JP2012206532A - Method for manufacturing clay model - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a clay model that can ensure the shape accuracy, and reduce the working hours and the working cost.SOLUTION: The method includes a changing die manufacturing step I of manufacturing a changing die 10 of a forming face 11 copying a shape of a bumper 101, a base set and clay mounting step II of setting a base part 50 for a clay model having an opening part 55 corresponding to a design change range 104 of the bumper 101 on the forming face 11 of the changing die 10, and mounting a clay 21 on the opening part 55, a step III of executing FRP works of forming an FRP part 30 for integrally binding the clay 21 with the base part 50 for the clay model, and a clay finishing step IV of finishing the surface of the clay 21. The shape accuracy of the clay model is improved, and the working cost is reduced by shortening the working time, and simplifying the work.

Description

  The present invention relates to a method for manufacturing a clay model, and more particularly to a method for manufacturing a clay model of a structural member whose shape is partially changed.

  Conventionally, various performance tests are indispensable in the development process of automobiles, and wind tunnel tests are performed as the performance tests. This wind tunnel test is performed in order to confirm the performance on the aerodynamic characteristics mainly brought about by appearance modeling by disposing the clay model in a stationary state in the wind tunnel through which the wind flows as disclosed in Patent Document 1.

  Then, a prototype vehicle whose appearance modeling is mainly determined based on a clay model that obtains a desired aerodynamic characteristic by a wind tunnel test is manufactured, and various running tests and the like are performed by this prototype vehicle.

  On the other hand, a wind tunnel test may be performed with a test clay model attached to the final stage of trial production or a change in the appearance modeling of some of the components of a current vehicle. The manufacturing process of the clay model accompanying the modeling change of a part of the vehicle body will be described with reference to FIG. 3 and FIG. 4 as an example of the modeling change of the corner portion of the bumper.

  FIG. 3 is a perspective view of the bumper 101 which is a constituent member whose partial range is to be modeled. The corner portion 103 indicated by hatching is the modeling change range 104, and other parts excluding the modeling change range 104 are reference modeling. Range 102.

  A manufacturing process of the bumper 101 for testing the bumper 101 having the shaping change range 104 of the corner portion 103, that is, a so-called clay model 120 for testing will be described with reference to a process chart shown in FIG.

  This production process consists of a rolling action type manufacturing process A for molding the FRP part which is the basic structure of the clay model 120, an FRP forming process B for molding the FRP part by the rolling action type, and an FRP part finishing process for finishing the FRP part. C, Clay placing step D for placing clay on the FRP portion, clay grinding step E for grinding clay, and clay finishing step F for finishing clay.

  In the rolling action manufacturing process A, the modeling change corresponding unit 114 corresponding to the modeling change range 104 of the bumper 101 is raised based on the product modeling of the bumper 101, and the reference modeling corresponding unit 112 corresponding to the reference modeling range 102 is provided. A rolling action mold 110 having a molding surface 111 is manufactured. The bulging amount of the modeling change corresponding unit 114 with respect to the reference modeling corresponding unit 112 is set to, for example, 40 to 60 mm in consideration of the allowance for the later-described clay 125 and the like. The molding of the molding surface 111 having the reference modeling corresponding part 112 and the modeling change corresponding part 114 is performed by NC processing by an end mill 115 or the like based on the modeling shape of the bumper 101 and the processing data of the set modeling change corresponding part 114, for example.

  In the FRP process B, a pretreatment such as a process of applying a release agent to the molding surface 111 provided with the reference shaping corresponding part 112 and the shaping change corresponding part 114 of the rolling action mold 110 is performed, and the preprocessed reference is performed. For example, a base material called a prepreg that is made into a sheet shape by impregnating a reinforcing fiber with a semi-cured resin is repeatedly laminated and shaped on the molding surface 111 provided with the modeling corresponding portion 112 and the modeling change corresponding portion 114 and cured. The FRP part 121 in which the reference modeling part 122 and the concave clay mounting part 124 having the shape of the molding surface 111 having the reference molding corresponding part 112 and the modeling change corresponding part 114 are formed is molded. After the FRP part 121 is cured, the FRP part 121 molded following the molding surface 111 is released from the rolling action mold 110.

  In the FRP part finishing process C, surplus parts such as burrs formed on the FRP part 121 released from the rolling action mold 110 are removed, and the FRP part 121 is set on a processing table (not shown) and put into a predetermined posture state. While holding, the shape of the FRP part 121 is adjusted. The FRP unit 121 with the adjusted shape includes a reference modeling unit 122 that follows the reference modeling unit 112 and a concave clay mounting unit 124 that models the modeling change unit 114.

