JP2011045923A - Different thickness metal plate and method of producing the same - Google Patents

Different thickness metal plate and method of producing the same Download PDF

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JP2011045923A
JP2011045923A JP2009198654A JP2009198654A JP2011045923A JP 2011045923 A JP2011045923 A JP 2011045923A JP 2009198654 A JP2009198654 A JP 2009198654A JP 2009198654 A JP2009198654 A JP 2009198654A JP 2011045923 A JP2011045923 A JP 2011045923A
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thickness
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JP5402404B2 (en
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Yoshiyuki Kasurida
良之 綛田
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Sumitomo Metal Ind Ltd
住友金属工業株式会社
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<P>PROBLEM TO BE SOLVED: To provide a different thickness wide metal plate having good quality characterized in that the cross-sectional shape thereof is highly flexibly designed and the cross-sectional shape is easily changed and the metal plate does not include weld zones or the like, and to provide a method of producing the different thickness wide metal plate. <P>SOLUTION: A tubular base stock having a joined part extended in the longitudinal direction is produced by performing butt-joining of both ends of a flat plate made of metal which is bent into a tubular shape, a rotary mandrel mounted inside the tubular base stock pressurizes a working roll arranged outside the tubular base stock to the plate thickness direction of the tubular base stock while rotating the tubular base stock and also feeds the working roll in the longitudinal direction. the working roll and the mandrel perform thickness reducing work for reducing the plate thickness of the whole or a part in the longitudinal direction of the tubular base stock, and thus a tubular member having the plate thickness different in the longitudinal direction is produced. Further, a bent open member is produced by cutting and removing the joined part of the tubular member having different thickness, then the open member is expanded into a flat plate shape, thus the different thickness metal plate is produced. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、例えば自動車車体の製造等に用いられる差厚鋼板や差厚アルミニウム板といった差厚金属板およびその製造方法に関する。   The present invention relates to a differential thickness metal plate such as a differential thickness steel plate or a differential thickness aluminum plate used for manufacturing automobile bodies and the like, and a method for manufacturing the same.
従来から、例えばプレス加工により自動車のボディやフレーム等を製造する際の素材として、予め板厚の異なる鋼板同士を突き合わせ接合して板厚が部分的に異なる鋼板とした差厚鋼板が、軽量化を促進するために用いられる。板厚が部分的に異なる板材の製造方法として、種々の方法が提案されている。   Conventionally, as a material for manufacturing automobile bodies, frames, etc., by press working, for example, steel sheets with different plate thicknesses are butt-joined and made into steel plates with partially different plate thicknesses. Used to promote Various methods have been proposed as a method of manufacturing plate materials having partially different plate thicknesses.
例えば、特許文献1には、複数スタンドのカリバーロール圧延により幅方向に異なる板厚を有する異形断面鋼板を安定して圧延する方法に係る発明が開示されている。
特許文献2には、板材を長手方向に圧延し、長手方向に異なる板厚を有する差厚材を製造する圧延装置に係る発明が開示されている。
For example, Patent Document 1 discloses an invention relating to a method of stably rolling a deformed cross-section steel plate having different thicknesses in the width direction by multiple stand caliber roll rolling.
Patent Document 2 discloses an invention relating to a rolling apparatus that rolls a plate material in the longitudinal direction and manufactures a differential thickness material having different plate thicknesses in the longitudinal direction.
特許文献3には、板厚、強度が異なる異種の板材を突き合わせて接合して差厚テーラードブランク材を形成する差厚テーラードブランク材の形成方法に係る発明が開示されている。   Patent Document 3 discloses an invention relating to a method for forming a differential thickness tailored blank material in which different thickness plate materials having different thicknesses and strengths are butted and joined to form a differential thickness tailored blank material.
さらに、特許文献4には、押出加工により周方向に板厚が変化する環状部材を製造し、これを展開加工して差厚板を製造するアルミニウム合金差厚ブランク材の製造方法に係る発明が開示されている。   Furthermore, Patent Document 4 discloses an invention relating to a manufacturing method of an aluminum alloy differential thickness blank material, in which an annular member whose thickness changes in the circumferential direction by extrusion processing, and this is expanded to manufacture a differential thickness plate. It is disclosed.
特開平6−142710号公報JP-A-6-142710 特開2008−264850号公報JP 2008-264850 A 特開平10−180470号公報Japanese Patent Laid-Open No. 10-180470 特開2004―255400号公報JP 2004-255400 A
特許文献1に開示されるように、圧延により幅方向に板厚差を形成することによって差厚板を製造するには、差厚板の断面形状に合わせた、種々の異なる孔型形状を有する孔型ロールが必要となるので、小ロット、多品種の差厚板を製造することは、製造コストが嵩むことから、難しい。   As disclosed in Patent Document 1, in order to manufacture a differential thickness plate by forming a thickness difference in the width direction by rolling, it has various different hole shape shapes that match the cross-sectional shape of the differential thickness plate. Since a perforated roll is required, it is difficult to manufacture small lots and various types of differential thick plates due to increased manufacturing costs.
特許文献2に開示されるように、圧延によって長手方向に板厚の変化を形成して差厚板を製造しようとすると、長手方向の板厚変更領域が小さい差厚板を製造することが難しく、また、高い精度の板厚分布を有する差厚板を製造することが難しい。   As disclosed in Patent Document 2, it is difficult to manufacture a differential thickness plate having a small thickness change region in the longitudinal direction when an attempt is made to produce a differential thickness plate by forming a change in the thickness in the longitudinal direction by rolling. In addition, it is difficult to manufacture a differential thickness plate having a highly accurate thickness distribution.
特許文献3に開示されるように、溶接によって差厚板を製造する方法では、得られる差厚板に溶接に伴う熱影響部が不可避的に残存するので、溶接欠陥が発生し易く、また、板厚変更部が段差状になるといった問題や、長手方向に複数の板厚変更部を有する部材の製造が容易でないといった問題がある。   As disclosed in Patent Document 3, in the method of manufacturing a differential thickness plate by welding, a heat-affected zone accompanying welding is inevitably left in the resulting differential thickness plate, so that welding defects are likely to occur, There is a problem that the plate thickness changing portion has a stepped shape and a problem that it is not easy to manufacture a member having a plurality of plate thickness changing portions in the longitudinal direction.
さらに、特許文献4に開示されるように、押し出しによって差厚板を製造する方法では、断面形状の変更にはダイスの変更を伴うために断面形状の変更を容易に行うことができないといった問題や、薄肉で大径の押し出し管が必要となるため、広幅の差厚板の製造が難しいといった問題がある。   Furthermore, as disclosed in Patent Document 4, in the method of manufacturing a differential thickness plate by extrusion, the change in the cross-sectional shape involves a change in the die, and therefore the cross-sectional shape cannot be easily changed. However, since a thin and large-diameter extruded tube is required, there is a problem that it is difficult to manufacture a wide differential plate.
本発明は、このような従来の技術が有する課題に鑑みてなされたものであり、断面形状設計の自由度が大きく、しかも断面形状の変更も容易に行うことができ、溶接部等を含まないといった優れた特徴を有する、品質が良好な広幅の差厚金属板及びその製造方法を提供することを目的とする。   The present invention has been made in view of the problems of such conventional techniques, and has a high degree of freedom in cross-sectional shape design, can be easily changed in cross-sectional shape, and does not include welds or the like. An object of the present invention is to provide a wide-width differential thickness metal plate having excellent characteristics such as the above and a method for producing the same.
本発明者は、上述した課題を解決するため、管材の内部に装入したマンドレルと管材の外部に配置した加工ロールとで部分的に板厚を圧下する、所謂フローフォーミング加工に注目した検討を行い、以下に列記する知見(1)〜(3)を得た。   In order to solve the above-mentioned problems, the present inventor has studied a so-called flow forming process in which the plate thickness is partially reduced by a mandrel inserted inside the pipe material and a processing roll arranged outside the pipe material. The findings (1) to (3) listed below were obtained.
