JP2023046870A - Molded article, blank, manufacturing method of molded article, and metal mold - Google Patents

Abstract

To provide a molded article suppressed in break and wrinkle, to provide a blank for obtaining the molded article, to provide a manufacturing method of a molded article, and to provide a metal mold.SOLUTION: A molded article includes a first region part, a second region part and a third region part. A first ridge line, a second ridge line and a third ridge line are connected each other in corner parts. When a full length of a contour line formed by the first region part and the third region part is L1 (mm), and a full length of a contour line formed by the second region part and the third region part is L2 (mm), the following (formula 1) is satisfied. When a full length of an adjacent part along the extension direction of the third ridge line between the second region part and the third region part is L3 (mm), and a length of a non-contact part, obtained by subtracting the length of the third ridge line from the full length L3 is L4 (mm), the following (formula 2) is satisfied. L1>1.1×L2...(formula 1); 0.8×L3<L4<0.9×L3...(formula 2).SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a molded article obtained by molding a metal plate, a blank for obtaining the molded article, a method for manufacturing the molded article, and a mold used for the molding.

For example, in order to manufacture automobile parts, household appliance parts, and the like, it is widely practiced to press a metal plate to obtain a molded body. These molded bodies often have complex shapes even though they are integral bodies. For example, a dash panel of an automobile is roughly composed of three areas, namely, a first area, a second area, and a third area. Here, the first area portion has a substantially rectangular flat plate shape. The second region is integrally connected to one side edge of the first region and is inclined with respect to the first region when viewed from the side. The third region portion is integrally connected to the other side edge of the first region portion and is inclined in the same direction as the second region portion in a side view. The inclination directions of the second region portion and the third region portion are the same. In addition, the third area portion is formed with a wheel house that serves as a recess for accommodating a portion of the tire of the automobile.

When manufacturing such a compact, first, a member having the first region portion and the second region portion and a member having the third region portion are prepared in advance, and then spot welding is performed between these members. It is conceivable to join by such as. However, from the viewpoint of weight reduction and cost reduction, it is preferable to integrally form the first region to the third region by press-molding a metal plate.

However, when a compact having such a complicated shape is obtained by press molding, a local compressive stress acts on the third region, and as a result, wrinkles may occur. In order to suppress such quality defects, drawing may be performed while applying tension to the third region.
However, when using a metal plate with low formability such as a high-strength steel plate, the steel plate may crack due to the tension applied during drawing depending on the shape of the second region and the third region. Therefore, as disclosed in Patent Document 1, for example, techniques for efficiently forming while suppressing the occurrence of cracks are being studied even under forming conditions that make it difficult to apply draw forming.

JP 2015-110237 A

However, in the case of the dash panel, when forming a large wheelhouse from a high-tensile steel plate having a tensile strength of 980 MPa or more, the degree of difficulty in forming is significantly increased. In this case, even with the technique disclosed in Patent Document 1, it is not easy to stably obtain a compact without cracks or wrinkles.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a molded article in which cracks and wrinkles are suppressed. Another object of the present invention is to provide a blank, a method for manufacturing a molded body, and a mold for obtaining the molded body.

The present invention has been made in view of the above circumstances, and employs the following aspects.
(1) A molded article according to one aspect of the present invention is
a first area portion having a first ridgeline and a second ridgeline that are arranged with a corner interposed therebetween;
a second region portion integrally connected to the first region portion via the first ridge line and inclined to one side of front and back surfaces of the first region portion;
integrally connected to the first region via the second edge line, partially and integrally connected to the second region via a third edge line connecting to the corner, and connected to the first region a third area inclined to the one side;
with
the first edge line, the second edge line, and the third edge line are connected to each other at the corners;
Let L1 (mm) be the total length of the contour line formed by the first region portion and the third region portion, and L2 (mm) be the total length of the contour line formed by the second region portion and the third region portion. As, the following (Equation 1) is satisfied,
Let L3 (mm) be the total length of the adjacent portion between the second region portion and the third region portion along the extension direction of the third ridgeline, and the total length L3 minus the length of the third ridgeline is non-bonded Assuming that the length of the portion is L4 (mm), the following (Equation 2) is satisfied.
L1>1.1×L2 (Formula 1)
0.8×L3<L4<0.9×L3 (Formula 2)

Here, it is assumed that the first region portion is planar and positioned on the plane formed by the mutually orthogonal X-axis and Y-axis. It is assumed that the X-axis direction is the direction in which the first region portions and the second region portions are arranged, and the Y-axis direction is the direction in which the first region portions and the third region portions are arranged. In this case, the first region portion and the second region portion are aligned with the first edge in the X-axis direction, the first region portion and the third region portion are aligned with the second edge in the Y-axis direction, and the The second area portion and the third area portion are arranged with the third edge line and the non-bonded portion sandwiched in the Y-axis direction. In addition, in the first area portion, the first edge line is the edge in the X-axis direction, and the second edge line is the edge in the Y-axis direction.
In this case, the contour line formed by the first region portion and the third region portion (hereinafter referred to as the first contour line) is the X Fig. 3 is a contour line formed by an edge located on a first axial side; The outline formed by the second area and the third area (hereinafter referred to as the second outline) is the second edge in the X-axis direction of the two edges in the X-axis direction of the second area and the third area. 2 is an outline formed by edges located on two sides; Here, the first side in the X-axis direction is the side where the first region portion is located with respect to the second region portion, and the second side in the X-axis direction is the side where the second region portion is located with respect to the first region portion. is the side on which is located. The first ridgeline is located on the second side with respect to the first region portion and is located on the first side with respect to the second region portion. Both the first outline and the second outline extend in the Y-axis direction. The total length L1 of the first outline is the length of the first outline in the Y-axis direction. The total length L1 is the sum of the Y-axis length of the first side edge of the first region and the Y-axis length of the first side edge of the third region. The total length L2 of the second outline is the length of the second outline in the Y-axis direction. The total length L2 is the sum of the Y-axis length of the second side edge of the second region and the Y-axis length of the second side edge of the third region. The second outline does not include the above-described non-joint portion, and when the non-joint portion increases in the Y-axis direction, the total length L2 of the second outline is shortened.
According to the molded article described in (1) above, the second region portion and the third region portion are integrally connected to the first region portion, and the second region portion and the third region portion are connected to the first region portion. both slope in the same direction. Here, a non-bonded portion that satisfies Equations 1 and 2 is provided. When formula 1 is satisfied, the total length L2 of the second contour line is appropriately shorter than the total length L1 of the first contour line, so it is assumed that the size of the non-bonded portion in the Y-axis direction is appropriately secured. I can say When formula 2 is satisfied, it is assumed that the aforementioned non-joint portion is not excessively small or excessively large with respect to the third edge line, and that the size of the non-joint portion in the Y-axis direction is appropriately secured. I can say Therefore, when this molded body is obtained by press molding from a flat plate-shaped blank, wrinkles occur when the second region and the third region are all connected along the extending direction of the third ridgeline. can be suppressed. In addition, during press molding, at the position of the third ridgeline, a force acts in the direction of compression in which the second region portion and the third region portion approach each other. does not occur. Therefore, no wrinkles or cracks are generated between the second region and the third region of this compact.

(2) In the aspect of (1) above, the compact may be made of a steel plate having a tensile strength of 980 MPa or more.
In the case of (2) above, even in a molded body manufactured using a high-strength steel sheet with low formability as a blank, a force in the compression direction acts on the third ridge line during press molding, so cracks occur. and its soundness is ensured.

(3) In the aspect described in (1) or (2) above, the molded body may have a plate thickness of 0.8 mm or more and 2.3 mm or less.
In the case of (3) above, the molded article can be widely used as an automobile part such as a dash panel.

(4) In the aspect described in any one of (1) to (3) above, the molded article may have the following configuration:
further comprising a fourth region portion located on the opposite side of the first region portion with the third region portion interposed therebetween and integrally connected to the third region portion via a fourth ridgeline;
The fourth area portion includes an inclined portion that inclines in the same direction as the second area portion toward the alignment direction from the first area portion to the second area portion.
In the case of (4) above, in the blank in which the first region portion and the second region portion are formed, the fourth region portion is arranged relative to the first region portion in the same direction as the inclination direction of the second region portion. The third region is formed by utilizing the fact that the portion of the blank located between the first region and the fourth region inevitably inclines to the one side by moving the blank inevitably. be able to. Here, since the fourth region portion includes the inclined portion, for example, by forming the inclined portion in the fourth region portion when the fourth region portion is moved relative to the first region portion, Material flow within the third region during formation of the third region can be directed toward the second region. Therefore, the obtained molded body is molded while the force in the compression direction is applied to the third ridge line, so cracks are suppressed more reliably.

(5) A blank according to one aspect of the present invention may employ the following configuration:
A flat plate-shaped blank to be molded into a molded body according to any one of (1) to (4) above, which has a notch corresponding to the non-bonded portion.
When the blank of (5) is press-molded to produce the molded body of (1), there is a notch at a position corresponding to the non-joined portion, so wrinkles that occur when there is no notch can be suppressed. . In addition, since the force in the direction of compression acts on the position of the blank connected to the notch and forming the third ridge line, cracks do not occur. Therefore, when this blank is used to produce the compact according to any one of (1) to (4) above, wrinkles and cracks do not occur between the second region and the third region.

(6) In the aspect described in (5) above, the following formula 3 may be satisfied, where W1 (mm) is the interval dimension at the end of the notch.
W1>L1-L2 (Formula 3)
In the case of (6) above, since the notch satisfies Equation 3, it is possible to reliably avoid large interference between the portion of the blank corresponding to the second region and the portion corresponding to the third region. , it becomes possible to more reliably suppress wrinkles and cracks.

(7) A molded article manufacturing method according to an aspect of the present invention is a method for manufacturing the molded article according to (4) above,
a first region corresponding portion corresponding to the first region portion; a second region corresponding portion corresponding to the second region portion; a third region corresponding portion corresponding to the third region portion; A preparation step of preparing a blank having a fourth region corresponding portion corresponding to and a notch corresponding to the non-bonded portion;
a second region forming step of tilting the second region corresponding portion toward the one side with respect to the first region corresponding portion;
By moving the fourth region corresponding portion relative to the first region corresponding portion toward the one side while fixing the inclination of the second region corresponding portion with respect to the first region corresponding portion, a third region portion forming step of inclining the three region corresponding portion toward the one side with respect to the first region corresponding portion;
have

According to the molded body manufacturing method described in (7) above, first, a blank having a notch is prepared in the preparation step. In the subsequent step of forming the second region, the blank is formed with the second region. In the subsequent step of forming the third region, the blank is formed with the third region. At this time, since the blank has a notch at a position corresponding to the non-bonded portion, it is possible to suppress the occurrence of wrinkles that would otherwise occur when there is no notch. In addition, since the force in the direction of compression acts on the position of the blank connected to the notch and forming the third ridge line, cracks do not occur. Therefore, according to this molding manufacturing method, wrinkles and cracks do not occur between the second region portion and the third region portion.

(8) In the aspect described in (7) above, the preparation step may include a notch forming step of forming the notch in the blank.
In the case of (8) above, by forming the notch in advance in the preparation step, the transition from the second region portion forming step to the third region portion forming step can be performed smoothly without interruption.

