CN115427168A - Method for manufacturing bottomed cylindrical body - Google Patents
Method for manufacturing bottomed cylindrical body Download PDFInfo
- Publication number
- CN115427168A CN115427168A CN202180024790.5A CN202180024790A CN115427168A CN 115427168 A CN115427168 A CN 115427168A CN 202180024790 A CN202180024790 A CN 202180024790A CN 115427168 A CN115427168 A CN 115427168A
- Authority
- CN
- China
- Prior art keywords
- coolant
- thinning
- lubricant
- cylindrical body
- less
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 157
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 78
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- 229910052751 metal Inorganic materials 0.000 claims abstract description 75
- 239000002184 metal Substances 0.000 claims abstract description 75
- 238000009835 boiling Methods 0.000 claims abstract description 71
- 238000010409 ironing Methods 0.000 claims abstract description 70
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 34
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- 238000000465 moulding Methods 0.000 claims abstract description 10
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- 229910052581 Si3N4 Inorganic materials 0.000 description 2
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- 229910045601 alloy Inorganic materials 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
- 230000000844 anti-bacterial effect Effects 0.000 description 2
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- 239000002518 antifoaming agent Substances 0.000 description 2
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- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
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- 239000008213 purified water Substances 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 230000001846 repelling effect Effects 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 2
- 235000017557 sodium bicarbonate Nutrition 0.000 description 2
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- 239000000243 solution Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000001954 sterilising effect Effects 0.000 description 2
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- 150000003609 titanium compounds Chemical class 0.000 description 2
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- 239000004215 Carbon black (E152) Substances 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 1
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
- 239000006061 abrasive grain Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- CXOWYMLTGOFURZ-UHFFFAOYSA-N azanylidynechromium Chemical compound [Cr]#N CXOWYMLTGOFURZ-UHFFFAOYSA-N 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000011195 cermet Substances 0.000 description 1
- 239000010730 cutting oil Substances 0.000 description 1
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- 230000001771 impaired effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
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- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical class O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/28—Deep-drawing of cylindrical articles using consecutive dies
- B21D22/286—Deep-drawing of cylindrical articles using consecutive dies with lubricating or cooling means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/28—Deep-drawing of cylindrical articles using consecutive dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
- B21D24/16—Additional equipment in association with the tools, e.g. for shearing, for trimming
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/005—Processes combined with methods covered by groups B21D1/00 - B21D31/00 characterized by the material of the blank or the workpiece
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/005—Processes combined with methods covered by groups B21D1/00 - B21D31/00 characterized by the material of the blank or the workpiece
- B21D35/007—Layered blanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/18—Lubricating, e.g. lubricating tool and workpiece simultaneously
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
- B21D51/2669—Transforming the shape of formed can bodies; Forming can bodies from flattened tubular blanks; Flattening can bodies
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/02—Cleaning or pickling metallic material with solutions or molten salts with acid solutions
- C23G1/12—Light metals
- C23G1/125—Light metals aluminium
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/14—Cleaning or pickling metallic material with solutions or molten salts with alkaline solutions
- C23G1/22—Light metals
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/36—Regeneration of waste pickling liquors
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
The invention provides a method for manufacturing a bottomed tubular body, which can simultaneously achieve the cost reduction and the environmental load reduction in the harsh can manufacturing process such as the conventional drawing process and ironing process and the cleaning process. The method for manufacturing a bottomed cylindrical body includes: a drawing step of drawing a metal plate by using a forming member having a work surface with a hardness of Hv1500 to 12000; and a thinning step of forming a bottomed cylindrical body by thinning the member to be processed with a coolant, the coolant being a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃, by using a molding member having a carbon film on a processing surface. Alternatively, the method for manufacturing a bottomed cylindrical body includes: a drawing step of drawing a metal plate using a drawing die having a work surface with a hardness Hv of more than 1500 and 12000 or less and a drawing punch having a hardness Hv of 1000 to 12000; and a thinning step of thinning the workpiece member with a coolant by using a molded member having a machined surface with a hardness of Hv1500 to 12000, thereby forming a bottomed tubular body, wherein the coolant satisfies at least one of (a) a concentration of an oil component contained therein of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a boiling point of less than 300 ℃.
Description
Technical Field
The present invention relates to a method for manufacturing a bottomed cylindrical body, and more particularly, to a method for manufacturing a bottomed cylindrical body made of metal by drawing-ironing.
Background
A metallic bottomed tubular body, for example, a so-called seamless can body is manufactured by drawing and ironing using a die for press working.
Since the punch portion and the die portion used in the draw-ironing are generally placed in a severe environment, for example, dies as shown in patent documents 2 to 5 are proposed. That is, it has been proposed to coat a processed surface with a carbon film such as a diamond film or a DLC (diamond like carbon) film to improve the durability of the mold.
On the other hand, conventionally, for example, when a seamless can body is manufactured using an aluminum alloy material, it is common to perform molding in a wet environment using a lubricant or coolant (coolant). In this case, a cleaning step (washing step) of cleaning the processing oil, lubricant, coolant, and the like adhering to the can body with a cleaning agent or chemical after the can body processing is indispensable.
Documents of the prior art
Patent document
Patent document 1: japanese patent No. 6012804
Patent document 2: japanese patent laid-open publication No. H10-137861
Patent document 3: japanese patent laid-open publication No. 11-277160
Patent document 4: japanese patent laid-open publication No. 2013-163187
Patent document 5: international publication No. WO2017/033791
Disclosure of Invention
Problems to be solved by the invention
However, the conventional method for producing a seamless can body described above has the following problems: the cleaning process requires a large amount of energy and cost, and the environmental load is large.
For example, it is necessary to reduce the cost and environmental load associated with a large amount of water used in the cleaning process, reduce the environmental load due to chemicals used in the cleaning process, and reduce the energy required to heat the cleaning agent in the cleaning process.
Further, the present inventors have conducted intensive studies this time, and as a result, have found that, when a bottomed cylindrical body is produced using a coolant under specific conditions, both of the cost reduction and the environmental load reduction in the cleaning step and the severe working such as the conventional drawing and ironing can be achieved at the same time, and have completed the present invention.
Means for solving the problems
In order to achieve the above object, a method for manufacturing a bottomed cylindrical body according to an embodiment of the present invention is characterized in that (1) includes: a drawing step of drawing the metal plate using a forming member having a work surface hardness of Hv exceeding 1500 and 12000 or less; and a thinning step of forming a bottomed cylindrical body by thinning the workpiece member with a coolant having a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃ by using a molding member having a carbon film on a processing surface.
In the above (1), it is preferable that the bottomed tubular body in (2) is a seamless can body.
In the above (1) or (2), it is preferable that the metal plate in the above (3) is an aluminum alloy.
Further, in any one of the above (1) to (3), it is preferable that (4) the carbon film is a diamond film.
In any one of the above (1) to (4), it is preferable that (5) includes a lubricant application step of applying a water-soluble lubricant and/or a lubricant having a boiling point of less than 300 ℃ to the metal plate before a drawing step of drawing the metal plate, wherein a hardness of a work surface of the formed member in the drawing step is Hv1500 to 12000.
In any one of the above (1) to (5), it is preferable that the coolant of (6) contains a corrosion inhibitor and/or a rust inhibitor.
In the method for producing a bottomed cylindrical body according to an embodiment of the present invention, in any one of the above (1) to (6), (7) preferably further includes a cleaning step of removing the lubricant and/or the coolant adhering to the surface of the bottomed cylindrical body.
In the method for producing a bottomed cylindrical body according to an embodiment of the present invention, it is preferable that (8) further includes a purification step of purifying waste water discharged in the thinning step and/or the washing step, in any one of (1) to (7) above.
In order to achieve the above object, a method for manufacturing a bottomed cylindrical body according to another embodiment of the present invention is characterized in that (9) includes: a drawing step of drawing a metal plate using a drawing die having a work surface with a hardness of Hv of more than 1500 and 12000 or less and a drawing punch having a hardness of Hv of 1000 to 12000; and a thinning step of thinning the workpiece member with a coolant, using a molded member having a machined surface with a hardness of Hv1500 to 12000, to form a bottomed tubular body, wherein the coolant satisfies at least one of (a) a concentration of an oil component contained therein of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a boiling point of less than 300 ℃.
In the above (9), it is preferable that the bottomed cylindrical body in (10) is a seamless can body.
In the above (9) or (10), it is preferable that the metal plate in the above (11) is an aluminum alloy.
In any one of the above (9) to (11), (12) a carbon film is preferably formed on the working surface of the formed member in the drawing step and/or the working surface of the formed member in the ironing step.
In any one of the above (9) to (12), (13) preferably includes a lubricant application step of applying a lubricant to a surface of the metal plate before the drawing step, and the hardness of the work surface of the drawing die in the drawing step is Hv1000 to 12000.
In any one of the above (9) to (13), (14) preferably further includes a washing step of purifying waste water discharged in the thinning step or a washing step after the thinning step.
ADVANTAGEOUS EFFECTS OF INVENTION
The method for manufacturing a bottomed tubular body according to the present invention includes a step of performing thinning processing using a molding processing member (e.g., a punch and a die) having a carbon film on a processing surface.
Therefore, even when a water-soluble coolant or a coolant having a boiling point of less than 300 ℃ is used as the coolant used in the thinning step, a bottomed cylindrical body having a thinning ratio equal to or higher than that of the conventional one can be obtained.
Further, the method for producing a bottomed tubular body according to the present invention includes a step of drawing using a forming member (for example, a punch and a die) having a working surface whose hardness is equal to or higher than a predetermined value. Therefore, the lubricant application step of applying the lubricant to the surface of the metal plate (flat plate) before drawing can be omitted.
In the present invention, the drawing may be performed by applying a water-soluble lubricant and/or a lubricant having a boiling point of less than 300 ℃ to the surface of the metal plate (flat plate) before drawing. In this case, even if the lower limit of the hardness of the worked surface of the formed member in the drawing step is lowered, workability equal to or higher than that of the conventional one can be obtained.
In addition, according to the present embodiment, since the water-soluble lubricant and coolant, and the lubricant and coolant having a boiling point of less than 300 ℃ are used in the drawing step and the ironing step, the drawing step and the ironing step can be performed by washing with water or hot water without using a cleaning agent. Alternatively, the concentration of the cleaning component in the cleaning agent can be reduced.
Alternatively, the lubricant, coolant, and the like adhering to the can body may be dried and removed after the can manufacturing process without providing the cleaning step.
