Molding device

Abstract

This molding device is a molding device for molding an aluminum alloy metal material into a metal member, and is provided with a molding die having a corner molding surface that is curved in a recessed shape in a cross-sectional view and that is for molding a corner of the metal member. The molding die includes: a first main die and a second main die facing each other; and a double-acting mold which can move relative to the first main mold and the second main mold, and which presses the metal material with the double-acting mold so as to press a corner-corresponding portion corresponding to the corner in the metal material into the corner molding surface.

Description

Technical Field

[0001] The invention relates to a forming device. Background Art

[0002] Conventionally, there is a known molding device for molding a metal material. For example, Patent Document 1 below discloses a molding device having a mold having a lower mold and an upper mold that form a pair with each other. This molding device molds a metal part having a shape corresponding to the molding surface by bringing the metal material into contact with the molding surface in the mold.

[0003] Previous technical literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2009-220141 Summary of the invention

[0006] Technical problem to be solved by the invention

[0007] As a metal material, aluminum alloy is sometimes used from the viewpoint of lightness. Since the strength of aluminum alloy is lower than that of steel, a metal material with a thicker plate thickness needs to be used to ensure strength. Here, the forming die has a corner forming portion, which is curved in a concave shape in a cross-sectional view and is used to form the corner of the metal part. When the plate thickness of the metal material is thick, it is difficult to form the corner of the metal part into a shape corresponding to the corner forming portion.

[0008] Therefore, an object of the present invention is to provide a forming device capable of forming a corner portion of an aluminum alloy metal part into a desired shape after forming.

[0009] Means for solving technical problems

[0010] A forming device involved in one embodiment of the present invention is a forming device for forming an aluminum alloy metal material into a metal part, wherein the forming device has a forming mold having a corner forming surface, and the corner forming surface is concavely curved in a cross-sectional view and is used to form the corner of the metal part. The forming mold has: a first main mold and a second main mold facing each other; and a double-action mold that can move relative to the first main mold and the second main mold, and the double-action mold is used to press the metal material to press the corner-corresponding portion of the metal material corresponding to the corner into the corner forming surface.

[0011] The forming device has a forming die having a corner forming surface, and the corner forming surface is curved in a concave shape in the cross-sectional view, and is used to form the corner of the metal part. In the case where the plate thickness of the aluminum alloy metal material is thick, the deformation resistance is large, and the corresponding part of the corner is difficult to deform along the shape of the corner forming surface. In contrast, the forming die has a double-action die that can move relative to the first main die and the second main die. The forming device presses the metal material with the double-action die to press the corresponding part of the corner into the corner forming surface. At this time, the pressed corresponding part of the corner is bent into a shape along the corner forming surface. In this state, even if the deformation resistance is large, the corresponding part of the corner can easily be deformed into a shape along the corner forming surface. In this way, the corner of the aluminum alloy metal part after forming can be made into a desired shape.

[0012] The double-action mold can press the corner corresponding part into the corner molding surface before the first main mold and the second main mold move to the mold closing position. In this case, the corner corresponding part can be brought close to the corner molding surface before the first main mold and the second main mold move to the mold closing position to form the metal part. Therefore, when the metal part is formed, it is easy to form a corner that follows the shape of the corner molding surface.

[0013] The double-action mold can move in a second direction intersecting with the first direction facing the first main mold and the second main mold in the cross-sectional view, and the double-action mold can press a portion of the metal material different from the portion corresponding to the corner. At this time, the double-action mold presses the metal material from the second direction so that the portion near the portion corresponding to the corner of the metal material is pressed toward the main mold side. As a result, the portion corresponding to the corner is bent into a state pressed against the corner molding surface.

[0014] The double-action die has a corner molding surface, and the corner molding surface is pressed toward the corner corresponding portion. At this time, the vicinity of the corner corresponding portion of the metal material is bent into a shape along the corner molding surface of the double-action die.

[0015] Effects of the Invention

[0016] According to the present invention, it is possible to provide a forming device capable of forming a corner portion of an aluminum alloy metal part after forming into a desired shape. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic structural diagram showing a molding device according to an embodiment of the present invention.

[0018] Figure 2 (a) is a schematic side view showing the heating expansion unit. Figure 2 (b) is a cross-sectional view showing a state where the nozzle seals the metal tube material.

[0019] Figure 3 (a) and Figure 3 (b) is a schematic cross-sectional view of the molding die.

[0020] Figure 4 It is a schematic cross-sectional view showing the state of the molding die at each time point.

[0021] Figure 5 It is a graph showing the temporal changes in the position of the main mold, the position of the double-action mold, and the pressure of gas blowing on the metal tube material.

