JP5271728B2 - Manufacturing method of thin metal plate with irregularities formed - Google Patents

Manufacturing method of thin metal plate with irregularities formed Download PDF

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JP5271728B2
JP5271728B2 JP2009011491A JP2009011491A JP5271728B2 JP 5271728 B2 JP5271728 B2 JP 5271728B2 JP 2009011491 A JP2009011491 A JP 2009011491A JP 2009011491 A JP2009011491 A JP 2009011491A JP 5271728 B2 JP5271728 B2 JP 5271728B2
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拓人 下條
圭輔 成石
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東プレ株式会社
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<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a thin metal sheet on which recessed and projecting parts are formed, wherein a high quality molding is obtained by suppressing the surface strain in a planar part during forming. <P>SOLUTION: In a press working method of the thin metal sheet W' for forming the recessed and projecting parts on the thin metal sheet W' by press forming with a die 10, the recessed and projecting parts are formed on the thin metal sheet W' through a preliminary bulging stage for forming the approximate shape of the recessed and projecting parts on the thin metal sheet W' by bulging the thin metal sheet W' from the initial stage of the forming until reaching just before the final stage of the forming and a crushing stage where a material which is taken in at the preliminary bulging stage is returned to the origin part to the vertical wall part Wc of the groove by crushing the vertical wall parts Wc of the thin metal sheet W' with the die 10 and also the whole of the thin metal sheet W' is pressed. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

本発明は、金型によるプレス成形によって凹凸部が形成された金属薄板の製造方法に関するものである。   The present invention relates to a method for manufacturing a metal thin plate having uneven portions formed by press molding with a mold.
例えば、固体高分子型燃料電池に使用される金属セパレータは、ステンレス鋼やチタン合金等の金属薄板をプレス加工して高耐食のコーティング等を施して得られるが、これには凹凸部が面方向に交互に連続する断面波状の集電部が形成される。ここで、集電部の凹部はガス流路や反応後の生成水等の流路となり、凸部は電極構造体のガス拡散電極板に接触する部分となる。   For example, a metal separator used in a polymer electrolyte fuel cell is obtained by pressing a metal thin plate such as stainless steel or titanium alloy and applying a highly corrosion-resistant coating or the like. In this way, a current collecting section having a corrugated cross section that is alternately continuous is formed. Here, the concave portion of the current collecting portion becomes a gas flow passage or a flow passage such as generated water after reaction, and the convex portion becomes a portion in contact with the gas diffusion electrode plate of the electrode structure.
ところで、金属セパレータは、プレス加工による張出成形によって成形されるが、成形後の金属セパレータには反り(セパレータ全体の湾曲)と面歪み(集電部周囲の平面の波打ち)が発生することが知られている。金属セパレータにおいては、集電部の凹凸形状を成形する際に弾性回復(スプリングバック)が発生し、これが金属セパレータの反りの原因となる。   By the way, although a metal separator is shape | molded by the bulging forming by press work, a curvature (curvature of the whole separator) and surface distortion (surface undulation around a current collection part) may generate | occur | produce in the metal separator after shaping | molding. Are known. In the metal separator, elastic recovery (spring back) occurs when the irregular shape of the current collector is formed, which causes warpage of the metal separator.
又、金属セパレータの製造において、図8に示すように張出成形によって金属薄板W’に集電部WAを形成すると、集電部WAの周辺部WBの材料が図8に矢印にて示すように集電部WA方向に引き込まれる材料移動が生じる。この材料移動は集電部WAの縦部分と横部分では多いが、集電部WAのコーナー部(図8にXにて示す4箇所)では少なく、この材料移動の多少によって金属セパレータWに面歪みが発生する。   Further, in the manufacture of the metal separator, when the current collecting part WA is formed on the metal thin plate W ′ by overhanging as shown in FIG. 8, the material of the peripheral part WB of the current collecting part WA is indicated by an arrow in FIG. The material is moved in the direction of the current collector WA. This material movement is large in the vertical part and the horizontal part of the current collecting part WA, but is small in the corner parts (four places indicated by X in FIG. 8) of the current collecting part WA. Distortion occurs.
上述のように燃料電池用金属セパレータに反りや面歪みが発生すると、集電部の凸部がガス拡散電極板に十分な面圧をもって接触しなかったり、面圧が不均一となり、接触抵抗が大きくなって発電電圧の低下を招いてしまう。又、金属セパレータを間に挟みながら複数の電極構造体を積層して燃料電池を組み立てる作業においては、金属セパレータの反りや面歪みを矯正しながら組み立てる必要があるため、作業が煩雑で作業効率が悪い他、ガスシール性が低下するという問題がある。   As described above, when warpage or surface distortion occurs in the fuel cell metal separator, the convex portion of the current collector does not contact the gas diffusion electrode plate with sufficient surface pressure, or the surface pressure becomes uneven, resulting in contact resistance. It becomes large and causes a decrease in generated voltage. Also, in the work of assembling a fuel cell by laminating a plurality of electrode structures with the metal separator sandwiched between them, it is necessary to assemble while correcting the warp and surface distortion of the metal separator, so the work is complicated and the work efficiency is high. In addition to being bad, there is a problem that the gas sealing performance is lowered.
そこで、特許文献1には、燃料電池用金属セパレータ等の製造において、板材の弾性回復に起因する成形品の反りを抑制することができる板材のプレス加工方法が提案されている。この方法を図9(a)〜(c)に従って以下に説明する。   Therefore, Patent Document 1 proposes a plate material pressing method that can suppress warping of a molded product due to elastic recovery of the plate material in the manufacture of a fuel cell metal separator or the like. This method will be described below with reference to FIGS.
即ち、図9(a)〜(c)はプレス加工による板材の変形状態を示す部分断面図であり、図示の方法は、図9(a)に示す凹型(上型)81と凸型(下型)82から成る第1のプレス型80を用いて板材100に張出し部101を形成する第1工程と、図9(b),(c)に示す凹型(上型)91と凸型(下型)92から成る第2のプレス型90を用いて突起102を完成させる第2工程の少なくとも2工程に分けてプレス加工することを特徴とする。   That is, FIGS. 9A to 9C are partial cross-sectional views showing the state of deformation of the plate material by press working, and the illustrated method uses the concave (upper) 81 and convex (lower) shown in FIG. 9 (a). The first step of forming the overhanging portion 101 on the plate material 100 using the first press die 80 composed of the die 82, the concave die (upper die) 91 and the convex die (lower) shown in FIGS. The second press die 90 consisting of a die 92 is used to perform press working in at least two steps of the second step of completing the projection 102.
第2工程においては、図9(b)に示すように、凹型91に形成された凹部91aの開口部によって張出し部101の周縁部近傍の側壁部分を押圧するようプレス加工が行われる。このため、第1工程において板材100の表面に張出し部101を形成した時点では、該張出し部101の近傍には弾性回復の原因となる曲げモーメントが作用した状態となっているが、図9(c)に示すように突起102が完成したときには、突起102の周縁部の凹型91側部分に伸び変形が付与される。そして、この伸び変形が、弾性回復の原因と成る曲げモーメントを相殺するに必要且つ十分な大きさとなるようにプレス加工が行われた場合には、板厚方向全体が伸び変形となり、弾性回復に起因する反り等の形状不良が抑制される。   In the second step, as shown in FIG. 9B, pressing is performed so as to press the side wall portion in the vicinity of the peripheral portion of the overhang portion 101 by the opening portion of the concave portion 91 a formed in the concave die 91. For this reason, when the overhanging portion 101 is formed on the surface of the plate member 100 in the first step, a bending moment that causes elastic recovery is applied in the vicinity of the overhanging portion 101, but FIG. When the projection 102 is completed as shown in c), the deformation is applied to the concave portion 91 side portion of the peripheral portion of the projection 102. When the press working is performed so that the elongation deformation becomes necessary and sufficient to cancel the bending moment causing the elastic recovery, the entire plate thickness direction becomes the expansion deformation, and the elastic recovery is achieved. Defects such as warping due to the shape are suppressed.
