US20160263639A1 - Bottomed container and method for manufacturing the same - Google Patents
Bottomed container and method for manufacturing the same Download PDFInfo
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- US20160263639A1 US20160263639A1 US15/068,029 US201615068029A US2016263639A1 US 20160263639 A1 US20160263639 A1 US 20160263639A1 US 201615068029 A US201615068029 A US 201615068029A US 2016263639 A1 US2016263639 A1 US 2016263639A1
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- United States
- Prior art keywords
- corner portions
- bottomed container
- die
- blank
- view
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/201—Work-pieces; preparation of the work-pieces, e.g. lubricating, coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/18—Making hollow objects characterised by the use of the objects vessels, e.g. tubs, vats, tanks, sinks, or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/52—Making hollow objects characterised by the use of the objects boxes, cigarette cases, or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
- B65D5/24—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds
- B65D5/241—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds and the gussets folds connected to the inside of the container body
- B65D5/242—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds and the gussets folds connected to the inside of the container body the gussets folds comprising more than two gusset panels
Abstract
A method includes a main forming step in which a blank in which creases are formed by a preforming step is set between a die and a punch such that the die and the punch correspond to the shape of the blank, and is press-formed to form a square tubular component as a bottomed container. When, in the main forming step, a rib protruding outward from between each adjacent two of the vertical walls of the bottomed container in plan view is formed in press forming, a slit is provided in each of the corner portions of the inner side surface of the die.
Description
- 1. Field of the Invention
- The present invention relates to a bottomed container that is formed from a blank by press forming and that has a large forming height, and to a method for manufacturing the same.
- 2. Description of the Related Art
- A fuel tank, a battery tray, and the like mounted on a vehicle are often bottomed, substantially circular tubular or square tubular components formed from a plate material by press deep drawing forming. Such a fuel tank, such a battery tray, and the like are required to have a watertight structure, and are therefore integrally formed by press forming. In addition, they are desired to have as large an internal capacity as possible, and are therefore desired to have as small a corner R in plan view as possible, and as large a forming height as possible.
- However, there is a problem in that in the press deep drawing forming, the smaller the corner R, and the larger the forming height, the more easily a rupture occurs, and the more difficult the forming.
- As a technique to solve such a problem, there has been proposed a technique that reduces the drawing resistance and improves the forming limit (see, for example, Japanese Patent No. 4985909). This technique holds a material with a blank holder and a die, provides a recess in part of the die, actively generates a crease in this part, thereby forms a folded flange, reduces the drawing resistance of a flange in a corner portion, and thereby improves the forming limit.
- As another technique to solve the above problem, there has been proposed a forming method that forms a pair of folded flanges folded into the inside of a corner portion of a tubular component without using a blank holder (see, for example, Japanese Patent No. 3454656). This technique can perform manufacture by bending forming almost without drawing forming, and therefore promises significant improvement of forming limit.
- However, the technique disclosed in Japanese Patent No. 4985909 has a problem in that because forming is performed by deep drawing forming, there is a limit on reduction of drawing resistance, and when forming a very deep product (that is, a product having a large forming height), a rupture occurs.
- The art disclosed in Japanese Patent No. 3454656 has a problem in that in order to form a pair of folded flanges folded into the inside of a corner portion, a die and a punch need to be provided with a pair of special machined parts, that is, a die needs to be provided with a special guide protrusion, and a punch needs to be provided with a clearance groove corresponding thereto. In addition, a blank itself has no guide serving as a starting point of bending forming for forming a pair of folded flanges, in an area that will become a corner portion after completion of press forming, and therefore, large bending resistance is generated in the blank itself. A configuration based on such a principle has a problem in that, in press forming, it is difficult in terms of shape to prepare a pair of a die and a punch for forming two or more pairs of folded flanges in a corner portion, and in addition, the forming itself of folded flanges is unstable.
- It is an object of the present invention to provide a bottomed container having a large forming height and a method for manufacturing the same in which a die and a punch need not be provided with a pair of special machined parts, and in addition, a bottomed container can be formed from a blank using cold press forming, by which mass production is possible, substantially only by bending forming.
- According to a first aspect of the present invention, a bottomed container includes a bottom portion, and a plurality of vertical walls rising from the peripheral edge of the bottom portion. The bottomed container is formed by press-forming a blank, and has a plurality of corner portions integral with the bottom portion and the vertical walls adjacent to each other. The corner portions are each provided with one or more ribs that protrude outward or inward from between the vertical walls adjacent to each other in plan view. The ribs are each composed of a pair of folded flanges that are folded along creases that are preformed in the blank so as to substantially equally divide an area that will become one of the corner portions. The amount of outward or inward protrusion of the ribs becomes larger from the bottom portion toward the open end of the vertical walls in side view. The ribs are provided with no flanges extending outward from the open ends of the ribs in plan view.
- According to a second aspect of the present invention, in the first aspect of the present invention, the corner portions have a substantially arc shape in plan view, and the one or more ribs formed in each of the corner portions having a substantially arc shape are two to four ribs. Here, a substantially arc shape means a curved surface shape having a constant radius of curvature, a curved surface such that straight line parts are connected together, or a polygonal shape close to a curved surface. The ribs are formed so as to protrude from corner portions having such a substantially arc shape.
