JP2017222069A - Drawing mold of aluminum resin composite laminate, and press molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve moldability in the case of producing a square-type molded article using an aluminum resin composite laminate by press molding, and to perform deep-drawing while obtaining favorable appearance characteristics after molding.SOLUTION: A die of a drawing mold includes: a vertical heater arranged along a molding direction in each corner in the periphery of a molding square hole; and a die-side horizontal heater arranged in an area closer to an outer peripheral side than the vertical heater and along a horizontal direction in each side portion in the periphery. A blank holder includes a holder-side horizontal heater arranged along a horizontal direction in at least a long side portion of each side portion in the periphery of a penetration square hole. The plural vertical heaters, the die-side horizontal heaters, and the holder-side horizontal heaters are disposed so that the temperatures of the heaters can be independently adjusted.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a drawing mold and a press molding method for press-molding an aluminum resin composite laminate formed by laminating an aluminum plate and a foamed synthetic resin layer to form a square molded product.

  In recent years, in the plate-like member used for various uses, weight reduction of a material is a big subject, and it is not limited to the automobile field, but it is a railway vehicle, an aircraft, a ship and other transportation equipment, a household appliance, an IT related member, and There is a need to reduce the weight of houses and outer wall materials such as buildings. As an example, in an automobile, replacement of a part of a steel plate used for vehicle parts with an aluminum plate, a resin plate, or a CFRP (carbon fiber reinforced plastic) plate has been studied. Furthermore, depending on the application, in addition to light weight, additional performance such as vibration control, sound insulation, and heat insulation is often required. As one of the plate materials to meet such demands, two aluminum It has been proposed to use an aluminum resin composite laminate in which a synthetic resin layer is sandwiched between plates. And this kind of laminated board is normally processed by press molding.

  For example, Patent Document 1 discloses a laminated plate in which a foamable resin layer is provided between two aluminum alloy plates. Patent Document 2 discloses an example in which the laminated plate described in Patent Document 1 is applied to a lightweight heat ray shielding cover having a three-dimensional shape and excellent heat ray shielding properties, such as a heat insulator. Furthermore, in Patent Document 2, as a method of forming the laminated plate, press forming such as bulging forming, drawing forming, bending forming, and bending can be performed, and the resin layer is foamed by heating after the forming processing. Is described.

  In Patent Document 3, a thermoplastic resin layer and an aluminum material are laminated, and a surface layer of the aluminum material is provided with a porous aluminum oxide film layer having a small diameter on the surface side, and a barrier type on the substrate side. An aluminum oxide film layer is provided, and a non-foamed resin layer of the same component as the thermoplastic foam resin layer is formed on the porous aluminum oxide film layer from the surface thereof at the joint between the aluminum material and the thermoplastic foam resin layer. An aluminum material / thermoplastic foamed resin layer composite formed toward the inside of the small holes is disclosed. Patent Document 3 describes that by adopting such a configuration, a composite material having excellent adhesion and formability is obtained.

  In Patent Document 4, aluminum having a higher strength than the inner aluminum plate is used for the outer aluminum plate at the time of press molding, and the outer aluminum plate thickness is equal to or thicker than the inner aluminum plate thickness. An aluminum alloy press-molding composite plate is disclosed. In Patent Document 4, when the strength of the outer and inner aluminum plates is relatively viewed, a high strength material is used on the outer side, a low strength material is used on the inner side, and the outer plate thickness is equal to the inner plate thickness. Alternatively, it is described that, by increasing the thickness, it is possible to prevent the occurrence of cracks during press molding, and an aluminum composite plate having excellent press moldability is obtained.

International Publication No. 2010/029955 International Publication No. 2010/029946 JP 2012-25145 A JP-A-4-43027 JP 2013-116475 A JP 2014-18854 A JP 2009-242240 A

  By the way, as disclosed in, for example, Patent Documents 5 to 7, when forming a metal plate conventionally formed of a single metal, generation of wrinkles and cracks is prevented, and further, a spring back after forming is prevented. A molding method for reducing the number has been proposed. However, when a composite laminate as described in Patent Documents 1 to 4 is formed by the same method as Patent Documents 5 to 7, it is press-molded into a two-dimensional product or a three-dimensional product with a slight depth. It is useful in some cases, but if it is molded into a deeper and more complex shape (such as a square-shaped molded product), the surface of the aluminum sheet cannot prevent rough skin, wrinkles, cracks, etc. It is a problem to cause defects. Moreover, even if it forms the highly difficult three-dimensional shape as a composite laminated board described in patent document 4, it is difficult to prevent generation | occurrence | production of a crack etc. and cannot perform stable shaping | molding. In particular, in the case of a composite plate used for an outer plate of a vehicle, it is required to have a good surface without rough skin, and further improvement is desired. In addition, there is an attempt to ensure moldability by foaming the core resin after molding as in Patent Document 1 or 2, but it is easy to cause changes in the dimensions of the laminate and distortion in the resin foam after molding. There is a high risk of becoming an obstacle during assembly.

