JP2010120062A - Method and apparatus for manufacturing press formed product, and the press formed product - Google Patents
Method and apparatus for manufacturing press formed product, and the press formed product Download PDFInfo
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Abstract
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本発明は、プレス成形品の製造方法および製造装置、並びにプレス成形品に関する。 The present invention relates to a method and apparatus for manufacturing a press-formed product, and a press-formed product.
車両のサスペンション部品等のプレス成形品は、テーラードブランクから製造される（例えば、特許文献１参照。）。テーラードブランクは、２枚の異種鋼板を予め接合して一体化することで形成されており、例えば、一方の異種鋼板は、厚肉の鋼板からなり、剛性または強度が必要な局所部位に適用され、他方の異種鋼板は、薄肉の鋼板からなり、剛性または強度が比較的要求されない部位に適用される。
しかし、テーラードブランクでは、一方の異種鋼板が薄肉の鋼板からなるため、プレス成形品の軽量化を図ることが可能であるが、製造コストに問題を有する。つまり、異種鋼板の接合は、異種鋼板の突合せ部を溶接することで実施されるため、高い突合せ精度が要求され、生産性を向上させることが困難であり、製造コストの上昇を招いている。 However, in the tailored blank, since one dissimilar steel plate is made of a thin steel plate, it is possible to reduce the weight of the press-formed product, but there is a problem in manufacturing cost. That is, since joining of dissimilar steel plates is performed by welding the butt portions of dissimilar steel plates, high butt accuracy is required, and it is difficult to improve productivity, leading to an increase in manufacturing cost.
本発明は、上記従来技術に伴う課題を解決するためになされたものであり、プレス成形品の軽量化および製造コストの低減を図ることを目的とする。 The present invention has been made to solve the problems associated with the above-described prior art, and aims to reduce the weight of the press-formed product and the manufacturing cost.
上記目的を達成する本発明に係るプレス成形品の製造方法は、撓み部成形工程と、増肉工程と、プレス成形工程とを有している。撓み部成形工程では、平板形状のブランクに、部分的に撓んだ撓み部を形成して予備成形体とする。増肉工程では、前記予備成形体に平板形状で残る平板形状部を拘束しつつ、前記撓み部を平板形状に潰して板厚を増加させた増肉部を形成する。プレス成形工程では、前記増肉部を形成した予備成形体を、プレス成形する。 The method for manufacturing a press-formed product according to the present invention that achieves the above object includes a flexure forming step, a thickness increasing step, and a press forming step. In the bending portion forming step, a partially bent bending portion is formed on a flat plate-shaped blank to form a preform. In the thickening step, a thickened portion in which the plate thickness is increased by crushing the bent portion into a flat plate shape while restraining the flat plate shape portion remaining in the flat plate shape on the preform. In the press molding process, the preform with the thickened portion formed thereon is press molded.
上記目的を達成する本発明に係るプレス成形品の製造装置は、撓み部成形型と、増肉用成形型と、プレス成形型とを有している。撓み部成形型は、平板形状のブランクに、部分的に撓んだ撓み部を形成して予備成形体とする。増肉用成形型は、前記予備成形体に平板形状で残る平板形状部を拘束する拘束部、および前記撓み部を平板形状に潰して板厚を増加させる押圧部を備えている。プレス成形型は、前記板厚を増加された予備成形体を、プレス成形する。 An apparatus for manufacturing a press-formed product according to the present invention that achieves the above object includes a bending portion forming die, a thickening forming die, and a press forming die. A bending part shaping | molding die forms the bending part partially bent in the flat blank, and makes it a preforming body. The thickening mold includes a restraining portion that restrains a flat plate-shaped portion remaining in a flat plate shape on the preform, and a pressing portion that crushes the bent portion into a flat plate shape to increase the plate thickness. The press-molding die press-molds the preform with the plate thickness increased.
上記目的を達成する本発明に係るプレス成形品は、板材の部分的に撓んだ撓み部を平板形状に潰すことで他の部位よりも板厚を増加させた増肉部を有するプレス成形品である。 The press-formed product according to the present invention that achieves the above object is a press-formed product having a thickened portion in which the plate thickness is increased more than other portions by crushing a bent portion of the plate material into a flat plate shape. It is.
上記のように構成した本発明に係るプレス成形品の製造方法は、増肉工程において、予備成形体の平板形状部を拘束し、撓み部を平板形状に潰して増肉部を形成するため、薄肉の板材から板厚が増加した部分を有するプレス成形品（部品）を製造できる。このため、薄肉の予備成形体を適用しても、板厚が増加した部分によって、プレス成形品の剛性または強度が確保されるため、プレス成形品の軽量化を容易に図ることが可能である。また、板厚が増加した部分は、突合せ溶接が適用されるテーラードブランクに比較し、良好な生産性を有するプレス成形によって形成されるため、製造コストが低減される。したがって、プレス成形品の軽量化および製造コストの低減を図ることが可能である。 In the method for manufacturing a press-formed product according to the present invention configured as described above, in the thickening step, the flat plate-shaped portion of the preform is constrained, and the bent portion is crushed into a flat plate shape to form the thickened portion. A press-formed product (part) having a portion where the plate thickness is increased can be manufactured from a thin plate material. For this reason, even if a thin preform is applied, the rigidity or strength of the press-formed product is ensured by the portion where the plate thickness is increased, and thus it is possible to easily reduce the weight of the press-formed product. . Further, since the portion where the plate thickness is increased is formed by press molding having good productivity as compared with the tailored blank to which butt welding is applied, the manufacturing cost is reduced. Therefore, it is possible to reduce the weight of the press-formed product and reduce the manufacturing cost.
上記のように構成した本発明に係るプレス成形品の製造装置は、予備成形体の平板形状部を拘束する拘束部および撓み部を平板形状に潰して板厚を増加させる押圧部を備えた増肉用成形型を有するため、薄肉の板材から板厚が増加した部分を有するプレス成形品（部品）を製造できる。このため、薄肉の予備成形体を適用しても、板厚が増加した部分によって、プレス成形品の剛性または強度が確保されるため、プレス成形品の軽量化を容易に図ることが可能である。また、板厚が増加した部分は、突合せ溶接が適用されるテーラードブランクに比較し、良好な生産性を有するプレス成形によって形成されるため、製造コストが低減される。したがって、プレス成形品の軽量化および製造コストの低減を図ることが可能である。 An apparatus for manufacturing a press-formed product according to the present invention configured as described above includes an increasing portion including a restraining portion that restrains the flat plate-shaped portion of the preform and a pressing portion that crushes the bent portion into a flat plate shape and increases the plate thickness. Since it has a mold for meat, it is possible to manufacture a press-formed product (part) having a portion where the plate thickness is increased from a thin plate material. For this reason, even if a thin preform is applied, the rigidity or strength of the press-formed product is ensured by the portion where the plate thickness is increased, and thus it is possible to easily reduce the weight of the press-formed product. . Further, since the portion where the plate thickness is increased is formed by press molding having good productivity as compared with the tailored blank to which butt welding is applied, the manufacturing cost is reduced. Therefore, it is possible to reduce the weight of the press-formed product and reduce the manufacturing cost.
