WORKPIECE PROCESSING METHOD AND PROCESSING DEVICE

Abstract

A workpiece processing method includes: a section roll forming step of subjecting a flat plate shaped workpiece to forming to impart a prescribed cross-sectional shape thereto; a solution heat treatment step of subjecting the workpiece, after the section roll forming step has been performed, to solution heat treatment; a contour roll forming step of subjecting the workpiece, after the solution heat treatment step has been performed, to forming to bend the workpiece into an arcuate shape; and a stretch forming step of subjecting the workpiece, after the contour roll forming step has been performed, to forming to impart a curved shape, following a curved surface of a die, to the workpiece by bringing the workpiece into contact with the curved surface and inputting a tension load to the workpiece.

Claims

1. A workpiece processing method comprising: a first forming step of performing forming to impart a predetermined cross-sectional shape to a flat plate-shaped workpiece; a solution heat treatment step of performing solution heat treatment on the workpiece after the first forming step has been performed; and a second forming step of performing forming to bend the workpiece into an arcuate shape on the workpiece after the solution heat treatment step has been performed.

2. The workpiece processing method according to claim 1, further comprising: a third forming step of performing, on the workpiece after the second forming step has been performed, forming to impart a curved shape along a curved surface of a die having the curved surface to the workpiece by bringing the workpiece into contact with the curved surface of the die and inputting a tensile load in a tangential direction to the curved surface to the workpiece.

3. A processing device for performing forming to impart a predetermined cross-sectional shape to a flat plate-shaped workpiece and then bending the workpiece subjected to solution heat treatment into an arcuate shape, the device comprising: a plurality of supporting parts that support the workpiece so as to be transferable in a predetermined direction by gripping the workpiece between a pair of rollers disposed to face each other such that rotation axes are parallel to each other, wherein the plurality of supporting parts are disposed side by side in the predetermined direction, and in a state where the plurality of supporting parts support the workpiece, at least one of the supporting parts supporting the workpiece moves in an intersecting direction that is a direction intersecting the predetermined direction to bend the workpiece into an arcuate shape.

4. The processing device according to claim 3, wherein each of the plurality of supporting parts includes a drive unit that rotates the roller around the rotation axis, and changes a rotation speed of each drive unit.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0030] FIGS. 1A-E are diagrams showing a flow of a work processing method according to an embodiment of the present invention.

[0031] FIG. 2 is a schematic perspective view of a section roll forming device according to an embodiment of the present invention.

[0032] FIG. 3 is a schematic top view of a contour roll forming device according to an embodiment of the present invention.

[0033] FIG. 4 is a diagram schematically showing a main part of the contour roll forming device of FIG. 3.

DESCRIPTION OF EMBODIMENTS

[0034] Hereinafter, an embodiment of a workpiece processing method and a processing device according to the present invention will be described with reference to the drawings.

[0035] The processing method according to the present embodiment performs processing of imparting a predetermined cross-sectional shape to a plate-shaped work (workpiece) W made of an aluminum alloy, and performs processing of bending the work W with a predetermined cross-sectional shape imparted thereto such that a longitudinal direction thereof forms an arc. The processed work W is used, for example, for a frame or the like configuring an aircraft component such as a fuselage or a main wing of an aircraft. That is, the processing method according to the present embodiment is used when manufacturing a frame or the like configuring an aircraft component such as a fuselage or a main wing of an aircraft from the plate-shaped work W.

[0036] The processing method according to the present embodiment will be described with reference to FIGS. 1A to 1E. FIGS. 1A to 1E show the processing method.

[0037] As shown in FIG. 1A to FIG. 1E, the processing method of the present embodiment includes a section roll forming step (first forming step) of performing forming to impart a predetermined cross-sectional shape to a flat plate-shaped work W, a solution heat treatment step of performing solution heat treatment on the work W after the section roll forming step has been performed, a contour roll forming step (second forming step) of performing forming to bend the work W into an arcuate shape on the work W after the solution heat treatment step has been performed, and a stretch forming step (third forming step) of enhancing processing accuracy by imparting a curved shape to the work W after the contour roll forming step has been performed by bringing the work W into contact with a die 12 while pulling both ends.

[0038] The section roll forming step is performed by a section roll forming device 2 shown in FIG. 2. In the section roll forming step, forming to impart a predetermined cross-sectional shape to the work W by introducing a flat plate-shaped work W connected into a band shape between plural sets of forming rolls 3 provided in the section roll forming device 2 is performed. The work W with a predetermined cross-sectional shape imparted thereto is taken out from the section roll forming device 2 and cut to have a predetermined length, whereby a long work W with a predetermined cross-sectional shape imparted thereto is obtained. In the present embodiment, as an example, the long work W shown in FIG. 1B is formed by performing forming to impart a substantially Z-shaped cross-sectional shape to the work W and cutting the work W with a cross-sectional shape imparted thereto into a length in a range of 5 m to 6 m.

