Title of the invention: manufacturing method of press-molded product, press-molded product and press-molding apparatus
Technical field
[0001]
The present invention relates to a method for manufacturing a press-molded product, a press-molded product, and a press-molding apparatus.
This application claims priority based on Japanese Patent Application No. 2019-172982 filed in Japan on September 24, 2019, and the contents thereof are incorporated herein by reference.
Background technology
[0002]
For electric vehicles, it is necessary to install a large capacity battery. The battery is housed in, for example, a box-shaped battery case in which vertical walls rise from the four sides of a rectangular bottom plate under the seat (see, for example, Patent Document 1). In such a battery case, strength and impact resistance are required in order to prevent damage to the battery when a vehicle collides. On the other hand, if the member thickness is increased too much for strength and impact resistance, the weight becomes large and the fuel efficiency is lowered. Therefore, a high-strength material is used as the steel material used for the battery case. Further, in such a battery case, it is required to mount as many batteries as possible in the minimum space due to the space limitation inside the vehicle. That is, it is required to make the volume ratio of the battery that can be accommodated in the battery case to the capacity of the battery case itself as high as possible. Therefore, in the box-shaped member constituting the battery case, the curved shape of the cross section of the ridgeline portion formed by the bottom plate and the vertical wall and the ridgeline portion formed by the vertical walls should have a radius of curvature as small as possible. Is required.
[0003]
As one of the methods for manufacturing a box-shaped battery case as described above, there is a method of press forming a steel plate. Specifically, the steel plate is pressed with a mold corresponding to the shape of the battery case to perform drawing molding, and a portion to be a vertical wall is formed. Such press molding has an advantage in that a battery case having a desired shape can be manufactured with a minimum number of members and a minimum number of steps, as compared with the case of welding members or assembling a plurality of members. There is.
Prior art literature
Patent documents
[0004]
Patent Document 1: Japanese Patent Application Laid-Open No. 2017-196952
Outline of the invention
Problems to be solved by the invention
[0005]
However, when the corner where the three ridges of the bottom plate of a box-shaped battery case and the two vertical walls are connected to each other and the ridges to which the vertical walls are connected is formed by press molding is formed. Has the following problems. That is, in a work material formed in a rectangular shape such as a steel plate, a portion to be a vertical wall is formed by drawing from both edges connected to each other, and at that time, both vertical walls are formed in a corner portion. The material required for forming the above cannot flow into the vertical wall portion, resulting in a decrease in member thickness. In particular, the smaller the radius of curvature of the curved shape of the cross section of the ridgeline portion, the more the material is constrained to the ridgeline portion and sufficient material cannot flow into the vertical wall portion, and the decrease in member thickness becomes more remarkable. .. Further, if a high-strength material is used in order to achieve both strength and impact resistance and weight reduction, molding becomes even more difficult. For this reason, the shape has a corner where each ridge line connecting the bottom plate of a box-shaped battery case and each of the two vertical walls and the ridge line connecting the vertical walls intersects with each other. , A method of press molding while suppressing a decrease in member thickness has been desired.
[0006]
Therefore, the present invention has been made in view of the above-mentioned circumstances, and has three ridge lines, one is a ridge line in which the bottom plate and each of the two vertical walls are connected, and the other is a ridge line in which the vertical walls are connected to each other. The present invention provides a method for manufacturing a press-molded product, a press-molded product, and a press-molding apparatus capable of press-molding the intersecting corners while suppressing a decrease in member thickness.
Means to solve the problem
[0007]
In order to solve the above problems, the present invention employs the following means.
That is, the method for manufacturing a press-molded product according to one aspect of the present invention is a plate having a first edge portion and a second edge portion extending in a direction intersecting the first edge portion and connected to the first edge portion. From the material to be processed, the substrate portion, the first rising portion that rises from the substrate portion on the first edge portion side via the first ridge line and extends to the second edge portion, and the upper edge of the first rising portion. The first step of forming the first band portion extending to the opposite side of the substrate portion through the second ridge line extending along the portion to the second edge portion, and the substrate portion along the second edge portion. The first band-shaped range including the first rising portion and the second edge of the first band is sandwiched between the first upper mold and the first lower mold from both sides, and adjacent to the first range. The second range including the substrate portion, the first rising portion, and the first band portion is sandwiched between the second upper mold and the second lower mold from both sides, with respect to the second upper mold and the second lower mold. The first upper mold and the first lower mold are relatively moved to the side where the first rising portion rises with respect to the substrate portion, and the whole is said between the first lower mold and the second upper mold. It is provided with a second step of standing up on the same side as the first rising portion and forming a second rising portion connected to the first rising portion via a vertical ridge line. In the second step, the second rising portion is provided. Of these, the portion connected to the vertical ridge line is shear-deformed.
According to this method, in the first step, a first rising portion, which is one vertical wall portion, and a first band portion are formed from the work material on the first edge side of the plate-shaped work material. do. Next, in the second step, the first range is sandwiched between the first upper mold and the first lower mold on the second edge side of the work material, and the second range is sandwiched between the second upper mold and the second lower mold. By sandwiching the mold with the second upper mold and the second lower mold and moving the first upper mold and the first lower mold relative to each other, a second rising portion to be the other vertical wall portion is formed. Here, in the range where the substrate portion is in the state after the first step, the second rising portion is formed from a part of the material of the portion sandwiched between the first upper mold and the first lower mold. Therefore, it is possible to suppress the decrease in the member thickness of the second rising portion by flowing it into the second rising portion. In addition, in the range that is the first band part in the state after the first step, similarly, a part of the material of the part sandwiched between the first upper mold and the first lower mold is covered by the second rising part. By flowing into the second rising portion as it is formed, it is possible to suppress a decrease in the member thickness of the second rising portion. On the other hand, in the portion that becomes the second rising portion in the state after the first step, between the range that is the substrate portion and the range that is the first band portion, that is, the first standing portion at the second rising portion. At the part connected to the vertical ridge line where the upper part and the second rising part are connected, the part is sheared and deformed in the second step to follow the formation of the second rising part while suppressing the change in the member thickness. It can be plastically deformed into a desired shape.
[0008]
Further, in the above-mentioned method for manufacturing a press-molded product, the work material after the second step is sandwiched between the third upper mold and the third lower mold with the first ridge line as a boundary. At the same time, the substrate portion side is sandwiched between the fourth upper mold and the fourth lower mold, and the third upper mold and the third lower mold are relatively moved with respect to the fourth upper mold and the fourth lower mold. A third step of increasing the rising height of the first rising portion is provided. In the third step, the second rising portion is adjacent to the first band portion and is sheared and deformed in the second step. The range adjacent to the above range may be shear-deformed in the direction along the second edge.
According to this method, after the second step is carried out, the first band portion side is sandwiched between the third upper mold and the third lower mold, and the substrate portion side is sandwiched between the fourth upper mold and the fourth lower mold. The height of the first rising part is increased by moving the third upper mold and the third lower mold relative to the mold and the fourth lower mold. Therefore, the height of the first rising portion in the first step can be suppressed, the amount of shear deformation in one machining in the second step can be suppressed, and the first rising portion is formed to a desired height. can do. At this time, the material required for raising the first rising portion is inflowed from the first belt portion to suppress the decrease in the member thickness of the first rising portion, but the second of the second rising portions is In the part adjacent to the one band part, the range adjacent to the area sheared in the second step is sheared and deformed in the direction along the second edge, so that the change in the member thickness is suppressed and the upper part of the first riser. It can be plastically deformed into a desired shape following the formation.
[0009]
Further, in the above-mentioned method for manufacturing a press-molded product, the second step is further carried out after the third step is carried out, and the second step and the third step are alternately carried out at least once each. May be.
According to this method, by alternately performing the second step and the third step at least once, the formation of the first rising portion and the second rising portion can be divided into a plurality of times, whereby in each step. It is possible to suppress the amount of shear deformation in one processing.
[0010]
Further, in the above-mentioned method for manufacturing a press-molded product, the work material is provided with the first edge portion and the second edge portion in pairs so as to face each other, and the first step is performed in pairs. Perform for each of the first edges that form a pair, perform the second step for each of the paired second edges, and perform the third step for each of the paired first edges. Then, the pair of the first rising portion and the pair of the second rising portions may form a box body opened on one side so as to surround the substrate portion.
According to this method, it is possible to form a box body having an opening on one side, such as a battery case.
[0011]
Further, in the above-mentioned method for manufacturing a press-molded product, the second band portion sandwiched between the first upper mold and the first lower mold after the last step of the second step and the third step. And, at the height position between the first band portion, the fourth step of cutting the first rising portion along the first edge portion, and after the fourth step is carried out, the first rising portion of the first rising portion. Among them, the portion rising above the first band portion may be provided with a fifth step of bending the portion so as to be a surface continuous with the first band portion.
According to this method, the flange-shaped band portion connected to each upper edge of the first rising portion and the second rising portion can be formed so as to be a continuous surface.
[0012]
Further, in the above-mentioned method for manufacturing a press-molded product, in the second step, the first upper mold and the first lower mold are used in the first band portion and the first rising portion of the work material, respectively. It is composed of an end mold that sandwiches at least the end mold and a central mold that is arranged at a distance from the end mold and sandwiches the substrate portion side from the first rising portion of the work material. As the upper mold and the first lower mold are moved relative to the second upper mold and the second lower mold, the end molds of the first upper mold and the first lower mold are brought closer to the central mold. It may be moved so as to make it move.
According to this method, by moving the end molds relative to the central mold so as to narrow the gap between them, they are located between the central mold and the end mold in the direction along the first edge, and the second The part of the rising part connected to the vertical ridge can be effectively sheared and deformed.
[0013]
Further, in the above method for manufacturing a press-molded product, the gap between the end mold and the central mold is formed so as to have a portion along the second edge portion in the middle of the direction along the first edge portion. It may be a thing.
According to this method, in the second step, the portion of the second rising portion connected to the vertical ridge can be effectively sheared and deformed according to the size of the gap, and the gap is formed. It is possible to prevent the surface pressure of the first upper die and the first lower die from decreasing in the above range.
[0014]
Further, in the above method for manufacturing a press-molded product, a concave curve shape having a radius of curvature of 20 mm or less may be formed with the inner portion of the vertical ridge line viewed from above.
According to this method, the volume of the space surrounded by the substrate portion and the first rising portion and the second rising portion can be increased by setting the concave curve shape of the inner portion of the vertical ridge line to have a radius of curvature of 20 mm or less.
[0015]
Further, in the above-mentioned method for manufacturing a press-molded product, in the second step, the surface pressure of sandwiching the material to be processed by the first upper mold and the first lower mold, and the second upper mold and the second lower mold. The surface pressure for sandwiching the work material by the mold is the surface obtained based on the formula (1).It may be pressure.
P = Y / 590 x t / 1.4 x P0 (1)
However, P: Surface pressure (MPa) that sandwiches the work material
Y: Tensile strength (MPa) of the work material
T: Thickness of work material (mm)
P0: Reference surface pressure = 0.1 MPa
According to this method, the second step can be carried out by applying an appropriate surface pressure according to the strength and thickness of the material to be processed.
[0016]
Further, in the above method for manufacturing a press-formed product, the tensile strength of the steel material forming the work material may be 440 MPa or more.
According to this method, it is possible to provide a high-strength press-molded product while suppressing a decrease in member thickness.
[0017]
Further, in the above-mentioned method for manufacturing a press-molded product, the shear-deformed portion may be formed to have a thickness of 85% or more of the thickness of the work material before the first step is carried out.
According to this method, it is possible to provide a press-molded product having high strength and a smaller roundness at the corner where the three ridges intersect.
[0018]
Further, in the above-mentioned method for manufacturing a press-molded product, only the second rising portion may be shear-deformed.
According to this method, it is possible to provide a high-strength press-molded product while further suppressing a decrease in member thickness.
[0019]
Further, the press-molded product according to one aspect of the present invention includes a plate-shaped bottom plate portion, a first wall portion rising from the first side edge of the bottom plate portion via the first ridge line, and the first wall portion of the bottom plate portion. From the second side edge extending in the direction intersecting the side edge and connected to the first side edge, the whole rises to the same side as the first wall portion via the second ridge line, and is vertical to the first wall portion. It is provided with a second wall portion connected via a ridge line, and the thickness of the first wall portion and the second wall portion is 85% or more of the thickness of the center of the bottom plate portion.
The radius of curvature of the inner part of the first ridge line and the radius of curvature of the inner part of the second ridge line are different.
According to this configuration, the thickness of the first wall portion and the second wall portion is 85% or more of the thickness of the center of the bottom plate portion, the decrease in the member thickness is suppressed, and the first wall portion and the second wall portion are formed. It is possible to secure a constant and predetermined strength in each portion including the portion near the corner where the one wall portion is connected.
[0020]
Further, in the above press-molded product, from the upper edge of the first wall portion, the first flange extending from the upper edge of the first wall portion to the opposite side of the bottom plate portion, and from the upper edge of the second wall portion. A second flange extending to the side opposite to the bottom plate portion with respect to the second wall portion and integrally connecting with the first flange is provided, and the thickness of the first flange and the second flange is the thickness of the bottom plate portion. It may be 85% or more of the central thickness.
According to this configuration, the thickness of the first flange and the second flange is 85% or more of the thickness of the center of the bottom plate portion, the decrease in the member thickness is suppressed, and a constant and predetermined strength is ensured. be able to.
[0021]
Further, in the above press-molded product, the radius of curvature of the inner portion of the third ridge line connecting the first wall portion and the first flange and the fourth ridge line connecting the second wall portion and the second flange. The radius of curvature of the inner part of the may be different.
According to this configuration, even if a material having low elongation is used in each part including the part near the corner where the first wall part and the first wall part are connected while ensuring a constant and predetermined strength. It can be plastically deformed without breaking, and in particular, the height of the wall portion can be made higher.
[0022]
Further, in the above press-molded product, the inner portion of the vertical ridge line may be formed in a curved shape having a radius of curvature of 20 mm or less when viewed from above.
According to this configuration, the volume of the space surrounded by the substrate portion and the first rising portion and the second rising portion can be increased by setting the concave curve shape of the inner portion of the vertical ridge line to have a radius of curvature of 20 mm or less.
