WO2016052644A1 - プレス成形品の製造方法、及びプレス成形品 - Google Patents
プレス成形品の製造方法、及びプレス成形品 Download PDFInfo
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- WO2016052644A1 WO2016052644A1 PCT/JP2015/077798 JP2015077798W WO2016052644A1 WO 2016052644 A1 WO2016052644 A1 WO 2016052644A1 JP 2015077798 W JP2015077798 W JP 2015077798W WO 2016052644 A1 WO2016052644 A1 WO 2016052644A1
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- Prior art keywords
- press
- formed product
- mold
- flat plate
- product
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 28
- 238000005452 bending Methods 0.000 claims abstract description 117
- 238000003825 pressing Methods 0.000 claims abstract description 18
- 238000000034 method Methods 0.000 claims description 32
- 238000005304 joining Methods 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 14
- 238000000465 moulding Methods 0.000 description 60
- 238000009966 trimming Methods 0.000 description 24
- 230000004048 modification Effects 0.000 description 14
- 238000012986 modification Methods 0.000 description 14
- 230000007547 defect Effects 0.000 description 10
- 238000003466 welding Methods 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- 238000007493 shaping process Methods 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000011796 hollow space material Substances 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 238000003908 quality control method Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- 239000004566 building material Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 235000013372 meat Nutrition 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
Images
Classifications
-
- 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
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/08—Dies with different parts for several steps in a process
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
- B21D5/015—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments for making tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- 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
-
- 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
-
- 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 for manufacturing a press-formed product and a press-formed product.
- a cylindrical part curved in one virtual plane that is, curved two-dimensionally
- a hollow pipe having a cylindrical portion that is curved in two virtual planes that intersect each other that is, a cylindrical portion that is curved three-dimensionally
- Patent Document 1 discloses a method of manufacturing a hollow pipe having a cylindrical portion that is two-dimensionally curved by pressing (pressing) a flat plate in its thickness direction.
- a hollow pipe having a cylindrical portion that is two-dimensionally curved can be manufactured by pressing.
- the hollow pipe is further pressed to be three-dimensionally curved.
- a molding defect such as a dent occurs.
- stress concentration occurs when a load is applied to the hollow pipe, and there is a possibility that cracks or cracks may occur. Therefore, in order to produce a hollow pipe having a three-dimensionally curved cylindrical portion and having a stable strength by pressing, a hollow is formed when the hollow material is pressed to form a bent portion. It is required to suppress the occurrence of molding defects such as.
- the present invention has been made in view of the above circumstances, and when a hollow material is pressed to form a bent portion, a method for manufacturing a press-formed product capable of suppressing the occurrence of molding defects such as dents, and the like, and An object is to provide a press-formed product.
- the method for manufacturing a press-formed product according to one aspect of the present invention is a second method in which the cross section is orthogonal to the first direction when viewed in a cross section that is long in the first direction and perpendicular to the first direction.
- the flat plate may be configured as follows: the first step is configured so that the flat plate is formed so that both end portions in the width direction of the flat plate face each other.
- the first step may further include a joining step for joining the edges of the flat plates after the abutting step.
- the flat plate bending step by pressing the flat plate in the thickness direction, both end portions in the width direction of the flat plate are opposed to each other, and The flat plate may be bent in the thickness direction.
- the material in the aspect described in any one of (1) to (4) above, in the second step, the material may be pressed stepwise along the second direction.
- a press-formed product includes: a tubular portion that is long in one direction; and a bent portion provided in the tubular portion; and each of the tubular portion and the bent portion. Moreover, residual stress is formed along the circumferential direction. (7) In the aspect described in the above (6), it may further include a joint provided in at least one of the cylindrical part and the bent part, and residual stress may be formed in the joint. (8) In the aspect described in the above (6) or (7), at least one of a press mark or a sliding mark may be formed on the outer surface of the cylindrical part.
- each aspect of the present invention when a hollow material is pressed to form a bent portion, it is possible to suppress the occurrence of molding defects such as dents.
- FIG. 1 is a perspective view showing a U-bending mold according to a first embodiment of the present invention. It is a cross-sectional view showing the U-bending mold.
- 1 is a perspective view showing a circular bending mold according to a first embodiment of the present invention. It is a top view which shows the lower metal mold
- FIG. 3 is an enlarged view of a portion indicated by reference numeral B in FIG. 2B and showing residual stress generated in the press-formed product. It is a top view which shows the state in which the press trace was formed in the said press molded product. It is a top view which shows the state in which the sliding trace was formed in the said press molded product. It is the schematic which shows the modification of the said circular bending mold. It is the schematic which shows the modification of the said circular bending mold.
- FIG. 20 is a schematic view showing a press-formed product obtained by the circular bending mold shown in FIGS. 20A to 20C. It is a figure for demonstrating the 1st modification of the said press-formed product. It is a figure for demonstrating the 1st modification of the said press-formed product. It is a figure for demonstrating the 1st modification of the said press-formed product. It is a figure for demonstrating the 2nd modification of the said press-formed product. It is a figure for demonstrating the 2nd modification of the said press-formed product. It is a figure for demonstrating the 2nd modification of the said press-formed product. It is a figure for demonstrating the 2nd modification of the said press-formed product.
- FIG. 2B is a cross-sectional view taken along the line AA in FIG. 2A, showing another example of the press-formed product according to the first embodiment.
- FIG. 2A to 2D are views showing the press-formed product 50 according to the first embodiment of the present invention.
- 2A is a front view of the press-formed product 50
- FIG. 2B is a plan view of the press-formed product 50
- FIG. 2C is a cross-sectional view taken along line AA of the press-formed product 50 shown in FIG. 2A
- FIG. It is an enlarged view of 2B.
- the press-formed product 50 is suitably used for an automobile part such as a rear side frame or a torsion beam side, for example.
- the press-formed product 50 is not limited to the above-described application, and can be used for, for example, passenger vehicles such as motorcycles, truck vehicles, rail vehicles, building materials, ships, and home appliances.
- the press-formed product 50 is manufactured by press-molding the flat plate 1 shown in FIG.
- the x direction is the longitudinal direction of the flat plate 1
- the y direction is the width direction of the flat plate 1
- the z direction is the thickness direction of the flat plate 1 and these directions are orthogonal to each other.
- the material of the flat plate 1 is, for example, a metal such as iron, aluminum, stainless steel, copper, titanium, magnesium, or steel.
- the material of the flat plate 1 is not limited to those listed above, and may be any material that can be plastically deformed.
- a steel plate as the flat plate 1 it is preferable to use a hot rolled 440 MPa class steel plate.
- the thickness of the flat plate 1 is preferably 0.5 to 10.0 mm, more preferably 1.0 to 3.2 mm.
- the press-formed product 50 includes three straight pipe portions 51, 53, and 55, a first curved pipe portion 52 (bending portion) provided between the straight pipe portion 51 and the straight pipe portion 53, and a straight pipe.
- a second curved pipe portion 54 (bending portion) provided between the portion 53 and the straight pipe portion 55 and a welding portion 56 (joining portion) provided on the upper portion are provided.
- the weld part 56 is provided in the press-formed product 50 by welding the edge 2a (end surface in the width direction) of the both ends 2 in the y direction (width direction) of the flat plate 1 to each other.
