JP2014108444A

JP2014108444A - Method and apparatus for manufacturing long member

Info

Publication number: JP2014108444A
Application number: JP2012264424A
Authority: JP
Inventors: Hiroyuki Tanizaki; 祐幸谷崎; Noboru Tayasu; 昇田安
Original assignee: Shiroki Corp
Current assignee: Shiroki Corp
Priority date: 2012-12-03
Filing date: 2012-12-03
Publication date: 2014-06-12

Abstract

PROBLEM TO BE SOLVED: To obtain a method and an apparatus for manufacturing a long member having a cross section of a substantially V-shaped part in which a risk of applying a large burden to a forming die and a formed article is reduced, and an unintentional recess is hard to be formed in the bottom of a finished long member.SOLUTION: A method for manufacturing a long member includes the steps of: preparing a pair of first forming dies intersecting at an angle α°, and a second forming die contacting and separating to/from the first forming dies and linearly movable in one direction; forming a pair of first inclined parts W2 in which connection ends being one end of both are connected with each other so that mutual inner surfaces intersect at the angle α° in a base material, by making the second forming die come close to the first forming dies, and sandwiching a base material W between a pair of first die surfaces and a pair of second die surfaces; and forming a pair of second inclined parts in which the angle formed by mutual inner surfaces is β° in the base material, by sandwiching the portions apart from the connection ends of the pair of first inclined parts between a pair of fourth die surfaces 34 and a pair of sixth die surfaces 42, respectively, while sandwiching the pair of first inclined parts with a pair of third die surfaces 33 and a pair of fifth die surfaces 41.

Description

本発明は長尺部材の製造方法及び長尺部材製造装置に関する。 The present invention relates to a long member manufacturing method and a long member manufacturing apparatus.

断面略Ｖ字形状部を有する長尺部材の製造方法としては、例えば特許文献１に開示されたものがある。
この製造方法は、Ｖ字形の成形凹部を有する一つの固定型（折り曲げ金型）と、固定型に対して接近及び離間する方向に直線的に移動可能で固定型との対向端部に断面Ｖ字形の成形部を有する一つの可動型（折り曲げ金型）と、を利用したものである。即ち、固定型と可動型の間に平板状の母材（板材）を配置し、可動型を固定型側に接近移動させて（可動型の成形部を成形凹部内に移動させて）固定型（成形凹部）と可動型（成形部）の間で母材を挟み込むことにより母材をプレス成形する方法である。
このようにしてプレス成形を行うと、固定型の成形凹部の内面を構成する一対の成形面と可動型の成形部の両面を構成する一対の成形面とによって母材が断面Ｖ字形に曲折されるので、母材から断面Ｖ字形状の長尺部材が成形される。 As a manufacturing method of the elongate member which has a cross-sectional substantially V-shaped part, there exist some which were disclosed by patent document 1, for example.
In this manufacturing method, there is one fixed mold (bending mold) having a V-shaped molding recess, and linear movement is possible in a direction approaching and separating from the fixed mold, and a cross-section V is formed at the opposite end of the fixed mold. One movable mold (bending mold) having a letter-shaped molded part is used. That is, a flat base material (plate material) is disposed between the fixed mold and the movable mold, and the movable mold is moved closer to the fixed mold side (the movable mold forming portion is moved into the molding recess) to fix the fixed mold. In this method, the base material is press-molded by sandwiching the base material between the (forming concave portion) and the movable mold (forming portion).
When press molding is performed in this manner, the base material is bent into a V-shaped cross section by a pair of molding surfaces constituting the inner surface of the molding recess of the fixed mold and a pair of molding surfaces constituting both surfaces of the molding portion of the movable mold. Therefore, a long member having a V-shaped cross section is formed from the base material.

特開昭６２−７２４３４号公報JP 62-72434 A

上記成形方法では、固定型の一対の成形面がなす角度及び可動型の一対の成形面がなす角度が小さいので、長尺部材の内面の底部（可動型の成形部の先端部を構成する先鋭部によって成形された部分）に意図しない凹部（溝、ヒケ）が形成されてしまうおそれが高い（図１０参照）。
さらに固定型の一対の成形面がなす角度及び可動型の一対の成形面がなす角度が小さいので、成形時に可動型の成形部の先端部（を構成する先鋭部）と長尺部材の内面の底部の間に大きな力が生じる。そのため、成形時に可動型と長尺部材（成形品）に掛かる負担が大きく、可動型と長尺部材に破損が生じ易い。 In the molding method described above, the angle formed by the pair of molding surfaces of the fixed mold and the angle formed by the pair of molding surfaces of the movable mold are small, so that the bottom of the inner surface of the long member (the sharp tip constituting the tip of the movable mold molding section) There is a high possibility that unintended recesses (grooves, sink marks) are formed in the part formed by the part (see FIG. 10).
Furthermore, since the angle formed by the pair of molding surfaces of the fixed mold and the angle formed by the pair of molding surfaces of the movable mold are small, the tip of the molding part of the movable mold (the sharpened part constituting it) and the inner surface of the long member are formed during molding. A large force is created between the bottoms. For this reason, the load applied to the movable mold and the long member (molded product) during molding is large, and the movable mold and the long member are easily damaged.

本発明は、成形型や成形品に大きな負担を掛けるおそれが小さく、かつ完成した長尺部材の底部に意図しない凹部が形成され難い断面略Ｖ字形状部を有する長尺部材の製造方法及び長尺部材製造装置を提供することを目的とする。 The present invention provides a method for producing a long member having a substantially V-shaped cross section, which is less likely to place a large burden on a mold or a molded product, and is difficult to form an unintended recess on the bottom of a finished long member. An object of the present invention is to provide a scale member manufacturing apparatus.

本発明の長尺部材の製造方法は、互いの一端が接続する一対の第一傾斜部及び各第一傾斜部の他端に対して自身の一端がそれぞれ接続する一対の第二傾斜部によって構成した断面略Ｖ字形状部を有する長尺部材を、平板状の母材から製造する方法であって、角度α°（α＜１８０）で交差するように両者の一端が互いに接続する一対の第一成形面を備える第一成形型及び角度α°で交差するように両者の一端が互いに接続する一対の第二成形面を備えかつ上記第一成形型に対して接離する一方向に直線移動可能な第二成形型を準備するステップ、該第二成形型を上記第一成形型に対して接近させて、上記一対の第一成形面と上記一対の第二成形面との間で上記母材を挟み込むことにより、互いの内面同士が角度α°で交差するように両者の一端である接続端が互いに接続する上記一対の第一傾斜部を上記母材に成形するステップ、角度α°で交差するように両者の一端が互いに接続する一対の第三成形面及び上記一対の第三成形面の両側に位置しかつ両者のなす角度がβ°（β＜α）である一対の第四成形面を備える第三成形型を準備するステップ、上記第三成形型と上記一方向に対向し、角度α°で交差するように両者の一端が互いに接続する一対の第五成形面及び上記一対の第五成形面の他端とそれぞれ接続しかつ両者のなす角度がβ°である一対の第六成形面を備える、上記一方向に直線移動可能な第四成形型を準備するステップ、及び上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込みながら、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むことにより、互いの内面がなす角度がβ°である上記一対の第二傾斜部を上記母材に成形するステップを有することを特徴としている。 The manufacturing method of the elongate member of this invention is comprised by a pair of 2nd inclination part to which one end each connects with respect to the other end of each pair of 1st inclination part and each 1st inclination part which a mutual end connects. A long member having a substantially V-shaped cross section is produced from a flat base material, and a pair of first members whose ends are connected to each other so as to intersect at an angle α ° (α <180). A first mold having one molding surface and a pair of second molding surfaces whose ends are connected to each other so as to intersect at an angle α °, and linearly move in one direction in contact with and away from the first molding die Preparing a possible second mold, bringing the second mold close to the first mold, and forming the mother between the pair of first mold surfaces and the pair of second mold surfaces By sandwiching the material, at one end of both sides so that the inner surfaces of each other intersect at an angle α ° Forming the pair of first inclined portions to which the connection ends are connected to each other on the base material, a pair of third forming surfaces whose ends are connected to each other so as to intersect at an angle α °, and the pair of thirds Preparing a third mold having a pair of fourth molding surfaces located on both sides of the molding surface and having an angle of β ° (β <α), opposite the third molding die in the one direction And a pair of fifth molding surfaces whose one ends are connected to each other so as to intersect at an angle α ° and a pair of the other ends of the pair of fifth molding surfaces, respectively, and an angle between them is β ° A step of preparing a fourth molding die having a sixth molding surface and linearly movable in the one direction, and sandwiching the pair of first inclined portions between the pair of third molding surfaces and the pair of fifth molding surfaces However, the upper side between the pair of fourth molding surfaces and the pair of sixth molding surfaces Forming the pair of second inclined portions having an angle of β ° between the pair of first inclined portions into the base material by sandwiching portions of the pair of first inclined portions away from the connection ends, respectively. It is a feature.

