JP3869783B2 - Metal plate forming method and forming apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for forming a metal plate and a forming apparatus according to the method.
[0002]
[Prior art]
As processing methods using shot projection energy, shot blasting generally used for removing sand from castings and shot peening used for removing scales and increasing fatigue strength are known. By the way, it is known that these processing methods can be applied to the formation of a metal plate. For example, the techniques are disclosed in Patent Document 1 and Patent Document 2 below.
[0003]
[Patent Document 1]
Japanese Patent Publication No. 1-26833 [Patent Document 2]
JP-A-52-99961
That is, the above technique called “peening” is a processing method using a phenomenon in which when a shot is projected onto the metal plate, the metal plate is deformed so as to be convex toward the projection surface. Although peen forming has a proven track record in forming aircraft wings, it has no track record in other fields. However, it is expected as a forming method that replaces press working, and is particularly expected to be applied to small-volume products, prototypes, and the like where it is difficult to amortize the cost of mold tools.
[0005]
[Problems to be solved by the invention]
In general, in order to carry out pea forming, an apparatus as shown in FIG. Such an apparatus is easily increased in size because it requires a configuration for preventing small particles called shots from scattering around and a configuration for collecting shots. If the equipment (apparatus) is increased in size, productivity per unit floor area decreases, which is not preferable.
[0006]
Then, this invention makes it a subject to provide the shaping | molding method and shaping | molding apparatus of a metal plate which can attain space saving of an installation.
[0007]
[Means for solving the problems and actions / effects]
In order to solve the above problems, the method for forming a metal plate of the present invention,
Vehicles, metal furniture, appliances, wherein one of the major surfaces of the metal plate to constitute a part of the building, so that the energy and impact at the tip of the needle was controlled, is convex on its main surface To form a metal plate ,
A power for advancing and retreating in the axial direction is given to each of a plurality of gathered needles in a random or constant rule, and the main surface of the metal plate is impacted by the needles .
And as the first aspect,
The metal plate includes a metal plate to be molded and a back side bonding material that covers the metal plate from the back side and is joined directly or indirectly to the metal plate directly or through another member. It is a portion that cannot be formed by inserting a molding tool between the back side joining material and is randomly or constant to each of the plurality of gathered needles at a non-joining portion with the back side joining material. According to this rule, power is applied to advance and retract in the axial direction, and impact is applied from the front side of the metal sheet to be formed.
Moreover, as the second aspect,
The metal plate is configured as an assembled metal plate in which a plurality of metal plates to be formed are assembled, and a shaft is arranged at random or in a fixed rule on each of the plurality of collected needles so as to cross an assembly boundary. It is characterized in that a uniform linear shape or a constant design is formed across the boundary of the assembly by applying a power for advancing and retreating in the direction and impacting the main surface of the assembly metal plate.
[0008]
In the molding method of the present invention, a metal plate, which is a workpiece, is impacted at the tip of a needle instead of a shot so as to be molded into a desired shape (peen forming). According to the present invention, there is an advantage that it is possible to save time and effort for collecting shots and no equipment for preventing the shots from being scattered around as compared with the case of projecting shots.
[0009]
Specifically, the metal plate includes a metal plate to be formed and a back side bonding material that covers the metal plate from the back side and is integrally joined to the metal plate directly or indirectly through another member. It can be configured. And it is a part that cannot be formed by inserting a molding tool between the back side joining material, and at the non-joining part with the back side joining material, molding is performed by impacting with the needle from the front side of the metal plate to be molded. The form to perform is suitable.
[0010]
In general, it is conceivable to bond the back side bonding material after applying the desired shape to the metal sheet to be formed by press working or the like. However, in the above-described form, the metal sheet is formed by projecting the needle from the front side while the back side bonding material remains integrated. In other words, peening is extremely effective when it is impossible to perform molding using a tool or a mold if the back side bonding material remains integral.
[0011]
In addition, in order to solve the above problems, the metal plate forming apparatus of the present invention includes:
Vehicles, metal furniture, appliances, wherein one of the major surfaces of the metal plate to constitute a part of the building, so that the energy and impact at the tip of the needle was controlled, is convex on its main surface To form a metal plate,
A head portion in which a plurality of the needle is formed by a set, characterized by comprising a power unit providing power for advancing and retracting in the axial direction of each needle at a random or a predetermined rule.
