[Name of Document] DESCRIPTION
[Title of the Invention] PRESS-MOLDED PRODUCT, PRESS-MOLDED
PRODUCT PRODUCING METHOD, AND PRESS-MOLDED PRODUCT
PRODUCING APPARATUS
5 [Technical Field]
[0001]
The present invention relates to a press-molded product having excellent
rigidity and strength and appropriately used as, for example, a vehicle body
reinforcing member and also relates to a press-molded product producing method
10 and a press-molded product producing apparatus used to produce the press-molded
product.
[Background Art]
[0002]
A vehicle body has a structure in which a plurality of molding panels is
15 bonded into a box shape by, for example, resistance spot-welding while edge
portions of the molding panels overlap one another. A reinforcing member or a
strengthening member (hereinafter, generally referred to as a "reinforcing member")
is bonded to the box-shaped structure by, for example, resistance spot-welding. As
such vehicle body reinforcing members, there are a bumper reinforcement, a locker
20 (side sill), a beltline, a cross member, and a side member.
[0003]
Each of these reinforcing members is formed as, for example, a
press-molded member that has a substantially hat-shaped or groove-shaped
cross-section and includes a ceiling plate, two ridge lines connected to the ceiling
25 plate, and two flanges connected to two ridge lines. An end portion opened in the
extension direction of the ridge line of such a reinforcing member is bent inward or
2
outward so as to form a flange in the end portion. When the flange overlaps the
other member and the flange and the other member are bonded to each other by, for
example, resistance spot-welding, a vehicle body reinforcing member is assembled.
Depending on the plate thickness of the material, arc-welding may be used instead of
5 spot-welding.
[0004]
Here, in the specification, a flange obtained by bending the end portion of
the reinforcing member toward an area in which an angle formed by two surfaces
respectively connected to both ends of the ridge line is smaller than 180° will be
10 referred to as an inward flange. Further, a flange obtained by bending the end
portion of the reinforcing member toward an area in which an angle formed by two
surfaces respectively connected to both ends of the ridge line is larger than 180° will
be referred to as an outward flange.
[0005]
15 When the inward flange is formed in the end portion of the reinforcing
member, a ridge-portion flange located on the extension line of the ridge line is
molded as a flange by shrinking, and hence wrinkles are generated in the
ridge-portion flange. For that reason, when such an inward flange overlaps the
other member and the inward flange and the other member are bonded to each other
20 by spot-welding, a gap is generated between the inward flange and the other member
due to the wrinkles, and hence there is a concern that an assembling problem may
occur. Thus, when the reinforcing member having the inward flange formed at the
end portion is used, there is a need to weld the reinforcing member to the other
member by using the inward flange as a bonding edge while avoiding the generation
25 of wrinkles by, for example, forming a notch in the ridge-portion flange.
[0006]
3
However, when the notch is formed in the inward ridge-portion flange so
that the flange is not continuous, the performance of the vehicle body reinforcing
member involved with torsional rigidity or load transfer efficiency is essentially
degraded. Thus, in order to ensure the performance demanded for the reinforcing
5 member by bonding the reinforcing member to the other member tln·ough the inward
flange, there is a need to mold the sln·inking flange while suppressing the generation
of wrinkles in the ridge-portion flange without any notch formed in the inward
flange.
[0007]
10 In addition, in the specification, the "notch formed in the flange" indicates a
state where the notch is formed in the entire flange in the width direction so that the
flange is not continuous. Fmther, the width of the flange is used as the meaning of
the height of .theJlange ... Thus, when the width of the flange is partially decreased
so that a part of the flange is left, the notch is not formed in the flange.
15 [0008]
So far, a technique of suppressing the generation of wrinkles during the
shrinking flange molding process has been proposed. For example, Patent
Literature 1 discloses a teclmique of forming an unevenness shape, absorbing a
difference in length between a front end portion and a base portion in a sln·inking
20 flange pmtion,''in11 nmfpanel having a sunroof opening. Further, Patent Literature
2 discloses a technique of preventing the generation of wrinkles by providing a
specific drawing bead in a shrinking flange portion during a rectangular tube drawing
process. Furthermore, Patent Literature 3 discloses a technique of suppressing the
generation of wrinkles by performing a molding process while applying a pressure to
25 a shrinking flange portion using a cam structure.
[0009]
4
Further, Patent Literature 4 discloses a plate member molding method in
which a flange corresponding portion extending in a direction interesting a bending
load direction is formed in a portion to be used as a bent portion and the flange
corresponding pmiion is stretched into a flange so as to have a desired shape. Such
5 a plate member molding method is used to suppress tearing caused by the wrinkles in
the flange.
[0010]
Patent Literature 5 discloses a method in which a plane metal member is
bent, upright portions of both side pmtions are bent outward, and both inclined side
10 portions are strongly pressed by a processing roller of a pressing surface of a side
surface of a receiving die so as to be sequentially raised. Such a processing method
is used to reduce the distortion or the wrinkles of the upright portion.
[Prior Alt Literature(s)]. '•"
[Patent Literature(s)]
15 [0011]
[Patent Literature 1] JP 2554768B
[Patent Literature 2] JP 2560416B
[Patent Literature 3] JP I-l4-118118A
[Patent Literature 4] JP S59-144530A
20 [Patent Literature'S] JPHV104420A
[Sunmmry of the Invention]
[Problem( s) to Be Solved by the Invention]
[0012]
The techniques disclosed in Patent Literatures I and 2 are used to absorb the
25 extra line length causing the generation of wrinkles and excessive padding by an
excessive pmtion formed in advance. Thus, the spot-welding is not easily
5
performed on the excessive portion and the excessive portion disturbs the
spot-welding of the other portion. In such a case, it is difficult to perform the
techniques disclosed in Patent Literatures 1 and 2.
[0013]
5 Further, the technique disclosed in Patent Literature 3 can suppress the
generation of wrinkles of the flange portion of the large-curvature-radius portion
having, for example, a curvature radius of 21 00 mm and having a feature that the
slu·inkage rate of the flange portion and the reaction force for the cam structure are
small. However, it is difficult to suppress the generation of wrinkles of the flange
10 portion of the small-curvature-radius pmtion having, for example, a curvature radius
of 5 mm and having a feature that the shrinkage rate of the flange pmtion and the
reaction force for the cam structure are large. Particularly, when a high-strength
steel plate haviQg a large tensile strength is used, excessive wrinkles are generated,
and hence the reaction force from the flange portion increases. For that reason, the
15 cam stmcture disclosed in Patent Literature 3 cannot suppress the generation of
wrinkles.
[0014]
Further, the technique disclosed in Patent Literature 4 is used to suppress the
generation of wrinkles by the stretching process. Thus, the plate thickness of the
20 obtained flange is decreased. As a result, there is a concern that the rigidity of the
reinforcing member or the strength of the flange portion may be degraded.
[0015]
Further, the teclmique disclosed in Patent Literature 5 is used to form the
upright pmtion by sequentially strongly pressing a plurality of processing rqllers.
25 Here, a product in which the curvature radius of the bent portion of the plane metal
member is comparatively large is considered as a target. Thus, it is difficult to
6
suppress the generation of wrinkles of, for example, the flange portion of the
small-cmvature-radius portion having a cmvature radius of 5 nun.
[0016]
In this way, in the member having a substantially hat-shaped or
5 groove-shaped cross-section, it is difficult to form the inward flange without forming
the notch in the end portion opened in the extension direction of the ridge portion
from the viewpoint of press-moldability. Pmticularly, Patent Literatures I to 5
above are not contrived in consideration of the formation of the flange in the
high-strength steel plate having a tensile strength of 340 MPa or more. For that
10 reason, there is no example in which a press-molded product formed by a
high-strength steel plate and including a continuons, inward flange without a notch in
a ridge-portion flange is used as the vehicle body reinforcing member so far.
[0017] ·.· ;•-·-··.
