Method for trimming blanks

Abstract

A system and method for manufacturing a metal component, for example a steel or aluminum component for a vehicle, is provided. The system include a plurality of die stations in a production line. One of the die stations includes an upper drawing die and a lower drawing die design to both draw and trim a metal blank, preferably in the same die stroke, to form the metal component having a desired shape. The metal component can be transferred to additional die stations to remove the scrap and for additional processing, such as rough trimming, trimming with a cam, or flanging. Trimming the metal blank during the drawing step can eliminate additional die stations and allows a cam to more easily trim the metal component at another die station.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63 / 431,786, filed Dec. 12, 2022, titled “Method For Trimming Blanks,” the entire disclosure of which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The invention relates generally to a system and method for manufacturing metal components, for example steel or aluminum components for vehicles.2. Related Art

[0003] Metal components, such as components formed of steel, aluminum or aluminum alloys for vehicle applications, are oftentimes formed by drawing, stamping, and / or pressing a blank in dies which are located in a production line. The method of manufacturing the components also typically includes trimming, piercing, and / or flanging in separate dies or outside of the production line entirely. Oftentimes, the manufacturing process is costly and time consuming. In addition, the production line including the dies typically requires a significant amount of space. More efficient methods of manufacturing the metal components is desired.SUMMARY

[0004] One aspect of the disclosure provides a system for manufacturing a metal component, for example a steel or aluminum component for a vehicle. The system includes a plurality of die stations. One of the die stations includes an upper drawing and die and a lower drawing die designed to perform a drawing and trimming step on a metal blank in a single die stroke. Alternatively, one of the die stations includes an upper forming and die and a lower forming die designed to perform a forming and trimming step on a metal blank in a single die stroke.

[0005] Another aspect of the disclosure provides a method for manufacturing a metal component, for example a steel or aluminum component for a vehicle. The method includes drawing and trimming, or forming and trimming, a metal blank into the shape of a metal component at a single die station and during a single die stroke.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0007] FIG. 1 illustrates a system for manufacturing metal components, including a plurality of die stations in a production line, according to an example embodiment;

[0008] FIGS. 2a and 2b illustrate an upper drawing die and a lower drawing die according to an example embodiment;

[0009] FIGS. 3a and 3b illustrate an upper forming die and a lower forming die according to an example embodiment; and

[0010] FIG. 4 illustrates a form shape present in an upper drawing die according to an example embodiment.DESCRIPTION OF EXAMPLE EMBODIMENTS

[0011] One aspect of the invention provides a system 10 and method for manufacturing metal components 12, for example, metal components 12 formed of steel, aluminum, or aluminum alloys for vehicle applications. The system 10 includes a plurality of die stations 14 arranged in a production line. An example of the production line including the die stations 14 is shown in FIG. 1.

[0012] According to the example embodiment of FIG. 1, the first die station 14a of the production line includes an upper drawing die 16 and a lower drawing die 18. During the manufacturing process, a blank formed of metal, such as steel, aluminum, or aluminum alloy, is disposed between the upper drawing die 16 and the lower drawing die 18. The blank could be formed of another type of metal, as long as the metal has characteristics suitable for a drawing and trimming operation, for example sufficient flow. During the drawing operation, the metal blank is heated, and the upper and lower drawing dies 16, 18 apply a tensile force to the blank. The metal blank is pulled so that it stretches and transforms into the metal component 12 having a desired shape. The desired shape depends on the shape of the upper and lower drawing dies 16, 18. According to the example embodiment of FIG. 1, the metal component 12 is a hood for a vehicle. However, various different parts could be formed, for example a fender, door, or another part for a vehicle.

[0013] During the step of drawing the blank to form the metal component 12, the upper and lower drawing dies 16, 18 also perform a trimming or cutting step on the metal blank. According to the example embodiments, the drawing dies 16, 18 are designed with features sufficient to trim an edge off the metal blank while the drawing dies 16, 18 apply the tensile stress to the metal blank and form the metal blank to the desired shape. An example of the upper drawing die 16 and the lower drawing die 18 of the first die station 14a is shown in FIGS. 2a and 2b. According to this example, the upper and lower drawing dies 16, 18 include an upper cutting edge 20 and a lower cutting edge 22 which together trim the metal component 12. The upper and lower drawing dies 16, 18 are typically formed of steel. The upper drawing die 16 is preferably solid, and the lower drawing die 18 can be designed to trim the metal component 12 on a solid pedestal, outside a binder surface of the lower drawing die 18 which is used during the forming process. The trimming along the lower drawing die 18 can also be conducted at different stages.

