Flanged component

Abstract

[Problem] To provide a flanged member that is excellent in joining workability at a time of manufacturing, for example, automobiles and excellent in durability, and can be used for an automobile member. [Solution] An automobile part 90A, which is a flanged member, is formed into a tubular shape and has a flange portion 92. The automobile part 90A has a cross-section changing unit 902, a cross-sectional shape of which is changed along an axis direction thereof. Further, in any two cross-sections in the cross-section changing unit 92, a perimeter of one cross-section is equal to or less than 1.25 times a perimeter of the other cross-section.

Description

Technical Field

[0005] , Joining members together , ,

[0004] , , , , , , , , , ,

[0006] ,

[0001] The present invention relates to a member with a flange.

Background Art

[0002] As a frame constituting the skeleton of an automobile, a steering member is known (for example, see Patent Document 1). The steering member described in Patent Document 1 is basically cylindrical as a whole. This steering member is provided with, for example, a steering support for supporting a steering column, a bracket for coupling to a dash panel, and an instay for coupling to a floor.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] According to the present invention, in any two cross-sectional areas at the cross-sectional change section, the circumference of one cross-sectional area falls within a range of 1.25 times or less the circumference of the other cross-sectional area. By satisfying this numerical range, the flanged member is prevented from forming a thin-walled section. As a result, for example, when the flanged member is used as an automotive component, the automotive component becomes a highly durable component that can withstand the operating environment of the vehicle in which it is mounted.

[0008] Furthermore, other automotive components can be easily joined to the flange portion. For this joining, for example, spot welding can be used. Spot welding generally reduces the cost of joining components compared to arc welding. Also, while arc welding usually requires a jig to position the components, spot welding does not require such a jig. of This eliminates the need for additional welding. Automotive components that can be fitted with spot welding in this manner offer superior ease of joining with other automotive components. [Brief explanation of the drawing]

[0009] [Figure 1]FIG. 1 is a perspective view showing a first embodiment of a member for an automobile. [Figure 2] FIG. 2 is a view seen from the direction of arrow i in FIG. 1. [Figure 3] FIG. 3 is a view seen from the direction of arrow ii in FIG. 1. [Figure 4] FIG. 4 is a view seen from the direction of arrow iii in FIG. 1. [Figure 5] FIG. 5 is a sectional view taken along the line iv-iv in FIG. 1. [Figure 6] FIG. 6 is a sectional view taken along the line v-v in FIG. 1. [Figure 7] FIG. 7 is a sectional view taken along the line vi-vi in FIG. 1. [Figure 8] FIG. 8 is a sectional view taken along the line vii-vii in FIG. 1. [Figure 9] FIG. 9 is a vertical sectional view showing the operating state (die-opening state) of the molding apparatus (first embodiment) in sequence. [Figure 10] FIG. 10 is a vertical sectional view showing the operating state (first intermediate state) of the molding apparatus (first embodiment) in sequence. [Figure 11] FIG. 11 is a vertical sectional view showing the operating state (second intermediate state) of the molding apparatus (first embodiment) in sequence. [Figure 12] FIG. 12 is a vertical sectional view showing the operating state (third intermediate state) of the molding apparatus (first embodiment) in sequence. [Figure 13] FIG. 13 is a vertical sectional view showing the operating state (fourth intermediate state) of the molding apparatus (first embodiment) in sequence. [Figure 14] FIG. 14 is a vertical sectional view showing the operating state (fifth intermediate state) of the molding apparatus (first embodiment) in sequence. [Figure 15] FIG. 15 is a vertical sectional view showing the operating state (die-clamping state) of the molding apparatus (first embodiment) in sequence. [Figure 16] FIG. 16 is a perspective view showing a second embodiment of a member for an automobile. [Figure 17] FIG. 17 is a vertical sectional view showing the molding apparatus (second embodiment). [Figure 18]Figure 18 is a perspective view showing a third embodiment of an automotive member. [Figure 19] Figure 19 is a perspective view showing a fourth embodiment of an automotive member. [Figure 20] Figure 20 is a vertical cross-sectional view showing a molding apparatus (third embodiment). [Figure 21] Figure 21 is a perspective view showing a fifth embodiment of an automotive member. [Figure 22] Figure 22 is a plan view showing a molding apparatus (fourth embodiment). [Figure 23] Figure 23 is a perspective view showing a sixth embodiment of an automotive member. [Figure 24] Figure 24 is a perspective view showing an example of use of the automotive member shown in Figure 23. [Figure 25] Figure 25 is a perspective view showing an example of use of another automotive member. [Figure 26] Figure 26 is an enlarged perspective view of the area [A] surrounded by the two-dot chain line in Figure 25. [Figure 27] Figure 27 is an enlarged plan view of the area [A] surrounded by the two-dot chain line in Figure 25. [Figure 28] Figure 28 is a vertical longitudinal cross-sectional side view showing a fifth embodiment of a molding apparatus. [Figure 29] Figure 29 is a block diagram of the molding apparatus shown in Figure 28. [Figure 30] Figure 30 is a vertical cross-sectional view (sectional views taken along lines B-B and C-C in Figure 28) sequentially showing the operating state (mold open state) of the molding apparatus shown in Figure 28. [Figure 31] Figure 31 is a vertical cross-sectional view (sectional views taken along lines B-B and C-C in Figure 28) sequentially showing the operating state (intermediate state) of the molding apparatus shown in Figure 28. [Figure 32] Figure 32 is a vertical cross-sectional view (sectional views taken along lines B-B and C-C in Figure 28) sequentially showing the operating state (mold clamping state) of the molding apparatus shown in Figure 28. [Figure 33] Figure 33 is a vertical longitudinal cross-sectional side view showing a sixth embodiment of a molding apparatus. [Figure 34]Figure 34 is a vertical cross-sectional view (cross-sectional view along lines DD and EE in Figure 33) showing the operating state (mold open state) of the molding apparatus shown in Figure 33 in sequence. [Figure 35] Figure 35 is a vertical cross-sectional view (cross-sectional view along line DD and line EE in Figure 33) showing the operating state (intermediate state) of the molding apparatus shown in Figure 33 in sequence. [Figure 36] Figure 36 is a vertical cross-sectional view (cross-sectional view along lines DD and EE in Figure 33) showing the operating state (clip-closure state) of the molding apparatus shown in Figure 33. [Figure 37] Figure 37 is a perspective view showing the operating state (before the formation of the enlarged diameter portion) of the molding apparatus (seventh embodiment) in sequence. [Figure 38] Figure 38 is a perspective view showing the operating state (during the formation of the enlarged diameter section) of the molding apparatus (seventh embodiment) in sequence. [Figure 39] Figure 39 is a perspective view showing the operating state of the molding apparatus (7th embodiment) (before flange formation). [Figure 40] Figure 40 is a perspective view showing the operating state (during flange formation) of the molding apparatus (7th embodiment). [Figure 41] Figure 41 is a perspective view showing the operating state (after flange formation) of the molding apparatus (7th embodiment). [Modes for carrying out the invention]

[0010] The flanged member of the present invention will be described in detail below based on preferred embodiments shown in the accompanying drawings. <First Embodiment of Automotive Components> A first embodiment of the flanged member of the present invention will be described with reference to Figures 1 to 8. For the sake of explanation, in the following, the left side in Figures 1 to 3 will be referred to as "left (or left-hand side)" and the right side as "right (or right-hand side)". Also, in Figures 1 and 4 to 8, the upper side will be referred to as "up (or upward)" and the lower side as "down (or downward)".

[0011] The automotive part 90A shown in Figure 1 is an application of the flanged member of the present invention. The automotive part 90A has a pipe portion 91 and a flange portion 92. The automotive part 90A is made of a metallic material such as an iron-carbon alloy. As described later, the automotive component 90A, that is, the flanged component of the present invention, is obtained by hot blow molding a tubular body, which is the base material 90', using a molding apparatus 20, which will be described later. Whether or not the automotive component 90A is obtained by hot blow molding the base material 90' (tubular body) can be determined, for example, by examining the internal composition of the automotive component 90A with an electron microscope. In this case, it can be seen that the automotive component 90A is a compression molded product and not, for example, an extruded product.