  In the clay assembling step D, the clay-like portion 124 of the FRP portion 121 is loaded with the sheet-like clay 125 to an amount that enables grinding according to the product shape in the clay grinding step E, which is a subsequent step, and the clay 125 is ground. Let it cure to a possible state. The clay 125 is referred to as an industrial clay, has an appropriate hardness and viscosity, is highly accurate and fine, and is excellent in modeling workability such as cutting.

  In the clay grinding step E, the surface 125a of the clay 125 that is placed and cured on the clay mounting portion 124 of the FRP portion 121 is ground into a shape that follows the product shape. That is, there is no step between the surface 122a of the reference modeling part 122 of the FRP part 121 and the surface 125a of the clay 125, and the surface 122a of the reference modeling part 122 and the surface 125a of the clay 125 are ground into a continuous shape. The clay 125 is ground by, for example, NC cutting using an end mill 126 or the like based on the processing data of the product shape of the bumper 101.

  In the clay finishing step F, the surface 125a of the clay 125 NC-cut in the clay grinding step E and the surface 122a of the reference modeling portion 122 are corrected to a smooth and continuous shape, and the surface 125a of the clay 125 is cut by NC cutting. Remove the eyes and finish on a smooth surface. This finishing process is performed by an electric tool such as a grinder or a hand tool such as a file or a polishing cloth.

  Thus, the clay model 120 is produced by the rolling action production process A, the FRP process B, the FRP part finishing process C, the clay assembling process D, the clay grinding process E, and the clay finishing process F.

JP 2001-324409 A

  In the production of the above test clay model, the clay 125 is placed on the FRP portion 121 molded by the rolling die 110, and the clay 125 placed on the FRP portion 121 is NC-cut and finished to perform the test clay model. 120 is produced.

  However, since the FRP part 121 is molded by the rolling action mold 110 and the FRP part 121 is released from the rolling action mold 110, the clay 125 is placed on the clay mounting part 124 of the FRP part 121. Since a step or the like is generated between the surface 122a of the modeling part 122 and the surface 125a of the clay 125, and the FRP part 121 is positioned and set on the work table in order to NC-cut the clay part 125, the clay There is a concern that the shape accuracy of the FRP part 121 may be lowered due to an attachment error due to posture positioning or a slight deformation of the FRP part 121 when the 125 is set on a work table or the like for NC cutting.

  In addition, in order to perform NC cutting of the clay 125, the work of securing the position and orientation with high accuracy and setting the clay 125 on the work table is troublesome and has skill in the work. Furthermore, much work time and work cost are required for NC cutting of the clay 125.

  Accordingly, an object of the present invention made in view of such a point is to provide a method for manufacturing a clay model that ensures shape accuracy and can reduce working time and working cost.

  The invention of the method for manufacturing a clay model according to claim 1, which achieves the above object, is a method for manufacturing a clay model of a component member whose modeling is partially changed, wherein a molding surface following the shape of the component member is formed. A rolling model manufacturing process for manufacturing the provided rolling model, and a clay model base having an opening corresponding to the modeling change range of the component member is set on the molding surface of the rolling model, and the molding surface A base set and clay placing step for shaping the shape following the molding surface on the clay by pressing and placing semi-cured clay into the opening of the clay model base set in the clay, and opening of the clay model base FRP forming step of forming an FRP portion that laminates the prepreg on the clay exposed from the portion to cover the opening and integrally bonds the clay and the clay model base; and The body combined clay models for the base and released from the rolling action type, characterized by having a a clay finishing step of finishing the surface of the clay.

  According to this, a clay model base having an opening corresponding to a modeling change range of a component to be modeled is prepared in advance, and the clay model base is set on a rolling action molding surface, and a clay model is prepared. By pressing the clay into the opening of the base, the shape of the processed surface is reshaped on the surface of the clay and shaped into a shape that follows the components, so the clay model base is set in the rolling type The clay is placed and shaped, and the shape accuracy of the clay model is improved.

  Furthermore, there is no need to NC-clay the clay, and there are many troublesome operations such as setting a processing table for securing a high-accuracy position and orientation for NC-cutting conventional clay, and NC-cutting clay. Thus, the work time and work cost are not required, and the work time and work cost can be reduced.

  According to a second aspect of the present invention, in the clay model manufacturing method according to the first aspect, the rolling action manufacturing step includes forming a molding surface following the shape of the constituent member by NC processing based on processing data based on the shape of the constituent member. In the FRP process, a prepreg impregnated with a reinforcing fiber with a semi-cured resin is laminated on the clay exposed from the opening of the clay model base, and the opening is closed. An FRP portion that covers the clay and the clay model base is integrally formed while being covered.

