(19)
(11)EP 3 401 033 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
22.04.2020 Bulletin 2020/17

(21)Application number: 17756457.2

(22)Date of filing:  21.02.2017
(51)International Patent Classification (IPC): 
B21D 22/28(2006.01)
B21D 22/22(2006.01)
(86)International application number:
PCT/JP2017/006292
(87)International publication number:
WO 2017/146019 (31.08.2017 Gazette  2017/35)

(54)

MOLDED MATERIAL PRODUCTION METHOD AND MOLDED MATERIAL

FORMMATERIALHERSTELLUNGSVERFAHREN UND FORMMATERIAL

PROCÉDÉ DE PRODUCTION DE MATÉRIAU MOULÉ ET MATÉRIAU MOULÉ


(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

(30)Priority: 23.02.2016 JP 2016032443

(43)Date of publication of application:
14.11.2018 Bulletin 2018/46

(73)Proprietor: Nippon Steel Nisshin Co., Ltd.
Tokyo 100-8366 (JP)

(72)Inventors:
  • NAKAMURA, Naofumi
    Tokyo 100-8366 (JP)
  • YAMAMOTO, Yudai
    Tokyo 100-8366 (JP)

(74)Representative: Mewburn Ellis LLP 
City Tower 40 Basinghall Street
London EC2V 5DE
London EC2V 5DE (GB)


(56)References cited: : 
WO-A1-2014/109263
JP-A- 2016 002 552
JP-A- 2013 051 765
  
      
    Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


    Description

    TECHNICAL FIELD



    [0001] This invention relates to a method for producing a molded material including a tubular body and a flange formed at an end portion of the body, and also relates to a molded material.

    BACKGROUND ART



    [0002] As disclosed, for example, in non-patent document 1, a molded material including a tubular body and a flange formed at an end portion of the body is produced by performing a drawing process. The drawing process forms the body by drawing a base metal sheet, so that the thickness of the body is lower than that of the base sheet. On the other hand, a region of the metal sheet corresponding to the flange shrinks as a whole in response to the formation of the body, so that the thickness of the flange is higher than that of the base sheet. Hereinafter, the base material may be referred to as a "blank".

    [0003] The molded material as described above may be used as a motor case disclosed, for example, in patent document 1 or 2 as described below. In this case, the body is expected to function as a shielding material for preventing magnetic leakage to the outside of the motor case. Depending on motor structures, the body is also expected to function as a back yoke of a stator. The performance of the body as the shield material or back yoke is improved as the thickness of the body increases. Therefore, when a molded material is produced by drawing, as described above, a base metal sheet with a thickness larger than the required thickness of the body is selected taking into account the reduction in thickness of the body caused by the drawing process. Meanwhile, the flange is often used for mounting the motor case on a mounting object. Therefore, the flange is expected to have a certain strength.

    CITATION LIST


    Patent Document



    [0004] 

    Patent Document 1: Japanese Patent Application Publication No. 2013-51765 A

    Patent Document 2: Japanese Patent Application Publication No. 2016-2552 A. J


    Non-Patent Document



    [0005] Non-patent Document 1: Masao Murakawa, et.al., "Basics of Plastic Processing", First Edition, SANGYO-TOSHO Publishing Co. Ltd., January 16, 1990, pp. 104 to 107

    SUMMARY OF INVENTION


    Technical Problem



    [0006] However, the conventional method for producing the molded material as described above produces the molded material including the tubular body and the flange formed at the end portion of the body by the drawing process, so that the thickness of the flange is larger than that of the base sheet. For this reason, the flange may become unnecessarily thicker over a thickness required for obtaining the expected performance of the flange. This means that the molded material becomes unnecessarily heavy, which cannot be ignored in applications in which weight reduction is required, such as motor cases.

    [0007] On the other hand, in a multi-stage drawing process, when a change in diameter reduction of the flange before and after the drawing process is large, in other words, when a diameter of the flange after the drawing process becomes significantly smaller than the diameter of the flange before the drawing process, the lower thickness of the flange after the drawing process may generate wrinkles and/or buckling in the flange. The wrinkles and/or buckling may cause cracks during the subsequent drawing process.

    [0008] In such a case, a drawing process using a drawing sleeve may be carried out in order to prevent the wrinkles and/or buckling. However, the drawing process is carried out by sandwiching the flange between a die and the drawing sleeve, so that a tensile stress will act on the body, causing a decrease in thickness of a circumferential wall of the body.

    [0009] The present invention has been made to solve the above problems. An object of the present invention is to provide a method for producing a molded material and the molded material, which can avoid unnecessary thickening of the flange, reduce a weight of the molded material and achieve size reduction of the base metal sheet.

