WO2016051765A1 - プレス成形品の製造方法、製造装置及び製造設備列 - Google Patents
プレス成形品の製造方法、製造装置及び製造設備列 Download PDFInfo
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- WO2016051765A1 WO2016051765A1 PCT/JP2015/004926 JP2015004926W WO2016051765A1 WO 2016051765 A1 WO2016051765 A1 WO 2016051765A1 JP 2015004926 W JP2015004926 W JP 2015004926W WO 2016051765 A1 WO2016051765 A1 WO 2016051765A1
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- punch
- press
- die
- pad
- vertical wall
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
- B21D22/06—Stamping using rigid devices or tools having relatively-movable die parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/10—Stamping using yieldable or resilient pads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/21—Deep-drawing without fixing the border of the blank
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
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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
- B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
- B21D24/04—Blank holders; Mounting means therefor
- B21D24/06—Mechanically spring-loaded blank holders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
- B21D47/01—Making rigid structural elements or units, e.g. honeycomb structures beams or pillars
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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
Definitions
- the present invention relates to a method, an apparatus, and an equipment row for manufacturing a press-formed product used for automobiles, various vehicles other than automobiles, home appliances, ships, building materials and the like.
- the body of an automobile includes various structural members (eg, floor cross members, side sills, side members, etc.).
- a press-formed product made of a metal plate such as a steel plate is often used.
- a press-formed product is obtained by subjecting a metal plate to press working by bending because of material breakage at the time of press forming, shape freezing property, and superiority in manufacturing cost.
- the press-formed product has, for example, a groove shape or a hat-shaped cross-sectional shape.
- the press-formed product having a groove-shaped cross section includes a top plate portion and a pair of vertical wall portions extending from the top plate portion.
- the press-formed product having a hat-shaped cross section further includes a pair of flange portions extending from each vertical wall portion.
- FIG. 1 is a cross-sectional view schematically showing a configuration example of a press forming apparatus that performs general bending forming.
- the press molding apparatus 1 is an apparatus for manufacturing a press-formed product having a groove-shaped cross section or a hat-shaped cross section.
- FIG. 1 exemplifies a case of manufacturing a press-formed product having a hat-shaped cross section (refer to a one-dot chain line in the drawing).
- the press molding apparatus 1 includes a punch 2 as a lower mold, and includes a die 3 and a pad 5 as upper molds.
- the pad 5 is supported via the pressure member 4 on the die 3 or a die holder or slide that operates integrally with the die 3.
- the pad 5 can be accommodated in the die 3 and constitutes a part of the die 3 while being accommodated in the die 3.
- Bending molding in which the metal plate 6 is molded into a press-molded product by such a press molding apparatus 1 is performed as follows. Prior to forming, the metal plate 6 is sandwiched between the punch 2 and the pad 5. That is, before the punch 2 starts to push the metal plate 6 into the die 3, the portion of the metal plate 6 that is formed on the top plate portion of the press-formed product is restrained by the punch 2 and the pad 5. In this state, the die 3 is lowered to the bottom dead center. Thereby, the top plate portion of the press-formed product is formed along the upper surface (tip surface) 2 a of the punch 2. The vertical wall portion is formed along the side surface 2 b of the punch 2. A ridge line portion is formed between the top plate portion and the vertical wall portion. A ridge line portion connecting the top plate portion and the vertical wall portion is formed along the punch shoulder portion 2 c of the punch 2.
- pad bending such referred to as pad bending.
- a high-strength steel plate having a tensile strength of 590 MPa or more is used as the metal plate 6 that is a material of the structural member.
- a 980 MPa class high strength steel sheet may be used, and a 1180 MPa class high strength steel sheet may be used in some cases.
- the shape of the structural member may be relatively complicated. This is due to design restrictions such as prevention of interference between the structural member and other members, joining of the structural member and other members, and securing of a desired space.
- FIGS. 2A and 2B, and FIGS. 3 to 8 are perspective views showing an example of a press-formed product having a relatively complicated shape.
- FIGS. 2A and 2B are diagrams showing a first example of a high-strength steel plate (alloyed hot-dip galvanized steel plate having a thickness of 1.2 mm made of DP (Dual Phase) steel) having a tensile strength of 590 MPa or more.
- An example of a press-formed product 7 is shown.
- FIG. 2A shows the entire press-formed product 7 of the first example
- FIG. 2B shows an A portion in FIG. 2A in an enlarged manner.
- 3 to 8 show a second example to a second example formed from a high-strength steel plate having a tensile strength of 590 MPa or more (alloyed hot-dip galvanized steel plate, non-plated steel plate, etc. having a plate thickness of about 1.2 mm). Seven examples of press-formed products 7 are shown.
- any press-formed product 7 in the first to seventh examples are all hat-shaped. That is, any press-formed product 7 includes a top plate portion 7a, a vertical wall portion 7c extending from the left and right ends of the top plate portion 7a, and a ridge line portion 7b between the top plate portion 7a and the vertical wall portion 7c. And a flange portion 7d extending from the lower end of each vertical wall portion 7c. Further, the press-formed product 7 has a shape changing portion 9 in a part of the ridge line portion 7b.
- the shape changing portions 9 are provided on both the ridge line portions 7b at both ends of the top plate portion 7a. These shape changing portions 9 are portions in which the height of the ridge line portion 7 b changes at a location approximately in the center in the longitudinal direction of the press-formed product 7. In this case, a stepped portion 8 is formed on the top plate portion 7a in a region connecting the shape changing portions 9 to each other.
- the shape changing portions 9 are provided on both the ridge line portions 7b at both ends of the top plate portion 7a.
- These shape changing portions 9 are those in which the height of the ridge line portion 7 b changes in a wide range substantially at the center in the longitudinal direction of the press-formed product 7. In this case, the height of the top plate portion 7a changes gently corresponding to the position of the shape changing portion 9.
- the shape changing portion 9 is provided on one of the ridge line portions 7b at both ends of the top plate portion 7a.
- the shape changing portion 9 is a portion in which the arc length in the cross section of the ridge line portion 7b changes at a location approximately at the center in the longitudinal direction of the press-formed product 7. In this case, the angle formed by the top plate portion 7a and the vertical wall portion 7c changes corresponding to the position of the shape changing portion 9.
- the shape changing portions 9 are provided on both the ridge line portions 7b at both ends of the top plate portion 7a.
- These shape change parts 9 are those in which the ridge line part 7 b is twisted in a wide range substantially at the center in the longitudinal direction of the press-formed product 7. In this case, the top plate portion 7a and the vertical wall portion 7c are twisted corresponding to the position of the shape changing portion 9.
- the shape changing portions 9 are provided on both the ridge line portions 7b at both ends of the top plate portion 7a. These shape changing portions 9 are a wide area in the center of the press-formed product 7 in the longitudinal direction, and the ridge line portion 7 b is bent in the width direction of the press-formed product 7. In this case, the top plate portion 7 a and the vertical wall portion 7 c are bent in the width direction of the press-formed product 7 in correspondence with the position of the shape changing portion 9.
- the shape changing portion 9 is provided on one of the ridge line portions 7b at both ends of the top plate portion 7a.
- the shape changing portion 9 is a portion approximately in the center in the longitudinal direction of the press-formed product 7, and the ridge line portion 7 b is recessed in the width direction of the press-formed product 7.
- the top plate portion 7 a and the vertical wall portion 7 c are recessed in the width direction of the press-formed product 7, corresponding to the position of the shape changing portion 9.
- the shape changing portion 9 is provided on one of the ridge line portions 7b at both ends of the top plate portion 7a.
- the shape changing portion 9 is a portion in which the radius of curvature in the cross section of the ridge line portion changes in a range from the substantially center in the longitudinal direction of the press-formed product 7 to one end.
- the width of the top plate portion 7a and the height of the vertical wall portion 7c change corresponding to the position of the shape changing portion 9.
