Technical Field
[0001] The present disclosure relates to a manufacturing method for a pressed component, a
pressed component, and a press apparatus.
Background Art
[0002] Automotive bodies are assembled by superimposing edges of multiple formed panels,
joining the formed panels together by spot welding to configure a box body, and joining
structural members to required locations on the box body by spot welding. Examples of
structural members employed at a side section of an automotive body (body side) include side
sills joined to the two sides of a floor panel, an A-pillar lower and an A-pillar upper provided
standing upward from a front portion of the side sill, a roof rail joined to an upper end portion
of the A-pillar upper, and a B-pillar joining the side sill and the roof rail together.
[0003] Generally speaking, configuration elements (such as respective outer panels) of
structural members including A-pillar lowers, A-pillar uppers, and roof rails often have a
substantially hat-shaped lateral cross-section profile configured by a top plate extending in a
length direction, two convex ridge line portions respectively connected to the two sides of the
top plate, two vertical walls respectively connected to the two convex ridge line portions, two
concave ridge line portions respectively connected to the two vertical walls, and two flanges
respectively connected to the two concave ridge line portions.
SUMMARY OF INVENTION
Technical Problem
[0004] The configuration elements described above have comparatively complex lateral
cross-section profiles and are elongated. In order to suppress an increase in manufacturing
costs, the above configuration elements are generally manufactured by cold pressing.
Moreover, in order to both increase strength and achieve a reduction in vehicle body weight in
the interests of improving fuel consumption, thickness reduction of the above structural
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members through the use of, for example, high tensile sheet steel having a tensile strength of
440 MPa or greater is being promoted.
[0005] However, when high tensile sheet steel is cold pressed in an attempt to manufacture
configuration elements that curve along their length direction, such as roof rail outer panels
(referred to below as "roof members"; roof members are automotive structural members),
spring-back occurs during press mold removal, leading to concerns of twisting in the top plate.
This gives rise to issues with regard to shape fixability, whereby roof members cannot be
formed in a desired shape.
[0006] For example, Japanese Patent Application Laid-Open (JP-A) No. 2004-314123
(referred to below as "Patent Document 1 ") describes an invention in which a pressed
component having a uniform hat-shaped lateral cross-section along its length direction is
applied with a step during manufacture in order to suppress opening-out, and thus improve the
shape fixability.
[0007] Moreover, the specification of Japanese Patent No. 5382281 (referred to below as
"Patent Document 2") describes an invention in which, during the manufacture of a pressed
component that includes a top plate, vertical walls, and flanges, and that curves along its
length direction, a flange formed in a first process is bent back in a second process so as to
reduce residual stress in the flange, thereby improving the shape fixability.
[0008] When the invention described in Patent Document 1 is used to manufacture pressed
components shaped so as to curve along a length direction, for example in configuration
elements of configuration members such as A-pillar lowers, A-pillar uppers, or roof rails,
bending occurs in curved walls as a result of spring-back after removal from the mold, such
that the desired shape cannot be formed.
[0009] According to the invention described in Patent Document 2, when manufacturing
pressed components that curve along their length direction and height direction and that
include a bent portion in the vicinity of the length direction center, residual stress arises in the
flange, residual stress arises at inner faces of the vertical walls and the top plate, and
deviatoric residual stress arises at inner faces of the vertical walls and the top plate. As a
result, as viewed ±rom the top plate side, bending occurs as a result of spring-back in the
pressed component after removal from the mold, such that the desired shape cannot be
formed.
[001 0] An object of the present disclosure is to provide a manufacturing method for a
pressed component in which the occurrence of bending as viewed from a top plate side is
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suppressed. Note that in the present specification, a "pressed component" includes: an
elongated top plate; a wall having one end connected to a short direction end portion of the
top plate, that curves with a convex shape bowing toward an opposite side to the top plate as
viewed from an upper side of the top plate, and that includes a sharp curve portion having a
smaller radius of curvature than at both sides of the sharp curve portion in the top plate length
direction; and a flange that is connected to another end of the wall and that extends in a plate
thickness direction of the wall toward the opposite side to the top plate side.
Solution to Problem
[0011] A pressed component manufacturing method according to the present disclosure is a
method for manufacturing a pressed component including an elongated top plate, a wall
having one end connected to a short direction end portion of the top plate, that curves with a
convex shape bowing toward an opposite side to the top plate as viewed from an upper side of
the top plate, and that includes a sharp curve portion having a smaller radius of curvature than
at both sides of the sharp curve portion in the top plate length direction, and a flange that is
connected to another end ofthe wall and that extends in a plate thickness direction of the wall
toward the opposite side to the top plate side. The manufacturing method includes a first
process of pressing to form an intermediate formed component including the top plate, the
wall, and a preliminary flange connected to another end of the wall and extending in a plate
thickness direction of the wall toward the opposite side to the top plate side. The
manufacturing method also includes a second process of pressing to deform the preliminary
flange such that an angle of a comer formed between a specific portion of the preliminary
flange connected to the sharp curve portion and the sharp curve portion progressively
increases or decreases at respective portions from one end to another end along the length
direction, so as to form the preliminary flange into the flange.
[001 2] A pressed component according to the present disclosure includes an elongated top
plate, a wall, and a flange. The wall has one end connected to a short direction end portion
of the top plate, curves with a convex shape bowing toward an opposite side to the top plate
as viewed from an upper side ofthe top plate, and includes a sharp curve portion having a
smaller radius of curvature than at both sides of the sharp curve portion in the top plate length
direction. The flange is connected to another end ofthe wall and extends in a plate thickness
direction of the wall toward the opposite side to the top plate side, with an angle of a corner
formed between the flange and the sharp curve portion progressively increasing or decreasing
from one end to the other end ofthe flange in the length direction.
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[0013] Moreover, a pressed component according to the present disclosure is the pressed
component described above, wherein a Vickers hardness value of a portion of the flange
connected to the sharp curve portion is lower than a Vickers hardness value of a portion of the
flange having a high Vickers hardness value out of portions ofthe flange connected to the
wall on one end side and on the other end side of the sharp curve portion in the length
direction.
