JP2005270998A - Bearing surface forming apparatus and bearing surface forming method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bearing surface forming apparatus that facilitates formation of a hydraulically formed article having a bearing surface from an aluminum extruded material. <P>SOLUTION: The bearing surface forming apparatus is equipped with: dies 60 (61, 71) having an aluminum extruded material 10 arranged inside and cavity faces 62, 72 corresponding to the contour of a formed article; an opening part 64 formed on the cavity face 62; a male die 91 disposed in a freely advanceable manner from the opening part 64 and having an end face 92 formed with a bearing shape; and a hydraulic pressure imparting means 81 (82-86) which imparts a hydraulic pressure to the inside of the aluminum extruded material 10 clamped by the dies 60 for the purpose of bulge-deforming it to a shape coincident with the cavity faces 62, 72. The male die 91, after completion of the bulge-deformation, is advanced from the opening part 64 and pushed in the part of the aluminum extruded material 10 abutting on the end face 92, causing deformation accompanied by shearing to form the bearing surface. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a seat surface forming apparatus and a seat surface forming method.

In recent years, in the automotive field, we have attempted to reduce costs and reduce weight by reducing the number of parts by switching from hydroformed products that use steel pipes to hydroformed products that use extruded aluminum (for example, patents). Reference 1).
JP 2002-11530 A

  However, the total elongation characteristics of the extruded aluminum material are not as good as those of the steel pipe. For example, a steel pipe according to a standard such as STKM11A can have a total elongation of about 40%, while an aluminum extruded material according to a standard such as 6N01-T5 can only have a total elongation of about 12%.

  Therefore, when forming a seating surface after hydroforming, the extruded aluminum material has a problem that it is more likely to burst as compared to a steel pipe and the seating surface is difficult to form.

  The present invention has been made to solve the above-described problems associated with the prior art, and a seat surface forming apparatus and a seat surface capable of easily forming a hydroformed product having a seat surface from an extruded aluminum material. An object is to provide a forming method.

In order to achieve the above object, the invention described in claim 1
A mold having a cavity surface corresponding to the outer shape of the molded article, the aluminum extruded material being disposed inside;
An opening formed in the cavity surface;
A male type having an end face that is disposed so as to be freely advanced from the opening and in which a seating surface shape is formed;
A hydraulic pressure applying means for applying a hydraulic pressure to the inside of the extruded aluminum material clamped by the mold, and bulging and deforming to a shape matching the cavity surface;
After completion of the bulging deformation, the male mold advances from the opening and is pushed into the portion of the aluminum extruding material that is in contact with the end surface to cause deformation with shearing, thereby causing the seat surface It is a seat surface formation device characterized by forming.

In order to achieve the above object, the invention according to claim 9 provides:
Inside the mold having a cavity surface corresponding to the outer shape of the molded product, an aluminum extruded material is placed and clamped,
Applying hydraulic pressure to the inside of the aluminum extruded material clamped by the mold, bulging and deforming to a shape that matches the cavity surface,
After completion of the bulging deformation, a male die having an end surface on which a seat surface shape is formed is advanced from an opening formed in the cavity surface and pushed into a portion of the aluminum extruded material that is in contact with the end surface. The seating surface forming method is characterized in that the seating surface is formed by causing deformation with shearing.

  The present invention configured as described above has the following effects.

  According to the first aspect of the present invention, after completion of the bulging deformation, shearing is performed so that the material is not greatly stretched with respect to the portion of the aluminum extruded material in contact with the male end face. It is possible to deform and form a seating surface. Therefore, it is possible to suppress a burst of material when forming the seating surface. That is, it is possible to provide a seat surface forming apparatus capable of easily forming a hydroformed product having a seat surface from an extruded aluminum material.

  According to the seventh aspect of the present invention, after completion of the bulging deformation, shearing is performed so that the material is not greatly stretched with respect to the portion of the aluminum extruded material that is in contact with the male end face. The seat surface is formed by deformation. Therefore, the burst of material during the formation of the seating surface is suppressed. That is, it is possible to provide a seat surface forming method capable of easily forming a hydroformed product having a seat surface from an extruded aluminum material.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view for explaining a hydraulic molded product according to the embodiment of the present invention, and FIG. 2 is a cross-sectional view for explaining the hydraulic molded product according to the embodiment of the present invention.