- 2A and 2B, the X direction (first direction), the Y direction (third direction), and the Z direction (second direction) are respectively the x direction, y direction, and z direction in FIG. It corresponds.
- the axis C2 of the first curved pipe portion 52 has a curvature radius R1 of 126 mm.
- the 1st curved pipe part 52 is curving so that angle (theta) 1 between the axis C1 of the straight pipe part 51 and the axis C3 of the straight pipe part 53 may be set to 130 degrees. That is, the first curved pipe portion 52 of the press-formed product 50 is curved in a plane including the X direction and the Z direction.
- the axis C4 of the second curved pipe portion 54 has a curvature radius R2 of 95 mm.
- the second curved pipe portion 54 is curved so that the angle ⁇ 2 between the axis C3 of the straight pipe portion 53 and the axis C5 of the straight pipe portion 55 is 160 °. That is, the second curved pipe portion 54 of the press-formed product 50 is curved in a plane including the X direction and the Y direction. In addition, when angle (theta) 2 is 160 degrees or more, the press molded product 50 can be manufactured efficiently.
- the axis C4 is formed in a plane P4 orthogonal to the plane P2 and including the axis C3 of the straight pipe portion 53.
- the plane P2 is a plane including the axis C1 of the straight pipe portion 51, the axis C2 of the first curved pipe portion 52, and the axis C3 of the straight pipe portion 53.
- FIG. 3 is a flowchart showing a method for manufacturing the press-formed product 50 according to the present embodiment.
- the manufacturing method of the press-formed product 50 includes a U-bending forming step S1, a trimming step S2, an oval forming step S3, a joining step S4, and a circular bending forming step S5. Yes. Note that these steps are performed cold or hot.
- U-bending molding step S1 In the U-bending molding step S1 (flat plate bending step), both ends 2 in the width direction of the flat plate 1 are pressed by pressing the flat plate 1 in the thickness direction using the U-bending mold 100 shown in FIGS. 4A and 4B. While facing each other, the flat plate 1 is bent in the thickness direction.
- 4A is a perspective view showing the U-bending mold 100
- FIG. 4B is a cross-sectional view (cross-sectional view perpendicular to the X direction) showing the U-bending mold 100.
- the U-bending mold 100 includes a lower mold 101, an upper mold 106 disposed above the lower mold 101, a lower mold 101, and And a pair of flat plate pressing jigs 110 disposed so as to sandwich the upper mold 106 therebetween.
- the flat plate 1 is disposed between the lower mold 101 and the upper mold 106.
- the lower mold 101 and the upper mold 106 are installed in a press molding machine (not shown).
- the press molding machine may be a normal press molding machine, but is more preferably a servo press molding machine capable of arbitrarily adjusting the bottom dead center and the lowering speed of the mold.
- the lower mold 101 of the U-bending mold 100 has a recess 103 extending in the X direction.
- the recess 103 is formed by a pair of side surfaces 103a parallel to the Z direction and facing each other, and a bottom surface 103b that is convex toward the bottom surface 101b of the lower mold 101.
- the recessed part 103 becomes a shape along the axis lines C1, C2, and C3 (refer FIG. 2A) of the press molded product 50, when it sees from a Y direction. Therefore, a curved portion 103X for forming the first curved pipe portion 52 of the press-formed product 50 is formed in the middle of the concave portion 103.
- the flat plate pressing jig 110 Similar to the bottom surface 103 b of the recess 103, the flat plate pressing jig 110 has a shape along the axes C 1, C 2, and C 3 of the press-formed product 50 while the bottom surface 111 faces the top surface 101 a of the lower mold 101. Yes. Therefore, since the flat plate 1 can be pressed between the upper surface 101a of the lower mold 101 and the bottom surface 111 of the flat plate holding jig 110, the flat plate 1 can be pressed. it can.
- the upper mold 106 of the U-bending mold 100 has a convex portion 107 at the bottom in the Z direction.
- the convex portion 107 of the upper mold 106 has a shape corresponding to the concave portion 103 of the lower mold 101, and in the middle of the convex portion 107, similarly to the concave portion 103 of the lower mold 101, A curved portion 107X for forming the first curved pipe portion 52 is formed.
- the convex portion 107 of the upper die 106 is located in the concave portion 103 of the lower die 101 when the upper die 106 is lowered along the Z direction to bring the upper die 106 and the lower die 101 close to each other. Enter.
- the flat plate 1 is disposed immediately above the lower mold 101 of the U-bending mold 100. Then, the flat plate pressing jig 110 is lowered along the Z direction, and the flat plate 1 is sandwiched and pressed between the bottom surface 111 of the flat plate pressing jig 110 and the upper surface 101a of the lower mold 101. Subsequently, as shown in FIG. 5, the upper mold 106 is lowered to the bottom dead center along the Z direction, and the flat plate 1 is press-molded.
- the convex portion 107 of the upper mold 106 presses the flat plate 1, whereby the flat plate 1 is drawn into the gap between the concave portion 103 of the lower mold 101 and the convex portion 107 of the upper mold 106.
- the flat plate 1 is press-molded so that both end portions 2 in the width direction of the flat plate 1 face each other, and an intermediate press-formed product 10 can be obtained from the flat plate 1.
- the U-bending molding step S1 is thus completed.
- the flat plate 1 is sandwiched between the bottom surface 111 of the flat plate holding jig 110 and the upper surface 101 a of the lower mold 101, the occurrence of buckling and wrinkles on the flat plate 1 is suppressed. can do.
- FIGS. 6A to 6C are views showing the intermediate press-formed product 10 obtained by the U-bending forming step S1.
- 6A is a front view of the intermediate press-formed product 10
- FIG. 6B is a bottom view of the intermediate press-formed product 10
- FIG. 6C is a cross-sectional view of the intermediate press-formed product 10.
- the intermediate press-formed product 10 has a U-shaped cross section, two straight portions 11 and 13, and a curved portion 12 formed between the straight portion 11 and the straight portion 13.
- the straight portion 11 corresponds to the straight tube portion 51 of the press-formed product 50
- the straight portion 13 corresponds to the straight tube portions 53 and 55 and the second bent tube portion 54 of the press-formed product 50
- the curved portion 12 is pressed. It corresponds to the first curved pipe portion 52 of the molded product 50 (see FIG. 2A).
- a surplus wall 14 is formed at the upper end portion of the intermediate press-formed product 10.
- FIG. 7 is a perspective view showing the trimming mold 120 used in the trimming step S2.
- the trimming mold 120 includes a stationary mold 121, a pair of trim blades 126 disposed above the stationary mold 121, and a wedge-shaped disposed between the pair of trim blades 126. And a movable mold 128.
- the fixed mold 121 of the trimming mold 120 is provided with a recess 122 extending in the X direction.
- the recess 122 is different from the recess 103 of the lower mold 101 of the U-bending mold 100 in that the depth (length in the Z direction) is small.
- the intermediate press-molded product 10 is placed along the concave portion 122 of the fixed mold 121 of the trimming mold 120, only the excess 14 of the intermediate press-molded product 10 is exposed from the upper surface of the fixed mold 121.
- the movable die 128 is movable along the Z direction, and the pair of trim blades 126 can be moved away from each other as the movable die 128 moves.
