Note: Descriptions are shown in the official language in which they were submitted.
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DESCRIPTION
Title of Invention
FORMING SYSTEM AND FORMING METHOD
Technical Field
[0001]
The present invention relates to a forming system and a
forming method.
Background Art
[0002]
In the related art, a forming system described in Patent
Document 1 is known. The forming system has a heating unit that
heats a metal material, and a forming die that forms the heated
metal material. The forming device obtains a shape
corresponding to a forming surface as the shape of the metal
material by bringing the forming surface of the forming die into
contact with the heated metal material.
Citation List
[0003]
Patent Literature
[PTL 1] Japanese Unexamined Patent Publication No.
2009-220141
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Summary of Invention
Technical Problem
[0004]
Here, in the forming system described in the
above-described Patent Document 1, there is a case where a formed
product is trimmed by cutting and removing an end portion of
a formed body portion. Here, the forming device forms the formed
product from the heated metal material. Therefore, the formed
product may be taken out from the forming die in a
high-temperature state. When the cutting unit trims the formed
product in a high-temperature state, there is a problem in that
the formed product is cooled and contracted after cutting, and
the cutting accuracy of the formed product decreases.
[0005]
The present invention has been made to solve such a problem,
and an object of the present invention is to provide a forming
system and a forming method capable of improving the cutting
accuracy of a formed product.
Solution to Problem
[0006]
A forming system according to the present invention
includes a forming device that forms a heated metal material
with a forming die; and a cutting unit that cuts and trims an
end portion of a formed body portion of a formed product. The
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cutting unit performs the trimming when a temperature of the
formed product is equal to or lower than a predetermined
temperature.
[0007]
In the forming system, the cutting unit cuts and trims the
end portion of the formed body portion of the formed product
formed by the forming device. Accordingly, the formed product
is cut to a desired length. Here, the cutting unit performs the
trimming when the temperature of the formed product is equal
to or lower than a predetermined temperature. For that reason,
the cutting unit can perform the trimming in a state where the
temperature of the formed product is lowered to reduce the
influence of the cooling contraction. From the above, the
cutting accuracy of the formed product can be improved.
[0008]
The predetermined temperature may be a temperature at
which thermal expansion of the formed product is in a range of
0.5% or less. In this case, the influence of the cooling
contraction of the formed product can be sufficiently reduced.
[0009]
The forming system may further include a cooling unit that
actively cools the formed product in a stage before the trimming
performed by the cutting unit. In this case, the cooling unit
can quickly cool the formed product to a predetermined
temperature or lower.
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[0010]
A forming system according to the present invention
includes a forming device including a fluid supply unit that
supplies a fluid to a heated metal pipe material, and a forming
die that forms a formed product by bringing an expanded metal
pipe material into contact with a forming surface; and a cutting
unit that cuts and trims an end portion of a formed body portion
of the formed product. Additionally, a forming system according
to the present invention includes a forming device that forms
a heated metal material with a forming die; and a cutting unit
that cuts and trims an end portion of a formed body portion of
a formed product.
[0011]
In these forming systems, the cutting unit can obtain the
formed product having a desired length by cutting and trimming
the end portion of the formed body portion of the formed product.
[0012]
A forming method according to the present invention
includes a forming process of forming a heated metal material
with a forming die; and a cutting process of cutting and trimming
an end portion of a formed body portion of a formed product.
In the cutting process, the trimming is performed when a
temperature of the formed product is equal to or lower than a
predetermined temperature.
[0013]
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According to the forming method, the same operation and
effects as those of the above-described forming system can be
obtained.
5 Advantageous Effects of Invention
[0014]
According to the present invention, it is possible to
provide the forming system and the forming method capable of
improving the cutting accuracy of the formed product.
Brief Description of Drawings
[0015]
Fig. 1 is a schematic configuration diagram showing a
configuration of a forming system according to a first
embodiment.
Fig. 2 is a schematic diagram of a forming device 1 used
in the forming system according to the present embodiment.
Figs. 3A and 3B are enlarged cross-sectional views showing
a state of a metal pipe material and a forming die during blow
forming. Figs. 4A to 4C are perspective views showing an aspect
of laser machining by a laser machining device.
