WO2015005285A1

WO2015005285A1 - Hollow operating lever and method for manufacturing same

Info

Publication number: WO2015005285A1
Application number: PCT/JP2014/068062
Authority: WO
Inventors: 宏樹福井; 昇外山; 正春石附; 豊黒井; 正樹上野
Original assignee: 株式会社ヨロズ
Priority date: 2013-07-08
Filing date: 2014-07-07
Publication date: 2015-01-15
Also published as: JP6139304B2; JP2015016474A

Abstract

To provide a hollow operating lever which has good operability and can be easily manufactured, a hollow operating lever (4) has a hollow shape by being formed by joining ends (W1, W2) of a material to be worked (W) that is a flat plate to each other, also has a bent shape bent as viewed from a crossing direction crossing a joint surface of a joint portion (31) formed by joining the ends to each other, and is rotatable with respect to a support shaft (3), the hollow operating lever being characterized by comprising a first wall (10) which is provided on the recessed side of the bent shape and located on the operating surface side on which rotation force (F) for rotation acts, a pair of second walls (20) in which holes (21) through which the support shaft is inserted are coaxially provided and which are bent from and continuous with both ends of the first wall, a third wall (30) which is provided to face the first wall and connects the pair of second walls via the joint portion, and a dent (13) which is provided in a bent portion (12) of the bent shape of the first wall and dented along a direction from the first wall to the third wall.

Description

Hollow control lever and manufacturing method thereof

The present invention relates to a hollow operation lever and a manufacturing method thereof.

As a method of manufacturing a curved vehicle hollow control lever such as a vehicle brake pedal, for example, there is a manufacturing method disclosed in Patent Document 1. In this method, a pair of halved members connected via a connecting portion are press-formed by bending the connecting portion, both flange portions provided on the halved member are brought into contact with each other, hemming is performed, The flange portion is joined. According to this method, since both flange parts can be connected without welding, a brake pedal for a vehicle without a welded part can be manufactured.

JP 2010-247757 A

However, the arm part for a vehicle manufactured by the manufacturing method described in Patent Document 1 is a joint in which both flange portions are coupled to the operation surface side on which the turning force for rotating is applied on the rear side of the vehicle. There is a possibility that the operability is hindered by the joint. For this reason, it is necessary to cover the joint portion with a cover or to perform additional processing to such an extent that the operability is not hindered, resulting in an increase in manufacturing cost and a complicated manufacturing process. In addition, by arranging the joint on the side of the vehicle, it is possible to arrange without a protrusion on the rear side of the vehicle, but in this case, the operability when changing the pedal may be hindered. It is not appropriate because of its nature.

Also, in the manufacturing method described in Patent Document 1, an arm part having a bent shape is formed by press-molding a half member in which a bent shape is previously formed. For this reason, when hemming is performed on the portion where the bent shape is formed, there is a possibility that a portion where the material does not stretch sufficiently is generated. As a countermeasure, for example, there is a method in which a slit is formed in advance at a portion where the bent shape of the half member is formed, and bonding is performed after press molding. As described above, in the manufacturing method described in Patent Document 1, it is not easy to form a bent shape in the arm component.

The present invention has been made to solve the problems associated with the above-described prior art, and an object thereof is to provide a hollow operation lever that is easy to manufacture and easy to manufacture, and a method for manufacturing the same. Moreover, it aims at providing the manufacturing method of the hollow operation lever which can form a bending shape easily.

The above object is achieved by the inventions described in (1) to (7) below.

(1) From the crossing direction which intersects with the joint surface of the joined part where the above-mentioned end parts were joined while having a hollow shape by joining and forming the end parts of the work pieces which are flat plates A hollow operation lever that has a bent shape that is bent when viewed and is rotatable with respect to the support shaft, and is provided on the concave side of the bent shape and is on the operation surface side on which a turning force is applied for rotation. A first wall, a hole through which the support shaft is inserted are provided coaxially, a pair of second walls that are bent and continuous at both ends of the first wall, and facing the first wall A third wall that connects the pair of second walls via the joint, and a bent portion of the bent shape in the first wall, from the first wall to the third wall. A hollow operating lever having a recess recessed along the direction toward the wall.

(2) The above (1) further including a ridge line portion extending in a direction intersecting the support axis of the first wall and bulging along a direction from the third wall toward the first wall. ).

