JP2007319892A - Sequential forming method and sequential forming apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sequential forming method and a sequential forming apparatus by which the dimensional accuracy of finishing is improved and formability is improved so that even a complicated shape which is previously difficult to be worked can be worked. <P>SOLUTION: In the sequential forming method in which the forming work is performed by clamping a part of a metal plate M with clamping members 41, 42 on a mold tool 2, performing relative movement while pressing a pressing tool 3 to the metal plate M and matching the metal plate M to the shape of a mold tool 2, in this sequential forming method, a plurality of the clamping members 41, 42 for imparting energizing force FO having a desired direction and magnitude to the metal plate M are arranged and the forming work is performed while individually imparting the energizing force FO from the plurality of the clamping members 41, 42 by being linked with the relative movement of the pressing tool 3. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a sequential molding method and a sequential molding apparatus that perform a relative processing while pressing a pressing tool against a plate material made of metal, resin, or the like to form a predetermined three-dimensional shape.

  As a plastic working method for mass production of automobile parts, press working using a mold is widely used. However, since processing with a press machine and molds increases the size of the equipment and the cost of manufacturing the molds, new processing methods with excellent economic efficiency suitable for high-mix low-volume production in response to diversifying consumer needs Is required. In addition, the shape of parts that can be manufactured by press working is limited, and an advanced processing method capable of manufacturing parts with more complicated shapes is required. In response to these demands, a sequential molding method has recently been put into practical use and is becoming popular as a production facility.

  The dieless forming apparatus for a plate material disclosed in Patent Document 1 as an example of a sequential forming apparatus includes a base, a fixed pressing mechanism, a tool set and a pressing mechanism, and a driving device, and can be formed without a dieless, that is, without a mold. I have to. That is, in the sequential molding apparatus, a general-purpose pressing tool is used instead of a specific-shaped die, and a predetermined three-dimensional shape is molded by being moved against the plate material such as metal or resin. Further, in order to form a complicated shape, a mold tool having a desired shape and a bar-shaped tool for bringing a plate material along the mold tool may be used in combination. Furthermore, numerical control is used for the movement of the pressing tool, and movement control corresponding to a complicated shape is performed, and parts of different shapes can be handled with the same apparatus configuration.

In the sequential forming apparatus including the apparatus of Patent Document 1, usually, the periphery of a plate material is sandwiched and held by a pair of clamp members with a certain clamping force, and a pressing tool is pressed against the center of the plate material to form I do. At this time, when the stress generated by the deformation of the plate material becomes larger than the clamping force, the plate material is slid between the clamp members and fed. However, it is difficult to feed the plate material accurately with pinching with a constant clamping force, and Patent Document 2 discloses an improved example. In the sequential forming method of Patent Document 2, a plurality of blank holders for holding the periphery of the plate material are arranged, and each clamping force can be individually controlled by hydraulic pressure, and the clamping force is changed in conjunction with the movement of the rod-shaped pressing member. Yes.
International Publication No. WO99 / 38627 Pamphlet JP 2003-236628 A

  By the way, the clamping force of the clamp member is easily affected by the surface roughness of the contact surface of the plate material and the manufacturing dimensional accuracy, and even if the individual control of Patent Document 2 is performed, it may be difficult to feed the plate material accurately. It was. For example, in a forming process with a large amount of deformation, such as deep drawing, the plate material is not sufficiently fed, and the finished size becomes too thin. Further, as the part shape becomes complicated, the molding process has become more difficult.

  The present invention has been made in view of the above background, and can improve the finished dimensional accuracy so as not to cause “shrinkage” and the like, and can be molded even in complicated shapes that were difficult in the past. A sequential molding method and a sequential molding apparatus with improved properties are provided.

  In the sequential forming method of the present invention, a part of a plate material is clamped by a clamp member on the mold tool, and is moved relative to the plate material while pressing the pressing tool, and the plate material is molded along the shape of the mold tool. In the sequential forming method for performing processing, a plurality of the clamp members for providing an urging force in a desired direction and size to the plate material are disposed, and the urging forces are provided in conjunction with the relative movement of the pressing tool. The molding process is performed while individually applying from the individual clamp members.

