WO2018034104A1 - 自動車車体用プレス成形部品およびその製造方法 - Google Patents
自動車車体用プレス成形部品およびその製造方法 Download PDFInfo
- Publication number
- WO2018034104A1 WO2018034104A1 PCT/JP2017/026671 JP2017026671W WO2018034104A1 WO 2018034104 A1 WO2018034104 A1 WO 2018034104A1 JP 2017026671 W JP2017026671 W JP 2017026671W WO 2018034104 A1 WO2018034104 A1 WO 2018034104A1
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- WIPO (PCT)
- Prior art keywords
- vertical wall
- flange
- ridge line
- top plate
- floor
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
- B62D25/20—Floors or bottom sub-units
- B62D25/2009—Floors or bottom sub-units in connection with other superstructure subunits
-
- 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
- B21D19/00—Flanging or other edge treatment, e.g. of tubes
- B21D19/08—Flanging or other edge treatment, e.g. of tubes by single or successive action of pressing tools, e.g. vice jaws
-
- 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
-
- 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
- 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
-
- 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
- B21D47/04—Making rigid structural elements or units, e.g. honeycomb structures composite sheet metal profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/52—Making hollow objects characterised by the use of the objects boxes, cigarette cases, or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
- B62D25/20—Floors or bottom sub-units
Definitions
- the present invention relates to a press-molded part for an automobile body that can effectively increase the strength and rigidity of the automobile body and a method for manufacturing the same.
- the present invention relates to a press body for an automobile body having a hat-shaped cross-sectional shape having a top plate, a vertical wall, a flange, and a ridge line formed between the top plate-vertical wall and the vertical wall-flange.
- the present invention relates to a component and a manufacturing method thereof.
- This press-molded part for an automobile body has an outward flange formed by bending outward from a vertical wall with respect to a cross section of the part at at least one end in the extending direction of the ridgeline.
- the press-molded part for an automobile body has an outward flange (hereinafter referred to as “vertical wall flange”) connected to the vertical wall and a flange (hereinafter referred to as “floor flange”) continuously formed, and the vertical wall.
- This is a press-formed part made of a metal plate having a small radius of curvature (hereinafter referred to as a vertical wall angle R) at the corner portion adjacent to the outward flange and the floor flange.
- the metal plate include steel plate and aluminum plate.
- An automobile body is usually a box body formed by joining a plurality of molded panels with their edges overlapped by resistance spot welding, and a reinforcing member and a strength member are attached to the important points of the box body by resistance spot welding. Composed by joining.
- the member thus formed is referred to as an automobile body structural member.
- Such a structural member for an automobile body includes a floor cross member, a rocker (side sill), a belt line, and the like.
- a floor cross member is taken as an example of a structural member for an automobile body.
- the floor cross member includes, for example, a press-formed top plate, two ridge lines connected to the top plate (hereinafter referred to as “upper ridge line”), two vertical walls connected to each of the two upper ridge lines, and two vertical walls. It has a substantially hat-shaped cross-sectional shape composed of two ridge lines connected to each (hereinafter referred to as “lower ridge line”) and two floor flanges connected to each of the two lower ridge lines.
- An outward flange bent outward with respect to the cross section of the component is formed at the end of the upper ridge line and the lower ridge line in the steel plate main body having the cross-sectional shape, and the outward flange is a side sill inner.
- the floor cross member is an important structural member for an automobile body that contributes to the rigidity of the vehicle body and the suppression of the collapse of the passenger compartment at the time of a side collision. For this reason, many inventions relating to a method for manufacturing a member and an invention for improving the strength of a vehicle body by reviewing the shape of a member and the structure of a connecting portion between members have been disclosed.
- Patent Document 1 a member is formed by continuously forming a top plate, a vertical wall, and an outward flange adjacent to an upper ridge line provided at an end portion in a longitudinal direction of a press-formed product having a hat-shaped cross section.
- Patent Document 2 discloses an invention in which an opening is provided on a side surface of a side sill inner, and the sill inner reinforcement disposed inside the side sill and the floor cross member are welded to increase the bonding strength between the side sill and the floor cross member. It is disclosed.
- Patent Document 3 discloses an invention in which the side sill inner is opened without enlarging the cross section, and the joint strength between the side sill and the floor cross member is increased by providing a plurality of welds with the floor cross member. Yes.
- Patent Documents 1 to 3 were invented for the purpose of improving side collision safety.
- None of the patent documents focus on the vertical wall angle R.
- Patent Document 1 shows a member in which the vertical wall angle R is large and the wall between the vertical wall flange and the floor flange is gently and continuously formed.
- Patent Document 2 unlike the one illustrated in Patent Document 1, the vertical wall angle R is relatively small.
- Patent Document 3 the state in the vicinity of the vertical wall angle R is unclear.
- there is no detailed description of the dimension of the vertical wall angle R there is no detailed description of the dimension of the vertical wall angle R. From the above, little attention has been paid to the influence of the vertical wall angle R on the member performance, and no detailed examination has been made.
- the present inventors have intensively studied to solve the above problems, and as a result, obtained the knowledge A to D listed below and completed the present invention.
- A By reducing the size (curvature radius) of the vertical wall angle R, the cross-sectional line length at the end of the member increases. Therefore, the member performance (load bearing performance) is improved in the axial crushing deformation mode that is input to the floor cross member at the time of a side collision.
- the dimension of the vertical wall angle R is preferably 13% or less with respect to the cross-sectional line length at the end of the member.
- C As the vertical wall angle R decreases, the areas of the vertical wall flange and the floor flange increase.
