Patent Grant
10464116
The present invention relates to a method of manufacturing a plate-like molded body having a plurality of thickened portions, and particularly relates to a method including a step of molding a plate-like molded body by press processing.
Some plate-like members used in transport airplanes, construction structures, and the like are fastened to other members with bolts.
When the surface of the plate-like member 1 serves as the bearing surface of the bolts, the fastening strength is influenced by the thickness around the fastening portions 2 of the plate-like member 1 to a large extent. When the fastening strength is required to be increased, it is necessary to either increase the thickness of the plate-like member 1 or to attach a reinforcing plate to the fastening portions 2.
However, when the thickness of the whole of the plate-like member is increased, the weight of the plate-like member markedly increases. When a product including the plate-like member is demanded to be decreased in weight, such demand cannot be satisfied. Furthermore, the use of the reinforcing plate increases the number of components, thereby raising the costs of management and assembling. To address these concerns, it is conceivable that only a necessary portion (in the example of
Patent Literature 1 discloses a thickening press process including: a previous step of deep-drawing a work; and a step of pressing the deep-drawn work to thicken a predetermined portion. Patent Literature 2 discloses a method of clamping a pressed work having an end wall and a bent portion that is bent from the outer circumference toward one side, at the bent portion from the outer circumference of this end wall, so that the bent portion is compressed in the radial direction for thickening. Patent Literature 3 discloses a method of manufacturing a molded component having a bent corner, including a thickening step of increasing in thickness of a corner by molding under pressure.
Patent Literature 1: JP 3594845B
Patent Literature 2: JP 2010-247199A
Patent Literature 3: JP 2007-175765A
However, the methods disclosed in Patent Literatures 1 to 3 are intended to thicken a bent portion or a portion adjacent to an edge in a plate-like member. Therefore, these methods cannot be applied to other portions, for example, when a region spaced apart from a margin is thickened in a substantially flat plate-like portion (that is, an unbent portion), like the fastening portions 2 illustrated in
The present invention has been devised in view of the above-described problems. An object of the present invention is to provide a novel and improved plate-like molded body having a thickened portion in a region spaced apart from an edge in a substantially flat plate-like portion, and a method of manufacturing the plate-like molded body.
In order to solve the above problems, according to an aspect of the present invention, there is provided a method of manufacturing a plate-like molded body having a plurality of thickened portions, including at least a drawing step of obtaining by a drawing process a cylindrical drawn molded body including a flat plate portion and a cylindrical drawn portion that swells in such a manner as to project from the flat plate portion and has a circular top portion. The drawing step includes a first step of pressing a region spaced apart from an edge in a plate-like member having a flat plate shape, with a first mold and a second mold, to form a concave curved portion in the plate-like member, and a second step of holding an outer circumferential section of the plate-like member between a third mold and a fourth hold while a region containing the concave curved portion in the plate-like member is held between the first mold and the second mold, and moving the first mold and the second mold relative to the third mold and the fourth mold to cause the region containing the concave curved portion to project with respect to the outer circumferential section and to obtain the cylindrical drawn molded body.
The first step may include forming the concave curved portion in a region corresponding to the top portion, and the second step may include setting a plurality of thickening target regions containing at least a part of the concave curved portion along a circumferential direction with respect to a specific center in a region corresponding to the cylindrical drawn portion, and performing a drawing process such that in a cross section that is vertical to the flat plate portion and contains the specific center, an actual length of the thickening target region becomes longer than an actual length of the thickened portion in the plate-like molded body.
The method may further include, after the drawing step, a thickening step of pressing the cylindrical drawn molded body such that an actual length of each of the thickening target regions in the cross section decreases, and the thickening target region and the flat plate portion finally become flat as a whole.
The concave curved portion may include a hole-like curved portion that is curved in a hole shape.
The concave curved portion may further include a ring groove-like curved portion that is curved in a groove shape and formed around the hole-like curved portion in such a manner as to have a polygonal shape as a whole when seen vertically to the flat plate portion.
The concave curved portion may include a ring groove-like curved portion that is curved in a groove shape and formed in such a manner as to have a polygonal shape as a whole when seen vertically to the flat plate portion.
The thickened portion may have a plate thickness with a thickening rate of 20% or more with respect to an initial plate thickness as a plate thickness of the cylindrical drawn molded body, and may have a length of five times or more the initial plate thickness in the cross section.
