JP5206813B2 - Method and apparatus for manufacturing a closed cross-section structure part having a bent shape - Google Patents

Method and apparatus for manufacturing a closed cross-section structure part having a bent shape Download PDF

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JP5206813B2
JP5206813B2 JP2011018406A JP2011018406A JP5206813B2 JP 5206813 B2 JP5206813 B2 JP 5206813B2 JP 2011018406 A JP2011018406 A JP 2011018406A JP 2011018406 A JP2011018406 A JP 2011018406A JP 5206813 B2 JP5206813 B2 JP 5206813B2
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和彦 樋貝
雄司 山崎
豊久 新宮
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Jfeスチール株式会社
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本発明は、曲がり形状を有する閉断面構造部品の製造方法及び装置に関し、特に、従来、自動車、家電、その他分野において、個別成形してなる二体を接合して閉断面化することにより製造されていた部品について、軽量化と衝突特性、剛性性能向上を目的とした曲がり形状且つ部品全長にわたる異形断面形状を有利に付与しうる、曲がり形状を有する閉断面構造部品の製造方法及び装置に関する。   The present invention relates to a method and an apparatus for manufacturing a closed cross-section structure part having a bent shape, and in particular, in the conventional automobile, home appliance, and other fields, it is manufactured by joining two separately formed bodies to form a closed cross section. The present invention relates to a method and an apparatus for manufacturing a closed cross-section structure part having a bent shape, which can advantageously give a bent shape for the purpose of weight reduction, impact characteristics, and improvement of rigidity performance and an irregular cross-sectional shape over the entire length of the part.
特許文献1には、高張力鋼板をロール成形して一定断面形状を有する成形体を製造し、その後該成形体を高周波焼入れし、さらにその長手方向(断面に直交する方向)で一定曲率を有するように円弧状に曲げ加工(スイープ成形)して車両用衝撃吸収具としてのバンパーレインフォースメントを製造する技術が記載されている。
特許文献2には、金属薄板の搬送経路を挟むように配置された一対の回転ロールとその下方に配置された回転ロールとが設けられ、一対の回転ロールはロール間隔可変であり、その下方に配置された回転ロールは昇降可能であるロール成形装置、及び、該装置での部品製造方法として、長尺の金属薄板の一部が一対の回転ロール間を搬送されている時に一対の回転ロールのロール間隔を変化させるとともに、搬送されている金属薄板を局所的に変形させるように下方に設置された回転ロールを昇降させることによって、長手方向に関して、同一断面を有しないロール成形部品を製造する技術が記載されている。
In Patent Document 1, a high-tensile steel sheet is roll-formed to produce a formed body having a constant cross-sectional shape, and then the formed body is induction-hardened and further has a constant curvature in its longitudinal direction (direction perpendicular to the cross-section). Thus, a technique for manufacturing a bumper reinforcement as a shock absorber for a vehicle by bending into a circular arc shape (sweep molding) is described.
Patent Document 2 is provided with a pair of rotating rolls arranged so as to sandwich the conveyance path of the thin metal plate and a rotating roll arranged below the pair of rotating rolls, and the pair of rotating rolls is variable in the roll interval. As a roll forming apparatus that can move up and down the disposed rotating rolls, and a part manufacturing method in the apparatus, when a part of a long thin metal plate is conveyed between the pair of rotating rolls, A technique for manufacturing a roll-formed part that does not have the same cross section in the longitudinal direction by changing the roll interval and raising and lowering a rotating roll installed below so as to locally deform the metal sheet being conveyed. Is described.
特開2008−120227号公報JP 2008-120227 A 特開2007−30023号公報Japanese Patent Laid-Open No. 2007-30023
特許文献1の技術では、一般的なロール成形により、一定断面形状を有する閉断面部品を成形した後、高周波焼入れし、さらに3つの曲げ駒により曲率が付与され、曲げ閉断面部品が製造される。しかしながら、部品長手方向の断面形状が一定でない部品については成形不可能である。また曲率は二次元方向のみに限定される。
特許文献2の技術は、一対の回転ロールを有する一般的なロール成形に加えて、一対の回転ロールの下方に断面形状を部品長手方向で変化させるための回転ロールが付随した成形装置により、部品長手方向で断面形状を変化させることが可能となる成形技術であるが、同時に長手方向への曲がり形状を付与することは不可能である。
In the technique of Patent Document 1, a closed cross-section part having a constant cross-sectional shape is formed by general roll forming, and then induction-quenched, and further, a curvature is given by three bending pieces to produce a bent closed cross-section part. . However, it is impossible to mold a part whose sectional shape in the longitudinal direction of the part is not constant. Further, the curvature is limited only to the two-dimensional direction.
