A method for manufacturing a three-dimensional part from at least one metal sheet comprising a network of pre-folds, and a three-dimensional part obtained from said method.

Abstract

Method for manufacturing a three-dimensional part from at least one metal sheet comprising a pre-fold network, three-dimensional part obtained by said method. The invention relates to a method for manufacturing a three-dimensional part from at least one flat metal sheet (12), comprising a step of creating at least one pre-fold network (14, 16, 18) on the metal sheet (12) and a step of deforming the metal sheet (12) provided with the pre-fold network (14, 16, 18) by bending it along some of the pre-folds so as to conform the three-dimensional part. The invention also relates to a three-dimensional part obtained by said method. Figure 2

Description

Title of the invention: Method for manufacturing a three-dimensional part from at least one metal sheet comprising a network of pre-folds, three-dimensional part obtained from said method

[0001] The present application relates to a method for manufacturing a three-dimensional part from at least one metal sheet comprising a network of pre-folds as well as to a three-dimensional part obtained from said method.

[0002] According to a known embodiment, a three-dimensional part is obtained from a deformed metal sheet by a stamping manufacturing process. According to this process, a metal sheet is positioned between two dies which are mounted on a stamping press and shaped like the part to be produced. Thus, a first die is shaped like the inner face of the part to be produced and a second die is shaped like the outer face of the part to be produced. This stamping manufacturing process leads, depending on the areas, to an elongation or a contraction of the metal sheet.

[0003] This stamping manufacturing process requires a high-power stamping press and the design and manufacture of a pair of dies specific to each part to be produced. Consequently, this process is not suitable for producing parts individually or in small series.

[0004] According to another known embodiment, a three-dimensional part is obtained from a metal sheet by successively making several folds by positioning, for each fold, the metal sheet between a V-shaped die and a punch. Depending on the complexity of the three-dimensional shape of the part to be obtained, it may be necessary to use other forming techniques, such as hammering for example.

[0005] This manufacturing process is suitable for producing individual or small-scale parts. However, it takes a relatively long time to implement and requires great dexterity.

[0006] The present invention aims to remedy all or part of the drawbacks of the prior art.

[0007] To this end, the invention relates to a method for manufacturing a three-dimensional part from at least one flat metal sheet.

[0008] According to the invention, the method comprises a step of producing at least one network of pre-folds on the metal sheet so as to delimit a plurality of facets as well as a step of deformation of the metal sheet provided with the network of pre-folds. folds by folding it along some of the pre-folds so as to conform the three-dimensional piece.

[0009] According to the invention, it is possible to manufacture, from metal sheets having the same network of pre-folds obtained with the same tool, three-dimensional parts of different shapes by folding them in different ways.

[0010] According to another characteristic, the network of pre-folds comprises at least first and second series of pre-folds, each of the first and second series comprising pre-folds parallel to each other, the pre-folds of the first series being oriented in a first direction, the pre-folds of the second series being oriented in a second direction secant to the first direction.

[0011] According to another characteristic, the network of pre-folds comprises three series of pre-folds, the pre-folds of the third series being oriented in a third direction intersecting the first and second directions.

[0012] According to another characteristic, the first, second and third directions form angles of 60° between them, the pre-folds of the first, second and third series concurring at the same points.

[0013] According to another characteristic, the step of producing the network of pre-folds is a plastic deformation step during which the metal sheet is pressed against at least one matrix which has grooves corresponding to the pre-folds and bosses corresponding to the facets.

[0014] According to a first embodiment, during the plastic deformation step, the metal sheet is compressed between first and second dies in contact respectively with the first and second faces of the metal sheet, the first die comprising grooves which correspond to the pre-folds and bosses which correspond to the facets, the second die comprising hollows which correspond to the facets and ribs which correspond to the pre-folds.

[0015] According to a second embodiment, during the plastic deformation step, the metal sheet is compressed between a rigid die and a deformable cushion in contact respectively with the first and second faces of the metal sheet, the die comprising grooves which correspond to the pre-folds and bosses which correspond to the facets.

[0016] According to another characteristic, the metal sheet and at least one die comprise shapes which cooperate with each other so as to immobilize the metal sheet relative to the die in a plane parallel to the first and second faces during the embossing step.

[0017] According to another characteristic, the step of deforming the metal sheet is carried out manually.

[0018] The invention also relates to a three-dimensional part obtained from the manufacturing process according to one of the preceding characteristics.

