"Press Formed Product, And Production Method And Production Device For Production Of Press Formed Product"
Abstract:
Provided is a bulkhead (10) which is a press molded article comprising a top plate part (11) side flange parts (14) and corner flange parts (15). The side flange parts (14) respectively extend from each side (12) of the top plate part (11). The corner flange parts (15) respectively extend from each corner part (13) of the top plate part (11). The corner flange parts (15) connect two of the side flange parts (14) to each other. A center part of each corner flange part (15) in the peripheral direction has a section that exhibits a minimum thickness value and the two side parts thereof each have a section that exhibits a maximum thickness value. The ratio between the maximum value and the minimum value is in the range of more than 1.0 and less than or equal to 1.6. This press molded article suppresses wrinkling at the corner flange parts and is suitable as a reinforcing member for an automotive structural member.
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Notices, Deadlines & Correspondence
c/o Nippon Steel & Sumitomo Metal Corporation 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
2. NAKAZAWA Yoshiaki
c/o Nippon Steel & Sumitomo Metal Corporation 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
Specification
DESCRIPTION
TITLE OF INVENTION:
PRESS-FORMED PRODUCT AUTOMOBILE STRUCTURAL MEMBER
INCLIIDING THE SAME, PRODUCTION METHOD AND PRODUCTION
DEVICE FOR THE PRESS-FORMED PRODUCT
TECHNICAL FIELD
[0001]
The present invention relates to a press-formed product of a steel plate,
and particularly relates to a press-formed product suitable as a reinforcing member
for a structural member constituting an automobile body. Further, the present
invention relates to an automobile structural member including the press-formed
product, and a production method and a production device for the press-formed
product.
BACKGROLIND ART
[0002]
Al automobile body includes various structural members (for example, a
rocker (also referred to as a side sill), a cross member, a side member, a center pillar,
and the like). For the structural members, press-formed products of steel plates are
frequently used. The press-formed products for use in the structural members have
char¡rel-shaped or hat-shaped sectional shapes, for example. A press-formed
product having a channel-shaped section includes a top plate part and a pair of
flange parts connecting to the top plate part. A press-formed product having a hatshaped
section includes a top plate part, apair of vertical wall parts connecting to
the top plate part, and a pair of flange parts connecting to the respective vertical wall
parts. In general, mutual edge portions of a plurality of press-formed products are
laid on one another, and are joined by resistance spot welding. In this way, a
hollow structural member is assembled.
[0003]
ln an automobile structural member as above, reinforcing members are
3
1l
joined by resistance spot welding to important parts such as those where the formed
products are joined to each other, and those where high loads are applied. For the
reinforcing members, press-formed products of steel plates are frequently used. In
the case of a rocker, for example, reinforcing members that partition an inside of the
rocker are disposed at one spot or a plurality of spots in a lengthwise direction of the
rocker. This is for ensuring three-point bending crush performance of the rocker
with respect to the load of a lateral collision. The reinforcing member is referred to
as a bulkhead or a stiffener.
[0004]
FIG. 1 is a perspective view showing an example of a rocker including a
conventional bulkhead inside. FIG. I shows a state in which a bulkhead 110 inside
is seen through. In the following explanation, the case where the structural member
is a rocker 1 is taken as an example.
[000s]
As shown in FIG. 1, the rocker 1 is a long hollow cylindrical body. A
sectional shape of the rocker 1 illustrated in FIG. 1 is substantially rectangular. The
bulkhead 110 includes a top plate part 111 and flange parts 114. An outline shape
of the top plate part 11 1 substantially corresponds to an inner sectional shape of the
rocker 1. The flange parts I 14 are formed at respective four sides 112 of the top
plate part I11. The bulkhead 110 is disposed in a predetermined position in a
lengthwise direction in the inside of the rocker 1 . The respective flange parts 1 14
of the bulkhead 110 are overlaid on inner surfaces of the rocker 1, and are joined to
the rocker 1 by resistance spot welding or the like. From the viewpoint of reducing
the weight of an automobile body, press-formed products formed from a high+ensile
strength steel plate are used for the rocker I and the butkhead 110. Tensile strength
of the high-tensile strength steel plate in this case is usually set aT 440 MPa or more,
and is sometimes set to be more than 440 MPa in accordance with required
performance or the like.
