JP2018187669A - Sequential molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem that a conventional sequential molding method keeps a most part of the cost of manufacture occupied by the manufacturing cost of a molding tool.SOLUTION: When ribs R having rib bevels D, D on both sides of a ridge line B from a first flange plane F1 to a second plane F2 are formed on the first and second flange planes F1, F2 continuing via a corner part C by a sequential molding method which makes a metal plate A move by pressing a tool 3, after a processing bevel S including the ridge line B of a rib R is formed on the metal plate A, processing regions KL, KR on both sides of the ridge line B on the processing bevel S are forced in toward a corner part C by means of the tool 3 to deform gradually to form the first and second flange planes F1, F2, so that a molding tool is abolished to realize a reduction in manufacturing cost, and a ribbed flange F is molded without using a molding tool.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a sequential forming method for forming a three-dimensional shape by gradually deforming a metal plate by pressing and moving a tool against the metal plate, and particularly to a sequential forming method used for forming a flange with a rib. Is.

  Examples of conventional sequential molding methods include those described in Patent Document 1 and Patent Document 2. The sequential forming method described in Patent Document 1 forms a flange on a metal plate by fixing the metal plate to a forming die and moving the periphery of the metal plate while pressing it with a roller.

  Further, the sequential forming method described in Patent Document 2 uses a support frame that fixes the periphery of a metal plate, a mold-shaped pressing member that is disposed on the lower surface side of the plate material, and a bar-shaped tool that is disposed on the upper surface side of the plate material. . In short, the mold pressing member is a mold. In this sequential forming method, a mold-shaped pressing member is pressed against the lower surface of the plate material whose periphery is fixed, the plate material is initially deformed by the mold-shaped pressing member, and then the tip of the tool is pressed against the upper surface of the plate material to form a predetermined path. By moving it, the plate is gradually deformed in the thickness direction.

JP 2000-5834 A JP 2003-236618 A

  However, since the conventional sequential molding methods as described above all use a molding die, it is necessary to produce a molding die for each shape of the molded product, and the production cost of the molding die is a large part of the manufacturing cost. Since there is a problem of occupying, it was a problem to solve such a problem.

  The present invention was made paying attention to the above-mentioned conventional problems, and when forming a flange with a rib, the molding die is eliminated to realize a reduction in manufacturing cost, and without using a molding die. It is an object of the present invention to provide a sequential molding method capable of molding a flange with a rib.

  The sequential forming method according to the present invention is a sequential forming method in which a metal plate is gradually deformed in the thickness direction and formed into a three-dimensional shape by pressing and moving the tip of a tool against a metal plate holding the periphery. Then, ribs having rib slopes are formed on both sides of the ridge line extending from the first flange surface to the second flange surface on the first and second flange surfaces continuous through the corners. In the sequential forming method, after forming the processing slope including the ridge line of the rib on the metal plate, the processing regions on both sides of the ridge line on the processing slope are pushed toward the corner by the tool and gradually deformed. The first and second flange surfaces and ribs are formed.

  In the sequential forming method according to the present invention, the first and second flange surfaces and ribs are formed on the processing slope of the metal plate by a tool arranged on one side of the metal plate, and the manufacturing cost is eliminated by eliminating the forming die. And a ribbed flange can be formed without using a mold.

