WO2021181982A1 - プレス部品の製造方法、プレス成形用の金属板、及び高張力鋼板 - Google Patents
プレス部品の製造方法、プレス成形用の金属板、及び高張力鋼板 Download PDFInfo
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- WO2021181982A1 WO2021181982A1 PCT/JP2021/004801 JP2021004801W WO2021181982A1 WO 2021181982 A1 WO2021181982 A1 WO 2021181982A1 JP 2021004801 W JP2021004801 W JP 2021004801W WO 2021181982 A1 WO2021181982 A1 WO 2021181982A1
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- Prior art keywords
- bead
- metal plate
- shape
- curved
- top plate
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 122
- 239000002184 metal Substances 0.000 title claims abstract description 122
- 238000000465 moulding Methods 0.000 title claims abstract description 98
- 238000000034 method Methods 0.000 title claims abstract description 61
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 28
- 229910000831 Steel Inorganic materials 0.000 title claims description 10
- 239000010959 steel Substances 0.000 title claims description 10
- 239000011324 bead Substances 0.000 claims abstract description 178
- 238000005452 bending Methods 0.000 claims description 31
- 230000037303 wrinkles Effects 0.000 abstract description 57
- 239000000463 material Substances 0.000 description 16
- 230000000052 comparative effect Effects 0.000 description 8
- 238000012545 processing Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 238000010097 foam moulding Methods 0.000 description 4
- 238000009751 slip forming Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 230000000452 restraining effect Effects 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 230000001131 transforming effect 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
- B21D17/00—Forming single grooves in sheet metal or tubular or hollow articles
- B21D17/02—Forming single grooves in sheet metal or tubular or hollow articles by pressing
-
- 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
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
-
- 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
- B21D22/206—Deep-drawing articles from a strip in several steps, the articles being coherent with the strip during the operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
- B21D24/005—Multi-stage presses
-
- 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
- B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
- B21D11/08—Bending by altering the thickness of part of the cross-section of the work
Definitions
- the present invention has a cross section such as a U-shaped cross section, a hat-shaped cross section, an L-shaped cross section, etc. having at least a top plate portion and a side wall portion continuous with at least one of the width directions of the top plate portion, and the above-mentioned cross section has a cross section.
- the manufacturing method technology of pressed parts to manufacture Regarding the manufacturing method technology of pressed parts to manufacture.
- stamped parts including automobiles and home appliances, are made by transforming a flat metal plate into various shapes.
- press forming in which a metal plate is deformed by using a press machine and a die is widely used for manufacturing the pressed parts.
- the metal plate before processing is flat, and in order to deform it into a complicated three-dimensional shape, the metal plate must expand and contract according to the three-dimensional shape.
- the more complicated the shape of the pressed part the more difficult it is to give the metal plate expansion and contraction according to the three-dimensional shape.
- the metal plate to be press-formed is made of a high-tensile steel plate or an aluminum alloy plate having a tensile strength of 590 MPa or more and a difficult-to-mold member having inferior ductility or Rankford value is used as the metal plate, the above difficulty is solved. It is easy to occur.
- the metal plate In press molding, if the metal plate cannot be expanded or contracted according to the three-dimensional shape, molding defects such as cracks and wrinkles will occur in the metal plate. That is, when the metal plate is deformed into a three-dimensional shape, the metal plate has to stretch in a part where the length of the metal plate is insufficient to make up for the shortage from the surroundings, and the metal plate exceeds its own ductility. When pulled, cracks occur. On the other hand, when the metal plate is deformed into a three-dimensional shape, the length of the metal plate must be shortened, or wrinkles tend to occur at a portion where the metal plate excessively flows from the surroundings.
- a part shape that is difficult to press-mold has a cross section including a top plate portion, a vertical wall portion continuous with the top plate portion, and a flange portion continuously formed on the vertical wall portion, and has a longitudinal length.
- press-molded parts having one or more curved shapes in a side view along the direction.
- the top plate portion is restrained by the pad and the flange portion is also restrained by the blank holder to suppress tensile / compressive deformation of both the top plate portion and the flange portion. be able to.
- the method described in Patent Document 1 also has a high mold cost.
- the present invention has been made by paying attention to the above points, and is used in the case of press molding into a pressed part shape having one or more curved portions in which the top plate portion is curved convexly or concavely in a side view.
- the purpose is to suppress the occurrence of wrinkles by simple means.
- the inventors have a hat-shaped cross section including a top plate portion, vertical wall portions formed on both sides of the top plate portion, and flange portions continuously formed on the vertical wall portion, and up and down in a side view.
- a press method was investigated for press-molded parts having a curved shape, which can be molded without cracking or wrinkling and does not require a complicated mold structure. Then, the following findings were obtained. (1) It is possible to suppress wrinkles in the flange portion by increasing the shape rigidity of the die shoulder ridge portion by preforming and forming the product shape by the bending method in the next step. (2) In addition to the die shoulder ridge, the shape rigidity of the punch shoulder ridge is increased, and the product shape is formed by the bending method in the next process. It can be suppressed.
- the present invention has been made based on the above findings.
- one aspect of the present invention has a cross section having a top plate portion and a side wall portion continuous with the first bent portion in at least one of the width directions of the top plate portion, and A pressed part that forms a metal plate into a pressed part shape that has one or more curved parts that are curved so that the top plate part is convex or concave in a side view along the longitudinal direction that intersects the cross section.
- the first method of manufacturing the above method which comprises a step of forming a first bead that extends continuously or partially along the longitudinal direction at a position serving as the first bending portion with respect to the metal plate. It is a gist to include a pre-molding step and a first part molding step of molding the metal plate after the first pre-molding step into the shape of the pressed part.
- one aspect of the present invention is a side wall portion continuous with the top plate portion and at least one of the top plate portions in the width direction via the first bent portion, and a flange continuous with the side wall portion via the second bent portion.
- a pressed part having a cross section having a portion and having one or two curved portions curved so that the top plate portion is convex or concave in a side view along a longitudinal direction which is a direction intersecting the cross section.
- one aspect of the present invention has a cross section having a top plate portion and a side wall portion continuous with the first bent portion in at least one of the width directions of the top plate portion, and a direction intersecting the cross section.
- a metal plate for press-molding into a pressed part shape having one or more curved portions curved so that the top plate portion is convex or concave in a side view along the longitudinal direction.
- the gist is to have a first bead extending along the longitudinal direction at a position to be a bent portion.
- one aspect of the present invention is a side wall portion continuous with the top plate portion and at least one of the top plate portions in the width direction via the first bent portion, and a flange continuous with the side wall portion via the second bent portion.
