U.S. patent application number 15/775633 was filed with the patent office on 2018-11-08 for method and device for manufacturing vehicle arm component.
The applicant listed for this patent is Yorozu Corporation. Invention is credited to Hironori ITO, YUTAKA KUROI.
Application Number | 20180318902 15/775633 |
Document ID | / |
Family ID | 58694973 |
Filed Date | 2018-11-08 |
United States Patent
Application |
20180318902 |
Kind Code |
A1 |
KUROI; YUTAKA ; et
al. |
November 8, 2018 |
METHOD AND DEVICE FOR MANUFACTURING VEHICLE ARM COMPONENT
Abstract
Providing a manufacturing method for a vehicular arm component
that can further increase material yield. Including an expanding
process S05 of pressing a pressurized portion P8 provided in a
plane of a workpiece W in a Z direction to expand an X-directional
width of the workpiece from a first width X1 to a second width X2,
and a separating process S06 of cutting off the workpiece having an
X-directional width expanded to the first width from a processed
material M.
Inventors: |
KUROI; YUTAKA; (Yokohama,
JP) ; ITO; Hironori; (Yokohama, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Yorozu Corporation |
Yokohama |
|
JP |
|
|
Family ID: |
58694973 |
Appl. No.: |
15/775633 |
Filed: |
November 13, 2015 |
PCT Filed: |
November 13, 2015 |
PCT NO: |
PCT/JP2015/081987 |
371 Date: |
May 11, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 31/04 20130101;
B21D 53/88 20130101; B21D 37/08 20130101; B21D 35/001 20130101;
B21D 28/06 20130101; B21D 22/02 20130101; G05G 1/506 20130101 |
International
Class: |
B21D 28/06 20060101
B21D028/06; B21D 53/88 20060101 B21D053/88; B21D 35/00 20060101
B21D035/00 |
Claims
1.-15. (canceled)
16. A manufacturing method for a vehicular arm component for
manufacturing by a progressive press working method in which a
long-shaped processed material for which a blank layout is set such
that a feed bridge width, which is a separation distance between
workpieces that are contiguously adjacent in a feed direction, is
zero is intermittently fed at a constant pitch in the feed
direction and is simultaneously pressed in a plurality of positions
in the feed direction, the manufacturing method for a vehicular arm
component comprising: an expanding process of pressing a
pressurized portion provided in a plane of the workpiece in a
thickness direction to expand a width of the workpiece in the feed
direction; and a separating process of cutting off the workpiece
having an expanded width in the feed direction from the processed
material.
17. The manufacturing method for a vehicular arm component
according to claim 16, wherein a position of pressing is adjusted
to perform positioning depending on expansion of the width of the
workpiece in the feed direction in the expanding process.
18. The manufacturing method for a vehicular arm component
according to claim 16, wherein the pressurized portion is
pressurized from both sides in the thickness direction in the
expanding process.
19. The manufacturing method for a vehicular arm component
according to claim 16, wherein a length of the processed material
in a perpendicular direction perpendicular to the feed direction is
the same as a length of a component of the vehicular arm component
in the perpendicular direction.
20. The manufacturing method for a vehicular arm component
according to claim 19, further comprising, prior to the expanding
process: a forming process of forming, in a position that is on one
side of the workpiece in the perpendicular direction and where a
hole into which a support shaft for supporting the vehicular arm
component to a bracket is inserted is formed, a precursor hole,
which is smaller than the hole, and forming a positioning hole in a
position that is on another side in the perpendicular direction; a
first cutting process of cutting out a first end at one end of a
boundary portion between the adjacent workpieces in the
perpendicular direction to form a notched portion and cutting out a
first unnecessary portion that is provided on a side of the
positioning hole facing the notched portion and follows a shape of
the vehicular arm component; a second cutting process of forming
the hole in a vicinity of a position where the precursor hole is
formed in the forming process and cutting out a second end that is
provided at another end in the perpendicular direction and follows
a shape of the vehicular arm component; and a third cutting process
of cutting out a second unnecessary portion that surrounds the
positioning hole, is provided between the first unnecessary portion
and the second end, and follows a shape of the vehicular arm
component.
21. The manufacturing method for a vehicular arm component
according to claim 20, wherein the pressurized portion is extended
such that both ends of the pressurized portion in the perpendicular
direction exceed a width extending along the perpendicular
direction of the boundary portion when viewed from the feed
direction.
22. The manufacturing method for a vehicular arm component
according to claim 20, wherein the notched portion is formed to be
longer in the perpendicular direction than in the feed
direction.
23. The manufacturing method for a vehicular arm component
according to claim 16, wherein the pressurized portion is formed
along a direction crossing the feed direction.
