JP3628643B2

JP3628643B2 - Extruded profile for unfolding

Info

Publication number: JP3628643B2
Application number: JP2001344820A
Authority: JP
Inventors: 寛達神田; 泰彦北野; 秀雄矢崎
Original assignee: Honda Motor Co Ltd
Current assignee: Honda Motor Co Ltd
Priority date: 2001-11-09
Filing date: 2001-11-09
Publication date: 2005-03-16
Anticipated expiration: 2021-11-09
Also published as: JP2003145215A

Description

【０００１】
【発明の属する技術分野】
本発明は、押出し成形で製造する展開加工用押出し形材に係り、特に、展開加工用押出し形材を押出し成形した後、この形材を展開することで平坦なパネル部材に曲げ加工し、この平坦なパネル部材を所望の形状にプレス成形する展開加工用押出し形材に関する。
【０００２】
【従来の技術】
自動車のダッシュボードやフロアプレートを製造する方法として、平坦なパネル部材をプレス成形してダッシュボードやフロアプレートを一体に成形する方法がある。この方法を採用する際には、平坦なパネル部材を準備する必要があり、平坦なパネル部材の製造例が、特開平４−３４４８２０号公報「押出成形法による広幅形材の製造方法及び広幅形材」に開示されている。
この技術は螺旋状に巻回した状態で押出し形材（以下、「展開加工用押出材」として説明する）を押出し成形し、押出し成形後に、螺旋状の押出し材を平坦に展開して平坦なパネル部材を形成するものである。この技術内容を次図で詳しく説明する。
【０００３】
図１４は従来の展開加工用押出材を示す正面図である。押出型から展開加工用押出材１００を螺旋状に巻回した状態で押出し成形し、その展開加工用押出材１００を矢印の如く展開することにより平坦なパネル部材に加工する。この方法によれば、展開加工用押出材１００を螺旋状に巻回した状態で押出し成形することで、押出型のコンパクト化が可能になり、平坦はパネル部材を比較的簡単に得ることができる。
【０００４】
しかし、展開加工用押出材１００を螺旋状に巻回することで展開加工用押出材１００間の間隔Ｓは狭くなる。このため、押出型の押出口も、押出口間の間隔がＳと狭くなるので、押出型の強度を十分に確保することが難しい。
さらに、螺旋状に巻回した展開加工用押出材１００は両端１００ａ，１００ｂが自由端になっているので、押出型で押出し成形する際に、両端１００ａ，１００ｂが押出し成形し難くなり、押出型で展開加工用押出材１００をバランスよく押出し成形することは難しい。
【０００５】
この不具合を解消する方法として、例えば特開平９−２４８６２１号公報「展開加工用押出材」が知られている。この技術は展開加工用押出材を６角形に成形するとともに、展開加工用押出材の両端をイミテーションでつないで押出し成形するものである。この技術内容を次図で詳しく説明する。
【０００６】
図１５は従来の展開加工用押出材のもう一つの例を示す説明図である。
展開加工用押出材１１０を６角形状に形成し、かつた展開加工用押出材１１０の両端１１０ａ，１１０ｂをイミテーション１１１で連結し、この状態で押出型から押出し成形する。
そして、押出し成形後に展開加工用押出材１１０からイミテーション１１１を除去し、イミテーション１１１を除去した後、展開加工用押出材１１０を矢印の如く展開して平坦なパネル部材を得る。
【０００７】
押出型から押出し成形する際に、展開加工用押出材１１０の両端１１０ａ，１１０ｂをイミテーション１１１で連結することで、展開加工用押出材１１０の両端１１０ａ，１１０ｂを他の部位と同様に押出し成形することができる。よって、展開加工用押出材１１０の全体をある程度バランスよく押出し成形することができる。
【０００８】
【発明が解決しようとする課題】
しかし、展開加工用押出材１１０を６角形に形成したので、５個のコーナ部１１２ａ、１１２ｂ，１１２ｃ，１１２ｄ，１１２ｅ（６個目はイミテーション１１１）が存在する。５個のコーナ部１１２ａ〜１１２ｅは比較的大きく折曲げた部位であるため、５個のコーナ部１１２ａ〜１１２ｅを平坦に展開するためには大きく曲げ加工する必要がある。このため、５個のコーナ部１１２ａ〜１１２ｅは加工硬化する。
【０００９】
ところで、展開加工用押出材１１０を平坦に展開した後、例えば自動車用のダッシュボードとして使用するために、平坦に展開した展開加工用押出材をダッシュボードにプレス加工する場合がある。
この際に、展開加工用押出材１１０のうちの加工硬化した５個のコーナ部１１２ａ〜１１２ｅをプレス成形することになる。しかし、加工硬化した５個のコーナ部１１２ａ〜１１２ｅはその他の部位と比較してプレス成形し難い部位になっており、展開加工用押出材１１０を好適にプレス成形することはできない。
【００１０】
加えて、５個のコーナ部１１２ａ〜１１２ｅは比較的大きく折曲げた部位であるため、展開加工用押出材１１０を展開した際に、５個のコーナ部１１２ａ〜１１２ｅを平坦にすることができない虞れもある。５個のコーナ部１１２ａ〜１１２ｅを平坦にできない状態で、展開加工用押出材１１０をプレス成形すると、５個のコーナ部１１２ａ〜１１２ｅがプレス成形を良好におこなう妨げになり、展開加工用押出材１１０を好適にプレス成形することができない。
【００１１】
そこで、本発明の目的は、好適に押出し成形することができ、さらに展開した展開加工用押出し形材を好適にプレス成形することができる展開加工用押出し形材を提供することにある。
【００１２】
【課題を解決するための手段】
上記目的を達成するために請求項１は、フレーム部とこのフレーム部より延出した板状の屈曲部とを有する展開加工用押出し形材であって、フレーム部を屈曲部により囲繞するようにし、この屈曲部の先端を屈曲部に連結して環状としたことを特徴とする。
【００１３】
ここで、展開加工用押出し形材をバランスよく好適に押出し成形するためには、押出比を小さく押えることが好ましい。押出比は、押出し前のビレットの断面積をＳ１、押出し後の展開加工用押出し形材の断面積をＳ２とすると、押出比＝Ｓ１／Ｓ２と定義できる。よって、押出比を好ましい状態にするためには、展開加工用押出し形材の断面積をＳ２を大きく設定すればよい。
【００１４】
そこで、請求項１では、展開加工用押出し形材の形状を、フレーム部から板状の屈曲部を延出し、この延出した屈曲部でフレーム部を囲繞するようにした。これにより、環状の屈曲部内にフレーム部及び屈曲部の一部を設けることができるので、展開加工用押出し形材の断面積を、従来技術で説明した６角形の展開加工用押出材の断面積より大きくすることができる。
よって、押出比を好ましい状態に設定して展開加工用押出し形材をバランスよく押出し成形することができる。
【００１５】
加えて、屈曲部の先端を屈曲部に連結して屈曲部を環状に形成した。このため、屈曲部の先端を押出型から良好に押出し成形することができる。
また、屈曲部を環状に形成したので、屈曲部を展開して平坦にする際に、屈曲部を大きく曲げ加工する必要がない。このため、展開した後の屈曲部に加工硬化が発生することを防ぐことができる。
【００１６】
請求項２は、屈曲部の先端を屈曲部より薄い仮つなぎ材により屈曲部に連結したことを特徴とする。
【００１７】
屈曲部の先端を屈曲部より薄い仮つなぎ材で屈曲部に連結したので、屈曲部の先端と屈曲部との連結を比較的簡単に解除することができる。
【００１８】
請求項３は、フレーム部の外周から放射状に複数の仮ステー材を延ばし、これの仮ステー材の先端を前記屈曲部の内周に係合するとともに、前記仮ステー材の両端を仮ステー材より薄くしたことを特徴とする。
【００１９】
フレーム部の外周から放射状に複数の仮ステー材を延ばし、仮ステー材の先端を屈曲部の内周に係合することで展開加工用押出し形材の強度を高めることができる。このため、例えば展開加工用押出し形材のハンドリング性がよくなり、後工程への搬送を簡単におこなうことができるので、生産性を高めることが可能になる。
