Punching device and method for manufacturing a differential thickness metal plate

Abstract

The present application provides a stamping device and a method for manufacturing a metal plate capable of performing differential thickness processing in a short time and at low cost. The stamping device according to the present embodiment includes an upper die and a lower die for manufacturing a differential thickness metal plate, the lower die including a wall surface facing a cavity, a fixing portion for fixing both end portions of the metal plate placed in a manner that a plate surface of the metal plate faces upward, and a rotating mechanism for rotating the metal plate to make the metal plate stand along the wall surface, the upper die including a slider moving portion having an opposite surface opposite to the wall surface, descending in the cavity along the wall surface, and a cutting tool disposed on the opposite surface, performing finishing processing on at least a portion of the plate surface of the metal plate standing along the wall surface by descending the slider moving portion.

Description

TECHNICAL FIELD

[0001] The present application relates to a press device and a manufacturing method of a differential thickness metal plate. BACKGROUND

[0002] In order to perform surface finishing of a workpiece, a shaving machining method using a press device is widely used as in Japanese Patent Application Publication No. 2008-161945. The press device of Japanese Patent Application Publication No. 2008-161945 has a slide block movably supported to a body in an up-down direction, and a shaving machining punch is installed to the slide block. Thereby, the press device performs shaving machining by cutting action to the workpiece. SUMMARY

[0003] In a case where shaving machining is performed to a workpiece (metal plate) after bulging by using a press device, it is appropriate to lay flat if transportation of the workpiece is considered. On the other hand, a device that performs press in a horizontal direction is a large device, and cannot be used by a general press device.

[0004] The present application has been made to solve such a problem, and provides a press device that can perform shaving machining to a metal plate by lowering a cutting tool, and a manufacturing method of a differential thickness metal plate.

[0005] The press device related to the present embodiment has an upper die and a lower die for manufacturing a differential thickness metal plate, and is characterized in that the lower die includes a wall surface facing a cavity, a fixing portion that fixes both end portions of the metal plate placed in a manner that a plate surface of the metal plate faces upward, and a rotation mechanism that rotates the metal plate to stand the metal plate along the wall surface, the upper die includes a slide block moving portion having an opposite surface opposite to the wall surface, and descending in the cavity along the wall surface, and a cutting tool disposed to the opposite surface, and performs shaving machining to at least a portion of the plate surface of the metal plate standing along the wall surface by lowering the slide block moving portion. According to this configuration, shaving machining can be performed to the metal plate in a vertical direction, and differential thickness machining can be performed in a short time and at a low cost.

[0006] In the press device described above, the upper die can have a roller protruding from the opposite surface of the slide block moving portion, the cutting tool can protrude more than the roller on the opposite surface, and shaving machining can be performed while pressing the metal plate by the roller when the slide block moving portion is lowered. According to this configuration, shaving machining can be performed in a short time while the metal plate is fixed in the upper die.

[0007] In the above stamping device, the cutting tool can have a parallelogram cross section as viewed in a direction orthogonal to a direction in which the metal plate is oriented with the plate face facing upward and a direction in which the slide block moves, the opposing face of the slide block can have a step face parallel to the opposing face, a face constituting one side of the parallelogram can be disposed on the step face, and a face constituting the other side opposite to the one side can protrude more on the opposing face than the roller. According to this configuration, the life of the cutting tool can be extended.

[0008] In the above stamping device, the lower die can include a cylinder that fixes the metal plate. According to this configuration, the metal plate can be fixed in the lower die, and durability can be improved.

[0009] The manufacturing method of the differential thickness metal plate according to the present embodiment is a manufacturing method of a differential thickness metal plate using a stamping device including an upper die and a lower die, and includes the following steps: fixing both end portions of the metal plate placed with the plate face facing upward by a fixing portion of the lower die; rotating the metal plate by a rotation mechanism of the lower die to make the metal plate stand along a wall surface of a cavity in the lower die; and performing finishing processing on at least a portion of the plate face of the metal plate standing along the wall surface by a cutting tool disposed on an opposing face of the slide block moving portion of the upper die opposite to the wall surface when the slide block moving portion of the upper die is lowered in the cavity along the wall surface. According to this configuration, the metal plate can be finished in the vertical direction, and differential thickness processing can be performed in a short time and at low cost.

[0010] In the above manufacturing method of the differential thickness metal plate, in the step of performing the finishing processing, the upper die can have a roller protruding from the opposing face of the slide block moving portion, the cutting tool can protrude more on the opposing face than the roller, and the finishing processing can be performed while the metal plate is pressed by the roller when the slide block moving portion is lowered. According to this configuration, the finishing processing can be performed in a short time while the metal plate is fixed in the upper die.