Therefore, the environmental load in the cleaning process can be reduced and the cost can be reduced.
Further, the method for producing a bottomed tubular body according to the present invention includes a step of performing drawing and ironing using a forming member (for example, a punch and a die) having a processed surface whose hardness is equal to or higher than a predetermined value.
Therefore, in the thinning step, when a coolant satisfying at least one of (a) a concentration of an oil component contained therein of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a boiling point of less than 300 ℃ is used, a bottomed tubular body having a thinning ratio equal to or greater than that of the conventional one can be obtained.
In addition, according to the present embodiment, the step of applying the working oil or the lubricant to the surface of the metal plate (flat plate) before the drawing work can be omitted. The coolant used in the thinning step may be at least one coolant having (a) a concentration of an oil component of less than 4.0 vol%, (b) a water-soluble coolant, or (c) a boiling point of less than 300 ℃. Therefore, the cleaning process can be performed with water or hot water without using a cleaning agent. Alternatively, the lubricant component, coolant, and the like adhering to the can body may be dried and removed after the can body is formed without providing the cleaning step.
Therefore, the environmental load in the cleaning process can be reduced and the cost can be reduced.
Drawings
Fig. 1 is a schematic view showing a drawing step in a method for producing a bottomed tubular body according to an embodiment of the present invention.
Fig. 2 is a schematic view showing a thinning step in the method for manufacturing a bottomed cylindrical body according to the embodiment of the present invention.
Fig. 3 is a schematic view showing a flow of a method for manufacturing a bottomed cylindrical body in one embodiment of the present invention.
Fig. 4 is a schematic diagram showing a flow of a method for manufacturing a bottomed cylindrical body in another embodiment of the present invention.
Detailed Description
[ method for producing bottomed cylindrical body ]
The applicant of the present invention found a method of manufacturing a seamless can body as disclosed in japanese patent application No. 2018-204896 and japanese patent application No. 2018-204823. That is, it has been found that, when a die having a diamond film or the like having high sliding properties formed on a working surface is used and press working is performed so that the oil content in the coolant is equal to or less than a predetermined amount, even if severe working such as ironing is performed, a degree of working (for example, a limit reduction ratio) equal to or more than that of a press-worked product produced using a conventional amount of lubricant can be obtained.
Further, the present inventors have now found a method for producing a bottomed cylindrical body, which is related to the above method for producing a seamless can body.
Hereinafter, a method for producing a bottomed tubular body according to the present invention will be described in detail with reference to the drawings as appropriate. The following embodiments are illustrative of the present invention, and the contents thereof will be described without intending to limit the present invention. In the following embodiments, a seamless can body is described as an example of a bottomed cylindrical body, but the present invention is not intended to be limited thereto.
(first embodiment)
First, a method for manufacturing a bottomed cylindrical body according to a first embodiment will be described. Fig. 1 is a schematic view showing a drawing step in a method of manufacturing a bottomed tubular body according to a first embodiment. Fig. 2 is a schematic view showing a thinning step in the method for manufacturing a bottomed cylindrical body according to the first embodiment. Fig. 3 is a schematic diagram showing a flow of the method for manufacturing a bottomed cylindrical body according to the first embodiment.
< Metal plate >
The metal plate as the workpiece in the present embodiment is not particularly limited as long as it is subjected to general metal press working. For example, various known metal plates such as aluminum, copper, iron, steel, titanium (further, not only pure metals but also alloys thereof) and the like can be used. Among these, aluminum alloy sheets are particularly preferable for forming seamless can bodies.
The thickness of the metal plate in the present embodiment is not particularly limited, and a normal thickness in the production of a seamless can body can be applied. For example, as an example of the thickness of a metal plate when can manufacturing is performed using an aluminum alloy plate, the thickness of a mother plate (thickness of a raw plate) is 0.1mm to 0.5mm.
< procedure for applying lubricant >
The method of manufacturing a bottomed tubular body according to the present embodiment may further include a lubricant application step of applying a lubricant to the surface of the metal plate. As is generally known, by applying a lubricant, even if severe draw-ironing is performed in the subsequent drawing step and ironing step, the metal sheet can be worked into a desired shape such as a bottomed tubular body without being damaged or broken. In the present embodiment, the lubricant application step is not essential, and may be omitted as appropriate.
As the kind of the lubricant in the present embodiment, a water-soluble lubricant and/or a lubricant having a boiling point of less than 300 ℃.
The water-soluble lubricant in the present embodiment is defined as a lubricant soluble in water. The use of a water-soluble lubricant is preferable because it can remove lubricant components adhered after can formation without using a chemical (such as an acid, an alkali, or a surfactant). In the present embodiment, for example, when washing with water in a washing step described later, it is preferable to remove the lubricant component and the coolant component to such an extent that a defect such as unevenness or repulsion (shrinkage) of the paint does not occur in printing in a subsequent step.
In the present embodiment, the phrase "water-soluble lubricant and/or lubricant having a boiling point of less than 300" means that either or both of the "water-soluble lubricant" and the "lubricant having a boiling point of less than 300" may be included. Further, it means that a lubricant having either of the properties of "water solubility" and "boiling point less than 300 ℃ may be used as a lubricant, or a lubricant having both of the properties of" water solubility "and" boiling point less than 300 ℃ may be used as a lubricant.
In addition, in the present embodiment, the lubricant having a boiling point of less than 300 ℃ is preferable because adhered lubricant components can be vaporized and removed at a relatively low temperature after the can manufacturing process. From the viewpoint of facility cost, energy cost, and the like, the boiling point of the lubricant is more preferably less than 250 ℃.
Specifically, as the lubricant in the present embodiment, a commercially available wash-free oil can be used as the volatile lubricating oil.
As for the amount of lubricant to be applied and the method of applying the lubricant, a known amount and a known method can be applied.
< deep drawing Process >
Next, a drawing step in the present embodiment will be described.
In the drawing step of the present embodiment, it is preferable that the working surface of the formed member (for example, drawing die or drawing punch) in the drawing step is a predetermined hardness or more. Specifically, the hardness of the work surface should be set to have a Hv of more than 1500 and 12000 or less on a vickers scale. In the case where the lubricant application step is provided before the drawing step, the lower limit of the hardness of the worked surface of the formed member in the drawing step can be set to Hv1500.
The reason for this is as follows.
That is, in the case of explaining an example of the drawing step of the metal plate with reference to fig. 1, the metal plate 10 is interposed between the drawing die D D And drawing punch P D In the state of being in between, the punch P is processed by drawing D Drawing is performed to manufacture a shallow drawn cup M. At this time, a strong impact load acts on the drawing die D D And a drawing punch P D Therefore, high durability and wear resistance to the extent of withstanding mass production are required.
In the present embodiment, in order to reduce the environmental load and cost in the washing step, the lubricant applied in the lubricant application step is preferably a water-soluble lubricant and/or a lubricant having a boiling point of less than 300 ℃. In this case, in order to avoid damage or breakage of the metal plate due to the molding member, it is necessary to impart high hardness or slidability to the metal plate by using a mold.
From the above-described points of view, the present inventors have made trial and error, and as a result, have found that, in the present embodiment, when the hardness of the worked surface of the formed and worked member is set to Hv exceeding 1500 and 12000 or less, there is no problem from the point of view of durability, wear resistance, damage to the metal plate, and the like even when severe drawing work is performed.
In the present embodiment, the formed member (die) in the drawing step may be manufactured using a base material made of a known material, or may be formed by forming a surface-treated film L (see fig. 1) on the formed surface of the base material, as long as the formed surface has the above hardness.
Specific examples of the material of the base material in the mold include cemented carbide obtained by sintering a mixture of tungsten carbide (WC) and a metal binder such as cobalt; a cermet obtained by sintering a mixture of a metal carbide such as titanium carbide (TiC), a titanium compound such as titanium carbonitride (TiNC), and a metal binder such as nickel or cobalt; ceramics, and the like.
As the surface treatment film L formed on the substrate, for example, a carbon film, a ceramic film, or the like can be preferably used.
Examples of the carbon film include a diamond film and a DLC film. The method for forming these carbon films is not particularly limited, and for example, a Chemical Vapor Deposition (CVD) method, a Physical Vapor Deposition (PVD) method, or the like can be applied.
Examples of the ceramic film include silicon carbide (SiC) and silicon nitride (Si) 3 N 4 ) Aluminum oxide (Al) 2 O 3 ) Zirconium oxide (ZrO) 2 ) And hard ceramics such as titanium nitride (TiN), titanium carbide (TiC), and chromium nitride (CrN).
In the present embodiment, as a combination of the types of the forming members used in the drawing step, the same material or surface-treated film may be used for both the drawing die and the drawing punch, or different materials or surface-treated films may be used. For example, both the drawing die and the drawing punch may be made of cemented carbide, or one of the drawing die and the drawing punch may be made of cemented carbide. Alternatively, a carbon film may be formed on the processing surface of both the drawing die and the drawing punch, or on the processing surface of one of the drawing die and the drawing punch.
In the case where the surface-treated film of one of the drawing die and the drawing punch is a diamond film, the other is preferably a surface-treated film other than the diamond film, from the viewpoints of dimensional control between dies and suppression of damage between dies.
< thinning Process >
Next, the thinning step in the present embodiment will be described.
In the thinning step in the present embodiment, it is preferable to form a carbon film on the processing surface of the molding member (for example, a thinning die or a thinning punch) in the thinning step.
The thinning step of the present embodiment will be described more specifically with reference to the drawings, and as shown in fig. 2 (a) and (b), for example, includes the steps of: using a thinning die D having a diamond film 20 formed on the working surface I And a thinning punch P having a surface treatment film 30 different from the diamond film formed on the processing surface I With the coolant C interposed, using a die D I And a punch P I The working surface of the drawing die is reduced for the shallow drawing cup MAnd (5) thinning and processing.
At this time, the thinning die D I And a thinning punch P I High durability and wear resistance to such an extent that they can withstand mass production are required. In the present embodiment, the coolant C needs to be a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃. Therefore, the ironing die D is required for the reason of avoiding damage, breakage, and the like of the workpiece (the metal plate 10, the shallow drawing cup M) I And a thinning punch P I Any one of the processed surfaces of (1) forms a carbon film having both hardness and slidability. Examples of the carbon film include a diamond film and a DLC film. The method for forming these carbon films is not particularly limited, and for example, a Chemical Vapor Deposition (CVD) method, a Physical Vapor Deposition (PVD) method, or the like can be applied.
