JP2012110941A - Method for manufacturing member with various thicknesses, and member with various thicknesses - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a member with various thicknesses, which manufactures an elongated member with various thicknesses, and which has partly different plate thicknesses from each other, without welding.SOLUTION: The method for manufacturing the elongated member 10, 20 with various thicknesses, which has partly different plate thicknesses from each other, includes: a rolling step 30 of rolling a part of an elongated plate material 1 with substantially uniformed plate thickness and obtaining a material 2, 3, 4 with various thicknesses, in which a plate thickness of a rolled part 3a, 4a is thinner than that of a non-rolled part 3b, 4b; and a roll forming step 80 of forming the material with various thicknesses by roll forming.

Description

  The present invention relates to a method for manufacturing a differential thickness member and a differential thickness member. Specifically, the present invention relates to a method for manufacturing a long-shaped differential thickness member having a partially different plate thickness, and a differential thickness member manufactured thereby.

  Conventionally, weight reduction of automobiles has been widely studied, and the demand for weight reduction extends to reinforcing members having various cross-sectional shapes. The reinforcing member only needs to have the necessary strength in the necessary portion. Therefore, the portion requiring strength has a large plate thickness, and the portion that does not require much strength, such as holding other parts, may have a small thickness. . For such applications, long-shaped differential thickness members having partially different plate thicknesses are used.

Conventionally, in order to manufacture a differential thickness member, there is a technique in which a thick plate and a thin plate are prepared, joined together (butt welding) to create a differential thickness material, and the differential thickness material is wound into a tubular shape. (For example, refer to Patent Document 1).
It is also possible to manufacture differential thickness members having various cross-sectional shapes by press molding the differential thickness materials obtained by joining.

JP 2004-337887 A

  Conventionally, however, a joining step is required because a thick plate and a thin plate are joined to create a differential thickness material. The resulting differential thickness material has a large change in material properties at the joint due to work hardening due to plate thickness difference and heat input at the weld. Therefore, when the differential thickness member formed from the differential thickness material is applied to an automobile, continuous winding or bending (for example, roll forming) is performed, but with a uniform processing force in the longitudinal direction of the differential thickness member. Even if the processing is performed, there is a possibility that distortion or the like may occur in the vicinity of the joint portion which is a boundary portion where the plate thickness changes.

  The present invention has been made in view of the above-described problems, and provides a manufacturing method for a differential thickness member and a differential thickness member for manufacturing a long differential thickness member having a partially different plate thickness without welding. The purpose is to do.

  The manufacturing method of the differential thickness member of the present invention is a method of manufacturing an elongated differential thickness member (for example, differential thickness members 10 and 20 described later) having partially different plate thicknesses, and the plate thickness is substantially uniform. A part of a long plate material (for example, plate material 1 described later) is rolled, and the remaining thickness (for example, non-rolled portions 3b, 4b described later) of the rolled portion (for example, rolled portions 3a, 4a described later) remains. Rolling process (for example, a rolling process 30 described later) for obtaining a differential thickness material (for example, a differential thickness material 2, 3, 4 described later) thinner than the plate thickness, and a molding process for forming the differential thickness material by roll forming (For example, a roll forming step 80 described later).

According to this invention, a differential thickness material is obtained by rolling from a long plate material having a substantially uniform thickness. Therefore, the change in material properties at the boundary portion where the plate thickness changes is smaller than that in the case of obtaining a differential thickness material by welding.
Therefore, distortion is unlikely to occur at the boundary portion when molding by roll forming.

  In this case, in the rolling step, the rolled portion is uneven so that an apparent thickness (for example, a thickness t1 described later) is the same as a thickness of the remaining portion (for example, a thickness t1 described later). It is preferable to shape the shape (for example, convex portions 55a and 65a and concave portions 55b and 65b described later).

  According to the present invention, the apparent thickness of the rolled portion and the remaining plate thickness are made uniform. Therefore, even if the rolling part and the remaining part are roll-formed by a common roller, the roller can be surely brought into contact with the rolling part and the remaining part, and can be formed into a desired shape.

  In this case, in the rolling step, when viewed at an arbitrary position in the width direction of the plate material, the plurality of convex portions (for example, convex portions 55a and 65a described later) and concave portions (for example, concave portions 55b described later), Preferably, 65b) is mixed along the longitudinal direction of the plate material.

  According to this invention, even if a bending line is set at any position in the width direction of the plate material, a convex portion and a concave portion are mixed on the bending line. Therefore, there is no great difference in bending strength necessary for the bending process depending on the position of the bending line, and the bending process can be performed at a desired bending line position.

  In this case, it is preferable that the said rolling part equips the top part of the said uneven | corrugated shape with a flat part (for example, flat part 3c, 4c mentioned later).

  According to this invention, lap welding can be easily performed using the flat portion.

  The differential thickness member of the present invention (for example, a differential thickness member 20 described later) includes a first differential thickness portion (for example, a non-rolled portion 3b described below) having a first plate thickness (for example, a thickness t1 described below), A differential thickness plate material (for example, a differential thickness material 3 to be described later) having a second differential thickness part (for example, a rolling portion 3a to be described later) having a thickness (for example, a thickness t2 to be described later) smaller than the first plate thickness. In the differential thickness member welded to the other member, the second differential thickness portion has an uneven shape so that the apparent thickness is the same as that of the first differential thickness portion.

