JP3771769B2

JP3771769B2 - Method and apparatus for forming plate material having three-dimensional curved surface shape

Info

Publication number: JP3771769B2
Application number: JP2000059471A
Authority: JP
Inventors: 良治田浦; 幸男真鍋
Original assignee: Mitsubishi Heavy Industries Ltd
Current assignee: Mitsubishi Heavy Industries Ltd
Priority date: 2000-03-03
Filing date: 2000-03-03
Publication date: 2006-04-26
Anticipated expiration: 2020-03-03
Also published as: JP2001246423A

Description

【０００１】
【発明の属する技術分野】
本発明は、三次元曲面形状を有する板材の成形方法および成形装置に関するものである。
【０００２】
【従来の技術】
板状の構造体としては、コルゲート成形された補強材を側面材で両側から挟んで接着したコルゲート補強構造体や、真空ガス圧成形法で作られたアルミハニカムを側面材で両側から挟んで真空ろう付けにより接合したアルミハニカム補強構造体等が一般的である。
【０００３】
ところで、上記構造体のうちのコルゲート補強構造体においては、コルゲートの筋目（すじめ）方向に高い剛性が得られるのに対し筋目に直交する方向には十分な剛性が得られないといった問題がある。また、コルゲート補強構造体に三次元曲面形状を与えようとしても筋目に直交する方向に曲がった形状にしか製作できない。
【０００４】
アルミハニカム補強構造体においては、コルゲート補強構造体とは異なりあらゆる方向に均等に高い剛性が得られるが、上記の方法により製作されるために製作費が嵩む、アルミ材を使用するため耐熱性に乏しいといった問題がある。また、曲面形状をなすアルミハニカムを製作するのは非常に難しく、アルミハニカム補強構造体に三次元曲面形状を与えることは容易ではない。
【０００５】
【発明が解決しようとする課題】
そこで、本発明者らは、コルゲート補強構造体やアルミハニカム補強構造体にかわる構造体として、凹凸を千鳥状に形成した補強材を側面材で挟んだ構造に注目した。この構造ならば、コルゲート補強構造体のように所定の方向にしか曲面成形できないような性質がなく所望の三次元曲面形状が得られるばかりか、補強材の材料としてステンレス鋼等を採用すれば耐熱性に乏しいアルミハニカム補強構造体の欠点を補うことも可能である。
しかしながら、現在のところ上記のような千鳥状の凹凸を有する補強材を簡単かつ安価に製作することは非常に困難であるのが実状である。
【０００６】
本発明は上記の事情に鑑みてなされたものであり、あらゆる方向に均等に高い剛性を有する板状の構造体を、より簡単かつ安価に製作することを目的としている。
【０００７】
【課題を解決するための手段】
上記の課題を解決するための手段として、次のような三次元曲面形状を有する板材の成形方法および成形装置、ならびに板材の接合方法を採用する。
すなわち請求項１記載の三次元曲面形状を有する板材の成形方法は、加工対象の板材を挟んで該板材の両側に分けて複数配置され、前記板材の厚さ方向から見ると上下に存在するものがひとつおきに隣り合って千鳥状に配置された第１、第２をもって、前記板材上の格子状の被加工箇所を両側から押圧することで、前記第１の押圧部によって前記板材上の被加工箇所を一側面から押圧して凹部を形成し、前記第２の押圧部によって前記板材状の被加工箇所を他側面から押圧して前記一側面に突出する凸部を形成し、前記第２押圧部と第１押圧部との間を縫うように設けられた誘導加熱コイルを用いて、前記第１の押圧部による被加工箇所と前記第２の押圧部による被加工箇所との間を、押圧に先んじて加熱しておくことを特徴とする。
【０００８】
この成形方法においては、第１の押圧部による被加工箇所を板材の一側面から押さえながら、第２の押圧部による被加工箇所を板材の他側面から押圧することにより、隣り合う被加工箇所間に曲げ加工を施すことができる。
【００１０】
また、第１の押圧部による被加工箇所を板材の一側面から押圧して凹部を形成し、第２の押圧部による被加工箇所を板材の他側面から押圧して一側面に突出する凸部を形成することにより、板材に千鳥状の凹凸を形成することができる。
【００１２】
さらに、第１の押圧部による被施工箇所、および第２の押圧部による被施工箇所をそれぞれ小群に分けて各小群ごとに押圧を行うことにより、作業性が向上して成形加工が行い易くなる。
【００１４】
そして、第１の押圧部による被加工箇所と第２の押圧部による被加工箇所との間を加熱しておくことにより、当該の被加熱部分が変形し易くなるので、曲げ加工が行い易くなる。また、凹部や凸部を形成する場合も、その頂部や底部の間にあたる部分が伸びるため、凹部や凸部が深く（高く）形成される。
【００１５】
請求項２記載の三次元曲面形状を有する板材の成形装置は、加工対象の板材を挟んで該板材の両側に分けて複数配置され、板材の厚さ方向から見ると上下に存在するものがひとつおきに隣り合って千鳥状に配置された第１、第２の押圧部と、前記板材を前記第１、第２の押圧部間を通じて搬送する搬送手段とを備え、前記第１の押圧部が前記板材の搬送方向に対する直交方向に複数配列され、前記第２の押圧部も前記直交方向に複数配列され、さらに前記搬送方向から見ると前記第１、第２の押圧部が前記板材を挟んで互い違いに配置され、前記第１の押圧部による被加工箇所と前記第２の押圧部による被加工箇所との間の前記板材を加熱する加熱手段を備えることを特徴とする。
【００１６】
この成形装置においては、板材の搬送過程で板材を第１の押圧部と第２の押圧部とで押圧し、それぞれの押圧力を相手方への押し付け力として利用しながら板材の曲げ加工や凹凸の形成を行うことにより、成形加工が行い易くなる。
【００１８】
また、第１の押圧部を板材の搬送方向に対する直交方向に複数配列し、第２の押圧部をも直交方向に複数配列し、さらに搬送方向から見ると第１、第２の押圧部を板材を挟んで互い違いに配置することにより、板材を搬送する過程で該板材に一側面から凹部が複数個ずつ一度に形成され、他側面からは一側面に突出する凸部が複数個ずつ一度に形成される。
【００２０】
さらに、第１の押圧部による被加工箇所と第２の押圧部による被加工箇所との間の板材を押圧に先んじて加熱しておくことにより、当該の被加熱部分が変形し易くなるので、曲げ加工が行い易くなる。また、凹部や凸部を形成する場合も、その頂部や底部の間にあたる部分が伸びるため、凹部や凸部がより深く（高く）形成される。
【００２１】
請求項３記載の三次元曲面形状を有する板材の成形装置は、請求項２記載の三次元曲面形状を有する板材の成形装置において、前記第１、第２の押圧部の前記搬送方向の前後に、押圧に際して前記板材を保持する保持手段がそれぞれ設けられていることを特徴とする。
【００２２】
この成形装置においては、保持手段を設けることにより、板材の曲げ加工や凹凸の形成がより正確に行えるようになる。
【００２３】
請求項４記載の三次元曲面形状を有する板材の成形装置は、請求項２または３記載の三次元曲面形状を有する板材の成形装置において、前記保持手段が、前記第１の押圧部と同じ構造を有する第１の保持部と、前記第２の押圧部と同じ構造を有する第２の保持部とからなることを特徴とする。
【００２４】
この成形装置においては、搬送方向の前方、すなわち押圧を終えた板材が流れる側の保持手段を、第１の押圧部と同じ構造を有する第１の保持部と、第２の押圧部と同じ構造を有する第２の保持部とにより構成することにより、曲げ加工されたり凹凸の形成された板材をその被加工箇所で保持できるので、板材の保持がより確実に行えるようになる。また、板材の被加工箇所を２度押しすることで加工精度が高まる。
【００２５】