- the press-formed product 7 of the first example shown in FIG. 2A is manufactured cold from a high-strength steel plate by the pad bending shown in FIG. 1, the following problems occur. As shown by a thick line in FIG. 2B, the press-formed product 7 is cracked in the region of the shape changing portion 9 in the ridge line portion 7b. This crack also occurs in a region near the shape changing portion 9 (stepped portion 8, top plate portion 7a, etc.). During pad bending, bending stress acts on the ridge line portion 7b in a direction perpendicular to the direction along the ridge line portion 7b. Further, a tensile stress acts on the shape changing portion 9 in the ridge line portion 7b in a direction along the ridge line portion 7b.
- both the bending stress and the tensile stress act on the shape changing portion 9. Therefore, the region of the shape changing portion 9 and the region in the vicinity thereof undergo tensile bending deformation. It is considered that a crack occurs in the region of the shape change portion 9 due to this tensile bending deformation.
- Patent Document 1 International Publication No. 2014/042067 pamphlet
- Patent Document 2 Japanese Patent Application Laid-Open No. 11-319963
- Patent document 1 is directed to the production of a press-molded product having a hat-shaped cross section and curved in the height direction, and discloses a technique for suppressing cracks that occur in the top plate portion of the convex curved portion of the press-molded product. .
- press molding by this technique is drawing using a blank holder. In the drawing, tensile stress is generated in a direction orthogonal to the direction along the ridge line portion. Therefore, in a press-molded product having a shape change portion at a part of the ridge line portion, the tensile stress generated in the shape change portion increases, and the occurrence of cracks cannot be suppressed.
- Patent Document 2 there is a possibility that the occurrence of cracks can be reduced.
- the material is compressed prior to press molding. Therefore, an additional process and equipment are required, and an increase in manufacturing cost is inevitable.
- the object of the present invention is to change the shape even when a high-strength steel sheet is used as a material, for example, when forming a press-formed product having a groove-shaped cross section or a hat-shaped cross section having a shape change portion at a part of the ridge line portion. It is providing the manufacturing method of the press-molded product which can reduce generation
- Another object of the present invention is to provide a vertical wall even when, for example, a high-strength steel plate is used as a material when forming a press-formed product having a hat-shaped cross section having a shape change portion at a part of a ridge line portion. It is providing the manufacturing method of the press-molded product which can reduce generation
- a manufacturing method is a method for manufacturing a press-formed product from a material.
- the press-molded product includes a top plate portion, a vertical wall portion extending from each end of the top plate portion, and a ridge line portion between the vertical wall portion and the top plate portion, A part has a shape change part.
- the manufacturing method includes: A preparation step of preparing a metal plate as the material; A punch, a pad disposed opposite to the tip end surface of the punch, and a pressing process for pressing the material using a die that can accommodate the pad.
- the pressing process includes The pad is removed from the punch during a period from when the punch starts to push the material into the die or immediately after the punch reaches the predetermined distance from the bottom dead center of the push.
- the predetermined distance is preferably 3 to 30 mm.
- the manufacturing method of (1) above In the press working step, the top plate portion and the ridge line portion are formed, and a predetermined region from the top plate portion to a predetermined height is formed among regions formed in the vertical wall portion.
- the manufacturing method further includes a second press working step of pressing the intermediate molded product obtained in the press working step.
- the vertical wall portion is formed from a surplus region excluding the predetermined region among regions formed in the vertical wall portion.
- the second press working step includes a main second punch, a sub second punch disposed adjacent to the main second punch, a second pad disposed to face the front end surface of the main second punch, and A second die that can accommodate the second pad is used.
- the second pressing process includes Starting to push the intermediate molded product into the second die by the main second punch in a state where the top plate portion of the intermediate molded product is sandwiched between the main second punch and the second pad; The pressing of the main second punch with respect to the second die is continued to the bottom dead center of the pressing, the second pad is accommodated in the second die, and the vertical wall portion from the surplus region of the intermediate molded product Forming the step, Starting the pressing of the secondary second punch into the second die and the second pad, and continuing the pressing of the secondary second punch to the bottom dead center of the pressing, from the surplus area of the intermediate molded product Forming a flange portion.
- the manufacturing method is a method for manufacturing a press-formed product from a material.
- the press-formed product includes a top plate portion, a vertical wall portion extending from both ends of the top plate portion, a ridge line portion between the vertical wall portion and the top plate portion, and an end of each vertical wall portion.
- a flange portion extending from the ridge line portion, and a shape changing portion at a part of the ridge line portion.
- the manufacturing method includes: A preparation step of preparing a metal plate as the material; And a pressing process for pressing the material.
- the press working step uses a main punch, a sub-punch arranged adjacent to the main punch, a pad arranged facing the front end surface of the main punch, and a die that can accommodate the pad.
- the pressing process includes Starting the pressing of the material into the die by the main punch with the material sandwiched between the main punch and the pad; Continuing the pushing of the main punch against the die to the bottom dead center of the pushing, accommodating the pad in the die, and forming the top plate portion, the ridge line portion, and the vertical wall portion; Forming the flange portion by starting to push the sub punch into the die and the pad and continuing the pushing of the sub punch to the bottom dead center of the pushing.
- the manufacturing method includes: Prior to the pressing process, a pre-pressing process is performed in which the metal plate prepared in the preparing process is pressed to obtain an intermediate molded product as the material.
- the intermediate molded product As the intermediate molded product, the top plate portion and the ridge line portion are formed, and a predetermined region from the top plate portion to a predetermined height is formed among the regions formed in the vertical wall portion. Mold.
- the pressing process In the pressing process, In the state where the top plate portion of the intermediate molded product is sandwiched between the main punch and the pad, the pressing of the intermediate molded product into the die by the main punch is started.
- the pressing of the main punch into the die is continued to the bottom dead center of the pressing, the pad is accommodated in the die, and the surplus area excluding the predetermined area among the areas formed in the vertical wall portion
- the said vertical wall part is shape
- the pressing of the sub punch into the die and the pad is started, and the pressing of the sub punch is continued to the bottom dead center of the pressing, thereby forming the flange portion from the surplus region of the intermediate molded product.
- the manufacturing method of (2) or (4) preferably employs the following configuration.
- the predetermined height h (mm) satisfies the condition of the following formula (1).
- H shows the height (mm) of the said press-molded product
- Rp shows the curvature radius (mm) in the cross section of the said ridgeline part.
- the manufacturing method described above can employ the following configuration.
- the shape changing portion of the ridge line portion is at least one of the following (a) to (f).
- the curvature radius in the cross section of the ridge line portion changes.
- a manufacturing apparatus is an apparatus for manufacturing a press-formed product from a material.
- the press-molded product includes a top plate portion, a vertical wall portion extending from each end of the top plate portion, and a ridge line portion between the vertical wall portion and the top plate portion, A part has a shape change part.
- the manufacturing apparatus includes: A punch including a front end surface corresponding to the top plate portion, a side surface corresponding to the vertical wall portion, and a punch shoulder portion corresponding to the ridge line portion; A pad disposed opposite to the tip surface of the punch; A die capable of accommodating the pad; A pad adjusting mechanism for adjusting the distance of the pad from the tip surface of the punch.
- An apparatus for manufacturing a press-formed product includes a punch, a pad, a die, and a pad adjustment mechanism.
- the punch includes a front end surface, a side surface, and a punch shoulder portion provided between the front end surface and the side surface, and has a shape changing portion whose shape changes in a part of the extending direction of the punch shoulder portion.
- the pad is disposed to face the tip end surface of the punch at least in a cross section perpendicular to the extending direction of the punch shoulder at the shape changing portion.
- the die includes a recess that can receive the pad on a surface facing the tip surface of the punch, and a corner that has a shape that matches the shape of the punch shoulder at a location facing the punch shoulder.
- the pad adjusting mechanism adjusts a distance between the tip surface of the punch and the pad.
- the pad adjusting mechanism is The pad is removed from the punch during a period from when the punch starts to push the material into the die or immediately after the punch reaches the predetermined distance from the bottom dead center of the push. Hold at a position away from the predetermined distance, When the pressing of the punch into the die reaches the predetermined distance before the bottom dead center, the pad is accommodated in the die.
- the predetermined distance is preferably 3 to 30 mm.
- the manufacturing equipment line according to the embodiment of the present invention is an equipment line for manufacturing a press-formed product from a material.
- the press-formed product includes a top plate portion, a vertical wall portion extending from both ends of the top plate portion, a ridge line portion between the vertical wall portion and the top plate portion, and an end of each vertical wall portion.
