JP3298805B2 - Male forming method for sheet material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a plate, and more particularly to a method for forming a plate into a desired male shape by pressing.

[0002]

2. Description of the Related Art For example, wheel caps for automobiles are generally mass-produced by press working, but there are cases where many kinds of wheel caps are produced in small quantities or individually by custom production. In the case of manufacturing such a small or one-piece wheel cap, conventionally, if a mold is manufactured for each of the shapes, the manufacturing cost is increased. However, in such a case, there is a problem that the time required to manufacture one product is lengthened and the manufacturing cost is increased.

In order to reduce the production cost without producing a molding die for each shape in the case of production of a large number of varieties in small quantities, Japanese Patent Application Laid-Open No. 48-48358 discloses a molding method. And JP-A-7-1
No. 32329, entitled "Method and Apparatus for Forming Plate Material".

[0004] In other words, Japanese Patent Application Laid-Open No. 48-48358 discloses that, as shown in FIG. While gradually moving to the female mold 23 by a forming roll member rotating at high speed around a vertical axis.
There is disclosed a forming method of forming the plate material 4 into a female mold by sequentially pressing the plate material 4 on the entire surface.

[0005] A method of forming a plate material disclosed in Japanese Patent Application Laid-Open No. Hei 7-132329 is a method of processing a plate material using a numerically controlled vertical milling machine (hereinafter referred to as "NC vertical milling machine") as shown in FIG. However, the table 30 of the NC vertical milling machine has a jig 20 for holding the periphery of the plate material.
Is fixed, and an NC vertical milling machine is equipped with an incremental forming tool 5 for gradually pressing a plate material.

As shown in FIG. 15, the jig 20 has guide posts 12 attached to the four corners of the base plate 1, and a lower tool 13 for supporting the plate from below at the center of the base plate 1. . At four corners of the upper plate 14, guide post holes 14a are provided, and at the center of the upper plate 14, a lower tool hole 1a is provided.
4b is provided. Therefore, the guide post 12 and the lower tool 13 are fitted into the guide post hole 14a and the lower tool hole 14b, respectively. Thereby, the upper plate 14 can slide smoothly up and down. The plate material 4, which is a plate material for molding, is placed on the upper plate 14, and a plate material fixing frame 6 having an opening 6a largely opened at the center is placed on the plate material 4. The plate 4 is fixed by bolts passing through holes 16 b provided at the four corners of the plate fixing frame 6 and holes 14 c provided in the upper plate 14 and screwed.

On the other hand, the NC vertical milling machine stores contour line data in a previously created planned shape.

Therefore, as shown in FIG. 16, a set of jigs 20 is placed on a table 30 of an NC vertical milling machine and fixed.
By rotating and moving the rod-shaped incremental forming tool 5 attached to the NC vertical milling machine in accordance with contour data according to contour data in advance, one by one from the top, press-forming is performed to obtain a desired plate material. It is processed into a shape. During this press molding, the upper plate 14
It slides downward according to the press forming of the incremental forming tool 5.

[0009]

However, according to the molding method disclosed in Japanese Patent Application Laid-Open No. 48-58358, FIG.
As shown in (1), the plate member 4 interferes with the product shape portion of the male die 33, and the peripheral edge of the plate member 4 cannot be gripped by the male die 33. Therefore, in the molding method of the above publication,
It was not possible to perform male molding.

Further, using the plate material forming method and the plate forming device described in Japanese Patent Application Laid-Open No. 7-132329, for example, a molded panel having a male mold planned shape shown by broken lines in FIGS. 11, 12 and 13 is pressed. In the case of molding, since the rigidity of the plate material 4 is small, the plate material 4 loses pressure and shifts to the shape of the flat portion as shown by the solid line in FIGS.
And the cross section is deformed as shown in FIG.

The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to provide a molding method for incrementally molding a plate material into a male shape without causing sagging or cross-sectional deformation.

[0012]

Means for Solving the Problems In order to solve the above problems, the method of forming a plate according to the present invention has the following features.