- a member comprising a top plate and two opposing vertical walls on both sides of the top plate via an upper ridge line
- the member via a top plate flange extending to the outside of the member through a top plate ridge line on the end side of the member of the top plate and a vertical wall ridge line extending to the end side of the member of the vertical wall
- Two vertical wall flanges extending outwardly of the vertical wall flange and two vertical wall flanges adjacent to the vertical wall flange and extending to the outside of the member via a lower ridge line extending to the end of the vertical wall different from the end of the vertical wall
- floor flanges The vertical wall flange and the floor flange adjacent to each other at the end are continuous
- the sum ⁇ R of the curvature radii of the corners of the vertical wall between the lower ridge line and the vertical wall ridge line and the sum ⁇ L of the width of the top plate and the vertical wall at the member end are ⁇
- a vertical wall that is continuous with the top plate flange and the top plate flange in at least two places between at least two places in the first step of the blank next to the first step and the first step of partially shrinking flange molding A method for producing a press-molded product, comprising a second step of extending and molding the remaining flange portions.
- the present invention aims to provide a member such as the floor cross member of FIG.
- the member which is the subject of the present invention is not limited to the floor cross member, and the vertical wall is not limited to a quadrangle.
- a press-molded product having a triangular vertical wall may be used.
- Patent Document 4 discloses a method of manufacturing a member disclosed in Patent Document 1, but when a shrinkage flange portion between a vertical wall flange and a floor flange is press-molded using Patent Document 4, press molding is performed. Occasionally, wrinkles are generated because tension cannot be applied to the steel sheet. For this reason, generation
- Patent Document 5 discloses an invention that prevents the generation of wrinkles by giving a specific shape to a contracted flange portion in rectangular tube drawing
- Patent Documents 6 and 7 disclose a roof having a sunroof opening.
- An invention is disclosed in which a panel is provided with a shape that absorbs excess line length in a shrinkage flange portion.
- Patent Document 8 discloses that a wrinkle is formed by applying a pressing pressure to a shrinkage flange portion using a cam structure. An invention for suppressing the occurrence of this is disclosed.
- Patent Document 5 can be implemented when it does not affect the appearance and performance of the product, for example, a specific shape is given to a portion connected to another part (side sill) such as a floor cross member. If it exists, joining will become difficult and the load transmission performance at the time of collision deformation will also fall.
- Patent Documents 6 and 7 absorb a surplus line length that causes wrinkles and excess meat by a preset surplus shape. For this reason, in addition to resistance spot welding at this pre-walled portion, the invention disclosed in Patent Documents 6 and 7 cannot be implemented when the surplus portion obstructs spot welding at other sites.
- Patent Document 8 can surely suppress the out-of-plane deformation due to buckling, there is no change in the location where the contraction deformation is concentrated and the plate thickness increases. For this reason, an excessively thickened portion has a strong contact with the mold, which lowers the durability of the mold and consequently the productivity.
- the present inventors have obtained the knowledge (A) to (C) listed below and completed the present invention.
- the blank is shrink-flanged under arbitrary restraint conditions to form a joint between the vertical wall flange and the floor flange to obtain an intermediate molded product.
- a press having a desired cross-sectional shape including a top plate, a vertical wall, and a flange is formed by press-forming the intermediate molded product formed with a joint between the vertical wall flange and the floor flange. It is a molded part.
- an outward flange continuous shape adjacent to the top plate, the vertical wall, and the upper ridge line can be produced by using inner pad molding described later.
- a first step of manufacturing an intermediate molded product having at least the lower flange joint portion by press forming a blank to shrink the lower flange joint portion to form a flange, and press molding the intermediate molded product
- a second step of manufacturing the press-molded part having the cross section
- the present invention can provide a member that is used by being joined to another member and that has a high load resistance at the joint when the member receives a collision load. Moreover, the method of manufacturing this member by press molding can be provided.
- FIG. 1 is an explanatory view of an end portion of a member.
- FIG. 2 is an explanatory diagram of another member.
- FIG. 3 is an explanatory view showing members according to the present invention.
- FIG. 4 is an explanatory view showing another member according to the present invention.
- FIG. 5 is an explanatory diagram of a corner portion of a member having high strength.
- FIG. 6 is an explanatory diagram of a corner portion of a member having low strength.
- 7 (a) and 7 (b) show a shaft when a member is axially crushed by applying an impact load in the extending direction of the upper ridge line in a state where the member is joined to another member via an outward flange.
- FIG. 8 is an explanatory diagram showing an analysis result.
- FIG. 9 is an explanatory diagram showing an analysis result.
- FIG. 10 is an explanatory diagram showing an analysis result.
- FIG. 11 is an explanatory diagram showing an analysis result.
- FIG. 12 is an explanatory diagram of an impact test.
- FIG. 13 is an explanatory diagram of a manufacturing process by press molding.
- FIG. 14 is an explanatory view showing the manufacturing apparatus 20.
- FIG. 15 is an explanatory diagram showing the arrangement of blanks before the start of molding in the manufacturing apparatus 20.
- FIG. 16 is an explanatory view showing the situation of the bottom dead center of the manufacturing apparatus 20.
- FIG. 17 is an explanatory diagram showing the manufacturing apparatus 30.
- FIG. 18 is an explanatory diagram showing a blank before the start of preforming in the manufacturing apparatus 30.
- FIG. 19 is an explanatory view showing a blank after completion of the preforming by the manufacturing apparatus 30.
- FIG. 20 is an explanatory view showing the manufacturing apparatus 40.
- FIG. 21 is an explanatory view showing the arrangement of the preformed product before the start of molding in the manufacturing apparatus 40.
