Press forming method, method for manufacturing press-formed component and method for determining preform shape used in these methods

Abstract

A method is provided for press forming a product having a shape of a top board portion, a vertical wall portion continuously formed from the top board portion and a flange portion continuously formed from the vertical wall portion at a press process of two or more stages, wherein a convex or concave bead shape is preformed in a position of a flat metal sheet as a raw material corresponding to a neighborhood of a position generating breakage or flange wrinkles when the raw material is formed into a product shape, and thereafter a product shape is press formed from the raw material having the preformed bead shape.

Claims

1. A method for press forming a product having a shape of a top board portion, a vertical wall portion continuously formed from the top board portion and a flange portion continuously formed from the vertical wall portion in a press process of two or more stages, the method comprising: preforming a convex or concave bead shape at a position of a flat metal sheet as a raw material corresponding to at least one of the top board portion and the vertical wall portion of the product shape when the flat metal sheet is formed into the product shape, and thereafter, press forming the product shape from the metal sheet having the preformed bead shape, while feeding the material of the metal sheet from the preformed bead shape outwardly relative to a center of the metal sheet during the press forming.

2. The method according to claim 1, further comprising, prior to the preforming, performing a shape analysis with FEM in simulated press forming of the flat metal sheet to the product shape carried out by a computer, and judging a position at which breakage is generated based on results of the shape analysis with FEM.

3. The method according to claim 1, further comprising a blanking step of the raw material, the blanking step including the preforming of the bead shape.

4. The method according to claim 1, further comprising: an initial shape analysis step of performing a first shape analysis with FEM when the metal sheet is press formed to the product shape, a step of setting the bead shape and setting a position of introducing the bead shape based on a position at which breakage is generated if breakage is revealed by the initial shape analysis step, a preform analysis step of performing a second shape analysis with FEM when the metal sheet having the bead shape is press formed to the product shape, a step of changing the bead shape and/or changing the position of introducing the bead shape if breakage is revealed by the preform analysis step, and a step of determining the bead shape to be the convex or concave bead shape and determining the position of introducing the bead shape to be the position of the flat metal sheet corresponding to the at least one of the top board portion and the vertical wall portion of the product shape when no breakage is revealed by the preform analysis step.

5. The method according to claim 4, wherein: the step of setting the bead shape comprises setting the bead shape so as to extend in a direction parallel to an extending direction of the breakage.

6. The method according to claim 4, wherein the method further comprises a step of determining a maximum principal strain direction of the position at which breakage is generated and then setting the bead shape so as to extend in a direction perpendicular to the maximum principal strain direction.

7. The method according to claim 4, wherein the method further comprises a step of determining a maximum principal strain distribution in the position at which breakage is generated in a direction perpendicular to an extending direction of the breakage; and setting a rising position of the strain as the position of introducing the bead shape.

8. The method according to claim 4, wherein the method further comprises a step of determining a stretching quantity L0 of the raw material in the position at which breakage is generated in a direction perpendicular to an extending direction of the breakage; and setting the preforming bead shape to have a section such that a stretching quantity L of the raw material in a portion of the bead shape is 0.1L0L1.0L0.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic view in a section of a mold showing a usual forming method for two kinds of press forming as a target example of applying a press forming method according to an embodiment of the invention.

(2) FIG. 2 is a schematic view illustrating an example of a product shape applied by an embodiment of the press forming method according to the invention.

(3) FIG. 3 is a schematic view in a section of a mold showing an embodiment of the press forming method according to the invention applied to the bulging shown in a left side of FIG. 1.

(4) FIG. 4 is a schematic view in a section of a mold showing an embodiment of the press forming method according to the invention applied to the drawing shown in a right side of FIG. 1.

(5) FIG. 5 is a diagram showing a relation between a position (site) of a raw material and a magnitude of maximum principal strain in the drawing shown in a right side of FIG. 1.

(6) FIG. 6 is a schematic view illustrating an example of a position of introducing a preforming bead portion into a product shape shown in FIG. 2.

(7) FIG. 7 is a flow chart showing a procedure in an embodiment of the method for determining a preform shape according to the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(8) An embodiment of the invention will be described in detail with reference to the accompanying drawings below. As shown in FIG. 1, a breakage in a blank B as a raw steel sheet material being a flat metal sheet at a shoulder portion of a punch in the bulging or drawing is generated by concentration of strain into a site of the raw material located at the shoulder portion of the punch because a site of the raw material located at a top face of the punch is not deformed by frictional resistance between the mold and the raw material (outflow of the material from the position of punch top face is small).