In addition to the general roll forming having a pair of rotating rolls, the technology of Patent Document 2 uses a forming apparatus with a rotating roll for changing the cross-sectional shape in the longitudinal direction of the part below the pair of rotating rolls. Although it is a molding technique that makes it possible to change the cross-sectional shape in the longitudinal direction, it is impossible to impart a curved shape in the longitudinal direction at the same time.
以上のように、従来の技術では、断面形状(詳しくは部品長手方向に直交する方向すなわち部品短手方向の、断面形状)を部品長手方向で変化させる異形断面化と、部品長手方向の曲がり(或いは更に、ねじり)を付与する三次元形状付与とは、同時進行させるのが不可能であったため、部品各断面の異形化と三次元形状付与とを個別の成形工程とせざるをえず、その分コストがかかっていた。又、軽量化のために高強度鋼板を素材とした場合、部品各断面の異形化後の曲げ加工において成形不良が生じ易かった。   As described above, in the conventional technique, the cross-sectional shape (specifically, the cross-sectional shape perpendicular to the component longitudinal direction, that is, the cross-sectional shape of the component short direction) is changed in the component longitudinal direction, and the bending in the component longitudinal direction ( Or, furthermore, the three-dimensional shape imparting torsion) was impossible to proceed at the same time, so the cross-section of each part and the three-dimensional shape impartation had to be made into separate molding processes, It was costing minutes. In addition, when a high-strength steel plate is used as a material for weight reduction, forming defects are likely to occur in the bending process after deforming the cross-section of each part.
発明者らは、上記の課題を解決するために鋭意検討し、その結果、2枚の金属板から部品長手方向に曲がりを有する異形断面形状の閉断面構造部品を、部品各断面の異形化と三次元形状付与とが同時進行する成形工程にて、製造しうる手段を見出し、本発明をなした。
すなわち、本発明は以下のとおりである。
(1)2枚の金属板から部品長手方向に曲がり及び溶接部を有し該溶接部にはフランジ部が連なる異形断面形状の閉断面構造部品を製造する方法であって、
部品長手方向曲がりに対応する板長手方向曲がりを設け、前記フランジ部に板幅両端部を対応させた2枚の金属板を、部品断面内での非溶接曲がり部及び溶接部にそれぞれ対応する板部位に折目が付くようにプレス成形する第1工程と、
前記プレス成形後の2枚の金属板を、その凸面側が外側となるように上下に重ね合わせて幅の左右両側でそれぞれ上下に向かい合わせたフランジ部対応部位の折目同士を長手方向に溶接して溶接部を形成することで、閉断面構造体となす第2工程と、
得られた閉断面構造体を、左右一対の回転ロール或いは更に下方の回転ロールでガイドして搬送しつつ、前記回転ロールのロール間隔の変更或いは更に前記回転ロールの昇降により、前記折目及び前記溶接部を起点として立体化させて目標形状の部品となす第3工程と
を有することを特徴とする閉断面構造部品の製造方法。
(2)2枚の金属板から部品長手方向に曲がり及び溶接部を有し該溶接部にはフランジ部が連なる異形断面形状の閉断面構造部品を製造する装置であって、
部品長手方向曲がりに対応する板長手方向曲がりを設け、前記フランジ部に板幅両端部を対応させた2枚の金属板を、部品断面内での非溶接曲がり部及び溶接部にそれぞれ対応する板部位に折目が付くようにプレス成形するプレス成形機と、
前記プレス成形後の2枚の金属板を、その凸面側が外側となるように上下に重ね合わせて幅の左右両側でそれぞれ上下に向かい合わせたフランジ部対応部位の折目同士を長手方向に溶接して溶接部を形成することで、閉断面構造体となす溶接機と、
得られた閉断面構造体を、左右一対の回転ロール或いは更に下方の回転ロールでガイドして搬送しつつ、前記回転ロールのロール間隔の変更或いは更に前記回転ロールの昇降により、前記折目及び前記溶接部を起点として立体化させて目標形状の部品となすロール成形機と
を有することを特徴とする閉断面構造部品の製造装置。
The inventors have intensively studied to solve the above-mentioned problems, and as a result, a closed cross-section structural part having a modified cross-sectional shape having a bend in the longitudinal direction of the part from two metal plates can be obtained by deforming each cross-section of the part. In the molding process in which the three-dimensional shape formation proceeds simultaneously, a means that can be manufactured was found and the present invention was made.
That is, the present invention is as follows.