上記のように構成した本発明に係るプレス成形品は、板材の部分的に撓んだ撓み部を平板形状に潰すことで他の部位よりも板厚を増加させた増肉部を有するため、プレス成形品の剛性または強度が確保され、プレス成形品の軽量化を容易に図ることが可能である。また、板厚が増加した部分は、突合せ溶接が適用されるテーラードブランクに比較し、良好な生産性を有するプレス成形によって形成されるため、製造コストが低減される。したがって、プレス成形品の軽量化および製造コストの低減を図ることが可能である。 Since the press-formed product according to the present invention configured as described above has a thickened portion in which the plate thickness is increased more than other portions by crushing the bent portion of the plate material into a flat plate shape, The rigidity or strength of the press-formed product is ensured, and the press-formed product can be easily reduced in weight. Further, since the portion where the plate thickness is increased is formed by press molding having good productivity as compared with the tailored blank to which butt welding is applied, the manufacturing cost is reduced. Therefore, it is possible to reduce the weight of the press-formed product and reduce the manufacturing cost.
以下、本発明の実施の形態を、図面を参照しつつ説明する。なお、図面の説明において同一の要素には同一の符号を付し、重複する説明を省略する。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted.
図１は、本実施形態に係る製造方法によりブランクを段階的に加工した形状を示す斜視図であり、（Ａ）はブランク、（Ｂ）は予備成形体、（Ｃ）は増肉された予備成形体、（Ｄ）はプレス成形品を示す。図２〜６は、本実施形態に係る成形方法によりブランクに撓み部を形成する工程を段階的に示す断面図である。図７，８は、同成形方法により撓み部を途中まで潰す第１増肉工程を示す断面図、図９，１０は、同成形方法により撓み部を完全に潰して増肉する第２増肉工程を示す断面図である。図１１は、増肉工程において座屈が生じる例を示す斜視図である。 FIG. 1 is a perspective view showing a shape in which a blank is processed stepwise by the manufacturing method according to the present embodiment, in which (A) is a blank, (B) is a preformed body, and (C) is a spare with increased thickness. A molded body, (D) shows a press-formed product. 2-6 is sectional drawing which shows the process in which a bending part is formed in a blank by the shaping | molding method concerning this embodiment in steps. 7 and 8 are cross-sectional views showing a first thickness-increasing step in which the bending portion is crushed halfway by the molding method, and FIGS. 9 and 10 are second thickness-increasing steps in which the bending portion is completely crushed by the molding method. It is sectional drawing which shows a process. FIG. 11 is a perspective view showing an example in which buckling occurs in the thickening process.
本実施形態に係るプレス成形品の製造方法は、平板形状のブランク１の一部の板厚を予め増加させて増肉部５を有する予備成形体３とした後に、当該予備成形体３を所定の形状へプレス成形することで、補強部５１を有するプレス成形品５０を成形するものである。本製造方法は、ブランク１に湾曲した撓み部２を形成して予備成形体３とする撓み部成形工程（図１（Ｂ））と、撓み部２を平板形状に潰して板厚を増加させる増肉工程（図１（Ｃ））と、増肉された予備成形体３をプレス成形するプレス成形工程（図１（Ｄ））とを備えている。 In the method for manufacturing a press-formed product according to the present embodiment, after the plate thickness of a part of the flat blank 1 is increased in advance to obtain the preform 3 having the thickened portion 5, the preform 3 is predetermined. The press-formed product 50 having the reinforcing portion 51 is formed by press-molding into the shape. In this manufacturing method, a bent portion 2 is formed in the blank 1 by forming a bent portion 2 that is curved to form a preformed body 3, and the bent portion 2 is crushed into a flat plate shape to increase the plate thickness. A thickening step (FIG. 1C) and a press molding step (FIG. 1D) for press-molding the thickened preform 3 are provided.
ブランク１に撓み部２を形成する撓み部成形工程では、図２〜６に示すように、撓み部成形型６を使用する。撓み部成形型６は、ブランク１の一方の縁部から他方の縁部へ達するように峰状に延び、かつ断面が湾曲した撓み部２をブランク１に形成して、予備成形体３とする装置である。撓み部成形型６は、撓み部成形用上型７と、撓み部成形用下型８とを有している。なお、撓み部２は、かならずしもブランク１の一方の縁部から他方の縁部へ達するように形成されなくてもよく、例えばブランク１の中央に形成されてもよい（例えば、図１６参照）。 In the bending part forming step for forming the bending part 2 in the blank 1, as shown in FIGS. The bending part forming die 6 is formed in the blank 1 with a bending part 2 extending in a ridge shape so as to reach one edge from the other edge of the blank 1 and having a curved cross section, thereby forming a preform 3. Device. The bending portion forming die 6 includes a bending portion forming upper die 7 and a bending portion forming lower die 8. In addition, the bending part 2 does not necessarily need to be formed so that it may reach from one edge part of the blank 1 to the other edge part, for example, may be formed in the center of the blank 1 (for example, refer FIG. 16).
撓み部成形用下型８には、バネ９により上方へ付勢された下方押さえ部１０が一端に摺動可能に設けられている。下方押さえ部１０は、撓み部成形用下型８と摺動する側の上方端部に、撓み部２の面の一部と対応する曲面の曲面形状部１１が形成されている。下方押さえ部１０の上端面は、上方から力が作用しない状態において、撓み部成形用下型８の上端面よりも上方に位置している。撓み部成形用下型８の下方押さえ部１０と摺動する側の上方端部には、撓み部２の面の一部と対応する曲面形状の凹部１２が形成されている。 A lower pressing portion 10 urged upward by a spring 9 is slidably provided at one end of the bending portion forming lower mold 8. The lower pressing portion 10 has a curved surface portion 11 having a curved surface corresponding to a part of the surface of the bending portion 2 at the upper end portion on the side sliding with the bending portion forming lower mold 8. The upper end surface of the lower pressing portion 10 is located above the upper end surface of the bending portion forming lower mold 8 in a state where no force acts from above. A curved concave portion 12 corresponding to a part of the surface of the bending portion 2 is formed at the upper end portion of the bending portion forming lower mold 8 on the side sliding with the lower pressing portion 10.
撓み部成形用上型７には、バネ１３により下方へ付勢された上方押さえ部１５および、バネ１６により下方へ付勢された可動押し込み部１７が、一端に並んで設けられており、可動押し込み部１７の下面は、撓み部２の面の一部と対応する曲面形状で形成されている。上方押さえ部１５は、撓み部成形用下型８の下方押さえ部１０と対向して設けられ、可動押し込み部１７は、下方押さえ部１０の曲面形状部１１および撓み部成形用下型８の凹部１２と対向して設けられる。上方押さえ部１５は、可動押し込み部１７と摺動可能に隣接し、可動押し込み部１７は、上方押さえ部１５と接する側と反対側で、撓み部成形用上型７と摺動可能に隣接する。 The upper die 7 for bending portion molding is provided with an upper pressing portion 15 urged downward by a spring 13 and a movable pushing portion 17 urged downward by a spring 16 side by side. The lower surface of the pushing portion 17 is formed in a curved shape corresponding to a part of the surface of the bending portion 2. The upper pressing portion 15 is provided so as to face the lower pressing portion 10 of the bending portion forming lower mold 8, and the movable pressing portion 17 is a concave portion of the curved shape portion 11 of the lower pressing portion 10 and the bending portion forming lower mold 8. 12 is provided to face. The upper pressing portion 15 is slidably adjacent to the movable pressing portion 17, and the movable pressing portion 17 is slidably adjacent to the upper mold 7 for bending portion molding on the side opposite to the side in contact with the upper pressing portion 15. .