  According to this invention, when other members are combined across the first differential thickness portion and the second differential thickness portion, the apparent thickness of the second differential thickness portion is the same as the first differential thickness portion, Positioning with other members can be easily performed. Further, the rigidity can be improved by the uneven shape.

According to the present invention, a differential thickness material is obtained by rolling from a long plate material having a substantially uniform thickness. Therefore, the change in material properties at the boundary portion where the plate thickness changes is smaller than that in the case of obtaining a differential thickness material by welding.
Therefore, distortion is unlikely to occur at the boundary portion when molding by roll forming.

It is a figure which shows the difference thickness member manufactured by the manufacturing method which concerns on 1st Embodiment of this invention, (a) is a perspective view, (b) is sectional drawing along the AA. It is a schematic plan view which shows the manufacturing method of the differential thickness member which concerns on 1st Embodiment of this invention. It is sectional drawing which shows the rolling process of FIG. It is sectional drawing which shows the trim process of FIG. It is sectional drawing which shows the roll forming process of FIG. It is sectional drawing which shows the roll forming process of FIG. It is sectional drawing which shows the roll forming process of FIG. It is sectional drawing which shows the roll forming process of FIG. It is sectional drawing which shows the roll forming process of FIG. It is a figure which shows the difference thickness member manufactured by the manufacturing method which concerns on 2nd Embodiment of this invention, (a) is a perspective view, (b) is sectional drawing along the BB line, (c) is C It is sectional drawing along the -C line. It is a schematic plan view of the principal part which shows the manufacturing method of the differential thickness member which concerns on 2nd Embodiment of this invention. It is sectional drawing which shows the rolling process of FIG. FIG. 8 is a cross-sectional view showing a difference in bending accuracy between a non-rolled part and a rolled part in the rolling process of FIG. 7. It is a figure which shows the difference thickness member formed so that the apparent thickness of a rolling part may be the same as the thickness of a non-rolling part, (a) is sectional drawing, (b) is sectional drawing which shows a bending precision. It is a figure which shows the rolling roller for manufacturing a differential thickness member with the manufacturing method which concerns on 3rd Embodiment of this invention, (a) is a side view, (b) is sectional drawing along DD line. . It is a figure which shows the difference thickness material rolled with the rolling roller of FIG. 11, (a) is a schematic plan view, (b) is sectional drawing along EE line, (c) is FF line FIG. It is a figure which shows the rolling roller for manufacturing a differential thickness member with the manufacturing method which concerns on 4th Embodiment of this invention, (a) is a side view, (b) is sectional drawing along the GG line. . It is a figure which shows the difference thickness material rolled with the rolling roller of FIG. 13, (a) is a schematic plan view, (b) is sectional drawing along the HH line, (c) is II line FIG. It is sectional drawing which shows the difference in the bending position precision of the difference thickness material of FIG. 12, and the difference thickness material of FIG. It is a figure which expand | deploys and shows the surface shape of another rolling roller, (a) is a side view, (b) is sectional drawing along JJ line, (c) is sectional drawing along KK line It is. It is a perspective view which expand | deploys and shows the surface shape of another rolling roller. It is a perspective view which expand | deploys and shows the surface shape of another rolling roller. It is a perspective view which expand | deploys and shows the surface shape of another rolling roller.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
<First Embodiment>
Drawing 1 is a perspective view (a) and AA sectional view (b) of differential thickness member 10 manufactured by the manufacturing method concerning a 1st embodiment of the present invention.
The differential thickness member 10 is a long member having a substantially rectangular cross section, and includes a rectangular portion 11 and a protruding portion 12 that protrudes outward from the rectangular portion 11. The rectangular portion 11 and the overhang portion 12 are connected via a boundary portion 13. The rectangular portion 11 is formed in a rectangular shape by the bent portions b1, b2, and b3. The overhang portion 12 is formed thinner than the rectangular portion 11. The thin part (overhang part) 12 is shown with dots.

2 is a schematic plan view showing a manufacturing method of the differential thickness member 10, FIG. 3 is a cross-sectional view of a rolling process 30, FIG. 4 is a cross-sectional view of a trim process 70, and FIG. 5 is a cross-section of a roll forming process 80 as a forming process. FIG.
The differential thickness member 10 is manufactured by being processed in the order of the rolling step 30, the trim step 70, and the roll forming step 80.

First, the long plate material 1 having a substantially uniform plate thickness is introduced into the rolling step 30 while being rewound from a rolled state (not shown). In the rolling process 30, the front and back surfaces of the plate material 1 are pressed between the rolling rollers 31 a and 31 b so as to increase the thickness of the plate material 1.
The rolling rollers 31 a and 31 b roll only a predetermined portion of the full width of the plate material 1. That is, the rolling rollers 31a and 31b include pressing portions 32a and 32b that press the front and back surfaces of the plate material 1 and non-pressing portions 33a and 33b that do not press the front and back surfaces of the plate material 1 along the axial direction of the rollers. Prepare separately.

The long plate material 1 having a substantially uniform plate thickness is rolled thin by rolling the portions of the rolling rollers 31a and 31b that pass through the pressing portions 32a and 32b.
The portion of the plate 1 that passes through the non-pressurizing portions 33a and 33b of the rolling rollers 31a and 31b is not rolled.
Therefore, the plate material 1 is formed on the differential thickness material 2 by passing through the rolling rollers 31a and 31b.

