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WO2020201793A1 - Method for manufacturing molded body having three-dimensional shape - Google Patents

Method for manufacturing molded body having three-dimensional shape Download PDF

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Publication number
WO2020201793A1
WO2020201793A1 PCT/IB2019/000371 IB2019000371W WO2020201793A1 WO 2020201793 A1 WO2020201793 A1 WO 2020201793A1 IB 2019000371 W IB2019000371 W IB 2019000371W WO 2020201793 A1 WO2020201793 A1 WO 2020201793A1
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WO
WIPO (PCT)
Prior art keywords
metal
resin
molded portion
plate material
dimensional shape
Prior art date
Application number
PCT/IB2019/000371
Other languages
French (fr)
Japanese (ja)
Inventor
内山典子
宮本健二
三輪紘敬
中川成幸
村上亮
Original Assignee
日産自動車株式会社
ルノー エス． ア． エス．
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 日産自動車株式会社, ルノー エス． ア． エス． filed Critical 日産自動車株式会社
Priority to PCT/IB2019/000371 priority Critical patent/WO2020201793A1/en
Publication of WO2020201793A1 publication Critical patent/WO2020201793A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/14—Spinning
    • B21D22/18—Spinning using tools guided to produce the required profile

Definitions

  • the present invention relates to a method for manufacturing a three-dimensional molded product. More specifically, the present invention relates to a method for manufacturing a three-dimensional molded product, and panel parts obtained thereby.
  • This thin plate molding method is characterized in that the steps including the following steps (1) to (4) are repeated one or more times (see Patent Document 1).
  • Step (1) With the edge of the blank material sandwiched, a mold punch having a molding shape is pushed to a predetermined height from the plate thickness direction to perform drawing molding.
  • Step (2) After the step (1), the shape is formed by a tool from the opposite side with the die punch and the plate thickness sandwiched in a state where the wrinkle pressing force is increased while the die punch is pushed in and the flow of the material is locked. ..
  • Step (3) After the step (2), the wrinkle pressing force is reduced, and the mold punch is raised again by the required height to perform drawing molding.
  • Step (4) After the step (3), the shape is formed by the tool in a state where the wrinkle pressing force is increased and the flow of the material is locked.
  • the present inventors do not use a molding die, and sequentially mold a three-dimensional shape into a molded portion of a metal-containing plate material having a molded portion and a non-molded portion located around the molded portion.
  • the molded portion before trimming the non-molded portion from the molded portion, the molded portion has a non-molded portion around the molded portion, so that the occurrence of twisting of the molded portion is suppressed.
  • this manufacturing method there is a problem to be solved that after trimming the non-molded portion from the molded portion, the occurrence of twisting of the molded portion cannot be suppressed and the molded portion is greatly deformed.
  • An object of the present invention is to provide a method for manufacturing a three-dimensional shape molded product, which can obtain a three-dimensional shape molded product having excellent dimensional accuracy even after the non-molded portion is trimmed from the molded portion.
  • the present inventors have made extensive studies to achieve the above object. As a result, they have found that the above object can be achieved by forming the resin-containing coating film at a predetermined position on the metal-containing plate material at a predetermined stage, and have completed the present invention.
  • the present invention even after the non-molded portion is trimmed from the molded portion, the occurrence of twisting of the molded portion can be suppressed and the molded portion is not significantly deformed. Therefore, three-dimensional shape molding having excellent dimensional accuracy It is possible to provide a method for producing a three-dimensional shape molded article capable of obtaining a body.
  • FIG. 1 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the first embodiment.
  • FIG. 2 is a plan view showing the distribution of the deformed region in an example of the three-dimensional shape molded body.
  • FIG. 3 is a graph showing the relationship between the presence or absence of the resin-containing coating and the dimensional difference between the design value of the three-dimensional shape molded product.
  • FIG. 4 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the second embodiment.
  • the method for manufacturing the three-dimensional molded body of this embodiment includes a sequential molding step, a trimming step, and a film forming step.
  • the non-molded portion of the metal-containing plate material having the molded portion and the non-molded portion located around the molded portion is held by a jig and arranged on one surface side of the metal-containing plate material.
  • This is a step of sequentially forming a three-dimensional shape on a molded portion by relatively moving the metal-containing plate material and the tool in a state where the metal-containing plate material is pressed against the metal-containing plate material.
  • a conventionally known NC machine tool can be used.
  • a rod-shaped tool having a machined surface at the tip may be attached to the tool head of the NC machine tool.
  • the trimming step is executed after the sequential molding step and is a step of trimming the non-molded portion.
  • conventionally known trimming can be appropriately used.
  • the film forming step is a step executed before at least one of the sequential forming step and the trimming step to form a resin-containing film on the surface side opposite to at least one surface of the metal-containing plate material.
  • the resin-containing coating may be formed on the surface of the metal-containing plate material opposite to the surface on which the tool is pressed, but is formed on both the surface of the metal-containing plate material on which the tool is pressed and the surface on the opposite side. You may.
  • the resin-containing coating can suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be suppressed.
  • the molded portion is not significantly deformed, a three-dimensional shape molded body having excellent dimensional accuracy can be obtained.
  • the film forming step is executed before the sequential molding step.
  • the resin-containing coating can suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be suppressed.
  • the molded portion is not significantly deformed, a three-dimensional shape molded body having excellent dimensional accuracy can be obtained.
  • the stress generated in the resin-containing coating material may be larger than the stress generated in the metal-containing plate material. Suitable.
  • stress in this specification means the thing which added the cross-sectional area.
  • the resin-containing coating can further suppress the release of strain in the metal-containing plate material, and the occurrence of twisting in the molded portion can be further suppressed.
  • the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
  • the film forming step is executed after the sequential molding step and before the trimming step. In the method for producing a three-dimensional molded product of the present embodiment, it is also preferable that the film forming step is executed at each stage before the sequential molding step and before the trimming step.
  • the resin-containing coating can suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be suppressed.
  • the molded portion is not significantly deformed, a three-dimensional shape molded body having excellent dimensional accuracy can be obtained.
  • steel, aluminum alloy, magnesium alloy and titanium alloy can be mentioned as preferable examples of the metal-containing plate material.
  • one of these may be used alone, or two or more thereof may be used in any combination.
  • a metal-based composite plate material containing one of steel, an aluminum alloy, a magnesium alloy and a titanium alloy as a main component can be mentioned.
  • the "main component" means the component having the largest mass ratio in the composite plate material.
  • the resin-containing coating can further suppress the release of strain in the metal plate material, and the occurrence of twisting of the molded portion can be further suppressed.
  • the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
  • the thickness of the metal-containing plate material is not particularly limited, but for example, it is preferably the thickness of the metal-containing plate material applied to conventionally known vehicle body components.
  • the metal-containing plate material is a steel plate material
  • the thickness thereof is preferably 0.5 to 2 mm, more preferably 0.5 to 1.5 mm, and 0.5 to 1.2 mm. It is more preferable to have.
  • the metal-containing plate material is an aluminum alloy plate material, it is preferably 5 mm or less, and more preferably 3 mm or less.
  • the resin-containing coating include epoxy resin, melamine resin, acrylic resin, urethane resin, polyester resin and fluororesin.
  • epoxy resin melamine resin
  • acrylic resin urethane resin
  • polyester resin fluororesin
  • one of these may be used alone, or two or more thereof may be used in any combination.
  • thermosetting resin film and an ultraviolet curable resin film can be mentioned as preferable examples of the resin-containing film.
  • an ultraviolet curable resin is preferable to a thermosetting resin film.
  • the resin-containing coating film contains components such as a coloring pigment and a metal powder pigment like a conventionally known coating film. For example, when the three-dimensional shape molded body is applied to a vehicle, if the resin-containing coating has a monochromatic or multicolor decorative function, there is an advantage that the painting step can be omitted.
