Flange component

Abstract

An object of the present invention is to provide a flanged member that can be used for automotive parts and has excellent joining operability and durability, for example, when manufacturing an automobile. The flanged member, that is, the automotive part (90A) is tubular and has a flange portion (92). The automotive part (90A) has a cross-section changing portion (902), and the cross-sectional shape of the cross-section changing portion (902) changes in its axial direction. Moreover, in any two cross-sections of the cross-section changing portion (902), the perimeter of one cross-section is 1.25 times or less the perimeter of the other cross-section.

Description

Technical Field

[0001] The present invention relates to a flanged member. Background Art

[0002] As a frame constituting an automobile skeleton, a steering member is known (for example, refer to Patent Document 1). The steering member described in Patent Document 1 is substantially cylindrical in shape as a whole. The steering member is provided with, for example, a steering support for supporting a steering column, a bracket coupled to an instrument panel, and an instrument bracket coupled to a floor panel.

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2007-22214 Summary of the Invention

[0006] Technical Problem to be Solved by the Invention

[0007] When a steering support, a bracket, and an instrument bracket are provided on the steering member described in Patent Document 1, it is conceivable to use arc welding to join the members to each other. However, arc welding generally has problems such as an increase in cost when joining the members to each other or a decrease in joining workability such as the need to provide jigs for positioning the members to each other.

[0008] An object of the present invention is to provide a flanged member for automobile parts that has excellent joining workability and excellent durability, for example, when manufacturing an automobile.

[0009] Means for Solving the Technical Problem

[0010] An embodiment of the flanged member of the present invention is a flanged member having a flange portion and being tubular, characterized in that

[0011] the flanged member has a cross-sectional change portion, and the cross-sectional shape of the cross-sectional change portion changes in the axial direction of the flanged member,

[0012] in any two cross-sections of the cross-sectional change portion, the perimeter of one cross-section is 1.25 times or less the perimeter of the other cross-section.

[0013] Advantageous Effects of the Invention

[0014] According to the present invention, in any two cross sections of the cross-sectional change portion, the perimeter of one cross section falls within a range of 1.25 times or less of the perimeter of the other cross section. By satisfying this numerical range, it is possible to prevent a thin-walled portion from being formed in the flanged component. Thus, for example, when the flanged component is used as an automotive component, the automotive component becomes a component with excellent durability that can fully withstand the use environment regardless of the use environment of the automobile to which the automotive component is mounted.

[0015] Furthermore, other automotive parts can be easily joined to the flange. Moreover, the joining can be performed by, for example, spot welding. Compared with arc welding, spot welding can generally reduce the cost of joining parts to each other. Moreover, in arc welding, a jig is generally used to position the parts to each other, but in spot welding, the use of the jig can be omitted. In this way, the automotive parts that can be spot welded become parts with excellent joining operability with other parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a perspective view showing a first embodiment of the automobile component.

[0017] Figure 2 is from Figure 1 The diagram is shown when viewed in the direction of arrow i.

[0018] Figure 3 is from Figure 1 The figure is viewed in the direction of arrow ii.

[0019] Figure 4 is from Figure 1 The figure is viewed in the direction of arrow ⅲ.

[0020] Figure 5 yes Figure 1 Sectional view along line ⅳ-ⅳ.

[0021] Figure 6 yes Figure 1 The vv line section view in.

[0022] Figure 7 yes Figure 1 Sectional view along line ⅵ-ⅵ in the figure.

[0023] Figure 8 yes Figure 1 The ⅶ-ⅶ line section view.

[0024] Figure 9 The vertical cross-sectional views sequentially show the operating states (mold opening states) of the molding device (first embodiment).

[0025] Figure 10It is a vertical sectional view showing the working state (the first intermediate state) of the molding device (the first embodiment) in sequence.

[0026] Figure 11 It is a vertical sectional view showing the working state (the second intermediate state) of the molding device (the first embodiment) in sequence.

[0027] Figure 12 It is a vertical sectional view showing the working state (the third intermediate state) of the molding device (the first embodiment) in sequence.

[0028] Figure 13 It is a vertical sectional view showing the working state (the fourth intermediate state) of the molding device (the first embodiment) in sequence.

[0029] Figure 14 It is a vertical sectional view showing the working state (the fifth intermediate state) of the molding device (the first embodiment) in sequence.

[0030] Figure 15 It is a vertical sectional view showing the working state (the mold clamping state) of the molding device (the first embodiment) in sequence.

[0031] Figure 16 It is a perspective view showing the second embodiment of the automotive part.

[0032] Figure 17 It is a vertical sectional view showing the molding device (the second embodiment).

[0033] Figure 18 It is a perspective view showing the third embodiment of the automotive part.

[0034] Figure 19 It is a perspective view showing the fourth embodiment of the automotive part.

[0035] Figure 20 It is a vertical sectional view showing the molding device (the third embodiment).

[0036] Figure 21 It is a perspective view showing the fifth embodiment of the automotive part.

[0037] Figure 22 It is a top view showing the molding device (the fourth embodiment).

[0038] Figure 23 It is a perspective view showing the sixth embodiment of the automotive part.

[0039] Figure 24 It is showing Figure 23 A perspective view of the usage example of the automotive part shown.

[0040] Figure 25It is a perspective view showing a usage example of other automotive components.

[0041] Figure 26 It is Figure 25 an enlarged perspective view of the area [A] enclosed by a double-dashed line in

[0042] Figure 27 It is Figure 25 an enlarged top view of the area [A] enclosed by a double-dashed line in

[0043] Figure 28 It is a vertical longitudinal sectional side view showing the fifth embodiment of the molding device.

[0044] Figure 29 It is Figure 28 a block diagram of the molding device shown in

[0045] Figure 30 It is sequentially showing Figure 28 a vertical cross-sectional view (a sectional view taken along line B-B and line C-C in Figure 28 ) of the working state (open mold state) of the molding device shown in

[0046] Figure 31 It is sequentially showing Figure 28 a vertical cross-sectional view (a sectional view taken along line B-B and line C-C in Figure 28 ) of the working state (intermediate state) of the molding device shown in

[0047] Figure 32 It is sequentially showing Figure 28 a vertical cross-sectional view (a sectional view taken along line B-B and line C-C in Figure 28 ) of the working state (closed mold state) of the molding device shown in

[0048] Figure 33 It is a vertical longitudinal sectional side view showing the sixth embodiment of the molding device.

[0049] Figure 34 It is sequentially showing Figure 33 a vertical cross-sectional view (a sectional view taken along line D-D and line E-E in Figure 33 ) of the working state (open mold state) of the molding device shown in

[0050] Figure 35 It is sequentially showing Figure 33 a vertical cross-sectional view (a sectional view taken along line D-D and line E-E in Figure 33 ) of the working state (intermediate state) of the molding device shown in

[0051] Figure 36 It is sequentially showing Figure 33Vertical cross-sectional view of the working state (mold clamping state) of the forming device shown (cross-sectional views taken along line D-D and line E-E in Figure 33 ).

[0052] Figure 37 are perspective views successively showing the working state (before forming the enlarged diameter portion) of the forming device (7th embodiment).

[0053] Figure 38 are perspective views successively showing the working state (during forming the enlarged diameter portion) of the forming device (7th embodiment).

[0054] Figure 39 is a perspective view showing the working state (before forming the flange portion) of the forming device (7th embodiment).

[0055] Figure 40 is a perspective view showing the working state (during forming the flange portion) of the forming device (7th embodiment).

[0056] Figure 41 is a perspective view showing the working state (after forming the flange portion) of the forming device (7th embodiment). Detailed Embodiments

[0057] Hereinafter, preferred embodiments of the flanged member of the present invention will be described in detail with reference to the drawings.

[0058] <First Embodiment of an Automotive Component>

[0059] Reference Figures 1 to 8 is made to describe the first embodiment of the flanged member of the present invention. In addition, hereinafter, for convenience of description, the Figures 1 to 3 left side in Figure 1 and Figures 4 to 8 is referred to as "left (or the left side)", and the right side is referred to as "right (the right side)". Also, the

[0060] Figure 1 upper side in

[0061] As described below, the automotive component 90A (i.e., the flanged component of the present invention) is obtained by thermally blow molding a base material 90' (i.e., a tubular body) using a molding device 20 described below. In addition, as to whether the automotive component 90A is obtained by thermally blow molding the base material 90' (tubular body), for example, it can be determined by simply using an electron microscope to confirm the internal composition of the automotive component 90A. At this time, it can be seen that the automotive component 90A is a compression molded product, rather than, for example, an extrusion molded product.

[0062] As Figures 1 to 3 shown, the tube portion 91 is tubular and is a portion that extends linearly from the left side toward the right side. The cross-sectional shape of the tube portion 91 is not particularly limited. For example, in the present embodiment, as Figures 5 to 8 shown, it is a quadrilateral (rectangle) with rounded corners at the corners. Therefore, in the present embodiment, the tube portion 91 can also be referred to as a "rectangular portion".