24. A manufacturing apparatus for a vehicular arm component for
manufacturing by a progressive press working method in which a
long-shaped processed material for which a blank layout is set such
that a feed bridge width, which is a separation distance between
workpieces that are contiguously adjacent in a feed direction, is
zero is intermittently fed at a constant pitch in the feed
direction and is simultaneously pressed in a plurality of positions
in the feed direction, the manufacturing apparatus for a vehicular
arm component comprising: an expanding portion configured to press
a pressurized portion provided in a plane of the workpiece in a
thickness direction to expand a width of the workpiece in the feed
direction; and a separating portion configured to cut off the
workpiece having an expanded width in the feed direction from the
processed material.
25. The manufacturing apparatus for a vehicular arm component
according to claim 24, further comprising a biasing member
configured to adjust a position of pressing to perform positioning
depending on expansion of the width of the workpiece in the feed
direction in the expanding portion.
26. The manufacturing apparatus for a vehicular arm component
according to claim 25, wherein the expanding portion presses the
pressurized portion from both sides in the thickness direction.
27. The manufacturing apparatus for a vehicular arm component
according to claim 25, further comprising: a forming portion
configured to form, in a position that is on one side of the
workpiece in a perpendicular direction perpendicular to the feed
direction and where a hole into which a support shaft for
supporting the vehicular arm component to a bracket is inserted is
formed, a precursor hole, which is smaller than the hole, and form
a positioning hole in a position that is on another side in the
perpendicular direction; a first cutting portion configured to cut
out a first end at one end of a boundary portion between the
adjacent workpieces in the perpendicular direction to form a
notched portion and cut out a first unnecessary portion that is
provided on a side of the positioning hole facing the notched
portion and follows a shape of the vehicular arm component; a
second cutting portion configured to form the hole in a vicinity of
a position where the precursor hole is formed by the forming
portion and cut out a second end that is provided at another end in
the perpendicular direction and follows a shape of the vehicular
arm component; and a third cutting portion configured to cut out a
second unnecessary portion that surrounds the positioning hole, is
provided between the first unnecessary portion and the second end,
and follows a shape of the vehicular arm component.
28. The manufacturing apparatus for a vehicular arm component
according to claim 27, wherein the pressurized portion is extended
such that both ends of the pressurized portion in the perpendicular
direction exceed a width extending along the perpendicular
direction of the boundary portion when viewed from the feed
direction.
29. The manufacturing apparatus for a vehicular arm component
according to claim 27, wherein the notched portion is formed to be
longer in the perpendicular direction than in the feed
direction.
30. The manufacturing apparatus for a vehicular arm component
according to claim 24, wherein the pressurized portion is formed
along a direction crossing the feed direction.
31. The manufacturing method for a vehicular arm component
according to claim 17, wherein the pressurized portion is
pressurized from both sides in the thickness direction in the
expanding process.
32. The manufacturing method for a vehicular arm component
according to claims 17, wherein a length of the processed material
in a perpendicular direction perpendicular to the feed direction is
the same as a length of a component of the vehicular arm component
in the perpendicular direction.
33. The manufacturing method for a vehicular arm component
according to claims 18, wherein a length of the processed material
in a perpendicular direction perpendicular to the feed direction is
the same as a length of a component of the vehicular arm component
in the perpendicular direction.
34. The manufacturing method for a vehicular arm component
according to claim 21, wherein the notched portion is formed to be
longer in the perpendicular direction than in the feed
direction.
35. The manufacturing apparatus for a vehicular arm component
according to claim 26, further comprising: a forming portion
configured to form, in a position that is on one side of the
workpiece in a perpendicular direction perpendicular to the feed
direction and where a hole into which a support shaft for
supporting the vehicular arm component to a bracket is inserted is
formed, a precursor hole, which is smaller than the hole, and form
a positioning hole in a position that is on another side in the
perpendicular direction; a first cutting portion configured to cut
out a first end at one end of a boundary portion between the
adjacent workpieces in the perpendicular direction to form a
notched portion and cut out a first unnecessary portion that is
provided on a side of the positioning hole facing the notched
portion and follows a shape of the vehicular arm component; a
second cutting portion configured to form the hole in a vicinity of
a position where the precursor hole is formed by the forming
portion and cut out a second end that is provided at another end in
the perpendicular direction and follows a shape of the vehicular
arm component; and a third cutting portion configured to cut out a
second unnecessary portion that surrounds the positioning hole, is
provided between the first unnecessary portion and the second end,
and follows a shape of the vehicular arm component.
Description
TECHNICAL FIELD
[0001] The present invention relates to a manufacturing method and
a manufacturing apparatus for a vehicular arm component.
BACKGROUND ART
[0002] As a manufacturing method for a vehicular arm component, for
example, Patent Literature 1 described below discloses a method of
manufacturing a vehicular arm component by progressive press
working. A progressive press working method is a method in which a
long-shaped processed material is intermittently fed at a constant
pitch in a feed direction and is simultaneously pressed in a
plurality of positions in the feed direction.
[0003] In addition, Patent Literature 2 described below discloses
the progressive press working method in which a feed bridge width,
which is a separation distance between workpiece portions that are
contiguously adjacent in a feed direction, is zero. This method
enables an increase in material yield since the feed bridge width
is zero.