[0011] In the above manufacturing method of the differential thickness metal plate, in the step of performing the finishing processing, the cutting tool can have a parallelogram cross section as viewed in a direction orthogonal to a direction in which the metal plate is oriented with the plate face facing upward and a direction in which the slide block moves, the opposing face of the slide block moving portion can have a step face parallel to the opposing face, a face constituting one side of the parallelogram can be disposed on the step face, and a face constituting the other side opposite to the one side can protrude more on the opposing face than the roller. According to this configuration, the life of the cutting tool can be extended.

[0012] In the manufacturing method of the differential thickness metal plate described above, after the rotating process, a process of fixing the metal plate by a cylinder provided to the lower mold can be further provided. According to this configuration, the metal plate can be fixed in the lower mold, and the durability can be improved.

[0013] In the manufacturing method of the differential thickness metal plate described above, before the process of performing the finishing process, a process of pressing the metal plate with a press die so that a protruding portion is formed on one of the plate surfaces of the metal plate and a recessed portion is formed on the opposite plate surface can be further provided. According to this configuration, the degree of freedom of the shape of the differential thickness metal plate can be improved.

[0014] In the manufacturing method of the differential thickness metal plate described above, in the process of performing the finishing process, the protruding portion can be subjected to the finishing process. According to this configuration, the protruding portion of the differential thickness metal plate can be subjected to the differential thickness process.

[0015] In the manufacturing method of the differential thickness metal plate described above, in the process of performing the finishing process, the recessed portion can be subjected to the finishing process. According to this configuration, the recessed portion of the differential thickness metal plate can be subjected to the differential thickness process.

[0016] In the manufacturing method of the differential thickness metal plate described above, before the process of performing the finishing process, a process of at least one of a punching process and an end bending process of the metal plate can be further provided. According to this configuration, the degree of freedom of the shape of the differential thickness metal plate can be improved.

[0017] In the manufacturing method of the differential thickness metal plate described above, in the process of performing the finishing process, the thickness of the metal plate cut by the finishing process can be set to be 5% or less of the sliding distance of the cutting tool. According to this configuration, the quality of the differential thickness metal plate can be improved.

[0018] According to the present embodiment, a press device and a manufacturing method of a metal plate can be provided, which can perform a finishing process on a metal plate by lowering a cutting tool provided in the press device, and can perform a differential thickness process in a short time and at a low cost.

[0019] The above and other objects, features and advantages of the present application will become more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which: BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 is a perspective view illustrating a metal plate subjected to a finishing process according to Embodiment 1.

[0021] Figure 2 is a perspective view illustrating a configuration of a press device according to Embodiment 1 and a process of a manufacturing method of a differential thickness metal plate using the press device.

[0022] Figure 3 is a process perspective view illustrating the configuration of the press device and the manufacturing method of the differential thickness metal plate using the press device according to Embodiment 1.

[0023] Figure 4 is a process perspective view illustrating the configuration of the press device and the manufacturing method of the differential thickness metal plate using the press device according to Embodiment 1.

[0024] Figure 5 is a process perspective view illustrating the configuration of the press device and the manufacturing method of the differential thickness metal plate using the press device according to Embodiment 1.

[0025] Figure 6 is a process perspective view illustrating the configuration of the press device and the manufacturing method of the differential thickness metal plate using the press device according to Embodiment 1.

[0026] Figure 7 is a process perspective view illustrating the configuration of the press device and the manufacturing method of the differential thickness metal plate using the press device according to Embodiment 1.

[0027] Figure 8 is a process perspective view illustrating the configuration of the press device and the manufacturing method of the differential thickness metal plate using the press device according to Embodiment 1.

[0028] Figure 9A is a plan view illustrating the protruding portions after the bulging of the metal plate before the finishing processing in the press device according to Embodiment 1.

[0029] Figure 9B is a plan view illustrating the protruding portions after the bulging of the metal plate before the finishing processing in the press device according to Embodiment 1.

[0030] Figure 10A is a plan view illustrating the protruding portions after the bulging of the metal plate after the finishing processing in the press device according to Embodiment 1.

[0031] Figure 10B is a plan view illustrating the protruding portions after the bulging of the metal plate after the finishing processing in the press device according to Embodiment 1.

[0032] Figure 11 is a view illustrating the differential thickness processing in the manufacturing method of the differential thickness metal plate according to Embodiment 1.

[0033] Figure 12 is a chart illustrating the relationship between the press capacity and the slide stroke in the press device, in which the horizontal axis represents the press capacity and the vertical axis represents the slide stroke.

[0034] Figure 13 is a plan view illustrating a press device to which the comparative example relates.

[0035] Figure 14 is a sectional view illustrating a roller provided in a slider moving section in a press device to which Embodiment 2 relates.

[0036] Figure 15 is a front view illustrating a roller provided in a slider moving section in a press device to which Embodiment 2 relates.