[0023]
Further, in the above-mentioned press-formed product, the tensile strength of the steel material forming the bottom plate portion, the first wall portion and the second wall portion may be 440 MPa or more.
According to this configuration, it is possible to provide a high-strength press-molded product.
[0024]
Further, in the press molding apparatus according to one aspect of the present invention, the first bottom surface, the first wall surface rising from the first bottom surface, and the first flange extending from the upper edge of the first wall surface to the side opposite to the first bottom surface. From the first lower mold having a surface, the first upper mold which is formed in a shape corresponding to the first lower mold and sandwiches the work material between the first lower mold, the second bottom surface, and the second bottom surface. A second lower mold having a rising second wall surface and a second flange surface extending from the upper edge of the second wall surface to the side opposite to the second bottom surface, and a second lower mold arranged adjacent to the first lower mold, and the above. The distance between the second upper mold, which is formed in a shape corresponding to the second lower mold and sandwiches the work material between the second lower mold, and the first upper mold and the second upper mold, and the first. While maintaining the distance between the first lower mold and the second lower mold, the second upper mold and the second lower mold are the first upper mold with respect to the first upper mold and the first lower mold. A drive unit for relatively moving from the mold side to the first lower mold side is provided.
According to this configuration, the work material on which the above-mentioned substrate portion, first rising portion and first band portion are formed is sandwiched between the first lower mold and the first upper mold, and the second upper mold and the second lower mold are formed. The second step can be carried out by sandwiching the mold with the mold and moving the second upper mold and the second lower mold relative to the first upper mold and the first lower mold by the driving unit.
[0025]
Further, in the press forming apparatus, the first lower mold has a space between the lower end mold including at least the first wall surface and the first flange surface and the lower end mold, and is among the workpieces. A lower center type that sandwiches a portion opposite to the second flange surface with respect to the second wall surface is provided, and the first upper type is an upper end type corresponding to the lower end type of the first lower type. The lower central mold of the first lower mold and the corresponding upper central mold are provided, and the drive unit has the second upper mold and the second lower mold with respect to the first upper mold and the first lower mold. As the molds are moved relative to each other, the lower end mold and the upper end mold are moved closer to the lower center mold and the upper center mold for each of the first lower mold and the first upper mold.
According to this configuration, the lower end type and the upper end type are moved closer to the lower center type and the upper center type for each of the first lower mold and the first upper mold by the drive unit, so that the substrate portion is formed. Shear deformation is performed between the range and the range that is the first zone, that is, the portion connected to the vertical ridge line connecting the first rising portion and the second rising portion in the second rising portion. Therefore, it is possible to plastically deform to a desired shape by following the formation of the second rising portion while suppressing the change in the member thickness.
[0026]
Further, in the above press molding apparatus, a third bottom surface, a third wall surface rising from the third bottom surface, and a third flange surface extending from the upper edge of the third wall surface to the side opposite to the third bottom surface are provided. The third upper mold, which is formed in a shape corresponding to the third lower mold and sandwiches the work material between the lower mold, the fourth bottom surface, and the fourth wall surface rising from the fourth bottom surface. A fourth lower mold having a fourth flange surface extending from the upper edge of the fourth wall surface to the opposite side of the fourth bottom surface and arranged adjacent to the third lower mold, and the fourth lower mold. Further provided with a fourth upper mold formed in a corresponding shape and sandwiching the work material with the fourth lower mold, the first lower mold, the first upper mold, the second lower mold and the second lower mold are provided. The set of the upper mold can be exchanged with the set of the third lower mold, the third upper mold, the fourth lower mold and the fourth upper mold, and the drive unit is the third upper mold and the said fourth upper mold. The fourth upper mold and the fourth lower mold may be relatively moved with respect to the third lower mold.
According to this configuration, from the set of the first lower type, the first upper type, the second lower type and the second upper type, the set of the third lower type, the third upper type, the fourth lower type and the fourth upper type. The third step can be carried out by moving the fourth upper mold and the fourth lower mold relative to the third upper mold and the third lower mold by the driving unit.
Effect of the invention
[0027]
According to the present invention, the corner where the three ridges of the bottom plate and each of the two vertical walls connected to each other and the ridges connected to the vertical walls intersect is pressed by suppressing the decrease in member thickness. Can be molded.
A brief description of the drawing
[0028]
FIG. 1 is an upward perspective view showing an example of a press-molded product manufactured by the method for manufacturing a press-molded product according to the first embodiment.
FIG. 2 is a first-direction cross-sectional view taken along the cross-sectional line I-I shown in FIG.
FIG. 3 is a cross-sectional view taken in the second direction broken along the cross-sectional line II-II shown in FIG.
FIG. 4 is an enlarged partial perspective view of the vicinity of the vertical ridge line shown in FIG.
FIG. 5 is a flow chart showing a method for manufacturing a press-molded product according to the first embodiment.
FIG. 6 is an upward perspective view showing a blank used in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 7 is an upward perspective view showing a mold used in the first step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 8 is an upward perspective view showing a first intermediate press-molded product after the first step is carried out in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 9 is a first-direction cross-sectional view taken along the cross-sectional line III-III shown in FIG.
FIG. 10 is an upward perspective view showing a mold used in the second step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 11 is a downward perspective view showing an upper mold among the molds used in the second step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 12 is an upward perspective view showing a lower mold among the molds used in the second step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 13 is an upward perspective view showing a state of a mold in the second step of the method for manufacturing a press-molded product according to the first embodiment, in which (a) before the second step is carried out and (b) the second step. The state during the implementation and (c) after the implementation of the second step are shown.
FIG. 14 is an upward perspective view showing a state of an intermediate press-molded product in the second step of the method for manufacturing a press-molded product according to the first embodiment, in which (a) before the second step is performed and (b) first. The states during the implementation of the two processes and (c) after the implementation of the second process are shown.
15 is a first-direction cross-sectional view taken along the cross-sectional line IV-IV shown in FIG. 14, where (a) before the second step is carried out, (b) the second step is being carried out, and (c) the second step. The state after the implementation is shown respectively.
FIG. 16 is an upward perspective view showing a second intermediate press-molded product after the second step is performed in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 17 is an upward perspective view showing a mold used in the third step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 18 is a downward perspective view showing an upper mold among the molds used in the third step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 19 is an upward perspective view showing a lower mold among the molds used in the third step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 20 is an upward perspective view showing a state of a mold in a third step of the method for manufacturing a press-molded product according to the first embodiment, in which (a) before the third step is carried out and (b) the third step. The state after the implementation is shown respectively.
FIG. 21 is an upward perspective view showing a state of an intermediate press-molded product in the third step of the method for manufacturing a press-molded product according to the first embodiment, in which (a) before the third step is performed and (b) first. The state after the three steps are carried out is shown respectively.
22 is a first-direction cross-sectional view taken along the cross-sectional line IV-IV shown in FIG. 21, showing states (a) before the third step and (b) after the third step, respectively. ..
FIG. 23 is an upward perspective view showing a third intermediate press-molded product after the third step is performed in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 24 is an upward perspective view showing a fourth intermediate press-molded product after the fourth step is performed in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 25 is an upward perspective view showing a mold used in the fifth step in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 26 is a second-direction cross-sectional view taken along the cross-sectional line VV shown in FIG. 25.
[Fig. 27] Pressing of the first embodiment It is a partial perspective view which showed the 5th intermediate press-molded article after the 5th process execution in the manufacturing method of a shaped article.
FIG. 28 is an upward perspective view showing a first modification of the press-molded product manufactured by the method for manufacturing the press-molded product according to the first embodiment.
FIG. 29 is an upward perspective view showing a second modification of the press-molded product manufactured by the method for manufacturing the press-molded product according to the first embodiment.
FIG. 30 is a first-direction cross-sectional view showing a third modification of a deformation mode of shear deformation carried out in the second step of the method for manufacturing a press-molded product according to the first embodiment.
FIG. 31 is a first-directional cross-sectional view showing a fourth modification of a deformation mode of shear deformation carried out in the second step of the method for manufacturing a press-molded product according to the first embodiment.
FIG. 32 shows an outline of the press molding apparatus of the second embodiment, which is an apparatus used in the second step in the method of manufacturing the press molded product of the first embodiment, and is the cross-sectional line VII-VII of FIG. 33. It is a cross section broken in.
FIG. 33 shows an outline of the press molding apparatus according to the second embodiment, and is an apparatus used in the second step in the method for manufacturing a press molded product according to the first embodiment, wherein the cross-sectional line VI-VI of FIG. 32 is shown. It is a cross section broken in.
FIG. 34 shows an outline of the press molding apparatus according to the second embodiment, and is an apparatus used in the third step in the method for manufacturing a press molded product according to the first embodiment, wherein the cross-sectional line IX-IX of FIG. 35 is shown. It is a cross section broken in.
FIG. 35 shows an outline of the press molding apparatus of the second embodiment, and is an apparatus used in the third step in the method of manufacturing the press molded product of the first embodiment, which is the cross-sectional line VIII-VIII of FIG. 34. It is a cross section broken in.
FIG. 36 shows an outline of a press molding apparatus according to a modification of the second embodiment, and is an apparatus used in the second step in the method for manufacturing a press molded product according to the first embodiment.
FIG. 37 is an upward perspective view showing the analysis result of strain of the second intermediate press-molded product after the second step in the method for manufacturing the press-molded product of the first embodiment.
FIG. 38 is a graph showing the relationship between the minimum main strain and the maximum main strain of the second intermediate press-molded product after the second step is performed in the method for manufacturing the press-molded product of the first embodiment.
FIG. 39 is an upward perspective view showing the analysis result of the thickness of the second intermediate press-molded product after the second step in the method for manufacturing the press-molded product of the first embodiment.
FIG. 40 is an upward perspective view showing the analysis result of strain of the third intermediate press-molded product after the third step in the method for manufacturing the press-molded product of the first embodiment.
FIG. 41 is a graph showing the relationship between the minimum main strain and the maximum main strain of the third intermediate press-molded product after the third step is performed in the method for manufacturing the press-molded product of the first embodiment.
FIG. 42 is an upward perspective view showing the analysis result of the thickness of the third intermediate press-molded product after the third step in the method for manufacturing the press-molded product of the first embodiment.
FIG. 43 is an upward perspective view showing an analysis result of the thickness of a completed press-molded product in the method for manufacturing a press-molded product according to the first embodiment.
FIG. 44 is a table showing analysis results of the thickness of the press-molded product when the radius of curvature R3 of the inner portion of the vertical ridge line is 5 mm in the method for manufacturing the press-molded product of the second embodiment.
FIG. 45 is a table showing analysis results of the thickness of the press-molded product when the radius of curvature R3 of the inner portion of the vertical ridge line is 10 mm in the method for manufacturing the press-molded product of the second embodiment.
FIG. 46 is a table showing analysis results of the thickness of the press-molded product when the radius of curvature R3 of the inner portion of the vertical ridge line is 15 mm in the method for manufacturing the press-molded product of the second embodiment.
FIG. 47 is a table showing analysis results of the thickness of the press-molded product when the radius of curvature R3 of the inner portion of the vertical ridge line is 20 mm in the method for manufacturing the press-molded product of the second embodiment.
Embodiment for carrying out the invention
[0029]
(First Embodiment)
Hereinafter, the first embodiment according to the present invention will be described with reference to FIGS. 1 to 27. FIG. 1 shows an example of a press-molded product 100 manufactured by the method for manufacturing a press-molded product 100 of the present embodiment. As shown in FIG. 1, the press-molded product 100 of the present embodiment is, for example, a battery accommodating case arranged below a seat in an electric vehicle and accommodating a battery. As shown in FIGS. 1 to 4, the press-molded product 100 includes a bottom plate portion 101, a first wall portion 110 and a second wall portion 120 arranged along the side edges of the bottom plate portion 101, and a first wall portion. It includes a first flange 130 and a second flange 140 arranged along the upper edge of the 110 and the second wall portion 120. The bottom plate portion 101 is formed in a plate shape having an upper surface 102 and a lower surface 103. In the present embodiment, the bottom plate portion 101 is formed in a rectangular shape having a pair of first side edges 101a and a pair of second side edges 101b orthogonal to the first side edge 101a. Further, a groove 104 extending along the second side edge 101b is formed on the upper surface 102 of the bottom plate portion 101. A plurality of grooves 104 are arranged at intervals along the first side edge 101a. Further, on the lower surface 103 of the bottom plate portion 101, a ridge 105 extending along the second side edge 101b corresponding to the groove 104 is formed. In the following, the direction in which the first side edge 101a extends is the first direction X, the direction in which the second side edge 101b extends and is orthogonal to the first direction X is the second direction Y, the first direction X and the second direction Y. The direction orthogonal to, that is, the vertical direction orthogonal to the upper surface 102 and the lower surface 103 of the bottom plate portion 101 is referred to as a third direction Z.