- the intermediate press-formed product 10 is placed on the fixed mold 121 along the recess 122 of the fixed mold 121. At this time, only the surplus wall 14 of the intermediate press-formed product 10 is exposed from the upper surface of the fixed mold 121 as described above. Subsequently, the pair of trim blades 126 and the movable die 128 are lowered along the Z direction so that the pair of trim blades 126 are positioned between the surplus portions 14 of the intermediate press-formed product 10. Thereafter, as shown in FIG.
- the movable die 128 is further lowered along the Z direction to move the pair of trim blades 126 to both sides in the Y direction, thereby removing the excess wall 14 of the intermediate press-formed product 10. . As described above, the excess 14 is removed from the intermediate press-formed product 10 and the trimming step S2 is completed.
- FIGS. 9A to 9C are views showing the intermediate press-formed product 20 obtained by the trimming step S2.
- 9A is a front view of the intermediate press-formed product 20
- FIG. 9B is a bottom view of the intermediate press-formed product 20
- FIG. 9C is a cross-sectional view of the intermediate press-formed product 20.
- the intermediate press-formed product 20 has a U-shaped cross section, and has two straight portions 21 and 23 and one curved portion 22.
- the straight line portions 21 and 23 correspond to portions where the surplus portion 14 is removed from the straight line portions 11 and 13 (see FIG. 6A) of the intermediate press-formed product 10, and the curved portion 22 is from the curved portion 12 of the intermediate press-formed product 10. This corresponds to the portion from which the excess meat 14 has been removed.
- FIG. 10A and FIG. 10B are diagrams showing the ellipse molding die 130 used in the ellipse molding step S3.
- 10A is a perspective view of the oval molding die 130
- FIG. 10B is a cross-sectional view of the oval molding die 130.
- the oval molding die 130 includes a lower die 131 and an upper die 136 disposed so as to face the lower die 131.
- a recess 132 extending in the X direction is formed in the lower mold 131 of the oval molding mold 130.
- the recess 132 differs from the recess 122 (see FIG. 7) of the fixed mold 121 of the trimming mold 120 in that the depth is small. Therefore, in the state where the intermediate press-formed product 20 obtained in the trimming step S ⁇ b> 2 is placed in the recess 132, the upper part of the intermediate press-formed product 20 is exposed from the upper surface of the lower mold 131.
- the upper die 136 of the oval molding die 130 has a recess 137 that faces the recess 132 of the lower die 131. Then, as shown in FIG. 11, when the upper mold 136 is lowered in the Z direction and brought into contact with the lower mold 131, the recess 132 of the lower mold 131 and the recess 137 of the upper mold 136 are used. A space 138 (molding space) is formed.
- the intermediate press-formed product 20 is placed on the lower die 131 along the recess 132 of the lower die 131 as shown in FIGS. 10A and 10B. Thereafter, as shown in FIG. 11, the upper mold 136 is lowered in the Z direction until the bottom surface 136 a of the upper mold 136 contacts the upper surface 131 a of the lower mold 131. At this time, since the concave portion 137 of the upper mold 136 and the end edge 24a of the intermediate press-formed product 20 are in contact with each other, the intermediate press-formed product 20 is formed into a shape along the concave portion 137.
- the pair of end edges 24a of the intermediate press-formed product 20 are abutted with each other.
- the intermediate press-formed product 20 is formed into an oval cross-section (elliptical shape), and the oval forming step S3 is completed.
- 12A to 12C are views showing the intermediate press-formed product 30 obtained in the oval forming step S3.
- 12A is a front view of the intermediate press-formed product 30
- FIG. 12B is a plan view of the intermediate press-formed product 30
- FIG. 12C is a cross-sectional view of the intermediate press-formed product 30.
- the intermediate press-formed product 30 has a hollow elliptical cross section, and includes two straight portions 31 and 33 and one curved portion 32. Further, since the intermediate press-formed product 30 is formed by abutting both end edges 24a of the intermediate press-formed product 20 with each other, a seam portion 34 is formed.
- FIGS. 13A to 13C are views showing the intermediate press-formed product 40 obtained in the joining step S4.
- the intermediate press-formed product 40 has a hollow oval cross section and is welded to a portion corresponding to the joint portion 34 (see FIGS. 12B and 12C) of the intermediate press-formed product 30.
- a portion 46 is formed.
- L1 represents the length in the Z direction (length in the major axis direction)
- W1 represents the length in the Y direction (length in the minor axis direction).
- FIGS. 14A and 14C are views showing a circular bending mold 140 used in the circular bending step S5.
- 14A is a perspective view of the circular bending mold 140
- FIG. 14B is a plan view of the circular bending mold 140
- FIG. 14C is a cross-sectional view of the circular bending mold 140.
- illustration of the upper mold 146 of the circular bending mold 140 is omitted.
- the circular bending mold 140 includes a lower mold 141 and an upper mold 146 disposed so as to face the lower mold 141.
- the circular bending mold 140 presses the intermediate press-formed product 40 placed between the lower mold 141 and the upper mold 146 when the upper mold 146 descends along the Z direction.
- a concave portion 142 having a semicircular cross section is formed between both ends of the lower mold 141 in the X direction.
- a first curved pipe portion forming portion 142b for forming the first curved pipe portion 52 of the press-formed product 50 and a second curved pipe portion 54 of the press-formed product 50 are formed.
- a second curved pipe forming part 142a is formed.
- a concave part 147 having a semicircular cross section is formed on the upper mold 146 of the circular bending mold 140 across the both ends in the X direction of the upper mold 146 so as to face the concave part 142 of the lower mold 141. Yes.
- a first curved pipe part molding part 147 b for forming the first curved pipe part 52 of the press-formed product 50 and a second curved pipe part 54 of the press-molded product 50 are formed.
- a second curved pipe part forming part 147a is formed.
- the upper mold 146 When the intermediate press-formed product 40 is press-molded by the circular bending mold 140, the upper mold 146 is lowered along the Z direction until the bottom surface 146a of the upper mold 146 contacts the upper surface 141a of the lower mold 141.
- a space 148 surrounded by the recess 142 of the lower mold 141 and the recess 147 of the upper mold 146 as shown in FIG. (Forming space) is formed. Since the space 148 has a shape that follows the outer shape of the press-formed product 50, the intermediate press-formed product 40 is press-molded by pressing the intermediate press-formed product 40 using the circular bending mold 140.
- the product 50 can be formed.
- the intermediate press-formed product 40 having an elliptical cross section is placed in the concave portion 142 of the lower die 141 so that the major axis direction is parallel to the Z direction. Placed on.
- the intermediate press-formed product 40 is close to the recess 142 of the lower mold at the positions L, M, and N of the recess 142 of the lower mold 141 when viewed in plan. .
- the intermediate press-formed product 40 is placed in the recess 142 of the lower mold 141 without applying an external force to the intermediate press-formed product 40.
- the intermediate press molded product 40 may be placed in the concave portion 142 of the lower mold 141 by applying an external force or the like to the intermediate press molded product 40.
- the upper die 146 is lowered along the Z direction (along the major axis direction of the intermediate press-formed product 40), and the intermediate press-formed product 40 is press-formed.
- the intermediate press-formed product 40 is compressed in the Z direction and swells in a direction intersecting the Z direction.
- the intermediate press-formed product 40 is moved along the recess 142 of the lower mold 141 and the recess 147 of the upper mold 146 by lowering the upper mold 146 to the bottom dead center.
- the press-formed product 50 can be obtained.
