Multipart subassembly composed of metallic parts, and method for the production thereof

• US 20090280349A1
• Filed: 07/13/2005
• Published: 11/12/2009
• Est. Priority Date: 07/27/2004
• Status: Abandoned Application

• Current Assignee: Stiwa Holding GmbH (Automation Privatstiftung)
• Original Assignee: Stiwa Holding GmbH (Automation Privatstiftung)
• Inventors: Heiml, Roland, Bittendorfer, Markus
• Application Number:
  US11/658,442
• Publication Number:
  US 20090280349A1
• Time in Patent Office: Days
• US Class Current: 428/594
• CPC Class Codes: B23K 26/242 Fillet welding, i.e. involving a weld of substantially triangular cross section joining two parts
• CPC Class Codes: B23K 26/26 of rectilinear seams
• CPC Class Codes: B23K 33/00 Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby B23K11/14 takes precedence
• CPC Class Codes: Y10T 428/12347 Plural layers discontinuously bonded [e.g., spot-weld, mechanical fastener, etc.]

Abstract

The invention relates to an assembly (1) and a method for producing the latter, with a first and second part (2, 3), the first part (2, 3) of which is cold formed and the parts (2, 3) with parallel surface parts (20, 21) and mounting surfaces running at an angle to the latter are provided for arranging them relative to one another without a gap and are joined together at the joint (16) by a weld (17) produced by beam welding. The surface parts (20, 21) are arranged offset relative to one another by an offset (19). One of the parts (2, 3) comprises a mounting projection (6), which forms the mounting surface of the first part (2). The parts (2, 3) are positioned relative to one another so that the second part (3) forms the joint (16) with the first part (2) in the section of the first part (2) at which the dislocation density of the base material is lower than the dislocation density of the joint in a deformation area (18) on the first part (2) produced by cold forming.

Claims

1-53. -53. (canceled)

54. Assembly (1) consisting of at least one first and second metal part (2, 3), of which at least the first part (2) is subjected to cold forming, in particular bending or cold forging, and the parts (2, 3) have first surface parts (20, 21;

29 to 32;

29, 31, 37, 39, 46;

52, 53) that are parallel to one another in sections and corresponding mounting surfaces (7, 14) running at an angle, in particular at right angles to the latter for their mutual arrangement essentially without a gap, and the first surface parts (20, 21;

29 to 32;

29, 31, 37, 39, 46;

52, 53) are arranged offset relative to one another by an offset (19, 19′

) in the direction of a plane defined by the mounting surfaces (7, 14), so that the parts (2, 3) to be welded together at least on at least one joint (16) formed by the mounting surfaces (7, 14) of the parts (2, 3) contacting one another without a gap form a step, and on at least one part (2, 3) the mounting surface (7, 14) is formed by at least one mounting projection (6) projecting over a second surface part (5;

27;

37, 39;

50), and the parts (2, 3) are joined together by at least one weld (17) produced by beam welding, in particular laser or electron beam welding, on the joint (16) formed by the mounting surfaces (7, 14) of the parts (2, 3) contacting one another without a gap, wherein the weld (17) consists of base material partly melted from the parts (2, 3) to be welded together in sections and the weld (17) is designed as a square-groove weld or fillet weld and is essentially continuous over the entire length of the joint (16), wherein the mounting surface (7, 14) on the mounting projection (6) is largely parallel to the second surface part (5;

27;

37;

39;

50) and wherein the parts (2, 3) are positioned relative to one another so that the second part (3) forms the joint (16) with the first part (2) in that section of the first part (2) in which a dislocation density of the base material is lower than the dislocation density of the joint in a deformation area (18) formed on the first part (2) by cold forming, and wherein the offset (19, 19′

) between the first surface parts (20, 21;

29 to 32;

29, 31, 37, 39, 46;

52, 53) is between 5% and 50% of the maximum thickness of a part (2, 3).

55. Assembly (1) according to claim 54, wherein the first part (2) in a plane perpendicular to its longitudinal extension has a profile-like, in particular essentially U-shaped or trapezoid cross section, and first surface parts (37, 39) on its outer casing, and the second part (3) is designed as a sleeve with a circular-shaped cross section in a plane perpendicular to its longitudinal extension and its outer circumference forms its first surface part (36), wherein the first surface parts (36, 37, 39) of the parts (2, 3) pointing in the same direction are arranged offset relative to one another by an offset (40, 40′

) in the direction of a plane defined by the mounting surfaces (7, 14), so that the parts (2, 3) to be welded together at least at the joints (16) formed by the mounting surfaces (7, 14) of the parts (2, 3) contacting one another without any gap form a step respectively, wherein both parts (2, 3) on their facing front sides respectively comprise the mounting surfaces (7, 14) respectively and between the first part (2) and the second part (3) at least separate joints (16) are formed.

