JP2013078987A - Outer panel for railway vehicle structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an outer panel in which a bead different from a conventional bead Bc can be further easily and inexpensively formed.SOLUTION: The outer panel for railway vehicle structure Peg includes a plurality of beads B, which are formed on an outer panel Pe regulated by an upper surface and a lower surface Sbp mutually opposed in parallel while having a bead press outer panel thickness T so as to extend in a vehicle width direction Dw. Each of the beads B is protruded in a vehicle longitudinal direction DI while having a predetermined cross-sectional shape regulated by a bead width Wb and a bead height Hb, and an edge Ce regulated by a predetermined curvature radius Rc is formed at the boundary between the bead B and the lower surface Sbp.

Description

  The present invention relates to an outer plate used for a railway vehicle structure.

  Conventionally, the outer plate of a railway vehicle employs a beaded outer plate that can bear part of the structural strength in order to ensure the structural strength required for the vehicle structure. As an example, referring to FIGS. 9, 10, 11, 12, 13, 14, 15, 16, and 17, the outer panel used in the conventional vehicle body structure. (Hereinafter, “wife outer plate”) will be described. First, the first and second conventional wife structures as described in Patent Document 1 will be described with reference to FIGS. 9 to 15, and then with reference to FIGS. A conventional wife structure will be described.

(First conventional wife structure)
A first conventional wife outer plate Pegc1 shown in FIG. 9A is attached to a wife structure Sgc1 shown in FIG. 9B by spot welding Ws. In the wife outer plate Pegc1, several (12 in this example) parallel to the height direction of the vehicle (hereinafter referred to as the vehicle height direction Dv) are parallel to the outer plate Pec1 having a plate thickness Tc1 (FIG. 10) of 1.5 mm. The bead Bcv extends to the vicinity of the end portion of the outer plate Pec1. In the wife structure Sgc1, a pillar Pt configured in an H shape extending from a position higher than the ceiling to the underframe Fu is disposed in the center. In the column Pt, left and right vertical frames Fvr and Fvl are connected by a horizontal frame Fh.

  Four (total 8) transverse bones Fmh are provided on the left and right sides of the column Pt. Vertical bones Fmv are respectively provided between the top horizontal bone Fmh and horizontal frame Fh and the roof. The transverse bone Fmh and the longitudinal bone Fmv are formed of a steel material having a hat-shaped cross section. Generally, rigidity equivalent to a bone can be obtained in the extending direction of the bead. Therefore, in the wife structure Sgc1, only the above-described three vertical bones Fmv are arranged.

  In FIG. 9A, a cross section of the bead Bcv cut along the straight line Xa-Xa is shown in FIG. 10A, and a vertical cross section cut along the straight line Xb-Xb is shown in FIG. 10B. As shown in FIG. 10 (a), the cross-sectional shape of the bead Bcv is a curved surface defined by a radius of curvature Rfc1 having a center above the outer plate Pec1, and the longitudinal direction of the vehicle (hereinafter, vehicle longitudinal direction Dl) / vehicle. In the vehicle width direction (hereinafter referred to as the vehicle width direction Dw), and further extends from the middle with a curved surface defined by a curvature radius Rpc1 having a center below the outer plate Pec1, and a peak height Hbc1 in the vehicle longitudinal direction Dl. (Hereinafter, “bead height Hbc1”). Then, the cross-sectional shape of the bead Bcv passes through the peak point and descends on the center plane Cp1 perpendicular to both the vehicle width direction Dw and the vehicle height direction Dv to return to the outer plate Pec1. Thus, the cross-sectional shape of the bead Bcv is formed so that the shape continuously changes with a smooth curved surface from the ridge region to the top region and from the top region to the ridge region. The distance between two points of interest with respect to the center plane Cp1 at which the upper surface of the outer plate Pec1 starts to rise is called a bead width Wbc1.

  As shown in FIG. 10 (b), the vertical cross-sectional shape of the bead Bcv rises in the vehicle height direction Dv / vehicle longitudinal direction Dl with a curved surface defined by a radius of curvature Rec1 having the center above the outer plate Pec1. It further extends with a curved surface defined by a curvature radius Resc1 having a center below the outer plate Pec1, and reaches a bead height Hbc1. In this way, the vertical cross-sectional shape of the bead Bcv changes continuously with a smooth curved surface from the outer plate Pec1 to the lower heel region, from the lower heel region to the upper heel region, and from the upper heel region to the top region. Is formed. The distance between the rising start point and the rising end point of the bead Bcv in the vehicle height direction Dv direction is referred to as a bead length Lbc1. The regions of the bead Bcv defined by the curvature radius Rec1 and the curvature radius Resc1 are referred to as a lower heel region and an upper heel region, respectively. The lengths of the lower saddle region and the upper saddle region in the vehicle height direction Dv direction are referred to as the vertical saddle length Ls1.

  In a general bead Bcv, the plate thickness Tc1 is 1.5 mm, the curvature radius Rfc1 is 10 mm, the curvature radius Rpc1 is 5 mm, the bead height Hbc1 is 8 mm, the bead width Wbc1 is 26.53 mm, the curvature radius Rec1 is 30 mm, and the curvature radius. Resc1 is 30 mm, and the longitudinal length Ls1 is 15 mm.

(Second conventional wife structure)
A wife outer plate Pegc2 shown in FIG. 11 (a) is attached to a wife structure Sgc2 shown in FIG. 11 (b) by spot welding Ws. In the wife outer plate Pegc2, several (26 in this example) beads Bcw are pressed out parallel to the vehicle width direction Dw and extended to the outer plate Pec2 having a plate thickness Tc2 (FIG. 12) of 1.2 mm. doing. In the wife structure Sgc2, similarly to the wife structure Sgc1, a pillar Pt configured in an H shape extending from a position higher than the ceiling to the underframe Fu is disposed in the center. From the opposite side of the horizontal frame Fh of the left and right vertical frames Fvr and Fvl, a right horizontal frame Fhr and a left horizontal frame Fhl extend left and right, respectively.

  Longitudinal bones Fmv are provided between the right horizontal frame Fhr and the left horizontal frame Fhl and the roof, respectively. The transverse bone Fmh is not provided. That is, the wife structure Sgc2 deletes the central vertical bone Fmv and the six left and right horizontal bones Fmh from the wife structure Sgc1, and the two horizontal bones Fmh in the uppermost stage are the right horizontal frame Fhr and the left horizontal frame. It has a structure exchanged with Fhl. This is because the end face plate Pegc2 achieves a strength equivalent to a lateral bone by a plurality of beads Bcw extending in the vehicle width direction Dw direction. That is, the lateral bone in the wife structure Sgc2 is abolished by the bead Bcw.

  In FIG. 11 (a), a cross section of the bead Bcw cut along a straight line XIIa-XIIa is shown in FIG. 12 (a), and a vertical cross section cut along the straight line XIIb-XIIb is shown in FIG. 12 (b). As shown in FIG. 12 (a), the cross-sectional shape of the bead Bcw is a curved surface defined by a curvature radius Rfc2 having a center above the outer plate Pec2, and swells in the vehicle longitudinal direction Dl / vehicle height direction Dv. It further extends with a curved surface defined by a curvature radius Rpc2 having a center below the outer plate Pec2, and reaches a peak height Hbc2 in the vehicle longitudinal direction Dl (hereinafter, “bead height Hbc2”). The cross-sectional shape of the bead Bcw extends in the vehicle height direction Dv direction by a predetermined distance while maintaining the bead height Hbc2. Then, it descends with a curved surface defined by a curvature radius Rpc2 having a center below the outer plate Pec2, and descends along a curved surface defined by a curvature radius Rfc2 having a center above the outer plate Pec2. And it returns to outer plate Pec2.