(9) As shown in FIG. 2, when a press-formed component having a hat type sectional shape of a top board portion P1, a vertical wall portion P2 continuously formed in the top board portion P1 and a flange portion P3 continuously formed in the vertical wall portion P2, for example, an L-shaped press-forming component P in a planar view is manufactured by drawing as a press-formed product, an inflow of a material from the flange portion P3 is small in a corner portion, while an inflow of the material from the flange portion P3 is large in a portion adjacent to the corner portion so that flange wrinkles are generated in the portion adjacent to the corner portion resulting from the inflow quantity difference in the flange portion P3.

(10) Therefore, it is possible to avoid any forming failures such as breakage and flange wrinkles by promoting an inflow of a raw material into a special portion.

(11) As a state of a raw material before and after final forming is shown in right and left of FIG. 3, a blank B having a preformed concave bead portion (preformed portion) PF is used in a side of a punch lateral to a position of generating breakage in the bulging, whereby the preformed bead portion PF is collapsed on the way of forming to a product shape to produce outflow of material from the bead portion PF of the raw material to a stress concentrating portion located at a shoulder portion of the punch, and hence strain can be dispersed to improve the formability.

(12) Also, as a state of a raw material before and after final forming is shown in right and left of FIG. 4, the preforming of the bead portion PF is introduced to breakage of the raw material generated in the drawing and located at the shoulder portion of the punch in the same manner as mentioned above, whereby the formability is improved. In the drawing, the preforming of the bead portion PF is introduced into the vertical wall portion in addition to the top board portion located in a top of the punch to mitigate tension from the side of the flange portion, which is effective to improve the formability.

(13) As to flange wrinkles generated in the vicinity of the corner portion or the like during the drawing, the preforming of the bead portion PF is introduced into the top board portion located at a top of the punch, which portions being large in the inflow of material into the vertical wall portion, and vertical wall portion, whereby the inflow quantity from the flange portion is decreased due to the outflow of material from the bead portion in the top board portion and the vertical wall portion to mitigate the flange wrinkles.

(14) In FIG. 5 is shown a maximum principal strain distribution of the raw material in a cross-sectional direction during the drawing shown in FIG. 4. A position of introducing the preformed portion (bead portion PF) is appropriate to be a rising (increasing) portion of the maximum principal strain. If the preformed portion is introduced into a large zone of the maximum principal strain (breakage risking portion), strain generated in the preforming is added to strain generated in the final forming, and hence breakage is apt to be easily generated in the preformed portion.

(15) Since the vertical wall portion is large in strain quantity, if the preformed portion is introduced thereinto, the possibility of generating breakage cannot be denied. Therefore, it is preferable to introduce the preformed portion into the top board portion having strain quantity smaller than that of the vertical wall portion and located at the top of the punch. Also, as the preformed portion is exceedingly remote from the rising portion of the maximum principal strain, the effect of outflowing material from the preformed portion to the breakage risking portion becomes small. Furthermore, a direction of introducing the preforming of the bead shape (extending direction of bead shape) is a direction parallel to an extending direction of breakage portion simply. If the maximum principal strain direction of the breakage portion can be specified by shape analysis through a program of FEM (Finite Element Method), use of a scribed circle or the like, a higher effect can be expected by introduction of the preforming of the bead shape extending in a direction perpendicular to the maximum principal strain direction.

(16) A bulging quantity (stretching quantity) L in the preforming is set to be not more than a stretching quantity L0 calculated from a maximum principal strain of a breakage portion located at a shoulder portion of a punch shown in FIG. 5. L0 is determined by subtracting a line length of a flat raw material before preforming from a line length of a bulged portion. L is defined by 0.1L0L1.0L0. In the case of L>1.0L0, the line length becomes excessive to generate wrinkles. In the case of L<0.1L0, the supply of the material from the preformed portion is insufficient, so that breakage cannot be suppressed. In order to obtain sufficient effect of suppressing breakage, it is preferable to be 0.3L0L1.0L0.

(17) As previously mentioned, the flange wrinkles are apt to be easily generated in a portion producing a difference in the inflow quantity of material from the flange portion to the vertical wall portion such as a neighborhood of a corner portion in the drawing of a L-shaped component. Although it is possible to suppress wrinkles by increasing a wrinkle-pressing force, as the strength of the material becomes higher, it is necessary to more increase the wrinkle-pressing force. As the wrinkle-pressing force is increased, inflow of the material is decreased, and hence breakage is generated in the shoulder portion of the punch or the like.

