WO2016043280A1 - 成形品の製造方法、金型、及び管状成形品 - Google Patents
成形品の製造方法、金型、及び管状成形品 Download PDFInfo
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- WO2016043280A1 WO2016043280A1 PCT/JP2015/076535 JP2015076535W WO2016043280A1 WO 2016043280 A1 WO2016043280 A1 WO 2016043280A1 JP 2015076535 W JP2015076535 W JP 2015076535W WO 2016043280 A1 WO2016043280 A1 WO 2016043280A1
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- molded product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/065—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes starting from a specific blank, e.g. tailored blank
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/08—Making tubes with welded or soldered seams
- B21C37/0803—Making tubes with welded or soldered seams the tubes having a special shape, e.g. polygonal tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/08—Making tubes with welded or soldered seams
- B21C37/0815—Making tubes with welded or soldered seams without continuous longitudinal movement of the sheet during the bending operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/15—Making tubes of special shape; Making tube fittings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/15—Making tubes of special shape; Making tube fittings
- B21C37/155—Making tubes with non circular section
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/15—Making tubes of special shape; Making tube fittings
- B21C37/16—Making tubes with varying diameter in longitudinal direction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/15—Making tubes of special shape; Making tube fittings
- B21C37/16—Making tubes with varying diameter in longitudinal direction
- B21C37/18—Making tubes with varying diameter in longitudinal direction conical tubes
- B21C37/185—Making tubes with varying diameter in longitudinal direction conical tubes starting from sheet material
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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
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
-
- 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
- B21D7/00—Bending rods, profiles, or tubes
- B21D7/06—Bending rods, profiles, or tubes in press brakes or between rams and anvils or abutments; Pliers with forming dies
Definitions
- the present invention relates to a method of manufacturing a molded product using a metal plate, a mold used in the manufacturing method, and a tubular molded product manufactured by the manufacturing method.
- Japanese Patent Laid-Open No. 58-32010 discloses a technique for forming a straight steel pipe by sequentially performing C press, U press and O press.
- C press C press
- U press O press
- UO molding has been developed to develop a technique for forming tubular parts having a three-dimensional shape such as a curved pipe, a different diameter pipe, and a modified cross-section pipe.
- International Publication No. 2005/002753 pamphlet proposes a method of manufacturing a straight-shaped different-diameter pipe by performing UO molding using a mold having a guide blade for a longitudinal end portion.
- Japanese Patent No. 3114918 and Japanese Patent Application Laid-Open No. 2008-80381 describe a method of bending a longitudinal direction at the time of U molding, and manufacturing a curved hollow pipe in which the U molding process includes a drawing process. A method has been proposed.
- the method described in the pamphlet of International Publication No. 2005/002753 is a method for producing a straight-shaped different diameter pipe, and it is difficult to form a curved pipe.
- the methods described in Japanese Patent No. 3114918 and Japanese Patent Application Laid-Open No. 2008-80381 have a problem that the number of processes is actually large and the yield is low.
- the present invention has been made in view of the above-described problems, and in manufacturing a molded product by bending in the longitudinal direction, the method for manufacturing the molded product capable of suppressing the occurrence of molding defects, and the manufacturing thereof. It aims at providing the metal mold
- the gist of the invention completed by the present inventors in order to achieve the above object is as follows.
- a mold for bending a U-shaped product in the longitudinal direction so that the bottom is convex inward to obtain a U-section bent product, on the die, the punch, and the side surface of the punch A mold comprising: a pad that is disposed and compresses at least a part of a planned bending portion of the U-shaped product at an end portion along the longitudinal direction of the U-shaped product in an in-plane direction.
- a ratio H1 / H2 of a plate thickness H1 at the butt portion of the bent portion and a plate thickness H2 at the bottom portion of the bent portion satisfies the following formula (1).
- Ri is the radius of curvature on the bottom side of the bent portion
- D is the width of the bent portion of the cross section including the butt portion and the center line of the tubular molded product.
- the manufacturing method of the molded product of the basic form includes a first step of pressing a metal plate into a U shape and obtaining a U molded product having a bottom portion extending linearly in the longitudinal direction, and the bottom of the U molded product is formed by press molding.
- the manufacturing method of the molded product of a basic form after the said 2nd process is complete
- piercing (drilling), burring, trimming (cutting the pipe end), or the like can be performed. Further, piercing or the like can be performed before the first step, before the second step, or before the third step.
- FIGS. 2 (a) to 2 (c) are process diagrams showing an example of a method for producing a molded article of a basic form.
- 1 (a) and 1 (d) are front views
- FIG. 1 (b) is a cross-sectional view taken along line AA in FIG. 1 (a)
- FIG. 1 (e) is a cross-sectional view taken along line AA in FIG. 1 (c)
- 1 (f) are perspective views
- FIG. 2 (a) is a front view
- FIG. 2 (b) is a cross-sectional view taken along line AA in FIG. 2 (a)
- FIG. 2 (c) is a perspective view. It is.
- a first mold for U molding is prepared.
- the first mold for U molding has a die 11 and a punch 12, and the bottom 11 a of the recess of the die 11 and the bottom 12 a of the punch 12 both extend linearly in the longitudinal direction.
- the metal plate 1a is placed between the die 11 and the punch 12 of the first mold for U forming, and the metal plate 1a is U formed.
- FIG.1 (c) the U molded product 1b which has the bottom part 2 extended linearly in the longitudinal direction x is obtained.
- a second mold for bending is prepared.
- the second mold for bending has a die 21 and a punch 22, and the bottom 21 a of the concave portion of the die 21 is formed to be curved in the longitudinal direction, and the bottom 22 a of the punch 22 is recessed in the longitudinal direction. It is formed to be curved.
- the U molded product 1b is placed between the die 21 and the punch 22 of the second mold for bending, and the U molded product 1b is bent in the longitudinal direction x. Thereby, as shown in FIG.1 (f), the U-section bending processed product 1c is obtained.
- the U-section bent product 1c is formed such that the bottom 3 is curved inwardly in the longitudinal direction, the bent portion 10a is convex inward in the longitudinal direction, and the bottom extends linearly in the longitudinal direction. 3 and a straight portion 10b in which the entire length of the U-shape in the U cross section is equal along the center line.
- a third mold for O molding is prepared.
- the third mold for O molding has a die 31 and a punch 32, and the bottom 31a of the concave portion of the die 31 is formed to be convex in the longitudinal direction, and the bottom 32a of the concave portion of the punch 32 is formed in the longitudinal direction.
- the concave portion of the die 31 and the concave portion of the punch 32 both have a semicircular cross-sectional shape.
- a U-section bent product 1c is placed between the die 31 and the punch 32 of the third mold for O-molding, and the U-section bent product 1c is O-molded.