    Solution to Problem



    [0010] The present invention relates to a method for producing a molded material, the molded material comprising a tubular body and a flange formed at an end portion of the body, the molded material being produced by performing at least two molding processes on a base metal sheet, wherein the at least two molding processes comprise at least one drawing-out process and at least one drawing process performed after the drawing-out process; wherein the drawing-out process is carried out using a mold that comprises a punch and a die having a pushing hole; wherein a width of the punch on a rear end side is wider than a width of the punch on a distal end side so that when the punch is pushed into the pushing hole of the die, a clearance between the die and the punch is narrower on the rear end side than on the distal end side; and wherein an ironing process is performed on a region of the base material sheet corresponding to the flange of the molded material by pushing the base metal sheet together with the punch into the pushing hole in the drawing-out process. In the method for producing the molded material, the drawing process is carried out using a mold comprising a die and a drawing sleeve, and in the drawing process, an ironing process is performed on a region of the base material sheet corresponding to the flange of the molded material subjected to the ironing process in the drawing-out process, while maintaining a constant mold gap between the die and the drawing sleeve.

    [0011] Further, the drawing process performed at the constant mold gap between the die and the drawing sleeve is preferably carried out such that the mold gap is 1.0 times or more and 1.35 times or less an average thickness of the flange before the drawing process. Alternatively, the drawing process is carried out using a mold comprising a die, a drawing sleeve and a punch, and the drawing process that does not reduce a diameter of the flange is preferably carried out while opening the mold gap between the die and the drawing sleeve, and the drawing process that reduces a diameter of the flange is preferably carried out such that the mold gap between the die and the drawing sleeve is 1.0 times or more and 1.35 times or less an average thickness of the flange before the drawing process.

    Advantageous Effects of Invention



    [0012] According to the method for producing the molded material and the molded material according to the present invention, the drawing-out process involves the ironing process performed on the region corresponding to the flange of the base metal sheet by pushing the base metal sheet together with the punch into the pushing hole, and during the drawing process, only the region corresponding to the flange of the molded material subjected to the ironing process in the drawing-out process is subjected to the ironing process and molded while sandwiching the region between the die and the drawing sleeve. Therefore, generation of wrinkles and buckling in the flange can be prevented, and breakage can be avoided. Further, an unnecessary increase in the thickness of the flange can be avoided so that the weight of the molded material can be reduced. This configuration is particularly useful for various applications in which weight reduction is required, such as motor cases.

    BRIEF DESCRIPTION OF DRAWINGS



    [0013] 

    FIG. 1 is a perspective view showing a molded material produced by a method for producing a molded material according to Embodiment 1 of the present invention.

    FIG. 2 is a sectional view taken along the line II-II in FIG. 1.

    FIG. 3 is an explanatory view illustrating a method for producing the molded material shown in FIG. 1.

    FIG. 4 is an explanatory view illustrating a mold used in the drawing-out process shown in FIG. 3.

    FIG. 5 is an explanatory view illustrating the drawing-out process performed with the mold shown in FIG. 4.

    FIG. 6 is an explanatory view illustrating the punch shown in FIG. 4, in more detail.

    FIG. 7 is an explanatory view illustrating the mold used in a first drawing process show in FIG. 3.

    FIG. 8 is an explanatory view illustrating a first drawing process performed with the mold shown in Fig. 7.

    FIG. 9 is a graph showing a thickness distribution of a molded material produced by a method for producing a molded material according to the present embodiment.

    FIG. 10 is an explanatory view showing the sheet thickness measured positions in FIG. 9.


    DESCRIPTION OF THE PREFERRED EMBODIMENTS



    [0014] Embodiments of the present invention will be described below with reference to the drawings.

    Embodiment 1



    [0015] FIG. 1 is a perspective view showing a molded material 1 produced by a method for producing a mold material according to Embodiment 1 of the present invention. As shown in FIG. 1, the molded material 1 produced by the method for producing the molded material according to the present embodiment includes a body 10 and a flange 11. The body 10 is a tubular portion having a top wall 100 and a circumferential wall 101 that extends from an outer edge of the top wall 100. Depending on the orientation of the molded material 1 to be used, the top wall 100 may be referred to by other terms, such as a bottom wall. In FIG. 1, the body 10 is shown to have a perfectly circular sectional shape, but the body 10 may have another shape, for example, such as an elliptical sectional shape or angular tubular shape. The top wall 100 may be subjected to further processing. For example, a protrusion further projecting from the top wall 100 can be formed. The flange 11 is a sheet portion formed on an end portion (an end of the circumferential wall 101) of the body 10.

    [0016] FIG. 2 is a sectional view taken along the line II-II in Fig. 1. As shown in FIG. 2, a sheet thickness t11 of the flange 11 is lower than a sheet thickness t101 of the circumferential wall 101 of the body 10. The reason for this is that the ironing process is performed on a region of corresponding to the flange 11 of a base metal sheet 2 (see Fig. 3), as will be described in detail below. As used herein, the sheet thickness t11 of the flange 11 means an average value of the sheet thickness of the flange 11 from a lower end of a lower side shoulder portion Rd between the circumferential wall 101 and the flange 11 to an outer end of the flange 11. Similarly, the sheet thickness t101 of the circumferential wall 101 means an average value of the sheet thickness of the circumferential wall 101 from an upper end of the lower side shoulder portion Rd to a lower end of an upper side shoulder portion Rp.

    [0017] FIG. 3 is an explanatory view illustrating the method for producing the molded material 1 shown in FIG. 1. The method for producing the molded material according to the present invention produces the molded material 1 by performing at least two molding processes on a flat base metal sheet 2. The at least two molding processes include at least one drawing-out process and at least one drawing process performed after the drawing-out process. In the method for producing the molded material according to this embodiment, the molded material 1 is produced by one drawing-out process and four redrawing processes (first to fourth drawing processes).