- FIG. 22 is an explanatory diagram showing the state of the molding bottom dead center of the manufacturing apparatus 40.
- FIG. 23 is an explanatory diagram illustrating a configuration of a manufacturing apparatus as an example of the manufacturing apparatus 50.
- FIG. 23 is an explanatory diagram illustrating a configuration of a manufacturing apparatus as an example of the manufacturing apparatus 50.
- FIG. 24 is an explanatory diagram showing an arrangement state of the intermediate molded product in the manufacturing apparatus 50.
- FIG. 25 is an explanatory view showing the state of the molding bottom dead center in the manufacturing apparatus 50.
- FIG. 26 is an explanatory diagram illustrating a configuration of a manufacturing apparatus as another example of the manufacturing apparatus 60.
- FIG. 27 is an explanatory diagram showing an arrangement state of intermediate molded products in the manufacturing apparatus 60.
- FIG. 28 is an explanatory diagram illustrating a situation when the ridge line pad is held in the manufacturing apparatus 60.
- FIG. 29 is an explanatory diagram showing the state of the molding bottom dead center in the manufacturing apparatus 60.
- FIG. 3 is an explanatory view showing the member 1 according to the present invention
- FIG. 4 is an explanatory view showing another member 12 according to the present invention.
- a single line means an edge of the member
- a double line means a ridge line
- a dotted line means a portion hidden behind the member.
- 3 is a member made of a high-tensile steel plate having a tensile strength of 440 MPa or more, desirably 590 MPa or more, more desirably 980 MPa or more, and a plate thickness of 0.7 mm or more and 2.3 mm or less.
- 3 has a hat-shaped cross section including a top plate 2, two upper ridge lines 4, two opposing vertical walls 3, two lower ridge lines 5, and two floor flanges 9.
- the upper ridge line 4 exists between the top plate 2 and the vertical wall 3.
- the lower ridge line 5 exists between the vertical wall 3 and the floor flange 9, respectively.
- the member 1 has an outward flange via the ridge line at least one end of the upper ridge line 4.
- a top plate flange 11 extends outside the member via a top plate ridge line 6 extending between the ends of the upper ridge line 4.
- a vertical wall flange 10 extends outside the member via a vertical wall ridge line 7 adjacent to the top plate ridge line 6 and extending to the end of the vertical wall 3.
- the top plate flange 11 and the vertical wall flange 10 are continuous, and the top plate flange 11 and the vertical wall flange 10 constitute an outward flange.
- the end of the vertical wall flange 10 and the floor flange 9 are also continuous via the flange ridgeline 8, and the end of the vertical wall ridgeline 7, the end of the lower ridgeline 5, and the end of the flange ridgeline 8 are connected at one point.
- the top plate flange 11 and the vertical wall flange 10 do not have to be continuous at the end of the upper ridgeline 4. However, when the top plate flange 11 and the vertical wall flange 10 are continuous at the end of the upper ridgeline 4, the performance of the member is improved. When the top plate flange 11 and the vertical wall flange 10 are made continuous, the difficulty of molding increases, so care must be taken in selecting the material, the flange width, and the like.
- the difference between the member 12 in FIG. 4 and the member 1 in FIG. 3 is that the vertical wall 3 of the member 12 is triangular, and the upper ridge line 4 and the lower ridge line 5 at the other end of the upper ridge line 4 without the vertical wall flange 10. Is connected to the end of As a result, the top plate flange 11 and the floor flange 9 are connected at the other end. From another viewpoint, since the vertical wall 3 has a triangular shape, the floor flange 9 and the vertical wall flange 10 are also used at the other end.
- the top plate flange 11 is allowed not to be continuous with the floor flange 9 or the vertical wall flange 10 as in the case where the vertical wall in FIG. .
- the vertical wall 3 is a triangle.
- the vertical wall 3 is a corner where the upper ridge line 4 and the vertical ridge line 7 intersect, a corner where the vertical wall ridge line 7 and the lower ridge line 5 intersect, and the upper ridge line 4 and the lower ridge line 5 intersect. This means that the corner portion is provided with three corner portions. Even if the corner portion is rounded or the ridgeline is meandering, it is allowed to deviate slightly from the triangle composed of three straight sides.
- FIG. 5 shows the case where the strength of part B in FIG. 1 is high.
- FIG. 6 shows a case where the strength of part B in FIG. 1 is low.
- the cross section of the ridgeline is bent between the two lines in the figure.
- a range where the radius of curvature of the cross section of the ridge line is small is indicated by an arrow.
- the curvature radius R of the corner portion of the vertical wall 3 between the lower ridge line 5 and the vertical wall ridge line 7 is sag at the end of the lower ridge line 5 and the vertical wall ridge line 7 (the cross section of the ridge line).
- the bending radius of curvature increases).
- the strength of the end of the lower ridge line 7 and the end of the vertical wall ridge line 5 decreases, and further, the vertical wall flange 10 and the floor Since the flange 9 cannot be joined to another member up to the vicinity of the flange ridgeline 8, the load resistance and rigidity of the member are reduced.
- the total sum ⁇ L of the lengths of the vertical wall ridgelines 7 of the vertical wall 3 has a relationship of ⁇ R / ⁇ L ⁇ 0.13.
- variety of the top plate 2 and the vertical wall 3 in a member edge part is the length when the corner
- the ⁇ L of the member for automobiles is approximately 300 mm, so that the radius of curvature of the corner of the vertical wall 3 between the lower ridge line 5 and the vertical wall ridge line 7 (vertical wall)
- the angle R) is approximately 20 mm or less.