[0063] In addition, in the present specification, as "tubular", it also includes a state where the space is continuous from the tube portion 91 toward the tunnel portion 907 as Figure 16 shown.

[0064] As Figure 4 shown, a plate-like flange portion 92 protrudes from the lower portion of the outer peripheral portion of the tube portion 91, and the flange portion 92 is formed integrally with the tube portion 91. The flange portions 92 are respectively formed on both sides in the width direction of the tube portion 91. Each flange portion 92 protrudes in opposite directions.

[0065] As Figure 2 shown, each flange portion 92 is formed along the direction of the central axis (axis) O91 of the tube portion 91 (base material 90'). In the present embodiment, each flange portion 92 is formed from the left end 911 of the tube portion 91 along the central axis O91 to the middle of the tube portion 91, and no flange portion 92 is formed from the middle to the right end 912 of the tube portion 91.

[0066] Moreover, each flange portion 92 has a width constant portion 921 with a constant width (projection amount) W92 in the direction along the central axis O91 and a width change portion (width decreasing portion) 922 where the width (projection amount) W92 changes in the direction along the central axis O91 (i.e., the width (projection amount) W92 decreases as it moves from the width constant portion 921 side toward the right end 912 side).

[0067] On the other hand, the tube portion 91 also has a height-constant portion 913 with a constant height H91 in the direction along the central axis O91, a height-changing portion (height-increasing portion) 914 where the height H91 changes in the direction along the central axis O91 (i.e., the height H91 increases as moving from the height-constant portion 913 side toward the right end 912 side), and a height-constant portion 915 with a constant height H91 in the direction along the central axis O91. The height of the height-constant portion 915 is higher than that of the height-constant portion 913. Also, a width-constant portion 921 of the flange portion 92 is formed in the height-constant portion 913, and a width-changing portion 922 of the flange portion 92 is formed in the height-changing portion 914. In addition, the width W91 of the entire tube portion 91 is constant in the direction along the central axis O91. Thus, the height-constant portion 913, the height-changing portion 914, and the height-constant portion 915 all have the same width W91.

[0068] Therefore, the automotive component 90A has three parts according to the cross-sectional shape, namely, a cross-section-constant portion 901, a cross-section-changing portion 902, and a cross-section-constant portion 903 (refer to Figure 1 , Figures 5 to 8 ).

[0069] As Figure 5 shown, the cross-section-constant portion 901 includes the height-constant portion 913 of the tube portion 91 and the width-constant portion 921 of the flange portion 92. As described above, the height H91 of the height-constant portion 913 is constant in the direction along the central axis O91, and the width W92 of the width-constant portion 921 is also constant in the direction along the central axis O91. Thus, the cross-sectional shape of the cross-section-constant portion 901 is constant in the direction along the central axis O91.

[0070] As Figure 8 shown, the cross-section-constant portion 903 includes the height-constant portion 915 of the tube portion 91. As described above, the height H91 of the height-constant portion 915 is constant in the direction along the central axis O91. Thus, the cross-sectional shape of the cross-section-constant portion 903 is constant in the direction along the central axis O91.

[0071] The cross-section-changing portion 902 is located between the cross-section-constant portion 901 and the cross-section-constant portion 903. As Figure 6 and Figure 7 shown, the cross-section-changing portion 902 includes the height-changing portion 914 of the tube portion 91 and the width-changing portion 922 of the flange portion 92. As described above, the height H91 of the height-changing portion 914 changes in the direction along the central axis O91, and the width W92 of the width-changing portion 922 also changes in the direction along the central axis O91. Thus, the cross-section-changing portion 902 becomes a part where the cross-sectional shape continuously changes in the direction along the central axis O91.

[0072] And, if any two cross-sections of the cross-section changing portion 902 are compared (for example, Figure 6 the cross-section shown in Figure 7 and the cross-section shown in Figure 6 ), and the perimeters along the outer circumference are considered, the following relationship is satisfied. Additionally, "perimeter" refers to the outermost perimeter of the cross-section. Also, let the perimeter of the cross-section shown in Figure 7 be PM6, and let the perimeter of the cross-section shown in

[0073] The perimeter PM6 (≥PM7) is in the range of 1 times or more and 1.25 times or less of the perimeter PM7, preferably in the range of 1 times or more and less than 1.1 times of the perimeter PM7. Hereinafter, this numerical range is referred to as the "perimeter numerical range". In the automotive component 90A, by increasing or decreasing the height of the tube portion 91 according to the size of the width of the flange portion 92, it is ensured that the value falls within the above perimeter numerical range.

[0074] If the upper limit value of the perimeter numerical range is exceeded, the cross-section changing portion 902 of the automotive component 90A will be overstretched and become a deformed state. As a result, a thin-walled portion will be generated in the cross-section changing portion 902, and the strength at this thin-walled portion will decrease. If such an automotive component 90A is mounted on a vehicle, for example, it may break depending on the usage environment of the vehicle, and thus it cannot be used.

[0075] In contrast, by satisfying the perimeter numerical range, it is possible to prevent the formation of a thin-walled portion in the automotive component 90A. Thus, regardless of the usage environment of the vehicle on which the automotive component 90A is to be mounted, the automotive component 90A will become a component with excellent durability that can sufficiently withstand its usage environment.

[0076] And, for example, sometimes a plate-shaped other automotive part is joined to the flange portion 92 of the automotive component 90A. As the joining method, it is not particularly limited, and a welding method can be used. In the case of this example, in order to join the plate-shaped flange portion 92 and the plate-shaped other automotive part, spot welding can be particularly used. Compared with arc welding, spot welding can generally reduce the joining cost. And, in arc welding, a jig for positioning the joined target components to each other is usually used, but in spot welding, the use of the jig can be omitted. In this way, the automotive component 90A that can use spot welding becomes a component with excellent joining operability with other automotive parts.

[0077] <First Embodiment of the Molding Device>

[0078] Hereinafter, with reference to Figures 9 to 15A first embodiment of the molding device will be described. Hereinafter, for convenience of explanation, three mutually orthogonal axes are set as the X-axis, Y-axis, and Z-axis. As an example, the XY plane including the X-axis and Y-axis is horizontal, and the Z-axis is vertical. Also, the positive side in the Z-axis direction is sometimes referred to as "upper (or above)", and the negative side in the Z-axis direction is sometimes referred to as "lower (or below)". Also, the negative side in the X-axis direction is sometimes referred to as "left (or left side)", and the positive side in the X-axis direction is sometimes referred to as "right (or right side)".

[0079] As Figures 9 to 15 shown, the molding device 20 includes a device main body 30 and a flange portion adjusting member 40. The molding device 20 can mold a base material 90' into an automotive component 90A. Also, in Figures 9 to 15 the molding device 20 shown, the portions for molding the base material 90' into the iv-iv cross section (in the figure (A)), the portions for molding the base material 90' into the v-v cross section (in the figure (B)), the portions for molding the base material 90' into the vi-vi cross section (in the figure (C)), and the portions for molding the base material 90' into the vii-vii cross section (in the figure (D)) are representatively illustrated in order from the left.

[0080] The device main body 30 includes a first mold 50 disposed on the upper side and a second mold 60 disposed on the lower side. The first mold 50 is supported so as to be movable in the Z-axis direction, and the second mold 60 is fixed. Thus, the first mold 50 can approach and move away from the second mold 60.

[0081] The first mold 50 includes a first mold 50A shown in the figure (A), a first mold 50B shown in the figure (B), a first mold 50C shown in the figure (C), and a first mold 50D shown in the figure (D). Each of the first molds 50A to 50D is divided into a first member 501 located on the left side, a second member 502 located on the right side, and a third member 503 located between the first member 501 and the second member 502.

[0082] The third member 503 is supported so as to be independently movable in the Z-axis direction with respect to the first member 501 and the second member 502. And, a concave portion 504 responsible for molding the pipe portion 91 is formed on the third member 503. The concave portion 504 of the third member 503 of the first mold 50A is the deepest, and the depths of the concave portions 504 of the third members 503 of the first molds 50B to 50D are the same.

[0083] The second mold 60 is common among the figures (A) to (D) in the figure.

[0084] The flange adjustment member 40 includes two flange adjustment members 40B shown in (B) of the figure, two flange adjustment members 40C shown in (C) of the figure, and two flange adjustment members 40D shown in (D) of the figure. Each flange adjustment member 40B is disposed 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 disposed 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 disposed between the first mold 50D and the second mold 60 and is supported so as to be movable in the X-axis direction.

