WO2013179618A1 - 閉断面構造体の成形方法及び閉断面構造体の成形装置 - Google Patents
閉断面構造体の成形方法及び閉断面構造体の成形装置 Download PDFInfo
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- WO2013179618A1 WO2013179618A1 PCT/JP2013/003285 JP2013003285W WO2013179618A1 WO 2013179618 A1 WO2013179618 A1 WO 2013179618A1 JP 2013003285 W JP2013003285 W JP 2013003285W WO 2013179618 A1 WO2013179618 A1 WO 2013179618A1
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- closed cross
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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
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
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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
- B21D53/00—Making other particular articles
- B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
-
- 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
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/02—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
-
- 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
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
- B21D5/015—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments for making tubes
-
- 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
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/02—Bending sheet metal along straight lines, e.g. to form simple curves on press brakes without making use of clamping means
-
- 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
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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
- B21D9/00—Bending tubes using mandrels or the like
- B21D9/08—Bending tubes using mandrels or the like in press brakes or between rams and anvils or abutments; Pliers with forming dies
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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
- B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
- B21D11/08—Bending by altering the thickness of part of the cross-section of the work
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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
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
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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
- B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
- B21D47/01—Making rigid structural elements or units, e.g. honeycomb structures beams or pillars
Definitions
- the present invention relates to a method for forming a closed cross-section structure and a forming apparatus for forming a closed cross-section structure for forming a plate-shaped workpiece into a closed cross-section structure (forming method and apparatus of structure having closed cross section).
- Patent Document 1 a technique disclosed in Patent Document 1 is known as a method for manufacturing a component having a closed cross-sectional structure.
- a half of a pair of closed cross-section structures is raised from both ends of a connecting section having a flat cross section by press forming a metal plate.
- Patent Document 1 discloses a method for forming a closed cross-section structure for a cylinder, a square tube, a pentagonal cross section, and a polygonal cross section.
- a flat punch having a raised portion at the tip is inserted between the half halves of the closed cross-section structure, and the connecting portion is pressed from the inside by the flat punch to form a bent portion having a V-shaped cross section.
- this is a technology for further raising both half of the closed cross-section structure half to make a closed cross-section.
- the present invention has been made paying attention to the unsolved problems of the above-described conventional example, and can form a closed cross-section structure having a three-dimensional bent shape applied as, for example, an automobile structural component with high accuracy. It is an object of the present invention to provide a method for forming a closed cross-section structure and a forming apparatus for forming the closed cross-section structure, which can be manufactured with reduced production costs.
- the present invention provides the following method for forming a closed section structure and a molding apparatus for forming the closed section structure.
- a plate-shaped workpiece is bent at a position that becomes a plurality of bending lines extending in the longitudinal direction, and a bottom portion formed on the width direction center portion side of the workpiece and positions on both sides in the width direction of the bottom portion.
- a method of forming a closed cross-sectional structure with left and right side walls By press forming, the workpiece is formed into a curvature shape required for the final closed cross-sectional shape in the longitudinal direction and the width direction, and a bending guide line is provided at a position where the final closed cross-sectional shape becomes a bending line.
- the first step The workpiece formed in the first step is bent in the direction in which the left and right side walls approach each other by sandwiching the bottom portion between the plate thickness direction with a punch and a pad and pushing the punch between a pair of dies.
- the bending guide wire is a portion in which a groove is formed on one surface of the processed material, and a convex portion is formed on the other surface corresponding to the groove, and the depth of the groove is the thickness of the plate.
- the closed cross-section structure according to any one of [1] to [3], in which the groove width of the groove portion is 0.2 mm or more and 3.0 mm or less. Method.
- a plate-shaped workpiece is bent at positions that form a plurality of bending lines extending in the longitudinal direction, and is located on the widthwise center portion side of the workpiece and on both sides of the bottom in the width direction.
- An apparatus for forming a closed cross-sectional structure having left and right side walls The workpiece is formed into a curvature shape required in the final closed cross-sectional shape in the longitudinal direction and the width direction, and a bending guide line is provided at a position that becomes a bending line in the final closed cross-sectional shape,
- a press die having an upper die and a lower die for press-molding a plate-shaped workpiece; and
- the workpiece formed by the pressing mold is bent in a direction in which the left and right side walls approach each other by sandwiching the bottom portion with a punch and a pad from the thickness direction and pushing the punch between a pair of dies.
