JP5437907B2 - Panel member manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a panel member in which a plurality of plate members are stacked and edges are fastened.

  Conventionally, the second plate member is overlaid on the first plate member, the first flange portion is erected substantially at a right angle from one end of the first plate member, and is erected at a substantially right angle from one end of the second plate member. A method of fastening the second flange portion to be tightened by winding is known (for example, see Non-Patent Document 1).

Japan Society for Invention and Innovation Technical Report No. 2004-502296

  When a panel member is manufactured using the method of Non-Patent Document 1, a first flange portion is usually formed at the edge (one end) of the first plate member and a second flange portion is formed at the edge of the second plate member. After the first plate member is formed, the first plate member and the second plate member are overlapped by lowering the second plate member from above the first plate member.

  And in order to wind up the 1st flange part and the 2nd flange part, since it is necessary to arrange the 1st flange part and the 2nd flange part close, on the 1st plate member When the second plate member is stacked, the first flange portion and the second flange portion may come into contact with each other and be damaged.

  In order to improve the formability of the first flange portion, for example, the tip of the first flange portion may be bent inward. In this case, the tip of the first flange portion and the first flange portion may be bent. It becomes easier to contact 2 flange parts.

  As a countermeasure against such a problem, as shown in FIGS. 17A and 17B, the angle (flange angle θ1) formed by the extension line L0 on the lower surface of the first plate member body 200 and the first flange portion 202 is set to an acute angle. In addition, after the second plate member 206 is overlaid on the first plate member 204, a method of pushing the first flange portion 202 inward so that the flange angle θ1 becomes a substantially right angle is conceivable.

  However, in this case, as shown in FIG. 18, when the first flange portion 202 is pushed in, a portion of the first plate member body 200 that is close to the first flange portion 202 is pulled toward the first flange portion 202 ( For this reason, the boundary between the first plate member body 200 and the first flange 202 (the base 208 of the first flange 202) may be lifted. When the base portion 208 of the first flange portion 202 is lifted, the curvature of the edge portion of the panel member is reduced when the first flange portion 202 and the second flange portion 210 are tightened (the edge of the panel member). And the appearance quality of the panel member may be deteriorated.

  The present invention has been made in consideration of such problems, and facilitates the stacking of the second plate member on the first plate member, and suppresses the floating of the base portion of the flange portion of the first plate member. It is an object of the present invention to provide a method for manufacturing a panel member that can improve the appearance quality of the panel member.

[1] In the method for manufacturing a panel member according to the present invention, the first portion rising from the first plate member main body and the outside of the first portion from the tip of the first portion with respect to the edge of the first plate member A first step of forming a first flange portion having a second portion that bends, a second step of overlapping a second plate member on the first plate member on which the first flange portion is formed, and the second A third step that is performed after the step and pushes the second portion inward; and a third step that is performed after the third step and the edge of the first plate member is formed by curling the first flange portion. And a fourth step of fastening the edge of the second plate member.

  According to such a method, in the first step, the first flange portion having the second portion bent from the tip of the first portion to the outside of the first portion is formed on the edge portion of the first plate member. Therefore, in the second step, when the second plate member is stacked on the first plate member, the distance between the second plate member and the second portion is compared with the case where the second portion is not bent outward. Can be widened. Thereby, it becomes easy to overlap the second plate member on the first plate member.

  That is, for example, even when the angle (first angle) formed between the extension line of the lower surface of the first plate member main body and the first part is set at a substantially right angle, the angle formed between the extension line and the second part. Can be made smaller than the first angle, so that the contact between the second portion and the second plate member can be suitably suppressed.

  Further, in the third step, the bent portion of the second portion can be suitably deformed by pushing the second portion inward, so that the lifting of the base portion of the first flange portion is suppressed. In this state, the second part can be displaced to a predetermined position. Thereby, the external appearance quality of a panel member can be improved.

[2] The present invention is characterized in that, in the first step, a step of forming a bending portion that curves toward the side where the first plate member main body is located is performed on the second portion. Thereby, in the fourth step, when the first flange portion is curled, the first flange portion is likely to curl from the curved portion, so that the molding resistance of the first flange portion can be reduced. As a result, the formability of the first flange portion is improved.

