Workpiece manufacturing device

Abstract

A workpiece manufacturing apparatus includes a fixed die assembly (10) and a movable die assembly (20). The fixed die assembly (10) includes a fixed die main body (10a) and a die (11). The movable die assembly (20) includes a movable die main body (20a), a forming punch (21), a blanking punch (22), a first push member (30), and a second push member (40) having higher rigidity than the first push member (30). The workpiece manufacturing apparatus is configured to sequentially perform preforming of a plate material, punching out a workpiece from the plate material, and final forming of the workpiece by pushing an end (42) of the second push member (40) against the forming punch (21) with compression deformation of the first push member (30) by bringing the movable die assembly (20) close to the fixed die assembly (10).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a workpiece manufacturing apparatus. BACKGROUND

[0002] Patent Document 1 discloses a method for manufacturing a grooved plate. In this manufacturing method, a corrugated plate is formed by preforming a metal plate with a first mold having a corrugated mold surface. Subsequently, the plate is subjected to final forming using a second mold having a mold surface of the same shape as the shape of a groove to be formed. Thereby, a plurality of grooves each including a flat surface are formed.

[0003] PRIOR ART DOCUMENTS

[0004] PATENT DOCUMENT

[0005] Patent Document 1: Japanese Patent Application Publication No. 2003-249238 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] The manufacturing method described in Patent Document 1 requires a first mold for performing preforming and a second mold for performing final forming. The manufacturing method also requires a step of transferring the plate from the first mold to the second mold. Thereby, the manufacturing process of the workpiece is complicated.

[0008] An object of the present application is to provide a workpiece manufacturing apparatus that simplifies the manufacturing process.

[0009] SOLUTION TO PROBLEM

[0010] To achieve the foregoing object, a workpiece manufacturing apparatus is configured to manufacture a workpiece from a metal plate. The workpiece manufacturing apparatus includes a fixed die assembly and a movable die assembly. The fixed die assembly includes a fixed die main body and a die including a die-side forming surface. The die-side forming surface is configured to form the plate. The movable die assembly includes a movable die main body, a forming punch, a blanking punch, a first pressing member, and a second pressing member. The movable die main body is configured to be able to approach the fixed die assembly and move away from the fixed die assembly. The forming punch includes a punch-side forming surface and a base end surface. The punch-side forming surface cooperates with the die-side forming surface to form the plate. The base end surface is on an opposite side of the punch-side forming surface. The blanking punch is fixed to the movable die main body on an outer side of the forming punch. The blanking punch is configured to cooperate with the die to punch out the workpiece from the plate. The first pressing member includes a base end fixed to the movable die main body and a tip end fixed to the base end surface of the forming punch. The second pressing member includes a base end fixed to the movable die main body and a tip end. A gap is provided between the tip end and the base end surface of the forming punch. The second pressing member has higher rigidity than the first pressing member. The workpiece manufacturing apparatus is configured to cause the movable die assembly to approach the fixed die assembly, thereby sequentially performing preforming of the plate, punching out the workpiece from the plate, and final forming of the workpiece by tip-end pressing of the forming punch with the second pressing member in compression deformation accompanying compression of the first pressing member. BRIEF DESCRIPTION OF DRAWINGS

[0011] [ Figure 1 ] Figure 1 is a cross-sectional view of a workpiece manufacturing apparatus according to one embodiment, showing a movable die assembly and a fixed die assembly separated from each other.

[0012] [ Figure 2 ] Figure 2 is a cross-sectional view showing a plate in a state of being restrained by the fixed die assembly and the movable die assembly of this embodiment.

[0013] [ Figure 3 ] Figure 3 is a cross-sectional view showing a preforming step performed by the workpiece manufacturing apparatus of this embodiment.

[0014] [ Figure 4 ] Figure 4 is a cross-sectional view showing a punching step performed by the workpiece manufacturing apparatus of this embodiment.

[0015] [ Figure 5 ] Figure 5 is a cross-sectional view showing a main forming step performed by the workpiece manufacturing apparatus of this embodiment. DETAILED DESCRIPTION

[0016] Reference will now be made to Figures 1 to 5This describes a workpiece manufacturing apparatus according to one embodiment. The workpiece 100 in this embodiment is a separator for a fuel cell.

[0017] like Figures 1 to 5 As shown, the manufacturing apparatus is an apparatus for manufacturing workpiece 100 from metal sheet 50, and includes a fixed mold assembly 10 and a movable mold assembly 20.

