Press mold design support system

Abstract

To reduce a press load while bringing a design shape of a press mold into a range of tolerance.SOLUTION: An acquisition unit of a press mold design support system acquires a load application portion of a press mold in which a load equal to or more than a predetermined threshold is applied to a press molded product through press mold processing. A correction value setting unit sets, within the tolerance range, a correction value for the shape or dimensions of the load application portion of the press mold so as to reduce a press mold load. A press mold correction model generation unit generates a press mold correction model according to the correction value for the shape or dimensions of the load application portion set by the correction value setting unit.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a press die design support system. [Background technology]

[0002] As the strength of press-molding materials increases, the press-molding load increases, which requires the press-molding device to have a high pressing capacity and causes problems such as increased molding costs.

[0003] To solve this problem, there is a demand to reduce the press load, while at the same time, there is a demand to keep the design shape of the press die within the tolerance range.

[0004] Patent Document 1 describes an invention in which pressing conditions and a material shape are determined by performing an analysis using an analytical model of a provisionally set material shape.

[0005] Patent Document 2 describes an invention in which a press die shape is automatically created using part manufacturing method data relating to the press molding of a part similar to the product.

[0006] Patent Document 3 describes an invention in which a press die for drawing a press product of a predetermined shape is designed using a parametric CAD device. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 6741514 [Patent Document 2] Patent No. 5832682 [Patent Document 3] Japanese Patent Application Publication No. 8-6986 Summary of the Invention [Problem to be solved by the invention]

[0008] An object of the present invention is to reduce the press load while keeping the design shape of the press die within the tolerance range. [Means for solving the problem]

[0009] The first aspect is a press die design support system that includes an acquisition unit that acquires load application locations of a press die where a load equal to or greater than a predetermined threshold is applied to a press-molded product during press molding processing, a correction value setting unit that sets a correction value for the shape or dimension of the load application locations of the press die within a tolerance range so as to reduce the press molding load, and a press die correction model generation unit that generates a press die correction model in accordance with the correction value for the shape or dimension of the load application locations set by the correction value setting unit.

[0010] A second aspect is a press die design support system in which, in the first aspect, load application locations of a press die are acquired by executing a press forming simulation.

[0011] A third aspect is the press die design support system according to the first aspect, wherein the load is an FLD value, a maximum principal strain, a minimum principal strain, a plate thickness reduction rate, or a stress.

[0012] The fourth aspect is a press die design support system in which, in the first aspect, the load application points of the press die are acquired as CAD coordinate positions, and the load application points of the press die model corresponding to the acquired CAD coordinate positions are corrected.

[0013] A fifth aspect is a press die design support system according to the first aspect, in which the correction values are set using a parametric CAD.

[0014] A sixth aspect is a press die design support system according to the first aspect, wherein the load application point of the press die is a corner portion, and correction values are set so that the radius of curvature of the corner portion is increased and the corrected positions of each coordinate portion corresponding to the corrected radius of curvature of the corner portion fall within a tolerance range. [Effects of the Invention]

[0015] According to the first to sixth aspects, the press load can be reduced while keeping the design shape of the press die within the tolerance range. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is a block diagram showing the functional configuration of a press die design support system according to an embodiment. [Figure 2] FIG. 2 is a diagram illustrating a network configuration of the press die design support system according to the embodiment. [Figure 3] FIG. 3 is a diagram illustrating an example of the hardware configuration of the design-side computer terminal, the processing-side computer terminal, and the server according to the embodiment. [Figure 4] FIG. 4 is a flowchart showing the procedure of each process performed in the press die design support system of the embodiment. [Figure 5A] FIG. 5A is a diagram showing a load application location display screen displayed on the display screen of the display device of the design-side computer terminal. [Figure 5B] FIG. 5B is a diagram illustrating a press-formed product design model. [Figure 6A] FIG. 6A is a diagram showing a correction value setting screen displayed on the display screen of the display device of the design-side computer terminal. [Figure 6B] FIG. 6B is a diagram showing a correction value setting screen displayed on the display screen of the display device of the design-side computer terminal. [Figure 6C] FIG. 6C is a diagram showing a correction value setting screen displayed on the display screen of the display device of the design-side computer terminal. [Figure 7] 7A, 7B, and 7C are diagrams showing an algorithm for a process of setting correction values using parametric CAD. [Figure 8] FIG. 8 is a diagram corresponding to FIG. 5B, showing the results of a press-forming simulation performed on the corrected press die model. [Figure 9A]FIG. 9A is a diagram showing the parts to be corrected in the press die design model, with the upper die and the lower die of the press die being separated. [Figure 9B] FIG. 9B is a diagram showing a state in which the press die design model is divided into an upper die and a lower die of the press die, and dimension (radius of curvature) correction values are input for each corner portion. [Figure 9C] FIG. 9C is a diagram showing a press-formed product (solid line) obtained by pressing a plate material using the corrected press die model, in comparison with a press-formed product (dashed line) obtained by pressing using the corrected press die model before correction. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, an embodiment of a press die design support system according to the present invention will be described with reference to the drawings.