  The region of the bead Bcw defined by the curvature radius Rfc2 and the curvature radius Rpc2 is referred to as a recumbent region and a lateral top region. A distance between a point connecting the recumbent region and the top region to the bead height Hbc2 and a point at the target position on the center plane Cp2 with respect to the same point is referred to as a top width Wpc2. In the heel region, the distance between two target points with respect to the center plane Cp2 in which the lower surface of the outer plate Pec2 is at the height of the upper surface of the outer plate Pec2 is referred to as a heel width Wsc2. Further, a distance between two target points with respect to the center plane Cp2 where the upper surface of the outer plate Pec2 begins to rise in the heel region is referred to as a bead width Wbc2. Thus, the cross-sectional shape of the bead Bcw is a distance of (Wbc2-Wsc2) / 2 from the outer plate Pec2 to the eaves region in the vehicle height direction Dv direction, and from the eaves region to the top region in the vehicle height direction Dv direction (Wsc2- Over the distance Wpc2) / 2 and the distance Wpc2 in the vehicle height direction Dv direction between the saddle regions, the shape is continuously changed with a smooth curved surface.

  As shown in FIG. 12 (b), the vertical cross-sectional shape of the bead Bcw rises in the vehicle width direction Dw / vehicle longitudinal direction Dl with a curved surface defined by a radius of curvature Rec2 having the center above the outer plate Pec2, and from the middle It further extends with a curved surface defined by a curvature radius Resc2 having a center below the outer plate Pec2, and reaches a bead height Hbc2. The distance between the rising start point and the rising end point of the bead Bcw in the vehicle width direction Dw direction is referred to as a bead length Lbc2. The regions of the bead Bcw defined by the curvature radius Rec2 and the curvature radius Resc2 are referred to as a lower heel region and an upper heel region, respectively. The lengths of the lower rod area and the upper rod area in the vehicle width direction Dw direction are referred to as the vertical rod length Ls2. In this way, the vertical cross-sectional shape of the bead Bcw continuously changes with a smooth curved surface from the outer plate Pec2 to the lower heel region, from the lower heel region to the upper heel region, and from the upper heel region to the top region. Is formed.

  In a typical bead Bcw, the plate thickness Tc2 is 1.2 mm, the curvature radius Rfc2 is 7 mm, the curvature radius Rpc2 is 7 mm, the bead height Hbc2 is 15 mm, the top width Wpc2 is 18 mm, the collar width Wsc2 is 30 mm, and the bead width Wbc2 is 39.48 mm, the radius of curvature Rec2 is 30 mm, the radius of curvature Resc2 is 30 mm, and the vertical hook length Ls2 is 20 mm. Thus, the bead Bcw (wife outer plate Pegc2) has a bead height Hbc2 that is approximately twice the bead height Hbc1 (15/8) and the bead width Wbc2 has a bead width compared to the above-described bead Bcv (wife outer plate Pegc1). It can be seen that the width is about 1.5 times (39.48 / 26.53) of Wbc1, which is wider and higher than the bead Bcv. Furthermore, the top width Wpc2 which is a flat portion at the tip of the bead Bcw is 18 mm, whereas the tip of the bead Bcv is also arcuate, and its width is about the radius of curvature Rpc1 (5 mm).

  That is, the end face plate Pegc2 is provided with a bead Bcw that is wider and has a rectangular cross section than the bead Bcv of the end face plate Pegc1, thereby realizing strength corresponding to the aggregate. As a result, as shown in FIG. 11B, it is possible to abolish the lateral bone from the wife structure Sgc2.

  With reference to FIG. 13 and FIG. 14, a bead unloading process when a general bead unloading press forming method (hereinafter “bead pressing method”) is applied to the outer plate will be described. FIG. 13A shows an example of a bead pressed outer plate (hereinafter referred to as a bead press outer plate). In the same figure, the bead press outer plate Pec in the posture when attached to the vehicle on the left side is shown as viewed from the front in the room, and the cross section taken along the straight line XIII (a) -XIII (a) in the same figure is shown on the right side. Show.

  In this example, only a predetermined height Hbc (hereinafter “bead height Hbc”) in the vehicle longitudinal direction D1 is applied to the bead press outer plate Pec having a plate thickness of Tbc (hereinafter “bead press outer plate thickness Tbc”). The four beads Bc projecting in an arc shape have a width Wbc in the vehicle height direction Dv (hereinafter “bead width Wbc”) and a length Lbc in the vehicle width direction Dw (hereinafter “bead length Lbc”). Is formed. The arc-shaped protruding surface of the bead Bc is called a convex surface Sp, and the concave surface is called a concave surface Sr for identification. The bead height Hbc corresponds to the above-described bead heights Hbc1 and Hbc2, the bead press outer plate thickness Tbc corresponds to the above-described plate thickness Tc1 and Tc2, and the bead press outer plate Pec corresponds to the above-described outer plates Pec1 and Pec2. Equivalent to.

The bead press outer plate Pec is set to satisfy the requirements described below in order to achieve the structural strength required as part of the wife structure.
Bead press outer plate thickness Tbc = 1.0 to 1.5 mm
Bead height Hbc = 8-15mm
Bead width Wbc = 25-60mm
Bead height Hbc / bead width Wbc = 0.2 to 0.6
Bead height Hbc / bead press outer plate thickness Tbc = 5-15
Bead width Wbc / bead press outer plate thickness Tbc = 17-40

The structural strength of the bead press outer plate Pec is determined by the bead press outer plate thickness Tbc and the bead Bc (bead height Hbc, bead width Wbc). That is, when the structural strength of the outer plate Pec is S and the material of the bead press outer plate Pec is M,
It can be generalized as S = f (Hbc, Wbc, Tbc, M).

  Since the bead press outer plate Pec is usually spot-welded to the structure, the material M of the bead press outer plate Pec is selected from the same material as the structure. In the case of a steel vehicle, a bead press outer plate Pec that can reduce the bone without increasing the thickness of the outer plate is often used to suppress an increase in weight. However, in the case of an aluminum alloy vehicle, the Young's modulus is used. Is about 1/3 that of steel, so the thickness of the outer skin is about 1.4 times that of steel, and press workability is reduced. It has not been.

  FIG. 13B shows an example of a male die Dcm (hereinafter referred to as “press male die Dcm”) used for molding the above-described bead press outer plate Pec. In the figure, the left side shows a state where the press male die Dcm in the pressing process is viewed from above, and the right side shows a section cut along a straight line XIII (b) -XIII (b) in the figure. On the lower surface of the press male die Dcm, four protrusions P (hereinafter referred to as “bulb shape depth Hbcm”) projecting in an arc shape corresponding to the concave surface Sr of the bead Bc. , “Bead type P”) has a width Wbcm in the vehicle height direction Dv (hereinafter “bead type width Wbcm”) and extends in the vehicle width direction Dw by a length Lbcm (hereinafter “bead type length Lbcm”). Is formed. The bead mold length Lbcm is shorter than the bead length Lbc, the bead mold width Wbcm is narrower than the bead width Wbc, and the bead mold depth Hbcm is the same as the bead height Hbc.

  FIG. 13C shows an example of a press die female die Dcf (hereinafter referred to as “press female die Dcf”) used for forming the above-described bead press outer plate Pec. In the figure, the left side shows a state of the press female die Dcf in the pressing process as viewed from above, and the right side shows a cross section cut along a straight line XIII (c) -XIII (c) in the figure. On the upper surface of the press female die Dcf, there are four grooves R (hereinafter referred to as arcs) recessed by a predetermined length Hbcf (hereinafter referred to as “bead shape depth Hbcf”) corresponding to the convex surface Sp of the bead Bc. , “Bead type groove R”) has a width Wbcf (hereinafter “bead type width Wbcf”) in the vehicle height direction Dv, and a length Lbcf (hereinafter “bead type length Lbcf”) in the vehicle width direction Dw. It is formed to extend. The press male die Dcm and the press female die Dcf are collectively referred to as a press die Dc.

