Technical field
[0001]
The present invention relates to a method for producing a panel-shaped molded article. More particularly, a method of manufacturing a motor vehicle door inner panel into a suitable panel-shaped molded article.
Priority is claimed on Japanese Patent Application No. 2016-052766 filed in Japan on March 16, 2016, which is incorporated herein by reference.
BACKGROUND
[0002]
Car door is produced mainly combining the door inner panel and a door outer panel. The automobile door, window, window driving device, acoustic speakers, and a handle or the like is attached. For housing them, space is required between the door inner panel and a door outer panel. Therefore, for example, the vertical wall portion is provided in the door inner panel. Further, when the vehicle door is closed, it is necessary to seal the interior by a door. Therefore, for example, stepped portion is provided on the vertical wall portion of the door inner panel. By the step portion of the vertical wall portion opposes the vehicle body pillar and the like, car sealing is ensured.
[0003]
Door inner panels used in automotive side door, etc., is formed by pressing a metal plate such as a steel plate. In general, since the shape of the door inner panel is complicated, in some cases significantly deforming the metal plate in molding the metal plate to the door inner panel. In this case, the molded door inner panel, cracks or wrinkles may occur. Therefore, high workability metal plate is used as a door inner panel material. For high workability metal plate has low strength, the strength of the door inner panel molded from the metal plate also decreases. Accordingly, the door inner panel, belt line reinforcement or often reinforcing member such as a door impact beam is mounted.
[0004]
Here, Patent Documents 1 to 4, a metal plate by pressing, a method of manufacturing the mobile member of the B-pillar, etc. is disclosed.
Specifically, in Patent Document 1, and welding the first molded body and a second molded body having a vertical wall portion, by processing the welded moldings by hot pressing or roll, per unit weight technology to improve the load-bearing performance is disclosed.
[0005]
In Patent Document 2, is obtained in advance the relationship between the curvature and the blank holding force of wall warping that occurs during molding, on the basis of this relationship, to impart wrinkle holding force as the curvature of the wall warp is reduced it allows high dimensional accuracy, a technique for forming a trapezoidal member high-strength steel sheet is disclosed.
[0006]
In Patent Document 3, by pressing a workpiece plate die and in conjunction with the holder of the press working apparatus, thereby preventing the occurrence of fracture or wrinkle of the work plate in the middle of molding, molding after molding completion technology to ensure the dimensional accuracy of the article is disclosed.
[0007]
In Patent Document 4, when the hot press forming, by controlling the distance between the die and the holder, suppressing technology is disclosed wrinkles of the molded article.
CITATION
Patent Document
[0008]
Patent Document 1: Japanese Patent 2013-189173 JP
Patent Document 2: Japanese Patent 2001-38426 JP
Patent Document 3: Japanese Patent 2011-147970 JP
Patent Document 4: Japanese Patent 2011-50971 No.
Summary of the Invention
Problems that the Invention is to Solve
[0009]
However, the method disclosed in Patent Documents 1 to 4 is for forming a metal plate into a lower molding difficulty shape. Therefore, by the methods disclosed in Patent Documents 1 to 4, such as a door inner panel, if the molding difficulty is high shape was molded (the vertical wall portion adjacent shape having a step portion), cracks or wrinkles may molding defects may occur.
Also, in general, the hot press forming, in comparison with the cold press forming, has high moldability, the steel sheet strength can be press-molded while suppressing molding failure. However, when performing hot press forming, it is necessary to introduce a facility for hot press forming, the cost of equipment cost, etc. is increased. Therefore, the technical significance of processing the high strength steel plate by cold press forming with high accuracy is large.
[0010]
The present invention has been made in view of the above circumstances, when forming a metal plate to press working is high molding difficulty in shape, capable of suppressing molding failure such as cracking or wrinkling panel and an object thereof is to provide a method for manufacturing Jo moldings.
Means for Solving the Problems
[0011]
In order to solve the above problems, the present invention employs the following.