[0030]
As shown in FIG. 1, the pair of first wall portions 110 rises upward from the first side edge 101a located on both sides of the second direction Y in the bottom plate portion 101 toward the upper side of the third direction Z. In top view (third direction Z view), the edges of the bottom plate portion 101 on both sides of the second direction Y are defined as the first side edge 101a. The first wall portion 110 and the bottom plate portion 101 are connected via the first ridge line 106. The first wall portion 110 has a first inner surface 111 connected to the upper surface 102 of the bottom plate portion 101, and a first outer surface 112 connected to the lower surface 103 of the bottom plate portion 101. As shown in FIG. 2, the first ridge line 106 is formed in a concave curve shape at an inner portion where the upper surface 102 of the bottom plate portion 101 and the first inner surface 111 of the first wall portion 110 are connected. Further, the first ridge line 106 is formed in a convex curve shape at an outer portion where the lower surface 103 of the bottom plate portion 101 and the first outer surface 112 of the first wall portion 110 are connected. The radius of curvature R1 of the inner portion of the first ridge line 106 is preferably 40 mm or less in terms of increasing the capacity that can be accommodated inside the press-molded product 100. Furthermore, the radius of curvature R1 of the inner portion of the first ridge line 106 is 20 mm or less, and the geometric structure of the corner where the three ridge lines intersect is composed of a plane, and the internal filler / material has a geometric structure. From the viewpoint of protection from impact force, it is preferable because it can be used even with a high-strength material. Further, the pair of second wall portions 120 rise from the second side edges 101b located on both sides of the first direction X in the bottom plate portion 101 toward the upper side of the third direction Z. In top view (third direction Z view), the edges of the bottom plate portion 101 on both sides of the first direction X are referred to as the second side edge 101b. The second wall portion 120 and the bottom plate portion 101 are connected via a second ridge line 107. The second wall portion 120 has a second inner surface 121 connected to the upper surface 102 of the bottom plate portion 101 and a second outer surface 122 connected to the lower surface 103 of the bottom plate portion 101. As shown in FIG. 3, the second ridge line 107 is formed in a concave curve shape at the inner portion where the upper surface 102 of the bottom plate portion 101 and the second inner surface 121 of the second wall portion 120 are connected. Further, the second ridge line 107 is formed in a convex curve shape at an outer portion where the lower surface of the bottom plate portion 101 and the second outer surface 122 of the second wall portion 120 are connected. The radius of curvature R2 of the inner portion of the second ridge line 107 is preferably 20 mm or less in terms of increasing the capacity that can be accommodated inside the press-molded product 100. Furthermore, the radius of curvature R2 of the inner portion of the second ridge line 107 must be 10 mm or less, and the structure of the corner portion where the three ridge lines intersect, which is composed of a flat surface, is a high-strength material and can be cut / joined. It is preferable because it can be easily established as a structure composed of expandable surfaces that do not require overlapping. Further, as shown in FIG. 4, the first wall portion 110 and the second wall portion 120 are connected via a vertical ridge line 108 extending in the third direction Z. As shown in FIG. 4, the vertical ridge line 108 is formed in a concave curve shape at the inner portion where the first inner surface 111 and the second inner surface 121 are connected. Further, the vertical ridge line 108 is formed in a convex curve shape at an outer portion where the first outer surface 112 and the second outer surface 122 are connected. The radius of curvature R3 of the inner portion of the vertical ridge line 108 is preferably 20 mm or less when viewed from above (Z-view in the third direction) in terms of increasing the capacity that can be accommodated inside the press-molded product 100. The fact that the radius of curvature R1 of the inner portion of the first ridge line 106 and the radius of curvature R2 of the inner portion of the second ridge line 107 are different from the viewpoint that the geometrical relationship between the third ridge line 115 and the fourth ridge line 125, which will be described later, is established. It is preferable that a single flat plate can be easily formed as a structure having a high-strength material at a corner and a expandable surface that does not require notch cutting / joining or overlapping. The radius of curvature R1 is the radius of curvature of the inner portion of the first ridge line 106 in the cross-sectional view in the direction along the first ridge line 106. The radius of curvature R2 is the radius of curvature of the inner portion of the second ridge line 107 in the cross-sectional view in the direction along the second ridge line 107.
[0031]
As shown in FIG. 1, the first flange 130 projects from the upper edge of each of the pair of first wall portions 110 toward the side opposite to the bottom plate portion 101 with respect to the first wall portion 110, that is, toward the outside. .. The first flange 130 extends along the first direction X along the upper edge of the first wall portion 110. The first flange 130 has a first upper surface 131 connected to the first inner surface 111 and a first lower surface 132 connected to the first outer surface 112. The first flange 130 and the first wall portion 110 are connected via a third ridge line 115. As shown in FIG. 2, the third ridge line 115 is formed in a convex curve shape at an inner portion where the first inner surface 111 of the first wall portion 110 and the first upper surface 131 of the first flange 130 are connected. Further, the third ridge line 115 is formed in a concave curve shape at an outer portion where the first outer surface 112 of the first wall portion 110 and the first lower surface 132 of the first flange 130 are connected.
[0032]
As shown in FIG. 1, the second flange 140 projects from the upper edge of each of the pair of second wall portions 120 toward the side opposite to the bottom plate portion 101 with respect to the second wall portion 120, that is, toward the outside. .. The second flange 140 extends along the second direction Y along the upper edge of the second wall portion 120. The second flange 140 has a second upper surface 141 connected to the second inner surface 121 and a second lower surface 142 connected to the second outer surface 122. The second flange 140 and the second wall portion 120 are connected via a fourth ridge line 125. As shown in FIG. 3, the fourth ridge line 125 is formed in a convex curve shape at the inner portion where the second inner surface 121 of the second wall portion 120 and the second upper surface 141 of the second flange 140 are connected. Further, the fourth ridge line 125 is formed in a concave curve shape at an outer portion where the second outer surface 122 of the second wall portion 120 and the second lower surface 142 of the second flange 140 are connected. The first upper surface 131 of the first flange 130 and the second upper surface 141 of the second flange 140 are connected so as to be flush with each other. The fact that the radius of curvature R4 of the inner part of the third ridge line 115 and the radius of curvature R5 of the inner part of the fourth ridge line 125 are different means that the corners are made of a flat surface and the shape of the corners is a high-strength material and the notch is cut. It is preferable because it can be easily established as a structure having a expandable surface that does not require joining or overlapping. The radius of curvature R4 is the radius of curvature of the inner portion of the third ridge 115 in the cross-sectional view in the direction along the third ridge 115. The radius of curvature R5 is the radius of curvature of the inner portion of the fourth ridge line 125 in the cross-sectional view in the direction along the fourth ridge line 125. The radius of curvature R4 is easily established as a structure consisting of a flat surface having a radius of curvature of 40 mm or less, a high-strength material at the corners, and a deployable surface that does not require notch cutting / joining or overlapping. preferable. Further, the radius of curvature R5 is easily established as a structure consisting of a flat surface having a radius of curvature R5 of 10 mm or less, a high-strength material at the corners, and a deployable surface that does not require notch cutting / joining or overlapping. Is preferable.
[0033] The material for forming such a press-molded product 100 is a metal material that can be plastically processed when press-molded by the method for producing the press-molded product 100 described later, and is, for example, a steel material. Further, when the press-molded product 100 is applied to the battery housing case as described above, the tensile strength of the material forming the press-molded product 100 is 440 MPa or more from the viewpoint of battery protection in the event of an automobile collision. Is preferable. Further, from the viewpoint of improving workability, the tensile strength of the material forming the press-molded product 100 may be set to 1180 MPa or less. Further, the thickness of the first wall portion 110 of the press-molded product 100 is preferably 85% or more of the thickness of the center of the bottom plate portion 101. The second wall portion 120 of the press-molded product 100 preferably has a thickness of 85% or more of the thickness of the center of the bottom plate portion 101. The first flange 130 of the press-molded product 100 preferably has a thickness of 85% or more of the thickness of the center of the bottom plate portion 101. The thickness of the second flange 140 of the press-molded product 100 is preferably 85% or more of the thickness of the center of the bottom plate portion 101. Although the thickness of the first wall portion 110, the second wall portion 120, the first flange 130 or the second flange 140 is defined based on the thickness of the center of the bottom plate portion 101, the production of the press-molded product 100 described later is specified. When press molding from the blank 1 by the method, if there is another portion that does not change from the thickness of the blank 1, the thickness may be specified with reference to the other portion.
[0034]
Next, a method for manufacturing the press-molded product 100 of the present embodiment will be described. As shown in FIG. 5, in the manufacturing method of the press-molded product 100 of the present embodiment, the first step S1 for forming the portion corresponding to the first wall portion 110 and the portion corresponding to the second wall portion 120 are formed. The second step S2, the third step S3 for forming the portion corresponding to the first wall portion 110, the fourth step S4 and the fifth step S5 for forming the second flange 140, the first flange 130 and the first The second step S6 for adjusting the two flanges 140 into a desired shape is provided. Hereinafter, each process will be described in detail. The unprocessed flat plate before the first step S1 is formed as a blank, the blank processed in each step is referred to as an intermediate press-molded product, and each step is referred to as an intermediate press-molded product. A product having a desired shape by carrying out the process is referred to as a press-molded product. Further, as a concept including a blank and an intermediate press-molded product, a target to which each step of the manufacturing method of the press-molded product 100 of the present embodiment is carried out is referred to as a work material.
[0035]
In the first step S1, the first rising portion 10A is formed from the flat plate-shaped blank 1 as shown in FIG. 6 as a portion corresponding to the first wall portion 110 as shown in FIG. 8, and the first flange 130 is formed. The first band portion 20A is formed as the corresponding portion, and the first intermediate press-molded product is molded. The blank 1 includes a pair of first edge portions 1a along the first direction X and a pair of second edge portions 1b connected to the pair of first edge portions 1a and along the second direction Y. By carrying out the first step S1 to the sixth step S6, the blank 1 forms the bottom plate portion 101 of the press-molded product 100 shown in FIG. 1 by the range A surrounded by the two-point chain line shown in the center, and the periphery thereof. The first wall portion 110, the second wall portion 120, the first flange 130 and the second flange 140 are formed by the range B of. The first step S1 is a shape construction for carrying out the second step S2, and can be carried out by various processing methods such as stamping molding. Then, it is desirable that the forming method is such that the member thickness of the first intermediate press-molded product 2 after the first step S1 is carried out is 85% or more of the member thickness of the blank 1 before the first step S1 is carried out. .. From the viewpoint of performing molding more accurately, that is, the plate thickness decreases / increases due to processing elongation / shrinkage and is close to the original plate thickness, the first step S1 is carried out to form the first rising portion 10A. After that, it is preferable to change the mold and carry out the second step S2 to form the second rising portion 40A described later. Further, if the first intermediate press-molded product 2 can be formed from the blank 1 by sandwiching the blank 1 with the mold used in the second step S2 described later when the second step S2 is carried out, the first step S1 is performed. It is not necessary to carry out the first step S2 independently of the second step S2, and the first step S1 may be carried out together with the second step S2.
[0036]
FIG. 7 shows an outline of the mold of the first set 200 composed of the mold used in the first step S1. The mold of the first set 200 includes a bottom plate upper mold 210 and a bottom plate lower mold 220 that sandwich the substrate portion 30A including a portion corresponding to the bottom plate portion 101 from the third direction Z, and a first rising portion 10A and a first band portion 20A. The side upper mold 230 and the side lower mold 240 are provided. The bottom plate upper mold 210 and the bottom plate lower mold 220, and the side upper mold 230 and the side lower mold 240 are separated in the second direction Y by the size corresponding to the thickness of the first rising portion 10A formed in this step. A gap is formed between each other. The bottom plate upper mold 210 has a press surface 212 on which a convex portion 211 capable of forming a groove 104 corresponding to the upper surface 102 of the bottom plate portion 101 is formed. Further, the bottom plate lower mold 220 has a press surface 222 in which a recess 221 capable of forming a ridge 105 corresponding to the lower surface 103 of the bottom plate portion 101 is formed. The bottom plate upper mold 210 and the bottom plate lower mold 220 sandwich the blank 1 over the entire surface along the first direction X, and sandwich only the portion to be the substrate portion 30A in the second direction Y. Both sides of the second direction Y in the range sandwiched by the bottom plate upper mold 210 and the bottom plate lower mold 220 are sandwiched by the side upper mold 230 and the side lower mold 240.
[0037]
The side upper mold 230 and the side lower mold 240 are provided in pairs corresponding to the pair of the first rising portion 10A and the first band portion 20A. Each of the side upper mold 230 and the side lower mold 240 sandwiches a portion to be the corresponding first rising portion 10A and the first belt portion 20A. Then, surface pressure is applied to the blank 1 by the bottom plate upper mold 210 and the bottom plate lower mold 220, and the side upper mold 230 and the side lower mold 240, respectively. In this state, the bottom plate upper mold 210 and the bottom plate lower mold 220 are relatively moved downward in the third direction with respect to the side upper mold 230 and the side lower mold 240. The magnitude of the surface pressure can be obtained, for example, by the formula (1) of the second step S2 described later. In the present embodiment, the side upper mold 230 and the side lower mold 240 are fixed and the bottom plate upper mold 210 and the bottom plate lower mold 220 are moved downward in the third direction Z, but the present invention is not limited to this, and the bottom plate upper mold 210 and the bottom plate are not limited to this. The lower mold 220 may be fixed and the side upper mold 230 and the side lower mold 240 may be moved upward in the third direction Z, and the side upper mold 230, the side lower mold 240, and the bottom plate upper mold 210 may be used. Both sets of the bottom plate lower mold 220 may be moved in the third direction Z so as to be relatively moved.
[0038]
Then, when the first rising portion 10A reaches a desired height, the relative movement of the bottom plate upper mold 210 and the bottom plate lower mold 220 with respect to the side upper mold 230 and the side lower mold 240 is stopped. As a result, the first intermediate press-molded product 2 shown in FIGS. 8 and 9 is formed. That is, the first rising portion 10A is connected between the pair of second edge portions 1b along the first direction X via the first ridge line 106a extending in the first direction X in the substrate portion 30A and extends upward in the third direction Z. Is formed. Further, the portion remaining sandwiched between the side upper die 230 and the side lower die 240 extends along the upper edge of the first rising portion 10A and projects outward in the second direction Y, the first band portion 20A. Is formed. The height of the first rising portion 10A after the first step S1 may be lower than the height of the first wall portion 110 of the finished press-molded product 100.
[0039]
Next, the second step S2 is carried out. In the second step S2, the second rising portion 40A is formed from the first intermediate press-molded product 2 molded in the first step S1 as a portion corresponding to the second wall portion 120, and a portion corresponding to the second flange 140. The second band portion 50A is formed. When the second step S2 and the subsequent third step S3 are repeated as described later, in the second step S2 after the third step S3 is carried out, the third intermediate press molding after the third step S3 is carried out. Item 4 is used. FIG. 10 shows an outline of the mold of the second set 300 composed of the mold used in the second step S2. As shown in FIG. 10, the mold of the second set 300 includes a first upper mold 310 and a first lower mold 320, and a second upper mold 330 and a second lower mold 340. The first upper mold 310 and the first lower mold 320 have a second edge portion 1b of the substrate portion 30A, the first rising portion 10A, and the first band portion 20A along the second edge portion 1b in the substrate portion 30A. The band-shaped first range C including the above is sandwiched from both sides of the third direction Z. The first range C is provided in pairs corresponding to the pair of second edge portions 1b. Further, the second upper mold 330 and the second lower mold 340 are adjacent to the first range C and have a third direction in the second range D including the substrate portion 30A, the first rising portion 10A, and the first band portion 20A. It is sandwiched from both sides of Z. In this embodiment, the second range D is a range between a pair of first ranges C.