- a flange portion extending from the ridge line portion, and a shape changing portion at a part of the ridge line portion.
- the manufacturing equipment row includes the manufacturing apparatus according to any one of (5) to (7) above, and a second manufacturing apparatus that presses an intermediate molded product obtained by the manufacturing apparatus.
- the intermediate molded product is obtained by molding a region from the top plate portion to a predetermined height in the vertical wall portion.
- the second manufacturing apparatus is The front end surface corresponding to the top plate portion, the side surface corresponding to the vertical wall portion, the punch shoulder portion corresponding to the ridge line portion, and the corner portion corresponding to the ridge line portion between the vertical wall portion and the flange portion
- a main second punch including A sub-second punch disposed adjacent to the main second punch and including a tip surface corresponding to the flange portion;
- a second pad disposed to face the front end surface of the main second punch;
- a sub punch adjusting mechanism for delaying the pressing of the intermediate molded product into the second die by the sub second punch rather than the pressing of the intermediate molded product into the second die by the main second punch.
- the sub punch adjusting mechanism is After the pressing of the main second punch into the second die reaches bottom dead center, the pressing of the sub second punch into the second die is started.
- the die of the manufacturing apparatus is formed such that the predetermined height h (mm) satisfies the condition of the following formula (1).
- H shows the height (mm) of the said press-molded product
- Rp shows the curvature radius (mm) in the cross section of the said ridgeline part.
- the shape change The occurrence of cracks can be reduced in the region of the part.
- the occurrence of warping of the vertical wall portion can be reduced.
- FIG. 1 is a cross-sectional view schematically showing a configuration example of a press forming apparatus that performs general bending forming.
- FIG. 2A is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 2B is an enlarged perspective view showing a portion A in FIG. 2A.
- FIG. 3 is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 4 is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 5 is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 6 is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 1 is a cross-sectional view schematically showing a configuration example of a press forming apparatus that performs general bending forming.
- FIG. 2A is a perspective view showing an example of a press-formed product having a relatively
- FIG. 7 is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 8 is a perspective view showing an example of a press-formed product having a relatively complicated shape.
- FIG. 9 is a perspective view showing an example of a configuration of a first manufacturing apparatus used for manufacturing a press-formed product in the first embodiment of the present invention.
- FIG. 10 is a perspective view showing an example of the configuration of the second manufacturing apparatus used for manufacturing the press-formed product in the first embodiment of the present invention.
- FIG. 11A is a diagram illustrating a state of the first press working step by the first manufacturing apparatus in the first embodiment, and shows a state before the start of molding.
- FIG. 11B is a diagram showing a state of the first press working step by the first manufacturing apparatus in the first embodiment, and shows a state in the initial stage of molding.
- FIG. 11C is a diagram showing a state of the first press working step by the first manufacturing apparatus in the first embodiment, and shows a state at the end of molding.
- FIG. 11D is a diagram showing a state of the first press working step by the first manufacturing apparatus in the first embodiment, and shows a state when the molding is completed.
- FIG. 12A is a diagram showing a state of the second press working step by the second manufacturing apparatus in the first embodiment, and shows a state before the start of molding.
- FIG. 12A is a diagram showing a state of the second press working step by the second manufacturing apparatus in the first embodiment, and shows a state before the start of molding.
- FIG. 12B is a diagram showing a state of the second press working step by the second manufacturing apparatus in the first embodiment, and shows a state at the end of molding.
- FIG. 12C is a diagram showing a state of the second press working step by the second manufacturing apparatus in the first embodiment, and shows a state when the molding is completed.
- the present inventors obtained the following findings (A) and (B) as a result of intensive studies to solve the above problems.
- FIG. 9 is a perspective view showing an example of a configuration of a first manufacturing apparatus used for manufacturing a press-formed product in the first embodiment of the present invention.
- FIG. 10 is a perspective view showing an example of the configuration of the second manufacturing apparatus used for manufacturing the press-formed product in the first embodiment of the present invention.
- the press-formed product is manufactured through a first press working step and a second press working step in order.
- a first press molding apparatus 10 first manufacturing apparatus shown in FIG. 9
- a second press molding apparatus 20 shown in FIG. 10 is used. That is, the 1st press molding apparatus 10 and the 2nd press molding apparatus 20 comprise a series of manufacturing equipment rows.
- FIG. 11A to FIG. 11D are views showing the state of the first press working process by the first manufacturing apparatus in the first embodiment.
- FIG. 11A shows a state before the start of molding.
- FIG. 11B shows an initial state of molding.
- FIG. 11C shows a state at the end of molding.
- FIG. 11D shows a state when the molding is completed.
- 12A to 12C are views showing the state of the second press working process by the second manufacturing apparatus in the first embodiment.
- FIG. 12A shows a state before the start of molding.
- FIG. 12B shows a state at the end of molding.
- FIG. 12C shows a state when the molding is completed.
- These drawings show a cross section of the region of the shape changing portion.
- the first press molding apparatus 10 includes a first punch 11 as a lower mold and a first die 12 and a first pad 13 as an upper mold. That is, the first punch 11, the first die 12 and the first pad 13 make a pair.
- dye 12 is shown with a dashed-dotted line.
- the first punch 11 includes an upper surface 11a (tip surface), a pair of side surfaces 11b, and a punch shoulder portion 11c provided between the upper surface 11a and the side surface 11b.
- the punch shoulder 11c is a part connecting the upper surface 11a and the side surface 11b.
- the shape of the upper surface 11a is a shape corresponding to the top plate portion of the press-formed product.
- the shape of the side surface 11b is a shape corresponding to the vertical wall portion of the press-formed product.
- the shape of the punch shoulder portion 11c is a shape corresponding to the ridge line portion of the press-formed product.
- a shape changing portion whose shape changes is formed in a part of the extending direction of the punch shoulder portion 11c.
- the shape of the shape changing portion of the punch shoulder portion 11c is a shape corresponding to the shape changing portion existing in a part of the ridge line portion of the press-formed product. That is, the punch shoulder portion 11c includes a portion where the cross-sectional shape changes in the extending direction or the extending direction is bent.
- the first pad 13 is disposed to face the upper surface 11 a of the first punch 11.
- the first die 12 includes a recess 12 c at a position facing the upper surface 11 a of the first punch 11.
- the first pad 13 can be accommodated in the recess 12c.
- the first pad 13 constitutes a part of the first die 12 while being accommodated in the recess 12 c of the first die 12.
- the first die 12 includes a corner 12 d at a position facing the punch shoulder 11 c of the first punch 11.
- the shape of the corner 12d is a shape that matches the shape of the punch shoulder 11c.
- the first die 12 includes a pair of first inner side surfaces 12a adjacent to the corner 12d.
- the first inner side surface 12 a faces the side surface 11 b of the first punch 11.
- the shape of the 1st inner surface 12a is a shape corresponding to the predetermined area
- the first die 12 includes a pair of second inner side surfaces 12b adjacent to the first inner side surface 12a. The interval between the opposing second inner side surfaces 12b widens outwardly in the width direction of the first die 12.
- the first pad 13 is supported by the die holder 15 holding the first die 12 via the first pressure member 16.
- the first pressurizing member 16 is a hydraulic cylinder, a gas cylinder, a spring, rubber, or the like, and applies a downward force (force toward the first punch 11) to the first pad 13.
- the arm portion 13a protrudes from the first pad 13, and the first pressure member 16 is provided between the arm portion 13a and the die holder 15.
- the first pad 13 may be supported by a slide that operates integrally with the first die 12 or the die holder 15 as long as the first pad 13 is supported via the first pressure member 16.
- the first press molding apparatus 10 includes a pad adjustment mechanism that adjusts the distance of the first pad 13 from the upper surface 11a of the first punch 11.
- the pad adjustment mechanism is configured as follows, for example. As shown in FIGS. 11A to 11D, a block 17 is provided immediately below the arm portion 13a protruding from the first pad 13. The block 17 is supported by a punch holder 18 that holds the first punch 11 via a second pressure member 19.
- the second pressurizing member 19 is a hydraulic cylinder, a gas cylinder, a spring, rubber or the like, and applies an upward force (a force toward the first die 12) to the block 17.
