Method for manufacturing metal component, mold, and metal component

Abstract

Provided is a method for manufacturing a metal member having excellent corrosion resistance on a cut end surface. This method for manufacturing a metal member is a method for manufacturing a metal member by punching a metal plate (10), the front and rear surfaces of which are covered with a coating layer, by means of a mold (20). A die (20) is provided with a punch (21), a back pad (22), a platen (23), and a die (24). The pressing plate (23) has a protruding portion (231) on the peripheral edge portion of the inner periphery of the surface facing the metal plate (10), the protruding portion (231) of the pressing plate (23) has a shoulder portion having a radius of curvature (R1) on the inner peripheral side, and the radius of curvature (R1) is at least 0.10 times the thickness of the metal plate (10). The manufacturing method comprises the following steps: a step of pressing the protruding part (231) of the pressing plate (23) into the metal plate (10); and a step for punching the metal plate (10) by bringing the punch (21) close to the die (24).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a metal component, a mold, and a metal component. Background Art

[0002] Most steel parts for automobiles and building materials are manufactured by stamping. When corrosion resistance is required for steel parts, cold-rolled steel sheets or hot-rolled steel sheets as blanks are stamped and then painted or plated. However, if a painting process or a plating process is provided after stamping, the operation time and cost will increase.

[0003] In order to solve such a problem, it is considered to use the plated steel sheet as a blank for stamping. However, when the plated steel sheet is subjected to stamping accompanied by cutting such as blanking, the plating layer is cut off at the cut end surface, exposing the steel substrate. If the steel substrate is exposed at the cut end surface in this way, corrosion will occur from the cut end surface. Therefore, a process of plating the cut end surface where the steel substrate is exposed is required, which increases the operation time and cost.

[0004] Japanese Patent Publication No. 2021-133391 describes a mold for cutting composed of a fixed mold and a movable mold. The movable mold is configured to perform the following processing: a first stage cutting process, in which the gap between the fixed mold and the movable mold is c+Δc (Δc>0) as the movable mold cuts the metal plate; a second stage cutting process, in which the gap between the fixed mold and the movable mold is c after the first stage cutting process.

[0005] In Japanese Patent Gazette No. 2017-87294, the following cutting processing method is recorded: a gap between a die and a punch is 1 to 20% of the thickness of the surface-treated steel plate, and a die is used to cut the shoulder of at least one of the die or the punch with a curvature radius of more than 0.12 times the thickness of the surface-treated steel plate.

[0006] Japanese Patent Publication No. 2009-287082 describes a method for cutting a galvanized steel sheet. When a die consisting of a die, a punch, and a die holder is used, the Zn unit area weight of each single side is 10 g / m 2 As described above, when a galvanized steel plate with a thickness of less than 2.0 mm is cut, a die is used in which the shoulder of either the die or the punch on the product steel plate side has an arc with a curvature radius of 0.10 to 0.50 times the thickness of the above-mentioned steel plate, and the shoulder of the other forms a right angle with the shoulder of the die base, and the side surfaces of the die and the die base are aligned, and the gap between the die and the punch is set to less than 1.0% of the thickness of the steel plate to implement the cutting process.

[0007] Japanese Patent Publication No. 2020-32437 describes a cut-off product formed by cutting a multilayer material formed by coating the surface of a base material with a coating material. The cut end surface of the cut-off product includes: a first inclined surface, which is inclined from the first surface toward the center in the plate thickness direction; a second inclined surface, which is inclined from the second surface toward the center in the plate thickness direction; and a fracture surface formed between the first inclined surface and the second inclined surface. At least a portion of the first inclined surface and the second inclined surface is coated with a coating material covering the surface of the base material.

[0008] In addition, as a precision cutting process capable of obtaining a smooth cut end surface, an “opposed die cutting method” is known (for example, refer to Japanese Patent Application Laid-Open Nos. 6-182461, 2000-210731, and 2005-14062).

[0009] Prior art literature

[0010] Patent Literature

[0011] Patent Document 1: Japanese Patent Application Publication No. 2021-133391

[0012] Patent Document 2: Japanese Patent Application Publication No. 2017-87294

[0013] Patent Document 3: Japanese Patent Application Publication No. 2009-287082

[0014] Patent Document 4: Japanese Patent Application Publication No. 2020-32437

[0015] Patent Document 5: Japanese Patent Application Laid-Open No. 6-182461

[0016] Patent Document 6: Japanese Patent Application Publication No. 2000-210731

[0017] Patent Document 7: Japanese Patent Application Publication No. 2005-14062 Summary of the invention

[0018] Problem that the invention aims to solve

[0019] In Japanese Patent Publication No. 2021-133391, Japanese Patent Publication No. 2017-87294 and Japanese Patent Publication No. 2009-287082, a method of winding the plating layer of the blank toward the cut end face by designing the shape of the mold is recorded. However, since these methods can only wind the plating layer back from one direction, there is a limit to the amount of plating components that can be supplied to the cut end face.

[0020] An object of the present invention is to provide a method for manufacturing a metal component having a cut end surface with excellent corrosion resistance, a die capable of manufacturing a metal component having a cut end surface with excellent corrosion resistance, and a metal component having a cut end surface with excellent corrosion resistance.

[0021] Solutions for solving problems

[0022] The manufacturing method of a metal component according to one embodiment of the present invention is a method for manufacturing a metal component by punching a metal plate whose surface and back are covered with a coating layer by a die, the die comprising: a punch; a counter pad, which is arranged opposite to the punch with the metal plate interposed therebetween; a pressing plate, which is arranged on the punch side in the thickness direction of the metal plate and is arranged to surround the punch in the in-plane direction of the metal plate; and a die, which is arranged on the counter pad side in the thickness direction of the metal plate and is arranged to surround the counter pad in the in-plane direction of the metal plate, the pressing plate having a protrusion at the peripheral edge of the inner periphery of the surface opposite to the metal plate, the protrusion of the pressing plate having a shoulder with a curvature radius R1 on the inner periphery, the curvature radius R1 being greater than 0.10 times the thickness of the metal plate, the manufacturing method comprising: a step of pressing the protrusion of the pressing plate into the metal plate; and a step of punching the metal plate by bringing the punch and the die close to each other.

[0023] 14. The method for manufacturing a metal component according to an embodiment of the present invention is a method for manufacturing a metal component by punching a metal plate whose surface and back are covered with a coating layer using a die, the die comprising: a punch; a counter pad, which is arranged opposite to the punch with the metal plate interposed therebetween; a pressure plate, which is arranged on the side of the punch in the thickness direction of the metal plate and is arranged to surround the punch in the in-plane direction of the metal plate; and a die, which is arranged on the side of the counter pad in the thickness direction of the metal plate and is arranged to surround the counter pad in the in-plane direction of the metal plate, the punch having a protrusion at the peripheral edge of the surface opposite to the metal plate, the protrusion of the punch having a shoulder with a curvature radius R3 on the outer peripheral side, the curvature radius R3 being greater than 0.10 times the thickness of the metal plate, the manufacturing method comprising: a step of pressing the protrusion of the punch into the metal plate; and a step of punching the metal plate by bringing the counter pad close to the pressure plate.

[0024] A mold according to one embodiment of the present invention comprises: a punch; a counter pad, which is arranged opposite to the punch via a metal plate as a workpiece; a pressing plate, which is arranged on the punch side in the thickness direction of the metal plate and is arranged to surround the punch in the in-plane direction of the metal plate; and a die, which is arranged on the counter pad side in the thickness direction of the metal plate and is arranged to surround the counter pad in the in-plane direction of the metal plate, the pressing plate having a protrusion at the peripheral edge of the inner circumference of the surface opposite to the metal plate, the protrusion of the pressing plate having a shoulder with a curvature radius R1 on the inner circumference, and the curvature radius R1 is greater than 0.2 mm.

[0025] A mold according to one embodiment of the present invention comprises: a punch; a counter pad, which is arranged opposite to the punch via a metal plate as a workpiece; a pressure plate, which is arranged on the punch side in the thickness direction of the metal plate and is arranged to surround the punch in the in-plane direction of the metal plate; and a die, which is arranged on the counter pad side in the thickness direction of the metal plate and is arranged to surround the counter pad in the in-plane direction of the metal plate, the punch having a protrusion at the peripheral edge of the surface opposite to the metal plate, the protrusion of the punch having a shoulder with a curvature radius R3 on the outer peripheral side, and the curvature radius R3 is greater than 0.2 mm.

