JP2020163397A - Press molding method and metal plate - Google Patents

Abstract

To reduce costs of a facility for forming a thickened part in a metal plate.SOLUTION: A thickening scheduled part 110 including an inclined part 111 whose thickness direction is inclined with respect to a pressing direction is arranged in a metal plate 100, and the thickening scheduled part 110 is crushed in the pressing direction without increasing a dimension in a direction (a width direction) orthogonal to the pressing direction, so as to form a thickened part 101.SELECTED DRAWING: Figure 5

Description

The present invention relates to a press forming method for forming a thick portion on a metal plate, and a metal plate formed by the method.

For example, when increasing the strength of a part having a cross-section hat shape used for an automobile body, it is not preferable to increase the thickness of the entire part because it causes an increase in weight and cost. Therefore, it is performed to thicken only the bent portion (ridge line) that is functionally required to have the highest strength. As such a partially thickened metal plate, for example, a patchwork material (see Patent Document 1 below) in which a plate-shaped patchwork is attached to a metal plate and partially thickened, or a thickness. A tailored blank material (see Patent Document 2 below) in which a plurality of different metal plates are joined by welding or the like is known.

JP-A-2017-177115 Japanese Unexamined Patent Publication No. 2005-152975

However, the above-mentioned patchwork material and tailored blank material require special equipment for attaching the patchwork to the metal plate and joining metal plates of different thicknesses, so that the equipment cost is high. ..

Therefore, an object of the present invention is to reduce the cost of equipment for forming a thick portion on a metal plate.

In order to solve the above problems, the present invention provides a metal plate with a planned thickening portion including an inclined portion whose thickness direction is inclined with respect to the pressing direction, and the planned thickening portion is orthogonal to the pressing direction. Provided is a press forming method for forming a thick portion by crushing in the pressing direction without increasing the dimension in the pressing direction.

In this way, a thick portion can be formed by crushing the portion to be thickened including the inclined portion in the press direction without increasing the dimension in the direction orthogonal to the press direction (width direction). In this case, since the thick portion can be formed on the metal plate by using the press equipment usually used for forming the metal plate, a dedicated equipment such as a patchwork material or a tailored blank material becomes unnecessary.

The thick portion formed by crushing the portion to be thickened including the inclined portion as described above is formed in a relatively small region (width). If another thick portion is formed in the region adjacent to the thick portion by the same method as described above, the thick region can be expanded. Specifically, in a region adjacent to the thick portion, another planned thickening portion including an inclined portion whose thickness direction is inclined with respect to the pressing direction is formed, and the pressing direction of the other scheduled thickening portion. By crushing the other planned thickening portion in the pressing direction while restricting the dimension increase in the direction orthogonal to the thick portion, another thick portion can be formed in the vicinity of the thick portion. At this time, if the thickened portion is formed by crushing the previously formed thickened portion and at the same time another planned thickened portion is formed in the region adjacent to the thickened portion, the thickened portion can be formed. Compared with the case where the formation of the planned thickening portion is performed in a different process, the man-hours are reduced and the cost is reduced.

The planned thickening portion includes, for example, the inclined portion whose thickness direction is inclined to one side with respect to the press direction, another inclined portion whose thickness direction is inclined to the other side with respect to the press direction, and both inclined portions. It can be configured to have a top provided between the two. By crushing the planned thickening portion in the press direction, both inclined portions are crushed to form a thick wall portion, so that a wider thick wall region can be obtained with one press. At this time, the wall thickness of the top may be made larger than the wall thickness of both inclined portions in advance. In this case, by crushing the planned thickening portion, it is possible to provide thick-walled portions formed by crushing the inclined portions on both sides of the thick-walled portion caused by the originally thick-walled top.

The metal plate press-molded by the above method has a thick portion formed by the plastic flow of the material by press-molding. Since the thickness of this thick portion is not uniform, the entire surface of the thick portion is not formed by the mold, but a part of the surface of the thick portion is not in contact with the mold. Therefore, the surface of the thick portion is provided with a molded surface formed by the press molding and a non-molded surface not formed by the press molding.

