阅读说明：本技术 冲压成型用的金属板、冲压成型装置和冲压部件的制造方法 (Metal plate for press molding, press molding device, and method for manufacturing press member ) 是由 三宅弘人 新宫丰久 山崎雄司 于 2019-02-21 设计创作，主要内容包括：提供以下技术,针对俯视观察时具有一个或者两个以上弯曲部的帽形截面形状的冲压部件,能够更加减少破裂、皱褶、尺寸精度降低之类的成型不良。冲压成型用的金属板(10)针对以在与弯曲部(1A)对应的区域中使与棱线对应的位置的线长和冲压部件形状(1)的顶板部(2)与纵壁部(3)之间的棱线的线长相等的方式将冲压部件形状在平面上展开的展开形状,成为针对与弯曲部(1A)对应的区域,为在比同顶板部(2)与弯曲凹侧的纵壁部(3)之间的棱线对应的位置靠弯曲凹侧的位置设定旋转中心(P),在面内,使与弯曲部(1A)对应的区域和其他区域之间的边界位置,向弯曲凸侧的凸缘部(4)的位置的外缘的线长接近冲压部件形状的弯曲凸侧的凸缘部4外缘的线长的方向进行了旋转位移而得到的形状。(Provided is a technique which can further reduce molding defects such as cracking, wrinkling, and a reduction in dimensional accuracy in a press member having a hat-shaped cross-sectional shape with one or more curved portions in plan view. A metal plate (10) for press forming is formed into an expanded shape in which a shape of a press member is expanded on a plane so that a line length of a position corresponding to a ridge line in a region corresponding to a bent portion (1A) is equal to a line length of a ridge line between a top plate portion (2) and a vertical wall portion (3) of the press member shape (1), and a rotation center (P) is set in a region corresponding to the bent portion (1A) so as to be closer to a bending concave side than a position corresponding to a ridge line between the top plate portion (2) and the vertical wall portion (3) on the bending concave side, in the surface, the boundary position between the region corresponding to the bending portion (1A) and the other region is rotationally displaced in a direction in which the line length of the outer edge of the flange portion (4) on the bending convex side approaches the line length of the outer edge of the flange portion (4) on the bending convex side of the punched-out part shape.)

1. A metal plate for press forming, which is press-formed into a press part shape having a hat-shaped cross section having a vertical wall portion and a flange portion on both sides in a width direction of a top plate portion, and having a bent portion at one or two or more portions of the top plate portion in a longitudinal direction so as to be convex toward one side in the width direction of the top plate portion in a plan view,

the metal plate for press molding is characterized in that,

in the expanded shape obtained by expanding the punched-out component shape on a plane so that a line length of a position corresponding to the ridge line in a region corresponding to the bent portion is equal to a line length of a ridge line between the top plate portion and the vertical wall portion of the punched-out component shape,

in order to set a rotation center at a position closer to the curved concave side than a position corresponding to a ridge line between the top plate portion and the vertical wall portion on the curved concave side, a boundary between a region corresponding to the curved portion and another region of the expanded shape is rotationally displaced in a direction in which a line length of an outer edge of a position of the flange portion on the curved convex side of the expanded shape is made closer to a line length of an outer edge of the flange portion on the curved convex side in the pressed part shape.

2. The metal plate for press molding according to claim 1,

the difference between the linear length of the outer edge of the flange portion at the position of the convex side of the bent portion in the metal plate having the shape obtained by the rotational displacement and the linear length of the outer edge of the flange portion at the convex side of the bent portion in the pressed portion shape is set to be 10% or less of the linear length of the outer edge of the flange portion at the convex side of the bent portion in the pressed portion shape.

3. The metal plate for press molding according to claim 1 or 2,

the metal plate of the shape obtained by the rotational displacement has an extension portion extending outward in a plane in a region corresponding to the top plate portion and the vertical wall portion on the convex side, and a difference between a line length of a position corresponding to a ridge line between the top plate portion and the vertical wall portion on the convex side and a line length of a ridge line between the top plate portion and the vertical wall portion on the convex side in the shape of the press member is set to 10% or less of a line length of a ridge line between the top plate portion and the vertical wall portion on the convex side in the shape of the press member by the extension portion.

4. The metal plate for press molding according to any one of claims 1 to 3,

In the region of the linear portion other than the region corresponding to the bent portion, at least one of a position corresponding to a ridge line between the top plate portion and the vertical wall portion and a position corresponding to a ridge line between the vertical wall portion and the flange portion has at least one rib shape or a fold shape extending in a direction along the corresponding ridge line.

5. The metal plate for press molding according to any one of claims 1 to 4,

is made of a material having a tensile strength of 590MPa or more.

6. A press-forming apparatus for press-forming the metal plate according to any one of claims 1 to 5 into a press-formed component shape having a hat-shaped cross section having a longitudinal wall portion and a flange portion on both sides in a width direction of a top plate portion, and having a curved portion that is convexly curved to one side in the width direction of the top plate portion when viewed from above at one or two or more portions of the top plate portion in a length direction,

the press-molding apparatus is characterized in that,

the disclosed device is provided with: an upper die having a die, a shoe and a bending blade, and a lower die having a punch opposed to the shoe in a punching direction,

The pad is divided into a 1 st pad for pressurizing a region corresponding to the curved portion of the top plate portion and a 2 nd pad for pressurizing a region of the straight portion of the top plate portion other than the curved portion,

the vertical wall portion and the flange portion can be bent by the bending blade.

7. The punch forming apparatus according to claim 6,

when the pressing force applied to the top plate by the 1 st pad during the bending process is P1 and the pressing force applied to the top plate by the 2 nd pad is P2, P1 < P2 is set.