- According to a third aspect of the present invention, in the second aspect of the present invention, recesses or protrusions that are continuous in plan view and that correspond to the ribs protruding outward or inward from the corner portions having a substantially arc shape are formed in the bottom portion. The definition of the substantially arc shape is as described above.
- According to a fourth aspect of the present invention, in the third aspect of the present invention, the recesses or protrusions provided in the bottom portion are formed so as to extend radially from the center of each of the corner portions having a substantially arc shape in plan view. The definition of the substantially arc shape is as described above.
- According to a fifth aspect of the present invention, in any one of the first to fourth aspects of the present invention, the bottomed container is provided with flanges extending outward from the open ends of the vertical walls.
- According to a sixth aspect of the present invention, a method for manufacturing the bottomed container according to the first aspect of the present invention includes a preforming step in which creases are formed in a blank having areas that will become the bottom portion, the plurality of vertical walls, and the plurality of corner portions of the bottomed container after press forming using a preforming die, the creases being formed at borders between an area that will become the bottom portion and areas that will become the vertical walls, borders between the areas that will become the vertical walls and areas that will become the corner portions, and positions for substantially equally dividing the areas that will become the corner portions, and a main forming step in which the blank in which creases are formed by the preforming step is set between a die and a punch such that the die and the punch correspond to the shape of the blank, and is press-formed to form the bottomed container. In the main forming step, when one or more ribs protruding outward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in corner portions of the die, and when one or more ribs protruding inward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in corner portions of the outer side surface of the punch.
- According to a seventh aspect of the present invention, in the sixth aspect of the present invention, in the preforming step, the number of creases formed for substantially equally dividing each of the areas that will become the corner portions is three to seven.
- According to an eighth aspect of the present invention, in the sixth or seventh aspect of the present invention, the inside of each of the corner portions of the die is formed such that the radius of curvature of the inscribed circle is R1 in plan view, the corner portions of the outer side surface of the punch are formed in a shape having a curved surface having a radius of curvature of R2 in plan view corresponding to the inscribed circle of each of the corner portions of the die, the clearance between the punch and the die defined as R1−R2 is set to 100% to 200% of the thickness of the blank, and R1>R2.
- According to a ninth aspect of the present invention, in the eighth aspect of the present invention, in the main forming step, when one or more ribs protruding outward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in the corner portions of the bottom surface of the die, and when one or more ribs protruding inward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in the corner portions of the bottom surface of the punch.
- According to a tenth aspect of the present invention, in the ninth aspect of the present invention, the slits provided in the corner portions of the bottom surface of the die or the corner portions of the bottom surface of the punch are formed so as to extend radially from the center of each corner portion.
- According to an eleventh aspect of the present invention, in any one of the sixth to tenth aspect of the present invention, flanges extending outward from the outer side surface other than the corner portions of the punch are provided at the upper end of the punch.
- As described above, a bottomed container of the present invention includes a bottom portion, and a plurality of vertical walls rising from the peripheral edge of the bottom portion. The bottomed container is formed by press-forming a blank, and has a plurality of corner portions integral with the bottom portion and the vertical walls adjacent to each other. The corner portions are each provided with one or more ribs that protrude outward or inward from between the vertical walls adjacent to each other in plan view. The ribs are each composed of a pair of folded flanges that are folded along creases that are preformed in the blank so as to substantially equally divide an area that will become one of the corner portions. The amount of outward or inward protrusion of the ribs becomes larger from the bottom portion toward the open end of the vertical walls in side view. The ribs are provided with no flanges extending outward from the open ends of the ribs in plan view. Therefore, a die and a punch need not be provided with a pair of special machined parts, and in addition, a bottomed container having a large forming height can be formed from a blank using cold press forming, by which mass production is possible, substantially only by bending forming.
- A method for manufacturing a bottomed container of the present invention includes a preforming step in which creases are formed in a blank having areas that will become the bottom portion, the plurality of vertical walls, and the plurality of corner portions of the bottomed container after press forming using a preforming die, the creases being formed at borders between an area that will become the bottom portion and areas that will become the vertical walls, borders between the areas that will become the vertical walls and areas that will become the corner portions, and positions for substantially equally dividing the areas that will become the corner portions, and a main forming step in which the blank in which creases are formed by the preforming step is set between a die and a punch such that the die and the punch correspond to the shape of the blank, and is press-formed to form the bottomed container. In the main forming step, when one or more ribs protruding outward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in corner portions of the die, and when one or more ribs protruding inward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in corner portions of the outer side surface of the punch. Therefore, a manufacturing method in which a die and a punch need not be provided with a pair of special machined parts, and in addition, a bottomed container can be formed from a blank using cold press forming, by which mass production is possible, substantially only by bending forming, can be provided.