Note that, in this embodiment, "a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃ means that either one of the" water-soluble coolant "and the" coolant having a boiling point of less than 300 ℃ may be included, or both of them may be included. Further, it means that a coolant having either of the properties of "water solubility" and "boiling point lower than 300 ℃ in a certain coolant may be used, and a coolant having both of the properties of" water solubility "and" boiling point lower than 300 ℃ may also be used.
In the present embodiment, it is particularly preferable that the diamond film having a vickers hardness Hv of about 8000 to 12000 be formed on the working surface of either the punch or the die of the mold in the thinning step.
That is, as shown in FIG. 2, the diamond film 20 having high hardness may be formed on the thinning die D I On the thinning punch P I The surface treatment film 30 is formed on the machined surface of (2), but not shown, the opposite is also possible.
In general, the thinning die is subjected to a much more severe processing load than the thinning punch, and therefore, it is particularly preferable to form the diamond film 20 on the processing surface of the thinning die.
The thickness of the diamond film 20 is preferably 5 μm to 30 μm. When the thickness is less than 5 μm, cracks are likely to occur in the obtained diamond film, and peeling is likely to occur, which is not preferable. On the other hand, if the thickness exceeds 30 μm, the internal stress of the diamond film increases, and peeling becomes easy, which is not preferable.
In the present embodiment, it is preferable that the surface roughness Ra (JIS B-0601-1994) of the diamond film 20 is 0.12 μm or less from the viewpoint of imparting high sliding properties to the mold. Further, when Ra is 0.08 μm or less, the appearance of the workpiece (e.g., can body) can be made to be a mirror surface or a smooth surface close to a mirror surface, and is more preferable.
In this case, the friction coefficient μ between the diamond film 20 and the material to be processed at the time of press working is preferably less than 0.1.
Next, the coolant used in the thinning step of the present embodiment will be described.
The coolant used in the present embodiment may contain oil as a component thereof, but it is preferable that the coolant can be easily cleaned in a subsequent cleaning step or can be removed by drying even when a cleaning step is not provided. Therefore, the coolant in the present embodiment needs to be a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃.
The water-soluble coolant is defined as a coolant soluble in water. The use of a water-soluble coolant is preferable because it is possible to remove the coolant component adhering after can formation without using a chemical (acid, alkali, surfactant, or the like). In the present embodiment, for example, when washing is performed with water in a washing step described later, it is preferable to remove the lubricant component and the coolant component to such an extent that defects such as unevenness and repulsion of the paint do not occur in printing in the subsequent step.
Further, the coolant having a boiling point of less than 300 ℃ is preferable because the adhered coolant component can be vaporized and removed at a relatively low temperature after the can manufacturing process. From the viewpoint of facility cost, energy cost, and the like, the boiling point of the coolant is more preferably less than 250 ℃.
Specifically, as the coolant in the present embodiment, a commercially available wash-free oil can be used as the volatile lubricating oil.
The coolant in the present embodiment may contain additives as long as the characteristics of water solubility and/or a boiling point of less than 300 ℃ are not impaired. For example, water, a surfactant, a rust preventive, an extreme pressure additive, a coupling agent, a non-ferrous metal anticorrosive, a preservative, a rust preventive, an antifoaming agent, a chelating agent, a colorant, a perfume, and the like may be appropriately contained.
In particular, the coolant of the present embodiment preferably contains a corrosion inhibitor and/or a rust inhibitor. This is for the following reason.
That is, in the case of a water-soluble coolant, a large amount of substances that serve as nutrient sources for microorganisms such as bacteria and mold are contained. Therefore, there are problems as follows: the diluted coolant is easily putrefy, and a portion of the processing equipment in contact with the coolant is easily rusted.
In the present embodiment, "anticorrosive agent and/or rust inhibitor" means that either one of "anticorrosive agent" and "rust inhibitor" may be included, or both of them may be included. Further, it means that a substance having either of "corrosion prevention" and "rust prevention" properties may be used, or a substance having both of "corrosion prevention" and "rust prevention" properties may be used.
If the coolant is decomposed, not only the lubricating function and the cooling function as the functions of the coolant are reduced, but also the bad odor caused by the decomposition becomes a problem. In addition, if rust forms, the life of the machining device is significantly reduced, and the workpiece is damaged.
In addition, there is a problem in cost due to an increase in the frequency of coolant replacement caused by corrosion or rust. Further, when mildewing or rusting occurs, the piping may be clogged in a circulation system such as a pump.
As the corrosion inhibitor and the rust inhibitor, known ones can be suitably used as long as the coolant is water-soluble and/or has a boiling point of less than 300 ℃. For example, a formaldehyde-releasing or phenol-based substance or an amine-based substance may be added as appropriate.
As described above, in the production method of the present embodiment, even when a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃ is used, molding defects and the like at the time of can formation can be suppressed, and as a result, molding stability can be improved.
In addition, in the present embodiment, since a water-soluble coolant and/or a coolant having a boiling point of less than 300 ℃ is used as described above, the cleaning process described later can be performed with a chemical or water having a low environmental load. Alternatively, the cleaning process itself can be omitted, and thus the load on the environment can be reduced.
Further, since the waste water after washing is easily treated, when the waste water is recycled, the recycling rate can be improved, and the cost and the load on the environment can be reduced.
The thinning step of the present embodiment preferably includes a step of thinning the metal material to form a can body portion so that a reduction ratio (a reduction ratio in sheet thickness) becomes 10% or more. The thinning may be performed a plurality of times, or the thinning rate may be changed for each time. For example, the thinning ratio in the initial thinning step may be set to 10% or more, and the thinning ratio in the final thinning step may be set to 30% or more.
The reduction ratio in the present embodiment is expressed by the following equation where the plate thickness before the reduction is t0 and the plate thickness after the reduction (the portion 60mm from the can bottom) is t 1.
Reduction ratio (%) =100 × (t 0-t 1)/t 0
< cleaning Process >
Next, the cleaning step in the present embodiment will be described.
The cleaning step in the present embodiment is a step of: the cleaning agent is brought into contact with the bottomed cylindrical body obtained in the drawing step and the ironing step described above, and the lubricant and/or the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body are removed. In the present embodiment, the cleaning step is not essential, and may be omitted as appropriate.
As a method of bringing the cleaning agent into contact with the bottomed cylindrical body, a known method can be suitably used. For example, the bottomed cylindrical body may be immersed in the cleaning agent, or the cleaning agent may be sprayed by spraying or showering.
As the cleaning agent used in the present embodiment, water may be used in addition to known alkaline cleaning agents, acid cleaning agents, and neutral cleaning agents.
Examples of the alkaline cleaning agent include aqueous solutions of inorganic compounds such as sodium carbonate, potassium carbonate, sodium hydrogen carbonate, sodium hydroxide, and potassium hydroxide. Examples of the acid washing agent include aqueous solutions of inorganic acids such as sulfuric acid, nitric acid, hydrochloric acid, and hydrofluoric acid. As the neutral detergent, a surfactant or the like can be used.
After the cleaning treatment with an alkali cleaning agent, an acid cleaning agent, or a neutral cleaning agent, it is preferable to remove the water on the surface of the metal plate by a method such as air blast or hot air drying after the water washing treatment in order to remove the cleaning agent remaining on the surface of the metal plate as is known.
The concentration of the cleaning component in the cleaning agent using an alkaline cleaning agent, an acid cleaning agent, or the like is preferably 3.0 vol% or less from the viewpoint of cost reduction and environmental load reduction.
In the cleaning step in the present embodiment, the temperature of the cleaning agent to be used is preferably less than 70 ℃. That is, in the present embodiment, since both the lubricant in the drawing step and the coolant in the ironing step are water-soluble and/or have a boiling point of less than 300 ℃, even if the temperature of the cleaning agent is less than 70 ℃, the oil can be sufficiently removed from the inner surface and the outer surface of the bottomed tubular body.
On the other hand, the lower limit of the temperature of the cleaning agent is preferably room temperature (for example, 20 ℃).
Generally, when cleaning process oil or the like in metal press working, a cleaning agent is heated for use in order to improve cleaning performance. However, for heating the cleaning agent, corresponding energy resources are consumed. Therefore, in the present embodiment, from the viewpoint of cost reduction and reduction in environmental load, the cleaning agent can be used at room temperature without deteriorating the cleaning performance.
Further, in the present embodiment, it is preferable that the cleaning time in the cleaning step is 45 seconds or less from the viewpoint of cost reduction and reduction of environmental load. That is, in the present embodiment, since both the lubricant in the drawing step and the coolant in the ironing step are water-soluble and/or have a boiling point of less than 300 ℃, the inside surface and the outside surface of the bottomed tubular body can be sufficiently cleaned even if the cleaning time is 45 seconds or less.
The lower limit of the washing time is not particularly limited, but is preferably, for example, more than 10 seconds as a lower limit of the washing time that can be practically washed without problems and has no problem in wastewater treatment performance. In the case of spraying or showering the cleaning agent as a cleaning method, the amount of the cleaning agent sprayed per tank is preferably 60 to 70 ml/sec.
In the cleaning step of the present embodiment, the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body are removed by the cleaning agent. Therefore, the weight of the bottomed cylindrical body before and after washing changes, and preferably the weight change is less than 100mg/m 2 。
That is, in the present embodiment, as described above, since both the lubricant in the drawing step and the coolant in the ironing step are water-soluble and/or have a boiling point of less than 300 ℃, the amounts of the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body after the can forming step (drawing step and ironing step) can be reduced.
Therefore, the change of the weight of the bottomed cylindrical body before and after cleaning is made to be less than 100mg/m 2 The amount of lubricant and coolant contained in the waste water generated in the washing step can be reduced, and the environmental load can be reduced.
< drying Process >
In the present embodiment, as described above, the cleaning step can be appropriately omitted. In this case, it is preferable to provide a drying step for removing the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body.
That is, in the present embodiment, it is preferable to use a lubricant in the drawing step and a coolant in the ironing step, both of which are water-soluble and/or have a boiling point of less than 300 ℃. Therefore, after the can forming process (drawing process and ironing process), the lubricant and the coolant adhering to the inner surface and the outer surface can be removed by the drying process without providing a washing process.
In the drying step of the present embodiment, specifically, for example, the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body can be removed by heating at about 150 to 300 ℃ for 30 to 180 seconds in a drying oven.
< purification Process >
Next, in the present embodiment, a purification step of purifying waste water discharged in the thinning step and/or the cleaning step in the method for producing a bottomed cylindrical body will be described.
