Excess Meat Shape Creation System and Excess Meat Shape Creation Method
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-09-26
- Publication Date
- 2026-04-07
Smart Images
Figure 2026059082000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a flash shape creation system and a flash shape creation method.
Background Art
[0002] Conventionally, a flash shape creation system for designing a die model capable of press-forming products with high yield has been known (see, for example, Patent Document 1). Specifically, this system repeatedly modifies parameters related to flash so that the thickness reduction rate, which is a criterion for evaluating deformations (defects) such as cracks and wrinkles generated in a press-formed product (product part), falls within a predetermined range, thereby determining the final flash shape formed in the die model.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] By the way, generally, before a product design created by a designer is finalized as a specific product shape, verification of the product shape is performed as to whether or not deformations (defects) occur during press forming. In this verification, it is also conceivable to use a conventional flash shape creation system (see, for example, Patent Document 1) when conducting a simulation test for evaluating defects that may occur in the product shape. However, the conventional system has a problem that the man-hours (generation time) required until the final flash shape is determined increase. Further, in the conventional system, there is a problem that it is impossible to determine whether the evaluation of the deformation of the product until the final flash shape is determined is due to the shape of the product itself or due to the flash shape.
[0005] The object of the present invention is to provide a material waste shape creation system and method that can reduce the time required to generate material waste compared to conventional methods, and that can accurately verify whether or not deformation will occur during the initial design phase. [Means for solving the problem]
[0006] The present invention, which solves the above problems, is a excess material shape creation system for creating an excess material shape of a press die from a product shape, comprising: a basic cross section setting means for generating excess material at a predetermined cross section from the cutting line of the product shape; a determination means for determining whether a defect occurs during pressing due to the excess material generated by the basic cross section setting means; a correction means for correcting the portion of the cutting line that the determination means has determined to cause a defect to a corrected cutting line that the determination means has determined not to cause a defect; and a generation means for generating excess material from the corrected cutting line based on a predetermined cross section generated by the basic cross section setting means.
[0007] Furthermore, the present invention, which solves the above problems, is a method for creating excess material shape for a press die from a product shape, comprising: a basic cross section setting step for generating excess material at a predetermined cross section from the cutting line of the product shape; a determination step for determining whether a defect occurs during pressing due to the excess material generated by the basic cross section setting step; a correction step for correcting the portion of the cutting line that is determined to cause a defect by the determination step to a corrected cutting line that is determined not to cause a defect by the determination step; and a generation step for generating excess material from the corrected cutting line based on the predetermined cross section generated by the basic cross section setting step. [Effects of the Invention]
[0008] According to the excess material shape creation system and excess material shape creation method of the present invention, the time required to generate excess material can be reduced compared to conventional methods, and it is possible to accurately verify whether or not deformation will occur during the initial design stage. [Brief explanation of the drawing]
[0009] [Figure 1] This is an overall perspective view of an outer panel of an automobile door, which is an example of a product shape to be applied in the excess material shape creation system of this embodiment. [Figure 2] Figure 1 is a magnified perspective view of a portion of the outer panel. [Figure 3] This is a partially enlarged perspective view of the draw model generated based on the design of the outer panel shown in Figure 1. [Figure 4] This is a side view of the draw model showing the excess material generated extending from the revised cutting line. [Figure 5] This is a block diagram of the excess material shape creation system of this embodiment. [Figure 6] This is a flowchart of the excess material shape creation method of this embodiment, including the excess material shape creation procedure performed by the excess material shape creation system of this embodiment. [Figure 7] This is an explanatory diagram of the basic cross-sectional structure in the drawing model shown in the VII-VII section of Figure 3. [Figure 8] Figure 3 is an explanatory diagram of the R value and scissor angle detected by the determination unit of the excess material shape creation system for the determination points on the boundary line in the draw model. [Figure 9A] This table shows examples of detecting the R value of the judgment point on the dividing line and the scissor angle. [Figure 9B] This graph shows the change in the R value and the angle of the scissors in Figure 9A. [Figure 10] This graph shows the relationship between the threshold value TH1 for the scissor angle [degrees] and the threshold value TH2 for the R value [mm], which are referenced by the judgment unit of the excess material shape creation system when determining whether a defect occurs during pressing due to excess material. [Modes for carrying out the invention]
[0010] Next, embodiments for implementing the excess material shape creation system of the present invention will be described in detail with reference to the drawings as appropriate. Automotive panel products, such as outer panels and roof panels, are formed by pressing a sheet of material into a mold shaped to a predetermined product form. The panel product is then obtained by cutting out a portion of the product from this press-formed product and, for example, applying hemming to the edges to form a flange and creating bolt insertion holes.