(3) The hollow operation lever according to (1) or (2), wherein the end portions are joined to each other by hemming joining or welding joining in the joining portion.

(4) The hollow operation lever according to any one of (1) to (3), which is used for a vehicle operation pedal.

(5) By pressing a workpiece, which is a flat plate extending in a first plane formed by a first direction and a second direction orthogonal to the first direction, in stages using a plurality of molds, A hollow operating lever manufacturing method for manufacturing a hollow operating lever having a hollow shape and having a bent shape as viewed from the first direction and capable of rotating with respect to a support shaft. In the second plane formed by one direction and the third direction, the extruded material is extruded along the third direction and formed in the second direction, and is connected to both ends of the extruded portion while forming an extruded portion extending in the second direction. And an extension portion extending in a direction opposite to the direction in which the push-out portion is pushed out, and a direction in which the push-out portion of the extension portion is connected to opposite ends of the extension portion and connected to both ends in the first direction. An extruding step for forming an extending collar, and the second In the surface, a protruding portion that protrudes in the direction opposite to the direction in which the extruded portion is pushed out is formed near the center of the extruded portion, and between the extruded portion and the extended portion, and the extended portion and the flange portion. While maintaining the bending, the pushing portion, the extending portion, and the flange portion are bent in the direction opposite to the direction in which the pushing portion is pushed out, with the connecting portion that connects the protruding portion and the pushing portion as the center. In the projecting step, and in the second plane, the projecting portion, the pushing portion, the pushing portion, the extending portion, and the bending portion, while maintaining the bend between the extending portion and the flange portion, A rough forming step of further bending the extruded portion, the extending portion, and the flange portion in the direction opposite to the direction in which the extruded portion is extruded, with the connecting portion as a center, by pressing the extruded portion in the extruded direction. And in the second plane While maintaining the bend between the extruding part and the extending part and the extending part and the flange part, the extruding part is bent so as to be substantially parallel to the direction in which the extruding part is extruded, An abutting step for abutting portions, a joining step for joining the flanges, a hole forming step for forming a hole through which the support shaft is coaxially inserted in both of the extruding portions, and the first In the third plane formed by the two directions and the third direction, the projecting portion is formed with a recess that is recessed in a direction opposite to the direction in which the pushing portion is pushed out, and the extending portion with the bent portion having the bent shape as a center. And a bending step of bending both end portions in the direction in which the extruded portion is pushed out.

(6) Between the rough forming step and the abutting step, in the second plane, the protruding portion is bulged in the direction in which the extruded portion is pushed out to form a ridge line portion, and the flange portions are It is a manufacturing method of the hollow operation lever as described in said (5) which further has the swelling process which approaches.

(7) The method for manufacturing a hollow operation lever according to (5) or (6), wherein in the joining step, the flanges are joined together by hemming joining or welding joining.

According to the invention described in (1) above, since the first wall provided on the concave side of the bent shape is the operation surface side on which the rotational force is applied, there is no joint on the operation surface side, and the operation A hollow control lever with good characteristics can be provided.

According to the invention described in (2) above, the ridge line portion bulges along the direction from the third wall toward the first wall along the direction intersecting the support axis of the first wall. , The strength against rotational power is improved.

According to the invention described in (3) above, since the end portions are joined to each other by hemming joining or welding joining in the joining portion, the end portions of the workpieces can be joined easily and reliably. .

According to the invention described in (4) above, since the hollow operation lever described in (1) to (3) is used for the vehicle operation pedal, there is no joint on the operation surface side of the vehicle operation pedal. It is possible to provide a vehicular operation pedal with good operability.

According to the invention described in (5) above, since the projecting portion is on the operation surface side on which the rotational force is applied, there is no joint on the operation surface side, so that the hollow operation is easy and easy to manufacture. A method for manufacturing a lever can be provided. Moreover, in order to bend the both ends of the extending part around the bent part of the bent shape in the direction of pushing the extruded part, while forming a dent recessed along the direction opposite to the direction of pushing the extruded part to the protruding part, A bent shape can be easily formed without causing a portion where the material is not sufficiently stretched.

According to the invention described in (6) above, since the ridge line portion is formed in the protruding portion, the strength against the rotational force is improved.