    [0018] FIG. 4 is an explanatory view illustrating a mold 3 used in the drawing-out process shown in FIG. 3, and FIG. 5 is an explanatory view illustrating the drawing-out process performed with the mold 3 shown in FIG. 4. As shown in FIG. 4, the mold 3 used in the drawing-out process includes a die 30; a punch 31; and a cushion pad 32. The die 30 is provided with a pushing hole 30a into which the base metal sheet 2 is pushed together with the punch 31. The cushion pad 32 is disposed at an outer peripheral position of the punch 31 so as to face an outer end surface of the die 30. As shown in FIG. 5, in the drawing-out process, an outer edge portion of the base metal sheet 2 is not completely constrained by the die 30 and the cushion pad 32, and the outer edge portion of the base metal sheet 2 is drawn out until it escapes from the constraint applied thereto by the die 30 and the cushion pad 32. The entire base metal sheet 2 may be pushed together with the punch 31 into the pushing hole 30a and drawn out.

    [0019] FIG. 6 is an explanatory view illustrating the punch 31 shown in Fig. 4, in more detail. As shown in FIG. 6, a width w311 of a rear end side 311 of the punch 31 used in the drawing-out process is wider than a width w310 of a distal end side 310 of the punch 31. Meanwhile a width of the pushing hole 30a is substantially uniform along an insertion direction in which the punch 31 is inserted into the pushing hole 30a. In other words, an inner wall of the die 30 extends substantially parallel to the insertion direction of the punch 31.

    [0020] Thus, as shown in FIG. 6, a clearance C30-31 between the die 30 and the punch 31 in a state where the punch 31 has been pushed into the pushing hole 30a is narrower on the rear end side 311 of the punch 31 than on the distal end side 310 of the punch 31. The clearance C30-31 on the rear end side 311 of the punch 31 is set to be narrower than the sheet thickness of the base metal sheet 2 before the drawing-out process is performed. This allows the base metal sheet 2 to be pushed together with the punch 31 into the pushing hole 30a in the drawing-out process, so that the ironing process is performed on the outer edge portion of the base metal sheet 2, that is, on a region corresponding to the flange 11. The ironing process reduces the sheet thickness of the region corresponding to the flange 11 (decreases the thickness).

    [0021] It should be noted that between the distal end side 310 and the rear end side 311 of the punch 31 is provided a width variation portion 31a comprised of an inclined surface that continuously changes a width of the punch 31. The width variation portion 31a is disposed so as to be in contact with a region of the base metal sheet 2 corresponding to the lower side shoulder portion Rd (see FIG. 2) between the width variation portion 31a and the inner wall of the die 30 when the base metal sheet 2 is pushed together with the punch 31 into the pushing hole 30a in the drawing-out process.

    [0022] Next, FIG. 7 is an explanatory view illustrating a mold 4 used in the first drawing process in FIG. 3, and FIG. 8 is an explanatory drawing showing the first drawing by means of the mold 4 in FIG. 7. With reference to FIGS. 7 and 8, the movement of the mold and the state of processing during the first drawing process will be described in detail.

    [0023] As shown in FIG. 7, the mold 4 used in the first drawing process includes a die 40; a punch 41; a drawing sleeve 42; a lifter plate 43; a killer pin 44; and a stopper 45. The die 40 is provided with a pushing hole 40a into which a first intermediate body 20 formed by the above drawing-out process is pushed together with the punch 41. The drawing sleeve 42 is disposed at an outer peripheral position of the punch 41 so as to face an outer end surface 40b of the die 40.

    [0024]  The left half of FIG. 7 shows a state where the first intermediate body 20 is placed on an upper surface of the lifter plate 43 and an inner peripheral surface of the first intermediate body 20 is in contact with an outer peripheral surface 42a of the drawing sleeve 42. At this time, although the die 40 begins to descend, the outer end surface 40b of the die 40 is not in contact with the first intermediate body 20, so that the drawing process of the first intermediate body 20 is not started yet. The tip of the killer pin 44 provided on the outer end surface 40b of the die 40 does not reach the upper surface of the lifter plate 43.

    [0025] The right half of FIG. 7 shows a state where the die 40 has further descended to be in contact with the first intermediate body 20, and the drawing process has been started. At this time, the tip of the killer pin 44 reaches the upper surface of the lifter plate 43, so that the die 40 descends and the killer pin 44 pushes down the lifter plate 43. This allows maintenance of the state where the lower end of the body of the first intermediate body 20 is not in contact with the upper surface of the lifter plate 43. That is, the killer pin 44 is longer than the height of the circumferential wall of the first intermediate body 20.

