JP2004034117A - Method for working plate material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for working a plate material with which flow-out of the material with an upsetting work by performing a different thickness formation having a bending part while interposing the bending part. <P>SOLUTION: In the method for working the plate material, with which for producing a product having thicker plate of the one side of member 8b than the thickness of the other side of member 8c in the plate having the bending part 8a while interposing the bending part 8a, after applying the bending work, the thickness-increasing formation of the other side of member 8b is applied, the upsetting work process for forming the increased thickness part 8d having the difference of level 8de on the outer peripheral surface of the other side of member 8d extended to the outside of the bending part 8a by upsetting the other side of member 8b, is provided. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は板材の加工方法に関し、特に曲げ形状、例えばＬ型断面形状を有し、かつ曲げ部を挟んで差厚成形を行なうための板材の加工方法に関する。
【０００２】
【従来の技術】
Ｌ型断面形状等の曲げ部を有し、かつ曲げ部を挟んで一方を他方の板厚より厚くする製品を製造する方法として、切削加工により製造する方法が知られている。
【０００３】
【発明が解決しようとする課題】
従来技術による製造方法では、切削による無駄材料が発生する。この対策として、プレス加工により製造する方法が考えられる。しかしながら、プレス加工で行なうためには、以下の問題がある。第１に、一方の側壁部を他方の底部の肉厚より厚くなるように増肉させるため、側壁部を据え込み加工する場合において、底部へも据え込み加工に伴って材料の流れ込みが生じる。この材料の流れ込みによる底部の肉厚増加は、後工程にて、潰し加工によって成形し直す必要がある場合がある。この材料の流れ込みは据え込み加工による塑性変形を伴うため、潰し加工を行なうには、大きな加工荷重が必要となる。この流れ込み量が大きくなるに従い加工荷重もさらに大きくなるため、使用設備も大型化してしまって、結果として製造コストの増大を招く恐れがある。
【０００４】
第２に、プレス加工の生産性向上を図るためには、据え込み加工において、増肉比率を高める必要があり、材料の挫屈による巻き込みが発生する。この巻き込み量が大きくなると、製品に望ましくない強度低下等の製品品質への悪影響を及ぼす可能性がある。
【０００５】
本発明は、このような事情を考慮してなされたものであり、その目的は、曲げ部を有し曲げ部を挟んで差厚成形を行なうもので、据え込み加工による材料の流れ込みを抑制可能な板材の加工方法を提供することにある。
【０００６】
また、別の目的は、据え込み加工による材料の流れ込みの抑制が図れるとともに、生産性の向上が図れる板材の加工方法を提供することにある。
【０００７】
【課題を解決するための手段】
本発明の請求項１によると、曲げ部を有し、この曲げ部を挟んで一方の部材を他方の部材より板厚を厚くする製品を製造するため曲げ加工後、その一方の部材の増肉成形を行なう板材の加工方法であって、一方の部材を据え込むことで、曲げ部の外側に延在する一方の部材の外周面に、段差を有する増肉部を形成する据え込み加工工程を備えている。
【０００８】
一般に、曲げ部から延びる部材すなわち一方の部材を据え込み加工によって増肉させる場合、据え込み加工による加工荷重は、一方の部材および曲げ部に加わる。このため、曲げ部の曲げＲは、増肉成形されるに従いその曲げＲが小さくなる傾向がある。その結果、据え込み加工すなわち塑性加工中、加工荷重による材料流動が一方の部材だけでなく、曲げ部にも発生する。据え込み加工による所定の外側Ｒになるまでは、一方の部材および曲げ部の塑性変形によって挫屈し易い。
【０００９】
これに対して、本発明の板材の加工方法では、曲げ部の外側に延在する一方の部材の外周面に形成される増肉部に段差を設けるので、段差を形成する据え込み加工用冶具によって段差には、挫屈時に働く力と逆向きの力いわゆる反力を加えることが可能である。したがって、挫屈現象の発生を抑制するとともに、曲げ部への材料流動を抑制することが可能である。
【００１０】
本発明の請求項２によると、段差とは、他方の部材の底面より一方の部材が延在する方向に向かって、所定の高さに形成される段差である。
【００１１】
すなわち、曲げ部の外側に延在する一方の部材の外周面に形成される増肉部の段差は、所定の高さに対応する曲げ部の外側Ｒの途中に形成される。これにより、据え込み加工による曲げ部への材料流動を確実に抑制できる。
【００１２】
本発明の請求項３によると、据え込み加工工程に使用する据え込みパンチとダイにおいて、ダイの内周は、他方の部材の底面に沿う底支持部と、他方の部材から延びる曲げ部の途中まで曲げ部に沿う曲げ支持部と、曲げ支持部から他方の部材の延在する方向に向かって形成される段差支持部と、段差支持部から一方の部材が延在する方向に延びる増肉支持部を備えている。
【００１３】
すなわち、ダイの内周は、他方の部材の底面、他方の部材から延びる曲げ部、および他方の部材の延在する方向のぞれぞれに沿って形成される底支持部と曲げ支持部と段差支持部とから構成されている。これにより、ダイは、増肉部の段差に、挫屈時に働く力と逆向きの力いわゆる反力を加えることが容易となる。
【００１４】
なお、その結果、据え込み加工による材料の流れは、段差支持部と増肉支持部とで区画される空間つまり増肉部を形成するための空間に流れ込み易くなる。
【００１５】