上記第三成形型が、上記第四成形面を備える固定型と、上記第三成形面を備えかつ上記一方向に移動自在な可動型と、を備え、上記一対の第二傾斜部を成形するステップが、上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込んだ状態で上記可動型及び第四成形型を上記固定型側に移動させることにより、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むステップであってもよい。 The third mold includes a fixed mold having the fourth molding surface, and a movable mold having the third molding surface and movable in the one direction, and molding the pair of second inclined portions. The step moves the movable mold and the fourth molding die toward the fixed die in a state where the pair of first inclined portions are sandwiched between the pair of third molding surfaces and the pair of fifth molding surfaces. It may be a step of sandwiching a portion of the pair of first inclined portions away from the connection end between the pair of fourth molding surfaces and the pair of sixth molding surfaces.

本発明の長尺部材製造装置は、互いの一端が接続する一対の第一傾斜部及び各第一傾斜部の他端に対して自身の一端がそれぞれ接続する一対の第二傾斜部によって構成した断面略Ｖ字形状部を有する長尺部材を、平板状の母材から製造する装置であって、角度α°（α＜１８０）で交差するように両者の一端が互いに接続する一対の第一成形面を備える第一成形型及び角度α°で交差するように両者の一端が互いに接続する一対の第二成形面を備えかつ上記第一成形型に対して接離する一方向に直線移動可能な第二成形型と、角度α°で交差するように両者の一端が互いに接続する一対の第三成形面及び上記一対の第三成形面の両側に位置しかつ両者のなす角度がβ°（β＜α）である一対の第四成形面を備える第三成形型と、上記第三成形型と上記一方向に対向し、角度α°で交差するように両者の一端が互いに接続する一対の第五成形面及び上記一対の第五成形面の他端とそれぞれ接続しかつ両者のなす角度がβ°である一対の第六成形面を備える、上記一方向に直線移動可能な第四成形型と、を具備し、該第二成形型を上記第一成形型に対して接近させて、上記一対の第一成形面と上記一対の第二成形面との間で上記母材を挟み込むことにより、互いの内面同士が角度α°で交差するように両者の一端である接続端が互いに接続する上記一対の第一傾斜部を上記母材に成形可能であり、上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込みながら、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むことにより、互いの内面がなす角度がβ°である上記一対の第二傾斜部を上記母材に成形可能であることを特徴としている。 The long member manufacturing apparatus of the present invention is configured by a pair of first inclined portions to which one end of each other is connected and a pair of second inclined portions to which one end thereof is connected to the other end of each first inclined portion. A device for manufacturing a long member having a substantially V-shaped cross section from a flat base material, and a pair of first members whose ends are connected to each other so as to intersect at an angle α ° (α <180) A first mold having a molding surface and a pair of second molding surfaces whose ends are connected to each other so as to intersect at an angle α °, and can be linearly moved in one direction in contact with and away from the first molding die And a pair of third molding surfaces whose ends are connected to each other so as to intersect with each other at an angle α °, and the angle formed between both sides of the pair of third molding surfaces is β ° ( β <α), a third mold having a pair of fourth molding surfaces, the third mold, and the third mold A pair of fifth molding surfaces facing each other and intersecting at an angle α ° with each other are connected to the other end of the pair of fifth molding surfaces and the pair of fifth molding surfaces, respectively, and the angle formed by both is β ° A fourth mold that includes a pair of sixth molding surfaces that can move linearly in the one direction, and the second mold is brought close to the first mold so that the pair of By sandwiching the base material between the first molding surface and the pair of second molding surfaces, the pair of connection ends that are one end of the two are connected to each other so that the inner surfaces intersect at an angle α °. The first inclined portions can be formed on the base material, and the pair of first inclined portions are sandwiched between the pair of third forming surfaces and the pair of fifth forming surfaces, A portion separated from the connection end of the pair of first inclined portions between the pair of sixth molding surfaces. By sandwiching Re respectively, are characterized by the angle formed with each other of the inner surface can be formed a second inclined portion of the pair is a beta ° to the base material.

上記第三成形型が、上記第四成形面を備える固定型と、上記第三成形面を備えかつ上記一方向に移動自在な可動型と、を備え、上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込んだ状態で上記可動型及び第四成形型を上記固定型側に移動させ、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むことにより上記一対の第二傾斜部を成形可能であってもよい。 The third mold includes a fixed mold having the fourth molding surface, and a movable mold having the third molding surface and movable in the one direction, and the pair of first inclined portions is the pair of first inclined portions. The movable mold and the fourth molding die are moved to the fixed mold side while being sandwiched between the third molding surface and the pair of fifth molding surfaces, and the pair of fourth molding surfaces and the pair of sixth molding surfaces. The pair of second inclined portions may be moldable by sandwiching a portion of the pair of first inclined portions away from the connection end between the pair of first inclined portions.

請求項１、３の発明では、母材に対して両者の内面の交差角（α°）が大きい一対の第一傾斜部を一旦成形し、その後に、一対の第一傾斜部の（一対の第一傾斜部どうしの）接続端から離れた部位に互いの内面がなす角度が（α°より小さい）β°である一対の第二傾斜部を形成している。
このように一対の第一傾斜部の内面（一対の第一傾斜部の内面）がなす角度（α°）を（一対の第二傾斜部の内面がなす角度より）大きくしているので、第一傾斜部の成形時に第一傾斜部の底部の内面に意図しない凹部（溝）が形成されるおそれは小さい。
さらに第一傾斜部の底部の一対の内面（一対の第一傾斜部の内面）がなす角度（α°）を（一対の第二傾斜部の内面がなす角度より）大きくしているので、第一傾斜部の成形時に第二成形型と第一傾斜部の内面の底部の間に大きな力が生じ難い（第二成形型から第一傾斜部の内面に及ぶ面圧が小さくなる）。そのため、第二成形型と第一傾斜部に掛かる負担を抑制し、第二成形型と第一傾斜部（長尺部材）に破損が生じ難くすることが可能である。 In the first and third aspects of the invention, a pair of first inclined portions having a large crossing angle (α °) between both inner surfaces with respect to the base material is once molded, and thereafter, the pair of first inclined portions (the pair of first inclined portions) A pair of second inclined portions having an angle of β ° (smaller than α °) formed between the inner surfaces of the first inclined portions is formed at a portion away from the connection end (between the first inclined portions).
Thus, the angle (α °) formed by the inner surfaces of the pair of first inclined portions (the inner surfaces of the pair of first inclined portions) is made larger (than the angle formed by the inner surfaces of the pair of second inclined portions). There is little risk that unintended recesses (grooves) are formed on the inner surface of the bottom of the first inclined portion during molding of the one inclined portion.
Furthermore, the angle (α °) formed by the pair of inner surfaces (the inner surfaces of the pair of first inclined portions) at the bottom of the first inclined portion is larger (than the angle formed by the inner surfaces of the pair of second inclined portions). It is difficult for a large force to be generated between the second mold and the bottom of the inner surface of the first inclined portion during molding of the one inclined portion (the surface pressure extending from the second mold to the inner surface of the first inclined portion is reduced). Therefore, it is possible to suppress a load applied to the second mold and the first inclined portion, and to prevent the second mold and the first inclined portion (long member) from being damaged.