According to the invention described in (7) above, since the flanges are joined to each other by hemming or welding in the joining step, the collars of the workpieces can be easily joined.

It is a schematic side view showing an example of a brake pedal device according to an embodiment of the present invention. It is a perspective view which shows the brake pedal which concerns on this embodiment. It is a perspective view which shows the workpiece which is a flat plate before the press work of the brake pedal which concerns on this embodiment. It is sectional drawing orthogonal to the Y-axis which shows the extrusion process of the manufacturing method of the brake pedal which concerns on this embodiment. It is sectional drawing orthogonal to the Y-axis which shows the protrusion process of the manufacturing method of the brake pedal which concerns on this embodiment. It is sectional drawing orthogonal to the Y-axis which shows the rough forming process of the manufacture direction of the brake pedal which concerns on this embodiment. It is sectional drawing orthogonal to the Y-axis which shows the bulging process of the manufacturing method of the brake pedal which concerns on this embodiment. It is sectional drawing orthogonal to the Y-axis which shows the contact process of the manufacturing method of the brake pedal which concerns on this embodiment. It is sectional drawing orthogonal to the Y-axis which shows the joining process of the manufacturing method of the brake pedal which concerns on this embodiment. It is a perspective view which shows the to-be-processed material after completion | finish of a hole formation process. It is sectional drawing orthogonal to the X-axis which shows the bending process of the manufacturing method of the brake pedal which concerns on this embodiment. It is sectional drawing which follows the AA line of FIG.

Embodiments of the present invention will be described with reference to the drawings. In this embodiment, the plane on which the flat plate is arranged is the XY plane (first plane), the direction in which the flat plate extends perpendicular to the X direction (first direction) is the Y direction (second direction), and the XY plane. The vertical direction is defined as the Z direction (third direction).

As a hollow operation lever according to the present embodiment, for example, there is a brake pedal used in a brake pedal device. As shown in FIG. 1, the brake pedal device generally includes a bracket 2 attached to a dash panel 1, a brake pedal 4 rotatably attached to a support shaft 3 provided on the bracket 2, and a brake pedal 4. A penetrating pin 5 penetrating through the upper part, a rod 6 having one end connected to the pin 5 and the other end connected to a master back (not shown), and a footboard 7 attached to the lower part of the brake pedal 4, have.

As shown in FIG. 2, the brake pedal 4 is formed by joining the end portions W1 and W2 of the workpiece W, which is a flat plate, to each other, so that the end portions W1 and W2 are joined to each other while having a hollow shape. The bent portion 31 is bent when viewed from the X direction (crossing direction) intersecting the bonding surface (YZ plane) of the bonding portion 31, and is provided so as to be rotatable with respect to the support shaft 3.

Further, the brake pedal 4 is provided on the concave side of the bent shape, and the first wall 10 which is the operation surface side on which the rotational force F for rotating is applied and the hole portion 21 through which the support shaft 3 is inserted are coaxial. A pair of second walls 20 which are provided on and bent at both ends of the first wall 10 and are continuous, and a pair of second walls which are provided to face the first wall 10 and are connected to each other via the joint portion 31. And a third wall 30 connecting the two. The brake pedal 4 further includes a recess 13 provided in the bent portion 12 of the bent shape in the first wall 10 and recessed along the direction from the first wall 10 toward the third wall 30.

The brake pedal 4 further includes a ridge 11 that extends in a direction intersecting the support shaft 3 of the first wall 10 and bulges along the direction from the third wall 30 toward the first wall 10. .

Further, the end portions W1 and W2 are joined to each other by hemming joining at the joining portion 31.

Next, a method for manufacturing the hollow operation lever according to this embodiment will be described. Here, the manufacturing method of the brake pedal 4 is demonstrated as an example of a hollow operation lever. In general, the brake pedal 4 is formed by pressing a workpiece W, which is a flat plate extending in an XY plane formed by an X direction and a Y direction orthogonal to the X direction, in stages using a plurality of molds. Manufactured. Details will be described below.

FIG. 3 is a perspective view showing a workpiece W that is a flat plate before press working of the brake pedal 4 according to the present embodiment.