また、仮ステー材の両端を仮ステー材より薄くすることで、展開加工用押出し形材から仮ステー材を比較的簡単に解除することができる。
【００２０】
【発明の実施の形態】
本発明の実施の形態を添付図に基づいて以下に説明する。なお、図面は符号の向きに見るものとする。
図１は本発明に係る展開加工用押出し形材を展開した後プレス成形して得た自動車用ダッシュボードの斜視図を示す。
自動車用ダッシュボード１０は、車体の左サイド部材から右サイド部材に渡って設けることにより、エンジンルームと運転席とを仕切るボードである。この自動車用ダッシュボード１０は、上端にクロスメンバー１１を備え、このクロスメンバー１１の下端にボード１２を一体形成したものである。
【００２１】
クロスメンバー１１は、略５角形の中空筒体であり、ダッシュボード１０の補強を兼ねる部材である。
ボード１２は、平坦なパネル部材をプレス成形することにより所望部位に折曲部１３ａ，１３ｂ，１３ｃ，１３ｄを成形し、その後トリミング処理で周縁１４を切断し、さらにピアス処理で貫通孔１５ａ，１５ｂなどを形成した部材である。
以下、この自動車用ダッシュボード１０を製造するための展開加工用押出し形材について説明する。
【００２２】
次に、図２に基づいて展開加工用押出し形材を押出し成形する例を説明する。
図２（ａ），（ｂ）は本発明に係る展開加工用押出し形材の押出し成形する例を説明した図である。
（ａ）において、押出型１８の押出し口１８ａから展開加工用押出し形材２０を矢印▲１▼の如く押出し成形する。
（ｂ）において、押出し成形工程が完了することにより、展開加工用押出し形材２０を得る。この展開加工用押出し形材２０について次図で詳しく説明する。
【００２３】
図３は本発明に係る展開加工用押出し形材の正面図である。
展開加工用押出し形材２０は、フレーム部２１とこのフレーム部２１より延出した板状の屈曲部２３とを有し、フレーム部２１を屈曲部２３により囲繞するようにし、この屈曲部２３の先端２３ａを屈曲部２３より薄い仮つなぎ材２４により屈曲部２３の連結部位２３ｂに連結して円環状（環状）とし、フレーム部２１の外周から放射状に第１〜第３の仮ステー材（複数の仮ステー材）２６，２７，２８を延ばし、第１〜第３の仮ステー材２６，２７，２８の先端部２６ａ，２７ａ，２８ａを屈曲部２３の内周２３ｄに係合するとともに、第１〜第３の仮ステー材２６，２７，２８の先端部２６ａ，２７ａ，２８ａ及び基端部２６ｂ，２７ｂ，２８ｂ（両端）を第１〜第３の仮ステー材２６，２７，２８の中央部２６ｃ，２７ｃ，２８ｃより薄くしたものである。
【００２４】
フレーム部２１は、第１〜第５辺２１ａ，２１ｂ，２１ｃ，２１ｄ，２１ｅで略５角形の中空体に形成した中空筒体であり、この中空筒体の第３辺２１ｃの右寄り部位から下方に向けて板状の屈曲部２３が延出する部材である。
屈曲部２３は、フレーム部２１の第３辺２１ｃの右寄り部位から下方に向けて延出し、湾曲開始部位２３ｃで左廻りに湾曲し、連結部位２３ｂでフレーム部２１を中心とする半径Ｒの円弧状に湾曲し、先端２３ａを仮つなぎ材２４で連結部位２３ｂに連結した部材である。
屈曲部２３の板厚はｔ１、仮つなぎ材２４の板厚はｔ２である。
【００２５】
ここで、屈曲部の板厚ｔ１と、仮つなぎ材２４の板厚ｔ２とはの関係は以下の通りである。
ｔ２≦（１／３）×ｔ１
仮つなぎ材２４の板厚ｔ２が（１／３）×ｔ１を越えると、仮つなぎ材２４の除去に手間がかかりすぎて、仮つなぎ材２４の除去時間が長くなり、生産性を高める妨げになる。
そこで、仮つなぎ材２４の板厚ｔ２を（１／３）×ｔ１以下に設定することで、仮つなぎ材２４の除去を短い時間でおこなうようにした。
【００２６】
第１仮ステー材２６は、フレーム部２１の第１辺２１ａの外周から上方に延ばし、先端部２６ａを屈曲部２３の内周２３ｄに連結するとともに、この先端部２６ａ及び基端部２６ｂ（両端）の板厚ｔ４を中央部２６ｃの板厚ｔ３より薄くしたものである。
第２仮ステー材２７は、フレーム部２１の第１辺２１ａの外周から右側方に延ばし、先端部２７ａを屈曲部２３の内周２３ｄに連結するとともに、この先端部２７ａ及び基端部２７ｂ（両端）の板厚ｔ４を中央部２７ｃの板厚ｔ３より薄くしたものである。
【００２７】
第３仮ステー材２８は、フレーム部２１の第４辺２１ｄの外周から左側方に延ばし、先端部２８ａを屈曲部２３の内周２３ｄに連結するとともに、この先端部２８ａ及び基端部２８ｂ（両端）の板厚ｔ４を中央部２８ｃの板厚ｔ３より薄くしたものである。
【００２８】
ここで、第１〜第３の仮ステー材２６，２７，２８の中央部２６ｃ，２７ｃ，２８ｃの板厚ｔ３と、先端部２６ａ，２７ａ，２８ａ及び基端部２６ｂ，２７ｂ，２８ｂの板厚ｔ４との関係は以下の通りである。
ｔ４≦（１／３）×ｔ３
【００２９】
第１〜第３の仮ステー材２４の２６，２７，２８の先端部２６ａ，２７ａ，２８ａ及び基端部２６ｂ，２７ｂ，２８ｂの板厚ｔ４が（１／３）×ｔ３を越えると、第１〜第３の仮ステー材２４の２６，２７，２８の除去に手間がかかりすぎて、第１〜第３の仮ステー材２４の２６，２７，２８の除去時間が長くなり、生産性を高める妨げになる。
そこで、先端部２６ａ，２７ａ，２８ａ及び基端部２６ｂ，２７ｂ，２８ｂの板厚ｔ４を（１／３）×ｔ３以下に設定することで、第１〜第３の仮ステー材２４の２６，２７，２８の除去を短い時間でおこなうようにした。
【００３０】
以上説明したように、展開加工用押出し形材２０の形状を、フレーム部２１から板状の屈曲部２３を延出し、この延出した屈曲部２３でフレーム部２１を囲繞するようにした。
これにより、円環状の屈曲部２３内にフレーム部２１及び屈曲部の一部（すなわち、フレーム部２１の第３辺２１ｃから連結部位２３ｂまでの延出部位２３ｇ）を設けることができるので、展開加工用押出し形材２０の断面積を、従来技術で説明した６角形の展開加工用押出材の断面積より大きくすることができる。
よって、押出比を好ましい状態に設定して展開加工用押出し形材２０をバランスよく押出し成形することができる。
【００３１】
さらに、屈曲部２３の先端２３ａを屈曲部２３より薄い仮つなぎ材２４で連結部位２３ｂに連結することで、屈曲部２３を円環状（環状）に形成した。よって、図２（ａ）に示すように屈曲部２３の先端２３ａを押出型１８から良好に押出し成形することができる。
【００３２】
加えて、フレーム部２１の外周から放射状に第１〜第３の仮ステー材２４の２６，２７，２８を延ばし、第１〜第３の仮ステー材２４の２６，２７，２８の先端２６ａ，２７ａ，２８ａを屈曲部２３の内周２３ｄに連結することで展開加工用押出し形材２０の強度をより一層高めることができる。
このため、例えば展開加工用押出し形材２０のハンドリング性がよくなり、後工程への搬送を簡単におこなうことができる。
【００３３】
次に、展開加工用押出し形材２０を展開する方法を図４〜図７に基づいて説明する。
図４は本発明に係る展開加工用押出し形材を展開する方法を示す第１説明図である。
図２（ｂ）において展開加工用押出し形材２０を押出し成形した後、この展開加工用押出し形材２０の第３ステー材２８の基端部２８ｂをのこ刃３０を使用して切断する。のこ刃３０の仕様としては、一例として回転数ｎを３０００ｒｐｍ以上に設定し、送り速度ｖを０．５ｍ／ｓｅｃに設定する。
【００３４】
次に、のこ刃３０を使用して第３ステー材２８の先端部２８ａ（図３に示す）を切断することにより、第３ステー材２８を展開加工用押出し形材２０から除去する。
以下、同様に、第１〜第２のステー材２６，２７を除去し、さらに（図３に示す）屈曲部２３の先端２３ａに備えた仮つなぎ材２４をのこ刃３０で切断することにより、屈曲部２３の先端２３ａを屈曲部２３の連結部位２３ｂから切離す。
【００３５】
図３で説明したように、展開加工用押出し形材２０の屈曲部２３の先端２３ａを屈曲部２３より薄い仮つなぎ材２４で連結部位２３ｂに連結したので、屈曲部２３の先端２３ａと連結部位２３ｂとの連結を簡単に解除することができる。
加えて、第１〜第３の仮ステー材２６，２７，２８の先端部２６ａ，２７ａ，２８ａ及び基端部２６ｂ，２７ｂ，２８ｂを中央部２６ｃ，２７ｃ，２８ｃより薄くすることで、展開加工用押出し形材２０から第１〜第３の仮ステー材２６，２７，２８を簡単に解除することができる。
【００３６】
なお、第１実施形態では、展開加工用押出し形材２０を押出し成形した後、第１〜第３のステー部２６〜２８や仮つなぎ材２４をのこ刃３０で切断する例について説明したが、これに限らないで、シャーリングなどの機械加工やエッチングなどのケミカル加工で第１〜第３のステー部２６〜２８や仮つなぎ材２４を除去することも可能である。