  • thermosetting resin contained in the thermosetting resin film examples include acrylic resin (baking temperature: 170 ° C., baking time: 20 minutes, hardness: 3H (“hardness” is measured in accordance with JIS K5600-5-4). (The same applies hereinafter))), Fluorine resin (baking temperature: 170 ° C, baking time: 20 minutes, hardness: 4H to 5H), epoxy resin (baking temperature: 100 ° C, baking time: 20 minutes, Hardness: H), melamine resin (baking temperature: 150 ° C, baking time: 20 minutes, hardness: H), urethane resin (baking temperature: 150 ° C, baking time: 20 minutes, hardness: H) and alkyd resin (baking temperature) : 100 ° C., baking time: 20 minutes, hardness: H).
  • acrylic resin baking temperature: 170 ° C., baking time: 20 minutes, hardness: 3H (“hardness” is measured in accordance with JIS K5600-5-4). (The same applies hereinafter)
  • thermosetting resin coating is not limited to these, and can be formed of an unsaturated polyester resin, which is an example of a polyester resin, and is formed of a phenol resin, a urea resin, a diallyl phthalate resin, and a silicone resin. It is also possible to do.
  • the thermosetting resin described above one type may be used alone, or two or more types may be used in any combination. Further, among the above-mentioned thermosetting resins, it is particularly preferable to apply an acrylic resin, a fluororesin, or an epoxy resin.
  • Examples of the ultraviolet curable resin contained in the ultraviolet curable resin film include an epoxy resin (prepolymer: epoxy acrylate, ultraviolet irradiation output: 500 mW / cm 2 , ultraviolet irradiation time: 30 seconds, hardness: greater than 5H), urethane resin.
  • an epoxy resin prepolymer: epoxy acrylate, ultraviolet irradiation output: 500 mW / cm 2 , ultraviolet irradiation time: 30 seconds, hardness: greater than 5H
  • urethane resin urethane resin.
  • Polyester resin Prepolymer: Polyester acrylate, UV irradiation output: 200 mW / cm 2 , UV irradiation time: 75 seconds, hardness: 2H
  • acrylic resin prepolymer: acrylic acrylate, UV irradiation output: 100mW / cm 2 , UV irradiation time: 150 seconds, hardness: H
  • polyether tree prepolymer: polyether acrylate, Ultraviolet irradiation output: 50 mW / cm 2 , ultraviolet irradiation time: 300 seconds, hardness: B
  • one of these may be used alone, or two or more thereof may be used in any combination.
  • the coating can further suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be further suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
  • the thickness of the resin-containing film is preferably 1 to 100 ⁇ m.
  • the thickness of the resin-containing film is less than 1 ⁇ m, the stress generated in the resin-containing film tends to be smaller than the stress generated in the metal-containing plate material when the same deformation is applied to the metal-containing plate material and the resin-containing film.
  • the thickness of the resin-containing film is larger than 100 ⁇ m, the elongation performance of the resin-containing film is lowered, in other words, the rigidity is increased, and the resin-containing film is easily broken.
  • the stress generated in the resin-containing coating material tends to be smaller than the stress generated in the metal-containing plate material.
  • the film forming step when executed after the sequential forming step and before the trimming step, the higher the rigidity of the resin-containing coating, the more suitable it is.
  • the resin-containing coating is not particularly limited as long as a three-dimensional shape molded product having excellent dimensional accuracy can be obtained, but the resin-containing coating is formed only on a part of the surface of the metal-containing plate material opposite to the surface on which the tool is pressed. It may be formed on the entire surface.
  • the resin-containing coating is preferably formed on, for example, 50 area% or more of the surface of the metal-containing plate material opposite to the surface on which the tool is pressed, and more preferably 90 area% or more. The coverage of the resin-containing coating on the metal-containing plate material can be appropriately changed depending on the three-dimensional shape that is sequentially molded on the molded portion.
  • the elongation of the resin-containing film is preferably 120% or more, and more preferably 200% or more.
  • the resin is easily broken.
  • the stress generated in the resin-containing coating material tends to be smaller than the stress generated in the metal-containing plate material.
  • the hardness of the resin-containing film is preferably 3H or less. When the hardness of the resin-containing film is larger than 3H, the elongation performance of the resin-containing film is lowered, and the resin-containing film is easily broken.
  • a coating method, a printing method, and a coating method can be mentioned as preferable examples of the method for forming the resin-containing film.
  • one of these may be used alone, or two or more thereof may be used in any combination.
  • Examples of the above coating method include air gun coating, airless gun coating, fluidized immersion, electrostatic coating and dipping.
  • Examples of the above printing method include inkjet printing, gravure printing, silk printing, silk screen printing, water surface transfer printing, pad printing and tampo printing.
  • Examples of the coating method include thermal spraying and ion plating (chemical vapor deposition method, physical vapor deposition method).
  • the resin-containing film can be appropriately formed. Therefore, after the non-molded portion is trimmed, the resin-containing coating can appropriately suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be appropriately suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
  • the panel component of this embodiment is a three-dimensional shape molded body obtained by the above-mentioned manufacturing method of the three-dimensional shape molded body. Since this panel part is obtained by the above-mentioned manufacturing method of the three-dimensional shape molded body, the dimensional accuracy is excellent.
  • This panel part is preferably used as a vehicle body component.
  • vehicle body component examples include various outer panel parts and inner panel parts.
  • the present invention is not limited to these, and this panel component can also be applied to a door mirror housing for a vehicle and a refueling palate.
  • FIG. 1 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the first embodiment.
  • a metal-containing plate material 10 having a molded portion 11 and a non-molded portion 12 located around the molded portion 11 is prepared. Specifically, a steel plate having a thickness of 1.2 mm is prepared as a metal-containing plate material.
  • the resin-containing coating 20 is formed on one surface side of the metal-containing plate material 10 on the entire surface.
  • an acrylic resin film having a thickness of 10 ⁇ m, which is an ultraviolet curable resin film, is formed by inkjet printing.
  • the non-molded portion 12 of the metal-containing plate material 10 is held by the jig 50. Specifically, the outer periphery of the plane of the metal-containing plate material is restrained by a jig.
  • the tool 60 is held on the non-molded portion 12 of the metal-containing plate material 10 by the jig 50 and arranged on the side opposite to the surface on which the resin-containing coating 20 of the metal-containing plate material 10 is formed. While being pressed against the metal-containing plate material 10, the metal-containing plate material 10 and the tool 60 are relatively moved to sequentially form a three-dimensional shape on the molding portion 11.
  • the jig 50 is removed from the metal-containing plate material 10 and the resin-containing coating 20 in which the three-dimensional shape is sequentially formed.
  • the non-molded portion 12 is trimmed from the metal-containing plate material 10 in which the three-dimensional shape is sequentially molded to obtain the three-dimensional shape molded body 1.
  • a part 22 of the resin-containing coating 20 is also trimmed.
  • FIG. 2 is a plan view showing the distribution of the deformed region in an example of the three-dimensional shape molded body.
  • FIG. 3 is a graph showing the relationship between the presence / absence of the resin-containing coating and the dimensional difference between the design value of the three-dimensional shape molded product.
  • the same reference numerals are given to those equivalent to those described above, and the description thereof will be omitted.
  • the deformation region Z in FIG. 2 indicates a region in which the dimensional difference from the design value is larger than ⁇ 5.0 mm.
  • FIG. 4 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the second embodiment.
  • a metal-containing plate material 10 having a molded portion 11 and a non-molded portion 12 located around the molded portion 11 is prepared. Specifically, a steel plate having a thickness of 1.2 mm is prepared as a metal-containing plate material.
