JP2018176271A - Method for manufacturing metal embossed plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a metal embossed plate in which a sufficient of a strength rigidity of the plate can be assured while achieving weight saving thereof by adoption of a raw material metal plate of which a thickness is thin as much as possible, the plate has a large degree-of-freedom for deep drawing and a slight residual strain.SOLUTION: According to this method, plural first waveform parts 11 are sequentially formed onto a raw material metal plate along a first direction X by embossing, plural second waveform parts 12 are sequentially formed onto a primary molded plate, on which the first waveform parts 11 are formed, along a second direction Y crossing the first direction X by embossing of projections provided on a set of molds, which can approach each other, so that an amplitude and a waveform of the second waveform part are longer than that of the first waveform part 11, and plural third waveform parts 13 are sequentially formed onto a secondary molded plate 17, on which the second waveform parts 12 are formed, along substantially the first direction X by embossing of projections 43, 47 provided on a set of molds, which can approach each other, so that an amplitude and a waveform of the third waveform part are longer than that of the first waveform part 11.SELECTED DRAWING: Figure 10

Description

  The present invention relates to a metal embossed plate suitably usable as a cover member for covering an exhaust system of an automobile, an exhaust system cover member of an automobile using the same, and a method of manufacturing the metal embossed plate.

As the weight of the car increases, the fuel consumption also increases. Fuel consumption standards are becoming stricter year by year together with CO ₂ emission standards, and reduction of vehicle weight is absolutely indispensable. However, the weight of the vehicle tends to further increase, for example, from the viewpoint of collision safety standards, the vehicle is required to have high strength to cope with the offset collision, or the number of devices mounted to improve the comfort of the vehicle increases. . Therefore, in order to reduce the weight of individual parts of an automobile, it is expected to expand the use of aluminum alloy materials (aluminum materials) having the features of integration of multiple parts and light weight, high strength and excellent corrosion resistance.

  In the exhaust system of automobiles (cars), the requirements for weight reduction, heat insulation and compactness are regarded as important from the necessity of environmental design.

  For example, regarding the cover covering the exhaust manifold, an aluminum alloy cover is becoming mainstream instead of the iron plate cover for weight reduction, and the exhaust manifold is improved to improve the heat insulation and the catalyst efficiency. A cover of a suitable shape and a full hood system that covers the entire exhaust manifold are being adopted. Furthermore, as the exhaust manifold becomes more compact, the shape of the cover also becomes deeper, and it is becoming difficult to perform deep drawing.

  In order to meet such requirements, for example, Patent Document 1 discloses a heat shield panel consisting of a metal sheet made of aluminum alloy, wherein the sheet is formed into a plurality of generally parallel upstanding ridges separated by grooves. In those grooves where the grooves have inwardly curved side walls, the width of each ridge regularly changes along its length and the height of each ridge changes along its length to a maximum height Thermal barrier panels have been proposed, which occur at the narrowest point of the ridge, and the depths of the grooves vary along their length, such that the maximum depth occurs at the narrowest point of the grooves .

  Further, according to Patent Document 2, after an aluminum plate is passed through a pair of gear-like first corrugating rolls to form a first corrugating projection, the first corrugating projection is made to be orthogonal to the first corrugating projection, A motor vehicle in which ridges of the first corrugated projection and ridges of the second corrugated projection are arranged in a grid by forming the second corrugated projection through a pair of second corrugated rolls in a gear shape There has been proposed a method of manufacturing an aluminum molded plate which can be suitably used as a shielding cover disposed in a heat generating portion such as an exhaust pipe or an engine.

