EP3702061A1 - Method for manufacturing conical metal objects - Google Patents

Abstract

Method for producing a component (3) from a sheet metal with an at least partially curved or linearly conical area (15) from a pot-shaped blank (1) with an essentially cylindrical wall section (7). The method is characterized in that it comprises at least the following steps: a stepped train (64), in which the cylindrical edge section (7) of the blank (1) between a drawing die (23) and a drawing punch ( 24) is formed into a stepped area (11) with two cylinder sections (12, 13); at least one subsequent conical section (65) in which at least the stepped area (11) is formed into a curved or linear conical component section (15) between two tools (27-29).

Description

TECHNICAL AREA

The present invention relates to a method for producing a component from a metal sheet, the component having an at least partially curved or linearly conical area and being shaped starting from a pot-shaped blank with an essentially cylindrical wall section, as well as devices for performing such a method and using components manufactured using the process. In particular, the method is suitable for the production of aerosol dome elements or capsules, in particular for food, for example for coffee.

STATE OF THE ART

Pot-shaped objects made of metal can be formed from a flat sheet metal section in a cold forming process. Typically this takes place after a stamping process or combined with one in a single forming step (deep drawing) in which the finished component is given its final shape. Such processes are used, for example, for the production of pots, spray cans, components in the automotive industry or in the furniture industry, for food packaging, etc. In particular, aluminum and tinplate are used as materials.

In particular, if small material thicknesses are used, the forming process must be carried out carefully in order to avoid the formation of cracks, wrinkles etc. and thus rejects or unsatisfactory quality. This applies above all to the formation of conical wall areas because, in contrast to the formation of axially cylindrical wall areas, guidance in the tool is not guaranteed to the same extent in such areas.

DISCLOSURE OF THE INVENTION

It is, inter alia, the object of the present invention to provide an improved method for producing a component from a sheet metal with at least one in sections curved or linearly conical area starting from a pot-shaped blank with an essentially cylindrical wall section, which can solve the problems mentioned at the beginning, in particular can prevent cracks or folds from forming during the forming process, in particular in the curved or linearly conical area, or Inhomogeneous wall areas, ie wall areas with variable wall thickness, which can then lead to cracks or deformations when the components are used, for example under increased pressure (in the case of coffee capsules, for example in the brewing process).

The present invention accordingly relates to a method for producing a component from a metal sheet, the component having an area that is curved or linearly conical at least in sections and is produced starting from a pot-shaped blank with an essentially cylindrical wall section.

1. (I) Wenigstens einen Stufenzug, in welchem der zylindrische Randabschnitt des Rohlings wenigstens abschnittsweise zwischen einer Ziehmatrize und einem in einem Faltenhalter verschieblich geführten Ziehstempel in einen gestuften Bereich mit zwei Zylinderabschnitten umgeformt wird. Dies in einen ersten Zylinderabschnitt mit im Wesentlichen axial verlaufender umlaufender Wand mit einem ersten Radius R₁ und einen zweiten, entlang einer Bauteilachse (insbesondere bodenseitig) folgenden zweiten Zylinderabschnitt mit im Wesentlichen axial oder konisch (vorzugsweise axial) zusammenlaufend umlaufender Wand mit einem zweiten Radius R₂, der geringer ist als der erste Radius R₁. Dabei sind der erste und der zweite Zylinderabschnitt über einen im Wesentlichen radial verlaufenden oder stärker konisch zusammenlaufend als der zweite Zylinderabschnitt ausgebildeten Übergangsabschnitt des gestuften Bereichs umlaufend verbunden. In diesem Schritt wird zudem der erste Zylinderabschnitt und/oder der Übergangsabschnitt im Stufenzug wenigstens bereichsweise und wenigstens phasenweise zwischen dem Faltenhalter und der Ziehmatrize geklemmt oder geführt und der zweite Zylinderabschnitt wird vom Ziehstempel umgeformt.
2. (II) Wenigstens einen darauf folgenden Konuszug, in welchem wenigstens der gestufte Bereich zum gekrümmt oder linear konischen Bauteil-Abschnitt zwischen zwei Werkzeugen umgeformt wird, wobei die beiden Werkzeuge wenigstens gebildet werden durch eine Konuszug-Ziehmatrize und einen in einer Konuszug-Zentrierhülse verschieblich geführten Konuszug-Ziehstempel. Dabei wird der erste Zylinderabschnitt im Konuszug wenigstens bereichsweise zwischen der Konuszug-Zentrierhülse und der Konuszug-Ziehmatrize geklemmt oder geführt, und der Übergangsabschnitt und der zweite Zylinderabschnitt, ggf. auch wenigstens Bereiche des ersten Zylinderabschnitts, werden zwischen Konuszug-Ziehstempel und Konuszug-Zentrierhülse zum gekrümmt oder linear konischen Bauteil-Abschnitt umgeformt.

The method is particularly characterized in that it comprises at least the following steps (I) and (II):

1. (I) At least one stepped train in which the cylindrical edge section of the blank is formed at least in sections between a drawing die and a drawing punch guided displaceably in a fold holder into a stepped area with two cylinder sections. This is done in a first cylinder section with an essentially axially extending circumferential wall with a first radius R ₁ and a second cylinder section following along a component axis (in particular on the bottom) with an essentially axially or conically (preferably axially) converging circumferential wall with a second radius R. ₂ , which is less than the first radius R ₁ . The first and the second cylinder section are circumferentially connected via a transition section of the stepped region that extends essentially radially or converges more conically than the second cylinder section. In this step, the first cylinder section and / or the transition section in the stepped train is clamped or guided at least in some areas and at least in phases between the fold holder and the drawing die and the second cylinder section is reshaped by the drawing punch.
2. (II) at least one subsequent Konuszug in which at least the stepped portion is shaped to be curved or linear conical part-section between two tools, the two tools are at least formed by means of a conical pulling die and a conical pulling punch guided in a conical pulling centering sleeve. The first cylinder section is clamped or guided in the conical train at least in some areas between the conical train centering sleeve and the conical train drawing die, and the transition section and the second cylinder section, possibly also at least areas of the first cylinder section, are used between the conical train drawing punch and the conical train centering sleeve curved or linearly conical component section reshaped.