[0039] The work W to be subjected to the section roll forming is an annealed material (so-called O material).

[0040] In the solution heat treatment step, as shown in FIG. 1C, the long work W formed by the section roll forming step is accommodated in a treatment furnace 4. Then, solution heat treatment is performed on the work W accommodated in the treatment furnace 4.

[0041] The contour roll forming step is performed by a contour roll forming device (a processing device) 5 shown in FIGS. 3 and 4. The contour roll forming step is performed on the work W that is the work W after the solution heat treatment has been performed and is a material (so-called W material) before natural aging. In this manner, in the present embodiment, the temper of the work W to be subjected to the contour roll forming step is different from the temper of the work W to be subjected to the section roll forming step.

[0042] The contour roll forming device 5 includes a main body part 6 in which bending forming is performed while transferring the long work W in a predetermined direction, a first pinch roll (not shown) for introducing the work W into the main body part 6, a second pinch roll (not shown) for taking out the work W from the main body part 6, and a control device (not shown) for controlling the main body part 6, and performs forming in which the introduced work W is transferred in a predetermined direction and bent into an arcuate shape such that the longitudinal direction thereof describes an arc. The black arrow in FIG. 3 indicates the direction in which the work is introduced.

[0043] The main body part 6 includes five supporting parts 9 which are disposed side by side in the transfer direction of the work W (the predetermined direction), and a moving part 10 that moves a specific supporting part 9 in an intersecting direction that is a direction intersecting the transfer direction.

[0044] Each of the supporting parts 9 has a pair of (two) rollers 11 disposed to face each other such that rotation axes extending in an up-down direction are parallel to each other, and grips the long work W between the pair of rollers 11 to support the long work W so as to be able to be transferred in a predetermined direction. Further, a servomotor (drive unit) (not shown) that rotationally drives the roller 11 around the rotation axis is directly connected to each roller 11 provided in each supporting part. That is, the servomotors are directly connected to all of the ten rollers 11 of the main body part 6.

[0045] Each supporting part 9 transfers the introduced work W to the adjacent supporting part 9 on the downstream side in the transfer direction of the work W by the rotational driving forces of the rollers 11.

[0046] The five supporting parts 9 are disposed side by side in the transfer direction of the work W, as described above. In the following description, a first supporting part 9a, a second supporting part 9b, a third supporting part 9c a fourth supporting part 9d, and a fifth supporting part 9e are arranged in this order from the supporting part 9 disposed on the first pinch roll side (that is, on the upstream side in the transfer direction of the work W). Further, the third supporting part 9c, the fourth supporting part 9d, and the fifth supporting part 9e are disposed so as to be inclined by a predetermined angle with respect to the first supporting part 9a and the second supporting part 9b. Further, each supporting part 9 is disposed such that the inclination angle of the third supporting part 9c, the inclination angle of the fourth supporting part 9d, and the inclination angle of the fifth supporting part 9e are different from each other. That is, the third supporting part 9c, the fourth supporting part 9d, and the fifth supporting part 9e are not disposed in parallel. The disposition of each supporting part 9 is set in accordance with the bend aspect (curvature or the like) of the work W after forming.

[0047] The three moving parts 10 are provided so as to correspond to the third supporting part 9c, the fourth supporting part 9d, and the fifth supporting part 9e. That is, in the present embodiment, the third supporting part 9c, the fourth supporting part 9d, and the fifth supporting part 9e among the five supporting parts 9 provided in the main body part 6 are movable at the time of the processing of the work W, and the first supporting part 9a and the second supporting part 9b are configured not to move at the time of the processing of the work W.

[0048] The moving part 10 linearly moves the supporting part 9 in the intersecting direction by the driving force of a driving source (not shown). The moving directions of the third supporting part 9c, the fourth supporting part 9d, and the fifth supporting part 9e are not parallel. The moving direction of each supporting part 9 is set in accordance with the bend aspect (curvature or the like) of the work W after forming.

[0049] Further, as shown in FIG. 4, the movement distance of each supporting part 9 increases as it goes toward the supporting part 9 disposed on the downstream side. That is, when the movement distance of the third supporting part 9c is set to be L3, the movement distance of the fourth supporting part 9d is set to be L4, and the movement distance of the fifth supporting part 9e is set to be L5, the relationship between the movement distances is L3<L4<L5.