(9) A method for producing a molded article according to another aspect of the present invention is a method for producing the molded article according to (4) above,
a first region corresponding portion corresponding to the first region portion; a second region corresponding portion corresponding to the second region portion; a third region corresponding portion corresponding to the third region portion; A preparation step of preparing a blank comprising a fourth region corresponding part corresponding to
a second region forming step of inclining the second region corresponding portion toward one of the front and back surfaces of the first region corresponding portion;
a notch forming step of forming a notch corresponding to the non-bonded portion between the second region corresponding portion and the third region corresponding portion;
By moving the fourth region corresponding portion relative to the first region corresponding portion toward the one side while fixing the inclination of the second region corresponding portion with respect to the first region corresponding portion, a third region portion forming step of inclining the three region corresponding portion toward the one side with respect to the first region corresponding portion;
have

According to the molded body manufacturing method described in (9) above, first, a blank is prepared in the preparation step. In the subsequent step of forming the second region, the blank is formed with the second region. In the subsequent notch forming step, notches are formed in the blank. In the subsequent step of forming the third region, the blank is formed with the third region. At this time, since the blank has a notch at a position corresponding to the non-bonded portion, it is possible to suppress the occurrence of wrinkles that would otherwise occur when there is no notch. In addition, since the force in the direction of compression acts on the position of the blank connected to the notch and forming the third ridge line, cracks do not occur. Therefore, according to this molding manufacturing method, wrinkles and cracks do not occur between the second region portion and the third region portion.
The cutout may be formed in the preparation step as in (8) above, or may be formed in the cutout formation step between the second region portion formation step and the third region portion formation step as in (9) above. You may

(10) In the aspect described in any one of (7) to (9) above,
In the third region forming step, the material flow from the third region corresponding portion toward the notch may be formed by relatively moving the fourth region corresponding portion while constrained by the material flow control means. good.
In the case of (10) above, by restraining the fourth region corresponding portion by the material flow control means, it is possible to form a material flow that directs the third region corresponding portion toward the second region portion. As a result, the force in the compression direction can be applied more reliably to the portion of the blank that becomes the third ridge line connected to the notch. Therefore, cracks can be suppressed more reliably.

(11) A mold according to one aspect of the present invention is
a first region corresponding portion corresponding to the first region portion; a second region corresponding portion corresponding to the second region portion; a third region corresponding portion corresponding to the third region portion; A mold for manufacturing the molded article according to (4) above from a blank comprising a fourth area corresponding part corresponding to
A first mold and a second mold facing each other are provided,
The first mold is
a first region holder surface on which the first region corresponding portion is arranged; and a second region holder surface that is connected to the first region holder surface and inclined with respect to the first region holder surface to form the second region portion. , a third region holder surface connected to the first region holder surface and inclined with respect to the first region holder surface to form the third region portion;
a first pad disposed adjacent to the holder and having a fourth region pad surface on which the fourth region corresponding portion is placed;
The second mold is
a second pad having a first area pad surface facing the first area holder surface and a second area pad surface facing the second area holder surface;
a die having a fourth area die surface disposed adjacent to the second pad and facing the fourth area pad surface;
Prepare.

According to the mold described in (11) above, a compact can be produced by the following production method, for example.
First, the blank is placed in the first mold (holder and first pad). At this time, the first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface, Position the blank.
Subsequently, the blank is sandwiched between the holder and the second pad by pressing the second pad against the holder. Thereby, a first region portion and a second region portion are formed in the blank.
If notches are formed in the blank in advance, the molding of the third region and the fourth region is started without opening the mold. On the other hand, when the blank is not formed with the notch before forming the third region and the fourth region, the mold is once opened, the blank is taken out during molding, and the notch is formed. Subsequently, the blank with the notch formed is placed again and the mold is closed.
After that, the second mold is pressed against the first mold. As a result, the first region corresponding portion is sandwiched between the first region holder surface and the first region pad surface, the second region corresponding portion is sandwiched between the second region holder surface and the second region pad surface, and the second region corresponding portion is sandwiched between the second region holder surface and the second region pad surface. The four-region corresponding portion is sandwiched between the fourth region pad surface and the fourth region die surface. In this state, the combination of the first pad and the die is relatively moved to the one side with respect to the combination of the holder and the second pad. Thereby, the third region portion and the fourth region portion are formed. At this time, since the blank has a notch at a position corresponding to the non-bonded portion, it is possible to suppress the occurrence of wrinkles that would otherwise occur when there is no notch. In addition, since the force in the direction of compression acts on the position of the blank connected to the notch and forming the third ridge line, cracks do not occur.

(12) In the aspect described in (11) above, the second pad may include a leading pad having the first region pad surface and a trailing pad having the second region pad surface.

According to the mold described in (12) above, it is possible to produce a molded article in which cracks and wrinkles are suppressed as in the case of the mold described in (11) above.
Furthermore, according to this mold, when the second pad is pressed against the holder in the step of forming the second region portion, first, the preceding pad is pressed against the holder, so that the portion corresponding to the first region is pressed against the holder in the first region. sandwiched between the surface and the first area pad surface; This secures the blank to the holder. Subsequently, by pressing the trailing pad against the holder, the portion corresponding to the second region is inclined with respect to the portion corresponding to the first region. Thereby, a first region portion and a second region portion are formed in the blank.

(13) In the aspect described in (11) or (12) above, the holder includes a blank holder having the first area holder surface and a punch arranged adjacent to the blank holder and having the third area holder surface. , may be provided.

According to the mold described in (13) above, it is possible to produce a molded article in which cracks and wrinkles are suppressed in the same manner as the mold described in (11) above.
Furthermore, according to this mold, when forming the third region portion and the fourth region portion, the combination of the first pad and the die is relatively moved to the one side with respect to the combination of the blank holder and the second pad. . Also, the punch is relatively moved in the direction opposite to the one side with respect to the combination of the blank holder and the second pad. As a result, the punch is pressed against the third region corresponding portion of the blank to form the third region portion and the fourth region portion.

(14) A molded article manufacturing method according to still another aspect of the present invention includes:
A method for producing the molded article using the mold according to (11) above,
The first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface. a placement step of placing the blank in the first mold;
a second region forming step of pressing the second pad against the holder to form the second region;
The second mold is pressed against the first mold in a state in which notches corresponding to the non-bonded portions are formed in the blank, and the first region corresponding portions are formed on the first region holder surface and the first region holder surface. sandwiched between the first area pad surfaces, sandwiching the second area corresponding portion between the second area holder surface and the second area pad surface, and sandwiching the fourth area corresponding portion between the fourth area pad surface; and the fourth area die surface, the first pad and the die are relatively moved toward the one side with respect to the holder and the second pad to move the third die. a third region portion forming step of forming a region portion;
have

According to the method for manufacturing a molded body of (14) above, the same effect as that of (11) above can be obtained. Therefore, it is possible to produce a molded article in which cracks and wrinkles are suppressed.

(15) A molded product manufacturing method according to still another aspect of the present invention includes:
A method for producing the molded article using the mold according to (12) above,
The first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface. a placement step of placing the blank in the first mold;
a second region forming step of pressing the second pad against the holder to form the second region;
The second mold is pressed against the first mold in a state in which notches corresponding to the non-bonded portions are formed in the blank, and the first region corresponding portions are formed on the first region holder surface and the first region holder surface. sandwiched between the first area pad surfaces, sandwiching the second area corresponding portion between the second area holder surface and the second area pad surface, and sandwiching the fourth area corresponding portion between the fourth area pad surface; and the fourth area die surface, the first pad and the die are relatively moved toward the one side with respect to the holder and the second pad to move the third die. a third region portion forming step of forming a region portion;
has
In the second area portion forming step, the preceding pad is pressed against the holder, and the first area corresponding portion is sandwiched between the first area holder surface and the first area pad surface, and then the following area is formed. A pad is pressed against the holder to form the second region.

According to the method for manufacturing a molded body of (15) above, the same effect as that of (12) above can be obtained. Therefore, it is possible to produce a molded article in which cracks and wrinkles are suppressed.

(16) A molded article manufacturing method according to still another aspect of the present invention includes:
A method for producing the molded article using the mold according to (13) above,
The first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface. a placement step of placing the blank in the first mold;
a second region forming step of pressing the second pad against the holder to form the second region;
The second mold is pressed against the first mold in a state in which notches corresponding to the non-bonded portions are formed in the blank, and the first region corresponding portions are formed on the first region holder surface and the first region holder surface. sandwiched between the first area pad surfaces, sandwiching the second area corresponding portion between the second area holder surface and the second area pad surface, and sandwiching the fourth area corresponding portion between the fourth area pad surface; and the fourth area die surface, the first pad and the die are relatively moved toward the one side with respect to the holder and the second pad to move the third die. a third region portion forming step of forming a region portion;
has
In the third region forming step, the first pad and the die are placed on the blank holder and the second pad while the punch is positioned on the one side of the blank holder. While relatively moving toward one side, the punch is relatively moved in a direction opposite to the one side with respect to the blank holder and the second pad to form the third region. .

According to the molded body manufacturing method of (16) above, the same effect as that of (13) above can be obtained. Therefore, it is possible to produce a molded article in which cracks and wrinkles are suppressed.

According to each aspect described above, it is possible to provide a compact in which cracks and wrinkles are suppressed. Further, according to each aspect described above, it is possible to provide a blank, a method for manufacturing a molded body, and a mold for obtaining the molded body.

1 is a perspective view illustrating a schematic configuration of a dash panel, which is a molded body according to a first embodiment of the present invention; FIG. It is a flowchart explaining the molded object manufacturing method of the same embodiment. It is a perspective view of a blank used in the same molding manufacturing method. It is a perspective view of the intermediate molded product obtained by the same molding manufacturing method. It is a perspective view of the molded object obtained by the molded object manufacturing method. FIG. 3B is a plan view for explaining the first to fourth region corresponding portions in the notched blank shown in FIG. 3A; It is a perspective view which shows the structure of the metal mold|die used by the same molded object manufacturing method. It is a perspective view for demonstrating the arrangement|positioning process in the molded object manufacturing method using the same metal mold|die. FIG. 10 is a perspective view for explaining a second region portion forming step in a method for manufacturing a molded body using the same mold; FIG. 10 is a perspective view for explaining a step of forming a third region in a method of manufacturing a molded body using the same mold; FIG. 11 is a partially enlarged perspective view for explaining details of a third region portion forming step in a molded body manufacturing method using the same mold; It is the elements on larger scale explaining the detail of the 3rd area|region part formation process in the molded object manufacturing method using the same metal mold|die, Comprising: (a) is a longitudinal cross-sectional view, (b) is a perspective view. FIG. 10B is a partial enlarged view illustrating the continuation of FIG. 10A, where (a) is a longitudinal sectional view and (b) is a perspective view; FIG. 10B is a partial enlarged view continued from FIG. 10B, where (a) is a longitudinal sectional view and (b) is a perspective view; FIG. 10C is a partial enlarged view continued from FIG. 10C, where (a) is a vertical cross-sectional view and (b) is a perspective view. It is a flow chart explaining a setting procedure of material flow control conditions concerning the embodiment. It is a figure explaining the setting procedure of the material flow control conditions which concern on the same embodiment, and is a flowchart which shows the procedure which determines the structure of a blank with a notch, after setting the structure of a draw bead previously. FIG. 4 is a diagram illustrating a procedure for setting material flow control conditions according to the first embodiment of the present invention, and is a flowchart showing an example of a procedure for setting the configuration of a notched blank in advance and determining the configuration of a draw bead. 6 is a flow chart illustrating a method for manufacturing a molded body according to a second embodiment of the present invention; FIG. 11 is a perspective view for explaining a method for manufacturing a molded body using a mold according to a third embodiment of the present invention; FIG. 11 is a perspective view for explaining a step of forming a first region portion in a method for manufacturing a molded body using a mold according to the third embodiment; FIG. 10 is a perspective view for explaining a second region portion forming step in a method for manufacturing a molded body using the same mold; FIG. 10 is a perspective view for explaining a step of forming a third region in a method of manufacturing a molded body using the same mold; FIG. 10 is a perspective view for explaining a fourth region portion forming step in a method for manufacturing a molded body using the same mold; FIG. 11 is a perspective view for explaining a method for manufacturing a molded body using a mold according to a fourth embodiment of the present invention; FIG. 18 is a cross-sectional view for explaining a step of forming a first region portion in the method of manufacturing a molded body using the mold shown in FIG. 17; 18 is a cross-sectional view for explaining the first half of the step of forming a third region portion in the method of manufacturing a molded body using the mold shown in FIG. 17; FIG. FIG. 18 is a cross-sectional view for explaining the second half of the step of forming the third region in the method of manufacturing a molded body using the mold shown in FIG. 17;

Hereinafter, each embodiment of a molded body obtained by molding a metal plate, a molded body manufacturing method for obtaining this molded body, and a mold used for this molding will be described based on the drawings. In each embodiment, a case in which a dash panel, which is an example of a compact, is manufactured from a high-strength steel plate, which is an example of a metal plate, will be described. However, the present invention may be applied not only to high-strength steel plates but also to other metal plates. Further, the molded article to be manufactured by the present invention is not limited to the dash panel, and may be other structural parts. Furthermore, the molded article obtained by applying the present invention may be used as a final product as it is, or may be an intermediate product to which post-processing such as trimming is applied.

