JP3419027B2 - Press working method - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plate-like material having a plate length longer than a plate thickness and is advanced into a press die in the plate length direction. As described above. 2. Description of the Related Art As shown in FIG. 17, a header tank 102 constituting, for example, a header 101 of a refrigerant condenser has an inverted U-shaped top plate 103 at a central portion thereof. A bent portion 104 extending in a substantially horizontal direction from both end edges, and a side plate portion 10 suspended from an outer end of the bent portion 104
Had five. If the arc-shaped portion 106 exists at the inner end of the bent portion 104 of the header tank 102, a notch 108 is formed when the header tank 102 and the header plate 107 are brazed, and such a header 101 is formed. If the is used for a long time, the header 101 may be cracked. Therefore, as shown in FIG. 18, a sharp corner 109 is formed at the inner end of the bent portion 104 of the header tank 110 so that the header tank 110 and the header plate 107 are liquid-tight. To connect to. However, in order to manufacture the header tank 110 having such a shape, the header tank 110 cannot be processed only by bending the material into an inverted U shape. For this reason, in the manufacture of the header tank 110, a processing method called transfer press processing has been adopted. In this transfer press working, for example, a plate material is cut in accordance with the plate length L of the header tank 110 for the refrigerant condenser to obtain a plate material 111 having a plate length L {FIG. a) Performs｝. Thereafter, the plate-shaped material 111 is put into a first press die (not shown), and the plate-shaped material 111 is bent into an inverted U-shape.
Temporary bending and U-bending process for forming a bent portion 113 extending in a substantially horizontal direction from both end edges of the top plate portion 112 and a side plate portion 114 hanging down from the outer end of the bent portion 113 {FIG. }It is carried out. [0005] Then, the plate-like material 111 is put into a second press die (not shown), and the bent portion 113 is pressurized with a large processing load at a time.
A corner shaping step {FIG. 19 (c)} for forming a sharp corner 115 at the inner end of 3 is performed. Then, the plate material 1
11 is placed in a third press die (not shown), and a punching step {FIG. 19 (d)} for forming a punching hole 116 in the top plate 112 at a predetermined punching position 1 is performed. The header tank 110 was manufactured. However, the conventional press working method does not employ the sequential working, so that a sharp corner 115 is formed at the inner end of the bent portion 113 by one working. It is formed. As a result, the processing load in the corner shaping process becomes very large, so that a very large press machine is required, and there is a problem that the equipment cost of the press machine becomes enormous. Further, when manufacturing a product having various types of plate length L and punching position l (for example, about 40 types in a header tank for a refrigerant condenser), the product plate length L and punching position l are required. Therefore, there is a problem that the cost of manufacturing the press die is enormous because it is necessary to replace the press die with the type of press die. If the number of times of press die exchange is increased in one day, the press die operation is reduced due to the press die exchange setup work. There was a problem. The present invention is directed to a press working method capable of sequentially processing the plate material to reduce the processing load on the plate material in the corner shaping step and to reduce the equipment cost of the press machine. In addition to the purpose of providing, even in the case of manufacturing a product having many types of plate lengths, it is possible to reduce the manufacturing cost of the press die by making it possible to respond with one type of press die, An object of the present invention is to provide a press working method capable of improving the operation rate of a mold. [0009] According to an aspect of the present invention is a press-forming method of sequentially processed by a press die plate length to forward a long plate material, the plate width direction of the plate-like material Is bent in the thickness direction to form an inverted U-shaped top plate in the center of the plate-shaped material, and to make both end edges of the top plate portion outward from both end edges of the top plate portion. by folding <br/> gel, a bending process to form a bent portion at each end edge of the top plate portion, the bent portion of the plate-like material after the bending process, the plate-like material by pressurizing so that processing load gradually <br/> people in along the forward direction increases the angular shaping to form respective sharp corners inside end located innermost among the bent portion And a technical means having a process. [0010] According to the present invention, in the bending step, by the plate length bending the plate width direction of the long sheet material in the thickness direction, the top plate of the inverted U-shaped in the center of the sheet material Portions are formed, and both end edges of the top plate portion are defined as both end edges of the top plate portion.
By bending outwardly, bent portions are respectively formed at both end edges of the top plate portion. Subsequently, the angular shaping step, the bent portion of the sheet material after the bending step, the plate
Processing load gradually increases along the progressive feed direction of sheet material
By pressurizing as, innermost among the bent portion
Sharp corners are formed at the inner ends located on the sides. That is, the bending process and the corner shaping process are sequentially performed by sequentially feeding the plate material into the press die and processing the plate material sequentially. According to the press working method as described above, even when a product having many types of plate lengths is manufactured, it is not necessary to replace the press die, and the setup work of the press die replacement becomes unnecessary. Further, in the corner shaping step, since the bent portion of the plate-shaped material is sequentially processed, the amount of processing of the bent portion of the plate-shaped material per feed amount is reduced. Processing load on FIG. 1 shows a press working method according to the present invention.