Japanese Patent Publication No. 2001-504393 Patent No. 5705402

  However, although the metal sheet described in Patent Document 1 is likely to extend in the width direction of the ridge, it is difficult to extend in the length direction of the ridge, so the critical drawing rate is adversely affected by the extension in the lengthwise direction of the ridge. There is a problem of becoming smaller. Therefore, depending on the shape of the exhaust manifold, the metal sheet can not be deep-drawn three-dimensionally according to the shape of the exhaust manifold, which may not satisfy the requirements of the automobile manufacturer, or may be a factor of expensive product cost. There is. Further, in the metal sheet described in Patent Document 1, since the mechanical clinch by the inner bending side wall is disposed on the entire surface and bonded to the two laminated plates, in the case of three-dimensional forming close to the shape of the exhaust manifold, There is concern that the mechanical clinch portion may adversely affect formability.

  On the other hand, in the aluminum molded plate manufactured by the manufacturing method described in Patent Document 2, the ridges of the first wave-shaped protrusions of the sine wave and the ridges of the second wave-shaped protrusions of the sine wave are arranged in a grid shape. Since it is processed, compared with the metal sheet of Patent Document 1, the elongation in the first direction and the elongation in the second direction in the aluminum formed plate approach each other, and the critical drawing rate becomes large. As a result, the degree of freedom in design of a deep-drawable molded article is increased.

  However, in the manufacturing method described in Patent Document 2, the amplitude of the wave-like protrusion depends on the tooth height of the wave-like roll because the wave-like projections are formed by passing through the pair of gear-like wave-like rolls. If the length is increased, residual strain in the formed plate may increase, and there is a concern that cracks may occur. If the tooth length is shortened, the total thickness of the formed plate may be reduced, and the rigidity of the formed plate may not be sufficiently secured. It is also possible to increase the rigidity of the formed plate by increasing the thickness of the raw metal plate, but increasing the thickness causes another problem of an increase in weight.

  Also, in order to improve the combustion efficiency as much as possible, it has been proposed to constitute the cover member of the exhaust manifold with a stainless steel having a thermal conductivity smaller than that of the aluminum alloy, but the stainless steel has an elongation compared to the aluminum alloy. Because of the small size, further improvement of formability is required.

  SUMMARY OF THE INVENTION The object of the present invention is to manufacture a metal embossed plate which can secure sufficient strength and rigidity while adopting weight as thin as possible by using a metal base plate as thin as possible, yet having a large design freedom for deep drawing and little residual strain. To provide.

The present invention includes the following inventions.
(1) forming a plurality of first waved portions sequentially by embossing on a material metal plate along a first direction; and for the primary forming plate formed with the first waved portion, Forming a plurality of second waveform portions sequentially by embossing a ridge along a second direction intersecting the first direction so that the amplitude and the wavelength are longer than the first waveform portion; A plurality of third waveform portions are formed in a ridge pattern substantially along the first direction so that the amplitude and wavelength of the secondary molded plate on which the two waveform portions are formed is longer than that of the first waveform portion. Forming sequentially by pressing, and manufacturing method of metal emboss board characterized by the above-mentioned.

  In this manufacturing method, with respect to the first waveform portion having a small amplitude, the material metal plate is embossed between a pair of gear-like corrugated rolls, or the material metal plate is embossed by a protrusion, The first corrugated portion is sequentially formed on the metal plate. And since this 1st waveform part has amplitude smaller than a 2nd waveform part and a 3rd waveform part, it can decrease the residual distortion to a material metal plate.

  On the other hand, with regard to the second waveform portion and the third waveform portion having a larger amplitude than the first waveform portion, the primary molded plate or the secondary molded plate is embossed by the ridges and sequentially waved, so a metal embossed plate It is possible to wave without difficulty.

  Therefore, it is possible to improve the rigidity of the metal embossing plate by setting the total thickness of the metal embossing plate large while suppressing the residual distortion of the metal embossing plate as a whole, and adopting an extremely thin metal plate. At the same time, it is possible to obtain a rigid metal embossing plate. Moreover, by forming the second waveform portion and the third waveform portion having a large amplitude on the metal embossed plate, the expansion ratio of the metal embossed plate in the first direction and the second direction can be set large, and deep drawing The degree of freedom in design of moldable molded articles can be expanded. Therefore, needless to say, the aluminum alloy sheet can be drawn without difficulty even if it is a stainless steel plate, and a cover member conforming to the shape of an exhaust system member of an automobile such as an exhaust manifold can be easily manufactured without force. It becomes possible.