  The extruded aluminum material 10 according to the present embodiment forms a hollow hydroformed product 20 that is bent with respect to the longitudinal direction by applying hydroforming after pre-molding. The hydroformed product 20 is, for example, an automobile part. As shown in FIG. 1, the hydroformed product 20 is a pillar member such as a reinforcement front pillar, a reinforcement center pillar, or a sill inner pillar, or an inner member such as a rail roof side inner. is there.

  The hydroformed product 20 has a seating surface 30 composed of a recess having a substantially flat bottom surface. The seating surface 30 is applied as a positioning reference surface for attaching a separate part, for example. The separate part is, for example, a pillar part or an inner part. In addition, the seat surface 30 is not limited to being comprised from the recessed part which has a substantially flat bottom face.

  FIG. 3 is a cross-sectional view for explaining the seat surface forming apparatus according to the embodiment of the present invention, and FIG. 4 is a cross-sectional view for explaining the aluminum extruded material according to the embodiment of the present invention.

  The seat surface forming device 50 also serves as a hydraulic molding device, and includes a hydraulic molding die 60, a fluid pressure applying unit 81, a seat surface forming unit 90, and a fluid pressure control unit (not shown). The mold 60 includes an upper mold 61 and a lower mold 71 for clamping the aluminum extruded material 10 disposed inside. The upper mold 61 and the lower mold 71 are close to and away from each other, and cavity surfaces 62 and 72 corresponding to the outer shape of the hydroformed product 20 are formed.

  The aluminum extruded material 10 is deformed by being pressed by the cavity surfaces 62 and 72 when the upper mold 61 and the lower mold 71 are clamped, and is subjected to a preliminary molding corresponding to the longitudinal shape of the hydroformed product 20. . Preliminary molding can be appropriately performed as an independent process as needed before the aluminum extruded material 10 is placed on the upper mold 61 and the lower mold 71.

Aluminum extruded material 10 has a substantially rectangular cross-section, having four side surfaces 13 extending between four corners C ₁ and the corner portion. The side surface 13 has a recessed portion 15 that extends along the longitudinal direction and protrudes inward, and has an outer peripheral length that is longer than that in the case where the recessed portion 15 is not provided. The indented portion 15 corresponds to a portion (bulging portion) that bulges and deforms when a hydraulic pressure is applied during hydraulic molding.

  That is, since the outer peripheral length of the aluminum extruded material 10 is increased due to the presence of the recessed portion 15, the amount of elongation required at the bulging portion is smaller than when the recessed portion 15 is not provided. Therefore, the total elongation characteristic of the extruded aluminum material 10 is not relatively good, but it is possible to suppress the burst during the hydraulic forming. In addition, the recessed part 15 is not limited to forming in all the side surfaces 13, It is also possible to select suitably the side surface which forms a recessed part as needed.

  In order to reliably suppress the burst at the time of hydraulic forming, the outer peripheral length of the side surface 13 having the recess 15 is substantially equal to the inner peripheral length of the cavity surfaces 62 and 72 with which the side surface 13 abuts by hydraulic forming. It is preferable to match.

The final pressure at the time of hydroforming is the shape along the corner portion of the cavity surface corresponds to the hydraulic pressure required for deforming the corner portion C _1. Therefore, the shape of the corner portion C _1, by setting in advance to the shape substantially coincides along the corner portion of the cavity surface, it is possible to lower the final pressure. Furthermore, the recessed portion 15 is not limited to being formed on all the side surfaces 13, and a side surface on which the recessed portion is formed can be appropriately selected as necessary.

  The hydraulic pressure imparting means 81 is a means for imparting hydraulic pressure to the inside of the extruded aluminum material 10 clamped by the upper mold 61 and the lower mold 71 to bulge and deform to a shape matching the cavity surfaces 62 and 72. And a shaft pushing punch 82 and a shaft pushing cylinder 85 connected to the shaft pushing punch 82.