請求項２、４の発明によれば、母材に予め形成した断面Ｖ字形状部（一対の第一傾斜部）を一対の第三成形面及び一対の第五成形面によって挟み込みながら一対の第二傾斜部を成形するので、第二傾斜部を成形するときの第四成形面（第三成形型）及び第六成形面（第四成形型）と母材との間の位置精度が高くなる。そのため、長尺部材に対して一対の第二傾斜部を精度よく成形可能である。 According to the second and fourth aspects of the present invention, a pair of first shapes are formed while sandwiching a V-shaped section (a pair of first inclined portions) formed in advance in the base material between the pair of third molding surfaces and the pair of fifth molding surfaces. Since the two inclined portions are formed, the positional accuracy between the base material and the fourth forming surface (third forming die) and the sixth forming surface (fourth forming die) when forming the second inclined portion is increased. . Therefore, it is possible to accurately form the pair of second inclined portions with respect to the long member.

本発明の一実施形態のプレス成形装置の模式図である。It is a schematic diagram of the press molding apparatus of one Embodiment of this invention. プレス成形装置の一次成形装置と母材を示す横断面図である。It is a cross-sectional view showing a primary forming apparatus and a base material of a press forming apparatus. プレス成形装置の初期位置に位置する二次成形装置と母材を示す図２と同様の横断面図である。FIG. 3 is a cross-sectional view similar to FIG. 2 showing a secondary forming apparatus and a base material positioned at an initial position of the press forming apparatus. 二次成形装置の上側可動型が下降して断面略Ｖ字形状の母材の上面に当接することにより下側可動型と上側可動型により母材を上下から挟み込んだときの図２と同様の横断面図である。Similar to FIG. 2 when the upper movable die of the secondary molding apparatus is lowered and abuts against the upper surface of the base material having a substantially V-shaped cross section, so that the base material is sandwiched from above and below by the lower movable die and the upper movable die. It is a cross-sectional view. 下側可動型と上側可動型で母材を挟み込んだまま下側可動型と上側可動型を下降させて、固定型と上側可動型の間で母材を挟み込んだときの図２と同様の横断面図である。The same crossing as in FIG. 2 when the lower movable mold and the upper movable mold are lowered while the base metal is sandwiched between the lower movable mold and the upper movable mold, and the preform is sandwiched between the fixed mold and the upper movable mold. FIG. 二次成形装置を初期位置に戻したときの図２と同様の横断面図である。It is a cross-sectional view similar to FIG. 2 when the secondary molding apparatus is returned to the initial position. プレス成形装置の初期位置に位置する平戻し装置と長尺部材を示す横断面図である。It is a cross-sectional view which shows the flat return apparatus and long member which are located in the initial position of a press molding apparatus. 平戻し装置により一対の第一傾斜部を平板状態に加工した状態を示す横断面図である。It is a cross-sectional view which shows the state which processed a pair of 1st inclination part into the flat plate state with the flat return apparatus. 成形品であるロアレールの上方から見た斜視図である。It is the perspective view seen from the upper part of the lower rail which is a molded article. 従来の断面略Ｖ字形状の長尺部材の横断面図である。It is a cross-sectional view of a conventional long member having a substantially V-shaped cross section.

以下、図１〜図９を参照しながら本発明の一実施形態について説明する。なお、以下の説明中の方向は図中に記載した矢線方向を基準とする。
本実施形態のプレス成形装置１０は、複数の成形装置（成形工程）を有しかつ母材Ｗ（ワーク）を左から右側へ順次移送する順送プレス装置であり、平板状の金属板からなる母材Ｗから車両シート用スライドレール装置のロアレールＬＲ（図９参照。図示を省略したアッパレールをスライド可能に支持するレール）を成形するものである。即ち、図１に示すようにプレス成形装置１０は、トリム工程（平板状の母材Ｗに対する打抜工程）、曲げ工程、ピアス工程、及びセパレート工程の順で各工程を行い、各工程を実施する複数の装置を具備している。 Hereinafter, an embodiment of the present invention will be described with reference to FIGS. The direction in the following description is based on the arrow direction indicated in the figure.
The press forming apparatus 10 of the present embodiment is a progressive press apparatus that has a plurality of forming apparatuses (forming processes) and sequentially transfers a base material W (workpiece) from left to right, and is made of a flat metal plate. A lower rail LR of a vehicle seat slide rail device (see FIG. 9, a rail that supports an upper rail that is not shown in a slidable manner) is formed from the base material W. That is, as shown in FIG. 1, the press forming apparatus 10 performs each process in the order of a trim process (punching process for a flat base material W), a bending process, a piercing process, and a separation process. A plurality of devices.

以下、プレス成形装置１０が行う各成形工程及び各成形工程を実行する装置について説明する。
最初のトリム工程は、平板状の金属板からなる母材Ｗに対してロアレールＬＲの外形やロアレールＬＲに成形した切り起こし片（図９参照）の外形に沿った切れ込みを入れる工程である。但し、ロアレールＬＲの外形に沿った切れ込みによって囲まれた部分は母材Ｗの本体部から完全に切り離すのではなく、一部を母材Ｗの本体部と繋げたままとしておく。 Hereinafter, each forming process performed by the press forming apparatus 10 and an apparatus for executing each forming process will be described.
The first trimming step is a step of making a cut along the outer shape of the lower rail LR and the outer shape of the cut and raised piece formed on the lower rail LR (see FIG. 9) with respect to the base material W made of a flat metal plate. However, the portion surrounded by the cut along the outer shape of the lower rail LR is not completely separated from the main body portion of the base material W, but a part is left connected to the main body portion of the base material W.

