JP5989431B2 - Forming method of light metal material with irregular cross section - Google Patents

Description

  The present invention relates to a method for forming an irregular (non-uniform) cross-section light metal material.

  For example, sash members (window frame members) such as vehicle door sashes and residential window sashes are made of aluminum alloy extruded products instead of conventional iron-based roll-formed products for the purpose of weight reduction. Has been proposed and put to practical use. However, since the extruded product has a uniform cross section, it cannot cope with a partial increase in strength.

JP 2011-25855 A

On the other hand, for example, for a vertical sash of a vehicle door sash, it is indispensable to bend (extend sash sash bending) in accordance with the bulge in the left and right (vehicle width) direction of the vehicle door after extrusion molding, so that partial strength is increased. It is preferable.
In particular, the present invention can partially increase the strength of an extruded product having a bag-shaped portion having a closed cross-section and a non-bag-shaped portion connected to the bag-shaped portion via a connection wall when the extrusion is completed. An object of the present invention is to obtain a method for forming a deformed cross-section light metal material.

  The present invention maintains the uniform cross-section of the non-bag-like portion in the length direction, while changing the cross-sectional shape of the bag-like portion of the closed cross-section in the length direction (partially enlarged), thereby providing partial strength. It was made on the basis of aiming to improve.

The method for forming a deformed cross-section light metal material according to the present invention includes:
An extrusion step of forming an extruded material having a uniform cross section made of a light metal having a bag-like portion having a closed cross-section and a non-bag-like portion connected to the bag-like portion in a cross section orthogonal to the extending direction;
A step of preparing a mold having a uniform cross-section holding portion for holding a non-bag-like portion of the extrusion molding material and a non-uniform cross-section molding portion having a non-uniform cross-section in the longitudinal direction for holding the bag-like portion. ;
The non-bag-like portion of the extruded material having a uniform cross section formed in the extrusion step is set in the uniform cross-section holding portion of the mold, and the bag-like portion is set in the non-uniform cross-section molding portion. Applying hydraulic pressure into the bag-shaped portion of the extrusion molding material set in the mold, and forming the bag-shaped portion into a non-uniform cross-section in the extending direction according to the shape of the non-uniform cross-section molded portion of the mold An internal pressure forming step to form;
Have
The non-bag-shaped part is a design part located on the vehicle outer side of the vehicle door sash upright,
The bag-like part is located on the inner side of the vehicle and is connected to the design part via a connection wall.
The bag-like portion has a constant cross-section having a vehicle outer wall, a vehicle inner wall narrower than the vehicle outer wall, and a pair of front and rear side walls connecting both ends of the vehicle outer wall and the vehicle inner wall in the vehicle front-rear direction. When, characterized that you have a gradually changing cross-section which is formed by changing the amount of projection of the inner side of the pair of front and rear side walls.

As an aspect of the gradually changing cross section of the pair of front and rear side walls and the inner side wall, at least
A mode having a parallel plate portion that gradually changes the amount of protrusion to the vehicle inner side that is parallel to each other, and a convex arc cross-sectional portion that connects the vehicle inner side of the parallel plate portion,
An aspect in which the amount of protrusion and shape of the pair of front and rear side walls to the vehicle inner side is changed without changing the width of the vehicle inner side wall in the vehicle front-rear direction, or
A mode in which the pair of front and rear side walls that are closer to each other as they go toward the vehicle interior are formed by front and rear side wall extensions that extend to the vehicle inner side,
Is possible.

  In each of these aspects, it is preferable that the connecting portion between the bag-like portion and the connecting wall be the thickest at the end of the extrusion step.

  The internal pressure forming step may include an axial force applying step of applying an axial compressive force to both end portions of the bag-like portion while maintaining the liquid tightness of the bag-like portion.

The present invention applies an internal pressure to the bag-shaped portion in an extruded product having a bag-shaped portion having a closed cross-section and a non-bag-shaped portion connected to the bag-shaped portion via a connection wall in a state where the extrusion is completed. Te a predetermined portion of the cross-sectional shape gradually changed (partially enlarged) to the simple method of (adding a simple internal pressure molding to extrusion), modified cross-section metal materials up the strength of the enlarged portion (a vehicle door Sash column) .