- a bending mold to be molded A plug formed on the same outer peripheral shape as the final closed cross-sectional shape and disposed on the bottom of the workpiece formed by the bending mold; a support pad for supporting the bottom of the workpiece; and A pair of pressing cams arranged on the outer side in the width direction of the plug, and the bending guide wire is formed by pressing the bottom portion and the left and right side wall portions against the outer periphery of the plug with the support pad and the pair of pressing cams.
- molds in the closed cross-section structure which has the metal mold
- the plug having the same outer peripheral shape as the final closed cross-sectional shape is disposed on the bottom of the workpiece, and the bottom and the left and right side wall portions are plugged. Since it has a third process of bending the bottom and left and right side walls with the bending guide line as a boundary by pressing against the outer periphery of the steel, it is possible to easily form a highly accurate closed cross-section structure and produce it. A closed cross-section structure can be formed at a reduced cost. Further, according to the method for forming a closed cross-section structure described in [2], the plug can be easily removed from the work material bent and formed into the final closed cross-sectional shape in the third step.
- a closed cross-section structure having a predetermined three-dimensional curved shape can be formed with high accuracy.
- the bending guide wire formed at the boundary between the bottom part and the left and right side wall parts has a groove depth of 0.05 of the thickness T of the workpiece. Since it is not less than 0.3 times and not more than 0.3 times and the groove width is 0.2 mm or more and 3.0 mm or less, the bottom part and the left and right side wall parts are bent with high accuracy along the bending guide line in the third step. can do.
- the closed cross-section structure forming apparatus described in [5] the closed cross-section structure having a predetermined shape can be easily formed, and the production cost can be greatly reduced.
- FIG. 1 shows the shape of a workpiece 1 in the process of forming a closed section structure having an irregular pentagonal closed section shape according to the present invention.
- the workpiece 1 includes bottom portions 2 and 3 constituting two sides of an irregular pentagon shape, left side wall portions 4 and 5 constituting two sides of the irregular pentagon shape, and the remaining one side of the irregular pentagon shape. It has a right side wall portion 6 and a pair of flange portions 7 and 8 which are continuously formed on the right side wall portion 6 and the left side wall portion 5 and face each other, and extend in the longitudinal direction.
- a plurality of hemming protrusions 9 are formed at the front end of one flange portion 7 at predetermined intervals in the longitudinal direction.
- the bottom portions 2 and 3, the left side wall portions 4 and 5, the right side wall portion 6 and the flange portions 7 and 8 are orthogonal to the Y axis direction in the longitudinal direction, the X axis direction in the width direction, and the plane including the Y axis and the X axis.
- FIG. 2 (b) is a view showing a workpiece pressing die, and is composed of an upper die 10 and a lower die 11.
- the press molding surface facing the lower side of the upper die 10 and the press molding surface facing the upper side of the lower die 11 are formed so as to follow each other, and between the press molding surfaces of the upper die 10 and the lower die 11, FIG. Press forming is performed by placing the flat plate-shaped workpiece 1 shown in (a) and inserting the upper die 10 toward the lower die 11.
- the processed material 1 press-molded with the work material pressing die has the bottom portions 2 and 3 formed at the substantially central portion in the width direction, and the left side wall portion in the width direction on the bottom portion 2 side. 4 and 5 are formed, the right wall 6 is formed in the width direction on the bottom 3 side, the flange 8 is formed on the width direction end on the left wall 5 side, and the width direction end on the right wall 6 side is formed.
- the flange portion 7 (having a hemming projection 9) is formed on the base plate, and the line length is adjusted by forming the bending lines B1 to B6 along the longitudinal direction at the boundary portions of the portions 2 to 8. .
- bending guide lines G are formed in the bending lines B1 to B6 along the longitudinal direction at positions where the final closed sectional shape becomes the bending lines.
- the bending guide line G is a substantially U-shaped projecting portion in which the groove portion 12 is formed on one surface of the bending lines B1 to B6 and the convex portion 13 is formed on the other surface facing the groove portion 12.
- the bending guide line G has a depth F of the groove portion 12 that is not less than 0.05 times and not more than 0.3 times the plate thickness T of the workpiece 1, and the groove width H of the groove portion 12. Is 0.2 mm or more and 3.0 mm or less.