The boundary portion of the differential thickness member 2 (see the boundary portion 13 of the differential thickness member 10) is formed by rolling the elongated plate member 1 having a substantially uniform plate thickness. There is no work hardening due to heat input.
Therefore, the change of the material characteristic in the boundary part 13 can be made smaller compared with the case of welding joining.
Therefore, when the differential thickness material 2 is roll-formed in the roll forming step 80, there is less possibility that distortion or the like will occur in the vicinity of the boundary portion 13 as compared with the case where the boundary portion is welded.

The boundary portion 13 of the differential thickness material 2 is not a so-called linear boundary portion where the plate thickness changes suddenly at the boundary portion, but from the non-rolling side (refer to the rectangular portion 11 side of the differential thickness member 10) to the rolling side (difference). You may form in the strip | belt shape which has the inclined surface which thickness decreases gradually toward the overhang | projection part 12 side of the thick member 10).
That is, the width of the band of the boundary portion 13 can be set to an arbitrary width according to the shape of the boundary portion between the pressing portions 32a and 32b and the non-pressing portions 33a and 33b of the rolling rollers 31a and 31b. The thickness difference between 11 and the rolling side 12 may be rolled so as to change little by little.
If formed in this way, the change in the material properties at the boundary portion 13 can be further reduced as compared with the case of welding joint.
Therefore, when the differential thickness material 2 is roll-formed in the roll forming step 80, there is less possibility that distortion or the like will occur in the vicinity of the boundary portion 13 as compared with the case where the boundary portion is welded.

The differential thickness material 2 output from the rolling process 30 is then introduced into the trim process 70. In the trim process 70, the front and back surfaces of the differential thickness material 2 are cut by being sandwiched between the trim rollers 71a and 71b.
The trim rollers 71 a and 71 b include cutting blades 72 a and 72 b at the left and right positions of a predetermined cutting width of the differential thickness material 2.
The differential thickness material 2 is cut into a predetermined cutting width by passing through the trim rollers 71a and 71b.

The differential thickness material 2 output from the trimming process 70 is then introduced into the roll forming process 80. In the roll forming step 80, a large number of mold rollers 90a and 90b are arranged along the feeding direction of the differential thickness material 2, and the differential thickness material 2 is passed through the gap 90G between the opposing mold rollers 90a and 90b. Processing for forming the cross-sectional shape of the differential thickness material 2 into an arbitrary shape is performed.
The mold rollers 90a and 90b are arranged as shown in FIG. 5, for example. The mold rollers 90a and 90b include non-bending rollers 91a and 91b described below, intermediate bending rollers 92a and 92b of the bending portions b1 and b3 of the differential thickness member 10, and final bending rollers 93a and 93b of the bending portions b1 and b3. Intermediate bending rollers 94a and 94b of the bending portion b2 of the differential thickness member 10, final bending rollers 95a and 95b of the bending portion b2, and the like are included.

First, as shown in FIG. 5A, the peripheral surface is formed in a cylindrical shape, the rotation axis is parallel, and a pair of upper and lower non-bending rollers 91a and 91b are arranged.
The differential thickness material 2 introduced into the roll forming step 80 and including the bent portions b1, b2, and b3 of the differential thickness member 10 in a flat state passes through the gap 91G between the non-bending rollers 91a and 91b. It is positioned and held in preparation for the subsequent bending process while the whole is flat.

Next, as shown in FIG. 5 (b), the intermediate bending roller whose peripheral surface is formed in a convex shape having a bent portion with an angle of approximately 45 ° at a portion corresponding to the bent portions b1 and b3 of the differential thickness member 10. 92a and an intermediate bending roller 92b formed in the same concave shape are arranged vertically with their rotation axes parallel to each other.
When the differential thickness material 2 passes through the gap 92G between the intermediate bending rollers 92a and 92b, the portions corresponding to the bending portions b1 and b3 of the differential thickness member 10 are bent and formed at an angle of approximately 45 °.

Although not shown, between the non-bending rollers 91a and 91b shown in FIG. 5A and the intermediate bending rollers 92a and 92b shown in FIG. 5B, the bent portions b1 and b3 of the differential thickness member 10 are provided. In order to gradually bend the portion corresponding to, a large number of bending rollers whose bending angles (0 ° to 45 °) are gradually increased are arranged. These bending rollers are also included in the mold rollers 90a and 90b.
The difference thickness material 2 passes through the gaps between these many bending rollers in order, so that the portions corresponding to the bending portions b1 and b3 of the difference thickness member 10 gradually increase the bending angle (0 ° to 45 °). I will do it.

Next, as shown in FIG. 5 (c), the final bending roller whose peripheral surface is formed in a convex shape having a bent portion with an angle of approximately 90 ° at a portion corresponding to the bent portions b1 and b3 of the differential thickness member 10. 93a and a final bending roller 93b formed in the same concave shape are arranged vertically with their rotation axes parallel to each other.
The differential thickness material 2 passes through the gap 93G between the final bending rollers 93a and 93b, and the portions corresponding to the bent portions b1 and b3 of the differential thickness member 10 are bent and formed at an angle of approximately 90 °.

Although not shown, between the intermediate bending rollers 92a and 92b shown in FIG. 5B and the final bending rollers 93a and 93b shown in FIG. 5C, the bending portions b1 and b3 of the differential thickness member 10 are provided. In order to gradually bend the portion corresponding to, a large number of bending rollers whose bending angles (45 ° to 90 °) gradually increase are arranged. These bending rollers are also included in the mold rollers 90a and 90b.
The difference thickness material 2 passes through the gaps between these many bending rollers in order, so that the portions corresponding to the bending portions b1 and b3 of the difference thickness member 10 gradually increase the bending angle (45 ° to 90 °). I will do it.