(2) The method according to (1), wherein the first direction and the second direction are substantially orthogonal to each other. By configuring in this manner, it is possible to uniformly set the elongation percentage of the metal embossing plate in a well-balanced manner.

(3) The metal emboss board according to (1) or (2), wherein the amplitude and the wavelength of the second waveform portion and the amplitude and the wavelength of the third waveform portion are set to substantially the same size, respectively. Production method. By configuring in this manner, it is possible to uniformly set the elongation percentage of the metal embossing plate in a well-balanced manner. In this specification, the amplitude of the first waveform portion means the half distance of the distance between the top and bottom of the wave of the primary formed plate after forming the first waveform portion on the material metal plate, ie, It means half the total thickness of the primary formed plate. In addition, the amplitude of the second waveform portion means half of the distance between the top and bottom portions of the waves of the secondary formed plate after forming the first waveform portion and the second waveform portion on the material metal plate. It means the distance, that is, half the total thickness of the secondary forming plate. Furthermore, the amplitude of the third waveform portion means the distance between the uppermost portion and the bottom portion of the wave of the metal embossing plate after forming the first waveform portion, the second waveform portion and the third waveform portion on the material metal plate. This means half of the distance of, that is, half the total thickness of the metal embossing plate.

(4) The amplitude of the third waveform portion is set to be not less than twice and not more than 4 times the amplitude of the first waveform portion, and the wavelength of the third waveform portion is 2. of the wavelength of the first waveform portion. The manufacturing method of the metal embossing boards in any one of said (1)-(3) set to 14 times or more and 5.5 times or less. The amplitude of the third waveform portion is preferably twice or more the amplitude of the first waveform portion in order to improve formability (elongation) in the second direction, and in particular, to reduce residual stress in the first waveform portion. The first corrugated portion formed at the top or valley of the third corrugated portion is crushed at the time of molding of the third corrugated portion and the residual stress is increased. preferable. Further, the wavelength of the third waveform portion is such that two or more first waveform portions are provided between the adjacent valley portion and the top portion of the third waveform portion, and the formability (elongation) in the second direction is improved. Therefore, 2.14 times or more of the wavelength of the first waveform portion is preferable, and the wavelength of the third waveform portion becomes large, and it is suppressed that the bending rigidity in the second direction per unit length becomes small. It is preferable to set it at 5.5 times or less in order to secure.

(5) The manufacturing method of the metal embossing boards in any one of said (1)-(4) which used the stainless steel plate as said raw material metal plate. Stainless steel has a smaller elongation than aluminum alloy, but as in the present invention, the second corrugated part and the third corrugated part are stamped by the ridges to form the second corrugated part and the third corrugated part, so that the corrugated part can be easily formed on the metal embossing plate. It can be formed. In addition, stainless steel is a material that can meet customer needs for heat insulation because it has lower thermal conductivity than aluminum alloys, but there is a problem with formability.

(6) Any one of the above-mentioned (1) to (5) in which a surface treatment for enhancing dry lubricity is applied to a mold for embossing any one of the first waveform portion, the second waveform portion and the third waveform portion. The manufacturing method of the metal embossing board as described in.

