JP5206805B2 - Manufacturing method and apparatus for closed-section structural parts - Google Patents

Description

  The present invention relates to a technique for manufacturing a press part having a closed cross-sectional structure in which a flat processed material (blank) has a bent shape with a bottom surface curved along a longitudinal direction.

Conventionally, in the field of automobiles, home appliances, architecture, etc., in order to manufacture a pressed part of a closed cross-section part, two parts each having a substantially U-shaped cross section having a pair of flanges on both end faces in the cross section direction of the part. After forming separately, each part was joined by continuous welding, such as spot welding and a laser, at the flange part, and it was set as the closed cross-section part as a product.
In order to achieve low-cost manufacturing, weight reduction, impact characteristics, improved rigidity performance, etc., compared with the manufacture of press parts with such a closed cross-section structure, a closed section having a polygonal cross section is formed from a single blank by press molding. A method of forming a cross-sectional component has been proposed.

  Here, in Patent Document 1, a shape in which a center portion of a flat plate material is supported by a pad, has a curvature when the end portion of the material is viewed in plan, and has a flange surface below the side wall when viewed from the side. A method of pressing is disclosed. And in patent document 1, the convex bead which protruded in the convex shape was provided to the side wall surface of a press-molding body, and a concave bead was given to the flange surface under it, and the line of the material edge part before and behind bending It is described that the length difference is almost completely eliminated and wrinkling of the molded part is suppressed.

  Patent Document 2 includes a curved portion that is curved in the longitudinal direction from a flat material plate, an extended portion that extends in the longitudinal direction from the curved portion, and a flange that extends the sides of the curved portion and the expanded portion. A press molding apparatus for obtaining a molded product is disclosed. The press molding apparatus has a pressing portion for pressing the edge of the material plate constituting the flange of the bending portion, and the expansion portion forming die and the pressing portion of the expansion portion forming die are connected to the flange surface of the bending portion. Drive means for moving in a direction to cancel the residual stress generated in the.

JP 2010-115674 A JP 2008-200688 A

  When the technology described in Patent Document 1 is formed into a press part having a curved surface, the wire length difference before and after forming is compared when the wire length (D1) corresponding to the blank flange is compared with the wire length (D2) after forming. When the value of the expression D1-D2 representing the occurrence is positive, that is, when the length before forming is longer than the line length after forming, wrinkles and buckling are likely to occur. In order to eliminate this difference in line length, Patent Document 1 proposes a technique for providing a convex protruding bead on the side wall and a concave bead recessed on the flange surface immediately below. ing.

  However, the technique described in Patent Document 1 can only provide a concavo-convex shape to the side wall portion of the component and the flange portion continuous thereto due to the structure of the mold. For this reason, the technique of Patent Document 1 can be applied only to a part having a curvature when viewed in plan (that is, a press part having a linear shape when viewed from the side). Moreover, there is a problem that it cannot be applied to a closed cross-section component formed from one blank material.

  In addition, the technique described in Patent Document 2 is designed to reduce the residual stress generated on the flange surface by forming a part having curvature when viewed in plan while applying a compressive load in the longitudinal direction of the part during press molding. It is a construction method that reduces and improves dimensional accuracy. The technique described in Patent Document 2 also has a problem that it can be applied only to a part having a curvature when viewed in plan (that is, a press part having a linear shape when viewed from the side).

As described above, in the prior art, it is impossible to easily press-form a bent cross-sectional component having a curved surface at least on the bottom surface of a press-processed product.
The present invention has been made by paying attention to the above points, and is capable of reducing a manufacturing cost by reducing the number of molding steps and the number of molds, and a press part having a curved closed-section structure having a curved surface on the bottom surface. The object is to enable manufacture with high dimensional accuracy.

In order to solve the above-mentioned problems, the invention described in claim 1 of the present invention manufactures a closed cross-section structural component by forming a flat plate-shaped workpiece into a closed cross-section structure whose bottom surface is curved along the longitudinal direction. A way to
A first molding step of forming a plurality of first out-of-plane deformed portions each having a concave shape or a convex shape along the longitudinal direction and forming a bent portion with respect to at least a bottom surface portion position of the processed material,
With the position of the bottom surface of the workpiece sandwiched between the pad and punch, the punch is pushed between the dies to crush the first out-of-plane deformed portion and bend the bent portion with the pad and punch. And a second molding step for molding.

Next, the invention described in claim 2 is the same as that described in claim 1, except that the plate-like processed material includes the bottom surface portion, left and right side wall portions located on the left and right sides of the bottom surface portion, and A method of manufacturing a closed cross-section structure part by molding into a closed cross-section structure provided with a pair of joining end portions continuous to the left and right side wall portions,
In the first forming step, a plurality of second out-of-plane deformed portions each having a concave shape or a convex shape with respect to the side wall portion position are formed along the longitudinal direction together with the first out-of-plane deformed portion. And forming a bent portion at the boundary between the bottom surface and the side wall,
In the second molding step, the second out-of-plane deformed portion is crushed by the punch side surface and the die side surface.

Next, the invention described in claim 3 is directed to the configuration described in claim 1 or claim 2 after the first forming step and before bending the bent portion in the second forming step. A bulkhead is installed on the bottom surface of the processed material.
Next, the invention described in claim 4 is an apparatus for manufacturing a closed cross-section structure component by forming a flat plate-shaped workpiece into a closed cross-section structure in which the bottom surface portion is curved along the longitudinal direction.
A plurality of first out-of-plane deformed portions each having a concave shape or a convex shape are formed along the longitudinal direction with respect to at least the bottom surface position of the workpiece, and an upper die and a lower die that form a bent portion are formed. A press mold provided,
A pad and a punch for crushing the first out-of-plane deformed portion while sandwiching the bottom portion of the workpiece, and pressing the punch in a state where the bottom portion of the workpiece is sandwiched between the pad and the punch And a die for bending the bent portion.

