Patent Application
20240208575
The present invention relates to a frame member having excellent energy absorption efficiency.
Priority is claimed on Japanese Patent Application No. 2021-078461, filed on May 6, 2021, the content of which is incorporated herein by reference.
In the related art, a hollow member obtained by processing a steel sheet into a predetermined closed cross-sectional shape has been used as a frame member of a vehicle. Such a frame member is required to realize the weight reduction and to exhibit a sufficient proof stress and energy absorption performance in a case where an input load in an axial direction is applied thereto due to a collision.
Examples of the method primarily used for realizing the weight reduction include a method of reducing the weight by thinning a member by an increase in the proof stress and energy absorption performance due to an increase of the strength of a steel sheet. Therefore, in recent years, a steel sheet capable of exhibiting a tensile strength of 1.5 GPa or greater may be used as a material of a frame member through the use of a hot stamping method.
Patent Document 1 discloses a collision-proof reinforcing member for a vehicle which is formed of a formed thin sheet to increase buckling resistance, including at least a main body portion and a pair of side wall portions integrated with the main body portion via folding portions, in which the main body portion is provided with a recessed bead extending in a center of the main body portion in a width direction along a longitudinal direction of the main body portion, and the recessed bead is provided so that an effective width c′ as a distance between the recessed bead and the folding portion satisfies a specific range.
[Patent Document 1] Japanese Unexamined Patent Application, First Publication No. 2009-286351
According to the technology of Patent Document 1, the bead is provided in consideration of the effective width, and thus it is possible to suppress elastic buckling and to improve the proof stress. However, in order to reduce the weight by further thinning, it is required to take measures for further increasing the energy absorption efficiency which is the amount of energy absorbed per unit cross-section area of the frame member.
The present invention has been made in view of the above problems, and an object of the present invention is to provide a frame member having excellent energy absorption efficiency.
Specific aspects of the present invention are as described below.
According to the above aspect, in a case where the width and the hardness standard deviation ratio are controlled within appropriate ranges in the reference flat part, it is possible to prevent the fracture during bellows deformation due to a load in an axial direction while suppressing elastic buckling. Accordingly, a high degree of energy absorption performance can be obtained even in a case where a high-strength thin member is used. Accordingly, it is possible to exhibit excellent energy absorption efficiency.
The present inventors intensively studied the configuration of a frame member capable of exhibiting excellent energy absorption efficiency.
First, in order to exhibit excellent energy absorption efficiency, it is important that the frame member has a proof stress of a certain level or higher. In a case where an input load in an axial direction is applied due to a collision, elastic buckling may occur in a flat part in the initial stage of deformation. In a case where elastic buckling occurs, a required proof stress may not be obtained, and excellent energy absorption efficiency may not be exhibited.
In addition, in order to exhibit excellent energy absorption efficiency, it is also important that the frame member realizes folding deformation in a desired deformation mode immediately after an input load in an axial direction is applied thereto due to a collision, in order to efficiently absorb impact energy. In particular, in a case where fracture (fracture at a folded portion) occurs during bellows deformation due to the load in the axial direction, excellent energy absorption efficiency may not be exhibited.
Accordingly, it can be said that in a case where a cross section where elastic buckling hardly occurs in a flat part is designed and high bending performance can be imparted so that fracture hardly occurs, excellent energy absorption efficiency can be exhibited.
Here, in a case where the member is increased in strength and thinned as a method for realizing the weight reduction, the following problems occur.
The present inventors paid attention to the fact that the above-described problems hinder a further increase of the strength and thinning of a high strength steel sheet.
The present inventors further conducted studies, and found that in a case where the width and the hardness standard deviation ratio are controlled within appropriate ranges in a reference flat part, it is possible to prevent the fracture during bellows deformation due to a load in an axial direction while suppressing elastic buckling. The present inventors found that thanks to such control, it is possible to solve the above-described problems which may occur in using a high strength steel sheet, and to exhibit excellent energy absorption efficiency, and completed the present invention.
Hereinafter, a frame member 10 according to a first embodiment of the present invention contrived based on the above findings will be described.
In the present specification and the drawings, constituent elements having substantially the same functional configuration are designated by the same reference numerals to avoid duplicating description.