  According to the method for manufacturing a metal embossed plate according to the present invention, sufficient strength and rigidity can be secured while achieving weight reduction by adopting a thin metal plate as much as possible, and moreover design freedom for deep drawing is large, residual strain It is possible to realize a metal emboss board with a small amount of

Perspective view of metal embossing board A arrow view of FIG. 1 B arrow view of FIG. 1 Explanatory drawing of the manufacturing method of the primary forming plate Front view of primary forming plate and first forming die Explanatory drawing of the manufacturing method of the secondary forming board Front view of secondary forming plate and second forming die A arrow view of the forming plate of FIG. 6 B arrow view of the forming plate of FIG. 6 Explanatory drawing of the manufacturing method of the metal embossing board Front view of the metal embossing board and the third mold Cross section of the material metal plate The perspective view of the 1st shaping die of other composition The perspective view of the 1st shaping die of other composition Front view of the second mold of another configuration Sound insulation cover manufactured using metal embossing board and perspective view of exhaust system of engine

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
As shown in FIGS. 1 to 3, in the metal embossing plate 10 manufactured by the manufacturing method of the present invention, the plurality of first corrugated portions 11 along the first direction X and the first corrugated portion 11 Also, the plurality of second waveform portions 12 along the second direction Y substantially orthogonal to the first direction X, and the plurality of third waveforms along the first direction X so that the amplitude and the wavelength become long. A composite waveform with the part 13 is formed entirely. Curves a and b in the figure are auxiliary lines for explanation drawn to indicate the uneven state of the waveform portion.

  The manufacturing method of the metal embossing board 10 is, as shown in FIGS. 4 and 5, by embossing the plurality of first wave portions 11 along the first direction X with respect to the flat material metal plate 15. As shown in FIGS. 6 and 7, the amplitude and the wavelength of the primary shaping plate 16 on which the first waveform portion 11 is formed are longer than those of the first waveform portion 11 as shown in FIGS. 6 and 7. A second corrugating step in which a plurality of second corrugations 12 are sequentially formed by embossing the ridges 33 and 37 along a second direction Y intersecting the first direction X, and FIGS. As shown in the figure, with respect to the secondary molding plate 17 on which the second waveform portion 12 is formed, a plurality of the second molding plates 17 are formed substantially along the first direction X so that the amplitude and the wavelength become longer than the first waveform portion 11. And a third corrugating step of sequentially forming the three waveform portions 13 by embossing of the projections 43 and 47.

  As the material metal plate 15, one made of any metal material such as aluminum alloy, iron or stainless steel can be adopted as long as it can be press-formed. When manufacturing the cover members 51 and 52 covering the exhaust manifold 50 of an automobile engine as shown in FIG. 16 using the metal embossing plate 10, the material metal plate 15 is used to reduce the weight of the vehicle body. In order to improve the engine performance by using an aluminum alloy plate or enhancing the heat insulation, a stainless steel plate is used. A material metal plate 15 made of one metal plate may be used as the material metal plate 15, or a material metal of a multiple plate structure formed by overlapping a plurality of metal plates and integrating them by spot welding or the like. A board can also be used. For example, as in the case of a raw metal plate 15A shown in FIG. 12, it is also possible to use a raw metal plate 15A of a multi-plate configuration, which is integrated by spot welding two metal plates 52 and 53 in layers. it can. Moreover, in the raw material metal plate of a multiple plate structure, although the metal plate of the same thickness can also be provided in a lamination form, as shown in FIG. 12, providing metal plates 52 and 53 of different thickness in a lamination form Therefore, the resonance frequency of the metal plates 52 and 53 can be made different to improve the anti-vibration performance of the metal embossing plate, which is preferable.

  A flat plate having a thickness t of 0.1 mm to 0.5 mm can be adopted as the material metal plate 15. The dimension of the material metal plate 15 in the first direction X and the dimension of the second direction Y substantially orthogonal to the first direction X can be set to an arbitrary length in accordance with the dimension of the molded product to be manufactured.