CITATION LIST
Patent Literatures
[0004] Patent Literature 1: JP 2010-86052 A
[0005] Patent Literature 2: JP H08-19823 A
SUMMARY OF INVENTION
Technical Problem
[0006] For a manufacturing method for a vehicular arm component,
the progressive press working method disclosed in Patent Literature
2 described above requires a further increase in material
yield.
[0007] The present invention has been made in view of the above
circumstances, and it is an object of the present invention to
provide a manufacturing method and a manufacturing apparatus for a
vehicular arm component that enables a further increase in material
yield for a manufacturing method and a manufacturing apparatus for
a vehicular arm component for manufacturing a vehicular arm
component by a progressive press working method in which the feed
bridge width is set to zero.
Solution to Problem
[0008] A manufacturing method for a vehicular arm component
according to the present invention to solve the above object is a
manufacturing method for a vehicular arm component for
manufacturing by a progressive press working method in which a
long-shaped processed material for which a blank layout is set such
that a feed bridge width, which is a separation distance between
workpieces that are contiguously adjacent in a feed direction, is
zero is intermittently fed at a constant pitch in the feed
direction and is simultaneously pressed in a plurality of positions
in the feed direction, the manufacturing method for a vehicular arm
component including: an expanding process of pressing a pressurized
portion provided in a plane of the workpiece in a thickness
direction to expand a width of the workpiece in the feed direction;
and a separating process of cutting off the workpiece having an
expanded width in the feed direction from the processed
material.
[0009] Furthermore, a manufacturing apparatus for a vehicular arm
component according to the present invention to solve the above
object is a manufacturing apparatus for a vehicular arm component
for manufacturing by a progressive press working method in which a
long-shaped processed material for which a blank layout is set such
that a feed bridge width, which is a separation distance between
workpieces that are contiguously adjacent in a feed direction, is
zero is intermittently fed at a constant pitch in the feed
direction and is simultaneously pressed in a plurality of positions
in the feed direction, the manufacturing apparatus for a vehicular
arm component including: an expanding portion configured to press a
pressurized portion provided in a plane of the workpiece in a
thickness direction to expand a width of the workpiece in the feed
direction; and a separating portion configured to cut off the
workpiece having an expanded width in the feed direction from the
processed material.
Advantageous Effects of Invention
[0010] With the aforementioned manufacturing method and
manufacturing apparatus for a vehicular arm component, an expanding
portion enables expansion to a desired width in an expanding
process. Thus, as compared with the case where the width in a feed
direction is preset to a desired width, the material yield can be
increased further. Hence, a manufacturing method and a
manufacturing apparatus for a vehicular arm component that can
further increase the material yield can be provided.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a schematic side view illustrating an example of a
brake pedal device according to an embodiment of the present
invention.
[0012] FIG. 2 is a perspective view illustrating a brake pedal
according to the present embodiment.
[0013] FIG. 3 is a view illustrating a manufacturing apparatus for
a brake pedal and a processed material that is fed
progressively.
[0014] FIG. 4 is a plan view illustrating a processed material,
which has been pressed in a plurality of positions in an X
direction.
[0015] FIG. 5 is a view illustrating a state in which an expanding
portion presses a pressurized portion.
[0016] FIG. 6 is a schematic cross-sectional view along an X
direction illustrating a manufacturing apparatus for a brake
pedal.
[0017] FIG. 7 is a schematic cross-sectional view along a Y
direction illustrating an expanding portion of a manufacturing
apparatus for a brake pedal.
[0018] FIG. 8 is a flowchart of a manufacturing method for a brake
pedal according to the present embodiment.
[0019] FIG. 9 is a view for describing an example.
[0020] FIG. 10 is a graph illustrating a relationship between a
pressing force and an amount of expansion.
[0021] FIG. 11 is a graph illustrating a relationship between a
pressing force and an amount of reduction in thickness.
[0022] FIG. 12 is a graph illustrating a relationship between an
amount of reduction in thickness and an amount of expansion.
DESCRIPTION OF EMBODIMENTS
[0023] An embodiment of the present invention is described with
reference to the drawings. In the description of the drawings, like
elements are designated with like reference numerals, and a
redundant description is omitted. The dimensional ratio in the
drawings is exaggerated for the sake of convenience of description
and differs from the actual ratio. Herein, "workpiece W" indicates
a portion for one of brake pedals 4 which are manufactured
continuously in a processed material M.
[0024] FIG. 1 is a schematic side view illustrating an example of a
brake pedal device according to an embodiment of the present
invention. FIG. 2 is a perspective view illustrating a brake pedal
4 according to the present embodiment.
[0025] Examples of the vehicular arm component according to the
present embodiment include the brake pedal 4 for use in a brake
pedal device. As illustrated in FIG. 1, the brake pedal device
generally includes a bracket 2 attached to a dash panel 1, the
brake pedal 4 rotatably mounted on a support shaft 3 provided on
the bracket 2, a pin 5 extending through an upper part of the brake
pedal 4, a rod 6 having one end coupled to the pin 5 and another
end coupled to a Master vac (not illustrated), and a foot plate 7
attached to a lower portion of the brake pedal 4.