- a pressed part having a cross section having a portion and having one or two curved portions curved so that the top plate portion is convex or concave in a side view along a longitudinal direction which is a direction intersecting the cross section. It is a metal plate for press-molding into a shape, and has a second bead extending continuously or partially along the longitudinal direction at a position to be the second bending portion.
- a ridgeline portion or a side wall formed of a bent portion that connects the top plate portion and the side wall portion.
- Beads are formed continuously (continuously) or partially along at least one of the ridges at the position of the ridge consisting of the bent portion connecting the portions and the flanges.
- FIG. 1 It is a figure which shows the shape of the pressed part which concerns on embodiment based on this invention, (a) is a perspective view, (b) is a side view, (c) is a cross-sectional view of AA. It is a figure which shows the process example of the manufacturing method of the pressed part which concerns on embodiment based on this invention. It is a figure explaining the molding surface of a mold in a pre-molding process. It is a figure explaining the molding surface of a mold in a part molding process. It is a schematic diagram seen from the side which explains the cause of the wrinkle occurrence in the conventional. It is a schematic view seen from the front which shows the bead example after a premolding process. It is a schematic view from the side which explains the wrinkle suppression in the embodiment based on this invention. It is a figure explaining the processing process in the modified example which concerns on embodiment based on this invention. It is a figure which shows the example of wrinkle occurrence.
- the shape of the pressed part after press molding which is the target of the present embodiment, has a U-shaped cross section and a hat having at least a top plate portion and a side wall portion continuous with at least one of both sides in the left-right width direction via the first bent portion. It has a cross-sectional shape such as a cross section or an L-shaped cross section. Further, the shape of the pressed part is such that the top plate portion is convex or concave in the side view along the longitudinal direction at one or more locations in the longitudinal direction, which is the direction intersecting the cross section (plate width direction). It has a shape having one or more curved portions. In the case of the hat-shaped cross section, the shape of the pressed part is a shape that follows the curvature of the top plate portion in the side view along the longitudinal direction.
- the present embodiment is a technique suitable for manufacturing pressed parts using a metal plate made of a difficult-to-mold member having inferior ductility and Rankford value, such as a high-strength steel plate having a tensile strength of 590 MPa or more and an aluminum alloy plate.
- a metal plate made of a difficult-to-mold member having inferior ductility and Rankford value such as a high-strength steel plate having a tensile strength of 590 MPa or more and an aluminum alloy plate.
- the press part shape 1 has a hat-shaped cross section and has two curved portions 10 along the longitudinal direction as shown in FIG.
- the target press part shape 1 has a hat-shaped cross section and has two curved portions 10 along the longitudinal direction as shown in FIG.
- the target pressed part shape 1 has a hat-shaped cross section, and two places along the longitudinal direction, that is, the top plate portion 1A is concavely curved (bent downward). ),
- the case where the curved portion 10A and the top plate portion 1A are convexly curved (bent upward) is illustrated.
- the curved portion 10 may be at one location, or the curved portion 10 may be at three or more locations.
- the shape may be such that the two adjacent curved portions 10 are both curved in the same direction. It should be noted that the dimensions shown in FIG. 1 are the dimensions in the embodiment and do not limit the present invention in any way.
- the method for manufacturing a pressed part of the present embodiment includes a premolding step 2 and a part molding step 3.
- the preforming step 2 is a step of performing preliminary molding before the main molding on the metal plate to obtain a metal plate for the main molding, which is less likely to cause wrinkles.
- a second step 2B for forming the first bead 4a and the second bead 4b is provided at positions serving as the bent portion 1d and the second bent portion 1e.
- the first bead 4a and the second bead 4b extend continuously or partially along the longitudinal direction, respectively.
- the second step 2B may be a step of forming only one of the first bead 4a and the second bead 4b. Further, in the longitudinal direction, the formation position of the first bead 4a and the formation position of the second bead 4b may not overlap with each other. Further, the preforming step 2 may be composed of only the second step 2B.
- a bead that extends continuously or partially along the longitudinal direction refers to the case where the bead is continuously formed over the entire length of the metal plate 4 in the longitudinal direction, and the metal. This includes the case where a bead is formed in a part of the plate 4 along the longitudinal direction.
- a plurality of beads may be formed at intervals along the longitudinal direction of the metal plate 4. For example, when the pressed part shape 1 has a plurality of curved portions 10, beads may be continuously formed at two or more curved portions 10, or beads may be formed individually for each of the curved portions 10. It may have been done.
- FIG. 6 An example of the cross-sectional shape of the first bead 4a and the second bead 4b is shown in FIG.
- the example shown in FIG. 6 is an example in which the first bead 4a and the second bead 4b are composed of full beads.
- the beads 4a and 4b of the present embodiment have a shape extending in the direction in which the cross section of the bent shape intersects the cross section (longitudinal direction (longitudinal direction of the top plate portion of the metal plate 4)).
- the beads 4a and 4b are composed of a full bead, a half bead having a stepped cross section, and the like.
- the curved shape following the curvature of the curved portion 10 provided in the pressed part shape 1 is the contour shape in the side view of the top plate portion 1A of the pressed part shape 1 (for example, the longitudinal length of the ridge line portion formed by the first bent portion 1d). Profile shape along the direction) is adopted. It is preferable that the radius of curvature of the curved portion 10 of the curved shape given to the metal plate 4 in the side view is set to be equal to the radius of curvature of the curved portion 10 provided in the pressed part shape 1.
- the difference between the radius of curvature of the curved portion 10 provided by the metal plate 4 and the radius of curvature of the curved portion 10 provided in the pressed part shape 1 is, for example, ⁇ 10% of the radius of curvature of the curved portion 10 provided in the pressed part shape 1. The following is preferable.
- the first bent portion 1d corresponds to the cross section of the ridge line portion 1D formed between the top plate portion 1A and the vertical wall portion.
- the ridge line portion 1D is bent so as to be convex upward.
- the second bent portion 1e corresponds to the cross section of the ridge line portion 1E formed between the vertical wall portion and the flange portion 1C.
- the ridge line portion 1E is bent so as to be concave on the upper side.
- the second step 2B may have a processing configuration in which only one of the first bead 4a and the second bead 4b is formed.
- the first step 2A and the second step 2B are executed by press working with one die.
- the dies used are provided with the same curvature as the curved shape of the pressed part shape 1 on the molding surfaces 20 and 21 of the upper die (die) and the lower die (punch) in a side view.
- the pressed part shape 1 of the present embodiment has a curved portion 10A in which the top plate portion 1A is concavely curved (bent downward) and a curved portion 10B in which the top plate portion 1A is curved convexly (bent upward). It has become.
- the molded surfaces 20 and 21 of the upper mold (die) and the lower mold (punch) are curved concavely (bent downward) and the top plate portion 1A is curved convexly in a shape that follows the shape of the side view. It has a surface shape with a portion that bends upward.