(1)板材を突き合わせ接合して溶接管材を製作し、この溶接管材の内部に回転可能なマンドレルを配置するとともに、溶接管材の外部に配置した加工ロールで溶接管材を肉厚方向に押圧して、溶接管材の肉厚を部分的に減少する減厚加工を行うことにより、長手方向に肉厚変動を有する差厚管材を製作し、この差厚管材を接合部で切断除去し、切断除去した差厚管材を展開加工することにより、溶接部を有さない、平坦性の良好な差厚金属板を効率的に製造できること。   (1) A plate material is butt-joined to produce a welded tube material, and a rotatable mandrel is disposed inside the welded tube material, and the welded tube material is pressed in the thickness direction with a processing roll disposed outside the welded tube material. By performing a thickness reduction process that partially reduces the thickness of the welded pipe material, a differential thickness pipe material having a thickness variation in the longitudinal direction is manufactured, and this differential thickness pipe material is cut and removed at the joint, and then removed by cutting. By developing the differential thickness tube material, it is possible to efficiently manufacture a differential thickness metal plate having no welded portion and good flatness.
(2)減厚加工により板厚減少部の内径が縮径する。そのため、溶接管材の内径寸法に比べてマンドレルの外形寸法が過小で、特に板厚減少量が大きい場合には、縮径が大きくなり、板厚減少部の周長が、減厚加工を行われない部分の周長に比べて過小となるため、展開加工後の差厚金属板の平坦性が悪化し易いこと。   (2) The inner diameter of the reduced thickness portion is reduced by the thickness reduction process. Therefore, when the mandrel's outer dimensions are too small compared to the inner diameter of the welded pipe material, especially when the plate thickness reduction amount is large, the diameter is reduced, and the peripheral length of the plate thickness reduction portion is reduced. The flatness of the differential thickness metal plate after unfolding is likely to be deteriorated because it is too small compared to the peripheral length of the unexposed portion.
(3)溶接管材を展開加工する前に、溶接管材の内周を拡大する拡管加工を行うことにより、差厚金属板の平坦性が向上すること。
本発明は、これらの知見に基づいてなされたものである。
(3) The flatness of the differential thickness metal plate is improved by performing a pipe expanding process for expanding the inner circumference of the welded pipe material before the welded pipe material is developed.
The present invention has been made based on these findings.
本発明に係る差厚金属板の製造方法は、金属製の板、例えば平板を円筒状に曲げ成形し、その両端部を突き合わせ接合して長手方向に延びる接合部を有する円筒素材を製造する第1の工程と、この円筒素材の内部に装着した回転可能なマンドレルにより円筒素材を回転しながら、円筒素材の外部に配置した加工ロールを円筒素材の肉厚方向に押圧するとともに長手方向に送り、加工ロールとマンドレルとにより円筒素材の長手方向の全部または一部の領域の肉厚を減少させる減厚加工を行い長手方向に肉厚が異なる差厚円筒部材を製造する第2の工程と、この差厚円筒部材の接合部を切断除去して湾曲した開口部材を製造し、次いでこの開口部材を平板状に展開加工して差厚金属板を製造する第3の工程とを備えることを特徴とする。本明細書では、この製造方法を「第1の製造方法」という。   The manufacturing method of a differential thickness metal plate according to the present invention is a method of manufacturing a cylindrical material having a joint portion extending in the longitudinal direction by bending a metal plate, for example, a flat plate into a cylindrical shape, and butt-joining both ends thereof. While rotating the cylindrical material by the process 1 and the rotatable mandrel mounted inside the cylindrical material, the processing roll disposed outside the cylindrical material is pressed in the thickness direction of the cylindrical material and sent in the longitudinal direction, A second step of manufacturing a differential thickness cylindrical member having a different thickness in the longitudinal direction by reducing the thickness of the whole or a part of the longitudinal direction of the cylindrical material by the processing roll and the mandrel; A third step of producing a curved opening member by cutting and removing the joint portion of the differential thickness cylindrical member, and then developing the opening member into a flat plate shape to produce a differential thickness metal plate. To do. In this specification, this manufacturing method is referred to as a “first manufacturing method”.
この本発明に係る第1の製造方法により、断面形状の設計自由度が高く、しかも断面形状の変更も容易に行うことが可能であり、品質欠陥の起点となる溶接部を有しない、平坦性が良好な差厚金属板を製造することが可能になる。   The first manufacturing method according to the present invention has a high degree of freedom in design of the cross-sectional shape, can be easily changed in cross-sectional shape, and does not have a welded portion as a starting point of quality defects. However, it becomes possible to manufacture a metal plate having a good difference thickness.
また、本発明に係る差厚金属板の製造方法は、金属製の板、例えば平板を円筒状に曲げ成形し、その両端部を突き合わせ接合して長手方向に延びる接合部を有する円筒素材を製造する第1の工程と、この円筒素材の内部に装着したマンドレルにより円筒素材を回転しながら、円筒素材の外部に配置した加工ロールを円筒素材の肉厚方向に押圧するとともに長手方向に送り、加工ロールとマンドレルとにより円筒素材の長手方向の全部または一部の領域の肉厚を減少させる減厚加工を行い長手方向に肉厚が異なる差厚円筒部材を製造する第2の工程と、この差厚円筒部材の内径を拡大する拡管加工を行う拡管工程と、拡管された差厚円筒部材の接合部を切断除去して湾曲した開口部材を製造し、次いでこの開口部材を平板状に展開加工して差厚金属板を製造する第3の工程とを備えることを特徴とする。本明細書では、この製造方法を「第2の製造方法」という。   In addition, the method for manufacturing a differential thickness metal plate according to the present invention manufactures a cylindrical material having a joining portion extending in the longitudinal direction by bending a metal plate, for example, a flat plate into a cylindrical shape, and butt-joining both ends thereof. The first process and the mandrel mounted inside this cylindrical material, while rotating the cylindrical material, press the processing roll placed outside the cylindrical material in the thickness direction of the cylindrical material and feed it in the longitudinal direction A second step of manufacturing a differential cylindrical member having a different thickness in the longitudinal direction by reducing the thickness of the whole or a part of the longitudinal direction of the cylindrical material by using a roll and a mandrel; A tube expanding process for expanding the inner diameter of the thick cylindrical member, and manufacturing a curved opening member by cutting and removing the joint portion of the expanded differential thickness cylindrical member, and then developing the opening member into a flat plate shape. Differential thickness Characterized in that it comprises a third step of producing a genus plate. In this specification, this manufacturing method is referred to as a “second manufacturing method”.
この本発明に係る第2の製造方法により、断面形状の設計自由度が高く、しかも断面形状の変更も容易に行うことが可能であり、品質欠陥の起点となる溶接部を有しない、平坦性が極めて良好な差厚金属板を製造することができる。   The second manufacturing method according to the present invention has a high degree of freedom in design of the cross-sectional shape, can be easily changed in cross-sectional shape, and does not have a welded portion as a starting point of quality defects, and is flat. However, a very good differential thickness metal plate can be produced.
この本発明に係る第2の製造方法における拡管加工は、差厚円筒部材の内部に周方向に分割した金型を装入し、金型を半径方向に移動させることにより行うことが望ましい。
本発明に係る差厚金属板は、例えば、熱間プレス用鋼板として用いることができる。すなわち、熱間プレスは、素材である、本発明により製造される差厚鋼板をA変態点以上の温度に加熱し、加熱した差厚鋼板を金型に装入してプレス成形を行うと同時にA変態点以上の温度から焼入れすることにより、行われる。
The tube expansion process in the second manufacturing method according to the present invention is desirably performed by inserting a die divided in the circumferential direction into the inside of the differential thickness cylindrical member and moving the die in the radial direction.
The differential thickness metal plate according to the present invention can be used, for example, as a steel plate for hot pressing. Namely, the hot pressing is a material, the tailor welded blank made according to the present invention is heated to a temperature above the A 1 transformation point, when the press-molding the heated tailor welded blank was charged into a mold by quenching the a 1 transformation point or above the temperature at the same time, it is performed.