(1st wave attachment process)
First, the first forming die 20 used in the first corrugating process will be described. As shown in FIGS. 4 and 5, the elongated first upper die 21 and the first lower die 25 are provided along the second direction Y. An upper projection 23 is formed on the fixing plate 22 of the first upper mold 21 so as to project downward, and a pair of lower projections 27 is formed on the fixing plate 26 of the first lower mold 25 in the first direction X. Are formed to project upward at intervals. The upper projection 23 is disposed above the middle position of the pair of lower projections 27. When the first upper die 21 is lowered to the lower limit position shown by an imaginary line in FIG. It is configured to be inserted between the lower protrusions 27. Further, in a state where the upper ridges 23 are fitted to the pair of lower ridges 27, 0.1 mm is added to the thickness t of the material metal plate 15 between the upper ridges 23 and the lower ridges 27 A clearance C1 is formed.

  The distance W1 of the pair of lower ribs 27 in the first direction X is set to the same size as the wavelength λ1 of the first waveform portion 11. The vertical distance d1 between the lower end of the upper ridge 23 and the upper end of the lower ridge 27 when the first upper die 21 is lowered to the lower limit position, the amplitude A1 of the first waveform portion 11, and the plate thickness The relationship with t is set to d1 = 2 × (A1−t). The distance d1 is represented by a negative value when the lower end of the upper protrusion 23 is disposed above the upper end of the lower protrusion 27, and is represented by a positive value when the lower protrusion is disposed below. It shall be.

  Specifically, the amplitude A1 of the first waveform portion 11 is set to 0.22 to 1.25 mm, the wavelength λ1 of the first waveform portion 11 is set to 2 to 2.8 mm, and the distance d1 is It is set to 0.56 to +1.5 mm, and the distance W1 is set to 2 to 2.8 mm.

  When forming the first corrugated portion 11 with the first forming die 20, as shown in FIGS. 4 and 5, the first metal plate 15 is arranged with the material metal plate 15 disposed substantially horizontally. The material metal plate 15 is set to a feeding device (not shown) so that the direction X is the feeding direction F1 to the first forming die 20. Then, the material metal plate 15 is directed by the feeding device in the feeding direction F1 by tact feeding at a pitch that matches the distance W1 between the pair of lower protrusions 27, and the first upper die 21 of the first forming die 20 And the first lower mold 25 sequentially. On the other hand, every time one tact feed is completed, the first upper die 21 is lowered to the lower limit position shown by an imaginary line in FIG. 15 is pressed to form one of the wave portions constituting the first waveform portion 11, and then the first upper die 21 is moved upward to separate the upper protrusion 23 from the material metal plate 15. The embossing operation is sequentially repeated to manufacture a primary forming plate 16 in which the first waveform portion 11 is sequentially formed on the entire surface of the raw metal plate 15.

  Note that, instead of the first lower die 25, as shown in FIG. 13, a flat plate-like first lower die 25A in which a slit 27A having the same size as the gap between the facing surfaces of the pair of lower protrusions 27 is formed. It can also be used. Furthermore, since the first waveform portion 11 has a smaller amplitude than the second waveform portion 12 and the third waveform portion 13 described later, as shown in FIG. It is also possible to form the first corrugated portion 11 by providing the first forming die 20B having the pair of corrugated rolls 28 and 29 and passing the material metal plate 15 between both the corrugated rolls 28 and 29.

(2nd wave attachment process)
First, the second molding die 30 used in the second corrugating process will be described. As shown in FIGS. 6 and 7, the elongated second upper die 31 and the second lower die 35 are provided along the first direction X. An upper projection 33 is formed on the fixing plate 32 of the second upper mold 31 so as to project downward, and a pair of lower projections 37 is formed on the fixing plate 36 of the second lower mold 35 in the second direction Y. Are formed to project upward at intervals. The upper projection 33 is disposed above the middle position of the pair of lower projections 37, and when the second upper die 31 is lowered to the lower limit position shown by an imaginary line in FIG. It is configured to be inserted between the lower protrusions 37. Further, in a state where the upper ridge 33 is fitted to the pair of lower ridges 37, 0.1 mm is added to the thickness t1 of the primary formed plate 16 between the upper ridge 33 and the lower ridge 37 A gap C2 is formed.