It should be noted that in the context of the present invention, a fold holder is to be understood as a tool element which, in the forming process, makes a significant contribution to preventing the formation of folds. This is done in such a way that the fold holder clamps the processed material against a counter-element, typically the drawing die, and during the forming process the material slides between the fold holder and the counter-element under this clamping, thus preventing or at least significantly reducing the formation of folds in the deep-drawing process. A centering sleeve can take on the function of a fold holder if it is not only centered but also realizes the clamping described above at the same time.

With the classic step sequence: blank, 1st train, possibly further trains such as 2nd train, 3rd train, etc., whereby the curved or linear conical component section is formed directly in the 1st train in one step, creases can form cannot always be avoided in the step of the blank in the first move.

This probably has the following causes: In such a first stage the draw ratio is high; a possibly inserted fold holder cannot have sufficient effect and thus a large area of the machined part is not held (clamped) during the forming process, which can result in folds.

By introducing the intermediate pull in the form of said stepped pull (essentially cylindrical pulling), the fold holder of the intermediate pull can stabilize the sheet metal, and with the following conical pull the free "frame" is inherently more stable due to the radii.

A first preferred embodiment of the proposed method is characterized in that the transition section runs essentially circumferentially and radially and the respective circumferential walls of the first and second cylinder sections run essentially circumferentially axially. Thus, the guidance through the fold holder in the stepped train can be optimized, since it is essentially a cylindrical drawing.

The conical centering sleeve can preferably also be designed as a fold holder, which clamps the first cylinder section and / or the transition section in the conical section at least in some areas between the conical fold holder and the conical draw die.

The ratio of the radius of the first cylinder section to the radius of the second cylinder section is preferably in the range of 2: 1-1.1: 1, in particular in the range of 1.6: 1-1.25: 1, particularly preferably in the range of 1.5: 1-1.3: 1 .

The ratio of the radius of the first cylinder section to the bottom radius of the second cylinder section is preferably in the range of 2.5: 1-1.2: 1, preferably in the range of 2.0: 1-1.4: 1, particularly preferably in the range of 1.9: 1-1.5: 1.

The bottom radius in the conical line preferably remains essentially unchanged, ie the bottom radius of the component made of sheet metal with an at least partially curved or linearly conical area corresponds to the bottom radius after the step line. The ratio of the axial length L _{1 of} the first cylinder section to the axial length L _{2 of} the second cylinder section is preferably in the range of 4: 1-0.5: 1, in particular in the range of 3: 1-0.75: 1, particularly preferably in the range of 2.5: 1-1: 1.

The radii of curvature for the transitions from the flange to the axial cylindrical wall area of the blank and / or the transition radius from the second cylindrical area to the base of the component after the step is for sheet iron e.g. 5-20 x, especially preferably 7-13 x the material thickness. In the case of aluminum sheet, in particular the transition radius from the second cylindrical area to the floor of the component after the step can be selected in this area or also larger, e.g. 10-30 x the material thickness, the transition radii from the first axial cylindrical wall area to the radial wall area and / or from the radial wall area to the second axial cylindrical wall area for the component after the stepped train are e.g. 5-20 x, especially preferably 7-13 x the material thickness.

Another preferred embodiment of the method is characterized in that a preferably circular die cut, for example in an alternating transversely offset manner, is punched from a flat sheet metal, preferably supplied in the form of a strip, in particular from a roll, before the stepped drawing. In a subsequent forming step (either in the same tool as the punching or in a subsequent tool), this die cut becomes a pot-shaped blank with a cylindrical wall section is formed with blank radius R _R. In this case, the free circumferential edge of the pot-shaped blank is either folded over to form a radial flange or is designed to be curved and conically widening. Particularly in the case of low material thicknesses, this ensures that the machined component is stable and is not deformed by the transfer device during transport to the next and subsequent machining stations. The component is typically gripped radially, and if the free surrounding edge made of thin material is not stabilized by such an edge formation, the components either cannot be gripped sufficiently or they deform when gripped. In this step, the outer diameter R _{F of} the flange or the widening is preferably designed to be 1-50 times the material thickness of the sheet metal greater than the blank radius R _R , preferably in the case of a curved, conically widening circumferential edge by 2-20 or 5- 15 times the material thickness of the sheet metal larger than the blank radius.

The components are preferably machined in that the opening of the cup-shaped workpieces is each directed upwards. But it is also possible to run the process so that the opening is directed downwards, the tools typically work in a vertical direction.

The blank or the sheet metal supplied preferably consists of aluminum or an aluminum alloy, preferably with a tensile strength R _m , cf., for example, EN ISO 6892-1: 2009) in the range of 80-120 MPa. Aluminum sheets of the following types EN AW-8011A, 8079, 8176, 8021, 8090, sintered 6061, sintered 2014 are possible.

Sheets made of iron or an iron alloy with a tensile strength R _m , see e.g. EN ISO 6892-1: 2009) of at least 500 MPa, preferably of at least 550 MPa, in particular tinplate of the following types are also possible: TH550, TH580, TH600, TH620, TH650, TH700.

These materials in each case in uncoated form or in one-sided or both-sided, possibly colored lacquered form (e.g. polyester lacquer, if necessary on primer and with a layer of hot-seal lacquer).

Preferably, the at least partially curved or linearly conical area encloses an average angle in the range of 5-40 °, preferably in the range of 7-15 °, particularly preferably in the range of 8-12 °, with the symmetry axis of the component. The formation of folds is particularly problematic for these angles when reshaping is carried out in one step, ie the method is as proposed for this Angle particularly suitable.