A description will be given based on an embodiment shown in FIG. FIG.
FIG. 2 is a diagram showing a refrigerant condenser incorporated in the vehicle air conditioner, and FIG. 2 is a diagram showing a main part of the refrigerant condenser.
In the refrigerant condenser 1, tubes 2 and corrugated fins 3 are alternately stacked, side plates 4 are arranged on both sides thereof, and headers 5 are connected to both ends of the plurality of tubes 2 to be integrally brazed. It is assembled by means of. The tube 2 is made of a metal such as an aluminum alloy, and is a tube that condenses and liquefies the refrigerant by exchanging heat between the refrigerant flowing inside and the outdoor air passing outside. The corrugated fin 3 is formed by forming a thin metal plate such as an aluminum alloy into a corrugated shape, and has a louver (not shown) formed on the surface thereof for improving the heat exchange efficiency between the refrigerant and the outdoor air. The side plate 4 is made of a metal such as an aluminum alloy, and includes a plurality of tubes 2 and a plurality of corrugated fins 3.
And also functions as a bracket for attaching the refrigerant condenser 1 to, for example, an engine room of a vehicle. As shown in FIG. 3, the header 5 has a reverse U-shaped section on a header plate 6 having a semi-circular section.
It is formed in a cylindrical shape by assembling a letter-shaped header tank 7. Caps 8 for closing the openings are attached to the openings at both ends of the header 5 in the plate length direction. The header plate 6 is made of a metal plate such as an aluminum alloy, and is connected to ends of a plurality of tubes 2 by brazing or the like. Side wall portions 9 are formed on both end edges of the header plate 6 in the plate width direction so as to be fitted to the ends of the header tank 7. A substantially planar bottom wall 1 is provided between the side walls 9.
0 is formed. The bottom wall 10 has a one-letter recess 1.
1 are continuously formed at a constant pitch in the plate length direction of the header plate 6 at a plurality of locations. The plurality of recesses 11 are formed with oval holes 12 into which the ends of the plurality of tubes 2 are inserted. Further, through holes 13 into which the insertion pieces 16 of the side plate 4 are inserted are formed outside the holes 12 located at both ends of the bottom wall portion 10. Next, the structure of the header tank 7 of this embodiment will be described in detail. 4 and 5 are views showing the header tank 7. FIG. The header tank 7 has, for example, a plate thickness of 1.
A top plate portion 17 made of a metal plate such as an aluminum alloy having a plate length of 6 mm and a length of 380 mm and having an inverted U-shaped cross section is formed at the center in the plate width direction. The top plate portion 17 has a substantially rectangular hole 18 for connecting a refrigerant pipe (not shown),
And a separator S for dividing the inside of the header 5 into a plurality of chambers
A one-letter shaped hole 19 is formed for inserting (see FIG. 1). The holes 18 and 19 are provided at predetermined hole positions l1 and l2 from the end of the header tank 7, respectively. The header tank 7 includes a top plate 17.
A fold portion 20 it extending in the horizontal direction from both ends of the
Is formed. The most of these bends 20
Inside the top plate portion 17 of the bent portion 20 which is located inside
As shown in FIGS. 3 and 4, an inner end provided continuously with the surface (hereinafter referred to as an inner end of the bent portion 20 ) is liquid-tightly attached to an upper end surface of the side wall 9 of the header plate 6. Sharp corners 21 that contact each other are formed. In addition, two
The sharp corners 21 of the
It is provided so as to be located on one plane. Also, two
From the outer end of the bent portion 20, it is formed as side plate portions 22 extend in a direction substantially perpendicular (shown below). These side plates 22 are fitted respectively on the outer circumferential surface of the side wall portion 9 of the header plate 6, a plurality of the caulking pawl portion 23 for crimping connecting to the side wall portion 9, as shown in FIG. 4
As such, it to extend from the lower end of the side plate portion 22
Is formed. The product of this embodiment, that is, the production of the header tank 7, is performed by using a metal plate material 24 having a plate length sufficiently longer than the plate thickness, as shown in FIGS.
Forward feeder (not shown) consisting of a plurality of guide rollers
At a constant pitch (1 feed amount: for example, 19 m) in a press die (progressive die) 25 in the plate length direction of the plate material 24.