56. Assembly according to claim 54, wherein the parts (2, 3) to be welded together on their facing sides respectively have at least one mounting surface (7, 14) and in addition at least one positioning surface (8, 15) parallel to the mounting surface (7, 14), wherein on at least one part (2, 3) the mounting and/or positioning surface (7, 8, 14, 15) of at least one mounting and/or positioning projection (6;

6′

) is formed, and wherein the parts (2, 3) are aligned relative to one another and positioned by their facing positioning surfaces (8, 15).

57. Assembly according to claim 55, wherein a third part (4) is provided which is produced by stamping and/or cold forming, in particular bending or cold forging, which is designed as a sleeve with a circular-shaped cross section in a plane perpendicular to its longitudinal extension and is also joined to the profile-like part (2), wherein the sleeves are arranged on opposite face ends of the profile-like part (2) and their axes (26) form a common axis, and wherein the profile-like part (2) on its opposite face ends respectively has at least two mounting surfaces (7) and in addition at least two positioning surfaces (8) parallel to the mounting surfaces (7) and the sleeves in turn on their side facing the face end of the profile-like part (2) have at least two mounting surfaces (14) and in addition at least two positioning surfaces (15) parallel to the mounting surfaces (14), and wherein the sleeves and the profile-like part (2) are positioned relative to one another and aligned by their facing positioning surfaces (8, 15), and each sleeve is connected by welds (17) produced by beam welding at at least two joints (16) formed separately by the mounting surfaces (7, 14) of the parts (2, 3, 4) that contact one another without a gap, and each weld (17) is in the form of a square-groove weld or fillet weld and is formed essentially over the entire length of the relevant joint (16).

58. Assembly according to claim 55, wherein the profile-like part (2) has two legs (12) and a base (11) connecting the latter and on the face ends in turn forms the face side second surface parts (27) facing away from one another, wherein on the second surface parts (27) of the legs (12) and if necessary the base (11) respectively at least one mounting surface (7) and at least one positioning surface (8) parallel to the mounting surfaces (7) are arranged.

59. Assembly according to claim 55, wherein a fourth part (34) is provided which is produced to be essentially flat by stamping and/or cold forming, in particular bending or cold forging, which is connected to the legs (12) of the profile-like part (2), and on the lateral second surface parts (5) facing the legs (12) respectively has at least two mounting surfaces (14) or on the lower surface part (48) facing the two legs (12) has at least two mounting surfaces (7) and in addition at least two positioning surfaces (8) parallel thereto, and the legs (12) on the surface parts (13;

47) facing the fourth part (34) are provided respectively with at least two mounting surfaces (8) and in addition at least two positioning surfaces (15) parallel to the latter, and wherein the parts (2, 34) via their facing positioning surfaces (8, 15) are positioned relative to one another and aligned and are connected by welds (17) produced by beam welding, in particular laser or electron beam welding, onto at least two joints (16) formed separately by the mounting surfaces (7, 14) of the parts (2, 34) contacting one another without a gap, wherein each weld (17) is designed to be a square-groove weld or fillet weld and is essentially continuous over the entire length of the relevant joint (16), and/or wherein the surface parts (37) formed on the legs (12) and lateral first surface parts (49) formed on the fourth part (34) parallel to the surface parts (20) are arranged to be mutually offset by an offset (19) in the direction of a plane defined by the mounting surfaces (7, 14), so that the parts (2, 34) to be welded together form a step at least at the joints (16), wherein said offset (19) is between 5% and 50% of the maximum thickness of a part (2, 34).

60. Assembly according to claim 57, wherein the fourth part (34) on its mutually averted face end second surface parts (35) respectively has at least one mounting surface (7) and in addition at least one positioning surface (8) parallel to the latter and each of the sleeves on the surface part (28) facing the face end surface part (35) of the fourth part (34) has at least one mounting surface (14) and in addition at least one positioning surface (15) parallel thereto, and is connected to the fourth part (34) by a weld (17) formed by beam welding, in particular laser or electron beam welding, at at least one joint (16) formed by the mounting surfaces (7, 14) contacting one another without a gap, wherein the weld (17) is in the form of a square groove weld or fillet weld and is continuous over the entire length of the joint (16), wherein the sleeves and the fourth part (34) are positioned relative to one another and aligned by the mutually aligned positioning surfaces (8, 15) and/or wherein the first surface parts (36, 21) of the parts (3, 4, 34) pointing in the same direction are arranged offset relative to one another by an offset (40′

) in the direction of a plane defined by the mounting surfaces (7, 14), so that the parts (3, 4, 34) to be welded together form a step at least at the joint, and the axes (26) of the sleeves form a common axis and the offset (40′

) is between 5% and 50% of the maximum thickness of a part (3, 4, 34).

