Field
[0001] The present invention relates to a method of manufacturing a press-formed part including
at least a top portion having a concave curved portion that curves concavely in a
side view and a side wall portion continuous from the top portion via a punch shoulder
R portion. In the present specification, for example, the term "punch shoulder R portion"
refers to a portion of a formed part, and the term "punch shoulder" refers to a portion
of a mold.
Background
[0002] While the vehicle body collision safety is being improved due to the tightening of
the vehicle collision safety standards, it is also necessary to reduce the weight
of the vehicle body for improvement in fuel consumption and electrification of vehicles
due to the carbon dioxide emission control. In order to achieve both the improvement
in collision safety and reduction in weight of vehicle bodies, application of high-strength
steel sheet (also referred to as high-tensile steel sheet) having a tensile strength
of 590 MPa or more to structural parts of vehicle bodies is in progress.
[0003] Examples of vehicle parts or partial structures thereof include a press-formed part
having at least a top portion and a side wall portion continuous from the top portion
via a punch shoulder R portion, in which the top portion has a curved portion that
curves concavely in a side view. When such a press-formed part is press-formed, the
distal end portion of the side wall portion continuous with the punch shoulder R portion
at the bottom of the concave curved portion of the top portion and in the vicinity
of the bottom undergo stretch flange deformation. Therefore, the sheet thickness is
reduced at the portion, and cracking is likely to occur. In addition, the sheet thickness
of the punch shoulder R portion at the bottom of the concave curved portion of the
top portion and in the vicinity of the bottom increases, and buckling (wrinkles, folds)
is likely to occur.
[0004] In particular, in the case of a high-tensile steel sheet, cracking of the portion
having undergone the stretch flange deformation and buckling (wrinkles, folds) of
the punch shoulder R portion are likely to occur due to the increase in strength,
which is particularly a problem.
[0005] In this regard, Patent Literature 1, for example, conventionally proposes a countermeasure
against cracking due to stretch flange deformation of a press-formed part including
a flat top portion having a concave outer peripheral edge in a top view and a side
wall portion continuous from the top portion along the concave outer peripheral edge.
Citation List
Patent Literature
Summary
Technical Problem
[0007] The press-forming method described in Patent Literature 1 is targeted to a press-formed
part in which the top portion is flat and has a concave outer peripheral edge in a
top view. On the other hand, the present invention is targeted to a press-formed part
including at least a top portion having a concave curved portion that curves concavely
in a side view and a side wall portion continuous from the top portion via a punch
shoulder R portion. As described above, the press-formed part targeted by Patent Literature
1 and the press-formed part targeted by the present invention have different shapes.
[0008] Therefore, even if the press-forming method of Patent Literature 1 is applied to
the press-formed part targeted by the invention of the present application, it is
not possible to prevent cracking of a portion of the press-formed part having undergone
the stretch flange deformation, or wrinkles and folds at the punch shoulder R portion.
[0009] The present invention has been made in view of the above problems, and an object
of the present invention is to provide a method of manufacturing a press-formed part
including at least a top portion having a concave curved portion that curves concavely
in a side view and a side wall portion continuous from the top portion via a punch
shoulder R portion, the method capable of suppressing cracking of the press-formed
part, or preventing wrinkles and folds.
Solution to Problem
[0010] To solve the problem and achieve the object, (1) a method of manufacturing a press-formed
part according to the present invention is the method of manufacturing the press-formed
part including at least a top portion having a concave curved portion that curves
concavely in a side view and a side wall portion continuous from the top portion via
a punch shoulder R portion. The method includes: a first forming step of press-forming
an intermediate forming part including an intermediate top portion curved in the same
direction as the top portion, a step-shaped portion formed of a step which is continuous
with a ridge line portion formed at a portion corresponding to the punch shoulder
R portion, and an outer surface portion that extends outward continuously from the
step-shaped portion and curves in the same direction as the intermediate top portion;
and a second forming step of press-forming the intermediate forming part into the
press-formed part.
[0011] (2) Moreover, in the method of manufacturing the press-formed part according to above
(1), a radius of curvature of the ridge line portion of the intermediate forming part
may be greater than or equal to a radius of curvature of the punch shoulder R portion
of the press-formed part.
