JP3764637B2 - Body panel or vehicle part manufacturing method and body panel or vehicle part - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in manufacturing technology of a vehicle body panel or vehicle parts.
[0002]
[Prior art]
For example, FIG. 2 of Japanese Patent Application Laid-Open No. 10-129527 “Synthetic resin panel for automobiles” shows a bonnet 1 (the reference numerals are those described in the publication), and the main body 6 and both side ends of the bonnet 1 are illustrated. FIG. 3 shows a cross section of the connecting portion 8 that connects the portion 7, and the connecting portion 8 adopts a structure in which the reinforcing rib 4 extending from the stiffener 3 is “welded” to the outer skin 2. The reinforcement rib 4 can increase the rigidity of the bonnet 1.
[0003]
Since the bonnet 1 of the above publication is a resin panel, there is no difficulty in carrying out the welding at the time of resin molding and heat-sealing the two members (the reinforcing ribs 4 and the outer skin 2) after molding. However, steel panels obtained by bending a blank material are used much more than bonnets than resin panels. Steel bonnets have different challenges than resins. In particular, a structure in which a reinforcing plate called a backing plate is attached to a thin steel panel in order to attach a hinge or striker is normally adopted, but when this backing plate is a curved plate, The following issues arise.
[0004]
[Problems to be solved by the invention]
11 (a) and 11 (b) are manufacturing procedure diagrams of a conventional vehicle body panel.
In (a), a hood frame 101 formed by bending a steel blank material and a steel backing plate 102 formed by bending the hood frame 101 in a shape following the bent shape of the hood frame 101 are prepared, and the arrow (1) is prepared. , (1) Attaching the contact plate 102 to the food frame 101.
In (b), the edge of the contact plate 102 is joined by the weld bead 103. Such a method of attaching a backing plate is widely used.
[0005]
In this attachment method, the hood frame 101 and the contact plate 102 are first bent by a bending press or a bending machine, so that there are two bending processes.
[0006]
In many cases, the plate 102 is thicker than the plate thickness of the hood frame 101. However, the plate thickness of the hood frame 101 and the plate 102 are generally not equal. Depending on the plate thickness and the bending radius, the springback (a phenomenon in which the press material is slightly restored after pressing) differs, so that there is a slight difference in the curved shape between the hood frame 101 and the backing plate 102. In this way, if the curved shapes are different from each other, gaps are likely to occur at the corners 104 and 105 shown in FIG. The backing plate 102 locally reinforces the thin hood frame 101, but the reinforcing action is reduced when a gap is left.
[0007]
As described above, the conventional method described in FIG. 11 requires two bending processes, increases the processing cost, and reduces the reinforcing effect of the backing plate due to a gap.
An object of the present invention is to achieve a single molding process and eliminate the gap.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the method for manufacturing a vehicle body panel or vehicle part according to claim 1 includes a step of preparing a blank for vehicle body panel or a blank for vehicle part on the premise of molding, and a section modulus of the blank material. A step of preparing a contact plate that has been subjected to hole machining so as to have an equal or small section modulus, a joining step of joining the contact plate to the blank material, and a shape of a hole opened in the contact plate And a molding process for molding the backing plate together with the blank material.
[0009]
“Molding” means plastic forming such as bending, drawing, and overhanging. Hereinafter, the molding will be described by taking bending as an example.
By adopting a contact plate with a hole, the blank material can be bent after joining the contact plates. Since the backing plate is bent at the same time as the blank material, only one bending process is required. Compared to bending the backing plate and the blank material separately, the bending cost can be halved according to claim 1.
[0010]
Body panel or vehicle part according to claim 2, accompanied by backing plate blank material before molding, in a vehicle body panel or vehicle part comprising subjecting the molded plate against together with the blank, the caul plate is cross-section of the blank from the coefficient, as well as a hole opened-out plate subjected to hole drilling to be equal to or smaller section modulus, characterized in that it is a perforated plate which is molded at a point drilled hole.
[0011]
Since the perforated plate is adopted as the backing plate, the backing plate can be well adapted to the blank material. That is, there is no concern that the backing plate is locally released from the blank material and there is no gap, and the finished quality of the vehicle body panel or vehicle part can be improved.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is an exploded perspective view of a bonnet according to the present invention. The bonnet 10 is a double plate structure in which an inner skin 12 is stacked in the middle of an outer skin 11 and is applied to the upper surface of the inner skin 12. Plates 13 and 13 are attached, and brackets 14 and 15 for attaching hinges, electric small parts and the like to the contact plates 13 and 13 are bolts 16 (... indicates a plurality, the same applies hereinafter). It is also a structure that can be attached. That is, when a local load is applied to the relatively thin inner skin 12, the inner skin 12 may be locally deformed. Therefore, the contact plates 13 and 13 are attached for the purpose of local reinforcement.