Figs. 5A and 5B are conceptual diagrams showing an aspect
of blasting by a blasting device.
Fig. 6 is a process diagram showing a forming method
according to the first embodiment.
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Fig. 7 is a schematic configuration diagram showing a
configuration of a forming system according to a second
embodiment.
Fig. 8 is a schematic diagram of a forming device according
to a modification example.
Figs. 9A and 9B are views showing an example of a structure
around a nozzle for supplying gas.
Description of Embodiments
[0016]
Hereinafter, preferred embodiments of the present
invention will be described with reference to the drawings. In
addition, in the respective drawings, the same portions or
corresponding portions are designated by the same reference
numerals, and duplicate descriptions will be omitted.
[0017]
[First Embodiment]
Fig. 1 is a schematic configuration diagram showing the
configuration of a forming system 100 according to a first
embodiment. As shown in Fig. 1, the forming system 100 includes
a forming device 1, a cooling unit 90, a laser machining 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 the present embodiment, a STAF
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forming device, which performs the forming and hardening by
supplying a fluid to a heated metal pipe material to bring the
fluid into contact with a forming surface of the forming die,
is adopted as the forming device 1. The detailed configuration
of the forming device 1 will be described with reference to Fig.
2.
[0019]
Fig. 2 is a schematic diagram of the forming device 1 used
in the forming system 100 according to the present embodiment.
As shown in Fig. 2, the forming device 1 is a device that forms
a metal pipe (formed product) having a hollow shape by blow
forming. In the present embodiment, the forming device 1 is
installed on a horizontal plane. The forming device 1 includes
a forming 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 addition, in the present specification, the metal
pipe material 40 (metal material) refers to a hollow article
before the completion of the forming by the forming device 1.
The metal pipe material 40 is a steel type pipe material that
can be hardened. Additionally, in the horizontal direction, a
direction in which the metal pipe material 40 extends during
forming may be referred to as a "longitudinal direction", and
a direction perpendicular to the longitudinal direction may be
referred to as a "width direction".
[0020]
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The forming die 2 is a die that forms a metal pipe 140 from
the metal pipe material 40, and includes a lower die 11 and an
upper die 12 that face 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 recessed part in which the metal pipe material 40 is
accommodated. With the lower die 11 and the upper die 12 inclose
contact with each other (die closed state) each other, respective
recessed parts thereof form a space having a target shape in
which the metal pipe material is to be formed. Therefore, the
surfaces of the respective recessed parts become the forming
surfaces of the forming die 2. The lower die 11 is fixed to a
base stage 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 drive mechanism 3 is a mechanism that moves at least
one of the lower die 11 and the upper die 12. In Fig. 2, the
drive mechanism 3 has a configuration in which only the upper
die 12 is moved. The drive mechanism 3 includes a slide 21 that
moves the upper die 12 such that the lower die 11 and the upper
die 12 are joined together, and a pull-back cylinder 22 serving
as an actuator that generates a force for pulling the slide 21
upward, a main cylinder 23 serving as a drive source that
downward-pressurizes the slide 21, and a drive source 24 that
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applies a driving force to the main cylinder 23.
[0022]
The holding unit 4 is a mechanism that holds 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 that hold the metal pipe material 40 on one end
side in the longitudinal direction of the forming die 2, and
a lower electrode 26 and an upper electrode 27 that holds the
metal pipe material 40 on the other end side in the longitudinal
direction of the forming die 2. The lower electrodes 26 and the
upper electrodes 27 on both sides in the longitudinal direction
hold the metal pipe material 40 by sandwiching the vicinity of
an end portion of the metal pipe material 40 from the vertical
direction. In addition, groove portions having a shape
corresponding to an outer peripheral surface of the metal pipe
material 40 are formed on an upper surface of the lower electrode
26 and a lower surface of the upper electrode 27. The lower
electrode 26 and the upper electrode 27 are provided with drive
mechanisms (not shown) and are movable independently in the
vertical direction.
