Molding system and molding method

Abstract

A molding system according to the present invention is provided with: a molding device that molds a heated metal material by using a molding die; and a cutting part that cuts and trims an end section of a molded body section of a molded article. The cutting part implements trimming after the temperature of the molded article has reached a predetermined temperature or lower.

Description

[Technical field]

[0001] The present invention relates to a molding system and a molding method. [Background technology]

[0002] Conventionally, a molding system such as that described in Patent Document 1 has been known. This molding system has a heating unit that heats a metal material and a molding die that molds the heated metal material. The molding device brings the molding surface of the molding die into contact with the heated metal material, thereby forming the shape of the metal material into a shape that corresponds to the molding surface. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2009-220141 A Summary of the Invention [Problem to be solved by the invention]

[0004] Here, in the molding system described in the above-mentioned Patent Document 1, trimming may be performed on the molded product, in which an end portion of the molded main body portion is cut and removed. Here, the molding device molds the molded product from a heated metal material. Therefore, the molded product after molding may be removed from the molding die while still at a high temperature. If the cut portion is trimmed from a molded product while the molded product is at a high temperature, there is a problem that the molded product cools and shrinks after cutting, resulting in a decrease in cutting accuracy of the molded product.

[0005] The present invention has been made to solve such problems, and has an object to provide a molding system and molding method that can improve the cutting accuracy of molded products. [Means for solving the problem]

[0006] The molding system of the present invention comprises a molding device that molds a heated metal material using a molding die, and a cutting section that cuts and trims the end of the molded main body of the molded product, and the cutting section performs trimming when the molded product drops below a predetermined temperature.

[0007] In the molding system, the cutting unit trims the end of the molded main body of the molded product molded by the molding device. This allows the molded product to be cut to a desired length. Here, the cutting unit performs trimming when the molded product has reached a predetermined temperature or lower. Therefore, the cutting unit can perform trimming in a state where the temperature of the molded product has been lowered to reduce the effects of cooling shrinkage. As a result, the cutting accuracy of the molded product can be improved.

[0008] The predetermined temperature may be a temperature at which the thermal expansion of the molded article is in the range of 0.5% or less, in which case the influence of the cooling shrinkage of the molded article can be sufficiently reduced.

[0009] The molding system may further include a cooling section that actively cools the molded product before the trimming by the cutting section. In this case, the cooling section can quickly cool the molded product to a predetermined temperature or lower.

[0010] The molding system according to the present invention includes a molding device including a fluid supplying unit that supplies a fluid to a heated metal pipe material and a molding die that molds a molded product by bringing the expanded metal pipe material into contact with a molding surface, and a cutting unit that cuts and trims an end of a molded main body of the molded product. The molding system according to the present invention also includes a molding device that molds a heated metal material with a molding die, and a cutting unit that cuts and trims an end of a molded main body of the molded product.

[0011] In these molding systems, the cutting section cuts and trims the end of the molded main body of the molded product, thereby enabling a molded product of a desired length to be obtained.

[0012] The molding method of the present invention comprises a molding process in which a heated metal material is molded using a molding die, and a cutting process in which the end portion of the molded main body portion of the molded product is cut and trimmed. In the cutting process, trimming is performed when the molded product reaches a predetermined temperature or below.

[0013] According to this molding method, it is possible to obtain the same functions and effects as the above-mentioned molding system. Effect of the Invention

[0014] According to the present invention, it is possible to provide a molding system and a molding method that can improve the cutting accuracy of a molded product. [Brief description of the drawings]

[0015] [Figure 1] 1 is a schematic diagram showing the configuration of a molding system according to a first embodiment. [Diagram 2] FIG. 1 is a schematic diagram of a molding device 1 used in a molding system according to an embodiment of the present invention. [Diagram 3] FIG. 2 is an enlarged cross-sectional view showing the state of a metal pipe material and a molding die during blow molding. [Figure 4] FIG. 2 is a perspective view showing a state of laser processing by a laser processing device. [Diagram 5] FIG. 2 is a conceptual diagram showing blasting by a blasting device. [Figure 6] FIG. 2 is a process diagram showing a molding method according to the first embodiment. [Figure 7] FIG. 11 is a schematic diagram showing the configuration of a molding system according to a second embodiment. [Figure 8] FIG. 11 is a schematic view of a molding device according to a modified example. [Figure 9] 1A and 1B are diagrams illustrating an example of a structure around a nozzle for supplying gas. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In each drawing, the same or corresponding parts are designated by the same reference numerals, and duplicated explanations will be omitted.