[0050] The control device controls each moving part 10, based on information which is sent from a determination unit (not shown) that determines whether or not each supporting part has supported the work W. Specifically, after the determination unit determines that the supporting part 9 has supported the work W, the control device moves the moving part 10 corresponding to the supporting part 9.

[0051] As the determination unit, motor rotation speed measurement means for measuring the rotation speed provided in the servomotor can be given as an example, and the control device may determine that the rollers 11 have supported the work W, in a case where the rotation speed of the servomotor measured by the motor rotation speed measurement means is reduced. The motor rotation speed measurement means is an example of the determination unit, and the present invention is not limited to this. The determination unit may be any device as long as it can determine whether or not the supporting part 9 has supported the work W.

[0052] The control device includes, for example, a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), a computer-readable storage medium, and the like. Then, a series of processes for realizing various functions are stored in the storage medium or the like in the form of a program as an example, and the CPU reads the program into the RAM or the like and executes information processing and arithmetic processing, whereby various functions are realized. As the program, a form installed in advance in a ROM or other storage medium, a form which is provided in a state of being stored in a computer-readable storage medium, a form which is distributed through wired or wireless communication means, or the like may be applied. The computer-readable storage medium is a magnetic disk, a magneto-optical disk, a CD-ROM, a DVD-ROM, a semiconductor memory, or the like.

[0053] The first pinch roll is disposed on the upstream side of the first supporting part 9a. The first pinch roll assists in the introduction of the work W into the first supporting part 9a. The second pinch roll is disposed the downstream side of the fifth supporting part 9e. The second pinch roll assists in the pulling-out of the work W from the fifth supporting part 9e.

[0054] The contour roll forming device 5 according to the present embodiment is configured in this manner. That is, in the contour roll forming device 5, in a state where the plurality of supporting parts 9 support the introduced work W, at least one of the supporting parts 9 supporting the work W moves in the intersecting direction, thereby bending the work W into an arcuate shape.

[0055] Specifically, describing the operation of the contour roll forming device 5 with reference to FIG. 4, first, a tip portion of the work W introduced into the contour roll forming device 5 is gripped by rollers 11a of the first supporting part 9a under the assist of the first pinch roll. The tip portion of the work W gripped by the rollers 11a of the first supporting part 9a is transferred to the second supporting part 9b by the rotational driving forces of the rollers 11a. At this time, the portion other than the tip portion of the work W is still in a state of being gripped by the first supporting part 9a.

[0056] The tip portion of the work W transferred to the second supporting part 9b is gripped by rollers 11b of the second supporting part 9b and is transferred to the third supporting part 9c by the driving forces of the rollers 11b. If the tip portion of the work W is transferred to the third supporting part 9c, rollers 11c of the third supporting part 9c grip the tip portion of the work W. At this time, a substantially central portion in the longitudinal direction of the work W is still in a state of being gripped by the second supporting part 9b, and a downstream end portion of the work W is still in a state of being gripped by the first supporting part 9a. That is, the work W is in a state of being supported by the three supporting parts 9: the first supporting part 9a, the second supporting part 9b, and the third supporting part 9c.

[0057] If the determination unit determines that the third supporting part 9c has gripped the tip portion of the work W, the control device transmits a signal to the moving part 10 corresponding to the third supporting part 9c to drive the moving part 10, thereby moving the third supporting part 9c. That is, the rollers 11c of the third supporting part 9c move by a predetermined distance L3 from the initial position indicated by a broken line circle to the position indicated by a solid line circle. At this time, since the first supporting part 9a and the second supporting part 9b do not move, if the third supporting part 9c moves, the work W is bent according to the movement of the third supporting part 9c. Specifically, the work W is bent into an arc shape connecting the respective end portions of the roller 11a, the roller lib, and the moved roller 11c, as shown by a solid line arc in FIG. 4.

[0058] The third supporting part 9c moves and also transfers the tip portion of the work W to the fourth supporting part 9d by the driving forces of the rollers 11c. If the tip portion of the work W is transferred to the fourth supporting part 9d, rollers 11d of the fourth supporting part 9d grip the tip portion of the work W. At this time, the downstream end portion of the work W is released from being gripped by the first supporting part 9a and is gripped by the second supporting part 9b. That is, the work W is in a state of being supported by the three supporting parts 9: the second supporting part 9b, the third supporting part 9c, and the fourth supporting part 9d.