[0006]
Conventionally, the flange parts 114 have been formed by individually
folding respective edge parts of the four sides 112 of the top plate part 111.
Hereinafter, the individual flange parts 114 which extend frorn the respective sides
1 12 of the top plate part 1 I I will also be referred to as "side flange parts". In this
case, the flange parts 114 are separated to be discontinuous at comer parts 113 that
connectthe adjacent sides 112 of the topplatepart 111. In some cases, cutouts 117
are provided at both side ends of each of the side flange parts 1 14, as shown in FIG.
1.
[0007]
Speaking from a performance aspect of the bulkhead 1 10 (the reinforcing
member) in the rocker 1 (the automobile structural member), it is more desirable that
the flange parts are configured as follows, than the flange parts 114 are discontinued
in the corner parts 113 of the top plate part 111 as in the conventional bulkhead 110
shown in FIG. 1, from an idealistic viewpoint. The flange parts also extend from
therespectivecornerparts 113 ofthetopplatepart 111. Hereinafter,theindividual
flange parts which extend from the respective corner parts 113 of the top plate part
111 will also be referred to as "corner flange parts". The adjacent side flange parts
are connected via the comer flange part. In this case, the flange parts continue from
the certain side 1 12 of the top plate part 1 11 throughout the corner parts I 13 and the
adjacent sides 112. Hereinafter, the flange part that continues without being
separated in the corner part I I 3 of the top plate part 1 I I will also be referred to a
"continuous flange part".
[0008]
However, it is very diffrcult to obtain the product including the continuous
flange part by press forming. It has been, of course, conventionally possible to
obtain a product such as a tid of a can by press-forming a soft plate material of soft
steel, aluminum or the like. However, it is difficult to produce a product including
the continuous flange part by especially press-forming a high-tensile strength steel
plate, in order to obtain a reinforcing member in the automobile structural member
described above. This is for the following reason.
[000e]
When producing the product including a continuous flange part from a
steel plate by press forming, forming of the corner flange part is shrink-flanging.
Consequently, wrinkles easily occur in the corner flange parts. The wrinkles occur
more remarkably as strength of the steel plate is higher.
[0010]
When wrinkles occur in the corner flange part, the following problem
arises. Referring to the example shown in FIG. 1, when the bulkhead 110 is
disposed inside the rocker 1 and mutual overlapping portions are joined by
resistance spot welding, gaps due to wrinkles are generated in the overlapping
portions. Thereby, a trouble such as poor welding easily occurs. Further, position
of the bulkhead I l0 in the rocker I easily becomes unstable. Accordingly, if
wrinkles occur in the corner fTange parts of the bulkhead 1 10, the bulkhead I I 0
cannot be used as an actual product.
[0011]
Prior arts that suppress occurrence of wrinkles in the regions to be shrinkflanged
at the time of press-forming steel plates are as follows.
[0012]
For example, Japanese Patent No.2554768 (Patent Literature 1) and
Japanese Patent Application Publication No. 07-1 12219 (Patent Literature 2) each
disclose a technique of forming a roof panel having an opening for a sunroof. Each
of the techniques of Patent Literatures I and2 indicates that in order to absorb an
excess line length of the region to be shrink-flanged at a time of forming, an excess
thickness part is given in advance. Japanese Patent No. 2560416 (Patent Literature
3) discloses a technique of square cylinder draw forming. In the technique of
Patent Literature 3, a specif'rc shape is given to a region to be shrink-flanged.
Japanese Patent Application Publication No. 04-l 18118 (Patent Literature 4)
discloses a technique of press forming using a cam structure. It is indicated that in
the technique of Patent Literature 4, forming is performed while presser bar pressure
is given to a region to be shrink-flanged.