It is a figure explaining 1st Embodiment of the sequential shaping | molding method concerning this invention, Comprising: It is sectional drawing explaining the apparatus applicable to a sequential shaping | molding method. It is a front view which shows the fender panel of the motor vehicle which is an example of a molded article. It is a perspective view explaining the bending process of a metal plate. It is a perspective view which shows the metal plate after a bending process. It is a perspective view which shows the metal plate of an initial stage. FIG. 6 is a perspective view illustrating a molding process following FIG. 5. FIG. 7 is a perspective view illustrating a molding process following FIG. 6. FIG. 8 is a perspective view illustrating a molding process following FIG. 7. FIG. 9 is a perspective view illustrating a molding process following FIG. 8. FIG. 10 is a perspective view showing a state of completion of molding following FIG. 9. It is a figure explaining 2nd Embodiment of the sequential shaping | molding method concerning this invention, Comprising: It is a perspective view which shows the initial stage of shaping | molding. FIG. 12 is a perspective view illustrating a molding process following FIG. 11. FIG. 13 is a perspective view illustrating a molding process following FIG. 12. It is a figure explaining 3rd Embodiment of the sequential shaping | molding method concerning this invention, Comprising: It is a perspective view which shows the initial stage of shaping | molding. FIG. 15 is a perspective view illustrating a molding process following FIG. 14. FIG. 16 is a perspective view illustrating a molding process following FIG. 15. FIG. 17 is a perspective view illustrating a molding process following FIG. 16. FIG. 18 is a perspective view illustrating a molding process following FIG. 17. FIG. 19 is a perspective view showing a state of completion of molding following FIG. 18.

<First Embodiment>
FIGS. 1-10 is a figure explaining 1st Embodiment of the sequential shaping | molding method concerning this invention.
The sequential forming method is a method of forming the metal plate A into a three-dimensional shape by gradually deforming the metal plate A in the thickness direction by pressing the tip of the tool 3 against the metal plate A holding the periphery and moving a predetermined movement path. is there. Further, in the sequential forming method of this embodiment, the first and second flange surfaces F1 and F2 that are continuous through the corner portion C, on both sides of the ridge line B that extends from the first flange surface F1 to the second flange surface F2. A rib R having a rib slope D is formed.

  In the sequential forming method, as shown in FIG. 1, a fixed jig 1 that holds an intermediate portion of a horizontal metal plate A, a movable jig 2 that holds an end portion of the metal plate A, and an upper side of the metal plate A. And the tool 3 arranged in the above. The metal plate A has a processed part A2 in which a flange with a rib is formed at the end of the main body part A1. For this reason, in particular, the metal plate A is held by the fixed jig 1 and the movable jig 2 around the processed part A2.

  FIG. 2 is a diagram showing a fender panel FP of an automobile that is an example of a molded product. The fender panel FP corresponds to the metal plate A. This fender panel FP has a flange F at the door side edge on the right side in the figure, and ribs R are formed on the flange F at predetermined intervals. As an example, the sequential forming method is used to form a flange F having ribs R on a fender panel FP.

  The fixing jig 1 includes a lower fixing tool 1A and an upper movable tool 1B, and firmly holds the metal plate A between the fixing tool 1A and the movable tool 1B. The movable jig 2 includes a pair of sandwiching portions 2B and 2B that can be opened and closed on the main body 2A, and sandwiches the metal plate A between the sandwiching portions 2B and 2B to be firmly restrained. The movable jig 2 is held by a holding device (not shown) so as to be movable up and down.

  The tool 3 is a round bar-shaped tool having a spherical tip, and is placed with the tip facing the metal plate A. Since the metal sheet A and the tool 3 only need to move relatively, the sequential forming method of the present invention is performed as long as at least one of the fixed jig 1, the movable jig 2, and the tool 3 is movable. be able to. Specifically, a multi-axis control type working robot or NC machine tool can be used.

  In this embodiment, the tool 3 is held so as to be movable in two horizontal horizontal directions (X and Y directions) and a vertical direction (Z direction) orthogonal to each other, and is rotated to be inclined with respect to the metal plate A. It may be possible. In this case, it is desirable to use a multi-axis control type work robot as the holding device for the tool 3, and if a work robot is employed, the occupation area of the device becomes relatively small and the attitude control of the tool 2 is easy. There are advantages such as being.

  In the sequential forming method, the processing slope S including the ridge line B of the rib R is formed on the metal plate A. At this time, the metal plate A can be bent by pressing, but can be bent by sequential forming using the tool 3. That is, as shown in FIG. 3, the tool 3 is pressed against the flat metal plate A and moved, and at this time, the movable jig 2 can be bent up and down to be bent along the path of the tool 3. it can. The metal plate A in the illustrated example forms four surfaces by setting three parallel fold lines L1 to L3 at predetermined intervals and bending the fold lines L1 to L3 in predetermined directions.