[0018] <Fixed mold assembly 10>

[0019] like Figure 1 As shown, the fixed mold assembly 10 includes a fixed mold body 10a and a cuboid mold 11. The mold 11 includes a mold-side forming surface 11a configured to form the plate 50.

[0020] like Figure 5 As shown, a mold-side forming surface 11a is provided on the upper surface of the mold 11. The mold-side forming surface 11a includes a plurality of grooves for forming a plurality of flow paths 101 on the plate 50.

[0021] like Figure 1 As shown, the fixed mold body 10a includes a fixed mold frame 16, a fixed side back plate 15, a mold plate 14, a base plate 13, and a fixed side unloader 12.

[0022] The fixed side back plate 15 is fixed to the upper surface of the fixed mold frame 16 by bolts (not shown).

[0023] The mold 11, mold plate 14 and base plate 13 are fixed to the upper surface of the fixed side back plate 15.

[0024] A mold plate 14 with a rectangular frame shape is disposed on the outside of the mold 11.

[0025] The substrate 13 has a cuboid shape and is sandwiched between the mold plate 14 and the mold 11.

[0026] A fixed-side ejector 12 with a rectangular frame shape is fixed to the upper surface of the substrate 13. A gap S1 is provided on the entire circumference between the inner circumferential surface of the fixed-side ejector 12 and the outer circumferential surface of the mold 11.

[0027] The upper inner periphery 12a of the fixed-side unloader 12 is chamfered around the entire circumference to give it an arc-shaped cross-section. Figure 2 ).

[0028] <Modible mold assembly 20>

[0029] like Figure 1As shown, the movable mold assembly 20 includes a movable mold body 20a and a forming punch 21 having a cuboid shape. The movable mold body 20a is located above the fixed mold assembly 10 and can move up and down. The forming punch 21 includes a punch-side forming surface 21a that cooperates with the mold-side forming surface 11a of the mold 11 to form the plate 50. The movable mold body 20a is configured to be able to approach the fixed mold assembly 10 and move away from the fixed mold assembly 10.

[0030] like Figure 5 As shown, a punch-side forming surface 21a is provided on the lower surface of the forming punch 21. The punch-side forming surface 21a includes a plurality of grooves for forming a plurality of flow paths 101 on the plate 50. A base end face 21b is provided on the upper surface of the forming punch 21. That is, the forming punch 21 includes a base end face 21b on the side opposite to the punch-side forming surface 21a.

[0031] like Figure 1 and Figure 2 As shown, the movable die assembly 20 includes a blanking punch 22. The blanking punch 22 is fixed to the movable die body 20a outside the forming punch 21. The blanking punch 22 is configured to cooperate with the die 11 to punch a workpiece 100 from the plate 50.

[0032] like Figure 1 As shown, the movable mold body 20a includes a movable mold frame 28, a movable side back plate 27, a punch back plate 26, a punch plate 25, a punch retainer 24, and a movable side unloader 23.

[0033] The movable mold 28 is configured to move vertically via a drive device (not shown).

[0034] The movable side back plate 27 is fixed to the lower surface of the movable mold frame 28 by bolts (not shown).

[0035] The punch back plate 26 is fixed to the lower surface of the movable side back plate 27. The punch back plate 26 includes a central hole 26a extending vertically through the punch back plate 26.

[0036] Punch holder 24, punch plate 25 and punching punch 22 are fixed to the lower surface of punch back plate 26.

[0037] The punch retainer 24 includes a central hole 24a extending vertically through the punch retainer 24. The punch retainer 24 is fixed to the inner circumferential portion of the lower surface of the punch back plate 26.

[0038] A punch plate 25 with a rectangular frame shape is disposed on the outside of the punch holder 24.

[0039] A blanking punch 22 with a rectangular frame shape is held between a punch holder 24 and a punch plate 25.

[0040] The punching punch 22 includes a base 22a opposite to the inner peripheral surface of the punch plate 25 and a protrusion 22b protruding downward from the base 22a. The outer peripheral surface of the protrusion 22b is located inside the outer peripheral surface of the base 22a. The inner peripheral surface of the protrusion 22b is flush with the inner peripheral surface of the base 22a.

[0041] The forming punch 21 is disposed within the blanking punch 22 in such a way that it can be displaced in the vertical direction relative to the blanking punch 22.

