JP2018043260A - Apparatus and method for manufacturing three-dimensional molding formed of aluminum resin composite laminated plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an apparatus for manufacturing a three-dimensional molding.SOLUTION: An apparatus for manufacturing a three-dimensional molding formed of an aluminum resin composite laminated plate includes a base having a punch, a die plate having a die hole, a wrinkle presser plate of a frame mold provided in the periphery of the punch, a plurality of support shaft members horizontally supporting the wrinkle presser plate, and a spring member which is wound around the support shaft members and energizes the wrinkle presser plate in a direction apart from the base; and pulls the aluminum resin composite laminated plate to the die hole by inserting the punch into the die hole and draws the aluminum resin composite laminated plate, where before inserting the punch into the die hole, the wrinkle presser plate is supported to such a position that the aluminum resin composite laminated plate can be pressed to the die plate while resisting against an energization force of the spring member, and a spring constant of the spring member is set at 60 N/mm or more and 150 N/mm or less, and a unit load is set at 120 kg or more and 300 kg or less.SELECTED DRAWING: Figure 2

Description

  The present invention relates to an apparatus and a manufacturing method for manufacturing a three-dimensional molded article made of an aluminum resin composite laminate.

Conventionally, as a metal plate drawing device, as shown in FIG. 10, a die plate 101 in which a metal plate 100 to be processed is horizontally installed and a pad that is accommodated in a central hole 102 of the die plate 101 so as to be vertically movable. There is known a drawing processing apparatus having 103, a wrinkle pressing plate 105 provided above the die plate 101, and a drawing punch 106.
In this drawing apparatus, as shown in FIG. 11, the drawing punch 106 is lowered to the inside of the central hole 102, the drawing processing is performed on the metal plate 100, and the box-shaped molded product 107 is manufactured. In the drawing apparatus shown in FIGS. 10 and 11, the drawing punch 106 is formed in a substantially rectangular shape in plan view, and the molded product 107 is manufactured as a rectangular box-shaped three-dimensional molded product.

When the metal plate 100 is drawn by the drawing apparatus shown in FIGS. 10 and 11, it is a portion where the peripheral edge portion of the drawing punch 106 greatly squeezes and deforms the metal plate 100 when the metal plate 100 is drawn.
For example, there is no possibility of causing defects in the side surface and the bottom surface formed by simple bending in the molded product 107. However, since the corner portion where the two side surfaces and the bottom surface intersect and the ridge line portion where the two side surfaces intersect are portions where the material necessary for forming is squeezed out from the metal plate 100, defects such as cracks, wrinkles or rough skin are likely to occur. Part.
In the current drawing processing technology, technology development that enables drawing without particular hindrance has been made as long as it is a metal plate having a general workability by developing a lubricating oil or improving the drawing processing technology.

For example, when an alloy plate made of a low-elongation metal material is square-drawn as described in Patent Document 1 below, the corners and ridges are first formed using a partially tapered die plate, drawing punch, and pad. There has been provided a technique for performing a drawing process by locally increasing the thickness at the time of one drawing process, and then processing the increased portions of the corners and ridge lines.
Further, in order to prevent wrinkles generated in the standing wall portion formed by drawing as described in Patent Document 2 below, the ratio between the initial flange length with respect to the center of the curved corner portion and the initial flange length corresponding to the straight side portion. There is provided a technique for defining the ratio of the shock line length at the center of the curved corner portion and the shock line length at the straight side portion.

In addition, when a metal plate is drawn into a box-like body as described in Patent Document 3 below, the metal plate is drawn into a box-like body with an R which is three times the thickness of the metal plate, which is a size of R that can be drawn. Later, a technique for reducing R by hitting with a V-shaped punch is provided.
As described above, not only a general metal plate but also a metal plate that is assumed to be difficult to machine has been provided with a drawing technique that hardly causes defects.

JP 2002-239644 A Japanese Patent Laid-Open No. 9-308921 JP 2001-239327 A

By the way, in recent years, development of a lighter plate material has been studied in themes such as development of next-generation automobiles, and in particular, an aluminum resin composite laminate having a sandwich structure in which front and back surfaces of a foamed resin plate are sandwiched between aluminum plates has been studied.
Since this aluminum resin composite laminate is lightweight, has a surface gloss, and is excellent in design, development of manufacturing technology for a three-dimensional molded product made of the aluminum resin composite laminate is expected.
However, the foamed resin and the aluminum plate are a resin material and a metal material, and the two have greatly different coefficients of thermal expansion, elongation, and shrinkage, so even if various conventional drawing techniques are applied, It was not easy to draw a three-dimensional molded product without causing wrinkles, cracks, surface flaws, and the like.

When manufacturing a three-dimensional molded product made of an aluminum resin composite laminate by drawing, as a device for preventing defects such as wrinkles, cracks, and surface wrinkles at corners and ridges, die plate 101 and wrinkle holding plate 105 are used. It is conceivable to draw the aluminum resin composite laminate while controlling the wrinkle holding force generated by the desired value.
However, as described above, the aluminum resin composite laminate is a laminate of metal and foamed resin, and since it is a material that has been attracting attention recently, what is the level of wrinkle holding force during drawing? However, there is a situation that has not been sufficiently analyzed to control defects such as wrinkles, cracks and wrinkles.

  In view of these backgrounds, the present invention is a tertiary that is well-formed without producing defects such as wrinkles, cracks, surface defects, and shape defects when producing a three-dimensional molded product from an aluminum resin composite laminate by drawing. It aims at providing the apparatus which can manufacture an original molded product.