- FIGS. 7A and 7B are graphs showing the results of analyzing the axial crush characteristics of the member 1 by computer simulation. Analysis is performed with a model in which the impact load in the direction in which the upper ridge line 4 extends is applied while the member 1 is joined to another member (side sill inner) via an outward flange (vertical wall flange 10 and top plate flange 11). went.
- FIGS. 7A and 7B show the radius of curvature R (vertical wall angle R) of the corner portion of the vertical wall 3 between the lower ridge line 5 and the vertical wall ridge line 7 that affects the axial crushing characteristics when the axial crushing occurs. The influence of (mm) is shown.
- FIG. 7A shows the relationship between the crushing stroke and the load in the extending direction of the upper ridge line 4 when the curvature radius R is 2 mm and 20 mm.
- a solid line indicates a case where the radius of curvature R is 2 mm
- a broken line indicates a case where the radius of curvature R is 20 mm.
- FIG. 7B shows the relationship between the radius of curvature R and the maximum load (withstand load).
- the cross-sectional shape of the member 1 is such that the sum ⁇ L of the widths of the top plate 2 and the vertical wall 3 at the end of the member is 300 mm.
- the material was a steel plate with a tensile strength of 980 MPa and a plate thickness of 1.2 mm.
- the load increases.
- the member 1 has a smaller radius of curvature R (vertical wall angle R) (mm) of the corner portion of the vertical wall 3 between the lower ridge line 5 and the vertical wall ridge line 7, and the like when the shaft is collapsed at the time of collision.
- Load transmission characteristics (impact performance) can be improved.
- FIG. 8 shows a comparison of load resistance (maximum load) when the height of the vertical wall 3 of the member 1 of FIG. 3 and the width of the top plate 2 are changed. In either case, the total sum ⁇ L of the widths of the top plate 2 and the vertical wall 3 at the end of the member is 300 mm.
- FIG. 8 shows an analysis result simulating a case where an impact load is input to the member 1 made of a material having a tensile strength of 980 MPa and a plate thickness of 1.2 mm in the direction in which the upper ridge line 4 extends.
- FIG. 9 shows a comparison of load resistance (maximum load) when the sectional line length is changed without changing the ratio of the length of the vertical wall ridge line 7 to the top plate ridge line 6 of the member 1 in FIG.
- the height of the vertical wall 3 and the width of the top plate 2 are equal.
- the analysis conditions in FIG. 9 are the same as those in FIG.
- the section line length was changed without changing the ratio of the width of the top plate 2 to the width of the vertical wall 3 at the end of the member, but no change was found in the point that the load resistance was improved when ⁇ R / ⁇ L ⁇ 0.13.
- FIG. 10 shows an analysis result in which the curvature radius R (vertical wall angle R) of the corner portion of the vertical wall 3 between the vertical wall ridge line 7 and the lower ridge line 5 of the member 1 in FIG. 3 is changed.
- the analysis model of FIG. 10 shows that the total sum of the widths of the top plate 2 and the vertical wall 3 at the end of the member 1 is 300 mm and ⁇ R / ⁇ L is 0.13, and the vertical wall between the vertical wall ridgeline 7 and the lower ridgeline 5 is maintained.
- the radius of curvature R (vertical wall angle R) at the corner of the wall 3 was changed. That is, the sum of one vertical wall angle R and the other vertical wall angle R was made constant, and the curvature radius of one vertical wall angle R was changed.
- the analysis conditions in FIG. 10 are the same as those in FIG.
- the horizontal axis of the graph in FIG. 10 indicates the curvature radius R (vertical wall angle R) of the corner portion of the vertical wall 3 between the vertical wall ridge line 7 and the lower ridge line 5. If ⁇ R / ⁇ L was constant, no significant change was observed in the load resistance even when the curvature radius of the corner of the vertical wall 3 changed.
- the member 1 has a high load resistance (maximum load) when ⁇ R / ⁇ L ⁇ 0.13 regardless of the cross-sectional shape of the member 1.
- FIG. 11 shows a comparison of maximum loads when the width of the vertical wall 3 and the width of the top plate 2 at the end of the member 12 of FIG. 4 are changed.
- the cross-sectional line length L is 300 mm.
- the material of the member 12 is the same as the analysis of FIG. As shown in FIG. 12, the analysis simulated the case where the member 12 was placed in the hat material and an impact load was input from the top plate surface of the hat material. As a result, similar to FIG. 8, the result that the load resistance was improved when ⁇ R / ⁇ L ⁇ 0.13 was obtained.
- the member 1 in FIG. 3 and the member 12 in FIG. 4 are different in shape, but share a high load resistance (maximum load) when ⁇ R / ⁇ L ⁇ 0.13.
- FIG. 13 shows a process flow when the member of the present invention is manufactured by press molding.
- an intermediate molded product 27 is manufactured from the blanks 26 and 34.
- Case 1-1 using the manufacturing apparatus 20 and the manufacturing apparatus 30 are used to manufacture the preform 35, and the manufacturing apparatus 40 is used to manufacture the intermediate molding 27 from the preform 35. 2 is exemplified, but either method may be used.
- the members 1 and 12 are manufactured from the intermediate molded product 27. Examples of the manufacturing method include Casse 2-1 using the manufacturing apparatus 50 and Case 2-2 using the manufacturing apparatus 60, but either method may be used.
- Case1-1 (first process, manufacturing equipment 20)
- the apparatus 20 press-forms the blank 26 and shrinks a part of the vertical wall flange 10 continuous to the floor flange 9 through the floor flange 9 and the flange ridgeline 8 to form an intermediate molded product 27.
- FIG. 14 is an explanatory view showing the manufacturing apparatus 20.