  According to this, in the rolling action manufacturing process, the rolling action manufacturing can be easily performed by controlling the NC machining based on the machining data based on the product shape of the constituent members. In addition, in the FRP process, a prepreg impregnated with a reinforcing fiber with a semi-cured resin is laminated on the clay exposed from the opening to close the opening, and the clay and the clay model base are integrally bonded. A strong FRP portion can be formed.

  A third aspect of the present invention is the clay model manufacturing method according to the first or second aspect, wherein the clay model is a notch instead of the opening.

  According to this, a function similar to that of the opening can be obtained by the notch, and it can be formed even in a region where it is difficult to set the opening.

  The invention according to claim 4 is the method for manufacturing a clay model according to any one of claims 1 to 3, wherein the constituent member is a bumper for an automobile, and a modeling change range in which a part of the modeling change is performed It is a corner part of a bumper.

  This shows a specific example of a constituent member, where the constituent member is a bumper, and the modeling change range is a corner portion of the bumper.

  According to the present invention, a clay model base having an opening corresponding to a modeling change range of a component to be modeled is prepared, and the clay model base is set on a rolling-type molding surface, and for a clay model. By pushing clay into the opening of the base, the shape of the processed surface is reshaped and shaped on the surface of the clay, so clay is placed and shaped with the clay model base set on the rolling type. The shape accuracy of the crack clay model can be improved.

  Furthermore, there is no need to NC-clay the clay, and there are many troublesome operations such as setting a processing table for securing a high-accuracy position and orientation for NC-cutting conventional clay, and NC-cutting clay. The work time and work cost are not required, and the work time can be reduced by shortening the work time and simplifying the work.

It is a manufacturing process figure which shows the outline | summary of the manufacturing method of the clay model in one embodiment of this invention. It is explanatory drawing of the base for clay models. It is a perspective view of the bumper corresponding to the clay model which should be modeled. It is a manufacturing process figure which shows the outline | summary of the manufacturing method of the conventional clay model.

  One embodiment of the present invention will be described with reference to FIGS. 1 to 3 by taking as an example the case of producing a clay model for modeling a corner of a bumper.

  FIG. 1 is a manufacturing process diagram of the clay model 1, FIG. 2 is an explanatory view of a clay model base, and FIG. 3 is a perspective view of a bumper corresponding to the modeling clay model.

  FIG. 3 is a perspective view of the bumper 101 which is a component to be partially modeled. The corner 103 shown by hatching is the modeling change range 104, and other parts excluding the modeling change range 104 are the standard modeling range. 102.

  A description will be given with reference to a manufacturing process diagram of a bumper 101 for testing the bumper 101 having the modeling change range 104 corresponding to the corner portion 103, that is, a so-called clay model 1 for testing.

  This manufacturing process includes a rolling action type manufacturing process I for manufacturing a rolling action mold for molding the clay model 1, a base set for setting the clay model base to the rolling action type, and a clay setting process II, a FRP process. III, a clay finishing step IV for finishing the clay.

  On the other hand, as shown in FIG. 2, a clay model base 50 is prepared in which an opening 55 serving as a modeling change range setting unit is formed in a range corresponding to the modeling change range 104 in the bumper 101. That is, the clay model base 50 is formed by the reference modeling range 102 and the opening 55 of the bumper 101.

  In the rolling action manufacturing process I, the rolling action mold 10 having the molding surface 11 that follows the product shape of the bumper 101 is manufactured. The molding surface 11 includes a modeling change corresponding unit 14 that follows modeling of the modeling change range 104 of the bumper 101 and a reference modeling corresponding unit 12 that models modeling of the reference modeling unit 102. The molding of the molding surface 11 is performed by, for example, the bumper 101. It can be performed by NC machining by an end mill 15 or the like by an NC milling machine or the like based on machining data based on the product shape. A surface 52 of the reference modeling range 102 of the clay model base 50 is formed in the reference modeling corresponding portion 12 of the molding surface 11 so as to be fitted. This NC machining can be easily performed by controlling machining with machining data based on the product shape of the bumper 101.

  In the base set and clay assembling step II, a pretreatment such as a release agent treatment for applying a release agent is performed on the molding surface 11 of the rolling die 10, and the clay modeling base portion 50 is applied to the reference shaping corresponding portion 12 of the molding surface 11. The reference modeling range 102 is fitted and set. The surface 52 of the clay model base 50 is maintained in close contact with the molding surface 11, and, for example, the semi-cured clay 21 is pushed or stuffed from the opening 55 of the clay model base 50, so that the molding surface 11 can be modified. The clay 21 is filled into the opening portion 55 so as to be in close contact with the opening edge 56 of the portion 14 and the opening portion 55. The clay 21 is in close contact with the shaping change corresponding portion 14 of the molding surface 11 and the opening edge 56 of the opening 55 and prevents bubbles from being mixed in the clay 21. As a result, the shape of the modeling change corresponding portion 14 is rolled on the surface 22 of the clay 21 to be shaped to follow the corner portion 103 of the bumper 101, and the inner surface 23 exposed from the opening 55 is formed smoothly. The The surface 22 of the clay 21 shaped by the modeling change unit 14 is smooth and continuous with the surface 52 of the clay model base 50.

