Method for producing a shaped product and shaped product

Abstract

Method for producing a shaped product, wherein the method comprises: Welding a first metal sheet (2) superimposed with a second metal sheet (3) to the second metal sheet (3); and Pressing the first metal sheet (2) together with the second metal sheet (3), wherein during pressing a base surface (21A), a wall surface (23A), a bottom surface (25A) and an angled section (26) are formed on the first metal sheet (2), wherein the wall surface (23A) is arranged to intersect the base surface (21A), wherein the bottom surface (25A) is arranged opposite the base surface (21A) with respect to the wall surface (23A) and intersects the wall surface (23A), wherein the angled section (26) couples the wall surface (23A) and the bottom surface (25A) together, wherein a first weld is performed on a reinforcing section (41) of the second metal sheet (3) which is placed on an area of ​​the first metal sheet (2) which is formed to form the wall surface (23A); and subsequently a second weld is performed in a direction intersecting one direction of the first weld, where one direction of the first weld and one direction of the second weld are straight, and wherein the first weld and the second weld do not reach a section of the second metal sheet (3) that lies above an area of ​​the first metal sheet (2) formed in the base surface (25A).

Description

STATE OF THE ART

[0001] The present disclosure relates to a process for manufacturing a shaped product and the shaped product.

[0002] A method for obtaining a formed product by placing a reinforcing sheet onto a metal sheet which is a base material; welding the reinforcing sheet to the metal sheet; and pressing a section of the metal sheet superimposed with the reinforcing sheet to draw it is publicly known (JP 2016-124029 A).

[0003] Furthermore, DE 10 2015 218 152 B4 discloses a vehicle body frame structure with a frame element bent into a predetermined shape; and a reinforcing element welded to the frame element along several weld lines to connect it to a surface of the frame element and bent along the surface, wherein the frame element is a central column with an outer wall and an inner wall. The reinforcing element is a reinforcement connected to an inner surface of the outer wall, wherein the outer wall and the reinforcement are welded together along several lateral weld lines in a lower section of the central column, while the outer wall and the reinforcement are welded together along several vertical weld lines in a region of the central column extending upwards from the center. SUMMARY

[0004] If, during the pressing process described above, the position of the reinforcing plate shifts relative to the base material, this positional misalignment reduces the quality of the formed product. Such positional misalignment can be reduced by increasing the weld length of the reinforcing plate.

[0005] Nevertheless, the hardness of the welded section of the reinforcing plate increases due to quenching during welding, which reduces the ductility of the welded section. Consequently, an increase in the weld length of the reinforcing plate can cause problems, such as breakage at the welded section during pressing.

[0006] One object of the invention is to provide a method for producing a shaped product and a product that can reduce problems on the reinforcement plate during pressing.

[0007] This problem is solved by a method for producing a shaped product according to claim 1 and a shaped product according to claim 4. The method comprises welding a first metal sheet, overlaid with a second metal sheet, to the second metal sheet; and pressing the first metal sheet together with the second metal sheet. During pressing, a base surface and a wall surface are formed on the first metal sheet. The wall surface is arranged to intersect the base surface. During welding, a first weld is performed on a reinforcing section of the second metal sheet, which is placed on a region of the first metal sheet that forms the wall surface; and a second weld is then performed in a direction intersecting one direction of the first weld.

[0008] In the aforementioned embodiment, by forming two weld beads whose welding directions intersect during welding, at least one weld bead whose welding direction intersects a pressing direction (i.e., a drawing direction) is formed in an area to be pressed into a wall surface. Consequently, the tensile strength of the second metal sheet at the bearing section can be increased without increasing the weld length, which in turn reduces the positional misalignment of the second metal sheet relative to the first metal sheet. In other words, problems such as positional misalignment and breakage of the second metal sheet, which is the reinforcing sheet, during pressing can be reduced.

[0009] In one aspect of the present disclosure, the direction of the first weld and the direction of the second weld can be straight. This design reduces the positional offset of the second metal sheet while also reducing the increase in weld length.

[0010] In one aspect of this disclosure, a bottom surface and an angled section can be formed on the first metal sheet during pressing. The bottom surface can be positioned opposite the base surface with respect to the wall surface and intersects the wall surface. The angled section can couple the wall surface and the bottom surface. The direction of the first weld can run parallel to an edge line of the angled section. The direction of the second weld can be orthogonal to the direction of the first weld. In this embodiment, the weld bead formed during the first weld runs orthogonal to the drawing direction, and therefore the tensile strength of the second metal sheet at the supporting section can be increased. This facilitates the reduction of the positional misalignment of the second metal sheet.