<First embodiment>
[Molded body]
A first embodiment of the present invention will be described below with reference to FIGS. 1 to 13. First, a compact will be described with reference to FIG.
FIG. 1 is a perspective view illustrating a schematic configuration of a dash panel 100, which is a molded product to be manufactured in this embodiment. This dash panel 100 is an automobile part.
In the following description, for example, as shown in FIG. may explain. For example, the press molding direction of the dash panel 100 is the Z-axis direction (third direction).
Also, when describing a plane defined by the X-axis and the Z-axis as the first plane, a plane defined by the X-axis and the Y-axis as the second plane, and a plane defined by the Y-axis and the Z-axis as the third plane. There is

The dash panel 100 is obtained by punching a high-tensile steel plate (metal plate) having a plate thickness t of 1.2 mm and a tensile strength of 980 MPa to obtain a notched blank B100 (described later), and then the notched blank B100. It is obtained by cold press molding (pad drawing molding).
The plate thickness t can be appropriately selected from the range of 0.8 mm to 2.3 mm. The plate thickness t referred to here is the thickness at the time of the notched blank B100, but since it basically does not change significantly after being processed into the dash panel 100, the thickness of the dash panel 100 is also 0.8 mm to 2 mm. 0.3 mm. As the plate thickness t, for example, an average value of plate thicknesses measured at three points in the X-axis direction at the center position in the Y-axis direction of the main wall portion 10 described later can be used.
Moreover, the tensile strength of the notched blank B100 shown in FIG. 3A may be greater than 980 MPa, or conversely less than 980 MPa. As the tensile strength of the notched blank B100 increases, the formability decreases, so the effect of suppressing wrinkles and cracks can be maximized when the present invention is applied to a high-tensile steel plate having a tensile strength of 980 MPa or more. As the tensile strength, for example, a test piece cut from the center position in both the X-axis direction and the Y-axis direction of the main wall portion 10 described later, and the tensile strength measured with the test piece can be adopted. Here, generally the tensile strength of a steel plate has anisotropy. Therefore, when cutting out the above-mentioned test piece, cut out a plurality of test pieces, measure the tensile strength in each different direction in each test piece, and select the highest value among the measurement results for the notched blank B100. It can also be employed as tensile strength.

As shown in FIG. 1 , the dash panel 100 includes a main wall portion (first area portion) 10 and an inclined wall portion (second 2 area portion) 20, and a pair of first side wall portions disposed on both sides of the main wall portion 10 in the Y-axis direction and connected to the main wall portion 10 via a second connection portion (second ridge line) 12. (third region portion) 30 and a second side wall portion (fourth region portion) connected via a fourth connection portion 14 to the side opposite to the main wall portion 10 with the first side wall portion 30 interposed therebetween. ) 40 and The dash panel 100 is symmetrical in the Y-axis direction.
The inclined wall portion 20 and the first side wall portion 30 are connected via a third connecting portion (third ridge line) 13, and a notch 50 is formed in the extending direction of the third connecting portion 13. It is Therefore, the inclined wall portion 20 and the first side wall portion 30 are partially connected.

The first connecting portion 11 is a fold that connects the main wall portion 10 and the inclined wall portion 20, and is formed substantially linearly along the Y-axis direction. When the first connecting portion 11 is viewed in a longitudinal section perpendicular to the Y-axis direction, it has an obtuse inverted V shape with a curved apex.
The second connecting portion 12 is a crease that connects the main wall portion 10 and the first side wall portions 30, and is formed in a curved shape in plan view. When the second connecting portion 12 is viewed in a longitudinal section perpendicular to the X-axis direction, it has an obtuse inverted V shape with a curved apex. The second connecting portion 12 extends in a direction inclined in both the X-axis direction and the Y-axis direction in plan view.
The fourth connecting portion 14 is a fold connecting the first side wall portion 30 and the second side wall portion 40, and is formed linearly in a plan view. When viewed in a longitudinal section perpendicular to the X-axis direction, the fourth connection portion 14 has an obtuse V shape with a curved bottom.
The third connecting portion 13 is a fold that connects the inclined wall portion 20 and the first side wall portion 30, and is formed linearly in a plan view. When viewed in a longitudinal section perpendicular to the X-axis direction, the third connecting portion 13 has an obtuse inverted V shape with a curved top portion.

The main wall portion 10 is formed in a planar shape extending along a plane direction orthogonal to the Z-axis direction, that is, along a second plane defined by the X-axis and the Y-axis. When viewed from above, the main wall portion 10 is formed in a substantially trapezoidal shape whose width dimension (dimension in the Y-axis direction) gradually decreases as it approaches the first connection portion 11 along the X-axis direction.

The inclined wall portion 20 is integrally connected to the main wall portion 10 via the first connecting portion 11 at its edge in the X-axis direction. The inclined wall portion 20 is inclined in the Z-axis direction with respect to the main wall portion 10 . In FIG. 1, of the front and back surfaces of the main wall portion 10, when the surface visible in FIG. is slanted.
The inclined wall portion 20 is formed in a substantially trapezoidal planar shape in which the width dimension gradually increases as the distance from the first connection portion 11 increases in plan view.

The first side wall portion 30 is integrally connected to the main wall portion 10 via the second connection portion 12 at the edge in the Y-axis direction. The first side wall portion 30 is inclined toward the one side with respect to the main wall portion 10 . That is, the first side wall portion 30 is inclined toward the one side in the same direction as the inclined wall portion 20 . Therefore, since the inclined wall portion 20 and the pair of first side wall portions 30 are inclined in the same direction, an inner space 100P that is a recess defined by these three wall portions is formed.

A concave curved wall portion 30A and a convex curved wall portion 30B are formed in the first side wall portion 30 . A ridge line 15 is formed between the concave curved wall portion 30A and the convex curved wall portion 30B.
The concave curved wall portion 30A is a wall portion that bulges toward the inner space 100P, and has a concave curved surface on the near side of the paper surface in FIG. The concave wall portion 30</b>A is a wall portion partitioned by the second connection portion 12 , the ridgeline 15 , the fourth connection portion 14 , the third connection portion 13 , and the notch 50 . The recessed curved surface wall portion 30A is partly thickened when the notched blank B100 (described later), which is the material of the dash panel 100, is press-molded, so that the wall portion 30A is thicker than the notched blank B100. A thick portion is formed. Therefore, the concave wall portion 30A is thicker than the main wall portion 10 that is not plastically worked.
The recess formed in the concavely curved wall portion 30A serves as a wheelhouse in which a portion of the tire is accommodated when the dash panel 100 is assembled to an automobile. That is, in this dash panel 100 , a pair of wheel houses are integrally formed on both sides of the main wall portion 10 .

The convex curved wall portion 30B is a wall portion that bulges toward the opposite side of the concave curved wall portion 30A. The convex wall portion 30B is a wall portion partitioned by the ridgeline 15 and the fourth connection portion 14 . The convex curved wall portion 30B is formed integrally with the concave curved wall portion 30A via the ridgeline 15 . Also, the convex wall portion 30B is formed integrally with the second side wall portion 40 via the fourth connection portion 14 .

The second side wall portion 40 has a side flat portion 40A and a side inclined portion 40B.
The side flat portion 40A is flat and rectangular and substantially parallel to the main wall portion 10 .
The side inclined portion 40B is integrally connected to the side flat portion 40A via the ridge line 16. As shown in FIG. The inclined side portion 40B is flat and rectangular, and like the inclined wall portion 20, is inclined toward the one side.
The ridgeline 16 is a crease connecting the side flat portion 40A and the side inclined portion 40B, and is formed substantially linearly along the Y-axis direction. When the ridge line 16 is viewed in a longitudinal section perpendicular to the Y-axis direction, it forms an obtuse inverted V shape with a curved apex.

The notch 50 is a triangular space formed between the inclined wall portion 20 and the first side wall portion 30 . More specifically, it is a triangular space having two sides, the edge 50b of the concave wall portion 30A and the edge 50a of the inclined wall portion 20, and an open base. Both edges 50a and 50b are linear. Also, the edge 50a is shorter than the edge 50b. The edges 50a, 50b are joined at their apexes, said apexes being arcuate with a small radius of curvature. The top portion continues to the third connection portion 13 . A notch 50 is formed along the extension direction of the third connecting portion 13 . The edge 50a is inclined so as to approach the widthwise center (Y-axis direction center) of the dash panel 100 as it approaches the top. Similarly, the edge 50b is also inclined so as to approach the center in the width direction of the dash panel 100 as it approaches the top. In this way, the edges 50a and 50b are inclined in the same direction, but the width between these edges 50a and 50b gradually widens from the top portion closest to the third connecting portion 13. It has a V shape.

As described above, the molded article obtained by applying the present invention may be used as a final product as it is, or may be an intermediate product to which post-processing such as trimming is applied. The dash panel 100 of this embodiment is an intermediate product at the time of FIG. 1, and the hatched portion is removed by trimming to become a final product.

As described above, the dash panel 100 of the present embodiment has the first connecting portion (first ridgeline) 11 and the second connecting portion (second ridgeline) 12 arranged with the corner portion C shown in FIG. a main wall portion (first region portion) 10 having; an inclined wall portion (second area portion) 20; integrally connected to the main wall portion 10 via the second connection portion 12, and partially and integrally connected to the inclined wall portion 20 via the third connection portion (third ridgeline) 13 connected to the corner portion C and a first side wall portion (third region portion) 30 which is continuously connected to the main wall portion 10 and inclined to the one side.
The first connecting portion 11, the second connecting portion 12, and the third connecting portion 13 are connected to each other at the corner portion C. As shown in FIG.