  As shown in FIG. 4, the bent metal plate A includes an edge E held by the fixing jig 1, a first flange surface F <b> 1 continuous in a direction perpendicular to the edge E, an edge E, And a second flange surface F2 extending in a direction perpendicular to the first flange surface F1. The metal plate A has a processing slope S between the first flange surface F1 and the second flange surface F2.

  Next, the sequential forming method uses the tool 3 to process the machining regions KL. The KR is pushed toward the corner portion C to be gradually deformed, and the first and second flange surfaces F1 and F2 and the rib R are formed.

  Further, in the sequential forming method, when the processing regions KL and KR are pushed toward the corner portion C and gradually deformed, the processing regions KL and KR form a rectangle, and the processing regions KL and KR are formed from the rectangle to the ridge line. It is gradually deformed so as to shift to a triangle having B as the base and corner C as the apex.

  Further, in the sequential forming method, after the processing regions KL and KR are deformed into a triangle, the vertex is gradually deformed so that the apex moves along the corner C to the ridge line B side.

  Hereinafter, the sequential molding method will be specifically described. Here, in FIG. 5, the shape after molding is indicated by a virtual line, and in order to facilitate understanding, the upper end portion of the ridge line B is P1 and the lower end portion of the ridge line B is P2 in the processing region KL on the left side in the drawing. And the upper end, which is the end of the boundary between the first flange surface F1 and the processing slope S (the end of the metal plate A), is P3, and the end of the boundary between the processing slope S and the second flange surface F2 The lower end part which is a part is set to P4, and the corner | angular part C and the rib slope D and the intersection are set to P5.

  That is, in the sequential forming method, the tool 3 travels a rectangular path from the upper end P1 of the ridge line B through the upper end P3, the lower end P4, and the lower end P2 of the ridge line B to the upper end P1 of the ridge line B. A path is set, and the tool 3 is pressed to move around the circuit path. At this time, in the sequential forming method, the processing region KL is gradually deformed so that the upper end portion P3 and the lower end portion P4 are directed to the corner portion C while maintaining the ridge line B as shown in FIG. 5 to FIG. .

  Then, the sequential forming method increases the advance amount of the tool 3 relative to the metal plate A for each round movement of the tool 3, and repeats the round movement of the tool 3 and the increase in the advance amount, as shown in FIG. The machining region KL is gradually deformed until the upper end P3 and the lower end P4 coincide with the corner C. Thereby, as shown in FIGS. 5 to 7, the processing region KL is deformed so as to shift from a rectangle to a triangle having a ridge line B as a base and a corner C as a vertex P6.

  Next, in the sequential forming method, as shown in FIG. 7 to FIG. 8, the triangular processing region KL is deformed so that the vertex P6 moves to the ridge line B side along the corner C, and the vertex P6 is Molding is performed until it coincides with the intersection P5 between the corner C and the rib slope D. At this point, the formation of the rib slope D on one side of the first and second flange surfaces F1, F2 and one side of the rib R is completed.

  Thereafter, as shown in FIG. 9, the sequential forming method performs the same process on the right processing region KR as shown in FIG. 10, so that the first and second flange surfaces F <b> 1, F <b> 2 and The ribs R having rib slopes D, D are formed on both sides of the ridge line B.

  As described above, in the sequential forming method, after the processing slope S including the ridge line B of the rib R is formed on the metal plate A, both the ridge lines on the processing slope S are formed by the tool 3 arranged on one side of the metal plate A. The processing regions KL and KR on both sides of the steel plate are pushed toward the corner portion C to be gradually deformed, and the first and second flange surfaces F1 and F2 and the rib R are formed. Thereby, according to said sequential shaping | molding method, while eliminating a shaping | molding die and implement | achieving reduction of manufacturing cost, the flange F with the rib R can be shape | molded without using a shaping | molding die.