- the circular bending process S5 is completed.
- the intermediate press-formed product 40 having an elliptical cross section is pressed in the major axis direction and compressed, so that the length L1 in the major axis direction of the intermediate press-molded product 40 (the length in the Z direction). : See FIG. 13C) becomes smaller, while the length W1 in the minor axis direction of the intermediate press-formed product 40 becomes larger.
- a press-formed product 50 having a circular cross section can be obtained.
- the intermediate press-formed product 40 (that is, the press-formed product 50) after the circular bending process S5 is aligned along the circumferential direction by the circumferential stress F1 (compressive stress in the circumferential direction). Since residual stress is formed, the strength of the press-formed product 50 can be increased. Similarly, since residual stress is also formed in the welded portion 56 of the press-formed product 50, the strength of the welded portion 56 can be increased.
- the residual stress ⁇ 1 is formed in the second curved pipe portion 54 along the X direction.
- the residual stress ⁇ 1 is, for example, a residual tensile stress
- the residual tensile stress generated on the outer side (the side with the larger curvature radius) of the second curved pipe portion 54 is the inner side (the radius of curvature) of the second curved pipe portion 54. Is larger than the residual tensile stress generated on the smaller side.
- the residual stress ⁇ 1 formed in the second curved pipe portion 54 changes depending on the radius of curvature (or the degree of bending), and when no residual tensile stress is formed on the inner side of the second curved pipe portion 54, Alternatively, residual compressive stress may be formed on the inner side of the second curved pipe portion 54.
- the press-formed product 50 includes a press direction (Z direction) of the outer surfaces of the straight pipe parts 51, 53 and 55, the first curved pipe part 52, and the second curved pipe part 54. It is preferable that the press mark 57 is formed in the orthogonal part. In this case, by identifying whether the press marks 57 are formed, molding defects such as dents can be easily found, and quality control can be performed efficiently.
- the press-formed product 50 preferably has a sliding mark 58 formed on a portion of the outer surface of the second curved pipe portion 54 that is orthogonal to the press direction (Z direction).
- the sliding marks 58 are formed on the outer surfaces of the straight pipe portions 51, 53 and 55, the first curved pipe portion 52, and the second curved pipe portion 54 at a portion orthogonal to the pressing direction (Z direction). Also good.
- the surplus wall 14 of the intermediate press-formed product 10 is removed by trimming. Therefore, in the ellipse forming step S3, the edges 24a of the intermediate press-formed product 20 obtained in the trimming step S2 can be easily and accurately brought into contact with each other.
- the intermediate press-formed product 30 obtained in the oval forming step S3 is joined (welded) after the oval forming step S3, the end portions are suppressed from being separated from each other in the circular bending step S5.
- the product 50 can be manufactured stably.
- the circular bending process S ⁇ b> 5 residual stress is formed in the welded portion 46 by compressing the welded portion 46 of the intermediate press-formed product 40. Therefore, the strength of the welded portion 56 of the press-formed product 50 can be increased. Therefore, the order of the joining step S4 and the circular bending step S5 may be reversed, but for the above reason, it is preferable to carry out the circular bending step S5 after the joining step S4.
- the intermediate press-formed product 40 having an elliptical cross section is pressed along the major axis direction, so that the intermediate press-molded product 40 can be expanded in a direction intersecting the major axis direction. Since the intermediate press-formed product 40 is bent using the force generated by the swelling, it is possible to suppress the occurrence of molding defects such as dents in the press-formed product 50.
- the ratio between the length L1 (major axis) and W1 (minor axis) of the intermediate press-formed product 40 (see FIG. 13C) obtained in the joining step S4 is 1.1 ⁇ L1 / W1 ⁇ 5.0. It is preferable. By setting L1 / W1 to 5.0 or less, wrinkles can be prevented from occurring in the flat plate 1 in the U-bending molding step S1. In addition, by setting L1 / W1 to 1.1 or more, the intermediate press-formed product 40 can be swelled with a small load in the circular bending process S5, so that the press load can be reduced.
- the intermediate press-formed product 40 is press-molded using the circular bending mold 140 in the circular bending process S5 is shown.
- the intermediate press-formed product 40 may be press-molded step by step (in a plurality of times) using the circular bending mold 160 shown in FIG. 20A and the circular bending mold 170 shown in FIG. 20B.
- the concave portion 162 of the lower mold 161 of the circular bending mold 160 has a smaller width and a larger depth than the concave portion 142 of the lower mold 141 of the circular bending mold 140.
- FIG. 20A the concave portion 162 of the lower mold 161 of the circular bending mold 160 has a smaller width and a larger depth than the concave portion 142 of the lower mold 141 of the circular bending mold 140.
- the concave portion 172 of the lower mold 171 of the circular bending mold 170 is larger in width than the concave portion 162 of the lower mold 161 of the circular bending mold 160, but the depth is smaller. small. Further, the recess 172 of the lower mold 171 of the circular bending mold 170 is smaller in width and larger in depth than the recess 142 of the lower mold 141 of the circular bending mold 140.
- the intermediate press-formed product 40 is press-molded with a circular bending mold 160, then press-molded with a circular bending mold 170, and finally a circular bending mold is formed.
- a press-formed product 50 shown in FIG. 20D is obtained.
- the intermediate press-formed product 40 can be sequentially deformed, it is possible to more reliably suppress the occurrence of molding defects in the press-formed product 50.
- the press-formed product 50 having a circular cross section from the flat plate 1 is manufactured is shown.
- press-formed products having various cross-sectional shapes can be manufactured.
- FIG. 21C is a cross-sectional view showing the press-formed product 63. As shown in FIG. 21C, the press-formed product 63 has a substantially octagonal cross-sectional shape.
- the press-formed product 63 is manufactured by the following procedure.
- the intermediate press-formed product 61 includes a bottom wall portion 61a extending in the Y direction, a pair of first side wall portions 61b extending from both ends of the bottom wall portion 61a upward in the Z direction, and upper ends of the first side wall portions 61b. And a pair of second side wall portions 61c facing each other and parallel to the Z direction. Subsequently, the end surfaces 61d of the intermediate press-formed product 61 are brought into contact with each other in the same manner as in the oval forming step S3. Thereafter, similarly to the joining step S4, the intermediate press-formed product 61 shown in FIG.
- the intermediate press-formed product 62 is obtained by welding the intermediate press-formed product 61.
- the intermediate press-formed product 62 is provided between the pair of third side wall portions 62e that narrows upward in the Z direction and the pair of third side wall portions 62e and faces the bottom wall portion 61a. It differs from the intermediate press-formed product 61 in that it has an upper wall portion 62f and a welded portion 46.
- the intermediate press-formed product 62 is pressed in the Z direction (the direction in which the cross section is long) to obtain a press-formed product 63 shown in FIG. 21C.
- a press-formed product 73 having a horizontally long oval cross section shown in FIG. 22C can be manufactured.
- the press-formed product 73 is manufactured by the following procedure.
- the flat plate 1 is formed into an intermediate press-formed product 71 shown in FIG. 22A.
- the intermediate press-formed product 71 includes a bottom wall portion 71a and a pair of side wall portions 71b that are provided at both ends of the bottom wall portion 71a and face each other and parallel to the Z direction.
- the end faces 71d of the intermediate press-formed product 71 are brought into contact with each other and welded in the same manner as in the oval forming step S3 and the joining step S4.