[0011] Once the product shape design is complete, a draw model of the press-formed part is generated from this design. The model shape is then evaluated using CAE (Computer-Aided Engineering) to verify whether the designed shape is actually press-formable. The excess material shape creation system of the present invention is used when conducting simulation tests to evaluate product shapes. Below, the excess material shape creation system of the present invention will be described in detail using the outer panel of an automobile door as an example product shape.
[0012] Figure 1 is an overall perspective view of the designed outer panel 10. Figure 2 is a partially enlarged perspective view of the outer panel 10 viewed from the direction indicated by arrow II in Figure 1. Figure 3 is a partially enlarged perspective view of the draw model 9 generated based on the designed outer panel 10 in Figure 1. In Figure 3, the symbol PL represents the trim line in the product part 91 (outer panel 10). Figure 4 is a partially side view of the draw model 9 in which a modified trim line PLa has been generated, which has been modified to prevent deformation (defects) such as cracks and wrinkles from occurring in the product part 91, based on the judgment criteria described later, for the part Pa of the trim line PL of the draw model 9.
[0013] The outer panel 10 shown in Figure 1 is assumed to be the outer panel 10 of a side door located on the left side of the automobile. This side door, although not shown in the illustration, has a hinge at the front and the rear edge is the pivot side. As shown in Figure 2, the designed outer panel 10 is curved such that its central vertical section bulges slightly outward from the vehicle body (left side in Figure 2) compared to both vertical ends. In addition, it is assumed that the outer panel 10 forms a cut-off line PL at the trailing edge side between it and the center pillar (not shown) when the side door (not shown) is closed.
[0014] Next, referring to FIG. 3, the relationship between the outer panel 10 (product) and the draw model 9 will be described. The draw model 9 includes a product part 91 which is the outer panel 10 designed in terms of design, a surplus 92 assumed to be cut off, and a die face part 93 assumed to suppress wrinkles when pressing with a mold. In FIG. 3, for the sake of drawing convenience, the surplus 92 is shaded.
[0015] When the design is carried out, the product shape of the outer panel 10 is obtained, so the product part 91 of the draw model 9 can be generated along with the design. Also, since the die face part 93 is a part assumed to suppress wrinkles, it is basically a substantially flat surface and can be generated relatively easily. On the other hand, the surplus 92 is deformed according to the press working of the product shape. For this reason, in a conventional surplus shape creation system (for example, refer to Patent Document 1), a lot of time has been taken for the generation of the surplus 92 by repeatedly correcting the parameters related to the surplus 92 so that deformations (defects) such as cracks and wrinkles do not occur in the product part 91.
[0016] In contrast, as shown in FIG. 4, the present invention sets a corrected cut-off line PLa where no deformation (defect) occurs for a part Pa determined to cause deformation (defect) during pressing due to the surplus 92 (refer to FIG. 7) generated by the following basic cross-section setting among the cut-off lines PL, and is configured to generate the surplus 92 (refer to FIG. 7) by the basic cross-section setting from this corrected cut-off line PLa. That is, the surplus 92 at the part Pa determined to cause deformation (defect) is formed from the corrected cut-off line PLa offset toward the die face part 93 side from the cut-off line PL toward the die face part 93 side. Furthermore, this corrected boundary line PLa is composed of tangent arcs to the Pa-side end of boundary line PL (parts other than part Pa) that have been determined not to cause deformation (defects). Furthermore, a buffer surface 94 is formed between the dividing line PL and the corrected dividing line PLa in the area Pa where deformation (defect) was determined to occur, with a lighter shade than the excess material 92. This buffer surface 94 will be explained later along with the basic excess material cross section Be (see Figure 7).
