JP2004090055A - Layered resin die for press working and method for manufacturing it - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a layered resin die for press working with which manufacturing man-hours and the number of components are extremely reduced and a manufacturing method of it. <P>SOLUTION: The layered resin die 35 has a punch die 37 and die mold 36 which are respectively formed from a resin material having physical characteristics required for the press working of a relatively soft metallic sheet and at least either of the punch die 37 and the die mold 36 is composed by attachably/detachably layering a plurality of the partial dies 38-41 respectively having internal shapes 38a, 39a, 40a, 41a corresponding to the plurality of partial shapes of a product mutually attachably and detachably which are obtained by dividing the shape of a product by a plurality of virtual planes. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated resin mold for press working and a method for producing the same, and more particularly, for example, a laminated resin mold for press working used to press a relatively soft metal plate such as an aluminum plate, and a method for producing the same. About.
[0002]
[Prior art]
BACKGROUND ART In manufacturing covers that are mounted on an exhaust manifold (hereinafter, referred to as an exhaust manifold) of an internal combustion engine and perform heat insulation and sound absorption, conventionally, steel plates such as aluminum-plated steel plates are used as materials. Such a steel sheet is formed into a product by pressing with a mold having a shape corresponding to the shape of the cover designed to cover the outer shape of the exhaust manifold.
[0003]
The production of sheet metal products using such a mold is widely known as an economical production method suitable for mass-producing products having relatively complicated shapes. On the other hand, in a manufacturing method using such a mold, large-scale manufacturing equipment including a large-sized cutting machine is required when manufacturing the mold, and a great amount of cutting time and labor are required. There is a problem that it becomes up. It is also known as a problem that a great deal of trouble and time are required for changing the shape of a mold accompanying a change in product design.
[0004]
On the other hand, based on three-dimensional CAD (computer-aided design) data (hereinafter abbreviated as data) relating to a product, a laminating die technology for manufacturing a die by cutting a metal plate into a required planar shape and sequentially laminating the metal plates has been developed. Recently developed. According to this conventional technique, it is possible to greatly reduce the time for manufacturing a mold as compared with the conventional technique for cutting a metal lump.
[0005]
[Problems to be solved by the invention]
FIG. 19 is a cross-sectional view for explaining a problem of the prior art of the lamination mold technology. As shown in FIG. 19, in the mold of the related art, a step is generated for each metal plate of each layer. For this reason, there is a problem that the step between the punch die A and the die die B sandwiches the material C, and prevents plastic deformation of the material at the time of pressing, that is, the flow of the material.
[0006]
On the other hand, Japanese Patent Application Laid-Open No. Hei 9-150228 discloses that, when a metal plate is cut into a required planar shape based on three-dimensional CAD data and laminated sequentially to produce a laminated mold, steps for each layer are removed by cutting or the like. A technique for performing this is disclosed. However, it takes a lot of time to completely remove the step by cutting or the like. In particular, when the generated step is large, the time for removing the step becomes longer. Therefore, according to this method, in order to facilitate processing at the time of manufacturing, it is necessary to reduce the thickness of the metal plates to be laminated, and the number of metal plates increases, the number of parts increases, and Inconvenience that the time required for cutting the metal plate is increased.
[0007]
Such a problem also occurs when dealing with a design change that often occurs when designing and manufacturing a laminated mold. If a design change occurs in a predetermined portion of the laminated mold once manufactured, it is necessary to cut the portion including the portion again. Since this cutting process is a metal cutting process, there is a problem that a great deal of labor and time are required.
[0008]
The present invention has been made to solve the above problems, and an object of the present invention is to provide a laminated resin mold for press working in which the number of manufacturing steps and the number of parts are significantly reduced, and a method for manufacturing the same. .
[0009]
[Means for Solving the Problems]
The laminated resin mold for press working according to claim 1 is a laminated resin mold for press working used for pressing a relatively soft metal plate, and has physical properties capable of pressing a metal plate. It has a punch for press working and a die for press working, each formed from a resin material, and at least one of the punch for press working and the die for press working has a product shape in a plurality of virtual planes. A plurality of partial resin molds each having a shape corresponding to the plurality of partial product shapes obtained by division are stacked so as to be detachable from each other.
[0010]
The method for producing a laminated resin mold for press working according to claim 2 is a method for producing a laminated resin mold for press working used for press-forming a relatively soft metal plate. A step of determining the number of lamination stages of a plurality of partial resin molds each having a shape corresponding to a plurality of partial product shapes obtained by dividing the plane, and based on the three-dimensional product shape data, a plurality of partial resin mold shape data The step of creating, based on each partial resin mold shape data, the step of processing a resin material having physical properties capable of pressing a metal plate to form a plurality of partial resin molds, each partial resin mold, Forming a laminated resin mold for press working by removably laminating each other.