  The present invention has been made in view of the above circumstances, and further improves the formability when a square-shaped molded article using an aluminum resin composite laminate is manufactured by press molding to obtain good appearance characteristics after molding. While aiming to form deeply.

  The drawing mold of the present invention is a drawing mold for deep-drawing a blank material made of an aluminum resin composite laminate in which aluminum plate materials are laminated on both sides of a foamed synthetic resin layer into a rectangular shaped molded product. The die is a die having a forming square hole having substantially the same shape as the bottom surface of the square-shaped molded article, and a through-angle hole having substantially the same shape as the forming square hole and the die surface. A blank holder that holds the material, and a prismatic punch that is inserted into the forming square hole and the through-angle hole to draw the blank material, and the die includes a peripheral portion of the forming square hole. Built-in vertical heaters arranged along the molding direction at each corner, and die side horizontal heaters arranged along the horizontal direction on each side of the peripheral part on the outer peripheral side of the vertical heater. To the blank holder A holder side horizontal heater arranged along the horizontal direction is built in at least the long side part of each of the peripheral parts of the through-angle hole, and a plurality of the vertical heaters and the die side horizontal heaters are incorporated. The holder-side horizontal heater is provided so that the temperature can be adjusted independently.

The aluminum resin composite laminated plate is very difficult to be drawn compared to the case of forming a metal plate formed of a single metal. In other words, since the appropriate molding conditions differ between the foamed synthetic resin and aluminum, the difference in deformation amount between the foamed synthetic resin layer formed of the foamed synthetic resin that is the core material and the aluminum plate disposed on both surfaces thereof. Appearance defects are likely to occur due to the occurrence of rough skin, wrinkles, cracks, etc. including fine irregularities on the surface of the aluminum plate. In addition, in the square molded product, the corner is the most difficult to mold, and depending on the processing conditions, the foamed synthetic resin itself is deformed and contracted by the applied pressure, and this influence is affected by the aluminum plate material. There is a risk of promoting the appearance defects occurring on the surface of the plate material. For this reason, in an aluminum resin composite laminate composed of three layers in which an aluminum plate material is laminated on both surfaces of a foamed synthetic resin layer, the molding process must be performed in consideration of the molding conditions for each of these materials. It has become complicated.
In this regard, in the drawing mold of the present invention, since the arrangement of the plurality of heaters arranged in the die and the blank holder is optimized, the heating temperature control of the blank material can be performed at an appropriate temperature for each molding part. . In addition, if the temperature difference between the inner peripheral part side and the outer peripheral part side of the forming square hole is too large, the deformability difference becomes too large, and there is a possibility that cracks due to wrinkles and wrinkles may occur. Vertical heaters are arranged at the corners of the forming square holes of the die forming the die, and further, the die side horizontal heaters are arranged along the sides of the forming square holes on the outer peripheral side of the vertical heaters. In addition, by arranging the holder side horizontal heater, it is possible to adjust the temperature of the corner of the molded square hole higher than other parts, and to reduce the temperature difference between the inner and outer sides of the molded square hole. The peripheral portion excluding the corner portion can be heated uniformly.
In this way, with the optimized heater arrangement, the temperature difference between the inner peripheral side and the outer peripheral side of the molding square hole can be reduced, but the temperature can be controlled to an appropriate temperature for each molding part, and the aluminum resin composite laminate blank It is possible to realize temperature control in a high temperature range in which the foamed synthetic resin as the core material is heated to a temperature near the heat-resistant temperature so that stable warm forming can be performed. Therefore, it is possible to improve moldability when a square molded product using the aluminum resin composite laminate is manufactured by press molding, and it is possible to form deeply while obtaining good appearance characteristics.

  In the drawing die of the present invention, the holder side horizontal heater may be disposed at a position facing the die side horizontal heater.

  Thus, the blank material can be efficiently heated from both sides by disposing the holder side horizontal heater at a position facing the die side horizontal heater. Therefore, the blank can be quickly heated with the temperature distribution by the arrangement of the heaters, and highly accurate temperature management can be performed.

  In the drawing mold of the present invention, it is preferable that a heat insulating material is provided on an attachment surface of the die with the press machine body.

  By providing a heat insulating material on the die mounting surface, heat from the die and blank holder can be prevented from being transmitted to the main body of the press, thus preventing temperature drop of the die and blank holder, and high accuracy of the die and blank holder. Temperature management becomes possible.

  The press molding method of the present invention is a blank material comprising an aluminum resin composite laminate having a thickness of 1 mm or more and 10 mm or less in which an aluminum plate is bonded to both surfaces of a foamed synthetic resin layer having an expansion ratio of 1.5 to 10 times. Is a press-molding method for deep-drawing a square-shaped product having a depth of 10 mm or more, and using the drawing mold, the outer periphery of the blank material is placed between the die and the blank holder. The blank material is moved in a state of being sandwiched between the die and the punch, and a forming step is performed between the die and the punch. In the forming step, before forming the blank material, The temperature of the side portion and the temperature of the corner portion are lower than the heat resistant temperature of the foamed synthetic resin layer, and the temperature difference between the heat resistant temperature of the foamed synthetic resin layer is more than 10 ° C and not more than 22 ° C. When That together keep heating to a temperature, the average temperature of the corner portion of the forming rectangular holes, previously heated to a higher average temperature Temperature 5 ° C. or higher than the side portion of the molded rectangular holes.

