Press Molding Method And Metal Mold For Press Molding
Abstract:
In the present invention a press molding method includes: a first step for determining a pressing force that a material to be molded exerts on each part of a metal mold during press molding such determination carried out while press molding the material to be molded by individually driving each part of the metal mold divided into a plurality of pieces; and a second step for adjusting for each part of the metal mold at least one of an applied driving force driving speed and driving timing so that processing portions of the material to be molded detected to be approaching an overload state on the basis of the pressing force are caused to flow into other processing portions of the material to be molded.
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Notices, Deadlines & Correspondence
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
2. YAMAMOTO Shuji
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
3. YAMAGATA Mitsuharu
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
Specification
The present invention relates to a press forming method for a workpiece material
which is made of steel, and a tool for press fol-ming which is used in the press forming
method.
Priority is claimed on Japanese Patent Application No. 2014-103735, filed on
May 19,2014, the content of \vIiich is incorporated herein by reference.
[Related Art]
[0002]
As a method for fom~inga final product such as a bottoriied cylindrical member
having a vertical wall portion and a bottom \vall portion which is continuous with the
vertical wall portion from a plate-shaped material, a cup-shaped intermediate material, or
the like, a drawing method is widely used.
For example, Non-Patent Document 1 discloses a method \vIlich fornis a
cylindrical container having a constant inner diameter frotii a bottorn portion to an opening
portion, or a stepped cylindrical product having a step portion in \vhich an inner diameter
changes on the way from the bottom portion to the opening portion. That is, in general, a
method is widely used, in which an intermediate material ~vhichis fornled into a cup
shape fro111 a disk-shaped material in a first process is drawn in a second process again,
and tlie cup-shaped ititelmediate material is further dtawn by the re-dta~vingm ethod.
[0003]
In this re-drawing method, tlie cup-shaped intermediate material formed in the
first process is nipped between a die in ~vhichth e intermediate matet ial is accotnmodated,
and a blank holder \\4iicli is a cplindrical tool inserted into the inner portion of the
intermediate material. hi addition, a punch coaxially passing through the inner portion of
the blank holder is pushed to be inserted into a colur~mars pace \\~hichi s fornled on the
- 1 -
bottom of the die, and a cylindrical protrusion is for~ned on the bottom \\call portio~io f the
cup-shaped intermediate material. Ho\vever, in this fortiiing method, the material
configuring the bottom \\(all portion of tlie cop-shaped intermediate material may not be
sutficiently fed into the columnar space by the punch. In this case, there are problems
that tlie bottom wall portion of the intermediate material nlay be broken by the tip angle
portion of the punch, and a forming failure due to insufficient supply of a material into the
colu~iinasrp ace may occur.
[0004]
With respect to the above-described problems, in Patent Document 1, Non-Patent
Document 1, and Non-Patent Document 2, a method for preventing a forming failure
using a tool divided into multiple portions is disclosed. That is, as \vitli the re-drawing
method of the related art, the upper edge portion of the intertnediate material is pressed by
the second punch \vhile the first punch is poslied into the bottom wall portion of tlie
cup-shaped intermediate material so as to fonn a cylindrical protnision. According to
this nietl~ods, upply of a material into the periphery of the tip angle portion of the first
punch is promoted doe to a pressing force by the second punch, and as a result, it is
possible to prevent a forming failure due to a material breakage or the like.
In addition, Patent Document 2 discloses a method in which fortning is not perfonned on a
cup-shaped intermediate material, and a f i ~ aplr oduct is obtained from a plate-shaped
material by a single process.
[OOOS]
In these forming methods, in order to perform forming in a state where a fortning
failure does not occur, it is impo~tantto maintain the movement speed of each tool divided
into multiple portions (for example, first punch and second punch) at an appropriate value.
In this case, in consideration of variation in material dimensions before fortning, or
variation in lubrication states between the tool and the material during the fortning, it is
preferable to proceed fortiling while the movement speed of each portion of the tool is
suitably corrected to an appropriate value according to the fornring progress situation such
as filling of the niatcrial into tlie tool.
