JP6269131B2 - Roll flange processing method - Google Patents

Description

  The present invention relates to a roll flange processing method in which a flange is bent using a roller at an end of a panel, and more specifically, a flange is bent from a so-called flat plate state without a bend to the end of a panel. The present invention relates to a roll flange processing method.

  In assembling an opening / closing body composed of an outer panel and an inner panel, as typified by an automobile door panel, a hemming coupling method is widely adopted. In this hemming connection method, a hemming flange portion is formed upright in advance on the peripheral edge portion of the outer panel, and after the outer panel and the inner panel are overlapped, prehemming and main hemming processing are sequentially performed on the hemming flange portion. Thus, the hemming flange portion is folded back to the inner panel side so as to be in a so-called clinched state, and the outer panel and the inner panel are firmly hemmed together. Patent Documents 1 and 2 disclose hemming technology using a roller for each of the flange standing processing, pre-hemming processing, and main hemming processing.

JP-A-5-253626 JP-A-6-91330

  However, in the technique described in Patent Document 1, since it is difficult to bend the end portion of the outer panel without a bend as a flange portion at the time of standing up the flange, it is shown in FIG. As described above, it is necessary to bend the end 4a of the outer panel in advance, which increases the number of man-hours.

  The present invention has been made paying attention to such a problem, and a roll flange processing method that is considered so that the flange portion can be bent even when the end portion of the panel is not bent. In addition, the present invention provides a roll flange processing method capable of suppressing the generation of “wrinkles” at a portion to be a contracted flange portion and improving the quality of the flange portion.

  In the present invention, when a flange portion is formed by bending an end portion of a panel that is not bent, the front and back sides of the end portion region of the end region are left and left, leaving an end region to be the flange portion. A panel positioning process that presses and restrains from both sides with a pressing mold, and a roller provided to an industrial robot is rolled in the longitudinal direction while pressing it in the bending direction against the end region, and this roller has a pressing operation. A pre-bending step of bending the end region from the bent base while bending the corner portion corresponding to the press die in the end region, and pressing the bent end region against the press die with a roller. And a finishing step of pressurizing and restraining the end region with the presser mold and the roller to finish the flange portion in a substantially upright posture.

  The preliminary bending step is characterized in that, in the pressing and rolling operation by the roller, a portion of the end region that has a high degree of becoming a contracted flange portion is bent with a higher degree of bending than the other portions.

  According to the present invention, since the end region of the panel can be folded and finished as a flange portion without the bend crease at the end of the panel, it is not necessary to bend the end of the panel in advance, and the number of processing steps is reduced. Can be reduced.

  Further, in the pre-bending process, in the pressing and rolling operation by the roller, a part having a large degree of becoming a contracted flange part in the end part region is bent with a degree of bending larger than other parts, in particular, the flange part. Of these, the occurrence of “wrinkles” at the portion that becomes the shrinking flange portion can be suppressed, and the quality of the flange portion is improved.

It is a figure which shows an example of the outer panel of the front door for motor vehicles, (A) is the front explanatory drawing, (B) is an expanded sectional view along the aa line of the same figure (A). It is a figure which shows embodiment of the roll flange processing method which concerns on this invention, (A) is process explanatory drawing of the 1st step, (B) is process explanatory drawing of the 2nd step, (C) is the process of the 3rd step. Illustration. The perspective view which shows an example of the roller unit used with the roll flange processing method of FIG. The perspective view which looked at the roller unit of FIG. 3 from the opposite direction. Explanatory drawing which shows the relationship between the outer panel shown to (A) of FIG. 1, and the end elevation before and behind that. FIG. 6 is an enlarged explanatory view showing a processing form in the vicinity area e of FIG. 5. Explanatory drawing which shows the processing form in the corner part g part and h part of FIG. Front explanatory drawing which shows an example of the outer panel of the rear door for motor vehicles.

  FIGS. 1-7 show the more concrete form for implementing the roll flange processing method which concerns on this invention, and especially FIG. 1 has shown the outline of the outer panel of the front door (side door) for motor vehicles.