  As a result of studying the relationship between the generation of defects such as cracks, wrinkles, surface wrinkles, and shape defects in the method of producing a three-dimensional molded article from an aluminum resin composite laminate by drawing, the inventor has drawn It was found that better results can be obtained by strengthening the wrinkle holding force in the second half than in the first half. For this reason, the present inventor has developed a manufacturing apparatus and a manufacturing method capable of controlling the wrinkle holding force according to the progress of the drawing and has reached the present invention.

  Based on the above-mentioned background, the manufacturing apparatus according to the present invention is composed of an aluminum resin composite laminate in which a face material made of aluminum or an aluminum alloy is laminated on both surfaces of a core material made of foamed resin. In an apparatus for producing a three-dimensional molded product having a continuous side wall, a base base provided with a punch, a die plate provided opposite to the punch and provided with a mold hole for inserting the punch, A frame-type wrinkle pressing plate provided around the punch, a support shaft member attached to the base base and movably supporting the wrinkle pressing plate between the base base and the die plate; and the support shaft A compression spring type spring member wound around the member, wherein the punch is provided so as to be able to approach and separate from a die hole of the die plate, and the punch and the die A manufacturing apparatus for pressing the aluminum resin composite laminate sandwiched between rates into the mold hole and drawing the aluminum resin composite laminate, wherein the aluminum resin composite laminate is inserted before the punch is inserted into the mold hole. The wrinkle holding plate is supported at a position where the laminated plate can be pressed against the die plate while resisting the biasing force of the spring member by the wrinkle holding plate, and the spring constant of the spring member is 60 N / mm or more, 150 N / Mm or less, and the unit load of the spring member is set to 120 kg or more and 300 kg or less.

  In the present invention, a stopper member is provided between the die plate and the base base so as to define an end point position of the movement of the punch toward the die plate, and the punch toward the die plate is provided. It is preferable that the end point position is set at a position where a deflection amount of the spring member generated in accordance with the movement is smaller than a deflection limit of the spring member.

In the present invention, the foaming resin may be applied to an aluminum resin composite laminate having a foaming ratio of 1.5 to 10 times, a total thickness of 2 to 10 mm, and a thickness of the face material of 0.1 to 4 mm. preferable.
In the present invention, the base base includes a support plate for supporting the plurality of support shaft members, a plurality of support walls erected on the support plate, and a base plate joined to the support walls, and the base plate is a mounting base. Are supported in such a manner that they can be slidably positioned in a horizontal direction, and thread portions are formed at the tip portions of the plurality of support shaft members, and the plurality of support shaft members are threaded into screw holes formed in the wrinkle holding plate. It is preferable that the wrinkle holding plate is supported by screwing.
In the present invention, it is preferable that the wrinkle pressing force generated by the wrinkle pressing plate is increased in conjunction with the progress of insertion of the punch into the mold hole.

  The method for producing a three-dimensional molded article of the present invention comprises an aluminum resin composite laminate in which a face material made of aluminum or an aluminum alloy is laminated on both surfaces of a core material made of foamed resin, and either the top wall or the bottom wall and In a manufacturing method of a three-dimensional molded product having side walls that are continuous with each other, a die plate having a mold hole, a punch for pushing the blank material of the aluminum resin composite laminate into the mold hole, and a peripheral portion of the blank material on the die plate A method for producing a three-dimensional molded product, in which a wrinkle pressing plate is used to press and the blank material is pressed into the mold hole by the punch while a wrinkle pressing force is applied to the peripheral portion of the blank material by the punch. The urging force is generated by compressing a compression spring type spring member, and the wrinkle holding plate is moved to the blank. A pressing force is generated by pressing against the material, the spring constant of the spring member is set to 60 N / mm or more and 150 N / mm or less, and the unit load of the spring member is set to 120 kg or more and 300 kg or less. And

In the method for producing a three-dimensional molded article according to the present invention, an aluminum resin composite laminate in which the foaming ratio of the foamed resin is 1.5 to 10 times, the total thickness is 2 to 10 mm, and the thickness of the face material is 0.1 to 4 mm. It is preferable to apply to a blank made of a plate.
The method for producing a three-dimensional molded product of the present invention is characterized in that the wrinkle pressing force generated by the spring member using the wrinkle pressing plate is sequentially increased from the initial stage to the final stage of the blank material. .

  According to the manufacturing apparatus and the manufacturing method of the present invention, even when a three-dimensional molded product is manufactured from an aluminum resin composite laminated plate, the shape is prepared without causing defects such as wrinkles, cracks, surface defects, and shape defects. A three-dimensional molded product can be obtained.

The perspective view which shows an example of the three-dimensional molded product which consists of an aluminum resin composite laminated board made into the manufacturing object by the manufacturing apparatus which concerns on this invention. The perspective view of the manufacturing apparatus of 1st Embodiment which concerns on this invention. The perspective view which shows the state which installed the blank material on the die plate of the manufacturing apparatus of the said 1st Embodiment. The perspective view which looked at the die plate and wrinkle holding board with which the manufacturing apparatus of the said 1st Embodiment was diagonally viewed from upper direction. The perspective view which looked at the same die plate and wrinkle pressing board from diagonally downward. The side view which shows the state which separated the wrinkle pressing board and punch upwards with respect to the die plate. The side view which shows the state which lowered | hung the punch to the state which made the wrinkle pressing plate contact with the die plate. The side view which shows the state which lowered | hung the punch to the inside of the type | mold hole of the same die plate. The side view which shows the state which lowered | hung the punch to the die hole inner bottom side of the same die plate. Sectional drawing which shows the state which installed the metal plate between the die plate and the punch in the conventional drawing processing apparatus. Sectional drawing which shows the state which lowered | hung the punch in the conventional drawing processing apparatus, and processed the metal plate into the three-dimensional molded product.

