Specification
DESCRIPTION
Title of Invention: Method of Producing Shaped article,
Tooling, and Tubular Shaped article
Technical Field
[0001] The present invention relates to a method of
producing a shaped article using a metal plate, tooling
used for that method of production,·. and a tubular shaped
10 article produced by that method ~f production.
Background Art
[0002] Auto parts and household electric appliances
first and foremost and vehicles, building materials,
ships, etc. make frequent use of bent tubes having bent
15 shapes, irregular diameter tubes having different outside
diameters in the longitudinal direction, irregular crosssection
tubes having different cross-sectional shapes in
the longitudinal direction, and other tubular products.
For this reason, technology for producing such tubular
20 parts is being developed.
[0003] In the past, in the production of tubular
parts, mainly straight shaped thick wall large diameter
tubes have been UO-formed. For example, Japanese Patent
Publication No. 58-32010A discloses the art of
25 successively using a C-press, U-press, and 0-press to
form a straight shaped steel tube. However, \•lith
conventional UO-forming, forming a bent tube, irregular
diameter tube, and irregular cross-section tube is
difficult.
30 [0004] In recent years, UO-forming has been further
improved to develop the art of forming a bent tube,
irregular diameter tube, irregular cross-section tube,
and other tubular parts having 30 shapes. For example,
International Publication No. 2005/002753A proposes a
35 method of using tooling provided with guide blades for
edges in the vertical direction for UO-forming and
producing straight shaped irregular diameter tubes.
- 2 -
Further, Japanese Patent No. 3114918 and Japanese Patent
Publication No. 2008-80381A propose a method of
production of a curved hollow tube comprised of a method
of bending the tube in the longitudinal direction at the
5 time of U-forming the tube wherein the U-forming step is
made a step including dra~oling process.
[0005] However, the method described in International
Publication No. 2005/002753A is a method of production of
a straight shaped irregular diameter tube. Formation of a
10 bent tube is difficult. Further, the methods described in
Japanese Patent No. 3114918 and Japanese Patent
Publication No. 2008-80381A have the problems that the
numbers of steps are large and the yields are low.
Summary of Invention
15 Technical Problem
[0006] With the method of bending in the longitudinal
direction at the time of U-forming such as described in
Japanese Patent No. 3114918 and Japanese Patent
Publication No. 2008-80381A, depending on the shape or
20 material of the shaped article, there is the problem of
fracture or wrinkling during U-forming, creasing of the
vertical 1o1alls, and other shaping defects.
[0007] The present invention was made in consideration
of the above problem and has as its object the provision
25 of a method of producing a shaped article able to
suppress shaping defects 1o1hen bending in the longitudinal
direction to produce a shaped article, tooling used for
that method of production, and a tubular shaped article
obtained by that method of production.
30 Solution to Problem
[0008] To achieve the above ob]ect, the gist of the
invention perfected by the inventors is as follows:
[0009] [1] A method of producing a shaped article
comprising:
35 a first step of press-forming a metal plate into a Ushape
to obtain a U-shaped article having a bottom part
straight extending in a longitudinal direction and
5
- 3 -
a second step of press-forming said U-shaped
article to bend it in the longitudinal direction so that
the bottom part of the U-shaped article projects to an
inside and to obtain a U-cross-section bent article.
[0010] [2] The method of producing a shaped article
according to [1] characterized in that, in said second
step, an external force in a·direction connecting an edge
and the bottom part is applied to at least a part of a
planned bending part of said U-shaped article, at the
10 same time as said bending.
[0011] [3] The method of producing a shaped article
according to [2] characterized in that said external
force is applied by compressing, in in-plane directions,
said edge along the longitudinal direction of said U-
15 shaped article toward the outside of the bottom part of
said U-shaped article.
[0012] [4] The method of producing a shaped article
according to any one of [1] to [3] further comprising a
third step of shaping said U-cross-section bent article
20 into a closed cross-section to obtain a tubular shaped
article.
[0013] [5] A tooling for bending a U-shaped article in
a longitudinal direction so that the bottom part projects
to an inside and for obtaining a U-cross-section bent
25 article, said tooling provided with a die, a punch, and
pads arranged at side surfaces of said punch and
compressing, in in-plane directions, at least parts of a
planned bending part of said U-shaped article in end
parts along the longitudinal direction of said U-shaped
30 article.
[0014] [6] A tubular shaped article comprised of a
metal plate and including only one seam extending in an
axial direction, wherein a bottom part positioned at an
opposite side to said seam in a peripheral direction
35 includes a bent part projecting to an inside in an axial
direction, and a ratio .H1/H2 of a plate thickness H1 of
said bent article at said seam and a plate thickness H2
- 4 -
of said bent article at said bottom part satisfies a
following equation (1): H1/H22Ri/(Ri+D) (1) (wherein in
said equation (1), Ri is a radius of curvature of a
bottom part side of the bent part, and D is a width of
5 the bent part at a cross-section including a seam and a
centerline of the_tubular shaped article)
Advantageous Effects of Invention
[0015] In the method of producing a shaped article
according to the present invention, U-forming and bending
10 in the longitudinal direction are performed separately.
Therefore, according to the method of producing a shaped
article according to the present invention, it is
possible to suppress shaping defects of the U-crosssection.
bentarticle and in turn possible to suppress
15 shaping defects even in the shaped article. Note that,
according to the tooling according to the present
invention, it is possible to efficiently perform the
above method of production and in turn possible to obtain
a tubular shaped article according to the present
20 invention.
Brief Description of Dravlings
[0016] FIGS. 1 are process diagrams showing an example
of a first step and second step in the method of
producing a shaped article according to the present
25 invention.
FIGS. 2 are process diagrams shovling an example of a
third step in the method of producing a shaped article
according to the present invention.
FIG. 3 is a schematic plan view showing one example of a
30 metal plate used in the method of producing a shaped
article according to the present invention.
FIGS. 4 are schematic perspective vie1·1s showing an
example of a tubular shaped article according to the
present invention.