In order to solve the above problems, according to another aspect of the present invention, there is provided a plate-like molded body having a plurality of thickened portions, including a flat plate portion, and a cylindrical drawn portion that swells in such a manner as to project from the flat plate portion and has a circular top portion. When t [mm] is a standard plate thickness, a plate thickness ti [mm] of the thickened portion and a plate thickness td [mm] of a thinned portion having a smaller thickness than the standard plate thickness satisfy relational formulas below:
when 2.0<t<3.0, td≥0.9t, ti≥1.25t,
when 3.0<t<4.0, td≥0.9t, ti≥1.35t, and
when 4.0<t<5.0, td≥0.9t, ti≥1.45t.
As described above, according to the present invention, there can be provided a plate-like molded body having a thickened portion in a region spaced apart from an edge in a substantially flat plate-like portion, and a method of manufacturing the plate-like molded body.
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the appended drawings. Note that, in this specification and the appended drawings, structural elements that have substantially the same function and structure are denoted with the same reference numerals, and repeated explanation of these structural elements is omitted.
A method of manufacturing a plate-like molded body having a plurality of thickened portions according to the present embodiments includes a drawing step and a thickening step.
The drawing step is to obtain by a drawing process a cylindrical drawn molded body including a flat plate portion and a cylindrical drawn portion that swells in such a manner as to project from the flat plate portion and has a circular top portion. The drawing step includes: forming, in a region corresponding to the top portion, a concave curved portion containing a hole-like curved portion that is curved in a hole shape; setting a plurality of thickening target regions containing at least part of the concave curved portion along a circumferential direction with respect to a specific center in a region corresponding to the cylindrical drawn portion; and performing a drawing process such that an actual length of the thickening target region in a cross section that is vertical to the flat plate portion and contains the specific center becomes longer than an actual length of the thickened portion in the plate-like molded body.
The thickening step includes pressing the cylindrical drawn molded body such that an actual length of each of the thickening target regions in the cross section decreases, and the thickening target regions and the flat plate portion finally become flat as a whole.
Here, the “actual length” indicates a length along a surface of an object in a prescribed cross section of the object.
The thickening step may include a plurality of steps for pressing the cylindrical drawn molded body such that the actual length of each of the thickening target regions in the cross section decreases. In this case, the thickening target regions and the flat plate portion can be made in a flat state as a whole in at least one of these steps.
The material of the plate-like member is not particularly limited, but can be, for example, a high tensile steel plate having a tensile strength of 390 MPa or more. For example, the high tensile steel plate may have a tensile strength of 440 MPa or more.
The plate-like molded body manufactured by this manufacturing method can be used as, for example, a drive train component and a suspension attachment part. In this case, the thickened portions can serve as a portion to which a bolt is fastened.
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
<First Embodiment>
In this embodiment, there is manufactured a plate-like molded body including three thickened portions formed around a center, such as a plate-like member 1 illustrated in
In this embodiment, the cylindrical drawn portion 7 has a dome-like shape, and is approximately circular when seen vertically to the flat plate portion 6. The cylindrical drawn portion 7 includes a ring-shaped side portion 7a that rises from the flat plate portion 6, and a circular top portion 7b. The top portion 7b includes a concave curved portion 10 having a hole-like curved portion 8 that is curved in a hole shape and a ring groove-like curved portion 9 that is formed around the hole-like curved portion 8 and curved in a groove shape.
The ring groove-like curved portion 9 approximately has a shape of an equilateral triangle when seen vertically to the flat plate portion 6. In this embodiment, the formed ring groove-like curved portion 9 has a shape of a triangle corresponding to formation of three thickened portions. When N thickened portions are formed, a ring groove-like curved portion having an N-angular shape is formed. Although the ring groove-like curved portion 9 formed around the hole-like curved portion 8 has a single groove (one groove) in this embodiment, the ring groove-like curved portion 9 may have double or more grooves.
In each of the following cross-sectional views (
A cylindrical hole penetrating in the vertical direction is formed in the lower die 11. The punch 12 is arranged in this hole. The relative positional relationship between the lower die 11 and the punch 12 is changed by the movement of the lower die 11 in the vertical direction. The upper surfaces of the lower die 11 and the punch 12 constitute a pressing surface 11a and a press surface 12a, respectively.
A columnar hole extending in the vertical direction and having a width smaller than the hole of the lower die 11 is formed in the upper die 13. The pad 14 is arranged in this hole and attached to the upper die 13 via a press spring or a gas cylinder, and is movable along the axial direction of this hole.
Of the lower surface of the upper die 13, the outer circumferential section constitutes a pressing surface 13a and faces the pressing surface 11a of the lower die 11, and the inner circumferential section constitutes a press surface 13b and faces the outer circumferential section of the press surface 12a of the punch 12. The lower surface of the pad 14 constitutes a press surface 14a and faces the central section of the press surface 12a of the punch 12. A load is applied to the pad 14 from the upper die 13 via a press spring or a gas cylinder. While such a load is not applied, the lower end of the pad 14 is positioned slightly lower than the height of the pressing surface 13a.