本発明の請求項４によると、据え込みパンチと協働するダイには、他方の部材を挟んで、他方の部材をダイに向かって押圧する付勢手段を有する材料押さえ冶具が設けられている。
【００１６】
これにより、本発明の板材の加工方法では、増肉部に段差を設ける据え込み加工を行なうことで、材料流動の抑制を図るので、加工対象の板材つまり他方の部材をダイに押さえ付ける手段として、例えば簡単な圧縮ばね等の付勢手段で対応可能である。
【００１７】
本発明の請求項５によると、ダイと協働する据え込みパンチを型締め方向に駆動し、ダイと材料押さえ冶具の離間距離が所定長になったとき、据え込みパンチは、ダイへの押圧を開始する。
【００１８】
これにより、本発明の板材の加工方法では、据え込み加工による材料流動の抑制を図ることで、他の部材への材料の流れ込みを少なくすることが可能であるので、一方の部材の増肉形成のための据え込み加工と、据え込み加工による材料流動によって生じた他方の部材の部分的な板厚増加を、整形する潰し加工の同時加工が可能である。従って工程が簡素になり、生産性向上が図れる。
【００１９】
【発明の実施の形態】
以下、本発明の板材の加工方法を、曲げ部を有し、その曲げ部を挟んで一方の部材を他方の部材より板厚を厚くする製品における板材の加工方法に具体化した実施形態を図面に従って説明する。
【００２０】
（第１の実施形態）
図１は、本実施形態に係わる板材の加工方法の工程を説明する模式図である。図２は、本発明の板材の加工方法を適用して製造する製品の形状の一実施例を表す断面図である。図３は、図１中の増肉工程において、据え込み加工により被加工物を増肉するために用いる冶具および被加工物としての板材に増肉部が形成される過程を表す模式的断面図であって、図３（ａ）は据え込み加工開始前の状態、図３（ｂ）は据え込み加工開始直後の状態、図３（ｃ）は据え込み加工を継続している状態、図３（ｄ）は据え込み加工が終了した状態を表す断面図である。なお、図４は、本実施形態に係わる被加工物の板材において、曲げ加工後にその板材を据え込み加工する際、据え込み加工による板材内部の材料流動と段差との関係を示す模式図である。
【００２１】
図１に示すように、本発明の板材の加工方法は、曲げ工程Ｐ１と増肉工程Ｐ２とを備えている。これにより、本実施形態では、被加工物としての板材８に、曲げ部８ａを形成させ、その曲げ部８ａを挟んで一方の部材８ｂの板厚を他方の部材８ｃの肉厚より大きくなるように、加工を行なう。なお、本発明の板材の加工方法を適用する板材の製品形状としては、図２に示すように、被加工物８は、曲げ形状を有している。その曲げ部８ａは略直角に曲げられるものに限らず、鈍角に曲げられているものであってもよい。本発明の板材の加工方法を用いて形成可能な被加工物８の製品形状の詳細については後述する（図８に示す各実施態様を参照）。なお、本実施形態で説明する被加工物８は、以下、図２の上下方向に延在する一方の部材８ｂを側壁部と呼び、図２の左右方向に延在する他方の部材８ｃを底部と呼ぶ。なお、図１は、本実施形態に係わる工程順に従って、板材８が加工される状態を説明する。図１の左から右方向に向かって、工程名、その工程の説明、および板材８が加工される状態を順に示す。また、図１の上から下に向かって本実施形態に係わる工程の流れを示している。
【００２２】
曲げ工程Ｐ１は、図１に示すように、初期状態で平板状の板材８を、最終的に内側曲げＲが略所定の半径Ｒａｉになるように曲げ加工を行なう周知の曲げ加工冶具または設備であればいずれでもよい。
【００２３】
増肉工程Ｐ２は、図１に示すように、曲げ工程Ｐ１にて曲げ部８ａが形成された板材８に据え込み加工を繰返し行なう。詳しくは、板材８の側壁部８ｂの端部を曲げ部８ａ側に向かって据え込む。増肉工程Ｐ２は、図１に示すように、据え込み加工工程Ｐ２１を備えている。この据え込み加工工程Ｐ２１を、Ｎ＝１からＮ＝ｎ回繰り返すことで、側壁部８ｂを繰返し据え込んで所望の増肉形状に成形する（本実施形態では、Ｎ＝４回の繰返しを実施）。なお、据え込み加工工程Ｐ２１に使用する冶具の詳細構造については後述する。本実施形態では、この据え込み加工工程Ｐ２１による据え込み加工によって、側壁部８ｂの外周面（詳しくは、曲げ部８ａの外側Ｒａｏ側に延在する外周面）に、図１に示すように、段差８ｄｅを有する増肉部８ｄを形成する。
【００２４】
ここで、据え込み加工工程Ｐ２１に使用する冶具、およびその冶具を使用して形成される増肉部８ｄ、特に段差８ｄｅについて、図３および図４に従って説明する。なお、図５は、本実施形態（図３参照）と比較する比較例であって、増肉部８ｄに段差８ｄｅを有しない板材８の製品を製造する場合の工程を示す。また、図６は、その比較例に係わる据え込み加工による板材内部の材料流動を示す模式図である。
【００２５】
図３（ａ）の据え込み加工開始前の状態では、曲げ部８ａを有する板材８は、ダイ２に保持され、側壁部８ｂが延在する方向（図３（ａ）の上下方向）に向かって側壁部８ｂの上方に据え込みパンチ１が配置されている。この据え込みパンチ１とダイ２は、据え込み加工用冶具を構成し、協働する。本実施形態では、互いに協働する据え込みパンチ１とダイ２は、型締めする方向に駆動され、据え込みパンチ１とダイ２の軸方向端面が当接して、１回分に当たる据え込み加工が終了できる構成となっている。なお、本実施形態では、ダイ２の内周に収容された板材８において、板材８の内側曲げＲａｉ側の内周をガイドする材料押さえ冶具３を設けている。これにより、板材８（詳しくは、側壁部８ｂ）を据え込み加工時に、側壁部８ｂの内周側が増肉されないように保持することができるとともに、曲げ加工Ｐ１にて成形された板材８の曲げ部８ａの曲げ形状の維持することが可能である。
【００２６】
ダイの内周は、底部８ｃの底面に沿う底支持部２ａと、底部８ｃから延びる曲げ部８ａの途中まで曲げ部８ａに沿う曲げ支持部２ｂと、曲げ支持部２ｂから底部８ｃが延材する方向（図３（ａ）の左右方向）に向かって形成される段差支持部２ｃと、段差支持部２ｃから側壁部８ｂが延在する方向（図３（ａ）の上下方向）に延びるように形成される増肉支持部２ｄを備えている。段差支持部２ｃと増肉支持部２ｄ、および側壁部８ｂの外周面とで区画される空間Ｒ１（図３（ａ）参照）は、増肉部８ｄの一部を構成する空間Ｒ２である。なお、この空間Ｒ２は、板材８の製品としての所望の形状に応じて、増肉部８ｄを構成する空間であってもよい。さらになお、空間Ｒ２を増肉部８ｄの一部とする場合は、据え込みパンチ１の内周は、同様に図３（ｂ）に図示する空間Ｒ１を形成するように構成されている。空間Ｒ１と空間Ｒ２を合せた容積が、板材８つまり側壁部８ｂを据え込んで増肉成形させる増肉部８ｄの容積である。
【００２７】
次に、図３（ｂ）の据え込み加工開始直後の状態では、ダイ２に協働する据え込みパンチ１が、いわゆる型締め方向（図３（ｂ）の矢印方向）に駆動される。この結果、据え込みパンチ１は、側壁部８ｂの軸方向端部に当接し、据え込み荷重を側壁部８ｂすなわち板材８に加える。これにより、側壁部８ｂおよび曲げ部８ａは、据え込み加工によって塑性変形が開始され、板材８内部の材料流動が始まる。なお、板材８内部の材料流動の詳細については後述する。