[0022] Figure 6 It is a schematic cross-sectional view showing the state of the molding die at each time point.

[0023] Figure 7 It is a graph showing the temporal changes in the position of the main mold, the position of the double-action mold, and the pressure of gas blowing on the metal tube material.

[0024] Figure 8 It is a schematic cross-sectional view showing the state of the molding die at each time point.

[0025] Fig. 9 It is a graph showing the temporal changes in the position of the main mold, the position of the double-action mold, and the pressure of gas blowing on the metal tube material.

[0026] Fig.10 It is a schematic cross-sectional view showing a molding die according to a modified example.

[0027] Fig.11 This is a graph showing the relationship between the plate thickness and the forming limit of the corner portion.

[0028] Explanation of symbols:

[0029] 1-molding device, 11-main mold (1st main mold), 12-main mold (2nd main mold), 18A, 18B-double-action mold, 19A, 19B, 19C, 19D-double-action mold, 40-metal tube material (metal material), 41-metal tube (metal part), 44A, 44B, 44C, 44D-corner, 46A, 46B, 46C, 46D-corresponding parts of corners, 83A, 83B, 83C, 83D-corner molding surfaces. DETAILED DESCRIPTION

[0030] Hereinafter, preferred embodiments of the molding device of the present invention will be described with reference to the accompanying drawings. In addition, in each figure, the same or equivalent parts are marked with the same reference numerals, and repeated description is omitted.

[0031] Figure 1 1 is a schematic structural diagram of the molding device 1 according to the present embodiment. Figure 1As shown, the molding device 1 is a device for molding a metal tube having a hollow shape by blow molding. In the present embodiment, the molding device 1 is arranged on a horizontal plane. The molding device 1 comprises a molding die 2, a drive mechanism 3, a holding portion 4, a heating portion 5, a fluid supply portion 6, a cooling portion 7 and a control portion 8. In addition, in the present specification, the metal tube material 40 (metal material) refers to a hollow object before the molding in the molding device 1 is completed. The metal tube material 40 is a tube material of a steel type that can be quenched. In addition, the direction in which the metal tube material 40 extends in the horizontal direction during molding is sometimes referred to as the "length direction", and the direction orthogonal to the length direction is referred to as the "width direction".

[0032] The forming die 2 is used to form the metal tube material 40 into a metal tube 41 ( Figure 3 The mold (b) is provided with a lower main mold 11 (first main mold) and an upper main mold 12 (second main mold) facing each other in the up and down direction. The lower main mold 11 and the upper main mold 12 are composed of steel blocks. Recesses for accommodating the metal tube material 40 are respectively provided in the lower main mold 11 and the upper main mold 12. When the lower main mold 11 and the upper main mold 12 are in close contact with each other (closed mold state), a space of a target shape to be formed of the metal tube material is formed by each recess. Therefore, the surface of each recess becomes the molding surface of the molding mold 2. The lower main mold 11 is fixed to the base 13 via a mold base, etc. The upper main mold 12 is fixed to the sliding part of the driving mechanism 3 via a mold base, etc.

[0033] The driving mechanism 3 is a mechanism for moving at least one of the lower main mold 11 and the upper main mold 12. Figure 1 In the embodiment, the driving mechanism 3 has a structure that moves only the upper main mold 12. The driving mechanism 3 includes: a slide 21 that moves the upper main mold 12 so that the lower main mold 11 and the upper main mold 12 are closed together; a pull-back cylinder 22 as an actuator that generates a force to pull the slide 21 upward; a main cylinder 23 as a driving source that lowers and pressurizes the slide 21; and a driving source 24 that applies driving force to the main cylinder 23.

[0034] The holding part 4 is a mechanism for holding the metal tube material 40 disposed between the lower main mold 11 and the upper main mold 12. The holding part 4 includes a lower electrode 26 and an upper electrode 27 for holding the metal tube material 40 at one end side of the molding die 2 in the longitudinal direction, and a lower electrode 26 and an upper electrode 27 for holding the metal tube material 40 at the other end side of the molding die 2 in the longitudinal direction. The lower electrode 26 and the upper electrode 27 on both sides in the longitudinal direction hold the metal tube material 40 by clamping the vicinity of the end of the metal tube material 40 from the upper and lower directions. In addition, a groove having a shape corresponding to the outer peripheral surface of the metal tube material 40 is formed on the upper surface of the lower electrode 26 and the lower surface of the upper electrode 27. The lower electrode 26 and the upper electrode 27 are provided with a driving mechanism (not shown) so that the lower electrode 26 and the upper electrode 27 can be independently moved in the upper and lower directions.