(1) A method of manufacturing a panel-like molded article according to one embodiment of the present invention includes a top plate portion of the polygon, and the vertical wall portion extending from the at least two adjacent sides of the sides of the top plate portion, among the vertical wall portion, a method for producing a panel-shaped molded article having a set of at least one pair stepped portion provided on each longitudinal wall of the adjacent vertical wall portions, tensile strength more than 390 MPa 980 MPa a preparation step of preparing a blank consisting of a metal plate; subjected to press working the blank by cold, and a press forming step of forming said blank to the panel-shaped molded article; has, the press in the molding step, a die having a die engraved portion shape of the panel-shaped molded article is shaped, and in opposition to the die, a first punch having a tip surface shape of the top plate portion is shaped, cutlet adjacent to the outside of the first punch With facing the serial die, a second punch having a tip surface shape is shaped in the step portion, and adjacent to at least a portion of an outer side of the second punch, the blank holder facing the die, using a press working apparatus having the die and the blank holder, the first placing the blank between the punch and the second punch relative to the die, the blank holder, the first punch , and the second punch are relatively moved, the blank material pushing the first punch and the second punch, the blank pushed in to the blank by the second punch by the first punch completed earlier than the push to.
(2) In the aspect described in (1) above, wherein the press molding step, after the or its pushing when pushed in to the blank by the second punch is completed is completed, the blank according to the first punch it may be the start of the push to.
(3) In the aspect described in the above (1), in the press molding process, before pushing to the blank by the second punch is completed, it has begun pushing into the blank by the first punch it may be.
(4) In the aspect described in any one of the above (1) to (3), the type engraved portion of the die of the pressing device, said second punch from a reference plane facing the blank holder the depth to the opposite step surface as d1 (mm), when the depth from the reference surface to the mold bottom facing the first punch was d2 (mm), d2 ≧ 40 , and, d1 / d2
stamping apparatus 10 according to the first embodiment, and using the press working apparatus 10 'according to the second embodiment, the pressing of the blank with an opening S (see FIG. 2) assumed, it was carried out analysis of each pressing. From the analysis results, to evaluate the sheet thickness reduction rate and the curvature of the door inner panel obtained by each pressing. Here, as the present invention Example 1, assuming a press process using a press working apparatus 10 according to the first embodiment. Further, as the present invention example 2, assuming a press process using a press working apparatus 10 'according to the second embodiment. Further, as a comparative example, assuming a press process using a conventional press working apparatus 200 shown in FIG.
[0048]
[Analysis conditions]
the blank material, with five steel sheets shown in Table 1 below. As shown in Table 1, these five steel sheet, the chemical composition and tensile strength are different from each other. The thickness of these five steel sheet was set to 0.8 mm.
Taking into account the strain rate dependence of the mechanical properties, the moving speed of the first and second punch to the die was set to 40 mm / s equivalent. Punch, die, and the friction coefficient of the blank relative to the blank holder was 0.4. The analysis, using a general-purpose FEM (Finite Element Method) software (LIVERMORE SOFTWARE TECHNOLOGY Co., Ltd. under the trade name "LS-DYNA").
[0049]
[Table 1]
[0050]
Further, a molded depth of the door inner panel h2 (mm) (see FIG. 1), to verify the relationship between the effects of the present invention, the depth dimension using two different dies. More specifically, in order to mold the molded depth is shallow door inner panel (40
Next, as a second embodiment, the a press working apparatus 10 according to the first embodiment, by using the press working apparatus 10 'according to the second embodiment, the first punch and second punch and operation timing of the investigated the relationship between the sheet thickness reduction rate and curvature.
[0062]
[Analysis conditions]
the blank, of Table 1 of Example 1, the tensile strength using steel sheet 590 MPa. The thickness of the steel plate were the same 0.8mm as in Example 1.
Further, the die of the die and different dimensions used in Example 1 was one prepared. Specifically, the depth d1 is 30 mm, the depth d2 is prepared 60mm die.
Then, in each of the press working apparatus 10 and the press working apparatus 10 ', the second position of the first punch 12 at the time the punch 13 is poked bottom (when the second punch 13 has reached the bottom dead center) (Die 15 distance from the reference surface 16C to the front end surface 12A of the first punch 12 p1: under conditions of varying see FIG. 3B and FIG. 5C), was prepared the door inner panel 1.