- the tubular molded product 1d is obtained.
- the tubular molded product 1d is formed such that the butting portion 4 is convexly curved outward, and the bottom portion 5 located on the opposite side in the circumferential direction of the butting portion 4 is curved convexly inward in the axial direction.
- 5 has a bent portion 10a that protrudes inward in the axial direction, and a bottom portion 5 that extends linearly in the axial direction, and has a straight portion 10b that has the same circumferential length along the center line.
- the U molding (first process) and the longitudinal bending process (second process) are performed in separate processes. Can reduce the force acting in the out-of-plane direction on the U-shaped product at both ends of the U-shape, and as a result, folding occurs at the end (particularly near the end of the straight portion). Can be suppressed.
- the U-shaped product obtained by once bending the metal plate in the plate width direction is bent in the longitudinal direction, instead of bending the metal plate in the plate width direction and the longitudinal direction simultaneously as in the prior art. Therefore, when bending in the longitudinal direction, the rigidity of the bottom (U-shaped bottom) can be maintained at a high level. For this reason, stable bending in the longitudinal direction is possible, generation of wrinkles at the bottom of the bent portion can be suppressed, and as a result, a U-section bent product without molding defects and a tubular molded product can be obtained. it can.
- a metal plate is press-formed into a U shape, and a U-shaped product having a bottom portion extending linearly in the longitudinal direction is obtained.
- press molding or roll forming can be employed.
- the metal plate is not particularly limited as long as it can be formed, and for example, a hot rolled steel plate, a cold rolled steel plate, a plated steel plate and the like can be used.
- a so-called tailored blank obtained by connecting a plurality of metal plates may be used as the metal plate.
- a difference thickness steel plate can also be used.
- a stack of a plurality of metal plates or a stack of non-metal materials on a metal plate, that is, a so-called laminated plate may be used.
- the material of the metal plate is not particularly limited as long as it can be molded.
- Fe-based for example, carbon steel, stainless steel, etc.
- Al-based for example, Al, or Al and Cu, Mn, Alloys containing at least one of Si, Mg, Zn, etc.
- Cu-based for example, Cu or Cu and Al, Ag, As, Be, Co, Cr, Fe, Mn, Ni, P, Pb, S, Se) , Sd, Sn, Si, Te, Zn, Zr, etc.
- Ti-based for example, Ti, or Ti and at least one of N, C, H, Fe, O, Al, V, etc.
- alloys for example, Ti, or Ti and at least one of N, C, H, Fe, O, Al, V, etc.
- the thickness of the metal plate is not limited as long as it can be molded, and varies depending on the material and the shape of the molded product, but can be within a range of 0.5 mm to 30 mm, for example. However, if the plate thickness is too small, wrinkles and cracks may occur at the bent portion during bending, whereas if the plate thickness is too large, an excessive load may be required for molding. It is preferably 0 mm to 5.0 mm.
- the shape of the metal plate is appropriately adjusted according to the shape of the molded product. For example, since the total length of the U-shape in the U cross section of the bent portion is reduced during bending, the plate width of the region that becomes the bent portion of the metal plate becomes larger than the length of the U cross section of the intended U cross-section bent product. It is preferable to design as follows. Specifically, when a U-section bent product 1c having a bent portion 10a and a straight portion 10b as shown in FIG. 1 (f) is produced, a region to be a bent portion of the metal plate 1a as shown in FIG. It is preferable to design the plate width d2 wider than the plate width d1 of the region that becomes the straight portion.
- the U molded product obtained in the first step has a bottom portion extending linearly in the longitudinal direction, and the bottom portion is formed linearly in the longitudinal section of the U molded product.
- the U-shaped product is bent in the longitudinal direction by press molding so that the bottom is convex inward to obtain a U-section bent product.
- press molding can be adopted as a bending method in this step.
- the radius of curvature in bending varies depending on the material and the shape of the molded product, but can be set within a range of 0.5 to 10 times the width of the U cross section, for example. If the curvature radius is small, wrinkles and cracks may occur in the bent portion during bending. Further, if the radius of curvature is large, the effect of performing U molding and bending in the longitudinal direction in separate steps (that is, suppression of occurrence of molding defects) may not be sufficiently obtained.
- the width of the U cross section refers to a width w as shown in FIG.
- a U-shaped bent product is press-formed into a closed cross section to obtain a tubular molded product.
- the closed cross section is a concept that includes not only a completely closed cross section but also a case where a gap exists between the end portions that face each other. That is, at the butt portion of the tubular molded product, the end portions may be in close contact with each other or may be separated from each other. That is, there may be a gap in the butt portion.
- press molding can be employed. Further, when forming into a closed cross section, a core may be used as necessary. By using the core, a tubular molded product can be stably molded even if the circumferential cross-sectional shape is complicated.
- the tubular molded product obtained in the third step has a bent portion that protrudes inward in the axial direction at the bottom located on the opposite side in the circumferential direction of the butted portion, and the bottom protrudes inward in the axial cross section. It is formed so as to be curved.
- the butting portion may be formed to be curved so as to be convex outward, for example, or may be formed in a straight line.
- the cross-sectional shape in the circumferential direction of the tubular molded product is not particularly limited, and can be various shapes such as a circle, an ellipse, a quadrangle, and a vertically asymmetric shape.
- a welding step of welding the butt portion of the tubular molded product may be performed after the third step.
- the welding method include arc welding and laser welding.
- processing such as end bending of the metal plate, so-called C forming, may be performed before the first step.
- the molded product manufactured by a basic form is a tubular molded product.
- the shape of the tubular molded product is not particularly limited as long as it can be satisfactorily molded by the method of the basic form.
- the circumferential cross-sectional shape as shown in FIG. 4 a curved pipe whose circumferential cross-sectional shape is asymmetrical in the vertical direction as shown in FIG. 4B, a non-diameter pipe, a deformed cross-section pipe, and the like (not shown).
- Applied form 1 Modification relating to applying an external force in the direction connecting the end and the bottom to at least a part of the planned bending portion of the U molded product
- an external force in the direction connecting the end portion and the bottom portion is applied to at least a part of the planned bending portion of the U molded product simultaneously with the bending process.
- the bent portion of the U molded product refers to a region corresponding to a region that is a bent portion in the U-section bent product obtained at the end of the second step.
- the outer side of a bottom part means the movement direction side of the punch at the time of a bending process.
- the external force is applied to the longitudinal direction of the U molded product.
- the end along the direction is applied by compressing in the in-plane direction toward the outside of the bottom of the U-molded product "and” the external force is applied to the vertical wall of the U-molded product inside the bottom of the U-molded product ( And “type added by pulling in the in-plane direction toward the direction of movement of the punch during bending”.