(18) In order to suppress the flange wrinkles, it is enough to make inflow difference of material small, or to reduce inflow of material in a portion having a large inflow of material. As shown in FIG. 6, when the preforming of a bead shape PF extending in a direction parallel to an extending direction (up and down directions in the figure) of a flange portion P3 is introduced into a position of a vertical wall portion P2 adjacent to a region generating flange wrinkles in the flange portion P3 of a press-formed component P as a press product shown in FIG. 2, outflow of material is promoted in the vertical wall portion P2 by flattening of the bead shape PF in the final forming to thereby cause an effect of suppressing flange wrinkles in the flange portion P3.

(19) When an inflow quantity of material at a position generating flange wrinkles is W and an inflow quantity of material at a position generating no flange wrinkle in its vicinity is W0, an inflow quantity difference is WW0. Therefore, it is enough to extend the line length by not more than WW0 in the preformed portion, wherein a stretching quantity L of the preformed portion is set to be 0.1(WW0)L(WW0). In the case of L>(WW0), excessive outflow of material from the preformed portion is generated to cause flange wrinkles. In the case of L<0.1(WW0), the outflow effect of material from the preformed portion is small and the generation of flange wrinkles cannot be suppressed sufficiently. In order to suppress flange wrinkles sufficiently, it is preferable to be 0.3(WW0)L(WW0).

(20) The cross-sectional shape of the preformed portion is preferable to be a curved shape in view of the easy collapsing of the preformed portion, but may be a rectangular section or the like as long as the predetermined line length can be ensured. From a viewpoint of decreasing the number of steps, it is also preferable to perform the preforming of the bead shape by bulging at a time of punching in a blanking step of punching out a raw material of a given contour profile from a rectangular or band-shaped raw material sheet before the raw material is formed to a product shape.

(21) Further, the shape and introduction position of the preformed portion may be determined by observing breakage or wrinkles of a product actually press formed from a flat type blank. In the method for determining the preform shape according to an embodiment of the invention, however, the determination can be performed more effectively by using a shape analysis through a usual program of FEM (Finite Element Method) carried by a computer when the blank is press formed to a product shape as shown in a flow chart of FIG. 7.

(22) In the flow chart of FIG. 7, a proper blank shape is first set at a step S1, and then shape analysis with FEM is performed in the press forming from the blank shape to a product shape (press-formed component shape) at a step S2, and subsequently the presence or absence of breakage or wrinkles in the product shape is examined from the analytical results at a step S3, and the presence or absence of generating breakage or wrinkles is judged from the examined results at the next step S4, and a shape, height, length and the like of a preforming bead shape and a position thereof are set at a step S5 if the breakage or wrinkles are generated or are changed if they are already set, and thereafter the shape analysis with FEM at step S2 is again performed on the blank shape having the bead shape in the press forming to a product shape. On the other hand, the above procedure is ended when the generation of breakage or wrinkles are not revealed by judging the generation of breakage or wrinkles from the examination results at the step S4.

(23) According to the method of this embodiment, the preform analysis is repeated by changing a preforming bead shape and/or a position of introducing such a bead shape until no generation of breakage or flange wrinkles is revealed, so that a preforming bead shape and a position of introducing such a bead shape in the actual press forming can be accurately determined to a bead shape and a position of generating no breakage or flange wrinkles in the press forming from the preformed raw material shape to a product shape at a final step.

EXAMPLE

(24) An example of the above embodiment and a comparative example will be described below. Assuming that a L-shaped component shape of a press-formed component P shown in FIG. 2 is used as a product shape, an FEM analysis is conducted in the drawing performed with a press mold comprised of an upper die and a lower mold provided with a punch cooperated with the upper die and a blank holder clipping a blank together with the upper die as shown in FIG. 4. As conditions of FEM analysis, a solver is a LD-DYNA version 971 (dynamic explicit method) and a mesh size is 2 mm. A blank material is a steel sheet of 1180 MPa grade with a thickness of 1.6 mm, and a stress-strain relation approximated by Swift equation of stress-strain curve measured from JIS No. 5 specimen for tensile test. A frictional coefficient between the blank and the mold is 0.12. A cushion force (wrinkle-pressing force) is 50 tons and 80 tons. The judgement of breakage risking portion and flange wrinkle risking portion shown in FIG. 2 is performed by adopting a forming limit diagram (FLD) of a material used in the analysis results.

(25) The results of the above judgement are shown in Table 1.