- FIG. 4A is a view showing a bending die, which includes a first punch 15, a pad 16, and a pair of dies 17.
- the cross-sectional shape of the pushing portion of the first punch 15, that is, the cross-sectional shape of the lower end portion is the same shape as the bottom portions 2 and 3 of the closed cross-section structure.
- the pad 16 is opposed to the first punch 15 in the vertical direction, and the upper surface thereof has the same shape as the cross-sectional shape of the lower end portion of the first punch 15, and as shown in FIG.
- the bottom portions 2 and 3 of the workpiece 1 press-molded with a mold are sandwiched between the first punch 15 and the pad 16 from the thickness direction.
- the pair of dies 17 oppose each other with an interval corresponding to the width of the bottoms 2 and 3.
- FIG. 5A is a view showing a hemming press apparatus, and a plug 20 having the same outer peripheral shape (final closed cross-sectional shape) as the shape of the closed cross-sectional structure, and an upper side of the plug 20. 2, a support pad 22 disposed below the plug 20, and a pair of pressure cams 23 and 24 disposed on the outer side in the width direction of the plug 20.
- the plug 20 is a short member that is disposed at an end portion in the longitudinal direction of the workpiece 1 that is bent by a bending die.
- the plug 20 is disposed at one end in the longitudinal direction of the workpiece 1, but the plug 20 is also disposed at the other end.
- the second punch 21 is a long member having substantially the same length as the longitudinal direction of the workpiece 1, and moves up and down by the operation of the hydraulic actuator 25.
- the pair of pressing cams 23 and 24 are also long members having substantially the same length as the longitudinal direction of the workpiece 1, and a cam drive mechanism 26 that is linked to the operation of a hydraulic actuator 25 is connected thereto. . Then, the cam drive mechanism 26 moves the pair of pressing cams 23 and 24 to a pushing position close to the plug 20 or moves to a standby position away from the plug 20.
- the support pad 22 is a long member having substantially the same length as the longitudinal direction of the workpiece 1, and has a three-dimensional bent shape that is the same shape as the bottom portions 2 and 3 of the closed cross-section structure on the upper surface side. Is formed.
- the pressing surface of the one pressing cam 23 facing the plug 20 has a three-dimensional curved shape that is the same shape as the left side walls 4 and 5 of the closed section structure.
- the pressing surface of the other pressing cam 24 facing the plug 20 is also formed to have a three-dimensional curved shape that is the same shape as the right side wall portion 6 of the closed section structure.
- a slit groove 27 is formed at the center in the width direction of the lower end surface, and an insertion guide surface 28 is formed at the opening periphery of the slit groove 27.
- the final closed cross-section bending die according to the present invention corresponds to the plug 20, the support pad 22, and the pair of pressing cams 23, 24, and the second step and bending punch according to the present invention are punched. Corresponds to the first punch 15.
- the bottom portions 2 and 3 are formed at the substantially center portion in the width direction of the workpiece 1, and the left side wall portions 4 and 5 are formed in the width direction on the bottom portion 2 side.
- the right wall 6 is formed in the width direction on the bottom 3 side
- the flange 8 is formed on the width direction end on the left wall 5 side
- the flange 7 (hemming projection) is formed on the width direction end on the right wall 6 side. 9) is formed, and bending lines B1 to B6 are formed along the longitudinal direction at the boundaries between the portions 2 to 8.
- bending guide lines G are formed in the bending lines B1 to B6 along the longitudinal direction at positions where the final closed cross-sectional shape becomes bending lines.
- the plug 20 is arrange
- the second punch 21 is moved downward by the operation of the hydraulic actuator 25, and a pair of presses in which the cam drive mechanism 26 is in the standby position in conjunction with the operation of the hydraulic actuator 25.
- the cams 23 and 24 are moved toward the pushing surface. Thereby, the left side wall part 5 and the right side wall part 6 of the workpiece 1 pressed against the pressing surfaces of the pair of pressing cams 23 and 24 are brought closer to each other.
- the pair of flange portions 7 and 8 are closed, and the bottom portion 2, 3.
- the left side wall portions 4 and 5 and the right side wall portion 6 have the same closed cross-sectional structure as the final closed cross-sectional shape.