  As shown in FIGS. 1A and 1B, the outer panel 1 drawn into a predetermined three-dimensional shape in the previous process is provided with a door waist portion in preparation for hemming connection with the inner panel in the next process. The hemming flange portion 2 is formed upright on the three surrounding sides excluding 1d, that is, the three sides of the front edge portion 1a, the rear edge portion 1b, and the lower edge portion 1c. 2A to 2C show a basic procedure of roll flange processing for the hemming flange portion 2.

  As shown in FIG. 2A, the outer panel 1 is positioned on the lower mold 3 as a pressing mold with the outer plate surface facing upward, using a nest block not shown in the figure, and is opposed to the lower mold 3. Similarly, the outer panel 1 is pressed by the upper mold 4 as a pressing mold, and the lower panel 3 and the upper mold 4 pressurize and restrain the outer panel 1 from both the front and back sides.

  In this case, the end region 2a to be the flange portion 2 of the outer panel 1 remains in a so-called straight flat plate state (a state indicated by an imaginary line in FIG. 1A) that is not yet bent. The lower die 3 and the upper die 4 are pressure-constrained from both the front and back surfaces in the vicinity of the bent base 2b that is the bending point of the end region 2a, leaving the end region 2a. Thereafter, a cylindrical roller 5 for bending the flange is pressed against the end region 2a and rolled along the longitudinal direction of the end region 2a, whereby the flange portion shown in FIG. Bending for 2 is performed.

  Then, the end region 2a of the outer panel 1 is divided into a plurality of stages without being bent at once from the so-called flat plate state indicated by the phantom line in FIG. 2A to the flange portion 2 in the upright state as shown in FIG. For example, as shown in FIGS. 2A to 2C, flange bending is performed in three stages. Here, (A) and (B) in FIG. 2 correspond to the preliminary bending process, and (C) in FIG. 2 corresponds to the finishing process. In FIG. 2, a gap is provided between the outer panel 1 and the lower mold 3 and the upper mold 4 for easy understanding. However, in actuality, the lower mold 3 and the upper mold 4 are in close contact with the outer panel 2. Yes.

  As the roller 5, for example, a roller unit 6 as shown in FIGS. 3 and 4 is used. The roller unit 6 has a bracket 7 as a connecting portion and is not shown in the figure, for example, a teaching / playback type industry. The robot is supported at the tip of an arm of a robot (hereinafter simply referred to as a robot). The holder 8 of the roller unit 6 is provided with three types of rotatable rollers 9A to 9C having different diameters on the same axis, and selectively using these three types of rollers 9A to 9C as required. In addition to the flange bending process for the flange portion 2, it is possible to cope with the subsequent pre-hemming process and the main hemming process. Of these three types of rollers 9A to 9C, the middle roller 9B corresponds to the roller 5 in FIG. 2, and the locus (including the angle or posture of the roller 5) on which the roller 5 should be moved is taught in advance. ing. As a result, the roller 5 moves based on a predetermined angle (posture) and locus.

  In the first stage shown in FIG. 2A, the end region of the outer panel 1 is pressed against the cylindrical outer peripheral surface 5a of the roller 5 inclined by a predetermined angle with respect to the end region 2a in a so-called flat plate state. While rolling along the longitudinal direction of 2a, and bending the bent base 2b as a bending point so as to follow the corner 3a of the lower mold 3, for example, a bending angle in the form of a flange down A process of bending downward under θ1 is performed.

  Subsequently, in the second stage shown in FIG. 2B, the cylindrical outer peripheral surface 5a of the roller 5 whose inclination angle is larger than that in the first stage shown in FIG. 2A is pressed downward against the end region 2a. Rolling along the longitudinal direction of the end region 2a and bending under a bending angle θ2 (θ2> θ1) so that the bending angle from the bending base 2b of the end region 2a is further increased. I do.

  In the first and second stages shown in FIGS. 2A and 2B, the roller 5 is provided with a lower mold 3 or an upper mold in order to provide a degree of freedom in the contact angle of the roller 5 with respect to the end region 2a. 4 is not touched.