[0023]
The heating unit 5 heats the metal pipe material 40. The
heating unit 5 is a mechanism that heats the metal pipe material
40 by energizing the metal pipe material 40. The heating unit
5 heats the metal pipe material 40 in a state where the metal
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pipe material 40 is spaced apart from the lower die 11 and the
upper die 12 between the lower die 11 and the upper die 12. The
heating unit 5 includes the lower electrodes 26 and the upper
electrodes 27 on both sides in the longitudinal direction
5 described above, and a power supply 28 that allows an electric
current to flow to the metal pipe material 40 through the
electrodes 26 and 27. In addition, the heating unit may be
disposed in the previous process of the forming device 1 and
performs heating externally.
10 [0024]
The fluid supply unit 6 is a mechanism that supplies 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 the high-pressure fluid to the metal pipe material
40 that has been brought into a high-temperature state by being
heated by the heating unit 5, and expands the metal pipe material
40. The fluid supply unit 6 is provided on both end sides of
the forming die 2 in the longitudinal direction. The fluid
supply unit 6 includes a nozzle 31 that supplies fluid from an
opening of an end portion of the metal pipe material 40 to the
inside of the metal pipe material 40, and a drive mechanism 32
that moves the nozzle 31 forward and backward with respect to
the opening of the metal pipe material 40, and a supply source
33 that supplies the high-pressure fluid into the metal pipe
material 40 via the nozzle 31. In the drive mechanism 32, the
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nozzle 31 is brought into close contact with the end portion
of the metal pipe material 40 in a state where the sealing
performance is secured during fluid supply and exhaust, and at
other times, the nozzle 31 is spaced apart from the end portion
of the metal pipe material 40. In addition, the fluid supply
unit 6 may supply a gas such as high-pressure air or an inert
gas as the fluid. Additionally, the fluid supply unit 6 may be
the same device including the heating unit 5 together with the
holding unit 4 having a mechanism that moves the metal pipe
material 40 in the vertical direction.
[0025]
The cooling unit 7 is a mechanism that cools the forming
die 2. By cooling the forming die 2, the cooling unit 7 can
rapidly cool the metal pipe material 40 when the expanded metal
pipe material 40 has come into contact with a forming surface
of the forming die 2. The cooling unit 7 includes a flow path
36 formed inside the lower die 11 and the upper die 12, and a
water circulation mechanism 37 that supplies and circulates
cooling water to the flow path 36.
[0026]
The control unit 8 is a device that controls the entire
forming device 1. The control unit 8 controls the drive
mechanism 3, the holding unit 4, the heating unit 5, the fluid
supply unit 6, and the cooling unit 7. The control unit 8
repeatedly performs an operation of forming the metal pipe
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material 40 with the forming die 2.
[0027]
Specifically, the control unit 8 controls, for example,
the transport timing from a transport device such as a robot
arm to dispose the metal pipe material 40 between the lower die
11 and the upper die 12 in an open state. Alternatively, in the
control unit 8, a worker may manually dispose the metal pipe
material 40 between the lower die 11 and the upper die 12.
Additionally, the control unit 8 supports the metal pipe material
40 with the lower electrodes 26 on both sides in the longitudinal
direction, and then controls the actuator of the holding unit
4 so as to lower the upper electrode 27 to sandwich the metal
pipe material 40. Additionally, the control unit 8 controls the
heating unit 5 to energize and heat the metal pipe material 40.
Accordingly, an axial electric current flows through the metal
pipe material 40, and the electric resistance of the metal pipe
material 40 itself causes the metal pipe material 40 itself to
generate heat due to Joule heat.
[0028]
The control unit 8 controls the drive mechanism 3 to lower
the upper die 12 and bring the upper die 12 closer to the lower
die 11 to close the forming die 2. On the other hand, the control
unit 8 controls the fluid supply unit 6 to seal the openings
of both ends of the metal pipe material 40 with the nozzle 31
and supply the fluid. Accordingly, the metal pipe material 40
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softened by heating expands and comes into contact with the
forming surface of the forming die 2. Then, the metal pipe
material 40 is formed so as to follow the shape of the forming
surface of the forming die 2. In addition, in a case where a
metal pipe with a flange is formed, a part of the metal pipe
material 40 is made to enter a gap between the lower die 11 and
the upper die 12, and then the die is further closed to crush
the entering portion to form a flange portion. When the metal
pipe material 40 comes into contact with the forming surface,
hardening of the metal pipe material 40 is performed by being
quenched with the forming die 2 cooled by the cooling unit 7.