- the intermediate press-formed product 72 obtained as a result is shown in FIG. 22B.
- the intermediate press-formed product 72 is different from the intermediate press-formed product 71 in that it has an arc-shaped side wall portion 72 b and a welded portion 46. Thereafter, similarly to the circular bending process S5, the intermediate press-formed product 72 can be pressed in the Z direction to obtain a press-formed product 73. At this time, as in the case of the first embodiment, the intermediate press-formed product 72 is compressed in the Z direction and bulged in a direction intersecting the Z direction.
- a press-formed product 83 shown in FIG. 23C can be manufactured from the flat plate 1.
- the press-formed product 83 includes an arc-shaped side wall portion 83b and a bottom wall portion 83a that is convexly curved upward in the Z direction.
- the press-formed product 83 is manufactured by the following procedure.
- the flat plate 1 is press-molded into an intermediate press-molded product 81 shown in FIG. 23A.
- the intermediate press-formed product 81 is provided at both ends of a bottom wall portion 81a that is convexly convex upward in the Z direction, and at both ends of the bottom wall portion 81a, and has arcuate first side wall portions 81b and ends of the first side wall portions 81b. And a pair of second side wall portions 81c facing each other and parallel to the Z direction.
- the end faces 81d of the intermediate press-formed product 81 are butted together and welded.
- the intermediate press-formed product 82 is different from the intermediate press-formed product 81 in that the intermediate press-formed product 82 has an elliptical arc-shaped side wall portion 82 b and a welded portion 46. Thereafter, similarly to the circular bending process S5, the intermediate press-formed product 82 can be pressed in the Z direction to obtain a press-formed product 83. At this time, as in the case of the first embodiment, the intermediate press-formed product 82 is compressed in the Z direction and bulged in a direction intersecting the Z direction.
- the press-formed product 250 is manufactured from the cylindrical tube 201 shown in FIG.
- the material of the cylindrical tube 201 is, for example, a metal such as iron, aluminum, stainless steel, copper, titanium, magnesium, or steel.
- the cylindrical tube 201 is, for example, a pipe manufactured by extrusion molding, a pipe manufactured by pultrusion molding, or an electric sewing tube.
- the thickness (wall thickness) of the cylindrical tube 201 is preferably 0.5 to 10.0 mm, and more preferably 1.0 to 3.2 mm.
- 25A to 25C are views showing a press-formed product 250 according to the present embodiment.
- 25A is a front view of the press-formed product 250
- FIG. 25B is a plan view of the press-formed product 250
- FIG. 25C is a cross-sectional view of the press-formed product 250.
- the press-formed product 250 has a long cylindrical shape in the X direction, and includes two straight pipe portions 251 and 253 and a curved pipe portion 252 ( Bending portion).
- the curved pipe part 252 of the press-formed product 250 is curved in a plane including the X direction and the Y direction, as shown in FIG. 25B.
- FIG. 26 is a flowchart showing a method for manufacturing the press-formed product 250 according to this embodiment.
- the manufacturing method of the press-formed product 250 includes an ellipse forming step S201 and a circular bending forming step S202. Note that these steps are performed cold or hot.
- the cylindrical tube 201 is press-molded into an intermediate press-molded product 210 having an elliptical cross section shown in FIG. 28 using an oval molding die 230 shown in FIGS. 27A and 27B.
- 27A is a perspective view of the oval molding die 230 (the cylindrical tube 201 is not shown), and
- FIG. 27B is a cross-sectional view of the oval molding die 230.
- the ellipse molding die 230 includes a lower die 231 and an upper die 236 arranged to face the lower die 231.
- the lower mold 231 of the ellipse mold 230 is formed with a recess 232 that extends linearly along the X direction.
- the upper mold 236 of the oval mold 230 is formed with a recess 237 that faces the recess 232 of the lower mold 231. Then, in a state where the upper mold 236 is lowered in the Z direction and the upper mold 236 is brought into contact with the lower mold 231, as shown in FIG. 28, the recess 232 of the lower mold 231 and the upper mold 236 are arranged.
- the recess 237 forms an oval space 238 (molding space).
- the cylindrical tube 201 is placed in the recess 232 of the lower mold 231 as shown in FIG. 27B. Thereafter, as shown in FIG. 28, the upper mold 236 is lowered along the Z direction until the bottom surface of the upper mold 236 contacts the upper surface of the lower mold 231. At this time, since the concave portion 237 of the upper mold 236 and the outer surface of the cylindrical tube 201 are in contact, the cylindrical tube 201 is formed into a shape along the concave portion 232 of the lower mold 231 and the concave portion 237 of the upper mold 236.
- the intermediate press formed product 210 obtained in the oval forming step S201 is pressed using the circular bend forming mold 240 to manufacture the press formed product 250.
- FIGS. 29A to 29C are views showing a circular bending mold 240 used in the circular bending step S202.
- 29A is a perspective view of the circular bending mold 240
- FIG. 29B is a plan view of the circular bending mold 240
- FIG. 29C is a cross-sectional view of the circular bending mold 240.
- the intermediate press-molded product 210 is not shown
- the upper mold 246 of the circular bending mold 240 is omitted.
- the circular bending mold 240 includes a lower mold 241 and an upper mold 246 arranged to face the lower mold 241.
- the circular bending mold 240 presses the intermediate press-molded product 210 placed between the lower mold 241 and the upper mold 246 by the upper mold 246 being lowered along the Z direction, A press-formed product 250 is manufactured.
- a concave portion 242 having a semicircular cross section is formed between both ends of the lower mold 241 in the X direction.
- the concave portion 242 includes a curved pipe portion molding portion 242b for forming the curved pipe portion 252 of the press molded product 250, a straight pipe portion molding portion 242c for forming the straight pipe portion 251 of the press molded product 250, and a press. It has a straight pipe part molding part 242a for forming the straight pipe part 253 of the molded product 250.
- a concave part 247 having a semicircular cross section is formed on the upper mold 246 of the circular bending mold 240 across the both ends in the X direction of the upper mold 246 so as to face the concave part 242 of the lower mold 241.
- the concave portion 247 includes a curved pipe part molding part 247b for forming the curved pipe part 252 of the press molded product 250, a straight pipe part molding part 247c for forming the straight pipe part 251 of the press molded product 250, and press molding.
- a straight pipe part forming part 247a for forming the straight pipe part 253 of the product 250.
- the upper mold 246 When press-molding the intermediate press-molded product 210 with the circular bending mold 240, the upper mold 246 is lowered along the Z direction until the bottom surface of the upper mold 246 comes into contact with the upper surface of the lower mold 241. In a state where the bottom surface of the upper mold 246 is in contact with the upper surface of the lower mold 241, one space is formed by the recess 242 of the lower mold 241 and the recess 247 of the upper mold 246. This space has a shape that conforms to the outer shape of the press-molded product 250. When the intermediate press-molded product 210 is pressed, the outer surface of the intermediate press-molded product 210 has the concave portion 242 of the lower mold 241 and the upper mold. The shape is along the recess 247 of the mold 246.
- the intermediate press-formed product 210 having an elliptical cross section is formed so that the major axis direction is parallel to the Z direction. It is placed in the recess 242 of the lower mold 241.
- the press mold 250 can be obtained by lowering the upper mold 246 in the Z direction and press-molding the intermediate press-molded product 210.