It is a side view which shows an example of the vehicle door which used the odd-shaped cross-section light metal material by this invention for the vertical pillar sash. It is sectional drawing of the standing pillar sash along the II-II line of FIG. (A), (B) is sectional drawing of the mold opening state and mold clamping state which show the internal pressure molding process after the extrusion molding of the irregular cross-section light metal material by this invention. It is a side view of the mold clamping state of FIG. (A), (B), (C) is sectional drawing which shows another cross-sectional shape example of a bag-like part drawn by overlapping the cross section which follows the V1-V1 line and V2-V2 line of FIG. . FIG. 5 is a view of a vertical pole sash that has undergone the internal pressure forming process of FIGS. 3 and 4, as viewed from the rear of the vehicle, showing a shape example after bending (vertical pillar sash bending) according to the swelling of the vehicle door in the left-right (vehicle width) direction.

  FIG. 1 shows a side shape of a passenger car having a vehicle door 10. A vehicle door 10 that opens and closes a door opening (body opening) A of a vehicle body B includes a door sash (window frame) 20 that forms a window opening 12 on an upper portion of a door body (inner panel and outer panel) 11.

  The door sash 20 has an upper sash 21 bent in a side view for receiving the upper edge of the window glass G, and a vertical pillar sash 22 for receiving the vertical edge of the window glass G along the center pillar 16 of the vehicle body B. Yes. The upper end portion of the upright sash 22 and the end portion of the upper sash 21 are connected and fixed by known means, and the lower portions of the upper sash 21 and the upright sash 22 extend into the door body 11 and are fixed to the door body 11. This embodiment is applied to the upright pillar sash 22 of the door sash 20.

  The vertical pillar sash 22 is made of an aluminum alloy (light metal). As shown in FIG. 2, the vertical pillar sash 22 has a non-bag-like portion (plate-like portion, design portion) 22a that is located on the vehicle outer side and extends in the vehicle front-rear direction. It has the bag-like part 22b which consists of a closed cross section located, and the connection wall 22c which connects the non-bag-like part 22a and the bag-like part 22b. A glass run holding projection 22d is formed on the back surface (surface on the vehicle inner side) of the front portion 22a1 positioned in front of the connection wall 22c of the non-bag-like portion 22a. A weather strip holding projection 22e is formed on the rear surface (the vehicle inner surface) of the rear portion 22a2 located behind the connection wall 22c of the non-bag-like portion 22a. A synthetic resin garnish 23 is mounted on the vehicle exterior side of the non-bag-shaped portion (design portion) 22a. In FIG. 2 to FIG. 6, “inside”, “outside”, “front”, “rear”, “upper”, and “lower” indicate directions with respect to the upright pillar sash 22.

  The bag-like portion 22b is located in front of the connection wall 22c, and is arranged in the vehicle front-rear direction of the vehicle outer wall 22b1, the vehicle inner wall 22b2 narrower than the vehicle outer wall 22b1, and the vehicle outer wall 22b1 and the vehicle inner wall 22b2. And a pair of front and rear side walls 22b3 for connecting the both ends. When the vehicle door 10 is closed, the vehicle inner side wall 22b2 abuts on the body-side weather strip BW supported by the vehicle body B and elastically deforms the body-side weather strip BW (the body-side weather strip BW is a vertical column). The position changes from the upper side to the lower side of the sash 22 toward the inside of the door opening). The vehicle inner wall 22b2 may be formed in a convex arc shape in cross section. A glass run holding projection 22f that protrudes outside the vehicle is formed on the vehicle outer side wall 22b1, and the glass run holding projection 22f and the glass run holding projection 22d on the back side of the non-bag-like portion 22a (front portion 22a1) are formed. In the meantime, the glass run GR is held.

  Further, a weather strip holding projection 22g is formed at the vehicle inner end portion of the connection wall 22c so as to protrude to the opposite side of the bag-like portion 22b and the front end portion is bent outward. The door-side weather strip DW is held between the weather strip holding projection 22g and the non-bag-like portion 22a (rear portion 22a2) on the back side of the weather strip holding projection 22e.

