EP1123764A1 - Procede de forgeage par matrices - Google Patents

Procede de forgeage par matrices Download PDF

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Publication number
EP1123764A1
EP1123764A1 EP99931517A EP99931517A EP1123764A1 EP 1123764 A1 EP1123764 A1 EP 1123764A1 EP 99931517 A EP99931517 A EP 99931517A EP 99931517 A EP99931517 A EP 99931517A EP 1123764 A1 EP1123764 A1 EP 1123764A1
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EP
European Patent Office
Prior art keywords
forging
die
punch
mentioned
forming
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.)
Withdrawn
Application number
EP99931517A
Other languages
German (de)
English (en)
Inventor
Takahiro Toto Ltd SATOH
Masateru Toto Ltd SHIRAISHI
Ryoichi Toto Ltd SUGIMOTO
Katsuaki Toto Ltd NAKAMURA
Hiroshi Toto Ltd AZUMA
Atsushi Toto Ltd YAMAUCHI
Kenji Toto Ltd UCHIO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toto Ltd
Original Assignee
Toto Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from JP10209173A external-priority patent/JP2000042674A/ja
Priority claimed from JP10275792A external-priority patent/JP2000102834A/ja
Priority claimed from JP34556298A external-priority patent/JP2000176596A/ja
Priority claimed from JP36814998A external-priority patent/JP2000193501A/ja
Priority claimed from JP11070156A external-priority patent/JP2000263179A/ja
Priority claimed from JP11070155A external-priority patent/JP2000263178A/ja
Priority claimed from JP11122856A external-priority patent/JP2000314157A/ja
Application filed by Toto Ltd filed Critical Toto Ltd
Publication of EP1123764A1 publication Critical patent/EP1123764A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/28—Making tube fittings for connecting pipes, e.g. U-pieces
    • B21C37/29—Making branched pieces, e.g. T-pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/12—Forming profiles on internal or external surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J9/00—Forging presses
    • B21J9/02—Special design or construction
    • B21J9/027—Special design or construction with punches moving along auxiliary lateral directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/20—Making machine elements valve parts

Definitions

  • the present invention relates to a die forging method.
  • a closed type forging method for a ultraplastic metal is described. According to this forging method, there is disclosed that a dimensional accuracy can be heightened by forming a void for filling at the inside of a die by movement of a movable portion provided at a part of the die, wherein the part moves when a forming power becomes a certain value in the course of forging forming, and flowing an excessive metal therein and removing the excessive part at a later stage.
  • An object of the present invention is to provide a die forging method having characteristics such as high productivity and forming accuracy, and the like.
  • a die forging method of the present invention is: a die forging method in which a forging material is subjected to plastic fluidization in a forging die under pressure to form a predetermined shape; which comprises a pre-forging step and a hole forming step thereafter by using an identical die, in the above-mentioned pre-forging step, forging is carried out so that at least a part of the above-mentioned forging material is forged to fill in a cavity of the die to obtain a part of a shape of a formed product, and in the above-mentioned hole forming step, the hole is formed by driving a punch into said forging material while a die pin is in touch with one end surface of the forging material and moving back under applying a back pressure thereto.
  • a preferable embodiment of "moving back under applying a back pressure thereto" is, in the case of a die inner pressure is higher than the back pressure, naturally moving back occurs depending on the pressure difference.
  • a die pin is moved back before a forging material is filled in a die cavity in the pre-forging step.
  • part of the forging material is filled in a die cavity in a forging step (closed forging) so that a shape of the forming part in the pre-forging step can be accurately prepared.
  • a die forging method of another embodiment of the present invention comprises a pre-forging step and a hole forming step thereafter by using an identical die, in the above-mentioned pre-forging step, a part of a shape of a formed product is obtained and, in the above-mentioned hole forming step, a hole is formed by driving a punch into the forging material while a die pin is in touch with one end surface of the forging material and moving back under applying a back pressure thereto, wherein the die pin is not moved during the above-mentioned pre-forging step.
  • a die pin is moved during a pre-forging step.
  • the die pin is not moved until forming of an outer shape of a formed product is finished so that forging can be carried out stably and a shape of the formed part in the pre-forging step can be accurately prepared.
  • a die forging method of another embodiment of the present invention comprises a hole forming step and a post-forging step thereafter by using an identical die, in the above-mentioned hole forming step, a hole is formed by driving a punch into the forging material while a die pin is in touch with one end surface of the forging material and moving back under applying a back pressure thereto and, in the above-mentioned post-forging step, a part of a shape of a formed product is obtained by forging at least a part of the above-mentioned forging material.
  • a die forging method of another embodiment of the present invention comprises a hole forming step and a pre- or post-forging step by using an identical die, wherein in the above-mentioned hole forming step, a hole is formed by driving a punch into the forging material while a die pin is in touch with one end surface of the forging material and moving back under applying a back pressure thereto and, in the forging step, the above-mentioned die pin is maintained not to move basically back against a forming pressure of the forging material.
  • a die forging method of another embodiment of the present invention comprises a hole forming step wherein a hole is formed by driving a punch into the forging material while a die pin is in touch with one end surface of the forging material and moving back under applying a back pressure thereto and the above-mentioned punch is driven from a direction other than the moving back direction of the above-mentioned die pin or the opposite direction of the same.
  • a punch driving direction is an opposite direction to the moving back direction of the die pin, and in Japanese Patent Publication number Kokai Hei. 4(1992)-344845, it is limited only to the same direction.
  • a punch is driven from a direction other than the moving back direction of the die pin or the opposite direction of the above so that a product having a complicated and various shapes, such as a tee, can be formed.
  • forging is carried out by pressurizing the forging material using a die for die forging an outer shape of a formed product and a punch for forming an recessed part of the formed product in combination from the same direction, and moving a die pin back under applying a back pressure thereto during the forging.
  • a product having a complicated shape such as shuttlecock wheel, can be formed.
  • forging is carried out by pressurizing the forging material using a plural number of punches for forming a plural number of recessed parts from a same direction, and moving a die pin back under applying a back pressure thereto during the forging.
  • a punch for forming a recessed part is each one at top and bottom.
  • forging is carried out by pressurizing a forging material using a plural number of punches for forming a plural number of recessed parts from the same direction, so that a product having a complex and various shapes, such as deep hole with steps, can be formed.
  • forming may be carried out by using the above-mentioned die and the punch at different timings. Or else, forming may be carried out by using a plural number of punches at different timings.
  • forging is carried out by driving a plural number of punches into the forging material from different directions simultaneously to carry out forming and by moving a die pin back under applying a back pressure thereto during the forging.
  • a forging formed product having a complicated and various shapes such as a tee, can be obtained.
  • a die forging method of another embodiment of the present invention comprises a forging step by driving a punch into the forging material or by pressing a die to the forging material while a die pin is in touch with one end surface of said forging material and moving back under applying a back pressure thereto, wherein a plural number of die pins are provided to form a plural number of holes.
  • a product with a complicated shape having a number of holes such as a multi-header, can be formed.