曲げ工程は、図２〜図６に示すＶ字曲げ工程と、図７及び図８に示す平戻し工程と、を具備する工程である（図１参照。曲げ工程には、その他の工程も存在するが、その他の工程の説明は省略する）。
Ｖ字曲げ工程は図２〜図６に示した長尺部材製造装置１１を利用して行う。図示するように長尺部材製造装置１１は、図２に示した一次成形装置１５及び図３〜図６に示す二次成形装置３０を具備している。
一次成形装置１５は、下側に配置した下側固定型２０（第一成形型）と、下側固定型２０の直上に配置した可動型２５Ａ（第二成形型）及び上側固定型２５Ｂと、を具備している。下側固定型２０、可動型２５Ａ、及び上側固定型２５Ｂは、一次成形装置１５の長手方向（図面に対して直交する方向）に延びる部材であり、各部材の横断面形状は図２に示した形状である（後述する二次成形装置３０及び平戻し装置４５も同様）。
下側固定型２０は移動不能な成形型であり、下側固定型２０の上面には成形面が形成してある。この成形面は、当該上面の幅方向（左右方向）の中央部から左斜め上方と右斜め上方に向かって直線的に延びる平面からなる一対の成形面２１（第一成形面）と、左右の成形面２１の外側端部とそれぞれ連続する湾曲面からなる端部成形面２２と、を有している。左右の成形面２１がなす角度はα°（α＜１８０）である。
下側固定型２０の直上には上下方向（一方向）に直線移動可能な移動部材（例えば油圧シリンダなど）が配設してあり、この移動部材の下面に圧力源となるガススプリング（空気バネ）からなる付勢手段２４が設けてある。即ち、付勢手段２４の上部を構成するシリンダの上部が移動部材の下面に固定してある。シリンダ内にはピストンが摺動自在に設けてあり、ピストンからは可動ロッドが下方に延びている。可動ロッドは、シリンダの底面に形成した孔に対して気密状態で上下方向に摺動可能に嵌合しており、可動ロッドの下端部はシリンダの底面から下方に突出している。この可動ロッドの下端部には可動型２５Ａの上端部が固定してある。可動型２５Ａの下面に形成した成形面は、当該下面の幅方向（左右方向）の中央部から左斜め上方と右斜め上方に向かって直線的に延びる平面からなる一対の成形面２６（第二成形面）により構成してある。左右の成形面２６は左右の成形面２１とそれぞれ平行（左右の成形面２６がなす角度はα°）かつ左右の成形面２１とそれぞれ上下方向に対向している。
上側固定型２５Ｂの上面は上記移動部材の下面に固定してある。上側固定型２５Ｂの下面には上方に向かって延びる貫通孔が形成してあり、この貫通孔内に可動型２５Ａが位置している。上側固定型２５Ｂの下面には、可動型２５Ａの左右両側に位置する湾曲面からなる端部成形面２７が形成してある。左右の端部成形面２７は左右の端部成形面２２と上下方向に対向している。 The bending process is a process comprising a V-shaped bending process shown in FIGS. 2 to 6 and a flattening process shown in FIGS. 7 and 8 (see FIG. 1. Other processes exist in the bending process). However, explanation of other steps is omitted).
A V-shaped bending process is performed using the elongate member manufacturing apparatus 11 shown in FIGS. As shown in the figure, the long member manufacturing apparatus 11 includes a primary forming apparatus 15 shown in FIG. 2 and a secondary forming apparatus 30 shown in FIGS. 3 to 6.
The primary molding device 15 includes a lower fixed mold 20 (first molding mold) disposed on the lower side, a movable mold 25A (second molding mold) and an upper fixed mold 25B disposed immediately above the lower fixed mold 20, and It has. The lower fixed mold 20, the movable mold 25 </ b> A, and the upper fixed mold 25 </ b> B are members that extend in the longitudinal direction of the primary molding device 15 (direction orthogonal to the drawing), and the cross-sectional shape of each member is shown in FIG. 2. (The same applies to a secondary molding device 30 and a flattening device 45 described later).
The lower fixed mold 20 is a non-movable mold, and a molding surface is formed on the upper surface of the lower fixed mold 20. This molding surface includes a pair of molding surfaces 21 (first molding surfaces) consisting of a plane extending linearly from the center in the width direction (left-right direction) of the upper surface to diagonally upward left and diagonally upward to the right, It has the outer side edge part of the molding surface 21, and the edge part molding surface 22 which consists of a curved surface respectively continuous. The angle formed by the left and right molding surfaces 21 is α ° (α <180).
A moving member (for example, a hydraulic cylinder) that can move linearly in the vertical direction (one direction) is disposed immediately above the lower fixed mold 20, and a gas spring (air spring) serving as a pressure source is provided on the lower surface of the moving member. ) Is provided. That is, the upper part of the cylinder constituting the upper part of the urging means 24 is fixed to the lower surface of the moving member. A piston is slidably provided in the cylinder, and a movable rod extends downward from the piston. The movable rod is fitted in a hole formed in the bottom surface of the cylinder so as to be slidable in the vertical direction in an airtight state, and a lower end portion of the movable rod projects downward from the bottom surface of the cylinder. The upper end of the movable mold 25A is fixed to the lower end of the movable rod. The molding surface formed on the lower surface of the movable mold 25A is a pair of molding surfaces 26 (second second) composed of a plane extending linearly from the center in the width direction (left-right direction) of the lower surface toward the upper left and the upper right. (Molded surface). The left and right molding surfaces 26 are parallel to the left and right molding surfaces 21 (the angle formed by the left and right molding surfaces 26 is α °) and are opposed to the left and right molding surfaces 21 in the vertical direction.
The upper surface of the upper fixed mold 25B is fixed to the lower surface of the moving member. A through hole extending upward is formed in the lower surface of the upper fixed mold 25B, and the movable mold 25A is located in the through hole. On the lower surface of the upper fixed mold 25B, end molding surfaces 27 made of curved surfaces located on the left and right sides of the movable mold 25A are formed. The left and right end molding surfaces 27 face the left and right end molding surfaces 22 in the vertical direction.

トリム工程を経た母材Ｗが図２に示すＶ字曲げ工程の一次成形工程（一次成形装置１５）に送られると、図２に示すように母材Ｗは下側固定型２０と初期位置に位置する可動型２５Ａ（仮想線参照）の間に水平状態で挿入され、かつ母材Ｗ（のロアレールＬＲの外形に沿った切れ込みによって囲まれた部分。以下レール構成部Ｗ１と呼ぶ）の下面が下側固定型２０の上端部によって支持される。
続いて上記移動部材が可動型２５Ａ及び上側固定型２５Ｂと一緒に下方に移動すると、まず可動型２５Ａの下端部が母材Ｗのレール構成部Ｗ１の上面に接触する。そして可動型２５Ａが図２に実線で示す下死点に到達したときに、一対の成形面２１と一対の成形面２６によってレール構成部Ｗ１の左右両端部を除く部分が挟み込まれるので、レール構成部Ｗ１の左右両端部を除く部分に左右一対の第一傾斜部Ｗ２が形成される。左右の第一傾斜部Ｗ２の内面（上面）がなす角度はα°である。さらに移動部材が下降すると、上側固定型２５Ｂの左右の端部成形面２７がレール構成部Ｗ１の左右両端部の上面に接触し、上側固定型２５Ｂが図２に実線で示す下死点に到達したときに、一対の端部成形面２２と一対の端部成形面２７によってレール構成部Ｗ１の左右両端部が挟み込まれるので、レール構成部Ｗ１の左右両端部に左右一対の曲折端部Ｗ３が形成される。
この後に上記移動部材、可動型２５Ａ、及び上側固定型２５Ｂが初期位置に復帰することによりＶ字曲げ工程の一次成形工程が終了する。 When the base material W that has undergone the trimming process is sent to the primary forming step (primary forming apparatus 15) of the V-shaped bending step shown in FIG. The lower surface of the movable mold 25A (see the phantom line) that is inserted in a horizontal state and surrounded by a notch along the outer shape of the lower rail LR (hereinafter referred to as the rail component W1) It is supported by the upper end portion of the lower fixed mold 20.
Subsequently, when the moving member moves downward together with the movable mold 25A and the upper fixed mold 25B, first, the lower end portion of the movable mold 25A comes into contact with the upper surface of the rail component W1 of the base material W. When the movable mold 25A reaches the bottom dead center indicated by the solid line in FIG. 2, the rail configuration portion is sandwiched between the pair of molding surfaces 21 and the pair of molding surfaces 26 except for the left and right end portions. A pair of left and right first inclined portions W2 is formed in a portion excluding the left and right end portions of the portion W1. The angle formed by the inner surfaces (upper surfaces) of the left and right first inclined portions W2 is α °. When the moving member further descends, the left and right end molding surfaces 27 of the upper fixed mold 25B come into contact with the upper surfaces of the left and right end portions of the rail component W1, and the upper fixed mold 25B reaches the bottom dead center indicated by the solid line in FIG. When this is done, the left and right ends of the rail component W1 are sandwiched between the pair of end molding surfaces 22 and the pair of end molding surfaces 27, so that a pair of left and right bent ends W3 are formed at the left and right ends of the rail component W1. It is formed.
Thereafter, the primary forming process of the V-shaped bending process is completed by returning the moving member, the movable mold 25A, and the upper fixed mold 25B to the initial positions.