請求項５記載の三次元曲面形状を有する板材の成形装置は、請求項２〜４の何れか一項に記載の三次元曲面形状を有する板材の成形装置において、前記第１、第２の押圧部の少なくともいずれか一方が、前記板材の面方向に突出する高さを調節可能であることを特徴とする。
【００２６】
この成形装置においては、第１、第２の押圧部の少なくともいずれか一方について、板材の面方向に突出する高さを調節可能とすることにより、曲げ加工の状態や凹凸の深さ（高さ）を自在に設定できるようになる。
【００３５】
【発明の実施の形態】
本発明に係る三次元曲面形状を有する板材の成形方法および成形装置、ならびに板材の接合方法の第１の実施形態を図１ないし図６に示して説明する。
図１(ａ)、(ｂ)には成形装置の全体図を示している。この成形装置は、板材を加工する成型装置本体１と、該成形装置本体１を挟んで配置されて矩形平板状のワーク（加工対象の金属製の板材）Ｗを成形装置本体１に搬入、搬出する搬入テーブルおよび搬出テーブル（いずれも搬送手段）２，３とから構成されている。
【００３６】
搬入テーブル２と搬出テーブル３の構造について先に説明すると、いずれのテーブルにもワークＷを搬送する略水平な搬送面が設けられており、その搬送面には、ワークＷの搬送方向に回転しワークＷを乗せて送り出す搬送ローラ４が複数設けられている。また、いずれのテーブルにも、対をなすガイドローラ５がワークＷの搬送方向に離間して複数組設けられている。対をなすガイドローラ５，５はワークＷの幅方向に離間して配置されており、搬送されるワークＷの両側縁に当接してワークＷを搬送方向に向けて流し易くしている。
【００３７】
さらに、いずれのテーブルにも、ワークＷを搬送方向に運ぶ押出機構６が設けられている。押出機構６は搬送ローラ４に乗ったワークＷの後縁に当接し、これを押し出すようにして搬送する。また、搬出テーブル３については、加工後のワークＷの形状に合わせて搬送面を傾斜させることも可能である。
【００３８】
続いて成形装置本体１について説明すると、図２、図３に示すように、成形装置本体１には、ワークＷを上面から押圧する第１の押圧機構１０と、ワークＷを下面から押圧する第２の押圧機構２０とが設けられている。
【００３９】
第１の押圧機構１０は、昇降機構１１と、昇降機構１１により昇降可能に支持されたベース１２と、ワークＷの搬送面に平行なベース１２の下面に垂下されるように取り付けられた複数の押圧ピン１３とから構成されている。
【００４０】
押圧ピン１３は、ワークＷの幅方向に等間隔に離間するグループが、ワークＷの搬送方向に４列に並んで配置されており、昇降機構１１を駆動してベース１２を下降させることで押圧ピン１３の先端（下端）をワークＷの上面に押し当てるようになっている。また、各押圧ピン１３は、ベース１２の下面からの突出長を個々に調節できるようになっている。
【００４１】
図４に示すように、押圧ピン１３は、ベース１２に縦横に等ピッチで開けられた多数の取付孔１２ａに、連結部材１４を介して取り付けられている。
【００４２】
押圧ピン１３は、断面円形の先端部１３Ｐと断面矩形の基端部１３Ｅとを有し、隣り合うものどうし基端部１３Ｅの側面を突き合わせて隙間なくベース１２上に並べられており、互いに回動や水平方向の移動を規制し合って鉛直方向への移動のみを許容している。押圧ピン１３の基端部１３Ｅには下端面から有底の孔１３ｃが穿設されるとともに孔１３Ｈの開口に雌ネジ部１５が固定され、雌ネジ部１５には連結部材１４の一端に形成された雄ネジ部１４ａが螺合されている。
【００４３】
連結部材１４は中間部を取付孔１２ａに通して回動自在に支持されている。また、ベース１２内に位置する他端には後述するチャックに回動不能に嵌合する多角形断面部１４ｂが形成されている。
【００４４】
ベース１２の上方には、連結部材１４を回動させる回動機構１６が設けられている。回動機構１６は、多角形断面部１４ｂを掴むチャック１７と、チャック１７を昇降させて多角形断面部１４ｂに嵌合、離脱させる継手部１８と、チャック１７を回転させる駆動部１９とを備えている。
【００４５】
押圧ピン１３の高さ調節は、多角形断面部１４ｂをチャックで把持して連結部材１４を回動させ、回動を規制された押圧ピン１３の基端部１３Ｅを雄ネジ部１４ａと雌ネジ部１５との螺合関係により送り出したり引き寄せたりすることによって行われる。
【００４６】
第２の押圧機構２０は、昇降機構２１と、昇降機構２１により昇降可能に支持されたベース２２と、ワークの搬送面に平行なベース２２の上面に垂直に取り付けられた複数の押圧ピン２３とから構成されている。
【００４７】
押圧ピン２３は、ワークＷの幅方向に等間隔に離間（押圧ピン１３と同間隔）するグループが、ワークＷの搬送方向に３列並んで配置されており、昇降機構２１を駆動してベース２２を上昇させることで押圧ピン２３の先端（上端）を各列ごとにワークＷの下面に押し当てるようになっている。なお、各押圧ピン２３にも、押圧ピン１３と同じ構造の高さ調節機構が設けられている（説明は省略）。
【００４８】
押圧ピン１３と押圧ピン２３の位置関係は次のようになっている。
まず、押圧ピン１３および押圧ピン２３を上方視すると、図５のようにそれぞれがひとつおきに格子の頂点にあたる位置に配置されて千鳥状に配列されている。ただし、押圧ピン１３および押圧ピン２３はそれぞれの列がワークＷの幅方向に配列されていることから、格子の方向はワークＷの搬送方向に対し９０゜の角度をなすように与えられる。
【００４９】
また、押圧ピン１３および押圧ピン２３をワークＷの搬送方向から側方視すると、それらはワークＷの幅方向にオフセットして互い違いに配置され（図２参照）、ワークＷの幅方向から側方視すると搬送方向にオフセットして互い違いに配置されることとなる（図３参照）。
【００５０】
第２の押圧機構２０側には、上方視すると３列の中央の列に属する押圧ピン２３と４列のうちの中２列に属する押圧ピン１３との間を縫うように誘導加熱コイル（加熱手段）３０が設けられている（図４参照）。この誘導加熱コイル３０に通電すれば、ワークＷ上の押圧ピン１３により押圧される被加工箇所と押圧ピン２３により押圧される被加工箇所との間を加熱できるようになっている。
【００５１】
次に、三次元曲面形状を有する板状の構造体を製作するにあたってその構成要素である側面材と補強材とを上記成形装置を使って成形加工する手順を説明する。
最初に、図６をもとに側面材の成形加工について説明する。側面材の素となるワークＷ_Oを搬入テーブル２に載せると、ワークＷ_Oは搬送ローラ４に乗って成形装置本体１に向け搬送される。ワークＷ_Oが第１、第２の押圧機構１０，２０間に到達すると、ワークＷ_Oの搬送は一旦停止され、ワークＷ_Oに対して曲げ加工が施される。
【００５２】
ここで、４列に並ぶ押圧ピン１３のうち搬送方向の上流側の第１列に属する押圧ピン（第１の保持部）１３ａの先端、および上流寄り中央の第２列に属する押圧ピン（第１の押圧部）１３ｂの先端は、いずれも搬入テーブル２の搬送面とほぼ面一の高さに設定されている。また、下流寄り中央の第３列に属する押圧ピン（第１の押圧部）１３ｃの先端、および下流側の第４列に属する押圧ピン（第１の保持部）１３ｄの先端は、ワークＷ_Oの成形すべき形状に合わせて他の押圧ピン１３ａ，１３ｂよりもやや上方に突き出した高さに設定されている。ただし、いずれもワークＷ_Oの搬送時にはベース１２ごと上昇して搬送面から離間した状態にある。
【００５３】
３列に並ぶ押圧ピン２３のうち搬送方向の上流側の第１列に属する押圧ピン（第２の保持部）２３ａ、および中央の第２列に属する押圧ピン（第２の押圧部）２３ｂの先端はいずれも搬入テーブル２の搬送面とほぼ面一の高さに設定され、下流側の第３列に属する押圧ピン（第２の保持部）２３ｃの先端はワークＷ_Oの成形すべき形状に合わせて他の押圧ピン２３ａ，２３ｂよりもやや上方に突き出した高さに設定されている。
【００５４】
ワークＷ_Oが停止すると、押圧ピン１３ｂ，１３ｃにより押圧される被加工箇所と押圧ピン２３ｂにより押圧される被加工箇所との間が誘導加熱コイル３０によって加熱される（図６(ａ)）。この状態では、ワークＷ_Oは曲げ加工を受けておらず押圧ピン２３ｂとの間には若干の隙間を生じている。
【００５５】