In a press-molded product having an outward flange, a hat-shaped or
15 groove-shaped cross-section cmmot be enlarged to the fullest extent of the design
cross-section by the area of the outward flange. In other words, when the
press-molded product can be bonded to the other member through the inward flange
instead of the outward flange, the cross-section of the press-molded product can be
enlarged to the fullest extent of the design cross-section by the area in which the
20 outward flange ··is· not provided. For that reason, it is possible to improve the
bonding strength between the vehicle body reinforcing member and the other
member or the bending rigidity or the torsional rigidity of the vehicle body. Thus,
there is a desire to realize a press-molded product formed by a high-strength steel
plate and including an inward flange.
25 [0018]
An object of the invention is to provide a press-molded product including an
7
inward continuous flange without a notch and capable of improving performance
involved with the bonding strength between a reinforcing member and the other
member or the rigidity of a vehicle body without forming a notch in a ridge-pmiion
flange so as to prevent a defect generated during a press-molding process. Further,
5 another object of the invention is to provide a press-molded product producing
method and a press-molded product producing apparatus.
[Means for Solving the Problem( s)]
[0019]
In order to solve the above problems, according to an aspect of the present
10 invention, there is provided a press-molded product of a metal plate which is formed
by a steel plate having a tensile strength of 340 MPa or more and includes a ridge
portion extending in a predetermined direction and first and second surface pmiions
respectively extending from both ends of a ridge line formed by the ridge portion, the
press-molded product including: an inward continuous flange in at least one end
15 portion in the predetermined direction. The inward continuous flange is obtained by
continuously forming a ridge-portion flange formed inward in the end portion of the
ridge portion, a first flange formed inward in at least a part of an area of the end
portion of the first surface portion, and a second flange formed inward in at least a
part of an area of the end p01iion of the second surface portion. A flange width (Lf)
20 of the ridge-portion flange, a curvature radius (rf) of the ridge portion, and an angle
(8) formed by the first surface portion and the second surface portion satisf)'
Equation (I) below:
LL 0.22 X rf + 0.13 X e- 5.9 ... (I),
where 0 mm :<: rf :<: 35 mm and 90° :<: e :<: 145°.
25 [0020]
A flange width of at least a part of the ridge-portion flange may be smaller
8
than a flange width of at least a patt of each of the first flange and the second flange.
[0021]
A cross-section of the press-molded product when viewed in the
predetermined direction may be a hat -shaped or groove-shaped opened cross-section
5 or a closed cross-section.
[0022]
The press-molded product may be a vehicle body reinforcing member.
[0023]
A plate thickness of at least an area of an edge portion of the ridge-portion
10 flange in a width direction may be equal to or larger than a plate thickness obtained
before a press-molding process.
[0024]
A plate thickness of at least an area of an edge pmtion of the ridge-pmtion
flange in a width direction may be equal to or smaller than 1.5 times a plate thickness
15 obtained before a press-molding process.
[0025]
In order to solve the above problems, according to another aspect of the
present invention, there is provided a press-molded product producing method
including: a first intermediate molding step of bending at least one end portion of a
20 blank formed ·by a steel plate having a tensile strength of 340 MPa or more in a
predetermined direction so as to mold the blank into a first intermediate member
having a flange; and a first press-molding step of bending the first intermediate
member in the predetermined direction by press-molding the first intermediate
member while nipping the flange inside a predetermined first gap so as to mold a
25 ridge portion extending in the predetermined direction and a first surface portion and
a second snrface portion respectively extending from both ends of a ridge line
9
formed by the ridge portion and to mold the flange into an inward continuous flange
in which a ridge-portion flange formed inward in the end portion of the ridge portion,
a first flange formed inward in at least a part of an area of the end potiion of the first
surface portion, and a second flange formed inward in at least a pati of an area of the
5 end portion of the second surface portion are continuous to one another.
[0026]
In the first press-molding step, a press-molding mold including a die, a
punch disposed so as to face the die, and an out-of-plane deformation restricting tool
disposed so as to face a side surface of the punch during the press-molding process
10 and to suppress out -of-plane deformation of the flange may be used, and the first
intermediate member may be disposed on the punch and the first intermediate
member may be press-molded by the die and the punch while the flange is nipped
inside the first gap .. formed by the side surface of the punch and the out-of-plane
deformation restricting tool.
15 [0027]
The die may support a pad pressing the first intermediate member in a
manner that the pad is movable in a pressing direction.
[0028]
In the first press-molding step, the press-molding mold further including a
20 blank holder whicll fuces the die may be used, and a part of the first intermediate
member may be drawn while being constrained by the die and the blank holder.
[0029]
The punch of the press-molding mold may support an inner pad contacting
one surface of the first intermediate member in a manner that the inner pad is
25 movable in a mold clamping direction. In the first press-molding step, the first
intermediate member may be press-molded by the die, the punch, and the inner pad
10
while the flange is nipped inside the first gap formed by side surfaces of the punch
and the inner pad and the out -of-plane deformation restricting tool.
[0030]
According to still another aspect of the present invention, there is provided a
5 press-molded product producing method including: a first intermediate molding step
of bending at least one end p01tion of a blank formed by a steel plate having a tensile
strength of 340 MPa or more in a predetermined direction so as to mold the blank
into a first intermediate member having a flange; a second intermediate molding step
of bending the first intermediate member in the predetermined direction by
10 press-molding the first intermediate member while nipping the flange inside a
predetermined first gap so as to form an intermediate ridge portion extending in the
predetermined direction and a first intermediate surface p01tion and a second
intermediate surface,,pQqkm respectively extending fi·om both ends of a ridge line
formed by the intermediate ridge portion and to mold the flange into an intermediate
15 continuous flange in which an intermediate ridge-portion flange formed in the end
portion of the intermediate ridge portion, a first intermediate flange formed in at least
a part of an area of the end portion of the first intermediate surface portion, and a
second intermediate flange formed in at least a part of an area of the end portion of
the second intermediate surface portion are continuous to one another, thereby
20 molding the first -intermediate member into a second intermediate member; and a
second press-molding step of further bending at least one of the first intermediate
surface portion and the second intermediate surface portion formed in the second
intermediate member in the predetermined direction while nipping the intermediate
continuous flange inside a predetermined second gap so as to mold a ridge portion
25 extending in the predetermined direction and a first surface portion and a second
surface portion respectively extending fi·om both ends of a ridge line formed by the
II
ridge pmtion and to mold the intermediate continuous flange into an inward
continuous flange in which a ridge-portion flange formed inward in the end portion
of the ridge portion, a first flange formed inward in at least a part of an area of the
end portion of the first surface portion, and a second flange formed inward in at least
5 a part of an area of the end pmtion of the second surface pmtion are continuous to
one another.
[0031]
In the second intermediate molding step, a press-molding mold including a
die, a punch disposed so as to face the die, and an out-of-plane deformation
10 restricting tool disposed so as to face a side surface of the punch during the
press-molding process and to suppress out-of-plane deformation of the flange may be
used, and the first intermediate member may be disposed on the punch and the first
intermediate memb.er.may be press-molded by the die and the punch while the flange
is nipped inside the first gap formed by the side surface of the punch and the
15 out-of-plane deformation restricting tool.
[0032]
In the second intermediate molding step, the press-molding mold further
including a blank holder which faces the die may be used, and a part of the first
intermediate member may be drawn while being constrained by the die and the blank
20 holder.
[0033]
The punch of the press-molding mold may suppmi an hmer pad contacting
one surface of the first intermediate member in a mam1er that the inner pad is
movable in a mold clamping direction. In the second intermediate molding step, the
25 first intermediate member may be press-molded by the die, the punch, and the inner
pad while the flange is nipped inside the first gap formed by side surfaces of the
12
punch and the inner pad and the out-of-plane deformation restricting tool.
[0034]
In the second press-molding step, a press-molding mold including a die, a
punch disposed so as to face the die, and an out-of-plane deformation restricting tool
5 disposed so as to face a side surface of the punch during the press-molding process
and to suppress out-of-plane deformation of the flange may be used, and the second
intermediate member may be disposed on the punch and the second intermediate
member may be press-molded by the die and the punch while the intermediate
continuous flange is nipped inside the second gap formed by the side surface of the
10 punch and the out -of-plane deformation restricting tool.
[0035]
The die may support a pad pressing the first intermediate member in a
manner that tbl
First, a press-molded product according to a first embodiment of the
invention will be described.