Advantageous Effects of Invention
[0012] The method of manufacturing a press-formed part according to the present invention
has an effect of preventing wrinkles and folds in the punch shoulder R portion and
the vicinity thereof at the bottom of the concave curved portion of the top portion
and in the vicinity of the bottom, and suppressing cracking in the distal end portion
of the side wall portion continuous with the punch shoulder R portion.
Brief Description of Drawings
[0013]
FIG. 1 is an explanatory view concerning a method of manufacturing a press-formed
part according to an embodiment.
FIG. 2 is an explanatory view of an intermediate forming part formed according to
the present embodiment.
FIG. 3 is an explanatory diagram concerning a forming process in a second forming
step according to the present embodiment.
FIG. 4 is an explanatory diagram concerning functions and effects according to the
present embodiment.
FIG. 5 is an explanatory view concerning a method of manufacturing a press-formed
part according to another aspect of the present invention.
FIG. 6 is an explanatory view of a press-formed part to be manufactured in Examples.
FIG. 7 is an explanatory view of a press-formed part targeted by the present invention.
FIG. 8 is an explanatory view concerning a conventional method of manufacturing a
press-formed part.
FIG. 9 is an explanatory diagram concerning a forming process in the conventional
press-forming method.
FIG. 10 is an explanatory diagram concerning a problem of a press-formed part manufactured
by the conventional press-forming method.
Description of Embodiments
[0014] Hereinafter, an embodiment of a method of manufacturing a press-formed part according
to the present invention will be described. Note that the present invention is not
limited by the present embodiment.
[0015] An example of a press-formed part of a target shape targeted by the present invention
will be described with reference to FIG. 7. The press-formed part 1 targeted by the
present invention includes at least a top portion 3 having a concave curved portion
that curves concavely in a side view, and a side wall portion 7 continuous from the
top portion 3 via a punch shoulder R portion 5, and an example thereof is an article
having an L-shaped cross section as illustrated in FIG. 7.
[0016] A problem that occurs when the press-formed part 1 is press-formed will be described
with reference to a case where a steel sheet having a sheet thickness of 1.4 mm and
a tensile strength of 980 MPa class is press-formed as a blank. FIG. 8 illustrates
a conventional mold used when the press-formed part 1 targeted by the present invention
is press-formed by one step. The conventional mold includes a punch 9 having a concave
curved portion, a pad 11 having a concave curved portion similar to that of the punch
9, and a die 13. While the blank 15 being a metal sheet is pressed by the pad 11 and
the punch 9 so that the concave curved portion of the top portion 3 is formed, the
die 13 is relatively moved to form the side wall portion 7.
[0017] The conventional press forming process will be described with reference to FIG. 9.
FIG. 9 illustrates a cross section (a cross section cut in the direction of arrow
A illustrated in FIG. 7) of the bottom of the curve in the concave curved portion
of the top portion 3 of the press-formed part 1 during the press forming. Note that
a numerical value such as [28mmup] in FIG. 9 represents a gap in the press forming
direction between a punch shoulder 33 of the punch 9 and a die jaw portion 13a (see
FIG. 8 and [2mmup] of FIG. 9) up to the bottom dead center, in which the sheet thickness
is taken into account. For example, the gap between the punch shoulder 33 of the punch
9 and the die jaw portion 13a at [28mmup] is obtained by adding 28 mm to the sheet
thickness of the press-formed part 1.
[0018] As illustrated in FIG. 9, the blank 15 is pressed against the punch 9 by the pad
11 at [47mmup], and a concave curved portion is formed. In this state, the entire
blank 15 including the portion to be formed into the side wall is curved in a concave
shape in the direction perpendicular to the drawing plane.
[0019] At [35mmup], a die shoulder 13b comes into contact with the blank 15 so that the
side wall portion 7 starts to be formed. Therefore, the end of the portion corresponding
to the side wall of the blank 15 is curved downward. When the side wall portion 7
starts to be formed, the portion corresponding to the side wall is curved in a concave
shape in the direction perpendicular to the drawing plane and thus has high rigidity,
and is less likely to be deformed along the punch shoulder R portion 5 (ridge line)
serving as a boundary between the top portion 3 and the side wall portion 7. Therefore,
at [28mmup], the bottom of the concave curved portion of the blank 15 brought into
contact with the die shoulder 13b of the die 13 is bent, and a buckled fold is generated.