Hereinafter, the present invention will be described in detail based on embodiments shown in the accompanying drawings.
FIG. 1 is a perspective view showing an example of a three-dimensional molded product to be manufactured by the manufacturing apparatus A shown in FIG.
The three-dimensional molded product B of this example is composed of a core material 2a made of a foamed resin plate such as polypropylene foam resin, and face materials 2b and 2b made of aluminum or aluminum alloy laminated on both front and back sides of the core material 2a. The resulting aluminum resin composite laminate 2 having a three-layer structure is obtained by square drawing with a manufacturing apparatus A described later.
The three-dimensional molded product B shown in FIG. 1 is formed in a shallow bottom-opening box shape, and is erected at right angles to the bottom wall 2A from a rectangular bottom wall 2A in plan view and the periphery of the bottom wall 2A. 4 side walls 2B.

A first corner portion 2D is formed at a portion where the side wall 2B extends on the peripheral edge of the bottom wall 2A, and a second corner portion 2E is formed at a ridge portion where the adjacent side walls 2B, 2B are connected.
The above-mentioned aluminum resin composite laminate 2 desirably has a thickness (total thickness) of 2 mm or more and 10 mm or less, desirably the thickness of the face material 2b is 0.1 mm or more and 4 mm or less, and desirably the thickness of the core material 2a. A laminate of 1.9 mm or more and 9.8 mm or less can be used.

  As an example, the thickness of the core material 2a is 2.5 mm, the thickness of the outer face material 2b is 0.3 mm, the thickness of the inner face material 2b is 0.2 mm, and the total thickness is about 3.0 mm. The aluminum resin composite laminate 2 having a structure in which the face material 2b is bonded to both sides can be applied. The thickness of the core material 2a and the thickness of the face material 2b are merely examples, and the thickness is not limited to the above thickness. In order to reduce the weight of the entire aluminum resin composite laminate as much as possible, the face material 2b is more preferable than the core material 2a. It is preferable to make the side thinner. Further, when the core material 2a is formed from a polypropylene resin foam, the specific gravity of the core material 2a can be formed to about 1.6, and the specific gravity of aluminum is about 2.7. By forming it thicker than 2b, the aluminum resin composite laminate as a whole is advantageous for weight reduction. In addition, as resin which comprises the core material 2a, it is not limited to a polypropylene resin, Polyethylene, polystyrene, a polyurethane, a polyethylene terephthalate, a polycarbonate, etc. can be used, and a foaming magnification is uniformly 1.5 to 10 times. A foamed product can be selected as appropriate. The expansion ratio of the core material 2a applied in the present embodiment is more preferably in the range of 1.5 to 5 times.

Both aluminum or aluminum alloy plates forming the face materials 2b and 2b may be formed of the same kind of aluminum or aluminum alloy, or may be formed of different aluminum alloys. As an example, the outer face material 2b can be made of a 5000 series aluminum alloy such as AA5151, and the inner face material 2b can be made of a 1000 series aluminum alloy such as AA1050.
In this embodiment, the reason why the materials and thicknesses of the inner and outer face materials 2b and 2b are made different as described above is to release distortion caused by deformation in the inner face material 2b and facilitate molding. The description is an example and is not limited to the above description.

The three-dimensional molded product B shown in FIG. 1 is obtained by subjecting the blank 4 made of the flat aluminum resin composite laminate shown in FIG. 3 to corner drawing using the manufacturing apparatus A having the configuration shown in FIGS. Manufactured.
However, since the core material 2a of the blank material 4 made of an aluminum resin composite laminate has a smaller specific gravity than the face material 2b and is a resin foam, the core material 2a is like a cushion material when simply drawn. It becomes a buffer layer of the face material 2b to be deformed and deformed. For this reason, for example, when drawing is performed, there are problems that the corner portions 2D and 2E of the three-dimensional molded product B are likely to be wrinkled and cracked, and surface flaws are likely to occur.
Therefore, in this embodiment, the manufacturing apparatus A shown in FIGS. 2 to 5 is used, the die plate 12 shown in FIG. 4 is mounted on the manufacturing apparatus A, and the blank 4 made of an aluminum resin composite laminate is used. By performing the angular drawing described later, the three-dimensional molded product B with the above-described shape free from defects can be obtained.

The manufacturing apparatus A includes an upper mold 6 and a lower mold 7 between an upper surface plate 3 and a lower surface plate 5 as shown in FIGS. 2 and 3, and the upper surface plate 3 and the lower surface plate 5 are not shown in the drawing. By being connected to a reduction device, the upper die 6 and the lower die 7 are configured to be movable in the direction of approaching and separating.
The upper die 6 is provided with a punch 9 attached to the lower surface side of the upper surface plate 3 via a rectangular attachment base 8 in plan view. In this embodiment, since the box-shaped three-dimensional molded product B shown in FIG. 1 is a manufacturing object, the flat bottom surface 9a and the side surface 9b shown in FIG. 5 for molding the box-shaped three-dimensional molded product B are provided. A convex punch 9 is mounted below the mounting base 8. In addition, since the shape of the punch 9 can employ | adopt a suitable shape according to the shape of the target three-dimensional molded product, the convex shape shown in each figure is only an example.
The lower die 7 is provided with a die-side base 11 having a block-type core 10 that can be moved up and down inside. A frame-type die plate 12 is attached to the upper portion of the die 7 and a die is formed at the center of the die plate 12. A hole 12a is formed.