[0017] The excess material shape creation system of an embodiment of the present invention that generates such excess material 92 (see Figure 4) will be described in detail below. Figure 5 is a block diagram of the excess material shape creation system 1 of this embodiment. As shown in Figure 5, the excess material shape creation system 1 includes an input device 2 into which an operator inputs various data and commands, a calculation device 4 that performs various calculations in response to the input from the input device 2, a display device 6 that displays images, and a storage device 8 that stores various data.
[0018] Input device 2 consists of hardware such as a keyboard and mouse that can be operated by the operator. This input device 2 also includes removable devices such as a stick memory and an internet connection port. Data and commands output from input device 2 by the operator are input to the arithmetic unit 4.
[0019] The display device 6 consists of hardware such as a liquid crystal display capable of displaying images. The display unit of this display device 6 displays, for example, a 3D image of the drawing model 9 as a result of processing by the arithmetic unit 4.
[0020] The storage device 8 is mainly composed of ROM (Read Only Memory) and RAM (Random Access Memory). The ROM (Read Only Memory) stores the shape data of the product section 91, the shape data of the die face section 93, and the shape data of the basic excess material cross section, all generated using CAD (Computer Aided Design). The shape data of this basic excess material cross section will be explained in detail later. Furthermore, the ROM stores a predetermined program. The RAM then loads the program read from the ROM.
[0021] The arithmetic unit 4 is composed of hardware such as a CPU (central processing unit). The arithmetic unit 4 generates excess material 92 (see Figure 4) extending from the base edge of the modified cutting line PLa (see Figure 4) by executing a program deployed in the RAM of the storage device 8, while referring to the shape data of the product section 91, the shape data of the die face section 93, and the shape data of the basic excess material cross section described later, all stored in the ROM of the storage device 8. Specifically, as shown in Figure 5, the calculation unit 4 includes a basic cross-section setting unit 41, a determination unit 42, a cutting line correction unit 43, and an excess material generation unit 44. The basic cross-section setting unit 41 corresponds to the "basic cross-section setting means" as referred to in the claims. The determination unit 42 corresponds to the "determination means" as referred to in the claims. The border line correction unit 43 corresponds to the "correction means" as referred to in the claims. The excess material generation unit 44 corresponds to the "generation means" as referred to in the claims. The specific procedures performed by these elements constituting the computing unit 4 will be explained next, along with the operation of the excess material shape creation system 1 (see Figure 5).
[0022] The following describes the method for creating the excess material shape in this embodiment, while showing the specific steps performed by the elements constituting the arithmetic unit 4. Figure 6 is a flowchart of the excess material shape creation method of this embodiment, including the excess material shape creation procedure performed by the excess material shape creation system 1. As shown in Figure 6, the excess material shape creation method of this embodiment, implemented in this excess material shape creation system 1, first involves an operator operating an input device 2 (see Figure 5) to input shape data (CAD data) of the product section 91 (see Figure 3) and the die face section 93 (see Figure 3), which are then stored in the storage device 8 (see Figure 5) (step S1). The shape data of the product section 91 can be the CAD data used when the outer panel 10 (see Figure 1) was designed. In this embodiment, the shape data of the die face section 93 is assumed to be pre-prepared shape data consisting of a substantially flat plane that matches the contour of the product section 91.
[0023] Next, the shape data of the basic excess material cross section is input by the operator using the input device 2 (see Figure 5) and stored in the storage device 8 (see Figure 5) (step S2). Here, we will explain the basic section of the excess meat. Figure 7 is an explanatory diagram of the configuration of basic section B in draw model 9 (see Figure 3), which includes the basic excess section Be, and is a cross-sectional view taken along line VII-VII in Figure 3.