[0012] As shown in Figures 1 to 3, the pipe section 91 is tubular and extends in a straight line from left to right. The cross-sectional shape of the pipe section 91 is not particularly limited, but for example, in this embodiment, as shown in Figures 5 to 8, it forms a quadrilateral (rectangle) with rounded corners. Therefore, in this embodiment, the pipe section 91 can also be called a "rectangular section". In this specification, the term "tubular" also includes a state in which the space is continuous from the pipe section 91 to the tunnel section 907, as shown in Figure 16.

[0013] As shown in Figure 4, a flange portion 92 is integrally formed with the lower outer circumference of the pipe portion 91, protruding in a plate-like manner. The flange portions 92 are formed on both sides of the pipe portion 91 in the width direction. Each flange portion 92 protrudes in opposite directions from the other.

[0014] As shown in Figure 2, each flange portion 92 is formed along the direction of the central axis (axis) O91 of the pipe portion 91 (base material 90'). In this embodiment, each flange portion 92 is formed from the left end 911 of the pipe portion 91 to partway along the central axis O91 of the pipe portion 91, and the formation of each flange portion 92 is omitted from that point to the right end 912 of the pipe portion 91.

[0015] Furthermore, each flange portion 92 has a constant width portion 921 where the width (protrusion amount) W92 is constant along the direction of the central axis O91, and a width-changing portion (width-decreasing portion) 922 where the width (protrusion amount) W92 changes along the direction of the central axis O91, that is, gradually decreases from the constant width portion 912 side toward the right end 912 side.

[0016] On the other hand, the pipe section 91 also has a constant height section 913 where the height H91 is constant along the direction of the central axis O91, a height-changing section (height-increasing section) 914 where the height H91 changes along the direction of the central axis O91, that is, gradually increases from the constant height section 913 side toward the right end 912 side, and a constant height section 915 where the height H91 is constant along the direction of the central axis O91. The constant height section 915 is taller than the constant height section 913. A constant width section 921 of the flange section 92 is formed in the constant height section 913, and a width-changing section 922 of the flange section 92 is formed in the height-changing section 914. The pipe section 91 has a constant width W91 along the direction of the central axis O91 throughout its entire length. As a result, the constant height section 913, the height-changing section 914, and the constant height section 915 each have the same width W91.

[0017] Therefore, the automotive component 90A has three parts corresponding to its cross-sectional shape: a section with a constant cross-section 901, a section with a changing cross-section 902, and a section with a constant cross-section 903 (see Figures 1 and 5 to 8).

[0018] As shown in Figure 5, the constant cross-sectional portion 901 includes the constant height portion 913 of the pipe portion 91 and the constant width portion 921 of the flange portion 92. As mentioned above, the height portion 913 has a constant height H91 along the direction of the central axis O91, and the width portion 921 also has a constant width W92 along the direction of the central axis O91. As a result, Cross-sectional fixed portion 901 The cross-sectional shape is constant along the central axis O91 direction.

[0019] As shown in Figure 8, the constant cross-sectional portion 903 includes the constant height portion 915 of the pipe portion 91. As mentioned above, the height H91 of the constant height portion 915 is constant along the direction of the central axis O91. As a result, the cross-sectional shape of the constant cross-sectional portion 903 is constant along the direction of the central axis O91.

[0020] A section of the cross-section that changes shape 902 is located between the section of the cross-section that has a constant cross-section 901 and the section of the cross-section that has a constant cross-section 903. As shown in Figures 6 and 7, the section of the cross-section that changes shape 902 includes a section of the pipe section 91 that has a height change 914 and a section of the flange section 92 that has a width change 922. As mentioned above, the height of the section of the height change 914 changes along the direction of the central axis O91, and the width of the section of the width change 922 also changes along the direction of the central axis O91. As a result, the section of the cross-section that changes shape 902 is a part in which the cross-sectional shape changes continuously along the direction of the central axis O91.

[0021] Then, comparing the perimeters along the outer edges of any two cross-sections in the cross-sectional change section 902 (for example, the cross-section shown in Figure 6 and the cross-section shown in Figure 7), the following relationship is satisfied. Note that "perimeter" refers to the outermost length of the cross-section. Let the perimeter of the cross-section shown in Figure 6 be PM6, and the perimeter of the cross-section shown in Figure 7 be PM7.

[0022] The circumference PM6 (≧PM7) is within the range of 1 to 1.25 times the circumference PM7, preferably within the range of 1 to less than 1.1 times the circumference PM7. Hereinafter, this numerical range will be referred to as the "circumference numerical range". In the automotive component 90A, the circumference is kept within this numerical range by increasing or decreasing the height of the pipe section 91 according to the width of the flange section 92.

[0023] If the circumference exceeds the upper limit of the numerical range, the cross-sectional change portion 902 of the automotive component 90A will be excessively stretched and deformed. As a result, a thin-walled portion will be created in the cross-sectional change portion 902, and the strength of that thin-walled portion will decrease. If such an automotive component 90A is installed in a vehicle, it may break depending on the operating environment of the vehicle, for example, and therefore cannot be used. In contrast, by satisfying the specified circumference range, the automotive component 90A is prevented from forming thin sections. As a result, the automotive component 90A becomes a component with excellent durability, capable of withstanding various operating environments in the vehicle in which it is installed.

[0024] Furthermore, other automotive parts, such as plate-shaped ones, may be joined to the flange portion 92 of the automotive component 90A. While there are no particular limitations on the joining method, welding can be used. In this example, spot welding can be used to join the plate-shaped flange portion 92 to the other plate-shaped automotive part. Spot welding generally reduces joining costs compared to arc welding. Also, while arc welding typically uses jigs to position the members to be joined, spot welding does not require such jigs. of This eliminates the need for spot welding. Automotive component 90A, which can be used in this way, offers excellent workability in joining with other automotive parts.

[0025] <First Embodiment of a Molding Apparatus> The first embodiment of the molding apparatus will be described below with reference to Figures 9 to 15. For the sake of explanation, the three mutually orthogonal axes will be set as the X-axis, Y-axis, and Z-axis. For example, the XY plane containing the X and Y axes is horizontal, and the Z-axis is vertical. Also, the positive side in the Z-axis direction may be referred to as "up (or upward)," and the negative side in the Z-axis direction may be referred to as "down (or downward)." Also, the negative side in the X-axis direction may be referred to as "left (or leftward)," and the positive side in the X-axis direction may be referred to as "right (or right They sometimes say, "(the way)."

[0026] As shown in Figures 9 to 15, the molding apparatus 20 comprises an apparatus body 30 and a flange adjustment member 40. The molding apparatus 20 can mold a base material 90' into an automotive component 90A. In the molding apparatus 20 shown in Figures 9 to 15, the following are typically illustrated from left to right: a section for molding the base material 90' into an iv-iv cross section (Figure (A)), a section for molding the base material 90' into a vv cross section (Figure (B)), a section for molding the base material 90' into a vi-vi cross section (Figure (C)), and a section for molding the base material 90' into a vii-vii cross section (Figure (D)).

[0027] The apparatus body 30 comprises a first mold 50 positioned on the upper side and a second mold 60 positioned on the lower side. The first mold 50 is supported so as to be movable in the Z-axis direction, while the second mold 60 is fixed. This allows the first mold 50 to move closer to and further away from the second mold 60.

[0028] The first mold 50 includes the first mold 50A shown in Figure (A), the first mold 50B shown in Figure (B), the first mold 50C shown in Figure (C), and the first mold 50D shown in Figure (D). The first molds 50A to 50D are each divided into a first member 501 located on the left, a second member 502 located on the right, and a third member 503 located between the first member 501 and the second member 502.

[0029] The third member 503 is supported so as to be movable in the Z-axis direction independently of the first member 501 and the second member 502. Furthermore, a recess 504 is formed in the third member 503, which is responsible for forming the pipe portion 91. The recess 504 of the third member 503 in the first mold 50A is the deepest, while the recesses 504 of the third member 503 in the first molds 50B to 50D are of the same depth. The second mold 60 is used in common from Figure (A) to Figure (D).