  • the non-molded portion 12 of the metal-containing plate material 10 is held by the jig 50. Specifically, the outer periphery of the plane of the metal-containing plate material is restrained by a jig.
  • the non-molded portion 12 of the metal-containing plate material 10 is held by the jig 50, and the tool 60 arranged on one surface of the metal-containing plate material 10 is pressed against the metal-containing plate material 10. , The metal-containing plate material 10 and the tool 60 are relatively moved to sequentially form a three-dimensional shape on the forming portion 11.
  • the resin-containing coating 20 is formed on the side opposite to the surface on which the tool of the metal-containing plate material 10 is pressed and moved.
  • the resin-containing film an acrylic resin film having a thickness of 10 ⁇ m, which is a thermosetting resin film, is formed by air gun coating.
  • the jig 50 is removed from the metal-containing plate material 10 and the resin-containing coating 20 in which the three-dimensional shape is sequentially formed.
  • the non-molded portion 12 is trimmed from the metal-containing plate material 10 in which the three-dimensional shape is sequentially molded to obtain the three-dimensional shape molded body 1.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

This method for manufacturing a molded body having a three-dimensional shape includes: a sequential molding step in which, with respect to a metal-containing sheet material having a molding part and a non-molding part around the molding part, the non-molding part of the metal-containing sheet material is held by a jig, and the metal-containing sheet material and a tool arranged on one side of the metal-containing sheet material are moved relative to one another while the tool is pressed against the metal-containing sheet material to sequentially mold the molding part into a three-dimensional shape; a trimming step, carried out after the sequential molding step, in which the non-molding part is trimmed; and a coating film formation step, carried out prior to the sequential molding step and/or the trimming step, in which a resin-containing coating film is formed on at least the side of the metal-containing sheet material on the opposite side from the one side.

Description

３次元形状成形体の製造方法Manufacturing method of 3D shape molded product
　本発明は、３次元形状成形体の製造方法に関する。さらに詳細には、本発明は、３次元形状成形体の製造方法、及びこれによって得られるパネル部品に関する。 The present invention relates to a method for manufacturing a three-dimensional molded product. More specifically, the present invention relates to a method for manufacturing a three-dimensional molded product, and panel parts obtained thereby.
　従来、量産用プレス成形用試作品の立体形状製品を、形状の制限なしに、材料余りによるボディーしわの発生なく、高精度にしかも短時間で成形することができる薄板の成形方法が提案されている。 Conventionally, a thin plate molding method has been proposed in which a three-dimensional shape product of a mass-produced press-molded prototype can be molded with high accuracy and in a short time without any shape limitation and without body wrinkles due to excess material. There is.
　この薄板の成形方法は、次の工程（１）~工程（４）を含むステップを１回以上繰り返すことを特徴とする（特許文献１参照。）。 This thin plate molding method is characterized in that the steps including the following steps (1) to (4) are repeated one or more times (see Patent Document 1).
工程（１）：ブランク材の縁部を挟持した状態で板厚方向から成形形状を有する型パンチを所定高さまで押し込んで絞り成形を行う。 Step (1): With the edge of the blank material sandwiched, a mold punch having a molding shape is pushed to a predetermined height from the plate thickness direction to perform drawing molding.
工程（２）：工程（１）の後、型パンチの押込み状態のまましわ押さえ力を増して材料の流動をロックした状態で型パンチと板厚を挟んで反対側から工具により形状成形を行う。 Step (2): After the step (1), the shape is formed by a tool from the opposite side with the die punch and the plate thickness sandwiched in a state where the wrinkle pressing force is increased while the die punch is pushed in and the flow of the material is locked. ..
工程（３）：工程（２）の後、しわ押さえ力を低下させ、型パンチを再び所要高さだけ上昇させて絞り成形を行う。 Step (3): After the step (2), the wrinkle pressing force is reduced, and the mold punch is raised again by the required height to perform drawing molding.
工程（４）：工程（３）の後、しわ押さえ力を高くし材料の流動をロックした状態で前記工具により形状成形を行う。 Step (4): After the step (3), the shape is formed by the tool in a state where the wrinkle pressing force is increased and the flow of the material is locked.
日本国特許第４７８７５４８号公報Japanese Patent No. 4787548
　これに対して、本発明者らは、成形型を用いず、成形部と成形部の周囲に位置する非成形部とを有する金属含有板材の成形部に３次元形状を逐次成形する３次元形状成形体の製造方法について鋭意研究をした。
　この製造方法においては、成形部から非成形部をトリミングする前において、成形部が周囲に非成形部を有ることによって、成形部のねじれの発生が抑制されている。
　しかしながら、この製造方法においては、成形部から非成形部をトリミングした後において、成形部のねじれの発生を抑制できず、成形部に大きな変形が生じてしまうという解決すべき課題があった。 On the other hand, the present inventors do not use a molding die, and sequentially mold a three-dimensional shape into a molded portion of a metal-containing plate material having a molded portion and a non-molded portion located around the molded portion. We have been diligently researching the manufacturing method of molded products.
In this manufacturing method, before trimming the non-molded portion from the molded portion, the molded portion has a non-molded portion around the molded portion, so that the occurrence of twisting of the molded portion is suppressed.
However, in this manufacturing method, there is a problem to be solved that after trimming the non-molded portion from the molded portion, the occurrence of twisting of the molded portion cannot be suppressed and the molded portion is greatly deformed.
　本発明は、このような従来技術の有する課題に鑑みてなされたものである。そして、本発明は、成形部から非成形部をトリミングした後においても、寸法精度に優れた３次元形状成形体が得られる３次元形状成形体の製造方法を提供することを目的とする。 The present invention has been made in view of the problems of the prior art. An object of the present invention is to provide a method for manufacturing a three-dimensional shape molded product, which can obtain a three-dimensional shape molded product having excellent dimensional accuracy even after the non-molded portion is trimmed from the molded portion.
　本発明者らは、上記目的を達成するため鋭意検討を重ねた。その結果、樹脂含有被膜を所定の段階で金属含有板材の所定の位置に形成することにより、上記目的が達成できることを見出し、本発明を完成するに至った。 The present inventors have made extensive studies to achieve the above object. As a result, they have found that the above object can be achieved by forming the resin-containing coating film at a predetermined position on the metal-containing plate material at a predetermined stage, and have completed the present invention.
　本発明によれば、成形部から非成形部をトリミングした後においても、成形部のねじれの発生が抑制でき、成形部に大きな変形が生じることがないので、寸法精度に優れた３次元形状成形体を得ることが可能な３次元形状成形体の製造方法を提供することができる。 According to the present invention, even after the non-molded portion is trimmed from the molded portion, the occurrence of twisting of the molded portion can be suppressed and the molded portion is not significantly deformed. Therefore, three-dimensional shape molding having excellent dimensional accuracy It is possible to provide a method for producing a three-dimensional shape molded article capable of obtaining a body.
図１は、第１の形態に係る３次元形状成形体の製造方法の説明図である。FIG. 1 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the first embodiment. 図２は、３次元形状成形体の一例における変形領域の分布を示す平面図である。FIG. 2 is a plan view showing the distribution of the deformed region in an example of the three-dimensional shape molded body. 図３は、樹脂含有被膜の有無と３次元形状成形体の設計値との寸法差との関係を示すグラフである。FIG. 3 is a graph showing the relationship between the presence or absence of the resin-containing coating and the dimensional difference between the design value of the three-dimensional shape molded product. 図４は、第２の形態に係る３次元形状成形体の製造方法の説明図である。FIG. 4 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the second embodiment.
　以下、本発明の一形態に係る３次元形状成形体の製造方法及びこれによって得られるパネル部品について詳細に説明する。 Hereinafter, a method for manufacturing a three-dimensional molded product according to one embodiment of the present invention and panel parts obtained by the method will be described in detail.