The pressing surface 11a of the lower die 11 and the pressing surface 13a of the upper die 13 are flat. The press surface 14a of the pad 14 and a region facing the press surface 14a in the press surface 12a of the punch 12 have a shape corresponding to the concave curved portion 10 (see
With reference to
Next, the work W is held between the lower die 11 and the upper die 13 with a cushion force in the case of a single-acting press machine and with an acted outer load in the case of a double-acting press machine (a single-acting press machine in the drawing). At this time, the lower die 11 and the upper die 13 applies a force in an in-plane direction (referred to as “blank holding force” or “wrinkle suppressing force”) to the work W to a degree that allows the work W to move.
Subsequently, the upper die 13 is moved downward. This allows the pad 14 attached to the upper die 13 to also move downward, and causes the lower end of the upper die 13 to be firstly brought into contact with the work W. Then, the upper die 13 is further moved downward, so that the work W is pressed with the punch 12 and the pad 14 with a pressure given by the pad 14. This allows formation of the concave curved portion 10 in the central section of the work W (see
Thereafter, the upper die 13 is continuously moved downward while the work W is held between the punch 12 and the pad 14 for a drawing process. Accordingly, a cylindrical surface-like portion is formed in the work W (see
The upper die 13 is further continuously moved downward so that the work W is pressed with the press surface 13b and the outer circumferential section of the press surface 12a of the punch 12 (see
In the cross section illustrated in
Since three thickened portions are formed in this embodiment as described above, three thickening target regions T are set. The three thickening target regions T are set in such a manner as to appear at intervals of approximately 120° in the circumferential direction with respect to the center (a specific center) of the hole-like curved portion 8 (see
The cross-sectional views of
In the step illustrated in
In the step illustrated in
Next, the cylindrical drawn portion 7 is deformed in such a manner as to be gathered toward the central axis (cylindrical axis) side, and the portion around the concave curved portion 10 of the work W is thickened.
In this step, there are used a lower die (blank holder) 16 and a punch 17 as well as first and second upper dies 18 and 19 that are paired with and disposed above these members 16 and 17.
A columnar hole penetrating in the vertical direction is formed in the lower die 16. The punch 17 is guided in this hole and movable along the axial direction of this hole. The upper surfaces of the lower die 16 and the punch 17 constitute a pressing surface 16a and a press surface 17a, respectively.
A columnar hole penetrating in the vertical direction and having the substantially same lateral cross-sectional shape and size as those of the hole of the lower die 16 is formed in the first upper die 18. The second upper die 19 is guided in this hole and movable along the axial direction of this hole. The lower surface of the first upper die 18 constitutes a pressing surface 18a, and faces the pressing surface 16a of the lower die 16. The lower surface of the second upper die 19 constitutes a press surface 19a, and faces the press surface 17a of the punch 17.
The pressing surfaces 16a and 18a are flat. The central section of the press surfaces 17a and 19a has a dome-like shape having a diameter smaller than that of the cylindrical drawn portion 7. The outer circumferential sections of the press surfaces 17a and 19a are a flat surface. In the central cross section, the actual length of the press surfaces 17a and 19a is shorter than the actual length of the portion corresponding to the press surfaces 17a and 19a in the work W as the cylindrical drawn molded body 5. The actual length of the portion facing the concave curved portion 10 of the cylindrical drawn molded body 5 in the press surfaces 17a and 19a is particularly shorter than the actual length of the concave curved portion 10.
With reference to
Subsequently, the second upper die 19 is moved downward to be pressed against the work W. Since the diameter of the dome-like portion of the press surfaces 17a and 19a is smaller than the diameter of the cylindrical drawn portion 7, the work W is drawn in such a manner as to be gathered toward the central axis side (see
The second upper die 19 is further moved downward. Accordingly, the work W is gradually drawn toward the central axis side, and the second upper die 19 is pressed against the concave curved portion 10 of the work W (see
According to this step, the vicinity of three tops of the ring groove-like curved portion 9 having a triangular shape (see
In the step illustrated in
Next, the major portion of the thickening target region T in the work W is thickened by pressing.
In this step, there are used a lower die 21 and first and second upper dies 23 and 24 disposed above the lower die 21.
A columnar hole penetrating in the vertical direction is formed in the first upper die 23. The second upper die 24 is guided in this hole and movable along the axial direction of this hole.