- the line length adjustment for forming the bending lines B2 to B5 at the boundary portions along the longitudinal direction of at least the bottom portions 2 and 3 and the left and right side wall portions 4, 5 and 6 of the flat work material 1 is performed. And performing a first step of performing press forming to give a bending guide line G to a position that becomes a bending line in the final closed cross-sectional shape of the bottom parts 2 and 3 and the left and right side wall parts 4, 5 and 6, After performing the second step of bending the bending line B4 in the direction in which the left side wall portions 4 and 5 and the right side wall portion 6 approach, the final end of the workpiece 1 formed in the second step is placed at the end.
- the plug 20 having the same outer peripheral shape as the closed cross-sectional shape is arranged, and the bottoms 2, 3 and the left and right side walls 4, 5, 6 are pressed against the outer periphery of the plug 20, with the bending guide line G as a boundary
- a closed cross-section structure is constructed by bending the left and right side walls 4, 5, and 6.
- the bottom 2, 3 and left and right side wall portions 4, 5, 6, can be formed into simple and high accuracy.
- the plug 20 having the same outer peripheral shape as the final closed cross-sectional shape is disposed at the end of the workpiece 1 in the longitudinal direction, and the bottom portions 2 and 3 and the left and right side wall portions 4, 5 and 6 are plugged 20.
- the bottom portions 2, 3 and the left and right side wall portions 4, 5, 6 are bent with the bending guide line G, which is a bending line in the final closed cross-sectional shape, as a boundary while being pressed against the outer periphery of the substrate.
- a closed cross-section structure having a curved shape can be formed with high accuracy.
- the plug 20 is disposed at the end of the workpiece 1 in the longitudinal direction, the plug 20 can be easily removed even after the closed cross-section structure is formed.
- the bending guide line G formed at the boundary between the bottom portions 2 and 3, the left side wall portions 4 and 5, the right side wall portion 6, and the pair of flange portions 7 and 8 is shown in FIG.
- the depth F of the groove 12 is 0.05 to 0.3 times the plate thickness T of the workpiece 1, and the groove width H of the groove 12 is 0.2 to 3.0 mm. .
- the depth F of the groove portion 12 of the bending guide line G is less than 0.05 times the plate thickness T of the workpiece 1, the depth F of the groove portion 12 is shallow, and therefore along the bending guide line G in the third step.
- the bottom portions 2 and 3 and the left and right side wall portions 4, 5 and 6 may not be bent.
- the depth F of the groove 12 exceeds 0.3 times the plate thickness T of the workpiece 1, the depth F of the groove 12 is deep. As a result, cracks or the like may occur.
- the groove width H of the groove portion 12 is less than 0.2 mm, the groove width H is narrow, so that the bottom portions 2 and 3 and the left and right side wall portions 4, 5, and 6 are formed along the bending guide line G in the third step. It may not be bent.
- the groove width H of the groove portion 12 exceeds 3.0 mm, the groove width H is wide, and depending on the material, there is a possibility that a crack or the like may occur at the bending guide line G in the third step.
- the bending guide wire G formed at the boundary between the bottom portions 2 and 3, the left side wall portions 4 and 5, the right side wall portion 6, and the pair of flange portions 7 and 8, as in this embodiment, F is not less than 0.05 times and not more than 0.3 times the plate thickness T of the workpiece 1, and the groove width H of the groove portion 12 is not less than 0.2 mm and not more than 3.0 mm.
- the bottom portions 2 and 3 and the left and right side wall portions 4, 5 and 6 can be bent and formed with high accuracy along G.
- the molding method of the present embodiment when employed, it is possible to easily manufacture an integrally molded product having a flange minimized for the purpose of reducing the weight in the automobile, home appliance, and other fields. Moreover, even a part having a curved surface on the side surface of the part can be molded with high dimensional accuracy.
- the method of forming the flat plate-like workpiece 1 of the present embodiment into a closed cross-section structure is not limited to the shape of the closed cross-section described above, and even when forming into various other shapes. Applicable.
- Example Here, in order to confirm the effect of this invention, a present Example and a comparative example are shown.
- the following materials are used as processing materials.
- Steel sheet used 980 MPa class cold rolled steel sheet Plate thickness: 1.6mm
- the above tensile properties are property values measured in accordance with JISZ2241 using JIS No. 5 test specimens taken from the vertical direction of rolling.