First, in the XZ plane (second plane) formed by the X direction and the Z direction, both ends of the extrusion part P are formed while forming the extrusion part P that is extruded along the Z direction downward and extends in the Y direction on the workpiece W. An extension part E that is connected to the part and extends upward in the Z direction, and an extension part E that is connected to both ends opposite to the side where the extrusion part P of the extension part E is connected and extends away from each other in the X direction. Part T is formed (extrusion process).

FIG. 4 is a cross-sectional view perpendicular to the Y axis showing the extrusion process of the method for manufacturing the brake pedal 4 according to the present embodiment.

The workpiece W, which is a flat plate, is extruded downward in the Z direction by the first molding die 80 as shown in FIG. The first molding die 80 includes a first upper die 81, a first lower die 82 provided to face the first upper die 81, and a blank holder 83. The first upper mold 81 has a convex portion 84 that protrudes toward the first lower mold 82. The first lower mold 82 has a recessed groove 85 corresponding to the convex portion 84 of the first upper mold 81. The blank holder 83 is provided on the outer periphery of the first upper mold 81.

In the extrusion process, first, the workpiece W is installed in the first mold 80, and the first lower mold 82 and the blank holder 83 are brought close to each other while the first upper mold 81 is separated from the first lower mold 82, The workpiece W is sandwiched between the first lower mold 82 and the blank holder 83. Thereafter, the first upper mold 81 is brought close to the first lower mold 82. As a result, an extruded portion P that is extruded along the Z-direction downward and extends in the Y-direction to the workpiece W is formed, and an extended portion E that is connected to both ends of the extruded portion P and extends upward in the Z-direction. And the collar part T extended in the direction which mutually separates in the X direction is connected with the both ends on the opposite side to the side where the extrusion part P of the extension part E is connected. In order to perform hemming bonding in a bonding process described later, the first flange T1 provided on the right side in the X direction is formed shorter than the second flange T2 provided on the left side in the X direction.

In this extruding process, since the workpiece W is sandwiched between the first lower mold 82 and the blank holder 83, the unevenness of the inflow of the workpiece W is suppressed, and the generation of wrinkles and the like can be prevented.

Next, in the XZ plane, a protrusion S protruding upward in the Z direction is formed in the vicinity of the center of the extrusion portion P, and bending between the extrusion portion P and the extension portion E, and the extension portion E and the flange portion T is performed. The extrusion part P, the extension part E, and the collar part T are bent upward in the Z direction with the connection part C connecting the protrusion part S and the extrusion part P as the center (maintenance process).

FIG. 5 is a cross-sectional view orthogonal to the Y axis showing the protruding step of the method for manufacturing the brake pedal 4 according to the present embodiment.

As shown in FIG. 5, the workpiece W on which the extruded portion P, the extending portion E, and the flange portion T are formed in the extrusion process has a protruding portion S formed by the second mold 90. The second molding die 90 includes a second upper die 91 and a second lower die 92 provided to face the second upper die 91. The second upper mold 91 has a convex portion 93 that protrudes toward the second lower mold 92. The lower surface 93a of the convex portion 93 and the upper surface 92a of the second lower mold 92 have a shape corresponding to the protruding portion S. Further, the lower surface 93a of the convex portion 93 and the upper surface 92a of the second lower mold 92 have inclined

portions

93b and 92b on the X direction outer side of the shape corresponding to the protruding portion S, respectively.

In the protruding step, the workpiece W is first installed in the second mold 90, and the second upper mold 91 and the second lower mold 92 are brought close to each other. Thus, a protruding portion S that protrudes upward in the Z direction is formed in the vicinity of the center in the X direction of the extruded portion P. Moreover, while the connection part C which connects the protrusion part S and the extrusion part P is formed by the

inclination parts

93b and 92b, the extrusion part P, the extension part E, and the collar part T are Z direction centering | focusing on the connection part C. It is bent upward.

Next, in the XZ plane, the protrusion S is directed downward in the Z direction while maintaining the bending between the protrusion S and the extrusion part P, the extrusion part P and the extension part E, and the extension part E and the flange part T. By pressing, the extruded portion P, the extending portion E, and the flange portion T are further bent upward in the Z direction centering on the connecting portion C (rough forming step).

FIG. 6 is a cross-sectional view orthogonal to the Y axis showing the rough forming step of the method for manufacturing the brake pedal 4 according to the present embodiment.