[0026] A metal component according to one embodiment of the present invention is a metal component formed by punching a metal plate whose surface and back sides are covered with a coating layer. The metal component has a cut end face formed by the punching process, and the cut end face includes: a cut surface; and a recessed surface, which is a curved surface having a convex shape toward the interior of the component, and at least a portion of the recessed surface is covered by the coating layer.

[0027] A method for manufacturing a metal component according to one embodiment of the present invention is a method for manufacturing a metal component by punching a metal plate whose front and back surfaces are covered with a coating layer using a die.

[0028] The mold has:

[0029] Punch;

[0030] a counter washer disposed opposite to the punch via the metal plate;

[0031] a pressing plate disposed on the punch side in the thickness direction of the metal plate and disposed so as to surround the punch in the in-plane direction of the metal plate; and

[0032] a punching die arranged on the counter-pad side in the thickness direction of the metal plate and arranged to surround the counter-pad in the in-plane direction of the metal plate,

[0033] The mold also has the following structure A) or B):

[0034] A) The pressing plate has a protrusion at the inner peripheral edge of the surface facing the metal plate, and the protrusion of the pressing plate has a shoulder with a curvature radius R1 on the inner peripheral side, and the curvature radius R1 is greater than or equal to 0.10 times the thickness of the metal plate.

[0035] B) The punch has a protrusion at the peripheral edge of the surface facing the metal plate, and the protrusion of the punch has a shoulder with a curvature radius R3 on the outer peripheral side, and the curvature radius R3 is 0.10 times or more of the thickness of the metal plate.

[0036] The manufacturing method comprises:

[0037] The step of pressing the protrusion of the pressing plate into the metal plate; and

[0038] A step of punching the metal plate.

[0039] A mold according to one embodiment of the present invention includes:

[0040] Punch;

[0041] a counter washer disposed opposite to the punch via a metal plate as a workpiece;

[0042] a pressing plate disposed on the punch side in the thickness direction of the metal plate and disposed so as to surround the punch in the in-plane direction of the metal plate; and

[0043] a punching die arranged on the counter-pad side in the thickness direction of the metal plate and arranged to surround the counter-pad in the in-plane direction of the metal plate,

[0044] The mold also has the following structure A) or B):

[0045] A) The pressing plate has a protrusion at the inner peripheral edge of the surface facing the metal plate, and the protrusion of the pressing plate has a shoulder with a curvature radius R1 on the inner peripheral side, and the curvature radius R1 is 0.2 mm or more.

[0046] B) The punch has a protrusion at the peripheral edge of the surface facing the metal plate, and the protrusion of the punch has a shoulder with a curvature radius R3 on the outer peripheral side, and the curvature radius R3 is 0.2 mm or more.

[0047] Effects of the Invention

[0048] According to the present invention, it is possible to obtain a metal component having a cut end surface having excellent corrosion resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a cross-sectional view schematically showing the structure of a mold according to the first embodiment of the present invention.

[0050] Figure 2 Yes Figure 1 A cross-sectional view showing a portion of the pressing plate of the mold extracted.

[0051] Figure 3 Yes means Figure 1 A cross-sectional view of a modified example of a pressing plate of a mold.

[0052] Figure 4 This is a flowchart of a method for manufacturing a metal component according to one embodiment of the present invention.

[0053] Figure 5 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0054] Figure 6 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0055] Figure 7 It is a schematic cross-sectional view showing the vicinity of the protrusion in an enlarged manner.

[0056] Figure 8 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0057] Fig. 9 It is a cross-sectional view schematically showing the structure of a metal member according to one embodiment of the present invention.

[0058] Fig.10 It is a cross-sectional view schematically showing the structure of a mold according to a second embodiment of the present invention.

[0059] Fig.11 Yes Fig.10 A cross-sectional view showing a portion of the die of a mold being extracted.

[0060] Fig.12 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0061] Fig.13 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0062] Fig.14 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0063] Fig.15 It is a cross-sectional view schematically showing the structure of a metal member according to one embodiment of the present invention.

[0064] Fig.16It is a cross-sectional view schematically showing the structure of a mold according to a third embodiment of the present invention.

[0065] Fig.17 Yes Fig.16 A cross-sectional view showing a portion of the die of a mold being extracted.

[0066] Fig.18 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0067] Fig.19 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0068] Fig. 20 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0069] Fig.21 It is a cross-sectional view schematically showing the structure of a metal member according to one embodiment of the present invention.

[0070] Fig. 22 It is a cross-sectional view schematically showing the structure of a mold according to a fourth embodiment of the present invention.

[0071] Fig.23 Yes Fig. 22 A cross-sectional view showing a part of the punch of the die extracted.

[0072] Fig.24 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0073] Fig.25 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0074] Fig.26 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0075] Fig. 27 It is a cross-sectional view schematically showing the structure of a mold according to a fifth embodiment of the present invention.

[0076] Fig.28 Yes Fig. 27 A cross-sectional view showing a partial extraction of the counter pad of the mold.

[0077] Fig.29 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0078] Fig.30 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0079] Fig.31 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0080] Fig.32 It is a cross-sectional view schematically showing the structure of a mold according to a sixth embodiment of the present invention.

[0081] Fig.33 Yes Fig.32 A cross-sectional view showing a partial extraction of the counter pad of the mold.

[0082] Fig.34 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0083] Fig.35 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0084] Fig.36 It is a schematic cross-sectional view during the manufacturing of a metal component.

[0085] Fig.37 This is a diagram schematically showing the distribution of the plating layer when the protrusion of the pressing plate is pressed into the metal plate, which is obtained by CAE.

[0086] Fig.38 : is a graph showing the relationship between the curvature radius R1 and the plating covering distance d.

[0087] Fig.39 This is a diagram for explaining the plating coverage.

[0088] Fig.40 This is a graph showing the plating coverage ratio obtained by CAE. DETAILED DESCRIPTION

[0089] Hereinafter, the embodiments of the present invention will be described in detail with reference to the accompanying drawings. The same or equivalent parts in the accompanying drawings are marked with the same symbols, and no repeated description thereof will be given. The dimensional ratios between the structural components shown in the various drawings do not necessarily represent the actual dimensional ratios.

[0090] [First embodiment]

[0091] [Mold]

[0092] Figure 1 2 is a cross-sectional view schematically showing the structure of a die 20 according to the first embodiment of the present invention. The die 20 is a die used for blanking of a metal plate. The die 20 includes a punch 21, a backing pad 22, a pressing plate (upper punch) 23, and a punch (lower punch) 24. The backing pad 22 is disposed opposite to the punch 21 with the metal plate 10 as the workpiece interposed therebetween. The pressing plate 23 is disposed in the thickness direction ( Figure 1 The punch 21 is arranged on the side of the punch 21 in the z direction and in the in-plane direction of the metal plate 10 ( Figure 1The die 24 is arranged on the counter pad 22 side in the thickness direction of the metal plate 10 and is arranged to surround the counter pad 22 in the in-plane direction of the metal plate 10.

[0093] The punch 21 and the counter washer 22 have a surface 21a and a surface 22a respectively opposite to the metal plate 10. The surface 21a and the surface 22a are both flat surfaces parallel to the metal plate 10. The surface 21a and the surface 22a have the same planar shape (shape of the xy plane). The planar shapes of the surface 21a and the surface 22a can be any shape, and can also be, for example, circular, elliptical, rectangular, etc.

[0094] A gap CL of a predetermined size is provided between the punch 21 and the pressing plate 23. A gap CL of a predetermined size is also provided between the counter pad 22 and the die 24. Preferably, the gap CL has a substantially constant size over the entire periphery of the punch 21 or the counter pad 22.

[0095] The pressing plate 23 has a protrusion 231 at the inner peripheral edge of the surface 23a facing the metal plate 10. Here, the inner peripheral edge of the surface 23a refers to the peripheral edge adjacent to the punch 21.

[0096] A surface 24 a of the die 24 facing the metal plate 10 is a flat surface parallel to the metal plate 10 .