本発明によれば、フローフォーミング加工において個々の円筒材に対して個別の断面形状を付与することが可能であり、圧延に比べて容易に差厚形状を変更できるので、差厚金属板の少量多品種生産に容易に対応できる。また、多段数の板厚分布を有する差厚金属板の製造においては、突き合わせ溶接で製造すると差厚箇所に対応するだけ溶接工程が増えて工数増大を招くが、本発明では差厚の数や形状にかかわらず、一回のフローフォーミングで差厚形状を得ることができるため、生産性が大幅に向上する。また、薄板金属板を素材としてさらに減肉加工を施すことにより差厚金属板を製造するため、薄物で広幅・長尺な差厚金属板を容易に製造できるなど、製造方法として有益である。   According to the present invention, it is possible to give individual cross-sectional shapes to individual cylindrical materials in the flow forming process, and the difference thickness shape can be easily changed as compared with rolling. Can easily handle multi-product production. In addition, in the manufacture of a differential thickness metal plate having a multi-stage thickness distribution, if it is manufactured by butt welding, the number of differential thicknesses is increased in the present invention. Regardless of the shape, a difference thickness shape can be obtained by a single flow forming, which greatly improves productivity. Further, since the differential thickness metal plate is manufactured by further reducing the thickness using the thin metal plate as a raw material, it is useful as a manufacturing method such that a thin and wide and long differential thickness metal plate can be easily manufactured.
さらに、本発明では、円筒材の段階で一旦溶接部が形成されるものの、この部分の溶接精度としては次工程のフローフォーミング及び拡管加工で破断しない程度で良く、最終製品には溶接部が残存しないため、本発明によって製造される金属板は接合部の欠陥や熱影響部などの影響がなく、板厚変化部もローラ送りによって連続的に変化するため段差の形成もなく良好な形状特性を有し、しかも差厚分布の形態の自由度が大きいという差厚金属板としての利点も大きい。   Furthermore, in the present invention, although the welded portion is once formed at the stage of the cylindrical material, the welding accuracy of this portion may be such that it does not break in the next process of flow forming and tube expansion, and the welded portion remains in the final product. Therefore, the metal plate manufactured according to the present invention is not affected by the defect of the joint or the heat affected zone, and the thickness changing portion is continuously changed by the roller feed, so that there is no formation of a step and has good shape characteristics. Moreover, the advantage as a differential thickness metal plate that the degree of freedom of the form of the differential thickness distribution is large is also great.
図1は、加工前の金属板材を示す説明図である。FIG. 1 is an explanatory view showing a metal plate material before processing. 図2は、フローフォーミング加工前の円筒部材を示す説明図である。FIG. 2 is an explanatory view showing the cylindrical member before the flow forming process. 図3は、フローフォーミング加工の一例を示す説明図である。FIG. 3 is an explanatory diagram showing an example of the flow forming process. 図4は、フローフォーミング加工の別の例を示す説明図である。FIG. 4 is an explanatory diagram showing another example of the flow forming process. 図5は、フローフォーミング加工後の差厚円筒材の一例を示す説明図である。FIG. 5 is an explanatory diagram showing an example of the differential thickness cylindrical material after the flow forming process. 図6は、フローフォーミング加工後の断面形態の一例を示す説明図である。FIG. 6 is an explanatory view showing an example of a cross-sectional form after the flow forming process. 図7は、ロール曲げによる巻き癖矯正の例を示す説明図である。FIG. 7 is an explanatory diagram showing an example of curl correction by roll bending. 図8は、差厚金属板の一例を示す説明図である。FIG. 8 is an explanatory view showing an example of the differential thickness metal plate. 図9は、ロール曲げによる巻き癖矯正の別の例を示す説明図である。FIG. 9 is an explanatory view showing another example of curl correction by roll bending. 図10は、プレス曲げによる巻き癖矯正の例を示す説明図である。FIG. 10 is an explanatory view showing an example of curl correction by press bending. 図11は、差厚円筒部材に対する拡管加工の例(金型拡大前)を示す説明図である。FIG. 11 is an explanatory diagram showing an example of tube expansion processing (before mold expansion) for the differential thickness cylindrical member. 図12は、差厚円筒部材に対する拡管加工の例(金型拡大後)を示す説明図である。FIG. 12 is an explanatory view showing an example of tube expansion processing (after mold expansion) for the differential thickness cylindrical member. 図13は、差厚円筒部材に対する拡管加工の要領を説明する概要図である。FIG. 13 is a schematic diagram for explaining the point of tube expansion processing for the differential thickness cylindrical member. 図14は、差厚鋼板を用いた熱間プレス成形を説明する概要図である。FIG. 14 is a schematic diagram illustrating hot press forming using a differential thickness steel plate. 図15は、実施例2によるフローフォーミング加工後の差厚円筒部材の断面形態を示す説明図である。FIG. 15 is an explanatory view showing a cross-sectional form of the differential thickness cylindrical member after the flow forming process according to the second embodiment. 図16は、実施例2によるフローフォーミング加工後の差厚円筒部材の断面形態を示す説明図である。FIG. 16 is an explanatory view showing a cross-sectional form of the differential thickness cylindrical member after the flow forming process according to the second embodiment. 図17は、実施例2によるフローフォーミング加工後の差厚円筒部材の断面形態を示す説明図である。FIG. 17 is an explanatory view showing a cross-sectional form of the differential thickness cylindrical member after the flow forming process according to the second embodiment. 図18は、実施例2によるフローフォーミング加工後の差厚円筒部材の断面形態を示す説明図である。FIG. 18 is an explanatory view showing a cross-sectional form of the differential thickness cylindrical member after the flow forming process according to the second embodiment.
以下、本発明を実施するための形態を、添付図面を参照しながら説明する。最初に第1の製造方法について説明する。
図1〜10により、第1の製造方法を模式的に示す。図1は、加工前の金属板材1を示す説明図であり、図2は、フローフォーミング加工前の円筒部材2を示す説明図であり、図3は、フローフォーミング加工の一例を示す説明図であり、図4は、フローフォーミング加工の別の例を示す説明図であり、図5は、フローフォーミング加工後の差厚円筒部材2−1の一例を示す説明図であり、図6は、フローフォーミング加工後の差厚円筒部材2−1の断面形態の一例を示す説明図であり、図7は、ロール曲げによる巻き癖矯正の例を示す説明図であり、図8は、差厚金属板16の一例を示す説明図であり、図9は、ロール曲げによる巻き癖矯正の別の例を示す説明図であり、さらに、図10は、プレス曲げによる巻き癖矯正の例を示す説明図である。
DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described with reference to the accompanying drawings. First, the first manufacturing method will be described.
1 to 10 schematically show the first manufacturing method. FIG. 1 is an explanatory view showing a metal plate 1 before processing, FIG. 2 is an explanatory view showing a cylindrical member 2 before flow forming, and FIG. 3 is an explanatory view showing an example of flow forming. FIG. 4 is an explanatory view showing another example of the flow forming process, FIG. 5 is an explanatory view showing an example of the differential thickness cylindrical member 2-1 after the flow forming process, and FIG. FIG. 7 is an explanatory view showing an example of a cross-sectional form of the differential thickness cylindrical member 2-1 after forming, FIG. 7 is an explanatory view showing an example of curl correction by roll bending, and FIG. 8 is a differential thickness metal plate FIG. 9 is an explanatory diagram showing another example of curl correction by roll bending, and FIG. 10 is an explanatory diagram showing an example of curling correction by press bending. is there.
第1の工程では、図1に示す所定の略長方形状の金属板1に、その対向する2辺1a、1bが長手方向に延びて配置されるように曲げ加工を行うことによって金属板1の対向する2辺1a、1bを突き合わせ、この突き合わせ部を溶接することによって、図2に示すように溶接部3が長手方向へ延びて存在する円筒部材2を製造する。   In the first step, the metal plate 1 is bent by bending the predetermined substantially rectangular metal plate 1 shown in FIG. 1 so that the two opposite sides 1a and 1b extend in the longitudinal direction. The opposing two sides 1a and 1b are butted and the butted portions are welded to manufacture the cylindrical member 2 in which the welded portion 3 extends in the longitudinal direction as shown in FIG.
金属板1に対する曲げ加工は、例えば公知のロールベンダやUOプレス等を用いて行うことができる。ロールベンダを用いる曲げ加工は、例えば、3ロール式ロールベンダに金属板1を送り込みながら行うことが例示される。   The bending process with respect to the metal plate 1 can be performed using a well-known roll bender, a UO press, etc., for example. For example, the bending process using a roll bender is performed while feeding the metal plate 1 into a three-roll type roll bender.