Next, as shown in FIG. 5 (d), the peripheral surface corresponds to the bent portion b 2 while maintaining a bent portion having an angle of approximately 90 ° at a portion corresponding to the bent portions b 1 and b 3 of the differential thickness member 10. An intermediate bending roller 94a formed in a convex shape having a bent portion with an angle of approximately 45 ° at a portion and an intermediate bending roller 94b formed in the same concave shape are arranged above and below with their rotation axes parallel to each other.
When the differential thickness material 2 passes through the gap 94G between the intermediate bending rollers 94a and 94b, a portion corresponding to the bending portion b2 of the differential thickness member 10 is bent and formed at an angle of approximately 45 °.

Although not shown, the gap between the final bending rollers 93a and 93b shown in FIG. 5C and the intermediate bending rollers 94a and 94b shown in FIG. 5D corresponds to the bending portion b2 of the differential thickness member 10. In order to bend the part to be gradually bent, a large number of bending rollers whose bending angles (0 ° to 45 °) gradually increase are arranged. These bending rollers are also included in the mold rollers 90a and 90b.
The thickness difference material 2 passes through the gaps between the plurality of bending rollers in order, so that the portion corresponding to the bending portion b2 of the thickness difference member 10 gradually increases the bending angle (0 ° to 45 °). Go.

Next, as shown in FIG. 5 (e), the peripheral surface corresponds to the bent portion b 2 while maintaining the bent portion at an angle of approximately 90 ° at the portion corresponding to the bent portions b 1 and b 3 of the differential thickness member 10. A final bending roller 95a formed in a convex shape having a bent portion with an angle of approximately 90 ° at a portion and a final bending roller 95b formed in a similar concave shape are arranged above and below with their rotation axes parallel to each other.
By passing the gap 95G between the final bending rollers 95a and 95b, the portion corresponding to the bending portion b2 of the differential thickness member 10 is bent at an angle of approximately 90 °.

Although not shown, between the intermediate bending die rollers 94a and 94b shown in FIG. 5 (d) and the final bending rollers 95a and 95b shown in FIG. 5 (e), the bending portion b2 of the differential thickness member 10 is provided. In order to gradually bend the portion corresponding to, a large number of bending rollers whose bending angles (45 ° to 90 °) gradually increase are arranged. These bending rollers are also included in the mold rollers 90a and 90b.
The differential thickness material 2 is made to pass through the gaps between these many bending rollers in order, so that the portion corresponding to the bending portion b2 of the differential thickness member 10 gradually increases the bending angle (45 ° to 90 °). Go.

  After the rolling process, the trim process, and the forming (roll forming) process are sequentially performed, the thickness difference member 10 as shown in FIG. 1 is manufactured by cutting into a predetermined length.

According to the first embodiment, there are the following effects.
(1) A differential thickness material 2 is obtained from a long plate material 1 having a substantially uniform thickness by rolling. Therefore, the change of the material characteristic in the boundary part 13 in which plate | board thickness changes is small compared with the case where a difference thickness material is obtained by welding.
Therefore, distortion is unlikely to occur at the boundary portion 13 when molding by roll forming.

Second Embodiment
FIG. 6 is a perspective view (a), a BB sectional view (b), and a CC sectional view (c) of the differential thickness member 20 manufactured by the manufacturing method according to the second embodiment of the present invention. .
The differential thickness member 20 is a long member having a substantially rectangular cross section, and includes a rectangular portion 21 and a protruding portion 22 that protrudes outward from the rectangular portion 21. Including the rectangular portion 21 and the overhang portion 22, the differential thickness member 20 has a middle portion in the longitudinal direction as a boundary portion 23, and one end side (upper right portion in FIG. 6A) 24 is at the other end side. (The lower left portion in FIG. 6A) is formed thinner than 25. The thin portion 24 is shown with dots.

FIG. 7 is a schematic plan view showing a manufacturing method of the differential thickness member 20, and FIG. 8 is a cross-sectional view of the rolling process 30, and a roll forming process as a forming process is not shown. Since the description of the roll forming process 80 described above with respect to the differential thickness member 10 of the first embodiment is applied as it is with reference to FIGS. 2 and 5, the roll forming process is performed in the roll forming method of the differential thickness member 20 of the present embodiment. The description of the forming process is also used, and the same reference numerals are used for each part.
Although the trimming process 70 is illustrated, the description of the trimming process 70 described above with reference to the differential thickness member 10 of the first embodiment is also used with reference to FIGS. 2 and 4.
The differential thickness member 20 is manufactured by being processed in the order of the rolling step 30, the trim step 70, and the roll forming step 80.