- the upward force applied to the block 17 by the second pressure member 19 is greater than the downward force applied to the first pad 13 by the first pressure member 16. As long as the block 17 is supported via the second pressure member 19, it may be supported by the base of the press machine.
- the first pad 13 descends following the descending of the first die 12, and the distance of the first pad 13 from the upper surface 11a of the first punch 11 is a predetermined distance. When it becomes, arm part 13a and block 17 contact. Thereafter, as shown in FIG. 11B, even if the first die 12 continues to descend, the first pad 13 is held in that position until it is received in the recess 12 c of the first die 12. This is because an upward force from the second pressure member 19 that is greater than the downward force from the first pressure member 16 is acting on the first pad 13. 11C and 11D, when the first pad 13 is received in the recess 12c of the first die 12, the first pad 13 is lowered integrally with the first die 12.
- the second press molding apparatus 20 includes a main second punch 21 and a sub second punch 24 as a lower die, and a second die 22 and a second pad as an upper die. 23. That is, the main second punch 21 and the sub second punch 24, and the second die 22 and the second pad 23 form a pair.
- dye 22 is shown with a dashed-dotted line.
- the main second punch 21 includes an upper surface 21a (tip surface), a pair of side surfaces 21b, and a punch shoulder portion 21c provided between the upper surface 21a and the side surface 21b.
- the punch shoulder 21c is a portion connecting the upper surface 21a and the side surface 21b.
- the shape of the upper surface 21a is a shape corresponding to the top plate portion of the press-formed product.
- the shape of the side surface 21b is a shape corresponding to the vertical wall portion of the press-formed product.
- the shape of the punch shoulder portion 21c is a shape corresponding to the ridge line portion of the press-formed product.
- a shape changing portion whose shape changes is formed in a part of the extending direction of the punch shoulder portion 21c.
- the shape of the shape changing portion of the punch shoulder portion 21c is a shape corresponding to the shape changing portion existing in a part of the ridge line portion of the press-formed product. Further, the main second punch 21 includes a curved surface 21d adjacent to the side surface 21b.
- the secondary second punch 24 is disposed adjacent to the outside of the main second punch 21.
- the sub second punch 24 includes an upper surface 24a (tip surface).
- the shape of the upper surface 24a is a shape corresponding to the flange portion of the press-formed product.
- the second pad 23 is disposed to face the upper surface 21a of the main second punch 21.
- the second die 22 includes a recess 22 c at a position facing the upper surface 21 a of the main second punch 21.
- the 2nd pad 23 can be accommodated in the recessed part 22c.
- the second pad 23 constitutes a part of the second die 22 while being accommodated in the recess 22 c of the second die 22.
- the second die 22 has a corner 22 d at a position facing the punch shoulder 21 c of the main second punch 21.
- the shape of the corner 22d is a shape that matches the shape of the punch shoulder 21c.
- the second die 22 includes a pair of inner side surfaces 22a adjacent to the corner 22d.
- the inner side surface 22 a faces the side surface 21 b of the main second punch 21.
- the shape of the inner side surface 22a is a formation corresponding to the vertical wall portion of the press-formed product.
- the second die 22 includes a pair of die shoulder portions 22e adjacent to the inner side surface 22a.
- the shape of the die shoulder portion 22e is a shape corresponding to the ridge line portion existing between the vertical wall portion and the flange portion of the press-formed product.
- the second die 22 includes a pair of lower surfaces 22e (tip surfaces) adjacent to the die shoulder 22e.
- the lower surface 22e faces the sub second punch 24.
- the second pad 23 is supported by a die holder 27 holding the second die 22 via a third pressure member (not shown).
- the third pressurizing member is a hydraulic cylinder, a gas cylinder, a spring, rubber, or the like, and applies a downward force (force toward the main second punch 21) to the second pad 23.
- the second pad 23 may be supported by a slide that operates integrally with the second die 22 or the die holder 27 as long as the second pad 23 is supported via the third pressure member.
- the second press molding apparatus 20 includes a sub punch adjusting mechanism that delays the pressing of the sub second punch 24 into the second die 22 rather than the pressing of the main second punch 21 into the second die 22.
- the auxiliary punch adjusting mechanism is configured as follows, for example. As shown in FIGS. 12A to 12C, the secondary second punch 24 is held by the punch holder 28. The main second punch 21 protrudes from the sub second punch 24 and is supported by the punch holder 28 via the fourth pressure member 26.
- the fourth pressure member 26 is a hydraulic cylinder, a gas cylinder, a spring, rubber, or the like, and applies an upward force (force toward the second die 22) to the main second punch 21. The upward force applied to the main second punch 21 by the fourth pressure member 26 is greater than the downward force applied to the second pad 23 by the third pressure member.
- the main second punch 21 may be supported by the base of the press machine as long as it is supported via the fourth pressure member 26.
- the second pad 23 is accommodated in the recess 22 c of the second die 22 as the second die 22 descends. Thereby, pushing of the main second punch 21 into the second die 22 is completed. Thereafter, when the second die 22 continues to descend, the main second punch 21 descends integrally with the second die 22 and the second pad 23 thereafter. Thereby, the auxiliary second punch 24 is pushed into the second die 22.
- the manufacturing method of the press-formed product 7 using the first press molding apparatus 10 (first manufacturing apparatus) and the second press molding apparatus 20 (second manufacturing apparatus) includes the following steps.
- a metal plate 14 is prepared as a material.
- a high strength steel plate having a tensile strength of 590 MPa or more can be used.
- the metal plate 14 may be a 980 MPa class high strength steel plate or a 1180 MPa class high strength steel plate.
- a stainless steel plate, an aluminum plate, a copper plate, or the like can be used.
- the intermediate molded product 25 includes a top plate portion 25a, a ridge line portion 25b, and a vertical wall portion 25c.
- the top plate portion 25 a corresponds to the top plate portion 7 a of the press-formed product 7.
- the ridge line portion 25 b corresponds to the ridge line portion 7 b of the press-formed product 7.
- the region of the vertical wall portion 25c is divided into a predetermined region 25ca connected to the ridge line portion 25b and a surplus region 25cb connected to the first vertical wall portion 25c.
- the predetermined region 25ca corresponds to a region from the top plate portion 7a to the predetermined height h in the region of the vertical wall portion 7c of the press-formed product 7.
- the surplus area 25cb is an area that exceeds the predetermined height h. That is, the surplus area 25 cb is an area excluding the predetermined area 25 ca among the areas formed on the vertical wall portion 7 c of the press-formed product 7.
- the surplus area 25cb includes an area formed on the flange portion 7d of the press-formed product 7.
- the first die 12 After placing the metal plate 14 on the first punch 11, the first die 12 is lowered. At this time, the arm portion 13 a and the block 17 are separated from each other, and the first pad 13 is lowered integrally with the first die 12. Thereafter, as shown in FIG. 11A, the arm portion 13 a contacts the block 17. At this time, the distance of the first pad 13 from the upper surface 11a of the first punch 11 is a predetermined distance. Further, the second inner side surface 12 b of the first die 12 is in contact with both edge portions of the metal plate 14. The lowering of the first pad 13 is restricted by the contact between the arm portion 13 a and the block 17.
- the lowering of the first die 12 is continued. Thereby, pushing of the metal plate 14 into the first die 12 by the first punch 11 starts, and bending of the metal plate 14 starts.
- the first pad 13 is held at a position away from the upper surface 11a of the first punch 11 by a predetermined distance. Therefore, the metal plate 14 is gradually deformed and comes into contact with the first pad 13, but is not sandwiched between the first pad 13 and the first punch 11. That is, the metal plate 14 is not restrained by the first pad 13 and the first punch 11.
- the pressing of the first punch 11 into the first die 12 reaches a predetermined distance before the bottom dead center of the pressing.
- the first pad 13 is accommodated in the recess 12 c of the first die 12 and integrated with the first die 12. That is, when the first punch 11 starts to push the metal plate 14 into the first die 12 or immediately after that, the first punch 11 is pushed into the first die 12 a predetermined distance before the bottom dead center of the push. The first pad 13 is held at a position away from the upper surface 11a of the first punch 11 by a predetermined distance until it reaches.