- FIG. 15 is an explanatory diagram showing the arrangement of the blanks 26 before the start of molding in the manufacturing apparatus 20.
- FIG. 16 is an explanatory view showing the situation of the bottom dead center of the molding by the manufacturing apparatus 20, and the punch 21 is omitted for easy understanding of the drawing.
- the manufacturing apparatus 20 includes a punch 21, a die 22 with a protrusion, and a pad 23 as shown in FIG.
- the die 22 with protrusions is disposed to face the punch 21.
- the protrusion-equipped die 22 is integrally provided with a bending tool 25 having a protrusion 24.
- the bending tool 25 may be configured as a separate body from the die 22.
- the manufacturing apparatus 20 presses the portion corresponding to the flange ridge line 8 in the blank 26 before the portion other than the protrusion 24 in the bending tool 25.
- a portion to be formed on the flange ridgeline 8 by stretch flange molding is subjected to shear deformation.
- the manufacturing apparatus 20 forms the blank 26 into the intermediate molded product 27 including the flange ridgeline 8.
- the part 28 to be molded on the top plate flange 11 of the intermediate molded product 27 may not be molded by the manufacturing apparatus 20.
- the deformation element of the flange ridge line 8 is subjected to shear deformation from the shrinkage flange deformation field (strain ratio ⁇ ( ⁇ 2 / ⁇ 1) ⁇ 1: increased thickness). This is for changing to a field (strain ratio ⁇ ( ⁇ 2 / ⁇ 1) ⁇ 1: no change in plate thickness).
- the surplus portion of the flange ridgeline 8 is pushed out and dispersed. As a result, wrinkles and an excessive increase in the thickness of the flange ridgeline 8 and its periphery can be effectively suppressed.
- the pressing by the protrusion 24 is preferably performed on the center position of the flange ridge line 8 in the circumferential direction, but may be performed on a position shifted from the center position of the flange ridge line 8 in the circumferential direction.
- the height h (mm) of the protrusion 24 provided on the surface of the bending tool 25 desirably satisfies the following formula (1) with respect to the radius of curvature rf (mm) of the bending of the flange ridgeline 8. If the height h of the protrusion 24 is less than (0.5 ⁇ rf), the effect of suppressing the increase in the plate thickness by forming a shear deformation field at the flange ridgeline 8 is reduced, and (3.5 ⁇ This is because if it exceeds rf), the protrusion 24 may be damaged. 0.5 ⁇ rf ⁇ h ⁇ 3.5 ⁇ rf (1)
- the manufacturing apparatus 20 uses the blank 26, the punch 21, the die 22 with protrusions, and the pad 23, and the protrusion 24 corresponds to the flange ridge line 8.
- the intermediate molded product 27 is formed by pressing before the portion other than 24.
- FIG. 17 is an explanatory diagram showing a manufacturing apparatus 30 used in Case 1-2.
- FIG. 18 is an explanatory diagram showing the blank 34 before the start of preforming in the manufacturing apparatus 30.
- FIG. 19 is an explanatory view showing a preform 35 manufactured by being preformed by the manufacturing apparatus 30. 17-19 illustrate half of the manufacturing apparatus 30.
- FIG. 18 and FIG. 19 of the manufacturing apparatus 30, the description of the die 31 is omitted for easy understanding of the drawings.
- the manufacturing apparatus 30 includes a die 31, a pad 32, and a punch 33 disposed so as to face the die 31 and the pad 32. By performing press molding on the blank 34, a portion corresponding to the floor flange 9 is formed.
- the preform 35 is manufactured by molding.
- FIG. 20 is an explanatory diagram showing the manufacturing apparatus 40.
- FIG. 21 is an explanatory diagram showing the arrangement of the preform 35 before the start of molding in the manufacturing apparatus 40.
- FIG. 22 is an explanatory diagram showing the situation of the bottom dead center of the molding by the manufacturing apparatus 40. 21 and 22, the punch 36 is not shown for the sake of clarity. In the upper right view of FIG. 21, the punch 36 is indicated by a broken line.
- the manufacturing apparatus 40 forms the preform 35 into the intermediate product 27.
- the tool which comprises the manufacturing apparatus 40 is the out-of-plane deformation
- transformation suppression tool arrange
- dye 37 arrange
- the portion corresponding to the floor flange 9 of the preform 35 is restrained by the out-of-plane deformation suppressing tool 38 and the side surface of the punch 36, thereby suppressing the out-of-plane deformation of this portion during molding. .
- the out-of-plane deformation suppressing tool 38 is disposed from the side surface of the punch 36 with a gap obtained by adding a clearance to the plate thickness of the preform 35 as necessary.
- the out-of-plane deformation suppressing tool 38 is opposed to the surface of a portion corresponding to the floor flange 9 of the preform 35 during press molding, and has a predetermined distance x in the thickness direction of the preform 35. It is desirable to arrange with a gap. As a result, the out-of-plane deformation of the portion corresponding to the floor flange 9 can be reliably suppressed.
- the predetermined distance x is defined by the equation (2): 1.00 ⁇ t ⁇ x ⁇ 1.40 ⁇ t (where t is the thickness (mm) of the preform 35 and x is the distance (mm)). Is done.
- the plate thickness in the flange ridgeline 8 where the plate thickness has increased compared to the plate thickness before press molding of the preform 35 and the surrounding area exceeds 1.5 times the plate thickness before press molding at the maximum. Do not. In order to suppress mold galling during molding, it is better to provide a slight gap. Further, since the occurrence of out-of-plane deformation becomes significant when the plate thickness is thin, there is a gap of a predetermined distance x in the plate thickness direction of the preform 35 between the out-of-plane deformation suppressing tool 38 and the punch 36. Is desirable.