(1) A method of manufacturing a closed cross-section structure part having a deformed cross-sectional shape in which a bent part and a welded part are bent from two metal plates in a longitudinal direction of the part, and a flange part is connected to the welded part.
A plate corresponding to a non-weld bent portion and a welded portion in the cross section of the component is provided by providing two metal plates each having a plate longitudinal direction curve corresponding to the component longitudinal direction curve and corresponding to both ends of the plate width to the flange portion. A first step of press molding so that a crease is attached to the site;
The two metal plates after the press forming are overlapped vertically so that the convex side is on the outside, and the folds of the flange corresponding parts are welded in the longitudinal direction facing each other on both the left and right sides of the width. Forming a welded portion to form a closed cross-section structure,
The obtained closed cross-section structure is guided and transported by a pair of left and right rotating rolls or further lower rotating rolls, and the folds and the folds are changed by changing the roll interval of the rotating rolls or raising and lowering the rotating rolls. And a third step of forming a three-dimensional object with a welded portion as a starting point to form a part having a target shape.
(2) An apparatus for manufacturing a closed cross-section structure part having a modified cross-sectional shape having a bent portion and a welded portion in the longitudinal direction of the component from two metal plates, and a flange portion connected to the welded portion,
A plate corresponding to a non-weld bent portion and a welded portion in the cross section of the component is provided by providing two metal plates each having a plate longitudinal direction curve corresponding to the component longitudinal direction curve and corresponding to both ends of the plate width to the flange portion. A press molding machine that performs press molding so that a crease is attached to the site;
The two metal plates after the press forming are overlapped vertically so that the convex side is on the outside, and the folds of the flange corresponding parts are welded in the longitudinal direction facing each other on both the left and right sides of the width. A welder that forms a closed section structure by forming a welded portion,
The obtained closed cross-section structure is guided and transported by a pair of left and right rotating rolls or further lower rotating rolls, and the folds and the folds are changed by changing the roll interval of the rotating rolls or raising and lowering the rotating rolls. An apparatus for manufacturing a closed cross-section structure part, comprising: a roll forming machine that forms a three-dimensional object from a welded part as a starting part.
本発明によれば、断面形状を変化させつつ、部品長手方向およびその垂直方向の曲がり、すなわち三次元形状を1回の成形で付与することが可能となり、金型数削減,組立て工程削減による製造工程簡略化の効果による大幅なコストダウンが可能となる。
さらに主として曲げ加工で所定の形状を得ることが可能であるため、超高張力鋼板を素材とした部品製造が容易となる。
According to the present invention, it is possible to impart a bending in the longitudinal direction of a part and its vertical direction, that is, a three-dimensional shape, by changing the cross-sectional shape, and manufacturing by reducing the number of molds and the assembly process. The cost can be greatly reduced by the effect of process simplification.
Furthermore, since it is possible to obtain a predetermined shape mainly by bending, it is easy to manufacture parts using ultra-high strength steel sheets.
本発明に係る製造工程についての説明図である。It is explanatory drawing about the manufacturing process which concerns on this invention. 部品の目標形状の1例を示す概略立体図である。It is a schematic three-dimensional view which shows an example of the target shape of components. 実施例及び比較例の部品製造要領を示す概略図である。It is the schematic which shows the components manufacture point of an Example and a comparative example. 六角形断面部品の製造工程についての説明図である。It is explanatory drawing about the manufacturing process of hexagonal cross-section components. 六角形断面部品の目標形状の1例を示す概略立体図である。It is a schematic solid figure which shows an example of the target shape of a hexagonal cross-section component. 六角形断面部品の製造要領を示す概略図である。It is the schematic which shows the manufacture point of a hexagonal cross-section component.
図2は、本発明が製造対象とする部品(曲がり形状を有する閉断面構造部品)10の1例を示す概略立体図である。
図2の例では、断面形状(短手方向断面形状の意、以下同じ)が四角形をなし、長手方向に曲がりを有し、尚且つ長手方向の始端部と終端部とでは断面形状が異なっている(すなわち、異形である)。四角形断面の始端部の一辺長は30mm、終端部の一辺長は20mm、長手方向全長(長手方向両端間の最短距離)が300mm、曲がりの曲率半径は始端側400mm、終端側で400mmであり、部品長手方向中央部(長手方向両端から150mmの位置)で曲がりの方向が左右逆転した形状である。又、四角形の対角位置にある二対の頂点の中の一対が溶接部11、もう一対が非溶接曲がり部12をなしている。溶接部11にはフランジ部13が連なっている。フランジ部13の幅は5mmである。
FIG. 2 is a schematic three-dimensional view showing an example of a part (a closed cross-section structure part having a curved shape) 10 to be manufactured by the present invention.