The total length of the outline OL1 (hereinafter referred to as the first outline) formed by the main wall portion 10 and the first side wall portion 30 is L1 (mm), and the length formed by the inclined wall portion 20 and the first side wall portion 30 is When the total length of the outline OL2 (hereinafter referred to as the second outline) is L2 (mm), the following (Equation 4) is satisfied.
L1>1.1×L2 (Formula 4)

Here, the first outline OL1 is the outline formed by the edge located on the first side in the X-axis direction among both edges of the main wall portion 10 and the first side wall portion 30 in the X-axis direction. . The second outline OL2 is the outline formed by the edge located on the second side in the X-axis direction among both edges in the X-axis direction of the inclined wall portion 20 and the first side wall portion 30 . Here, the first side in the X-axis direction is the side where the main wall portion 10 is located with respect to the inclined wall portion 20 , and the second side in the X-axis direction is the inclined wall portion 20 with respect to the main wall portion 10 . is the side on which is located. The first connecting portion 11 is positioned on the second side with respect to the main wall portion 10 and is positioned on the first side with respect to the inclined wall portion 20 .
Both the first outline OL1 and the second outline OL2 extend in the Y-axis direction.
The total length L1 of the first outline OL1 is the length of the first outline OL1 in the Y-axis direction. and the length L12 in the Y-axis direction of the edge of the wall portion 30 on the first side. However, in the illustrated example, the two first side wall portions 30 are arranged in the Y-axis direction, so the total length L1 of the first outline OL1 includes the length L12 of each of the two first side wall portions 30. .
The total length L2 of the second outline OL2 is the length of the second outline OL2 in the Y-axis direction. and the length L22 in the Y-axis direction of the edge on the second side of the wall portion 30 . However, in the illustrated example, since the two first side wall portions 30 are arranged in the Y-axis direction, the total length L2 of the second outline OL2 includes the length L22 of each of the two first side wall portions 30. . Further, the second outline OL2 does not include the notch 50 described above, and when the notch 50 becomes larger in the Y-axis direction, the total length L2 of the second outline OL2 becomes shorter.

In the dash panel 100, the length of the second side wall portion 40 is not included in the total lengths L1 and L2. However, if the length dimension along the total length L1 and the length dimension along the total length L2 of the second side wall portion 40 are the same, the dimension of the second side wall portion 40 is equal to the total length in Equation 4 above. It may be included in L1 and L2.

In addition, the total length of the adjacent portion along the extension direction of the third connection portion 13 between the inclined wall portion 20 and the first side wall portion 30 is defined as L3 (mm), and the length of the third connection portion 13 from this total length L3 Assuming that the length of the notch (non-bonded portion) 50 excluding the length is L4 (mm), the following (Equation 5) is satisfied. When the lengths of the edges 50a and 50b are different from each other, the average value of the lengths is calculated and set as L4. Then, L3 is obtained by adding the length of the third connecting portion 13 to the obtained L4.
0.8×L3<L4<0.9×L3 (Formula 5)

Furthermore, each notch B50, which is a non-joined portion in this notched blank B100 (described later), has the above-described total length L1 (mm) and L2 (mm ), the following formula 6 is satisfied. Here, the spacing dimension W1 is the spacing dimension between the edges 50a and 50b.
W1>L1-L2 (Formula 6)

According to the dash panel 100 having the above configuration, the inclined wall portion 20 and the first side wall portion 30 are integrally connected to the main wall portion 10, and the inclined wall portion 20 and the first side wall portion 30 are connected to the main wall portion 10. are both inclined in the same direction (said one side). Here, a notch 50 is provided that satisfies Equations 4 and 5. When Expression 1 is satisfied, the total length L2 of the second outline OL2 is moderately shorter than the total length L1 of the first outline OL1, so the size of the notch 50 in the Y-axis direction is appropriately secured. It can be said that there are When Expression 2 is satisfied, the notch 50 described above is neither excessively small nor excessively large with respect to the third connecting portion 13, and the size of the notch 50 in the Y-axis direction is appropriately secured. It can be said that there are Therefore, when the dash panel 100 is obtained by press-molding the flat notched blank B100, the inclined wall portion 20 and the first side wall portion 30 are all connected along the extending direction of the third connecting portion 13. It is possible to suppress the occurrence of wrinkles that occur when the In addition, at the time of press molding, a force in the direction of compression acts on the position of the third connection portion 13 so that the inclined wall portion 20 and the first side wall portion 30 approach each other, and the position of the third connection portion 13 is pulled. Therefore, no cracking occurs. Therefore, no wrinkles or cracks occur between the inclined wall portion 20 and the first side wall portion 30 of the dash panel 100 .

Moreover, the dash panel 100 is made of a steel plate having a tensile strength of 980 MPa or more. In this way, even if the dash panel 100 is a molded body made of a notched blank B100 made of a high-strength steel plate with low moldability, a force in the compression direction acts on the third connecting portion 13 during press molding. Therefore, cracks do not occur and the soundness is ensured.

Moreover, the plate thickness of the dash panel 100 is 1.2 mm, which is within the thickness range of 0.8 mm or more and 2.3 mm or less. By setting the thickness of the molded body within this range, the present invention can be widely applied to automobile parts such as the dash panel 100 of the present embodiment.

Also, the dash panel 100 is located on the opposite side of the main wall portion 10 with the first side wall portion 30 interposed therebetween, and is connected to the first side wall portion 30 via a fourth connection portion (fourth ridgeline) 14 . It further includes a second side wall portion (fourth region portion) 40 that is integrally connected. The second side wall portion 40 includes a side inclined portion 40B that is inclined in the same direction as the inclined wall portion 20 in the alignment direction from the main wall portion 10 toward the inclined wall portion 20 .
According to this configuration, in the notched blank B100 in which the inclined wall portion 20 and the first side wall portion 30 are formed, the second side wall portion 40 is mainly arranged in the same direction as the inclination direction of the inclined wall portion 20. The first side wall portion 30 can be formed by moving relative to the wall portion 10 . Here, since the second side wall portion 40 includes the side inclined portion 40B, for example, when the second side wall portion 40 is moved relative to the main wall portion 10, the second side wall portion 40 is also moved. By forming the side inclined portion 40</b>B, the material flow inside the first side wall portion 30 when forming the first side wall portion 30 can be directed toward the inclined wall portion 20 . Therefore, the obtained dash panel 100 is molded while a force in the compression direction is applied to the third connecting portion 13, so cracking is more reliably suppressed.

[Method for producing compact and mold]
A method of manufacturing a molded body for manufacturing the dash panel 100 will be described below with reference to FIGS. 2 to 4. FIG. FIG. 2 is a flow chart for explaining the method for manufacturing a molded body according to this embodiment. FIG. 3A is a perspective view of a notched blank B100 used in the same molding manufacturing method. FIG. 3B is a perspective view of an intermediate molded product obtained by the molded product manufacturing method. FIG. 3C is a perspective view of the dash panel 100, which is a molded body obtained by the molded body manufacturing method. FIG. 4 is a plan view for explaining the first to fourth region corresponding portions of the notched blank B100 shown in FIG. 3A.

As shown in FIG. 2, the molded body manufacturing method of the present embodiment includes a notched blank preparation step (preparation step) S1, a notched blank setting step (arranging step) S2, and an intermediate molded body forming step (second 2 region portion forming step) S3, final molded body forming step (third region portion forming step) S4, and molded body removing step S5. The molded body obtained after the molded body taking-out step S5 is the dash panel 100 shown in FIG.
Details of each step are described below.

(1) Notched blank preparation step S1
In the notched blank preparation step, a notched blank B100 is prepared by processing a high-strength steel plate (metal plate) having a plate thickness t of 1.2 mm and a tensile strength of 980 MPa. Although 1.2 mm is exemplified as the plate thickness t here, it may be selected from within the thickness range of 0.8 mm or more and 2.3 mm or less as necessary. Also, a steel sheet having a tensile strength of more than 980 MPa or less than 980 MPa may be selected as necessary.
Punching is suitable as a method for forming the notched blank B100, but other processing means such as mechanical processing, plasma cutting, and laser cutting may be employed instead of punching.

As shown in FIGS. 3A and 4, the notched blank B100 has an outer shape in which two notches B50 are formed in a rectangular high-strength steel plate (metal plate).
As shown in FIG. 4, the notched blank B100 includes a main wall corresponding portion B10, a pair of inclined wall corresponding portions B20, a pair of first side wall corresponding portions B30, and a pair of second side wall corresponding portions B40. , a pair of notches B50, a pair of first connection portion corresponding portions B11, a pair of second connection portion corresponding portions B12, a pair of third connection portion corresponding portions B13, and a pair of fourth connection portion corresponding portions B14 and.
The main wall corresponding portion B10 is a portion that becomes the main wall portion 10 after press molding. The inclined wall corresponding portion B20 is a portion that becomes the inclined wall portion 20 after press molding. The first side wall corresponding portion B30 is a portion that becomes the first side wall portion 30 after press molding. The second side wall corresponding portion B40 is a portion that becomes the second side wall portion 40 after press molding. The notch B50 is a portion that becomes the notch 50 after press molding. The first connecting portion corresponding portion B11 is a portion that becomes the first connecting portion 11 after press molding. The second connecting portion corresponding portion B12 is a portion that becomes the second connecting portion 12 after press molding. The portion corresponding to the third connecting portion B13 is a portion that becomes the third connecting portion 13 after press molding. The fourth connecting portion corresponding portion B14 is a portion that becomes the fourth connecting portion 14 after press molding. A part of the second side wall corresponding part B40 moves during press molding and becomes a part of the first side wall part 30 .

The pair of cutouts B50 are arranged symmetrically with respect to the center of the cutout blank B100 in the width direction (Y-axis direction). Each notch B50 is positioned between the portion B20 corresponding to the inclined wall and the portion B30 corresponding to the first side wall.
A pair of cutouts B50 have a symmetrical shape with respect to the center in the width direction. The outline along the Y-axis direction (outline on the first side in the X-axis direction) of the blank B100 on which the notches B50 are not formed is denoted by E1, and the notches B50 are formed on the blank B100. When the outline along the Y-axis direction (the outline on the second side in the X-axis direction) is indicated by E2, each notch B50 is open at the outline E2.

Each notch B50 is a triangular space formed between the portion B20 corresponding to the inclined wall and the portion B30 corresponding to the first side wall. More specifically, it is a triangular space having two sides, the edge B50b of the first side wall corresponding portion B30 and the edge B50a of the inclined wall corresponding portion B20, and having an open base. Both the edges B50a and B50b have a linear shape. Also, the edge B50a is shorter than the edge B50b. The edges B50a and B50b are connected at their tops, and the tops are arcuate with a small radius of curvature. The top portion continues to the third connecting portion corresponding portion B13. A notch B50 is formed along the extending direction of the third connecting portion corresponding portion B13. The edge B50a is inclined so as to approach the center in the width direction of the notched blank B100 as it approaches the top. Similarly, the edge B50b is also inclined so as to approach the center of the notched blank B100 in the width direction as it approaches the top. As described above, the edges B50a and B50b are inclined in the same direction, but the width between the edges B50a and B50b gradually widens as the distance from the top portion closest to the third connecting portion corresponding portion B13 increases. It has an inverted V shape.

The configuration (position, shape, size) of the notch B50 is determined by first assuming that the dash panel 100 is formed from a rectangular blank in which the notch B50 is not formed, and when forming the first side wall portion 30. Determine the position, shape, and size of wrinkles expected to occur due to the material flow, and set based on these results. Here, the position, shape, and size of wrinkles may be obtained by numerical calculation by CAE (computer aided engineering), or may be obtained based on the results of actual trial production.
Then, a portion where wrinkles occur is set as a notch B50. As a result, the compressive force when press-molding the first side wall corresponding portion B30 can be absorbed as the force for closing the notch B50, so the material concentrates between the inclined wall corresponding portion B20 and the first side wall corresponding portion B30. wrinkles can be suppressed.

The notch B50 is not limited to an inverted V shape, and can be set according to the material flow (material displacement) when forming the first side wall portion 30 . Moreover, it is preferable that the notch B50 is included in a region to be removed before becoming the final product. For example, in this embodiment, the hatched portion in FIG. 4 is removed by post-processing using a trimming press device (not shown).

(2) Notched blank setting step S2
In this step, the notched blank B100 obtained in the notched blank step is set in a mold D100 described later. That is, as shown in FIG. 6, the notched blank B100 is arranged and positioned in the mold D100.