35 FIGS. 5 are process diagrams showing an example of a
first step in the method of producing a shaped article
according to the present invention.
- 5 -
FIGS. 6 are process diagrams showing an example .of a
second step in. the method of producing a shaped article
according to the present invention.
FIGS. 7 are process diagrams shm;ing another example of a
5 first step in the method of producing a shaped article
according to the present invention.
FIGS. 8 are process diagrams showing another example of a
second step in the method of producing a shaped article
according to the present invention.
10 FIGS. 9 are process diagrams showing an example qf a
third step in the method of producing a shaped article
according to the present invention.
FIGS. 10 are schematic perspective views showing another
example of a tubular shaped article according ~o the
15 present invention.
FIGS. 11 are a schematic front view, side view, top view,
and cross-sectional view of another example of a tubular
shaped article according to the present invention.
FIGS. 12 are a schematic front vie~;, side vie"', top vie~;,
20 and cross-sectional vie~; of another example of a tubular
shaped article according to the present invention.
FIG. 13 is a graph sho,ling a thickness reduction rate at
a cross-section at the center of bending of Example 3.
FIG. 14 is a graph showing the results of investigation
25 of the ratio (Hl/H2) of Examples 2 and 3.
Description of Embodiments
[0017] Below, the method of producing a shaped
article, tooling, and tubular shaped article according to
the present invention Hill be explained in detail.
30 [0018] A. Method of producing Shaped article
Basic Embodiment
The method of producing a shaped article of the basic
embodiment includes a first step of press-forming a metal
plate into a U-shape to obtain a U-shaped article having
35 a bottom part straight extending in a longitudinal
direction and a second step of press-forming the U-shaped
article to bend it in the longitudinal direction so that
- 6 -
the bottom part of the part projects to the inside and
obtain a U-cross-section bent article. Further, in the
method of producing a shaped article of the basic
embodiment, after the end of the above second step, for
5 example, it is possible to perform a third step of
shaping the above U-cross-section bent article into a
closed cross-section to obtain a tubular shaped article.
Note that, instead of the third step, piercing or
burling, trimming, etc. can be performed. Further,
10 piercing etc. can be performed before the first step,
before the second step, or before the third step.
[0019] The method of producing a shaped article of the
basic embodiment v1ill be explained while referring to the
drawings.
15 FIGS. 1A to 1F and FIGS. 2A ·to 2C are process diagrams
shov1ing one example of the method of producing a shaped
article of the basic embodiment. FIGS. 1A and 10 are
front views, FIG. 1B is a cross-sectional view along the
line A-A of FIG. 1A, FIG. 1E is a cross-sectional view
20 along the line A-A of FIG. 10, FIGS. 1C and 1F are
perspective viev1s, FIG. 2A is a front vievl, FIG. 2B is a
cross-sectional view along the line A-A of FIG. 2A, and
FIG. 2C is a perspective view.
[0020] First, at the first step, as shown in FIGS. 1A
25 and 1B, first tooling for U-forming use is prepared. The
first tooling for U-forming use has a die 11 and punch
12. The bottom part 11a of the recessed part of the die
11 and the bottom part 12a of the punch 12 both extend
straight in the longitudinal direction. Between the die
30 11 and punch 12 of the first tooling for U-forming use, a
metal plate 1a is placed. The metal plate 1a is U-formed.
Due to this, as shown in FIG. 1C, a U-shaped article 1b
having a bottom part 2 extending straight in the
longitudinal direction x is obtained.
35 [0021] Next, at the second step, as shown in FIGS. 10
and 1E, second tooling for bending use is prepared. The
second tooling for bending use has a die 21 and punch 22.
- 7 -
The bottom part 2la of the recessed part of the die 21 is
formed curved projecting upward in the longitudinal
direction. The~ bottom part 22a of the punch 22 is formed
curved recessed in the longitudinal direction. Between
5 the die 21 and punch 22 of this second tooling for
bending use, the U-shaped article lb is placed and the Ushaped
article lb is bent in the longitudinal direction
x. Due to this, as shown in FIG. lF, a U-cross-section
bent article lc is obtained. The U~cross~section bent
10 article lc is formed with the bottom part 3 curved
projecting to the inside in the longitudinal direction.
It has a bent part lOa with a bottom part 3 projecting
inside in the longitudinal direction and a straight part
lOb with a bottom part 3 extending straight in the
15 longitudinal direction and having a total length of the
U-shape in the U-cross-section equal along the
centerline.
[0022] Next, at third step, as shown in FIGS. 2A and
2B, third tooling for 0-forming use is prepared. The
20 third tooling for 0-forming use has a die 31 and punch
32. The bottom part 31a of the recess of the die 31 is
formed curved projecting in the longitudinal direction,
the bottom part 32a of the recess of the punch 32 is
formed curved recessed in the longitudinal direction, and
25 the recess of the die 31 and the recess of the punch 32
both have semicircular cross-sectional shapes. Between
the die 31 and punch 32 of this third tooling for 0-
forming use, the U-cross-section bent article lc is
placed and the U-cross-section bent article lc is 0-
30 formed. Due to this, as shown in FIG. 2C, a tubular
shaped article ld is obtained. The tubular shaped article
ld has a seam 4 formed curved projecting to the outside
and a bottom part 5 positioned at the opposite side from
the seam 4 in the peripheral direction formed curved
35 projecting inside in the axial direction. It has a bent
part lOa having a bottom part 5 projecting inside in the
axial direction and a straight part lOb having a bottom
- 8 -
part 5 extending straight in the axial direction and 11ith
an equal length in the peripheral direction along the
centerline.
[0023] If, like in the past, performing the U-forming
5 and bending in the longitudinal direction simultaneously,
a force in a direction outside the plane easily acts on
the vertical walls (straight parts·at the ends of U-shape
of worked object seen from side view) and creasing easily
occurs at the edges (in particular near final edges of
10 the straight parts) . Further, in this case, the metal
plate is bent in the plate 1·Tidth direction and is bent in
the longitudinal direction as well, so a compressing
force is generated at the bottom part in the
substantially flat state and wrinkling easily occurs.