特開2000−317531号公報JP 2000-317531 A
しかしながら、特許文献1において提案されたプレス加工方法では、金属セパレータの反りの問題を解決することはできるが、集電部周辺の面歪みの問題は解決することができず、燃料電池の性能や耐久性或いは組み立ての作業効率の低下については一向に解決されていない。   However, the press working method proposed in Patent Document 1 can solve the problem of warping of the metal separator, but cannot solve the problem of surface distortion around the current collector, and the performance of the fuel cell There has been no solution to the deterioration of durability or assembly work efficiency.
本発明は上記問題に鑑みてなされたもので、その目的とする処は、成形時の面歪みを抑えて高品位な凹凸部が形成された金属薄板の製造方法を提供することにある。   The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for manufacturing a metal thin plate in which high-quality concavo-convex portions are formed while suppressing surface distortion during molding.
上記目的を達成するため、請求項1記載の発明は、金属薄板を、金型によるプレス成形によって、凹部と、凸部と、凹部の端縁から凸部の端縁に向けて傾斜した直線状の溝縦壁部と、からなる凹凸部が形成された金属薄板をプレス加工するために、
少なくとも前記金属薄板を張出成形して該金属薄板に凹凸部の概形を形成する予備張出工程と、
金属薄板の前記凹凸部の溝縦壁部を潰して前記予備張出工程時に該溝縦壁部に引き込まれた材料を元に戻すとともに、金属薄板の全体を押圧する潰し工程と、
を経て製造する方法であって、
前記潰し工程における前記金型の、前記溝縦壁部を成形する上型と下型のクリアランスは、
前記金属薄板の潰し量が前記予備張出工程における材料の前記溝縦壁部への引込量と同量となるよう寸法を決定したことを特徴とする凹凸部が形成された金属薄板の製造方法。
In order to achieve the above-mentioned object, the invention according to claim 1 is characterized in that the thin metal plate is formed by press molding with a mold , and the linear shape is inclined from the edge of the concave portion toward the edge of the convex portion. In order to press the metal thin plate on which the concavo-convex part formed of the groove vertical wall part of
A pre-extrusion step in which at least the metal thin plate is stretched to form a rough shape on the metal thin plate;
A crushing step of crushing the groove vertical wall portion of the uneven portion of the metal thin plate to return the material drawn into the groove vertical wall portion during the preliminary overhanging step and pressing the entire metal thin plate,
A method of manufacturing via
The clearance between the upper mold and the lower mold for molding the vertical wall portion of the mold in the crushing step is as follows:
The method of manufacturing a metal thin plate with a concavo-convex portion formed , wherein the dimension is determined so that the amount of crushing of the metal thin plate is the same as the amount of material drawn into the vertical wall portion of the groove in the preliminary overhanging step .
請求項記載の発明は、請求項1又は2記載の発明において、前記予備張出工程と潰し工程の間に、空間が形成された金型により、予備張出工程において成形した金属薄板の溝縦壁部を潰して、材料を前記金型の空間に流入させる第2の予備張出工程を経て金属薄板を製造することを特徴とする。 The invention according to claim 2 is the invention according to claim 1 or 2, wherein the groove of the metal thin plate formed in the pre-extrusion step is formed by a mold in which a space is formed between the pre-extraction step and the crushing step. A metal thin plate is manufactured through a second preliminary projecting step in which the vertical wall portion is crushed and the material flows into the mold space.
請求項記載に発明は、請求項記載の発明において、前記第2予備張出工程と潰し工程を複数回繰り返して金属薄板を製造することを特徴とする。 A third aspect of the invention is characterized in that, in the second aspect of the invention, the thin metal sheet is manufactured by repeating the second preliminary overhanging step and the crushing step a plurality of times.
請求項記載の発明は、請求項記載の発明において、前記予備張出工程において凹凸部概形に必要なボリュームを確保するように前記予備張出工程の前に第3の予備張出工程を経て製造することを特徴とする。 According to a fourth aspect of the present invention, in the first aspect of the present invention, a third preliminary overhanging step is performed before the preliminary overhanging step so as to secure a volume necessary for the rough shape of the uneven portion in the preliminary overhanging step. It is characterized by manufacturing through.
請求項1記載の発明によれば、予備張出工程における金属薄板の張出成形によって溝周辺部から溝縦壁部に引き込まれた材料は、次の潰し工程において金属薄板の溝縦壁部を潰すことによって元の溝周辺部に戻されるため、金属薄板の溝縦壁部のみが鍛造のように潰して伸ばされる。このため、溝周辺部から溝縦壁部に引き込まれた材料は、逆に溝縦壁部から 溝周辺部へ戻されるために面歪みを抑えた高品位な成形品が得られる。   According to the first aspect of the present invention, the material drawn into the vertical wall portion of the groove from the peripheral portion of the groove by the extension forming of the thin metal plate in the preliminary overhanging step is used for the vertical wall portion of the thin metal plate in the next crushing step. Since it is returned to the original groove peripheral part by crushing, only the groove vertical wall part of the metal thin plate is crushed and extended like forging. For this reason, since the material drawn into the groove vertical wall portion from the groove peripheral portion is returned from the groove vertical wall portion to the groove peripheral portion, a high-quality molded product with reduced surface distortion can be obtained.
また、請求項記載の発明によれば、金型の溝縦壁部成形部のクリアランスを適切に設定することによって、潰し工程における金属薄板の潰し量が予備張出工程における材料の溝縦壁部への引込量と同量となるよう設定することができ、金属薄板の成形部の断面積(体積)を一定に保って成形部以外の周辺部と成形部間での材料の引込量と戻し量が同量となり、材料の移動に伴う面歪みの発生を抑えることができる。 In addition, according to the first aspect of the present invention, by appropriately setting the clearance of the groove vertical wall portion molding portion of the mold, the amount of squeezing of the metal thin plate in the squeezing step is the groove vertical wall of the material in the preliminary overhanging step. It can be set to be the same amount as the amount drawn into the part, and the amount of material drawn between the peripheral part other than the molded part and the molded part while keeping the cross-sectional area (volume) of the molded part of the metal thin plate constant The return amount becomes the same amount, and the occurrence of surface distortion accompanying the movement of the material can be suppressed.