In this press molding method, by using the above-mentioned drawing mold, drawing molding is performed while controlling the heating temperature of the blank material to an appropriate temperature for each molding part by each heater built in the die and the blank holder. Can be applied.
In this case, the vertical heater arranged at the corner of the molded square hole can adjust the temperature of the corner of the molded square hole higher than other parts of the peripheral part, and is arranged on the outer peripheral side of the vertical heater. The peripheral side excluding the corners can be uniformly heated while the temperature difference between the inner peripheral side and the outer peripheral side of the forming square hole is reduced by the die side horizontal heater. That is, as in the press molding method of the present invention, the side temperature and the corner temperature of the molding square hole are lower than the heat resistance temperature of the foamed synthetic resin layer of the blank material, and the foamed synthetic resin layer The temperature difference from the heat-resistant temperature is higher than 10 ° C. and 22 ° C. or lower, and the average temperature of the corners of the molded square holes is 5 ° C. or more higher than the average temperature of the sides of the molded square holes. Can be controlled to an appropriate temperature for each molded part, while reducing the temperature difference between the inner peripheral side and the outer peripheral side of the molded square hole, for the blank plate of the aluminum resin composite laminate, Temperature control in a high temperature range heated to near the heat-resistant temperature at which the foamed synthetic resin as the core material does not elute can be realized, and stable warm molding can be performed.
Therefore, it is possible to improve moldability when a square molded product using the aluminum resin composite laminate is manufactured by press molding, and it is possible to form deeply while obtaining good appearance characteristics.

  According to the present invention, since appropriate temperature control can be performed for each molding part of the blank material, it is possible to further improve the formability when manufacturing a square molded product using the aluminum resin composite laminate by press molding. It is possible to mold deeply while obtaining good appearance characteristics after molding.

It is a schematic cross section showing the drawing mold of the present invention. It is a perspective view which shows the die | dye which comprises the drawing mold of FIG. FIG. 3 is a plan view of the die shown in FIG. 2. It is a perspective view which shows the blank holder which comprises the drawing mold of FIG. It is a top view of the blank holder shown in FIG. It is principal part sectional drawing of the aluminum resin composite laminated board used for this invention. It is a perspective view which shows the example of the square shape molded article shape | molded by this invention. It is the die | dye schematic diagram explaining the heater arrangement | positioning of other embodiment. It is a schematic diagram of the blank holder explaining the heater arrangement of other embodiments. It is a schematic diagram of the blank holder explaining the heater arrangement of other embodiments. It is a schematic diagram explaining the heater arrangement | positioning in the drawing die of an Example, (a) shows die | dye and (b) shows a blank holder. It is a schematic diagram explaining the heater arrangement | positioning in the drawing metal mold | die of a comparative example, (a) shows die | dye and (b) shows a blank holder. It is a schematic diagram explaining the heater arrangement | positioning in the drawing metal mold | die of a comparative example, (a) shows die | dye and (b) shows a blank holder. It is a schematic diagram explaining the heater arrangement | positioning in the drawing metal mold | die of a comparative example, (a) shows die | dye and (b) shows a blank holder.

Hereinafter, embodiments of a drawing mold and a press molding method for an aluminum resin composite laminate according to the present invention will be described.
As shown in FIG. 7, the square molded product 60 molded by the aluminum resin composite laminate press molding method of the present invention is formed in a rectangular shape as a whole. Specifically, the square molded product 60 is a cylindrical molded product such as a bottomed square tube in which a plurality of corner portions 62 and a side surface portion 63 connecting the corner portions 62 are formed on the bottom portion 61. On the other hand, one (usually the outer surface side) is a convex surface and the other (inner surface side) is a concave surface.

<Structure of aluminum resin composite laminate>
As schematically shown in FIG. 6, the aluminum resin composite laminated plate 10 used in the present invention has a configuration in which aluminum plate materials 11 and 12 are bonded to both surfaces of a foamed synthetic resin layer 13 in a laminated state. The aluminum plate 11 on the convex surface side of the square molded product 60 is the outer surface side, and the aluminum plate material 12 on the concave surface side of the three-dimensional molded product is the inner surface side.

  The types of the aluminum plate 11 on the outer surface side and the aluminum plate 12 on the inner surface side are not particularly limited, but in order to form the aluminum resin composite laminate 10 deeper, the mechanical properties of the aluminum plate 11 on the outer surface side. (Tensile strength, yield strength, etc.) may be larger than the aluminum plate 12 on the inner surface side.