8. The punch forming apparatus according to claim 6 or 7,

when the plate thickness direction of the top plate portion is set as a press direction, at least one of the bending blades is configured to bend the vertical wall portion and the flange portion by moving at an angle of 0 degree or more and 90 degrees or less with respect to the press direction.

9. The press-molding apparatus according to any one of claims 6 to 8,

an embossed shape is formed on the 1 st pad and the punch portion facing the 1 st pad, and a surface of the curved portion abutting on a region on a curved concave side of the top plate.

10. A method of manufacturing a stamped part, characterized in that,

a press-formed member produced by, after a metal plate according to any one of claims 1 to 5 is set on a punch, lowering an upper die toward a lower die to clamp a position of a top plate portion by a shoe of the upper die and the punch, further lowering the upper die to bend a vertical wall portion and a flange portion by a bending blade of the upper die, and relatively increasing a pressing force at a position of a straight portion other than a bent portion with respect to a pressing force applied to the top plate portion by the shoe to perform the bending processing.

Technical Field

The present invention relates to a technology for manufacturing a stamped member having a hat-shaped cross-section including a vertical wall portion and a flange portion that are continuous in the lateral width direction of a top plate portion, and having one or two bent portions that are bent in one direction in the lateral width direction of the top plate portion in a plan view along the longitudinal direction of the top plate portion. In particular, the present invention is a technique suitable for manufacturing a stamped part to be a vehicle frame member.

Background

The automobile frame member has, for example, a hat-shaped cross-section having a vertical wall portion and a flange portion continuous to both sides in the width direction of the top plate portion, and at least a part in the longitudinal direction of the top plate portion has one or more bent portions that are bent so as to protrude in one direction in the width direction of the top plate portion in a plan view. When an automobile frame member having such a member shape is press-molded from a metal plate, cracks and wrinkles may occur locally in the molded member, which may cause molding defects. Further, when the above-described member shape is press-formed, springback or the like of a predetermined degree or more tends to occur in the molded product after the mold release, and there is also a problem that dimensional accuracy is lowered.

In particular, in recent years, in order to achieve weight reduction of a vehicle body and collision safety together, the use of a metal plate made of a thin high-tensile steel plate has been increasing. However, as the material strength (tensile strength) of the metal plate increases, the ductility of the metal plate decreases and the spring back increases. Therefore, when a high-tensile steel sheet is simply press-formed into a desired member shape, problems such as cracking or wrinkling of the press-formed member and allowance of springback become apparent.

For example, when a metal plate is press-formed into a member shape having a shape curved in the width direction of the top plate at a predetermined position along the longitudinal direction in a plan view as described above, a crack due to insufficient ductility of the material is likely to occur in the flange portion on the inner side (curved concave side) of the curve in a plan view. In addition, wrinkles are likely to occur in the flange portion on the outer side (curved convex side) that is curved in plan view due to excess material. Further, dimensional accuracy defects such as three-dimensional distortion of the pressed part after molding are likely to occur due to a difference in stress in the longitudinal direction between the top plate portion and the flange portion, together with the opening in the cross section that accompanies springback. Some countermeasures have been proposed to prevent such molding defects.

For example, patent document 1 discloses a countermeasure against a crack in a flange portion inside a bend of a press member shape that bends in a plan view. Patent document 1 proposes: in order to prevent the concentration of deformation during press forming, a metal plate having an extension portion protruding toward a bending concave side with respect to an outer edge portion of the rupture risk portion is used.

Further, for wrinkles of the outer flange portion that is bent in a plan view, there is a countermeasure method described in patent document 2, for example. Patent document 2 proposes: the excess material is given a rib shape to a portion where the excess material is generated, and the excess line length is eliminated, thereby suppressing wrinkles.

In addition, in patent documents 3 to 5, when the intermediate molded member bent in the width direction of the top plate portion along the longitudinal direction is press-molded in the first molding step 1, the intermediate molded member is formed in a shape in which the width of the top plate portion is different from the final product shape, and then, the intermediate molded member is press-molded in the second molding step 2 so that the shape of the intermediate molded member becomes the final product shape. Thus, patent documents 3 to 5 propose a method of relaxing stress that causes occurrence of springback.

Patent document 1 Japanese patent No. 6119848

Patent document 2 Japanese patent No. 5217928

Patent document 3 Japanese patent No. 4920649

Patent document 4 Japanese patent No. 5031702

Patent document 5 Japanese patent No. 5031703

However, in the method described in patent document 1, a post-process of cutting unnecessary portions is required as a next process of the press process of press-forming the target press component shape.

In the method described in patent document 2, when a rib shape is provided to eliminate an excess material, there is a possibility that the shape of the member is largely changed, and thus there is a limit to the rib shape that can be provided.

In addition, in the methods described in patent documents 3 to 5, when a crack or wrinkle is generated in the intermediate molded member during molding in the press molding in the 1 st molding step, which is the 1 st step, it is difficult to use the method for press molding. In addition, in the methods described in patent documents 3 to 5, when the drawing is used for the forming in the 1 st forming step, a large warpage occurs in the vertical wall portion, and it is difficult to cope with the warpage in the subsequent steps.

Disclosure of Invention

The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a technique that can further reduce molding defects such as cracking, wrinkles, and a reduction in dimensional accuracy when a press member having a hat-shaped cross-sectional shape with one or more bending portions that bend to one side in the width direction of a top plate portion in plan view is manufactured by press forming.