[0085] Moreover, the flange adjustment members 40B, 40C, and 40D are all block-shaped, but their heights are different. In the molding apparatus 20, the flange adjustment member 40B is the lowest, the flange adjustment member 40D is the highest, and the height of the flange adjustment member 40C is the intermediate height between the height of the flange adjustment member 40B and the height of the flange adjustment member 40D.

[0086] The molding apparatus 20 operates as follows.

[0087] First, as Figure 9 shown, the first mold 50 and the second mold 60 are brought into an open mold state, and the base material 90' is disposed between the first mold 50 and the second mold 60. In addition, in the present embodiment, the base material 90' is a tubular body having a substantially rectangular cross-sectional shape.

[0088] Then, while maintaining the open mold state, the base material 90' is heated to soften it. And at this time, each flange adjustment member 40 retracts to the position farthest from the base material 90'. Thereby, it is possible to prevent each flange adjustment member 40 from being heated.

[0089] Next, as Figure 10 shown, the first mold 50 is lowered so that each third member 503 comes into contact with the base material 90'. And at this time, the upper portion of the base material 90' enters the concave portion 504 of each third member 503, and the distance between it and the second mold 60 is constant in (A) to (D) of the figure.

[0090] And each flange adjustment member 40 is moved so as to abut against the base material 90', and it is pressed against the third member 503 from below by a spring mechanism (not shown) or the like. Thereby, the upper portion of each flange adjustment member 40 enters between the first member 501 and the second member 502.

[0091] Next, as Figure 11As shown, if the first mold 50 is further lowered, the base material 90' abuts against the second mold 60, and thus deformation (i.e., being flattened) starts. The deformed part of the base material 90' is the protruding part 904 protruding (exposed) from the concave part 504 in Fig. (A), the protruding part 905 protruding from between the flange part adjustment members 40B in Fig. (B), and the protruding part 906 protruding from between the flange part adjustment members 40C in Fig. (C). Regarding the protruding amount, the protruding part 904 is the largest, followed by the protruding part 905 and the protruding part 906 in sequence. In addition, as shown in Fig. (D), the base material 90' does not protrude from between the flange part adjustment members 40D, and thus does not deform.

[0092] Next, gas is supplied into the base material 90', and primary blow molding starts. Thereby, as Figure 12 shown, the protruding parts 904 to 906 all expand in the X-axis direction.

[0093] Next, while supplying gas into the base material 90' for a predetermined time, as Figure 13 shown, the first mold 50 is further lowered. And the descending amounts of the respective third components at this time are not consistent and are adjusted appropriately. Then, the supply of gas into the base material 90' is temporarily stopped. Thereby, the protruding parts 904 to 906 all expand further in the X-axis direction. Regarding the expansion amount in the X-axis direction, the protruding part 904 is the largest, and then, in sequence, are the protruding part 905 and the protruding part 906.

[0094] Next, in the state where the supply of gas into the base material 90' is stopped, as Figure 14 shown, the first mold 50 is further lowered. Thereby, the protruding part 904 is gradually flattened between the third component 503 and the second mold 60, the protruding part 905 is gradually flattened between the flange part adjustment member 40B and the second mold 60, and the protruding part 906 is gradually flattened between the flange part adjustment member 40C and the second mold 60.

[0095] Next, gas is supplied into the base material 90', and secondary blow molding starts. Thereby, as Figure 15 shown, the entire length range of the pipe part 91 is formed between each concave part 504 and the second mold 60.

[0096] And, along with the secondary blow molding, the first mold 50 is further lowered. Thereby, the protruding part 904 is further flattened between the third component 503 and the second mold 60 to become the flange part 92. This flange part 92 is the constant-width part 921.

[0097] Similarly, the protrusion 905 is further flattened between the flange adjustment member 40B and the second mold 60 to form the flange portion 92, and the protrusion 906 is also flattened between the flange adjustment member 40C and the second mold 60 to form the flange portion 92. The flange portion 92 is a width-changing portion 922.

[0098] Next, the automotive component 90A is rapidly cooled. Then, the mold is returned to the open state again, and the automotive component 90A is taken out.

[0099] Through the above process, the automotive component 90A can be molded.

[0100] Moreover, as described above, the flange portion 92 is a portion where a part of the base material 90' is flattened, causing the tube walls of the base material 90' to overlap each other and form a plate-like part. Thus, the strength of the automotive component 90A is increased at the flange portion 92, and it can withstand actual use when mounted on an automobile.

[0101] Also, the forming device 20 cannot sufficiently adjust the width W92 of the flange portion 92 only by appropriately adjusting the height of each flange adjustment member 40. Therefore, by appropriately adjusting the lowering amount of each third member, it becomes possible to adjust the width W92.

[0102] <Second Embodiment of Automotive Component>

[0103] Hereinafter, with reference to Figure 16 The second embodiment of the flanged component of the present invention will be described. However, the description will focus on the points different from the above-described embodiment, and the description of the same points will be omitted.

[0104] As Figure 16 shown, the automotive component 90B has a constant cross-section portion 901 and a variable cross-section portion 902. In the variable cross-section portion 902, the perimeter value range is satisfied.

[0105] Moreover, in the portion where the tube portion 91 of the variable cross-section portion 902 disappears and only the flange portion 92 remains, a tunnel portion 907 communicating with the inside of the tube portion 91 is formed. The tunnel portion 907 functions as a discharge portion for discharging the gas inside the tube portion 91 during the molding of the automotive component 90B. In addition, in the present embodiment, the cross-sectional shape of the tunnel portion 907 is a semi-circular arc shape, but it is not limited thereto.

[0106] <Second Embodiment of Forming Device>

[0107] Hereinafter, with reference to Figure 17 The second embodiment of the forming device will be described. However, the description will focus on the points different from the above-described embodiment, and the description of the same points will be omitted.

[0108] Figure 17The molding device 20 shown is a device for molding an automotive component 90B. In this molding device 20, the third component 503 of the first mold 50 has a groove (tunnel portion molding groove) 505 for molding the tunnel portion 907. The groove 505 is formed along the Y-axis direction, and its cross-sectional shape is semi-circular.

[0109] <Third Embodiment of Automotive Component>

[0110] Hereinafter, with reference to Figure 18 The third embodiment of the flanged component of the present invention will be described. However, the description will focus on the points different from the above embodiments, and the description of the same points will be omitted.

[0111] As Figure 18 shown, the automotive component 90C has a constant cross-section portion 901 and a varying cross-section portion 902. In the varying cross-section portion 902, the perimeter value range is satisfied.

[0112] Moreover, in the automotive component 90C, at least the varying cross-section portion 902 is bent downward in the figure into an arcuate shape.

[0113] <Fourth Embodiment of Automotive Component>

[0114] Hereinafter, with reference to Figure 19 The fourth embodiment of the flanged component of the present invention will be described. However, the description will focus on the points different from the above embodiments, and the description of the same points will be omitted.

[0115] As Figure 19 shown, the automotive component 90D has a constant cross-section portion 901 and a varying cross-section portion 902. In the varying cross-section portion 902, the perimeter value range is satisfied.

[0116] Moreover, in the automotive component 90D, at least the varying cross-section portion 902 is bent downward in the figure into an arcuate shape.

[0117] Furthermore, in the tube portion 91 from the middle of the varying cross-section portion 902 to the constant cross-section portion 901, a groove 908 is formed along the central axis O91 as a reinforcing rib portion. And because the groove 908 is formed, the strength of the automotive component 90D is increased accordingly. Additionally, in this embodiment, the cross-sectional shape of the groove 908 is semi-circular, but it is not limited thereto.

[0118] As the reinforcing rib portion, it is not limited to the groove 908. For example, it can also be a rib formed along the central axis O91. The strength of the automotive component 90D can also be increased by the rib. As Figure 19As shown, the flange portion 92 is not provided in the constant cross-section portion 901 provided with the reinforcing rib portion (i.e., the groove 908). On the other hand, in the variable cross-section portion 902, the shallower the depth of the groove 908 with the flange portion 92 as the reinforcing rib portion, the larger its width. Thus, the strength of the automotive component 90D can be ensured without changing the perimeter.

[0119] <Third Embodiment of the Molding Device>

[0120] Hereinafter, with reference to Figure 20 the third embodiment of the molding device will be described. However, the description will focus on the points different from the above-described embodiment, and the description of the same points will be omitted.

[0121] Figure 20 The molding device 20 shown is a device for molding the automotive component 90D. In this molding device 20, in the concave portion 504 of the third component 503, a rib (groove-forming convex portion) 506 for forming the groove 908 is formed along the Y-axis direction, and its cross-sectional shape is semi-circular.

[0122] <Fifth Embodiment of the Automotive Component>

[0123] Hereinafter, with reference to Figure 21 the fifth embodiment of the flanged component of the present invention will be described. However, the description will focus on the points different from the above-described embodiment, and the description of the same points will be omitted.

