JP5077211B2 - Molded body having odd-shaped U-shaped portion and manufacturing method thereof - Google Patents

Molded body having odd-shaped U-shaped portion and manufacturing method thereof Download PDF

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JP5077211B2
JP5077211B2 JP2008310489A JP2008310489A JP5077211B2 JP 5077211 B2 JP5077211 B2 JP 5077211B2 JP 2008310489 A JP2008310489 A JP 2008310489A JP 2008310489 A JP2008310489 A JP 2008310489A JP 5077211 B2 JP5077211 B2 JP 5077211B2
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久佳 加藤
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トヨタ車体株式会社
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本発明は、底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体を製造する方法に関する。   The present invention relates to a method of manufacturing a molded body having a deformed U-shaped portion that has a concave curved surface bent so that a bottom surface portion is recessed inward along a longitudinal direction.
例えば、車両用シートのシートバック内に内蔵されるフレーム部品として、断面長方形状を有し、その長辺部に相当する面(以下、適宜、長辺部面という)の2面は略平坦な面となっているが、その短辺部に相当する面(以下、適宜、短辺部面という)がシートバックの形状に沿って湾曲した形状を有している部品がある。一方の短辺部面は長手方向に沿って外側に凸状となるように湾曲し、他方の短辺部面は長手方向に沿って内側に凸状となる(内方に窪む)ように湾曲している。   For example, a frame component incorporated in a seat back of a vehicle seat has a rectangular cross section, and two surfaces corresponding to the long side portion (hereinafter, referred to as a long side surface as appropriate) are substantially flat. Although there is a surface, there is a component having a shape in which a surface corresponding to the short side portion (hereinafter, referred to as a short side surface as appropriate) is curved along the shape of the seat back. One short side surface is curved to be convex outward along the longitudinal direction, and the other short side surface is convex inward along the longitudinal direction (indented inward) It is curved.
このような特殊な形状の部材は、1枚の素材から1部品のまま製造することが困難である。そのため、従来は、ほぼ平坦な長辺部面における湾曲した両側端部から短辺部面を立設させた部品を2つ成形し、これらの短辺部面を互いに溶接して断面長方形状とすることによって製造していた。   Such a specially shaped member is difficult to manufacture as a single part from a single material. For this reason, conventionally, two parts having a short side surface erected from both curved end portions of a substantially flat long side surface are formed, and these short side surfaces are welded together to form a rectangular cross section. Was manufactured by doing.
特公平6−61581号公報Japanese Patent Publication No. 6-61581 特開2002−1445号公報JP 2002-1445 A 特許第2855492号公報Japanese Patent No. 2855492
しかしながら、上記のごとく2つの部品を作ってから接合する製造方法では、製造工程数が多く、また、材料歩留まりも良くない。さらに、完成品においても2箇所の溶接を行っているので強度上不利であり、溶接部の重量増加によって軽量化を図ることも困難である。
このような問題を解決するには、1枚の素材から最後まで1部品のままで製造でき、かつ、溶接すべき部分を少なくできる方法を見出す必要がある。
However, in the manufacturing method in which two parts are formed and bonded as described above, the number of manufacturing steps is large and the material yield is not good. Furthermore, since the welding is performed at two locations in the finished product, it is disadvantageous in strength, and it is difficult to reduce the weight by increasing the weight of the welded portion.
In order to solve such a problem, it is necessary to find a method that can be manufactured with one component from one material to the end and that can reduce the number of parts to be welded.
このような製造方法を確立するためには、上記短辺部面を底面とした断面コ字状の成形体を作製することが不可欠であると考えられる。
ところが、上記のごとく湾曲した面を底面部とするいわば異形コ字状部を有する成形体を成形することは非常に困難である。単純な成形方法では、いわゆる伸びフランジ成形等の加工が必要となり、側面部に大きなそりと不要なしわ状の外観不良が生じ、製品化が難しい。上記3つの文献を参酌しても解決することは困難である。
また、このような異形コ字状部を有する製品は、上述したシートバック内に内蔵されるフレーム部品に限らず、様々な用途の機械部品にも存在する。
そのため、上記異形コ字状部を有する成形体を容易に製造できる方法が完成すれば、非常に有効である。
In order to establish such a manufacturing method, it is considered indispensable to produce a molded article having a U-shaped cross section with the short side surface as the bottom.
However, it is very difficult to form a molded body having a so-called deformed U-shaped portion with the curved surface as described above as the bottom surface portion. In a simple molding method, processing such as so-called stretch flange molding is required, and a large warp and an unnecessary wrinkle-like appearance defect occur on the side surface, making it difficult to produce a product. It is difficult to solve even if the above three documents are considered.
In addition, products having such an irregular U-shaped portion are not limited to the frame components incorporated in the seat back described above, but also exist in machine components for various applications.
Therefore, it is very effective if a method for easily producing a molded body having the odd-shaped U-shaped portion is completed.
本発明は、かかる従来の課題に鑑みてなされたもので、底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体を、外観特性に優れた状態で、1枚の素材から1部品のまま高い歩留まりで製造することができる方法を提供しようとするものである。   The present invention has been made in view of such conventional problems, and a molded body having a deformed U-shaped portion having a concave curved surface bent so that a bottom surface portion is recessed inward along the longitudinal direction has an appearance characteristic. The present invention is intended to provide a method capable of producing a single component from a single material with a high yield.
第1の発明は、底面部と該底面部の両側から立設した左右一対の側面部とを有する断面コ字状形状を呈し、上記底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体を製造する方法であって、
平板状のブランク材を準備し、
該ブランク材を上記底面部と上記側面部との間の直線状の境界線を起点に曲げ加工して、上記底面部が平坦面であると共にその両側の上記側面部との間のなす角度がいずれも鈍角である中間成形体を形成し、
上記底面部における所望の上記凹状曲面の内面形状に対応した凹状挟持面を有するパンチと、上記凹状曲面の外面形状に対応した凸状挟持面を有するクッションと、上記底面部の外幅寸法に対応する間隔を空けて配置されたダイス刃部を有するダイスとを備えた金型を用いて、上記中間成形体の内部に配置した上記パンチの上記凹状挟持面とこれに対向配置させた上記クッションの上記凸状挟持面によって上記底面部を挟持して該底面部を上記凹状曲面に変形させ、
その後、上記パンチと上記クッションとによる挟持状態を維持したまま上記底面部全体を先頭にして上記ダイス刃部間に挿入し、上記側面部の一部のみが上記ダイス刃部を通過した時点で上記底面部と上記ダイスとの相対移動を停止することにより、上記側面部のうち上記ダイス刃部間を通過していない部分の一部が外方に膨らんだ膨出部となると共に、その周囲が上記底面部に対して略直角に立設した平面状側面部となるように上記異形コ字状部を形成することを特徴とする異形コ字状部を有する成形体の製造方法にある(請求項1)。
1st invention exhibited the cross-sectional U-shape which has a bottom face part and a pair of left and right side parts erected from both sides of the bottom face part, and the bottom face part was bent so as to be recessed inward along the longitudinal direction. A method for producing a molded body having a deformed U-shaped portion having a concave curved surface,
Prepare a flat blank,
The blank material is bent starting from a linear boundary line between the bottom surface portion and the side surface portion, and the bottom surface portion is a flat surface and the angle formed between the side surface portions on both sides thereof is Both form an intermediate molded body that is obtuse,
Corresponding to the punch having a concave clamping surface corresponding to the desired inner surface shape of the concave curved surface in the bottom surface portion, the cushion having the convex clamping surface corresponding to the outer surface shape of the concave curved surface, and the outer width dimension of the bottom surface portion Using a die having a die having a die blade portion arranged at an interval of the punch, the concave sandwiching surface of the punch disposed inside the intermediate molded body and the cushion disposed opposite thereto The bottom surface portion is sandwiched by the convex sandwiching surface to deform the bottom surface portion into the concave curved surface,
Then, while maintaining the clamping state between the punch and the cushion, the entire bottom surface portion is inserted between the die blade portions, and when only a part of the side surface portion passes through the die blade portion, By stopping the relative movement between the bottom surface portion and the die, a part of the side surface portion that does not pass between the die blade portions becomes a bulging portion that bulges outward, and its periphery is In the method for producing a molded body having a deformed U-shaped portion, the deformed U-shaped portion is formed so as to be a planar side surface portion erected substantially perpendicular to the bottom surface portion (claim) Item 1).