And as the first aspect,
The metal plate includes a metal plate to be molded and a back side bonding material that covers the metal plate from the back side and is joined directly or indirectly to the metal plate directly or through another member. And a head portion in which a plurality of needles for impacting the main surface of the metal plate to be molded are assembled, and
It is a part that cannot be formed by inserting a molding tool between the back side joining material, and impacted by the needle from the front side of the metal plate to be molded at a non-joining portion with the back side joining material. When forming the metal plate to be formed, a power unit is provided that provides power for advancing and retracting each needle in the axial direction at random or with a certain rule.
Moreover, as the second aspect,
The metal plate is configured as an assembled metal plate in which a plurality of metal plates to be molded are assembled, and a head portion in which a plurality of needles for impacting the main surface of the assembled metal plate are assembled. ,
Forming a uniform linear or constant design across the assembly boundary by impacting the main surface of the assembly metal plate with the needle so as to cross the assembly boundary of the assembly metal plate And a power unit that provides power for advancing and retracting each needle in the axial direction at random or with a certain rule.
[0012]
According to the molding apparatus of the present invention, when the head part is sufficiently brought close to the metal plate as the workpiece while moving the needle back and forth, the needle comes to impact the metal plate. Thereby, the effect equivalent to the case where the small particle body called a shot is projected on a metal plate can be acquired. That is, by adjusting the energy (kinetic energy) of the needle, it is possible to leave a compressive stress on the metal plate so as to protrude toward the impacted side.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Pean forming is a forming method that utilizes the phenomenon that when a large number of shots 3 are projected onto the metal plate 1, the metal plate 1 swells in the direction opposite to the projection direction as shown in FIG. However, the rise in the metal plate 1 as shown in FIG. 1A is a case where the projection energy (kinetic energy) of the shot 3 is adjusted to be relatively small. However, as shown in FIG. 1B, a drop occurs in the projection direction of the shot 3. The height of the swell is generally known as an Almen value representing the degree of shot peening.
[0014]
Reference numerals 1 a and 1 b in FIG. 1 conceptually indicate a plastic deformation region caused by one shot 3. The difference between the plastic deformation zones 1 a and 1 b is due to the difference in the compressive stress field generated in the metal plate 1. When a large number of shots 3 are projected, minute plastic deformation is accumulated, and a difference occurs in the amount of plastic deformation between the upper surface 1p (front surface) and the lower surface 1q (back surface) of the metal plate 1. That is, when the elongation of the upper surface 1p is larger than the elongation of the lower surface 1q, the metal plate 1 rises as shown in FIG. 1A, and when the elongation of the lower surface 1q is larger than the elongation of the upper surface 1p, the metal plate 1 is as shown in FIG. It will drop like (b).
[0015]
In the model shown in FIG. 1, shot 3 such as a steel ball is projected onto a metal plate 1 for peening, but in the present invention, a plurality of needles 4 made of metal such as steel and stainless steel are used at high speed. The metal plate 1 is struck by the tip and the impact is applied to the metal plate 1, and the same effect as that obtained when a large number of shots 3 are projected onto the metal plate 1 is obtained.
[0016]
Specifically, as shown in (1) of FIG. 2, the main surface of the metal plate 1 is scanned in a predetermined pattern while impacting with the tip of the needle 4 so as to be convex on the main surface side where the impact is applied. The metal plate 1 is peaformed. According to this method, there is an advantage that the trouble of collecting the shot 3 after projection can be saved.
[0017]
In actual peening of the metal plate 1, since it is not possible to impact all areas necessary for obtaining a desired shape all at once, the metal plate 1 and the position are sequentially moved (scanning projection method). ). In the scanning projection method, by appropriately selecting the projection conditions, it is possible to obtain the same effect as when all the areas necessary for peening are impacted at once. In the form shown in (1) of FIG. 2, the metal plate 1 is impacted by the needle 4 while gradually shifting the position from one side of the rectangular metal plate 1 to the other side facing each other. As indicated by a broken line arrow, a smoothly curved shape can be imparted to the metal plate 1 by repeating scanning.
[0018]
2 shows a form in which linear concave portions and convex portions, that is, beads 20 and beads 22 are formed on a part of the metal plate 1. By appropriately adjusting the energy held by the needle 4, it can be switched between convex and concave with respect to the projection direction. When the energy of the needle 4 is larger than a certain value, a bead 22 recessed in the projection direction is formed. On the other hand, when the energy of the needle 4 is smaller than the predetermined value and is sufficient to form a compressive stress field on the metal plate 1, a bead 20 swelled in the direction opposite to the projection direction is formed. The portion where the needle 4 is not projected may be protected using a protective member 15 such as a rubber sheet so that an impact is not applied.
