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.
Patent Information
- Application Number
- FR2024010988
- Authority / Receiving Office
- FR · FR
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2023-10-12
- Filing Date
- 2024-10-10
- Publication Date
- 2026-09-11
- Estimated Expiration
- 2044-10-10
AI Technical Summary
Existing methods for manufacturing three-dimensional metal parts from sheets are complex, require specific tools for each design, are not suitable for small series production, and demand high power or dexterity, making them inefficient for flexible production.
A process involving a pre-plis network on a metal sheet, allowing for plastic deformation using common tools to create three-dimensional parts by folding along pre-plis, which can be oriented in different directions to achieve various forms without requiring high power or great dexterity.
Enables the production of diverse three-dimensional parts using the same pre-plis network with common tools, reducing complexity and effort, and facilitating rapid, stable formation of parts with varying geometries.
Smart Images
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Abstract
Description
Title of the invention: A method for manufacturing a three-dimensional part from at least one metal sheet comprising a network of pre-folds, the three-dimensional part obtained by 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 and to a three-dimensional part obtained from said method.
[0002] According to a known embodiment, a three-dimensional part is obtained from a metal sheet deformed by a stamping manufacturing process. According to this process, a metal sheet is positioned between two dies 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 results, depending on the areas, in an elongation or a contraction of the metal sheet.
[0003] This stamping manufacturing process requires a high-powered stamping press and the design and manufacture of a specific pair of dies for each part to be produced. Consequently, this process is not suitable for producing individual parts or small batches.
[0004] According to another known embodiment, a three-dimensional part is obtained from a metal sheet by successively making several folds, positioning the metal sheet between a V-die and a punch for each fold. 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.
[0005] This manufacturing process is suitable for producing individual parts or small series. However, it is relatively time-consuming to implement and requires considerable dexterity.
[0006] Document DE102005041555 describes a method for obtaining an embossed part. In this case, the part is obtained from a flat plate on which a network of folds is formed. According to this document, the plate is folded along each of the folds.
[0007] Document EP3395561 describes a method for obtaining a three-dimensional part from a plate. According to this document, a network of folds is formed on the plate, this network comprising a set of folds determined according to of the part to be made. The plate is folded along all the folds made in order to obtain the three-dimensional shape.
[0008] According to the embodiments described in documents DE102005041555 and EP3395561, the fold networks have specific geometries depending on each three-dimensional shape to be produced, and the plate is folded according to all the folds made. These embodiments are relatively complex to implement because for each three-dimensional shape, it is necessary to define a specific fold network.
[0009] The present invention aims to remedy all or part of the drawbacks of the prior art.
[0010] To this end, the invention relates to a method for manufacturing a three-dimensional part from at least one flat metal sheet.
[0011] According to the invention, the method includes a step of creating at least one network of pre-folds on the metal sheet so as to delimit a plurality of facets, this network of pre-folds being common to several three-dimensional shapes, as well as a step of deforming the metal sheet provided with the network of pre-folds by bending it along some of the pre-folds so as to conform the three-dimensional part.
[0012] According to the invention, it is possible to manufacture, from metal sheets having the same network of pre-folds obtained with the same tooling, three-dimensional parts of different shapes by folding them in different ways.
[0013] According to another feature, the pre-fold network 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 along a first direction, the pre-folds of the second series being oriented along a second direction secant to the first direction.
[0014] According to another feature, the pre-fold network comprises three series of pre-folds, the pre-folds of the third series being oriented along a third direction secant to the first and second directions.
[0015] According to another feature, the first, second and third directions form angles of 60° with each other, the pre-folds of the first, second and third series intersecting at the same points.
[0016] According to another feature, the pre-fold network fabrication step is a plastic deformation step in which the metal sheet is pressed against at least one die which has grooves corresponding to the pre-folds and bosses corresponding to the facets.
[0017] 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 having grooves that correspond to the pre-folds and bosses which correspond to the facets, the second matrix having hollows which correspond to the facets and ribs which correspond to the pre-folds.
[0018] According to a second embodiment, during the plastic deformation step, the metal sheet is compressed between a rigid matrix and a deformable cushion in contact respectively with the first and second faces of the metal sheet, the matrix comprising grooves which correspond to the pre-folds and bosses which correspond to the facets.
[0019] According to another feature, 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.
[0020] According to another feature, the metal sheet deformation step is carried out manually.