[0017] [First embodiment] 1 is a schematic diagram showing the configuration of a molding system 100 according to a first embodiment. As shown in FIG. 1, the molding system 100 includes a molding device 1, a cooling unit 90, a laser processing device 70 (cutting unit), and a blasting device 50.

[0018] The forming device 1 is a device that forms a heated metal material with a forming die. In this embodiment, a STAF forming device is used as the forming device 1, which forms and hardens the heated metal pipe material by supplying a fluid to the material and bringing it into contact with the forming surface of the forming die. The detailed configuration of this forming device 1 will be described with reference to FIG. 2.

[0019] FIG. 2 is a schematic diagram of a molding device 1 used in the molding system 100 according to this embodiment. As shown in FIG. 2, the molding device 1 is a device for molding a metal pipe having a hollow shape by blow molding. In this embodiment, the molding device 1 is installed on a horizontal plane. The molding device 1 includes a molding die 2, a drive mechanism 3, a holding unit 4, a heating unit 5, a fluid supply unit 6, a cooling unit 7, and a control unit 8. In this specification, the metal pipe material 40 (metal material) refers to a hollow article before the completion of molding in the molding device 1. The metal pipe material 40 is a pipe material of a steel type that can be quenched. In addition, among the horizontal directions, the direction in which the metal pipe material 40 extends during molding may be referred to as the "longitudinal direction", and the direction perpendicular to the longitudinal direction may be referred to as the "width direction".

[0020] The forming die 2 is a die for forming a metal pipe 140 from a metal pipe material 40, and includes a lower die 11 and an upper die 12 facing each other in the vertical direction. The lower die 11 and the upper die 12 are made of steel blocks. Each of the lower die 11 and the upper die 12 is provided with a recess for accommodating the metal pipe material 40. When the lower die 11 and the upper die 12 are in close contact with each other (closed state), each recess forms a space of a target shape for forming the metal pipe material. Therefore, the surface of each recess becomes the forming surface of the forming die 2. The lower die 11 is fixed to a base 13 via a die holder or the like. The upper die 12 is fixed to a slide of the drive mechanism 3 via a die holder or the like.

[0021] The driving mechanism 3 is a mechanism for moving at least one of the lower die 11 and the upper die 12. In Fig. 2, the driving mechanism 3 has a configuration for moving only the upper die 12. The driving mechanism 3 includes a slide 21 for moving the upper die 12 so that the lower die 11 and the upper die 12 are aligned with each other, a pullback cylinder 22 as an actuator for generating a force for pulling the slide 21 upward, a main cylinder 23 as a driving source for applying pressure downward to the slide 21, and a driving source 24 for applying a driving force to the main cylinder 23.

[0022] The holding unit 4 is a mechanism for holding the metal pipe material 40 disposed between the lower die 11 and the upper die 12. The holding unit 4 includes a lower electrode 26 and an upper electrode 27 for holding the metal pipe material 40 at one end in the longitudinal direction of the molding die 2, and a lower electrode 26 and an upper electrode 27 for holding the metal pipe material 40 at the other end in the longitudinal direction of the molding die 2. The lower electrode 26 and the upper electrode 27 on both sides in the longitudinal direction hold the metal pipe material 40 by sandwiching the vicinity of the end of the metal pipe material 40 from above and below. Note that a groove having a shape corresponding to the outer circumferential surface of the metal pipe material 40 is formed on the upper surface of the lower electrode 26 and the lower surface of the upper electrode 27. The lower electrode 26 and the upper electrode 27 are provided with a driving mechanism (not shown) and can move independently in the vertical direction.

[0023] The heating section 5 heats the metal pipe material 40. The heating section 5 is a mechanism for heating the metal pipe material 40 by passing electricity through the metal pipe material 40. The heating section 5 heats the metal pipe material 40 between the lower die 11 and the upper die 12 in a state in which the metal pipe material 40 is separated from the lower die 11 and the upper die 12. The heating section 5 includes the lower electrode 26 and the upper electrode 27 on both sides in the longitudinal direction, and a power source 28 for passing a current through the electrodes 26 and 27 to the metal pipe material 40. The heating section may be disposed in a process preceding the molding device 1 and may be an external heating section.