[0097] Figure 2 It is a cross-sectional view showing a part of the pressing plate 23. The protrusion 231 has a shoulder 231a having a curvature radius R1 on the inner peripheral side. Here, the inner peripheral side of the protrusion 231 refers to the side of the protrusion 231 adjacent to the punch 21.

[0098] The radius of curvature R1 of the shoulder 231a is preferably 0.2 mm or more. The radius of curvature R1 is more preferably 0.3 mm or more, more preferably 0.5 mm or more, more preferably 0.8 mm or more, and more preferably 1.0 mm or more. In addition, the radius of curvature R1 of the shoulder 231a is preferably 0.10 times or more of the thickness of the metal plate 10 as the workpiece. The lower limit of the radius of curvature R1 is more preferably 0.20 times the thickness of the metal plate 10, and more preferably 0.30 times the thickness of the metal plate 10. The upper limit of the radius of curvature R1 is preferably 0.40 times the thickness of the metal plate 10.

[0099] The height h1 of the protrusion 231 is preferably 0.25 times or more the thickness of the metal plate 10 as the workpiece. The lower limit of the height h1 is more preferably 0.30 times the thickness of the metal plate 10, and more preferably 0.50 times the thickness of the metal plate 10. The upper limit of the height h1 is preferably 1.00 times the thickness of the metal plate 10.

[0100] The shape of the side opposite to the shoulder 231a of the protrusion 231 is arbitrary. Figure 2 In the example, the protrusion 231 has an inclined portion 231b on the opposite side of the shoulder 231a. The inclined portion 231b has a shape that bulges toward the outer peripheral direction (the direction away from the punch 21) as it approaches the surface 23a. The protrusion 231 has such an inclined portion 231b, which can improve the durability of the protrusion 231. The inclined portion 231b may also be Figure 2 The straight line shape shown in FIG. Figure 3 A curved shape like the inclined portion 231Ab shown.

[0101] [Method for manufacturing metal parts]

[0102] Next, a method for manufacturing a metal component according to an embodiment of the present invention is described. The method for manufacturing a metal component according to this embodiment is a method for manufacturing a metal component by punching a metal plate whose surface and back are covered with a coating layer (hereinafter referred to as a "surface-coated metal plate") using the above-mentioned die 20.

[0103] The parent material of the surface coated metal plate is steel, copper, copper alloy, aluminum, aluminum alloy, etc., but is not limited to this. The manufacturing method of this embodiment is particularly suitable when the parent material of the surface coated metal plate is steel. This is because steel is easy to rust, and the benefit of imparting corrosion resistance is greater. The coating layer is a coating layer, a coating layer, a resin layer, etc. The representative of the coated metal plate is a plated steel plate. The plated steel plate is, for example, a Zn-plated steel plate, an Al-plated steel plate, etc. In the following description, the example in which the coating layer is a representative of the coating layer and the surface-coated metal plate is a representative of the surface coated metal plate is used for description.

[0104] The surface-plated metal plate is more preferably a Zn-plated steel plate. Zn-plating has a sacrificial anti-corrosion effect on the steel plate as the base material. Therefore, it is possible to suppress the corrosion of the exposed portion of the base material formed on the cut end surface by cutting, and the corrosion resistance of the manufactured metal parts can be further improved. Zn-plating can include: hot-dip galvanizing, alloyed hot-dip galvanizing, Zn-Ni plating, Zn-Al plating, Zn-Mg plating, Zn-Al-Mg plating, etc., but is not limited to this.

[0105] The thickness of the surface-plated metal plate is not particularly limited, and is, for example, 1.0 to 6.0 mm.

[0106] The thickness of the coating layer of the surface-coated metal plate (the thickness of one side, the same below) is preferably 15 μm or more. If the coating layer is too thin, the coating layer that can cover the cut end face is insufficient, and sometimes the cut end face cannot be given corrosion resistance. The lower limit of the thickness of the coating layer of the surface-coated metal plate is preferably 30 μm. The upper limit of the thickness of the coating layer of the surface-coated metal plate, although there is no particular restriction, is, for example, 150 μm.

[0107] Figure 4 This is a flow chart of a method for manufacturing a metal component according to an embodiment of the present invention. The manufacturing method includes: a process of placing a surface-plated metal plate (hereinafter referred to as "metal plate 10") on a counter pad 22 and a punch 24 (step S1); a process of pressing a protrusion 231 of a pressing plate 23 into the metal plate 10 (step S2); and a process of bringing the punch 21 and the punch 24 close to punch the metal plate 10 (step S3).

[0108] Below, refer to Figures 5 to 8 These figures are schematic diagrams. As mentioned above, the dimensional ratios between the structural components shown in the figures do not necessarily represent the actual dimensional ratios ( Figure 1 to Figure 3 ,and Fig. 9 The same applies to the following figures).

[0109] The metal plate 10 is placed on the counter pad 22 and the die 24 (see step S1, Figure 5 ). The metal plate 10, both the front and back sides are covered with a plating layer 10a. Figure 5 In the examples above, the end surface of the metal plate 10 is also covered with the plating layer 10 a , but the end surface of the metal plate 10 may not be covered with the plating layer 10 a .

[0110] The protrusion 231 of the pressing plate 23 is pressed into the metal plate 10 (refer to step S2, Figure 6 ). For example, by a punching machine not shown in the drawings, the same pressure is applied to the punch 21 and the counter pad 22 to clamp the metal plate 10 and hold the metal plate 10. In this state, the position of the die 24 is fixed, and the pressing plate 23 is moved in a manner close to the die 24, and the protrusion 231 of the pressing plate 23 is pressed into the metal plate 10. Alternatively, the metal plate 10 may be clamped by applying pressure to the other of the punch 21 and the counter pad 22 while the position of one of the punch 21 and the counter pad 22 is fixed, instead of applying the same pressure to the punch 21 and the counter pad 22.

[0111] Figure 72 is a schematic cross-sectional view showing the vicinity of the protrusion 231 in an enlarged manner. By pressing the protrusion 231 in, the recess 10b is formed in the metal plate 10, and a part of the plating layer 10a is wound back toward the inner wall of the recess 10b. At this time, since the shoulder 231a of the protrusion 231 has a predetermined curvature radius R1, the plating layer 10a can be wound back toward the inner wall 10b1 on the shoulder 231a side of the two inner walls 10b1 and 10b2 of the recess 10b.

[0112] The inner wall 10b1 is located inward (toward the center of the punch 21) of the surface of the protrusion 231 in the in-plane direction (xy in-plane direction) of the metal plate 10. In other words, a small gap is formed between the inner wall 10b1 and the protrusion 231. This is because the portion pressed by the protrusion 231 moves toward the center of the punch 21 due to plastic flow.

[0113] Although in Figure 7 2 shows a case where the plating layer 10a also goes around toward the inner wall 10b2 on the inclined portion 231b side, but the plating layer 10a does not need to go around toward the inner wall 10b2.

[0114] The punch 21 and the die 24 are brought close to each other to punch out the metal plate 10 (see step S3, Figure 8 ). For example, the metal plate 10 is held by applying pressure to the pressing plate 23 while the position of the punch 24 is fixed, and the pressing plate 23 and the punch 24 clamp the metal plate 10. In this state, the punch 21 is moved so as to approach the punch 24 to punch the metal plate 10. At this time, a pressure smaller than the pressure applied to the punch 21 may be applied to the counter pad 22 to support the metal plate 10 from the bottom.

[0115] In addition, instead of applying pressure to the press plate 23 with the die 24 fixed in position, pressure may be applied to the die 24 with the press plate 23 fixed in position, or the metal plate 10 may be clamped by applying equal pressure to the press plate 23 and the die 24 .

[0116] In addition, the metal plate 10 may be punched by moving the die 24 instead of moving the punch 21. That is, the metal plate 10 may be punched by moving the die 24 so as to approach the punch 21 while the metal plate 10 is clamped by the punch 21 and the counter washer 22. In addition, the metal plate 10 may be punched by moving both the punch 21 and the die 24.