[0124] As Figure 21 shown, the automotive component 90E alternately arranges variable cross-section portions 902 and constant cross-section portions 903 along the central axis O91. And, in the variable cross-section portion 902, the width W92 of the flange portion 92 increases from the lower left side to the upper right side in the figure, and then decreases toward the upper right side after reaching the maximum.

[0125] <Fourth Embodiment of the Molding Device>

[0126] Hereinafter, with reference to Figure 22 the fourth embodiment of the molding device will be described. However, the description will focus on the points different from the above-described embodiment, and the description of the same points will be omitted.

[0127] Figure 22The molding device 20 shown is a device for molding an automotive component 90E. In this molding device 20, a flange portion adjustment member 40B, a flange portion adjustment member 40C, a flange portion adjustment member 40D, a flange portion adjustment member 40C, and a flange portion adjustment member 40B arranged along the Y-axis direction form a group 401. And this group 401 is arranged along the Y-axis direction with an interval 402 therebetween. Through the group 401, a flange portion 92 in a cross-section change portion 902 is molded. And through the portion having the interval 402, a cross-section constant portion 903 is molded.

[0128] <Sixth Embodiment of Automotive Component>

[0129] Hereinafter, with reference to Figure 23 and Figure 24 the sixth embodiment of the automotive component will be described.

[0130] Figure 23 The shown automotive component 9A is a tube (flanged component) which has a tube portion 91 and a flange portion 92 and is a component used as an automotive part. The automotive component 9A is made of a metal material such as an iron-carbon alloy, for example.

[0131] The tube portion 91 is a tubular part. The cross-sectional shape of the tube portion 91 is not particularly limited. For example, in the present embodiment, the cross-sectional shape of the tube portion 91 is a non-circular ring shape.

[0132] The flange portion 92 protrudes from the outer peripheral portion of the tube portion 91 and is formed integrally with the tube portion 91. In the automotive component 9A, the flange portions 92 are respectively formed on both sides in the width direction of the tube portion 91 and are spaced apart from each other by the central axis O91 of the tube portion 91. Each flange portion 92 protrudes in opposite directions. In addition, in the present embodiment, the automotive component 9A is configured to have two flange portions 92, but the number of formed flange portions 92 is not limited thereto. For example, it may also be one or three or more.

[0133] Each flange portion 92 is configured to include two flange portions with different amounts of protrusion (i.e., widths) from the outer peripheral portion of the tube portion 91. One of the two flange portions is referred to as the "first flange portion 93", and the other flange portion having a width (amount of protrusion) W94 smaller than the width (amount of protrusion) W93 of the first flange portion 93 is referred to as the "second flange portion 94". Here, in the present invention, the "width W94 smaller than the width W93" also includes the case where the width W94 is zero.

[0134] In addition, the difference (maximum difference) between the width W93 and the width W94 is not particularly limited.

[0135] The first flange portion 93 and the second flange portion 94 are formed at different positions in the direction of the central axis O91 of the tube portion 91. In the present embodiment, the first flange portion 93 is formed at the central portion in the longitudinal direction (the direction of the central axis O91) of the tube portion 91, and the second flange portions 94 are formed at both ends thereof respectively.

[0136] In addition, in the present embodiment, the total length L93 of the first flange portion 93 in the direction of the central axis O91 is shorter than the total length L94 of the second flange portion 94 in the direction of the central axis O91, but it is not limited thereto. For example, the total length L93 may be longer than the total length L94, or the total length L93 may be the same as the total length L94.

[0137] Moreover, in the present embodiment, the total lengths L94 of the two second flange portions 94 in each flange portion 92 are the same as each other, but it is not limited thereto, and the total lengths L94 may be different from each other.

[0138] And, the portion of the tube portion 91 where the first flange portion 93 is formed protruding is referred to as "the first tube portion 95", and the portion where the second flange portion 94 is formed protruding is referred to as "the second tube portion 96".

[0139] Next, an example of the usage mode of the automotive component 9A will be described.

[0140] The automotive component 9A is used as a part (beam) of a steering member support structure 10 that supports a steering member and its peripheral components on the front side of an automobile. Usually, the steering member support structure 10 is sometimes also referred to as, for example, "a steering member", "an instrument panel reinforcement", etc.

[0141] As Figure 24 shown, the steering member support structure 10 includes the automotive component 9A and a sheet metal component 11.

[0142] The sheet metal component 11 is obtained by subjecting a metal plate to mechanical processing such as bending, and is, for example, a component that functions as a bracket or a stay, etc.

[0143] The sheet metal component 11 is joined to the first flange portion 93 of the automotive component 9A. In addition, in the Figure 24 shown structure, the sheet metal component 11 and the first flange portion 93 are joined together by one welding portion (welding point) 101, but it is not limited thereto. For example, according to the sizes of the sheet metal component 11 and the first flange portion 93, they may also be joined by a plurality of welding portions 101.

[0144] Moreover, as the joining method, there is no particular limitation, but since it is for joining plate-shaped parts to each other, a welding method (in particular, spot welding) can be used. Compared with arc welding, spot welding generally can reduce the joining cost between parts. Also, in arc welding, a jig for positioning the parts to be joined to each other is usually used, but in spot welding, the use of the above jig can be omitted. Thus, the automotive part 9A that can use spot welding becomes a part with excellent joining operability with other parts (i.e., the sheet metal part 11) when manufacturing an automobile.

[0145] Moreover, the width W93 of the first flange portion 93 is the largest among the flange portions 92, so the joining with the sheet metal part 11 also becomes easy. Also, the joining portion of the sheet metal part 11 is the first flange portion 93 with the largest width W93 and this joining can use spot welding, so due to the synergistic effect of these two cases, the joining operability is further improved.

[0146] <Sixth Embodiment of Automotive Part>

[0147] Hereinafter, Figures 25 to 27 an explanation will be given of the sixth embodiment of the automotive part.

[0148] As Figure 25 shown, the steering member support structure 10 of this embodiment includes an automotive part 9B, an automotive part 9C, and four sheet metal parts 11.

[0149] As Figure 26 and Figure 27 shown, in the automotive part 9B and the automotive part 9C, the width of the flange portion 92 is constant in the direction along the central axis O91. Also, the thicknesses (widths) of the automotive part 9B and the automotive part 9C are different from each other, the automotive part 9B is thicker, and the automotive part 9C is thinner. In the steering member support structure 10, the automotive part 9B and the automotive part 9C are arranged along the vehicle width direction of the vehicle, and the thicker automotive part 9B is arranged on the driver's seat side of the vehicle.

[0150] As Figure 27 shown, the end faces 97 of the automotive part 9B and the automotive part 9C abut against each other (i.e., are in contact with each other), and this state is maintained by one sheet metal part 11 (sheet metal part 11A).

[0151] The four sheet metal parts 11 include one sheet metal part 11A that joins both the automotive part 9B and the automotive part 9C and three sheet metal parts 11B that join the automotive part 9B. In addition, spot welding is used for joining each sheet metal part 11.

[0152] The sheet metal component 11A has a joint portion 111 that collectively covers the ends of the automotive component 9B and the automotive component 9C and connects these components to each other. The joint portion 111 is a plate-like portion shaped along the outer shape of the automotive component 9B and the automotive component 9C, and it engages with each flange portion 92 of the automotive component 9B and each flange portion 92 of the automotive component 9C. Thereby, the positional relationship between the automotive component 9B and the automotive component 9C is maintained. In addition, the sheet metal component 11A and each flange portion 92 are joined together by one welding portion 101, but it is not limited thereto, and they may also be joined together by a plurality of welding portions 101.

[0153] Each sheet metal component 11B is joined to a desired position of the flange portion 92 of the automotive component 9B. In addition, each sheet metal component 11B and the flange portion 92 may be joined together by one welding portion 101, or may be joined together by a plurality of welding portions 101.

[0154] Moreover, the number of sheet metal components 11 arranged is not limited to four, and for example, it may be one to three or five or more.

[0155] <Fifth Embodiment of the Forming Device>

[0156] Hereinafter, Figures 28 to 32 the fifth embodiment of the forming device will be described. However, the description will focus on the points different from the above-described embodiments, and the description of the same points will be omitted.

[0157] As Figure 28 and Figure 29 shown, the forming device 1 includes a device 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 forming device 1 can form a circular tubular base material 9' into an automotive component 9A.

[0158] The device main body 2 includes a first forming portion 21 and a second forming portion 22 arranged along the Y-axis direction. In addition, although not shown, in the device main body 2, one second forming portion 22 is arranged on the positive side in the Y-axis direction of the first forming portion 21, and one second forming portion 22 is arranged on the negative side in the Y-axis direction of the first forming portion 21. The two second forming portions 22 have the same structure except for the arrangement positions, so the second forming portion 22 on the positive side in the Y-axis direction will be described as a representative.