(3) Intermediate compact forming step S3
In this step, the notched blank B100 is press-molded by the die to form an intermediate molded product W100.
Before describing this step, the mold (hereinafter referred to as mold D100) will be described with reference to the perspective view of FIG.

The mold D100 is attached to a press molding device (not shown) to constitute a molded product manufacturing device.
The mold D100 includes an upper mold U100 (second mold) and a lower mold L100 (first mold) movable relative to the upper mold U100 along the arrow UD direction.
The lower mold L100 includes a holder L101, which is movable in the vertical direction (Z-axis direction) indicated by P1, and a holder L101 which is arranged on both sides of the holder L101 in the Y-axis direction and moves in the vertical direction (Z-axis direction), which is indicated by P2. possible lower pads L102, L103 (first pads).

The holder L101 includes a holder top surface L101a (first area holder surface), a holder first inclined surface L101b (second area holder surface), and a holder second inclined surface L101c (third area holder surface). The main wall corresponding portion B10 of the notched blank B100 is arranged on the holder top surface L101a. Both the holder first inclined surface L101b and the holder second inclined surface L101c continue to the holder top surface L101a, and both are inclined with respect to the holder top surface L101a. The holder first inclined surface L101b forms the inclined wall portion 20 . The holder second inclined surface L101c forms the first side wall portion 30 .
The lower pads 102, 103 have pad top surfaces L102a, L103a (fourth area pad surfaces). The second side wall corresponding portion B40 of the notched blank B100 is placed on the pad top surfaces L102a and L103a.

The upper mold U100 includes an upper pad U101 (second pad), a pad cushioning mechanism (not shown) that suspends and supports the upper pad U101, and is arranged on both sides of the upper pad U101 in the Y-axis direction at intervals. It comprises dies U102, U103 and a die buffering mechanism (not shown) that suspends and supports the dies U102, U103.

The upper pad U101 includes a pad bottom surface U101a (first area pad surface) and a pad inclined surface U101b (second area pad surface). The pad bottom surface U101a faces the holder top surface L101a. The pad inclined surface U101b faces the holder first inclined surface L101b.
The dice U102 and U103 have first dice bottom surfaces U102a and U103a (fourth area dice surfaces) and dice second bottom surfaces U102b and U103b (third area dice surfaces). The die first bottom surfaces U102a, U103a face the pad top surfaces L102a, L103a. The die second bottom surfaces U102b and U103b face the holder second inclined surface L101c.
The pad cushioning mechanism and the die cushioning mechanism are mechanisms for receiving force during press molding, and press cushions, gas cylinders, springs, and the like can be employed.

Each of the above-described configurations of the mold D100 includes a main wall forming portion D10, an inclined wall forming portion D20, a first side wall forming portion D30, a second side wall forming portion D40, a first connection portion forming portion D11, and a second connecting portion forming portion D12.
The main wall forming portion D10 is a portion forming the main wall portion 10 of the dash panel 100 shown in FIG. The inclined wall molding portion D20 is a portion forming the inclined wall portion 20 of the dash panel 100. As shown in FIG. The first side wall forming portion D30 is a portion forming the first side wall portion 30 of the dash panel 100. As shown in FIG. The second side wall forming portion D40 is a portion forming the second side wall portion 40 of the dash panel 100. As shown in FIG. The first connecting portion forming portion D11 is a portion forming the first connecting portion 11 of the dash panel 100 . The second connecting portion forming portion D12 is a portion forming the second connecting portion 12 of the dash panel 100 .

The main wall forming portion D10, the inclined wall forming portion D20, the first side wall forming portion D30, the second side wall forming portion D40, the first connecting portion forming portion D11, and the second connecting portion forming portion D12 are formed in the lower mold L100. Each formed molding surface and each molding surface formed on the upper mold U100 are configured by facing each other.
That is, as shown in FIG. 5, the main wall forming portion D10, the inclined wall forming portion D20, and the first connecting portion forming portion D11 are formed by the forming surface of the holder L101 and the forming surface of the upper pad U101. For example, the main wall forming portion D10 is configured by a holder top surface L101a and a pad bottom surface U101a. The inclined wall molding portion D20 is configured by a holder first inclined surface L101b and a pad inclined surface U101b. Further, the second connecting portion molding portion D12 is configured by edges formed on both sides in the Y-axis direction of the holder L101.

Further, the first side wall forming portion D30 is configured by the forming surface of the holder L101 and the forming surfaces of the dies U102 and U103. The first side wall forming portion D30 is configured by the holder second inclined surface L101c and the die second bottom surfaces U102b and U103b (third area die surface).
The first side wall forming portion D30 includes a concave wall portion D30A forming the concave wall portion 30A and a convex wall portion D30B forming the convex wall portion 30B. Both the concave curved wall portion D30A and the convex curved wall portion D30B are formed on both sides of the holder L101 in the Y-axis direction and on the dies U102 and U103.

The second side wall molding portion D40 is composed of the molding surfaces of the lower pads L102 and L103 and the molding surfaces of the dies U102 and U103. The second side wall molding portion D40 is configured by pad top surfaces L102a and L103a and die first bottom surfaces U102a and U103a.

The mold D100 further includes a draw bead D50 (material flow control means). The draw bead D50 partially strongly presses the second side wall corresponding portion W40 of the intermediate molded product W100. This clamping pressure controls the material flow from the first side wall corresponding portion W30 toward the inclined wall corresponding portion W20 when forming the first side wall portion 30 from the first side wall corresponding portion W30.
The draw beads D50 are convex bodies elongated along the X-axis direction, and a pair of draw beads D50 are arranged side by side along the X-axis direction on the lower pad L102. Similarly, a pair of draw beads D50 are arranged side by side along the X-axis direction on the lower pad L103 as well. A pair of draw beads D50 may be provided on either one of the lower pad L102 and the die U102, or may be provided on both. Similarly, only one of the lower pad L103 and the die U103 may be provided, or both may be provided. The draw bead D50 is provided on the second sidewall molding portion D40 (pad top surfaces L102a, L103a, die first bottom surfaces U102a, U103a).

Using the mold D100 having the configuration described above, the main step (intermediate molded body molding step S3) of molding the intermediate molded product W100 shown in FIG. 3B from the blank B100 shown in FIG. 3A is shown in FIGS. will be used for explanation.
First, as described with reference to FIG. 6 in the previous step, the notched blank B100 is set on the lower die L100. When setting the notched blank B100 in the lower die L100, it is preferable to position the blank B100 with reference to, for example, the first connecting portion forming portion D11 and the second connecting portion forming portion D12.

Next, as shown in FIG. 7, the lower mold L100 is raised in the direction of arrow UD. As a result, the notched blank B100 is sandwiched between the upper mold U100 and the lower mold L100 for press molding.
That is, while the upper pad U101 and the dies U102, U103 are arranged at the same height, the holder L101 on which the notched blank B100 is placed and the lower pads L102, L103 are simultaneously moved upward. By completely closing the space between the upper mold U100 and the lower mold L100, the intermediate molded product W100 is formed.
As shown in FIG. 3B, the intermediate molded product W100 includes a main wall corresponding portion W10, an inclined wall corresponding portion W20 connected to the main wall corresponding portion W10 via a first connection portion corresponding portion W11, and a main wall corresponding portion W10. A first side wall corresponding portion W30 connected to W10 via a second connection portion corresponding portion W12 is provided.
As described above, the intermediate compact molding step S3 is completed, but the next step is performed while the mold D100 is closed.

(4) Final molding step S4
In this step, the intermediate molded product W100 obtained in the previous step is further press-molded (pad draw-molded) while being set in the mold D100 to obtain the dash panel 100. FIG.
The details of this step will be described below with reference to the drawings including FIG. In FIG. 8, after the state shown in FIG. 7, the combination of the lower pad L102 and the dice U102 and the combination of the lower pad L103 and the dice U103 are lowered relative to the combination of the holder L101 and the upper pad U101. FIG. 10 is a perspective view showing a state in which the dash panel 100 is formed by performing pad draw forming that allows the pad to be formed.

This step is started from the state where the above-mentioned intermediate molded body forming step S3 is completed.
As shown in FIG. 7, the intermediate molded product W100 after the intermediate molded product molding step S3 has the main wall corresponding portion W10 and the inclined wall corresponding portion W20 held between the holder L101 and the upper pad U101. The left and right first side wall corresponding portions W30 are pressed between the die U102 and the lower pad L102 and between the die U103 and the lower pad L103.

Next, the die U102 and lower pad L102 and the die U103 and lower pad L103 are lowered in the direction of arrow TP1 in FIG. 8 with respect to the holder L101 and upper pad U101. As a result, the first side wall portion 30 is formed and the dash panel 100 is manufactured.
When forming the first side wall portion 30, the second side wall corresponding portion W40 is strongly pressed by the draw bead D50. This causes a difference in the degree of pinching between the portion pinched by the drawbead D50 and the surrounding portion in the second side wall corresponding portion W40. Accordingly, when forming the first side wall portion 30 from the first side wall corresponding portion W30, a material flow can be formed in the direction from the first side wall corresponding portion W30 toward the inclined wall corresponding portion W20.

The process of forming the concave wall portion 30A in this step will be described below with reference to FIGS. 9 to 10D.
FIG. 9 is a partially enlarged perspective view for explaining the details of the process of forming the first side wall portion 30 in the molded body manufacturing method using the mold D100. FIG. 10A is a partially enlarged view for explaining the initial stage of forming the first side wall portion 30, where (a) is a vertical cross-sectional view and (b) is a perspective view. FIG. 10B is a partial enlarged view for explaining the continuation of FIG. 10A, in which (a) is a vertical sectional view and (b) is a perspective view. FIG. 10C is a partial enlarged view for explaining the continuation of FIG. 10B, in which (a) is a vertical sectional view and (b) is a perspective view. FIG. 10D is a partial enlarged view for explaining the continuation of FIG. 10C, in which (a) is a vertical cross-sectional view and (b) is a perspective view.

As described above, when forming the first side wall corresponding portion W30 on the first side wall portion 30, the second side wall corresponding portion W40 is partially strongly pressed by the draw bead D50.
As the press forming proceeds while maintaining this clamping pressure, the shape of the first side wall corresponding portion W30 gradually changes as shown in FIG. Here, the symbols WL1, WL2, WL3, and WL4 shown in FIG. It shows how the outer shape changes in the order of the panel 100 (marked at WL4). Similarly, reference numerals ML2 and ML3 shown in FIG. 9 indicate the process of gradually forming the concave wall portion 30A. handle.

First, as shown in FIG. 10A(a), before the formation of the concave curved wall portion 30A is started, the cross section showing the first side wall corresponding portion W30 of the intermediate molded product W100 when viewed along the Y-axis direction is , the main wall corresponding portion W10 and the inclined wall corresponding portion W20 have a cross-sectional shape in which the first connecting portion corresponding portion W11 is continuous.

Next, as shown in FIG. 10B(a), in the first stage in which the concave curved wall portion 30A begins to be formed, a forming line ML2 is formed in the process of forming the concave curved wall portion 30A.
Here, the sum of the dimensions G11 and G12 of the two straight lines forming the bent portion (the bent portion in the state before the concave curved wall portion 30A is formed) formed in the first side wall corresponding portion W30 of the intermediate molded product W100 The excess thickness is caused by the dimension and the dimension difference (G11+G12>G13) of the dimension G13 of the forming line ML2. Such surplus meat causes wrinkles, but in the present embodiment, since the cutouts W50 are formed in advance, the occurrence of wrinkles is suppressed.
That is, as indicated by an arrow T50 in FIG. 10B(b), the edge B50a of the first side wall corresponding portion W30 moves toward the edge B50b, and the interval between the notches W50 is reduced. As a result, the occurrence of out-of-plane deformation such as wrinkles due to the excess thickness formed in the first side wall corresponding portion W30 and the occurrence of excessive compressive stress are suppressed.