  The present invention is characterized by a clamping method and a feeding method for actively energizing a plate material. That is, the plate material clamped by the clamp member is not passively pulled by deformation stress as in the conventional case, but the biasing force is actively applied from the clamp member to force the plate material to be pushed in, and the pressing tool is pressed. It is intended to facilitate the molding process.

  First, an apparatus configuration for performing the sequential molding method of the present invention will be described. The plate material to be sequentially formed can be plastically deformed metal or resin, and is not particularly limited. As the mold tool, a mold having a desired shape manufactured in advance can be used. The pressing tool may be a general general-purpose bar-shaped tool, or may be a specific mold manufactured according to the mold tool. Furthermore, instead of the mold tool and the pressing tool, two general-purpose bar-shaped tools that face each other with a plate material interposed therebetween may be used. In the relative movement between the plate material and the pressing tool, either of them may be moved, and a drive unit for the relative movement can be provided as appropriate.

  The plurality of clamp members sandwich a part of the plate material and apply an urging force in a desired direction and size to the plate material. The clamping force with which each clamping member clamps the plate material may be constant, or may be controlled individually. Moreover, each clamp member is formed so that the urging | biasing force of a desired direction and magnitude | size can be separately provided with respect to a board | plate material. For example, actuators that output an urging force are individually provided and are individually controlled.

  Next, a method for performing sequential molding will be described. In the present invention, when the plate tool is relatively moved while pressing the pressing tool, the forming process is performed while individually applying an urging force from a plurality of clamp members in conjunction with the relative movement.

  The urging force includes a pushing force for feeding the plate material in the center direction, a pulling force for expanding the plate material in the circumferential end direction, a shearing force in the plate thickness direction of the plate material, a rotational force in a twisting direction of the plate material, and a direction of bending the plate material Or a combined external force in which these forces are combined.

  For example, when deep drawing is performed by sandwiching a plate material between a mold tool and a pressing tool, a stress is generated to draw the plate material from around the deformed processing site. At this time, according to the progress of processing, it is possible to apply an urging force from the clamp member toward the center and push the plate material toward the center. As a result, since a sufficient amount of the plate material is fed more easily than in the past, the “retraction” of the thickness reduction due to the excessive elongation of the plate material is suppressed. In addition, since the stress generated in the plate material is reduced, the amount of deformation of a portion that is not originally desired to be deformed, such as a springback, is reduced, and the finished dimensional accuracy is improved. Furthermore, it becomes possible to perform deep drawing and complicated shape drawing that were difficult in the past, and the required force on the tool side to be processed can be reduced, so that formability is improved.

  Further, in the molding process similar to the rolling process, a tensile force can be applied to the plate material to promote the stretching of the plate material. In the forming process in which the height difference is provided around the plate material, it is possible to apply a shearing force that is biased upward by the clamp member at the heightened portion and biased downward by the clamp member at the heightened portion. In the process of forming a twisted component such as a fan, a rotational force in the twisting direction can be applied to the plate material. In the forming process of bending the plate material into a V shape, it is possible to apply a rotational force that gradually inclines both ends so that the center of the plate material gradually decreases. Furthermore, in the molding process of a complicated shape, it can also superimpose and give, adjusting the magnitude | size of each above-mentioned urging | biasing force according to the progress of the relative movement of a press tool. In any case, by applying the urging force, the deformation of the plate material is facilitated and the forming process is facilitated.

  In the sequential molding method of the present invention, the molding process may be performed in two stages, a rough molding process and a precision molding process. For example, for a part with a rough overall shape and a detailed shape with partial irregularities, the entire shape can be formed by a rough forming process using a mold tool, and then the detailed shape can be formed by a precision forming process using a pressing tool. it can. At this time, in the rough forming step, the clamping force of the clamping member is reduced and a large biasing force is applied to facilitate the feeding of the plate material, thereby facilitating the formation of the entire shape. Further, in the precision forming process, the clamping force of the clamp member is strengthened and the urging force is excluded, and the plate material can be stably brought into close contact with the mold tool to facilitate the formation of the detailed shape by the pressing tool. This is an example in the case where it is not necessary to feed a plate material to form a detailed shape.

  In addition to the above description, various methods can be applied to the method for controlling the clamping force and urging force of the clamping member and the method for dividing the molding process depending on the shape of the part to be manufactured.