15 [0024] As opposed to this·;- in the basic embodiment
according to the present invention, U-forming (first
step) and bending in the longitudinal direction (second
step) are performed in separate steps, so it is possible
to decrease the force acting in the direction outside the
20 plane on the vertical walls (straight parts of the two
ends of the U-shaped article in the side view) at the
time of bending of the second step and in turn it is
possible to suppress the occurrence of creasing at the
edges (in particular near final edges of the straight
25 parts). Further, in the basic embodiment, the metal plate
is not simultaneously bent in the plate width direction
and longitudinal direction like in the past. The metal
plate is bent once in the plate width direction to obtain
a U-shaped article which is then bent in the longitudinal
30 direction, so when bending in the longitudinal direction,
it is possible to maintain the rigidity of the bottom
part (U-shaped bottom part) at a high state. For this
reason, stable bending in the longitudinal direction
becomes possible, occurrence of wrinkling of the bent
35 part at the bottom part can be suppressed, and in turn it
is possible to obtain a U-cross-section bent article free
of shaping defects and in turn a tubular shaped article.
- 9 -
[0025] Below, the different steps of the method of
producing a shaped article of the basic embodiment will
be explained in more detail.
[0026] (1) First Step
5 At the first step, the metal plate is press-formed into a
U-shape to obtain a U-shaped article having a bottom part
extending straight in the longitudinal direction. As the
U-forming method, press-forming and roll forming can be
employed.
10 [0027] The metal plate is not particularly limited so
long as one able to be shaped. For example, a hot rolled
steel plate, cold rolled steel plate, plated steel plate,
etc. may be used. Further, for the metal plate, one
comprised of a plurality of metal plates joined together,
15 a so-called "tailored blank", may a·lso be used. Further,
a differential thickness steel plate can also be used.
Further, a plate comprised of a plurality of metal plates
superposed or a plate comprised of a metal plate >lith
which a nonmetal material is superposed, that is,
20 multilayer plates, may also be used.
[0028] The material of the metal plate is not
particularly limited so long as one able to be shaped.
For example, an Fe-based one (for example, carbon steel,
stainless steel, etc.), anAl-based one (for example, Al
25 or an alloy including Al and at least one of Cu, Mn, Si,
Mg, Zn, etc.), a Cu-based one (for example, Cu or an
alloy including Cu and at least one of Al, Ag, As, Be,
Co, Cr, Fe, Mn, Ni, P, Pb, S, Se, Sd, Sn, Si, Te, Zn, Zr,
etc.), a Ti-based one (for example, Ti or an alloy
30 including Ti and at least one of N, C, H, Fe, o, Al, V,
etc.), or other material may be mentioned.
[0029] The plate thickness of the metal plate need
only be made an extent able to be shaped. While differing
according to the material or the shape of the shaped
35 article or the like, for example, it can be made vlithin
0.5 mm to 30 mm in range. However, if the plate thickness
is too small, at the time of bending, the bent part .is
- 10 -
liable.to wrinkle or fracture, while if the plate
thickness· is too great, sometimes an excessive ·load· is
required for shaping operations, so the plate thickness
is preferably made 1.0 rom to 5.0 rom.
5 [0030] The shape of the metal plate is suitably
adjusted in accordance with the shape of the shaped
article. For example, at the time of bending, the total
length of the U-shape at the U-cross-section of the bent
article ~ecreases, so the plate width of the region to be
10 the bent part of the metal plate is preferably designed
so as to become larger than the targeted length of the ucross-
section of the U-cross-section bent article.
Specifically", when fabricating the U-cross-section bent
article lc having the bent part lOa and straight part lOb
· 15 sho~>m in FIG. lF, as sho~>m in FIG. 3, it is preferable to
design the plate width d2 of the region to be the bent
part of the metal plate la larger than the plate 11idth dl
of the region becoming the straight part.
[0031] The U-shaped article obtained at the first step
20 has a bottom part extending straight in the longitudinal
direction. At the cross-section of the U-shaped article
in the longitudinal direction, the bottom part is formed
straight.
[0032] (2) Second Step
25 At the second step, press-forming is used to bend the
above U-shaped article in the longitudinal direction so
that the above bottom part projects inside so as to
obtain a U-cross-section bent article. As the bending
method in this step, press-forming can be employed.
30 [0033] The radius of curvature at the bending differs
according to the material, the shape of the shaped
article or the like, but for example can be set in the
range of 0.5 to 10 times the width of the U-crosssection.
If the radius of curvature is small, the bent
35 part is liable to wrinkle or fracture at the time of
bending. Further, if the radius of curvature is large,
the effect of performing the U-forming and bending in the
5
- 11 -
longitudinal 'direction by separate steps (that is,
suppress the occurrence of shaping defects) sometimes
cannot be sufficiently obtained. Here, the "width of the
U-cross-section'' indicates the width w such as shown in
FIG. lE.
[0034] (3) Third Step
At the third step, the U-cross-section bent arti·cl-e ·is
press-formed into a closed cross-section to obtain a
tubular shaped.article. Here, the "closed cross-section"
10 is a concept including not only a completely closed
cross-section but also the case where there is a
clearance between the abutting edges. That is, at the
seam of the tubular shaped article, the edges may be
closely in contact or may be separated. That is, th.e seam
15 may also have clearance.
[0035] As the method of forming the closed crosssection,
press-forming can be employed. Further, \vhen
forming the closed cross-section, it is possible to use a
mandrel in accordance \'lith need. By using a mandrel, it
20 is possible to stably form the tubular shaped article
even if the cross-sectional shape of the peripheral
direction is a complicated shape.
[0036] The tubular shaped article obtained at the
third step has a bent part v1ith a bottom part positioned
25 at the opposite side from the seam in the peripheral
direction and projecting inside in the axial direction.
It is formed curved so that the bottom part projects
inside in the cross-section of the axial direction. The
seam may for example be formed curved so that it projects
30 to the outside and may be formed straight.