(1) A male molding method for a plate material in which a plate material is gradually pressed and processed into a desired male shape, wherein a male-type support having a desired male shape is surrounded by an outer peripheral frame; A peripheral edge of a plate material is gripped on the upper surface of the outer peripheral frame so that the plate material abuts on a vertex of the male-shaped support member, and a peripheral processing of a peripheral space region existing between the male-shaped support member and the outer peripheral frame is performed. The incremental forming tool is moved based on the forming contour data obtained by combining the contour data and the male processing contour data, and the plate material supported by the male support is gradually pressed and processed into a male shape.

Accordingly, since the plate material is supported by the male-shaped support and the male shape and the peripheral region shape are gradually pressed together to form the male shape, the molding failure such as sagging and deformation is caused. Generation can be suppressed, and sheet metal processing can be performed with high accuracy.

(2) In the sheet material forming method according to the above (1), the forming contour data is obtained by alternately combining contour data of one or more contour lines of the male working contour data and one or more contour contour data. Based on this contour data, the incremental molding tool is moved based on the contour data, and the male material forming process and the peripheral forming process are alternately repeated to go through the plate material one by one or in multiple layers. Press forming into shape.

Therefore, even if the rigidity of the plate material is small, the male molding process and the peripheral molding process are alternately repeated, and the plate material is pressed into a male shape one by one or a plurality of layers. It is possible to suppress a shift (so-called sagging) in the shape and a deformation of the cross section.

(3) In the method of forming a plate according to any one of the above (1) and (2), a soft member is fitted into a part of the surface of the male-shaped support, and the flexible member is fitted into the fitted portion. An incremental forming tool is pressed to partially process the plate material.

Therefore, it is possible to precisely perform the partial decoration processing together without manufacturing a mold for the partial processing.

[0019]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described.

Embodiment 1 The method of forming a plate according to the present embodiment will be described with reference to FIGS. Note that, in the present embodiment, Japanese Patent Laid-Open No. 7-132329 described in the related art is used.
Since the incremental molding is performed basically using the plate material forming method and the forming device of the publication, the same components as those of the conventional forming device are denoted by the same reference numerals, and the description thereof will be omitted.

The configuration of the apparatus used in the molding method of this embodiment is as follows. As shown in FIG. 1, an outer peripheral frame 2 is attached to a peripheral portion of the base plate 1. At the center of the base plate 1, a male support 3 having a desired male molded shape (hereinafter referred to as "support 3") is placed. Further, a peripheral portion of the plate 4 is gripped by bolts or the like (not shown) on the upper surface of the outer peripheral frame 2 so that the plate 4 such as a steel plate abuts on the top of the support 3. The set of jigs in this state is fixed to the above-described NC vertical milling machine table 30 (see FIG. 14), and an incremental forming tool 5 (hereinafter, referred to as “tool 5”) having a spherical tip is used as a spindle of the NC vertical milling machine. The plate 4 is formed into a male shape by moving the plate 4 in accordance with processing data described later.

Next, the male mold forming method of this embodiment will be described. First, male machining contour data 6 of a desired male molding shape (that is, a planned molding shape) as shown in FIG. 2 is created. Next, as shown in FIG. 3, peripheral processing contour data 7 of a peripheral space region existing between the support 3 and the outer peripheral frame 2 is created at the same vertical interval as the male processing contour data 6. As shown in FIG. 3, the contour machining contour data 7 is contour data having a shape obtained by inverting a truncated square pyramid having the upper surface of the outer peripheral frame 2 as a bottom surface.

Further, the contour contour data 8 and the male contour contour data 6 are combined to form the contour contour data 8.
Create The molded contour data 8 is created by alternately combining contour data of one or more contour lines of the male machining contour data 6 and the peripheral machining contour data 7. Therefore, even if the rigidity of the plate material 4 is small, the male molding process and the peripheral molding process are alternately repeated, and the plate material 4 is pressed and molded into a male shape one by one or a plurality of layers. (So-called sagging) and deformation of the cross section can be suppressed.

Here, the contour line data shown in FIGS. 2 to 4 has a rough upper limit pitch, but in actual molding, the contour is finely planned according to the inclination of the slope of the planned molding shape. It is necessary to create contour data precisely according to the molding shape.