  Next, a sequential molding apparatus that can perform the sequential molding method of the present invention will be described. The sequential forming apparatus of the present invention includes a mold tool, a plurality of clamp members that sandwich a part of the plate material on the mold tool, a pressing tool that is pressed by the plate material and is relatively movable with respect to the plate material. And a drive unit that drives the relative movement of the pressing tool, and a sequential forming apparatus that forms the plate material along the shape of the mold tool, wherein a plurality of the clamp members are attached to the plate material An urging force having a desired direction and size can be applied, and the urging force is individually applied in conjunction with the relative movement of the pressing tool.

  As the mold tool, a mold having a desired shape manufactured in advance can be used. The pressing tool may be a general general-purpose bar-shaped tool, or may be a specific mold manufactured according to the mold tool. A drive part performs the relative movement of a board | plate material and a press tool, and the press of the press tool to a board | plate material. The drive unit needs a sufficient relative movement range and a pressing force necessary for the forming process, for example, a moving mechanism that moves the pressing tool in two dimensions in parallel to the plate material, and the plate material as the pressing tool. And a pressing operation mechanism that presses vertically.

  The plurality of clamp members sandwich a part of the plate material and apply an urging force in a desired direction and size to the plate material. For example, a certain elastic force such as a spring member can be applied to the clamping force with which each clamping member clamps the plate material. Further, the clamping force may be individually variably controlled using a hydraulic mechanism or the like. The means for generating the urging force of each clamp member can be realized, for example, by providing an actuator individually. When a motor is used as an actuator, a power transmission mechanism or power conversion mechanism can be added to the output shaft to obtain a biasing force in a desired direction, and the magnitude of the biasing force can be increased or decreased by adjusting the electrical input. Can do. Note that the means for generating the clamping force and the urging force may be common or may be provided separately.

  As a control means for individually applying an urging force to each clamp member in conjunction with the relative movement of the pressing tool, for example, a numerical control type electronic control device using a microcomputer can be used. In the electronic control unit, the dimensions of each part expressing the part shape, the relative movement order of the pressing tool, the magnitude and generation timing of the urging force, etc. are held as numerical data, and the drive part and each clamp member are automatically linked by the program. Can be controlled. In addition, when variably controlling the clamping force of the clamp member, this can also be interlocked.

  Next, specific means for applying the urging force will be described. The clamp member may include a roller that is in sliding contact with the plate member, a pinion gear that rotates integrally with the roller, a rack gear that meshes with the pinion gear, and an operation source that operates the rack gear. For example, when a direct current motor is used as the operation source and a linear motion is given to the rack gear, the pinion gear and the roller rotate to drive the plate material in a sliding manner, thereby applying an urging force. The urging force can be controlled to increase / decrease by controlling the electric input of the DC motor to increase / decrease, and the pushing force and the pulling force can be switched by inverting the power supply polarity.

  The clamp member may be provided with a moving tilt mechanism that can relatively move and tilt a part of the periphery of the plate member. For example, if the clamp member itself holding the plate material is relatively moved and inclined, an urging force can be applied to the plate material.

  In the sequential forming method of the present invention, the forming process is performed while individually applying the urging force from each clamp member in conjunction with the relative movement of the pressing tool. Improved. In addition, even complex shapes that were difficult in the past can be molded, and moldability has been improved.

  In addition, the sequential forming apparatus of the present invention includes a plurality of clamp members that can apply an urging force in a desired direction and size and that is interlocked with the relative movement of the pressing tool. Therefore, the sequential forming method of the present invention can be performed. it can.

  The best mode for carrying out the present invention will be described with reference to FIGS. FIG. 1 is a diagram schematically illustrating a sequential molding apparatus according to an embodiment of the present invention. The sequential forming apparatus 1 of the embodiment includes a mold tool 2, a pressing tool 3, an upper clamp 51 and an urging mechanism 6, and a mold driving unit 81 and a pressing driving unit 82, which constitute the left and right clamp members 41 and 42, respectively. A control unit. The sequential forming apparatus 1 is an apparatus for forming the plate material M along the mold tool 2, and by changing the mold tool 2, parts having various shapes can be manufactured.