  The thicknesses of the aluminum plate members 11 and 12 are not particularly limited, but it is preferable that the aluminum resin composite laminate plate 10 have a thickness that can provide desired strength and rigidity. For this purpose, the aluminum resin composite laminated plate 10 should be 1 mm or more and 10 mm or less, and the thicknesses of the aluminum plate materials 11 and 12 on both sides should be 0.1 mm or more and 4 mm or less. It may be thinner than the aluminum plate 11.

  In addition, the aluminum plate materials 11 and 12 as described above can be obtained by performing a semi-continuous casting, homogenization treatment, hot rolling, cold rolling, and intermediate annealing as required by performing a conventional method. A plate having mechanical properties can be produced. Moreover, the molten metal rolling method like continuous casting rolling can also be used as a cold rolling raw material.

On the other hand, the foamed synthetic resin layer 13 is a thermoplastic resin having a heat resistant temperature in the range of 100 ° C. or higher and 200 ° C. or lower. Specifically, polypropylene (PP), polyethylene (PE), polycarbonate (PC), polyethylene terephthalate. (PET), polyvinylidene chloride (PVDC), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF), polyamide (PA6, PA12, etc.), polyamide (PEI), polysulfone (PSF), polychlorotrifluoroethylene ( PCTFF) can be used.
For example, when the foamed synthetic resin layer 13 is polypropylene, the melting point is around 170 ° C. and the heat resistant temperature is around 120 ° C. The deflection temperature under load is around 60 ° C., and as will be described later, the aluminum resin composite laminate 10 is press-molded at a temperature equal to or higher than the deflection temperature under load.

Here, the heat-resistant temperature of the resin and the deflection temperature under load are determined based on whether or not the resin test piece is placed in a certain temperature for a predetermined time and the appearance changes or the mechanical characteristics are deteriorated at that time.
In JIS (Japanese Industrial Standard), it is a temperature obtained by a test method (Method A, flatwise) defined in Plastics-How to obtain deflection temperature under load (JIS K 7191), and forms a foamed synthetic resin layer 13. It represents the temperature at which the foamed synthetic resin deforms when it receives a certain load (also referred to as heat deformation temperature). For example, it is determined that the temperature range is 110 to 180 ° C. and the time is 2 hours. Under this condition, the heat-resistant temperature is a temperature at which the product can be maintained without being deformed and deformed in a state where the product such as the resin container is not subjected to force, and the deflection temperature under load is a force that the product such as the resin container receives. It becomes the temperature which causes deformation in the state. In the case of polypropylene, the temperatures are as described above, and the relationship is such that the heat resistance temperature> the deflection temperature under load.

The foamed synthetic resin layer 13 is formed in a film shape or plate shape having a thickness of 1.8 mm or more and 9.8 mm or less, and has an expansion ratio of 1.5 times or more and 10 to provide sound insulation and heat insulation. Those less than double are used. If the expansion ratio is less than 1.5 times, it is insufficient in terms of vibration damping, sound insulation, and heat insulation. Conversely, if the expansion ratio exceeds 10 times, a uniform and stable foam state cannot be obtained, and processing of an aluminum resin composite laminate Causes problems such as cracks and wrinkles due to local deformation.
The foamed synthetic resin layer 13 and the aluminum plate members 11 and 12 are preferably bonded together, and in this case, the adhesive may be selected from the material of the foamed synthetic resin layer 13 as the core material and the main component of the same resin. Preferably, when the foamed synthetic resin layer 13 is polypropylene, an adhesive or the like whose main component is polypropylene is suitable.

  And this adhesive agent is apply | coated to both surfaces of the foamed synthetic resin layer 13, or the aluminum plate materials 11 and 12, the foamed synthetic resin layer 13 is pinched | interposed between both aluminum plate materials 11 and 12, and these are hot-pressed or hot-rolled. By pressurizing and heating, aluminum plate materials 11 and 12 are integrally laminated on both surfaces of the foamed synthetic resin layer 13 to provide an aluminum resin composite laminate.

The aluminum resin composite laminate 10 thus formed is punched into a blank material having an appropriate shape, and a square molded product 60 having a depth of 10 mm or more is manufactured by the press molding method of the present invention. Hereinafter, the blank material will be described with the same reference numeral 10 as that of the aluminum resin composite laminate.
<Configuration of drawing mold>
In the press molding method of the present invention, for example, as shown in FIGS. 1 to 3, a drawing mold 101 to which the present invention is applied is used. As shown in FIG. 1, the drawing mold 101 includes a die 20 having a forming square hole 21 having substantially the same shape as the bottom surface of the bottom portion 61 of the formed square-shaped product 60, and a forming square hole 21 of the die 20. A blank holder 30 that has a through-angle hole 31 of substantially the same shape and holds the blank material 10 between the surface of the die 20 and a blank material 10 that is inserted into the forming square hole 21 and the through-angle hole 31 to be drawn. That is, a prismatic punch 40 capable of squeezing the bottom of the square shaped product 60 is provided.