[0024] As shown in Figure 7, the basic cross section B is composed of the cross section Cs1 of the product section 91, the cross section Cs2 of the die face section 93, and the basic excess material cross section Be. In the basic cross-section B, the shape of the cross-section Cs1 of the product section 91 and the shape of the cross-section Cs2 of the die face section 93 fundamentally change when the cross-sectional position is displaced in the vertical direction as shown in Figure 3. In contrast, the shape of the basic excess material cross-section Be in this embodiment remains the same in the vertical direction. In other words, the basic excess material cross-section Be maintains the shape of the basic excess material cross-section Be stored in step S2 of Figure 6 along the longitudinal direction of the trim line PL.
[0025] As shown in Figure 7, the basic excess material cross section Be is composed of a cross section line consisting of a straight line and a curved section that connects the position of the cutting line PL of the product section 91 and the position of the inside Pe of the die face section 93. In step S2 of Figure 6, the length L2 (see Figure 7) of the horizontal section 92b including the position Cp of the cutting line after press forming, the length L1 (see Figure 7) of the product section-side inclined section 92a connecting the horizontal section 92b and the product section 91, and the length L3 (see Figure 7) of the die-face section-side inclined section 92c connecting the horizontal section 92b and the die-face section 93 are input.
[0026] Furthermore, in step S2 of Figure 6, the radius of curvature r1 in the R section between the product section 91 and the product section-side inclined section 92a shown in Figure 7, and the wall angle a1 formed by the product section 91 and the product section-side inclined section 92a are input. Also in step S2 of Figure 6, the radius of curvature r2 and wall angle a2 between the product section-side inclined section 92a and the horizontal section 92b shown in Figure 7, the radius of curvature r3 and wall angle a3 between the horizontal section 92b and the die face section-side inclined section 92c, and the radius of curvature r4 and wall angle a4 between the die face section-side inclined section 92c and the die face section 93 are input. As a result, the shape data of the basic excess material cross section Be (see Figure 7) is stored in the storage device 8 (see Figure 5) (step S2 of Figure 6).
[0027] The shape of the basic excess material cross-section Be shown in Figure 7 is merely an example of a basic excess material cross-section Be applicable to this embodiment, and the basic excess material cross-section Be is not limited to this. Other examples of the basic excess material cross-section Be, although not shown in the figures, include, for example, one in which the horizontal section 92b is omitted and it consists only of the R section and one or more inclined sections, or one in which it consists of the R section, multiple horizontal sections and multiple inclined sections.
[0028] Next, the excess material shape creation system 1 (see Figure 5) forms the excess material 92 (see Figure 3) from the dividing line PL (see Figure 3), as shown in Figure 6 (step S3). In this process, the excess material shape creation system 1 (see Figure 5) sets the basic cross section B (see Figure 7) at any position in the vertical direction of Figure 3 by referring to the shape data of the product section 91, the shape data of the die face section 93, and the shape data of the basic excess material cross section Be stored in the storage device 8. The basic section setting unit 41 then generates a draw model 9 (see Figure 3) having excess material 92 (see Figure 3) by connecting a plurality of basic section B (see Figure 7A) generated along the extension direction of the trim line PL (see Figure 3), while referring to the shape data of the product section 91 (see Figure 3) and the shape data of the die face section 93 (see Figure 3).
[0029] Next, the excess material shape creation system 1 (see Figure 5) detects an improper portion of the cutoff line PL of the generated draw model 9 (see Figure 3) as shown in Figure 6 (step S4). In this step, the excess material shape creation system 1 (see Figure 5) determines whether deformation (defect) occurs during pressing due to the excess material 92 (see Figure 3) formed from the cutoff line PL (see Figure 3) by the determination unit 42 (see Figure 5). In this determination, the determination unit 42 (see Figure 5) refers to the shape data of the product unit 91 (see Figure 3) stored in the storage device 8 (see Figure 5), and sets multiple determination points d between the starting point PL1 and the ending point PL2 of the dividing line PL, as shown in Figure 3. There are no particular restrictions on the pitch between the determination points d as long as they are equally spaced, but it is desirable to set them at minute intervals of about 1 mm. Note that in Figure 3, the determination point d in the vertical center of the dividing line PL is omitted for ease of drawing.