[0024] The fluid supply unit 6 is a mechanism for supplying a high-pressure fluid into the metal pipe material 40 held between the lower die 11 and the upper die 12. The fluid supply unit 6 supplies a high-pressure fluid to the metal pipe material 40 that has been heated by the heating unit 5 and is in a high-temperature state, thereby expanding the metal pipe material 40. The fluid supply unit 6 is provided on both ends of the molding die 2 in the longitudinal direction. The fluid supply unit 6 includes a nozzle 31 that supplies a fluid to the inside of the metal pipe material 40 from an opening at the end of the metal pipe material 40, a drive mechanism 32 that moves the nozzle 31 forward and backward relative to the opening of the metal pipe material 40, and a supply source 33 that supplies a high-pressure fluid into the metal pipe material 40 through the nozzle 31. The drive mechanism 32 brings the nozzle 31 into close contact with the end of the metal pipe material 40 while ensuring sealing when supplying and discharging the fluid, and separates the nozzle 31 from the end of the metal pipe material 40 at other times. The fluid supply unit 6 may supply a gas such as high-pressure air or an inert gas as the fluid. Furthermore, the fluid supply unit 6 may be integrated into a single device including the heating unit 5 together with the holding unit 4 having a mechanism for moving the metal pipe material 40 in the vertical direction.

[0025] The cooling unit 7 is a mechanism for cooling the molding die 2. By cooling the molding die 2, the cooling unit 7 can rapidly cool the expanded metal pipe material 40 when it comes into contact with the molding surface of the molding die 2. The cooling unit 7 includes flow paths 36 formed inside the lower die 11 and the upper die 12, and a water circulation mechanism 37 that supplies cooling water to the flow paths 36 and circulates the water.

[0026] The control unit 8 is a device that controls the entire molding apparatus 1. The control unit 8 controls the drive mechanism 3, the holding unit 4, the heating unit 5, the fluid supplying unit 6, and the cooling unit 7. The control unit 8 repeatedly performs an operation of molding the metal pipe material 40 in the molding die 2.

[0027] Specifically, the control unit 8 controls the timing of conveyance from a conveying device such as a robot arm, and places the metal pipe material 40 between the lower die 11 and the upper die 12 in the open state. Alternatively, the control unit 8 may have an operator manually place the metal pipe material 40 between the lower die 11 and the upper die 12. The control unit 8 also controls the actuators of the holding unit 4 so that the lower electrodes 26 on both sides in the longitudinal direction support the metal pipe material 40, and then the upper electrode 27 is lowered to sandwich the metal pipe material 40. The control unit 8 also controls the heating unit 5 to electrically heat the metal pipe material 40. As a result, an axial current flows through the metal pipe material 40, and the metal pipe material 40 itself generates heat due to Joule heat due to the electrical resistance of the metal pipe material 40 itself.

[0028] The control unit 8 controls the drive mechanism 3 to lower the upper die 12 and bring it close to the lower die 11, and closes the molding die 2. Meanwhile, the control unit 8 controls the fluid supply unit 6 to seal the openings at both ends of the metal pipe material 40 with the nozzle 31 and supply the fluid. As a result, the metal pipe material 40 softened by heating expands and comes into contact with the molding surface of the molding die 2. Then, the metal pipe material 40 is molded to conform to the shape of the molding surface of the molding die 2. When a metal pipe with a flange is formed, a part of the metal pipe material 40 is inserted into the gap between the lower die 11 and the upper die 12, and then the mold is closed to crush the inserted part to form a flange part. When the metal pipe material 40 comes into contact with the molding surface, it is quenched by the molding die 2 cooled by the cooling unit 7, and the metal pipe material 40 is quenched. The temperature of the molded product 41 at the end of quenching is 200 to 250°C, which is the temperature at the end of martensitic transformation.