- the top-plate part 25a and the ridgeline part 25b are shape
- the shapes of the top plate portion 25a and the ridge line portion 25b of the intermediate molded product 25 match the shapes of the top plate portion 7a and the ridge line portion 7b (including part of the shape change portion) of the press-formed product 7.
- the metal plate 14 is not moved to the bottom dead center of the first die 11 and the first pad 13 pushed to the bottom dead center. It is not restrained by the pad 13 and the first punch 11. Therefore, the metal plate restraint by the punch and die is eased during the molding. Thereby, the tensile bending deformation
- the first pad 13 is temporarily held at a position away from the upper surface 11a of the first punch 11 during molding by the first press working step.
- the predetermined distance is preferably 3 to 30 mm. The reason is as follows. If the predetermined distance is less than 3 mm, the material metal plate may be restrained. On the other hand, when the predetermined distance exceeds 30 mm, the metal plate 14 does not come into contact with the first pad 13 during molding, and the reason for the existence of the first pad 13 is lost.
- a predetermined region 25ca from the top plate portion 7a to a predetermined height h in the region of the vertical wall portion 7c of the press-formed product 7 is formed.
- the predetermined height h (mm) preferably satisfies the condition of the following formula (1).
- H shows the height (mm) of a press-molded product
- Rp shows the curvature radius (mm) in the cross section of a ridgeline part.
- the curvature radius Rp is the curvature radius of the inner periphery of the inner periphery and outer periphery of the ridge line portion. That is, it corresponds to the radius of curvature of the punch shoulder of the first punch.
- the predetermined height h may satisfy the condition of the following formula (2). H / 4 ⁇ h ⁇ 3 ⁇ H / 4 (2)
- the second die 22 After placing the intermediate molded product 25 on the main second punch 21, the second die 22 is lowered. As a result, the second pad 23 is lowered integrally with the second die 22. Thereafter, as shown in FIG. 12A, the second pad 23 contacts the top plate portion 25 a of the intermediate molded product 25. Thereby, the intermediate molded product 25 is sandwiched between the second pad 23 and the main second punch 21. Further, the lowering of the second pad 23 is restricted in a state where the intermediate molded product 25 is restrained by the second pad 23 and the main second punch 21.
- the second die 22 continues to descend. Thereby, pushing of the intermediate molded product 25 into the second die 22 by the main second punch 21 is started, and bending molding of the intermediate molded product 25 is started.
- the pressing of the main second punch 21 against the second die 22 reaches the bottom dead center of the pressing.
- the second pad 23 is accommodated in the recess 22 c of the second die 22 and integrated with the second die 22.
- the main second punch 21 is integrated with the second die 22 and the second pad 23.
- the top plate part 7a and the ridge line part 7b of the press-formed product 7 are completely formed.
- the region of the vertical wall portion 7 c of the press-formed product 7 is completely formed from the predetermined region 25 ca of the intermediate molded product 25 and is formed from the surplus region 25 cb of the intermediate molded product 25.
- the lowering of the second die 22 and the second pad 23 is continued.
- the pressing of the intermediate molded product 25 into the second die 22 and the second pad 23 by the sub second punch 24 is started.
- the second die 22 and the second pad 23 are lowered, and the sub second punch 24 is pushed into the second die 22 and the second pad 23 until the bottom dead center.
- the flange part 7d is shape
- the flange portion is molded last. Thereby, the curvature of the vertical wall part resulting from a springback can be reduced. That is, the shape freezing property is improved.
- the press-formed product 7 of the first example having the hat-shaped cross section shown in FIG. 2A was manufactured by the manufacturing method of the first embodiment. As a material, a 590 MPa class high strength steel plate was used. In the press molded product 7, no cracks occurred in the region of the shape changing portion 9.
- the maximum principal strain in the area of the shape changing portion 9 was investigated.
- the maximum principal strain was 0.22.
- the maximum principal strain was as large as 0.26.
- the amount of warpage of the vertical wall 7c was investigated. As the amount of warpage, the distance between the lower ends of the pair of vertical wall portions 7c was evaluated. The warpage amount of the press-formed product 7 according to the first embodiment was reduced to about 13% compared to the warpage amount of the press-formed product by the pad bending molding shown in FIG.
- the press-formed product to be manufactured in the first embodiment is not limited to the press-formed product 7 of the first example having the hat-shaped cross section shown in FIG. 2A. That is, the press-formed product may be the press-formed product 7 of the second to seventh examples shown in FIGS. 3 to 8 as long as it has a shape changing portion at a part of the ridge line portion.
- the shape changing portion of the ridge line portion of the press-formed product is at least one of the following (a) to (f).
- C) The ridge line portion is twisted,
- D) The ridge line portion is bent in the width direction. (E) The ridge line portion protrudes or dents in the width direction,
- the pair of ridge lines of the press-formed product may not be parallel.
- a pair of ridge lines may intersect at the ends.
- the second embodiment is based on the first embodiment described above, and a part thereof is modified.
- the second press working step by the second press molding apparatus can be omitted.
- the first die 12 shown in FIGS. 9 and 11A to 11D the second inner side surface 12b is omitted, and the first inner side surface 12a having a shape corresponding to the vertical wall portion 7c of the press-formed product 7 is It extends to the region of the second inner surface 12b.
- a final press molded product is shape
- the second embodiment can be applied to the manufacture of a press-formed product that is not so high, and in particular, can be applied to the manufacture of a press-formed product having a groove-shaped cross section that does not have a flange portion.
- the third embodiment is based on the first embodiment described above, and a part thereof is modified. Similar to the second embodiment, when the main purpose is to reduce cracks in the region of the shape change portion, simple pad bending is performed on the intermediate molded product in the second press working step. Alternatively, bending may be performed without a pad.
- the fourth embodiment is based on the first embodiment described above, and a part thereof is modified.
- the first press working step by the first press molding apparatus can be omitted.
- a final press-molded product is formed using a metal plate as a raw material in the second press working step by the second press-molding apparatus.
- a preliminary press working step can be introduced in place of the first press working, and the intermediate molded product can be formed in this preliminary press working step. In the preliminary pressing process, simple pad bending may be performed on the metal plate.
- the present invention is not limited to the above-described embodiment, and it goes without saying that various modifications can be made without departing from the spirit of the present invention.
- the first punch is provided as the lower die and the first die and the first pad are provided as the upper die, but the upper and lower molds are arranged vertically. An inverted configuration may be used.
- the main die punch and the secondary second punch are provided as the lower die, and the second die and the second pad are provided as the upper die. The arrangement may be reversed upside down.
- the first pad of the first press molding apparatus is disposed to face the tip surface of the first punch at least in a cross section perpendicular to the extending direction of the punch shoulder at the shape changing portion. That is, it is preferable that the first pad is provided at a position at least overlapping with the shape change portion in the ridge line portion of the press-formed product.
- the first pad does not need to be provided at a position overlapping the shape change portion in the ridge line portion of the press-formed product. That is, the first pad may be provided at a position overlapping the vicinity if the vicinity is within 100 mm from the shape change portion in the ridge line portion of the press-formed product.