The bead height Hbc matches the bead type depth Hbcf and the bead type depth Hbcm. On the other hand, bead length Lbc coincides with either bead type length Lbcf or bead type length Lbcm, and bead width Wbc also coincides with either bead type width Wbcf or bead type width Wbcm. In the present embodiment, for convenience of explanation, bead length Lbc and bead width Wbc are assumed to match bead type length Lbcf and bead type width Wbcf, respectively. That is, the relationship shown in the following expressions (1), (2), and (3) is established.
Lbcf = Lbc> Lbcm (1)
Wbcf = Wbc> Wbcm (2)
Hbcf = Hbc = Hbcm (3)

  14A, the outer plate Pc is placed on the press female die Dcf, and the press male die Dcm is held above the bead die P so that the bead die P corresponds to the bead die groove R. The state seen in the vehicle width direction Dw direction is shown. In this state, the press male die Dcm is lowered toward the press female die Dcf (hereinafter, “bead press direction Dpb”) by a press machine (not shown), thereby starting the bead press process.

  FIG. 14B shows a state when the press male die Dcm reaches the bottom dead center. The outer plate Pc is pressed between the press male die Dcm and the press female die Dcf, and is extended by the bead die P and the bead die groove R to form a bead Bc. In addition, positioning of the outer plate Pc and prevention of displacement and jumping up are performed by a presser device (not shown) included in the press machine. When the press male die Dcm is pulled up, the bead press outer plate Pec is completed on the press female die Dcf.

  FIG. 14 (c) shows an enlarged cross-sectional shape of the bead Bc surrounded by a circle A in FIG. 14 (b). As shown in the figure, the bead press outer plate Pec changes while the convex surface Sp side and the concave surface Sr side have both continuous surfaces. This is as described with reference to FIGS. 10 and 12, and will be described in more detail below from the viewpoint of press molding with a mold. As described above, since the bead press is formed by utilizing the ductility of the outer plate Pc, if a bent portion is provided, local extension occurs, and there is a risk of strength reduction or breakage due to thinning. Accompany. For this reason, the presence of an edge (angular portion) is not allowed on the press surfaces of the press male die Dcm and the press female die Dcf. Further, in order to prevent a scratch when the bead press outer plate Pec is released after pressing, the contour shape (convex surface Sp and concave surface Sr) of the bead Bc is formed in a generally U-shaped and gently-curved curved surface. There is a need.

  For convenience of explanation, referring to FIGS. 13 and 14, a general press die Dc (hereinafter referred to as “multiple bead press die”) that simultaneously press-molds a plurality of (four in this example) beads Bc. A general bead press molding method has been described by taking Dc ") as an example. However, since the multiple bead press mold Dc is made of steel, the cost required for mold creation and maintenance is high. In addition, in order to press-mold a plurality of beads simultaneously, it is necessary to prepare for each outer plate having a different number of beads, a different length, and a different bead arrangement pattern, and mold production and maintenance costs respectively occur. In order to suppress such costs as much as possible, a single bead press die Dcs for forming one bead Bc at a time is usually used instead of the multiple bead press die Dc.

  With reference to FIG. 15, the bead press by the single bead press metal mold | die Dcs is demonstrated. 15 (a) and 15 (b) are respectively compared with FIG. 14 (a) showing a plurality of bead press dies Dc before pressing and FIG. 14 (c) showing a bead press outer plate Pec after pressing. It is shown. In short, in the single bead press die Dcs, the press female die Dcf provided with a plurality of bead-type grooves R is replaced with a press female die Dcsf provided with a single bead-type groove Rs. The press male die Dcm provided with the bead die P is replaced with a press male die Dcsm provided with a single bead die Ps.

  The bead mold Ps in the press male mold Dcsm is formed such that the bead mold P extends longer in the press direction. The bead mold groove Rs in the press female mold Dcsf is formed so as to receive the bead mold Ps through the outer plate Pc. The outer plate Pc is pressed against the bead mold groove Rs of the press female mold Dcsf by the descending press male mold Dcsm (bead mold Ps), and deformed along the curved surface of the bead mold groove Rs to form the bead Bc. . Therefore, the press male die Dcsm does not need a portion for pressing the outer plate Pc against the bead-type groove Rs from the flat portion of the bead Bc to the flange region. As for the single bead press die Dcs, a pressing device for positioning the outer plate and preventing displacement is included in the press machine as in the case of the press die Dc described above.

  Bead extraction by the above-described press male die Dcsm and press female die Dcsf is performed as follows. For example, when the outer plate Pc is a side outer plate extending over the vehicle length of 19.5 m, when forming a bead Bc that passes from end to end of the side outer plate Pc, the reference length (1 to 1) is used. Using the bead type Ps of about 2 m), the side outer plate Pc is sent in order while being shifted in the longitudinal direction to form a bead Bc having a required length. The bead type Ps length is smaller than the bead type groove Rs length, and at least one end of the bead type groove Rs is formed in an open state. This is because the single bead press die Dcs is fixed to the press machine and the bead is removed while feeding the outer plate Pc. More specifically, the bead mold Ps and the bead mold groove Rs have substantially the same mold length, but when the outer plate Pc is fed, a guide for forming a bead so as not to deviate from the previously formed bead. In order to fulfill the role, the bead-shaped groove Rs is configured to be slightly longer. A plurality of beads Bc parallel to each other can be formed by performing the above-described operation in parallel with the already formed beads Bc. Thereby, versatility is given to the length and the pitch of the male and female molds called the press male mold Dcsm and the press female mold Dcsf.

  In the above-mentioned wife outer plate Pegc1, beading is employed in order to avoid deterioration in appearance due to shear buckling of the outer plate. Further, in order to bear structural strength as a part of the wife structure like the wife outer plate Pegc2, an increasing number of vehicles are used to bead out the outer plate Pec, but in order to obtain high rigidity in the bead shape, it is thick. It is necessary to press-mold a wide and high bead on the steel sheet, which increases the degree of drawing. The mold creation and maintenance cost for that purpose is one of the factors that push up the cost of the wife structure, and thus the vehicle.

  In addition to the cost of the mold, there is a problem of the number of bead presses. As described above, when a single bead press die Dcs is used, a plurality of beads cannot be formed at the same time, so one bead is press-formed one by one, or a long bead is divided into several times and pressed. It is necessary to mold. Therefore, the number of presses occupies most of the processing cost of the end plate. Also, with respect to the wife outer plate Pegc2, there is actually a facility that is not shown in the wife part of the vehicle, so that there are few vehicles that can completely abolish the vertical bone Fmv and the horizontal bone Fmh as shown in the figure. .

  However, due to recent advances in vehicle structure, it has become possible to produce a wife structure without having the wife outer plate bear part of the structural strength. As a result, there is currently a strong aesthetic demand for the wife skin that the wife structure is not exposed to the human eye (covering the wife's skeleton).

  With reference to FIG. 16, a description will be given of a wife outer plate manufactured without providing beads for aesthetic purposes. A wife outer plate Pegc3 shown in FIG. 16A is attached to a wife structure Sgc3 shown in FIG. 16B by spot welding Ws. Since the bead outer plate Pegc3 (outer plate Pec3) is not provided with a bead, it can be simply considered as a flat plate. With respect to shear buckling, the structural strength is made by the thickness Tc3 of the outer skin plate Pegc3 and the bone pitch. Therefore, if the thickness Tc3 is reduced, the bone pitch must be reduced, and if the thickness Tc3 is increased. The bone pitch can be widened.

