Formed material manufacturing method and formed material

Patent metadata

Field	Value
Publication number	US-11117178-B2
Application number	US-201515317244-A
Country	US
Kind code	B2
Filing date	Feb 6, 2015
Priority date	Jun 13, 2014
Publication date	Sep 14, 2021
Grant date	Sep 14, 2021

Abstract

The invention provides a formed material manufacturing method by which unnecessary thickening of a flange can be avoided. The formed material manufacturing method allows a formed material to be manufactured by forming processes that include at least one drawing-out process, at least one drawing process performed after the drawing-out process, and at least one coining process performed after the drawing process. The width of the rear end side of a punch used in the drawing-out process is set to be wider than the width of the tip end side thereof. An ironing process is performed on a region corresponding to the flange of the base metal sheet by pushing the base metal sheet together with the punch into a pushing hole.

First claim

The invention claimed is:

1. A method of manufacturing a formed material having a tubular body and a flange, which is formed at an end of the body, the method comprising performing at least three forming processes on a base metal sheet,
wherein the at least three forming processes include at least one drawing-out process, at least one drawing process, and at least one coining process, wherein each of the drawing processes are performed after all of the drawing-out processes are completed, and each of the coining processes are performed after all of the at least one drawing processes are completed,
wherein each of the at least one drawing-out process comprises using a mold that includes a punch and a die having a pushing hole and placing the base metal sheet that is substantially flat between the punch and the die,
wherein a width of a rear end side of the punch is set to be wider than a width of a tip end side thereof so that a clearance between the die and the punch, when the punch is pushed into the pushing hole in the die, is narrower on the rear end side than on the tip end side,
wherein each of the at least one drawing-out process comprises performing an ironing process on a region of the base metal sheet corresponding to the flange of the formed material by pushing the base metal sheet together with the punch into the pushing hole,
wherein the tubular body is formed during a first drawing-out process of the at least one drawing-out processes,
wherein the flange is formed during a first drawing process of the at least one drawing processes, and
wherein one or more of the at least one coining process comprises inserting and compressing the flange formed in the at least one drawing process between a pushing mold and a receiving mold so that the flange receives a pushing pressure when the pushing mold is pushed toward the receiving mold, whereby a flange region is compressed and reduced in thickness, and
wherein one or more of the at least one coining processes forms a flat portion extending over an entire circumference of the flange on both a top surface and bottom surface of the flange.

2. The method of manufacturing a formed material according to claim 1 , wherein an ironing ratio of the ironing process is 50% or less.

3. The method of manufacturing a formed material according to claim 1 , wherein each of the at least one coining process is performed on a part of the base metal sheet where the ironing process has been performed in each of the at least one drawing-out process.

4. The method of manufacturing a formed material according to claim 1 , wherein a thickness of the flange of the formed material is less than a thickness of the base metal sheet.

Assignees

• Nisshin Steel Co Ltd

Inventors

• Nakamura Naofumi
• Yamamoto Yudai
• Nishio Katsuhide

Classifications

• B21D22/28 Primary

  of cylindrical articles using consecutive dies · CPC title

• B21D35/006

  Blanks having varying thickness, e.g. tailored blanks · CPC title

• B21D22/30

  to finish articles formed by deep-drawing · CPC title

• B21D22/21

  without fixing the border of the blank · CPC title