The at least partially curved or linearly conical area is preferably designed linearly conical at least partially; apart from any steps that may be present, it preferably has exclusively linearly conical areas, preferably all with essentially the same cone angle.

According to a further preferred embodiment, the method can be characterized in that a further cylindrical or conical area, preferably connected via a radial area, is formed on the bottom side adjoining the at least partially curved or linearly conical area in the conical section or in one or more subsequent forming steps. A hole can also be punched out in the floor.

As an alternative or in addition, it is possible, particularly preferably in the conical line, to form a further conical area on the bottom side adjoining the at least partially curved or linearly conical area, this further conical area enclosing a larger mean angle with the axis of symmetry of the component than that which is curved at least partially or linear conical area. The further conical area preferably forms a cone angle in the range of 30-80 °, particularly preferably in the range of 50-70 °.

The sheet metal that is fed in or from which the blank is made preferably has a thickness in the range from 0.05-0.4 mm, preferably in the range from 0.08-0.35 mm.

• das Metallblech hat eine Dicke im Bereich von 0.05-0.4 mm, vorzugsweise im Fall von Aluminium eine Dicke im Bereich von 0.08-0.2 mm, und vorzugsweise im Fall von Eisen oder einer Eisenlegierung eine Dicke im Bereich von 0.25-0.34 mm,
• das Metallblech hat im Fall einer Aluminium Legierung eine Zugfestigkeit (Tensile strength R_m, vgl. z.B. EN ISO 6892-1:2009) im Bereich von 80 - 120 MPa und im Fall von Eisen oder einer Eisenlegierung eine Zugfestigkeit (Tensile strength R_m, vgl. z.B. EN ISO 6892-1:2009) von wenigstens 500 MPa, vorzugsweise von wenigstens 550 MPa, und
• das Verhältnis von Radius R₁ des ersten Zylinderabschnittes zum Bodenradius R_B des zweiten Zylinderabschnittes liegt im Bereich von 2.5:1-1.2:1, vorzugsweise im Bereich von 2.0:1-1.4:1, insbesondere bevorzugt im Bereich von 1.9:1-1.5:1.

It has been shown that the method proposed here can prevent the formation of wrinkles in particular, even when using particularly thin metal sheets, if the parameters are set as follows:

• the metal sheet has a thickness in the range of 0.05-0.4 mm, preferably in the case of aluminum a thickness in the range of 0.08-0.2 mm, and preferably in the case of iron or an iron alloy a thickness in the range of 0.25-0.34 mm,
• In the case of an aluminum alloy, the metal sheet has a tensile strength R _m , see e.g. EN ISO 6892-1: 2009) in the range of 80 - 120 MPa and in the case of iron or an iron alloy it has a tensile strength (tensile strength R _m , see e.g. EN ISO 6892-1: 2009) of at least 500 MPa, preferably of at least 550 MPa, and
• the ratio of the radius R _{1 of} the first cylinder section to the bottom radius R _{B of} the second cylinder section is in the range of 2.5: 1-1.2: 1, preferably in the range from 2.0: 1-1.4: 1, particularly preferably in the range from 1.9: 1-1.5: 1.

The method can preferably be carried out in a transfer station in several parallel processed tracks, with identical components being processed in parallel in the same stroke, preferably in at least two, particularly preferably 2-8, or 3-5 such parallel tracks.

Further processing steps typically follow the taper. In particular selected from the following group: further forming steps, in particular flange formation, optionally combined with grooving and / or edge rolling; Punching steps; Coating steps; Application steps, in particular application of inserts or application of closures; Filling steps; Quality control steps; Purification steps; Assembly steps on further components, these further steps preferably being carried out at least partially in the same transfer system as the step train and the cone train.

Such subsequent steps can in particular be designed in such a way, for example for the production of coffee capsules from aluminum sheet or tin plate, that a circumferential radial flange and an axial cylindrical edge area are formed in the cone line on the opening side, and a groove line is then formed on the cone line in a further step in the same transfer system is carried out, in which between a shaped piece and a die, optionally in combination with a further shaped piece, a bottom-side directed circumferential bead is formed.

Furthermore, preferably following the formation of the bead, the axial cylindrical edge area can be rolled on the bottom side into a rolled edge in an edge rolling with a roller die, the rolled edge preferably protruding over the plane of the flange both on the bottom side and on the opening side.

The present invention further relates to a device for carrying out a method as described above in the form of a transfer system with at least one station for the stepped train and a downstream station for the conical train. If necessary, there can be a station for the punching step or a station for the production of the blank upstream in the same transfer system, whereby these two stations can also be combined in one station, and in particular also subsequent stations for example for the above-described formation of a flange, one therein arranged bead, as well as a rolled edge. Furthermore, stations can be provided in the same transfer system for the application of further elements, For example filter elements, or for filling in ingredients, for closing the capsule, or for quality control. Other stations with punching operations can also follow, for example to punch a hole from the bottom of the cup-shaped component.

The tool for the stepped train preferably comprises a drawing die and a drawing punch guided displaceably in a fold holder, and the first cylinder section is clamped in the step train at least in some areas and in phases between the fold holder and the drawing die and the second cylinder section is formed by the drawing punch.

Furthermore, the tool preferably has a conical pulling die and a conical pulling punch guided displaceably in a conical pulling centering sleeve, and the first cylinder section is clamped in the conical pulling at least in some areas between the conical pulling centering sleeve and the conical pulling drawing die, and the transition section and the second cylinder section are formed between the conical pull drawing punch and the conical pull centering sleeve.

Finally, the present invention also relates to components produced in a method as described above or in a device as described above with an area that is curved or linearly conical at least in sections.