請求項及び記載の発明によれば、予備張出工程の前工程において金属薄板に溝縦壁部を通常の張出加工によって成形可能な高さまで成形し、予備張出工程の後工程(第2の予備張出工程)において金型に空間を形成し、前工程において成形した金属薄板の溝縦壁部を潰して材料を空間に流入させることによって、潰し工程で使用するための余肉を形成する。予備張出工程の後工程を追加することによって、材料の流出が可能な限り、より高い凹凸部、或いは伸びが小さい材料であっても成形することができる。 According to the inventions of claims 2 and 3 , the vertical wall portion of the groove is formed in the metal thin plate to a height that can be formed by a normal overhanging process in the pre-step of the pre-overhanging step, and the post-step of the pre-overhanging step ( Forming a space in the mold in the second pre-extrusion step), crushing the vertical wall portion of the groove of the thin metal sheet formed in the previous step and allowing the material to flow into the space, thereby allowing extra space for use in the crushing step Form. By adding a post process of the pre-extrusion process, as long as the material can flow out, even a material with a higher unevenness or a material with a small elongation can be molded.
請求項記載の発明によれば、請求項1の予備張出工程で張出成形ができない場合、予備張出工程の前工程において予備張出工程で凹凸部の概形の成形に必要なボリュームを確保するように金属薄板を張出成形し、次工程(潰し工程)において前工程において金属薄板の溝縦壁部に流入した材料を用いて張出成形を行うことによって所望の高さの凹凸部を成形することができる。 According to the fourth aspect of the present invention, when the overhanging process cannot be performed in the preliminary overhanging process according to the first aspect, the volume required for forming the rough shape of the concavo-convex portion in the preliminary overhanging process in the previous process of the preliminary overhanging process. The metal sheet is stretched so as to ensure the ruggedness, and in the next process (crushing process), the material that has flowed into the vertical wall of the groove of the metal sheet in the previous process is stretched and formed to have a desired height. The part can be molded.
本発明に係る凹凸部が形成された金属薄板の製造方法によって成形された燃料電池用金属セパレータの斜視図である。It is a perspective view of the metal separator for fuel cells shape | molded by the manufacturing method of the metal thin plate in which the uneven | corrugated | grooved part based on this invention was formed. 図1のA−A線断面図である。It is the sectional view on the AA line of FIG. (a),(b)は本発明の実施の形態1に係る製造方法の予備張出工程と潰し工程をそれぞれ示す金型の部分断面図である。(A), (b) is the fragmentary sectional view of the metal mold | die which each shows the preliminary | backup extension process and crushing process of the manufacturing method which concerns on Embodiment 1 of this invention. (a),(b)は本発明の実施の形態1に係る製造方法における金属薄板の溝縦壁部成形部(中間直線部)の成形前後の断面図である。(A), (b) is sectional drawing before and behind shaping | molding of the groove | channel vertical wall part shaping | molding part (intermediate linear part) of a metal thin plate in the manufacturing method which concerns on Embodiment 1 of this invention. (a),(b)は本発明の実施の形態1に係る製造方法における金属薄板の溝縦壁部成形部(端部曲面部)の成形前後の斜視図である。(A), (b) is a perspective view before and behind shaping | molding of the groove | channel vertical wall part shaping | molding part (edge curved surface part) of a metal thin plate in the manufacturing method which concerns on Embodiment 1 of this invention. (a)〜(c)は本発明の実施の形態2に係る製造方法の予備張出工程の前工程、予備張出工程の後工程(第2の予備張出工程及び潰し工程をそれぞれ示す金型の部分断面図である。(A)-(c) is the pre-process of the preliminary overhang process of the manufacturing method which concerns on Embodiment 2 of this invention, and the post process of a preliminary overhang process (The gold | metal | money which each shows a 2nd preliminary overhang process and a crushing process) It is a fragmentary sectional view of a type | mold. (a)〜(c)は本発明の実施の形態3に係る製造方法の予備張出工程の前工程(第3の予備張出工程)、予備張出工程の後工程及び潰し工程をそれぞれ示す金型の部分断面図である。(A)-(c) shows the pre-process (3rd preliminary | backup extension process) of the preliminary | backup extension process of the manufacturing method which concerns on Embodiment 3 of this invention, the post process of a preliminary | backup extension process, and a crushing process, respectively. It is a fragmentary sectional view of a metal mold | die. 金属薄板のプレス加工時の材料の移動状況を示す斜視図である。It is a perspective view which shows the movement condition of the material at the time of the press work of a metal thin plate. (a)〜(c)は特許文献1において提案されたプレス加工方法による板材の変形状態を示す部分断面図である。(A)-(c) is a fragmentary sectional view which shows the deformation | transformation state of the board | plate material by the press work method proposed in patent document 1. FIG.
以下に本発明の実施の形態を添付図面に基づいて説明する。   Embodiments of the present invention will be described below with reference to the accompanying drawings.
図1は本発明に係る凹凸部が形成された金属薄板の製造方法によって成形された燃料電池用金属セパレータの斜視図、図2は図1のA−A線断面図である。   FIG. 1 is a perspective view of a metal separator for a fuel cell formed by the method for manufacturing a metal thin plate having a concavo-convex portion according to the present invention, and FIG. 2 is a cross-sectional view taken along line AA of FIG.
図1に示す燃料電池用金属セパレータWは、例えばステンレス鋼を素材とする厚さ0.1〜0.2mmの金属薄板W’(図3(a)参照)をプレス加工することによって得られ、その中央部には集電部WAが形成され、該集電部WAの周囲は平坦な周辺部WBで囲まれている。   The metal separator W for fuel cells shown in FIG. 1 is obtained by pressing a thin metal plate W ′ (see FIG. 3A) having a thickness of 0.1 to 0.2 mm made of, for example, stainless steel, A current collector WA is formed at the center, and the periphery of the current collector WA is surrounded by a flat peripheral portion WB.
上記集電部WAは、図2に詳細に示すように、複数の溝縦壁部Wcによって形成された凹部Waと凸部Wbが面方向に交互に連続する断面波状の波板部を構成しており、凹部Waはガス流路や反応後の生成水等の流路となり、凸部Wbは不図示の電極構造体のガス拡散電極板に接触する部分となる。尚、図1に示す燃料電池用金属セパレータWは、固体高分子型燃料電池に使用されるものであって、これらを間に挟みながら複数の電極構造体を積層して燃料電池スタックが組み立てられる。   As shown in detail in FIG. 2, the current collector WA constitutes a corrugated plate having a corrugated cross section in which concave portions Wa and convex portions Wb formed by a plurality of groove vertical wall portions Wc are alternately continued in the surface direction. The concave portion Wa serves as a gas flow channel or a flow channel such as product water after reaction, and the convex portion Wb serves as a portion that contacts a gas diffusion electrode plate of an electrode structure (not shown). The fuel cell metal separator W shown in FIG. 1 is used for a polymer electrolyte fuel cell, and a fuel cell stack is assembled by laminating a plurality of electrode structures while sandwiching them. .
而して、図1に示す燃料電池用金属セパレータWは、本発明に係る製造方法によって成形されるが、以下、本発明に係る製造方法の実施の形態について説明する。   Thus, the fuel cell metal separator W shown in FIG. 1 is formed by the manufacturing method according to the present invention. Hereinafter, an embodiment of the manufacturing method according to the present invention will be described.