  • the above-mentioned plural number of die pins are operated successively along a time difference and the above-mentioned plural number of holes are successively formed.
  • a flow of a material is simple than simultaneously forming a plural number of holes by simultaneously operating the die pins, so that defects such as roll in or defect unfilled material with in the gorging die can be reduced.
  • a die forging method of another embodiment of the present invention comprises a forging step in which forging is completed by advancing a punch or a die to a predetermined position by pressing the punch or the die to the forging material while a die pin is in touch with one end surface of the forging material and pressured thereto, wherein in this step, when a die inner pressure is a predetermined pressure or lower, the above-mentioned die pin is not moved back and, when a die inner pressure exceeds said predetermined pressure, the die pin is moved back.
  • a closed type forging method for a ultraplastic metal is disclosed, in this forging method, when a forming power is reached to a certain value in the course of forging forming, a void for filling is formed at a inside of a die by moving a movable portion arranged at a part of a die, an excess metal is poured therein, and then, the excess part is removed later to improve a dimensional accuracy.
  • inside of the die is not a closed state (filled up state) when an excess metal is poured into the void for filling.
  • the die pin is moved back depending on the pressure of a material in the die, i.e., the die pin is moved back while maintaining the closed state.
  • a die forging method of another embodiment of the present invention comprises a hole-forming step by driving a punch into the forging material while a die pin is in touch with one end surface of the forging material and the die pin is moving back under applying a back pressure to the forging material, wherein a recessed or protruded part is provided at the end surface of the above-mentioned die pin, which applies the back pressure, and a part of product shape is formed by using the recessed or protruded part.
  • the end surface of the die pin which applies a back pressure, is a flat surface without a recessed or protruded part.
  • a protruded part or a recessed part can be shaped at the formed surface, thus a forged formed product having complicated and various shapes can be obtained.
  • a die forging method of another embodiment of the present invention comprises a pushing out step by forming an pushed out part by forging, and a forming step by forming the pushed out part to a predetermined shape by forging further, wherein the above-mentioned both steps are carried out in an identical die.
  • a pushing out step and a forming step are carried out in different dies.
  • a punch or a die is not pressed to a pushed out part and forming is carried out only by pushing out.
  • forging is carried out by a punch, etc., in the forming step so that a filling property of a material is better as compared with forming only by pushing out.
  • the pushing out step and the forming step are carried out in an identical die so that kind of dies required decreases and the cost of the die is less. Further, it is not necessary to transfer the forging material to the other press during forging so that its productivity is high.
  • a die forging method of another embodiment of the present invention comprises a pushing out step by forming an pushed out part by forging, and a forming step by forming the pushed out part to a predetermined shape by forging further, wherein the above-mentioned pushing out part is pushed out to the same direction or the opposite direction with or to the forging in the above-mentioned pushing out step.
  • a pushing out part is pushed out to the side direction of the forging direction.
  • the same direction or the opposite direction with or to the forging means to push out a part of the forging material to the same direction with or the opposite direction of the moving direction of the die or pin at forging. According to the die forging method, a forging formed product having complicated and various shapes can be obtained.
  • a die forging method of another embodiment of the present invention comprises a pushing out step by forming a pushed out part by forging, and a forming step by forming the pushed out part to a predetermined shape by forging further, wherein a forging material is forged a plural number of times in the above-mentioned pushing out step.
  • the forging material is processed by a second punch or a die without moving said first punch back.
  • a hole is formed by driving a first punch into a forging material, and forming around the hole by a second punch or a die without drawing out said punch after finishing of forming said hole.
  • a forging material is formed to a predetermined shape by subjecting to plastic fluidization in a forging die under pressure; which comprises a first step by making a cavity at a side of one end part of the above-mentioned forging material, a second step by pressing the above-mentioned forging material from the other side of the above-mentioned forging material to push out said one end part of the above-mentioned forging material and fill the above-mentioned cavity whereby forming an outer shape thereof, thereby obtaining a pushed out body, and a third step by driving a punch into the above-mentioned pushed out body from said one end surface of the end part to an axis direction after the above-mentioned second step to form a recessed part in the above-mentioned pushed out body.
  • a second recessed part with a larger diameter and shallower than the first recessed part may be continuously formed at the pushed out part by using a second punch arranged at an outer peripheral of the punch.
  • a fluidity inhibition of the material which occurs in the case of simultaneously forming of the first recessed part and the second recessed part, does not occur and defect unfilled material with in the forging die of the pushed out part can be prevented.
  • a protruded part can be formed at a part of the end surface of the forging material simultaneously with forming the pushed out part.
  • a forging material is formed to a predetermined shape by subjecting to plastic fluidization in a forging die under pressure; which comprises a step A by forming an recessed part by driving a punch into the forging material from a end surface of one end part of the above-mentioned forging material to the axis direction, and thereafter, a step B by forming a second recessed part with a larger diameter and shallower than the first recessed part at the above-mentioned end surface by using a second punch arranged at an outer peripheral of the punch, wherein the die pin contacted to the other end of the above-mentioned forging material is moved back under applying a back pressure thereto.
  • a pressure of the punch may only be set to substantially the same as the working force to the material whereby buckling of the punch does not occur and a depth of the recessed part can be freely set.
  • a forging material is formed by subjecting to plastic fluidization in a forging die under pressure to obtain a formed product which has a closed bottom cylindrical shape as a whole and also has a protruded part having an undercut; wherein the method comprises a first step by pushing out an starting part of the above-mentioned protruded part at the tip of the above-mentioned forging material, and after the above-mentioned first step, a second step by pushing out the above-mentioned protruded part to the side direction by pushing said original part from the opposite direction to the pushing out direction.
  • a forging material is formed by subjecting to plastic fluidization in a forging die under pressure to obtain a formed product having a closed bottom cylindrical shape; wherein the method comprises a step A by a back extrusion forming the cylindrical part by driving a punch into the center portion of the above-mentioned forging material while forming the outer surface of the cylindrical part by a die cavity surface and applying a back pressure to the end surface of the cylindrical part,
  • die forging methods having characteristic features such as high productivity or forming accuracy can be provided.
  • Fig. 1 is a drawing schematically showing a structure of a faucet made of brass and formed by the die forging method according to the first example of the present invention
  • Fig. 1(A) is a plane view
  • Fig. 1(B) is a side sectional view
  • Fig. 1(C) is a perspective view.
  • Fig. 2 is a sectional view schematically showing an apparatus for forging the spout tip of faucet of Fig. 1 and forging steps thereof.
  • Fig. 3 is a sectional view schematically showing an apparatus for forging the spout tip of faucet of Fig. 1 and forging steps thereof.
  • Fig. 4 is a sectional view schematically showing an apparatus for forging the spout tip of faucet of Fig. 1 and forging steps thereof.
  • Fig. 5 is a drawing schematically showing a construction of a hydraulic controlling system of the forging machine for brass material shown in Figs. 2, 3 and 4.