[0042] The frame-shaped movable side unloader 23 is fixed to the outer peripheral surface of the end portion of the protrusion 22b.

[0043] Movable side unloader 23 and fixed side unloader 12 clamping plate 50.

[0044] <Push-pressing components 30, 40>

[0045] like Figure 1 As shown, the forming punch 21 is fixed to the movable side back plate 27 by the first pressing member 30. The first pressing member 30 passes through the center hole 26a of the punch back plate 26 and the center hole 24a of the punch holder 24.

[0046] The first pressing member 30 has the shape of a quadrangular prism extending in the vertical direction (that is, in the direction of movement of the movable mold assembly 20). The first pressing member 30 includes a through hole 30a extending in the vertical direction. The through hole 30a has, for example, a circular cross-section.

[0047] The base end 31 of the first pushing member 30 is fixed to the lower surface of the movable side back plate 27 by bolts (not shown).

[0048] The end 32 of the first pressing member 30 is fixed to the base end face 21b of the forming punch 21 by bolts (not shown).

[0049] The upper end (base end) of the through hole 30a has a larger diameter than the portion below it. Therefore, a step 33 is provided on the inner circumferential surface of the through hole 30a.

[0050] A second pushing member 40 with higher rigidity than the first pushing member 30 is inserted into the through hole 30a of the first pushing member 30.

[0051] The second pressing member 40 has a cylindrical shape extending in the vertical direction (that is, in the direction of movement of the movable mold assembly 20). In the following description, the radial direction orthogonal to the axial direction of the second pressing member 40 is... Figure 1 The left and right directions in the middle can be simply referred to as radial.

[0052] The base end portion 43 of the second pressing member 40 has a larger diameter than the rest of the second pressing member 40 44. The lower surface of the base end portion 43 engages with the step 33 of the through hole 30a. The base end 41 of the second pressing member 40 contacts the lower surface of the movable side back plate 27. Thus, the base end 41 is fixed to the movable side back plate 27, that is, fixed to the movable mold body 20a. A specific gap S3 is provided between the end portion 42 of the second pressing member 40 and the base end face 21b of the forming punch 21.

[0053] A specific gap S2 is provided between the outer peripheral surface of the first pressing member 30 and the inner peripheral surface of the punch back plate 26 along the entire length in the vertical direction.

[0054] A specific gap (not shown) is provided between the outer peripheral surface of the first pressing member 30 and the inner peripheral surface of the punch holder 24 along the entire length in the vertical direction.

[0055] When the first pressing member 30 is compressed and deformed in the vertical direction and expanded and deformed in the radial direction, these gaps have dimensions that allow the first pressing member 30 to be displaced relative to the punch back plate 26 and the punch holder 24.

[0056] A gap (not shown) is provided between the inner peripheral surface of the first pressing member 30 and the outer peripheral surface of the second pressing member 40. When the first pressing member 30 is compressed and deformed in the vertical direction and expanded and deformed in the radial direction, the gap has a size that allows the first pressing member 30 and the second pressing member 40 to displace relative to each other.

[0057] The Young's modulus of the material of the first pressing member 30 is preferably 70 GPa to 80 GPa. As such a material, high-grade duralumin or ultra-high-grade duralumin, as an aluminum alloy, is preferred. In this embodiment, the first pressing member 30 is made of ultra-high-grade duralumin.

[0058] The Young's modulus of the material of the second pressing member 40 is preferably 500 GPa to 600 GPa. This material is preferably cemented carbide. In this embodiment, the second pressing member 40 is made of cemented carbide whose main component is tungsten carbide.

[0059] This embodiment is configured such that the movable mold assembly 20 is brought close to the fixed mold assembly 10, thereby sequentially performing pre-forming of the plate 50, stamping of the workpiece 100 from the plate 50, and final forming of the workpiece 100 by pushing the forming punch 21 with the end 42 of the second pressing member 40 through compression deformation accompanied by the first pressing member 30.

[0060] The operation of this implementation method will now be explained.

[0061] When the movable mold assembly 20 approaches the fixed mold assembly 10, the plate 50 is clamped between the fixed-side ejector 12 and the movable-side ejector 23, such as Figure 2 As shown. Thus, plate 50 is constrained between fixed mold assembly 10 and movable mold assembly 20.