[0014] A pressing apparatus according to the present disclosure includes a first press device
to press a blank using a first die and a first punch so as to form an intermediate formed
component, and a second press device to press the intermediate formed component using a
second die and a second punch. In the first press device, an elongated first groove
configured including an elongated first groove-bottom face and an elongated first side face is
formed in the first die. Moreover, in the first press device, the first side face is configured
including a first curved face that has one end connected to a short direction end portion of the
first groove-bottom face, that is curved with a convex shape bowing toward an opposite side
to the first groove-bottom face side as viewed along a mold closing direction, and that
includes a first sharp curve portion having a smaller radius of curvature than at both sides of
the first sharp curve portion in the first groove-bottom face length direction. The first side
face is further configured including a first inclined face that is connected to another end of the
first curved face, that is fmmed on the opposite side to the first groove-bottom face side as
viewed along the mold closing direction, and that is inclined with respect to the first curved
face. Fmihermore, in the first press device, the shape of the first punch is a shape that fits
together with the shape of the first groove during mold closure. In fhe second press device,
an elongated second groove configured including an elongated second groove-bottom face
and an elongated second side face is formed in the second die. Moreover, in the second
press device, the second side face is configured including a second curved face that has one
end connected to a short direction end portion ofthe second groove-bottom face, that is
formed at a position corresponding to the first sharp curve portion, that is curved in a concave
shape opening toward an opposite side to the second groove-bottom face side as viewed along
the mold closing direction, and that includes a second sharp curve portion having a smaller
radius of curvature than at both sides of the second sharp curve portion in the second
groove-bottom face length direction. The second side face is further configured including a
second inclined face that is connected to another end ofthe second curved face and that is
formed on the opposite side to the second groove-bottom face side as viewed along the mold
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closing direction, with an angle of a comer formed between the second inclined face and the
second sharp curve portion progressively increasing or decreasing from one end to the other
end of the second inclined face in the length direction. Furthermore, in the second press
device, the shape of the second punch is a shape that fits together with the shape of the second
groove during mold closure.
Advantageous Effects ofTnvention
[0015] Employing the pressed component manufacturing method according to the present
disclosure enables a pressed component to be manufactured while suppressing the occurrence
of bending as viewed from the top plate side.
[00 16] The pressed component according to the present disclosure has little bending as
viewed from the top plate side.
[00 I 7] Employing the press apparatus of the present disclosure enables a pressed component
to be manufactured while suppressing the occurrence of bending as viewed from the top plate
side.
BRIEF DESCRIPTION OF DRAWINGS
[0018] Fig. 1 is a plan view of a roof member and a face-on view of one end portion of the
roof member of an exemplary embodiment.
Fig. 2A is a perspective view and partial cross-section of a roof member of an
exemplary embodiment.
Fig. 2B is a cross-section (B-B cross-section) of a roof member, sectioned along line
B-B in Fig. 2A.
Fig. 2C is a cross-section (C-C cross-section) of a roof member, sectioned along line
C-C in Fig. 2A.
Fig. 2D is a cross-section (D-D cross-section) of a roof member, sectioned along line
D-D in Fig. 2A.
Fig. 2E is a cross-section (E-E cross-section) of a roof member, sectioned along line
E-E in Fig. 2A.
Fig. 2F is a cross-section (F-F cross-section) of a roof member, sectioned along line
F-F in Fig. 2A.
Fig. 3A is a perspective view and partial cross-section of an intermediate formed
component of an exemplary embodiment.
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Fig. 3B is a cross-section (B-B cross-section) of an intermediate formed component,
sectioned along line B-B in Fig. 3A.
Fig. 3C is a cross-section (C-C cross-section) of an intermediate formed component,
sectioned along line C-C in Fig. 3A.
Fig. 3D is a cross-section (D-D cross-section) of an intermediate formed component,
sectioned along lineD-Din Fig. 3A.
Fig. 3E is a cross-section (E-E cross-section) of an intermediate formed component,
sectioned along line E-E in Fig. 3A.
Fig. 3F is a cross-section (F-F cross-section) of an intermediate formed component,
sectioned along line F -F in Fig. 3A.
Fig. 4 is a perspective view illustrating a mold of a first press device employed in a
first process of a roof member manufacturing method of an exemplary embodiment.
Fig. 5 is a vertical cross-section of a first press device employed in a first process of a
roof member manufacturing method of an exemplary embodiment.
Fig. 6 is a perspective view illustrating a mold of a second press device employed in
a second process of a roof member manufacturing method of an exemplary embodiment.
Fig. 7 is a vertical cross-section of a second press device employed in a second
process of a roof member manufacturing method of an exemplary embodiment.
Fig. 8 is a diagram to explain evaluation methods for twisting and bending.
Fig. 9 is a table illustrating evaluation results obtained through simulation for
twisting and bending in roof members of Examples (Examples I to 12) of an exemplary
embodiment, and twisting and bending in roof members of Comparative Examples
(Comparative Examples I to 4).
Fig. I 0 is a graph illustrating a fitted curve of measured values for the Vickers
hardness of a flange of a roof member of an exemplary embodiment, taken from one end to
another end along a length direction.
DESCRIPTION OF EMBODIMENTS
[0019] Summary
The following explanation relates to an embodiment for implementing the present
disclosure, namely, an exemplary embodiment. Explanation follows regarding an Example
ofthe present exemplary embodiment.
[0020] Present Exemplary Embodiment
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Explanation follows regarding the present exemplary embodiment. First,
explanation follows regarding configuration of a roof member I of the present exemplary
embodiment illustrated in, for example, Fig. 1, Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E,
and Fig. 2F. Explanation then follows regarding configuration of a press apparatus 17 of the
present exemplary embodiment illustrated in, for example, Fig. 4 to Fig. 7. This will be
followed by explanation regarding a manufacturing method of the roof member of the present
exemplary embodiment. This will then be followed by explanation regarding advantageous
effects of the present exemplary embodiment. Note that the roof member I ofthe present
exemplary embodiment corresponds to an Example I, described later, illustrated in Fig. 9.
[0021] Roof Member Configuration
First, explanation follows regarding configuration of the roof member I of the
present exemplary embodiment, with reference to the drawings. Note that the roof member
l is an example of a pressed component.
[0022] As illustrated in Fig. I, Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E, and Fig. 2F, the
roof member 1 is an elongated member integrally configured including a top plate 2, two
vertical walls 4a, 4b, and two flanges 6a, 6b, and having a substantially hat-shaped
cross-section profile. The roof member 1 is, for example, configured by a component cold
pressed from a high tensile steel stock sheet having 131 0 MPa grade tensile strength.
Namely, the roof member 1 of the present exemplary embodiment is, for example, configured
by a component cold pressed from a high tensile steel stock sheet having a tensile strength of
from 440 MPa to 1600 MPa.
[0023] As illustrated in Fig. I, Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E, and Fig. 2F, the
top plate 2 is elongated. As illustrated in Fig. 1, as viewed fi·om the upper side of the top
plate 2, the top plate 2 is curved along its length direction, namely along the arrow Ll in the
drawings.
[0024] The two vertical walls 4a, 4b oppose each other in a state respectively extending
from both short direction ends of the top plate 2. As illustrated in Fig. I, as viewed from the
upper side of the top plate 2, the two vertical walls 4a, 4b curve along the length direction of
the top plate 2. Namely, the two vertical walls 4a, 4b of the present exemplary embodiment
oppose each other in a state extending from both short direction ends ofthe top plate 2, and
are curved as viewed from the upper side of the top plate 2. The vertical wall4a is curved in
a concave shape opening toward the opposite side to the vertical wall 4b side, namely the side
facing the vertical wall 4b side. The vertical wall4b is curved in a convex shape bowing
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toward the opposite side to the vertical wall 4a side, namely the side facing the vertical wall
4a side. From another perspective, one end of the vertical wal14b is connected to a short
direction end portion of the top plate 2, and curves with a convex shape bowing toward the
opposite side to the top plate 2 as viewed from the upper side of the top plate 2, namely
toward the side indicated by arrow A in the drawings. Note that vertical wall 4b is an
example of a wall.