In the example of FIG. 2, the cross-sectional shape (meaning the cross-sectional shape in the short direction, hereinafter the same) is a quadrangle and has a bend in the longitudinal direction, and the cross-sectional shape is different at the start and end portions in the longitudinal direction. (Ie, it is a variant). The side length of the start end of the rectangular cross section is 30 mm, the length of one end of the end is 20 mm, the total length in the longitudinal direction (the shortest distance between both ends in the length direction) is 300 mm, the curvature radius of the bend is 400 mm on the start end side, and 400 mm on the end side. It is a shape in which the direction of bending is reversed left and right at the center in the longitudinal direction of the part (position 150 mm from both ends in the longitudinal direction). In addition, a pair of two vertices at diagonal positions of the quadrangle form a welded portion 11 and the other pair forms a non-welded bent portion 12. A flange portion 13 is connected to the welded portion 11. The width of the flange portion 13 is 5 mm.
図1は、本発明に係る製造工程についての説明図である。ここでは図2の部品を製造する場合を例にとって説明する。図2の例の部品は図3(a)に示す実施例1の部品である。図3において、2枚の金属板1a,1bには、部品長手方向曲がりに対応する板長手方向曲がりを表すために、部品10のフランジ部13に連なる溶接部11に対応する幅端側の2本の曲げ線として、金属板1aでは曲げ線(B)(B)、金属板1bでは曲げ線(B’)(B’)がそれぞれ設けてあり、且つ、非溶接曲がり部12に対応する幅内側の1本の曲げ線として、金属板1aでは曲げ線(A)、金属板1bでは曲げ線(A’)がそれぞれ設けてある。
(第1工程)
第1工程は予成形工程である。パンチ3とダイ4を有するプレス成形機20を用い、金属板1に対し、部品四角断面の4つの頂点の中、非溶接曲がり部12に対応する幅内側の曲げ線(A)(A’)の部位と溶接部11に対応する幅端側の曲げ線(B)(B’)の部位とに、折目2が付くようにプレス成形する。かかる折目2が付くように、パンチ3とダイ4の型形状は設計されている。尚、折目2の箇所における板幅方向の曲率半径は、各折目2毎に、板の全長にわたって一定の値をとるようにした。
(第2工程)
第2工程は幅端部溶接工程である。前記予成形後の金属板1a,1bを、その張り出し側(第1工程にて、曲げ成形により折目2が形成され凸面となっている側)が外側となるように上下に重ね合わせて溶接機30内に配置し、幅の左右両側でそれぞれ上下に向かい合ったフランジ部13対応部位を、上下の押さえ治具6a,6bにて押さえ、上下に重なった幅の左端の曲げ線(B)(B’)部位の折目2同士、右端の曲げ線(B)(B’)部位の折目2同士をそれぞれ長手方向に溶接して溶接部11を形成し、閉断面構造体5となす。この溶接は、スポット溶接又はレーザ溶接等で行うのが好適である。溶接装置(図示せず)は、公知のスポット溶接装置、レーザ溶接装置等を用いることができる。
(第3工程)
第3工程はロール成形工程である。すなわち、前工程で得られた閉断面構造体5をロール成形機40に通す。ロール成形機40は、閉断面構造体5を、左右一対の回転ロール40a,40b、或いは更に下方の回転ロール40cでガイドして搬送しつつ、前記回転ロール40a,40bのロール間隔の変更、或いは更に前記回転ロール40cの昇降により、前記折目2及び前記溶接部11を起点として立体化させて目標形状の部品10となす。
FIG. 1 is an explanatory view of a manufacturing process according to the present invention. Here, the case of manufacturing the component of FIG. 2 will be described as an example. The part in the example of FIG. 2 is the part of Example 1 shown in FIG. In FIG. 3, the two metal plates 1 a and 1 b have 2 on the width end side corresponding to the welded portion 11 connected to the flange portion 13 of the component 10 in order to represent the plate longitudinal direction bending corresponding to the component longitudinal direction bending. As the bending lines of the book, bending lines (B) and (B) are provided in the metal plate 1a, and bending lines (B ') and (B') are provided in the metal plate 1b, respectively, and the width corresponding to the non-weld bent portion 12 is provided. As one inner bending line, a bending line (A) is provided on the metal plate 1a, and a bending line (A ') is provided on the metal plate 1b.
