WO2010137467A1

WO2010137467A1 - Method and apparatus for incremental forming

Info

Publication number: WO2010137467A1
Application number: PCT/JP2010/058143
Authority: WO
Inventors: 明生関口
Original assignee: Sekiguchi Akio
Priority date: 2009-05-25
Filing date: 2010-05-07
Publication date: 2010-12-02
Also published as: JP2010269358A; JP4530301B1

Abstract

Disclosed are a method and an apparatus for incremental forming wherein conventionally difficult product can be formed. A workpiece plate is placed between supporting frames (20, 21) and fixed by a fixing mechanism (22), and then a forming die (42) is attached to the upper plane of a forming die supporting device (10). A tool (30) is pressed from above while being moved in the XY direction so that the workpiece is held along the forming die (42) and, at the same time, a cylinder (23) is lowered. Thereafter, the workpiece is formed incrementally in the Z direction while tilting the forming die (42) to a desired angle by the forming die tilt mechanism (11, 12). When the workpiece is fully supported by the tool (30) and the forming die (42), fixing by the fixing mechanism (22) is relaxed so that the workpiece can move in the horizontal direction.

Description

Sequential molding method and apparatus

The present invention relates to a sequential molding method and apparatus for molding a workpiece into a predetermined three-dimensional shape.

Conventionally, drawing and counter-hydraulic forming are known as methods for obtaining irregularities and cup-shaped shapes by plastically deforming thin steel plates, aluminum plates, copper plates and the like. Further, tube hydroforming is known as a method for producing a product by applying plastic deformation to a pipe material. Although these moldings can mold products at a relatively high speed, it is necessary to prepare expensive molds for molding, and the problem is that mold costs account for a large proportion of product prices in small-volume production. there were.
On the other hand, in recent years, there has been a proposal to solve this problem by so-called sequential stretch forming in which a workpiece is subjected to successive deformations and formed. Sequential stretch forming is to move the base plate fixed to the support frame with a tool trajectory that draws a contour trajectory along the mold using a rod-like tool that is just attached to the spindle of the milling machine. In this method, the plate material is formed. In this processing method, there are many cases where only a part of the mold is required or a general-purpose mold can be substituted, and it is possible to reduce the cost of the mold, especially for various types such as prototypes and custom-made products. Suitable for small volume production. The shape of the part from which the mold is omitted is characterized in that its shape is determined mainly by the movement pattern of the tool.

JP-A-9-85355 Japanese Patent Laid-Open No. 10-314855

Sequential stretch forming is advantageous in terms of cost compared to other processing methods, especially in high-mix low-volume production because the cost of the mold can be suppressed. However, in this processing method, the steeper inclination of the portion to be processed with respect to the plane on which the workpiece is placed, the more the thickness of the portion to be processed decreases, and the more easily breaks. For this reason, it is impossible to process a shape with a vertical wall or a recessed wall, or even if it can be molded, trial and error, special contrivance, and particularly time required for processing are difficult. . Accordingly, an object of the present invention is to provide a sequential molding method and a processing method that can easily and quickly be molded without causing molding defects such as fractures by suppressing the reduction in thickness of shapes that have been difficult to mold. It is in providing the apparatus for implementation of.

In order to solve the above-mentioned problems, according to a first aspect of the sequential forming method of the present invention, a plate-like workpiece is fixed to a work support device, and a tool is moved in a three-dimensional direction relative to a predetermined shape. In the sequential forming method for forming the workpiece, the tool is moved on the XY plane parallel to the plane on which the plate-like workpiece is fixed, and the workpiece is kept parallel to the XY plane. At the same time, the mold is tilted with respect to the XY plane at the time of machining, and moved in the Z direction relative to the mold having a predetermined three-dimensional shape, so that the XY plane on which the tool moves at the time of the machining is Thus, the machining is performed by relatively moving in the Z direction and relatively tilting in at least one direction.
According to a second aspect of the present invention, in the sequential molding method of the plate material according to the first aspect, the workpiece is moved in the Z direction relative to a predetermined three-dimensional shape while keeping the workpiece parallel to the XY plane in which the tool moves during machining. When the workpiece is distorted by tilting the mold relative to the XY plane while fixing the workpiece with the workpiece support device, the workpiece is fixed by the support device and Machining is performed by freely moving the workpiece on the XY plane.
According to a third aspect of the sequential forming apparatus of the present invention, a forming die or a partial forming die, a tool attached to the main shaft, a drive mechanism for driving the tool in a three-dimensional direction relative to the forming die, and A sequential molding apparatus for molding a plate-shaped workpiece with a molding die support, and a mounting portion for fixing the molding die to perform the sequential molding method for a plate material according to claim 1, and the mounting portion And a drive device for the tilt mechanism.

