Hardened Profile Component Forming With Joined Profile Segments
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Solution Overview
Problem
Current methods for producing structural profile components for motor vehicles, such as A-pillars, face challenges in balancing strength and flexibility, with complex processes and high investment costs due to the need for specialized tools and iterative development across different forming steps, and require compensation for strain hardening during production.
Innovation Solution
A method involving the joining of a first profile segment with a uniform cross-sectional shape and a second segment with a non-uniform shape, heated to a hardening temperature for hydroforming or pressing, followed by quenching within the forming tool, allowing for simplified development and reduced costs by focusing manufacturing complexity on the second segment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex forming steps are concentrated on the second profile segment, then mechanical properties are optimized and material usage is minimized, but device complexity increases
Solution Approach 1:
The profile component is divided into two distinct profile segments: a first segment with uniform cross-sectional shape and a second segment with non-uniform cross-sectional shape. This segmentation allows complex forming operations to be concentrated on the second segment while the first segment can be produced by simpler, more cost-effective methods such as profile rolling.
Solution Approach 2:
Different regions of the profile component are given different cross-sectional characteristics - the first segment has uniform cross-section suitable for simple loading conditions, while the second segment has non-uniform cross-section optimized for complex loading conditions. This local differentiation optimizes mechanical properties where needed while reducing complexity elsewhere.
2Adaptability or versatility
If profile segments are joined together to form semi-finished product, then components with varying mechanical requirements can be produced, but manufacturing precision requirements increase
Solution Approach 1:
The joining operation is localized to specific connection ends of the profile segments, where the cross-sectional shapes are designed to match. This allows the majority of each segment to maintain its optimized cross-sectional characteristics while enabling precise joining at the interface through dedicated connection end geometry.
3Shape
If traditional U-O bending process is used, then closed cross-sectional profiles can be produced, but design freedom is limited by mandrel requirements
Solution Approach 1:
The profile component is segmented into at least two profile segments that are joined together. The second profile segment can have a non-uniform cross-sectional shape that is produced without requiring a drawing mandrel to pass through the entire component, thereby increasing design freedom while still achieving closed cross-sectional profiles in critical areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the development process, reduces investment costs, and optimizes mechanical properties by concentrating complex forming steps on the second segment, enabling the production of components with varying mechanical requirements while minimizing material usage and design constraints.
Implementation Method 1
heating to a hardening temperature in a forming tool
Implementation Method 2
hardened by quenching after forming in the forming tool
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The invention relates to a method for producing an at least partially hardened profiled component and to a corresponding semifinished product (1). The object on which the invention is based is to specify an improved method and an improved semifinished product therefor which allows a simplification of the development process and a reduction of the investment costs in production machines. This object is achieved in that at first a first profiled segment (19), which has a uniform cross-sectional shape (9, 10) along its extent (22), and a second profiled segment (20), which has a non-uniform cross-sectional shape (9, 10) along its extent (22), are joined together at a joining point (6) in order to form at least part of a semifinished product (1), and, for this purpose, the first and the second profiled segments (19, 20) have, at the joining point (6), cross-sectional shapes (9, 10) which substantially correspond with one another, wherein, after heating (25) to a hardening temperature, the semifinished product (1) is formed in a forming tool (11) by means of internal high-pressure forming (26) or pressing to give the profiled component (2) which, after the forming (26) within the forming tool (11), is hardened by quenching (27).