  • Fig. 6 is a sectional view showing enlarged details of a lower die set 11 and a upper die set 17 of the brass material forging machines 10 shown in Figs. 2 to 4, and a forging material 3A.
  • Fig. 7 is a sectional view showing enlarged details of a lower die set 11 and a upper die set 17 of the brass material forging machines 10 shown in Figs. 2 to 4, and a forging material 3A.
  • Fig. 8 is a sectional view showing enlarged details of a lower die set 11 and a upper die set 17 of the brass material forging machines 10 shown in Figs. 2 to 4, and a forging material 3A.
  • Fig. 9 is a sectional view showing enlarged details of a lower die set 11 and a upper die set 17 of the brass material forging machines 10 shown in Figs. 2 to 4, and a forging material 3A.
  • Fig. 10 is a stroke diagram of the die or punch during forging forming.
  • Fig. 11 is a sectional view showing the structure of a flange formed by the die forging method according to the second example of the present invention.
  • Fig. 12 is a sectional view showing a semi-finished forged product of the flange of Fig. 11.
  • Fig. 13 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the flange of Fig. 12.
  • Fig. 14 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the flange of Fig. 12.
  • Fig. 15 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the flange of Fig. 12.
  • Fig. 16 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the flange of Fig. 12.
  • Fig. 17 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the flange of Fig. 12.
  • Fig. 18 is a drawing showing the structure of a shuttlecock wheel according to the third example of the present invention, and Fig. 18(A) is a plane view and Fig. 18(B) is a sectional view.
  • Fig. 19 is a drawing showing the structure of the semi-finished forged product of the shuttlecock wheel of Fig. 18, and Fig. 19(A) is a plane view and Fig. 19(B) is a sectional view.
  • Fig. 20 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 21 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 22 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 23 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 24 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 25 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 26 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 27 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 28 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 29 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 30 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 31 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 32 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 33 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 34 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 35 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 36 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 37 is a sectional view schematically showing an apparatus and forging steps of another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • Fig. 38 is a drawing showing the structure of a water meter formed by the die forging method according to the sixth example of the present invention, and Fig. 38(A) is a front sectional view and Fig. 38(B) is a partial sectional plane view.
  • Fig. 39 is a drawing showing the structure of the semi-finished forged product of the water meter of Fig. 38, and Fig. 39(A) is a front sectional view and Fig. 39(B) is a partial sectional plane view.
  • Fig. 40 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 41 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 42 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 43 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 44 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 45 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 46 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 47 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 48 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 49 is a drawing showing a SCC( Stress Corrosion Cracking) resistance test equipment.
  • Fig. 50 is a drawing showing a erosion resistance test equipment.
  • Fig. 51 is a graph showing erosion resistance test results.
  • Fig. 52 is a drawing showing the structure of a lightening shaft formed by the die forging method according to the seventh example of the present invention, and Fig. 52(A) is a perspective view and Fig. 52(B) is a sectional view.
  • Fig. 53 is a drawing showing the structure of the semi-finished forged product of the lightening shaft of Fig. 52, and Fig. 53(A) is a perspective view and Fig. 53(B) is a sectional view.
  • Fig. 54 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 53.
  • Fig. 55 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 53.
  • Fig. 56 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 53.
  • Fig. 57 is a drawing showing the structure of a lightening shaft formed by the die forging method according to the eighth example of the present invention, and Fig. 57(A) is a perspective view and Fig. 57(B) is a sectional view.
  • Fig. 58 is a drawing showing the structure of the semi-finished forged product of the lightening shaft of Fig. 57, and Fig. 58(A) is a perspective view and Fig. 53(B) is a sectional view.
  • Fig. 59 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 58.
  • Fig. 60 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 58.
  • Fig. 61 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 58.
  • Fig. 62 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 58.
  • Fig. 63 is a drawing showing the structure of a hand shower supporting fitting formed by the die forging method according to the ninth example of the present invention, and Fig. 63(A) is a plane sectional view and Fig. 63(B) is a side surface sectional view.
  • Fig. 64 is a sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the hand shower supporting fitting of Fig. 63.
  • Fig. 65 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 63.
  • Fig. 66 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 63.
  • Fig. 67 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 63.
  • Fig. 68 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 63.
  • Fig. 69 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 63.
  • Fig. 70 is a drawing showing the structure of a flush valve lid formed by the die forging method according to the tenth example of the present invention.
  • Fig. 71 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 70.
  • Fig. 72 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 70.
  • Fig. 73 is a sectional view schematically showing an apparatus and forging steps for forging hand shower supporting fitting of Fig. 70.
  • Fig. 74 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 70.
  • Fig. 75 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 70.
  • Fig. 76 is a sectional view schematically showing an apparatus and forging steps for forging the hand shower supporting fitting of Fig. 70.
  • Fig. 77 is a sectional view schematically showing an apparatus and forging steps for forging hand shower supporting fitting of Fig. 70.
  • Fig. 78 is a side surface sectional view showing the structure of a H-shaped bushing formed by the die forging method according to the eleventh example of the present invention.
  • Fig. 79 is a sectional view schematically showing an apparatus and forging steps for forging the H-shaped bushing of Fig. 78.
  • Fig. 80 is a sectional view schematically showing an apparatus and forging steps for forging the H-shaped bushing of Fig. 78.
  • Fig. 81 is a side surface sectional view showing the structure of a tee formed by the die forging method according to the twelfth example of the present invention.
  • Fig. 82 is a sectional view schematically showing an apparatus and forging steps for forging the tee of Fig. 81.
  • Fig. 83 is a sectional view schematically showing an apparatus and forging steps for forging the tee of Fig. 81.
  • Fig. 84 is a sectional view schematically showing an apparatus and forging steps for forging the tee of Fig. 81.
  • Fig. 85 is a sectional view schematically showing an apparatus and forging steps for forging the tee of Fig. 81.
  • Fig. 86 is a sectional view schematically showing an apparatus and forging steps for forging the tee of Fig. 81.
  • Fig. 87 is a side sectional view showing the structure of a multi header formed by the die forging method according to the thirteenth example of the present invention.
  • Fig. 88 is a sectional view schematically showing an apparatus and forging steps for forging the multi header of Fig. 87.
  • Fig. 89 is a sectional view schematically showing an apparatus and forging steps for forging the multi header of Fig. 87.
  • Fig. 90 is a sectional view schematically showing an apparatus and forging steps for forging the multi header of Fig. 87.
  • Fig. 91 is an assembling drawing showing a faucet apparatus according to the fourteenth example of the present invention.
  • Fig. 92 is a drawing of parts of the faucet apparatus of Fig. 1 in which machining has finished, and Fig. 92(A) is a plane view, Fig. 92(B) is a longitudinal sectional view and Fig. 92(C) is a side view.
  • Fig. 93 is a drawing showing an semi-finished forged product of the parts of the faucet apparatus of Fig. 92, and Fig. 93(A) is a plane view, Fig. 93(B) is a longitudinal sectional view and Fig. 93(C) is a side view.