  The axial push punch 82 is inserted into the end surface opening 11 of the aluminum extruded material 10 and has a protruding portion 83 for sealing the internal space of the aluminum extruded material 10. Further, the shaft pushing punch 82 is connected to a piping system 86 extending from a high-pressure pump for supplying a forming medium, and a supply path 84 for supplying the forming medium to the aluminum extruded material 10 is formed. The forming medium is, for example, water.

  5 is a cross-sectional view for explaining an opening formed in the cavity surface of the mold of the seat surface forming apparatus shown in FIG. 3, and FIG. 6 is a seat surface formation of the seat surface forming apparatus shown in FIG. 7 is a cross-sectional view for explaining the means, FIG. 7 is an enlarged view of a main part of FIG. 6, and FIG.

  The seat surface forming means 90 is disposed so as to be able to advance from an opening 64 formed in the cavity surface 62, and has a male type 91 and a driving means 95 for the male type 91. The opening 64 is arranged at a position where the seat surface 30 can be formed on the side surface 13 by the male die 91.

  The male die 91 is made of, for example, a pierce punch and has an end surface 92 in which a seating surface shape is formed. Since the seat surface 30 is a concave portion having a substantially flat bottom surface, the end surface 92 of the male die 91 is formed in a substantially flat shape. The drive means 95 is composed of, for example, a hydraulic cylinder.

  The male die 91 is advanced from the opening 64 after hydraulic forming (after completion of the bulging deformation), and is pushed into the portion (contact portion) 23 of the aluminum extruded material 10 that is in contact with the end surface 92 to be sheared. The seating surface 30 is formed by causing deformation along with. Therefore, the wall part 31 surrounding the substantially flat bottom surface of the seating surface 30 is a shearing part formed by half cutting (see FIG. 8).

  That is, since the seat surface 30 is formed by being deformed with shearing so as not to greatly extend the material, the total elongation characteristic of the aluminum extruded material 10 is not relatively good, but after hydroforming. It is possible to suppress the burst of material when forming the seating surface. In the present embodiment, the contact portion 23 of the extruded aluminum material 10 corresponds to the bulging portion 25 (see FIG. 5).

  It is preferable that the amount of protrusion of the recessed portion 15 on the side surface 13 where the seat surface 30 is formed be larger than the amount of protrusion of the recessed portion 15 on the side surface 13 where the seat surface 30 is not formed. In this case, since it is possible to further suppress the reduction in the plate thickness of the side surface 13 where the seat surface 30 is formed during the hydraulic forming, the seat surface 30 is easily formed after the hydraulic forming. can do.

  The hydraulic pressure control means includes, for example, valve means arranged in a piping system 86 extending from a high-pressure pump for supplying a forming medium, and hydraulic pressure detection means. The hydraulic pressure control means adjusts the discharge amount of the molding medium present in the internal space of the hydraulic molded product 20 after the supply of the molding medium is stopped, thereby pushing out the aluminum when the seat surface 30 is formed by the male die 91. The hydraulic pressure P inside the material 10 is controlled to be equal to or lower than the final hydraulic pressure Pmax and higher than the hydraulic pressure at which the aluminum extruded material 10 is not deformed by the load in forming the seat surface by the male die 91.

  In this case, since the force required for forming the seating surface can be reduced, the equipment cost of the seating surface forming means 90 can be reduced. The final hydraulic pressure Pmax is set according to conditions such as the material of the extruded aluminum material 10 and the shape of the corner portion of the hydroformed product 20, and is, for example, 20 to 400 MPa.

  As described above, the present embodiment can provide a seat surface forming apparatus that can easily form a hydroformed product having a seat surface from an aluminum extruded material.

  Next, a method for forming the seating surface of the aluminum extruded material 10 to which the seating surface forming apparatus 50 is applied will be described. FIG. 9 is a cross-sectional view for explaining a set of aluminum extrudates on a mold, FIG. 10 is a cross-sectional view for explaining pre-forming and clamping, following FIG. 9, and FIG. 11 is following FIG. FIG. 12 is a sectional view for explaining the hydraulic pressure injection, FIG. 12 is a sectional view for explaining the completion of the bulging deformation following FIG. 11, and FIG. 13 is for explaining the seat surface formation following FIG. FIG.