[0026] As illustrated in FIG. 2, the brake pedal 4 includes a hole
11 into which the support shaft 3 is inserted, a clevis hole 12
into which the pin 5 is inserted, and a recess 13 formed by
pressing in an expanding process S05 to be described later.
[0027] Next, a manufacturing apparatus 100 and a manufacturing
method for a vehicular arm component according to the present
embodiment are described. Here, the manufacturing apparatus 100 and
the manufacturing method for, as an example of the vehicular arm
component, the brake pedal 4 are described. The brake pedal 4, when
described briefly, is manufactured by a progressive press working
method in which a long-shaped processed material M for which a
blank layout is set such that the feed bridge width, which is a
separation distance between workpieces W1 to W6 that are
contiguously adjacent in an X direction (feed direction), is zero
is intermittently fed at a constant pitch in the X direction and is
simultaneously pressed in a plurality of positions in the X
direction. The detailed description is given below.
[0028] FIG. 3 is a view illustrating the manufacturing apparatus
100 for the brake pedal 4 and the processed material M that is fed
progressively. FIG. 4 is a plan view illustrating the processed
material M, which has been pressed in a plurality of positions in
the X direction. FIG. 5 is a view illustrating a state in which an
expanding portion 150 presses a pressurized portion P8. FIG. 6 is a
schematic cross-sectional view along the X direction illustrating
the manufacturing apparatus 100 for the brake pedal 4. FIG. 7 is a
schematic cross-sectional view along the Y direction (perpendicular
direction) illustrating the expanding portion 150 of the
manufacturing apparatus 100 for the brake pedal 4. FIG. 8 is a
flowchart of a manufacturing method for the brake pedal 4 according
to the present embodiment.
[0029] As illustrated in FIG. 3, it is preferable that the
Y-directional length of the processed material M be the same as the
length of a Y-directional component of the brake pedal 4.
[0030] First, a configuration of the manufacturing apparatus 100
for the brake pedal 4 is described.
[0031] The manufacturing apparatus 100 for the brake pedal 4
includes a forming portion 110, a first cutting portion 120, a
second cutting portion 130, a third cutting portion 140, the
expanding portion 150, and a separating portion 160. Each portion
is formed of one press working device.
[0032] As illustrated in FIGS. 3 and 4, the forming portion 110
forms, in a position P1 that is on one side (upper side in FIG. 3)
of the workpiece W1 in the Y direction (perpendicular direction)
and where the hole 11 into which the support shaft 3 is inserted is
formed, a precursor hole 11A, which is smaller than the hole 11,
and forms a positioning hole H in a position P2 that is on another
side (lower side in FIG. 3) in the Y direction. The forming portion
110 is, for example, a publicly known piercing die for hole
making.
[0033] The first cutting portion 120 cuts out a first end P3 at one
end (upper end in FIG. 3) of a boundary portion B between the
adjacent workplaces W1, W2 in the Y direction to form a notched
portion N, and cuts out a first unnecessary portion P4 that is
provided on the side of the positioning hole H facing the notched
portion N and follows the shape of the brake pedal 4. The first
cutting portion 120 includes a publicly known notching die for
cutting out the first end P3 to form the notched portion N, and a
publicly known piercing die for cutting out the first unnecessary
portion P4. As illustrated in FIG. 4, it is preferable that the
notched portion N be formed to be longer in the Y direction than in
the X direction.
[0034] The second cutting portion 130 forms the hole 11 in a
vicinity P5 of the position where the precursor hole 11A formed
formed by the forming portion 110 and cuts out a second end P6 that
is provided at another end (lower end in FIG. 3) in the Y direction
and follows the shape of the brake pedal 4. The second cutting
portion 130 includes a publicly known piercing die for forming the
hole 11 and a publicly known notching die for cutting out the
second end P6.
[0035] The third cutting portion 140 cuts out a second unnecessary
portion P7 that surrounds the positioning hole H, is provided
between the first unnecessary portion P4 and the second end P6, and
follows the shape of the brake pedal 4. The third cutting portion
140 is, for example, a publicly known notching die.
[0036] As illustrated in FIG. 5, the expanding portion. 150 presses
the pressurized portion P8 provided in the plane of the workpiece
W5 from both sides in the Z direction (thickness direction) to
expand the X-directional width of the workpiece W5. Pressing from
both sides in the Z direction shifts the center of gravity to the
center in the thickness direction. As illustrated in FIG. 5, the
expanding portion 150 includes an upper expanding portion 151 and a
lower expanding portion 152. When the expanding portion 150 presses
the pressurized portion P8, as illustrated in FIG. 4, the
X-directional width of the workpiece W5 is expanded from a first
width X1 to a second width X2. The pressurized portion P8 is
extended such that both ends of the pressurized portion P8 exceed a
width L1 extending along the Y direction of the boundary portion B
when viewed from the X direction. In addition, the pressurized
portion P8 is formed along a direction crossing the X direction. In
addition, the recess 13 is formed on the portion where the
pressurized portion P8 is pressed. As described above, because the
pressurized portion P8 is extended long in the Y direction, when
the pressurized portion P8 is pressurized, the X-directional width
of the brake pedal 4 can be expanded substantially uniformly along
the Y direction in line with the shape of the pressurized portion
P8.