[0018] FIG. 1 is a block diagram showing the functional configuration of a press die design support system according to an embodiment.

[0019] The press die design support system 100 of the embodiment includes an acquisition unit 110, a correction value setting unit 120, and a press die correction model generation unit .

[0020] FIG. 2 is a diagram illustrating a network configuration of the press die design support system according to the embodiment.

[0021] The functions of Figure 1 can be realized by a combination of a design-side computer terminal 10, a processing-side computer terminal 20, a server 30, and a network 40 that communicatively connects the design-side computer terminal 10, the processing-side computer terminal 20, and the server 30, as shown in Figure 2.

[0022] The functions of FIG. 1 can also be realized by a single computer terminal, that is, the design-side computer terminal 10 alone.

[0023] The network 40 is configured from the Internet, an intranet, etc. The server 30 is configured from a server device or a virtual server built on a cloud computing service, etc.

[0024] FIG. 3 is a diagram illustrating the hardware configuration of the design-side computer terminal 10, the processing-side computer terminal 20, and the server 30 according to the embodiment, and is a hardware configuration diagram for realizing the functional configuration of FIG.

[0025] As shown in Figure 3, the design-side computer terminal 10, the processing-side computer terminal 20, and the server 30 are configured so that a CPU (Central Processing Unit) 11, a ROM (Read Only Memory) 12, a RAM (Random Access Memory) 13, a storage 14, an input device 16, a display device 17, a communication interface 18, and an external storage device 19 are connected to each other so that they can communicate with each other via a system bus 15. The CPU 11 is a central processing unit that executes various programs and controls each device connected to the system bus 15. That is, the CPU 11 reads a program from the ROM 12 or the storage 14 and executes the program using the RAM 13 as a work area. The CPU 11 controls each device connected to the system bus 15 and performs various arithmetic processing in accordance with the program recorded in the ROM 12 or the storage 14.

[0026] The ROM 12 or storage 14 stores the BIOS (Basic Input / Output System) and OS (Operating System), which are control programs executed by the CPU 11, as well as various programs and necessary data that can be read and executed by a computer to realize this embodiment.

[0027] The RAM 13 functions as the main memory, work area, etc. of the CPU 11 and temporarily stores programs or data as a working area. The storage 14 is configured with an HDD (Hard Disk Drive) or an SSD (Solid State Drive) and stores various programs including the BIOS and OS, and various data.

[0028] The input device 16 includes a pointing device such as a mouse, a keyboard, a reading device such as a scanner, and is used to input various types of information.

[0029] The display device 17 is, for example, a liquid crystal display, and displays various information. The display device 17 may also function as the input device 16 by adopting a touch panel system.

[0030] The communication interface 18 is an interface for communicating with other devices, and uses standards such as Ethernet (registered trademark), FDDI, Wi-Fi (registered trademark), etc. The communication interface 18 connects to a network 40 and controls the transmission and reception of data.

[0031] The external storage device 19 is configured with various types of memory cards such as USB memory, HDD, SSD, or other external storage media that can be detachably connected.

[0032] (First embodiment)

[0033] The design-side computer terminal 10 is located in the design department of an organization that manufactures press dies (for example, a manufacturer). In the design-side computer terminal 10, three-dimensional mechanical design data MD' of a corrected press die model PM' is generated.

[0034] Here, the corrected press die model PM' is generated by correcting the pre-correction press die design model PM.