[0047]
(l-1. Entire Configuration)
The -press~molded product according to the embodiment is a molded product
obtained by press-molding a steel plate. Such a press-molded product 100 is
suitable for, for example, a vehicle body reinforcing member such as a bumper
reinforcement, a locker (side sill), a beltline, and a cross member. The
press-molded product I 00 used for such an application may be obtained by
25 press-molding a high-strength steel plate having a tensile strength of 340 MPa or
more and desirably 590 MPa or more. The tensile strength is a value measured by
18
the tensile test based on JIS Z 2241. Fmiher, the plate thickness of the blank
formed by the steel plate may be, for example, in the range of 0.8 to 2.0 mm.
[0048]
FIG. 1(a) is a perspective view schematically illustrating the press-molded
5 product 100 according to the embodiment. Further, FIG. 1(b) is a view (a front
view of a ridge-portion flange ll5a) in the direction A of FIG. 1(a). FIG. !(c) is a
view (a perspective view of the ridge-portion flange ll5a) in the direction B of FIG.
1(a). In the embodiment, the longitudinal direction of the press-molded product
I 00 or the blank corresponds to the extension direction of the ridge portions 112a and
10 ll2b of the press-molded product 100, but the extension direction of the ridge
pmiions ll2a and 112b is not limited to the longitudinal direction of the
press-molded product 100.
[0049]
Futiher, in the embodiment, a predetermined direction in which the ridge
15 portions 112a and 112b extend is not limited to a direction which is recognized as a
straight line. A direction which is recognized as a curved shape (curve) other than
the straight line found in many vehicle body reinforcing members is also included in
the predetermined direction. When the predetermined direction is recognized as a
curve, the predetermined direction includes, for example, a direction which is curved
20 in the left and-right direction or the up and down direction of the reinforcing member
or a direction obtained by the combination of these directions. Further, the entire
length in the predetermined direction includes, for example, all kinds of length from
the length of about 1000 mm of a bumper or a side member to the length of about
I 00 mm of a cubic bulkhead.
25 [0050]
FIG. 2 is an explanatory diagram illustrating an example of a cross-section
19
shape of the press-molded product I 00 in a cross-section orthogonal to the
longitudinal direction of the press-molded product I 00. The cross-section shape of
the press-molded product I 00 according to the embodiment can be set to a
hat-shaped cross-section illustrated in FIG. 2(A) or a groove-shaped cross-section
5 illustrated in FIG. 2(B), but the invention is not limited thereto. As illustrated in
FIG. 2(C) or 2(D), the cross-section shape of the press-molded product I 00 includes
a cross-section shape in which a convex shape 1 OOb or a concave shape (not
illustrated) is provided in a wall surface 1 OOa in a hat-shaped or groove-shaped
cross-section.
10 [0051]
Furthe1~ the cross-section shape of the press-molded product I 00 also
includes, for example, a substantially hollow-square-shaped closed cross-section
shape other than th~. opened cross-section shapes illustrated in FIGS. 2(A) to 2(D).
In addition, the press-molded product 100 is not limited to these cross-section shapes.
15 For example, a press-molded product having a cross-section shape including a ridge
p01tion and a first surface portion and a second surface portion respectively
extending from both ends of the ridge line formed by the ridge portion and called a
V-shaped cross-section may be used. The press-molded product I 00 illustrated in
FIG. 1(a) is the press-molded product 100 having a hat-shaped cross-section.
20 Hereinafte1~ the13ress~molded product 100 having a hat-shaped cross-section will be
described as an example.
[0052]
As illustrated in FIG. 1(a), the press-molded product 100 includes the ridge
portions 112a and 112b, the first surface portions 113a and 113b, and the second
25 surface portion 114. Both ridge portions 112a and 112b are formed so as to extend
in the longitudinal direction of the press-molded product I 00. One first surface
20
pmiion 113a is connected to the ridge portion 112a and is formed so as to extend in
the first direction intersecting the longitudinal direction of the press-molded product
I 00. The other first surface portion 113b is com1ected to the ridge portion 112b and
is formed so as to extend in the first direction intersecting the longitudinal direction
5 of the press-molded product I 00. The first direction as the extension direction of
one first surface pmiion 113a and the first direction as the extension direction of the
other first surface portion 113b may be different from each other.
[0053]
The second surface pmiion 114 is connected to the ridge pmiions 112a and
10 112b and is formed so as to intersect the longitudinal direction of the press-molded
product 100 and to extend in a second direction different from the first direction.
The second surface pmiion 114 is formed between the ridge portions 112a and 112b.
In this way, the., .. press.,molded product 100 has a substantially hat-shaped opened
cross-section including the ridge pmiions 112a and 112b which extend in the
15 longitudinal direction of the press-molded product 100 and including the first surface
portions 113a and 113b and the second surface pmiion 114 which are continuous to
the ridge pmiions 112a and 112b.
[0054]
In order to apply the press-molded product 100 molded by a high-strength
20 steel plate to, fm example, a vehicle body reinforcing member, it is desirable that the
curvature radius rf of each of ridge portions 112a and 112b be in the range of 0 mm
to 3 5 mm. The curvature radius of the ridge portion indicates the curvature radius
of the inner smface of the ridge portion. Fmiher, in order to apply the press-molded
product I 00 to, for example, the vehicle body reinforcing member, it is desirable that
25 an angle formed between each of first surface pmiions 113a and 113b and a second
surface portion 114 be in the range of 90° to 145°.
21
[0055]
(1-2. Inward Continuous Flange)
The press-molded product 100 includes the ridge-portion flanges 115a and
115b, the first flanges 116a and 116b, and the second flange 117 provided in at least
5 one outer end pmiion I OOA in the longitudinal direction. The ridge-portion flanges
115a and 115b are formed at the outer end portion 1 OOA in the longitudinal direction
of the ridge pmiions 112a and 112b. The first flanges 116a and 116b are formed in
at least a pmi of the area of the outer end portion 1 OOA in the longitudinal direction
of the first surface portions 113a and 113b. Fmiher, the second flange 117 is
10 formed in at least a part of the area of the onter end portion 1 OOA in the longitndinal
direction of the second surface pmiion 114. In the embodiment, the first flanges
116a and 116b and the second flange 117 are formed in the entire area of the outer
end portion IODA,af,each .of the first surface portions 113a and 113b and the second
surface pmiion 114.
15 [0056]
The ridge-portion flanges 115a and 115b, the first flanges 116a and 116b,
and the second flange 117 are all formed continuously as the inward flange. The
ridge-portion flanges ll5a and ll5b, the first flanges ll6a and 116b, and the second
flange 117 constitute the inward continuous flange 118. Since the flange provided
20 in the end ,mrtioo. "l}f ·the press-molded product 100 is formed as the inward
continuous flange 118, for example, the cross-section of the vehicle body reinforcing
member can be enlarged to the fullest extent of the design cross-section. Thus, it is
possible to further improve the bonding strength between the reinforcing member
and the other member or the rigidity of the vehicle body.
25 [0057]
The press-molded product 1 00 according to the embodiment includes the
22
inward continuous flange 118 provided in the longitudinal outer end pmiion I OOA so
as to be continuous in the entire length of the first surface pmiions 113a and 113b,
the ridge portions 112a and 112b, and the second surface portion 114. Here, the
first flanges 116a and 116b and the second flange 117 may be continuous to the
5 ridge-pmiion flanges 115a and 115b and the inward continuous flange 118 is not
necessarily continuous in the entire length. For example, the first flanges 116a and
116b or the second flange 117 may be formed in a part of the area of the outer end
pmiion lOOA of the first surface portions ll3a and 113b or the second surface
portion 114. When the second flange 117 is not formed in the entire area of the
10 second surface portion 114, two divided inward continuous flanges 118 are formed.