[0040]
As shown in FIGS. 10 and 11, the second upper mold 330 has a substrate portion side press surface 331 that abuts on the upper surface of the substrate portion 30A and a band portion side press surface 332 that abuts on the upper surface of the first band portion 20A. It has a stepped portion 333 formed between the substrate portion side press surface 331 and the band portion side press surface 332 and along the first rising portion 10A. Further, the second upper mold 330 has a guide surface 334 forming the second rising portion 40A on the first upper mold 310 side along the second direction Y. The guide surface 334 is formed so as to cross the substrate portion side press surface 331, the step portion 333, and the band portion side press surface 332 as a whole along the second direction Y. A convex portion 331a corresponding to the groove 104 formed in the first step S1 is formed on the substrate portion side press surface 331 of the second upper mold 330. As shown in FIGS. 10 and 12, in the second lower mold 340, the substrate portion side press surface (second bottom surface) 341 that abuts on the lower surface of the substrate portion 30A and the band portion that abuts on the lower surface of the first band portion 20A. It has a side press surface (second flange surface) 342 and a step portion (second wall surface) 343 formed between the substrate portion side press surface 341 and the band portion side press surface 342 and along the first rising portion 10A. The band-side press surface 342 extends from the upper edge of the step portion 343 to the opposite side of the substrate-side press surface 341. The first rising portion 10A formed in the first step S1 is arranged between the stepped portion 333 of the second upper mold 330 and the stepped portion 343 of the second lower mold 340. Further, a recess 341a corresponding to the groove 104 formed in the first step S1 is formed on the substrate portion side press surface 341 of the second lower mold 340.
[0041]
As shown in FIGS. 10 and 11, the first upper mold 310 has a substrate portion side press surface 311 that abuts on the upper surface of the substrate portion 30A and a band portion side press surface 312 that abuts on the upper surface of the first band portion 20A. It has a stepped portion 313 formed between the substrate portion side press surface 311 and the band portion side press surface 312 and along the first rising portion 10A. Further, the first upper mold 310 includes a guide surface 314 forming the second rising portion 40A so as to face the guide surface 334 of the adjacent second upper mold 330. The guide surface 314 is formed so as to cross the substrate portion side press surface 331, the step portion 333, and the band portion side press surface 332 as a whole along the second direction Y. The guide surface 314 of the first upper mold 310 is separated from the guide surface 334 of the second upper mold 330 in the first direction X by a dimension corresponding to the thickness of the second rising portion 40A formed in this step. , A gap is formed between each other. As shown in FIGS. 10 and 12, the first lower mold 320 has a substrate portion side press surface (first bottom surface) 321 that abuts on the lower surface of the substrate portion 30A and a band portion that abuts on the lower surface of the first band portion 20A. It has a side press surface (first flange surface) 322 and a step portion (first wall surface) 323 formed between the substrate portion side press surface 321 and the band portion side press surface 322 and along the first rising portion 10A. The band side press surface 322 extends from the upper edge of the step portion 323 to the side opposite to the substrate portion side press surface 321. Further, the first rising portion 10A formed in the first step S1 is arranged between the stepped portion 313 of the first upper mold 310 and the stepped portion 323 of the first lower mold 320.
[0042]
Here, in the present embodiment, both the first upper mold 310 and the first lower mold 320 are divided into a plurality of molds along the second direction Y. Specifically, the first upper mold 310 includes a pair of end molds (upper end molds) 310A and a central mold (upper middle mold).Central type) 310B. The pair of end molds 310A includes a band portion side press surface 312 and a step portion 313, and a part of the substrate portion side press surface 311 adjacent to the step portion 313. The central type 310B is arranged adjacent to the end type 310A. The central mold 310B sandwiches a portion of the work material that is opposite to the strip side press surface 322 with respect to the step portion 323. The central type 310B is arranged between the pair of end types 310A with each end type 310A and a gap M1. The gap M1 between the central mold 310B and the end mold 310A crosses the first direction X, but is not formed linearly. Specifically, the gap M1 has an inner portion M1a that reaches the inner guide surface 314 along the first direction X and an outer side of the first upper mold 310 on the opposite side of the guide surface 314 along the first direction X. It has an outer portion M1b that reaches, and an intermediate portion M1c that connects the inner portion M1a and the outer portion M1b and is along the second direction Y. Similarly, the first lower mold 320 is composed of a pair of end molds (lower end molds) 320A and a central mold (lower center mold) 320B. The pair of end molds 320A includes a band portion side press surface 332 and a step portion 333, and a part of the substrate portion side press surface 331 adjacent to the step portion 333. The central type 320B is arranged adjacent to the end type 320A. Similarly, in the first lower mold 320, the central mold 320B is arranged between the pair of end molds 320A with each end mold 320A and a gap M2. The gap M2 between the central mold 320B and the end mold 320A crosses the first direction X, but is not formed in a linear shape. Specifically, the gap M2 connects the inner portion M2a that reaches the inside along the first direction X, the outer portion M2b that reaches the outside of the first upper mold 310, and the inner portion M2a and the outer portion M2b. It has an intermediate portion M2c along the second direction Y. The end molds 310A and 320A of the first upper mold 310 and the first lower mold 320 are movable in the second direction Y.
[0043]
With the above mold configuration, press molding is performed as follows in the second step S2. That is, first, the first intermediate press-molded product 2 is sandwiched between the first upper mold 310 and the first lower mold 320, and the first intermediate press-molded product 2 is sandwiched between the second upper mold 330 and the second lower mold 340. Sandwich.
Specifically, for example, as shown in FIG. 13A, the first lower mold 320 and the second lower mold 340 are fixed, and the first upper mold 310 and the second upper mold 330 are lowered to perform the first intermediate press. The molded product 2 is sandwiched. In addition, instead of sandwiching the first intermediate press-molded product 2 formed by independently performing the first step S1 as described above, the first upper mold 310, the first lower mold 320, and the second upper die The blank 1 may be sandwiched between the mold 330 and the second lower mold 340, and the first step S1 may be performed when sandwiching the blank 1 to form the first intermediate press-molded product 2.
[0044]
Then, a surface pressure is applied to the first intermediate press-molded product 2 first band portion 20A so that out-of-plane deformation becomes impossible. Such a surface pressure can be obtained by, for example, the following equation.
P = Y / 590 x t / 1.4 x P0 ... (1)
However, P: Surface pressure (MPa) that sandwiches the intermediate press molded product
Y: Tensile strength (MPa) of intermediate press molded product
T: Thickness of intermediate press molded product (mm)
P0: Reference surface pressure = 0.1 MPa
[0045]
In this state, with respect to the first upper mold 310 and the first lower mold 320 so as to shift from the state of FIG. 13 (a) to the state of FIG. 13 (c) through the state of FIG. 13 (b). The upper mold 330 and the second lower mold 340 are relatively moved downward in the third direction Z. In the present embodiment, the first upper mold 310 and the first lower mold 320 are fixed in the third direction Z, and the second upper mold 330 and the second lower mold 340 are moved downward in the third direction Z, but the present invention is limited to this. There is no. The second upper mold 330 and the second lower mold 340 may be fixed and the first upper mold 310 and the first lower mold 320 may be moved upward in the third direction Z, and the first upper mold 310 and the first lower mold 310 may be moved. The mold 320 and both the second upper mold 330 and the second lower mold 340 may be moved in the third direction Z so as to be relatively moved. Further, as shown in FIGS. 13 (b) and 13 (c), in the present embodiment, the second upper mold 330 and the second lower mold 340 are Z downward in the third direction with respect to the first upper mold 310 and the first lower mold 320. Along with the relative movement to, the end molds 310A and 320A of the first upper mold 310 and the first lower mold 320 are moved inward in the second direction Y so as to be closer to the central molds 310B and 320B. As a result, the first intermediate press-molded product 2 is moved so as to move the first rising portion 10A sandwiched between the stepped portions 313 and 323 of the first upper mold 310 and the first lower mold 320 inward in the second direction Y. Can be loaded.
[0046]
Here, in the first intermediate press-molded product 2, the substrate portion 30A sandwiched between the second upper mold 330 and the second lower mold 340 is the first while being sandwiched between the second upper mold 330 and the second lower mold 340. Sufficient frictional resistance is provided to prevent the material from moving to both sides of the direction X. Such frictional resistance is given by the surface pressure applied by the second upper die 330 and the second lower die 340 and the friction coefficient between the second upper die 330 and the second lower die 340 and the first intermediate press molded product 2. Has been done. The friction coefficient is the surface roughness of each press surface 331, 332, 341, 342 of the second upper mold 330 and the second lower mold 340, the second upper mold 330 and the second lower mold 340, and the first intermediate press molded product 2. It can be adjusted by the type of lubricant between and.
[0047]
Further, in the portion sandwiched between the first upper mold 310 and the first lower mold 320, a surface pressure that prevents the portion from being out-of-plane deformation (deformation in the third direction Z) is applied to the first upper mold 310 and the first. It is hung by the lower mold 320. Further, in the portion sandwiched between the first upper mold 310 and the first lower mold 320, the first upper portion is moved toward the substrate portion 30A by the press molding in the second step S2. The friction coefficient between the mold 310 and the first lower mold 320 and the first intermediate press-molded product 2 is adjusted. The friction coefficient is the surface roughness of each press surface 311, 312, 321, 322 of the first upper mold 310 and the first lower mold 320, the first upper mold 310 and the first lower mold 320, and the first intermediate press molded product 2. It can be adjusted by the type of lubricant between and.
[0048]
Therefore, by moving the second upper mold 330 and the second lower mold 340 relative to the first upper mold 310 and the first lower mold 320, the first upper mold 310 and the first lower mold 340 are moved downward in the third direction Z. The portion sandwiched between the 320s flows into the substrate portion 30A side while suppressing out-of-plane deformation, and a second rising portion 40A rising upward from the substrate portion 30A in the third direction Z is formed. The entire second rising portion 40A is formed on the side where the first rising portion 10A rises from the substrate portion 30A. It should be noted that, with the formation of the second rising portion 40A, tensile plastic deformation may be included as the deformation mode in the second rising portion 40A and the second band portion 50A, but the second step is compared to before the second step S2 is carried out. It is preferable that the tensile plastic deformation is in the range where the member thickness after performing S2 is 85% or more. Then, when the second rising portion 40A reaches a desired height, the relative movement of the second upper mold 330 and the second lower mold 340 with respect to the first upper mold 310 and the first lower mold 320 is stopped. As a result, the second intermediate press-molded product 3 as shown in FIG. 16 is formed. That is, it is connected to the substrate portion 30A via the second ridge line 107a across the pair of first edge portions 1a along the second direction Y and extends upward in the third direction Z, and also has the first rising portion 10A and the vertical ridge line. A second rising portion 40A connected via 108 is formed. Further, the portion remaining sandwiched between the first upper mold 310 and the first lower mold 320 forms a second band portion 50A extending along the upper edge of the second rising portion 40A and projecting outward. .. In this embodiment, the height of the second rising portion 40A after the implementation of the second step S2 is made higher than the height of the first rising portion 10A after the implementation of the first step S1 immediately before.
[0049]
Here, as described above, along with the relative movement of the second upper mold 330 and the second lower mold 340 downward to the third direction Z with respect to the first upper mold 310 and the first lower mold 320, the first upper mold 310 and the first The end molds 310A and 320A of the lower mold 320 are moved inward in the second direction Y so as to be closer to the central molds 310B and 320B. Therefore, of the second rising portion 40A formed in the second step S2, the portion connected to the vertical ridge line 108 has a different deformation mode from the other portions. 14 (a) to 14 (c) show the details of the second rising portion 40A corresponding to the states of the respective molds of FIGS. 13 (a) to 13 (c), respectively. Further, FIGS. 15 (a) to 15 (c) show the states of the intermediate press-molded products in the vicinity of the vertical ridge line 108 corresponding to the states of the molds of FIGS. 13 (a) to 13 (c) in the first direction X cross section. Is shown. From the first intermediate press-molded product 2 before the implementation of the second step S2 shown in FIGS. 14 (a) and 15 (a), the states shown in FIGS. 14 (b) and 15 (b), and further to FIG. 14 (c). ) And the state of completion of the second step S2 shown in FIG. 15 (c), the second rising portion 40A is gradually formed. Then, as the second rising portion 40A is formed, the material flows into the second rising portion 40A from the first band portion 20A, and is sandwiched between the second upper mold 330 and the second lower mold 340. The portion of the first rising portion 10A sandwiched between the first upper mold 310 and the first lower mold 320 is separated from the portion of the rising upper portion 10A in the third direction Z and also in the second direction Y.
[0050]
Therefore, in the second rising portion 40A, the range E connected to the vertical ridge line 108, in other words, the portion of the first rising portion 10A sandwiched between the second upper mold 330 and the second lower mold 340, and the first upper mold 310. And in the range between the portion of the first rising portion 10A sandwiched by the first lower mold 320, shear deformation can be effectively caused. Since the shear deformation deforms without changing the area (or in a state where the change in the area is suppressed), the deformation can be performed without the change in the member thickness (or the change in the member thickness is suppressed). As a result, in the second rising portion 40A, the press molding can be performed by suppressing the change in the member thickness even in the range E which is connected to the vertical ridge line 108 and is constrained by the shape of the first rising portion 10A.
[0051]
Next, the third step S3 is carried out. In the third step S3, the height of the first rising portion 10A from the second intermediate press-molded product 3 shown in FIG. 16 formed in the second step S2 is increased. FIG. 17 shows an outline of the mold of the third set 400 composed of the mold used in the third step S3. As shown in FIG. 17, the mold of the third set 400 includes a third upper mold 410 and a third lower mold 420, and a fourth upper mold 430 and a fourth lower mold 440. The third upper mold 410 and the third lower mold 420 sandwich the first band portion 20A side from both sides with the first ridge line 106a between the substrate portion 30A and the first rising portion 10A as a boundary. The fourth upper mold 430 and the fourth lower mold 440 sandwich the substrate portion 30A side with the first ridge line 106a as a boundary.
