The present invention relates to a heating method and a heating apparatus for heating a plate workpiece by a direct resistance heating, and a method for manufacturing a press-molded article.
Methods for heating steel workpieces include indirect heating and direct heating. The indirect heating includes, for example, a furnace heating. The direct heating includes, for example, an induction heating and a direct resistance heating. In the induction heating, eddy current is applied to a workpiece by electromagnetic induction to heat the workpiece. In the direct resistance heating, electric current is applied directly to a workpiece to heat the workpiece.
According to a first related art heating method, a plate workpiece having a heating target region whose width varies along a longitudinal direction of the workpiece is heated by a direct resistance heating. The heating target region is divided into a plurality of strip-shaped segment regions arranged side by side in the longitudinal direction of the workpiece. A pair of electrodes is provided for each segment region. Electric current is applied to each pair of electrodes so that the heating target region is heated uniformly (see, e.g., JP3587501B2).
Also according to a second related art heating method, a plate workpiece having a heating target region whose width varies along a longitudinal direction of the workpiece is heated by a direct resistance heating. The heating target region of the workpiece has a width decreasing monotonously from one end toward the other end in the longitudinal direction. A pair of electrodes is placed on the wide end portion of the heating target region of the workpiece, and one of the electrodes is moved toward the narrow end portion while applying electric current to the pair of electrodes so that the heating target region is heated uniformly (see, e.g., JP2013-114942A).
According to the first related art healing method, a configuration of a heating apparatus is complicated because multiple pairs of electrodes are required for one heating target region. On the other hand, according to the second related art healing method, a heating target region can be heated uniformly by a single pair of electrodes. Thus, the configuration of the heating apparatus can be simplified.
However, when the heating target region whose width varies along its longitudinal direction is divided into a plurality of strip-shaped segment regions such that the segment regions are arranged side by side in the width direction of the heating target region, the lengths of the segment regions between the pair of electrodes are different from one another, and resistances of the segment regions are also different from one another. Electric current flowing through a segment region having a relatively long length between the pair of electrodes, that is, having relatively large resistance, is relatively small. Thus, the amount of heat generated in the segment region is relatively small. Therefore, in the second related art heating method, the temperature distribution along the width direction of the heating target region may not be uniform.
Illustrative aspects of the present invention provide a heating method and a heating apparatus capable of uniformly heating a heating target region of a workpiece and also capable of providing a desired temperature distribution on the heating target region of the workpiece.
According to an illustrative aspect of the present invention, a heating method includes placing a pair of electrodes on a workpiece along a first direction, the pair of electrodes having a length extending across a heating target region of the workpiece in the first direction, moving at least one of the electrodes in a second direction perpendicular to the first direction over the heating target region while applying electric current to the pair of electrodes, to heat the heating target region by a direct resistance heating, and adjusting a distribution of contact pressure between at least one of the electrodes and the workpiece along the first direction, with a plurality of segment regions being defined by dividing the heating target region such that the segment regions are arranged side by side in the first direction, and in accordance with a length of each of the segment regions between the pair of electrodes, to adjust a heating temperature of each of the segment regions of the heating target region.
According to another illustrative aspect of the present invention, a heating apparatus includes pair of electrodes arranged to extend across a heating target region of a workpiece in a first direction, a power supply unit configured to supply electric current to the pair of electrodes, a moving section configured to move at least one of the electrodes in a second direction perpendicular to the first direction over the heating target region, a presser configured to press at least one of the electrodes against the workpiece such that a distribution of contact pressure against the workpiece along the first direction is adjustable, and a control unit configured to control the presser, with a plurality of segment regions being defined by dividing the heating target region such that the segment regions are arranged side by side in the first direction, and in accordance with a length of each of the segment regions between the pair of electrodes, to adjust the distribution of the contact pressure along the first direction.
According to another illustrative aspect of the present invention, a method for manufacturing a press-molded article is provided. The method includes heating a plate workpiece by the heating method described above, and applying pressure to the plate workpiece with a press mold to perform hot press molding on the plate workpiece.
Other aspects and advantages of the invention will be apparent from the following description, the drawings and the claims.
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
A heating apparatus 1 has a pair of electrodes 10 including electrodes 11, 12, a power supply unit 13, a moving section 14, a presser 15, and a control unit 16.
The electrodes 11, 12 forming the pair of electrodes 10 are disposed across the workpiece W (heating target region) in its width direction thereof. In this example, the electrode 11 is supported by the moving section 14 so as to be movable in the longitudinal direction of the workpiece W, while the electrode 12 is disposed at the wide end portion R of the workpiece W and is fixed in place. Alternatively, the electrode 12 may also be supported by a moving section 14 so as to be movable in the longitudinal direction of the workpiece W.
