Formed article, structural member using the same, and manufacturing method of formed article

A long formed article made of one steel sheet, the formed article comprising:

• a top sheet portion which extends in a longitudinal direction;
• a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction;
• and
• a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion,
• wherein in the longitudinal direction of the formed article, when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region,
• in the non-protrusion region, the top sheet portion includes an enlarged top sheet portion which extends in the width direction from the top sheet portion and is connected to the standing wall portion, and
• a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion including the enlarged top sheet portion and the standing wall portion in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/60 ≤1.50.

A long formed article made of one steel sheet, the formed article comprising:

• a top sheet portion which extends in a longitudinal direction;
• a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction;
• and
• a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion,
• wherein in the longitudinal direction of the formed article, when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region,
• in the non-protrusion region, the standing wall portion includes an enlarged standing wall portion which extends upward from the standing wall portion and is connected to the top sheet portion, and
• a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion and the standing wall portion including the enlarged standing wall portion in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/60 ≤1.50.

A manufacturing method of a formed article which is long and made of one steel sheet, the formed article including a top sheet portion which extends in a longitudinal direction, a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction, a flange portion which extends from a lower end of the standing wall portion, and a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion, in which when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region in the longitudinal direction of the formed article, in the non-protrusion region, a recessed part extending in the longitudinal direction is formed in the top sheet portion, and a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion, the standing wall portion, and the recessed part in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/α≤1.50,

• the manufacturing method being performed using a pressing apparatus including an upper die and a lower die having a shape corresponding to the recessed part in the non-protrusion region and two movable dies movable in a vertical direction and a horizontal direction, the lower die including a punch die, and two movable plates which are disposed to sandwich the punch die therebetween and movable in the vertical direction, and comprising:
• (Ia) disposing a material steel sheet between the upper die and the two movable dies, and the lower die;
• (Ib) obtaining a deformed steel sheet in a state in which an end portion of the material steel sheet is interposed between the two movable dies and the two movable plates by lowering the two movable dies together with the two movable plates and moving the two movable dies toward the punch die;
• (IIa) restraining a portion of the deformed steel sheet by the two movable dies and a side surface portion of the punch die by further moving the two movable dies toward the punch die;
• and
• (IIb) pressing a portion of the deformed steel sheet by the upper die and the punch die by lowering the upper die and overlapping a portion of the deformed steel sheet between the upper die and the movable die to form the formed article having the top sheet portion with the recessed part formed thereon.

A manufacturing method of a formed article which is long and made of one steel sheet, the formed article including a top sheet portion which extends in a longitudinal direction, a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction, a flange portion which extends from a lower end of the standing wall portion, and a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion, in which when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region in the longitudinal direction of the formed article, in the non-protrusion region, the top sheet portion includes an enlarged top sheet portion which extends in the width direction from the top sheet portion and is connected to the standing wall portion, and a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion including the enlarged top sheet portion and the standing wall portion in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/α≤1.50,

• the manufacturing method being performed using a pressing apparatus including an upper die and a lower die having a shape corresponding to the enlarged top sheet portion in the non-protrusion region and two movable dies movable in a vertical direction and a horizontal direction, the lower die including a punch die, and two movable plates which are disposed to sandwich the punch die therebetween and movable in the vertical direction, and comprising:
• (Ia) disposing a material steel sheet between the upper die and the two movable dies, and the lower die;
• (IIb) obtaining a deformed steel sheet in a state in which an end portion of the material steel sheet is interposed between the two movable dies and the two movable plates by lowering the two movable dies together with the two movable plates and moving the two movable dies toward the punch die;
• (IIa) restraining a portion of the deformed steel sheet by the two movable dies and a side surface portion of the punch die by further moving the two movable dies toward the punch die;
• and
• (IIb) pressing a portion of the deformed steel sheet by the upper die and the punch die by lowering the upper die and overlapping a portion of the deformed steel sheet between the upper die and the movable die to form the formed article having the top sheet portion including the enlarged top sheet portion.

A manufacturing method of a formed article which is long and made of one steel sheet, the formed article including a top sheet portion which extends in a longitudinal direction, a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction, a flange portion which extends from a lower end of the standing wall portion, and a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion, in which when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region in the longitudinal direction of the formed article, in the non-protrusion region, the standing wall portion includes an enlarged standing wall portion which extends upward from the standing wall portion and is connected to the top sheet portion, and a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion and the standing wall portion including the enlarged standing wall portion in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/α≤1.50,