撓み部成形用上型７は、可動押し込み部１７と摺動する側の下方端部に、撓み部２の面の一部と対応する曲面形状で形成された突出形状部１９が形成されている。上方押さえ部１５の下端面は、図２に示すように、下方から力が作用しない状態において、可動押し込み部１７の下端部よりも下方に位置し、可動押し込み部１７の下端部は、撓み部成形用上型７の下端部より下方に位置している。 The upper part 7 for bending part shaping | molding has the protrusion shape part 19 formed in the curved end shape corresponding to a part of surface of the bending part 2 in the lower end part by the side which slides with the movable pushing part 17. As shown in FIG. . As shown in FIG. 2, the lower end surface of the upper pressing portion 15 is positioned below the lower end portion of the movable pushing portion 17 in a state where no force is applied from below, and the lower end portion of the movable pushing portion 17 is a bending portion. It is located below the lower end of the molding upper die 7.
撓み部成形工程を実施するには、まず、撓み部成形用上型７を撓み部成形用下型８から上方へ離隔した状態で、ブランク１を撓み部成形用上型７と撓み部成形用下型８の間に配置する。この後、図２に示すように、撓み部成形用上型７を下方へ移動させて、上方押さえ部１５と下方押さえ部１０の間にブランク１の一端を挟持して固定する。このとき、ブランク１の他端は拘束されず、自由となっている。 In order to carry out the bending portion forming step, first, the blank 1 is formed with the bending portion forming upper die 7 and the bending portion forming portion in a state where the bending portion forming upper die 7 is separated upward from the bending portion forming lower die 8. It arrange | positions between the lower mold | types 8. FIG. After that, as shown in FIG. 2, the upper part 7 for bending part forming is moved downward, and one end of the blank 1 is sandwiched and fixed between the upper pressing part 15 and the lower pressing part 10. At this time, the other end of the blank 1 is not restricted and is free.
更に撓み部成形用上型７を下方へ移動させると、上方押さえ部１５の上方を付勢するバネ１３が収縮して上方押さえ部１５と下方押さえ部１０の位置が不動のまま保持されつつ（もしくは多少下降しつつ）、撓み部成形用上型７および可動押し込み部１７が下降することとなる。したがって、上方押さえ部１５を付勢するバネ１３は、下方押さえ部１０を付勢するバネ９よりもバネ剛性が低く設定される必要がある。 When the upper die 7 for bending part molding is further moved downward, the spring 13 biasing the upper part of the upper pressing part 15 contracts, and the positions of the upper pressing part 15 and the lower pressing part 10 are held unchanged ( (Alternatively, the upper die 7 and the movable push-in portion 17 are lowered). Therefore, the spring 13 that biases the upper pressing portion 15 needs to be set to have lower spring rigidity than the spring 9 that biases the lower pressing portion 10.
この後、更に撓み部成形用上型７を下方へ移動させると、図３に示すように、上方押さえ部１５と下方押さえ部１０の位置が不動のまま保持されつつ（もしくは多少下降しつつ）、可動押し込み部１７がブランク１に接してブランク１を下方へ押し込む。このとき、ブランク１は、下方押さえ部１０の端部の曲面形状部１１に沿って下方へ折り曲げられる。この後、更に撓み部成形用上型７を下方へ移動させると、図４に示すように、ブランク１が可動押し込み部１７と下方押さえ部１０の曲面形状部１１の間に完全に挟まれる。 Thereafter, when the upper die 7 for forming the bending portion is further moved downward, the positions of the upper pressing portion 15 and the lower pressing portion 10 are held unchanged (or slightly lowered) as shown in FIG. The movable pushing portion 17 contacts the blank 1 and pushes the blank 1 downward. At this time, the blank 1 is bent downward along the curved surface shape portion 11 at the end of the lower pressing portion 10. Thereafter, when the upper die 7 for bending portion molding is further moved downward, the blank 1 is completely sandwiched between the movable push-in portion 17 and the curved shape portion 11 of the lower pressing portion 10 as shown in FIG.
この後、更に撓み部成形用上型７を下方へ移動させると、図５に示すように、下方押さえ部１０の下方を付勢するバネ９が収縮して下方押さえ部１０が後退し、可動押し込み部１７がブランク１を凹部１２に押し込む。すなわち、ブランク１は、押し込み部の１つとして機能する撓み部成形用下型８によって上方へ折り曲げられることとなる。これにより、ブランク１の自由側の端部は、上方へ反り返って撓み部成形用上型７に接する。なお、この際に下方押さえ部１０が下方へ後退するように、下方押さえ部１０を付勢するバネ９のバネ剛性は、上方押さえ部１５および可動押し込み部１７を付勢する２つのバネ１３，１６のバネ剛性の合計よりも小さく設定される必要がある。 Thereafter, when the upper die 7 for bending portion molding is further moved downward, as shown in FIG. 5, the spring 9 for urging the lower portion of the lower pressing portion 10 is contracted and the lower pressing portion 10 is retracted to move. The pushing portion 17 pushes the blank 1 into the recess 12. That is, the blank 1 is bent upward by the bending portion forming lower mold 8 that functions as one of the pushing portions. As a result, the end portion on the free side of the blank 1 warps upward and comes into contact with the upper mold 7 for forming the bent portion. At this time, the spring stiffness of the spring 9 that biases the lower pressing portion 10 is such that the lower pressing portion 10 retreats downward, and the two springs 13 that bias the upper pressing portion 15 and the movable pushing portion 17 are It is necessary to set it smaller than the total of 16 spring stiffnesses.
この後、更に撓み部成形用上型７を下方へ移動させると、可動押し込み部１７が既に凹部１２に嵌合しているため、可動押し込み部１７、上方押さえ部１５および下方押さえ部１０は位置を不動のまま、撓み部成形用上型７が押し込み部として機能してブランク１の他端を下方へ折り曲げる。更に撓み部成形用上型７を下方へ移動させると、図６に示すように、撓み部成形用上型７の突出形状部１９が凹部１２へ嵌合するようにブランク１を折り曲げ、撓み部２を備えた予備成形体３が完成する。この後、装置から予備成形体３を取り出し、撓み部成形工程が完了する。 Thereafter, when the upper mold 7 for bending portion molding is further moved downward, the movable push portion 17, the upper press portion 15 and the lower press portion 10 are positioned because the movable push portion 17 is already fitted in the recess 12. The upper part 7 for bending part shaping | molding functions as a pushing part, and bends the other end of the blank 1 below. When the upper mold 7 for bending part molding is further moved downward, the blank 1 is bent so that the protruding shape part 19 of the upper mold 7 for bending part molding fits into the recess 12 as shown in FIG. 2 is completed. Thereafter, the preformed body 3 is taken out from the apparatus, and the bending portion forming step is completed.
なお、本実施形態では、予備成形体３に撓み部２が１つ形成されているが、図７のように、バネ１６，２０，２１に付勢される可動押し込み部１７，１８，１９を増やすことで、２つ以上の撓み部２を備えた予備成形体３を、ブランク１の一端側から折り曲げつつ形成することもできる。この際には、可動押し込み部１７，１８，１９が一方側からブランク１に接するように、可動押し込み部１７，１８，１９を付勢するバネ１６，２０，２１のバネ剛性を設定する必要がある。 In the present embodiment, one bending portion 2 is formed on the preform 3, but as shown in FIG. 7, the movable pushing portions 17, 18, and 19 that are biased by the springs 16, 20, and 21 are provided. By increasing the number, it is possible to form the preform 3 having two or more bent portions 2 while being bent from one end side of the blank 1. At this time, it is necessary to set the spring stiffness of the springs 16, 20, and 21 that urge the movable pushing portions 17, 18, and 19 so that the movable pushing portions 17, 18, and 19 come into contact with the blank 1 from one side. is there.