ワークＷ_Oが十分に加熱されたら、第１の押圧機構１０が駆動して押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄが下降する（図６(ｂ)）。これにより、ワークＷ_Oは押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄと押圧ピン２３ａ，２３ｂ，２３ｃとに上下から挟まれた状態となるが、このとき、加熱されたワークＷ_Oの前後が押圧ピン１３ｂ，１３ｃにより下方に押圧されることとなり、押圧ピン２３ｂとの間の隙間を解消するようにワークＷ_Oが塑性変形して被加工箇所とその周辺が曲げ加工される。またこのとき、押圧ピン１３ａ，２３ａ、ならびに押圧ピン１３ｄ，２３ｃは曲げ加工の手段としてではなく、被加工箇所の前後でワークＷ_Oを保持する保持手段として機能する。
【００５６】
ワークＷ_Oが塑性変形し当該の被加工箇所とその周辺が曲げ加工されたら、第１の押圧機構１０が再び駆動して押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄが上昇し、ワークＷ_Oの拘束が解かれる（図６(ｃ)）。続いて、搬入テーブル２が駆動してワークＷ_Oが所定量分前方に搬送される。以降は上記の手順が繰り返され、ワークＷ_Oに対して順次曲げ加工が施される。以上の作業はすべて自動で行われ、加工を終えたワークＷ_Oは側面材として所定の三次元曲面形状に成形されて搬出テーブル３上に送り出され、板状の構造体の側面材Ｗ_Oが完成する。
【００５７】
次に、図７をもとに補強材の成形加工について説明する。補強材の素となるワークＷ_Iを搬入テーブル２に載せると、ワークＷ_Iは搬送ローラ４に乗って成形装置本体１に向け搬送される。ワークＷ_Iが第１、第２の押圧機構１０，２０間に到達すると、ワークＷ_Iの搬送は一旦停止され、ワークＷ_Iに対して凹凸が形成される。
【００５８】
ここで、押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄの先端はいずれも搬入テーブル２の搬送面とほぼ面一の高さに設定され、押圧ピン２３ａ，２３ｂ，２３ｃの先端もすべて搬入テーブル２の搬送面とほぼ面一の高さに設定されている。ただし、押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄは、ワークＷ_Iの搬送時にはいずれもベース１２ごと上昇して搬送面から離間した状態にある。
【００５９】
ワークＷ_Iが停止すると、押圧ピン１３ｂ，１３ｃによる被加工箇所と押圧ピン２３ｂによる被加工箇所との間が誘導加熱コイル３０によって加熱される（図７(ａ)）。
【００６０】
ワークＷ_Iが十分に加熱されたら、第１の押圧機構１０が駆動して押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄが下降する。これと同時に第２の押圧機構２０が駆動して押圧ピン２３ｃが搬送面を越えて上昇し、その先端がワークＷ_Iの凸部（前回に押圧ピン２３ｂにより形成されたもの）に下面側から押し当てられる（図７(ｂ)）。これにより、ワークＷ_Iは押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄと押圧ピン２３ａ，２３ｂ，２３ｃとに上下から挟まれた状態となる。
【００６１】
続いて、第２の押圧機構２０が駆動して被加工箇所を押し上げるように押圧ピン２３ｂが上昇する（図７(ｃ)）。これにより、ワークＷ_Iは上方に張り出すようにして塑性変形し、押圧ピン２３ｂによる凸部と、押圧ピン１３ｂ，１３ｃによる凹部が新たに形成される。このとき、押圧ピン１３ａ，２３ａ、ならびに押圧ピン１３ｄ，２３ｃは曲げ加工の手段としてではなく、被加工箇所の前後でワークＷ_Iを保持する保持手段として機能する。
【００６２】
ワークＷ_Iが塑性変形し当該の被加工箇所とその周辺に凹凸が形成されたら、第１の押圧機構１０が再び駆動して押圧ピン１３ａ，１３ｂ，１３ｃ，１３ｄが上昇するとともに押圧ピン２３ｂ，２３ｃが下降し、ワークＷ_Iの拘束が解かれる（図７(ｄ)）。続いて、搬入テーブル２が駆動してワークＷ_Iが所定量分前方に搬送される。以降は上記の手順を繰り返してワークＷ_Iに対して順次凹凸が形成される。以上の作業はすべて自動で行われ、加工を終えたワークＷ_Iは補強材として所定の三次元曲面形状に成形されて搬出テーブル３に送り出され、板状の構造体の補強材Ｗ_Iが完成する。
【００６３】
完成した補強材Ｗ_Iには、上面から見ると押圧ピン１３によって形成された凹部と押圧ピン２３によって形成された凸部とが互い違いに存在する。ここで、凹部を第１の被施工箇所とし、凸部を第２の被施工箇所とすれば、これらは押圧ピン１３，２３の配列に習って格子の頂点にあたる位置に配置されて千鳥状に配列されたものとなっている。
【００６４】
これら凹部と凸部とは、格子の対角線方向（つまりワークＷ_Iの幅方向）に隣り合う小群に分かれて交互に存在すると見なせるが、これらはワークＷ_Iの成形加工にあたって押圧ピン１３ｂ，１３ｃと押圧ピン２３ｂとで各小群ごとに押圧されて形成されたものである。
【００６５】
次に、上記のようにして所定の三次元曲面形状に成形加工された側面材Ｗ_Oと補強材Ｗ_Iとを接合する手順を図８をもとに説明する。
側面材Ｗ_Oと補強材Ｗ_Iとを重ね合わせると、両者は補強材Ｗ_I側の個々の凸部の頂部と側面材Ｗ_Oとが点に近い状態で当接し合うこととなる。そこで、レーザ溶接技術を利用して両者の当接部における接合を図る。
【００６６】
まず、成形加工を終えた補強材Ｗ_Iについて、予め各凸部の頂部に側面材Ｗ_Oや補強材Ｗ_Iよりも融点の低いろう材Ｒを溶射や塗布により付着させておく。
【００６７】
側面材Ｗ_Oと補強材Ｗ_Iとを重ね合わせると、個々の凸部の頂部と側面材Ｗ_Oとが点に近い状態で当接するので（図８(ａ)）、両者の当接部に対し側面材Ｗ_O側からレーザＬを照射して側面材Ｗ_Oと補強材Ｗ_Iとを貫通溶接する。これにより、側面材Ｗ_Oと補強材Ｗ_Iの当接部は溶融して固着するが、溶接の際に生じる熱でろう材Ｒが溶け、当接部の周囲に生まれる側面材Ｗ_Oと補強材Ｗ_Iとの間の僅かな隙間を埋めるように広がり、溶接の熱が冷めるとそのままの状態で固まって両者間に溶着する（図８(ｂ)）。
【００６８】
上記のようにして個々の当接部を接合していき、最終的には補強材Ｗ_Iの両側に側面材Ｗ_Oを接合すると、所定の三次元曲面形状を有する板状の構造体が完成する。
【００６９】
本実施形態によれば、押圧ピン１３，２３の高さ調節を随時行いながら成形加工を進めることにより、側面材Ｗ_Oを所望の三次元曲面形状に成形することができるばかりか、同様に押圧ピン１３，２３の高さ調節を随時行いながら成形加工を進めることにより、千鳥状に凹凸が形成された補強材Ｗ_Iを成形することができる。またこういった成形加工作業は自動的に進められるので、生産性の向上も図れる。
【００７０】
また、成形加工に先んじて曲げ加工や凹凸の形成を行うべき被加工箇所の周辺を誘導加熱コイル３０によって加熱しておくことにより、ワークＷ_O，Ｗ_Iの加工性を向上させて成形品の形状の自由度を高めることができる。
【００７１】
さらに、ワークＷ_O，Ｗ_Iに対し曲げ加工や凹凸の形成を行う押圧ピン１３ｂ，１３ｃ、押圧ピン２３ｂと同形状でしかも互いに千鳥配列された押圧ピン１３ａ，１３ｄ、押圧ピン２３ａ，２３ｃを、ワークＷ_O，Ｗ_Iの保持手段として機能させることにより、曲げ加工や凹凸の形成がより正確に行えるので、成形品の加工精度を高めることができる。
【００７２】
次に、本発明に係る板材の接合方法の第２の実施形態を図９に示して説明する。なお、上記第１の実施形態において既に説明した構成要素には同一符号を付して説明は省略する。
側面材Ｗ_Oと補強材Ｗ_Iとを重ね合わせると、ところによっては凸部の頂部と側面材Ｗ_Oとの間に隙間が生じることがあり、その箇所はレーザ溶接を行ってもうまく貫通溶接が行えないことがある。そこで、本実施形態においては、図７に示すように側面材Ｗ_Oと補強材Ｗ_Iの当接部の周囲を加圧リング３１で押さえながらレーザ溶接を行う。加圧リング３１は中央をレーザアークで射抜かれるようにして配置され、図示しない駆動手段で側面材Ｗ_Oに押し付けられるようになっている。