- the metal plate 4 is given the same curved shape in the width direction (the same direction as the width direction of the press part shape 1), for example.
- the curved shape of the molded surfaces 20 and 21 of the upper die (die) and the lower die (punch) in the side view is preferably equal to the curved shape of the top plate portion 1A in the side view of the press part shape 1.
- the curved shape of the top plate portion 1A and the curved shape of the flange portion 1C in the side view along the longitudinal direction are equal to or almost equal to each other. Therefore, the curved shape of the molded surface of the upper die (die) and the lower die (punch) in the side view may be a shape that follows the curved shape of the top plate portion 1A along the longitudinal direction.
- the curved shapes of the surface position of the top plate portion 1A and the surface position of the flange portion 1C are set as different shapes. Is also good. In this case, the difference in curved shape may be absorbed by the molding surface forming the vertical wall portion.
- the molding surfaces 20 and 21 of the upper die and the lower die extend along the positions of the first bent portion 1d and the second bent portion 1e, that is, along the longitudinal direction, respectively.
- the bead shapes 20a and 21a following the first bead 4a and the bead shapes 20b and 21b following the second bead 4b are formed.
- the positions where the first bead shapes 20a and 21a and the second bead shapes 20b and 21b are formed abut on the punch shoulder ridges and die shoulder ridges of the mold in the part molding step 3 in the part molding step 3. It is a possible position.
- the first bead 4a preferably has a shape that is convex in the same direction as the convex direction of the first bent portion 1d (a shape that is convex upward in the cross section) (see FIG. 6).
- the bead height of the first bead 4a is preferably twice or more the plate thickness of the metal plate 4.
- the upper limit of the bead height of the first bead 4a is 20 mm.
- the second bead 4b preferably has a shape that is convex in the same direction as the convex direction of the second bent portion 1e (a shape that is convex downward) (see FIG. 6).
- the bead height of the second bead 4b is preferably twice or more the plate thickness of the metal plate 4.
- the upper limit of the height of the second bead 4b is 20 mm. Then, in the preforming step 2, the metal plate 4 is press-molded using the above upper and lower dies, and the first bead 4a and the second bead 4a and the second bead 4a are curved along the longitudinal direction and extend along the longitudinal direction. It is a metal plate 4 provided with a bead 4b.
- the part molding step 3 is a main molding step of molding the metal plate 4 processed in the preforming step into the target pressed part shape 1.
- the metal plate 4 after the treatment of the preforming step 2 is press-molded using a mold having molding surfaces 22 and 23 as shown in FIG. 4, and the desired press part shape 1 is formed. It is a pressed part.
- FIG. 4 illustrates a case where the mold has a pad 24 for holding a position of the top plate portion 1A of the metal plate 4. That is, in this example, a case where bending molding is adopted as press molding is illustrated.
- foam molding in which the top plate portion 1A is not pressed by the pad 24 may be adopted.
- the preforming step 2 constitutes at least one of the first preforming step and the second preforming step.
- the part molding step 3 constitutes at least one of a first part molding step and a second part molding step.
- the preforming step 2 as preforming, a process of imparting a curved shape (curved shape in the plate thickness direction) along the longitudinal direction to the metal plate 4, and the first bead 4a and The process of imparting at least one of the second beads 4b is executed (FIG. 3).
- the metal plate 4 when the metal plate 4 is pressed by the upper die and the lower die for the preforming step 2, as the upper die approaches the lower die, the metal plate 4 first forms the upper die and the lower die. It deforms into a curved shape along the surfaces 20 and 21.
- the upper die relatively approaches the lower die and moves to the bottom dead center, so that the first bead 4a and the second bead 4b are press-molded on the metal plate 4 in a curved plate shape. That is, the beads 4a and 4b are formed after the curved shape is given to the metal plate 4.
- the first bead 4a and the second bead 4b extending in the longitudinal direction are formed, so that the spring along the longitudinal direction of the curved shape provided as the first step 2A at the time of mold release is formed.
- the back can be kept small.
- the metal plate 4 in the preforming step 2 has high shape rigidity in the longitudinal direction due to the addition of the beads 4a and 4b.
- the metal plate 4 after the preforming step 2 is pressed in the part molding step 3 to form a U-shaped cross section or a hat-shaped cross section having a curved portion 10 curved vertically in a side view
- the metal plate 4 Since the bead 4a and 4b increase the shape rigidity in the longitudinal direction, wrinkles due to buckling are suppressed.
- the metal plate 4 made of a flat plate is press-molded into a part shape having a curved portion 10 curved vertically in a side view, as shown in FIG. 5, the curved portion 10 convex toward the top plate portion 1A side has a curved portion 10.
- the top plate portion 1A side (convex side) is stretched in the longitudinal direction
- the flange portion 1C side (concave side) is contracted in the longitudinal direction.
- shrinkage occurs in the longitudinal direction on the top plate portion 1A side (concave side), and in the flange portion 1C side (convex side) in the longitudinal direction. Stretches to occur.
- the material moves in the longitudinal direction on the top plate portion 1A side and the flange portion 1C side, which causes wrinkles.
- wrinkles due to buckling may occur in the flange portion 1C where the material can move freely and the curved portion 10 which is convex toward the top plate portion 1A.
- draw molding since the flange portion 1C is restrained, there is a possibility that wrinkles due to buckling may occur in the top plate portion 1A where the material can move freely and the curved portion 10 of the recess on the top plate portion 1A side.
- foam molding since the material is freely moved in both the top plate portion 1A and the flange portion 1C, wrinkles may occur in the top plate portion 1A and the flange portion 1C.
- the first bead 4a and the second bead 4b as shown in FIG. 6 are formed in advance on the metal plate 4, so that the shape of the metal plate 4 in the longitudinal direction is formed. Increases rigidity.
- wrinkles due to buckling of the metal plate 4 are suppressed, and the ridge line portion 1D and the side wall portion 1B between the top plate portion 1A and the side wall portion 1B are formed. It prevents the ridge line portion 1E from the flange portion 1C from being deformed.
- the flange surface is translated with respect to the top plate portion 1A in the pressing direction, which causes wrinkles. Material movement is suppressed. Further, by imparting a curved shape along the longitudinal direction to the metal plate 4 in advance, the flange surface is further formed by translating the top plate portion 1A in the press direction during press molding. As a result, the movement of materials that cause wrinkles is further suppressed.
- the first step 2A and the second step 2B are executed in the preforming step 2 has been illustrated.
- the first step 2A may be omitted and only the second step 2B (the step of forming the bead) may be executed.
- the part molding step 3 the curved shape that curves in the vertical direction in the side view and the bending process at the positions of the first bending portion 1d and the second bending portion 1e along the width direction may be executed. ..