In the present embodiment, the "wastewater discharged in the thinning step and/or the cleaning step" means either one of the "wastewater discharged in the thinning step" and the "wastewater discharged in the cleaning step", or both of them.
That is, as described above, in the method of manufacturing a bottomed cylindrical body according to the present embodiment, thinning is performed via the coolant in the thinning step. In the cleaning step, in addition to the main cleaning for removing the lubricant and the coolant adhering to the surface of the bottomed cylindrical body with the cleaning agent, pre-cleaning with water, rinsing for removing the cleaning agent with water after the main cleaning, and the like are performed. Therefore, a large amount of wastewater is generated in the washing process.
Therefore, the method for producing a bottomed cylindrical body in the present embodiment may further include a purification step of purifying the wastewater as shown in fig. 3. In this case, the wastewater purified as described above is preferably reused (recycled) as purified water in the thinning step and the cleaning step for the reason described later.
That is, in the method for producing a bottomed tubular body in the present embodiment, as described above, the lubricant applied in the lubricant application step is water-soluble and/or has a boiling point of less than 300 ℃. As described above, the coolant used in the thinning step is a water-soluble coolant and/or has a boiling point of less than 300 ℃. Therefore, the oil content in the wastewater discharged in the thinning step and the washing step is less than a predetermined value.
Therefore, the waste water generated in the thinning step and/or the cleaning step can be purified by a relatively simple method. Further, by performing the cleaning step, the environmental load can be further reduced and the cost can be reduced.
As a method for purifying wastewater in the above-mentioned purification step, a known method can be suitably used. That is, the purification can be carried out by appropriately combining methods such as filtration, neutralization, boiling, precipitation, floatation, biological treatment, and UV sterilization. In addition, a flocculant, a disinfectant, a bactericide, or the like may be appropriately mixed.
As described above, according to the method for manufacturing a bottomed cylindrical body of the present embodiment, the following effects can be obtained.
(A) Since the processing surface of the molded member in the thinning step has the carbon film, the coolant used in the thinning step can be made water-soluble and/or have a boiling point of less than 300 ℃.
(B) Since the hardness of the worked surface of the formed member in the drawing step is set to a predetermined value or more, a lubricant application step of applying a lubricant to the surface of the metal plate (flat plate) before the drawing step can be omitted.
(C) As a result, the heating of the cleaning agent in the cleaning step can be suppressed, and/or the cleaning time can be shortened. Further, the cleaning step may not be provided.
(D) As a result, the environmental load can be reduced and the cost can be reduced.
In the present embodiment, if the cleaning step is further performed, the following effects can be further exhibited.
(E) The wastewater discharged in the thinning step and/or the washing step can be easily purified.
(F) The waste water can be purified and reused (recycled), and the cost and the load on the environment can be reduced.
(second embodiment)
Next, a method for manufacturing a bottomed tubular body according to a second embodiment will be described. The schematic diagram showing the drawing step shown in fig. 1 can also be applied to the second embodiment. In addition, the schematic diagram showing the thinning process shown in fig. 2 can also be applied to the second embodiment. Fig. 4 is a schematic diagram showing a flow of a method for manufacturing a bottomed cylindrical body according to a second embodiment.
< Metal plate >
The metal plate as the workpiece in the present embodiment is not particularly limited as long as it is subjected to general metal press working. For example, various known metal plates such as aluminum, copper, iron, steel, titanium (further, not only pure metals but also alloys thereof) and the like can be used. Among these, aluminum alloy sheets are particularly preferable for forming seamless can bodies.
The thickness of the metal plate in the present embodiment is not particularly limited, and a normal thickness in the production of a seamless can body can be applied. For example, as an example of the thickness of the metal plate in can forming using an aluminum alloy plate, the thickness of the mother plate (thickness of the original plate) is 0.1mm to 0.5mm.
< procedure of applying Lubricant >
The method of manufacturing a bottomed tubular body according to the present embodiment may further include a lubricant application step of applying a lubricant to the surface of the metal plate (flat plate) before drawing. In the present embodiment, the lubricant generally contains an oil component called "metal working oil" or "metal cutting oil".
As is generally known, by applying a known processing oil or lubricant before drawing, even if severe drawing-ironing is performed in the subsequent drawing step or ironing step, the metal sheet can be worked into a desired shape such as a bottomed tubular body without being damaged or broken. However, in the present embodiment, this step is not an essential step for the reason described later.
The following lubricants are examples of the type of the lubricant in the present embodiment.
For example, mineral oil composed of fatty acid ester, fatty acid alcohol, fatty acid, or the like can be used.
Alternatively, water soluble lubricants or lubricants with a boiling point of less than 300 ℃ may be used.
The water-soluble lubricant in the present embodiment is defined as a lubricant soluble in water. The use of a water-soluble lubricant is preferable because it enables removal of lubricant components adhering after can formation without using a chemical (such as an acid, an alkali, or a surfactant). In the present embodiment, for example, when washing with water in a washing step described later, it is preferable to remove the lubricant component and the coolant component to such an extent that defects such as unevenness and repelling of the coating material do not occur in printing in the subsequent step.
As the lubricant having a boiling point of less than 300 ℃, specifically, a commercially available wash-free oil can be used as the volatile lubricating oil. The reason why the lubricant having a boiling point of less than 300 ℃ is preferable is that the adhered lubricant component can be vaporized and removed at a relatively low temperature after the can manufacturing process. From the viewpoint of facility cost, energy cost, and the like, the boiling point of the lubricant is more preferably less than 250 ℃.
In this step, a known amount and a known method can be applied to the amount and method of applying the lubricant.
In the present embodiment, the viscosity of the lubricant is preferably less than 200mPa · s from the viewpoint of reducing the environmental load and cost in the cleaning step, which are objects of the present invention. When the viscosity of the lubricant is 200mPa · s or more, the lubricant may not be sufficiently washed and removed in the subsequent washing step and drying step, which is not preferable. The viscosity of the lubricant is more preferably less than 100mPa · s.
< deep drawing Process >
Next, a drawing step in the present embodiment will be described.
In the drawing step of the present embodiment, it is preferable that the working surface of the formed member (for example, drawing die or drawing punch) in the drawing step is a predetermined hardness or more. Specifically, the hardness of the machined surface is required to be Hv1000 to 12000 on the Vickers scale. Specifically, the method for producing a bottomed tubular body according to the present embodiment is characterized in that the hardness of the working surface of the drawing die is set to Hv exceeding 1500 and 12000 or less, and the hardness of the working surface of the drawing punch is set to Hv1000 to 12000.
The reason for this is as follows.
That is, in the case of describing an example of the drawing step of the metal plate with reference to fig. 1, the metal plate 10 is interposed between the drawing die D D And drawing punch P D In the state of the above, the punch P is drawn D Drawing is performed to manufacture a shallow drawn cup M. At this time, a strong impact load acts on the drawing die D D And a drawing punch P D Therefore, high durability and wear resistance to the extent of withstanding mass production are required.
In the present embodiment, in order to reduce the environmental load and the cost in the cleaning step, the step of applying the working oil or the lubricant to the surface of the metal plate (flat plate) before the drawing process may be omitted. In this case, in order to avoid damage or breakage of the metal plate due to the molding member, it is necessary to impart high hardness or slidability to the metal plate by using a mold.
From the above-described viewpoints, the present inventors have made trial and error, and as a result, have found that, in the present embodiment, when the hardness of the worked surface of the formed member during drawing is represented by vickers hardness, the hardness of the worked surface of the drawing die is Hv exceeding 1500 and 12000 or less, and the hardness of the worked surface of the drawing punch is Hv1000 to 12000, even when severe drawing and ironing are performed, there is no problem from the viewpoints of durability, wear resistance, damage to the metal plate, and the like.
In the present embodiment, the formed member (die) in the drawing step may be manufactured from a base material made of a known material, or may be formed with a surface-treated film L (see fig. 2) on the formed surface of the base material, as long as the formed surface has the above hardness.
Specific examples of the material of the base material in the mold include cemented carbide obtained by sintering a mixture of tungsten carbide (WC) and a metal binder such as cobalt; and cermets obtained by sintering a mixture of a metal carbide such as titanium carbide (TiC), a titanium compound such as titanium carbonitride (TiNC), and a metal binder such as nickel or cobalt.
As the surface treatment film L formed on the substrate, for example, a carbon film, a ceramic film, a fluororesin film, or the like can be preferably used.
Examples of the carbon film include a diamond film having a vickers hardness of about 8000 to 12000, and a DLC film having a vickers hardness of about 3000 to 7000. The method for forming these carbon films is not particularly limited, and for example, chemical Vapor Deposition (CVD) method, physical Vapor Deposition (PVD) method, or the like can be applied.
Examples of the ceramic film include silicon carbide (SiC) and silicon nitride (Si) 3 N 4 ) Alumina (Al) 2 O 3 ) Zirconium oxide (ZrO) 2 ) Such hard ceramics, and the like.
In the present embodiment, as a combination of types of the forming members used in the drawing step, the same material or surface-treated film L may be used for both the drawing die and the drawing punch, or different materials or surface-treated films L may be used. For example, both the drawing die and the drawing punch may be made of cemented carbide, or one of the drawing die and the drawing punch may be made of cemented carbide. Alternatively, a carbon film may be formed on the processing surface of both the drawing die and the drawing punch, or on the processing surface of one of the drawing die and the drawing punch. That is, in fig. 2, the drawing die D D The working surface of (2) is formed with a surface treatment film L, and a drawing punch P D The surface treatment film L is not formed on the work surface of (1), but the present invention is not limited thereto.
In the present embodiment, it is preferable that a carbon film be formed on the working surface of at least one of the male die and the female die during the drawing. For example, when a drawing die is used as a female die and a drawing punch is used as a male die, a carbon film is preferably formed on at least one of the processing surfaces.
More specifically, the DLC film may be formed on the working surfaces of both the drawing die and the drawing punch, or a diamond film may be formed on one of the drawing die and the drawing punch and a DLC film may be formed on the other.
In particular, from the viewpoint of dimensional control between dies and suppression of damage between dies, when the surface treatment film of one of the drawing die and the drawing punch is a diamond film, the other is more preferably a surface treatment film other than the diamond film. In this case, it is more preferable to form the diamond film on a drawing die to which a higher processing load is applied. The diamond film may be formed on at least the machined surface of the die section, or may be formed on other portions.