[0037] The cross-sectional shape of the tubular shaped
article in the peripheral direction is not particularly
limited. It may be made a round shape, oval shape, square
shape, vertically asymmetric shape, or various other
35 shapes.
[0038] (4) Other Steps
In the basic embodiment, after the third step, it is also
- 12 -
possible to perform a welding step of 1•/elding the seam of
the tubular shaped article. As the welding method, for
example, arc welding, laser welding,·· etc. may be
mentioned. Further, in the basic embodiment, before the
5 first step, edge bending of the metal plate, so-called
curling or other processing may be performed.
[0039] (5) Shaped article
The shaped article produced by the basic embodiment is a
tubular shaped article. Further, the shape of the tubular
10 shaped article is not particularly limited so long as one
able to be formed well by the method of the basic
embodiment. For example, a bent tube 1·1ith a circular
cross-sectional shape in the peripheral direction such as
shown in FIG. 4A, a bent tube vii th a vertically
15 asymmetric cross-sectional shape in the peripheral
direction such as shown in FIG. 4B, a not shown irregular
diameter tube or irregular cross-section tube etc. may be
illustrated .
[0040] . Due to the above, according to the method of
20 producing a shaped article shovm in FIGS. 1 and FIGS. 2
(basic embodiment), in particular, at the second step, aforming
and bending in the longitudinal direction can be
separately performed so as to suppress the occurrence of
shaping defects.
25 [0041] Applied Embodiments
Next, the Applied Embodiments 1 and 2 improved over the
above basic embodiment will be explained in detail.
[0042] Applied Embodiment 1: Modification Applying to
at Least Part of Planned Bending Part of U-Shaped article
30 External Force in Directions Connecting Edges and Bottom
Part
In the method of producing a shaped article of the
Applied Embodiment 1, in the second step explained in the
basic embodiment, at the same time as the bending,
35 external force in directions connecting the edges and
bottom part is applied to at least part of the planned
bending part of the U-shaped article. Here, the "planned
- 13 -
bending part of the U-shaped article" means the region
corresponding to the region to be the bent part in the Ucross-
section bent article obtained at the time of end of
the second step. Further, the "outside of the bottom
5 part" means the side in the direction of movement of the
punch at the time of bending.
[0043] As such an example of "at ·the same time as the
bending, external force in directions connecting the
edges and bottom part is applied to at least parts of the
10 planned bending part of the U-shaped article", the type
of "applying the external force by compressing the edges
along the longitudinal direction of the U-shaped article
toward the outside of the bottom part of the U-shaped
article in the planar direction" and the type of
15 "applying the external force by pulling the vertical
v1alls of the U-shaped article tm-1ard the inside of the
bottom part of the U-shaped article (direction opposite
to direction of movement of punch at time of bending) in
the planar direction" may be mentioned.
20 [0044] The method of producing a shaped article of the
Applied Embodiment 1 v1ill be explained 1vhile referring to
the drawings. Note that, below, the type of "applying the
external force at the second step by compressing the
edges along the longitudinal direction of U-shaped
25 article tov1ard the outside of the bottom part of the Ushaped
article in the planar direction" will be explained
in detail.
[0045] FIGS. 5A to 5D and FIGS. 6A to 6E are process
diagrams .showing an example of the method of producing a
30 shaped article of the present embodiment. FIG. 5A is a
top view, FIG. 5B is a front view, FIG. 5C is a crosssectional
view along the line A-A of FIG. 5B, and FIG. 5D
is a perspective vie1v. Further, FIGS. 6A and 6C are front
viev1s, FIG. 6B is a cross-sectional viev1 along the line
35 A-A of FIG. 6A, FIG. 6D is a cross-sectional view along
the line A-A of FIG. 6C, and FIG. 6E is a perspective
view.
- 14 -
_ [0046] First, as shown ~n FIG. SA, a metal plate la
vlith a plate width d2 of the planned bending part (region
to be a bent part) larger than the plate width dl of the
region becoming the straight part is prepared.
5 [0047] Next, at first step, as shown in FIGS. 5B and
5C, first tooling for U-forming use is prepared. The
first tooling for U-forming use has a· die 11 and punch
12. The bottom part lla of the recessed part of the die
11 and the bottom part 12a of the punch 12 both extend
10 straight in the longitudinal direction. The metal plate
la is placed between the die 11 and punch 12 of the first
tooling for U-forming use and the metal plate 1a is Uformed.
Due to this, as shown in FIG. 50, a U-shaped
article 1b having a bottom part 2 extending straight in
15 the longitudinal direction x is obtained.
[0048] Furthermore, at the second step, as shmm in
FIGS. 6A and 6B, second tooling for bending use is
prepared. The second tooling for bending use has a die
21, punch 22, and pads 23 arranged at the two side
20 surfaces of the punch 22. The bottom part 2la of the
recess of the die 21 is formed curved projecting in the
longitudinal direction, while the bottom part 22a of the
punch 22 is formed curved recessed in the longitudinal
direction.
25 [0049] The pads 23 compress at least parts of the
planned bending part (in U-cross-section bent article,
region to be a bent part) 7 of the U-shaped article 1b at
the edges 6 in the longitudinal direction x of the Ushaped
article 1b in the planar direction and can move up
30 and d01m. In the example shovm in FIGS. 6, the pads 23
are a type compressing the entire part of the planned
bending part 7, but the pads according to the present
invention are not limited to such a type. They may also
be a type compressing parts of the planned bending part
35 7.
[0050] Next, as shown in FIGS. 6A to 60, the U-shaped
article 1b is placed between the die 21 and punch 22 of
- 15 -
the second tooling for bending use, then the U-shaped
article lb is bent in the longitudinal direction x. At
this time, at least parts of the planned bending part 7
of the U-cross-section bent article at the edges 6 of the
5 U-shaped article lb in the longitudinal direction x are
compressed in the planar direction. Due to this, as shovm
in·FIG. 6E, aU-cross-section bent article lc is'
obtained. The U-cross-section bent article lc has a
bottom part 3 formed curved projecting inside in the_
10 longitudinal direction. It has a bent part lOa with a
bottom part 3 projecting inside in the longitudinal
direction and a straight part lOb having a bottom part 3
extending straight in the longitudinal direction and with
an equal U-cross-section along the centerline.