[0159] Here, Figures 30 to 32 is a vertical cross-sectional view sequentially showing Figure 28 the working states of the forming device shown. And, Figure 28 the cross-sectional view taken along line B-B in

[0160] The first forming part 21 is a part for performing a first forming process of forming a part of the base material 9' (i.e., the central part in the longitudinal direction (the direction of the central axis O9') of the base material 9' in the present embodiment) into the first pipe part 95 and the first flange part 93.

[0161] The second forming part 22 is a part for performing a second forming process of forming a part of the base material 9' (i.e., one end side of the base material 9' (the positive side in the Y-axis direction) in the present embodiment) into the second pipe part 96 and the second flange part 94.

[0162] The first forming part 21 and the second forming part 22 share the first die 3 and the second die 4 that can form an open die state (refer to Figure 30 ), a closed die state (refer to Figure 32 ), and an intermediate state between the open die state and the closed die state (refer to Figure 31 ). Thus, in the first forming part 21 and the second forming part 22, the first die 3 and the second die 4 can move simultaneously from the open die state until the closed die state, so that the automotive component 9A can be formed smoothly.

[0163] In the device main body 2, the first die 3 is arranged on the upper side, and the second die 4 is arranged on the lower side. And a cavity 23 for arranging and accommodating the base material 9' is formed between the first die 3 and the second die 4.

[0164] And, in the present embodiment, the first die 3 and the second die 4 are supported so that both can move in the Z-axis direction and thus can approach and separate from each other. In addition, the device main body 2 may be configured such that the first die 3 is fixed and the second die 4 is supported so as to be able to approach and separate from the first die 3, or may be configured such that the second die 4 is fixed and the first die 3 is supported so as to be able to approach and separate from the second die 4.

[0165] As Figures 30 to 32 shown, the first die 3 is in a block shape and has a lower surface 31 parallel to the XY plane. And the first die 3 has a groove 32 formed on the lower surface 31 and extending along the Y-axis direction. Each side surface 321 of the groove 32 is inclined with respect to the lower surface 31, and the interval between each side surface 321 increases as it goes toward the negative side in the Z-axis direction. And the bottom surface 322 is formed parallel to the lower surface 31.

[0166] The second mold 4 is in a block shape and has an upper surface 41 parallel to the XY plane (i.e., the upper surface 41 facing the lower surface 31 of the first mold 3). Moreover, the second mold 4 has a groove 42 formed in the upper surface 41 and extending along the Y-axis direction. When viewed from 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 interval between each side surface 421 increases as it goes toward the positive side in the Z-axis direction. Also, the bottom surface 422 is formed parallel to the upper surface 41.

[0167] Moreover, the first forming portion 21 includes a flange portion adjusting member 5. As will be described later, when forming the first flange portion 93, the flange portion adjusting member 5 can adjust the width W93 of the first flange portion 93 to be larger than the width W94 of the second flange portion 94. In the present embodiment, the first forming portion 21 includes two flange portion adjusting members 5. One flange portion adjusting member 5A is disposed on the first mold 3, and the other flange portion adjusting member 5B is disposed on the second mold 4. Additionally, the flange portion adjusting member 5 is not limited to being disposed on both the first mold 3 and the second mold 4. For example, it may be disposed only on one of the first mold 3 and the second mold 4.

[0168] The flange portion adjusting member 5A is supported by the first mold 3 so as to be movable along the Z-axis direction. The flange portion adjusting member 5A has a first protruding portion (protruding portion) 51, two second protruding portions 52, and a connecting portion 53 connecting the first protruding portion 51 and each second protruding portion 52.

[0169] The first protruding portion 51 protrudes downward from the bottom surface 322 of the groove 32 of the first mold 3.

[0170] The second protruding portions 52 are respectively disposed on the positive side and the negative side in the X-axis direction of the first protruding portion 51. Each second protruding portion 52 protrudes downward from the lower surface 31 of the first mold 3.

[0171] Moreover, when the flange portion adjusting member 5A moves along the Z-axis direction, the first protruding portion 51 and each second protruding portion 52 can move forward and backward together with respect to the cavity 23. As Figure 30 shown, in the open mold state, the first protruding portion 51 and each second protruding portion 52 are in the state of protruding the most. As Figure 32 shown, in the closed mold state, the first protruding portion 51 and each second protruding portion 52 are in the state of being retracted the most.

[0172] The flange portion adjusting member 5B is supported by the second mold 4 so as to be movable along the Z-axis direction. The flange portion adjusting member 5B has a first protruding portion (protruding portion) 54, two second protruding portions 55, and a connecting portion 56 connecting the first protruding portion 54 and each second protruding portion 55.

[0173] The first protrusion 54 protrudes upward from the bottom surface 422 of the groove 42 of the second mold 4.

[0174] Second protrusions 55 are respectively arranged on the positive side and the negative side in the X-axis direction of the first protrusion 54. Each second protrusion 55 protrudes upward from the upper surface 41 of the second mold 4.

[0175] Moreover, when the flange part adjusting member 5B moves along the Z-axis direction, the first protrusion 54 and each second protrusion 55 can move forward and backward together with the cavity 23. As Figure 30 shown, in the open mold state, the first protrusion 54 and each second protrusion 55 are in the state of protruding maximally. As Figure 32 shown, in the closed mold state, the first protrusion 54 and each second protrusion 55 are in the most retracted state.

[0176] And, the first molding part 21 includes a gas damper 24 built in the first mold 3 and a gas damper 25 built in the second mold 4.

[0177] The gas damper 24 is arranged on the side of the flange part adjusting member 5A opposite to the first protrusion 51, and functions as a biasing part that biases the flange part adjusting member 5A toward the negative side in the Z-axis direction. Thereby, in the open mold state, the first protrusion 51 and each second protrusion 52 maintain the state of protruding maximally.

[0178] The gas damper 25 is arranged on the side of the flange part adjusting member 5B opposite to the first protrusion 54, and functions as a biasing part that biases the flange part adjusting member 5B toward the positive side in the Z-axis direction. Thereby, in the open mold state, the first protrusion 54 and each second protrusion 55 maintain the state of protruding maximally.

[0179] In addition, in the molding device 1, for example, a compression coil spring can also be used instead of the gas damper 24 and the gas damper 25.

[0180] The heating part 62 is a part for performing a heating process of heating the base material 9'. The structure of the heating part 62 is not particularly limited. For example, it can be configured to have two electrodes electrically connected to the base material 9' and a voltage application part for applying a voltage between the two electrodes. Thereby, the base material 9' can be made in an energized state before the molding of the first molding part 21 and the molding of the second molding part 22, so as to heat the base material 9' to soften it.

[0181] The gas supply unit 61 is a part for performing a gas supply process of supplying high-pressure air into the base material 9'. Thereby, when performing molding using the first molding part 21 and molding using the second molding part 22 respectively in the mold-closed state of the first mold 3 and the second mold 4, it is possible to prevent the base material 9' from being overly flattened. The structure of the gas supply unit 61 is not particularly limited. For example, it can be configured to have a compressor.

[0182] The cooling unit 63 is a part for performing a cooling process of rapidly cooling the automotive component 9A (base material 9'). The structure of the cooling unit 63 is not particularly limited. For example, it can be configured to have flow paths that are respectively provided in the first mold 3 and the second mold 4 and through which a refrigerant passes. And when the refrigerant passes through the flow paths, it is possible to rapidly cool the automotive component 9A together with the first mold 3 and the second mold 4. In addition, the refrigerant can be a liquid or a gas.

[0183] The drive unit 64 can move the first mold 3 and the second mold 4 so that the first mold 3 and the second mold 4 approach each other and move away from each other. Thereby, it is possible to switch between the mold-open state and the mold-closed state. The structure of the drive unit 64 is not particularly limited. For example, it can be configured to have a motor, a ball screw connected to the motor, and a linear guide connected to the ball screw.

[0184] The control unit 65 controls the operations of the gas supply unit 61, the heating unit 62, the cooling unit 63, and the drive unit 64. The structure of the control unit 65 is not particularly limited. For example, it can be configured to have a CPU 651 and a storage unit 652. The CPU 651 can execute, for example, a control program pre-stored in the storage unit 652. The control program includes, for example, programs for controlling the operation conditions (operation timings) of the gas supply unit 61, the heating unit 62, the cooling unit 63, and the drive unit 64 to mold the base material 9' into the automotive component 9A.

[0185] The molding device 1 operates as follows.

[0186] First, as Figure 30 shown, the first mold 3 and the second mold 4 are brought into the mold-open state, and the base material 9' is disposed between the first mold 3 and the second mold 4 (i.e., inside the cavity 23). At this time, as described above, in the first molding part 21, the first protrusion 51 and each second protrusion 52 on the side of the first mold 3 are in the state of protruding maximally, and the first protrusion 54 and each second protrusion 55 on the side of the second mold 4 are in the state of protruding maximally (refer to the cross-sectional view taken along the line B-B in Figure 30 ). On the other hand, in the second molding part 22, there are no protrusions 51, etc. (refer to the cross-sectional view taken along the line C-C in Figure 30 ).