[0035] The heating unit 5 heats the metal tube material 40. The heating unit 5 is a mechanism that heats the metal tube material 40 by passing electricity through the metal tube material 40. The heating unit 5 heats the metal tube material 40 when the metal tube material 40 is between the lower main mold 11 and the upper main mold 12 and the metal tube material 40 is separated from the lower main mold 11 and the upper main mold 12. The heating unit 5 includes a lower electrode 26 and an upper electrode 27 on both sides in the longitudinal direction, and a power source 28 that allows current to flow to the metal tube material 40 via these electrodes 26 and 27. In addition, the heating unit can be arranged in the previous process of the molding device 1 and perform heating externally.

[0036] The fluid supply unit 6 is a mechanism for supplying high-pressure fluid into the metal tube material 40 held between the lower main mold 11 and the upper main mold 12. The fluid supply unit 6 supplies high-pressure fluid to the metal tube material 40 heated by the heating unit 5 to a high-temperature state, so as to expand the metal tube material 40. The fluid supply unit 6 is provided at both ends of the molding die 2 in the longitudinal direction. The fluid supply unit 6 includes: a nozzle 31 for supplying fluid into the metal tube material 40 from the opening at the end of the metal tube material 40; a driving mechanism 32 for moving the nozzle 31 forward and backward relative to the opening of the metal tube material 40; and a supply source 33 for supplying high-pressure fluid into the metal tube material 40 via the nozzle 31. The driving mechanism 32 makes the nozzle 31 close to the end of the metal tube material 40 in a state of ensuring sealing when supplying the fluid and when exhausting the fluid, and separates the nozzle 31 from the end of the metal tube material 40 at other times. In addition, the fluid supply unit 6 may also supply a gas such as high-pressure air or an inert gas as the fluid. Furthermore, the fluid supply unit 6, the holding unit 4 having a mechanism for moving the metal tube material 40 in the vertical direction, and the heating unit 5 may be provided as the same device.

[0037] The components of the holding unit 4 , the heating unit 5 , and the fluid supply unit 6 may be configured as a unitized heating expansion unit 150 . Figure 2 (a) is a schematic side view showing the heating expansion unit 150. Figure 2 (b) is a cross-sectional view showing a state where the nozzle 31 seals the metal tube material 40 .

[0038] like Figure 2 As shown in (a), the heating expansion unit 150 includes the lower electrode 26 and the upper electrode 27, the electrode mounting unit 151 on which the electrodes 26 and 27 are mounted, the nozzle 31 and the driving mechanism 32, the lifting unit 152, and the unit base 153. The electrode mounting unit 151 includes a lifting frame 154 and electrode frames 156 and 157. The electrode frames 156 and 157 function as a part of the driving mechanism 60 that supports and moves the electrodes 26 and 27. The driving mechanism 32 drives the nozzle 31 and is lifted and lowered together with the electrode mounting unit 151. The driving mechanism 32 includes a piston 61 that holds the nozzle 31 and a cylinder 62 that drives the piston. The lifting unit 152 includes: a lifting frame base 64 mounted on the upper surface of the unit base 153; and a lifting actuator 66, which imparts a lifting action to the lifting frame 154 of the electrode mounting unit 151 through these lifting frame bases 64. The lifting frame base 64 has guide parts 64a and 64b for guiding the lifting frame 154 to perform lifting and lowering actions relative to the unit base 153. The lifting unit 152 functions as a part of the driving mechanism 60 of the holding part 4. The heating expansion unit 150 has a plurality of unit bases 153 with different inclination angles of the upper surface, and by replacing these unit bases, the inclination angles of the lower electrode 26 and the upper electrode 27, the nozzle 31, the electrode mounting unit 151, the driving mechanism 32, and the lifting unit 152 can be changed and adjusted at the same time.

[0039] The nozzle 31 is a cylindrical member that can be inserted into the end of the metal tube material 40. The nozzle 31 is supported by the drive mechanism 32 in such a manner that the center line of the nozzle 31 coincides with the reference line SL1. The inner diameter of the supply port 31a at the end of the nozzle 31 on the metal tube material 40 side is substantially consistent with the outer diameter of the metal tube material 40 after expansion molding. In this state, the nozzle 31 supplies a high-pressure fluid to the metal tube material 40 through the internal flow path 63. In addition, as an example of a high-pressure fluid, gas and the like can be cited.

[0040] Back to Figure 1The cooling unit 7 is a mechanism for cooling the forming die 2. The cooling unit 7 can quickly cool the metal tube material 40 when the expanded metal tube material 40 contacts the forming surface of the forming die 2 by cooling the forming die 2. The cooling unit 7 includes a flow path 36 formed inside the lower main die 11 and the upper main die 12, and a water circulation mechanism 37 for supplying cooling water to the flow path 36 and circulating the cooling water.