[0019]
The molding apparatus 102 used in the method of the present invention includes a main body portion 71 and a head portion 14. The head portion 14 has a shape in which a plurality (for example, several tens) of needles 4 are assembled so as to be able to advance and retreat. The main body 71 is configured to include a power unit that provides power (compressed air, electric power, etc.) for advancing and retracting the needle 4 in the axial direction at random or with a certain rule. The main body portion 71 and the head portion 14 are connected via a flexible hose 16 made of resin or metal. A control signal line for advancing and retracting the needle 4 and a compressed air circulation pipe are passed through the flexible hose 16.
[0020]
The needle 4 may be a round bar having a curved surface at the tip that contacts the metal plate 1. Specifically, the needle 4 that has a spherical shape at the tip that contacts the metal plate 1 and is adjusted so that the diameter of the spherical surface is approximately the same as the thickness of the metal plate 1 is suitable. The metal plate 1 is subjected to, for example, thousands of times per minute by such a needle 4.
[0021]
In order to advance and retract the needle 4 in the axial direction, for example, a head portion 14 can be provided as shown in FIG. In the example shown in FIG. 3, the needle 4 is driven using electromagnetic force. Specifically, a solenoid 25 is provided corresponding to each needle 4, and the needle 4 is advanced and retracted in the axial direction by switching the excitation / non-excitation at high speed. Power supply to each solenoid 25 and switching between excitation / non-excitation are performed by the controller 26 provided in the main body 71. The controller 26 is composed of a microcomputer, a driver, etc. (not shown). Each needle 4 repeats advancing and retreating individually in a predetermined order stored in the microcomputer. When a large number of needles 4 impact the metal plate 1 all at once, the metal plate 1 falls as shown in FIG. 1B, and therefore the same action as when a large number of shots 3 are projected with a large number of needles 4. Note that works on the metal plate 1.
[0022]
The amount of deformation such as the raised height and bending angle of the metal plate 1 due to the pin forming is determined by the total projection energy applied to the metal plate 1 regardless of the projection density. Therefore, the projection energy (kinetic energy) of the needle 4 is appropriately adjusted to peen-form the metal plate 1 into a desired shape. In the example of FIG. 3, it is preferable to use a DC solenoid as the solenoid 25 because the stroke amount of the needle 4 and thus the energy applied to the metal plate 1 by the needle 4 can be adjusted. In addition, the code | symbol 24 in a figure represents the casing 24 which comprises the head part 14. FIG.
[0023]
On the other hand, a pneumatic actuator can be used instead of the electromagnetic actuator such as the solenoid described above. For example, as shown in FIG. 4, a single-acting cylinder mechanism is configured by the needle 4, the spring 23, and the cylinder tube 35. The compressed air supplied from the compressor provided in the main body 71 described above is supplied to the cylinder tube 35 through the on-off valve 39. The compressed air sent into the cylinder tube 35 pushes the needle 4 in the axial direction. The cylinder tube 35 is provided with a relief hole that appears when the needle 4 moves forward, and the compressed air is discharged from the escape hole to the outside of the cylinder tube 35. As a result, the needle 4 moves forward by inertia and moves backward by the restoring force of the spring 23 after hitting the metal plate 1. According to such a mechanism, there is an advantage that the energy of the needle 4 can be adjusted relatively easily by adjusting the pressure of the compressed air. If the opening / closing of the on-off valve 39 is controlled, the plurality of needles 4 can be individually advanced and retracted. The on-off valve 39 may be accommodated in the casing 24 of the head portion 14 or in the main body portion 71.
[0024]
Next, FIG. 5 is a schematic diagram of a system that adopts a method of performing peening with impacting the metal plate 1 with the needle 4. The pine forming system 200 includes a molding apparatus 110 and a transport mechanism 9. In the molding apparatus 110, the head unit 14 holding the needle 4 is attached to the tip of the hand of the robot 29. By controlling the position and orientation of the robot 29, the relative positional relationship between the metal plate 1 carried by the transport mechanism 9 and the head unit 14 can be set freely and accurately.
[0025]
The transport mechanism 9 can be composed of, for example, a rail 9b and a hoist 9a. In the form shown in FIG. 5, the metal plate 1 is erected substantially vertically to make an impact from the horizontal direction. However, for example, the metal plate 1 is held so that the main surface is substantially horizontal, A form in which the head portion 14 is approached from above or vertically below to perform peening is also conceivable. In addition, the main surface means the front surface (Otemen) and the back surface (Uramen) having the largest area in the metal plate 1.