The thickness of the diamond film is preferably 5 to 30 μm. When the thickness is less than 5 μm, cracks are likely to occur in the obtained diamond film, and peeling is likely to occur, which is not preferable. On the other hand, if the thickness exceeds 30 μm, the internal stress of the diamond film increases, and peeling becomes easy, which is not preferable.
On the other hand, when the surface-treated film of one of the drawing die and the drawing punch is a diamond film, the thickness of the surface-treated film formed on the other is preferably about 0.1 to 10 μm, and particularly preferably set to be thinner than the thickness of the diamond film.
This is for the following reason. That is, for example, when the thickness of the surface treatment film formed on the drawing punch is made thinner than the thickness of the diamond film formed on the drawing die, the film is formed, and therefore, the dimensional error due to the film formation can be reduced. In addition, since the surface treatment film has a soft vickers hardness relative to the diamond film, it can be easily polished by using known diamond abrasive grains, and not only can the processing cost be reduced, but also the target mold size can be achieved with high accuracy.
< thinning Process >
Next, the thinning step in the present embodiment will be described.
The thinning step in the present embodiment is characterized in that the hardness of the machined surface of the formed member (e.g., a thinning die or a thinning punch) in the thinning step is Hv1500 to 12000.
The thinning step of the present embodiment will be described more specifically with reference to the drawings, and as shown in fig. 2 (a) and (b), for example, includes the steps of: using a thinning die D having a diamond film 20 formed on the working surface I And a thinning punch P having a surface treatment film 30 different from the diamond film formed on the machining surface I With the coolant C interposed, using a die D I And a punch P I The shallow drawn cup M is subjected to ironing.
At this time, for the thinning die D I And a thinning punch P I High durability and wear resistance to such an extent that they can withstand mass production are required. In the present embodiment, as described later, the concentration of the oil contained in the coolant C needs to be less than 4.0 vol%, or the coolant C needs to be a water-soluble coolant or a coolant having a boiling point of less than 300 ℃. Therefore, the ironing die D is required to be used for the reason of avoiding damage, breakage, and the like of the workpiece (the metal plate 10, the shallow drawing cup M) I And a thinning punch P I The hardness of the machined surface of (2) is Hv1500 to 12000.
Among the above, the thinning die D is particularly preferable I And a thinning punch P I The carbon film is formed on any one of the processed surfaces of (1). Examples of the carbon film include a diamond film having a vickers hardness Hv of about 8000 to 12000, and a DLC film having a vickers hardness Hv of about 3000 to 7000. The method for forming these carbon films is not particularly limited, and for example, a Chemical Vapor Deposition (CVD) method, a Physical Vapor Deposition (PVD) method, or the like can be applied.
It is to be noted thatIn the embodiment, the diamond film is particularly preferably formed on the working surface of either one of the male die and the female die of the mold. That is, as shown in FIG. 2, the diamond film 20 having a high hardness may be formed on the thinning die D I On the thinning punch P I The surface treatment film 30 is formed on the machined surface of (a), but not shown, it may be reversed.
In general, since the thinning die is often subjected to a more severe processing load than the thinning punch, it is particularly preferable to form the diamond film 20 on the processing surface of the thinning die.
The thickness of the diamond film 20 is preferably 5 to 30 μm. When the thickness is less than 5 μm, cracks are likely to occur in the obtained diamond film, and peeling is likely to occur, which is not preferable. On the other hand, if the thickness exceeds 30 μm, the internal stress of the diamond film increases, and peeling becomes easy, which is not preferable.
On the other hand, the thickness of the surface treatment film 30 different from the diamond film 20 is preferably about 0.1 to 10 μm, and particularly preferably set to be thinner than the thickness of the diamond film 20.
This is for the following reason. That is, for example, when the thickness of the surface treatment film 30 is made thinner than the thickness of the diamond film 20, since the surface treatment film is a thin film, a dimensional error due to film formation can be reduced.
In the present embodiment, the surface roughness Ra (JIS B-0601-1994) of the diamond film 20 is preferably 0.12 μm or less, from the viewpoint of imparting high sliding properties to the mold. Further, when Ra is 0.08 μm or less, the appearance of the workpiece (for example, can body) can be made to be a mirror surface or a smooth surface close to a mirror surface, which is more preferable.
In this case, the friction coefficient μ between the diamond film 20 and the material to be processed at the time of press working is preferably less than 0.1.
Next, the coolant used in the thinning step of the present embodiment will be described.
The coolant used in the present embodiment may contain an oil component as a component thereof, but it is preferable that the coolant can be easily cleaned in a subsequent cleaning step or can be removed by drying when a cleaning step is not provided. Therefore, the coolant in the present embodiment is preferably a coolant that satisfies at least one of (a) an oil content of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a boiling point of less than 300 ℃.
When the coolant is a coolant containing less than 4.0 vol% of oil component (a), the oil component may be an oil component contained in a normal water-soluble metal working oil composition. The oil component may be natural oil component or synthetic oil component.
Examples of the natural oil include mineral oils such as paraffin-based, naphthene-based, and aromatic-based oils. In addition, fatty acid glycerides may be exemplified as natural oil components.
Examples of the synthetic oil include hydrocarbon-based oils such as polyolefins, ester-based oils such as fatty acid esters, ether-based oils such as polyalkylene glycols, fluorine-containing oils such as perfluorocarbons, phosphorus-containing oils such as phosphoric acid esters, and silicon-containing oils such as silicic acid esters.
The above-listed oil components may be used alone or in combination of 2 or more.
Specifically, for example, A1 (emulsion type) or A2 (soluble type) water-soluble metal working oil prescribed in JIS K2241 may be mentioned. Although not specified in JIS standards, a water-soluble metal working oil agent called a so-called synthetic type (a metal working oil agent containing a chemically synthesized oil component without mineral oil) may be cited.
In the present embodiment, the concentration of the oil in the coolant is preferably less than 4.0 vol%.
In this case, a stock solution containing an oil content of 4.0 vol% or more is prepared first, and when the stock solution is stored and used, the stock solution is diluted with a solvent such as water at the time of use, whereby a coolant having an oil content of less than 4.0 vol% can be prepared. That is, the concentration of the oil component in the coolant may be less than 4.0 vol% in the use state.
Next, among the coolants used in the present embodiment, (b) a water-soluble coolant is defined as a coolant soluble in water. The use of a water-soluble coolant is preferable because it is possible to remove the coolant component adhering after can formation without using a chemical (acid, alkali, surfactant, or the like). In the present embodiment, for example, when washing is performed with water in a washing step described later, it is preferable to remove the lubricant component and the coolant component to such an extent that defects such as unevenness and repulsion of the paint do not occur in printing in the subsequent step.
In the present embodiment, as the coolant (c) having a boiling point of less than 300 ℃, specifically, a non-cleaning oil commercially available as a volatile lubricating oil can be applied. The coolant having a boiling point of less than 300 ℃ is preferable because the adhered coolant component can be vaporized and removed at a relatively low temperature after the can manufacturing process. From the viewpoint of facility cost, energy cost, and the like, the boiling point of the coolant is more preferably less than 250 ℃.
As the coolant of the present embodiment, the above-described coolants (a), (b), and (c) may be used in combination. Further, a coolant having a plurality of properties of (a), (b), and (c) may be used.
The coolant in the present embodiment may contain an additive as long as at least one of the characteristics of (a) containing an oil content of less than 4.0 vol%, that (b) being water-soluble, and that (c) having a boiling point of less than 300 ℃. For example, water, a surfactant, a rust preventive, an extreme pressure additive, a coupling agent, a non-ferrous metal anticorrosive, a preservative, a rust preventive, an antifoaming agent, a chelating agent, a colorant, a perfume, and the like may be appropriately contained.
In particular, the coolant of the present embodiment preferably contains a corrosion inhibitor and/or a rust inhibitor. This is for the following reason.
That is, in the case of a water-soluble coolant, a large amount of substances serving as nutrient sources for microorganisms such as bacteria and mold are contained. Therefore, there are problems as follows: the diluted coolant is easily putrefy, and a portion of the processing equipment in contact with the coolant is easily rusted.
In the present embodiment, "anticorrosive agent and/or rust inhibitor" means that either one of "anticorrosive agent" and "rust inhibitor" may be included, or both of them may be included. Further, it means that a substance having either of "corrosion prevention" and "rust prevention" properties may be used, or a substance having both of "corrosion prevention" and "rust prevention" properties may be used.
If the coolant is deteriorated, not only the lubricating function and the cooling function as the functions of the coolant are deteriorated, but also the bad odor caused by the deterioration becomes a problem. In addition, if rust forms, the workpiece may be damaged.
In addition, there is a problem in cost due to an increase in the frequency of coolant replacement caused by corrosion or rust. Further, when mold or rust develops, the pipe may be clogged in a circulation system such as a pump.
As the corrosion inhibitor and/or rust inhibitor, any known one can be used as long as it does not impair at least any of the characteristics of the coolant that (a) contains an oil content of less than 4.0 vol%, (b) is water-soluble, and (c) has a boiling point of less than 300 ℃. For example, a formaldehyde-releasing or phenol-based substance or an amine-based substance may be added as appropriate.
As described above, in the manufacturing method of the present embodiment, when the coolant used in the thinning process is at least one of (a) the oil content is less than 4.0 vol%, (b) the water-soluble coolant, and (c) the coolant having a boiling point of less than 300 ℃.
In addition, in the present embodiment, since the coolant as described above is used, cleaning with a chemical or water having a low environmental load can be performed in a cleaning step described later. Alternatively, the cleaning process itself can be omitted, and thus the load on the environment can be reduced.
Further, since the waste water after washing is easily treated, when the waste water is recycled, the recycling rate can be improved, and the cost and the load on the environment can be reduced.
The thinning step of the present embodiment preferably includes a thinning step of forming a can body portion by thinning the metal material so that a thinning ratio (a reduction ratio in sheet thickness) becomes 10% or more. The thinning process may be performed a plurality of times, and the thinning rate may be changed for each time. For example, the reduction ratio in the initial reduction step may be 10% or more, and the reduction ratio in the final reduction step may be 30% or more.
The reduction ratio in the present embodiment is expressed by the following equation where the plate thickness before the reduction is t0 and the plate thickness after the reduction (the portion 60mm from the can bottom) is t 1.
Reduction ratio (%) =100 × (t 0-t 1)/t 0
< cleaning Process >
Next, the cleaning step in the present embodiment will be described.
The cleaning step in the present embodiment is a step of: the cleaning agent is brought into contact with the bottomed cylindrical body obtained in the drawing step and the ironing step described above, and the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body are removed. In this embodiment, the cleaning step is not essential, and may be omitted as appropriate.
