also relates to a motor vehicle comprising a part as defined above.

[0018] The invention also relates to a method for manufacturing a part as defined above.

[0019] Said process comprises the following steps:

[0020] - stamping a part in a stamping press along a stamping axis Z, the part being metallic and comprising a base and a peripheral rim connected by a wall with a cutaway relative to the Z-axis of stamping,

[0021] - to be made on the drafted wall, the part being in the stamping press, at less an undercut dent by means of a denting tool, an external surface of the at least one dent being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

[0022] A part manufactured by such a process is therefore easily stackable, and the presence of at least one indentation simply limits the risk of jamming.

[0023] Furthermore, the range of inclination angles relative to the Z-axis of the stamping allows for at least one undercut dent without breakage or material rupture. Beyond 10°, the material reconsolidation effect is lost, and the material undergoes deformation leading to breakage. Between 5° and 8°, the reconsolidation effect is significant and is optimal for an inclination angle of 5°. An inclination angle of less than 4° does not prevent the risk of jamming. Moreover, with an inclination angle of less than 3°, during the creation of at least one indentation, the material undergoes deformation leading to breakage. An optimal compromise is achieved for an inclination angle of 5°.

[0024] The process is, for example, such that the step of creating at least one indentation is carried out directly after the part has been stamped. Thus, the finalization of the part's manufacture is simplified, since at least one indentation is created in the stamping press without requiring any movement, handling, or processing of the stamped part.

[0025] The method is, for example, such that, during the step of making at least one indentation, the indentation tool slides in the stamping press inclined relative to the stamping axis Z, the indentation tool being A cam-operated slide is preferred. This allows the insertion tool to push material from an area of ​​the draft wall far from the point of failure. This material is then displaced towards an area of ​​the draft wall closer to the edge and therefore closer to the point of failure. In other words, the insertion tool moves material from a work-hardened area of ​​the draft wall near the bottom of the part to an area near the point of failure and further from the bottom of the part, thus reinforcing the area near the point of failure and enabling at least one insertion without breaking the continuity of the material.

[0026] The process is, for example, such that the part is stamped from a metal strip. Thus, mass production is simplified, since it is sufficient to move the metal strip to move the stamped part, until it is extracted from the metal strip.

[0027] The process includes, for example, the following step: after at least one indentation has been made, the part is separated and extracted from the metal strip. Thus, separation and extraction take place once at least one indentation has been made, thereby greatly reducing the risk of jamming when several parts are stacked after manufacturing.

[0028] Other advantages and features of the invention will become more apparent upon reading the following description, given by way of illustrative and non-limiting example, and the accompanying drawings, among which:

[0029] [Fig. 1] is a perspective view of an example of an embodiment of a part according to the invention.

[0030] [Fig.2] is a partial cross-sectional view of a stack of several pieces according to [Fig.1].

[0031] [Fig.3] is seen in perspective of an example of the realization of a part according to the [Fig.1], during its manufacture according to the invention.

[0032] [Fig.4] is a schematic partial side view of an example embodiment of a part according to [Fig.1], during its manufacture according to the invention.

[0033] [Fig.5] is a schematic partial side view of an example embodiment of a part following [Fig.1], during its manufacture according to the invention.

[0034] In these figures, identical elements bear the same reference numerals.

[0035] The following embodiments are examples. Although the description refers to one or more embodiments, this does not necessarily mean that each reference numeral relates to the same embodiment, or that the features apply only to a single embodiment. Simple features from different embodiments can also be combined or interchanged to provide other embodiments.

[0036] In the description, certain elements can be indexed, for example, first element or second element. In this case, it is simply an indexing to differentiate and name similar but not identical elements. This indexing does not imply any priority of one element over another, and such designations can easily be interchanged without departing from the scope of the present invention. Nor does this indexing imply any chronological order.

[0037] With reference to [Fig.1], the invention relates to a stamped metal part, hereafter referred to as part 1. Thus, part 1 is metallic and is manufactured by stamping.

[0038] Part 1 is intended to be installed in a motor vehicle, not shown in the figures. The invention also relates to such a motor vehicle comprising part 1.