[0026]
When performing pea forming by projecting shot 3 as shown in FIG. 1, in addition to the projection unit and the transport mechanism for projecting shot 3, the recovery / circulation mechanism of shot 3 and shot 3 do not scatter. As a result, a projection chamber is required to make the entire equipment larger. However, according to the method of the present invention in which the metal plate 1 is impacted by the needle 4, pea forming can be performed with simple equipment as shown in FIG. 5. Therefore, there are few cases where the layout becomes a problem in a factory or the like.
[0027]
The metal plate 1 is a member that should be a part of, for example, a vehicle, metal furniture, an electrical appliance, or a building. Although it does not specifically limit as a material of the metal plate 1, For example, iron, steel, aluminum, copper etc. can be illustrated. In addition, when the surface roughness of the metal plate 1 after the peening is important, it is preferable to finish with a sander or the like.
[0028]
Up to now, it has been described that the single metal plate 1 is subjected to peening, but as a case where peening can be a very effective forming method, there are cases where tools and molds for forming cannot be used. For example, as shown in FIG. FIG. 6 shows that a metal plate 61 (molded metal plate 61) to be molded is joined to another metal plate 63 (back side joining material 63) via a joining member 6c to be integrated. This is an example of peening the assembled metal plate 6.
[0029]
The back side surface 6q of the metal plate 61 to be formed is covered with another metal plate 63, and a slight hollow space SH is formed between the two (metal plates 61, 63). The metal plate 61 to be formed cannot be formed by inserting a forming tool such as a hammer in the hollow space SH. In addition, the two (metal plates 61 and 63) cannot be separated. When forming the non-joint part 6a with the metal plate 63, which is a part that cannot be formed by the forming tool, on the metal plate 61 placed in such a situation, the front side surface 6p of the metal plate 61 to be formed is formed. It is possible to project the shot 3 and perform pea forming to form the raised portion 6d. Note that the same applies to the case where welding is directly performed without using the joining member 6c.
[0030]
Further, a form in which peening is performed after a plurality of metal plates are joined by welding as shown in FIG. 7 or assembled by a fastening means such as a bolt / nut is also suitable. That is, as shown in FIG. 7A, the assembled metal plate 2 is configured by assembling the first metal plate 2a and the second metal plate 2b in a positional relationship in which the main surfaces are substantially parallel to each other. Then, peening is performed by impacting the assembled metal plate 2 with the needle 4 in a form crossing the assembly boundary HL, and a uniform linear or fixed design 30 (stretching across the left and right of the assembly boundary HL). Bead). As a specific example, as shown in FIG. 7B, the door 32 (first metal plate) of the automobile 40 is assembled to the body main body 33 (second metal plate) to form a final form, and thereafter Peanfoaming is performed to form a suddenly raised portion 34 (bead) that spans the door 32 and the body main body 33. According to this method, the raised portion 34 can be formed without causing a positional shift. The assembly boundary HL is defined as the boundary between the first metal plate 2a and the second metal plate 2b before assembly.
[0031]
In addition, when extremely high forming accuracy is required, the metal plate 1 may be subjected to peening by bringing the abutting jig 28 into contact with the metal plate 1 as shown in FIG. it can. Specifically, the needle 4 is projected by bringing the head portion 14 closer from the side opposite to the side on which the abutting jig 28 is disposed while the metal plate 1 is placed along the abutting jig 28. In this way, the shape of the abutting jig 28 is transferred to the metal plate 1.
[0032]
Further, as shown in FIG. 8B, the metal plate 1 is forcibly aligned with the abutting jig 28 in a form that elastically deforms the metal plate 1 before the needle 4 is projected, and the fixture 27 is used to fix each other. Then, a method of projecting the needle 4 and performing peening is also employable. According to this method, the generated elastic stress promotes the deformation of the metal plate 1, and when the desired shape is reached, the elastic stress disappears and the forming progress is stopped. High molding accuracy can be obtained. Of course, when performing pea forming using the pea forming system 200 shown in FIG. 5, the abutting jig 28 may be arranged behind the metal plate 1. In that case, the needle 4 can be projected onto the metal plate 1 while the fixture 27 shown in FIG. 8B is suspended by the hoist 9a (see FIG. 5). In addition, since the intensity | strength and durability which are unlike a press die are not required, the contact jig | tool 28 can be produced comparatively cheaply, for example with materials, such as a timber and gypsum.
[Brief description of the drawings]
FIG. 1 is a diagram illustrating the principle of pea forming.
FIG. 2 is a diagram for explaining peening with a needle.
FIG. 3 is a schematic diagram illustrating a configuration of a head unit.