According to the first aspect of the present invention, the plate-like workpiece is fixed to the workpiece support device, and the tool is moved relative to the predetermined shape in the three-dimensional direction, thereby sequentially forming the workpiece. In the molding method, the tool is moved on the XY plane parallel to the plane on which the plate-like workpiece is fixed, and the workpiece is kept parallel to the XY plane, and the molding die is moved with respect to the XY plane at the time of machining. The XY plane on which the tool moves during machining is moved in the Z direction relative to the predetermined three-dimensional shape by moving the tool in the Z direction relative to the predetermined three-dimensional mold. Since we decided to work with the direction relatively inclined, there was no difficulty in the movement of the tool and the material flow of the workpiece, and it was easy and high-speed without causing molding defects such as fractures. Can be molded.
According to a second aspect of the present invention, in the method of sequentially forming a plate material according to the first aspect, the Z direction is relatively relative to a predetermined three-dimensional shape while keeping the workpiece parallel to the XY plane in which the tool moves during processing. The workpiece is fixed by the support device when the workpiece is distorted by tilting the mold relative to the XY plane while fixing the workpiece with the workpiece support device. In addition, since it was decided to process by moving the workpiece on the XY plane at the time of machining, even if the molding die or part of the molding die is continuously inclined during molding, the workpiece being worked is intended. Therefore, it is possible to prevent the product from being molded into a predetermined shape due to excessive force.
According to invention of Claim 3, a shaping | molding die or a partial shaping | molding die, the tool attached to the main axis | shaft, the drive mechanism which drives a tool to a three-dimensional direction relatively with respect to a shaping | molding die, and a shaping | molding die support part A sequential molding apparatus for molding a plate-shaped workpiece, comprising: a mounting portion for fixing a molding die, and an inclination for tilting the mounting portion in order to perform the sequential molding method for a plate material according to claim 1. Since at least one tilting mechanism and a drive device for the tilting mechanism are provided, it is possible to tilt a mold or a part of the mold during processing and to support the mold with high rigidity. The invention of Item 2 can be implemented with high accuracy.

FIG. 1 is a three-dimensional view of an apparatus in a sequential molding method according to the present invention.
FIG. 2 is a view showing the structure of an apparatus for inclining a mold or a workpiece during processing.
FIG. 3 is an example of a tool that can be used in the present invention.
FIG. 4 is an example of a processing machine in which the present invention can be implemented.
FIG. 5 is an example of a processing machine in which the present invention can be implemented.
FIG. 6 is an example of a processing machine in which the present invention can be implemented.
FIG. 7 is a diagram showing the procedure of the embodiment of the present invention. Example 1
FIG. 8 is an example of the shape of a product molded by the implementation of the present invention. Example 1
FIG. 9 is a diagram showing the procedure of the embodiment of the present invention. (Example 2)
FIG. 10 is an example of the shape of a product molded by the implementation of the present invention. (Example 2)
FIG. 11 is a diagram showing the procedure of the embodiment of the present invention. (Example 3)
FIG. 12 is an example of the shape of a product molded by the implementation of the present invention. (Example 3)
FIG. 13 is a diagram showing the procedure of the embodiment of the present invention. Example 4
FIG. 14 is an example of the shape of a product molded by the implementation of the present invention. Example 4
FIG. 15 is a diagram showing the procedure of the embodiment of the present invention. (Example 5)
FIG. 16 is an example of the shape of a product molded by the implementation of the present invention. (Example 5)

As shown in FIG. 1, the sequential forming apparatus of the present invention includes an apparatus for inclining a forming die or a workpiece at the time of processing according to claim 3 and an apparatus for horizontally supporting a plate-shaped workpiece at the time of processing. In the following description, an apparatus for inclining a forming die or a workpiece during processing according to claim 3 is referred to as an inclination supporting apparatus, and an apparatus for horizontally supporting a plate-shaped workpiece during processing is referred to as a horizontal supporting apparatus.
In order to carry out the sheet material sequential forming method according to claim 1 and claim 2, the inclined support device and the horizontal support device are used. In order to implement the sequential forming method of the three-dimensional workpiece, only the inclined support device is used.
The inclined support device has a structure shown in FIG. The face plate 10 to which the forming die or the work is attached can be given an arbitrary inclination in two directions orthogonal to each other along the rotation center 14 separated above the base 13 of the inclination apparatus by the inclination mechanism and the