Next, the invention according to claim 5 is the same as that according to claim 4, except that the plate-like processed material includes the bottom surface portion, left and right side wall portions located on the left and right sides of the bottom surface portion, and An apparatus for manufacturing a closed cross-section structure part by molding into a closed cross-section structure provided with a pair of joining end portions continuous to the left and right side wall portions,
The upper mold and the lower mold have a plurality of second out-of-plane deformed portions each having a concave shape or a convex shape along the longitudinal direction along with the first out-of-plane deformed portion. And is formed so that a bent portion can be formed at the boundary between the bottom surface and the side wall,
Further, the second out-of-plane deformed portion is crushed by the punch side surface and the die side surface.
Next, the invention described in claim 6 is the configuration described in claim 4 or claim 5 before the bending portion is bent by sandwiching the bottom surface portion of the workpiece with a pad and a punch. A bulkhead is installed on the bottom surface of the processed material.

According to the invention according to claim 1 or claim 4, a plurality of first out-of-plane deformed portions are formed in advance along the longitudinal direction with respect to the bottom surface portion to increase the longitudinal line length. A punch having a curved surface is press-formed into a bent shape with a curved bottom surface. Thereby, the shape of the bottom surface portion can be processed into the desired curved surface shape while earning the elongation in the longitudinal direction due to the bending at the bottom surface portion by crushing the first out-of-plane deformation portion.
As a result, it is possible to manufacture a curved closed cross-sectional structure part having a curved surface on the bottom surface with high dimensional accuracy while reducing the manufacturing cost by reducing the number of molding steps and the number of molds.

Further, in the inventions according to claim 2 and claim 5, the second out-of-plane deformed portion is further provided in advance on the side wall portion, and the elongation by the side wall portion is earned by crushing the second out-of-plane deformed portion. Thus, it is possible to process into a desired curved surface shape in a press part having a more closed cross-sectional structure.
Further, as in the inventions according to claims 3 and 6, by installing the bulkhead before forming into a closed section, the bulkhead can be easily installed in a press part having a closed section structure.

It is a figure which shows the press part of the closed cross-section structure after shaping | molding by the press molding which concerns on 1st Embodiment based on this invention, Comprising: (a) is a side view, (b) is a perspective view. It is a figure explaining the metal mold | die and press molding which are used at the 1st shaping | molding process based on 1st Embodiment based on this invention. It is a figure explaining the metal mold | die used in the 2nd shaping | molding process based on 1st Embodiment based on this invention, and bending press molding. It is a figure which shows the side view of the metal mold | die used at the 2nd shaping | molding process based on 1st Embodiment based on this invention. It is a figure which shows shaping | molding of the processed material which concerns on 1st Embodiment based on this invention. It is a figure which shows the modification which concerns on 1st Embodiment based on this invention. It is a figure explaining press molding concerning a 2nd embodiment based on the present invention. It is a perspective view which shows the structural example of a bulkhead. It is a schematic diagram which shows the bending of an insertion piece. It is a figure which shows the modification which concerns on 2nd Embodiment based on this invention. It is a figure explaining shaping | molding of a comparative example. It is a figure explaining shaping | molding of a comparative example.

Next, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
First, the first embodiment will be described.
As the flat plate-like processed material B (also referred to as a blank), for example, a metal plate or a metal plate obtained by subjecting the metal single plate to a blank shape corresponding to a target molded product shape and performing a shearing process or a cutting process is used. be able to. In addition, single metal sheets include hot-rolled steel sheets, cold-rolled steel sheets, or steel sheets obtained by subjecting these steel sheets to surface treatment (electrogalvanizing, hot-dip galvanizing, aluminum-based plating, etc.), SUS, aluminum, magnesium, etc. A single plate made of various metals may be used. In the case of a hot dip galvanized steel sheet, an alloying treatment may be performed, and the plated steel sheet may be further subjected to a surface treatment (such as an organic film treatment) after plating. In addition, when using a steel plate as a single metal plate, it is possible to use a hard steel plate (high-strength steel plate, ultra-high-strength steel plate) as well as a soft steel plate. It is suitable for forming steel plates and ultra high strength steel plates.

  Further, the press molding according to the present invention is performed by using the flat plate-like workpiece B, and the molded product has a cross-sectional shape (closed cross-sectional shape) of, for example, a polygon such as a tetragon, a hexagon, and an octagon. Have a closed cross-sectional shape such as a circular shape with a rounded cross section, an elliptical shape (including a substantially circular shape approximated to these, or a substantially elliptical shape). It is what you are doing. However, the pressed part after the molding has a closed cross-sectional structure having a curved shape curved downward along the longitudinal direction.

In addition, the closed cross-sectional structure in the present invention has a joint end B3 (also referred to as a weld end in the present specification) for finally joining the end. The joining end B3 is not limited to welding such as laser welding or arc welding, but can be appropriately joined by rivet joining, bolt joining, joining by an adhesive, or the like. In the following example, it illustrates in the case of joining by welding.
In the following description, as a pressed part having a closed cross-sectional structure after the flat plate-shaped workpiece B is formed in the present embodiment, as illustrated in FIG. 1, the cross-sectional shape is a substantially quadrangular shape. However, as shown in FIG. 1A, the shape is curved along the longitudinal direction.