[0037] Figure 16 is a sectional view illustrating a cutting tool provided in a slider moving section in a press device to which Embodiment 3 relates.

[0038] Figure 17 is a sectional view illustrating a cutting tool provided in a slider moving section in a press device to which Embodiment 3 relates.

[0039] Figure 18 is a sectional view illustrating a cutting tool in a press device to which Embodiment 3 relates.

[0040] Figure 19 is a sectional view illustrating a cutting tool in a press device to which Embodiment 3 relates. DETAILED DESCRIPTION

[0041] Hereinafter, the present application will be described by embodiments of the application, but the application claimed in the claims is not limited to the following embodiments. In addition, not all of the configurations described in the embodiments are necessarily essential to the technical solution for solving the technical problem. In order to make the description clearer, the following description and drawings are appropriately omitted and simplified. In each drawing, the same elements are denoted by the same reference numerals, and repeated description is omitted as necessary.

[0042] (Embodiment 1)

[0043] A press device and a manufacturing method of a differential thickness metal plate relating to Embodiment 1 will be described. From the viewpoint of short time and low cost, in order to form a differential thickness metal plate having a plate thickness difference from a single metal plate, for example, it is appropriate to perform cutting of a metal plate at a prescribed thickness using a cutting tool in a general-purpose clamping press device, that is, so-called finishing. The press device and the manufacturing method of the differential thickness metal plate of the present embodiment perform finishing machining by rotating a metal plate from a flat state to a standing state by 90 degrees, and lowering a cutting tool from an upper portion to a lower portion, for example. Then, after machining, -90 degrees is rotated, and the flat state is returned again. In this way, finishing machining using a press device can be performed on a metal plate by lowering a cutting tool. Hereinafter, first, <outline of finishing machining> will be described, and then <configuration of a press device> will be described. Then, <manufacturing method of a differential thickness metal plate using a press device> will be described.

[0044] <Summary of finishing processing>

[0045] Figure 1 is a perspective view illustrating a metal sheet subjected to finishing processing according to Embodiment 1. As shown in Figure 1 , the press device of the present embodiment performs finishing processing on the sheet surface 310 of the metal sheet 300 by sliding the cutting tool 130 downward. The length of the direction of movement of the cutting tool 130 subjected to finishing processing is referred to as the finishing processing length L, and the thickness cut from the metal sheet 300 by finishing processing is referred to as the finishing processing thickness At. The finishing processing length L is also referred to as the sliding distance of the cutting tool 130. The finishing processing is performed so that the finishing processing thickness At is 5% or less of the finishing processing length L (sliding distance). That is, in the process of performing finishing processing, the thickness At cut from the metal sheet 300 by finishing processing is set to be 5% or less of the sliding distance of the cutting tool 130.

[0046] By such finishing processing, it is possible to make the thickness of a portion of the metal sheet 300 thinner than the thickness of other portions. Furthermore, it is possible to improve the processing accuracy in finishing processing, and improve the quality of the differential thickness metal sheet. If the thickness At cut from the metal sheet 300 by finishing processing exceeds 5% of the sliding distance of the cutting tool 130, the processing mode becomes a punch shear mode, and becomes a completely different mode from finishing processing. Note that the metal sheet 300 can be subjected to finishing processing multiple times. Furthermore, the product can be formed by press forming after finishing processing, or can be subjected to press forming to some extent before finishing processing. The metal sheet 300 can be exemplified by a steel sheet, an aluminum sheet, a stainless steel sheet, and the like, but is not limited thereto. As a member utilizing finishing processing, for example, a vehicle body constituent member can be exemplified, but is not limited thereto.

[0047] <Configuration of press device>

[0048] Next, the configuration of the press device 1 will be described. Figures 2-8 is a perspective view illustrating the configuration of the press device according to Embodiment 1 and the process of the manufacturing method of the differential thickness metal sheet utilizing the press device. As shown in Figures 2-8 , the press device 1 is provided with an upper die 100 and a lower die 200. Figures 3-7 is also shown in cross-sectional view. Furthermore, Figure 2 , Figure 5 , and Figure 8 are also shown in enlarged view. As shown in Figure 5 , at least when performing finishing processing, the upper die 100 is positioned above the lower die 200. The upper die 100 includes a body portion 110, a slider moving portion 120, and a cutting tool 130. The lower die 200 includes a body portion 210, a fixing portion 220, a rotation mechanism 230, and a wall surface 240.

[0049] First, the configuration of the lower die 200 will be described. As shown in Figure 2 and Figure 3 The body portion 210 of the lower die 200 is, for example, a substantially rectangular parallelepiped shape, and is disposed on a floor surface. The body portion 210 supports the fixing portion 220 and the rotation mechanism 230. Note that the body portion 210 only needs to be able to support the fixing portion 220 and the rotation mechanism 230, and is not limited in shape and disposition position.