Further embodiments are given in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1

axialen Schnitt durch ein Werkstück in den verschiedenen Bearbeitungsphasen (Aerosoldom);

Fig. 2

die Ausgangsposition für den Zwischenzug im Werkzeug für den Aerosoldom;

Fig. 3

die Zwischenzug Endlage im Werkzeug für den Aerosoldom;

Fig. 4

die Ausgangsposition für den ersten Zug beim Aerosoldom;

Fig. 5

die Endlage des ersten Zuges beim Aerosoldom;

Fig. 6

eine a) kombinierte Stanz- und Umformstation zum Stanzen der Stanzlinge und zum Umformen im Schnitt-Zug zum Rohling einer Kaffeekapsel im geöffneten Zustand (OT); b) das Werkzeug gemäss Figur 6a) in der Position, in der das Blech gestanzt wird; c) das Werkzeug gemäss Figur 6a) im geschlossenen Zustand (UT), wenn der Rohling tiefgezogen ist;

Fig. 7

a) das Werkzeug für den Zwischenzug bei der Herstellung der Kaffeekapsel im offenen Zustand (OT); b) das Werkzeug für den Zwischenzug bei der Herstellung der Kaffeekapsel im geschlossenen Zustand (UT);

Fig. 8

a) das Werkzeug für den Konuszug bei der Herstellung der Kaffeekapsel im offenen Zustand (OT); b) das Werkzeug für den Konuszug gemäss Figur 8a) im halb-geschlossenen Zustand; c) das Werkzeug gemäss Figur 8a) im geschlossenen Zustand (UT);

Fig. 9

einen Ausschnitt aus dem Randbereich der Kaffeekapsel im Werkzeug nach dem Rillenzug mit zusätzlich schematisch eingezeichnetem Rollrand;

Fig. 10

einen Ausschnitt aus dem Randbereich der Kaffeekapsel im Werkzeug nach Abschluss des Rollen des Randes;

Fig. 11

die einzelnen Verarbeitungsschritte bei der Herstellung einer Kaffeekapsel.

Preferred embodiments of the invention are described below with reference to the drawings, which are only used for explanation and are not to be interpreted as restrictive. In the drawings show:

Fig. 1

axial section through a workpiece in the various processing phases (aerosol dome);

Fig. 2

the starting position for the intermediate draw in the tool for the aerosol dome;

Fig. 3

the intermediate pull end position in the tool for the aerosol dome;

Fig. 4

the starting position for the first puff at the aerosol dome;

Fig. 5

the end position of the first train at the aerosol dome;

Fig. 6

a) combined punching and reshaping station for punching the diecuts and for reshaping in the cut-pull to the blank of a coffee capsule in the open state (OT); b) the tool according to Figure 6a ) in the Position in which the sheet is punched; c) the tool according to Figure 6a ) in the closed state (UT) when the blank is deep-drawn;

Fig. 7

a) the tool for the intermediate pull in the production of the coffee capsule in the open state (OT); b) the tool for the intermediate draw in the production of the coffee capsule in the closed state (UT);

Fig. 8

a) the tool for the cone train in the production of the coffee capsule in the open state (OT); b) the tool for the cone pull according to Figure 8a ) in the semi-closed state; c) the tool according to Figure 8a ) when closed (UT);

Fig. 9

a section from the edge area of the coffee capsule in the tool after the grooving with an additionally schematically drawn rolled edge;

Fig. 10

a section from the edge area of the coffee capsule in the tool after the end of the rolling of the edge;

Fig. 11

the individual processing steps in the manufacture of a coffee capsule.

DESCRIPTION OF PREFERRED EMBODIMENTS

In the Figures 1-5 the method proposed here is illustrated using the various forming operations on a component that ultimately serves as an aerosol dome.

Figure 1 shows an axial section through the workpiece in the various machining phases. The first phase in which the flat sheet metal section, a punched part, is presented and shaped is not shown. In a first step, this die cut is formed into the blank 1, this blank 1 is cylindrical, pot-shaped, it has a folded edge section 10 in the form of a radial flange, then a circumferential cylindrical section 7 with radius R ₁ , followed by a curved section 9 this cylindrical section 7, and the blank 1 is closed off at the bottom by the bottom section 8, which runs perpendicular to the main axis 6, and therefore axially.

This blank 1 is initially formed into a stepped component 2 in a first forming step, the intermediate draw or step draw. On the opening side, this stepped component now initially has a first cylinder section 12 with a radius R ₁ , which merges via a curved transition section 14 into a second cylinder section 13 with a smaller radius R ₂ . The area of the transitions from 12 through 14 to 13 is also referred to as the stepped area 11. Bottom side the second cylinder section 13 is followed by a short curved area and then the bottom 25 of the component after the stepped section with a bottom radius R _B , which is defined as the radius of the flat area without the transition curve to the second cylinder section.

A second forming step now follows, in which this component 2 is formed into a conical component 3 in a first train, the actual conical train. The previously stepped area 11 is reshaped in this conical section into a here curved conical area 15. This curved, conical area 15 is in turn followed by a bottom area. The bottom radius R _B remains unchanged.

This is followed by further pulling steps, in a second pulling towards component 4, the cone angle is enlarged, and consequently the cone is designed to converge more closely, and a cylindrical section 17 is formed in the bottom area.

In a last pulling step, the component 4 is further deformed by deforming the cylindrical area 17 into a radial area 18, which is followed on the bottom by a cylindrical area 19, on the bottom the component is closed by the bottom 20. This component 5 after the third Zug is typically then punched in the bottom area, and further operations can then follow, such as the formation of a rolled edge, etc.

The tools for implementing intermediate pull and conical pull for the production of such a component are in the Figures 2-5 illustrated.

In the tool for the intermediate pull as shown in the illustration in Figure 2 the blank 1 is guided into a drawing die 23 by a punch. The drawing die 23 forms the outer contour of the stepped area 11. The punch is now made in two parts according to the invention. An annular fold holder 21 is arranged in a circumferential area on the outside. A cylindrical drawing punch 24 is arranged displaceably in this fold holder 23. At the beginning of this step, the front edge of the drawing punch 24 lies essentially flush with the front edge of the fold holder 21, and these lie with the front edge or plane essentially on the bottom section 8 of the blank 1.