  • Fig. 94 is a plane view schematically showing an apparatus for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 95 is a side sectional view schematically showing an apparatus for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 96 is a sectional view schematically showing a step for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 97 is a sectional view schematically showing a step for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 98 is a sectional view schematically showing a step for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 99 is a sectional view schematically showing a step for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 100 is a sectional view schematically showing a step for forging the semi-finished forged product of the parts of the faucet apparatus of Fig. 93.
  • Fig. 101 is a drawing showing the structure of a shower hanger according to the fifteenth example of the present invention
  • Fig. 101(A) is a perspective view
  • Fig. 101(B) is a side view
  • Fig. 101(C) is a front view
  • Fig. 101(D) is a plane view.
  • Fig. 102 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 103 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 104 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 105 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 106 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 107 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 108 is a sectional view schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • Fig. 109 is a longitudinal sectional view showing the structure of a part X according to the sixteenth example of the present invention.
  • Fig. 110 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 111 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 112 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 113 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 114 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 115 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 116 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 117 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 118 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 119 is a drawing schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • Fig. 120 is a longitudinal sectional view showing the structure of a part Y according to the sixteenth example of the present invention.
  • Fig. 121 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 122 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 123 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 124 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 125 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 126 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 127 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 128 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 129 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 130 is a drawing schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • Fig. 131 is a longitudinal sectional view showing the structure of a part Z according to the seventeenth example of the present invention.
  • Fig. 132 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 133 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 134 is a sectional view schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 135 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 136 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 137 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 138 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 139 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 140 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 141 is a drawing schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • Fig. 1 is a drawing schematically showing a structure of a faucet made of brass and formed by the die forging method according to the first example of the present invention
  • Fig. 1(A) is a plane view
  • Fig. 1(B) is a side sectional view
  • Fig. 1(C) is a perspective view.
  • a spout tip of faucet 3 made of brass has been attached.
  • the upper end part of the spout tip of faucet 3 made of brass of this example is substantially a D-shaped inserted part 4. At the edge of the inserted part 4, an inclined surface 4a as a guide is provided. And, at the spout tip of faucet 3, a flange part 5 having a diameter slightly larger than the inserted part 4, a stepped inserted part 6, and a recessed and protruded part 7 extending to downward from the stepped inserted part 6 are integrally provided.
  • This recessed and protruded part 7 is a relatively small sized closed bottom cylindrical shape having a protruded part 7b with a circular sectional shape and a recessed part 7a at the inside thereof.
  • the protruded part 7b is formed on a extended line of the recessed part forming direction at the same time of forming with the recessed part 7a.
  • the part other than the recessed and protruded part 7 can be formed in a final state by forming the brass material to the state, in which a volume of a forming cavity becomes substantially equal to the volume of the brass material (a state in which the forging material is fulfilled in the cavity) after die-clamping and an early stage of forming (pre-forging step). And the recessed and protruded part 7 is continuously formed in a following deep hole forming step.
  • the spout tip of faucet 3 has a plural number of sharp edge parts 6a.
  • these plural number of sharp edge parts 6a can be also formed with high accuracy.
  • This brass material preferably has the following crystal structure in order to lower flow stress at the time of forging forming.
  • Fig. 2 to Fig. 4 are sectional views schematically showing the apparatus and forging steps for forging the spout tip of faucet of Fig. 1.
  • the brass material forging machine 10 has a body flame (not shown in the drawing), a lower die set 11, and an upper die set 17 corresponding to the lower die set 11.
  • the lower die set 11 has a lower die 12, a die pin 13, and a first hydraulic cylinder 14 which can retain and drive the die pin 13 up and down.
  • the lower die 12 is fixed and the upper surface of the lower die 12 is flat.
  • a pin inserting hole 15 extending to the vertical direction with a circular sectional surface is provided.
  • the die pin 13 is slidably mounted up and down in the pin inserting hole 15. By the pin inserting hole 15 and the die pin 13, an outer shape of the recessed and protruded part 7 of the spout tip of faucet 3 is formed.
  • a step forming hole 16 (also refer to Fig. 6) is formed, which is connected to the upper end of the pin inserting hole 15.
  • This step forming hole 16 is provided to form a stepped inserted part 6 of the spout tip of faucet 3.
  • the first hydraulic cylinder 14 is provided at the downward of the die pin 13 to the vertical direction, and the upper end part of a piston rod 14a of the first hydraulic cylinder 14 is connected to the die pin 13.
  • the die pin 13 can be retained at the position shown in Fig. 3 or Fig. 4, also is pulled down while applying a retaining force to the die pin 13.
  • the die pin 13 can be moved to upward to eject the spout tip of faucet 3 after forming.
  • the upper die set 17 has an upper slide 18 and an upper die 19.
  • the upper die set 17 also has an upper outer punch 20 and an upper inner punch 21.
  • the upper slide 18 moves up and down by a main hydraulic cylinder 22.
  • the upper inner punch 21 moves up and down by a third hydraulic cylinder 23.
  • the upper slide 18 is movably guided vertically up and down along a guided part, which is slidably engaged to a guide part provided at the body flame, and moved up and down by the main hydraulic cylinder 22.
  • a recessed part 24 with a circular sectional shape is so provided as to open at a lower surface.
  • At least upper tip part of the upper die 19 is slidably mounted up and down in the recessed part 24.
  • a flange part 19a is formed and said flange part 19a is stopped to a stopping plate 25 fixed to the lower surface of the upper slide 18.
  • the lower surface of the upper die 19 is provided to be a flat surface contacting with the upper surface of the lower die 12.
  • a plural number of springs receiving holes 26 are so formed that whose upper end is open.
  • compression springs 27 are inserted, respectively.
  • the upper end of these compression springs 27 are supported by the upper end wall surface of the recessed part 24, and the upper die 19 is elastically biased strongly downward by these compression springs 27.
  • a punch inserting hole 28 having substantially D-shaped sectional shape is provided to the vertical direction, into which the upper outer punch 20 and the upper inner punch 21 can be fed into.
  • the upper outer punch 20 and the upper inner punch 21 are slidably inserted.
  • a flange forming part 29 (also refer to Fig. 6) positioned at the outside of the punch inserting hole 28 is provided. This flange forming part 29 is provided to form the flange part 5 of the spout tip of faucet 3.
  • the flange forming part 29 of the upper die 19 is connected to the step forming part 16 of the lower die 12.
  • the upper outer punch 20 is integrally formed with the upper slide 18, and slidably inserted into the punch inserting hole 28.
  • the outer shape of the sectional surface of the upper outer punch 20 is provided to be a substantially D-shape.
  • a inserted part forming part 30 (also refer to Fig. 6) for forming the inserted part 4 of the spout tip of faucet 3 is formed. As shown in Fig. 2, in the die-clamped state, the inserted part forming part 30 is spatially connected to the step forming part 16.
  • the upper inner punch 21 is mainly provided to form the recessed and protruded portion 7 of the spout tip of faucet 3 and has a circular sectional shape.
  • the upper inner punch 21 is slidably inserted into an inner punch inserting hole 31 up and down at the center portion of the upper outer punch 20.