[0025] As illustrated in Fig. 1, Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E, and Fig. 2F, the
roof member 1 is further integrally configured including a first portion 8 including one end
portion I a, a third portion 10 including another end portion 1 b, and a second portion 9
connecting the first portion 8 and the third portion 10 together.
[0026] Note that in the present exemplary embodiment, in plan view, namely as viewed
from the upper side of the top plate 2, the radius of curvature Rl of the first portion 8 is, for
example, set to greater than 2000 mm and no greater than 9000 mm. The radius of curvature
R2 of the second portion 9 is, for example, set to from 500 mm to 2000 mm, and the radius of
curvature R3 of the third portion 10 is, for example, set to greater than 2000 mm and no
greater than 9000 mm. The radius of curvature R1 of the vertical wall4b at the first portion
8 (referred to below as the portion 4b 1) is, for example, set to greater than 2000 mm and no
greater than 9000 mm, the radius of curvature R2 of the vertical wall4b at the second portion
9 (referred to below as the portion 4b2) is, for example, set to from 500 mm to 2000 mm, and
the radius of curvature R3 of the vertical wall4b at the third portion 10 (referred to below as
the pmiion 4b3) is set to greater than 2000 mm and no greater than 9000 mm. Namely, the
portion 4b2 has a smaller radius of curvature R than at both sides of the portion 4b2 in the top
plate 2length direction (the portion 4bl and the portion 4b3). Note that the portion 4b2 is an
example of a sharp curve portion.
[0027] As illustrated in Fig. I, Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E, and Fig. 2F, one
end of the flange 6a is connected to the end of the vertical wall4a on the opposite side to the
side connected to the top plate 2. Moreover, as viewed from the upper side of the top plate 2,
the flange 6a curves in a concave shape opening toward the opposite side to the top plate 2.
Note that the flange 6a is connected to the end of the vertical wall4a on the opposite side to
the side connected to the top plate 2 over the entire length direction range. The flange 6a
extends in a plate thickness direction of the vertical wall 4a toward the opposite side to the top
plate 2. The smaller angle out of the angles formed between the flange 6a and the vertical
wall4a is, for example, set to 120° over the entire length direction range.
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[0028] As illustrated in Fig. 1, Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E, and Fig. 2F, one
end of the flange 6b is connected to the end of the vertical wall4b on the opposite side to the
side connected to the top plate 2. Moreover, as viewed from the upper side of the top plate 2,
the flange 6b is curved in a convex shape bowing toward the opposite side to the top plate 2.
Moreover, the flange 6b extends in a plate thickness direction of the vertical wall 4b toward
the opposite side to the top plate 2. Note that the flange 6a is connected to the end of the
vertical wall 4b on the opposite side to the side connected to the top plate 2 over the entire
length direction range.
[0029] As illustrated in Fig. 2F, the smaller angle out of the angles formed between the
flange 6b and the portion 4b 1 of the vertical wall 4b is, for example, set to 140°, namely to an
obtuse angle. As illustrated in Fig. 2A, the smaller angle out of the angles formed between
the flange 6b and the potiion 4b3 of the vertical wall 4b is, for example, set to 150°, namely to
an obtuse angle. On the other hand, the smaller angle out of the angles formed between the
flange 6b and the portion 4b2 of the vertical wall4b differs at respective portions in the length
direction. More specifically, as illustrated in Fig. 2A, Fig. 2B, Fig. 2C, Fig. 2D, Fig. 2E, and
Fig. 2F, the smaller angle out of respective angles formed between the flange 6b and the
respective portions of the portion 4b2 along the length direction is set to 140° at a boundary
with the portion 4b 1, is set to 150° at a boundary with the portion 4b3, and progressively
increases from 140° to 150° between the boundary with the portion 4b1, namely from one end
in the length direction of the portion 4b1, to the boundary with the portion 4b3, namely the
other end in the length direction of the portion 4bl. From another perspective, the smaller
angle out ofthe respective angles formed between the flange 6b and the respective portions of
the portion 4b2 along the length direction is set to 150° at the boundary with the portion 4b3
and to 140° at the boundary with the portion 4b I, and progressively decreases from 150° to
140° from the boundary with the portion 4b3, namely one end in the length direction of the
portion 4b1 to the boundary with the portion 4b1, namely the other end in the length direction
of the portion 4bl. From yet another perspective, the flange 6b connected to the portion 4b2
is twisted between one length direction end and the other length direction end. Note that the
smaller angles out ofthe respective angles formed between the flange 6b and the respective
portions of the portion 4b2 along the length direction are set to obtuse angles.
[0030] The graph of Fig. 10 plots a fitted curve of measured values (measurement points
indicated by black squares) for the Vickers hardness HV of the flange 6b of the roof member
1 of the present exemplary embodiment from one end Ia to the other end lb along the length
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direction of the top plate 2. In the present exemplary embodiment, a portion of the flange 6b
(referred to below as the portion 6b I) that is connected to the vertical wall 4b at the first
portion 8, namely the portion 4b I has, for example, a Vickers hardness HV value of 410 HV
at a short direction end portion. A portion of the flange 6b (referred to below as the portion
6b3) that is connected to the vertical wal14b at the third portion 10, namely the portion 4b3
has, for example, a Vickers hardness HV value of 420 HV at a short direction end portion.
A portion of the flange 6b (referred to below as the portion 6b2) that is connected to the
vertical wal14b at the second portion 9, namely the portion 4b2, has a Vickers hardness HV
value at a short direction end portion of 410 HV at the boundary with the portion 6b I and of
4 20 HV at the boundary with the portion 6b3. In the length direction, from the boundary
with the portion 6b I to the boundary with the portion 6b3, there is a gradual decrease to a
minimum value (for example 395 HV), followed by a gradual increase. Namely, the Vickers
hardness HV value of an end portion of the portion 6b2 may be said to be lower than the
highest Vickers hardness HV value out of the Vickers hardness HV values of an end portion
of the portion6bl and an end portion of the portion 6b3. From another perspective, the end
portion of the portion 6b2 may be said to include a portion having a lower Vickers hardness
HV value than the lowest Vickers hardness HV values of the end portion ofthe pmiion 6b I
and the end portion of the portion 6b3. From yet another perspective, it could be said that
the minimum value of the Vickers hardness HV value of the end portion of the portion 6b2 is
lower than the Vickers hardness HV values of the end portion of the portion 6bl and the end
portion of the portion 6b3. Note that there is no limitation to the end portions, and as long as
the hardness is measured at the same position in the short direction of the flange, the portion
6b2 similarly has a portion with a lower Vickers hardness HV value than the pmiions with the
lowest Vickers hardness HV value in the portion 6bl and the portion6b3.
[0031] The foregoing explanation concerns configuration of the roof member 1 of the
present exemplary embodiment.