  First, the upper die 61 is raised to be separated from the lower die 71, and the aluminum extruded material 10 is set between the cavity surfaces 62 and 72 of the upper die 61 and the lower die 71 (see FIG. 9).

  Thereafter, the upper mold 61 is lowered, and the aluminum extruded material 10 is sandwiched between the upper mold 61 and the lower mold 71 and clamped (see FIG. 10). At this time, the aluminum extruded material 10 is deformed by being pressed by the cavity surfaces 62 and 72, and is subjected to a preliminary molding corresponding to the longitudinal shape of the hydroformed product.

  Then, the shaft pushing cylinder 85 is operated to push the shaft pushing punch 82 into the mold side (see FIG. 11). The open end 11 of the extruded aluminum material 10 is expanded by the protruding portion 83 of the axial push punch 82 and is restricted by the upper die 61 and the lower die 71. Therefore, the opening end portion 11 of the aluminum extruded material 10 is in close contact with the axial push punch 82 to ensure airtightness.

  Thereafter, the high pressure pump is operated to start supplying the forming medium. The forming medium is supplied into the aluminum extruded material 10 through the piping system 86 and the supply path 84.

  As the forming medium continues to be supplied and the hydraulic pressure P increases, the extruded aluminum material 10 gradually expands and deforms (see FIG. 11).

  Then, after reaching the final hydraulic pressure Pmax, it is held for a predetermined time. Thus, the extruded aluminum material 10 is swelled to a shape that matches the cavity surfaces 62 and 72 corresponding to the outer shape of the hydroformed product, and the hydroforming is completed (see FIG. 12). At this time, the bulging portion 25 of the extruded aluminum material 10 has a longer outer peripheral length due to the indented portion. Therefore, the amount of elongation due to the bulging is smaller than that without the indented portion, and the burst is suppressed.

  After completion of the hydroforming, the high pressure pump is stopped and, for example, by partially discharging the molding medium existing in the inner space of the swelled and deformed aluminum extruded material 10, the hydraulic pressure P is less than the final hydraulic pressure Pmax and The hydraulic pressure is controlled to be higher than the hydraulic pressure at which the extruded aluminum material 10 is not deformed by the load in forming the seat surface by the male die 91.

  Then, a male die 91 having an end surface formed with a seating surface shape is advanced from the opening 64 formed in the cavity surface 62 and pushed into the contact portion 23 of the aluminum extruded material 10 to cause deformation with shearing. As a result, the seating surface 30 is formed (see FIGS. 7 and 13).

  The wall portion 31 surrounding the substantially flat bottom surface of the seating surface 30 is a shearing portion formed by half cutting (see FIG. 8). That is, since the seat surface 30 is formed by being deformed with shearing so as not to greatly extend the material, the total elongation characteristic of the aluminum extruded material 10 is not relatively good, but after hydroforming. The material burst during the formation of the seating surface is suppressed.

  The pushing amount of the male die 91 needs to be not less than 0 for forming the seating surface 30 and not more than the plate thickness of the contact portion 23 where the seating surface 30 is formed in order to avoid perforation. In order to secure the strength in the vicinity of the seating surface 30, it is preferable that the pushing amount of the male die 91 is not more than one half of the plate thickness of the contact portion 23 where the seating surface 30 is formed.

  The formation of the seat surface by the male die 91 can be executed simultaneously at a plurality of locations or sequentially. When the seat surface formation is sequentially performed, it is preferable to provide a lock mechanism for fixing the position of the male die 91 that has completed the seat surface formation.

  After the formation of the seat surface, the molding medium remaining in the internal space of the hydraulic molded product 20 is discharged, the mold is opened, and the hydraulic molded product 20 is taken out.

  As described above, the present embodiment can provide a seat surface forming method capable of easily forming a hydroformed product having a seat surface from an aluminum extruded material.

  14-16 is sectional drawing for demonstrating the modifications 1-3 of the aluminum extrusion material which concerns on embodiment of this invention.