[0011]
The method for manufacturing a laminated resin mold for press working according to claim 3 is a method for manufacturing a laminated resin mold for press working used for pressing a relatively soft metal plate, wherein a plurality of virtual shapes are formed. A step of determining the number of lamination stages of a plurality of partial resin molds each having a shape corresponding to the plurality of partial product shapes obtained by dividing the plane, and forming the laminated resin mold shape data for press working based on the three-dimensional product shape data The step of creating and laminating resin materials having physical properties capable of pressing a metal plate in a mutually detachable manner and corresponding to each resin mold, based on the laminated resin mold shape data for press working Processing step.
[0012]
[Operation]
Since the laminated resin mold for press working according to claim 1 is formed by laminating partial resin molds made of a synthetic resin material, if the material to be pressed is a relatively soft type, the hardness of the resin material is increased. By appropriately selecting physical properties such as heat resistance and durability, the laminated resin mold for press working is sufficiently useful in terms of workability in press working and durability of the mold accompanying use.
[0013]
Since the laminated resin mold for press working of the present invention is formed from a synthetic resin material used for a normal resin mold, the need to cut a metal lump as in the case of manufacturing a mold is eliminated. It is easy to manufacture.
[0014]
Further, each partial resin mold of the laminated resin mold for press working of the present invention is formed so as to have a shape corresponding to a plurality of partial product shapes relating to a product. As described above, since the material is formed of a synthetic resin material, the operation of forming the partial product shape of the partial resin mold can be realized much more easily than the mold. Therefore, as in the case of the laminated mold, the necessity of reducing the thickness of the plate in order to minimize the level difference between the laminated stages is eliminated. Therefore, the situation in which the number of stacked layers increases is eliminated, and the configuration can be simplified and the number of components can be reduced.
[0015]
Further, the laminated resin mold for press working of the present invention can be divided into respective partial resin molds. Therefore, when a design change occurs, repair work such as processing and replacement needs to be performed only on the required partial resin mold, and the number of work steps is significantly reduced as compared with the case of the mold. Further, the repair work and the new creation work of the partial resin mold are also facilitated by the above-mentioned material characteristics.
[0016]
The work of forming the partial product shape of the partial resin mold may be performed when the partial resin shape is formed on the partial resin mold and then laminated to form a laminated resin mold for press working, or the resin material may be formed into each partial resin mold. In the case of forming the laminated resin mold for press working after lamination corresponding to the above, the working is similarly easy. As a result, in each case, the number of manufacturing steps including the above-described design change can be significantly reduced as compared with the case of using a mold.
[0017]
In the method for manufacturing a laminated resin mold for press working according to claim 2, first, a plurality of partial resin molds are formed, and then the obtained partial resin molds are laminated to form a laminated resin mold for press working. Things.
[0018]
Therefore, according to the present invention, as described above, the necessity of cutting a metal lump is eliminated, so that the manufacturing process is simplified. In addition, since the laminated resin mold for press working of the present invention can be divided into respective partial resin molds, in response to circumstances such as design changes, repairs such as processing and replacement of only the required partial resin molds. Work only needs to be performed, and man-hours for repair and alteration work are significantly reduced. Further, in the present invention, the operation of forming a plurality of partial product shapes of each of the partial resin molds is remarkably easily realized because the material is made of a synthetic resin material.
[0019]
In the present invention, since the laminated resin mold for press working is formed by laminating the partial resin molds having the partial product shape, the processing is easy. As a result, it is possible to significantly reduce the number of manufacturing steps including the response to a design change.
[0020]
According to a third aspect of the present invention, there is provided a method for manufacturing a laminated mold, comprising: laminating resin materials corresponding to a plurality of partial resin molds; and laminating the laminated resin materials based on shape data of the laminated resin mold for press working. It is processed into a resin mold.
[0021]
Therefore, according to the present invention, as described above, the necessity of cutting a metal lump is eliminated, so that the manufacturing process is simplified. In addition, since the laminated resin mold for press working of the present invention can be divided into respective partial resin molds, in response to circumstances such as design changes, repairs such as processing and replacement of only the required partial resin molds. Work only needs to be performed, and man-hours for repair and alteration work are significantly reduced. Further, in the present invention, the operation of forming a plurality of partial product shapes of each of the partial resin molds is remarkably easily realized because the material is made of a synthetic resin material.