  • the upper inner punch 21 is connected to the piston rod 23a of the third hydraulic cylinder 23 provided over thereof and drivable up and down by the cylinder 23 freely movable up and down.
  • a brass raw material 3A with a short column shape is set in a die.
  • the brass raw material 3A is formed to the spout tip of faucet 3 shown in Fig. 4 through an semi-finished formed material 3B shown in Fig. 3.
  • Fig. 5 is a drawing schematically showing a construction of a hydraulic controlling system of the brass material forging machine shown in Figs. 2, 3 and 4.
  • This hydraulic control system has a hydraulic feeding machine 41 which feeds a hydraulic pressure to a first hydraulic cylinder 14, a second hydraulic cylinder 22 and a third hydraulic cylinder 23. Also, it has a hydraulic circuit containing electromagnetic directional switching valves 42 to 44 and electromagnetic proportional relief valves 45 and 46. Also, it has a plural number of detection switches 47 and control units 48.
  • the hydraulic feeding machine 41 has a hydraulic pump, a driving motor, an oil tank, etc. which are not shown in the drawing.
  • the electromagnetic directional switching valve 42 is provided at an oil line that feeds a hydraulic pressure to the second hydraulic cylinder 22, the electromagnetic directional switching valve 43 is provided at an oil line that feeds a hydraulic pressure to the first hydraulic cylinder 14, and the electromagnetic directional switching valve 44 is provided at an oil line that feeds a hydraulic pressure to the third hydraulic cylinder 23.
  • the electromagnetic proportional relief valves 45 is connected to an oil line that feeds a hydraulic pressure to the first hydraulic cylinder 14, and a hydraulic pressure set at the electromagnetic proportional relief valves 45 is fed to the cylinder 14. According to the arrangement of the electromagnetic proportional relief valves 45, a back pressure of the die pin 13 is controlled. Similarly, the electromagnetic proportional relief valves 46 is connected to an oil line to feed a hydraulic pressure to the third hydraulic cylinder 23, and a hydraulic pressure controlled by the electromagnetic proportional relief valves 46 is fed to the cylinder 23.
  • a plural number of detection switches 47 contains a detection switch for detecting the upper limit position and the lower limit position of the upper die 19, a detection switch for detecting the upper limit position and the lower limit position of the upper inner punch 21, etc.
  • a control unit 48 has a microcomputer and input-output interface.
  • a control program is stored for controlling the hydraulic feeding machine 41, the electromagnetic directional switching valves 42 to 44 and the electromagnetic proportional relief valves 45 and 46 based on the detection signal from a plural number of the detection switches 47.
  • the microcomputer carriers out controlling according to the control program.
  • Figs. 6 to 9 are sectional views showing enlarged details of a lower die set 11 and an upper die set 17 of the brass material forging machine 10 shown in Figs. 2 to 4, and a forging material 3A.
  • Fig. 10 is a stroke diagram of the die or punch during forging forming.
  • the forging material 3A made of the brass material heated at about 300 to 600°C is set in the step forming hole 16 of the lower die 12.
  • the brass raw material 3A is formed under maintaining the temperature to 550°C or lower.
  • the volume of the brass raw material 3A is so set as to equal to the net volume of the spout tip of faucet 3.
  • the upper die 19 is fed down to contact the lower surface of the upper die 19 to the upper surface of the lower die 12 and to die-clamp the upper die set 17 to the lower die set 11.
  • This clamping is carried out by switching the electromagnetic directional switching valve 42 shown in Fig. 5 to extend a piston rod 22a of the second hydraulic cylinder 22 and going down the upper slide 18.
  • the lower end of the upper outer punch 20 and the lower end of the upper inner punch 21 is located on a coincident plane, and closely faced to the upper end surface of the brass raw material 3A. This state corresponds to time t1 to t2 of Fig. 10.
  • a setting pressure of the electromagnetic proportional relief valve 45 is set to a high pressure to set a retaining force (a pressing force or a supporting force) of the die pin 13 to a high value.
  • the electromagnetic directional switching valve 43 by operating the electromagnetic directional switching valve 43, the first hydraulic cylinder 14 is driven to set the height position of the die pin 13 so that the upper end of the die pin 13 is located on a coincident plane with the lower end of the step forming hole 16 as shown in Fig. 8.
  • the electromagnetic directional switching valve 43 is switched to the block position a.
  • the upper outer punch 20 and the upper inner punch 21 are integrally driven to go down and, as shown in Fig. 8, the brass raw material 3A is formed to the state that the volume of the forming cavity C becomes substantially equal to the volume of the brass raw material 3A.
  • forming (pre-forging step) of parts other than the recessed and protruded part 7 (that is, the inserted part 4, the flange part 5 and the stepped inserted part 6) is finished.
  • the electromagnetic directional switching valves 42 and 44 are switched to synchronously drive the piston rod 22a of the second hydraulic cylinder 22 and the piston rod 23a of the third hydraulic cylinder 23 down.
  • the electromagnetic directional switching valve 43 is retained at the block position a. Since an oil in the hydraulic system is a non-compressive fluid, an oil pressure of a head side oil room (lower side oil room) of the first hydraulic cylinder 14 is maintained at a high level during the pre-forging step and the die pin 13 does not move back downward. Accordingly, in the pre-forging step, the brass raw material 3A is formed into a semi-finished formed material 3B as shown in Fig. 8 (or Fig. 3) by a closed forging. This state corresponds to the time t2 to t3 of Fig. 10.
  • the upper inner punch 21 is moved downward and also the die pin 13 is moved back downward. According to this action, the recessed and protruded part 7 is formed continuously following to the above-mentioned pre-forging step.
  • the electromagnetic proportional relief valve 45 is switched to a lower pressure than the pressure of the upper inner punch 21, the electromagnetic directional switching valve 43 is switched to a rod moving back position b, and further the retention force (back pressure) of the die pin 13 is retained to low value through a throttle 43a of the rod moving back position b of the electromagnetic directional switching valve 43.
  • This state corresponds to the time t3 to t4 of Fig. 10.
  • a hydraulic pressure of a head side oil room of the first hydraulic cylinder 14 can be maintained to a low value.
  • a going down force of the upper inner punch 21 is optionally set through the electromagnetic proportional relief valve 46 and the setting pressure is set to a relatively low pressure capable of forming.
  • the recessed and protruded part 7 is formed by using a part of the material of the semi-finished formed product 3B shown in Fig. 8, which is located under the upper inner punch 21.
  • the volume of the brass material at the part is so set that it is substantially equal to the net volume of the recessed and protruded part 7. If this condition is satisfied, the position of the upper end of the die pin 13 during forming the semi-finished formed product 3B is not limited to the positions shown in Fig. 7 and Fig. 8, and may be set slightly higher or lower than the position shown in the drawings.
  • the upper die set 17 is returned to the upper limit position.
  • the die pin 13 is elevated to the upper limit position by the hydraulic cylinder 14. Accordingly, the spout tip of faucet 3 which forming is finished is ejected to remove from the lower die set 11.