- the predetermined distance x is expressed by equation (3): 1.03 ⁇ t ⁇ x ⁇ 1.35 ⁇ t (where t is the plate thickness (mm) of the preform 35 and x is the distance (mm)). It is prescribed.
- the out-of-plane deformation suppressing tool 38 may be provided on the die 37, but is not limited to this example.
- the out-of-plane deformation suppressing tool 38 only needs to be able to restrain a portion corresponding to the floor flange 9 in the preform 35. For this reason, the installation position of the out-of-plane deformation suppressing tool 38 is not limited to a specific position. Further, the out-of-plane deformation suppressing tool 38 may be arranged as a lower die, not accompanying the upper die.
- the manufacturing apparatus 30 performs press molding on the blank 26 using the pad 32, the die 31, and the punch 33. Thereby, the preform 35 in which a portion corresponding to the floor flange 9 is molded is manufactured.
- the manufacturing apparatus 40 forms a portion corresponding to the flange ridge line 8 of the preform 35 using the punch 36, the die 37, the out-of-plane deformation suppressing tool 38, and the pad 39, so that an intermediate formed product is obtained. 27.
- press molding may be performed while pressing the blanks 26 and 34 together with the dies 22 and 31 by a blank holder disposed facing the dies 22 and 31.
- FIG. 23 is an explanatory diagram showing the configuration of the manufacturing apparatus 50.
- FIG. 24 is an explanatory diagram showing an arrangement state of the intermediate molded product 27 in the manufacturing apparatus 50.
- FIG. 25 is an explanatory view showing the state of the molding bottom dead center in the manufacturing apparatus 50. In FIG. 25, the description of the die 53 is omitted.
- the manufacturing apparatus 50 includes a punch 51 including an inner pad 52 that is disposed so as to freely enter and exit the punch top 51a, and a die 53 that is disposed to face the punch 51 and supports the die pad 54. With.
- the second device 50 starts press molding by separating the intermediate molded product 27 from the punch top 51a using the inner pad 52 and the die pad 54. More specifically, the intermediate molded products 27 and 40 are sandwiched between the inner pad 52 and the die pad 54 with the inner pad 52 protruding.
- the die 53 is moved downward, the die 53 pushes the die pad 54, and the intermediate molded products 27 and 40 and the inner pad 52 are pushed against the die pad 54, and the molding proceeds.
- the inner pad 52 is housed in the punch 51 at the bottom dead center. Thereby, the part which was not shape
- FIG. 26 is an explanatory diagram showing the configuration of the manufacturing apparatus 60.
- FIG. 27 is an explanatory view showing an arrangement state of the intermediate molded product 27 in the manufacturing apparatus 60.
- FIG. 28 is an explanatory diagram illustrating a situation when the ridge line pad 63 is held in the manufacturing apparatus 60.
- FIG. 29 is an explanatory view showing the state of the molding bottom dead center in the manufacturing apparatus 60. In FIG. 29, the die 62 is omitted.
- the second apparatus 60 includes a punch 61, a die 62 disposed opposite to the punch 61, the top plate ridge line 6, the upper ridge line 4, and the end portions of the vertical wall ridge line 7.