15 [0051] Due to the above, according to the method of
producing a shaped article shown in FIGS. 5 and· FIGs·. 6
(Applied Embodiment 1), not only the effect exhibited by
the above basic embodiment of "suppressing the occurrence
of shaping defects", in particular, not only the effect
20 that at the second step, by applying external force to at
least parts of the planned bending part of the U-shaped
article toward the outside of the bottom part of the Ushaped
article, it is possible to suppress local changes
in the plate thickness in the U-cross-section bent
25 article, that is, decrease of thickness and increase of
thickness, but also it is possible to further suppress
the occurrence of wrinkling at the bottom part of the
bent part. Further, by going through a third step in the
same way as the basic embodiment, a desired tubular
30 shaped article can be obtained.
[0052] Here, the specific grounds why it is possible
to suppress local changes in the plate thickness, that
is, decrease of thickness and increase of thickness, for
the v10rked part· lc shm1n in FIG. 6E, are as follm·1s: That
35 is, in Applied Embodiment 1, at the second step, by using
the pads 23 to compress at least parts of the planned
bending part 7 in the planar direction, at least parts of
- 16 -
the bottom part·of the planned bending part are pressed
against the tooling and the neutral axis of bending
(position not stretching or contracting in longitudinal
direction) moves to the bottom part side compared Hith
5 the case of not compressing in the planar direction. For
this reason, in the worked part lc shm·m in FIG. 6E, not
only it is possible to suppress the increase in plate
thickness at the bottom part 3 side at the bent part lOa,
but also it is possible to suppress the decrease in plate
10 thickness due to material being supplied by compressing
to the edge 8 side along the longitudinal direction.
Therefore, not only is it possible to suppress the
occurrence of fractures at the edge along the
longitudinal direc;tion of the bent part lOa and Vlrinkling
15 at the bottom part, but it also pos·sible to make the
distribution of plate thickness of the U-cross-section of
the U-cross-section bent article uniform.
[0053] In this Hay, in the Applied Embodiment 1, it is
possible to make the distribution of plate thickness
20 uniform, so it is possible to enlarge the range of
possible shaping of the bent part in the longitudinal
direction of the U-cross-section bent article lc compared
with the basic embodiment. For this reason, for example,
a U-cross-section bent article having a bent part Hith
25 the relatively small radius of curvature and a U-crosssection
bent article having a taper part also can
suppress the occurrence of >lrinkling and fracture Vlhile
enabling stable shaping.
[0054] Furthermore, when compressing at least parts of
30 the planned bending part at the edges along the
longitudinal direction of the U-shaped article (region to
be a bent part of U-cross-section bent article) in the
planar direction, it is not necessary to constantly apply
pressure during bending. It is sufficient to apply
35 pressure at any time during bending.
[0055] In addition, as the pressure at the time of
compressing at least parts of the planned bending part at
- 17 -
the edges along the longitudinal direction of the Ushaped
article in the planar direction, one of an extent
enabling· suppression of the decrease of plate thickness
at the edges along the longitudinal direction of the bent
5 part and increase of plate thickness at the bottom part
is sufficient. It may be suitably adjusted in accordance
vii th the shape of the shaped article, the shape ·of the
pads of the bending-use second too'ling, the plate
thickness or material of the metal plate, etc.
10 [0056] Applied Embodiment 2: Modification Relating to
Shape of Tubular Shaped article
The method of producing a shaped article of the Applied
Embodiment 2 is a method of production improving ·the
shape of the shaped article obtained in the basic
15 embodiment and Applied Embodiment 1.
[0057] FIGS. 7A to 7F and FIGS. SA to SF are process
diagrams shm1ing an example of the method of producing a
shaped article of the Applied Embodiment 2. FIG. 7A is a
top vie~<, FIG. 7B is a perspective vie1·1, FIG. 7C is a
20 front vie1'1, FIG. 70 is a left side vie~< of FIG. 7C, FIG.
7E is a right side vievl of FIG. 7C, and FIG. 7F is a top
viev1 of FIG. 7C. Further, FIG. SA is a perspective vie~<,
FIG. SB is a front view, FIG. SC is a front view, FIG. SO
is a left side view of FIG. SC, FIG. BE is a right side
25 view of FIG. SC, and FIG. SF is a top view of FIG. SC.
[0058] First, the metal plate la such as shown in FIG.
7A is prepared.
[0059] Next, at a first step, as shown in FIG. 7B,
first tooling for U-forming use is prepared. The first
30 tooling for U-forming use has a die 11 and punch 12. The
bottom part lla of the recessed part of the die 11 and
the bottom part 12a of the punch 12 both extend straight
in the longitudinal direction. A metal plate la is placed
bet1-1een the die 11 and punch 12 of the first tooling for
35 U-forming use, then the metal plate la is U-formed. Due
to this, as shown in FIGS. 7C to 7F, a U-shaped article
lb having a bottom part 2 extending straight in the
- 18 -
longitudinal direction x is obtained.
[0060] Further, in the second step, as shmvn .. in FIGS.
SA and SB, second tooling for bending use is prepared.
The second tooling for bending use has a die 21, punch
5 22, and pads 23 arranged at the two side surfaces of the
punch 22. The bottom part 21a of the recessed part of the
die 21 is formed curved projecting in the longitudinal
direction, 1·1hile the bottom part 22a of the punch 22 is
formed curved recessed in the longitudinal direction. The
10 pads 23 compress the region to be the bent part 7 of the
U-cross-section bent article of the edge 6 along the
longitudinal direction x of the U-shaped article lb in
the planar direction and can move up and down.·
[0061] Next, as shmm in FIG. SB, the U-shaped article
15 lb is placed bet1o1een the die 21 and punch 22 of the
second tooling for bending use and the U-shaped article
lb is bent in the longitudinal direction x. At this time,
the region to be the bent part 7 of the U-cross-section
bent article of the edge 6 along the longitudinal
20 direction x of the U-shaped article lb is compressed in
the planar direction. Due to this, as shovm in FIGS. 8C
to SF, a U-cross-section bent article lc is obtained. The
U-cross-section bent article lc has a bottom part 3
formed curved projecting inside in the longitudinal
25 direction. It has a bent part lOa 1vith a bottom part 3
projecting inside in the longitudinal direction, a
straight part lOb having a bottom part 3 extending
straight in the longitudinal direction and having an
equal length of the U-cross-section along the centerline,
30 and a taper part lOc having and a bottom part 3 extending
straight in the longitudinal direction and having a
length of the U-cross-section increasing along the
centerline.