- FIG. 8 shows that in the first step, the bending guide lines G are placed on the bending lines B2 to B5 of the bottom parts 2, 3 and the left and right side wall parts 4, 5, 6 at positions where they become bending lines in the final closed cross-sectional shape.
- the bottom section 2, 3 and the left and right side wall sections 4, 5, 6 are bent without using a plug in the third step, and the pair of flange sections 7, 8 are fixed to form a closed cross section.
- the first step and the second step can be molded, but the third step cannot be molded. That is, the closed cross-section structure formed in FIG.
- FIG. 9 shows that in the first step, the bending guide lines G are not given to the bending lines B2 to B5 of the bottom portions 2, 3 and the left and right side wall portions 4, 5, 6, and the plug 20 is used in the third step.
- This is a comparative example 2 in which the bottom portions 2 and 3 and the left and right side wall portions 4, 5 and 6 are bent and a pair of flange portions 7 and 8 are fixed to form a closed cross-section structure.
- the first step and the second step can be molded, but the third step cannot be molded. That is, the closed cross-section structure molded in FIG.
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Abstract
Description
特許文献1に記載の技術は、金属平板(metal plate)をプレス成形(press forming)することで、断面平坦な連結部(connecting part)の両端から一対の閉断面構造体半部を立ち上がらせてなる半成品を製作する工程と、両閉断面構造体半部の間に挿入した偏平ポンチ(flat punch)により連結部を内側から押圧して断面V字状の屈曲部(bent part)に成形しながら両閉断面構造体半部を更に立ち上がらせる工程と、両閉断面構造体半部間から偏平ポンチを引き上げた後、両閉断面構造体半部の外端を相互に突き合わせて溶接する工程とを順次実行している。
このため、特許文献1の技術は、自動車構造部品、例えばフロントサイドメンバーなどに適用した場合に、成形性の点で課題がある。また仮にV字状屈曲部の先端にアールを付与したとすると、両閉断面構造体半部の立ち上がり量が小さくなり、次工程の溶接が困難となる。
そこで、本発明は、上記従来例の未解決の課題に着目してなされたものであり、例えば自動車構造部品として適用される3次元の曲がり形状を有する閉断面構造体を、高精度に成形でき、生産コストを低減して製造することができる閉断面構造体の成形方法及び閉断面構造体成形用の成形装置を提供することを目的としている。
[1]平板状の加工材を長手方向に延在する複数の曲げ線となる位置で曲げて、前記加工材の幅方向中央部側に形成される底部と、この底部の幅方向両側に位置する左右の側壁部とを備えた閉断面構造体に成形する方法であって、
プレス成形により、前記加工材に対して長手方向及び幅方向に最終の閉断面形状で要求される曲率形状に成形するとともに、最終の閉断面形状で曲げ線となる位置に曲げ誘導線を付与する第1工程と、