As shown in FIG. 6, the workpiece W on which the projecting portion S is formed in the projecting step is formed by the third molding die 100 so that the extruded portion P, the extending portion E, and the flange portion T are centered on the connecting portion C. It is further bent upward in the Z direction. The third mold 100 includes a third upper mold 101 and a third lower mold 102 provided to face the third upper mold 101. The third upper mold 101 has a convex portion 103 that protrudes toward the third lower mold 102. The lower surface 103a of the convex portion 103 and the upper surface 102a of the third lower mold 102 are provided substantially parallel to the X direction. Further, the width of the convex portion 103 in the X direction is formed smaller than the width between the portions where the extending portion E and the flange portion T are connected.

In the rough molding process, first, the workpiece W is arranged in the third molding die 100 so that the connecting portion C contacts the third lower die 102, and the third upper die 101 and the third lower die 102 are brought close to each other. . As a result, the protruding portion S protruding upward in the Z direction in the protruding step becomes a flat surface. And while the bending part between the protrusion part S and the extrusion part P and the extrusion part P and the extension part E and the extension part E and the collar part T is maintained, the extrusion part P, the extension part E, and the collar part T are: It is further bent upward in the Z direction around the connecting portion C.

Next, in the XZ plane, the protruding portion S is bulged downward in the Z direction to form the ridge line portion 11, and the flange portions T are brought closer to each other (bulging step).

FIG. 7 is a cross-sectional view orthogonal to the Y axis showing the bulging process of the method for manufacturing the brake pedal 4 according to the present embodiment.

In the rough molding step, the workpiece W in which the extruded portion P, the extending portion E, and the flange portion T are further bent upward in the Z direction with the connecting portion C as the center is, as shown in FIG. By 110, the ridge line portion 11 is formed. The fourth mold 110 includes a fourth upper mold 111 and a fourth lower mold 112 provided to face the fourth upper mold 111. The fourth upper mold 111 has a protrusion 113 that protrudes toward the fourth lower mold 112. The lower surface 113 a of the convex portion 113 and the upper surface 112 a of the second lower mold 112 have a shape corresponding to the ridge line portion 11. Moreover, the convex part 113 is longer than the convex part 103 of the 3rd shaping | molding die 100 in a press direction, and the width | variety of a X direction is narrowly formed. The width of the convex portion 113 in the X direction is smaller than the width between the portions where the extending portion E and the flange portion T are connected.

In the bulging process, the workpiece W is first installed in the fourth mold 110, and the fourth upper mold 111 and the fourth lower mold 112 are brought close to each other. Thereby, the ridge line part 11 bulging downward in the Z direction is formed on the projecting part S that has become a flat surface in the rough forming step. At this time, the protrusions S, the extrusion parts P, the extrusion parts P, the extension parts E, the extension parts E, and the flange parts T are maintained, and the flange parts T approach each other.

Next, in the XZ plane, the extrusion portion P is bent so as to be substantially parallel to the X direction while maintaining the bending between the extrusion portion P and the extension portion E and the extension portion E and the flange portion T. The parts T are brought into contact with each other (contact process).

FIG. 8 is a cross-sectional view perpendicular to the Y axis showing the contact step of the method for manufacturing the brake pedal 4 according to the present embodiment.

As shown in FIG. 8, the workpiece W on which the ridge line portion 11 is formed in the bulging process is rotated 90 degrees counterclockwise, and the fifth molding die 120 causes the extruded portion P to be substantially parallel to the X direction. The ridges T are brought into contact with each other. The fifth mold 120 includes a fifth upper mold 121 and a fifth lower mold 122 provided to face the fifth upper mold 121. The fifth upper mold 121 includes a first groove portion 123 for bending the extruded portion P so as to be substantially parallel to the X direction and a second groove portion 124 for avoiding interference with the flange portion T. Similar to the fifth upper mold 121, the fifth lower mold 122 has a first groove part 125 and a second groove part 126.

In the abutting step, first, the workpiece W rotated 90 degrees counterclockwise is installed in the fifth mold 120, and the fifth upper mold 121 and the fifth lower mold 122 are brought close to each other. As a result, the first groove 123 of the fifth upper mold 121 presses the extruded portion P downward in the Z direction, the first groove 125 of the fifth lower mold 122 presses the extruded portion P upward in the Z direction, and the extruded portion P It is bent so as to be substantially parallel to the X direction. Moreover, at this time, the bending part T contacts | abuts, maintaining the bending between the extrusion part P and the extension part E, the extension part E, and the collar part T. FIG.