CITAIION LIST
PATENT LITERATURE
[0013]
Patent Literature 1: Japanese Patent No. 2554768
Patent Literature 2: Japanese Fatent Application Publication No. 07-l I22I9
Patent Literature 3: Japanese Patent No. 256041 6
Patent Literature 4: Japanese Patent Application Publication No. 04-118118
SUMMARY OF INVENTION
TECHNICAL PROBLEM
[0014]
In development of automobiles, higher functionality and higher value
addition of structural members are always studied, and study on enhancement of
three-point bending crush performance of the structural members at a time of
crushing is not an exception.
[0015]
Therefore, an objective ofthe present invention is to provide a pressformed
product suitable as a reinforcing member (a bulkhead) that contributes to
enhancement of three-point bending crush performance of a structural member
(example: a rocker or the like) at a time of a collision, for example, in particular, a
press-formed product including a continuous flange part in which wrinkles are
suppressed in corner flange parts. Further, another objective of the present
invention is to provide an automobile structural member that includes the pressformed
product as a reinforcing membe¡ and is excellent in three-point bending
crush performance.
[00r6]
In each of the aforementioned techniques of Patent Literatures 1 to 3, the
excess line length to be the cause of wrinkles and excessive thickness at the time of
press formíng is absorbed by the excess thickness part which is given in advance.
The excess thickness part remains in the product after press forming. Consequently,
not only the excess thickness part becomes a hindrance to resistance spot welding in
a domain of the excess thickness part, but also the excess thickness part sometimes
becomes a hindrance to resistance spot welding in other domains.
[0017]
In the aforementioned technique of Patent Literature 4, a shrinkage degree
and a reaction force received by a cam structure are small when a product having a
region with a large radius of curvature (2100 rnm, for example) is formed.
consequently, wrinkles can be suppressed in the region with a large radius of
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cwvattue. However, when a product having a region with a small radius of
curvature (5 mrr, for example) is formed, a shrinkage degree and a reaction force
received by a cam structure are large. Consequently, wrinkles cannot be suppressed
in the region with a small radius of curvature. Especially in press-forming with use
of a high-tensile strength steel plate as a blank, yield stress of the blank is high, and
therefore, out-of-plane deformation of the blank under elastic deformation becomes
large. consequently, excessively large wrinkles occur. In addition, the reaction
force received by the cam structure becomes excessively large, and therefore,
handling is difficult with the cam structure.
[0018]
As above, it is difficutt to obtain a product including a continuous flange
part by press forming in the prior technique. In particular, it is nearly impossible in
the prior technique to press-form a high-tensile strength steel plate of 440 MPa-class
or more, and produce a product with wrinkles suppressed, in order to obtain a pressformed
product suitable for a reinforcing member for an automobile structural
mernber.
[001e]
Therefore, still another objective of the present invention is to provide a
production method and a production device capable of producing a press-formed
product which is a press-formed product including a continuous flange, and in which
wrilkles are suppressed in corner flange parts.
SOLUTION TO PROBLEM
[0020]
A press-formed product according to one embodiment of the present
invention is formed from a steel plate.
The press-formed product includes a top plate part and flange parts.
The flange parts each extend from some or all of sides constituting an
outline of the top plate part.
A comer flange part extends from a corner part connecting, among the
sides of the top plate part, at least a pair of the sides which are adjacent to each other
and from which the flange parts extend.
The flange parts each extending from the pair of the sides are connected to
each other via the corner flange part.
In the comer flange part,
a part having a minimum value of plate thickness is present in a central
portion in a direction along a circumferential direction of the corner part of the top
plate part,
parts having a maximum value of the plate thickness are present on both
sides of the central portion, and
aratio of the maximum value and the minimum value is in a range of
more than 1.0 to 1.6 or less.
[0021]
In the above described press-formed product, a radius of curvature of the
corner flange part is preferably 30 mm or less.
100221
. h the above described press-formed product, a width of at least a part of
the flange parts is preferably 10 mm or more.