(Device configuration)
As described above, the manufacturing apparatus is configured so that the plate-like processed material B is divided into the bottom surface portion B1 formed on the center side in the width direction of the processed material B, and the left and right side walls located on both sides in the width direction of the bottom surface portion B1. And forming a closed cross-sectional structure having a portion B2 and a pair of welded end portions B3 (flange portions) continuous to the left and right side wall portions B2, respectively, and the side wall portion B2 below the longitudinal direction. It is press-molded into a convex curved shape (see FIG. 1).

The manufacturing apparatus includes a pressing mold for the first molding process and a bending mold for the second molding process.
As shown in FIG. 2, which is a schematic diagram, the pressing mold includes a lower mold 1 and an upper mold 2 that are press-molded with a flat plate-shaped workpiece B interposed therebetween.
The upper surface of the lower mold 1 constitutes a press molding surface opened upward. That is, the press-molding surface has a substantially U-shaped concave portion with the concave portion facing upward, the substantially central portion in the width direction is the bottom surface molded portion 1a, and the left and right portions of the bottom surface molded portion 1a are the side wall molded portions. 1b. On the outside of the side wall forming portion 1b, there is a rising surface 1c for forming a welded end portion made of a flange.

  As shown in FIG. 2C, the bottom surface forming portion 1a is formed with a plurality of wavy uneven shapes along the longitudinal direction in a side view. Each concave shape and convex shape are each arcuate when viewed from the side, and the adjacent concave shape and convex shape are connected by a smooth curved surface so that there is no sharp curvature. This concave shape or convex shape becomes a portion of the press-molding surface that forms the first out-of-plane deformed portion 10.

  Each concave shape or convex shape extends in the width direction, and is also formed continuously at the side wall forming portion 1b position. Each concave shape or convex shape formed in the side wall molding portion 1b becomes a portion of the press molding surface that forms the second out-of-plane deformation portion 11. Each concave shape or convex shape formed in the side wall molded portion 1b is set so that the width in the longitudinal direction becomes smaller as it goes in the width direction.

Further, a steep portion is formed at the boundary between the bottom surface molded portion 1a and the side wall molded portion 1b, and the bent portion B4 is formed at the boundary portion.
Further, the side wall molded portion 1b is formed to be inclined with respect to the bottom surface molded portion 1a.
Moreover, the upper mold | type 2 becomes a shape inserted in the press molding surface of the said lower mold | type 1, and the lower surface and the left-right end surface of the width direction are press molding surfaces. And the press molding surface which consists of the lower surface of the upper mold | type 2 has a shape which followed the upper surface (press molding surface) of the said lower mold | type 1 which opposes. That is, a concave bottom surface molding portion is formed at the center in the width direction, and side wall molding portions are formed on the left and right sides thereof.

Then, with the workpiece B interposed between the lower die 1 and the upper die 2, the upper die 2 is inserted toward the lower die 1 so that the workpiece B is press-formed.
Further, the bending mold includes a punch 3, a pad 4, and a pair of dies 5, as shown in FIG.
The cross-sectional shape of the pressed portion of the punch 3, that is, the cross-sectional shape of the lower end portion, is the same shape as the bottom surface portion B1 after the lower end surface 3a is formed into a closed cross-sectional structure. That is, as shown in FIG. 4, the lower end surface 3a has a gently curved shape that protrudes downward along the longitudinal direction. Moreover, the side shape of the pressing portion of the punch 3 is a flat shape.

The pad 4 is disposed so as to face the punch 3 in the vertical direction, and the upper surface 4 a has a shape that follows the lower end surface of the punch 3.
The pair of dies 5 oppose each other with an interval corresponding to the width of the bottom surface portion B1. The pair of dies 5 is formed by bending the side wall B2 with the bent part B4 as a fulcrum in the direction in which the left and right side wall parts B2 approach by pressing the punch 3. The shape of the pair of dies 5 in the longitudinal direction is a shape that follows the shape of the molded part.

(Production method)
Next, the manufacturing method of the closed cross-section structural component using the said manufacturing apparatus is demonstrated.
In the present embodiment, the workpiece B made of a flat metal plate is press-molded into a press part having the above-mentioned closed cross-sectional structure by two-step press molding. Then, a welding assembly process is performed.
Here, the process of the present embodiment will be described on the assumption that the front pillar R / F of the automobile is manufactured. The component manufacturing process includes the following two processes: (1) forming process and (2) welding assembly process.

(1) Molding process The molding process is divided into a first molding process and a second molding process.
(1-1) 1st shaping | molding process The uneven | corrugated shape used as the 1st and 2nd out-of-plane deformation | transformation parts 10 and 11 is formed in the position used as the bottom face part B1 and side wall part B2 of the plate-shaped workpiece B (blank). At the same time, it is a step of forming the bent portion B4.
That is, as shown in FIG. 2, the upper die 2 is inserted toward the lower die 1 in a state where the flat work material B is interposed between the lower die 1 and the upper die 2 (FIG. 2A). Thus, press molding is performed (FIG. 2B).
At this time, as shown in FIG. 5A, a bent portion B4 is formed at the boundary between the bottom surface portion B1 and the side wall portion B2, and the left and right side wall portions B2 are lifted obliquely upward with respect to the bottom surface portion B1. Molded into a shape.

  In addition, the concave and convex shapes of the bottom surface molding portion 1a and the side wall molding portion 1b are transferred to the workpiece B, and the first out-of-plane deformation portion 10 having a concave shape or a convex shape with respect to the position of the bottom surface portion B1 is the longitudinal direction. A plurality are formed along the direction (FIG. 5A). At the same time, a plurality of second out-of-plane deformed portions 11 each having a concave shape or a convex shape are formed along the longitudinal direction with respect to the positions of the left and right side wall portions B2 located on the left and right sides.