[0029] With reference to FIG. 3, the molding procedure of the molding device 1 will be described. As shown in FIG. 3(a), the control unit 8 closes the molding die 2 and supplies a fluid to the metal pipe material 40 with the fluid supply unit 6, thereby performing blow molding (primary blow). In the primary blow, the control unit 8 molds the pipe portion 43 in the main cavity portion MC and causes the portion corresponding to the flange portion 44 to advance into the sub-cavity portion SC. Then, as shown in FIG. 3(b), the control unit 8 further closes the molding die 2 to further crush the portion that has advanced into the sub-cavity portion SC, thereby forming the flange portion 44. Next, the control unit 8 lifts the upper die 12 to separate it from the metal pipe material 40, thereby performing mold opening. As a result, a molded product 41 is molded.

[0030] The molded product 41 will be described with reference to FIG. 4(a). The molded product 41 includes a molded main body 45 having a pipe portion 43 and a flange portion 44, a held portion 46 at both ends in the longitudinal direction, and a gradually changing portion 47 between the molded main body 45 and the held portion 46. The molded main body 45 is a portion that becomes a final product by laser processing. The pipe portion 43 is a hollow portion. The flange portion 44 is a plate-like portion that protrudes from the pipe portion 43 by crushing a part of the metal pipe material 40. The held portion 46 is a cylindrical portion that is held by the electrodes 26, 27. A nozzle 31 is inserted into the held portion 46. The gradually changing portion 47 is a transition portion that changes from the shape of the held portion 46 to the shape of the molded main body 45.

[0031] Returning to Fig. 1, the molded articles 41 molded by the molding apparatus 1 are supplied to the cooling section 90. The molded articles 41 may be supplied to the cooling section 90 in the order in which they are molded by the molding apparatus 1. Alternatively, after a certain number of molded articles 41 are accumulated in an accumulation location, they may be collectively supplied to the cooling section 90. When the molded articles 41 are accumulated, the temperature of the molded articles 41 can be lowered before laser processing by the cooling effect due to natural heat dissipation.

[0032] The cooling section 90 is a device that actively cools the molded product 41 removed from the molding die 2. The cooling section 90 actively cools the molded product 41 in a stage prior to trimming by the laser processing device 70. Active cooling refers to actively processing the molded product 41 to cool the molded product 41 with a higher cooling capacity than if it were left at room temperature. As such a cooling section 90, a mechanism that supplies a cooling medium such as cold air, cold water, ice, and dry ice to the molded product 41 may be adopted. For example, if there is a conveying facility to the laser processing device 70, the cooling section 90 may blow cold air onto the molded product 41 on the conveyor. In addition, when the conveying facility is provided, even if a mechanism for blowing cold air or the like is not provided, if the cooling time is adjusted and the conveying speed is set so that the molded product 41 is cooled to a desired temperature by natural cooling, the conveying facility corresponds to the cooling section 90 that actively cools. The cooling section 90 may blast dry ice. Alternatively, a device that stores the molded article 41 in a low-temperature atmosphere, such as a refrigerator, may be used as the cooling unit 90. Even a configuration that merely rotates a fan near the molded article 41 is an active process for promoting cooling, and therefore corresponds to active cooling by the cooling unit 90. The temperature to which the cooling unit 90 cools the molded article 41 will be described later.

[0033] The molded articles 41 cooled in the cooling section 90 are supplied to the laser processing device 70. The molded articles 41 may be supplied to the laser processing device 70 in the order of those cooled in the cooling section 90. Alternatively, after a certain number of molded articles 41 are accumulated in an accumulation area, they may be collectively supplied to the laser processing device 70. When the molded articles 41 are accumulated, the temperature of the molded articles 41 can be further lowered before laser processing by the cooling effect due to natural heat dissipation.

[0034] The laser processing device 70 is a device that uses a laser to process the molded product 41 cooled in the cooling section 90. The laser processing device 70 irradiates the molded product 41 with a laser to perform processing such as cutting, drilling, and notching.

[0035] FIG. 4 is a perspective view showing the state of laser processing by a laser processing device 70. As shown in FIG. 4(a), the laser processing device 70 includes an installation unit 71 and a laser head 72. The installation unit 71 is a part that installs the molded article 41 at a position facing the laser head 72. The installation unit 71 has a support unit (not shown) that supports the molded article 41. As a result, the molded article 41 is installed on the installation unit 51 at a position and in a posture suitable for laser processing. The laser head 72 is a part that processes the molded article 41 by irradiating the molded article 41 with a laser.