[0062] In the Applied Embodiment 2, in the same v1ay as
35 the Applied Embodiment 1, Hhen bending the U-shaped
article at the second step to obtain the U-cross-section
bent article, the U-shaped article is bent and at least
- 19 -
part of the planned bending part (region to be a bent
part) of the above U-cross-section bent article is
compressed in the planar direction.
[0063] Due to the above, according to the method of
5 producing a shaped article shown in FIGS. 7 and FIGS. 8
(Applied Embodiment 2), in the same way as the Applied
Embodiment 1, not only is there the effect exhibited by
the basic embodiment of "suppressing the occurrence of
shaping defects", in particular, at the secondstep, by
10 applying external force to at least parts of the planned
bending part of the U-shaped article toward the outside
of the bottom part of the U-shaped article, it is
possible to suppress local changes in the plate thickness
in the U-cross-section bent article, that is, decrease of
15 thickness. Further, by going through a third step in the
same "'ay as the basic embodiment and Applied Embodiment
1, a desired tubular shaped article can be obtained.
[0064] Here, the third step in the Applied Embodiment
2 will be explained in detail. That is, in the above
20 formed U-cross-section bent article (FIG. 8C to FIG. SF),
further, as shown in FIG. 9, the U-cross-section bent
article is shaped to a closed cross-section.
[0065] FIG. 9A is a perspective vie•1, FIG. 98 is a
front view, FIG. 9C is a front view, FIG. 9D is a left
25 side view of FIG. 9C, and FIG. 9E is a right side vie1·1 of
FIG. 9C.
[0066] At the third step, as shmm in FIGS. 9A and 98,
third tooling for a-forming use is prepared. The third
tooling for 0-forming use has a die 31 and punch 32, the
30 bottom part 31a of the recessed part of the die 31 is
formed curved projecting in the longitudinal direction,
the bottom part 32a of the recessed part of the punch 32
is formed curved recessed in the longitudinal direction,
and both the recessed part of the die 31 and the recessed
35 part of the punch 32 have semicircular cross-sectional
shapes.
[0067] A U-cross-section bent article 1c is placed
- 20 -
between the die.31 and punch 32 of the third tooling for
0-forming use, and the U-cross~section bent article 1c is
0-formed. Due to this, as shown in FIGS. 9C to 9E, a
tubular shaped article ld is obtained. The tubular shaped
5 article ld has a seam 4 formed curved projecting inside
and has a bottom part 5 positioned at the opposite side
from the seam 4 in the peripheral direction and formed
curved projecting inside in the axial direction. It has a
bent part lOa having a bottom part 5 projecting inside in
10 the axial direction, a straight part lOb having a bottom
part 5 extending straight in the axial direction and
having an equal length in the peripheral direction along
the centerline; and a taper part lOc having a bottom part
5 extending straight in the axial direction and having a
15 length in the peripheral direction increasing alorig the
centerline.
[0068] Due to the basic embodiment and Applied
Embodiments 1 and 2 shmm above, various shaped articles
are obtained. That is, as the obtained shaped articles,
20 there are various shapes of tubular shaped articles
obtained through various shapes of U-cross-section bent
articles. These are suitably selected in accordance with
the presence/absence of the third step, Helding step,
etc.
25 [0069] Further, as the shape of the shaped article,
for example, in the case of the tubular shaped article
ld, a bent tube such as sho>m in FIGS. lOA and lOB having
a cross-sectional shape in the peripheral direction of a
circular shape and having a bent part lOa and straight
30 part lOb, a trumpet-shaped irregular diameter tube such
as shoHn in FIG. lOC having a cross-sectional shape in
the peripheral direction of a circular shape and having a
bent part lOa, straight part lOb, and taper part lOc, a
trumpet-shaped irregular diameter tube such as shmm in
35 FIG. lOD having a cross-sectional shape in the peripheral
direction changing from a circular shape to a square
shape and having a bent part lOa, straight part lOb, and
- 21 -
taper part lOc, a bent tube such as shown in FIG. lOE
having a cross-sectional shape in the peripheral
direction of a vertically asymmetrical shape and having a
bent part lOa and straight part lOb, an irregular
5 diameter tube such as shm-m in FIG. lOF having
pluralities of bent parts lOa, straight parts lOb, and
taper parts lOc can be mentioned.
[0070] B. Tooling
The tooling according to the present invention is .for
10 bending a U-shaped article in the longitudinal direction
so that the bottom part projects inside so as to obtain a
U-cross-section bent article and is characterized by the
provision of a die, a punch, and pads arranged at side
surfaces of the above punch and compressing at least
15 parts of the planned bending part of the U-shaped article
at the edged along the longitudinal direction of the Ushaped
article in the planar direction. That is, the
tooling according to the present invention is used in the
second step of the method of producing a shaped article
20 in the above Applied Embodiments 1 and 2.
[0071] FIGS. 6A and 6B show an example of tooling
according to the present invention, while FIGS. BA and BB
shov1 another example of tooling according to the present
invention. As shm-m in FIGS. 6A and 6B (FIGS. BA and 88),
25 the tooling has a die 21, punch 22, and pads 23 arranged
at the two side surfaces of the punch 22. The bottom part
21a of the recessed part of the die 21 is formed curved
projecting in the longitudinal direction, v1hile the
bottom part 22a of the punch 22 is formed curved recessed
30 in the longitudinal direction. The pads 23 compress at
least parts of the planned bending part 7 of the U-shaped
article at the edges 6 along the longitudinal direction x
of the U-shaped article lb in the planar direction and
can move up and do\•ln.