[0058]
(1-3. Ridge-portion Flange)
In the .. press~molded product 100 according to the embodiment, a concave
portion 119 where a flange width is small is provided in each of the ridge-portion
15 flanges 115a and 115b. Accordingly, the width Lf of each of the ridge-pmiion
flanges 115a and 115b is smaller than the widths Lfs 1 and Lfs2 of each of the first
flanges 116a and 116b and the second flange 117 in the vetiex of each of the ridge
portions 112a and 112b. The width of the flange indicates a flat portion except for a
curved portion formed in the base portion in which the flange is uprightly formed
20 from the ridge'Pl'rtion, the first surface potiion, or the second surface portion. For
example, in the ridge-portion flange 115a, as illustrated in FIG. !(b), the width Lf of
the ridge-portion flange 115a indicates the width Lf of a flat poliion 115aa except for
a curved portion 115ab formed so as to be continuous to the ridge portion 112a in the
longitudinal outer end portion 1 OOA.
25 [0059]
Since the width Lf of each of the ridge-portion flanges 115a and 115b is
23
smaller than the widths of the first flanges 116a and 116b and the second flange 117,
the extra extension amount of the front end of the flange of each of the ridge-portion
flanges 115a and 115b is small, and hence the generation of wrinkles is reduced.
Patticularly, the press-molded product 100 according to the embodiment is suitable
5 for the vehicle body reinforcing member, and is molded by using a high-strength
10
15
steel plate. In order to suppress the generation of wrinkles in ridge-portion flanges
115a and 115b of the press-molded product 100 obtained by such a high-strength
steel plate, the width Lf (ll1111) of a flat pmtion 115aa of each of the ridge-portion
flanges 115a and 115b satisfies Equation (1) as below.
Lf::; 0.22rf+ 0.130-5.9 ... (1)
rf (mm): curvature radius of ridge portion 112a (112b) (curvature radius of
inner surface of ridge portion)
9: angle .. formed between first surface portion 113a (113b) and second
surface pmtion 114
(here, 0 mm ::; rf::; 35 mm and 90° ::; (:) ::; 145°)
[0060]
When the width Lf of each of the ridge-portion flanges 115a and 115b
exceeds a range defined by Equation (1 ), the extra extension of the edge portions of
the ridge-pmtion flanges 115a and 115b increases, and hence wrinkles are easily
20 generated. Here,·in order to ensure the strength of the press-molded product 100
suitable for the vehicle body reinforcing member, it is desirable that the width Lf of
each of the ridge-portion flanges 115a and 115b satisfy the relation ofLf::O: 0.2 rf.
[0061]
In addition, when the flange width Lf of each of the ridge-portion flanges
25 115a and 115b is set to be smaller than the flange widths Lfs 1 and Lfs2 of the first
flanges 116a and 116b and the second flange 117, the flange width Lf of at least a
24
part of the ridge-portion flanges liSa and llSb may be smaller than the flange
widths Lfs 1 and Lfs2 of at least a patt of the first flanges !16a and 116b and the
second flange 117. That is, when a concave portion 119 is formed inside the
ridge-portion flanges !!Sa and l!Sb, the flange width Lf of a patt of the
5 ridge-pmtion flanges 11Sa and 11Sb may be smaller than the flange widths Lfs1 and
Lfs2 of the first flanges 116a and 116b and the second flange 117. Further, when
the concave portion 119 is formed throughout the first flanges 116a and 116b and the
second flange 117, the flange widths Lfsl and Lfs2 of a part of the first flanges 116a
and 116b and the second flange 117 may be equal to the flange width Lf of the
10 ridge-portion flanges 11Sa and 11Sb.
[0062]
Futther, it is desirable that the plate thickness of an edge pmtion of an
inward continuous flange 118 in the width direction be equal to or larger than the
plate thickness obtained before a press-molding process. Since the edge pottion of
15 the inward continuous flange 118 has such a plate thickness, it is possible to improve
the rigidity or the load transfer strength of the press-molded product 100 used as the
vehicle body reinforcing member.
[0063]
Further, it is desirable that the plate thickness of the edge portion of the
20 inward continuous flange 118 in the width direction be equal to or smaller than l.S
times the plate thickness obtained before the press-molding process. Particularly, it
is desirable that the plate thickness of each of the edge portions of the ridge-portion
flanges liSa and l!Sb be equal to or smaller than l.S times the plate thickness
obtained before a press-molding process. Since the edge portion of the inward
25 continuous flange 118 has such a plate thickness, it is possible to decrease a gap of
an overlapping portion causing poor welding when a welding process such as
25
spot-welding is performed while the inward flange serving as a bonding margin
overlaps the other member. Thus, it is possible to maintain a sufficient bonding
strength when the press-molded product I 00 used as the vehicle body reinforcing
member is bonded to the other member.
5 [0064]
As described above, in the press-molded product I 00 according to the
embodiment, a notch is not formed in the ridge-portion flanges liSa and 115b and
there are no wrinkles in the inward continuous flange 118. Thus, when the
press-molded product 100 is used as, for example the vehicle body reinforcing
10 member, it is possible to improve the bonding strength between the press-molded
product 100 and the other member and to improve the performance involved with the
rigidity or the load transfer efficiency of the reinforcing member.
[0065]
<2. Second Embodiment>
15 Next, an example of a method of producing the press-molded product 100
according to a second embodiment of the invention will be described along with a
configuration example of an apparatus of producing the press-molded product 100.
A method and an apparatus of producing the press-molded product I 00 according to
the embodiment are used to produce, for example, the press-molded product 100
20 according to ·the first embodiment. A method of producing the press-molded
product 1 00 according to the embodiment includes a first intermediate molding step
and a first press-molding step.
[0066]
(2-1. First Intermediate Molding Step)
25 First, a press-molding method performed in a first intermediate molding step
of obtaining a first intennediate member 130 from a blank 120 formed by a steel
26
plate and a press-molding apparatus used in the corresponding step will be described.
FIGS. 3(A) and 3(B) are explanatory diagrams schematically illustrating a state
where the first intermediate member 130 is obtained from the blank 120 by a
press-molding process. FIG. 3(A) illustrates a state where the blank 120 is set in a
5 press-molding apparatus 90. FIG. 3(B) illustrates a state where the press-molding
process ends.
[0067]
As illustrated in FIG. 3(A), the blank 120 is set in the press-molding
apparatus 90, and then the blank 120 is nipped between a punch 95 and a pad 92
10 attached to a die 91 so as to be movable in the mold clamping direction. Next, as
illustrated in FIG. 3(B), when the die 91 moves downward, both longitudinal end
pmiions 121 of the blank 120 are bent by the die 91. By such a bending process, it
is possible to obtain the first intermediate member 130 having a flange 131 at both
longitudinal end portions of the blank 120.
15 [0068]
Here, an example is described in which both longitudinal end portions 121
of the blank 120 are bent, but any one of both longitudinal end potiions 121may be
bent. The press-molding apparatus 90 used in the first intermediate molding step
may be a known press-molding apparatus 90 which performs a bending process by
20 including the punch 95 and the die 91 having the pad 92 attached thereto so as to be
movable in the mold clamping direction.
[0069]
(2-2. First Press-molding Step)
Next, a press-molding method performed in a first press-molding step of
25 obtaining the press-molded product I 00 from the first intermediate member 130 and
a press-molding apparatus used in the first press-molding step will be described.
27
[0070]
(2-2-1. Press-molding Apparatus)
FIG. 4 is a schematic diagram illustrating a part of a configuration example
of a press-molding apparatus 10 used in the first press-molding step. The
5 press-molding apparatus used in the first press-molding step corresponds to one type
of a press-molded product producing apparatus of the invention. In addition, FIG. 4
partially illustrates the press-molding apparatus l 0 in the periphery of the end p011ion
of the blank 120 in the longitudinal direction (a direction indicated by the white
arrow of FIG. 4).
10 [0071]
As illustrated in FIG. 4, the press-molding apparatus 10 includes a die 30, a
blank holder 32, a punch 35, a pad 31, and an inner pad 33. The die 30 and the
blank holder 32 constrain and hold the end portions of the blank 120 in the width
direction intersecting the longitudinal direction thereof. The pad 31 is suppmied by
15 the die 30 so as to be movable in the mold clamping direction. The im1er pad 33 is
supported by the punch 35 so as to be movable in the mold clamping direction.