Here, it is preferable that the first out-of-plane deformed portions 10 and the second out-of-plane deformed portions 11 located on both sides thereof are continuous along the width direction of the workpiece B. Moreover, each 1st out-of-plane deformation | transformation part 10 of this embodiment is extended in the width direction, respectively. That is, the boundary between the adjacent first out-of-plane deforming portions 10 extends in the width direction.
Here, the larger the number of first out-of-plane deformed portions 10 formed along the longitudinal direction, the more it can be crushed so as to extend uniformly in the longitudinal direction. Therefore, for example, the number of the first out-of-plane deforming portions 10 is preferably 6 or more, depending on the degree of bending downward.

In addition, the plurality of second out-of-plane deforming portions 11 arranged in the longitudinal direction has the second out-of-plane deforming portion so that the line length along the longitudinal direction at the side wall portion B2 decreases as the distance from the bottom surface portion B1 increases. 11 shapes and numbers are set in advance.
That is, drawing / extrusion molding is performed so that the shape after molding becomes the cross-sectional length of the final part shape. In addition, the first and second out-of-plane deformed portions 10 and 11 are formed in order to reduce or eliminate the vertical line length difference when forming a curved surface in the vertical direction when viewed from the side.

(1-2) Second Forming Step Subsequently, the wavy uneven surface (first out-of-plane deformed portion 10) of the panel bottom surface portion B1 formed in the first forming step is sandwiched between the pad 4 and the punch 3, and the pad 4 The punch 3 is pushed between the pair of dies 5 while applying a load between the punches 3. The load at this time may be constant or variable.
At this time, as shown in FIG. 3B, by applying a load between the pad 4 and the punch 3 as shown in FIG. 3A to FIG. While being crushed, the bottom surface portion B1 is formed into a shape that follows the forming surface of the punch 3, that is, a shape that curves along the longitudinal direction that protrudes downward.
Further, as shown in FIG. 3 (b) → (c), by pushing the punch 3 between the dies 5, the second out-of-plane deformed portion 11 of the side wall B2 is crushed, and the side wall B2 is It stands up as a vertical wall and has a closed cross section as shown in FIG.

(2) Welding assembling process The abutting portion on the upper surface in a side view of the press-formed part having a closed cross section is joined by continuous welding such as laser welding or arc welding.
(Action and others)
In order to give a curved surface shape to the punch bottom, that is, to form a pressed part after forming into a bent shape in a side view, as a first forming step, as shown in FIG. The 1st and 2nd out-of-plane deformation | transformation parts 10 and 11 which consist of etc. are provided by press molding.

  Next, in the second molding step, the molded product molded in the first molding step is molded by the punch 3 and the die 5 having the curved surface having the final shape shown in FIG. In the second molding step, the wavy uneven surface (first out-of-plane deformed portion 10) of the panel bottom surface portion B1 molded in the first molding step is sandwiched between the pad 4 and the punch 3, and between the pad 4 and the punch 3 Push into die 5 while applying load. At this time, while the second out-of-plane deformed portion 11 formed of the concavo-convex shape portion of the panel side surface portion is crushed between the side surface of the die 5 and the side surface of the punch 3, the side wall portion B2 rises as a vertical wall to form a closed cross section. (FIGS. 5B and 5C).

When the punch 3 reaches the bottom dead center, the upper side in the side view of the part is abutted with the other end face in a slit (not shown) provided in the punch 3 to form a closed cross section (FIG. 3C).
When the closed cross-section progresses, the shape of the upper surface in a side view changes so as to wind around the punch 3, but a slit (not shown) is provided in the support part of the punch 3 so that the workpiece does not interfere with the support of the punch 3. It is like that. Further, the molded part is extracted from the punch 3 by removing the lock (not shown) of the portal structure on the longitudinal end face of the punch 3 and extracting the punch 3 in the longitudinal direction.

Here, as illustrated in FIG. 6, a pair of bonding surfaces B <b> 5 may be formed in advance on the workpiece B. By adopting the press molding of this embodiment, the pair of joining surfaces B5 can be arranged to face each other with high accuracy in the closed cross-sectional structure after press molding.
As described above, in the molding method according to the present invention, it is possible to accurately manufacture a bent press part from a single blank. As a result, it is possible to reduce the number of molds, greatly reduce the cost by simplifying the manufacturing process by eliminating the assembly process, and reduce the weight by eliminating the flange.

  That is, in the first molding step, a plurality of first out-of-plane deformed portions 10 are formed in advance along the longitudinal direction with respect to the bottom surface portion B1 to increase the longitudinal line length, and then the curved shape is formed on the punch bottom. The punch 3 is press-molded into a bent shape with a curved bottom surface B1. At this time, the shape of the bottom surface portion B1 can be processed into the desired curved surface shape while earning the elongation in the longitudinal direction due to the bending at the bottom surface portion B1 by the first out-of-plane deformation portion 10 being crushed. As a result, it becomes possible to form a press part with a curved closed cross-sectional structure having a curved surface on the bottom surface B1 with high dimensional accuracy, while reducing the manufacturing cost by reducing the number of molding steps and the number of molds.