本発明の製造方法においては、上記のごとく、平板状のブランク材を用いて、一旦上記中間成形体を形成する。この中間成形体は、底面部が平坦面であると共にその両側の側面部との間のなす角度がいずれも鈍角である形状を有するものなので、単純な曲げ成形によって容易に得ることができる。   In the production method of the present invention, as described above, the intermediate molded body is once formed using a flat blank. Since this intermediate molded body has a shape in which the bottom surface portion is a flat surface and the angle between the side surface portions on both sides thereof is an obtuse angle, it can be easily obtained by simple bending.
次に、上記中間成形体に対して上記金型により加工を加える。まず、上記パンチの上記凹状挟持面と上記クッションの上記凸状挟持面によって上記底面部を挟持して該底面部を上記凹状曲面に変形させる。この底面部の変形を実行すると、その両側の側面部に対し、底面部から離れるほど長手方向に強い引張応力が付与される状態となる。そのため、側面部同士の間が開くように変形すると共に側面部の一部が膨らんで平坦でない状態となる。なお、この時点の変形は、弾性変形の割合も大きいので、上記パンチと上記クッションの挟持状態を解除すると、もとの中間成形体の形状に近づく。そのため、次の工程は、上記パンチと上記クッションとの挟持状態を維持したまま行う。   Next, the intermediate molded body is processed by the mold. First, the bottom surface portion is sandwiched by the concave sandwiching surface of the punch and the convex sandwiching surface of the cushion to deform the bottom surface portion into the concave curved surface. When the deformation of the bottom surface portion is executed, a stronger tensile stress is applied to the side surface portions on both sides of the bottom surface portion as the distance from the bottom surface portion increases. Therefore, it deform | transforms so that it may open between side parts, and a part of side part will swell and will be in the state which is not flat. In addition, since the deformation | transformation at this time also has the ratio of elastic deformation, if the clamping state of the said punch and the said cushion is cancelled | released, it will approximate the shape of the original intermediate molded object. Therefore, the next step is performed while maintaining the sandwiched state between the punch and the cushion.
具体的には、上記パンチと上記クッションとによる挟持状態を維持したまま上記底面部全体を先頭にして上記ダイス刃部間に挿入する。すなわち、上記底面部と上記側面部との間の境界線の部分は、すべて上記ダイス刃部間を通過させる。これにより、上記底面部と上記側面部との間の角部は略直角となる。
そして、上記中間成形体のダイスに対する相対的な前進は、上記底面部全体がダイス刃部を通過した後、上記側面部の一部のみが上記ダイス刃部を通過した時点で停止させる。そして、側面部全体がダイス刃部を通過することを避ける。これにより、底面部とその両側から立設した左右一対の側面部とが断面コ字状形状を呈し、かつ、底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体を得ることができる。
Specifically, it is inserted between the die blades with the entire bottom surface being at the top while maintaining the clamping state between the punch and the cushion. That is, the boundary line portion between the bottom surface portion and the side surface portion is all passed between the die blade portions. Thereby, the corner | angular part between the said bottom face part and the said side part becomes a substantially right angle.
And the relative advance with respect to the die | dye of the said intermediate molded object is stopped when only a part of said side part passes the said die blade part after the said whole bottom face part passed the die blade part. And it avoids that the whole side part passes a die blade part. As a result, the bottom surface portion and the pair of left and right side surfaces standing from both sides thereof have a U-shaped cross section, and the bottom surface portion exhibits a concave curved surface that is bent inward along the longitudinal direction. A molded body having a deformed U-shaped portion can be obtained.
このようにして得られた成形体の上記異形コ字状部は、必然的に、その側面部全体が平坦な面ではなく、一部が外方に膨らんだ上記膨出部となる。この膨出部の存在により、側面部の剛性を高めることができる。一方、このような膨出部の形状が許容されない製品には、上記製造方法を適用することはできない。   The odd-shaped U-shaped part of the molded body thus obtained is inevitably the bulging part partially bulging outward, not the entire side part. Due to the presence of the bulging portion, the rigidity of the side surface portion can be increased. On the other hand, the above manufacturing method cannot be applied to products in which the shape of the bulging portion is not allowed.
また、上記側面部に形成された上記膨出部は、その周囲の平面状側面部の中に非常に滑らかな自然な形状変化で形成され、不要なしわ等の外観特性を低下させるような特徴は生じない。むしろ、上記膨出部を積極的に設けた形状と見ることもでき、斬新な意匠性さえ醸し出す優れた外観特性が得られる。
一方、上記中間成形体をダイス刃部間を通過させる際に、側面部の全体を通過させた場合には、全体形状が略平坦状になった後、ダイス間から取り出した後に所謂スプリングバック現象によって両側面部間が底面部と離れるほど広がるという現象が生じてしまう。さらに、側面部にしわ状の外観不良が残ってしまい、製品化することが困難となる。
In addition, the bulging portion formed on the side surface portion is formed with a very smooth natural shape change in the surrounding flat side surface portion, and the appearance characteristics such as unnecessary wrinkles are reduced. Does not occur. Rather, it can be regarded as a shape in which the above-mentioned bulging portion is positively provided, and an excellent appearance characteristic that brings out even a novel design can be obtained.
On the other hand, when the intermediate formed body is passed between the die blade portions, when the entire side surface portion is passed, the so-called springback phenomenon occurs after the entire shape becomes substantially flat and is taken out between the dies. As a result, a phenomenon occurs in which the distance between both side surfaces increases as the distance from the bottom surface increases. Furthermore, wrinkle-like appearance defects remain on the side portions, making it difficult to produce a product.