    [0026] Next, the left half of FIG. 8 shows a state where the die 40 continues to further descend and the first intermediate body 20 is pushed into the pushing hole 40a of the die 40, that is, a state where the drawing process is carried out on the body of the first intermediate body 20. Also at this time, the tip of the killer pin 44 reaches the upper surface of the lifter plate 43, and the killer pin 44 pushes down the lifter plate 43 as the die 40 descends. Therefore, when undergoing the drawing process, the lower end of the body of the first intermediate body 20 is not in contact with the upper surface of the lifter plate 43 and is in an uplifting state. Since the lower end of the body is uplifting from the upper surface of the lifter plate 43, any compressive stress in the upward direction is not applied to the circumferential wall of the body.
    Further, a space between the die 40 and the drawing sleeve 42 is open, and the lower portion of the body of the first intermediate body 20 (a region corresponding to the flange 11 in FIG. 2) is not sandwiched by the die 40 and the drawing sleeve 42.

    [0027] In the state shown in the left half of FIG. 8, the inner side of the lower portion of the body of the first intermediate body 20 is in contact with the outer peripheral surface 42a of the drawing sleeve 42. In such a state, the radius of the lower end of the body of the first intermediate body 20 does not change even if the drawing process progresses to the body of the first intermediate body 20. In this case, since the lower end of the body of the first intermediate body 20 is not sandwiched by the die 40 and the drawing sleeve 42 as described above, it is possible to suppress a decrease in the sheet thickness of the circumferential wall of the body.

    [0028] The right half of FIG. 8 shows a state where the die 40 further continue to descent, so that the lower surface of the lifter plate 43 is brought into contact with the stopper 45 provided on the outer peripheral surface 42a of the drawing sleeve 42. The lower surface of the lifter plate 43 is brought into contact with the stopper 45, whereby the drawing sleeve 42 will descend in synchronization with the die 40. This leads to a constant mold gap between the die 40 and the drawing sleeve 42.

    [0029] In the state shown in the right half of FIG. 8, the lower portion of the body of the first intermediate body 20 is located above the outer peripheral surface 42a of the drawing sleeve 42. Therefore, as the drawing process of the body of the first intermediate body 20 progresses, the radius of the lower end of the body of the first intermediate body 20 gradually decreases, and the sheet thickness of the lower portion of the body begins to gradually increase. The mold gap between the die 40 and the drawing sleeve 42 after the lower surface of the lifter plate 43 is brought into contact with the stopper 45 is set to be narrower than the sheet thickness of the lower portion of the body of the first intermediate body 20, which thickness has been increased with the progress of the drawing process. By setting the mold gap in such a way, an ironing process can be performed on the lower portion of the body of the first intermediate body 20. The ironing process can decrease an amount of reducing the radius of the lower end of the body of the first intermediate body 20. Further, the ironing process can allow prevention of wrinkles and buckling. As will be described below, the mold gap between the die 40 and the drawing sleeve 42 during the ironing process is preferably 1.0 times or more and 1.35 times or less an average sheet thickness of the lower portion of the body of the first intermediate body 20 before the first drawing process is performed.

    [0030] The second and third drawing processes shown in FIG. 3 can be carried out using a conventional mold (not shown). In the second drawing process, the drawing process is further performed on a region of a second intermediate body 21 (see FIG. 3) formed in the first drawing process, the region corresponding to the body 10. The third drawing process corresponds to a re-striking process, in which the ironing process is performed on a region of a third intermediate body 22 (see FIG. 3) formed in the second drawing process, the region corresponding to the body 10.

    [0031] In the first to third drawing processes, shrinkage occurs in the region corresponding to the flange 11 in FIG. 2, and an increase in the thickness occurs in this region. However, by sufficiently reducing the sheet thickness of the region corresponding to the flange 11 in the drawing-out process, the sheet thickness t11 of the flange 11 can be decreased as compared with the sheet thickness t101 of the circumferential wall 101 of the body 10, in the final molded material 1. An amount of reducing the sheet thickness of the region corresponding to the flange 11 in the drawing-out process can be adjusted, as needed, by changing the clearance C30-31 on the rear end side 311 of the punch 31 of the mold 3 used in the drawing-out process.

    EXAMPLES



    [0032] Next, Examples will be described. The present inventors prepared a round sheet having a thickness of 1.8 mm and a diameter of 116 mm and formed by conducting Zn-AI-Mg alloy plating on a common cold-rolled steel sheet, as the base metal sheet 2. The drawing-out process was then carried out under the following processing conditions. Here, the Zn-AI-Mg alloy plating was applied onto both surface of the cold-rolled steel sheet, and a plating coverage was 90 g/m2 for each surface.
    • Ironing ratio of region corresponding to flange 11: -20% to 60%;
    • Curvature radius Rd of mold 3: 6 mm;
    • Diameter of pushing hole 30a: 70 mm;
    • Diameter of distal end side 310 of punch 31: 65.7 mm;
    • Diameter of rear end side 311 of punch 31: 65.7 mm to 68.6 mm;
    • Shape of width variation portion 31a: inclined surface or right angle step;
    • Position of width variation portion 31a: region corresponding to lower side shoulder portion Rd, region corresponding to flange 11 or region corresponding to body 10;
    • Press oil: TN-20; and
    • Material of die and punch: SKD 11 (HRC hardness: 60).