[0032] Press Apparatus Configuration
Next, explanation follows regarding configuration ofthe press apparatus 17 of the
present exemplary embodiment, with reference to the drawings. The press apparatus 17 of
the present exemplary embodiment is used to manufacture the roof member 1 of the present
exemplary embodiment. As illustrated in Fig. 4 to Fig. 7, the press apparatus 17 is
configured including a first press device 18 and a second press device 19. As illustrated in
Fig. 3A, Fig. 3B, Fig. 3C, Fig. 3D, Fig. 3E, Fig. 3F, Fig. 5, and Fig. 7, the press apparatus 17
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of the present exemplary embodiment employs the first press device 18 to draw a blank BL so
as to press the blank BL to form an intennediate formed component 30, and then uses the
second press device 19 to press the intennediate formed component 30 to manufacture a
manufactured component, namely the roof member 1. Note that the blank BL is configured
by an elongated high tensile sheet steel as a base material for manufacturing the roof member
1.
[0033] Note that as illustrated in Fig. 3A, Fig. 3B, Fig. 3C, Fig. 3D, Fig. 3E, and Fig. 3F, the
intennediate fanned component 30 is a substantially hat-shaped member configured including
the top plate 2, the two vertical walls 4a, 4b, and two preliminary flanges 7a, 7b. Moreover,
in the present specification, "pressing" refers to a process spanning, for example, setting a
forming target such as the blank BL or the intermediate fanned component 30 in a mold such
as a first mold 20 or a second mold 40, described later, closing the mold, and then opening the
mold. Note that "pressing" refers to forming by pressing or applying pressing pressure to the
fanning target.
[0034] First Press Device
The first press device 18 has a function of pressing the blank BL, this being the
fanning target, to form the intermediate fanned component 30.
[0035] As illustrated in Fig. 5, the first press device 18 is configured including the first mold
20 and a first moving device 25. As illustrated in Fig. 4, the first mold 20 includes an upper
mold 21, a lower mold 22, a first holder 23, and a second holder 24. The upper mold 21 is
disposed at an upper side, and the lower mold 22 is disposed at a lower side. Note that the
upper mold 21 is an example of a first die, and the lower mold 22 is an example of a first
punch.
[0036] As illustrated in Fig. 4, the upper mold 21 and the lower mold 22 are both elongated.
When the upper mold 21 and the lower mold 22 are viewed along the direction in which the
upper mold 21 and the lower mold 22 face each other (the direction in which the upper mold
21 and the lower mold 22 face each other is also sometimes referred to below as the up-down
direction in the present specification), the lower mold 22 projects out in a curve along its
length direction, and as illustrated in Fig. 4 and Fig. 5, the upper mold 21 is formed with an
elongated groove 21 a that curves following the lower mold 22. Note that as illustrated in
Fig. 4 and Fig. 5, the elongated groove 2la of the upper mold 21 is formed by faces including
an elongated groove-bottom face 2lal, a curved face 2la2 connected to one short direction
end of the groove-bottom face 2lal, and a curved face 21a3 connected to the other short
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direction end of the groove-bottom face 21al. Note that the groove-bottom face 21a1 is an
example of a first groove-bottom face, and the curved face 21 a2 is an example of a first side
face. Moreover, the curved face 21a2 is configured including a first curved face 21a21
connected to one short direction end of the groove-bottom face 21a1, and an inclined face
21 a22 inclined with respect to the first curved face 21 a21. As viewed along the up-down
direction, namely as viewed along a mold closing direction, the inclined face 21 a22 is
connected to the opposite side of the first curved face 2la21 to the groove-bottom face 21a1
side, and is formed toward the opposite side to the groove-bottom face 21a1 side. The
inclined face 21a22 is, for example, inclined at 160° with respect to the vertical wall4b.
Note that the inclined face 2la22 is an example of a first inclined face. Moreover, as
illustrated in Fig. 4, when the upper mold 21 is viewed along the up-down direction, the
curved face 21a2 is curved with a concave shape in its short direction, and the curved face
21a3 is curved with a convex shape in its short direction. Note that a sharp curve portion
21a4 that has a smaller radius of curvature than at both length direction end sides is fotmed at
the length direction center of the first curved face 21a21. The sharp curve portion 21 a4 is an
example of a first sharp curve portion. Note that the radius of curvature R of the sharp curve
portion 21a4 is, for example, set to from 500 mm to 2000 mm.
[0037] When the npper mold 21 is viewed along the length direction of the upper mold 21,
the width of the groove 21a becomes progressively wider on progression from the groove
bottom of the groove 21 a, namely from the groove-bottom face 21 a 1, toward the opening side
ofthe groove 21a, that is to say, on progression from the upper side toward the lower side.
When the lower mold 22 is viewed along the length direction of the lower mold 22, the width
of the projecting portion becomes progressively narrower on progression from the lower side
toward the upper side.
[0038] As illustrated in Fig. 4, the first holder 23 and the second holder 24 are elongated,
and are disposed at both short direction sides of the lower mold 22. Moreover, the first
holder 23 and the second holder 24 are respectively biased toward the upper side by springs
26, 27.
[0039] The first moving device 25 is configured to move the upper mold 21 toward the
lower mold 22. Namely, the first moving device 25 moves the upper mold 21 relative to the
lower mold 22.
[0040] Moreover, in a state in which the blank BL has been disposed at a predetermined
position in a gap between the upper mold 21 and the lower mold 22, the first moving device
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25 moves the upper mold 21 toward the lower mold 22, as illustrated in Fig. 5, and the blank
BL is pressed to form the intermediate formed component 30 in a state in which the two short
direction end sides of the blank BLare respectively interposed between the first holder 23 and
the upper mold 21, and the second holder 24 and the upper mold 21.
[0041] Explanation has been given above regarding the first press device 18. However,
from another perspective, the first press device 18 can be described in the following manner.
Namely, the upper mold 21 is formed with an elongated groove 21 a configured including the
elongated groove-bottom face 21 a! and the curved face 21 a2 of which one end is connected
to a short direction end portion of the groove-bottom face 2lal. Moreover, the curved face
2la2 is configured including the first curved face 2la21 that, as viewed along the mold
closing direction, is curved in a concave shape opening toward the opposite side to the
groove-bottom face 21a1 side and that includes the sharp curve portion 21 a4 having a smaller
radius of curvature R than at both sides of the sharp curve portion 2Ja4 in the length direction
ofthe groove-bottom face 21al. The curved face 21a2 is also configured including the
inclined face 21a22 that is connected to the other end ofthe first curved face 21a21, that, as
viewed along the mold closing direction, is formed on the opposite side to the groove-bottom
face 21a side, and that is inclined with respect to the first curved face 21 a21. Moreover, the
shape of the lower mold 22 is a shape that fits together with the shape of the first groove
during mold closure.
[0042] Second Press Device
The second press device 19 has a function of pressing the intermediate formed
component 30, this being a forming target, to form the intermediate formed component 30
into a roof member.