First, terms and phrases in the present specification will be described.
The “longitudinal direction” means a member axis direction of a frame member, that is, a direction in which the axis extends.
The “flat part” means a linear part in a cross section perpendicular to the longitudinal direction of the frame member, specifically, a part having a radius of curvature larger than a maximum external dimension of the cross section. The maximum external dimension means the maximum straight line length between end portions at two arbitrary points in the cross section.
The “corner part” means a non-linear part excluding the flat part in the cross section perpendicular to the longitudinal direction of the frame member.
The “width” means a line length along the circumferential direction of a closed cross section portion, and the “width of the flat part” means a line length between one end and the other end of the flat part.
The “effective width” is an effective width We obtained from Formula (1) based on Karman's effective width theory, that is, Karman's effective width formula.
Here, the meanings of the symbols are as follows.
In addition, in the steel sheet, as the Young's modulus of the flat part and the Poisson's ratio of the flat part, general physical property values may be used, and by replacing the yield stress of the flat part with the Vickers hardness of the thickness middle portion, the effective width We can be obtained from Expression We=577 t/√h.
Here, the meanings of the symbols are as follows.
In a case where it is difficult to obtain the effective width We from Formula (1), the effective width We can be obtained from the above expression.
The “effective width ratio” is a ratio of a width W of the flat part to the effective width We, and is a value calculated by W/We. It can be said that the smaller the value of the effective width ratio, the more hardly the elastic buckling occurs in the cross-sectional shape.
The “reference flat part” means a flat part where the effective width ratio is maximum in the flat part of the closed cross section portion in an optional position in the longitudinal direction.
The “surface layer portion” means a region between: a depth position where a distance from a surface of the steel sheet to the depth position separated therefrom in the sheet thickness direction is 1% of the sheet thickness of the steel sheet; and a depth position where a distance from the surface of the steel sheet to the depth position separated therefrom in the sheet thickness direction is 5% of the sheet thickness of the steel sheet.
The “thickness middle portion” means a depth position where a distance from the surface of the steel sheet to the depth position separated therefrom in the sheet thickness direction of the steel sheet is ⅜ of the sheet thickness.
The “surface of the steel sheet” set as the reference of the depth position means a surface of a base steel sheet. For example, in a case where the steel sheet is plated or painted, or rust or the like is formed thereon, the surface of the steel sheet in a state where the plating, painting, and rust have been removed is set as the reference of the depth position. In a case where a surface layer coating such as plating, painting, rust, or the like is formed on the surface of the base steel sheet, the boundary between the surface layer coating and the surface of the base steel sheet is easily identified by various known methods.
The “amount of energy absorbed” is an amount of energy absorbed calculated from the relationship between the impactor reaction force (load) and the stroke when the frame member is subjected to bellows deformation. Regarding the impactor reaction force (load) and the stroke, in a state in which the frame member is disposed so that the longitudinal direction thereof is in the vertical direction, and a lower end side is completely restricted as shown in
The “energy absorption efficiency” is an amount of energy absorbed per cross-section area (sheet thickness×cross section line length) of the frame member. In a case where the frame member does not have a uniform cross section in the longitudinal direction, the energy absorption efficiency is an amount of energy absorbed per cross-section area (sheet thickness×cross section line length) in a closed cross section where the cross-section area (sheet thickness×cross section line length) is minimum in a closed cross section perpendicular to the longitudinal direction of the member.
Specifically, the closed cross section portion is formed by being provided with a first flat part 11a, a second flat part 11b which is connected to the first flat part 11a via a corner part C, a third flat part 11c which is connected to the second flat part 11b via a corner part C, and a fourth flat part 11d which is connected to the third flat part 11c via a corner part C, and by connecting the fourth flat part 11d to the first flat part via a corner part C.
All the four corner parts C have the same radius of curvature r. For example, in a case where the maximum external dimension is 140 mm, the radius of curvature r may be 140 mm or less. The radii of curvature of the four corner parts C do not need to be the same, and may be different from each other. The upper limit of the radius of curvature is not particularly specified. However, a part having a radius of curvature larger than the maximum external dimension of the cross section is not regarded as a corner part, but as a separate flat part or a part of an adjacent flat part. Therefore, it can be said that the upper limit of the radius of curvature of the corner part C is substantially “less than the maximum external dimension of the cross section”.