　本形態の３次元形状成形体の製造方法は、逐次成形工程と、トリミング工程と、被膜形成工程とを含む。 The method for manufacturing the three-dimensional molded body of this embodiment includes a sequential molding step, a trimming step, and a film forming step.
　ここで、逐次成形工程は、成形部と成形部の周囲に位置する非成形部とを有する金属含有板材の非成形部を治具によって保持し、かつ、金属含有板材の一方の面側に配置した工具を金属含有板材に押し付けた状態で、金属含有板材と工具を相対的に移動させ、成形部に３次元形状を逐次成形する工程である。なお、この逐次成形工程では、例えば、従来公知のＮＣ工作機械を用いることが可能である。このとき、ＮＣ工作機械の工具ヘッドに、先端に加工面を有する棒状工具を装着すればよい。 Here, in the sequential molding step, the non-molded portion of the metal-containing plate material having the molded portion and the non-molded portion located around the molded portion is held by a jig and arranged on one surface side of the metal-containing plate material. This is a step of sequentially forming a three-dimensional shape on a molded portion by relatively moving the metal-containing plate material and the tool in a state where the metal-containing plate material is pressed against the metal-containing plate material. In this sequential molding step, for example, a conventionally known NC machine tool can be used. At this time, a rod-shaped tool having a machined surface at the tip may be attached to the tool head of the NC machine tool.
　トリミング工程は、逐次成形工程の後に実行され、非成形部をトリミングする工程である。なお、トリミング工程では、従来公知のトリミングを適宜利用することができる。 The trimming step is executed after the sequential molding step and is a step of trimming the non-molded portion. In the trimming step, conventionally known trimming can be appropriately used.
　被膜形成工程は、逐次成形工程及びトリミング工程の少なくとも一方の前に実行され、金属含有板材の少なくとも一方の面と反対の面側に樹脂含有被膜を形成する工程である。 The film forming step is a step executed before at least one of the sequential forming step and the trimming step to form a resin-containing film on the surface side opposite to at least one surface of the metal-containing plate material.
　なお、樹脂含有被膜は、金属含有板材において工具が押し付けられる面の反対側の面に形成されていればよいが、金属含有板材において工具が押し付けられる面及び反対側の面の双方に形成されていてもよい。 The resin-containing coating may be formed on the surface of the metal-containing plate material opposite to the surface on which the tool is pressed, but is formed on both the surface of the metal-containing plate material on which the tool is pressed and the surface on the opposite side. You may.
　このような工程を経ることにより、成形部から非成形部をトリミングした後においても、樹脂含有被膜が金属含有板材における歪の解放を抑制し、成形部のねじれの発生を抑制できる。その結果、成形部に大きな変形が生じることがないので、寸法精度に優れた３次元形状成形体を得ることができる。 By going through such a process, even after trimming the non-molded portion from the molded portion, the resin-containing coating can suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having excellent dimensional accuracy can be obtained.
　本形態の３次元形状成形体の製造方法においては、被膜形成工程が逐次成形工程の前に実行されることが好適である。 In the method for producing a three-dimensional molded product of this embodiment, it is preferable that the film forming step is executed before the sequential molding step.
　このような工程を経ても、成形部から非成形部をトリミングした後において、樹脂含有被膜が金属含有板材における歪の解放を抑制し、成形部のねじれの発生を抑制できる。その結果、成形部に大きな変形が生じることがないので、寸法精度に優れた３次元形状成形体を得ることができる。 Even through such a process, after trimming the non-molded portion from the molded portion, the resin-containing coating can suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having excellent dimensional accuracy can be obtained.
　本形態の３次元形状成形体の製造方法においては、金属含有板材と樹脂含有被膜とに同じ変形が付与された際に、樹脂含有被膜に生じる応力が金属含有板材に生じる応力よりも大きいことが好適である。なお、本明細書における「応力」とは、断面積を加味したものを意味する。 In the method for producing the three-dimensional shape molded body of the present embodiment, when the same deformation is applied to the metal-containing plate material and the resin-containing coating material, the stress generated in the resin-containing coating material may be larger than the stress generated in the metal-containing plate material. Suitable. In addition, "stress" in this specification means the thing which added the cross-sectional area.
　このような応力の関係があると、成形部から非成形部をトリミングした後において、樹脂含有被膜が金属含有板材における歪の解放をより抑制し、成形部のねじれの発生をより抑制できる。その結果、成形部に大きな変形が生じることがないので、より寸法精度に優れた３次元形状成形体を得ることができる。 With such a stress relationship, after trimming the non-molded portion from the molded portion, the resin-containing coating can further suppress the release of strain in the metal-containing plate material, and the occurrence of twisting in the molded portion can be further suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
　本形態の３次元形状成形体の製造方法においては、被膜形成工程が、逐次成形工程の後で、かつ、トリミング工程の前に実行されることが好適である。なお、本形態の３次元形状成形体の製造方法においては、逐次成形工程前及びトリミング工程前のそれぞれの段階で被膜形成工程が実行されることも好適である。 In the method for producing a three-dimensional molded product of this embodiment, it is preferable that the film forming step is executed after the sequential molding step and before the trimming step. In the method for producing a three-dimensional molded product of the present embodiment, it is also preferable that the film forming step is executed at each stage before the sequential molding step and before the trimming step.
　このような工程を経ても、成形部から非成形部をトリミングした後において、樹脂含有被膜が金属含有板材における歪の解放を抑制し、成形部のねじれの発生を抑制できる。その結果、成形部に大きな変形が生じることがないので、寸法精度に優れた３次元形状成形体を得ることができる。 Even through such a process, after trimming the non-molded portion from the molded portion, the resin-containing coating can suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having excellent dimensional accuracy can be obtained.
　本形態の３次元形状成形体の製造方法においては、金属含有板材の好適例として、鋼、アルミニウム合金、マグネシウム合金及びチタン合金を挙げることができる。また、これらは、１種を単独で用いてもよく、２種以上を任意に組み合わせて用いてもよい。更に、金属含有板材の具体例としては、鋼、アルミニウム合金、マグネシウム合金及びチタン合金のうちの１種を主成分として含む金属基複合板材を挙げることもできる。なお、「主成分」とは、複合板材に占める質量割合が最も大きい成分を意味する。 In the method for producing the three-dimensional shape molded body of this embodiment, steel, aluminum alloy, magnesium alloy and titanium alloy can be mentioned as preferable examples of the metal-containing plate material. In addition, one of these may be used alone, or two or more thereof may be used in any combination. Further, as a specific example of the metal-containing plate material, a metal-based composite plate material containing one of steel, an aluminum alloy, a magnesium alloy and a titanium alloy as a main component can be mentioned. The "main component" means the component having the largest mass ratio in the composite plate material.
　このような金属からなる板材であると、非成形部をトリミングした後において、樹脂含有被膜が金属板材における歪の解放をより抑制し、成形部のねじれの発生をより抑制できる。その結果、成形部に大きな変形が生じることがないので、より寸法精度に優れた３次元形状成形体を得ることができる。 In the case of such a plate material made of metal, after trimming the non-molded portion, the resin-containing coating can further suppress the release of strain in the metal plate material, and the occurrence of twisting of the molded portion can be further suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
　金属含有板材の厚みは、特に限定されるものではないが、例えば、従来公知の車体用構成部品に適用される金属含有板材の厚みとすることが好ましい。例えば、金属含有板材が鋼板材である場合には、その厚みは０．５~２ｍｍであることが好ましく、０．５~１．５ｍｍであることがより好ましく、０．５~１．２ｍｍであることが更に好ましい。金属含有板材がアルミニウム合金板材である場合には、５ｍｍ以下であることが好ましく、３ｍｍ以下であることがより好ましい。 The thickness of the metal-containing plate material is not particularly limited, but for example, it is preferably the thickness of the metal-containing plate material applied to conventionally known vehicle body components. For example, when the metal-containing plate material is a steel plate material, the thickness thereof is preferably 0.5 to 2 mm, more preferably 0.5 to 1.5 mm, and 0.5 to 1.2 mm. It is more preferable to have. When the metal-containing plate material is an aluminum alloy plate material, it is preferably 5 mm or less, and more preferably 3 mm or less.