- FIGS. 6 (a) to 6 (e) are process diagrams showing an example of a method for producing a molded product according to this embodiment.
- 5 (a) is a top view
- FIG. 5 (b) is a front view
- FIG. 5 (c) is a cross-sectional view taken along line AA of FIG. 5 (b)
- FIG. 5 (d) is a perspective view.
- 6 (a) and 6 (c) are front views
- FIG. 6 (b) is a cross-sectional view along line AA in FIG. 6 (a)
- FIG. 6 (d) is along line AA in FIG. 6 (c).
- Sectional drawing and FIG.6 (e) are perspective views.
- a metal plate 1a is prepared in which the plate width d2 of the planned bending portion (region that becomes the bent portion) is larger than the plate width d1 of the region that becomes the straight portion.
- a first mold for U molding is prepared.
- the first mold for U molding has a die 11 and a punch 12, and the bottom 11 a of the recess of the die 11 and the bottom 12 a of the punch 12 both extend linearly in the longitudinal direction.
- the metal plate 1a is placed between the die 11 and the punch 12 of the first mold for U forming, and the metal plate 1a is U formed.
- the U molded product 1b which has the bottom part 2 extended linearly in the longitudinal direction x is obtained.
- a second mold for bending is prepared.
- the second metal mold for bending includes a die 21, a punch 22, and pads 23 arranged on both side surfaces of the punch 22.
- the bottom 21a of the concave portion of the die 21 is curved so as to protrude in the longitudinal direction.
- the bottom 22a of the punch 22 is formed to be concavely curved in the longitudinal direction.
- the pad 23 has at least a part of a planned bending portion 7 of the end portion 6 along the longitudinal direction x of the U molded product 1b (a region to be a bent portion in the U-section bent product) in an in-plane direction. It can be moved up and down.
- the pad 23 is of a type that compresses the entire planned bending portion 7, but the pad according to the present invention is not limited to such a type, and compresses a part of the planned bending portion 7. May be of type.
- the U molded product 1b is placed between the die 21 and the punch 22 of the second mold for bending, and the U molded product 1b is placed in the longitudinal direction. Bend to x. At this time, at least a part of the planned bending portion 7 of the U-section bent product at the end 6 along the longitudinal direction x of the U-shaped product 1b is compressed in the in-plane direction. Thereby, as shown in FIG.6 (e), the U-section bending processed product 1c is obtained.
- the U-section bent product 1c is formed such that the bottom 3 is curved inwardly in the longitudinal direction, the bent portion 10a is convex inward in the longitudinal direction, and the bottom extends linearly in the longitudinal direction. 3 and a straight portion 10b having the same U-section length along the center line.
- the specific grounds for suppressing the local change in the plate thickness that is, the thinning and the thickening are as follows. That is, in the application mode 1, in the second step, at least a part of the bottom of the planned bending portion 7 is pressed against the mold by the compression in the in-plane direction of at least a part of the planned bending portion 7 by the pad 23, and the bending is performed.
- the neutral axis of processing (a position where it does not expand or contract in the longitudinal direction) moves to the bottom side as compared with the case where it is not compressed in the in-plane direction. For this reason, in the processed product 1c shown in FIG.
- the formable range of the bent portion in the longitudinal direction of the U-section bending product 1c can be expanded as compared with the basic form. .
- a U-section bent product having a bent portion with a relatively small radius of curvature and a U-section bent product having a tapered portion can be stably molded while suppressing the occurrence of wrinkles and cracks.
- the compression may not always be performed, and at least at any point during the bending process.
- the plate thickness at the end portion along the longitudinal direction of the bending portion is used. It is only necessary to be able to suppress the decrease and the increase in the plate thickness at the bottom, and it is appropriately determined according to the shape of the molded product, the shape of the pad of the second mold for bending, the plate thickness and material of the metal plate, etc. Can be adjusted.
- the manufacturing method of the molded product of the application form 2 is a manufacturing method in which the shape of the molded product obtained in the basic form and the application form 1 is improved.
- FIGS. 8 (a) to 8 (f) are process diagrams showing an example of a method for manufacturing a molded article of the application mode 2.
- FIG. 7 (a) is a top view
- FIG. 7 (b) is a perspective view
- FIG. 7 (c) is a front view
- FIG. 7 (d) is a left side view of FIG. 7 (c)
- FIG. 7 (c) is a right side view
- FIG. 7 (f) is a top view of FIG. 7 (c).
- 8 (a) is a perspective view
- FIG. 8 (b) is a front view
- FIG. 8 (c) is a front view
- FIG. 8 (d) is a left side view of FIG. 8 (c)
- Fig. 8C is a right side view of Fig. 8C
- Fig. 8F is a top view of Fig. 8C.
- a first mold for U molding is prepared.
- the first mold for U molding has a die 11 and a punch 12, and the bottom 11 a of the recess of the die 11 and the bottom 12 a of the punch 12 both extend linearly in the longitudinal direction.
- the metal plate 1a is placed between the die 11 and the punch 12 of the first mold for U forming, and the metal plate 1a is U formed.
- FIGS. 7C to 7F a U molded product 1b having a bottom 2 extending linearly in the longitudinal direction x is obtained.
- a second die for bending is prepared.
- the second metal mold for bending includes a die 21, a punch 22, and pads 23 arranged on both side surfaces of the punch 22.
- the bottom 21a of the concave portion of the die 21 is curved so as to protrude in the longitudinal direction.
- the bottom 22a of the punch 22 is formed to be concavely curved in the longitudinal direction.
- the pad 23 compresses the region 7 of the end portion 6 along the longitudinal direction x of the U-shaped product 1b in the in-plane direction, and can move up and down.
- the U molded product 1b is placed between the die 21 and the punch 22 of the second mold for bending, and the U molded product 1b is bent in the longitudinal direction x. To do. At this time, the region 7 of the end portion 6 along the longitudinal direction x of the U-shaped product 1b, which becomes the bent portion of the U-section bent product, is compressed in the in-plane direction. As a result, as shown in FIGS. 8C to 8F, a U-section bent product 1c is obtained.
- the U-section bent product 1c is formed such that the bottom 3 is curved inwardly in the longitudinal direction, the bent portion 10a is convex inward in the longitudinal direction, and the bottom extends linearly in the longitudinal direction. 3 and a straight portion 10b having the same length in the U section along the center line, and a bottom portion 3 extending linearly in the longitudinal direction, and the length of the U section increases along the center line. 10c.
- the U-shaped product when the U-shaped product is bent in the second step to obtain a U-section bent product, the U-shaped product is bent and the U-shaped product as described above is used. At least a part of a planned bending portion (region to be a bending portion) of the cross-section bending product is compressed in the in-plane direction.