[0052]
As shown in FIGS. 17 and 18, in the fourth upper mold 430, the substrate portion side press surface 431 that abuts on the upper surface 102 of the substrate portion 30A and the band portion side press surface 432 that abuts on the upper surface of the second band portion 50A. And a stepped portion 433 formed between the substrate portion side press surface 431 and the band portion side press surface 432 and along the second rising portion 40A. Further, the fourth upper mold 430 includes a guide surface 434 forming the first rising portion 10A. The guide surface 434 is formed on both sides of the second direction Y so as to cross the substrate portion side press surface 431, the step portion 433, and the band portion side press surface 432 as a whole along the first direction X. A convex portion 431a corresponding to the groove 104 formed in the first step S1 is formed on the substrate portion side press surface 431 of the fourth upper mold 430. As shown in FIGS. 17 and 19, the fourth lower mold 440 has a substrate portion side press surface (fourth bottom surface) 441 that abuts on the lower surface of the substrate portion 30A and a band portion that abuts on the lower surface of the second band portion 50A. It has a side press surface (fourth flange surface) 442 and a step portion (fourth wall surface) 443 formed between the substrate portion side press surface 441 and the band portion side press surface 442 and along the second rising portion 40A. The band portion side press surface 442 extends from the step portion 443 to the side opposite to the substrate portion side press surface 441. Further, in the second step S2, between the step portion 433 of the fourth upper mold 430 and the step portion 443 of the fourth lower mold 440.The formed second rising portion 40A is arranged. Further, a recess 441a corresponding to the groove 104 formed in the first step S1 is formed on the substrate portion side press surface 441 of the fourth lower mold 440.
[0053]
As shown in FIGS. 17 and 18, the third upper mold 410 has a band side press surface 411 that abuts on the upper surface of the first band portion 20A and a second rising portion 40A that is connected to the first band portion 20A. It has a stepped portion 412 along the line. The band-side press surface 411 is separated into a first portion 411a by a step portion 412 and a second portion 411b arranged on both sides of the first portion 411a in the first direction X. Further, the third upper mold 410 includes a guide surface 414 forming the first rising portion 10A. The guide surface 414 is formed so as to face the guide surface 434 of the adjacent fourth upper die 430 and cross the band side press surface 411 and the step portion 412 along the first direction X as a whole. The guide surface 414 of the third upper mold 410 is separated from the guide surface 434 of the fourth upper mold 430 in the second direction Y by a dimension corresponding to the thickness of the first rising portion 10A formed in this step. , A gap is formed between each other. As shown in FIGS. 17 and 19, the third lower mold 420 is provided on the band side press surface 421 that abuts on the lower surface of the first band portion 20A and the second rising portion 40A that is connected to the first band portion 20A. It has a stepped portion (third wall surface) 422 along the line. A portion of the second rising portion 40A formed in the second step S2, which is connected to the first band portion 20A, is arranged between the step portion 412 of the third upper mold 410 and the step portion 422 of the third lower mold 420. Will be done. That is, the band side press surface 421 has a first portion (third bottom surface) 421a and a second portion (third flange surface) arranged on both sides of the first portion 421a in the first direction X by the step portion 422. ) It is separated from 421b. The second portion 421b extends from the upper edge of the step portion 422 to the side opposite to the first portion 421a.
[0054]
With the above mold configuration, press molding is performed as follows in the third step S3. That is, first, the second intermediate press-molded product 3 is sandwiched between the third upper mold 410 and the third lower mold 420, and the second intermediate press-molded product 3 is sandwiched between the fourth upper mold 430 and the fourth lower mold 440. Sandwich. Specifically, for example, as shown in FIG. 20A, the third lower mold 420 and the fourth lower mold 440 are fixed, and the third upper mold 410 and the fourth upper mold 430 are lowered to lower the second intermediate press. The molded product 3 is sandwiched. Then, a surface pressure is applied to the first band portion 20A and the second band portion 50A of the second intermediate press-molded product 3 so as to prevent out-of-plane deformation. The magnitude of the surface pressure is obtained, for example, based on the equation (1) in the same manner as in the second step S2. In this state, the fourth upper mold 430 and the fourth lower mold 440 are compared with the third upper mold 410 and the third lower mold 420 so as to shift from the state of FIG. 20 (a) to the state of FIG. 20 (b). Is relatively moved downward in the third direction Z. In the present embodiment, the third upper mold 410 and the third lower mold 420 are fixed in the third direction Z, and the fourth upper mold 430 and the fourth lower mold 440 are moved downward in the third direction Z, but the present invention is limited to this. There is no. The fourth upper mold 430 and the fourth lower mold 440 may be fixed and the third upper mold 410 and the third lower mold 420 may be moved upward in the third direction Z, and the third upper mold 410 and the third lower mold may be moved. The mold 420 and both the fourth upper mold 430 and the fourth lower mold 440 may be moved in the third direction Z so as to be relatively moved.
[0055]
Here, in the second intermediate press-molded product 3, the material does not flow into the substrate portion 30A and the second band portion 50A sandwiched between the fourth upper mold 430 and the fourth lower mold 440 on both sides of the second direction Y. Sufficient frictional resistance is given. The frictional resistance is given by the surface pressure applied by the fourth upper mold 430 and the fourth lower mold 440 and the friction coefficient between the fourth upper mold 430 and the fourth lower mold 440 and the second intermediate press molded product 3. There is. The friction coefficient is the surface roughness of the press surface of the fourth upper mold 430 and the fourth lower mold 440, and the type of the lubricant between the fourth upper mold 430 and the fourth lower mold 440 and the second intermediate press molded product 3. It can be adjusted by such as.
[0056]
Further, the surface pressure of the first band portion 20A sandwiched between the third upper mold 410 and the third lower mold 420 is applied to the third upper mold so that the portion does not undergo out-of-plane deformation (deformation in the third direction Z). It is hung by 410 and the third lower mold 420. On the other hand, in the first band portion 20A sandwiched between the third upper mold 410 and the third lower mold 420, the portion can be moved toward the substrate portion 30A by the press molding in the third step S3. , The friction coefficient between the third upper mold 410 and the third lower mold 420 and the second intermediate press-molded product 3 is adjusted. The friction coefficient is the surface roughness of the pressed surface of the third upper mold 410 and the third lower mold 420, and the type of the lubricant between the third upper mold 410 and the third lower mold 420 and the second intermediate press molded product 3. It can be adjusted by such as.
[0057]
Therefore, by moving the fourth upper mold 430 and the fourth lower mold 440 relative to the third upper mold 410 and the third lower mold 420 in the third direction Z downward, the third upper mold 410 and the third lower mold The first band portion 20A sandwiched between the 420s flows into the substrate portion 30A side while suppressing out-of-plane deformation, and the first rising portion 10B rising upward from the substrate portion 30A in the third direction Z is formed to be higher. .. Further, the first band portion 20B is formed by the portion remaining sandwiched between the third upper mold 410 and the third lower mold 420. It should be noted that, with the formation of the first rising portion 10B, tensile plastic deformation may be included as the deformation mode in the first rising portion 10B and the first band portion 20B, but the third step is compared to before the third step S3 is carried out. It is preferable that the tensile plastic deformation is in the range where the member thickness after performing S3 is 85% or more. Then, when the first rising portion 10B reaches a desired height, the relative movement of the fourth upper mold 430 and the fourth lower mold 440 with respect to the third upper mold 410 and the third lower mold 420 is stopped. As a result, the third intermediate press-molded product 4 shown in FIG. 23 is formed. In this embodiment, the height of the first rising portion 10B after the implementation of the third step S3 is lower than the height of the second rising portion 40A after the implementation of the second step S2 immediately before, and it is completed. The height is equal to the height of the first wall portion 110 of the press-molded product 100 as a product. Further, the width of the first band portion 20B is the same as or larger than the width of the first flange 130 as a finished product.
[0058]
Here, in the third step S3, as the first rising portion 10B is formed, the second rising portion 40A also undergoes deformation in the range in the vicinity of the first rising portion 10B. 21 (a) and 21 (b) are detailed views showing the details of the second rising portion 40A corresponding to the state of the mold of FIGS. 20 (a) and 20 (b), respectively. 22 (a) and 22 (b) show the state of the intermediate press-molded product in the vicinity of the vertical ridge line 108 corresponding to the state of the mold shown in FIGS. 20 (a) and 20 (b), respectively, in the first direction X cross section. Is shown. As shown in FIGS. 21 and 22, of the portions of the first band portion 20A adjacent to the second rising portion 40A, the portion located below the second rising portion 40A is restrained by the second rising portion 40A. Therefore, the inflow of the material into the first rising portion 10A is relatively suppressed as compared with the other portions. On the other hand, of the portion of the first belt portion 20A adjacent to the second rising portion 40A, the portion located above the second rising portion 40A is similarly restrained by the second rising portion 40A, but is a free end. Since it is near the second edge 1b, the binding force is relatively small. Therefore, of the second rising portion 40A, the range F adjacent to the range E adjacent to the first band portion 20A and shear-deformed in the second step S2 is each part of the first band portion 20A on both sides thereof. Under the influence of the relative difference, it can be sheared and deformed in the direction along the second edge portion 1b to follow the change in the height of the first rising portion 10B. Therefore, it is possible to prevent the second rising portion 40A from being tensile-plastically deformed in the vicinity of the first rising portion 10B and the member thickness from being reduced.
[0059]
Next, the fourth step S4 is carried out. In the fourth step S4, an unnecessary portion of the intermediate press-molded product formed by carrying out the first step S1 to the third step S3 is cut. Specifically, as shown in FIG. 23, in the present embodiment, the second rising portion 40A of the third intermediate press-formed product 4 after the third step S3 is carried out is predetermined from the upper surface of the first band portion 20B. Cut at the cutting line G having a height H. The predetermined height H is set to a size equal to or larger than the width of the second flange 140 of the press-molded product 100 which is a finished product. As a result, as shown in FIG. 24, of the second rising portion 40A, the portion higher than the predetermined height H is removed from the first belt portion 20B to become the second rising portion 40B, and the second rising portion 50A. The fourth intermediate press-molded product 5 from which is removed is formed.
[0060]
Next, the fifth step S5 is carried out. In the fifth step S5, a portion to be the second flange 140 is formed from the fourth intermediate press-formed product 5. FIG. 25 shows an outline of the mold 500 used in the fifth step S5. As shown in FIG. 25, the mold 500 used in the fifth step S5 includes a punch 510 that supports the fourth intermediate press-molded product 5, a pad 520 that sandwiches the fourth intermediate press-molded product 5 together with the punch 510, and a second. It is provided with a die 530 that can bend the rising portion 40B. The punch 510 includes a first support surface 511 that supports the lower surface of the substrate portion 30A of the fourth intermediate press-molded product 5, a second support surface 512 that supports the first rising portion 10B, and a fourth intermediate press-molded product 5. It has a third support surface 513 that supports the second rising portion 40B, and a fourth support surface 514 that supports a portion that becomes the second flange 140 after bending by the first band portion 20B and the die 530. The first support surface 511 is formed with a recess 511a corresponding to the ridge 105 formed in the first step S1. Further, the pad 520 has a first contact surface 521 that abuts on the upper surface of the substrate portion 30A of the fourth intermediate press molded product 5, a second contact surface 522 that supports the first rising portion 10B, and a fourth intermediate press. It has a third contact surface 523 that abuts on the second rising portion 40B of the molded product 5, and a fourth contact surface 524 that abuts on the first band portion 20B. A convex portion 521a corresponding to the groove 104 formed in the first step S1 is formed on the first contact surface 521. Further, the dies 530 are provided in pairs corresponding to the second rising portion 40B, and are arranged along the second direction Y, respectively. The pair of dies 530 can move in the first direction X so as to be close to each other.
[0061]
Then, the fourth intermediate press-molded product 5 is placed on the punch 510 and sandwiched between the pad 520 and the punch 510. In this state, as shown in FIG. 26, by arranging the die 530 inside the first direction X of the second rising portion 40A and moving it to the outside of the first direction X, the first zone of the second rising portion 40B is formed. The portion protruding from the portion 20B is bent outward to form the fifth intermediate press-molded product 6 shown in FIG. 27 in which the portion 140 ′ to be the second flange 140 is formed. At this time, the upper surface of the portion 140'that becomes the second flange 140 and the upper surface of the first band portion 20A are bent so as to be continuous on the same surface.
[0062]
Finally, as the sixth step S6, as shown in FIG. 27, the outer edge side of the first band portion 20A is cut to the required width as the first flange 130 by the cutting line K, and is formed in the fifth step S5. The press-molded product 100 shown in FIG. 1 is completed by cutting the outer edge side of the portion 140'that becomes the second flange 140 to a width required as the second flange 140.
[0063]
As described above, according to the manufacturing method of the press-molded product 100 of the present embodiment, in the second step S2, in the range where the substrate portion 30A is in the state after the first step S1, the first upper mold 310 and By allowing a part of the material of the portion sandwiched by the first lower mold 320 to flow into the second rising portion 40A as the second rising portion 40A is formed, the member thickness of the second rising portion 40A can be reduced. It can be suppressed. Further, in the range where the first band portion 20A is formed after the first step S1, similarly, a part of the material of the portion sandwiched between the first upper mold 310 and the first lower mold 320 is used. It is possible to suppress a decrease in the member thickness of the second rising portion 40A by allowing the second rising portion 40A to flow into the second rising portion 40A as it is formed. On the other hand, in the portion that becomes the second rising portion 40A in the state after the first step S1, between the range that becomes the substrate portion 30A and the range that becomes the first band portion 20A, that is, the second rising portion. At 40A, the first rising top 10A and the second rising The portion connected to the vertical ridge line 108 to which the portion 40A is connected is subjected to shear deformation in the second step S2 to suppress a change in the member thickness and to follow the formation of the second rising portion 40A to have a desired shape. Can be plastically deformed. The portion to be sheared and deformed is formed to have a thickness of 85% or more of the thickness of the work material (blank) before the first step S1 is carried out, thereby minimizing the decrease in the member thickness. can do.