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FIG. 1 is a schematic plan view illustrating a blank before being formed into a bottomed container ofEmbodiment 1 of the present invention; -
FIG. 2 is a partial enlarged perspective view of a preforming die according toEmbodiment 1; -
FIGS. 3A and 3B are partial enlarged views of the blank before and after preforming according toEmbodiment 1,FIG. 3A is an enlarged view of part IIIA before preforming shown inFIG. 1 , andFIG. 3B is a perspective view after preforming; -
FIG. 4 is a schematic perspective view showing the positional relationship between a punch, the blank after preforming, and a die in main forming according toEmbodiment 1; -
FIGS. 5A and 5B show the shape and dimensions of the punch and die shown inFIG. 4 ; -
FIGS. 6A to 6D show the transformation state of the blank during main forming according toEmbodiment 1; -
FIG. 7 is a schematic plan view illustrating a blank before being formed into a bottomed container ofEmbodiment 2 of the present invention; -
FIG. 8 is a partial enlarged perspective view of a preforming die according toEmbodiment 2; -
FIGS. 9A and 9B are partial enlarged views of the blank before and after preforming according toEmbodiment 2,FIG. 9A is an enlarged view of part IXA before preforming shown inFIG. 7 , andFIG. 9B is a perspective view after preforming; -
FIG. 10 is a schematic perspective view showing the positional relationship between a punch, the blank after preforming, and a die in main forming according toEmbodiment 2; -
FIGS. 11A to 11D show the transformation state of the blank during main forming according toEmbodiment 2; -
FIG. 12 is a schematic plan view illustrating a blank before being formed into a bottomed container ofEmbodiment 3 of the present invention; -
FIG. 13 is a partial enlarged perspective view of a preforming die according toEmbodiment 3; -
FIGS. 14A and 14B are partial enlarged views of the blank before and after preforming according toEmbodiment 3,FIG. 14A is an enlarged view of part XIVA before preforming shown inFIG. 12 , andFIG. 14B is a perspective view after preforming; -
FIG. 15 is a schematic perspective view showing the positional relationship between a punch, the blank after preforming, and a die in main forming according toEmbodiment 3; -
FIGS. 16A and 16B show the shape and dimensions of the punch and die shown inFIG. 15 ; and -
FIGS. 17A to 17E show the transformation state of the blank during main forming according toEmbodiment 3. - Embodiments of the present invention will now be described in detail.
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FIG. 1 is a schematic plan view illustrating a blank before being formed into a bottomed container ofEmbodiment 1 of the present invention.FIG. 2 is a partial enlarged perspective view of a preforming die according toEmbodiment 1.FIGS. 3A and 3B are partial enlarged views of the blank before and after preforming according toEmbodiment 1,FIG. 3A is an enlarged view of part IIIA before preforming shown inFIG. 1 , andFIG. 3B is a perspective view of part IIIA after preforming.FIG. 4 is a schematic perspective view showing the positional relationship between a punch, the blank after preforming, and a die in main forming according toEmbodiment 1.FIGS. 5A and 5B show the shape and dimensions of the punch and die shown inFIG. 4 .FIGS. 6A to 6D show the transformation state of the blank during main forming according toEmbodiment 1. - In
FIG. 1 ,reference sign 1 denotes a blank 800 mm by 1000 mm and 1.0 mm thick made of 6000 series aluminum alloy before cold press forming (hereinafter also simply referred to as “press forming”),reference sign 1 a denotes an area that will become a bottom portion of a square tubular component as a bottomed container after press forming,reference sign 1 b denotes areas that will become a plurality of (four) vertical walls of the square tubular component after press forming, andreference sign 1 c denotes areas that will become a plurality of (four) corner portions of the square tubular component after press forming. -
FIG. 2 shows a preformingdie 2 for forming creases (for detail, seeFIG. 3B described later) in the blank 1 having theareas FIG. 1 , the creases being formed at the borders between thearea 1 a that will become the bottom portion and theareas 1 b that will become the vertical walls, the borders between theareas 1 b that will become the vertical walls and theareas 1 c that will become the corner portions, and positions that substantially equally divide (into two halves) theareas 1 c that will become the corner portions. InFIG. 2 ,reference sign 2 a denotes an area of the preforming die 2 corresponding to thearea 1 a that will become the bottom portion,reference sign 2 b denotes areas of the preforming die 2 corresponding to theareas 1 b that will become the vertical walls, andreference sign 2 c denotes areas of the preforming die 2 corresponding to theareas 1 c that will become the corner portions. -
FIG. 3A is an enlarged view of part IIIA of the blank 1 before preforming shown inFIG. 1 .FIG. 3B is a perspective view of part IIIA of the blank 1 aftercreases FIG. 1 using the preforming die 2 shown inFIG. 2 , the creases being formed at the borders between thearea 1 a that will become the bottom portion and theareas 1 b that will become the vertical walls, the borders between theareas 1 b that will become the vertical walls and theareas 1 c that will become the corner portions, and positions that substantially equally divide (into two halves) theareas 1 c that will become the corner portions. -