The movable electrode 11 includes a main electrode portion 11a and an auxiliary electrode portion 11b holding the workpiece W in the thickness direction thereof. The fixed electrode 12 to be fixed on the workpiece W also includes a main electrode portion 12a and an auxiliary electrode portion 12b holding the workpiece W in the thickness direction thereof. The main electrode portion 11a and the auxiliary electrode portion 11b of the movable electrode 11 are configured as rollers respectively. When the movable electrode 11 is moved by the moving section 14, the main electrode portion 11a and the auxiliary electrode portion 11b roll on the surface of the workpiece W while contacting the workpiece W.
The main electrode portion 11a of the movable electrode 11 rolls on a bus bar 11d through an auxiliary roller 11c. The bus bar 11d extends in the longitudinal direction of the workpiece W. The bus bar 11d is connected to the power supply unit 13. An electric current is supplied from the power supply unit 13 to the main electrode portion 11a through the bus bar 11d and the auxiliary roller 11c. The main electrode portion 11a and the auxiliary electrode portion 11b may be electrically connected, to each other so that the electric current can be supplied to the main electrode portion 11a and the auxiliary electrode portion 11b.
The presser 15 is configured to adjust the distribution of width-direction contact pressure between at least one of the pair of electrodes 10 and the workpiece W. In the illustrated example, the presser 15 includes a first presser 15a configured to adjust the distribution of contact pressure between the movable electrode 11 and the workpiece W and a second presser 15b configured to adjust the distribution of contact pressure between the fixed electrode 12 and the workpiece W.
The first presser 15a includes, for example, a plurality of pressing elements, such as cylinders, provided at intervals along the auxiliary electrode portion 11b of the movable electrode 11 and driven independently of one another. A plurality of locations on the auxiliary electrode portion 11b are pressed by the respective pressing elements to adjust the distribution of contact pressure between the workpiece W and the movable electrode 11.
The second presser 15b may also be configured in the same manner. That is, the second presser 15b may include a plurality of pressing elements, such as cylinders, provided at intervals along the auxiliary electrode portion 12b of the fixed electrode 12 and driven independently of one another. A plurality of locations on the auxiliary electrode portion 12b are pressed by the pressing elements to adjust the distribution of contact pressure between the fixed electrode 12 and the workpiece W.
The power supply unit 13 is configured to supply DC or AC current to the pair of electrodes 10 under the control of the control unit 16. The moving section 14 is configured to move the movable electrode 11 in the longitudinal direction of the workpiece W under the control of the control unit 16. The presser 15 is configured to adjust the distribution of contact pressure between each of the movable electrode 11 and the fixed electrode 12 and the workpiece W under the control of the control unit 16.
Next, a method for heating the workpiece W by a direct resistance heating using the heating apparatus 1 will be described.
When the movable electrode 11 is being moved from the end portion R of the workpiece W toward the end portion L of the same, the electric current applied between the pair of electrodes 10 and/or the moving speed of the movable electrode 11 are adjusted suitably. Thus, the heating temperature of each segment region Ai (i=1, 2, 3, . . . n) into which the workpiece W is virtually divided in the longitudinal direction thereof can be adjusted individually.
For example, with the workpiece W having a width that monotonously decreases along the moving direction of the movable electrode 11 moving in the longitudinal direction of the workpiece W, in other words, the workpiece W having a cross sectional area that decreases monotonously along the moving direction of the movable electrode 11, i.e., the resistance per unit length of the workpiece W increases monotonously, the workpiece W can be heated uniformly along the longitudinal direction.
With Ii being electric current applied when the movable electrode 11 passes through each segment region A; with a unit length D1, and ti being a current application time (sec), the temperature (amount of temperature rise) qi in the segment region Ai can be obtained by the following expression, because the segment region Ai is heated after the movable electrode 11 passes through the segment region Ai.
where re is resistivity (Q×m), r is density (kg/m3), c is specific heat (J/kg×° C.), and ai is the cross sectional area (m2) of the segment region Ai.
The temperature qi in each segment region Ai can be made uniform as q1=q2= . . . . =qn if the applied current Ii or the current application time ti (electrode moving speed Vi) for each segment region Ai is adjusted to satisfy the following expression. When the speed is constant, only the applied current Ii may be adjusted because the current application time ti is constant. When the current is constant, only the current application time ti may be adjusted because the applied current Ii is constant. Both the applied current Ii and the current application time ti may be adjusted.