<実施の形態1>
図3(a),(b)は本発明の実施の形態1に係るプレス加工方法の予備張出工程と潰し工程をそれぞれ示す金型の部分断面図、図4(a),(b)は金属薄板の溝縦壁部成形部(中間直線部)の成形前後の断面図、図5(a),(b)は金属薄板の溝縦壁部成形部(端部曲面部)の成形前後の斜視図である。尚、図3〜図5は説明の便宜上から金型又は金属薄板の一部を示すものであって、図1に示す実際の燃料電池用金属セパレータWの集電部WAに形成された凹凸部Wa,Wbの数には対応していない。
<Embodiment 1>
3 (a) and 3 (b) are partial cross-sectional views of the mold showing the preliminary overhanging step and the crushing step of the press working method according to Embodiment 1 of the present invention, and FIGS. 4 (a) and 4 (b) are views. Sectional views before and after forming the groove vertical wall forming part (intermediate straight line part) of the metal thin plate, FIGS. 5 (a) and 5 (b) are before and after forming the groove vertical wall forming part (end curved surface part) of the metal thin plate. It is a perspective view. 3 to 5 show a part of a mold or a thin metal plate for convenience of explanation, and the uneven portion formed in the current collector WA of the actual fuel cell metal separator W shown in FIG. It does not correspond to the number of Wa and Wb.
本発明に係る製造方法は、予備張出工程と潰し工程を経て金属薄板に凹凸部を形成する方法であって、予備張出工程は、成形初期から成形終期直前に至るまでに金属薄板を張出成形して該金属薄板に凹凸部の概形を形成する工程であり、潰し工程は、成形終期において金属薄板の溝縦壁部を潰して予備張出工程時に該溝縦壁部に引き込まれた材料を元に戻すとともに、金属薄板の全体を押圧する工程である。以下、予備張出工程と潰し工程を具体的に説明する。   The manufacturing method according to the present invention is a method of forming an uneven portion on a metal thin plate through a pre-extrusion step and a crushing step, and the pre-extrusion step stretches the metal thin plate from the initial stage of forming to immediately before the end of forming. It is a process of forming the rough shape of the concavo-convex portion on the metal thin plate by extrusion molding. This is a step of returning the original material and pressing the entire thin metal plate. Hereinafter, the preliminary overhanging step and the crushing step will be specifically described.
1)予備張出工程:
本実施の形態に係る製造方法には図3に示す上型11と下型12とから成る金型10が使用され、上型11には、図1に示す燃料電池用金属セパレータWの集電部WAの凸部Wb(図2参照)の形状に対応する横断面台形状の凹部11aが形成され、下型12には、同金属セパレータWの集電部WAの凹部Wa(図2参照)の形状に対応する横断面台形状の凸部12aが形成されている。
1) Preliminary overhanging process:
In the manufacturing method according to the present embodiment, a mold 10 comprising an upper mold 11 and a lower mold 12 shown in FIG. 3 is used, and the upper mold 11 has a current collector for a fuel cell metal separator W shown in FIG. A concave portion 11a having a trapezoidal cross section corresponding to the shape of the convex portion Wb (see FIG. 2) of the portion WA is formed, and the concave portion Wa (see FIG. 2) of the current collecting portion WA of the metal separator W is formed in the lower mold 12. The convex part 12a of the cross-sectional trapezoid shape corresponding to the shape of is formed.
而して、予備張出工程においては、図3(a)に示すように、上型11と下型12の間に素材である金属薄板W’が挿入セットされ、この状態で上型11が不図示のプレス機構によって下降する。   Thus, in the preliminary overhanging process, as shown in FIG. 3A, the metal thin plate W ′ as a material is inserted and set between the upper mold 11 and the lower mold 12, and in this state, the upper mold 11 is It is lowered by a pressing mechanism (not shown).
図3(a)は成形初期の状態を示し、この状態では金属薄板W’に対して材料そのものの伸びによる通常の張出成形が行われ、上型11の下降に伴って金属薄板W’の溝縦壁部Wcを形成する部分の材料は伸び変形し、これに伴って周辺の材料が矢印にて示すように溝縦壁部Wcに引き込まれる。そして、予備張出工程が完了し、次工程の潰し工程に移行するとき、金属薄板W’は金属薄板Wの凹凸部Wa,Wb(図2参照)の概形の形成が完了している。   FIG. 3 (a) shows a state in the initial stage of molding. In this state, the metal sheet W ′ is subjected to normal bulging by the elongation of the material itself, and as the upper die 11 is lowered, the metal sheet W ′ is deformed. The material of the portion forming the groove vertical wall portion Wc is stretched and deformed, and accordingly, the surrounding material is drawn into the groove vertical wall portion Wc as indicated by the arrow. When the preliminary overhanging process is completed and the process proceeds to the crushing process of the next process, the rough shape Wa and Wb (see FIG. 2) of the metal thin plate W has been formed in the metal thin plate W ′.
2)潰し工程:
潰し工程では、図3(b)に示すように、上型11が下死点付近まで下降する成形終期において金属薄板W’の溝縦壁部Wcが上型11と下型12によって潰されて予備張出工程時に該溝縦壁部Wcに引き込まれた材料が元の溝周辺部に戻されるとともに、金属薄板W’の全体が押圧され、図1に示す燃料電池用金属セパレータWが得られる。
2) Crushing process:
In the crushing step, as shown in FIG. 3 (b), the groove vertical wall portion Wc of the metal thin plate W 'is crushed by the upper mold 11 and the lower mold 12 at the final stage of molding when the upper mold 11 descends to near the bottom dead center. The material drawn into the groove vertical wall portion Wc during the pre-extrusion step is returned to the original groove peripheral portion, and the entire metal thin plate W ′ is pressed to obtain the fuel cell metal separator W shown in FIG. .
ここで、上型11と下型12の溝縦壁部成形部のクリアランスは、潰し工程における金属薄板W’の潰し量が予備張出工程における材料の溝縦壁部Wcへの引込量と同量となるよう決定される。具体的には、図4(a)に示す金属薄板W’の溝縦壁部成形部(中間直線部)の成形前の断面積が図4(b)に示す金属薄板W’の成形後の溝縦壁部Wcの断面積に等しくなるように上型11と下型12の溝縦壁部成形部のクリアランス(成形後の溝縦壁部Wcの板厚)を決定すれば良い。   Here, the clearance between the groove vertical wall portion forming portions of the upper die 11 and the lower die 12 is the same as the amount of material squeezed into the groove vertical wall portion Wc in the preliminary overhanging step. Determined to be a quantity. Specifically, the cross-sectional area of the thin metal plate W ′ shown in FIG. 4A before forming the groove vertical wall portion forming portion (intermediate straight line portion) is the same as that after forming the thin metal plate W ′ shown in FIG. What is necessary is just to determine the clearance (plate thickness of the groove | channel vertical wall part Wc after shaping | molding) of the groove | channel vertical wall part shaping | molding part of the upper mold | type 11 and the lower mold | type 12 so that it may become equal to the cross-sectional area of the groove | channel vertical wall part Wc.
即ち、金属薄板W’の溝縦壁部Wcの成形範囲をa、成形前の金属薄板W’の板厚をtaとすると、図4(a)に示す金属薄板W’の溝縦壁部成形部(中間直線部)の成形前の断面積Saは次式にて求められる。   That is, assuming that the forming range of the groove vertical wall Wc of the metal thin plate W ′ is a and the plate thickness of the metal thin plate W ′ before forming is ta, the groove vertical wall forming of the metal thin plate W ′ shown in FIG. The cross-sectional area Sa before forming the part (intermediate straight line part) is obtained by the following equation.