[0036] The laser head 72 cuts the vicinity of both ends of the formed main body portion 45, thereby removing the gradually changing portion 47 and the held portion 46 from the formed main body portion 45, as shown in Fig. 4(b). The laser head 72 also forms holes 49 at predetermined positions of the formed main body portion 45.

[0037] Here, the laser processing device 70 cuts and trims the end of the molded main body portion 45 of the molded product 41. Trimming will be described with reference to FIG. 4(c). Trimming is a cutting process for cutting the end portion 45a of the molded main body portion 45. The "end portion of the molded main body portion" here refers to the region near the boundary portion BL between the gradually changing portion 47 and the molded main body portion 45. The cutting line CL made by the laser is set at a position spaced a predetermined dimension t inward in the longitudinal direction from the boundary portion BL. The predetermined dimension t is set appropriately within a range of 5 mm to 20 mm.

[0038] The laser processing device 70 performs trimming when the molded product 41 becomes equal to or lower than a predetermined temperature. The predetermined temperature may be a temperature at which the thermal expansion of the molded product 41 is in a range of 0.5% or less. In addition, when the length dimension L1 of the metal pipe material 40 at room temperature before heating is taken as a reference and the length dimension L2 of the molded product 41 at the time of cutting is taken as a reference, the value defined by "100 x (L2-L1) / L1" corresponds to the value of thermal expansion. In addition, the term "thermal expansion" here refers to a state in which the metal material is thermally expanded from the viewpoint of the metal material at room temperature before heating. That is, the metal material thermally expands due to heating, and then cools and contracts due to cooling by the cooling unit 90. However, the metal material after cooling is also in a thermally expanded state from the viewpoint of the metal material before heating, so the term "thermal expansion" is used. This predetermined temperature is at least lower than the temperature of 200 to 250°C, which is the temperature at the end point of the martensitic transformation described above. The predetermined temperature may be, for example, 150°C. However, it is not limited to this temperature. The predetermined temperature may be set within the range of room temperature (approximately 20°C) to 150°C, for example. This allows the molded product 41 to be cooled during cutting, thereby preventing cutting errors from occurring due to the effect of shrinkage caused by the cooling. The cooling unit 90 adjusts the cooling capacity so that the temperature of the molded product 41 when cutting satisfies the above conditions. The laser processing device 70 may perform trimming after the molded product 41 has reached room temperature.

[0039] Returning to Fig. 1, the molded articles 41 processed by the laser processing device 70 are supplied to the blasting device 50. The molded articles 41 may be supplied to the blasting device 50 in the order of those processed by the laser processing device 70. Alternatively, after a certain number of molded articles 41 are accumulated in an accumulation area, they may be supplied to the blasting device 50 all at once.

[0040] The blasting device 50 is a device that removes scale from the molded product 41 processed by the laser processing device 70. The scale is an oxide film formed on the surface of the material by heating the metal pipe material 40 in the molding device 1. The blasting device 50 sprays particles onto the surface of the molded product 41. The blasting device 50 removes scale from the surface of the molded product 41 by the impact of the particles colliding with each other.

[0041] FIG. 5(a) is a schematic diagram showing a blasting device 50 of this embodiment. The blasting device 50 of this embodiment removes scales from the outer peripheral surface of the molded product 41. On the other hand, the blasting device 50 does not inject particles onto the inner peripheral surface so as not to leave particles inside the molded product 41. For example, as shown in FIG. 4, the molded product 41 has a flange portion 44 formed by crushing a part of the metal pipe material 40. In the internal space of the molded product 41, particles are likely to remain in such a flange portion 44. Therefore, the blasting device 50 injects particles only onto the outer peripheral surface of the molded product 41.