drive units

11 and 12. it can.
As shown in FIG. 1, the horizontal support device can sandwich the base plate between the work support frames 20 and 21 at the start of processing, and can restrain the movement in the XY directions by the work fixing mechanism 22, and can be fixed as necessary. Can be released to freely move the workpiece in the XY directions. Further, the position of the workpiece at the time of machining can be appropriately maintained by the cylinder 23.
The tool 30 shown in FIG. 1 can be moved in three-dimensional directions such as horizontal and vertical directions or rotation. Moreover, it can change to the shape suitable for every use not only in the shape of FIG. FIG. 3 is an example of a tool that can be replaced. Since these could also be used in conventional sequential molding methods, their usage is not explained for each.
4, 5, and 6 are examples of processing machines that can implement the present invention by moving a tool in a three-dimensional direction. Since the tool can be supported with high rigidity in the processing machine shown in FIG. 4, it is suitable for processing a hard work material. In the processing machine of FIG. 5, since the contact angle of a tool can be changed flexibly, a product with good surface quality can be processed. The processing machine of FIG. 6 has a structure like a so-called vertical lathe and can rotate the inclined support device of the present invention, so that a shell shape close to a circle can be formed at high speed.
A feature common to these processing machines applicable to the present processing method is that the positional relationship between the apparatus of the present processing method and the tool can be relatively moved in a three-dimensional direction. That is, for the present machining method, moving the tool relative to the fixed apparatus and moving the tool relative to the fixed tool or both have the same meaning. A so-called multi-axis multi-tasking machine in recent years can also be used. In addition, when each device is provided with a shaft for rotating the tool itself, the tool for cutting the workpiece is rotated as shown in step 7 of FIG. Can be adjusted, or extra portions can be cut.
FIG. 7 shows an example of an embodiment of the present invention. Moreover, the example of the shape of the product shape | molded by this example is shown in FIG.

First, the workpiece is sandwiched between the work support frames 20 and 21 of the horizontal support device as in Procedure 1 of FIG. 7, and the movement in the XY directions is restricted by the work fixing mechanism. Moreover, the partial shaping | molding die 42 is attached to the face plate 10 of an inclination support mechanism. A tool 30 suitable for processing is attached to the processing machine.
Next, after the tool 30 is lowered by a predetermined minute amount in the vertical direction, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43. Repeat this several times if necessary. Thereafter, in order to make an inclination, after the tool 30 is retracted to a position where it does not interfere, the inclination mechanism is inclined by a predetermined minute amount, the tool is returned to the position where it contacts the workpiece, and the tool 30 is lowered by a predetermined minute amount in the vertical direction. After that, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43.
By repeating this, a predetermined product shape is obtained as shown in Procedure 2, Procedure 3, and Procedure 4 of FIG. However, the workpiece may be distorted by giving an inclination while fixing the workpiece with the support frame 20 during machining. For this reason, when the movement of the workpiece in the horizontal direction is sufficiently suppressed by the mold, this is prevented by releasing the fixation by the workpiece fixing mechanism 22.
FIG. 8 is an example of the shape of the product molded by this embodiment, and is a shape in which the cross section at the end of processing is translated / inclined with respect to the original surface where the workpiece was located. As an effect of this processing, the thickness of the original surface of the workpiece of the product is kept at the original plate thickness of the workpiece.

FIG. 9 shows another example of the embodiment of the present invention. Moreover, the example of the shape of the product shape | molded by this example is shown in FIG.
First, as shown in procedure 1 of FIG. 9, the workpiece is sandwiched between the work support frames 20 and 21 of the horizontal support device, and the movement in the XY directions is restricted by the work fixing mechanism. Moreover, the partial shaping | molding die 42 is attached to the face plate 10 of an inclination support mechanism. A tool 30 suitable for processing is attached to the processing machine.
Next, after the tool 30 is lowered by a predetermined minute amount in the vertical direction, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43. Repeat this several times if necessary. Thereafter, in order to make an inclination, after the tool 30 is retracted to a position where it does not interfere, the inclination mechanism is inclined by a predetermined minute amount, the tool is returned to the position where it contacts the workpiece, and the tool 30 is lowered by a predetermined minute amount in the vertical direction. After that, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43.
By repeating this, a predetermined product shape is obtained as shown in Procedure 2, Procedure 3, and Procedure 4 of FIG. However, the workpiece may be distorted by giving an inclination while fixing the workpiece with the support frame 20 during machining. For this reason, when the movement of the workpiece in the horizontal direction is sufficiently suppressed by the mold, this is prevented by releasing the fixation by the workpiece fixing mechanism 22.
FIG. 10 shows an example of the shape of a product molded according to this embodiment. The shape is such that the original surface on which the workpiece is located and the cross section at the end of processing are concentric, similar and horizontal. As an effect of this processing, the thickness on the side surface of the product can be controlled by tilting the tilt mechanism during processing. That is, products having different thickness distributions can be formed even if the shapes are the same.