Next, as shown in FIG. 10C(a), in the second stage in which the formation of the concave wall portion 30A has progressed, a forming line ML3 is formed on which the concave wall portion 30A is being formed.
Here, the dimensional difference between the sum of the dimensions G11 and G12 of the two straight lines forming the bent portion formed in the first side wall corresponding portion W30 of the intermediate molded product W100 and the dimension G14 of the forming line ML3 (G11+G12>G14). resulting in a larger excess meat.
However, as indicated by an arrow T50 in FIG. 10C(b), the edge B50a of the first side wall corresponding portion W30 moves further toward the edge B50b, further reducing the interval between the notches W50. As a result, wrinkles and excessive compressive stresses continue to be suppressed even at this point.

Next, as shown in FIG. 10D(a), as the press molding is further advanced, the ridgeline 15 having the concave wall portion 30A and the third connecting portion 13 are formed. At this point, the edge B50a of the first side wall corresponding portion W30 moves further toward the edge B50b as indicated by an arrow T50 in FIG. The occurrence of surplus meat continues to be suppressed. Moreover, since only the force in the compression direction acts on the third connecting portion 13, cracks do not occur. Therefore, it is possible to manufacture the dash panel 100 that has a complicated shape while suppressing the occurrence of cracks and wrinkles.

As described above, the molded body manufacturing method of the present embodiment includes, as summarized below, a notched blank preparation step (preparation step) S1, an intermediate molded body molding step (second region portion forming step) S3, A final molded body forming step (third region portion forming step) S4 is performed.
In the notched blank preparation step S1, a notched blank B100 is prepared. This notched blank preparation step S1 includes a notch forming step of forming a notch B50 in the rectangular blank. The notched blank B100 thus prepared has a main wall corresponding portion (first region corresponding portion) B10 corresponding to the main wall portion (first region portion) 10, and an inclined wall portion (second region portion). 20, a first side wall corresponding portion (third region corresponding portion) B30 corresponding to the first side wall portion (third region portion) 30, a third region corresponding portion B30 corresponding to the It has a second side wall corresponding portion (fourth region corresponding portion) B40 corresponding to the second side wall portion (fourth region portion) 40, and a notch B50 corresponding to the non-joining portion.
In the intermediate molded body forming step (second region portion forming step) S3, the inclined wall corresponding portion W20 is inclined to the one side with respect to the main wall corresponding portion W10.
In the final molded body forming step (third region forming step) S4, the first side wall corresponding portion W30 is formed with respect to the main wall corresponding portion W10 while fixing the inclination of the inclined wall corresponding portion W20 with respect to the main wall corresponding portion W10. Relatively move toward the one side. At this time, the second side wall corresponding portion W40 is restrained by the draw bead (material flow control means) D50 and relatively moved, thereby forming a material flow from the first side wall corresponding portion W30 toward the notch W50.

According to the molded body manufacturing method, first, in the notched blank preparation step S1, the notched blank B100 having the notch B50 is prepared. Subsequently, in the intermediate molded body forming step S3, the inclined wall portion 20 is formed in the notched blank B100. Subsequently, in the final molded body forming step S4, the first side walls 30 are formed in the notched blank B100. At this time, since the notched blank B100 has the notch B50 at the position corresponding to the non-bonded portion, it is possible to suppress the occurrence of wrinkles that would otherwise occur when the notch B50 is not present. In addition, since the force in the compression direction acts on the position of the notched blank B100 that becomes the third connecting portion (third ridgeline) 13 connected to the notch B50, cracks do not occur. Therefore, according to this molding manufacturing method, wrinkles and cracks do not occur between the inclined wall portion 20 and the first side wall portion 30 .

In addition, in this embodiment, although the notch B50 was formed in the rectangular blank in the notched blank preparation step S1, the timing of forming the notch B50 may be changed, for example, as follows.
That is, the molded body manufacturing method in this case includes a preparation step, an intermediate molded body molding step (second region portion forming step), a notch forming step, and a final molded body forming step (third region portion forming step). ,I do.
In the preparation step, a rectangular blank in which the notch B50 is not formed is prepared. This blank has a main wall corresponding portion (first region corresponding portion) B10 corresponding to the main wall portion (first region portion) 10 and an inclined wall corresponding portion (second region corresponding portion) B10 corresponding to the inclined wall portion (second region portion) 20. 2nd area corresponding part) B20, a first side wall corresponding part (third area corresponding part) B30 corresponding to the first side wall part (third area part) 30, and a second side wall part (fourth area part) 40 and a second side wall corresponding portion (fourth area corresponding portion) B40.

In the step of forming the intermediate molded body (the step of forming the second region portion), the portion W20 corresponding to the inclined wall is inclined to the one side with respect to the portion W10 corresponding to the main wall, as in the above-described embodiment. After that, the blank is once removed from the mold D100.
In the notch forming step, a notch B50 corresponding to the non-bonded portion is formed in the blank taken out from the mold D100 at a position between the inclined wall corresponding portion W20 and the first side wall corresponding portion W30.
In the final molded body forming step (third region forming step) S4, as in the above-described embodiment, while fixing the inclination of the inclined wall corresponding portion W20 with respect to the main wall corresponding portion W10, The 1 side wall corresponding portion W30 is relatively moved toward the one side.
Even with this molded body manufacturing method, wrinkles and cracks do not occur between the inclined wall portion 20 and the first side wall portion 30 .

<Molding condition setting method>
Next, with reference to FIGS. 11 to 13, the procedure for setting the notched blank B100 according to the present embodiment, the molding conditions related to the drawbead D50, the configuration of the notched blank B100, and the configuration of the drawbead D50 will be described. do.

An example of a molding condition setting method will be described below with reference to FIG. FIG. 11 is a flowchart for explaining an example of the molding condition setting procedure.

First, the configuration of the dash panel 100, the configuration of the notched blank B100, the first press molding conditions, the configuration of the draw bead D50, and the second press molding conditions are set (step S11).
Here, the configuration of the dash panel 100 includes, for example, the three-dimensional shape, material characteristics, thickness (or thickness distribution), etc. of the dash panel 100 . The thickness of the dash panel 100 can be substituted by the thickness of the notched blank B100, for example.
Material properties include, for example, Young's modulus, yield strength (proof stress), and the relationship between stress and strain in a tensile test (stress-strain curve, etc.). If the material properties are known, the material of the metal material or the like may be set instead of the material properties.
The configuration of the notched blank B100 includes the thickness of the steel plate (metal plate), the steel type (material), the external shape (excluding the notch W50), and the configuration of the notch W50 (e.g., shape, arrangement, etc.). be.

As the first press molding condition, for example, a three-dimensional shape or the like for the mold D100 to mold the intermediate product W100 in the intermediate product molding step is targeted.
The configuration of the drawbead D50 includes a three-dimensional shape for molding the dash panel 100 when the mold D100 molds the dash panel 100 from the intermediate molded product W100 in the final molded product molding process, and a portion corresponding to the second side wall. The clamping state of W40 (for example, arrangement of draw bead D50, width, height, cross-sectional shape of draw bead D50, etc.) is targeted.
The second press molding conditions include the three-dimensional shape of the mold D100 used in the final molded product molding process, and the shape change of the second side wall corresponding portion W40 when molding the dash panel 100 from the intermediate molded product W100. It is said that
Various conditions may be added to the configuration of the dash panel 100, the configuration of the notched blank B100, the first press molding conditions, the configuration of the drawbead D50, and the second press molding conditions, if necessary. Moreover, the content of each setting condition can be arbitrarily set as needed.
After performing step S11, the process proceeds to step S12.

Next, the configuration of the intermediate molded product W100 is calculated (step S12).
The configuration of the intermediate molded product W100 is calculated using the finite element method based on, for example, the configuration of the notched blank B100 and the first press molding conditions in the intermediate molded body molding step.
The configuration of the intermediate molded product W100 includes, for example, the three-dimensional shape of the intermediate molded product W100 and the shape and position of the molding notch W50 in the intermediate molded product W100.
When calculating the configuration of the intermediate molded product W100, the configuration of the intermediate molded product W100 may be calculated by a method other than the finite element method, such as calculation based on experimental results instead of the finite element method.
After performing step S12, the process proceeds to step S13.

Next, the stress in the portion W30 corresponding to the first side wall of the dash panel 100 is calculated (step S13).
The stress generated in the first side wall corresponding portion W30 when molding the dash panel 100 in the final molded body molding process is, for example, the configuration of the intermediate molded product W100, the configuration of the dash panel 100, the configuration of the drawbead D50, the second press It is calculated using the finite element method based on the molding conditions.
Calculation of the stress in the first side wall corresponding portion W30 is performed, for example, when the mold D100 molds the dash panel 100 from the intermediate molded product W100 in the final molded product molding process from the configuration of the intermediate molded product W100 and the configuration of the drawbead D50. Second, the material flow is calculated from the order of contact (pressing) of the mold D100 with respect to the intermediate molded product W100, the distribution of the pressing force, and the control state of the material flow by the drawbead D50. A stress distribution in the first side wall corresponding portion W30 is calculated.
When calculating the stress in the first side wall corresponding portion W30 of the dash panel 100, the stress generated in the first side wall corresponding portion W30 is calculated by a method other than the finite element method, such as calculation based on experimental results instead of the finite element method. Stress may be calculated.
After executing step S13, the process proceeds to step S14.

Next, the stress of the first side wall corresponding portion W30 of the dash panel 100 is evaluated (step S14).
The stress evaluation of the first side wall corresponding portion W30 is performed based on whether or not "the stress of the first side wall corresponding portion W30≦the set compressive stress".
If "the stress of the first side wall corresponding portion W30≦the set compressive stress" (step S14: Yes), the molding conditions set in step S11 are set, and the flow chart ends. If it is not "the stress of the first side wall corresponding portion W30≦the set compressive stress" (step S14: No), the process proceeds to step S15.

The configuration of the notched blank B100 and the configuration of the drawbead D50 are reviewed (step S15).
When reviewing the configuration of the notched blank B100 and the configuration of the drawbead D50, either the configuration of the notched blank B100 or the configuration of the drawbead D50 is taken into consideration, such as the stress distribution of the first side wall corresponding portion W30. Alternatively, both the configuration of the notched blank B100 and the configuration of the drawbead D50 may be reviewed.
After executing step S15, the process proceeds to step S11.
The above steps S11 to S15 are repeatedly executed.

In addition, in the method of setting the molding conditions described above, it is assumed that both the configuration of the notched blank B100 and the configuration of the draw bead D50 can be reviewed. However, as in the modification shown below, it is also possible to set the molding conditions on the premise that only one of the configuration of the notched blank B100 and the configuration of the draw bead D50 is reviewed. .

<Setting the configuration of the notched blank B100>
Next, with reference to FIG. 12, an example of a procedure for setting (fixing) the configuration of the drawbead D50 in advance and determining the configuration of the notched blank B100 suitable for the drawbead D50 will be described. FIG. 13 is a flow chart showing an example of a procedure for setting the configuration of the drawbead D50 in advance and then determining the configuration of the notched blank B100 according to the first embodiment.

Steps S21 to S25 in the flowchart shown in FIG. 12 respectively correspond to S11 to S15 in the flowchart shown in FIG.
The difference between the two is that when setting each condition in step S21, first, the configuration of the notched blank B100 is set as a provisional configuration, and the configuration of the drawbead D50 is set as a fixed configuration.
After that, when step S24 becomes No and the process proceeds to step S25, only the configuration of the notched blank B100 is reviewed, and the configuration of the drawbead D50 is not reviewed.