  • brass having good workability is one of the preferred materials.
  • the conventionally used brass involved problems in corrosion resistance, etc. as compared with bronze.
  • the formed product after cooling is at least one of the crystal structures of (1) to (3) shown below, the problem of corrosion resistance, etc. can be below an allowable level.
  • the corrosion resistance which the maximum dezinking depth is 100 ⁇ m or smaller when the working direction is parallel to it, and it is 70 ⁇ m or smaller when the working direction is perpendicular to it, can be satisfied.
  • a brass material having a composition of an apparent Zn content of 37 to 50% by weight and an Sn content of 1.7 to 2.2% by weight may be used.
  • an apparent Zn content is used in the meaning of " ⁇ (B+t ⁇ Q)/(A+B+t ⁇ Q) ⁇ 100" wherein A is a Cu content (% by weight), B is a Zn content (% by weight), t is a Zn equivalent of the added third element (e.g., Sn), and Q is a content of the third element (% by weight).
  • the brass material of the above-mentioned composition preferably has a ⁇ phase having an average crystal grain diameter of the short axis of 15 ⁇ m or smaller in the crystal structure of the forging material during forging. According to such a crystal structure during working, even when it is subjected to plastic deformation while recrystallization is caused at a low temperature region of 300 to 550°C, sufficient ductility of the forging material can be ensured.
  • the ductility of the raw material can be made substantially constant and formability of the forging material is improved.
  • the temperature difference between the forging raw material and the punch or the die is made within 20° or the punch or the die is heated to 300 to 550°C.
  • a heater and a temperature sensor are provided in the punch or the die and an amount of heat of the heater can be controlled by a temperature controller based on the detected signal output from the temperature sensor.
  • Fig. 11 is a sectional view showing the structure of a flange formed by the die forging method according to the second example of the present invention.
  • Fig. 12 is a sectional view showing a semi-finished forged product of the flange of Fig. 11.
  • the flange 50 in this example has a short tubular shape, and has a flange part 51 to be fixed at predetermined attaching surfaces and a stepped part 52.
  • a semi-finished forged product 50B is firstly forged.
  • the semi-finished forged product 50B has a bottom part 53, a flange starting part 54 having an edge 54a, and a step starting part 55.
  • the lower part 53 and the edge 54a of the flange original part 54 are removed by machining, etc. to obtain the flange of Fig. 11.
  • Fig. 13 to Fig. 17 are sectional views schematically showing an apparatus and forging steps for forging the semi-finished forged product of the flange of Fig. 12.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12 and an ejector pin 15 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19, and an upper punch 24 which slides in a punch inserting hole of the upper die 19 up and down by the cylinder.
  • the lower die 12 is fixed and the upper die 19 moves up and down between a die-opening state and a die-clamping state.
  • a step forming hole 12a is provided at the upper surface of the lower die 12. This step forming hole 12a is to form the stepped starting part 55 and the flange starting part 54 of the semi-finished forged product 50B. A part 12b surrounded by the step forming hole 12a is positioned at higher than the other upper surface of the lower die 12. A part 24a of the lower surface of the upper punch 24, which faces to the above-mentioned step forming hole 12a, is provided to be a recessed shape. At the state of die-clamping, the recessed part 24a of the upper punch 24 is connected to the step forming hole 12a of the lower die 12.
  • a heated forging material 50A is set on a part 12b surrounded by the step forming hole 12a of the lower die 12.
  • the upper punch 24 is positioned at the back of the lower surface of the upper die 19.
  • the upper die 19 and the punch 24 are simultaneously went down, and the lower surface of the upper die 19 and the upper surface of the lower die 12 are contacted to each other and die-clamped.
  • the ejector pin 15 is retained at a predetermined position (the upper surface thereof is positioned at the same plane as the surface of the lower die 12).
  • the forged raw material 50A is fluidized and deformed, and a part of the starting part 53' of the bottom part 53 of the semi-finished forged product 50B, a part of starting part 54' of the flange starting part 54 and a part of the starting part 55' of the stepped starting part 55 are formed.
  • the forging raw material 50A is filled in the each part so that a semi-finished forged product 50B having the lower part 53, the flange starting part 54 and the stepped starting part 55 are formed.
  • the upper die set is returned to the upper limit position.
  • the ejector pin 15 is risen to remove the semi-finished forged product 50B.
  • the bottom part 53 and the edge 54a of the flange starting part 54 are removed from the semi-finished forged product 50B by machining, etc., to obtain a final flange50.
  • a hole which becomes the bottom part 53 and the step starting part 55 are formed by the punch 24 and the flange starting part 54 around the hole is continuously formed by the punch 24 so that feeding of a raw material from the center portion to the surroundings becomes smooth whereby formability is improved.
  • Fig. 18 is a drawing showing the structure of a shuttlecock wheel according to the third example of the present invention, and Fig. 18(A) is a plane view and Fig. 18(B) is a sectional view.
  • Fig. 19 is a drawing showing the structure of the semi-finished forged product of the shuttlecock wheel of Fig. 18, and Fig. 19(A) is a plane view and Fig. 19(B) is a sectional view.
  • the shuttlecock wheel of 60 of this example has a hub part 61 and a blade part 62, and an axis hole 63 is penetrated at the center portion.
  • an semi-finished forged product 60B is firstly forged.
  • the semi-finished forged product 60B has an outer flash part 62a, an edge surface flash part 63a, a raw material placing step part 62b and a punch step part 62c.
  • Fig. 20 to Fig. 26 are sectional views schematically showing an apparatus and forging steps for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • This brass material forging machine has a lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12 and an ejector pin 15 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19 provided with an upper outer punch 20 and an upper inner punch 21.
  • the upper outer punch 20 is not connected to a driving source and slidably provided in a punch inserting hole of the upper die 19 up and down. Descending of the upper outer punch 20 is stopped by a stopping surface 19b of the upper die 19.
  • the upper inner punch 21 slides in a punch inserting hole of the upper outer punch 20 up and down. Descending of the upper inner punch 21 is stopped by a stopping surface 20a of the upper outer punch 20.
  • a step forming hole 12a is provided at the upper surface of the lower die 12.
  • This step forming hole 12a is to form the outer flash part 62a, the raw material placing step part 62b, the punch step part 62c, and the edge surface flash part 63a of the semi-finished forged product 60B.
  • a step forming hole 19a is formed at the part of the lower surface of the upper die 19, which faces to the above-mentioned step forming hole 12a.
  • these step forming holes 12a and 19a are connected to each other.
  • a heated forging material 60A is set on the step forming hole 12a of the lower die 12.
  • the upper die 19 and the upper inner punch 21 are simultaneously gone down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12 and clamped.
  • the lower surface of the upper outer punch 20 is contacted to the upper surface of the forging material 60A and stopped. Since no load is applied to the upper outer punch 20, the punch 20 is relatively moved back to the upper die 19.
  • the upper inner punch 21 is went down until contacting with the stopping surface 20a of the upper outer punch 20.