FIG. 4 is a schematic perspective view showing the positional relationship between apunch 3, the blank 1 after preforming, and adie 4 in main forming according toEmbodiment 1. - In
FIG. 4 , the blank 1 in which creases 1 d, 1 e, and 1 f are formed by the above-described preforming step is set between a die 4 (for detail, seeFIG. 5B described later) and a punch 3 (for detail, seeFIG. 5A described later) such that thedie 4 and thepunch 3 correspond to the shape of the blank 1, and is press-formed to form a square tubular component as a bottomed container (main forming step). In this main forming step, a blank holder need not be used. - The
die 4 shown inFIG. 4 is provided with abottom surface 4 a,inner side surfaces 4 b, andcorner portions 4 c respectively corresponding to thearea 1 a that will become a bottom portion, theareas 1 b that will become vertical walls, and theareas 1 c that will become corner portions, of the blank 1. Thecorner portions 4 c of thedie 4 are each provided with aslit 4 f that is used when arib 1 g (seeFIG. 6D described later) that protrudes outward from between each adjacent two of thevertical walls 1 b of the square tubular component in plan view is formed during press forming. - The transformation state of the blank 1 after preforming in the case where the above-described main forming step was performed on the basis of the blank 1 having
creases punch 3 and thedie 4 shown inFIGS. 5A and 5B , the clearance between thepunch 3 and the die 4 (the thickness of the blank 1 (1 mm)+(20% of the thickness of the blank 1 (1 mm)=0.2 mm)=1.2 mm), and lubricant (wash oil for steel plate is assumed) and coefficient of friction μ=0.14, was calculated using general-purpose dynamic explicit method software PAM-STAMP (calculation result is shown inFIGS. 6A to 6D as deformation state diagrams). The calculation model was in ¼ symmetric condition. -
FIGS. 6A to 6D are transformation state diagrams showing the above-described calculation result.FIGS. 6A, 6B, 6C, and 6D respectively show the transformation state of the blank 1 after preforming at a position 70 mm above the bottom dead center (BDC) (at which thepunch 3 is in its lowest position) (hereinafter referred to as BDC 70 mm UP), BDC 50 mm UP,BDC 20 mm UP, and BDC. From this, it can be seen that the main forming step progresses stably. InFIG. 6D , it can be seen that arib 1 g composed of a pair of folded flanges that protrude outward from between each adjacent two of thevertical walls 1 b of the square tubular component is formed excellently in eachcorner portion 1 c. That is, a square tubular component can be formed only by bending without drawing thecorner portions 1 c. For this reason, if the height of the square tubular component is increased, the drawing resistance to the blank 1 does not increase. In other words, a square tubular component (bottomed container) that is free from rupture can be obtained without increasing the amount of strain in each parts. Thisrib 1 g becomes larger from thebottom portion 1 a toward the open ends of thevertical walls 1 b in side view, and therib 1 g is provided with no flanges extending outward from the open end of therib 1 g in plan view. - Although, in
Embodiment 1, an example in which arib 1 g protruding outward from between each adjacent two of thevertical walls 1 b of the square tubular component is formed in eachcorner portion 1 c has been described, the present invention is not limited to this. For example, when a rib protruding inward from between each adjacent two of thevertical walls 1 b of the square tubular component is formed in eachcorner portion 1 c, a slit may be provided in each corner portion of the outer side surface of thepunch 3. Although, inEmbodiment 1, an example in which a square tubular component is formed as a bottomed container has been described, the present invention is not limited to this. The present invention can be widely applied, for example, to a triangular tubular component, and a five or more-sided polygonal tubular component. Although, inEmbodiment 1, an example in which arib 1 g protruding outward from between each adjacent two of thevertical walls 1 b in plan view is formed in eachcorner portion 1 c has been described, the present invention is not limited to this. For example, two ormore ribs 1 g that protrude outward or inward from between each adjacent two of thevertical walls 1 b in plan view may be provided in eachcorner portion 1 c (for details, see Embodiments 2 and 3 described later). Although, inEmbodiment 1, an example in which a blank 1 is made of 6000 series aluminum alloy has been described, the present invention is not limited to this. For example, a blank 1 may be made of an aluminum alloy other than 6000 series, a titanium alloy, which is a material difficult to machine, or an ordinary steel. The advantage that thisrib 1 g serves as a reinforcing part resisting against bending deformation of eachcorner portion 1 c can also be obtained. - As described above, use of the configuration of the present invention not only eliminates the need to provide a die and a punch with a pair of special machined parts, but also makes it possible to form a bottomed container having a large forming height from a blank using cold press forming, by which mass production is possible, substantially only by bending forming.