- the third step in the application mode 2 will be described in detail. That is, for the U-section bending product formed as described above (FIGS. 8C to 8F), the U-section bending product is formed into a closed section as shown in FIG. To do.
- FIG. 9 (a) is a perspective view
- FIG. 9 (b) is a front view
- FIG. 9 (c) is a front view
- FIG. 9 (d) is a left side view of FIG. 9 (c)
- FIG. It is a right view of 9 (c).
- a third mold for O molding is prepared.
- the third mold for O molding has a die 31 and a punch 32, and the bottom 31a of the concave portion of the die 31 is formed to be convex in the longitudinal direction, and the bottom 32a of the concave portion of the punch 32 is formed in the longitudinal direction.
- the concave portion of the die 31 and the concave portion of the punch 32 both have a semicircular cross-sectional shape.
- the U-section bent product 1c is placed between the die 31 and the punch 32 of the third mold for O-molding, and the U-section bent product 1c is O-molded.
- a tubular molded product 1d is obtained.
- the tubular molded product 1d is formed such that the butting portion 4 is convexly curved inward, and the bottom portion 5 located on the opposite side in the circumferential direction of the butting portion 4 is convexly curved inward in the axial direction.
- the obtained molded product is a tubular molded product having various shapes obtained through U-shaped bending products having various shapes, and these are appropriately determined depending on the presence or absence of the third process or the welding process. Selected.
- FIG. 10 (d) shows a curved tube having a circular cross section in the circumferential direction as shown in FIG. 10 (c), and a trumpet-shaped different diameter tube having a bent portion 10a, a straight portion 10b, and a tapered portion 10c. 10), a trumpet-shaped different-diameter pipe having a bent portion 10a, a straight portion 10b, and a tapered portion 10c, as shown in FIG. 10 (e).
- the cross-sectional shape in the circumferential direction is asymmetrical in the vertical direction, and includes a bent tube having a bent portion 10a and a straight portion 10b, and a bent portion 10a, a straight portion 10b, and a tapered portion 10c as shown in FIG. It can be exemplified different diameter pipe or the like having a plurality Re.
- Mold A mold according to the present invention is for bending a U-shaped product in the longitudinal direction so that the bottom is convex inward to obtain a U-section bent product, which includes a die, a punch, A pad that is arranged on a side surface of the punch and compresses in an in-plane direction at least a part of the planned bending portion of the U molded product at an end portion along the longitudinal direction of the U molded product. It is a feature. That is, the metal mold
- FIGS. 6A and 6B show an example of the mold according to the present invention
- FIGS. 8 (a) and 8 (b) show another example of the mold according to the present invention
- the mold includes a die 21, a punch 22, and pads 23 arranged on both side surfaces of the punch 22.
- the bottom 21a of the concave portion of the die 21 is formed to be convexly curved in the longitudinal direction
- the bottom 22a of the punch 22 is formed to be concavely concave in the longitudinal direction.
- the pad 23 compresses at least a part of the planned bending portion 7 of the U molded product at the end 6 along the longitudinal direction x of the U molded product 1b in the in-plane direction, and is movable up and down.
- die which concerns on this invention, by having a predetermined pad as mentioned above, at the time of the bending process using a metal mold
- the mold according to the present invention it is possible not only to suppress generation of wrinkles at the bottom of the bent portion and cracks at the end along the longitudinal direction at a high level, but also U-section bending.
- the thickness distribution of the U section of the product can be made uniform.
- the mold according to the present invention it is possible to form a bendable range in the longitudinal direction of the U-section bent product 1c (the number of types of shapes of moldable parts and the degree of complexity). As compared with the above, it can be appropriately enlarged.
- the pad is arranged on both side surfaces of the punch and compresses at least a part of the planned bending portion at the end portion along the longitudinal direction of the U-shaped product in the in-plane direction.
- the portion where the pad and the U molded product abut is at least a part of the planned bending portion (that is, the region to be a bent portion in the U cross-section bent product) at the end along the longitudinal direction of the U molded product. If the planned bending portion is too wide, an unintended region is also compressed in the in-plane direction, which may cause molding defects. Moreover, if the planned bending portion is too narrow, it is not possible to sufficiently suppress the decrease in the plate thickness at the end portion along the longitudinal direction of the bent portion and the increase in the plate thickness at the bottom portion, and the level of suppression of molding defects is high. Not only that, but it may be difficult to make the thickness distribution of the U section uniform.
- the shape of the portion that contacts the molded product of the pad may be any shape that can compress at least a part of the planned bending portion in the longitudinal direction of the U molded product in the in-plane direction. It can design suitably according to the shape etc. of goods. As the U molded product is bent, the shape of the U molded product changes, and the shape of the end portion along the longitudinal direction of the U molded product also changes. Therefore, for example, assuming the shape of the end portion along the longitudinal direction of the U-shaped product in the initial stage, the middle stage, and the latter stage of the bending process, the shape of the portion contacting the U-shaped product of the pad It is preferable that it is a shape corresponding to the shape of the edge part along the longitudinal direction of U molded article.
- the pad When the shape of the portion of the pad that contacts the U-shaped product is a shape corresponding to the shape of the end portion along the longitudinal direction of the molded product in the latter stage of bending, the pad is aligned along the longitudinal direction of the U-shaped product. It may be difficult to compress at least a portion of the end portion of the planned bending portion in the in-plane direction.
- the pad may be divided into a plurality of blocks along the traveling direction of the pad.
- each block constituting the pad is individually moved up and down to change the shape of the portion of the pad that comes into contact with the U-shaped product as the shape of the end of the U-shaped product being bent is changed. be able to.
- an elastic member may be disposed at a portion of the pad that contacts the U-shaped product.
- the elastic member can be elastically deformed with a change in the shape of the end of the U-shaped product during bending.
- the material of the elastic member include hard rubber, urethane, and resin material.
- Pads are arranged on both sides of the punch.
- the pad may be integrated with the punch or may be disposed independently of the punch. Even when the pad is integrated with the punch and fixed to the punch, the pad compresses at least a part of the planned bending portion of the end portion along the longitudinal direction of the U-shaped product in the in-plane direction. Therefore, it is possible to obtain an effect of suppressing a decrease in the thickness of the end portion along the longitudinal direction of the U-section bent product and an increase in the thickness of the bottom portion.
- the fact that the pad is arranged independently of the punch, and that the pad and the punch can be individually moved up and down allows the timing of longitudinal bending and end compression to be freely controlled. preferable.
- the pad is attached to a punch or a press device (device for controlling the relative position of the die and the punch) via a spring or the like so as to be movable up and down relatively with respect to the punch.
