Method for manufacturing bracket part of rear frame of vehicle using progressive mold

Abstract

The present invention relates to a method for manufacturing a bracket component of a rear frame of a vehicle, the method being capable of reducing product dispersion by preventing a material plate from rattling when a material plate is transferred between processes of a progressive mold device and stably transferring the material plate. The method for manufacturing a bracket component of a rear frame of a vehicle comprises the steps of: transferring (S1) a material plate of a bracket component to a progressive mold; piercing (S2) a pilot pin insertion hole in the center of the left and right sides of the material plate; notching (S3) the outline of a bracket on the material plate; marking (S4) an embossing part on the bracket; primarily bending (S5) the front and rear parts of the bracket; secondarily bending (S6) the front and rear parts of the bracket; piercing (S7) a component hole in a marking part formed in the embossing part marking step (S4); and parting (S8) the left and right parts into a required bracket shape.

Description

Method for manufacturing bracket parts for automobile rear frames using progressive molds

[0001] The present invention relates to a method for manufacturing a bracket part of an automobile rear frame using a progressive mold, and more particularly, to a method for manufacturing a bracket part of an automobile rear frame, which comprises a plate lifter provided in a progressive mold device to prevent the material plate from shaking during processing and forming of the material plate, thereby forming a product stably without dispersion.

[0002] Press processing, one type of various forming methods, refers to processing a material plate into a specific shape by plastically deforming it or drilling holes in it.

[0003] The processing method using progressive molds is one of the press processing methods.

[0004] In the progressive die machining method, a long material plate is placed into a progressive die and processed sequentially while being transported.

[0005] That is, the progressive mold is composed of an upper mold assembly installed on the lower side of the upper and lower slides, and a lower mold assembly installed on the upper side of the bolster.

[0006] The upper mold assembly and the lower mold assembly are shaped so that forming occurs as the material plates progress in stages.

[0007] For example, as shown in A of Fig. 1, a finished product in which a sawtooth-shaped hole (H) is formed in the center of a rectangular plate and sunken grooves (G, G2, G3, G4) are formed at positions spaced from the hole (H) can be produced using a progressive mold.

[0008] In this case, a hole like the one formed on the far left in B of Fig. 1 can be drilled by the first process of drilling a circular hole in the material plate.

[0009] In addition, the edge of the perforated hole can be processed as in the second image from the left in B of Fig. 1 through a second process of cutting it into a sawtooth shape.

[0010] In addition, it can be processed as in the third image from the left in B of Fig. 1 by the third process of forming a sunken groove (G).

[0011] In addition, by the fourth process of cutting the plate into a rectangular shape with a sawtooth-shaped hole (H) placed in the center, the material plate can be cut as in the shape on the far right in B of Fig. 1. (The part formed as a solid line on the inside of the material plate is the cutting line.)

[0012] To this end, a punch structure for perforating a hole, a punch structure for cutting the edge of the hole in a sawtooth shape, a structure for forming a sunken groove, and a punch structure for cutting a material plate in a rectangular shape with a sawtooth hole in the center are formed in one upper mold assembly and a lower mold assembly.

[0013] Since the upper mold assembly and the lower mold assembly are provided with shapes for four processes, when the upper mold assembly and the lower mold assembly are moved in a direction facing each other and pressurized, the four processes are performed simultaneously.

[0014] Therefore, by pushing the material plate between the upper mold assembly and the lower mold assembly and moving it sequentially, the material plate moves step by step and goes through four processes to be processed into the final finished product.

[0015] Progressive molds are disclosed in Patent Publication No. 10-2009-0044874 and Patent Registration No. 10-1895588, etc.

[0016] The processing method using progressive molds is suitable for mass production systems because it can increase productivity and contribute to quality improvement compared to multiple processing methods using single-shot molds.

[0017] However, as described above, the processing method using a progressive mold is a method of sequentially processing a long material plate by putting it into a progressive mold and transporting it, so the material may wobble when moving between processes. For this reason, there is a concern that the material plate may not be seated in the correct position if it enters the die incorrectly, or that the product's left-right dimensions may vary. In addition, the wobbling of the material plate may cause a collision with the lower mold, causing the material plate to come off, which may lead to damage to the mold in severe cases.