Fmihet~ the width of the inner pad 33 in a direction intersecting the longitudinal
direction of the first intermediate member 130 is set to be smaller than the width of
the punch 35 in the same direction. Thus, the pad 31 and the inner pad 33 constrain
20 the center -portion of the blank 120 in the width direction. Further, the
press-molding apparatus I 0 includes an out-of-plane deformation restricting tool 34
which is disposed so as to face a side surface 35a of the punch 35 and a side surface
33a of the inner pad 33 during a press-molding process. In FIG. 4, for example,
only the surface of the die 30 or the out-of-plane deformation restricting tool 34 is
25 schematically illustrated.
[0072]
28
All the die 30, the blank holder 32, the punch 35, the pad 3 I, and the inner
pad 33 used for an existing press-molding apparatus performing such a drawing
process may be used. Thus, the description thereof will be omitted herein. The
out -of-plane deformation restricting tool 34 is disposed between the side surfaces 3 3a
5 and 35a with a gap (a first gap) of a predetermined distance therebetween so as to
·face the side surface 35a of the punch 35 and the side surface 33a of the illller pad 33
during a press-molding process.
[0073]
During the press-molding process, the press-molding process is performed
10 while the flange 13 I formed in the first intermediate member 130 is nipped in the
gap (the first gap) formed between each of the side surface 35a of the punch 35 and
the side surface 33a of the inner pad 33, and the out-of-plane deformation restricting
tool 34. Thus,,an increase or a change in the plate thickness of the flange 13 I is
restricted, and hence the generation of wrinkles is suppressed. The distance of the
15 gap may be, for example, a value obtained by adding a predetermined clearance to
the plate thickness of the flange 131. For example, the gap may be provided so as
to satisfy Equation (2) as below.
1.00 X t :':X< 1.40 X t ... (2)
t: plate thickness (mm) of blank
20 x: distance (mm) of gap
[0074]
Since the distance x of the gap satisfies Equation (2) above, the out-of-plane
deformation of the flange 13 I can be reliably suppressed without setting the plate
thickness of the flange 13 I to be smaller than the plate thickness obtained before a
25 press-molding process. Particularly, the out-of-plane deformation of the
ridge-portion flanges I 15a and I I 5b easily causing the generation of wrinkles is
29
suppressed.
[0075]
At this time, in order to suppress the die-galling during the press-molding
process, a slight clearance may be provided between the surface of the flange 131
5 and the out-of-plane deformation restricting tool 34. Further, the out-of-plane
10
deformation is easily generated as the plate thickness of the flange 131 decreases.
Thus, it is desirable to provide the gap so as to satisfY Equation (3) as below.
[0076]
1.03 X (:';X < 1.35 X t ... (3)
t: plate thickness (mm) of blank
x: distance (mm) of gap
The press-molding apparatus 10 illustrated in FIG. 4 corresponds to a
configuration example of the press-molding apparatus 10 having the inner pad 33
provided in the punch 35, but a press-molding apparatus without the itmer pad 33
15 may be used. The press-molding apparatus without snch an inner pad 33 may have
the same configuration as the press-molding apparatus 10 except that the punch 35
does not include the inner pad 33. In the specification, the press-molding apparatus
without the inner pad 33 will be simply referred to as a "drawing device" and the
press-molding apparatus with the inner pad 33 will be referred to as an "inner pad
20 drawing device'',
[0077]
(2-2-2. First Press-molding Step by Drawing Device)
Next, a state in which a drawing process is performed on the first
intermediate member 130 by a drawing device 1 OA without an imler pad will be
25 described. Since the drawing device lOA is provided such that the im1er pad 33 is
not provided in the press-molding apparatus I 0 illustrated in FIG. 4, a description
30
will be made as below with reference to FIG. 4.
[0078]
FIG. 5 is an explanatory diagram schematically illustrating a state where the
press-molded product 100 is obtained from the first intermediate member 130 by the
5 drawing process using the drawing device lOA. In FIG. 5, the column (a) indicates
a diagram when viewed in a direction intersecting the longitudinal direction of the
first intermediate member 130 and the column (b) indicates a diagram when viewed
in the longitudinal direction of the first intermediate member 130. That is, the
flange 131 can be viewed from the front side thereof in the column (b) of FIG. 5.
10 Fmther, FIG. 5(A) illustrates a state where the first intermediate member 130 is set in
the drawing device 1 OA, and FIG. 5(B) illustrates a state where the pad 31 contacts
the first intermediate member 130. Fmther, FIG. 5(C) illustrates a state where a
drawing process:.is :being performed and FIG. 5(0) illustrates a state where the
drawing process ends.
15 [0079]
As illustrated in FIG. 5, in the drawing process, the first intermediate
member 130 is set in the drawing device 1 OA and then the end p01tion 132 in the
width direction intersecting the longitudinal direction of the first intermediate
member 130 is constrained and held by the die 30 and the blank holder 32. In this
20 state, the die 30 moves toward the punch 35 while the first intermediate member 130
is nipped between the flat pad 31 which is supp01ted by the die 30 so as to be
movable in the mold clamping direction and the punch 35 having a flat top p01tion.
In this way, a drawing process is performed on the first intermediate member 130.
[0080]
25 During the drawing process, the flange 131 of the first intermediate member
130 is disposed inside the gap (the first gap) formed by the side surface 35a of the
31
punch 35 and the out-of-plane deformation restricting tool 34 disposed so as to face
the side surface 35a of the punch 35. Thus, the flange 131 is constrained by the
out-of-plane deformation restricting tool 34 and the side surface 35a of the punch 35
during the drawing process. Accordingly, the out-of-plane deformation of the
5 flange 131 during the drawing process is suppressed, and the ridge-portion flanges
115a and 115b are formed by an in-plane compression molding process. Thus, an
increase or a change in the plate thickness of each of the ridge-portion flanges ll5a
and 115b causing the generation of wrinkles decreases.
10
15
[0081]
As described above, the gap is provided between the side surface 3 Sa of the
punch 35 and the out-of-plane deformation restricting tool 34 so as to satisfy
Equation (2) as below.
[0082]
l.OQxJ.s;.x,~,L40.x t ... (2)
t: plate thickness (mm) of blank
x: distance (mm) of gap
Since Equation (2) is satisfied, it is possible to reliably suppress the
out-of-plane deformation of the inward continuous flange 118 obtained by
continuously forming the first flange 116a (116b ), the ridge-portion flange 115a
20 (115b), and tl\e-recond flange 117. Particnlarly, it is possible to suppress the
out -of-plane deformation of the ridge-portion flanges ll5a and 115b easily causing
the generation of wrinkles.
[0083]
Further, as described above, it is desirable that the gap satisfy Equation (3)
25 as below in order to suppress the die-galling during the press-molding process and
the out-of-plane deformation in the case of a thin plate thickness of the flange 131.
32
1.03 X t S X < J.35 X t ... (3)
t: plate thickness (mm) of blank
x: distance (mm) of gap
(0084]
5 In the example illustrated in FIG. 5, the out-of-plane deformation restricting
tool 34 is integrated with the die 30, but the configuration of the out-of-plane
deformation restricting tool 34 is not limited to this example. As long as the
out-of-plane deformation restricting tool 34 can constrain the flange 131 of the first
intermediate member 130, the installation position of the out-of-plane deformation
10 restricting tool 34 is not limited to a specific position. Further, the invention is not
limited to the configuration in which the out-of-plane deformation restricting tool 34
is disposed on the upper die as in the example of the embodiment, but the
out-of-plane . defonnatioll_restricting tool may be disposed in the lower die. Fmiher,
the invention is not limited to the configuration in which the out -of-plane
15 deformation restricting tool 34 constrains the flange 131 in collaboration with the
side surface 35a of the punch 35, but the out-of-plane deformation restricting tool34
may independently constrain the flange 131.
[0085]
By the drawing process performed by such a drawing device I OA, as
20 illustrated in HG. i, -the press-molded product I 00 including the ridge pmiions 112a
and 112b, the first surface pmtions 113a and 113b, the second surface portion 114,
and the inward continuous flange 118 is molded. At this time, since the drawing
process is performed while the flange 131 is nipped by the side surface 35a of the
punch 35 and the out-of-plane deformation restricting tool 34, the generation of
25 wrinkles of the formed inward continuous flange 118 is suppressed without forming
a notch in the flange 131.