[0064]
Then, as described above, in the second step S2, the first upper mold 310 and the first lower mold 320 are used in the first band portion 20A and the first rising portion 10A of the work material (intermediate press molded product), respectively. The end molds 310A and 320A that sandwich at least the end molds 310A and 320A, and the central molds 310B and 320B that are arranged at intervals with respect to the end molds 310A and 320A and sandwich the substrate portion 30A side of the first rising portion 10A of the work material. The first upper mold 310 and the first lower mold 320 are end molds of the first upper mold 310 and the first lower mold 320 according to the relative movement of the first upper mold 310 and the first lower mold 320 with respect to the second upper mold 330 and the second lower mold 340. The 310A and 320A are moved so as to be close to the central type 310B and 320B. In this way, by moving the end molds 310A and 320A relative to the central molds 310B and 320B so as to narrow the gap between them, the central mold is viewed in the direction along the first edge portion 1a (first direction X). The portion of the second rising portion 40A located between the 310B and 320B and the end molds 310A and 320A and connected to the vertical ridge line 108 can be effectively sheared and deformed. Further, the gaps M1 and M2 between the end molds 310A and 320A and the central molds 310B and 320B are formed by having intermediate portions M1c and M2c along the second edge portion 1b in the middle of the direction along the first edge portion 1a. Therefore, it is possible to prevent the surface pressure of the first upper mold 310 and the first lower mold 320 from decreasing in the range where the gaps M1 and M2 are formed.
[0065]
The number of divisions of the first upper mold 310 and the first lower mold 320 is not limited to the three divisions of the pair of end molds 310A and 320A and the central molds 310B and 320B as described above. The end molds 310A and 320A that move in the second direction Y as the first upper mold 310 and the first lower mold 320 move relative to the second upper mold 330 and the second lower mold 340 in the third direction Z are the first. It suffices that it is configured to include the standing upper portion 10A and sandwich the work material. For example, a pair of end molds 310A and 320A may be arranged with a gap and the central mold may be omitted, or a plurality of central molds having a gap between each other and arranged in the second direction Y may be provided. You may be doing it. Further, the gap M1 includes outer portions M1a and M2a along the first direction X, inner portions M1b and M2b, and intermediate portions M1c and M2c along the second direction Y, but is not limited thereto. For example, even if the gap M1 is linear so as to be inclined in the second direction Y with respect to the first direction X, it is possible to prevent the surface pressure from dropping at the position where the gap M1 is formed along the second direction Y. can do. Further, when the influence of the decrease in the surface pressure is small, the gap M1 may be a linear gap extending in the first direction X.
[0066]
Further, in the above embodiment, by carrying out the third step S3, the height of the first rising portion 10A in the first step S1 is suppressed and the amount of shear deformation in one machining in the second step S2 is suppressed. At the same time, the first rising portion 10B can be formed at a desired height. At this time, the material required for raising the first rising portion 10A is inflowed from the first band portion 20A to suppress the decrease in the member thickness of the first rising portion 10A, but the second rising portion is increased. In the portion of 40A adjacent to the first band portion 20A, the range adjacent to the shear deformed range in the second step S2 is shear deformed in the direction along the second edge portion 1b (second direction Y). It can be plastically deformed into a desired shape by following the formation of the first rising portion 10A while suppressing the change in the member thickness. Then, the portion to be shear-deformed is formed to have a thickness of 85% or more of the thickness of the work material before the second step S2, so that the decrease in the member thickness can be suppressed to the minimum. can.
[0067]
Further, in the above embodiment, the first step S1 is carried out for each of the paired first edge portions 1a, the second step S2 is carried out for each of the paired second edge portions 1b, and the third step S3 is performed. By carrying out for each of the paired first edge portions 1a, a box body can be formed so that a pair of first rising portions 10A and a pair of second rising portions 40A surround the substrate portion 30A, whereby, for example, a battery. A box body having an opening on one side, such as a case, can be formed while suppressing a decrease in the member thickness. The method for manufacturing the press-molded product of the present embodiment is not limited to the method for manufacturing the box body, and can be applied to the shapes shown in FIGS. 28 and 29. That is, as shown in FIG. 28, the first wall portion 110 (first rising portion 10A, 10B) is formed on only one side of the rectangular bottom plate portion 101 (board portion 30A), and the first wall portion 110 (the first wall portion 110) is formed. A U-shape with a third direction Z of the portion rising from the bottom plate portion 101 (board portion 30A) so as to form the second wall portion 120 (second rising portion 40A) on both sides of the first rising portion 10A and 10B). May be formed in. Further, as shown in FIG. 29, the first wall portion 110 (first rising portion 10A, 10B) is formed on only one side of the rectangular bottom plate portion 101 (board portion 30A), and the first wall portion 110 (the first wall portion 110) is formed. The portion rising from the bottom plate portion 101 (board portion 30A) is L-shaped in the third direction Z so as to form the second wall portion 120 (second rising portion 40A) on one side of the first rising portion 10A, 10B). May be formed in. Further, in the above embodiment, the bottom plate portion 101 (board portion 30A) has a rectangular shape, and the first wall portion 110 (first rising portion 10A, 10B) and the second wall portion 120 (second rising portion 40A) are third. It is assumed that the bottom plate portion 101 (board portion 30A) is orthogonal to the direction Z, but it is not limited to this. The wall portion 110 (first rising portion 10A, 10B) and the second wall portion 120 (second rising portion 40A) may intersect at an angle other than a right angle when viewed in the third direction Z. It is applicable when forming two wall portions rising from adjacent side edges of the bottom plate portion 101 (board portion 30A), and is applicable to a vertical ridge line connecting to the first rising portion 10A in forming at least the second rising portion 40A. Similar effects can be obtained by subjecting shear deformation in a range including 108.
[0068]
Further, in the above embodiment, of the second step S2 and the third step S3, the second band portion 50A sandwiched between the first upper mold 310 and the first lower mold 320 after the last step carried out, and the first. After the fourth step S4 for cutting the second rising portion 40A along the second edge portion 1b at the height position between the band portion 20A and the fourth step S4, the second rising portion 40A of the second rising portion 40A is performed. The fifth step S5 was carried out in which the portion rising above the one band portion 20A was bent so as to be a continuous surface with the first band portion 20A. Thereby, the flange-shaped band portion connected to each upper edge of the first rising portion 10A and the second rising portion 40A can be formed so as to be a continuous surface.
[0069]
However, in the above embodiment, the press-molded product 100 is manufactured by carrying out the first step S1 to the sixth step S6, but the present invention is not limited to this. At least the first step S1 and the second step S2 are carried out, and in the second step S2, the desired shape is press-formed by shearing and deforming in the range E connected to the vertical ridge line 108 in the second rising portion 40A shown in FIG. It suffices if the product is formed. That is, the shape after the second step S2 or the shape after the third step S3 may be used as a finished product, and further, the fourth after the second step S2 or the third step S3 is carried out. Step S4, fourth step S4 and fifth step S5, or fourth step S4 to sixth step S6 may be carried out, and the shape after any one of the steps may be a press-molded product which is a finished product.
[0070]
Further, the second step S2 may be further carried out after the third step S3 is carried out, and the third step S3 may be further carried out after the second step S2 is carried out. It may be alternately carried out at least once or more, and further, one of them may be carried out a plurality of times. In this way, by dividing the formation of the first rising portion 10A and the second rising portion 40A into a plurality of times, it is possible to suppress the amount of shear deformation in one processing in each step. Then, after any one of the second step S2 and the third step S3 is carried out a plurality of times, the shape after the carrying out may be a press-molded product which is a finished product, and further, after the second step S2 is carried out or the third step. After the implementation of S3, the fourth step S4, the fourth step S4 and the fifth step S5, or the fourth step S4 to the fourth step S6 are carried out, and the shape after any one of the steps can be used as a finished press-molded product. good.
[0071]
Further, in the second step S2, as shown in FIG. 15, the first wall portion 110 and the first flange 130 in the press-molded product 100 have a range E connected to the vertical ridge line 108 in the second rising portion 40A. In the connecting portion between the first rising portion 10A and the second rising portion 40A including the convex curved portion forming the third ridge line 115 between them, the convex curved portion is set as the side E1 inclined in the third direction Z. , The side E1 is set as a range of a parallel quadrilateral that moves in parallel in the direction inclined in the second direction Y with respect to the third direction Z, and the range E is subjected to shear deformation, but the present invention is not limited to this. 30 and 31 show modified examples. As shown in FIG. 30, the inclined side E1 may be shear-deformed with respect to the range E'of a parallel quadrilateral that moves in parallel in the third direction Z. For example, in the second step S2, the second upper mold 330 and the second lower mold 340 are third to the first upper mold 310 and the first lower mold 320 without moving the end mold with respect to the central mold. This can be achieved by moving relative to the direction Z. Further, the shear deformation is not limited to the range of the parallel quadrilateral including the inclined side. As shown in FIG. 31, one side of the shear deformation range E ″ is set as a side E1 ″ parallel to the third direction Z, and the side is inclined in the second direction Y with respect to the third direction Z. It may be sheared and deformed as a range of parallel quadrilaterals that move in parallel to. At least in a range in which the direction along the side forming the vertical ridge line 108 connecting the first rising portion 10A and the second rising portion 40A formed in the second step S2 and the direction of shear deformation are not parallel or orthogonal to each other. It may be subjected to shear deformation.
[0072]
(Second Embodiment)
Next, a second embodiment of the present invention will be described. 32 to 35 show a second embodiment of the present invention. In this embodiment, the same reference numerals are given to the members common to the members used in the above-described embodiment, and the description thereof will be omitted.
[0073]
32 and 33 show an example of the press molding apparatus used in the second step S2 in the method for manufacturing the press molded product of the first embodiment. Further, FIGS. 34 and 35 show an example of the press molding apparatus used in the third step S3 in the method for manufacturing the press molded product of the first embodiment. As shown in FIGS. 32 and 33, the first press molding apparatus 600 used in the second step S2 includes a mold of the second set 300 shown in FIGS. 10 to 12 and a mold mounting portion 610 for mounting the mold. , A bolster 620 and a slider 625 that support the mold mounting portion 610, and a drive portion 630 that moves the mold. The mold mounting portion 610 has an upper mounting portion 611 for supporting the upper mold and a lower mounting portion 612 for supporting the lower mold. The bolster 620 is fixed to the support surface 600a. Further, the slider 625 is fixed to the ceiling surface 600b via the drive unit 630, and can be moved in the third direction Z by the drive of the drive unit 630. Further, the first upper mold 310 has a pair of end molds 310A and a pair of overhanging portions 310C extending from the central mold 310B on both sides of the second direction Y in addition to the central mold 310B. The overhanging portion 310C is fixed to the upper part of the central mold 310B and overhangs in the second direction Y. The pair of end molds 310A can move in the second direction Y along the lower surface of the corresponding overhanging portion 310C.It is supported by the overhanging portion 310C so as to be.
[0074]
The upper mounting portion 611 is fixed to the slider 625. The upper mounting portion 611 is provided between the pair of first upper support portions 611a for supporting the first upper mold 310 and the pair of first upper support portions 611a to support the second upper mold 330. It has a portion 611b. The central mold 310B and the overhanging portion 310C of the first upper mold 310 are supported by the first upper support portion 611a via the drive portion 630. The second upper mold 330 is fixed to the lower surface of the second upper support portion 611b. Further, the upper mounting portion 611 is a second of the first upper support portion 611a corresponding to the upper guide portion 611c arranged outside the first direction X of the first upper support portion 611a and the pair of first lower molds 320. It has a pair of cam portions 611d arranged outside in the direction Y. In the pair of end molds 310A, the upward movement is restricted by the overhanging portion 310C, and the movement in the first direction X is restricted by the upper guide portion 611c and the second upper support portion 611b, while being restricted in the second direction Y. It is movable. Further, the cam portion 611d projects downward from the first upper support portion 611a. A cam surface 611e facing the end mold 310A is formed on the tip end side of the cam portion 611d. The cam surface 611e is inclined inward in the second direction Y from the lower end toward the upper side.
[0075]
The lower mounting portion 612 is fixed to the bolster 620. The lower mounting portion 612 is provided between the pair of first lower support portions 612a for supporting the first lower mold 320 and the pair of first lower support portions 612a to support the second lower mold 340. (Ii) It has a lower support portion 612b. The second lower mold 340 is supported by the second lower support portion 612b via the drive portion 630. Further, of the first lower mold 320, the central mold 320B is fixed to the corresponding first lower support portion 612a. Of the first lower mold 320, the end mold 320A is movably supported on the upper surface of the corresponding first lower support portion 612a. Further, the lower mounting portion 612 corresponds to the pair of first lower molds 320, and the pair of lower guide portions 612c provided on the outer side of the first direction X of the pair of first lower support portions 612a, respectively. Each further has a pair of lower regulating portions 612d provided on the outer side of the second direction Y of the pair of first lower supporting portions 612a. Each of the pair of end molds 320A is restricted from moving outward in the second direction Y by the corresponding lower regulating portion 612d. Further, each of the pair of end molds 320A is restricted from moving to both sides in the first direction X by the corresponding lower guide portion 612c and the central mold 320B, thereby along the upper surface of the first lower support portion 612a. It is possible to move in the second direction Y. Further, in each of the pair of end molds 320A, an inclined surface 320e facing the cam surface 611e of the upper mounting portion 611 is formed at the outer end portion in the second direction Y. The inclined surface 320e is inclined so as to be inward in the second direction Y from the lower end toward the upper side.