[0037] The separating portion 160 cuts off the workpiece W6 having
an expanded X-directional width from the processed material M. The
separating portion 160 is, for example, a publicly known notching
die.
[0038] A configuration of the manufacturing apparatus 100 for the
brake pedal 4 is described below in more detail with reference to
FIGS. 6 and 7.
[0039] As illustrated in FIG. 6, the manufacturing apparatus 100
for the brake pedal 4 includes an upper die 100U and a lower die
100L.
[0040] The upper die 100U includes a movable portion 101U, an upper
die support plate 102U, and six upper die plates 103U, 104U, 105U,
106U, 107U, 108U.
[0041] The lower die 100L includes a stationary portion 101L, a
lower die support plate 102L, and six lower die plates 103L, 104L,
105L, 106L, 107L, 108L.
[0042] The movable portion 101U is provided on the uppermost side
of the upper die 100U. The movable portion 101U is configured to be
movable in an up-and-down direction of FIG. 6 (see the arrow in
FIG. 6).
[0043] The upper die support plate 102U is fixedly provided on a
lower side of the movable portion 101U.
[0044] The six upper die plates 103U, 104U, 105U, 106U, 107U, 108U
are separated from one another by a predetermined distance in the X
direction and are fixedly provided on a lower side of the upper die
support plate 102U.
[0045] The forming portion 110 is fixed to a lower side of the
upper die plate 103U. The first cutting portion 120 is fixed to a
lower side of the upper die plate 104U. The second cutting portion
130 is fixed to a lower side of the upper die plate 105U. The third
cutting portion 140 is fixed to a lower side of the upper die plate
106U. The expanding portion 150 is fixed to a lower side of the
upper die plate 107U. The separating portion 160 is fixed to a
lower side of the upper die plate 108U.
[0046] The upper die plate 106U to which the third cutting portion
140 is fixed and the upper die plate 107U to which the expanding
portion 150 (upper expanding portion 151) is fixed axe coupled by a
biasing member 109A. In addition, the upper die plate 107U to which
the expanding portion 150 (upper expanding portion 151) is fixed
and the upper die plate 108U to which the separating portion 160 is
fixed are coupled by a biasing member 109B.
[0047] The stationary portion 101L is provided on the lowermost
side of the lower die 100L.
[0048] The lower die support plate 102L is fixedly provided on an
upper side of the stationary portion 101L.
[0049] The six lower die plates 103L, 104L, 1051, 106L, 107L, 108L
are separated from one another by a predetermined distance in the X
direction and are fixedly provided on an upper side of the lower
die support plate 102L.
[0050] The forming portion 110 is fixed to an upper side of the
lower die plate 103L. The first cutting portion 120 is fixed to an
upper side of the lower die plate 104L. The second cutting portion
130 is fixed to an upper side of the lower die plate 105L. The
third cutting portion 140 is fixed to an upper side of the lower
die plate 106L. The expanding portion 150 is fixed to an upper side
of the lower die plate 107L. The separating portion 160 is fixed to
an upper side of the lower die plate 108L.
[0051] The lower die plate 106L to which the third cutting portion
140 is fixed and the lower die plate 107L to which the expanding
portion 150 (lower expanding portion 152) is fixed are coupled by a
biasing member 109C. In addition, the lower die plate 107L to which
the expanding portion 150 (lower expanding portion 152) is fixed
and the lower die plate 108L to which the separating portion 160 is
fixed are coupled by a biasing member 109D.
[0052] The biasing members 109A, 109B, 109C, 109D adjust the
position of pressing to perform positioning depending on the
expansion of the X-directional width of the workpiece W5 by the
expanding portion 150.
[0053] In addition, as illustrated in FIG. 7, guide pins 111U
extending downward in FIG. 7 are fixedly provided on the upper die
plate 107U. In addition, through-holes 111L through which the guide
pins 111U are inserted are formed on the lower die plate 107L. The
guide pins 111U are inserted into the through-holes 111L to correct
the positions of the upper die 100U and the lower die 100L.
[0054] In addition, as illustrated in FIG. 7, a locator pin 112U is
provided on the upper expanding portion 151. The locator pin 112U
is inserted into the hole 11 of the workplace W5 to correct the
positions of the upper die plate 107U, the lower die plate 107L,
and the workpiece W5.
[0055] As with the upper die plate 107U, guide pins are provided on
the upper die plates 103U, 104U, 105U, 106U, 108U. In addition, as
with the expanding portion 150, locator pins are provided on the
forming portion 110, the first cutting portion 120, the second
cutting portion 130, the third cutting portion 140, and the
separating portion 160.