As a method for bringing the cleaning agent into contact with the bottomed cylindrical body, a known method can be suitably used. For example, the bottomed cylindrical body may be immersed in the cleaning agent, or the cleaning agent may be sprayed by spraying or showering.
As the cleaning agent used in the present embodiment, known alkaline cleaning agents, acid cleaning agents, neutral cleaning agents, or water may be used.
Examples of the alkaline cleaning agent include aqueous solutions of inorganic compounds such as sodium carbonate, potassium carbonate, sodium hydrogen carbonate, sodium hydroxide, and potassium hydroxide.
Examples of the acid washing agent include aqueous solutions of inorganic acids such as sulfuric acid, nitric acid, hydrochloric acid, and hydrofluoric acid.
After the cleaning treatment with an alkali cleaning agent or an acid cleaning agent, it is preferable to remove the water on the surface of the metal plate by a method such as air blowing or hot air drying after the water washing treatment in order to remove the cleaning agent remaining on the surface of the metal plate as is well known.
The concentration of the cleaning component of the cleaning agent when an alkaline cleaning agent, an acid cleaning agent, or the like is used is preferably 2.0 to 5.0 wt% from the viewpoint of maintaining cleaning performance and suppressing cost and environmental load.
In the cleaning step in the present embodiment, the temperature of the cleaning agent to be used is preferably less than 70 ℃. That is, in the present embodiment, the step of applying the working oil or the lubricant to the surface of the metal plate (flat plate) before drawing may be omitted, and at least one of (a) the oil content of less than 4.0 vol%, (b) the water-soluble coolant, and (c) the coolant having a boiling point of less than 300 ℃ may be used as the coolant in the ironing step. Therefore, even if the temperature of the cleaning agent is lower than 70 ℃, the oil on the inner surface and the outer surface of the bottomed cylindrical body can be sufficiently removed.
On the other hand, the lower limit of the temperature of the cleaning agent is preferably room temperature (for example, 20 ℃). Generally, when cleaning processing oil or the like in metal press working, a cleaning agent is heated for use in order to improve cleaning performance. However, in order to heat the cleaning agent, corresponding energy resources are consumed. Therefore, in the present embodiment, from the viewpoint of cost reduction and reduction in environmental load, the cleaning agent can be used at room temperature without deteriorating the cleaning performance.
Further, in the present embodiment, it is preferable that the cleaning time in the cleaning step is 45 seconds or less from the viewpoints of cost reduction and environmental load reduction. That is, in the present embodiment, since both the lubricant in the drawing step and the coolant in the ironing step are water-soluble and/or have a boiling point of less than 300 ℃, the inner surface and the outer surface of the bottomed tubular body can be sufficiently cleaned even if the cleaning time is 45 seconds or less.
The lower limit of the washing time is not particularly limited, but is preferably, for example, more than 10 seconds as a lower limit of the washing time that can be practically washed without problems and has no problem in wastewater treatment performance. In the case of spraying or showering the cleaning agent as a cleaning method, the amount of the cleaning agent sprayed per tank is preferably 60 to 70 ml/sec.
In the cleaning step of the present embodiment, the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed tubular body are removed by the cleaning agent. Therefore, the weight of the bottomed cylindrical body before and after washing changes, but the weight change is preferably less than 100mg/m 2 。
That is, in the present embodiment, the amounts of lubricant and coolant adhering to the inner surface and the outer surface of the bottomed tubular body after the can forming step (drawing step and ironing step) can be reduced.
Therefore, the change in weight of the bottomed cylindrical body before and after cleaning is made to be less than 100mg/m 2 The amount of the lubricant and the coolant contained in the waste water generated in the washing step can be reduced, and the environmental load can be reduced.
< drying Process >
In the present embodiment, as described above, the cleaning step can be appropriately omitted. In this case, a drying step is preferably provided to remove the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed tubular body.
That is, in the present embodiment, the step of applying the working oil or the lubricant to the surface of the metal plate (flat plate) before drawing may be omitted, and at least one of (a) an oil content of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a coolant having a boiling point of less than 300 ℃ may be used as the coolant in the ironing step.
Among them, in the case where the working oil and the lubricant are not applied to the surface of the metal plate (flat plate) before drawing and the (c) coolant having a boiling point of less than 300 ℃ is used as the coolant in the ironing step, even in the case where the washing step is not provided after the can forming step (drawing step and ironing step), the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed tubular body can be removed by the drying step.
In the drying step of the present embodiment, specifically, the lubricant and the coolant adhering to the inner surface and the outer surface of the bottomed cylindrical body can be removed by heating at about 150 to 300 ℃ for 30 to 180 seconds, for example, in a drying oven.
< purification Process >
Next, the cleaning step in the present embodiment will be described. As shown in fig. 3, the method for producing a bottomed cylindrical body according to the present embodiment may include a cleaning step of cleaning the waste water discharged in the thinning step and/or the cleaning step.
That is, as described above, in the method of manufacturing a bottomed cylindrical body according to the present embodiment, thinning is performed via the coolant in the thinning step. In the cleaning step, the coolant component adhering to the surface of the bottomed cylindrical body is removed using a cleaning agent. Thus, a large amount of wastewater is generated in both processes.
Therefore, the method for producing a bottomed cylindrical body in the present embodiment may further include a purification step of purifying the wastewater as shown in fig. 3. In this case, the wastewater purified as described above is preferably reused (recycled) as purified water in the thinning step and the cleaning step for the reason described later.
In the method of manufacturing a bottomed tubular body according to the present embodiment, as described above, the step of applying the working oil or the lubricant to the surface of the metal plate (flat plate) before the drawing work can be omitted. As described above, at least one of (a) a coolant containing an oil content of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a coolant having a boiling point of less than 300 ℃.
Therefore, the waste water generated in the thinning step and/or the cleaning step can be purified by a relatively simple method. Further, by performing the above-described cleaning step, the environmental load can be further reduced and the cost can be further reduced.
As a method for purifying wastewater in the above-mentioned purification step, a known method can be suitably used. That is, the purification can be performed by appropriately combining methods such as filtration, neutralization, boiling, precipitation, floatation, biological treatment, and UV sterilization. In addition, a flocculant, a disinfectant, a bactericide, or the like may be appropriately mixed.
As described above, according to the method for manufacturing a bottomed cylindrical body of the present embodiment, the following effects can be obtained.
(A) Since the hardness of the worked surface of the formed member in the drawing step is set to a predetermined value or more, the step of applying a lubricant to the surface of the metal plate (flat plate) before the drawing step can be omitted.
(B) Since the hardness of the worked surface of the molded member in the thinning step is not less than a predetermined value, a coolant satisfying at least one of (a) an oil content of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a coolant having a boiling point of less than 300 ℃ can be used as the coolant in the thinning step.
(C) As a result, the concentration of the cleaning component in the cleaning agent in the cleaning step can be reduced, heating of the cleaning agent can be suppressed, and/or the cleaning time can be shortened. In addition, the cleaning process may be omitted.
(D) As a result, the environmental load can be reduced and the cost can be reduced.
In the present embodiment, if the cleaning step is further performed, the following effects can be further exhibited.
(E) The wastewater discharged in the thinning step and/or the washing step can be easily purified.
(F) The wastewater can be purified and reused (recycled), and the cost and the load on the environment can be reduced.
Examples
The present invention will be described in further detail below with reference to examples, but the present invention is not limited to the following examples.
(example 1)
A drawn and ironed can (DI can) having an internal volume of 350mL was produced by the following method.
First, an aluminum alloy plate (JIS H4000 3104 material, 0.28 mm) was prepared. Then, coating 1.0-1.3 g/m on both sides of the aluminum alloy plate 2 The water-soluble lubricant (2) is used as a lubricant in drawing.
Next, the aluminum alloy sheet was punched out into a disk shape having a diameter of 160mm by using a drawing machine, and immediately thereafter, was drawn into a cup having a diameter of 90 mm. The hardness of the worked surface of the formed member during drawing was Hv1500.
The obtained cup was conveyed to a can body maker (can body maker), redrawn into a shape having a diameter of 66mm, and then ironed with a coolant to a shape having a diameter of 66mm and a height of 130 mm.
As the thinning die in this case, a thinning die having a diamond film with an average thickness of about 10 μm formed on the surface thereof was used. The surface hardness of the diamond film was Hv10000.
As the thinning punch used, a thinning punch having a diamond-like carbon film of 0.5 μm thickness formed on the surface thereof was used. The surface hardness of the diamond-like carbon film was Hv3000.
The reduction ratio in the reduction processing is shown in table 1. A water-soluble coolant is used in the thinning process. The coolant is added with known surfactant, antirust agent, extreme pressure additive and antiseptic.
The resulting DI can is subjected to cleaning for removing lubricant and coolant components adhering to the inside and outside surfaces. As a cleaning agent used for cleaning, sulfuric acid (concentration: 3.0 vol%) was used. The temperature of the cleaning agent during cleaning was set to 20 ℃ and the cleaning time was set to 30 seconds.
(example 2)
The drawing was performed in the same manner as in example 1, except that a lubricant having a boiling point shown in table 1 was used as the lubricant in the drawing. The results are shown in Table 1.
(example 3)
The same procedure as in example 1 was repeated except that the worked surface hardness of the formed member in the drawing was changed to the worked surface hardness shown in table 1. The results are shown in Table 1.
(example 4)
The drawing was performed in the same manner as in example 1, except that the working surface hardness of the drawing die during drawing was changed to the working surface hardness shown in table 1. The results are shown in Table 1.
(example 5)
The same procedure as in example 1 was repeated, except that the working surface hardness of the drawing punch in the drawing was changed to the working surface hardness shown in table 1. The results are shown in Table 1.
(example 6)
As the thinning die used in the thinning process, a thinning die having a diamond-like carbon film with an average thickness of 0.5 μm formed on the surface thereof was used. The surface hardness of the diamond-like carbon film was Hv3000. Otherwise, the procedure was performed in the same manner as in example 1. The results are shown in Table 1.
(example 7)
As the thinning punch used in the thinning process, a thinning punch having a diamond film with an average thickness of about 10 μm formed on the surface thereof was used. The surface hardness of the diamond film was Hv10000. Otherwise, the procedure was performed in the same manner as in example 1. The results are shown in Table 1.
(example 8)
The coolant used in the thinning process had a boiling point shown in table 1. Otherwise, the procedure was performed in the same manner as in example 1. The results are shown in Table 1.