Now how that shifts based on Figure 3 It can be seen that the fold holder 21 is completely inserted into the corresponding mating contour of the drawing die 23, so that the contact surface 22 of the fold holder 21 clamps the curved section 9. Subsequently or at the same time as this, the drawing punch 24 moves along the axis of symmetry 6 further towards the bottom, and the essentially axial outer contour of the drawing punch 24 now forms the second cylinder section 13 of the stepped section 11, while the first cylinder section 12 is clamped or at least guided between the fold holder 21 and the drawing die 23. In this way, a controlled tapering towards the newly emerging floor area 25 with a smaller radius than the original floor area 8 is produced, with cylindrical drawing being possible.

In other words, the fold holder is in contact with the part at the beginning of this stepped train or at least in a phase of the stepped train, so that no creases can form during the deformation. The train is basically cylindrical. In the end position of the step train, the sheet is held comprehensively. The height of the intermediate pull can be adjusted as required. The height of the intermediate train can be adjusted to the geometry of the following conical train.

The tool of the following cone train is in Figure 4 shown in the position in which the forming process is just beginning on the still stepped component 2. Here there is a drawing die 27 and a radially outer annular fold holder 28 for the cone train, and in this again a drawing punch 29 for the cone train is displaceably mounted.

At the beginning of the formation of the conical area, the cylindrical first section 12 is already guided or even clamped between the centering sleeve 28 and the corresponding counter-contour with the cylindrical formation of the drawing die. Now the centering sleeve 28 and, parallel to it, the drawing punch 29 for the conical pulling into the drawing die, the first cylinder section 12 being guided and partially deformed at the same time, and above all the transition section 14 and the second cylinder section 13 through the conical contact surface 31 of the drawing punch 29 are reshaped.

The drawing punch then moves further than the centering sleeve 28 into the drawing die 27 until the conical contact surface 30 is reached, and consequently the conical area 15 between the surfaces 30 and 31 is reshaped, as shown in FIG Figure 5 can be seen.

Due to the two radii at the beginning of this conical section, the component is inherently more resistant to wrinkling. The free frame is reduced in size by the two contact points of the drawing die and the drawing punch. In the end position, the component is formed without creases and is ready for the second pull.

In the Figures 6-8 the various tools for the corresponding implementation of the method according to the invention are illustrated using the example of a production of a coffee capsule, for example from polyester-coated aluminum sheet of the type 8011A with a thickness of 0.1 mm. The weight per unit area of the aluminum is approx. 270 g / m ² and of the paint (including primer) approx. 18 g / m ² .

The complete process of making the coffee capsule (sequence of steps) is in Figure 11 and should be preferred in the description for a better understanding of the forming steps.

In a cutting train 63, a pot-shaped blank 1 is formed in a combined sequential punching and forming operation in a tool. It is also possible to first punch out only the flat punched part in a pure punching step 62 in a first tool and then to shape this into the blank 1 in a next tool. The cup-shaped blank 1 has a closed bottom section 8 and an opening, the wall 8 of the blank is cylindrical and therefore runs axially circumferentially in a circular manner. In this step, a folded edge 47 is immediately formed on the free upper edge to stabilize the subsequent transport and to prepare for the rolling of the rolled edge.

This blank 1 is then formed into the stepped component 2 in an intermediate draw or stepped train 64. This stepped component now still has the folded edge 47 on the free edge, a first cylinder section 12 with the same radius as the original radius of the blank 1, but this goes approximately halfway up over a transition section 14 into a second cylinder section 13 with a smaller radius.

This stepped component 2 is formed in a conical train 65 into the component 3 with a linear conical section. A cylindrical edge area 52 remains, which has essentially the same radius as the original first cylinder section 12. This merges into the actual conical area 15 of the component 3 via a radial flange. The bottom is also in one with a second cone angle further conical area 69 is formed. Both conical areas are formed in this conical train.

In a subsequent step, the overlying circumferential flange is further deformed in a groove train 66, as will be detailed below.

This is followed by a step in which the edge still protruding axially is rolled in edge rolling 67 to a rolled edge 55.

This is followed by an embossing step 68, in which further structures can be embossed, for example inscriptions but also special structuring of wall sections such as, for example, decorative grooves or the like.

The tool for a combined punching and forming step for producing the blank 1 from a supplied sheet metal is shown in FIG Figure 6 shown.

The tool is designed as a transfer station with an upper carrier plate 41 and a lower carrier plate 42, the plates are guided via guide cylinders 23 and can only be displaced relative to one another in the vertical direction. Figure 6a shows the top dead center (TDC) of the tool. The forming steps are carried out in such a way that the opening of the component is directed upwards. The tape is fed in as a sheet metal strip and held by a hold-down pin 40 and a further hold-down pin 34 centered in the tool.

The drawing punch 35 for the drawing process is provided on the upper support plate, as is the associated fold holder 33, which radially surrounds the drawing punch. Furthermore, this fold holder 33 is now also enclosed by a cutting ring 36 or a cutting die, which has the task of providing the round, flat die-cut part before the deep-drawing process. This cutting die 36 is carried by a support element 36a, this is at top dead center on a stop 36b of the corresponding guide 36d. Cutting ring 36 and fold holder 33 are axially displaceable relative to one another to a small extent.

On the lower carrier plate 42 there is initially a lifting device 39 radially on the outside, which is braced upwards with a spring system 39. Following radially inward is the annular cutting punch 37 for the cutting train, which is at the same time a deep-drawing die for the train to form the blank. The ejector 38 for the cutting train then follows in the very center.