The contour data 8 formed as described above is stored in a machining data storage section (not shown) of the NC vertical milling machine.

Next, as shown in FIG. 5, an outer peripheral frame 2 is attached to the peripheral edge of the base plate 1, a support 3 is placed at the center of the base plate 1, and a plate 4 A set of jigs in a state where the plate material 4 is gripped on the upper surface of the outer peripheral frame 2 by the bolt 10 so that
The above-described NC vertical milling machine is fixed to the table 30 (see FIG. 14). Next, based on the above-mentioned forming contour data 8, the tool 5 is moved so as to alternately repeat the surrounding forming process and the male forming process, and the plate material 4 supported by the support 3 is layered one by one or in layers from above. It is pressed and processed into a male shape. Here, when press-molding one layer or two layers at a time, the tool 5 is always moved from the peripheral region of the outer peripheral frame 2 toward the center.

FIG. 6 shows a state where the above-mentioned molding method has been pressed and formed halfway. By moving the tool 5 in all the paths of the forming contour data 8 by the above forming method, a formed panel having a desired male shape (planned shape) can be obtained. FIG. 7 shows a state at the end of molding.

According to the molding method of the present embodiment, the male shape and the peripheral region shape are gradually combined while grasping the peripheral edge of the plate material 4 and supporting the plate material 4 by the desired male shape support 3. To form a male mold shape, it is possible to suppress the occurrence of molding defects such as sagging and deformation, and to perform sheet metal processing with high accuracy.

The male molding method of the present embodiment requires a dedicated support 3 corresponding to the planned molding shape, but has a large versatility by keeping the size of the outer peripheral frame 2 large. Can be made. Further, by exchanging only the support 3, the present invention can be applied to the molding of molded panels of various shapes, and the equipment cost for molding can be minimized.

Further, since the support 3 only has to have a function of simply supporting the plate member 4 when pressed, the material of the support 3 is not limited to metal, but may be any material as long as it can fulfill the above function. It is also possible to use a resin having the above hardness.

Embodiment 2 As shown in FIG. 8, the support member 3 used in the male mold forming method of the present embodiment includes a soft member 9 such as a rubber plate or clay on a part of the surface of the male mold-shaped support member 3. The plate member 4 is partially worked by pressing the incremental forming tool 5a onto the fitted portion without manufacturing a mold for partial processing.

Therefore, it is possible to precisely perform a partial decoration process such as a mark and an initial at a desired position without manufacturing a mold for partial processing.

[0033]

As described above, according to the male forming method for a plate material according to the present invention, the plate material is supported by the male-shaped support and the male shape and the peripheral region shape are gradually pressed together. Since the male shape is formed, it is possible to suppress a shift (so-called sagging) in the shape of the flat portion and a deformation of the cross section. Therefore, sheet metal processing can be performed with high accuracy.

Furthermore, even if the rigidity of the plate material is small, the male molding process and the peripheral molding process are alternately repeated, and the plate material is pressed into a male shape one by one or a plurality of layers. Can be suppressed.

Further, a flexible member is fitted into a part of the surface of the male-shaped support, and an incremental forming tool is pressed into the fitted portion to partially process the plate material, so that a mold for partial processing is manufactured. Without this, it is possible to perform the partial decoration processing precisely.

[Brief description of the drawings]

FIG. 1 is a diagram for explaining a mounting state of a jig used in a method of forming a plate material into a male mold according to the present invention.

FIG. 2 is a diagram for explaining male machining contour data used in the male molding method of a plate material according to the present invention.

FIG. 3 is a view illustrating contour contour data used in the male forming method of a plate material according to the present invention.

FIG. 4 is a diagram illustrating molding contour data used in the male molding method of a plate material according to the present invention.

FIG. 5 is a view for explaining a state before molding in which a set of jigs is fixed to a table of an NC vertical milling machine in a male molding method of a plate material according to the present invention.

FIG. 6 is a view for explaining a situation in which incremental molding is being performed by the male molding method for a plate material according to the present invention.