In addition, the temperature of the formed product 41 at the
end of the hardening is 200 to 250 C, which is the temperature
at an end point of martensitic transformation.
[0029]
A forming procedure of the forming device 1 will be
described with reference to Figs. 3A and 3B. As shown in Fig.
3A, the control unit 8 performs blow forming (primary blowing)
by closing the forming die 2 and supplying the fluid to the metal
pipe material 40 by the fluid supply unit 6. In the primary
blowing, the control unit 8 forms a pipe portion 43 at a main
cavity portion MC and causes a portion corresponding to a flange
portion 44 to enter a sub-cavity portion SC. Then, as shown in
Fig. 3B, the control unit 8 forms the flange portion 44 by further
closing the forming die 2 and further crushing the portion that
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has entered the sub-cavity portion SC. Next, the control unit
8 performs die opening by raising the upper die 12 to space the
upper die 21 apart from the metal pipe material 40. Accordingly,
the formed product 41 is formed.
[0030]
The formed product 41 will be described with reference to
Fig. 4A. The formed product 41 includes a formed body portion
45 having the pipe portion 43 and the flange portion 44, held
portions 46 on both end sides in the longitudinal direction,
and a gradual change portion 47 between the formed body portion
45 and the held portion 46. The formed body portion 45 is a
portion that becomes a final product by being laser-machined.
The pipe portion 43 is a hollow portion. The flange portion 44
is a plate-shaped 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 and 27. The nozzle 31 is inserted into the held portion 46.
The gradual change portion 47 is a transition portion that
changes from the shape of the held portion 46 to the shape of
the formed body portion 45.
[0031]
Returning to Fig. 1, the formed product 41 formed by the
forming device 1 is supplied to the cooling unit 90. The formed
product 41 may be sequentially supplied to the cooling unit 90
from the one formed by the forming device 1. Alternatively,
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after a certain amount of formed products 41 are accumulated
in an accumulation place, the formed products maybe collectively
supplied to the cooling unit 90. In a case where the formed
product 41 is accumulated, the temperature of the formed product
5 41 can be lowered before the laser machining due to the cooling
effect of natural heat dissipation.
[0032]
The cooling unit 90 is a device that actively cools the
formed product 41 removed from the forming die 2. The cooling
10 unit 90 actively cools the formed product 41 in a stage before
trimming by the laser machining device 70. The active cooling
means that the formed product 41 is cooled with a higher cooling
capacity than that of leaving the formed product 41 at room
temperature by performing active treatment on the formed product
15 41. As such a cooling unit 90, a mechanism that supplies a
cooling medium such as cold air, cold water, ice, and dry ice
to the formed product 41 may be adopted. For example, in a case
where there is a transport facility up to the laser machining
device 70, the cooling unit 90 may blow cold air onto the formed
product 41 on a conveyor. In addition, in a case where the
transport facility is provided, even if a mechanism for blowing
cold air or the like is not provided, the transport facility
corresponds to the cooling unit 90 that cools actively in a case
where transport speed or the like is set by adjusting cooling
time such that the formed product 41 is cooled to a desired
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temperature by natural cooling. The cooling unit 90 may blast
dry ice. Alternatively, a device such as a refrigerator that
accommodates the formed product 41 in a low-temperature
atmosphere may be adopted as the cooling unit 90. Additionally,
even in a configuration in which a fan is rotated near the formed
product 41, the active treatment is performed such that the
cooling is promoted. Thus, this configuration corresponds to
the active cooling performed by the cooling unit 90. In addition,
to what temperature the cooling unit 90 cools the formed product
41 will be described below.
[0033]
The formed product 41 cooled by the cooling unit 90 is
supplied to the laser machining device 70. The formed product
41 may be sequentially supplied to the laser machining device
70 from the one cooled by the cooling unit 90. Alternatively,
after a certain amount of formed products 41 are accumulated
in the accumulation place, the formed products may be
collectively supplied to the laser machining device 70. In a
case where the formed product 41 is accumulated, the temperature
of the formed product 41 can be further lowered before the laser
machining due to the cooling effect of natural heat dissipation.