First, the long plate material 1 having a substantially uniform plate thickness is introduced into the rolling step 30 while being rewound from a rolled state (not shown). In the rolling step 30, as shown in FIG. 8, the front and back surfaces of the plate material 1 are pressed between the rolling rollers 41 a and 41 b to press the plate material 1 so that the thickness of the plate material 1 is reduced.
The rolling rollers 41a and 41b alternately repeat a predetermined length of rolling along the longitudinal direction of the plate member 1 and another non-rolling of a predetermined length. In other words, the rolling rollers 41a and 41b include pressing portions 42a and 42b that press both the front and back surfaces of the plate material 1 and non-pressing portions 43a and 43b that do not press the front and back surfaces of the plate material 1 along the circumferential direction. Prepare separately.
The plate material 1 is rolled thinly by rolling the portions of the rolling rollers 41a and 41b that pass through the pressure portions 42a and 42b.
The plate material 1 in a portion passing through the non-pressurizing portions 43a and 43b of the rolling rollers 41a and 41b is not rolled.
Therefore, the plate material 1 is formed on the differential thickness material 3 by passing through the rolling rollers 41a and 41b.

As described above with respect to the boundary portion of the differential thickness member 2 (see the boundary portion 13 of the differential thickness member 10), the boundary portion of the differential thickness member 3 (see the boundary portion 23 of the differential thickness member 20) has a substantially equal plate thickness. It is formed by rolling a uniform long plate 1 and is not welded, so there is no work hardening due to heat input.
Therefore, the change of the material characteristic in the boundary part 23 can be made smaller compared with the case of welding joining.
Therefore, when the differential thickness material 3 is roll-formed in the roll forming step 80, there is less risk that distortion or the like will occur in the vicinity of the boundary portion 23 as compared with the case where the boundary portion is welded.

The boundary portion 23 of the differential thickness material 3 is not a so-called linear boundary portion in which the plate thickness changes suddenly at the boundary portion, but a strip shape having an inclined surface in which the thickness gradually decreases from the non-rolling side to the rolling side. You may form in.
That is, the width of the band of the boundary portion 23 can be set to an arbitrary width according to the shape of the boundary portion between the pressing portions 42a and 42b and the non-pressing portions 43a and 43b of the rolling rollers 41a and 41b. Rolling may be performed so that the wall thickness difference between and the rolling side changes little by little.
If formed in this way, the change in the material properties at the boundary portion 23 can be further reduced as compared with the case of welding joint.
Therefore, when the differential thickness material 3 is roll-formed in the roll forming step 80, the risk of distortion or the like in the vicinity of the boundary portion 23 is even smaller than when the boundary portion is welded.

In the differential thickness material 3 output from the rolling process 30, the rolling portions 3 a and the remaining non-rolled portions 3 b are alternately formed along the feed direction of the differential thickness material 3. This differential thickness material 3 is then introduced into the trim step 70. In the trim process 70, the front and back surfaces of the differential thickness material 3 are cut by being sandwiched between trim rollers 71a and 71b.
Specifically, it is the same as the case of the differential thickness member 10 of the first embodiment.

The differential thickness material 3 output from the trimming process 70 is then introduced into the roll forming process 80. In the roll forming step 80, a large number of mold rollers 90a and 90b are arranged along the feeding direction of the differential thickness material 3, and the differential thickness material 3 is passed through the gap 90G between the opposing mold rollers 90a and 90b. Processing for forming the cross-sectional shape of the differential thickness material 3 into an arbitrary shape is performed.
Specifically, it is the same as the case of the differential thickness member 10 of the first embodiment.

  After the rolling process, the trim process, and the forming (roll forming) process are sequentially performed, the thickness difference member 20 as shown in FIG. 6 is manufactured by cutting into a predetermined length.

According to the second embodiment, there are the same effects as in (1). That is,
(2) The differential thickness material 3 is obtained from the long plate material 1 having a substantially uniform thickness by rolling. Therefore, the change of the material characteristic in the boundary part 23 in which plate thickness changes is small compared with the case where a differential thickness material is obtained by welding.
Therefore, when forming by roll forming, the boundary portion 23 is unlikely to be distorted.

<Third Embodiment>
Here, the configuration of the thin portion that is bent in the roll forming step 80, such as the thin portion 24 of the differential thickness member 20, will be specifically described with reference to FIGS.
In the case of the differential thickness member 3 from which the differential thickness member 20 is obtained, the rolled portions 3 a and the non-rolled portions 3 b are alternately formed along the feed direction of the differential thickness material 3.
In the roll forming step 80, the gap 90G between the bending die rollers 90a and 90b is formed to be equal to the thickness of the relatively thick non-rolled portion 3b among the rolled portion 3a and the non-rolled portion 3b of the differential thickness material 3.
In the case of the differential thickness material 3 in which the rolling portion 3a and the non-rolled portion 3b are alternately formed along the feeding direction, the gap 90G between the bending die rollers 90a and 90b is formed in the rolling portion 3a of the differential thickness material 3. In contrast, the thickness of the non-rolled portion 3b cannot be changed.

Therefore, as shown in FIG. 9A, the gap 90G between the bending die rollers 90a and 90b is formed to be equal to the thickness of the non-rolled portion 3b of the differential thickness material 3, so When the rolling portion 3b passes through the gap 90G between the bending die rollers 90a and 90b, the non-rolling portion 3b is brought into close contact with the bending die rollers 90a and 90b and is bent exactly as the gap 90G.
On the other hand, as shown in FIG. 9 (b), when the rolled part 3a of the differential thickness material 3 passes through the gap 90G between the bending die rollers 90a and 90b, the rolling part 3a has the bending die roller 90a, Since it does not adhere to 90b, it cannot be bent exactly as the gap 90G, and it is inevitable that the bending accuracy is lowered.