  The above-described vertical pillar sash 22 is different from a roll-formed product of an iron-based material, after an aluminum alloy (light metal) is formed into a uniform cross section by a well-known extrusion molding, and then bent according to swelling in the left and right (vehicle width) direction of the vehicle door. Finished by processing (vertical column sash bending). That is, the vertical column sash 22 after extrusion is a linear member having a uniform cross section and the strength in the length direction is uniform, whereas in the vertical column sash bending, locally (particularly in the middle in the length direction). It is preferable to increase the strength of the part. Therefore, in the present embodiment, before the vertical column sash is bent, the cross-sectional area is changed using the bag-shaped portion 22b of the vertical column sash 22 in order to locally increase the strength of the vertical column sash 22. 3 and 4 show the state of internal pressure molding in which the cross-sectional shape of the bag-like portion 22b is changed in the length direction. Strictly speaking, the vertical column sash 22 has different shapes after extrusion molding, after internal pressure molding, and after vertical column sash bending, but in the description of the present embodiment, for convenience, all states are referred to as vertical column sash 22. To do.

  The internal pressure molding die 30 includes an upper die 31, a lower die 32, a core metal 33, and left and right seal pressing shafts 34 and 35. The upper mold 31 includes a recess 31a that mainly holds the bag-like portion 22b of the upright pillar sash 22, a weather strip holding projection 22g, and a recess 31b that corresponds to the weather strip holding projection 22e. The lower mold 32 includes a recess (a uniform cross-section holding portion) 32a for accommodating the non-bag-like portion 22a of the upright pillar sash 22, and a rear portion 22a2 of the non-bag-like portion 22a (behind the weather strip holding protrusion 22e) Portion) is held between the non-bag-like portion holding recess 32 a and the lower surface of the upper die 31. The cored bar 33 includes a recess 33a that holds the vehicle outer side wall 22b1 (glass run holding projection 22f) of the bag-like portion 22b, and a contact surface 33b that contacts the front surface of the connection wall 22c.

  The internal pressure mold 30 described above has the same cross-sectional shape in the length direction (direction perpendicular to the paper surface of FIG. 3) except for the bag-shaped portion holding concave portion (non-uniform cross-section portion forming portion) 31a of the upper die 31. doing. On the other hand, the shape of the bag-shaped portion holding recess 31a is gradually changed in the length direction so as to change (increase / decrease) the cross-sectional shape of the bag-shaped portion 22b in the length direction. Since the shape of the bag-shaped portion holding recess 31a of the upper mold 31 and the shape of the bag-shaped portion 22 of the upright pillar sash 22 formed by the holding recess 31a are uneven, both will be discussed below. Specifically, the bag-shaped portion holding recessed portion 31a (bag-shaped portion 22b) includes a constant cross-sectional portion 31ac (constant cross-sectional portion 22bc) at both ends in the length direction, and a gradually changing cross-sectional portion 31av (gradual speed) at the intermediate portion. A variable cross section 22bv) is provided. The gradually changing cross-sectional portion 31av (gradually changing cross-sectional portion 22bv) is obtained by once expanding the cross-sectional area of the constant cross-sectional portion 31ac (constant cross-sectional portion 22bc) at both ends in the length direction and then reducing it again. The cross-sectional area (skeleton shape) is increased or decreased by changing the amount of protrusion of the bag-like portion holding recess 31a (bag-like portion 22b) toward the vehicle interior.

  The seal pressing shaft 34 and the seal pressing shaft 35 are members that apply a compressive force in the axial direction to the bag-like portion 22b of the upright pillar sash 22 and exert a hydraulic pressure in the bag-like portion 22b. The hydraulic pressure application passage 34a and the hydraulic pressure application passage 35a are connected to a hydraulic pressure source (not shown), and the upper die 31 and the lower die 32 are closed as shown in FIGS. When a predetermined hydraulic pressure is applied to the bag-like portion 22b, the shape of the gradually changing cross section 22bv changes according to the shape of the gradually changing cross section 31av. The illustration of the liquid-tight means between the seal pressing shaft 34 (35) and the bag-like portion 22b is omitted. When an axial force is exerted on the vertical pillar sash 22 by the seal pressing shaft 34 and the seal pressing shaft 35, the bag-like portion 22b can be compressed in the axial direction, and the gradually changing cross-sectional portion 22bv can be satisfactorily formed in the bag-like portion 22b. .