61. Assembly according to claim 59, wherein the averted face end second surface parts (35) of the fourth part (34) close flush with the second surface parts (27) of the profile-like part (2).

62. Assembly according to claim 59, wherein the mounting and/or positioning surfaces (7, 8) on the averted face end second surface parts (27) of the profile-like part (2) and the mounting and/or positioning surfaces (14, 15) on the averted face end second surface parts (35) of the fourth part (34) are arranged in planes running perpendicular to the longitudinal direction of the profile-like part (2).

63. Assembly according to claim 55, wherein the parts (2, 3, 4, 34) are aligned relative to one another by their mutually arranged positioning surfaces (8, 15) and/or are positioned relative to one another so that the second and third part (3, 4) with the first and/or fourth part (2) in each section of the first and/or fourth part (2) respectively forms the at least one joint (16), in which the dislocation density of the base material is lower than the dislocation density of the joint in a deformation area (18) formed on the first and/or fourth part (2) by cold forming.

67. Assembly according to claim 54, wherein the mounting and positioning surfaces (7, 8, 14, 15) are formed on a part (2, 3, 4, 34) or parts (2, 3, 4, 34) in the same plane.

68. Assembly according to claim 54, wherein two parts (2, 3, 4, 34) are connected together by at least two welds (17) on at least two separately formed joints (16), wherein the welds (17) respectively are in the form of a square-groove weld or fillet weld extending at the joints (17) essentially continuously over their entire length.

69. Assembly according to claim 54, wherein on at least one of the parts (2, 3, 4, 34) at least one mounting and positioning projection (6;

6′

) is formed, which forms the mounting and/or positioning surface (7, 8, 14, 15) and on a second surface part (5;

27;

37;

47;

50) of the first part (3;

2) parallel to the mounting surface (7, 14) projects in the direction of the other part (2;

3).

70. Assembly according to claim 54, wherein the surface part (13), the mounting and positioning surfaces (14, 15) of the first part (2;

3;

4) are arranged in one plane and the other part (3;

2) comprises at least one mounting and/or positioning projection (6, 6′

) allocated to the mounting and/or positioning surface (14, 15).

71. Assembly according to claim 55, wherein the surface part (50, 51), the mounting and positioning surfaces (7, 8, 14, 15) of each of the parts (2, 3, 4, 34) to be welded are arranged lying in one plane.

72. Assembly according to claim 54, wherein the mounting and positioning surfaces (7, 8, 14, 15) are immediately adjacent to one part or parts (2, 3, 34) to be welded and are formed by a mounting and/or positioning projection (6).

73. Assembly according to claim 54, wherein the mounting and positioning surfaces (7, 8, 14, 15) on one part or parts (2, 3, 4, 34) to be welded are separated from one another spatially and are formed respectively by a mounting projection (6) and a positioning projection (6′

).

74. Assembly according to claim 57, wherein the sleeves form bearing eyes (24), in which bearings (44) are arranged, in particular pressed in, by means of which a shaft is mounted rotatably.

75. Assembly according to claim 55, wherein an internal diameter of the sleeve is greater than the distance between the legs (12) and the sleeve on the planar mounting surfaces (7) of at least two joints (16) delimits circle sections, which form support surfaces (43) against which the bearing (44) is positioned.

76. Assembly according to claim 54, wherein the opposite parts (2, 3, 4, 34) to be welded together comprise respectively at least one mounting and/or positioning projection (6, 6′

), which forms the mounting and/or positioning surface (7, 8, 14, 15) and is formed on each part (2, 3, 4, 34), wherein the mounting and/or positioning projection (6;

6′

) of the first part (2, 3, 4, 34) of its surface part (50, 51) facing the other part (2, 3, 4, 34) projects in the direction of the other part (2, 3, 4, 34) and the mounting and/or positioning projection (6;

6′

) of the other part (2, 3, 4, 34) projects from its surface part (50, 51) facing the first part (2, 3, 4, 34) in the direction of the first part (2, 3, 4, 34), and the mounting and/or positioning projection (6;

6′

) of the first part (2, 3, 4, 34) and mounting and/or positioning projection (6;

6′

) of the other part (2, 3, 4, 34) run towards one another and contact one another essentially without a gap with their mounting and/or positioning surfaces (7, 8, 14, 15).