  The addition of aggregate is accompanied by an increase in assembly man-hours. From this point of view, in order to suppress the addition of aggregate as much as possible, in the wife structure Sgc3, the thickness of the outer skin of the wife is increased to Tc3 = 2.0 mm, so that the pitch of the lateral bone is equal to that of the conventional wife structures Sgc1 and Sgc2. And longitudinal bones are added to bring the aspect ratio between the bones close to 1: 1. In this case, the number of longitudinal bones added is smaller than the number of additional lateral bones required when no longitudinal bone is added, and the number of additional bones is reduced as a whole. As a result, although the weight of the wife outer plate increases, the man-hour of the bead press can be omitted, and as a result, the manufacturing cost is reduced.

No. 7-39720

  The above-mentioned wife outer plate Pegc3 is based on the current situation that it is no longer necessary to bear a part of the structural strength of the wife outer plate due to the progress of the structure of the vehicle, and the bead Bcv in the wife outer plate Pegc1 and the wife outer plate Pegc2. And bead Bcw are abolished. In other words, by providing the conventional bead Bcv and bead Bcw on the outer plate Pec1 and outer plate Pec2, unnecessary or excessive quality is obtained, and the processing cost due to the increase in press man-hours in addition to the mold creation / maintenance cost Is being passed on to vehicle costs. For this reason, in the end plate Pegc3, the plate thickness Tc3 = 2.0 mm is thicker than the plate thickness Tc1 = 1.5 mm of the end plate Pegc1 and the thickness Tc2 = 1.2 mm of the end plate Pegc2. .

  As a result, in a static state, that is, a state where it is attached to a vehicle, there is no problem of deformation due to its own weight. However, since the end face is constituted by a wide plane, a slight distortion D as illustrated in FIG. 17 may appear as a wrinkle on the surface of the end face plate Pegc3. The causes are mainly physical factors such as slight deviation in flatness, extension of the outer plate due to the outside air temperature, and material factors that make the surface of the peg outer plate Pegc3 have a semi-gloss finish. It is done. As described above, the slight deformation that occurs in the wife outer plate Pegc3 does not cause a problem in the strength of the vehicle. However, there is a problem with respect to the beauty of the wife outer plate Pegc3.

  As a method of solving the problem that the appearance of the outer plate is impaired due to distortion (slight deformation) generated in the wife outer plate, it is conceivable to restore the conventional bead Bc to the outer plate. However, when the conventional bead Bc is revived, the above-mentioned unnecessary cost due to unnecessary or excessive quality is transferred to the vehicle cost as usual. Therefore, in the present invention, in order to suppress the occurrence of distortion on the outer plate surface and improve the visual tolerance of the generated distortion, a bead different from the conventional bead Bc can be formed more easily and at a lower cost. The purpose is to provide a board.

In order to achieve the above object, an outer plate for a railway vehicle structure according to the present invention is:
A plurality of beads are formed to extend in a first direction on a flat plate defined by a first main surface and a second main surface facing each other in parallel and having a first predetermined plate thickness. ,
Each of the beads has a predetermined cross-sectional shape defined by a predetermined width and a predetermined height and protrudes from the first main surface to the second main surface side,
An edge defined by a predetermined radius of curvature is formed at a boundary between the bead and the second main surface.

  According to the present invention, beads for aesthetics and strength reinforcement can be formed on a structure outer plate of a railway vehicle at a lower cost and with a simple method.

It is explanatory drawing of the wife outer plate which concerns on embodiment of this invention. In FIG. 1, it is a cross section of the end face plate cut | disconnected by the straight line II-II. It is explanatory drawing of the metal mold | die used for the bead extraction which concerns on embodiment of this invention. It is sectional drawing which shows the cross-sectional shape of the bead type | mold hole provided in the press female metal mold | die shown in FIG. It is explanatory drawing of the bead extraction press work to an outer plate | board based on embodiment of this invention. FIG. 6 is a detailed explanatory diagram of a bead dispensing press operation to the outer plate using the press female mold of FIG. 5. It is a consideration figure of the relationship between the corner | angular part of a press female metal mold | die, and the shape of the edge formed in an outer plate | board. It is explanatory drawing of the shape of the bead formed in an outer plate with the press female metal mold | die shown in FIG. It is explanatory drawing of the conventional beaded-out wife outer plate. It is explanatory drawing of the shape of the bead shown in FIG. FIG. 10 is an explanatory view of a conventional bead-out wife outer plate different from FIG. 9. It is explanatory drawing of the shape of the bead shown in FIG. It is explanatory drawing of the metal mold | die used for a general bead taking out. It is explanatory drawing of the bead taking-out press work by the metal mold | die shown in FIG. It is explanatory drawing of the bead extraction press work by the metal mold | die used for the conventional bead extraction. It is explanatory drawing of the conventional wife skin | plate which does not have a bead. It is explanatory drawing of the surface distortion of the wife outer plate shown in FIG.

  Before specifically describing the embodiments of the present invention, the technical idea thereof will be described. The present invention is the same as the conventional one in that a bead is provided in order to suppress the occurrence of distortion in the outer plate. However, a plurality of beads whose bead height is lower than that of a conventional bead are provided simultaneously. In addition, the bead portion of the conventional bead changes continuously from the outer plate with a smooth curved surface, whereas the bead according to the present invention makes the ridge portion steep (discontinuous) from the outer plate. Launched. Lowering the bead height and lowering the quality requirements for the bead press mold reduces the cost due to the mold. Then, the generated distortion is prevented from propagating on the outer plate due to the boundary (bead contour) between the collar and the outer plate raised steeply (discontinuously).

  Below, with reference to FIG. 1, FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 7 and FIG. 8, a wife skin will be described as an example of the skin according to the embodiment of the present invention. To do. A wife outer plate Peg shown in FIG. 1 (a) is attached to a wife structure Sg shown in FIG. 1 (b) by spot welding Ws. FIG. 2 shows a cross section of the end face plate Peg cut along a straight line II-II in FIG. As shown in FIG. 1 (a), the wife outer plate Peg has a plurality of (28 in this example) beads B protruding from the outer plate Pe in the vehicle longitudinal direction Dl extending in the vehicle width direction Dw at a predetermined interval. Is provided. As shown in FIG. 1B, the wife structure Sg is not provided with the transverse bone Fmh.

  As shown in FIG. 2, in the end plate Peg, several bead B (28 in this example) are pressed in parallel with the vehicle width direction Dw on the outer plate Pe having a thickness T of 1.5 mm. It is extended. The bead B is not responsible for the structural strength of the wife structure Sg, and is provided for aesthetic purposes (preventing slight distortion on the outer plate Pe and making the generated distortion inconspicuous). ing. The cross-sectional shape of the bead B forms an edge Ce with respect to the outer plate Pe, and rises in a vehicle longitudinal direction Dl / vehicle height direction Dv with a curved surface defined by a predetermined radius of curvature Rb. The peak height Hb (hereinafter “bead height Hb”) is reached. That is, the bead B is wide (bead width Wb = 35 mm) and has a low (bead height Hb = 6 mm) arched cross section. In the bead B, the edge Ce along the contour of the bead B is generated on the convex surface Sp side, that is, the cross-sectional shape of the bead B on the convex surface Sp side changes abruptly / discontinuously at the edge Ce. On the other hand, the cross-sectional shape on the concave surface Sr side changes smoothly and continuously.

