Manufacturing method of press-formed member and press forming apparatus
10022764 ยท 2018-07-17
Assignee
Inventors
Cpc classification
B21D53/88
PERFORMING OPERATIONS; TRANSPORTING
B21D5/01
PERFORMING OPERATIONS; TRANSPORTING
International classification
B21D5/02
PERFORMING OPERATIONS; TRANSPORTING
B21D5/01
PERFORMING OPERATIONS; TRANSPORTING
Abstract
In a press forming step of obtaining, from a blank of high-tensile strength steel sheet of 390 MPa or more, a press-formed product with a shape of cross section having a groove bottom part, ridge line parts, and vertical wall parts. An outward flange including parts along the ridge line parts is formed at an end part in a longitudinal direction. Forming parts to the ridge line parts is started by creating a region positioned at an end portion, in a longitudinal direction, of a part to be formed to the groove bottom part of the blank, which is separated from a punch top part. At that time or thereafter, the region is made to approach the punch top part. When forming the ridge line parts, forming of the parts of the outward flange are conducted, the parts are formed from the start to the middle of the press forming, to reduce or prevent an occurrence of stretch flange fracture and a generation of wrinkling
Claims
1. A manufacturing method of a press-formed member, comprising a press forming step of obtaining, from a blank of high-tensile strength steel sheet of 390MPa or more, a press-formed product with a shape of cross section having at least a groove bottom part, a ridge line part continued to an end portion in a width direction of the groove bottom part, and a vertical wall part continued to the ridge line part, and in which an outward flange including a part along the ridge line part is formed at an end part in a longitudinal direction, by using a press forming apparatus including a punch and a die, wherein the press forming step includes: creating a state where a radius of curvature r.sub.p of a part to be formed to the ridge line part of the blank once becomes larger than a radius of curvature r.sub.f of the ridge line part at a point of time of completion of the press forming, in the middle of the press forming; making the radius of curvature r.sub.p approach the radius of curvature r.sub.f in a process of the press forming thereafter; and completing, when the press forming is completed, the forming of the groove bottom part, the forming of the ridge line part, the forming of the vertical wall part, and the forming of the outward flange.
2. The manufacturing method of the press-formed member according to claim 1, wherein in the state where the radius of curvature r.sub.p becomes larger than the radius of curvature r.sub.f, a region in which the curvature is formed is in a state of being wider than a region of the ridge line part at the point of time of completion of the press forming, and is in a state of being widened by being extended toward the groove bottom part side.
3. A manufacturing method of a press-formed member, comprising a press forming step of obtaining, from a blank of high-tensile strength steel sheet of 390 MPa or more, a press-formed product with a shape of cross section having at least a groove bottom part, a ridge line part continued to an end portion in a width direction of the groove bottom part, and a vertical wall part continued to the ridge line part, and in which an outward flange including a part along the ridge line part is formed at an end part in a longitudinal direction, by using a press forming apparatus including a punch and a die, wherein the press forming step includes: a first step of starting forming of a part to be formed to the ridge line part and forming of the outward flange, by creating a state where a region positioned at least at an end portion in a longitudinal direction of a part to be formed to the groove bottom part of the blank is separated from a punch top part, in the punch, which forms the groove bottom part; a second step of making, at the time of starting the forming of the part to be formed to the ridge line part or thereafter, the region approach the punch top part; and completing, when the press forming is completed, the forming of the groove bottom part, the forming of the ridge line part, the forming of the vertical wall part, and the forming of the outward flange.
4. The manufacturing method of the press-formed member according to claim 3, wherein: in the first step, the region is set to be in the state of being separated from the punch top part by creating a state where a first pad provided to be able to freely protrude from or withdraw into the punch top part, is protruded from the punch top part; and in the second step, the first pad is lowered to make the region approach the punch top part.
5. The manufacturing method of the press-formed member according to claim 4, wherein the first pad and a second pad provided on a side opposite to that of the first pad with the blank provided therebetween are used to sandwich and bind the blank.