[0035] The press die design model PM and the press die correction model PM' are configured, for example, with mesh data for structural analysis. This mesh data indicates the model shapes of each member constituting the press die, namely, the punch (upper die), the die (lower die), the blank holder, and the pad.

[0036] The three-dimensional mechanical design data MD, MD' of the press die design model PM and the press die correction model PM' include CAD (Computer-Aided Design) data. The three-dimensional mechanical design data MD, MD' of the press die design model PM and the press die correction model PM' include design dimension data SZD, material data, and processing condition data for each part of the press die. The three-dimensional mechanical design data MD, MD' of the press die design model PM and the press die correction model PM' can be constructed using parametric CAD. For example, the corner R of the press die is defined by the coordinate positions of multiple (e.g., three) points A1, A2, and A3 on the corner R.

[0037] The three-dimensional mechanical design data MD, MD' of the press die design model PM and the press die modified model PM' created on the design-side computer terminal 10 are stored in a database 31 of the server 30 via a network 40. Similarly, for the press-molded product, the three-dimensional mechanical design data SD of the press-molded product design model SM is stored in the database 31 of the server 30.

[0038] The processing-side computer terminal 20 is located in the factory processing department of an organization (for example, a manufacturer) that manufactures press dies.

[0039] The machining-side computer terminal 20 accesses the server 30 via the network 40 and acquires the three-dimensional mechanical design data MD′ of the corrected press die model PM′ stored in the database 31 .

[0040] The processing-side computer terminal 20 generates NC data based on the acquired three-dimensional mechanical design data MD' of the corrected press die model PM'. An NC machine tool is controlled according to the generated NC data, and the press die is manufactured.

[0041] 4 is a flowchart showing the procedure of each process performed in the press die design support system of the embodiment. A program for executing each process performed in the press die design support system is stored in a database 31 of a server 30.

[0042] Each process performed in the press die design support system of the embodiment will be described below with reference to the flowchart shown in FIG.

[0043] (Acquisition process S1)

[0044] The acquisition unit 110 acquires load application locations of a press die where a load equal to or greater than a predetermined threshold value is applied to a press-molded product by press-molding.

[0045] Here, the load is the FLD value, maximum principal strain, minimum principal strain, thickness reduction rate, or stress. The FLD value is a physical quantity such as limit strain in the forming limit diagram (FLD).

[0046] The acquisition unit 110 acquires the load application locations of the press die by executing a press forming simulation.

[0047] An instruction to execute a press forming simulation is given on the display screen of the display device 17 of the design-side computer terminal 10, and the execution results are displayed on the display screen.

[0048] That is, when an instruction to start a press forming simulation is given on the display screen of the display device 17 of the design side computer terminal 10, the server 30 is accessed via the network 40, the program and data necessary for calculating the press forming simulation are read from the database 31, and the press forming simulation is started.

[0049] When the press-forming simulation is started, the press-forming simulation is performed using the three-dimensional mechanical design data SD of the press-formed product design model SM and the three-dimensional mechanical design data MD of the press die design model PM. The material of the press-formed product is, for example, high tensile strength steel (HTSS). Such press-formed products have high material strength, and a large press-forming load is applied to the press die due to the processing reaction force, which may cause cracks, wrinkles, springback, etc.

[0050] FIG. 5A shows a load application location display screen 210 displayed on the display screen of the display device 17 of the design-side computer terminal 10. As shown in FIG.

[0051] When the press forming simulation is executed, by comparing the forming limit diagram FLD with the distortion state obtained by executing the simulation, the load application points 211, 212 of the press die design model PM where the load such as the FLD value of the press-molded product design model SM is equal to or greater than a predetermined threshold value are obtained.

[0052] The load application point display screen 210 displays load application points 211 and 212 of the press die design model PM.

[0053] 5B is a diagram illustrating an example of the press-molded product design model SM, and shows load application points 211' and 212' of the press-molded product design model SM that correspond to the load application points 211 and 212 of the press die design model PM. At the load application points 211' and 212', the FLD values are equal to or greater than a predetermined threshold value, and there is a risk of cracks occurring.

[0054] The acquisition unit 110 acquires the load application points 211 and 212 of the press die design model PM as CAD coordinate positions of the press die design model PM'.