このように、本発明の製造方法を用いれば、上記のごとく底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体を外観特性に優れた状態で容易に製造することができ、かつ、1枚の素材から1部品のまま高い歩留まりで製造することができる。そして、得られた成形体の上記異形コ字状部が、底面部とその両側の側面部とを一体的に連ねたものとなるので、溶接による接合を行う必要がない。それ故、その分、軽量化を図ることができる。さらには、上記側面部の剛性向上と溶接部の不要化による強度向上効果によって、素材自体の板厚を減少させることもでき、これによる軽量化効果も得ることができる。   Thus, by using the manufacturing method of the present invention, as described above, a molded body having a deformed U-shaped portion that has a concave curved surface that is curved so that the bottom surface portion is recessed inward along the longitudinal direction has an appearance characteristic. It can be easily manufactured in an excellent state, and can be manufactured from a single material with a high yield as a single component. And since the said odd-shaped U-shaped part of the obtained molded object becomes what integrally connected the bottom face part and the side part on the both sides, it is not necessary to join by welding. Therefore, the weight can be reduced accordingly. Furthermore, the plate | board thickness of raw material itself can also be reduced by the strength improvement effect by the rigidity improvement of the said side part, and the necessity of a welding part, and the weight reduction effect by this can also be acquired.
次に、第2の発明は、底面部と該底面部の両側から立設した左右一対の側面部とを有する断面コ字状形状を呈し、上記底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体であって、
上記側面部は、外方に膨らんだ膨出部を有すると共に、該膨出部の周囲には上記底面部に対して略直角に立設した平面状側面部を有することを特徴とする異形コ字状部を有する成形体にある(請求項5)。
Next, the second invention presents a U-shaped cross section having a bottom surface portion and a pair of left and right side surface portions erected from both sides of the bottom surface portion, and the bottom surface portion is recessed inward along the longitudinal direction. A molded body having a deformed U-shaped portion that has a concavely curved curved surface,
The side surface portion has a bulging portion that bulges outward, and has a flat side surface portion erected substantially perpendicular to the bottom surface portion around the bulging portion. It exists in the molded object which has a character-shaped part (Claim 5).
本発明の成形体は、たとえば上記製造方法によって得ることができ、上述したごとく、上記側面部に上記膨出部を有しているので、側面部の剛性に優れ強度的に優れたものとなる。さらに、上記側面部に形成された上記膨出部は、その周囲の平面状側面部の中に非常に滑らかな自然な形状変化で形成され、不要なしわ等の外観特性を低下させるような特徴はなく、斬新な意匠性を醸し出す優れた外観特性を有する。
また、上記異形コ字状部が、底面部とその両側の側面部とを一体的に連ねた構成となっており、溶接による接合を行っていない。そのため、溶接を行っていないことによる底面部の強度向上を図ることもできる。また、これらの強度向上分を素材の薄肉化に繋げることもでき、軽量化することも可能である。
The molded body of the present invention can be obtained, for example, by the above-described manufacturing method. As described above, the side surface portion has the bulged portion, so that the side surface portion has excellent rigidity and strength. . Further, the bulging portion formed on the side surface portion is formed with a very smooth natural shape change in the surrounding flat side surface portion, and the appearance characteristics such as unnecessary wrinkles are reduced. No, it has excellent appearance characteristics that create a novel design.
Further, the odd-shaped U-shaped portion is configured such that the bottom surface portion and the side surface portions on both sides thereof are integrally connected, and is not joined by welding. For this reason, it is possible to improve the strength of the bottom surface portion by not performing welding. Moreover, these strength improvement parts can also be connected to the thinning of a raw material, and it is also possible to reduce in weight.
本発明の製造方法においては、上記ダイスの上記ダイス刃部は平行な2本の直線上に設けられていることが好ましい(請求項2)。この場合には、湾曲した上記底部の長手方向両端部近傍における側面部は比較的深い位置までダイス刃部を通過させ、中央部近傍は比較的浅い位置までだけダイス刃部を通過させるように成形することができる。これにより、上記膨出部の形成位置を中央よりに設定することが可能となる。
なお、上記ダイスのダイス刃部を曲線状に設けて上記膨出部の位置や形を調整することも可能である。
In the manufacturing method of this invention, it is preferable that the said die blade part of the said die | dye is provided on two parallel straight lines (Claim 2). In this case, the side surface portion in the vicinity of both ends in the longitudinal direction of the curved bottom portion passes through the die blade portion to a relatively deep position, and the vicinity of the central portion is formed to pass the die blade portion only to a relatively shallow position. can do. Thereby, it becomes possible to set the formation position of the said bulging part from the center.
It is also possible to adjust the position and shape of the bulging portion by providing the die blade portion of the die in a curved shape.
また、上記中間成形体は、上記底面部と上記側面部とのなす角度が135°±10°の範囲にあることが好ましい(請求項3)。この場合には、上記パンチとクッションによって上記中間成形体の底面部を挟持した際の変形を容易化することができる。一方、上記底面部と上記側面部とのなす角度が125°未満の場合及び145°を超えてもその後の成形は可能であるが、上記の挟持の際の変形が安定化しないおそれがある。   The intermediate molded body preferably has an angle formed by the bottom surface portion and the side surface portion in a range of 135 ° ± 10 °. In this case, it is possible to facilitate deformation when the bottom portion of the intermediate molded body is sandwiched between the punch and the cushion. On the other hand, when the angle formed between the bottom surface portion and the side surface portion is less than 125 ° or exceeding 145 °, subsequent molding is possible, but the deformation at the time of clamping may not be stabilized.
また、上記中間成形体を形成するための上記曲げ加工は、該中間成形体における上記底面部と上記側面部の曲げ形状に対応した谷状成形面を有する予備加工ダイスと、上記曲げ形状に対応した山状成形面を有する予備加工パンチとを用いてこれらの間に上記ブランク材を挟持することによって行うことが好ましい(請求項4)。この場合には、上記予備加工ダイスと予備加工パンチによってブランク材を挟持するだけで容易に中間成形体を成形することができる。   Further, the bending process for forming the intermediate molded body corresponds to a pre-processed die having a valley-shaped molding surface corresponding to the bent shape of the bottom surface part and the side surface part of the intermediate molded body, and the bent shape. It is preferable to carry out by sandwiching the blank material between them using a pre-processed punch having a chevron-shaped molding surface (Claim 4). In this case, it is possible to easily form the intermediate molded body simply by sandwiching the blank material with the preliminary processing die and the preliminary processing punch.
次に、上記成形体においては、左右一対の上記側面部は、上記底面部と反対側の端部同士が互いに近づくように少なくとも一方が成形されて互いに接合されており、断面形状が上記コ字状形状を含む閉断面形状となっている構成とすることもできる(請求項6)。この場合には、少なくとも上記異形コ字状部の底面部に溶接を施す必要がなく、高強度化及び軽量化を図ることができる。   Next, in the molded body, at least one of the pair of left and right side surfaces is molded and joined to each other so that end portions on the opposite side to the bottom surface are close to each other, and the cross-sectional shape is the U-shape. It can also be set as the structure used as the closed cross-sectional shape containing a shape (Claim 6). In this case, it is not necessary to weld at least the bottom surface portion of the odd-shaped U-shaped portion, and high strength and light weight can be achieved.
また、上記成形体は、車両用シートのシートバック内に内蔵されるフレーム部品に適用することができる(請求項7)。この場合には、上述したような高強度化及び軽量化を図ることができ、車両用シートのシートバック内に内蔵されるフレーム部品として最適である。   Moreover, the said molded object is applicable to the frame components incorporated in the seat back of a vehicle seat (Claim 7). In this case, it is possible to increase the strength and weight as described above, and it is optimal as a frame component built in the seat back of the vehicle seat.