Further, the second out-of-plane deformed portion 11 is also provided in the side wall B2 in advance, and the expansion by the side wall B2 is also earned by crushing the second out-of-plane deformed portion 11, so that a press with a more closed cross-section structure is obtained. It becomes possible to process the desired bent shape of the part.
Here, the shape of the first out-of-plane deformed portion 10 and the shape of the boundary portion of the first out-of-plane deformed portion 10 are formed so that there is no portion where the curvature is steep along the longitudinal direction and the width direction. It is preferable to keep it. The same applies to the second out-of-plane deformed portion 11.

  In the above embodiment, the first out-of-plane deformed portion 10 has been described as being formed into a shape that undulates along the longitudinal direction, that is, a shape in which a concave shape and a convex shape are continuously repeated. The 1st out-of-plane deformation | transformation part 10 is not limited to this. For example, the first out-of-plane deforming portion 10 may be formed only with a concave shape or only with a convex shape. However, as described above, the boundary portion of the first out-of-plane deformable portion 10 with respect to the bottom surface portion B1 is preferably formed into a curved shape so that there is no portion where the curvature is steep along the longitudinal direction and the width direction. .

(Second Embodiment)
Next, a second embodiment will be described with reference to the drawings. In addition, the same code | symbol is attached | subjected and demonstrated about the structure similar to the said 1st Embodiment.
The basic configuration of the present embodiment is the same as that of the first embodiment as shown in FIG. However, the point that the bulkhead 16 is installed after the molding by the first molding step is different.
That is, a bulkhead installation process was provided between the first molding process and the second molding process.

Next, the process of this embodiment is demonstrated.
(First molding process)
The first molding step is the same as in the first embodiment. However, as shown in FIG. 7A, a slit-shaped bulkhead installation hole 15 is opened at a position on the outer side in the longitudinal direction from the position where the first out-of-plane deformed portion 10 is formed.
And before implementing a 2nd shaping | molding process, the bulkhead installation process demonstrated below is implemented. In addition, you may make it implement the process of bulkhead installation in a 2nd shaping | molding process. In this case, the bulkhead installation process may be performed before the bending of the bent portion B4 in the second forming step.

(Bulkhead installation process)
Here, separately from the processing for the processing material B, a bulkhead 16 as shown in FIG. 8 is prepared by processing another blank material. As shown in FIG. 8, the bulkhead 16 is composed of a bulkhead body and an insertion piece 16d. The bulkhead main body has a rising portion 16a that is erected upward with its lower end abutting on the bottom surface portion B1, and left and right protruding continuously in a lateral direction intersecting the surface of the rising portion 16a on the side surface of the rising portion 16a. It consists of side piece parts 16b and 16c. The left and right side piece portions 16b and 16c can contact the side wall portion B2. Thus, the bulkhead body is substantially U-shaped when viewed from above. A bottom plate extending rearward from the lower end of the rising portion 16a is provided. Insert pieces 16d bent downward at both ends in the width direction of the bottom plate protrude downward. The bulkhead 16 of the present embodiment is configured as described above and can be processed from a single metal plate.

  Then, the processed material B molded in the first forming step is attached to the mold set for installing the bulkhead, and the insertion piece 16d is inserted into the bulkhead installing hole 15 of the processed material B from the upper side to make the bulk. The head 16 is attached to the bottom surface portion B1 (FIG. 7C). At this time, the bulkhead installation hole 15 is positioned on the outer side in the longitudinal direction from the position sandwiched between the bulkhead installation pad and the punch. In addition, in the metal mold | die structure shown in FIG. 7, the case where the installation process of the bulkhead 16 is implemented at a 2nd shaping | molding process is illustrated.

By inserting the insertion piece 16d into the bulkhead installation hole 15, the mounting position of the bulkhead 16 is positioned, and the bulkhead main body is in a state of standing independently with respect to the bottom surface portion B1.
From this state, the bulkhead installation punch is lowered, and the insertion piece 16d protruding downward from the bottom surface of the bottom surface portion B1 is bent 90 degrees toward the bottom surface portion B1 to perform caulking. Thereby, the bulkhead 16 is installed. Then, it moves to the die set of the 2nd molding process which is the next process with a robot etc.

  Here, as a part of the die surface of the die for installing the bulkhead, there is provided an inclined surface 17 that comes into contact with the lower end of the insertion piece 16d descending from the upper side as shown in FIG. And then. When the lower end of the insertion piece 16d comes into contact with the inclined surface 17, the insertion piece 16d is bent inward by the inclined surface 17, so that the insertion piece 16d is bent 90 degrees toward the bottom surface portion B1 as described above.

(Second molding process)
The second molding step is the same as that in the first embodiment.
That is, the wavy uneven surface (first out-of-plane deformed portion 10) of the bottom surface portion B1 formed in the first forming step is sandwiched between the pad 4 and the punch 3, and a die is applied while applying a load between the pad 4 and the punch 3. Push into 5. And while crushing the 1st out-of-plane deformation | transformation part 10 formed in bottom face part B1 between pad 4-punch 3, the uneven | corrugated shaped part (2nd surface of a panel side surface part between die | dye 5 side surface and punch 3 side surface is crushed. While the outer deformable portion 11) is crushed, the side wall B2 is raised to make a closed cross section. At this time, the side piece portions 16b and 16c of the bulk head 16 abut on the side wall portion B2, so that the side piece portions 16b and 16c also serve as part of the side surface of the punch 3.
Note that the punch 3 has a shape in which the position of the bulkhead 16 is hollowed out, thereby preventing a load from being applied to the bulkhead body.
Here, as described above, the bending of the insertion piece 16d may be performed simultaneously with the processing in the second molding step.