[0056] Next, a procedure of manufacturing the brake pedal 4
according to the present embodiment is described with reference to
FIG. 8.
[0057] The manufacturing method for the brake pedal 4 according to
the present embodiment includes a forming process S01, a first
cutting process S02, a second cutting process S03, a third cutting
process S04, an expanding process S05, and a separating process
S06. The processes are simultaneously performed by the upper die
100U and the lower die 100L.
[0058] First, in the forming process S01, by the forming portion
110, in the position P1 that in on one side of the workpiece W1 in
the Y direction and where the hole 11 into which the support shaft
3 is inserted is formed, the precursor hole 11A, which is smaller
than the hole 11, is formed, and the positioning hole H is formed
in the position P2 that is on the other side in the Y
direction.
[0059] Next, in the first cutting process S02, by the first cutting
portion 120, the first end P3 at one end of the boundary portion B
between the adjacent workpieces W1, W2 in the Y direction is cut
out to form the notched portion N, and the first unnecessary
portion P4 that is provided on the side of the positioning hole H
facing the notched portion N and follows the shape of the brake
pedal 4 is cut out.
[0060] Next, in the second cutting process S03, by the second
cutting portion 130, the hole 11 is formed in the vicinity P5 of
the position where the precursor hole 11A is formed by the forming
portion 110, and the second end P6 that is provided at the other
end in the Y direction and follows the shape of the brake pedal 4
is cut out.
[0061] Next, in the third cutting process S04, by the third cutting
portion 140, the second unnecessary portion P7 that surrounds the
positioning hole H, is provided between the first unnecessary
portion P4 and the second end P6, and follows the shape of the
brake pedal 4 is cut out.
[0062] Next, in the expanding process S05, by the expanding portion
150, the pressurized portion P8 provided in the plane of the
workpiece W5 is pressed from both sides in the Z direction to
expand the X-directional width of the workpiece W5. In the
expanding process S05, it is preferable that the workpiece W5 be
pressed in a position different from that of the clevis hole 12.
When the workpiece W5 is thus pressed in a position different from
that of the clevis hole, the thickness of a portion where the
clevis hole 12 that becomes a highly stressed portion during pedal
operation is formed is not reduced, and therefore the brake pedal 4
having increased reliability can be provided.
[0063] Next, in the separating process S06, by the separating
portion 160, the workpiece W6 having an expanded X-directional
width is cut off from the processed material M.
[0064] In the expanding process S05, the X-directional width of the
workpiece W5 is expanded. The upper die 100U and the lower die 100L
are provided with the biasing members 109A, 109B, 109C, 109D.
Therefore, depending on the expansion of the X-directional width of
the workpiece W5, the upper die plates 106U, 107U, 108U and the
lower die plates 106L, 107L, 108L are moved by the biasing members
109A, 109B, 109C, 109D so that the locator pins 112U are inserted
into the holes 11.
[0065] The brake pedal 4 is manufactured by the series of
procedures described above.
[0066] As described above, the manufacturing method for the brake
pedal 4 according to the present embodiment is a manufacturing
method for the brake pedal 4 for manufacturing by a progressive
press working method in which the long-shaped processed material M
for which the blank layout is set such that the feed bridge width,
which is a separation distance between the workpieces W that are
contiguously adjacent in the X direction, is zero is intermittently
fed at a constant pitch in the X direction and is simultaneously
pressed in a plurality of positions in the X direction. The
manufacturing method for the brake pedal 4 includes the expanding
process S05 of pressing the pressurized portion P8 provided in the
plane of the workpiece W5 in the Z direction to expand the
X-directional width of the workpiece W5 and the separating process
S06 of cutting off the workpiece W6 having an expanded
X-directional width from the processed material M. By this
manufacturing method, in the expanding process S05, the workpiece
W5 is expanded to a desired width. Thus, as compared with the case
where the X-directional width is preset to a desired width, the
material yield can be increased further. Thus, the manufacturing
method for the brake pedal 4 that can further increase the material
yield can be provided.
[0067] In addition, the position of pressing is adjusted to perform
positioning depending on the expansion of the X-directional width
of the workpiece W5 in the expanding process S05. Therefore, the
press working can be performed precisely.
[0068] In addition, the pressurized portion P8 is pressurized from
both sides in the Z direction in the expanding process S05.
Therefore, the center of gravity can be shifted to the center in
the thickness direction, and the workpiece W5 can be further
expanded in the X direction.
[0069] In addition, the Y-directional length of the processed
material M is the same as the length of the Y-directional component
of the brake pedal 4. Therefore, the material yield can be
increased further.