- a ridge line pad 63 for holding a portion to be formed at a connected portion is provided.
- the manufacturing apparatus 60 performs press molding using the ridge line pad 63 in the second step.
- the ridge line pad 63 presses a portion formed at a location where the ends of the top plate ridge line 6, the upper ridge line 4 and the vertical wall ridge line 7 of the intermediate molded product 27 are connected.
- the edge part of the upper ridgeline 4, the top-plate ridgeline 6, and the top-plate flange 11 are shape
- the die 62 is moved toward the punch 61 to form the upper ridge line 4 on the intermediate molded product 27. In this way, the members 1 and 12 are manufactured.
- molded by the 1st process among the vertical wall flanges 10 in the members 1 and 12, the top-plate flange 11, and the upper ridgeline 4 can be shape
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Abstract
Description
(A)縦壁角Rの大きさ(曲率半径)を小さくすることで、部材端部における断面線長が増大する。そのため、側面衝突時にフロアクロスメンバに入力されるような軸圧壊変形モードにおいて部材性能(耐荷重性能)が向上する。
(B)(A)において具体的には、縦壁角Rの寸法を、部材端部における断面線長に対して13%以下にすると良い。
(C)縦壁角Rの縮小に伴って、縦壁フランジおよび床フランジの面積が増大する。そのため、他部材と結合する際は、スポット溶接の打点数、あるいはアーク溶接やレーザー溶接の溶接長を増やすことが可能となり、部材間の結合効率および剛性等の車体性能の向上に繋がる。
(D)縦壁角Rの縮小により、他部材と結合する際に生じる隙間を埋めることができる。部材間の結合効率および剛性等の車体性能の向上に繋がる。
(E)縦壁角Rの縮小に加え、ハット型の断面のプレス成形品の長手方向の端部に設けられた、天板、縦壁、および上稜線に隣接する外向きフランジを連続して形成することで、さらに部材性能を高めることが可能となる。
(1)天板と該天板の両側に上稜線を介して二つの向き合う縦壁を備える部材であって、
前記天板の前記部材の端部側にある天板稜線を介して前記部材の外側に延びる天板フランジと
前記縦壁の前記部材の端部側に延在する縦壁稜線を介して前記部材の外側に延びる二つの縦壁フランジと
前記縦壁フランジに隣接し前記縦壁の端部とは別の前記縦壁の端部に延在する下稜線を介して前記部材の外側に延びる二つの床フランジを備え、
前記縦壁フランジとその端部で隣接する床フランジはそれぞれ連続し、
前記部材の端部において、前記下稜線と前記縦壁稜線の間の前記縦壁の角の曲率半径の総和ΣRと部材端部における天板と縦壁の幅の総和ΣLは、ΣR/ΣL≦0.13の関係になっていることを特徴とする部材。
(2)前記下稜線と前記縦壁稜線の間の前記縦壁の角の曲率半径は20mm以下であることを特徴とする請求項1に記載の部材。
(3)前記天板フランジと前記縦壁フランジが連続している請求項1または請求項2に記載の部材。
(4)前記縦壁が三角形であり、前記床フランジが前記縦壁フランジを兼ねていることを特徴とする請求項1から請求項3のいずれかに記載の部材。
(5)請求項1から請求項4のいずれかに記載の部材のプレス成形による製造方法であって、ブランクの少なくとも二箇所に床フランジの少なくとも一部と前記床フランジに連続する縦壁フランジの一部をそれぞれ縮みフランジ成形する第1工程と
前記第1工程の次に前記ブランクの前記第1工程における少なくとも二箇所の間の少なくとも二箇所に天板フランジと前記天板フランジに連続する縦壁フランジの残部をそれぞれ伸びフランジ成形する第2工程を備えることを特徴とするプレス成形品の製造方法。
(A)第1工程で、ブランクに任意の拘束条件下で縮みフランジ成形を行って縦壁フランジ-床フランジの間の繋ぎ部を成形して中間成形品とする。
(B)第2工程で、縦壁フランジ-床フランジの間の繋ぎ部を成形された中間成形品にプレス成形を行って、天板、縦壁およびフランジを備える所望の横断面形状を有するプレス成形部品とする。
(C)第2工程では、後述するインナーパッド成形を用いることにより,天板、縦壁、および上稜線に隣接する外向きフランジ連続した形状を作製できる。
(1)ブランクにプレス成形を行って前記下部フランジ繋ぎ部を縮みフランジ形成することにより、少なくとも前記下部フランジ繋ぎ部を備える中間成形品を製造する第1工程と、該中間成形品にプレス成形を行って、前記横断面を有する前記プレス成形部品を製造する第2工程とを有することを特徴とするプレス成形部品の製造方法。
(1)部材の形状
図3は、本発明に係る部材1を示す説明図であり、図4は、本発明に係る他の部材12を示す説明図である。図中で1本線は部材の縁、2本線は稜線、点線は部材の陰に隠れている箇所を意味する。
図7(a)および図7(b)は、部材1の軸圧壊特性をコンピュータシミュレーションにより解析した結果を示すグラフである。部材1を他の部材(サイドシルインナ)と外向きフランジ(縦壁フランジ10と天板フランジ11)を介して接合した状態で上稜線4の延在する方向の衝撃荷重を負荷したモデルで解析を行った。図7(a)および図7(b)は、軸圧壊した際の軸圧壊特性に及ぼす下稜線5と縦壁稜線7の間の縦壁3のコーナー部の曲率半径R(縦壁角R)(mm)の影響を示す。図7(a)は、曲率半径Rが2mmと20mmの場合について、上稜線4の延在方向への圧壊ストロークと荷重との関係を示す。図7(a)において、実線は曲率半径Rが2mmの場合を示しており、破線は曲率半径Rが20mmの場合を示している。図7(b)は、曲率半径Rと最大荷重(耐荷重)との関係を示す。部材1の断面形状は、部材端部における天板2と縦壁3の幅の総和ΣLが300mmである。素材は引っ張り強さ980MPa、板厚1.2mmの鋼板を模擬した。なお、下稜線5と縦壁稜線7の間の縦壁3のコーナー部の曲率半径R(縦壁角R)の影響のみに着目するため、他の天板2と縦壁3の角はピン角(角の曲率半径が0)で模擬している。
本発明の部材(部材1、部材12)をプレス成形により製造する場合は、2つの工程によって製造することができる。第1の工程は、床フランジ9とフランジ稜線8を介して床フランジ9に連続する縦壁フランジ10の一部を縮みフランジ成形する。第2の工程は、第1の工程の次に行われ、天板フランジ11と天板フランジ11に連続する第1の工程で成形しなかった縦壁フランジ10の残部を成形する。本発明の部材をプレス成形で製造する場合の工程の流れを図13に示す。第1の工程では、ブランク26,34から中間成形品27を製造する。製造方法には製造装置20を使用するCase1-1と製造装置30を使用して予備成形品35を製造し、製造装置40を使用して予備成形品35から中間成形品27を製造するCase1-2が例示されるが、どちらの方法でもよい。第2の工程では中間成形品27から部材1、部材12を製造する。製造方法には製造装置50を使用するCasse2-1と製造装置60を使用するCase2-2が例示されるが、どちらの方法でもよい。