This is done by sequential processing in step m). The press mold 25 has a backing plate 26 up and down,
27, and the first to fifth stages for manufacturing the header tank 7 having an arbitrary plate length are integrally incorporated. As shown in FIGS. 7 and 8, the first stage for performing the temporary bending step of the press die 25 includes a die 29,
Punch 30, punch plate 31, and stripper 32
The processing for forming the longitudinal groove 33 extending in the plate length direction (forward feeding direction) of the plate-shaped material 24 is performed. The punch 30 is attached to a punch plate 31 by bolts 34. The second step of performing the step of removing the outer shape of the press die 25
The stage includes a die 35 and a punch 3 as shown in FIG.
6, a punch plate 37, a stripper 38, and the like, and perform processing for forming the outer shape of the plate-like material 24 fed by the progressive feeding device. The die 35 has two discharge holes 39 for discharging chips (not shown) punched from the plate material 24 from the second stage. As shown in FIG. 10, the third stage for performing the bending step of the press die 25 includes a die 41, a punch 4
2. A punch plate 43, a stripper 44, and the like are provided. The plate material 24 fed by the progressive feeding device is bent into an inverted U-shape so that both ends of the plate material 24 face the plate thickness direction (downward in the drawing). The punch 42 is a punch plate 4
3 is attached by bolts 45. As shown in FIG. 11, the fourth stage for performing the corner shaping step of the press die 25 includes a die 46, a punch 4
71, 472, punch plate 48 and stripper 4
9 and the plate-like material 2 fed by the progressive feeding device
4 is processed to form a sharp corner 21. The length L1 of the die 46 in the forward feed direction (see FIG. 14) is formed to be approximately three times (for example, 58 mm) the feed amount (for example, 19 mm) of the plate material 24. As shown in FIGS. 12 to 14, the die 46 has two inclined portions (slope) 50 having a gradient in the forward direction of the plate material 24, and these inclined portions 50.
An arc-shaped convex portion 51 and the like formed between them are formed. As shown in FIG. 12, the two inclined portions 50 are formed so as to have a predetermined inclination angle with respect to the horizontal direction (dashed line in the drawing). Two flat portions 52 extending in the horizontal direction are formed on the fifth stage side of the two inclined portions 50, respectively. Further, as shown in FIGS. 12 and 14, the tip of the punches 471 and 472 is provided with a plate-like material 24.
Along the forward feed direction of each of the ridges 531, 532,
Stepped portions 541 and 542 formed inside the ridges 531 and 532 and arc-shaped concave portions 551 and 552 facing a part of the arc-shaped convex portion 51 are formed. The fifth stage for performing the punching / cutting step of the press die 25 includes a die, a punch, a cutting punch (none of which is shown), etc., and has an arbitrary plate length having punched holes 18 and 19. A process for obtaining the header tank 7 is performed. [Manufacturing method of the embodiment] Next, the refrigerant condenser 1
The method of manufacturing the header tank 7 will be briefly described with reference to FIGS. First, a metal plate material 24 having a plate length sufficiently longer than the plate thickness wound multiple times is pressed at a constant pitch (for example, a feed amount of 19 mm) in a plate length direction into a press die 2.
Send into 5. At this time, the plate-shaped material 24 may be centered by a plurality of guide rollers so as to pass through a predetermined position of the press die 25. (Temporary Bending Step) The plate-like material 24 fed into the first stage of the press die 25 by the progressive device
As shown in FIGS. 7 and 8, when the backing plates 26 and 27 approach each other, a longitudinal groove extending between the die 29 and the punch 30 and extending in the plate length direction of the plate material 24 is formed. 33 are formed, and flat plate portions 56 are formed on both sides of the longitudinal groove 33. (Outer shape removing step) The plate-like material 24 fed from the first stage of the press die 25 into the second stage by the sequential feeding device is backed by plates 26 and 27.
6 and 9, the flat portion 56 of the plate-shaped material 24 is cut by being pressed between the die 35 and the punch 36, as shown in FIGS.
6, a side plate 22 and a plurality of caulking claws 23 are formed. (Bending process) The plate-like material 24 fed from the second stage of the press die 25 into the third stage by the progressive feeding device is brought into contact with the backing plates 26 and 27 as shown in FIG. In the meantime, the pressure is applied between the die 41 and the punch 42 to
3 is bent in an inverted U-shape in the thickness direction.