ケミカル加工に使用する水溶液として、例えば強塩基性水溶液（水酸化ナトリウム、濃度３０〜７０％、温度７０〜９０℃）が該当する。
【００３７】
図５は本発明に係る展開加工用押出し形材を展開する方法を示す第２説明図である。
展開加工用押出し形材２０からフレーム部２１と屈曲部２３との間に放射状に備えた第１〜第３の仮ステー材２６，２７，２８をそれぞれ矢印▲２▼、▲３▼、▲４▼の如く除去し、屈曲部２３の先端２３ａから仮つなぎ材２４を矢印▲５▼の如く除去した状態を示す。
【００３８】
図６は本発明に係る展開加工用押出し形材を展開する方法を示す第３説明図である。
屈曲部２３を矢印▲６▼の如く展開することにより、屈曲部２３の湾曲形状を平坦な形状に加工する。
ここで、屈曲部２３は半径Ｒで湾曲形状に曲げた形状なので、屈曲部２３を展開することにより、簡単に平坦な形状に加工することができる。
また、上述したように、屈曲部２３の先端２３ａと連結部位２３ｂとの連結を簡単に解除することができ、加えて、展開加工用押出し形材２０から第１〜第３の仮ステー材２６，２７，２８を簡単に解除することができるので、展開加工用押出し形材２０の屈曲部２３を手間をかけないで簡単に展開することができる。
【００３９】
図７は本発明に係る展開加工用押出し形材を展開する方法を示す第４説明図である。
屈曲部２３を平坦に展開してパネル部材３２とし、このパネル部材３２をフレーム部２１の第３辺２１ｃから下方に延出する。
屈曲部２３を円環状に形成したので、屈曲部２３を展開する際に、屈曲部２３を必要以上に曲げ加工することがない。よって、屈曲部２３に加工硬化が発生することを防ぐことができる。このため、展開加工用押出し形材２０を好適に展開することができるので、展開した後のパネル部材３２を所望の形状に良好にプレス成形することができる。
【００４０】
次に、パネル部材３２をプレス成形してダッシュボード１０を製造する例を図８に基づいて説明する。
図８は本発明に係る展開加工用押出し形材からダッシュボードをプレス成形する例を説明した図である。
平坦なパネル部材３２をプレス成形することにより所望部位に折曲加工部１３ａ〜１３ｄを成形し、その後トリミング処理で周縁１４を切断し、さらにピアス処理で貫通孔１５ａ，１５ｂなどを形成することでボード１２を得る。
また、フレーム部２１は車体の左側部から右側部に掛け渡すクロスメンバー１１としてして使用する。すなわち、クロスメンバー１１及びボード１２で自動車用ダッシュボード１０を構成する。
なお、クロスメンバー１１はフレーム部２１を曲げ形成してもよく、曲げ形成しない状態で使用してもよい。
【００４１】
次に、屈曲部の半径Ｒと屈曲部２３の板厚ｔ１との関係を図９に基づいて説明する。
図９（ａ）〜（ｃ）は本発明に係る展開加工用押出し形材を展開する際に発生する歪みについて説明した図であり、（ｃ）は（ｂ）のｃ部を拡大した状態を示す。
（ａ）は、屈曲部２３の板厚ｔ１、屈曲部２３の半径をＲとして、屈曲部２３をフレーム部２１（図３に示す）を中心にして円弧状に成形した状態を示す。
屈曲部２３の半径をＲとすると、屈曲部２３の外周２３ｅの長さＬ１、屈曲部２３の中央２３ｆの長さＬ２、屈曲部２３の内周２３ｄの長さＬ３は以下の通りである。
Ｌ１＝２π×（Ｒ＋ｔ１）
Ｌ２＝２π×［Ｒ＋（１／２）×ｔ１］
Ｌ３＝２π×Ｒ
（ｂ）は、円弧状の屈曲部２３を展開して平坦に延ばしてパネル部材３２を加工した状態を示す。
【００４２】
（ｃ）は、屈曲部２３を円弧状から平坦状に展開してパネル部材３２を加工した際に、パネル部材３２の外周２３ｅ及び内周２３ｄに発生するそれぞれの歪みε１及び歪みε２を示す。
パネル部材３２の外周２３ｅは、Ｌ１−Ｌ２だけ収縮する。
Ｌ１−Ｌ２＝２π×（Ｒ＋ｔ１）−２π×［Ｒ＋（１／２）×ｔ１］
よって、パネル部材３２の外周２３ｅにはε１の歪みが発生する。
ε１＝（Ｌ１−Ｌ２）／Ｌ１＝ｔ１／２（Ｒ＋ｔ）
【００４３】
一方、パネル部材２３の内周２３ｄは、Ｌ２−Ｌ３だけ収縮する。
Ｌ２−Ｌ３＝π×［Ｒ＋（１／２）×ｔ１］−π×Ｒ
よって、パネル部材２３の内周２３ｄにはε２の歪みが発生する。
ε２＝（Ｌ２−Ｌ３）／Ｌ３＝ｔ１／２Ｒ
歪みε１、歪みε２には、ε１＜ε２の関係が成立するので、以下、屈曲部２３を平坦に展開してパネル部材３２としたときの展開歪みをε２と仮定する。
【００４４】
ここで、屈曲部２３の許容伸びをＥｌとし、屈曲部２３を平坦に展開してパネル部材３２とした後に、パネル部材３２をプレス成形する際のプレス歪みをγとすると、許容伸びＥｌ、展開歪みε２及びプレス歪みγに次の関係が成立する。
Ｅｌ＞ε２＋γ
従って、展開歪みε２が、（１）式の関係を満たせば、屈曲部２３を展開した後、展開したパネル部材３２をプレス成形することが可能になる。
ε２＜Ｅｌ−γ・・・（１）
【００４５】
一方、ε２は、上述したようにε２＝ｔ１／２Ｒの関係が成立しているので、（２）式が成立し、
ε２＝ｔ／２Ｒ＜Ｅｌ−γ・・・（２）
（２）式から、（３）式が成立する。
Ｒ＞ｔ１／２（Ｅｌ−γ）・・・（３）
従って、（３）式を満たすように、屈曲部２３の半径Ｒと板厚ｔ１を決定すれば、屈曲部２３を平坦に展開してパネル部材３２とした後のプレス成形が可能になる。
【００４６】
具体例として、屈曲部２３に許容伸びＥｌが２７％の材料を使用し、プレス歪みγが２５％のプレス成形をおこなう場合には、（３）式から（４）式が成立し、
Ｒ＞ｔ１／２（０．２７−０．２５）
Ｒ＞２５×ｔ１・・・（４）
（４）式から、屈曲部２３の板厚ｔ１を１．０ｍｍとした場合には、屈曲部２３の半径Ｒを２６ｍｍ以上に設定することで、好適なプレス成形をおこなうことができることがわかる。
【００４７】
次に、第２〜第５実施形態を図１０〜図１３に基づいて説明する。なお、第２〜第５実施形態において第１実施形態と同一部材については同じ符号を付して説明を省略する。
図１０は本発明に係る展開加工用押出し形材（第２実施形態）の正面図である。
展開加工用押出し形材４０は、フレーム部４１を中実のロッドとし、屈曲部２３の先端２３ａを屈曲部２３の連結部位２３ｂに連結して円環状としたもので、その他の構成は第１実施形態の展開加工用押出し形材２０と同じ構成である。
フレーム部４１を中実にすることで、フレーム部４１を細く形成した場合でも、比較的容易に押出し成形することが可能になり、展開加工用押出し形材４０の適用範囲を拡大することができる。
また、屈曲部２３の先端２３ａを屈曲部２３の連結部位２３ｂに直接連結するという構成にすることで、第１実施形態と第２実施形態の連結状態を展開加工用押出し形材４０の適用範囲に合せて適宜選択することが可能になる。
【００４８】
図１１は本発明に係る展開加工用押出し形材（第３実施形態）の正面図である。
展開加工用押出し形材４５は、フレーム部４６を略コ字形に形成したもので、その他の構成は第１実施形態の展開加工用押出し形材２０と同じ構成である。
フレーム部４６を略コ字形とすることで、フレーム部の形状を用途に合せて適宜選択することが可能になり、展開加工用押出し形材４５の適用範囲を拡大することができる。
【００４９】
図１２は本発明に係る展開加工用押出し形材（第４実施形態）の正面図である。
展開加工用押出し形材５０は、フレーム部２１とこのフレーム部２１より延出した板状の屈曲部５３とを有し、フレーム部２１を屈曲部５３により囲繞するようにし、この屈曲部５３の先端５３ａを屈曲部５３より薄い仮つなぎ材５４により屈曲部５３の連結部位５３ｂに連結して波形の環状（環状）とし、フレーム部２１の外周から放射状に４本の仮ステー材（複数の仮ステー材）５６・・・を延ばし、それぞれの仮ステー材５６・・・の先端部５６ａ・・・を屈曲部５３の内周５３ｄに係合するとともに、それぞれの仮ステー材５６・・・の先端部５６ａ・・・及び基端部５６ｂ・・・（両端）の肉厚ｔ４を仮ステー材５６・・・の中央部５６ｃ・・・の肉厚ｔ３より薄くしたものである。
【００５０】
ここで、屈曲部５３の肉厚をｔ１、仮つなぎ材５４の肉厚をｔ２とすると、肉厚ｔ１と肉厚ｔ２との関係は第１実施形態と同様に、ｔ２≦（１／３）×ｔ１が成立する。
また、肉厚ｔ３と肉厚ｔ４との関係は第１実施形態と同様に、ｔ４≦（１／３）×ｔ３が成立する。