6. The manufacturing method of the press-formed member according to claim 5, further comprising a post-press forming step with respect to the press-formed product, wherein in the post-press forming step, the outward flange of the press-formed product is further raised.
7. The manufacturing method of the press-formed member according to claim 4, further comprising a post-press forming step with respect to the press-formed product, wherein in the post-press forming step, the outward flange of the press-formed product is further raised.
8. The manufacturing method of the press-formed member according to claim 3, further comprising a post-press forming step with respect to the press-formed product, wherein in the post-press forming step, the outward flange of the press-formed product is further raised.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(22) Hereinafter, embodiments for carrying out the present invention will be described with reference to the attached drawings.
(23) A manufacturing method of a press-formed member according to the present embodiment includes a press forming step of obtaining a press-formed product from an expanded blank (which will be simply referred to as blank, hereinafter) of a steel sheet having a shape based on a product shape. Further, if a predetermined shape cannot be achieved only by the press step, the method further includes a post-press forming step of performing forming on the press-formed product to set the product to be a press-formed member as a product. Note that although it is set that the expanded blank is used, the present invention is not limited to this, and it is also possible to apply the present invention to a case where trimming in which a part of the outward flange is cut-off, is performed after the press forming step, for example.
(24) Accordingly, a shape of the press-formed member as a product will be first described, and subsequently, the press forming step and the post-press forming step will be described in this order.
(25) (1) Press-Formed Member
(26)
(27) The press-formed member 100 is obtained by performing press forming on a blank of high-tensile strength steel sheet of 390 MPa or more, and has a long length and approximately hat-shaped cross section. Specifically, the press-formed member 100 has a long groove bottom part 101, two ridge line parts 102, 102 continued to both end portions in a width direction of the groove bottom part 101, two vertical wall parts 103, 103 respectively continued to the two ridge line parts 102, 102, two curved parts 104, 104 respectively continued to the two vertical wall parts 103, 103, and two flanges 105, 105 respectively continued to the two curved parts 104, 104.
(28) At an end part in the longitudinal direction of the press-formed member 100, an outward flange 106 including parts 106a along the ridge line parts 102 is formed. In this example, at both end parts in the longitudinal direction of the press-formed member 100, outward flanges 106 continued from the groove bottom part 101 along lower portions of the two vertical wall parts 103, 103 are formed, and the outward flanges 106 are continued also to the flanges 105.
(29) As illustrated in
(30) Such a press-formed member 100 is particularly suitable for structural members of automobile (for example, cross members such as a floor cross member, and members such as a side sill and a side member). Further, in such an application, it is preferable to use, as a steel material, a high-tensile strength steel sheet such as a 980 MPa class dual phase steel sheet, for example, and by applying the present invention, it is possible to manufacture the press-formed member 100 even if the high-tensile strength steel sheet having a difficulty in forming is used.
(31) In the present embodiment, explanation is given by setting a press-formed member having a long length and having an approximately hat-shaped cross section as above, as a typical example. However, a press-formed member targeted by the present invention is not limited to this, and the present invention can also be similarly applied to, for example, one having an approximately U-shaped cross section, one having a shape which is a part of an approximately hat shape (a shape of a half side of the approximately hat shape of the cross section, as an example), and one in which a length in a longitudinal direction of a groove bottom part is relatively short such that it is about the same as a width.
(32) (2) Press Forming Step
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(34) The press forming apparatus 200 includes a punch 201 and a die 202. On both ends of the punch 201 and the die 202, wall surfaces are provided, and on the wall surfaces, outward flange forming surfaces 201a, 202a for forming the outward flanges 106 are provided.
(35) Further, the press forming apparatus 200 includes a first pad (inner pad) 203 which can freely protrude from or withdraw into a punch top part 201b, and which abuts against one surface of a blank 300 (not-illustrated in
(36) Further, the press forming apparatus 200 includes a second pad 204 which abuts against the other surface of the blank 300 (not-illustrated in
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(39) The first pad 203 is provided at a center in a width direction of the punch top part 201b, and at a position facing a region 300a being one part of a part to be formed to the groove bottom part 101 of the blank 300.