33
[0086]
In addition, in the description above, the press-molded product 100 having
the inward continuous flange 118 continuously formed in the entire area of the
longitudinal outer end portions lOOA of the first surface portions 113a and 113b, the
5 ridge portions 112a and 112b, and the second surface portion 114 has been described.
Here, the first flanges 116a and 116b may be formed in a part of outer end portions
IOOA of the first surface portions 113a and 113b instead of the entire area thereof.
Further, the second flange 117 may be formed in a part of the outer end portion 1 OOA
of the second surface portion 114 instead of the entire area thereof. That is, the first
10 flanges 116a and 116b, and the second flange 117 may be formed so as to be
respectively continuous to the ridge-portion flanges liSa and 115b.
[0087]
(2-2-3. First Press-molding Step by Inner Pad Drawing Device)
Next, a state where an itmer pad drawing process is performed on the first
15 intermediate member 130 by an inner pad drawing device 1 OB will be described.
FIG. 6 is an explanatory diagram schematically illustrating a state where the
press-molded product 100 is obtained from the first intermediate member 130 by the
inner pad drawing process using the inner pad drawing device lOB. In FIG. 6, the
column (a) indicates a diagram when viewed in a direction intersecting the
20 longitudinal direction of the first intermediate member 130, and the column (b)
indicates a diagram when viewed in the longitudinal direction of the first
intermediate member 130.
[0088]
Further, FIG. 6(A) illustrates a state where the first intermediate member
25 130 is set in the inner pad drawing device lOB, and FIG. 6(B) illustrates a state
where the pad 31 contacts the first intermediate member 130. Fmther, FIG. 6(C)
34
illustrates a state where an inner pad drawing process is being performed, FIG. 6(D)
illustrates a state immediately before the inner pad drawing process ends, and FIG.
6(E) illustrates a state where the inner pad drawing process ends. In addition, the
signs of FIG. 6 are the same as those of FIG. S except that the im1er pad 33 is added.
5 [0089]
As illustrated in FIG. 6, the illller pad drawing process can be performed
similarly to the drawing process illustrated in FIG. S except that the drawing process
is performed by the punch 3 S with the illller pad 3 3 snppotted so as to be movable in
the mold clamping direction. Thus, the flange 131 is nipped by the side surface 3 Sa
10 of the punch 3S, the side surface 33a of the inner pad 33, and the out-of-plane
deformation restricting tool 34 during the inner pad drawing process, and hence the
out -of-plane deformation of the flange 131 is suppressed. Accordingly, the
ridge-portion flanges 115a;~nd llSb are formed by the in-plane compression molding
process. Also, since the punch 3S with the inner pad 33 is used, an increase in the
15 plate thickness of the edge portion of the inward continuous flange 118, particularly,
an increase in plate thickness of the edge portion of each of the ridge-portion flanges
liSa and llSb is reduced, and the generation of wrinkles is fmther suppressed.
[0090]
FIG. 7 is an explanatory diagram schematically illustrating the curvature
20 radius of each of the ridge portions 112a and 112b formed during a drawing process
or an inner pad drawing process. FIG. 7(A) illustrates a state where a drawing
process is performed without the illller pad. FIG. 7(B) illustrates a state of an inner
pad drawing process. As illustrated in FIG. 7(B), in the inner pad drawing process,
the curvature radius of the curved pmtion B formed in each of the ridge pmtions
25 112a and 112b during the molding process becomes larger than that of the drawing
process illustrated in FIG. 7(A). For that reason, it is possible to reduce an increase
35
in the plate thickness of the edge portion of each of the ridge-portion flanges liSa
and ll5b formed after the molding process. As a result, the satisfactory inward
continuous flange 118 suppressing the generation of wrinkles is formed.
[0091]
5 In addition, in the im1er pad drawing process illustrated in FIG. 7(8), the
illller pad 33 moves downward so as to be received inside the punch 35 at the time
point when the drawing process ends, and hence the curvature radius of each of the
ridge portions ll2a and 112b is defined by the curvature radius of the corner portion
of the punch 35. Thus, a difference in curvature radius of the ridge portions ll2a
10 and ll2b does not occur compared with the drawing process illustrated in FIG. 7(A).
[0092]
(2-2-3. First Press-molding by Bending Device)
The first press-molding step described so far is performed by the drawing
process, but the first press-molding step may be performed by a bending process
15 instead of the drawing process. FIG. 8 is an explanatory diagram schematically
illustrating a state where the press-molded product 100 is obtained from the first
intermediate member 130 by a bending process using a bending device 50 instead of
the drawing device 1 OA or the inner pad drawing device 1 OB.
[0093]
20 In FIG, S, theoolumn (a) indicates a diagram when viewed in a direction
intersecting the longitudinal direction of the first intermediate member 130, and the
column (b) indicates a diagram when viewed from the longitudinal direction of the
first intermediate member 130. Fmther, FIG. 8(A) illustrates a state where the first
intermediate member 130 is set in the bending device 50, and FIG. 8(8) illustrates a
25 state where the pad 31 contacts the first intermediate member 130. Further, FIG.
8(C) illustrates a state where a bending process is being performed, and FIG. 8(D)
36
illustrates a state where the bending process ends.
[0094]
As illustrated in FIG. 8, the first intermediate member 130 is set in the
bending device 50 in the bending process. At tllis time, the flange 131 of the first
5 intermediate member 130 is disposed inside the gap (the first gap) formed by the side
surface 35a of the punch 35, the side surface 33a of the hmer pad 33, and the
out-of-plane deformation restricting tool 34 disposed so as to face the side surfaces
33a and 35a. Accordingly, the flange 131 of the first intermediate member 130 is
constrained by the side surface 35a of the punch 35, the side surface 33a of the inner
10 pad 33, and the out-of-plane deformation restricting tool 34.
[0095]
In this state, the die 30 and the punch 35 move close to each other while the
first intermediate. member 130..is nipped between the pad 31 attached to the die 30
and the punch 35. Accordingly, both ends in the width direction intersecting the
15 longitudinal direction of the first intermediate member 130 are bent. As a result,
the out -of-plane deformation of the flange 131 is suppressed during the bending
process, and the ridge-portion flanges liSa and l!Sb are formed by the in-plane
compression molding process.
20
[0096]
Such a bending vrocess can be performed by a mold having a simple
configuration compared with the drawing process. Meanwhile, in the bending
process, a large increase in the. plate thickness of the ridge-portion flanges liSa and
llSb easily occurs compared with the drawing process. However, the press-molded
product 100 described in the first embodiment can be formed. Here, the drawing
25 process is better than the bending process in that the die-galling of the press-molded
product 100 can be reduced and the loss of the mold can be reduced.
37
[0097]
As described above, in the press-molded product producing method
according to the embodiment, it is possible to produce the press-molded product 100
with the inward continuous flange 118 suppressing the generation of wrinkles
5 without forming a notch by the use of the high-strength steel plate. Thus, it is
10
possible to obtain the press-molded product 100 which can be used in the vehicle
body reinforcing member and has high rigidity and excellent load transfer efficiency.
[0098]
<3. Third Embodiment>
Next, an example of a method of producing the press-molded product 100
according to a third embodiment of the invention will be described along with a
configuration example of a press-molding apparatus. A me~hod of producing the
press-molded product. I 00 according to the embodiment and a press-molding
apparatus thereof are used to produce the press-molded product 100 of the first
15 embodiment. The method of producing the press-molded product 100 according to
the embodiment includes a first intermediate molding step, a second intermediate
molding step, and a second press-molding step. The method of producing the
press-molded product 100 according to the embodiment is performed, for example,
when the length of each of the first surface portions 113a and 113b of the
20 press-molded product HJO is long in a direction orthogonal to the extension direction
of each of the ridge pmtions 112a and 112b. Among these, since the first
intermediate molding step is performed similarly to the first intermediate molding
step of the second embodiment, the description thereof will be omitted herein.