[0050] The fixing portion 220 fixes the metal plate 300. Specifically, for example, the fixing portion 220 fixes both end portions of the metal plate 300 in a flat state in which the plate face 310 of the metal plate 300 is oriented upward. Specifically, for example, the metal plate 300 is laid on the blank table 250. The fixing portion 220 includes a jig, and the metal plate 300 is fixed to the blank table 250 by the jig with the air cylinder 260. The rotation mechanism 230 rotates the metal plate 300 so as to stand the metal plate 300 along the wall face 240.

[0051] As shown in Figure 4 The lower die 200 can have a blank pad 270 and a blank pad air cylinder 280. The blank pad 270 presses the metal plate 300 that stands along the wall face 240 against the blank table 250 and / or the wall face 240 by the blank pad air cylinder 280. In this way, the lower die 200 can be provided with a cylinder that presses and fixes the metal plate 300 against the blank table 250 and / or the wall face 240. The wall face 240 faces a cavity. The metal plate 300 is rotated in the cavity faced by the wall face 240.

[0052] Next, the configuration of the upper die 100 will be described. As shown in Figure 5 For example, when performing a finishing process, the body portion 110 is disposed above the lower die 200. The body portion 110 supports the slide block moving portion 120. The body portion 110 has, for example, a plurality of support portions 111 and a plurality of beam portions 112 that connect the plurality of support portions 111. Then, the beam portions 112 of the body portion 110 support the slide block moving portion 120 in a manner in which the slide block moving portion 120 can be lowered and raised. Note that the body portion 110 only needs to be able to support the slide block moving portion 120 in a manner in which the slide block moving portion 120 can be lowered and raised with respect to the body portion 110, and is not limited in configuration of the support portions 111 and the beam portions 112.

[0053] When the finishing process is performed, the slider moving portion 120 is lowered with respect to the body portion 110 of the upper die 100. At this time, the slider moving portion 120 is lowered in the cavity along the wall surface 240 of the lower die 200. The slider moving portion 120 has a surface opposite to the wall surface 240. The surface of the slider moving portion 120 opposite to the wall surface 240 is referred to as an opposite surface 121. The cutting tool 130 is attached to the opposite surface 121 of the slider moving portion 120. The cutting tool 130 is attached, for example, near the lower end of the opposite surface 121 of the slider moving portion 120. By lowering the slider moving portion 120, the finishing process can be performed on at least a portion of the plate surface 310 of the metal plate 300 standing along the wall surface 240.

[0054] The cutting tool 130 is arranged on the opposite surface 121 of the slider moving portion 120. The cutting tool 130 performs the finishing process on the surface of the metal plate 300. The upper die 100 can be provided with a lubricating oil injection gun 150 that injects lubricating oil when the finishing process is performed.

[0055] <Method of manufacturing a differential thickness metal plate>

[0056] Next, a method of manufacturing a differential thickness metal plate using a press device for manufacturing a differential thickness metal plate will be described. As shown in FIG. 1, first, a metal plate 300 is arranged on a lower die 200. The metal plate 300 is arranged on a blank table 250 in a flat state in which the plate surface 310 faces upward. Then, both end portions of the metal plate 300 are fixed by a fixing portion 220. Specifically, for example, a jig is operated by an air cylinder 260 for the jig, so that the metal plate 300 is clamped to the blank table 250. Figure 2

[0057] Next, as shown in FIG. 2, the blank table 250 on which the metal plate 300 is fixed is rotated by 90 degrees. Specifically, the metal plate 300 in the flat state is rotated by a rotation mechanism 230, so that the metal plate 300 stands along a wall surface 240 of a cavity in the lower die 200. For example, the metal plate 300 that stands vertically upward can be made to stand along the wall surface 240, so that the plate surface 310 of the metal plate 300 faces in the horizontal direction. Figure 3

[0058] Next, as shown in FIG. 3, a slider moving portion 120 is lowered with respect to the body portion 110 of the upper die 100. At this time, the slider moving portion 120 is lowered in the cavity along the wall surface 240 of the lower die 200. The cutting tool 130 is attached to the opposite surface 121 of the slider moving portion 120. The cutting tool 130 is attached, for example, near the lower end of the opposite surface 121 of the slider moving portion 120. By lowering the slider moving portion 120, the finishing process can be performed on at least a portion of the plate surface 310 of the metal plate 300 standing along the wall surface 240. Figure 4 ​​As shown, after the process of rotating the metal plate 300, the metal plate 300 is fixed by a cylinder provided on the lower die 200. Specifically, for example, the blank pad air cylinder 280 can be operated to press the metal plate 300, which is erected along the wall surface 240, against the blank table 250 and / or the wall surface 240 via the blank pad 270. The blank pad air cylinder 280 is configured to maintain a finishing force of more than 3.5% on both sides of the metal plate 300. That is, it is configured such that PA (the restraining force of the air pad) = 0.035 × PS (the finishing force). If the restraining force of the blank pad air cylinder 280 is less than 3.5% of the finishing force, the metal plate 300 may fall off the blank pad 270 and damage the cutting tool 130, etc.