77. Assembly according to claim 54, wherein the mounting and/or positioning projection (6;

6′

) has a length corresponding approximately to double the thickness of a part (2, 3, 4, 34).

78. Assembly according to claim 54, wherein the mounting and/or positioning projection (6;

6′

) has height (9) which is between 5% and 50% of the thickness of a part (2, 3, 4, 34).

79. Assembly according to claim 54, wherein the mounting and positioning surfaces (7, 8, 14, 15) of at least one of the parts (2, 3, 4, 34) to be welded lie in two planes and enclose an angle of preferably 90°

.

80. Assembly according to claim 54, wherein the parts (2, 3, 4, 34) to be welded are arranged in two planes and enclose an angle of preferably 90°

.

81. Assembly according to claim 54, wherein the parts (2, 3) to be welded with their mounting and positioning surfaces (7, 8, 14, 15) lie on top of one another in a butt joint and are arranged offset relative to one another about the offset (19) in a direction perpendicular to their surface parts (52, 53).

82. Assembly according to claim 54, wherein two parts (2, 3, 4, 34) are joined together via two welds (17) on two separate joints (16) that run towards one another and are produced in opposite welding direction, wherein adjacent end sections of the welds (17) lie in a low-tension or non critical section of the assembly (1).

83. Assembly according to claim 54, wherein two parts (2, 3, 4, 34) are connected at a joint (16) by at least two welds (17) that run from its outer sections to its inner section and are produced in opposite welding direction, wherein adjacent end sections of the welds (17) lie in a low-tension or non critical section of the assembly (1).

84. Assembly according to claim 82, wherein the welds (17) are directed towards one another and in a direction towards a common meeting point, wherein the end sections of the welds (17) overlap with one another at the common meeting point.

85. Assembly according to claim 82, wherein the welds (17) are directed towards one another and in the direction of a common meeting point, wherein the end sections of the welds (17) end at the common meeting point.

86. Assembly according to claim 85, wherein the meeting point lies in a low-tension or non critical section of the assembly (1).

87. Assembly according to claim 54, wherein two parts (2, 3, 4, 34) are connected together by two welds (17) running towards one another and produced in the same welding direction at two separate joints (16), wherein adjacent end sections of the welds (17) lie in a low-tension or non critical section of the assembly (1).

88. Assembly according to claim 54, wherein an end section of the at least one weld (17) is placed on a mechanically less stressed section of the assembly (1) and an initial section of the at least one weld (17) is placed on a mechanically more stressed section of the assembly (1).

89. Assembly according to claim 54, wherein the joint (16) or the joints (16) and the at least one weld (17) on the joint (16) or on the joints (16) are arranged between the parts (2, 3, 4, 34) in a low-tension or non critical section of the assembly (1).

90. Method for producing an assembly (1) according to claim 54, with a metal, first part (2) and at least one metal second part (3), shaped to form a profile, in which on both parts (2, 3) respectively at least one mounting surface (7, 14) is formed, whereupon the parts (2, 3) are fixed respectively by means of at least one clamping tool (57, 57′

, 57″

, 63) by the clamping and positioning devices (57, 60) and positioned relative to one another, and are pressed against one another on their corresponding mounting surfaces (7, 14) and afterwards are joined together by means of beam welding, in particular laser or electron beam welding, at at least one joint (16) formed by the mounting surfaces (7, 14) of the parts contacting one another without any gap by melting the base material in sections, wherein the first part (2) is secured by means of the clamping tool (57, 57′

, 57″

) of the first clamping and positioning device (56) and immediately prior to the welding of the second part (3) to the first part (2), the second part (3), whose mounting surface (14) is oriented perpendicular to the longitudinal axis (69) of its profile, in the case of deviation from the desired shape of its profile is shaped radially to the longitudinal axis (69) of its profile by means of the adjustable clamping tool (63) of the second clamping and positioning device (60) into the desired shape and is held in the latter, and wherein during or after this shaping of the part (3) into the desired shape, the said shaped second part (3) and the first part (2) are aligned relative to one another, pressed against one another with their corresponding mounting surfaces (7, 14) and then are joined together by beam welding at the joint (16).