(Welding assembly process)
Similar to the first embodiment, the abutting portions on the upper surface in a side view of the molded part having a closed cross-section are joined by continuous welding such as laser welding, arc welding, spot welding or the like.
In the present embodiment, the bent insert piece 16d of the installed bulkhead 16 may be joined to a press-molded product, which is a molded part having a closed cross section, by welding or an adhesive, or in a caulked state. You can leave it.
Here, as shown in FIG. 10, a pair of bonding surfaces B <b> 5 may be formed in advance on the workpiece B. By adopting the press molding of this embodiment, the pair of joining surfaces B5 can be arranged to face each other with high accuracy in the closed cross-sectional structure after press molding.

(Action and others)
In addition to the operational effects described in the first embodiment, the following operational effects occur in the present embodiment.
That is, as in the first embodiment, it is possible to manufacture a press part having a closed cross-sectional structure having a bent shape from one blank material. As a result, it is possible to significantly reduce costs by reducing the number of molds and simplifying the manufacturing process by eliminating the assembly process, and to reduce the weight by eliminating the flange.
In addition, as described above, the bulkhead 16 is installed before bending the bent portion in the second molding step. Accordingly, the bulkhead 16 can be attached to the press part main body without forming an opening for attaching the bulkhead 16 later. As a result, the performance of the press part main body is not impaired, the number of manufacturing steps can be reduced, and the cost can be reduced.

Next, examples based on the first embodiment will be described.
"Applicable materials (steel grade, composition, dimensions, etc.)"
Target shape after molding: A square closed cross-section part (front pillar upper R / F model) has a cross section of 40 mmH × 30 mmW L = 300 mm. However, as described in the embodiment, the press part has a closed cross-sectional structure curved downward.
First, common conditions will be described.
"Use steel plate"
The tensile strength is 980 MPa (alloyed hot dip galvanized (both sides)), and the plate thickness is 1.2 mm and the plating adhesion (one side) is 45 g / m ² .
"Welding method"
Welding in the welding assembly process was YAG laser welding.
Welding conditions are welding speed: 1500mm / min
YAG laser output: 3.5kW
Focus diameter: 2mm
It was.
With the above as common conditions, manufacturing of closed cross-section structural parts was carried out for the following three examples.

(First embodiment)
In the first embodiment, the press molding shown in FIGS. 2 to 5 is adopted.
In the first molding step, wavy uneven shapes (first and second out-of-plane deformed portions 10 and 11) by stretch molding were applied to the bottom surface B1 position and the side wall B2 position by press molding. At this time, the flanges (joint end part B3) of the vertical direction were provided in the both ends of the steel plate used as a side view upper surface by the 2nd shaping | molding process.

  In the second molding step, the undulating uneven surface (first out-of-plane deformed portion 10) of the bottom surface portion B1 molded in the first molding step with the punch 3 and the die 5 having a curved surface having the final shape is connected to the pad 4. The punch 3 was applied with a load of 50 tons, and the undulating uneven surface was crushed and a camper (curved along the longitudinal direction) was attached. Further, while applying a load of 50 tons between the pad 4 and the punch 3, it is pushed into the die 5, and the uneven portion of the panel side surface portion (second out-of-plane deformed portion 11) at the contact surface between the side surface of the die 5 and the side surface of the punch 3. The side wall B2 was erected while crushing. When the side wall portion B2 was erected, the portion that became the upper surface in a side view passed through the slit provided in the punch 3 to complete the closed cross section. For extraction from the punch 3, a removal mechanism was provided on the side surface of the punch 3 and extracted in the longitudinal direction of the component. Then, it joined by laser welding.

(Second embodiment)
In the second embodiment, press molding shown in FIG. 6 is adopted.
In the first forming step, wavy uneven shapes (first and second out-of-plane deformed portions 10 and 11) obtained by overhang forming are applied to the bottom surface portion B1 position and the side wall portion B2 position of the workpiece B by press forming. . At this time, the component end surface was further provided with a flange in the component width direction at a portion where the vertical flange was provided at both ends of the steel plate, which became the upper surface in a side view in the second forming step.

In the second molding step, the undulating uneven surface (first out-of-plane deformed portion 10) of the panel bottom surface portion B1 molded in the first molding step is formed on the pad 4 with the punch 3 and the die 5 having a curved surface having the final shape. The punch 3 was applied with a load of 50 tons, and the undulating uneven surface was crushed and a camper was attached. Further, while applying a load of 50 tons between the pad 4 and the punch 3, it is pushed into the die 5, and the uneven portion of the panel side surface portion (second out-of-plane deformed portion 11) at the contact surface between the side surface of the die 5 and the side surface of the punch 3. The side wall B2 was erected while crushing.
At this time, when the side wall portion B2 was erected, the portion that became the upper surface in a side view passed through the slit provided in the punch 3, but the flange portion was abutted to complete the closed cross section. For extraction from the punch 3, a removal mechanism was provided on the side surface of the punch 3 and extracted in the longitudinal direction of the component. Then, the flange part was joined by spot welding.

(Comparative Example 1)
This comparative example 1 employs press molding shown in FIG.
In the first forming step, unlike the first and second embodiments, the wavy uneven shape (first and second out-of-plane deformed portions 10, 1 and 2) by overhang forming at the bottom surface B 1 position and the side wall B 2 position. 11) was not provided, and the end face of the component was provided with flanges in the vertical direction at both ends of the steel plate, which became the upper surface in a side view in the second forming step.