[0030] Furthermore, the determination unit 42 (see Figure 5) detects the R value [mm] and the scissor angle [degrees] at the determination point d (see Figure 3) on the dividing line PL (see Figure 3). Figure 8 is an explanatory diagram of the R value [mm] and scissor angle [degrees] detected by the determination unit 42 for the determination point d on the dividing line PL. In Figure 8, the symbol d1 is an arbitrary determination point among the multiple determination points d (see Figure 3) set by the determination unit 42, which is subject to detection of the R value [mm] and the scissor angle [degrees]. The symbols d2 and d3 are determination points among the multiple determination points d (see Figure 3) that are adjacent to determination point d1 on the dividing line PL so as to sandwich it. As shown in Figure 8, the R value [mm] is the radius of the arc passing through the three judgment points d1, d2, and d3. The scissor angle [degrees] is the interior angle formed by the line segment connecting judgment point d1 and judgment point d2 and the line segment connecting judgment point d1 and judgment point d3. In this embodiment, the reciprocal of the curvature can also be applied to the R value.
[0031] The determination unit 42 detects the R value [mm] and the scissor angle [degrees] for all determination points d shown in Figure 3, except for the determination point d at the starting point PL1 and the determination point d at the ending point PL2 of the dividing line PL. Figure 9A is a table showing an example of detection of the R value [mm] and scissor angle [degrees] of the determination point d on the boundary line PL by the determination unit 42. In Figure 9A, the point sequence numbers represent the order of the determination points d (see Figure 3) that are continuous from the starting point PL1 (see Figure 3) to the ending point PL2 (see Figure 3) on the boundary line PL (see Figure 3). Figure 9B is a graph showing the changes in R value [mm] and scissor angle [degrees] in Figure 9A. In Figure 9B, TH1 is the threshold scissor angle [degrees] at which deformation (defects) does not occur in the product part 91 (see Figure 4) during pressing, and TH2 is the threshold R value [mm] at which deformation (defects) does not occur in the product part 91 (see Figure 4) during pressing.
[0032] Then, the determination unit 42 determines that if the scissor angle [degrees] shown in Figure 9B falls below the threshold TH1, or if the R value [mm] falls below the threshold TH2, the range to which the determination point d (see Figure 3) belongs is an improper section Pa (see Figure 4) of the border line PL. In other words, the area between the R value shaded in Figure 9A and the determination point d (see Figure 3), indicated by point sequence numbers 17 and 22 to which the shaded scissor angle belongs, is determined to be an improper section Pa of the border line PL, as shown in Figure 4.
[0033] In this embodiment, the thresholds TH1 and TH2 are set as follows. Figure 10 is a graph showing the relationship between the threshold value TH1 of the clamping angle [degrees] and the threshold value TH2 of the R value [mm], which the determination unit 42 (see Figure 5) refers to when determining whether a defect occurs during pressing due to excess material 92 (see Figure 3). This graph was created from the results of simulation tests conducted on a draw model 9 (see Figure 3) of a press die in which excess material 92 was formed by the basic cross-section setting unit 41 (basic cross-section setting means) for multiple combinations of clamping angle [degrees] and R value [mm].
[0034] In this embodiment, the determination unit 42 (see Figure 5) uses the minimum stress value at which deformation (defects) may occur in the product part 91 during pressing as an indicator, and sets a reference value for stress at which deformation (defects) will not occur. As shown in Figure 10, the stress value used as the reference value in this embodiment is set to 0.1 Gpa based on simulation tests conducted in advance. In Figure 10, as indicated by the white arrow labeled OK, if the stress during pressing is less than or equal to the reference value of 0.1 Gpa, no deformation (defects) such as cracks or wrinkles will occur in the product part 91 of the draw model 9 (see Figure 3). Also, as indicated by the white arrow labeled NG in Figure 10, if the stress during pressing exceeds the reference value of 0.1 Gpa, deformation (defects) such as cracks or wrinkles will occur in the product part 91 of the draw model 9 (see Figure 3).