[0117] Thus, the metal plate 10 is separated into the metal component 11 and the residual portion 119. In the present embodiment, the portion sandwiched by the punch 21 and the counter washer 22 becomes the metal component 11. At this time, at the cut end surface 111 of the metal component 11, part of the plating layer 10a is wound back from one surface of the metal plate 10 (the surface in contact with the counter washer 22).

[0118] Step S2 and step S3 can also be performed as one process by using a double-action punching machine or a device capable of independently driving the punch 21 and the pressing plate 23. However, it is more preferable to perform step S2 and step S3 separately because the structure of the device can be simplified. For example, the following simple structure can be formed: in step S2, the pressing plate 23 is used only by the descent of the punching machine to form, and in step S3, the pressing plate 23 is pressurized by a spring or the like to descend the punch 21 to perform blanking.

[0119] In the above description, the case where the metal plate 10 is placed on the counter pad 22 and the die 24 and then the metal plate 10 is processed is described. However, the configuration of the die 20 in the up-down direction (z direction) may be reversed, and the metal plate 10 may be placed on the punch 21 and the pressing plate 23 and then processed. In this case, the process of pressing the protrusion 231 of the pressing plate 23 into the metal plate 10 (step S2) and the process of bringing the punch 21 and the die 24 close to punch the metal plate 10 (step S3) can also be performed in the same manner.

[0120] [Metal parts]

[0121] Fig. 9 1 is a cross-sectional view schematically showing the structure of a metal component 11 according to one embodiment of the present invention. The metal component 11 is formed by punching a surface-plated metal plate. The metal component 11 has a cut end surface 111 formed by the punching process.

[0122] The metal component 11 has a first surface 112 and a second surface 113, which is the opposite surface of the first surface 112, in addition to the cut end surface 111. The planar shape (shape of the xy plane) of the first surface 112 and the second surface 113 can be any shape. The first surface 112 and the second surface 113 are covered with a coating layer 10a. The coating layer 10a is a coating layer derived from a coating layer of a surface-coated metal plate as a blank.

[0123] The cut end surface 111 includes a cut surface 111 a , a recessed surface 111 b , and a collapsed edge 111 e adjacent to the recessed surface 111 b .

[0124] The cut end surface 111 further includes a fracture surface 111c and a collapsed edge (second collapsed edge) 111d adjacent to the cut surface 111a. The fracture surface 111c is located between the cut surface 111a and the recessed surface 111b in the thickness direction (z direction) of the metal component 11. The collapsed edge 111d is located on the opposite side of the recessed surface 111b with respect to the cut surface 111a in the thickness direction (z direction) of the metal component 11. In other words, the cut surface 111a is located between the recessed surface 111b and the collapsed edge 111d in the thickness direction (z direction) of the metal component 11.

[0125] Depending on processing conditions and the like, the cut end surface 111 may not have the fracture surface 111 c .

[0126] The concave surface 111b is formed by pressing the protrusion 231 into the metal plate 10 ( Figure 4 The collapsed edges 111d and 111e are curved surfaces that are convex toward the outside of the component, whereas the concave surface 111b is a curved surface that is convex toward the inside of the component.

[0127] The concave surface 111b is a surface that is concave by an amount W1 compared to the cut surface 111a. The amount W1 is set as the distance between the tangent line of the cut surface 111a and the most concave position of the concave surface 111b in the cross section of the metal component 11. The amount W1 is, for example, 0.01 to 0.15 times the thickness of the metal component 11. The lower limit of the amount W1 is preferably 0.02 times the thickness of the metal component 11. The upper limit of the amount W1 is preferably 0.10 times the thickness of the metal component 11.

[0128] In this embodiment, at least a portion of the recessed surface 111 b is covered with the plating layer 10 a , thereby improving the corrosion resistance of the cut end surface 111 .

[0129] In addition to at least a portion of the recessed surface 111b being covered by the plating layer 10a, more than 50% of the combined area of ​​the recessed surface 111b and the collapsed edge 111e adjacent to the recessed surface 111b is preferably covered by the plating layer 10a. More specifically, when the dimensions of the recessed surface 111b and the collapsed edge 111e along the thickness direction of the metal plate 10 are defined as t1 and t2, respectively, and the dimension of the portion covered by the plating layer 10a in the combined area of ​​the recessed surface 111b and the collapsed edge 111e along the thickness direction of the metal plate 10 is defined as d, d / (t1+t2) is preferably greater than 0.5 (greater than 50%). For example, it is possible to measure the cut end surface 111 using an energy dispersive X-ray analyzer (EDX) to determine whether it is covered by the plating layer 10a.

[0130] More preferably, d / (t1+t2) is 75% or more. Most preferably, the entire recessed surface 111b is covered with the plating layer 10a.

[0131] The collapsed edge 111d adjacent to the cut surface 111a is usually entirely covered by the plating layer 10a. At least a portion of the cut surface 111a is covered by the plating layer 10a. The fracture surface 111c is usually not covered by the plating layer 10a.

[0132] The plating layer 10a covering the cut surface 111a, the recessed surface 111b, the collapsed edge 111d, and the collapsed edge 111e is the same as the plating layer 10a covering the first surface 112 and the second surface 113, and is a plating layer derived from the plating layer of the surface-plated metal plate as the blank. Therefore, the plating layer 10a covering the cut surface 111a, the recessed surface 111b, and the collapsed edge 111d is the same as the plating layer 10a covering the first surface 112 and the second surface 113.

[0133] [Effects of this embodiment]

[0134] The above describes the mold 20, the method for manufacturing a metal component, and the metal component 11 according to the first embodiment of the present invention. The pressing plate 23 of the mold 20 has a protrusion 231 at the inner peripheral edge of the surface 23a facing the metal plate 10. The protrusion 231 has a curvature radius R1 ( Figure 2 ) shoulder 231a. By pressing the protrusion 231 into the metal plate 10, a recess 10b ( Figure 7 ), and partially the plating layer 10a is wound back toward the inner wall of the recess 10b. The shoulder 231a of the protrusion 231 has a predetermined curvature radius R1, so that the plating layer 10a can be wound back toward the inner wall 10b1 on the shoulder 231a side of the two inner walls 10b1 and 10b2 of the recess 10b. The inner wall 10b1 corresponds to the recessed surface 111b ( Fig. 9 ). At least a portion of the recessed surface 111b is covered by the plating layer 10a.

[0135] According to the mold 20 of the present embodiment and the method for manufacturing a metal component of the present embodiment, the plating layer 10a can be supplied from both sides in the thickness direction (z direction) of the cut end surface 111. That is, the plating layer 10a can be supplied not only from the second surface 113 but also from the first surface 112. Specifically, in addition to the collapsed edge 111d and the cut surface 111a, at least a portion of the concave surface 111b can also be covered with the plating layer 10a. Thus, the metal component 11 having excellent corrosion resistance on the cut end surface 111 can be obtained.

[0136] Hereinafter, the second to sixth embodiments of the present invention will be described. In these descriptions, the parts different from the first embodiment will be mainly described, and the description of the overlapping parts will be appropriately omitted.

[0137] [Second embodiment]

[0138] [Mold]

[0139] Fig.10 2 is a cross-sectional view schematically showing the structure of a mold 30 according to a second embodiment of the present invention. The mold 30 includes a punch 34 instead of the mold 20 ( Figure 1 ) of the die 24.

[0140] The die 34 has a protrusion 341 at the inner peripheral edge of the surface 34a facing the metal plate 10. Here, the inner peripheral edge of the surface 34a refers to the peripheral edge adjacent to the counter pad 22.

[0141] Fig.11 It is a cross-sectional view showing a part of the punch 34. The punch 34 has a shoulder 341a having a curvature radius R2 on the inner peripheral side. Here, the inner peripheral side of the protrusion 341 refers to the side of the protrusion 341 adjacent to the counter pad 22.

[0142] The preferred range of the curvature radius R2 of the shoulder 431a is the same as the curvature radius R1 of the shoulder 231a of the protrusion 231 of the pressing plate 23 ( Figure 2 The radius of curvature R1 and the radius of curvature R2 may be the same or different.

[0143] The preferred range of the height h2 of the protrusion 431 is the same as the height h1 of the protrusion 231 of the pressing plate 23 ( Figure 2 The height h1 and the height h2 may be the same or different.