  In the second forming step, the die 5 while sandwiching the panel bottom surface B1 formed in the first forming step with the pad 4 and the punch 3 by applying a load of 50 tons with the punch 3 and the die 5 having the curved surface of the final shape. And the side wall B2 was raised. When the side wall portion B2 was erected, the portion that became the upper surface in a side view passed through the slit provided in the punch 3 to complete the closed cross section. For extraction from the punch 3, a removal mechanism was provided on the side surface of the punch 3 and extracted in the longitudinal direction of the component. Then, it joined by laser welding.

"Evaluation"
When a closed cross-sectional structure having a bent shape curved in the longitudinal direction is processed by press molding, in the first and second examples employing this embodiment, a pair of welded end portions can be accurately associated. It was. On the other hand, in the comparative example 1, since the butt | matching of a pair of welding edge part is greatly disturb | confused, the process of shaping the butt | matching surface of a pair of welding edge part separately was needed.
Thus, by adopting the present embodiment, it is possible to reduce the number of steps and the number of dies compared to the comparative example.
Moreover, when the example based on this embodiment was employ | adopted, the external shape after shaping | molding was able to be shape | molded without a fracture | rupture and a wrinkle generate | occur | producing in any Example. On the other hand, in Comparative Example 1, wrinkles occurred.

Next, an example based on the second embodiment will be described.
The conditions such as the applied material and welding were the same as in Example 1 above, and the manufacture of closed cross-section structural parts was carried out for the following three examples.
(Third embodiment)
In the third embodiment, press molding shown in FIG. 7 is adopted.
In the first molding step, wavy uneven shapes (first and second out-of-plane deformed portions 10 and 11) by stretch molding were applied to the bottom surface B1 position and the side wall B2 position by press molding. At this time, vertical flanges were provided on both ends of the steel sheet, which are upper surfaces in the side view in the second forming step, on the component end surfaces.

  In the bulkhead installation process, the molded bulkhead 16 and the parts molded in the previous first molding process are set on the mold set set at a fixed position in the die 5, and the bulkhead installation hole and The bulkhead 16 was aligned, and the insertion piece 16d formed on the bulkhead 16 was inserted into a hole for installing the bulkhead opened in the bottom surface portion B1. Subsequently, the punch 3 was lowered, and the bulkhead 16 was installed by bending the insertion piece 16d of the bulkhead 16 protruding downward from the bottom surface portion B1 to the bottom surface portion B1 side by 90 degrees.

  Next, the wavy uneven surface (first out-of-plane deformed portion 10) of the bottom surface portion B1 formed in the first forming step with the punch 3 and the die 5 having the curved surface having the final shape in the second forming step. The pad 4 and the punch 3 were applied with a load of 50 tons, and the undulating uneven surface was crushed and a camper was attached. Further, while applying a load of 50 tons between the pad 4 and the punch 3, it is pushed into the die 5, and the uneven portion of the panel side surface portion (second out-of-plane deformed portion 11) at the contact surface between the side surface of the die 5 and the side surface of the punch 3. The side wall B2 was erected while crushing. When the side wall portion B2 is erected, the portion that becomes the upper surface in a side view passes through the slit provided in the punch 3 to complete the closed cross section. For extraction from the punch 3, a removal mechanism was provided on the side surface of the punch 3 and extracted in the longitudinal direction of the component. Then, it joined by laser welding.

(Fourth embodiment)
In the fourth embodiment, press molding shown in FIG. 10 is employed.
In the first molding step, wavy uneven shapes (first and second out-of-plane deformed portions 10 and 11) by stretch molding were applied to the bottom surface B1 position and the side wall B2 position by press molding. At this time, a flange was further provided in the part width direction at the part where the vertical flanges were provided at both ends of the steel plate, which became the upper surface in a side view in the second forming step.

  In the bulkhead installation process, the molded bulkhead 16 and the parts molded in the previous first molding process are set on the mold set set at a fixed position in the die 5, and the bulkhead installation hole and The bulkhead 16 was aligned, and the insertion piece 16d provided in the bulkhead 16 was inserted into the hole for installing the bulkhead opened in the bottom surface portion B1. Subsequently, the punch 3 was lowered, and the bulkhead 16 was installed by bending the insertion piece 16d of the bulkhead 16 protruding downward from the bottom surface portion B1 to the bottom surface portion B1 side by 90 degrees.

  In the second molding step, the undulating uneven surface (first out-of-plane deformed portion 10) of the bottom surface portion B1 molded in the first molding step with the punch 3 and the die 5 having a curved surface having the final shape is connected to the pad 4. The punch 3 was applied with a load of 50 tons, and the undulating uneven surface was crushed and a camper was attached. Further, while applying a load of 50 tons between the pad 4 and the punch 3, it is pushed into the die 5, and the uneven portion of the panel side surface portion (second out-of-plane deformed portion 11) at the contact surface between the side surface of the die 5 and the side surface of the punch 3. The side wall B2 was erected while crushing. When the side wall stood up, the portion that became the upper surface in a side view passed through a slit provided in the punch 3 and abutted the flange portion to complete the closed cross section. For extraction from the punch 3, a removal mechanism was provided on the side surface of the punch 3 and extracted in the longitudinal direction of the component. Then, the flange part was joined by spot welding.

(Comparative Example 2)
This comparative example 2 employs press molding shown in FIG.
In the first forming step, unlike the third and fourth embodiments, the wavy uneven shape (first and second out-of-plane deformed portions 10, 1 and 2) by overhang forming at the bottom surface portion B 1 position and the side wall portion B 2 position. 11) was not provided, and the flanges in the vertical direction were provided on both ends of the steel plate, which became the upper surface in a side view in the second forming step, on the component end surface.