【００２８】
次に、図３（ｃ）の据え込み加工を継続している状態では、据え込み加工によって側壁部８ｂの軸方向端部に加工荷重が加えられた結果、側壁部８ｂの根元側、つまり曲げ部８ａの周りから塑性変形による材料流動によって増肉部８ｄの一部が形成され始める。本実施形態では、ダイ２の内周に曲げ支持部２ｂおよび段差支持部２ｃを備えるので、曲げ支持部２ｂによって支持された曲げ部８ａは塑性変形が抑制され、曲げ支持部２ｂによって支持されていない曲げ部８ａが段差支持部２ｃに沿って、塑性変形により材料流動する、すなわち増肉成形される。この結果、段差支持部８ｃに形成された初期状態の増肉部８ｄは、据え込み加工を継続するに従って、側壁部８ｂの延在する方向へその増肉部８ｄの容積を拡大していく。
【００２９】
つまり、側壁部８ｂに形成される増肉部８ｄは、据え込み加工の全過程を通じて、段差８ｄｅを支持する段差支持部２ｃによって保持されている。これにより、据え込み加工を継続（つまり、いわゆる増肉比率Ｔ２／Ｔ１（図２参照）の増加）に従い挫屈が生じるような加工荷重が加えられるようになったとしても、段差支持部２ｃによって、挫屈時に働く力と逆向きの力である反力を、段差８ｄｅつまり増肉部８ｄに加えることができる。したがって、挫屈現象の発生を抑制することが可能である。さらにまた、これにより、１回の据え込み加工による増肉比率Ｔ２／Ｔ１を高めて（本実施形態では、Ｔ２／Ｔ１が約１．３程度）、増肉工程Ｐ２内の工程数の削減、つまり据え込み加工工程Ｐ２１の据え込み回数Ｎの低減が図れる。したがって、本発明の板材の加工方法に係わる工程の簡素化が図れるとともに、生産性の向上が図れる。
【００３０】
さらに本実施形態では、ダイ２の内周は、底部８ｃの底面、底部８ｃから延びる曲げ部８ａ、および底部８ｃが延材する方向のそれぞれに沿って形成される底支持部２ａ、曲げ支持部２ｂ、段差支持部２ｃを備えるので、底支持部２ａ、曲げ支持部２ｂによって曲げ部８ａへの材料流動の抑制を図れる。さらに、成形する板材８に、切欠き形状の段差を設けることなく、挫屈時に働く力と逆向きの力となる反力を加えることが可能な、板材８の表面に形成される滑らかな段差を容易に形成することが可能である。さらに、本実施形態では板材８の表面に滑らかな段差８ｄｅを形成することが可能であるので、切欠き形状を有する段差のように切欠き等を起点として発生する強度低下等の製品品質を阻害するような現象の防止が図れる。
【００３１】
さらにまた、ダイ２の内周は、底支持部２ａ、曲げ支持部２ｂ、段差支持部２ｃを備えるので、据え込み加工による板材８内部の材料の流れを、少なくとも空間Ｒ１つまり増肉部８ｄを形成するための空間Ｒ１、Ｒ２に流れ込み易くする相乗効果がある。
【００３２】
次に、図３（ｄ）の据え込み加工を終了した状態では、段差８ｄｅを起点として増肉された増肉部８ｄｅの容積が、ダイ２および据え込みパンチ１のそれぞれの内周に形成された空間Ｒ２（図３（ａ）参照）と空間Ｒ１（図３（ｂ）参照）との和の容積まで成形することができる。しかも、上記据え込み加工にて挫屈現象による巻き込み不具合の防止が可能である。
【００３３】
ここで、本発明の板材の加工方法の特徴である段差８ｄｅを有する増肉部８ｄを増肉成形する際の、板材８内部の材料流動について検証確認を行なったので、以下図４に従って説明する。なお、増肉部８ｄに段差８ｄｅなく増肉成形する従来技術を適用した比較例（図５、図６参照）と対比して説明する。
【００３４】
まず、従来技術を適用して板材の製品を製造する場合の比較例では、図５に示すように、ダイ２の内周は、底支持部２ａ、および増肉支持部２ｄから構成されている。すなわち、曲げ部８ａの少なくとも途中まで曲げ部８ａに沿って曲げ部８ａを支持する曲げ支持部２ｂがない。なお、増肉部支持部２ｄとして、増肉によって形成された曲げＲ形状を支持する増肉曲げ形状支持部２ｄｂはある。このため、据え込み加工を開始すると、据え込み加工による加工荷重が側壁部８ｂだけでなく、曲げ部８ａ全体に加わってしまう。その結果、図６に示すように、板材８の内部の材料流動が顕著になる。曲げ部８ａに流れ込んだ材料の流れは、底部８ｃの根元側の曲げ部８ａの周辺で、板厚が当初の板厚、あるいは曲げ工程Ｐ１で成形された板厚に反して、材料の流れ込み分だけ板厚が増加する現象が発生する。さらになお、場合によっては、図３（Ｃ）に示すように挫屈現象が進行してしまって、内側Ｒａｉが小さくなり、曲げ工程Ｐ１の曲げ加工による材料硬化した板材８の部分と、後工程である増肉工程Ｐ２の据え込み加工によって新たに材料硬化した板材８の部分との境界で巻き込み現象（例えば比較例の図１０参照）が発生する。
【００３５】
これに対して、本実施形態では、ダイ２の内周の構成として、曲げ部８ａの少なくとも途中まで曲げ部８ａに沿って曲げ部８ａを支持する曲げ支持部２ｂを有する。さらに、図４に示すように、挫屈時に働く力に対して、段差支持部２ｃによって挫屈時に働く力とは逆向きの反力を、板材８つまり側壁部８ｂおよび曲げ部８ａに作用させることができる。その結果、本実施形態では、図４に示すように、板材８内部の材料の流れが曲げ部８ａへ流れ込む材料流動を抑制することができる。
【００３６】
上述の実施形態において、据え込み加工工程Ｐ２１に係わる冶具を構成する据え込みパンチ１、ダイ２、および材料押さえ冶具３のうち、材料押さえ冶具３に底部８ｃをダイ２に向かって押圧する付勢手段Ｐを設けてもよい。これにより、段差８ｄｅに起因して曲げ部８ａへ流れ込む材料流動が抑制された状態で、なお曲げ部８ａに流れ込む材料流動を、付勢手段Ｐによる付勢荷重によって抑制することが可能である。
【００３７】
さらになお、曲げ部８ａに流れ込む材料流動の抑制が図られているので、付勢手段Ｐの付勢力は所定の荷重程度でよく、付勢手段Ｐとして簡単な圧縮ばね等であればよい。これにより、加工設備の大型化を伴うことなく、簡素な構成で対応可能である。
【００３８】
さらになお、ダイ２と協働する据え込みパンチ１を型締め方向に駆動し、ダイ２と材料押さえ冶具３の離間距離が所定長になったとき、据え込みパンチ１は、ダイ２への押圧を開始するように、構成としてもよい。これにより、据え込み加工工程Ｐ２１において、側壁部８ｂの増肉形成のための据え込み加工と、据え込み加工による材料流動によって生じた底部８ｃの部分的な板厚増加を整形する潰し加工とを同時に行なうことが可能である。従って工程が簡素になり、生産性向上が図れる。例えば図３（ａ）に示すダイ２と据え込みパンチ１の離間距離ｈと、据え込みパンチ１の上端と材料押さえ冶具３の上端との離間距離Ｈとを調整し、図３（ｃ）の据え込み加工の終段（詳しくは、据え込み加工の終了直前）にて、段差ΔＨ１がなくなる（ΔＨ１＝０）ように設定し、据え込みパンチ１の上部に設けられた駆動装置（図示せず）によって材料押さえ冶具３の上端を押圧する構成とすればよい。