(実施例1)
本発明の実施例に係る異形コ字状部を有する成形体及びその製造方法につき、図1〜図9を用いて説明する。
本例で製造する成形体1は、図1〜図3に示すごとく、底面部21と該底面部21の両側から立設した左右一対の側面部22、23とを有する断面コ字状形状を呈し、上記底面部21が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部20を有する成形体である。側面部22、23は、外方に膨らんだ膨出部225、235を有すると共に、該膨出部225、235の周囲には上記底面部21に対して略直角に立設した平面状側面部226、236を有する。
Example 1
A molded body having a deformed U-shaped portion according to an embodiment of the present invention and a manufacturing method thereof will be described with reference to FIGS.
As shown in FIGS. 1 to 3, the molded body 1 manufactured in this example has a U-shaped cross section having a bottom surface portion 21 and a pair of left and right side surface portions 22 and 23 erected from both sides of the bottom surface portion 21. It is a molded body having a deformed U-shaped portion 20 which is formed and presents a concave curved surface in which the bottom surface portion 21 is bent inward along the longitudinal direction. The side surface portions 22 and 23 have bulging portions 225 and 235 that bulge outward, and the planar side surface portions erected substantially perpendicular to the bottom surface portion 21 around the bulging portions 225 and 235. 226, 236.
上記成形体1を製造するに当たっては、まず、図4に示すごとく、平板状の鋼板よりなるブランク材10を準備する。本例では、側面部22、23の幅寸法に対応させ、ブランク材10の幅寸法を変化させ、概略台形状の形状とした。また、ブランク材10には、予め軽量化のための貫通穴19を複数設けた。
次に、図5、図6に示すごとく、このブランク材10を用いて、中間成形体15を形成する。
In producing the molded body 1, first, as shown in FIG. 4, a blank 10 made of a flat steel plate is prepared. In this example, the width dimension of the blank material 10 is changed to correspond to the width dimension of the side surface portions 22 and 23, and a substantially trapezoidal shape is obtained. Further, the blank 10 was provided with a plurality of through holes 19 for weight reduction in advance.
Next, as shown in FIGS. 5 and 6, an intermediate molded body 15 is formed using the blank material 10.
本例では、図5に示すごとく、一対の予備成形金型4を用いて曲げ加工を実施する。予備成形金型4は、得ようとする中間成形体15における底面部21と上記側面部22、23の曲げ形状に対応した谷状成形面410を有する予備加工ダイス41と、上記曲げ形状に対応した山状成形面420を有する予備加工パンチ42とよりなる。   In this example, as shown in FIG. 5, bending is performed using a pair of preforming molds 4. The preforming die 4 corresponds to a pre-processing die 41 having a valley forming surface 410 corresponding to the bent shape of the bottom surface portion 21 and the side surface portions 22 and 23 of the intermediate molded body 15 to be obtained, and the bent shape. And the pre-processed punch 42 having the ridge-shaped forming surface 420.
より具体的には、予備加工ダイス41は、平坦な上面411から下方に窪んだ上記谷状成形面410を有し、谷状成形面410は、平坦な受面412を上面に有するクッション部413を底部に備え、その左右に、上方に近づくほど両者の間の空間距離が広くなるように傾斜した一対のテーパダイス面414を有している。上記クッション部413は、予備加工パンチ42からの押圧力に応じて後退可能に配設されている。   More specifically, the preliminary processing die 41 has the above-described valley-shaped molding surface 410 that is recessed downward from the flat upper surface 411, and the valley-shaped molding surface 410 has a cushion portion 413 having a flat receiving surface 412 on the upper surface. And a pair of tapered die surfaces 414 that are inclined so that a spatial distance between the two becomes wider toward the upper side. The cushion portion 413 is disposed so as to be retractable in accordance with the pressing force from the preliminary machining punch 42.
予備加工パンチ42の山状成形面420は、平坦な先端面421の左右に、上方に近づくほど両者の間の肉厚寸法が広くなるように傾斜した一対のテーパパンチ面424を有している。先端面421とテーパパンチ面424との間の一対の角部425は、それぞれ得ようとする中間成形体15及び成形体1の底面部21と側面部22、23との間の境界線aに対応するよう設けてある。また、上記予備加工ダイス41のテーパダイス面414とテーパパンチ面424とは、得ようとする中間成形体15の側面部21、22の形成角度に対応させて傾斜させてある。本例では、傾斜角αは予備加工パンチ42の相対的な移動方向に対して45°、つまり、底面部21と側面部22、23との間の角度が135°となるよう設定した。   The mountain-shaped forming surface 420 of the pre-processed punch 42 has a pair of tapered punch surfaces 424 that are inclined to the left and right of the flat front end surface 421 so that the thickness dimension between the two becomes wider as it approaches the upper side. A pair of corners 425 between the tip surface 421 and the taper punch surface 424 correspond to the boundary line a between the intermediate part 15 and the bottom part 21 and the side parts 22 and 23 of the intermediate part 15 to be obtained, respectively. It is provided to do. Further, the taper die surface 414 and the taper punch surface 424 of the preliminary machining die 41 are inclined according to the formation angle of the side surface portions 21 and 22 of the intermediate molded body 15 to be obtained. In this example, the inclination angle α is set to 45 ° with respect to the relative movement direction of the preliminary machining punch 42, that is, the angle between the bottom surface portion 21 and the side surface portions 22 and 23 is set to 135 °.
このような予備成形ダイス4を用い、まずは、図5(a)に示すごとく、予備加工ダイス41の上面411にブランク材10を載置する。このとき、底面部21と側面部22、23との間の境界線a(図6)となる位置を、予備加工パンチ42の上記角部425に対面する位置に合わせる。   Using such a preforming die 4, first, as shown in FIG. 5A, the blank material 10 is placed on the upper surface 411 of the preforming die 41. At this time, the position that becomes the boundary line a (FIG. 6) between the bottom surface portion 21 and the side surface portions 22 and 23 is matched with the position facing the corner portion 425 of the preliminary machining punch 42.
次に、図5(b)に示すごとく、予備加工パンチ42を相対的に予備加工ダイス41に向けて前進させ、山状成形面420を谷状成形面410内に挿入する。これにより、ブランク材10は、底面部21と側面部22、23との間の直線状の境界線aを起点に曲げ加工される。そして、図6に示すごとく、底面部21が平坦面であると共にその両側の上記側面部22、23との間のなす角度βがいずれも鈍角の略135°である中間成形体15が得られる。   Next, as shown in FIG. 5B, the preliminary processing punch 42 is relatively advanced toward the preliminary processing die 41 to insert the mountain-shaped forming surface 420 into the valley-shaped forming surface 410. Thereby, the blank material 10 is bent with the linear boundary line a between the bottom surface portion 21 and the side surface portions 22 and 23 as a starting point. As shown in FIG. 6, an intermediate molded body 15 is obtained in which the bottom surface portion 21 is a flat surface and the angle β between the side surface portions 22 and 23 on both sides thereof is an obtuse angle of approximately 135 °. .