(First step)
The first step is a preforming step. Using a press molding machine 20 having a punch 3 and a die 4, a bending line (A) (A ') on the inner side of the width corresponding to the non-weld bent portion 12 among the four vertices of the component square cross section with respect to the metal plate 1 And the bend line (B) (B ′) on the width end side corresponding to the welded portion 11 are press-formed so that the crease 2 is attached. The mold shapes of the punch 3 and the die 4 are designed so that the crease 2 is formed. The radius of curvature in the plate width direction at the location of the crease 2 takes a constant value over the entire length of the plate for each crease 2.
(Second step)
The second step is a width end welding step. The pre-formed metal plates 1a and 1b are overlapped and welded so that the projecting side (the side where the crease 2 is formed by bending in the first step is the convex surface) is the outside. Place the part corresponding to the flange 13 that is placed in the machine 30 and facing the upper and lower sides on both the left and right sides of the width with the upper and lower pressing jigs 6a and 6b, and the bending line (B) (B) ( B ′) creases 2 at the part and folds 2 at the right end bending line (B) (B ′) part are welded in the longitudinal direction to form a welded portion 11 to form a closed cross-section structure 5. This welding is preferably performed by spot welding or laser welding. A well-known spot welding apparatus, a laser welding apparatus, etc. can be used for a welding apparatus (not shown).
(Third step)
The third step is a roll forming step. That is, the closed cross-section structure 5 obtained in the previous step is passed through the roll forming machine 40. The roll forming machine 40 changes the roll interval between the rotating rolls 40a, 40b while guiding and transporting the closed cross-section structure 5 with a pair of left and right rotating rolls 40a, 40b, or further rotating rolls 40c below. Further, by moving the rotary roll 40c up and down, the fold 2 and the welded portion 11 are used as a starting point to form a part 10 having a target shape.
回転ロールの形状は、被加工材である閉断面構造体のロール当接部を、位置ずれ等させずに安定してガイドしうる形状に設定されている。図1の40a、40b、40cの回転ロールは1例としてV字形状を示しているが、これに限定されるものではない。特に、フランジ部13をガイドする回転ロール40a,40bには底部にフランジガイド用の切欠14が設けられている。回転ロールのロール間隔(閉断面構造体に対するロールによる左右からの押圧力に対応)及び回転ロールの昇降位置(閉断面構造体に対するロールによる下方からの押し上げ力に対応)は、部品目標形状が得られるように変化させる。その変化のさせ方は予め理論解析乃至実験で求めておくことができる。また、更に、下方の回転ロールに対応した回転ロールを、上方にも設置して、部品の目標形状を形成するために用いても良い。   The shape of the rotary roll is set to a shape that can stably guide the roll contact portion of the closed cross-section structure, which is a workpiece, without misalignment. The rotary rolls 40a, 40b, and 40c in FIG. 1 have a V shape as an example, but are not limited thereto. In particular, the rotary rolls 40a and 40b that guide the flange portion 13 are provided with a notch 14 for flange guide at the bottom. The roll interval of the rotating roll (corresponding to the pressing force from the left and right by the roll to the closed cross-section structure) and the raising and lowering position of the rotating roll (corresponding to the pushing force from the lower side by the roll to the closed cross-section structure) are obtained by the target part shape. To change. How to make the change can be obtained in advance by theoretical analysis or experiment. Further, a rotating roll corresponding to the lower rotating roll may be installed on the upper side and used to form the target shape of the component.
尚、この例では部品の目標形状がねじれの無い形状であったので、その形状を達成すべく、図3(a)において、2枚の金属板1の各々で、幅端側の2本の曲げ線と幅内側の1本の曲げ線との計3本の曲げ線に関し、曲率を同一とし且つ曲率中心点を同一直線上に乗せたが、部品の目標形状がねじれの有る形状である場合は、前記計3本の曲げ線に関し、曲率を相違させるか或いは曲率中心点を同一直線上に乗せないようにするかの何れか一方又は両方により、ねじれの有る目標形状を達成することが可能である。四角形以外の形状について、第1〜第3工程は、四角形状の部品の場合と同様、その部品形状に対応した形状を有する金型、回転ロール等を用いて閉断面構造部品を製造することができる。   In this example, since the target shape of the part is a shape without twisting, in order to achieve the shape, two metal plates 1 on each of the two metal plates 1 in FIG. For a total of three bend lines, the bend line and one bend line inside the width, where the curvature is the same and the center of curvature is placed on the same straight line, but the target shape of the part is a twisted shape Is able to achieve a twisted target shape with respect to the total of three bending lines by either changing the curvature or preventing the center of curvature from being placed on the same straight line. It is. For shapes other than a quadrangle, the first to third steps can produce a closed cross-section structure part using a mold, a rotating roll, etc. having a shape corresponding to the part shape, as in the case of a square part. it can.