FIG. 11 shows another example of the embodiment of the present invention. Moreover, the example of the shape of the product shape | molded by this example is shown in FIG.
First, the workpiece is sandwiched between the work support frames 20 and 21 of the horizontal support device as in procedure 1 of FIG. 11, and the movement in the XY directions is restricted by the work fixing mechanism. Moreover, the partial shaping | molding die 42 is attached to the face plate 10 of an inclination support mechanism. A tool 30 suitable for processing is attached to the processing machine.
Next, after the tool 30 is lowered by a predetermined minute amount in the vertical direction, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43. Repeat this several times if necessary. Thereafter, in order to make an inclination, after the tool 30 is retracted to a position where it does not interfere, the inclination mechanism is inclined by a predetermined minute amount, the tool is returned to the position where it contacts the workpiece, and the tool 30 is lowered by a predetermined minute amount in the vertical direction. After that, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43.
By repeating this, a predetermined product shape is obtained as shown in Procedure 2, Procedure 3, and Procedure 4 of FIG. However, the workpiece may be distorted by giving an inclination while fixing the workpiece with the support frame 20 during machining. For this reason, when the movement of the workpiece in the horizontal direction is sufficiently suppressed by the mold, this is prevented by releasing the fixation by the workpiece fixing mechanism 22.
FIG. 12 is an example of the shape of the product molded by this embodiment, and is a shape that cannot be represented by simple projection from the plane remaining on the support frame. Such a shape is difficult or time-consuming to be formed by the conventional forming method, but according to this processing of the present invention, it can be formed at high speed and easily.

FIG. 13 shows another example of the embodiment of the present invention. Moreover, the example of the shape of the product shape | molded by this example is shown in FIG.
First, as shown in the procedure 1 of FIG. 13, the workpiece is sandwiched between the work support frames 20 and 21 of the horizontal support device, and the movement in the XY directions is restricted by the work fixing mechanism. Further, the forming die 41 is attached to the face plate 10 of the inclined support mechanism. A tool 30 suitable for processing is attached to the processing machine. As shown in the procedure 2 of FIG. 13, when there is a part to be processed in advance, the mold 41 is processed in accordance with an example of a conventional sequential forming method.
Next, after lowering the tool 30 by a predetermined minute amount in the vertical direction, the tool is rotated in the horizontal direction so as to press the work along the mold 41. Repeat this several times if necessary. Thereafter, in order to make an inclination, after the tool 30 is retracted to a position where it does not interfere, the inclination mechanism is inclined by a predetermined minute amount, the tool is returned to the position where it contacts the workpiece, and the tool 30 is lowered by a predetermined minute amount in the vertical direction. After that, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43.
By repeating this, a predetermined product shape is obtained as shown in Procedure 2, Procedure 3, Procedure 4, Procedure 5, and Procedure 6 in FIG. However, the workpiece may be distorted by giving an inclination while fixing the workpiece with the support frame 20 during machining. For this reason, when the movement of the workpiece in the horizontal direction is sufficiently suppressed by the mold, this is prevented by releasing the fixation by the workpiece fixing mechanism 22.
FIG. 14 is an example of the shape of the product molded by this embodiment, and has a shape having a dent on the head and a wall surface perpendicular to the head plane. Such a shape is difficult or time-consuming to be formed by the conventional forming method, but according to this processing of the present invention, it can be formed at high speed and easily. In the process from step 3 to step 5 in FIG. 13, the wall thickness of the vertical wall portion can be adjusted by changing the inclination of the mold by the inclined support mechanism.