[0022]
In the present invention, since the resin material is laminated corresponding to each of the partial resin molds, and processed based on the shape data of the laminated resin mold for press working to produce the laminated resin mold for press working, the processing accuracy is significantly improved. be able to. Further, the processing is easier than the cutting processing of the mold. As a result, it is possible to significantly reduce the number of manufacturing steps including the response to a design change.
[0023]
BEST MODE FOR CARRYING OUT THE INVENTION
The present invention will be described below with reference to examples.
[0024]
1 to 18 show an embodiment of the present invention.
[0025]
FIG. 1 is a front view of a laminated resin mold for press working 35 according to an embodiment of the present invention, and FIG. 2 is a plan view of a die for press working (hereinafter, die mold) 36 included in the laminated resin mold for press working 35. FIG. 3 is a front view of a die 36, FIG. 4 is a plan view of a punch for press working (hereinafter, punch) 37, and FIG. 5 is a front view of the punch 37. 6 is a side view of a punch die 37, and FIG. 7 shows a state in which the cover 1, which is a product formed by press working using the laminated resin mold 35 for press working of the present embodiment, is attached to the exhaust manifold 3. FIG. 8 is a front view, FIG. 8 is a sectional view taken along section line X8-X8 in FIG. 7, FIG. 9 is a plan view of the cover 1, FIG. 10 is an enlarged perspective view of the cover 1, and FIG. FIG. 12 is an enlarged plan view of the cover 1, and FIG. 12 is a sectional view taken along the line X12-X12 in FIG. FIG. 13 is a cross-sectional view taken along section line X13-X13 in FIG. 11, FIG. 14 is a cross-sectional view taken along section line X14-X14 in FIG. 11, and FIG. FIG. 16 is a simplified cross-sectional view taken along section line X15-X15 of FIG. 1, FIG. 16 is a diagram for explaining features of the present embodiment, and FIG. 17 is a process diagram for explaining a manufacturing process of the cover 1. FIG. 18 is a process diagram illustrating a manufacturing process of another embodiment of the cover 1.
[0026]
(1) Outline of cover 1
Hereinafter, an outline of the cover 1 as a product will be described with reference to FIGS.
[0027]
Exhaust manifolds (hereinafter referred to as "exhaust manifolds") 3 of an internal combustion engine such as an automobile engine 2 pass through the combustion chamber of the internal combustion engine at a high temperature of, for example, 600 to 700 [deg.] C. at a frequency of several thousand cycles per minute. Therefore, the exhaust manifold 3 itself becomes high temperature and becomes a heat source that generates high-temperature heat radiation, and also becomes a sound source and a vibration source that dissipates noise caused by fuel combustion noise in the engine 2 to the outside.
[0028]
In this embodiment, in order to suppress such high-temperature heat radiation and noise from the exhaust manifold 3 as much as possible, a cover 1 having a configuration described later is installed so as to cover the exhaust manifold 3. As shown in FIG. 8 and FIG. 10, the cover 1 of this embodiment includes a pair of metal plates (for example, NIMBUS manufactured by T & N Corporation) 4 and 5 made of an aluminum alloy having a specific gravity of about 2.7, A heat-resistant sound-absorbing material (hereinafter, sound-absorbing material) 6 made of inorganic fibers and the like sandwiched between metal plates 4 and 5 is laminated.
[0029]
As shown in FIGS. 7 to 9 and 15, the cover 1 is formed in a three-dimensional shape along the external shape of the exhaust manifold 3, and includes a side wall T 1 and a top part T 2 connecting the entire periphery of the end of the side wall T 1. Have. The side wall T1 and the top T2 are connected at an obtuse angle θ. In this embodiment, the metal plates 4 and 5 include an aluminum foil or an aluminum alloy foil, and a thin plate made of aluminum or an alloy thereof.
[0030]
As shown in FIGS. 9 to 14, the metal plates 4 and 5 used for the cover 1 of the present embodiment have a plurality of wavy shapes 9 in which raised portions 7 and valley portions 8 are alternately repeated. It has a shape extending along the direction A1 and continuing along a direction intersecting the first direction A1 at an acute angle, preferably a second direction A2 which is preferably a direction orthogonal to the first direction A1. As shown in FIGS. 11 to 13, the first raised portions 10 and the second raised portions 11 are alternately arranged along the longitudinal direction of the raised portions 7 from the valley portions 8. In the valley portion 8, flat portions 12 and concave portions 13 are alternately arranged as shown in FIGS.