The present inventors have conducted extensive studies on a press-forming method capable of forming a hat-shaped cross-sectional shape having a top plate portion, and a vertical wall portion and a flange portion continuous thereto without cracking or wrinkling and forming a pressed part shape (final part shape) having a bent portion at an upper portion at least at one point in a longitudinal direction of the top plate portion in a plan view, and capable of suppressing springback. As a result of this study, the present inventors have found that excessive shortage of the material of the flange portion, which is a factor causing cracking, wrinkles, and springback, can be reduced by forming the metal plate into a punched component shape while performing local rotational displacement of the material. The present inventors have also found that the shortage of the material of the top plate portion, which causes the springback, can be significantly reduced by obtaining a desired shortage of the length of the wire by performing the bulging at a predetermined place in the step prior to the step of forming into the shape of the press member.

The present invention has been completed based on such findings.

In order to solve the above-described problems, a metal plate for press forming according to an aspect of the present invention is a metal plate for press forming that is press-formed into a pressed part shape having a hat-shaped cross section having a vertical wall portion and a flange portion on both sides in a width direction of a top plate portion, and that has a bent portion at one or two or more portions of the top plate portion along a longitudinal direction thereof and that is bent so as to protrude to one side in the width direction of the top plate portion in a plan view, wherein in the metal plate for press forming, a rotation center is provided at a position on a bending concave side with respect to a position corresponding to a ridge line between the top plate portion and the vertical wall portion of the pressed part shape so that a line length of a position corresponding to the ridge line in a region corresponding to the bent portion is equal to a line length of the ridge line between the top plate portion and the vertical wall portion on the bending concave side, in the plane, the boundary between the region corresponding to the bent portion and the other region of the expanded shape is rotationally displaced in a direction in which a linear length of an outer edge of the expanded shape at a position of the flange portion on the convex side of bending is brought closer to a linear length of an outer edge of the flange portion on the convex side of bending in the shape of the pressing member.

A press forming apparatus according to an aspect of the present invention is a press forming apparatus for press forming a metal plate for press forming according to an aspect of the present invention into a press component shape having a hat-shaped cross section including a vertical wall portion and a flange portion on both sides in a width direction of a top plate portion, and having a curved portion that is curved so as to protrude toward one side in the width direction of the top plate portion in a plan view at one or two or more portions of the top plate portion along a longitudinal direction, the press forming apparatus including: the die includes an upper die having a die, a pad, and a bending blade, and a lower die having a punch facing the pad in a press direction, wherein the pad is divided into a 1 st pad for pressing a region corresponding to a bent portion of the top plate and a 2 nd pad for pressing a region of a straight portion of the top plate other than the bent portion, and the bending blade is configured to bend the vertical wall portion and the flange portion.

A method of manufacturing a press-formed member according to an aspect of the present invention is characterized in that a press-formed metal plate according to an aspect of the present invention is set on a punch, and then an upper die is lowered toward a lower die to clamp a position of a top plate portion by a pad of the upper die and the punch, and the upper die is further lowered to bend a vertical wall portion and a flange portion by a bending blade of the upper die, and a pressing force applied to the top plate portion by the pad is relatively increased at a straight portion position other than a bent portion than at the bent portion to manufacture the press-formed member.

According to an aspect of the present invention, it is possible to provide a technique for press-forming a press-formed member having a hat-shaped cross-sectional shape having one or more bent portions that are bent to one side in the width direction of the top plate when viewed in plan along the longitudinal direction of the top plate, in such a manner that molding defects such as cracking, wrinkling, and dimensional accuracy degradation are further reduced.

Drawings

Fig. 1 is a view showing an example of the shape of a press member, wherein (a) is a perspective view, (b) is a cross-sectional view, and (c) is a plan view.

Fig. 2 is a diagram illustrating an example of the shape of a press member to which the present invention can be applied.

Fig. 3 is a view showing an expanded shape of a metal plate obtained by expanding the shape of the press-formed member shown in fig. 1 into a flat surface.

Fig. 4 is a view showing an example of the plate shape (the developed shape after rotational displacement) of the metal plate (press-formed metal plate) after rotational displacement of the boundary between the region of the bent portion and the other region in the developed shape.

Fig. 5 is a diagram showing an example of a plate shape of a metal plate to which a projecting portion and a rib shape are given.

Fig. 6 is a diagram illustrating an example of a mold used in a protruding portion forming step for providing a protruding portion and a bead shape.

Fig. 7 is a diagram illustrating an example of a bending mold used in the main molding step.

Fig. 8 is a diagram showing the operation of the bending die in the main molding step.

Fig. 9 is a diagram illustrating an example of a moving direction of the bending blade in bending by an arrow in the main molding step.

Fig. 10 is a diagram showing the operation of the material in the present molding.

Fig. 11 is a perspective view showing one form of the shape of the press member formed by the main forming process.

Fig. 12 is a diagram showing a relationship between β and a design variable based on the present development method in the embodiment. The horizontal axis represents β, and the vertical axis represents f (β).

Fig. 13 shows a metal plate designed based on the present invention in an example.

Fig. 14 is a diagram showing a structure of a conventional drawing die according to an embodiment.

Fig. 15 is a graph showing the rate of reduction in sheet thickness at bottom dead center after drawing molding in the prior art according to the example.

Fig. 16 is a graph showing the rate of decrease in sheet thickness at bottom dead center by the forming of the present invention in an example.

Fig. 17 is a diagram showing the distribution of the axial force in the longitudinal direction of the bottom dead center after the drawing forming in the related art according to the embodiment.

Fig. 18 is a diagram showing the axial force distribution in the longitudinal direction of the bottom dead center after molding according to the present invention in an example.

Fig. 19 is a diagram showing the distribution of the plate thickness front-back stress difference in the width direction of the bottom dead center after drawing forming in the conventional example.