これにより、第１実施形態と同様に、仮つなぎ材５４や仮ステー材５６・・・のの除去を短い時間でおこなうことができる。
【００５１】
加えて、屈曲部５３を波形状に形成した際のそれぞれの曲げ部位の半径をＲ、許容伸びＥｌ及びプレス歪みγとすると、第１実施形態と同様に（３）式、すなわち、Ｒ＞ｔ１／２（Ｅｌ−γ）の関係が成立する。
従って、（３）式を満たすように、屈曲部２３の半径Ｒと板厚ｔ１を決定すれば、屈曲部５３を平坦に展開してパネル部材３２とした後のプレス成形が可能になる。
【００５２】
以上説明したように、展開加工用押出し形材５０は、屈曲部５３を波形状に形成した点で、第１実施形態の展開加工用押出し形材２０と異なるだけで、その他の構成は展開加工用押出し形材２０と同様である。
展開加工用押出し形材５０によれば、屈曲部５３を波形状に形成することで屈曲部５３を展開したパネル部材３２（図７に示す）を長く確保することができる。よって、パネル部材３２の長さを用途に合せて適宜選択することが可能になり、展開加工用押出し形材の適用範囲を拡大することができる。
【００５３】
図１３は本発明に係る展開加工用押出し形材（第５実施形態）の正面図である。
展開加工用押出し形材６０は、第４実施形態の展開加工用押出し形材５０から４本の仮ステー材５６・・・を取除いた点で、第４実施形態の展開加工用押出し形材５０と異なるだけで、その他の構成は展開加工用押出し形材５０と同じである。
【００５４】
フレーム部２１から連結部位５３ｂまでの間に第１実施形態の延出部位２３ｇに相当する延出部位５３ｇを設けることで、展開加工用押出し形材６０の断面積を、従来技術で説明した６角形の展開加工用押出材の断面積より大きくすることができる。
よって、押出比を好ましい状態に設定して展開加工用押出し形材６０をバランスよく押出し成形することができる。
加えて、押出成形の際に４本の仮ステー材５６・・・を不要とすることで、展開の際に仮ステー材５６・・・を除去する必要がないので、展開加工用押出し形材６０の展開加工をより一層容易にすることができる。
【００５５】
なお、前記実施形態１〜３では、仮ステー材として第１〜第３の仮ステー材２６〜２８を使用した例について説明したが、仮ステー材の本数は展開加工用押出し形材の形状に合せて適宜選択することができる。
また、第１〜第３の仮ステー材２６〜２８を備えない状態で展開加工用押出し形材を押出し成形することも可能である。円環状の屈曲部２３内にフレーム部２１及び屈曲部の一部（延出部位２３ｇ）を設けているので、展開加工用押出し形材の断面積を、従来技術で説明した６角形の展開加工用押出材の断面積より大きくすることができる。よって、第１〜第３の仮ステー材２６〜２８がなくても、押出比を好ましい状態に設定して展開加工用押出し形材２０をバランスよく押出し成形することができる。
【００５６】
また、前記実施形態では、展開加工用押出し形材２０，４０，４５，５０，６０を自動車用ダッシュドード１０にプレス成形する例について説明したが、これに限らないで、展開加工用押出し形材２０，４０，４５，５０，６０を自動車用フロアなどのその他の部材にプレス成形することも可能である。
【００５７】
【発明の効果】
本発明は上記構成により次の効果を発揮する。
請求項１は、展開加工用押出し形材の形状を、フレーム部から板状の屈曲部を延出し、この延出した屈曲部でフレーム部を囲繞するようにした。これにより、環状の屈曲部内にフレーム部及び屈曲部の一部を設けることができるので、展開加工用押出し形材の断面積を、従来技術で説明した６角形の展開加工用押出材の断面積より大きくすることができる。
このため、押出比を好ましい状態に設定することば可能になり、展開加工用押出し形材をバランスよく押出し成形することができる。
【００５８】
加えて、屈曲部の先端を屈曲部に連結して屈曲部を環状に形成した。このため、屈曲部の先端を押出型から良好に押出し成形することができる。このように、展開加工用押出し形材の中央にフレーム部を配置する上に、さらに屈曲部の先端を屈曲部に連結することで、展開加工用押出し形材をより一層バランスよく押出し成形することができる。
【００５９】
また、屈曲部を環状に形成したので、屈曲部を展開して平坦にする際に、屈曲部を大きく曲げ加工する必要がない。このため、展開した後の屈曲部に加工硬化が発生することを防ぐことができる。
このため、展開加工用押出し形材を好適に展開することができるので、展開加工用押出し形材を展開した後、展開したパネル部材を所望の形状に良好にプレス成形することができる。
【００６０】
請求項２は、屈曲部の先端を屈曲部より薄い仮つなぎ材で屈曲部に連結したので、屈曲部の先端と屈曲部との連結を比較的簡単に解除することができる。このため、展開加工用押出し形材を簡単に展開することができるので、生産性を高めることができる。
【００６１】
請求項３は、フレーム部の外周から放射状に複数の仮ステー材を延ばし、仮ステー材の先端を屈曲部の内周に係合することで展開加工用押出し形材の強度を高めることができる。このため、例えば展開加工用押出し形材のハンドリング性がよくなり、後工程への搬送を簡単におこなうことができるので、生産性を高めることが可能になる。
さらに、仮ステー材の両端を仮ステー材より薄くすることで、展開加工用押出し形材から仮ステー材を比較的簡単に解除することができる。このため、展開加工用押出し形材を手間をかけないで簡単に展開することができる。
【図面の簡単な説明】
【図１】本発明に係る展開加工用押出し形材を展開した後プレス成形して得た自動車用ダッシュボードの斜視図
【図２】本発明に係る展開加工用押出し形材の押出し成形する例を説明した図
【図３】本発明に係る展開加工用押出し形材の正面図
【図４】本発明に係る展開加工用押出し形材を展開する方法を示す第１説明図
【図５】本発明に係る展開加工用押出し形材を展開する方法を示す第２説明図
【図６】本発明に係る展開加工用押出し形材を展開する方法を示す第３説明図
【図７】本発明に係る展開加工用押出し形材を展開する方法を示す第４説明図
【図８】本発明に係る展開加工用押出し形材からダッシュボードをプレス成形する例を説明した図
【図９】本発明に係る展開加工用押出し形材を展開する際に発生する歪みについて説明した図
【図１０】本発明に係る展開加工用押出し形材（第２実施形態）の正面図
【図１１】本発明に係る展開加工用押出し形材（第３実施形態）の正面図
【図１２】本発明に係る展開加工用押出し形材（第４実施形態）の正面図
【図１３】本発明に係る展開加工用押出し形材（第５実施形態）の正面図
【図１４】従来の展開加工用押出材を示す正面図
【図１５】従来の展開加工用押出材のもう一つの例を示す説明図
【符号の説明】
２０，４０，４５，５０，６０…展開加工用押出し形材、２１，４１，４６…フレーム部、２３，５３…屈曲部、２３ａ，５３ａ…屈曲部の先端、２３ｂ，５３ｂ…屈曲部の連結部位、２４，５４…仮つなぎ材、２６…第１仮ステー材（仮ステー材）、２６ａ…第１仮ステー材の先端部（先端部）、２６ｂ…第１仮ステー材の基端部（基端部）、２７…第２仮ステー材（仮ステー材）、２７ａ…第２仮ステー材の先端部（先端部）、２７ｂ…第２仮ステー材の基端部（基端部）、２８…第３仮ステー材（仮ステー材）、２８ａ…第３仮ステー材の先端部（先端部）、２８ｂ…第３仮ステー材の基端部（基端部）、２３ｄ，５３ｄ…屈曲部２３の内周、２６ｃ，２７ｃ，２８ｃ…第１〜第３の仮ステー材の中央部、５６…仮ステー材、５６ａ…仮ステー材の先端部（先端部）、５６ｂ…仮ステー材の基端部（基端部）。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an extruded shape for unfolding produced by extrusion molding, and in particular, after extruding an extruded shape for unfolding, the shape is expanded to be bent into a flat panel member. The present invention relates to an extruded shape material for unfolding that press-molds a flat panel member into a desired shape.