Figure 6b now illustrates the position in which the circular die-cut 46 is being punched out of the sheet metal band. The upper support plate 41 lowers downwards, the cutting punch 37 is fixed in its position, whereas the lifter 39 can be pushed down slightly by the suspension 39a. Now the front surfaces of the fold holder 33 and cutting die 36 meet the surface of the sheet metal, the cutting die 36 is fixed by the stop on the support element 36a, the fold retainer 33, however, can yield slightly upwards. As a result, the cutting ring 36 emerges, as in FIG the enlargement at the bottom left in Figure 6b it can be seen, a little deeper down, the fold holder 33 and cutting punch 37 clamp the sheet metal and the inner ring edge of the cutting ring 36 punches the sheet metal by dipping a little around the edge contour of the cutting punch 37 downwards.

Now there is no transfer to the next station, but the die 46 held between the fold holder 33 and the cutting punch 37 is immediately formed into the blank 1 in the same station by moving the tool further down to the bottom dead center (UT), which is shown in Figure 6c is illustrated. The drawing punch 35 now moves into the annular recess in the cutting punch 37, the ejector 38 being displaced downward via the drawing punch 35. The base is always pressed against the drawing punch 35 by the pneumatic cylinder 38a. The cylindrical wall 7 of the blank 1 is thus formed between the drawing punch 35 and the cutting punch or deep-drawing die 37. At the same time, the upper circumferential inner edge of the deep-drawing die 37 is convexly curved and the drawing height is set in such a way that the above-mentioned edge section 47, which is already slightly turned outwards, is formed on the blank 1, thus a short flange that widens in a trumpet-shaped manner to stabilize the blank 1 the top edge.

Now this blank 1 is transported to the next station with a transfer system, which now carries out the step pull, the corresponding tool is in Figure 7 shown.

Here again there is an upper carrier plate 41 and a lower carrier plate 42. The fold holder 21 for the stepped pull is provided on the upper carrier plate, and the drawing punch 24 is axially displaceably mounted in this. In a central recess of this drawing punch there is also a hold-down pin 48, which is mounted axially displaceably with its guide pin 48a in this central recess. The front surface of the drawing punch 24 has a concave front surface contour 24a, which corresponds to the rear convex contour of the hold-down pin in the foremost extension area, so that when the hold-down pin 48 is in the completely retracted position in the drawing punch 24, these two elements together form a flush, radially extending front surface (compare Figure 7b ).

On the lower carrier plate 42, the lower drawing die 23 is provided as an annular element, axially immovable. The ejector 49 is provided axially displaceably in this drawing die 23. In Figure 7a the tool for the stepped train is shown in top dead center. The blank 1, which is transferred to this station by a transfer device was transported, now lies as a blank 1 on the ejector 49, and the upper tool part moves downwards. The blank 1 is initially clamped between the ejector 49 and the front surface of the hold-down pin 48. The fold holder 21 then first moves into the upper recess of the blank without having a deforming effect, which is facilitated by the slight enlargement 47. At the appropriate point in time for the desired drawing height for the first and second drawing sections, the drawing punch 24 also begins to move further downwards than the front edge of the fold holder 21, and the stepped area is formed by the radial circumferential surface in the front region of the fold holder 21 The blank leads, the transition section 14 is formed on the upper edge of the drawing die and the second cylinder section through the radial outer surface of the drawing punch and the radial inner surface of the drawing die. In Figure 7b the tool for the stepped train is shown in the bottom dead center reached.

The now following taper 65 is in Figure 8 shown tool realized. In Figure 8a the tool for the cone pull is shown in top dead center. Here there is again a fold holder 28 on the upper carrier plate, which is annular and whose position is not fixed relative to the upper carrier plate, but is axially displaceable. The drawing punch 29 for the conical pull is formed in this fold holder 28; it has a double conical outer contour, the actual first cone 29a for the actual conical area and a further cone 29b for the conical formation of a bottom area 69.

In this drawing punch 29, a hold-down pin 15 is again provided, axially centered, which is mounted axially displaceably in the drawing punch.

On the lower support plate there is the ring-shaped drawing die 27, which, to a certain extent, provides the counter contour for the outer surface of the drawing punch 29. The counter surface for the second cone 29b is provided by the lower conical surface 27b, and the counter surface for the formation of the actual conical area over the surface 29a of the drawing punch is provided by the area 27a of the drawing die.

In this drawing die 27, an ejector 51 is again provided, which is displaceably provided, exactly as with the tool according to FIG Figure 7 Among other things, it also serves to push the finished component out of the tool from below when the top plate is pushed up again and make it available for the gripper of the transfer system.

The component after the step 2 is now between the hold-down pin 50 and the The ejector is clamped as soon as it has been moved to the position of this station by the transfer system, and then the upper part of the mold descends further.

In Figure 8b the position is shown at which the actual forming process on component 2 is just beginning. The fold holder 28 has already moved into the first cylindrical section 12 of the component 2, and the foremost surface of the drawing punch 29 is, as it were, shifted downwards onto the bottom of the component 2. The actual forming process now begins when the tool is closed further and the drawing punch dips further into the drawing die 27. The transition area 14 and the second cylinder section 13 are first reshaped, and then the second cylinder section 12 is drawn further down into the mold, so to speak, until only one cylindrical edge area 52 of the outer contour of the fold holder is in the completely closed position, as in FIG Figure 8c shown, is held.

The contours of the drawing punch 29 and the drawing die 27 now lie completely on top of one another, and the further conical area 69 has also been formed in the bottom area in particular.

This component 3 is now the above in connection with Figure 4 operations described, the tools for this are no longer shown in full.

Figure 9 shows only the flange area in the transfer tool for the grooved train 66. The circumferential bead 53 is formed in this tool by a molding 59 from above, which dips into a die 58 with an internal molding 60. In this step, the cylindrical edge area 52 and likewise the folded edge 47 initially remain.