Fig. 20 is a diagram showing the distribution of the plate thickness front-back stress difference in the width direction of the bottom dead center after the molding according to the present invention in the example.

Fig. 21 is a diagram showing a deviation amount distribution of the shape of the punched member after the die release after the conventional drawing forming in the example.

Fig. 22 is a diagram showing a distribution of deviation from the shape of a stamped part after demolding after molding according to the present invention in an example.

Detailed Description

Next, embodiments of the present invention will be described with reference to the drawings. In the following description of the embodiments, a case where a metal plate is press-formed into a stamped component shape 1 as shown in fig. 1 to manufacture a final component will be described as an example. The press-formed part shape 1 shown in fig. 1 is a hat-shaped cross-sectional shape having a top plate 2, a vertical wall portion 3 and a flange portion 4, each of which is continuous on both sides in the width direction of the top plate 2, and has a bent portion 1A at a middle position of the top plate 2 along the longitudinal direction, the bent portion being bent so as to be convex toward one side in the width direction of the top plate 2 in a plan view. In fig. 1, reference numeral 2A denotes a top plate portion in the bent portion 1A. Reference numeral 3Aa denotes a vertical wall portion on the curved convex side in the curved portion 1A. Reference numeral 4Aa denotes a flange portion on the curved convex side in the curved portion 1A. Reference numeral 3Ab denotes a vertical wall portion on the curved concave side in the curved portion 1A. Reference numeral 4Ab denotes a flange portion on the bending concave side in the bending portion 1A.

The metal plate 10 used for manufacturing the stamped member of the present embodiment is made of a material having a tensile strength of 590MPa or more, and the like, and particularly preferable effects are obtained when the metal plate 10 is a high-strength material.

However, the present invention is also applicable to the production of a stamped component having a shape having bent portions 1A at a plurality of positions along the longitudinal direction in plan view. When there are a plurality of bending portions 1A, the bending directions of adjacent bending portions 1A may be the same direction or opposite directions in a plan view. Fig. 2 shows an example of a pressed part shape 1 to which the present invention is applied. As shown in fig. 2, the punched-out component shape 1 that is the object of the present invention is the one having a bent portion 1A that is bent so as to be convex toward one side in the width direction of the top plate portion 2 in a plan view at a halfway position of the top plate portion 2 along the longitudinal direction. In the pressing member shape 1, the adjacent bent portions 1A may be formed continuously in a plan view, and no portion extending linearly may be present between the adjacent bent portions 1A. Further, the punched-out part shape 1 may have a portion bent up and down along the longitudinal direction in a side view. Further, the punched component shape 1 may be such that no straight portion 1B exists between adjacent bent portions 1A. Here, in the punched member shape 1 shown in fig. 1, a case where the bent portion 1A is bent so as to be convex toward the upper side of the paper surface (concave toward the lower side of the paper surface) is illustrated in fig. 1 (c). In the present specification, the curved convex side is also referred to as a curved outer side, and the curved concave side is also referred to as a curved inner side.

< Metal plate for Press Molding 10 >

In the case of producing a member having the stamped component shape 1 shown in fig. 1 by press forming, for example, a metal plate 10 punched out into an expanded shape in which a plane of the target stamped component shape 1 is expanded as shown in fig. 3 is used as the metal plate 10 to be used. In this example, the stamped-out member shape 1 is composed of one bent portion 1A and the left and right straight portions 1B, and therefore the developed shape is also composed of one bent portion 10A and the left and right straight portions 10B.

In the above developed shape, the left and right straight portions 10B are developed as they are while maintaining the dimensions of the punch member shape 1. On the other hand, the bent portion 10A is developed such that the linear length of the position n3 corresponding to the ridge line m3 (particularly, the convex side of the bend) between the top plate 2 and the vertical wall portion 3 is equal to the linear length of the punched-out component shape 1, and that the angle 2 α formed by the flange portion 4Ab on the concave side of the bend of the punched-out component shape 1 and the angle formed by the flange portion 4 on the concave side of the bend of the developed shape (the angle formed between the right and left linear portions 1B on the inner side of the bend) are generally equal in plan view. In fig. 1, since the outline of the outer edge m2 on the curved concave side is an example of a shape in which two straight lines are combined, the expanded shape is also illustrated as a linear length at a curve n2 formed by two straight lines. However, if the contour of the outer edge m2 on the curved concave side is an arc shape, the contour of the outer edge n2 on the curved concave side in the developed shape is also an arc shape.

In the metal plate 10 having the spread shape as described above, in the bent portion 10A, the length of the outer edge n1 on the bending convex side of the metal plate 10 corresponding to the length of the outer edge m1 (see fig. 1) of the flange portion 4Aa on the bending outer side in the stamped component shape 1 is in the relationship "the linear length of m1 < the linear length of n 1". The length of the curved inner outer edge n2 of the metal plate 10 corresponding to the length of the outer edge m2 (see fig. 1) of the curved inner flange portion 4Ab in the stamped component shape 1 is "the linear length of m2 > the linear length of n 2". Therefore, when the metal plate 10 (see fig. 3) having the expanded shape is press-formed into the press member shape 1 of fig. 1, the material becomes redundant at the outer side of bending and wrinkles occur, and the material becomes insufficient at the inner side of bending and cracks occur.

In the present embodiment, the sheet-shaped metal plate 10 for press forming is formed by changing the simply developed shape to a shape in which the boundary h2 between the curved portion 10A and the linear portion 10B is rotationally displaced in the plane about the rotational center P set in a region (a range shown by a cross-sectional line in fig. 3) on the curved concave side of the position n4 corresponding to the ridge line m4 between the top plate 2 and the curved concave side vertical wall portion 3, as shown in fig. 4. The expanded shape after the rotational displacement (the metal plate having undergone the rotational displacement) is also referred to as a deformed expanded shape.