Next, the contacted flanges T are joined by hemming joining (joining process).

FIG. 9 is a cross-sectional view perpendicular to the Y-axis showing the joining process of the method for manufacturing a brake pedal according to the present embodiment.

As shown in FIG. 9, the workpiece W in which the flange portions T are in contact with each other in the contact step is hemmed and joined stepwise by a sixth mold (not shown).

In the abutting step, the second collar T2 is hemmed and joined so as to cover the first collar T1 formed shorter than the second collar T2.

Next, a hole 21 through which the support shaft 3 is inserted is formed coaxially on both sides of the extruded portion P by flow drilling (hole forming step). In addition, the formation method of the hole part 21 is not restricted to a flow drill process, A press work etc. may be sufficient.

FIG. 10 is a perspective view showing the workpiece W after completion of the hole forming step.

The workpiece W in which the flanges T are hemmed and joined in the abutting step, the support shaft 3 is coaxially disposed on both sides of the extrusion part P as shown in FIG. 10 by a flow drilling machine (not shown). A hole 21 to be inserted is formed.

Next, in the YZ plane (third plane), a recess 13 is formed in the projecting portion S so as to be depressed downward in the Z direction, and both end portions of the extending portion E are bent upward in the Z direction with the bent portion 12 as a center. (Bending process).

FIG. 11 is a cross-sectional view orthogonal to the X axis showing the bending process of the method for manufacturing the brake pedal 4 according to the present embodiment. 12 is a cross-sectional view taken along line AA in FIG.

The workpiece W in which the hole 21 is formed in the hole forming step is turned upside down as shown in FIGS. 11 and 12, and the seventh forming die 130 extends the Y of the extending portion E around the bent portion 12. Both ends of the direction are bent upward in the Z direction. The seventh molding die 130 includes a seventh upper die 131 and a pair of seventh lower portions 132 provided to face the seventh upper die 131. The seventh upper mold 131 includes a convex portion 133 having a shape corresponding to the recess 13 and a holding portion 134 for holding the width dimension L in the X direction when both ends of the extending portion E are bent. . The pair of seventh lower molds 132 are arranged in directions away from each other from the vicinity of the center in the Y direction, and are provided so as to be rotatable.

In the bending process, first, the workpiece W that is turned upside down is installed in the seventh mold 130, and the seventh upper mold 131 so that the convex portion 133 is in contact with the vicinity of the center of the workpiece W in the Y direction. And the seventh lower mold 132 are brought close to each other. Accordingly, the seventh lower mold 132 is rotated upward in the Z direction together with the proximity of the seventh upper mold 131 and the seventh lower mold 132. Therefore, a recess 13 is formed in the projecting portion S so as to be depressed downward in the Z direction while the width dimension L in the X direction is maintained, and at the same time, both end portions of the extending portion E are bent upward in the Z direction with the bent portion 12 as a center. Is done.

The brake pedal 4 is manufactured through the above processes.

In addition, the extrusion part P, the extension part E, the protrusion part S, and the collar parts T1 and T2 which were demonstrated in the manufacturing method are respectively a pair of 2nd wall 20, 3rd wall 30, and 1st wall demonstrated in embodiment. 10 corresponds to the end portions W1 and W2.

As described above, the brake pedal 4 according to the present embodiment has the hollow portion while joining the end portions W1, W2 of the workpiece W, which is a flat plate, to form the end portions W1, W1. It is provided with a bent shape as viewed from the X direction intersecting the YZ plane where W2 are joined, and is rotatable with respect to the support shaft 3. Further, the brake pedal 4 is provided on the concave side of the bent shape, and the first wall 10 which is the operation surface side on which the rotational force F for rotating is applied and the hole portion 21 through which the support shaft 3 is inserted are coaxial. A pair of second walls 20 that are bent and continuous at both ends of the first wall 10, and a pair of second walls 20 that are provided to face the first wall 10 and that are connected to each other via the joint portion 31. And a third wall 30 connecting the two. The brake pedal 4 further includes a recess 13 provided in the bent portion 12 of the bent shape in the first wall 10 and recessed along the direction from the first wall 10 toward the third wall 30. For this reason, the junction part 31 does not exist in the operation surface side, and the brake pedal 4 with sufficient operativity can be provided.