次に、図7に示すごとく、上記底面部21における所望の上記凹状曲面の内面形状に対応した凹状挟持面510を有するパンチ51と、上記凹状曲面の外面形状に対応した凸状挟持面520を有するクッション52と、上記底面部21の外幅寸法に対応する間隔を空けて配置されたダイス刃部530を有するダイス53とを備えた金型5を用いた加工を行う。   Next, as shown in FIG. 7, a punch 51 having a concave clamping surface 510 corresponding to the desired inner surface shape of the concave curved surface in the bottom surface portion 21 and a convex clamping surface 520 corresponding to the outer surface shape of the concave curved surface. Processing is performed using the mold 5 including the cushion 52 having the die 52 and the die 53 having the die blade portion 530 arranged at an interval corresponding to the outer width dimension of the bottom surface portion 21.
上記パンチ51は、厚み寸法が得ようとする成形体1の側面部21、22の内寸法に対応した厚みを有する挿入部511を有し、その先端に上記凹状挟持面510を設けてある。そして、挿入部511の側面512と凹状挟持面510とのなす角度γは直角(90°)とした。   The punch 51 has an insertion part 511 having a thickness corresponding to the inner dimension of the side parts 21 and 22 of the molded body 1 to be obtained, and the concave sandwiching surface 510 is provided at the tip thereof. The angle γ formed between the side surface 512 of the insertion portion 511 and the concave sandwiching surface 510 is a right angle (90 °).
上記クッション52は、上記パンチ51の挿入部511と同じ厚みを有し、その上端面に上記凸状挟持面520を有している。
上記ダイス53は、左右一対の上記ダイス刃部530を備え、その間に上記クッション52が配置されている。ダイス刃部530は、その断面形状が曲率半径Rが____mmの円弧状形状に設定してある。また、ダイス53の上面531を平坦面とすることによって、ダイス刃部530の長手方向に沿った形状を2本の平行な直線上に設けた。
そして、クッション52は、初期状態において凸状挟持面520をダイス53の上方に突出させた状態で昇降可能に配置されている。
The cushion 52 has the same thickness as the insertion portion 511 of the punch 51, and has the convex sandwiching surface 520 on the upper end surface.
The die 53 includes a pair of left and right die blade portions 530, and the cushion 52 is disposed therebetween. The die blade portion 530 has a cross-sectional shape set to an arc shape having a radius of curvature R of ____mm. In addition, by making the upper surface 531 of the die 53 a flat surface, the shape along the longitudinal direction of the die blade portion 530 was provided on two parallel straight lines.
The cushion 52 is arranged so that it can be raised and lowered in a state in which the convex clamping surface 520 protrudes above the die 53 in the initial state.
上記金型5を用い、図8(a)に示すごとく、上記中間成形体15の内部に配置した上記パンチ51の凹状挟持面510とこれに対向配置させたクッション52の凸状挟持面520によって底面部21を挟持して該底面部21を凹状曲面に変形させる。
この底面部21の変形を実行すると、その両側の側面部22、23に対し、底面部21から離れるほど長手方向に強い引張応力が付与される状態となる。そのため、同図に示すごとく、側面部22、23同士の間が開くように変形すると共に側面部22、23の一部(b部)が膨らんで平坦でない状態となる。なお、この時点の変形は、弾性変形の割合も大きいので、上記パンチ51とクッション52の挟持状態を解除すると、もとの中間成形体15の形状に近づく。そのため、次の工程は、パンチ51とクッション52との挟持状態を維持したまま行う。
As shown in FIG. 8 (a), using the mold 5, the concave sandwiching surface 510 of the punch 51 disposed inside the intermediate molded body 15 and the convex sandwiching surface 520 of the cushion 52 disposed opposite thereto are used. The bottom surface portion 21 is sandwiched to deform the bottom surface portion 21 into a concave curved surface.
When the deformation of the bottom surface portion 21 is executed, a stronger tensile stress is applied to the side surface portions 22 and 23 on both sides in the longitudinal direction as the distance from the bottom surface portion 21 increases. Therefore, as shown in the figure, the side surface portions 22 and 23 are deformed so as to be opened, and a part (b portion) of the side surface portions 22 and 23 swells and is not flat. In addition, since the deformation | transformation at this time also has the ratio of elastic deformation, if the clamping state of the said punch 51 and the cushion 52 is cancelled | released, the shape of the original intermediate molded object 15 will be approached. Therefore, the next step is performed while maintaining the sandwiched state between the punch 51 and the cushion 52.
すなわち、図8(b)に示すごとく、パンチ51とクッション52とによる挟持状態を維持したまま底面部21全体を先頭にしてダイス刃部530間に挿入する。そして、底面部21と側面部22、23との間の境界線aの部分は、すべてダイス刃部530間を通過させる。これにより、底面部21と側面部22、23との間の角部は略直角となる。   That is, as shown in FIG. 8B, the entire bottom surface 21 is inserted between the die blades 530 while maintaining the sandwiched state between the punch 51 and the cushion 52. And the part of the boundary line a between the bottom face part 21 and the side face parts 22 and 23 is made to pass between the die blade parts 530. Thereby, the corner | angular part between the bottom face part 21 and the side part 22 and 23 becomes a substantially right angle.
また、同図に示すごとく、中間成形体15のダイス53に対する相対的な前進は、底面部21全体がダイス刃部530を通過した後、側面部22、23の一部のみがダイス刃部530を通過した時点で停止させ、側面部22、23全体がダイス刃部530を通過することを避ける。これにより、底面部21とその両側から立設した左右一対の側面部22、23とが断面コ字状形状を呈し、かつ、底面部21が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部20を有する成形体1が得られる。得られた成形体1の上記異形コ字状部20は、必然的に、その側面部22、23全体が平坦な面ではなく、一部が外方に膨らんだ上記膨出部225、235となる。この膨出部225、235の存在により、側面部全体が平坦な場合よりも、側面部22、23の剛性を高めることができる。   Further, as shown in the figure, relative advancement of the intermediate molded body 15 with respect to the die 53 is such that after the entire bottom surface portion 21 passes through the die blade portion 530, only a part of the side surface portions 22 and 23 is the die blade portion 530. Is stopped at the time of passing, so that the entire side portions 22 and 23 do not pass the die blade portion 530. Accordingly, the bottom surface portion 21 and the pair of left and right side surface portions 22 and 23 erected from both sides thereof have a U-shaped cross section, and the bottom surface portion 21 is a concave shape that is bent inward along the longitudinal direction. A molded body 1 having a deformed U-shaped portion 20 having a curved surface is obtained. The deformed U-shaped portion 20 of the obtained molded body 1 inevitably has the side surface portions 22 and 23 not flat surfaces, and the bulging portions 225 and 235 partially swelled outwardly. Become. Due to the presence of the bulging portions 225 and 235, the rigidity of the side surface portions 22 and 23 can be increased as compared with the case where the entire side surface portion is flat.
また、側面部22、23に形成された上記膨出部225、235は、その周囲の平面状側面部226、236の中に非常に滑らかな自然な形状変化で形成され、不要なしわ等の外観特性を低下させるような特徴は生じない。むしろ、膨出部225、235を積極的に設けた形状と見ることができ、斬新な意匠性を有する優れた外観特性が得られる。また、予めブランク材10に設けておいた貫通穴19の存在は、成形上まったく問題とならず、上記の優れた外観特性を悪化させることはなかった。   Further, the bulging portions 225 and 235 formed on the side surface portions 22 and 23 are formed by a very smooth natural shape change in the surrounding planar side surface portions 226 and 236, and unnecessary wrinkles and the like are formed. Features that reduce appearance characteristics do not occur. Rather, it can be regarded as a shape in which the bulging portions 225 and 235 are actively provided, and an excellent appearance characteristic having a novel design can be obtained. Further, the presence of the through holes 19 provided in the blank 10 in advance did not cause any problem in molding, and the above-described excellent appearance characteristics were not deteriorated.