In the upper mold 6, an L-shaped hook portion 15 is formed downward on the short side lower surface of the mounting base 8 provided on the lower surface side of the upper surface plate 3, and is suspended and supported by the hook portions 15 on both sides of the mounting base. The base plate 16 having a substantially rectangular shape in plan view is supported horizontally, and a support plate 18 is supported horizontally on the lower surface side of the base plate 16 via four support walls 17. The base plate 16 is supported so as to be slidable along the lower surface of the mounting base 8 with its both ends in the length direction suspended and supported by the hook portions 15 and 15. Therefore, the support position of the base plate 16 with respect to the mounting base 8 can be finely adjusted, and the punch 9 to be described later can be accurately centered with respect to the die plate 12.
A stopper that prevents the base plate 16 from moving back and forth is formed on the back side of the support plate 18 located on the back side of the hook portions 15 and 15 shown in FIGS. 2 and 3 until the base plate 16 reaches the stopper. It is slidably supported along the hook portions 15 and 15. The base plate 16 is formed in a size (depth width) that can be centered at a position in contact with the stopper, and a bolt (not shown) that passes through the base plate 16 and is screwed into the screw hole of the mounting base 8 at the centering position. It is attached to the attachment base 8. In other words, the plurality of through holes formed in the base plate 16 and the plurality of screw holes formed in the mounting base 8 are aligned with the base plate 16 abutting against the stopper, and the base plate 16 is centered at this position. It has come to be.

Four support walls 17 are arranged on the lower surface side of the base plate 16 at an equal interval parallel to the short side of the base plate 16 and at a right angle to the base plate 16, and a rectangular support plate 18 in a plan view is formed on the lower end side of the four support walls 17. It is integrated horizontally.
As an example, the support wall 17 and the support plate 18 are integrated with the base plate 16 by a plurality of bolts that pass through the integrated support plate 18 and the support wall 17 and are screwed into screw holes (not shown) of the base plate 16. .
In this embodiment, as shown in FIG. 3, four support walls 17 and a support plate 18 are integrated in a comb shape, and the base wall 19 is configured by bolting the support wall 17 to the base plate 16.
A space K having an opening in the left-right direction is formed between the adjacent support walls 17 and 17. By providing the space portion K and configuring the four support walls 17 and the support plate 18 in a comb shape, the base base 19 can be reduced in weight and the later-described spring member 25 can be easily replaced.
The structure of the portion for fixing the support wall 17 and the support plate 18 to the base plate 16 is not limited to bolting.

A plurality of support holes 18a are formed in the vicinity of the support wall 17 located on the short side of the support plate 18 at a desired position in the space K in the support plate 18 so that the support holes 18a are inserted vertically. The support shaft member 20 is suspended. Since the support holes 18a are formed at positions close to the respective corner portions of the support plate 18, four support holes 18a are formed in the support plate 18.
The support shaft member 20 is made of a stripper bolt as shown in FIGS. The support shaft member 20 includes a rod-shaped shaft portion 20a having no screw portion, a head portion 20b formed at the upper end portion of the shaft portion 20a, and a screw portion 20c formed at the lower end portion of the shaft portion 20a. Become.
The support shaft member 20 is inserted into the support hole 18a of the support plate 18 through a cylindrical bush member 21 having a flange portion 21a. The head portion 20b extends above the support plate 18, and the screw portion 20c extends below the support plate 18. Is supported by hanging on the support plate 18. The bush member 21 is made of a material having a small friction coefficient in order to make the support shaft member 20 move smoothly up and down. The head portion 20b of the support shaft member 2 is supported by the flange portion 21a of the bush member 21 inserted in the support hole 18a of the support plate 18, and the support shaft member 20 is supported by the bush member 21 with respect to the support hole 18a of the support plate 18. It is supported so that it can be prevented from coming off. The support hole 18 a is formed in a stepped hole type, and the flange portion 21 a of the support shaft member 20 is installed at the step portion, and the upper surface of the flange portion 21 a is flush with the upper surface of the support plate 18. Since the outer diameter of the head portion 20b of the support shaft member 20 is larger than the inner diameter of the cylindrical portion of the bush member 21 and smaller than the outer diameter of the cylindrical portion, the bush member 21 mounted in the support hole 18a of the support plate 18 is formed. The support shaft member 20 is supported in a suspended state in a state where it is supported by.

A convex punch 9 is attached downward between the four support shaft members 20 on the lower surface center side of the support plate 18, and a frame-shaped wrinkle pressing plate 22 is provided on the lower end side of the punch 9. Is supported horizontally by four support shaft members 20 so as to surround them. The bottom surface 9a of the punch 9 is formed in a flat shape, and the lower surface of the wrinkle pressing plate 22 is set slightly below (about several millimeters below) from the bottom surface 9a of the punch 9.
Screw holes 22a that open only on the upper surface side are formed on the upper surface side of the corner portion of the wrinkle pressing plate 22, and the wrinkle pressing plate 20 is suspended by screwing the threaded portion 20c of the support shaft member 20 into each screw hole 22a. It is supported by lowering. An insertion hole 22b having a size capable of inserting the punch 9 is formed in the inner portion of the wrinkle holding plate 22, and the punch 9 is installed so as to be inserted through the insertion hole 22b.

A coil-shaped spring member 25 is wound around each of the four support shaft members 20 between the support plate 18 and the wrinkle holding plate 22. The spring constants of these spring members 25 are set to 60 N / mm or more and 150 N / mm or less, and the unit load is set to 120 kg or more and 300 kg or less. These spring members 25 are compression springs because they are used to control the wrinkle holding force by adjusting the pressure applied to the wrinkle holding plate 22.
When the spring constant of the spring member 25 is less than 60 N / mm, as will be described later, when the blank member 4 of the aluminum resin composite laminate is square-drawn to produce the three-dimensional molded product B shown in FIG. Wrinkles are easy to enter. When the spring constant of the spring member 25 exceeds 150 N / mm, the blank member 4 of the aluminum resin composite laminate is square-drawn to produce the three-dimensional molded product B shown in FIG. Is too hard and the spring member 25 does not shrink, and the three-dimensional molded product B is cracked. When the unit load is less than 120 kg, shape defects are likely to occur in the three-dimensional molded product B, and when the unit load exceeds 300 kg, surface flaws due to the spring member become conspicuous.