[0030] The flange adjustment member 40 includes two flange adjustment members 40B shown in Figure (B), two flange adjustment members 40C shown in Figure (C), and two flange adjustment members 40D shown in Figure (D). Each flange adjustment member 40B is positioned between the first mold 50B and the second mold 60 and is supported so as to be movable in the X-axis direction. Each flange adjustment member 40C is positioned between the first mold 50C and the second mold 60 and is supported so as to be movable in the X-axis direction. Each flange adjustment member 40D is positioned between the first mold 50D and the second mold 60 and is supported so as to be movable in the X-axis direction.

[0031] Furthermore, the flange adjustment members 40B, 40C, and 40D are block-shaped and have different heights. In the molding apparatus 20, the flange adjustment member 40B is the lowest, the flange adjustment member 40D is the highest, and the flange adjustment member 40C is at an intermediate height between the flange adjustment member 40B and the flange adjustment member 40D.

[0032] The molding apparatus 20 operates as follows: First, as shown in Figure 9, the first mold 50 and the second mold 60 are opened, and the base material 90' is placed between the first mold 50 and the second mold 60. In this embodiment, the base material 90' is a tubular body with a roughly rectangular cross-sectional shape. Then, with the mold open, the base material 90' is heated to soften it. At this time, each flange adjustment member 40 is retracted and furthest away from the base material 90'. This prevents each flange adjustment member 40 from being heated.

[0033] Next, as shown in Figure 10, the first mold 50 is lowered to bring each third member 503 into contact with the base material 90'. At this time, the upper part of the base material 90' fits into the recess 504 of each third member 503, and the distance to the second mold 60 becomes constant from Figure (A) to Figure (D). Furthermore, each flange adjustment member 40 moves and comes into contact with the base material 90', and is pressed from below against the third member 503 by a spring mechanism (not shown) or the like. As a result, the upper part of each flange adjustment member 40 fits between the first member 501 and the second member 502.

[0034] Next, as shown in Figure 11, when the first mold 50 is lowered further, the base material 90' comes into contact with the second mold 60 and deformation begins, that is, it collapses. The deformed portion of the base material 90' is the protruding portion 904 that protrudes (is exposed) from the recess 504 in Figure (A), the protruding portion 905 that protrudes from between the flange adjustment members 40B in Figure (B), and the protruding portion 906 that protrudes from between the flange adjustment members 40C in Figure (C). The amount of protrusion is largest for the protruding portion 904, followed by the protruding portion 905, and then the protruding portion 906. Note that, as shown in Figure (D), the base material 90' does not protrude from between the flange adjustment members 40D, and therefore does not deform.

[0035] Next, gas is supplied into the base material 90' to start the primary blowing process. As a result, as shown in Figure 12, the protrusions 904 to 906 all expand in the X-axis direction. Next, while supplying gas into the base material 90' for a predetermined time, the first mold 50 is lowered further, as shown in Figure 13. The amount of descent of each third member at this time is not uniform but is adjusted as appropriate. After that, the supply of gas into the base material 90' is temporarily stopped. As a result, the protrusions 904 to 906 all expand further in the X-axis direction. The amount of expansion in the X-axis direction is greatest for protrusion 904, followed by protrusion 905, and then protrusion 906.

[0036] Next, with the supply of gas to the base material 90' still stopped, the first mold 50 is lowered further, as shown in Figure 14. As a result, the protrusion 904 is crushed between the third member 503 and the second mold 60, the protrusion 905 is crushed between the flange adjustment member 40B and the second mold 60, and the protrusion 906 is crushed between the flange adjustment member 40C and the second mold 60.

[0037] Next, gas is supplied into the base material 90' to start secondary blowing. As a result, as shown in Figure 15, pipe sections 91 are formed along their entire length between each recess 504 and the second mold 6. Furthermore, the first mold 50 is lowered further during the secondary blowing. As a result, the protruding portion 904 is further crushed between the third member 503 and the second mold 60, becoming a flange portion 92. This flange portion 92 is a constant width portion 921.

[0038] Similarly, the protruding portion 905 is further crushed between the flange portion adjustment member 40B and the second mold 60 to become the flange portion 92, and the protruding portion 906 is also crushed between the flange portion adjustment member 40C and the second mold 60 to become the flange portion 92. This flange portion 92 is the width-changing portion 922. Next, the automotive component 90A is rapidly cooled. Then, the mold is opened again, and the automotive component 90A is removed.

[0039] By going through the process described above, the automotive component 90A can be molded. Furthermore, as mentioned above, the flange portion 92 is a part where a portion of the base material 90' is crushed, and the pipe walls of the base material 90' overlap to form a plate-like structure. As a result, the automotive component 90A gains increased strength at the flange portion 92, making it durable enough for actual use when mounted in an automobile. Furthermore, since the molding apparatus 20 cannot fully adjust the width W92 of the flange portion 92 simply by appropriately adjusting the height of each flange portion adjustment member 40, the width W92 is made adjustable by appropriately adjusting the amount of each third member lowered.

[0040] <Second Embodiment of Automotive Components> The following description of a second embodiment of the flanged member of the present invention will be made with reference to Figure 16, focusing on the differences from the previously described embodiment, and omitting explanations of similar matters.

[0041] As shown in Figure 16, the automotive component 90B has a section with a constant cross-section 901 and a section with a changing cross-section 902. The section with a changing cross-section 902 satisfies the specified range of circumference values. Furthermore, in the cross-sectional change section 902, a tunnel section 907 is formed in the portion where the pipe section 91 disappears and only the flange section 92 remains, communicating with the inside of the pipe section 91. The tunnel section 907 functions as a discharge section for releasing gas from inside the pipe section 91 during the molding of the automotive component 90B. In this embodiment, the cross-sectional shape of the tunnel section 907 is a semi-circular arc, but it is not limited to this.

[0042] <Second Embodiment of Molding Apparatus> The following describes a second embodiment of the molding apparatus with reference to Figure 17. I will explain, This explanation will focus on the differences from the previously described embodiment, and similar matters will be omitted.

[0043] The molding apparatus 20 shown in Figure 17 is a device for molding automotive components 90B. In this molding apparatus 20, the third component 503 of the first mold 50 has a groove (tunnel forming groove) 505 for forming the tunnel portion 907. The groove 505 is formed along the Y-axis direction and has a semicircular cross-sectional shape.

[0044] <Third Embodiment of Automotive Components> A third embodiment of the flanged member of the present invention will be described below with reference to Figure 18, focusing on the differences from the previously described embodiments, and similar matters will be omitted from the explanation.

[0045] As shown in Figure 18, the automotive component 90C has a section with a constant cross-section 901 and a section with a changing cross-section 902. The section with a changing cross-section 902 satisfies the specified range of circumference values. Furthermore, in the automotive component 90C, at least the cross-sectional change portion 902 is curved in an arc shape, towards the bottom in the figure.

[0046] <Fourth embodiment of an automotive component> A fourth embodiment of the flanged member of the present invention will be described below with reference to Figure 19, focusing on the differences from the previously described embodiments, and similar matters will be omitted from the explanation.

[0047] As shown in Figure 19, the automotive component 90D has a section with a constant cross-section 901 and a section with a changing cross-section 902. The section with a changing cross-section 902 satisfies the specified perimeter numerical range. Furthermore, the automotive component 90D has at least one cross-sectional change portion 902 that is curved downwards in the figure in an arc shape.

[0048] Furthermore, a groove 908, which serves as a bead, is formed in the pipe section 91, extending from the middle of the cross-sectional change section 902 to the section with a constant cross-section 901, that is, along the central axis O91. The strength of the automotive component 90D is increased due to the formation of the groove 908. In this embodiment, the cross-sectional shape of the groove 908 is a semi-circular arc, but it is not limited to this. The bead portion is not limited to the groove 908, but may also be a ridge formed along the central axis O91, for example. The strength of the automotive component 90D can also be increased by the ridge. As shown in Figure 19, the constant cross-section portion 901 where the groove 908 as the bead portion is provided does not have a flange 92. On the other hand, in the cross-section change portion 902, the strength of the automotive component 90d can be ensured without changing the circumference by increasing the width of the flange width 92 as the depth of the groove 908 as the bead portion becomes shallower.