[0013]
The inner skin 12 to which these contact plates 13 and 13 are attached is a specific example of the vehicle body panel of the present invention. A method for manufacturing the inner skin 12 as a vehicle body panel will be described in detail below.
[0014]
2 (a) and 2 (b) are explanatory views of preparation steps in the manufacturing method of the present invention.
As shown in (a), a backing plate 13, 13 of the pair of holes opening-out plate shape. How to open the holes 17 will be described later.
Moreover, the blank material 18 is prepared as shown in (b).
Preparing a hole open-out strip shape of caul 13, preparation of the blank 18 is not permissible able preceding one both simultaneously or any one, short then it Maniae before bonding step described.
[0015]
3 (a) and 3 (b) are explanatory views of a joining step and a bending step in the manufacturing method of the present invention.
As shown to (a), the contact plates 13 and 13 are joined to the predetermined location of the blank material 18 by an adhesive, a welding method, or a similar method.
Next, in (b), the contact plates 13 and 13 and the blank member 18 are bent along the mountain fold line 21 and the valley fold line 22 that substantially pass through the holes 17. The finished bent product is the inner skin 12 shown in FIG.
[0016]
Next will be described in detail the operation and structure of the backing plate holes open-out plate shape.
FIG. 4 is a perspective view of the contact plate according to the present invention, and shows the contact plate 13 in a state of being joined to the blank 18. In order to facilitate the explanation, three holes 17 are formed in a horizontal row.
FIG. 5A is a sectional view taken along the line 5a-5a in FIG. 4, and FIG. That is, when the flat blank material 18 and the contact plate 13 shown in (a) are bent together, the shape shown in (b) is obtained. At this time, the holes 17 are expanded or deformed in a V shape. Show. The structural mechanical explanation of the hole 17 on the premise of such spreading or deformation will be given in the following figure.
[0017]
FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 4. If the width of the blank 18 is b1, the thickness is h1, and the section modulus in this section is Z1, Z1 = (b1) · (h1) ² / 6 This section modulus Z1 represents the degree of bending rigidity, and it becomes difficult to bend as it increases.
[0018]
Similarly, if the width of the backing plate 13 is b2, the diameter of the holes 17 is d, the number of the holes 17 is n (n = 3 in this example), the thickness is h2, and the section modulus in this section is Z2. the Z2 = (b2-n · d ) · (h2) 2/6. This section modulus Z2 also represents the degree of bending rigidity, and it becomes difficult to bend as it increases.
[0019]
The backing plate 13 is thicker than the blank material 18 when used as a reinforcing material. That is, the relationship of h1 <h2 is established. If the contact plate 13 is thicker and the hole 17 is not present, naturally, Z1 <Z2, and the contact plate 13 hinders molding.
Therefore, when h1 <h2, Z1 = Z2 is satisfied (n · d), that is, the diameter of the holes 17 and the number of the holes 17 are determined.
This process corresponds to performing hole processing on the contact plate to match the characteristics of the blank material.
[0020]
Next, the case where h1 ≧ h2 will be described. If the bending rigidity of the backing plate 13 is smaller than that of the blank material 18, the backing plate 13 is easily bent and easily stretched and contracted along with the bending. If holes 17... Are further formed in such a backing plate 13, the rigidity is further reduced and the stretchability is increased. As a result, the bending workability of the blank material 18 becomes better.
Therefore, it is effective to open the holes 17 in the pad 13 even in the pad 13 thinner than the blank 18.
[0021]
FIGS. 7A to 7C are explanatory views of the shape change of the holes provided in the contact plate.
(A) shows the cross section of the blank material 18 and the backing plate 13 before bending, and the hole 17 becomes a perfect circle 23 when viewed from above.
(B) shows the cross section of the blank material 18 and the backing plate 13 bent convexly upward. At this time, the hole 17 becomes an ellipse 25 extending long along the axis 24 when viewed from above.
(C) shows the cross section of the blank 18 and the backing plate 13 bent convexly downward, and at this time, the hole 17 becomes an ellipse 27 extending long along the axis 26 when viewed from above.
(D) shows the blank material 18 and the contact plate 13 which are stretched or drawn, and at this time, the hole 17 becomes a diameter-increased hole 28 extending radially outward when viewed from above, that is, radially outward.
[0022]
In this way, in the hole 17, when the perfect circle 23 is changed to a horizontal (or vertical) ellipse 25, a vertical (or horizontal) ellipse 27, or an increased diameter hole 28, the contact plate 13 is adapted to the bending of the blank material 18. That is, it can be said that the bending of the contact plate 13 is synchronized with the bending of the blank 18.
If this kind of hole 17 is not provided, that is, if it is a plate without holes, the plate without holes will break without following the bending and extension of the blank 18. By opening the holes 17, such inconvenience has been successfully solved.