または、上述のようなバネを用いてブランク１を一端側から折り曲げる作動機構ではなく、可動押し込み部１７、押さえ部１０，１５、撓み部成形用上型７および撓み部成形用下型８の各々を、独立して進退可能に制御する加圧機構やストッパー構造を作動機構として組み込んでもよい。 Alternatively, each of the movable push-in portion 17, the pressing portions 10 and 15, the bending portion forming upper die 7, and the bending portion forming lower die 8 is not an operation mechanism that bends the blank 1 from one end side using the spring as described above. A pressurizing mechanism and a stopper structure that are controlled to be able to advance and retreat independently may be incorporated as an operation mechanism.
撓み部成形工程により予備成形体３を形成した後には、予備成形体３の撓み部２を押圧して平板形状となるまで潰し、予備成形体３の板厚を増加させる増肉工程を行う。本実施形態では、増肉工程を２段階に分けて実施する。すなわち、図８に示す第１増肉用成形型３１と、図９に示す第２増肉用成形型４１とを用いて、予備成形体３を段階的に増肉させる。 After the preformed body 3 is formed by the bending portion forming step, a thickening step for increasing the plate thickness of the preformed body 3 is performed by pressing the bending portion 2 of the preformed body 3 until it is flattened. In this embodiment, the thickening process is performed in two stages. That is, the preform 3 is increased in thickness step by step using the first thickening mold 31 shown in FIG. 8 and the second thickening mold 41 shown in FIG. 9.
図８に示す第１増肉用成形型３１は、第１増肉用上型３２と、第１増肉用下型３３と、第１増肉用上型３２および第１増肉用下型３３の周囲を囲んで予備成形体３の側端を保持する第１外周保持部３４と、予備成形体３の撓み部２を押圧する第１押圧部３５とを有している。 A first thickening mold 31 shown in FIG. 8 includes a first thickening upper mold 32, a first thickening lower mold 33, a first thickening upper mold 32, and a first thickening lower mold. A first outer peripheral holding portion 34 that surrounds the periphery of 33 and holds the side end of the preformed body 3, and a first pressing portion 35 that presses the bending portion 2 of the preformed body 3.
第１増肉用下型３３には、予備成形体３の撓み部２に対応して、撓み部２よりも突出の高さが小さい湾曲形状の下型凸部３６が形成されている。 In the first thickening lower mold 33, a curved lower mold convex portion 36 having a protruding height smaller than that of the bent portion 2 is formed corresponding to the bent portion 2 of the preform 3.
第１増肉用上型３２には、予備成形体３の撓み部２を含む範囲に対応して、上下に貫通する貫通孔３７が形成されており、この貫通孔３７に、摺動可能に第１押圧部３５が挿入される。第１押圧部３５の下端面には、予備成形体３の撓み部２に対応する位置に、下型凸部３６の形状に対応する上型凹部３８が形成されている。 The first thickening upper mold 32 is formed with a through hole 37 penetrating vertically corresponding to the range including the bent portion 2 of the preform 3, and can be slid in the through hole 37. The first pressing part 35 is inserted. An upper mold recess 38 corresponding to the shape of the lower mold protrusion 36 is formed on the lower end surface of the first pressing portion 35 at a position corresponding to the bending portion 2 of the preform 3.
予備成形体３を挟む第１増肉用上型３２および第１増肉用下型３３、予備成形体３の側端を保持する第１外周保持部３４は、第１増肉工程において予備成形体３を拘束する拘束部として機能する。 The first thickening upper mold 32 and the first thickening lower mold 33 sandwiching the preformed body 3, and the first outer peripheral holding part 34 that holds the side edges of the preformed body 3 are preformed in the first thickening step. It functions as a restraining part that restrains the body 3.
図９に示す第２増肉用成形型４１は、第２増肉用上型４２と、第２増肉用下型４３と、第２増肉用上型４２および第２増肉用下型４３の周囲を囲んで予備成形体３の側端を保持する第２外周保持部４４と、予備成形体３の撓み部２を押圧する第２押圧部４５とを有している。 The second thickening mold 41 shown in FIG. 9 includes a second thickening upper mold 42, a second thickening lower mold 43, a second thickening upper mold 42, and a second thickening lower mold. A second outer peripheral holding portion 44 that surrounds the periphery of 43 and holds the side end of the preformed body 3, and a second pressing portion 45 that presses the bending portion 2 of the preformed body 3.
第２増肉用下型４３の上面は、第１増肉用下型３３と異なり、突出することなく平坦に形成されている。 Unlike the first thickening lower mold 33, the upper surface of the second thickening lower mold 43 is formed flat without protruding.
第２増肉用上型４２には、予備成形体３の撓み部２を含む範囲に対応して、上下に貫通する貫通孔４７が形成されており、この貫通孔４７に、摺動可能に第２押圧部４５が挿入される。第２押圧部４５の下面は、第１押圧部３５と異なり、凹部が形成されずに平坦に形成されている。 The second thickening upper mold 42 is formed with a through hole 47 penetrating vertically corresponding to the range including the bent portion 2 of the preform 3, and can be slid in the through hole 47. The second pressing part 45 is inserted. Unlike the first pressing portion 35, the lower surface of the second pressing portion 45 is formed flat without forming a recess.
予備成形体３を挟む第２増肉用上型４２および第２増肉用下型４３、予備成形体３の側端を保持する第２外周保持部４４は、第２増肉工程において予備成形体３を拘束する拘束部として機能する。 The second thickening upper mold 42 and the second thickening lower mold 43 that sandwich the preformed body 3 and the second outer peripheral holding portion 44 that holds the side edges of the preformed body 3 are preformed in the second thickening step. It functions as a restraining part that restrains the body 3.
増肉工程を実施するには、まず、撓み部成形工程により形成された予備成形体３を、図８（Ａ）に示すように、第１増肉用成形型３１の第１増肉用上型３２と第１増肉用下型３３の間に挟持する。このときの予備成形体３の撓み部２は、湾曲している部位の幅Ｗの範囲で、第１周長α（図１０（Ａ）参照）を有している。ここで周長とは、図１０に示すように、撓みの一方から他方までの撓み部２の面に沿う長さを表している。 In order to carry out the thickening step, first, the preform 3 formed by the bending portion forming step is used for the first thickening of the first thickening mold 31 as shown in FIG. The mold 32 is sandwiched between the first thickening lower mold 33. The bending part 2 of the preform 3 at this time has a first circumferential length α (see FIG. 10A) in the range of the width W of the curved portion. Here, as shown in FIG. 10, the circumferential length represents the length along the surface of the bending portion 2 from one of the bending to the other.