35 [0072] In the tooling according to the present
invention, by having the above such predetermined pads,
at the time of bending using the tooling, the pads can
- 22 -
compress at least parts of the planned bending part at
the edges along the longitudinal direction of the Ushaped
article in the planar direction. For this reason,
in the U-cross-section bent article lc shown in FIG. 6E
5 and FIGS. 8C to SF, it is possible to suppress the
decrease in plate thickness at the bent part lOa at the
edges 8 along the longitudinal direction and the increase
in plate thickness at the bottom part 3. Therefore, by
using the tooling according to the present invention, it
10 is possible to suppress the occurrence of wrinkling at
the bottom part of the bent part and fracture at the
edges along the longitudinal direction to a high level.
Not only that, it is possible to make the distribution of
plate thickness at the U-cross-section. of the U-cross-
15 sect.ion bent article uniform. Due to this, by using the
tooling according to the present invention, it is·
possible to suitably enlarge the possible range of
shaping of the bent article in the longitudinal direction
of the U-cross-section bent article lc (number of types
20 of shapes and extent of complexity of parts which can be
formed) compared with the past. Due to this, for example,
even "'i th a U-cross-section bent article having a bent
part with a relatively small radius of curvature or a Ucross-
section bent article having a taper part, it is
25 possible to suppress the occurrence of wrinkling or
fracture and in turn possible to suppress the occurrence
of shaping defects at a high level.
[0073] Below, the different components in the tooling
according to the present invention will be explained.
30 [0074] 1. Pads
The pads are arranged at the two side surfaces of the
punch and compress at least parts of the planned bending
part at the edges along the longitudinal direction of ushaped
article in the planar direction.
35 [0075] The parts where the pads abut against the Ushaped
article arc made at least parts of the planned
bending part (that is, region to be a bent part in u-
23 -
cross-section bent article) of the edges. along the
longitudinal direction of the U-shaped article; If the
planned bending part is too broad, even untargeted
regions end up being compressed in the planar direction
5 and shaping defects are liable to occur. Further, if the
planned bending part is too narrow, the reduction of
plate thickness at the edges along the longitudinal
direction of the bent part and increase of plate
thickness at the bottom part could .not·be sufficiently
10 suppressed. Not only cannot shaping defects be suppressed
to a high level, but also it becomes difficult to make
the distribution of plate thickness of the U-crosssection
uniform.
[0076] The shapes of the parts of the pads abutting
15 against the shaped article need only be shapes enabling
at least parts of the planned bending part at the edges
along the longitudinal direction of the U-shaped article
to be compressed in the planar direction. It is possible
to suitably design them in accordance with the shapes
20 etc. of the U-shaped article. Along with the bending of
the U-shaped article, the U-shaped article changes in
shape and the edges along the longitudinal direction of
the U-shaped article also change in shape. For this
reason, for example, if assuming the shapes of the edges
25 along the longitudinal direction of the U-shaped article
at the initial stage, middle stage, and later stage of
bending, the shapes of the parts of the pads abutting
against the U-shaped article are preferably shapes
corresponding to the shapes of the edges along the
30 longitudinal direction of the U-shaped article at the
initial stage or middle stage of bending. If the shapes
of the parts of the pads abutting against the U-shaped
article are shapes corresponding to the shapes .of the
edges along the longitudinal direction of the shaped
35 articles at the later stage of bending, due to the pads,
sometimes it becomes difficult to compress at least parts
of the planned bending part of the edges along the
- 24 -
longitudinal direction of the U-shape-d article in the
planar direction.
[0077] Further, the pads may be divided into
pluralities of blocks along the direction of advance of
5 the pads. In this case, by making the individual blocks
forming the pads move up and dmIing equation
( 2) :
Hl/H22':Ri/ (Ri+D) (2)
(>Iherein in the above equation (2), Ri is the radius of
curvature of the bottom part side of the bent part and D
25 is the width of the bent part of the cross-section
including the seam and centerline of the tubular shaped
article)
[0084] FIGS. llA to llE are vie>Is sho>Iing one example
of a tubular shaped article according to the present
30 invention, 11herein FIG. llA is a front view, FIG. llB is
a left side view, FIG. llC is a right side view, FIG. llD
is a top view, and FIG. llE is a cross-sectional view
along the line C-C of FIG. llA. The tubular shaped
article ld shmm in FIGS. llA to llE is comprised of a
35 metal plate. It has only one seam 4 extending in the
axial direction and is comprised of a single metal plate
formed into a tubular shape. The tubular shaped article
- 26 -
ld has a bent part lOa having a bottom part 5 positioned
at the opposite side to the seam 4 in the peripheral
direction projecting inside in the axial direction and a
straight part lOb having a bottom part 5 extending
5 straight in the axial direction and having an equal
length in the peripheral direction along the centerline
S. Further, the ratio Hl/H2 of the plate thickness Hl at
the seam 4 of the bent part lOa and the plate thickness
H2 at the bottom part 5 of the bent part lOa is a
10 predetermined range.
[OOBS] FIGS. 12A to 12E are views showing another
example of a tubular shaped article according to the
present invention, wherein FIG. 12A is a front vie1-1, FIG.
128 is a left side view, FIG. 12C is a right side view,
15 FIG. 120 is a top view, and FIG. 12e is a cross-sectional
vie1-1 along the line C-C of FIG. 12A. The tubular shaped
article ld shown in FIGS. 12A to 12E is comprised of a
metal plate. It has only one seam 4 extending in the
axial direction. A single metal plate is formed into a
20 tubular shape. The tubular shaped article ld has a bent
part lOa having a bottom part 5 positioned at the
opposite side to the seam 4 in the peripheral direction
and projecting inside in the axial direction, a straight
part lOb having a bottom part 5 extending straight in the
25 axial direction and having an equal length in the
peripheral direction along the centerline s, and a taper
part lOc having a bottom part 5 extending straight in the
axial direction and increasing in length in the
peripheral direction along the centerline s. There are
30 pluralities of the bent part lOa, straight part lOb, and
taper part lOc. Further, in the bent part lOa, in any
case, the ratio Hl/H2 of the plate thickness Hl at the
seam 4 of the bent part lOa and the plate thickness H2 at
the bottom part 5 of the bent part lOa is a predetermined
35 range.