[0031]
The first upright portion 10 includes a pair of side walls 14 and 15 rising from the valley 8 in a substantially trapezoidal shape, and a relatively flat top 18 formed by connecting the tips of the side walls 14 and 15 to each other. It is composed of The first upright portion 10 is bent inward, and the tip portion of the first upright portion 10 is wider than the base end portion.
[0032]
On the other hand, the second upright portion 11 is formed by crushing the first upright portion 10 in the width direction by a predetermined degree, and a pair of side walls 19, 20 rising from the flat portion 12, respectively. The distal ends are connected to each other, and include a concave recess 23 on the lower side in FIG. Each of the second upright portions 11 and the concave portions 13 is intermittently continuous along a second direction A2 which is a direction substantially orthogonal to the first direction A1 which is a direction in which the plurality of waveforms 9 extend. It is formed as follows.
[0033]
Therefore, as shown in FIGS. 12 and 13, the protruding portion of the raised portion 7 of the metal plate 5 fits into the inwardly curved inner peripheral portion of the raised portion 7 of the metal plate 4. Also in the second upright portion 11, the side walls 19 and 20 are wider at the distal end than at the proximal end and are formed in an inwardly curved shape. Even in such a second upright portion 11, the protruding portion of the second upright portion 11 of the metal plate 5 fits into the inwardly curved inner peripheral portion of the second upright portion 11 of the metal plate 4. Thereby, the metal plates 4 and 5 can be firmly fixed to each other without using any special fixing tool or fastener. This mutual fixing is also performed firmly even when the sound absorbing material 6 made of inorganic fiber or the like is interposed between the metal plates 4 and 5. This is because the mutual connection of the metal plates 4 and 5 depends on the mechanical engagement between them.
[0034]
The cover 1 has such a shape, and is formed by pressing the metal plates 4 and 5 sandwiching the sound absorbing material 6 into a three-dimensional shape along the outer shape of the exhaust manifold 3.
[0035]
At the outer peripheral portion of the side wall T1 of the cover 1 formed in a three-dimensional shape, a flange 28 is formed in which the corrugated shape is fully bent, and the flange 28 is folded inside the cover 1 to form a folded portion 29. You. When the folded portion 29 is not formed, the outer peripheral portion of the cover 1 is in a state where the sharp cut ends of the blanked metal plates 4 and 5 are directly exposed to the outside. Therefore, in the process of assembling the cover 1 to the exhaust manifold 3 of the vehicle engine 2 in the manufacturing process of the vehicle, the folded portion 29 is used by an assembling worker working with the cover 1 or maintenance of the vehicle after manufacturing. In this case, a worker or a general user who may have the cover 1 does not injure his / her finger.
[0036]
(2) Features of cover 1
Hereinafter, one of the features of the cover 1 of the present embodiment will be described with reference to FIG. Since the cover 1 of this embodiment is formed in a three-dimensional shape along the three-dimensional appearance of the exhaust manifold 3 as described above, the cover 1 has a metal plate as shown in FIGS. One or a plurality of ridge-line-equivalent portions 30 that are the four or five bent portions are formed. In the present embodiment, the metal plates 4, 5 and 5 are arranged such that the first direction A <b> 1 which is the longitudinal direction of the corrugated shape 9 intersects with the main ridge line equivalent part 30 among the plurality of ridge line equivalent parts 30. Is pressed into a three-dimensional shape.
[0037]
Here, the main ridge line equivalent portion 30 is a portion where a relatively large curvature that characterizes the overall shape of the cover 1 continues. In other words, among various large and small bent portions formed on the cover 1, it refers to a bent portion that extends over a relatively long dimension that substantially determines the external shape of the cover 1. When the cover 1 is attached to the exhaust manifold 3, the cover 1 also vibrates due to the transmission of vibration from the exhaust manifold 3. When the cover 1 vibrates due to this vibration, the parts of the cover 1 on both sides of the main ridgeline equivalent part 30 vibrate so as to flutter. When such vibration is generated, a portion near the ridge line equivalent portion 30 of the cover 1 repeatedly bends to cause metal fatigue, thereby easily causing a crack.
[0038]
On the other hand, in the present embodiment, the first direction A1 of the plurality of corrugated shapes 9 formed on the cover 1 is a direction that intersects the main ridge line equivalent portion 30, and is preferably a direction that is orthogonal to the main ridge line equivalent portion 30. Therefore, the corrugated shape 9 realizes the action of the rib against the vibration centered on the ridge line equivalent portion 30. Thereby, the vibration of the cover 1 can be suppressed, the occurrence of cracks in the cover 1 can be prevented, and the quality of the cover 1 can be significantly improved.