[0144] [Method for manufacturing metal parts]

[0145] The manufacturing method of the metal component of the present embodiment is a method for manufacturing the metal component by punching the surface-plated metal plate using the above-mentioned die 30. The manufacturing method includes: placing the metal plate 10 on the counter pad 22 and the die 34; pressing the protrusion 231 of the pressing plate 23 and the protrusion 341 of the die 34 into the metal plate 10; and bringing the punch 21 and the die 34 close to punch the metal plate 10. Figure 12 to Figure 14 Each process is described.

[0146] The metal plate 10 is placed on the counter pad 22 and the die 34 (see Fig.12). In the present embodiment as well, the arrangement of the die 30 in the vertical direction (z direction) may be reversed, and the metal plate 10 may be placed on the punch 21 and the pressing plate 23 before processing.

[0147] The protrusion 231 of the pressing plate 23 and the protrusion 341 of the die 34 are pressed into the metal plate 10 (see Fig.13 ). For example, the metal plate 10 is clamped by the punch 21 and the counter pad 22 to hold the metal plate 10. In this state, the pressing plate 23 and the die 34 are moved so as to approach each other, and the protrusion 231 of the pressing plate 23 and the protrusion 341 of the die 34 are pressed into the metal plate 10. Instead of moving both the pressing plate 23 and the die 34, one of the pressing plate 23 and the die 34 may be fixed and only the other may be moved. In this case, by appropriately controlling the pressure applied to the punch 21 and the counter pad 22, the protrusion 231 of the pressing plate 23 and the protrusion 341 of the die 34 can also be pressed into the metal plate 10.

[0148] The punch 21 and the die 34 are brought close to each other to punch out the metal plate 10 (see Fig.14 ). Thus, the metal plate 10 is separated into the metal member 12 and the residual portion 129. In the present embodiment, the portion sandwiched by the punch 21 and the counter washer 22 becomes the metal member 12.

[0149] [Metal parts]

[0150] Fig.15 1 is a cross-sectional view schematically showing the structure of a metal component 12 according to an embodiment of the present invention. The metal component 12 is a metal component formed by punching a surface-plated metal plate. The metal component 12 has a cut end face 121 formed by punching. In addition to the cut end face 121, the metal component 12 also has a first surface 122 and a second surface 123. The first surface 122 and the second surface 123 are covered with a plating layer 10a.

[0151] The cut end surface 121 includes a cut surface 121 a , a recessed surface 121 b , and a collapsed edge 121 e adjacent to the recessed surface 121 b .

[0152] The cut end surface 121 further includes a fracture surface 121c, a second recessed surface 121d, and a collapsed edge 121f adjacent to the second recessed surface 121d. The fracture surface 121c is located between the cut surface 121a and the recessed surface 121b in the thickness direction (z direction) of the metal component 12. The second recessed surface 121d is located on the opposite side of the recessed surface 121b with respect to the cut surface 121a in the thickness direction (z direction) of the metal component 12. In other words, the cut surface 121a is located between the recessed surface 121b and the second recessed surface 121d in the thickness direction (z direction) of the metal component 12.

[0153] In the present embodiment as well, the cut end surface 121 may not have the fracture surface 121 c depending on processing conditions and the like.

[0154] The concave surface 121b and the second concave surface 121d are also curved surfaces that are convex toward the inside of the component. The range of the concave amount W2 of the concave surface 121b and the range of the concave amount W3 of the second concave surface 121d are the same as the concave amount W1 ( Fig. 9 The depression amount W3 of the second depression surface 121d tends to be smaller than the depression amount W2 of the depression surface 121b.

[0155] In the present embodiment, at least a portion of the recessed surface 121b is covered by the plating layer 10a. Thus, the corrosion resistance of the cut end surface 121 can be improved. In the present embodiment, in addition to at least a portion of the recessed surface 121b being covered by the plating layer 10a, preferably, more than 50% of the combined area of ​​the recessed surface 121b and the collapsed edge 121e adjacent to the recessed surface 121b is covered by the plating layer 10a. The preferred ratio of the combined area of ​​the recessed surface 121b and the collapsed edge 121e covered by the plating layer 10a is the same as that of the metal component 11.

[0156] The collapsed edge 121f adjacent to the second recessed surface 121d is usually entirely covered by the plating layer 10a. At least a portion of the second recessed surface 121d is covered by the plating layer 10a. The cut surface 121a may be entirely covered by the plating layer 10a, partially covered, or not covered at all. The fracture surface 121c is usually not covered by the plating layer 10a.

[0157] [Effects of this embodiment]

[0158] The die 30, the method for manufacturing a metal component, and the metal component 12 according to the second embodiment of the present invention have been described above. According to the present embodiment, by pressing the protrusion 231 and the protrusion 341 into the metal plate 10, the plating layer 10a can be supplied from both sides in the thickness direction of the metal plate 10. Furthermore, when the remaining central portion is punched, the shoulder 341a of the protrusion 341 has a predetermined curvature radius R2, so that more plating layer 10a can be wound back toward the cut end surface 121. Thus, the metal component 12 having the cut end surface 121 having excellent corrosion resistance can be obtained.

[0159] [Third Embodiment]

[0160] [Mold]

[0161] Fig.162 is a cross-sectional view schematically showing the structure of a mold 40 according to a third embodiment of the present invention. The mold 40 includes a punch 44 instead of the mold 20 ( Figure 1 ) of the die 24.

[0162] Fig.17 It is a cross-sectional view showing a part of the die 44 extracted. The surface 44a of the die 44 opposite to the metal plate 10 is a flat surface parallel to the metal plate 10. The die 44 has a double-layer shoulder on the inner peripheral side. Here, the inner peripheral side of the die 44 refers to the side adjacent to the counter pad 22. The double-layer shoulder includes a first shoulder 441 and a second shoulder 442. The second shoulder 442 is located farther away from the metal plate 10 than the first shoulder 441 in the thickness direction (z direction) of the metal plate 10, and is located closer to the counter pad 22 than the first shoulder 441 in the in-plane direction (xy in-plane direction) of the metal plate 10.

[0163] The layer height sh1 of the double-layer shoulder is preferably greater than 0 times and less than 0.50 times the thickness of the metal plate 10 as the workpiece. The layer height sh1 is set to be the distance along the z direction from the surface 44a to the vertex (the position closest to the surface 44a) of the second shoulder 442. The lower limit of the layer height sh1 is preferably 0.10 times the thickness of the metal plate 10, and more preferably 0.20 times.

[0164] The width w1 of the double-layer shoulder is preferably 0.10 to 0.70 times the thickness of the metal plate 10 as the workpiece. The width w1 is set to be the distance along the xy plane from the side surface of the first shoulder 441 to the side surface of the second shoulder 442 (the inner peripheral surface of the die 44). The lower limit of the width w1 is preferably 0.10 times the thickness of the metal plate 10, and more preferably 0.20 times.

[0165] The curvature radius Rp2 of the second shoulder 442 is preferably 0.1 mm or more. The curvature radius Rp2 is preferably 0.2 mm or more, and more preferably 0.3 mm or more. In addition, the curvature radius Rp2 of the second shoulder 442 is preferably 0.10 times or more of the thickness of the metal plate 10 as the workpiece. The lower limit of the curvature radius Rp2 is more preferably 0.20 times the thickness of the metal plate 10. The upper limit of the curvature radius Rp2 is preferably 0.70 times the thickness of the metal plate 10.

[0166] The curvature radius Rp1 of the first shoulder portion 441 is not particularly limited. The curvature radius Rp1 is, for example, 0 to 0.50 times the curvature radius Rp2. The curvature radius Rp1 may also be 0.

[0167] [Method for manufacturing metal parts]

[0168] The manufacturing method of the metal component of the present embodiment is a method for manufacturing the metal component by punching the surface-plated metal plate using the above-mentioned die 40. The manufacturing method includes: a step of placing the metal plate 10 on the counter pad 22 and the die 44; a step of pressing the protrusion 231 of the pressing plate 23 into the metal plate 10; and a step of bringing the punch 21 and the die 44 close to punch the metal plate 10. Figure 18 to Figure 20 Each process is described.