  Therefore, as shown in FIG. 10A, an uneven shape is formed in the rolled portion 3 a of the differential thickness material 3 when viewed in cross section. That is, when the thickness of the non-rolled portion 3b of the differential thickness material 3 is t1, and the thickness of the rolled portion 3a is t2, an uneven shape is formed in the thickness direction of the rolled portion 3a, and the rolling portion 3a of the differential thickness material 3 is formed. The apparent thickness is formed equal to the thickness t1 of the non-rolled portion 3b. Here, the “apparent thickness” of the rolled portion 3 a of the differential thickness material 3 is the distance between the uppermost portion and the lowermost portion of the uneven portion in the plate thickness direction of the differential thickness material 3.

  By doing in this way, as shown in FIG.10 (b), even when the rolling part 3a of the differential thickness material 3 passes the gap 90G between the bending die rollers 90a and 90b, the non-rolling part of the differential thickness material 3 When 3b passes through the gap 90G between the bending die rollers 90a and 90b (see FIG. 9A), the rolling part 3a is in close contact with the bending die rollers 90a and 90b and exactly as in the gap 90G. Bend.

A method for forming such an uneven shape will be described.
FIG. 11 shows a side view (a) and a DD sectional view (b) of the rolling rollers 51a and 51b in the present embodiment.
As shown in FIGS. 11 (a) and 11 (b), the rolling rollers 51a and 51b are pressurizing portions 52a that pressurize both the front and back surfaces of a long plate 1 having a substantially uniform thickness on the peripheral surfaces thereof. , 52b and non-pressurizing portions 53a, 53b that do not pressurize both the front and back surfaces of the plate 1 are formed along the circumferential direction.
The pressurizing portion 52a of the rolling roller 51a has a large number of quadrangular pyramid-shaped convex portions 55a on its peripheral surface.
The pressurizing portion 52b of the rolling roller 51b has a large number of inverted quadrangular frustum-shaped concave portions 55b on its peripheral surface.
The convex portion 55a of the rolling roller 51a and the concave portion 55b of the rolling roller 51b are arranged corresponding to each other.
The plate part 1 passes through the pressing parts 52a and 52b of the rolling rollers 51a and 51b, thereby forming the rolling part 3a.
The plate material 1 becomes a non-rolled portion 3b by passing through the non-pressurized portions 53a and 53b of the rolling rollers 51a and 51b.

FIG. 12 is a schematic plan view (a) of the differential thickness material 3 processed using the rolling rollers 51a and 51b in the rolling step 30 of the manufacturing method according to the present embodiment, and an EE cross-sectional view (b). It is FF sectional drawing (c).
The differential thickness material 3 is formed with a rolled portion 3a and a non-rolled portion 3b as a remaining portion, and the uneven shape on the surface of the pressing portions 52a and 52b of the rolling rollers 51a and 51b is transferred to the rolled portion 3a. ing.
That is, in the EE cross section shown in FIG. 12B, a large number of quadrangular frustum-shaped convex portions 55a and inverted quadrangular frustum-shaped concave portions 55b are formed.
In the FF cross section shown in FIG. 12C, the quadrangular frustum-shaped convex portion 55a and the inverted quadrangular frustum-shaped concave portion 55b are not formed at all.
Furthermore, as shown in the EE cross section of FIG. 12B and the FF cross section of FIG. 12C, a flat portion 3c suitable for lap welding is formed on the top surface of the rolled portion 3a. Has been.

According to 3rd Embodiment, in addition to the effect of said (2), there exist the following effects.
(3) The apparent thickness t1 of the rolled part 3a and the plate thickness t1 of the non-rolled part 3b are made uniform. Therefore, even if the rolling part 3a and the non-rolling part 3b are roll-formed by the common rollers 90a and 90b, the rollers 90a and 90b can be reliably brought into contact with the rolling part 3a and the non-rolling part 3b. It can be formed into a desired shape.
(4) The differential thickness material 3 can be easily lap welded using the flat portion 3c.
(5) The difference thickness material 3 can improve rigidity by uneven | corrugated shape.

<Fourth embodiment>
FIG. 13: shows the side view (a) and GG sectional drawing (b) of the rolling rollers 61a and 61b in 4th Embodiment.
The rolling rollers 61a and 61b are different from the rolling rollers 51a and 51b shown in FIG. 11 in that the quadrangular frustum-shaped convex portions 65a and the inverted quadrangular frustum-shaped concave portions 65b are formed in a staggered manner.

FIG. 14 is a schematic plan view (a) and a HH sectional view (b) of the differential thickness material 4 processed using the rolling rollers 61a and 61b in the rolling step 30 of the manufacturing method according to the present embodiment. It is II sectional drawing (c).
The differential thickness material 4 is formed with a rolled portion 4a and a non-rolled portion 4b as a remaining portion. The uneven shape on the surfaces of the pressure portions 62a and 62b of the rolling rollers 61a and 61b is transferred to the rolled portion 4a. ing.
Furthermore, as shown in the HH cross section of FIG. 14B and the II cross section of FIG. 14C, a flat portion 4c suitable for lap welding is formed on the top surface of the rolled portion 4a. Has been.

In the case of the differential thickness material 3 processed by the rolling rollers 51a and 51b shown in FIG. 11, the FF cross section shown in FIG. 12 (c) has a quadrangular frustum-shaped convex portion 55a and an inverted quadrangular frustum-shaped concave portion. 55b is not formed at all.
Therefore, as shown in FIG. 15A, the hit in the mold rollers 90a and 90b varies depending on the position of the differential thickness material 3, and the bending position may deviate from the target position.