[0043] As illustrated in Fig. 7, the second press device 19 is configured including the second
mold 40 and a second moving device 45. As illustrated in Fig. 7, the second mold 40
includes an upper mold 41 and a lower mold 43. Note that the upper mold 41 is an example
of a second die, and the lower mold 42 is an example of a second punch. The upper mold 41
is disposed at the upper side, and the lower mold 42 is disposed at the lower side. The lower
mold 42 is biased from the lower side by a spring 43. Moreover, in the second press device
19, in a state in which the intermediate formed component 30 has been fitted onto the lower
mold 42, the upper mold 41 is moved toward the lower mold 42 side by the second moving
device 19 so as to change the angle of the preliminary flange 7b of the intermediate formed
component 30.
13
[0044] As illustrated in Fig. 6, the upper mold 41 and the lower mold 42 are both elongated.
When the upper mold 41 and the lower mold 42 are viewed along the direction in which the
upper mold 41 and the lower mold 42 face each other (the direction in which the upper mold
41 and the lower mold 42 face each other is also sometimes referred to below as the up-down
direction in the present specification), as illustrated in Fig. 6 and Fig. 7, the lower mold 42
projects out in a curve along its length direction, and the upper mold 41 is formed with an
elongated groove 41a that curves following the lower mold 42. Note that as illustrated in
Fig. 6 and Fig. 7, the elongated groove 41 a ofthe upper mold 41 is formed by faces including
an elongated groove-bottom face 41 a!, a curved face 4la2 connected to one short direction
end of the elongated groove-bottom face 41 a I, and a curved face 41 a3 connected to the other
short direction end ofthe elongated groove-bottom face 41 a!. Note that the elongated
groove-bottom face 41a1 is an example of a second groove-bottom face, and the curved face
41 a2 is an example of a second side face. Moreover, the curved face 41 a2 is configured
including a second curved face 41a21 that is connected to one short direction end of the
groove-bottom face 41 a I, and an inclined face 41 a22 that is inclined with respect to the
second curved face 41a21. As viewed along the up-down direction, namely, as viewed
along a mold closing direction, the inclined face 4la22 is connected to the opposite side of the
second curved face 41a21 to the groove-bottom face 21al side, and is formed on the opposite
side to the groove-bottom face 4la1 side. Note that the inclined face 4la22 is an example of
a second inclined face.
[0045] Moreover, as illustrated in Fig. 6, when the upper mold 41 is viewed along the
up-down direction, the curved face 4la2 is curved in a concave shape along its short direction,
and the curved face 41a3 is curved in a convex shape along its short direction. Note that a
sharp curve portion 41a4 having a smaller radius of curvature than at both length direction
end sides is formed at the length direction center of the second curved face 4la21. Note that
the sharp curve portion 41a4 is an example of a second sharp curve portion. The radius of
curvature R of the sharp curve portion 4la4 is, for example, set to from 500 mm to 2000 mm.
[0046] Note that the angle formed between the inclined face 41 a22 and the vertical wall4b
differs at each portion along the length direction of the upper mold 41. Specifically, along
the length direction, the angles of respective portions of the part of the inclined face 41a22
connected to the sharp curve portion 41a4 are set at an angle of 150° at one end and an angle
of 140° at the other end, and progressively decrease from 150° to 140° from the one end to the
other end. From another perspective, along the length direction, the angles of the respective
14
portions of the part of the inclined face 4la22 connected to the sharp curve portion 4la4 are
set to an angle of 140° at one end and to an angle of 150° at the other end, and progressively
increase from 140° to 150° from the one end to the other end. Moreover, the angle of the
respective portions of the inclined face 41 a22 on one end side of the sharp curve portion 41 a4
in the length direction is set to 150°, and the angle of the respective portions of the inclined
face 41a22 on the other end side of the sharp curve pmiion 4la4 in the length direction is set
to 140°.
[0047] Moreover, when the upper mold 41 is viewed along the length direction of the upper
mold 41, the width of the groove 4la becomes progressively wider from the groove bottom of
the groove 4la, namely, from the groove-bottom face 4lal, toward the open side of the
groove 41 a, that is to say, on progression from the upper side toward the lower side. When
the lower mold 42 is viewed along the length direction of the lower mold 42, the width of the
projecting pmiion becomes progressively narrower on progression from the lower side toward
the upper side.
[0048] Moreover, in a state in which the intermediate formed component 30 has been placed
on the lower mold 42, the second moving device moves the upper mold 41 toward the lower
mold 42, and the intermediate formed component 30 is pressed so as to form the roof member
I.
[0049] Explanation has been given above regarding configuration of the second press device
19. However, from another perspective, the second press device 19 can be described in the
following manner. Namely, the upper mold 41 is fom1ed with the elongated groove 41 a
configured including the elongated groove-bottom face 2la1 and the curved face 41a2 of
which one end is connected to a short direction end portion of the groove-bottom face 41al.
The curved face 41a2 is configured including the curved face 4la2 that, as viewed along the
mold closing direction, is curved in a convex shape bowing toward the opposite side to the
groove-bottom face 4lal side, and that includes the sharp curve portion 4la4 having a smaller
radius of curvature R than at both sides of the sharp curve portion 4la4 in the length direction
of the groove-bottom face 4lal. The curved face 41a2 is also configured including the
inclined face 4la22 that is connected to the other end of the curved face 4la2, that, as viewed
along the mold closing direction, is fonned on the opposite side to the groove-bottom face
4lal side, with the angle of a corner formed with respect to the sharp curve portion 4la4
differing at respective portions along the length direction. Moreover, the shape of the lower
mold 42 is a shape that fits together with the shape of the groove 4la during mold closure.
15
[0050] The foregoing explanation concerns the configuration of the press apparatns 17 of the
present exemplary embodiment.
[0051] Roof Member Manufacturing Method
Next, explanation follows regarding a manufacturing method of the roof member 1
of the present exemplary embodiment, with reference to the drawings. The manufacturing
method of the roof member I of the present exemplary embodiment is petformed employing
the press apparatns 17. Moreover, the manufactnring method ofthe roof member I of the
present exemplary embodiment includes a first process, this being a process performed using
the first press device 18, and a second process, this being a process performed using the
second press device 19.
[0052] First Process
As illustrated in Fig. 5, in the first process, the blank BL is disposed at a
predetermined position in the gap between the upper mold 21 and the lower mold 22. Next,
an operator operates the first press device 18 such that the upper mold 21 is moved toward the
lower mold 22 side by the first moving device, and the blank BL is drawn so as to press the
blank BL. Namely, in the first process, the upper mold 21 and the lower mold 22 are
employed to press the blank BL, this being a forming target. The intermediate formed
component 30 is fanned from the blank BL as a result. Note that as illustrated in Fig. 3A,
Fig. 3B, Fig. 3C, Fig. 3D, Fig. 3E, and Fig. 3F, the preliminary flange 7a is formed such that
the smaller angle out of the angles formed between the flange 6a of the intermediate formed
component 30 and the vetiical wall 4a is 120° over the entire length direction range.