(26) TABLE-US-00001 TABLE 1 Cushion Position of Presence or Presence or force introducing absence of absence of No. (ton) Preform preform L/L0 L/W-W0 breakage wrinkles Remarks 1 50 Absence Presence Presence Comparative (flange) Example 1 2 50 Presence Top of punch 1.0 Absence Absence Example 1 3 80 Presence Top of punch 0.8 Absence Absence Example 2 4 80 Presence Top of punch 0.12 Absence Absence Example 3 5 80 Presence Top of punch 0.09 Presence Absence Comparative Example 2 6 50 Presence Top of punch 1.10 Absence Presence Comparative (top of punch) Example 3 7 50 Presence Top of punch and 1.0 1.0 Absence Absence Example 4 vertical wall 8 50 Presence Top of punch and 1.0 0.8 Absence Absence Example 5 vertical wall 9 50 Presence Top of punch and 1.0 0.12 Absence Absence Example 6 vertical wall 10 50 Presence Top of punch and 1.0 0.09 Absence Presence Comparative vertical wall (flange) Example 4 11 50 Presence Top of punch and 1.0 1.1 Absence Presence Comparative vertical wall (flange) Example 5 12 30 Presence Vertical wall 0.5 Absence Absence Example 7 13 30 Presence Vertical wall 0.9 Absence Absence Example 8 14 80 Absence Presence Absence Comparative Example 6 15 30 Presence Vertical wall 0.09 Absence Presence Comparative (flange) Example 7 16 30 Presence Vertical wall 1.1 Absence Presence Comparative (flange) Example 8

(27) No. 1 (Comparative Example 1) shows results of usual drawing having no preform, in which breakage is generated in a position corresponding to a shoulder portion of a punch and wrinkles are generated in a flange portion. In No. 2-No. 4 (Examples 1-3), a preform is introduced into a position corresponding to a top of a punch as a countermeasure to breakage, and a cushion force of 80 tons is used as a countermeasure to flange wrinkles, but breakage is not observed at a position corresponding to a shoulder portion of the punch. In No. 5 (Comparative Example 2), a line length of the preform is lacking, so that breakage is generated at a position corresponding to the shoulder portion of the punch. In No. 6 (Comparative Example 3), the line length of the preform is sufficient against breakage in a position corresponding to the shoulder portion of the punch, but is too long and hence a surplus of the line length is produced in the top board portion corresponding to the bottom of the punch to generate wrinkles. In No. 7-No. 9 (Examples 4-6), a proper preform is introduced into the top board portion corresponding to the top of the punch and the vertical wall portion, so that not only the breakage at a position corresponding to the shoulder portion of the punch but also the flange wrinkles are not observed.

(28) In No. 10 and No. 11 (Comparative Examples 4 and 5), the line length of the preform introduced into the vertical wall portion is lacking, so that the flange wrinkles are generated in the flange portion. In No. 12 and No. 13 (Examples 7 and 8), the breakage at a position corresponding to the shoulder portion of the punch is suppressed by decreasing the cushion force to 30 tons, while the flange wrinkles are not observed by introducing the preform into the vertical wall portion. When the cushion force is increased for suppressing the flange wrinkle as shown in No. 14 (Comparative Example 6), the breakage is generated at a position corresponding to the shoulder portion of the punch. When the line length of the preform shape is too short as shown in No. 15 (Comparative Example 7), the outflow of material from the flange portion becomes larger and hence the flange wrinkles are generated. On the other hand, when the line length of the preform shape is too long as shown in No. 16 (Comparative Example 8), the outflow of material from the flange portion becomes too small to cause the surplus of the material and hence the flange wrinkles are generated.

(29) Although the above is described based on the illustrated examples, the invention is not limited to such examples and may be properly modified within a scope of the claims, if necessary. For example, the product shape and press-formed component shape may be formed by spherical head bulging with a top board portion of a curved form, or may be other shape such as U shape, channel shape or the like in addition to L shape in a planar view.

(30) The press mold is comprised of an upper die and a lower mold provided with a punch cooperated with the upper die and a blank holder clipping a blank together with the upper die in the above examples, but is not limited thereto. The upper die may be provided with a die positively collapsing a bead portion of a blank between the lower punch, or the mold may be upside-down structure of the above mold.

(31) According to the press forming method and the method for manufacturing a press-formed component according to the invention, the generation of breakage or wrinkles can be suppressed in the drawing or bulging to improve the yield and the formability effectively without involving a mold of a complicated structure, an increase of a press process or a restriction of a component shape.

(32) Also, according to the method for determining a preform shape according to an embodiment of the invention, the procedure of performing the preform analysis by changing the preforming bead shape and/or the position of introducing such a bead shape is repeated until no generation of breakage or flange wrinkles is revealed, so that the bead shape and the position of introducing such a bead shape to be preformed in the actual press forming can be accurately determined to a bead shape and a position not generating breakage and flange wrinkles when the preformed raw material is press formed to a product shape or a press-formed component shape at a final step.

DESCRIPTION OF REFERENCE SYMBOLS

(33) B blank P pressed product (press-formed component) P1 top board portion P2 vertical wall portion P3 flange portion PF preformed portion (bead portion)