(example 9)
The procedure of example 1 was repeated, except that pure water was used as the cleaning agent. The results are shown in Table 1.
(example 10)
The same procedure as in example 1 was repeated except that drying (300 ℃ C. For 30 seconds) was performed instead of the washing step after the draw-ironing. The results are shown in Table 1.
(example 11)
The coolant used in the ironing process has a boiling point shown in table 1. Otherwise, the procedure was performed in the same manner as in example 2. The results are shown in Table 1.
(example 12)
The same procedure as in example 2 was repeated, except that pure water was used as the cleaning agent used for cleaning. The results are shown in Table 1.
(example 13)
The same procedure as in example 2 was repeated except that drying (300 ℃ C. For 30 seconds) was performed instead of the washing step after the draw-ironing. The results are shown in Table 1.
(example 14)
The procedure of example 8 was repeated, except that pure water was used as the cleaning agent. The results are shown in Table 1.
(example 15)
The procedure was carried out in the same manner as in example 8 except that drying (300 ℃ C. For 30 seconds) was carried out in place of the washing step after the draw-ironing. The results are shown in Table 1.
(example 16)
The same procedure as in example 11 was repeated, except that pure water was used as the cleaning agent used for cleaning. The results are shown in Table 1.
(example 17)
The procedure was carried out in the same manner as in example 11 except that drying (300 ℃ C. For 30 seconds) was carried out in place of the washing step after the draw-ironing. The results are shown in Table 1.
(example 18)
After the washing step after the draw-ironing, the sheet was further dried (300 ℃ C. For 30 seconds). Except for this, the same procedure as in example 14 was carried out. The results are shown in Table 1.
(example 19)
After the washing step after the draw-ironing, the sheet was further dried (300 ℃ C. For 30 seconds). Except for this, the same procedure as in example 12 was carried out. The results are shown in Table 1.
(example 20)
The same procedure as in example 3 was repeated, except that no lubricant was used during the drawing and that the reduction ratio during the reduction was changed to the value shown in table 1. The results are shown in Table 1.
Comparative example 1
The same procedure as in example 1 was repeated, except that a water-insoluble lubricant was applied as the lubricant in the drawing. The results are shown in Table 1.
Comparative example 2
The drawing was performed in the same manner as in example 1, except that a lubricant having a boiling point shown in table 1 was used as the lubricant in the drawing. The results are shown in Table 1.
Comparative example 3
The same procedure as in example 1 was carried out except that the working surface hardness of the drawing die at the time of drawing was changed to the working surface hardness shown in table 1, but the can body was broken at the drawing step. The results are shown in Table 1.
Comparative example 4
For the thinning die and the thinning punch used in the thinning process, those made of cemented carbide (Hv 1000) were used. Otherwise, the procedure was performed in the same manner as in example 1. The results are shown in Table 1.
Comparative example 5
The same procedure as in example 1 was repeated, except that the coolant used for the thinning process was a water-insoluble coolant. The results are shown in Table 1.
Comparative example 6
The ironing was performed in the same manner as in example 1, except that the coolant used in the ironing had a boiling point shown in table 1 and was dried (300 ℃ c. For 30 seconds) instead of the washing step after the drawing-ironing. The results are shown in Table 1.
Comparative example 7
The same procedure as in example 1 was repeated except that the coolant used in the ironing was a water-insoluble coolant and drying (300 ℃ C. For 30 seconds) was performed in place of the washing step after the draw-ironing.
The results are shown in Table 1.
Comparative example 8
The same procedure as in example 1 was carried out except that no lubricant was used in the drawing, but the can body was broken in the drawing step. The results are shown in Table 1.
[ evaluation ]
The DI cans obtained by the above-described method were evaluated by the following method. The results are shown in Table 1.
[ thinning processability ]
The following 3 items were visually observed: (i) presence or absence of breakage during ironing, (ii) penetration of the opening of the obtained DI can (black streaks), discoloration of the inner and outer surfaces of the can body, and (iii) scratches on the outer surface of the can body. The evaluation results were "good" when none of the 3 items was defective and excellent, "good" when some item was defective but was able to withstand practical use, and "poor" when some item was defective and was not able to withstand practical use.
[ suitability for printing ]
After the water-based paint was applied to the cleaned can surface of the obtained DI can, the can surface was sintered by a known method to evaluate the unevenness of the paint. The case where no coating unevenness was observed by visual observation was evaluated as "o", and the case where unevenness was caused by paint repelling (shrinkage) or the like was evaluated as "x". When the coating material had been unevenly distributed, it was evaluated that the lubricant and/or the coolant used in the drawing step or the ironing step remained.
[ wastewater treatability ]
The waste water obtained by spray-cleaning the DI tank with the cleaning solution and washing the tank with water was stored in a beaker, and the Chemical Oxygen Demand (COD) was measured by a known method. If the COD is less than 200ppm, it is judged as O (good wastewater treatment); when the concentration is 200ppm or more, it is judged as X (poor wastewater treatment property). The results are shown in Table 1.
[ Table 1]
(example 21)
A draw-ironed can (DI can) having an internal volume of 350mL was produced by the method described below.
First, an aluminum alloy plate (JIS H4000 3104 material, 0.28 mm) was prepared. The lubricant was not applied to both surfaces of the aluminum alloy sheet.
Next, the aluminum alloy plate was punched out into a disk shape having a diameter of 160mm by a drawing machine, and immediately thereafter, was drawn into a cup having a diameter of 90 mm. The hardness of the worked surface of the formed member during drawing is shown in table 1.
The obtained cup was conveyed to a can body maker (can body maker), redrawn into a shape having a diameter of 66mm, and then ironed with a coolant to a shape having a diameter of 66mm and a height of 130 mm.
As the thinning die in this case, a thinning die having a diamond film with an average thickness of about 10 μm formed on the surface thereof was used. The surface hardness of the diamond film is shown in table 1.
As the thinning punch used, a thinning punch having a diamond-like carbon film of 0.5 μm thickness formed on the surface thereof was used. The surface hardness of the diamond-like carbon film is shown in table 1.
The reduction ratio in the reduction processing is shown in table 1. The content of oil in the coolant is shown in table 1. The coolant is added with known surfactant, antirust agent, extreme pressure additive and antiseptic.
The resulting DI can is cleaned to remove lubricant and coolant components adhering to the inside and outside surfaces. Sulfuric acid (concentration: 3.0%) was used as a cleaning agent used for cleaning. The temperature of the cleaning agent during cleaning was 50 ℃ and the cleaning time was 30 seconds.
(example 22)
The same procedure as in example 21 was repeated except that the working surface hardness of the ironing die during ironing was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 23)
The same procedure as in example 21 was carried out, except that the working surface hardness of the ironing die during the ironing process was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 24)
The same procedure as in example 21 was carried out, except that the working surface hardness of the ironing punch in the ironing process was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 25)
The oil content of the coolant used for the thinning process is shown in table 2. Otherwise, the procedure was performed in the same manner as in example 21. The results are shown in Table 2.
(example 26)
The coolant used in the thinning process had a boiling point shown in table 2. Otherwise, the procedure was performed in the same manner as in example 21. The results are shown in Table 2.
(example 27)
The same procedure as in example 21 was repeated except that pure water was used as the cleaning agent for cleaning. The results are shown in Table 2.
(example 28)
The same procedure as in example 21 was repeated, except that the coolant used in the ironing had a boiling point shown in table 2 and was dried (300 ℃ c. For 30 seconds) in place of the washing step after the draw-ironing. The results are shown in Table 2.
(example 29)
The same procedure as in example 27 was repeated except that the working surface hardness of the punch and the die in the drawing step and the ironing step was changed to those shown in table 2. The results are shown in Table 2.
(example 30)
The same procedure as in example 27 was repeated except that the working surface hardness of the punch and the die in the drawing step and the ironing step was changed to those shown in table 2. The results are shown in Table 2.
(example 31)
The same procedure as in example 28 was repeated, except that the working surface hardness of the punch and the die in the drawing step and the ironing step was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 32)
The same procedure as in example 21 was repeated, except that the working surface hardness of the punch and the die in the drawing step and the ironing step was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 33)
The same procedure as in example 27 was repeated except that a water-soluble lubricating oil was applied before the drawing step and the working surface hardness of the drawing punch and drawing die in the drawing step was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 34)
The same procedure as in example 21 was repeated, except that the working surface hardness of the drawing punch in the drawing step was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 35)
The same procedure as in example 34 was repeated, except that the water-soluble lubricating oil was applied before the drawing step. The results are shown in Table 2.
(example 36)
The same procedure as in example 21 was repeated, except that the working surface hardness of the punch in the drawing step and the ironing step was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
(example 37)
The same procedure as in example 34 was repeated except that the working surface hardness of the punch in the ironing step was changed to those shown in table 2. The results are shown in Table 2.
Comparative example 9
The same procedure as in example 21 was carried out except that the working surface hardness of the drawing die at the drawing was changed to the working surface hardness shown in table 2, but the can body was broken at the drawing step. The results are shown in Table 2.
Comparative example 10
The same procedure as in example 21 was carried out, except that the working surface hardness of the drawing die and the drawing punch in the drawing was changed to the working surface hardness shown in table 2, but the can body was broken in the drawing step. The results are shown in Table 2.
Comparative example 11
The same procedure as in example 21 was carried out, except that the working surface hardness of the ironing die and the ironing punch in the ironing process was changed to the working surface hardness shown in table 2. The results are shown in Table 2.
Comparative example 12
The drawing was performed in the same manner as in comparative example 11, except that the water-soluble lubricating oil was applied before the drawing step. The results are shown in Table 2.
Comparative example 13
The procedure of example 21 was repeated except that drying (300 ℃ C. For 30 seconds) was performed instead of the washing step after the draw-ironing. The results are shown in Table 2.
Comparative example 14
The working surface hardness of the punch and the die in the drawing step and the ironing step was set to the working surface hardness shown in table 2, and the oil content of the coolant used in the ironing was shown in table 2. Except for this, the same procedure as in example 27 was repeated. The results are shown in Table 2.
Comparative example 15
The oil content of the coolant used for the thinning process is shown in table 2. Otherwise, the procedure was performed in the same manner as in example 21. The results are shown in Table 2.
Comparative example 16
The drawing was performed in the same manner as in comparative example 13, except that the water-soluble lubricating oil was applied before the drawing step. The results are shown in Table 2.
[ evaluation ]
The DI cans obtained by the above method were evaluated by the following method. The results are shown in Table 1.