  According to the present invention, since the first flange portion having the second portion bent from the tip of the first portion to the outside of the first portion is formed at the edge of the first plate member, in the second step, When stacking the second plate member on the first plate member, the interval between the second plate member and the second portion is increased to facilitate the stacking of the second plate member on the first plate member. be able to. Further, by pushing the second portion inward, the second portion can be displaced to a predetermined position while suppressing the lifting of the base portion of the first flange portion. Can be increased.

It is a perspective view of the automobile rear door to which the panel member manufactured by the manufacturing method concerning this embodiment was applied. It is a front view of the motor vehicle rear door from the A arrow direction of FIG. It is a flowchart for demonstrating the manufacturing method of a motor vehicle rear door. It is a figure which shows the state which stamped and processed the outer panel raw material and the inner panel raw material. It is a flowchart for demonstrating in detail step S2 of the flowchart of FIG. 6A is a cross-sectional explanatory view showing a first bending process, FIG. 6B is a cross-sectional explanatory view showing a cutting process, and FIG. 6C is a cross-sectional explanatory view showing the process of forming the first flange portion on the outer panel. FIG. 6D is an explanatory sectional view showing a state in which the outer panel after the cutting process is placed on the second die and held by the pad, and FIG. 6D is an explanatory sectional view showing the second bending process. It is a flowchart for demonstrating in detail step S3 of the flowchart of FIG. FIG. 8A is a cross-sectional explanatory view showing a draw process, FIG. 8B is a cross-sectional explanatory view showing a re-striking process, and FIG. 8C is a cross-sectional explanatory view showing a process of forming the second flange portion on the inner panel. FIG. 8D is an explanatory cross-sectional view showing a cutting process, and FIG. 8D is an explanatory cross-sectional view showing a curling process. It is sectional explanatory drawing which shows the process of stacking an inner panel on an outer panel. FIG. 5 is a perspective view showing a state in which an inner panel is overlaid on an outer panel and showing a positional relationship among a first long flange portion, a first short flange portion, and a second flange portion. FIG. 11A is a cross-sectional explanatory view showing a state in which the outer panel and the inner panel are held by a pad, and FIG. 11B is a curl punch in the cross-sectional explanatory view showing the step of curling the first long flange portion and the second flange portion. FIG. 11C is a cross-sectional explanatory view showing a state in which the second part is in contact, FIG. 11C is a cross-sectional explanatory view showing a process of pushing the second part inward, and FIG. 11D is a state in which the first curl edge is formed FIG. It is an expanded sectional explanatory view showing the state where the 2nd part is pushed inward. It is sectional explanatory drawing which shows the state which carried out the seam shaping | molding of the 1st curl edge part. 14A is a cross-sectional explanatory view showing a state in which the outer panel and the inner panel are held by pads, and FIG. 14B is a horizontal movement of the curl punch. 14C is a cross-sectional explanatory view showing a state, FIG. 14C is a cross-sectional explanatory view showing a state where the vertical surface of the curl punch and the first short flange portion are in contact, and FIG. 14D is a second curl edge portion formed It is sectional explanatory drawing which shows a state. It is sectional explanatory drawing which shows the state which carried out the seam shaping | molding of the 2nd curl edge part. FIG. 16A is a cross-sectional explanatory view showing a modification of the present embodiment, FIG. 16A is a cross-sectional explanatory view showing a process of stacking the inner panel on the outer panel, and FIG. 16B is a second portion of the first flange portion pushed inward. It is sectional explanatory drawing which shows a process. FIG. 17A is a cross-sectional explanatory view for explaining the problem of the present invention, FIG. 17A is a cross-sectional explanatory view showing a process of stacking the second plate member on the first plate member, and FIG. 17B is a first view of the first plate member. It is sectional explanatory drawing which shows the process of pushing a flange part inward. It is a section explanatory view showing the state where the base of the 1st flange part rose.

  Hereinafter, a preferred embodiment of the panel member manufacturing method according to the present invention will be described in detail with reference to the accompanying drawings.

  First, the structure of the automobile rear door 10 to which the panel member 16 manufactured by the manufacturing method according to the present embodiment is applied will be described with reference to FIGS. 1 and 2.