また、本例の製造方法を用いれば、上記のごとく底面部21が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部20を有する成形体1を外観特性に優れた状態で容易に製造することができ、かつ、1枚の素材から1部品のまま高い歩留まりで製造することができる。
歩留まりの向上は、図9に示すごとく、帯状の鋼板からブランク材10を採取する際に、ブランク材10の周囲の屑とする部分109が、後述する比較例や従来の材料の2部品化の場合よりも少なくできることから容易に理解できる。
Moreover, if the manufacturing method of this example is used, the molded object 1 which has the odd-shaped U-shaped part 20 which exhibits the concave curved surface curved so that the bottom face part 21 may be depressed inward along a longitudinal direction as mentioned above is an external appearance characteristic. Can be easily manufactured in a superior state, and can be manufactured with a high yield as a single component from a single material.
As shown in FIG. 9, when the blank material 10 is sampled from the strip-shaped steel plate, the yield 109 is improved as a result of the comparison of the later-described comparative material and the conventional material into two parts. It can be easily understood because it can be less than the case.
また、得られた成形体1の異形コ字状部20が、底面部21とその両側の側面部22、23とを一体的に連ねたものとなるので、溶接による接合を行う必要がない。それ故、その分、軽量化を図ることができる。さらには、上記側面部22、23の剛性向上と溶接部の不要化による強度向上効果によって、素材自体の板厚を減少させることもでき、これによる軽量化効果も得ることができる。   Further, since the odd-shaped U-shaped portion 20 of the obtained molded body 1 is obtained by integrally connecting the bottom surface portion 21 and the side surface portions 22 and 23 on both sides thereof, it is not necessary to perform joining by welding. Therefore, the weight can be reduced accordingly. Furthermore, the plate | board thickness of raw material itself can also be reduced by the strength improvement effect by the rigidity improvement of the said side parts 22 and 23, and the necessity of a welding part, and the weight reduction effect by this can also be acquired.
(比較例1)
本例では、図10(b)に示すごとく、上記膨出部225、235がなく全体が平坦上の側面部922、923を有し、底面部921が実施例1と同様の長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる成形体9を製造することを試みた。成形に使用した金型は、実施例1の金型5と同じである。
(Comparative Example 1)
In this example, as shown in FIG. 10B, the bulging portions 225 and 235 are not provided, and the entire surface has flat side portions 922 and 923, and the bottom portion 921 is along the longitudinal direction as in the first embodiment. An attempt was made to produce a molded body 9 having a concave curved surface bent so as to be recessed inward. The mold used for molding is the same as the mold 5 of the first embodiment.
まず、図10(a)に示すごとく、ブランク材10を準備し、平板状のブランク材10をパンチ51の凹状挟持面510とこれに対向配置させたクッション52の凸状挟持面520によって底面部921となるべき部位を挟持してブランク材10全体を凹状曲面に変形させる。   First, as shown in FIG. 10A, a blank 10 is prepared, and a flat blank 10 is formed by a concave sandwiching surface 510 of a punch 51 and a convex sandwiching surface 520 of a cushion 52 in which the blank 51 is opposed to this. The entire blank material 10 is deformed into a concave curved surface by sandwiching a portion to be 921.
次いで、図10(b)に示すごとく、パンチ51とクッション52とによる挟持状態を維持したままブランク材10における底面部921となる部分全体を先頭にしてダイス刃部530間に挿入し、一気に側面部922、923全体をダイス刃部530間を通過させる。これにより、底面部921と側面部922、923との間の角部は略直角となった成形体9が得られる。   Next, as shown in FIG. 10B, the blank material 10 is inserted between the die blade portions 530 with the entire portion that becomes the bottom surface portion 921 being maintained, while maintaining the sandwiched state between the punch 51 and the cushion 52, and the side surface at a stretch. The entire portions 922 and 923 are passed between the die blade portions 530. Thereby, the molded body 9 in which the corners between the bottom surface portion 921 and the side surface portions 922 and 923 are substantially perpendicular is obtained.
次に、図10(c)に示すごとく、パンチ51及びクッション52とを上昇させて、成形体9をダイス53から抜き出す。これにより、図11に示すごとく、得られた成形体9は、側面部921、922が底面部921から離れるほど広がるように変形し、所望のコ字状部は得られなかった。また、側面部921、922は、実施例1の場合のような膨出部225、235は形成されず、全体的に平坦な状態ではあったが、多数のしわ状の外観不良が形成されており、その外観不良によって製品化は難しい状態であった。   Next, as shown in FIG. 10C, the punch 51 and the cushion 52 are raised and the molded body 9 is extracted from the die 53. As a result, as shown in FIG. 11, the obtained molded body 9 was deformed so that the side surface portions 921 and 922 spread away from the bottom surface portion 921, and a desired U-shaped portion was not obtained. Further, the side portions 921 and 922 were not formed with the bulging portions 225 and 235 as in the case of the first embodiment, and were in a flat state as a whole, but a large number of wrinkle-like appearance defects were formed. The product was difficult to commercialize due to the poor appearance.
(実施例2)
本例では、実施例1によって得られた成形体1を用い、車両用シートのシートバック内に内蔵されるフレーム部品としての成形体102を作製した。この成形体102は、実施例1における成形体1における左右一対の側面部22、23における、底面部21と反対側の端部227、237同士が互いに近づくように成形されて互いに接合されている。そして、成形体102の断面形状は、上記コ字状形状を含む略長方形の閉断面形状となっている。
(Example 2)
In this example, a molded body 102 as a frame part built in a seat back of a vehicle seat was manufactured using the molded body 1 obtained in Example 1. The molded body 102 is molded such that the end portions 227 and 237 on the opposite side to the bottom surface portion 21 of the pair of left and right side surface portions 22 and 23 in the molded body 1 in the first embodiment are joined to each other. . The cross-sectional shape of the molded body 102 is a substantially rectangular closed cross-sectional shape including the U-shape.
すなわち、上記側面部22、23の端部227、237は、いずれも略直角に内方に曲げられている。この曲げ加工は、側面部22、23の間に所望の曲げ角度に対応した角部を有する型部材(図示略)を挿入配置し、外部から側面部22、23の端部227、237を押圧することによって行うことができる。なお、この曲げ加工は、公知の様々な方法によって行うことが可能である。
また、上記側面部22、23の端部227、237は、一部が重ね合わされ、溶接によって接合されている。
That is, the end portions 227 and 237 of the side surface portions 22 and 23 are both bent inward at substantially right angles. In this bending process, a mold member (not shown) having a corner corresponding to a desired bending angle is inserted between the side portions 22 and 23 and the end portions 227 and 237 of the side portions 22 and 23 are pressed from the outside. Can be done. This bending process can be performed by various known methods.