FIG. 15 shows another example of the embodiment of the present invention. Moreover, the example of the shape of the product shape | molded by this example is shown in FIG.
First, as shown in procedure 1 of FIG. 15, the workpiece is attached to the chuck 44 attached to the face plate 10 of the inclined support mechanism. A horizontal support device is not used. A tool 30 suitable for processing is attached to the processing machine.
Next, after lowering the tool 30 by a predetermined minute amount in the vertical direction, the tool is rotated in the horizontal direction so as to press the work along the mold 41. Repeat this several times if necessary. Thereafter, in order to make an inclination, after the tool 30 is retracted to a position where it does not interfere, the inclination mechanism is inclined by a predetermined minute amount, the tool is returned to the position where it contacts the workpiece, and the tool 30 is lowered by a predetermined minute amount in the vertical direction. After that, the tool is rotated in the horizontal direction so as to trace the surface of the predetermined product shape 43.
In the case of a workpiece having a three-dimensional shape such as a tubular shape as shown in FIG. 15, the strength of the workpiece is high, and a predetermined molding amount cannot be given only by one cycle. For this reason, the above-described cycle is repeated a plurality of times, such as procedure 1 to procedure 2, procedure 3 to procedure 4, and procedure 5 to procedure 6, and the deformation is given. Depending on the shape of the original workpiece, as shown in step 6 of FIG. 15, an extra portion may occur with respect to a predetermined shape. Unnecessary parts are cut and the procedure 8 is reached.
FIG. 16 is an example of the shape of a product molded according to this embodiment, and is a shape having a processed portion that is inclined with respect to the central axis of the material and has a non-circular cross section. Such a shape is not easy to determine the trajectory of the tool in the conventional forming method because the tool must be actively moved in the vertical direction with respect to the circumference of the work, and it takes extra time. However, this shape can be formed relatively easily and at high speed by using this processing method.

By carrying out the processing method of the present invention, it is possible to easily and rapidly form products that have been difficult to form without being limited to special shapes. In addition, since the processing apparatus of the present invention has the feature that it can be easily used by combining it with a conventional processing apparatus, the processing apparatus itself becomes a product, or the processing machine itself incorporating this apparatus becomes a product. Can do.

DESCRIPTION OF SYMBOLS 10 Face plate which attaches a shaping | molding die or a workpiece |

work

11,12 Inclination mechanism and drive part 13 Base of inclination apparatus 14 Rotation center of

inclination mechanism

20,21 Work support frame 22 Work fixing mechanism 23 Cylinder which raises / lowers work support frame 30 Tool 31 Processing Machine 32 Work position of processing machine 40 Work 41 Mold 42 Partial mold 43 Predetermined product shape 44 Chuck for fixing work

Claims

In a sequential forming method for forming a workpiece by fixing the plate-like workpiece to a workpiece support device and moving the tool relative to a predetermined shape in a three-dimensional direction, the tool is The workpiece is moved on an XY plane parallel to the plane on which the workpiece is fixed, and the workpiece is kept parallel to the XY plane. At the time of machining, the mold is tilted with respect to the XY plane to form a predetermined three-dimensional shape. The tool moves at the time of machining by moving the XY plane in which the tool moves in the Z direction in order to move the plane on which the plate-like workpiece is fixed relative to the mold in the Z direction. A plate material sequential forming method, wherein a plane is moved relative to a predetermined three-dimensional shape in the Z direction and is inclined relative to at least one direction.
The sequential forming method of a plate material according to claim 1, wherein the workpiece is moved in the Z direction relative to a predetermined three-dimensional shape while being kept parallel to the XY plane on which the tool moves during processing, When the workpiece is distorted by tilting the mold relative to the XY plane while fixing the workpiece, the workpiece is fixed by the support device, and the workpiece on the XY plane is processed. A method for forming a plate material, characterized in that the plate material is processed by freely moving it.
A plate-like workpiece having a mold or a partial mold, a tool attached to the spindle, a drive mechanism for driving the tool in a three-dimensional direction relative to the mold, and a mold support section In a sequential forming apparatus for forming a material, in order to carry out the method for sequentially forming a plate material according to claim 1, a workpiece support portion / fixing mechanism for supporting and fixing a plate-like workpiece material, and the workpiece material as the XY An apparatus that is used in combination with the work support device having a cylinder that is kept parallel to a plane, an attachment portion that fixes the mold, at least one inclination mechanism for inclining the attachment portion, and an inclination mechanism A sequential forming apparatus for forming a plate-shaped workpiece, characterized by comprising the above drive device.