[0023]
In the above described press-formed product, tensile strength of the pressformed
product is preferably 440 MPa or more.
L0o24l
An automobile structural member according to one embodiment of the
present invention is a hollow structural member constituting an automobile body.
The automobile structural member
includes therein the press-formed product descrjbed above as a reinforcing
member, wherein the flange parts are joined to the automobile structural member.
[0025]
A production rnethod for a press-formed product according to one
embodiment of the present invention is for producing the press-formed product from
a blank ofa steel plate.
The press-formed product includes a top plate part, flange parts and a
corner flange part.
The flange parts each extend from sorne or all of sides constituting an
outline of the top plate part.
The corner flange part extends from a corner part connecting, among the
sides of the top plate part, at least a pair of the sides which are adjacent to each other
and from which the flange parts extend. The corner flange part connects the flange
parts each extending from the pair of the sides, to each other.
The production method
uses a punch, a die and a convex-shaped tool that is disposed in a position
corresponding to the corner flange part, with both of the die and the convex-shaped
tool being paired with the punch,
folds the blank by relative movement of the die to the punch, and thereby
forms the flange parts, and
folds the blank prior to the folding of the blank by the die, by relative
movement of the convex-shaped tool to the punch, and thereby forms the corner
flange part.
[0026]
In the above described production method, the convex-shaped tool is
preferably constructed integrally with or separately from the die.
10a27)
In the above described production method,
the production method preferably fuither uses a blank holder that is paired
with the die, and
performs forming of the corner flange part and the flange parts in a state
where the blank is sandwiched by the die and the blank holder.
[0028]
A production device for a press-formed product according to one
embodiment of the present invention is for producing a press-formed product from a
blank ofa steel plate.
The press-formed product includes a top plate part, flange parts, and a
corner flange part.
The flange parts each extend from some or all of sides constituting an
outline of the top plate part.
The comer flange part extends frorn a corner part connecting, among the
sides of the top plate part, at least a pair of the sides which are adjacent to each other
and from which the flange parts extend. The corner flange part connects the flange
parts each extending from the pair of the sides, to each other.
The production device includes a punch, a die and a convex-shaped tool
that is disposed in a position corresponding to the corner flange part, with both of
the die and the convex-shaped tool being paired with the punch.
The die folds the blank by relative movement to the punch, and thereby
forms the flange parts.
The convex-shaped tool folds the blank prior to the folding of the blank by
the die, by relative movement to the punch, and thereby forms the corner flange part.
l0tzel
In the production device,
a radius Rt [mm] of curvature of a front end of the convex-shaped tool
preferably satisfies conditions of Formula (a) as follows.
Rt
Documents
Orders
Section
Controller
Decision Date
Application Documents
#
Name
Date
1
201617032170-IntimationOfGrant20-10-2023.pdf
2023-10-20
1
Power of Attorney [21-09-2016(online)].pdf
2016-09-21
2
201617032170-PatentCertificate20-10-2023.pdf
2023-10-20
2
Form 5 [21-09-2016(online)].pdf
2016-09-21
3
Form 3 [21-09-2016(online)].pdf
2016-09-21
3
201617032170-PETITION UNDER RULE 137 [18-10-2023(online)].pdf
2023-10-18
4
Form 18 [21-09-2016(online)].pdf_31.pdf
2016-09-21
4
201617032170-Written submissions and relevant documents [18-10-2023(online)].pdf
2023-10-18
5
Form 18 [21-09-2016(online)].pdf
2016-09-21
5
201617032170-Correspondence to notify the Controller [29-09-2023(online)].pdf
2023-09-29
6
Drawing [21-09-2016(online)].pdf
2016-09-21
6
201617032170-PETITION UNDER RULE 137 [18-09-2023(online)].pdf
2023-09-18
7
Description(Complete) [21-09-2016(online)].pdf
2016-09-21
7
201617032170-REQUEST FOR ADJOURNMENT OF HEARING UNDER RULE 129A [18-09-2023(online)].pdf