　本形態の３次元形状成形体の製造方法においては、樹脂含有被膜の好適例として、エポキシ樹脂、メラミン樹脂、アクリル樹脂、ウレタン樹脂、ポリエステル樹脂及びフッ素樹脂を挙げることができる。また、これらは１種を単独で用いてもよく、２種以上を任意に組み合わせて用いてもよい。 In the method for producing the three-dimensional shape molded body of the present embodiment, preferable examples of the resin-containing coating include epoxy resin, melamine resin, acrylic resin, urethane resin, polyester resin and fluororesin. In addition, one of these may be used alone, or two or more thereof may be used in any combination.
　なお、樹脂含有被膜の好適例として、熱硬化樹脂被膜及び紫外線硬化樹脂被膜を挙げることができる。硬化時間が短いという観点からは、熱硬化樹脂被膜よりも紫外線硬化樹脂が好適である。また、樹脂含有被膜は、従来公知の塗膜のように着色顔料、金属粉顔料等の成分を含んでいることが好適である。例えば、３次元形状成形体を車両に適用する場合に、樹脂含有被膜が単色又は多色の加飾機能を有していると、塗装工程を省略することが可能になるという利点がある。 A thermosetting resin film and an ultraviolet curable resin film can be mentioned as preferable examples of the resin-containing film. From the viewpoint of short curing time, an ultraviolet curable resin is preferable to a thermosetting resin film. Further, it is preferable that the resin-containing coating film contains components such as a coloring pigment and a metal powder pigment like a conventionally known coating film. For example, when the three-dimensional shape molded body is applied to a vehicle, if the resin-containing coating has a monochromatic or multicolor decorative function, there is an advantage that the painting step can be omitted.
　熱硬化樹脂被膜に含まれる熱硬化樹脂としては、例えば、アクリル樹脂（焼付温度：１７０℃、焼付時間：２０分間、硬度：３Ｈ（「硬度」とは、ＪＩＳＫ５６００−５−４に準拠して測定されたものである（以下同様。）））、フッ素樹脂（焼付温度：１７０℃、焼付時間：２０分間、硬度：４Ｈ~５Ｈ）、エポキシ樹脂（焼付温度：１００℃、焼付時間：２０分間、硬度：Ｈ）、メラミン樹脂（焼付温度：１５０℃、焼付時間：２０分間、硬度：Ｈ）、ウレタン樹脂（焼付温度：１５０℃、焼付時間：２０分間、硬度：Ｈ）及びアルキド樹脂（焼付温度：１００℃、焼付時間：２０分間、硬度：Ｈ）を挙げることができる。しかしながら、これらに限定されるものではなく、熱硬化樹脂被膜は、ポリエステル樹脂の一例である不飽和ポリエステル樹脂で形成することも可能であり、フェノール樹脂、ユリア樹脂、ジアリルフタレート樹脂及びシリコーン樹脂で形成することも可能である。上述した熱硬化樹脂は、１種を単独で用いてもよく、２種以上を任意に組み合わせて用いてもよい。また、上述した熱硬化樹脂の中では、特にアクリル樹脂、フッ素樹脂、エポキシ樹脂を適用することが好適である。 Examples of the thermosetting resin contained in the thermosetting resin film include acrylic resin (baking temperature: 170 ° C., baking time: 20 minutes, hardness: 3H (“hardness” is measured in accordance with JIS K5600-5-4). (The same applies hereinafter))), Fluorine resin (baking temperature: 170 ° C, baking time: 20 minutes, hardness: 4H to 5H), epoxy resin (baking temperature: 100 ° C, baking time: 20 minutes, Hardness: H), melamine resin (baking temperature: 150 ° C, baking time: 20 minutes, hardness: H), urethane resin (baking temperature: 150 ° C, baking time: 20 minutes, hardness: H) and alkyd resin (baking temperature) : 100 ° C., baking time: 20 minutes, hardness: H). However, the thermosetting resin coating is not limited to these, and can be formed of an unsaturated polyester resin, which is an example of a polyester resin, and is formed of a phenol resin, a urea resin, a diallyl phthalate resin, and a silicone resin. It is also possible to do. As the thermosetting resin described above, one type may be used alone, or two or more types may be used in any combination. Further, among the above-mentioned thermosetting resins, it is particularly preferable to apply an acrylic resin, a fluororesin, or an epoxy resin.
　紫外線硬化樹脂被膜に含まれる紫外線硬化樹脂としては、例えば、エポキシ樹脂（プレポリマー：エポキシアクリレート、紫外線照射出力：５００ｍＷ／ｃｍ２、紫外線照射時間：３０秒間、硬度：５Ｈよりも大きい）、ウレタン樹脂（プレポリマー：ウレタンアクリレート、紫外線照射出力：４００ｍＷ／ｃｍ２、紫外線照射時間：３７秒間、硬度：４Ｈ）、ポリエステル樹脂（プレポリマー：ポリエステルアクリレート、紫外線照射出力：２００ｍＷ／ｃｍ２、紫外線照射時間：７５秒間、硬度：２Ｈ）、アクリル樹脂（プレポリマー：アクリルアクリレート、紫外線照射出力：１００ｍＷ／ｃｍ２、紫外線照射時間：１５０秒間、硬度：Ｈ）及びポリエーテル樹詣（プレポリマー：ポリエーテルアクリレート、紫外線照射出力：５０ｍＷ／ｃｍ２、紫外線照射時間：３００秒間、硬度：Ｂ）及びを挙げることができる。また、これらは１種を単独で用いてもよく、２種以上を任意に組み合わせて用いてもよい。 Examples of the ultraviolet curable resin contained in the ultraviolet curable resin film include an epoxy resin (prepolymer: epoxy acrylate, ultraviolet irradiation output: 500 mW / cm 2 , ultraviolet irradiation time: 30 seconds, hardness: greater than 5H), urethane resin. (Prepolymer: Urethane acrylate, UV irradiation output: 400 mW / cm 2 , UV irradiation time: 37 seconds, Hardness: 4H), Polyester resin (Prepolymer: Polyester acrylate, UV irradiation output: 200 mW / cm 2 , UV irradiation time: 75 seconds, hardness: 2H), acrylic resin (prepolymer: acrylic acrylate, UV irradiation output: 100mW / cm 2 , UV irradiation time: 150 seconds, hardness: H) and polyether tree (prepolymer: polyether acrylate, Ultraviolet irradiation output: 50 mW / cm 2 , ultraviolet irradiation time: 300 seconds, hardness: B) and the like. In addition, one of these may be used alone, or two or more thereof may be used in any combination.