金属板1の対向する2辺1a、1bの突き合わせ溶接には、抵抗溶接、レーザ溶接さらにはフラッシュ溶接等を用いることができる。なお、本発明における金属板1の対向する2辺1a、1bの接合は、溶接に限定されるものではなく、例えば摩擦圧接、熱間圧接あるいは摩擦攪拌接合等の接合手段を用いてもよい。   For butt welding of the two opposite sides 1a and 1b of the metal plate 1, resistance welding, laser welding, flash welding, or the like can be used. The joining of the two opposite sides 1a and 1b of the metal plate 1 in the present invention is not limited to welding, and for example, a joining means such as friction welding, hot welding or friction stir welding may be used.
第2工程では、図3に示すように図示しない駆動装置により回転可能に配置されたマンドレル4と、図示しない駆動装置によりマンドレル4の半径方向への押し込みおよびマンドレル4の軸方向への送りが可能な加工ロール5とを備えるフローフォーミング装置13によって、円筒部材2の長手方向の一部の領域の板厚tを、この領域以外の領域の板厚tよりも小さくする減肉加工を行う。 In the second step, as shown in FIG. 3, the mandrel 4 arranged rotatably by a driving device (not shown), and the mandrel 4 can be pushed in the radial direction and the mandrel 4 can be fed in the axial direction by a driving device (not shown). With the flow forming device 13 including the processing roll 5, a thickness reduction process is performed in which the plate thickness t 1 in a part of the longitudinal direction of the cylindrical member 2 is made smaller than the plate thickness t 0 in a region other than this region. .
すなわち、図3に示すように、円筒部材2をマンドレル4に装着し、円筒部材2の外側に配置した加工ロール5、5を円筒部材2の肉厚方向へ圧下する。マンドレル4の回転によりマンドレル4との摩擦力により円筒部材2が従動回転し、加工ロール5のマンドレル半径方向への押し込みと軸方向への送り6とによって、円筒部材2に対する減厚加工を行う。   That is, as shown in FIG. 3, the cylindrical member 2 is attached to the mandrel 4, and the processing rolls 5, 5 arranged outside the cylindrical member 2 are pressed down in the thickness direction of the cylindrical member 2. As the mandrel 4 rotates, the cylindrical member 2 is driven and rotated by the frictional force with the mandrel 4, and the cylindrical member 2 is reduced in thickness by pushing the processing roll 5 in the mandrel radial direction and in the axial direction 6.
この場合、製造する差厚形状に応じて、図3に示すように加工ロール5を符号6に示す軌跡となるように円筒部材2の軸方向に送ることにより円筒部材2の管端部に減肉部7を形成することや、図4に示すように加工ロール5を符号8に示す軌跡となるように円筒部材2の軸方向に送ることにより図4および図5に示すように円筒部材2の長手方向の中央部に減肉部7を形成することが可能になる。   In this case, according to the thickness difference shape to be manufactured, the processing roll 5 is fed in the axial direction of the cylindrical member 2 so as to have a locus indicated by reference numeral 6 as shown in FIG. The cylindrical member 2 is formed as shown in FIGS. 4 and 5 by forming the meat portion 7 or by sending the processing roll 5 in the axial direction of the cylindrical member 2 so as to have a locus indicated by reference numeral 8 as shown in FIG. It is possible to form the thinned portion 7 at the central portion in the longitudinal direction.
また、加工ロール5の軸方向への送り量と、マンドレル4に対する加工ロール5の押し込み量とを適宜設定することによって、円筒部材2の加工後の断面形状を長手方向に任意に設定することができる。   Moreover, the cross-sectional shape after the process of the cylindrical member 2 can be arbitrarily set in the longitudinal direction by appropriately setting the feed amount of the process roll 5 in the axial direction and the pushing amount of the process roll 5 against the mandrel 4. it can.
フローフォーミング装置13を用いた加工によって、円筒部材2の内径および板厚によらず、所望の位置に減肉部(肉厚減少部)7を形成することができるが、例えば、内径が200mm以上600mm以下程度で板厚が0.5mm以上6mm以下程度で板厚tと内径Dとの比(t/D)が0.0008以上0.03以下程度の薄肉かつ大径の円筒部材2に対しても、減肉部7を形成することができる。   By the processing using the flow forming apparatus 13, the thinned portion (thickness reduced portion) 7 can be formed at a desired position regardless of the inner diameter and the plate thickness of the cylindrical member 2. For example, the inner diameter is 200 mm or more. For a thin and large cylindrical member 2 having a thickness of about 600 mm or less, a thickness of about 0.5 mm to 6 mm, and a ratio (t / D) of the thickness t to the inner diameter D of about 0.0008 to 0.03. However, the thinned portion 7 can be formed.
なお、円筒部材2は、マンドレル4の外面と円筒部材2の内面との摩擦力により回転するが、マンドレル4の外面と円筒部材2の内面との間にゴムブッシュを挿入して介在させることによって、マンドレル4の外面と円筒部材2との間の滑りを抑制できるので、より確実にマンドレル4の回転を円筒部材2へ伝達することができる。   The cylindrical member 2 is rotated by the frictional force between the outer surface of the mandrel 4 and the inner surface of the cylindrical member 2. By inserting a rubber bush between the outer surface of the mandrel 4 and the inner surface of the cylindrical member 2, the cylindrical member 2 is interposed. Since the slip between the outer surface of the mandrel 4 and the cylindrical member 2 can be suppressed, the rotation of the mandrel 4 can be more reliably transmitted to the cylindrical member 2.
円筒部材2の内径とマンドレル4の外径とは、(マンドレル4の外径×0.995≦円筒部材2の内径≦マンドレル4の外径×1.005)の関係を充足することが望ましい。円筒部材2の内径がマンドレル4の外径に比べて、過大であると後述する展開加工後の差厚金属板16の平坦性が不良となるおそれがあり、一方過小であるとマンドレル4への円筒部材2の取付けが困難となり易いからである。   It is desirable that the inner diameter of the cylindrical member 2 and the outer diameter of the mandrel 4 satisfy the relationship of (the outer diameter of the mandrel 4 × 0.995 ≦ the inner diameter of the cylindrical member 2 ≦ the outer diameter of the mandrel 4 × 1.005). If the inner diameter of the cylindrical member 2 is too large compared to the outer diameter of the mandrel 4, the flatness of the differential thickness metal plate 16 after the unfolding process described later may be poor. This is because it is difficult to attach the cylindrical member 2.
図3、4に示すフローフォーミング装置13は、2個の加工ロール5を備えるものであるが、加工ロール5を1個または3個備えていてもよい。
図3、4に示すフローフォーミング装置13は、マンドレル4の軸方向を水平方向とした横型タイプであるが、これに限定されるものではなく、マンドレル4の軸方向を垂直方向とした縦型タイプでもよい。
The flow forming apparatus 13 shown in FIGS. 3 and 4 includes two processing rolls 5, but may include one or three processing rolls 5.
The flow forming apparatus 13 shown in FIGS. 3 and 4 is a horizontal type in which the axial direction of the mandrel 4 is horizontal, but is not limited to this, and is a vertical type in which the axial direction of the mandrel 4 is vertical. But you can.
その後、突き合わせ溶接箇所3で円筒部材2を切断することにより、溶接部3が切断除去され、例えば、図6に示すような断面形状を有する湾曲した開口部材14が得られる。切断方法としては、例えば、シャーによる切断、レーザによる切断、あるいは溶断等が例示される。   Thereafter, the cylindrical member 2 is cut at the butt welding portion 3, whereby the welded portion 3 is cut and removed. For example, a curved opening member 14 having a cross-sectional shape as shown in FIG. 6 is obtained. Examples of the cutting method include cutting with a shear, cutting with a laser, or fusing.
次に、図7に示すように、3ロールタイプの曲げ矯正装置15を用い、開口部材14を切断箇所10からロール9により順次曲げ加工を施し、巻き癖矯正を連続して行うことにより平板状に展開し、図8に示す差厚板16を製造する。一回のパスで曲がり取りが不十分である場合には、各ロール9の回転方向を変更し、往復して曲がりを矯正するようにして、行えばよい。   Next, as shown in FIG. 7, a three-roll type bending straightening device 15 is used to sequentially bend the opening member 14 from the cut portion 10 with the roll 9, and the curl correction is continuously performed to form a flat plate shape. 8 to produce the differential thickness plate 16 shown in FIG. If the bending is insufficient in one pass, the rotation direction of each roll 9 may be changed and the bending may be corrected by reciprocating.