- 2 -
Patent Documents 3 to 5 disclosc a method and a device for tlleasuring a load
distribution or a strain amount in a tool during press fonning. Ho~vever, in a fonning
method which is used in general, forming is only perfonned wl~ilee ach tool dividcd into
nlultiple portions llloves at a co~lstatlst peed which is set in advance before shaping starts.
Accordinglj: the move~lle~slpte ed is not corrected according to the material dimensions 01.
the progress sittiation of press fornling during for~ning.
[Prior Art Documents]
[Patent Docoment]
[0006]
[Patent Document I] Japanese Unexamined Patent Application, First
Publication No. 2004-322104
[Patent Documeut 21 Japanese Unexa~ninedP atent Applicatioa, First
Publication No. 2010-214381
[Patent Document 31 Japanese Unexamit~edP atent Application, First
Pr~blicationN o. 2008-149349
[Patent Docume~l4t 1 Japanese Unexamiued Patent Application, First
Publicatio~Nl o. 2008-173686
[Patent Document 51 Japanese Uuexanlined Patent Application, First
Publication No. 2010-1 15702
won-Patent Document]
[0007]
[Nan-Patent Document 11 Takashi SUZUMURA, JOURNAL OF THE JAPAN
SOCIETY FOR TECHNOLOGY OF PLASTTCITY, P. 9, vol. 5 I, No. 594 (2010)
won-Patent Document 21 Michiharo YOKOI, JOURNAL 01: THE JAPAN
SOCIETY FOR TECHNOLOGY OF PLASTICITY, P 13, vol. 51, No. 594 (2010)
[Disclosure of the Invention]
[Problems to be Solved by the Invention]
[0008]
In the above-described press fornliog method, if a movement speed ratio between
- 3 -
a first p~tncal~nd a second punch which move indepet~dentlyfr om eacll other during
forming is not appropriate, a load of any one of the turo punches becotnes excessive, the
load may exceed a fortning load lirnit of the drawing device, and there is a concern that
further fornling may be inlpossible.
On the contrary, although both loads of the first punch and the second punch are
within the forming load limit of the drawing device, an [tnfilled portion where the tool is
not filled with a material remains, and as a result, there is a concern that a forming failure
of a product may occur.
[0009]
The present invention is made in consideratiot~o fthe above-described
circutnstances, and an object thereof is to provide a press fanning method and a tool for
press fortning in \\~hich it is not inlpossible to perform fortning if a forming load exceeds a
load limit of a press forn~ingd evice when each portions of a tool divided into multiple
portions are operated independently from each other, atid a product in which a for~ning
failure due to unfilling the tool with a material does not occur can be stably fonned .
[Means for Solving the Problem]
[OO lo]
In order to solve the problem and achieve the object, the inventors investigated a
method for ascertaining a material inflo~va t a predetermined position inside a tool in a
non-contact manner. In addition, as an example of the method, the inventor adopted a
nlethod which provides a sensor in tlie tool for measuring deformation of the tool,
measures a defomlation amount generated in the tool by the sensor, and detects an
overload situation of the tool during forn~ing. According to this method, it is possible to
prevent the load applied to the tool from excessively exceeding the load limit of the press
fortning device so as not to be itnpossible to perforn forming, and it is possible to prevent
a fortning failore of a product associated \\rith the unfilling the tool ~vitha material.
[OOll]
That is, the primary points of the present invention are as follo~\~s.
(1) According to an aspect of the present invention, there is provided a press
- 4 -
forming metllod, including: a first process of obtaining a pressing force applied to each
portion of a tool by an workpiece nlaterial during press forn~ing\v hile independently
driving the respective each portion of the tool divided into nll~ltiplep ortions and press
fortning the \\arkpiece material; and a second process of adjusting at least one of an
applied driving force, an applied driving speed, and an applied driving tinling for each
portion of the tool to cause a processing portion of the workpiece material in which the
state approacl~inga 1 overload state is detected based on the pressing force to flow to other
processing portions of the workpiece material.