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FIG. 7 is a schematic plan view illustrating a blank before being formed into a bottomed container ofEmbodiment 2 of the present invention.FIG. 8 is a partial enlarged perspective view of a preforming die according toEmbodiment 2.FIGS. 9A and 9B are partial enlarged views of the blank before and after preforming according toEmbodiment 2,FIG. 9A is an enlarged view of part IXA before preforming shown inFIG. 7 , andFIG. 9B is a perspective view after preforming.FIG. 10 is a schematic perspective view showing the positional relationship between a punch, the blank after preforming, and a die in main forming according toEmbodiment 2.FIGS. 11A to 11D show the transformation state of the blank during main forming according toEmbodiment 2. In this embodiment, the same reference signs will be used to designate the same components as those ofEmbodiment 1, detailed description thereof will be omitted, and only differences will be described in detail. - In
FIG. 7 , the blank 1 is formed in a shape based on the premise that two ribs are formed in each of theareas 1 c that will become corner portions. That is, the blank 1 is formed in such a shape thatvertical walls 1 b are equal in height to two ribs in side view after main forming (press forming) (seeFIG. 9A ). -
FIG. 8 shows a preformingdie 5 for forming creases (for detail, seeFIG. 9R described later) in the blank 1 having theareas FIG. 7 , the creases being formed at the borders between thearea 1 a that will become the bottom portion and theareas 1 b that will become the vertical walls, the borders between theareas 1 b that will become the vertical walls and theareas 1 c that will become the corner portions, and positions that substantially equally divide (into four parts) theareas 1 c that will become the corner portions. InFIG. 8 ,reference sign 5 a denotes an area of the preforming die 5 corresponding to thearea 1 a that will become the bottom portion,reference sign 5 b denotes areas of the preforming die 5 corresponding to theareas 1 b that will become the vertical walls, andreference sign 5 c denotes areas of the preforming die 5 corresponding to theareas 1 c that will become the corner portions. -
FIG. 10 is a schematic perspective view showing the positional relationship between apunch 3, the blank 1 after preforming, and adie 4 in main forming according toEmbodiment 2. - In
FIG. 10 , the blank 1 in which acrease 1 d, acrease 1 e, and threecreases 1 f are formed by the above-described preforming step is set between adie 4 and apunch 3 such that thedie 4 and thepunch 3 correspond to the shape of the blank 1, and is press-formed to form a square tubular component as a bottomed container (main forming step). In this main forming step, a blank holder need not be used. - The
corner portions 4 c of thedie 4 shown inFIG. 10 are each provided with twoslits 4 f that are used when tworibs 1 g (seeFIG. 11D described later) that protrude outward from between each adjacent two of thevertical walls 1 b of the square tubular component in plan view are formed during press forming. - The transformation state of the blank 1 after preforming in the case where the above-described main forming step was performed on the basis of the blank 1 having a
crease 1 d, acrease 1 e, and threecreases 1 f formed by the above-described preforming step, thepunch 3 and thedie 4 shown inFIG. 10 , the clearance between thepunch 3 and the die 4 (the thickness of the blank 1 (1 mm)+(20% of the thickness of the blank 1 (1 mm)=0.2 mm)=1.2 mm), lubricant (wash oil for steel plate is assumed) and coefficient of friction μ=0.14, was calculated using general-purpose dynamic explicit method software PAM-STAMP (calculation result, is shown inFIGS. 11A to 11D as deformation state diagrams). The calculation model was in ¼ symmetric condition. -
FIGS. 11A to 11D are transformation state diagrams showing the above-described calculation result.FIGS. 11A, 11B, 11C, and 11D respectively show the transformation state of the blank 1 after preforming at BDC 70 mm UP, BDC 50 mm UP,RDC 20 mm UP, and BDC. From this, it can be seen that the main forming step progresses stably. TnFIG. 11D , it can be seen that tworibs 1 g each composed of a pair of folded flanges that protrude outward from between adjacentvertical walls 1 b of the square tubular component are formed excellently in thecorner portion 1 c. That is, a square tubular component can be formed only by bending without drawing thecorner portions 1 c. For this reason, if the height of the square tubular component is increased, the drawing resistance to the blank 1 does not increase. In other words, a square tubular component (bottomed container) that is free from rupture can be obtained without increasing the amount of strain in each parts. However, in the case ofEmbodiment 2, apunch 3 and adie 4 that have a very small corner R in plan view are provided with a plurality ofribs 1 g, and therefore the clearance between thepunch 3 and die 4 is large in theslits 4 f in eachcorner portion 4 c of thedie 4. For this reason, there is a problem in that the shape ofribs 1 g after press forming is not formed as sharp as the shape ofEmbodiment 1. When it is desired to formsuch ribs 1 g more sharply, the corner R needs to be set slightly larger according to the number of theribs 1 g as inEmbodiment 3 described later. The tworibs 1 g become larger from thebottom portion 1 a toward the open ends of thevertical walls 1 b in side view, and the tworibs 1 g are provided with no flanges extending outward from the open ends of theribs 1 g in plan view. - When two
ribs 1 g are provided in eachcorner portion 1 c as inEmbodiment 2, the amount of protrusion of theribs 1 g can be reduced compared to the case where tworibs 1 g are provided in eachcorner portion 1 c as inEmbodiment 1. Therefore, the number ofribs 1 g provided in eachcorner portion 1 c is preferably two or more. However, if the number ofribs 1 g provided in eachcorner portion 1 c is increased as described above, ends ofslits 4 f facing the inside of eachcorner portion 4 c ofdie 4 overlap. In such a part, the clearance between thepunch 3 and thedie 4 is large, and therefore the shape ofribs 1 g is not formed stably. If the width of theslits 4 f is reduced so that the ends of theslits 4 f do not overlap, the volume of the part subjected to deformation load is also reduced, and it is a challenge to secure the strength of thedie 4. In order to secure a certain width of theslits 4 f and to form a necessary number of relativelysharp ribs 1 g, the radius of curvature R ofcorner portions 4 c needs to be set, larger according to the number of theribs 1 g. That is, if the number ofribs 1 g is too small, the amount, of protrusion ofribs 1 g into or out of eachcorner portion 1 c is large, and if the number ofribs 1 g is too large, the radius of curvature R ofcorner portions 4 c in plan view is large. From the viewpoint of shape limitation and securing of internal capacity, a square tubular component (bottomed container) that has a relatively small corner R (the radius of curvature R is about 80 mm or less) and in which the amount of protrusion ofribs 1 g out of or into the production is small, is desired. In order to obtain such a square tubular component (bottomed container), the number ofribs 1 g provided in eachcorner portion 1 c is preferably four or less. - As described above, use of the configuration of the present invention not only eliminates the need to provide a die and a punch with a pair of special machined parts, but also makes it possible to form a bottomed container having a large forming height from a blank using cold press forming, by which mass production is possible, substantially only by bending forming.