巻き癖の矯正手段としては、図7に示す3ロールタイプの曲げ矯正装置15のみならず、図9に示す、一対の支持ロール9−1、9−2および昇降ロール9−2を有する曲げ矯正装置17を用いることができる。また、巻き癖の矯正手段は、ロール曲げに限定されるものではなく、図10に示す3基の金型11を有するプレス矯正装置18を用いて行うプレス曲げでも、逐次送りながら行うことにより平板である差厚板16への展開が可能である。また、一般的なローラレベラにて矯正することも可能である。   As a curl correction means, not only the three-roll type bending correction device 15 shown in FIG. 7, but also a bending correction having a pair of support rolls 9-1 and 9-2 and a lifting roll 9-2 shown in FIG. A device 17 can be used. Further, the curl correction means is not limited to roll bending, and flat bending can be performed by sequentially feeding even press bending using the press straightening device 18 having the three molds 11 shown in FIG. It is possible to develop the difference thick plate 16. It is also possible to correct with a general roller leveler.
なお、ロール曲げ矯正装置による曲げ矯正では、長手方向の端部、すなわち溶接部3の近傍の矯正が不十分となり易い。したがって、この端部の矯正効果を高めるために、切断前の円筒部材2を片持ち支持タイプのロール曲げ矯正装置に装入して、溶接部を跨ぐ近傍のみを矯正し、その後、溶接部3を切断し、次いで再度ロール曲げ矯正装置で全長の曲がり矯正を行うこともできる。   In the bending correction by the roll bending correction device, the correction in the end portion in the longitudinal direction, that is, in the vicinity of the welded portion 3 tends to be insufficient. Therefore, in order to enhance the straightening effect of the end portion, the cylindrical member 2 before cutting is inserted into a cantilever support type roll bending straightening device to correct only the vicinity straddling the welded portion, and then the welded portion 3. Can be cut, and then the full-bend straightening can be performed again using a roll bending straightener.
以上のようにして、本発明に係る第1の製造方法により、断面形状の設計自由度が高く、しかも断面形状の変更も容易に行えることが可能であり、品質欠陥の起点となる溶接部3を有しない、平坦性が良好な差厚金属板16を製造することが可能になる。   As described above, the first manufacturing method according to the present invention has a high degree of freedom in designing the cross-sectional shape, can be easily changed in cross-sectional shape, and is a starting point of quality defects. It is possible to manufacture the differential thickness metal plate 16 that has no flatness and good flatness.
次に、本発明の第2の製造方法を説明する。第2の製造方法は、フローフォーミングの後の差厚円筒筒材2に拡管加工を行うことが特徴であり、第1の製造方法と同じ工程の説明は省略し、第1の製造方法とは異なる工程のみ説明する。   Next, the 2nd manufacturing method of this invention is demonstrated. The second manufacturing method is characterized in that tube expansion processing is performed on the differential thickness cylindrical tube member 2 after the flow forming, and the description of the same steps as the first manufacturing method is omitted, and what is the first manufacturing method? Only different steps will be described.
図11は、差厚円筒部材2−1に対する拡管加工の例(金型拡大前)を示す説明図である。図12は、差厚円筒部材2−1に対する拡管加工の例(金型拡大後)を示す説明図である。さらに、図13は、差厚円筒部材2−1に対する拡管加工の要領を説明する概要図である。   FIG. 11 is an explanatory view showing an example of the pipe expansion process (before the mold expansion) for the differential thickness cylindrical member 2-1. FIG. 12 is an explanatory view showing an example of pipe expansion processing (after mold enlargement) for the differential thickness cylindrical member 2-1. Furthermore, FIG. 13 is a schematic diagram for explaining the point of tube expansion processing for the differential thickness cylindrical member 2-1.
拡管加工の工程では、図11〜13に示すように円周方向に複数(この例では8個)のセグメント12a〜12hに分割された金型12を用いて差厚円筒部材2−1の内径の拡大を行う。すなわち、図11に示すように、フローフォーミング加工により部分的に減厚された差厚円筒部材2−1の内部に金型12を挿入し、例えば図13に示すように金型12の内部にくさび状部材19を押し込むことにより、図12および13に示すように金型12を構成する各セグメント12a〜12hが半径方向の外向きに等方的に移動し、これにより、差厚円筒部材2−1に対する拡管加工が行われる。   In the tube expansion process, as shown in FIGS. 11 to 13, the inner diameter of the differential thickness cylindrical member 2-1 using the mold 12 divided into a plurality of (eight in this example) segments 12 a to 12 h in the circumferential direction. To enlarge. That is, as shown in FIG. 11, the mold 12 is inserted into the differential thickness cylindrical member 2-1 partially reduced in thickness by the flow forming process. For example, as shown in FIG. By pushing in the wedge-shaped member 19, the segments 12a to 12h constituting the mold 12 are isotropically moved outward in the radial direction as shown in FIGS. Tube expansion processing for -1 is performed.
この拡管加工により、板厚減少部の内径が拡大するため、板厚減少部と非板厚減少部との周長差が小さくなり、展開加工後の差厚材16の平坦性が著しく向上するため、厳しい精度の要求に対応することができる。すなわち、差厚円筒部材2−1の内径とマンドレル4の外径のクリアランスが大きい場合に、減厚加工を行われない部分に比べて減厚加工部の径が小さくなる傾向が見られ、長手方向に周方向長さの差が発生するが、拡管加工を行うことにより、この周方向長さの差を著しく小さくすることができる。拡管加工は、長手方向の全長において円筒直径で2〜3%程度拡大することが望ましい。   Since the inner diameter of the plate thickness reducing portion is expanded by this pipe expansion processing, the circumferential length difference between the plate thickness reducing portion and the non-plate thickness reducing portion is reduced, and the flatness of the differential thickness material 16 after unfolding processing is significantly improved. Therefore, it is possible to meet demands for strict accuracy. That is, when the clearance between the inner diameter of the differential thickness cylindrical member 2-1 and the outer diameter of the mandrel 4 is large, the diameter of the reduced thickness portion tends to be smaller than the portion where the thickness reduction processing is not performed. Although a difference in circumferential length occurs in the direction, the difference in circumferential length can be remarkably reduced by performing tube expansion processing. The tube expansion process is desirably expanded by about 2 to 3% in terms of the cylindrical diameter over the entire length in the longitudinal direction.
なお、マンドレル4とのクリアランスを十分に小さくして、差厚円筒部材2−1をマンドレルに対して密着して減厚加工を行うことにより、拡管加工を省略した場合でも、高い平坦性を確保することができる。   In addition, even when the pipe expansion process is omitted, high flatness is ensured by sufficiently reducing the clearance with the mandrel 4 and performing the thickness reduction process by closely attaching the differential thickness cylindrical member 2-1 to the mandrel. can do.
拡管加工を行った後は、差厚円筒部材2−1をその溶接部3で切断して平板に展開することにより差厚金属板16を製造する。
本発明の方法により得られる差厚金属板16は、例えば、マンドレルサイズ直径を200mm以上600mm以下程度で、差厚円筒部材2−1の軸方向長さを200mm以上1800mm以下程度とすると、幅600mm×長さ200mmのサイズから幅1800mm×長さ1800mmのサイズとすることができる。
After the pipe expansion process is performed, the differential thickness metal plate 16 is manufactured by cutting the differential thickness cylindrical member 2-1 at the welded portion 3 and developing it onto a flat plate.
The differential thickness metal plate 16 obtained by the method of the present invention has a mandrel size diameter of about 200 mm to about 600 mm and a differential thickness cylindrical member 2-1 having an axial length of about 200 mm to about 1800 mm with a width of 600 mm. X From a size of 200 mm in length to a size of 1800 mm in width x 1800 mm in length.