The in Figure 9 The rolled edge 55 shown is to be understood only schematically, it is only produced in the next tool or in a subsequent step in the same tool as that in FIG Figure 10 is shown. A roller die 56 with a correspondingly designed roller contour 57 moves from above along a molded piece 56 downwards, can optimally start the rolling process through the already slightly expanded upper contour 47 and folds the rolled edge 55 into a completely closed edge. REFERENCE LIST 1 blank Intermediate pull / step pull 2 Component after 3 Component after the first move 4th Component after the second move 27b lower conical inner surface of 27 5 Component after the third move 6th Axis of symmetry 28 Centering sleeve / fold holder for conical pull 7th cylindrical section of 1 8th Bottom section of 1 28a OT stop from 28 9 curved section of 1 between 7 and 8 28b UT stop from 28 29 Drawing punch for cone pull 10 folded edge section of 1 29a 1. Cone for conical area 15 11 stepped area of 2 29b 2. Cone for conical bottom area 69 12 first cylinder section of FIG 30th conical contact surface of 27 13 second cylinder section of FIG 31 conical contact surface of 29 14th Transitional section between 12 and 13 32 circumferential front edge of 28 15th conical area of 3 16 conical area of 4 and 5 33 Fold holder for cut-pull 33a Hold-down pin from 33 17th cylindrical area of 4 34 Hold-down pin 18th radial area of 5 35 Drawing punch for cut-pull 19th cylindrical area of 5 36 Cutting ring, cutting die 20th Floor of 5 36a Support element from 36 and guide element from 33 21st Fold holder for intermediate pull 22nd Contact area of 21 36b OT stop of 36a 23 Drawing die for intermediate drawing 36c UT stop of 36a 24 Drawing punch for intermediate draw 36d Leadership of 36a 24a Front surface contour of 24 37 Cutting punch for cutting and pulling and thermoforming die for pulling to form the blank 25th Floor of 2 26th Contact area of 23 for 22 27 Drawing die for conical pull 27a upper conical inner surface of 27 38 Ejector for cut-pull 38a Stop element for 38 in UT 57 Roll contour of 56 39 Liftoff 58 die 39a Suspension of 39 59 Fitting 40 Hold-down pin for empty station 60 Fitting 61 Roll die 41 upper support plate 62 Punching, possible separately, unless the next step is designed as a cut-pull 42 lower support plate 43 Guide cylinder between 41 and 42 44 curved edge area of 37 63 Cut train 64 Intermediate train 45 Drive-on block 65 Finished train / conical train 46 Die cut 66 Grooved train 47 folded edge of 1 67 Edge rolls 48 Hold-down pin 68 Shape 48a Guide pin from 48 69 further conical area 49 Ejector 50 Hold-down pin L ₁ axial length of the first cylinder section 51 Ejector 51a OT stop of 51 L ₂ axial length of the second cylinder section 52 cylindrical edge area of 3 R ₁ Radius of the first cylinder section 12 53 circumferential bead in 53 54 circumferential radial flange R ₂ Radius of the second cylinder section 13 55 Rolled edge 56 Roller stamp R _B Bottom radius

Claims (15)