As described above, if the thick portion is formed on the metal plate by the press molding method of the present invention, it is molded by using general-purpose press equipment without requiring special equipment such as patchwork material and tailored blank material. Therefore, the cost of equipment can be reduced.

(A) is a metal plate, (B) is a metal plate having a thick portion formed, and (C) is a perspective view of a metal plate formed into a hat shape. (A) and (B) are cross-sectional views showing a step of forming a thickening part (inclined part) on a metal plate. It is sectional drawing of the mold which forms a thick part. It is sectional drawing which shows the state in the process of crushing the planned thickening part with the die of FIG. It is sectional drawing which shows the state which the formation of the thick part is completed in the mold of FIG. It is sectional drawing which shows the state in the process of crushing the planned thickening part which the angle of the inclined part is excessive. FIG. 6 is a cross-sectional view and an enlarged view thereof showing a state in which a thickened portion is formed by crushing the planned thickening portion of FIG. It is sectional drawing of the mold which forms another thick-walled portion adjacent to a thick-walled portion. It is sectional drawing which shows the state which formed the other thick part by the mold of FIG. It is sectional drawing which shows another example of the mold which forms a thick part. It is sectional drawing which shows the state in the process of crushing the planned thickening part with the die of FIG. It is sectional drawing which shows the state which the formation of the thick part is completed in the mold of FIG. FIG. 5 is a cross-sectional view showing a state in which another thick portion is formed adjacent to the thick portion in the mold of FIG. It is sectional drawing which shows the state which formed the other thick part by the mold of FIG. It is sectional drawing which shows still another example of the mold which forms a thick part. It is sectional drawing which shows the state in the process of crushing the planned thickening part with the die of FIG. It is sectional drawing which shows the state which the formation of the thick part is completed in the mold of FIG. It is sectional drawing which shows still another example of the mold which forms a thick part. It is sectional drawing which shows the state which the formation of the thick part is completed in the mold of FIG. It is sectional drawing which shows still another example of the mold which forms a thick part.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

In the press molding method according to the embodiment of the present invention, a thick portion 101 is formed on a flat metal plate 100 (for example, a steel plate) shown in FIG. 1 (A) as shown in FIG. 1 (B). It has a forming step and a hat forming step of forming the metal plate 100 into a cross-sectional hat shape as shown in FIG. 1 (C). The metal plate 100 formed into a cross-sectional hat shape includes a top surface portion 102, a pair of vertical wall portions 103 extending downward from both ends in the width direction (X direction in the drawing) of the top surface portion 102, and a width direction from each vertical wall portion 103. It has a pair of flange portions 104 extending outward. In the illustrated example, the thick portion 101 is formed along the longitudinal direction (Y direction in the drawing) of the metal plate 100, and specifically, the ridgeline of the metal plate 100 formed into a cross-sectional hat shape (in the illustrated example, in the illustrated example). It is formed along a region that serves as a ridge line between the top surface portion 102 and the vertical wall portion 103). In this way, by providing the thick portion only on the ridge line, it is possible to secure the strength while suppressing the weight increase. Each of the above steps is performed in a normal temperature environment (cold press).

In the thick portion forming step, first, press molding (bending molding) is performed on the flat metal plate 100 by the dies 11 and 12 shown in FIG. 2 (A). As a result, as shown in FIG. 2B, the thickening planned portion 110 having the inclined portion 111 is formed on the metal plate 100.