[0169] The metal plate 10 is placed on the counter pad 22 and the die 44 (see Fig.18 ). In the present embodiment as well, the arrangement of the die 40 in the vertical direction (z direction) may be reversed, and the metal plate 10 may be placed on the punch 21 and the pressing plate 23 before processing.

[0170] The protrusion 231 of the pressing plate 23 is pressed into the metal plate 10 (see Fig.19 For example, the metal plate 10 is held by the punch 21 and the counter washer 22 . In this state, the pressing plate 23 is moved close to the die 44 , and the protrusion 231 of the pressing plate 23 is pressed into the metal plate 10 .

[0171] The punch 21 and the die 44 are brought close to each other to punch out the metal plate 10 (see Fig. 20 ). Thus, the metal plate 10 is separated into the metal member 13 and the residual portion 139. In the present embodiment, the portion sandwiched by the punch 21 and the counter washer 22 becomes the metal member 13.

[0172] [Metal parts]

[0173] Fig.21 1 is a cross-sectional view schematically showing the structure of a metal component 13 according to an embodiment of the present invention. The metal component 13 is a metal component formed by punching a surface-plated metal plate. The metal component 13 has a cut end face 131 formed by punching. In addition to the cut end face 131, the metal component 13 also has a first surface 132 and a second surface 133. The first surface 132 and the second surface 133 are covered by the plating layer 10a.

[0174] The cut end surface 131 includes a cut surface 131a, a recessed surface 131b, a fracture surface 131c, a collapsed edge 131d, and a collapsed edge 131e. Fig. 9 ) is substantially the same as the cut end face 111. In the cut end face 131, more specifically, the size of the collapsed edge 131d is the same as the collapsed edge 111d ( Fig. 9 ) is relatively large, and accordingly, the ratio of the cut surface 131a and the fracture surface 131c is different from that of the metal component 11.

[0175] [Effects of this embodiment]

[0176] According to the present embodiment, when the metal plate 10 is punched, the width w1 ( Fig.17 ) and the gap between the punch 21 and the die 44 is enlarged, and the collapsed edge of the cut end surface is enlarged. As a result, the portion in contact with the second shoulder 442 becomes moderately inclined, and when forming is performed using the second shoulder 442, it is easier to move the plating layer 10a to the cut end surface. As a result, a metal component 13 having a cut end surface 131 with excellent corrosion resistance can be obtained.

[0177] [Fourth embodiment]

[0178] [Mold]

[0179] Fig. 22 2 is a cross-sectional view schematically showing the structure of a die 50 according to a fourth embodiment of the present invention. The die 50 includes a punch 51 instead of the die 20 ( Figure 1 ) of the punch 21, and a pressing plate 53 is provided to replace the pressing plate 23.

[0180] The punch 51 has a protrusion 511 on the peripheral edge of a surface 51 a facing the metal plate 10 .

[0181] A surface 53 a of the pressing plate 53 facing the metal plate 10 is a flat surface parallel to the metal plate 10 .

[0182] Fig.23 It is a cross-sectional view showing a part of the punch 51 extracted and shown. The protrusion 511 has a shoulder 511a with a curvature radius R3 on the outer peripheral side. Here, the outer peripheral side of the protrusion 511 refers to the side of the protrusion 511 adjacent to the pressing plate 53.

[0183] The preferred range of the curvature radius R3 of the shoulder 511a is the same as the curvature radius R1 ( Figure 2 The preferred range of the height h3 of the protrusion 511 is the same as the height h1 ( Figure 2 )same.

[0184] [Method for manufacturing metal parts]

[0185] The manufacturing method of the metal component of the present embodiment is a method for manufacturing the metal component by punching the surface-plated metal plate using the above-mentioned die 50. The manufacturing method includes: a step of placing the metal plate 10 on the counter pad 22 and the die 24; a step of pressing the protrusion 511 of the punch 51 into the metal plate 10; and a step of making the counter pad 22 and the pressing plate 53 approach each other to punch the metal plate 10. Figure 24 to Figure 26 Each process is described.

[0186] The metal plate 10 is placed on the counter pad 22 and the die 24 (see Fig.24 ). In the present embodiment as well, the arrangement of the die 50 in the vertical direction (z direction) can be reversed, and the metal plate 10 can be placed on the punch 51 and the pressing plate 53 and then processed.

[0187] The protrusion 511 of the punch 51 is pressed into the metal plate 10 (see Fig.25 For example, the metal plate 10 is held by clamping the metal plate 10 with the pressing plate 53 and the die 24 . In this state, the punch 51 is moved so as to approach the counter pad 22 , and the protrusion 511 of the punch 51 is pressed into the metal plate 10 .

[0188] The metal plate 10 is punched by bringing the counter pad 22 and the pressing plate 53 close to each other (see Fig.26 ). Thus, the metal plate 10 is separated into the metal member 14 and the residual portion 149. In the present embodiment, the portion sandwiched between the pressing plate 53 and the die 24 becomes the metal member 14.

[0189] [Metal parts]

[0190] The metal member 14 has the same structure as the metal member 11 ( Fig. 9 ) The same structure. That is, the metal component 14 is a metal component formed by punching a surface-plated metal plate, and has a cut end surface formed by punching. The cut end surface has a cut surface and a recessed surface, and at least a portion of the recessed surface is covered by the plating layer 10a.

[0191] [Effects of this embodiment]

[0192] The mold 50, the method for manufacturing a metal component, and the metal component 14 according to the fourth embodiment of the present invention have been described above. The mold 50 and the method for manufacturing a metal component according to the present embodiment can also cause the plating layer 10a to be wound back from both sides of the cut end surface in the thickness direction. Thus, a metal component 14 having a cut end surface having excellent corrosion resistance can be obtained.

[0193] [Fifth embodiment]

[0194] [Mold]

[0195] Fig. 27 2 is a cross-sectional view schematically showing the structure of a mold 60 according to a fifth embodiment of the present invention. The mold 60 includes a counter pad 62 instead of the mold 50 ( Fig. 22 )'s counter pad 22.

[0196] The counter washer 62 has a protrusion 621 on the peripheral edge of a surface 62 a facing the metal plate 10 .

[0197] Fig.28 2 is a cross-sectional view showing a part of the counter washer 62. The protrusion 621 has a shoulder 621a having a curvature radius R4 on the outer peripheral side. Here, the outer peripheral side of the protrusion 621 refers to the side of the protrusion 621 adjacent to the die 24.

[0198] The preferred range of the curvature radius R4 of the shoulder 621a is the same as the curvature radius R1 ( Figure 2 ) are the same. The radius of curvature R3( Fig.23 ) can be the same as or different from the radius of curvature R4.

[0199] The preferred range of the height h4 of the protrusion 621 is the same as the height h1 of the protrusion 231 of the pressing plate 23 ( Figure 2 ) are the same. Height h3( Fig.23 ) can be the same as or different from the height h4.

[0200] [Method for manufacturing metal parts]

[0201] The manufacturing method of the metal component of the present embodiment is a method for manufacturing the metal component by punching the surface-plated metal plate using the above-mentioned die 60. The manufacturing method includes: a step of placing the metal plate 10 on the counter pad 62 and the punch die 24; a step of pressing the protrusion 511 of the punch 51 and the protrusion 621 of the counter pad 62 into the metal plate 10; and a step of punching the metal plate 10 by bringing the counter pad 62 and the pressing plate 53 close to each other. Figure 29 to Figure 31 Each process is described.

[0202] The metal plate 10 is placed on the counter pad 62 and the die 24 (see Fig.29 ). In the present embodiment as well, the arrangement of the die 60 in the vertical direction (z direction) can be reversed, and the metal plate 10 can be placed on the punch 51 and the pressing plate 53 and then processed.

[0203] The protrusion 511 of the punch 51 and the protrusion 621 of the counter washer 62 are pressed into the metal plate 10 (see Fig.30 For example, the metal plate 10 is held by clamping the metal plate 10 with the pressing plate 53 and the die 24. In this state, the punch 51 and the counter washer 62 are moved toward each other, and the protrusion 511 of the punch 51 and the protrusion 621 of the counter washer 62 are pressed into the metal plate 10.

[0204] The metal plate 10 is punched by bringing the counter pad 62 and the pressing plate 53 close to each other (see Fig.31). Thus, the metal plate 10 is separated into the metal member 15 and the residual portion 159. In the present embodiment, the portion sandwiched between the pressing plate 53 and the die 24 becomes the metal member 15.