[0011] In one aspect of this disclosure, the first and second welding steps can be performed using laser or plasma welding. This design can reduce welding stress and welding time.

[0012] Another aspect of the present disclosure is a formed product comprising a first metal sheet, comprising a base surface and a wall surface intersecting the base surface; a second metal sheet, which is placed on and welded to at least the wall surface of the first metal sheet; a first weld bead arranged on a reinforcing section of the second metal sheet, the reinforcing section being placed on the wall surface of the first metal sheet; and a second weld bead arranged on the reinforcing section of the second metal sheet. The welding directions of the first weld bead and the welding directions of the second weld bead intersect.

[0013] This design reduces problems during pressing, such as positional misalignment and breakage of the second metal sheet, which is the reinforcing sheet.

[0014] In one aspect of this disclosure, the first and second weld beads can be linear. This design can reduce the positional offset of the second metal sheet while simultaneously reducing the increase in weld length.

[0015] In one aspect of this disclosure, the first metal sheet may further comprise a bottom surface and an angled section. The bottom surface may be positioned opposite the base surface with respect to the wall surface and intersects the wall surface. The angled section may couple the wall surface and the bottom surface. The welding direction of the first weld bead may run parallel to an edge line of the angled section. The welding direction of the second weld bead may run perpendicular to the welding direction of the first weld bead. This configuration enables simple and precise welding, which reduces the positional misalignment of the second metal sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] An exemplary embodiment of the present disclosure is described below with reference to the accompanying drawings, in which: Fig. 1 a schematic, perspective view of a shaped product in one embodiment; Fig. 2A a schematic cross-sectional view along a line IIA-IIA in Fig. 1 is; Fig. 2B a schematic cross-sectional view along a line IIB-IIB in Fig. 1 is; Fig. 3 a schematic top view of a material blank after it has been subjected to welding; Fig. 4. A flowchart of a process for producing a shaped product in one embodiment; and Fig. 5 is a schematic representation showing the shape patterns of weld beads in a design of Fig. 4 different embodiments are shown. DETAILED DESCRIPTION OF EXAMPLE EXECUTIONS[1. First embodiment][1-1. Design]

[0017] A in Fig. 1 The shaped product 1 shown is formed by pressing a material blank, which is prepared by placing a second metal sheet 3 onto a first metal sheet 2.

[0018] The materials of the first metal sheet 2 and the second metal sheet 3 are not particularly restricted; however, an aluminum-coated iron sheet is illustrated as an example. The thicknesses of the first metal sheet 2 and the second metal sheet 3 are also not particularly restricted; however, metal sheets with thicknesses of 1 mm or more to 3 mm or less are preferably used. It should be noted that the thicknesses of the first metal sheet 2 and the second metal sheet 3 can differ from each other.

[0019] The molded product 1 is used as a component of automobile bodies, such as reinforcements, structural elements, pillars and plates.

[0020] The formed product 1 includes a projecting rib 10. The projecting rib 10 is formed by pressing and drawing the material blank in its thickness direction.

[0021] As it is in Fig. 2A and Fig. As shown in Figure 2B, the first metal sheet 2 comprises a first end 21, a second end 22, a first side wall 23, a second side wall 24, a bottom wall 25, a first angled section 26 and a second angled section 27.

[0022] The first end 21 and the second end 22 are designed to accommodate the projecting rib 10 between them. The first side wall 23, the second side wall 24, and the bottom wall 25 together form the projecting rib 10. The first side wall 23 and the second side wall 24 are arranged facing each other and coupled to each other via the bottom wall 25.

[0023] A first base surface 21A is a sheet metal surface of the first end 21 and extends parallel to a second base surface 22A, which is a sheet metal surface of the second end 22. A first wall surface 23 is a sheet metal surface of the first side wall 23 and intersects the first base surface 21A and a bottom surface 25A (positioned orthogonally to it in the present embodiment), which is a sheet metal surface of the bottom wall 25. A second wall surface 24A is a sheet metal surface of the second side wall 24 and intersects the second base surface 22A and the bottom surface 25A (positioned orthogonally to it in the present embodiment).