The end portions 227 and 237 of the side surface portions 22 and 23 are partially overlapped and joined by welding.
以上のような構成の成形体102からなるフレーム部品は、溶接部が上記の端部227、237の当接部のみである。すなわち、断面長方形状における2つの短辺部面のうち一方のみが溶接され、他方の上記底面部21は最初から一体となっている。これにより、従来の2枚の材料から構成して2つの短辺部面の両方を溶接によって接合してある構造に比べ、強度面及び重量面において非常に優れたものとなる。   In the frame part formed of the molded body 102 having the above-described configuration, the welded portion is only the contact portion of the end portions 227 and 237. That is, only one of the two short side surfaces in the rectangular cross section is welded, and the other bottom surface 21 is integrated from the beginning. Thereby, compared with the structure comprised from the material of the conventional 2 sheets, and both the two short side part surfaces were joined by welding, it becomes the thing excellent in the strength surface and the weight surface.
(比較例2)
本比較例は、実施例2と同様の車両用シートのシートバック内に内蔵されるフレーム部品としての成形体902(図15)を、実施例1、2と異なる方法で1枚の素材から1部品のまま製造する例である。
(Comparative Example 2)
In this comparative example, a molded body 902 (FIG. 15) as a frame component incorporated in the seat back of a vehicle seat similar to that in the second embodiment is changed from one material to a first material by a method different from that in the first and second embodiments. It is an example which manufactures with components.
本比較例では、図13に示すごとく、略V字状のブランク材90を素材として用いる。そして、図14に示すごとく、ブランク材90のV字の外側の両側端部及び内側の端部を直角に折り返して、短辺部面931〜934を形成する。
次に、図14、図15に示すごとく、境界線cを起点として曲げ加工を行い、短辺部面931と短辺部面932とを当接させると共に、短辺部面933と短辺部面934とを当接させる。その後、各短辺部面の当接部を溶接することにより、断面略長方形状の兵断面形状を有する成形体902が得られる。
In this comparative example, as shown in FIG. 13, a substantially V-shaped blank 90 is used as a material. And as shown in FIG. 14, the both-sides edge part of the outer side of the V-shape of the blank material 90, and an inner edge part are turned up at right angle, and the short side part surfaces 931-934 are formed.
Next, as shown in FIGS. 14 and 15, bending is performed starting from the boundary line c, the short side surface 931 and the short side surface 932 are brought into contact, and the short side surface 933 and the short side portion are brought into contact with each other. The surface 934 is brought into contact. Then, the molded object 902 which has the cross section of a substantially rectangular cross section is obtained by welding the contact part of each short side part surface.
得られた成形体902は、実施例2の底面部21とは異なる方向、つまり、長手方向に沿って外側に凸状となる曲面を呈してなる短辺面部における略直線状の平面部939を最初から一体化した構造とし、その両側の境界線cを起点として曲げ加工を行う。これにより、いわゆる伸びフランジ加工を行うことなく加工を完了させることができる。   The obtained molded body 902 has a substantially straight flat surface portion 939 in a different direction from the bottom surface portion 21 of Example 2, that is, a short side surface portion that has a curved surface that protrudes outward along the longitudinal direction. The structure is integrated from the beginning, and bending is performed starting from the boundary line c on both sides. Thereby, processing can be completed without performing so-called stretch flange processing.
しかしながら、成形体902は、溶接部が実施例2に比べて約1.5倍の長さとなる。その分、重量面及び強度面で実施例2の成形体102に比べて劣る。さらに、図13に示すごとく、帯状鋼板からブランク材90を抜いた残りの屑部が、実施例2(実施例1)の場合に比べて増大し、歩留まりも低下する。   However, the molded body 902 has a welded portion that is approximately 1.5 times as long as the second embodiment. Accordingly, it is inferior to the molded body 102 of Example 2 in terms of weight and strength. Furthermore, as shown in FIG. 13, the remaining scrap portion obtained by removing the blank material 90 from the belt-shaped steel plate increases as compared with the case of Example 2 (Example 1), and the yield also decreases.
実施例1における、異形コ字状部を立てた状態の成形体を示す斜視図。The perspective view which shows the molded object in the state which stood up the odd-shaped U-shaped part in Example 1. FIG. 実施例1における、異形コ字状部を寝かせた状態の成形体を示す斜視図。The perspective view which shows the molded object in the state which laid the deformed U-shaped part in Example 1. FIG. 実施例1における、断面図(図1のA−A線矢視断面図)。Sectional drawing in Example 1 (AA arrow directional cross-sectional view of FIG. 1). 実施例1における、ブランク材を示す平面図。The top view which shows the blank material in Example 1. FIG. 実施例1における、(a)予備加工ダイスと予備加工パンチとの間にブランク材を配置した状態、(b)予備加工ダイスと予備加工パンチとによってブランク材を挟持して曲げ加工を施した直後の状態を示す説明図。In Example 1, (a) a state in which the blank material is disposed between the preliminary processing die and the preliminary processing punch, and (b) immediately after the blank material is sandwiched between the preliminary processing die and the preliminary processing punch and bent. Explanatory drawing which shows the state of. 実施例1における、中間成形の斜視図。2 is a perspective view of intermediate molding in Example 1. FIG. 実施例1における、パンチ、クッション及びダイスを備えた金型の構成を示す説明図。Explanatory drawing which shows the structure of the metal mold | die provided with the punch, cushion, and die in Example 1. FIG. 実施例1における、(a)パンチとクッションとの間にブランク材を挟持した状態、(b)底面部全体及び側面部の一部のみをダイス刃部間を通過させた状態を示す説明図。In Example 1, (a) The state which pinched | interposed the blank material between the punch and the cushion, (b) The explanatory view which shows the state which made the whole bottom face part and only a part of side part pass between die blade parts. 実施例1における、帯状鋼板からブランク材を採取する方法を示す説明図。Explanatory drawing which shows the method of extract | collecting a blank material from a strip | belt-shaped steel plate in Example 1. FIG. 比較例1における、(a)パンチとクッションとの間にブランク材を挟持した状態、(b)底面部全体及び側面部全体をダイス刃部間を通過させた状態、(c)成形体をダイスから取り出した状態を示す説明図。In Comparative Example 1, (a) a state in which a blank material is sandwiched between the punch and the cushion, (b) a state in which the entire bottom surface portion and the entire side surface portion are passed between the die blade portions, and (c) the molded body is dies. Explanatory drawing which shows the state taken out from. 比較例1における、成形体の斜視図。The perspective view of the molded object in the comparative example 1. FIG. 実施例2における、成形体の斜視図。The perspective view of the molded object in Example 2. FIG. 比較例2における、帯状鋼板からブランク材を採取する方法を示す説明図。Explanatory drawing which shows the method in which the blank material is extract | collected from the strip | belt-shaped steel plate in the comparative example 2. FIG. 比較例2における、ブランク材に曲げ加工を施した状態を示す説明図。Explanatory drawing which shows the state which performed the bending process in the blank material in the comparative example 2. FIG. 比較例2における、成形体の斜視図。The perspective view of the molded object in the comparative example 2. FIG.