【００７３】
本実施形態によれば、加圧リング３１で側面材Ｗ_Oを僅かに変形させて側面材Ｗ_Oと補強材Ｗ_Iとの間の隙間を解消したうえでレーザ溶接を行うので、いずれの当接部においても両者の接合が良好に行える。
【００７４】
ところで、板状の構造体に求められる強度が高い場合は、さらに高度な溶接技術を採用する必要がある。こういった場合は、溶接材として、溶融することにより側面材Ｗ_Oや補強材Ｗ_Iの材質と混ざって溶接後も側面材Ｗ_Oや補強材Ｗ_Iの劣化を阻んで同程度の強度を発揮する材料を使用するのが適当である。これによると、当接部における両者の接合強度が格段に高められる。
【００７５】
次に、本発明に係る板材の接合方法の第３の実施形態を図１０に示して説明する。なお、上記の各実施形態において既に説明した構成要素には同一符号を付して説明は省略する。
板状の構造体に求められる強度によっては、側面材Ｗ_Oと補強材Ｗ_Iとの溶接は行わず、ろう材Ｒのみによって接合するようにしてもよい。そこで、本実施形態においては、側面材Ｗ_Oを補強材Ｗ_Iに押し付けながら同時に加熱してろう材Ｒを溶着させる。
【００７６】
側面材Ｗ_Oと補強材Ｗ_Iの当接部は、側面材Ｗ_O側から見ると等間隔に離間して直線的に配列されている。そこで、当接部の配列方向に沿って側面材Ｗ_O上を移動しながら当接部の両側を加圧する加圧ローラ３２と、加圧ローラ３２とともに移動しながら当接部を加熱する誘導加熱コイル３３を設ける。加圧ローラ３２には、加熱される当接部を挟んで転動する前輪（３２ａ）と、それらの後方を追従するように転動する後輪（３２ｂ）が設けられており、後輪の２つは溶けたろう材が固まるまで加圧状態を保つために設けられている。
【００７７】
本実施形態によれば、加圧ローラ３２ａで側面材Ｗ_Oを押さえながら誘導加熱コイル３３で加熱してろう材Ｒを溶かすと、溶けたろう材Ｒが側面材Ｗ_Oと補強材Ｗ_Iとの間の僅かな隙間を埋めるように広がる。側面材Ｗ_Oを加圧した状態は加圧ローラ３２ｂが通過するまで保たれ、その間にろう材Ｒが冷め固まって両者間に溶着する。これにより、溶接を行わずに簡単に側面材Ｗ_Oと補強材Ｗ_Iとを接合することができる。
【００７８】
上記各実施形態に示した技術を採用することにより、所望の三次元曲面形状を有する板状の構造体を製作することができる。ところで、上記の技術はそれぞれを組み合わせることも可能である。例えば、第２の実施形態において、加圧リングにかえて第３の実施形態で説明した加圧ローラを採用しても同様の効果が得られる。また、この技術を使えば、コルゲート補強構造体やアルミハニカム補強構造体についても側面材と補強材との接合を容易に行うことができる。
【００７９】
【発明の効果】
以上説明したように、本発明に係る請求項１記載の三次元曲面形状を有する板材の成形方法によれば、第１の押圧部による被加工箇所を板材の一側面から押さえながら、第２の押圧部による被加工箇所を板材の他側面から押圧することにより、隣り合う被加工箇所間に曲げ加工を施すことができ、これによって板材に三次元曲面形状を与えることができる。
【００８０】
また、第１の押圧部による被加工箇所を板材の一側面から押圧して凹部を形成し、第２の押圧部による被加工箇所を板材の他側面から押圧して一側面に突出する凸部を形成することにより、板材に千鳥状の凹凸を形成することができ、これによって板材により複雑な三次元曲面形状を与えることができる。
【００８１】
さらに、第１の押圧部による被施工箇所、および第２の押圧部による被施工箇所をそれぞれ小群に分けて各小群ごとに押圧を行うことにより、作業性が向上して成形加工が行い易くなるので、製作コストの削減が可能となる。
【００８２】
そして、第１の押圧部による被加工箇所と第２の押圧部による被加工箇所との間を加熱しておくことにより、当該の被加熱部分が変形し易くなるので、曲げ加工が行い易くなる。また、凹部や凸部を形成する場合も、その頂部や底部の間にあたる部分が伸びるため、凹部や凸部が深く（高く）形成できるようになり、これによって加工性が高まるので、成形品の形状の自由度を高めることができる。
【００８３】
請求項２記載の三次元曲面形状を有する板材の成形装置によれば、板材の搬送過程で板材を第１の押圧部と第２の押圧部とで押圧し、それぞれの押圧力を相手方への押し付け力として利用しながら板材の曲げ加工や凹凸の形成を行うことにより、成形加工が行い易くなるので、製作コストの削減が可能となる。
【００８４】
また、第１の押圧部を板材の搬送方向に対する直交方向に複数配列し、第２の押圧部をも直交方向に複数配列し、さらに搬送方向から見ると第１、第２の押圧部を板材を挟んで互い違いに配置することにより、板材を搬送する過程で該板材に一側面から凹部が複数個ずつ一度に形成され、他側面からは一側面に突出する凸部が複数個ずつ一度に形成されるので、千鳥状の凹凸を簡単かつ迅速に形成することができる。
【００８５】
さらに、第１の押圧部による被加工箇所と第２の押圧部による被加工箇所との間の板材を押圧に先んじて加熱しておくことにより、当該の被加熱部分が変形し易くなるので、曲げ加工が行い易くなる。また、凹部や凸部を形成する場合も、その頂部や底部の間にあたる部分が伸びるため、凹部や凸部がより深く（高く）形成できるようになり、これによって加工性が高まるので、成形品の形状の自由度を高めることができる。
【００８６】
請求項３記載の三次元曲面形状を有する板材の成形装置によれば、保持手段を設けることにより、板材の曲げ加工や凹凸の形成がより正確に行えるようになるので、成形品の加工精度を高めることができる。
【００８７】
請求項４記載の三次元曲面形状を有する板材の成形装置によれば、搬送方向の前方、すなわち押圧を終えた板材が流れる側の保持手段を、第１の押圧部と同じ構造を有する第１の保持部と、第２の押圧部と同じ構造を有する第２の保持部とにより構成することにより、曲げ加工されたり凹凸の形成された板材をその被加工箇所で保持できるので、板材の保持がより確実に行え、成形品の加工精度を高めることができる。また、板材の被加工箇所を２度押しすることでも加工精度が高まる。
【００８８】
請求項５記載の三次元曲面形状を有する板材の成形装置によれば、第１、第２の押圧部の少なくともいずれか一方について、板材の面方向に突出する高さを調節可能とすることにより、曲げ加工の状態や凹凸の深さ（高さ）を自在に設定でき、これによって加工性が高まるので、成形品の形状の自由度を高めることができる。
【図面の簡単な説明】
【図１】本発明に係る第１の実施形態を示す図であって、成形装置の平面図および側面図である。
【図２】成形装置本体１の構造を示す側面図である。
【図３】成形装置本体１の構造を示す断面図（図２におけるIII-III線矢視断面図）である。
【図４】押圧ピン１３，２３の高さを調節する機構を示す斜視断面図である。
【図５】押圧ピン１３，２３の位置関係を示す平面図である。
【図６】板状の構造体を構成する側面材Ｗ_Oの成形加工の手順を示す工程図である。
【図７】板状の構造体を構成する補強材の成形加工Ｗ_Iの手順を示す工程図である。
【図８】側面材Ｗ_Oと補強材Ｗ_Iとの接合の仕方を示す状態説明図である。
【図９】本発明に係る第２の実施形態を示す図であって、側面材Ｗ_Oと補強材Ｗ_Iとの接合の仕方を示す状態説明図である。
【図１０】本発明に係る第３の実施形態を示す図であって、側面材Ｗ_Oと補強材Ｗ_Iとの接合の仕方を示す状態説明図である。
【符号の説明】
１成形装置本体
２搬入テーブル（搬送手段）
３搬出テーブル（搬送手段）
１０第１の押圧機構
１３ａ，１３ｂ，１３ｃ，１３ｄ押圧ピン（第１の押圧部）
２０第２の押圧機構
２３ａ，２３ｂ，２３ｃ押圧ピン（第２の押圧部）
３０誘導加熱コイル（加熱手段）
３１加圧リング（加圧手段）
３２加圧ローラ（加圧手段）
Ｗワーク（板材）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for molding a plate material having a three-dimensional curved surface shape and a molding apparatus. In place It is related.