A truncated cone-like protrusion 21P is formed on the top of the lower die 21. The upper surface of the lower die 21 constitutes a press surface 21a. On the press surface 21a, there is, around the protrusion 21P, a downward slope region in a direction away from the protrusion 21P. Around this downward slope region, there is a flat region arranged on the substantially same plane.
The lower surface of the second upper die 24 constitutes a press surface 24a, and faces the surface of the protrusion 21P and the downward slope region in the press surface 21a. The lower surface of the first upper die 23 constitutes a holding surface 23a which is flat, and faces the flat region in the press surface 21a.
Part of the downward slope region in the press surface 21a and the corresponding region in the press surface 24a correspond to the thickening target region T of a work W. As illustrated in
When the thickening target region T is thickened, the flat portion in the outer circumferential section of the work W is first held between the lower die 21 and the first upper die 23. At this time, the work W is pressed in a sufficiently strong manner with the lower die 21 and the first upper die 23, so that even application of a force in an in-plane direction to the work W by pressing does not cause the work W to move in such a direction. Then, the second upper die 24 is moved downward to be pushed against the work W for pressing the work W with the lower die 21 and the second upper die 24.
In the central cross section, the actual length of the region corresponding to the thickening target region T in the press surfaces 21a and 24a is shorter than the actual length of the thickening target region T. Therefore, this pressing causes the work W to be deformed such that the actual length of the thickening target region T decreases (see
On the other hand, in the region other than the thickening target region T in the work W, thickening is not caused to a degree similar to that in the thickening target region T.
Thereafter, a step of adjusting the shape of the work W, the thickness of the thickening target region T, and the like is further performed.
In this step, there are used a lower die 26 and first and second upper dies 28 and 29 disposed above the lower die 26.
A columnar hole penetrating in the vertical direction is formed in the first upper die 28. The second upper die 29 is guided in this hole and movable along the axial direction of this hole. The upper surface of the lower die 26 constitutes a press surface 26a. The lower surfaces of the first and second upper dies 28 and 29 constitute press surfaces 28a and 29a, respectively.
The shape of the press surface 26a is approximately the same as the shape obtained by aligning the positions of the holding surface 23a and the press surface 24a illustrated in
The press surface 29a and a region facing the press surface 29a in the press surface 26a correspond to the thickening target region T of the work W. In the press surface 21a illustrated in
For adjusting the shape of the work W and the thickness of the thickening target region T, the work W is first vertically inverted with respect to the state illustrated in
Subsequently, while the pressing of the work W with the lower die 26 and the first upper die 28 is maintained, the thickening target region T of the work W is pressed with the lower die 26 and the second upper die 29. In the central cross section, the actual length of the region corresponding to the thickening target region T in the press surface 26a and the actual length of the press surface 29a are shorter than the actual length of the thickening target region T. For this reason, this pressing causes the actual length of the thickening target region T to decrease. As a result, the thickening target region T is thickened to become a thickened portion A. At the same time, the thickened portion A and the flat portion (the flat plate portion 6 of the cylindrical drawn molded body 5) in the outer circumferential section of the work W become in a substantially flat state as a whole (see
Two other thickening target regions T which are not illustrated in
Consequently, there is obtained a plate-like molded body 40 including a plurality of thickened portions A in a region spaced apart from the edge in a substantially flat plate-like portion.
In the above-described embodiment, the major step for decreasing the actual length of the thickening target region T in the central cross section is the step illustrated in
<Second Embodiment>
In this embodiment, a plate-like member including three thickened portions formed around the center is manufactured.
The cylindrical drawn molded body 5 used in the first embodiment included the hole-like curved portion 8 and the ring groove-like curved portion 9. However, a cylindrical drawn molded body including only one of the hole-like curved portion 8 and the ring groove-like curved portion 9 may be used.
Hereinafter, a method of forming such a cylindrical drawn molded body 5A and using this for manufacturing a plate-like molded body will be described.
The lower die 31, the punch 32, the upper die 33, and the pad 34 have the approximately same configurations as the lower die 11, the punch 12, the upper die 13, and the pad 14 illustrated in
With reference to
Subsequently, the upper die 33 is moved downward, so that the work W is pressed with the punch 32 and the pad 44 with a pressure given by the pad 34 attached to the upper die 33. This allows formation of the concave curved portion 10A in the central section of the work W (see
Thereafter, the upper die 33 is continuously moved downward while the work W is held between the punch 32 and the pad 34 for a drawing process. Accordingly, a cylindrical surface-like portion is formed in the work W (see
The upper die 33 is further continuously moved downward so that the work W is pressed with the press surface 33b and the outer circumferential section of the press surface 32a of the punch 32 (see
In the cross section illustrated in
In the step illustrated in
Next, the cylindrical drawn portion 7 is deformed in such a manner as to be gathered toward the central axis side, and the portion around the concave curved portion 10A of the work W is thickened.