[0041] The control unit 8 is a device for controlling the entire molding device 1. The control unit 8 controls the driving mechanism 3, the holding unit 4, the heating unit 5, the fluid supply unit 6, and the cooling unit 7. The control unit 8 repeatedly performs the operation of molding the metal tube material 40 using the molding die 2.

[0042] Specifically, the control unit 8 controls the conveying timing of the conveying device such as a robot arm, so as to arrange the metal tube material 40 between the lower main mold 11 and the upper main mold 12 in the opened state. Alternatively, the metal tube material 40 may be manually arranged between the lower main mold 11 and the upper main mold 12 by an operator. In addition, the control unit 8 controls the actuator of the holding unit 4 so as to support the metal tube material 40 by the lower electrodes 26 on both sides in the longitudinal direction, and then lower the upper electrode 27 to clamp the metal tube material 40. In addition, the control unit 8 controls the heating unit 5 to electrically heat the metal tube material 40. As a result, a current flows in the metal tube material 40 in the axial direction, and the metal tube material 40 itself generates heat due to Joule heat due to the resistance of the metal tube material 40 itself.

[0043] The control unit 8 controls the driving mechanism 3 so that the upper main mold 12 descends and approaches the lower main mold 11, thereby closing the molding die 2. On the other hand, the control unit 8 controls the fluid supply unit 6 to seal the openings at both ends of the metal tube material 40 with the nozzle 31 and supply fluid. As a result, the metal tube material 40 softened by heating is expanded and contacts the molding surface of the molding die 2. Moreover, the metal tube material 40 is formed into a shape identical to the shape of the molding surface of the molding die 2. In addition, in the case of forming a metal tube with a flange, after a part of the metal tube material 40 is allowed to enter the gap between the lower main mold 11 and the upper main mold 12, the mold is further closed to flatten the entered part to form a flange. When the metal tube material 40 contacts the molding surface, the metal tube material 40 is quenched by rapidly cooling the molding die 2 cooled by the cooling unit 7.

[0044] refer to Figure 3 In (b), the metal pipe 41 after forming is described. Figure 3(b) is a schematic cross-sectional view showing the state of the metal tube 41 immediately after being formed by the forming die 2. The metal tube 41 has a tube portion 42 and a pair of flange portions 43. The tube portion 42 has a rectangular shape when viewed in cross section. The tube portion 42 has four corner portions 44A, 44B, 44C, and 44D. The corner portions 44A, 44B, 44C, and 44D have an R shape that is bent to protrude toward the outer peripheral side. The pair of flange portions 43 protrude from the side wall portions on both sides of the tube portion 42 toward the outer peripheral side in the width direction.

[0045] refer to Figure 3 In (a), the molding die 2 is described in detail. Figure 3 (a) is a schematic cross-sectional view showing the molding die 2 in the initial molding state. The molding die 2 has main molds 11 and 12 facing each other in the up-down direction (first direction) and double-action molds 18A and 18B that can move relative to the main molds 11 and 12. The double-action molds 18A and 18B can move in the direction intersecting the up-down direction in the cross-sectional view, that is, the width direction. The double-action mold 18A is arranged on one side in the width direction relative to the main molds 11 and 12. The double-action mold 18B is arranged on the other side in the width direction relative to the main molds 11 and 12. The double-action molds 18A and 18B are arranged at a position between the main mold 11 and the main mold 12 in the up-down direction.

[0046] The main molds 11 and 12 have a tube molding surface 81 for molding the tube 42 and a flange molding surface 82 for molding the flange 43. The main mold 12 has a corner molding surface 83A for molding the corner 44A and a corner molding surface 83B for molding the corner 44B. The main mold 11 has a corner molding surface 83C for molding the corner 44C and a corner molding surface 83D for molding the corner 44D. The corner molding surfaces 83A, 83B, 83C, and 83D have an R shape that is curved like a concave shape in a cross-sectional view.

[0047] In the initial state of forming, the metal tube material 40 is arranged between the main molds 11 and 12 in the vertical direction and between the double-action molds 18A and 18B in the width direction. The metal tube material 40 is an aluminum alloy metal material. In order to ensure sufficient strength, the plate thickness of the metal tube material 40 is set to about 1.0 to 5.0 mm. The curvature radius of the R shape of the corner forming surface 83 (that is, the corner 44) is set to about 8.0 to 15.0 mm.

