Press-forming apparatus and press-forming method

1. A press-forming apparatus comprising a die and a punch, said apparatus being configured for manufacturing a press-formed article from a workpiece sheet by moving at least one of the die and the punch so as to be close to each other in a press-forming direction, the press-formed article having a top portion, a first sidewall portion, and a second sidewall portion, the first sidewall portion and the second sidewall portion being connected to ridge portions formed on both edges of the top portion, wherein the die comprises:

a die slide;

a first divisional die arranged at the die slide so as to be adjacent to a first side face of the punch in a state where the die and the punch are the closest to each other;

a second divisional die arranged at the die slide so as to be adjacent to a second side face of the punch in a state where the die and the punch are the closest to each other, the second side face being an opposite side face of the first side face;

a second divisional die driving unit configured to move the second divisional die in the press-forming direction so as to separate the second divisional die from the die slide;

a die pad arranged between the first divisional die and the second divisional die;

a die pad driving unit, including a pressing mechanism or an electrical motor, configured to move the die pad in the press-forming direction;

an insert block having a base end portion configured to be inserted between the die slide and the second divisional die in a state where the die slide and the second divisional die are separated from each other; and

an insert block driving unit, including a pressing mechanism or an electrical motor configured to move the insert block in a direction perpendicular to the press-forming direction.

2. The press-forming apparatus according to claim 1 , wherein

the insert block has a tip end portion which extends from the base end portion in the direction perpendicular to the press-forming direction, and which is configured to be inserted between the die slide and the die pad in a state where the die slide and the die pad are separated from each other, and

a thickness of the base end portion is thicker than a thickness of the tip end portion.

3. The press-forming apparatus according to claim 1 , wherein

the press-forming apparatus is configured to manufacture the press-formed article to have a flange portion which connects a bending portion formed on an edge of at least one of the first sidewall portion and the second sidewall portion.

4. The press-forming apparatus according to claim 3 , comprising:

a flange forming tool arranged between the die and the punch; and

a flange forming tool driving unit configured to move the flange forming tool between a position where a stroke range of the first divisional die or the second divisional die is interfered, and a position where a stroke range of the first divisional die or the second divisional die is not interfered, wherein

an upper face of the flange forming tool and a lower face of at least one of the first divisional die and the second divisional die have a shape corresponding to a face shape of the bending portion and the flange portion.

5. The press-forming apparatus according to claim 4 , wherein

the flange forming tool driving unit is configured to move the flange forming tool into the direction perpendicular to the press-forming direction.

6. The press-forming apparatus according to claim 4 , wherein

a lower face of the flange forming tool is in surface-contact with a ground face of the punch.

7. The press-forming apparatus according to claim 1 , comprising:

a punch pad configured to be housed in a recessed portion formed in a top face of the punch, and

a punch pad driving unit configured to move the punch pad in the press-forming direction.

8. The press-forming apparatus according to claim 1 , wherein

the first divisional die is formed integrally with the die slide.

9. The press-forming apparatus according to claim 1 , wherein

the die slide is connected to a single driving shaft.

10. The press-forming apparatus according to claim 1 , wherein

the press-forming apparatus is configured to form the press-formed article from a workpiece sheet that is a steel sheet.

11. The press-forming apparatus according to claim 1 , wherein

the press-forming apparatus is configured to form the press-formed article from a workpiece sheet having a tensile strength not less than 980 MPa.

12. The press-forming apparatus according to claim 1 , wherein

the press-forming apparatus is configured to form the press-formed article from a workpiece sheet having a total length more than 1700 mm.

13. A press-forming method for manufacturing the press-formed article by using the press-forming apparatus according to claim 1 , the press-forming method comprising;

forming the first sidewall portion by positioning the insert block outside an area between the die slide and the second divisional die and then moving the die slide toward the punch; and

forming the second sidewall portion by positioning the insert block within the area between the die slide and the second divisional die and then moving the die slide toward the punch.

14. The press-forming method according to claim 13 , further comprising:

after performing the forming of the first sidewall portion, inserting the insert block in the area between the die slide and the second divisional die, and then performing the forming of the second sidewall portion.

15. The press-forming method according to claim 14 , wherein

in the forming of the first sidewall portion, a portion in the workpiece sheet corresponding to the second sidewall portion is pre-formed by using the second divisional die.

16. The press-forming method according to claim 13 , wherein

after performing the forming of the second sidewall portion, pulling the insert block out of the area between the die slide and the second divisional die, and then performing the forming of the first sidewall portion.

17. The press-forming method according to claim 16 , wherein

in the forming of the second sidewall portion, a portion in the workpiece sheet corresponding to the first sidewall portion is pre-formed by using the first divisional die.

18. The press-forming method according to claim 13 , wherein

before performing the forming of the first sidewall portion and the forming of the second sidewall portion, the die slide is relatively moved toward the punch in a state where a flange forming tool is arranged at a position interfering with a stroke range of the first divisional die and the second divisional die, thereby forming a flange portion in the workpiece sheet by using the flange forming tool and at least one of the first divisional die and the second divisional die.

19. The press-forming method according to claim 13 , wherein

in at least one of the forming of the first sidewall portion and the forming of the second sidewall portion, the die slide is lowered in a state where a punch pad configured to be housed in a recess portion formed in a top face of the punch is positioned high above a top face of the punch, and the punch pad is lowered in accordance with the lowering of the die slide to complete a press-forming.