- the cross section of the press-formed product is a hollow circle
- the cross section of the press-formed product may be a hollow ellipse or a hollow polygon.
- the press molded product 50 showed the case where each had the 1st curved pipe part 52 and the 2nd curved pipe part 54, the 1st curved pipe part 52 and the 2nd were shown.
- a plurality of curved pipe portions 54 may be provided.
- the press-formed product according to each of the above embodiments has a circular cross section that is continuous in the X direction and has substantially the same circumference.
- the press-molded product may have a hollow cross section whose peripheral length varies along the X direction.
- the press-formed product according to each of the above embodiments may have a blade shape, a bracket, or the like.
- a welding part may be formed in a part of press-formed product.
- the axis C4 of the second curved pipe portion 54 is the straight pipe portion 51, the first curved pipe portion 52, the axial lines C1, C2 of the straight pipe portion 53, The case where it is formed in a plane P4 orthogonal to the plane P2 including C3 and including the axis C3 of the straight pipe portion 53 is shown (see FIG. 2C).
- the second curved pipe portion so that the line connecting the axis C3 of the straight pipe portion 53 and the axis C4 of the second curved pipe portion 54 intersects both the plane P2 and the plane P4. 54 may be formed.
- the trimming step S2 is performed between the U-bending molding step S1 and the oval molding step S3 has been described.
- the trimming step S2 is not necessary when the width of the flat plate 1 is appropriately adjusted and no surplus wall 14 is generated in the intermediate press-formed product 10 obtained in the U-bending forming step S1.
- the curved portion 12 corresponding to the first curved pipe portion 52 of the press-formed product 50 is formed at the same time that the flat plate 1 is press-formed into a U-shaped cross section. Showed the case. However, after the flat plate 1 is press-molded into a U-shaped cross section, the curved portion 12 may be formed by further press-molding the flat plate 1.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Forging (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
Description
本願は、2014年10月3日に日本に出願された特願2014-205272号、及び2015年6月5日に日本に出願された特願2015-114974号に基づき優先権を主張し、それらの内容をここに援用する。
(1)本発明の一態様に係るプレス成形品の製造方法は、第1方向に長くかつ、前記第1方向に垂直な断面で見た場合に前記断面が前記第1方向と直交する第2方向に長い中空断面である素材を準備する第1工程と;前記素材を前記第2方向に沿って押圧することにより、前記第1方向から見た場合に前記第2方向に対して交差する方向に前記素材を曲げる第2工程と;を有する。
(2)上記(1)に記載の態様において、以下のように構成してもよい:前記第1工程が、平板を、前記平板の幅方向における両端部が互いに対向するように、前記平板の厚さ方向に沿って押圧する平板曲げ工程と;前記平板曲げ工程後に、前記平板の前記両端部の端縁を突き合わせる突き合わせ工程と;を有し、前記素材として、前記突き合わせ工程後の前記平板を用いる。
(3)上記(2)に記載の態様において、前記第1工程が、前記突き合わせ工程後の前記平板の前記端縁を接合する接合工程をさらに有していてもよい。
(4)上記(2)または(3)に記載の態様において、前記平板曲げ工程で、前記平板を厚さ方向に押圧することにより、前記平板の幅方向における両端部を互いに対向させるとともに、前記平板を厚さ方向に曲げてもよい。
(5)上記(1)~(4)のいずれか一項に記載の態様において、前記第2工程で、前記素材を、前記第2方向に沿って段階的に押圧してもよい。
(6)本発明の他の態様に係るプレス成形品は、一方向に長い筒状部と;前記筒状部に設けられた曲げ部と;を備え、前記筒状部および前記曲げ部のそれぞれに、それらの周方向に沿って残留応力が形成されている。
(7)上記(6)に記載の態様において、前記筒状部および前記曲げ部の少なくとも一方に設けられた接合部をさらに備え、前記接合部に残留応力が形成されていてもよい。
(8)上記(6)または(7)に記載の態様において、前記筒状部の外面に、プレス痕または摺動痕の少なくとも一方が形成されていてもよい。
図2A~図2Dは、本発明の第1実施形態に係るプレス成形品50を示す図である。図2Aはプレス成形品50の正面図であり、図2Bはプレス成形品50の平面図であり、図2Cは図2Aに示すプレス成形品50のA-A断面図であり、図2Dは図2Bの拡大図である。プレス成形品50は、例えば、リアサイドフレーム、またはトーションビームサイド等の自動車部品に好適に用いられる。また、プレス成形品50は、上記の用途のみに限られず、例えば、自動二輪等の乗用車両、トラック車両、鉄道車両、建材、船舶、および家電製品等に用いることができる。
プレス成形品50は、図1に示す平板1をプレス成形することにより製造される。なお、図1において、x方向は平板1の長手方向であり、y方向は平板1の幅方向であり、z方向は平板1の厚さ方向であり、これらの方向は互いに直交している。
また、平板1の厚さは、0.5~10.0mmであることが好ましく、1.0~3.2mmであることがより好ましい。
ここで、図2Aおよび図2Bにおける、X方向(第1方向)、Y方向(第3方向)、およびZ方向(第2方向)は、図1のx方向、y方向、およびz方向とそれぞれ対応している。
図2Dに示すように、第2曲管部54の軸線C4は、95mmの曲率半径R2を有する。そして、直管部53の軸線C3と直管部55の軸線C5との間の角度θ2が160°となるように、第2曲管部54は湾曲している。すなわち、プレス成形品50の第2曲管部54は、X方向およびY方向を含む平面内で湾曲している。なお、角度θ2が160°以上の場合、プレス成形品50を効率的に製造することができる。
図3に示すように、プレス成形品50の製造方法は、U曲げ成形工程S1と、トリミング工程S2と、長円成形工程S3と、接合工程S4と、円形曲げ成形工程S5とを有している。なお、これらの工程は、冷間または熱間で行われる。