• the manufacturing method being performed using a pressing apparatus including an upper die and a lower die having a shape corresponding to the enlarged standing wall portion in the non-protrusion region and two movable dies movable in a vertical direction and a horizontal direction, the lower die including a punch die, and two movable plates which are disposed to sandwich the punch die therebetween and movable in the vertical direction, and comprising:
• (Ia) disposing a material steel sheet between the upper die and the two movable dies, and the lower die;
• (IIb) obtaining a deformed steel sheet in a state in which an end portion of the material steel sheet is interposed between the two movable dies and the two movable plates by lowering the two movable dies together with the two movable plates and moving the two movable dies toward the punch die;
• (IIa) restraining a portion of the deformed steel sheet by the two movable dies and a side surface portion of the punch die by further moving the two movable dies toward the punch die;
• and
• (IIb) pressing a portion of the deformed steel sheet by the upper die and the punch die by lowering the upper die and overlapping a portion of the deformed steel sheet between the upper die and the movable die to form the formed article having the standing wall portion including the enlarged standing wall portion.

A manufacturing method of a formed article which is long and made of one steel sheet, the formed article including a top sheet portion which extends in a longitudinal direction, a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction, a flange portion which extends from a lower end of the standing wall portion, and a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion, in which when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region in the longitudinal direction of the formed article, in the non-protrusion region, a recessed part extending in the longitudinal direction is formed in the top sheet portion, and a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion, the standing wall portion, and the recessed part in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/α≤1.50,

• the manufacturing method comprising:
• a first step of deforming a material steel sheet to obtain a deformed steel sheet which has a long shape and includes a top sheet portion equivalent portion which becomes the top sheet portion, a standing wall portion equivalent portion which becomes the standing wall portion, a protrusion portion equivalent portion which becomes the protrusion portion, and a flange portion equivalent portion which becomes the flange portion;
• and
• a second step of forming the deformed steel sheet to form the formed article,
• wherein in the second step, the protrusion portion having the top sheet portion formed with the recessed part is formed by overlapping at least a portion of the protrusion portion equivalent portion.

A manufacturing method of a formed article which is long and made of one steel sheet, the formed article including a top sheet portion which extends in a longitudinal direction, a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction, a flange portion which extends from a lower end of the standing wall portion, and a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion, in which when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region in the longitudinal direction of the formed article, in the non-protrusion region, the top sheet portion includes an enlarged top sheet portion which extends in the width direction from the top sheet portion and is connected to the standing wall portion, and a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion including the enlarged top sheet portion and the standing wall portion in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/α≤1.50,

• the manufacturing method comprising:
• a first step of deforming a material steel sheet to obtain a deformed steel sheet which has a long shape and includes a top sheet portion equivalent portion which becomes the top sheet portion, a standing wall portion equivalent portion which becomes the standing wall portion, a protrusion portion equivalent portion which becomes the protrusion portion, and a flange portion equivalent portion which becomes the flange portion;
• and
• a second step of forming the deformed steel sheet to form the formed article,
• wherein in the second step, the protrusion portion having the top sheet portion including the enlarged top sheet portion is formed by overlapping at least a portion of the protrusion portion equivalent portion.

A manufacturing method of a formed article which is long and made of one steel sheet, the formed article including a top sheet portion which extends in a longitudinal direction, a standing wall portion which extends downward from each of both edges of the top sheet portion in a width direction, a flange portion which extends from a lower end of the standing wall portion, and a protrusion portion which is formed in a portion of the top sheet portion in the longitudinal direction by overlapping a portion extending toward an outside from each of both ends of the top sheet portion in the width direction and a portion extending toward the outside from an upper end of the standing wall portion, in which when a region provided with the protrusion portion is defined as a protrusion region and a region not provided with the protrusion portion is defined as a non-protrusion region in the longitudinal direction of the formed article, in the non-protrusion region, the standing wall portion includes an enlarged standing wall portion which extends upward from the standing wall portion and is connected to the top sheet portion, and a total value α of inner surface peripheral lengths of the top sheet portion and the standing wall portion in a cross section of the formed article perpendicular to the longitudinal direction in the protrusion region and a total value β of inner surface peripheral lengths of the top sheet portion and the standing wall portion including the enlarged standing wall portion in the cross section of the formed article perpendicular to the longitudinal direction in the non-protrusion region satisfy 1.01≤β/α≤1.50,

• the manufacturing method comprising:
• a first step of deforming a material steel sheet to obtain a deformed steel sheet which has a long shape and includes a top sheet portion equivalent portion which becomes the top sheet portion, a standing wall portion equivalent portion which becomes the standing wall portion, a protrusion portion equivalent portion which becomes the protrusion portion, and a flange portion equivalent portion which becomes the flange portion;
• and
• a second step of forming the deformed steel sheet to form the formed article,
• wherein in the second step, the protrusion portion having the standing wall portion including the enlarged standing wall portion is formed by overlapping at least a portion of the protrusion portion equivalent portion.