The direction of the in-plane rotational displacement is set in a direction in which the linear length of the position n1 of the outer edge of the flange portion 14Aa on the convex side of bending is made to approach the linear length of the outer edge m1 of the flange portion 4Aa on the convex side of bending in the stamped component shape (in other words, the direction in which the linear length of n1 is made shorter), and in a direction in which the linear length of the outer edge n2 of the position 14Ab of the flange portion 4Ab on the concave side of bending is made to approach the linear length of the position m2 of the outer edge of the flange portion 4Ab on the concave side of bending in the stamped component shape (in other words, the direction in which the linear length of n2 is made longer), with respect to the region of the fan-shaped bending portion 10A in the above-mentioned simply-developed.

In the example of fig. 4, only the boundary h2 on one side is rotationally displaced.

Preferably, the rotational displacement amount is set such that the difference between the linear length of the outer edge q1 at the position of the flange portion 4Aa on the convex side to be bent in the deformed and expanded shape and the linear length of the outer edge m1 of the flange portion 4Aa on the convex side to be bent in the press member shape is 10% or less of the linear length of the outer edge m1 of the flange portion 4Aa on the convex side to be bent in the press member shape.

In the deformed and expanded shape, it is preferable that the extension portions 20 (see fig. 5) extending in the out-of-plane direction be formed in the portions of the regions 12A and 13Aa corresponding to the top plate portion 2A and the curved convex-side vertical wall portion 3Aa in the region corresponding to the curved portion 1A. At this time, the extension portion 20 preferably sets the difference between the line length of the position q3 corresponding to the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 and the line length of the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 of the stamped part shape to 10% or less of the line length of the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 of the stamped part shape. The extending direction of the extending portion 20 may be downward.

It is preferable that the linear portion 10B has at least one rib 21 or fold shape extending in a direction along the ridge line at least one position corresponding to the ridge line between the top plate 2 and the vertical wall 3 or the ridge line between the vertical wall 3 and the flange 4 in a region other than the region 10A corresponding to the bent portion 1A (bent portion of the metal plate 10) (see fig. 5). Fig. 5 illustrates a case where the rib shape 21 is provided.

A specific example of the shape of the press-molding metal plate 10 according to the present embodiment will be described below. That is, a design change example of the shape of the bending portion 10A from the simply developed shape to the deformed developed shape will be described.

A case where the above-described rotation center P is set at the center position of the outer edge n2 on the curved concave side of the developed shape (see fig. 3) will be described as an example (see fig. 4).

The shape of the metal plate 10 for press forming is designed such that the center position of the outer edge (the angle of the flange portion 4 Ab) on the inner side of the bend in the metal plate 10 obtained by simply spreading out the press part shape 1 (i.e., the length of the line q1 on the convex side of the bend of the metal plate 10 is "the length of the line m1 equal to the length of the line q 1" is set as the rotation center P, and the boundary h2 between the bent portion 10A and the linear portion 10B is rotationally displaced in a direction in which the angle formed on the concave side of the bend (the angle formed on the flange portion 4 on the inner side of the bent portion 1A of the press part shape 1) is increased by 2 β (deg). Here, in fig. 4, the broken line indicates the developed shape before rotation.

Here, when the sheet metal 10 is rotationally displaced in a direction in which the linear length of the outer edge on the convex side of the curve becomes shorter in the plane with the rotation center P as the center, the linear length of the outer edge n2 on the concave side of the curve changes in a direction in which the linear length becomes longer. Fig. 4 illustrates a case where the line length is changed by fixing the boundary h1 between the region corresponding to the bent portion 1A and the right linear portion 1B and rotationally displacing the boundary h2 between the region corresponding to the bent portion and the left linear portion 1B. The boundaries h1 and h2 on both sides may be rotationally displaced. For example, the boundaries h1 and h2 on both sides may be rotated by the shift β, respectively. The position of the rotation center P may be adjusted so that the line length of m2 becomes q 2.

In this example, a value of 2 β, which is a line length of m1 equal to a line length of q1, is obtained from the geometrical relationship between the plate shape (deformed and expanded shape) of the metal plate 10 subjected to the rotational displacement and the punched part shape 1. The specific solving method is as follows.

Here, as shown in fig. 1, the curvature radius of the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 is r (mm), the width of the top plate 2 is w (mm), the vertical height of the vertical wall portion 3 is h (mm), the angle formed by the vertical surface of the top plate 2 and the vertical wall portion 3 is θ (deg), and the width of the flange portion 4 is f (mm).

In this case, in the formula of f (β) in the following formula, when β where f (β) is 0 is satisfied, the line length of m1 is the line length of q 1.

[ mathematical formula 1]

f(β)＝BE(90-α-β)³-CE(90-α-β)²-BD(90-α-β)+CD-A

Wherein the content of the first and second substances,

A＝(R-W)sin(90-α)

C＝(90-α)(R+H tanθ+f)

however, if β satisfying f (β) ═ 0 is β', the angle β for disclination may be designed to satisfy the following expression with a margin.

0.9×β′≤β≤1.1×β′

The line length of q1 may be set to satisfy the following expression.

The line length of q1 is less than or equal to 1.1 Xm 1 and the line length of 0.9 Xm 1 is less than or equal to q

< projecting part 20>

In the modified plate shape (deformed expanded shape), the length of the line at the position q3 corresponding to the ridge line m3 between the top plate portion 12 and the curved convex-side vertical wall portion 13Aa is shorter than the line of the ridge line m3 of the punch member shape 1.