[0019] Other characteristics and advantages will emerge from the description of the invention which follows, a description given by way of example only, with reference to the appended drawings, among which:

[0020] [Fig-1] is a cross-section of a metal sheet before its shaping,

[0021] [Fig.2] is a front view of an embossed metal sheet illustrating a method of rea lization of the invention,

[0022] [Fig.3] is a cross-section of a metal sheet and tooling during of an embossing step illustrating an embodiment of the invention,

[0023] [Fig.4] is a cross-section of a metal sheet and tooling during of an embossing step illustrating another embodiment of the invention,

[0024] [Fig.5] is a perspective view of a three-dimensional part obtained from of an embossed metal sheet illustrating one embodiment of the invention.

[0025] A three-dimensional part 10 visible in [Fig.5] is obtained by deformation of a substantially flat metal sheet 12, visible in [Fig.l]. This three-dimensional part 10 has developable shapes.

[0026] This metal sheet 12 can be made of copper, brass, titanium, steel, aluminum alloy or others.

[0027] This metal sheet 12 has first and second faces 12.1, 12.2 which are substantially flat and parallel to each other, as well as a thickness corresponding to the distance which separates the first and second faces 12.1, 12.2 from a few tenths of a millimeter to several millimeters. According to one configuration, this metal sheet 12 has a thickness of between 0.5 mm and 5 mm.

[0028] According to one embodiment, the flat metal sheet 12 is obtained by rolling.

[0029] The manufacturing method comprises a step of producing at least one network of pre-folds 14, 16, 18 on the flat metal sheet 12.

[0030] For the present application, a pre-fold is understood to mean a shape produced on a metal sheet 12 allowing it to be folded in line with the pre-fold with less effort, potentially manually.

[0031] According to one embodiment, the network of pre-folds comprises at least first and second series of pre-folds 14, 16, each of the first and second series comprising pre-folds 14, 16 parallel to each other, the pre-folds 14 of the first series being oriented in a first direction, the pre-folds 16 of the second series being oriented in a second direction secant to the first direction.

[0032] According to one embodiment, the network of pre-folds comprises three series of pre-folds 14, 16, 18, the pre-folds 18 of the third series being oriented in a third direction intersecting the first and second directions.

[0033] According to one configuration, the first, second and third directions form between they have angles of 60° and the pre-folds of the first, second and third series meet at the same points. Thus, the network of pre-folds 14, 16, 18 is of the isogrid type, as illustrated in [Fig.2].

[0034] Of course, the invention is not limited to this type of pre-fold network.

[0035] Whatever the configuration of the network of pre-folds 14, 16, 18, the metal sheet 12 comprises a plurality of facets 20 delimited by the pre-folds 14, 16, 16. In the case of an isogrid type network, the facets 20 are equilateral triangles.

[0036] According to a first embodiment visible in [Fig. 3], the step of producing the network of pre-folds is a plastic deformation step, such as an embossing step, during which the metal sheet 12 is compressed between first and second dies 22.1, 22.2 in contact respectively with the first and second faces of the metal sheet 12. The first die 22.1 comprises grooves 24 corresponding to the pre-folds 14, 16, 18 and bosses 26 corresponding to the facets 20. In addition, the second die 22.2 comprises hollows 28 corresponding to the facets 20 and ribs 30 (projecting) corresponding to the pre-folds 14, 16, 18.

[0037] According to one method of operation, the first and second dies are mounted on a press. Given the deformations to be produced, this press is not necessarily as powerful as a stamping press.

[0038] To correctly position the metal sheet 12 relative to at least the first and second dies 22.1, 22.2, the metal sheet 12 and at least one of the first and second dies 22.1, 22.2 comprise shapes which cooperate with each other, before the pre-folds 14, 16, 18 are produced, so as to immobilize the metal sheet 12 relative to the first and second dies 22.1, 22.2 in a plane parallel to the first and second faces 12.1, 12.2. According to one embodiment, the metal sheet 12 comprises two housings 12.3 which cooperate with two centering pins 32 secured to the first die 22.1. Of course, the invention is not limited to this embodiment for immobilizing the metal sheet 12 relative to the first and second dies 22.1, 22.2.

[0039] According to a second embodiment visible in [Fig. 4], the step of producing the network of pre-folds is a plastic deformation step, such as an elastoforming step (also called elastoforming in English) or a flexoforming step (also called flexforming in English), during which the metal sheet 12 is compressed between a rigid die 22.1 and a deformable cushion 22.3 in contact respectively with the first and second faces of the metal sheet 12. The die 22.1 comprises grooves 24 corresponding to the pre-folds 14, 16, 18 and bosses 26 corresponding to the facets 20. During the plastic deformation step, the deformable cushion 22.3 deforms by matching the shapes of the die 22.1 and presses the metal sheet 12 against the die 22.1.

[0040] As in the case of the first embodiment, to correctly position the metal sheet 12 relative to the die 22.1, the metal sheet 12 and the die 22.1 comprise shapes which cooperate with each other, before the production of the pre-folds 14, 16, 18, so as to immobilize the metal sheet 12 relative to the die 22.1 in a plane parallel to the first and second faces 12.1, 12.2.