[0086] Here, when bending the U-shaped article, 1-1ith a
tubular shaped article obtained 1-1ithout compressing the
- 27 -
planned bending part of the edge along the longitudinal
direction of the U-shaped article at all in the planar
~direction, usually, Hl/H2 becomes less than Ri/(Ri+D) and
the above equation (2) is not satisfied. This is because
5 in general, at the time of bending, at the seam of the
bent part (outside of bending), a tensile stress acts, so
the plate thickness easily decreases and at the bottom
part of the bent part (inside of bending), compressive
stress acts, so~the plate thickness easily increases. As
10 opposed to~ this, in a tubular shaped article according to
the present invention, H1/H2 satisfies the above equation
(2), so at the bent part, a uniform distribution of plate
thickness can be obtained. Therefore, according to the
tubular shaped article according to the present
15 invention, not only is it possible to suppress the
occurrence of fractures at the seam and IYrinkling at the
bottom part of the bent part to a high level and
eliminate shaping defects, but also it is possible to
make the distribution of plate thickness in the
20 peripheral direction uniform.
[0087] BeloVI, the components of the tubular shaped
article according to the present invention vlill be
explained.
[0088] 1. Seam
25 The tubular shaped article according to the present
invention has only one seam extending in the axial
direction. Here, the fact that the tubular shaped article
has only one seam extending in the axial direction means
that one metal plate is shaped into a tubular shape.
30 Therefore, a tubular shaped article obtained by shaping a
metal plate in advance into a tubular shape to fabricate
a plurality of tubular members and vlelding the tubular
members not only has a plurality of seams in the
longitudinal direction, but also has seams in the
35 peripheral direction, so is not included in a tubular
shaped article according to the present invention.
[0089] At the seam, the edges may be in close contact
- 28 -
with each other or may be separated. That is, there may
be clearance in the seam. Further, the seam may also be
vlelded. If the edges of the seam are separated, the
degree of separation may be made a distance (shortest)
5 between the edges of 1 mm to 100% of the total length of
the cross-sectional U-shape.
[0090] When viewing the tubular shaped article so that
the seam is positioned right above, the seam and
centerline are preferably straight since there is
10 resistance to shaping defects, but these may also be
slightly curved.
[0091] Further, the tubular shaped article need only
be one formed by shaping a single metal plate into a
tubular shape. For example, it may be comprised of a
15 single tailored blank shaped into a tubular shape.
[0092] 2. Bent Part
The bent part is a part l·lith a bottom part positioned at
the opposite side from the above seam in the peripheral
direction and projecting to the inside in the axial
20 direction. Here, the bottom part of the tubular shaped
article means a part positioned at the opposite side from
the seam at the cross-section including the seam and
centerline. The tubular shaped article may have a single
bent part or may have several.
25 [0093] The ratio H1/H2 of the plate thickness H1 at
the seam of the bent part and the plate thickness H2 at
the bottom part of the bent part satisfies the follovling
equation (3):
H1/H2~Ri/ (Ri+D) ( 3)
30 {where in the above equation (3), Ri is the radius of
curvature at the bottom part side of the bent part, Hhile
D is the Hidth of the bent part of a cross-section
including the seam and centerline of the tubular shaped
article)
35 [0094] The plate thickness Hl at the seam of the bent
part and the plate thickness H2 at the bottom part of the
bent part may be distributed in the longitudinal
5
- 29 -
direction or peripheral direction, but preferably. is
uniform in the longitudinal direction or peripheral
direction. Here, the plate thickness Hl at the seam of
the bent part is made a plate thickness of the seam at
the center of bending in the longitudinal direction of
the tubular shaped article. Similarly, the plate
thickness H2 at the bottom part of the bent part is made
the plate thickness of the bottom part at the center of
bending in the longitudinal direction .of the tubular
10 shaped article.
[0095] Further, in the cross-section including the
seam and centerline of the tubular shaped article, the
vlidth D of the bent part (for example, see FIG. 11) ·is
made the width at the center of bending. Similarly, the
15 radius of curvature Ri at the bottom part si'de of the
bent part (for example, see same figure) is made the
radius of curvature of the intersection between the
bottom part of the bent part and the plane including the
seam and bending centerline.
20 [0096] Next, the rate of reduction of plate thickness
T of the seam of the bent part preferably satisfies the
following equation (4):
Tlard the outside of the bottom part of
said U-shaped article.
Claim 4. The method of producing a shaped article
25 according to any one of claims 1 to 3 further comprising
a third step of shaping said U-cross-section bent article
into a closed cross-section to obtain a tubular shaped
article.
Claim 5. A tooling for bending a U-shaped article in
30 a longitudinal direction so that the bottom part projects
to an inside and for obtaining a U-cross-section bent
article, said tooling provided with
a die,
a punch, and
35 pads arranged at side surfaces of said punch
and compressing, in in-plane directions, at least parts
of a planned bending part of said U-shaped article in
- 39 -
edges along the longitudinal direction of said U-shaped
article.
Claim 6. A tubular shaped article comprised of a
metal plate and including only one seam extending in an
5 axial direction, wherein
a bottom part positioned at an opposite side to
said seam in a peripheral direction includes a bent part
projecting to an inside in an axial direction, and
a ratio H1/H2 of a plate thickness· Hl .0f said
10 bent article at said seam and a plate thickness H2 of
said bent article at said bottom part satisfies a
folloHing equation (1}:
H1/H2?Ri/ (Ri+D} (1}
.(wherein in said equation (1}, Ri is a radius
15 ·of curvature of a bottom part side of the bent part, and
D is a width of the bent part at a cross-section
including a seam and a centerline of the tubular shaped
article}.