In the present application, the reference flat part is defined as a flat part where the effective width ratio is maximum in the flat part of the closed cross section portion.
The first flat part 11a, the second flat part 11b, the third flat part 11c, and the fourth flat part 11d all have the same yield stress σy, Young's modulus E, sheet thickness t, and Poisson's ratio v.
Accordingly, the effective width ratio in each flat part 11 calculated by width W/effective width We is determined depending only on the width W of each flat part 11.
Therefore, in the present embodiment, the first flat part 11a and the third flat part 11c having the largest width W in the closed cross section portion are set as the reference flat parts.
In the reference flat part, when the frame member 10 receives a compression force in the axial direction, elastic buckling is most likely to occur in the initial stage of deformation. Accordingly, in a case where a width WS of the reference flat part is too large, a required proof stress cannot be obtained, and it becomes difficult to exhibit excellent energy absorption efficiency. Accordingly, the upper limit of the width WS of the reference flat part is set to 2.0 times or less the effective width We.
The lower limit of the width WS of the reference flat part is not particularly set. However, in a case where the width WS of the reference flat part is too small, the area of the closed cross section portion of the frame member 10 is reduced, and it becomes difficult to ensure the proof stress.
Accordingly, the width WS s of the reference flat part is preferably 0.1 times or greater the effective width We.
The sheet thickness of the reference flat part is preferably 4.2 mm or less from the viewpoint of weight reduction.
Meanwhile, in a case where the sheet thickness of the reference flat part is less than 0.4 mm, elastic buckling is likely to occur in the reference flat part, and thus the limitation of the setting range of the width WS of the reference flat part is increased. Accordingly, the sheet thickness of the reference flat part is preferably 0.4 mm or greater.
The frame member 10 is formed by forming a steel sheet for hot stamping into a predetermined shape by hot stamping and by then joining end surfaces together. The frame member 10 formed as described above has a strength of 1.5 GPa or greater in terms of tensile strength. In addition, since the frame member is formed as described above, the Vickers hardness of the thickness middle portion of the reference flat part in the frame member 10 is 300 Hv or greater in a hardness test performed by the method described in JIS Z 2244: 2009 with a test load of 300 gf (2.9 N).
In the present application, since excellent energy absorption efficiency is exhibited by increasing the deformability on the premise of an increase of the strength, the hardness of the thickness middle portion of the reference flat part is specified to be 300 Hv or greater in terms of Vickers hardness.
The upper limit of the hardness of the thickness middle portion is not particularly specified, but may be 900 Hv or less in terms of Vickers hardness.
A method of measuring the hardness of the thickness middle portion is as follows.
A sample having a cross section perpendicular to the sheet surface is collected from the frame member. The cross section is prepared as a measurement surface, and the measurement surface is subjected to a hardness test.
The size of the measurement surface depends on the measuring apparatus, but may be about 10 mm×10 mm.
The method of preparing the measurement surface is performed according to JIS Z 2244: 2009. After the measurement surface is polished using silicon carbide paper ranging from #600 to #1500, the measurement surface is mirror-finished using a liquid obtained by dispersing a diamond powder having a particle size of 1 μm to 6 μm in a dilution liquid such as alcohol or pure water. The hardness test is performed by the method disclosed in JIS Z 2244: 2009. Hardness is measured using a micro-Vickers hardness tester at 30 points that are arranged at intervals of three times or more the indentation under a load of 300 gf in the position at a depth of ⅜ of the sheet thickness of the sample, and the average value of the measured values is defined as the hardness of the thickness middle portion.
As described above, in a case where the width WS of the reference flat part is 2.0 times or less the effective width We, elastic buckling can be suppressed. However, in a high-strength material, e.g., a hot-stamped material (hot-stamped formed body) having a tensile strength of 1.5 GPa or greater, in a case where the bending performance is insufficient, fracture occurs during bellows deformation due to a load in an axial direction even in a case where elastic buckling can be suppressed by controlling the effective width We, whereby excellent energy absorption efficiency cannot be obtained.
In the related art, the standard deviation of hardness frequency distribution in the thickness middle portion and the standard deviation of hardness frequency distribution in the surface layer portion in the reference flat part are almost the same, and the hardness standard deviation ratio is 1.0.