  The cross section of the extruded aluminum material is not limited to a substantially square shape, and other polygonal shapes can be applied. For example, it is possible to apply the aluminum extruded material 110 (see FIG. 14) having a substantially triangular cross section or the aluminum extruded material 210 (see FIG. 15) having a substantially hexagonal cross section. Further, the aluminum extruded material can have internal ribs 218 (see FIG. 15) extending along the longitudinal direction, or external ribs protruding from the outer peripheral surface and extending along the longitudinal direction. Furthermore, the aluminum extrusion material 310 (refer FIG. 16) which does not have a hollow part can also be applied to an aluminum extrusion material.

  The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims.

  For example, the hydroformed product is not limited to the pillar member or the inner member, and can be applied to other automobile parts. In addition to the positioning reference surface of the separate part, the seat surface of the hydroformed product can be used as, for example, an attachment part for directly joining (for example, welding) the separate part. Moreover, an aluminum extrusion material is not limited to what is preformed. Furthermore, the arrangement position and the number of installation of the seat surface forming means are not particularly limited, and can be appropriately set as necessary.

It is a perspective view for demonstrating the hydraulic-pressure molded article which concerns on embodiment of this invention. It is sectional drawing for demonstrating the hydraulic-molded article which concerns on embodiment of this invention. It is sectional drawing for demonstrating the seat surface formation apparatus which concerns on embodiment of this invention. It is sectional drawing for demonstrating the aluminum extrusion material which concerns on embodiment of this invention. It is sectional drawing for demonstrating the opening part formed in the cavity surface of the metal mold | die of the seat surface formation apparatus shown by FIG. It is sectional drawing for demonstrating the seat surface formation means of the seat surface formation apparatus shown by FIG. It is a principal part enlarged view of FIG. It is a principal part expanded sectional view for demonstrating a seat surface shape. It is sectional drawing for demonstrating the seat surface formation method which concerns on embodiment of this invention, and has shown the set of the aluminum extrusion material with respect to a metal mold | die. FIG. 10 is a cross-sectional view for explaining pre-forming and clamping following FIG. 9. FIG. 11 is a cross-sectional view for explaining hydraulic pressure injection following FIG. 10. FIG. 12 is a cross-sectional view for explaining the completion of the bulging deformation following FIG. 11. FIG. 13 is a cross-sectional view for explaining the seat surface formation following FIG. 12. It is sectional drawing for demonstrating the modification 1 of the aluminum extrusion material which concerns on embodiment of this invention. It is sectional drawing for demonstrating the modification 2 of the aluminum extrusion material which concerns on embodiment of this invention. It is sectional drawing for demonstrating the modification 3 of the aluminum extrusion material which concerns on embodiment of this invention.

Explanation of symbols

10. Aluminum extrusion material,
11..End face opening,
13. Side surface,
15. Recessed part,
20. ・ Hydraulic molded products,
23 .. Contact part,
25 .. bulging part,
30 .. Bearing surface,
31..Wall part,
50 .. Seat surface forming device,
60 .. Mold for hydraulic molding,
61 .. Upper mold,
62 .. cavity surface,
64 .. opening,
71 ... Lower mold,
72 .. cavity surface,
81 .. Hydraulic pressure applying means,
82 ...
83 .. Protruding part,
84 .. supply path,
85 ・ ・ Cylinder,
86 ... Piping system
90 .. Bearing surface forming means,
91..Male type,
92 .. end face,
95 .. Driving means,
110 .. Aluminum extruded material,
210 .. Aluminum extruded material,
218 .. Internal rib,
310 .. Extruded aluminum material,
C _1. Corner section,
P ・ ・ Hydraulic pressure,
Pmax ... Final hydraulic pressure.