    <Evaluation of ironing ratio>



    [0033] When the ironing ratio was 30% or less (when the diameter of the rear end side 311 of the punch 31 was 67.5 mm or less), the processing could be performed without any problem. However, when the ironing ratio was greater than 30% and equal to or less than 50% (when the diameter of the rear end side 311 of the punch 31 was greater than 67.5 mm and equal to or less than 68.2 mm), a slight scratching mark was found at a portion sliding against the die 30. Further, when the ironing ratio exceeded 50% (when the diameter of the rear end side 311 of the punch 31 was greater than 68.2 mm), seizure and cracking occurred against the inner wall of the die 30. Therefore, these results demonstrate that the ironing ratio of the region corresponding to the flange 11 in the drawing-out process is preferably equal to or less than 50%, and more preferably equal to or less than 30%. However, the scratching is not a significant problem because it can be improved by subjecting the die or punch to a ceramic coating treatment or the like.

    <Ironing Ratio>



    [0034] The ironing ratio is as represented by the following equation:



    [0035] Here, a value of the sheet thickness of the base metal sheet can be used as the sheet thickness before ironing.

    <Evaluation of Shape of Width Variation Portion 31a>



    [0036] As shown in FIG. 6, when the width variation portion 31a was formed with the inclined surface, the processing could be performed without any problem. However, when the width variation portion 31a was formed with the right angle step, that is, when the front end side 310 and the rear end side 311 of the punch 31 are formed with one step difference, plating residue was generated at a portion that was in contact with the right angle step. These results demonstrate that it is preferable to form the width variation portion 31a with the inclined surface.

    <Evaluation of Position of Width Variation Portion 31a>



    [0037] When the width variation portion 31a was provided so as to be in contact with the region corresponding to the lower side shoulder portion Rd, the ironing process of the region corresponding to the flange 11 could be satisfactorily performed. However, when the width variation portion 31a was provided so as to be in contact with the region corresponding to the flange 11, the thickness of a part of the flange portion 11 could not be sufficiently decreased. Further, when the width variation portion 31a was provided so as to be in contact with the region corresponding to the body 10, a part of the body 10 became thinner than the target sheet thickness. These results demonstrate that it is preferable to provide the width variation portion 31a so as to be in contact with the region corresponding to the lower side shoulder portion Rd.

    [0038] It should be noted that the position of the width variation portion 31a is determined by performing the molding to the molded material which has completed the redrawing process in advance after determining mold conditions for mass production, and then counting backward from the position corresponding to the lower side shoulder portion Rd.

    [0039] In Examples, hereinafter, the lower end of the body of the first intermediate body is referred to as a flange.

    <Effect of Presence and Absence of Drawing Sleeve>



    [0040] Table 1 shows a relationship between an average sheet thickness of the flange before the drawing process and a diameter of the flange before and after the drawing process, on the generation of wrinkles and/or buckling when the drawing sleeve is not used. The symbol t0 is a sheet thickness of the base metal plate, and the symbol t1 is an average sheet thickness of the flange before the drawing process, that is, an average sheet thickness of the region corresponding to the flange after the drawing-out process. The symbol D(n-1) is a diameter of the flange after the n-1th drawing process, and the symbol Dn is a diameter of the flange after the nth drawing process. The wrinkles and/or buckling were generated under conditions of t1 < t0 and Dn < 0.93 × D(n-1), that is, conditions where the average sheet thickness t1 of the flange before the drawing process is thinner than the sheet thickness t0 of the base metal sheet (t1 < t0) and the diameter of the flange Dn after the nth drawing process is significantly smaller than the diameter of the flange D(n-1) after the n-1th drawing process (Dn < 0.93 × D(n-1)).
    [Table 1
     t1 > t0t1 = t0t1 < t0
    Dn>D(n-1) Good Good Good
    Dn = 0.98 × D(n-1) Good Good Slight Wrinkles
    Dn < 0.93 × D(n-1) Good Good Wrinkles and Buckling

    Sheet Thickness of Base Material: t0, Sheet Thickness of Flange before Drawing

    Process: t1

    Diameter of Flange after n-1th Drawing Process: Dn-1

    Diameter of Flange after nth drawing process: Dn



    [0041] The results in the case of using the drawing sleeve are shown in Table 2. In this case, the diameter of the flange is not changed when performing the drawing process on the body. Therefore, in this case, a space between the die 40 and the drawing sleeve 42 was opened such that the outer edge portion was not sandwiched, thereby suppressing a decrease in the sheet thickness of the circumferential wall of the body. Further, when the ironing process is performed on the region where the sheet thickness has been decreased by carrying out the ironing process in the step of the drawing-out process, the diameter of the flange is reduced. In this case, the mold gap (clearance) between the die 40 and the drawing sleeve 42 was set to be constant at various values.
    [Table 2]
    Mold Gap (Clearance)Evaluation
    Flange Average Sheet Thickness × 1.5 Wrinkles and Buckling
    Flange Average Sheet Thickness × 1.35 good
    Flange Average Sheet Thickness × 1.2 good
    Flange Average Sheet Thickness × 1.0 good


    [0042] Here, for the region where the ironing process was performed to decrease the sheet thickness, the mold gap was made constant at the timing when contraction processing began.
    Further, it was carried out under the condition where the diameter of the flange after the nth drawing process was significantly smaller than the diameter of the flange after the (n-1)th drawing process (Dn <0.93 × D(n-1)).