[0034]
The laser machining device 70 is a device that machines
the formed product 41 cooled by the cooling unit 90 with a laser
beam. The laser machining device 70 irradiates the formed
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product 41 with a laser beam to perform machining such as cutting,
drilling, and cutout formation.
[0035]
Figs. 4A to 4C are perspective views showing an aspect of
the laser machining by the laser machining device 70. As shown
in Fig. 4A, the laser machining device 70 includes an
installation portion 71 and a laser head 72. The installation
portion 71 is a portion where the formed product 41 is installed
at a position facing the laser head 72. The installation portion
71 has a support portion (not shown) , and supports the formed
product 41 with the support portion. Accordingly, the formed
product 41 is installed in the installation portion 51 at a
position and in a posture suitable for the laser machining. The
laser head 72 is a portion that machines the formed product 41
by irradiating the formed product 41 with a laser beam.
[0036]
The laser head 72 removes the gradual change portion 47
and the held portion 46 from the formed body portion 45 by cutting
the vicinities of both end portions of the formed body portion
45 as shown in Fig. 4B. Additionally, the laser head 72 forms
a hole 49 at a predetermined position of the formed body portion
45.
[0037]
Here, the laser machining device 70 cuts and trims the end
portion of the formed body portion 45 of the formed product 41.
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The trimming will be described with reference to Fig. 4C. The
trimming is cutting processing of cutting an end portion 45a
of the formed body portion 45. Here, the "end portion of the
formed body portion" is a region near a boundary portion BL
between the gradual change portion 47 and the formed body portion
45. A cutting line CL obtained by a laser beam is set at a
position spaced apart from the boundary portion BL inward in
the longitudinal direction by a predetermined dimension t. In
addition, the predetermined dimension t is appropriately set
in a range of 5 mm to 20 mm.
[0038]
The laser machining device 70 performs the trimming when
the temperature of the formed product 41 is equal to or lower
than a predetermined temperature. The predetermined
temperature may be a temperature at which thermal expansion of
the formed product 41 is in a range of 0.5% or less. In addition,
in a case where a length dimension L2 of the formed product 41
during cutting is set with a length dimension L1 of the metal
pipe material 40 at room temperature before heating as a
reference, a 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 of thermal expansion
when viewed from the metal material at room temperature before
the heating. That is, the metal material thermally expands by
the heating and then cools and contracts by the cooling of the
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cooling unit 90. However, when viewed from the metal material
before the heating, the metal material after the cooling is also
in a state of thermal expansion. Therefore, the term "thermal
expansion" is used. The predetermined temperature is at least
lower than the temperature of 200 to 250 C, which is the
temperature at the end point of the aforementioned martensitic
transformation. The predetermined temperature may be, for
example, 150 C. However, the predetermined temperature may not
limited to the temperature. The predetermined temperature may
be set in a range of, for example, room temperature (about 20 C)
to 150 C. Accordingly, it is possible to prevent the formed
product 41 from being cooled during cutting to cause a cutting
error due to the influence of contraction caused by the cooling.
The cooling unit 90 adjusts the cooling capacity such that the
temperature of the formed product 41 when the cutting is
performed satisfies the above conditions. In addition, the
laser machining device 70 may perform the trimming after the
formed product 41 has reached room temperature.
[0039]
Returning to Fig. 1, the formed product 41 machined by the
laser machining device 70 is supplied to the blasting device
50. The formed product 41 may be sequentially supplied to the
blasting device 50 in order from the one machined by the laser
machining device 70. Alternatively, after a certain amount of
formed products 41 are accumulated in the accumulation place,
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the formed products may be collectively supplied to the blasting
device 50.
[0040]
The blasting device 50 is a device that removes scales from
5 the formed product 41 machined by the laser machining device
70. The scales are an oxide film formed on the surface of the
metal pipe material 40 by heating the metal pipe material 40
in the forming device 1. The blasting device 50 jets particles
onto the surface of the formed product 41. The blasting device
10 50 removes the scales from the surface of the formed product
41 by the impact caused by the collision of the particles.