Sa=a×ta …(1)
又、金属薄板W’の成形後の溝縦壁部Wcの板厚をtb、高さをcとすると、成形後の金属薄板W’の溝縦壁部Wcの断面積Sbは次式にて求められる。
Sa = a × ta (1)
Further, when the thickness of the groove vertical wall portion Wc after forming the thin metal plate W ′ is tb and the height is c, the cross-sectional area Sb of the groove vertical wall portion Wc of the thin metal plate W ′ after forming is as follows: Desired.
Sb=√(a +c )×tb …(2)
Sa=Sb=Sを満足する金属薄板の成形後の溝縦壁部の板厚をtbは、(1),(2)式より次のように求められる。
Sb = √ (a 2 + c 2 ) × tb (2)
The thickness tb of the vertical wall portion of the groove after forming a thin metal plate satisfying Sa = Sb = S is obtained as follows from equations (1) and (2).
tb=(a×ta)/√(a +c ) …(3)
従って、上型11と下型12の溝縦壁部成形部のクリアランスを(3)式にて求められるtbに、且つ、溝縦壁部Wc以外のクリアランスを成形前の金属薄板W’の板厚taに設定すれば、潰し工程における金属薄板W’の潰し量が予備張出工程における材料の溝縦壁部Wcへの引込量と同量となるようにすることができる。
tb = (a × ta) / √ (a 2 + c 2 ) (3)
Therefore, the clearance of the groove vertical wall portion forming portion of the upper die 11 and the lower die 12 is set to tb obtained by the expression (3), and the clearance other than the groove vertical wall portion Wc is set to the plate of the metal thin plate W ′ before forming. If the thickness ta is set, the amount of squeezing of the metal thin plate W ′ in the squeezing step can be made equal to the amount of material drawn into the groove vertical wall portion Wc in the preliminary overhanging step.
又、金属薄板W’の溝縦壁部成形部のうちの端部曲面部においても、潰し工程における金属薄板W’の潰し量が予備張出工程における材料の溝縦壁部Wcへの引込量と同量となるように、上型11と下型12の溝縦壁部成形部のクリアランスが決定される。即ち、図5(a)に示す金属薄板W’の溝縦壁部成形部(ハッチングを付して示す端部曲面部)の成形前の体積Vaが図5(b)に示す金属薄板W’の溝縦壁部成形部(ハッチングを付して示す端部曲面部)の成形後の体積Vbに等しくなる(Va=Vb)ように上型11と下型12の溝縦壁部成形部のクリアランスが決定される。   Also, in the curved end portion of the groove vertical wall portion of the metal thin plate W ′, the amount of the metal thin plate W ′ in the crushing step is the amount of material drawn into the groove vertical wall portion Wc in the preliminary overhanging step. The clearance of the groove vertical wall portion molding portion of the upper die 11 and the lower die 12 is determined so as to be the same amount. That is, the volume Va before forming the groove vertical wall forming portion (the end curved surface portion shown by hatching) of the metal thin plate W ′ shown in FIG. 5A is the metal thin plate W ′ shown in FIG. 5B. Of the groove vertical wall portion of the upper die 11 and the lower die 12 so as to be equal to the volume Vb after forming of the groove vertical wall portion forming portion (end curved surface portion indicated by hatching) (Va = Vb). Clearance is determined.
以上のように、本実施の形態に係る製造方法によれば、予備張出工程における金属薄板W’の張出成形によって金属薄板W’の溝周辺部から溝縦壁部Wcに引き込まれた材料は、次の潰し工程において金属薄板W’の溝縦壁部Wcを潰すことによって元の溝周辺部に戻されるため、金属薄板W’の溝縦壁部Wcのみが鍛造のように潰して伸ばされる。このため、材料の移動は金属薄板W’の溝周辺部を含む成形部の範囲内でのみ行われることとなり、成形部の断面積(体積)は変化せず、従って、成形部以外の周辺部と成形部との間で材料の流出入はなく、材料の流出入に伴う面歪みの発生が抑えられ、高品位な燃料電池用金属セパレータW(図1参照)が得られる。   As described above, according to the manufacturing method according to the present embodiment, the material drawn into the groove vertical wall portion Wc from the groove peripheral portion of the metal thin plate W ′ by the overhang forming of the metal thin plate W ′ in the preliminary overhanging step. In the next crushing step, the groove vertical wall portion Wc of the metal thin plate W ′ is returned to the original groove peripheral portion by crushing, so that only the groove vertical wall portion Wc of the metal thin plate W ′ is crushed and stretched like forging. It is. For this reason, the movement of the material is performed only within the range of the molded part including the peripheral part of the groove of the thin metal plate W ′, and the cross-sectional area (volume) of the molded part does not change. There is no inflow / outflow of material between the molding part and the molding part, generation of surface distortion accompanying the inflow / outflow of material is suppressed, and a high-quality metal separator W for fuel cells (see FIG. 1) is obtained.
具体的には、金型10の上型11と下型12の溝縦壁部成形部のクリアランスを適切に設定することによって、潰し工程における金属薄板W’の潰し量が予備張出工程における材料の溝縦壁部Wcへの引込量と同量となるよう設定することができ、金属薄板W’の成形部の断面積(体積)を一定に保って成形部以外の周辺部と成形部間での材料の流出入を無くし、材料の流出入に伴う面歪みの発生を抑えることができる。   Specifically, the amount of crushing of the metal thin plate W ′ in the crushing process is set to be a material in the pre-extrusion process by appropriately setting the clearance between the groove vertical wall forming portions of the upper mold 11 and the lower mold 12 of the mold 10. Can be set to be the same as the amount drawn into the vertical wall portion Wc of the groove, and the cross-sectional area (volume) of the forming portion of the metal thin plate W ′ is kept constant, between the peripheral portion other than the forming portion and the forming portion Inflow and outflow of material at the surface can be eliminated, and the occurrence of surface distortion accompanying the inflow and outflow of material can be suppressed.
そして、本実施の形態では、1つの金型で面歪みの無い高品位な燃料電池用金属セパレータWを効率良く短時間で成形することができる。尚、本発明方法は、金属薄板W’の材質や成形すべき凹凸部Wa,Wbの寸法を問わず適用することができ、ステンレス、アルミニウム、チタン等の任意の材質の金属薄板W’に任意のサイズの凹凸部Wa,Wbを形成することができる。尚、本実施の形態では1つの金型で成形を行ったが、予備張出工程と潰し工程を別の金型にて加工を行っても同様の効果が得られる。   And in this Embodiment, the high quality metal separator W for fuel cells without a surface distortion can be efficiently shape | molded in a short time with one metal mold | die. The method of the present invention can be applied regardless of the material of the metal thin plate W ′ and the dimensions of the concave and convex portions Wa and Wb to be formed, and can be arbitrarily applied to the metal thin plate W ′ of any material such as stainless steel, aluminum, titanium, etc. The uneven portions Wa and Wb of the size can be formed. In this embodiment, the molding is performed with one mold, but the same effect can be obtained even when the preliminary overhanging process and the crushing process are performed with different molds.
<実施の形態2>
次に、本発明の実施の形態2を図6(a)〜(c)に基づいて説明する。
<Embodiment 2>
Next, a second embodiment of the present invention will be described with reference to FIGS.
図6(a)〜(c)は本発明の実施の形態2に係る製造方法の予備張出工程の前工程、予備張出工程の後工程(第2の予備張出工程)及び潰し工程をそれぞれ示す金型の部分断面図である。   6 (a) to 6 (c) show the pre-process of the pre-expansion process, the post-process of the pre-expansion process (second pre-expansion process), and the crushing process of the manufacturing method according to Embodiment 2 of the present invention. It is a fragmentary sectional view of a metallic mold shown, respectively.