[0205] [Metal parts]

[0206] The metal member 15 has the same configuration as the metal member 12 ( Fig.15 ) The same structure. That is, the metal component 15 is a metal component formed by punching a surface-plated metal plate, and has a cut end surface formed by punching. The cut end surface has a cut surface and a recessed surface, and at least a portion of the recessed surface is covered by the plating layer 10a.

[0207] [Effects of this embodiment]

[0208] The die 60, the method for manufacturing a metal component, and the metal component 15 according to the fifth embodiment of the present invention have been described above. According to this embodiment, by pressing the protrusion 511 and the protrusion 621 into the metal plate 10, the plating layer 10a can be supplied from both sides in the thickness direction of the metal plate 10. Furthermore, when the remaining central portion is punched, the shoulder 621a of the protrusion 621 has a predetermined curvature radius R4, so that more plating layer 10a can be wound back toward the cut end surface. Thus, the metal component 15 having excellent corrosion resistance on the cut end surface can be obtained.

[0209] [Sixth embodiment]

[0210] [Mold]

[0211] Fig.32 2 is a cross-sectional view schematically showing the structure of a mold 70 according to a sixth embodiment of the present invention. The mold 70 includes a counter pad 72 instead of the mold 50 ( Fig. 22 )'s counter pad 22.

[0212] Fig.33 It is a cross-sectional view showing a part of the counter pad 72 extracted. The surface 72a of the counter pad 72 opposite to the metal plate 10 is a flat surface parallel to the metal plate 10. The counter pad 72 has a double-layer shoulder on the outer peripheral side. Here, the outer peripheral side of the counter pad 72 refers to the side adjacent to the die 24. The double-layer shoulder includes a first shoulder 721 and a second shoulder 722. The second shoulder 722 is located farther away from the metal plate 10 than the first shoulder 721 in the thickness direction (z direction) of the metal plate 10, and is located closer to the die 24 than the first shoulder 721 in the in-plane direction (xy in-plane direction) of the metal plate 10.

[0213] The preferred range of the layer height sh2 of the double-layer shoulder is the same as the layer height sh1 of the double-layer shoulder of the punch 44 ( Fig.17 The preferred range of the width w2 of the double-layer shoulder is also the same as the width w1 of the double-layer shoulder of the punch 44 ( Fig.17 )same.

[0214] The preferred range of the curvature radius Rp4 of the second shoulder 722 is the same as the curvature radius Rp2 ( Fig.17 ) are the same. The curvature radius Rp3 of the first shoulder portion 721 is not particularly limited. The curvature radius Rp3 is, for example, 0 to 0.5 times the curvature radius Rp4. The curvature radius Rp3 may also be 0.

[0215] [Method for manufacturing metal parts]

[0216] The manufacturing method of the metal component of the present embodiment is a method for manufacturing the metal component by punching the surface-plated metal plate using the above-mentioned die 70. The manufacturing method includes: a step of placing the metal plate 10 on the counter pad 72 and the die 24; a step of pressing the protrusion 511 of the punch 51 into the metal plate 10; and a step of making the counter pad 72 and the pressing plate 53 approach each other to punch the metal plate 10. Figure 34 to Figure 36 Each process is described.

[0217] The metal plate 10 is placed on the counter pad 72 and the die 24 (see Fig.34 ). In the present embodiment as well, the arrangement of the die 70 in the vertical direction (z direction) can be reversed, and the metal plate 10 can be placed on the punch 51 and the pressing plate 53 and then processed.

[0218] The protrusion 511 of the punch 51 is pressed into the metal plate 10 (see Fig.35 For example, the metal plate 10 is held by clamping the metal plate 10 with the pressing plate 53 and the die 24 . In this state, the punch 51 is moved so as to approach the counter pad 72 , and the protrusion 511 of the punch 51 is pressed into the metal plate 10 .

[0219] The metal plate 10 is punched by bringing the counter pad 72 and the pressing plate 53 close to each other (see Fig.36 ). Thus, the metal plate 10 is separated into the metal member 16 and the residual portion 169. In the present embodiment, the portion sandwiched between the pressing plate 53 and the die 24 becomes the metal member 16.

[0220] [Metal parts]

[0221] The metal member 16 has the same structure as the metal member 13 ( Fig.21) The same structure. That is, the metal component 16 is a metal component formed by punching a surface-plated metal plate, and has a cut end surface formed by punching. The cut end surface has a cut surface and a recessed surface, and at least a portion of the recessed surface is covered by the plating layer 10a.

[0222] [Effects of this embodiment]

[0223] According to the present embodiment, when the metal plate 10 is punched, the width w2 ( Fig.33 ) and the gap between the counter pad 72 and the pressing plate 53 becomes larger, and the collapsed edge of the cut end surface becomes larger. As a result, the portion in contact with the second shoulder 722 becomes moderately inclined, and when forming is performed using the second shoulder 722, it is easy to move the plating layer 10a to the cut end surface. As a result, a metal component 16 having excellent corrosion resistance on the cut end surface can be obtained.

[0224] Example

[0225] Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited to these examples.

[0226] The CAE analysis was performed on the mold 20 ( Figure 1 ) The behavior of the plating layer when processing a surface-plated metal plate. The software used was LS-DYNA (registered trademark). Fig.37 2 is a diagram schematically showing the distribution of the plating layer when the protrusion 231 of the pressing plate 23 is pressed into the surface plated metal plate, obtained by CAE. The plate thickness of the target surface plated metal plate is set to 3.2 mm, and the pressing depth S is set to 1.6 mm regardless of the plating thickness. Figure 2 ) was analyzed and the relationship between the curvature radius R1 and the plating covering distance (the dimension of the portion covered by the plating layer along the thickness direction of the surface plated metal plate) d was investigated.

[0227] The results are shown in Fig.38 .like Fig.38 As shown, it is known that the larger the curvature radius R1 is, the larger the area covered by the plating layer can be.

[0228] Next, the CAE analysis was performed using the mold 20 ( Figure 1 )、Mold 30( Fig.10 ) and mold 40( Fig.16 ) is the coating coverage of the cut end surface when the surface-plated metal plate is punched. The plate thickness of the surface-plated metal plate of interest is set to 3.2 mm, and the plating thickness is not considered. Gap CL ( Figure 1 etc.) is set to 0.1mm.

[0229] The protrusion 231 of the pressing plate 23 ( Figure 2 ) is set to 1.6 mm, and the curvature radius R1 of the shoulder 231a is set to 0.9 mm. Fig.10 ) analysis, the protrusion 341 ( Fig.11 ) is set to 1.6 mm, and the radius of curvature R2 of the shoulder 341a is set to 0.9 mm. Fig.16 ) analysis, the first shoulder 441 ( Fig.17 ) is set to 0.05 mm, the curvature radius Rp1 of the second shoulder 442 is set to 0.5 mm, the layer height sh1 is set to 0.5 mm, and the width w1 is set to 0.5 mm. As a comparative example, in the mold 20 ( Figure 1 ), the protrusion 231 ( Figure 2 )'s shoulder 231a has a curvature radius R1 of 0 mm, and other conditions are the same as those described above. This case is also analyzed.

[0230] and Fig.37 Similarly, set points simulating the plating layer on the board surface and estimate the plating coverage distance by tracking their movement. Fig.39 As shown, at the cut end face, the dimensions of the portion covered by the plating layer along the thickness direction of the surface plated metal plate are set to d1 and d2 respectively, and the value obtained by dividing the sum of d1+d2 by the plate thickness T ((d1+d2) / T) is set as the plating coverage rate.

[0231] The results are shown in Fig.40 .like Fig.40 As shown, it was confirmed that the plating coverage ratio can be improved by using the mold 20, the mold 30, or the mold 40, compared with the case of using the mold of the comparative example.

[0232] Although the embodiments of the present invention have been described above, the above embodiments are merely examples for implementing the present invention. Therefore, the present invention is not limited to the above embodiments, and the above embodiments can be appropriately modified and implemented within the scope of the invention.