Since the length of the spring itself changes depending on the magnitude of the force applied to the spring (it is directly proportional), it can be interpreted that a larger spring constant value is a hard spring and a smaller value is a soft spring. There is a relationship of load = spring constant × warm, spring constant (N / mm) = (lateral elastic modulus × fourth of wire diameter) / (8 × effective number of turns × third power of center diameter). = There is a relationship of the force generated per 1 mm of thigh, and the spring constant can be used when obtaining the maximum load. It is preferable that the limit load at which the spring member can be used is usually up to 80% of the maximum load. From these relationships, the spring constant is a reference for adjusting the length, and the unit load can be used as a reference for adjusting the load applied from the spring member to the aluminum resin composite laminate. In consideration of these, a spring member having a spring constant and unit load can be selected according to the angular drawing of the target three-dimensional molded product B.
The three-dimensional molded product B obtained as described later by using the spring member 25 in which each value is set in the above-described spring constant range and unit load range does not cause cracks and wrinkles, and the surface wrinkles are not generated. It is possible to produce a three-dimensional molded article B having a well-formed shape that does not occur and does not have a defective shape.

As described above, the aluminum resin composite laminate constituting the three-dimensional molded product B has desirable ranges in the total thickness, the thickness of the core material 2a, and the thickness of the face material 2b, and the three-dimensional molded product B to be manufactured. Various sizes can be considered. For all of these, it is not desirable to manufacture by applying only the spring member 25 having a specific spring constant and a specific unit load. The total thickness, the thickness of the core material, the thickness of the face material, Prepare multiple types of spring members with different spring constants and unit loads according to the size of the three-dimensional molded product to be used, and replace with a suitable spring member according to the three-dimensional molded product to be manufactured. It is preferable to manufacture.
For this reason, in the manufacturing apparatus A having the above configuration, a suitable one selected from a plurality of types of spring members having different spring constants and unit loads according to the size and scale of each part of the target three-dimensional molded product B is used. It is preferable to manufacture.
For this reason, it is desirable that the replacement work can be easily performed when the support shaft member 20 supporting the spring member 25 is removed as easily as possible and replaced with a spring member having a different spring constant or a different unit load. In this respect, the support wall 17 is provided on the support plate 18 so as to be spaced apart, and the space K is provided around the head of the support shaft member 20, so that the rotation of the support shaft member 20 is performed using this space K. Since the operation can be easily performed and the support shaft member 20 and the wrinkle holding plate 22 are easily separated, the replacement operation of the spring member 25 can be facilitated. Further, since the space K is provided so that the support wall 17 and the support plate 18 are integrated into a comb shape and the base base 19 is lightened, the spring member can be replaced even when it is desired to replace the spring restraining force by the spring member 25 with a smaller one. Thus, the overall weight on the upper mold 6 side including 25 can be suppressed, and the weight effect of the upper mold 6 can be suppressed.

  The die plate 12 is composed of a thick rectangular frame-shaped metal block body having a mold hole 12a at the center, and the punch 9 pushes the blank material 4 into the mold hole 12a to perform angular drawing. For this reason, the mold hole 12a is formed in a dimension necessary for molding the three-dimensional molded product B shown in FIG. Specifically, the opening of the mold hole 12a has a slightly larger contour shape than the contour of the bottom surface of the box-shaped three-dimensional molded product B, and when the punch 9 is inserted into the mold hole 12a, the inner peripheral surface of the mold hole 12a A gap corresponding to the thickness of the aluminum resin composite laminate is formed between the punch 9 and the outer peripheral surface. For this reason, the aluminum resin composite laminate can be pushed into the mold cavity from the opening of the die hole 12 a together with the bottom side of the punch 9, and the aluminum resin composite laminate can be drawn by the punch 9.

  Further, four columnar stopper members 24 are erected on the upper surface side corner portion of the die plate 12. These stopper members 24 are provided in order to abut on the corner portion of the mounting plate 18 when the upper die 6 is lowered to define the maximum lowered position (bottom dead center) of the bottom surface 9a of the punch 9. Therefore, the stopper member 24 is erected so as to face the corner portion of the die plate 18 that descends together with the punch 9 at a corner position of the die plate 12 that does not hinder the vertical movement of the wrinkle pressing plate 22.

  A hollow die-side base 11 is provided at the center of the upper surface of the lower surface plate 5, and a die plate 12 is attached on the die-side base 11. A core 10 is supported below the mold hole 12a of the die plate 12 by a plurality of ejector pins 26 so as to be movable up and down, while supporting the lower surface side of the aluminum resin composite laminate formed by the lowering of the punch 9. The child 10 can move downward. The ejector pins 26 are provided to raise the core 10 after completion of the drawing and push out the three-dimensional molded product B after the drawing to the upper side of the die plate 12.

With the above configuration, the punch 9 and the wrinkle holding plate 22 can be lowered simultaneously by lowering the upper die 6 together with the upper surface plate 3, but the punch 9 can be inserted into the die hole 12a to a predetermined depth. It is configured. Further, as the punch 9 is lowered, the wrinkle holding plate 22 can be lowered until it reaches the upper surface of the die plate 12, and even if the wrinkle holding plate 22 is in contact with the upper surface of the die plate 12 and the descent is stopped, the punch 9 is stopped. Can be inserted at a predetermined depth into the inner side of the mold cavity 12a. Further, the wrinkle pressing plate 22 can be pressed against the upper surface side of the die plate 12 by the urging force corresponding to the spring force of the spring member 25 while the bottom portion of the punch 9 is inserted into the mold hole 12 a.
The lowering operation of the punch 9 and the wrinkle holding plate 22 in that case will be described below with reference to FIGS.