[0035] Furthermore, as shown in Figure 10, there is a correlation between the stress generated in the product part 91 during pressing, the R value, and the clamp angle. Specifically, if 0.1 Gpa is set as the upper limit of stress at which deformation (defects) does not occur in the product part 91, then deformation (defects) may occur in the product part 91 of the draw model 9 (see Figure 3) if the clamp angle falls below 160 degrees. Also, if 0.1 Gpa is set as the upper limit of stress at which deformation (defects) does not occur in the product part 91, then deformation (defects) may occur in the product part 91 of the draw model 9 (see Figure 3) if the R value falls below 650 mm.
[0036] In other words, in the examples shown in Figures 9A, 9B, and 10, the determination unit 42 (see Figure 5) detects an inappropriate area Pa (see Figure 4) on the dividing line PL (see Figure 4) by setting a scissor angle of 160 degrees as the threshold TH1 and an R value of 650 mm as the threshold TH2 (step S4 in Figure 6). In this embodiment, the reference value for stress can be set to a value smaller than the reference value (0.1 Gpa), such as 0.01 Gpa, as shown in Figure 10, taking into account safety factors and the like.
[0037] Next, the excess material shape creation system 1 (see Figure 5) generates a corrected boundary line PLa (see Figure 4) for the inappropriate part Pa (see Figure 4), as shown in Figure 6 (step S5). In this process, the trim line correction unit 43 (see Figure 5) of the excess material shape creation system 1 (see Figure 5) readjusts the inappropriate part Pa (see Figure 4) to an appropriate corrected trim line PLa (see Figure 4) that does not cause deformation (defects) in the product part 91. Specifically, the demarcation line correction unit 43 (see Figure 5) applies a scissor angle of 160 degrees and an R value of 650 mm, corresponding to the standard stress value of 0.1 Gpa determined by the determination unit 42 to prevent deformation (defects) in the product part 91, to each determination point d (not shown in Figure 4) located between point sequence numbers 17 and 22 shown in Figure 4, thereby generating the corrected demarcation line PLa (see Figure 4), which is the aforementioned tangent arc (step S5 in Figure 6).
[0038] Next, the excess material shape creation system 1 (see Figure 5) forms the excess material 92 (see Figure 4) from the modified cutting line PLa (see Figure 4), as shown in Figure 6 (step S6). In this process, the excess material generation unit 44 (see Figure 5) of the excess material shape creation system 1 (see Figure 5) generates excess material 92 (see Figure 4) so as to extend from the modified boundary line PLa (see Figure 4), based on the basic excess material cross section Be (see Figure 7) of the basic cross section B (see Figure 7). In Figure 4, the excess material 92 (see Figure 4) is maintained to extend from the boundary line PL (see Figure 4), except for the inappropriate part Pa (see Figure 4) on the boundary line PL (see Figure 4).
[0039] Furthermore, as described above, a buffer surface 94 (see Figure 4) is formed between the dividing line PL (see Figure 4) and the corrected dividing line PLa (see Figure 4) in the area Pa (see Figure 4) where deformation (defect) is determined to occur. As shown in Figure 7, this buffer surface 94 is formed by a flat plate portion that connects the product portion 91 corresponding to portion Pa (see Figure 4) and the basic excess material cross section Be corresponding to portion Pa (see Figure 4).
[0040] Specifically, the buffer surface 94 is connected tangentially to the R portion with a radius of curvature r1, which is the end of the product-side inclined portion 92a in the basic excess material cross section Be in the cross-sectional view of Figure 7, and is formed to be flush with the edge of the product portion 91. This completes the drawing model 9 (see Figure 4) having a predetermined amount of excess material 92 (see Figure 4) in the excess material shape creation system 1 (see Figure 5), and the series of excess material generation processes in the excess material shape creation system 1 are completed.
[0041] <Effects> Next, the effects and benefits of the excess material shape creation system 1 and excess material shape creation method of this embodiment will be described. The excess material shape creation system 1 of this embodiment includes: a basic cross section setting unit 41 (basic cross section setting means) for generating excess material 92 with a predetermined basic cross section B from the dividing line PL of the outer panel 10 (product shape); a determination unit 42 (determination means) for determining whether a defect occurs during pressing due to the excess material 92 generated by the basic cross section setting unit 41 (basic cross section setting means); a dividing line correction unit 43 (correction means) for correcting the part Pa of the dividing line PL that the determination unit 42 (determination means) has determined to be a defect to a corrected dividing line PLa that the determination unit 42 (determination means) has determined not to be a defect; and an excess material generation unit 44 (generation means) for generating excess material 92 from the corrected dividing line PLa based on the predetermined basic cross section B generated by the basic cross section setting unit 41 (basic cross section setting means).