- first bead 4a and the second bead 4b are formed at the entire positions of the ridges 1D and 1E composed of the first bent portion 1d and the second bent portion 1e is exemplified.
- the first bead 4a and the second bead 4b may be partially provided along the longitudinal direction with respect to the positions of the corresponding ridges 1D and 1E.
- at least the first estimation region where wrinkles are estimated to occur in the top plate portion 1A when the metal plate 4 made of a flat plate is press-molded into the pressed part shape 1 and the metal plate 4 made of a flat plate are described above.
- each bead is formed at a position that becomes a second estimation region where wrinkles are estimated to occur in the flange portion 1C when the press part shape 1 is press-formed.
- the first estimation area acquisition unit 6 executes a process of obtaining a first estimation area in which wrinkles are estimated to occur in the top plate portion 1A when the metal plate 4 made of a flat plate is press-formed into the press part shape 1.
- the second estimation area acquisition unit 7 executes a process of obtaining a second estimation area that is estimated to cause wrinkles in the flange portion 1C when the metal plate 4 made of a flat plate is press-formed into the press part shape 1.
- the processing by the first estimation area acquisition unit 6 and the second estimation area acquisition unit 7 may be executed by molding analysis using a computer, or may actually be press molding. Further, since wrinkles during molding occur in the curved portion 10 on the side where the material gathers in the curved portion 10, the curved portion 10 in which the top plate portion 1A is curved in a concave shape is simply estimated as the first estimation region. The curved portion 10 in which the top plate portion 1A is curved convexly may be estimated as the second estimation region.
- the top plate portion 1A and the top plate portion 1A have a cross section having a continuous side wall portion 1B via the first bending portion 1d on at least one of them in the width direction, and the cross section has a cross section.
- a first preforming step of forming the metal plate 4 after the first preforming step into the pressed part shape 1 is provided.
- this configuration before press molding into the pressed part shape 1 having a vertically curved shape in the side view, along the position of the ridge line portion formed by the bent portion connecting the top plate portion 1A and the side wall portion 1B.
- the shape rigidity along the longitudinal direction at the time of forming into the pressed part shape 1 is improved, and it is possible to suppress the occurrence of wrinkles at least in the top plate portion 1A.
- the shape of the pressed part is a cross section having a flange portion continuous with the side wall portion via the second bent portion
- the first preforming step includes the step of forming the first bead and the step of forming the first bead. It has a step of forming a second bead that extends continuously or partially along the longitudinal direction at a position serving as the second bending portion with respect to the metal plate.
- the first bead and the second bead each partially extend to at least the position where the first bead is formed, and the position where the first bead is formed and the position where the first bead is formed and the above.
- the position of the curved portion where the second bead is formed is different. According to this configuration, the bead formation position can be suppressed.
- the first bead 4a preferably has a shape that is convex in the same direction as the convex direction of the first bent portion 1d. According to this configuration, the bead shape of the first bead 4a can be easily crushed in the part molding step 3.
- the target press component shape 1 may have a bead formed along a ridgeline portion connecting the top plate portion 1A and the side wall portion 1B. Since the top plate portion 1A is a surface serving as a connecting portion with other parts, it is preferable that no bead is formed.
- the first preforming step includes a step of imparting a curve to the metal plate 4 along the longitudinal direction in accordance with the curve of the curved portion 10, and a step of forming the first bead 4a. You may have. According to this configuration, the first preforming step imparts a curved shape together with the first bead 4a, and for example, the shape accuracy in the longitudinal direction is improved.
- the bead height of the first bead 4a is preferably twice or more the plate thickness of the metal plate 4. According to this configuration, it is possible to surely improve the shape rigidity in the longitudinal direction.
- the second estimation area acquisition unit 7 obtains the second estimation area in which the flange portion 1C is estimated to be wrinkled when the metal plate 4 made of a flat plate is press-formed into the press part shape 1.
- the metal plate 4 portion corresponding to the second bent portion 1e including the region to be the second estimated region among the ridge line portions formed by the second bent portion 1e is formed.
- a configuration in which the second bead 4b is partially formed may be used. According to this configuration, it is possible to prevent the second bead 4b from being added more than necessary.
- a second bent portion 1e is provided on the side wall portion 1B and the side wall portion 1B which are continuous with the first bent portion 1d on at least one of the top plate portion 1A and the top plate portion 1A in the width direction.
- a curved portion 10 having a cross section having a continuous flange portion 1C via the cross section and curved so that the top plate portion 1A is convex or concave in a side view along a longitudinal direction which is a direction intersecting the cross section.
- the second preforming step includes a step of imparting a curve to the metal plate 4 along the longitudinal direction in accordance with the curve of the curved portion 10, and a step of forming the second bead 4b. You may have. According to this configuration, the second preforming step imparts a curved shape together with the second bead 4b, and for example, the shape accuracy in the longitudinal direction is improved.
- the second estimation area acquisition unit 7 for obtaining the second estimation area in which the flange portion 1C is estimated to be wrinkled when the metal plate 4 made of a flat plate is press-formed into the press part shape 1.
- the metal plate 4 portion corresponding to the second bent portion 1e including the region to be the second estimated region among the ridge line portions formed by the second bent portion 1e is formed.
- the configuration may be such that the second bead 4b is partially formed. According to this configuration, it is possible to prevent the second bead 4b from being added more than necessary.
- the second bead 4b preferably has a shape that is concave in the same direction as the concave direction of the second bent portion 1e. According to this configuration, the bead shape of the second bead 4b can be easily crushed in the part molding step 3.
- the target press component shape 1 may have a bead formed along a ridgeline portion connecting the side wall portion 1B and the flange portion 1C.
- the bead height of the second bead 4b is preferably twice or more the plate thickness of the metal plate 4. According to this configuration, it is possible to surely improve the shape rigidity in the longitudinal direction.
- the present embodiment has a cross section having a top plate portion 1A and a side wall portion 1B continuous with the first bending portion 1d on at least one of the top plate portions 1A in the width direction, and the cross section thereof.
- the configuration may include a first bead 4a that extends continuously or partially along the longitudinal direction at a position that becomes the first bent portion 1d.
- the top plate portion 1A and the top plate portion 1A have a cross section having a continuous side wall portion 1B via the first bending portion 1d on at least one of them in the width direction, and intersect the cross section.
- a pressed part shape 1 having one or two or more curved portions 10 curved so that the top plate portion 1A is convex or concave in a side view along the longitudinal direction, which is the direction, at least the top plate portion Wrinkles generated in 1A can be suppressed.
- the metal plate 4 is a metal plate 4 press-molded into the press part shape 1 having a cross section having a flange portion 1C continuous with the side wall portion 1B via a second bent portion 1e.