本発明の方法により、板厚0.5mm以上6mm以下程度の部材に対して、減肉部の板厚をその(1/5)以上(4/5)以下とすることができる。
金属板の素材としては、鋼板、ステンレス鋼板、アルミニウム板や銅板などに適用できる。また、溶融亜鉛メッキ鋼板などの表面処理鋼板を母材として用いても良い。
By the method of the present invention, the thickness of the thinned portion can be set to (1/5) or more (4/5) or less for a member having a thickness of about 0.5 mm or more and 6 mm or less.
As a material of the metal plate, it can be applied to a steel plate, a stainless steel plate, an aluminum plate, a copper plate and the like. Moreover, you may use surface-treated steel plates, such as a hot-dip galvanized steel plate, as a base material.
本願発明による差厚金属板16は、差厚形成の段階で塑性加工が加えられるため、加工硬化が顕著な金属材料であれば、薄肉部で強度が上昇するため薄肉化による強度低下を抑制することができる。なお、板厚に関係なく均一な母材強度が要求される場合は、差厚金属板16に熱処理等を行えばよい。   Since the differential thickness metal plate 16 according to the present invention is subjected to plastic working at the stage of differential thickness formation, if the metal material is markedly work hardened, the strength increases at the thin wall portion, thereby suppressing a decrease in strength due to thinning. be able to. If a uniform base material strength is required regardless of the plate thickness, the differential thickness metal plate 16 may be heat treated.
また、高温度に加熱した鋼板素材を熱間にてプレスすると同時に焼入れを行う熱間プレス加工において、鋼板素材として本発明により製造された差厚鋼板を使用する場合は、フローフォーミング加工によって生じる加工歪みが、熱間プレス前の加熱処理中に解放されるため、差厚鋼板の製造段階で母材特性を均一化するための熱処理を特別に施す必要がないので、熱間プレス用鋼材として好適である。   Also, in the hot pressing process in which the steel sheet material heated to a high temperature is hot pressed and simultaneously quenched, when using the differential thickness steel sheet manufactured according to the present invention as the steel sheet material, the process caused by the flow forming process Since the strain is released during the heat treatment before hot pressing, it is not necessary to perform special heat treatment to make the base material characteristics uniform in the production stage of the differential thickness steel plate, so it is suitable as a steel material for hot pressing. It is.
なお、熱間プレスは公知の方法、例えば、質量0.2%程度の炭素を含有する鋼板において、一旦900℃以上に加熱してオーステナイト化した後、高温状態のまま金型に装入してプレス成形を行うことにより行えばよい。熱間プレスではプレス成形の下死点で鋼板を保持することにより成形と同時に焼き入れが行われる。   In addition, the hot press is a known method, for example, in a steel sheet containing about 0.2% by mass of carbon, once heated to 900 ° C. or more to austenite, and then charged into a mold in a high temperature state. What is necessary is just to carry out by performing press molding. In the hot press, quenching is performed at the same time as forming by holding the steel plate at the bottom dead center of press forming.
図14は、差厚鋼板を用いた熱間プレス成形を説明する概要図である。
熱間プレスでは、鋼板は金型20との接触によって冷却されるため、本発明に係る差厚鋼板16を用いるときには、図14に示すように、差厚鋼板16の板厚分布に応じて、図16の右図により示す下死点における金型のクリアランスを設定すればよい。
FIG. 14 is a schematic diagram illustrating hot press forming using a differential thickness steel plate.
In the hot press, the steel plate is cooled by contact with the mold 20, so when using the differential thickness steel plate 16 according to the present invention, as shown in FIG. 14, according to the thickness distribution of the differential thickness steel plate 16, What is necessary is just to set the clearance of the metal mold | die in the bottom dead center shown by the right figure of FIG.
以上のようにして、本発明に係る第2の製造方法により、断面形状の設計自由度が高く、しかも断面形状の変更も容易に行うことが可能であり、品質欠陥の基点となる溶接部を有しない、平坦性が極めて良好な差厚金属板16を製造することができる。   As described above, the second manufacturing method according to the present invention has a high degree of freedom in design of the cross-sectional shape, can be easily changed in cross-sectional shape, and a welded portion that is a base point of quality defects is provided. It is possible to manufacture the differential thickness metal plate 16 which has no flatness and has very good flatness.
本発明を、実施例を参照しながら、より具体的に説明する。
図1〜8に示すようにして、差厚金属板16を製造した。すなわち、板厚t=3.0mm、板幅L=1200mm、長さL=200mmの590MPa級熱延鋼板1に3ロールベンダにて曲げ加工を加えて半径190mmの曲げ曲率を与え、その後、対向する長さLの辺1a,1bを突き合わせて抵抗溶接にて接合し、円筒部材2を製造した。
The present invention will be described more specifically with reference to examples.
A differential thickness metal plate 16 was manufactured as shown in FIGS. That is, a 590 MPa class hot-rolled steel sheet 1 having a sheet thickness t 0 = 3.0 mm, a sheet width L 1 = 1200 mm, and a length L 2 = 200 mm is subjected to bending by a three-roll bender to give a bending curvature having a radius of 190 mm, then, the length L 2 of the side 1a opposite, against the 1b are joined by resistance welding, to produce a cylindrical member 2.
この円筒部材2は、接合時に端面同志に圧力を加え若干周長を小さくして、相当内径を376mm〜381mmとした。なお、相当内径とは、円筒部材2の内周長の測定値を3.14で除算した値である。   The cylindrical member 2 was made to have an equivalent inner diameter of 376 to 381 mm by applying pressure to the end faces during joining to slightly reduce the circumference. The equivalent inner diameter is a value obtained by dividing the measured value of the inner peripheral length of the cylindrical member 2 by 3.14.
次いで、この円筒部材2に外径378mm、長さ600mmのマンドレル4を圧入した後、2ロール型のフローフォーミング装置13にて図4に示すように円筒部材2の中央部50mm幅に対してフローフォーミング加工を行い、図5に示すように長手方向の中央部に減肉部7を有する差厚円筒部材2−1とした。なお、円筒部材2に対する加工ロール5の押し込み量を変更するのみで、図6に示すようにt=1.0mm、1.5mmの差厚円筒部材2−1を作り分けた。なお、フローフォーミング加工では、マンドレル軸に対して対向するように直径が150mmの非駆動回転タイプの2個の加工ロール5を配置し、マンドレル4の回転数を800rpm、加工ロール5の送り速度を150mm/minとし、加工ロール5を減厚加工部で板厚方向(半径方向)に押し込むことにより行った。半径方向の押し込み速度は5mm/secとした。 Next, a mandrel 4 having an outer diameter of 378 mm and a length of 600 mm is press-fitted into the cylindrical member 2, and then the two-roll type flow forming apparatus 13 is used to flow against the central portion 50 mm width of the cylindrical member 2 as shown in FIG. Forming was performed to obtain a differential thickness cylindrical member 2-1 having a thinned portion 7 at the center in the longitudinal direction as shown in FIG. 5. Incidentally, only by changing the pushing amount of the work roll 5 with respect to the cylindrical member 2, it was separately formed t 1 = 1.0 mm, 1.5 mm of different thickness cylindrical member 2-1 as shown in FIG. In the flow forming process, two non-driven rotation type processing rolls 5 having a diameter of 150 mm are arranged so as to face the mandrel axis, the rotation speed of the mandrel 4 is set to 800 rpm, and the feed speed of the processing roll 5 is set. It was set to 150 mm / min, and it was performed by pushing the processing roll 5 in the thickness direction (radial direction) at the thickness reduction processed portion. The pushing speed in the radial direction was 5 mm / sec.
その後、レーザ切断装置を用いて溶接部3で差厚円筒部材2−1をレーザ切断し、溶接部3を除去した後、図7に示す直径60mmのロール9を3基有する曲げ矯正装置15にて一方の切断端部から展開加工を順次実施し、差厚鋼板16を製造した。   Thereafter, the differential thickness cylindrical member 2-1 is laser-cut by the welded portion 3 using a laser cutting device, and after removing the welded portion 3, the bending straightening device 15 having three rolls 9 having a diameter of 60 mm shown in FIG. Then, the differential thickness steel plate 16 was manufactured by sequentially performing the unfolding process from one cut end.