[0039] A trihedral XYZ frame is schematically represented in [Fig. 1]. The stamping axis Z is the axis along which the stamping of part 1 is performed. Part 1 is thus manufactured by stamping along the stamping axis Z. The stamping axis Z can also coincide with the vertical top / bottom axis of the motor vehicle, i.e., along the height of the motor vehicle, when part 1 is mounted inside the vehicle. The X-axis is a longitudinal axis of part 1. This X-axis can also correspond to the front / rear longitudinal axis of the motor vehicle, i.e., along the length of the motor vehicle, when part 1 is mounted inside the motor vehicle. The Y-axis is a transverse axis of part 1. This Y-axis can also correspond to the right / left transverse axis of the vehicle, i.e., along the width of the motor vehicle, when device 1 is mounted inside the motor vehicle. The X, Y, Z axes are orthogonal to each other.

[0040] The part 1 comprises a bottom 3 and a peripheral rim 5. The bottom 3 and the peripheral rim 5 are at least partially parallel to each other and orthogonal to the stamping axis Z. The bottom 3 and the peripheral rim 5 are connected to each other by a wall with a draft 7 relative to the stamping axis Z.

[0041] According to the invention, the undercut wall 7 has at least one undercut 9a, 9b, 9c, 9d, an external surface 1la, 11b, 1le, 1Id of the at least one undercut 9a, 9b, 9c, 9d being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

[0042] For example, at least one recess 9a, 9b, 9c, 9d is continuous, such that there is continuity of material at every point in at least one recess 9a, 9b, 9c, 9d and in the bond zone between the cut wall 7 and at least one recess 9a, 9b, 9c, 9d.

[0043] In the example shown in [Fig. 1], the chamfered wall 7 has at least four recesses 9a, 9b, 9c, 9d in undercut, an external surface 1 la, 11b, 1 le, 1 Id of each recess 9a, 9b, 9c, 9d being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

[0044] In this example, a first indentation 9a and a second indentation 9b are substantially opposite to a third indentation 9c and a fourth indentation 9d. Such an arrangement allows for regular stacking of parts 1 on top of each other, as partially shown in [Fig.2], and facilitates their storage and handling.

[0045] For example, the first indentation 9a and the second indentation 9b are offset along the transverse axis Y, and are, for example, symmetrical with respect to a plane parallel to the plane formed by the longitudinal axis X and the stamping axis Z. For example, the third indentation 9c and the fourth indentation 9d are offset along the transverse axis Y. For example, the first indentation 9a and the second indentation 9b are offset along the longitudinal axis X with respect to the third indentation 9c and the fourth indentation 9d.

[0046] In this example, part 1 includes a notch 13 formed between the first recess 9a and the second recess 9b, a through hole 15 formed in the bottom 3. The notch 13 and / or the through hole 15 are configured for example for the passage of at least one electrical cable, and / or for the passage of at least one fluid conduit, and / or for being closed by means of a plug.

[0047] In this example, part 1 also includes fixing holes 17 and positioning holes 19, which are distributed on the peripheral rim 5 and allow the positioning and fixing of part 1 on the motor vehicle, for example via positioning means such as pins and via fixing means such as screws.

[0048] Part 1 is obtained by stamping a metal plate, for example made of aluminum, with a thickness between 0.6 and 1.5 mm, preferably equal to 0.6 mm. For example, part 1 is made of aluminum.

[0049] Part 1 can be manufactured according to a manufacturing process comprising the following steps, with reference to Figures 3 to 5.

[0050] The process first comprises the following step: stamping the part 1 in a stamping press 21 along a stamping axis Z. For example, the part 1 is obtained by stamping a metal plate, for example made of aluminum, with a thickness between 0.6 and 1.5 mm, preferably equal to 0.6 mm. At the end of this step, the part 1 thus comprises a base 3 and a peripheral rim 5 connected to each other by a draft wall 7 with respect to the stamping axis Z, as shown in [Fig. 3].

[0051] The process then comprises the following step, shown in [Fig.4] and [Fig.5]: making on the undercut wall 7, with the part 1 in the stamping press 21, at least one undercut indentation 9a, 9b, 9c, 9d by means of a stamping tool 23, an external surface of the at least one indentation 9a, 9b, 9c, 9d being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

[0052] For example, the step of making at least one indentation 9a, 9b, 9c, 9d is carried out directly after stamping of the part 1.

[0053] Figure 4 partially represents part 1 in the stamping press 21 before making at least one indentation 9a, 9b, 9c, 9d, and [Fig.5] partially represents part 1 in the stamping press 21 after making at least one indentation 9a, 9b, 9c, 9d.