[0002]
[Prior art]
As plate-like structures, corrugated reinforcing structures with corrugated reinforcing material sandwiched from both sides with side members, and aluminum honeycombs made by vacuum gas pressure forming from both sides are vacuumed. An aluminum honeycomb reinforced structure joined by brazing is generally used.
[0003]
By the way, in the corrugated reinforcing structure among the structures described above, there is a problem that high rigidity is obtained in the direction of the corrugated line (straightening), but sufficient rigidity cannot be obtained in the direction perpendicular to the line. . Moreover, even if it is going to give a three-dimensional curved surface shape to a corrugated reinforcement structure, it can manufacture only in the shape bent in the direction orthogonal to a streak.
[0004]
In the aluminum honeycomb reinforced structure, unlike the corrugated reinforced structure, high rigidity is obtained evenly in all directions, but the manufacturing cost increases because it is manufactured by the above method. There is a problem of being scarce. Moreover, it is very difficult to manufacture an aluminum honeycomb having a curved shape, and it is not easy to give a three-dimensional curved shape to the aluminum honeycomb reinforcing structure.
[0005]
[Problems to be solved by the invention]
Therefore, the present inventors paid attention to a structure in which a reinforcing material in which irregularities are formed in a staggered pattern is sandwiched between side members as a structure that replaces a corrugated reinforcing structure or an aluminum honeycomb reinforcing structure. With this structure, the corrugated reinforcing structure does not have the property of being able to be curved only in a predetermined direction, and a desired three-dimensional curved shape can be obtained. It is also possible to compensate for the shortcomings of the aluminum honeycomb reinforcing structure having poor properties.
However, at present, it is very difficult to easily and inexpensively manufacture the reinforcing material having the staggered irregularities as described above.
[0006]
The present invention has been made in view of the above circumstances, and an object thereof is to manufacture a plate-like structure having high rigidity equally in all directions more easily and inexpensively.
[0007]
[Means for Solving the Problems]
As means for solving the above-mentioned problems, a plate material forming method and forming apparatus having the following three-dimensional curved surface shape, and a plate material joining method are employed.
That is, the method for forming a plate material having a three-dimensional curved surface according to claim 1 is arranged in plural on both sides of the plate material across the plate material to be processed, and exists above and below when viewed from the thickness direction of the plate material. 1st and 2nd are arranged next to every other in a staggered pattern And pressing the grid-like processed portion on the plate material from both sides, the first The pressed portion of the plate material is pressed from one side by the pressing portion to form a recess, and the plate-like processed portion is pressed from the other side by the second pressing portion to protrude from the one side. Using the induction heating coil formed so as to form a convex portion and sew between the second pressing portion and the first pressing portion, the portion to be processed by the first pressing portion and the second pressing portion It is characterized by heating between the parts to be processed by the step prior to pressing.
[0008]
In this molding method, while pressing the processed portion by the first pressing portion from one side surface of the plate material, by pressing the processed portion by the second pressing portion from the other side surface of the plate material, Can be bent.
[0010]
Also, The processed part by the first pressing part is pressed from one side of the plate material to form a recess, and the processed part by the second pressing unit is pressed from the other side of the plate material to form a convex part protruding to one side. By doing so, staggered irregularities can be formed on the plate material.
[0012]
further, By dividing the work place by the first pressing part and the work place by the second pressing part into small groups and pressing each small group, the workability is improved and the molding process is facilitated. .
[0014]
And By heating the portion to be processed by the first pressing portion and the portion to be processed by the second pressing portion, the portion to be heated is easily deformed, so that bending is facilitated. Moreover, when forming a recessed part and a convex part, since the part which hits between the top part and the bottom part is extended, a recessed part and a convex part are formed deeply (highly).
[0015]
The apparatus for forming a plate material having a three-dimensional curved surface according to claim 2 is arranged in plural on both sides of the plate material with the plate material to be processed interposed therebetween, and there is one device that exists above and below when viewed from the thickness direction of the plate material. 1st, 2nd press part arrange | positioned adjacently every other, and the conveyance means which conveys the said board | plate material through between the said 1st, 2nd press part. A plurality of the first pressing parts are arranged in a direction orthogonal to the conveying direction of the plate material, a plurality of the second pressing parts are also arranged in the orthogonal direction, and when viewed from the conveying direction, the first and second The pressing portions are arranged alternately with the plate material in between, and include heating means for heating the plate material between the processed portion by the first pressing portion and the processed portion by the second pressing portion. It is characterized by that.
[0016]
In this forming apparatus, the plate material is pressed by the first pressing portion and the second pressing portion in the process of conveying the plate material, and the bending process of the plate material and the unevenness are performed while using the respective pressing forces as the pressing force to the other party. By forming, it becomes easy to perform a forming process.
[0018]
Also, A plurality of first pressing portions are arranged in a direction orthogonal to the conveying direction of the plate material, a plurality of second pressing portions are also arranged in the orthogonal direction, and the first and second pressing portions are sandwiched between the plate materials when viewed from the conveying direction. In the process of transporting the plate material, a plurality of concave portions are formed from one side surface at a time, and a plurality of convex portions projecting from one side surface are formed at a time from the other side surface. .
[0020]
further, Since the plate material between the portion to be processed by the first pressing portion and the portion to be processed by the second pressing portion is heated prior to pressing, the portion to be heated is easily deformed. Is easier to do. Moreover, when forming a recessed part and a convex part, since the part which hits between the top part and the bottom part is extended, a recessed part and a convex part are formed deeper (higher).
[0021]
Claim 3 An apparatus for forming a plate material having the described three-dimensional curved surface shape, Claim 2 In the apparatus for forming a plate material having a three-dimensional curved surface shape described above, holding means for holding the plate material at the time of pressing is respectively provided before and after the first and second pressing portions in the transport direction. To do.
[0022]
In this molding apparatus, by providing the holding means, the plate material can be bent and the unevenness can be formed more accurately.
[0023]
Claim 4 An apparatus for forming a plate material having the described three-dimensional curved surface shape, Claim 2 or 3 In the forming apparatus for a plate member having the three-dimensional curved surface shape described above, the holding means has a first holding portion having the same structure as the first pressing portion, and a second having the same structure as the second pressing portion. And a holding portion.
[0024]
In this molding apparatus, the holding means on the front side in the conveying direction, that is, the side on which the pressed plate material flows, has the same structure as the first pressing portion and the first holding portion having the same structure as the first pressing portion. With the second holding portion having the structure, it is possible to hold the plate material that has been bent or formed with unevenness at the portion to be processed, so that the plate material can be held more reliably. In addition, the processing accuracy is increased by pressing the processed portion of the plate material twice.
[0025]
Claim 5 An apparatus for forming a plate material having the described three-dimensional curved surface shape, In any one of Claims 2-4 In the molding apparatus for a plate material having the three-dimensional curved surface shape described above, the height at which at least one of the first and second pressing portions protrudes in the surface direction of the plate material can be adjusted. .
[0026]
In this molding apparatus, the height of the plate material protruding in the surface direction of at least one of the first and second pressing portions can be adjusted, so that the bending state and the depth of the unevenness (height) ) Can be set freely.
[0035]
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of a method and apparatus for forming a plate material having a three-dimensional curved surface shape and a method for joining plate materials according to the present invention will be described with reference to FIGS.
1 (a) and 1 (b) show an overall view of the molding apparatus. This forming apparatus carries a molding apparatus main body 1 for processing a plate material, and a rectangular flat plate-shaped workpiece (a metal plate material to be processed) W placed between the forming apparatus main body 1 into and out of the molding apparatus main body 1. And a carry-out table (both transport means) 2 and 3.
[0036]
The structure of the carry-in table 2 and the carry-out table 3 will be described first. Each table is provided with a substantially horizontal transfer surface for transferring the workpiece W, and the transfer surface rotates in the transfer direction of the workpiece W. A plurality of conveying rollers 4 for feeding the workpiece W on it are provided. Each table is provided with a plurality of pairs of guide rollers 5 which are paired apart in the conveying direction of the workpiece W. The paired guide rollers 5 and 5 are spaced apart from each other in the width direction of the workpiece W, and are in contact with both side edges of the workpiece W to be conveyed so that the workpiece W can easily flow in the conveyance direction.