For example, when the thickness difference material 3 is bent along the EE cross section shown in FIG. 12B and the case where the differential thickness material 3 is bent along the FF cross section shown in FIG. In the case of bending along the FF cross section, the bending strength required for the bending is small, so that bending is easier.
Therefore, when attempting to bend the differential thickness material 3 at an uneven portion close to a region where there are no convex portions 55a and concave portions 55b, the bending position moves to the region side where there are no convex portions 55a and concave portions 55b. There is a case.

On the other hand, in the case of the differential thickness material 4 processed by the rolling rollers 61a and 61b shown in FIG. 13, as shown in FIGS. 14 (b) and (c), where in the width direction of the differential thickness material 4 In addition, there is always a quadrangular frustum-shaped convex portion 65a and an inverted quadrangular frustum-shaped concave portion 65b.
Therefore, as shown in FIG. 15B, regardless of the position of the differential thickness material 4, the entire surface hits the mold rollers 90a and 90b, thereby ensuring high bending position accuracy.

For example, when the differential thickness material 4 is bent along the HH cross section shown in FIG. 14B and bent along the II cross section shown in FIG. There is no difference in bending strength required for processing.
Therefore, the bending position accuracy can always be ensured wherever the differential thickness material 4 is bent in the width direction.

According to the fourth embodiment, in addition to the effects (2), (3), (4), and (5), there are the following effects.
(6) Regardless of where the bending line is set in the width direction of the long plate 1 having a substantially uniform plate thickness, the convex portion 65a and the concave portion 65b are mixed on the bending line. Therefore, there is no great difference in bending strength necessary for the bending process depending on the position of the bending line, and the bending process can be performed at a desired bending line position.

<Fifth Embodiment>
In the rolling step 30, instead of the rolling rollers 31a and 31b of the first embodiment, rolling rollers 51a and 51b provided with the convex portions 55a and the concave portions 55b of the third embodiment are used.
In this case, the rolling rollers 51a and 51b are pressure parts 52a and 52b that press the front and back surfaces of the long plate 1 having a substantially uniform plate thickness, and the non-pressure that does not press the front and back surfaces of the plate 1 Needless to say, the portions 53a and 53b are formed along the axial direction of the roller.

  According to the fifth embodiment, the effects (1), (3), (4), and (5) are provided.

<Sixth Embodiment>
In the rolling step 30, instead of the rolling rollers 41a and 41b of the second embodiment, rolling rollers 51a and 51b provided with the convex portions 55a and the concave portions 55b of the third embodiment are used.

  According to the sixth embodiment, the effects (2), (3), (4), and (5) are provided.

<Seventh embodiment>
In the rolling step 30, instead of the rolling rollers 31a and 31b of the first embodiment, the rolling rollers 61a and 61b having the convex portions 65a and the concave portions 65b of the fourth embodiment are used.
In this case, the rolling rollers 61a and 61b are pressure portions 62a and 62b that pressurize both front and back surfaces of the long plate material 1 having a substantially uniform plate thickness, and non-pressurization that does not press both front and back surfaces of the plate material 1 Needless to say, the portions 63a and 63b are formed along the axial direction of the roller.

  According to the seventh embodiment, the effects (1), (3), (4), (5), and (6) are provided.

<Eighth Embodiment>
In the rolling step 30, instead of the rolling rollers 41a and 41b of the second embodiment, the rolling rollers 61a and 61b provided with the convex portions 65a and the concave portions 65b of the fourth embodiment are used.

  According to the eighth embodiment, the effects (2), (3), (4), (5), and (6) are provided.

  In addition, rolling roller 51a, 51b provided with the convex part 55a of a truncated pyramid shape as shown in FIG. 11 and the recessed part 55b of an inverted square truncated pyramid, or the convex part 65a of a truncated pyramid shape as shown in FIG. Instead of the rolling rollers 61a and 61b provided with the inverted quadrangular truncated pyramid-shaped recesses 65b, rolling rollers 101 to 131 having uneven shapes as shown in FIGS. 16 to 19 may be used.

FIG. 16 is a side view (a), a JJ cross-sectional view (b), and a KK cross-sectional view (c) showing a developed uneven shape on the surface of the rolling roller 101.
The rolling roller 101 includes convex portions 105a and concave portions 105b alternately. Adjacent convex portions 105a and concave portions 105b are connected by an inclined portion 105c. A pair of rolling rollers 101a and 101b (not shown) can be configured by using two identical rolling rollers 101 having such an uneven shape.

On the differential thickness material rolled using the rolling roller 101, a convex portion 105a corresponding to the convex portion 105a of the rolling roller 101, a concave portion 105b corresponding to the concave portion 105b, and an inclined portion 105c corresponding to the inclined portion 105c are formed. Is done. These convex portions 105a, concave portions 105b, and inclined portions 105c are all flat.
Therefore, the differential thickness material rolled using the rolling roller 101 can be easily lap welded using a flat portion (convex portion 105a) which is a flat top surface.
Moreover, this differential thickness material can improve rigidity by uneven | corrugated shape.