[0049] <Third embodiment of the molding apparatus> The third embodiment of the molding apparatus will be described below with reference to Figure 20, focusing on the differences from the previously described embodiment, and similar matters will be omitted from the explanation.

[0050] The molding apparatus 20 shown in Figure 20 is a device for molding automotive components 90D. In this molding apparatus 20, the protrusions (groove-forming protrusions) 506 for forming grooves 908 in the recesses 504 of the third component 503 are formed along the Y-axis direction, and their cross-sectional shape is semicircular.

[0051] <Fifth Embodiment of Automotive Components> The fifth embodiment of the flanged member of the present invention will be described below with reference to Figure 21, focusing on the differences from the previously described embodiments, and similar matters will be omitted from the explanation.

[0052] As shown in Figure 21, the automotive component 90E has alternating sections of cross-section change 902 and sections of cross-section constant 903 arranged along the central axis O91. In the section of cross-section change 902, the width W92 of the flange section 92 gradually increases from the lower left to the upper right in the figure, and once it reaches its maximum, it gradually decreases towards the upper right.

[0053] <Fourth embodiment of the molding apparatus> The following describes the molding apparatus, referring to Figure 22. 4 The embodiments will now be described, focusing on the differences from the embodiments described above, and similar matters will be omitted from the explanation.

[0054] The molding apparatus 20 shown in Figure 22 is a device for molding automotive components 90E. In this molding apparatus 20, flange adjustment members 40B, 40C, 40D, 40C, and 40B, arranged along the Y-axis, form a set 401. This set 401 is arranged along the Y-axis with a gap 402 between them. The set 401 forms the flange portion 92 in the cross-sectional change portion 902. In the portions with a gap 402, the cross-sectional constant portion 903 is formed. <Sixth Embodiment of Automotive Components> A sixth embodiment of the automotive component will be described below with reference to Figures 23 and 24.

[0055] The automotive component 9A shown in Figure 23 is a pipe (flanged component) comprising a pipe portion 91 and a flange portion 92, and is a component used as an automobile part. The automotive component 9A is made of a metallic material such as an iron-carbon alloy. The pipe portion 91 is a tubular part. The cross-sectional shape of the pipe portion 91 is not particularly limited, but for example, in this embodiment it is a non-circular ring shape.

[0056] The flange portion 92 is integrally formed and protrudes from the outer circumference of the pipe portion 91. In the automotive component 9A, the flange portions 92 are formed on both sides of the pipe portion 91 in the width direction, via the central axis O91 of the pipe portion 91. Each flange portion 92 protrudes in opposite directions from the others. In this embodiment, the automotive component 9A has a configuration with two flange portions 92, but the number of flange portions 92 is not limited to this, and may be, for example, one or three or more.

[0057] Each flange portion 92 is configured to include two flange portions with different protrusion amounts from the outer circumference of the pipe portion 91, i.e., different widths. Of the two flange portions, one flange portion is called the "first flange portion 93," and the other flange portion having a width (protrusion amount) W94 smaller than the width (protrusion amount) W93 of the first flange portion 93 is called the "second flange portion 94." Here, in this invention, "width W94 smaller than width W93" includes the case where the width W94 is zero. Furthermore, the difference (maximum difference) between width W93 and width W94 is not particularly limited.

[0058] The first flange portion 93 and the second flange portion 94 are formed at different positions relative to each other in the direction of the central axis O91 of the pipe portion 91. In this embodiment, the first flange portion 93 is formed in the central part of the pipe portion 91 in the longitudinal direction (direction of the central axis O91), and the second flange portions 94 are formed at both ends thereof.

[0059] In this embodiment, the total length L93 of the first flange portion 93 along the central axis O91 is shorter than the total length L94 of the second flange portion 94 along the central axis O91, but this is not limited to this. For example, the total length L93 may be longer than the total length L94, or the total lengths L93 and L94 may be the same.

[0060] Furthermore, although the two second flange portions 94 in each flange portion 92 have the same total length L94 in this embodiment, the invention is not limited to this, and their total lengths L94 may be different. Furthermore, with respect to the pipe section 91, the portion where the first flange section 93 is formed to protrude is called the "first pipe section 95," and the portion where the second flange section 94 is formed to protrude is called the "second pipe section 96."

[0061] Next, automotive component 9A of An example of usage will be described. Automotive component 9A is used as part (a beam) of a steering support structure 10 that supports the steering wheel and surrounding components on the front side of the vehicle. The steering support structure 10 is commonly referred to as, for example, a "steering member" or "instrument panel reinforcement."

[0062] As shown in Figure 24, the steering support structure 10 comprises an automotive component 9A and a sheet metal component 11. The sheet metal member 11 is obtained by mechanically processing a metal plate, such as bending, and functions as a bracket, stay, or the like.

[0063] The sheet metal member 11 is joined to the first flange portion 93 of the automotive member 9A. In the configuration shown in Figure 24, the sheet metal member 11 and the first flange portion 93 are joined at one welding point 101, but this is not limited to this configuration. For example, depending on the size of the sheet metal member 11 and the first flange portion 93, they may be joined at multiple welding points 101.

[0064] The joining method is not particularly limited, but since it involves joining plate-like parts, a welding method, especially spot welding, can be used. Spot welding generally reduces the cost of joining members compared to arc welding. Also, while arc welding usually requires a jig to position the members to be joined, spot welding does not require such a jig. ofThe use of spot welding can be omitted. Automotive component 9A, which can be used in this way, is a component that offers excellent workability in joining with other components, namely sheet metal components 11, during automobile manufacturing.

[0065] Furthermore, the first flange portion 93 has the widest width W93 within the flange portion 92, which makes it easier to join it with the sheet metal member 11. The synergistic effect of the fact that the area where the sheet metal member 11 is joined is the first flange portion 93 with the widest width W93, and that spot welding can be used for joining, further improves the ease of joining.

[0066] History of Automotive Components 7 Embodiments > The following are the first automotive components, referring to Figures 25 to 27. 7 Embodiments will be described.

[0067] As shown in Figure 25, the steering support structure 10 of this embodiment comprises an automotive member 9B, an automotive member 9C, and four sheet metal members 11. As shown in Figures 26 and 27, both automotive component 9B and automotive component 9C have a flange portion width 92 that is constant along the direction of the central axis O91. Furthermore, automotive component 9B and automotive component 9C differ in thickness (width), with automotive component 9B being thicker and automotive component 9C being thinner. In the steering support structure 10, automotive component 9B and automotive component 9C are arranged along the vehicle width direction, with the thicker automotive component 9B positioned on the driver's side of the vehicle.

[0068] As shown in Figure 27, the end faces 97 of the automotive component 9B and the automotive component 9C are abutting against each other, that is, in contact, and this state is maintained by a single sheet metal component 11 (sheet metal component 11A). The four sheet metal members 11 include one sheet metal member 11A that is joined to both the automotive member 9B and the automotive member 9C, and three sheet metal members 11B that are joined to the automotive member 9B. Spot welding is used to join each sheet metal member 11.

[0069] The sheet metal member 11A covers the ends of the automotive members 9B and 9C together and has a joint portion 111 that connects these members. The joint portion 111 is a plate-like portion that conforms to the outer shape of the automotive members 9B and 9C, and is joined to each flange portion 92 of the automotive member 9B and each flange portion 92 of the automotive member 9C. This maintains the positional relationship between the automotive members 9B and 9C. In this example, the sheet metal member 11A and each flange portion 92 are joined at one welding point 101, but are not limited to this, and may be joined at multiple welding points 101.

[0070] Each sheet metal member 11B is joined to a desired position on the flange portion 92 of the automotive member 9B. Each sheet metal member 11B and the flange portion 92 may be joined at one welding point 101 or at multiple welding points 101. Furthermore, the number of sheet metal members 11 is not limited to four; for example, it may be one to three or five or more.

[0071] <Fifth embodiment of the molding apparatus> The fifth embodiment of the molding apparatus will be described below with reference to Figures 28 to 32, focusing on the differences from the previously described embodiment, and similar matters will be omitted from the explanation.