[0039]
11 to 13 that intermittently extend along the second direction A2 and continue along the first direction A1 with respect to vibration generated along the direction in which the ridge line-equivalent portion 30 extends. The second upright portion 11 also realizes the function of a rib and suppresses vibration.
[0040]
(3) About the laminated resin mold 35 for press working
Hereinafter, the laminated resin mold 35 used for manufacturing the cover 1 will be described with reference to FIGS. As the laminated resin mold 35, a die mold 36 shown in FIGS. 1 to 3 and a punch mold 37 shown in FIGS. 1 and 4 to 6 are used in combination as shown in FIG.
[0041]
The inventor of the present invention states that the laminated resin mold 35 can use a mold resin material conventionally used as a model mold material or a trial mold material under a predetermined condition for press working for mass production. It is based on the new knowledge of One of the conditions is that the material to be pressed is a relatively soft aluminum material described above as an example, and the other condition is that the laminated resin mold 35 is made of a synthetic resin material capable of plastically deforming the aluminum material ( For example, RS450 manufactured by Bantico Co., Ltd. is used. As long as such conditions are satisfied, the type of the material to be pressed and the material of the laminated resin mold 35 are not limited.
[0042]
The die mold 36 of the present embodiment has a four-layer structure in which partial molds 38, 39, 40, and 41, which are partial resin molds, are laminated in this order. Each of the partial molds 38 to 41 has an outer shape of a plurality of partial products obtained by dividing the three-dimensional cover 1 shown in FIGS. 7 to 10 by a virtual plane corresponding to the boundary of each of the partial molds 38 to 41. It has a corresponding three-dimensional concave internal shape 38a, 39a, 40a, 41a, respectively.
[0043]
The punch die 37 of the present embodiment has an outer shape 37a corresponding to the inner shape of the product. The punch die 37 of the present embodiment has, for example, an integral structure that does not have a laminated structure like the die die 36. This integrated structure is an example of the present invention. As a modification of the present invention, when the die 36 and the punch 37 are both of a laminated structure, the die 36 is of an integrated structure and the punch 37 is of a laminated structure. Some examples are also included. Each of these partial molds 38 to 41 is detachably fixed to each other by, for example, a fastening bolt 42 or the like.
[0044]
(4) Manufacturing method of laminated resin mold 35
Hereinafter, a preferred embodiment of a method for manufacturing a laminated resin mold 35 according to the present invention will be described with reference to the drawings.
[0045]
Hereinafter, description will be made with reference to FIGS. 1 to 6 and FIG. 17. In step a1 of FIG. 17, the number of layers of the laminated resin mold 35 is determined. The number of steps is determined by factors such as the depth of drawing of the product and the complexity of the 3D shape. In step a2, the mold data of the punch die 37 is created as processing data based on the 3D data of the product, and further, based on the 3D data of the product, the virtual division plane that has the number of steps determined in step a1 in the product shape is accumulated. Is set, and mold shape data for each of the partial molds 38 to 41 of the die mold 36 is created as processing data.
[0046]
In step a3, a work material, that is, a resin material that is a material of the laminated resin mold 35, is prepared for each of the punch mold 37 and each of the partial molds 38 to 41. In step a4, the punch die 37 is formed by performing resin processing based on the processing data of the punch die 37 created in step a2. In step a5, as an example, the lowermost partial mold 38 is machined based on the machining data on the partial molds 38 to 41 of the die mold 36 created in step a2. Thereafter, processing for forming the partial dies 38 to 41 by the required number of steps is performed. In the present embodiment, since the die 36 has four stages, four-stage partial dies 38 to 41 are created. In step a7, the partial molds 38 to 41 are set on a base (not shown), the partial molds 38 to 41 are fixed to each other using the fastening bolts 42, and the die mold 36 is fixed to the base. I do. Further, the punch die 37 is fixed to a similar base (not shown). Thus, the production of the laminated resin mold 35 is performed.
[0047]
(5) Modification of manufacturing method of laminated resin mold 35
The manufacturing method of the laminated resin mold 35 of the present invention is not limited to the above-described manufacturing method, and may be a manufacturing method as shown in the process diagram of FIG.
[0048]
Hereinafter, a modification of the manufacturing method of the present invention will be described with reference to FIG.