  The distance W2 with respect to the second direction Y of the pair of lower ribs 37 is set to the same size as the wavelength λ2 of the second waveform portion 12.

  The amplitude A2 of the second waveform section 12 is set to 2 times or more and 4 times or less the amplitude A1 of the first waveform section 11, and the wavelength λ2 of the second waveform section 12 is 2 of the wavelength λ1 of the first waveform section 11. It is set to .14 or more and 5.5 times or less. The vertical distance d2 between the lower end of the upper ridge 33 and the upper end of the lower ridge 37 when the second upper die 31 is lowered to the lower limit position is such that the amplitude A2 falls within the above numerical range It is set to a reasonable number.

  When forming the second corrugated portion 12 with the second molding die 30, as shown in FIGS. 6 and 7, with the primary molding plate 16 disposed substantially horizontally, the second molding member 16 of the primary molding plate 16 is formed. The primary molding plate 16 is set to a feeding device (not shown) so that the direction Y is the feeding direction F2 to the second molding die 30. Then, the primary forming plate 16 is directed by the feeding device in the feeding direction F2, and tact feeding is performed at a pitch that matches the distance W2 between the pair of lower ribs 37, and the second upper die 31 of the second forming die 30 And the second lower mold 35 sequentially. On the other hand, every time tact feed is completed, the second upper die 31 is lowered to the lower limit position shown by an imaginary line in FIG. 7, and the primary forming plate is formed by the upper protrusion 33 between the pair of lower protrusions 37. 16 is embossed to form one of the wave portions constituting the second waveform portion 12, and then the second upper die 31 is moved upward to separate the upper protrusion 33 from the primary molding plate 16. The embossing operation is sequentially repeated to manufacture a secondary molding plate 17 in which the second wave portion 12 is sequentially formed on the entire surface of the primary molding plate 16.

  As in the first lower mold 25A shown in FIG. 13 described above, a flat plate in which a slit having the same size as the gap between the facing surfaces of the pair of lower protrusions 37 is formed instead of the second lower mold 35. The second lower mold can also be used. In addition, since the second waveform section 12 has a larger amplitude than the first waveform section 11, the second waveform section 12 can be configured to have a deeper embossing in a stepwise manner. Specifically, as in the second molding die 30A shown in FIG. 15, a second lower die 35A provided with three or more lower ridges 37 in parallel is provided, corresponding to each of the adjacent lower ridges 37. A second upper die 31A provided with a plurality of upper ridges 33A, and the lower end positions of the plurality of upper ridges 33A are configured to be disposed on the lower side as going to the front side of tact feed; It can also be configured so that the embossing becomes deeper gradually. Furthermore, although the second waveform portion 12 is formed substantially orthogonal to the first waveform portion 11, if the second waveform portion 12 and the first waveform portion 11 are formed to intersect with each other, the second waveform portion 12 does not necessarily have a substantially orthogonal shape. There is no need to form.

(3rd wave attachment process)
First, the third mold 40 used in the third corrugating process will be described. As shown in FIGS. 10 and 11, the elongated third upper mold 41 and the third lower mold 42 are provided along the second direction Y. The upper projection 43 is formed in a downward protruding shape on the fixing plate 42 of the third upper mold 41, and a pair of lower projections 47 is formed on the fixing plate 46 of the third lower mold 45 in the first direction X. Are formed to project upward at intervals. The upper ridge 43 is disposed above the middle position of the pair of lower ridges 47, and when the third upper die 41 is lowered to the lower limit position shown by an imaginary line in FIG. It is configured to be inserted between the lower protrusions 47. Further, with the upper ridge 43 fitted to the pair of lower ridges 47, an additional 0.1 mm is added to the thickness t2 of the secondary formed plate 17 between the upper ridge 43 and the lower ridge 47 A clearance C3 is formed.

  The distance W3 of the pair of lower ribs 47 in the first direction X is set to the same size as the wavelength λ3 of the third waveform portion 13. The thickness t2 of the secondary forming plate 17 is set to t2 = A2 × 2.

