METHOD FOR MANUFACTURING A REINFORCED PART BY SOLIDARIZING RIBBED PAVEMENT(S)

Abstract

A process allows the fabrication of a reinforced part from a part containing at least one area requiring reinforcement. This process includes a step (10-30) in which at least one stiffening rib of a chosen shape is defined on a metal block by 3D printing, in order to produce a ribbed block, and then this ribbed block is permanently fixed in the area to produce the reinforced part. Figure 1

Description

Title of the invention: METHOD FOR MANUFACTURING A PART REINFORCED BY SOLIDARIZING RIBBED PAVEMENT(S) Technical field of the invention

[0001] The invention relates to parts reinforced by stiffening ribs, and more specifically the manufacture of such reinforced parts. State of the art

[0002] In certain fields, such as vehicles (possibly automobiles), parts are used that have at least one reinforced area to provide greater strength. This reinforced area is generally a part of the component with a reduced thickness.

[0003] One solution for reinforcing a part consists of defining, by 3D printing (or three-dimensional printing), at least one stiffening rib of a chosen shape directly in each area to be reinforced. This is what is proposed, in particular, in US patent document B2 11,351,611.

[0004] The 3D printing technique uses a rather bulky torch, and therefore it can only be applied directly to a part if the area to be reinforced is easily accessible or if it is part of a system located in a relatively unobstructed space that does not impede the torch's passage. Furthermore, the torch's bulk limits the dimensions and shapes of the stiffening ribs that can be defined directly on the part to be reinforced, and leads to excessive material deposition in certain confined areas. Moreover, the 3D printing technique generates significant thermal gradients that frequently cause local deformations of the part to be reinforced and residual stresses that can induce delamination of the layers during deposition and a significant degradation of fatigue strength.Furthermore, when reinforcement is carried out on an assembly line, it causes a significant slowdown in the main production line. Finally, 3D printing technology is only compatible with certain metals, which proves to be a limitation.

[0005] The invention therefore aims in particular to improve the situation. Presentation of the invention

[0006] In particular, it proposes for this purpose a method intended to allow the manufacture of a reinforced part from a part comprising at least one area to be reinforced.

[0007] This process is characterized by the fact that it includes a step in which one defines on a metal block, by 3D printing, at least one stiffening rib of chosen shape, in order to produce a ribbed block, then the (each) ribbed block produced is fixedly joined in the (each) area to be reinforced, in order to produce a reinforced part.

[0008] Thanks to the invention, it is now possible to produce stiffening ribs of almost any shape because there is no longer a local constraint due to bulk or narrowness, and the 3D printing technique can be used without the risk of causing local deformations of the reinforced part and residual stresses in the latter.

[0009] The method according to the invention may include other features which may be taken separately or in combination, and in particular:

[0010] - in its step, a 3D printing technique of the so-called fa type can be used additive manufacturing by wire arc or of the type known as additive manufacturing by powder arc;

[0011] - in its step, the ribbed block can be fixedly joined by welding;

[0012] - in the presence of the last option, in its step, the can be fixedly secured ribbed paving by means of weld points, or weld beads;

[0013] - in its step, the block can be stamped before carrying out the 3D printing.

[0014] The invention also proposes a vehicle comprising at least one piece of equipment including at least one reinforced part obtained by implementing a process of the type presented above.

[0015] For example, this (each) piece of equipment can be chosen from a body, a part of a front or rear axle, and a mechanical component. Brief description of the figures

[0016] Other features and advantages of the invention will become apparent from an examination of the detailed description below, and the accompanying drawings (mostly obtained using CAD / CAM (“Computer-Aided Design / Computer-Aided Manufacturing”), hence some shades of grey), in which:

[0017] [Fig. 1] schematically illustrates an example of an algorithm implementing a manufacturing process according to the invention,

[0018] [Fig.2] schematically illustrates, in a perspective view, a metal block to be joined to a part to be reinforced, before the definition of stiffening rib(s),

[0019] [Fig. 3] schematically illustrates, in a perspective view, the metal block of [Fig. 2] during the definition of stiffening rib(s) by 3D printing,

[0020] [Fig. 4] schematically illustrates, in a perspective view, the ribbed metal block of [Fig. 3] just before its attachment to a part to be reinforced in an area to be reinforced, and

[0021] [Fig.5] schematically illustrates, in a perspective view, a part of the reinforced piece of [Fig.4], after fixed attachment of the ribbed metal block of [Fig.3] in an area to be reinforced. Detailed description of the invention

[0022] The invention aims in particular to propose a manufacturing process intended to enable the manufacture of reinforced PR parts from metallic PC parts and comprising at least one ZR zone which must be reinforced.

[0023] In what follows, it is considered, by way of non-limiting example, that the reinforced PR parts are intended to equip vehicles, possibly of the automotive type (for example, cars). But the invention is not limited to this application. It relates in fact to any system, and in particular to vehicles (land, sea (or river), or air), appliances (possibly household appliances (including consumer appliances)), installations (including industrial ones), and buildings.

[0024] Furthermore, in the following, by way of non-limiting example, reinforced PR parts are considered to be intended to form part of vehicle bodies. However, a reinforced PR part may, for example, be part of a vehicle's front or rear axle, or a mechanical component, such as a vehicle suspension wishbone or a front subframe of a vehicle structure.