<Setting the configuration of the drawbead D50>
Next, referring to FIG. 13, an example of a procedure for setting (fixing) the configuration of the notched blank B100 in advance and determining the configuration of the drawbead D50 according to the configuration of the notched blank B100 will be described. . FIG. 13 is a flow chart showing an example of a procedure for setting the configuration of the notched blank B100 in advance and determining the configuration of the drawbead D50 according to the first embodiment.

Steps S31 to S35 in the flowchart shown in FIG. 13 respectively correspond to S11 to S15 in the flowchart shown in FIG.
The difference between the two is that when setting the conditions in step S31, first, the configuration of the drawbead D50 is assumed to be a temporary configuration, and the configuration of the notched blank B100 is assumed to be a fixed configuration.
After that, when step S34 becomes No and the process proceeds to step S35, only the configuration of the drawbead D50 is reviewed, and the configuration of the notched blank B100 is not reviewed.

According to the dash panel 100 and the molded body manufacturing method according to the present embodiment, in the notched blank forming step, the notched blank B100 in which the notched B50 is formed is prepared, and the intermediate molded body forming step (second region forming step), an intermediate molded product W100 is formed from the notched blank B100; is held, and the first side wall corresponding portion W30 of the intermediate molded product W100 is moved downward relative to the main wall corresponding portion W10 to form the dash panel 100. Since the first side wall corresponding portion W30 is compressed by D50 and the material flows toward the notch W50, the first side wall corresponding portion W3030 is suppressed from being subjected to compressive stress, and the first side wall portion 30 is wrinkled. It is possible to suppress the occurrence of out-of-plane deformation such as
As a result, the dash panel 100 can be manufactured efficiently and stably while ensuring desired quality.
Moreover, the strength of the dash panel 100 (product), which is difficult to draw, can be efficiently improved.

Further, according to the dash panel 100 and the method for manufacturing the molded body according to the present embodiment, the thickness of the first side wall corresponding portion W30 of the intermediate molded product W100 is increased when the first side wall corresponding portion W30 of the intermediate molded product W100 is molded into the concave curved wall portion 30A in the molded body molding process. Even if there is a surplus, the edge of the notch W50 on the side of the first side wall corresponding portion W30 is displaced in the direction of the arrow T50. occurrence is suppressed.

Further, according to the dash panel 100 and the molding manufacturing method according to the present embodiment, the compressive stress generated in the first side wall corresponding portion W30 of the intermediate molded product W100 is set to a predetermined value (for example, Since the compressive stress (allowable compressive stress) is controlled to be less than the compressive stress that is formed, the quality of the first side wall portion 30 of the dash panel 100 can be reliably ensured.

In addition, according to the dash panel 100 and the molding manufacturing method according to the present embodiment, since the notch W50 is removed in the post-process, it is configured so that it does not remain when the dash panel 100 is distributed as a product or part. Therefore, the degree of freedom in designing the dash panel 100 can be improved, and the performance and strength of products and parts can be fully exhibited.

In addition, according to the dash panel 100 and the molded body manufacturing method according to the present embodiment, the dash panel 100, which is difficult to form by drawing a steel plate made of high-tensile steel having a tensile strength of 980 MPa or more, can be stably formed. be able to.

Further, according to the molding condition setting method according to the present embodiment, the configuration of the notched blank B100 and the configuration of the drawbead D50 can be efficiently determined by calculating the material flow in the first side wall corresponding portion W30. can be done.

Further, according to the method of setting the configuration of the notched blank B100 according to the present embodiment, the notched blank B100 is calculated by calculating the material flow in the first sidewall corresponding portion W30 based on the predetermined configuration of the drawbead D50. Since the configuration of B100 is determined, the configuration of notched blank B100 can be efficiently determined.

Further, according to the method for setting the configuration of the drawbead D50 according to the present embodiment, the configuration of the drawbead D50 is calculated by calculating the material flow in the first side wall corresponding portion W30 based on the configuration of the notched blank B100 determined in advance. is determined, the configuration of the drawbead D50 can be determined efficiently.

<Second embodiment>
A second embodiment of the present invention will be described below with reference to FIG.
FIG. 14 is a flow chart for explaining the outline of the molding manufacturing process according to the second embodiment.

As shown in FIG. 14, the molded body manufacturing process according to the present embodiment includes a notched blank preparation process (step S101), an intermediate molded body forming process (second region portion forming process) (step S102), and a molding and a body shaping step (third region forming step) (step S103). "Set a notched blank", "set an intermediate molded product", and "take out a molded body" shown in FIG. is shown.

In the molded body manufacturing process according to the present embodiment, when manufacturing the dash panel 100, the mold D100 for molding the intermediate molded body molding process and the final molded body molding process at the same station is used. A first press mold for forming the intermediate molded product W100 from the notched blank B100 in the molding process and a second press mold for forming the dash panel 100 from the intermediate molded product W100 in the second molding process are prepared, An intermediate molded product W100 is formed with a first press mold, the intermediate molded product W100 taken out from the first press mold is set in a second press mold, and press-molded (pad draw molding) is performed with the second press mold. are configured to form the dash panel 100 together.

The first press mold has a shaped portion formed by forming the intermediate product W100 in the intermediate product forming process according to the first embodiment.
In addition, the second press mold has a molding shape portion and functions used when forming the dash panel 100 from the intermediate molded product W100 in the molded body molding process according to the first embodiment.
Others are the same as those of the first embodiment, so description thereof will be omitted.

<Third Embodiment>
A third embodiment of the present invention will be described below with reference to FIGS. 15 and 16A to 16D.
FIG. 15 is a perspective view for explaining a method for manufacturing a molded body using the mold according to this embodiment. 16A to 16D are perspective views for explaining the steps of forming a first region to a fourth region in a method of manufacturing a molded body using a mold according to the third embodiment.
In the mold D500 according to the third embodiment, the same reference numerals are given to the same parts as the components in the mold D100 according to the first embodiment, the description thereof is omitted, and only the points of difference are explain.

The mold D500 of this embodiment is attached to a press molding device (not shown) to constitute a molded product manufacturing device. As shown in FIG. 15, the mold D500 includes an upper mold U500 and a lower mold L100 that can move relative to the upper mold U500 along the arrow UD direction.
The mold D500 is a mold for manufacturing the dash panel (molded body) 100 shown in FIG. 1 from the notched blank B100 shown in FIG.

The lower mold L100 includes a holder L101 and lower pads L102 and L103, like the mold D100 according to the first embodiment.

The upper mold U500 includes an upper pad U501 and dies U102 and U103. The dies U102 and U103 have the same configuration as the mold D100 according to the first embodiment. On the other hand, the upper pad U501 includes a leading pad U501A having a pad bottom surface U101a and a trailing pad U501B having a pad inclined surface U101b. These leading pad U501A and trailing pad U501B can be raised and lowered independently of each other.
In the mold D100 according to the first embodiment, since the upper pad U101 is integrated, the mold D100 and the mold D500 differ in the configuration of the upper pads U101 and U501.

When manufacturing the dash panel 100 from the notched blank B100 using this mold D500, basically the same steps as in the manufacturing method according to the first embodiment are performed (1) notched blank preparation step S1, (2) notched blank setting step S2, (3) intermediate compact forming step S3, and (4) final compact forming step S4 are carried out. However, as in the manufacturing method according to the first embodiment, it is also possible to form the notch B50 between the intermediate compact forming step S3 and the final compact forming step S4.
The manufacturing method according to this embodiment will be described below, focusing on the main differences from the first embodiment.

In the manufacturing method according to the present embodiment, in (2) notched blank setting step S2, as shown in FIG. (near the mold L100).

After that, in the (3) intermediate molded body forming step S3, by moving the leading pad U501A toward the holder L101, as shown in FIG. Fix (blank fixation step).
Subsequently, the trailing pad U501B is moved toward the holder L101. Thereby, as shown to FIG. 16B, the main wall part 10 and the inclined wall part 20 are formed in blank B100 with a notch.
Then, the combination of dice U102, U103 is moved toward the combination of lower pads L102, L103. As a result, as shown in FIG. 16C, the second side wall corresponding portion B40 is sandwiched between the pad top surfaces L102a, L103a and the die first bottom surfaces U102a, U103a.

After that, in (4) the final compact forming step S4, as shown in FIG. are moved relative to each other (third region forming step). Thereby, the first side wall portion 30 and the second side wall portion 40 are formed.

<Fourth Embodiment>
A fourth embodiment of the present invention will be described below with reference to FIGS. 17 to 20. FIG.
FIG. 17 is a perspective view for explaining a method for manufacturing a molded body using the mold according to this embodiment. 18 to 20 are diagrams for explaining the method of manufacturing a molded body using the mold according to this embodiment.
In the mold D600 according to the fourth embodiment, the same parts as those in the mold D500 according to the third embodiment are denoted by the same reference numerals, and the description thereof is omitted. explain.

The mold D600 of this embodiment is attached to a press molding device (not shown) to constitute a molded product manufacturing device. As shown in FIG. 17, the mold D600 includes an upper mold U500 and a lower mold L600 that can move relative to the upper mold U500 along the arrow UD direction.
The mold D600 is a mold for manufacturing the dash panel (molded body) 100 shown in FIG. 1 from the notched blank B100 shown in FIG.

The upper mold U500 includes an upper pad U501 and dies U102 and U103, like the mold D500 according to the third embodiment. However, the upper pad U501 may have the same configuration as the upper pad U101 of the mold D100 according to the first embodiment (that is, the upper pad is not divided into the leading pad U501A and the trailing pad U501B). configuration).

The lower mold L600 includes a holder L601 and lower pads L102 and L103. The lower pads L102 and L103 have the same configuration as the mold D100 according to the first embodiment. On the other hand, the holder L601 includes a blank holder L601A having a holder top surface L101a and a punch L601B arranged adjacent to the blank holder L601A and having a holder second inclined surface L101c. These blank holder L601A and punch L601B can be raised and lowered independently of each other. In this embodiment, the blank holder L601A further includes a holder first inclined surface L101b. Further, in this embodiment, a pair of punches L601B are provided symmetrically with the blank holder L601A interposed therebetween.
In the mold D500 according to the third embodiment, since the holder L101 is integrated, the structures of the holders L101 and L601 are different between the mold D500 and the mold D600.

When manufacturing the dash panel 100 from the notched blank B100 using this mold D600, basically, the same steps as in the manufacturing method according to the first embodiment and the third embodiment are performed (1) notch (2) notched blank setting step S2; (3) intermediate compact forming step S3; and (4) final compact forming step S4. However, as in the manufacturing methods according to the first embodiment and the third embodiment, the timing of forming the notch B50 may be set between the intermediate compact molding step S3 and the final compact molding step S4. It is possible.
In the following, the manufacturing method according to this embodiment will be described with a focus on main differences from the above-described third embodiment.

In the manufacturing method according to the present embodiment, in the (3) intermediate molded body molding step S3, as shown in FIG. and the combination of lower pads L102 and L103. As a result, the main wall portion 10 and the inclined wall portion 20 are formed in the notched blank B100, and the second side wall corresponding portion B40 is sandwiched between the pad top surfaces L102a and L103a and the die first bottom surfaces U102a and U103a. . At this time, the punch L601B is arranged below the blank holder L601A.