[0042] As shown in FIG. 5(a), the blasting device 50 has a mounting section 51, a nozzle 52, and a shielding wall 53. The mounting section 51 is a section for mounting the molded product 41 at a position facing the nozzle 52. The mounting section 51 has a support section (not shown) and supports the molded product 41 at the support section. As a result, the molded product 41 is mounted on the mounting section 51 at a position and in a posture suitable for blasting. The mounting section 51 suspends the molded product 41 and mounts it in a posture extending in the vertical direction. The nozzle 52 is a member for irradiating the molded product 41 with particles 55. As the particles, materials such as sand, plastic, dry ice, and iron pieces are used. The nozzle 52 is disposed around the molded product 41 mounted on the mounting section 51. The nozzle 52 is disposed so that the nozzle orifice faces the outer peripheral surface of the molded product 41. As a result, the nozzle 52 can spray the particles 55 onto the outer peripheral surface of the molded product 41.

[0043] The shielding wall 53 is a wall that shields the particles 55. The shielding wall 53 is disposed so as to surround the periphery of the installation portion 51 and the nozzle 52. This allows the shielding wall 53 to prevent the particles 55 from scattering around the blasting device 50. That is, the shielding wall 53 allows the particles 55 to be prevented from scattering toward the molding device 1 and the laser processing device 70. In addition to the shielding wall 53, a wall that separates the space between the blasting device 50 and the laser processing device 70 may be provided.

[0044] Next, referring to FIG. 6, a molding method according to this embodiment will be described. FIG. 6 is a process diagram showing the molding method according to this embodiment. As shown in FIG. 6, the molding method includes a molding step S10, a cooling step S20, a laser processing step S30 (cutting step), and a blasting step S40. In the molding step S10, a fluid is supplied to a heated metal pipe material 40, and the expanded metal pipe material 40 is brought into contact with the molding surface of a molding die 2 to mold a molded product 41. In the molding step S10, molding of the molded product 41 is performed using a molding device 1 shown in FIG. 2. In the cooling step S20, the molded product 41 removed from the molding die 2 is actively cooled. In the cooling step S20, cooling is performed using a cooling unit 90 shown in FIG. 1. In the laser processing step S30, the molded product 41 removed from the molding die 2 is processed. In the laser processing step S30, a laser processing device 70 shown in FIG. 4 processes the molded product 41. The blasting step S40 is a step for removing scale from the molded article 41 processed in the laser processing step S30. In the blasting step S40, a blasting device 50 shown in Fig. 5(a) performs a blasting process to remove scale from the molded article 41.

[0045] Next, the functions and effects of the molding system 100 and molding method according to this embodiment will be described.

[0046] In STAF molding, in order to shorten the molding time, i.e., the cycle time, it is desirable to lower the temperature in the molding die 2 to a level where the shape can be frozen, and to remove it as quickly as possible (at a high temperature) and pass it on to the next process. For example, after STAF molding, when holes are drilled by laser processing or non-product parts at both ends are cut off, if the temperature of the molded product 41 itself is 200°C or higher, it will be cooled during cutting. The temperature error of the molded product 41 itself caused by this cooling can cause length changes, which can lead to cutting errors in the hole drilling position and the product length.

[0047] In contrast, the molding system 100 of this embodiment includes a molding device 1 that molds a heated metal pipe material 40 using a molding die 2, and a laser processing device 70 that cuts and trims the end 45a of the molded main body portion 45 of the molded product 41, and the laser processing device 70 performs trimming when the molded product 41 drops below a predetermined temperature.

[0048] In the molding system 100, the laser processing device 70 cuts and trims the end 45a of the molded main body 45 of the molded product 41 molded by the molding device 1. As a result, the molded product 41 is cut to a desired length. Here, the laser processing device 70 performs trimming when the molded product 41 is cooled to a predetermined temperature or lower. Therefore, the laser processing device 70 can perform trimming in a state where the temperature of the molded product 41 is lowered to reduce the effect of cooling shrinkage. As a result, the cutting accuracy of the molded product 41 can be improved.

[0049] The predetermined temperature may be 150° C. In this case, the influence of cooling shrinkage of the molded article 41 can be sufficiently reduced.

[0050] The molding system 100 may further include a cooling section 90 that actively cools the molded article 41 before the trimming by the laser processing device 70. In this case, the cooling section 90 can quickly cool the molded article 41 to a predetermined temperature or lower.