[0018] (Patent Document 0001) Patent Publication No. 10-2009-0044874 "Upper Mold Assembly Mounting Structure of Progressive Mold" (May 7, 2009)

[0019] (Patent Document 0002) Patent Publication No. 10-1895588, "Progressive Mold Device for Forming Base Plate of Door Lock Device" (October 18, 2018)

[0020] The purpose of the present invention to solve the above-mentioned problem is to provide a method for manufacturing a bracket part of an automobile rear frame, which can reduce product dispersion by preventing the material plate from swaying during the transfer of the material plate between processes of a progressive mold and enabling the material plate to be transferred straightly.

[0021] In order to achieve the above object, the present invention provides a method for manufacturing a bracket part of an automobile rear frame using a progressive mold having an upper mold and a lower mold so as to be able to process a pair of left and right bracket parts having different shapes, the method comprising the steps of: (S1) inserting a material plate of the bracket part into the progressive mold; (S2) piercing a pilot pin insertion hole in the left and right centers of the material plate; (S3) notching the outer shape of the bracket part in the material plate; (S4) marking an embossing portion on the bracket part; (S5) first bending the front and rear ends of the bracket part; (S6) second bending the front and rear ends of the bracket part; (S7) piercing a part hole in the marking portion formed in the embossing portion marking step (S4); and (S8) parting the left and right parts into a desired bracket shape.

[0022] In addition, the present invention further comprises a step (S2-3) of piercing a hole for forming a protrusion to be a plate guide protrusion between the pilot pin insertion hole piercing step (S2) and the bracket component outer shape notching step (S3); and a step (S3-4) of bending the protrusion to form the plate guide protrusion between the bracket component outer shape notching step (S3) and the embossing portion marking step (S4).

[0023] In addition, the present invention includes a step of raising a plate lifter disposed below the material plate to fix the material plate between the upper mold and the lower mold when the material plate is transferred between the upper mold and the lower mold in steps (S2) to (S8); and a step of lowering the material plate fixed between the upper mold and the plate lifter as a whole relative to the lower mold to process or form a part.

[0024] In addition, the present invention is characterized by being a bracket part of an automobile rear frame manufactured by the above methods.

[0025] According to the method for manufacturing an automobile rear frame bracket of the present invention, the phenomenon of the material plate swaying when the material plate is transferred between processes of a progressive mold device is prevented, and the material plate is transferred straightly, thereby reducing dispersion of the automobile rear frame bracket product and reducing molding defects.

[0026] Figure 1 is a schematic diagram for explaining a conventional progressive mold.

[0027] A: Schematic diagram of the final product

[0028] B: Schematic diagram of the material plate during the processing process to explain the processing performed by the progressive mold.

[0029] Figure 2 is a real photograph of a pair of left and right bracket parts manufactured according to the present invention.

[0030] Figure 3 is a process diagram for manufacturing a pair of left and right bracket parts manufactured according to the present invention.

[0031] Figure 4 is a mold used in the progressive mold device of the present invention.

[0032] Figure 5 is a lower mold used in the progressive mold device of the present invention.

[0033] Figure 6 is a cross-sectional view of the FF of Figure 5.

[0034] Figure 7 is a front cross-sectional view of the upper mold and lower mold of the present invention combined.

[0035] Figure 8 is a plan view and front view of the plate guide and lifter of the present invention.

[0036] Figure 9 is a real photograph of the rail-type plate guide and lifter of the present invention.

[0037] Figure 10 is a conceptual diagram of the operation of the plate lifter of Figure 8.

[0038]

[0039] The terms used in this application are used only to describe specific embodiments and are not intended to limit the present invention. Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0040] In this application, the terms “include” or “have” are intended to indicate the presence of a feature, number, step, operation, component, part, or combination thereof described in the specification, but should be understood as not excluding in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0041] In describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description will be omitted.