一次成形工程が終了すると、母材Ｗ（レール構成部Ｗ１）は、Ｖ字曲げ工程の二次成形工程（二次成形装置３０）に移送される。
二次成形装置３０は、下側に配置した固定型３１（第三成形型）、付勢手段３５、及び下側可動型３７（第三成形型）（可動型）と、固定型３１及び下側可動型３７の直上に配置した上側可動型４０（第四成形型）と、を具備している。
固定型３１は移動不能な成形型であり、上面の中央部には有底の受容凹部３２が下向きに形成してある。さらに固定型３１の上面には、受容凹部３２の上端開口縁部から左斜め上方と右斜め上方に向かって直線的に延びる平面からなる一対の内側成形面３３（第三成形面）と、左右の内側成形面３３の外側端部から左斜め上方と右斜め上方に向かって直線的に延びる平面からなる一対の外側成形面３４（第四成形面）と、が形成してある。左右の内側成形面３３がなす角度はα°である。一方、左右の外側成形面３４がなす角度はβ°（β＜α）である。
固定型３１の受容凹部３２の底部にはガススプリング（空気バネ）からなる付勢手段３５が設けてある。即ち、付勢手段３５の下部を構成するシリンダの下部が受容凹部３２の底部に固定してある。シリンダ内にはピストンが摺動自在に設けてあり、ピストンからは可動ロッドが上方に延びている。可動ロッドは、シリンダの上面に形成した孔に対して気密状態で上下方向に摺動可能に嵌合しており、可動ロッドの上端部はシリンダの上面から上方に突出している。
付勢手段３５の可動ロッドの上端には下側可動型３７の底面が固定してある。下側可動型３７の上端部には、該上端部の左右方向の中央から左斜め上方と右斜め上方に向かって直線的に延びる平面からなる一対の成形面３８（第三成形面）が形成してある。左右の成形面３８がなす角度はα°である。さらに二次成形装置３０が初期位置に位置するとき、下側可動型３７の成形面３８は、固定型３１の外側成形面３４より上方に位置している。 When the primary molding process is completed, the base material W (rail component W1) is transferred to the secondary molding process (secondary molding apparatus 30) in the V-shaped bending process.
The secondary molding apparatus 30 includes a fixed mold 31 (third mold) arranged on the lower side, an urging means 35, a lower movable mold 37 (third mold) (movable mold), a fixed mold 31 and a lower mold. And an upper movable mold 40 (fourth molding mold) disposed immediately above the side movable mold 37.
The fixed die 31 is a non-movable molding die, and a bottomed receiving recess 32 is formed downward in the center of the upper surface. Further, on the upper surface of the fixed die 31, a pair of inner molding surfaces 33 (third molding surfaces) formed of a plane extending linearly from the upper end opening edge of the receiving recess 32 toward the upper left and the upper right, and left and right A pair of outer molding surfaces 34 (fourth molding surfaces) are formed from a plane extending linearly from the outer end of the inner molding surface 33 to the left diagonally upward and right diagonally upward. The angle formed by the left and right inner molding surfaces 33 is α °. On the other hand, the angle formed by the left and right outer molding surfaces 34 is β ° (β <α).
An urging means 35 comprising a gas spring (air spring) is provided at the bottom of the receiving recess 32 of the fixed mold 31. That is, the lower part of the cylinder constituting the lower part of the urging means 35 is fixed to the bottom part of the receiving recess 32. A piston is slidably provided in the cylinder, and a movable rod extends upward from the piston. The movable rod is fitted in a hole formed in the upper surface of the cylinder so as to be slidable in the vertical direction in an airtight state, and the upper end portion of the movable rod protrudes upward from the upper surface of the cylinder.
The bottom surface of the lower movable die 37 is fixed to the upper end of the movable rod of the urging means 35. A pair of molding surfaces 38 (third molding surfaces) are formed on the upper end portion of the lower movable mold 37. The pair of molding surfaces 38 is a flat surface extending linearly from the center in the left-right direction of the upper end portion toward the upper left and the upper right. It is. The angle formed by the left and right molding surfaces 38 is α °. Further, when the secondary molding device 30 is positioned at the initial position, the molding surface 38 of the lower movable mold 37 is positioned above the outer molding surface 34 of the fixed mold 31.

固定型３１及び下側可動型３７の直上には上下方向に直線移動可能な移動部材（例えば油圧シリンダなど）が配設してあり、この移動部材の下面に上側可動型４０の上端部が固定してある。
上側可動型４０の下面には、当該下面の中央部から左右にそれぞれ延びかつ左右の成形面３８とそれぞれ平行な平面からなる一対の内側成形面４１（第五成形面）が形成してある。上側可動型４０の下部の側面には、一端（下端）が左右の内側成形面４１の上端にそれぞれ接続する一対の外側成形面４２（第六成形面）が形成してある。左右の外側成形面４２は左右の外側成形面３４とそれぞれ平行な平面から構成してある。従って、左右の内側成形面４１がなす角度はα°であり、左右の外側成形面４２がなす角度はβ°である。左右の内側成形面４１は左右の内側成形面３３及び左右の成形面３８とそれぞれ上下方向に対向しており、左右の外側成形面４２は左右の外側成形面３４とそれぞれ上下方向に対向している。 A moving member (for example, a hydraulic cylinder) that can move linearly in the vertical direction is disposed immediately above the fixed mold 31 and the lower movable mold 37, and the upper end of the upper movable mold 40 is fixed to the lower surface of the moving member. It is.
On the lower surface of the upper movable mold 40, a pair of inner molding surfaces 41 (fifth molding surfaces) are formed which extend from the center of the lower surface to the left and right and are parallel to the left and right molding surfaces 38, respectively. A pair of outer molding surfaces 42 (sixth molding surfaces) whose one ends (lower ends) are respectively connected to upper ends of the left and right inner molding surfaces 41 are formed on the lower side surface of the upper movable mold 40. The left and right outer molding surfaces 42 are constituted by planes parallel to the left and right outer molding surfaces 34, respectively. Therefore, the angle formed by the left and right inner molding surfaces 41 is α °, and the angle formed by the left and right outer molding surfaces 42 is β °. The left and right inner molding surfaces 41 respectively oppose the left and right inner molding surfaces 33 and the left and right molding surfaces 38 in the vertical direction, and the left and right outer molding surfaces 42 respectively oppose the left and right outer molding surfaces 34 in the vertical direction. Yes.

Ｖ字曲げ工程の一次成形工程を経た母材Ｗが図３〜図６に示す二次成形工程（二次成形装置３０）に送られると、図３に示すようにレール構成部Ｗ１の下面（一対の第一傾斜部Ｗ２の下面）が左右の成形面３８とそれぞれ面接触した状態で下側可動型３７によって支持される。
続いて上記移動部材が上側可動型４０と一緒に下方に移動する。すると上側可動型４０の左右の内側成形面４１がレール構成部Ｗ１の左右の第一傾斜部Ｗ２の上面に面接触するので、レール構成部Ｗ１（左右の第一傾斜部Ｗ２）が左右の成形面３８（下側可動型３７）と左右の内側成形面４１（上側可動型４０）によって上下から挟み込まれる（図４参照）。
この挟み込み状態を維持しながら移動部材及び上側可動型４０がさらに下降すると、付勢手段３５を圧縮させながら下側可動型３７及び上側可動型４０が下方へ移動し、下側可動型３７及び上側可動型４０が図５に示す下死点に到達する。するとレール構成部Ｗ１の左右の第一傾斜部Ｗ２の一部が固定型３１の左右の内側成形面３３によって支持される（内側成形面３３に面接触する）。さらに、固定型３１の左右の外側成形面３４と上側可動型４０の左右の外側成形面４２が、左右の第一傾斜部Ｗ２の左右の内側成形面３３より外側に位置する部位を挟み込むので、左右の第一傾斜部Ｗ２の左右の内側成形面３３より外側に位置する部位が第一傾斜部Ｗ２とは異なる角度で傾斜する第二傾斜部Ｗ４となる（ように加工される）。その結果、（一対の第一傾斜部Ｗ２及び一対の第二傾斜部Ｗ４からなる）断面略Ｖ字形状部を有する（図面に対して直交する方向に延びる）長尺部材（レール構成部Ｗ１）が得られる（図５、６参照）。長尺部材（レール構成部Ｗ１）に形成された左右の第二傾斜部Ｗ４の内面（上面）がなす角度はβ°である。
図６に示すように、この後に上記移動部材が初期位置に向けて上昇すると、付勢手段３５が初期状態に復帰し、かつ下側可動型３７及び上側可動型４０が初期位置に移動復帰することによりＶ字曲げ工程の二次成形工程が終了する。 When the base material W that has undergone the primary forming process in the V-shaped bending process is sent to the secondary forming process (secondary forming apparatus 30) shown in FIGS. 3 to 6, as shown in FIG. The lower surfaces of the pair of first inclined portions W2 are supported by the lower movable die 37 in surface contact with the left and right molding surfaces 38, respectively.
Subsequently, the moving member moves downward together with the upper movable mold 40. Then, the left and right inner molding surfaces 41 of the upper movable mold 40 are in surface contact with the upper surfaces of the left and right first inclined portions W2 of the rail constituting portion W1, so that the rail constituting portion W1 (left and right first inclined portions W2) is left and right molded. It is sandwiched from above and below by the surface 38 (lower movable mold 37) and the left and right inner molding surfaces 41 (upper movable mold 40) (see FIG. 4).
When the moving member and the upper movable mold 40 are further lowered while maintaining this sandwiched state, the lower movable mold 37 and the upper movable mold 40 move downward while compressing the biasing means 35, and the lower movable mold 37 and the upper movable mold 40 are moved upward. The movable mold 40 reaches the bottom dead center shown in FIG. Then, a part of the left and right first inclined portions W2 of the rail constituting portion W1 is supported by the left and right inner molding surfaces 33 of the fixed mold 31 (surface contact with the inner molding surface 33). Furthermore, since the left and right outer molding surfaces 34 of the fixed mold 31 and the left and right outer molding surfaces 42 of the upper movable mold 40 sandwich a portion located outside the left and right inner molding surfaces 33 of the left and right first inclined portions W2, The part located outside the left and right inner molding surfaces 33 of the left and right first inclined portions W2 becomes a second inclined portion W4 that is inclined at a different angle from the first inclined portion W2. As a result, a long member (rail construction portion W1) having a substantially V-shaped section (extending in a direction orthogonal to the drawing) (consisting of a pair of first inclined portions W2 and a pair of second inclined portions W4). Is obtained (see FIGS. 5 and 6). The angle formed by the inner surfaces (upper surfaces) of the left and right second inclined portions W4 formed on the long member (rail constituent portion W1) is β °.
As shown in FIG. 6, when the moving member ascends toward the initial position thereafter, the urging means 35 returns to the initial state, and the lower movable mold 37 and the upper movable mold 40 move back to the initial positions. This completes the secondary forming step of the V-shaped bending step.