[0099]
25 (3-1. Second Intermediate Molding Step)
Hereinafter, a press-molding method performed in the second intermediate
38
molding step of obtaining a second intermediate member 140 from the first
intermediate member 130 and a press-molding apparatus used in the second
intermediate molding step will be described. Similarly to the first press-molding
step of the second embodiment, the second intermediate molding step may be also
5 performed by any one of the drawing process not using the inner pad and the drawing
process using the imter pad.
[0100]
(3-1-1. Second Intermediate Molding by Drawing Device)
First, a state where a drawing process is performed on the first intermediate
10 member I30 by a drawing device 60 without the inner pad will be described.
Similarly to the drawing device I OA used in the first press-molding step, the drawing
device 60 may not include the itmer pad 33 in the press-molding apparatus I 0
illustrated in FIG. 4.
[OlOI]
15 FIG. 9(A) is a schematic diagram illustrating a part of a configuration
example of the drawing device 60. Further, FIG. 9(B) is a perspective view
illustrating an example of the appearance of the second intermediate member I40
obtained by a drawing process using such a drawing device 60. The basic
configuration of the drawing device 60 can be the same as that of the drawing device
20 I OA used in {he first ·press-molding step of the second embodiment. In addition,
FIG. 9(A) partially illustrates the drawing device 60 in the periphery of the end
portion of the first intermediate member 130 in the longitudinal direction (a direction
indicated by the white arrow of FIG. 9(A)).
[0102]
25 FIG. I 0 is an explanatory diagram schematically illustrating a state where
the second intermediate member 140 is obtained li-mn the first intermediate member
39
130 by a drawing process using the drawing device 60. In FIG. 10, the column (a)
indicates a diagram when viewed in a direction intersecting the longitudinal direction
of the first intermediate member 130, and the column (b) indicates a diagram when
viewed in the longitudinal direction of the first intermediate member 130. Fmiher,
5 FIG. lO(A) illustrates a state where the first intermediate member 130 is set in the
drawing device 60, FIG. 1 O(B) illustrates a state where the pad 31 contacts the first
intermediate member 130, and Fig. 1 OC illustrates a state where a drawing process
ends.
[0103]
10 As illustrated in FIG. 10, the second intermediate molding step using the
drawing process can be performed basically similarly to the first press-molding step
of the second embodiment. That is, the first intermediate member 130 is set in the
drawing device 60 and then the end portion 132 of the first intermediate member 130
is constrained and held by the die 30 and the blank holder 32. In this state, the die
15 30 moves close to the punch 35 while the first intermediate member 130 is nipped by
the flat pad 31 supp01ied by the die 30 so as to be movable in the mold clamping
direction and the punch 35 having a flat top portion. Accordingly, a drawing
process is performed on the first intermediate member 130. Such a drawing process
may be a so-called shallow drawing process.
20 [0104]
During such a drawing process, the flange 131 of the first intermediate
member 130 is constrained inside the gap (the first gap) formed by the side surface
35a of the punch 35 and the out-of-plane deformation restricting tool 34, and hence
the out-of-plane deformation of the flange 131 is suppressed. Here, in the second
25 intermediate molding step, when the die 30 moves close to the punch 35, the
movement of the die 30 and the blank holder 32 is stopped halfway while the die 30
40
is not completely moved close to the punch 35. At this time, the end portion 132 of
the first intermediate member 130 nipped by the die 30 and the blank holder 32 is
held while not being completely bent.
[0105]
5 By such a drawing process, as illustrated in FIG. 9(B), intermediate ridge
portions 142a and 142b, and first intermediate surface portions 143a and 143b and a
second intermediate surface portion 144 respectively connected to the intermediate
ridge pmtions I 42a and 142b are formed. In the embodiment, the first intermediate
surface portions 14 3a and 14 3 b are parallel to the second intermediate surface
10 portion 144 in the second intermediate member 140.
[OI06]
Further, the flange 131 formed in the first intermediate member 130 by such
a drawing process .is molded into an intermediate continuous flange 148 in which
intermediate ridge-pmtion flanges I 45a and 145b, first intermediate flanges 146a and
15 146b, and a second intermediate flange 147 are continuous to one another. The
intermediate ridge-portion flanges 145a and 145b are flanges which are formed in the
end portions of the intermediate ridge portions 142a and 142b. The first
intermediate flanges 146a and 146b are flanges which are formed in at least a part of
the area of the longitudinal end pmtions of the first intermediate surface portions
20 I43a and I43b. Thereoond intermediate flange 147 is a flange which is formed in
at least a part of the area of the longitudinal end portion of the second intermediate
surface portion 144.
[0107]
During the drawing process, the flange 13 I formed in the first intermediate
25 member I30 is nipped by the side surface 35a of the punch 35 and the out-of-plane
deformation restricting tool 34, and hence the out-of-plane deformation of the flange
41
131 is suppressed. Thus, the intermediate ridge-portion flanges 145a and 145b are
formed by an in-plane compression molding process, and hence the generation of
wrinkles in the intermediate continuous flange 148 is suppressed.
[0108]
5 When the first intermediate member 130 is drawn in this way, it is possible
to obtain the second intermediate member 140 including the intermediate ridge
portions 142a and 142b, the first intermediate surface portions 143a and 143b, the
second intermediate surface pmtion 144, and the intermediate continuous flange 148.
The second intermediate member 140 is also one type of the press-molded product.
10 Thus, the drawing device 60 is one type of the press-molded product producing
apparatus of the invention used to produce the press-molded product 100 as a final
molded product.
[0109]
(3-1-2. Second Intermediate Molding by Inner Pad Drawing Device)
15 Next, a state where a drawing process is performed on the first intermediate
member 130 by an inner pad drawing device 70 with an inner pad will be described.
The basic configuration of the inner pad drawing device 70 may be the same as that
of the im1er pad drawing device 1 OB used in the first press-molding step of the
second embodiment.
20 [0110]
FIG. 11 is an explanatory diagram schematically illustrating a state where
the second intermediate member 140 is obtained from the first intermediate member
130 by an inner pad drawing process using the im1er pad drawing device 70. In FIG.
11, the column (a) indicates a diagram when viewed in a direction intersecting the
25 longitudinal direction of the first intermediate member 130 and the column (b)
indicates a diagram when viewed in the longitudinal direction of the first
42
intermediate member 130. Fmiher, FIG. 11 (A) illustrates a state where the first
intermediate member 130 is set in the i1mer pad drawing device 70, FIG. 11(B)
illustrates a state where the pad 31 contacts the first intermediate member 130, and
FIG. 1l(C) illustrates a state immediately before an inner pad drawing process ends.
5 [0111]
As illustrated in FIG. 11, the inner pad drawing process can be perfonned
similarly to the drawing process illustrated in FIG. I 0 except that the drawing
process is performed by the punch 35 with the inner pad 33 supported so as to be
movable in the mold clamping direction. Thus, the flange 131 is nipped inside the
10 gap (the first gap) formed by the side surface 35a of the punch 35, the side surface
33a of the inner pad 33, and the out-of-plane deformation restricting tool 34 during
the inner pad drawing process, and hence the out-of-plane deformation of the flange
131 is suppressed.. Accordingly, the intermediate ridge-portion flanges 145a and
145b are formed by an in-plane compression molding process. Also, since the
15 punch 35 with the inner pad 33 is used, an increase in the plate thickness of the area
of the edge portion of the intermediate continuous flange 148 in the width direction
is reduced. Particularly, an increase in the plate thickness of the area of the edge
portions of the intermediate ridge-portion flanges 145a and 145b is reduced. Thus,
it is possible to further suppress the generation of wrinkles in the inward continuous
20 flange 118 formed in tile press-molded product I 00 as a final molded product.
[0112]
In this. way, since an inner pad drawing process is performed on the first
intermediate member 130 in the second intermediate molding step, it is possible to
obtain the second intermediate member 140 including the intermediate ridge portions
25 142a and 142b, the first intermediate surface portions 143a and 143b, the second
intermediate surface portion 144, and the intermediate continuous flange 148. The
43
second intermediate member I 40 also corresponds to one type of the press-molded
product. Thus, the inner pad drawing device 70 is one type of the press-molded
product producing apparatus of the invention used to produce the press-molded
product 100 as a final molded product.