[0024] The floor surface 25A is positioned relative to the first base surface 21A with respect to the first wall surface 23A. The first angled section 26 couples the first wall surface 23A to the floor surface 25A. The second angled section 27 couples the second wall surface 24A to the floor surface 25A.

[0025] The second metal sheet 3 is placed on top of the first metal sheet 2 and thus welded to it. The second metal sheet 3 forms a section of an inner surface of the projecting rib 10. As shown in Fig. 2A and Fig. As shown in Figure 2B, the second metal sheet 3, which forms an inside of the projecting rib 10, is bent along the first side wall 23, the bottom wall 25 and the second side wall 24 of the first metal sheet 2.

[0026] As it is in Fig. As shown in Figure 3, the formed product 1 comprises a first weld bead 51, a second weld bead 52, a third weld bead 53, a fourth weld bead 54, a fifth weld bead 55, a sixth weld bead 56 and a seventh weld bead 57, which join the second metal sheet 3 to the first metal sheet 2. Fig. Figure 3 shows the raw material that has not yet been pressed into the shaped product 1.

[0027] Each weld bead penetrates the first metal sheet 2 and the second metal sheet 3. In other words, with each weld bead, a section of the second metal sheet 3 melts through the first metal sheet 2 onto a surface on the opposite side of the first metal sheet 2.

[0028] The first weld bead 51, the second weld bead 52 and the third weld bead 53 are formed on a first reinforcement section 41 of the second metal sheet 3, which rests on the first wall surface 23A of the first metal sheet 2.

[0029] A welding direction of the first weld bead 51 (which is a direction of a first weld forming the first weld bead 51, as well as an extension direction of the first weld bead 51) intersects a welding direction of the second weld bead 52 (which is a direction of a second weld forming the second weld bead 52, as well as an extension direction of the second weld bead 52). The welding direction of the first weld bead 51 also intersects a welding direction of the third weld bead 53 (which is a direction of a third weld forming the third weld bead 53, as well as an extension direction of the third weld bead 53).

[0030] The first weld bead 51, the second weld bead 52, and the third weld bead 53 are each linear. In other words, the directions of the first weld, the second weld, and the third weld are each straight.

[0031] The welding direction of the first weld bead 51 runs parallel to an edge line 26A of the first angled section 26. The first weld bead 51 is located near an end section of the second metal sheet 3 opposite the bottom surface 25A.

[0032] The welding directions of the second weld bead 52 and the third weld bead 53 are both orthogonal to the welding direction of the first weld bead 51. The second weld bead 52 extends from one end of the first weld bead 51 towards the base surface 25A. The third weld bead 53 extends from the other end of the first weld bead 51 towards the base surface 25A.

[0033] The second weld bead 52 and the first weld bead 53 do not extend beyond the edge line 26A of the first angled section 26. In other words, the second weld bead 52 and the third weld bead 53 are located only within the first reinforcement section 41.

[0034] The fourth weld bead 54, the fifth weld bead 55 and the sixth weld bead 56 are formed on a second reinforcement section 42 of the second metal sheet 3, which rests on the first wall surface 24A of the first metal sheet 2.

[0035] A welding direction of the fourth weld bead 54 intersects a welding direction of the fifth weld bead 55. The welding direction of the fourth weld bead 54 also intersects a welding direction of the sixth weld bead 56. The fourth weld bead 54, the fifth weld bead 55, and the sixth weld bead 56 are each linear.

[0036] The welding direction of the fourth weld bead 54 runs parallel to an edge line 27A of the second angled section 27. The fourth weld bead 54 is located near an end section of the second metal sheet 3 opposite the bottom surface 25A.

[0037] The welding directions of the fifth weld bead 55 and the third weld bead 56 are both orthogonal to the welding direction of the fourth weld bead 54. The fifth weld bead 55 extends from one end of the fourth weld bead 54 towards the base surface 25A. The third weld bead 56 extends from the other end of the first weld bead 54 towards the base surface 25A.

[0038] The fifth weld bead 55 and the sixth weld bead 56 do not extend beyond the edge line 27A of the second angled section 27. In other words, the fifth weld bead 55 and the sixth weld bead 56 are located only within the second reinforcement section 42.