Furthermore, the portion where the buckled fold is generated is bent in the forming
direction up to [19mmup] without coming into contact with the punch shoulder 33 of
the punch 9. At [8mmup] and [2mmup], the portion where the buckled fold is generated
is formed into the side wall portion 7 by the gap between the die 13 and the punch
9, and becomes the punch shoulder R portion 5 by coming into contact with the punch
shoulder 33 of the punch 9 at the bottom dead center.
[0020] FIG. 10 is a diagram illustrating a sheet thickness distribution at the bottom dead
center obtained by subjecting a conventional press forming process to FEM analysis.
The dotted line A-A in FIG. 10 indicates the position of the bottom of the concave
curved portion similarly to FIG. 7. As illustrated in FIG. 10, the distal end portion
of the side wall portion 7 continuous with the bottom of the concave curved portion
having undergone stretch flange deformation exhibits a maximum sheet thickness decrease
rate of as large as 12.3%, so that cracking is likely to occur. On the other hand,
the punch shoulder R portion 5 exhibits a maximum sheet thickness increase rate of
as large as 10.0%, and hence a wrinkle or fold is likely to be generated.
[0021] In the conventional press forming process, the curved portion having a concave shape
in a side view formed at an initial stage of press forming has high rigidity due to
its shape. Therefore, when the side wall portion 7 is to be subsequently formed by
the die 13, a large compressive force acts on the blank 15 to increase the sheet thickness,
so that a buckled fold is generated and hence a wrinkle or fold is likely to be generated.
In addition, since the top portion 3 curves concavely, the side wall portion 7 continuous
with the concave curved portion expands to the left and right of the concave curved
portion and undergoes stretch flange deformation, and a large tension acts on the
distal end of the side wall portion 7 continuous with the bottom of the curve, so
that the sheet thickness decreases and cracking is likely to occur.
[0022] In the study for suppressing the sheet thickness increase and the sheet thickness
decrease in such a series of forming processes, the present inventor has focused on
the deformation of the blank 15 from [28mmup] to [2mmup] in FIG. 9. That is, the present
inventor has considered that if the blank 15 can be brought into contact with the
punch shoulder 33 of the punch 9 at the initial stage of forming at [28mmup], the
blank 15 will not suffer from a buckled fold in the forming direction without coming
into contact with the punch shoulder 33 of the punch 9, and wrinkles and folds as
in the conventional art can be prevented. Furthermore, the present inventor has considered
that if the forming height of the side wall portion 7 at the time of forming the side
wall portion 7 of the target shape can be reduced, the degree of stretch flange deformation
is reduced and hence cracking is less likely to occur.
[0023] Therefore, in the present invention, the press forming step is divided into two steps
of a first forming step and a second forming step, as illustrated in FIG. 1. In the
first forming step, an intermediate forming part 19 curved in the same direction as
a press-formed part 1 and having a step-shaped portion 17 is press-formed, and in
the second forming step, the intermediate forming part 19 is press-formed into the
press-formed part 1 of a target shape. The intermediate forming part 19 includes an
intermediate top portion 21 curved in the same direction as the top portion 3 of the
press-formed part 1, a ridge line portion 23 formed at a portion corresponding to
a punch shoulder R portion 5, and the step-shaped portion 17 formed of a step which
is continuous with the ridge line portion 23. FIG. 2 illustrates an example in which
the intermediate top portion 21 having the same shape as the top portion 3 of the
press-formed part 1 is provided. In addition, an outer surface portion 25 which extends
outward continuously with the step-shaped portion 17 and is curved in the same direction
as the intermediate top portion 21 is provided. The outer surface portion 25 is formed
into a side wall portion 7 in the second forming step. FIG. 2 illustrates an example
in which the outer surface portion 25 is parallel to the intermediate top portion
21, but in the present invention, the outer surface portion 25 only needs to be curved
in the same direction as the intermediate top portion 21, and does not need to have
the same curvature as the intermediate top portion 21. In addition, the intermediate
top portion 21 only needs to reach a curvature of the top portion 3 of the press-formed
part 1 in the second forming step, and thus does not need to completely match the
shape of the top portion 3 of the press-formed part 1 of the target shape. Hereinafter,
the first forming step and the second forming step will be described in detail with
reference to FIG. 1, taking the case where the intermediate forming part 19 has the
shape illustrated in FIG. 2 as an example.