[0076]
The drive unit 630 is provided between the first drive unit 631 that moves the slider 625 in the third direction Z, the first upper support portion 611a, and the overhanging portion 310C of the first upper mold 310, and is provided in the third direction Z. It has a second drive unit 632 that gives a reaction force to the second lower support portion 612b and a third drive unit 633 that is provided between the second lower support portion 612b and the second lower mold 340 and gives a reaction force to the third direction Z. The first drive unit 631 is immovably fixed to the ceiling surface 600b. The first drive unit 631 can be extended in the third direction Z by generating a driving force (hereinafter referred to as a molding load) with, for example, a hydraulic cylinder. Further, the second drive unit 632 is, for example, a gas cylinder, and the inside thereof is filled with a working gas. Therefore, while the second drive unit 632 is compressed by the drive force of the first drive unit 631, the reaction force (hereinafter referred to as pad load) corresponding to the compression amount is applied to the first upper support portion 611a and the first upper mold. It is possible to give to the overhanging portion 310C of 310. Further, the third drive unit 633 is, for example, a cushion pin, and the inside thereof is filled with hydraulic oil. Therefore, while the third drive unit 633 is compressed by the drive force of the first drive unit 631, the reaction force (hereinafter referred to as cushion load) corresponding to the amount of compression is applied to the second lower support portion 612b and the second lower. It is possible to give to mold 340. The third drive unit 633 may be supported on the support surface 600a through the through hole by forming a through hole in the second lower support portion 612b of the lower mounting portion 612 and the bolster 620.
[0077]
Therefore, by driving and extending the first drive unit 631, the slider 625, the upper mounting portion 611, the first upper mold 310 and the second upper mold 330 are moved downward in the third direction Z, and the first upper mold It is possible to sandwich the first intermediate press-molded product 2 which is the work material between the 310 and the second upper mold 330 and the first lower mold 320 and the second lower mold 340. Then, by further extending the first drive unit 631, the second drive unit 632 compresses and absorbs the displacement of the first upper support portion 611a, and the second drive unit 632 responds to the reaction force generated by the second drive unit 632. It is possible to apply a pressing force between the upper die 310 and the first lower die 320 so as to prevent out-of-plane deformation on the first intermediate press-molded product 2. Further, the third drive unit 633 compresses and absorbs the displacement of the second upper mold 330 and the second lower mold 340, while the second upper mold 330 and the second die according to the reaction force generated by the third drive unit 633. It is possible to apply a pressing force to the first intermediate press-molded product 2 with the lower mold 340. Then, the second upper mold 330 and the second lower mold 340 are displaced downward with respect to the first upper mold 310 and the first lower mold 320, so that the second step S2 is performed with respect to the first intermediate press-molded product 2. It becomes possible to carry out the processing in. At this time, as the cam surface 611e and the inclined surface 320e slide, the end mold 320A of the first lower mold 320 and the end mold 310A of the first upper mold 310 move to the Y center side in the second direction. It is possible to narrow the gaps M1 and M2 between the central molds 310B and 320B and the end molds 310A and 320A. The drive unit 630 maintains the distance between the first upper mold 310 and the second upper mold 330 and the distance between the first lower mold 320 and the second lower mold 340, and the first upper mold. The second upper die 330 and the second lower die 340 may be configured to be relatively moved from the first upper die 310 side to the first lower die 320 side with respect to the 310 and the first lower die 320.
[0078]
As shown in FIGS. 34 and 35, the second press molding apparatus 700 used in the third step S3 includes the mold of the third set 400 shown in FIGS. 17 to 19 and the mold mounting portion 710 for mounting the mold. It has a bolster 720 and a slider 725 that support the mold mounting portion 710, and a drive portion 730 that moves the mold. The mold mounting portion 710 has an upper mounting portion 711 that supports the upper mold and a lower mounting portion 712 that supports the lower mold. The bolster 720 is fixed to the support surface 700a. Further, the slider 725 is fixed to the ceiling surface 700b via the drive unit 730, and can be moved in the third direction Z by the drive of the drive unit 730.
[0079]
The upper mounting portion 711 is fixed to the slider 725. The upper mounting portion 711 is provided between the pair of first upper support portions 711a for supporting the third upper mold 410 and the pair of first upper support portions 711a, and is provided between the pair of first upper support portions 711a to support the fourth upper mold 430. It has a portion 711b. The third upper die 410 is supported by the first upper support portion 711a via the drive portion 730. The fourth upper mold 430 is fixed to the lower surface of the second upper support portion 711b. Further, the upper mounting portion 711 has an upper regulating portion 711c arranged on both outer sides of the first direction X of the second upper support portion 711b and an upper side arranged on the outer side of the second direction Y of the pair of first upper support portions 711a. It has a guide portion 711d. The upper guide portion 711d allows the third upper mold 410 to move in the third direction Z while restricting the movement of the third upper mold 410 to the outside in the second direction Y.
[0080] [0080]
The lower mounting portion 712 is fixed to the bolster 720. The lower mounting portion 712 is provided between the pair of first lower support portions 712a for supporting the third lower mold 420 and the pair of first lower support portions 712a to support the fourth lower mold 440. (Ii) It has a lower support portion 712b. The third lower mold 420 is fixed to the upper surface of the first lower support portion 712a. The fourth lower mold 440 is supported by the second lower support portion 712b of the lower mounting portion 712 via the drive portion 730. Further, the lower mounting portion 712 is arranged on both outer sides of the first direction X of the second lower support portion 712b, and on the outer side of the second direction Y of the first lower support portion 712a, respectively. It has a lower regulation unit 712d. The lower guide portion 712c allows the fourth lower mold 440 to move in the third direction Z while being restricted from moving outward in the first direction X.
[0081]
The drive unit 730 is provided between the first drive unit 731 that moves the slider 725 in the third direction Z, the first upper support portion 711a, and the third upper mold 410, and applies a reaction force to the third direction Z. It has a second drive unit 732 and a third drive unit 733 provided between the second lower support portion 712b and the fourth lower mold 440 and applying a reaction force in the third direction Z. The first drive unit 731 is immovably fixed to the ceiling surface 700b. The first drive unit 731 can be extended in the third direction Z by generating a driving force (hereinafter referred to as a molding load), for example, with a hydraulic cylinder. Further, the second drive unit 732 is, for example, a gas cylinder, and the inside thereof is filled with a working gas. Therefore, while the second drive unit 732 is compressed by the drive force of the first drive unit 731, the reaction force (hereinafter referred to as pad load) corresponding to the amount of compression is applied to the first upper support portion 711a and the third upper mold. It is possible to give to 410. Further, the third drive unit 733 is, for example, a cushion pin, and the inside thereof is filled with hydraulic oil. Therefore, the third drive unit 733 compresses by the drive force of the first drive unit 731, and applies a reaction force (hereinafter referred to as a cushion load) according to the amount of compression to the second lower support portion 712b and the fourth lower portion. It is possible to give to mold 440. The third drive unit 733 may be supported on the support surface 700a through the through hole by forming a through hole in the second lower support portion 712b of the lower mounting portion 712 and the bolster 720.
[0082]
Therefore, by driving and extending the first drive unit 731, the slider 725, the upper mounting unit 711, the third upper mold 410 and the fourth upper mold 430 are moved downward in the third direction Z, and the third upper mold It is possible to sandwich the second intermediate press-molded product 3 which is the work material between the 410 and the fourth upper mold 430 and the third lower mold 420 and the fourth lower mold 440. Then, by further extending the first drive unit 731, the second drive unit 732 compresses and absorbs the displacement of the first upper support portion 711a, and at the same time, the second drive unit 732 responds to the reaction force generated by the second drive unit 732. It is possible to apply a pressing force between the Mikami mold 410 and the third lower mold 420 so that the second intermediate press-molded product 3 cannot be deformed out of the plane. Further, while the third drive unit 733 compresses and absorbs the displacement of the fourth upper mold 430 and the fourth lower mold 440, the fourth upper mold 430 and the fourth upper mold 430 and the fourth according to the reaction force generated by the third drive unit 733. It is possible to apply a pressing force to the second intermediate press-molded product 3 with the lower mold 440. Then, the fourth upper mold 430 and the fourth lower mold 440 are displaced downward with respect to the third upper mold 410 and the third lower mold 420, so that the third step S3 with respect to the second intermediate press-molded product 3 It becomes possible to carry out the processing in.
[0083]
The first press forming apparatus 600 and the second press forming apparatus 700 shown in the above embodiment are examples of the apparatus capable of carrying out the second step S2 and the third step S3, and are not limited thereto. The configuration of each upper mounting portion and lower mounting portion, and the configuration of each driving portion can be appropriately changed. Further, in the first press molding apparatus 600 of the above embodiment, the mechanism for moving the end molds 310A and 320A in the second direction Y by the cam surface 611e and the inclined surface 320e is not limited to this. FIG. 36 shows a modified example of the first press molding apparatus 600'. As shown in FIG. 36, the first press molding apparatus 600 ′ has a configuration in which the upper mounting portion 611 ′ of the mold mounting portion 610 ′ does not have a cam portion. Further, the drive unit 630'is the first drive unit 631.It has a fourth drive unit 634 in addition to the second drive unit 632 and the third drive unit 633. The fourth drive unit 634 is, for example, a hydraulic cylinder, and is provided on both outer sides of the pair of end molds 320B of the first lower mold 320 in the second direction Y corresponding to each end mold 320B. Then, the fourth drive unit 634 can move the corresponding end mold 320B toward the center of the second direction Y by driving together with the drive of the first drive unit 631. Instead of the mechanism for moving the end molds 310A and 320A in the second direction Y by the cam in this way, the end molds 310A and 320A may be moved in the second direction Y by the independent fourth drive unit 634.
[0084]
Further, in the above embodiment, the first press molding apparatus 600 for carrying out the second step S2 and the second press forming apparatus 700 for carrying out the third step S3 are separate devices, but the present invention is not limited to this, and one device is used. The mold may be replaceable. For example, the mold of the mold mounting portion 610 and the second set 300 shown in FIGS. 32 and 33, and the second drive portion 632 and the third drive portion 633 constitute the first unit. Further, the second unit is composed of the mold of the mold mounting portion 710 and the third set 400, and the second drive portion 732 and the third drive portion 733. Then, the first unit and the second unit may be interchangeable between the slider 625 and the bolster 620 shown in FIGS. 32 and 33.
Example
[0085]
Next, Example 1 in which the stress state when the press-molded product 100 is manufactured by the method for manufacturing the press-molded product of the first embodiment will be described. In the example of the invention shown in Example 1, a GA590DP material (tensile strength 626 MPa, yield strength 342 MPa, Young ratio 21000 MPa, Poisson ratio 0.30) was used for the press-molded product 100. The thickness of the blank 1 was 2 mm. As a specific shape, the heights of the first wall portion 110 and the second wall portion 120 (the third from the upper surface 102 of the bottom plate portion 101 to the first upper surface 131 of the first flange 130 and the second upper surface 141 of the second flange 140). The distance in the direction Z) was set to 100 mm. Further, the width of the first flange 130 and the second flange 140 was set to 30 mm. The size of the bottom plate portion 101 is such that the width of the first direction X is 910 mm and the width of the second direction Y is 1500 mm. Further, R1 shown in FIG. 1 was set to 40 mm, R2 was set to 10 mm, and R3 was set to 10 mm.
[0086]
First, the first step S1 was carried out until the height of the first rising portion 10A (the distance in the third direction Z from the upper surface of the substrate portion 30A to the upper surface of the first band portion 20A) became 60 mm. Next, the second step S2 was carried out until the height of the second rising portion 40A (the distance in the third direction Z from the upper surface of the substrate portion 30A to the upper surface of the second band portion 50A) became 150 mm. At this time, the pad load was 25.7 tonf, the cushion load was 56.8 tonf, and the molding load was 250.0 tonf.
[0087]
FIG. 37 shows the magnitude of strain of the first intermediate press-molded product 2 after the second step S2 is carried out by the color depth. The darker the color, the greater the distortion. No distortion occurs in the thinnest range (colorless portion) including the substrate portion 30A. On the other hand, it is shown that the second rising portion 40A formed in the second step S2 is distorted in the range adjacent to the first rising portion 10A. FIG. 38 is a plot of the strain at each position of the first intermediate press-formed product 2 shown in FIG. 37, with the horizontal axis as the minimum main strain and the vertical axis as the maximum main strain. The straight line L is a straight line inclined by 45 degrees with respect to the horizontal axis and the vertical axis, that is, a straight line having | maximum main strain | = | minimum main strain |. The straight line L1 is a straight line having | maximum principal strain | = 2 × | minimum principal strain |, and the straight line L2 is a straight line having | maximum principal strain | = 0.5 × | minimum principal strain |. Since the straight line L is | maximum principal strain | = | minimum principal strain |, it means that the straight line L contracts at the same ratio in the direction orthogonal to the stretching direction with respect to the stretching in a certain direction. That is, in the portion where the strain as plotted on the straight line L occurs, there is no change in the thickness direction of the member because the shear deformation occurs. On the other hand, in the region outside the straight lines L1 and L2 with respect to the straight line L, the expansion / contraction ratio of the strain is significantly different, the thickness of the member decreases on the straight line L1 side, and the thickness of the member increases on the straight line L2 side. The larger the size, the more remarkable the influence on the moldability. Looking at the plot distribution for the example of the present invention, it is clear that all of them are distributed in the vicinity of the straight line L, and that the thickness reduction due to shear deformation is suppressed. In this way, since the strain at each position is distributed along the straight line L, the strain due to shear deformation also occurs at the portion where the strain occurs in the first intermediate press-molded product 2, and therefore the thickness decreases. Is clearly suppressed.
[0088]
FIG. 39 shows the rate of decrease in the thickness of the member after the second step S2 is carried out by the color depth. The thickness reduction rate indicates the reduction rate of the thickness at the same position after the second step is carried out with respect to the thickness before the second step S2 is carried out. The darker the color, the greater the thickness reduction rate. In the range where the color including the substrate portion 30A is the lightest (colorless portion), the reduction rate of the thickness is kept at less than 2.5%. The thickness reduction rate is kept at less than 2.5% even in the corner portion where the shear deformation occurs in which the first ridge line 106, the second ridge line 107, and the vertical ridge line 108 are connected. On the other hand, the thickness reduction rate can be suppressed to 6.5% even at the portion connected to the third ridge line 115 in the second rising portion 40A, which has the smallest thickness.
[0089]
Next, the third step S3 was carried out until the height of the first rising portion 10B (the distance in the third direction Z from the upper surface of the substrate portion 30A to the upper surface of the first band portion 20B) became 100 mm. At this time, the pad load was 59.7 tonf, the cushion load was 99.4 tonf, and the molding load was 318.0 tonf.