[0014] The shape of the metal component 12 formed during the drawing step should allow the metal component 12 to be trimmed in the drawing dies 16, 18. The trimming step creates a piece of scrap metal along the edge of the metal component 12. The scrap metal remains very loosely attached to the metal component 12 after the trimming step. After the drawing and trimming step, the metal component 12 is transferred from the first die station 14a to a subsequent die station 14 for additional processing.

[0015] According to the example embodiment, after drawing and trimming the metal component 12 at the first die station 14a, the process includes transferring the metal component 12, with the scrap still connected, to a second die station 14b. An automated method can be used to transfer the metal component 12 from the first die station 14a to the second die station 14b. The second die station 14b can include various different types of dies. According to the example embodiment, the second die station 14b is referred to as a holding station and no forming of the metal component 12 is done at this station. However, the second die station 14b does include an upper forming die 24 and a lower forming die 26 capable of performing additional shaping of the metal component 12. Blowers are preferably located near the second die station 14b, and the lower forming die 26 of the second die station 14b of the example embodiment includes a scrap shoot 28. During the manufacturing process, the blowers blow the loose scrap off the metal component 12 and into the scrap shoot 28 for removal from the system 10. According to the example embodiment, when the metal component 12 arrives at the second die station 14b, the metal component 12 is placed on the lower forming die 26 and the scrap metal is immediately removed by the blowers and scrap shoot 28. An example of the upper and lower forming dies 24, 26, and the scrap shoot 28, is shown in FIGS. 3a and 3b.

[0016] According to an alternate embodiment, instead of trimming the metal component 12 during the drawing step at the first die station 14a, only the drawing occurs at the first die station 14a, and the upper and lower forming dies 24, 26 of the second die station 14b are designed with features for trimming the metal component 12 during the forming step. According to yet other embodiments, other types of forming dies are designed for both forming and trimming the metal component 12 in a single die station 14 and in a single die stroke.

[0017] According to preferred embodiments, the upper drawing die 16 is designed with a form shape 30, typically a protrusion, in the area of the scrap of the metal component 12 which is cut away during the trimming step. The form shape 30 or protrusion pulls the edge or scrap portion of the metal component 12 away from the upper drawing die during the drawing and trimming step to eliminate burring. An example of the form shape 32 or protrusion is shown in FIG. 4. This form shape 30 or protrusion can also be formed in the upper forming die 24 or in another die which is used to both form and trim the metal component 12.

[0018] The production line can include one or more additional die stations 14 following the second die station 14b. In the example embodiment of FIG. 1, the third die station 14c, which typically includes trimming and piercing, is removed since the trimming is conducted during the drawing step at the first die station 14a. The fourth die station 14d includes additional trimming of the metal component 12 using a cam, and the fifth die station 14e includes flanging the metal component 12. However, the die stations 14 could perform various different operations instead of or in addition to those disclosed herein.

[0019] The system 10 and method disclosed herein provides numerous advantages over comparative systems and methods that including drawing or forming separate from trimming. For example, an offline blanking step to trim the metal blank prior to the drawing step may be eliminated when the drawing or forming and trimming steps are combined. Also, as indicated above, the system 10 and method provides for improved management of the scrap metal. Drawing and trimming the metal component 12 at the first die station 14a leads to less scrap on the metal component 12 when the metal component 12 enters the following die stations 14 where additional trimming occurs. It is desirable to have less scrap during the additional trimming steps to avoid packaging issues. The combined drawing and trimming step may eliminate the need for certain die stations entirely. Further, when the drawing and trimming are conducted together, for example at the first die station 14a, the subsequent trimming step using the cam is improved. Since a significant portion of the excess material is already removed from the metal component 12, the cam is able to more easily travel between the dies of the die station 14, and cam overhead is reduced.

[0020] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the following disclosure and claims.

Examples

Embodiment Construction

[0011]One aspect of the invention provides a system 10 and method for manufacturing metal components 12, for example, metal components 12 formed of steel, aluminum, or aluminum alloys for vehicle applications. The system 10 includes a plurality of die stations 14 arranged in a production line. An example of the production line including the die stations 14 is shown in FIG. 1.