Further, the first wall 10 further includes a ridge portion 11 that extends in a direction intersecting the support shaft 3 and bulges along the direction from the third wall 30 toward the first wall 10. For this reason, the strength against the rotational force F is improved.

Further, in the joint portion 31, the end portions W1, W2 are joined to each other by hemming joining. For this reason, end part W1, W2 of the workpiece W can be joined easily and reliably.

Further, as described above, the method for manufacturing the brake pedal 4 according to the present embodiment uses a plurality of molds to form the workpiece W, which is a flat plate extending in the XY plane formed by the X direction and the Y direction. This is a manufacturing method of the brake pedal 4 for manufacturing the brake pedal 4 having a hollow shape and a bent shape as viewed from the X direction by pressing in stages. In the XZ plane, the manufacturing method of the brake pedal 4 according to the present embodiment forms both the end portions of the extrusion portion P while forming the extrusion portions P that are extruded along the Z direction downward and extend in the Y direction on the workpiece W. And an extending portion E that extends upward in the Z direction, and a flange portion that is connected to both ends of the extending portion E opposite to the side to which the extruded portion P is connected and extends away from each other in the X direction. An extrusion process for forming T. In the XZ plane, the manufacturing method of the brake pedal 4 according to the present embodiment further forms a protruding portion S that protrudes upward in the Z direction in the vicinity of the center of the protruding portion P, and the protruding portion P, the extending portion E, and the extending portion. While maintaining the bend between the portion E and the flange portion T, the extrusion portion P, the extension portion E, and the flange portion T are directed upward in the Z direction with the connection portion C connecting the protrusion S and the extrusion portion P as the center. A projecting step of bending the The manufacturing method of the brake pedal 4 according to the present embodiment further maintains the bending between the protruding portion S and the pushing portion P, the pushing portion P and the extending portion E, and the extending portion E and the flange portion T in the XZ plane. On the other hand, by pressing the protruding portion S downward in the Z direction, there is a rough forming step in which the extruded portion P, the extending portion E, and the flange portion T are further bent upward in the Z direction around the connecting portion C. In the XZ plane, the manufacturing method of the brake pedal 4 according to the present embodiment further maintains the bending between the extrusion portion P and the extension portion E, and the extension portion E and the flange portion T, while the extrusion portion P is moved in the Z direction. And a contact step in which the flange portions T are contacted with each other and a joining step in which the flange portions T are hemmed to each other. The method for manufacturing the brake pedal 4 according to the present embodiment further includes a hole forming process for forming the hole 21 through which the support shaft 3 is inserted coaxially by flow drilling in both of the extrusion parts P. In the method for manufacturing the brake pedal 4 according to the present embodiment, the recesses 13 that are recessed downward in the Z direction are formed in the projecting portion S in the YZ plane, and both end portions of the extending portion E around the bent portion 12 are formed. Has a bending step of bending upward in the Z direction. For this reason, by making the protrusion part S into the operation surface side on which the rotational force F acts, the junction part 31 does not exist in the operation surface side. Therefore, the manufacturing method of the brake pedal 4 with easy operability and easy manufacture can be provided. Further, in the bending process, the recess 13 is formed in the projecting portion S so as to be recessed downward in the Z direction, and both ends of the extending portion E are bent upward in the Z direction around the bent portion 12 having a bent shape. It is possible to easily form a bent shape without producing a portion lacking.

In addition, between the rough forming step and the contact step, the protruding portion S bulges downward in the Z direction on the XZ plane to form the ridge line portion 11 and further includes a bulging step for bringing the flange portions T closer to each other. For this reason, the strength against the rotational force F is improved.

Also, in the joining process, the flanges T are joined together by hemming joining. For this reason, the collar parts T of the workpiece W can be easily and reliably joined.

Note that the present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims.

For example, in the joining process, the flanges T are joined by hemming joining, but may be joined by welding joining. According to this structure, the brake pedal 4 with higher strength can be provided.

Further, although the hole forming process is performed after the joining process is completed, it may be performed after the bending process is completed.