(40) The first pad 203 is applied force in the direction of the blank 300 by the pressure device, and supports the region 300a of the blank 300 at a position at which it protrudes from the punch top part 201b. In a manner as described above, the first pad 203 separates one part of the part to be formed to the groove bottom part 101 of the blank 300 from a punch surface of the punch top part 201b by an inner pad stroke (specifically, a length of the first pad 203 protruded from the punch top part 201b) Ip.
(41) Meanwhile, the second pad 204 is applied force in the direction of the blank 300 by the pressure device, and sandwiches and binds the part to be formed to the groove bottom part 101 of the blank 300 with the first pad 203.
(42) The blank 300 at this time is approximately flat when seen from a cross section in a width direction as illustrated in
(43) The region 300a, in the blank 300, supported by the first pad 203 corresponds to a region at a center portion in the width direction of the part to be foamed to the groove bottom part 101 and along an entire length in the longitudinal direction, in examples of
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(45) Note that as described above, there is a case in which the blank 300 is already deformed as illustrated in
(46) As illustrated in
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(48) When the press forming is completed, the first pad 203 is housed in the pad housing hole 201c, and the inner pad stroke Ip becomes zero. Specifically, the first pad 203 becomes flush with the punch top part 201b.
(49) Here, when the press forming in the press forming step is completed, the forming of the groove bottom part 101, the forming of the ridge line parts 102, the forming of the vertical wall parts 103, the forming of the curved parts 104, the forming of the flanges 105, and the forming of the outward flange 106 are completed. However, the outward flange 106 is in a state of extending in a diagonally outer direction in a longitudinal direction of a press-formed product, as illustrated in
(50) If the above-described steps are stated in other words, by creating a state where the region 300a of the blank 300 is pushed up by the first pad 203, there is a state where, in the middle of the press forming, a radius of curvature r.sub.p of each of the parts to be formed to the ridge line parts 102 of the blank 300 once becomes larger than a radius of curvature r.sub.f of each of the ridge line parts 102 at the point of time of completion of the press forming (refer to
(51) Further, in the process of the press forming thereafter, the region 300a of the blank 300 is made to approach the punch top part 201b, so that the radius of curvature r.sub.p becomes small to be close to the radius of curvature r.sub.f. Note that, although there locally exists a portion, in the part to be formed to the ridge line part 102, whose radius of curvature is smaller than the radius of curvature r.sub.f due to the reason that the portion is brought into contact with a shoulder of the first pad 203 and the like, the radius of curvature r.sub.p is not a value regarding such a micro-shape, and is a value regarding an entire shape of the part to be formed to the ridge line part 102.
(52) Further, at the bottom dead center of the forming being the time of completion of the press forming, the first pad 203 is completely housed in the pad housing hole 201c, resulting in that the radius of curvature r.sub.f coincides with the radius of curvature r.sub.p.
(53) As described above, when the forming of the ridge line parts 102, and in accordance with that, the forming of the parts 106a of the outward flange 106 are conducted, the parts are not formed rapidly into their final shapes, but formed relatively moderately from the start to the middle of the press forming by using the first pad 203, to thereby reduce or prevent the occurrence of stretch flange fracture at the outer peripheral edge portions of the parts 106a of the outward flange 106, and the generation of wrinkling at the portion of the ridge line part 102 in the vicinity of the outward flange 106 or the portion in the vicinity of the root in the outward flange 106 (refer to portions 102a in
(54) Further, it is desirable to sandwich and bind the region 300a of the blank 300 using the first pad 203 and the second pad 204 from the start to the completion of the press forming, for preventing the reduction in formability due to the positional displacement of the blank 300, and for suppressing the reduction in dimensional accuracy of the formed product.
(55) The press-formed product obtained through the press forming step is sometimes a press-formed member as it is as a product, and in some cases, the process proceeds to the post-press forming step by using the press-formed product as an intermediate formed product, as will be described later.