<First forming step>
[0024] In the first forming step, a step-forming punch 27 and a step-forming die 29 are
used, as illustrated in FIG. 1(a). The intermediate forming part 19 having the intermediate
top portion 21, the step-shaped portion 17, and the outer surface portion 25 is press-formed
by the step-forming punch 27 and the step-forming die 29. The radius of curvature
of the ridge line portion 23 of the intermediate forming part 19 is preferably greater
than or equal to the radius of curvature of the punch shoulder R portion 5 of the
press-formed part 1. The upper limit of the radius of curvature of the ridge line
portion 23 is not particularly limited, but it is preferably up to 5 times the radius
of curvature of the punch shoulder R portion 5 of the press-formed part 1 in accordance
with the shape of the press-formed part 1 and the thickness of the metal sheet. This
is because it allows the ridge line portion 23 to easily come into contact with the
punch shoulder 33 of the punch 9 in the second forming step.
<Second forming step>
[0025] In the second forming step, the punch 9, the pad 11, and the die 13 for forming the
press-formed part 1 of a target shape are used, as illustrated in FIG. 1(b). The tools
illustrated in FIG. 1(b) is similar to those illustrated in FIG. 8 as a conventional
example. The intermediate forming part 19 is placed on the punch 9 and pressed by
the pad 11, and the die 13 is relatively moved toward the punch 9 to form the outer
surface portion 25 into the side wall portion 7, thereby forming the press-formed
part 1 of a target shape.
[0026] FIG. 3 illustrates movements of the punch 9 and the die 13 in the second forming
step and a deformation process of the intermediate forming part 19 in a cross section
cut in the direction of the arrow A illustrated in FIG. 2. Note that a numerical value
such as [28mmup] represents a gap in the press forming direction between the punch
shoulder 33 and the die jaw portion 13a up to the bottom dead center, in which the
sheet thickness is taken into account, similarly to the case of FIG. 9 described above.
Therefore, the gap between the punch shoulder 33 and the die jaw portion 13a at [28mmup]
is obtained by adding 28 mm to the sheet thickness of the press-formed part 1.
[0027] As illustrated in FIG. 3, the intermediate forming part 19 is placed on the punch
9 and pressed by the pad 11 in the second forming step. At this time, the ridge line
portion 23 of the step-shaped portion 17 comes into contact with the punch shoulder
33 of the punch 9, as illustrated in the drawing of [47mmup]. Since the step-shaped
portion 17 of the intermediate forming part 19 is along the punch shoulder 33 in this
manner, the degree of deformation of the ridge line portion 23 in the subsequent forming
processes is reduced, thereby suppressing the increase in the sheet thickness and
thus preventing a buckled fold.
[0028] Subsequently, the die 13 relatively moves toward the punch 9 and then both end portions
of the die 13 in the longitudinal direction come into contact with both end portions
of the outer surface portion 25 of the intermediate forming part 19 at [35mmup], whereby
the end portion of the outer surface portion 25 of the intermediate forming part 19
slightly rises.
[0029] Furthermore, when the forming proceeds from [28mmup] to [19mmup], the die shoulder
13b of the die 13 comes into contact with the bottom of the concave curved portion
of the outer surface portion 25, and the entire outer surface portion 25 is bent back.
The forming of the side wall portion 7 further proceeds through [8mmup] and [2mmup],
and the forming is completed at the bottom dead center.
[0030] Since the step-shaped portion 17 is formed in the intermediate forming part 19, the
forming height of the side wall portion in the second forming step in the forming
process of the side wall portion 7 corresponds to the distance from the lower portion
of the step-shaped portion 17 to the end portion of the outer surface portion 25.
Therefore, the forming height of the side wall portion in the second forming step
is shorter than the distance from the R start position of the ridge line portion 23
of the top portion 3 to the end portion of the blank 15 as in the conventional example.
Therefore, a decrease in sheet thickness due to stretch flange deformation is suppressed,
and occurrence of cracking can be prevented.
