A certain embodiment of the present disclosure relates to a molding device.
In the related art, a device described in the related art is known as a molding device that molds a metal material. The molding device molds a plate-shaped member into a component having a desired shape by pressing the member.
According to an aspect of the present disclosure, there is provided a molding device that heats a metal material and performs quenching and that molds a plurality of components having shapes different from each other in one time of molding with respect to one metal material.
According to another aspect of the present disclosure, there is provided a molding device that performs expansion molding by supplying a fluid to a metal material and that molds a plurality of components having shapes different from each other in one time of molding with respect to one metal material.
The component molded by the molding device described above is used in order to construct a predetermined structure. Therefore, it is required for the molding device to mold a plurality of components by performing a plurality of times of pressing. However, in a case where the number of components of the structure increases, a problem of an increase in man-hours arises since the number of times of pressing increases.
Therefore, it is desirable to provide a molding device that can reduce man-hours for manufacturing a plurality of components.
The molding device is the molding device that performs molding by heating the metal material and performing quenching. The molding device molds the plurality of components having shapes different from each other in one time of molding with respect to the one metal material. For this reason, the molding device can mold the plurality of components at once only by performing one time of molding with respect to the one metal material. For this reason, man-hours for manufacturing the plurality of components can be reduced.
The molding device is the molding device that performs expansion molding by supplying the fluid to the metal material. The molding device molds the plurality of components having shapes different from each other in one time of molding with respect to the one metal material. For this reason, the molding device can mold the plurality of components at once only by performing one time of molding with respect to the one metal material. For this reason, man-hours for manufacturing the plurality of components can be reduced.
The molding device may mold a component having a closed section as the component. In this case, the number of components can be reduced compared to a case of forming a structure in which a plurality of components are combined.
The molding device may mold a long first component and a second component and a third component, which are on both sides of the first component in a longitudinal direction, as the plurality of components. Accordingly, as the long first component is molded, the second component and the third component can be added to both sides thereof in the longitudinal direction and be molded.
The molding device may have differential strength between one component and another component of the plurality of components. Accordingly, strength is easily adjusted according to use of each component.
Hereinafter, a preferred embodiment of a molding device according to the present disclosure will be described with reference to the drawings. In each drawing, the same reference signs will be assigned to the same portions or equivalent portions, and redundant description thereof will be omitted.
The molding die 2 is a die that molds the metal pipe material 40 into a metal pipe 140 and includes a lower die 11 and an upper die 12 that face each other in an up-down direction. The lower die 11 and the upper die 12 are configured by blocks made of steel. Each of the lower die 11 and the upper die 12 is provided with a recessed part in which the metal pipe material 40 is accommodated. In a state where the lower die 11 and the upper die 12 are in close contact with each other (die closed state), respective recessed parts form a space having a target shape, into which the metal pipe material is to be molded. Therefore, surfaces of the respective recessed parts become forming surfaces of the molding die 2. The lower die 11 is fixed to a base stage 13 via a die holder or the like. The upper die 12 is fixed to a slide of the drive mechanism 3 via a die holder or the like.
The drive mechanism 3 is a mechanism that moves at least one of the lower die 11 and the upper die 12. In
The holding unit 4 is a mechanism that holds the metal pipe material 40 disposed between the lower die 11 and the upper die 12. The holding unit 4 includes a lower electrode 26 and an upper electrode 27 that hold the metal pipe material 40 on one end side in the longitudinal direction of the molding die 2 and a lower electrode 26 and an upper electrode 27 that hold the metal pipe material 40 on the other end side in the longitudinal direction of the molding die 2. The lower electrodes 26 and the upper electrodes 27 on both sides in the longitudinal direction hold the metal pipe material 40 with vicinities of end portions of the metal pipe material 40 sandwiched therebetween from the up-down direction. Groove portions having a shape corresponding to an outer peripheral surface of the metal pipe material 40 are formed in upper surfaces of the lower electrodes 26 and lower surfaces of the upper electrodes 27. Drive mechanisms (not shown) are provided in the lower electrode 26 and the upper electrode 27 and are movable independently of each other in the up-down direction.
The heating unit 5 heats the metal pipe material 40. The heating unit 5 is a mechanism that heats the metal pipe material 40 by energizing the metal pipe material 40. The heating unit 5 heats the metal pipe material 40 in a state where the metal pipe material 40 is separated apart from the lower die 11 and the upper die 12 between the lower die 11 and the upper die 12. The heating unit 5 includes the lower electrodes 26 and the upper electrodes 27 on both sides in the longitudinal direction described above and a power supply 28 that causes a current to flow to the metal pipe material 40 via the electrodes 26 and 27. The heating unit may be disposed in a preceding process of the molding device 1 and may perform heating externally.