[0059] If the determination unit determines that the fourth supporting part 9d has gripped the tip portion of the work W, the control device transmits a signal to the moving part 10 corresponding to the fourth supporting part 9d to drive the moving part 10, thereby moving the fourth supporting part 9d. That is, the rollers 11d of the fourth supporting part 9d move by a predetermined distance L4 from the initial position indicated by the broken line circle to the position indicated by the solid line circle. If the fourth supporting part 9d moves, the work W is bent according to the movement of the fourth supporting part 9d. Specifically, the work W is bent into an arc shape connecting the respective end portions of the roller lib, the moved roller 11c, and the moved roller 11d, as shown by a dashed-dotted line arc in FIG. 4.

[0060] The fourth supporting part 9d moves and also transfers the tip portion of the work W to the fifth supporting part 9e by the driving forces of the rollers 11d. If the tip portion of the work W is transferred to the fifth supporting part 9e, rollers 11e of the fifth supporting part 9e grip the tip portion of the work W. At this time, the downstream end portion of the work W is released from being gripped by the second supporting part 9b and is gripped by the third supporting part 9c. That is, the work W is in a state of being supported by the three supporting parts 9: the third supporting part 9c, the fourth supporting part 9d, and the fifth supporting part 9e.

[0061] If the determination unit determines that the fifth supporting part 9e has gripped the tip portion of the work W, the control device transmits a signal to the moving part 10 corresponding to the fifth supporting part 9e to drive the moving part 10, thereby moving the fifth supporting part 9e. That is, the rollers 11e of the fifth supporting part 9e move by a predetermined distance L5 from the initial position indicated by the broken line circle to the position indicated by the solid line circle. If the fifth supporting part 9e moves, the work W is bent according to the movement of the fifth supporting part 9e. Specifically, the work W is bent into an arc shape connecting the respective end portions of the moved roller 11c, the moved roller 11d, and the moved roller 11e, as shown by a two-dot chain line arc in FIG. 4.

[0062] The fifth supporting part 9e moves and also discharges the work W by the driving forces of the rollers 11e. At this time, the second pinch roll assists in the discharge of the work W.

[0063] In this way, the forming by the contour roll forming device 5 is performed.

[0064] The stretch forming step is performed by a stretch forming device 14, as shown in FIG. 1E. In the stretch forming step, plastic deformation is performed on the work W bent into an arcuate shape by the forming in the contour roll forming step, thereby further imparting a curved shape to the work W.

[0065] Specifically, in the stretch forming step, a curved shape along the curved surface of the die 12 having a curved shape is imparted to the work W by bringing the work W into contact with the curved surface of the die 12, and pulling the work W by gripping devices 13 that grip both ends of the work W, thereby inputting a tensile load in a tangential direction to the curved surface to the work W. At this time, since the curved surface of the die 12 has a curved shape which is required for a product or a shape close to the curved shape, highly accurate processing can be performed by performing the stretch forming.

[0066] In this manner, in the processing method according to the present embodiment, after the section roll forming is performed on the work W that is an O material, the solution heat treatment is performed, and the contour roll forming and the stretch forming are performed on the work W that has been subjected to the solution heat treatment to become a W material, whereby the work W is processed into a bent work W with a predetermined cross-sectional shape imparted thereto. In the present embodiment, since the contour roll forming and the stretch forming are performed on the work W that is the W material, the contour roll forming and the stretch forming are performed before the work W which has been subjected to the solution heat treatment is naturally aged.

[0067] The work W that is the W material may be temporarily stored in a freezer maintained at a temperature equal to or less that a predetermined temperature, between the solution heat treatment step and the contour roll forming step or between the contour roll forming step and the stretch forming step. By storing the work W in the freezer, the state of the W material can be maintained for a long time without the natural aging of the work W progressing.

[0068] According to the present embodiment, the following operation and effects can be obtained.

[0069] If the forming (section roll forming) to impart a predetermined cross-sectional shape to the flat plate-shaped work W is performed, a strain generates in the work W (particularly, a deformed portion of the work W). In the present embodiment, the solution heat treatment is performed after the section roll forming step of performing the forming to impart a predetermined cross-sectional shape is performed. In this way, the strain generated in the work W when performing the section roll forming step is recovered by the solution heat treatment (heat treatment). Therefore, in the contour roll forming step and the stretch forming step which are performed after the solution heat treatment step, it is possible to create a state where the strain of the work W is suppressed. Therefore, as compared with a method in which the section roll forming, the contour roll forming, and the stretch forming are performed after the solution heat treatment is performed, the strength of the work W in the section roll forming step and the stretch forming step is improved, and thus it is possible to make it difficult for the work W to break in the section roll forming step and the stretch forming step. Further, it is possible to make it difficult for the work W to break even when the work W is used as a product.