[0233] Description of Reference Numerals

[0234] 10. Metal plate (surface-coated metal plate); 10a. Coating layer (coating layer); 11, 12, 13, 14, 15, 16. Metal parts; 111, 121, 131. Cut end faces; 111a, 121a, 131a. Cut surfaces; 111b, 121b, 131b. Concave surfaces; 111c, 121c, 131c. Fracture surfaces; 111d, 131d. Collapsed edges; 121d, second recessed surface; 111e, 121e, 131e, collapsed edge; 121f, collapsed edge; 119, 129, 139, 149, 159, 169, residual portion; 20, 30, 40, 50, 60, mold; 21, 51, punch; 22, 62, 72, counter pad; 23, 53, pressing plate; 231, protrusion; 231a, shoulder; 24, 34, 44, die.

Claims

1. A method for manufacturing a metal component, comprising punching a metal plate whose front and back surfaces are covered with a coating layer using a die, wherein: The mold has: Punch; a counter washer disposed opposite to the punch via the metal plate; a pressing plate disposed on the punch side in the thickness direction of the metal plate and disposed so as to surround the punch in the in-plane direction of the metal plate; as well as a punching die arranged on the counter-pad side in the thickness direction of the metal plate and arranged to surround the counter-pad in the in-plane direction of the metal plate, The pressing plate has a protrusion at the inner peripheral edge of the surface facing the metal plate. The protrusion of the pressure plate has a shoulder with a curvature radius R1 on the inner circumference side. The curvature radius R1 is greater than 0.10 times the thickness of the metal plate. The manufacturing method comprises: The step of pressing the protrusion of the pressing plate into the metal plate; as well as The step of bringing the punch and the die close to each other to punch out the metal plate.

2. The method for manufacturing a metal component according to claim 1, wherein: The die has a protrusion at the inner peripheral edge of the surface facing the metal plate. The protrusion of the punch has a shoulder with a curvature radius R2 on the inner circumference side, The curvature radius R2 is greater than 0.10 times the thickness of the metal plate. In the step of pressing the protrusion of the pressing plate into the metal plate, the protrusion of the die is also pressed into the metal plate.

3. The method for manufacturing a metal component according to claim 1, wherein: The punch has a double-layer shoulder on the inner circumference side. The double-layer shoulder has: 1st shoulder; and a second shoulder portion, which is located farther from the metal plate than the first shoulder portion in the thickness direction of the metal plate, and is located closer to the counter pad than the first shoulder portion in the in-plane direction of the metal plate, The curvature radius Rp2 of the second shoulder portion is greater than or equal to 0.10 times the thickness of the metal plate.

4. A method for manufacturing a metal component, which is a method for manufacturing a metal component by punching a metal plate whose front and back surfaces are covered with a coating layer using a die, wherein: The mold has: Punch; a counter washer disposed opposite to the punch via the metal plate; a pressing plate disposed on the punch side in the thickness direction of the metal plate and disposed so as to surround the punch in the in-plane direction of the metal plate; as well as a punching die arranged on the counter-pad side in the thickness direction of the metal plate and arranged to surround the counter-pad in the in-plane direction of the metal plate, The punch has a protrusion on the peripheral edge of the surface facing the metal plate. The protrusion of the punch has a shoulder with a curvature radius R3 on the outer peripheral side, The curvature radius R3 is greater than 0.10 times the thickness of the metal plate. The manufacturing method comprises: The step of pressing the protrusion of the punch into the metal plate; as well as A step of bringing the counter pad and the pressing plate close to each other to punch out the metal plate.

5. The method for manufacturing a metal component according to claim 4, wherein: The counter washer has a protrusion on the peripheral edge of the surface facing the metal plate. The protrusion of the counter pad has a shoulder with a curvature radius R4 on the outer peripheral side. The curvature radius R4 is greater than 0.10 times the thickness of the metal plate. In the step of pressing the protrusion of the punch into the metal plate, the protrusion of the counter washer is also pressed into the metal plate.

6. The method for manufacturing a metal component according to claim 4, wherein: The counter pad has a double-layer shoulder at the peripheral edge of the surface opposite to the metal plate. The double-layer shoulder has: 1st shoulder; as well as a second shoulder portion located farther from the metal plate than the first shoulder portion in the thickness direction of the metal plate and located closer to the die than the first shoulder portion in the in-plane direction of the metal plate, The curvature radius Rp4 of the second shoulder portion is equal to or greater than 0.10 times the thickness of the metal plate.

7. A mold, wherein: The mold has: Punch; a counter washer disposed opposite to the punch via a metal plate as a workpiece; a pressing plate disposed on the punch side in the thickness direction of the metal plate and disposed so as to surround the punch in the in-plane direction of the metal plate; as well as a punching die arranged on the counter-pad side in the thickness direction of the metal plate and arranged to surround the counter-pad in the in-plane direction of the metal plate, The pressing plate has a protrusion at the inner peripheral edge of the surface facing the metal plate. The protrusion of the pressure plate has a shoulder with a curvature radius R1 on the inner circumference side. The curvature radius R1 is greater than 0.2 mm.

8. The mold according to claim 7, wherein: The die has a protrusion at the inner peripheral edge of the surface facing the metal plate. The protrusion of the punch has a shoulder with a curvature radius R2 on the inner circumference side, The curvature radius R2 is greater than 0.2 mm.

9. The mold according to claim 7, wherein: The punch has a double-layer shoulder on the inner circumference side. The double-layer shoulder has: 1st shoulder; and a second shoulder portion, which is located farther from the metal plate than the first shoulder portion in the thickness direction of the metal plate, and is located closer to the counter pad than the first shoulder portion in the in-plane direction of the metal plate, The curvature radius Rp2 of the second shoulder portion is greater than or equal to 0.1 mm.

10. A mold, wherein: The mold has: Punch; a counter washer disposed opposite to the punch via a metal plate as a workpiece; a pressing plate disposed on the punch side in the thickness direction of the metal plate and disposed so as to surround the punch in the in-plane direction of the metal plate; as well as a punching die arranged on the counter-pad side in the thickness direction of the metal plate and arranged to surround the counter-pad in the in-plane direction of the metal plate, The punch has a protrusion on the peripheral edge of the surface facing the metal plate. The protrusion of the punch has a shoulder with a curvature radius R3 on the outer peripheral side, The curvature radius R3 is greater than 0.2 mm.

11. The mold according to claim 10, wherein: The counter washer has a protrusion on the peripheral edge of the surface facing the metal plate. The protrusion of the counter pad has a shoulder with a curvature radius R4 on the outer peripheral side. The curvature radius R4 is greater than 0.2 mm.

12. The mold according to claim 10, wherein: The counter pad has a double-layer shoulder at the peripheral edge of the surface opposite to the metal plate. The double-layer shoulder has: 1st shoulder; as well as The second shoulder is located farther from the metal plate than the first shoulder in the thickness direction of the metal plate, and is located closer to the die than the first shoulder in the in-plane direction of the metal plate. The curvature radius Rp4 of the second shoulder portion is greater than or equal to 0.1 mm.

13. A metal component formed by punching a metal plate whose front and back surfaces are covered with coating layers, wherein: The metal component has a cut end surface formed by the punching process. The cut end surface has: Cut surface; and a concave surface which is a curved surface having a shape formed convexly toward the inside of the component; At least a portion of the recessed surface is covered by the coating layer.

14. The metal component according to claim 13, wherein The cut end surface also has a collapsed edge adjacent to the recessed surface, More than 50% of the combined area of ​​the recessed surface and the collapsed edge is covered by the coating layer.

15. The metal component according to claim 13 or 14, wherein: The cut end surface further has a second collapsed edge adjacent to the cut surface, The cut surface is located between the recessed surface and the second collapsed edge in the thickness direction of the metal member.

16. The metal component according to claim 13 or 14, wherein The cut end surface further includes: a second concave surface, which is a curved surface having a convex shape toward the inside of the component; and a second collapsed edge, which is adjacent to the second concave surface. The cut surface is located between the recessed surface and the second recessed surface in the thickness direction of the metal member.

17. The metal component according to claim 13 or 14, wherein: The distance between the tangent line of the cut surface and the most depressed position of the depressed surface, that is, the depression amount, is 0.01 to 0.10 times the thickness of the metal member.

Images