　このような樹脂からなる被膜であると、非成形部をトリミングした後において、被膜が金属含有板材における歪の解放をより抑制し、成形部のねじれの発生をより抑制できる。その結果、成形部に大きな変形が生じることがないので、より寸法精度に優れた３次元形状成形体を得ることができる。 With a coating made of such a resin, after trimming the non-molded portion, the coating can further suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be further suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
　特に限定されるものではないが、被膜形成工程が逐次成形工程の前に実行される場合には、樹脂含有被膜の厚みは１~１００μｍであることが好適である。樹脂含有被膜の厚みが１μｍ未満の場合、金属含有板材と樹脂含有被膜とに同じ変形が付与された際に、樹脂含有被膜に生じる応力が金属含有板材に生じる応力よりも小さくなり易い。一方、樹脂含有被膜の厚みが１００μｍよりも大きい場合、樹脂含有被膜の伸び性能が低下、換言すれば剛性が高くなり、樹脂含有被膜が破断し易くなる。その結果、金属含有板材と樹脂含有被膜とに同じ変形が付与された際に、樹脂含有被膜に生じる応力が金属含有板材に生じる応力よりも小さくなり易い。 Although not particularly limited, when the film forming step is executed before the sequential forming step, the thickness of the resin-containing film is preferably 1 to 100 μm. When the thickness of the resin-containing film is less than 1 μm, the stress generated in the resin-containing film tends to be smaller than the stress generated in the metal-containing plate material when the same deformation is applied to the metal-containing plate material and the resin-containing film. On the other hand, when the thickness of the resin-containing film is larger than 100 μm, the elongation performance of the resin-containing film is lowered, in other words, the rigidity is increased, and the resin-containing film is easily broken. As a result, when the same deformation is applied to the metal-containing plate material and the resin-containing coating material, the stress generated in the resin-containing coating material tends to be smaller than the stress generated in the metal-containing plate material.
　また、特に限定されるものではないが、被膜形成工程が逐次成形工程の後で、かつ、トリミング工程の前に実行される場合には、樹脂含有被膜の剛性が高ければ高いほど好適であるので、後述する樹脂含有被膜の形成方法によって形成可能な範囲内で樹脂含有被膜の厚みも大きければ大きいほど好適である。 Further, although not particularly limited, when the film forming step is executed after the sequential forming step and before the trimming step, the higher the rigidity of the resin-containing coating, the more suitable it is. The larger the thickness of the resin-containing film within the range that can be formed by the method for forming the resin-containing film described later, the more suitable it is.
　寸法精度が優れた３次元形状成形体が得られれば特に限定されるものではないが、樹脂含有被膜は、金属含有板材において工具が押し付けられる面と反対側の面の一部だけに形成してもよく、全面に形成してもよい。樹脂含有被膜は、例えば、金属含有板材において工具が押し付けられる面と反対側の面の５０面積％以上に形成することが好適であり、９０面積％以上に形成することがより好適である。なお、樹脂含有被膜の金属含有板材における被覆率は成形部に逐次成形される３次元形状によって適宜変更することが可能である。 The resin-containing coating is not particularly limited as long as a three-dimensional shape molded product having excellent dimensional accuracy can be obtained, but the resin-containing coating is formed only on a part of the surface of the metal-containing plate material opposite to the surface on which the tool is pressed. It may be formed on the entire surface. The resin-containing coating is preferably formed on, for example, 50 area% or more of the surface of the metal-containing plate material opposite to the surface on which the tool is pressed, and more preferably 90 area% or more. The coverage of the resin-containing coating on the metal-containing plate material can be appropriately changed depending on the three-dimensional shape that is sequentially molded on the molded portion.
　また、特に限定されるものではないが、樹脂含有被膜の伸びは１２０％以上であることが好ましく、２００％以上であることがより好ましい。樹脂含有被膜の伸びが１２０％未満の場合、樹脂が破断し易い。その結果、金属含有板材と樹脂含有被膜とに同じ変形が付与された際に、樹脂含有被膜に生じる応力が金属含有板材に生じる応力よりも小さくなり易い。 Further, although not particularly limited, the elongation of the resin-containing film is preferably 120% or more, and more preferably 200% or more. When the elongation of the resin-containing film is less than 120%, the resin is easily broken. As a result, when the same deformation is applied to the metal-containing plate material and the resin-containing coating material, the stress generated in the resin-containing coating material tends to be smaller than the stress generated in the metal-containing plate material.
　特に限定されるものではないが、樹脂含有被膜の硬度は３Ｈ以下であることが好適である。樹脂含有被膜の硬度が３Ｈよりも大きい場合、樹脂含有被膜の伸び性能が低下して、樹脂含有被膜が破断し易くなる。 Although not particularly limited, the hardness of the resin-containing film is preferably 3H or less. When the hardness of the resin-containing film is larger than 3H, the elongation performance of the resin-containing film is lowered, and the resin-containing film is easily broken.
　本形態の３次元形状成形体の製造方法においては、樹脂含有被膜の形成方法の好適例として、塗装方法、印刷方法及びコーティング方法を挙げることができる。また、これらは１種を単独で用いてもよく、２種以上を任意に組み合わせて用いてもよい。 In the method for producing the three-dimensional molded product of this embodiment, a coating method, a printing method, and a coating method can be mentioned as preferable examples of the method for forming the resin-containing film. In addition, one of these may be used alone, or two or more thereof may be used in any combination.
　上記塗装方法としては、エアガン塗装、エアレスガン塗装、流動浸漬、静電塗装及びディッピングを挙げることができる。 Examples of the above coating method include air gun coating, airless gun coating, fluidized immersion, electrostatic coating and dipping.
　上記印刷方法としては、インクジェット印刷、グラビア印刷、シルク印刷、シルクスクリーン印刷、水面転写印刷、パット印刷及びタンポ印刷を挙げることができる。 Examples of the above printing method include inkjet printing, gravure printing, silk printing, silk screen printing, water surface transfer printing, pad printing and tampo printing.
　上記コーティング方法としては、溶射及びイオンプレーティング（化学蒸着法、物理蒸着法）を挙げることができる。 Examples of the coating method include thermal spraying and ion plating (chemical vapor deposition method, physical vapor deposition method).
　このような樹脂含有被膜の形成方法を用いると、樹脂含有被膜を適切に形成することができる。そのため、非成形部をトリミングした後において、樹脂含有被膜が金属含有板材における歪の解放を適切に抑制し、成形部のねじれの発生を適切に抑制できる。その結果、成形部に大きな変形が生じることがないので、より寸法精度に優れた３次元形状成形体を得ることができる。 By using such a resin-containing film forming method, the resin-containing film can be appropriately formed. Therefore, after the non-molded portion is trimmed, the resin-containing coating can appropriately suppress the release of strain in the metal-containing plate material, and the occurrence of twisting of the molded portion can be appropriately suppressed. As a result, since the molded portion is not significantly deformed, a three-dimensional shape molded body having more excellent dimensional accuracy can be obtained.
　本形態のパネル部品は、上述した３次元形状成形体の製造方法によって得られる３次元形状成形体である。このパネル部品は、上述した３次元形状成形体の製造方法によって得られるので、寸法精度が優れている。 The panel component of this embodiment is a three-dimensional shape molded body obtained by the above-mentioned manufacturing method of the three-dimensional shape molded body. Since this panel part is obtained by the above-mentioned manufacturing method of the three-dimensional shape molded body, the dimensional accuracy is excellent.
　このパネル部品は、車体用構成部品として用いることが好適である。この車体用構成部品としては、各種のアウターパネル部品及びインナーパネル部品を挙げることができる。しかしながら、これらに限定されるものではなく、このパネル部品は、車両用のドアミラーハウジング、給油口蓋に適用することも可能である。 This panel part is preferably used as a vehicle body component. Examples of the vehicle body component include various outer panel parts and inner panel parts. However, the present invention is not limited to these, and this panel component can also be applied to a door mirror housing for a vehicle and a refueling palate.
　以下、本発明の一形態に係る３次元形状成形体の製造方法及びこれによって得られるパネル部品について図面を参照しながら詳細に説明する。 Hereinafter, a method for manufacturing a three-dimensional molded product according to one embodiment of the present invention and panel parts obtained by the method will be described in detail with reference to the drawings.