[0059] Next, as Figure 5 As shown, the upper mold 100 is positioned above the lower mold 200, causing the slider moving part 120 of the upper mold 100 to descend along the wall surface 240 in the cavity. At this time, at least a portion of the plate surface 310 of the metal plate 300, which is erected along the wall surface 240, is finished by the cutting tool 130 disposed on the opposite surface 121 of the slider moving part 120.

[0060] Next, as Figure 6 As shown, the blank pad is operated by the air cylinder 280, and the blank pad 270 is returned, thereby releasing the pad of the metal plate 300.

[0061] Next, as Figure 7 As shown, the blank platform 250 that holds the fixed metal plate 300 is rotated 90 degrees in the opposite direction. Specifically, the metal plate 300 is rotated using the rotating mechanism 230, so that the metal plate 300 is placed flat.

[0062] Next, as Figure 8 As shown, the clamping part 220 releases its grip on the metal plate 300. Then, the metal plate 300 is removed from the lower mold 200. This allows for the manufacture of metal plates with varying thicknesses. It should be noted that... Figure 5 Other processes are set as automatic actions based on PLC (Programmable Logic Control).

[0063] Figure 9A This is a top view illustrating the raised portion 320 of the metal sheet 300 before finishing processing in the stamping apparatus 1 according to Embodiment 1. Figure 9B This is a top view illustrating the raised portion 320 of the metal sheet 300 before finishing processing in the stamping apparatus 1 according to Embodiment 1. Figure 10A This is a top view illustrating the raised portion 320 of a metal sheet 300 after finishing processing in the stamping apparatus 1 according to Embodiment 1. Figure 10Bis a plan view illustrating the protruding portions 320 of the metal plate 300 after the finishing process in the press device 1 according to Embodiment 1. Figure 9A , Figure 9B , Figure 10A and Figure 10B The cross section of the protruding portions 320 is also illustrated in

[0064] As illustrated in Figure 9A , Figure 9B , Figure 10A and Figure 10B , before the process of performing the finishing process, a protruding process, i.e., a process of pressing the metal plate 300 with a press die so that the protruding portions 320 are formed on one of the plate surfaces 310 of the metal plate 300 and the recessed portions 330 are formed on the opposite surface of the plate surface 310, can be provided. The protruding portions 320 have, for example, a width Wl and a length LI. Here, Wl is, for example, 120 mm. LI is, for example, 160 mm. Further, the protruding portions 320 have, for example, a width W2 and a length L2. Here, W2 is, for example, 280 mm. L2 is, for example, 30 mm. Then, in the process of performing the finishing process, the protruding portions 320 can be subjected to the finishing process, or the recessed portions 330 can be subjected to the finishing process. Δt is, for example, 0.5 to 1 mm or less than 0.5 mm. In this way, Δt is 5% or less of LI and L2.

[0065] Figure 11 is a diagram illustrating the differential thickness processing process in the manufacturing method of the differential thickness metal plate according to Embodiment 1. As illustrated in Figure 11 , the manufacturing method of the differential thickness metal plate can include a process of preparing a rectangular material, a process of performing differential thickness processing, and a process of performing product molding. The process of performing differential thickness processing can have punching / protruding (#1), end bending (#2), finishing (#3), and finishing (#4) as (A) lines. Further, the process of performing differential thickness processing can have punching / protruding (#1), finishing (#2), finishing (#3), and finishing (#4) as (B) lines. In addition, the process of performing differential thickness processing can have punching (#1), end bending (#2), finishing (#3), and finishing (#4) as (C) lines. Further, the process of performing differential thickness processing can have punching / surface mounting (#1), finishing (#2), and finishing (#3) as (D) lines. In this way, before the process of performing the finishing process, at least either one of the punching process and the end bending process of the metal plate can be provided.

[0066] Next, the effects of the present embodiment will be described. The press device 1 of the present embodiment has the rotation mechanism 230 that rotates the metal plate 300 from the flat state to the state of standing along the wall surface 240. Therefore, the finishing machining can be performed on the metal plate 300 by lowering the cutting tool 130. Thus, a general press device can be used, and a large device for press machining in the horizontal direction is not necessary. Further, after the finishing machining, the metal plate 300 is transported in the flat state. Thus, the differential thickness machining can be performed in a short time and at low cost.

[0067] Further, since the machining is performed using the die including the upper die 100 and the lower die 200, the machining can be performed using a general press device. Therefore, the machining can be performed by investment of only the die, and the equipment investment can be suppressed.