[0041]
Fig. 5A is a schematic diagram showing the blasting device
50 of the present embodiment. The blasting device 50 according
15 to the present embodiment removes the scales on an outer
peripheral surface of the formed product 41. On the other hand,
the blasting device 50 does not jet particles onto the inner
peripheral surface so as not to leave the particles inside the
formed product 41. For example, as shown in Figs. 4A to 4C, the
20 formed product 41 has the flange portion 44 by crushing a part
of the metal pipe material 40. In an internal space of the formed
product 41, the particles tend to remain in such a flange portion
44. Therefore, the blasting device 50 jets the particles only
onto the outer peripheral surface of the formed product 41.
[0042]
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As shown in Fig. 5A, the blasting device 50 has the
installation portion 51, a nozzle 52, and a blockade wall 53.
The installation portion 51 is a portion where the formed product
41 is installed at a position facing the nozzle 52. The
installation portion 51 has a support portion (not shown) , and
supports the formed product 41 with the support portion.
Accordingly, the formed product 41 is installed in the
installation portion 51 at a position and in a posture suitable
for the blasting. The installation portion 51 suspends the
formed product 41 and installs the formed product in a posture
that extends in the vertical direction. The nozzle 52 is a member
that irradiates the formed product 41 with particles 55. As the
particles, for example, materials such as sand, plastic, dry
ice, and iron pieces are adopted. The nozzle 52 is disposed
around the formed product 41 installed in the installation
portion 51. The nozzle 52 is disposed such that a jetting port
faces the outer peripheral surface of the formed product 41.
Accordingly, the nozzle 52 can jet the particles 55 onto the
outer peripheral surface of the formed product 41.
[0043]
The blockade wall 53 is a wall body that shields the
particles 55. The blockade wall 53 is disposed so as to surround
the peripheries of the installation portion 51 and the nozzle
52. Accordingly, the blockade wall 53 can prevent the particles
55 from being scattered around the blasting device 50. That is,
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the blockade wall 53 can prevent the particles 55 from being
scattered to the forming device 1 and the laser machining device
70. In addition, a wall portion that partitions a space between
the blasting device 50 and the laser machining device 70 may
be provided in addition to the blockade wall 53.
[0044]
Next, a forming method according to the present embodiment
will be described with reference to Fig. 6. Fig. 6 is a process
diagram showing the forming method according to the present
embodiment. As shown in Fig. 6, the forming method includes a
forming process S10, a cooling process S20, a laser machining
process S30 (cutting process) , and a blasting process S40. In
the forming process S10, the fluid is supplied to the heated
metal pipe material 40, and the expanded metal pipe material
40 is brought into contact with the forming surface of the forming
die 2 to form the formed product 41. In the forming process S10,
the formed product 41 is formed using the forming device 1 shown
in Fig. 2. The cooling process S20 is a process of actively
cooling the formed product 41 taken out from the forming die
2. In the cooling process S20, cooling is performed using the
cooling unit 90 shown in Fig. 1. The laser machining process
S30 is a process of machining the formed product 41 removed from
the forming die 2. In the laser machining process S30, the laser
machining device 70 shown in Figs. 4A to 4C performs machining
of the formed product 41. The blasting process S40 is a process
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of removing scales from the formed product 41 machined in the
laser machining process S30. In the blasting process S40, the
blasting device 50 shown in Fig. 5A performs blasting processing
to remove the scales from the formed product 41.
[0045]
Next, the operation and effects of the forming system 100
and the forming method according to the present embodiment will
be described.
[0046]
In the STAF forming, in order to shorten the forming time,
that is, the cycle time, it is desired to lower the temperature
to a temperature at which the shape can be frozen in the forming
die 2, take out the formed product 41 in the earliest possible
state (high-temperature state), and pass the formed product 41
to the next process. For example, after the STAF forming, in
a case where the temperature of the formed product 41 itself
is 200 C or higher when holes are drilled by laser machining
or non-product portions at both end portions are cut off, the
formed product 41 itself is cooled during the cutting. The
temperature error of the formed product 41 itself due to this
cooling may cause a cutting error of drilling position and
product length due to a change in length.