（第１の形態）
　まず、第１の形態に係る３次元形状成形体の製造方法についで説明する。図１は、第１の形態に係る３次元形状成形体の製造方法の説明図である。 (First form)
First, a method for manufacturing a three-dimensional molded product according to the first embodiment will be described. FIG. 1 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the first embodiment.
　工程（Ａ）において、成形部１１と成形部１１の周囲に位置する非成形部１２とを有する金属含有板材１０を用意する。具体的には、金属含有板材として厚み１．２ｍｍの鋼板を用意する。 In the step (A), a metal-containing plate material 10 having a molded portion 11 and a non-molded portion 12 located around the molded portion 11 is prepared. Specifically, a steel plate having a thickness of 1.2 mm is prepared as a metal-containing plate material.
　次いで、工程（Ｂ）において、金属含有板材１０の一方の面側に樹脂含有被膜２０を全面に形成する。具体的には、樹脂含有被膜として、紫外線硬化樹脂被膜である厚み１０μｍのアクリル樹脂被膜をインクジェット印刷によって形成する。 Next, in the step (B), the resin-containing coating 20 is formed on one surface side of the metal-containing plate material 10 on the entire surface. Specifically, as the resin-containing film, an acrylic resin film having a thickness of 10 μm, which is an ultraviolet curable resin film, is formed by inkjet printing.
　次いで、工程（Ｃ）において、金属含有板材１０の非成形部１２を治具５０によって保持する。具体的には、金属含有板材の平面外周を治具によって拘束する。 Next, in the step (C), the non-molded portion 12 of the metal-containing plate material 10 is held by the jig 50. Specifically, the outer periphery of the plane of the metal-containing plate material is restrained by a jig.
　次いで、工程（Ｄ）において、金属含有板材１０の非成形部１２を治具５０によって保持し、かつ、金属含有板材１０の樹脂含有被膜２０が形成された面と反対側に配置した工具６０を金属含有板材１０に押し付けた状態で、金属含有板材１０と工具６０を相対的に移動させ、成形部１１に３次元形状を逐次成形する。 Next, in the step (D), the tool 60 is held on the non-molded portion 12 of the metal-containing plate material 10 by the jig 50 and arranged on the side opposite to the surface on which the resin-containing coating 20 of the metal-containing plate material 10 is formed. While being pressed against the metal-containing plate material 10, the metal-containing plate material 10 and the tool 60 are relatively moved to sequentially form a three-dimensional shape on the molding portion 11.
　さらに、工程（Ｅ）において、３次元形状が逐次成形された金属含有板材１０と樹脂含有被膜２０とから治具５０を取り外す。 Further, in the step (E), the jig 50 is removed from the metal-containing plate material 10 and the resin-containing coating 20 in which the three-dimensional shape is sequentially formed.
　しかる後、工程（Ｆ）においで、３次元形状が逐次成形された金属含有板材１０から非成形部１２をトリミングして、３次元形状成形体１を得る。なお、非成形部１２をトリミングするに際して、樹脂含有被膜２０の一部２２もトリミングされる。 After that, in the step (F), the non-molded portion 12 is trimmed from the metal-containing plate material 10 in which the three-dimensional shape is sequentially molded to obtain the three-dimensional shape molded body 1. When the non-molded portion 12 is trimmed, a part 22 of the resin-containing coating 20 is also trimmed.
　図２は、３次元形状成形体の一例における変形領域の分布を示す平面図である。また、図３は、樹脂含有被膜の有無と３次元形状成形体の設計値との寸法差との関係を示すグラフである。なお、上記説明したものと同等のものについては同一の符号を付して説明を省略する。図２中の変形領域Ｚは、設計値との寸法差が±５．０ｍｍより大きい領域を示す。 FIG. 2 is a plan view showing the distribution of the deformed region in an example of the three-dimensional shape molded body. Further, FIG. 3 is a graph showing the relationship between the presence / absence of the resin-containing coating and the dimensional difference between the design value of the three-dimensional shape molded product. The same reference numerals are given to those equivalent to those described above, and the description thereof will be omitted. The deformation region Z in FIG. 2 indicates a region in which the dimensional difference from the design value is larger than ± 5.0 mm.
　図２及び図３より、樹脂含有被膜が有ると、成形部から非成形部をトリミングした後においても、成形部のねじれの発生が抑制でき、成形部に大きな変形が生じることがないので、寸法精度に優れた３次元形状成形体を得ることが可能なことが分かる。 From FIGS. 2 and 3, when the resin-containing coating is present, the occurrence of twisting of the molded portion can be suppressed even after the non-molded portion is trimmed from the molded portion, and the molded portion is not significantly deformed. It can be seen that it is possible to obtain a three-dimensional shape molded product having excellent accuracy.
（第２の形態）
　次に、第２の形態に係る３次元形状成形体の製造方法について説明する。図４は、第２の形態に係る３次元形状成形体の製造方法の説明図である。 (Second form)
Next, a method of manufacturing the three-dimensional shape molded body according to the second embodiment will be described. FIG. 4 is an explanatory diagram of a method for manufacturing a three-dimensional molded product according to the second embodiment.
　工程（Ａ）において、成形部１１と成形部１１の周囲に位置する非成形部１２とを有する金属含有板材１０を用意する。具体的には、金属含有板材として厚み１．２ｍｍの鋼板を用意する。 In the step (A), a metal-containing plate material 10 having a molded portion 11 and a non-molded portion 12 located around the molded portion 11 is prepared. Specifically, a steel plate having a thickness of 1.2 mm is prepared as a metal-containing plate material.
　次いで、工程（Ｂ）において、金属含有板材１０の非成形部１２を治具５０によって保持する。具体的には、金属含有板材の平面外周を治具によって拘束する。 Next, in the step (B), the non-molded portion 12 of the metal-containing plate material 10 is held by the jig 50. Specifically, the outer periphery of the plane of the metal-containing plate material is restrained by a jig.
　次いで、工程（Ｃ）において、金属含有板材１０の非成形部１２を治具５０によって保持し、かつ、金属含有板材１０の一方の面に配置した工具６０を金属含有板材１０に押し付けた状態で、金属含有板材１０と工具６０を相対的に移動させ、成形部１１に３次元形状を逐次成形する。 Next, in the step (C), the non-molded portion 12 of the metal-containing plate material 10 is held by the jig 50, and the tool 60 arranged on one surface of the metal-containing plate material 10 is pressed against the metal-containing plate material 10. , The metal-containing plate material 10 and the tool 60 are relatively moved to sequentially form a three-dimensional shape on the forming portion 11.
　次いで、工程（Ｄ）において、金属含有板材１０の工具を押し付け移動させた面と反対側に樹脂含有被膜２０を形成する。具体的には、樹脂含有被膜として、熱硬化樹脂被膜である厚み１０μｍのアクリル樹脂被膜をエアガン塗装によって形成する。 Next, in the step (D), the resin-containing coating 20 is formed on the side opposite to the surface on which the tool of the metal-containing plate material 10 is pressed and moved. Specifically, as the resin-containing film, an acrylic resin film having a thickness of 10 μm, which is a thermosetting resin film, is formed by air gun coating.
　さらに、工程（Ｅ）において、３次元形状が逐次成形された金属含有板材１０と樹脂含有被膜２０とから治具５０を取り外す。 Further, in the step (E), the jig 50 is removed from the metal-containing plate material 10 and the resin-containing coating 20 in which the three-dimensional shape is sequentially formed.
　しかる後、工程（Ｆ）において、３次元形状が逐次成形された金属含有板材１０から非成形部１２をトリミングして、３次元形状成形体１を得る。 After that, in the step (F), the non-molded portion 12 is trimmed from the metal-containing plate material 10 in which the three-dimensional shape is sequentially molded to obtain the three-dimensional shape molded body 1.