本実施の形態に係る製造方法は、予備張出工程と潰し工程の間に、予備張出工程の後工程(第2の予備張出工程)を追加する方法であって、予備張出工程の後工程において金属薄板を成形可能な高さまで張出成形し、予備張出工程の後工程において金型に空間を形成し、前工程において成形した金属薄板の溝縦壁部を潰して材料を前記空間に流入させることを特徴とする。又、予備張出工程の後工程と潰し工程を複数回繰り返して加工することもできる。以下、その方法を図6(a)〜(c)に従って具体的に説明する。   The manufacturing method according to the present embodiment is a method of adding a post-expansion step (second pre-expansion step) between the pre-expansion step and the crushing step. In the subsequent process, the metal sheet is stretched to a moldable height, a space is formed in the mold in the subsequent process of the preliminary stretching process, and the material is obtained by crushing the vertical wall portion of the metal sheet formed in the previous process. It is characterized by flowing into the space. Further, the post-process and the crushing process of the preliminary overhanging process can be repeated multiple times. Hereinafter, the method will be specifically described with reference to FIGS.
1)予備張出工程(前工程):
この予備張出工程(前工程)では、図6(a)に示すように、図1に示す最終成形品である燃料電池用金属セパレータWの図2に示す凹凸部Wa,Wb(溝縦壁部Wc)の高さ(深さ)よりも低い(浅い)凹部21aが形成された上型21と凸部22aが形成された下型22から成る金型20が使用され、上型21と下型22の間に素材である金属薄板W’が挿入セットされ、この状態で上型21が不図示のプレス機構によって下降する。
1) Preliminary overhanging process (previous process):
In this preliminary overhanging step (previous step), as shown in FIG. 6A, the concavo-convex portions Wa and Wb (groove vertical walls) shown in FIG. A mold 20 comprising an upper mold 21 formed with a recess 21a (shallow) lower than a height (depth) of the portion Wc) and a lower mold 22 formed with a projection 22a is used. A metal thin plate W ′, which is a material, is inserted and set between the molds 22, and the upper mold 21 is lowered by a press mechanism (not shown) in this state.
図6(a)は予備張出工程の前工程の加工完了状態を示し、この状態では材料そのものの伸びによる通常の張出成形が行われ、上型21の下降に伴って金属薄板W’の溝縦壁部Wcを形成する部分の材料は伸び変形し、これに伴って周辺の材料が矢印にて示すように溝縦壁部Wcに引き込まれる。この予備張出工程の前工程においては、金属薄板に溝縦壁部Wcが通常の張出加工によって成形可能な高さまで成形されて凹凸部Wa,Wb(図2参照)の概形が形成される。尚、本予備張出工程の前工程は前記実施の形態1の予備張出工程に相当する。   FIG. 6 (a) shows the completed state of the process prior to the preliminary overhanging step. In this state, normal overhanging is performed by the elongation of the material itself, and as the upper die 21 is lowered, the metal thin plate W ′ is moved. The material of the portion forming the groove vertical wall portion Wc is stretched and deformed, and accordingly, the surrounding material is drawn into the groove vertical wall portion Wc as indicated by the arrow. In the pre-step of the preliminary overhanging step, the groove vertical wall Wc is formed on a metal thin plate to a height that can be formed by a normal overhanging process, and rough shapes Wa and Wb (see FIG. 2) are formed. The Note that the pre-step of the preliminary overhanging step corresponds to the preliminary overhanging step of the first embodiment.
2)予備張出工程(後工程):
予備張出工程の後工程においては、図6(b)に示すように、前工程で使用された上型21の凹部21aよりも深い凹部31aが形成された上型31を備える金型30が使用され、この金型30の上型31と下型32の間には空間Vが形成されている。そして、この工程では、前工程において成形した金属薄板W’の溝縦壁部Wcを潰して材料を空間Vに流入させることによって、次の潰し工程で使用するための余肉が形成される。
2) Preliminary overhanging process (post process):
In the subsequent process of the preliminary overhanging process, as shown in FIG. 6B, a mold 30 including an upper mold 31 in which a recess 31a deeper than the recess 21a of the upper mold 21 used in the previous process is formed. A space V is formed between the upper mold 31 and the lower mold 32 of the mold 30. In this step, the groove vertical wall portion Wc of the metal thin plate W ′ formed in the previous step is crushed to allow the material to flow into the space V, thereby forming a surplus wall for use in the next crushing step.
3)潰し工程:
潰し工程では、図6(c)に示すように、最終製品である図1に示す燃料電池用金属セパレータWの凹凸部Wa,Wb(溝縦壁部Wc)の高さ(深さ)と同等の凹部41aが形成された上型41と凸部42aが形成された下型42から成る金型40が使用され、前工程で金属薄板W’に形成された余肉を含む溝縦壁部Wcが、上型41が下死点付近まで下降する成形終期において上型41と下型42によって潰され、予備張出工程時に該溝縦壁部Wcに引き込まれた材料が元の溝周辺部に戻されるとともに、金属薄板W’の全体が押圧され、図1に示す燃料電池用金属セパレータWが得られる。
3) Crushing process:
In the crushing step, as shown in FIG. 6 (c), the height (depth) of the uneven portions Wa, Wb (groove vertical wall portion Wc) of the fuel cell metal separator W shown in FIG. A vertical wall portion Wc including a surplus wall formed on the metal thin plate W ′ in the previous step is used, which is a mold 40 including an upper die 41 having a concave portion 41a and a lower die 42 having a convex portion 42a. However, in the final stage of molding when the upper die 41 is lowered to the vicinity of the bottom dead center, the upper die 41 and the lower die 42 are crushed, and the material drawn into the groove vertical wall portion Wc in the preliminary overhanging process is returned to the original groove peripheral portion. At the same time, the entire thin metal plate W ′ is pressed, and the fuel cell metal separator W shown in FIG. 1 is obtained.
ここで、上型41と下型42の溝縦壁部成形部のクリアランスは、前記実施の形態1と同様に、潰し工程における金属薄板W’の潰し量が予備張出工程における材料の溝縦壁部Wcへの引込量と同量となるよう決定される。   Here, as in the first embodiment, the clearance between the groove vertical wall portion forming portions of the upper die 41 and the lower die 42 is such that the amount of crushing of the metal thin plate W ′ in the crushing step is the length of the groove of the material in the preliminary overhanging step. It is determined to be the same amount as the amount drawn into the wall Wc.
而して、本実施の形態においても、予備張出工程における金属薄板W’の張出成形によって該金属薄板W’の溝周辺部から溝縦壁部Wcに引き込まれた材料は、次の潰し工程において金属薄板W’の溝縦壁部Wcを潰すことによって元の溝周辺部に戻されるため、成形部以外の周辺部と成形部との間で材料の流出入はなく、材料の流出入に伴う面歪みの発生が抑えられ、高品位な燃料電池用金属セパレータWが得られる。   Thus, also in the present embodiment, the material drawn into the groove vertical wall portion Wc from the groove peripheral portion of the metal thin plate W ′ by the stretch forming of the metal thin plate W ′ in the pre-stretching step is In the process, the groove vertical wall portion Wc of the thin metal plate W ′ is returned to the original groove peripheral portion by crushing, so there is no material inflow / outflow between the peripheral portion other than the forming portion and the forming portion. As a result, the occurrence of surface distortion associated with is suppressed, and a high-quality metal separator W for fuel cells is obtained.