However, in the frame member 10 according to the present embodiment, the bending performance is increased by appropriately controlling the ratio between the standard deviation of hardness frequency distribution in the thickness middle portion and the standard deviation of hardness frequency distribution in the surface layer portion in the reference flat part.
Accordingly, even in a case where a high-strength material is applied, fracture during bellows deformation is suppressed, and it is possible to exhibit significantly excellent energy absorption efficiency compared to the related art.
Specifically, in the frame member 10 according to the present embodiment, the hardness standard deviation ratio which is a value obtained by dividing the standard deviation of hardness frequency distribution in the surface layer portion by the standard deviation of hardness frequency distribution in the thickness middle portion in the reference flat part is controlled to be less than 1.0.
The present inventors have found through experiments that in a case where the hardness standard deviation ratio is less than 1.0 in applying a hot-stamped material having a tensile strength of 1.5 GPa or greater, the maximum bending angle in a VDA bending test based on the VDA standard (VDA238-100) specified by the German Association of the Automotive Industry can be considerably improved.
Accordingly, the hardness standard deviation ratio is preferably less than 0.95, and more preferably less than 0.80.
The hardness standard deviation ratio is preferably as small as possible, but even in a case where the hardness standard deviation ratio is less than 0.01, the bendability increase effect is saturated. Accordingly, the hardness standard deviation ratio is preferably 0.01 or greater.
Here, the hardness frequency distribution in the thickness middle portion and the hardness frequency distribution in the surface layer portion are acquired by a Vickers hardness test.
A sample having a cross section perpendicular to the sheet surface is collected from the frame member. The cross section is prepared as a measurement surface, and the measurement surface is subjected to a hardness test.
The size of the measurement surface depends on the measuring apparatus, but may be about 10 mm×10 mm.
The method of preparing the measurement surface is performed according to JIS Z 2244: 2009.
After the measurement surface is polished using silicon carbide paper ranging from #600 to #1500, the measurement surface is mirror-finished using a liquid obtained by dispersing a diamond powder having a particle size of 1 μm to 6 μm in a dilution liquid such as alcohol or pure water.
The measurement surface mirror-finished as described above is subjected to the hardness test by the method described in JIS Z 2244: 2009.
The hardness in the surface layer portion is measured using a micro-Vickers hardness tester.
Hardness is measured at 30 points that are arranged at intervals of three times or more the indentation under a load of 300 gf, and the hardness frequency distribution in the surface layer portion is obtained.
Similarly, in the depth position of ⅜ of the sheet thickness, hardness is measured at 30 points that are arranged at intervals of three times or more the indentation under a load of 300 gf, and the hardness frequency distribution in the thickness middle portion is obtained.
In addition, a known statistical method is used to obtain the standard deviations of the hardness frequency distribution in the surface layer portion and the hardness frequency distribution in the thickness middle portion, obtained as a result of the Vickers hardness test described above.
In a case where the metallographic structure is the same in a thickness middle portion and a surface layer portion of a steel sheet for hot stamping as in the related art, the hardness frequency distribution in the surface layer portion is the same as the hardness frequency distribution in the thickness middle portion, and the hardness standard deviation ratio is 1.0.
Meanwhile, in a case where the metallographic structure in only the surface layer portion and the vicinity thereof is modified, the hardness standard deviation ratio becomes a value different from 1.0.
In the frame member 10 formed of a steel sheet for hot stamping according to the present embodiment, in a case where the metallographic structure in only the surface layer portion and the vicinity thereof is modified, the distribution and unevenness of the hardness in the surface layer portion are suppressed, and the hardness standard deviation ratio between the surface layer portion and the thickness middle portion can be made less than 1.0.
Specifically, the hardness standard deviation ratio can be controlled by adjusting a highest heating temperature and a holding time in decarburization annealing of the steel sheet for hot stamping, which is a known technology. As for preferable conditions of the decarburization annealing, the decarburization annealing temperature (maximum attainment temperature of the steel sheet) is 700° C. to 950° ° C., and the residence time in a temperature range of 700° C. to 950° C. is 5 seconds to 1,200 seconds under a moist atmosphere containing hydrogen, nitrogen, or oxygen.