These other analysis conditions are the same as the analysis conditions of Example 1.
[0063]
[Evaluation Method]
Using the above equation (1), was investigated thick plate reduction index of the top plate portion. From this distribution, the maximum value of the sheet thickness reduction rate of the top plate portion. This will not, be the same as the evaluation method of Example 1.
[0064]
[Analysis Result]
shows the analysis results in FIG. 6, the horizontal axis represents the ratio p1 / d1 of p1 for d1, the vertical axis represents the absolute value of the sheet thickness reduction rate (%) and curvature (1 / mm). Incidentally, the plate thickness reduction rate (%) is the maximum value of the sheet thickness reduction rate of the top plate portion.
Here, p1 / d1 is less than one plot shows the results obtained with the press working apparatus 10. The plot of p1 / d1 = 1, when the pushing of the second punch 13 is completed, the height position of the distal end surface 12A of the first punch 12, and the height position of the distal end surface 13A of the second punch 13 There is a result of the case of producing a door inner panel in identical is condition (see FIG. 3B). The condition p1 / d1 <1 plot, when the second punch 13 is poked bottom height position of the distal end surface 12A of the first punch 12 is located between the reference surface 16C and the stepped surface 16B of the die 15 is a (0 1 shows the results obtained with the press working apparatus 10 '. As described above, in this embodiment, since the depth d1 is 30 mm, the depth d2 was used 60mm die, plot of p1 / d1 = 2, the first punch 12 and second punch 13 If push is completed at the same time, i.e., it corresponds to case produced using the conventional press working apparatus 200 (see FIG. 4).
[0065]
As shown in FIG. 6, the boundary of p1 / d1 = 1, as the p1 / d1 is large, the curvature is increased. From this result, towards the stamping device 10 (first embodiment), as compared with the pressing device 10 '(second embodiment), it was confirmed that the occurrence of wrinkles can be suppressed.
On the other hand, the boundary of p1 / d1 = 1, as the p1 / d1 is large, the thickness reduction rate of the top plate is reduced. From this result, towards the stamping device 10 '(second embodiment), as compared with the pressing device 10 (first embodiment), it was confirmed that the cracking of the top plate portion can be suppressed.
Furthermore, in the case of 1.1 ≦ p1 / d1 ≦ 1.7, thickness reduction ratio and 15% or less, the curvature is 0.01 mm -1 becomes less. That is, by setting p1 / d1 in the range, cracking of the top plate portion, and was found to be suppressed both wrinkles of the stepped portion.
[0066]
Having described the embodiments of the present invention, these embodiments have been presented by way of example, the scope of the present invention is not limited only to these embodiments. These embodiments described herein may be embodied in other various forms, without departing from the spirit of the invention, various omissions, substitutions, and changes can be made. Such embodiments and modifications as would fall within the scope and spirit of the invention, and are included in the invention and the scope of their equivalents are claimed.
[0067]
For example, in the first embodiment, four adjacent vertical wall section 4 (3 sets of vertical wall portion 4) showed a case having a step portion 5. However, as shown in FIG. 7, three adjacent vertical wall section 4 (two pairs of vertical wall portion 4) may be a door inner panel having a stepped portion 5.
[0068]
Further, for example, in the above-described first embodiment, one of the first punch 12, by pressing device 10 and a one second punch 13 has been described a case of manufacturing the door inner panel 1. However, for example, the second punch 13, may be divided into a plurality. That may be used and one of the first punch, a press working apparatus having two second punch.
[0069]
Further, for example, in the above-described first embodiment, the press working apparatus 10, which has a punch 11 and the blank holder 14 upward, showing the case where a die 15 downward. However, the punch 11 and the blank holder 14 may be vertically inverted arrangement of the die 15. That is, the press working apparatus 10, the punch 11 and the blank holder 14 may be configured to move relative to the die 15.