[0187] Next, while maintaining the mold-open state, the heating unit 62 is operated. Thereby, the base material 9' can be softened.

[0188] Next, the drive unit 64 is operated so that, as Figure 31 shown, the first mold 3 and the second mold 4 are brought into an intermediate state closer to each other than the state Figure 30 shown. Thereby, the upper portion of the base material 9' can enter deeper into the groove 32 of the first mold 3 than the state Figure 30 shown, and the lower portion of the base material 9' can enter deeper into the groove 42 of the second mold 4 than the state Figure 30 shown.

[0189] And at this time, in the first molding portion 21, the end face 511 of the first protrusion 51 abuts on the base material 9' from above, and the end face 541 of the first protrusion 54 abuts on the base material 9' from below. On the other hand, in the second molding portion 22 ( Figure 31 a cross-sectional view taken along the C-C line), the bottom face 322 of the groove 32 abuts on the base material 9' from above, and the bottom face 422 of the groove 42 abuts on the base material 9' from below. The interval 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 interval distance SD2 between the bottom face 322 of the groove 32 and the bottom face 422 of the groove 42. Thereby, the base material 9' is flattened more between the end face 511 of the first protrusion 51 and the end face 541 of the first protrusion 54 than between the bottom face 322 of the groove 32 and the bottom face 422 of the groove 42.

[0190] And, in the state Figure 31 shown, the gas supply unit 61 is operated to perform primary blow molding. And by this primary blow molding and the flattening between the end face 511 of the first protrusion 51 and the end face 541 of the first protrusion 54, the base material 9' expands more in the X-axis direction in the first molding portion 21 ( Figure 31 a cross-sectional view taken along the B-B line) than in the second molding portion 22 ( Figure 31 a cross-sectional view taken along the C-C line). By this expansion, the portion 93' that becomes the first flange portion 93 of the base material 9' can enter more between the lower surface 31 of the first mold 3 and the upper surface 41 of the second mold 4 than the portion 94' that becomes the second flange portion 94. Thereby, in the subsequent mold-closed state, the portion 93' can be flattened without any excess to form the first flange portion 93 having a larger width W93, and the portion 94' can be flattened to form the second flange portion 94 having a smaller width W94.

[0191] Next, the mold is adjusted to the mold-closed state Figure 32 shown, and the gas supply unit 61 is operated to perform secondary blow molding. In addition, the supply amount of the high-pressure air into the base material 9' or the pressure of the high-pressure air is larger or higher in the secondary blow molding than in the primary blow molding.

[0192] In the mold-closed state, the base material 9' can enter deeper into the groove 32 of the first mold 3 and the groove 42 of the second mold 4. Thus, the first pipe portion 95 and the second pipe portion 96 are formed on the base material 9' following the shapes of the groove 32 and the groove 42. Also, the above-mentioned portion 93' can be completely flattened between the first mold 3 and the second mold 4 to reliably form the first flange portion 93, and the above-mentioned portion 94' can be completely flattened between them to reliably form the second flange portion 94.

[0193] And at this time, the first protrusion 51 of the flange portion adjusting member 5A is pressed by the base material 9' toward the positive side in the Z-axis direction, and each second protrusion 52 is pressed by the upper surface 41 of the second mold 4 toward the positive side in the Z-axis direction. Thus, the flange portion adjusting member 5A moves toward the positive side in the Z-axis direction against the acting force of the gas damper 24. On the other hand, the first protrusion 54 of the flange portion adjusting member 5B is pressed by the base material 9' toward the negative side in the Z-axis direction, and each second protrusion 55 is pressed by the lower surface 31 of the first mold 3 toward the negative side in the Z-axis direction. Thus, the flange portion adjusting member 5B moves toward the negative side in the Z-axis direction against the acting force of the gas damper 25.

[0194] Through this mold-closed state, the base material 9' is formed into an automotive component 9A having the first pipe portion 95, the first flange portion 93, the second pipe portion 96, and the second flange portion 94. Although the first pipe portion 95 and the second pipe portion 96 are formed at different positions in the direction of the central axis O9' (central axis O91) of the base material 9', they become portions having a tubular shape different from that of the base material 9' (i.e., a tubular shape with a non-circular cross-sectional shape). The first flange portion 93 protrudes from the outer peripheral portion of the first pipe portion 95 and is formed integrally with the first pipe portion 95. The second flange portion 94 protrudes from the outer peripheral portion of the second pipe portion 96 and is formed integrally with the second pipe portion 9. Also, the width W93 of the first flange portion 93 is greater than the width W94 of the second flange portion 94.

[0195] In addition, the total length L93 of the first flange portion 93 depends on the length of the first forming portion 21 in the Y-axis direction, and the total length L94 of the second flange portion 94 depends on the length of the second forming portion 22 in the Y-axis direction.

[0196] Next, the cooling portion 63 is operated to rapidly cool the automotive component 9A.

[0197] In addition, if the base material 9' is closely attached to the first mold 3 and the second mold 4 by secondary blow molding, the base material 9' is quenched. Thus, the base material 9' transforms from austenite to martensite and can directly become the final molded product (i.e., the automotive component 9A).

[0198] Next, the mold opening state is adjusted back again, and the automotive component 9A is taken out.

[0199] As described above, by using the molding device 1, the automotive component 9A can be molded quickly and accurately. And, as described above, the automotive component 9A obtained by the molding device 1 becomes a component with excellent joining workability when manufacturing an automobile.

[0200] Also, in the molding device 1, the width W93 of the first flange portion 93 in the mold closed state is determined according to the maximum protrusion amounts of the first protrusion portion 51 and the first protrusion portion 54 in the mold open state. Thus, the larger the maximum protrusion amounts of the first protrusion portion 51 and the first protrusion portion 54 are, the larger the width W93 of the first flange portion 93 will become. Conversely, if the maximum protrusion amounts of the first protrusion portion 51 and the first protrusion portion 54 are suppressed, the width W93 of the first flange portion 93 can also be suppressed accordingly.

[0201] <Sixth Embodiment of the Molding Device>

[0202] Hereinafter, with reference to Figures 33 to 36 the sixth embodiment of the molding device will be described. However, the description will focus on the points different from the above-described embodiments, and the description of the same points will be omitted.

[0203] Figure 33 The molding device 1 of the present embodiment shown has a device main body 2. This device main body 2 has a first molding portion 21 and a second molding portion 22 having the Figures 34 to 36 internal structure shown.

[0204] As Figures 34 to 36 shown, in the first molding portion 21, the first mold 3 has a lower surface 31 parallel to the XY plane and a groove 32 formed in the lower surface 31. And, the second mold 4 has an upper surface 41 parallel to the XY plane and a groove 42 formed in the upper surface 41.

[0205] The second molding portion 22 is provided with a flange portion adjusting member 7. As will be described later, when molding the second flange portion 94, the flange portion adjusting member 7 can adjust the width W94 of the second flange portion 94 to be smaller than the width W93 of the first flange portion 93. In the present embodiment, the second molding portion 22 is provided with two flange portion adjusting members 7A disposed on the first mold 3 and two flange portion adjusting members 7B disposed on the second mold 4 as the flange portion adjusting member 7. In addition, the flange portion adjusting member 7 is not limited to being disposed on both the first mold 3 and the second mold 4. For example, it may be disposed only on one of the first mold 3 and the second mold 4.

[0206] The two flange adjustment members 7A are arranged at intervals in the X-axis direction. Since these two flange adjustment members 7A have the same structure except for the different arrangement positions, the flange adjustment member 7A on the positive side in the X-axis direction will be described as a representative hereinafter.

[0207] The flange adjustment member 7A is supported by the first mold 3 so as to be movable along the Z-axis direction. The flange adjustment member 7A has a protruding portion 71.

[0208] The protruding portion 71 protrudes downward from the lower surface 31 of the first mold 3. And the protruding portion 71 has an end face 711 parallel to the XY plane and an inclined face 712 facing the side of the base material 9' disposed in the cavity 23 and inclined with respect to the end face 711. In addition, the inclination degree of the inclined face 712 is the same as that of the side face 321 of the groove 32, and in the mold-closed state, when viewed from the Y-axis direction, the inclined face 712 overlaps with the side face 321. And between the two flange adjustment members 7A, the interval between the inclined faces 712 increases as it goes toward the negative side in the Z-axis direction.

[0209] And when the flange adjustment member 7A moves along the Z-axis direction, the protruding portion 71 can move forward and backward with respect to the cavity 23. As Figure 34 shown, in the mold-open state, the protruding portion 71 is in the state of protruding the most. As Figure 36 shown, in the mold-closed state, the protruding portion 71 is in the most retracted state.