  FIGS. 5A, 5 </ b> B, and 5 </ b> C show examples of the shape of the gradually changing cross-sectional portion 22 bv (gradually changing cross-sectional portion 31 av). 5 shows a cross-sectional shape along the line V1-V1 in FIG. 4 (cross-sectional shape of the constant cross-sectional portion 22bc, solid-line hatching) and a cross-sectional shape along the line V2-V2 (maximum cross-sectional area shape of the gradually changing cross-sectional portion 22bv, (Dashed hatching) is drawn on top of each other. The connecting portion 22h (FIG. 5) between the connecting wall 22c of the upright column sash 22 and the bag-like portion 22b (vehicle outer side wall 22b1) is the thickest in the end state of the extrusion step (the uniform cross-sectional state of the upright column sash 22). It is molded into.

  FIG. 5A shows a pair of parallel plate portions 22b4 for changing the amount of protrusion of the gradually changing cross-sectional portion 22bv (gradually changing cross-sectional portion 31av) in parallel with each other, and the pair of parallel plate portions 22b4. It is embodiment comprised from the convex circular arc cross-section part 22b5 which connects the vehicle inside. According to this embodiment, although the reduction of the wall thickness is large, there is an advantage that the second moment of inertia (section modulus) can be increased.

  FIG. 5 (B) shows the projecting amount and shape of the pair of vehicle interior side walls 22b2 to the vehicle inner side without changing the width of the vehicle interior side wall 22b2 in the vehicle front-rear direction. This is an embodiment formed by the front / rear asymmetric front / rear side wall extension 22b6 in which the (projection angle) is changed. According to this embodiment, since the width of the vehicle inner side wall 22b2 in the vehicle front-rear direction is constant, there is an advantage that the ground contact surface with the body-side weather strip WP of the gradually changing cross section 22bv can be made equal in the length direction. .

  FIG. 5C shows a pair of front and rear sections 22bv (gradient section section 31av) that shorten the distance from each other toward the vehicle inner side without changing the angle of the pair of front and rear side walls 22b3. In this embodiment, the symmetrical front and rear side wall extensions 22b7 are formed in a triangular cross section. According to this embodiment, the thickness change is small and smaller than that of FIG. 5 (A), but molding is performed without increasing the axial moment of inertia (section modulus) and applying axial pressing force. There is an advantage that can be.

  In the above-described internal pressure molding, in particular, when the gradual change cross section 22bv is deformed, the meat flows from the thick connection portion 22h of the upright pillar sash 22, so that by applying an axial pressing force, the gradual change cross section 22bv can be molded well.

  As shown in FIG. 6, the vertical column sash 22 having been subjected to the above internal pressure molding has a non-bag-like portion 22 a located on the outside of the vehicle in a convex shape and a bag-like portion 22 b located on the inside of the vehicle has a concave shape. Then, post-processing (vertical column sash bending) is performed in accordance with the swelling of the vehicle door in the left-right (vehicle width) direction. At this time, since the bag-like portion 22b of the upright pillar sash 22 has the gradually changing cross-sectional portion 22bv in the middle portion in the length direction, sufficient strength can be secured.

  The above is an embodiment in which the present invention is applied to the molding of the 20 vertical pillar sashes 22, but the present invention is a bag-shaped portion having a closed cross section and a non-bag connected to the bag-shaped portion via a connection wall. And is generally applicable to light metal materials that are extruded first. For example, the present invention can be applied to a door belt reinforcement disposed in a lateral direction in a vehicle door and an aluminum sash as a building material.