Next, with the mold shown in FIG. 3, the thickened portion 110 of the metal plate 100 is crushed to form the thickened portion 101. Specifically, first, the metal plate 100 is set in the mold, and the flat portion 120 on one side (left side in the drawing) of the metal plate 100 in the width direction of the planned thickening portion 110 is the lower mold 1 and the pressing portion 3. The flat portion 130 on the other side (right side in the drawing) in the width direction of the planned thickening portion 110 is sandwiched and fixed by the upper die 2 and the pressing portion 4. In the state where the metal plate 100 is set in the mold in this way, the thickness direction of the inclined portion 111 provided in the planned thickening portion 110 is inclined with respect to the pressing direction (vertical direction in the drawing).

In this state, as shown in FIG. 4, the upper mold 2 and the pressing portion 4 are integrally lowered, and the molding surface 1a provided on the upper surface of the lower mold 1 and the molding surface 2a provided on the lower surface of the upper mold 2 Then, the thickening portion 110 is compressed in the pressing direction (vertical direction). In the illustrated example, the molding surfaces 1a and 2a are flat surfaces orthogonal to the pressing direction. At this time, since the flat portions 120 and 130 on both sides of the planned thickening portion 110 in the width direction are sandwiched and fixed, the dimension increase in the width direction of the planned thickening portion 110 is restricted. In this state, by compressing the planned thickening portion 110 in the pressing direction, the material plastically flows to increase the wall thickness of the inclined portion 111, and the angle of the inclined portion 111 rises. Further, when the thickening portion 110 is compressed in the pressing direction, as shown in FIG. 5, the inclined portion 111 is crushed by the molding surface 1a of the lower mold 1 and the molding surface 2a of the upper mold 2, and the thick portion 101 is formed. Is formed.

By the way, if the width direction dimension L or height H (see FIG. 3) of the inclined portion 111 is excessive, or the angle θ of the inclined portion 111 is excessive, the inclined portion 111 is in the middle of pressing as shown in FIG. The angle θ'is excessive, and pressing in this state causes the inclined portion 111 to bend, and as shown in FIG. 7, there is a possibility that a steep step 101a or a crack 101b may occur in the thick portion 101. Therefore, the angle θ of the inclined portion 111 before compression, the width direction dimension L and the height H of the inclined portion 111 are set so that the inclined portion 111 does not bend during pressing. These values differ depending on the material and wall thickness of the metal plate 100, but generally, the width direction dimension L and height H of the inclined portion 111 are about 5 to 20 mm, and the angle θ of the inclined portion 111 is about 30 to 60 °. Is set to.

As shown in FIG. 5, the lower surface and the upper surface of the thick portion 101 formed in this way are formed by the forming surfaces 101c formed by the forming surfaces 1a and 2a of the dies 1 and 2 and the dies 1 and 2. A non-molded surface 101d is provided. In the illustrated example, of the lower surface of the thick portion 101, a flat molding surface formed by the molding surface 1a of the lower mold 1 in a region continuous with the maximum wall thickness portion and one side (left side in the drawing) in the width direction. 101c is provided. Of the lower surface of the thick portion 101, the region on the other side in the width direction (right side in the figure) of the maximum thickness portion recedes upward from the molding surface 101c and inclines upward as it goes to the other side in the width direction. A non-molded surface 101d is provided. Further, in the upper surface of the thick portion 101, the region continuous with the maximum thick portion and the other side (right side in the drawing) in the width direction is a flat molding surface 101c formed by the molding surface 2a of the upper mold 2. Is provided. Of the upper surface of the thick portion 101, the region on the other side (right side in the figure) in the width direction from the maximum wall thickness portion recedes downward from the molding surface 101c and inclines downward toward one side in the width direction. A non-molded surface 101d is provided.

In the hat forming step, the metal plate 100 on which the thick portion 101 is formed is press-formed (for example, bent-formed) to form a hat-shaped cross section as shown in FIG. 1 (C). At this time, the metal plate 100 is formed so that the thick portion 101 is arranged on the hat-shaped ridgeline.