When the fixed electrode 12 is fixed to the end portion R of the workpiece W and the movable electrode 11 is moved from the end portion R of the workpiece W toward the end portion L of the same, a current application section put between the movable electrode 11 and the fixed electrode 12 in the workpiece W is expanded gradually from the end portion R side where the resistance per unit length in the moving direction of the movable electrode 11 is relatively small.
Accordingly, the current application time t1 differs from one segment region Ai to another. The current application time is longer in a segment region closer to the end portion R. When the same current is applied to a segment region on the end portion R side and a segment region on the end portion L side for the same time, the amount of heat is smaller in the segment region on the end portion R side where the resistance per unit length in the moving direction of the movable electrode 11 is relatively small.
Therefore, based on the variation in resistance per unit length in the moving direction of the movable electrode 11, the electric current applied between the pair of electrodes 10 and/or the moving speed of the movable electrode 11 are adjusted in accordance with the relationship to the current application time ti for each segment region Ai, so as to adjust the amount of heat generated in the segment region Ai. In this manner, the workpiece W can be heated uniformly m the longitudinal direction.
In the example shown in
In the example shown in
In the workpiece W whose width decreases monotonously in the moving direction of the movable electrode 11, the lengths b; of respective segment region Bj (j=1, 2, 3 . . . m) between the pair of electrodes are different from one another, and electric resistances thereof are also different from one another accordingly. In the illustrated example, the length between the pair of electrodes is longer on a side of a segment region Bm along one side of the workpiece W than on a side of a segment region Bl along the other side of the workpiece W, and the electric resistance is also larger on the side of the segment region Bm accordingly.
Here, if the movable electrode 11 is in uniform contact with the workpiece W and the contact resistance is uniform as Rc11=Rc12= . . . =Rc1m, and if the fixed electrode 12 is also in uniform contact with the workpiece W and the contact resistance is uniform as Rc2j=Rc22= . . . =RC2m, the current flowing through the segment region Bm whose electric resistance Rs is relatively large is relatively small, and the amount of heat generated in the segment region Bm is relatively small accordingly.
Here, each contact resistance Rc1j or Rc2j decreases in accordance with increase, in contact area between the workpiece W and the movable electrode 11 or the fixed electrode 12 in the segment region Bj. In relation to the contact pressure between the workpiece W and the movable electrode 11 or the fixed electrode 12 in the segment region Bj, the contact area also increases as the contact pressure increases.
Therefore, based on the relationship to the electric resistance Rsj, that is, based on the relationship to the distance bj between the pair of electrodes in the segment region Bj, the contact pressure between the workpiece W and the movable electrode 11 or the fixed electrode 12 in the segment, region Bj is adjusted to adjust the contact resistance Rc1j or Rc2j. Thus, the amount of heat generated in the workpiece W in the segment region Bj can be adjusted so that the heating temperature of the workpiece W can be controlled in the width direction of the workpiece W.
For example, when the contact, pressure between the workpiece W and the movable electrode 11 or the fixed electrode 12 on the side of the segment region Bm whose electric resistance Rs is relatively large is increased, the work W can be heated uniformly in the width direction. In combination with the current adjustment shown in
Test Examples will be described below.
In each Test Example, as shown in
The distribution of contact pressure between the movable electrode 11 and the workpiece W was detected using pressure sensitive paper. In
In Test example 1, as shown in
In Test example 2, as shown in
The heating method described above may be, for example, applied to hardening process based on quenching after heating, or may be applied to a method for manufacturing a press-molded article by hot press molding with pressure applied by a press mold at a high temperature state after heating. According to the aforementioned heating method, equipment for heating may have a simple configuration so that the equipment for heating can be disposed closely to a press machine or integrally built into the press machine. Accordingly, a plate workpiece can be press-molded in a short time after heating. Thus, a temperature drop in the heated plate workpiece can be suppressed to reduce an energy loss. In addition, the surface of the plate workpiece can be prevented from being oxidized, so that a high-quality press-molded article can be manufactured.
This application is based on Japanese Patent Application No. 2015-043557 filed on Mar. 5, 2015, the entire content of which is incorporated herein by reference.
Number | Date | Country | Kind |
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2015-043557 | Mar 2015 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2016/001141 | 3/2/2016 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2016/139944 | 9/9/2016 | WO | A |
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Number | Date | Country |
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3587501 | Nov 2004 | JP |
2013-114942 | Jun 2013 | JP |
2009138869 | Nov 2009 | WO |
2013081180 | Jun 2013 | WO |
2013180313 | Dec 2013 | WO |
Entry |
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Number | Date | Country | |
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20180029103 A1 | Feb 2018 | US |