[0042]

[0043] Hereinafter, preferred embodiments for achieving the purpose of the present invention will be described with reference to the drawings attached to the present invention.

[0044]

[0045] FIG. 2 is an actual photograph of a pair of left and right bracket parts manufactured by the present invention, FIG. 3 is a process diagram for manufacturing a pair of left and right bracket parts manufactured by a progressive mold device of the present invention, FIG. 4 is an upper mold used in the progressive mold device of the present invention, FIG. 5 is a lower mold used in the progressive mold device of the present invention, FIG. 6 is a FF cross-sectional view of FIG. 5, FIG. 7 is a front cross-sectional view of the upper mold and the lower mold of the present invention combined, FIG. 8 is a plan view and a front view of a plate guide and lifter of the present invention, FIG. 9 is an actual photograph of a rail-type plate guide and lifter of the present invention, and FIG. 10 is a conceptual diagram of the operation of the plate lifter of FIG. 8.

[0046]

[0047] The progressive mold device configured to process a pair of left and right bracket parts (180) having different shapes according to the present invention will be described in detail below, but first, to briefly explain, similar to a conventional progressive mold device, an upper mold (120) assembly mounted on the lower side of an upper and lower slide (110) and a lower mold (140) assembly fixed on the upper side of a bolster (130) are sequentially installed, and a material plate (200) is continuously and stepwise transferred between the upper mold (120) assembly and the lower mold (140) assembly to form a product (bracket part of an automobile rear frame) having a required shape.

[0048] The above progressive mold device is equipped with a plate-shaped plate lifter (150) and a stripper (170) used in a step of processing a required outer shape of a product from a material plate (200) prior to a molding step, and also equipped with a rail-type plate guide (160) and plate lifter used in a step of forming a material plate (200) processed into a required outer shape of a product into a required shape.

[0049] The above plate-type plate lifter (150) and rail-type plate lifter (160) are installed on the upper part of the bolster (130) and can support the material plate (200), and the stripper (170) is installed on the upper part of the plate-type plate lifter (150) with the material plate (200) therebetween.

[0050] The above-mentioned plate-type lifter (150) and rail-type plate lifter (160) operate to raise and support the transported material plate (200) so that it is in close contact with the upper mold (120) when processing the outer shape of the material plate (200) or forming it into a required shape using a progressive mold device, and then lower it together with the upper mold (120) with respect to the lower mold (140). In particular, the rail-type plate lifter (160) also functions as a guide to prevent the material plate (200) from shaking in the left and right directions when transporting the material plate (200).

[0051] That is, the rail-type plate lifter (160) and plate guide (160) is a plate lifter formed with a narrow width to avoid the bending portion so as to solve the problem of difficulty in supporting and transporting the material plate (200) in the front-back direction by the plate-type plate lifter (150) due to the bending portion formed in the material plate (200) after the front-back and rear-back parts (260) of the bracket part are bent in the up-and-down direction.

[0052]

[0053] Hereinafter, with reference to FIGS. 2 to 10, a method for manufacturing a bracket part of an automobile rear frame using the progressive mold device will be described.

[0054]

[0055] A progressive mold device is a mold device for continuous press processing. It is a device that sequentially moves a material plate (200) between an upper mold (120) and a lower mold (140) and forms a shape of a product through a multi-stage process within the mold.

[0056] As shown in FIG. 2, the bracket part (180) of the rear frame of the automobile is composed of a left part (181) having a roughly 'L' shape in which the front and rear parts (260) of the bracket part are bent up and down and convex left and right, an embossed part (250) is formed on one side of the convex surface, and a through hole (270) is formed in the embossed part (250), when viewed based on the transport direction of the material plate (200), and a right part (182) having a roughly 'L' shape in which the front and rear parts (260) of the bracket part are bent up and down and convex left and right, an embossed part (250) is formed on one side of the convex surface, and a through hole (270) is formed in the embossed part (250).