  Compared with the conventional wife outer plate Pegc2 and wife structure Sgc2 shown in FIG. 11, the plate thickness T of the outer plate Pe according to the present embodiment is increased by 0.3 mm to 1.5 mm (plate thickness Tc2 = 1.2 mm). At the same time, the bead Bcw is replaced with the bead B. Specifically, the bead Bcw is wider than the bead B on the outer plate Pec2 having a plate thickness Tc2 = 1.2 mm (bead width Wbc2 = 39.48 mm, ridge width Wsc2 = 30 mm, top width Wpc2 = 18 mm / Wb = 35 mm). And high (Hbc2 = 15 mm / Hb = 6 mm), and has a strength corresponding to the transverse bone Fmh. Thus, the bead B is a simplified version compared to the bead Bcw, and the cost due to the mold is reduced by lowering the quality requirement for the bead press mold.

  Further, since the bead B is a simple bead, its structural strength is not so large as the bead Bcw corresponding to the transverse bone Fmh. For this purpose, the plate thickness T (= 1.5 mm) of the outer plate Pe is increased by 0.3 mm compared to the plate thickness Tc2 (= 1.2 mm) to secure the structural strength as the wife outer plate Peg. .

  Compared with the conventional wife outer plate Pegc3 and wife structure Sgc3 shown in FIG. 16, the plate thickness T of the outer plate Pe in the present embodiment is reduced by 1.5 mm to 1.5 mm (plate thickness Tc3 = 2.0 mm). ) And a plurality of beads B are added. Further, the wife structure Sg is configured by removing the lateral bone Fmh from the wife structure Sgc3. This is because the structural strength of the outer plate Pe is increased by the added bead B compared to the outer plate Pec3, so that the plate thickness can be reduced by 0.5 mm (plate thickness T = 1.5 mm). It becomes possible. As a result, the cost reduction due to the reduction of the thickness of the outer plate Pe is realized, and in the wife structure Sg, the transverse bone Fmh is abolished from the wife structure Sgc, and the cost reduction due to the abolished transverse bone Fmh is realized. Yes.

  Further, the cross-sectional shape of the bead B on the convex surface Sp side changes rapidly / discontinuously at the edge Ce. Contrary to the conventional bead Bcw having no outline, the bead B has a boundary between the edge Ce and another region on the outer plate Pe. This boundary is called a bead outline Ob. That is, the bead B protrudes in a generally arcuate shape (FIG. 2) toward the outside (the vehicle longitudinal direction Dl) at the wife outer plate Peg, and the edge Ce (bead) rises suddenly with respect to the flat portion of the outer plate Pe. It is formed discontinuously by the contour Ob).

  The bead B (convex surface Sp) functions to suppress the generation of distortion D on the surface of the outer surface plate Peg. Furthermore, even when a distortion occurs on the surface of the outer face plate Peg (bead B or a portion excluding bead B), the bead outline Ob (edge Ce) prevents the distortion from propagating on the surface of the outer face plate Peg. The Moreover, the shadow formed on the surface of the wife outer plate Peg by the bead B has an effect of making the generated distortion inconspicuous. Furthermore, wrinkles (distortion D) extending in a direction substantially parallel to the bead contour Ob also have an effect that the bead contour Ob is not noticeable.

  Next, with reference to FIG. 3, FIG. 4, and FIG. 5, the bead unloading process according to the present embodiment will be described. FIG. 3A shows an example of the outer plate Pe from which the bead B is pressed (hereinafter referred to as “bead press outer plate Pe”. In FIG. 3, the bead press outer plate in a posture when attached to the vehicle on the left side. A state in which Pe is viewed from the front side of the vehicle exterior is shown, and a cross section cut along a straight line IIIa-IIIa in the same drawing is shown on the right side.

  In this example, four beads B projecting in an arc shape by a bead height Hb in the vehicle longitudinal direction Dl on the bead press outer plate Pe having a bead press outer plate thickness T have a bead width Wb in the vehicle high direction Dv. And it is formed extending in the vehicle width direction Dw by a length Lb (hereinafter, “bead length Lb”). In the bead press outer plate Pe, the portion other than the bead B is generally flat, and this portion is referred to as a flat portion of the bead press outer plate Pe. The arc-shaped protruding surface of the bead B is referred to as a convex surface Sp, and the concave surface is referred to as a concave surface Sr for identification. The bead height Hb corresponds to the above-described conventional bead height Hbc, the bead press outer plate thickness T corresponds to the above-described bead press outer plate thickness Tbc, and the bead press outer plate Pe corresponds to the above-described bead press outer plate Pec. To do.

The bead press outer plate Pe is set so as to satisfy the requirements described below in order to suppress the generation of distortion, to prevent propagation of the generated distortion, and to reduce the quality requirements for the mold.
Bead press outer plate thickness T = 1.0-1.5mm
Bead height Hb = 5-8mm
Bead width Wb = 30-60mm
Bead height Hb / bead width Wb = 0.13 to 0.17
Bead height Hb / bead press outer plate thickness T = 3-6
Bead width Wb / bead press outer plate thickness T = 20-60

The structural strength of the bead press outer plate Pe is determined by the bead press outer plate thickness T and the bead B (bead height Hb, bead width Wb). That is, when the structural strength of the outer plate Pe is Se and the material of the bead press outer plate Pe is M,
It can be generalized as Se = f (Hb, Wb, T, M).

  Since the bead press outer plate Pe is usually spot-welded to the structure, the material M of the bead press outer plate Pe is selected from the same material as the structure. In the case of a steel vehicle, a bead press outer plate Pe that can reduce bones without increasing the thickness of the outer plate is often used to suppress an increase in weight. Is about 1/3 of steel, so the thickness of the outer skin is about 1.4 times that of steel, and the press workability is reduced. What is not performed is the same as that of the above-described conventional bead press outer plate Pec.

  FIG. 3B shows an example of a press-type male die Dm (hereinafter, “press male die Dm”) used for forming the above-described bead press outer plate Pe. In the drawing, the left side shows the state of the press male die Dm in the pressing process as viewed from above, and the right side shows a cross section taken along the line IIIb-IIIb in the drawing. As shown in the drawing, the press male die Dm has a predetermined thickness Tbm (hereinafter referred to as “press male die thickness Tbm”) and has a rectangular block shape corresponding to the bead press outer plate Pe (FIG. 3A). Is formed. The press male die Dm is not provided with anything corresponding to the bead die P provided corresponding to the bead Bc formed in the press male die Dcm. The press male die Dm is made of urethane rubber from the viewpoint of mechanical strength. The press male mold thickness Tbm> the bead height Hb.

  FIG. 3C shows an example of a press die female die Df (hereinafter referred to as “press female die Df”) used for forming the bead press outer plate Pe. In the drawing, the left side shows a state of the press female die Df in the pressing step as viewed from above, and the right side shows a cross section taken along a line IIIc-IIIc in the drawing. The press female die Df has a predetermined thickness Tbf (hereinafter, “press female die thickness Tbf”) and is formed in a rectangular plate shape corresponding to the bead press outer plate Pe (FIG. 3A). Yes. The press female mold thickness Tbf ≧ bead height Hb. In the press female die Df, a bead die hole H is formed by a laser beam L that forms a predetermined angle θ (45 ° ≦ θ ≦ 135 °) with respect to two parallel surfaces thereof. The bead mold hole H has a width Wbf in the vehicle height direction Dv (hereinafter “bead mold hole width Wbf”) and extends in the vehicle width direction Dw by a length Lbf (hereinafter “bead mold hole length Lbf”). Exist.