例えば図5に示すような六角形断面部品を製造対象とする場合、非溶接曲がり部12は図2の四角形断面の場合に比べて2つ増える。そこで、これに応じて、図6に示すように幅内側の曲げ線(A)(B)(A’)(B’)を上側と下側のブランクに対し、4本ずつ設定する。
そして、製造工程としては、四角形断面を六角形断面に変更したことに対応して、図1において用いる装置部材に変更を加えてなる、例えば図4に示すような工程を採用する。すなわち、第1工程(予成形工程)に用いる金型形状を、図6の曲げ線(A)(B)(A’)(B’)の箇所に折目2が付くような金型形状とする。第2工程(フランジ部溶接工程)では、押さえ治具6を予成形後のブランク形状に合った断面形状のものとする。第3工程(ロール成形工程)では、下方の回転ロール40cのロールプロファイルを、例えば六角形の一辺部の安定的案内が可能な平底形状とする。これら変更点以外は図1と同様である。これにより、図6下側に示す成形後形状が、高精度且つ容易に達成される。
For example, when a hexagonal cross-section component as shown in FIG. 5 is a manufacturing target, the number of non-weld bent portions 12 is increased by two compared to the case of the square cross-section of FIG. Accordingly, in accordance with this, as shown in FIG. 6, four bending lines (A), (B), (A ′) and (B ′) on the inner side are set for each of the upper and lower blanks.
Then, as a manufacturing process, for example, a process as shown in FIG. 4 is adopted in which the apparatus member used in FIG. 1 is changed in response to the change from the rectangular cross section to the hexagonal cross section. That is, the mold shape used in the first process (pre-molding process) is a mold shape in which the crease 2 is attached at the positions of the bending lines (A), (B), (A ′), and (B ′) in FIG. To do. In the second step (flange portion welding step), the holding jig 6 has a cross-sectional shape that matches the blank shape after preforming. In the third step (roll forming step), the roll profile of the lower rotating roll 40c is formed into a flat bottom shape that can stably guide one side of the hexagon, for example. Except for these changes, the configuration is the same as in FIG. Thereby, the post-molding shape shown in the lower side of FIG. 6 is achieved with high accuracy and ease.
実施例では、次の諸事項を共通事項とした。
[部品目標形状] 断面が部品長手方向に異形の四角(各角は直角)形状で、溶接部に連なるフランジ部を有し、部品長手方向にS字形の曲がりを有する形状である。
[素材金属板] 引張強度が1180MPaの冷延鋼板(板厚1.4mm)から、部品目標形状に対応するS字形の曲がりを有する2枚のブランクA,Bを切り出して素材とした。
[溶接条件] レーザ溶接、レーザ出力3.8kW、溶接速度2.5m/分、レーザフォーカス直径2mm
(実施例1)
図3(a)に示すように、1枚のブランク1a(ブランクA)は幅端側の2本の曲げ線(B)(B)間の中央の位置に、折目2となすべき曲げ線(A)を設定され、もう1枚のブランク1b(ブランクB)は幅端側の2本の曲げ線(B’)(B’)間の中央の位置に、折目2となすべき曲げ線(A’)を設定された。これら2枚のブランクA,Bを、第1工程で前述のとおり予成形して曲げ線(A)(A’) (B)(B’)にそれぞれ沿った折目2を付け、第2工程で前述のとおり重ね合わせる際にブランクAを上側、ブランクBを下側とし、上下に向かい合った幅端側の曲げ線(B)(B’)部位をレーザ溶接し、得られた閉断面構造体5を第3工程で前述のとおりロール成形して、部品10を得た。
(実施例2)
図3(b)に示すように、1枚のブランク1a(ブランクA)は幅端側の2本の曲げ線(B)(B)間の中央より左寄りの位置に、折目2となすべき曲げ線(A)を設定され、もう1枚のブランク1b(ブランクB)は幅端側の2本の曲げ線(B’)(B’)間の中央より右寄りの位置(中央の位置に関して前記左寄りの位置と対称の位置)に、折目2となすべき曲げ線(A’)を設定された。これら2枚のブランクA,Bを、第1工程で前述のとおり予成形して曲げ線(A)(A’)(B)(B’)にそれぞれ沿った折目2を付け、第2工程で前述のとおり重ね合わせる際にブランクAを上側、ブランクBを下側とし、上下に向かい合った幅端側の曲げ線(B)(B’)部位をレーザ溶接し、得られた閉断面構造体5を第3工程で前述のとおりロール成形して、部品10を得た。
(比較例)
実施例と同じ鋼板から、実施例とは異なる形状に切り出した1枚のブランクを素材とし、従来通りロール成形にて成形開始部分と成形終了部分とが異形の断面形状となるように成形加工(異形断面化)を行い、図3(c)に示す、中間形状部品15となし、これをロール成形にて三点曲げの要領で曲げ加工し、最終形状部品16を得た。
In the examples, the following items are common items.