【００３９】
（第２の実施形態）
以下、本発明を適用した他の実施形態を説明する。なお、以下の実施形態おいては、第１の実施形態と同じもしくは均等の構成には同一の符号を付し、説明を繰り返さない。
【００４０】
第２の実施形態では、第１の実施形態に係わる工程に加えて、図７に示す工程を加える。図７は、実施形態に係わる板材の加工方法の工程を説明する模式図である。本発明の板材の加工方法を適用する板材８の製品形状として、単に側壁部８ｂが底部８ｃに対して所定の増肉比率Ｔ２／Ｔ１にするだけでは、製品としての要求を満足しない場合がある。例えば、内燃機関へ燃料を噴射する燃料噴射弁いわゆるインジェクタの電磁駆動部に用いられ固定子鉄心としてのステータハウジング（図示せず）を形成するような場合、側壁部８ｂの軸方向端部は、図示しない電磁駆動部のコイルに発生する電磁力の磁気通路を形成するため、左右方向に幅広であることが望ましい（図８（ｇ）参照）。本実施形態では、このようないた板材８の製品形状に対する要求に対して好適な板材の加工方法を提供する。図７は、本実施形態に係わる板材の加工方法の工程を説明する模式図である。なお、図７は、本実施形態に係わる工程順に従って、板材８が加工される状態を説明する。図７の左から右方向に向かって、工程名、その工程の説明、および板材８が加工される状態を順に示す。また、図７の上から下に向かって本実施形態に係わる工程の流れを示している。
【００４１】
図７に示すように、本実施形態では、被加工物である板材８を製品形状に応じて整形するように、曲げ整形工程Ｐ１２と、増肉整形工程Ｐ２２とを備えている。なお、本実施形態で説明する曲げ整形工程Ｐ１２および増肉整形工程Ｐ２２を備えた板材の加工方法に限らず、板材の加工方法として、製品形状の要求に応じて、曲げ整形工程Ｐ１２および増肉整形工程Ｐ２２のうち少なくともいずれか一方があればよい。図７に示すように、曲げ整形工程Ｐ１２は、ダイ２２と、曲げパンチ１１とを備え、周知の曲げ加工用冶具または設備であればよい。曲げ部８ａの形状を、略直角から鈍角にしてもよい。さらになお、後述の増肉整形工程Ｐ２２の前工程として、増肉整形工程Ｐ２２にて増肉部の整形がし易い形状に曲げ加工してもよい。増肉整形工程Ｐ２２は、図７に示すように、ダイ２３と、曲げパンチ１３とを備えている。
【００４２】
以上説明した実施形態では、板材８の製品形状として、図８に示す形状であって適用可能である。図８は、本発明の板材の加工方法を用いて成形可能な形状を示す被加工物としての板材の模式的断面図であって、図８（ａ）〜図８（ｇ）は他の実施形態に係わるそれぞれ一態様を示す断面図である。側壁部８ｂの外周に設ける増肉部が、側壁部８ｂが外周の一部または全部に形成されているものであってもよい（図８（ａ）〜図（ｅ）参照）。また、側壁部８ｂと底部９ｃとのなす傾斜角を略直角に限らず、鈍角にすることが可能である（図８（ｆ）参照）。
【００４３】
なお、これら板材８の製品形状であっても、増肉工程Ｐ２の据え込み加工工程Ｐ２１での据え込み加工を繰り返し行なったとしても、曲げ部８ａへの材料流動を抑制することができるとともに、製品に有害な巻き込みの発生を防止できる（例えば図９参照）。
【図面の簡単な説明】
【図１】本発明の第１の実施形態に係わる板材の加工方法の工程を説明する模式図である。
【図２】本発明の板材の加工方法を適用して製造する製品の形状の一実施例を表す断面図である。
【図３】図１中の増肉工程において、据え込み加工により被加工物を増肉するために用いる冶具および被加工物としての板材に増肉部が形成される過程を表す模式的断面図であって、図３（ａ）は据え込み加工前の状態、図３（ｂ）は据え込み加工開始直後の状態、図３（ｃ）は据え込み加工を継続している状態、図３（ｄ）は据え込み加工が終了した状態を表す断面図である。
【図４】第１の実施形態に係わる被加工物の板材において、曲げ加工後にその板材を据え込み加工する際、据え込み加工による板材内部の材料流動と段差との関係を示す模式図である。
【図５】比較例としての増肉部に段差を形成しない板材の加工方法に係わる増肉工程において、据え込み加工により被加工物を増肉するために用いる冶具および被加工物としての板材に増肉部が形成される過程を表す模式的断面図であって、図５（ａ）は据え込み加工開始前の状態、図５（ｂ）は据え込み加工開始直後の状態、図５（ｃ）は据え込み加工を継続している状態、図５（ｄ）は据え込み加工が終了した状態を表す断面図である。
【図６】比較例に係わる被加工物の板材において、曲げ加工後にその板材を据え込み加工する際、据え込み加工による板材内部の材料流動を示す模式図である。
【図７】第２の実施形態に係わる板材の加工方法の工程を説明する模式図である。
【図８】本発明の板材の加工方法を用いて成形可能な形状を示す被加工物としての板材の模式的断面図であって、図８（ａ）〜図８（ｇ）は他の実施形態に係わるそれぞれ一態様を示す断面図である。
【図９】本発明の板材の加工方法を適用して加工された被加工物の状態を示す模式的断面図である。
【図１０】比較例の板材の加工方法を適用して加工された被加工物の状態を示す模式的断面図である。
【符号の説明】
１　据え込みパンチ
２　ダイ
２ａ　底支持部
２ｂ　曲げ支持部
２ｃ　段差支持部
２ｄ　増肉支持部
３　材料押さえ冶具
８　板材
８ａ　曲げ部
８ｂ　側壁部（一方の部材）
８ｃ　底部（他方の部材）
８ｄ　増肉部
８ｄｅ　段差
Ｐ　付勢手段
Ｐ１　曲げ工程
Ｐ２　増肉工程
Ｐ２１　据え込み加工工程[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for processing a sheet material, and more particularly to a method for processing a sheet material having a bent shape, for example, an L-shaped cross-sectional shape, and performing thickness difference forming across a bent portion.
[0002]
[Prior art]
2. Description of the Related Art As a method of manufacturing a product having a bent portion such as an L-shaped cross section and making one of the products thicker than the other plate with the bent portion interposed therebetween, a method of manufacturing by cutting is known.