In consideration of this, it is preferable that, in the plate shape (deformed and expanded shape) described above, the extension portion 20 extending in the out-of-plane direction be formed in the region to be the top plate portion 12A and the bending convex-side vertical wall portion 13Aa in the region 10A corresponding to the bent portion 1A. Thus, the linear length of the metal plate 10 at the position q3 corresponding to the ridge line m3 between the top plate 2 and the curved convex-side vertical wall 3 is designed to be close to the linear length of the stamped part shape 1.

In this example, the extension portion 20 is designed such that an increase Δ L in the linear length of the metal plate 10 at a position q3 corresponding to the ridge line m3 between the top plate portion 12 and the curved convex-side vertical wall portion 13Aa satisfies the following expression.

[ mathematical formula.2 ]

By designing to satisfy this equation, the line length of the position q3 of the metal plate 10 corresponding to the ridge line m3 between the top plate portion 12 and the vertical wall portion 13Aa on the bending convex side approaches the line length of the corresponding ridge line m3 of the stamped part shape 1. Specifically, the difference in line length can be set to 10% or less. Further, the extension portion 20 is preferably designed in a convex shape in which the increase in the linear length position of the ridge between the top plate portion 2 and the curved convex-side vertical wall portion 3 of the metal plate 10 is the largest with respect to the increase in the linear length in the longitudinal direction due to the formation of the extension portion.

< Rib shape 21 and fold line >

As shown in fig. 5, it is preferable that a rib shape 21 extending along the ridge line be formed in advance in at least one of the positions corresponding to the ridge line of the linear portion 10B. In fig. 5, the rib shape 21 is formed at a position corresponding to the ridge line on both sides of the top plate 2, but the present invention is not limited thereto. The rib shape 21 may be formed at a position corresponding to the ridge between the vertical wall portion 3 and the flange portion 4, or the rib shape 21 may be formed only at a part of the ridge positions. Further, the rib shape 21 need not be formed over the entire length of one ridge line, and the rib shape 21 may be formed intermittently along the ridge line. When the rib shapes 21 are formed partially over the entire length of the ridge line, the length of the rib shapes 21 added up is preferably set to be equal to or greater than 1/3 over the entire length of the corresponding ridge line, for example. Instead of the rib shape 21, a fold line may be provided. Further, the rib shape 21 and the folding line may be used in combination so that the rib shape 21 is provided in a part and the folding line is provided in another part.

< Process for Forming protruding part >

Next, a method of forming the extension portion 20 by press forming on the flat plate-like metal plate 10 will be described. The extension portion forming step is a step of forming the extension portion 20 by performing bulging on the metal plate 10. The extension portion 20 may be formed by drawing or foaming. In the following description, the case of forming by drawing is exemplified.

Here, the plate shape as shown in fig. 4 in which the shape of the extended curved portion 10A is changed as described above is designed such that the length of the position q3 of the metal plate 10 corresponding to the ridge line m3 of the top plate portion 2 on the convex side of the curve is rotationally displaced 2 β in the plane about the rotational center P. Therefore, the length of the position q3 is shorter than the line of the ridgeline m3 of the top plate 2 on the convex side of the punch shape 1. As a result, if the press forming is performed as it is, the formed press member is subjected to tensile deformation in accordance with the press forming. When the tensile deformation acts, it causes springback. Therefore, it is preferable to form the extension portion 20 in the metal plate 10 in the extension portion forming step so as to obtain a line length approximately equal to the length of the ridge line m3 of the top plate portion 2 on the bending convex side of the stamped component shape 1.

From such a viewpoint, in the extension portion forming step of the present embodiment, for example, a drawing die having an upper die made of a die 30 and a lower die made of a punch 31 and a blank holder 32 as shown in fig. 6 is prepared, and bulging for forming the extension portion 20 is performed by the drawing die. A recess 30A corresponding to the shape of the extension portion 20 is provided in a portion of the die 30 facing the punch 31.

The length of the extension portion 20 at the position q3 corresponding to the ridge line m3 is designed to be longer by Δ L than the length before the extension portion 20 is molded. Here, Δ L may be set based on the above.

The projecting portion 20 in the present embodiment is designed to project across positions corresponding to the top plate portion 12A of the curved portion 10A and the curved convex-side vertical wall portion 13Aa, as shown in fig. 5, for example. The shape of the extension portion 20 is designed to be a dome shape having a maximum extension height at a position q3 where a required line length Δ L is obtained and a gradually decreasing extension height toward the width direction of the top plate portion 2. However, if a linear length is available, the shape of the extension portion 20 may be other contour shapes.

The die shown in fig. 6 is set so that a rib shape 21 is imparted to the stamped-out part shape 1 in advance in the protruding part forming step at a position corresponding to the ridge line adjacent to the top plate part 2, except for the forming position of the protruding part 20. The metal plate 10 provided with the rib shape 21 stabilizes the bending forming for the target press-formed part shape 1. In fig. 5, the rib shape 21 is given as an example, but a fold may be given instead of the rib shape 21. Further, the rib shape 21 may be provided at a local ridge position, and a fold may be provided at another ridge position.

< Main Forming Process for stamped part shape 1 >

In the present embodiment, a case is exemplified in which the metal plate 10 in which the overhang portion 20 and the bead shape 21 are molded in the overhang portion molding step is used as the shape of the metal plate 10 molded in the main molding step (see fig. 5). However, the metal plate 10 such as in fig. 4 in which one or both of the extension portion 20 and the rib shape 21 are not formed may be used as the metal plate 10 for the main forming process, and thus the processing accuracy may be slightly lowered.