    [0043] The mold gap (clearance) was set to various values under the above condition that the flange diameter Dn after the nth drawing process was significantly smaller than the flange diameter D(n-1) after the n-1th drawing process, and the drawing process was carried out. As shown in Table 2, no winkle or buckling was generated when the mold gap (clearance) was 1.0 times or more and 1.35 times or less the average sheet thickness of the flange before the drawing process.

    <Sheet Thickness of Flange>



    [0044] Next, FIG. 9 is a graph showing the sheet thickness distribution of the molded material produced from the first intermediate body. FIG. 10 is an explanatory view showing the sheet thickness measured positions in FIG. 9.

    [0045] The implementation of the drawing-out process involving the ironing process prior to the drawing process could allow the thinner sheet thickness of the flange 11 in the final molded material than the sheet thickness of the base metal sheet (1.8 mm) and the sheet thickness of the circumferential wall of the body (about 1.6 mm). Further, assuming that outer dimensions of both molded materials are the same, the molded material subjected to the drawing-out process involving the ironing process prior to the drawing process (the present invention) had a weight lighter than the molded material subjected to the conventional common drawing method by 10%.

    [0046] When the drawing-out process involving the ironing is carried out, the region corresponding to the flange 11 of the base metal sheet 2 is stretched. In order to form the molded material subjected to the drawing-out process involving the ironing (the present invention) and the molded material subjected to the conventional common drawing method, both of which have the same dimensions, either a smaller base metal sheet may be used taking into consideration, in advance, an amount of stretching the region corresponding to the flange 11, or an unnecessary portion of the flange 11 may be trimmed.

    [0047] In such a method for producing the molded material and the molded material produced thereby, the drawing-out process involves an ironing process performed on the region corresponding to the flange 11 of the base metal sheet 2 by pushing the base metal sheet 2 together with the punch 31 into the pushing hole 30a, and the subsequent drawing process molds the portion where the sheet thickness has been decreased by the ironing process, while being sandwiched by the die 40 and the drawing sleeve. Therefore, the wrinkles and buckling can be prevented, the sheet thickness of the flange can be prevented from becoming unnecessarily thicker, and the weight of the molded material can be reduced. This configuration is particularly useful for applications in which weight reduction of the molded material and size reduction of the base metal sheet are required, such as motor cases.

    [0048] Further, the ironing ratio of the ironing process performed during the drawing-out process is equal to or less than 50%, and therefore the generation of seizure and cracking can be avoided.

    [0049] Furthermore, the width variation portion 31a comprised of the inclined surface that continuously changes the width of the punch 31 is provided between the distal end side 310 and the rear end side 311, so that it is possible to avoid the generation of plating residue due to the contact with the width variation portion 31 a in the ironing process.

    [0050] Moreover, the width variation portion 31a is disposed so as to be in contact with the region corresponding to the lower side shoulder portion Rd formed between the circumferential wall 101 of the body 10 and the flange 11, so that the thickness of the flange 11 can be sufficiently decreased and the target sheet thickness of the body 10 can be more reliably achieved.

    [0051] Further, when the drawing process is performed on the body, that is, when the flange diameter does not change, a decrease in the sheet thickness of the circumferential wall of the body is suppressed by opening the space between the die 40 and the drawing sleeve 42 so as not to sandwich the material. On the other hand, when the drawing process is performed on the region where the sheet thickness has been decreased by the ironing process in the drawing-out process, the molding is carried out while maintaining the constant mold gap between the die 40 and the drawing sleeve 42, whereby the generation of wrinkles and buckling in the region corresponding to the flange can be avoided.

    [0052] Further, although the present embodiment illustrates that the three drawing processes are performed, the number of the drawing processes may be changed, as needed, according to the size and required dimensional accuracy of the molded material.


    Claims

    1. A method for producing a molded material (1), the molded material (1) comprising a tubular body (10) and a flange (11) formed at an end portion of the body (10), the molded material (1) being produced by performing at least two molding processes on a base metal sheet (2),
    wherein the at least two molding processes comprise at least one drawing-out process and at least one drawing process performed after the drawing-out process;
    wherein the drawing-out process is carried out using a mold (3) that comprises a punch (31) and a die (30) having a pushing hole (30a);
    wherein a width (w311) of the punch (31) on a rear end side (311) is wider than a width (w310) of the punch (31) on a distal end side (310) so that when the punch (31) is pushed into the pushing hole (30a) of the die (30), a clearance (C30-31) between the die (30) and the punch (31) is narrower on the rear end side (311) than on the distal end side (310);
    wherein an ironing process is performed on only a region of the base material sheet (2) corresponding to the flange (11) of the molded material (1) by pushing the base metal sheet (2) together with the punch (31) into the pushing hole (30a) in the drawing-out process;
    wherein the drawing process is carried out using a mold (4) comprising a die (40) and a drawing sleeve (42); and
    the method being characterized in that, in the drawing process, an ironing process is performed on a region of the base material sheet (2) corresponding to the flange (11) of the molded material (1) subjected to the ironing process in the drawing-out process, while maintaining a constant mold gap between the die (40) and the drawing sleeve (42).
     