この後、図８（Ｂ）に示すように、第１押圧部３５を下降させて、予備成形体３の撓み部２を、第１増肉用下型３３の下型凸部３６と第１押圧部３５の上型凹部３８の間で押圧する。これにより、予備成形体３の撓み部２は圧縮されて、幅Ｗの範囲内の周長が、第１周長αよりも周長の短い第２周長β（図１０（Ｂ）参照）へ変化する。このとき、予備成形体３は、側端が第１外周保持部３４により保持され、かつ第１増肉用上型３２と第１増肉用下型３３の間で押圧されて拘束されているため、側端方向への材料の流れが抑制されて、撓み部２の板厚が効率よく増加される。 Thereafter, as shown in FIG. 8 (B), the first pressing portion 35 is lowered, and the bending portion 2 of the preform 3 is moved to the lower mold convex portion 36 of the first thickening lower mold 33 and the first mold. It presses between the upper mold | type recessed parts 38 of the press part 35. FIG. Thereby, the bending part 2 of the preform 3 is compressed, and the circumferential length within the range of the width W is a second circumferential length β shorter than the first circumferential length α (see FIG. 10B). To change. At this time, the preform 3 is held by the first outer periphery holding portion 34 at the side end and is pressed and restrained between the first thickening upper mold 32 and the first thickening lower mold 33. Therefore, the material flow in the side end direction is suppressed, and the plate thickness of the bending portion 2 is efficiently increased.
この後、第１増肉用成形型３１から予備成形体３を取り出し、図９（Ａ）に示すように、第２増肉用成形型４１の第２増肉用上型４２と第２増肉用下型４３の間に、予備成形体３を挟持する。このときの予備成形体３の撓み部２は、第２周長βを有している。 Thereafter, the preform 3 is taken out from the first thickening mold 31, and as shown in FIG. 9A, the second thickening upper mold 42 and the second thickening mold 41 of the second thickening mold 41 are taken. The preform 3 is sandwiched between the meat lower molds 43. At this time, the bending portion 2 of the preform 3 has a second circumferential length β.
この後、図９（Ｂ）に示すように、第２押圧部４５を下降させて、予備成形体３の撓み部２を、第２増肉用下型４３の上面と第２押圧部４５の下面の間で押圧する。これにより、予備成形体３の撓み部２は押し潰されて平面形状の増肉部５となり、幅Ｗの範囲内の周長が、第２周長βよりも長さの短い第３周長γ（図１０（Ｃ）参照）を備える。このとき、予備成形体３は、側端が第２外周保持部４４により保持されて、かつ第２増肉用上型４２と第２増肉用下型４３で押圧されて拘束されているため、側端方向への材料の流れが抑制されて、撓み部２の板厚が効率よく増加されて、増肉部５が形成される。なお、増肉部５は平板形状となるので、上述の第３周長γは幅Ｗと等しい。また、ここで言う平板形状の増肉部５は、かならずしも正確な平板形状とは限らず、局所的に小さなウネリ等を有する場合もある。 Thereafter, as shown in FIG. 9B, the second pressing portion 45 is lowered, and the bending portion 2 of the preform 3 is moved between the upper surface of the second die for increasing the thickness 43 and the second pressing portion 45. Press between the bottom surfaces. As a result, the flexible portion 2 of the preform 3 is crushed into a planar thickened portion 5, and the circumferential length in the range of the width W is shorter than the second circumferential length β. γ (see FIG. 10C). At this time, the preform 3 is held by the second outer periphery holding portion 44 and is pressed and restrained by the second upper thickening mold 42 and the second thickening lower mold 43. The material flow in the side end direction is suppressed, the thickness of the bent portion 2 is efficiently increased, and the thickened portion 5 is formed. Since the thickened portion 5 has a flat plate shape, the above-described third circumferential length γ is equal to the width W. Further, the flat plate-shaped thickening portion 5 referred to here is not necessarily an accurate flat plate shape, and may have small undulations locally.
この後、第２増肉用成形型４１から予備成形体３を取り出し、増肉工程が終了する。板厚が増加された予備成形体３は、プレス成形型により所定形状にプレス加工されて、増肉部５が補強部５１に加工される（図１（Ｄ）参照）。 Thereafter, the preform 3 is taken out from the second thickening mold 41, and the thickening process is completed. The preform 3 with the increased thickness is pressed into a predetermined shape by a press mold, and the thickened portion 5 is processed into the reinforcing portion 51 (see FIG. 1D).
ここで、複数の増肉工程のうちの最終段階の増肉工程（本実施形態では第２増肉工程）の前後における周長の変化率Ｘ（％）を、以下のように定義する。 Here, the change rate X (%) of the circumferential length before and after the final thickening step (second thickening step in the present embodiment) among the plurality of thickening steps is defined as follows.
周長変化率Ｘ（％）＝（１−γ／β）×１００ ・・・式（１）
この周長変化率Ｘが大き過ぎると、図１１に示すように、座屈が生じやすくなり板厚の増加が困難となる。この最終の増肉工程の前後における周長変化率Ｘ（％）は、解析により、２５％以下とすることが望ましいことが確認された。
Perimeter change rate X (%) = (1−γ / β) × 100 (1)
If the peripheral length change rate X is too large, as shown in FIG. 11, buckling is likely to occur and it is difficult to increase the plate thickness. It was confirmed by analysis that the circumferential length change rate X (%) before and after this final thickening step is preferably 25% or less.
また、撓み部２の平板形状部４に対して最も傾いている部位の最大傾き角度θ（図１１参照）が４５度を超えると、撓み部２を潰す方向に力Ｆが作用する際に、傾き角度が４５度以上の部位における潰し方向（押し込み方向）への反力Ｐ１が、潰し方向と垂直な方向への反力Ｐ２よりも大きくなるため、座屈が生じやすくなる。したがって、複数の増肉工程のうちの最終の増肉工程の前の最大傾き角度θは、４５度以下であることが好ましい。 Further, when the maximum inclination angle θ (see FIG. 11) of the portion most inclined with respect to the flat plate-shaped portion 4 of the bending portion 2 exceeds 45 degrees, when the force F acts in the direction of crushing the bending portion 2, Since the reaction force P1 in the crushing direction (push-in direction) at the portion where the inclination angle is 45 degrees or more is larger than the reaction force P2 in the direction perpendicular to the crushing direction, buckling is likely to occur. Therefore, the maximum inclination angle θ before the final thickening step among the plurality of thickening steps is preferably 45 degrees or less.
このような周長変化率Ｘおよび最大傾き角度θを実現するには、予備成形体３を平板形状とする最終の第２増肉用成形型４１の前に使用される第１増肉用成形型３１において、撓み部２の形状に対応する下型凸部３６と上型凹部３８のキャビティー面に沿う周長Ｌが、第２周長βと一致することが必要である（図８参照）。この周長Ｌは、幅Ｗの範囲内に形成されている。更に、下型凸部３６および上型凹部３８のキャビティー面の平板形状部４に対して最も傾いている部位の傾き角度が、前述の撓み部２の最大傾き角度θと一致することが必要である。なお、厳密には、成形型による成形品には形状の戻りが生じるので、形状の戻りを考慮して下型凸部３６および上型凹部３８のキャビティー面を設計することが好ましい。 In order to realize such a peripheral length change rate X and the maximum inclination angle θ, the first thickening molding used before the final second thickening molding die 41 in which the preform 3 is formed into a flat plate shape. In the mold 31, it is necessary that the circumferential length L along the cavity surface of the lower mold convex portion 36 and the upper mold concave portion 38 corresponding to the shape of the flexure portion 2 coincides with the second circumferential length β (see FIG. 8). ). The circumferential length L is formed within the range of the width W. Furthermore, it is necessary that the inclination angle of the portion of the cavity surface of the lower mold convex portion 36 and the upper mold concave portion 38 that is most inclined with respect to the flat plate-shaped portion 4 coincides with the aforementioned maximum inclination angle θ of the bent portion 2. It is. Strictly speaking, since the shape of the molded product is returned, it is preferable to design the cavity surfaces of the lower mold protrusion 36 and the upper mold recess 38 in consideration of the shape return.