  As shown in FIGS. 2 to 4, the die 20 and the blank holder 30 incorporate a plurality of rod-shaped heaters 22, 23 </ b> S, 23 </ b> L, 33 </ b> S, 33 </ b> L for heating in advance prior to molding. The die 20 incorporates four vertical heaters 22 arranged along the molding direction in each corner portion of the peripheral portion of the molding square hole 21, and the outer peripheral side of these four vertical heaters 22. In addition, four die-side horizontal heaters 23S and 23L arranged in the horizontal direction in each side portion (long side portion and short side portion) of the peripheral portion of the forming square hole 21 are incorporated. A die side horizontal heater disposed along the horizontal direction in the long side portion of the forming square hole 21 is denoted by reference numeral 23L, and a die side horizontal heater disposed along the horizontal direction in the short side portion of the forming square hole 21 is provided. This is indicated by reference numeral 23S. Then, one die is inserted from each side portion of the die 20 so that the die side horizontal heaters 23S and 23L arranged along the side portions of the forming square hole 21 do not overlap each other in the depth direction. It has been arranged.

The blank holder 30 is arranged along the horizontal direction on each side portion (long side portion and short side portion) of the peripheral portion of the through hole 31 at a position facing each die side horizontal heater 23S, 23L. The holder-side horizontal heaters 33S and 33L are incorporated. 4 and 5, the holder-side horizontal heater disposed along the horizontal direction on the long side portion of the through-angle hole 31 is denoted by reference numeral 33 </ b> L, and is disposed along the long side portion of the through-angle hole 31. A holder-side horizontal heater 33L is disposed to face the die-side horizontal heater 23L. 4 and 5, the holder-side horizontal heater disposed along the horizontal direction on the short side portion of the through-angle hole 31 is represented by reference numeral 33 </ b> S, and along the short side portion of the through-angle hole 31. The arranged holder side horizontal heater 33S is arranged to face the die side horizontal heater 23S.
The vertical heater 22, the die side horizontal heaters 23S and 23L, and the holder side horizontal heaters 33S and 33L are provided so as to be independently adjustable in temperature.

  The die 20 and the blank holder 30 are provided with mounting holes for embedding the heaters 22, 23S, 23L, 33S, 33L. By embedding the heaters in the mounting holes, the heaters 22, 23S, 23L, 33S, 33L are accommodated inside the die 20 and the blank holder 30, and each heater 22, 23S, 23L, 33S, 33L is provided integrally with the die 20 or the blank holder 30. A wiring groove 24 extending toward the side surface of the die 20 is connected to the mounting hole of the vertical heater 22, and the wiring of the vertical heater 22 disposed inside the die 20 is connected to the outside via the wiring groove 24. Can be taken out.

The die 20 and the blank holder 30 have a temperature sensor 28 built therein. In the drawing mold 101 of this embodiment, only one temperature sensor 28 is displayed and the rest is omitted. The temperature sensor 28 is, for example, a thermocouple type having a tip provided in a rod shape. Like the heaters 22, 23S, 23L, 33S, and 33L, the temperature sensor 28 is embedded in mounting holes provided in the die 20 and the blank holder 30, thereby 20 or the blank holder 30 is integrally provided.
Furthermore, a heat insulating material 29 is provided on the mounting surface of the die 20 with the press machine main body 102. Since the heat of the die 20 and the blank holder 30 can be prevented from being transmitted to the press machine main body 102 by the heat insulating material 29, the temperature drop of the die 20 and the blank holder 30 can be prevented.

  Note that the blank holder 30 is provided with a guide hole 38 through which a guide rod (not shown) for supporting the body portion of the blank holder 30 so as to be movable up and down is omitted. An elastic member such as a spring that biases toward the surface is provided.

  As described above, in the drawing mold 101, the vertical heater 22 is arranged at the corner of the forming square hole 21 of the die 20 for forming the corner 62 of the square molded product 60, and the outer periphery of the vertical heater 22 is further increased. Die-side horizontal heaters 23S, 23L are arranged along the sides of the forming square hole 21 on the side, and the holder-side horizontal heaters 33S, 33L are also arranged on the blank holder 30 at positions facing the die-side horizontal heaters 23S, 23L. By arranging, the temperature of the corner portion of the forming square hole 21 can be adjusted higher than other portions, and the temperature difference between the inner peripheral side and the outer peripheral side of the forming square hole 21 can be reduced to reduce the corner portion. The peripheral part except for it can be heated uniformly. And by sandwiching the peripheral part of the blank material 10 between the die 20 and the blank holder 30, the peripheral part of the blank material 10 can be promptly distributed by the temperature distribution by the arrangement of the heaters 22, 23S, 23L, 33S, 33L. It can be heated. Further, the temperature control between the die 20 and the blank holder 30 can be performed with high accuracy by the heaters 22, 23S, 23L, 33S, 33L and the temperature sensors 28 that can be independently adjusted in temperature. Heating can be performed efficiently with a predetermined temperature distribution. Further, since the temperature of the die 20 and the blank holder 30 can be prevented from being lowered by the heat insulating material 29, high-precision temperature management of the die 20 and the blank holder 30 is possible.