[0047]
In contrast, the forming system 100 according to the
present embodiment includes the forming device 1 that forms the
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heated metal pipe material 40 with the forming die 2 and the
laser machining device 70 that cuts and trims the end portion
45a of the formed body portion 45 of the formed product 41, and
the laser machining device 70 performs the trimming when the
temperature of the formed product 41 is equal to or lower than
a predetermined temperature.
[0048]
In the forming system 100, the laser machining device 70
cuts and trims the end portion 45a of the formed body portion
45 of the formed product 41 formed by the forming device 1.
Accordingly, the formed product 41 is cut to a desired length.
Here, the laser machining device 70 performs the trimming when
the temperature of the formed product 41 is equal to or lower
than a predetermined temperature. For that reason, the laser
machining device 70 can perform the trimming in a state where
the temperature of the formed product 41 is lowered to reduce
the influence of the cooling contraction. From the above, the
cutting accuracy of the formed product 41 can be improved.
[0049]
The predetermined temperature maybe 150 C. In this case,
the influence of the cooling contraction of the formed product
41 can be sufficiently reduced.
[0050]
The forming system 100 may further include the cooling unit
90 that actively cools the formed product 41 in the stage before
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the trimming performed by the laser machining device 70. In this
case, the cooling unit 90 can quickly cool the formed product
41 to a predetermined temperature or lower.
[0051]
5 The
forming system 100 according to the present embodiment
includes the forming device 1 including the fluid supply unit
6 that supplies the fluid to the heated metal pipe material 40
and the forming die 2 that forms the formed product 41 by bringing
the expanded metal pipe material 40 into contact with the forming
10 surface, and the laser machining device 70 that cuts and trims
the end portion 45a of the formed body portion 45 of the formed
product 41. Additionally, the forming system 100 according to
the present embodiment includes the forming device 1 that forms
the heated metal pipe material 40 with the forming die 2, and
15 the laser
machining device 70 that cuts and trims the end portion
45a of the formed body portion 45 of the formed product 41.
[0052]
In these forming systems 100, the laser machining device
70 can obtain the formed product 41 having a desired length by
20 cutting and trimming the end portion 45a of the formed body
portion 45 of the formed product 41.
[0053]
The forming method according to the present embodiment
includes the forming process S10 of forming the heated metal
25 pipe material 40 with the forming die 2 and the cutting process
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26
S20 of cutting and trimming the end portion 45a of the formed
body portion 45 of the formed product 41. In the cutting process
S20, the trimming is performed when the temperature of the formed
product 41 is equal to or lower than a predetermined temperature.
[0054]
According to the forming method, the same operation and
effects as those of the above-described forming system 100 can
be obtained.
[0055]
[Second Embodiment]
Next, a forming system 200 according to a second embodiment
will be described with reference to Fig. 7. As shown in Fig.
7, the forming system 200 includes a first blasting device 50
disposed in a stage before the laser machining device 70 and
a second blasting device 80 that removes scales from the formed
product 41 machined by the laser machining device 70. In
addition, here, the first blasting device 50 corresponding to
the "cooling unit" in the claims may jet the dry ice as the
particles 55. Even if the first blasting device 50 jets the
particles 55 other than the dry ice, a cooling effect can be
obtained due to the influence of blowing air, but a high cooling
effect can be obtained by jetting the dry ice.
[0056]
As shown in Fig. 5B, the second blasting device 80 jets
the particles 55 from a blast hose 56 onto the inner peripheral
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27
surface of the formed product 41. The blast hose 56 is inserted
inside the formed product 41 and ejects the particles toward
an inner peripheral surface inside the formed product 41. In
this case, the blast hose 56 may jet the dry ice as the particles
55. Although the dry ice collides against the inner peripheral
surface of the formed product 41 as a solid matter to remove
the scales, the dry ice turns into gas and disappears with the
elapse of time. Therefore, it is possible to prevent the
particles 55 from remaining on the flange portion 44.