[0025] As mentioned above, the invention proposes in particular a manufacturing process intended to enable the manufacture of reinforced PR parts from metallic PC parts and comprising at least one ZR zone to be reinforced.

[0026] As illustrated non-limitingly in [Fig.1], a (manufacturing) process according to the invention comprises a step 10-30 including a substep 20 in which at least one stiffening rib ND of chosen shape is defined on a metallic PM block by 3D (or three-dimensional) printing, in order to produce a ribbed PN block.

[0027] Figure 2 schematically illustrates an example of a metallic PM block before the definition of a stiffening rib ND by 3D printing. It should be noted that in the example illustrated, but not limited to, Figure 2, the PM block has an elongated and curved, non-geometric shape, adapted to the area to be reinforced ZR of the PC part in Figures 4 and 5. However, a PM block can have any geometric or non-geometric shape.

[0028] Furthermore, Figure 3 schematically illustrates the PM block of Figure 2 on a first face Fl (here, the upper face) of which a 3D printing tool OI (here, a gooseneck torch) is defining an example of a stiffening rib ND. It should be noted that in the example illustrated, but not limited to, in Figures 3 and 4, only one stiffening rib ND, having a shape particular with multiple curvatures. But we can define several (at least two) ND stiffening ribs on the same PM block, and each ND stiffening rib can have only one curvature or be straight or in the shape of L, V, U, X, Y, Z, or W, for example.

[0029] Step 10-30 also includes a substep 30 in which the (one) ribbed block PN, produced in substep 10, is fixedly joined in the (each) area to be reinforced ZR, in order to produce a reinforced part PR.

[0030] Figure 5 schematically illustrates an example of a reinforced part PR resulting from the implementation of the method according to the invention (here, the second face F2 (opposite to the first face Fl) of a single ribbed block PN is joined to the face F3 of a single area to be reinforced ZR of a part PC). However, a reinforced part PR may comprise several (at least two) areas to be reinforced ZR, each comprising at least one ribbed block PN, and the different ribbed blocks PN of a reinforced part PR may be different or identical.

[0031] Thanks to this definition of a ribbed pad PN, which can then be attached to the face F3 of a reinforcement zone ZR of a part PC, it is now possible to produce stiffening ribs ND with virtually any shape (complex or simple), since there is no longer a local constraint due to space limitations or limited room. Furthermore, 3D printing can now be used without the risk of causing local deformations of the reinforced part PR and residual stresses within it (PR). Moreover, since there is space to move the tool OI relative to the pad PM (or vice versa), material deposition can be minimized, thus avoiding any final overload of the ribbed pad PN. In addition, the ribbed pads PN can be produced outside the main production line of a system (here, a vehicle), which prevents production slowdowns.Finally, there is more flexibility in the choice of material for the stiffening ribs ND, as it only needs to be compatible with the metal of the ribbed block PN and the latter metal must be able to be bonded to the part to be reinforced PC.

[0032] For example, in substep 20 of step 10-30, a 3D printing technique of the so-called wire arc additive manufacturing (or WAAM) type can be used. In an alternative embodiment, a 3D printing technique of the so-called powder arc additive manufacturing type could be used, for example.

[0033] Also, for example, in substep 30 of step 10-30, the ribbed block PN can be permanently joined by welding. In this case, and as illustrated, but not limited to, in [Fig. 5], in substep 30, the ribbed block PN can, for example, be permanently joined by means of spot welds PS. In an alternative embodiment not shown, the ribbed block PN could be permanently joined by means of of weld beads.

[0034] It should be noted, however, that other fixed fastening techniques can be considered, in particular gluing.

[0035] Also, for example, and as illustrated, but not limited to, in [Fig. 1], step 10-30 may also include, before substep 20, a substep 10 in which the PM block can be stamped before 3D printing. This allows it to be given a shape that is well adapted to that of face F3 of the area to be reinforced ZR of the relevant PC part. However, when face F3 of the area to be reinforced ZR is flat, it is not necessary to stamp the PM block.

Claims

Demands

1. Method of manufacturing a reinforced part (PR) from a part (PC) having at least one zone (ZR) to be reinforced, characterized in that it includes a step (10-30) in which at least one stiffening rib (ND) of chosen shape is defined on a metallic block (PM) by 3D printing, in order to produce a ribbed block (PN), then said ribbed block (PN) produced is fixedly joined in said zone (ZR), in order to produce said reinforced part (PR).

2. A method according to claim 1, characterized in that in said step (10-30) a 3D printing technique of the type known as wire arc additive manufacturing is used.

3. A method according to claim 1, characterized in that in said step (10-30) a 3D printing technique of the type known as powder arc additive manufacturing is used.

4. A method according to any one of claims 1 to 3, characterized in that in said step (10-30) said ribbed block (PN) is fixedly joined by welding.

5. Method according to claim 4, characterized in that in said step (10-30) said ribbed block (PN) is fixedly joined by means of weld points (PS).

6. Method according to claim 4, characterized in that in said step (10-30) said ribbed block (PN) is fixedly joined by means of weld beads.

7. A method according to any one of claims 1 to 6, characterized in that in said step (10-30) said block (PM) is stamped before carrying out said 3D printing.

8. Vehicle, characterized in that it comprises at least one piece of equipment comprising at least one reinforced part (RP) obtained by implementing a process according to any one of claims 1 to 7.

9. Vehicle according to claim 8, characterized in that said equipment is selected from a body, a part of a front or rear axle, and a mechanical component.

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