[OO 121
(2) In the aspect according to (I), in the first process, the pressing force may be
obtained based on a deformation amount of the tool generated according to the flow of the
workpiece material during press forn~ing.
[OO 131
(3) In the aspect according to (1) or (2), in the second process, whether or not
the state has approached the overload state may be determined by whether or not the
pressing force exceeds a predetermined threshold valae.
[0014]
(4) In the aspect according to any one of (I) to (3), press fonning may be
drawing for forming the workpiece material into a cylindrical member having an axis line,
and the pressing force rnay be obtained at multiple locations along a circmnferential
direction of which the center is the axis line.
[OO 151
(5) 111 the aspect according to any one of (1) to (3), press forming may be
drawing for fonning the workpiece rnaterial into a cylindrical member having a1 axis line,
and the pressing force may be obtained at multiple locations along an extension direction
of the axis line.
[OO 161
(6) In the case of (S), the pressing force may be further obtained at multiple
locations along a circumferential direction of \vhich the center is the axis line.
- 6 .
100 I 71
(7) In the aspect according to any one of (I) to (6), the tool nlay include a die
and a punch, and tile pressing force may be obtained by a strain sensor which is provided
on at least one of the die-and the poncl~.
100 1 81
(8) In the aspect according to any one of (1) to (7), a preliminary process may
be perfot-riled before the first process, and the preli~ninatyp rocessing rnay include: a
calculation process of obtaining a prediction correspondence relationship between at least
one of the driving force, the driving speed, and the driving timing, and the pressing force
in which the overload state is not generated, in numerical calculations; a measurement
process of measuring the pressing force applied to each portion of the tool by the
workpiece material during forming while indepelldently driving the respective each
portions of the tool and press forming the workpiece material according to the prediction
correspondence relationship obtained by the calculation process, and obtaining a
tneasuretnent correspondence relationship between the measured pressing force and at
least one of the driving force, the driving speed, and the driving timing; and a correction
process of obtaining a difference between the prediction correspondence relationship
obtained by the calcolation process and the lneasilrement correspondence relationship
obtained by the measurement process, and correcting the prediction correspondence
relationship, in which the first process may be performed according to the corrected
prediction correspondence relationship obtained by the preliniinary process.
100 191
(9) According to another aspect of the present invention, there is provided a tool
for press fortning including a tool divided into tnultiple portions in which each portion
individually receives a driving force and press fortns an workpiece material; in which a
sensor which acquires a pressing force \\~11ichi s applied to a forming surface of the tool
from the workpiece ~nateriald uring press forming.
[0020]
(10) Jn tllc aspect according to (9), a configuration may be adopted, in which
- G -
the tool for prcss forn~ingis i~sedf or drawing so that the \vorkpiece material is fortncd into
a cylindrical member having an axis line, and the sensor is provided at multiple locations
along a circumferential direction of which the center is the axis line.
[0021]
(11) In the aspect according to (9), a configuration nlay be adopted, in ~vhich
the tool for press fornting is usetl for drawing so that the \vorkpiece material is formed into
a cylindrical n~embehr aviag i u ~as is line, and the sensor is provided at multiple locations
along an extension direction of the axis line.
[0022]
(12) In the case of (1 l), the sensors be further provided at multiple
locations along a circumferential direction of which the center is the axis line.
[0023]
(13) hl the aspect according to any one of (9) to (12), a configi~rationtn ay be
adopted, in which the tool for press forming inclodes a die and a puocl~a, nd the sensor is a
strain sensor which is provided on at least one of the die and the punch.
[0024]
(14) In the case of (13), a detection unit of the strain sensor may be provided at a
position at a depth of 5 mrn to 50 tntn frotn the fortning surface of at least one of the die
and the punch on \vIvhich the strain sensor is provided.