[0070]
Further, for example, in the above-described first embodiment, the top plate portion 2 of the door inner panel 1, showing a case having one opening 3. However, the top plate portion 2 of the door inner panel 1 may have a plurality of openings 3.
[0071]
Further, for example, the case of using the steel plate as the blank material S used in the manufacturing method according to the above embodiments, the steel sheet may be tailored blanks. Tailored blank is tailored welded blanks (hereinafter, also referred to as "TWB") and, tailored rolled blanks (hereinafter, also referred to as "TRB") are classified into. TWB is obtained by integrating thickness, by welding the tensile strength and the like different kinds of steel sheets (e.g., butt welding). Meanwhile, TRB by changing the distance between the rolling rolls when producing the steel sheet, in which varying thickness. With this tailored blank, it is possible to place only the high strength required, it is also possible to reduce the plate thickness. Further, the panel-like molded article using a tailored blank can be applied to the door inner panel for an automobile. Thus, it is possible to improve the crashworthiness of the door inner panel, further views of the lighter.
[0072]
In the above embodiments showed the case of producing the automotive door inner panel as a panel-shaped molded article. However, not limited only to the above applications, for example, can be used in a vehicle, construction machine or aircraft or the like.
DESCRIPTION OF SYMBOLS
[0073]
1: a door inner panel (panel-shaped molded
article) 2: top plate
3: opening
4: vertical wall portion
4A: top plate portion side vertical wall
4B: flange portion side vertical wall
5: the stepped portion
6: flange
10: stamping device
12: first punch
13: the second punch
14: blank holder
15: die
BL: beltline
S: blank
The scope of the claims
[Requested item 1]
A top plate portion of the polygon, and the vertical wall portion extending from the at least two adjacent sides of the sides of the top plate portion, of the vertical wall portion, adjacent the vertical wall portion set of at least one pair of a method of manufacturing a panel-shaped molded article having a stepped portion provided on each longitudinal wall,
preparation step of preparing a blank tensile strength is from the metal plate 980MPa or 390MPa and;
the cold subjected to press working the blank, the blank and a press forming step of forming the panel-shaped molded product;
has,
in the press molding process,
a mold engraved portion shape of the panel-shaped molded article is shaped a die having,
and to face the die, a first punch having a tip surface shape of the top plate portion is shaped,
together with facing the adjacent and the die to the outside of the first punch, the shape of the step portion is shaped A second punch having an end face,
and adjacent to at least a portion of an outer side of the second punch, a blank holder which faces the die
using a press working apparatus having,
and the die, the blank holder, wherein the blank is disposed between the first punch and the second punch relative to the die, the blank holder, the first punch, and the second punch relatively moved, the blank said first punch and push the second punch,
the push to the blank by the second punch is completed earlier than the pushing to the blank by the first punch
panel-shaped molded article, characterized in that the method of production.
[Requested item 2]
Wherein the press molding step, pushing into the blank by the second punch when completed or after the pushing is completed, push to the blank by the first punch begins
claim 1, characterized in that panel-shaped molded article manufacturing method according to.
[Requested item 3]
In the press molding step, before pushing to the blank by the second punch is completed, push to the blank by the first punch begins
panel-like molding according to claim 1, characterized in that method of manufacturing the goods.
[Requested item 4]
Wherein said mold engraved portion of the die of the press working apparatus,
wherein a depth from the blank holder facing the reference surface to the step surface facing the second punch and d1 (mm), the first from the reference plane when the depth to mold bottom punch facing was d2 (mm), d2 ≧ 40 , and satisfies d1 / d2 <0.8
any one of claims 1 to 3, wherein the panel-shaped molded article manufacturing method according to.
[Requested item 5]
The blank material is a steel
panel-shaped molded article manufacturing method according to any one of claims 1 to 4, characterized in that.
[Requested item 6]
The steel sheet is a tailored blank
panel-shaped molded article manufacturing method according to claim 5, characterized in that.
[Requested item 7]
The blank has an opening at a position corresponding to the top plate
panel-shaped molded product manufacturing method according to any one of claims 1 to 6, characterized in that.