Moreover, as illustrated in Fig. 3A, Fig. 3B, Fig. 3C, Fig. 3D, Fig. 3E, and Fig. 3F, the
preliminary flange 7b is formed such that the smaller angle out ofthe angles formed between
the preliminary flange 7b of the intermediate formed component 30 and the vertical wall4b is
160° over the entire length direction range, namely such that the angle between the
preliminary flange 7b and the vertical wall 4b is an obtuse angle.
[0053] Second Process
Next, as illustrated in Fig. 7, the intermediate formed component 30 is fitted onto the
lower mold 43 of the second mold 40 of the second press device 19. The operator then
operates the second press device 19 such that the upper mold 41 is moved toward the lower
mold 42 side by the second moving device 19, thereby pressing the intermediate formed
component 30. The roof member I is formed from the intermediate formed component 30
as a result. Note that in the second process, when the intermediate formed component 30 is
16
pressed by the upper mold 41 and the lower mold 42, the angle between the preliminary
flange 7a and the vertical wall4a does not change. On the other hand, the angle of the
portion of the preliminary flange 7b connected to the portion 4b1 of the vertical wall4b is
changed to 140°, and the angle of the portion ofthe preliminary flange 7b connected to the
portion 4b3 of the vertical wall4b is changed to 150°. Of the angles of the portion
connected to the portion 4b2 of the ve1iical wall 4b (an example of a specific pmiion), tbe
angle at the boundary witb the portion 4b3 is changed to 150°, and the angle at the boundary
with the portion 4bl is changed to 140°, such that the angle progressively decreases along the
length direction from the boundary with the portion 4b3 to the boundary with the portion 4b I.
Moreover, when the preliminary flange 7b is deformed as described above in the second
process, the preliminary flange 7b becomes the flange 6b. Accompanying this process, the
length of a leading end side of the portion of the flange 6b connected to the portion 4b2 of the
vertical wall 4b becomes longer than the length of a leading end side of the portion of the
preliminary flange 7b connected to the portion 4b2 of the vertical wall4b.
[0054] The foregoing explanation concerns the manufacturing method of the roof member I
ofthe present exemplary embodiment.
[0055] Advantageous Effects
Next, explanation follows regarding advantageous effects ofthe present exemplary
embodiment, drawing comparison to a comparative embodiment ofthe present exemplary
embodiment, described later. Note that the roof member I of the comparative embodiment,
which is not illustrated in the drawings, corresponds to Comparative Example 1 in Fig. 9,
described later.
[0056] Jn the comparative embodiment, in the second process, the angle of the preliminary
flange 7b with respect to the vertical wall 4b is changed to 150° from one end to the other end
along the length direction. · Namely, in the comparative embodiment, the angle of a sharp
curve portion ofthe preliminary flange 7b, namely of the respective portions of the portion of
the preliminary flange 7b connected to the portion 4b2, is the same from the one end to the
other end along the length direction.
[0057] Moreover, according to evaluation results for Comparative Example 1 configured by
the comparative embodiment, as illustrated in the table in Fig. 9, leading end portion twisting
was 21.64°, rear end pmiion twisting was 17.63°, leading end portion bending was 6.66 mm,
rear end portion bending was 9.78 mm, and the average bend amount was 8.22 mm.
17
[0058] Note that in the evaluation of leading end portion twisting and rear end portion
twisting, a computer, not illustrated in the drawings, was employed to compare data SD for a
roof member produced using a simulation based on the manufacture of a roof member of the
comparative embodiment against design data DD. Specifically, the cross-sections of length
direction central portions of the top plate 2 were aligned, namely, a best fit was found, and the
angle of the top plate 2 in its short direction at a leading end portion and a rear end portion in
the design data DD were set as references, with twisting being evaluated by the amount by
which the angles of the top plate 2 at the leading end portion and the rear end portion in the
measured data SD varied from these references, namely, X(0
) in Fig. 8. Moreover, bending
was taken to be the amount of width direction displacement of center positions 02 of a
leading end portion and rear end portion in the measured data SD from center positions 0 I of
the leading end portion and rear end portion in the design data DD, namely, Yin Fig. 8. The
average value of the leading end portion bending value and the rear end portion bending value
was taken as the average bend amount.
[0059] By contrast, according to the evaluation results of Example l configured by the
present exemplary embodiment, as illustrated the table of in Fig. 9, for a roof member l
produced using a simulation based on the manufacture of a roof member of the present
exemplary embodiment, leading end portion twisting was 16.64°, rear end portion twisting
was 14.38°, leading end portion bending was 9.55 mm, rear end portion bending was 3.28 mm,
and the average bend amount was 6.42 mm. Namely, in the evaluation results for the
present exemplary embodiment, the values for all evaluation categories were lower than the
values for all evaluation categories in the evaluation results for the comparative embodiment.
In other words, the present exemplary embodiment may be said to suppress the occurrence of
twisting better than the comparative embodiment. Moreover, the present exemplary
embodiment may be said to suppress the occurrence of bending better than the comparative
embodiment.
[0060] The reason that the present exemplary embodiment suppresses the occurrence of
twisting and the occurrence of bending better than the comparative embodiment is speculated
to be as follows. Namely, in the comparative embodiment, as described above, the angle of
the respective portions of the portion of the preliminary flange 7b connected to the portion
4b2 is changed to the same angle from the one end to the other end along the length direction.
On the other hand, in the present exemplary embodiment, in the second process, the angle of
the portion of the preliminary flange 7b connected to the portion 4b2 of the vertical wall4b is
18
changed so as to progressively decrease along the length direction from the boundary with the
pmiion 4b3 to the boundary with the portion 4bl, thereby configuring the flange 6b.
Accompanying this process, the length ofthe leading end side of the portion of the flange 6b
connected to the portion 4b2 becomes longer than the length of the leading end side of the
portion of the preliminary flange 7b connected to the portion 4b2. Moreover, in the present
exemplary embodiment, the length of a leading end side of the portion of the preliminary
flange 7b connected to the portion 4b2 that becomes longer due to deformation of the flange
6b is greater than in the comparative embodiment. As a result, in the roof member 1 ofthe
present exemplary embodiment, compressive stress at the portion of the flange 6b connected
to the portion 4b2, namely the portion of the flange 6b subject to the greatest compressive
stress out oflength direction pmiions of the flange 6b, is decreased in comparison to in the
roof member of the comparative embodiment. Note that in the present specification,
"compressive stress" refers to residual stress in the material when at the pressing bottom dead
center.
[0061] Accordingly, according to the present exemplary embodiment, in the second process,
the occurrence of bending as viewed from the top plate 2 side is better suppressed than in
cases in which the angle of the sharp curve portion of the preliminary flange 7b, namely of
respective portions of the portion ofthe preliminary flange 7b connected to the portion 4b2, is
changed to the same angle from the one end to the other end along the length direction.