-
FIG. 12 is a schematic plan view illustrating a blank before being formed into a bottomed container ofEmbodiment 3 of the present invention.FIG. 13 is a partial enlarged perspective view of a preforming die according toEmbodiment 3.FIGS. 14A and 14B are partial enlarged views of the blank before and after preforming according toEmbodiment 3,FIG. 14A is an enlarged view of part XIVA before preforming shown inFIG. 12 , andFIG. 14B is a perspective view after preforming.FIG. 15 is a schematic perspective view showing the positional relationship between a punch, the blank after preforming, and a die in main forming according toEmbodiment 3.FIGS. 16A and 16B show the shape and dimensions of the punch and die shown inFIG. 15 .FIGS. 17A to 17E show the transformation state of the blank during main forming according toEmbodiment 3. In this embodiment, the same reference signs will be used to designate the same components as those ofEmbodiments - In
FIG. 12 , the blank 1 is formed in a shape based on the premise that four ribs are formed in each of theareas 1 c that will become a corner portions. That is, the blank 1 is formed in such a shape thatvertical walls 1 b are equal in height to four ribs in side view after main forming (press forming) (seeFIG. 14A ). -
FIG. 13 shows a preformingdie 6 for forming creases (for detail, seeFIG. 14B described later) in the blank 1 having theareas FIG. 12 , the creases being formed at the borders between thearea 1 a that will become the bottom portion and theareas 1 b that will become the vertical walls, the borders between theareas 1 b that will become the vertical walls and theareas 1 c that will become the corner portions, and positions that divide equally (into eight parts) theareas 1 c that will become the corner portions. InFIG. 13 ,reference sign 6 a denotes an area of the preforming die 6 corresponding to thearea 1 a that will become the bottom portion,reference sign 6 b denotes areas of the preforming die 6 corresponding to theareas 1 b that will become the vertical walls, andreference sign 6 c denotes areas of the preforming die 6 corresponding to theareas 1 c that will become the corner portions. -
FIG. 15 is a schematic perspective view showing the positional relationship between apunch 7, the blank 1 after preforming, and adie 8 in main forming according toEmbodiment 3. - In
FIG. 15 , the blank 1 in which acrease 1 d, acrease 1 e, and sevencreases 1 f are formed by the above-described preforming step is set between a die 8 (for detail, seeFIG. 16B described later) and a punch 7 (for detail, seeFIG. 16A described later) such that thedie 8 and thepunch 7 correspond to the shape of the blank 1, and is press-formed to form a square tubular component as a bottomed container (main forming step). In this main forming step, a blank holder need not be used. - The inside of each
corner portion 8 c of thedie 8 shown inFIG. 16B is formed such that the radius of curvature R1 of the inscribed circle is 66.9 mm. Thecorner portions 8 c are further provided with fourslits 8 f that are used when fourribs 1 g (seeFIG. 17E described later) that protrudes outward from between adjacentvertical walls 1 b of the square tubular component in plan view is formed during press forming. Thecorner portions 7 c of the outer side surface ofpunch 7 are formed in a shape having a curved surface having a radius of curvature R2 of 65.7 mm in plan view corresponding to the inscribed circle of eachcorner portion 8 c of thedie 8. Here, R1>R2. The clearance betweenpunch 7 and die 8 defined as the difference between the radius of curvature R1 of the inscribed circle and the radius of curvature R2 is 1.2 mm. In the main forming step, a bottomed container is formed without drawing forming, only by bending forming, and therefore, the change in thickness of blank 1 is very small. For this reason, the above-described clearance can be up to about 100% of the thickness of blank 1. If the clearance is too large, the shape ofribs 1 g is not formed sharply, and therefore, it can be said that the clearance is preferably at most 200% (of the thickness of the blank 1). As described above, in the case of a bottomed container formed by the main forming step, the change in thickness of blank 1 as a material is very small compared to the case of an ordinary drawn component. That is, in the case of ordinary drawing forming, the thickness of the blank 1 decreases in the vicinity of the shoulder R of thepunch 7 and increases on the shoulder R side of thedie 8 owing to inflow of material. If the product performance is designed based on the vicinity of the shoulder R where local reduction in thickness occurs, the weight of the formed component increases slightly. A manufacturing method including the main forming step has the advantage that the change in thickness of the blank 1 associated with forming is small, and therefore, compared to the above-described drawing forming, the product is lightweight, and the strength and rigidity of the product can be secured. - The transformation state of the blank 1 after preforming in the case where the above-described main forming step was performed on the basis of the blank 1 in which a