[0070] In addition, the manufacturing method further includes,
prior to the expanding process S05, the forming process S01 of
forming, in the position P1 that is on one side of the workpiece W1
in the Y direction and where the hole 11 into which the support
shaft 3 is inserted is formed, the precursor hole 11A, which is
smaller than the hole 11, and forming the positioning hole H in the
position P2 that is on the other side in the Y direction, the first
cutting process S02 of cutting out the first end P3 at one end of
the boundary portion B between the adjacent workpieces W1, W2 in
the Y direction to form the notched portion N and cutting out the
first unnecessary portion P4 that is provided on the side of the
positioning hole H facing the notched portion N and follows the
shape of the brake pedal 4, the second cutting process S03 of
forming the hole 11 in the vicinity P5 of the position where the
precursor hole 11A is formed in the forming process S01 and cutting
out the second end P6 that is provided at the other end in the Y
direction and follows the shape of the brake pedal 4, and the third
cutting process S04 of cutting out the second unnecessary portion
P7 that surrounds the positioning hole H, is provided between the
first unnecessary portion P4 and the second end P6, and follows the
shape of the brake pedal 4. Therefore, the brake pedal 4 can be
manufactured more reliably.
[0071] In addition, the pressurized portion P8 is extended such
that both ends of the pressurized portion P8 in the Y direction
exceed the width L1 extending along the Y direction of the boundary
portion B when viewed from the X direction. Therefore, when the
pressurized portion P8 is pressurized, the X-directional width of
the brake pedal 4 can be expanded substantially uniformly along the
Y direction in line with the shape of the pressurized portion
P8.
[0072] In addition, the notched portion N is formed to be longer in
the Y direction than in the X direction. Therefore, in the
expanding process S05, the effect of extension in the X direction
is increased with respect to the pressurized portion P8, enabling
easier expansion in the X direction.
[0073] In addition, the pressurized portion P8 is formed along a
direction crossing the X direction. Therefore, the X-directional
width of the brake pedal 4 can be expanded substantially uniformly
along the Y direction in line with the shape of the pressurized
portion P8.
[0074] In addition, as described above, the manufacturing apparatus
100 for the brake pedal 4 according to the present embodiment is
the manufacturing apparatus 100 for the brake pedal 4 for
manufacturing by a progressive press working method in which the
long-shaped processed material M for which the blank layout is set
such that the feed bridge width, which is a separation distance
between the workpieces W that are contiguously adjacent in the X
direction, is zero is intermittently fed at a constant pitch in the
X direction and is simultaneously pressed in a plurality of
positions in the X direction. The manufacturing apparatus 100
includes the expanding portion 150 for pressing the pressurized
portion P8 provided in the plane of the workpiece W5 in the Z
direction to expand the X-directional width of the workpiece W5,
and the separating portion 160 for cutting off the workpiece W6
having an expanded X-directional width from the processed material
M. With this manufacturing apparatus, the workpiece W5 can be
expanded to a desired width by the expanding portion 150. Thus, as
compared with the case where the width in the X direction is preset
to a desired width, the material yield can be increased further.
Thus, the manufacturing apparatus 100 for the brake pedal 4 that
can further increase the material yield can be provided.
[0075] In addition, the manufacturing apparatus 100 further
includes the biasing members 109A, 109B, 109C, 109D that adjust the
position of pressing to perform positioning depending on the
expansion of the X-directional width of the workpiece W5 by the
expanding portion 150. Thus, the press working can be performed
precisely.
[0076] In addition, the expanding portion 150 presses the
pressurized portion P8 from both sides in the Z direction. Thus,
the center of gravity can be shifted to the center in the thickness
direction, and the workpiece W5 can be further expanded in the X
direction.
[0077] In addition, the manufacturing apparatus 100 further
includes the forming portion 110 for forming, in the position P1
that is on one side of the workpiece W1 in the Y direction and
where the hole 11 into which the support shaft 3 is inserted is
formed, the precursor hole 11A, which is smaller than the hole 11,
and forming the positioning hole H in the position P2 that is on
the other side in the Y direction, the first cutting portion 120
for cutting out the first end P3 at one end of the boundary portion
B between the adjacent workpieces W1, W2 in the Y direction to form
the notched portion N and cutting out the first unnecessary portion
P4 that is provided on the side of the positioning hole H facing
the notched portion N and follows the shape of the brake pedal 4,
the second cutting portion 130 for forming the hole 11 in the
vicinity P5 of the position where the precursor hole 11A is formed
by the forming portion 110 and cutting out the second end P6 that
is provided at the other end in the Y direction and follows the
shape of the brake pedal 4, and the third cutting portion 140 for
cutting out the second unnecessary portion P7 that surrounds the
positioning hole H, is provided between the first unnecessary
portion P4 and the second end P6, and follows the shape of the
brake pedal 4. Thus, the brake pedal 4 can be manufactured more
reliably.
[0078] In addition, the pressurized portion P8 is extended such
that both ends of the pressurized portion P8 in the Y direction
exceed the width L1 extending along the Y direction of the boundary
portion B when viewed from the X direction. Thus, the X-directional
width of the brake pedal 4 can be expanded substantially uniformly
along the Y direction in line with the shape of the pressurized
portion P8.
[0079] In addition, the notched portion N is formed to be longer in
the Y direction than in the X direction. Therefore, in the
expanding process S05, the effect of extension in the X direction
is increased with respect to the pressurized portion P8, enabling
easier expansion in the X direction.