Abstract
Description
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、を備え、前記稜線部の一部に形状変化部を有する。
前記製造方法は、
前記素材として金属板を準備する準備工程と、
パンチ、前記パンチの先端面に対向して配置されるパッド、及び前記パッドを収容可能なダイを用い、前記素材にプレス加工を施すプレス加工工程と、を含む。
前記プレス加工工程は、
前記パンチによる前記素材の前記ダイへの押し込みを開始したとき又はその直後から、前記ダイに対する前記パンチの押し込みがその押し込みの下死点より所定距離手前に達するまでの期間、前記パッドを前記パンチから前記所定距離離れた位置に保持する工程と、
前記ダイに対する前記パンチの押し込みが前記下死点より前記所定距離手前に達したとき、前記パッドを前記ダイに収容する工程と、
前記ダイ及び前記パッドに対する前記パンチの押し込みを前記下死点まで継続し、前記天板部、前記稜線部、及び前記縦壁部を成形する工程と、を含む。
前記プレス加工工程では、前記天板部及び前記稜線部を成形するとともに、前記縦壁部に成形される領域のうちで前記天板部から所定高さまでの所定領域を成形する。
前記製造方法は、更に、前記プレス加工工程で得られた中間成形品にプレス加工を施す第2プレス加工工程を含む。
前記第2プレス加工工程では、前記縦壁部に成形される領域のうちで前記所定領域を除く余剰領域から前記縦壁部を成形する。
前記第2プレス加工工程は、主第2パンチ、前記主第2パンチに隣接して配置される副第2パンチ、前記主第2パンチの先端面に対向して配置される第2パッド、及び前記第2パッドを収容可能な第2ダイを用いる。
前記第2プレス加工工程は、
前記主第2パンチと前記第2パッドによって前記中間成形品の前記天板部を挟み込んだ状態で、前記主第2パンチによる前記中間成形品の前記第2ダイへの押し込みを開始する工程と、
前記第2ダイに対する前記主第2パンチの押し込みをその押し込みの下死点まで継続し、前記第2パッドを前記第2ダイに収容するとともに、前記中間成形品の前記余剰領域から前記縦壁部を成形する工程と、
前記第2ダイ及び前記第2パッドに対する前記副第2パンチの押し込みを開始し、前記副第2パンチの押し込みをその押し込みの下死点まで継続することによって前記中間成形品の前記余剰領域から前記フランジ部を成形する工程と、を含む。
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、前記各縦壁部の端から伸びるフランジ部と、を備え、前記稜線部の一部に形状変化部を有する。
前記製造方法は、
前記素材として金属板を準備する準備工程と、
前記素材にプレス加工を施すプレス加工工程と、を含む。
前記プレス加工工程は、主パンチ、前記主パンチに隣接して配置される副パンチ、前記主パンチの先端面に対向して配置されるパッド、及び前記パッドを収容可能なダイを用いる。
前記プレス加工工程は、
前記主パンチと前記パッドによって前記素材を挟み込んだ状態で、前記主パンチによる前記素材の前記ダイへの押し込みを開始する工程と、
前記ダイに対する前記主パンチの押し込みをその押し込みの下死点まで継続し、前記パッドを前記ダイに収容するとともに、前記天板部、前記稜線部、及び前記縦壁部を成形する工程と、
前記ダイ及び前記パッドに対する前記副パンチの押し込みを開始し、前記副パンチの押し込みをその押し込みの下死点まで継続することによって前記フランジ部を成形する工程と、を含む。
前記製造方法は、
前記プレス加工工程の前に、前記準備工程で準備した前記金属板にプレス加工を施して前記素材としての中間成形品を得る予備プレス加工工程を含む。
前記予備プレス加工工程では、前記中間成形品として、前記天板部及び前記稜線部を成形するとともに、前記縦壁部に成形される領域のうちで前記天板部から所定高さまでの所定領域を成形する。
前記プレス加工工程では、
前記主パンチと前記パッドによって前記中間成形品の前記天板部を挟み込んだ状態で、前記主パンチによる前記中間成形品の前記ダイへの押し込みを開始する。
その後、前記ダイに対する前記主パンチの押し込みをその押し込みの下死点まで継続し、前記パッドを前記ダイに収容するとともに、前記縦壁部に成形される領域のうちで前記所定領域を除く余剰領域から前記縦壁部を成形する。
その後、前記ダイ及び前記パッドに対する前記副パンチの押し込みを開始し、前記副パンチの押し込みをその押し込みの下死点まで継続することによって前記中間成形品の前記余剰領域から前記フランジ部を成形する。
前記所定高さh(mm)が下記式(1)の条件を満たす。
Rp≦h≦H-Rp …(1)
ただし、上記式(1)中、Hは前記プレス成形品の高さ(mm)を示し、Rpは前記稜線部の断面における曲率半径(mm)を示す。
前記稜線部の前記形状変化部が下記(a)~(f)のうちの少なくとも一つである。
(a)前記稜線部の高さが変化する、
(b)前記稜線部の断面における円弧長さが変化する、
(c)前記稜線部がねじれる、
(d)前記稜線部が幅方向に折れ曲がる、
(e)前記稜線部が幅方向に突出する又は窪む、
(f)前記稜線部の断面における曲率半径が変化する。
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、を備え、前記稜線部の一部に形状変化部を有する。
前記製造装置は、
前記天板部に対応する先端面、前記縦壁部に対応する側面、及び前記稜線部に対応するパンチ肩部を含むパンチと、
前記パンチの前記先端面に対向して配置されるパッドと、
前記パッドを収容可能なダイと、
前記パンチの前記先端面からの前記パッドの距離を調整するパッド調整機構と、を備える。
パンチは、先端面、側面、及び前記先端面と前記側面の間に設けられたパンチ肩部を備え、前記パンチ肩部の延在方向の一部に形状の変化する形状変化部を有する。
パッドは、少なくとも前記形状変化部における前記パンチ肩部の延在方向に垂直な断面において、前記パンチの前記先端面に対向して配置される。
ダイは、前記パンチの前記先端面に対向する面に前記パッドを収容できる凹部、及び前記パンチ肩部に対向する箇所が前記パンチ肩部の形状にあわせた形状である隅部を備える。
パッド調整機構は、前記パンチの前記先端面と前記パッドの間の間隔を調整する。
前記パッド調整機構は、
前記パンチによる前記素材の前記ダイへの押し込みを開始したとき又はその直後から、前記ダイに対する前記パンチの押し込みがその押し込みの下死点より所定距離手前に達するまでの期間、前記パッドを前記パンチから前記所定距離離れた位置に保持し、
前記ダイに対する前記パンチの押し込みが前記下死点より前記所定距離手前に達したとき、前記パッドを前記ダイに収容する。
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、前記各縦壁部の端から伸びるフランジ部と、を備え、前記稜線部の一部に形状変化部を有する。
前記製造設備列は、上記(5)~(7)のいずれかの製造装置と、前記製造装置で得られた中間成形品にプレス加工を施す第2製造装置と、を含む。
前記中間成形品は、前記縦壁部の領域のうちで前記天板部から所定高さまでの領域が成形されたものである。
前記第2製造装置は、
前記天板部に対応する先端面、前記縦壁部に対応する側面、前記稜線部に対応するパンチ肩部、及び前記縦壁部と前記フランジ部との間にある稜線部に対応する隅部を含む主第2パンチと、
前記主第2パンチに隣接して配置され、前記フランジ部に対応する先端面を含む副第2パンチと、
前記主第2パンチの先端面に対向して配置される第2パッドと、
前記縦壁部と前記フランジ部との間にある前記稜線部に対応するダイ肩部、及び前記フランジ部に対応する先端面を含み、前記第2パッドを収容可能な第2ダイと、
前記主第2パンチによる前記中間成形品の前記第2ダイへの押し込みよりも、前記副第2パンチによる前記中間成形品の前記第2ダイへの押し込みを遅らせる副パンチ調整機構と、を備える。
前記副パンチ調整機構は、
前記第2ダイに対する前記主第2パンチの押し込みが下死点に達した後に、前記第2ダイに対する前記副第2パンチの押し込みを開始する。
前記製造装置の前記ダイは、前記所定高さh(mm)が下記式(1)の条件を満たすように形成される。
Rp≦h≦H-Rp …(1)
ただし、上記式(1)中、Hは前記プレス成形品の高さ(mm)を示し、Rpは前記稜線部の断面における曲率半径(mm)を示す。