　以上、本発明を若干の形態によって説明したが、本発明はこれらに限定されるものではなく、本発明の要旨の範囲内で種々の変形が可能である。 Although the present invention has been described above in some forms, the present invention is not limited to these, and various modifications can be made within the scope of the gist of the present invention.
　１　３次元形状成形体
１０　金属含有板材
１１　成形部
１２　非成形部
２０　樹脂含有被膜
２２　樹脂含有被膜の一部
５０　治具
６０　工具 1 Three-dimensional shape molded body 10 Metal-containing plate material 11 Molded part 12 Non-molded part 20 Resin-containing film 22 Part of resin-containing film 50 Jig 60 Tool

Claims (8)

  1. 　成形部と前記成形部の周囲に位置する非成形部とを有する金属含有板材の前記非成形部を治具によって保持し、かつ、前記金属含有板材の一方の面側に配置した工具を前記金属含有板材に押し付けた状態で、前記金属含有板材と前記工具を相対的に移動させ、前記成形部に３次元形状を逐次成形する逐次成形工程と、
    　前記逐次成形工程の後に実行され、前記非成形部をトリミングするトリミング工程と、
    　前記逐次成形工程及び前記トリミング工程の少なくとも一方の前に実行され、前記金属含有板材の少なくとも前記一方の面と反対の面側に樹脂含有被膜を形成する被膜形成工程と、を含む
    ことを特徴とする３次元形状成形体の製造方法。     A tool that holds the non-molded portion of a metal-containing plate material having a molded portion and a non-molded portion located around the molded portion by a jig and is arranged on one surface side of the metal-containing plate material is the metal. A sequential molding step in which the metal-containing plate and the tool are relatively moved in a state of being pressed against the containing plate to sequentially form a three-dimensional shape on the molded portion.
    A trimming step, which is executed after the sequential molding step and trims the non-molded portion,
    It is characterized by including a film forming step which is executed before at least one of the sequential forming step and the trimming step and forms a resin-containing film on at least one surface side of the metal-containing plate material opposite to the one surface side. A method for manufacturing a three-dimensional shaped molded article.
  2. 　前記被膜形成工程が、前記逐次成形工程の前に実行されることを特徴とする請求項１に記載の３次元形状成形体の製造方法。 The method for manufacturing a three-dimensional molded product according to claim 1, wherein the film forming step is executed before the sequential molding step.
  3. 　前記金属含有板材と前記樹脂含有被膜とに同じ変形が付与された際に、前記樹脂含有被膜に生じる応力が前記金属含有板材に生じる応力よりも大きい
    ことを特徴とする請求項２に記載の３次元形状成形体の製造方法。     3. The third aspect of claim 2, wherein when the same deformation is applied to the metal-containing plate material and the resin-containing coating material, the stress generated in the resin-containing coating material is larger than the stress generated in the metal-containing plate material. A method for manufacturing a three-dimensional shape molded body.
  4. 　前記被膜形成工程が、前記逐次成形工程の後で、かつ、前記トリミング工程の前に実行されることを特徴とする請求項１~３のいずれか１つの項に記載の３次元形状成形体の製造方法。 The three-dimensional shape molded product according to any one of claims 1 to 3, wherein the film forming step is executed after the sequential molding step and before the trimming step. Production method.
  5. 　前記金属含有板材が、鋼、アルミニウム合金、マグネシウム合金及びチタン合金からなる群より選ばれる少なくとも１種を含むことを特徴とする請求項１~４のいずれか１つの項に記載の３次元形状成形体の製造方法。 The three-dimensional shape molding according to any one of claims 1 to 4, wherein the metal-containing sheet material contains at least one selected from the group consisting of steel, aluminum alloys, magnesium alloys and titanium alloys. How to make a body.
  6. 　前記樹脂含有被膜が、エポキシ樹脂、メラミン樹脂、アクリル樹脂、ウレタン樹脂、ポリエステル樹脂及びフッ素樹脂からなる群より選ばれる少なくとも１種を含むことを特徴とする請求項１~５のいずれか１つの項に記載の３次元形状成形体の製造方法。 One of claims 1 to 5, wherein the resin-containing film contains at least one selected from the group consisting of epoxy resin, melamine resin, acrylic resin, urethane resin, polyester resin and fluororesin. The method for producing a three-dimensional shape molded body according to.
  7. 　前記樹脂含有被膜が、塗装、印刷及びコーティングからなる群より選ばれる少なくとも１種の方法によって形成されることを特徴とする請求項１~６のいずれか１つの項に記載の３次元形状成形体の製造方法。 The three-dimensional shape molded product according to any one of claims 1 to 6, wherein the resin-containing film is formed by at least one method selected from the group consisting of coating, printing and coating. Manufacturing method.
  8. 　成形部と前記成形部の周囲に位置する非成形部とを有する金属含有板材の前記非成形部を治具によって保持し、かつ、前記金属含有板材の一方の面側に配置した工具を前記金属含有板材に押し付けた状態で、前記金属含有板材と前記工具を相対的に移動させ、前記成形部に３次元形状を逐次成形する逐次成形工程と、
    　前記逐次成形工程の後に実行され、前記非成形部をトリミングするトリミング工程と、
    　前記逐次成形工程及び前記トリミング工程の少なくとも一方の前に実行され、前記金属含有板材の少なくとも前記一方の面と反対の面側に樹脂含有被膜を形成する被膜形成工程と、を含む３次元形状成形体の製造方法によって得られたことを特徴とするパネル部品。     A tool that holds the non-molded portion of a metal-containing plate material having a molded portion and a non-molded portion located around the molded portion by a jig and is arranged on one surface side of the metal-containing plate material is the metal. A sequential molding step in which the metal-containing plate and the tool are relatively moved in a state of being pressed against the containing plate to sequentially form a three-dimensional shape on the molded portion.
    A trimming step, which is executed after the sequential molding step and trims the non-molded portion,
    Three-dimensional shape forming including a film forming step executed before at least one of the sequential forming step and the trimming step to form a resin-containing film on at least one surface side of the metal-containing plate material opposite to the one surface side. A panel part characterized by being obtained by a body manufacturing method.
PCT/IB2019/000371 2019-04-02 2019-04-02 Method for manufacturing molded body having three-dimensional shape WO2020201793A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11285741A (en) * 1998-04-03 1999-10-19 Hitachi Ltd Forming method and processing tool for metal plate
JP2001162222A (en) * 1999-12-13 2001-06-19 Nippon Tokushu Toryo Co Ltd Coating type steel panel reinforcing material and method for applying the same
JP4787548B2 (en) * 2005-06-07 2011-10-05 株式会社アミノ Thin plate forming method and apparatus
JP2014527468A (en) * 2011-08-19 2014-10-16 スリーエム イノベイティブ プロパティズ カンパニー Method for forming coated sheet metal and article produced using the same
JP2018192487A (en) * 2017-05-15 2018-12-06 日産自動車株式会社 Sliding mechanism

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11285741A (en) * 1998-04-03 1999-10-19 Hitachi Ltd Forming method and processing tool for metal plate
JP2001162222A (en) * 1999-12-13 2001-06-19 Nippon Tokushu Toryo Co Ltd Coating type steel panel reinforcing material and method for applying the same
JP4787548B2 (en) * 2005-06-07 2011-10-05 株式会社アミノ Thin plate forming method and apparatus
JP2014527468A (en) * 2011-08-19 2014-10-16 スリーエム イノベイティブ プロパティズ カンパニー Method for forming coated sheet metal and article produced using the same
JP2018192487A (en) * 2017-05-15 2018-12-06 日産自動車株式会社 Sliding mechanism

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