前記第1工程で成形した前記加工材に対し、前記底部を板厚方向からポンチとパッドで挟み込み、一対のダイスの間に前記ポンチを押し込むことで、前記左右の側壁部が近づく方向に曲げ成形する第2工程と、
前記第2工程で成形した前記加工材の前記底部の上に、前記最終の閉断面形状と同一外周形状のプラグを配置した状態で、前記底部及び前記左右の側壁部を前記プラグの外周に押し当てることで前記曲げ誘導線を境界として前記底部及び前記左右の側壁部を曲げ成形する第3工程と、
を有する閉断面構造体の成形方法。
[3]前記底部及び前記左右の側壁部が曲がりを有する形状となるように前記曲げ誘導線を付与する[1]又は[2]に記載の閉断面構造体の成形方法。
前記加工材に対して長手方向及び幅方向に最終の閉断面形状で要求される曲率形状に成形し、且つ最終の閉断面形状で曲げ線となる位置に曲げ誘導線を付与するように、前記平板状の加工材をプレス成形する上型及び下型を備えたプレス用金型と、
前記プレス用金型で成形した前記加工材に対し、前記底部を板厚方向からポンチとパッドで挟み込み、一対のダイスの間に前記ポンチを押し込むことで、前記左右の側壁部が近づく方向に曲げ成形する曲げ加工用金型と、
前記最終の閉断面形状と同一外周形状に形成され、前記曲げ加工用金型で成形した前記加工材の前記底部の上に配置されるプラグと、前記加工材の底部を支持する支持パッド及び前記プラグの幅方向外側に配置された一対の押圧カムとを備え、前記支持パッド及び前記一対の押圧カムで前記底部及び前記左右の側壁部を前記プラグの外周に押し当てることで前記曲げ誘導線を境界として前記底部及び前記左右の側壁部を曲げ成形する最終閉断面曲げ加工用金型と
を有する閉断面構造体に成形する装置。
また、[2]に記載の閉断面構造体の成形方法によると、第3工程で最終の閉断面形状に曲げ成形された加工材からプラグを容易に取り外すことができる。
また、[4]に記載の閉断面構造体の成形方法によると、底部及び左右の側壁部の境界部に形成した曲げ誘導線を、溝部の深さが加工材の板厚Tの0.05倍以上0.3倍以下であり、溝部の溝幅が0.2mm以上3.0mm以下としたことで、第3工程において曲げ誘導線に沿って底部及び左右の側壁部を高精度に曲げ成形することができる。
さらに、[5]に記載の閉断面構造体の成形装置によると、所定形状の閉断面構造体を容易に成形することができ、生産コストを大幅に低減することができる。
図1は、本発明に係る変則5角形状の閉断面形状を有する閉断面構造体を成形する途中の加工材1の形状を示すものである。前記加工材1は、変則5角形状の2辺を構成する底部2、3と、変則5角形状の2辺を構成する左側壁部4,5と、変則5角形状の残りの1辺を構成する右側壁部6と、右側壁部6及び左側壁部5に連続して形成され、互いに突き合わされる一対のフランジ部7,8とを有し、長手方向に延在している。
そして、底部2、3、左側壁部4,5、右側壁部6及びフランジ部7,8は、長手方向をY軸方向、幅方向をX軸方向及びY軸とX軸を含む面に直交した方向をZ軸方向とした三次元座標軸上において、Y軸方向、X軸方向及びZ軸方向に曲率を有した形状で(3次元の曲がり形状を有して)成形されている。
閉断面構造体を成形する成形装置は、加工材プレス用金型、曲げ加工用金型、及びヘミングプレス装置(最終閉断面曲げ加工用金型)で構成されている。
図2(b)は、加工材プレス用金型を示す図であり、上型10及び下型11で構成されている。
上型10の下方を向くプレス成形面及び下型11の上方を向くプレス成形面は、互いに倣った形状に形成されており、上型10及び下型11のプレス成形面の間に、図2(a)で示す平板状の加工材1を配置して下型11に向けて上型10を差し込むことで、プレス成形が行われる。
曲げ誘導線Gは、図3(b)に示すように、溝部12の深さFが加工材1の板厚Tの0.05倍以上0.3倍以下であり、溝部12の溝幅Hが0.2mm以上3.0mm以下となるように形成されている。
また、図4(a)は、曲げ加工用金型を示す図であり、第1ポンチ15、パッド16及び一対のダイス17で構成されている。
第1ポンチ15の押込部分の断面形状、つまり下端部の断面形状は、閉断面構造体の底部2、3と同一形状となっている。
一対のダイス17は、底部2、3の幅に応じた間隔を開けて対向する。
さらに、図5(a)は、ヘミングプレス装置(hemming press apparatus)を示す図であり、閉断面構造体の形状と同一外周形状(最終の閉断面形状)であるプラグ20と、プラグ20の上側に配置した第2ポンチ21と、プラグ20の下側に配置した支持パッド22と、プラグ20の幅方向外側に配置された一対の押圧カム(pressure cam)23,24とを備えている。