Claims (17)

A mold having a cavity surface corresponding to the outer shape of the molded article, the aluminum extruded material being disposed inside;
An opening formed in the cavity surface;
A male type having an end face that is disposed so as to be freely advanced from the opening and in which a seating surface shape is formed;
A hydraulic pressure applying means for applying a hydraulic pressure to the inside of the extruded aluminum material clamped by the mold, and bulging and deforming to a shape matching the cavity surface;
After completion of the bulging deformation, the male mold advances from the opening and is pushed into the portion of the aluminum extruding material that is in contact with the end surface to cause deformation with shearing, thereby causing the seat surface A seating surface forming device characterized by comprising:   The seating surface forming apparatus according to claim 1, wherein the male type includes a pierce punch.   The seating surface forming apparatus according to claim 1 or 2, wherein the seating surface is a concave portion having a substantially flat bottom surface, and the male end surface is formed in a substantially flat shape. The aluminum extruded material has a polygonal cross section having a corner portion and a side surface extending between the corner portions, and the side surface extends along the longitudinal direction and protrudes inwardly. The indented part corresponds to a part that bulges and deforms by applying hydraulic pressure,
The opening part formed in the said cavity surface is arrange | positioned in the position which can form the said seat surface in the said side surface by the said male type | mold, The any one of Claims 1-3 characterized by the above-mentioned. Seat surface forming device.   The seat surface forming apparatus according to claim 4, wherein an amount of protrusion of the recessed portion on the side surface on which the seat surface is formed is larger than an amount of protrusion of the recessed portion on the side surface on which the seat surface is not formed.   In forming the seat surface by the male mold, the hydraulic pressure inside the aluminum extruded material is equal to or lower than the final hydraulic pressure and the hydraulic pressure at which the swelled and deformed aluminum extruded material is not deformed by a load in the seat surface formation by the male mold. The seat surface forming apparatus according to any one of claims 1 to 5, further comprising a hydraulic pressure control means for controlling the pressure.   The said molded article is a pillar member of a motor vehicle, The said seat surface is applied as a positioning reference plane for attaching a separate pillar component, The any one of Claims 1-6 characterized by the above-mentioned. Seating surface forming device.   The said molded product is an inner member of a motor vehicle, and the said seat surface is applied as a positioning reference surface for attaching a separate inner part, The one of Claims 1-6 characterized by the above-mentioned. Seating surface forming device. Inside the mold having a cavity surface corresponding to the outer shape of the molded product, an aluminum extruded material is placed and clamped,
Applying hydraulic pressure to the inside of the aluminum extruded material clamped by the mold, bulging and deforming to a shape that matches the cavity surface,
After completion of the bulging deformation, a male die having an end surface on which a seat surface shape is formed is advanced from an opening formed in the cavity surface and pushed into a portion of the aluminum extruded material that is in contact with the end surface. A method of forming a seating surface, comprising forming a seating surface by causing deformation with shearing.   The seat surface forming method according to claim 9, wherein the male type includes a pierce punch.   The seating surface forming method according to claim 9 or 10, wherein the seating surface is a recess having a substantially flat bottom surface, and the male end surface is formed in a substantially flat shape.   The seating surface according to any one of claims 9 to 11, wherein the pushing amount of the male type is not more than one half and not less than 0 of a thickness of a portion where the seating surface is formed. Forming method. The aluminum extruded material has a polygonal cross section having a corner portion and a side surface extending between the corner portions, and the side surface extends along the longitudinal direction and protrudes inwardly. The indented part corresponds to a part that bulges and deforms by applying hydraulic pressure,
The opening part formed in the said cavity surface is arrange | positioned in the position which can form the said seat surface in the said side surface by the said male type | mold, The any one of Claims 9-12 characterized by the above-mentioned. Bearing surface forming method.   The method of forming a seating surface according to claim 13, wherein an amount of protrusion in the recessed portion of the side surface where the seating surface is formed is larger than an amount of protrusion in the recessed portion of the side surface where the seating surface is not formed.   In forming the seat surface by the male mold, the hydraulic pressure inside the aluminum extruded material is equal to or lower than the final hydraulic pressure and the hydraulic pressure at which the swelled and deformed aluminum extruded material is not deformed by a load in the seat surface formation by the male mold. The seating surface forming method according to claim 9, wherein the seating surface forming method is controlled.   The said molded article is a pillar member of a motor vehicle, The said seat surface is applied as a positioning reference plane for attaching a separate pillar component, The any one of Claims 9-15 characterized by the above-mentioned. Seating surface forming method.   16. The molded article according to claim 9, wherein the molded product is an inner member of an automobile, and the seating surface is applied as a positioning reference surface for mounting a separate inner part. Seating surface forming method.

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