[Effects of the Invention]
[0025]
According to the aspect described in (I) of the present invention, after the flow
state in the material of the workpiece material in the tool is ascertained based on the
pressing force acquired by the first process, it is possible to control the operation of each
portion of the tool in the second process. Accordingly, it is not itnpossible to perfonn
fortning if a fonning load exceeds a load limit of a press forming device when each
portions of a tool are operated independently from each other, and it is possible to perform
press fonning a ptoduct in whic11 a forming failure due to unfilling the tool \\it11 a inaterial
does not occur.
. 7 .
[0026]
111 the case of (2), since the flo\v in the material of the workpiece tnaterial can be
ascertained \writ11 favorable responsiveness, even wllell press forming is performed in a
short time, it is possible to secure a tilne required for controlling the driving of each
portion of the tool, and it is possible to acarrately perfor111 press fonning of the \vorkpiece
material.
I11 tlie case of (3), it is possible to control the operation of each portion of the tool,
hen tlie flow state of the Iwrorkpiece material during press fortning is instantaneously
determined.
[0027]
In the case (4), since pressing forces are obtained at multiple locations along the
circumferential direction of wl~ichth e center is the axis line, it is possible to reliably
prevent failed operations doe to variation in the flow states of the workpiece material in
the circu~nferer~tidailr ection.
In the case (5), since pressing forces are obtained at multiple locations along the
extension direction of the axis line, it is possible to ascertain the fortning process of the
\vorkpiece material with higher sensitivity. In addition, an application can be performed,
in whicll data of the pressing forces obtained along the axis line direction is input to a
numerical calculation model so that press forn~ingis sit~~ulatetod increase calculation
accuracy.
In the case of (6), since the pressing forces are obtained both along the extension
direction of the axis line and the circunlferential direction thereof, it is possible to
three-dimensionally ascertain the fortning process of the workpiece ~naterial.
[0028]
In the case of (7), since the flow of the \\forkpiece material can be ascertained
with appropriate sensitivity and responsiveness by the strain sensol; it is possible to more
accurately perfonn press fonning of the workpiece material.
[0029]
In the case of (S), since the first process and the second process can be perfortned,
- 8 -
\vl~ena t least one of the driving force, the driving speed, and the driving timing is
optitnized by the preliminaty process, it is possible to tnore accurately perfortn press
forming.
[0030]
According to the aspect described in (9) of the present invention, it is possible to
ascertain the flow state of the material of the \\corkpiece material in the tool based on the
pressing force acquired by the sensor. Accordingly, it is not inlpossible to perfor111
forming if a fonning load exceeds a load limit of a press fonning device when each
portions of a tool are operated independently frotn each other, and it is possible to control
so as to be stably drawn a product in which a fornlitig failure due to i~nfillingth e tool with
a material does not occur.
[003 11
In the case of (lo), since the pressing forces can be obtained at n~ultiplelo cations
along the circumferential direction of which the center is the axis line, it is possible to
reliably prevent failed operations due to variation in the flow states of the material of the
workpiece material in the circumferential direction.
In the case of (1 l), since the pressing forces are obtained at nn~ltiplelo cations
along the extension direction of the axis line, it is possible to ascertain the forn~ingp rocess
of the workpiece material with higher sensitivity. In addition, at1 application can be
performed, in which data of the pressing forces obtained along the axis line direction is
input to a numerical calculation model so that press forming is simulated to increase
calculation accuracy.
In the case of (12), since the pressing forces are obtained both along the extension
dil-ection of the axis line and the circumferential direction thereof, it is possible to
three-dimensionally ascertain the fortning process of the \\forkpiece material.
[0032]
In the case of (13), since the flow in the material ofthe workpiece material cat) be
ascertained with favorable respot~sivenessb y the strain sensor, even when press forming is
performed in a short time, it is possible to secure a time requit-ed for controlling the
- 9 -
driving of each portion of the tool, and it is possible to accurately perform press forming
of the workpiece material.
111 the case of (14), measurement can be accurately perfomled \vitIlin a sensitivity
range of the strain sensor.
[Brief Description of the Drawings]
[0033]
Fig. 1A is a view showing a first enlbodinlent of a press forming method of the
present invention, and is a longitudit~als ectional view when viewed from a cross section
i~lcludinga n axis line of a tool.