  Further, in the third stage shown in FIG. 2C, the cylindrical outer peripheral surface 5a of the roller 5 whose rotation center is substantially upright is pressed against the end region 2a along the longitudinal direction of the end region 2a. Then, the end region 2a is bent to a target flange angle to finish the flange portion 2 in a substantially upright posture. In this third stage, the roller 5 comes into contact with the lower die 3 through the end region 2a (flange portion 2) for the first time.

  In this way, the flange portion 2 in a substantially upright posture can be formed smoothly and accurately from a flat plate state without a so-called bend, only by controlling the posture (angle) and movement trajectory of the roller 5. . As is clear from the above description, the first and second steps in FIGS. 2A and 2B correspond to the preliminary bending step, and the third step in FIG. 2C corresponds to the finishing step. Will do.

  Here, FIG. 5 shows the relationship between the outer panel 1 shown in FIG. 1A and the front and rear (left and right) end views, and as shown in FIG. For example, in the vicinity of the door waist portion 1d, a convex bead portion 10 is formed along the front-rear direction of the vehicle body. Sometimes formed. The bead portion 10 contributes to further improvement of the surface rigidity of the outer panel 1 and functions as a character line or an accent line in which the ridge line portion (top portion) of the bead portion 10 extends in the longitudinal direction of the vehicle body.

  In the vicinity regions e and f including the bead portion 10, the cross-sectional round-shaped portion is convex toward the outside, and the degree of curvature is greater than that of the other general portions. Therefore, when the roll flange bending process as described above is uniformly applied to the front edge portion 1a of the outer panel 1 including the neighboring regions e and f, the curvature in the neighboring regions e and f is larger than that in other regions. As a result, since the degree of becoming a contracted flange portion is larger than that of other portions, “wrinkles” are generated in the flange portion 2 after molding.

  Therefore, when the first stage roll flange bending process shown in FIG. 2A is performed on the front edge portion 1a of the outer panel 1, as shown in FIG. In the regions Q1Q and Q2 before and after the vicinity region e, the end region 2a to be the flange portion 2 is subjected to the roll flange bending process by the roller 5 at a predetermined bending angle θ1, while the bead portion 10 is included. In the vicinity region e, the roll flange bending process is performed by the roller 5 under a bending angle θ1 + α larger than the previous bending angle θ1. However, θ1 + α <θ2.

  In this case, since it is not preferable that the bending angle of the end region 2a changes suddenly between the neighboring region e and the regions Q1 and Q2 before and after the neighboring region e, for example, the end region 2a The bending angle is smoothly and gradually changed from the angle θ1 to the angle θ1 + α, while the bending angle of the end region 2a is gradually and gradually changed from the angle θ1 + α to the angle θ from the neighboring region e toward the region Q1. Since the change in the bending angle of the end region 2a as described above is nothing but the change in the inclination angle of the rotation center of the roller 5, the roller 5 rolls along the longitudinal direction of the end region 2a to be the flange portion 2. 3 and 4, the posture of the entire roller unit 6 is appropriately variably controlled using the degree of freedom of swinging of the robot supporting the roller unit 6 shown in FIGS.

  Such variable control of the bending angle θ1 of the end region e is not only performed in the first stage of roll flange bending shown in FIG. 2A but also in the second stage shown in FIG. The roll flange bending process is similarly performed.

  As described above, in the roll flange bending process in the first and second stages of FIGS. 2A and 2B, the bending angle θ1 in the vicinity region e including the bead portion 10 is relatively compared with other parts. By increasing the size of the edge region 2a, the material volume of the excess flavor that causes “wrinkles” is generated in the end region 2a even though the degree of the shrinkage flange portion in the vicinity region e is larger than that of other portions. Dispersed in the longitudinal direction, the occurrence of “wrinkles” is suppressed in advance.

  Thereafter, in the third stage roll flange bending process shown in FIG. 2C, as described above, the end region 2a is pushed between the roller 5 and the lower mold 3 while being pushed. The pressure is restrained, the sheet is bent to the target flange angle, and the flange portion 2 is finished in a substantially upright posture.