Moreover, according to the present exemplary embodiment, in the second process, the
occurrence of twisting as viewed along the length direction is better suppressed than in cases
in which the angle of the sharp curve portion of the preliminary flange 7b, namely of the
respective portions of the portion of the preliminary flange 7b connected to the portion 4b2, is
changed to the same angle from the one end to the other end along the length direction.
[0062] T11e foregoing explanation concerns the advantageous effects of the present
exemplary embodiment.
[0063] Examples
Next, explanation follows regarding Examples and Comparative Examples, with
reference to the drawings. Note that in the following explanation, when the reference signs
used for components and the like are similar to the reference signs used for components and
the like in the present exemplary embodiment and the comparative embodiment, the reference
signs for these components are being carried over as-is.
[0064] Explanation regarding the table of Fig. 9
19
The table of Fig. 9 lists simulation parameters and evaluation results for Examples I
to 12 and Comparative Examples I to 5. Note that in the table of Fig. 9, "plate thickness" is
the thickness of the blank BL employed in the simulation. "Strength" is the tensile strength
of the blank BL employed in the simulation. Under the first process, entries are listed for the
portion 4bl, the portion 4b2, and the portion 4b3. The angle (0
) between the preliminary
flange 7b where connected to the portion 4b I and the vertical wall 4b, the angle C) between
the preliminary flange 7b where connected to the portion 4b2 and the vertical wall 4b, and the
angle (0
) between the preliminary flange 7b where connected to the portion 4b3 and the
vertical wall 4b are listed separately. Likewise, under the second process, entries are listed
for the portion 4bl, the portion 4b2, and the pmiion 4b3. The angle CO) between the
preliminary flange 7b where connected to the portion 4b 1 and the vertical wall 4b, the angle
(") between the preliminary flange 7b where connected to the portion 4b2 and the vertical
wall4b, and the angle C) between the preliminary flange 7b where connected to the portion
4b3 and the vertical wall4b are listed separately. Note that in the case of Example 2, the
entries under the first process give "160 to 165" as the angle (0
) between the preliminary
flange 7b where connected to the portion 4b2 and the vertical wall 4b. This is in reference to
the fact that the angle varies progressively from 160° to 165° from the boundary of the portion
4b2 with the portion 4b1 to the boundary of the portion 4b2 with the portion 4b3. Moreover,
in tbe cases of Examples 2 to 7, the entries under the second process give "140 to 150" as the
angle (0
) between the flange 6b where connected to the portion 4b2 and the vertical wall4b.
This is in reference to the fact that the angle varies progressively from 140° to 150° from the
boundary of the portion 4b2 with the portion 4bl to the boundary of the portion 4b2 with the
portion 4b3. Moreover, in the cases of Examples 8, 10, and II, the entries under the second
process give "1 00 to 90" as the angle (0
) between the flange 6b where connected to the portion
4b2 and the vertical wall 4b. This is in reference to the fact that the angle varies
progressively from 100° to 90° from the boundary of the portion 4b2 with the portion 4b1 to
the boundary of the portion 4b2 with the portion 4b3. In the cases of Examples 9 and 12,
although the angle ranges given under the second process are different to those given in the
cases of Examples 8, I 0, and 11, this is similarly in reference to the fact that the angle varies
progressively from 130° to 110° from the boundary of the portion 4b2 with the pmiion 4b 1 to
the boundary of the portion 4b2 with the portion 4b3. The leading end portion twisting, rear
end portion twisting, leading end portion bending, rear end portion bending, and average bend
amount are as described above.
20
[0065] Evaluation Results and Interpretation
In the table in Fig. 9, the roof members I of Examples I to 12 have a smaller average
bend amount than the roof members of Comparative Examples I to 4 under the same plate
thickness and strength parameters. In other words, it is apparent that less bending occurs.
Moreover, it can be seen that the roof members I of Examples I to 12 undergo less twisting
than the roof members of Comparative Examples I to 4 under the same plate thickness and
strength parameters. It may therefore be considered that Examples 2 to 12, these being
examples of Example I configured by the present exemplary embodiment, exhibit the
advantageous effects of the present exemplary embodiment described above to a greater
extent than Comparative Examples 2 to 4, these being examples of Comparative Example 1
configured by the comparative embodiment.
[0066] The present disclosure has been explained above using the present exemplary
embodiment and the Examples 2 to 12, these being examples of the present exemplary
embodiment. However, other modes than those of the present exemplary embodiment and
the Examples 2 to 12 described above are also included within the technical scope of the
present disclosure. For example, the following modes are also included within the technical
scope of the present disclosure.
[0067] In the present exemplary embodiment and the Examples, explanation has been given
using the roof member as an example ofthe pressed component. However, the pressed
component may be an automotive component other than a roof member as long as it is
manufactured by a method including the first process and the second process of the present
exemplary embodiment. Moreover, the pressed component may also be a component other
than an automotive component as long as it is manufactured by a method including the first
process and the second process ofthe present exemplary embodiment.
[0068] In the present exemplary embodiment and the Examples, explanation has been given
in which drawing is performed in the first process and the second process. However, there is
no limitation to drawing as long as the preliminary flange 7b is formed in the first process,
and in the second process, the angle of the portion of the preliminary flange 7b connected to
the portion 4b2 of the vertical wall 4b is changed so as to vary progressively along the length
direction from the boundary with the portion 4b3 to the boundary with the portion 4bl. For
example, bending may be performed.
[0069] Explanation has been given in which the pressed components of the present
exemplary embodiment and the Examples are configured including a top plate, two vertical
21
walls, and two flanges. However, the presence or absence of other configuration elements is
does not matter as long as the pressed component is configured including: an elongated top
plate; a wall (vertical wall) having one end connected to a short direction end portion of the
top plate, that curves with a convex shape bowing toward the opposite side to the top plate as
viewed from the upper side of the top plate, and that includes a sharp curve portion having a
smaller radius of curvature than at both sides of the sharp curve portion in the top plate length
direction; and a flange that is connected to another end of the wall and that extends in a plate
thickness direction of the wall toward the opposite side to the top plate side, with an angle of
a corner fmmed between the flange and the sharp curve portion progressively increasing or
decreasing at respective portions from one end to the other end of the flange in the length
direction. For example, a pressed component included within the technical scope of the
present disclosure need not include a vetiical wall opposing the wall (vertical wall) that has
the sharp curve portion. Moreover, in pressed components included within the technical
scope ofthe present disclosure, a flange need not be connected to a vertical wall opposing the
sharp curve portion.
[0070] Explanation has been given in which the pressed components of the present
exemplary embodiment and the Examples are configured including a top plate, two vertical
walls, and two flanges, and the two vertical walls are curved along the length direction as
viewed from the upper side of the top plate. However, the shape ofthe vertical wall
opposing the sharp curve portion is not limited to the shapes of the present exemplary
embodiment and the Examples as long as the pressed component is configured including: an
elongated top plate; a wall, namely a vertical wall, having one end connected to a shmi
direction end portion of the top plate, that curves with a convex shape bowing toward the
opposite side to the top plate as viewed from an upper side of the top plate, and that includes a
sharp curve portion having a smaller radius of curvature than at both sides of the sharp curve
portion in the top plate kngth direction; and a flange that is connected to another end of the
wall and that extends in a plate thickness direction ofthe wall toward the opposite side to the
top plate side, with an angle of a comer formed between the flange and the sharp curve
portion differing at respective portions along the length direction. For example, in pressed
components included within the technical scope of the present disclosure, a vertical wall
opposing the sharp curve portion may have a linear shape as viewed from the upper side of
the top plate.
