Method of manufacturing formed product

Abstract

A method of manufacturing a formed product is provided. The method includes: joining a first member and a second member to each other by welding top plate corresponding portions to each other in a state where the first member is placed on the second member to include an extending portion; curving vertical wall corresponding portions and the extending portion of the plate members toward a moving direction by making a metal press mold contact the extending portion; and forming top plate portion and vertical wall portion by pressing the vertical wall corresponding portions of the plate members by the metal press mold.

What is claimed is: 
     
         1 . A method of manufacturing a formed product having a top plate portion and a vertical wall portion by pressing plate members placed on each other, the method comprising:
 joining a first member and a second member to each other by welding a first top plate corresponding portion and a second top plate corresponding portion to each other in a state where the first member is placed on the second member to include an extending portion;   curving a first vertical wall corresponding portion, a second vertical wall corresponding portion, and the extending portion of the plate members toward a moving direction by moving a metal press mold in the moving direction in a state where the first top plate corresponding portion and the second top plate corresponding portion after the joining are clamped to thereby make the metal press mold contact the extending portion; and   forming the top plate portion and the vertical wall portion by further moving the metal press mold in the moving direction in a state where the first vertical wall corresponding portion, the second vertical wall corresponding portion, and the extending portion are curved by the metal press mold to thereby press the first vertical wall corresponding portion and the second vertical wall corresponding portion of the plate members by the metal press mold;   the plate members comprising the first member and the second member,   the first member comprising the first top plate corresponding portion that corresponds to one part of the top plate portion of the formed product, the first vertical wall corresponding portion that corresponds to at least one part of the vertical wall portion of the formed product, and the extending portion,   the second member being placed on the first member and comprising the second top plate corresponding portion that corresponds to an other part of the top plate portion of the formed product, and the second vertical wall corresponding portion that corresponds to at least an other part of the vertical wall portion of the formed product,   in any planes parallel to the plate members, a downstream side in a direction in a plan view from the first vertical wall corresponding portion and the second vertical wall corresponding portion toward the first top plate corresponding portion and the second top plate corresponding portion being an inner side, and a downstream side in a direction in a plan view from the first vertical wall corresponding portion and the second vertical wall corresponding portion toward a side opposite to the first top plate corresponding portion and the second top plate corresponding portion being an outer side,   an end portion of the first member on the outer side being a first end, and an end portion of the second member on the outer side being a second end,   the first end being located on the outer side with respect to the second end,   the extending portion being a region of the first member from the first end to a portion of the first member on which the second end is placed, and   the moving direction being a direction from the first member toward the second member.   
     
     
         2 . The method of manufacturing a formed product according to  claim 1 ,
 wherein the metal press mold comprises:
 a vertical wall-forming portion for forming the vertical wall portion; and 
 a shoulder portion that is located on a downstream side in the moving direction with respect to an end of the vertical wall-forming portion on the downstream side in the moving direction and includes a surface on the outer side with respect to the vertical wall-forming portion whose angle to the moving direction is greater than an angle of the vertical wall portion to the moving direction; 
   wherein, in the curving, the second end is disposed on the inner side with respect to the shoulder portion, and   wherein, in the curving, the first vertical wall corresponding portion, the second vertical wall corresponding portion, and the extending portion of the plate members are curved toward the moving direction by the shoulder portion contacting the extending portion.   
     
     
         3 . The method of manufacturing a formed product according to  claim 1 ,
 wherein the metal press mold has a step shape having surfaces substantially parallel to the top plate portion,   wherein the surfaces comprise a first surface on an upstream side in the moving direction, and a second surface on a downstream side of the moving direction,   wherein, in the curving, the first vertical wall corresponding portion, the second vertical wall corresponding portion, and the extending portion of the plate members are curved toward the moving direction by the second surface contacting the extending portion, and   wherein, in the forming of the top plate portion and the vertical wall portion, a flange portion that extends toward the outer side from the vertical wall portion is formed by the first surface contacting the extending portion.   
     
     
         4 . The method of manufacturing a formed product according to  claim 2 ,
 wherein, in the forming of the top plate portion and the vertical wall portion, a forming of a flange portion that extends toward the outer side from the vertical wall portion is completed on the inner side with respect to the shoulder portion.   
     
     
         5 . The method of manufacturing a formed product according to  claim 1 ,
 wherein a plate thickness of the second member is equal to or greater than a plate thickness of the first member.   
     
     
         6 . The method of manufacturing a formed product according to  claim 1 , further comprising:
 welding the first member and the second member to each other in the vertical wall portion after the top plate portion and the vertical wall portion are formed.   
     
     
         7 . The method of manufacturing a formed product according to  claim 1 ,
 wherein the formed product is an automobile part.