The opening width Wht of the bead mold hole H (hereinafter referred to as “upper surface opening width Wht”) and the opening width Whb of the bead mold hole H (hereinafter referred to as “lower surface opening width Whb”) on each of the upper surface St and the lower surface Sb of the press female die Df. ) Is expressed by the following equations (4) and (5), as will be described later with reference to FIG.
Wht = Wbf (4)
Whb = Wbf + 2 tan (θ−90 °) · Tbf (5)

  FIG. 4 shows an enlarged view of the bead die hole H of the press female die Df shown in FIG. FIG. 4A shows that a bead mold hole H having a rectangular cross-sectional shape is formed by a laser beam L which forms a right angle (θ = 90 °) with respect to the upper surface St of the press female die Df. ing. A corner C having an angle of (180 ° −θ = 90 °) with respect to the laser beam L is formed on the upper surface St side of the press female die Df that forms the side surface of the bead die hole H.

The portions in the thickness direction of the press female die Df that form the side periphery of the bead die hole H are parallel to each other and perpendicular to the upper surface St and the lower surface Sb of the press female die Df. As a result, the bead mold hole width Wbf is constant over the entire area of the bead mold hole H as shown in FIG. Since tan (θ−90 °) = 0 from θ = 90 °, the above equation (5) is expressed by the following equation (6).
Whb = Wbf + 0 = Wbf (6)

Therefore, the following expression (7) is obtained from the above expressions (4) and (6).
Wht = Wbf = Whb (7)

Referring to FIG. 4B, a trapezoidal shape spreading from the upper surface St toward the lower surface Sb by a laser beam L having an obtuse angle (90 ° <θ ≦ 135 °) with respect to the upper surface St of the press female die Df. The formation of the bead mold hole H having a cross-sectional shape will be described. A corner C having an angle of (180 ° −θ) with respect to the laser beam L is formed on the upper surface St side of the press female die Df that forms the side surface of the bead die hole H. In the figure, as a representative example, θ = 135 °, and the angle of the corner C with respect to the laser beam L is 45 °. The upper surface opening width Wht and the lower surface opening width Whb correspond to the upper base and the lower base of the trapezoid, respectively. In this case, since 90 ° <θ ≦ 135 °, 0 <tan (θ−90 °) ≦ 1. That is, the above equation (5) can be expressed by the following equation (8).
Wbf <Whb ≦ Wbf + 2Tbf (8)

Referring to FIG. 4C, a trapezoidal shape that narrows from the upper surface St toward the lower surface Sb by a laser beam L that forms an acute angle (45 ° ≦ θ <90 °) with respect to the upper surface St of the press female die Df. The formation of the bead mold hole H having a cross-sectional shape will be described. In the figure, as a representative example, θ = 45 °, and the angle of the corner portion C with respect to the laser beam L is 135 °. The upper surface opening width Wht and the lower surface opening width Whb correspond to the upper base and the lower base of the trapezoid, respectively. In this case, since 45 ° ≦ θ <90 °, −1 ≦ tan (θ−90 °) <0. That is, Expression (5) can be expressed by the following Expression (9).
Wbf-2Tbf ≦ Whb <Wbf (9)

  The cross-sectional shape in the vehicle height direction Dv of the bead mold hole H of the press female mold Df has been described above with reference to FIG. However, the same applies to the cross-sectional shape of the bead mold hole H in the vehicle width direction Dw. Therefore, the description regarding the cross-sectional shape of the press female die Df in the vehicle width direction Dw is omitted. In addition, the corner | angular part C can take the range of 45 degrees-135 degrees from the above-mentioned.

  Next, referring to FIG. 5 and FIG. 6, the bead B is pressed on the bead press outer plate Pe using the press male die Dm and the press female die Df of θ = 90 ° illustrated in FIG. A bead press method for forming and producing a wife outer plate Peg will be described. In FIG. 5 (a), an outer plate Pe is placed on a press female die Df installed on a bolster DB of a press machine (not shown) so as to face the press female die Df above it. The state which looked at the vehicle width direction Dw direction in the state by which the press male type | mold Dm was hold | maintained is shown. In this state, the press male die Dm is lowered toward the press female die Df in the bead press direction Dpb by a slide (not shown) of the press machine, thereby starting the bead press process.

  FIG. 5B shows a state of the press male die Dm and the outer plate Pe when the slide reaches the bottom dead center. At this point, the bead B having the arcuate cross-sectional shape described with reference to FIG. 2 is formed in the bead die hole H of the press female die Df. Thereafter, the press male die Dm is raised and the outer plate Pe is taken out from the press female die Df, whereby the wife outer plate Peg can be obtained as shown in FIG.

  FIG. 6 is an enlarged view of the right half of one bead mold hole H in a state where the press male die Dm is in contact with the upper surface of the outer plate Pe placed on the press female die Df. Now, the above-described bead press process will be described. As shown in FIG. 6A, when the press male die Dm is in contact with the upper surface of the outer plate Pe placed on the press female die Df, the slide of the press machine further descends in the bead press direction Dpb. The press male die Dm made of rubber is pressed against the press female die Df through the outer plate Pe. At this time, the press male die Dm is compressed in the bead press direction Dpb, and starts elastic deformation so as to press the outer plate Pe against the press female die Df.

  Elastic deformation of the press male die Dm in the bead press direction Dpb direction is prevented by the press female die Df at portions other than the bead die hole H of the press female die Df. However, since no resistance is received in the bead mold hole H, the elastic deformation of the press male mold Dm in the bead press direction Dpb acts as a pressure (deformation pressure) for deforming the outer plate Pe in the bead press direction Dpb. As the deformation pressure increases as the slide descends, the portion of the outer plate Pe positioned above the bead mold hole H will eventually be unable to resist the deformation pressure of the press male mold Dm. It plastically deforms (produces extension) with the location in contact with the corner C of the hole H as the base point, and begins to deform in the longitudinal direction D1 as shown in FIG.

  At this time, an edge Ce that defines the contour of the bead B is formed on the lower surface of the outer plate Pe that is in contact with the corner portion C of the bead mold hole H. The shape of the corner portion C of the press female die Df and the edge Ce formed on the outer plate Pe will be described later with reference to FIG.

  After the edge Ce is formed, when the portion of the outer plate Pe located above the bead mold hole H starts to deform, the press male die Dm concentrates on the deformed portion of the outer plate Pe and protrudes elastically, A force for further deforming the plate Pe works. As shown in FIG. 6B, the portion of the outer plate Pe positioned above the bead mold hole H has a predetermined inclination angle θi with respect to the bead press direction Dpb with respect to the edge Ce on both sides (FIG. 7). Are formed into an arc shape in the bead press direction Dpb direction (vehicle longitudinal direction Dl). In this example, the bead press direction Dpb coincides with the inner peripheral wall surface of the bead mold hole H.

  Since the press male die Dm is made of an elastic material (urethane rubber in this example) as described above, at least when the outer plate Pe starts to be deformed, the outer plate Pe is attached to the press female die Df. It cannot be pressed completely into a non-bead type hole. That is, a portion of the press male mold Dm located at the center of the bead mold hole H of the outer plate Pe suppresses the deformation resistance of the outer plate Pe and pushes the outer plate Pe in the bead press direction Dpb and plastically deforms it.

  On the other hand, the portion of the outer plate Pe in contact with the upper surface of the press female die Df is not plastically deformed and remains substantially flat. As described above, in the outer plate Pe, the edge Ce is formed at the boundary between the portion that is plastically deformed and the portion that is not plastically deformed. Since the edge Ce is in close contact with the corner portion C of the bead mold hole H, the position shift of the portion that cannot be plastically deformed is prevented. Further, it is possible to prevent the outer plate Pe from being distorted due to the plastic deformation of a part of the outer plate Pe. Since the central part of the bead mold hole H has no obstacle to the outer plate Pe, the shape of the elastically deformed portion (bulged portion) of the press male mold Dm and the deformation of the outer plate Pe are also gentle.