[0021] According to another feature, a given area of the metal sheet comprises a determined number of facets such that a ratio of the sum of the areas of the facets present on the given area to the area of the given area is between 40% and 65%.
[0022] According to another feature, the metal sheet comprises at least first and second zones, the facets located in the first zone all having the same dimensions, the facets located in the second zone all having the same dimensions, different from those of the facets located in the first zone.
[0023] According to another feature, no more than 60% of the pre-folds are folded during the metal sheet deformation stage.
[0024] The invention also relates to a three-dimensional part obtained from the manufacturing process according to one of the preceding characteristics.
[0025] Other features and advantages will become apparent from the following description of the invention, given by way of example only, with reference to the accompanying drawings, among which:
[0026] [Fig-1] is a cross-section of a metal sheet before it is shaped,
[0027] [Fig.2] is a front view of an embossed metal sheet illustrating a method of realization of the invention,
[0028] [Fig.3] is a cross-section of a metal sheet and a tool during of an embossing step illustrating one embodiment of the invention,
[0029] [Fig.4] is a cross-section of a metal sheet and a tool during of an embossing step illustrating another embodiment of the invention,
[0030] [Fig.5] is a perspective view of a three-dimensional part obtained from of an embossed metal sheet illustrating one embodiment of the invention,
[0031] [Fig.6] is a front view of an embossed metal sheet illustrating another mode of realization.
[0032] A three-dimensional part 10, visible in [Fig. 5], is obtained by deforming a substantially flat metal sheet 12, visible in [Fig. 1]. This three-dimensional part 10 has developable shapes.
[0033] This metal sheet 12 can be made of copper, brass, titanium, steel, aluminum alloy or others.
[0034] This metal sheet 12 has first and second faces 12.1, 12.2 that are substantially flat and parallel to each other, and a thickness corresponding to the distance between the first and second faces 12.1, 12.2, ranging from a few tenths of a millimeter to several millimeters. Depending on one configuration, this metal sheet 12 has a thickness between 0.5 mm and 5 mm.
[0035] According to one embodiment, the flat metal sheet 12 is obtained by rolling.
[0036] The manufacturing process includes a step of producing at least one network of pre-folds 14, 16, 18 on the flat metal sheet 12.
[0037] For the present application, a pre-fold means a shape made on a metal sheet 12 allowing it to be folded at the pre-fold with less effort, potentially manually.
[0038] According to one embodiment, the pre-fold network 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 along a first direction, the pre-folds 16 of the second series being oriented along a second direction secant to the first direction.
[0039] According to one embodiment, the pre-fold network comprises three series of pre-folds 14, 16, 18, the pre-folds 18 of the third series being oriented along a third direction secant to the first and second directions.
[0040] According to one configuration, the first, second and third directions form angles of 60° with each other and the prefolds of the first, second and third series intersect at the same points. Thus, the network of prefolds 14, 16, 18 is of the isogrid type, as illustrated in [Fig.2].
[0041] Of course, the invention is not limited to this type of pre-fold network.
[0042] Regardless of the configuration of the pre-fold network 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.
[0043] According to a first embodiment shown in [Fig. 3], the step of creating the pre-fold network 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 matrix 22.1 includes grooves 24 corresponding to the pre-folds 14, 16, 18 and bosses 26 corresponding to the facets 20. In addition, the second matrix 22.2 includes hollows 28 corresponding to the facets 20 and ribs 30 (protruding) corresponding to the pre-folds 14, 16, 18.
[0044] According to one operating procedure, the first and second dies are mounted on a press. Given the deformations to be achieved, this press is not necessarily as powerful as a stamping press.
[0045] 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 forms that cooperate with each other before the pre-folds 14, 16, 18 are made 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 recesses 12.3 that cooperate with two centering pins 32 attached 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.
[0046] According to a second embodiment shown in [Fig. 4], the step of creating the pre-fold network is a plastic deformation step, such as an elastoforming step or a flexoforming step, in which the metal sheet 12 is compressed between a rigid die 22.1 and a deformable cushion 22.3 in contact with the first and second faces of the metal sheet 12, respectively. 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 to conform to the shapes of the die 22.1 and presses the metal sheet 12 against the die 22.1.
[0047] 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 forms which cooperate with each other before the making 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.