[0049]
In the step b1 of FIG. 18, the number of layers of the laminated resin mold 35 is determined as in the example of FIG. In step b2, based on the 3D data of the product, the mold data of the punch die 37 is created as processing data, and further, based on the 3D data of the product, the virtual division plane that has the number of steps determined in the step b1 in the product shape is accumulated. Is set, and mold shape data for each of the partial molds 38 to 41 of the die mold 36 is created as processing data.
[0050]
In step b3, a work material for the punch die 37, that is, a resin material that is a material of the laminated resin die 35 is prepared. In step b4, the resin is processed based on the processing data of the punch 37 created in step b2, and the punch 37 is created.
[0051]
In step b5, a work material, that is, a resin material that is a material of the laminated resin mold 35 is prepared for each of the partial molds 38 to 41 of the die mold 36, and these are laminated. In step a6, the entire die die 36 is processed based on the processing data of the die die 36 created in step b2.
[0052]
In step b7, the die 36 and the punch 37 are respectively set on the base, the partial dies 38 to 41 are fixed to each other using the fastening bolts 42 and the like, and the die 36 and the punch 37 are mounted on the base. Fixed to. Thus, the production of the laminated resin mold 35 is performed.
[0053]
(6) Effects of the embodiment
As described above, in the present embodiment, among the punch die 37 and the die die 36 of the laminated resin die 35, the die die 36 has a plurality of partial product shapes obtained by dividing the product shape by a plurality of virtual planes. A plurality of partial molds 38 to 41, each having a corresponding internal shape 38a, 39a, 40a, 41a, are stacked so as to be detachable from each other.
[0054]
As described above, the laminated resin mold 35 formed by laminating the partial molds 38 to 41 made of a resin material is used for pressing metal plates 4 and 5 made of an aluminum material which is a relatively soft material. Therefore, by appropriately selecting physical properties such as hardness and durability of the resin material as exemplified in the examples, sufficient workability in press working and durability of the mold accompanying use can be obtained. It has been found by the present inventors that the present invention is useful.
[0055]
By using such a laminated resin mold 35, since the laminated resin mold 35 is formed of a synthetic resin material used for a normal resin mold, a metal block is cut as in the case of manufacturing a mold. The need to do so is eliminated. This greatly facilitates the production of the press mold.
[0056]
Further, the laminated resin mold 35 of the present embodiment can be divided into the respective partial molds 38 to 41. Therefore, in the case where a design change occurs at the stage when the laminated resin mold 35 is manufactured, repair work such as processing and replacement may be performed only on the necessary partial molds 38 to 41. In comparison, the entire punch die or die die does not need to be subjected to repair work such as cutting, so that the number of work steps is significantly reduced.
[0057]
Further, each of the partial molds 38 to 41 of the laminated resin mold 35 of this embodiment is formed so as to have an internal shape 38a, 39a, 40a, 41a corresponding to a plurality of partial product shapes as described above. The formation of the internal shapes 38a, 39a, 40a, 41a of the partial molds 38 to 41 can be performed by a simple manufacturing method such as a laser sintering method, for example, since the material is made of a synthetic resin material as described above. Therefore, it can be manufactured much easier as compared with the time of forming a metal mold, which is a metal cutting operation.
[0058]
Further, as in the case of a lamination mold in which plate-shaped metal layers are laminated, it is possible to eliminate the need to reduce the plate thickness in order to minimize the step difference in each of the laminated stages. Therefore, the situation in which the number of stacked layers increases is eliminated, and the configuration can be simplified and the number of components can be reduced.
[0059]
The specific processing method of the resin material may vary depending on the type of the resin material, and the present invention does not limit the type.
[0060]
The forming operation of the internal shapes 38a, 39a, 40a, 41a for each of the partial dies 38 to 41 in the present embodiment is performed by forming the internal shapes 38a, 39a, 40a, 41a on each of the partial dies 38 to 41 and then laminating them. In the case where the laminated resin mold 35 is formed by the above method, or when the resin material is laminated corresponding to each of the partial molds 38 to 41 and processed into the shape of the laminated resin mold 35 at one time, the processing is also easy. .
[0061]
As a result, in each case, the number of manufacturing steps including the above-described design change can be significantly reduced as compared with the case of using a mold.
[0062]
In the present embodiment, the method of manufacturing the laminated resin mold 35 is performed according to the steps described with reference to FIG. 17 or FIG.
[0063]
Therefore, in the present embodiment, as described above, the necessity of cutting the metal lump is eliminated, so that the manufacturing process is simplified. Further, since the laminated resin mold 35 of the present embodiment can be divided into the respective partial molds 38 to 41, only the necessary partial molds 38 to 41 are processed and exchanged according to circumstances such as design change. Repair work such as repair work can be performed, and man-hours for repair and alteration work are significantly reduced.