[0054] As shown in [Fig.4], the draft wall 7 is inclined relative to the stamping axis Z by a draft angle D between 3° and 25°, preferably between 3° and 10°.

[0055] During the step of creating at least one indentation 9a, 9b, 9c, 9d, the indentation tool 23 slides in the stamping press 21 at an angle to the stamping axis Z, as shown in [Fig. 4] and [Fig. 5]. The angle of inclination is, for example, between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°. Thus, as shown in [Fig.5], the angle of inclination A of the sliding of the forging tool 23 in the stamping press 21 with respect to the stamping axis Z is equal to the angle of inclination of the external surface of at least one indentation 9a, 9b, 9c, 9d with respect to the stamping axis Z, once at least one indentation 9a, 9b, 9c, 9d has been made by the forging tool 23. The forging tool 23 is for example a cam slide.

[0056] For example, the end 25 of the driving tool 23 configured to come into contact with the draft wall 7 of the part 1 to make at least one drive 9a, 9b, 9c, 9d has a rounded end, for example in the form of a segment of a straight cylinder, having in this example a radius between 1 mm and 3 mm, preferably equal to 1.5 mm, in order to generate a corresponding fillet between the at least one drive 9a, 9b, 9c, 9d and the rest of the part 1, namely the draft wall 7 or even the peripheral rim 5.

[0057] The process can finally then include the following step, when part 1 is stamped from a metal strip: after making at least one indentation, part 1 is separated and extracted from the metal strip.

Claims

Demands

1. Part (1) for a motor vehicle, the part (1) being manufactured by stamping along a stamping axis Z, the part (1) being metallic and comprising a base (3) and a peripheral rim (5) connected to each other by a draft wall (7) relative to the stamping axis Z, the part (1) being characterized in that: the draft wall (7) has at least one undercut (9a, 9b, 9c, 9d), an external surface of the at least one undercut (9a, 9b, 9c, 9d) being flat and inclined relative to the stamping axis Z, the angle of inclination being between 5° and 8°.

2. Part (1) according to the preceding claim, wherein at least one recess (9a, 9b, 9c, 9d) is continuous, such that there is continuity of material at every point in at least one recess (9a, 9b, 9c, 9d) and in the bond zone between the draft wall (7) and at least one recess (9a, 9b, 9c, 9d).

3. Part (1) according to any one of the preceding claims, which is obtained by stamping a metal plate, preferably aluminum-based, of a thickness between 0.6 and 1.5 mm, preferably equal to 0.6 mm.

4. Part (1) according to any one of the preceding claims, wherein the undercut wall (7) has at least four undercut recesses (9a, 9b, 9c, 9d), an external surface of each recess (9a, 9b, 9c, 9d) being flat and inclined with respect to the stamping axis Z, the angle of inclination being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

5. Part (1) according to any one of the preceding claims, wherein the draft wall (7) is inclined with respect to the stamping axis Z by a draft angle D between 3° and 25°, preferably between 3° and 10°.

6. Motor vehicle, characterized in that it comprises a part (1) according to any one of the preceding claims.

7. A method for manufacturing a part (1) according to any one of claims 1 to 5, which comprises the following steps: - stamping a part (1) in a stamping press (21) along a stamping axis Z, the part being metallic and comprising a bottom (3) and a peripheral rim (5) connected to each other by a draft wall (7) with respect to the stamping axis Z, - to make on the undercut wall (7), the part (1) being in the stamping press (21), at least one undercut (9a, 9b, 9c, 9d) using a stamping tool (23), an external surface of at least one undercut (9a, 9b, 9c, 9d) being flat and inclined with respect to the stamping axis Z, the angle of inclination A being between 4° and 10°, preferably between 5° and 8°, more preferably equal to 5°.

8. Manufacturing method according to the preceding claim, wherein the step of making at least one indentation (9a, 9b, 9c, 9d) is carried out directly after stamping the part (1).

9. A manufacturing method according to claim 7 or 8, wherein, during the step of making at least one indentation (9a, 9b, 9c, 9d), the indentation tool (23) slides in the stamping press (21) in an inclined manner with respect to the stamping axis Z, the indentation tool (23) preferably being a cam slide.

10. A manufacturing method according to any one of claims 7 to 9, wherein the part (1) is stamped from a metal strip, the method comprising the following step: - after making at least one indentation (9a, 9b, 9c, 9d), the part (1) is separated and extracted from the metal strip.

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