As a result, a top plate portion 17 having an inverted U-shaped cross section is formed at the center of the plate material 24. At the same time as the top plate 17, the plate-like material 24 is bent outward from both ends of the top plate 17, and bent portions 20 are formed at both ends of the top plate 17. Then, in the second stage, the side plate portions 22 and the plurality of caulking claw portions 23 formed on both end edges of the plate material 24 are formed.
Is bent downward from the outer end of the bent portion 20 in the figure. (Square Shaping Step) As shown in FIGS. 11 and 12, the plate-like material 24 fed from the third stage of the press die 25 into the fourth stage by the progressive feeding device is used as the backing plates 26 and 27. Approaching, the bent portion 20 of the plate-shaped material 24 moves the die 46 in the plate thickness direction.
And between the punches 471 and 472. At this time, the bent portion 20 of the plate-like material 24
Is sandwiched between the inclined portion 50 and the flat portion 52 of the fourth stage die 46 and the stepped portion 54 of the punches 471 and 472. However, as shown in FIGS. 12 and 14, the inclined portion 50 of the die 46 is inclined so as to gradually approach the punches 471 and 472 in the forward direction of the plate-shaped material 24. A bending load is applied to the bent portion 20 of the material so as to gradually increase the processing load in the forward direction of the plate-shaped material 24. As shown in FIG. 14, the length L1 of the die 46 in the forward direction is about three times (for example, 58 mm) the feed amount (for example, 19 mm) of the plate-like material 24. It can be machined sequentially three times. Thereby, the plate-like material 24 per one feed amount (for example, 19 mm) is provided.
Since the processing amount of the bent portion 20 becomes small, the processing load per one feed amount (for example, 19 mm) also becomes small. Thereby, as shown in FIG. 3, a sharp corner portion 21 is formed at the inner end of the bent portion 20 of the plate-shaped material 24 so as to contact the upper end surface of the side wall portion 9 of the header plate 6 in a liquid-tight manner. You. Note that, in FIG. 3, a broken line indicates a state of forming the bent portion 20 in the third stage. Here, the reason why a sharp corner 21 can be formed at the inner end of the bent portion 20 of the plate material 24 in the fourth stage of the press die 25 of this embodiment will be described with reference to FIG. . Considering the minute area of the processed part (bent part 20) A processed in the corner shaping process in the plate-like material 24,
In the conventional corner shaping process, since the sequential processing is not adopted, the plate material 24 tends to flow in the plate width direction a and the plate length direction b when the pressing force P by the punches 471 and 472 is greatly applied at once. . However, in the corner shaping step of this embodiment, 1
Since the processing amount per feed amount (for example, 19 mm) is small,
The amount to be extended in the plate length direction b is also small. With only the force to extend in the plate length direction b, the non-processed portion (top plate portion 17) B that is not processed in the corner shaping process is much larger than the processed portion A. Accordingly, plastic deformation cannot be performed in the plate length direction b of the plate-shaped material 24. That is,
Processing can be performed in a plane strain state, and the plate material 24
The material can flow in the plate width direction a, and a sharp corner 21 can be formed. (Hole punching / cutting step) The plate-like material 24 fed from the fourth stage of the press die 25 into the fifth stage by the progressive feeding device is fed by two feeds (for example, 19 mm ×
Each time the backing plates 26 and 27 approach each other, punch holes 18 and 19 are formed at predetermined punch positions (11 and 12) from the ends of the top plate 17 of the sheet material 24 by the punch. The plate-shaped material 24 is formed and further divided into arbitrary plate lengths by the dividing punch. This allows
The header tank 7 having an arbitrary plate length L (for example, 380 mm) in which the holes 18 and 19 are formed in the top plate portion 17 is manufactured. [Effects of Embodiment] As described above, in this embodiment, in the fourth stage for performing the corner shaping step of the press die 25, the processing amount per one feed amount by the sequential processing can be reduced. Therefore, the processing load on the processed portion (bent portion 20) of the plate-like material can be reduced. This eliminates the need to make the press die 25 larger,
The equipment cost of the press die 25 can be reduced. In this embodiment, one header tank 7 having many types of plate lengths and types with different punching positions is used.
Since it can be manufactured by using different types of press dies 25, the manufacturing cost of the press dies 25 can be reduced. Thereby, the manufacturing cost of the header tank 7 can be reduced. And since many kinds of header tanks 7 can be manufactured by one type of press die 25, setup of press die 25 becomes unnecessary. As a result, the downtime of the press mold 25 for the setup work of replacing the press mold 25 becomes 0 hour.