  • part of an edge surface flash part 63a of the axis hole 63 is formed.
  • the upper outer punch 20 still contacts with the forging material 3A.
  • the upper inner punch 21 is further gone down.
  • the upper inner punch 21 is stopped to the stopping surface 20a of the upper outer punch 20, and the upper outer punch 20 and the upper inner punch 21 are simultaneously gone down so that the upper outer punch 20 is contacted to the stopping surface 19b of the upper die 19.
  • the axis hole 63 is formed.
  • the forging material is fluidized and deformed, and filled in a step forming hole whereby an outer flash part 62a is formed by a material pushed out to outer peripheral and an edge surface flash part 63a is completely formed.
  • the upper inner punch 21 is drawn out from the forged product.
  • the upper die set is returned to the upper limit position.
  • the upper outer punch 20 is also raised simultaneously.
  • an ejector pin 15 is risen to remove the semi-finished forged product 60B.
  • part of a part 12c of the lower die 12 is also raised like as the ejector pin 15 to support removing of the semi-finished forged product 60B.
  • the outer flash part 62a, the edge surface flash part 63a, the raw material placing step part 62b and the punch step part 62c are removed by machining, etc., to obtain an shuttlecock wheel 60 as a final product.
  • the forging material is worked by the upper outer punch 20 (the second punch or die) without moving the upper inner punch 21 (the first punch) back.
  • the upper outer punch 20 the second punch or die
  • Fig. 27 to Fig. 33 are sectional views schematically showing an apparatus and forging steps of the another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12 and an ejector pin 15 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19 provided with an upper outer punch 20 and an upper inner punch 21.
  • the upper outer punch 20 is not connected to a driving source and slidably provided in a punch inserting hole of the upper die 19 up and down. Descending of the upper outer punch 20 is stopped by a lower stopping surface 19a of the upper die 19 and rising thereof is stopped by an upper stopping surface 19b of the upper die 19.
  • the upper inner punch 21 slides in a punch inserting hole of the upper outer punch 20 up and down. Descending of the upper inner punch 21 is stopped by a stopping surface 20a of the upper outer punch 20.
  • a step forming hole 12a is provided at the upper surface of the lower die 12.
  • This step forming hole 12a is to form the outer flash part 62a, the raw material placing step part 62b, the punch step part 62c, and the edge surface flash part 63a of the semi-finished forged product 60B.
  • the step forming hole 19a is formed at the part of the lower surface of the upper die 19, which faces to the above-mentioned step forming hole 12a.
  • these step forming holes 12a and 19a are connected to each other.
  • a heated forging material 60A is set on the step forming hole 12a of the lower die 12.
  • the upper outer punch 20 is positioned on the lower stopping surface 19a of the upper die 19.
  • the upper die 19 and the upper inner punch 21 are simultaneously went down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12.
  • die-clamping is not carried out.
  • the lower surface of the upper outer punch 20 is contacted to the upper surface of the forging material 60A and stopped.
  • the punch 20 is moved back to the upper stopping surface 19b of the upper die 19 relative to the upper die 19.
  • the forging material 60A is pressed by the upper inner punch 20 and upper die 19 to fluidize and deform, and a part 62' of the shuttlecock wheel is started to forming by the pushed out part to the outer peripheral direction.
  • An edge surface flash part 63a is simultaneously started to being formed.
  • the upper inner punch 21 is gone down until contacting with the stopping surface 20a of the upper outer punch 20.
  • a part of the edge surface flash part 63a of the axis hole 63 is formed.
  • the Part 62' of the shuttlecock wheel part is simultaneously further formed.
  • the upper outer punch 20 is moved back due to the movement of the material pushed out by the upper inner punch 21 and the upper die set which dose not die-clamped is also moved back.
  • the upper inner punch 21 is further gone down.
  • the upper inner punch 21 is stopped to the stopping surface 20a of the upper outer punch 20, the upper outer punch 20 and the upper inner punch 21 are simultaneously gone down.
  • the upper die 19 is also gone down to die-clamp.
  • the axis hole 63 is formed. Simultaneously the forging material is fluidized and deformed, and filled in a step forming hole whereby an blade part 62 is completely formed by a material pushed out to outer peripheral and an edge surface flash part 63a is completely formed. Also, the upper inner punch 21 is driven into to form an axis hole 63 completely.
  • a hub part 61 is formed by compressing with the upper outer punch 20
  • the material is spread out from the center to the peripheral direction whereby a spreading of the raw material becomes uniform and forming property is improved.
  • the upper inner punch 21 is kept inserted into to ensure forming of the axis hole 63.
  • the upper inner punch 21 is drawn out from the forged product.
  • the upper die set is returned to the upper limit position.
  • the upper outer punch 20 is also raised.
  • an eject pin 15 is risen to remove the semi-finished forged product 60B.
  • a part 12c of the lower die 12 is also raised like as the ejector pin 15 to remove the semi-finished forged product 60B.
  • the outer flash part 62a, the edge surface flash part 63a, the raw material placing step part 62b and the punch step part 62c are removed by machining, etc., to obtain an shuttlecock wheel 60 as a final product.
  • the forging material is worked by the upper outer punch 20 (the second punch or die) without moving the upper inner punch 21 (the first punch) back.
  • the upper outer punch 20 the second punch or die
  • Fig. 34 to Fig. 37 are sectional views schematically showing an apparatus and forging steps of the another example for forging the semi-finished forged product of the shuttlecock wheel of Fig. 19.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a die pin 13 which slides in a punch inserting hole of the lower die 12 up and down, and an ejector pin 15 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19 and an upper punch 24 which slides a punch inserting hole of the upper die 19 up and down. Descending of the upper punch 24 is stopped by a lower stopping surface 19b of the upper die 19.
  • a step forming hole 12a is formed. This step forming hole 12a is to form the outer flash part 62a, the raw material placing step part 62b, the punch step part 62c, and the edge surface flash part 63a of the semi-finished forged product 60B.
  • a step forming hole 19a is also formed. At the state of die-clamping, these step forming holes 12a and 19a are connected to each other.
  • a heated forging material 60A is set on the step forming hole 12a of the lower die 12.
  • the upper surface of the die pin 13 is positioned on the same plane as the surface of the step forming hole 12a and is set at a lower retaining force.
  • the upper die 19 and the upper punch 24 are simultaneously went down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12 and die-clamped.
  • the forging material is fluidized and deformed to fill the each forming holes to form an blade part 62 completely.
  • back pressure back pressure
  • the upper punch 24 is went down until contacting with the stopping surface 19a of the upper die 19. Simultaneously, the die pin 13 is moved back. Here, an axis hole 63 is completely formed. After forming the blade part 62 completely, by forming the axis hole 63 by the upper punch 24, an outer shape of the blade part 62 can be accurately formed.
  • the upper punch 24 is drawn out from the forged product. Thereafter, the upper die set is returned to the upper limit position. Subsequently, the ejector pin 15 is raised to remove the semi-finished forged product 60B.