By press-forming the metal plate 10 in the main forming process, the punched member shape 1 in which the breakage, the wrinkle, and the springback are suppressed can be obtained. When the dimensional accuracy is to be further improved or when a desired shape is to be imparted to a part, a molding step for the purpose of coining may be added as a step after the main molding step. The main forming step is a step of bending the metal plate 10 to form a final stamped component shape 1.

As shown in fig. 7, the bending mold used in the main molding step has an upper mold 40 and a lower mold 44. The upper die 40 includes: a bending blade 43 for bending the ridge line of the member, and a pad 41 for pressing the top plate 2. The lower die 44 includes a punch 45.

The pad 41 for pressing the top plate 2 of the present embodiment is divided into a pad 41A for pressing the top plate 12A of the curved portion 10A and a pad 41B for pressing the top plate of the linear portion 10B excluding the curved portion 1A. The pad 41B is preferably set to press only the one-side top plate portion in the linear portion 1B located on both sides with the curved portion 1A interposed therebetween.

Next, an example of the operation of the bending die in the main molding step is shown with reference to fig. 8.

The metal plate 10 having the extension 20 formed in the extension forming step is set on the punch 45 (see fig. 8 (a)).

In this state, the upper die 40 is lowered. When the upper die 40 is lowered, first, the position 12 corresponding to the top plate portion of the metal plate 10 is pinched by the shoe 41 and the punch 45 (see fig. 8 (b)). When the upper die 40 is further lowered, the bending blade 43 comes into contact with the metal plate 10 (see fig. 8 c) to bend the ridge line, and the pressed part shape 1 is formed at the bottom dead center (see fig. 8 d).

At this time, as shown in fig. 9, the bending blade 43 may have a known cam mechanism that moves toward the punch 45 from a direction inclined at a certain constant angle θ with respect to the pressing direction when the plate thickness direction (vertical direction) of the position 12 corresponding to the top plate portion is taken as the pressing direction.

Finally, the upper mold 40 is lifted and released, thereby completing the molding.

The angle θ is preferably inclined by 0 degrees or more and 90 degrees or less in a direction away from the vertical wall portion 3 with respect to the press direction.

The operation of the material in the main molding step will be described with reference to fig. 10.

In the plate shape as shown in fig. 4 in which the position of the bent portion 10A in the expanded shape is rotationally displaced in the plane, the angle formed by the right linear portion 10B and the left linear portion 10B is relatively larger than the final angle of the punch member shape 1 in a plan view due to the rotational displacement.

Therefore, when the bending of the vertical wall portion 3 and the flange portion 4 is performed by bending the ridge line by the bending blade 43 in a state where the upper die 40 is lowered and the position 12 corresponding to the top plate portion is partially pinched by the shoe 41 and the punch 45, the material is bent while rotationally displacing 2 β the left-side linear portion 1B with respect to the right-side linear portion 1B pinched by the shoe 41B, as shown in fig. 10. In other words, the curved portion 1A is formed while rotating around the position of the curved concave side of the top plate portion 2.

At this time, the material is concentrated on the top plate 2 and the vertical wall 3 on the rotation center P side of the rotational displacement, and compression deformation acts. In consideration of this, as shown in fig. 7, an embossed shape is preliminarily provided on the curved concave side of the top plate portion 12A of the metal plate 10 of the present molding. By providing the embossed shapes 50, 51 having the irregularities on the facing surfaces of the shoe 41a and the punch 45, the formability is further improved.

Further, in order to facilitate relative rotational displacement of the material at the position corresponding to the bent portion 1A with respect to the right linear portion 10B with which the pad 41B is in contact in a plan view, the pad 41B of the pressing linear portion 10B and the pad 41A of the pressing bent portion 10A are configured to be independent from each other. In this case, in order to further facilitate the rotational displacement of the material at the position corresponding to the bent portion 10A, it is preferable that the relationship between the pressing force pressing the pad 41a of the bent portion 10A and the pressing force pressing the pad 41B of the right linear portion 10B is set to the relationship shown below.

Pressure of pad formed by pad 41a < pressure of pad formed by pad 41b

The pressing force of the pad 41 may be set by adjusting the pressing force (buffer pressure) actually applied to the pads 41a and 41 b. The pressure force of the pad 41 may be set by adjusting the stroke of each pad to set the height of the pad 41a to be relatively higher than the height of the pad 41b during bending.

Fig. 11 shows an example of the shape of the press-molded member after the main molding step. Reference numeral 9 is an embossed shape imparted.

(other effects)

(1) The press-formed component shape 1 is a hat-shaped cross-section having a vertical wall portion 3 and a flange portion 4 on both sides in the width direction of the top plate portion 2, and has a bent portion 1A bent so as to project to one side in the width direction of the top plate portion 2 in a plan view at one or two or more locations along the longitudinal direction, and the following plate shape is adopted as the press-forming metal plate 10 press-formed into the press-formed component shape 1.

That is, the metal plate 10 for press forming is formed into a plate shape which is changed into a shape, in the expanded shape in which the stamped component shape 1 is simply expanded on the plane so that the line length of the position n3 corresponding to the ridge line m3 in the region 10A corresponding to the bent portion 1A is equal to the line length of the ridge line m3 between the top plate portion 2 and the vertical wall portion 3 in the stamped component shape 1, the boundary h2 between the region 10A corresponding to the bent portion 1A and the other region 10B is rotationally displaced in the plane in a direction in which the line length of the position q1 of the outer edge m1 of the flange portion 4Aa which becomes the convex side of the bend approaches the line length of the outer edge m1 of the flange portion 4Aa which is the convex side of the bend in the stamped component shape, with the position Ab on the concave side of the bend being greater than the position q4 corresponding to the ridge line between the top plate portion 2 and the vertical wall portion 3 on the concave side of the bend as the rotation center P, in the region 10A corresponding to the region 1A corresponding to the bent portion 1A.