Operating rate can be improved. [Modification] In the present embodiment, the present invention is applied to the method of manufacturing the header tank 7 of the refrigerant condenser 1, but the present invention is applied to a refrigerant evaporator, a refrigerant subcooler, a heater core, a radiator, an oil cooler, and the like. May be employed in other methods of manufacturing a header tank for a heat exchanger. Further, the present invention may be applied to a method of manufacturing a header tank having no holes. Further, the shape, number, or formation position of the holes 18 and 19 may be freely changed. In this embodiment, the inclined portion 50 inclined with respect to the horizontal direction is formed in the die 46 of the fourth stage for performing the step of shaping the press mold 25. However, the step of shaping the press mold 25 is performed. As shown in FIG. 16, a plurality of steps 5 are formed on the die 46 of the fourth stage so as to gradually approach the punches 471 and 472 in the forward direction of the plate-shaped material 24.
7 may be formed. Further, the processed portion (corresponding to the inclined portion 50 and the flat portion 52) of the die 46 is flattened and the punch 471,
An inclined portion or a plurality of steps may be provided in the processed portion 472 (corresponding to the stepped portion 54). In addition, die 4
6 or the length of the inclined portions of the punches 471 and 472 in the forward feed direction can be set to an arbitrary length for one feed amount. As the length of the inclined portion in the forward direction becomes longer with respect to one feed amount, the processing load on the plate-shaped material 24 in the first corner shaping process is reduced, and the length of the inclined portion in the forward direction is one feed. The shorter the volume, the first plate-like material 24 in the corner shaping process
The processing load on the is increased. According to the present invention, the processing load on the bent portion of the plate-like material in the corner shaping step can be reduced, so that it is not necessary to increase the size of the press die, and the equipment of the press machine is eliminated. Costs can be reduced. In addition, the present invention can manufacture a product having various types of plate lengths by using one type of press die even when manufacturing products having various types of plate lengths. Costs can be reduced. Further, since it is not necessary to set up the press dies, there is no downtime of the press dies for the set up work of the press dies, and the operating rate of the press dies can be improved.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front view showing a refrigerant condenser according to one embodiment of the present invention. FIG. 2 is a perspective view showing a main part of the refrigerant condenser of FIG. FIG. 3 is a sectional view showing a header of the refrigerant condenser of FIG. 1; FIG. 4 is a perspective view showing a header tank of the embodiment. FIG. 5 is a sectional view showing a header tank according to the embodiment. FIG. 6 is a process diagram showing press working of the header tank of the example. FIG. 7 is a perspective view showing a first stage of the press die. FIG. 8 is a cross-sectional view showing a first stage of the press die. FIG. 9 is a sectional view showing a second stage of the press die. FIG. 10 is a sectional view showing a third stage of the press die. FIG. 11 is a sectional view showing a fourth stage of the press die. FIG. 12 is a perspective view showing a main part of a fourth stage of the press die. FIG. 13 is a cross-sectional view showing a fourth stage die of the press die. FIG. 14 is a side view showing a die and a punch of a fourth stage of the press die. FIG. 15 is an explanatory diagram showing a processing amount of a plate-like material in a corner shaping process. FIG. 16 is a cross-sectional view showing a modification of the die and the punch of the fourth stage of the press die. FIG. 17 is a sectional view showing an example of a header of a conventional refrigerant condenser. FIG. 18 is a cross-sectional view showing another example of the header of the conventional refrigerant condenser. FIGS. 19A to 19D are process diagrams showing conventional transfer press processing of a header tank. [Description of Signs] 1 Refrigerant condenser 7 Header tank 17 Top plate 18 Drilled hole 19 Drilled hole 20 Bent portion 21 Sharp corner portion 22 Side plate portion 24 Plate material 25 Press mold 46 Die (performs corner shaping process Die) 50 Inclined part

Continuation of the front page (56) References JP-A-5-123741 (JP, A) JP-A-4-172128 (JP, A) JP-A-62-220221 (JP, A) JP-A-60-115635 (JP, A) , U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B21D 5/01 B21D 53/04 B21D 22/02 B21D 22/20 B30B 13/00

Claims (1)

(57) A press-forming method [Claims 1. A plate length to forward a long sheet material sequentially processed by a press die, (a) the plate width of the plate-like material By bending the direction in the plate thickness direction, an inverted U-shaped top plate portion is formed at the center of the plate material, and both end edges of the top plate portion are outside the both end edges of the top plate portion.
By bending so as to be directed to the side, the bending process to form a bent portion at each end edge of the top plate portion, the bent portion of the (b) the plate-like material after the bending step, before
Processing load gradually increases along the forward direction of the plate-like material
By pressing so that
Press-forming method characterized by sharp corners in the inner end was a square shaping step of forming respectively located innermost.