  Specifically, the amplitude A3 of the third waveform portion 13 is set to be not less than twice and not more than 4 times the amplitude A1 of the first waveform portion 11, and the wavelength λ3 of the third waveform portion 13 is the first waveform portion 11 Is set to 2.14 or more and 5.5 times or less of the wavelength .lambda.1. The vertical distance d3 between the lower end of the upper rib 43 and the upper end of the lower rib 47 when the third upper die 41 is lowered to the lower limit position is such that the amplitude A3 falls within the above numerical range It is set to a reasonable number. Further, the amplitude A3 and the wavelength λ3 of the third waveform unit 13 may be set to the same numerical value as the amplitude A2 and the wavelength λ2 of the second waveform unit 12, respectively, or may be set to different numerical values.

  When forming the third corrugated portion 13 with the third molding die 40, as shown in FIGS. 10 and 11, with the secondary molding plate 17 disposed substantially horizontally, The secondary molding plate 17 is set to a feeding device (not shown) so that the direction X of 1 is the feeding direction F3 to the third molding die 40. Then, the secondary molding plate 17 is directed by the feeding device in the feeding direction F3 by tact feeding at a pitch that matches the distance W3 between the pair of lower ribs 47, and the third upper mold of the third molding die 40 It supplies sequentially between 41 and the 3rd lower mold | type 42. As shown in FIG. On the other hand, every time tact feed is completed, the third upper die 41 is lowered to the lower limit position shown by an imaginary line in FIG. 11, and secondary molding is performed by the upper ridge 43 between the pair of lower ridges 47. After the plate 17 is embossed to form one of the wave portions constituting the third waveform portion 13, the third upper die 41 is moved upward to separate the upper protrusion 43 from the material metal plate 15. The embossing operation is sequentially repeated to manufacture the metal embossing plate 10 in which the third corrugated portion 13 is sequentially formed on the entire surface of the secondary molding plate 17.

  In addition, it is also possible to abbreviate | omit the 3rd shaping | molding die 40 and to effectively utilize the 2nd shaping | molding die 30 as a 3rd shaping | molding die as it is. In this case, after the secondary forming plate 17 is manufactured, the secondary forming plate 17 is second-formed so that the first direction X of the secondary forming plate 17 is the feed direction F2 of the second forming die 30. By tact feeding to the mold 30, the third waveform portion 13 is formed. Further, like the first lower mold 25A shown in FIG. 13 described above, a flat plate in which a slit having the same size as the gap between the facing surfaces of the pair of lower ribs 47 is formed instead of the third lower mold 42. The third lower mold of can also be used. Furthermore, since the third waveform portion 13 has an amplitude larger than that of the first waveform portion 11, it is also possible to wave using the third molding die having the same configuration as that of the second molding die 30A shown in FIG. .

  In this manufacturing method, the first corrugated portion 11 is formed sequentially by embossing the material metal plate with the upper ridges 23 and the lower ridges 27, and the primary molding plate 16 is embossed with the upper ridges 33 and the lower ridges 37. Then, the second corrugated portion 12 is sequentially formed, and the secondary forming plate 17 is embossed by the upper ridge 43 and the lower ridge 47 to sequentially form the third corrugated portion 13. The wave can be applied without applying a large tensile load. For this reason, the total thickness of the metal embossing board 10 can be set large to improve the rigidity of the metal embossing board 10 while suppressing the residual distortion of the metal embossing board 10 as a whole, and the material metal plate 15 is extremely thin. The metal emboss plate 10 having high rigidity can be obtained while adopting the above. Moreover, by forming the second waveform portion 12 and the third waveform portion 13 having large amplitudes on the metal embossing plate 10, the elongation percentage in the first direction X and the second direction Y of the metal embossing plate 10 is made large. By setting, it is possible to expand the design freedom of deep-drawable molded articles. Therefore, needless to say, the aluminum alloy plate can be drawn without difficulty even if it is a stainless steel plate, and the cover member 51 conforming to the shape of the exhaust system member of the automobile such as the exhaust manifold 50 can be easily and reasonably easily It becomes possible to produce.