[Part target shape] The cross section is a shape that is irregularly shaped in the longitudinal direction of the component (each corner is a right angle), has a flange portion that continues to the welded portion, and has an S-shaped bend in the longitudinal direction of the component.
[Raw metal plate] Two blanks A and B having an S-shaped bend corresponding to the part target shape were cut out from a cold-rolled steel plate (plate thickness: 1.4 mm) having a tensile strength of 1180 MPa as a material.
[Welding conditions] Laser welding, laser output 3.8kW, welding speed 2.5m / min, laser focus diameter 2mm
Example 1
As shown in FIG. 3 (a), one blank 1a (blank A) has a bend line to be a crease 2 at the center position between two bend lines (B) and (B) on the width end side. (A) is set, and the other blank 1b (blank B) is a bend line to be the crease 2 at the center position between the two bend lines (B ') and (B') on the width end side. (A ') was set. These two blanks A and B are preformed as described above in the first step, and the creases 2 along the bending lines (A) (A ') (B) (B') are added, respectively, in the second step. As mentioned above, the blank A is the upper side, the blank B is the lower side, and the bending line (B) (B ') part on the width end side facing up and down is laser-welded, and the closed cross-section structure obtained 5 was roll-formed as described above in the third step to obtain a part 10.
(Example 2)
As shown in FIG. 3 (b), one blank 1a (blank A) should become a crease 2 at a position to the left of the center between the two bending lines (B) and (B) on the width end side. The bend line (A) is set, and the other blank 1b (blank B) is positioned to the right of the center between the two bend lines (B ') (B') on the width end side (the above-mentioned position with respect to the center position). The bend line (A ') that should be the crease 2 was set at a position symmetrical to the left side. These two blanks A and B are preformed as described above in the first step, and the creases 2 along the bend lines (A) (A ′) (B) (B ′) are added, respectively, in the second step. As mentioned above, the blank A is the upper side, the blank B is the lower side, and the bending line (B) (B ') part on the width end side facing up and down is laser-welded, and the closed cross-section structure obtained 5 was roll-formed as described above in the third step to obtain a part 10.
(Comparative example)
Using a single blank cut out from the same steel plate as in the example in a shape different from that in the example, the forming process is performed so that the forming start part and the forming end part have an irregular cross-sectional shape by roll forming as usual ( 3), the intermediate shape part 15 was formed, and this was bent in a three-point bending manner by roll forming to obtain a final shape part 16.
実施例と比較例とについて、成形可否を評価した。その結果、何れの実施例でも、第1〜第3工程の全てにおいて成形が可能であり、且つ、第3工程後の部品10は、目標形状を達成し、破断、座屈、しわ等の成形不良発生箇所は皆無であった。一方、比較例では、異形断面化後の中間形状部品15には成形不良発生箇所が無かったが、曲げ加工後の最終形状部品16には図示の箇所に座屈が発生していた。   About the Example and the comparative example, the moldability was evaluated. As a result, in any of the embodiments, molding can be performed in all of the first to third steps, and the part 10 after the third step achieves a target shape, and molding such as fracture, buckling, and wrinkle is achieved. There were no defects. On the other hand, in the comparative example, the intermediate shape part 15 after the irregular cross section did not have a molding defect occurrence place, but the final shape part 16 after the bending process was buckled at the shown position.