In this step, there are used a lower die 36 and a punch 37 as well as first and second upper dies 38 and 39 that are paired with and disposed above these members 36 and 37. The lower die (blank holder) 36, the punch 37, the first upper die 38, and the second upper die 39 have the approximately same configurations as the lower die 16, the punch 17, the first upper die 18, and the upper die 19 illustrated in
The central section of a press surface 37a of the punch 37 and the central section of a press surface 39a of the second upper die 39 have a dome-like shape having a diameter smaller than that of the cylindrical drawn portion 7. In the central cross section, the actual length of the press surfaces 37a and 39a is shorter than the actual length of a portion corresponding to the press surfaces 37a and 39a in the work W as the cylindrical drawn molded body 5A. The actual length of the portion corresponding to the concave curved portion 10A of the cylindrical drawn molded body 5A in the press surfaces 37a and 39a is particularly shorter than the actual length of the concave curved portion 10A.
With reference to
Subsequently, the second upper die 39 is moved downward to be pressed against the work W. Since the diameter of the dome-like portion of the press surfaces 37a and 39a is smaller than the diameter of the cylindrical drawn portion 7, the work W is deformed in such a manner as to be gathered toward the central axis side (see
Furthermore, the second upper die 39 is moved downward to press the second upper die 39 against the concave curved portion 10A of the work W (see
However, since the concave curved portion 10A does not contain the ring groove-like curved portion 9 (see
Thereafter, steps similar to the step illustrated in
However, since the thickening by pressing the ring groove-like curved portion 9 is not obtained, the thickening rate of the thickened portion obtained in the manufacturing method according to the second embodiment is smaller than the thickening rate of the thickened portion obtained by the manufacturing method according to the first embodiment. However, even in the second embodiment, the thickened portion has a thickening rate of 20% or more with respect to an initial plate thickness as the plate thickness of the cylindrical drawn molded body, and has a length of five times or more the initial plate thickness in the central cross section.
In the above description, when press is performed with a lower mold and an upper mold, the upper mold may be moved downward instead of moving the lower mold upward, and the lower mold may be moved upward instead of moving the upper mold downward.
As described above, in the thickening step, the actual length of the thickening target region T is decreased while wrinkles generated by out-of-plane deformation during molding are suppressed. Accordingly, the thickening target region T is thickened to become a thickened portion. Also, in the thickening step, the thickening target region T and the flat plate portion (the outer circumferential section of the cylindrical drawn molded body) come into a flat state as a whole. For this reason, according to this method, there can be manufactured a plate-like molded body having a thickened portion in a region spaced apart from the edge in a substantially flat plate-like portion.
In addition, two or more thickening target regions T are set along the circumferential direction with respect to a specific center. Therefore, according to this method, there can be manufactured a plate-like molded body on which a plurality of thickened portions appear along the circumferential direction with respect to the center.
Furthermore, the actual length of the concave curved portion 10 is longer than that of the cross section that does not include a concave curvature. Since the thickening target region T is formed in a region containing at least part of the concave curved portion 10, the concave curved portion 10 is thickened particularly thickly in the thickening target region T by pressing in the thickening step.
Therefore, according to the manufacturing methods of the above-described embodiments, there can be molded a plate-like molded body in which when t [mm] is a standard plate thickness, a plate thickness ti [mm] of a thickened portion and a plate thickness td [mm] of a thinned portion satisfy relational formulae below:
when 2.0<t<3.0, td≥0.9t, ti≥1.25t,
when 3.0<t<4.0, td≥0.9t, ti≥1.35t, and
when 4.0<t<5.0, td≥0.9t, ti≥1.45t.
Thus, according to the manufacturing methods of the above-described embodiments, the thickened portion having been thickened with respect to the standard plate thickness and the thinned portion having been slightly thinned with respect to the standard plate thickness are formed depending on the standard plate thickness. The maximum thinning rate in the thinned portion is approximately 90%, which demonstrates that the outflow of the material is suppressed to a minimum. Therefore, according to the above-described embodiments, molding in a state in which a material is held between the punch 12 and the pad 14 enables molding of the cylindrical drawn molded bodies 5 and 5A that suppress the outflow of the material in the thinned portion and that are thickened by 25% or more in the thickened portion.
It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof.
| Number | Date | Country | Kind |
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| 2014-069162 | Mar 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
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| PCT/JP2015/059764 | 3/27/2015 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2015/147297 | 10/1/2015 | WO | A |
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| 20160332205 A1 | Nov 2016 | US |