図9は、本発明の第1実施形態におけるプレス成形品の製造に用いられる第1製造装置の構成の一例を示す斜視図である。図10は、本発明の第1実施形態におけるプレス成形品の製造に用いられる第2製造装置の構成の一例を示す斜視図である。第1実施形態では、前記図2Aに示すハット形断面の第1例のプレス成形品7を製造する場合を例示する。第1実施形態では、プレス成形品は、第1プレス加工工程及び第2プレス加工工程を順に経て製造される。第1プレス加工工程では、図9に示す第1プレス成形装置10(第1製造装置)が用いられる。第2プレス加工工程では、図10に示す第2プレス成形装置20(第2製造装置)が用いられる。つまり、第1プレス成形装置10と第2プレス成形装置20は、一連の製造設備列を構成する。
図9、及び図11A~図11Dに示すように、第1プレス成形装置10は、下型として第1パンチ11を備え、上型として第1ダイ12及び第1パッド13を備える。つまり、第1パンチ11と、第1ダイ12及び第1パッド13と、が対を成す。なお、構成の理解を容易にするため、図9には、第1ダイ12を一点鎖線で示す。
図10、及び図12A~図12Cに示すように、第2プレス成形装置20は、下型として主第2パンチ21及び副第2パンチ24を備え、上型として第2ダイ22及び第2パッド23を備える。つまり、主第2パンチ21及び副第2パンチ24と、第2ダイ22及び第2パッド23と、が対を成す。なお、構成の理解を容易にするため、図10には、第2ダイ22を一点鎖線で示す。
上記の第1プレス成形装置10(第1製造装置)と第2プレス成形装置20(第2製造装置)を用いたプレス成形品7の製造方法は、以下の各工程を含む。
図9及び図11Aに示すように、素材として、金属板14を準備する。金属板14としては、例えば、引張強度が590MPa以上の高強度鋼板を用いることができる。金属板14は、980MPa級の高強度鋼板であってもよいし、1180MPa級の高強度鋼板であってもよい。また、金属板14として、ステンレス鋼板、アルミニウム板、銅板等を用いることもできる。
図9、及び図11A~図11Dに示すように、第1プレス加工工程では、第1プレス成形装置10を用いて金属板14に曲げ成形によるプレス加工を施し、中間成形品25を製造する。中間成形品25は、天板部25aと、稜線部25bと、縦壁部25cと、を備える。天板部25aは、プレス成形品7の天板部7aに対応する。稜線部25bは、プレス成形品7の稜線部7bに対応する。縦壁部25cの領域は、稜線部25bに繋がる所定領域25caと、第1縦壁部25cに繋がる余剰領域25cbに区分される。所定領域25caは、プレス成形品7の縦壁部7cの領域のうちで天板部7aから所定高さhまでの領域に対応する。余剰領域25cbは、その所定高さhを超える領域である。つまり、余剰領域25cbは、プレス成形品7の縦壁部7cに成形される領域のうちで所定領域25caを除く領域である。なお、余剰領域25cbには、プレス成形品7のフランジ部7dに成形される領域も含まれる。以下に、第1プレス加工工程での状況を具体的に説明する。
Rp≦h≦H-Rp …(1)
ただし、上記式(1)中、Hはプレス成形品の高さ(mm)を示し、Rpは稜線部の断面における曲率半径(mm)を示す。
ここでいう曲率半径Rpは、厳密には、稜線部の内周及び外周のうちの内周の曲率半径である。つまり、第1パンチのパンチ肩部の曲率半径に相当する。
H/4≦h≦3×H/4 …(2)
図10、及び図12A~図12Cに示すように、第2プレス加工工程では、第2プレス成形装置20を用いて中間成形品25に曲げ成形によるプレス加工を施し、最終的なプレス成形品7を製造する。以下に、第2プレス加工工程での状況を具体的に説明する。
第1実施形態の製造方法によって、前記図2Aに示すハット形断面の第1例のプレス成形品7を製造した。素材としては、590MPa級の高強度鋼板を用いた。このプレス成形品7には、形状変化部9の領域で割れが発生しなかった。
(a)稜線部の高さが変化する、
(b)稜線部の断面における円弧長さが変化する、
(c)稜線部がねじれる、
(d)稜線部が幅方向に曲がる、
(e)稜線部が幅方向に突出する又は窪む、
(f)稜線部の断面における曲率半径が変化する。
第2実施形態は上記の第1実施形態を基本とし、その一部を変形したものである。主な目的が形状変化部の領域での割れの低減にある場合、上記の第2プレス成形装置による第2プレス加工工程は省略できる。この場合、図9、及び図11A~図11Dに示す第1ダイ12に関し、第2内側面12bが省略され、プレス成形品7の縦壁部7cに対応する形状の第1内側面12aが、第2内側面12bの領域まで延長される。これにより、上記の第1プレス成形装置による第1プレス加工工程において、最終的なプレス成形品を成形する。第2実施形態は、高さがそれほど高くないプレス成形品の製造に適用することができ、特に、フランジ部を有しない溝形断面のプレス成形品の製造に適用することができる。
第3実施形態は上記の第1実施形態を基本とし、その一部を変形したものである。主な目的が、上記の第2実施形態と同様に、形状変化部の領域での割れの低減にある場合、上記の第2プレス加工工程において、中間成形品に、単純なパッド曲げ成形を行ってもよいし、パッド無しで曲げ成形を行ってもよい。
第4実施形態は上記の第1実施形態を基本とし、その一部を変形したものである。主な目的が縦壁部の反りの低減にある場合、上記の第1プレス成形装置による第1プレス加工工程は省略できる。この場合、上記の第2プレス成形装置による第2プレス加工工程において、素材として金属板を用い、最終的なプレス成形品を成形する。また、第1プレス加工に代わる予備プレス加工工程を導入し、この予備プレス加工工程において、上記の中間成形品を成形することもできる。予備プレス加工工程では、金属板に単純なパッド曲げ成形を行ってもよい。
7c:縦壁部、 7d:フランジ部、
8:段差部、 9:形状変化部、
10:第1プレス成形装置、
11:第1パンチ、 11a:先端面、 11b:側面、
11c:パンチ肩部、
13:第1パッド、 13a:アーム部、
12:第1ダイ、 12a:第1内側面、 12b:第2内側面、
12c:凹部、 12d:隅部、
14:素材(金属板)、 15:ダイホルダ、
16:第1加圧部材、 17:ブロック、
18:パンチホルダ、 19:第2加圧部材、
20:第2プレス成形装置、
21:主第2パンチ、 21a:先端面、 21b:側面、
21c:パンチ肩部、 21d:曲面、
22:第2ダイ、 22a:内側面、 22c:凹部、
22d:隅部、 22e:ダイ肩部、 22f:先端面、
23:第2パッド、
24:副第2パンチ、 24a:上面、
25:中間成形品、
25a:天板部、 25b:稜線部、 25c:縦壁部、
25ca:所定領域、 25cb:余剰領域、
26:第4加圧部材、 27:ダイホルダ、 28:パンチホルダ
Claims (15)
- 素材からプレス成形品を製造するための方法であって、
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、を備え、前記稜線部の一部に形状変化部を有し、
前記製造方法は、
前記素材として金属板を準備する準備工程と、
パンチ、前記パンチの先端面に対向して配置されるパッド、及び前記パッドを収容可能なダイを用い、前記素材にプレス加工を施すプレス加工工程と、を含み、
前記プレス加工工程は、
前記パンチによる前記素材の前記ダイへの押し込みを開始したとき又はその直後から、前記ダイに対する前記パンチの押し込みがその押し込みの下死点より所定距離手前に達するまでの期間、前記パッドを前記パンチから前記所定距離離れた位置に保持する工程と、
前記ダイに対する前記パンチの押し込みが前記下死点より前記所定距離手前に達したとき、前記パッドを前記ダイに収容する工程と、
前記ダイ及び前記パッドに対する前記パンチの押し込みを前記下死点まで継続し、前記天板部、前記稜線部、及び前記縦壁部を成形する工程と、を含む、プレス成形品の製造方法。 - 請求項1に記載のプレス成形品の製造方法であって、
前記所定距離が3~30mmである、プレス成形品の製造方法。 - 請求項1又は請求項2に記載のプレス成形品の製造方法であって、
前記プレス加工工程では、前記天板部及び前記稜線部を成形するとともに、前記縦壁部に成形される領域のうちで前記天板部から所定高さまでの所定領域を成形し、
前記製造方法は、更に、前記プレス加工工程で得られた中間成形品にプレス加工を施す第2プレス加工工程を含み、