Fig. 1B is a view showing subsequence of the press fonllirlg method, and is a
longit~ldinals ectional view when viewed from the same cross section as that of Fig. IA.
Fig. 1C is a vie111 showing further subsequence of the press fornling method, and
is a longitudinal sectional view w11en viewed fro111 the sarlle cross section as that of Fig.
1A.
Fig. 2 is a functional block diagram of a press forming device used in the
embodiment.
Fig. 3 is a view sho\ving cracks of a tip angle portion of a punch \\fhich beconles a
problem in drawing, and is a sectional view \\&en viewed from the cross section including
the axis line of the tool.
Fig. 4A is a vie\\( showiug an example of a filling process of a nlaterial inside the
tool in the press fortning method, and is a longitudinal sectional view when viewed from
the cross section including the axis line of the tool.
Fig. 4B is a view showing subsequence of the press forming rnethod, and is a
longitudinal sectional view when vielved from the same cross section as that of Fig. 4A.
Fig. 4C is a view showing subsequence of the press forniing method, and is a
longitudinal sectional view when viewed fro111 the sanle cross section as that of Fig. 4A.
Fig. 5 is a flo\rcIlart of a calcr~lationp rogram used to control the press forming
device.
Fig. 6A is a view showing disposition of a sensor of the tool for press for~ning
- 10-
used in the en~bodimcnat nd tile press forming method using the sensor, and is a
longitt~dinasl ectional view when vie\ved fro111t he cross section i~lcludi~th~eg a xis line of
the tool.
Fig. 6B is a view shoxving subsequence of the press forming method, and is a
longitudit~asl ectio~lavl iew ~vhenv ie~vedf rom the sane cross section as that of Fig. 6A.
Fig. 7A is a view sho~\~inthge press forming tnethod of the embodin~ent,a nd is a
longitudinal sectional view \vheo viewed from the cross section i~lcludingth e axis line of
the tool.
Fig. 7B is a view sho\ving the subsequence of the press forming method, and is a
longitudinal sectional view when viewed from the same cross section as that of Fig. 7A.
Fig. 8A is a view showing a modification example of the first embodiment, and is
a plan sectional view when viewed from an A-A cross section of Fig. 1A.
Fig. 8B is a view showing the n~odificatione xample, and is a plan sectional view
mhen viewed fiom line B-B of Fig. 1A.
Fig. 9 is a view showing the modification example of the first embodiment, and is
a partial sectio~~vaile w corresponding to a C portion of Fig. 1C.
Fig. 10A is a view showing a second embodiment of the press forming tnethod of
the present invention, and is a longitudinal sectional view when viewed from the cross
section including the axis line of the tool.
Fig. 10B is a view showing subsequence of the press forming method, and is a
lo~lgitudinals ectio~~vaile w when viewed from the same cross section as that of Fig. 10A.
Fig. 11A is a vie\\
Documents
Orders
Section
Controller
Decision Date
Application Documents
#
Name
Date
1
201617038103-IntimationOfGrant30-11-2023.pdf
2023-11-30
1
Priority Document [08-11-2016(online)].pdf
2016-11-08
2
201617038103-PatentCertificate30-11-2023.pdf
2023-11-30
2
Power of Attorney [08-11-2016(online)].pdf
2016-11-08
3
Form 5 [08-11-2016(online)].pdf
2016-11-08
3
201617038103-Written submissions and relevant documents [26-09-2023(online)].pdf
2023-09-26
4
Form 3 [08-11-2016(online)].pdf
2016-11-08
4
201617038103-PETITION UNDER RULE 138 [15-09-2023(online)].pdf
2023-09-15
5
Form 18 [08-11-2016(online)].pdf_23.pdf
2016-11-08
5
201617038103-FORM 3 [05-09-2023(online)].pdf
2023-09-05
6
Form 18 [08-11-2016(online)].pdf
2016-11-08
6
201617038103-Correspondence to notify the Controller [28-08-2023(online)].pdf