  As mentioned above, although embodiment of this invention was described, this invention is not limited at all to embodiment mentioned above, Of course in the range which does not deviate from the summary of this invention, the structure can be changed.

10 Metal Embossing Plate 11 First Corrugated Portion 12 Second Corrugated Portion 13 Third Corrugated Portion 15 Raw Material Metal Plate 16 Primary Forming Plate 17 Secondary Forming Plate 20 First Forming Die 21 First Upper Die 22 Fixing Plate 23 Upper ridge 25 first lower die 26 fixed plate 27 lower ridge 15A material metal plate 52 metal plate 53 metal plate 20A first forming die 25A first lower die 27A slit 20B first forming die 28 corrugated roll 29 corrugated roll 30 second Forming die 31 second upper die 32 fixing plate 33 upper ridge 35 second lower die 36 fixing plate 37 lower ridge 30A second molding die 31A second upper die 35A second lower die 40 third molding die 41 third upper Mold 42 Fixing plate 43 Upper ridge 45 Lower die 46 Fixing plate 47 Lower ridge 50 Exhaust manifold 51 Cover member A1 Amplitude A2 Amplitude A3 Amplitude C1 Clearance C2 Clearance C2 Clearance C3 Clearance d1 Distance d2 Distance d3 Distance F1 Feeding direction F2 Feeding direction F3 Feeding direction t Plate thickness t1 Plate thickness t2 Plate thickness W1 Interval W2 Interval W3 interval X 1st direction Y 2nd direction λ1 wavelength λ2 wavelength λ3 wavelength

Claims (8)

Forming a plurality of first wave-shaped portions in order along the first direction with respect to the material metal plate by embossing;
A plurality of second directions along the second direction intersecting the first direction so that the amplitude and the wavelength of the primary molded plate on which the first waveform portion is formed are longer than those of the first waveform portion. Forming the corrugations sequentially by embossing the ridges provided on at least one of the set of molds that can be moved closer and away;
A plurality of third waveform portions are approximated along the first direction so that the amplitude and the wavelength become longer than the first waveform portion with respect to the secondary molded plate on which the second waveform portion is formed. Forming sequentially by embossing a protrusion provided on at least one of a pair of molds that can be separated;
A method of manufacturing a metal emboss plate comprising:   The method according to claim 1, wherein the first direction and the second direction are substantially orthogonal to each other.   The method according to claim 1 or 2, wherein the amplitude and the wavelength of the second waveform portion and the amplitude and the wavelength of the third waveform portion are set to substantially the same size.   The amplitude of the third waveform portion is set to 2 times or more and 4 times or less the amplitude of the first waveform portion, and the wavelength of the third waveform portion is 2.14 times or more of the wavelength of the first waveform portion The manufacturing method of the metal embossing board of any one of Claims 1-3 set to 5.5 times or less.   The manufacturing method of the metal embossing board of any one of Claims 1-4 which used the stainless steel plate as said raw material metal plate.   The metal according to any one of claims 1 to 5, wherein a surface treatment for enhancing dry lubricity is applied to a mold for embossing any one of the first waveform portion, the second waveform portion and the third waveform portion. Manufacturing method of embossed board.   The method according to any one of claims 1 to 6, wherein at least one of the second waveform portion and the third waveform portion is formed by performing embossing a plurality of times on the same portion so that the embossing becomes deeper stepwise. The manufacturing method of the metal embossing boards of 1st term.   The metal according to any one of claims 1 to 7, wherein only the three waveform portions of the first waveform portion, the second waveform portion, and the third waveform portion are sequentially corrugated with respect to the material metal plate. Manufacturing method of embossed board.

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