[0070] In particular, in a case where the section roll forming, the contour roll forming, and the stretch forming are performed after the solution heat treatment is performed, the strain generated when the section roll forming is performed is cumulatively accumulated in the subsequent forming step, and therefore, a risk of breakage particularly increases in the stretch forming step. In particular, since a locally input load increases in the portion gripped by the gripping device 13, the risk of breakage increases.

[0071] In the present embodiment, as described above, since the strain generated in the work W when the section roll forming step is performed is recovered by the solution heat treatment (heat treatment), it is possible to make it difficult for the work W to break even in the stretch forming step. Therefore, the stretch forming is performed on the work W, whereby the processing accuracy can be improved and the risk of breakage can also be reduced.

[0072] In this manner, the yield can be improved by making it difficult for the work W to break. In a case where the possibility of the work W breaking can be reduced as much as possible, it is possible to eliminate the need to set the yield. Further, it is possible to prevent a situation in which normal production stops due to a recovery operation from the breakage of the work W.

[0073] Further, there is a case where a twist or the like occurs in the work W when the solution heat treatment is performed. In the present embodiment, the contour roll forming is performed after the solution heat treatment is performed. In this way, even in a case where a twist or the like occurs in the work W when the solution heat treatment is performed, the twist or the like can be eliminated by performing the contour roll forming on the work W. Therefore, when the stretch forming step is performed, the work W can be easily mounted on the stretch forming device 14. Therefore, the stretch forming step can be facilitated.

[0074] Further, in order to perform the solution heat treatment, it is necessary to accommodate the work W in the treatment furnace 4. In the present embodiment, the solution heat treatment is performed on the work W before the contour roll forming step of bending the work W into an arcuate shape is performed. In this way, the work W when performing the solution heat treatment has a straight line shape that is not bent in an arcuate shape. Therefore, the volume of the treatment furnace 4 which is required for accommodating the work W can be made smaller than that in an arcuate work W. Therefore, the size of the treatment furnace 4 for performing the solution heat treatment can be reduced as compared with a case where the solution heat treatment is performed after the work W is bent into an arcuate shape.

[0075] Further, when the work W is bent by the contour roll forming device 5, if the supporting part 9 moves in a state where it does not support the work W, the transferred work W collides with the supporting part 9, whereby there is a possibility that the work W may be damaged.

[0076] In the contour roll forming device 5 of the present embodiment, the supporting part 9 moves in the intersecting direction in a state where the supporting part 9 supports the work W. In other words, after the pair of rollers 11 of the supporting part 9 grips the work W, the supporting part 9 moves in the intersecting direction. In this manner, since the supporting part 9 moves in a state it reliably supports the work W, it is possible to prevent the work W from being damaged due to moving in a state where it does not support the work W.

[0077] Further, the work W after the solution heat treatment has been performed is in a state where the hardness is increased, and is formed such that the length in the longitudinal direction is relatively short, and therefore, the work W is difficult to be gripped by the rollers 11.

[0078] In the present embodiment, the servomotors are directly connected to all the rollers 11. In this way, the driving force for transferring the work W can be increased. Therefore, even the work W after the solution heat treatment has been performed can be reliably gripped by the rollers 11 and can be transferred in a predetermined direction by the rotational driving forces of the rollers 11.

[0079] By utilizing this, it is also possible to form the work W by changing the bending radius of curvature of the work W by changing the rotation speed of the rollers 11 at each stage. If the rotation speed increases toward the outlet, the bending radius of curvature becomes slightly larger, and conversely, if the speed is reduced, it is also possible to make the bending radius of curvature slightly smaller.

[0080] Further, in the present embodiment, the first pinch roll and the second pinch roll assisting in the introduction and taking-out of the work W into and from the contour roll forming device 5 are provided. In this way, the work W can be more reliably introduced into the contour roll forming device 5 and the work W can be more reliably taken out from the contour roll forming device 5.

[0081] The present invention is not limited to the invention according to the embodiment described above and can be appropriately modified within a scope which does not depart from the gist of the invention.

[0082] For example, in the embodiment described above, the example in which the servomotors are directly connected to all the rollers 11 included in the main body part 6 has been described. However, the present invention is not limited to this. A servomotor may be provided only at a specific roller 11. Further, instead of directly connecting the roller 11 and the servomotor, the roller 11 and the servomotor may be indirectly connected through a gear or the like.

[0083] Further, in the present embodiment, the example in which the five supporting parts 9 are provided has been described. However, the present invention is not limited to this. The number of the supporting parts 9 may be less than or more than five as long as it is the plural.