  As shown in FIG. 1, an automobile rear door 10 includes a panel member 16 formed by engaging (fastening) an outer panel 12 as a first plate member and an inner panel 14 as a second plate member at an edge. In addition, a window frame 18 is formed on the panel member 16.

  As shown in FIGS. 1 and 2, the edge 20 of the panel member 16 extends three-dimensionally over the entire periphery of the rear door 10 of the automobile, and is a first edge attached to a vehicle body (not shown). (A belt-like mesh portion H1 indicated by a dotted line in FIG. 2) 22 and a second edge portion (a belt-like mesh portion H2 indicated by a solid line in FIG. 2) 24 having a structure different from the structure of the first edge portion 22; Is included.

  As shown in FIG. 1, the first edge portion 22 is wound so that the end surface of the outer panel 12 and the end surface of the inner panel 14 are included, and the second edge portion 24 is an end portion of the inner panel 14. The outer panel 12 is bent toward the inner panel 14 so that the outer panel 12 covers the outer panel 12.

  As a result, it is possible to increase the fastening strength of the first edge portion 22 to which a load is applied in a state in which the vehicle rear door 10 is attached to the vehicle body, and to simplify the configuration of the second edge portion 24 where the load is not so much applied.

  Next, a method for manufacturing the automobile rear door 10 will be described with reference to FIGS. 11A to 11D and FIG. 13 show the manufacturing process of the first edge 22 described above, and FIGS. 14A to 15 show the manufacturing process of the second edge 24 described above. 11A to 11D correspond to FIGS. 14A to 14D, and FIG. 13 corresponds to FIG.

  First, the outer panel material and the inner panel material are punched into a predetermined shape (step S1 in FIG. 3). Thereby, the window frame 18 etc. mentioned above will be formed.

  As shown in FIG. 4, the punched outer panel 12 and inner panel 14 have portions corresponding to the first edge 22 of the automobile rear door 10 (first equivalent edges 22 a and 22 b) at the second edge 24. It extends outward from the corresponding portion (second equivalent edge portions 24a, 24b).

  Then, the 1st flange part 26 (refer FIG. 10) is formed with respect to the outer panel 12 stamped (step S2). Specifically, steps S21 to S24 in FIG. 5 described later are performed.

  That is, as shown to FIG. 6A, a 1st bending process is performed with respect to the 1st equivalent edge 22a of the outer panel 12 stamped (step S21 of FIG. 5). Specifically, the first punch 30 is lowered after placing the first equivalent edge portion 22a of the outer panel 12 punched on the first die 28, so that the first equivalent edge portion 22a is first moved. A bent portion 32 is formed.

  6B, the outer panel 12 subjected to the first bending process is placed on the cutting die 34 having the cutting blade 34a, and the outer panel 12 is held by the pad 36 while being cut. The vicinity of the first bent portion 32 is cut by lowering the cutting punch 38 having the blade 38a (step S22).

  Thereafter, as shown in FIG. 6C, the cut outer panel 12 is placed on the second die 40 and the outer panel 12 is held by the pad 42 (step S23). At this time, the cut outer panel 12 is disposed on the second die 40 such that the first equivalent edge portion 22 a and the second equivalent edge portion 24 a protrude from the second die 40.

  Next, as shown in FIG. 6D, the second bent portion 46 is formed by lowering the second punch 44 with respect to the first equivalent edge portion 22a and the second equivalent edge portion 24a (step S24).

  As shown in FIGS. 6C and 6D, the second punch 44 has a contact portion 48 that contacts the first equivalent edge portion 22a and the second equivalent edge portion 24a. Then, the contact portion 48 is gently inclined inwardly (on the right side in FIGS. 6C and 6D) toward the bottom surface of the second punch 44 from the vertical surface 48 a that forms part of the side surface of the second punch 44. And an inclined surface 48b which is inclined. Further, as can be seen from FIG. 6D, the side surface of the second die 40 has a vertical portion 50a extending substantially vertically downward from the end of the upper surface, and an outer side downward from the tip of the portion (FIG. 6D). And an inclined portion 50b that is gently inclined.