特に、本実施の形態では、予備張出工程の前工程において金属薄板W’に溝縦壁部Wcを通常の張出加工によって亀裂やネックが発生しない成形可能な高さまで成形し、次工程において金型30に空間Vを形成し、前工程において成形した金属薄板W’の溝縦壁部Wcを潰して材料を空間Vに流入させることによって、潰し工程で使用するための余肉を形成し、材料の流出が可能な限り、より高い凹凸部Wa,Wb(図2参照)を成形できたり、伸びの少ない材料でも成形することができる。   In particular, in the present embodiment, the groove vertical wall portion Wc is formed in the metal thin plate W ′ in the previous process of the pre-extrusion process to a moldable height that does not cause cracks and necks by the normal extension process, and in the next process. A space V is formed in the mold 30, and the groove vertical wall portion Wc of the thin metal plate W ′ formed in the previous process is crushed to allow the material to flow into the space V, thereby forming a surplus for use in the crushing process. As long as the material can flow out, higher concavo-convex portions Wa and Wb (see FIG. 2) can be formed, or even a material with less elongation can be formed.
又、予備張出工程の後工程と潰し工程の金型をそれぞれ複数用意し、先ず予備張出工程の前工程を実施し、次に予備張出工程の前工程と潰し工程を複数回行い加工することもできる。この場合は更に高い凹凸部の成形、或いは材料の伸びが少ない難成形材であっても成形が可能となる。   Also, prepare a plurality of molds for the preliminary overhanging process and the crushing process. First, perform the preliminary process for the preliminary overhanging process, and then perform the preliminary process for the preliminary overhanging process and the crushing process multiple times. You can also In this case, it is possible to mold a higher uneven portion or even a difficult-to-mold material with less material elongation.
<実施の形態3>
次に、本発明の実施の形態3を図7(a)〜(c)に基づいて説明する。
<Embodiment 3>
Next, a third embodiment of the present invention will be described with reference to FIGS.
図7(a)〜(c)は本発明の実施の形態3に係る製造方法の予備張出工程の前工程の前工程(第3の予備張出工程)、予備張出工程の後工程及び潰し工程をそれぞれ示す金型の部分断面図である。   7 (a) to 7 (c) are a pre-step (third pre-projection step) before the pre-extension step of the manufacturing method according to Embodiment 3 of the present invention, a post-step of the pre-extension step, and It is a fragmentary sectional view of the metal mold | die which each shows a crushing process.
本実施の形態に係る製造方法は、予備張出工程の前工程において凹凸部概形の成形に必要なボリュームを確保するように前記予備張出工程の前に第3の予備張出工程(予備張出工程の前工程)を経て製造することを特徴とする。以下、その方法を図7(a)〜(c)に従って具体的に説明する。   In the manufacturing method according to the present embodiment, the third preliminary overhanging step (preliminary step) is performed before the preliminary overhanging step so as to secure the volume necessary for forming the rough shape in the preliminary step. It is characterized by being manufactured through a pre-process of the overhang process. Hereinafter, the method will be specifically described with reference to FIGS.
1)予備張出工程(前工程):
この予備張出工程(前工程)では、図7(a)に示す上型51と下型52から成る金型50を用いて金属薄板W’に対する通常の張出成形がなされるが、この張出成形は次工程で必要なボリュームが確保される。この張出成形では、上型51の下降に伴って金属薄板W’の溝縦壁部Wcを形成する部分の材料が伸び変形し、これに伴って周辺の材料が矢印にて示すように溝縦壁部Wcに引き込まれる。
1) Preliminary overhanging process (previous process):
In this preliminary overhanging step (previous step), a normal overhang forming is performed on the metal thin plate W ′ using a mold 50 including an upper die 51 and a lower die 52 shown in FIG. 7A. The required volume for the next process is ensured in the extrusion process. In this overhang molding, the material of the portion forming the groove vertical wall portion Wc of the metal thin plate W ′ is stretched and deformed as the upper mold 51 is lowered, and the surrounding material is grooved as indicated by the arrow along with this. It is drawn into the vertical wall Wc.
2)予備張出工程(後工程):
予備張出工程の後工程では、図7(b)に示す上型61と下型62から成る金型60が使用され、前工程において金属薄板W’の溝縦壁部Wcに流入した材料を用いて張出成形が行われる。この後工程では、前工程で溝縦壁部Wcに流入した材料をそのまま用いて張出成形がなされるため、材料の流出入はないが、前工程での材料の溝縦壁部Wcへの流入に伴い、溝縦壁部Wcの外周(平坦部)には面歪みが発生したままとなっている。尚、本予備張出工程の前工程は前記実施の形態1の予備張出工程に相当する。
2) Preliminary overhanging process (post process):
In the subsequent process of the preliminary projecting process, a mold 60 including an upper mold 61 and a lower mold 62 shown in FIG. 7B is used, and the material that has flowed into the groove vertical wall portion Wc of the metal thin plate W ′ in the previous process is used. The overhanging process is carried out. In this subsequent process, the material that has flowed into the groove vertical wall portion Wc in the previous process is used as it is, so that the material does not flow in and out, but the material in the previous process flows into the groove vertical wall portion Wc. Along with the inflow, surface distortion is still generated on the outer periphery (flat portion) of the groove vertical wall Wc. Note that the pre-step of the preliminary overhanging step corresponds to the preliminary overhanging step of the first embodiment.
3)潰し工程:
潰し工程では、図7(c)に示すように、最終製品である図1に示す燃料電池用金属セパレータWの図2に示す凹凸部Wa,Wb(溝縦壁部Wc)の高さ(深さ)と同等の凹部が形成された上型71と凸部72aが形成された下型72から成る金型70が使用されて溝縦壁部Wcが潰され、予備張出工程(前工程)において溝縦壁部Wcに流入した材料と同量の材料が溝縦壁部Wcの外周の平坦部に流出して両者が相殺され、図1に示す燃料電池用金属セパレータWが成形される。
3) Crushing process:
In the crushing step, as shown in FIG. 7C, the height (depth) of the concavo-convex portions Wa and Wb (groove vertical wall portions Wc) shown in FIG. 2 of the fuel cell metal separator W shown in FIG. ) Is used, and the groove vertical wall portion Wc is crushed by using a mold 70 composed of an upper mold 71 in which a concave portion equivalent to the above is formed and a lower mold 72 in which a convex portion 72a is formed, and a preliminary overhanging process (previous process) 1 flows out to the flat portion on the outer periphery of the groove vertical wall portion Wc, and the two materials are offset to form the fuel cell metal separator W shown in FIG.
ここで、上型71と下型72の溝縦壁部成形部のクリアランスは、前記実施の形態1,2と同様に、潰し工程における金属薄板W’の潰し量が予備張出工程における材料の溝縦壁部Wcへの引込量と同量となるよう決定される。   Here, as in the first and second embodiments, the clearance between the groove vertical wall portion forming portions of the upper mold 71 and the lower mold 72 is equal to the amount of crushing of the metal thin plate W ′ in the crushing process. It is determined to be the same amount as the amount drawn into the groove vertical wall portion Wc.