[0003]
[Problems to be solved by the invention]
In the manufacturing method according to the prior art, waste material is generated by cutting. As a countermeasure for this, a method of manufacturing by press working can be considered. However, there are the following problems in performing by press working. First, in order to increase the thickness of one of the side wall portions so as to be thicker than the other bottom portion, when the side wall portion is upset, the material flows into the bottom along with the upsetting process. In order to increase the thickness of the bottom portion due to the flow of the material, it may be necessary to reshape the material by crushing in a later step. Since the inflow of this material is accompanied by plastic deformation due to the upsetting, a large working load is required to perform the crushing. Since the processing load is further increased as the flow-in amount is increased, the equipment used is also increased in size, and as a result, the production cost may be increased.
[0004]
Secondly, in order to improve the productivity of the press working, it is necessary to increase the wall thickness increase rate in the upsetting work, and the material is buckled due to buckling. When the entrainment amount is large, there is a possibility that the quality of the product such as an undesired decrease in strength is adversely affected on the product quality.
[0005]
The present invention has been made in consideration of such circumstances, and has as its object to perform a thickness difference forming with a bent portion sandwiching the bent portion, thereby suppressing the flow of material due to the upsetting process. Another object of the present invention is to provide a method for processing a flat plate material.
[0006]
Another object of the present invention is to provide a method of processing a sheet material capable of suppressing inflow of a material due to upsetting and improving productivity.
[0007]
[Means for Solving the Problems]
According to the first aspect of the present invention, after bending to manufacture a product having a bent portion and having one member thicker than the other member across the bent portion, the thickness of one member is increased. A method of processing a plate material to be formed, wherein the upsetting process of forming a thickened portion having a step on an outer peripheral surface of one member extending outside the bent portion by upsetting one member. Have.
[0008]
Generally, when a member extending from a bent portion, that is, one member is increased in thickness by upsetting, a processing load due to the upsetting is applied to the one member and the bent portion. For this reason, the bending R of the bending portion tends to become smaller as the thickness is increased. As a result, during upsetting or plastic working, material flow due to the working load occurs not only in one member but also in the bent portion. Until a predetermined outer radius R is obtained by the upsetting process, one of the members and the bent portion are easily buckled by plastic deformation.
[0009]
On the other hand, in the method for processing a plate material according to the present invention, since a step is provided in the thickened portion formed on the outer peripheral surface of one of the members extending outside the bent portion, the upsetting jig for forming the step is provided. Thus, it is possible to apply a so-called reaction force to the step that is opposite to the force acting when buckling. Therefore, it is possible to suppress the occurrence of the buckling phenomenon and to suppress the material flow to the bent portion.
[0010]
According to claim 2 of the present invention, the step is a step formed at a predetermined height from the bottom surface of the other member toward the direction in which one member extends.
[0011]
That is, the step of the thickened portion formed on the outer peripheral surface of one member extending outside the bent portion is formed in the middle of the outside R of the bent portion corresponding to the predetermined height. Thereby, the material flow to the bent portion due to the upsetting can be reliably suppressed.
[0012]
According to the third aspect of the present invention, in the upsetting punch and die used in the upsetting process, the inner periphery of the die has a bottom support portion along the bottom surface of the other member and a middle portion of a bent portion extending from the other member. A bending support portion extending along the bending portion, a step support portion formed from the bending support portion in a direction in which the other member extends, and a thickening support extending in the direction in which one member extends from the step support portion. It has a part.
[0013]
That is, the inner periphery of the die has a bottom support and a bending support formed along the bottom surface of the other member, a bent portion extending from the other member, and each of the extending directions of the other member. And a step supporting portion. This makes it easy for the die to apply a so-called reaction force to the step of the thickened portion in a direction opposite to the force applied when buckling.
[0014]
As a result, the flow of the material due to the upsetting process can easily flow into a space defined by the step supporting portion and the thickening supporting portion, that is, a space for forming the thickening portion.
[0015]
According to claim 4 of the present invention, the die cooperating with the upsetting punch is provided with the material holding jig having the urging means for pressing the other member toward the die with the other member interposed therebetween. .
[0016]
Thereby, in the processing method of the plate material of the present invention, by performing the upsetting process in which a step is provided in the thickened portion, the material flow is suppressed, so that the plate material to be processed, that is, the other member is pressed against the die. For example, a simple urging means such as a compression spring can be used.
[0017]
According to claim 5 of the present invention, the upsetting punch cooperating with the die is driven in the mold clamping direction, and when the separation distance between the die and the material holding jig becomes a predetermined length, the upsetting punch presses the die. To start.
[0018]
Thus, in the method for processing a plate material according to the present invention, it is possible to reduce the flow of the material into another member by suppressing the material flow by the upsetting process. It is possible to simultaneously carry out the upsetting process for forming and the crushing process for shaping the partial increase in the thickness of the other member caused by the material flow due to the upsetting process. Therefore, the process is simplified, and productivity can be improved.
[0019]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment in which a method of processing a plate material of the present invention is embodied as a method of processing a plate material in a product having a bent portion and having one member thicker than the other member with the bent portion interposed therebetween will be described. It will be described according to.
[0020]
(1st Embodiment)
FIG. 1 is a schematic diagram illustrating steps of a processing method of a plate material according to the present embodiment. FIG. 2 is a cross-sectional view illustrating an example of a shape of a product manufactured by applying the plate material processing method of the present invention. FIG. 3 is a schematic cross-sectional view showing a process of forming a thickened portion on a plate used as a workpiece and a jig used for increasing the thickness of the workpiece by upsetting in the thickness increasing step in FIG. 1. 3A is a state before the start of the upsetting, FIG. 3B is a state immediately after the start of the upsetting, FIG. 3C is a state where the upsetting is continued, and FIG. (D) is a sectional view showing a state in which the upsetting process has been completed. FIG. 4 is a schematic diagram showing the relationship between the material flow inside the plate material due to the upsetting process and the step when the plate material of the workpiece according to the present embodiment is upset after bending. .
[0021]
As shown in FIG. 1, the plate material processing method of the present invention includes a bending step P1 and a thickening step P2. Thereby, in the present embodiment, a bent portion 8a is formed in the plate material 8 as a workpiece, and the plate thickness of one member 8b is larger than the wall thickness of the other member 8c with the bent portion 8a interposed therebetween. Next, processing is performed. As a product shape of the plate material to which the method for processing a plate material of the present invention is applied, as shown in FIG. 2, the workpiece 8 has a bent shape. The bent portion 8a is not limited to being bent at a substantially right angle, but may be bent at an obtuse angle. The details of the product shape of the workpiece 8 that can be formed by using the plate material processing method of the present invention will be described later (see each embodiment shown in FIG. 8). In the workpiece 8 described in the present embodiment, one member 8b extending in the up-down direction in FIG. 2 is hereinafter referred to as a side wall, and the other member 8c extending in the left-right direction in FIG. Call. FIG. 1 illustrates a state in which the plate material 8 is processed according to a process sequence according to the present embodiment. From left to right in FIG. 1, a process name, a description of the process, and a state in which the plate material 8 is processed are shown in order. 1 shows a flow of processes according to the present embodiment from top to bottom in FIG.