  Here, the operation of step S24 will be specifically described. When the second punch 44 descends, first, a part of the inclined surface 48b comes into contact with the first equivalent edge 22a and the second equivalent edge 24a. When the second punch 44 is further lowered, the inclined surface 48b presses downward while sliding on the upper surfaces of the first equivalent edge 22a and the second equivalent edge 24a, so the first equivalent edge 22a and the second equivalent edge The second bent portion 46 is formed by bending the portion 24a downward. At this time, as understood from FIG. 6D, the tip end of the first equivalent edge portion 22 a contacts the inclined portion 50 b on the side surface of the second die 40, and the first bent portion 32 and the second bent portion 46. Is formed into a shape corresponding to the vertical surface 48 a and the inclined surface 48 b of the second punch 44. Although detailed illustration is omitted, since the second equivalent edge portion 24a is shorter than the first equivalent edge portion 22a as described above, the entirety thereof is formed into a shape corresponding to the vertical surface 48a. .

  Then, the formation of the first flange portion 26 on the outer panel 12 punched at this stage is completed. Next, before proceeding to the description of the next step (step S3 in FIG. 3), the configuration of the first flange portion 26 will be described in detail with reference to FIGS.

  As shown in FIG. 10, the first flange portion 26 has a first long flange portion 26a corresponding to the first equivalent edge portion 22a and a first short flange portion 26b corresponding to the second equivalent edge portion 24a. ing.

  As shown in FIGS. 9 and 10, the first long flange portion 26a includes a first portion 54 that rises from the outer panel main body 52, and outward from the tip of the first portion 54 (opposite to the side where the outer panel main body 52 is located). And a second portion 56 that bends to the side). The angle θ2 formed by the extension line L1 on the lower surface of the outer panel main body 52 and the first portion 54 can be set arbitrarily, but is set in the range of 85 ° to 95 °, for example. That is, the first portion 54 rises at a substantially right angle with respect to the outer panel main body 52.

  The second portion 56 includes a first curved portion 58 that is continuous with the first portion 54 and gently bends outwardly from the first portion 54, and the above-described first bent portion 32 that is located at the tip of the second portion 56. And a second bending portion 60 that is bent inwardly from the tip of the first bending portion 58 (on the side where the outer panel main body 52 is located) and continues to the first bending portion 32 is formed. Accordingly, as can be understood from FIG. 9, in the first long flange portion 26 a, the second bending portion 60 is located on the outermost side, and the inner surface of the first bent portion 32 is more than the inner surface of the first portion 54. It will be located outside.

  Moreover, the curvature of the 1st bending part 58 can be set arbitrarily. In addition, only the 1st site | part 54 mentioned above is formed in the 1st short flange part 26b.

  Next, the second flange portion 62 is formed on the punched inner panel 14 (step S3 in FIG. 3). Specifically, steps S31 to S34 in FIG. 7 described later are performed.

  That is, as shown in FIG. 8A, a draw process is performed on the punched inner panel 14 (step S31 in FIG. 7). Specifically, the third bent portion 68 is formed with respect to the first equivalent edge portion 22b by lowering the third punch 66 after placing the punched inner panel 14 on the third die 64. .

  Then, as shown in FIG. 8B, a re-striking process is performed on the inner panel 14 on which the drawing process has been performed (step S32). That is, after the inner panel 14 subjected to the draw process is placed on the fourth die 70, the fourth punch 72 is lowered to bend the third bent portion 68 at an acute angle and to the first equivalent edge portion 22b. Four bent portions 74 are formed.

  Thereafter, as shown in FIG. 8C, the inner panel 14 subjected to the re-striking process is placed on the cutting die 76 having the cutting blade 76a and the inner panel 14 is held by the pad 78. The vicinity of the fourth bent portion 74 is cut by lowering the cutting punch 80 having the cutting blade 80a (step S33).

  Subsequently, as shown in FIG. 8D, the cut inner panel 14 is placed on the fifth die 82 and the inner panel 14 is held by the pad 84. The first equivalent edge portion 22b is curled by sliding the five punches 86 (step S34). The formation of the second flange portion 62 on the inner panel 14 punched at this stage is completed. That is, as shown in FIGS. 9 and 10, the portion that was the first equivalent edge portion 22 b of the inner panel 14 becomes the second flange portion 62. And this 2nd flange part 62 is curving inward (the side in which the inner panel main body 87 is located) from the inner panel main body 87. As shown in FIG. In addition, the site | part which was the 2nd equivalent edge 24b of the inner panel 14 does not change.