After that, in (4) the final molded body molding step S4, as shown in FIG. downward). Further, as shown in FIG. 20, the punch L601B is relatively moved in the direction opposite to the one side (upward) with respect to the blank holder L601A and the upper pad U501. As a result, the first side wall corresponding portion W30 of the notched blank B100 is sandwiched between the holder second inclined surface L101c and the die second bottom surfaces U102b and U103b. Thereby, the first side wall portion 30 and the second side wall portion 40 are formed.

It should be noted that the present invention is not limited to the above embodiments, and various modifications can be made without departing from the scope of the invention.

For example, in the above embodiment, the case where the molded body is the dash panel 100 has been described, but it can be applied to various other products and parts.
Moreover, the main wall portion 10 and the inclined wall portion 20 of the dash panel 100 may be formed with a convex shape, a concave shape, a hole, or the like. Moreover, a hole etc. may be formed in blank B100 with a notch.

Further, in the above-described embodiment, the concave curved wall portion bulges out toward the opposite side of the bend on the extension of the first connecting portion corresponding portion W11 formed in the first side wall corresponding portion W30 of the intermediate molded product W100. Although the case of molding to 30A has been described, it is possible to arbitrarily set whether to mold to the dome-shaped wall portion. 100 can be applied. Also, it may be applied to the dash panel 100 that does not have excess thickness.
In other words, whether or not the dash panel 100 has a dome-shaped wall portion and what kind of three-dimensional shape the first side wall portion 30 has can be arbitrarily set.

In the above embodiment, the case where the mold D100 advances and retreats in the direction perpendicular to the main wall portion 10 to mold the dash panel 100 has been described. The direction of movement) can be arbitrarily set. For example, the mold D100 moves in a direction inclined with respect to the direction orthogonal to the main wall portion 10 to mold the intermediate molded product, the dash panel 100. may

In the above embodiment, the hatched portion of the dash panel 100 shown in FIG. 1 is removed in a post-process. However, the second side wall portion 40 and the notch 50 may be left as parts without being limited to this form.

Further, in the above embodiment, when setting the molding conditions, the configuration of the notched blank B100, and the configuration of the draw bead D50, the case where the flowcharts shown in FIGS. The flowchart shown in FIG. 13 is an example, and the setting procedure can be arbitrarily set as necessary. Also, the setting conditions to be set and the contents of the setting conditions can be set as appropriate.

Further, in the above embodiment, when setting the molding conditions, the configuration of the notched blank B100, and the configuration of the drawbead D50, the configuration of the intermediate molded product and the stress in the first side wall portion 30 of the dash panel 100 are applied. , the case of calculation using the finite element method has been described, but the calculation may be performed by a method other than the finite element method, such as calculation by experiment.
Further, in the above-described first embodiment, the case of plastic working by pad drawing has been described, but the present invention may be applied to various press molds having the same effects as those of the present invention.

Further, in the above embodiment, when the intermediate molded product W100 is molded by the mold D100, the upper mold U100 moves forward with respect to the lower mold L100. The upper mold U100 and the lower mold L100 may move relative to each other.

In the above embodiment, the case where the lower pads L102, L103 and the dies U102, U103 descend with respect to the holder L101 and the upper pad U101 when molding the dash panel 100 with the mold D100 has been described. , the holder L101 and the blank holder may rise relative to the U101 lower pads L102, L103 and the dies U102, U103, and the lower pads L102, L103, the dies U102, U103, the holder L101, and the upper pad U101 may move relative to each other. may be configured.

According to the present invention, it is possible to provide a compact in which cracks and wrinkles are suppressed. Further, according to the present invention, it is possible to provide a blank, a method for manufacturing a molded body, and a mold for obtaining the molded body. Therefore, industrial applicability is great.

100 Dash panel (molded body)
10 main wall portion (first region portion)
11 first connection portion 12 second connection portion 13 third connection portion 20 inclined wall portion (second area portion)
30 first side wall portion (third area portion)
40 Second side wall portion (fourth region portion)
50, B50 Notch B100 Blank with notch D100, D500 Mold L100, L500 Lower mold L101 Holder L102, L103 Lower pad (first pad)
U100, U500 Upper mold U101 Upper pad U102, U103 Die W100 Intermediate molded product

Claims (16)

a first area portion having a first ridgeline and a second ridgeline that are arranged with a corner interposed therebetween;
a second region portion integrally connected to the first region portion via the first ridge line and inclined to one side of front and back surfaces of the first region portion;
integrally connected to the first region via the second edge line, partially and integrally connected to the second region via a third edge line connecting to the corner, and connected to the first region a third area inclined to the one side;
with
the first edge line, the second edge line, and the third edge line are connected to each other at the corners;
Let L1 (mm) be the total length of the contour line formed by the first region portion and the third region portion, and L2 (mm) be the total length of the contour line formed by the second region portion and the third region portion. As, the following (Equation 1) is satisfied,
Let L3 (mm) be the total length of the adjacent portion between the second region portion and the third region portion along the extension direction of the third ridgeline, and the total length L3 minus the length of the third ridgeline is non-bonded A molded body characterized by satisfying the following (Equation 2) where L4 (mm) is the length of the portion.
L1>1.1×L2 (Formula 1)
0.8×L3<L4<0.9×L3 (Formula 2) 2. The compact according to claim 1, comprising a steel plate having a tensile strength of 980 MPa or more. 3. The molded product according to claim 1, wherein the plate thickness is 0.8 mm or more and 2.3 mm or less. further comprising a fourth region portion located on the opposite side of the first region portion with the third region portion interposed therebetween and integrally connected to the third region portion via a fourth ridgeline;
1-, wherein the fourth region portion includes an inclined portion inclined in the same direction as the second region portion toward the alignment direction from the first region portion toward the second region portion. 4. The molded article according to any one of 3. A flat plate-shaped blank that is molded into the molded body according to any one of claims 1 to 4,
A blank having a notch corresponding to the non-bonded portion. 6. The blank according to claim 5, which satisfies the following formula 3, where W1 (mm) is the separation dimension at the end of the notch.
W1>L1-L2 (Formula 3) A method for producing a molded article according to claim 4,
a first region corresponding portion corresponding to the first region portion; a second region corresponding portion corresponding to the second region portion; a third region corresponding portion corresponding to the third region portion; A preparation step of preparing a blank having a fourth region corresponding portion corresponding to and a notch corresponding to the non-bonded portion;
a second region forming step of tilting the second region corresponding portion toward the one side with respect to the first region corresponding portion;
By moving the fourth region corresponding portion relative to the first region corresponding portion toward the one side while fixing the inclination of the second region corresponding portion with respect to the first region corresponding portion, a third region portion forming step of inclining the three region corresponding portion toward the one side with respect to the first region corresponding portion;
A molded body manufacturing method characterized by having 8. The method of manufacturing a compact according to claim 7, wherein said preparation step includes a notch forming step of forming said notch in said blank. A method for producing a molded article according to claim 4,
a first region corresponding portion corresponding to the first region portion; a second region corresponding portion corresponding to the second region portion; a third region corresponding portion corresponding to the third region portion; A preparation step of preparing a blank comprising a fourth region corresponding part corresponding to
a second region forming step of inclining the second region corresponding portion toward one of the front and back surfaces of the first region corresponding portion;
a notch forming step of forming a notch corresponding to the non-bonded portion between the second region corresponding portion and the third region corresponding portion;
By moving the fourth region corresponding portion relative to the first region corresponding portion toward the one side while fixing the inclination of the second region corresponding portion with respect to the first region corresponding portion, a third region portion forming step of inclining the three region corresponding portion toward the one side with respect to the first region corresponding portion;
A molded body manufacturing method characterized by having forming a material flow from the third region corresponding portion toward the notch by causing the relative movement of the fourth region corresponding portion while restraining the fourth region corresponding portion by a material flow control means in the third region forming step; The method for producing a molded article according to any one of claims 7 to 9. a first region corresponding portion corresponding to the first region portion; a second region corresponding portion corresponding to the second region portion; a third region corresponding portion corresponding to the third region portion; A mold for manufacturing the molded article according to claim 4 from a blank comprising a fourth area corresponding part corresponding to
A first mold and a second mold facing each other are provided,
The first mold is
a first region holder surface on which the first region corresponding portion is arranged; and a second region holder surface that is connected to the first region holder surface and inclined with respect to the first region holder surface to form the second region portion. , a third region holder surface connected to the first region holder surface and inclined with respect to the first region holder surface to form the third region portion;
a first pad disposed adjacent to the holder and having a fourth region pad surface on which the fourth region corresponding portion is placed;
The second mold is
a second pad having a first area pad surface facing the first area holder surface and a second area pad surface facing the second area holder surface;
a die having a fourth area die surface disposed adjacent to the second pad and facing the fourth area pad surface;
A mold characterized by comprising: A mold according to claim 11,
A mold, wherein the second pad comprises a leading pad having the first region pad surface and a trailing pad having the second region pad surface. A mold according to claim 11 or 12,
The holder is
A mold, comprising: a blank holder having the first region holder surface; and a punch disposed adjacent to the blank holder and having the third region holder surface. A method for producing the molded body using the mold according to claim 11,
The first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface. a placement step of placing the blank in the first mold;
a second region forming step of pressing the second pad against the holder to form the second region;
The second mold is pressed against the first mold in a state in which notches corresponding to the non-bonded portions are formed in the blank, and the first region corresponding portions are formed on the first region holder surface and the first region holder surface. sandwiched between the first area pad surfaces, sandwiching the second area corresponding portion between the second area holder surface and the second area pad surface, and sandwiching the fourth area corresponding portion between the fourth area pad surface; and the fourth area die surface, the first pad and the die are relatively moved toward the one side with respect to the holder and the second pad to move the third die. a third region portion forming step of forming a region portion;
A molded body manufacturing method characterized by having A method for producing the molded article using the mold according to claim 12,
The first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface. a placement step of placing the blank in the first mold;
a second region forming step of pressing the second pad against the holder to form the second region;
The second mold is pressed against the first mold in a state in which notches corresponding to the non-bonded portions are formed in the blank, and the first region corresponding portions are formed on the first region holder surface and the first region holder surface. sandwiched between the first area pad surfaces, sandwiching the second area corresponding portion between the second area holder surface and the second area pad surface, and sandwiching the fourth area corresponding portion between the fourth area pad surface; and the fourth area die surface, the first pad and the die are relatively moved toward the one side with respect to the holder and the second pad to move the third die. a third region portion forming step of forming a region portion;
has
In the second area portion forming step, the preceding pad is pressed against the holder, and the first area corresponding portion is sandwiched between the first area holder surface and the first area pad surface, and then the following area is formed. A method of manufacturing a molded body, wherein the second region portion is molded by pressing a pad against the holder. A method for producing the molded article using the mold according to claim 13,
The first region corresponding portion is positioned on the first region holder surface, the second region corresponding portion is positioned on the second region holder surface, and the fourth region corresponding portion is positioned on the fourth region pad surface. a placement step of placing the blank in the first mold;
a second region forming step of pressing the second pad against the holder to form the second region;
The second mold is pressed against the first mold in a state in which notches corresponding to the non-bonded portions are formed in the blank, and the first region corresponding portions are formed on the first region holder surface and the first region holder surface. sandwiched between the first area pad surfaces, sandwiching the second area corresponding portion between the second area holder surface and the second area pad surface, and sandwiching the fourth area corresponding portion between the fourth area pad surface; and the fourth area die surface, the first pad and the die are relatively moved toward the one side with respect to the holder and the second pad to move the third die. a third region portion forming step of forming a region portion;
has
In the third region forming step, the first pad and the die are placed on the blank holder and the second pad while the punch is positioned on the one side of the blank holder. While relatively moving toward one side, the punch is relatively moved in a direction opposite to the one side with respect to the blank holder and the second pad to form the third region. A molded body manufacturing method characterized by:

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