[0037]
Furthermore, the extrusion mechanism 6 which conveys the workpiece | work W in a conveyance direction is provided in any table. The extruding mechanism 6 abuts on the rear edge of the workpiece W on the conveying roller 4 and conveys the workpiece W by pushing it out. Moreover, about the carry-out table 3, it is also possible to incline a conveyance surface according to the shape of the workpiece | work W after a process.
[0038]
Next, the molding apparatus main body 1 will be described. As shown in FIGS. 2 and 3, the molding apparatus main body 1 includes a first pressing mechanism 10 that presses the workpiece W from the upper surface, and a first pressing mechanism 10 that presses the workpiece W from the lower surface. Two pressing mechanisms 20 are provided.
[0039]
The first pressing mechanism 10 includes a lifting mechanism 11, a base 12 that is supported by the lifting mechanism 11 so as to be lifted and lowered, and a plurality of the pressing mechanisms 10 that are attached to the lower surface of the base 12 that is parallel to the conveying surface of the workpiece W. It consists of a pressing pin 13.
[0040]
The pressing pins 13 are arranged in groups of four rows in the direction of conveyance of the workpiece W that are spaced apart at equal intervals in the width direction of the workpiece W. The pressing pins 13 are pressed by driving the elevating mechanism 11 and lowering the base 12. The tip (lower end) of the pin 13 is pressed against the upper surface of the workpiece W. Moreover, each pressing pin 13 can adjust the protrusion length from the lower surface of the base 12 individually.
[0041]
As shown in FIG. 4, the pressing pin 13 is attached via a connecting member 14 to a large number of mounting holes 12 a that are opened in the base 12 at an equal pitch in the vertical and horizontal directions.
[0042]
The pressing pin 13 has a tip end portion 13P having a circular cross section and a base end portion 13E having a rectangular cross section. The pressing pins 13 are arranged on the base 12 with no gap therebetween by abutting the side surfaces of the adjacent base end portions 13E. Only movement in the vertical direction is allowed by restricting movement and movement in the horizontal direction. The base end portion 13E of the pressing pin 13 is provided with a bottomed hole 13c from the lower end surface, and the female screw portion 15 is fixed to the opening of the hole 13H. female A male screw portion 14 a formed at one end of the connecting member 14 is screwed into the screw portion 15.
[0043]
The connecting member 14 is rotatably supported by passing the intermediate portion through the mounting hole 12a. In addition, a polygonal cross-sectional portion 14b that is non-rotatably fitted to a chuck described later is formed at the other end located in the base 12.
[0044]
A rotation mechanism 16 that rotates the connecting member 14 is provided above the base 12. The rotation mechanism 16 includes a chuck 17 that grips the polygonal cross section 14 b, a joint portion 18 that moves the chuck 17 up and down to fit and remove from the polygon cross section 14 b, and a drive unit 19 that rotates the chuck 17. ing.
[0045]
The height of the pressing pin 13 is adjusted by holding the polygonal cross section 14b with a chuck and rotating the connecting member 14, and the base end portion 13E of the pressing pin 13 whose rotation is restricted is connected to the male screw portion 14a and the female screw. This is done by sending out or pulling it in due to the screwed relationship with the part 15.
[0046]
The second pressing mechanism 20 includes an elevating mechanism 21, a base 22 supported by the elevating mechanism 21 so as to be movable up and down, and a plurality of pressing pins 23 vertically attached to the upper surface of the base 22 parallel to the workpiece transfer surface. It is composed of
[0047]
The pressing pins 23 are arranged in groups of three rows spaced apart at equal intervals in the width direction of the workpiece W (same intervals as the pressing pins 13) in the conveying direction of the workpiece W, and drive the lifting mechanism 21 to drive the base The tip (upper end) of the pressing pin 23 is pressed against the lower surface of the workpiece W in each row by raising the 22. Each pressing pin 23 is also provided with a height adjusting mechanism having the same structure as the pressing pin 13 (the description is omitted).
[0048]
The positional relationship between the pressing pin 13 and the pressing pin 23 is as follows.
First, when the pressing pin 13 and the pressing pin 23 are viewed from above, every other pin is arranged at a position corresponding to the apex of the lattice and arranged in a staggered manner as shown in FIG. However, since the rows of the pressing pins 13 and the pressing pins 23 are arranged in the width direction of the workpiece W, the direction of the lattice is given so as to form an angle of 90 ° with respect to the conveying direction of the workpiece W.
[0049]
Further, when the pressing pin 13 and the pressing pin 23 are viewed laterally from the conveying direction of the workpiece W, they are offset in the width direction of the workpiece W and are alternately arranged (see FIG. 2). When viewed, they are alternately arranged offset in the transport direction (see FIG. 3).
[0050]
On the second pressing mechanism 20 side, when viewed from above, an induction heating coil (heating) (Means) 30 is provided (see FIG. 4). When the induction heating coil 30 is energized, the portion to be processed pressed by the pressing pin 13 on the workpiece W and the portion to be processed pressed by the pressing pin 23 can be heated.
[0051]
Next, a procedure for forming a side surface material and a reinforcing material, which are constituent elements of the plate-like structure having a three-dimensional curved surface shape, using the above-described forming apparatus will be described.
First, the side material forming process will be described with reference to FIG. Work W that is the base material of the side material _O Is placed on the carry-in table 2, the workpiece W _O Is carried on the conveyance roller 4 toward the molding apparatus main body 1. Work W _O Is reached between the first and second pressing mechanisms 10 and 20, the workpiece W _O Is temporarily stopped and the workpiece W _O Is bent.
[0052]
Here, of the pressing pins 13 arranged in four rows, the tip of the pressing pin (first holding portion) 13a belonging to the first row on the upstream side in the transport direction, and the pressing pin (first pin) belonging to the second row in the center near the upstream side (1 pressing portion) 13b is set to be substantially flush with the conveying surface of the carry-in table 2. Further, the tip of the pressing pin (first pressing portion) 13c belonging to the third row near the downstream side and the tip of the pressing pin (first holding portion) 13d belonging to the fourth row on the downstream side are the workpiece W _O In accordance with the shape to be formed, the height is set so as to protrude slightly above the other pressing pins 13a and 13b. However, both work W _O At the time of transport, the entire base 12 is raised and separated from the transport surface.
[0053]
Of the pressing pins 23 arranged in three rows, the pressing pins (second holding portions) 23a belonging to the first row on the upstream side in the conveying direction, and the pressing pins (second pressing portions) 23b belonging to the second row in the center All the tips are set to a level substantially flush with the conveying surface of the carry-in table 2, and the tips of the pressing pins (second holding portions) 23c belonging to the third row on the downstream side are the workpiece W. _O In accordance with the shape to be molded, the height is set so as to protrude slightly above the other pressing pins 23a and 23b.
[0054]
Work W _O When the operation stops, the induction heating coil 30 heats the portion to be processed pressed by the pressing pins 13b and 13c and the portion to be processed pressed by the pressing pin 23b (FIG. 6A). In this state, work W _O Is not subjected to bending, and a slight gap is generated between the pressing pin 23b.
[0055]
Work W _O Is sufficiently heated, the first pressing mechanism 10 is driven and the pressing pins 13a, 13b, 13c, 13d are lowered (FIG. 6B). As a result, work W _O Is sandwiched from above and below by the pressing pins 13a, 13b, 13c, 13d and the pressing pins 23a, 23b, 23c. At this time, the heated work W _O The workpiece W is pressed downward by the pressing pins 13b and 13c, so that the gap between the pressing pin 23b is eliminated. _O As a result of plastic deformation, the portion to be processed and its periphery are bent. At this time, the pressing pins 13a and 23a and the pressing pins 13d and 23c are not used as bending means, but before and after the workpiece W. _O Functions as a holding means for holding.
[0056]
Work W _O Is plastically deformed and the portion to be processed and its periphery are bent, the first pressing mechanism 10 is driven again, and the pressing pins 13a, 13b, 13c, 13d are raised, and the workpiece W _O Is released (FIG. 6C). Subsequently, the loading table 2 is driven and the workpiece W is driven. _O Is conveyed forward by a predetermined amount. Thereafter, the above procedure is repeated, and workpiece W _O Are sequentially bent. All the above operations are performed automatically, and the workpiece W has been processed. _O Is formed into a predetermined three-dimensional curved surface shape as a side member, and is sent out onto the carry-out table 3, and the side member W of the plate-like structure _O Is completed.