符号の説明Explanation of symbols
1、102、9、902 成形体
20 異形コ字状部
21 底面部
22、23 側面部
225、235 膨出部
226、236 平面状側面部
4 予備成形金型
41 予備加工ダイス
410 谷状成形面
42 予備加工パンチ
420 山状成形面
5 金型
51 パンチ
510 凹状挟持面
52 クッション
520 凸状挟持面
53 ダイス
530 ダイス刃部
DESCRIPTION OF SYMBOLS 1,102,9,902 Forming body 20 Profile-shaped U-shaped part 21 Bottom face part 22, 23 Side face part 225, 235 Swelling part 226, 236 Planar side face part 4 Pre-molding die 41 Pre-processing die 410 Valley-shaped forming surface 42 Pre-processed punch 420 Cone forming surface 5 Die 51 Punch 510 Concave pinching surface 52 Cushion 520 Convex pinching surface 53 Die 530 Die blade part

Claims (7)

  1. 底面部と該底面部の両側から立設した左右一対の側面部とを有する断面コ字状形状を呈し、上記底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体を製造する方法であって、
    平板状のブランク材を準備し、
    該ブランク材を上記底面部と上記側面部との間の直線状の境界線を起点に曲げ加工して、上記底面部が平坦面であると共にその両側の上記側面部との間のなす角度がいずれも鈍角である中間成形体を形成し、
    上記底面部における所望の上記凹状曲面の内面形状に対応した凹状挟持面を有するパンチと、上記凹状曲面の外面形状に対応した凸状挟持面を有するクッションと、上記底面部の外幅寸法に対応する間隔を空けて配置されたダイス刃部を有するダイスとを備えた金型を用いて、上記中間成形体の内部に配置した上記パンチの上記凹状挟持面とこれに対向配置させた上記クッションの上記凸状挟持面によって上記底面部を挟持して該底面部を上記凹状曲面に変形させ、
    その後、上記パンチと上記クッションとによる挟持状態を維持したまま上記底面部全体を先頭にして上記ダイス刃部間に挿入し、上記側面部の一部のみが上記ダイス刃部を通過した時点で上記底面部と上記ダイスとの相対移動を停止することにより、上記側面部のうち上記ダイス刃部間を通過していない部分の一部が外方に膨らんだ膨出部となると共に、その周囲が上記底面部に対して略直角に立設した平面状側面部となるように上記異形コ字状部を形成することを特徴とする異形コ字状部を有する成形体の製造方法。
    It has a U-shaped cross section having a bottom surface portion and a pair of left and right side portions erected from both sides of the bottom surface portion, and has a concave curved surface that is curved so as to be recessed inward along the longitudinal direction. A method for producing a molded body having an irregular U-shaped part,
    Prepare a flat blank,
    The blank material is bent starting from a linear boundary line between the bottom surface portion and the side surface portion, and the bottom surface portion is a flat surface and the angle formed between the side surface portions on both sides thereof is Both form an intermediate molded body that is obtuse,
    Corresponding to the punch having a concave clamping surface corresponding to the desired inner surface shape of the concave curved surface in the bottom surface portion, the cushion having the convex clamping surface corresponding to the outer surface shape of the concave curved surface, and the outer width dimension of the bottom surface portion Using a die having a die having a die blade portion arranged at an interval of the punch, the concave sandwiching surface of the punch disposed inside the intermediate molded body and the cushion disposed opposite thereto The bottom surface portion is sandwiched by the convex sandwiching surface to deform the bottom surface portion into the concave curved surface,
    Then, while maintaining the clamping state between the punch and the cushion, the entire bottom surface portion is inserted between the die blade portions, and when only a part of the side surface portion passes through the die blade portion, By stopping the relative movement between the bottom surface portion and the die, a part of the side surface portion that does not pass between the die blade portions becomes a bulging portion that bulges outward, and its periphery is The method for producing a molded body having a deformed U-shaped portion, wherein the deformed U-shaped portion is formed so as to be a planar side surface portion erected substantially perpendicular to the bottom surface portion.
  2. 請求項1において、上記ダイスの上記ダイス刃部は平行な2本の直線上に設けられていることを特徴とする異形コ字状部を有する成形体の製造方法。   2. The method for manufacturing a molded body having a deformed U-shaped portion according to claim 1, wherein the die blade portion of the die is provided on two parallel straight lines.
  3. 請求項1又は2において、上記中間成形体は、上記底面部と上記側面部とのなす角度が135°±10°の範囲にあることを特徴とする異形コ字状部を有する成形体の製造方法。   3. The production of a molded body having an odd-shaped U-shaped portion according to claim 1 or 2, wherein the intermediate molded body has an angle formed by the bottom surface portion and the side surface portion in a range of 135 ° ± 10 °. Method.
  4. 請求項1〜3のいずれか1項において、上記中間成形体を形成するための上記曲げ加工は、該中間成形体における上記底面部と上記側面部の曲げ形状に対応した谷状成形面を有する予備加工ダイスと、上記曲げ形状に対応した山状成形面を有する予備加工パンチとを用いてこれらの間に上記ブランク材を挟持することによって行うことを特徴とする異形コ字状部を有する成形体の製造方法。   The bending process for forming the intermediate molded body according to any one of claims 1 to 3 has a valley-shaped molding surface corresponding to a bent shape of the bottom surface portion and the side surface portion of the intermediate molded body. Forming with a deformed U-shaped portion characterized in that it is performed by sandwiching the blank material between a pre-processed die and a pre-processed punch having a mountain-shaped forming surface corresponding to the bent shape. Body manufacturing method.
  5. 底面部と該底面部の両側から立設した左右一対の側面部とを有する断面コ字状形状を呈し、上記底面部が長手方向に沿って内方に窪むように曲がった凹状曲面を呈してなる異形コ字状部を有する成形体であって、
    上記側面部は、外方に膨らんだ膨出部を有すると共に、該膨出部の周囲には上記底面部に対して略直角に立設した平面状側面部を有することを特徴とする異形コ字状部を有する成形体。
    It has a U-shaped cross section having a bottom surface portion and a pair of left and right side portions erected from both sides of the bottom surface portion, and has a concave curved surface that is curved so as to be recessed inward along the longitudinal direction. A molded body having a modified U-shaped part,
    The side surface portion has a bulging portion that bulges outward, and has a flat side surface portion erected substantially perpendicular to the bottom surface portion around the bulging portion. Molded body having a letter-shaped part.
  6. 請求項5において、左右一対の上記側面部は、上記底面部と反対側の端部同士が互いに近づくように少なくとも一方が成形されて互いに接合されており、断面形状が上記コ字状形状を含む閉断面形状となっていることを特徴とする異形コ字状部を有する成形体。   6. The pair of left and right side portions according to claim 5, wherein at least one of the pair of left and right side portions is molded and joined to each other so that ends opposite to the bottom portion are close to each other, and the cross-sectional shape includes the U-shape. A molded article having a modified U-shaped portion characterized by having a closed cross-sectional shape.
  7. 請求項6において、上記成形体は、車両用シートのシートバック内に内蔵されるフレーム部品であることを特徴とする異形コ字状部を有する成形体。   The molded body according to claim 6, wherein the molded body is a frame component built in a seat back of a vehicle seat.
JP2008310489A 2008-12-05 2008-12-05 Molded body having odd-shaped U-shaped portion and manufacturing method thereof Expired - Fee Related JP5077211B2 (en)

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