[0072] As shown in Figures 28 and 29, the molding apparatus 1 comprises a main body 2, a gas supply unit 61, a heating unit 62, a cooling unit 63, a drive unit 64, and a control unit 65. The molding apparatus 1 can mold a cylindrical base material 9' into an automotive component 9A. The apparatus body 2 comprises a first molding section 21 and a second molding section 22 arranged along the Y-axis direction. Although not shown in the figures, in the apparatus body 2, one second molding section 22 is located on the positive Y-axis side of the first molding section 21, and another second molding section 22 is located on the negative Y-axis side of the first molding section 21. Since the two second molding sections 22 have the same configuration except for their location, the second molding section 22 on the positive Y-axis side will be described as representative.

[0073] Here, Figures 30 to 32 are vertical cross-sectional views sequentially showing the operating state (mold open state) of the molding apparatus shown in Figure 28. In addition, the cross-sectional view along line BB in Figure 28 is a cross-sectional view of the first molding section 21, and the cross-sectional view along line CC is a cross-sectional view of the second molding section 22. The first molding section 21 is the part that performs a first molding process in which a part of the base material 9', that is, the central part in the longitudinal direction (central axis O9' direction) of the base material 9', is formed into a first pipe section 95 and a first flange section 93. The second molding section 22 is the part that performs a second molding process in which a part of the base material 9', that is, one end of the base material 9' (the positive side in the Y-axis direction) is formed into a second pipe section 96 and a second flange section 94.

[0074] The first molding section 21 and the second molding section 22 share a first mold 3 and a second mold 4 that can take on an open state (see Figure 30), a closed state (see Figure 32), and an intermediate state between the open state and the closed state (see Figure 31). As a result, in the first molding section 21 and the second molding section 22, the first mold 3 and the second mold 4 can operate at the same timing from the open state to the closed state, thus enabling smooth molding of automotive components 9A.

[0075] In the main body of the apparatus 2, the first mold 3 is positioned on the upper side and the second mold 4 is positioned on the lower side. A cavity 23 is formed between the first mold 3 and the second mold 4 for positioning and housing the base material 9'. Furthermore, in this embodiment, both the first mold 3 and the second mold 4 are supported so that they can move in the Z-axis direction and move closer to and further apart from each other. The apparatus body 2 may be configured such that the first mold 3 is fixed and the second mold 4 is supported so that it can move closer to and further apart from the first mold 3, or the second mold 4 is fixed and the first mold 3 is supported so that it can move closer to and further apart from the second mold 4.

[0076] As shown in Figures 30 to 32, the first mold 3 is block-shaped and has a bottom surface 31 parallel to the XY plane. The first mold 3 also has a groove 32 formed on the bottom surface 31 and aligned with the Y axis. Each side surface 321 of the groove 32 is inclined with respect to the bottom surface 31, and the distance between each side surface 321 gradually increases toward the negative side in the Z axis direction. The bottom surface 322 is formed parallel to the bottom surface 31.

[0077] The second mold 4 is block-shaped and has an upper surface 41 parallel to the XY plane, that is, facing the lower surface 31 of the first mold 3. The second mold 4 also has a groove 42 formed on its upper surface 41, which is aligned with the Y-axis direction. When viewed in the Z-axis direction, this groove 42 overlaps with the groove 32 of the first mold 3. Each side surface 421 of the groove 42 is inclined with respect to the upper surface 41, and the distance between each side surface 421 gradually increases toward the positive Z-axis direction. The bottom surface 422 is formed parallel to the upper surface 41.

[0078] Furthermore, the first molding section 21 includes a flange adjustment member 5. As will be described later, when molding the first flange section 93, the flange adjustment member 5 can adjust the width W93 of the first flange section 93 to be larger than the width W94 of the second flange section 94. In this embodiment, the first molding section 21 includes two flange adjustment members 5, one of which, flange adjustment member 5A, is located in the first mold 3, and the other, flange adjustment member 5B, is located in the second mold 4. Note that the flange adjustment member 5 is not limited to being located in both the first mold 3 and the second mold 4; for example, it may be located in only one of the first mold 3 and the second mold 4.

[0079] The flange adjustment member 5A is supported by the first mold 3 so as to be movable along the Z-axis direction. The flange adjustment member 5A has a first projection (projection) 51, two second projections 52, and a connecting portion 53 that connects the first projection 51 and each of the second projections 52. The first projection 51 protrudes downward from the bottom surface 322 of the groove 32 of the first mold 3. Second protrusions 52 are positioned on the positive and negative sides of the first protrusion 51 in the X-axis direction. Each second protrusion 52 protrudes downward from the lower surface 31 of the first mold 3.

[0080] When the flange adjustment member 5A moves along the Z-axis direction, the first protrusion 51 and each of the second protrusions 52 can be extended and retracted simultaneously relative to the cavity 23. As shown in Figure 30, in the open state, the first protrusion 51 and each of the second protrusions 52 are in their maximum extended state. As shown in Figure 32, in the clamped state, the first protrusion 51 and each of the second protrusions 52 are in their most retracted state.

[0081] The flange adjustment member 5B is supported by the second mold 4 so as to be movable along the Z-axis direction. The flange adjustment member 5B has a first projection (projection) 54, two second projections 55, and a connecting portion 56 that connects the first projection 54 and each of the second projections 55. The first projection 54 protrudes upward from the bottom surface 422 of the groove 42 of the second mold 4. Second protrusions 55 are positioned on the positive and negative sides of the first protrusion 54 in the X-axis direction. Each second protrusion 55 protrudes upward from the upper surface 41 of the second mold 4.

[0082] Then, when the flange adjustment member 5B moves along the Z-axis direction, the first protrusion 54 and each of the second protrusions 55 can be extended and retracted simultaneously relative to the cavity 23. As shown in Figure 30, in the open state, the first protrusion 54 and each of the second protrusions 55 are in their maximum extended state. As shown in Figure 32, in the clamped state, the first protrusion 54 and each of the second protrusions 55 are in their most retracted state.

[0083] Furthermore, the first molding section 21 includes a gas damper 24 built into the first mold 3 and a gas damper 25 built into the second mold 4. The gas damper 24 is positioned on the opposite side of the first projection 51 of the flange adjustment member 5A and functions as a biasing member that biases the flange adjustment member 5A toward the negative side in the Z-axis direction. As a result, in the open state, the first projection 51 and each of the second projections 52 are maintained in their maximum protruding state.

[0084] The gas damper 25 is positioned on the opposite side of the first projection 54 of the flange adjustment member 5B and functions as a biasing member that biases the flange adjustment member 5B toward the positive Z-axis direction. As a result, in the open state, the first projection 54 and each of the second projections 55 are maintained in their maximum protruding state. In addition, in the molding apparatus 1, a compression coil spring can be used instead of the gas dampers 24 and 25.

[0085] The heating section 62 is the part that performs a heating process to heat the base material 9'. The configuration of the heating section 62 is not particularly limited, and for example, it can have a configuration that includes two electrodes electrically connected to the base material 9' and a voltage application section that applies a voltage between these electrodes. This allows the base material 9' to be energized and heated to soften prior to molding by the first molding section 21 and molding by the second molding section 22.

[0086] The gas supply unit 61 is the part that performs the gas supply process of supplying high-pressure air into the base material 9'. This prevents excessive crushing of the base material 9' when molding by the first molding unit 21 and molding by the second molding unit 22 are performed while the first mold 3 and the second mold 4 are clamped together. The configuration of the gas supply unit 61 is not particularly limited, and for example, it can be configured to include a compressor.

[0087] The cooling section 63 is the part that performs a cooling process to rapidly cool the automotive component 9A (base material 9'). The configuration of the cooling section 63 is not particularly limited, and for example, it can be provided in the first mold 3 and the second mold 4 respectively, and have a flow path through which a refrigerant passes. When the refrigerant passes through the flow path, the automotive component 9A can be rapidly cooled in both the first mold 3 and the second mold 4. The refrigerant may be a liquid or a gas.

[0088] The drive unit 64 moves the first mold 3 and the second mold 4 and They can be moved closer together or further apart from each other. This allows switching between the mold open state and the mold closed state. The configuration of the drive unit 64 is not particularly limited, and for example, it can have a configuration that includes a motor, a ball screw connected to the motor, and a linear guide connected to the ball screw.