A method for producing a component (3) from a metal sheet with an at least partially curved or linearly conical area (15), from a pot-shaped blank (1) with an essentially cylindrical wall section (7),
characterized in that
the method comprises at least the following steps: a stepped train (64), in which the cylindrical edge section (7) of the blank (1) at least in sections between a drawing die (23) and a drawing punch (24) guided displaceably in a fold holder (21) in a stepped area (11) with two Cylinder sections (12, 13) is formed, a first cylinder section (12) with a substantially axially extending circumferential wall with a first radius (R ₁ ) and a second, following along a component axis (6) second cylinder section (13) with a substantially axial or conically tapering circumferential wall with a second radius (R ₂ ) which is smaller than the first radius (R ₁ ), wherein the first and the second cylinder section (13) tapering over a substantially radial or more conical than the second Cylinder section (13) formed transition section (14) of the stepped area (11) are circumferentially connected, and wherein the first cylinder section (12) in the The stepped pull is at least partially guided on the inside by the fold holder (21) and clamped between the fold holder (21) and the drawing die (23) and the second cylinder section (13) is reshaped by the drawing punch (24); at least one subsequent conical section (65), in which at least the transition section (14) and the second cylinder section (13) of the stepped area (11) are formed into a curved or linear conical component section (15) between two tools (27-29) The two tools are at least formed by a conical pulling die (27) and a conical pulling punch (29) displaceably guided in a conical pulling centering sleeve (28), and the first cylinder section (12) in the conical pulling (65) at least in some areas from the conical centering sleeve (28) is guided on the inside or is clamped and / or guided between the cone pull centering sleeve (28) and the cone pull die (27), and the transition section (14) and the second cylinder section (13) and the transition section (14) between the cone pull drawing punch ( 29) and conical pulling die (27) are reshaped. Method according to Claim 2, characterized in that the transition section (14) runs essentially circumferentially and radially and the circumferential walls of the first and second cylinder sections (12, 13) run essentially circumferentially axially,
and / or that the conical cable centering sleeve (21) is designed as a fold holder, which the first cylinder section (12) and / or the transition section (14) in the conical cable (65) at least in some areas between the conical cable fold holder (28) and the conical pull die (27) is stuck. Method according to one of the preceding claims, characterized in that the ratio of the radius (R ₁ ) of the first cylinder section (12) to the radius (R ₂ ) of the second cylinder section (13) is in the range of 2: 1-1.1: 1, preferably in Range from 1.6: 1-1.25: 1, particularly preferably in the range from 1.5: 1-1.3: 1;
and / or that the ratio of the radius (R ₁ ) of the first cylinder section (12) to the bottom radius (R _B ) of the second cylinder section (13) is in the range of 2.5: 1-1.2: 1, preferably in the range of 2.0: 1-1.4 : 1, particularly preferably in the range 1.9: 1-1.5: 1;
and / or that the ratio of the axial length (L ₁ ) of the first cylinder section (12) to the axial length (L ₂ ) of the second cylinder section (13) is in the range of 4: 1-0.5: 1, preferably in the range of 3: 1 -0.75: 1, particularly preferably in the range from 2.5: 1-1: 1. Method according to one of the preceding claims, characterized in that a preferably circular die-cut (46), preferably in an alternating transversely offset manner, is punched from a flat sheet metal, preferably supplied in the form of a strip, in particular from a roll, in front of the step train (64) (62), and this in a subsequent forming step (63) is formed into a pot-shaped blank (1) with a cylindrical wall section (7) with a blank radius (R _R ), preferably the free circumferential edge (10, 47) of the pot-shaped blank ( 1) is either folded over to form a radial flange (10) or curved and conically widening (47), with the outer diameter (R _F ) of the flange (10) or the widening (47) preferably being 1-50 times the material thickness of the sheet is made larger than the blank radius (R _R ), preferably in the case of a curved, conically widening circumferential edge (47) by 2-20 or 5-15 times the material thickness of the sheet is greater than the blank radius (R _R ). Method according to one of the preceding claims, characterized in that the blank is made of aluminum or an aluminum alloy, preferably with a tensile strength in the range of 80-120 MPa, in particular aluminum of the following types EN AW-8011A, 8079, 8176, 8021, 8090, sintered 6061, sintered 2014, or made of iron or an iron alloy with a tensile strength of at least 500 MPa, preferably of at least 550 MPa, in particular tinplate of the following types: TH550, TH580, TH600, TH620, TH650, TH700, in each case in uncoated or in Form painted on one or both sides, if necessary colored. Method according to one of the preceding claims, characterized in that the at least partially curved or linearly conical area (15) with the axis of symmetry (6) of the component (3) has an average angle in the range of 5-40 °, preferably in the range of 7- 15 °, particularly preferably in the range of 8-12 °. Method according to one of the preceding claims, characterized in that the at least partially curved or linearly conical area (15) is at least partially linearly conical, preferably, apart from any steps that may be present, has exclusively linearly conical areas. Method according to one of the preceding claims, characterized in that
a further cylindrical or conical area (19), preferably connected via a radial area (18), is formed in the conical section (65) or in one or more subsequent forming steps on the bottom side adjoining the at least partially curved or linearly conical area (15),
or, particularly preferably, a further conical area (69) is formed in the conical section (65) on the bottom side adjoining the at least partially curved or linearly conical area (15), this further conical area (69) with the axis of symmetry (6) of the component (3 ) includes a larger mean angle than the at least partially curved or linearly conical area (15), preferably a cone angle in the range of 30-80 °, particularly preferably in the range of 50-70 °. Method according to one of the preceding claims, characterized in that the metal sheet has a thickness in the range of 0.05-0.4 mm, preferably in the case of aluminum a thickness in the range of 0.08-0.2 mm, and in the case of iron or an iron alloy a thickness of Range of 0.25-0.34 mm, the metal sheet in the case of an aluminum alloy has a tensile strength in the range of 80-120 MPa and in the case of iron or an iron alloy a tensile strength of at least 500 MPa, preferably of at least 550 MPa, and the ratio of Radius (R ₁ ) of the first cylinder section (12) to the bottom radius (R _B ) of the second cylinder section (13) in the range of 2.5: 1-1.2: 1, preferably in the range of 2.0: 1-1.4: 1, particularly preferably in the range from 1.9: 1-1.5: 1. Method according to one of the preceding claims, characterized in that identical components (3) are processed in parallel in the same stroke in a transfer station in several parallel processed paths, preferably in at least two, particularly preferably 2-8, or 3-5 such parallel paths. Method according to one of the preceding claims, characterized in that the conical train (65) is followed by further processing steps, in particular selected from the following group: further forming steps, in particular flange formation, optionally combined with grooved train and / or edge rolling; Punching steps; Coating steps; Application steps, in particular application of inserts or application of closures; Filling steps; Quality control steps; Purification steps; Assembly steps on further components, these further steps preferably being carried out at least partially in the same transfer system as the step train (64) and the cone train (65). A method according to claim 11, characterized in that a circumferential radial flange (54) and an axial cylindrical edge region (52) are formed in the cone train (65) on the opening side, and a groove train (66) is executed next to the cone train (65), in which between a shaped piece (59) and a die (58), optionally in combination with a further shaped piece (60), a bottom-side directed circumferential bead (53) is formed. Method according to Claim 12, characterized in that, following the formation of the bead (53), the axial cylindrical edge area (52) is rolled on the bottom side in an edge roller (67) with a roller stamp (56) to form a rolled edge (55), the rolled edge (55) protrudes over the plane of the flange (54) both on the bottom side and on the opening side. Device for carrying out a method according to one of the preceding claims in the form of a transfer system with at least one station for the stepped train (64) and a downstream station for the conical train (65),
wherein the tool for the stepped train (64) comprises a drawing die (23) and a drawing punch (24) displaceably guided in a fold holder (21), and the first cylinder section (12) and / or the transition section (14) in the stepped train at least partially between the fold holder (21) and the drawing die (23) is clamped and the second cylinder section (13) and / or the Transition section (14) is formed from the die (24);
and wherein the tool for the subsequent conical pull (65) comprises a conical pulling die (27) and a conical pulling punch (29) displaceably guided in a conical pulling centering sleeve (28), and the first cylinder section (12) and / or the Transition section (14) is guided and / or clamped in the conical train at least in some areas between the conical train centering sleeve (28) and the conical train drawing die (27), and the transition section (14) and / or the second cylinder section (13) between the conical train drawing punch (29) and conical centering sleeve (27) is formed. Component produced in a method according to one of the preceding claims or in a device according to claim 14.

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