[0012]According to the example embodiment of FIG. 1, the first die station 14a of the production line includes an upper drawing die 16 and a lower drawing die 18. During the manufacturing process, a blank formed of metal, such as steel, aluminum, or aluminum alloy, is disposed between the upper drawing die 16 and the lower drawing die 18. The blank could be formed of another type of metal, as long as the metal has characteristics suitable for a drawing and trimming operation, for example sufficient flow. During the drawing operation, the metal blank is heated, and the upper and lower drawing dies 16, 18 apply a ...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63 / 431,786, filed Dec. 12, 2022, titled “Method For Trimming Blanks,” the entire disclosure of which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The invention relates generally to a system and method for manufacturing metal components, for example steel or aluminum components for vehicles.2. Related Art

[0003] Metal components, such as components formed of steel, aluminum or aluminum alloys for vehicle applications, are oftentimes formed by drawing, stamping, and / or pressing a blank in dies which are located in a production line. The method of manufacturing the components also typically includes trimming, piercing, and / or flanging in separate dies or outside of the production line entirely. Oftentimes, the manufacturing process is costly and time consuming. In addition, the production line including the dies typically requires a significant amount of space. More efficient methods of manufacturing the metal components is desired.SUMMARY

[0004] One aspect of the disclosure provides a system for manufacturing a metal component, for example a steel or aluminum component for a vehicle. The system includes a plurality of die stations. One of the die stations includes an upper drawing and die and a lower drawing die designed to perform a drawing and trimming step on a metal blank in a single die stroke. Alternatively, one of the die stations includes an upper forming and die and a lower forming die designed to perform a forming and trimming step on a metal blank in a single die stroke.

[0005] Another aspect of the disclosure provides a method for manufacturing a metal component, for example a steel or aluminum component for a vehicle. The method includes drawing and trimming, or forming and trimming, a metal blank into the shape of a metal component at a single die station and during a single die stroke.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0007] FIG. 1 illustrates a system for manufacturing metal components, including a plurality of die stations in a production line, according to an example embodiment;

[0008] FIGS. 2a and 2b illustrate an upper drawing die and a lower drawing die according to an example embodiment;

[0009] FIGS. 3a and 3b illustrate an upper forming die and a lower forming die according to an example embodiment; and

[0010] FIG. 4 illustrates a form shape present in an upper drawing die according to an example embodiment.DESCRIPTION OF EXAMPLE EMBODIMENTS

[0011] One aspect of the invention provides a system 10 and method for manufacturing metal components 12, for example, metal components 12 formed of steel, aluminum, or aluminum alloys for vehicle applications. The system 10 includes a plurality of die stations 14 arranged in a production line. An example of the production line including the die stations 14 is shown in FIG. 1.

[0012] According to the example embodiment of FIG. 1, the first die station 14a of the production line includes an upper drawing die 16 and a lower drawing die 18. During the manufacturing process, a blank formed of metal, such as steel, aluminum, or aluminum alloy, is disposed between the upper drawing die 16 and the lower drawing die 18. The blank could be formed of another type of metal, as long as the metal has characteristics suitable for a drawing and trimming operation, for example sufficient flow. During the drawing operation, the metal blank is heated, and the upper and lower drawing dies 16, 18 apply a tensile force to the blank. The metal blank is pulled so that it stretches and transforms into the metal component 12 having a desired shape. The desired shape depends on the shape of the upper and lower drawing dies 16, 18. According to the example embodiment of FIG. 1, the metal component 12 is a hood for a vehicle. However, various different parts could be formed, for example a fender, door, or another part for a vehicle.

[0013] During the step of drawing the blank to form the metal component 12, the upper and lower drawing dies 16, 18 also perform a trimming or cutting step on the metal blank. According to the example embodiments, the drawing dies 16, 18 are designed with features sufficient to trim an edge off the metal blank while the drawing dies 16, 18 apply the tensile stress to the metal blank and form the metal blank to the desired shape. An example of the upper drawing die 16 and the lower drawing die 18 of the first die station 14a is shown in FIGS. 2a and 2b. According to this example, the upper and lower drawing dies 16, 18 include an upper cutting edge 20 and a lower cutting edge 22 which together trim the metal component 12. The upper and lower drawing dies 16, 18 are typically formed of steel. The upper drawing die 16 is preferably solid, and the lower drawing die 18 can be designed to trim the metal component 12 on a solid pedestal, outside a binder surface of the lower drawing die 18 which is used during the forming process. The trimming along the lower drawing die 18 can also be conducted at different stages.

[0014] The shape of the metal component 12 formed during the drawing step should allow the metal component 12 to be trimmed in the drawing dies 16, 18. The trimming step creates a piece of scrap metal along the edge of the metal component 12. The scrap metal remains very loosely attached to the metal component 12 after the trimming step. After the drawing and trimming step, the metal component 12 is transferred from the first die station 14a to a subsequent die station 14 for additional processing.