  When the punch 9 and the wrinkle holding plate 22 are lowered as shown in FIG. 7 from the state where the punch 9 and the wrinkle holding plate 22 are spaced apart from each other above the die plate 12 as shown in FIG. Contacts the upper surface of the die plate 12. Although the wrinkle holding plate 22 cannot be lowered from this state, the punch 9 can be lowered to the required depth inside the mold hole 12a as shown in FIGS. While the punch 9 descends to the inside of the mold hole 12a, the wrinkle pressing plate 22 can generate a predetermined pressing force corresponding to the spring force of the four spring members 25.

  Although the description of the blank material 4 which consists of an aluminum resin composite laminated board is abbreviate | omitted in FIGS. 6-9, when the blank material 4 of an aluminum resin composite laminated board is installed on the die plate 12 as shown in FIG. The wrinkle pressing plate 22 can press the peripheral edge of the blank member 4 against the upper surface of the die plate 12 and press the peripheral edge of the blank member 4 with a predetermined wrinkle pressing force. Then, the blank 9 can be drawn by the punch 9 pushing the blank 4 into the mold hole 12 a side of the die plate 12 with a wrinkle pressing force applied to the peripheral edge of the blank 4.

  The lowering operation of the punch 9 and the support plate 18 is performed until the lower surface of the corner portion of the support plate 18 contacts the upper end of the stopper member 24, and the bottom dead center of the punch 9 contacts the upper end of the stopper member 24. It is set at the time. Since the stopper member 24 defines the bottom dead center of the punch 9, application of excessive pressing force of the support plate 18 to the spring member 25 is prevented, and damage to the spring member 25 can be prevented. It is preferable to set the height of the stopper member 24 so that the support plate 18 is brought into contact with the upper end of the stopper member 24 at a position of about 80% of the deflection limit of the spring member 25 to define the bottom dead center. Thereby, damage to the spring member 25 can be reliably prevented.

In addition, since the force by which the punch 9 presses the blank material 4 downward is set to be larger than the wrinkle pressure force applied by the wrinkle pressure plate 22, the blank material 4 has a predetermined wrinkle pressure force at the periphery. The three-dimensional molded product B shown in FIG. 1 is obtained by being subjected to corner drawing while being pressed into the mold hole 12 by the punch 9 while being pressed.
In addition, since the four spring members 25 are provided as compression springs, the initial length of the spring member 25 is long at the initial stage of molding, and the wrinkle pressing force that can be applied to the blank material 4 in this state is weak. The length of the spring member 25 is gradually shortened toward the middle stage and the final stage, and the wrinkle pressing force can be gradually increased. In addition, since the area of the portion pressed by the wrinkle pressing plate 22 in the peripheral portion of the blank material 4 becomes smaller as the drawing process proceeds, the wrinkle presser per unit area that acts on the peripheral portion of the blank material 4 also in this sense. The power increases.

If the punch 9 is lowered as shown in FIGS. 6 to 9 and the blank 4 placed on the die plate 12 is subjected to square drawing, the wrinkle pressing force that gradually increases as the molding progresses is suppressed. Square drawing of the aluminum resin composite laminate can be performed while being applied by the plate 22.
In the manufacturing apparatus A of the present embodiment, the wrinkle pressing force is generated in the peripheral portion of the blank member 4 via the spring member 25, so that the wrinkle pressing force is gradually and automatically increased as the drawing process proceeds. Square drawing can be performed.
In addition, in the spring member 25 that generates the wrinkle holding force, the spring constant is set in the range of 60 N / mm or more and 150 N / mm or less, and the unit load is set in the range of 120 kg or more and 300 kg or less. The aluminum resin composite laminate is square drawn while applying a suitable size of wrinkle holding force in order, so that it is free of wrinkles and cracks, has no surface wrinkles, and has a well-shaped three-dimensional molded product B Can be manufactured.

In the case of general draw forming, the blank material flows into the mold as the forming progresses, so that the wrinkle holding area at the peripheral portion of the blank material sandwiched between the die and the blank holder gradually decreases. Therefore, if the press load for wrinkle pressing by the die and blank holder is constant, the wrinkle pressing force per unit area will increase as the molding progresses, so to avoid excessive wrinkle pressing force, It is a general consideration at the time of drawing forming that it is necessary to gradually reduce the size.
However, depending on the molding method and the molded product, the wrinkle holding force may be substantially constant from the start to the end of molding (in the case of molding with overhanging as the main component). In this case, the amount of deformation of the material increases as the squeezing depth increases, and the amount of excessive deformation appears as “wrinkles” on the surface of the three-dimensional molded product. Therefore, in that case, it is necessary to gradually increase the wrinkle holding force. Also in this embodiment, such a way of thinking is adopted, and the blank material 4 is subjected to corner drawing while gradually increasing the wrinkle holding force as the drawing process proceeds. For this reason, the wrinkle pressing force by the spring member 25 which is a compression spring is utilized.

  Next, in order to apply the wrinkle pressing force evenly to the peripheral edge of the blank 4, it is preferable to support the wrinkle pressing plate 22 by the four support shaft members 20 as horizontally as possible so as not to be inclined. 9 is required to smoothly move the wrinkle holding plate 22 up and down. In this respect, as shown in FIGS. 7 to 9, a stripper bolt not provided with a thread portion is applied to the shaft portion 20 a of the support shaft member 20, and a bush member 21 is provided in the support shaft member insertion portion of the support plate 20. The support shaft member 20 can be moved smoothly when it is moved. By adopting a configuration in which the posture of the support shaft member 20 can be smoothly moved up and down, the wrinkle holding plate 22 can be evenly pressed to the peripheral portion of the blank material 4 via the four spring members 25, and the blank material The wrinkle pressing force can be applied evenly to the peripheral edge of 4. For this reason, it is possible to reduce the risk of shape defects in the three-dimensional molded product B manufactured by corner drawing.