[0080] In addition, the pressurized portion P8 is formed along a
direction crossing the X direction. Therefore, the X-directional
width of the brake pedal 4 can be expanded substantially uniformly
along the Y direction in line with the shape of the pressurized
portion P8.
[0081] The present invention is not limited to the aforementioned
embodiment, but various changes may be made within the scope of the
claims.
[0082] For example, the aforementioned embodiment includes the
forming process S01, the first cutting process S02, the second
cutting process S03, and the third cutting process S04, but may not
include these processes.
[0083] In addition, according to the aforementioned embodiment, the
Y-directional length of the processed material H is the same as the
length of the Y-directional component of the brake pedal 4.
However, the present invention is not limited thereto. The
Y-directional length of the processed material H may be configured
to be longer than the length of the Y-directional component of the
brake pedal 4.
[0084] In addition, according to the aforementioned embodiment, the
pressurized portion P8 is provided between the hole 11 and the
first unnecessary portion P4 when viewed from the X direction.
However, the present invention is no limited thereto. The
pressurized portion P8 may be formed in any position in the plane
of the workpiece W5.
[0085] In addition, according to the aforementioned embodiment, the
notched portion N is formed to be longer in the Y direction than in
the X direction. However, the present invention is not limited
thereto. The notched portion N may be formed to be longer in the X
direction than in the Y direction.
[0086] In addition, according to the aforementioned embodiment, the
pressurized portion P8 is formed along a direction crossing the X
direction. However, the present invention is not limited thereto.
The pressurized portion P8 may be formed in any direction in the
plane of the workpiece W5.
[0087] In addition, in the aforementioned embodiment, the brake
pedal 4 is indicated as an example of the vehicular arm component,
but the present invention may similarly be applied to any vehicular
component having a long arm shape, e.g., a clutch pedal arm, and
may also be applied to a clutch pedal arm or a suspension arm.
EXAMPLE
[0088] The present invention is described below in more detail in
conjunction with an example. However, the present invention is not
limited thereto.
[0089] With regard to a processed material having thickness of 7 mm
an X-directional width of 280 mm, and a tensile strength of 440
MPa, as illustrated in FIG. 9, pressing was performed over an area
of 15 mm.times.110 mm in the area of the pressurized portion P8.
FIG. 10 is a graph illustrating a relationship between a pressing
force and an amount of expansion of the X-directional width. FIG.
11 is a graph illustrating a relationship between a pressing force
and an amount of reduction in thickness. FIG. 12 is a graph
illustrating a relationship between an amount of reduction in
thickness and an amount of expansion of the X-directional
width.
[0090] As illustrated in FIG. 10, the processed material was
pressed with a force of 200 t and expanded about 1.7 mm. In
addition, the processed material was pressed with a force of 300 t
and expanded about 4.1 mm. In addition, the processed material was
pressed with a force of 400 t and expanded about 4.3 mm.
[0091] In addition, as illustrated in FIG. 11, the processed
material was pressed with a force of 200 t, so that the thickness
was reduced about 0.8 mm. In addition, the processed material was
pressed with a force of 300 t, so that the thickness was reduced
about 1.7 mm. In addition, the processed material was pressed with
a force of 400 t, so that the thickness was reduced about 1.8
mm.
[0092] In addition, as illustrated in FIG. 12, as the thickness was
reduced about 0.8 mm, the width was expanded about 1.7 mm. In
addition, as the thickness was reduced about 1.7 mm, the width was
expanded about 4.1 mm. In addition, as the thickness was reduced
about 1.8 mm, the width was expanded about 4.3 mm.
[0093] According to the above example, pressing was found to
provide a predetermined amount of extension.
REFERENCE SIGNS LIST
[0094] 2: bracket
[0095] 3: support shaft
[0096] 4: brake pedal (vehicular arm component)
[0097] 5: pin
[0098] 6: rod
[0099] 11: hole
[0100] 11A: precursor hole
[0101] 100: manufacturing apparatus for brake pedal
[0102] 109A, 109B, 109C, 109D: biasing member
[0103] 110: forming portion
[0104] 120: first cutting portion
[0105] 130: second cutting portion
[0106] 140: third cutting portion
[0107] 150: expanding portion
[0108] 160: separating portion
[0109] B: boundary portion of workpiece
[0110] H: positioning hole
[0111] M: processed material
[0112] N: notched portion
[0113] P1: position where hole is formed
[0114] P2: position on another side in Y direction
[0115] P3: first end
[0116] P4: first unnecessary portion
[0117] P5: vicinity of position where precursor hole is formed
[0118] P6: second end
[0119] P7: second unnecessary portion
[0120] P8: pressurized portion
[0121] S01: forming process
[0122] S02: first cutting process
[0123] S03: second cutting process
[0124] S04: third cutting process
[0125] S05: expanding process
[0126] S06: separating process
[0127] W: workpiece
* * * * *