crease 1 d, acrease 1 e, and sevencreases 1 f were formed by the above-described preforming step, thepunch 7 and thedie 8 shown inFIG. 15 , the clearance between thepunch 7 and the die 8 (the thickness of the blank 1 (1 mm)+(20% of the thickness of the blank 1 (1 mm)=0.2 mm)=1.2 mm), lubricant (wash oil for steel plate is assumed) and coefficient of friction μ=0.14, was calculated using general-purpose dynamic explicit method software PAM-STAMP (calculation result is shown inFIGS. 17A to 17E as deformation state diagrams). The calculation model was in ¼ symmetric condition. -
FIGS. 17A to 17E are transformation state diagrams showing the above-described calculation result.FIGS. 17A, 17B, 17C, 17D, and 17E respectively show the transformation state of the blank 1 after preforming at BDC 70 mm UP, BDC 50 mm UP,BDC 20 mm UP,BDC 10 mm UP, and BDC. From this, it can be seen that the main forming step progresses further stably compared toEmbodiments FIG. 17E , it can be seen that fourribs 1 g each composed of a pair of folded flanges that protrude outward from between adjacentvertical walls 1 b of the square tubular component are formed excellently in thecorner portion 1 c. That is, a square tubular component can be formed more easily only by bending without drawing thecorner portions 1 c. For this reason, if the height of the square tubular component is increased, the drawing resistance to the blank 1 does not increase. In other words, a square tubular component (bottomed container) that is free from rupture can be obtained without increasing the amount of strain in each parts. The fourribs 1 g become larger from thebottom portion 1 a toward the open ends of thevertical walls 1 b in side view, and the fourribs 1 g are provided with no flanges extending outward from the open ends of theribs 1 g in plan view. - When four
ribs 1 g are provided in eachcorner portion 1 c as inEmbodiment 3, the amount of protrusion ofribs 1 g is small compared toEmbodiment 2. The strength ofcorner portions 1 c ofEmbodiment 3 is high compared toEmbodiment 2. - As described above, use of the configuration of the present invention not only eliminates the need to provide a die and a punch with a pair of special machined parts, but also makes it possible to form a bottomed container having a large forming height from a blank using cold press forming, by which mass production is possible, substantially only by bending forming.
- In the main forming step of
Embodiment 3, providing slits in corner portions ofbottom surface 8 a ofdie 8 when one ormore ribs 1 g protruding outward from between adjacentvertical walls 1 b of square tubular component (bottomed container) in plan view in press forming, or providing slits in corner portions of bottom surface ofpunch 7 when one ormore ribs 1 g protruding inward from between adjacentvertical walls 1 b of square tubular component (bottomed container) in plan view in press forming, makes it easier and more stable to form a square tubular component (bottomed container). - Forming slits provided in the
corner portions 8 c of thebottom surface 8 a of thedie 8 or the corner portions of the bottom surface of thepunch 7 such that the slits extend radially from the center of each corner portion makes the forming positions of theribs 1 g more stable, and makes it much easier and much more stable to form a square tubular component (bottomed container). - By providing flanges (not shown) extending outward from the outer side surface other than the
corner portions 7 c ofpunch 7 on the upper end of thepunch 7, flanges (not shown) extending outward from the open ends of thevertical walls 1 b of the square tubular component (bottomed container) can be provided at the same time in press forming, without generating strain based on bending deformation resistance in theribs 1 g.
Claims (11)
1. A bottomed container comprising: a bottom portion; and a plurality of vertical walls rising from the peripheral edge of the bottom portion,
wherein the bottomed container is formed by press-forming a blank, and has a plurality of corner portions integral with the bottom portion and the vertical walls adjacent to each other,
the corner portions are each provided with one or more ribs that protrude outward or inward from between the vertical walls adjacent to each other in plan view,
the ribs are each composed of a pair of folded flanges that are folded along creases that are preformed in the blank so as to substantially equally divide an area that will become one of the corner portions,
the amount of outward or inward protrusion of the ribs becomes larger from the bottom portion toward the open end of the vertical walls in side view, and
the ribs are provided with no flanges extending outward from the open ends of the ribs in plan view.
2. The bottomed container according to claim 1 , wherein the corner portions have a substantially arc shape in plan view, and the one or more ribs formed in each of the corner portions having a substantially arc shape are two to four ribs.
3. The bottomed container according to claim 2 , wherein recesses or protrusions that are continuous in plan view and that correspond to the ribs protruding outward or inward from the corner portions having a substantially arc shape are formed in the bottom portion.