[0062] like Figure 3 As shown, when the movable mold assembly 20 moves closer to the fixed mold assembly 10, the plate 50 is pressed by the punch-side forming surface 21a of the forming punch 21 (which is pressed by the first pressing member 30) and the mold-side forming surface 11a of the mold 11 (pre-forming step).

[0063] like Figure 4 As shown, when the movable mold assembly 20 moves closer to the fixed mold assembly 10, causing the end of the protrusion 22b of the punching punch 22 to move to a position below the mold-side forming surface 11a of the mold 11, the workpiece 100 is punched out from the plate 50 through the cooperation of the punching punch 22 and the mold 11 (punching step).

[0064] At this time, the first pressing member 30 is deformed by being compressed in the vertical direction (i.e., in the direction of movement of the movable mold assembly 20), so that the distance between the end 42 of the second pressing member 40 and the base end face 21b of the forming punch 21 gradually decreases.

[0065] When the end 42 of the second pressing member 40 contacts the base end face 21b of the forming punch 21, the forming punch 21 is also pressed by the second pressing member 40 in addition to the first pressing member 30. Therefore, as Figure 5 As shown, the workpiece 100 is pressed by the forming punch 21 and the die 11. At this time, the protrusion 22b of the blanking punch 22 and the upper inner periphery 12a of the fixed side unloader 12 press the plate 50 that has already punched out the workpiece 100 (final forming step).

[0066] This implementation method has the following advantages.

[0067] (1) The movable mold assembly 20 includes a first pressing member 30 and a second pressing member 40, the second pressing member 40 having higher rigidity than the first pressing member 30. The first pressing member 30 includes a base end 31 fixed to the movable mold body 20a and an end end 32 fixed to the base end face 21b of the forming punch 21. The second pressing member 40 includes a base end 41 fixed to the movable mold body 20a and an end end 42. A gap S3 is provided between the end end 42 and the base end face 21b of the forming punch 21. The workpiece manufacturing apparatus is configured to bring the movable mold assembly 20 close to the fixed mold assembly 10, thereby sequentially performing pre-forming of the plate 50, stamping the workpiece 100 from the plate 50, and finally forming the workpiece 100 by pressing the forming punch 21 with the end end 42 of the second pressing member 40 during the compression deformation of the first pressing member 30.

[0068] The construct operates in the manner described above.

[0069] In the configuration where the workpiece 100 is stamped out from the plate 50 after final forming, the workpiece 100 may shrink due to the stamping process.

[0070] In this respect, in the above-described structure, after the workpiece 100 is stamped out from the plate 50, the shrinkage of the workpiece 100 is restored by performing final shaping on the workpiece 100.

[0071] In this way, the above-described configuration performs preforming, stamping, and final forming through a series of steps in which the movable mold assembly 20 is brought close to the fixed mold assembly 10. This simplifies the process of manufacturing the workpiece 100.

[0072] (2) The second pressing member 40 is made of a material whose Young's modulus is greater than that of the first pressing member 30. The first pressing member 30 has a column shape that extends in the direction of movement of the movable mold assembly 20.

[0073] For example, if a coil spring is used as the first pressing member 30, the rigidity of the first pressing member 30 needs to be increased in order to form a plate 50 with high rigidity. Therefore, the size of the first pressing member 30 needs to be increased. As a result, the size of the manufacturing apparatus increases.

[0074] In this respect, the above-described structure can easily increase the rigidity of the first pressing member 30 without increasing its size. Therefore, the size of the manufacturing apparatus does not increase.

[0075] (3) The second pushing member 40 has the shape of a column extending in the moving direction of the movable mold assembly 20.

[0076] For example, if a coil spring is used as the second pressing member 40, the rigidity of the second pressing member 40 needs to be increased in order to form a plate 50 with high rigidity. Therefore, the size of the second pressing member 40 needs to be increased. As a result, the size of the manufacturing apparatus increases.

[0077] In this respect, the above-described structure can easily increase the rigidity of the second pressing member 40 without increasing its size. Therefore, the size of the manufacturing device does not increase.

[0078] (4) The first pressing member 30 includes a through hole 30a extending in the moving direction of the movable mold assembly 20. The second pressing member 40 is inserted into the through hole 30a.

[0079] This configuration allows the second pressing member 40 to be easily positioned relative to the first pressing member 30.

[0080] (5) The upper inner periphery 12a of the fixed side unloader 12 is chamfered around the entire circumference so as to have an arc-shaped cross-section.