  The support shaft member 20 has a function of adjusting the lower surface position of the wrinkle pressing plate 22 with respect to the bottom surface 9 a of the punch 9. If the lower surface of the wrinkle retainer plate 22 is disposed below the bottom surface 9a of the punch 9 by a predetermined height, the blank retainer plate 22 is placed before the punch 9 reaches the center of the blank member 4. 4 can reliably reach the peripheral edge of the blank 4, and the desired wrinkle pressing force can be exhibited when the blank 4 is drawn.

Moreover, the blank material 4 itself may be distorted and the blank material 4 having a slightly different shape may be subjected to corner drawing. In this case, by finely adjusting the amount of screw portion 20c of support shaft member 20 screwed into screw hole 22a of wrinkle retainer plate 22, the inclination of wrinkle retainer plate 22 is finely adjusted, and wrinkle retainer plate against blank material 4 having distortion is provided. The pressing state of 22 can be finely adjusted.
For this reason, even if it is a case where corner drawing using the blank material 4 which has distortion, the shape-free three-dimensional molded product B without a shape defect can be manufactured.

In order to increase the wrinkle holding force in accordance with the progress of drawing, a hydraulic device or the like may be separately prepared instead of the spring member 25, and only the wrinkle holding plate 22 may be configured to be individually movable by the hydraulic device. Is possible. However, in this case, the configuration of the hydraulic device becomes complicated, and the unit price of the device increases. Therefore, the configuration using the spring member 25 described above is preferable in terms of simplification of the device.
Further, by using the spring member 25 without using a hydraulic device for controlling the wrinkle holding force, the entire upper mold can be reduced in weight, and the lighter upper mold 6 can be used to reduce the load. Even so, a stable wrinkle pressing force can be obtained.

An aluminum alloy plate made of AA1050 and made of AA1050 is bonded to one side of a 2.5 mm thick foamed resin plate made of 3 times foamed polypropylene, and an AA5151 made of AA5151 to the other side. A plurality of blank materials of an aluminum resin composite laminated plate (total thickness 3 mm, length 160 mm, width 230 mm) having a three-layer structure to which are attached are prepared.
A box-shaped three-dimensional molded product having a length of 100 mm, a width of 170 mm, and a depth of 30 mm was manufactured by square drawing with respect to these blanks using a manufacturing apparatus having the configuration shown in FIGS.
The size of the die hole of the die plate for corner drawing of the blank material is a rectangular shape with a length of 106 mm and a width of 176 mm. When the blank material is pushed into the mold hole by forming a round at the opening of the die hole Reduced resistance.

When the manufacturing apparatus having the configuration shown in FIGS. 2 to 9 is used, in order to optimize the wrinkle holding force by the wrinkle holding plate, coil springs wound around the four support shaft members that support the wrinkle holding plate are as follows. The spring constants (55 to 160 N / mm) and unit loads (100 to 320 kg) shown in No. 1 are replaced with the three-dimensional examples of Examples 1 to 9 and Comparative Examples 10 to 15, respectively, for each blank drawing. An original molded product was produced.
The obtained three-dimensional molded product was visually observed, and the occurrence of cracks, wrinkles and surface wrinkles was visually inspected. Moreover, the shape defect was visually observed. The results are shown in Table 1 below.
In Table 1, for cracks and wrinkles, three-dimensional molded products that were confirmed to have cracks, wrinkles, and surface wrinkles even at one location are indicated by x.
As for the surface flaw, if there is a small flaw, but there is no large conspicuous flaw, it will be judged as acceptable, and if a flaw is visible even with a standing light, it will be indicated with a cross, and it will not be visible with a standing light or visible with a fluorescent light. If the wrinkle disappears depending on the viewing angle, it is indicated by a circle.
Regarding the shape defect, the sample that became the case where the core of the blank material was shifted and became asymmetrical left and right, the bottom surface was not flat but a drum shape, the side wall part was recessed, etc. means. If a shape defect was observed with the naked eye, it was indicated by a cross in Table 1, and if a shape defect was not observed, it was indicated by a circle.

  As is clear from the results shown in Table 1, the spring constant was set to 60 N / mm or more and 150 N / mm or less, and the spring force with the unit load set to 120 kg or more and 300 kg or less was applied to set the wrinkle holding force. In the case of Examples 1 to 9, it has been found that a three-dimensional molded product having no cracks, no wrinkles and no surface flaws and having a well-formed shape can be produced.

On the other hand, the three-dimensional molded article of Comparative Example 10 to which the spring member in which the spring constant was set to 55 N / mm less than 60 N / mm and the unit load was set to 100 kg less than 120 kg was cracked, wrinkled, and surface wrinkled. Generated, and shape defects were also generated. In Comparative Example 11 in which the spring constant was 55 N / mm, which is less than 60 N / mm, wrinkles were generated and shape defects were also generated. In Comparative Example 12, in which the spring constant was set to 160 N / mm and increased too much, wrinkles and surface wrinkles occurred.
In Comparative Example 13 in which the spring constant was set too high by setting to 160 N / mm, and the unit load was set too high at 320 kg, cracks and wrinkles occurred, and surface defects and shape defects also occurred.
In Comparative Example 14 in which the unit load was set to 110 kg, wrinkles and shape defects occurred, and in the sample in which the unit load was set to 310 kg, cracks and surface flaws occurred, and shape defects also occurred.