而して、本実施の形態においても、予備張出工程における金属薄板W’の張出成形によって該金属薄板Wcの溝周辺部から溝縦壁部Wcに引き込まれた材料は、次の潰し工程において金属薄板W’の溝縦壁部Wcを潰すことによって元の溝周辺部に戻されるため、成形部以外の周辺部と成形部との間で材料の流出入はなく、材料の流出入に伴う面歪みの発生が抑えられ、反りや波打ち等の無い高品位な燃料電池用金属セパレータWが得られる。   Thus, also in the present embodiment, the material drawn into the groove vertical wall portion Wc from the groove peripheral portion of the metal thin plate Wc by the extension forming of the metal thin plate W ′ in the preliminary overhanging step is subjected to the next crushing step. In this case, by crushing the groove vertical wall portion Wc of the thin metal plate W ′, the material is returned to the peripheral portion of the original groove. Therefore, there is no inflow / outflow of material between the peripheral portion other than the forming portion and the forming portion. The generation of surface distortion is suppressed, and a high-quality metal separator W for fuel cells without warping or undulation is obtained.
特に、本実施の形態では、材料の伸び限界により1工程で張出成形ができない場合、予備張出工程の前工程において次工程で必要なボリュームを確保するように金属薄板W’を張出成形し、次工程において前工程において金属薄板W’の溝縦壁部Wcに流入した材料を用いて張出成形を行うようにしたため、燃料電池用金属セパレータWに所望の高さの凹凸部Wa,Wbを成形することができる。   In particular, in this embodiment, when stretch forming cannot be performed in one process due to the elongation limit of the material, the metal thin plate W ′ is stretched and formed so as to secure a necessary volume in the next process in the previous process of the preliminary projecting process. In the next step, since the overflow molding is performed using the material that has flowed into the groove vertical wall portion Wc of the thin metal plate W ′ in the previous step, the uneven portion Wa having a desired height is formed on the fuel cell metal separator W. Wb can be formed.
尚、以上は燃料電池用金属セパレータの成形に本発明を適用した形態について説明したが、本発明は、金属薄板に凹凸部を形成して成る他の任意の成形品のプレス加工に対しても同様に適用可能であることは勿論である。   In the above, the embodiment in which the present invention is applied to the molding of a metal separator for a fuel cell has been described. However, the present invention can also be applied to press processing of any other molded product formed by forming an uneven portion on a thin metal plate. Of course, the same applies.
10 金型
11 上型
11a 上型の凹部
12 下型
12a 下型の凸部
20 金型
21 上型
21a 上型の凹部
22 下型
22a 下型の凸部
30 金型
31 上型
31a 上型の凹部
32 下型
32a 下型の凸部
40 金型
41 上型
41a 上型の凹部
42 下型
42a 下型の凸部
50 金型
51 上型
52 下型
60 金型
61 上型
62 下型
70 金型
71 上型
71a 上型の凹部
72 下型
72a 下型の凸部
V 空間
W 燃料電池用金属セパレータ
W’ 金属薄板
WA 燃料電池用金属セパレータの集電部(凹凸部)
WB 燃料電池用金属セパレータの周辺部
Wa 集電部の凹部
Wb 集電部の凸部
Wc 集電部の溝縦壁部
DESCRIPTION OF SYMBOLS 10 Mold 11 Upper mold 11a Concavity of upper mold 12 Lower mold 12a Convex section of lower mold 20 Mold 21 Upper mold 21a Concavity of upper mold 22 Lower mold 22a Convex section of lower mold 30 Mold 31 Upper mold 31a Upper mold 31a Recess 32 Lower mold 32a Lower mold protrusion 40 Mold 41 Upper mold 41a Upper mold recess 42 Lower mold 42a Lower mold protrusion 50 Mold 51 Upper mold 52 Lower mold 60 Mold 61 Upper mold 62 Lower mold 70 Gold Mold 71 Upper mold 71a Upper mold concave part 72 Lower mold 72a Lower mold convex part V Space W Metal separator for fuel cell W 'Metal thin plate WA Current collector (uneven part) of metal separator for fuel cell
WB Peripheral part of fuel cell metal separator Wa Concave part of current collecting part Wb Convex part of current collecting part Wc Vertical wall part of groove of current collecting part

Claims (4)

  1. 金属薄板を、金型によるプレス成形によって、凹部と、凸部と、凹部の端縁から凸部の端縁に向けて傾斜した直線状の溝縦壁部と、からなる凹凸部が形成された金属薄板をプレス加工するために、
    少なくとも前記金属薄板を張出成形して該金属薄板に凹凸部の概形を形成する予備張出工程と、
    金属薄板の前記凹凸部の溝縦壁部を潰して前記予備張出工程時に該溝縦壁部に引き込まれた材料を元に戻すとともに、金属薄板の全体を押圧する潰し工程と、
    を経て製造する方法であって、
    前記潰し工程における前記金型の、前記溝縦壁部を成形する上型と下型のクリアランスは、
    前記金属薄板の潰し量が前記予備張出工程における材料の前記溝縦壁部への引込量と同量となるよう寸法を決定したことを特徴とする凹凸部が形成された金属薄板の製造方法。
    The metal thin plate was press-molded with a metal mold to form a concave and convex portion including a concave portion, a convex portion, and a linear groove vertical wall portion inclined from the edge of the concave portion toward the edge of the convex portion . To press the metal sheet,
    A pre-extrusion step in which at least the metal thin plate is stretched to form a rough shape on the metal thin plate;
    A crushing step of crushing the groove vertical wall portion of the uneven portion of the metal thin plate to return the material drawn into the groove vertical wall portion during the preliminary overhanging step and pressing the entire metal thin plate,
    A method of manufacturing via
    The clearance between the upper mold and the lower mold for molding the vertical wall portion of the mold in the crushing step is as follows:
    The method of manufacturing a metal thin plate with a concavo-convex portion formed , wherein the dimension is determined so that the amount of crushing of the metal thin plate is the same as the amount of material drawn into the vertical wall portion of the groove in the preliminary overhanging step .
  2. 前記予備張出工程と潰し工程の間に、空間が形成された金型により、予備張出工程において成形した金属薄板の溝縦壁部を潰して材料を前記金型の流入させる第2の予備張出工程を経て製造することを特徴とする請求項1記載の凹凸部が形成された金属薄板の製造方法。   A second spare in which a metal mold in which a space is formed between the preliminary overhanging step and the crushing step collapses the vertical wall portion of the groove of the thin metal sheet formed in the preliminary overhanging step and allows the material to flow into the mold. 2. The method for producing a metal thin plate having a concavo-convex portion formed thereon according to claim 1, wherein the metal thin plate is produced through an overhanging step.
  3. 前記第2予備張出工程と潰し工程を複数回繰り返して製造することを特徴とする請求項記載の凹凸部が形成された金属薄板の製造方法。 Method for producing the second preliminary overhanging step and the metal sheet an uneven portion of claim 2, wherein is formed, characterized in that to produce the crushing step is repeated a plurality of times.
  4. 前記予備張出工程において凹凸部概形に必要なボリュームを確保するように前記予備張出工程の前に第3の予備張出工程を経て製造することを特徴とする請求項記載の凹凸部が形成された金属薄板の製造方法。 The uneven portion according to claim 1 , wherein the uneven portion is manufactured through a third preliminary extending step before the preliminary extending step so as to secure a volume necessary for the rough shape of the uneven portion in the preliminary extending step. The manufacturing method of the metal thin plate in which this was formed.
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