[0015] According to the example embodiment, after drawing and trimming the metal component 12 at the first die station 14a, the process includes transferring the metal component 12, with the scrap still connected, to a second die station 14b. An automated method can be used to transfer the metal component 12 from the first die station 14a to the second die station 14b. The second die station 14b can include various different types of dies. According to the example embodiment, the second die station 14b is referred to as a holding station and no forming of the metal component 12 is done at this station. However, the second die station 14b does include an upper forming die 24 and a lower forming die 26 capable of performing additional shaping of the metal component 12. Blowers are preferably located near the second die station 14b, and the lower forming die 26 of the second die station 14b of the example embodiment includes a scrap shoot 28. During the manufacturing process, the blowers blow the loose scrap off the metal component 12 and into the scrap shoot 28 for removal from the system 10. According to the example embodiment, when the metal component 12 arrives at the second die station 14b, the metal component 12 is placed on the lower forming die 26 and the scrap metal is immediately removed by the blowers and scrap shoot 28. An example of the upper and lower forming dies 24, 26, and the scrap shoot 28, is shown in FIGS. 3a and 3b.

[0016] According to an alternate embodiment, instead of trimming the metal component 12 during the drawing step at the first die station 14a, only the drawing occurs at the first die station 14a, and the upper and lower forming dies 24, 26 of the second die station 14b are designed with features for trimming the metal component 12 during the forming step. According to yet other embodiments, other types of forming dies are designed for both forming and trimming the metal component 12 in a single die station 14 and in a single die stroke.

[0017] According to preferred embodiments, the upper drawing die 16 is designed with a form shape 30, typically a protrusion, in the area of the scrap of the metal component 12 which is cut away during the trimming step. The form shape 30 or protrusion pulls the edge or scrap portion of the metal component 12 away from the upper drawing die during the drawing and trimming step to eliminate burring. An example of the form shape 32 or protrusion is shown in FIG. 4. This form shape 30 or protrusion can also be formed in the upper forming die 24 or in another die which is used to both form and trim the metal component 12.

[0018] The production line can include one or more additional die stations 14 following the second die station 14b. In the example embodiment of FIG. 1, the third die station 14c, which typically includes trimming and piercing, is removed since the trimming is conducted during the drawing step at the first die station 14a. The fourth die station 14d includes additional trimming of the metal component 12 using a cam, and the fifth die station 14e includes flanging the metal component 12. However, the die stations 14 could perform various different operations instead of or in addition to those disclosed herein.

[0019] The system 10 and method disclosed herein provides numerous advantages over comparative systems and methods that including drawing or forming separate from trimming. For example, an offline blanking step to trim the metal blank prior to the drawing step may be eliminated when the drawing or forming and trimming steps are combined. Also, as indicated above, the system 10 and method provides for improved management of the scrap metal. Drawing and trimming the metal component 12 at the first die station 14a leads to less scrap on the metal component 12 when the metal component 12 enters the following die stations 14 where additional trimming occurs. It is desirable to have less scrap during the additional trimming steps to avoid packaging issues. The combined drawing and trimming step may eliminate the need for certain die stations entirely. Further, when the drawing and trimming are conducted together, for example at the first die station 14a, the subsequent trimming step using the cam is improved. Since a significant portion of the excess material is already removed from the metal component 12, the cam is able to more easily travel between the dies of the die station 14, and cam overhead is reduced.

[0020] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the following disclosure and claims.

Examples

Embodiment Construction

[0011]One aspect of the invention provides a system 10 and method for manufacturing metal components 12, for example, metal components 12 formed of steel, aluminum, or aluminum alloys for vehicle applications. The system 10 includes a plurality of die stations 14 arranged in a production line. An example of the production line including the die stations 14 is shown in FIG. 1.

[0012]According to the example embodiment of FIG. 1, the first die station 14a of the production line includes an upper drawing die 16 and a lower drawing die 18. During the manufacturing process, a blank formed of metal, such as steel, aluminum, or aluminum alloy, is disposed between the upper drawing die 16 and the lower drawing die 18. The blank could be formed of another type of metal, as long as the metal has characteristics suitable for a drawing and trimming operation, for example sufficient flow. During the drawing operation, the metal blank is heated, and the upper and lower drawing dies 16, 18 apply a ...

Claims

1. A system for manufacturing a metal component, comprising:a plurality of die stations, wherein one of the die stations is designed to perform a drawing or forming and trimming step on a metal blank during a single die stroke2. The system of claim 1, wherein the plurality of die stations includes a first die station and a second die station;the first die station includes a first upper drawing die and a first lower drawing die which are designed to apply a tensile force to the blank and stretch the metal blank;the first upper drawing die and first lower drawing die having a shape that forms the metal blank into the shape of a metal component; andthe first upper drawing die including a first upper cutting edge and the first lower drawing die including a first lower cutting edge for together trimming the metal blank while the first upper drawing die and the first lower drawing die apply the tensile force to the metal blank.