[ thinning workability ]
The following 3 items were visually observed: (i) presence or absence of fracture during ironing, (ii) penetration of the opening of the obtained DI can (black streaks), and (iii) scratches on the outer surface of the can body. The case where none of the 4 items had any problem and the surface of the can was mirror-polished was evaluated as "very good", the case where none had any problem and was excellent was evaluated as "good", the case where any one had a problem but could withstand practical use was evaluated as "fair", and the case where any one had a problem and could not withstand practical use was evaluated as "poor".
[ suitability for printing ]
The surface of the obtained DI can after washing was coated with an aqueous coating material, and then sintered by a known method to evaluate the unevenness of the coating material. The case where no coating unevenness was observed by visual observation was evaluated as "o", and the case where unevenness was observed due to paint repulsion or the like was evaluated as "x". When the coating material had unevenness, it was evaluated that the lubricant and/or the coolant used in the drawing step or the ironing step remained.
[ wastewater treatability ]
The waste water obtained by spray-cleaning the DI tank with the cleaning solution and washing the tank with water was stored in a beaker, and the Chemical Oxygen Demand (COD) was measured by a known method. If the COD is less than 200ppm, it is judged as O (good wastewater treatment); when the concentration is 200ppm or more, it is judged as X (poor wastewater treatment property). The results are shown in Table 2.
[ Table 2]
According to the method of manufacturing a bottomed cylindrical body of the first embodiment, even when the coolant used in the thinning step is water-soluble and/or has a boiling point of less than 300 ℃, a bottomed cylindrical body having a thinning rate equal to or greater than that of the conventional method can be obtained.
Further, according to the first embodiment, a lubricant application step of applying a lubricant to the surface of the metal plate (flat plate) before drawing can be further provided, and workability equal to or higher than that of the conventional one can be obtained even when the lubricant is water-soluble and/or has a boiling point lower than 300 ℃.
In the first embodiment, since the water-soluble lubricant and coolant, and the lubricant and coolant having a boiling point of less than 300 ℃ are used in the drawing step and the ironing step, the cleaning step can be performed with water or hot water without using a cleaning agent.
Alternatively, the lubricant, coolant, or the like adhered to the can body may be dried and removed after the can manufacturing process without providing the cleaning step.
It is also found that the waste water generated in the thinning step and the cleaning step can be reused (recycled) in the thinning step and the cleaning step again through the cleaning step for cleaning the waste water.
According to the method of manufacturing a bottomed cylindrical body of the second embodiment, even when the coolant used in the thinning step satisfies at least one of (a) a concentration of an oil component contained therein of less than 4.0 vol%, (b) a water-soluble coolant, and (c) a boiling point of less than 300 ℃, a bottomed cylindrical body having a thinning ratio equal to or higher than that of a conventional bottomed cylindrical body can be obtained.
In the second embodiment, since the coolant is used, the cleaning process can be performed with water or hot water without using a cleaning agent.
Alternatively, the lubricant, coolant, or the like adhering to the can body may be dried and removed after can manufacturing without providing the cleaning step.
It is also known that the waste water generated in the thinning step and the cleaning step can be reused (recycled) in the thinning step and the cleaning step again through the cleaning step.
Industrial applicability
The present invention can be suitably used in the field of metal press working in which workability, forming stability, and environmental considerations are maintained.
Description of reference numerals
D D Drawing die
P D Drawing punch
D I Thinning punching die
P I Thinning punch
C coolant
M shallow deep drawing cup
10. Metal plate
20. Diamond film
30. And (3) surface treatment of the film.
Claims (14)
1. A method for manufacturing a bottomed cylindrical body, comprising:
a drawing step of drawing the metal plate by using a forming member having a working surface with a hardness of Hv of more than 1500 and 12000 or less; and
a thinning step of forming a bottomed cylindrical body by thinning a member to be processed with a coolant by using a molding member having a carbon film on a processing surface,
wherein the coolant is a water-soluble coolant and/or a coolant with a boiling point of less than 300 ℃.
2. A method for manufacturing a bottomed cylinder according to claim 1, wherein the bottomed cylinder is a seamless can body.
3. A method of manufacturing a bottomed cylindrical body according to claim 1 or 2, wherein the metal plate is an aluminum alloy.
4. A method for producing a bottomed cylindrical body according to any one of claims 1 to 3, wherein the carbon film is a diamond film.
5. A method for producing a bottomed cylindrical body according to any one of claims 1 to 4, comprising a lubricant application step of applying a water-soluble lubricant and/or a lubricant having a boiling point of less than 300 ℃ to the metal plate before a drawing step of drawing the metal plate, wherein a hardness of a worked surface of the formed member in the drawing step is Hv1500 to 12000.
6. A method for producing a bottomed cylindrical body according to any one of claims 1 to 5, wherein the coolant contains an anticorrosive agent and/or a rust-preventing agent.
7. A method for manufacturing a bottomed cylinder according to any one of claims 1 to 6, further comprising a cleaning step of removing a lubricant and/or a coolant adhering to a surface of the bottomed cylinder.
8. The method of manufacturing a bottomed cylinder according to any one of claims 1 to 7, further comprising a purification step of purifying wastewater discharged in the thinning step and/or the cleaning step.
9. A method for manufacturing a bottomed cylindrical body, which is a method for manufacturing a bottomed cylindrical body, comprising:
a drawing step of drawing a metal plate using a drawing die having a work surface hardness Hv of more than 1500 and 12000 or less and a drawing punch having Hv of 1000 to 12000; and
a thinning step of forming a bottomed cylindrical body by thinning a workpiece member with a coolant by using a molded member having a machined surface with a hardness of Hv1500 to 12000,
wherein the coolant satisfies at least one of (a) a concentration of an oil component contained therein of less than 4.0% by volume, (b) a water-soluble coolant, and (c) a boiling point of less than 300 ℃.
10. A method for manufacturing a bottomed cylinder according to claim 9, wherein the bottomed cylinder is a seamless can body.
11. A method of manufacturing a bottomed cylindrical body according to claim 9 or 10, wherein the metal plate is an aluminum alloy.
12. A method for producing a bottomed tubular body according to any one of claims 9 to 11, wherein a carbon film is formed on a processing surface of a molded member in the drawing step and/or a processing surface of a molded member in the ironing step.
13. A method for producing a bottomed cylindrical body according to any one of claims 9 to 12, comprising a lubricant application step of applying a lubricant to a surface of the metal plate before the drawing step, wherein a hardness of a worked surface of a drawing die in the drawing step is Hv1000 to 12000.
14. A method for manufacturing a bottomed cylindrical body according to any one of claims 9 to 13, further comprising a purification step of purifying waste water discharged in the thinning step or a cleaning step after the thinning step.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2020058150A JP7472590B2 (en) | 2020-03-27 | 2020-03-27 | Manufacturing method of bottomed cylindrical body |
| JP2020-058150 | 2020-03-27 | ||
| JP2020058158A JP2021154355A (en) | 2020-03-27 | 2020-03-27 | Method of manufacturing cylindrical body with bottom |
| JP2020-058158 | 2020-03-27 | ||
| PCT/JP2021/009418 WO2021193043A1 (en) | 2020-03-27 | 2021-03-10 | Method for manufacturing bottomed cylindrical body |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115427168A true CN115427168A (en) | 2022-12-02 |
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ID=77891451
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202180024790.5A Pending CN115427168A (en) | 2020-03-27 | 2021-03-10 | Method for manufacturing bottomed cylindrical body |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US20230122197A1 (en) |
| EP (1) | EP4129516A4 (en) |
| CN (1) | CN115427168A (en) |
| BR (1) | BR112022019348A2 (en) |
| TW (1) | TW202140164A (en) |
| WO (1) | WO2021193043A1 (en) |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6028497A (en) * | 1983-07-27 | 1985-02-13 | Toyo Seikan Kaisha Ltd | Water-soluble coolant for forming can by deep drawing and ironing |
| JP3287764B2 (en) * | 1996-04-18 | 2002-06-04 | 東洋鋼鈑株式会社 | Resin-coated aluminum alloy plate for drawing and ironing cans |
| JPH09285826A (en) * | 1996-04-23 | 1997-11-04 | Sky Alum Co Ltd | Manufacture of drawing and ironing can |
| JPH1088178A (en) * | 1996-09-18 | 1998-04-07 | Yushiro Chem Ind Co Ltd | Undiluted solution composition of water-soluble lubricant for ironing |
| CN1060508C (en) * | 1996-09-18 | 2001-01-10 | 日石三菱株式会社 | Water soluble pinching lubricat composition |
| JPH10137861A (en) * | 1996-11-05 | 1998-05-26 | Sky Alum Co Ltd | Drawing and ironing method |
| JP2002327190A (en) * | 2001-05-07 | 2002-11-15 | Nippon Oil Corp | Mold-coating oil and plastic processing method using the same |
| JP4102145B2 (en) * | 2002-09-17 | 2008-06-18 | 新日本製鐵株式会社 | Resin-coated steel sheet and seamless can body for dry-drawing and ironing cans |
| JP5787094B2 (en) * | 2012-02-09 | 2015-09-30 | 三菱マテリアル株式会社 | Die for press working |
| JP2018204823A (en) | 2017-05-31 | 2018-12-27 | ダイキン工業株式会社 | Ventilation system |
| JP2018204896A (en) | 2017-06-07 | 2018-12-27 | 三菱重工サーマルシステムズ株式会社 | Control device of multiple air conditioner, multiple air conditioner, control method of multiple air conditioner, and control program of multiple air conditioner |
-
2021
- 2021-03-10 BR BR112022019348A patent/BR112022019348A2/en unknown
- 2021-03-10 CN CN202180024790.5A patent/CN115427168A/en active Pending
- 2021-03-10 WO PCT/JP2021/009418 patent/WO2021193043A1/en active Application Filing
- 2021-03-10 EP EP21776639.3A patent/EP4129516A4/en active Pending
- 2021-03-10 US US17/907,484 patent/US20230122197A1/en active Pending
- 2021-03-11 TW TW110108652A patent/TW202140164A/en unknown
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| Publication number | Publication date |
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| TW202140164A (en) | 2021-11-01 |
| EP4129516A4 (en) | 2024-04-10 |
| EP4129516A1 (en) | 2023-02-08 |
| US20230122197A1 (en) | 2023-04-20 |
| BR112022019348A2 (en) | 2022-11-16 |
| WO2021193043A1 (en) | 2021-09-30 |
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