Ｖ字曲げ工程が終了すると、母材Ｗ（レール構成部Ｗ１）は、左右の第二傾斜部Ｗ４を曲折加工（左右の第二傾斜部Ｗ４の内側端部が左右の第一傾斜部Ｗ２とそれぞれ直線的に連続し、かつ、左右の第二傾斜部Ｗ４の外側端部が第二傾斜部Ｗ４の内側端部とは異なる方向に曲げられる曲折加工）する別の工程を経た後に図７、図８に示す平戻し工程に移送される。
図７、図８に示した平戻し工程を実行する平戻し装置４５は、下側に配置した下側支持部材４６と、下側支持部材４６の直上に配置した平戻し用押圧部材４８と、を具備している。
下側支持部材４６の上面には断面Ｖ字形状（肉眼ではほぼ水平面に見える。さらに中央部には凹みが形成してある）の下側支持面４７が形成してある。下側支持部材４６の直上には上下方向に直線移動可能な移動部材（例えば油圧シリンダなど）が配設してあり、この移動部材の下面に平戻し用押圧部材４８が固定してある。平戻し用押圧部材４８の下面は下側支持面４７と対応する断面形状（断面Ｖ字形状であるが肉眼ではほぼ水平面に見える。さらに中央部には凸部が形成してある）の押圧面４９により構成してある。
平戻し工程に送られた母材Ｗ（レール構成部Ｗ１）は、図７に示すようにその下面（左右の第一傾斜部Ｗ２の接続端によって構成された稜線部）が下側支持部材４６の下側支持面４７（上記凹部）によって支持される。
この支持状態を維持したまま、平戻し装置４５の移動部材が平戻し用押圧部材４８と一緒に下方に移動すると、平戻し用押圧部材４８の押圧面４９（の上記凸部）がレール構成部Ｗ１の左右の第一傾斜部Ｗ２の上面を下方に押圧する。そして図８に示すように平戻し用押圧部材４８が下死点に到達すると、左右の第一傾斜部Ｗ２の上下両面に下側支持面４７と押圧面４９が面接触し（左右の第一傾斜部Ｗ２が略同一平面上に位置する。）、かつ左右の第二傾斜部Ｗ４の下側部分が垂直方向を向くので、レール構成部Ｗ１は（図面に対して直交する方向に延びる）チャンネル材となる。
この後に平戻し装置４５の上記移動部材が初期位置に向けて上昇し、平戻し用押圧部材４８が初期位置に移動復帰することにより平戻し工程が終了する。
さらに平戻し装置４５によって略平板状とされた左右の第一傾斜部Ｗ２は、成形後のスプリングバック現象によって完全な平板状となる（左右の第一傾斜部Ｗ２が同一平面上に位置するようになる）。 When the V-shaped bending process is finished, the base material W (rail constituent portion W1) is bent to the left and right second inclined portions W4 (the inner end portions of the left and right second inclined portions W4 are the left and right first inclined portions W2). FIG. 7 after undergoing another process in which the outer end portions of the left and right second inclined portions W4 are each bent continuously in a direction different from the inner end portion of the second inclined portion W4). It is transferred to the flattening step shown in FIG.
The flattening device 45 that performs the flattening step shown in FIGS. 7 and 8 includes a lower support member 46 disposed on the lower side, a flattening pressing member 48 disposed on the lower support member 46, and It has.
A lower support surface 47 is formed on the upper surface of the lower support member 46. The lower support surface 47 has a V-shaped cross section (appears to be almost horizontal with the naked eye and has a dent formed at the center). A moving member (for example, a hydraulic cylinder or the like) that is linearly movable in the vertical direction is disposed immediately above the lower support member 46, and a flat return pressing member 48 is fixed to the lower surface of the moving member. The lower surface of the flattening pressing member 48 has a cross-sectional shape corresponding to the lower support surface 47 (which is V-shaped in cross section but looks almost horizontal with the naked eye, and further has a convex portion at the center). 49.
As shown in FIG. 7, the base material W (rail constituent part W1) sent to the flattening process has a lower surface (ridge line part constituted by connecting ends of the left and right first inclined parts W2) as the lower support member 46. Is supported by the lower support surface 47 (the recess).
If the moving member of the flattening device 45 moves downward together with the flattening pressing member 48 while maintaining this supporting state, the pressing surface 49 (the convex portion thereof) of the flattening pressing member 48 becomes the rail component. The upper surfaces of the left and right first inclined portions W2 of W1 are pressed downward. As shown in FIG. 8, when the flat return pressing member 48 reaches the bottom dead center, the lower support surface 47 and the pressing surface 49 come into surface contact with the upper and lower surfaces of the left and right first inclined portions W2 (the left and right first surfaces). Since the inclined portion W2 is located on substantially the same plane.) And the lower portions of the left and right second inclined portions W4 face the vertical direction, the rail constituting portion W1 is a channel (extending in a direction orthogonal to the drawing). Become a material.
Thereafter, the moving member of the flattening device 45 rises toward the initial position, and the flattening pressing member 48 moves back to the initial position, thereby completing the flattening step.
Furthermore, the left and right first inclined portions W2 that have been made substantially flat by the flattening device 45 become completely flat due to the springback phenomenon after molding (so that the left and right first inclined portions W2 are positioned on the same plane). become).

平戻し工程が終了した母材Ｗ（レール構成部Ｗ１）はピアス工程に送られ、ピアス装置（図示略）によってレール構成部Ｗ１の数カ所に孔（図９に一つのみ図示）が穿設される。
さらにピアス工程が終了した母材Ｗ（レール構成部Ｗ１）はセパレート工程に送られ、セパレート装置（図示略）によって母材Ｗからレール構成部Ｗ１が（ロアレールＬＲの外形に沿った切れ込みに沿って）切り離され、その結果、図９に示すロアレールＬＲが完成する。 The base material W (rail constituent part W1) after the flattening process is sent to the piercing process, and holes (only one is shown in FIG. 9) are drilled in several places of the rail constituent part W1 by a piercing device (not shown). The
Further, the base material W (rail constituent part W1) for which the piercing process has been completed is sent to the separation process, and the rail constituent part W1 is separated from the base material W (not shown along the outer shape of the lower rail LR) by a separate device (not shown). ) As a result, the lower rail LR shown in FIG. 9 is completed.