[0057] In general, in a progressive mold, a carrier and a bridge are applied for transporting a material plate (200). However, in the present invention, since a bending portion is formed in the front-back direction of the left and right bracket parts of the rear frame, a temporary connecting portion (183) is formed in the left and right bracket parts (181, 182), and the temporary connecting portion is used as a carrier (184) for transporting the material plate, and the material plate (200) is transported along the horizontal center line shown in FIG. 3.

[0058] As shown in Fig. 3, a pilot pin insertion hole (210) is formed in the material plate (200), and a piercing step is performed to form a hole (220) for forming a protrusion (241) that will become a plate guide protrusion (240).

[0059] In the next step, the material plate (200) after the piercing step is removed by notching a hole roughly in the shape of the Chinese characters up and down (230) to create an outer material of the required shape, and the ends on the left and right sides are notched and removed based on the direction of material progress.

[0060] In the next step, in order to guide the material plate (200) to be transported along the plate guide (160) formed in the progressive mold device when being transported, the protrusion (241) formed in the piercing step is bent to form a plate guide protrusion (240).

[0061] Through the above steps, the part material processing step for forming the left and right bracket parts (181, 182) of the rear frame is completed.

[0062] As shown in FIG. 3, the necessary embossing portion (250) is formed on the left and right bracket parts (180) whose outer shape is formed through the component material processing step.

[0063] The front and rear parts (260) of the left and right bracket parts (181, 182) on which the embossing portion (250) is formed are first bent at about 45°, and then secondly bent at 90°.

[0064] The reason for dividing the front and rear parts (260) of the above bracket part into the first bending step and the second bending step is to compensate for the risk of forming defects in the bracket part (180) when the bracket part (180) formed convexly to the left and right in the embossing part (250) forming step is bent at once.

[0065] In the next step, a piercing step is performed to form a through hole (270) in the embossing portion (250).

[0066] As the final step, the bracket of the car rear frame is cut into the required shape and the product is removed.

[0067] At this time, the temporary connection formed on the left and right bracket parts (181, 182) is also cut off and discarded together.

[0068] Meanwhile, in order to improve the stability of processing the material plate (200) and the efficiency of mold placement, an idle stage may be added in which no processing is performed on the material plate (200) and only simple transport is performed.

[0069] Through the above steps, the part forming step for forming the left and right bracket parts (181, 182) of the rear frame is completed.

[0070] While the above process is being performed, the material plate (200) before the end of the component material processing step or the material plate (200) after the end of the component material processing step must be continuously transported, and during the transport process, the material plate (200) undergoes rolling and pitching motions, including left-right shaking.

[0071] When such a shaking, rolling or pitching motion occurs, the material plate (200) is not seated in the exact position of the upper mold (120) and the lower mold (140), resulting in molding defects and left-right dimensional dispersion.

[0072] To prevent this, the present invention provides a plate lifter (150, 160).

[0073] The above plate lifter is divided into a plate-type plate lifter (150) suitable for the component material processing stage and a rail-type plate lifter (160) suitable for the component forming stage.

[0074] That is, in the component material processing stage, the material plate (200) maintains a flat shape, so a wide area excluding the processing area of ​​the material plate (200) can be supported, and thus the material plate can be supported using a plate-shaped plate lifter (150). However, in the component forming stage, a bending area is formed in the material plate (200), and thus, there are many areas that are restricted in supporting the material plate (200) while smoothly transporting the material, and thus it is difficult to support the material plate using a plate-shaped plate lifter (150). Therefore, the temporary connecting portions (183) of the left and right bracket parts are made into flat portions, and a narrow rail-shaped plate lifter (160) capable of supporting the flat portions is used.

[0075] Figure 10 is a schematic diagram of the operation of a plate lifter.

[0076] (A) of Fig. 10 is a state when the material plate (200) is transferred in the previous step process, (B) is a state when the upper mold (120) is lowered to the material plate (200) while the plate lifter (150, 160) supports the material plate (200), and (C) is a state when the upper mold (120) and the plate lifter (150, 160) move together with the material plate (200) relative to the lower mold to form.