[0031] FIG. 4 is a diagram illustrating the sheet thickness distribution at the bottom dead
center in the first forming step and the second forming step obtained by subjecting
the press forming process of the present embodiment to FEM analysis. FIG. 4(a) illustrates
the sheet thickness distribution at the bottom dead center in the first forming step.
FIG. 4(b) illustrates the sheet thickness distribution at the bottom dead center in
the second forming step. In the first forming step, the maximum sheet thickness increase
rate was 3.1% at the ridge line portion 23, and the maximum sheet thickness decrease
rate was 3.7% at the outer surface portion 25, as described in FIG. 4(a). In the second
forming step, the maximum sheet thickness increase rate was 3.1% at the punch shoulder
R portion 5, and the maximum sheet thickness decrease rate was 10.8% at the distal
end portion of the side wall portion 7, as described in FIG. 4(b).
[0032] In comparison between FIG. 4(b) of the present embodiment and FIG. 10 of the conventional
example, the maximum sheet thickness increase rate at the punch shoulder R portion
5 (ridge line portion 23) was significantly reduced to 3.1% in the present embodiment
from 10.0% of the conventional example. Therefore, it can be seen that wrinkles and
folds at the ridge line portion 23 can be prevented. Furthermore, the maximum sheet
thickness decrease rate at the distal end portion of the side wall portion 7 was reduced
to 10.8% in the present embodiment from 12.3% of the conventional example. Therefore,
it can be seen that cracking caused by stretch flange deformation can be suppressed.
[0033] According to the above description, the die 13 used in the second forming step had
the linear die shoulder 13b for forming the side wall portion 7, as illustrated in
FIG. 1(b). However, the die used in the second forming step in the present invention
may be a die 31 having a die shoulder 31b curved along the outer surface portion 25
of the intermediate forming part 19, as illustrated in FIG. 5. With such a shape,
when the outer surface portion 25 is formed into the side wall portion 7, the outer
surface portion 25 can be simultaneously formed over the entire length. Note that
the reference numeral 31a in FIG. 5 denotes a die jaw portion.
Examples
[0034] A press-forming analysis by FEM for confirming the effect of the present invention
has been performed, which will be described below. A press-forming analysis was performed
on the press-formed part 1 having the top portion 3 curved in a concave shape in a
side view and the side wall portion 7 continuous with the top portion 3 as illustrated
in FIG. 6 with use of a 980 MPa-class steel sheet having a sheet thickness of 1.4
mm so that the sheet thickness distribution was determined. The dimensions of respective
portions of the press-formed part 1 were as described in FIG. 6. The press-forming
analysis was performed by changing the shape of the outer surface portion 25 of the
intermediate forming part 19 (FIG. 2) in addition to the press-forming analysis on
the conventional example formed by one step as illustrated in FIG. 8, thereby determining
the maximum sheet thickness increase rate of the ridge line portion 23 and the maximum
sheet thickness decrease rate of the distal end portion of the side wall of the press-formed
part 1 of a target shape. Note that it has been known that a wrinkle or fold is generated
when the maximum sheet thickness increase rate exceeds 8%, and cracking occurs when
the maximum sheet thickness decrease rate exceeds 12.0%, in the press-formed part
1 of FIG. 6. The analysis results are shown in Table 1. In Table 1, the height of
the step-shaped portion 17 at the bottom position of the concave curve of the intermediate
top portion 21 and the height of the step-shaped portion 17 at the end portion of
the intermediate forming part 19 are shown as the step height (mm).
