C.r.f. Societa Consortile Per Azioni

Daniele Bassan

Marco Colosseo

Silvano Sandri

Brunetto Martorana

Michele Longo

Stefano Paradiso

Carlo Carcioffi

Elisa Micucci

Davide Roncato

A method for moulding a sheet into a component of complex shape having areas with different mechanical properties, particularly a motor-vehicle component, includes a first heating step of the sheet carried out by a kiln, prior to forming the component. The kiln has a main body with a roller shape, having a plurality of sectors extending along a radial direction with respect to a longitudinal axis of the roller body. The sectors are configured to each receive a sheet, so that the main body with a roller shape is arranged to simultaneously carry a plurality of sheets. The kiln includes a plurality of heating elements incorporated in the roller-shaped main body, so as to heat the sheets in contact with the roller body. The kiln includes at least one electronically-controlled drive motor, arranged to rotate the roller-shaped main body around the longitudinal axis of the kiln, so as to vary the position of the sectors with respect to the inlet and outlet ports. An additional heating step follows extraction of the sheets from the kiln, wherein the sheets are locally heated only at one area, so as to obtain sheets with areas heated to different temperatures.

Method for moulding a sheet into a component of complex shape having areas with different mechanical properties, particularly a motor-vehicle component

A motor-vehicle lattice frame that includes a plurality of structural nodes each having a central body and at least one hollow arm protruding from the central body. The lattice frame also includes a plurality of beam elements connected to each other by means of the hollow protruding arms. The structural nodes are made by an additive manufacturing technique and at least one arm of one of the nodes has an end portion opposite to said central body having a channel shape with an open cavity both at a front end of the arm and along one side of the arm.

Motor-vehicle lattice frame

A hinge of a motor-vehicle mobile part includes a first and a second hinge element mounted articulated with respect to each other about a hinge axis. The second hinge element is articulated to the first hinge element by an articulation portion having two pins defining the hinge axis, and projecting in opposite directions from two sides of the second hinge element. The first hinge element and the second hinge element are obtained by an additive manufacturing technique in an already reciprocally articulated condition, with the pins mounted with clearance within respective articulation seats formed on two flanges of the first hinge element adjacent to the sides of the second hinge element. The hinge also includes two bushing-shaped members, each interposed between one of said two pins and the respective articulation seat.

Hinge of a motor-vehicle mobile part

A method for molding a sheet into a motor-vehicle component includes heating the sheet by a kiln, prior to forming the component. The kiln has a main body with a roller shape, having a plurality of sectors extending along a radial direction with respect to a longitudinal axis of the roller body. The sectors are configured to each receive a sheet, so that the main body with a roller shape is arranged to simultaneously carry a plurality of sheets. The kiln includes a plurality of heating elements in said main body with a roller shape and configured to heat only the first portion of the roller body, so that the roller shaped main body is designed to heat the sheets in a differentiated way, particularly at their areas in contact with said first portion of the roller body. The kiln includes at least one electronically-controlled drive motor, arranged to rotate the roller-shaped main body around the longitudinal axis of the kiln, so as to vary the position of the sectors with respect to the inlet and outlet ports.

A component of a vehicle structure is obtained by a hot forming operation on a hybrid panel having a sheet element of light alloy and a sheet of plastic material. The hybrid panel is hot formed by pressing it against a forming surface of a mould element by a pressurized gas or by a second mould element. Following this operation, the hybrid panel assumes a configuration corresponding to the forming surface, whereas the light alloy sheet element and the plastic material sheet constituting the hybrid panel adhere to each other following softening by heat of the plastic material. Before the hot forming step, a surface of said light alloy sheet element which must contact the plastic material sheet is subjected to a roughening treatment, thereby defining surface asperities between which the plastic material of the plastic material sheet is inserted when it is softened by heat.

Method for producing components for motor-vehicle structures, having a hybrid structure made of light alloy and plastic material

Described herein is a method for rolling metal sheets of variable thickness. The method makes it possible to impress, during rolling, any distribution of areas of increased thickness within a figure corresponding to the plane development of a motor-vehicle component prior to the pressing operation. Impression of the desired distribution of areas of increased thickness envisages simultaneous impression, during rolling, of a further distribution of areas of increased thickness, or compensation areas.

Method for rolling metal sheets with variable thickness

Described herein is a structure of a motor-vehicle door including a multi-thickness metal sheet pressed and shaped to define: a hinge area configured for fastening one or more hinges for connection to the body of a motor vehicle; a panel area configured for receiving an upholstery-trim element for the door; and a frame area configured for receiving a window of the door. The above multi-thickness metal sheet has a first thickness in said hinge area, a second thickness in said panel area, and a third thickness in said frame area.

Structure of a door for a motor-vehicle

A method for forming a sheet made of an aluminium alloy into a component of complex shape, particularly a motor-vehicle component, such as an outer panel or an inner frame of a bonnet or a door of a motor-vehicle, provides for blow-forming of the sheet, with the aid of pressurized gas, within a mould. The alloy constituting the sheet does not have superplasticity features and the sheet and/or the mould are heated to a temperature in the order of 400&#xb0;-450&#xb0; C. for 5XXX series alloys and 450&#xb0;-500&#xb0; C. and over for 6XXX and 7XXX series alloys. The maximum pressure reached by the forming gas is in the order of 20-30 bars and the time required for forming the sheet is between 40 and 150 seconds and therefore is consistent with production rates in the automotive field.

Method for forming a sheet made of an aluminum alloy into a component of complex shape, particularly a motor-vehicle component

A method for obtaining a camshaft for an internal-combustion engine having a structure made of a single piece includes obtaining the camshaft by starting from a metal tubular element. The cams are obtained by expanding the tubular element within a die using high-pressure fluid. The tubular element can have an enlarged thickness in portions that are to form the cams. Forming with high-pressure fluid can be obtained using gas or liquid (for example, water or oil) at high pressure, at room temperature or at a higher temperature. The piece obtained is subjected to thermal treatment and to a grinding operation.

Method for producing a camshaft for an internal-combustion engine

In a method for manufacturing a camshaft for an internal combustion engine a metal tubular element is expanded within a mold with the aid of a fluid at high pressure fed into the tubular element and with a simultaneous axial compression of the tubular element. The cams of the camshaft are formed in subsequent steps, starting from intermediate cams and ending with end cams. In a first step of the method, the intermediate cams are formed in a first mold. In a subsequent step, the end cams are formed within auxiliary molds which surround, only throughout a predetermined length, end portions of the tubular element which project from the mold which surrounds the already formed intermediate cams. In this subsequent step, the tubular element is compressed axially by axially displacing two clamp members, which grip and surround completely, throughout a predetermined length, the end portions of the tubular element which project outwardly from the auxiliary molds.

Method for manufacturing a camshaft for an internal combustion engine by expanding a tubular element with a high pressure fluid and simultaneously compressing the tubular element axially

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Orbassano, Italy

Daniele Bassan