The fluid supply unit 6 is a mechanism for supplying a high-pressure fluid into the metal pipe material 40 held between the lower die 11 and the upper die 12. The fluid supply unit 6 supplies the high-pressure fluid into the metal pipe material 40 that has been brought into a high-temperature state by being heated by the heating unit 5 and expands the metal pipe material 40. The fluid supply units 6 are provided on both end sides of the molding die 2 in the longitudinal direction. The fluid supply units 6 each include a nozzle 31 that supplies a fluid from opening portions of the end portions of the metal pipe material 40 to an inside of the metal pipe material 40, a drive mechanism 32 that moves the nozzle 31 to advance and retreat with respect to the opening portions of the metal pipe material 40, and a supply source 33 that supplies the high-pressure fluid into the metal pipe material 40 via the nozzle 31. The drive mechanism 32 brings the nozzle 31 into close contact with the end portion of the metal pipe material 40 in a state where a sealing property is secured during fluid supply and exhaust and separates the nozzle 31 from the end portion of the metal pipe material 40 at other times. The fluid supply unit 6 may supply a gas such as high-pressure air and an inert gas as the fluid. In addition, the fluid supply unit 6 may be the same device including the holding unit 4 that includes a mechanism which moves the metal pipe material 40 in the up-down direction and the heating unit 5.
Components of the holding unit 4, the heating unit 5, and the fluid supply unit 6 may be configured as a unitized heating and expanding unit 150.
As shown in
The nozzle 31 is a cylindrical member into which the end portion of the metal pipe material 40 can be inserted. The nozzle 31 is supported by the drive mechanism 32 such that a center line of the nozzle 31 matches a reference line SL1. An inner diameter of a feed port 31a at an end portion of the nozzle 31 on a metal pipe material 40 side substantially matches an outer diameter of the metal pipe material 40 after expansion molding. In this state, the nozzle 31 supplies a high-pressure fluid from an internal flow path 63 to the metal pipe material 40. Examples of the high-pressure fluid include a gas.
Returning to
The control unit 8 is a device that controls the entire molding device 1. The control unit 8 controls the drive mechanism 3, the holding unit 4, the heating unit 5, the fluid supply unit 6, and the cooling unit 7. The control unit 8 repeatedly performs an operation of molding the metal pipe material 40 with the molding die 2.
Specifically, the control unit 8 controls, for example, a transport timing from a transport device such as a robot arm to dispose the metal pipe material 40 between the lower die 11 and the upper die 12 in an open state. Alternatively, a worker may manually dispose the metal pipe material 40 between the lower die 11 and the upper die 12. In addition, the control unit 8 controls an actuator or the like of the holding unit 4 such that the metal pipe material 40 is supported by the lower electrodes 26 on both sides in the longitudinal direction and then the upper electrodes 27 are lowered to sandwich the metal pipe material 40. In addition, the control unit 8 controls the heating unit 5 to energize and heat the metal pipe material 40. Accordingly, a current in an axial direction flows through the metal pipe material 40, and an electric resistance of the metal pipe material 40 itself causes the metal pipe material 40 itself to generate heat due to Joule heat.
The control unit 8 controls the drive mechanism 3 to lower the upper die 12 and to bring the upper die 12 close to the lower die 11, closing the molding die 2. Meanwhile, the control unit 8 controls the fluid supply unit 6 to seal the opening portions of both ends of the metal pipe material 40 and to supply a fluid with the nozzle 31. Accordingly, the metal pipe material 40 softened by heating expands and comes into contact with the forming surface of the molding die 2. Then, the metal pipe material 40 is molded to follow the shape of the forming surface of the molding die 2. In a case of forming a metal pipe with a flange, after a part of the metal pipe material 40 has entered a gap between the lower die 11 and the upper die 12, die closing is further performed to crush the entered portion to become a flange portion. When the metal pipe material 40 comes into contact with the forming surface, quenching of the metal pipe material 40 is performed by being rapidly cooled with the molding die 2 cooled by the cooling unit 7.
Procedures of molding of the molding device 1 will be described with reference to
Next, what type of molding product 41 can be molded by the molding device 1 according to the present embodiment will be described. The molding device 1 is the molding device 1 that heats the metal pipe material 40 (metal material) and that performs quenching and can mold a plurality of components in one time of molding with respect to one metal pipe material 40. In addition, the molding device 1 is the molding device 1 that performs expansion molding by supplying a fluid to the metal pipe material 40 (metal material) and can mold a plurality of components in one time of molding with respect to one metal pipe material 40. One time of molding is a series of processes from the setting of a new metal pipe material 40 at the molding device 1 to molding of the molding product 41. In the molding device 1 according to the present embodiment, a series of processes including disposition, heating, and expansion molding of the metal pipe material 40 described above in the die 12 correspond to one time of molding. One metal material is a material made of a metal in a state of continuously extending without being cut in the middle.
The molding product 41 will be described with reference to
A boundary portion of each portion of the molding product 41 is cut through laser processing or the like. Accordingly, the first component 50, the second component 51, and the third component 52 can be treated as one independent component.
Since the entire molding product 41 is a tubular member, the components 50, 51, and 52 have a closed section. That is, the molding device 1 molds the components 50, 51, and 52 having a closed section as components.