[0071] Supplement
22
The following additional disclosure is a generalization from the present specification.
Namely, the additional disclosure is
"A manufacturing method for a pressed component in which:
a blank configured by sheet steel having a tensile strength of from 440 MPa to 1600
MPa is subjected to a first pressing using a punch, a die, and a holder so as to manufacture an
intermediate formed component that has a substantially hat-shaped lateral cross-section
profile configured including
a top plate present extending along a length direction,
two ridge lines respectively connected to both sides of the top plate,
two vertical walls respectively connected to the two ridge lines,
two concave ridge line portions respectively cmmected to the two vertical
walls, and
two flanges respectively connected to the two concave ridge line portions,
and that includes a curved portion cnrved from one end portion to another end
portion in the length direction in both plan view and side view when disposed in an
orientation in which the top plate is positioned at an upper portion; and
the intermediate formed component is subjected to a second pressing employing a
punch, a die, and a bolder such that the respective radii of curvature of a first pmiion along
the length direction including the one end portion and of a third portion along the length
direction including the other end portion are larger than the radius of curvature of a second
portion contiguous to both the first portion and the third portion, and at least one flange out of
the two flanges forms an angle that changes along the length direction with respect to the
vertical wall contiguous to the flange across the concave ridge line portion, wherein:
in the first pressing, the vertical wall and the flange on an outer side of the curved
portion of the intetmediate formed component are formed so as to satisfY Equation (I) below,
and in the second pressing, the vertical wall and the flange on an outer side of the curved
portion of the intermediate formed component are fanned into the vertical wall and the flange
on an outer side of the curved portion of the pressed component, and a length direction
change amount of the angle of the flange on the outer side of the curved portion of the pressed
component is greater than a length direction change amount of the angle of the flange on the
outer side of the curved portion of the intermediate formed component so as to satisfY
Equation (2) below.
Equation (I): 0.9 :0: DOF I I DOR 1 :0: I
23
Equation (2): i\002 >/\DOl
wherein
DOFI is an angle formed between the vertical wall and the flange on the outer side
of the curved portion, including at the one end potiion of the intermediate formed component,
DOR I is an angle formed between the vertical wall and the flange on the outer side
of the curved portion, including at the other end portion of the intermediate formed
component,
1\DOI is a length direction change amount of the angle of the flange on the outer side
of the curved portion of the intermediate formed component, and
i\D02 is a length direction change amount of the angle of the flange on the outer side
of the curved portion of the pressed component".
[0072] The disclosure of Japanese Patent Application No. 2015-087506, filed on April22,
2015, is incorporated in its entirety by reference herein. All cited documents, patent
applications, and technical standards mentioned in the present specification are incorporated
by reference in the present specification to the same extent as if the individual cited document,
patent application, or technical standard was specifically and individually indicated to be
incorporated by reference.

CLAIMS
1. A manufacturing method for a pressed component including an elongated top plate, a
wall having one end connected to a short direction end portion of the top plate, that curves
with a convex shape bowing toward an opposite side to the top plate as viewed from an upper
side of the top plate, and that includes a sharp curve portion having a smaller radius of
curvature than at both sides of the sharp curve portion in the top plate length direction, and a
flange that is connected to another end of the wall and that extends in a plate thickness
direction of the wall toward the opposite side to the top plate side, the manufacturing method
compnsmg:
a first process of pressing to form an intermediate formed component including the
top plate, the wall, and a preliminary flange connected to another end of the wall and
extending in a plate thickness direction of the wall toward the opposite side to the top plate
side; and
a second process of pressing to def01m the preliminary flange such that an angle of a
comer formed between a specific portion of the preliminary flange connected to the sharp
curve portion and the sharp curve portion progressively increases or decreases at respective
portions from one end to another end along the length direction, so as to form the preliminary
flange into the flange.
2. A pressed component comprising:
an elongated top plate;
a wall having one end connected to a short direction end portion ofthe top plate, that
curves with a convex shape bowing toward an opposite side to the top plate as viewed from
an upper side of the top plate, and that includes a sharp curve portion having a smaller radius
of curvature than at both sides of the sharp curve portion in the top plate length direction; and
a flange that is connected to another end of the wall and that extends in a plate
thickness direction of the wall toward the opposite side to the top plate side, with an angle of
a corner formed between the flange and the sharp curve portion progressively increasing or
decreasing from one end to the other end of the flange in the length direction.
3. The pressed component of claim 2, wherein a Vickers hardness value of a portion of the
flange connected to the sharp curve p01iion is lower than a Vickers hardness value of a
25
portion of the flange having a high Vickers hardness value out of portions of the flange
connected to the wall on one end side and on the other end side of the sharp curve portion in
the length direction.
4. A press apparatus comprising:
a first press device to press a blank using a first die and a first punch so as to form an
intermediate fonned component; and
a second press device to press the intermediate formed component using a second die
and a second punch; wherein
in the first press device,
an elongated first groove configured including an elongated first
groove-bottom face and an elongated first side face is formed in the first die;
the first side face is configured including a first curved face that has one end
connected to a short direction end portion of the first groove-bottom face, that is
curved in a convex shape bowing toward an opposite side to the first groove-bottom
face side as viewed along a mold closing direction, and that includes a first sharp
curve portion having a smaller radius of curvature than at both sides of the first sharp
curve portion in the first groove-bottom face length direction, and a first inclined face
that is connected to another end of the first curved face, that is formed on the
opposite side to the first groove-bottom face side as viewed along the mold closing
direction, and that is inclined with respect to the first curved face, and
the shape of the first punch is a shape that fits together with the shape of the
first groove during mold closure; and
in the second press device,
an elongated second groove configured including an elongated second
groove-bottom face and an elongated second side face is formed in the second die,
the second side face is configured including a second curved face that has
one end connected to a short direction end portion of the second groove-bottom face,
that is formed at a position corresponding to the first sharp curve portion, that is
curved in a concave shape opening toward an opposite side to the second
groove-bottom face side as viewed along the mold closing direction, and that
includes a second sharp curve portion having a smaller radius of curvature than at
both sides of the second sharp curve portion in the second groove-bottom face length
26
direction, and a second inclined face that is connected to another end of the second
curved face and that is fmmed on the opposite side to the second groove-bottom face
side as viewed along the mold closing direction, \\~th an angle of a comer formed
between the second inclined face and the second sharp curve portion progressively
increasing or decreasing fi·om one end to the other end of the second inclined face in
the length direction, and
the shape of the second punch is a shape that fits together with the shape of
the second groove during mold closure.