B Vehicle body D Vehicle door BW Body side weather strip DW Door side weather strip GR Glass run 10 Vehicle door 12 Door sash 20 Door frame 22 Standing pillar sash 22a Non-bag-like portion 22a1 Front portion 22a2 Rear portion 22b Bag-like portion 22b1 Outside wall of vehicle 22b2 Car interior side wall 22b3 Front / rear side wall 22b4 Parallel plate part 22b5 Convex arc cross-section part 22b6 Front / rear asymmetric front / rear side wall extension part 22b7 Front / rear symmetrical front / rear side wall extension part 22bc Constant cross section part 22bv Gradual change cross section part 22c Connection wall 22d Glass run holding projection 22e Weather strip holding Protrusion 22f Glass run holding protrusion 22g Weather strip holding protrusion 30 Internal pressure forming die 31 Upper die 31a Bag-like portion holding recess (non-uniform cross-sectional portion forming portion)
31ac Constant cross section 31av Gradually changing cross section 31b Recess 32 Lower mold 32a Non-bag-shaped portion holding recess (uniform cross section holding portion)
33 Metal core 34 35 Seal pressing shaft 34a 35a Fluid pressure applying passage

Claims (7)

An extrusion step of forming an extruded material having a uniform cross section made of a light metal having a bag-like portion having a closed cross-section and a non-bag-like portion connected to the bag-like portion in a cross section orthogonal to the extending direction;
A mold having a uniform cross-section holding portion for holding a non-bag-like portion of the extrusion molding material, and a non-uniform cross-section molding portion having a non-uniform cross section at least partially in the longitudinal direction for holding the bag-like portion. Steps to prepare;
The non-bag-like portion of the extruded material having a uniform cross section formed in the extrusion step is set in the uniform cross-section holding portion of the mold, and the bag-like portion is set in the non-uniform cross-section molding portion. Applying hydraulic pressure into the bag-shaped portion of the extrusion molding material set in the mold, and forming the bag-shaped portion into a non-uniform cross-section in the extending direction according to the shape of the non-uniform cross-section molded portion of the mold An internal pressure forming step to form;
I have a,
The non-bag-shaped part is a design part located on the vehicle outer side of the vehicle door sash upright,
The bag-like part is located on the inner side of the vehicle and is connected to the design part via a connection wall.
The bag-like portion has a constant cross-section having a vehicle outer wall, a vehicle inner wall narrower than the vehicle outer wall, and a pair of front and rear side walls connecting both ends of the vehicle outer wall and the vehicle inner wall in the vehicle front-rear direction. And a gradually changing cross-sectional portion formed by changing the amount of protrusion of the pair of front and rear side walls toward the inside of the vehicle . 2. The method of forming a modified cross-section light metal material according to claim 1, wherein the pair of front and rear side walls and the gradually changing cross-sectional portion of the inner side wall of the pair are parallel plate portions that gradually change the amount of protrusion to the inner side of the vehicle parallel to each other. A method of forming an irregular cross-section light metal material having a convex arc cross-section connecting the inner side of the plate portion. 2. The method of forming a deformed cross-section light metal material according to claim 1, wherein the gradually changing cross-sectional portions of the pair of front and rear side walls and the vehicle interior side wall are formed on the vehicle interior sides of the pair of front and rear side walls without changing the width of the vehicle interior side wall in the vehicle front and rear direction. A method for forming an irregular cross-section light metal material formed by changing the amount of protrusion and the shape thereof. 2. The method of forming a deformed cross-section light metal material according to claim 1, wherein the pair of front and rear side walls and the gradually changing cross-sectional portion of the vehicle inner side wall have the pair of front and rear side walls closer to each other toward the vehicle inner side. A method for forming a light metal material having a modified cross section formed by front and rear side wall extensions extending in a straight line. In the molding process of claims 1 to modified cross-section of light metal material according to any one of 4, modified cross connection between the bag portion and the connecting wall, in the end state of the extrusion step, which is the most thick A method for forming light metal materials. 6. The method of forming a deformed cross-section light metal material according to claim 1, wherein in the internal pressure forming step, the bag-shaped portion is maintained in a liquid-tight state while being axially provided at both end portions of the bag-shaped portion. A method for forming a light metal material having a modified cross-section including an axial force applying step that exerts a compressive force on the surface. 7. The method of forming a deformed cross-section light metal material according to claim 1, wherein the constant cross-section portion of the bag-like portion is formed at both ends in the length direction, and the gradually changing cross-section portion is A method of forming a light metal material having a modified cross- section, wherein the cross-sectional area of the intermediate portion is gradually increased in the length direction and then gradually reduced .

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