In the rolling roller 101 of FIG. 16, the convex portions 105a and the concave portions 105b are each formed in a square shape, and the ridge line connecting the adjacent convex portions 105a and the ridge line connecting the adjacent concave portions 105b intersect at right angles. did.
However, the present invention is not limited thereto, and for example, the shape of the convex portion and the concave portion may be formed in a triangle or a hexagon, respectively. In that case, it can arrange | position so that the ridgeline which connects adjacent convex parts and the ridgeline which connects adjacent recessed parts cross | intersect at an appropriate angle.

Thus, also in the case of the differential thickness material rolled using the rolling roller which each formed the shape of the convex part and the recessed part into the triangle and the hexagon, the convex part is a flat part. Therefore, lap welding can be easily performed using a flat part (convex part).
Also in the case of this differential thickness material, the rigidity can be improved by the uneven shape.

Such flat portions suitable for lap welding include any of the rolling rollers 31a and 31b, the rolling rollers 41a and 41b, the rolling rollers 51a and 51b, and the rolling rollers 61a and 61b in the first to eighth embodiments. Yes.
Therefore, in all of the first to eighth embodiments, the differential thickness materials 2, 3, 4,... Obtained by rolling can be easily lap welded using the flat portions. .

FIG. 17 is a perspective view showing a developed uneven shape on the surface of the rolling roller 111. The rolling roller 111 is alternately provided with convex portions 115 a and concave portions 115 b extending along the axial direction of the roller 111. Adjacent convex portions 115a and concave portions 115b are connected by a vertical portion 115c.
The rolling roller 111 having such a concavo-convex shape has a pair of rolling rollers 101a and 101b (by appropriately setting the width of the convex portion 115a and the width of the concave portion 115b for the convex roller 111a and the convex roller 111b, respectively. (Not shown) can be configured.

On the differential thickness material rolled using the rolling roller 111, a convex portion 115a corresponding to the convex portion 115a of the rolling roller 111, a concave portion 115b corresponding to the concave portion 115b, and a vertical portion 115c corresponding to the vertical portion 115c are formed. Is done. These convex portions 115a, concave portions 115b, and vertical portions 115c are all flat.
Therefore, the differential thickness material rolled using the rolling roller 111 can be easily lap welded using a flat portion (convex portion 115a) which is a flat top surface.
Moreover, this differential thickness material can improve rigidity by uneven | corrugated shape.

FIG. 18 is a perspective view showing a developed uneven shape on the surface of the rolling roller 121. The rolling roller 121 includes convex portions 125 a and concave portions 125 b that extend along the axial direction of the roller 121. The adjacent convex part 125a and the concave part 125b are connected by the inclined part 125c.
A pair of rolling rollers 121a and 121b (not shown) can be configured by using two identical rolling rollers 121 having such an uneven shape.

FIG. 19 is a perspective view showing a developed uneven shape on the surface of the rolling roller 131. The rolling roller 131 is alternately provided with convex portions 135 a and concave portions 135 b extending along the axial direction of the roller 131.
The rolling roller 131 having such a concavo-convex shape appropriately sets the width of the convex portion 135a and the width of the concave portion 135b for the convex roller 131a and the convex roller 131b, respectively, so that a pair of rolling rollers 101a, 101b ( (Not shown) can be configured.

Rolling rollers 51a and 51b having convex portions 55a and concave portions 55b as shown in FIG. 11, rolling rollers 61a and 61b having convex portions 65a and concave portions 65b as shown in FIG. 13, or as shown in FIG. When the plate 1 is rolled using the rolling roller 101 having the convex portion 105a and the concave portion 105b, if the target shape cannot be processed in one rolling process, the target shape is obtained by a plurality of rolling processes. Up to rolling.
Further, after the plate 1 is once rolled into a flat plate shape, it is possible to process the uneven shape on the surface.

DESCRIPTION OF SYMBOLS 1 ... Plate material 2, 3, 4 ... Differential thickness material 3a, 4a ... Rolled part 3b, 4b ... Non-rolled part (remaining part)
3c, 4c ... flat part 10, 20 ... differential thickness member 13 ... boundary part 30 ... rolling process 55a, 65a ... convex part 55b, 65b ... concave part 80 ... roll forming process (molding process)

Claims (5)

In the manufacturing method of the elongated differential thickness member partially different in plate thickness,
Rolling a part of a long plate material having a substantially uniform plate thickness, and obtaining a differential thickness material in which the plate thickness of the rolled portion is thinner than the remaining plate thickness;
Forming step of forming the differential thickness material by roll forming;
The manufacturing method of the difference thickness member characterized by including. In the manufacturing method of the differential thickness member according to claim 1,
In the rolling step, a concavo-convex shape is formed in the rolled portion so that the apparent thickness of the rolled portion is the same as the thickness of the remaining portion. In the manufacturing method of the differential thickness member according to claim 2,
In the rolling step, the thickness difference is characterized in that, when viewed at an arbitrary position in the width direction of the plate material, a plurality of convex and concave portions of the uneven shape are formed so as to be mixed along the longitudinal direction of the plate material. Manufacturing method of member. In the manufacturing method of the differential thickness member of Claim 2 or Claim 3,
The said rolling part equips the uneven | corrugated shaped top surface with a flat part, The manufacturing method of the differential thickness member characterized by the above-mentioned. A differential thickness composed of a differential thickness plate material including a first differential thickness portion having a first thickness and a second differential thickness portion having a thickness smaller than the first thickness, and being welded to another member. In the member,
The differential thickness member, wherein the second differential thickness portion has an uneven shape so that an apparent thickness is the same as the first differential thickness portion.

Images