In addition, in a case where the annealing temperature is set to a higher temperature range and the residence temperature is narrowed to a longer time range within the above condition ranges, the hardness standard deviation ratio can be made less than 0.80.
At least one surface layer portion of the frame member 10 may satisfy the above hardness standard deviation ratio condition. However, it is preferable that the surface layer portions on both sides of the frame member 10 satisfy the above hardness standard deviation ratio condition.
As described above, according to the frame member 10 of the present embodiment, in the reference flat part, elastic buckling is suppressed by controlling the width WS of the reference flat part, and fracture during bellows deformation can be suppressed by controlling the hardness standard deviation ratio.
Accordingly, the energy absorption efficiency can be significantly improved while the thickness middle portion of the reference flat part has sufficient hardness of 300 Hv or greater in terms of Vickers hardness.
Although the preferable embodiments of the present invention have been described in detail with reference to the accompanying drawings, the present invention is not limited to such examples.
It is apparent that a person having common knowledge in the technical field to which the present invention belongs is able to devise various changes or modifications within the scope of the technical idea of the present application, and it should be understood that such examples belong to the technical scope of the present invention as a matter of course.
For example, the frame member 10 described above is formed of a single member, but may be formed of a plurality of members.
The frame member 20 includes a first frame member 20A extending in a longitudinal direction and a second frame member 20B extending in the longitudinal direction and joined to the first frame member 20A. A closed cross section portion is formed by the first frame member 20A and the second frame member 20B.
The first frame member 20A is a member having an open cross section, which is provided by subjecting a steel sheet having a sheet thickness of 1.2 mm to hot stamp forming so that the cross section perpendicular to the longitudinal direction has a substantially hat shape.
As shown in
Specifically, the cross section portion of the first frame member 20A perpendicular to the longitudinal direction is provided with a first flat part 21a, a second flat part 21b which is connected to the first flat part 21a via a corner part C, a third flat part 21c which is connected to the second flat part 21b via a corner part C, a fourth flat part 21d which is connected to the third flat part 21c via a corner part C, and a fifth flat part 21e which is connected to the fourth flat part 21d via a corner part C.
The second frame member 20B is a member having an open cross section, which is provided by subjecting a steel sheet having a sheet thickness of 0.8 mm to hot stamp forming so that the cross section perpendicular to the longitudinal direction has a substantially hat shape.
As shown in
Specifically, the cross section portion of the second frame member 20B perpendicular to the longitudinal direction is provided with a first flat part 23a, a second flat part 23b which is connected to the first flat part 23a via a corner part C, a third flat part 23c which is connected to the second flat part 23b via a corner part C, a fourth flat part 23d which is connected to the third flat part 23c via a corner part C, and a fifth flat part 23e which is connected to the fourth flat part 23d via a corner part C.
In addition, the first flat part 21a and the fifth flat part 21e of the first frame member 20A are joined to the first flat part 23a and the fifth flat part 23e of the second frame member 20B by spot welding.
With such a configuration, the frame member 20 has a closed cross section portion in the cross section perpendicular to the longitudinal direction.
In the present application, the reference flat part is defined as a flat part where the effective width ratio is maximum in the flat part of the closed cross section portion.
The flat part 21 of the first frame member 20A and the flat part 23 of the second frame member 20B all have the same yield stress oy, Young's modulus E, and Poisson's ratio v. Accordingly, the effective width ratios in the flat parts 21, 23 calculated by width W/effective width We are determined depending on the width W and the sheet thickness t of the flat parts 21, 23.
In this closed cross section portion, the third flat part 21c of the first frame member 20A and the third flat part 23c of the second frame member 20B both are flat parts having the maximum width among all the flat parts 21, 23. However, since the third flat part 23c of the second frame member 20B has a smaller sheet thickness than the third flat part 21c of the first frame member 20A, the third flat part 23c of the second frame member 20B has the largest effective width ratio. Accordingly, the third flat part 23c of the second frame member 20B is the reference flat part.
Accordingly, in the frame member 20 according to the modification example, by controlling the Vickers hardness of the thickness middle portion to 300 Hv or greater, controlling the width Ws to 2.0 times or less the effective width We, and controlling the standard deviation ratio to a value smaller than 1.0 in the third flat part 23c of the second frame member 20B which is the reference flat part, excellent energy absorption efficiency can be exhibited.