Table 1
| No. |
The number of pressing steps |
Shape of outer surface portion |
Intermediate forming part |
Press-formed part (Target shape) |
Remarks |
| Step height (mm) |
Maximum sheet thickness increase rate at punch shoulder R portion (%) |
Maximum sheet thickness decrease rate at distal end portion of side wall (%) |
| Bottom of concave curve |
End portion |
| 1 |
1 |
- |
- |
|
10 |
12.3 |
Conventional example |
| 2 |
2 |
Convex chevron |
3 |
20 |
Cracking at distal end of outer surface portion in intermediate forming step |
Comparative example |
| 3 |
2 |
Concave |
3 |
1 |
6.4 |
12 |
Invention example |
| 4 |
2 |
Concave |
5 |
3 |
5.9 |
11.5 |
Invention example |
| 5 |
2 |
Concave |
8 |
5 |
5.2 |
11.6 |
Invention example |
| 6 |
2 |
Concave Parallel to curve of intermediate top portion |
8 |
8 |
3.7 |
11.4 |
Invention example |
| 7 |
2 |
Concave |
12 |
10 |
3 |
11 |
Invention example |
| 8 |
2 |
Concave Parallel to curve of intermediate top portion |
11 |
11 |
3.1 |
10.8 |
Invention example |
| 9 |
2 |
Concave |
15 |
12 |
3.2 |
11 |
Invention example |
| 10 |
2 |
Concave |
20 |
15 |
3.7 |
11.5 |
Invention example |
| 11 |
2 |
Concave Parallel to curve of intermediate top portion |
20 |
20 |
4 |
12 |
Invention example |
[0035] In the conventional example shown in No. 1 in which the top portion 3 and the side
wall portion 7 were press-formed by one step, the maximum sheet thickness increase
rate of the punch shoulder R portion 5 was 10.0%, and a wrinkle and a fold was generated.
The maximum sheet thickness decrease rate at the distal end portion of the side wall
was 12.3%, and cracking occurred. No. 2 representing a comparative example is a case
where the outer surface portion 25 of the intermediate forming part 19 had a convex
chevron shape pointing the top portion 3 as in Patent Literature 1. In this case,
cracking occurred at the distal end of the outer surface portion 25 having the convex
chevron shape during the press forming of the intermediate forming part 19, and the
press forming had to be stopped.
[0036] In the examples of the invention shown in No. 3 to No. 11, the intermediate forming
part 19 having the step-shaped portion 17 was formed first and the intermediate forming
part 19 was subsequently formed into a target shape. The outer surface portion 25
had a concavely curved shape similarly to the top portion 3, and the height of the
step-shaped portion 17 was changed in the range from 1 mm to 20 mm.
[0037] In any of the examples of the invention in No. 3 to No. 11, the maximum sheet thickness
increase rate at the punch shoulder R portion 5 of the target shape and the maximum
sheet thickness decrease rate at the distal end portion of the side wall were reduced
as compared with the conventional example No. 1. In addition, in any of the examples
of the invention in No. 3 to No. 11, the maximum sheet thickness increase rate in
the punch shoulder R portion 5 of the target shape was smaller than 8% at which a
wrinkle was generated, and therefore the generation of wrinkles was prevented. Furthermore,
in any of the examples of the invention in No. 3 to No. 11, the maximum sheet thickness
decrease rate at the distal end portion of the side wall of the target shape was 12.0%
or less, and therefore the occurrence of cracking was prevented. In particular, the
examples of the invention in No. 7 to No. 9 showed that the maximum sheet thickness
increase rate of the punch shoulder R portion 5 of the target shape can be significantly
reduced and hence wrinkles and folds can be reliably prevented, by setting the step
height of the intermediate forming part 19 in the range of 10 mm to 15 mm. In addition,
the examples of the invention in No. 7 to No. 9 showed that the maximum sheet thickness
decrease rate at the distal end portion of the side wall of the target shape can be
also reduced and hence cracking can be reliably prevented, by setting the step height
of the intermediate forming part 19 in the range of 10 mm to 15 mm.
Industrial Applicability
[0038] The present invention can provide a method of manufacturing a press-formed part including
at least a top portion having a concave curved portion that curves concavely in a
side view and a side wall portion continuous from the top portion via a punch shoulder
R portion, the method capable of suppressing cracking of the press-formed part, or
preventing wrinkles and folds.
Reference Signs List
[0039]
1 Press-formed part
3 Top portion
5 Punch shoulder R portion
7 Side wall portion
9 Punch
11 Pad
13 Die
13a Die jaw portion
13b Die shoulder
15 Blank
17 Step-shaped portion
19 Intermediate forming part
21 Intermediate top portion
23 Ridge line portion
25 Outer surface portion
27 Step-forming punch
29 Step-forming die
31 Die (another aspect)
31a Die jaw portion
31b Die shoulder
33 Punch shoulder