[0089] The control unit 65 controls the operation of the gas supply unit 61, heating unit 62, cooling unit 63, and drive unit 64. The configuration of the control unit 65 is not particularly limited and can include, for example, a CPU 651 and a memory unit 652. The CPU 651 can execute, for example, a control program pre-stored in the memory unit 652. The control program includes, for example, a program for controlling the operating conditions (operating timing) of the gas supply unit 61, heating unit 62, cooling unit 63, and drive unit 64 to form the base material 9' into an automotive component 9A.

[0090] The molding apparatus 1 operates as follows: First, as shown in Figure 30, the first mold 3 and the second mold 4 are opened, and the base material 9' is placed between the first mold 3 and the second mold 4, that is, in the cavity 23. At this time, as described above, in the first molding section 21, the first protrusion 51 and each of the second protrusions 52 on the first mold 3 side are in their maximum protruding state, and the first protrusion 54 and each of the second protrusions 55 on the second mold 4 side are also in their maximum protruding state (see the cross-sectional view along line BB in Figure 30). On the other hand, the second molding section 22 does not have any protrusions 51, etc. (see the cross-sectional view along line CC in Figure 30). Next, with the mold still open, the heating unit 62 is activated. This allows the base material 9' to be softened.

[0091] Next, the drive unit 64 is activated to bring the first mold 3 and the second mold 4 closer together than in the state shown in Figure 30, as shown in Figure 31. As a result, the upper part of the base material 9' can penetrate deeper into the groove 32 of the first mold 3 than in the state shown in Figure 30, and the lower part can penetrate deeper into the groove 42 of the second mold 4 than in the state shown in Figure 30. Furthermore, in the first molding section 21, the end face 511 of the first protrusion 51 abuts against the base material 9' from above, and the end face 541 of the first protrusion 54 abuts against the base material 9' from below. On the other hand, in the second molding section 22 (cross section of line CC in Figure 31), the bottom surface 322 of the groove 32 abuts against the base material 9' from above, and the bottom surface 422 of the groove 42 abuts against the base material 9' from below. The distance SD1 between the end face 511 of the first protrusion 51 and the end face 541 of the first protrusion 54 is shorter than the distance SD2 between the bottom surface 322 of the groove 32 and the bottom surface 422 of the groove 42. As a result, the base material 9' abuts against the bottom surface 322 of the groove 32 and the bottom surface 422 of the groove 42. of Rather than the space between the end face 511 of the first protrusion 51 and the end face 541 of the first protrusion 54 of They get crushed more in between.

[0092] Furthermore, in the state shown in Figure 31, the gas supply unit 61 is activated to perform a primary blow. This primary blow, combined with the crushing between the end face 511 of the first protrusion 51 and the end face 541 of the first protrusion 54, causes the base material 9' to expand in the X-axis direction at the first molding section 21 (cross-sectional view along line BB in Figure 31) more than at the second molding section 22 (cross-sectional view along line CC in Figure 31). This expansion allows the base material 9' to have more of the portion 93' that becomes the first flange portion 93 than the portion 94' that becomes the second flange portion 94, fitting between the lower surface 31 of the first mold 3 and the upper surface 41 of the second mold 4. As a result, in the subsequent mold clamping state, portion 93' is crushed without excess or deficiency, forming the first flange portion 93 with a larger width W93, and portion 94' is crushed, forming the second flange portion 94 with a smaller width W94.

[0093] Next, in the clamping state shown in Figure 32, the gas supply unit 61 is activated to perform a secondary blow-out. Note that in the secondary blow-out, the amount of high-pressure air supplied into the base material 9' is greater than in the primary blow-out, or the pressure of the high-pressure air is higher. In the clamped state, the base material 9' can penetrate even deeper into the groove 32 of the first mold 3 and the groove 42 of the second mold 4. As a result, the base material 9' conforms to the shape of the grooves 32 and 42, and the first pipe portion 95 and the second pipe portion 96 are formed on the base material 9'. In addition, between the first mold 3 and the second mold 4, the aforementioned portion 93' can be completely crushed to reliably form the first flange portion 93, and the aforementioned portion 94' can be completely crushed to reliably form the second flange portion 94.

[0094] At this time, the flange adjustment member 5A is pressed in the positive Z-axis direction by the base material 9' at the first projection 51, and each of the second projections 52 is pressed in the positive Z-axis direction by the upper surface 41 of the second mold 4. As a result, the flange adjustment member 5A moves in the positive Z-axis direction against the biasing force of the gas damper 24. On the other hand, the flange adjustment member 5B is pressed in the negative Z-axis direction by the base material 9' at the first projection 54, and each of the second projections 55 is pressed in the negative Z-axis direction by the lower surface 31 of the first mold 3. As a result, the flange adjustment member 5B moves in the negative Z-axis direction against the biasing force of the gas damper 25.

[0095] In this mold-clamping state, the base material 9' is formed into an automotive component 9A having a first pipe portion 95, a first flange portion 93, a second pipe portion 96, and a second flange portion 94. The first pipe portion 95 and the second pipe portion 96 are formed at different positions relative to each other in the direction of the central axis O9' (central axis O91) of the base material 9', but they have a different tubular shape from the base material 9', that is, they are portions with a non-circular tubular cross-sectional shape. The first flange portion 93 is integrally formed protruding from the outer circumference of the first pipe portion 95. The second flange portion 94 is integrally formed protruding from the outer circumference of the second pipe portion 96. The width W93 of the first flange portion 93 is greater than the width W94 of the second flange portion 94. The total length L93 of the first flange portion 93 follows the length of the first molded portion 21 along the Y-axis direction, and the total length L94 of the second flange portion 94 follows the length of the second molded portion 22 along the Y-axis direction.

[0096] Next, the cooling unit 63 is activated to rapidly cool the automotive component 9A. Furthermore, the base material is subjected to secondary blowing. 9’ When the first mold 3 and the second mold 4 come into close contact, the base material 9' The material undergoes quenching. As a result, the base material 9' transforms from austenite to martensite, becoming the final molded product, the automotive component 9A. Next, the mold is opened again, and the automotive component 9A is removed. As described above, by using the molding apparatus 1, the automotive component 9A can be molded quickly and accurately. Furthermore, as mentioned earlier, the automotive component 9A obtained from the molding apparatus 1 is a component with excellent joining workability during automobile manufacturing.

[0097] Furthermore, in the molding apparatus 1, the width W93 of the first flange portion 93 in the clamped state is determined according to the magnitude of the maximum protrusion amounts of the first protrusions 51 and 54 in the open state. As a result, the larger the maximum protrusion amounts of the first protrusions 51 and 54, the larger the width W93 of the first flange portion 93 becomes. Conversely, if the maximum protrusion amounts of the first protrusions 51 and 54 are reduced, the width W93 of the first flange portion 93 can be reduced accordingly.

[0098] <Sixth embodiment of the molding apparatus> The sixth embodiment of the molding apparatus will be described below with reference to Figures 33 to 36, focusing on the differences from the previously described embodiments, and similar matters will be omitted from the explanation.

[0099] The molding apparatus 1 of this embodiment, shown in Figure 33, comprises a main body 2. This main body 2 includes a first molding section 21 and a second molding section 22 having the internal structures shown in Figures 34 to 36. As shown in Figures 34 to 36, in the first molding section 21, the first mold 3 has a lower surface 31 parallel to the XY plane and a groove 32 formed on the lower surface 31. The second mold 4 has an upper surface 41 parallel to the XY plane and a groove 42 formed on the upper surface 41.

[0100] The second molding section 22 includes flange adjustment members 7. As will be described later, when molding the second flange section 94, the flange adjustment members 7 can adjust the width W94 of the second flange section 94 to be smaller than the width W93 of the first flange section 93. In this embodiment, the second molding section 22 includes two flange adjustment members 7A arranged in the first mold 3 and two flange adjustment members 7B arranged in the second mold 4 as flange adjustment members 7. Note that the flange adjustment members 7 are not limited to being arranged in both the first mold 3 and the second mold 4, but may be arranged in only one of them, for example.