[0022]
As shown in FIG. 1, the bending step P1 is performed by using a well-known bending jig or equipment for bending the flat plate material 8 in the initial state so that the inner bending R finally has a substantially predetermined radius Rai. Any may be used.
[0023]
In the thickening step P2, as shown in FIG. 1, upsetting is repeatedly performed on the plate material 8 on which the bent portion 8a is formed in the bending step P1. Specifically, the end of the side wall 8b of the plate 8 is set up toward the bent portion 8a. The thickening process P2 includes an upsetting process P21 as shown in FIG. By repeating the upsetting process P21 from N = 1 to N = n times, the side wall portion 8b is repeatedly upset and formed into a desired thickened shape (in the present embodiment, N = 4 repetitions are performed). ). The detailed structure of the jig used in the upsetting process P21 will be described later. In the present embodiment, as shown in FIG. 1, by the upsetting process in the upsetting process step P21, the outer peripheral surface of the side wall portion 8b (more specifically, the outer peripheral surface extending to the outside Rao side of the bent portion 8a) is formed as shown in FIG. A thickened portion 8d having a step 8de is formed.
[0024]
Here, the jig used in the upsetting process P21 and the thickened portion 8d formed using the jig, particularly the step 8de, will be described with reference to FIGS. FIG. 5 is a comparative example in comparison with the present embodiment (see FIG. 3), and shows a process in the case of manufacturing a product of the plate material 8 having no step 8de in the thickened portion 8d. FIG. 6 is a schematic diagram showing a material flow inside a plate material by upsetting according to the comparative example.
[0025]
In the state before the start of the upsetting process shown in FIG. 3A, the plate material 8 having the bent portion 8a is held by the die 2 and faces the direction in which the side wall portion 8b extends (the vertical direction in FIG. 3A). The upsetting punch 1 is disposed above the side wall 8b. The upsetting punch 1 and the die 2 constitute an upsetting jig and cooperate. In the present embodiment, the upsetting punch 1 and the die 2 that cooperate with each other are driven in the mold clamping direction, and the end faces in the axial direction of the upsetting punch 1 and the die 2 come into contact with each other, thereby completing the upsetting process corresponding to one time. It has a configuration that can be used. In this embodiment, the material holding jig 3 that guides the inner circumference of the plate material 8 housed in the inner periphery of the die 2 on the inner bending side of the plate material 8 is provided. Accordingly, the plate material 8 (specifically, the side wall portion 8b) can be held so that the inner peripheral side of the side wall portion 8b is not thickened at the time of upsetting, and the plate material 8 formed by the bending process P1 is bent. It is possible to maintain the bent shape of the portion 8a.
[0026]
On the inner periphery of the die, a bottom support portion 2a along the bottom surface of the bottom portion 8c, a bend support portion 2b along the bend portion 8a up to the middle of the bend portion 8a extending from the bottom portion 8c, and a bottom portion 8c extend from the bend support portion 2b. The step support portion 2c is formed in the direction (the left-right direction in FIG. 3A), and extends in the direction in which the side wall portion 8b extends from the step support portion 2c (the vertical direction in FIG. 3A). It has a thickening support portion 2d to be formed. A space R1 (see FIG. 3A) defined by the step support portion 2c, the thickened support portion 2d, and the outer peripheral surface of the side wall portion 8b is a space R2 that forms a part of the thickened portion 8d. The space R2 may be a space that forms the thickened portion 8d according to a desired shape of the plate material 8 as a product. Furthermore, when the space R2 is a part of the thickened portion 8d, the inner periphery of the upsetting punch 1 is similarly configured to form the space R1 illustrated in FIG. 3B. The combined volume of the space R1 and the space R2 is the volume of the thickened portion 8d which is formed by upsetting the plate member 8, that is, the side wall portion 8b.
[0027]
Next, in the state immediately after the start of the upsetting process in FIG. 3B, the upsetting punch 1 cooperating with the die 2 is driven in a so-called mold clamping direction (the direction of the arrow in FIG. 3B). As a result, the upsetting punch 1 comes into contact with the axial end of the side wall portion 8b, and applies an upsetting load to the side wall portion 8b, that is, the plate material 8. As a result, the side wall portion 8b and the bent portion 8a start plastic deformation by the upsetting process, and the material flow inside the plate 8 starts. The details of the material flow inside the plate member 8 will be described later.
[0028]
Next, in the state where the upsetting process shown in FIG. 3C is continued, a processing load is applied to the axial end of the side wall portion 8b by the upsetting process. A part of the thickened portion 8d starts to be formed around the portion 8a by material flow due to plastic deformation. In the present embodiment, since the bending support portion 2b and the step support portion 2c are provided on the inner periphery of the die 2, the bending portion 8a supported by the bending support portion 2b is suppressed from plastic deformation, and is supported by the bending support portion 2b. The bent portion 8a does not flow along the step supporting portion 2c due to plastic deformation, that is, the thickness is increased. As a result, the volume of the thickened portion 8d in the initial state formed on the step supporting portion 8c increases in the extending direction of the side wall portion 8b as the upsetting is continued.
[0029]
That is, the thickened portion 8d formed on the side wall portion 8b is held by the step supporting portion 2c that supports the step 8de throughout the upsetting process. As a result, even if a processing load that causes buckling is applied in accordance with the upsetting process being continued (that is, an increase in the so-called thickening ratio T2 / T1 (see FIG. 2)), the step supporting portion 2c causes In addition, a reaction force, which is a force opposite to the force exerted when buckling, can be applied to the step 8de, that is, the thickened portion 8d. Therefore, it is possible to suppress the occurrence of the buckling phenomenon. Furthermore, by this, the thickness increase ratio T2 / T1 by one upsetting process is increased (in this embodiment, T2 / T1 is about 1.3), and the number of steps in the thickness increase process P2 is reduced. That is, the number N of times of upsetting in the upsetting process P21 can be reduced. Therefore, it is possible to simplify the steps relating to the sheet material processing method of the present invention and to improve the productivity.
[0030]
Further, in the present embodiment, the inner periphery of the die 2 includes a bottom support portion 2a formed along the bottom surface of the bottom portion 8c, a bent portion 8a extending from the bottom portion 8c, and a bent support portion formed along the direction in which the bottom portion 8c extends. 2b and the step supporting portion 2c, the material flow to the bending portion 8a can be suppressed by the bottom supporting portion 2a and the bending supporting portion 2b. Furthermore, a smooth step formed on the surface of the plate member 8 can apply a reaction force which is a force opposite to the force acting at the time of buckling without providing a notch-shaped step in the plate member 8 to be formed. Can be easily formed. Further, in the present embodiment, since a smooth step 8de can be formed on the surface of the plate material 8, product quality such as a decrease in strength generated from the notch or the like as a starting point like a step having a notch shape is impaired. This can prevent such a phenomenon.