[0023]
Fig.8 (a)-(i) is a figure which shows the example of various patch plates.
(A) shows the contact plate 13 having a large-diameter round hole 17a.
(B) shows the contact plate 13 in which small circular holes 17b are arranged in a staggered manner.
(C) shows the contact plate 13 in which small square holes 17c are arranged in a staggered manner.
(D) shows the contact plate 13 having the oblong holes 17d.
(E) shows the contact plate 13 in which the oblong holes 17e are arranged in a staggered manner.
(F) shows the contact plate 13 having rectangular holes 17f.
(G) shows the contact plate 13 in which the rectangular holes 17g.
(H) shows the contact plate 13 in which holes 17h are formed in a lattice shape.
(I) shows the contact plate 13 having a cloud-shaped hole 17i having an arbitrary shape.
Thus, the shape of the hole opened in the molding part can be determined freely.
[0024]
FIG. 9 is a perspective view of the floor damper housing, and the floor damper housing 30 is a cylindrical vehicle component having a damper receiving seat 31 for receiving a strut damper of the wheel suspension device at the upper part. It is also a molded product made of stacked steel plates.
FIG. 10 is a partial cross-sectional view of the floor, damper, and housing. The backing plate 13 is overlaid on the cylindrical body 32 and finished by batch press forming. The backing plate 13 is thin and has a hole 17. A feature is that the caulking plate 13 is made to conform to the thick-walled cylinder 32 by opening.
[0025]
That is, the contact plate 13 having the holes 17... Is press-molded together with the cylinder 32, but the contact plate 13 is thin and has the holes 17. Turn in sync. As a result, the contact plate 13 can be sufficiently adhered to the cylindrical body 32.
[0026]
In the embodiment, the “body panel” has been described by taking the bonnet inner skin (stiffener) as an example. However, the body panel can be used freely as long as it is a panel constituting the body such as a door, a floor, and a roof.
Further, in the embodiment, the “vehicle component” has been described by taking the flow damper housing as an example. However, if it is a plastic molded product such as bending by overlapping a plurality of blank materials (metal plates) and a component attached to the vehicle, The type is not limited. That is, the present invention is suitable for bending and bending molded products, but can be widely applied to “molding” including drawing and stretch molding.
Therefore, the technology of the present invention can be applied to a vehicle body panel in a broad sense and a vehicle component in a broad sense.
[0027]
【The invention's effect】
The present invention exhibits the following effects by the above configuration.
In the method for manufacturing a vehicle body panel or vehicle component according to the first aspect, the blank member can be formed after the contact plate is joined by employing a contact plate having a hole. That is, since the backing plate is formed at the same time as the blank material, the forming process is only required once.
Compared to separately molding the backing plate and the blank material, according to the first aspect, the molding processing cost can be halved. In addition, since the backing plate is formed simultaneously with the blank material, it is possible to prevent the occurrence of a gap that is likely to occur between the backing plate and the blank material.
[0028]
The vehicle body panel or vehicle part according to claim 2 is characterized in that a contact plate subjected to hole machining is attached to the blank material. Since the perforated plate is adopted as the backing plate, the backing plate can be well adapted to the blank material. That is, there is no concern that the backing plate is locally separated from the blank material and there is no gap, and the finished quality of the vehicle body panel or vehicle part can be improved.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view of a bonnet according to the present invention. FIG. 2 is an explanatory diagram of a preparation process in the manufacturing method of the present invention. FIG. 3 is an explanatory diagram of a joining process and a bending process in the manufacturing method of the present invention. FIG. 5A is a sectional view taken along the line 5a-5a in FIG. 4, FIG. 5B is an image of bending molding, and FIG. 6 is a sectional view taken along line 6-6 in FIG. FIG. 8 is a diagram showing examples of various pad plates. FIG. 9 is a perspective view of a floor damper housing. FIG. 10 is a partial sectional view of the floor damper housing. [Fig. 11] Manufacturing procedure diagram of a conventional vehicle body panel
12 ... Inner skin as a vehicle body panel, 13 ... Watt plate, 17 ... Hole, 30 ... Floor damper housing as vehicle parts.

Claims (2)

Preparing a blank for vehicle body panels or a blank for vehicle parts on the premise of forming, and a patch plate that has been drilled so that the section modulus is equal to or smaller than the section modulus of the blank A vehicle body panel or a vehicle part comprising: a step, a joining step for joining a contact plate to the blank material, and a forming step for forming the contact plate together with the blank material so as to be formed at a hole formed in the contact plate. Manufacturing method. In vehicle body panels or vehicle parts formed by attaching a backing plate to a blank material before molding and molding the backing plate together with the blank material, the backing plate has a section modulus equal to or smaller than the section modulus of the blank material. body panel or vehicle part, characterized in that with a hole opened-out plate subjected to hole processing, a perforated plate which is molded at a point drilled hole as.

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