    2. The method for producing the molded material according to claim 1, wherein an ironing ratio of the ironing process performed during the drawing-out process is equal to or less than 50%,
    wherein the ironing ratio is calculated by the following equation:


     
    3. The method for producing the molded material according to claim 1 or 2, wherein between the distal end side (310) and the rear end side (311) of the punch (31) is provided a width variation portion (31a) comprised of an inclined surface that continuously changes a width of the punch (31).
     
    4. The method for producing the molded material according claim 3, wherein the width variation portion (31a) is disposed so as to be in contact with a region corresponding to a shoulder portion (Rd) formed between a circumferential wall (101) of the body (10) and the flange (11).
     
    5. The method for producing the molded material according to claim 1, wherein the mold gap between the die (40) and the drawing sleeve (42) is 1.0 times or more and 1.35 times or less than an average thickness of the region corresponding to the flange (11) before the drawing process and after the drawing-out process.
     
    6. The method for producing the molded material according to claim 1,
    wherein the drawing process is carried out while the mold gap between the die (40) and the drawing sleeve (42) is open, when the drawing process is performed on the region corresponding to the tubular body (10) of the molded material (1), and
    wherein the drawing process is carried out such that the mold gap between the die (40) and the drawing sleeve (42) is 1.0 times or more and 1.35 times or less than an average thickness of the region corresponding to the flange (11) before the drawing process and after the drawing-out process, when the drawing process is performed on the region corresponding to the flange (11) of the molded material (1).
     


    Ansprüche

    1. Verfahren zur Herstellung eines Formmaterials (1), wobei das Formmaterial (1) Folgendes umfasst: einen rohrfömigen Körper (10) und einen Flansch (11), der an einem Endabschnitt des Körpers (10) gebildet ist, wobei das Formmaterial (1) hergestellt wird, indem zumindest zwei Formvorgänge auf einem Grundmetallblech (2) durchgeführt werden,
    wobei die zumindest zwei Formvorgänge zumindest einen Reckvorgang und zumindest einen Ziehvorgang, der nach dem Reckvorgang erfolgt, umfassen;
    wobei der Reckvorgang unter Verwendung eines Formwerkzeugs (3), das einen Stempel (31) und eine Matrize (30) mit einem Schiebeloch (30a) umfasst, erfolgt;
    wobei eine Breite (w311) des Stempels (31) auf einer rückwärtigen Endseite (311) breiter ist als eine Breite (w310) des Stempels (31) auf einer distalen Endseite (310), sodass, wenn der Stempel (31) in das Schiebeloch (30a) der Matrize (30) geschoben wird, ein Abstand (C30-31) zwischen der Matrize (30) und dem Stempel (31) auf der rückwärtigen Endseite (311) enger ist als auf der distalen Endseite (310);
    wobei ein Abstreckziehvorgang nur in einem Bereich des Grundmetallblechs (2) erfolgt, der dem Flansch (11) des Formmaterials (1) entspricht, indem das Grundmetallblech (2) im Reckvorgang zusammen mit dem Stempel (31) in das Schiebeloch (30a) geschoben wird;
    wobei der Ziehvorgang unter Verwendung eines Formwerkzeugs (4), das eine Matrize (40) und eine Ziehhülse (42) umfasst, erfolgt; und
    wobei das Verfahren dadurch gekennzeichnet ist, dass
    in dem Ziehvorgang ein Abstreckziehvorgang in einem Bereich des Grundmetallblechs (2) erfolgt, der dem Flansch (11) des Formmaterials (1), das dem Abstreckziehvorgang im Reckvorgang unterzogen wird, entspricht, während ein konstanter Formspalt zwischen der Matrize (40) und der Ziehhülse (42) beibehalten wird.
     
    2. Verfahren zur Herstellung eines Formmaterials nach Anspruch 1, wobei ein Abstreckziehverhältnis des Abstreckziehvorgangs, der während des Reckvorgangs durchgeführt wird, 50 % oder weniger beträgt,
    wobei das Abstreckziehverhältnis durch die folgende Gleichung berechnet wird: Abstreckziehverhältnis


     
    3. Verfahren zur Herstellung eines Formmaterials nach Anspruch 1 oder Anspruch 2, wobei zwischen der distalen Endseite (310) und der rückwärtigen Endseite (311) des Stempels (31) ein Breitenänderungsabschnitt (31a) bereitgestellt ist, der aus einer geneigten Fläche, die ständig eine Breite des Stempels (31) verändert, besteht.
     
    4. Verfahren zur Herstellung eines Formmaterials nach Anspruch 3, wobei der Breitenänderungsabschnitt (31a) so angeordnet ist, dass er mit einem Bereich, der einem Schulterabschnitt (Rd), der zwischen einer Umfangswand (101) des Körpers (10) und dem Flansch (11) gebildet ist, in Kontakt ist.
     
    5. Verfahren zur Herstellung eines Formmaterials nach Anspruch 1, wobei der Formspalt zwischen der Matrize (40) und der Ziehhülse (42) 1,0 Mal oder mehr und 1,35 Mal oder weniger als eine mittlere Dicke des Bereichs berträgt, der dem Flansch (11) vor dem Ziehvorgang und nach dem Reckvorgang entspricht.
     