[0031]
Furthermore, since the inner periphery of the die 2 is provided with the bottom support 2a, the bending support 2b, and the step support 2c, the flow of the material inside the plate material 8 by the upsetting process is reduced to at least the space R1, that is, the thickened portion 8d. There is a synergistic effect that makes it easier to flow into the spaces R1 and R2 for forming.
[0032]
Next, in the state where the upsetting process of FIG. 3D has been completed, the volume of the thickened portion 8de which has been increased in thickness starting from the step 8de is formed on the inner periphery of each of the die 2 and the upsetting punch 1. It is possible to mold up to the sum of the space R2 (see FIG. 3A) and the space R1 (see FIG. 3B). In addition, it is possible to prevent a winding problem due to the buckling phenomenon in the upsetting process.
[0033]
Here, the material flow inside the plate 8 was verified and confirmed when the thickened portion 8d having the step 8de, which is a feature of the plate material processing method of the present invention, was formed. . A description will be given in comparison with a comparative example (see FIGS. 5 and 6) in which a conventional technique of increasing the thickness of the thickened portion 8d without the step 8de is applied.
[0034]
First, in a comparative example in which a product of a plate material is manufactured by applying the conventional technique, as shown in FIG. 5, the inner periphery of the die 2 includes a bottom support 2a and a thickened support 2d. . That is, there is no bending support portion 2b that supports the bending portion 8a along the bending portion 8a at least halfway through the bending portion 8a. In addition, as the thickened portion support portion 2d, there is a thickened bent shape support portion 2db that supports the bent R shape formed by the thickened portion. For this reason, when the upsetting is started, the processing load due to the upsetting is applied not only to the side wall portion 8b but also to the entire bent portion 8a. As a result, as shown in FIG. 6, the material flow inside the plate member 8 becomes remarkable. The flow of the material that has flowed into the bent portion 8a is, in the vicinity of the bent portion 8a on the base side of the bottom portion 8c, contrary to the original thickness or the thickness formed in the bending process P1, by the amount of the material that has flowed in. The phenomenon that the plate thickness increases only occurs. Furthermore, in some cases, as shown in FIG. 3 (C), the buckling phenomenon has progressed, the inside Rai has become smaller, and the portion of the sheet material 8 that has been hardened by the bending in the bending process P1 and the post-process The entrapment phenomenon (for example, see FIG. 10 of the comparative example) occurs at the boundary with the portion of the plate material 8 that has been newly hardened by the upsetting process in the thickening process P2.
[0035]
On the other hand, in the present embodiment, as the configuration of the inner periphery of the die 2, a bending support portion 2b that supports the bending portion 8a along the bending portion 8a at least halfway through the bending portion 8a is provided. Further, as shown in FIG. 4, a reaction force in the opposite direction to the force applied during buckling by the step supporting portion 2 c is applied to the plate member 8, that is, the side wall portion 8 b and the bent portion 8 a with respect to the force applied during buckling. be able to. As a result, in the present embodiment, as shown in FIG. 4, the flow of the material inside the plate member 8 can be suppressed from flowing into the bent portion 8a.
[0036]
In the above-described embodiment, of the upsetting punch 1, the die 2, and the material holding jig 3 constituting the jig related to the upsetting process P <b> 21, the urging for pressing the bottom 8 c toward the die 2 is performed on the material holding jig 3. Means P may be provided. Accordingly, in a state where the material flow flowing into the bending portion 8a due to the step 8de is suppressed, the material flow still flowing into the bending portion 8a can be suppressed by the urging load by the urging means P.
[0037]
Furthermore, since the flow of the material flowing into the bent portion 8a is suppressed, the urging force of the urging means P may be about a predetermined load, and the urging means P may be a simple compression spring or the like. This makes it possible to cope with a simple configuration without increasing the size of the processing equipment.
[0038]
Furthermore, the upsetting punch 1 cooperating with the die 2 is driven in the mold clamping direction, and when the separation distance between the die 2 and the material holding jig 3 becomes a predetermined length, the upsetting punch 1 presses the die 2. May be configured to start. Thus, in the upsetting process P21, the upsetting process for increasing the thickness of the side wall portion 8b and the crushing process for shaping a partial increase in the thickness of the bottom portion 8c caused by the material flow due to the upsetting process are performed. It is possible to do it at the same time. Therefore, the process is simplified, and productivity can be improved. For example, the separation distance h between the die 2 and the upsetting punch 1 shown in FIG. 3A and the separation distance H between the upper end of the upsetting punch 1 and the upper end of the material holding jig 3 are adjusted. At the final stage of the upsetting process (specifically, immediately before the end of the upsetting process), a setting is made so that the step ΔH1 disappears (ΔH1 = 0), and a driving device (not shown) provided above the upsetting punch 1 ) To press the upper end of the material holding jig 3.
[0039]
(Second embodiment)
Hereinafter, other embodiments to which the present invention is applied will be described. In the following embodiments, the same or equivalent components as those in the first embodiment are denoted by the same reference numerals, and description thereof will not be repeated.
[0040]
In the second embodiment, a step shown in FIG. 7 is added in addition to the steps according to the first embodiment. Drawing 7 is a mimetic diagram explaining a process of a plate material processing method concerning an embodiment. As the product shape of the plate material 8 to which the plate material processing method of the present invention is applied, simply setting the side wall portion 8b to the predetermined thickness increase ratio T2 / T1 with respect to the bottom portion 8c may not satisfy the requirements as a product. . For example, in a case where a stator housing (not shown) is used as a stator core and used as a fuel injection valve for injecting fuel into an internal combustion engine, that is, an electromagnetic drive unit of an injector, an axial end of the side wall 8b is In order to form a magnetic path for an electromagnetic force generated in a coil of an electromagnetic drive unit (not shown), it is desirable that the width be wide in the left-right direction (see FIG. 8G). In the present embodiment, a method of processing a plate material suitable for such a demand for the product shape of the plate material 8 is provided. FIG. 7 is a schematic diagram illustrating steps of a processing method of a plate material according to the present embodiment. FIG. 7 illustrates a state where the plate material 8 is processed in accordance with the process sequence according to the present embodiment. From left to right in FIG. 7, a process name, a description of the process, and a state in which the plate material 8 is processed are shown in order. 7 shows a flow of processes according to the present embodiment from top to bottom in FIG.