[0002]
[Prior art]
As a method for manufacturing a dashboard or a floor plate of an automobile, there is a method in which a flat panel member is press-molded to integrally mold the dashboard or the floor plate. When adopting this method, it is necessary to prepare a flat panel member, and an example of manufacturing a flat panel member is disclosed in Japanese Patent Application Laid-Open No. 4-344820 “Method for producing wide shape material by extrusion method and wide shape. Material ".
In this technique, an extruded shape member (hereinafter referred to as “extrusion material for unfolding process”) is extruded in a spirally wound state, and after the extrusion molding, the spiral extruded material is flatly developed to be flat. A panel member is formed. The technical contents will be described in detail in the following figure.
[0003]
FIG. 14 is a front view showing a conventional extruding material for development processing. Extrusion material 100 is extruded from an extrusion die while being spirally wound, and the flat material is processed into a flat panel member by unfolding the expansion material 100 as shown by an arrow. According to this method, it is possible to make the extrusion die compact by extruding the unfolded extruding material 100 in a spirally wound state, and a flat panel member can be obtained relatively easily. .
[0004]
However, the space | interval S between the extrusion material 100 for expansion | deployment processing becomes narrow by winding the extrusion material 100 for expansion | deployment processing spirally. For this reason, since the space | interval between extrusion ports also becomes narrow with the extrusion port of an extrusion die, it is difficult to ensure sufficient intensity | strength of an extrusion die.
Further, since the both ends 100a and 100b are free ends, the unfolded extrusion processing material 100 wound in a spiral shape is difficult to extrude both ends 100a and 100b when extruding with an extrusion die. Thus, it is difficult to extrude the extruding material 100 for development processing with a good balance.
[0005]
As a method for solving this problem, for example, Japanese Patent Application Laid-Open No. 9-248621 “Extruded Material for Development Processing” is known. In this technique, the unfolded extrusion material is formed into a hexagon, and the two ends of the unfolded extrusion material are connected by imitation and extruded. The technical contents will be described in detail in the following figure.
[0006]
FIG. 15 is an explanatory view showing another example of a conventional unfolded extrusion material.
The unfolding extrusion material 110 is formed in a hexagonal shape, and both ends 110a and 110b of the unfolding extrusion material 110 are connected by imitation 111, and in this state, extrusion is performed from the extrusion die.
Then, after the extrusion molding, the imitation 111 is removed from the unfolding material 110, and after removing the imitation 111, the unfolding material 110 is unfolded as shown by an arrow to obtain a flat panel member.
[0007]
When extruding from the extrusion mold, both ends 110a and 110b of the unfolding extrusion material 110 are connected by imitation 111 to extrude both ends 110a and 110b of the unfolding extrusion material 110 in the same manner as other parts. be able to. Therefore, the entire extrusion processing material 110 can be extruded with a certain degree of balance.
[0008]
[Problems to be solved by the invention]
However, since the unfolded extruding material 110 is formed in a hexagon, there are five corner portions 112a, 112b, 112c, 112d, and 112e (the sixth is an imitation 111). Since the five corner portions 112a to 112e are portions that are relatively bent, it is necessary to perform a large bending process in order to flatten the five corner portions 112a to 112e. Therefore, the five corner portions 112a to 112e are work hardened.
[0009]
By the way, after the unfolding material 110 for flattening processing is flattened, the flattening material for flattening processing may be pressed into a dashboard for use as, for example, a dashboard for an automobile.
At this time, the five work-cured corner portions 112a to 112e in the unfolded extruding material 110 are press-molded. However, the five corner portions 112a to 112e that are work-hardened are portions that are difficult to press-mold as compared with other portions, and the unfolded extrusion material 110 cannot be suitably press-formed.
[0010]
In addition, since the five corner portions 112a to 112e are relatively large bent portions, the five corner portions 112a to 112e cannot be flattened when the unfolding material 110 is expanded. There is also a fear. When the unfolded extrusion material 110 is press-molded in a state where the five corner portions 112a to 112e cannot be flattened, the five corner portions 112a to 112e are obstructed to perform press molding well, and the unfolded material for unfolding processing 110 cannot be suitably press molded.
[0011]
Accordingly, an object of the present invention is to provide an unfolded extruded shape material that can be suitably extruded, and further capable of suitably press-molding the unfolded expanded shape material.
[0012]
[Means for Solving the Problems]
In order to achieve the above object, claim 1 is an unfolded extruded shape member having a frame portion and a plate-like bent portion extending from the frame portion, wherein the frame portion is surrounded by the bent portion. The tip of the bent portion is connected to the bent portion to form an annular shape.
[0013]
Here, it is preferable to keep the extrusion ratio small in order to suitably extrude the extruded shape material for development in a balanced manner. The extrusion ratio can be defined as extrusion ratio = S1 / S2, where S1 is the cross-sectional area of the billet before extrusion and S2 is the cross-sectional area of the extruded shape material for extrusion after extrusion. Therefore, in order to obtain a preferable extrusion ratio, the cross sectional area of the extruded shape material for development may be set to be large.
[0014]
Accordingly, in claim 1, the shape of the unfolded extruded shape material is such that a plate-like bent portion is extended from the frame portion, and the frame portion is surrounded by the extended bent portion. Thus, since the frame portion and a part of the bent portion can be provided in the annular bent portion, the cross-sectional area of the extruded shape material for development processing is the cross-sectional area of the extruded shape material for hexagonal expansion processing described in the prior art. Can be larger.
Therefore, the extrusion ratio can be extruded in a well-balanced manner by setting the extrusion ratio to a preferable state.
[0015]
In addition, the tip of the bent portion is connected to the bent portion to form the bent portion in an annular shape. For this reason, the front-end | tip of a bending part can be favorably extruded from an extrusion die.
Further, since the bent portion is formed in an annular shape, it is not necessary to bend the bent portion greatly when the bent portion is expanded and flattened. For this reason, it can prevent that work hardening generate | occur | produces in the bending part after expand | deploying.
[0016]
According to a second aspect of the present invention, the tip of the bent portion is connected to the bent portion by a temporary connecting material thinner than the bent portion.
[0017]
Since the tip of the bent portion is connected to the bent portion with a temporary connecting material thinner than the bent portion, the connection between the tip of the bent portion and the bent portion can be released relatively easily.
[0018]
According to a third aspect of the present invention, a plurality of temporary stay members are radially extended from the outer periphery of the frame portion, the tips of the temporary stay members are engaged with the inner periphery of the bent portion, and both ends of the temporary stay member are connected to the temporary stay members. It is characterized by being thinner.
[0019]
By extending a plurality of temporary stay members radially from the outer periphery of the frame portion and engaging the tips of the temporary stay members with the inner periphery of the bent portion, the strength of the extruded shape member for development can be increased. For this reason, for example, the handleability of the extruded shape material for development processing is improved, and the conveyance to the subsequent process can be easily performed, so that the productivity can be increased.
Further, by making the both ends of the temporary stay material thinner than the temporary stay material, the temporary stay material can be released relatively easily from the extruded shape for development.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.
FIG. 1 is a perspective view of a dashboard for an automobile obtained by developing and then press-molding a developed extruded shape member according to the present invention.
The automobile dashboard 10 is a board that partitions the engine room and the driver's seat by providing the dashboard 10 from the left side member to the right side member. The automobile dashboard 10 includes a cross member 11 at an upper end, and a board 12 integrally formed at the lower end of the cross member 11.
[0021]
The cross member 11 is a substantially pentagonal hollow cylinder and is a member that also serves as a reinforcement for the dashboard 10.