[0068] Figure 12 is a graph illustrating the relationship between the press capacity and the slide stroke in the press device, and the horizontal axis indicates the press capacity and the vertical axis indicates the slide stroke. As shown in Figure 12 , in the machining using a general clamping press device, for example, 500 tons of press is performed at a stroke of 15 mm. On the other hand, in a case where the cutting load of the finishing machining is limited to 100 tons or less and the cutting speed is set to 200 mm / sec or more, 200 mm of the stroke is possible.

[0069] The machining stroke capacity of the finishing machining is about several tens times that of the mechanical machining. That is, if it is 100 tons or less, the machining can be performed from the upper portion of the stroke. Incidentally, if it is a 500-ton press device, the finishing machining of 200 mm in length x 800 mm in width x Δt = 0.7 is possible. Here, the strength of the metal plate 300 is 590 MPa or less. In this way, the press device 1 of the present embodiment can perform the wide and deep machining in a short time using the machining stroke capacity larger than the capacity of the mechanical machining.

[0070] Figure 13 is a plan view illustrating the press device involved in the comparative example. As shown in Figure 13 , in the press device of the comparative example, a cam mechanism for changing the metal plate 300 to the flat state and performing the finishing machining is used. Specifically, in the press device of the comparative example, the machining cam 400 is mirror-imaged and arranged in the lower die 200. Therefore, the finishing machining is performed from both sides of the metal plate 300. In this comparative example, the cam space for the machining cam 400 is expanded, and it is not possible to fit into the press device. Therefore, it is necessary to divide the cam process into two processes. In contrast, in the present embodiment, the rotation mechanism is used instead of the cam mechanism, and the number of processes is not increased by the simple die structure including the upper die 100 and the lower die 200. Thus, the manufacturing cost can be reduced.

[0071] Furthermore, by using a blank pad air cylinder 280 to fix the metal plate 300 to the blank pad 270, the stamping apparatus 1 of this embodiment can suppress the vibration of the metal plate 300 and perform finishing processing with high precision. In addition, since the blank pad air cylinder 280 has high durability, the lifespan of the stamping apparatus 1 can be improved.

[0072] Furthermore, the air cylinder 280 for the blank pad is configured to hold the front and back of the metal plate 300 at a working force of more than 3.5%. This prevents the metal plate 300 from detaching from the blank pad 270 and damaging the cutting tool 130, etc.

[0073] Before the finishing process, the following steps can be performed: pressing the metal sheet 300 with a stamping die to form a protrusion 320 on one side of the metal sheet 300 surface 310 and a recess 330 on the opposite side of the surface 310. Furthermore, before the finishing process, a punching process and an end bending process of the metal sheet 300 can be performed. In this way, by processing the unfinished parts beforehand, a series of operations on the production line can be unified, improving production efficiency.

[0074] (Implementation Method 2)

[0075] Next, the stamping apparatus and the method for manufacturing the differential thickness metal sheet according to Embodiment 2 will be described. In Embodiment 1, the method of fixing the metal sheet 300 using an air cylinder 280 for a blank pad was described. In contrast, in this embodiment, the metal sheet 300 is pressed against the blank table 250 and / or the wall surface 240 by rollers.

[0076] Figure 14 This is a cross-sectional view illustrating the roller 140 provided in the slider moving part 120 of the stamping device 2 according to Embodiment 2. Figure 15 This is a front view of the roller 140 provided in the slider moving part 120 in the stamping device 2 according to Embodiment 2.

[0077] like Figure 14 and Figure 15 As shown, the upper die 100 of the stamping apparatus 2 in this embodiment has a roller 140 protruding from the opposite surface 121 of the slider moving part 120. The roller 140 rotates and moves on the metal plate 300 that is erected along the wall surface 240. The roller 140 presses and fixes the metal plate 300 against the blank table 250 and / or the wall surface 240, etc. The cutting tool 130 protrudes further from the roller 140 on the opposite surface 121. When the slider moving part 120 descends, the metal plate 300 is pressed by the roller 140, and finishing processing is performed simultaneously.

[0078] According to the present embodiment, the press device 2 has the roller 140 that presses the metal plate 300. Therefore, it is possible to perform the finishing process in a short time while fixing the metal plate 300. Further, since the roller 140 rotates in conjunction with the lowering of the slide moving portion 120, it is possible to suppress the shaking in the left and right directions. Therefore, it is possible to improve the accuracy of the finishing process. The configurations and effects other than these are included in the description of Embodiment 1.