[0055] (Correction value setting process S2)

[0056] The correction value setting unit 120 sets correction values for the shapes or dimensions of the load application points 211, 212 of the press die design model PM within the tolerance range so as to reduce the press forming load.

[0057] The increase in press forming load is caused by the increase in material strength of the press-formed product and the shape of the press die. By using a press die with a shape and dimensions that reduce the load, it is possible to suppress the processing reaction force that accompanies the increase in material strength, and by maintaining the dimensions of the press die within the tolerance range, it is possible to suppress the occurrence of excessive contact points, i.e., the occurrence of stress concentration.

[0058] On the display screen of the display device 17 of the design-side computer terminal 10, correction values for the shape or dimensions of the load application points 211, 212 of the press die design model PM can be set.

[0059] FIG. 6A shows a correction value setting screen 220 displayed on the display screen of the display device 17 of the design-side computer terminal 10. As shown in FIG.

[0060] The correction value setting screen 220 has a display section 221 for displaying the load application points 211, 212 of the press die design model PM, and a correction value setting section 222 for setting a correction value.

[0061] As shown in the display section 221, the load application points 211 of the press die design model PM correspond to the corners R1 and R3, and the load application points 212 of the press die design model PM correspond to the corners R2 and R4.

[0062] A correction instruction 223 to reduce the radii of curvature of the corners R1, R3, R2, and R4 is displayed, for example, as a pop-up, on the correction value setting screen 220. Also, the display section 221 displays, for example, the pointer, the parts to be corrected and the dimension names R1, R2, R3, and R4 (corner parts).

[0063] Figure 9A shows the areas that need to be modified by dividing the press die design model PM into the upper die UD and lower die LD of the press die. The arrows indicate the direction in which the corners should be modified to reduce the radius of curvature of the corners.

[0064] As shown in FIG. 9A, it is displayed that the corners R4 and R3 of the upper mold UD, the corners R2 and R1 of the lower mold LD should be corrected in the directions indicated by the arrows to reduce their curvature radii.

[0065] The upper mold UD and the lower mold LD may be simply displayed without distinction as in the display unit 221, or the upper mold UD and the lower mold LD may be displayed in detail with distinction as shown in FIG. 9A.

[0066] In addition, when it is desired to significantly reduce the radius of curvature of the corners, as opposed to relaxing it, the corners R4, R3, R2, and R1 of the lower die LD, upper die UD, and upper die UD can be modified to significantly reduce their radius of curvature.

[0067] In response to this correction instruction, the operator can manually set the correction value.

[0068] The design dimension (radius of curvature) values (design values) r1, r2, r3, and r4 for each of the corners R1, R2, R3, and R4 are displayed in the correction value setting section 222. The operator can input the dimension (radius of curvature) correction value for each of the corners R1, R2, R3, and R4 in the correction value input section 222A (e.g., a text box) of the correction value setting section 222.

[0069] Fig. 6B shows the correction value setting screen 230 displayed on the display screen of the display device 17 of the design-side computer terminal 10. Fig. 6B shows a state in which dimension (radius of curvature) correction values r'1, r'2, r'3, and r'4 have been input for each of the corners R1, R2, R3, and R4 in the correction value input section 222A (e.g., text box) of the correction value setting section 222.

[0070] Figure 9B shows the state in which the press die design model PM is divided into the upper die UD and lower die LD of the press die, and dimension (radius of curvature) correction values r'1, r'2, r'3, and r'4 are input for each corner portion R1, R2, R3, and R4.

[0071] As shown in Figure 9B, corners R4 and R3 of the upper mold UD, corners R2 and R1 of the lower mold LD are corrected in the directions indicated by the arrows, and their radii of curvature are relaxed to r'4, r'3, r'2 and r'1, respectively.

[0072] The upper mold UD and the lower mold LD may be simply displayed without distinction as in the display unit 221, or the upper mold UD and the lower mold LD may be displayed in detail with distinction as shown in FIG. 9B.

[0073] In addition, when sharply reducing the radius of curvature of the corners, as opposed to relaxing it, the corners R4 of the lower die LD, R3 of the lower die LD, R2 of the upper die UD, and R1 of the upper die UD are each corrected, and their radii of curvature become sharply small.