- a second bead 4b extending along the longitudinal direction may be provided at a position serving as the second bent portion 1e.
- the top plate portion 1A and the top plate portion 1A have a cross section having a continuous side wall portion 1B via the first bending portion 1d on at least one of them in the width direction, and intersect the cross section.
- the metal plate 4 may have a configuration having a curvature that follows the curvature of the curved portion 10 along the longitudinal direction. According to this configuration, the shape accuracy in the longitudinal direction is improved when the press part shape 1 is press-molded.
- a second bent portion 1e is provided on the side wall portion 1B and the side wall portion 1B which are continuous with the first bent portion 1d on at least one of the top plate portion 1A and the top plate portion 1A in the width direction.
- a curved portion 10 having a cross section having a continuous flange portion 1C via the cross section and curved so that the top plate portion 1A is convex or concave in a side view along a longitudinal direction which is a direction intersecting the cross section.
- the top plate portion 1A and the top plate portion 1A have a cross section having a continuous side wall portion 1B via the first bending portion 1d on at least one of them in the width direction, and intersect the cross section.
- a pressed part shape 1 having one or two or more curved portions 10 curved so that the top plate portion 1A is convex or concave in a side view along the longitudinal direction, which is the direction, at least the flange portion 1C Wrinkles that occur in the area can be suppressed.
- the metal plate 4 may have a configuration having a curvature that follows the curvature of the curved portion 10 along the longitudinal direction. According to this configuration, the shape accuracy in the longitudinal direction is improved when the press part shape 1 is press-molded.
- a high-strength steel plate of 590 MPa or more was used as the metal plate 4.
- the metal plate 4 as shown in Table 1, a 590 MPa class steel sheet (590 material), a 980 MPa class steel sheet (980 material), a 1180 MPa class steel sheet (1180 material), and a 1470 MPa class steel sheet (1470 material) are used. Using.
- the shape of the target pressed part is a hat-shaped cross section and a shape having curved portions 10 at two points along the longitudinal direction in a side view as shown in FIG.
- a flat metal plate was directly press-molded into the above-mentioned pressed part shape by each molding method shown in Table 2. Further, in the invention example based on the present invention, the metal plate was press-molded into the above-mentioned pressed part shape by each molding method shown in Table 3.
- the pre-molding step 2 was omitted, and in the part molding step 3 (main molding step), the metal plate of the flat plate material was press-molded into the target pressed part shape 1.
- the premolding step 2 is performed, and then the pressed part shape desired in the part molding step 3 is obtained.
- Tables 2 and 3 show the evaluation results (moldability) of the molding method of the comparative example.
- Table 3 shows the evaluation results (moldability) of the molding method in the invention example.
- the P pressure is the putt pressure and the C pressure is the cushion pressure.
- the molded product was visually evaluated and evaluated on a three-point scale of “ ⁇ ”, “ ⁇ ”, and “ ⁇ ”, and the evaluations are shown in Tables 2 and 3. Specifically, the evaluation is "x" when significant wrinkles occur, “ ⁇ ” when no significant wrinkles occur but slight wrinkles are formed, and " ⁇ ” when no wrinkles occur. It was judged as.
- FIG. 9 shows an example of wrinkles occurring in the top plate portion 1A and the flange portion 1C when foam molding is performed using 1180 material.
- No. 1 is an example in which a curved shape is imparted and a first bead 4a and a second bead 4b made of full beads are imparted to the first bent portion 1d and the second bent portion 1e, respectively.
- the height of the beads 4a and 4b was set to 5 times the plate thickness.
- No. Reference numeral 2 denotes an example in which a curved shape is imparted, a first bead 4a made of a half bead is given to the first bent portion 1d, and a second bead 4b made of a full bead is given to the second bent portion 1e.
- No. No. 3 is an example in which a curved shape is imparted, a first bead 4a is not formed on the first bent portion 1d, and a second bead 4b made of a full bead is provided on the second bent portion 1e.
- No. No. 4 is an example in which a curved shape is imparted and a first bead 4a made of a full bead is not formed in the first bent portion 1d and a second bead 4b is not formed in the second bent portion 1e.
- Reference numeral 5 denotes an example in which a curved shape is imparted, a first bead 4a made of a half bead is given to the first bent portion 1d, and a second bead 4b made of a half bead is given to the second bent portion 1e.
- No. No. 6 is an example in which the first bead 4a made of a full bead is not formed in the first bent portion 1d and the second bead 4b is not formed in the second bent portion 1e without forming a curved shape.
- No. Reference numeral 7 denotes a first bead 4a partially composed of a full bead only at the position of the concave curved portion 10A in the first bent portion 1d, and a convex curved portion 10B in the second bent portion 1e.
- a second bead 4b partially composed of a full bead is provided only at a position along the longitudinal direction.