なお、増肉工程は、かならずしも２工程（２つの成形型）に分ける必要はなく、３工程以上としたり、１工程のみとすることもできる。したがって、本実施形態では、最終の増肉工程の前に使用される成形型は第１増肉用成形型３１であるが、増肉工程を３工程以上とすれば、最終の１つ前の増肉用成形型のキャビティー面の周長Ｌを、上述のように設定することとなる。また、増肉工程が１工程のみであれば、最終の増肉工程の前に使用される成形型は撓み部成形型となり、撓み部成形型のキャビティー面の周長Ｌを、上述のように設定することとなる。 In addition, it is not always necessary to divide the thickening step into two steps (two molds), and the number of steps may be three or more or only one. Therefore, in this embodiment, the mold used before the final thickening step is the first thickening mold 31. If the thickening step is three or more steps, the mold one before the final thickening step is used. The peripheral length L of the cavity surface of the thickening mold is set as described above. Further, if the thickness increasing process is only one process, the mold used before the final thickness increasing process is a flexure part mold, and the peripheral length L of the cavity surface of the flexure part mold is set as described above. Will be set.
補強部５１（増肉部５）の板厚のブランク１の板厚に対する比率（増肉量）は、１０％以上であることが好ましい。板材の剛性（断面２次モーメント）は板厚の３乗に比例するため、板厚が１０％増加することで、剛性が約３３％増加する。したがって、板厚を１０％以上増加させることで、剛性を３０％以上増加させることができ、プレス成形品５０の剛性または強度を効率よく確保できる。 The ratio (thickening amount) of the reinforcing portion 51 (thickening portion 5) to the thickness of the blank 1 is preferably 10% or more. Since the rigidity (secondary moment of section) of the plate material is proportional to the cube of the plate thickness, increasing the plate thickness by 10% increases the stiffness by about 33%. Therefore, by increasing the plate thickness by 10% or more, the rigidity can be increased by 30% or more, and the rigidity or strength of the press-formed product 50 can be efficiently secured.
上述したように、撓み部２（増肉部５）は１つの予備成形体３に複数形成されてもよく、この場合には、図８に示す第１増肉用下型３３および第１押圧部３５に、複数の下型凸部３６および上型凹部３８が形成されることとなる。 As described above, a plurality of the bending portions 2 (thickening portions 5) may be formed on one preformed body 3, and in this case, the first thickening lower mold 33 and the first pressing shown in FIG. A plurality of lower mold convex portions 36 and upper mold concave portions 38 are formed in the portion 35.
図１２は、２つの撓み部を有する予備成形体の板厚を増肉用成形型により増加した解析結果を示す図であり、（Ａ）は増肉工程の前の予備成形体、（Ｂ）は第１増肉工程の後の予備成形体、（Ｃ）は第２増肉工程の後の予備成形体を示す。図１３は、図１２（Ａ）〜（Ｃ）の予備成形体を示す斜視図である。図１２，１３で表された予備成形体３は、板厚の解析結果を色調により表している。なお、図１２の第１増肉用成形型３１および第２第２増肉用成形型４１は、予備成形体３の解析結果が明確となるように、予備成形体３から離して概略的に表されている。 FIG. 12 is a diagram showing an analysis result in which the thickness of a preform having two flexures is increased by a thickening mold, (A) is a preform before the thickening step, and (B). Indicates a preform after the first thickness increasing step, and (C) indicates a preform after the second thickness increasing step. FIG. 13 is a perspective view showing the preform of FIGS. 12 (A) to 12 (C). The preform 3 shown in FIGS. 12 and 13 represents the analysis result of the plate thickness by color tone. Note that the first thickening mold 31 and the second second thickening mold 41 in FIG. 12 are schematically separated from the preform 3 so that the analysis result of the preform 3 is clear. It is represented.
本解析では、予備成形体３（ブランク１）の材料として、板厚１．８ｍｍの鋼材（ＳＣＭ４４０）を用いている。本解析における周長変化率Ｘは２５％であり、最終の増肉工程の前の撓み部２の平板形状部４に対する最大傾き角度θは約４５度である。結果として、図１２（Ｃ）、図１３（Ｃ）に示すように、座屈が生じることなく、板厚が増加された２箇所の増肉部５が形成されることが確認できた。 In this analysis, a steel material (SCM440) having a plate thickness of 1.8 mm is used as the material of the preform 3 (blank 1). The circumferential length change rate X in this analysis is 25%, and the maximum inclination angle θ of the bent portion 2 with respect to the flat plate-shaped portion 4 before the final thickening step is about 45 degrees. As a result, as shown in FIG. 12C and FIG. 13C, it was confirmed that the two thickened portions 5 with increased plate thickness were formed without buckling.
図１４は、本実施形態を適用して成形されるプレス成形品の例を示す斜視図であり、（Ａ）は２つの撓み部を有する予備成形体、（Ｂ）は増肉工程後の予備成形体、（Ｃ）はプレス成形工程後のプレス成形品を示す。図１５は、図１４に示すプレス成形品を適用したサスペンション部品を示す斜視図である。 FIG. 14 is a perspective view showing an example of a press-formed product formed by applying the present embodiment, in which (A) is a preformed body having two flexures, and (B) is a preliminary product after a thickening step. A molded body (C) shows a press-molded product after the press-molding process. FIG. 15 is a perspective view showing a suspension component to which the press-formed product shown in FIG. 14 is applied.
図１４に示すように、２箇所の撓み部２を有する略Ｌ字形状の予備成形体３に、上述した手順で２箇所の増肉部５を形成してプレス成形を行うことで、プレス成形品５０に２箇所の補強部５１が形成される。この補強部５１は、図１５に示すように、車両のサスペンション部品５２の一部であるリアサイドメンバー５３の強度の必要な溶接部位として用いられる。したがって、リアサイドメンバー５３に他の補強部材を適用することなしに、強度の高い部位を設けることができる。 As shown in FIG. 14, press forming is performed by forming two thickened portions 5 in the substantially L-shaped preform 3 having the two bent portions 2 and performing the press forming in the above-described procedure. Two reinforcing portions 51 are formed on the product 50. As shown in FIG. 15, the reinforcing portion 51 is used as a welding portion that requires strength of the rear side member 53 that is a part of the suspension component 52 of the vehicle. Therefore, a portion having high strength can be provided without applying another reinforcing member to the rear side member 53.