[0074] A modified press die model PM' (shown by a solid line) whose shape and dimensions have been modified according to the inputted modification values r'1, r'2, r'3, and r'4 is displayed on the display unit 221. The pre-modification press die design model PM (shown by a broken line) may also be displayed.

[0075] 6C, the tolerance range ΔS (shown by a dashed line) may be displayed on the display unit 221 of the correction value setting screen 220, 230. Fig. 6C shows that the corner R'1, whose shape and dimensions have been corrected, falls between the upper limit SU and the lower limit SL of the tolerance range ΔS.

[0076] By displaying the display shown in FIG. 6C, it is possible to confirm whether the corner portion R'1 whose shape and dimensions have been corrected according to the correction value input to the correction value input section 222A of the correction value setting section 222, for example, the correction value r'1, falls within the tolerance range ΔS.

[0077] Note that the recommended correction values r'1, r'2, r'3, and r'4 for keeping the tolerance range ΔS may also be displayed. By displaying them in this manner, it is possible to use them as a guide when inputting the correction values r'1, r'2, r'3, and r'4 into the correction value input section 222A of the correction value setting section 222.

[0078] In addition, the upper limit correction value (upper limit correction value of the curvature radius) for keeping the tolerance range ΔS may also be displayed. By displaying this, it can be used as a guide when inputting the correction values r′1, r′2, r′3, and r′4 into the correction value input section 222A of the correction value setting section 222.

[0079] Furthermore, if the correction values r'1, r'2, r'3, r'4 input to the correction value input section 222A of the correction value setting section 222 are values that exceed the tolerance range ΔS, a warning may be displayed. By issuing this warning, it is possible to prompt the user to change the correction values r'1, r'2, r'3, r'4 input to the correction value input section 222A of the correction value setting section 222.

[0080] The correction values r'1, r'2, r'3, and r'4 are input to the correction value input section 222A of the correction value setting section 222, and if it is confirmed that they are within the tolerance range ΔS, the confirm button 224 is pressed. When the confirm button 224 is pressed, the design dimension data SZD is corrected according to the correction values r'1, r'2, r'3, and r'4, and the corrected design dimension data SZD' is stored in the database 31 of the server 30. The corrected design dimension data SZD' is used to generate a corrected press die model PM'.

[0081] Although the above description has been given taking an example where the correction values r'1, r'2, r'3, and r'4 are manually set, the correction values r'1, r'2, r'3, and r'4 may also be set automatically.

[0082] In this case, the design dimension data SZD may be corrected in accordance with the automatically set correction values r'1, r'2, r'3, and r'4 without any room for further correction by the operator.

[0083] In addition, leaving room for further correction by the operator, the design dimension data SZD may be corrected according to the automatically set correction values r'1, r'2, r'3, r'4 or correction values r'1, r'2, r'3, r'4 that are further corrected from the automatically set correction values r'1, r'2, r'3, r'4.

[0084] The correction value setting unit 120 can set the correction values r'1, r'2, r'3, and r'4 using parametric CAD.

[0085] 7(A), (B), and (C) show an algorithm for a process of setting a correction value, for example, correction value r'1, using parametric CAD. In parametric CAD, corner R1 is defined by the coordinate positions of multiple (for example, three) points on corner R1: start point A1, midpoint A2, and end point A3.

[0086] As shown in FIG. 7(A), the dimensions of the corner portion R1 of the press die design model PM are a radius of curvature r1 (=4 mm).

[0087] As shown in FIG. 7(B), when a correction value r'1 (=7 mm) is set for the curvature radius r1 of the corner R1, as shown in FIG. 7(C), the start point A1, midpoint A2, and end point A3 on the arc defined corresponding to the curvature radius r1 of the corner R1 before correction are offset to the start point A'1, midpoint A'2, and end point A'3 on the arc defined corresponding to the curvature radius r'1 (=4 mm) of the corner R'1 after correction, respectively. Here, the offset amount of the midpoint A2 is set so that the coordinate position of the midpoint A'2 after correction falls within the tolerance range ΔS (=±0.5 mm), that is,

[0088] A2-A´2<0.5mm

[0089] It is set so that:

[0090] In this way, corrected design dimension data R1D (radius of curvature r'1, start point A'1, midpoint A'2, end point A'3) is acquired for the corner portion R1.