Abstract
Description
このような複雑な部品形状を平坦な金属板からプレス成形する場合、成形途中で金属板に引張変形や圧縮変形が発生するため、プレス部品に割れやしわが発生しやすい。
この問題の対策として、例えば、特許文献1に記載のような湾曲部品の製造方法及び湾曲部品の製造装置がある。
ここで、特許文献1に記載の方法では、天板部をパッドで拘束し、かつフランジ部もブランクホルダーで拘束することで、天板部とフランジ部での両方の引張・圧縮変形を抑制することができる。しかし、通常の絞り工程に加えてパッドで材料を拘束する必要があり、生産性が劣る。また、特許文献1に記載の方法は、金型のコストも高い。
(1)予成形にてダイ肩稜線部の形状剛性を上げ、次工程で曲げ工法にて製品形状に成形することでフランジ部のしわを抑制することが可能である。
(2)また、ダイ肩稜線部に加え、パンチ肩稜線部の形状剛性を上げ、次工程で曲げ工法にて製品形状に成形することで、フランジ部のしわに加え、天板部のしわも抑制することが可能である。
本発明は、上記知見に基づきなされたものである。
(プレス部品形状)
本実施形態が対象とするプレス成形後のプレス部品形状は、少なくとも天板部とその左右幅方向両側の少なくとも一方に第1曲げ部を介して連続する側壁部とを有するコ字状断面、ハット形断面、L字状断面などの断面の形状となっている。更に、上記のプレス部品形状は、上記断面(板幅方向)に交差する方向である、長手方向の1箇所若しくは2箇所以上に、長手方向に沿って側面視で天板部が凸又は凹に湾曲した湾曲部を1又は2以上有する形状である。なお、ハット形断面の場合、プレス部品形状は、長手方向に沿って、側面視で、フランジ部も天板部の湾曲に倣った形状となっている。
なお、側面視で天板部が凸若しくは凹となるように湾曲とは、長手方向に沿って天板部の板厚方向に凸若しくは凹となるように湾曲する場合である。
なお、図1に併記した寸法は、実施例での寸法であって、本発明を何ら制限するものではない。
本実施形態のプレス部品の製造方法は、図2に示すように、予備成形工程2と部品成形工程3とを備える。
予備成形工程2は、本成形前の予備的な成形を金属板に施して、しわが発生し難い、本成形用の金属板を得る工程である。
予備成形工程2は、平坦な金属板に対し、プレス部品形状1の長手方向に沿ってプレス部品形状1に設ける湾曲部10の湾曲に倣った湾曲形状を付与する第1工程2Aと、第1曲げ部1d及び第2曲げ部1eとなる位置に、第1のビード4a及び第2のビード4bを形成する第2工程2Bと、を有する。第1のビード4a及び第2のビード4bは、それぞれ長手方向に沿って連続して若しくは部分的に延在する。
第2工程2Bは、第1のビード4a及び第2のビード4bの一方だけを形成する工程でも良い。また、長手方向において、第1のビード4aの形成位置と第2のビード4bの形成位置とが重ならないように配置してもよい。
また、予備成形工程2は、第2工程2Bだけから構成されていてもよい。
ここで、本実施形態のビード4a、4bは、屈曲形状の断面が断面に交叉する方向(長手方向(金属板4の天板部の長手方向))に延在した形状となっている。ビード4a、4bは、フルビードや、断面段差形状のハーフビードなどからなる。
ここで、第2工程2Bは、第1のビード4a及び第2のビード4bのうちの、一方のビードだけを形成する処理構成であっても良い。
本実施形態では、第1工程2Aと第2工程2Bが、1つの金型によるプレス加工によって実行される。
これによって、金属板4には、例えば、幅方向(プレス部品形状1の幅方向と同方向)に、同一の湾曲形状を付与される。
上型(ダイ)及び下型(パンチ)の成形面20、21の側面視における湾曲形状は、プレス部品形状1における側面視における天板部1Aでの湾曲形状に等しいことが好ましい。
また、第1のビード4aのビード高さは、上記金属板4の板厚の2倍以上であることが好ましい。第1のビード4aのビード高さの上限値は、20mmである。
また、第2のビード4bは、上記第2曲げ部1eの凸方向と同方向に凸となる形状(下方にとつとなる形状)であることが好ましい(図6参照)。
上記第2のビード4bのビード高さは、上記金属板4の板厚の2倍以上であることが好ましい。第2のビード4bの高さの上限値は、20mmである。
そして、予備成形工程2では、上記の上型及び下型を用いて金属板4をプレス成形し、長手方向に沿って湾曲し且つ、長手方向に沿って延びる第1のビード4a及び第2のビード4bを備えた金属板4とする。
部品成形工程3は、予備成形工程で処理後の金属板4を、目的のプレス部品形状1に成形する本成形工程である。
部品成形工程3は、図4に示すような成形面22、23を有する金型を用いて、予備成形工程2の処理後の金属板4をプレス成形して、目的とするプレス部品形状1のプレス部品とする。
図4では、金型が、金属板4の天板部1Aとなる位置を押さえるパッド24を有する場合を例示している。すなわち、この例では、プレス成形として曲げ成形を採用する場合を例示している。もっとも、部品成形工程3は、天板部1Aをパッド24で押さえないフォーム成形を採用しても良い。
ここで、予備成形工程2は、第1予備成形工程及び第2予備成形工程の少なくとも一方を構成する。部品成形工程3は、第1部品成形工程及び第2部品成形工程の少なくとも一方を構成する。
本実施形態では、予備成形工程2にて、予成形として、金属板4に対し、長手方向に沿った湾曲形状(板厚方向に湾曲した形状)を付与する処理と、第1のビード4a及び第2のビード4bの少なくとも一方を付与する処理とを実行する(図3)。
このとき、予備成形工程2用の上型と下型とで金属板4をプレスした場合、相対的に上型が下型に近づくにつれて、まず、金属板4は、上型と下型の成形面20,21に沿った湾曲形状に変形する。更に、相対的に上型が下型に近づき下死点まで移動することで、湾曲した板形状の状態で、第1のビード4a及び第2のビード4bを金属板4にプレス成形する。すなわち、金属板4に対し湾曲形状が付与された後にビード4a、4bの形成が実行される。
また、予備成形工程2の金属板4は、ビード4a、4bの付与によって、長手方向の形状剛性が高くなる。
次に、予備成形工程2後の金属板4を、部品成形工程3でのプレスによって、側面視で上下に湾曲した湾曲部10を有するコ字形断面若しくはハット形断面とした場合に、金属板4はビード4a、4bによって長手方向の形状剛性が高くなっているため、座屈によるシワ発生が抑制される。
また、金属板4に対し長手方向に沿った湾曲形状を予め付与しておくことで、更に、プレス成形の際に、天板部1Aに対し、プレス方向に平行移動でフランジ面が成形されるようになって、よりシワの原因となる材料移動が抑制される。
(1)上記説明では、予備成形工程2の第1工程2A及び第2工程2Bを、1つの金型によって実行する場合を例示した。
第1工程2Aと第2工程2Bとを、それぞれの個別の金型を用いて実行してもよい。但し、この場合、第1工程2Aで金属板4に湾曲形状を付与した後に、第2工程2Bでビード4a、4bの付与を実行することが好ましい。
この場合、少なくとも、平板からなる金属板4を上記プレス部品形状1にプレス成形した際に上記天板部1Aにしわが発生すると推定される第1推定領域、及び、平板からなる金属板4を上記プレス部品形状1にプレス成形した際に上記フランジ部1Cにしわが発生すると推定される第2推定領域となる位置には、各ビードを形成するようにすることが好ましい。