The board 12 is formed by bending a flat panel member to form bent portions 13a, 13b, 13c, and 13d at desired portions, then cutting the peripheral edge 14 by a trimming process, and further through holes 15a and 15b by a piercing process. And the like.
The unfolded extruded shape for manufacturing the automobile dashboard 10 will be described below.
[0022]
Next, an example in which the unfolded extruded shape material is extruded based on FIG. 2 will be described.
2 (a) and 2 (b) are diagrams illustrating an example of extruding the extruded shape material for development according to the present invention.
In (a), the unfolded extrusion shape member 20 is extruded from the extrusion port 18a of the extrusion die 18 as shown by the arrow (1).
In (b), when the extrusion molding step is completed, an unfolded extruded shape member 20 is obtained. The unfolded extruded shape member 20 will be described in detail with reference to the next drawing.
[0023]
FIG. 3 is a front view of the extruded shape material for development according to the present invention.
The unfolded extruded shape member 20 has a frame portion 21 and a plate-like bent portion 23 extending from the frame portion 21, so that the frame portion 21 is surrounded by the bent portion 23. The tip 23a is connected to the connecting portion 23b of the bent portion 23 by a temporary connecting material 24 thinner than the bent portion 23 to form an annular shape, and the first to third temporary stay materials (multiple) are radially formed from the outer periphery of the frame portion 21. The temporary stay members 26, 27, and 28 are extended, the tip portions 26 a, 27 a, and 28 a of the first to third temporary stay members 26, 27, and 28 are engaged with the inner periphery 23 d of the bent portion 23, and the first The distal end portions 26a, 27a, 28a and the base end portions 26b, 27b, 28b (both ends) of the first to third temporary stay members 26, 27, 28 are arranged at the center of the first to third temporary stay members 26, 27, 28. From parts 26c, 27c, 28c Those were the comb.
[0024]
The frame portion 21 is a hollow cylinder formed in a substantially pentagonal hollow body with the first to fifth sides 21a, 21b, 21c, 21d, and 21e, and is downward from the right side portion of the third side 21c of the hollow cylinder. A plate-like bent portion 23 extends toward the end.
The bent portion 23 extends downward from the right side portion of the third side 21c of the frame portion 21, curves in the counterclockwise direction at the bending start portion 23c, and has a radius R around the frame portion 21 at the connecting portion 23b. It is a member that is curved in an arc shape and has a distal end 23 a connected to a connecting portion 23 b by a temporary connecting member 24.
The thickness of the bent portion 23 is t1, and the thickness of the temporary connecting material 24 is t2.
[0025]
Here, the relationship between the plate thickness t1 of the bent portion and the plate thickness t2 of the temporary connecting material 24 is as follows.
t2 ≦ (1/3) × t1
If the thickness t2 of the temporary joining material 24 exceeds (1/3) × t1, it takes too much time to remove the temporary joining material 24, and the removal time of the temporary joining material 24 becomes longer, which hinders productivity. Become.
Therefore, the temporary tether 24 is removed in a short time by setting the plate thickness t2 of the temporary tether 24 to (1/3) × t1 or less.
[0026]
The first temporary stay member 26 extends upward from the outer periphery of the first side 21 a of the frame portion 21, connects the distal end portion 26 a to the inner periphery 23 d of the bent portion 23, and connects the distal end portion 26 a and the proximal end portion 26 b (both ends). ) Is made thinner than the thickness t3 of the central portion 26c.
The second temporary stay member 27 extends rightward from the outer periphery of the first side 21 a of the frame portion 21, connects the distal end portion 27 a to the inner periphery 23 d of the bent portion 23, and the distal end portion 27 a and the proximal end portion 27 b ( The plate thickness t4 at both ends is made thinner than the plate thickness t3 of the central portion 27c.
[0027]
The third temporary stay member 28 extends from the outer periphery of the fourth side 21d of the frame portion 21 to the left side, connects the distal end portion 28a to the inner periphery 23d of the bent portion 23, and the distal end portion 28a and the proximal end portion 28b ( The plate thickness t4 at both ends is made thinner than the plate thickness t3 of the central portion 28c.
[0028]
Here, the plate thickness t3 of the central portions 26c, 27c, 28c of the first to third temporary stay members 26, 27, 28, and the plate thicknesses of the distal end portions 26a, 27a, 28a and the base end portions 26b, 27b, 28b. The relationship with t4 is as follows.
t4 ≦ (1/3) × t3
[0029]
When the plate thickness t4 of the distal end portions 26a, 27a, 28a and the base end portions 26b, 27b, 28b of the first to third temporary stay members 24 exceeds (1/3) × t3, It takes too much time to remove 26, 27, and 28 of the first to third temporary stay members 24, and the removal time of 26, 27, and 28 of the first to third temporary stay members 24 becomes longer, which increases productivity. It becomes a hindrance to raise.
Therefore, by setting the plate thickness t4 of the distal end portions 26a, 27a, 28a and the base end portions 26b, 27b, 28b to be (1/3) × t3 or less, 26 of the first to third temporary stay members 24, 27 and 28 are removed in a short time.
[0030]
As described above, the shape of the extruded shape member 20 for development is such that the plate-like bent portion 23 is extended from the frame portion 21, and the extended bent portion 23 surrounds the frame portion 21.
Accordingly, the frame portion 21 and a part of the bent portion (that is, the extending portion 23g from the third side 21c of the frame portion 21 to the connecting portion 23b) can be provided in the annular bent portion 23. The cross-sectional area of the extruded shape member 20 for processing can be made larger than the cross-sectional area of the extruded material for hexagonal unfolding processing described in the prior art.
Therefore, the unfolded extruded shape member 20 can be extruded with a good balance by setting the extrusion ratio to a preferable state.
[0031]
Further, the bent portion 23 is formed in an annular shape by connecting the distal end 23a of the bent portion 23 to the connecting portion 23b with a temporary connecting material 24 thinner than the bent portion 23. Therefore, as shown in FIG. 2A, the tip 23 a of the bent portion 23 can be favorably extruded from the extrusion mold 18.
[0032]
In addition, the first, second, and third temporary stay members 24, 26, 27, and 28 are radially extended from the outer periphery of the frame portion 21, and the distal ends 26a, 26, 27, and 28 of the first to third temporary stay members 24, By connecting 27a and 28a to the inner periphery 23d of the bent portion 23, the strength of the extruded shape member 20 for unfolding can be further increased.
For this reason, for example, the handling property of the extruded shape member 20 for development processing is improved, and conveyance to a subsequent process can be easily performed.
[0033]
Next, a method for developing the unfolded extruded shape member 20 will be described with reference to FIGS.
FIG. 4 is a first explanatory view showing a method of developing the extruded shape material for development according to the present invention.
In FIG. 2 (b), the extruded shape member 20 for unfolding is extruded, and then the base end portion 28 b of the third stay member 28 of the unfolded shape 20 for unfolding processing is cut using a saw blade 30. As an example of the specification of the saw blade 30, the rotation speed n is set to 3000 rpm or more and the feed speed v is set to 0.5 m / sec.
[0034]
Next, the third stay material 28 is removed from the extruded shape member 20 for development by cutting the tip portion 28a (shown in FIG. 3) of the third stay material 28 using the saw blade 30.
Thereafter, similarly, the first and second stay members 26 and 27 are removed, and the temporary connecting member 24 provided at the tip 23a of the bent portion 23 (shown in FIG. 3) is cut with the saw blade 30. The tip 23a of the bent portion 23 is separated from the connecting portion 23b of the bent portion 23.
[0035]
As described with reference to FIG. 3, the distal end 23 a of the bent portion 23 of the unfolded extruded shape member 20 is connected to the connecting portion 23 b with the temporary connecting material 24 thinner than the bent portion 23, so that the distal end 23 a of the bent portion 23 and the connected portion are connected. The connection with 23b can be easily released.
In addition, the distal end portions 26a, 27a, 28a and the base end portions 26b, 27b, 28b of the first to third temporary stay members 26, 27, 28 are made thinner than the central portions 26c, 27c, 28c, so that the unfolding process is performed. The first to third temporary stay members 26, 27, 28 can be easily released from the extruded shape member 20.
[0036]
In addition, although 1st Embodiment demonstrated the example which cuts the 1st-3rd stay parts 26-28 and the temporary joining material 24 with the saw blade 30 after extruding the extrusion shape material 20 for an expansion | deployment process. However, the present invention is not limited to this, and the first to third stay portions 26 to 28 and the temporary connecting material 24 can be removed by mechanical processing such as shearing or chemical processing such as etching.
As an aqueous solution used for chemical processing, for example, a strongly basic aqueous solution (sodium hydroxide, concentration 30 to 70%, temperature 70 to 90 ° C.) is applicable.