FIG. 4 is a schematic diagram showing another embodiment of the configuration of the head unit.
FIG. 5 is an overall schematic diagram of a pea forming system.
FIG. 6 is an explanatory diagram of a form in which peening is performed after a plurality of metal plates are assembled to each other.
FIG. 7 is an explanatory view of another embodiment in which peening is performed after a plurality of metal plates are assembled to each other.
FIG. 8 is an explanatory diagram of a form in which peening is performed using an abutting jig.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Metal plate 4 Needle 6 Assembly metal plate 14 Head part 61 Molded metal plate 6p Front side surface 6q Back side surface 63 Other metal plates (back side joining material)
71 Body (Power unit)
102,110 Molding device

Claims (8)

The main surface of a metal plate that should constitute a part of a vehicle, metal furniture, electrical appliance, or building is impacted by the tip of an energy-controlled needle so that the main surface is convex. To form a metal plate ,
A method for forming a metal plate, comprising applying a power for advancing and retreating the needle in the axial direction at random or with a constant rule to each of the plurality of needles to impact the main surface of the metal plate with the needle . The main surface of a metal plate that should constitute a part of a vehicle, metal furniture, electrical appliance, or building is impacted by the tip of an energy-controlled needle so that the main surface is convex. To form a metal plate,
The metal plate includes a metal plate to be molded and a back side bonding material that covers the metal plate from the back side and is joined directly or indirectly to the metal plate directly or through another member. It is a portion that cannot be formed by inserting a molding tool between the back side joining material and is randomly or constant to each of the plurality of gathered needles at a non-joining portion with the back side joining material. A method for forming a metal plate, comprising applying power for advancing and retreating in the axial direction according to the above rule to impact from the front side of the metal plate to be formed. The main surface of a metal plate that should constitute a part of a vehicle, metal furniture, electrical appliance, or building is impacted by the tip of an energy-controlled needle so that the main surface is convex. To form a metal plate,
The metal plate is configured as an assembled metal plate in which a plurality of metal plates to be formed are assembled, and a shaft is arranged at random or in a fixed rule on each of the plurality of collected needles so as to cross an assembly boundary. A metal plate characterized by forming a uniform linear or constant design across the boundary of the assembly by impacting the main surface of the assembly metal plate by applying power for advancing and retreating in the direction. Molding method. The method for forming a metal plate according to any one of claims 1 to 3, wherein a portion of the metal plate that is not impacted by the needle is protected by using a protective member such as a rubber sheet so that the impact is not applied. The shape of the said contact jig is transcribe | transferred to the said metal plate by making an impact with the said needle from the opposite side to the side by which the said metal plate is arrange | positioned along the said metal plate. 4. The method for forming a metal plate according to any one of items 3 to 3. The main surface of a metal plate that should constitute a part of a vehicle, metal furniture, electrical appliance, or building is impacted by the tip of an energy-controlled needle so that the main surface is convex. To form a metal plate,
An apparatus for forming a metal plate, comprising: a head portion formed by aggregating a plurality of needles; and a power portion that applies power for advancing and retracting each needle in the axial direction at random or with a predetermined rule. The main surface of a metal plate that should constitute a part of a vehicle, metal furniture, electrical appliance, or building is impacted by the tip of an energy-controlled needle so that the main surface is convex. To form a metal plate,
The metal plate includes a metal plate to be formed and a back side bonding material that covers the metal plate from the back side and is joined directly or indirectly to the metal plate directly or through another member. And a head part in which a plurality of needles for impacting the main surface of the metal plate to be molded are assembled, and
It is a part that cannot be formed by inserting a molding tool between the back side joining material, and impacted by the needle from the front side of the metal plate to be molded at a non-joining portion with the back side joining material. An apparatus for forming a metal plate, comprising: a power unit that supplies power for advancing and retracting each needle in the axial direction at random or in a predetermined rule when forming the metal plate to be formed. The main surface of a metal plate that should constitute a part of a vehicle, metal furniture, electrical appliance, or building is impacted by the tip of an energy-controlled needle so that the main surface is convex. To form a metal plate,
The metal plate is configured as an assembled metal plate in which a plurality of metal plates to be molded are assembled, and a head unit in which a plurality of needles for impacting the main surface of the assembled metal plate are assembled. ,
Forming a uniform linear or constant design across the assembly boundary by impacting the main surface of the assembly metal plate with the needle so as to cross the assembly boundary of the assembly metal plate A metal plate forming apparatus, comprising: a power unit that applies power for advancing and retracting each needle in the axial direction at random or in a predetermined rule.

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