[0048] Next, refer to Figure 4 and Figure 5 , the operation of the molding device 1 during molding will be described. Figure 4 The state of the molding die 2 at each time is shown. Figure 4 In the figure, the arrows attached to each mold show the action (or action) of the mold in the next step. Figure 5It is a graph showing the temporal changes in the positions of the main molds 11 and 12 , the positions of the double-action molds 18A and 18B, and the pressure of the gas blow molding on the metal tube material 40 .

[0049] Figure 4 (a) shows the initial state and the state where the main molds 11 and 12 start to move ( Figure 5 moment T1a). Figure 4 (b) shows the state where the main molds 11 and 12 are arranged at the primary blow molding position and before the double-action molds 18A and 18B are inserted and before the primary blow molding ( Figure 5 At time T1b). In this state, the metal tube material 40 is in contact with (or close to) the main molds 11 and 12 in an undeformed state. The portions corresponding to the corners 44A, 44B, 44C, and 44D in the metal tube material 40 are set as corner corresponding portions 46A, 46B, 46C, and 46D. The corner corresponding portions 46A, 46B, 46C, and 46D are portions that become the corners 44A, 44B, 44C, and 44D after molding. At time T1b, the corner corresponding portions 46A, 46B, 46C, and 46D are in a state separated from the corner molding surfaces 83A, 83B, 83C, and 83D. Then, the double-action molds 18A and 18B are inserted. And, after the double-action molds 18A and 18B are inserted, a blow molding is performed.

[0050] Figure 4 (c) shows the state where the main molds 11 and 12 are arranged at the primary blow molding position and after the double-action molds 18A and 18B are inserted and the primary blow molding is performed ( Figure 5 At the moment T1c of the molding process). In this state, the two ends of the metal tube material 40 in the width direction are pressed to the center side in the width direction by the double-action molds 18A and 18B. At this time, the corner corresponding parts 46A, 46B, 46C, and 46D are bent to protrude toward the outer peripheral side after the bending process. As a result, the corner corresponding parts 46A, 46B, 46C, and 46D are pressed into a position close to the corner molding surfaces 83A, 83B, 83C, and 83D. That is, the molding device 1 presses the metal tube material 40 with the double-action molds 18A and 18B to press the corner corresponding parts 46A, 46B, 46C, and 46D into the corner molding surfaces 83A, 83B, 83C, and 83D. And, through one blow molding, the corner corresponding parts 46A, 46B, 46C, and 46D are further close to the corner molding surfaces 83A, 83B, 83C, and 83D. Then, the double-action mold 18A, 18B moves to the retreat position. In addition, the double-action mold insertion action and the primary blow molding pressurization can be performed separately or simultaneously. In the case of separate actions, which one can be performed first.

[0051] Figure 4(d) shows the state where the main molds 11 and 12 are arranged at the primary blow molding position and the double-action molds 18A and 18B are retracted to the retracted position and the primary blow molding is performed ( Figure 5 Then, the main molds 11 and 12 move to the mold closing position. Figure 4 (e) shows the state where the main molds 11 and 12 are arranged at the secondary blow molding position (mold clamping position) and before the secondary blow molding is performed ( Figure 5 Thus, the tube portion 42 and the flange portion 43 are formed. Then, secondary blow molding is performed. Figure 4 (f) shows the state where the main molds 11 and 12 are arranged at the secondary blow molding position (mold clamping position) and after the secondary blow molding is performed ( Figure 5 At the time T1f of the blow molding process, the corner corresponding parts 46A, 46B, 46C, 46D are pressed into the position close to the corner molding surfaces 83A, 83B, 83C, 83D. Therefore, by the secondary blow molding, the corner corresponding parts 46A, 46B, 46C, 46D are not affected by the large deformation resistance based on the plate thickness and are pressed against the corner molding surfaces 83A, 83B, 83C, 83D. As a result, the R-shaped corners 44A, 44B, 44C, 44D along the corner molding surfaces 83A, 83B, 83C, 83D are formed, and the metal tube 41 is manufactured.

[0052] Next, the effects of the molding device 1 according to the present embodiment will be described.

[0053] First, since the strength of aluminum is lower than that of steel, in order to make automotive parts have the same strength characteristics as steel, the plate thickness needs to be increased. For protruding shaped parts such as R-shaped corners, in order to obtain sufficient strength and rigidity, it is preferred to reduce their size as much as possible. However, in hot gas blow molding in which high-pressure gas is injected to form a shape along the mold, in principle, the corners are formed by expanding the parts, and the thicker the plate thickness, the more difficult it is to form. On the other hand, in order to save energy, it is preferred to set the pressure to, for example, 35MPa or less, which is the upper limit of the specification for general compressors. However, in this case, in order to obtain the desired R shape, the degree of processing becomes greater, and molding becomes difficult.