  Next, as shown in FIG. 9, the outer panel 12 in which the first flange portion 26 is formed is placed on the placing table 88 (step S4 in FIG. 3). Specifically, the outer panel 12 is mounted on the mounting table such that the second bent portion 46 is positioned at the end of the mounting table 88.

  And the inner panel 14 in which the 2nd flange part 62 was formed is accumulated on the outer panel 12 (step S5). As understood from FIG. 10, at this time, the inner panel 14 is overlaid on the outer panel 12 so that the second flange portion 62 is disposed at a position facing the first long flange portion 26 a.

  At this time, as shown in FIG. 9, the inner surface 32 a of the first bent portion 32 is positioned outward from the inner surface 54 a of the first portion 54, so that the second flange portion 62 and the first bent portion 32 A gap having a predetermined interval d0 can be formed therebetween. In other words, since the second portion 56 is bent outward from the tip of the first portion 54, the second flange portion 62 and the first bent portion 32 are compared with the case where the second portion 56 is not bent outward. Can be widened. Thereby, the inner panel 14 can be easily stacked on the outer panel 12.

  Subsequently, as shown in FIGS. 11A and 14A, the outer panel 12 and the inner panel 14 are held by pressing the pad 90 against the upper surface of the inner panel 14 (step S6).

  Thereafter, as shown in FIGS. 11A to 11C and FIG. 12, the curl punch 92 is horizontally moved toward the first long flange portion 26a to push the second portion 56 inward (step S7). The curl punch 92 has a vertical surface 94 and a curled surface 96 connected to the vertical surface 94.

  Here, the operation of step S7 will be specifically described. When the curl punch 92 moves horizontally, first, the vertical surface 94 of the curl punch 92 contacts the second curved portion 60 (see FIG. 11B). When the curl punch 92 is further moved horizontally, the second bending portion 60 is pressed inward, so that the second portion 56 is displaced inward (FIG. 11C).

  At this time, as shown in FIG. 12, since the first bending portion 58 is gently bent outward from the first portion 54, the pressing force received by the second bending portion 60 is a part of the first bending portion 58. (Strip-like mesh portion H3 in FIG. 12) or the whole, and as a result, the first bending portion 58 is deformed inwardly with priority over the second bending portion 46. Thereby, the 2nd site | part 56 can be displaced to a predetermined position in the state which suppressed the raising of the 2nd bending part (base part of the 1st long flange part 26a) 46. FIG.

  In addition, although the position which displaces the 2nd site | part 56 can be set arbitrarily, you may make it the outer surface of the 2nd bending part 60 be located on the extension line of the outer surface of the 1st site | part 54, for example. By doing so, the second portion 56 is positioned on the straight line of the first portion 54. Further, as shown in FIGS. 14B and 14C, by performing the process of step S7, the curl punch 92 moves to the first short flange part 26b side, and the outer surface of the first short flange part 26b is perpendicular to the curl punch 92. The surface 94 comes into contact.

  Next, as shown in FIGS. 11D and 14D, the curl punch 92 is lowered to perform the curl molding on the first flange portion 26 and the second flange portion 62 (step S8 in FIG. 3). As a result, the first long flange portion 26a and the second flange portion 62 are curled to form the first curled edge portion 98a. Further, the first short flange portion 26b is curled, and as a result, the first short flange portion 26b and the second equivalent edge portion 24b become the second curl edge portion 98b.

  At this time, as shown in FIGS. 11C and 11D, the curled surface 96 of the curl punch 92 contacts the second curved portion 60 of the first long flange portion 26a, so that the first long flange portion 26a becomes the second curved portion. Since it becomes easy to curl from 60, the molding resistance of the first long flange portion 26a can be reduced. As a result, the formability of the first long flange portion 26a is improved.