図１６は、予備成形体の端部まで達しない撓み部を備えた予備成形体を、増肉用成形型により増肉した解析結果を示す斜視図であり、（Ａ）は増肉工程の前の予備成形体、（Ｂ）は第１増肉工程の後の予備成形体、（Ｃ）は第２増肉工程の後の予備成形体を示す。図１７は、図１６（Ａ）〜（Ｃ）のＡ−Ａ線に沿う断面図、図１８は、図１６，１７で形成された予備成形体をプレス成形したプレス成形品を示す斜視図である。図１６，１７における予備成形体３は、板厚の解析結果を色調により表している。なお、図１７の第１増肉用成形型３１および第２増肉用成形型４１は、予備成形体３の解析結果が明確となるように、予備成形体３から離して概略的に表されている。 FIG. 16 is a perspective view showing an analysis result obtained by increasing the thickness of a preformed body having a bent portion that does not reach the end of the preformed body with a thickening mold, and FIG. (B) shows the preform after the first thickness increasing step, and (C) shows the preform after the second thickness increasing step. 17 is a cross-sectional view taken along the line AA in FIGS. 16A to 16C, and FIG. 18 is a perspective view showing a press-formed product obtained by press-forming the preform formed in FIGS. is there. The preform 3 in FIGS. 16 and 17 represents the analysis result of the plate thickness by color tone. Note that the first thickening mold 31 and the second thickening mold 41 in FIG. 17 are schematically shown separated from the preform 3 so that the analysis result of the preform 3 is clear. ing.
本解析では、端部から離れた撓み部２を有する予備成形体３を成形する。予備成形体３（ブランク１）の材料として、板厚１．８ｍｍの鋼材（ＳＣＭ４４０）を用いている。本解析における周長変化率Ｘは２５％であり、最終の増肉工程の前の撓み部２の平板形状部４に対する最大傾き角度θは約４５度である。結果として、図１６（Ｃ）、図１７（Ｃ）に示すように、座屈が生じることなく、板厚が増加された増肉部５が形成されることが確認できた。このように成形された予備成形体３は、図１６（Ｃ）に示す切断ラインＢに沿って余分な縁部をトリミングし、プレス工程によって、図１８に示すように端部から離れた補強部５１を有するプレス成形品５０（リアサイドメンバー）に成形することができる。 In this analysis, a preformed body 3 having a bent portion 2 away from the end portion is formed. As a material for the preform 3 (blank 1), a steel material (SCM440) having a thickness of 1.8 mm is used. The circumferential length change rate X in this analysis is 25%, and the maximum inclination angle θ of the bent portion 2 with respect to the flat plate-shaped portion 4 before the final thickening step is about 45 degrees. As a result, as shown in FIGS. 16C and 17C, it was confirmed that the thickened portion 5 having an increased plate thickness was formed without buckling. The preformed body 3 formed in this way is trimmed at the extra edge along the cutting line B shown in FIG. 16 (C), and is pressed away from the end as shown in FIG. 51 can be formed into a press-formed product 50 (rear side member).
なお、図１６（Ａ）に示す予備成形体３は、前工程である撓み部成形工程において、図１６中の撓み部２の奥側（図１７中の撓み部２の右側）の平板形状部４ａを拘束し、撓み部２を挟んで反対側の平板形状部４ｂを自由として解析を行った。したがって、図１６（Ａ）中の矢印方向へ材料が流れつつ撓み部２が形成されているが、撓み部２には板厚の薄い薄肉部２ａも形成されている。この薄肉部２ａでは、母材に対して板厚が２７％減少した。しかし、この後の第１，第２増肉工程を経ることで、薄肉部２ａの板厚は母材の板厚である１．８ｍｍまで回復することが確認された。 Note that the preform 3 shown in FIG. 16A is a flat plate-shaped portion on the back side (the right side of the flexible portion 2 in FIG. 17) of the flexible portion 2 in FIG. 4a was constrained, and the analysis was performed with the flat plate-shaped portion 4b on the opposite side sandwiching the bent portion 2 as free. Therefore, the bent portion 2 is formed while the material flows in the direction of the arrow in FIG. 16A, but the thin portion 2a having a thin plate thickness is also formed in the bent portion 2. In this thin portion 2a, the plate thickness was reduced by 27% with respect to the base material. However, it was confirmed that the plate thickness of the thin portion 2a recovered to 1.8 mm, which is the thickness of the base material, through the subsequent first and second thickness increasing steps.
本実施形態によれば、撓み部２を形成した後に、増肉工程において、平板形状部４を拘束しつつ撓み部２を平板形状に潰すため、予備成形体３の側端方向への材料の流動を極力抑えつつ、撓み部２に対応する位置の板厚を効果的に増加させることができる。このため、薄肉の予備成形体３を適用しても、補強部５１によって、プレス成形品５０の剛性または強度が確保されるため、プレス成形品５０の軽量化を容易に図ることが可能である。また、補強部５１は、突合せ溶接が適用されるテーラードブランクに比較し、良好な生産性を有するプレス成形によって形成されるため、製造コストが低減される。したがって、プレス成形品５０の軽量化および製造コストの低減を図ることが可能である。 According to this embodiment, after forming the bent portion 2, in the thickening step, the bent portion 2 is crushed into a flat plate shape while restraining the flat plate shaped portion 4. The plate thickness at the position corresponding to the bent portion 2 can be effectively increased while suppressing the flow as much as possible. For this reason, even if the thin preformed body 3 is applied, the rigidity or strength of the press-formed product 50 is ensured by the reinforcing portion 51, so that it is possible to easily reduce the weight of the press-formed product 50. . Moreover, since the reinforcement part 51 is formed by press molding which has favorable productivity compared with the tailored blank to which butt welding is applied, manufacturing cost is reduced. Therefore, it is possible to reduce the weight of the press-formed product 50 and reduce the manufacturing cost.
また、撓み部成形工程において、ブランク１の縁部から縁部まで延在する撓み部２を形成するため、延在する方向に均一な形状の撓み部２を形成でき、撓み部２の形成による材料の薄肉化を抑制することができる。更に、増肉工程において、この薄肉化が抑制された撓み部２を潰して予備成形体３の縁部から縁部まで延在する増肉部５を形成するため、良好に板厚が増加された増肉部５を形成できる。 Moreover, in the bending part formation process, in order to form the bending part 2 extended from the edge part of the blank 1 to an edge part, the bending part 2 of a uniform shape can be formed in the extending direction, and by forming the bending part 2 Thinning of the material can be suppressed. Furthermore, in the thickening step, the thickness 2 is extended favorably because the thickened portion 5 extending from the edge to the edge of the preform 3 is formed by crushing the bent portion 2 in which the thinning is suppressed. A thickened portion 5 can be formed.
また、撓み部成形工程において、ブランク１の一方側を固定し他方側を自由としてブランク１を折り曲げることで、撓み部２を一方側から他方側へ向かって形成するため、撓み部２の薄肉化を抑制し、良好に板厚が増加された増肉部５を形成できる。 In addition, in the bending portion forming step, the bending portion 2 is formed from one side to the other side by bending the blank 1 while fixing one side of the blank 1 and allowing the other side to be free. Can be formed, and the thickened portion 5 in which the plate thickness is favorably increased can be formed.
また、増肉工程において、撓み部２を１回の工程で、若しくは複数回の工程に分けて段階的に平板形状に潰すため、成形する製品の条件に応じて、増肉工程を１回若しくは複数回に分けることができる。すなわち、例えば増肉の程度を大きくするために、増肉工程を複数回に分けて実施できるため、１回分の板厚の変化を小さくし、座屈の発生を抑えつつ増肉部５を形成できる。 Further, in the thickness increasing process, the bending portion 2 is crushed into a flat plate shape in a single process or divided into a plurality of processes, so that the thickness increasing process is performed once or depending on the conditions of the product to be molded. Can be divided into multiple times. That is, for example, in order to increase the degree of thickening, the thickening process can be carried out in a plurality of times, so that the thickened portion 5 is formed while reducing the change in plate thickness for one time and suppressing the occurrence of buckling. it can.