[0039] The seventh weld bead 57 is formed on a third reinforcing section 43 of the second metal sheet 3, which is placed on the base surface 25A of the first metal sheet 2. The seventh weld bead 57 is linear. The welding direction of the seventh weld bead 57 runs parallel to the edge line 26A of the first angled section 26 and the edge line 27A of the second angled section 27. The seventh weld bead 57 is located between the first angled section 26 and the second angled section 27. [1-2. Manufacturing processes]

[0040] A in Fig. The method shown in section 4 for producing a shaped product is a method to shape the part 1 into Fig. 1. In the present embodiment, a method for producing a shaped product comprises a welding step S10 and a pressing step S20. <Schweißschritt>

[0041] In the welding step, the second metal sheet 3 is placed onto the first metal sheet 2 and thus welded together. Specifically, an unpressed second metal sheet 3 is placed onto an unpressed first metal sheet 2 to cover sections of the unpressed first metal sheet 2 that are to form the first wall surface 23A, the floor surface 25A, and the second wall surface 24A.

[0042] As it is in Fig. As shown in Figure 3, while the second metal sheet 3 is placed on the first metal sheet 2, the first weld is performed on the first reinforcement section 41 to form the first weld bead 51, followed by the second weld to form the second weld bead 52, and a third weld to form the third weld bead 53. The fourth weld bead 54, the fifth weld bead 55, and the sixth weld bead 56 are additionally formed on the second reinforcement section 42. Then the seventh weld bead 57 is formed on the third reinforcement section 43.

[0043] Each weld bead can be formed using welding techniques such as laser welding, plasma welding, arc welding, seam welding, hybrid welding, and adhesive welding. Laser welding or plasma welding is a preferred welding method, as it can reduce welding stress and welding time.

[0044] Laser welding can utilize lasers with different wavelengths, for example, a fiber laser, a CO2 laser, a blue laser, and a green laser. Plasma welding, for example, can employ an electron beam. <pressschritt>

[0045] In the pressing step, the formed product 1, which includes the protruding rib 10, is obtained by pressing the first metal sheet 2 with the second metal sheet 3.

[0046] The material blank obtained in welding step S10 is hot-pressed (hot-stamped) to form the projecting rib 10. The projecting rib 10 can also be formed by cold pressing if the materials of the first metal sheet 2 and the second metal sheet 3 are suitable for this process.

[0047] Accordingly, the first wall surface 23A, the second wall surface 24A, the bottom surface 25A, the first angled section 26, and the second angled section 27 are formed by drawing the first metal sheet 2 through pressing. The second metal sheet 3 is also bent along the first wall surface 23A and the second wall surface 24A. [1-3. Effects]

[0048] The first embodiment, which has been explained in detail above, produces the following effects.

[0049] (1a) By forming two weld beads whose welding directions intersect in welding step S10, at least one weld bead whose welding direction intersects a pressing direction (i.e., a drawing direction) is formed in an area to be pressed into the first wall surface 23A. Consequently, the tensile strength of the reinforcing sections 41 and 42 is increased without increasing the weld lengths, which in turn reduces the positional misalignment of the second metal sheet 3 with respect to the first metal sheet 2. In other words, problems such as positional misalignment and fracture of the second metal sheet 3, which is the reinforcing sheet, can be reduced.

[0050] In addition, in the first embodiment, the presence of the third weld bead 53 effectively reduces the positional offset of the second metal sheet 3 on the first wall surface 23A. Furthermore, the fourth weld bead 54, the fifth weld bead 55, and the sixth weld bead 56 reduce the positional offset of the second metal sheet 3 on the second wall surface 24A.

[0051] (1b) The first weld bead 51, the second weld bead 52, the third weld bead 53, the fourth weld bead 54, the fifth weld bead 55 and the sixth weld bead 56 are each linear. This reduces the positional offset of the second metal sheet 3, while also reducing the increase in weld length.

[0052] (1c) The welding direction of the first weld bead 51 runs parallel to the edge line 26A of the first angled section 26, and the welding directions of the first weld bead 51 and the second weld bead 52 are orthogonal to each other. Such a design helps to increase the tensile strength of the reinforcing sections 41 and 42 by means of the first weld bead 51, which runs orthogonally to the drawing direction. This facilitates the reduction of the positional misalignment of the second metal sheet 3. [2. Other embodiments]

[0053] The first embodiment of the present disclosure has been explained. However, the present disclosure is not limited to the embodiment mentioned above, but can be implemented in various other forms.

[0054] (2a) In the method for producing the formed product described in the first embodiment, the welding direction of the first weld bead 51 need not necessarily be parallel to the edge line 26A of the first angled section 26. Furthermore, the welding direction of the second weld bead 52 need not necessarily be orthogonal to the welding direction of the first weld bead 51.