なお、差厚円筒部材2−1のなかの一部の部材は、直径で2%の拡管加工を行った後に溶接部3で切断して溶接部3を除去し、その後展開加工を行い差厚鋼板16を製造した。この拡管加工では、図13に示す、くさび状部材19と8個のセグメント12a〜12hから構成される分割金型12とを用い、くさび状部材19を押し込むことでセグメント12a〜12hを半径方向に移動させることにより、円筒部材2の軸方向全長にわたって均一に拡管加工を行った。   In addition, some members of the differential thickness cylindrical member 2-1 are subjected to tube expansion processing of 2% in diameter, then cut by the welded portion 3 to remove the welded portion 3, and then developed to perform the differential thickness. A steel plate 16 was produced. In this pipe expansion process, the wedge-shaped member 19 and the split mold 12 composed of the eight segments 12a to 12h shown in FIG. 13 are used, and the wedge-shaped member 19 is pushed in to move the segments 12a to 12h in the radial direction. By moving it, the tube expansion process was performed uniformly over the entire axial length of the cylindrical member 2.
得られた差厚鋼板16の平坦性を調査し、その結果を試験条件とともに表1にまとめて示す。この表1において平坦性を、△:可、○:良好、◎:極めて良好と表した。   The flatness of the obtained differential thickness steel plate 16 was investigated, and the results are shown in Table 1 together with the test conditions. In Table 1, the flatness was expressed as Δ: acceptable, ○: good, ◎: extremely good.
表1に示すように、本発明に係る方法により、平坦性が良好な差厚鋼板16の製造が可能であることを確認した。特に拡管加工を行うことにより差厚鋼板16の平坦性が一層向上することがわかった。   As shown in Table 1, it was confirmed that the differential thickness steel plate 16 with good flatness can be produced by the method according to the present invention. In particular, it was found that the flatness of the differential thickness steel plate 16 is further improved by performing the tube expansion process.
図1〜8に示すようにして、差厚金属板16を製造した。すなわち、板厚t=2.6mm、板幅L=1200mm、長さL=200mmの440MPa級熱延鋼板1に3ロールベンダにて曲げ加工を加えて半径190mmの曲げ曲率を与え、その後、対向する長さLの辺1a,1bを突き合わせて抵抗溶接にて接合し、相当内径380mmの円筒部材2を製造した。 A differential thickness metal plate 16 was manufactured as shown in FIGS. That is, a 440 MPa class hot-rolled steel sheet 1 having a sheet thickness t 0 = 2.6 mm, a sheet width L 1 = 1200 mm, and a length L 2 = 200 mm is subjected to bending by a 3-roll bender to give a bending curvature having a radius of 190 mm, then, the length L 2 of the side 1a opposite, against the 1b are joined by resistance welding, to produce a cylindrical member 2 of the equivalent inner diameter of 380 mm.
次いで、この円筒部材2を用い、直径150mmの2個の加工ローラ5を直径378mm、長さ600mmのマンドレル4の軸に対して対向して配置した2ロール型のフローフォーミング装置13にて、マンドレル回転数を1000rpmとし、ローラ5の送り速度を100mm/minとし、非駆動の加工ロール5の押し込み量を変更することで、差厚円筒部材21〜23を製造した。   Next, using this cylindrical member 2, a mandrel is formed by a two-roll type flow forming apparatus 13 in which two processing rollers 5 having a diameter of 150 mm are arranged opposite to the axis of the mandrel 4 having a diameter of 378 mm and a length of 600 mm. The differential thickness cylindrical members 21 to 23 were manufactured by changing the number of rotations to 1000 rpm, the feed speed of the roller 5 to 100 mm / min, and changing the push-in amount of the non-driven processing roll 5.
図15〜18は、いずれも、本実施例によるフローフォーミング加工後の差厚円筒部材21〜23の断面形態を示す説明図である。
図15に示す差厚円筒部材21は、長手方向に階段状の板厚分布を有するものであり、t=2.6mm、t=2.1mm、t=1.6mm、t=1.0mmである。図16に示す差厚円筒部材22は、長手方向に複数の薄肉部を有するものであり、t=2.6mm、t=1.0mmである。図17に示す差厚円筒部材23は、なだらかな板厚変化を有するものであり、t=2.6mm、t=1.0mmである。さらに、図18に示す差厚円筒部材24は、長手方向に複数の薄肉部を有するものであり、軸方向全体を加工することでt=3.0mmに対して、t=2.4mm、t=0.6mmである。
15-18 is explanatory drawing which shows the cross-sectional form of the differential thickness cylindrical members 21-23 after the flow forming process by a present Example, respectively.
The differential thickness cylindrical member 21 shown in FIG. 15 has a stepwise plate thickness distribution in the longitudinal direction, and t 0 = 2.6 mm, t 1 = 2.1 mm, t 2 = 1.6 mm, t 3 = 1.0 mm. The differential thickness cylindrical member 22 shown in FIG. 16 has a plurality of thin portions in the longitudinal direction, and t 0 = 2.6 mm and t 1 = 1.0 mm. The differential thickness cylindrical member 23 shown in FIG. 17 has a gentle plate thickness change, and t 0 = 2.6 mm and t 1 = 1.0 mm. Further, the differential thickness cylindrical member 24 shown in FIG. 18 has a plurality of thin portions in the longitudinal direction, and t 1 = 2.4 mm with respect to t 0 = 3.0 mm by machining the entire axial direction. , T 2 = 0.6 mm.
これらの差厚円筒部材21〜24に、12個のセグメントを有する分割金型12を用いて直径で3%の拡管加工を施した後、溶接部3で切断し、ロール曲げにて展開加工を施すことで、上述の断面を有する差厚鋼板16を得た。   These differential thickness cylindrical members 21 to 24 are subjected to a tube expansion process of 3% in diameter using a split mold 12 having 12 segments, then cut at the welded portion 3 and developed by roll bending. By applying, the difference thickness steel plate 16 which has the above-mentioned cross section was obtained.
図1〜8に示すように、板厚t=6.0mm、板幅L=1200mm、長さL2=400mmのA1050板1(アルミニウム)を曲げ加工した後、突き合わせ溶接にて内径378.5mmの円筒部材2を製作した。この円筒部材2を直径378mm、長さ600mmのマンドレル4に取付け後、2ロール型のフローフォーミング装置13を用いて円筒部材2の中央部100mm幅に対して減肉部の板厚t=3.0mmとなるようにフローフォーミング加工を行った。その後、直径で2%の拡管加工と切断、曲げ矯正機による展開加工を行うことにより、図8に示すL=500mm、L=約1200mmの差厚金属板16を得た。本実施例により、鋼板以外の金属板でも製造可能であることを確認した。 As shown in FIGS. 1-8, after bending A1050 plate 1 (aluminum) having a plate thickness t 0 = 6.0 mm, a plate width L 1 = 1200 mm, and a length L2 = 400 mm, an inner diameter of 378. A 5 mm cylindrical member 2 was produced. After the cylindrical member 2 is attached to the mandrel 4 having a diameter of 378 mm and a length of 600 mm, the plate thickness t 1 = 3 of the thinned portion with respect to the width of the central portion 100 mm of the cylindrical member 2 using the two-roll type flow forming apparatus 13. Flow forming was performed so that the thickness became 0.0 mm. After that, by performing tube expansion processing and cutting with a diameter of 2%, and development processing using a bending straightener, a differential thickness metal plate 16 having L 3 = 500 mm and L 1 = about 1200 mm shown in FIG. 8 was obtained. According to this example, it was confirmed that a metal plate other than a steel plate could be manufactured.
板厚t=3.0mm、板幅L=1200mm、長さL=200mmの熱間プレス用鋼板1を用いて実施例1と同様にして、図6に示すt=1.5mmの差厚円筒部材2を製作し、レーザ切断装置を用いて溶接部3で切断した後、3ロール曲げにて展開加工を実施した。熱間プレスのブランクとして用いるために長さを整え、図8に示すL=1000mm、L=250mm、中央薄厚部100mmの差厚鋼板16を製作した。 In the same manner as in Example 1 using the steel plate 1 for hot pressing having a plate thickness t 0 = 3.0 mm, a plate width L 1 = 1200 mm, and a length L 2 = 200 mm, t 1 = 1.5 mm shown in FIG. The differential thickness cylindrical member 2 was manufactured, cut by the welded portion 3 using a laser cutting device, and then developed by 3-roll bending. The length was adjusted for use as a blank for hot pressing, and a differential thickness steel plate 16 having L 1 = 1000 mm, L 3 = 250 mm, and a central thin portion 100 mm shown in FIG. 8 was produced.