[0057]
Next, the reinforcing material forming process will be described with reference to FIG. Work W that is the base material of reinforcement _I Is placed on the carry-in table 2, the workpiece W _I Is carried on the conveyance roller 4 toward the molding apparatus main body 1. Work W _I Is reached between the first and second pressing mechanisms 10 and 20, the workpiece W _I Is temporarily stopped and the workpiece W _I Concavities and convexities are formed on the surface.
[0058]
Here, the tips of the pressing pins 13a, 13b, 13c, and 13d are all set to a level that is substantially flush with the carrying surface of the carry-in table 2, and the tips of the pressing pins 23a, 23b, and 23c are all carried by the carry-in table 2. The height is set almost flush with the surface. However, the pressing pins 13a, 13b, 13c, 13d _I During the transfer, both the base 12 is raised and separated from the transfer surface.
[0059]
Work W _I Is stopped, the space between the processed portion by the pressing pins 13b and 13c and the processed portion by the pressing pin 23b is heated by the induction heating coil 30 (FIG. 7A).
[0060]
Work W _I Is sufficiently heated, the first pressing mechanism 10 is driven and the pressing pins 13a, 13b, 13c, and 13d are lowered. At the same time, the second pressing mechanism 20 is driven and the pressing pin 23c rises over the conveying surface, and the tip of the pressing pin 23c is the workpiece W. _I Is pressed from the lower surface side to the convex portion (which was previously formed by the pressing pin 23b) (FIG. 7B). As a result, work W _I Is sandwiched from above and below by the pressing pins 13a, 13b, 13c, 13d and the pressing pins 23a, 23b, 23c.
[0061]
Subsequently, the pressing pin 23b is lifted so that the second pressing mechanism 20 is driven to push up the portion to be processed (FIG. 7 (c)). As a result, work W _I Is plastically deformed so as to project upward, and a convex portion by the pressing pin 23b and a concave portion by the pressing pins 13b and 13c are newly formed. At this time, the pressing pins 13a and 23a and the pressing pins 13d and 23c are not used as bending means, but before and after the workpiece W. _I Functions as a holding means for holding.
[0062]
Work W _I Is deformed plastically, and irregularities are formed in the processing location and its periphery, the first pressing mechanism 10 is driven again, and the pressing pins 13a, 13b, 13c, 13d are raised and the pressing pins 23b, 23c are lowered. Work W _I Is released (FIG. 7D). Subsequently, the loading table 2 is driven and the workpiece W is driven. _I Is conveyed forward by a predetermined amount. After that, repeat the above procedure to work W _I Concavities and convexities are formed sequentially. All the above operations are performed automatically, and the workpiece W has been processed. _I Is formed into a predetermined three-dimensional curved surface shape as a reinforcing material and fed to the carry-out table 3 to reinforce the reinforcing material W of the plate-like structure. _I Is completed.
[0063]
Completed reinforcement W _I When viewed from above, the concave portions formed by the pressing pins 13 and the convex portions formed by the pressing pins 23 are alternately present. Here, if the concave portion is the first construction location and the convex portion is the second construction location, these are arranged at positions corresponding to the apexes of the lattice according to the arrangement of the pressing pins 13 and 23 in a staggered manner. It has been arranged.
[0064]
These concave and convex portions are in the diagonal direction of the lattice (that is, the workpiece W _I Can be considered to be divided into small groups adjacent to each other in the width direction of the _I In this molding process, each small group is pressed by the pressing pins 13b and 13c and the pressing pin 23b.
[0065]
Next, the side material W molded into a predetermined three-dimensional curved surface shape as described above. _O And reinforcement W _I The procedure for joining the two will be described with reference to FIG.
Side material W _O And reinforcement W _I When the two are superimposed, the two are the reinforcing material W _I Top of each convex part and side material W _O Are in contact with each other in a state close to a point. Then, joining in the contact part of both is aimed at using a laser welding technique.
[0066]
First, the reinforcing material W that has been molded _I About side material W on the top of each convex part _O And reinforcement W _I A brazing material R having a lower melting point is adhered by thermal spraying or coating.
[0067]
Side material W _O And reinforcement W _I And the top of each convex part and the side material W _O Are in contact with each other in a state close to a point (FIG. 8 (a)). _O Side material W irradiated with laser L from the side _O And reinforcement W _I And are welded through. Thereby, the side material W _O And reinforcement W _I The abutting portion of the side material W is melted and fixed, but the brazing material R is melted by the heat generated during welding, and the side material W created around the abutting portion. _O And reinforcement W _I It spreads so as to fill a slight gap between them, and when the heat of welding cools, it solidifies as it is and welds between them (FIG. 8 (b)).
[0068]
The individual contact portions are joined as described above, and finally the reinforcing material W _I Side material W on both sides of _O Is joined, a plate-like structure having a predetermined three-dimensional curved surface shape is completed.
[0069]
According to the present embodiment, the side material W is obtained by advancing the forming process while adjusting the height of the pressing pins 13 and 23 as needed. _O Can be formed into a desired three-dimensional curved surface shape, and similarly, the reinforcing material W in which irregularities are formed in a zigzag pattern by proceeding with the forming process while adjusting the height of the pressing pins 13 and 23 as needed. _I Can be molded. In addition, since these molding operations are automatically performed, productivity can be improved.
[0070]
In addition, the work W is heated by the induction heating coil 30 in the vicinity of a portion to be processed that is to be bent or formed with irregularities prior to forming. _O , W _I The degree of freedom of the shape of the molded product can be increased by improving the workability of the molded product.
[0071]
Work W _O , W _I The pressing pins 13a and 13d and the pressing pins 23a and 23c, which have the same shape as that of the pressing pins 13b and 13c and the pressing pin 23b that are bent and formed uneven, are arranged in a staggered manner on the workpiece W. _O , W _I By functioning as a holding means, it is possible to more accurately perform the bending process and the formation of the unevenness, so that the processing accuracy of the molded product can be increased.
[0072]
Next, a second embodiment of the method for joining plate members according to the present invention will be described with reference to FIG. In addition, the same code | symbol is attached | subjected to the component already demonstrated in the said 1st Embodiment, and description is abbreviate | omitted.
Side material W _O And reinforcement W _I And the top part of the convex part and the side material W depending on the place. _O In some cases, a gap may be formed between the two and the through-welding may not be performed well even if laser welding is performed. Therefore, in the present embodiment, as shown in FIG. _O And reinforcement W _I Laser welding is performed while pressing the periphery of the contact portion with the pressure ring 31. The pressure ring 31 is arranged so that the center is ejected by a laser arc, and the side member W is driven by a driving means (not shown). _O Can be pressed against.
[0073]
According to the present embodiment, the pressure ring 31 is used for the side material W. _O Slightly deform the side material W _O And reinforcement W _I Since the laser welding is performed after eliminating the gap between the two, the two can be satisfactorily joined at any contact portion.
[0074]
By the way, when the strength required for the plate-like structure is high, it is necessary to employ a more advanced welding technique. In such cases, the side material W is melted as a welding material. _O And reinforcement W _I Side material W even after welding mixed with other materials _O And reinforcement W _I It is appropriate to use a material that prevents deterioration of the material and exhibits the same strength. According to this, the joint strength between the two at the contact portion is remarkably increased.
[0075]
Next, a third embodiment of the method for joining plate members according to the present invention will be described with reference to FIG. In addition, the same code | symbol is attached | subjected to the component already demonstrated in said each embodiment, and description is abbreviate | omitted.
Depending on the strength required for the plate-like structure, the side material W _O And reinforcement W _I May be joined only by the brazing material R. Therefore, in this embodiment, the side material W _O Reinforcement material W _I At the same time, the brazing material R is welded while being pressed.
[0076]
Side material W _O And reinforcement W _I The abutting part of the side material W _O When viewed from the side, they are linearly spaced apart at equal intervals. Therefore, the side material W along the arrangement direction of the contact portions. _O There are provided a pressure roller 32 that presses both sides of the contact portion while moving upward, and an induction heating coil 33 that heats the contact portion while moving together with the pressure roller 32. The pressure roller 32 is provided with a front wheel (32a) that rolls across a heated contact portion, and a rear wheel (32b) that rolls so as to follow the rear thereof. Two are provided to maintain a pressurized state until the molten brazing material is hardened.