第1推定領域取得部6は、平板からなる金属板4を上記プレス部品形状1にプレス成形した際に上記天板部1Aにしわが発生すると推定される第1推定領域を求める処理を実行する。
第2推定領域取得部7は、平板からなる金属板4を上記プレス部品形状1にプレス成形した際にフランジ部1Cにしわが発生すると推定される第2推定領域を求める処理を実行する。
また、成形時のシワは、湾曲部10における材料が集まる側の湾曲部10に発生するため、簡易的に、天板部1Aが凹に湾曲する湾曲部10を第1推定領域と推定し、天板部1Aが凸に湾曲する湾曲部10を第2推定領域として推定しても良い。
本実施形態は、次のような効果を奏する。
(1)本実施形態では、天板部1Aと上記天板部1Aの幅方向の少なくとも一方に第1曲げ部1dを介して連続する側壁部1Bとを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部1Aが凸又は凹となるように湾曲した湾曲部10を1又は2以上有するプレス部品形状1に、金属板4を成形するプレス部品の製造方法であって、上記金属板4に対し、上記第1曲げ部1dとなる位置に上記長手方向に沿って連続して若しくは部分的に延在する第1のビード4aを形成する工程を有する第1予備成形工程と、上記第1予備成形工程後の上記金属板4を上記プレス部品形状1に成形する第1部品成形工程と、を備える。
この構成によれば、側面視で上下に湾曲形状を有するプレス部品形状1にプレス成形する前に、天板部1Aと側壁部1Bとを接続する曲げ部からなる稜線部となる位置に沿って第1のビード4aを形成しておくことで、プレス部品形状1に成形する際における長手方向に沿った形状剛性が向上して、少なくとも天板部1Aでのしわ発生を抑制可能となる。
この構成によれば、天板部1A側の稜線部と共にフランジ側の稜線部の長手方向に沿った形状剛性が向上する結果、天板部1Aと共にフランジ部1Cでのしわ発生を抑制可能となる。
この構成によれば、ビードの形成位置を抑えることができる。
この構成によれば、部品成形工程3で第1のビード4aのビード形状を潰しやすくなる。なお、目的とするプレス部品形状1が、天板部1Aと側壁部1Bとを連結する稜線部に沿ってビードが形成されている形状であってもよい。
なお、天板部1Aは他の部品との接続部となる面であるため、ビードは形成されていない方が好ましい。
この構成によれば、第1予備成形工程によって、第1のビード4aと共に湾曲形状が付与され、例えば長手方向の形状精度が向上する。
この構成によれば、必要以上に第1のビード4aを付与することが防止される。
この構成によれば、確実に長手方向の形状剛性を向上可能となる。
この構成によれば、必要以上に第2のビード4bを付与することが防止される。
この構成によれば、側面視で上下に湾曲形状を有するプレス部品形状1にプレス成形する前に、側壁部1Bと天板部1Aとを接続する曲げ部からなる稜線部となる位置に沿って第2のビード4bを形成しておくことで、プレス部品形状1に成形する際における長手方向に沿った形状剛性が向上して、少なくともフランジ部1Cでのしわ発生を抑制可能となる。
この構成によれば、第2予備成形工程によって、第2のビード4bと共に湾曲形状が付与され、例えば長手方向の形状精度が向上する。
この構成によれば、必要以上に第2のビード4bを付与することが防止される。
この構成によれば、部品成形工程3で第2のビード4bのビード形状を潰しやすくなる。なお、目的とするプレス部品形状1が、側壁部1Bとフランジ部1Cとを連結する稜線部に沿ってビードが形成されている形状であってもよい。
この構成によれば、確実に長手方向の形状剛性を向上可能となる。
この構成によれば、天板部1Aと上記天板部1Aの幅方向の少なくとも一方に第1曲げ部1dを介して連続する側壁部1Bとを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部1Aが凸若しくは凹となるように湾曲した湾曲部10を1又は2以上有するプレス部品形状1にプレス成形する際に、少なくとも天板部1Aに発生するシワを抑制可能となる。
この構成によれば、天板部1Aと上記天板部1Aの幅方向の少なくとも一方に第1曲げ部1dを介して連続する側壁部1Bとを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部1Aが凸若しくは凹となるように湾曲した湾曲部10を1又は2以上有するプレス部品形状1にプレス成形する際に、天板部1A及びフランジ部1Cに発生するシワを抑制可能となる。
この構成によれば、プレス部品形状1にプレス成形した際に、長手方向の形状精度が向上する。
この構成によれば、天板部1Aと上記天板部1Aの幅方向の少なくとも一方に第1曲げ部1dを介して連続する側壁部1Bとを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部1Aが凸若しくは凹となるように湾曲した湾曲部10を1又は2以上有するプレス部品形状1にプレス成形する際に、少なくともフランジ部1Cに発生するシワを抑制可能となる。
この構成によれば、プレス部品形状1にプレス成形した際に、長手方向の形状精度が向上する。
「適用材」
本実施例では、金属板4として、590MPa以上の高強度鋼板を使用した。
具体的には、金属板4として、表1に示すように、590MPa級鋼板(590材)、980MPa級鋼板(980材)、1180MPa級鋼板(1180材)、及び1470MPa級鋼板(1470材)を用いた。
また、本実施形態では、対象とするプレス部品の部品形状を、図1に示すような、ハット形断面且つ側面視で、長手方向に沿った2箇所に湾曲部10を有する形状とした。
そして、比較例では、表2に示す各成形法で直接に平坦な金属板を上記のプレス部品形状にプレス成形した。また、本発明に基づく発明例では、表3に示す各成形法で、金属板を上記のプレス部品形状にプレス成形した。すなわち、比較例の成形法では、予備成形工程2を省略して、部品成形工程3(本成形工程)で、上記平坦な板材の金属板を目的のプレス部品形状1にプレス成形とした。本発明に基づく発明例での成形法では、本実施形態に基づき、予備成形工程2を行った後に、部品成形工程3で目的とするプレス部品形状とした。その結果を、表2及び表3に示す。
表2は、比較例の成形法の評価結果(成形可否)を示す。
表3は、発明例での成形法の評価結果(成形可否)を示す。
なお、表中、P圧はパット圧、C圧はクッション圧である。
具体的には、評価は、顕著なシワが発生した場合を「×」、顕著なしわが発生していないが僅かにシワが形成されていた場合を「△」、しわが発生しない場合を「○」として判定した。
比較例の成形法では、表2に示すように、980MPa以上の引張強度の鋼板を用いた場合、天板部1A若しくはフランジ部1Cの少なくとも一方で、顕著なシワが発生していた。
比較例において、1180材を用いて、フォーム成形した場合における、天板部1A及びフランジ部1Cでのシワ発生の例を図9に示す。
一方、発明例では、表3に示すように、比較例と比較して、第1のビード4aや第2のビード4bを付与した部位でのシワ発生が改善されていることが分かる。
No.1は、湾曲形状を付与すると共に、第1曲げ部1d及び第2曲げ部1eにそれぞれフルビードからなる第1のビード4a及び第2のビード4bを付与した例である。
なお、ビード4a、4bの高さは、板厚の5倍とした。他の発明例でも同様である。