91. Method according to claim 90, wherein the first and/or second part (3) is measured by means of a measuring device (64) for any deviation in shape, and the actual values of the dimensions according to the actual shape are determined, and the actual values of the dimensions (actual shape) are compared with the desired values of the dimensions (desired shape) and in the case of a deviation between the actual and desired values the first and/or second part (2, 3) is shaped by a specified amount (fixed value).

92. Method according to claim 90, wherein the first and/or second part (3) is measured by means of a measuring device (64) for deviation in shape and the actual values of the dimensions are determined according to the actual shape, and the actual values of the dimensions (actual shape) are compared with the desired values of the dimensions (desired shape), the deviation is established as the correction value and the correction value is supplied to a control unit (67), which depending on the correction value drives an actuator (65, 74, 74′

, 74″

) for the clamping tool (57, 57′

, 57″

, 63) of the first and/or second clamping and positioning device (56, 60), so that the deviation between the actual and desired values is adjusted/corrected.

93. Method according to claim 91, wherein the actual values of the dimensions of the first and/or second part (3) are determined by means of the optoelectronic measuring device (64) by non-contact methods.

94. Method according to claim 90, wherein the force of the clamping tool (57, 57′

, 57″

, 63) on the first and/or second part (2, 3) is set depending on the correction value and once the correction value has been adjusted and the first and/or second part (2, 3) has been shaped into the desired shape, the force of the clamping tool (57, 57′

, 57″

, 63) is kept constant on the first and/or second part (2, 3).

95. Method according to claim 90, wherein after the alignment and mutual pressing together of the parts (2, 3), the second part (3) is prefixed by welding points and afterwards is welded by at least one continuous weld (17) at the joint (16) to the first part (2).

96. Method according to claim 90, wherein during the shaping of the first and/or second part (3) from its actual shape into the desired shape the latter is shaped plastically.

97. Method according to claim 90, wherein during the shaping of the first and/or second part (3) from its actual shape into the desired shape the latter is shaped elastically.

98. Welding system for performing the method according to claim 90, which comprises a welding device (58), a first clamping and positioning device (56) with at least one clamping tool (57, 57′

, 57″

) for mounting, positioning and clamping a first part (2) against a second part (3), and a second clamping and positioning device (60) with at least one clamping tool (63) for mounting, positioning and clamping the second part (2) against the first part (2), a holder (59) or mounting one of the parts (2, 3) if necessary and a control (67), wherein at least one of the clamping tools (57, 57′

, 57″

, 63) of the clamping and positioning devices (56, 60) is designed for shaping the part (2, 3) mounted thereby in case of a deviation in shape into its desired shape as necessary, and is actively connected with at least one actuator (65, 74, 74′

, 74″

) which is connected in turn with the control (67) driving the latter.

99. Welding system according to claim 98, wherein the latter comprises a measuring device (64) for detecting the actual values of the dimensions of the first and/or second part (2, 3), which device is connected in turn to the control (67).

100. Welding system according to claim 99, wherein the measuring device (64) is formed by an optoelectronic or electromechanically operating measuring system.

101. Welding system according to claim 98, wherein the clamping tool (57, 57′

, 57″

, 63) is provided with a device for detecting the force exerted on the first and/or second part (2,3) for shaping the latter.

102. Welding system according to claim 98, wherein each clamping and positioning device (56, 60) is mounted on an adjusting device which comprises an actuator connected to the control (67).

64. Assembly (1) consisting of at least two metal parts (2, 3), which are provided with corresponding mounting surfaces (7, 14) for arranging them relative to one another essentially without a gap, and are to be joined together via at least one weld (17) produced by beam welding, in particular laser or electron beam welding, at at least one joint (16) formed by the mounting surfaces (7, 14) of the parts (2, 3) arranged next to one another without a gap, wherein the weld (17) is formed by the base material that is melted in sections from the parts (2, 3) to be welded together, and at least one of the parts (2, 3) has at least one welding bar (54) which adjoins the mounting surface (7, 14) and can be melted by a welding beam, in particular laser or electron beam, which is formed onto this part (2, 3) and is provided for forming a least one component of the weld (17) to be produced, wherein welding bar (54) projects over a positioning surface (8) formed by the first part (2) in the direction of the second part (3) opposite the first part (2), whereby the positioning surface (8) runs parallel to the mounting surface (7).

65. Assembly according to claim 64, wherein the welding bar (54) extends essentially over the entire length of the joint (16) or the edge to be formed by the mounting surfaces (7, 14) of the parts (2, 3) that contact one another without a gap.

66. Assembly according to claim 64, wherein the welding bar (54) has a height (55) and width (55′

) corresponding to about 5% to 50% of the maximum thickness of a part (2, 3).