装置20は、ブランク26にプレス成形を行って床フランジ9とフランジ稜線8を介して床フランジ9に連続する縦壁フランジ10の一部を縮みフランジ形成し、中間成形品27を製造する。
0.5×rf≦h≦3.5×rf ・・・・・・・(1)
図17は、Case1-2で使用される製造装置30を示す説明図である。図18は、製造装置30における予備成形開始前のブランク34を示す説明図である。図19は、製造装置30により予備成形されて製造された予備成形品35を示す説明図である。図17~19は、製造装置30の半分を図示する。製造装置30の図18、図19では図面を見易くするためにダイ31の記載を省略する。
加えて、予備成形品35のプレス成形前の板厚よりも板厚が増加したフランジ稜線8とその周辺の領域における板厚が、最大でも前記プレス成形前の板厚の1.5倍を超えないようにする。なお、成形時の型かじりを抑制するためには僅かに隙間を設けたほうがよい。また、板厚が薄い場合には面外変形の発生が顕著になるため、面外変形抑制工具38とパンチ36の間は予備成形品35の板厚方向へ所定の距離xの隙間を有することが望ましい。所定の距離xは、(3)式:1.03×t≦x<1.35×t(ただし、t:予備成形品35の板厚(mm)、x:距離(mm)である)により規定される。
また、面外変形抑制工具38はダイ37に設けられていてもよいが、この例に限定されるものでない。面外変形抑制工具38は予備成形品35における床フランジ9に相当する部分を拘束できればよい。このため、面外変形抑制工具38の設置位置は特定の位置には限定されない。また、面外変形抑制工具38は上型に付随してではなく、下型として配置されてもよい。
なお、図示していないが、第1工程では、ダイ22,31に対向して配置されるブランクホルダにより、ダイ22,31とともにブランク26,34を押えながらプレス成形を行うようにしてもよい。
図23は、製造装置50の構成を示す説明図である。図24は、製造装置50における中間成形品27の配置状況を示す説明図である。図25は、製造装置50における成形下死点の状況を示す説明図である。図25ではダイ53の記載を省略する。
図23~25に示すように、製造装置50は、パンチ頂部51aに出入り自在に配置されたインナーパッド52を備えるパンチ51と、パンチ51に対向して配置されるとともにダイパッド54を支持するダイ53とを備える。
第2装置50は、第2工程では、インナーパッド52とダイパッド54とを用いて中間成形品27をパンチ頂部51aより離してプレス成形を開始する。より詳細には、インナーパッド52を突き出した状態で、中間成形品27,40をインナーパッド52とダイパッド54とで挟持する。次に、ダイ53を下に移動させ、ダイ53がダイパッド54を押し、ダイパッド54に中間成形品27,40とインナーパッド52が押されて成形が進む。成形下死点では、インナーパッド52がパンチ51に収納された状態になる。これにより、部材1,12における縦壁フランジ10のうち第1工程で成形されなかった部分と、天板フランジ11と、上稜線4を成形することができる。
図26は、製造装置60の構成を示す説明図である。図27は、製造装置60における中間成形品27の配置状況を示す説明図である。図28は、製造装置60における稜線パッド63のホールド時の状況を示す説明図である。さらに、図29は、製造装置60における成形下死点の状況を示す説明図である。図29ではダイ62は省略する。
2 天板
3 縦壁
4 上稜線
5 下稜線
6 天板稜線
7 縦壁稜線
8 フランジ稜線
9 床フランジ
10 縦壁フランジ
11 天板フランジ
12 部材(縦壁が三角形)
26 展開ブランク
27 中間成形品
Claims (5)
- 天板と該天板の両側に上稜線を介して二つの向き合う縦壁を備える部材であって、
前記天板の前記部材の端部側にある天板稜線を介して前記部材の外側に延びる天板フランジと
前記縦壁の前記部材の端部側に延在する縦壁稜線を介して前記部材の外側に延びる二つの縦壁フランジと
前記縦壁フランジに隣接し前記縦壁の端部とは別の前記縦壁の端部に延在する下稜線を介して前記部材の外側に延びる二つの床フランジを備え、
前記縦壁フランジとその端部で隣接する床フランジはそれぞれ連続し、
前記部材の端部において、前記下稜線と前記縦壁稜線の間の前記縦壁の角の曲率半径の総和ΣRと部材端部における天板と縦壁の幅の総和ΣLは、ΣR/ΣL≦0.13の関係になっていることを特徴とする、部材。 - 前記下稜線と前記縦壁稜線の間の前記縦壁の角の曲率半径は20mm以下であることを特徴とする、請求項1に記載の部材。
- 前記天板フランジと前記縦壁フランジが連続していることを特徴とする、請求項1または請求項2に記載の部材。
- 前記縦壁が三角形であり、前記床フランジが前記縦壁フランジを兼ねていることを特徴とする、請求項1から請求項3のいずれかに記載の部材。
- 請求項1から請求項4のいずれかに記載の部材の製造方法であって、
ブランクの少なくとも二箇所に床フランジの少なくとも一部と前記床フランジに連続する縦壁フランジの一部をそれぞれ縮みフランジ成形する第1工程と
前記第1工程の次に前記ブランクの前記第1工程における少なくとも二箇所の間の少なくとも二箇所に天板フランジと前記天板フランジに連続する縦壁フランジの残部をそれぞれ伸びフランジ成形する第2工程を備えることを特徴とする、プレス成形品の製造方法。
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- 2017-07-24 KR KR1020197007366A patent/KR101999944B1/ko active IP Right Grant
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Also Published As
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US20190185070A1 (en) | 2019-06-20 |
US10577027B2 (en) | 2020-03-03 |
RU2706253C1 (ru) | 2019-11-15 |
KR20190030772A (ko) | 2019-03-22 |
CN109641259B (zh) | 2020-10-23 |
CN109641259A (zh) | 2019-04-16 |
KR101999944B1 (ko) | 2019-07-12 |
MX2019001892A (es) | 2019-07-01 |
TWI642579B (zh) | 2018-12-01 |
CA3034226A1 (en) | 2018-02-22 |
EP3501684A1 (en) | 2019-06-26 |
EP3501684A4 (en) | 2019-10-09 |
TW201808697A (zh) | 2018-03-16 |
CA3034226C (en) | 2019-07-02 |
BR112019002944A2 (pt) | 2019-05-14 |
EP3501684B1 (en) | 2023-04-19 |
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