[0054] The forming device 1 has a forming die 2 having corner forming surfaces 83A, 83B, 83C, and 83D, and the corner forming surfaces 83A, 83B, 83C, and 83D are curved in a concave shape in a cross-sectional view, and are used to form corners 44A, 44B, 44C, and 44D of the metal tube 41. When the plate thickness of the aluminum alloy metal tube 41 is thick, the deformation resistance is large, and it is difficult for the corner corresponding parts 46A, 46B, 46C, and 46D to deform along the shape of the corner forming surface. In contrast, the forming die 2 has double-action dies 18A and 18B that can move relative to the first main die and the second main die. The forming device 1 presses the metal tube material 40 with the double-action dies 18A and 18B to press the corner corresponding parts 46A, 46B, 46C, and 46D into the corner forming surfaces 83A, 83B, 83C, and 83D. At this time, the pressed corner corresponding parts 46A, 46B, 46C, 46D are bent into shapes along the corner forming surfaces 83A, 83B, 83C, 83D. In this state, even if the deformation resistance is large, the corner corresponding parts 46A, 46B, 46C, 46D are easily deformed into shapes along the corner forming surfaces 83A, 83B, 83C, 83D. Thus, the corners 44A, 44B, 44C, 44D of the aluminum alloy metal pipe 41 after forming can be made into desired shapes.

[0055] The double-action molds 18A and 18B can press the corner corresponding parts 46A, 46B, 46C, and 46D toward the corner molding surfaces 83A, 83B, 83C, and 83D before the main molds 11 and 12 are moved to the mold closing position. At this time, the corner corresponding parts 46A, 46B, 46C, and 46D can be brought close to the corner molding surfaces 83A, 83B, 83C, and 83D before the main molds 11 and 12 are moved to the mold closing position to form the metal tube 41. Therefore, when the metal tube 41 is formed, it is easy to form the corners 44A, 44B, 44C, and 44D in the shape along the corner molding surfaces 83A, 83B, 83C, and 83D.

[0056] The double-action dies 18A and 18B are movable in the width direction in the cross-sectional view, and the double-action dies 18A and 18B can press the portions of the metal tube material 40 other than the corner corresponding portions 46A, 46B, 46C, and 46D. At this time, the double-action dies 18A and 18B press the metal tube material 40 from the width direction, so that the portions of the metal tube material 40 near the corner corresponding portions 46A, 46B, 46C, and 46D are pressed into the main dies 11 and 12. As a result, the corner corresponding portions 46A, 46B, 46C, and 46D are bent to be pressed into the corner molding surfaces 83A, 83B, 83C, and 83D.

[0057] in addition, Fig.11It is the relationship between the plate thickness and the forming limit of the corner when the aluminum alloy tube is STAF-formed under the forming conditions of a heating temperature of 450°C and a gas blow molding pressure of 35MPa. If the formability is considered, the higher the heating temperature, the better, but if the melting point of the aluminum alloy is considered, about 450°C becomes the upper limit. Therefore, when the formability is confirmed under the conditions of 450°C and 35MPa, the relationship "y=7.11e^0.145x" holds between the forming limit (y) of the corner and the plate thickness (x).

[0058] The present invention is not limited to the above-mentioned embodiments.

[0059] The structure of the double-action mold is not limited to the above-mentioned embodiment. Figure 6 In (a), the molding die 2 involved in the modification is described in detail. The molding die 2 has main molds 11, 12 and double-action molds 19A, 19B, 19C, and 19D that can move relative to the main molds 11, 12. The double-action molds 19A and 19C are arranged on one side in the width direction relative to the main molds 11, 12. The double-action molds 19B and 19D are arranged on the other side in the width direction relative to the main molds 11, 12. The double-action molds 19A and 19B are arranged on the upper side. The double-action molds 19C and 19D are arranged on the lower side.

[0060] The main molds 11 and 12 have a tube molding surface 81. The flange molding surface 82 is provided in the double-action molds 19A, 19B, 19C, and 19D. The double-action mold 19A has a corner molding surface 83A. The double-action mold 19B has a corner molding surface 83B. The double-action mold 19C has a corner molding surface 83C. The double-action mold 19D has a corner molding surface 83D.

[0061] Next, refer to Figure 6 and Figure 7 , the operation of the molding device 1 during molding will be described. Figure 6 The states of the molding die 2 at each time are shown. Figure 7 It is a graph showing the temporal changes in the positions of the main molds 11 and 12 , the positions of the double-action molds 19A, 19B, 19C, and 19D, and the pressure of the gas blow molding on the metal tube material 40 .