[0051] The molding system 100 according to this embodiment includes a molding device 1 including a fluid supply unit 6 that supplies a fluid to a heated metal pipe material 40, and a molding die 2 that molds a molded product 41 by bringing the expanded metal pipe material 40 into contact with a molding surface, and a laser processing device 70 that cuts and trims an end 45a of a molded main body portion 45 of the molded product 41. The molding system 100 according to this embodiment also includes the molding device 1 that molds the heated metal pipe material 40 with the molding die 2, and the laser processing device 70 that cuts and trims an end 45a of a molded main body portion 45 of the molded product 41.

[0052] In these molding systems 100, the laser processing device 70 cuts and trims the end portion 45a of the molded main body portion 45 of the molded product 41, thereby making it possible to obtain a molded product 41 of a desired length.

[0053] The molding method according to this embodiment includes a molding process S10 in which a heated metal pipe material 40 is molded using a molding die 2, and a cutting process S20 in which an end portion 45a of a molded main body portion 45 of a molded product 41 is cut and trimmed. In the cutting process S20, trimming is performed when the molded product 41 reaches a predetermined temperature or lower.

[0054] According to this molding method, it is possible to obtain the same functions and effects as those of the molding system 100 described above.

[0055] [Second embodiment] Next, a molding system 200 according to a second embodiment will be described with reference to Fig. 7. As shown in Fig. 7, the molding system 200 includes a first blasting device 50 disposed in front of a laser processing device 70, and a second blasting device 80 for removing scale from a molded product 41 processed by the laser processing device 70. Here, the first blasting device 50 corresponds to the "cooling section" in the claims, and the first blasting device 50 may spray dry ice as particles 55. The first blasting device 50 can obtain a cooling effect by the effect of air blowing even if it sprays particles 55 other than dry ice, but a high cooling effect can be obtained by spraying dry ice.

[0056] As shown in FIG. 5(b), the second blasting device 80 sprays particles 55 from a blast hose 56 onto the inner circumferential surface of the molded product 41. The blast hose 56 is inserted inside the molded product 41 and sprays particles toward the inner circumferential surface inside the molded product 41. At this time, the blast hose 56 may spray dry ice as the particles 55. The dry ice collides as a solid with the inner circumferential surface of the molded product 41 and removes scale, but turns into gas and disappears over time. This makes it possible to prevent the particles 55 from remaining in the flange portion 44.

[0057] The first blasting device 50 and the second blasting device 80 may be configured by a common device. For example, a blast hose 56 in Fig. 5(b) may be added to the blasting device 50 in Fig. 5(a). In such a blasting device, the nozzle 52 blasts the outer peripheral surface of the molded product 41 in the first blasting process, and the blast hose 56 blasts the inner peripheral surface of the molded product 41 in the second blasting process. As a result, the number of devices in the molding system 200 can be reduced.

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

[0059] In the above-described embodiment, a blasting device is exemplified as the scale removal unit. However, any device capable of removing scale may be used as the scale removal unit. For example, a device that sprays a fluid onto the molded product or removes scale by ultrasonic cleaning may be used. Such a scale removal unit also provides a cooling effect.

[0060] The cutting section is not limited to a laser processing device, and devices using other cutting methods may be employed.

[0061] For example, the forming apparatus is exemplified as one that performs STAF forming, but there is no particular limitation as long as the forming method uses a heated metal material. For example, a forming method using hot stamping may be adopted. Therefore, the metal material does not necessarily have to be a metal pipe material, and may be a plate material or a column material.

[0062] The molding apparatus 1 is not limited to the configuration shown in Fig. 2. For example, the molding apparatus 1 may have a configuration as shown in Fig. 8. The molding apparatus 1 shown in Fig. 8 may have a thermal expansion unit 150 as shown in Fig. 9. Fig. 9(a) is a schematic side view showing the thermal expansion unit 150 in which the components of the holding section 4, the heating section 5, and the fluid supply section 6 are unitized. Fig. 9(b) is a cross-sectional view showing the state when the nozzle 31 seals the metal pipe material 40.