[0077]
According to the present embodiment, the side member W is pressed by the pressure roller 32a. _O When the brazing material R is melted by heating with the induction heating coil 33 while holding down, the melted brazing material R becomes the side material W. _O And reinforcement W _I Spread to fill a small gap between the two. Side material W _O The pressure is maintained until the pressure roller 32b passes, during which time the brazing material R cools and hardens and is welded between the two. As a result, the side material W can be easily used without welding. _O And reinforcement W _I And can be joined.
[0078]
By adopting the techniques shown in the above embodiments, a plate-like structure having a desired three-dimensional curved surface shape can be manufactured. By the way, the above techniques can be combined. For example, in the second embodiment, the same effect can be obtained even if the pressure roller described in the third embodiment is used instead of the pressure ring. Moreover, if this technique is used, the side material and the reinforcing material can be easily joined to the corrugated reinforcing structure and the aluminum honeycomb reinforcing structure.
[0079]
【The invention's effect】
As described above, according to the method for forming a plate material having a three-dimensional curved surface shape according to the first aspect of the present invention, the second portion is pressed while pressing the processed portion by the first pressing portion from one side surface of the plate material. By pressing the part to be processed by the pressing portion from the other side surface of the plate material, it is possible to perform bending between adjacent processed points, thereby giving the plate material a three-dimensional curved surface shape.
[0080]
Also, The processed part by the first pressing part is pressed from one side of the plate material to form a recess, and the processed part by the second pressing unit is pressed from the other side of the plate material to form a convex part protruding to one side. By doing so, staggered irregularities can be formed on the plate material, and thereby a complicated three-dimensional curved surface shape can be given to the plate material.
[0081]
further, By dividing the work place by the first pressing part and the work place by the second pressing part into small groups and pressing each small group, the workability is improved and the molding process is facilitated. Therefore, the production cost can be reduced.
[0082]
And By heating the portion to be processed by the first pressing portion and the portion to be processed by the second pressing portion, the portion to be heated is easily deformed, so that bending is facilitated. Also, when forming recesses and protrusions, the portions corresponding to the top and bottom are extended, so that the recesses and protrusions can be formed deeper (higher), and this improves the workability. The degree of freedom of shape can be increased.
[0083]
Claim 2 According to the plate forming apparatus having the described three-dimensional curved surface shape, the plate material is pressed by the first pressing portion and the second pressing portion in the conveying process of the plate material, and each pressing force is used as a pressing force to the other party. By bending the plate material and forming the irregularities while using it, it becomes easier to perform the forming process, so that the manufacturing cost can be reduced.
[0084]
Also A plurality of first pressing portions are arranged in a direction orthogonal to the conveying direction of the plate material, a plurality of second pressing portions are also arranged in the orthogonal direction, and when viewed from the conveying direction, the first and second pressing portions are arranged as plate materials. By arranging them alternately and sandwiching them, a plurality of concave portions are formed on one side of the plate at a time in the process of transporting the plate, and a plurality of convex portions protruding on one side are formed on the other side at a time. Therefore, staggered irregularities can be formed easily and quickly.
[0085]
further By heating the plate material between the part to be processed by the first pressing part and the part to be processed by the second pressing part prior to pressing, the part to be heated is easily deformed. Processing becomes easier. In addition, when forming recesses and protrusions, the portions corresponding to the top and bottom of the recesses extend so that the recesses and protrusions can be formed deeper (higher). The degree of freedom of the shape can be increased.
[0086]
Claim 3 According to the apparatus for forming a plate material having a three-dimensional curved surface shape described above, by providing the holding means, it becomes possible to more accurately perform the bending process of the plate material and the formation of the unevenness, thereby increasing the processing accuracy of the molded product. it can.
[0087]
Claim 4 According to the forming apparatus for a plate material having a three-dimensional curved surface shape described above, the first holding unit having the same structure as the first pressing unit is used as the holding unit on the front side in the conveying direction, that is, the side on which the pressed plate material flows. And the second holding portion having the same structure as the second pressing portion, the plate material that is bent or formed with unevenness can be held at the portion to be processed, so that the holding of the plate material is more reliable. It is possible to improve the processing accuracy of the molded product. In addition, the processing accuracy can be increased by pressing the processed portion of the plate material twice.
[0088]
Claim 5 According to the apparatus for forming a plate material having a three-dimensional curved surface shape described above, the height protruding in the surface direction of the plate material can be adjusted with respect to at least one of the first and second pressing portions. Since the processability and the depth (height) of the unevenness can be set freely, thereby improving the workability, the degree of freedom of the shape of the molded product can be increased.
[Brief description of the drawings]
FIG. 1 is a diagram showing a first embodiment according to the present invention, and is a plan view and a side view of a molding apparatus.
FIG. 2 is a side view showing the structure of the molding apparatus main body 1. FIG.
3 is a cross-sectional view (a cross-sectional view taken along the line III-III in FIG. 2) showing the structure of the molding apparatus body 1. FIG.
FIG. 4 is a perspective sectional view showing a mechanism for adjusting the height of pressing pins 13 and 23;
FIG. 5 is a plan view showing the positional relationship between pressing pins 13 and 23;
FIG. 6 shows a side member W constituting a plate-like structure. _O It is process drawing which shows the procedure of the shaping | molding process.
FIG. 7 shows a forming process W of a reinforcing material constituting a plate-like structure. _I It is process drawing which shows the procedure of.
[Fig. 8] Side material W _O And reinforcement W _I It is a state explanatory view showing how to join.
FIG. 9 is a view showing a second embodiment according to the present invention, and a side member W _O And reinforcement W _I It is a state explanatory view showing how to join.
FIG. 10 is a diagram showing a third embodiment according to the present invention, and a side member W _O And reinforcement W _I It is a state explanatory view showing how to join.
[Explanation of symbols]
1 Molding device body
2 Loading table (conveying means)
3 Unloading table (conveying means)
10 First pressing mechanism
13a, 13b, 13c, 13d Pressing pin (first pressing part)
20 Second pressing mechanism
23a, 23b, 23c Pressing pin (second pressing part)
30 Induction heating coil (heating means)
31 Pressure ring (Pressurizing means)
32 Pressure roller (Pressurizing means)
W Workpiece (plate material)

Claims

A plurality of plates arranged on both sides of the plate material to be processed are sandwiched, and when viewed from the thickness direction of the plate material, every other one located above and below is arranged in a staggered manner adjacent to each other. By pressing the grid-like processed portion on the plate material from both sides, the concave portion is formed by pressing the processed portion on the plate material from one side by the first pressing portion, Provided to press the plate-like workpiece portion from the other side surface by the second pressing portion to form a convex portion protruding from the one side surface, and to sew between the second pressing portion and the first pressing portion. Using the induction heating coil thus obtained, a space between the portion to be processed by the first pressing portion and the portion to be processed by the second pressing portion is heated prior to pressing. A method for forming a plate having a curved shape.

A plurality of plates are arranged separately on both sides of the plate material to be processed, and when viewed from the thickness direction of the plate material, every other one located above and below is arranged in a staggered manner adjacent to each other. A pressing part;
Conveying means for conveying the plate material through the first and second pressing portions;
A plurality of the first pressing portions are arranged in a direction orthogonal to the conveying direction of the plate material,
A plurality of the second pressing parts are also arranged in the orthogonal direction,
Furthermore, when viewed from the transport direction, the first and second pressing portions are alternately arranged with the plate material interposed therebetween,
An apparatus for forming a plate having a three-dimensional curved surface, comprising heating means for heating the plate between a portion to be processed by the first pressing portion and a portion to be processed by the second pressing portion.

The plate material having a three-dimensional curved surface shape according to claim 2, wherein holding means for holding the plate material at the time of pressing is respectively provided before and after the first and second pressing portions in the transport direction. Molding equipment.

The said holding | maintenance means consists of a 1st holding | maintenance part which has the same structure as a said 1st press part, and a 2nd holding | maintenance part which has the same structure as a said 2nd press part. Or the shaping | molding apparatus of the board | plate material which has the three-dimensional curved surface shape of 3 description.

The tertiary according to any one of claims 2 to 4, wherein at least one of the first and second pressing portions is adjustable in height protruding in the surface direction of the plate member. An apparatus for forming a plate material having an original curved shape.