  In the FRP forming step III, for example, a prepreg made into a sheet form by impregnating a reinforcing fiber with a semi-cured resin is repeatedly laminated on the inner surface 23 of the clay 21 exposed from the opening 55 of the clay model base 50. The opening 55 is closed by the FRP portion 30 in which the prepreg is cured. As a result, the clay 21 is closed and the clay 21 and the reference modeling range 102 of the clay model base 50 are firmly and integrally joined by the FRP portion 30 spanned over the opening 55.

  Thereafter, the clay model base 50 to which the clay 21 is integrally bonded is released from the rolling action mold 10 and taken out.

  In the clay finishing process IV, the clay model 1 is formed by finishing the surface 22 of the clay 21 shaped by the modeling changing unit 14 into a smooth surface. This finishing process is performed by an electric tool such as a grinder or a hand tool such as a file or a polishing cloth.

  Therefore, according to the embodiment, the clay model base 50 in which the opening 55 is formed in a range corresponding to the modeling range 104 of the bumper 101 to be modeled is prepared in advance, and the clay model base 50 is used as the rolling action type 10. The molding 21 is pushed into the opening 55 of the clay model base 50, and the shape of the modeling change corresponding portion 14 is reprinted on the surface 22 of the clay 21 to follow the corner 103 of the bumper 101. Therefore, the clay 21 is placed and shaped in a state in which the clay model base 50 is set on the rolling action mold 10 in the rolling action mold 10, and the shape accuracy of the clay model 1 is improved. can get.

  Furthermore, there is no level difference between the surface 22 of the clay 21 and the surface 52 of the clay model base 50, and it is not necessary to NC-cut the surface 22 of the clay 21, so that the conventional clay can be NC-cut with high accuracy. Troublesome work to be set on the work table to secure the position and orientation, and much work time and work cost for NC cutting of clay are no longer required, and work cost is reduced by shortening work time and simplifying work. Is obtained.

  The present invention is not limited to the above basic embodiment, and can be variously modified without departing from the spirit of the invention. For example, in the above embodiment, the opening 50 serving as the modeling change range setting unit is formed in the range corresponding to the modeling change range 104 in the bumper 101 of the clay model base 50, but instead of the opening 55, a concave cut The modeling change setting part can also be formed by the notch part. This notch provides the same function as that of the opening 50, and the opening 55 can also be formed at a difficult site. Also. Although the case of producing a bumper clay model has been described as an example, it can be applied to the production of other clay models such as a front fender and a hood.

I Rolling type manufacturing process II Base set and clay assembling process III FRP process IV Clay finishing process 1 Clay model 10 Rolling type 11 Molding surface 12 Reference shaping corresponding part 14 Modeling change corresponding part 21 Clay 22 Surface 23 Inner face 30 FRP part 50 Clay Model Base 52 Surface 55 Opening (Modeling Change Range Setting Unit)
56 Opening edge 101 Bumper (component)
103 Corner section 104 Modeling change range

Claims (4)

A method for producing a clay model of a component member for which a part of the shape is changed,
A rolling action production process for producing a rolling action mold having a molding surface that follows the shape of the component;
The clay model base having an opening corresponding to the modeling change range of the component member is set on the rolling action molding surface and semi-cured on the clay model base opening set on the molding surface. A base set and a clay assembling step for shaping the shape of the clay according to the molding surface by pushing and placing the clay in a state;
FRP-forming step of forming a FRP portion that laminates the prepreg on the clay exposed from the opening of the clay model base and closes the opening and integrally couples the clay and the clay model base;
A clay finishing step of releasing the clay model base unit integrally bonded with the clay from the rolling action mold and finishing the surface of the clay. In the rolling action manufacturing step, a rolling action mold is manufactured by processing a molding surface that follows the shape of the constituent member by NC processing based on processing data based on the shape of the constituent member,
The FRP process comprises laminating a prepreg impregnated with a reinforcing fiber with a semi-cured resin on the clay exposed from the opening of the clay model base and closing the opening, and the clay and the clay model base The method for producing a clay model according to claim 1, wherein an FRP portion that integrally couples with each other is formed.   3. The method for producing a clay model according to claim 1, wherein the clay model is a notch instead of the opening.   The said structural member is a bumper for motor vehicles, Comprising: The shaping | molding change range which changes a shaping | molding of a partial range is a corner part of this bumper, The clay model of any one of Claims 1-3 characterized by the above-mentioned. Production method.

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