[0101] The two flange adjustment members 7A are spaced apart in the X-axis direction. Since these two flange adjustment members 7A have the same configuration except for their different positions, the flange adjustment member 7A on the positive X-axis side will be described as representative below. The flange adjustment member 7A is supported on the first mold 3 so as to be movable along the Z-axis direction. The flange adjustment member 7A has a protrusion 71.

[0102] The protruding portion 71 protrudes downward from the lower surface 31 of the first mold 3. The protruding portion 71 has an end face 711 parallel to the XY plane and an inclined surface 712 facing the base material 9' side located in the cavity 23 and inclined relative to the end face 711. The inclined surface 712 is inclined to the same extent as the side surface 321 of the groove 32, and when viewed from the Y-axis direction in the mold clamped state, it overlaps with the side surface 321. In addition, the distance between the two flange portion adjustment members 7A gradually increases toward the negative side in the Z-axis direction.

[0103] As the flange adjustment member 7A moves along the Z-axis, the protruding portion 71 can extend and retract relative to the cavity 23. As shown in Figure 34, in the open mold state, the protruding portion 71 is in its maximum protruding state. As shown in Figure 36, in the clamped mold state, the protruding portion 71 is in its most retracted state.

[0104] The two flange adjustment members 7B are positioned spaced apart in the X-axis direction, similar to the flange adjustment member 7A. Since these two flange adjustment members 7B have the same configuration except for their positioning, the flange adjustment member 7B on the positive X-axis side will be described representatively below. The flange adjustment member 7B is supported on the second mold 4 so as to be movable along the Z-axis direction. The flange adjustment member 7B has a projection 72.

[0105] The projection 72 protrudes upward from the upper surface 41 of the second mold 4. The projection 72 has an end face 721 that is parallel to the XY plane, i.e., facing the end face 711 of the flange adjustment member 7A located on the positive side in the X-axis direction. The projection 72 also has an inclined surface 722 that faces the base material 9' side located in the cavity 23 and is inclined with respect to the end face 721. The inclined surface 722 is inclined to the same extent as the side surface 421 of the groove 42, and when viewed from the Y-axis direction in the mold clamped state, it overlaps with the side surface 421. Furthermore, the distance between the two flange adjustment members 7B gradually increases toward the negative side in the Z-axis direction.

[0106] Then, when the flange adjustment member 7B moves along the Z-axis direction, the protruding portion 72 can extend and retract relative to the cavity 23. As shown in Figure 34, in the open mold state, the protruding portion 72, like the protruding portion 71, is in its maximum protruding state. As shown in Figure 36, in the clamped mold state, the protruding portion 72, like the protruding portion 71, is in its most retracted state.

[0107] Furthermore, the first molding section 21 includes two gas dampers 26 built into the first mold 3 and two gas dampers 27 built into the second mold 4. Each gas damper 26 is positioned on the opposite side of the protruding portion 71 of each flange adjustment member 7A and functions as a biasing member that biases the flange adjustment member 7A toward the negative side in the Z-axis direction. As a result, when the mold is open, the protruding portion 71 is maintained in its maximum protruding state. The two flange adjustment members 7A may be connected to each other. This allows the number of gas dampers 26 to be reduced to one.

[0108] Each gas damper 27 is positioned on the opposite side of the protruding portion 72 of each flange adjustment member 7B and functions as a biasing member that biases the flange adjustment member 7B toward the positive Z-axis direction. As a result, when the mold is open, the protruding portion 72 is maintained in its maximum protruding state. The two flange adjustment members 7B may be connected to each other. This allows the number of gas dampers 27 to be reduced to one.

[0109] Next, the operation of the molding apparatus 1 will be described. First, as shown in Figure 34, the first mold 3 and the second mold 4 are opened, and the base material 9' is placed between the first mold 3 and the second mold 4, that is, in the cavity 23. At this time, as mentioned above, in the second molding section 22, the protruding portion 71 on the first mold 3 side is in its maximum protruding state, and the protruding portion 72 on the second mold 4 side is also in its maximum protruding state (see the cross-sectional view along line EE in Figure 30). On the other hand, the first molding section 23 does not have protruding portions 71, etc. (see the cross-sectional view along line DD in Figure 34). Next, with the mold still open, the heating unit 62 is activated. This allows the base material 9' to be softened.

[0110] Next, the drive unit 64 is activated to bring the first mold 3 and the second mold 4 closer together than in the state shown in Figure 34, as shown in Figure 35. As a result, in the first molding section 21, the base material 9' can penetrate deeper into the groove 32 of the first mold 3 and the groove 42 of the second mold 4. Also, in the second molding section 22, the base material 9' can penetrate deeper between the flange adjustment members 7A and between the flange adjustment members 7B.

[0111] Furthermore, in the state shown in Figure 35, the gas supply unit 61 is activated to perform a primary blow. At this time, the distance SD4 between the end face 711 of the flange adjustment member 7A (projection 71) and the end face 721 of the flange adjustment member 7B (projection 72) in the second molding section 22 is shorter than the distance SD3 between the lower surface 31 of the first mold 3 and the upper surface 41 of the second mold 4 in the first molding section 21. As a result, the amount that portion 94' which will become the second flange section 94 fits between the end face 711 and the end face 721 is made smaller than the amount that portion 93' which will become the first flange section 93 fits between the lower surface 31 and the upper surface 41, i.e., it is suppressed. As a result, in the subsequent mold clamping state, portions 93' and 94' are crushed without excess or deficiency, and the first flange section 93 and the second flange section 94 with different widths can be formed. In other words, in the mold-clamped state, a first flange portion 93 with a larger width W93 and a second flange portion 94 with a smaller width W94 can be formed.

[0112] Next, in the clamped state shown in Figure 36, the gas supply unit 61 is activated to perform a secondary blowdown. In the first molding section 21 in the clamped state, the base material 9' can penetrate even deeper into the groove 32 of the first mold 3 and the groove 42 of the second mold 4. Also, the portion 93' can be completely crushed between the first mold 3 and the second mold 4. On the other hand, in the second molding section 22, the base material 9' can penetrate even deeper between the flange adjustment members 7A and between the flange adjustment members 7B. As a result, the first pipe section 95 and the second pipe section 96 are formed in the base material 9'.

[0113] Furthermore, at this time, the protruding portion 71 of each flange adjustment member 7A is pressed in the positive Z-axis direction by the base material 9'. As a result, each flange adjustment member 7A moves in the positive Z-axis direction against the biasing force of the gas damper 26. On the other hand, the protruding portion 72 of each flange adjustment member 7B is pressed in the negative Z-axis direction by the base material 9'. As a result, each flange adjustment member 7B moves in the negative Z-axis direction against the biasing force of the gas damper 27. In addition, the portion 94' can be completely crushed between the flange adjustment member 7A and the flange adjustment member 7B.

[0114] In this mold clamping state, the base material 9' is formed into an automotive component 9A in which the width W93 of the first flange portion 93 is larger than the width W94 of the second flange portion 94. Next, the cooling unit 63 is activated to rapidly cool the automotive component 9A. Furthermore, the above 5 Similar to the embodiment, the base material is blown by secondary blowing. 9’ When the first mold 3 and the second mold 4 come into close contact, the base material 9' The material undergoes quenching. As a result, the base material 9' transforms from austenite to martensite, becoming the final molded product, the automotive component 9A. Next, the mold is opened again, and the automotive component 9A is removed. This allows the automotive component 9A to be obtained.

[0115] Furthermore, in the molding apparatus 1, the width W94 of the second flange portion 94 is determined according to the magnitude of the separation distance SD4 between the protrusions 71 and 72 in the intermediate state. As a result, the smaller the separation distance SD4, the smaller the width W94 of the second flange portion 94 becomes. For example, if the separation distance SD4 is set to zero, the molding of the second flange portion 94 can be omitted, that is, the width W94 can be set to zero, thereby restricting the molding of the second flange portion 94. This makes it possible to select whether or not to include the second flange portion 94 depending on the location (application) of use of the automotive component 9A inside the automobile.

[0116] <Seventh embodiment of the molding apparatus> The following description of the seventh embodiment of the molding apparatus will be based on Figures 37 to 41, focusing on the differences from the previously described embodiments, and omitting explanations of similar matters.