  The mold tool 2 is a mold having a specific shape manufactured according to the part to be manufactured, and has a height of three stages in the embodiment of FIG. That is, the center left side of the mold tool 2 is the highest upper surface 21, the center right side is the intermediate surface 22 that is lower than the upper surface 21 by the height H 1, the both ends are the left bottom surface 23 that is lower than the upper surface 21 by the height H 2, It is a bottom surface 24. The surfaces 23, 21, 22, 24 are connected by steep slopes 27, 28, 29. The mold tool 2 is arranged on the lower side of the plate material M, and is driven by the mold drive unit 81 to move up and down, that is, relatively move while pressing the plate material M upward.

  The pressing tool 3 is a general-purpose bar-shaped tool having a hemispherical tip at the downward direction, and is disposed on the upper side of the plate material M. The pressing tool 3 is driven by the pressing drive unit 82 and presses the plate material M downward while scanning in a two-dimensional manner so that the plate material M can be formed along the mold tool 2. .

  The clamp members 41 and 42 respectively disposed on the left and right ends of the plate material M are configured to sandwich the plate material M at a constant height. The upper clamp 51 constituting the clamp members 41 and 42 presses the plate material M from the upper side. The urging mechanism 6 constituting the clamp members 41 and 42 is formed by a roller (not shown), a pinion gear 61, a rack gear 62, and an operation source motor 63. The roller is disposed below the upper clamp 51 on the back side of the paper surface of the pinion gear 61 in FIG. The pinion gear 61 is formed integrally with the roller and meshes with the rack gear 62. The rack gear 62 meshes with a gear provided on the output shaft of the motor 63, and the rotational motion is converted into a linear motion so as to be driven left and right in the drawing.

  The plate material M is sandwiched between the upper clamp 51 and the roller, and an urging force is applied by the rotation of the sliding roller. For example, as shown by a thick arrow in FIG. 1, when the motor 63 of the right urging mechanism 6 rotates counterclockwise, the rack gear 62 is driven rightward, and the pinion gear 61 and the roller rotate counterclockwise. A pushing force F0 for urging the plate material M in the central direction is applied. As a result, the plate material M is fed in the central direction.

  The control unit (not shown) controls the mold driving unit 81 while detecting the height of the mold tool 2, controls the pressing drive unit 82 while detecting the position of the pressing tool 3, and further the motor of the biasing mechanism 6. It is configured to control 63 electrical inputs.

  Next, a sequential molding method using the sequential molding apparatus 1 of the embodiment configured as described above will be described with reference to FIGS. 1 and 2. FIG. 1 shows not only the configuration of the apparatus 1 but also the state of the initial setup process. In the setup process, the plate material M is sandwiched between the clamp members 41 and 42, and the mold tool 2 is disposed below the plate material M and the pressing tool 3 is disposed above. And a shaping | molding process process is started by starting a control part.

  2A and 2B are diagrams for explaining a situation in the middle of the molding process, where FIG. 2A shows a situation where machining is performed on the intermediate surface 22 of the mold tool 2, and FIG. Shows the situation. In the forming process, the control unit controls the mold driving unit 81 to gradually raise the mold tool 2 while pressing it from the lower side of the plate M, and controls the pressing drive unit 82 to move the pressing tool 3 from the upper side. Control is performed so that the inclined surfaces 27, 28, and 29 of the mold tool 2 are two-dimensionally scanned while being pressed. Further, the control unit controls the electric input of the motor 63 of the urging mechanism 6 so that the plate material M is fed in accordance with the scanning location of the pressing tool 3. As a result, the plate material M is processed at a height that is always held, and processed into a shape along the inclined surfaces 27, 28, and 29 of the mold tool 2.

  FIG. 2A shows a state in which the mold tool 2 has been raised by the height H1. The forming process is completed on the inclined surface 28 between the upper surface 21 and the intermediate surface 22, and the inclined surface 27 between the upper surface 21 and the left bottom surface 23 is obtained. Then, the molding process is progressing halfway. Further, FIG. 2B shows a state where the mold tool 2 is raised by the height H2, and a slope 27 between the upper surface 21 and the left bottom surface 23 and a slope between the intermediate surface 22 and the right bottom surface 24. In 29, the molding process is finished. In forming the slopes 27, 28, and 29, a large urging force is applied to the plate material M and fed in the central direction, and no urging force is applied in forming the intermediate surface 22, the left bottom surface 23, and the right bottom surface 24. It is controlled.

