Method and apparatus for sheet forming a blank using a variable bead

• US 5,901,599 A
• Filed: 07/17/1996
• Issued: 05/11/1999
• Est. Priority Date: 07/18/1995
• Status: Expired due to Fees

• Current Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho (Toyota Motor Corporation), Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho (Toyota Motor Corporation), Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Nakamura, Shinichiro, Murata, Atsunobu, Sato, Akihito, Hosoe, Takashi
• Primary Examiner(s): Hail, III, Joseph J.
• Assistant Examiner(s): BUTLER, RODNEY ALLEN
• Application Number:
  US08/682,411
• Time in Patent Office: 1,028 Days
• Field of Search: 72/350, 72/351, 72/379.2, 72/352, 72/354.6, 72/356, 72/358, 72/359
• US Class Current: 72/350
• CPC Class Codes: B21D 22/22 with devices for holding the edge of the blanks B21D22/24 - B21D22/30 take precedence; shaping over a die without external former B21D11/02
• CPC Class Codes: B21D 24/04 Blank holders; Mounting means therefor

Abstract

A sheet forming method including the steps of: holding a blank between a blank holder and an opposing die so that wrinkling is prevented in the blank; and forming the blank to an objective shape with a punch, while imposing a force of a variable bead on the blank at a selected position in a point manner and only during a part of the entire forming period selectively. An apparatus for conducting the above method.

Claims

1. A method for sheet forming a blank using at least one variable point bead comprising the following steps of:

holding said blank between a blank holder and an opposing die so that wrinkling is essentially prevented in said blank;

forming said blank to an objective shape with a punch; and

selectively imposing separate individual point-like bead forces on said blank at selected positions through one or more variable point beads and only during a partial time period of said forming step,

wherein said variable point beads are not line beads.

2. A method according to claim 1, wherein during said holding step, said blank is further held between one or more fixed beads formed in at least one of said blank holder and/or said opposing die.

3. A method according to claim 1, wherein during said forming step, single-action sheet forming is conducted.

4. A method according to claim 1, wherein during said forming step, double-action sheet forming is conducted.

5. A method according to claim 1, wherein said blank is a substantially square flat plate during said holding step, and said blank is formed, during said forming step, to a member having a square shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the square shell, and wherein said forces of said one or more variable point beads are imposed on a portion of said flange adjacent a midpoint of each straight side of a square cross section of said square shell only during an early stage of said forming time period.

6. A method according to claim 1, wherein during said holding step said blank is a substantially square flat plate with four corners cut off, and said blank is formed, during said forming step, to a member having a square shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the square shell with said cut four corners of said blank corresponding to four corners of a square cross section of said square shell, and wherein said forces of said one or more variable point beads are imposed on a portion of said flange adjacent said four corners of said square cross section of said square shell more greatly during an early stage of said forming time period than during a later stage of said forming.

7. A method according to claim 1, wherein said blank is a substantially circular flat plate during said holding step, and said blank is formed, during said forming step, to a member having a cylindrical shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the cylindrical shell, and wherein said forces of said one or more variable point beads are imposed on a portion of said flange positioned on a diametrical line of a circular cross section of said cylindrical shell only during an early stage of said forming time period.

8. A method according to claim 1, wherein said blank is a substantially square flat plate during said holding step, and said blank is formed, during said forming step, to a member having a square shell at a central portion of the member with an end plate having a central square opening and a flat wall surrounding said central square opening, and a flat flange at a portion of the member surrounding the square shell at a central portion of the member, and wherein said forces of said one or more variable point beads are imposed on a portion of said flat wall of said end plate adjacent a midpoint of each straight side of said central square opening only during a later stage of said forming time period.

9. A method according to claim 1, wherein said blank is a substantially circular flat plate during said holding step, and said blank is formed, during said forming step, to a member having a cylindrical shell at a central portion of the member with an end plate having a central semispherical portion, and a flat wall surrounding said central semispherical portion, and a flat flange at a portion of the member surrounding the cylindrical shell, and wherein said forces of said one or more variable point beads are imposed on said flat wall of said end plate only during an early stage of said forming time period.

10. A method according to claim 1, wherein said variable point beads are shaped substantially circular and not in a pinpoint shape.

11. A method according to claim 2, wherein said blank is a substantially square flat plate during said holding step, and said blank is formed, during said forming step, to a member having a square shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the square shell, and wherein forces of said one or more fixed beads are imposed on a portion of said flange along each straight side of a square cross section of said square shell during all stages of said forming time period, and said forces of said one or more variable point beads are imposed on a portion of said flange adjacent a midpoint of said each straight side of said square cross section of said square shell only during an early stage of said forming time period.