4. The bottomed container according to claim 3 , wherein the recesses or protrusions provided in the bottom portion are formed so as to extend radially from the center of each of the corner portions having a substantially arc shape in plan view.
5. The bottomed container according to claim 1 , wherein the bottomed container is provided with flanges extending outward from the open ends of the vertical walls.
6. A method for manufacturing the bottomed container according to claim 1 , the method comprising:
a preforming step comprising forming creases in a blank having areas that will become the bottom portion, the plurality of vertical walls, and the plurality of corner portions of the bottomed container after press forming using a preforming die, the creases being formed at borders between an area that will become the bottom portion and areas that will become the vertical walls, borders between the areas that will become the vertical walls and areas that will become the corner portions, and positions for substantially equally dividing the areas that will become the corner portions; and
a main forming step comprising setting the blank, in which creases are formed by the preforming step, between a die and a punch such that the die and the punch correspond to the shape of the blank, and press-forming said blank to form the bottomed container,
wherein in the main forming step, when one or more ribs protruding outward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in corner portions of the die, and when one or more ribs protruding inward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in corner portions of the outer side surface of the punch.
7. The method for manufacturing a bottomed container according to claim 6 , wherein in the preforming step, the number of creases formed for substantially equally dividing each of the areas that will become the corner portions is three to seven.
8. The method for manufacturing a bottomed container according to claim 6 , wherein the inside of each of the corner portions of the die is formed such that the radius of curvature of the inscribed circle is R1 in plan view, the corner portions of the outer side surface of the punch are formed in a shape having a curved surface having a radius of curvature of R2 in plan view corresponding to the inscribed circle of each of the corner portions of the die, the clearance between the punch and the die defined as R1−R2 is set to 100% to 200% of the thickness of the blank, and R1>R2.
9. The method for manufacturing a bottomed container according to claim 8 ,
wherein in the main forming step,
when one or more ribs protruding outward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in the corner portions of the bottom surface of the die, and
when one or more ribs protruding inward from between each adjacent two of the vertical walls of the bottomed container in plan view are formed in press forming, slits are provided in the corner portions of the bottom surface of the punch.
10. The method for manufacturing a bottomed container according to claim 9 , wherein the slits provided in the corner portions of the bottom surface of the die or the corner portions of the bottom surface of the punch are formed so as to extend radially from the center of each corner portion.
11. The method for manufacturing a bottomed container according to claim 6 , wherein flanges extending outward from the outer side surface other than the corner portions of the punch are provided at the upper end of the punch.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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JP2015051445A JP2016168619A (en) | 2015-03-13 | 2015-03-13 | Bottomed cylindrical component and manufacturing method for the same |
JP2015-051445 | 2015-03-13 |
Publications (1)
Publication Number | Publication Date |
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US20160263639A1 true US20160263639A1 (en) | 2016-09-15 |
Family
ID=56886394
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US15/068,029 Abandoned US20160263639A1 (en) | 2015-03-13 | 2016-03-11 | Bottomed container and method for manufacturing the same |
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US (1) | US20160263639A1 (en) |
JP (1) | JP2016168619A (en) |
CN (1) | CN105964754A (en) |
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DE102018121727A1 (en) | 2017-09-06 | 2019-03-07 | Benteler Automobiltechnik Gmbh | Battery carrier for an electric motor vehicle |
DE102017120544A1 (en) | 2017-09-06 | 2019-03-07 | Benteler Automobiltechnik Gmbh | Battery carrier for an electric motor vehicle and method for its production |
DE102017120533A1 (en) | 2017-09-06 | 2019-03-07 | Benteler Automobiltechnik Gmbh | Battery carrier and method for producing the battery carrier |
DE102017130859A1 (en) | 2017-12-21 | 2019-06-27 | Benteler Automobiltechnik Gmbh | Method for producing a battery carrier for motor vehicles with an electric drive |
DE102018105526A1 (en) * | 2018-03-09 | 2019-09-12 | Benteler Automobiltechnik Gmbh | Method for producing a battery carrier for holding an electric battery module |
DE102018120466A1 (en) * | 2018-08-22 | 2020-02-27 | GEDIA Gebrüder Dingerkus GmbH | Housing with a cuboid shape |
DE102018131374A1 (en) | 2018-12-07 | 2020-06-10 | Benteler Automobiltechnik Gmbh | Modular battery holder |
DE102018131376A1 (en) | 2018-12-07 | 2020-06-10 | Benteler Automobiltechnik Gmbh | Battery holder with all-round frame and defined adhesive gap |
DE102018131375A1 (en) | 2018-12-07 | 2020-06-10 | Benteler Automobiltechnik Gmbh | Battery holder with a step molded into the side wall |
DE102019101637A1 (en) | 2019-01-23 | 2020-07-23 | Benteler Automobiltechnik Gmbh | Battery holder with molded bead |
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Also Published As
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CN105964754A (en) | 2016-09-28 |
JP2016168619A (en) | 2016-09-23 |
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Owner name: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.) Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:YOSHIDA, MASATOSHI;REEL/FRAME:037959/0236 Effective date: 20151201 |
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