[0210] Similar to the flange adjustment member 7A, the two flange adjustment members 7B are also arranged at intervals in the X-axis direction. Since these two flange adjustment members 7B have the same structure except for the different arrangement positions, the flange adjustment member 7B on the positive side in the X-axis direction will be described as a representative hereinafter.

[0211] The flange adjustment member 7B is supported by the second mold 4 so as to be movable along the Z-axis direction. The flange adjustment member 7B has a protruding portion 72.

[0212] The protruding portion 72 protrudes upward from the upper surface 41 of the second mold 4. The protruding portion 72 has an end face 721 parallel to the XY plane (that is, the end face 721 facing the end face 711 of the flange adjustment member 7A located on the positive side in the Z-axis direction). And the protruding portion 72 has an inclined face 722 facing the side of the base material 9' disposed in the cavity 23 and inclined with respect to the end face 721. In addition, the inclination degree of the inclined face 722 is the same as that of the side face 421 of the groove 42, and in the mold-closed state, when viewed from the Y-axis direction, the inclined face 722 overlaps with the side face 421. And between the two flange adjustment members 7B, the interval between the inclined faces 722 decreases as it goes toward the negative side in the Z-axis direction.

[0213] Further, when the flange portion adjusting member 7B moves along the Z-axis direction, the protruding portion 72 can move forward and backward with respect to the cavity 23. As Figure 34 shown, in the mold open state, similar to the protruding portion 71, the protruding portion 72 is also in the state of maximum protrusion. As Figure 36 shown, in the mold closed state, similar to the protruding portion 71, the protruding portion 72 is also in the most retracted state.

[0214] Further, the second molding portion 22 includes two gas dampers 26 built in the first mold 3 and two gas dampers 27 built in the second mold 4.

[0215] Each gas damper 26 is disposed on the side of each flange portion adjusting member 7A opposite to the protruding portion 71, and functions as a biasing portion that biases the flange portion adjusting member 7A toward the negative side in the Z-axis direction. Thus, in the mold open state, the protruding portion 71 maintains the state of maximum protrusion.

[0216] In addition, the two flange portion adjusting members 7A may be connected to each other. Thus, the number of gas dampers 26 disposed can be set to one.

[0217] Each gas damper 27 is disposed on the side of each flange portion adjusting member 7B opposite to the protruding portion 72, and functions as a biasing portion that biases the flange portion adjusting member 7B toward the positive side in the Z-axis direction. Thus, in the mold open state, the protruding portion 72 maintains the state of maximum protrusion.

[0218] In addition, the two flange portion adjusting members 7B may be connected to each other. Thus, the number of gas dampers 27 disposed can be set to one.

[0219] Next, the operation of the molding apparatus 1 will be described.

[0220] First, as Figure 34 shown, the first mold 3 and the second mold 4 are brought into the mold open state, and the base material 9' is disposed between the first mold 3 and the second mold 4 (i.e., in the cavity 23). At this time, as described above, in the second molding portion 22, the protruding portion 71 on the first mold 3 side is in the state of maximum protrusion, and the protruding portion 72 on the second mold 4 side is also in the state of maximum protrusion (refer to the cross-sectional view taken along the E-E line of Figure 34 ). On the other hand, in the first molding portion 21, no protruding portion 71 or the like is provided (refer to the cross-sectional view taken along the D-D line of Figure 34 ).

[0221] Next, while maintaining the mold open state, the heating portion 62 is operated. Thus, the base material 9' can be softened.

[0222] Next, the drive portion 64 is operated so that asFigure 35 The first die 3 and the second die 4 are brought into an intermediate state closer to each other than the state shown in Figure 34 As a result, in the first forming portion 21, the base material 9' can enter deeper into the groove 32 of the first die 3 and the groove 42 of the second die 4. Also, in the second forming portion 22, the base material 9' can enter deeper between the flange portion adjusting members 7A and between the flange portion adjusting members 7B.

[0223] Also, in Figure 35 the state shown in, the gas supply portion 61 is operated to perform one-time blow molding. At this time, the distance SD4 between the end face 711 of the flange portion adjusting member 7A (protrusion 71) and the end face 721 of the flange portion adjusting member 7B (protrusion 72) in the second forming portion 22 is shorter than the distance SD3 between the lower surface 31 of the first die 3 and the upper surface 41 of the second die 4 in the first forming portion 21. As a result, the amount of entry of the portion 94' that becomes the second flange portion 94 between the end face 711 and the end face 721 can be made smaller than the amount of entry of the portion 93' that becomes the first flange portion 93 between the lower surface 31 and the upper surface 41, that is, the amount of entry can be suppressed. As a result, in the subsequent mold-closed state, the portion 93' and the portion 94' can be flattened without any surplus or deficiency to form the first flange portion 93 and the second flange portion 94 having different widths. That is, the first flange portion 93 having a larger width W93 and the second flange portion 94 having a smaller width W94 can be formed in the mold-closed state.

[0224] Next, in Figure 36 the mold-closed state shown in, the gas supply portion 61 is operated to perform secondary blow molding.

[0225] In the first forming portion 21 in the mold-closed state, the base material 9' can enter deeper into the groove 32 of the first die 3 and the groove 42 of the second die 4. Also, it can be completely flattened between the first die 3 and the second die 4.

[0226] On the other hand, in the second forming portion 22, the base material 9' can enter deeper between the flange portion adjusting members 7A and between the flange portion adjusting members 7B. As a result, the first pipe portion 95 and the second pipe portion 96 are formed on the base material 9'.

[0227] And at this time, the protrusions 71 of the flange portion adjusting members 7A are pressed by the base material 9' toward the positive side in the Z-axis direction. As a result, each flange portion adjusting member 7A moves toward the positive side in the Z-axis direction against the acting force of the gas damper 26. On the other hand, the protrusions 72 of the flange portion adjusting members 7B are pressed by the base material 9' toward the negative side in the Z-axis direction. As a result, each flange portion adjusting member 7B moves toward the negative side in the Z-axis direction against the acting force of the gas damper 27. And the completely flattened portion 94' is formed between the flange portion adjusting member 7A and the flange portion adjusting member 7B.

[0228] Through 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 greater than the width W94 of the second flange portion 94.

[0229] Next, the cooling unit 63 is operated to rapidly cool the automotive component 9A.

[0230] In addition, in the same manner as in the above-described first embodiment, when the base material 9' is closely adhered to the first mold 3 and the second mold 4 by secondary blow molding, the base material 9' is quenched. As a result, the base material 9' is transformed from austenite to martensite and can be directly formed into a final molded product (i.e., the automotive component 9A).

[0231] Next, the mold is opened again, and the automotive component 9A is taken out. Thus, the automotive component 9A can be obtained.

[0232] And in the molding apparatus 1, the width W94 of the second flange portion 94 is determined according to the size of the interval distance SD4 between the protrusion 71 and the protrusion 72 in the intermediate state. Thus, the smaller the interval distance SD4, the smaller the width W94 of the second flange portion 94 will be. For example, if the interval 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 to limit the molding of the second flange portion 94. Thus, the presence or absence of the second flange portion 94 can be selected according to the use part (purpose) of the automotive component 9A in the vehicle.

[0233] <Seventh Embodiment of the Molding Apparatus>

[0234] Hereinafter, reference will be made to Figures 37 to 41 The seventh embodiment of the molding apparatus will be described, but the description will focus on the points different from the above-described embodiments, and the description of the same points will be omitted.

[0235] As Figures 37 to 41As shown, in this embodiment, the molding device 1 includes a first device main body 2A that molds a primary base material 9-1' into a secondary base material 9-2', and a second device main body 2B that molds the secondary base material (base material) 9-2' into an automotive component 9A. Additionally, the first device main body 2A and the second device main body 2B can be separate or integrated.

[0236] As Figure 37 and Figure 38 shown, the first device main body 2A includes a first mold 81 and a second mold 82 that are supported so as to be able to approach and separate from each other.

[0237] A cavity 83 for disposing and accommodating the primary base material 9-1' is formed between the first mold 81 and the second mold 82. The cavity 83 is a cylindrical space and has a large-diameter portion 831 and a small-diameter portion 832 with different diameters. Additionally, in this embodiment, the cavity 83 has two small-diameter portions 832 and one large-diameter portion 831 disposed between the two small-diameter portions 832.

[0238] Moreover, the primary base material 9-1' is cylindrical and is a component with a constant outer diameter and inner diameter in the direction along the central axis O9-1'.