  Subsequently, as shown in FIGS. 13 and 15, the seam punch 100 is disposed at a predetermined position with the curl punch 92 retracted, and then the seam punch 100 is lowered to thereby form the first curl edge 98 a. Then, seam forming is performed on the second curl edge 98b (step S9 in FIG. 3). As a result, the first curl edge 98 a is seam-formed to become the first edge 22, and the second curl edge 98 b is seam-formed to become the second edge 24. At this stage, the manufacturing process of the automobile rear door 10 is completed.

  In the present embodiment, as described above, when the second portion 56 is pushed inward by the curl punch 92, it is possible to suitably suppress the second bent portion 46 from being lifted, as shown in FIG. The curvature of the seam-formed first edge 22 can be increased, and the appearance quality of the automobile rear door 10 to which the panel member 16 is applied can be enhanced.

(Modification)
Next, a modification of the method for manufacturing a panel member according to the present invention will be described with reference to FIGS. 16A and 16B.

  In this modified example, as shown in FIG. 16A, the first portion 106 rising from the outer panel main body 104 and the outer end of the first portion 106 are bent outward with respect to the entire periphery of the edge of the punched outer panel 102. A first flange portion 110 having a second portion 108 and a third portion 109 bent inward by a predetermined angle (for example, 90 degrees) from the distal end of the second portion 108 is formed. As a result, the innermost part of the third part 109 can be located more outward than the inner surface of the first part 106.

  Further, a second flange portion 118 that rises from the inner panel main body 116 is formed on the entire periphery of the edge portion of the punched inner panel 114. As can be understood from FIGS. 16A and 16B, the second flange portion 118 is curved in a substantially semicircular cross section from the base portion to the tip.

  And the inner panel 114 in which the 2nd flange part 118 was formed is piled up on the outer panel 102 in which the 1st flange part 110 was formed. At this time, the most inwardly located part of the third part 109 is located outward of the first part 106, so that a predetermined gap is provided between the second flange portion 118 and the third part 109. Can be formed. Thereby, the inner panel 114 can be easily stacked on the outer panel 102.

  Thereafter, as shown in FIG. 16B, the second portion 108 of the first flange portion 110 is pushed inward. Accordingly, the second portion 108 can be displaced inward while suppressing the base 122 of the first flange portion 110 from being lifted, so that the third portion 109 is positioned above the second flange portion 118. Can do. Therefore, the curvature of the edge part of the panel member formed by winding up the 1st flange part 110 and the 2nd flange part 118 can be enlarged, and the external appearance quality of a panel member can be improved.

  The present invention is not limited to the above embodiment, and various manufacturing methods can naturally be adopted without departing from the gist of the present invention.

  For example, in the above embodiment, the seam forming step may be omitted. Further, the step of forming the first bent portion 32 of the first long flange portion 26a may be omitted. In the step of forming the second flange portion 62, the second flange portion 62 is made substantially perpendicular to the inner panel body 87. You may form so that it may stand up.

10 ... Automobile rear door 12, 102 ... Outer panel (first plate member)
14, 114 ... Inner panel (second plate member)
DESCRIPTION OF SYMBOLS 16 ... Panel member 26, 110 ... 1st flange part 32 ... 1st bending part 46 ... 2nd bending part 52, 104 ... Outer panel main body 54, 106 ... 1st site | part 56, 108 ... 2nd site | part 58 ... 1st bending part 60 ... 2nd bending part 62, 118 ... 2nd flange part 68 ... 3rd bending part 74 ... 4th bending part 87, 116 ... Inner panel main body 88 ... Mounting stand 92 ... Curl punch 94 ... Vertical surface 96 ... Curl surface 98a ... 1st curl edge 98b ... 2nd curl edge

Claims (2)

A first flange portion having a first portion that rises from the first plate member main body and a second portion that bends outward from the tip of the first portion with respect to the edge portion of the first plate member is formed. A first step of
A second step of overlapping a second plate member on the first plate member on which the first flange portion is formed;
A third step that is performed after the second step and pushes the second portion inward;
Performing the fourth step, which is performed after the third step, and fastens the edge of the first plate member and the edge of the second plate member by curling the first flange portion. A method for producing a panel member. In the manufacturing method of the panel member of Claim 1,
In the first step, a method of manufacturing a panel member, wherein a step of forming a curved portion that curves toward the side where the first plate member main body is located is performed on the second portion.

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