- the material of the pad can be the same as that of a general mold material.
- the die and punch may be any one that can bend the U-shaped product in the longitudinal direction so that the bottom is convex inward to obtain a U-section bent product. It can be designed accordingly.
- the tubular molded article according to the present invention is made of a metal plate and has only one butted portion extending in the axial direction, and the bottom portion located on the opposite side in the circumferential direction from the butted portion is in the axial direction. It has a bent portion that protrudes inward, and the ratio H1 / H2 of the plate thickness H1 at the butt portion of the bent portion and the plate thickness H2 at the bottom portion of the bent portion satisfies the following formula (2). It is what.
- FIGS. 11 (a) to 11 (e) are views showing an example of a tubular molded product according to the present invention.
- FIG. 11 (a) is a front view
- FIG. 11 (b) is a left side view
- FIG. FIG. 11D is a right side view
- FIG. 11D is a top view
- FIG. 11E is a cross-sectional view taken along the line CC of FIG.
- a tubular molded product 1d shown in FIGS. 11 (a) to 11 (e) is made of a metal plate, has only one butting portion 4 extending in the axial direction, and is formed by forming one metal plate into a tubular shape. is there.
- the tubular molded product 1d has a bent portion 10a in which a bottom portion 5 located on the opposite side to the butting portion 4 is protruded inward in the axial direction, and a bottom portion 5 extending linearly in the axial direction.
- a straight portion 10b having the same length along the center line S is included. Further, the ratio H1 / H2 between the plate thickness H1 at the butting portion 4 of the bent portion 10a and the plate thickness H2 at the bottom portion 5 of the bent portion 10a is within a predetermined range.
- FIGS. 12 (a) to 12 (e) are views showing another example of the tubular molded product according to the present invention
- FIG. 12 (a) is a front view
- FIG. 12 (b) is a left side view
- FIG. ) Is a right side view
- FIG. 12 (d) is a top view
- FIG. 12 (e) is a cross-sectional view taken along the line CC of FIG. 12 (a).
- the tubular molded product 1d shown in FIGS. 12 (a) to 12 (e) is made of a metal plate, has only one butting portion 4 extending in the axial direction, and is formed by forming one metal plate into a tubular shape. is there.
- the tubular molded product 1d has a bent portion 10a in which a bottom portion 5 located on the opposite side to the butting portion 4 is protruded inward in the axial direction, and a bottom portion 5 extending linearly in the axial direction.
- a straight portion 10b having the same length along the center line S and a tapered portion 10c having a bottom portion 5 extending linearly in the axial direction and having a circumferential length increasing along the center line S.
- And has a plurality of bent portions 10a, straight portions 10b, and tapered portions 10c.
- the ratio H1 / H2 between the plate thickness H1 at the butt portion 4 of the bent portion 10a and the plate thickness H2 at the bottom portion 5 of the bent portion 10a is within a predetermined range.
- a tubular molded product obtained without compressing the bent portion of the end portion along the longitudinal direction of the U-shaped product in the in-plane direction is usually H1 / H2. Is less than Ri / (Ri + D), and does not satisfy the above formula (2).
- the plate thickness tends to decrease because tensile stress acts at the butt portion (bending outside) of the bent portion, and compressive stress acts at the bottom portion (bending inside) of the bent portion. This is because the thickness tends to increase.
- H1 / H2 satisfies the above formula (2), so that a uniform thickness distribution can be obtained at the bent portion.
- the tubular molded product according to the present invention not only can the cracking at the butt portion of the bent portion and the generation of wrinkles at the bottom portion be suppressed at a high level to eliminate molding defects, but also the plate thickness in the circumferential direction.
- the distribution can be uniform.
- the tubular molded article according to the present invention has only one butt portion extending in the axial direction.
- that the tubular molded product has only one butting portion extending in the axial direction means that one metal plate is formed into a tubular shape. Therefore, a tubular molded product obtained by forming a plurality of tubular members by previously forming a metal plate into a tubular shape and welding the tubular members together has not only a plurality of butted portions in the longitudinal direction, but also butt in the circumferential direction. Therefore, it is not included in the tubular molded product according to the present invention.
- the end portions may be in close contact with each other or may be separated from each other. That is, there may be a gap in the butt portion.
- matching part may be welded.
- the butt portion and the center line are straight because it is less likely to cause molding defects, but is slightly curved. It doesn't matter.
- tubular molded product may be any one in which a single metal plate is formed into a tubular shape, and may be, for example, a single tailored blank formed into a tubular shape.
- the bent part is a part where the bottom part located on the opposite side in the circumferential direction from the abutting part protrudes inward in the axial direction.
- the bottom portion of the tubular molded product refers to a portion located on the opposite side of the butt portion in the cross section including the butt portion and the center line.
- the tubular molded product may have one bent portion or a plurality of bent portions.
- the ratio H1 / H2 of the plate thickness H1 at the butt portion of the bent portion and the plate thickness H2 at the bottom portion of the bent portion satisfies the following formula (3).
- H1 / H2 ⁇ Ri / (Ri + D) (3) (In the above formula (3), Ri is the radius of curvature on the bottom side of the bent portion, and D is the width of the bent portion of the cross section including the butt portion and the center line of the tubular molded product.)
- the plate thickness H1 at the butt portion of the bent portion and the plate thickness H2 at the bottom portion of the bent portion may be distributed in the longitudinal direction and the circumferential direction, but are preferably uniform in the longitudinal direction and the circumferential direction.
- the plate thickness H1 at the butt portion of the bent portion is the plate thickness of the butt portion at the bending center in the longitudinal direction of the tubular molded product.
- the plate thickness H2 at the bottom of the bent portion is the plate thickness of the bottom at the bending center in the longitudinal direction of the tubular molded product.
- the width D (for example, see FIG. 11) of the bent portion in the cross section including the center line of the butted portion and the tubular molded product is the width at the bending center.
- a curvature radius Ri (see, for example, the figure) on the bottom side of the bent portion is a radius of curvature of an intersection line between the bottom portion of the bent portion and a surface including the butt portion and the bending center line.
- the thickness reduction rate T at the butt portion of the bent portion satisfies the following formula (4).
- T ⁇ D / 2 (Ri + D) (4) (In the above formula (4), Ri is the radius of curvature on the bottom side of the bent portion, and D is the width of the bent portion of the cross section including the butt portion and the center line of the tubular molded product.)
- the plate thickness reduction rate T at the butt portion of the bent portion is obtained by the following equation (5).
- T (H0 ⁇ H1) / H0 ⁇ 100 [%] (5)
- H0 is the thickness of the region that becomes the bent portion of the metal plate
- H1 is the thickness of the butt portion of the bent portion.