第2ポンチ21は、加工材1の長手方向と略同一長さの長尺部材であり、油圧アクチュエータ25の動作により上下方向に移動する。また、一対の押圧カム23,24も、加工材1の長手方向と略同一長さの長尺部材であり、油圧アクチュエータ(hydraulic actuator)25の動作に連動するカム駆動機構26が連結されている。そして、カム駆動機構26は、一対の押圧カム23,24をプラグ20に近接する押し込み位置まで移動させる、或いはプラグ20から離間する待機位置まで移動させる。
一方の押圧カム23のプラグ20に対向する押し込み面は、閉断面構造体の左側壁部4,5と同一形状の3次元の曲がり形状を有して形成されている。
そして、第2ポンチ21には、その下端面の幅方向中央にスリット溝27が形成されているとともに、スリット溝27の開口周縁に挿入ガイド面28が形成されている。
ここで、本発明に係る最終閉断面曲げ加工用金型が、プラグ20、支持パッド22及び一対の押圧カム23,24に相当し、本発明に係る第2工程及び曲げ加工用金型のポンチが第1ポンチ15に相当している。
次に、上記構成の加工材プレス用金型、曲げ加工用金型、及び閉断面・ヘミングプレス装置を使用した閉断面構造体の成形方法について説明する。
(第1工程)
図2(a)で示す平板状の加工材1を、図2(b)に示すように、加工材プレス用金型の上型10及び下型11のプレス成形面の間に配置し、下型11に向けて上型10を差し込むことでプレス成形を行う。
次に、図4(a)に示すように、上述したプレス成形後の加工材1の底部2,3を第1ポンチ15及びパッド16で挟み込んで挟持する。
続いて、第1ポンチ15及びパッド16で底部2,3を挟持した状態で、第1ポンチ15を一対のダイス17間に下死点まで差し込む。
そして、図4(b)に示すように、第1ポンチ15及びパッド16に挟み込まれた加工材1を一対のダイス17の間に押し込むことで、左側壁部4,5と右側壁部6とが近づく方向に曲げ線B4を境界として曲げ成形する。
次に、上述した曲げ成形した加工材1の長手方向の両端部にプラグ20を配置する。そして、図5(a)に示すように、プラグ20を長手方向の両端部に配置した加工材1の底部2,3を支持パッド22の支持面上に載せる。このとき、待機位置にある一対の押圧カム23,24の押し込み面は、加工材1の左側壁部5及び右側壁部6の外周に当接させておく。
そして、油圧アクチュエータ25の駆動により第2ポンチ21を最下点まで下降させていくと、加工材1の一対のフランジ部7,8の先端部が第2ポンチ21の挿入ガイド面28に沿ってスリット溝27側へ移動していく。
以上のように、平板状の加工材1の少なくとも底部2,3、左右の側壁部4,5,6の長手方向に沿った境界部位置にそれぞれ曲げ線B2~B5を形成する線長調整を行うとともに、これら底部2,3、左右の側壁部4,5,6の最終の閉断面形状で曲げ線となる位置に曲げ誘導線Gを付与するプレス成形を行う第1工程を行い、次いで、左側壁部4,5及び右側壁部6が近づく方向に曲げ線B4を曲げ成形する第2工程を行った後、この第2工程で形成した加工材1の長手方向の端部に、最終の閉断面形状と同一外周形状のプラグ20を配置し、底部2,3及び左右の側壁部4,5,6をプラグ20の外周に押し当てることで曲げ誘導線Gを境界として底部2,3及び左右の側壁部4,5,6を曲げ成形することで、閉断面構造体を構成する底部2,3及び左右の側壁部4,5,6を、簡単且つ高精度に成形することができる。
ここで、第1工程において、底部2,3、左側壁部4,5、右側壁部6、一対のフランジ部7,8の境界部に形成した曲げ誘導線Gは、図3(b)で示したように、溝部12の深さFが加工材1の板厚Tの0.05倍以上0.3倍以下であり、溝部12の溝幅Hが0.2mm以上3.0mm以下としている。
したがって、本実施形態のように、底部2,3、左側壁部4,5、右側壁部6、一対のフランジ部7,8の境界部に形成した曲げ誘導線Gを、溝部12の深さFが加工材1の板厚Tの0.05倍以上0.3倍以下であり、溝部12の溝幅Hが0.2mm以上3.0mm以下としたことで、第3工程において曲げ誘導線Gに沿って底部2,3及び左右の側壁部4,5,6を高精度に曲げ成形することができる。
ここで、本実施形態の平板状の加工材1を閉断面構造体に成形する方法は、閉断面の形状は上述したものに限定されず、他の色々な形状に成形する場合であっても適用可能である。
ここで、本発明の効果を確認するために、本実施例と比較例とを示す。
本実施例及び比較例は、次のような諸元の材料を加工材としている。
使用鋼板:980MPa級冷延鋼板(cold rolled steel sheet)
板厚:1.6mm
引張強度:1005MPa
降伏強度:680MPa