1 金属板(a,bは2枚の何れか一方と他方、ブランクともいう)
2 折目(曲げ線(A)(A’)、(B)(B’)に対応)
3 パンチ
4 ダイ
5 閉断面構造体
6 押さえ治具(a,bは上と下)
10 部品(本発明が製造対象とする曲がり形状を有する閉断面構造部品)
11 溶接部
12 非溶接曲がり部
13 フランジ部
14 切欠
15 比較例の中間形状部品
16 比較例の最終形状部品
20 プレス成形機
30 溶接機
40 ロール成形機
40a、40b 回転ロール
40c 回転ロール
1 Metal plate (a and b are either one of the two and the other, also called blank)
2 Fold (corresponding to bending line (A) (A '), (B) (B'))
3 Punch 4 Die 5 Closed section structure 6 Holding jig (a and b are upper and lower)
10 parts (closed cross-section structure parts having a bent shape to be manufactured by the present invention)
DESCRIPTION OF SYMBOLS 11 Welding part 12 Non-weld bending part 13 Flange part 14 Notch 15 Intermediate shape part 16 of comparative example 16 Final shape part 20 of comparative example Press molding machine 30 Welding machine 40 Roll molding machine 40a, 40b Rotary roll 40c Rotary roll

Claims (2)

  1. 2枚の金属板から部品長手方向に曲がり及び溶接部を有し該溶接部にはフランジ部が連なる異形断面形状の閉断面構造部品を製造する方法であって、
    部品長手方向曲がりに対応する板長手方向曲がりを設け、前記フランジ部に板幅両端部を対応させた2枚の金属板を、部品断面内での非溶接曲がり部及び溶接部にそれぞれ対応する板部位に折目が付くようにプレス成形する第1工程と、
    前記プレス成形後の2枚の金属板を、その凸面側が外側となるように上下に重ね合わせて幅の左右両側でそれぞれ上下に向かい合わせたフランジ部対応部位の折目同士を長手方向に溶接して溶接部を形成することで、閉断面構造体となす第2工程と、
    得られた閉断面構造体を、左右一対の回転ロール或いは更に下方の回転ロールでガイドして搬送しつつ、前記回転ロールのロール間隔の変更或いは更に前記回転ロールの昇降により、前記折目及び前記溶接部を起点として立体化させて目標形状の部品となす第3工程と
    を有することを特徴とする閉断面構造部品の製造方法。
    A method for producing a closed cross-section structure part having an irregular cross-sectional shape having a bent portion and a welded portion in a longitudinal direction of a component from two metal plates, and a flange portion connected to the welded portion,
    A plate corresponding to a non-weld bent portion and a welded portion in the cross section of the component is provided by providing two metal plates each having a plate longitudinal direction curve corresponding to the component longitudinal direction curve and corresponding to both ends of the plate width to the flange portion. A first step of press molding so that a crease is attached to the site;
    The two metal plates after the press forming are overlapped vertically so that the convex side is on the outside, and the folds of the flange corresponding parts are welded in the longitudinal direction facing each other on both the left and right sides of the width. Forming a welded portion to form a closed cross-section structure,
    The obtained closed cross-section structure is guided and transported by a pair of left and right rotating rolls or further lower rotating rolls, and the folds and the folds are changed by changing the roll interval of the rotating rolls or raising and lowering the rotating rolls. And a third step of forming a three-dimensional object with a welded portion as a starting point to form a part having a target shape.
  2. 2枚の金属板から部品長手方向に曲がり及び溶接部を有し該溶接部にはフランジ部が連なる異形断面形状の閉断面構造部品を製造する装置であって、
    部品長手方向曲がりに対応する板長手方向曲がりを設け、前記フランジ部に板幅両端部を対応させた2枚の金属板を、部品断面内での非溶接曲がり部及び溶接部にそれぞれ対応する板部位に折目が付くようにプレス成形するプレス成形機と、
    前記プレス成形後の2枚の金属板を、その凸面側が外側となるように上下に重ね合わせて幅の左右両側でそれぞれ上下に向かい合わせたフランジ部対応部位の折目同士を長手方向に溶接して溶接部を形成することで、閉断面構造体となす溶接機と、
    得られた閉断面構造体を、左右一対の回転ロール或いは更に下方の回転ロールでガイドして搬送しつつ、前記回転ロールのロール間隔の変更或いは更に前記回転ロールの昇降により、前記折目及び前記溶接部を起点として立体化させて目標形状の部品となすロール成形機と
    を有することを特徴とする閉断面構造部品の製造装置。
    An apparatus for manufacturing a closed cross-section structure part having a modified cross-sectional shape having a bent portion and a welded portion in the longitudinal direction of a component from two metal plates, and a flange portion connected to the welded portion,
    A plate corresponding to a non-weld bent portion and a welded portion in the cross section of the component is provided by providing two metal plates each having a plate longitudinal direction curve corresponding to the component longitudinal direction curve and corresponding to both ends of the plate width to the flange portion. A press molding machine that performs press molding so that a crease is attached to the site;
    The two metal plates after the press forming are overlapped vertically so that the convex side is on the outside, and the folds of the flange corresponding parts are welded in the longitudinal direction facing each other on both the left and right sides of the width. A welder that forms a closed section structure by forming a welded portion,
    The obtained closed cross-section structure is guided and transported by a pair of left and right rotating rolls or further lower rotating rolls, and the folds and the folds are changed by changing the roll interval of the rotating rolls or raising and lowering the rotating rolls. An apparatus for manufacturing a closed cross-section structure part, comprising: a roll forming machine that forms a three-dimensional object from a welded part as a starting part.
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