前記第2プレス加工工程では、前記縦壁部に成形される領域のうちで前記所定領域を除く余剰領域から前記縦壁部を成形する、プレス成形品の製造方法。 - 請求項3に記載のプレス成形品の製造方法であって、
前記プレス成形品は、更に、前記各縦壁部の端から伸びるフランジ部を備え、
前記第2プレス加工工程は、主第2パンチ、前記主第2パンチに隣接して配置される副第2パンチ、前記主第2パンチの先端面に対向して配置される第2パッド、及び前記第2パッドを収容可能な第2ダイを用い、
前記主第2パンチと前記第2パッドによって前記中間成形品の前記天板部を挟み込んだ状態で、前記主第2パンチによる前記中間成形品の前記第2ダイへの押し込みを開始する工程と、
前記第2ダイに対する前記主第2パンチの押し込みをその押し込みの下死点まで継続し、前記第2パッドを前記第2ダイに収容するとともに、前記中間成形品の前記余剰領域から前記縦壁部を成形する工程と、
前記第2ダイ及び前記第2パッドに対する前記副第2パンチの押し込みを開始し、前記副第2パンチの押し込みをその押し込みの下死点まで継続することによって前記中間成形品の前記余剰領域から前記フランジ部を成形する工程と、を含む、プレス成形品の製造方法。 - 素材からプレス成形品を製造するための方法であって、
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、前記各縦壁部の端から伸びるフランジ部と、を備え、前記稜線部の一部に形状変化部を有し、
前記製造方法は、
前記素材として金属板を準備する準備工程と、
前記素材にプレス加工を施すプレス加工工程と、を含み、
前記プレス加工工程は、主パンチ、前記主パンチに隣接して配置される副パンチ、前記主パンチの先端面に対向して配置されるパッド、及び前記パッドを収容可能なダイを用い、
前記主パンチと前記パッドによって前記素材を挟み込んだ状態で、前記主パンチによる前記素材の前記ダイへの押し込みを開始する工程と、
前記ダイに対する前記主パンチの押し込みをその押し込みの下死点まで継続し、前記パッドを前記ダイに収容するとともに、前記天板部、前記稜線部、及び前記縦壁部を成形する工程と、
前記ダイ及び前記パッドに対する前記副パンチの押し込みを開始し、前記副パンチの押し込みをその押し込みの下死点まで継続することによって前記フランジ部を成形する工程と、を含む、プレス成形品の製造方法。 - 請求項5に記載のプレス成形品の製造方法であって、
前記製造方法は、
前記プレス加工工程の前に、前記準備工程で準備した前記金属板にプレス加工を施して前記素材としての中間成形品を得る予備プレス加工工程を含み、
前記予備プレス加工工程では、前記中間成形品として、前記天板部及び前記稜線部を成形するとともに、前記縦壁部に成形される領域のうちで前記天板部から所定高さまでの所定領域を成形し、
前記プレス加工工程では、
前記主パンチと前記パッドによって前記中間成形品の前記天板部を挟み込んだ状態で、前記主パンチによる前記中間成形品の前記ダイへの押し込みを開始し、
その後、前記ダイに対する前記主パンチの押し込みをその押し込みの下死点まで継続し、前記パッドを前記ダイに収容するとともに、前記縦壁部に成形される領域のうちで前記所定領域を除く余剰領域から前記縦壁部を成形し、
その後、前記ダイ及び前記パッドに対する前記副パンチの押し込みを開始し、前記副パンチの押し込みをその押し込みの下死点まで継続することによって前記中間成形品の前記余剰領域から前記フランジ部を成形する、プレス成形品の製造方法。 - 請求項3、請求項4及び請求項6のいずれか1項に記載のプレス成形品の製造方法であって、
前記所定高さh(mm)が下記式(1)の条件を満たす、プレス成形品の製造方法。
Rp≦h≦H-Rp …(1)
ただし、上記式(1)中、Hは前記プレス成形品の高さ(mm)を示し、Rpは前記稜線部の断面における曲率半径(mm)を示す。 - 請求項1~請求項7のいずれか1項に記載のプレス成形品の製造方法であって、
前記稜線部の前記形状変化部が下記(a)~(f)のうちの少なくとも一つである、プレス成形品の製造方法。
(a)前記稜線部の高さが変化する、
(b)前記稜線部の断面における円弧長さが変化する、
(c)前記稜線部がねじれる、
(d)前記稜線部が幅方向に折れ曲がる、
(e)前記稜線部が幅方向に突出する又は窪む、
(f)前記稜線部の断面における曲率半径が変化する。 - 素材からプレス成形品を製造するための装置であって、
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、を備え、前記稜線部の一部に形状変化部を有し、
前記製造装置は、
前記天板部に対応する先端面、前記縦壁部に対応する側面、及び前記稜線部に対応するパンチ肩部を含むパンチと、
前記パンチの前記先端面に対向して配置されるパッドと、
前記パッドを収容可能なダイと、
前記パンチの前記先端面からの前記パッドの距離を調整するパッド調整機構と、を備える、プレス成形品の製造装置。 - 先端面、側面、及び前記先端面と前記側面の間に設けられたパンチ肩部を備え、前記パンチ肩部の延在方向の一部に形状の変化する形状変化部を有するパンチと、
少なくとも前記形状変化部における前記パンチ肩部の延在方向に垂直な断面において、前記パンチの前記先端面に対向して配置されるパッドと、
前記パンチの前記先端面に対向する面に前記パッドを収容できる凹部、及び前記パンチ肩部に対向する箇所が前記パンチ肩部の形状にあわせた形状である隅部を備えたダイと、
前記パンチの前記先端面と前記パッドの間の間隔を調整するパッド調整機構と、を備える、プレス成形品の製造装置。 - 請求項9に記載のプレス成形品の製造装置であって、
前記パッド調整機構は、
前記パンチによる前記素材の前記ダイへの押し込みを開始したとき又はその直後から、前記ダイに対する前記パンチの押し込みがその押し込みの下死点より所定距離手前に達するまでの期間、前記パッドを前記パンチから前記所定距離離れた位置に保持し、
前記ダイに対する前記パンチの押し込みが前記下死点より前記所定距離手前に達したとき、前記パッドを前記ダイに収容する、プレス成形品の製造装置。 - 請求項11に記載のプレス成形品の製造装置であって、
前記所定距離が3~30mmである、
プレス成形品の製造装置。 - 素材からプレス成形品を製造するための設備列であって、
前記プレス成形品は、天板部と、前記天板部の両端からそれぞれ伸びる縦壁部と、前記縦壁部と前記天板部との間にある稜線部と、前記各縦壁部の端から伸びるフランジ部と、を備え、前記稜線部の一部に形状変化部を有し、
前記製造設備列は、請求項9から請求項12のいずれか1項に記載の製造装置と、前記製造装置で得られた中間成形品にプレス加工を施す第2製造装置と、を含み、
前記中間成形品は、前記縦壁部の領域のうちで前記天板部から所定高さまでの領域が成形されたものであり、
前記第2製造装置は、
前記天板部に対応する先端面、前記縦壁部に対応する側面、前記稜線部に対応するパンチ肩部、及び前記縦壁部と前記フランジ部との間にある稜線部に対応する隅部を含む主第2パンチと、
前記主第2パンチに隣接して配置され、前記フランジ部に対応する先端面を含む副第2パンチと、
前記主第2パンチの先端面に対向して配置される第2パッドと、
前記縦壁部と前記フランジ部との間にある前記稜線部に対応するダイ肩部、及び前記フランジ部に対応する先端面を含み、前記第2パッドを収容可能な第2ダイと、
前記主第2パンチによる前記中間成形品の前記第2ダイへの押し込みよりも、前記副第2パンチによる前記中間成形品の前記第2ダイへの押し込みを遅らせる副パンチ調整機構と、を備える、プレス成形品の製造設備列。 - 請求項13に記載のプレス成形品の製造設備列であって、
前記副パンチ調整機構は、
前記第2ダイに対する前記主第2パンチの押し込みが下死点に達した後に、前記第2ダイに対する前記副第2パンチの押し込みを開始する、プレス成形品の製造設備列。 - 請求項13又は請求項14に記載のプレス成形品の製造設備列であって、
前記製造装置の前記ダイは、前記所定高さh(mm)が下記式(1)の条件を満たすように形成される、プレス成形品の製造設備列。
Rp≦h≦H-Rp …(1)
ただし、上記式(1)中、Hは前記プレス成形品の高さ(mm)を示し、Rpは前記稜線部の断面における曲率半径(mm)を示す。
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