  In the bulkhead installation process, the molded bulkhead 16 and the parts molded in the previous first molding process are set on the mold set set at a fixed position in the die 5, and the bulkhead installation hole and The bulkhead 16 was aligned, and the insertion piece 16d provided in the bulkhead 16 was inserted into the hole for installing the bulkhead opened in the bottom surface portion B1. Next, the punch 3 was lowered, and the bulkhead 16 was installed by bending the insertion piece 16d of the bulkhead 16 protruding downward from the bottom surface portion B1 by 90 degrees toward the bottom surface portion B1.

  The punch 3 and the die 5 having a curved surface of the final shape in the second molding step are pressed into the die 5 while sandwiching the bottom surface B1 molded in the first molding step with a pad 4 and a punch 3 applied with a load of 50 tons. The side wall B2 was raised. When the side wall portion B2 was erected, the portion that became the upper surface in a side view passed through the slit provided in the punch 3 to complete the closed cross section. For extraction from the punch 3, a removal mechanism was provided on the side surface of the punch 3 and extracted in the longitudinal direction of the component. Then, it joined by laser welding.

"Evaluation"
When a closed cross-sectional structure having a bent shape curved along the longitudinal direction is processed by press molding, in the third and fourth examples adopting this embodiment, a pair of welded end portions are associated with each other with high accuracy. It became possible. On the other hand, in the comparative example 2, since the butt | matching of a pair of welding edge part is greatly disturbed, the process of shaping the butt | matching surface of a pair of welding edge part separately was needed.
Thus, by adopting the present embodiment, it is possible to reduce the number of steps and the number of dies compared to the comparative example.
Moreover, when an example was adopted based on the present embodiment, the external shape after molding could be molded without any breakage or wrinkle in any of the examples.
On the other hand, in Comparative Example 2, wrinkles occurred.

DESCRIPTION OF SYMBOLS 1 Lower mold | type 1a Bottom face part shaping | molding part 1b Side wall shaping | molding part 1c Rising surface 2 Upper mold | type 3 Punch 3a Lower end surface 4 Pad 4a Upper surface 5 Die 5a Die side face 10 1st out-of-plane deformation part 11 2nd out-of-surface deformation part 15 Bulk Head installation hole 16 Bulkhead 16a Rising part 16b, 16c Side piece 16d Insert piece 17 Inclined surface B Work material B1 Bottom part B2 Side wall part B3 Joining end (welding end)
B4 Bend B5 Joint surface

Claims (6)

A method of manufacturing a closed cross-section structure component by molding a flat plate-shaped workpiece into a closed cross-section structure in which the bottom surface portion is curved along the longitudinal direction,
A first molding step of forming a plurality of first out-of-plane deformed portions each having a concave shape or a convex shape along the longitudinal direction and forming a bent portion with respect to at least a bottom surface portion position of the processed material,
With the position of the bottom surface of the workpiece sandwiched between the pad and punch, the punch is pushed between the dies to crush the first out-of-plane deformed portion and bend the bent portion with the pad and punch. A second molding step for molding;
A method for producing a closed-section structural component comprising: A flat plate-shaped workpiece is formed into a closed cross-sectional structure including the bottom surface portion, left and right side wall portions located on the left and right sides of the bottom surface portion, and a pair of joining end portions continuous to the left and right side wall portions, respectively. A method of manufacturing a closed cross-section structural component,
In the first forming step, a plurality of second out-of-plane deformed portions each having a concave shape or a convex shape with respect to the side wall portion position are formed along the longitudinal direction together with the first out-of-plane deformed portion. And forming a bent portion at the boundary between the bottom surface and the side wall,
2. The method for manufacturing a closed cross-section structure component according to claim 1, wherein, in the second forming step, the second out-of-plane deformed portion is crushed by a punch side surface and a die side surface.   The bulkhead is installed on the bottom surface of the workpiece after the first molding step and before the bent portion is bent in the second molding step. 2. A method for producing a closed-section structural component described in 2. An apparatus for manufacturing a closed cross-section structure component by molding a flat plate-shaped workpiece into a closed cross-section structure whose bottom surface portion is curved along the longitudinal direction,
A plurality of first out-of-plane deformed portions each having a concave shape or a convex shape are formed along the longitudinal direction with respect to at least the bottom surface position of the workpiece, and an upper die and a lower die that form a bent portion are formed. A press mold provided,
A pad and a punch for crushing the first out-of-plane deformed portion while sandwiching the bottom portion of the workpiece, and pressing the punch in a state where the bottom portion of the workpiece is sandwiched between the pad and the punch An apparatus for manufacturing a closed cross-section structure component, comprising: a die for bending the bent portion. A flat plate-shaped workpiece is formed into a closed cross-sectional structure including the bottom surface portion, left and right side wall portions located on the left and right sides of the bottom surface portion, and a pair of joining end portions continuous to the left and right side wall portions, respectively. An apparatus for manufacturing a closed cross-section structural component,
The upper mold and the lower mold have a plurality of second out-of-plane deformed portions each having a concave shape or a convex shape along the longitudinal direction along with the first out-of-plane deformed portion. And is formed so that a bent portion can be formed at the boundary between the bottom surface and the side wall,
Furthermore, the said 2nd out-of-plane deformation | transformation part is crushed by the said punch side surface and die | dye side surface, The manufacturing apparatus of the closed cross-section structural component described in Claim 4 characterized by the above-mentioned. 6. The bulkhead is installed on the bottom surface portion of the processed material before the bent portion is bent by sandwiching the bottom surface portion of the processed material with a pad and a punch. Manufacturing equipment for the described closed cross-section structural parts.

Images