また、No.2は、湾曲形状を付与すると共に、第1曲げ部1dにハーフビードからなる第1のビード4aを、第2曲げ部1eにフルビードからなる第2のビード4bを付与した例である。
また、No.4は、湾曲形状を付与すると共に、第1曲げ部1dにフルビードからなる第1のビード4aを、第2曲げ部1eに第2のビード4bを形成しなかった例である。
また、No.5は、湾曲形状を付与すると共に、第1曲げ部1dにハーフビードからなる第1のビード4aを、第2曲げ部1eにハーフビードからなる第2のビード4bを付与した例である。
また、No.7は、湾曲形状を付与すると共に、第1曲げ部1dにおける凹の湾曲部10Aの位置だけに部分的にフルビードからなる第1のビード4aを、第2曲げ部1eにおける凸の湾曲部10Bの位置だけに長手方向に沿って部分的にフルビードからなる第2のビード4bを付与した例である。No.7では、長手方向において、第1のビード4aを設けた湾曲部10Aとなる位置と、第2のビード4bを設けた凸の湾曲部10Bとが異なる。
このとき、No.7のように、シワが発生すると推定される領域にだけ、フルビードからなる第1のビード4a及び第2のビード4bを部分的に付与した場合であっても、天板部1A及びフランジ部1Cにシワが発生しなかった。
また、No.3のように、第2のビード4bだけ設けた場合には、フランジ部1Cでのシワ発生を抑制できることが分かった。
また、No.4のように、第1のビード4aだけ設けた場合には、天板部1Aでのシワ発生を抑制できることが分かった。
ここでは、限られた数の実施形態を参照しながら説明したが、権利範囲はそれらに限定されるものではなく、上記の開示に基づく各実施形態の改変は当業者にとって自明なことである。
1A 天板部
1B 側壁部
1C フランジ部
1D、1E 稜線部
1d 第1曲げ部
1e 第2曲げ部
2 予備成形工程(第1予備成形工程、第2予備成形工程)
2A 第1工程
2B 第2工程
3 部品成形工程(第1部品成形工程、第2部品成形工程)
4 金属板
4a 第1のビード
4b 第2のビード
6 第1推定領域取得部
7 第2推定領域取得部
10、10A、10B 湾曲部
Claims (16)
- 天板部と上記天板部の幅方向の少なくとも一方に第1曲げ部を介して連続する側壁部とを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部が凸又は凹となるように湾曲した湾曲部を1又は2以上有するプレス部品形状に、金属板を成形するプレス部品の製造方法であって、
上記金属板に対し、上記第1曲げ部となる位置に上記長手方向に沿って連続して若しくは部分的に延在する第1のビードを形成する工程を有する第1予備成形工程と、
上記第1予備成形工程後の上記金属板を上記プレス部品形状に成形する第1部品成形工程と、
を備えることを特徴とするプレス部品の製造方法。 - 上記プレス部品形状は、上記側壁部に第2曲げ部を介して連続するフランジ部を有する断面であり、
上記第1予備成形工程は、上記第1のビードを形成する工程と、上記金属板に対し上記第2曲げ部となる位置に上記長手方向に沿って連続して若しくは部分的に延在する第2のビードを形成する工程と、を有する、
ことを特徴とする請求項1に記載したプレス部品の製造方法。 - 上記第1のビード及び上記第2のビードはそれぞれ、少なくとも上記湾曲部となる位置に部分的に延在し、
上記第1のビードが形成される上記湾曲部となる位置と、上記第2のビードが形成される上記湾曲部となる位置とが異なる、
ことを特徴とする請求項2に記載したプレス部品の製造方法。 - 上記第1のビードは、上記第1曲げ部の凸方向と同方向に凸となる形状であることを特徴とする請求項1~請求項3のいずれか1項に記載したプレス部品の製造方法。
- 上記第1予備成形工程は、更に、上記金属板に上記長手方向に沿って上記湾曲部の湾曲に倣った湾曲を付与する工程を有することを特徴とする請求項1~請求項4のいずれか1項に記載したプレス部品の製造方法。
- 上記第1のビードのビード高さは、上記金属板の板厚の2倍以上であることを特徴とする請求項1~請求項5のいずれか1項に記載したプレス部品の製造方法。
- 天板部と上記天板部の幅方向の少なくとも一方に第1曲げ部を介して連続する側壁部と上記側壁部に第2曲げ部を介して連続するフランジ部とを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部が凸若しくは凹となるように湾曲した湾曲部を1又は2以上有するプレス部品形状に、金属板を成形するプレス部品の製造方法であって、
上記金属板に対し、上記第2曲げ部となる位置に上記長手方向に沿って連続して若しくは部分的に延在する第2のビードを形成する工程を有する第2予備成形工程と、
上記第2予備成形工程後の上記金属板を上記プレス部品形状に成形する第2部品成形工程と、
を備えることを特徴とするプレス部品の製造方法。 - 上記第2予備成形工程は、上記金属板に上記長手方向に沿って上記湾曲部の湾曲に倣った湾曲を付与する工程と、上記第2のビードを形成する工程とを有することを特徴とする請求項7に記載したプレス部品の製造方法。
- 上記第2のビードは、上記第2曲げ部の凹方向と同方向に凹となる形状であることを特徴とする請求項7又は請求項8に記載したプレス部品の製造方法。
- 上記第2のビードのビード高さは、上記金属板の板厚の2倍以上であることを特徴とする請求項7~請求項9のいずれか1項に記載したプレス部品の製造方法。
- 天板部と上記天板部の幅方向の少なくとも一方に第1曲げ部を介して連続する側壁部とを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部が凸若しくは凹となるように湾曲した湾曲部を1又は2以上有するプレス部品形状にプレス成形するための金属板であって、
上記第1曲げ部となる位置に上記長手方向に沿って連続して若しくは部分的に延在する第1のビードを有することを特徴とするプレス成形用の金属板。 - 上記側壁部に第2曲げ部を介して連続するフランジ部を有する断面の上記プレス部品形状にプレス成形する金属板であって、
上記第1のビードと共に、上記第2曲げ部となる位置に上記長手方向に沿って連続して若しくは部分的に延在する第2のビードを有することを特徴とする請求項11に記載したプレス成形用の金属板。 - 上記長手方向に沿って上記湾曲部の湾曲に倣った湾曲を有することを特徴とする請求項11又は請求項12に記載したプレス成形用の金属板。
- 天板部と上記天板部の幅方向の少なくとも一方に第1曲げ部を介して連続する側壁部とその側壁部に第2曲げ部を介して連続するフランジ部とを有する断面を有し、且つ上記断面に交差する方向である長手方向に沿って側面視で上記天板部が凸若しくは凹となるように湾曲した湾曲部を1又は2以上有するプレス部品形状にプレス成形するための金属板であって、
上記第2曲げ部となる位置に上記長手方向に沿って連続して若しくは部分的に延在する第2のビードを有することを特徴とするプレス成形用の金属板。 - 上記長手方向に沿って上記湾曲部の湾曲に倣った湾曲を有することを特徴とする請求項14に記載したプレス成形用の金属板。
- 請求項1~10のいずれか1項に記載のプレス部品の製造方法のための、引張強度が590MPa以上の高張力鋼板。
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