  Further, in the above sequential forming method, the processing regions KL and KR form a rectangle, and the processing regions KL and KR are changed from a rectangle to a triangle having the ridge line B as the base and the corner C as the vertex. Deform gradually. As a result, the sequential forming method can perform a series of forming operations using only the tool 3 arranged on one side of the metal plate A, and can form the rib R in a desired shape without sinking.

  Further, in the above-described sequential forming method, after the processing regions KL and KR are deformed into a triangle, the apex P6 is gradually deformed so as to move along the corner C to the ridge line B side. Thereby, the sequential forming method can form the rib R into a target shape without sinking, and the width dimension of the rib R can be freely changed by selecting the moving position of the vertex P6. In other words, it is easy to deal with various rib width dimensions.

  FIGS. 11-19 is a figure explaining 2nd and 3rd embodiment of the sequential shaping | molding method concerning this invention. In the following embodiments, the same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

Second Embodiment
11-13 is a figure explaining 2nd Embodiment of the sequential shaping | molding method concerning this invention.
The sequential forming method of this embodiment is basically the same as in the first embodiment. After forming the processing slope S including the ridge line B of the rib R on the metal plate A, the tool 3 is used to form the processing slope. S on the both sides of the ridge line B in S. KL. The KR is pushed toward the corner C and gradually deformed.

  In the sequential forming method of this embodiment, the processing regions KL and KR are rectangular, and these processing regions KL and KR are gradually deformed so that the rectangular area gradually decreases, and finally In addition, the first and second flange surfaces F1, F2 and the corner portion C are formed.

  That is, the sequential forming method of this embodiment is similar to the first embodiment, from the upper end portion P1 of the ridge line B to the upper end portion P3, the lower end portion P4, and the lower end portion P2 of the ridge line B, A rectangular circulation path that returns to the upper end portion P1 is formed, and the tool 3 is moved around. Then, after finishing the circular movement, the advance amount of the tool 3 is increased, and the circular path is changed inward by a predetermined pitch. After that, every time the tool 3 rotates, the molding is repeated by increasing the advance amount of the tool 3 and changing the circulation path.

  With the above forming, the processing region KL has an upper side and a lower side that are translated along the oblique side of the rib slope D to gradually decrease the length, and the left and right sides are also along the two oblique sides of the rib slope D. And the length gradually decreases, and finally disappears at the corner C. Thereby, as shown in FIG. 13, the sequential molding method simultaneously forms one side of the first and second flange surfaces F1, F2 and the rib slope D on one side. Further, in the sequential forming method, the first and second flange surfaces F1 and F2 and the rib R are formed by performing the same forming on the processing region KR on the right side in each drawing.

  Even in the above-described sequential forming method, the first and second flange surfaces F1, F2 and the rib R are formed by the tool 3 arranged on one side of the metal plate A as in the first embodiment. In addition, the manufacturing cost can be reduced by eliminating the mold, and the flange F with the rib R can be molded without using the mold. Further, according to the above-described sequential forming method, the first and second flange surfaces F1, F2 and the rib R can be formed simultaneously only by the circular movement of the tool 3, so that the forming time can be shortened.

<Third Embodiment>
14-19 is a figure explaining 3rd Embodiment of the sequential shaping | molding method concerning this invention.
In this embodiment, two ribs R are formed on the first and second flange surfaces F1 and F2, as indicated by phantom lines in FIG. As illustrated in FIG. 2, the number of ribs R may naturally be two or more. The processing slope S has a central processing region KC between the ribs R and R, and left and right processing regions KL and KR. These regions KC, KL, and KR are all rectangular.

  In the sequential forming method of this embodiment, in particular, regarding the forming of the central processing region KC, as shown in FIG. 15, the rectangular area is gradually deformed so that the rectangular area gradually decreases, and finally the corner portion C is formed. . Then, as shown in FIG. 16, at the stage where the corner C is formed, a triangle having the ridge line B as the base and the corner C as the vertex P6 is formed.