As described above, by crushing the inclined portion 111 of the planned thickening portion 110 to form the thick portion 101, general-purpose press equipment (press) used in the metal plate forming process without requiring dedicated equipment. The thick portion 101 can be formed by using a machine). For example, the die of the press machine used in the hat forming step can be replaced with the die shown in FIG. As a result, the cost of the equipment for forming the thick portion 101 on the metal plate 100 can be reduced.

The present invention is not limited to the above embodiments. Hereinafter, other embodiments of the present invention will be described, but the same points as those of the above-described embodiments will be omitted.

For example, after forming the thick portion 101 on the metal plate 100 by the method shown in the above embodiment, another thick portion 101 may be formed. Specifically, a substantially flat metal plate 100 (see FIG. 5) on which the thick portion 101 is formed is press-molded, and the inclined portion 111 is again formed on the other side (right side in the drawing) of the thick portion 101 in the width direction. The planned thickening portion 110 including the thickening portion 110 is formed (see FIG. 8). The thickening portion 110 of the metal plate 100 is crushed by the dies 1 and 2 in the same manner as in the above embodiment. Specifically, the thick portion 101 on one side (left side in the drawing) of the planned thickening portion 110 in the width direction is sandwiched and fixed between the lower mold 1 and the pressing portion 3, and the other side in the width direction of the planned thickening portion 110. The flat portion 130 provided (on the right side in the drawing) is sandwiched and fixed between the upper mold 2 and the pressing portion 4. In this state, as shown in FIG. 9, the upper die 2 and the pressing portion 4 are integrally lowered, and the planned thickening portion 110 is crushed to form a new thick portion 101. The width direction dimension of each thick portion 101 is about 2 to 3 times the wall thickness of the metal plate 100, but by providing a plurality of thick wall portions 101 adjacent to each other in the width direction as described above, the thick wall portion 101 is thickened. The area can be expanded.

Further, a plurality of thick portions 101 may be continuously formed by using the mold shown in FIG. In this embodiment, the inclined surface 2b is provided in a region of the upper mold 2 adjacent to the other side (right side in the drawing) of the molding surface 2a in the width direction. The molding surface 2a is provided with a flat surface 2a1 orthogonal to the pressing direction and a curved surface portion 2a2 in which the flat surface 2a1 and the inclined surface 2b are smoothly continuous. First, of the metal plate 100, the flat portion 120 provided on one side (left side in the drawing) of the planned thickening portion 110 in the width direction is sandwiched and fixed between the lower mold 1 and the pressing portion 3, and of the inclined portions 111. The region on the other side in the width direction from the planned thickening portion 110 is sandwiched and fixed between the inclined surface 2b of the upper die 2 and the pressing portion 4. In this state, by lowering the upper mold 2 and the pressing portion 4 integrally, as shown in FIG. 11, the metal plate 100 is formed by the molding surface 1a of the lower mold 1 and the flat surface 2a1 of the molding surface 2a of the upper mold 2. The planned thickening portion 110 (a part of the inclined portion 111) is compressed in the pressing direction. At the same time, a new bent portion 112 is formed on the inclined portion 111 on the curved surface portion 2a2 of the molding surface 2a of the upper mold 2. After that, by further lowering the upper mold 2, as shown in FIG. 12, a thick-walled portion 101 is formed on the metal plate 100, and a new thick-walled portion (thickening portion 101) is formed on the other side in the width direction of the thick portion 101. A bent portion 112 and an inclined portion 111) are provided.

After forming the thick portion 101 as described above, the mold is opened and the metal plate 100 is moved to one side (left side in the figure) in the width direction as shown in FIG. After that, the thick portion 101 of the metal plate 100 is sandwiched and fixed by the lower mold 1 and the pressing portion 3, and the inclined portion 111 is sandwiched and fixed by the upper mold 2 and the pressing portion 4. Then, by lowering the upper die 2 and the pressing portion 4, as shown in FIG. 14, the upper die 2 and the lower die 1 crush the planned thickening portion 110 (a part of the inclined portion 111) to make the thick wall thicker. Along with forming the portion 101, a new thickening planned portion 110 (bending portion 112 and inclined portion 111) is formed on the other side in the width direction. As described above, by forming the thick portion 101 and at the same time forming a new thickening portion 110 in the region adjacent to the thick portion 101, a plurality of thick portions 101 can be continuously formed without requiring a separate mold. Can be formed into.