全伸び:17%
上記の引張特性は、圧延垂直方向から採取したJIS5号試験片を用いて、JISZ2241に準拠して測定した特性値である。
比較例1では、第1工程、第2工程は成形可能であるが、第3工程では、成形できない。つまり、この図8で成形された閉断面構造体は、底部2,3及び左右の側壁部4,5,6を内側から支持する部材(プラグ20)が存在しないので、底部2,3及び左右の側壁部4,5,6は曲げ誘導線Gを境界として曲げ成形されず、3次元の曲がり形状の閉断面構造体を高精度に成形することができない。
Claims (5)
- 平板状の加工材を長手方向に延在する複数の曲げ線となる位置で曲げて、前記加工材の幅方向中央部側に形成される底部と、この底部の幅方向両側に位置する左右の側壁部とを備えた閉断面構造体に成形する方法であって、
プレス成形により、前記加工材に対して長手方向及び幅方向に最終の閉断面形状で要求される曲率形状に成形するとともに、最終の閉断面形状で曲げ線となる位置に曲げ誘導線を付与する第1工程と、
前記第1工程で成形した前記加工材に対し、前記底部を板厚方向からポンチとパッドで挟み込み、一対のダイスの間に前記ポンチを押し込むことで、前記左右の側壁部が近づく方向に曲げ成形する第2工程と、
前記第2工程で成形した前記加工材の前記底部の上に、前記最終の閉断面形状と同一外周形状のプラグを配置した状態で、前記底部及び前記左右の側壁部を前記プラグの外周に押し当てることで前記曲げ誘導線を境界として前記底部及び前記左右の側壁部を曲げ成形する第3工程と、
を有する閉断面構造体の成形方法。 - 第3工程において、前記加工材の長手方向の端部における前記底部の上に、前記プラグを配置する請求項1記載の閉断面構造体の成形方法。
- 前記底部及び前記左右の側壁部が曲がりを有する形状となるように、前記曲げ誘導線を付与する請求項1又は2記載の閉断面構造体の成形方法。
- 前記曲げ誘導線は、前記加工材の一方の面に溝部が形成され、この溝部に対応する他方の面に凸部が形成された部位であり、前記溝部の深さが、板厚の0.05倍以上0.3倍以下であり、前記溝部の溝幅が、0.2mm以上3.0mm以下である請求項1乃至3の何れか1項に記載の閉断面構造体の成形方法。
- 平板状の加工材を長手方向に延在する複数の曲げ線となる位置で曲げ、前記加工材の幅方向中央部側に形成される底部と、この底部の幅方向両側に位置する左右の側壁部とを備えた閉断面構造体に成形する装置であって、
前記加工材に対して長手方向及び幅方向に最終の閉断面形状で要求される曲率形状に成形し、且つ最終の閉断面形状で曲げ線となる位置に曲げ誘導線を付与するように、前記平板状の加工材をプレス成形する上型及び下型を備えたプレス用金型と、
前記プレス用金型で成形した前記加工材に対し、前記底部を板厚方向からポンチとパッドで挟み込み、一対のダイスの間に前記ポンチを押し込むことで、前記左右の側壁部が近づく方向に曲げ成形する曲げ加工用金型と、
前記最終の閉断面形状と同一外周形状に形成され、前記曲げ加工用金型で成形した前記加工材の前記底部の上に配置されるプラグと、前記加工材の底部を支持する支持パッド及び前記プラグの幅方向外側に配置された一対の押圧カムとを備え、前記支持パッド及び前記一対の押圧カムで前記底部及び前記左右の側壁部を前記プラグの外周に押し当てることで前記曲げ誘導線を境界として前記底部及び前記左右の側壁部を曲げ成形する最終閉断面曲げ加工用金型と、
を有する閉断面構造体の成形装置。
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KR101644260B1 (ko) | 2016-07-29 |
US9862017B2 (en) | 2018-01-09 |
CN104349852A (zh) | 2015-02-11 |
KR20140148495A (ko) | 2014-12-31 |
US20180078993A1 (en) | 2018-03-22 |
CN104349852B (zh) | 2016-03-23 |
JP2013244512A (ja) | 2013-12-09 |
EP2857116A4 (en) | 2015-09-02 |
US10160031B2 (en) | 2018-12-25 |
JP5454619B2 (ja) | 2014-03-26 |
US20150165511A1 (en) | 2015-06-18 |
EP2857116B1 (en) | 2020-12-09 |
EP2857116A1 (en) | 2015-04-08 |
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