Method for manufacturing metal parts and related metal parts

Abstract

A stamping method for forming a metal part (1) and related metal parts, wherein the geometric shape of the metal part is such that several regions need to be deformed in opposing directions during stamping. The stamping method comprises the step of providing a flexible metal blank (10) having at least two subblanks (101, 102) corresponding to subparts (11, 12) of a metal part, the flexible blank further comprising an overlapping region (100) in which the blanks overlap each other, the overlapping region (100) corresponding to a critical transition region 11T12 between the two subparts, and the overlapping region comprising a fixed pre-assembly region (1002) and a sliding region (1001). A punch used in the stamping operation has gaps between the regions of the punch corresponding to the first and second subparts (11, 12).

Claims

1. A manufacturing process for producing a metal part (1) by stamping a flexible metal blank (10) according to a stamping direction (S), The aforementioned metal part (1) is at least, - A first sub-part (11) having at least one first side wall (111) that extends substantially along a first direction (D1) perpendicular to the stamping direction (S), substantially parallel to the stamping direction (S), connected to a first upper section (113), and substantially extending in a plane perpendicular to the stamping direction (S), - A second sub-part (12) connected to the first sub-part (11), extending substantially along a second direction (D2) perpendicular to the stamping direction (S), and forming an angle α with the first direction (D1) that is strictly greater than 0°, comprising at least two vertical walls (121, 122) substantially parallel to the stamping direction (S), and a second upper section (123) connecting the two vertical walls (121, 122) and extending substantially in a plane perpendicular to the stamping direction (S), and Equipped with, The flexible metal blank (10) comprises at least, - Two subblanks (101, 102) each substantially corresponding to the first and second subparts (11, 12), - The subblanks (101, 102) overlap each other in at least one overlapping region (100) Equipped with, - The overlapping region (100) comprises at least one sliding region (1001) in which the subblanks (101, 102) can slide freely against each other during the stamping operation, and a fixed pre-assembled region (1002) in which the subblanks (101, 102) cannot move relative to each other during the stamping operation. The aforementioned manufacturing process includes at least, - A step of providing the at least two metal subblanks (101, 102), - A step of pre-assembling the at least two metal sub-blanks (101, 102) within the fixed pre-assembly area (1002) to form the flexible flat metal blank (10), - A step of performing the stamping operation by pressing the flexible metal blank (10) between a punch (2) and a die that move relative to each other in the stamping direction (S), wherein the punch (2) has at least one gap (4) between the regions corresponding to the first and second sub-components (101, 102) and A manufacturing process that includes this.

2. The manufacturing process according to claim 1, wherein the first and second directions (D1, D2) along which the first and second sub-components extend form an angle α between them of 30° and 90°.

3. The manufacturing process according to claim 2, wherein the first and second directions (D1, D2) along which the first and second sub-components extend form an angle α between them of 60° and 90°.

4. The manufacturing process according to claim 3, wherein the first and second directions (D1, D2) along which the first and second sub-components extend form an angle α of 80° to 90° with respect to each other.

5. The manufacturing process according to any one of claims 1 to 4, wherein the subblanks (101, 102) are assembled together in the fixed pre-assembly area (1002) by spot welding.

6. The manufacturing process according to any one of claims 1 to 4, wherein the subblanks (101, 102) are assembled together in the fixed pre-assembly area (1002) by laser welding.

7. The manufacturing process according to any one of claims 1 to 6, wherein the stamping operation is performed by hot stamping.

8. The manufacturing process according to any one of claims 1 to 6, wherein the stamping operation is performed by cold stamping.

9. The manufacturing process according to any one of claims 1 to 8, wherein the sliding region (1001) of the overlap region (100) further comprises at least one post-assembly region (1004) in which the first and second sub-components (11, 12) still overlap each other after the stamping operation, and the manufacturing process further comprises a post-assembly step in which at least the first and second sub-components (11, 12) are joined together in the at least one post-assembly region (1004) after the stamping operation.

10. The manufacturing process according to claim 9, wherein the post-assembly step is performed by spot welding.

11. The manufacturing process according to claim 9, wherein the post-assembly step is performed by laser welding.

12. The manufacturing process according to any one of claims 1 to 11, wherein the stamping operation is followed by a fitting operation using a fitting punch (21) having a fitting gap (41) between the regions corresponding to the first and second subcomponents, the fitting gap (41) being smaller than the gap (4) of the initial stamping tool (2).

13. The manufacturing process according to any one of claims 1 to 12, wherein the metal part (1) comprises at least two sub-parts (11) extending along the first direction (D1) and connected to at least one second sub-part (12), each extending substantially along the second direction (D2); the flexible metal blank (10) comprises at least three sub-blanks substantially corresponding to each of the sub-parts; the flexible blank further comprises at least two overlapping regions (100) where each sub-blank (101) extending in the first direction (D1) overlaps with a sub-blank (102) extending in the second direction (D2); and each of the overlapping regions (100) comprises at least a fixed pre-assembled region (1002) and a sliding region (1001).

14. A manufacturing process according to any one of claims 1 to 13, wherein at least the first and second sub-components (11, 12) have upper sections (113, 123) extending at different height levels, and the overlapping region (100) between two corresponding sub-blanks (101, 102) further comprises an extensible region (1005) connecting the fixed pre-assembled region (1002) and the sliding region (1001), wherein the fixed pre-assembled region (1002) has a shear strength resistance value RS expressed in MPa, and the extensible region (1005) has a plastic deformation resistance value RP expressed in MPa, where RP < RS.

15. A metal part (1) manufactured according to any one of claims 1 to 14.

16. A metal part (1) according to claim 15, comprising at least one pair of adjacent sub-parts (11, 12) having at least one pair of two adjacent vertical walls (111, 121), wherein the radius of curvature measured in the transition region (11T12) between the two adjacent vertical walls is no more than 20 times the minimum thickness of the two sub-parts.

17. A metal part (1) according to claim 15 or 16, designed for use in the body of an automobile.

18. An automobile comprising at least one metal part (1) as described in claim 17.

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