[0063] As shown in Fig. 9(a), the thermal expansion unit 150 includes the above-mentioned lower electrode 26 and upper electrode 27, an electrode mounting unit 151 mounting the electrodes 26, 27, the above-mentioned nozzle 31 and driving mechanism 32, a lifting unit 152, and a unit base 153. The electrode mounting unit 151 includes a lifting frame 154 and electrode frames 156, 157. The electrode frames 156, 157 function as part of a driving mechanism 60 that supports and moves the electrodes 26, 27. The driving mechanism 32 drives the nozzle 31 to lift and lower together with the electrode mounting unit 151. The driving mechanism 32 includes a piston 61 that holds the nozzle 31, and a cylinder 62 that drives the piston. The lifting unit 152 includes a lifting frame base 64 attached to the upper surface of the unit base 153, and a lifting actuator 66 that applies a lifting motion to the lifting frame 154 of the electrode mounting unit 151 by means of the lifting frame base 64. The lifting frame base 64 has guide portions 64a, 64b that guide the lifting motion of the lifting frame 154 relative to the unit base 153. The lifting unit 152 functions as a part of the drive mechanism 60 of the holding portion 4. The thermal expansion unit 150 has a plurality of unit bases 153 with different inclination angles of the upper surface, and by replacing these, it is possible to change and adjust the inclination angles of the lower electrode 26, the upper electrode 27, the nozzle 31, the electrode mounting unit 151, the drive mechanism 32, and the lifting unit 152 all at once.

[0064] The nozzle 31 is a cylindrical member into which the end of the metal pipe material 40 can be inserted. The nozzle 31 is supported by a drive mechanism 32 so that the center line of the nozzle 31 coincides with a reference line SL1. The inner diameter of a supply port 31a at the end of the nozzle 31 on the metal pipe material 40 side is approximately equal to the outer diameter of the metal pipe material 40 after expansion molding. In this state, the nozzle 31 supplies high-pressure fluid from an internal flow path 63 to the metal pipe material 40. An example of the high-pressure fluid is gas. [Explanation of symbols]

[0065] 1...molding device, 2...molding mold, 40...metal pipe material, 41...molded product, 70...laser processing device (cutting section), 90...cooling section, 100...molding system.

Claims

1. A molding device that molds the heated metal pipe material with a molding die; a cutting unit that cuts and trims the end of the formed main body portion of the metal pipe, The molding die includes a first cooling section that cools the molding die to cool the metal pipe material that comes into contact with a molding surface during molding, A second cooling section is provided to cool the metal pipe after the metal pipe is removed from the molding die. the second cooling unit cools the metal pipe by supplying at least one of cold air, cold water, ice, and dry ice to the metal pipe; a cutting unit that performs the trimming on the metal pipe when the metal pipe is cooled to a predetermined temperature or lower by the first cooling unit and the second cooling unit, said cutting unit performing the trimming on the metal pipe.

2. The molding system according to claim 1 , wherein the predetermined temperature is a temperature at which the thermal expansion of the metal pipe is in a range of 0.5% or less.

3. a molding device including a fluid supplying unit that supplies a fluid to a heated metal pipe material, and a molding die that molds a metal pipe by bringing the expanded metal pipe material into contact with a molding surface; a cutting unit that cuts and trims the end of the formed main body portion of the metal pipe, The molding die includes a first cooling section that cools the molding die to cool the metal pipe material that comes into contact with a molding surface during molding, A second cooling section is provided to cool the metal pipe after the metal pipe is removed from the molding die. the second cooling unit cools the metal pipe by supplying at least one of cold air, cold water, ice, and dry ice to the metal pipe; a cutting unit that performs the trimming on the metal pipe when the metal pipe is cooled to a predetermined temperature or lower by the first cooling unit and the second cooling unit, said cutting unit performing the trimming on the metal pipe.

4. a forming step of forming the heated metal pipe material with a forming die; a cutting step of cutting and trimming the end of the formed body portion of the metal pipe, In the cutting step, the trimming is performed when the metal pipe has reached a predetermined temperature or lower, a first cooling step in which the molding die cools the metal pipe material that is in contact with a molding surface during molding by cooling the molding die; The method further includes a second cooling step of cooling the metal pipe after the molding and after the metal pipe is removed from the molding die, the second cooling step is to cool the metal pipe by supplying at least one of cold air, cold water, ice, and dry ice to the metal pipe; a cutting step of cutting the metal pipe by cooling the metal pipe to a predetermined temperature or lower in the first cooling step and the second cooling step, the trimming being performed on the metal pipe.

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