16. An apparatus according to claim 11, wherein said variable point beads are shaped substantially circular and not in a pinpoint shape.

12. An apparatus for sheet forming a blank using at least one variable point bead comprising:

a blank holder and an opposing die for holding said blank therebetween so that wrinkling is essentially prevented in said blank;

a punch for forming said blank to an objective shape; and

one or more variable point beads for selectively imposing separate individual point-like bead forces on selected portions of said blank and during only a part of an entire forming time period,

wherein said variable point beads are not line beads.

13. An apparatus according to claim 12, further comprising one or more fixed beads formed in said blank holder and/or said opposing die.

14. An apparatus according to claim 12, wherein said apparatus includes a single-action press.

15. An apparatus according to claim 12, wherein said apparatus includes a double-action press.

17. An apparatus according to claim 13, wherein said one or more variable point beads are mounted to said blank holder and/or said opposing die, and said punch further comprises a cam surface, said cam surface being operatively coupled to each of said one or more variable point beads so that each of said one or more variable point breads is moved toward and away from said blank by said cam surface.

18. An apparatus according to claim 17, wherein said blank is formed from a substantially square flat plate to a member having a square shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the square shell, positions of said one or more variable point beads are selected so that said forces of said one or more variable point beads are imposed on portions of said flange adjacent a midpoint of each straight side of a square cross section of said square shell, and the operative coupling between each of said one or more variable point beads and said cam surface is selected so that said forces of said one or more variable point beads are imposed only during an early stage of said forming time period.

19. An apparatus according to claim 17, wherein said blank is formed from a substantially square flat plate to a member having a square shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the square shell, positions of said one or more fixed beads are selected so that forces of said one or more fixed beads are imposed on portions of said flange along each straight side of a square cross section of said square shell, positions of said one or more variable point beads are selected so that said forces of said one or more variable point beads are imposed on portions of said flange adjacent a midpoint of said each straight side of said square cross section of said square shell, and the operative coupling between each of said one or more variable point beads and said cam surface is selected so that said forces of said one or more variable point beads are imposed only during an early stage of said forming time period.

20. An apparatus according to claim 17, wherein said blank is formed from a substantially square flat plate with four corners cut off to a member having a square shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the square shell with said cut four corners of said blank corresponding to four corners of a square cross section of said square shell, positions of said one or more variable point beads are selected so that said forces of said one or more variable point beads are imposed on portions of said flange adjacent each of said four corners of said square cross section of said square shell, and the operative coupling between each of said one or more variable point beads and said cam surface is selected so that said forces of said one or more variable point beads are imposed more greatly during an early stage of said forming time period than during a later stage of said forming time period.

21. An apparatus according to claim 17, wherein said blank is formed from a substantially circular flat plate to a member having a cylindrical shell with an end plate at a central portion of the member and a flat flange at a portion of the member surrounding the cylindrical shell, positions of said one or more variable point beads are selected so that said forces of said one or more variable point beads are imposed on portions of said flange positioned on a diametrical line of a circular cross section of said cylindrical shell, and the operative coupling between each of said one or more variable point beads and said cam surface is selected so that said forces of said one or more variable point beads are imposed only during an early stage of said forming time period.

22. An apparatus according to claim 17, wherein said blank is formed from a substantially square flat plate to a member having a square shell at a central portion of the member with an end plate having a central square opening and a flat wall surrounding said central square opening, and a flat flange at a portion of the member surrounding the square shell, positions of said one or more variable point beads are selected so that said forces of said one or more variable point beads are imposed on portions of said flat wall of said end plate adjacent a midpoint of each straight side of said central square opening, and the operative coupling between each of said one or more variable point beads and said cam surface is selected so that said forces of said one or more variable point beads are imposed only during a later stage of said forming time period.

23. An apparatus according to claim 15, wherein said blank is formed from a substantially circular flat plate to a member having a cylindrical shell at a central portion of the member with an end plate having a central semispherical portion and a flat wall surrounding said central semispherical portion, and a flat flange at a portion of the member surrounding the cylindrical shell, positions of said one or more variable point beads are selected so that said forces of said one or more variable point beads are imposed on said flat wall of said end plate, and the operative coupling between each of said one or more variable point beads and said cam surface is selected so that said forces of said one or more variable point beads are imposed only during an early stage of said forming time period.