[0117] As shown in Figures 37 to 41, in this embodiment, the molding apparatus 1 comprises a first apparatus body 2A for molding a primary base material 9-1' into a secondary base material 9-2', and a second apparatus body 2B for molding the secondary base material (base material) 9-2' into an automotive component 9A. The first apparatus body 2A and the second apparatus body 2B may be separate or integrated. As shown in Figures 37 and 38, the first apparatus body 2A comprises a first mold 81 and a second mold 82 that are supported so as to be able to move closer to and further apart from each other.

[0118] A cavity 83 is formed between the first mold 81 and the second mold 82, in which the primary base material 9-1' is placed and housed. The cavity 83 is a cylindrical space and has a large-diameter portion 831 and a small-diameter portion 832 with different diameters. In this embodiment, the cavity 83 has two small-diameter portions 832 and one large-diameter portion 831 positioned between these two small-diameter portions 832. Furthermore, the primary base material 9-1' is cylindrical in shape, and its outer and inner diameters are constant along the central axis O9-1' direction.

[0119] Then, in order to form the primary base material 9-1' into the secondary base material 9-2' using the first apparatus body 2A, first, as shown in Figure 37, the primary base material 9-1' is placed between the first mold 81 and the second mold 82 in the open state, and the primary base material 9-1' is heated as is. Next, as shown in Figure 38, the mold is closed, and gas supply steps and the like are performed as appropriate, similar to the first embodiment of the molding apparatus. This yields the secondary base material 9-2'. The secondary base material 9-2' has a first portion 98 formed at the large diameter portion 831 and a second portion 99 formed at each small diameter portion 832. The outer diameter of the first portion 98 is larger than the outer diameter of the second portion 99, but the thickness of the tube wall is thinner than the thickness of the tube wall in the second portion 99.

[0120] As shown in Figures 39 and 40, the second apparatus body 2B comprises a first molding section 21 and a second molding section 22. To mold the secondary base material 9-2' into an automotive component 9A using the second apparatus body 2B, first, as shown in Figure 39, the secondary base material 9-2' is placed between the first mold 3 and the second mold 4 in the open state, and the secondary base material 9-2' is then heated. At this time, the first portion 98 of the secondary base material 9-2' faces the first molding section 21, and the second portion 99 faces the second molding section 22. In Figure 40, in the first molding section 21 located in the central part of the first mold 3 (upper mold) and the second mold 4 (lower mold), the top and bottom of the first mold 3 (upper mold) and the second mold 4 (lower mold) are recessed (protruding) toward the center of the secondary base material 9-2'.

[0121] Next, as shown in Figure 40, As a clamped state Then, as in the first embodiment of the molding apparatus, a gas supply process and the like are performed as appropriate. As a result, the first portion 98 is crushed, and by the amount of crushing, it expands in the X-axis direction, forming the first flange portion 93. In this embodiment, the forming of the second flange 94 is restricted. Next, the second apparatus body 2B is opened again. This yields an automotive component 9A having the first flange portion 93, as shown in Figure 41. This allows only the first flange portion 93 to be formed without forming the second flange portion 94 more than necessary, making it possible to form the flange portion 92 to the required amount of protrusion at the required welding points. Furthermore, in the first molding section 21 located in the central part of the upper mold (first mold 3) and the lower mold (second mold 4), the top and bottom of the first mold 3 (upper mold) and the second mold 4 (lower mold) do not necessarily have to be recessed toward the center of the secondary base material 9-2'. For example, even if the first molding section 21 has the same shape as the second molding section 22, the first flange section 93 can be molded by the amount that the first part 98 of the secondary base material 9-2' has a larger outer diameter than the second part 99.

[0122] Although the flanged member of the present invention has been described in the illustrated embodiment, the present invention is not limited thereto, and each part constituting the flanged member can be replaced with any configuration that can perform a similar function. Furthermore, any additional components may be added. Furthermore, the flanged member of the present invention may be a combination of any two or more configurations (features) from the above embodiments.

[0123] Furthermore, although the flanged member is applied to automotive parts in each of the above embodiments, the application is not limited to this, and can also be applied to aircraft, ships, and the like. Furthermore, when molding automotive components 9B and 9C, the molding can be performed by using a molding apparatus in which one of the first molding section 21 and the second molding section 22 is omitted. [Explanation of symbols]

[0124] 1 Molding equipment 2. Main unit of the device 2A 1st device body 2B 2nd device body 21 1st molding section 22 2nd molding section 23 Cavity 24 Gas dampers 25 Gas dampers 26 Gas dampers 27 Gas dampers 3. First mold 31 Bottom side 32 Groove 321 Side view 322 Bottom 4. Second mold 41 Top side 42 Groove 421 Side view 422 Bottom 5. Flange adjustment member 5A Flange adjustment member 5B Flange adjustment member 51 1st protrusion (protrusion) 511 End face 52 Second protrusion 53 Connecting part 54 1st protrusion (protrusion) 541 End face 55 Second protrusion 56 Connecting part 61 Gas supply unit 62 Heating section 63 Cooling section 64 Drive unit 65 Control Unit 651 CPU 652 Storage section 7. Flange adjustment member 7A Flange adjustment member 7B Flange adjustment member 71 Protrusion 711 End face 712 Slope 72 Protrusion 721 End face 722 Slope 81 First mold 82. Second mold 83 Cavity 831 Economics Department 832 Small diameter section 90A Automotive components 90B Automotive components 90C Automotive Components 90D Automotive Components 90E Automotive Components 90' Base material 901 Cross-sectional area 902 Cross-sectional change section 903 A fixed section of the cross-section 904 Protrusion 905 Protrusion 906 Protrusion 907 Tunnel section 908 Groove 9A Automotive components 9B Automotive components 9C Automotive Components 9' Base material 9-1' Primary base material 9-2' Secondary base material (base material) 91 Pipe section 911 Leftmost 912 Rightmost 913 Constant height section 914 Height change section (height gradual increase section) 915 Constant height section 92 Flange section 921 Constant width part 922 Width change section (width reduction section) 93 First flange section 93' part 94 Second flange section 94' part 95 First pipe section 96 Second pipe section 97 End face 98 Part 1 99 Part 2 10 Steering support structure 101 Welding points 11 Sheet metal components 11A Sheet metal component 11B Sheet metal component 111 Joint section 20 Molding equipment 30 Main unit of the device 40 Flange adjustment member 40B Flange adjustment member 40C Flange adjustment member 40D Flange adjustment member 401 pairs 402 interval 50 First mold 50A First mold 50B First mold 50C First mold 50D First mold 501 First Member 502 Second Member 503 Third Member 504 recess 505 Groove (groove for forming tunnel section) 506 Convex strip (convex part for groove forming) 60 Second mold H91 Height L93 Overall length L94 overall length O9' central axis O91 Central Axis (Axis) PM5 perimeter PM6 Perimeter PM7 Perimeter PM8 Perimeter SD1 Distance SD2 Distance SD3 Distance SD4 Distance W91 pieces W92 (prominent) W93 (prominent) W94 (prominent)

Claims

1. A tubular flanged member formed from a single component and having a flange portion, The flanged member is formed by heating a tubular body made of a metal material and then supplying gas to the heated tubular body while forming the flange portion. The flanged member has a cross-sectional changing portion in which the cross-sectional shape changes along the axial direction of the flanged member. Regardless of the position in the axial direction from which the two cross-sections in the cross-sectional change portion are selected, the relationship between the perimeters of the two cross-sections is such that the perimeters are the same, or the longer perimeter is greater than 1.0 times and less than or equal to 1.25 times the shorter perimeter. The cross-sectional change portion includes the flange portion, The flange portion is formed along the axial direction, At least a portion of the flange portion has the necessary width for joining other members. The width of the flange portion changes along the axial direction. A flanged member characterized by the following features.

2. The flanged member according to claim 1, having a rectangular portion whose cross-sectional shape is rectangular.

3. The flanged member according to claim 2, wherein the cross-sectional change portion includes the rectangular portion.

4. The flanged member according to claim 2 or 3, wherein a groove is formed in the rectangular portion along the axial direction.

5. The flanged member according to any one of claims 1 to 4, wherein the flange portion is a part formed in a plate shape by overlapping the walls of a tubular body.

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