Method of producing individualized vehicle parts, particularly individualized vehicle body skin parts consisting of series-produced vehicle body skin parts, as well as vehicle body skin parts manufactured by this method

Abstract

A method for producing vehicle parts is provided, particularly shell parts for vehicles, according to which a three-dimensionally preformed semi-finished or finished standard part, especially a standard shell part, is produced for a serially manufactured vehicle type. An individualized part is then produced from the preformed standard part by subsequently embossing a three-dimensional contour into the standard part by use of a mandrel-type reshaping tool which is pressed against the standard part from one side while being displaced relative to the standard part.

1 . A method of producing a vehicle part, the method comprising the acts of: 
 producing, from a starting material, a three-dimensional preformed serial part for a vehicle model manufactured in a series production, the preformed serial part being at least one of a semi-finished and finished serial part for the vehicle model manufactured in the series production;    pressing a mandrel-type forming tool against one side of the preformed serial part and simultaneously moving the mandrel-type forming tool relative to the serial part to impress an additional three-dimensional contour in the serial part to produce an individualized part from the serial part.    
   
   
       2 . The method according to  claim 1 , wherein the individualized vehicle part produced is at least one of a vehicle body skin part and a series-produced vehicle body skin part.  
   
   
       3 . The method according to  claim 2 , wherein the starting material is a metal sheet, and the serial part, as well as the body skin part to be produced therefrom, each are sheet metal parts.  
   
   
       4 . The method according to  claim 2 , wherein the starting material is a plastic material, and the serial part, as well as the body skin part to be produced therefrom, each are plastic parts.  
   
   
       5 . The method according to  claim 2 , wherein the starting material is a thermoplastic material.  
   
   
       6 . The method according to  claim 4 , wherein the starting material is a thermoplastic material.  
   
   
       7 . The method according to  claim 2 , wherein the series-produced body part is held by a holding device in edge areas of the series-produced body part during deforming by the mandrel-type forming tool.  
   
   
       8 . The method according to  claim 7 , wherein the holding device has a plurality of holding points.  
   
   
       9 . The method according to  claim 8 , wherein the holding points are each formed by a suction-cup-type holding element, which hold the serial part via a vacuum.  
   
   
       10 . The method according to  claim 7 , wherein the serial part is held during deforming by the mandrel-type forming tool exclusively in its edge areas by the holding device and is neither supported nor otherwise held in the component areas situated in-between.  
   
   
       11 . The method according to  claim 7 , wherein the serial part is held by the holding device during deforming by the mandrel-type forming tool and, in a component area situated in-between, is supported at least at one point by a counterholder, which is arranged on the side of the serial part situated opposite the mandrel-type forming tool.  
   
   
       12 . The method according to  claim 11 , wherein the counterholder is a die-type component which acts as a negative mold with respect to the three-dimensional contour to be produced.  
   
   
       13 . The method according to  claim 1 , wherein the mandrel-type forming tool has a smooth, convexly curved tool tip.  
   
   
       14 . The method according to  claim 1 , wherein the tool tip of the mandrel-type forming tool is formed by a rotatably disposed ball, which rolls on the serial part during the working of the serial part.  
   
   
       15 . The method according to  claim 1 , wherein the mandrel-type forming tool has an adjustable tool tip whose width transversely to the moving direction of the mandrel-type forming tool is changed relative to the serial part during the working operation.  
   
   
       16 . The method according to  claim 1 , wherein the mandrel-type forming tool is heated during deforming of the serial part at least in an area of the tool tip.  
   
   
       17 . The method according to  claim 1 , wherein the serial part is heated by a heat source during deformation.  
   
   
       18 . The method according to  claim 1 , wherein the forming tool is rotated about a longitudinal axis of the forming tool during deformation of the serial part.  
   
   
       19 . The method according to  claim 1 , wherein the forming mandrel is oscillated about an longitudinal axis of the forming mandrel during deformation of the serial part.  
   
   
       20 . The method according to  claim 1 , wherein design-relevant, line-type characteristic contours are impressed into the serial part by use of the mandrel-type forming tool.  
   
   
       21 . The method according to  claim 1 , wherein the serial part is a pressed piece, which is produced by using a mold-type tool.  
   
   
       22 . The method according to  claim 1 , wherein the serial part is a sheet metal part produced by deep drawing.  
   
   
       23 . The method according to  claim 1 , wherein a contour already existing in the serial part is redrawn or deepened by reworking with the mandrel-type forming tool.  
   
   
       24 . The method according to  claim 1 , wherein the serial part is one of a front opening hood, a tailgate, a door, a side part, a fender, or a roof.  
   
   
       25 . The method according to  claim 1 , wherein the mandrel-type forming tool is arranged on an arm of a robot.  
   
   
       26 . The method according to  claim 1 , wherein the mandrel-type forming tool is part of a CNC machine tool.  
   
   
       27 . The method according to  claim 1 , wherein, during working of the serial part, the mandrel-type forming tool rotates about its longitudinal axis, whereby a drilling-friction-type contact occurs between a tip of the forming mandrel and the serial part.  
   
   
       28 . The method according to  claim 1 , wherein, during deformation, the serial part is held such that its geometry in its edge areas is not changed with respect to its starting condition.  
   
   
       29 . The method according to  claim 28 , wherein connection measurements or gap measurements, which occur during a later installation into a vehicle body shell, do not change with respect to the serial part in its starting condition.  
   
   
       30 . The method according to  claim 1 , wherein the three-dimensional contour to be additionally produced in the serial part is produced by a one-time moving of the mandrel-type forming tool in a single pass.  
   
   
       31 . The method according to  claim 1 , wherein the three-dimensional contour to be additionally produced in the serial part is produced by a repeated moving and incremental application of the mandrel-type forming tool.  
   
   
       32 . The method according to  claim 31 , wherein the mandrel-type forming tool is applied from one reworking pass to the next reworking pass essentially perpendicularly with respect to the serial part, so that the contour is deepened from one reworking pass to the next.  
   
   
       33 . The method according to  claim 31 , wherein, from one reworking pass to the next reworking pass, the mandrel-type forming tool is applied essentially transversely to the moving direction of the forming tool, so that the contour is widened from one reworking pass to the next.  
   
   
       34 . The method according to  claim 32 , wherein, from one reworking pass to the next reworking pass, the mandrel-type forming tool is applied essentially transversely to the moving direction of the forming tool, so that the contour is widened from one reworking pass to the next.  
   
   
       35 . A vehicle body skin part which is produced from a serial part according to the method of  claim 1 .  
   
   
       36 . A vehicle body skin part according to  claim 35 , wherein the serial part is made of sheet metal.  
   
   
       37 . The vehicle body skin part according to  claim 35 , wherein the serial part is made of a plastic material.