<Press-molding method for square shaped products>
And in the press molding method of this embodiment, deep drawing is performed to the blank material 10 through the shaping | molding process demonstrated below using the drawing die 101 comprised in this way.

In the molding process, the blank member 10 is moved in a state where the outer peripheral portion (peripheral portion) of the blank member 10 is pressed and clamped between the die 20 and the blank holder 30, and the punch 40 is inserted into the through-angle hole 31 of the blank holder 30. And it inserts in the shaping | molding square hole 21 of the die | dye 20, and draw-forms the blank material 10 between the die | dye 20 and the punch 40. FIG.
At this time, the heaters 22, 23 S, 23 L, 33 S, and 33 L provided on the die 20 and the blank holder 30 are heated before the blank material 10 starts to be molded, and each side portion (long) of the forming square hole 21 of the die 20 is heated. The temperature of the side portion and the short side portion and the temperature of the corner portion (corner portion) are lower than the heat resistant temperature of the foamed synthetic resin layer 13 of the blank material 10 and the heat resistant temperature of the foamed synthetic resin layer 13. The temperature difference is heated to a temperature exceeding 10 ° C. and not more than 22 ° C., and the average temperature of the corners of the forming square holes 21 of the die 20 is set higher than the average temperature of each side of the forming square holes 21. Heat to a temperature 5 ° C or higher. Thus, since the die 20 and the blank holder 30 are preheated, the outer periphery of the blank material 10 is sandwiched between the die 20 and the blank holder 30 so that the die 20 and the blank holder 30 The outer peripheral portion of the blank 10 is also quickly heated with a temperature distribution similar to the temperature distribution. That is, the temperature of the blank material 10 at the portion corresponding to the corner portion of the forming square hole 21 is heated higher than the other portions, and the portion corresponding to the peripheral portion excluding the corner portion is the inner periphery of the forming square hole 21. Heating is performed uniformly while reducing the temperature difference between the outer side and the outer side.

And when the outer peripheral part of the blank material 10 pinched | interposed between these die | dye 20 blank holders 30 is heated to the same temperature as the temperature of the peripheral part of the shaping | molding square hole 21, the outer peripheral part of the blank material 10 is set to die 20. The blank 10 is moved downward while being sandwiched between the blank holder 30 and the blank 10 is drawn between the die 20 and the punch 40, and the square shaped product 60 shown in FIG. Is molded.
Thus, when the corner portion 62 of the square shaped product 60 that is difficult to be molded is molded, the outer peripheral portion of the blank member 10 corresponding to the peripheral portion of the molded square hole 21 is a foamed synthetic material that is a core material. The foamed synthetic resin of the resin layer 13 is heated to near the heat resistant temperature at which it does not elute, and among them, the molded portion of the corner portion 62 that is difficult to be molded is heated to a higher temperature than the other peripheral portions. Yes. That is, since the blank material 10 is controlled to an appropriate temperature for each molding part, the moldability of the blank material 10 can be improved and stable warm molding can be performed. Therefore, a deeply molded square shaped product 60 can be manufactured while preventing generation of wrinkles and the like and obtaining good appearance characteristics.

  As described above, in the press molding method of the present embodiment, the heaters 22, 23 </ b> S, 23 </ b> L built in the die 20 and the blank holder 30 are used by using the drawing mold 101 with the optimized heater arrangement. Since 33S and 33L can perform drawing while controlling the heating temperature of the blank 10 to an appropriate temperature for each molding part, a square molded product using an aluminum resin composite laminate is manufactured by press molding. The moldability at the time of molding can be further improved, and a square molded product can be molded deeply while obtaining good appearance characteristics after molding.

In addition, this invention is not limited to the said embodiment, A various change can be added in the range which does not deviate from the meaning of this invention.
For example, in the above embodiment, the die-side horizontal heaters 23S and 23L arranged along each side (long side and short side) of the forming square hole 21 do not overlap vertically in the depth direction. Thus, although it was set as the structure which inserts one heater from each side part of the die | dye 20, it is the structure which inserts two heaters from one side of the opposing side parts like the die | dye 25 shown in FIG. As an alternative, a part of the die side horizontal heater 23L arranged along the long side portion of the forming square hole 21 and the die side horizontal heater 23S arranged along the short side portion may be overlapped. In this case, since the wirings of the two heaters can be combined on one side, the wiring can be simplified.