  In the third stage of roll flange bending shown in FIG. 2C, the center line that bisects the roller 5 in the axial direction substantially coincides with the bent base portion 2b of the flange portion 2, and the overall height of the flange portion 2 is increased. It is assumed that the position of the roller 5 is controlled so as to be in contact with the cylindrical outer peripheral surface 5 a of the roller 5, and the rolling is performed along the longitudinal direction of the flange portion 2. As a result, the roller 5 does not come into contact with the upper die 4, and the pressing force of the roller 5 is entirely applied to the lower die 3, so that the flange portion 2 can be pushed down and lowered. Pressurized and restrained between the mold 3 and the roller 5.

  Therefore, there is no occurrence of so-called “sag” or the like in the bent base portion 2b, the accuracy of the corner (outer corner) of the bent base portion 2b is improved, and the wrinkle is grown in the flange portion 2 in the bending process. Even if a material volume with a surplus flavor that is easy to be retained is retained, the material volume with a surplus flavor can be completely extended and dispersed, and there is no occurrence of “wrinkles” in the finally formed flange portion 2. The shape accuracy of the flange portion 2 is also improved.

  In addition, since the end region 2a of the outer panel 1 positioned on the lower die 3 is bent downward as the flange portion 2 substantially following the lower die 3, the pressing force by the upper die 4 is reduced by the flange. The position and shape accuracy of the portion 2 are not affected, and this also improves the accuracy of the flange portion 2.

  Thus, the bending process of the flange portion 2 shown in FIG. 1B is completed. 2A to 2C, the remaining two sides of the outer panel 1 shown in FIG. 1A, that is, the rear edge 1b and the lower edge 1c are used. The same applies to the rear edge 1b, and the variable control of the bending angles θ1 and θ1 + α is also used in the same manner as the front edge 1a of FIGS.

  On the other hand, the outer panel 1 shown in FIG. 5 is molded into a corner portion (outer corner portion) g formed by the front edge portion 1a and the lower edge portion 1c, and a corner portion h formed by the lower edge portion 1c and the rear edge portion 1b. As for the flange portion 2 to be formed, it becomes a flat round shape portion that is convex toward the outside and becomes a flange portion that shrinks in the same manner as in the previous case, so that “wrinkles” occur in the flange portion 2 after molding. It will be easy.

  Therefore, the technical idea of variable control of the bending angle shown in FIG. 6 is also applied to the roll flange bending process for each of the corner portions g and h.

  FIG. 7 shows an enlarged view of the g part and the h part in FIG. 5, and as shown in the figure, the lower edge part 1c including both the corner parts g and h of the outer panel 1 is subjected to a roll flange bending process. In this case, the start end portion which is the processing start position of the roll flange bending processing is set as the g1 position which is the general portion on the front edge portion 1a side, and the terminal end portion which is the processing end position is the h2 position which is a general portion on the rear edge portion 1b side. And Then, in the section from the g1 position to the g2 position on the lower edge portion 1c side, similarly to FIG. 6, processing is performed with the bending angle of the end region 2a to be the flange portion 1 being relatively large θ1 + α. In the section from the g2 position on the part 1c side to the h1 position, which is also a general part, machining is performed with the bending angle of the end region 2a to be the flange portion 2 being relatively small θ1. Further, in the section from the h1 position, which is the general part on the lower edge part 1c side, to the h2 position, which is the general part on the rear edge part 1b side, the bending angle of the end region 2a to be the flange part 2 again is relatively set. It is assumed that processing is performed with a large θ1 + α. Note that, in the vicinity of the boundary portion of each section, as described above, a gradually changing section is included so that the angle change in the vicinity of the boundary portion does not become a sudden change.

  Such variable control of the bending angle is not limited to the first stage processing shown in FIG. 2A, but also in the second stage processing shown in FIG. In the final third stage shown in (C), the flange portion 2 is finished into a final shape by being pressure-restrained so that the end region 2 a is pushed by the lower mold 3 and the roller 5. By adopting such a processing procedure, in the corner portions g and h of the outer panel 1, the generation of “wrinkles” can be suppressed, but the quality of the flange portion 2 can be improved in spite of the shape of the contracted flange portion. You can plan.