以上説明したように本実施形態では、母材Ｗ（レール構成部Ｗ１）に対して両者の内面の交差角（α°）が大きい一対の第一傾斜部Ｗ２を一旦成形し、その後に、一対の第一傾斜部Ｗ２の（一対の第一傾斜部Ｗ２どうしの）接続端から離れた部位に互いの内面がなす角度が（α°より小さい）β°である一対の第二傾斜部Ｗ４を形成している。
このように長尺部材（レール構成部Ｗ１）の底部の一対の内面（一対の第一傾斜部Ｗ２の内面）がなす角度（α°）を（一対の第二傾斜部Ｗ４の内面がなす角度であるβ°より）大きくしているので、一対の第一傾斜部Ｗ２の成形時に長尺部材の底部の内面に意図しない凹部（溝）が形成されるおそれは小さい。
さらに長尺部材（レール構成部Ｗ１）の底部の一対の内面がなす角度（α°）を（一対の第二傾斜部Ｗ４の内面がなす角度であるβ°より）大きくしているので、一対の第一傾斜部Ｗ２の成形時に上側可動型４０（内側成形面４１）と第一傾斜部Ｗ２の内面の底部の間に大きな力が生じ難い。そのため、上側可動型４０と第一傾斜部Ｗ２に掛かる負担を抑制し、上側可動型４０（内側成形面４１）と第一傾斜部Ｗ２（長尺部材）に破損が生じ難くすることが可能である。 As described above, in the present embodiment, a pair of first inclined portions W2 having a large crossing angle (α °) between the inner surfaces of the base material W (rail constituent portion W1) is once molded, and then a pair of A pair of second inclined portions W4 having an angle of β ° (smaller than α °) formed between the inner surfaces of the first inclined portions W2 at positions away from the connection ends (between the pair of first inclined portions W2). Forming.
Thus, the angle (α °) formed by the pair of inner surfaces (the inner surfaces of the pair of first inclined portions W2) at the bottom of the long member (rail constituent portion W1) (the angle formed by the inner surfaces of the pair of second inclined portions W4). Therefore, there is little possibility that an unintended recess (groove) is formed on the inner surface of the bottom of the long member when the pair of first inclined portions W2 is formed.
Further, the angle (α °) formed by the pair of inner surfaces at the bottom of the long member (rail constituent portion W1) is larger (than the angle β ° formed by the inner surfaces of the pair of second inclined portions W4). When the first inclined portion W2 is molded, a large force is hardly generated between the upper movable mold 40 (inner molded surface 41) and the bottom of the inner surface of the first inclined portion W2. Therefore, it is possible to suppress the burden on the upper movable mold 40 and the first inclined portion W2, and to prevent the upper movable mold 40 (inner molding surface 41) and the first inclined portion W2 (long member) from being damaged. is there.

さらにレール構成部Ｗ１に予め形成した断面略Ｖ字形状部（一対の第一傾斜部Ｗ２）を下側可動型３７（成形面３８）と上側可動型４０（内側成形面４１）によって挟み込みながらレール構成部Ｗ１に一対の第二傾斜部Ｗ４を成形するので、第二傾斜部Ｗ４を成形するときの固定型３１（外側成形面３４）及び上側可動型４０（外側成形面４２）とレール構成部Ｗ１との間の位置精度が高くなる。そのため、長尺部材（レール構成部Ｗ１）に対して一対の第二傾斜部Ｗ４を精度よく成形可能である。 Further, the rail is formed by sandwiching a substantially V-shaped section (a pair of first inclined portions W2) formed in advance in the rail constituting section W1 between the lower movable mold 37 (molded surface 38) and the upper movable mold 40 (inner molded surface 41). Since the pair of second inclined portions W4 is formed in the component W1, the fixed mold 31 (outer molded surface 34) and the upper movable mold 40 (outer molded surface 42) and the rail component when the second inclined portion W4 is molded. The positional accuracy with respect to W1 increases. Therefore, a pair of 2nd inclination part W4 can be shape | molded with sufficient precision with respect to a long member (rail structure part W1).

以上本発明を上記実施形態に基づいて説明したが、本発明は様々な変更を施しながら実施可能である。
例えば、完成品（成形品）を車両シート用スライドレール装置のロアレールＬＲとしたが、その他の部材としてもよい。その他の部材の一例としては、例えば車両シート用スライドレール装置のアッパレールがある。また、図５、６に示した長尺部材又は図５、６に示した長尺部材から曲折端部Ｗ３を省略した部材を完成品（成形品）とすることも可能である。
また、左側の成形面３８の外側端（上端）と左側の内側成形面３３の内側端（下端）を連続させかつ右側の成形面３８の外側端（上端）と右側の内側成形面３３の内側端（下端）を連続させた上で、固定型３１と下側可動型３７を一体化（相対移動不能に）してもよい。さらに内側成形面３３及び成形面３８を一体化した成形面を下側可動型３７に形成し、固定型３１に（内側成形面３３を形成せずに）外側成形面３４のみを形成してもよい。
また固定型３１を左右二つの成形型（内側成形面３３と外側成形面３４を有するか又は外側成形面３４のみを有し、かつ両者の間に下側可動型３７が位置する）により構成してもよい。
さらに一次成形装置１５から端部成形面２２及び端部成形面２７を省略してもよい。 Although the present invention has been described based on the above embodiment, the present invention can be implemented with various modifications.
For example, the finished product (molded product) is the lower rail LR of the vehicle seat slide rail device, but may be other members. As an example of another member, there is an upper rail of a slide rail device for a vehicle seat, for example. Further, the long member shown in FIGS. 5 and 6 or the member obtained by omitting the bent end W3 from the long member shown in FIGS. 5 and 6 may be a finished product (molded product).
Further, the outer end (upper end) of the left molding surface 38 and the inner end (lower end) of the left inner molding surface 33 are connected, and the outer end (upper end) of the right molding surface 38 and the inner side of the right inner molding surface 33 are connected. The fixed mold 31 and the lower movable mold 37 may be integrated (cannot be relatively moved) after the ends (lower ends) are continuous. Further, a molding surface in which the inner molding surface 33 and the molding surface 38 are integrated may be formed in the lower movable mold 37, and only the outer molding surface 34 may be formed in the fixed mold 31 (without forming the inner molding surface 33). Good.
The fixed die 31 is composed of two right and left molding dies (having the inner molding surface 33 and the outer molding surface 34 or only the outer molding surface 34, and the lower movable die 37 is located between them). May be.
Further, the end molding surface 22 and the end molding surface 27 may be omitted from the primary molding device 15.

また、自動車とは異なる製品群及びこれら製品群の構成部品に対して本発明を適用してもよい。 Further, the present invention may be applied to product groups different from automobiles and components of these product groups.

１０プレス成形装置
１１長尺部材製造装置
１５一次成形装置
２０固定型（第一成形型）
２１成形面（第一成形面）
２２端部成形面
２４付勢手段
２５Ａ可動型（第二成形型）
２５Ｂ上側固定型
２６成形面（第二成形面）
２７端部成形面
３０二次成形装置
３１固定型（第三成形型）
３２受容凹部
３３内側成形面（第三成形面）
３４外側成形面（第四成形面）
３５付勢手段
３７下側可動型（第三成形型）（可動型）
３８成形面（第三成形面）
４０上側可動型（第四成形型）
４１内側成形面（第五成形面）
４２外側成形面（第六成形面）
４５平戻し装置
４６下側支持部材
４７下側支持面
４８平戻し用押圧部材
４９押圧面
ＬＲロアレール
Ｗ母材（ワーク）
Ｗ１レール構成部（長尺部材）（チャンネル材）
Ｗ２第一傾斜部
Ｗ３曲折端部
Ｗ４第二傾斜部 DESCRIPTION OF SYMBOLS 10 Press molding apparatus 11 Long member manufacturing apparatus 15 Primary molding apparatus 20 Fixed type | mold (1st shaping | molding die)
21 Molding surface (first molding surface)
22 End molding surface 24 Biasing means 25A Movable mold (second molding mold)
25B Upper fixed mold 26 Molding surface (second molding surface)
27 End molding surface 30 Secondary molding device 31 Fixed mold (third mold)
32 receiving recess 33 inner molding surface (third molding surface)
34 Outside molding surface (fourth molding surface)
35 Biasing means 37 Lower movable mold (third mold) (movable mold)
38 Molding surface (third molding surface)
40 Upper movable mold (fourth mold)
41 Inner molding surface (fifth molding surface)
42 Outside molding surface (sixth molding surface)
45 Flat return device 46 Lower support member 47 Lower support surface 48 Flat return pressing member 49 Press surface LR Lower rail W Base material (workpiece)
W1 rail component (long member) (channel material)
W2 First inclined part W3 Bent end W4 Second inclined part