また、増肉工程における最終周長変化率Ｘを２５％以下とすることで、予備成形体３における座屈の発生を抑えつつ、良好な増肉部５を形成することができる。 Moreover, the favorable thickness increase part 5 can be formed, suppressing generation | occurrence | production of buckling in the preforming body 3 by making the final circumference change rate X in a thickness increase process into 25% or less.
また、増肉工程における最終増肉工程（第２増肉工程）の前の撓み部２の最大傾き角度θを４５度以下とすることで、予備成形体３における座屈の発生を抑えつつ、良好な増肉部５を形成することができる。 Moreover, while suppressing the occurrence of buckling in the preform 3 by setting the maximum inclination angle θ of the bent portion 2 before the final thickening step (second thickening step) in the thickening step to 45 degrees or less, A good thickened portion 5 can be formed.
また、１つの予備成形体３に複数の撓み部２を設けることができるため、複数の補強部５１を備えたプレス成形品５０を製造でき、多様な構造部材に適用することができる。 Moreover, since the some bending part 2 can be provided in the one preforming body 3, the press molded product 50 provided with the some reinforcement part 51 can be manufactured, and it can apply to various structural members.
なお、本発明は、上述した実施の形態に限定されるものではなく、特許請求の範囲の範囲内で種々改変することができる。 The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims.
例えば、ブランク１の一方側から折り曲げつつ予備成形体３を成形するのではなく、予備成形体３の形状が刻まれた上型および下型を用いて、通常のプレス成形で成形してもよい。 For example, instead of forming the preform 3 while bending from one side of the blank 1, it may be formed by normal press molding using an upper die and a lower die in which the shape of the preform 3 is engraved. .
第１，第２増肉成形型において予備成形体３の端部を拘束する第１，第２外周保持部３４，４４は、増肉用上型３２，４２と増肉用下型３３，４３の外周に設けられるのではなく、増肉用上型３２，４２と増肉用下型３３，４３の間に挟まれる形態であってもよい。 The first and second outer peripheral holding portions 34 and 44 that restrain the end portion of the preform 3 in the first and second thickening molds are the upper molds 32 and 42 for thickening and the lower molds 33 and 43 for thickening. Instead of being provided on the outer periphery of the metal plate, it may be configured to be sandwiched between the thickening upper molds 32, 42 and the thickening lower molds 33, 43.
また、プレス成形品は、サスペンション部品に適用する形態に限定されず、他の車両用構造部材や、車両以外の構造部材に適用することも可能である。他の車両用構造部材は、例えば、リンク部品、ブラケット部品、サイドシルアウターレインフォース等のボディ本体部品、ラダーフレーム等のフレーム部材である。 Further, the press-formed product is not limited to the form applied to the suspension component, and can be applied to other structural members for vehicles and structural members other than vehicles. Other structural members for vehicles are frame main parts, such as link parts, bracket parts, side sill outer reinforcement, and ladder members, for example.
１ ブランク、
２ 撓み部、
３ 予備成形体、
４ 平板形状部、
５ 増肉部、
６ 撓み部成形型、
１０ 下方押さえ部、
１５ 上方押さえ部、
１７ 可動押し込み部、
３１ 第１増肉用成形型、
３４ 第１外周保持部（拘束部）、
３５ 第１押圧部、
３６ 下型凸部、
３８ 上型凹部、
４１ 第２増肉用成形型、
４４ 第２外周保持部（拘束部）、
４５ 第２押圧部、
５０ プレス成形品、
５１ 補強部、
Ｌ キャビティー面の周長、
Ｗ 幅、
Ｘ 周長変化率、
α 第１周長、
β 第２周長、
γ 第３周長、
θ 最大傾き角度。
1 blank,
2 flexures,
3 preformed body,
4 flat plate-shaped part,
5 Thickening part,
6 Flexible part mold,
10 Lower holding part,
15 Upper holding part,
17 Movable push-in part,
31 First mold for thickening,
34 1st outer periphery holding | maintenance part (restraint part),
35 first pressing portion,
36 Lower mold convex part,
38 Upper mold recess,
41 Second mold for thickening,
44 2nd outer periphery holding | maintenance part (restraint part),
45 second pressing portion,
50 press-formed products,
51 reinforcements,
L perimeter of cavity surface,
W width,
X Perimeter change rate,
α 1st circumference,
β second circumference,
γ 3rd circumference,
θ Maximum tilt angle.
Claims (18)
前記予備成形体に平板形状で残る平板形状部を拘束しつつ、前記撓み部を平板形状に潰して板厚を増加させた増肉部を形成する増肉工程と、
前記増肉部を形成した予備成形体をプレス成形するプレス成形工程と、を有することを特徴とするプレス成形品の製造方法。 In a flat blank, a bent part forming step in which a partially bent bent part is formed as a preform, and
While increasing the plate-shaped portion remaining in the shape of a flat plate in the preform, the thickening step of forming a thickened portion by crushing the bent portion into a flat plate shape and increasing the plate thickness;
And a press molding step of press molding the preform with the thickened portion formed thereon.
前記増肉工程において、前記予備成形体の縁部から縁部まで延在する増肉部を形成することを特徴とする請求項１に記載のプレス成形品の製造方法。 In the bending part forming step, forming a bending part extending from the edge of the blank to the edge,
The method for manufacturing a press-formed product according to claim 1, wherein, in the thickening step, a thickened portion extending from an edge portion to an edge portion of the preform is formed.
前記予備成形体に平板形状で残る平板形状部を拘束する拘束部、および前記撓み部を平板形状に潰して板厚を増加させる押圧部を備えた増肉用成形型と、
前記板厚を増加された予備成形体をプレス成形するプレス成形型と、を有することを特徴とするプレス成形品の製造装置。 A bending part mold for forming a preformed part by forming a partially bent bending part in a flat plate-shaped blank;
A restraint portion that restrains a flat plate-shaped portion remaining in a flat plate shape on the preform, and a mold for thickening provided with a pressing portion that crushes the flexible portion into a flat plate shape and increases a plate thickness,
An apparatus for manufacturing a press-molded product, comprising: a press-molding die for press-molding the preform having the increased thickness.
前記増肉用成形型は、前記予備成形体に縁部から縁部まで延在する増肉部を形成する成形型であることを特徴とする請求項８に記載の成形装置。 The flexible part mold is a mold that forms a flexible part extending from edge to edge in the blank,
The molding apparatus according to claim 8, wherein the mold for thickening is a mold for forming a thickened portion extending from edge to edge in the preform.
前記予備成形体の形状に対応する面形状を有し、前記ブランクの面に対して独立して進退動可能な少なくとも１つの押し込み部と、
前記ブランクを折り曲げることで撓み部を前記一方側から他方側へ向かって形成するように、前記押し込み部を順次作動させる作動機構と、を有することを特徴とする請求項８または９に記載のプレス成形品の製造装置。 The bending portion molding die includes a pressing portion that is fixed with one side of the blank interposed therebetween,
Having a surface shape corresponding to the shape of the preform, and at least one pushing portion capable of moving forward and backward independently with respect to the surface of the blank;
The press according to claim 8 or 9, further comprising an operating mechanism that sequentially operates the push-in portions so that a bent portion is formed from the one side toward the other side by bending the blank. Molded product manufacturing equipment.
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