  Further, when the flange bending process of the front edge part 1a including the vicinity area e of FIGS. 5 and 6 is performed, the front edge part is used in combination with the flange bending process of the lower edge part 1c including the corner part g. It is preferable to perform a roll flange bending process from the corner part g side of FIG. 5 toward the door waist part 1d side of 1a. Specifically, at the time of roll flange bending of the front edge portion 1a including the corner portion g, as shown in FIG. 7, the flange bending processing is started with the g3 position which is the general portion on the lower edge portion 1c side as the starting end portion. In the section up to the g4 position, which is the general part on the front edge portion 1a side, processing is performed with the bending angle of the end region 2a to be the flange portion 2 being relatively large θ1 + α. It is assumed that the processing is performed with the bending angle of the partial region 2a being relatively small θ1.

  Similarly, at the time of roll flange bending of the rear edge portion 1b including the corner portion h, as shown in FIG. 7, the roll flange bending processing is started with the h3 position, which is a general portion on the lower edge portion 1c side, as the start end portion. In the section up to the h4 position, which is the general part on the rear edge 1b side, the end region 2a to be the flange portion 2 is processed with a relatively large bending angle θ1 + α, and after the h4 position, the end portion It is assumed that processing is performed with the bending angle of the region 2a being relatively small θ1.

  By adopting such a processing procedure, at least the roll flange bending process at the corner portions g and h is performed by moving the roller 5 in both directions instead of in one direction. Therefore, the material volume of the surplus flavor can be extended in both directions along the longitudinal direction of the flange portion 2 and dispersed, which is further advantageous in preventing the occurrence of “wrinkles”.

  In addition, although the case where the flange bending process is independently performed for each of the front edge portion 1a, the lower edge portion 1c, and the rear edge portion 1b of the outer panel 1 is illustrated here, the lower edge from the front edge portion 1a is illustrated. The present invention can also be applied to a case where roll flange bending is performed continuously on the three sides of the outer panel 1 from the portion 1c and further from the lower edge portion 1c to the rear edge portion 1b. In the above embodiment, an example in which the flange portion 2 is bent downward in a so-called flange-down manner is shown, but the flange portion 2 is bent upward in a so-called flange-up manner as necessary. The present invention can also be applied to processing.

  Further, in the above embodiment, the outer panel 1 of the automobile front door as shown in FIGS. 1 and 5 has been described as an example. However, the roll flange bending process of the outer panel 11 of the automobile rear door as shown in FIG. The present invention can be similarly applied to the bending of the outer panel roll flange in the opening / closing body.

DESCRIPTION OF SYMBOLS 1 ... Outer panel 2 ... Flange part 2a ... End part region 2b ... Bending base part 3 ... Lower mold | type (pressing type | mold)
4… Upper mold (holding mold)
DESCRIPTION OF SYMBOLS 5 ... Roller 5a ... Cylindrical outer peripheral surface 5b ... End surface 10 ... Bead part

Claims (4)

A method of forming a flange portion by bending an end portion of a panel that is not bent,
A panel positioning step of pressing and restraining the vicinity of the bent base portion of the end region from both the front and back surfaces with a pressing die while leaving the end region to be the flange portion of the panel,
The roller provided to the industrial robot is rolled in the longitudinal direction while pressing in the bending direction against the end region, and the pressing portion by the roller is used to bend the position corresponding to the corner of the holding die in the end region. A pre-bending process in which the end region is bent from the bent base while bending as a point;
A finishing process in which the bent end region is pressed against a pressing die by a roller, and the end region is pressed and restrained by the pressing die and the roller to finish the flange portion in a substantially upright posture;
Including
In the pre-bending process, in the pressing and rolling operation by the roller, a roll flange process characterized in that a part having a large degree of becoming a contracted flange part in the end region is bent with a degree of bending larger than other parts. Method.   2. The roll flange processing method according to claim 1, wherein, in the preliminary bending step, the pressing and rolling operation by the roller is repeated at least twice by changing the angle of the roller. In the panel positioning step, the panel is pressure-restrained from the front and back surfaces with the upper mold and the lower mold,
3. The roll flange processing method according to claim 2, wherein in the preliminary bending step and the finishing step, the end region is bent downward by a pressing and rolling operation with a roller.   4. The pressing and rolling operation by a roller in the preliminary bending step and the finishing step is performed using a common roller and changing the angle of the roller. Roll flange processing method as described in one.

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