[0064]
Further, in the present embodiment, the operation of forming the plurality of internal shapes 38a, 39a, 40a, and 41a included in each of the partial molds 38 to 41 is compared with the manufacture of the mold by metal cutting because the material is made of a synthetic resin material. It is realized much easier.
[0065]
In this embodiment, since the laminated resin mold 35 is formed by laminating the partial molds 38 to 41 having the internal shapes 38a, 39a, 40a, and 41a, the processing is easy. As a result, it is possible to significantly reduce the number of manufacturing steps including the response to a design change.
[0066]
In addition, the method of manufacturing the laminated resin mold 35 of the present embodiment may be manufactured by the steps described with reference to FIG. Even in such a case, the same operation and effect as the operation and effect described for the example of the manufacturing method described with reference to FIG. 17 can be realized.
[0067]
As the cover 1 manufactured according to the present invention, an exhaust manifold cover that covers the exhaust manifold 3 of the engine 2 has been described as an example in the present embodiment. However, the present invention is not limited to the purpose of manufacturing the exhaust manifold described above. It can be widely applied to the manufacture of a wide variety of covers that generate heat and noise and are required to have a function of preventing the dissipation of the heat and noise, not limited to undercovers and muffler covers, or automobiles. Things.
[0068]
The present invention is not limited to the above embodiments, but includes a wide variety of modifications without departing from the spirit of the present invention.
[0069]
【The invention's effect】
By using the present invention, the following effects can be obtained.
[0070]
Since the laminated resin mold according to claim 1 is formed by laminating partial resin molds made of a synthetic resin material, if the material to be pressed is a relatively soft type, the hardness and durability of the resin material are improved. By appropriately selecting physical characteristics such as the above, the laminated resin mold is sufficiently useful in terms of workability in press working and durability of the mold accompanying use.
[0071]
Since the laminated resin mold of the present invention is made of a synthetic resin material used for a normal resin mold, the need for cutting a metal lump is eliminated as in the case of manufacturing a mold, so that the production is simplified. Easy.
[0072]
Further, each of the partial resin molds of the laminated resin mold of the present invention is formed so as to have a shape corresponding to a plurality of partial product shapes of the product. As described above, since the material is formed of a synthetic resin material, the operation of forming the partial product shape of the partial resin mold can be realized much more easily than the mold. Therefore, as in the case of the laminated mold, the necessity of reducing the thickness of the plate in order to minimize the level difference between the laminated stages is eliminated. Therefore, the situation in which the number of stacked layers increases is eliminated, and the configuration can be simplified and the number of components can be reduced.
[0073]
Further, the laminated resin mold of the present invention can be divided into respective partial resin molds. Therefore, when a design change occurs, repair work such as processing and replacement needs to be performed only on the required partial resin mold, and the number of work steps is significantly reduced as compared with the case of the mold. Further, the repair work and the new creation work of the partial resin mold are also facilitated by the above-mentioned material characteristics.
[0074]
The work of forming the partial product shape of the partial resin mold may be performed in a case where the partial resin shape is formed on each of the partial resin molds and then laminated to form a laminated resin mold, or alternatively, the resin material may correspond to each partial resin mold. In the case of processing into a laminated resin mold shape after lamination, the processing is similarly easy. As a result, in each case, the number of manufacturing steps including the above-described design change can be significantly reduced as compared with the case of using a mold.
[0075]
In the method for manufacturing a laminated resin mold according to the second aspect, first, a plurality of partial resin molds are formed, and then the obtained partial resin molds are laminated to form a laminated resin mold.
[0076]
Therefore, according to the present invention, as described above, the necessity of cutting a metal lump is eliminated, so that the manufacturing process is simplified. In addition, since the laminated resin mold of the present invention can be divided into partial resin molds, repair work such as processing and replacement is performed only on necessary partial resin molds in response to circumstances such as design changes. That is, the man-hours for repair and alteration work are significantly reduced. Further, in the present invention, the operation of forming a plurality of partial product shapes of each of the partial resin molds is remarkably easily realized because the material is made of a synthetic resin material.
[0077]
In the present invention, since the laminated resin mold is formed by laminating the partial resin molds having the partial product shape, the processing is easy. As a result, it is possible to significantly reduce the number of manufacturing steps including the response to a design change.