[0091] Similarly, for the other corners R2, R3, and R4, the corrected design dimension data R2D (radius of curvature r'2, start point A'1, midpoint A'2, end point A'3), R3D (radius of curvature r'3, start point A'1, midpoint A'2, end point A'3), and R4D (radius of curvature r'3, start point A'1, midpoint A'2, end point A'3) are obtained.

[0092] The design dimension data SZD is corrected using the corrected design dimension data R1D, R2D, R3D, and R4D for the corners R1, R2, R3, and R4, respectively. The corrected design dimension data SZD' is stored in the database 31 of the server 30. The corrected design dimension data SZD' is used to generate a corrected press die model PM'.

[0093] (Press die correction model generation process S3)

[0094] The press die corrected model generating unit 130 generates a press die corrected model PM' in accordance with the correction values r'1, r'2, r'3, r'4 of the shape or dimensions of the load application portion set by the correction value setting unit 120.

[0095] The design dimension data SZD' corrected according to the correction values r'1, r'2, r'3, and r'4 is stored in the database 31 of the server 30. The press die corrected model generation unit 130 generates a press die corrected model PM' using the corrected design dimension data SZD'.

[0096] It is also possible to perform a press forming simulation on the corrected press die model PM' and confirm that the quality of the press-formed product has been improved.

[0097] 9C shows a press-formed product SM′ (solid line) obtained by pressing a plate material using the modified press die model PM′, in comparison with a press-formed product SM (dashed line) obtained by pressing a plate material using the modified press die model PM before modification. The right side of the figure shows the shape of the plate material SMP before processing.

[0098] As shown in Figure 9C, the corrected press-formed product SM' (solid line) has a reduced radius of curvature at the corners R4 and R2 compared to the press-formed product SM (dashed line) before correction, and it was confirmed that there is no risk of cracks or other problems occurring.

[0099] FIG. 8 is a diagram corresponding to FIG. 5B, and shows the results of a press-forming simulation performed on the corrected press die model PM′.

[0100] As shown in FIG. 8, at the load application points 211' and 212' of the press-formed product design model SM, the FLD values were below a predetermined threshold value, and it was confirmed that there was no risk of cracks occurring.

[0101] It was also confirmed that the press load of the press molding device was reduced.

[0102] According to this embodiment, the press load can be reduced while keeping the design shape of the press die within the tolerance range.

[0103] According to this embodiment, it is possible to easily design a press die that can reduce the press load while keeping the design shape of the press die within the tolerance range, without requiring any skill.

[0104] According to this embodiment, it is possible to manufacture a press die that can reduce the press load while keeping the design shape of the press die within the tolerance range, in a short time and at low cost, without the need to create a prototype or manually modify the prototype. [Explanation of symbols]

[0105] 100 Press die design support system 110 Acquisition Department 120 Correction value setting section 130 Press die correction model generation unit

Claims

1. an acquisition unit that acquires load application locations of a press die where a load equal to or greater than a predetermined threshold is applied to a press-molded product by press molding; a correction value setting unit that sets a correction value for the shape or dimension of the load application portion of the press die within a tolerance range so as to reduce the press forming load; a press die correction model generation unit that generates a press die correction model in accordance with the correction value of the shape or dimension of the load application portion set by the correction value setting unit; A press die design support system equipped with

2. By performing a press forming simulation, the load application points of the press die are obtained. The press die design support system according to claim 1.

3. The load is an FLD value, a maximum principal strain, a minimum principal strain, a plate thickness reduction rate, or a stress. The press die design support system according to claim 1.

4. The load application point of the press die is acquired as a CAD coordinate position, The load application location of the press die model corresponding to the acquired CAD coordinate position is corrected. The press die design support system according to claim 1.

5. Correction values are set using parametric CAD; The press die design support system according to claim 1.

6. The load application portion of the press die is a corner portion, and a correction value is set so that the radius of curvature of the corner portion is increased and the corrected position of each coordinate portion corresponding to the corrected radius of curvature of the corner portion falls within a tolerance range. The press die design support system according to claim 5.

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