The frame member 10 has a substantially rectangular cross-sectional shape in which the sides facing each other have the same width, but may have a substantially square cross-sectional shape in which the four flat parts 11 have the same width.
The number of the flat parts 11 is not particularly limited, and may be at least one.
In addition, the frame member 10 according to the embodiment has a uniform cross-sectional shape over the whole length, but may not have a uniform cross-sectional shape over the whole length. A closed cross section where the cross-section area (sheet thickness x cross section line length) is minimum in the closed cross section perpendicular to the longitudinal direction of the member may be the above-described closed cross section portion, and may be present in a part of the whole length in the longitudinal direction. The closed cross section portion is present in preferably 50% or greater, and more preferably 80% or greater of the whole length in the longitudinal direction.
The frame members 10, 20 are applied to members to which a compression input is to be applied mainly in the axial direction at the time of the collision, among structural members of a vehicle body.
Referring to
A steel sheet A, a steel sheet B, and a steel sheet C having a sheet thickness of 1.6 mm were prepared.
In decarburization annealing of the steel sheet B and the steel sheet C, the decarburization annealing temperature (maximum attainment temperature of the steel sheet) was set to 700° C. to 900° C., and the residence time in a temperature range of 700° C. to 900° C. was set to 60 to 600 seconds under a moist atmosphere provided by mixing hydrogen and nitrogen, to modify the metallographic structure in only a surface layer portion and the vicinity thereof.
The steel sheet A, the steel sheet B, and the steel sheet C were subjected to hot stamp forming by being heated, held in a temperature range of 900° C., and rapidly cooled in a die and punch, end surfaces were welded to each other, and thus rectangular tube members of 300 mm in height, formed of the steel sheets, were obtained.
In the steel sheet A, the metallographic structure was the same in a thickness middle portion and a surface layer portion. Therefore, the standard deviation of hardness frequency distribution in the thickness middle portion in the reference flat part and the standard deviation of hardness frequency distribution in the surface layer portion in the reference flat part were the same, and the hardness standard deviation ratio was 1.0. Meanwhile, in the steel sheet B and the steel sheet C, the metallographic structure in the thickness middle portion was not modified, but the metallographic structure in the surface layer portion was modified to change the hardness frequency distribution in the surface layer portion, so that the standard deviation in the surface layer portion was adjusted. As a result, the hardness standard deviation ratio of the surface layer portion to the thickness middle portion in the reference flat part of the steel sheet B was 0.65, and the hardness standard deviation ratio in the reference flat part of the steel sheet C was 0.80.
Table 1 shows material characteristics in the flat parts after hot stamping.
As shown in
The radii of curvature of four corner portions C were all designed to be 5 mm.
A rigid flat impactor was allowed to collide with each of the rectangular tube members at a speed of 90 km/h from the upper end side in a state in which the lower end side was completely restricted, and the deformation states at the time of the collision, the states in which fracture occurred, and the absorbed energy calculated from the impactor reaction force (load) and the stroke were compared. Table 2 shows the setting conditions and the results for each experimental example.
In Experiment Nos. 1A, 2A, and 3A, since the hardness standard deviation ratio was 1.0, it was not possible to obtain good bendability. Fracture occurred in a folded portion during bellows deformation, and the deformation could not continue. As a result, the energy absorption efficiency was inferior. In addition, in Experiment Nos. 4A, 4B, 5A, and 5B, fracture did not occur during bellows deformation. However, since the effective width ratio was high, elastic buckling occurred in the reference flat part, and the axial force could not be exhibited. As a result, the energy absorption efficiency was inferior.
In Experiment Nos. 1B, 2B, 3B, and 3C, the hardness standard deviation ratio was appropriately controlled and the effective width ratio was also appropriate. Therefore, even though a 1500 MPa-grade hot-stamped material was used, neither fracture during bellows deformation nor elastic buckling occurred, and it was possible to exhibit excellent energy absorption efficiency.
According to the present invention, it is possible to provide a frame member having excellent energy absorption efficiency.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-078461 | May 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/018953 | 4/26/2022 | WO |