The molding device 1 may have differential strength between one component and another component of a plurality of components. For example, the molding device 1 may have differential strength by making the strength of the first component 50 higher than those of the second component 51 and the third component 52. As a method of providing differential strength, the molding device 1 may perform molding such that quenching is performed with respect to a component having high strength and quenching is not performed with respect to a component having low strength. For example, the cooling unit 7 (see
Next, further specific examples of components molded by the molding device 1 will be described with reference to
The bumper beam 80 and the crush tube 82 are components configuring a front bumper 100 of a vehicle shown in
As shown in
As shown in
As shown in
Next, operations and effects of the molding device 1 according to the present embodiment will be described.
The molding device 1 according to the present embodiment is the molding device 1 that heats the metal pipe material 40 (metal material) and that performs quenching and molds a plurality of components in one time of molding with respect to one metal pipe material 40.
The molding device 1 is the molding device 1 that performs molding by heating the metal pipe material 40 and performing quenching. The molding device 1 molds a plurality of components in one time of molding with respect to one metal pipe material 40. For this reason, the molding device 1 can mold the plurality of components at once only by performing one time of molding with respect to the one metal pipe material 40. For this reason, man-hours for manufacturing the plurality of components can be reduced.
The molding device 1 according to the present embodiment is the molding device 1 that performs expansion molding by supplying a fluid to the metal pipe material 40 (metal material) and molds a plurality of components in one time of molding with respect to one metal pipe material 40.
The molding device 1 is the molding device 1 that performs expansion molding by supplying a fluid to the metal pipe material 40. The molding device 1 molds a plurality of components in one time of molding with respect to one metal pipe material 40. For this reason, the molding device 1 can mold the plurality of components at once only by performing one time of molding with respect to the one metal pipe material 40. For this reason, man-hours for manufacturing the plurality of components can be reduced.
The molding device 1 may mold a component having a closed section as a component. In this case, the number of components can be reduced compared to a case of forming a structure in which a plurality of components are combined.
The molding device 1 may mold the long first component 50 and the second component 51 and the third component 52, which are on both sides of the first component 50 in the longitudinal direction, as a plurality of components. Accordingly, as the long first component 50 is molded, the second component 51 and the third component 52 can be added to both sides thereof in the longitudinal direction and be molded.
The molding device 1 may have differential strength between one component and another component of a plurality of components. Accordingly, strength is easily adjusted according to use of each component.
An effect in a case of creating the front bumper 100 using the molding device 1 of the present embodiment will be described. Such a front bumper 100 is simply called an “example” in some cases. A case of creating a front bumper 200 shown in
On the contrary, the molding device 1 of the present embodiment manufactures configuring components of the front bumper 100 according to the example in a steel tube air forming (STAF) process. Each of the bumper beam 80 and the crush tubes 81 and 82 is configured by one component. For this reason, the front bumper 100 can be kept to five components instead of eight components in the comparative example, and the number of components can be significantly reduced. In addition, in the front bumper 200 according to the comparative example, it is required to perform spot welding at dozens of places by bonding the components 180a and 180b that have been trimmed and drilled after being molded through pressing or roll forming. On the contrary, in the front bumper 100 according to the example, the process is completed only by trimming and drilling after molding the bumper beam 80. Accordingly, performance man-hours can be significantly reduced. The same applies to the crush tubes 81 and 82.
Further, as shown in
The front bumper 100 according to the example was evaluated through a strength test. The front bumper 100 according to the example and the front bumper 200 according to the comparative example were subjected to static press evaluation through analysis using a test device 170 shown by an imaginary line of
The present disclosure is not limited to the embodiment described above. For example, the entire configuration of the molding device is not limited to that shown in
An aspect of a combination of a plurality of components is not limited. For example, the molding device may mold two components including a first component and a second component from one metal material. In addition, the molding device may mold four or more components from one metal material.
Although an example in which the front bumper is manufactured using a component molded by the molding device 1 has been described, a component of a rear bumper may be molded.
In addition, a component molded by the molding device 1 is not limited to a configuring component of the front bumper, the rear bumper, or the like, and other components may be molded. For example, as shown in
The molding device may be a molding device that heats a metal material and that performs quenching, or a molding device using a hot stamping method may be adopted.
In addition, the molding device may be a molding device that performs expansion molding by supplying a fluid to a metal material, or a molding device using a hydroforming method may be adopted.
It should be understood that the invention is not limited to the above-described embodiment, but may be modified into various forms on the basis of the spirit of the invention. Additionally, the modifications are included in the scope of the invention.
Number | Date | Country | Kind |
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2021-146105 | Sep 2021 | JP | national |
This is a bypass continuation of International PCT Application No. PCT/JP2022/033727, filed on Sep. 8, 2022, which claims priority to Japanese Patent Application No. 2021-146105, filed on Sep. 8, 2021, which are incorporated by reference herein in their entirety.
Number | Date | Country | |
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Parent | PCT/JP2022/033727 | Sep 2022 | US |
Child | 18418187 | US |