[0062] Figure 6 (a) shows the initial state and the state where the main molds 11 and 12 start to move ( Figure 7 moment T2a). Figure 6 (b) shows the state where the main molds 11 and 12 are arranged at the primary blow molding position and before the double-action molds 19A, 19B, 19C, and 19D start to move in the width direction ( Figure 7At time T2b). In this state, the metal tube material 40 is in contact with (or close to) the main molds 11 and 12 in an undeformed state. At time T2b, the corner corresponding parts 46A, 46B, 46C, 46D are separated from the corner molding surfaces 83A, 83B, 83C, 83D. Then, the double-action molds 19A, 19B, 19C, 19D move in the width direction. And, after the double-action molds 19A, 19B, 19C, 19D move, a blow molding is performed.

[0063] Figure 6 (c) shows a state where the main molds 11 and 12 are arranged at the primary blow molding position and the double-action molds 19A, 19B, 19C, and 19D are moved in the width direction and arranged at the insertion position and before the primary blow molding is performed ( Figure 7 At the moment T2c of the molding process, the double-action molds 19A, 19B, 19C, and 19D are pressed near the corner corresponding parts 46A, 46B, 46C, and 46D of the metal tube material 40. At this time, the corner corresponding parts 46A, 46B, 46C, and 46D are bent to protrude toward the outer peripheral side after the bending process. As a result, the corner corresponding parts 46A, 46B, 46C, and 46D are pressed into a position close to the corner molding surfaces 83A, 83B, 83C, and 83D. That is, the molding device 1 presses the metal tube material 40 with the double-action molds 19A, 19B, 19C, and 19D to press the corner corresponding parts 46A, 46B, 46C, and 46D into the corner molding surfaces 83A, 83B, 83C, and 83D.

[0064] Figure 6 (d) shows the state after the main molds 11 and 12 are arranged at the primary blow molding position, the double-action molds 19A, 19B, 19C, and 19D are arranged at the insertion position, and the primary blow molding is performed ( Figure 7 At the time T2d). Through one blow molding, the corner corresponding parts 46A, 46B, 46C, 46D are further close to the corner molding surfaces 83A, 83B, 83C, 83D. Then, the main molds 11, 12 and the double-action molds 19A, 19B, 19C, 19D move to the mold closing position. Figure 6 (e) shows the state where the main molds 11, 12 and the double-action molds 19A, 19B, 19C, 19D are arranged at the secondary blow molding position (mold clamping position) and before the secondary blow molding is performed ( Figure 7 Thus, the tube portion 42 and the flange portion 43 are formed. Then, secondary blow molding is performed. Figure 6 (f) shows the state where the main molds 11, 12 and the double-action molds 19A, 19B, 19C, and 19D are arranged at the secondary blow molding position (mold clamping position) and after the secondary blow molding is performed ( Figure 7As a result, R-shaped corners 44A, 44B, 44C, and 44D are formed along the corner forming surfaces 83A, 83B, 83C, and 83D, thereby completing the metal tube 41.

[0065] As described above, the double-action dies 19A, 19B, 19C, 19D have corner molding surfaces 83A, 83B, 83C, 83D, and the corner molding surfaces 83A, 83B, 83C, 83D can be pressed toward the corner corresponding portions 46A, 46B, 46C, 46D. At this time, the vicinity of the corner corresponding portions 46A, 46B, 46C, 46D of the metal tube material 40 is bent into a shape along the corner molding surfaces 83A, 83B, 83C, 83D of the double-action dies 19A, 19B, 19C, 19D.

[0066] refer to Figure 8 In (a), the molding die 2 according to another modification is described in detail. The molding die 2 includes main molds 11 and 12, double-action molds 18A and 18B, and double-action molds 19A, 19B, 19C, and 19D. Figure 8 and Fig. 9 , the operation of the molding device 1 during molding will be described. Figure 8 The states of the molding die 2 at each time are shown. Fig. 9 It is a graph showing the temporal changes in the positions of the main molds 11 and 12 , the positions of the double-action molds 18A and 18B, the positions of the double-action molds 19A, 19B, 19C, and 19D, and the pressure of gas blowing on the metal tube material 40 .