[0055] (2b) The shape of the weld beads described in the first embodiment of the method for producing the shaped product is merely an example. The shapes of the weld beads described in Fig. The five weld beads shown can be used, for example, in the present disclosure. Different weld bead patterns that can be formed on the reinforcement sections 41 and 42 are shown in the boxes in Fig. 5 illustrates how it is in Fig. As shown in Figure 5, the number of weld beads formed in the welding step can be two, four, or more. Furthermore, a weld bead can be formed that is not coupled to another weld bead (in other words, that is arranged separately from another bead).

[0056] (2c) In the method for producing the shaped product in the first embodiment, not every weld bead necessarily needs to be linear. For example, at least the first weld bead 51 and / or the second weld bead 52 may be angled.

[0057] (2d) In the method for producing the shaped product in the first embodiment, it is not necessary for each weld bead to penetrate the first metal sheet 2 and the second metal sheet 3.

[0058] (2e) In the method for producing the shaped product in the first embodiment, the second metal sheet 3 can form a section of the outer surface of the projecting rib 10. In other words, the second metal sheet 3 can be placed on the outer surface of the first metal sheet 2 at the projecting rib 10.

[0059] (2f) Functions of one element in the aforementioned embodiments can be achieved by two or more elements. Functions of two or more elements can be integrated into one element. Part of the configuration in the aforementioned embodiments can be omitted. At least one part of the configuration in the aforementioned embodiments can be added to another part or replaced by another part of the configuration. It should be noted that all modes contained in the technical ideas characterized by the formulations listed in the claims are embodiments of the present disclosure.< / pressschritt>

Claims

[1] Method for producing a shaped product, wherein the method comprises: Welding a first metal sheet (2) superimposed with a second metal sheet (3) to the second metal sheet (3); and Pressing the first metal sheet (2) together with the second metal sheet (3), wherein during pressing a base surface (21A), a wall surface (23A), a bottom surface (25A) and an angled section (26) are formed on the first metal sheet (2), wherein the wall surface (23A) is arranged to intersect the base surface (21A), wherein the bottom surface (25A) is arranged opposite the base surface (21A) with respect to the wall surface (23A) and intersects the wall surface (23A), wherein the angled section (26) couples the wall surface (23A) and the bottom surface (25A) together, wherein a first weld is performed on a reinforcing section (41) of the second metal sheet (3) which is placed on an area of ​​the first metal sheet (2) which is formed to form the wall surface (23A); and subsequently a second weld is performed in a direction intersecting one direction of the first weld, where one direction of the first weld and one direction of the second weld are straight, and wherein the first weld and the second weld do not reach a section of the second metal sheet (3) that lies above an area of ​​the first metal sheet (2) formed in the base surface (25A). [2] Method for producing a shaped product according to claim 1, wherein one direction of the first weld runs parallel to an edge line (26A) of the angled section (26) and where one direction of the second weld is orthogonal to the direction of the first weld. [3] Method for producing a shaped product according to claim 1 or 2, wherein the first welding and the second welding are carried out by laser welding or plasma welding. [4] Formed product, comprising: a first metal sheet (2) comprising a base surface (21A) and a wall surface (23A) intersecting the base surface (21A), a bottom surface (25A) arranged opposite the base surface (21A) with respect to the wall surface (23A) and intersecting the wall surface (23A), and an angled section (26) coupling the wall surface (23A) and the bottom surface (25A) together; a second metal sheet (3) which is placed on and welded to at least the wall surface (23A) of the first metal sheet (2); a first weld bead (51) arranged on a reinforcing section (41) of the second metal sheet (3), the reinforcing section (41) being placed on the wall surface (23A) of the first metal sheet (2); and a second weld bead (52) which is arranged on the reinforcement section (41) of the second metal sheet (3), wherein a welding direction of the first weld bead (51) and a welding direction of the second weld bead (52) intersect, wherein the first weld bead (51) and the second weld bead (52) are linear, and wherein the first weld and the second weld do not reach a section of the second metal sheet (3) that lies above an area of ​​the first metal sheet (2) formed in the base surface (25A). [5] Shaped product according to claim 4, wherein the welding direction of the first weld bead (51) runs parallel to an edge line (26A) of the angled section (26) and wherein the welding direction of the second weld bead (52) is orthogonal to the welding direction of the first weld bead (51).

Images