[0239] And, in order to use the first device main body 2A to mold the primary base material 9-1' into the secondary base material 9-2', first, as Figure 37 shown, in the open mold state, the primary base material 9-1' is disposed between the first mold 81 and the second mold 82, and the primary base material 9-1' is heated in this state. Then, as Figure 38 shown, it is adjusted to the closed mold state, and, in the same manner as the first embodiment of the above molding device, a gas supply process and the like are appropriately performed. Thereby, the secondary base material 9-2' is obtained. The secondary base material 9-2' has a first portion 98 formed by the large-diameter portion 831 and a second portion 99 formed by 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 wall thickness of its tube is thinner than the wall thickness of the second portion 99.

[0240] As Figure 39 and Figure 40 shown, the second device main body 2B includes a first molding portion 21 and a second molding portion 22. And, in order to use the second device main body 2B to mold the secondary base material 9-2' into the automotive component 9A, first, as Figure 39 shown, in the open mold state, the secondary base material 9-2' is disposed between the first mold 3 and the second mold 4, and the secondary base material 9-2' is heated in this state. At this time, the first portion 98 of the secondary base material 9-2' faces the first molding portion 21, and the second portion 99 faces the second molding portion 22. In Figure 40In [the figure], a first molding portion 21 located at the central portion of a first mold 3 serving as an upper mold and a second mold 4 serving as a lower mold is formed in a shape that is recessed (projected) such that the upper and lower portions of the first mold 3 (upper mold) and the second mold 4 (lower mold) face the central side of the secondary base material 9-2'.

[0241] Next, as Figure 40 shown, the mold clamping state is adjusted, and, in the same manner as in the first embodiment of the above-described molding apparatus, a gas supply process or the like is appropriately performed. As a result, the first portion 98 is flattened and, correspondingly, expands in the X-axis direction, thereby molding the first flange portion 93. In addition, in the present embodiment, the molding of the second flange portion 94 is restricted.

[0242] Next, the second apparatus main body 2B is adjusted to the open mold state again. As a result, as Figure 41 shown, an automotive component 9A having the first flange portion 93 is obtained. Thus, without molding an unnecessary second flange portion 94, it is possible to form only the first flange portion 93, and therefore, it is possible to mold a flange portion 92 having a required protruding amount at a required welding portion.

[0243] In addition, in the first molding portion 21 located at the central portion of the first mold 3 serving as an upper mold and the second mold 4 serving as a lower mold, the upper and lower portions of the first mold 3 (upper mold) and the second mold 4 (lower mold) may not be in a shape that is recessed toward the central side of the secondary base material 9-2'. For example, even when the shape of the first molding portion 21 is the same as the shape of the second molding portion 22, it is possible to mold the first flange portion 93 corresponding to the amount by which the outer diameter of the first portion 98 of the secondary base material 9-2' is larger than the outer diameter of the second portion 99.

[0244] As described above, embodiments of the flanged component of the present invention have been described with reference to the drawings, but the present invention is not limited thereto, and each part constituting the flanged component may be replaced with any component having the same function. In addition, any structure may be added.

[0245] Moreover, the flanged component of the present invention may also be formed by combining any two or more structures (features) in the above-described respective embodiments.

[0246] In addition, in each of the above-described embodiments, the flanged component is applied to automotive parts, but as an application example, it is not limited thereto, and for example, it may also be applied to airplanes, ships, etc.

[0247] In addition, when molding the automotive component 9B and the automotive component 9C, the molding can also be achieved by using a molding apparatus in which one of the first molding portion 21 and the second molding portion 22 is omitted.

[0248] Reference Signs

[0249] 1 - Molding device, 2 - Device main body, 2A - First device main body, 2B - Second device main body, 21 - First molding part, 22 - Second molding part, 23 - Cavity, 24 - Gas damper, 25 - Gas damper, 26 - Gas damper, 27 - Gas damper, 3 - First mold, 31 - Lower surface, 32 - Groove, 321 - Side surface, 322 - Bottom surface, 4 - Second mold, 41 - Upper surface, 42 - Groove, 421 - Side surface, 422 - Bottom surface, 5 - Flange part adjustment component, 5A - Flange part adjustment component, 5B - Flange part adjustment component, 51 - First protrusion (protrusion part), 511 - End face, 52 - Second protrusion, 53 - Connecting part, 54 - First protrusion (protrusion part), 541 - End face, 55 - Second protrusion, 56 - Connecting part, 61 - Gas supply part, 62 - Heating part, 63 - Cooling part, 64 - Driving part, 65 - Control part, 651 - CPU, 652 - Storage part, 7 - Flange part adjustment component, 7A - Flange part adjustment component, 7B - Flange part adjustment component, 71 - Protrusion, 711 - End face, 712 - Inclined surface, 72 - Protrusion, 721 - End face, 722 - Inclined surface, 81 - First mold, 82 - Second mold, 83 - Cavity, 831 - Large diameter part, 832 - Small diameter part, 90A - Automotive part, 90B - Automotive part, 90C - Automotive part, 90D - Automotive part, 90E - Automotive part, 90’ - Base material, 901 - Constant cross-section part, 902 - Cross-section changing part, 903 - Constant cross-section part, 904 - Protrusion, 905 - Protrusion, 906 - Protrusion, 907 - Tunnel part, 908 - Groove, 9A - Automotive part, 9B - Automotive part, 9C - Automotive part, 9’ - Base material, 9 - 1’ - Primary base material, 9 - 2’ - Secondary base material (base material), 91 - Pipe part, 911 - Left end, 912 - Right end, 913 - Constant height part, 914 - Height changing part (height increasing part), 915 - Constant height part, 92 - Flange part, 921 - Constant width part, 922 - Width changing part (width decreasing part), 93 - First flange part, 93’ - Portion, 94 - Second flange part, 94’ - Portion, 95 - First pipe part, 96 - Second pipe part, 97 - End face, 98 - First portion, 99 - Second portion, 10 - Structure for supporting steering member, 101 - Welded part (welding point), 11 - Sheet metal part, 11A - Sheet metal part, 11B - Sheet metal part, 111 - Joint part, 20 - Molding device, 30 - Device main body, 40 - Flange part adjustment component, 40B - Flange part adjustment component, 40C - Flange part adjustment component, 40D - Flange part adjustment component, 401 - Group, 402 - Interval, 50 - First mold, 50A - First mold, 50B - First mold, 50C - First mold, 50D - First mold, 501 - First component, 502 - Second component, 503 - Third component, 504 - Recess505 - Groove (groove for forming tunnel part), 506 - Rib (convex part for forming groove), 60 - Second mold, H91 - Height, L93 - Total length, L94 - Total length, O9’ - Central axis, O91 - Central axis (axis), PM5 - Perimeter, PM6 - Perimeter, PM7 - Perimeter, PM8 - Perimeter, SD1 - Spacing distance, SD2 - Spacing distance, SD3 - Spacing distance, SD4 - Spacing distance, W91 - Width, W92 - Width (projection amount), W93 - Width (projection amount), W94 - Width (projection amount).

Claims

1. A manufacturing method of a flanged component, the flanged component being formed of one component and being a flanged component having a flange portion and being tubular, characterized in that, the manufacturing method includes: bringing a first mold and a second mold into an open mold state, and disposing a base material, which is the one component and is tubular, between the first mold and the second mold, wherein a plurality of flange portion adjusting components with different heights are disposed between the first mold and the second mold; heating the base material to soften it while maintaining the open mold state; moving the first mold toward the second mold and stopping the movement of the first mold at a predetermined position; moving a plurality of flange adjusting components to abut against the base material when the first mold stops; further moving the first mold toward the second mold so that the base material abuts against the second mold and starts to deform, wherein the deformed portion of the base material includes protruding portions that protrude different amounts from between the respective flange portion adjusting components; supplying gas to the base material so that the respective protruding portions protrude further; stopping the gas supply, and further moving the first mold and the respective flange portion adjusting components toward the second mold to flatten the respective protruding portions to form the flange portion; the formed flanged component has a cross-sectional change portion, and the cross-sectional shape of the cross-sectional change portion changes in the axial direction of the flanged component, in any two cross-sections of the cross-sectional change portion, the perimeter of one cross-section is 1.25 times or less of the perimeter of the other cross-section, the cross-sectional change portion includes the flange portion, the flange portion is formed along the axial direction, at least a part of the flange portion has a width required for engaging with other components, the width of the flange of the flange portion changes along the axial direction.

2. The manufacturing method according to claim 1, characterized in that, the perimeter of one cross-section is 1 time or more of the perimeter of the other cross-section.

3. The manufacturing method according to claim 1 or 2, characterized in that, the flanged component further has a rectangular portion with a rectangular cross-sectional shape.

4. The manufacturing method according to claim 3, characterized in that, the cross-sectional change portion includes the rectangular portion.

5. The manufacturing method according to claim 3 or 4, characterized in that, a groove formed along the axial direction is formed in the rectangular portion.

6. The manufacturing method according to any one of claims 1 to 5, characterized in that, the flange portion is a portion formed by overlapping the tube walls of the tubular body to form a plate shape.

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