[0067] Figure 8 (a) shows the initial state and the state where the main molds 11 and 12 start to move ( Fig. 9 time T3a). Figure 8 (b) shows the state where the main molds 11 and 12 are arranged at the primary blow molding position and before the double-action molds 18A, 18B, 19A, 19B, 19C, and 19D start to move in the width direction ( Fig. 9 At time T3b). In this state, the metal tube material 40 is in contact with (or close to) the main molds 11 and 12 in an undeformed state. At time T3b, the corner corresponding parts 46A, 46B, 46C, 46D are separated from the corner molding surfaces 83A, 83B, 83C, 83D. Then, the double-action molds 18A, 18B, 19A, 19B, 19C, 19D move in the width direction. And, after the double-action molds 18A, 18B, 19A, 19B, 19C, 19D move, a blow molding is performed.

[0068] Figure 8(c) shows a state where the main molds 11 and 12 are arranged at the primary blow molding position and the double-action molds 18A, 18B, 19A, 19B, 19C, and 19D are moved in the width direction and arranged at the insertion position and before the primary blow molding is performed ( Fig. 9 At time T3c). In this state, the double-action dies 19A, 19B, 19C, 19D are pressed near the corner corresponding parts 46A, 46B, 46C, 46D of the metal tube material 40. Moreover, both ends of the metal tube material 40 in the width direction are pressed to the center side in the width direction by the double-action dies 18A, 18B. At this time, the corner corresponding parts 46A, 46B, 46C, 46D are bent to protrude toward the outer peripheral side through the bending process. As a result, the corner corresponding parts 46A, 46B, 46C, 46D are pressed to a position close to the corner molding surfaces 83A, 83B, 83C, 83D. That is, the molding device 1 presses the metal tube material 40 with the double-action molds 18A, 18B, 19A, 19B, 19C, 19D to press the corner corresponding parts 46A, 46B, 46C, 46D into the corner molding surfaces 83A, 83B, 83C, 83D. In addition, the double-action molds 18A and 18B are then retracted to the retracted positions, but the subsequent actions are the same as Figure 6 Middle (c)~ Figure 6 Same as (f).

[0069] In addition, if Fig.10 As shown, the double-action molds 19A and 19B may be provided on the upper side, and only the main mold 11 may be provided on the lower side without providing the double-action molds 19C and 19D.

[0070] As long as the forming device is a forming device for forming an aluminum alloy metal material, a forming device such as a hot stamping method and a hydraulic forming method may be used.

[0071] In the above embodiment, the metal pipe has a flange portion, but it does not need to have a flange portion. Furthermore, the metal material does not need to be a pipe, but may be a plate material.

[0072] [Method 1]

[0073] A forming device, which forms a metal part from an aluminum alloy metal material, wherein:

[0074] The molding device includes a molding die having a corner molding surface, wherein the corner molding surface is curved in a concave shape in a cross-sectional view and is used to mold the corner of the metal part.

[0075] The molding die has:

[0076] A first main mold and a second main mold facing each other; and

[0077] The double-action mold is movable relative to the first main mold and the second main mold.

[0078] The metal material is pressed by the double-action die to press a corner corresponding portion of the metal material corresponding to the corner into the corner molding surface.

[0079] [Method 2]

[0080] The molding device according to embodiment 1, wherein

[0081] The double-action mold presses the corner corresponding portion toward the corner molding surface before the first main mold and the second main mold move to the mold clamping position.

[0082] [Method 3]

[0083] The molding device according to aspect 1 or aspect 2, wherein:

[0084] The double-action mold is movable in a second direction intersecting a first direction in which the first main mold and the second main mold face each other in a cross-sectional view.

[0085] The double-action die presses a portion of the metal material that is different from a portion corresponding to the corner.

[0086] [Method 4]

[0087] The molding device according to any one of Modes 1 to 3, wherein:

[0088] The double-action mold has the corner molding surface, and presses the corner molding surface toward the corresponding position of the corner.

Claims

1. A forming device, which forms a metal part from an aluminum alloy metal material, wherein: The molding device includes a molding die having a corner molding surface, wherein the corner molding surface is curved in a concave shape in a cross-sectional view and is used to mold the corner of the metal part. The molding die has: A first main mold and a second main mold facing each other; and The double-action mold is movable relative to the first main mold and the second main mold. The double-action mold is used to press the metal material so as to press a corner corresponding portion of the metal material corresponding to the corner into the corner molding surface.

2. The molding device according to claim 1, wherein: The double-action mold presses the corner corresponding portion toward the corner molding surface before the first main mold and the second main mold move to the mold clamping position.

3. The molding device according to claim 1, wherein: The double-action mold is movable in a second direction intersecting a first direction in which the first main mold and the second main mold face each other in a cross-sectional view. The double-action die presses a portion of the metal material that is different from the portion corresponding to the corner.

4. The molding device according to claim 1, wherein: The double-action mold has the corner molding surface, and presses the corner molding surface toward the corresponding position of the corner.

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