  That is, in the sequential forming method of this embodiment, the respective steps described in the first and second embodiments are applied particularly to the central processing region KC. That is, the central portion in the central processing region KC is gradually deformed so that the rectangular area gradually decreases, as in the second embodiment. On the other hand, the left and right portions in the central processing region KC are gradually deformed so as to shift to a triangle having the ridgeline B as the base and the corner C as the apex P6, as in the first embodiment. However, in this embodiment, the triangular apex P6 is formed in a state away from the intersection P5 between the corner C and the rib slope D.

  Thereafter, in the sequential forming method, as shown in FIG. 16 to FIG. 17, the tool 3 is pressed on the circulation path along the side of the triangle to move around, and the ridgeline B is maintained, and the vertex P6 of the triangle is square. Until the intersection P5 between the part C and the rib slope D is reached, the triangular processing region KC is gradually deformed so that the area gradually decreases.

  Thereafter, as shown in FIG. 18, the sequential forming method gradually deforms the left and right processing regions KL and KR as in the first embodiment (FIGS. 5 to 9). As a result, the sequential forming method forms the first and second flange surfaces F1, F2 and the two ribs R, R as shown in FIG.

  Even in the above sequential forming method, the first and second flange surfaces F1, F2 and the two ribs R, R are formed by the tool 3 arranged on one side of the metal plate A, as in the previous embodiment. At this time, the rib R can be formed into a desired shape without being sunk, and the width dimension of the rib R can be appropriately selected. Thereby, the sequential molding method can reduce the manufacturing cost by eliminating the molding die, and can form the flange F having the plurality of ribs R without using the molding die.

  The sequential molding method according to the present invention is not limited to the above-described embodiments, and details of the configuration can be appropriately changed without departing from the gist of the present invention. In each said embodiment, although the case where it shape | molds with the tool 3 arrange | positioned on the upper side of the metal plate A was illustrated, it is also possible to make the metal plate A upright and form it by pressing the tool 3 from the lateral direction or the downward direction. Is possible.

  In addition, the sequential molding method according to the present invention can form a flange with a rib even for various molded products other than the automobile fender panel. Furthermore, although the sequential forming method according to the present invention is mainly characterized by the movement path of the tool 3, the pressing force and movement speed of the tool 3 may be controlled. Furthermore, the tool 3 does not necessarily have a spherical tip, and it is also possible to use a tool having a different curvature or diameter at the tip.

3 Tool A Metal plate B Edge line C Corner D Rib slope F Flange F1 1st flange face F2 2nd flange face KL, KC, KR Machining area R Rib S Machining slope P1 Top edge of ridgeline P2 Bottom edge of ridgeline P3 Upper End P4 Lower end P5 Intersection of corner and rib slope P6 Triangle vertex

Claims (5)

A sequential forming method in which the metal plate is gradually deformed in the thickness direction and formed into a three-dimensional shape by pressing and moving the tip of the tool against the metal plate holding the periphery,
When forming ribs having rib slopes on both sides of the ridge line extending from the first flange surface to the second flange surface on the first and second flange surfaces continuous through the corners,
After forming the processing slope including the ridge line of the rib on the metal plate, the processing regions on both sides of the ridge line on the processing slope are pushed toward the corner by the tool to gradually deform the first and second. A sequential molding method characterized by forming a flange surface and a rib.   When the machining area on both sides of the ridge line on the slope for machining is pushed toward the corner and gradually deformed, the machining area forms a rectangle, the machining area is formed from the rectangle with the ridge line as the base and the corner as the apex. The sequential forming method according to claim 1, wherein the method is gradually deformed so as to shift to a triangular shape.   3. The sequential forming method according to claim 2, wherein after the processing region is deformed into a triangle, the processing region is gradually deformed so that a vertex thereof moves to a ridge line side along a corner portion.   When the machining area on both sides of the ridge line on the slope for machining is pushed toward the corner and gradually deformed, the machining area forms a rectangle, and the machining area is gradually deformed so that the area of the rectangle gradually decreases. The method according to claim 1, wherein corners are finally formed.   5. The sequential forming method according to claim 4, wherein a triangle having a ridge line as a base and a corner portion as a vertex is formed in the step of forming the corner portion.

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