- the tubular molded product according to the present invention since a uniform plate thickness distribution can be obtained at the bent portion, and a local reduction in the plate thickness can be suppressed, the plate at the butt portion of the bent portion.
- the thickness reduction rate T satisfies the above formula (5).
- the thickness reduction rate at the butt portion 4 of the bent portion 10a is less than D / 2 (Ri + D).
- the widths of the bent portions 10a in the cross section including the center line S of the butted portion 4 and the tubular molded product 1d are D1 and D2, respectively, and the curvature radii on the bottom 5 side of the bent portions 10a are respectively set.
- the plate thickness reduction rate at the butt portion 4 of the bent portion 10a is less than D1 / 2 (Ri1 + D1) and less than D2 / 2 (Ri2 + D2), respectively.
- the tubular molded product according to the present invention may have a straight part or a taper part. Further, the number of straight portions and taper portions may be one or plural.
- Shape of Tubular Molded Article As the shape of the tubular molded article, as described above, FIG. 2 (c), FIG. 4 (a), (b), FIG. 9 (c) to (e), and FIG. The type described in any of (f) may be sufficient.
- Example 1 A bent round tube (tubular molded product) as shown in FIG. 11 was produced.
- the curvature radius of the bent portion of the tubular molded product is 215 mm, and the bending angle (the acute angle formed by the extension line of the center line S in one straight portion 10b and the center line S in the other straight portion 10b. The same applies hereinafter).
- the outer diameter of the bent round tube was 40 mm, and the length of the straight portion was 150 mm.
- the metal plate has a shape in which the width of the bending center (longitudinal center) is wider than the width at both ends in the longitudinal direction, the tensile strength (TS) is 440 MPa, and the plate thickness is A 2.6 mm hot-rolled steel sheet was used.
- die as shown in FIG.1 and FIG.2, U shaping
- Comparative Example 1 A molded body of Comparative Example 1 was obtained in exactly the same manner as in the production of the tubular molded product of Example 1, except that U molding and bending were performed simultaneously. However, in the case of the comparative example 1, as will be described later, the process up to the second step of the present invention is performed, and the third step (closed cross-section) is not performed.
- Example 2 A tubular molded article of Example 2 was obtained in exactly the same manner as the production of the tubular molded article of Example 1, except that the mold shown in FIGS. 5 and 6 was used instead of the mold shown in FIG.
- Example 3 A tubular molded product of Example 3 was obtained in exactly the same manner as the production of the tubular molded product of Example 2, except that the radius of curvature of the bent portion of the tubular molded product was 65 mm.
- Comparative Example 2 A molded article of Comparative Example 2 was obtained in exactly the same manner as the production of the tubular molded article of Example 2, except that the U molding and bending were performed simultaneously. However, in the case of Comparative Example 2, similarly to the case of Comparative Example 1, as described later, the second step of the present invention is performed, and the third step (closed section) is not performed.
- Example 4 A trumpet-shaped different-diameter pipe (tubular molded product) as shown in FIGS. 9C to 9E was produced.
- the curvature radius of the bent part of the tubular molded product was 80 mm, the bending angle was 10 °, the outer diameter of the straight part was 40 mm, and the length of the straight part was 150 mm.
- a cold-rolled steel plate having a tensile strength (TS) of 390 MPa and a plate thickness of 2.0 mm was used.
- TS tensile strength
- die as shown in FIG.7, FIG8 and FIG.9, U shaping
- Comparative Example 3 A molded article of Comparative Example 3 was obtained in exactly the same manner as in the production of the tubular molded article of Example 4 except that the U molding and bending were performed simultaneously. However, in the case of Comparative Example 3, as described later, the second step of the present invention is performed and the third step (closed cross-section) is not performed, as will be described later.
- Example 1 when producing a tubular molded product, it was possible to perform bending without causing cracks or wrinkles in the bent portion. Moreover, in the O molding, the butt portion was in a good state and could be joined by laser arc hybrid welding. This is thought to be because U molding and bending were performed in separate steps.
- Comparative Example 1 and Comparative Example 2 when the molded body was produced, the vertical wall was folded during the production of the U-section bending product, and thus a molding defect occurred at the stage of the U-section bending product. This is considered to be because U molding and bending were performed in the same process.
- Example 2 Example 3, and Example 4 it was possible to perform bending without generating cracks or wrinkles in the bent portion when producing a tubular molded product. Moreover, in the O molding, the butt portion was in a good state and could be joined by laser arc hybrid welding. Furthermore, the plate thickness reduction rate of the butt portion after the O molding was almost zero. This is because U molding and bending are performed in separate processes, and an external force is applied to at least a part of the planned bent portion of the U molded product toward the outside of the bottom using a pad during the bending process. ,it is conceivable that.
- Comparative Example 3 when producing a tubular molded product, cracks occurred at the end in the circumferential direction during the production of the U-section bent product, so a molding failure occurred at the stage of the U-section bent product, and O-molding was attempted.
- joining was not possible by laser arc hybrid welding. This is considered to be because U molding and bending were performed in the same process.
- Example 3 the thickness reduction rate in the cross section of the bending center in the longitudinal direction of a tubular molded product was measured.
- the thickness reduction rate means the rate of reduction of the thickness of each part before and after bending.
- the thickness reduction rate was investigated when the position of the bottom portion was 0 degree and the position of the butt portion on the opposite side in the circumferential direction was 180 degrees. The result is shown in FIG.
- the solid line indicates the result of Example 3
- the dotted line indicates a calculated value when a tubular molded product having the same dimensions as in Example 3 is produced by uniform bending using a steel pipe as a raw material.
- FIG. 13 shows that in Example 3, the thinning rate is within the range of about ⁇ 5% to about ⁇ 15%, and it is understood that the thickness is not reduced at all. This is considered to be because the pad was used at the time of bending and the end portion along the longitudinal direction of the U molded product was compressed in the in-plane direction toward the outside of the bottom of the U molded product.
- Example 1A is a measured value when a tubular molded product having the same dimensions as in Example 1 is produced by rotational pulling using a steel pipe as a raw material.
- the value indicated by the bar graph corresponds to the left side (H1 / H2) of the above formula (6), and the dotted line corresponds to the right side of the above formula (6).