  In the drawing mold 101, four holder-side horizontal heaters 33S and 33L are incorporated along each side of the through-angle hole 31 of the blank holder 30, but are shown in FIGS. Like the blank holders 35 and 36, at least two holder-side horizontal heaters 33 </ b> L disposed along the long side portion of the through-angle hole 31 may be provided. Even in a configuration in which the holder side horizontal heater 33L is provided only on the long side portion, it can be combined with the vertical heater 22 incorporated in the die 20 and the die side horizontal heaters 23S and 23L to correspond to the peripheral portion of the forming square hole 21. The peripheral part of the blank 10 to be performed can be heated uniformly with a small temperature difference. In addition to the holder side horizontal heater 33 </ b> L arranged along the long side portion of the through-angle hole 31 as in the drawing mold 101, the holder side arranged along the short side portion of the through-angle hole 31. By combining the horizontal heater 33S, temperature management with higher accuracy becomes possible, so that the temperature difference (variation) can be further reduced.

As the blank material, an aluminum resin composite laminate having a tensile strength of 40 MPa, a proof stress of 25 MPa, and an elongation of 17.2% and a thickness of 3.5 mm was used, and the bottom surface was 98 mm × 170 mm (by the press molding method of this embodiment). A square tube container (square molded product) having a bottom area of 16660 mm ² ) and a depth of 30 mm was manufactured. The outer surface side aluminum plate material has a tensile strength of 190 MPa and a proof stress of 140 MPa formed from a H22 tempered material of 5000 series alloy through general semi-continuous casting, hot rolling and cold rolling (including intermediate annealing). Using a plate material having a thickness of 16% and a thickness of 0.35 mm, the inner surface side aluminum plate material has a tensile strength of 120 MPa and a proof stress formed from a H24 tempered material of 1000 series alloy in the same manner as the outer surface side aluminum plate material. Was a plate material having a thickness of 0.15 mm and an elongation of 27%. For the foamed synthetic resin layer, polypropylene (melting point: 170 ° C., heat resistant temperature: 140 ° C.) was selected, and the expansion ratio was 2.5 times. The heat resistant temperature is, for example, a temperature at which the function of the resin product can be maintained without being deformed or altered in a state where no external force is applied. The deflection temperature under load of polypropylene is 77 ° C. In addition, an adhesive mainly composed of polypropylene was used as the adhesive. As for the mechanical properties of the blank material, a No. 5 test piece of JIS-Z2241 was prepared and subjected to a tensile test, and the tensile strength, 0.2% proof stress and elongation were measured.

Then, the press mold was preheated to the heating temperature distribution shown in Table 1 to form a rectangular tube-drawn container (square molded product).
In the press mold in which the “horizontal heater arrangement” in Table 1 is “A”, as shown in FIG. 11A, the die side horizontal heaters 23S and 23L are not overlapped in the depth direction, and the die 20A. The side horizontal heaters 33S and 33L are arranged so as to face the die side horizontal heaters 23S and 23L, as shown in FIG. 11B.
Further, in the drawing mold in which the “horizontal heater arrangement” in Table 1 is set to “B”, as shown in FIG. 12A, it is arranged in the horizontal direction along the short side portion of the forming square hole 21. Only the die side horizontal heater 23S is arranged, and as shown in FIG. 12B, only the holder side horizontal heater 33S is arranged facing the die side horizontal heater 23S on the blank holder 30B side.

Further, in the drawing mold in which the “horizontal heater arrangement” in Table 1 is “C”, as shown in FIG. 13A, the horizontal direction along only one of the long side portions of the forming square hole 21. A die side horizontal heater 23L arranged in the horizontal direction and a die side horizontal heater 23S arranged in the horizontal direction along both short sides are arranged, and as shown in FIG. 13B, the blank holder 30C side is arranged. In addition, holder-side horizontal heaters 33S and 33L are arranged at positions facing the die-side horizontal heaters 23S and 23L.
Further, in the drawing mold in which the “horizontal heater arrangement” in Table 1 is “D”, as shown in FIG. 14A, the forming angle is formed along the diagonal line from the corner of the forming square hole 21. A die-side horizontal heater 23D extending in a direction away from the hole 21 is disposed, and as shown in FIG. 14B, the holder-side horizontal heater 33D is also provided on the blank holder 30D side at a position facing the die-side horizontal heater 23D. Arranged.
Further, in the drawing mold in which “insulating material” in Table 1 is “present”, a ceramic board having a thickness of 20 mm made of ceramic fiber, mullite powder and a binder was used as the insulating material.

The vertical heater 22 was heated at a set temperature of 120 ° C., and the die side horizontal heaters 23S, 23L, and 23D and the holder side horizontal heaters 33S, 33L, and 33D were heated at a set temperature of 125 ° C.
D1 to D4 in Table 1 are intermediate positions (centers) of the four sides of the forming square holes 21 in the dies 20A to 20D, respectively, as shown in FIGS. Position (D1 to D4) is set such that the tip of the thermocouple is placed at points D1 to D4 inside the dies 20A to 20D 5mm outside the inner surface of the forming square hole 21 at the position (center). This is a value obtained by measuring the temperature (° C.). Further, C1 to C4 in Table 1 are the deepest of the forming square holes 21 at the four corners (corner portions) of the forming square holes 21 in the dies 20A to 20D, respectively, as indicated by cross-hatched marks in FIGS. The temperature (° C.) at the positions (C1 to C4) was measured by setting the thermocouple tips to be located at points C1 to C4 inside the dies 20A to 20D at positions 5mm deeper from the section. It is.