[0037]
FIG. 5 is a second explanatory view showing a method for developing the extruded shape material for development according to the present invention.
The first to third temporary stay members 26, 27, 28 provided radially between the extruded shape member 20 for unfolding and the frame portion 21 and the bent portion 23 are respectively indicated by arrows (2), (3), (4). A state where the temporary connecting material 24 is removed from the tip 23a of the bent portion 23 is removed as shown by an arrow (5).
[0038]
FIG. 6 is a third explanatory view showing a method of developing the extruded shape material for development according to the present invention.
By unfolding the bent portion 23 as shown by the arrow (6), the curved shape of the bent portion 23 is processed into a flat shape.
Here, since the bent portion 23 is bent into a curved shape with a radius R, by developing the bent portion 23, it can be easily processed into a flat shape.
Further, as described above, the connection between the distal end 23a of the bent portion 23 and the connecting portion 23b can be easily released. In addition, the first to third temporary stay members 26 are extended from the extruded shape member 20 for development. , 27 and 28 can be easily released, and the bent portion 23 of the extruded shape member 20 for unfolding can be easily unfolded without taking time and effort.
[0039]
FIG. 7 is a fourth explanatory view showing a method of developing the extruded shape material for development according to the present invention.
The bent portion 23 is flattened to form a panel member 32, and the panel member 32 extends downward from the third side 21 c of the frame portion 21.
Since the bent portion 23 is formed in an annular shape, the bent portion 23 is not bent more than necessary when the bent portion 23 is expanded. Therefore, work hardening can be prevented from occurring in the bent portion 23. For this reason, since the extruded shape member 20 for unfolding can be unfolded suitably, the unfolded panel member 32 can be favorably pressed into a desired shape.
[0040]
Next, an example of manufacturing the dashboard 10 by press-molding the panel member 32 will be described with reference to FIG.
FIG. 8 is a diagram for explaining an example in which a dashboard is press-molded from the extruded shape for development according to the present invention.
By pressing the flat panel member 32 to form the bent portions 13a to 13d at desired portions, the peripheral edge 14 is then cut by trimming, and the through holes 15a and 15b are formed by piercing. A board 12 is obtained.
The frame portion 21 is used as the cross member 11 that spans from the left side of the vehicle body to the right side. That is, the automobile dashboard 10 is configured by the cross member 11 and the board 12.
Note that the cross member 11 may be formed by bending the frame portion 21 or may be used without being bent.
[0041]
Next, the relationship between the radius R of the bent portion and the plate thickness t1 of the bent portion 23 will be described with reference to FIG.
9 (a) to 9 (c) are diagrams for explaining distortions that occur when the extruded shape member for unfolding according to the present invention is unfolded, and FIG. 9 (c) is an enlarged view of part c in FIG. 9 (b). Show.
(A) shows the state which shape | molded the bending part 23 in circular arc shape centering on the flame | frame part 21 (shown in FIG. 3) by making plate | board thickness t1 of the bending part 23 and the radius of the bending part 23 into R. FIG.
When the radius of the bent portion 23 is R, the length L1 of the outer periphery 23e of the bent portion 23, the length L2 of the center 23f of the bent portion 23, and the length L3 of the inner periphery 23d of the bent portion 23 are as follows.
L1 = 2π × (R + t1)
L2 = 2π × [R + (1/2) × t1]
L3 = 2π × R
(B) shows the state which processed the panel member 32 by developing the arc-shaped bending part 23 and extending it flatly.
[0042]
(C) shows respective strains ε1 and ε2 generated on the outer periphery 23e and the inner periphery 23d of the panel member 32 when the panel member 32 is processed by developing the bent portion 23 from an arc shape to a flat shape.
The outer periphery 23e of the panel member 32 contracts by L1-L2.
L1−L2 = 2π × (R + t1) −2π × [R + (1/2) × t1]
Therefore, distortion of ε1 occurs on the outer periphery 23e of the panel member 32.
ε1 = (L1−L2) / L1 = t1 / 2 (R + t)
[0043]
On the other hand, the inner periphery 23d of the panel member 23 contracts by L2-L3.
L2−L3 = π × [R + (1/2) × t1] −π × R
Therefore, distortion of ε2 occurs on the inner periphery 23d of the panel member 23.
ε2 = (L2−L3) / L3 = t1 / 2R
Since the relationship of ε1 <ε2 is established between the strain ε1 and the strain ε2, hereinafter, it is assumed that the developed strain when the bent portion 23 is flattened to form the panel member 32 is ε2.
[0044]
Here, if the allowable elongation of the bent portion 23 is El, the bent portion 23 is flattened to form the panel member 32, and then the press strain when the panel member 32 is press-molded is γ, the allowable elongation El is expanded. The following relationship holds for the strain ε2 and the press strain γ.
El> ε2 + γ
Therefore, if the unfolding strain ε2 satisfies the relationship of the expression (1), it is possible to press-mold the unfolded panel member 32 after unfolding the bent portion 23.
ε2 <El−γ (1)
[0045]
On the other hand, since ε2 satisfies the relationship of ε2 = t1 / 2R as described above, the equation (2) is established,
ε2 = t / 2R <E1−γ (2)
From the equation (2), the equation (3) is established.
R> t1 / 2 (E1-γ) (3)
Therefore, if the radius R and the plate thickness t1 of the bent portion 23 are determined so as to satisfy the expression (3), press forming after the bent portion 23 is flattened to form the panel member 32 becomes possible.
[0046]
As a specific example, when a material having an allowable elongation El of 27% is used for the bent portion 23 and press molding with a press strain γ of 25% is performed, the formulas (3) to (4) are established,
R> t1 / 2 (0.27-0.25)
R> 25 × t1 (4)
From the equation (4), it can be seen that when the plate thickness t1 of the bent portion 23 is 1.0 mm, a suitable press molding can be performed by setting the radius R of the bent portion 23 to 26 mm or more.
[0047]
Next, 2nd-5th embodiment is described based on FIGS. In addition, in 2nd-5th embodiment, the same code | symbol is attached | subjected about the same member as 1st Embodiment, and description is abbreviate | omitted.
FIG. 10 is a front view of an extruded shape member for unfolding (second embodiment) according to the present invention.
The unfolded extruded shape member 40 has a frame portion 41 as a solid rod, and an end 23a of the bent portion 23 is connected to a connecting portion 23b of the bent portion 23 to form an annular shape. It is the same structure as the extruded shape member 20 for development processing of the embodiment.
By making the frame part 41 solid, even when the frame part 41 is formed thin, it can be extruded relatively easily, and the application range of the extruded shape member 40 for expansion processing can be expanded.
Moreover, the connection state of 1st Embodiment and 2nd Embodiment is made the structure which connects the front-end | tip 23a of the bending part 23 to the connection part 23b of the bending part 23, and the application range of the extruded shape member 40 for expansion | deployment processing It becomes possible to select suitably according to.
[0048]
FIG. 11 is a front view of a developed extruded shape member (third embodiment) according to the present invention.
The unfolded extruded shape 45 is formed by forming the frame portion 46 into a substantially U-shape, and the other configuration is the same as the unfolded shape extruded shape 20 of the first embodiment.
By making the frame portion 46 substantially U-shaped, the shape of the frame portion can be appropriately selected according to the intended use, and the application range of the extruded shape member 45 for development processing can be expanded.
[0049]
FIG. 12 is a front view of an extruded shape member for expansion processing (fourth embodiment) according to the present invention.
The unfolded extruded shape member 50 has a frame portion 21 and a plate-like bent portion 53 extending from the frame portion 21 so that the frame portion 21 is surrounded by the bent portion 53. The tip 53a is connected to the connecting portion 53b of the bent portion 53 by a temporary connecting material 54 thinner than the bent portion 53 to form a corrugated ring (annular), and four temporary stay members (a plurality of temporary stay members) radially from the outer periphery of the frame portion 21. Stay members 56... Are extended, the tip portions 56 a of the temporary stay members 56... Are engaged with the inner periphery 53 d of the bent portion 53, and the temporary stay members 56. The thickness t4 of the front end portions 56a... And the base end portions 56b... (Both ends) is made thinner than the thickness t3 of the central portions 56c.
[0050]
Here, if the thickness of the bent portion 53 is t1, and the thickness of the temporary joining material 54 is t2, the relationship between the thickness t1 and the thickness t2 is t2 ≦ (1/3), as in the first embodiment. Xt1 is established.
Further, as in the first embodiment, the relationship between the wall thickness t3 and the wall thickness t4 is t4 ≦ (1/3) × t3.
Thereby, removal of the temporary joining material 54 and the temporary stay material 56... Can be performed in a short time as in the first embodiment.