[0090]
FIG. 40 shows the magnitude of distortion of the second intermediate press-molded product 3 after the third step S3 is carried out by the color depth. The darker the color, the greater the distortion. No distortion occurs in the thinnest range (colorless portion) including the substrate portion 30A. On the other hand, in the second rising portion 40A, it is shown that distortion occurs in the range including the portion sheared and deformed in the second step S2 and the range connected to the first band portion 20B. FIG. 41 is a plot of the strain at each position of the second intermediate press-formed product 3 shown in FIG. 40, with the horizontal axis as the minimum main strain and the vertical axis as the maximum main strain. The details are the same as in FIG. 37. As shown in FIG. 41, the strains at any positions are distributed along the straight line L in the second quadrant. In this way, since the strain at each position is distributed along the straight line L, strain due to shear deformation also occurs at the portion where the strain is generated in the second intermediate press-molded product 3, and therefore the thickness is reduced. Is clearly suppressed.
[0091]
FIG. 42 shows the rate of decrease in the thickness of the member after the third step S3 is carried out by the color depth. The darker the color, the greater the thickness reduction rate. In the range where the color including the substrate portion 30A is the lightest (colorless portion), the reduction rate of the thickness is kept at less than 2.5%. On the other hand, it is recognized that the thickness is slightly smaller in the range adjacent to each other in the first rising portion 10B and the second rising portion 40A, and in the range where the second rising portion 40A and the second band portion 50A are connected. However, the thickness reduction rate can be suppressed to 6.6% even in the corner portion where the first ridge line 106, the second ridge line 107, and the vertical ridge line 108, which have the smallest thickness, are connected.
[0092]
FIG. 43 shows the thickness reduction rate of the member after the sixth step S6 is carried out by the color depth. The darker the color, the greater the thickness reduction rate. In the thinnest range (colorless portion) including the substrate portion 30A, the reduction rate of the thickness is kept at less than 2.5%. On the other hand, it is recognized that the thickness is slightly smaller in the range adjacent to each other in the first wall portion 110 and the second wall portion 120 and in the range close to the vertical ridge line 108 in the second flange 140. However, although the thickness was the smallest at the corner where the first ridge line 106, the second ridge line 107, and the vertical ridge line 108 were connected, the thickness reduction rate could be suppressed to 6.7%.
[0093]
As described above, the change in thickness before and after each process was suppressed so that the thickness after the process was 85% or more of the thickness before the process was performed, and the entire process was performed. It was possible to suppress the change in the thickness through the blank so that the thickness of each position after completion as the press-molded product 100 was 85% or more with respect to the thickness of the blank.
[0094]
Next, as Example 2, the invention example in which the press-molded product 100 was manufactured by the method for manufacturing the press-molded product of the above embodiment while changing the size of R3 of the vertical ridge line 108, and the first wall portion by drawing. In a comparative example in which 110 and the second wall portion 120 were formed at the same time, changes in thickness before and after processing were analyzed. The size of R3 was 5, 10, 15, and 20 mm. FIGS. 44 to 47 show the analysis results, and the smaller the thickness, the darker the result. In the analysis result of FIG. 44, R3 was set to 5 mm. In the analysis result of FIG. 45, R3 was set to 10 mm. In the analysis result of FIG. 46, R3 was set to 15 mm. In the analysis result of FIG. 47, R3 was set to 20 mm. As shown in FIGS. 44 to 47, in the example of the invention, processing was possible so that the thickness with respect to the blank 1 was 85% or more regardless of the condition of the radius of curvature R3. On the other hand, in the comparative example, the thickness with respect to the blank 1 was less than 85% at any site regardless of the conditions of R3. The portions where the thickness was significantly reduced were the corner portion where the first ridge line 106, the second ridge line 107 and the vertical ridge line 108 were connected, and the portion of the second wall portion 120 which was close to the vertical ridge line 108. In the example of the invention, as described above, the processing is performed at the relevant portion by shear deformation, so that the decrease in the member thickness is suppressed. On the other hand, in the comparative example, since the drawing process is performed, the tensile deformation is dominant even in the relevant portion, which causes the compression deformation in the direction orthogonal to the direction of the tensile deformation, that is, in the thickness direction. It is probable that the member thickness decreased.
[0095]
Although the embodiments and examples of the present invention have been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment and includes design changes and the like within a range that does not deviate from the gist of the present invention. Is done.
Industrial availability
[0096]
In the present invention, the corner where each ridge line connecting the bottom plate and each of the two vertical walls and the three ridge lines connecting the vertical walls intersect is press-molded while suppressing the decrease in member thickness. It is industrially useful because it can be used.
Description of the sign
[0097]
1 Blank (work material)
1a First edge
1b Second edge
10A, 10B First rising
20A, 20b 1st band
30A board part
40A Second rising top
50A second band
100 press-molded product
101 bottom plate
106 First ridgeline
107 Second ridgeline
108 Vertical ridgeline
110 First wall
120 Second wall
130 First flange
140 Second flange
310 first type
320 first lower model
330 Second upper model
340 Second lower model
310A, 320A end type
310B, 320B central type
410 Third upper model
420 Third lower model
430 Fourth type
440 4th lower type
600, 700 press molding equipment
630, 730 drive unit
M1 gap
S1 first step
S2 second process
S3 third process
S4 4th process
S5 5th step
The scope of the claims
[Claim 1]
From a plate-shaped workpiece having a first edge portion and a second edge portion extending in a direction intersecting the first edge portion and connected to the first edge portion, on the substrate portion and the first edge portion side. Through the first rising portion that rises from the substrate portion via the first ridge line and extends to the second edge portion, and the second ridge line that extends along the upper edge portion of the first rising portion to the second edge portion. The first step of forming the first band portion extending on the opposite side of the substrate portion,
Along the second edge portion, a strip-shaped first range including the substrate portion, the first rising portion, and the second edge portion of the first band portion is covered from both sides by the first upper mold and the first lower. While sandwiching it with a mold, the second range including the substrate portion, the first rising portion, and the first band portion adjacent to the first range is formed from both sides.It is sandwiched between the two upper molds and the second lower mold, and the first upper mold and the first lower mold are placed on the second upper mold and the second lower mold, and the side on which the first rising portion stands up with respect to the substrate portion. The whole rises between the first lower mold and the second upper mold on the same side as the first rising portion, and is connected to the first rising portion via a vertical ridge line. With a second step to form the upper part of the two
In the second step, a method for manufacturing a press-molded product in which a portion of the second rising portion connected to the vertical ridge line is shear-deformed.
[Claim 2]
The work material after the second step is sandwiched between the third upper mold and the third lower mold with the first ridge line as a boundary, and the substrate portion side is the fourth upper mold and the fourth upper mold. It is sandwiched between the fourth lower mold and the third upper mold and the third lower mold are relatively moved with respect to the fourth upper mold and the fourth lower mold to increase the rising height of the first rising portion. Equipped with a third process
In the third step, the range of the second rising portion adjacent to the first band portion and adjacent to the shear deformed range in the second step is shear deformed in the direction along the second edge portion. The method for manufacturing a press-molded product according to claim 1.
[Claim 3]
The method for producing a press-molded product according to claim 2, wherein the second step is further carried out after the third step is carried out, and the second step and the third step are alternately carried out at least once each.
[Claim 4]
The work material is provided with the first edge portion and the second edge portion in pairs so as to face each other.
The first step was carried out for each of the paired first edges,
The second step was carried out for each of the paired second edges,
By carrying out the third step for each of the paired first edges,
The method for manufacturing a press-molded product according to claim 2 or 3, wherein the pair of the first rising portions and the pair of the second rising portions surround the substrate portion to form a box body opened on one side.
[Claim 5]
The height between the second band portion sandwiched between the first upper mold and the first lower mold and the first band portion after the last step of the second step and the third step. In the fourth step of cutting the second rising portion along the second edge at the position,
After the fourth step is carried out, a fifth step is provided in which the portion of the second rising portion that rises above the first band portion is bent so as to be a surface continuous with the first band portion. The method for manufacturing a press-molded product according to any one of claims 2 to 4.
[Claim 6]
In the second step, the first upper mold and the first lower mold are used for the end mold that sandwiches at least the first band portion and the first rising portion of the work material, respectively, and the end mold. Of the materials to be processed, which are arranged at intervals, a central mold that sandwiches the substrate portion side from the first rising portion is formed, and the first upper mold and the first lower mold are the second. Claims 1 to 5 for moving the end molds of the first upper mold and the first lower mold so as to be close to the central mold according to the relative movement with respect to the upper mold and the second lower mold. The method for manufacturing a press-molded product according to any one of the above items.
[Claim 7]
The press-molded product according to claim 6, wherein the gap between the end mold and the central mold is formed by having a portion along the second edge portion in the middle of the direction along the first edge portion. Method.
[Claim 8]
The method for manufacturing a press-molded product according to any one of claims 1 to 7, wherein the inner portion of the vertical ridge is viewed from above and formed into a concave curve shape having a radius of curvature of 20 mm or less.
[Claim 9]
In the second step, the surface pressure of sandwiching the work material by the first upper mold and the first lower mold and the surface pressure of sandwiching the work material by the second upper mold and the second lower mold are , The method for manufacturing a press-molded product according to any one of claims 1 to 8, which is a surface pressure obtained based on the formula (1).
P = Y / 590 x t / 1.4 x P0 (1)
However, P: Surface pressure (MPa) that sandwiches the work material
Y: Tensile strength (MPa) of the work material
T: Thickness of work material (mm)
P0: Reference surface pressure = 0.1 MPa
[Claim 10]
The method for manufacturing a press-formed product according to any one of claims 1 to 9, wherein the steel material forming the work material has a tensile strength of 440 MPa or more.
[Claim 11]
The press molding according to any one of claims 1 to 10, wherein the shear deformed portion is formed with a thickness of 85% or more of the thickness of the work material before the first step. How to make the product.
[Claim 12]
The method for manufacturing a press-molded product according to any one of claims 1 to 11, wherein only the second rising portion is shear-deformed.
[Claim 13]
With a plate-shaped bottom plate
The first wall part that rises from the first side edge of the bottom plate part via the first ridgeline,
From the second side edge extending in the direction intersecting the first side edge of the bottom plate portion and connected to the first side edge, the whole rises to the same side as the first wall portion via the second ridge line. The first wall portion and the second wall portion connected via a vertical ridge line are provided.
The thickness of the first wall portion and the second wall portion is 85% or more of the thickness of the center of the bottom plate portion.
A press-molded product in which the radius of curvature of the inner part of the first ridge line and the radius of curvature of the inner part of the second ridge line are different.
[Claim 14]
The first flange extending from the upper edge of the first wall portion to the side opposite to the bottom plate portion with respect to the first wall portion,
A second flange extending from the upper edge of the second wall portion to the side opposite to the bottom plate portion with respect to the second wall portion and integrally connecting with the first flange is provided.
The press-molded product according to claim 13, wherein the thickness of the first flange and the second flange is 85% or more of the thickness of the center of the bottom plate portion.
[Claim 15]
Claims that the radius of curvature of the inner portion of the third ridge line connecting the first wall portion and the first flange is different from the radius of curvature of the inner portion of the fourth ridge line connecting the second wall portion and the second flange. Item 14. The press-molded product according to Item 14.
[Claim 16]
The press-molded product according to any one of claims 13 to 15, wherein the inner portion of the vertical ridge line is formed in a curved shape having a radius of curvature of 20 mm or less when viewed from above.
[Claim 17]
The press-molded product according to any one of claims 13 to 16, wherein the steel material forming the bottom plate portion, the first wall portion and the second wall portion has a tensile strength of 440 MPa or more.
[Claim 18]
A first lower mold having a first bottom surface, a first wall surface rising from the first bottom surface, and a first flange surface extending from the upper edge of the first wall surface to the side opposite to the first bottom surface.
The first upper mold, which is formed in a shape corresponding to the first lower mold and sandwiches the work material between the first lower mold,
It has a second bottom surface, a second wall surface rising from the second bottom surface, and a second flange surface extending from the upper edge of the second wall surface to the side opposite to the second bottom surface, and is arranged adjacent to the first lower mold. The second lower mold to be done,
The second upper mold, which is formed in a shape corresponding to the second lower mold and sandwiches the work material between the second lower mold,
The first upper mold and the first lower mold are maintained while maintaining the distance between the first upper mold and the second upper mold and the distance between the first lower mold and the second lower mold. A press molding apparatus including a drive unit for relatively moving the second upper mold and the second lower mold from the first upper mold side to the first lower mold side.
[Claim 19]
The first lower mold has a space between the lower end mold including at least the first wall surface and the first flange surface and the lower end mold, and is said to be the first wall surface of the work material. Equipped with a lower center type that sandwiches the part opposite to the first flange surface,
The first upper mold includes an upper end type corresponding to the lower end type of the first lower mold and an upper center type corresponding to the lower center type of the first lower mold.
The driving unit moves the second upper mold and the second lower mold relative to the first upper mold and the first lower mold, respectively, as described in the first lower mold and the first upper mold. The press molding apparatus according to claim 18, wherein the lower end mold and the upper end mold are moved so as to be close to the lower center mold and the upper center mold.
[Claim 20]
A third lower mold having a third bottom surface, a third wall surface rising from the third bottom surface, and a third flange surface extending from the upper edge of the third wall surface to the side opposite to the third bottom surface.
The third upper mold, which is formed in a shape corresponding to the third lower mold and sandwiches the work material between the third lower mold and the third lower mold,
It has a fourth bottom surface, a fourth wall surface rising from the fourth bottom surface, and a fourth flange surface extending from the upper edge of the fourth wall surface to the side opposite to the fourth bottom surface, and is arranged adjacent to the third lower mold. The fourth lower mold to be done,
Further equipped with a fourth upper mold that is formed in a shape corresponding to the fourth lower mold and sandwiches the work material between the fourth lower mold and the fourth lower mold.
The first lower mold, the first upper mold, the second lower mold and the second upper mold, and the third lower mold, the third upper mold, the fourth lower mold and the fourth upper mold. Can be exchanged with the set of
The press molding apparatus according to claim 18 or 19, wherein the driving unit moves the fourth upper mold and the fourth lower mold relative to the third upper mold and the third lower mold.