[0041]
As shown in FIG. 7, the present embodiment includes a bending and shaping step P12 and a thickening and shaping step P22 so as to shape the plate material 8 as a workpiece according to the product shape. In addition, not only the plate material processing method provided with the bending and shaping process P12 and the thickening and shaping process P22 described in the present embodiment, but also as the plate material processing method, the bending and shaping process P12 and the thickening process It suffices if there is at least one of the shaping steps P22. As shown in FIG. 7, the bending and shaping step P12 includes a die 22 and a bending punch 11, and may be any known bending jig or equipment. The shape of the bent portion 8a may be changed from a substantially right angle to an obtuse angle. Furthermore, as a step before the thickening shaping step P22 to be described later, in the thickening shaping step P22, a bending process may be performed so that the thickened portion can be easily shaped. The thickening shaping step P22 includes a die 23 and a bending punch 13 as shown in FIG.
[0042]
In the embodiment described above, the product shape of the plate 8 is the shape shown in FIG. FIG. 8 is a schematic cross-sectional view of a plate material as a workpiece showing a shape that can be formed by using the plate material processing method of the present invention, and FIGS. 8A to 8G show another embodiment. FIG. 3 is a cross-sectional view showing one aspect of each of the modes. The thickened portion provided on the outer periphery of the side wall portion 8b may be such that the side wall portion 8b is formed on a part or all of the outer periphery (see FIGS. 8A to 8E). In addition, the inclination angle between the side wall portion 8b and the bottom portion 9c is not limited to a substantially right angle, but can be an obtuse angle (see FIG. 8F).
[0043]
In addition, even if it is these product shapes of the plate material 8, even if the upsetting process in the upsetting process step P21 of the thickening process P2 is repeatedly performed, the material flow to the bending portion 8a can be suppressed, and The occurrence of harmful entrapment in the product can be prevented (for example, see FIG. 9).
[Brief description of the drawings]
FIG. 1 is a schematic diagram illustrating steps of a method for processing a plate material according to a first embodiment of the present invention.
FIG. 2 is a cross-sectional view illustrating an example of a shape of a product manufactured by applying the plate material processing method of the present invention.
FIG. 3 is a schematic cross-sectional view showing a process of forming a thickened portion on a plate used as a workpiece and a jig used to increase the thickness of the workpiece by upsetting in a thickening step in FIG. 3A shows a state before the upsetting, FIG. 3B shows a state immediately after the upsetting is started, FIG. 3C shows a state where the upsetting is continued, and FIG. d) is a cross-sectional view illustrating a state in which the upsetting is completed.
FIG. 4 is a schematic diagram showing a relationship between a material flow inside the plate material due to the upsetting process and a step when the plate material of the workpiece according to the first embodiment is upset after bending. .
FIG. 5 shows a jig used to increase the thickness of a workpiece by upsetting in a thickness increasing step related to a method of processing a thickness of a plate material without forming a step in a thickened portion as a comparative example, and a plate material as a workpiece. FIG. 5A is a schematic cross-sectional view illustrating a process of forming a thickened portion, where FIG. 5A is a state before the start of the upsetting, FIG. 5B is a state immediately after the start of the upsetting, and FIG. ) Is a state in which the upsetting is continued, and FIG. 5D is a cross-sectional view showing a state in which the upsetting has been completed.
FIG. 6 is a schematic diagram showing a material flow inside the plate material due to the upsetting when the plate material of the workpiece according to the comparative example is subjected to upsetting after bending.
FIG. 7 is a schematic view illustrating steps of a method for processing a plate material according to the second embodiment.
FIG. 8 is a schematic cross-sectional view of a plate material as a workpiece showing a shape that can be formed by using the plate material processing method of the present invention, and FIGS. 8 (a) to 8 (g) show another embodiment. FIG. 3 is a cross-sectional view showing one aspect of each of the modes.
FIG. 9 is a schematic cross-sectional view showing a state of a workpiece processed by applying the plate material processing method of the present invention.
FIG. 10 is a schematic cross-sectional view showing a state of a workpiece processed by applying a processing method of a plate material of a comparative example.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Upsetting punch 2 Die 2a Bottom support part 2b Bend support part 2c Step support part 2d Thickening support part 3 Material holding jig 8 Plate material 8a Bend part 8b Side wall part (one member)
8c Bottom (the other member)
8d Thickening portion 8de Step P Energizing means P1 Bending process P2 Thickening process P21 Upsetting process

Claims (5)

曲げ部を有し、前記曲げ部を挟んで一方の部材を他方の部材より板厚を厚くする製品を製造するため曲げ加工後、前記一方の部材の増肉成形を行なう板材の加工方法であって、
前記一方の部材を据え込むことで、前記曲げ部の外側に延在する前記一方の部材の外周面に、段差を有する増肉部を形成する据え込み加工工程を備えていることを特徴とする板材の加工方法。A method of processing a sheet material having a bent portion, wherein one of the members is bent to form a thicker sheet than the other member with the bent portion interposed therebetween, and then the one member is thickened. hand,
An upsetting process of forming a thickened portion having a step on an outer peripheral surface of the one member extending outside the bent portion by upsetting the one member is provided. Plate material processing method. 前記段差とは、前記他方の部材の底面より前記一方の部材が延在する方向に向かって、所定の高さに形成される段差であることを特徴とする請求項１に記載の板材の加工方法。The processing of a plate material according to claim 1, wherein the step is a step formed at a predetermined height from a bottom surface of the other member toward a direction in which the one member extends. Method. 前記据え込み加工工程に使用する据え込みパンチとダイにおいて、前記ダイの内周は、前記他方の部材の前記底面に沿う底支持部と、前記他方の部材から延びる前記曲げ部の途中まで前記曲げ部に沿う曲げ支持部と、前記曲げ支持部から前記他方の部材の延在する方向に向かって形成される段差支持部と、前記段差支持部から前記一方の部材が延在する方向に延びる増肉支持部を備えていることを特徴とする請求項１または請求項２に記載の板材の加工方法。In the upsetting punch and die used in the upsetting process, the inner periphery of the die has a bottom support portion along the bottom surface of the other member, and the bent portion extends halfway through the bent portion extending from the other member. A bending support portion along the portion, a step support portion formed from the bending support portion in a direction in which the other member extends, and a step extending in a direction in which the one member extends from the step support portion. The method for processing a plate material according to claim 1, further comprising a meat supporting portion. 前記据え込みパンチと協働する前記ダイには、前記他方の部材を挟んで、前記他方の部材を前記ダイに向かって押圧する付勢手段を有する材料押さえ冶具が設けられていることを特徴とする請求項３に記載の板材の加工方法。The die cooperating with the upsetting punch is provided with a material holding jig having a biasing unit for pressing the other member toward the die with the other member interposed therebetween. The method for processing a plate material according to claim 3. 前記ダイと協働する前記据え込みパンチを型締め方向に駆動し、前記ダイと前記材料押さえ冶具の離間距離が所定長になったとき、前記据え込みパンチは、前記ダイへの押圧を開始することを特徴とする請求項４に記載の板材の加工方法。The upsetting punch cooperating with the die is driven in a mold clamping direction, and when the separation distance between the die and the material holding jig becomes a predetermined length, the upsetting punch starts pressing on the die. The method for processing a plate material according to claim 4, wherein:

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