[0078]
The method of manufacturing a laminated mold according to claim 3 is a method of laminating a resin material corresponding to a plurality of partial resin molds and processing the laminated resin material into a laminated resin mold based on the laminated resin mold shape data. It is.
[0079]
Therefore, according to the present invention, as described above, the necessity of cutting a metal lump is eliminated, so that the manufacturing process is simplified. In addition, since the laminated resin mold of the present invention can be divided into partial resin molds, repair work such as processing and replacement is performed only on necessary partial resin molds in response to circumstances such as design changes. That is, the man-hours for repair and alteration work are significantly reduced. Further, in the present invention, the operation of forming a plurality of partial product shapes of each of the partial resin molds is remarkably easily realized because the material is made of a synthetic resin material.
[0080]
In the present invention, since the resin material is laminated corresponding to each partial resin mold and processed based on the laminated resin mold shape data to produce the laminated resin mold, the processing accuracy can be remarkably improved. Further, the processing is easier than the cutting processing of the mold. As a result, it is possible to significantly reduce the number of manufacturing steps including the response to a design change.
[Brief description of the drawings]
FIG. 1 is a front view of a laminated resin mold 35 according to an embodiment of the present invention.
FIG. 2 is a plan view of a die 36 included in the laminated resin mold 35.
FIG. 3 is a front view of a die 36. FIG.
FIG. 4 is a plan view of a punch die 37.
FIG. 5 is a front view of a punch die 37;
FIG. 6 is a side view of the punch die 37.
FIG. 7 is a front view of a state where the cover 1 is mounted on the exhaust manifold 3;
FIG. 8 is a cross-sectional view taken along the line X8-X8 of FIG. 7;
FIG. 9 is a plan view of the cover 1. FIG.
FIG. 10 is an enlarged perspective view of the cover 1.
FIG. 11 is an enlarged plan view of the cover 1.
FIG. 12 is a cross-sectional view taken along a section line X12-X12 in FIG. 11;
FIG. 13 is a cross-sectional view taken along the section line X13-X13 in FIG. 11;
FIG. 14 is a cross-sectional view taken along section line X14-X14 in FIG. 11;
FIG. 15 is a simplified sectional view taken along section line X15-X15 in FIG. 7;
FIG. 16 is a perspective view illustrating features of the cover 1.
FIG. 17 is a process diagram illustrating a manufacturing process of the cover 1.
FIG. 18 is a process diagram illustrating a manufacturing process of another example of the cover 1.
FIG. 19 is a cross-sectional view for explaining a problem of the conventional technology of the lamination mold technology.
[Explanation of symbols]
1 Cover
2 Engine
3 Exhaust
4, 5 metal plate
6 Sound absorbing material
7 ridge
8 Tanibe
10, 11 Standing part
14, 19 Side wall
28 flange
30 ridge line equivalent site
35 Multilayer resin type
36 die type
37 Punch type
38-41 each partial type
38a, 39a, 40a, 41a Internal shape
42 Fastening bolt
T1 side wall
T2 top

Claims (3)

A laminated resin mold for press working used to press a relatively soft metal plate,
The metal plate has a punching die for pressing and a die for pressing, each formed from a resin material having physical properties capable of pressing.
At least one of the press punching die and the press die is a plurality of partial resin molds each having a shape corresponding to a plurality of partial product shapes obtained by dividing a product shape by a plurality of virtual planes. Are laminated so as to be detachable from each other. A method for manufacturing a laminated resin mold for press working used for press working a relatively soft metal plate,
A step of determining the number of lamination stages of a plurality of partial resin molds each having a shape corresponding to a plurality of partial product shapes obtained by dividing the product shape by a plurality of virtual planes,
Based on the three-dimensional product shape data, a step of creating the plurality of partial resin mold shape data,
Based on each partial resin mold shape data, forming a plurality of partial resin molds by processing a resin material having physical properties capable of pressing the metal plate,
Forming a laminated resin mold by removably laminating each of the partial resin molds to form a laminated resin mold. A method for manufacturing a laminated resin mold for press working used for press working a relatively soft metal plate,
A step of determining the number of lamination stages of a plurality of partial resin molds each having a shape corresponding to a plurality of partial product shapes obtained by dividing the product shape by a plurality of virtual planes,
A step of creating laminated resin mold shape data based on the three-dimensional product shape data;
A step of laminating resin materials having physical characteristics capable of pressing the metal plate so as to be detachable from each other and corresponding to each of the partial resin molds, and processing based on the laminated resin mold shape data. A method for producing a laminated resin mold for press working, characterized by comprising:

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