[0081] Using this structure, the protrusion 22b of the punching punch 22 and the upper inner periphery 12a of the fixed-side unloader 12 apply pressure to the plate 50, which has already been punched out as workpiece 100, causing the inner periphery of the plate 50 to move outward. Therefore, the plate 50 can be removed without interfering with the workpiece 100.

[0082] <Variation>

[0083] The above implementation methods can be modified as follows. The above implementation methods and the following modifications can be combined, as long as the combined modifications do not contradict each other technically.

[0084] The number of second pushing members 40 is not limited to one as described in the above embodiments, but can be more than one. In this case, the number of through holes 30a can be varied depending on the number of second pushing members 40.

[0085] The configuration of the first pushing member 30 and the second pushing member 40 is not limited to that illustrated in the above embodiments, but can be changed. For example, the positions of the first pushing member 30 and the second pushing member 40 can be interchanged. That is, the second pushing member 40 may include a through hole for the first pushing member 30 to be inserted. Furthermore, the second pushing member 40 may be disposed outside the first pushing member 30. In this case, the through hole 30a of the first pushing member 30 can be omitted.

[0086] The shapes of the first pressing member 30 and the second pressing member 40 are not limited to those shown in the above embodiments. For example, the first pressing member 30 may have a cylindrical shape, and the second pressing member 40 may have a polygonal prism shape.

[0087] • The material of the second pressing member 40 is not limited to the hard alloy with tungsten carbide as the main component illustrated in the above embodiments, but can be other alloys, for example, manufactured by sintering powders of other hard metal carbides.

[0088] The second pressing member 40 may include, for example, a coil spring. In this case, it is sufficient as long as the second pressing member 40 has a higher rigidity than the first pressing member 30.

[0089] The material of the first pressing member 30 is not limited to high-grade hard aluminum or ultra-high-grade hard aluminum exemplified in the above embodiments, but may be, for example, other aluminum alloys.

[0090] The first pressing member 30 may include, for example, a coil spring. In this case, it is sufficient as long as the first pressing member 30 has lower rigidity (that is, more elastic) than the second pressing member 40.

[0091] • By applying pressure to the forming punch 21 using the end 42 of the second pressing member 40, forging can be performed on the workpiece 100 in the final forming of the workpiece 100.

[0092] • The structure of the fixed mold body 10a and the movable mold body 20a is not limited to the structure illustrated in the above embodiments, but can be changed.

[0093] • The workpiece manufacturing apparatus according to this disclosure is not limited to an apparatus for manufacturing separators for fuel cells, but can be used to manufacture any workpiece as long as the workpiece is made of a metal sheet.

Claims

1. A workpiece manufacturing apparatus configured to manufacture a workpiece from a metal sheet, the workpiece manufacturing apparatus comprising a fixed mold assembly and a movable mold assembly, wherein, The fixed mold assembly includes: Fixed mold body; and A mold, comprising mold-side forming surfaces configured to shape the plate. The movable mold assembly includes: A movable mold body, configured to be able to approach the fixed mold assembly and move away from the fixed mold assembly; A forming punch includes a punch-side forming surface and a base end face, the punch-side forming surface cooperating with the die-side forming surface to form the plate, and the base end face being on the opposite side of the punch-side forming surface; A blanking punch, which is fixed to the movable die body on the outside of the forming punch, the blanking punch being configured to cooperate with the die to punch the workpiece out of the plate; The first pressing member includes a base end fixed to the movable mold body and an end fixed to the base end face of the forming punch; and The second pressing member includes a base end and an end end fixed to the movable mold body, with a gap provided between the end end and the base end face of the forming punch. The second pressing member has higher rigidity than the first pressing member. The workpiece manufacturing apparatus is configured to bring the movable mold assembly close to the fixed mold assembly, thereby sequentially performing pre-forming of the plate, punching the workpiece from the plate, and finally forming the workpiece by pushing the forming punch with the end of the second pressing member during the compression deformation of the first pressing member. The second pressing member is made of a material with a Young's modulus greater than that of the first pressing member. The second pushing member has the shape of a column extending in the direction of movement of the movable mold assembly. The first pressing member has the shape of a column extending in the moving direction of the movable mold assembly, and the first pressing member has a through hole extending in the moving direction. The second pushing member is inserted into the through hole.

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