When the metal plate 10 is used, the linear length of the flange portion 4 on the bending convex side and the bending concave side of the bending portion 1A approaches the linear length of the punch member. As a result, it is possible to further reduce molding defects such as cracking, wrinkling, and reduction in dimensional accuracy, and to press-mold a press-formed member having a hat-shaped cross-sectional shape along the longitudinal direction, the press-formed member having one or more bent portions 1A bent toward one side in the width direction of the top plate portion 2 in plan view.

(2) In this case, the difference between the linear length of the position q1 of the outer edge of the flange portion 4 on the convex side to be bent in the deformed and expanded shape and the linear length of the outer edge m1 of the flange portion 4 on the convex side to be bent in the punching member shape is preferably set to 10% or less of the linear length of the outer edge m1 of the flange portion 4 on the convex side to be bent in the punching member shape.

According to this configuration, molding failures such as cracking, wrinkles, and reduction in dimensional accuracy can be more reliably reduced and press molding can be performed.

(3) It is preferable that the metal plate 10 has a protruding portion 20 protruding in the out-of-plane direction in a region corresponding to the top plate portion 2 and the bending convex-side vertical wall portion 3, of the region corresponding to the bent portion 1A. In this case, the extension portion 20 preferably sets the difference between the line length of the position q3 corresponding to the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 and the line length of the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 of the stamped part shape to 10% or less of the line length of the ridge line m3 between the top plate 2 and the curved convex-side vertical wall portion 3 of the stamped part shape.

According to this configuration, the reduction in the line length at the position q3 corresponding to the ridge line m3 between the top plate 2 and the curved convex-side vertical wall 3 due to the change in the expanded shape is eliminated, and the difference in the line length is reduced. As a result, molding defects such as cracking, wrinkles, and a reduction in dimensional accuracy can be more reliably reduced and the press molding can be performed.

(4) In the region of the linear portion 10B excluding the region corresponding to the bent portion 10A, at least one ridge line position that is a ridge line position preferably has at least one or more rib shapes 21 or fold shapes extending in a direction along the ridge line.

According to this configuration, when the metal plate 10 having the above-described configuration is bent, the bending can be performed more reliably at the ridge line position, and the press forming can be performed with higher accuracy.

(5) The present embodiment is effective when the metal plate 10 for press molding is made of a material having a tensile strength of 590MPa or more.

(6) The extension portion 20 of the press-molding metal plate 10 may be formed by, for example, drawing or foaming.

The extension portion 20 can be reliably formed by drawing or foam molding.

(7) The press-molding apparatus for press-molding the metal plate 10 into the target press-component shape 1 preferably includes: an upper die 40 having a die 42, a pad and a bending blade 43, and a lower die having a punch 45 facing the pad in a punching direction, wherein the pad 41 is divided into a pad 41A for pressing a region corresponding to a bent portion 1A of the top plate 2 and a pad 41B for pressing a region of a straight portion 1B of the top plate 2 other than the bent portion 1A, and the vertical wall portion 3 and the flange portion 4 are configured to be bendable by the bending blade 43, and a pressure force applied to the top plate 2 by the pad 41A during the bending is P1, and a pressure force applied to the top plate 2 by the pad 41B is P2, and P1 < P2 is set.

According to this structure, the restriction of the bent portion 1A by the shoe 41 is set relatively weak, and as a result, the material at the position of the bent portion 10A is easily moved relatively. As a result thereof, the rotational displacement at the position of the bent portion 10A can be allowed, and the metal plate 10 can be more reliably bent and formed into the target stamped component shape 1.

(8) The press-forming apparatus of the present embodiment is preferably configured such that, when the plate thickness direction of the top plate portion 2 is set as the pressing direction, at least one of the bending blades 43 is moved at an angle of 0 degree or more and 90 degrees or less with respect to the pressing direction (preferably, at an angle of 0 degree or more and 45 degrees or less with respect to the pressing direction) to bend the vertical wall portion 3 and the flange portion 4. More preferably, the angle is 5 degrees or more and 40 degrees or less.

(9) The press-forming device preferably has an embossed shape 50 formed on a surface of the shoe 41a that abuts against a region of the top plate 2 on the concave side of the curve, and an embossed shape 51 formed at a position of the punch 45 that faces the region of the top plate where the embossed shape is formed.

(10) In the method of manufacturing a stamped part according to the present embodiment, after the metal plate 10 is set on the punch 45, the upper die 40 is lowered to bring the upper die 40 close to the lower die 44, and the position of the top plate portion 2 is pinched by the pad 41 of the upper die 40 and the punch 45, thereby further lowering the upper die 40. Thus, the vertical wall portion 3 and the flange portion 4 are bent by the bending blade 43 of the upper die 40, and the pressing force applied to the top plate portion 12 by the shoe 41 during the bending is set so that the pressing force at the straight portion 10B other than the bent portion 10A is relatively larger than the pressing force at the bent portion 1A.

According to this configuration, the press-formed member having the hat-shaped cross-sectional shape having one or more bent portions 1A bent to one side in the width direction of the top plate portion 2 in a plan view can be press-formed while reducing forming defects such as cracking, wrinkles, and reduction in dimensional accuracy.

As described above, according to the present embodiment, the press-formed member shape 1 having the top plate portion 2, and the vertical wall portion 3 and the flange portion 4 continuous thereto and having a shape in which at least one portion is bent at an upper position in the longitudinal direction in a plan view can be formed without cracking or wrinkling, and springback due to a stress difference in the longitudinal direction between the top plate portion 2 and the flange portion 4 can be suppressed.