In the embodiment shown in FIG. 15, the planned thickening portion 110 of the metal plate 100 is composed of a convex curved portion 140 protruding in the pressing direction (upper part in the drawing). The convex curved portion 140 has a top portion 141 and a pair of inclined portions 142 provided on both sides in the width direction of the top portion 141, and the thickness direction of each inclined portion 142 is relative to the press direction (vertical direction in the drawing). They are inclined to the opposite side. Of the metal plate 100, the flat portions 120 and 130 provided on both sides of the convex curved portion 140 in the width direction are sandwiched and fixed by the lower mold 1 and the pressing portions 3 and 4. In this state, by lowering the upper mold 2, as shown in FIG. 16, the convex curved portion 140 is compressed in the pressing direction by the molding surface 1a of the lower mold 1 and the molding surface 2a of the upper mold 2, and a pair. The inclined portion 142 stands up while being thickened. By further lowering the upper mold 2, as shown in FIG. 17, the inclined portion 142 of the convex curved portion 140 is crushed to form the thick portion 101. By crushing the convex curved portion 140 having the pair of inclined portions 142 to form the thick portion 101 in this way, the thick portion 101 can be formed in a wider area by one press molding. ..

In the embodiment shown in FIG. 18, the planned thickening portion 110 of the metal plate 100 is curved in a waveform composed of a plurality of (three in the illustrated example) tops 141 and inclined portions 142 provided on both sides of each top 141. It is composed of parts. By compressing and crushing the planned thickening portion 110 with the lower mold 1 and the upper mold 2 in the pressing direction, the thick portion 101 is formed in a wider area as shown in FIG.

In the embodiment shown in FIG. 20, a metal plate 100 (for example, the metal plate 100 of FIG. 18) on which the thick portion 101 (indicated by scattered points) is formed in advance is press-molded, and the thick portion 101 is formed on the top 141. A planned thickening portion 110 is formed of the curved portions of the arranged waveforms (see FIG. 20 (A)). By compressing and crushing the planned thickening portion 110 of the metal plate 100 in the pressing direction with the lower mold 1 and the upper mold 2, a thicker portion is further formed in a region adjacent to the previously formed thick portion 101. 101 can be formed (see FIG. 20B).

In the above embodiment, the case where the thick portion 101 is formed on the metal plate 100 has been shown, but the metal plate 100 is plastically deformed by pressing the metal plate 100 in the thickness direction with a mold for forming the thick portion 101. , The thin portion may be formed at the same time. As a result, the metal plate 100 can be formed so as to have an appropriate wall thickness for each place.

The cross-section hat-shaped parts formed by the above press molding method can be applied to various frame parts such as skeleton parts (front side members and the like) of a vehicle body. The press molding method shown above is applicable not only when molding a part having a hat-shaped cross section but also when forming a partially thick portion on a metal plate and molding this metal plate into a predetermined shape. can do.

1 Lower mold 2 Upper mold 3 Pressing part 4 Pressing part 100 Metal plate 101 Thick part 101c Molded surface 101d Non-molded surface 110 Planned thickening part 111 Inclined part 140 Convex curved part 141 Top part 142 Inclined part

Claims (2)

The metal plate is provided with a planned thickening portion including an inclined portion whose thickness direction is inclined with respect to the pressing direction.
A press molding method for forming a thick portion by crushing the thickened portion in the pressing direction without increasing the dimension in the direction orthogonal to the pressing direction. A metal plate having a thick portion formed by the plastic flow of a material by press molding.
A metal plate provided with a molded surface formed by the press molding and a non-molded surface not formed by the press molding on the surface of the thick portion.

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