[0048] Regardless of the operating method during the plastic deformation step, the metal sheet 12 is pressed against at least one matrix 22.1 which has grooves 24 corresponding to the pre-folds 14, 16, 18 and bosses 26 corresponding to the facets 20.
[0049] After the embossing step, the metal sheet 12 is provided with the pre-fold network, the first face 12.1 of the metal sheet 12 comprising pre-folds 14, 16, 18 in protrusion and 20 facets in recess, the second face 12.2 comprising 14, 16, 18 pre-folds in recess and 20 facets in protrusion.
[0050] Of course, the invention is not limited to this embodiment for making the pre-folds 14, 16, 18. The embossing embodiment is preferred because the embossed metal sheet 12 has a substantially constant thickness.
[0051] According to a first configuration visible in [Fig.2], over the entire surface of the metal sheet 12, the facets 20 all have the same dimensions. Thus, the facets 20 are all identical.
[0052] According to a second configuration visible on [Fig.6], the metal sheet 12 comprises at least first and second zones 36.1, 36.2, the facets 20 located in the first zone 36.1 all having the same dimensions, the facets 20' located in the second zone 36.2 all having the same dimensions, different from those of the facets 20 located in the first zone 36.1.
[0053] According to a preferred embodiment, the number of facets 20 on a given area is determined such that the ratio of the sum of the surface areas of the facets 20 present on the given area to the surface area of the given area is between 40% and 65%. If the number of facets 20 is insufficient, folding the metal sheet 12 will not allow the metal sheet to be folded to obtain the desired geometry, as the fold network will not be large enough. Conversely, if the number of facets 20 is too large, the metal sheet 12 will be too malleable, and the three-dimensional shape obtained after folding will not be stable and will tend to deform.
[0054] The manufacturing process includes a step of deforming the metal sheet 12 provided with the pre-folds 14, 16, 18 by bending it along some of the pre-folds so as to conform the three-dimensional part 10. This deformation step is carried out manually, without tools.
[0055] Unlike the prior art, the metal sheet 12 is not folded at all the pre-folds.
[0056] Thus, starting from a common pre-fold network, it is possible to obtain different three-dimensional shapes by folding certain pre-folds of the pre-fold network for a given three-dimensional shape and by folding other pre-folds of the same pre-fold network to obtain a different three-dimensional shape. Depending on one configuration, no more than 60% of the pre-folds 14, 16, 18 are folded during the deformation step of the metal sheet 12.
[0057] The metal sheet 12 must be made of a material sufficiently ductile to be able to bend at the pre-folds without breaking.
[0058] According to the invention, with the same tooling, it is possible to produce three-dimensional parts of different shapes by bending them in different ways.
[0059] The shaping of the metal sheet 12, which has pre-folds 14, 16, 18, is effortless. This shaping is quick and does not require great dexterity, as the pre-folds prevent the formation of unwanted creases.
[0060] 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 with pre-folds defining small facets is more suitable for producing a three-dimensional part with complex shapes.
[0061] According to one embodiment, the three-dimensional part includes 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) which delimit a plurality of facets (20), this network of pre-folds (14, 16, 18) being common to several three-dimensional shapes, 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; the first, second and third directions forming angles of 60° between them, the pre-folds of the first, second and third series concurring at the same points.
4. 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).
5. 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 matrix (22.2) comprising hollows (28) which correspond to the facets (20) and ribs (30) which correspond to the pre-folds (14, 16, 18).
6. Manufacturing method according to claim 4, 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).
7. Manufacturing method according to one of claims 4 to 6, 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.
8. Manufacturing method according to one of the preceding claims, characterized in that the step of deforming the metal sheet (12) is carried out manually.
9. Manufacturing method according to one of the preceding claims, characterized in that a given area of the metal sheet (12) comprises a number of facets (20) determined so that a ratio of the sum of the surfaces of the facets (20) present on the given area on the surface of the given area is between 40% and 65%.
10. Manufacturing method according to one of the preceding claims, characterized in that the metal sheet (12) comprises at least first and second zones (36.1, 36.2), the facets (20) located in the first zone (36.1) all having the same dimensions, the facets (20') located in the second zone (36.2) all having the same dimensions, different from those of the facets (20) located in the first zone (36.1).
11. Manufacturing method according to one of the preceding claims, characterized in that no more than 60% of the pre-folds (14, 16, 18) are folded during the step of deforming the metal sheet (12).
12. Three-dimensional part obtained from the manufacturing method according to one of the preceding claims.