Claims

互いの一端が接続する一対の第一傾斜部及び各第一傾斜部の他端に対して自身の一端がそれぞれ接続する一対の第二傾斜部によって構成した断面略Ｖ字形状部を有する長尺部材を、平板状の母材から製造する方法であって、
角度α°（α＜１８０）で交差するように両者の一端が互いに接続する一対の第一成形面を備える第一成形型及び角度α°で交差するように両者の一端が互いに接続する一対の第二成形面を備えかつ上記第一成形型に対して接離する一方向に直線移動可能な第二成形型を準備するステップ、
該第二成形型を上記第一成形型に対して接近させて、上記一対の第一成形面と上記一対の第二成形面との間で上記母材を挟み込むことにより、互いの内面同士が角度α°で交差するように両者の一端である接続端が互いに接続する上記一対の第一傾斜部を上記母材に成形するステップ、
角度α°で交差するように両者の一端が互いに接続する一対の第三成形面及び上記一対の第三成形面の両側に位置しかつ両者のなす角度がβ°（β＜α）である一対の第四成形面を備える第三成形型を準備するステップ、
上記第三成形型と上記一方向に対向し、角度α°で交差するように両者の一端が互いに接続する一対の第五成形面及び上記一対の第五成形面の他端とそれぞれ接続しかつ両者のなす角度がβ°である一対の第六成形面を備える、上記一方向に直線移動可能な第四成形型を準備するステップ、及び
上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込みながら、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むことにより、互いの内面がなす角度がβ°である上記一対の第二傾斜部を上記母材に成形するステップ
を有することを特徴とする長尺部材の製造方法。 A long section having a substantially V-shaped section formed by a pair of first inclined portions connected to each other and a pair of second inclined portions connected to the other end of each first inclined portion. A method for producing a member from a flat base material,
A first mold having a pair of first molding surfaces that are connected to each other at an angle α ° (α <180) and a pair of ends that are connected to each other at an angle α ° Providing a second molding die having a second molding surface and linearly movable in one direction contacting and separating from the first molding die;
By bringing the second mold close to the first mold and sandwiching the base material between the pair of first molding surfaces and the pair of second molding surfaces, the inner surfaces of each other Forming the pair of first inclined portions in which the connection ends that are one ends of the two are connected to each other so as to intersect at an angle α ° to the base material;
A pair of third molding surfaces whose one ends are connected to each other so as to intersect at an angle α °, and a pair of which is located on both sides of the pair of third molding surfaces and an angle between both is β ° (β <α) Preparing a third mold with a fourth molding surface of
The third mold is opposed to the third molding die in the one direction and is connected to a pair of fifth molding surfaces whose ends are connected to each other so as to intersect at an angle α ° and the other ends of the pair of fifth molding surfaces, respectively. A step of preparing a fourth mold that includes a pair of sixth molding surfaces whose angle between them is β ° and that is linearly movable in the one direction; and the pair of first inclined portions is the pair of third moldings. While sandwiching between the pair of fifth molding surfaces and the pair of fifth molding surfaces, the portions apart from the connection ends of the pair of first inclined portions are sandwiched between the pair of fourth molding surfaces and the pair of sixth molding surfaces, respectively. Thus, there is provided a method for producing a long member, comprising: forming the pair of second inclined portions having an angle between the inner surfaces of each other by β ° into the base material.

請求項１記載の長尺部材の製造方法において、
上記第三成形型が、
上記第四成形面を備える固定型と、
上記第三成形面を備えかつ上記一方向に移動自在な可動型と、
を備え、
上記一対の第二傾斜部を成形するステップが、
上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込んだ状態で上記可動型及び第四成形型を上記固定型側に移動させることにより、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むステップである長尺部材の製造方法。 In the manufacturing method of the elongate member of Claim 1,
The third mold is
A fixed mold comprising the fourth molding surface;
A movable mold having the third molding surface and movable in the one direction;
With
Forming the pair of second inclined portions,
By moving the movable mold and the fourth molding die to the fixed mold side with the pair of first inclined portions sandwiched between the pair of third molding surfaces and the pair of fifth molding surfaces, A method for manufacturing a long member, which is a step of sandwiching a portion of the pair of first inclined portions away from the connection end between a fourth molding surface and the pair of sixth molding surfaces.

互いの一端が接続する一対の第一傾斜部及び各第一傾斜部の他端に対して自身の一端がそれぞれ接続する一対の第二傾斜部によって構成した断面略Ｖ字形状部を有する長尺部材を、平板状の母材から製造する装置であって、
角度α°（α＜１８０）で交差するように両者の一端が互いに接続する一対の第一成形面を備える第一成形型及び角度α°で交差するように両者の一端が互いに接続する一対の第二成形面を備えかつ上記第一成形型に対して接離する一方向に直線移動可能な第二成形型と、
角度α°で交差するように両者の一端が互いに接続する一対の第三成形面及び上記一対の第三成形面の両側に位置しかつ両者のなす角度がβ°（β＜α）である一対の第四成形面を備える第三成形型と、
上記第三成形型と上記一方向に対向し、角度α°で交差するように両者の一端が互いに接続する一対の第五成形面及び上記一対の第五成形面の他端とそれぞれ接続しかつ両者のなす角度がβ°である一対の第六成形面を備える、上記一方向に直線移動可能な第四成形型と、
を具備し、
該第二成形型を上記第一成形型に対して接近させて、上記一対の第一成形面と上記一対の第二成形面との間で上記母材を挟み込むことにより、互いの内面同士が角度α°で交差するように両者の一端である接続端が互いに接続する上記一対の第一傾斜部を上記母材に成形可能であり、
上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込みながら、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むことにより、互いの内面がなす角度がβ°である上記一対の第二傾斜部を上記母材に成形可能であることを特徴とする長尺部材製造装置。 A long section having a substantially V-shaped section formed by a pair of first inclined portions connected to each other and a pair of second inclined portions connected to the other end of each first inclined portion. An apparatus for manufacturing a member from a flat base material,
A first mold having a pair of first molding surfaces that are connected to each other at an angle α ° (α <180) and a pair of ends that are connected to each other at an angle α ° A second mold having a second molding surface and linearly movable in one direction contacting and separating from the first mold;
A pair of third molding surfaces whose one ends are connected to each other so as to intersect at an angle α °, and a pair of which is located on both sides of the pair of third molding surfaces and an angle between both is β ° (β <α) A third mold having the fourth molding surface of
The third mold is opposed to the third molding die in the one direction and is connected to a pair of fifth molding surfaces whose ends are connected to each other so as to intersect at an angle α ° and the other ends of the pair of fifth molding surfaces, respectively. A fourth molding die that includes a pair of sixth molding surfaces whose angle between them is β °, and that is linearly movable in the one direction;
Comprising
By bringing the second mold close to the first mold and sandwiching the base material between the pair of first molding surfaces and the pair of second molding surfaces, the inner surfaces of each other The pair of first inclined portions that are connected to each other so that the connection ends that are both ends of the two intersect with each other at an angle α ° can be formed on the base material,
The pair of first inclined portions are sandwiched between the pair of third molding surfaces and the pair of fifth molding surfaces, and the pair of first molding portions between the pair of fourth molding surfaces and the pair of sixth molding surfaces. The pair of second inclined portions whose angle formed between the inner surfaces is β ° can be formed on the base material by sandwiching portions of the one inclined portion away from the connection end, respectively. Scale member manufacturing equipment.

請求項３記載の長尺部材製造装置において、
上記第三成形型が、
上記第四成形面を備える固定型と、
上記第三成形面を備えかつ上記一方向に移動自在な可動型と、
を備え、
上記一対の第一傾斜部を上記一対の第三成形面及び上記一対の第五成形面で挟み込んだ状態で上記可動型及び第四成形型を上記固定型側に移動させ、上記一対の第四成形面と上記一対の第六成形面との間で上記一対の第一傾斜部の上記接続端から離れた部位をそれぞれ挟み込むことにより上記一対の第二傾斜部を成形可能である長尺部材製造装置。 In the elongate member manufacturing apparatus of Claim 3,
The third mold is
A fixed mold comprising the fourth molding surface;
A movable mold having the third molding surface and movable in the one direction;
With
The movable mold and the fourth molding die are moved to the fixed mold side with the pair of first inclined portions sandwiched between the pair of third molding surfaces and the pair of fifth molding surfaces, and the pair of fourth molding surfaces. Manufacturing a long member capable of forming the pair of second inclined portions by sandwiching a portion of the pair of first inclined portions away from the connection end between the forming surface and the pair of sixth forming surfaces, respectively. apparatus.