- Examples 2 and 3 both satisfy the above formula (6). Therefore, in Examples 2 and 3, it can be seen that a uniform thickness distribution can be obtained in the bent portion.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
Description
H1/H2≧Ri/(Ri+D) (1)
(上記式(1)中、Riは曲がり部の底部側の曲率半径であり、Dは突合せ部及び管状成形品の中心線を含む断面の曲がり部の幅である。)
<基本形態>
基本形態の成形品の製造方法は、金属板をU字形にプレス成形し、長手方向に直線状に延びる底部を有するU成形品を得る第1工程と、プレス成形により上記U成形品の底部が内側に凸になるように長手方向に曲げ加工し、U断面曲げ加工品を得る第2工程と、を含む。そして、基本形態の成形品の製造方法では、上記第2工程終了後に、例えば、上記U断面曲げ加工品を閉断面に成形し、管状成形品を得る第3工程をさらに行うことができる。なお、第3工程の代りに、ピアシング(穴あけ)やバーリング、トリミング(管端部切断)などを行うことができる。また、ピアシングなどは、第1工程の前、第2工程の前、又は第3工程の前に行うこともできる。
図1(a)~(f)及び図2(a)~(c)は基本形態の成形品の製造方法の一例を示す工程図である。図1(a)、(d)は正面図、図1(b)は図1(a)のA-A線断面図、図1(e)は図1(d)のA-A線断面図、図1(c)、(f)は斜視図、図2(a)は正面図、図2(b)は図2(a)のA-A線断面図、図2(c)は斜視図である。
第1工程では、金属板をU字形にプレス成形し、長手方向に直線状に延びる底部を有するU成形品を得る。U成形方法としては、プレス成形、ロールフォーミングを採用することができる。
第2工程では、プレス成形により上記U成形品を上記底部が内側に凸になるように長手方向に曲げ加工し、U断面曲げ加工品を得る。本工程における曲げ加工方法としては、プレス成形を採用することができる。
第3工程では、U断面曲げ加工品を閉断面にプレス成形し、管状成形品を得る。ここで、閉断面とは、完全に閉じた断面だけでなく、突き合わされた端部の間に隙間が存在する場合も含まれる概念である。即ち、管状成形品の突合せ部では、端部同士が密着していてもよく離れていてもよい。即ち、突合せ部には隙間があってもよい。
基本形態において、第3工程後に、管状成形品の突合せ部を溶接する溶接工程を行ってもよい。溶接方法としては、例えばアーク溶接、レーザ溶接等が挙げられる。また、基本形態においては、第1工程前に、金属板の端曲げ、いわゆるC成形等の加工を行ってもよい。
基本形態により製造される成形品は、管状成形品である。また、管状成形品の形状としては、基本形態の方法により良好に成形可能なものであれば特に限定されるものではなく、例えば図4(a)に示すような周方向の断面形状が円形状である曲管や、図4(b)に示すような周方向の断面形状が上下非対称の形状である曲管、図示しないが異径管や異形断面管等を例示することができる。
次に、上述した基本形態を改良した応用形態1、2について詳述する。
応用形態1の成形品の製造方法では、基本形態において述べた第2工程において、曲げ加工と同時に、U成形品の曲がり予定部の少なくとも一部に、端部と底部とを結ぶ方向の外力を加える。ここで、U成形品の曲がり予定部とは、第2工程終了時に得られるU断面曲げ加工品のうち曲がり部となっている領域、に対応する領域をいう。また、底部の外側とは、曲げ加工時のポンチの移動方向側をいう。
応用形態2の成形品の製造方法は、基本形態及び応用形態1において得られる成形品の形状に改良を加えた製造方法である。
本発明に係る金型は、U成形品を底部が内側に凸になるように長手方向に曲げ加工して、U断面曲げ加工品を得るためのものであって、ダイと、ポンチと、上記ポンチの側面に配置され、上記U成形品の長手方向に沿った端部の、上記U成形品の曲がり予定部の少なくとも一部を、面内方向に圧縮するパッドと、を備えることを特徴とするものである。即ち、本発明に係る金型は、上述の応用形態1、2において、成形品の製造方法における第2工程にて用いられるものである。
パッドは、ポンチの両側面に配置され、U成形品の長手方向に沿った端部の、曲がり予定部の少なくとも一部を面内方向に圧縮するものである。
ダイ及びポンチは、U成形品を底部が内側に凸になるように長手方向に曲げ加工し、U断面曲げ加工品を得ることができるものであればよく、成形品の形状等に応じて適宜設計することができる。
本発明に係る管状成形品は、金属板からなり、軸方向に延びる突合せ部を1つのみ有するものであって、上記突合せ部とは周方向反対側に位置する底部が軸方向に内側に凸になる曲がり部を有し、上記曲がり部の上記突合せ部における板厚H1と上記曲がり部の上記底部における板厚H2との比率H1/H2が下記式(2)を満たすことを特徴とするものである。
H1/H2≧Ri/(Ri+D) (2)
(上記式(2)中、Riは曲がり部の底部側の曲率半径であり、Dは突合せ部及び管状成形品の中心線を含む断面の曲がり部の幅である。)
本発明に係る管状成形品は、軸方向に延びる突合せ部を1つのみ有する。ここで、管状成形品が軸方向に延びる突合せ部を1つのみ有するとは、1枚の金属板が管状に成形されたものであることを意味する。従って、予め金属板を管状に成形して複数の管状部材を作製し、管状部材同士を溶接してなる管状成形品は、その長手方向において突合せ部を複数有するだけでなく、周方向にも突合せ部を有するため、本発明に係る管状成形品には含まれない。
曲がり部は、上記突合せ部とは周方向反対側に位置する底部が軸方向に内側に凸になる部分である。ここで、管状成形品の底部とは、突合せ部及び中心線を含む断面において、突合せ部とは反対側に位置する部分をいう。管状成形品は、曲がり部を1つ有していてもよく複数有していてもよい。
H1/H2≧Ri/(Ri+D) (3)
(上記式(3)中、Riは曲がり部の底部側の曲率半径であり、Dは突合せ部及び管状成形品の中心線を含む断面の曲がり部の幅である。)
T<D/2(Ri+D) (4)
(上記式(4)中、Riは曲がり部の底部側の曲率半径であり、Dは突合せ部及び管状成形品の中心線を含む断面の曲がり部の幅である。)
T=(H0-H1)/H0×100 [%] (5)
(上記式(5)中、H0は金属板の曲がり部になる領域の板厚であり、H1は曲がり部の突合せ部における板厚である。)
本発明に係る管状成形品は、ストレート部やテーパー部を有していてもよい。また、ストレート部及びテーパー部の数は1つであってもよく複数であってもよい。
管状成形品の形状としては、上述したとおり、図2(c)、図4(a)、(b)、図9(c)~(e)、及び図10(a)~(f)のいずれに記載されているタイプでもよい。
[実施例1]