    6. Verfahren zur Herstellung eines Formmaterials nach Anspruch 1, wobei der Ziehvorgang durchgeführt wird, während der Formspalt zwischen der Matrize (40) und der Ziehhülse (42) offen ist, wenn der Ziehvorgang auf dem Bereich, der dem rohrförmigen Körper (10) des Formmaterials (1) entspricht, durchgeführt wird, und
    wobei der Ziehvorgang so durchgeführt wird, dass der Formspalt zwischen der Matrize (40) und der Ziehhülse (42) 1,0 Mal oder mehr und 1,35 Mal oder weniger als eine mittlere Dicke des Bereichs beträgt, der dem Flansch (11) vor dem Ziehvorgang und nach dem Reckvorgang entspricht, wenn der Ziehvorgang auf dem Bereich erfolgt, der dem Flansch (11) des Formmaterials (1) entspricht.
     


    Revendications

    1. Procédé pour produire un matériau moulé (1), le matériau moulé (1) comprenant un corps tubulaire (10) et un rebord (11) formé au niveau d'une partie d'extrémité du corps (10), le matériau moulé (1) étant produit en effectuant au moins deux processus de moulage sur une feuille de métal de base (2),
    dans lequel lesdits au moins deux processus de moulage comprennent au moins un processus d'emboutissage profond et au moins un processus d'emboutissage effectué après le processus d'emboutissage profond ;
    dans lequel le processus d'emboutissage profond est effectué en utilisant un moule (3) qui comprend un poinçon (31) et une matrice (30) comportant un orifice de poussée (30a) ;
    dans lequel une largeur (w311) du poinçon (31) d'un côté d'extrémité arrière (311) est plus grande qu'une largeur (w310) du poinçon (31) d'un côté d'extrémité distale (310) de sorte que, lorsque le poinçon (31) est poussé dans l'orifice de poussée (30a) de la matrice (30), un jeu (C30-31) entre la matrice (30) et le poinçon (31) est plus étroit du côté d'extrémité arrière (311) que du côté d'extrémité distale (310) ;
    dans lequel un processus d'étirage est effectué uniquement sur une région de la feuille de matériau de base (2) correspondant au rebord (11) du matériau moulé (1) en poussant la feuille de métal de base (2) avec le poinçon (31) dans l'orifice de poussée (30a) dans le processus d'emboutissage profond ;
    dans lequel le processus d'emboutissage est effectué en utilisant un moule (4) comprenant une matrice (40) et une douille d'emboutissage (42) ; et
    le procédé étant caractérisé en ce que,
    dans le processus d'emboutissage, un processus d'étirage est effectué sur une région de la feuille de matériau de base (2) correspondant au rebord (11) du matériau moulé (1) soumis au processus d'étirage dans le processus d'emboutissage profond, tout en maintenant un espace de moule constant entre la matrice (40) et la douille d'emboutissage (42).
     
    2. Procédé pour produire le matériau moulé selon la revendication 1, dans lequel un rapport d'étirage du processus d'étirage effectué pendant le processus d'emboutissage profond est inférieur ou égal à 50 %,
    dans lequel le rapport d'étirage est calculé par l'équation suivante :


     
    3. Procédé pour produire le matériau moulé selon la revendication 1 ou 2, dans lequel, entre le côté d'extrémité distale (310) et le côté d'extrémité arrière (311) du poinçon (31), une partie de variation de largeur (31a) composée d'une surface inclinée qui change continûment une largeur du poinçon (31) est prévue.
     
    4. Procédé pour produire le matériau moulé selon la revendication 3, dans lequel la partie de variation de largeur (31a) est disposée de manière à être en contact avec une région correspondant à une partie d'épaulement (Rd) formée entre une paroi circonférentielle (101) du corps (10) et le rebord (11).
     
    5. Procédé pour produire le matériau moulé selon la revendication 1, dans lequel l'espace de moule entre la matrice (40) et la douille d'emboutissage (42) est égal à 1,0 fois ou plus et 1,35 fois ou moins une épaisseur moyenne de la région correspondant au rebord (11) avant le processus d'emboutissage et après le processus d'emboutissage profond.
     
    6. Procédé pour produire le matériau moulé selon la revendication 1,
    dans lequel le processus d'emboutissage est effectué alors que l'espace de moule entre la matrice (40) et la douille d'emboutissage (42) est ouvert, lorsque le processus d'emboutissage est effectué sur la région correspondant au corps tubulaire (10) du matériau moulé (1), et
    dans lequel le processus d'emboutissage est effectué de sorte que l'espace de moule entre la matrice (40) et la douille d'emboutissage (42) soit égal à 1,0 fois ou plus et 1,35 fois ou moins une épaisseur moyenne de la région correspondant au rebord (11) avant le processus d'emboutissage et après le processus d'emboutissage profond, lorsque le processus d'emboutissage est effectué sur la région correspondant au rebord (11) du matériau moulé (1).
     




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    Cited references

    REFERENCES CITED IN THE DESCRIPTION



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    Patent documents cited in the description




    Non-patent literature cited in the description