  When the deformation of the outer plate Pe in the beat “press direction Dpb” proceeds, as shown in FIG. 6C, the top of the deformed portion (bulged portion) of the outer plate Pe contacts the bolster DB. At this time, the cross-sectional shape of the bead B formed on the outer plate Pe is arcuate as shown in FIG. Thereafter, the deformed portion (bulged portion) of the press male Dm spreads along the bolster DB in the vehicle height direction Dv direction according to the slide descending amount, and the cross-sectional shape changes from an arc shape to a rectangular shape. Go. In other words, when the formed bead B comes closer to the cross-sectional shape of the transverse bone, the structural strength can be increased.

  Below, with reference to FIG. 7, the relationship between the corner | angular part C of the press female metal mold | die Df and the shape of the edge Ce formed in the outer plate Pe is considered. In the present discussion, it is assumed that both the outer plate Pe and the male press Dm have contradictory properties such that the deformation resistance is extremely small, however, it has sufficient mechanical strength and can be easily plastically deformed.

  FIG. 7 enlarges the periphery of the right corner C of the bead die hole H of the press female die Df (θ = 90 °) shown in FIG. More specifically, FIG. 7A shows an enlarged view of the edge Ce defining the contour of the bead B of the outer plate Pe and the corner C of the press female die Df, and FIG. FIG. 7A shows an enlarged portion of the edge Ce surrounded by the circle O1, and FIG. 7C shows a local portion of the edge Ce surrounded by the circle O2 in FIG. 7B, that is, the outer plate Pe. The part which changes to bead B is shown enlarged.

  As shown in FIG. 7A, the edge Ce formed on the lower surface Sbp of the outer plate Pe is located in the bead mold hole H from the state where the lower surface of the outer plate Pe is in close contact with the upper surface St of the press female die Df. It is deformed discontinuously in the press female die thickness Tbf direction from the corner C of the open end. As a result, an edge Ce is formed in the vicinity of the tip of the corner C. Since it is formed in this way, at least the center part of the edge Ce is deformed steeply and discontinuously from the outer plate Pe following the shape of the tip of the corner part C.

As shown in FIG. 7B, the cross-sectional shape of the tip end portion of the corner portion C of the press female die Df corresponding to the center portion of the edge Ce has a straight line corresponding to the lower surface Sbp of the outer plate Pe and the bead B. And a curve corresponding to the convex surface Sp. In the figure, a tangent line Lt to the convex surface Sp (curved surface) intersects the lower surface Sbp (the upper surface St of the press female die Df) at a predetermined angle θi (hereinafter referred to as “inclination angle θi”). The inclination angle θi is 0 ° when the position in contact with the convex surface Sp of the bead B of the tangent Lt is the tip of the arcuate portion, and increases as the edge Ce approaches and approaches θ. In this example, since θ = 90 °, the following equation (10) is established.
0 ° ≦ θi ≦ 90 ° (10)

As shown in FIG. 7C, the cross-sectional shape of the bent portion of the edge Ce (the boundary where the lower surface Sbp changes to the convex surface Sp) can be defined by the curvature radius Rc represented by the following equation (11).
0 ≦ Rc ≦ T (11)

  From the above equations (10) and (11), at the bent portion of the edge Ce, θi approaches θ (90 ° in this example) and the radius of curvature Rc approaches zero, and the tangent Lt of the convex surface Sp and the lower surface Sbp are It approaches the shape of the tip of the corner C as much as possible. When the radius of curvature Rc = 0, the edge Ce is completely the same as the shape of the corner C of the press female die Df.

  7A illustrates the shape in which the edge Ce is separated from both the lower surface Sbp and the side surface of the corner portion C, but the shape may be separated from either the lower surface Sbp or the corner portion C. Further, when the edge Ce has a shape that separates from the side surface of the corner portion C, the convex surface Sp can take a shape that does not contact the side surface of the corner portion C. In any of these cases, the tangent Lt of the surface Sp coincides with the lower surface Sbp as much as the tip shape of the corner C. In other words, θi≈90 °. Regarding the cross-sectional shape of the bead B in the vehicle width direction Dw and the contour shape by the edge Ce (bead contour Ob), the cross-sectional shape of the bead B in the vehicle height direction Dv, mainly the contour shape of the bead B by the edge Ce (bead contour Ob). Is the same as described above.

  The consideration of the relationship between the corner C of the press female die Df and the shape of the edge Ce formed on the outer plate Pe described with reference to FIG. 7 is that the outer plate Pe and the press male die Dm are actually Is assumed to be composed of materials that are not available. That is, in reality, stainless steel, which is a high tensile strength material, is used for the outer plate Pe, and urethane rubber, which is a highly elastic material, is used for the press male die Dm.

  4, 6, and 8, the corner C of the press female die Df when stainless steel is used for the outer plate Pe and urethane rubber is used for the press male die Dm, The relationship with the shape of the edge Ce formed on the plate Pe will be described. As described with reference to FIG. 4, the corner C around the bead die hole H of the press female die Df has an arbitrary angle in the range of 45 ° to 135 ° (preferably 90 °). I can take it.

  As shown in FIG. 4A, when the corner C of the press female die Df is 90 ° (180 ° −θ), the tangent to the convex surface Sp of the bead B having the cross-sectional shape shown in FIG. The inclination angle θi with respect to the lower surface Sbp of Lt is 45 °. This is different from the consideration result (θi≈90 °) described with reference to FIG. This phenomenon is caused by the elastic deformability of the press male die Dm and the plastic deformability of the outer plate Pe. That is, in the bead press process, the deformation of the outer plate Pe by the press male die Dm is established by a balance between the elastic deformation of the urethane rubber of the press male die Dm and the plastic deformation (extension) of the stainless steel of the outer plate Pe. Yes.

In order to be θi = 90 °, the tangent line Lt of the convex surface Sp needs to coincide with the inner peripheral wall surface (corner portion C) of the bead mold hole H in the vicinity of the edge Ce. However, in this example, θ = 90 °, so the outer plate Pe must be deformed suddenly at right angles in the bead press direction Dpb from a position slightly closer to the center of the bead mold hole H than the apex of the corner C. . However, it is impossible to deform the outer plate Pe made of a stainless steel plate material at right angles by the elastic deformation of urethane rubber (press male Dm). It is possible to increase the amount of deformation of the outer plate Pe by using urethane rubber having a higher hardness for the press male die Dm. However, when the deformation amount of the outer plate Pe increases, the tension generated in the outer plate Pe also becomes enormous. Therefore, the maximum deformation amount of the outer plate Pe is limited to θi = 45 °. In other words, the bead B has a cross-sectional shape that continuously changes in a range in which the inclination angle θi satisfies the following expression (12).
0 ° <| θi | ≦ 45 ° (12)

The curvature radius Rc of the bent portion of the edge Ce is expressed by the following equation (13).
0 <Rc ≦ T (13)

That is, the bent portion of the edge Ce is not the same as the tip shape of the corner portion C of the press female die Df. Further, the inclination angle θi continuously changes at the edge Ce in a range satisfying the following expression (14).
45 ° <| θi | ≦ 90 ° (14)

  Since the press female die Df shown in FIG. 4B has a corner portion C in the range of 45 ° to 90 °, the cross-sectional shape of the bead die hole H is the corner portion C (90 ° in FIG. 4A). ) And becomes wider toward the lower surface Sb. Therefore, the edge Ce formed on the lower surface of the outer plate Pe becomes very deep, and the cross section of the bead B is not a circular arc shape as shown in FIG. It seems to be. However, as described above, the outer plate Pe cannot be deformed even at right angles to the bead press direction Dpb, so that the press male mold Dm is deformed in the diverging direction and wraps around the corner portion C to enter the lower portion of the corner portion C. It cannot swell into space. That is, as in the case where the corner C is 90 °, θi = 45 ° is the limit. As a result, as shown in FIG. 8A, a bead B having an arcuate (FIG. 2) cross section is formed as in the case of the press female die Df shown in FIG.