[0057]
In addition, the first blasting device 50 and the second
blasting device 80 may be constituted by a common device. For
example, the blast hose 56 of Fig. 5B may be added to the blasting
device 50 of Fig. 5A. In such a blasting device, in a first
blasting process, the nozzle 52 performs blasting on the outer
peripheral surface of the formed product 41, and in a second
blasting process, the blast hose 56 performs blasting the inner
peripheral surface of the formed product 41. From the above,
the number of devices of the forming system 200 can be reduced.
[0058]
The present invention is not limited to the
above-described embodiment.
[0059]
In the above-described embodiment, the blasting device has
been exemplified as a scale removing unit. However, any device
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28
may be adopted as the scale removing unit as long as the device
can remove the scales. For example, a method of jetting the fluid
onto the formed product or removing the scales by ultrasonic
cleaning may be adopted. Such a scale removing unit also has
a cooling effect.
[0060]
The cutting unit is not limited to the laser machining
device, and a device using another cutting method may be adopted.
[0061]
For example, the forming device that performs the STAF
forming has been exemplified, but the forming device is not
particularly limited as long as a forming method using a heated
metal material is provided. For example, a forming method using
hot stamping may be adopted. Therefore, the metal material is
not necessarily the metal pipe material and may be a plate
material or a pillar material.
[0062]
The forming device 1 is not limited to the configuration
shown in Fig. 2, and for example, a configuration shown in Fig.
8 may be adopted as the forming device 1. In the forming device
1 shown in Fig. 8, a heating and expanding unit 150 as shown
in Figs. 9A and 9B may be adopted. Fig. 9A is a schematic side
view showing the heating and expanding unit 150 in which the
components of the holding unit 4, the heating unit 5, and the
fluid supply unit 6 are unitized. Fig. 9B is a cross-sectional
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29
view showing an aspect when the nozzle 31 has sealed the metal
pipe material 40.
[0063]
As shown in Fig. 9A, the heating and expanding unit 150
includes the above-described lower electrode 26 and upper
electrode 27, an electrode mounting unit 151 on which the
electrodes 26 and 27 are mounted, the above-described nozzle
31 and drive mechanism 32, an elevating unit 152, and a unit
base 153. The electrode mounting unit 151 includes an elevating
frame 154 and electrode frames 156 and 157. The electrode frames
156 and 157 function as a part of a drive mechanism 60 that
supports and moves the electrodes 26 and 27, respectively. The
drive mechanism 32 drives the nozzle 31 and lifts and lowers
together with the electrode mounting unit 151. The drive
mechanism 32 includes a piston 61 that holds the nozzle 31, and
a cylinder 62 that drives the piston. The elevating unit 152
includes elevating frame bases 64 attached to an upper surface
of the unit base 153, and an elevating actuator 66 that applies
an elevating operation to the elevating frame 154 of the
electrode mounting unit 151 by the elevating frame bases 64.
Each elevating frame base 64 has guide portions 64a and 64b that
guide the elevating operation of the elevating frame 154 with
respect to the unit base 153. The elevating unit 152 functions
as a part of the drive mechanism 60 of the holding unit 4. The
heating and expanding unit 150 has a plurality of unit bases
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153 having different inclination angles of the upper surface,
and is allowed to collectively change and adjust the inclination
angles of the lower electrode 26 and the upper electrode 27,
the nozzle 31, the electrode mounting unit 151, the drive
5 mechanism 32, and the elevating unit 152 by replacing the unit
bases 153.
[0064]
The nozzle 31 is a cylindrical member into which the end
portion of the metal pipe material 40 is insertable. The nozzle
10 31 is supported by the drive mechanism 32 such that a center
line of the nozzle 31 coincides with a reference line SL1. The
inner diameter of a feed port 31a of an end portion of the nozzle
31 on the metal pipe material 40 side substantially coincides
with the outer diameter of the metal pipe material 40 after
15 expansion forming. In this state, the nozzle 31 supplies the
high-pressure fluid from an internal flow path 63 to the metal
pipe material 40. In addition, an example of the high-pressure
fluid is gas or the like.
20 Reference Signs List
[0065]
1 forming device
2 forming die
metal pipe material
25 41 formed product
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31
70 laser machining device (cutting unit)
90 cooling unit
100 forming system.
Date Recue/Date Received 2022-05-03