  In the above description, the clamp members 41 and 42 are assumed to rise with the mold tool 2 at a constant height. However, the clamp tool 41 and 42 and the plate member M may be lowered while the mold tool 2 is fixed. Are equivalent.

  Another embodiment of the present invention will be described with reference to FIGS. FIG. 3 is a diagram schematically illustrating a sequential forming apparatus including a clamp member having a moving tilt mechanism according to another embodiment of the present invention, and FIG. 4 is a diagram illustrating the operation of the moving tilt mechanism. The sequential forming apparatus 11 of another embodiment of FIG. 3 includes a lower clamp 52 and a moving tilt mechanism 7 instead of the urging mechanism 6 of FIG. 1, and other configurations are substantially the same.

  The lower clamp 52 is disposed on the lower side of the plate material M so as to face the upper clamp 51. The plate material M is sandwiched between the upper clamp 51 and the lower clamp 52. The moving tilt mechanism 7 holds the upper clamp 51 and the lower clamp 52 together, and moves and tilts the plate material M together. Various known mechanisms can be applied to the moving tilt mechanism 7 and will not be described in detail. However, as shown in FIG. 4, the pushing force F1, the pulling force F2, the shearing force F3, and the twisting direction with respect to the plate material M The urging forces F1 to F5 in all directions such as the rotational force F4 and the rotational force F5 in the bending direction can be applied.

  Among these, by using the pushing force F1, it is possible to obtain the same operation and effect as the embodiment of FIG. In addition, in accordance with the relative movement of the pressing tool 3, by appropriately selecting and applying the urging forces F1 to F5, it is possible to perform free forming processing.

It is a figure explaining the sequential shaping | molding apparatus of the Example of this invention, and the first setup process. In the Example of FIG. 1, it is a figure explaining the condition in the middle of a shaping | molding process, (A) is the condition processed with the intermediate surface of a type | mold tool, (B) is processed with the right bottom face of a type | mold tool. Shows the situation. It is a figure which illustrates typically the sequential shaping | molding apparatus provided with the clamp member which has a moving inclination mechanism in another Example. FIG. 4 is a diagram for explaining the operation of a moving tilt mechanism in the embodiment of FIG.

Explanation of symbols

1, 11: Sequential forming device 2: Mold tool
21: Upper surface 22: Intermediate surface 23: Left bottom surface
24: Right bottom surface 27-29: Slope 3: Pressing tool 41, 42: Clamp member 51: Upper clamp 52: Lower clamp 6: Biasing mechanism
61: Pinion gear 62: Rack gear 63: Motor (operation source)
7: Moving tilt mechanism 81: Mold drive unit 82: Press drive unit M: Plate material H1, H2: Height of mold tool F0 to F5: Biasing force

Claims (5)

On the mold tool, in a sequential molding method in which a part of the plate material is sandwiched by a clamp member, moved relative to the plate material while pressing the pressing tool, and the plate material is molded along the shape of the mold tool.
A plurality of the clamp members for applying a biasing force in a desired direction and size to the plate material are disposed, and the biasing forces are individually separated from the plurality of the clamp members in conjunction with the relative movement of the pressing tool. A sequential molding method characterized by performing molding while applying.   The biasing force includes a pushing force for feeding the plate material in the center direction, a pulling force for expanding the plate material in the circumferential end direction, a shearing force in the plate thickness direction of the plate material, a rotational force in the direction of twisting the plate material, and a direction of bending the plate material The sequential molding method according to claim 1, wherein the rotational force is a combined external force obtained by combining these forces. A mold tool, a plurality of clamp members that sandwich a part of the plate material on the mold tool, a press tool that is pressed by the plate material and is relatively movable with respect to the plate material, and a relative movement of the press tool In a sequential molding apparatus that includes a drive unit that drives, and performs molding processing the plate material along the shape of the mold tool,
The plurality of clamp members can apply an urging force in a desired direction and size to the plate material, and individually apply the urging force in conjunction with relative movement of the pressing tool. A sequential molding device.   4. The sequential molding according to claim 3, wherein the clamp member includes a roller that is in sliding contact with the plate member, a pinion gear that rotates integrally with the roller, a rack gear that meshes with the pinion gear, and an operation source that operates the rack gear. apparatus.   The sequential forming apparatus according to claim 3, wherein the clamp member has a moving and tilting mechanism capable of relatively moving and tilting a part of the periphery of the plate member.

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