[0042] According to this excess material shape creation system 1, excess material 92 is generated from the basic excess material cross section Be of the corrected cutting line PLa, which is determined not to cause deformation (defects) in the product part 91. Thus, unlike conventional systems (see, for example, Patent Document 1), the excess material shape creation system 1 can generate excess material 92 without repeatedly simulating whether or not defects caused by the excess material 92 will occur. According to the excess material shape creation system 1 of this embodiment, the generation time of excess material 92 can be reduced compared to conventional systems.
[0043] Furthermore, the excess material shape creation system 1 generates excess material 92 using the basic excess material cross section Be. Unlike conventional systems (see, for example, Patent Document 1), it is possible to simulate the occurrence of defects caused by the product shape without being affected by the excess material 92. In other words, the excess material shape creation system 1 can reduce the man-hours required when simulating the product shape. With such an excess material shape creation system 1, unlike conventional systems that require time to generate excess material (see, for example, Patent Document 1), it is possible to accurately verify whether or not deformation (defects) will occur quickly at the pre-design stage.
[0044] Furthermore, in this excess material shape creation system 1, the determination unit 42 (determination means) is configured to determine whether or not deformation (defects) occurs in the cutting line PL based on the scissor angle and R value of the cutting line PL.
[0045] This excess material shape creation system 1 allows for more rapid and accurate verification of whether or not deformation (defects) will occur in the product.
[0046] Furthermore, in this excess material shape creation system 1, the determination unit 42 (determination means) is configured to determine whether or not a defect has occurred for any determination point d of the cutting line PL, based on a graph with the scissors angle and R value as axes, created from the results of simulation tests performed on a draw model 9 (see Figure 3) of a press die in which excess material 92 has been formed by the basic cross section setting unit 41 (basic cross section setting means) for multiple combinations of the scissors angle and R value.
[0047] According to this excess material shape creation system 1, simulation tests are performed using multiple combinations of R values and gripping angles while keeping the basic excess material cross section Be in the basic cross section B set by the basic cross section setting unit 41 (basic cross section setting means) common. Then, by forming the excess material 92 (see Figure 4) with the basic excess material cross section Be (see Figure 7) from the corrected cutting line PLa (see Figure 4) that is OK (see Figure 10) in the graph created from the results of the simulation tests, deformation (defects) will never occur. In this way, the excess material shape creation system 1 can reliably create a draw model 9 (see Figure 4) that does not produce deformation (defects).
[0048] Furthermore, the excess material shape creation method of this embodiment is an excess material shape creation method for creating an excess material shape of a press die from a product shape, and comprises: a basic cross section setting step (step S2) for generating excess material 92 with a predetermined basic cross section B from the dividing line PL of the outer panel 10 (product shape); a determination step (step S4) for determining whether a defect occurs during pressing due to the excess material 92 generated by the basic cross section setting step; a correction step (step S5) for correcting the part of the dividing line PL that is determined to cause a defect by the determination step to a corrected dividing line PLa that is determined not to cause a defect by the determination step; and a generation step (step S6) for generating excess material 92 from the corrected dividing line PLa based on the predetermined basic cross section B generated by the basic cross section setting step.
[0049] This method for creating excess material shapes allows for the generation of excess material 92 without repeatedly simulating whether or not defects caused by the excess material 92 occur. Furthermore, this method for creating excess material shapes reduces the generation time of excess material 92 compared to conventional methods.
[0050] Furthermore, this method for creating excess material shapes can reduce the man-hours required for simulating product shapes. This method also allows for accurate verification of whether or not deformation (defects) will occur during the initial design phase.
[0051] Furthermore, in this excess material shape creation method, the determination step (step S4) determines whether or not a defect occurs in the cutting line PL based on the scissor angle and R value of the cutting line PL.