[0079] (Embodiment 3)

[0080] Next, the cutting tool of the press device according to Embodiment 3 will be described. As the number of times of the finishing process of the metal plate 300 increases, the tip of the cutting tool 130 is worn. Due to this, since the quality of the processed surface decreases or the rigidity of the cutting tool 130 decreases, the cutting edge slightly moves, and a notch can be generated. Therefore, in the case where the finishing process reaches a predetermined number of times, the cutting edge of the cutting tool 130 is ground. In the present embodiment, the cross-sectional shape of the cutting tool 130 is set to a parallelogram shape including a rhombus. Due to this, it is possible to reduce the number of times of replacement of the cutting tool 130.

[0081] Figure 16 is a cross-sectional view illustrating the cutting tool 130 provided to the slide moving portion 120 in the press device according to Embodiment 3. As shown in Figure 16 , the cutting tool 130 has a parallelogram cross-section as viewed from a direction orthogonal to the direction in which the surface 310 of the metal plate 300 faces and the direction in which the cutting tool 130 moves. The cutting edge is provided at two diagonal positions of the cutting tool 130. Then, after the finishing process reaches a predetermined number of times, the two cutting edges are subjected to regrinding, and then surface treatment is performed. At the time of regrinding, the surface constituting one side 131 of the parallelogram cross-section and the surface constituting the other side 133 opposite to the one side 131 are regrinded. The surface constituting the one side 132 of the parallelogram cross-section and the surface constituting the other side 134 opposite to the one side 132 are not regrinded. By setting the cutting tool 130 to such a shape, it is possible to suppress the frequency of regrinding of one cutting tool 130 to 1 / 2. Finally, for example, the two cutting edges are subjected to regrinding three times or so, and surface treatment is performed three times.

[0082] The opposite surface 121 of the slide moving portion 120 in which the cutting tool 130 is installed can have a step surface 122 parallel to the opposite surface 121. Then, the surface constituting the one side 132 of the parallelogram is disposed on the step surface 122. Due to this, in the case of replacing the surface constituting the one side 131 and the surface constituting the other side 133, it is possible to suppress the positional deviation, and it is possible to improve the accuracy of the finishing process after regrinding.

[0083] Figure 17is a cross-sectional view illustrating the cutting tool 130 provided to the slide moving portion 120 in the press device 3 according to Embodiment 3. As shown in Figure 17 by grinding the cutting edge, the wear of the cutting edge of the cutting tool 130 can be suppressed. Thereby, the cutting edge can be made rigid. Thereby, even if the surface of the metal plate 300 is a slope of a = 10 degrees or so, the elastic deformation at the time of processing can be reduced. Therefore, in the case of applying the cutting tool 130 having a parallelogram cross section to the island-like embossing (in the case of performing the finishing processing to the protruding portion 320) and to the continuous embossing (in the case of performing the finishing processing to the flat portion), the slight movement of the cutting edge at the start of the finishing can be reduced. Therefore, the generation of the notch due to the slight movement of the cutting edge can be suppressed, the life of the cutting tool 130 can be extended, and the cost of the cutting tool 130 can be reduced.

[0084] Figure 18 is a cross-sectional view illustrating the cutting tool 130 in the press device 3 according to Embodiment 3. As shown in Figure 18 at the time of performing the finishing processing from the upper end to the lower end of the metal plate 300 as a workpiece, by processing the surface of the upper end with a shearing surface (drape + shearing) having a small surface roughness, compared to processing with a rough fracture surface, the life of the cutting tool 130 can be extended.

[0085] Figure 19 is a cross-sectional view illustrating the cutting tool 130 in the press device 3 according to Embodiment 3. As shown in Figure 19 by making the cutting tool 130 have a parallelogram cross section, the cutting tool 130 can be downsized. Therefore, the rigidity of the cutting tool 130 can be improved, the slight movement of the tip can be suppressed, and the notch of the tip of the cutting tool 130 can be suppressed. In addition, it can be expected to suppress the chips and improve the plate thickness accuracy.

[0086] According to the press device 3 of the present embodiment, the cutting tool 130 has a parallelogram cross section including a rhombus, and thus includes two cutting edges. Thereby, the number of replacements of the cutting tool 130 can be reduced.

[0087] Further, the cutting tool 130 having a parallelogram cross section and the roller 140 can be combined. The face constituting one side 132 of the parallelogram of the cutting tool 130 can be arranged on the step face 122, and the face constituting the other side 134 opposite to the one side 132 can be made to protrude more on the opposite face 121 than the roller 140. In the case where the roller 140 is used for dressing, the cutting tool 130 is made to protrude more on the opposite face 121 than the roller 140. At this time, the width protruding from the roller 140 is important for the machining accuracy of the dressing process. Since the cutting tool 130 of the present embodiment has a parallelogram cross section, the interval between the one side 132 and the other side 134 is fixed, and thus the width protruding from the roller 140 can be kept fixed. Therefore, the machining accuracy of the dressing can be improved.