FIG. 7 is a view illustrating a final stage in which incremental molding is completed by the male molding method for a plate material according to the present invention and a molded panel having a planned shape is obtained.

FIG. 8 is a cross-sectional view illustrating a configuration of a support according to a second embodiment of the method of forming a male member of a plate material according to the present invention.

FIG. 9 is a schematic diagram illustrating a molding method for molding a plate material into a female mold described in Japanese Patent Application Laid-Open No. 48-48358.

FIG. 10 is a diagram illustrating a situation in which a male mold is formed by using the plate material forming method described in JP-A-48-48358.

FIG. 11 is a view for explaining a problem when molding into a male molding shape by an incremental molding method using an NC vertical milling machine.

FIG. 12 is a view for explaining a problem when molding into a male molding shape by an incremental molding method using an NC vertical milling machine.

FIG. 13 is a view for explaining a problem when molding into a male molding shape by an incremental molding method using an NC vertical milling machine.

FIG. 14 is a perspective view showing the structure of an NC vertical milling machine.

FIG. 15 is an exploded enlarged view of a jig mounted on a table of an NC vertical milling machine.

FIG. 16 is a diagram illustrating an incremental molding method using an NC vertical milling machine.

FIG. 17 is a diagram illustrating an incremental molding method using an NC vertical milling machine.

[Explanation of symbols]

Reference Signs List 1 Base plate, 2 outer frame, 3 male shape support (support), 4 plate material, 5,5a incremental forming tool (tool), 6 male processing contour data, 7 peripheral processing contour data, 8 molding contour data, 9 Flexible member, 10 volts.

──────────────────────────────────────────────────続 き Continuing on the front page (72) Fumiyoshi Matsuda 1 Toyota Town, Toyota City, Aichi Prefecture Toyota Motor Corporation (72) Inventor Tatsuya Nagata 5-14 Midorigaoka, Toyota City, Aichi Prefecture Inside Daitoyo Seiki Co., Ltd. 72) Inventor Kazuhiko Yamamoto 5-14 Midorigaoka, Toyota City, Aichi Prefecture Inside Daitoyo Seiki Co., Ltd. Inventor Fumio Nonoyama 41-41, Yokomichi, Chukumi, Nagakute-cho, Aichi-gun, Aichi Prefecture Inside Toyota Central Research Laboratory, Inc. (56) References JP-A-9-10854 (JP, A) JP-A-9-10855 (JP, A) JP-A-9-85355 (JP, A) JP-A-10-76321 (JP, A) JP-A-48-48358 (JP, A) JP-A-7-132329 (J , A) Tokuoyake Akira 47-18517 (JP, B1) (58 ) investigated the field (Int.Cl. ^7, DB name) B21D 22/00 - 26/14 B23Q 15/00

Claims (3)

(57) [Claims] 1. A male forming method for a plate material in which a plate material is gradually pressed and formed into a desired male shape, wherein a male-type support having a desired male shape is surrounded by an outer peripheral frame, A peripheral edge of a plate material is gripped on the upper surface of the outer peripheral frame so that the plate material contacts the apex of the male-shaped support, and a peripheral processing contour line of a peripheral space region existing between the male-shaped support and the outer peripheral frame The incremental forming tool is moved based on the forming contour data obtained by combining the data and the male processing contour data, and the plate material supported by the male shape support is gradually pressed and processed into a male shape. Characteristic male forming method of plate material. 2. The method for forming a plate material according to claim 1, wherein the forming contour data is created by alternately combining contour data of one or more contour lines of the male machining contour data and one or more contour machining contour data. It is the contour data obtained, moving the incremental forming tool based on the contour data, alternately repeat the male forming process and the peripheral forming process, go one by one or multiple layers of the plate material into a male shape. A male forming method for a plate material, which comprises performing press forming. 3. The method for forming a plate material according to claim 1, wherein a flexible member is fitted into a part of a surface portion of the male-shaped support, and the incremental molding is carried out on the fitted portion. A male forming method for a plate material, wherein a part of the plate material is processed by pressing a tool.