  Since the press female die Df shown in FIG. 4C has a corner portion C in the range of 90 ° to 135 °, the cross-sectional shape of the bead die hole H is the corner portion C (90 °) in FIG. It is steeper as compared with, and narrows toward the lower surface Sb. Therefore, the edge Ce formed on the lower surface of the outer plate Pe becomes very shallow, and the cross section of the bead B is not an arc shape as shown in FIG. 2 but a tapered truncated cone shape from the upper end to the lower end. It seems to be. However, as described above, θi = 45 °. As a result, as shown in FIG. 8 (b), a bead B having an arcuate (FIG. 2) cross section is formed as in the case of the press female die Df shown in FIG. 4 (a).

  As described with reference to FIG. 6C, FIG. 8A, and FIG. 8B, if the corner C is in the range of 45 ° to 135 °, θi is approximately 45 °. The formed beads B have substantially the same cross-sectional shape.

  In addition, the press female mold Df is preferably a product in which the corner C shown in FIG. 4A is 90 °. That is, when the corner C is 90 °, the laser beam L irradiated at θ = 90 ° with respect to the outer plate Pe may be moved in parallel with the shape of the bead B. Is easy to cut, and it is easy to ensure the shape accuracy of the bead mold hole H. However, the irradiation angle of the laser beam L is not limited to θ = 90 °, and may be any angle in the range of θ = 45 ° to 135 °, and the laser beam L is not required to be translated. As described above, the bead B having substantially the same shape can be formed.

  As described above with the wife skin as an example, the skin according to the present invention is lower in cost and in a simple manner, and the skin is flat with a three-dimensional bead (convex surface, concave surface) by the edge forming the contour of the bead B. It is separated into a non-bead part. The bead (convex surface, concave surface) works to suppress the occurrence of distortion on the surface of the outer surface of the wife. Furthermore, even when distortion occurs on the surface of the outer plate (bead B or a portion excluding bead B), the bead contour prevents the distortion from propagating on the surface of the outer plate. In addition, the shadow formed on the surface of the outer plate by the bead provides an effect that does not make the generated distortion noticeable. Still further, wrinkles (distortions) extending in a direction substantially parallel to the bead contour are not noticeable due to the bead contour.

  As described above, the present invention is not limited to the illustrated outer skin plate but can be applied to an outer skin plate for a railway vehicle structure such as a side skin plate or a roof skin plate. Needless to say, the bead shape can be formed not only by the illustrated simple linear shape but also by a design shape imitating a mark such as a company emblem. Furthermore, since the male mold becomes a general-purpose mold, the bead can be partially abolished or thinned out easily by filling the female bead mold hole.

  INDUSTRIAL APPLICABILITY The present invention can be used for a railcar outer plate having aesthetics and strength.

Sg, Sgc1, Sgc2, Sgc3 Wife structure Peg, Pegc1, Pegc2, Pegc3 Wife skin Pe, Pc, Pec1, Pec2, Pec3 Outer plate B, Bc, Bcv, Bcw Bead Ce Edge Ob angle Sbp Pec bead press outer plate T, Tbc, Tc1, Tc2, Tc3 Bead press outer plate thickness Hb, Hbc, Hbc1, Hbc2 Bead height Wb, Wbc, Wbc1, Wbc2 Bead width Lb, Lbc, Lbc1, Lbc2 Total bead length Ls1, Lbc Spear length Sp Convex surface Sr Concave surface Dc Multiple bead press mold Dcs Single bead press mold Dcm, Dcsm Press male mold P, Ps Bead type Hbcm Bead type depth Wbcm Bead type width Lbcm Bead type length Dm Press male type Tbm Press male Mold thickness Dcf Dcsf Press female mold R, Rs Bead mold groove Hbcf Bead mold depth Wbcf Bead mold width Lbcf Bead mold length Df Press female mold Tbf Press female mold thickness St Upper surface Sb Lower surface H Bead mold hole Wbf Bead mold hole width Lbf Bead Cavity length C Corner Wht Upper surface opening width Whb Lower surface opening width L Laser beam DB Bolster Dpb Bead press direction Fmv Longitudinal bone Fmh Horizontal bone Pt Column Fvr, Fvl Vertical frame Fh Horizontal frame Fu Underframe Ws Spot welding Dv Vehicle height direction Dw Vehicle width direction Dl Vehicle longitudinal direction

Claims (10)

A plurality of beads are formed to extend in a first direction on a flat plate defined by a first main surface and a second main surface facing each other in parallel and having a first predetermined plate thickness. A rail vehicle structural skin,
Each of the beads has a predetermined cross-sectional shape defined by a predetermined width and a predetermined height and protrudes from the first main surface to the second main surface side,
An outer plate for a railway vehicle structure, wherein an edge defined by a predetermined radius of curvature is formed at a boundary between the bead and the second main surface.   2. The outer plate for a railway vehicle structure according to claim 1, wherein an outline of the bead is defined by the edge on the second main surface.   The cross-sectional shape is included in a plane perpendicular to the first direction, and 0 ° < The outer plate for a railway vehicle structure according to any one of claims 1 and 2, wherein the outer plate changes continuously in a range of | θi | ≦ 45 °.   The outer plate for a railway vehicle structure according to claim 3, wherein the θi continuously changes in the range of 45 ° <| θi | ≦ 90 ° at the edge. When the first predetermined plate thickness is T, the predetermined height is Hb, and the predetermined width is Wb,
1.0 mm ≦ T ≦ 1.5 mm,
5 mm ≦ Hb ≦ 8 mm,
0.13 ≦ Hb / Wb ≦ 0.17,
3 ≦ Hb / T ≦ 6, and
20 ≦ Wb / T ≦ 60
The outer plate for a railway vehicle structure according to any one of claims 1, 2, 3, and 4.   The outer plate for a railway vehicle structure according to claim 5, wherein the cross-sectional shape is an arc shape.   6. The outer plate for a railway vehicle structure according to claim 5, wherein the cross-sectional shape is a trapezoidal shape including two arc-shaped portions and one linear portion. A bead forming method for simultaneously forming a plurality of beads on a railcar structure outer plate according to claim 1, claim 2, claim 3, claim 4, claim 5, claim 6, and claim 7. There,
The second predetermined plate thickness larger than the predetermined height and formed in a flat plate shape defined by a third main surface and a fourth main surface facing each other in parallel, and the third The second main surface is in contact with the third main surface of the press female mold in which a plurality of bead mold holes having the contour of the bead are formed over the main surface and the fourth main surface. So as to place the flat plate,
An elastic body having a third plate thickness and defined by a fifth main surface and a sixth main surface is formed on the flat plate, and the sixth main surface is the first main body. Pressing in a direction perpendicular to the first, second, third, fourth, fifth and sixth main surfaces while abutting against the main surface of the flat plate, it corresponds to the bead type hole of the flat plate And a step of processing the portion to be processed into the bead.   The bead forming method according to claim 8, wherein the elastic body is made of urethane rubber.   The bead mold hole is formed in the fourth main surface at a predetermined angle with respect to the third main surface, and the predetermined angle is not less than 45 ° and not more than 135 °. The bead forming method according to claim 9.