[0088] Note that the present application is not limited to the above-described embodiments, and can be appropriately changed within a scope that does not depart from the gist. For example, a configuration obtained by appropriately combining each of the configurations of Embodiments 1 to 3 is also included in the scope of the technical idea of the present embodiment.

[0089] From the above description of the present application, it is apparent that embodiments of the present application can be modified in various ways. Such modifications should not be considered as departing from the spirit and scope of the present application, and all such modifications that are obvious to those skilled in the art are included in the scope of the appended claims.

Claims

1. A press device, which has an upper die and a lower die, for manufacturing a differential thickness metal sheet, the press device being characterized by the lower die including: a wall surface facing a cavity; a fixing portion that fixes both end portions of the metal sheet in a flat state in which a sheet surface of the metal sheet is oriented upward; and a rotating mechanism that rotates the metal sheet in the flat state in the cavity to stand the metal sheet along the wall surface, the upper die including: a slide block moving portion that has an opposite surface opposite to the wall surface, descends in the cavity along the wall surface; and a cutting tool disposed on the opposite surface, by descending the slide block moving portion, performing finishing processing on at least a portion of the sheet surface of the metal sheet that stands along the wall surface, wherein the upper die has a roller that protrudes from the opposite surface of the slide block moving portion, the cutting tool protrudes more on the opposite surface than the roller, and by the roller pressing the metal sheet while descending the slide block moving portion, performs finishing processing.

2. The press device according to claim 1, characterized by the cutting tool has a parallelogram cross section, as viewed from a direction orthogonal to a direction in which the sheet surface of the metal sheet is oriented and a direction in which the slide block moving portion moves, the opposite surface of the slide block moving portion has a step surface parallel to the opposite surface, a surface constituting one side of the parallelogram is disposed on the step surface, and a surface constituting another side opposite to the one side protrudes more on the opposite surface than the roller.

3. The press device according to claim 1 or 2, characterized by the lower die has a cylinder that fixes the metal sheet.

4. A manufacturing method of a differential thickness metal sheet, which manufactures a differential thickness metal sheet using a press device having an upper die and a lower die, the manufacturing method including the following steps: fixing both end portions of the metal sheet in a flat state in which a sheet surface of the metal sheet is oriented upward, by a fixing portion of the lower die; rotating the metal sheet in the flat state in a cavity, by a rotating mechanism of the lower die, to stand the metal sheet along a wall surface facing the cavity in the lower die; and performing finishing processing on at least a portion of the sheet surface of the metal sheet that stands along the wall surface, by a cutting tool disposed on an opposite surface of the slide block moving portion opposite to the wall surface, when a slide block moving portion of the upper die descends in the cavity along the wall surface, wherein in the step of performing the finishing processing, the upper die has a roller that protrudes from the opposite surface of the slide block moving portion, the cutting tool protrudes more on the opposite surface than the roller, by the roller pressing the metal sheet while descending the slide block moving portion, performs finishing processing.

5. The manufacturing method of a differential thickness metal sheet according to claim 4, wherein in the step of performing the finishing processing, the cutting tool has a parallelogram cross section, as viewed from a direction orthogonal to a direction in which the sheet surface of the metal sheet is oriented and a direction in which the slide block moving portion moves, the opposite surface of the slide block moving portion has a step surface parallel to the opposite surface, a surface constituting one side of the parallelogram is disposed on the step surface, and a surface constituting another side opposite to the one side protrudes more on the opposite surface than the roller. A surface constituting one side of the parallelogram is arranged on the stepped surface, and a surface constituting the other side opposite to the one side is arranged more protruding on the opposite surface than the roller.

6. The method of manufacturing a differential thickness metal sheet according to claim 4 or 5, wherein After the rotating process, the method further comprises a process of fixing the metal sheet by a cylinder provided in the lower mold.

7. The method of manufacturing a differential thickness metal sheet according to claim 4 or 5, wherein Before the process of performing the finishing process, the method further comprises a process of pressing the metal sheet with a press die so that a protruding portion is formed on one of the plate surfaces of the metal sheet and a recessed portion is formed on the opposite surface of the plate surface.

8. The method of manufacturing a differential thickness metal sheet according to claim 7, wherein In the process of performing the finishing process, the protruding portion is finished.

9. The method of manufacturing a differential thickness metal sheet according to claim 7, wherein In the process of performing the finishing process, the recessed portion is finished.

10. The method of manufacturing a differential thickness metal sheet according to claim 4 or 5, wherein Before the process of performing the finishing process, the method further comprises a process of at least one of a punching process and an end bending process of the metal sheet.

11. The method of manufacturing a differential thickness metal sheet according to claim 4 or 5, wherein In the process of performing the finishing process, a thickness cut from the metal sheet by the finishing process is set to be 5% or less of a sliding distance of the cutting tool.

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