5 [0113]
(3-1~3. Second Intermediate Molding Step by Bending Device)
The second intermediate molding step described so far is performed by the
drawing process, but the second intermediate molding step may be performed by a
bending process instead of the drawing process. The basic configuration of the
10 bending device used to perform the bending process in the second intermediate
molding step may be the same as that of the bending device used in the first
press-molding step of the second embodiment.
[0114]
Here, when the second intermediate member I 40 is formed by a bending
15 process, the moving distance in which the die 30 moves close to the punch 35 is set
to be shorter than the moving distance of the first press-molding step. For example,
the moving distance can be shortened when an area in which the punch 35 advances
in the die 30 is decreased. Accordingly, the end portion 132 of the first intermediate
member 130 is held while not being completely bent. By such a bending process,
20 the intermediate ridge portions I 42a and I 42b, and the first intermediate surface
portions I 43a and I 43b and the second intermediate surface portion I 44 respectively
connected to the intermediate ridge p01iions I 42a and I 42b are formed. In the
embodiment, the first intermediate surface portions 143a and 143b are not parallel to
the second intermediate surface portion I 44 in the second intermediate member I 40,
25 and the first intermediate surface portions 143a and 143b are formed so as to extend
in the inclination direction with respect to the second intermediate surface portion
144.
[0 115]
44
During such a bending process, the flange 131 formed in the first
intermediate member 130 is nipped inside the gap (the first gap) formed by the side
5 surface 35a of the punch 35 and the out-of-plane deformation restricting tool34, and
hence the out -of-plane deformation of the flange 131 is suppressed. Thus, the
intermediate ridge-portion flanges 145a and 145b are formed by an in-plane
compressiOn molding process, and hence the generation of wrinkles in the
intermediate continuous flange 148 is suppressed.
10 [0116]
Also in the embodiment, the bending process can be performed by a mold
having a simple configuration compared with the drawing process. Meanwhile, in
the bending process, a large increase in the plate thickness of the ridge-p01tion
flanges liSa and 115b easily occurs compared with the drawing process. Here, the
15 drawing process is better than the bending process in that the die-galling of the
second intermediate member 140 or the press-molded product 100 as a final molded
product can be reduced and the loss of the mold can be reduced.
[0117]
In this way, since the first intermediate member 130 is bent in the second
20 intermediate molding step, it is possible to obtain the second intermediate member
140 including the intermediate ridge portions 142a and 142b, the first intermediate
surface p01tions 143a and 143b, the second intermediate surface p01tion 144, and the
intermediate continuous flange 148. The second intermediate member 140 also
corresponds to one type of the press-molded product. Thus, the bending device
25 used in such a bending process corresponds to one type of the press-molded product
producing apparatus of the invention used to produce the press-molded product 100
45
as a final molded product.
[0118]
(3-2. Second Press-molding Step)
In the second press-molding step, the configuration of the press-molding
5 apparatus or the press-molding method is not particularly limited as long as the
press-molded product I 00 can be obtained from the second intermediate member 140
by, for example, a press-molding process such as a bending process. Hereinafter, an
example of a press-molding method of obtaining the press-molded product I 00 as a
final molded product from the second intermediate member 140 and a press-molding
10 apparatus 80 used in the second press-molding step will be described with reference
to FIGS. 12 and 13.
[0119]
FIG. 12(A) is a schematic diagram illustrating a patt of a configuration
example of the press-molding apparatus 80 used in the bending process. Further,
15 FIG. 12(B) is a perspective view illustrating an example of the appearance of the
press-molded product I 00 obtained by the bending process using such a
press-molding apparatus 80. The basic configuration of the press-molding
appm·atus 80 can be the same as that of the press-molding apparatus 90 used in the
first intermediate molding step of the second embodiment. Here, the press-molding
20 apparatus 80 used ··in· the second press-molding step includes an out-of-plane
deformation restricting tool 40 which is disposed so as to face a side surface 39a of a
punch 39 during a press-molding process.
[0120]
The distance of the gap (the second gap) formed by the side surface 39a of
25 the punch 39 and the out-of-plane deformation restricting tool40 may be equal to the
distance of the gap (the first gap) of the forming apparatus used in the first
46
press-molding step or the second intermediate molding step. In addition, FIG.
12(A) patiially illustrates the press-molding apparatus 80 in the periphery of the end
pmiion of the second intermediate member 140 in the longitudinal direction (a
direction indicated by the white arrow of FIG. 12(A)).
5 [0121]
FIG. 13 is an explanatory diagram schematically illustrating a state where
the press-molded product 100 is obtained from the second intermediate member 140
by a bending process using the press-molding apparatus 80. In FIG. 13, the column
(a) indicates a diagram when viewed in a direction intersecting the longitudinal
10 direction of the second intermediate member 140 and the colunm (b) indicates a
diagram when viewed in the longitudinal direction of the second intermediate
member 140. Further, FIG. 13(A) illustrates a state where a pad 38 contacts the
second intennediate member. 140, and FIG. 13(B) illustrates a state where a bending
process ends.
15 [0122]
As illustrated in FIG. 13, the second press-molding step using the bending
process can be performed basically similarly to the first intermediate molding step of
the second embodiment. That is, the second intermediate member 140 is set on the
punch 39, and then the second intermediate surface pmiion 144 of the second
20 intermediate member 140 is-oonstrained and held by the pad 38 supported by a die 37
so as to be movable in the mold clamping direction and the punch 39. In this state,
a press-molding process of bending the first intermediate surface pmiions 143a and
143b is performed in a mam1er that the punch 39 and the die 37 move relatively close
to each other.
25 [0123]
During such a bending process, the intermediate continuous flange 148
47
formed in the second intermediate member 140 is nipped inside the gap formed by
the side surface 39a of the punch 39 and the out-of-plane deformation restricting tool
40, and hence the out-of-plane deformation of the intermediate continuous flange
148 is suppressed. Thus, the ridge-portion flanges ll5a and 115b are formed by an
5 in-plane compression molding process, and the generation of wrinkles in the inward
continuous flange 118 is suppressed.
[0124]
By the bending process, as illustrated in FIG. 12(B), the press-molded
product 100 including the ridge portions ll2a and 112b, the first surface portions
10 113a and 113b, the second surface portion 114, and the inward continuous flange 118
can be obtained. The inward continuous flange ll8 does not include a notch and is
formed such that the ridge-pmtion flanges 115a and 115b, the first flanges 116a and
116b, and the second flange JlZ.are continuously formed inward in cross-section.
[0125]
15 In addition, in the embodiment, the end portion of the press-molded product
100 is provided with the inward continuous flange 118 formed in the entire area of
the end portions of the ridge portions 112a and 112b, the first surface portions 113a
and 113b, and the second surface portion 114. Here, the first flanges 116a and 116b
and the second flange 117 may be formed in a pa11 of the area of the end portions of
20 the first surface pmtions l Ba and ·113b and the second surface po1tion 114. The
first flanges ll6a and 116b and the second flange ll7 may be formed so as to be
continuous from the ridge-portion flanges 115a and 115b.
[0126]
Further, in the bending process of the second press-molding step, the ridge
25 pmtion is not subjected to an additional bending process or a load applied thereto
during the bending process is very small in accordance with the processing condition.
48
For that reason, the distance of the gap (the second gap) formed by the side surface
35a of the punch 35 and the out-of-plane deformation restricting tool 40 may be
larger than the gap (the first gap) formed in the forming apparatus used in the first
press-molding step or the second intermediate molding step.
5 [0127]
As described above, in the press-molded product producing method
according to the embodiment, it is possible to produce the press-molded product 100
with the inward continuous flange 118 suppressing the generation of wrinkles
without forming a notch by the use of the high-strength steel plate. Thus, it is
10 possible to obtain the press-molded product 100 which can be used in the vehicle
body reinforcing member and has high rigidity and excellent load transfer efficiency.
[Examples]
[0128]
Hereinafter, Examples of the invention will be described.
15 [0129]
(Examples 1 and 2 and Comparative Example 1)
First, the press-molded products were produced by two press-molding
apparatuses having the same configuration except for the existence of the
out-of-plane deformation restricting tool, and the inward continuous flanges were
20 compared with each