3. The system of claim 2, wherein the first lower drawing die includes a binder surface and a pedestal disposed outside of the binder surface.

4. The system of claim 1, wherein the second die station includes a second upper forming die and a second lower forming die capable of shaping the metal component after the metal component is formed at the first die station.

5. The system of claim 1, wherein the second die station includes a second upper forming die and a second lower forming die; and the second lower forming die includes a scrap shoot for receiving scrap trimmed from the metal component.

6. The system of claim 5 including a plurality of blowers for blowing the scrap off the metal component and into the scrap shoot.

7. The system of claim 1, wherein the metal component is a hood, fender, or door of a vehicle.

8. The system of claim 1, wherein the first upper forming die and the first lower forming die are formed of steel.

9. The system of claim 1, wherein the plurality of die stations includes a first die station and a second die station;the first die station includes a first upper drawing die and a first lower drawing die each formed of steel and which are designed to apply a tensile force to the blank and stretch the metal blank;the first upper drawing die and first lower drawing die having a shape that forms the metal blank into the shape of a metal component, wherein the metal component is a hood, fender, or door of a vehicle;the first upper drawing die including a first upper cutting edge and the first lower drawing die including a first lower cutting edge for together trimming the metal blank while the first upper drawing die and the first lower drawing die apply the tensile force to the metal blank;the first lower drawing die including a binder surface and a pedestal disposed outside of the binder surface;the second die station including a second upper forming die and a second lower forming die capable of shaping the metal component after the metal component is formed at the first die station;the second lower forming die including a scrap shoot for receiving scrap trimmed from the metal component; anda plurality of blowers for blowing the scrap off the metal component and into the scrap shoot.

10. The system of claim 1, wherein the plurality of die stations includes a first die station and a second die station;the first die station includes a first upper drawing die and a first lower drawing die each formed of steel and which are designed to apply a tensile force to the blank and stretch the metal blank;the first upper drawing die and the first lower drawing die having a shape that forms the metal blank into the shape of a metal component, wherein the metal component is a hood, fender, or door of a vehicle;the second die station including a second upper forming die and a second lower forming die capable of shaping the metal component after the metal component is formed at the first die station, the second lower forming die including a scrap shoot for receiving scrap trimmed from the metal component;the second upper drawing die including a second upper cutting edge and the second lower drawing die including a second lower cutting edge for together trimming the metal blank;the second lower forming die including a scrap shoot for receiving scrap trimmed from the metal component; anda plurality of blowers for blowing the scrap off the metal component and into the scrap shoot.

11. A die station, comprising:a first upper drawing die and a first lower drawing die each formed of steel and which are designed to apply a tensile force to the blank and stretch the metal blank;the first upper drawing die and first lower drawing die having a shape that forms the metal blank into the shape of a metal component, wherein the metal component is a hood, fender, or door of a vehicle; andthe first upper drawing die including a first upper cutting edge and the first lower drawing die including a first lower cutting edge for together trimming the metal blank while the first upper drawing die and the first lower drawing die apply the tensile force to the metal blank.

12. The die station of claim 11, wherein the first upper drawing die and the first lower drawing die are formed of steel.

13. A method for manufacturing a metal component, comprising the steps of:drawing or forming a metal blank into a shape of a metal component; andtrimming the metal component;wherein the drawing or forming and trimming steps are performed at a single die station.

14. The method of claim 13, wherein the drawing or forming and trimming steps are performed in a single die stroke.

15. The method of claim 13, wherein the drawing or forming and the trimming steps are performed at a first die station;the first die station including a first upper drawing die and a first lower drawing die each formed of steel;the first upper drawing die and the first lower drawing die applying a tensile force to the metal blank and / or stretching the metal blank during the drawing or forming step;the first upper drawing die including a first upper cutting edge and the first lower drawing die including a first lower cutting edge for together conducting the trimming step.

16. The method of claim 15 including transferring the metal component to a second die station; and blowing scrap trimmed from the metal component into a scrap shoot at the second die station.

17. The method of claim 16, wherein the step of transferring the metal component to the second die station is automated.

18. The method of claim 16 including additional shaping of the metal component at the second die station.

19. The method of claim 13, wherein the first lower drawing die includes a binder surface and a pedestal disposed outside of the binder surface for conducting the trimming step.

20. The method of claim 13, wherein the metal component is a hood, fender, or door of a vehicle.

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