  From these comparisons, when the aluminum resin composite laminate is formed by square drawing with the manufacturing apparatus shown in FIGS. 2 to 5, the spring constants of the four spring members supporting the wrinkle holding plate are 60 N / mm or more and 150 N / mm. If a spring member with a unit load set in the range of 120 kg or more and 300 kg or less is applied within the following range, a three-dimensional molded product with no cracks, wrinkles and surface wrinkles and a well-formed shape will be manufactured. It became clear that we could do it.

  According to the present invention, when a three-dimensional molded product is obtained by corner drawing of an aluminum resin composite laminate, a three-dimensional molded product with a good shape can be produced without causing defects such as wrinkles, cracks, and surface defects. It is possible to provide a member that has no defects with respect to a member such as a member, is excellent in aesthetics, and is reduced in weight.

  A ... Manufacturing apparatus, B ... Three-dimensional molded product, 2 ... Aluminum resin composite laminate, 2a ... Core material, 2b ... Face material, 2A ... Bottom wall, 2B ... Side wall, 3 ... Upper surface plate, 4 ... Blank material, 5 ... Lower surface plate, 6 ... Upper die, 7 ... Lower die, 8 ... Mounting base, 9 ... Punch, 10 ... Core, 11 ... Die side base, 12 ... Die plate, 12a ... Mold hole, 16 ... Base plate , 17 ... support wall, 18 ... support plate, 19 ... base base, 20 ... support shaft member, 22 ... wrinkle pressing plate, 22a ... screw hole, 24 ... stopper member, 25 ... spring member.

Claims (8)

A three-dimensional molded product comprising an aluminum resin composite laminated plate in which aluminum or an aluminum alloy face material is laminated on both sides of a core material made of foamed resin, and having a top wall or a bottom wall and a side wall continuous to either of them. In manufacturing equipment,
A base base provided with a punch; a die plate provided opposite to the punch and provided with a mold hole into which the punch is inserted; a frame-type wrinkle pressing plate provided around the punch; and the base base A plurality of support shaft members attached to a base and movably supporting the wrinkle holding plate between the base base and the die plate; and a compression spring type spring member wound around the support shaft member; The punch is provided so as to be close to and away from the die hole of the die plate,
A manufacturing apparatus for drawing the aluminum resin composite laminate by pressing the aluminum resin composite laminate sandwiched between the punch and the die plate into the mold hole,
Prior to insertion of the punch into the mold hole, the wrinkle holding plate is supported at a position where the aluminum resin composite laminated plate can be pressed to the die plate side against the urging force of the spring member by the wrinkle holding plate. And
The apparatus for manufacturing a three-dimensional molded product, wherein the spring constant of the spring member is set to 60 N / mm or more and 150 N / mm or less, and the unit load of the spring member is set to 120 kg or more and 300 kg or less.   A stopper member is provided between the die plate and the base base so as to define an end point position of the movement of the punch toward the die plate, and according to the movement of the punch toward the die plate. The apparatus for manufacturing a three-dimensional molded product according to claim 1, wherein the end point position is set at a position where the amount of deflection of the spring member generated is smaller than a deflection limit of the spring member.   The foaming resin is applied to an aluminum resin composite laminate having a foaming ratio of 1.5 to 10 times, a total thickness of 2 to 10 mm, and a thickness of the face material of 0.1 to 4 mm. The apparatus for manufacturing a three-dimensional molded product according to claim 1 or 2.   The base base includes a support plate that supports the plurality of support shaft members, a plurality of support walls that are erected on the support plate, and a base plate that is joined to the support walls. The plurality of support shaft members are supported so as to be slidably positioned, and thread portions are formed at the tip portions of the plurality of support shaft members, and the plurality of support shaft members are screwed into screw holes formed in the wrinkle holding plate. The apparatus for producing a three-dimensional molded product according to any one of claims 1 to 3, wherein the wrinkle pressing plate is supported.   The three-dimensional according to any one of claims 1 to 4, wherein a wrinkle pressing force generated by the wrinkle pressing plate is increased in conjunction with the progress of insertion of the punch into the mold hole. Molded product manufacturing equipment. A three-dimensional molded product comprising an aluminum resin composite laminated plate in which aluminum or an aluminum alloy face material is laminated on both sides of a core material made of foamed resin, and having a top wall or a bottom wall and a side wall continuous to either of them. In the manufacturing method,
Using a die plate having a mold hole, a punch for pressing the blank material of the aluminum resin composite laminate into the mold hole, and a wrinkle pressing plate for pressing the peripheral edge of the blank material to the die plate, the peripheral edge of the blank material A method for producing a three-dimensional molded product, in which the blank material is pressed into the mold hole by the punch while applying a wrinkle pressing force with a wrinkle pressing plate,
The urging force generated by compressing the compression spring type spring member is used to press the crease pressing plate against the blank material to generate a crease pressing force, and the spring constant of the spring member is set to 60 N / mm or more and 150 N / mm. A method for producing a three-dimensional molded product, characterized in that the unit load of the spring member is set to 120 kg or more and 300 kg or less.   The foaming resin is applied to a blank material made of an aluminum resin composite laminate having a foaming ratio of 1.5 to 10 times, a total thickness of 2 to 10 mm, and a thickness of the face material of 0.1 to 4 mm. The manufacturing method of the three-dimensional molded article of Claim 6.   8. The three-dimensional image according to claim 6, wherein a wrinkle holding force generated by the spring member using the wrinkle holding plate is sequentially increased from an initial stage to an end stage of drawing of the blank material. Manufacturing method of molded products.

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