[0077] Referring to FIG. 10, the plate lifter (150, 160) of the present invention operates to raise and support the material plate (200) so that the transferred material plate (200) is in close contact with the upper mold (120) and does not shake when processing the outer shape of the material plate (200) or forming it into a required shape using a progressive mold, and then lowers the material plate (200) together with the upper mold (120) relative to the lower mold (140).

[0078] Through this, the shaking, rolling and pitching phenomena occurring in the material plate (200) while the material plate (200) is being transported are suppressed, and the material plate (200) is formed while being fixed in the exact position between the upper mold (120) and the lower mold (140), thereby reducing forming defects and left-right dimensional dispersion.

[0079] In addition, the rail-type plate lifter (160) used in the component forming step is configured to serve as a guide to prevent the material plate (200) from shaking in the left-right direction when being transported by allowing the plate guide protrusion (240) formed in a 'ㄷ' shape on the material plate (200) to be hung on the left and right sides of the rail-type plate lifter (160).

[0080]

[0081] The present invention, configured as described above, can mold a complex product with a single mold structure, and has the remarkable effect of not only enabling mass production while suppressing molding defects and left-right dimensional dispersion, but also increasing productivity with a fast processing speed.

[0082]

[0083] Although the present invention has been described with reference to the embodiments shown in the drawings, these are merely exemplary, and those skilled in the art will understand that various modifications and equivalent other embodiments are possible therefrom, and therefore the true technical scope of the present invention should be determined by the technical idea of ​​the appended claims.

[0084] 110: Up and down slide 120: Prize type

[0085] 130: Bolster 140: Lower body

[0086] 150: Plate lifter

[0087] 160: Rail-type plate lifter, plate guide

[0088] 170: Stripper 180: Bracket Parts

[0089] 181: Left bracket part 182: Right bracket part

[0090] 183: Temporary connection of left and right bracket parts

[0091] 184: Carrier for transporting material plates

[0092] 200: Material plate 210: Pilot pin insertion hole

[0093] 220: Hole for forming a protrusion that will become a plate guide projection

[0094] 230: Chinese characters up and down 240: Plate guide protrusion

[0095] 241: Protrusion that will become the plate guide protrusion

[0096] 250: Embossed part 260: Front and rear of bracket part

[0097] 270: Through hole

Claims

1. A method for manufacturing a bracket part of an automobile rear frame using a progressive mold equipped with an upper mold and a lower mold so as to be able to process a pair of left and right bracket parts having different shapes, Step (S1) of transferring the material plate of the above bracket part to a progressive mold; Step (S2) of piercing a pilot pin insertion hole in the left and right center of the above material plate; Step (S3) of notching the outline of the bracket part on the above material plate; Step (S4) of marking an embossing portion on the above bracket part; Step (S5) of first bending the front and rear ends of the above bracket parts; Step (S6) of performing secondary bending of the front and rear ends of the above bracket parts; A step (S7) of piercing a component hole in the marking portion formed in the embossing portion marking step (S4); Step of parting the left and right parts into the required bracket shape (S8); Method for manufacturing bracket parts of automobile rear frame using progressive mold including 2. In claim 1, A step (S2-1) of piercing a hole for forming a protrusion to be a plate guide projection between the above pilot pin insertion hole piercing step (S2) and the bracket part outer shape notching step (S3); and, The protrusion bending step (S3-1) for forming the plate guide protrusion between the bracket component outer shape notching step (S3) and the embossing portion marking step (S4); Method for manufacturing a bracket part of an automobile rear frame using a progressive mold including a further 3. In claim 2, From step (S2) to step (S8) above, When the material plate is transferred between the upper mold and the lower mold, a step of raising a plate lifter disposed below the material plate to fix the material plate between the upper mold and the lower mold; A step of processing or forming a part by lowering a material plate fixed between the upper mold and the plate lifter as a whole relative to the lower mold; Method for manufacturing bracket parts of automobile rear frame using progressive mold in which a is performed 4. A bracket part for a rear frame of an automobile manufactured by any one of the methods of claims 1 to 3.

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