[0052] This method of creating excess material shapes allows for more rapid and accurate verification of whether or not deformation (defects) will occur in the product.
[0053] Furthermore, in this excess material shape creation method, the determination step (step S4) determines whether or not a defect has occurred for an arbitrary determination point d of the cutting line PL, based on a graph with the scissors angle and R value as axes, created from the results of a simulation test performed on the draw model 9 (see Figure 3) of the press die in which the excess material 92 was formed in the basic cross section setting step (step S2) for multiple combinations of the scissors angle and R value.
[0054] With this method of creating excess material shapes, simulation tests are performed using multiple combinations of R values and gripping angles, with the basic excess material cross section Be common to the basic cross section B set in the basic cross section setting process (step S2). Then, by forming the excess material 92 (see Figure 4) using the basic excess material cross section Be (see Figure 7) from the corrected cutting line PLa (see Figure 4) that is OK (see Figure 10) in the graph created from the results of the simulation tests, deformation (defects) will never occur. Thus, this method of creating excess material shapes can reliably create a draw model 9 (see Figure 4) that does not produce deformation (defects).
[0055] Although this embodiment has been described above, the present invention is not limited to the above embodiment and can be implemented in various forms. In the above embodiment, an outer panel for an automobile door was used as an example of the product shape, but the present invention is not limited thereto and can be applied to other panel products such as roof panels, fender panels, and hood panels. [Explanation of symbols]
[0056] 1. Excess Meat Shape Creation System 41 Basic section setting section (basic section setting means) 42 Judgment unit (judgment means) 43 Parting line correction section (correction means) 44 Excess meat generation section (generation means) 92 Extra meat B Basic cross section (predetermined cross section) d. Judgment point (any point on the dividing line) Pa: Area where a malfunction was determined to occur. PL (Plant Limiting Line) PLa Correction Boundary Line
Claims
1. A system for creating excess material shapes for press molds from product shapes, A basic cross-section setting means for generating excess material at a predetermined cross-section from the cutting line of the aforementioned product shape, A determination means for determining whether a problem occurs during pressing due to excess material generated by the basic cross-section setting means, A correction means for correcting the portion of the aforementioned dividing line that the determination means has determined to have a defect to be a corrected dividing line in which the determination means has determined not to have a defect, A generation means for generating excess material from the modified cutting line based on a predetermined cross-section generated by the basic cross-section setting means, A system for creating excess material shape, comprising the following components.
2. The excess material shape creation system according to claim 1, characterized in that the determination means is configured to determine whether or not a defect occurs in the cutting line based on the scissor angle and R value of the cutting line.
3. The determination means determines, based on a graph with the scissors angle and the R value as axes, which is created from the results of simulating the press die in which excess material is formed by the basic cross section setting means for multiple combinations of the scissors angle and the R value, The excess material shape creation system according to claim 2, characterized in that, for any point on the aforementioned dividing line, the scissor angle and the R value are used to determine whether or not a defect has occurred using the graph.
4. A method for creating excess material shape for a press die from the product shape, A basic cross-section setting step for generating excess material at a predetermined cross-section from the cutting line of the aforementioned product shape, A determination step to determine whether a defect occurs during pressing due to excess material generated by the basic cross-section setting step, A correction step is performed to correct the part of the aforementioned dividing line that is determined to have a defect by the determination step to a corrected dividing line that is determined not to have a defect by the determination step. A generation step that generates excess material from the modified cutting line based on a predetermined cross-section generated by the basic cross-section setting step, A method for creating a excess material shape having the following characteristics.
5. The method for creating excess material shape according to claim 4, characterized in that the determination step determines whether or not a defect occurs in the cutting line based on the scissor angle and R value of the cutting line.
6. The determination step is based on a graph with the scissors angle and the R value as axes, which is created from the results of simulating the press die in which excess material was formed in the basic cross section setting step for multiple combinations of the scissors angle and the R value. The method for creating excess material shape according to claim 5, characterized in that, for any point on the aforementioned dividing line, the scissor angle and the R value are used to determine whether or not a defect has occurred using the graph.
Citation Information
Patent Citations
Centrifugal separator
JP1978031260A