図11に示すような曲がり丸管(管状成形品)を作製した。管状成形品の曲がり部の曲率半径は215mm、曲げ角度(一方のストレート部10bにおける中心線Sの延長線と、他方のストレート部10bにおける中心線Sとのなす鋭角をいう。以下同様。)は40°、曲がり丸管の外径は65mm、ストレート部の長さはそれぞれ150mmとした。
U成形及び曲げ加工を同時に行ったこと以外は、実施例1の管状成形品の作製と全く同じ手法で、比較例1の成形体を得た。但し、比較例1の場合、後述するように、本発明の第2の工程までを行い、第3工程(閉断面化)は行っていない。
図1に示す金型の代りに図5、6に示す金型を用いたこと以外は、実施例1の管状成形品の作製と全く同じ手法で、実施例2の管状成形品を得た。
管状成形品の曲がり部の曲率半径を65mmとしたこと以外は実施例2の管状成形品の作製と全く同じ手法で、実施例3の管状成形品を得た。
U成形及び曲げ加工を同時に行ったこと以外は、実施例2の管状成形品の作製と全く同じ手法で、比較例2の成形体を得た。但し、比較例2の場合、比較例1の場合と同様に、後述するように、本発明の第2の工程までを行い、第3工程(閉断面化)は行っていない。
図9(c)~(e)に示すようなラッパ状の異径管(管状成形品)を作製した。管状成形品の曲がり部の曲率半径は80mm、曲げ角度は10°、ストレート部の外径は40mm、ストレート部の長さはそれぞれ150mmとした。
U成形及び曲げ加工を同時に行ったこと以外は、実施例4の管状成形品の作製と全く同じ手法で、比較例3の成形体を得た。但し、比較例3の場合、比較例1、2の場合と同様に、後述するように、本発明の第2の工程までを行い、第3工程(閉断面化)は行っていない。
[成形不良に関する評価]
このようにして得られた実施例1~4及び比較例1~3の管状成形品(又は成形体)のそれぞれについて、成形途中(U断面曲げ加工品)における縦壁の折れ込みの発生、周方向端部の割れの発生、及び底部のシワの発生を調査した。また、上記の管状成形品のそれぞれについて、成形完了時における溶接不良について調査した。これらの結果を以下に併記する。なお、「縦壁の折れ込みの発生」がある例(具体的には、比較例1、2)や、「周方向端部の割れの発生」がある例(具体的には、比較例3)については、それ以降の成形が不可能となるため、本発明の第3工程は行っていない。このため、「縦壁の折れ込みの発生」がある例では「割れ」「シワ」「溶接不良」が発生するかどうか判断できず、「周方向端部の割れの発生」がある例では「シワ」「溶接不良」が発生するかどうか判断できなかった。
また、実施例3については、管状成形品の長手方向における曲げ中心の断面における減肉率を測定した。ここで、減肉率とは、曲げ加工前後における、各部位の厚みの減少率をいう。本評価では、底部の位置を0度とし、その周方向反対側である突合せ部の位置を180度とした場合の、減肉率について調査した。その結果を図13に示す。なお、表13中実線は実施例3の結果を示し、点線は、実施例3と同寸法の管状成形品を、鋼管を素材とする均等曲げで作製した場合の計算値である。
さらに、実施例2、実施例3等について、下記式(6)を満たすか否か調査した。その結果を図14に示す。
H1/H2≧Ri/(Ri+D) (6)
(上記式(6)中、H1は曲がり部の突合せ部における板厚であり、H2は曲がり部の底部における板厚H2であり、Riは曲がり部の底部側の曲率半径であり、Dは突合せ部及び管状成形品の中心線を含む断面の曲がり部の幅である。)
1b U成形品
1c U断面曲げ加工品
1d 管状成形品
2、3、5 底部
4 突合せ部
6 U成形品の長手方向に沿った端部
7 曲がり予定部(曲がり部になる領域)
8 U断面曲げ加工品の長手方向に沿った端部
10a 曲がり部
10b ストレート部
10c テーパー部
11、21、31 ダイ
12、22、32 ポンチ
11a、21a、31a ダイの凹部の底部
12a、22a、32a ポンチの底部
23 パッド
x 長手方向
Claims (6)
- 金属板をU字形にプレス成形し、長手方向に直線状に延びる底部を有するU成形品を得る第1工程と、
プレス成形により前記U成形品の底部が内側に凸になるように長手方向に曲げ加工し、U断面曲げ加工品を得る第2工程と、
を含むことを特徴とする成形品の製造方法。 - 前記第2工程において、前記曲げ加工と同時に、前記U成形品の曲がり予定部の少なくとも一部に、端部と底部とを結ぶ方向の外力を加えることを特徴とする、請求項1に記載の成形品の製造方法。
- 前記外力を、前記U成形品の長手方向に沿った端部を前記U成形品の底部の外側に向けて面内方向に圧縮することにより加える、請求項2に記載の成形品の製造方法。
- 前記U断面曲げ加工品を閉断面に成形し、管状成形品を得る第3工程をさらに含む、請求項1から3のいずれか1項に記載の成形品の製造方法。
- U成形品を底部が内側に凸になるように長手方向に曲げ加工して、U断面曲げ加工品を得るための金型であって、
ダイと、
ポンチと、
前記ポンチの側面に配置され、前記U成形品の長手方向に沿った端部の、前記U成形品の曲がり予定部の少なくとも一部を、面内方向に圧縮するパッドと、
を備えることを特徴とする金型。 - 金属板からなり、軸方向に延びる突合せ部を1つのみ有する管状成形品であって、
前記突合せ部とは周方向反対側に位置する底部が軸方向に内側に凸になる曲がり部を有し、
前記曲がり部の前記突合せ部における板厚H1と前記曲がり部の前記底部における板厚H2との比率H1/H2が下記式(1)を満たすことを特徴とする管状成形品。
H1/H2≧Ri/(Ri+D) (1)
(前記式(1)中、Riは曲がり部の底部側の曲率半径であり、Dは突合せ部及び管状成形品の中心線を含む断面の曲がり部の幅である。)
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RU2017113078A RU2673365C2 (ru) | 2014-09-18 | 2015-09-17 | Способ изготовления формованного изделия, инструментальная оснастка и изделие трубчатой формы |
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US20170274434A1 (en) | 2017-09-28 |
RU2673365C2 (ru) | 2018-11-26 |
EP3195951A1 (en) | 2017-07-26 |
JP6477716B2 (ja) | 2019-03-06 |
US11148183B2 (en) | 2021-10-19 |
KR20170041871A (ko) | 2017-04-17 |
BR112017005184A2 (pt) | 2017-12-05 |
JP2019022912A (ja) | 2019-02-14 |
CA2960938C (en) | 2020-10-06 |
JP6690681B2 (ja) | 2020-04-28 |
KR101996155B1 (ko) | 2019-07-03 |
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