U曲げ成形工程S1(平板曲げ工程)では、図4A及び図4Bに示すU曲げ成形金型100を用いて平板1を厚さ方向に押圧することにより、平板1の幅方向における両端部2を互いに対向させるとともに、平板1を厚さ方向に曲げる。なお、図4Aは、U曲げ成形金型100を示す斜視図であり、図4Bは、U曲げ成形金型100を示す横断面図(X方向に垂直な断面図)である。
凹部103の底面103bと同様に、平板押さえ治具110は、その底面111が下金型101の上面101aと対向するとともに、プレス成形品50の軸線C1、C2及びC3に沿った形状となっている。そのため、下金型101の上面101aと平板押さえ治具110の底面111とにより平板1を挟み込んで、平板1を押圧することができるので、平板1にしわ等が発生することを抑制することができる。
続いて、図5に示すように、上金型106をZ方向に沿って下死点まで下降させて、平板1をプレス成形する。この際、上金型106の凸部107が平板1を押圧することにより、下金型101の凹部103と上金型106の凸部107との隙間に平板1が引き込まれる。その結果、平板1の幅方向における両端部2が互いに対向するように平板1はプレス成形され、平板1より中間プレス成形品10を得ることができる。以上によりU曲げ成形工程S1が完了する。
なお、平板1をプレス成形する間、平板押さえ治具110の底面111と下金型101の上面101aとにより平板1が挟まれているので、平板1に座屈及びしわが発生することを抑制することができる。
トリミング工程S2では、U曲げ成形工程S1で得られた中間プレス成形品10の余肉14をトリミング金型120により除去する。
トリミング金型120の固定金型121には、X方向に延在する凹部122が設けられている。この凹部122は、U曲げ成形金型100の下金型101の凹部103に対して、深さ(Z方向における長さ)が小さい点で異なっている。そのため、トリミング金型120の固定金型121の凹部122に沿って中間プレス成形品10を載置すると、中間プレス成形品10の余肉14のみが固定金型121の上面から露出する。
また、可動型128は、Z方向に沿って移動可能となっており、一対のトリム刃126は、可動型128が移動することにより、互いに離れる向きにそれぞれ移動可能となっている。
長円成形工程S3(突き合わせ工程)では、トリミング工程S2で得られた中間プレス成形品20の両端部24の端縁24a(図9Aおよび図9C参照)を長円成形金型130により互いに突き合わせる。
接合工程S4では、中間プレス成形品30の継目部34を溶接により接合する(すなわち、一対の端縁24a同士を接合する)。なお、溶接には、アーク溶接、またはレーザ溶接等を用いることができる。
図13A~図13Cは、接合工程S4で得られた中間プレス成形品40を示す図である。なお、図13A~図13Cに示すように、中間プレス成形品40は、断面が中空楕円形であり、中間プレス成形品30の継目部34(図12Bおよび図12C参照)に対応する箇所に溶接部46が形成されている。なお、図13Cにおいて、L1はZ方向における長さ(長径方向の長さ)を表し、W1はY方向における長さ(短径方向の長さ)を表している。
円形曲げ成形工程S5では、円形曲げ成形金型140を用いて、接合工程S4で得られた中間プレス成形品40をプレス成形して、プレス成形品50(図2A~図2D参照)を製造する。
図14Aおよび図14Cに示すように、円形曲げ成形金型140は、下金型141と、この下金型141に対向するように配置された上金型146とを備えている。円形曲げ成形金型140は、下金型141と上金型146との間に載置された中間プレス成形品40を、上金型146がZ方向に沿って下降することにより押圧する。
なお、本実施形態では、中間プレス成形品40に外力を加えることなく、下金型141の凹部142内に中間プレス成形品40を載置しているが、中間プレス成形品40の形状および下金型141の凹部142の形状等によっては、中間プレス成形品40に外力等を作用させて、中間プレス成形品40を下金型141の凹部142内に載置してもよい。
図16Bに示すように、中間プレス成形品40が膨出すると、中間プレス成形品40の外面は、下金型141の凹部142に対して位置L、M、Nで当接するため、上記各位置において反力F2、F3、F4を受ける。その結果、中間プレス成形品40に曲げモーメントが付与され、中間プレス成形品40はY方向に曲げられる。
また、図16Cに示すように、円形曲げ成形工程S5後の中間プレス成形品40(すなわち、プレス成形品50)には、周方向応力F1(周方向の圧縮応力)により、周方向に沿った残留応力が形成されるので、プレス成形品50の強度を高めることができる。同様に、プレス成形品50の溶接部56にも残留応力が形成されるので、溶接部56の強度を高めることができる。
また、プレス成形品50には、図19に示すように、第2曲管部54の外面のうちプレス方向(Z方向)と直交する部分に摺動痕58が形成されていることが好ましい。この場合、摺動痕58が形成されているかどうかを識別することにより、くぼみ等の成形不良を容易に発見することができ、品質管理を効率よく行うことができる。なお、摺動痕58は、直管部51、53及び55、第1曲管部52、および第2曲管部54の外面のうちプレス方向(Z方向)と直交する部分に形成されていてもよい。
したがって、接合工程S4と円形曲げ成形工程S5の順序を逆にしてもよいが、上記の理由により、接合工程S4の後に円形曲げ成形工程S5を実施することが好ましい。
本実施形態では、円形曲げ成形工程S5において、円形曲げ成形金型140を用いて、中間プレス成形品40をプレス成形する場合を示した。しかしながら、図20Aに示す円形曲げ成形金型160及び図20Bに示す円形曲げ成形金型170を用いて、中間プレス成形品40を段階的に(複数回に分けて)プレス成形してもよい。
図20Aに示すように、円形曲げ成形金型160の下金型161の凹部162は、円形曲げ成形金型140の下金型141の凹部142よりも、幅が小さい一方、深さが大きい。
また、図20Bに示すように、円形曲げ成形金型170の下金型171の凹部172は、円形曲げ成形金型160の下金型161の凹部162よりも、幅が大きい一方、深さが小さい。さらに、円形曲げ成形金型170の下金型171の凹部172は、円形曲げ成形金型140の下金型141の凹部142よりも、幅が小さい一方、深さが大きい。
続いて、長円成形工程S3と同様に、中間プレス成形品61の端面61d同士を突き合わせる。その後、接合工程S4と同様に、中間プレス成形品61を溶接することにより、図21Bに示す中間プレス成形品62が得られる。中間プレス成形品62は、図21Bに示すように、Z方向上方に向かって狭まる一対の第3側壁部62eと、一対の第3側壁部62e間に設けられてかつ底壁部61aと対向する上壁部62fと、溶接部46とを有する点で、中間プレス成形品61と異なっている。
その後、円形曲げ成形工程S5と同様に、中間プレス成形品62をZ方向(断面が長い方向)にプレスすることにより、図21Cに示すプレス成形品63が得られる。なお、この際、第1実施形態の場合と同様に、中間プレス成形品62は、Z方向に圧縮されるとともに、Z方向と交差する方向に膨出される。そのため、プレス成形品63のY方向の寸法W4に対するZ方向の寸法L4の比率(=L4/W4)は、中間プレス成形品62のY方向の寸法W3に対するZ方向の寸法L3の比率(=L3/W3)よりも小さくなっている。
続いて、長円成形工程S3および接合工程S4と同様に、中間プレス成形品71の端面71d同士を突き合わせて溶接する。これによって得られた中間プレス成形品72を図22Bに示す。中間プレス成形品72は、円弧状の側壁部72bと、溶接部46とを有する点で中間プレス成形品71と異なっている。
その後、円形曲げ成形工程S5と同様に、中間プレス成形品72をZ方向にプレスして、プレス成形品73を得ることができる。なお、この際、第1実施形態の場合と同様に、中間プレス成形品72は、Z方向に圧縮されるとともに、Z方向と交差する方向に膨出される。そのため、プレス成形品73のY方向の寸法W6に対するZ方向の寸法L6の比率(=L6/W6)は、中間プレス成形品72のY方向の寸法W5に対するZ方向の寸法L5の比率(=L5/W5)よりも小さくなっている。
続いて、長円成形工程S3および接合工程S4と同様に、中間プレス成形品81の端面81d同士を突き合わせて溶接する。図23Bは、上記により得られた中間プレス成形品82を示している。なお、中間プレス成形品82は、楕円弧状の側壁部82bと、溶接部46とを有する点で、中間プレス成形品81と異なっている。
その後、円形曲げ成形工程S5と同様に、中間プレス成形品82をZ方向にプレスして、プレス成形品83を得ることができる。なお、この際、第1実施形態の場合と同様に、中間プレス成形品82は、Z方向に圧縮されるとともに、Z方向と交差する方向に膨出される。そのため、プレス成形品83のY方向の寸法W8に対するZ方向の寸法L8の比率(=L8/W8)は、中間プレス成形品82のY方向の寸法W7に対するZ方向の寸法L7の比率(=L7/W7)よりも小さくなっている。