なお、熱間プレス用鋼板は、EP規格:20MnB5(C:0.17−0.23%、Si:0.40%以下、Mn:1.10−1.40%、P:0.035%以下、S:0.040%以下、B:0.0008−0.0050%、残部:鉄および不純物、ただし、「%」は「質量%」である)を用いた。   In addition, the steel plate for hot press is EP standard: 20MnB5 (C: 0.17-0.23%, Si: 0.40% or less, Mn: 1.10-1.40%, P: 0.035%. Hereinafter, S: 0.040% or less, B: 0.0008-0.0050%, balance: iron and impurities, where “%” is “mass%”.
次に、幅100mmのハットを有する金型を用いて、熱間プレスを行った。熱間プレスでは、差厚鋼板を950℃に加熱した後に金型に装入し、プレス成形を行うとともに、下死点にて20秒間の保持を行うことにより金型内でA点からの急速冷却を行い、55mm高さ×130mm幅×1000mm長さのハット状の焼き入れビームに成形した。ハット頂部、縦壁、フランジ部の硬度を、長手方向にわたって調査した結果一様な硬度が得られていることを確認した。 Next, hot pressing was performed using a mold having a hat having a width of 100 mm. In the hot press, the differential thickness steel sheet is heated to 950 ° C. and then inserted into a mold, press-molded, and held for 20 seconds at the bottom dead center, so that from the A 1 point in the mold. Rapid cooling was performed to form a hat-shaped quenching beam of 55 mm height × 130 mm width × 1000 mm length. As a result of investigating the hardness of the hat top, the vertical wall, and the flange portion in the longitudinal direction, it was confirmed that uniform hardness was obtained.
1 金属板
2 円筒材
2−1 差厚円筒部材
3 突き合わせ溶接部
4 マンドレル
5 加工ロール
6 加工ロールの移動方向概略
7 減肉加工部
8 加工ロールの移動方向概略
9 曲げ加工ロール
9−1 支持ロール
9−2 昇降ロール
10 溶接部を含む切断箇所
11 曲げ加工押し金型
12 セグメント
13 フローフォーミング装置
14 開口部材
15 3ロールタイプの曲げ矯正装置
16 差厚板
17 曲げ矯正装置
18 プレス矯正装置
19 くさび状部材
20 金型
21〜24 差厚円筒部材
元板厚
,t,t 減肉加工後の板厚
DESCRIPTION OF SYMBOLS 1 Metal plate 2 Cylindrical material 2-1 Differential thickness cylindrical member 3 Butt weld part 4 Mandrel 5 Work roll 6 Process roll movement direction outline 7 Thinning process part 8 Process roll movement direction outline 9 Bending process roll 9-1 Support roll 9-2 Elevating roll 10 Cutting point including welded portion 11 Bending stamping die 12 Segment 13 Flow forming device 14 Opening member 15 3-roll type bending straightening device 16 Differential thickness plate 17 Bending straightening device 18 Press straightening device 19 Wedge shape Member 20 Die 21-24 Thickness difference cylindrical member t 0 original plate thickness t 1 , t 2 , t 3 Plate thickness after thickness reduction processing

Claims (5)

  1. 金属製の板を円筒状に曲げ成形し、その両端部を突き合わせ接合して長手方向に延びる接合部を有する円筒素材を製造する第1の工程と、
    該円筒素材の内部に装着した回転可能なマンドレルにより前記円筒素材を回転しながら、該円筒素材の外部に配置した加工ロールを前記円筒素材の肉厚方向に押圧するとともに長手方向に送り、前記加工ロールと前記マンドレルとにより該円筒素材の長手方向の全部または一部の領域の板厚を減少させる減厚加工を行い、長手方向に板厚が異なる差厚円筒部材を製造する第2の工程と、
    該差厚円筒部材の前記接合部を切断除去して湾曲した開口部材を製造し、次いで該開口部材を平板状に展開加工して差厚金属板を製造する第3の工程と
    を備えることを特徴とする差厚金属板の製造方法。
    A first step of bending a metal plate into a cylindrical shape, producing a cylindrical material having a joint extending in the longitudinal direction by butting and joining both ends thereof;
    While rotating the cylindrical material by a rotatable mandrel mounted inside the cylindrical material, the processing roll disposed outside the cylindrical material is pressed in the thickness direction of the cylindrical material and sent in the longitudinal direction, and the processing A second step of manufacturing a differential thickness cylindrical member having a plate thickness different in the longitudinal direction by performing a thickness reduction process for reducing the plate thickness of all or part of the longitudinal direction of the cylindrical material by the roll and the mandrel; ,
    A third step of producing a curved opening member by cutting and removing the joining portion of the differential thickness cylindrical member, and then developing the opening member into a flat plate shape to produce a differential thickness metal plate. A method for producing a differential thickness metal plate.
  2. 金属製の板を円筒状に曲げ成形し、その両端部を突き合わせ接合して長手方向に延びる接合部を有する円筒素材を製造する第1の工程と、
    該円筒素材の内部に装着したマンドレルにより前記円筒素材を回転しながら、該円筒素材の外部に配置した加工ロールを前記円筒素材の肉厚方向に押圧するとともに長手方向に送り、前記加工ロールと前記マンドレルとにより該円筒素材の長手方向の全部または一部の領域の板厚を減少させる減厚加工を行い、長手方向に板厚が異なる差厚円筒部材を製造する第2の工程と、
    前記差厚円筒部材の内径を拡大する拡管加工を行う拡管工程と、拡管された前記差厚円筒部材の前記接合部を切断除去して湾曲した開口部材を製造し、次いで該開口部材を平板状に展開加工して差厚金属板を製造する第3の工程と
    を備えることを特徴とする差厚平板の製造方法。
    A first step of bending a metal plate into a cylindrical shape, producing a cylindrical material having a joint extending in the longitudinal direction by butting and joining both ends thereof;
    While rotating the cylindrical material with a mandrel mounted inside the cylindrical material, the processing roll disposed outside the cylindrical material is pressed in the thickness direction of the cylindrical material and sent in the longitudinal direction, and the processing roll and the A second step of manufacturing a differential cylindrical member having a plate thickness different in the longitudinal direction by performing a thickness reduction process for reducing the plate thickness of all or part of the longitudinal direction of the cylindrical material with a mandrel;
    A tube expanding step for expanding the inner diameter of the differential thickness cylindrical member, and manufacturing a curved opening member by cutting and removing the joint portion of the expanded differential thickness cylindrical member, and then forming the opening member into a flat plate shape And a third step of producing a differential thickness metal plate by developing the difference thickness flat plate.
  3. 前記拡管加工は、前記差厚円筒部材の内部に周方向に分割した金型を装入し、前記金型を半径方向に移動させることにより行う請求項2に記載された差厚金属板の製造方法。   3. The manufacturing of the differential thickness metal plate according to claim 2, wherein the pipe expanding process is performed by inserting a mold divided in a circumferential direction into the differential thickness cylindrical member and moving the mold in a radial direction. Method.
  4. 請求項1から請求項3までのいずれか1項に記載された差厚金属板の製造方法により製造されてなることを特徴とする差厚金属板。   A differential thickness metal plate manufactured by the method for manufacturing a differential thickness metal plate according to any one of claims 1 to 3.
  5. 熱間プレス用素材として用いられる請求項4に記載された差厚金属板。   The differential thickness metal plate according to claim 4, which is used as a material for hot pressing.
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CN110479922B (en) * 2019-08-02 2020-08-04 武汉理工大学 Large thin-wall external T-shaped annular component constraint rolling forming method
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CN110479928A (en) * 2019-08-02 2019-11-22 武汉理工大学 The split type space envelope manufacturing process of large-scale complex thin-wall abnormal shape annular construction member
CN110479922A (en) * 2019-08-02 2019-11-22 武汉理工大学 The outer T shape annular component of large thin-wall constrains roll-forming method
CN110479928B (en) * 2019-08-02 2021-10-22 武汉理工大学 Split type space envelope forming method for large-scale complex thin-wall special-shaped annular component

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