[0041] Whatever the operating mode during the plastic deformation step, the metal sheet 12 is pressed against at least one die 22.1 which has grooves 24 corresponding to the pre-folds 14, 16, 18 and bosses 26 corresponding to the facets 20.

[0042] After the embossing step, the metal sheet 12 is provided with the network of pre-folds, the first face 12.1 of the metal sheet 12 comprising projecting pre-folds 14, 16, 18 and recessed facets 20, the second face 12.2 comprising recessed pre-folds 14, 16, 18 and projecting facets 20.

[0043] Of course, the invention is not limited to this embodiment for producing the pre-folds 14, 16, 18.

[0044] The embossing embodiment is preferred because the embossed metal sheet 12 has a substantially constant thickness.

[0045] The manufacturing method comprises a step of deforming the metal sheet 12 provided with the pre-folds 14, 16, 18 by folding it along some of the pre-folds so as to shape the three-dimensional part 10. This deformation step is carried out manually, without tools.

[0046] The metal sheet 12 must be made of a material that is sufficiently ductile to be able to bend in line with the pre-folds without breaking.

[0047] According to the invention, with the same tooling, it is possible to produce three-dimensional parts of different shapes by folding them in different ways.

[0048] The shaping of the metal sheet 12 provided with pre-folds 14, 16, 18 is done effortlessly. This shaping is rapid and does not require great dexterity, the pre-folds preventing the formation of unwanted folds.

[0049] The dimensions of the facets 20, namely the spacing between the pre-folds of the same series, are adjusted according to the more or less complex geometry of the three-dimensional part to be produced. Thus, a metal sheet 12 provided with pre-folds delimiting small facets is more suitable for producing a three-dimensional part with complex shapes.

[0050] According to one embodiment, the three-dimensional part comprises at least one fixing zone 34, such as an orifice for example. According to one configuration, this fixing zone 34 is positioned in an intersection zone of the pre-folds.

Claims

Claims

1. Method for manufacturing a three-dimensional part from at least one flat metal sheet (12), characterized in that the method comprises a step of producing at least one network of pre-folds (14, 16, 18) on the metal sheet (12) delimiting a plurality of facets (20) as well as a step of deforming the metal sheet (12) provided with the network of pre-folds (14, 16, 18) by folding it along some of the pre-folds so as to shape the three-dimensional part.

2. Claim method according to the preceding claim, characterized in that the network of pre-folds comprises at least first and second series of pre-folds (14, 16), each of the first and second series comprising pre-folds (14, 16) parallel to each other, the pre-folds (14) of the first series being oriented in a first direction, the pre-folds (16) of the second series being oriented in a second direction secant to the first direction.

3. Manufacturing method according to the preceding claim, characterized in that the network of pre-folds comprises three series of pre-folds (14, 16, 18), the pre-folds (18) of the third series being oriented in a third direction intersecting the first and second directions.

4. Manufacturing method according to the preceding claim, characterized in that the first, second and third directions form angles of 60° between them, the pre-folds of the first, second and third series concurring at the same points.

5. Manufacturing method according to one of the preceding claims, characterized in that the step of producing the network of pre-folds is a plastic deformation step during which the metal sheet (12) is pressed against at least one die (22.1) which has grooves (24) corresponding to the pre-folds (14, 16, 18) and bosses (26) corresponding to the facets (20).

6. Manufacturing method according to the preceding claim, characterized in that, during the plastic deformation step, the metal sheet (12) is compressed between first and second dies (22.1, 22.2) in contact respectively with the first and second faces of the metal sheet (12), the first die (22.1) comprising grooves (24) which correspond to the pre-folds (14, 16, 18) and bosses (26) which correspond to the facets (20), the second die (22.2) comprising hollows (28) which correspond to the facets (20) and ribs (30) which correspond to the pre-folds (14, 16, 18).

7. Manufacturing method according to claim 5, characterized in that, during the plastic deformation step, the metal sheet (12) is compressed between a rigid die (22.1) and a deformable cushion (22.3) in contact respectively with the first and second faces of the metal sheet (12), the die (22.1) comprising grooves (24) which correspond to the pre-folds (14, 16, 18) and bosses (26) which correspond to the facets (20).

8. Manufacturing method according to one of claims 5 to 7, characterized in that the metal sheet (12) and at least one die (22.1) comprise shapes which cooperate with each other so as to immobilize the metal sheet (12) relative to the die (22.1) in a plane parallel to the first and second faces (12.1, 12.2) during the embossing step.

9. Manufacturing method according to one of the preceding claims, characterized in that the step of deforming the metal sheet (12) is carried out manually.

10. Three-dimensional part obtained from the manufacturing method according to one of the preceding claims.

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