(56) (3) Post-Press Forming Step
(57) As illustrated in
(58) In the post-press forming step, the outward flange 106 of the press-formed product obtained through the press forming step is further raised, as illustrated in
(59) As a method of raising the outward flange 106, a method of using a cam structure, or a bending method which does not use the cam structure, for example, can be employed.
(60) Specifically, it can also be said that the post-press forming step is a step in which the press-formed product obtained through the press forming step is set as the intermediate formed product, and by raising the outward flange 106 of the product, the press-formed member 100 as a product is obtained. Although there is certainly a case where the press-formed product obtained through the press forming step can be set as it is to the press-formed member as a product, in a case where a degree of dimensional accuracy and a degree of rising of the outward flange in the press-formed member are moderate and the like, and in this case, the post-press forming step may be omitted.
(61)
(62) In the targeted press-formed product, it was set that a height (from a lower surface of the flange 105 to an upper surface of the groove bottom part 101) is 100 mm, a curvature of the ridge line part 102 is 12 mm, a cross-sectional wall angle is 80 degrees, the rising angle is 80 degrees, a width of flat portion of the groove bottom part 101 is 60 mm, a flange width of the outward flange 106 (except for the vicinity of the parts 106a) is 15 mm, and a curvature of a rising portion of the outward flange 106 is 3 mm. Further, although the press forming tool has a shape which is nearly a shape corresponding to the press-formed member, in this case, the forming was conducted by the press forming step and the post-press forming step. In the press forming step, a rising angle of the outward flange 106 of the forming tool of the parts corresponding to the groove bottom part 101, the ridge line parts 102 and the vertical wall parts 103 was set to 60 degrees, and an inner pad width in the press forming step was set to 44 mm.
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(64) Note that a state where the inner pad stroke Ip is 0 mm, is equivalent to a state where the first pad 203 does not exist in a press forming tool.
(65) When the inner pad stroke Ip is 0 mm, since the sheet thickness strain at the outer peripheral edge portion of the part 106a of the outward flange 106 reaches up to about 0.18, as illustrated in
(66) On the contrary, in the press forming to which the present invention is applied, it can be understood that by providing the inner pad stroke Ip, it is possible to suppress the reduction in sheet thickness at the outer peripheral edge portion of the part 106a of the outward flange 106, and the increase in thickness in the vicinity 102a of the root portion of the part 106a of the outward flange 106 (the rising portion of the ridge line part 102). Accordingly, it becomes possible to effectively realize the suppression of the stretch flange fracture and the suppression of the generation of wrinkling.
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(69) As illustrated in
(70) As described above, it is possible to improve the formability of the continuous outward flange 106 including the parts 106a, without providing cutouts which are deep enough to reach the ridge line parts 102 to the parts 106a of the outward flange 106 and without generating lowering of material yield.
(71) As stated above, the present invention is described with various embodiments, but, the present invention is not limited only to these embodiments, and modifications and so on can be made within a scope of the present invention.
(72) The above-described embodiment is described by citing a case, as an example, in which both of the press forming step and the post-press forming step are conducted by the press forming through the bend forming which uses no blank holder, but, the present invention is not limited to this press forming, and can also be applied to press forming by drawing which uses the blank holder.
(73) Further, although the above-described embodiment describes that the punch 201 is positioned on the lower side, and the die 202 is positioned on the upper side, the relationship of the upper and lower positions may also be opposite, for example.
(74) Further, in the present invention, the press forming step or the post-press forming step is not limited to the cold forming, and may also be hot forming (so-called hot stamping). However, since the hot forming can originally realize good stretch flanging, it is further effective to apply the present invention particularly to the cold forming.
INDUSTRIAL APPLICABILITY
(75) The present invention can be utilized for manufacturing, not only a structural member of automobile but also a press-formed member, from a blank of high-tensile strength steel sheet of 390 MPa or more, with a shape of cross section having at least a groove bottom part, ridge line parts continued to end portions in a width direction of the groove bottom part, and vertical wall parts continued to the ridge line parts, and in which an outward flange including parts along the ridge line parts is formed at an end part in a longitudinal direction.