[0051]
In addition, assuming that the radius of each bending portion when the bent portion 53 is formed into a wave shape is R, allowable elongation El, and press strain γ, equation (3), that is, R> t1 as in the first embodiment. The relationship of / 2 (El-γ) is established.
Therefore, if the radius R and the plate thickness t1 of the bent portion 23 are determined so as to satisfy the expression (3), press forming after the bent portion 53 is flattened to form the panel member 32 becomes possible.
[0052]
As described above, the unfolded extruded shape member 50 is different from the unfolded extruded shape member 20 of the first embodiment in that the bent portion 53 is formed in a wave shape. This is the same as the extruded shape member 20 for use.
According to the extruded shape member 50 for unfolding processing, it is possible to ensure a long panel member 32 (shown in FIG. 7) in which the bend portion 53 is unfolded by forming the bend portion 53 in a wave shape. Therefore, it becomes possible to select the length of the panel member 32 suitably according to a use, and can expand the application range of the extrusion shape material for an expansion | deployment process.
[0053]
FIG. 13 is a front view of an extruded shape member for development (fifth embodiment) according to the present invention.
The unfolded extruded shape member 60 is the unfolded extruded shape member of the fourth embodiment in that the four temporary stay members 56 are removed from the unfolded extruded shape member 50 of the fourth embodiment. The other configuration is the same as that of the extruded shape member 50 for development.
[0054]
By providing the extension part 53g corresponding to the extension part 23g of the first embodiment between the frame portion 21 and the connection part 53b, the sectional area of the extruded shape member 60 for unfolding processing has been described in the related art 6. It can be made larger than the cross-sectional area of the extruded material for rectangular development processing.
Therefore, the unfolded extruded shape member 60 can be extruded with a good balance by setting the extrusion ratio to a preferable state.
In addition, since the four temporary stay members 56 are not required at the time of extrusion molding, there is no need to remove the temporary stay members 56 at the time of expansion. The development processing of 60 can be further facilitated.
[0055]
In the first to third embodiments, the example in which the first to third temporary stay materials 26 to 28 are used as the temporary stay material has been described. However, the number of temporary stay materials is the shape of the extruded shape material for development. It can be selected as appropriate.
It is also possible to extrude the unfolded extruded shape material in a state where the first to third temporary stay members 26 to 28 are not provided. Since the frame part 21 and a part of the bent part (extension part 23g) are provided in the annular bent part 23, the cross-sectional area of the extruded shape material for development processing is the hexagonal development process described in the prior art. It can be larger than the cross-sectional area of the extruded material. Therefore, even if the first to third temporary stay members 26 to 28 are not provided, the extrusion ratio 20 can be extruded with a good balance by setting the extrusion ratio to a preferable state.
[0056]
Moreover, although the said embodiment demonstrated the example which press-forms the extrusion shape material 20,40,45,50,60 for expansion | deployment processing to the dash dod 10 for motor vehicles, it is not restricted to this, The extrusion shape material for expansion | deployment processing It is also possible to press-mold 20, 40, 45, 50, 60 to other members such as an automobile floor.
[0057]
【The invention's effect】
The present invention exhibits the following effects by the above configuration.
According to the first aspect of the present invention, the shape of the extruded shape for development processing is such that a plate-like bent portion is extended from the frame portion, and the frame portion is surrounded by the extended bent portion. Thus, since the frame portion and a part of the bent portion can be provided in the annular bent portion, the cross-sectional area of the extruded shape material for development processing is the cross-sectional area of the extruded shape material for hexagonal expansion processing described in the prior art. Can be larger.
For this reason, it becomes possible to set the extrusion ratio in a preferable state, and the extruded shape material for development processing can be extruded with a good balance.
[0058]
In addition, the tip of the bent portion is connected to the bent portion to form the bent portion in an annular shape. For this reason, the front-end | tip of a bending part can be favorably extruded from an extrusion die. As described above, the frame portion is arranged in the center of the extruded shape material for development processing, and further, the extrusion shape material for development processing is extruded with a further balance by connecting the tip of the bent portion to the bent portion. Can do.
[0059]
Further, since the bent portion is formed in an annular shape, it is not necessary to bend the bent portion greatly when the bent portion is expanded and flattened. For this reason, it can prevent that work hardening generate | occur | produces in the bending part after expand | deploying.
For this reason, since the extrusion shape material for expansion | deployment processing can be expand | deployed suitably, after expand | deploying the extrusion shape material for expansion | deployment processing, the expand | deployed panel member can be favorably press-molded to a desired shape.
[0060]
According to the second aspect of the present invention, since the tip of the bent portion is connected to the bent portion with a temporary joining material thinner than the bent portion, the connection between the bent portion and the bent portion can be released relatively easily. For this reason, since the extruded shape material for unfolding can be easily unfolded, productivity can be enhanced.
[0061]
According to the third aspect of the present invention, it is possible to increase the strength of the extruded shape member for unfolding by extending a plurality of temporary stay members radially from the outer periphery of the frame portion and engaging the tips of the temporary stay members with the inner periphery of the bent portion. . For this reason, for example, the handleability of the extruded shape material for development processing is improved, and the conveyance to the subsequent process can be easily performed, so that the productivity can be increased.
Furthermore, by making both ends of the temporary stay material thinner than the temporary stay material, the temporary stay material can be released relatively easily from the extruded shape material for development. For this reason, the extruded shape material for development can be easily developed without taking time and effort.
[Brief description of the drawings]
FIG. 1 is a perspective view of an automobile dashboard obtained by developing and then press-molding an extruded shape material for development according to the present invention.
FIG. 2 is a diagram illustrating an example of extruding the extruded shape material for development according to the present invention.
FIG. 3 is a front view of an extruded shape material for unfolding according to the present invention.
FIG. 4 is a first explanatory view showing a method of developing the extruded shape material for development according to the present invention.
FIG. 5 is a second explanatory view showing a method of developing the expanded extruded shape member according to the present invention.
FIG. 6 is a third explanatory view showing a method for developing the unfolded extruded shape member according to the present invention.
FIG. 7 is a fourth explanatory view showing a method for developing the extruded shape material for development according to the present invention.
FIG. 8 is a diagram illustrating an example in which a dashboard is press-molded from the extruded shape for development according to the present invention.
FIG. 9 is a diagram for explaining distortion that occurs when the extruded shape material for unfolding according to the present invention is unfolded.
FIG. 10 is a front view of an extruded shape member for unfolding according to the present invention (second embodiment).
FIG. 11 is a front view of an extruded shape member for unfolding (third embodiment) according to the present invention.
FIG. 12 is a front view of an extruded shape member for expansion processing (fourth embodiment) according to the present invention.
FIG. 13 is a front view of an extruded shape member for unfolding according to the present invention (fifth embodiment).
FIG. 14 is a front view showing a conventional extruding material for development processing.
FIG. 15 is an explanatory view showing another example of a conventional extruding material for development processing.
[Explanation of symbols]
20, 40, 45, 50, 60 ... extruded shape members for unfolding, 21, 41, 46 ... frame portion, 23, 53 ... bent portion, 23a, 53a ... tip of bent portion, 23b, 53b ... connection of bent portion Site, 24, 54 ... Temporary connecting material, 26 ... First temporary stay material (temporary stay material), 26a ... First tip portion (tip portion) of the first temporary stay material, 26b ... Base end portion of the first temporary stay material ( Base end), 27 ... second temporary stay material (temporary stay material), 27a ... tip end portion (tip end portion) of the second temporary stay material, 27b ... base end portion (base end portion) of the second temporary stay material, 28 ... third temporary stay material (temporary stay material), 28a ... distal end portion (leading end portion) of the third temporary stay material, 28b ... proximal end portion (base end portion) of the third temporary stay material, 23d, 53d ... bent The inner periphery of the portion 23, 26c, 27c, 28c ... the central part of the first to third temporary stay materials, 56 ... the temporary stay material, 56a ... Tip of the strut (tip), 56b ... proximal end of the temporary strut (proximal end).

Claims

An extruded shape material for development having a frame portion and a plate-like bent portion extending from the frame portion,
An extruded shape member for unfolding, characterized in that the frame portion is surrounded by a bent portion, and the tip of the bent portion is connected to the bent portion to form an annular shape.

The extruded shape member for unfolding according to claim 1, wherein the tip of the bent portion is connected to the bent portion by a temporary joining material thinner than the bent portion.

A plurality of temporary stay members are radially extended from the outer periphery of the frame portion, the tips of these temporary stay members are engaged with the inner periphery of the bent portion, and both ends of the temporary stay member are made thinner than the temporary stay members. The extruded shape material for unfolding according to claim 1.