次に、本発明の第2実施形態について説明する。
円筒管201の材質は、例えば、鉄、アルミ、ステンレス、銅、チタン、マグネシウム、または鋼等の金属である。そして、円筒管201は、例えば、押し出し成形によって製造されたパイプ、引き抜き成形によって製造されたパイプ、または電縫管等である。また、円筒管201の厚さ(肉厚)は、0.5~10.0mmであることが好ましく、1.0~3.2mmであることがより好ましい。
図25A~図25Cに示すように、プレス成形品250は、X方向に長い円筒形状を有しており、2つの直管部251及び253と、これらの間に設けられた曲管部252(曲げ部)とを備えている。なお、プレス成形品250の曲管部252は、図25Bに示すように、X方向およびY方向を含む平面内において湾曲している。
図26に示すように、プレス成形品250の製造方法は、長円成形工程S201と、円形曲げ成形工程S202とを有している。なお、これらの工程は、冷間または熱間で行われる。
図29Aおよび図29Cに示すように、円形曲げ成形金型240は、下金型241と、この下金型241に対向するように配置された上金型246とを備えている。円形曲げ成形金型240は、下金型241と上金型246との間に載置された中間プレス成形品210を、上金型246がZ方向に沿って下降することによりプレスして、プレス成形品250を製造する。
10: 中間プレス成形品(U曲げ成形工程S1後の平板)
20: 中間プレス成形品(トリミング工程S2後の平板)
30: 中間プレス成形品(長円成形工程S3後の平板)
40: 中間プレス成形品(接合工程S4後の平板)
50: プレス成形品(第1実施形態)
100: U曲げ成形金型
110: 平板押さえ治具
120: トリミング金型
130: 長円成形金型
140: 円形曲げ成形金型
201: 円筒管
210: 中間プレス成形品(第2実施形態)
230: 長円成形金型(第2実施形態)
240: 円形曲げ成形金型(第2実施形態)
250: プレス成形品(第2実施形態)
Claims (8)
- 第1方向に長くかつ、前記第1方向に垂直な断面で見た場合に前記断面が前記第1方向と直交する第2方向に長い中空断面である素材を準備する第1工程と;
前記素材を前記第2方向に沿って押圧することにより、前記第1方向から見た場合に前記第2方向に対して交差する方向に前記素材を曲げる第2工程と;
を有することを特徴とするプレス成形品の製造方法。 - 前記第1工程が、
平板を、前記平板の幅方向における両端部が互いに対向するように、前記平板の厚さ方向に沿って押圧する平板曲げ工程と;
前記平板曲げ工程後に、前記平板の前記両端部の端縁を突き合わせる突き合わせ工程と;
を有し、
前記素材として、前記突き合わせ工程後の前記平板を用いる
ことを特徴とする請求項1に記載のプレス成形品の製造方法。 - 前記第1工程が、前記突き合わせ工程後の前記平板の前記端縁を接合する接合工程をさらに有する
ことを特徴とする請求項2に記載のプレス成形品の製造方法。 - 前記平板曲げ工程で、前記平板を厚さ方向に押圧することにより、前記平板の幅方向における両端部を互いに対向させるとともに、前記平板を厚さ方向に曲げる
ことを特徴とする請求項2または3に記載のプレス成形品の製造方法。 - 前記第2工程で、前記素材を、前記第2方向に沿って段階的に押圧する
ことを特徴とする請求項1~4のいずれか一項に記載のプレス成形品の製造方法。 - 一方向に長い筒状部と;
前記筒状部に設けられた曲げ部と;
を備え、
前記筒状部および前記曲げ部のそれぞれに、それらの周方向に沿って残留応力が形成されている
ことを特徴とするプレス成形品。 - 前記筒状部および前記曲げ部の少なくとも一方に設けられた接合部をさらに備え;
前記接合部に残留応力が形成されている;
ことを特徴とする請求項6に記載のプレス成形品。 - 前記筒状部の外面に、プレス痕または摺動痕の少なくとも一方が形成されている
ことを特徴とする請求項6または7に記載のプレス成形品。
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RU2017111593A RU2673266C2 (ru) | 2014-10-03 | 2015-09-30 | Способ изготовления изделия, получаемого обработкой давлением, и изделие, получаемое обработкой давлением |
MX2017004180A MX2017004180A (es) | 2014-10-03 | 2015-09-30 | Metodo de fabricacion de producto formado por prensado, y producto formado por prensado. |
US15/515,348 US10603703B2 (en) | 2014-10-03 | 2015-09-30 | Method of manufacturing press-formed product, and press-formed product |
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BR112017006604A BR112017006604A2 (pt) | 2014-10-03 | 2015-09-30 | método de produção de produto conformado por prensagem, e produto conformado por prensagem |
KR1020177009119A KR101948450B1 (ko) | 2014-10-03 | 2015-09-30 | 프레스 성형품의 제조 방법 |
CN201580053102.2A CN107073542B (zh) | 2014-10-03 | 2015-09-30 | 压制成形品的制造方法以及压制成形品 |
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JP2018179239A (ja) * | 2017-04-19 | 2018-11-15 | 東芝キヤリア株式会社 | 曲げ管、およびこの曲げ管を備えた圧縮機 |
JP2020535971A (ja) * | 2017-10-06 | 2020-12-10 | ティッセンクルップ スチール ヨーロッパ アクチェンゲゼルシャフトThyssenKrupp Steel Europe AG | 成形された板金部品を予備成形された部品によって製作するための方法およびデバイス |
JP2019156000A (ja) * | 2018-03-08 | 2019-09-19 | 日本製鉄株式会社 | トーションビーム製造方法及びトーションビーム製造装置 |
WO2022014262A1 (ja) * | 2020-07-14 | 2022-01-20 | 日本製鉄株式会社 | 中空部材の製造方法 |
WO2023136172A1 (ja) * | 2022-01-13 | 2023-07-20 | 日本製鉄株式会社 | 中空部材の製造方法 |
JP7339592B1 (ja) | 2022-01-13 | 2023-09-06 | 日本製鉄株式会社 | 中空部材の製造方法 |
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RU2017111593A3 (ja) | 2018-11-06 |
US20170232492A1 (en) | 2017-08-17 |
EP3202503B1 (en) | 2023-02-22 |
CN107073542B (zh) | 2019-03-29 |
US10603703B2 (en) | 2020-03-31 |
KR101948450B1 (ko) | 2019-05-20 |
RU2017111593A (ru) | 2018-11-06 |
RU2673266C2 (ru) | 2018-11-23 |
CN107073542A (zh) | 2017-08-18 |
MX2017004180A (es) | 2017-06-19 |
BR112017006604A2 (pt) | 2017-12-12 |
CA2962236A1 (en) | 2016-04-07 |
JPWO2016052644A1 (ja) | 2017-07-13 |
JP6341292B2 (ja) | 2018-06-13 |
CA2962236C (en) | 2018-11-27 |
EP3202503A4 (en) | 2018-07-04 |
KR20170053667A (ko) | 2017-05-16 |
EP3202503A1 (en) | 2017-08-09 |
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