In this embodiment, the brake pedal 4 is used. However, the present invention is also applicable to a vehicular part having a long arm shape such as a clutch pedal arm.

Furthermore, this application is based on Japanese Patent Application No. 2013-143023 filed on July 8, 2013, the disclosures of which are referenced and incorporated as a whole.

10 first wall,
11 Ridge part,
12 bends,
13 Recess,
20 a pair of second walls,
21 hole,
30 third wall,
31 joints,
4 Brake pedal,
80, 90, 100, 110, 120, 130 Mold,
C connecting part,
E extension,
F power,
P extrusion section,
S protrusion,
T, T1, T2 buttocks,
W Work material,
W1, W2 end.

Claims

By bending and joining the end portions of the workpieces that are flat plates, they have a hollow shape and are bent when viewed from the intersecting direction intersecting the joining surface of the joining portion where the end portions are joined together A hollow operation lever having a bent shape and rotatable with respect to the support shaft,
A first wall which is provided on the concave side of the bent shape and which is an operation surface side on which a rotational force for rotating is applied;
A hole portion through which the support shaft is inserted is provided coaxially, and a pair of second walls that are bent and continuous at both ends of the first wall;
A third wall provided opposite to the first wall and connecting the pair of second walls via the joint;
A hollow control lever provided at a bent portion of the bent shape in the first wall and having a recess recessed in a direction from the first wall toward the third wall.
2. The ridge line portion according to claim 1, further comprising a ridge line portion that extends in a direction intersecting the support shaft of the first wall and bulges along a direction from the third wall toward the first wall. Hollow operation lever.
The hollow operation lever according to claim 1 or 2, wherein the end portions are joined to each other by hemming joining or welding joining in the joining portion.
The hollow operation lever according to any one of claims 1 to 3, which is used for a vehicle operation pedal.
By pressing a workpiece, which is a flat plate extending in a first plane formed by a first direction and a second direction orthogonal to the first direction, in a stepwise manner using a plurality of molds, a hollow shape is formed. A hollow operating lever manufacturing method for manufacturing a hollow operating lever that has a bent shape as viewed from the first direction and has a bending shape that is rotatable with respect to a support shaft,
In the second plane formed by the first direction and the third direction, both end portions of the extruded portion are formed on the workpiece while forming extruded portions that are extruded along the third direction and extend in the second direction. Are connected to both ends of the extension portion opposite to the side to which the extrusion portion is connected and separated from each other in the first direction. An extrusion process for forming a flange extending in the direction;
In the second plane, a protruding portion that protrudes in a direction opposite to the direction in which the extruded portion is extruded is formed near the center of the extruded portion, and the extruded portion, the extended portion, the extended portion, and the flange portion Centering on the connecting portion that connects the protruding portion and the pushing portion while maintaining the bending between the pushing portion, the extending portion, and the flange portion in the direction opposite to the direction in which the pushing portion is pushed out. Projecting process to bend
In the second plane, the protrusion is pushed out from the protrusion while the bending between the protrusion and the push-out part, the push-out part and the extension part, and the extension part and the flange part is maintained. A rough molding step of further bending the extruded portion, the extending portion, and the flange portion in a direction opposite to the direction in which the extruded portion is pushed, by pressing the extruded portion, the extending portion, and the collar portion,
In the second plane, the pushing portion is substantially parallel to the direction in which the pushing portion is pushed out while maintaining the bending between the pushing portion, the extending portion, and the extending portion and the flange portion. A contact step of bending the flanges to contact each other,
A joining step for joining the flanges;
A hole forming step for forming a hole through which the support shaft is inserted coaxially with both of the extruding parts;
In the third plane formed by the second direction and the third direction, a recess is formed in the projecting portion along a direction opposite to the direction in which the push-out portion is pushed out, and the extension centering on the bent portion of the bent shape. A bending step of bending both ends of the existing portion in a direction in which the pushing portion is pushed out.
During the rough forming step and the abutting step, in the second plane, the protruding portion is bulged in the direction in which the extruded portion is pushed out to form a ridge line portion, and a bulge that brings the flange portions closer to each other. The manufacturing method of the hollow operation lever of Claim 5 which further has a taking-out process.
The method for manufacturing a hollow operation lever according to claim 5 or 6, wherein, in the joining step, the flanges are joined together by hemming joining or welding joining.