  Moreover, the "difference with resin heat-resistant temperature" of Table 1 subtracted temperature D1-D4 and C1-C4 of each measurement position from the heat-resistant temperature (140 degreeC) of the foaming synthetic resin layer which comprises an aluminum resin composite laminated board. Differences were calculated, and the minimum value of each difference was described as “minimum” and the maximum value as “maximum”. “C average−D average” in Table 1 is obtained by calculating a difference obtained by subtracting the average temperature of the corner measurement temperatures D1 to D4 from the average temperature of the side measurement temperatures C1 to C4.

  And the external appearance was observed about the rectangular tube aperture container obtained in this way. The results are shown in Table 2. In Table 2, No. 7 and no. No. 9 “bias of the molded product” indicates that the workability of the blank material varies depending on the position, the amount of material deformation varies depending on the direction, and the shape after processing becomes non-uniform.

As can be seen from Table 2, in Examples 1 to 4 using press-molding molds with optimized heater arrangement, the temperature of each side of the forming square hole (side measurement temperature) and the temperature of each corner. The (corner measurement temperature) is lower than the heat resistant temperature of the foamed synthetic resin layer constituting the aluminum resin composite laminate, and the temperature difference from the heat resistant temperature of the foamed synthetic resin layer exceeds 10 ° C and is 22 ° C or lower. And the average temperature at the corners can be higher by 5 ° C. or more than the average temperature at the sides. In addition, in the rectangular tube drawn container formed by the press mold with the optimized heating temperature distribution, generation of fine wrinkles was recognized, but appearance defects such as cracks and slight wrinkles occurred. In addition, good moldability was obtained without generating wrinkles or the like even in the highly difficult rectangular tube drawing.
In addition, it was found that by providing a heat insulating material, temperature variation can be reduced, and a suppression effect can be expected even for minute wrinkles.

10 Aluminum resin composite laminate (blank material)
11, 12 Aluminum plate 13 Foamed synthetic resin layer 20, 20A to 20D, 25 Die 21 Molding square hole 22 Vertical heater 23S, 23L, 23D Die side horizontal heater 24 Wiring groove 28 Temperature sensor 29 Heat insulating material 30, 30A to 30D, 35 , 36 Blank holder 31 Through-angle holes 33S, 33L, 33D Horizontal heater 38 on the holder side Guide hole 40 Punch 60 Square molded product 61 Bottom 62 Corner 63 Side surface 101 Drawing mold 102 Press machine main body

Claims (4)

A drawing mold for deep-drawing a blank material made of an aluminum resin composite laminate in which an aluminum plate is laminated on both surfaces of a foamed synthetic resin layer into a rectangular prismatic molded product,
A die having a molded square hole having substantially the same shape as the bottom surface of the square molded product;
A blank holder for holding the blank material between the die surface and a through-angle hole having substantially the same shape as the forming square hole;
A prismatic punch that is inserted into the forming square hole and the through-angle hole to draw the blank material, and
The die includes
A vertical heater arranged along the molding direction at each corner of the periphery of the molding square hole;
The die side horizontal heater arranged along the horizontal direction in each side part of the peripheral part on the outer peripheral side than the vertical heater is incorporated,
In the blank holder,
A holder-side horizontal heater arranged along the horizontal direction is incorporated in at least the long side part of each side part of the peripheral part of the through-angle hole,
The plurality of vertical heaters, the die-side horizontal heater, and the holder-side horizontal heater are provided independently so as to be capable of temperature adjustment, respectively.   The drawing mold according to claim 1, wherein the holder side horizontal heater is disposed at a position facing the die side horizontal heater.   The drawing mold according to claim 1 or 2, wherein a heat insulating material is provided on a surface of the die attached to the press machine body. A blank material made of an aluminum resin composite laminate having a thickness of 1 mm or more and 10 mm or less, in which an aluminum plate material is bonded to both surfaces of a foamed synthetic resin layer having an expansion ratio of 1.5 times or more and 10 times or less, is a corner having a depth of 10 mm or more. A press molding method for deep-drawing a molded product,
Using the said drawing die as described in any one of Claim 1 to 3, the said blank material is moved in the state which clamped the outer peripheral part of the said blank material between the said die | dye and the said blank holder. Having a molding step of drawing between the die and the punch,
In the molding step, before starting the molding of the blank material,
The temperature of the side portion of the molded square hole and the temperature of the corner portion are lower than the heat resistant temperature of the foamed synthetic resin layer, and the temperature difference between the heat resistant temperature of the foamed synthetic resin layer is 10 ° C. While heating to a temperature that exceeds 22 ° C,
A press molding method characterized by heating the average temperature of the corner of the molded square hole to a temperature higher by 5 ° C. than the average temperature of the side of the molded square hole.

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