  • the outer flash part 62a, the edge surface flash part 63a, the raw material placing step part 62b and the punch step part 62c are removed by machining, etc., to obtain an shuttlecock wheel 60 as a final product.
  • the forging material 60A is forged by pressurizing using the upper die 19 (a die for die forging an outer shape of the formed product) and the upper punch 24 (a punch for forming the recessed portion of the formed product) in combination from the same direction, and the die pin 13 is moved back under applying a back pressure during forging.
  • the upper die 19 a die for die forging an outer shape of the formed product
  • the upper punch 24 a punch for forming the recessed portion of the formed product
  • forming is carried out by using the upper die 19 (die) and the upper punch 24 (punch) at different timings.
  • the die and the punch or a plural number of punch
  • the two are used at different timings, or forming is carried out using a plural number of punches at different timings, such defect can be prevented.
  • Fig. 38 is a drawing showing the structure of a water meter formed by the die forging method according to the sixth example of the present invention, and Fig. 38(A) is a front sectional view and Fig. 38(B) is a partial sectional plane view.
  • Fig. 39 is a drawing showing the structure of the semi-finished forged product of the water meter of Fig. 38, and Fig. 39(A) is a front sectional view and Fig. 39(B) is a partial sectional plane view.
  • the water meter 70 of this example has a blade inserting part 71, which a rotating blade(not shown in the drawing)is attached at the center thereof, and a lid screw part 72. Also, it has a running water outlet passage 74 extending from an inserting part 71 to the right lower direction and a running water inlet passage 73 extending to the left lower direction. At the tip parts of the running water outlet passage 74 and the running water inlet passage 73, an outlet screw part 74a and an inlet screw part 73a are provided.
  • the semi-finished forged product 70B has, as shown in Fig. 44, flash parts 74b and 73b at the tips of the outlet screw part 74a and the inlet screw part 73a, respectively.
  • flash parts 74c and 73c are provided at where the each running water passages are getting in the inserting part 71. These flash parts 74b, 73b, 74c and 73c are removed to obtain a finished product of the water meter 70.
  • Fig. 40 to Fig. 48 are sectional views schematically showing an apparatus and forging steps for forging the semi-finished forged product of the water meter of Fig. 39.
  • Fig. 40 is a side sectional view of the forging machine
  • Fig. 41 is a plan view
  • Fig. 42 is a side sectional view of the A-A sectional surface.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, left and right side punches 226 and 227, a center punch 228, and an ejector pin 15 which slides in a pin inserting hole of the lower die 12 up and down.
  • the left and right side punches 226 and 227 slide, as shown in Fig. 45, in the punch inserting holes provided at the right and left sides of the lower die 19.
  • the center punch 228 slides, as shown in Fig. 41, in a punch inserting hole provided at the front surface of the lower die 19.
  • the left and right punches inserting holes are as shown in Fig.
  • the center punch hole and the left and right punches inserting holes are positioned perpendicular on the horizontal sectional surface. Also, the left punch inserting hole and the right punch inserting hole are inclined to the outer downward direction.
  • a step forming hole 12a is formed at the upper surface of the lower die 12.
  • a step forming hole 19a is formed at the part of the lower surface of the upper die 19, which faces to the above-mentioned step forming hole 12a.
  • these step forming holes 12a and 19a are connected to each other.
  • a heater (not shown in the drawing) is built-in. Also, as shown in Fig. 42, heat-insulating materials are wound around the outer peripheral of the lower die 12 and the upper die 19. The die clamping surfaces of the each dies are covered by the heat-insulating material 229 and a stainless steel plate 230 to keep the temperature.
  • a heated forging material 70A is set on the step forming hole 12a on the lower die 12.
  • the upper die 19 is went down, and is contacted to the lower die 12 and die-clamped.
  • the center punch 228 is driven into.
  • the forging material 70A is fluidized and deformed, and the blade inserting part 71, the lid screw part 72 and a part of the each running water passages 74' and 73' are formed.
  • a retaining force is still applied to the middle punch 228.
  • the left side punch 226 and the right side punch 227 are simultaneously inserted until the stopping surface.
  • the screw parts 74b and 73b of the respective running water flow passages and the flash parts 74c and 73c are formed.
  • the center punch 228, the left side punch 226 and the right side punch 227 are moved back. Thereafter, as shown in Fig. 48, the upper die set is returned to the upper limit position. Then, the ejector pin 15 is raised to remove the semi-finished forged product 70B.
  • the semi-finished formed product is worked by the above-mentioned machining, etc., to remove unnecessary parts to obtain a final formed product.
  • the die forging method of the sixth example comprises a pushing out step by forming a pushed out part by forging, and a forming step of forming the pushed out part to a predetermined shape by further forging, and the above-mentioned both steps are carried out in the identical die.
  • forging is carried out in the forming step by the left and right side punches 226 and 227 (punches, et al.) to the pushed out part pushed out by the pushing out step so that a filling property of the material is better than the case that forming is carried out by pushing out only.
  • the pushing out step and the forging step are carried out in an identical die so that kind of dies required decreases and the cost of the dies is less. Moreover, it is not necessary to transfer the forging material to the other press during forging so that its productivity is high.
  • This final formed product has a SCC resistance.
  • Fig. 49 is a drawing showing a SCC resistance test equipment.
  • the SCC resistance is a characteristic in which a sample is not cracked when it is exposed to an ammonia atmosphere on 14% aqueous ammonia while applying a load of a stress 180 N/mm 2 to the sample. Evaluation of this SCC test is carried out by exposing a sample to a NH 3 vapor atmosphere for 24 hours in a glass desiccator 231 while applying a load vertically to a cylindrical shaped sample 232, and then occurrence of cracks is examined.
  • Fig. 50 is a drawing showing a erosion resistance test equipment.
  • the erosion resistance can be measured by using a cylindrical shaped sample 53 having an orifice 233 at the inside thereof, flowing water in the orifice 233 with a flow rate of 40 m/sec for a predetermined time, and then, measuring a clamping torque to a resin stopper 234 required for sealing the orifice under a water pressure of 4.9x105 Pa (Kg/cm 2 ).
  • Fig. 51 is a graph showing erosion resistance test results.
  • Fig. 52 is a drawing showing the structure of a lightening shaft formed by the die forging method according to the seventh example of the present invention, and Fig. 52(A) is a perspective view and Fig. 52(B) is a sectional view.
  • Fig. 53 is a drawing showing the structure of the semi-finished forged product of the lightening shaft of Fig. 52, and Fig. 53(A) is a perspective view and Fig. 53(B) is a sectional view.
  • the semi-finished forged product 80 of this example has an axis part 81, an upper small diameter part 82, a large diameter part 83, and a lower small diameter part 84.
  • a lightening margin 80a is projected from the lower small diameter part 84. This lightening margin 80a is removed by machining, etc., to obtain a final semi-finished forged product 80.
  • Fig. 54 to Fig. 56 are sectional view schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 53.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a die pin 13 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19, and an upper punch 20 is integrally provided.
  • a step forming hole 12a is provided at the upper surface of the lower die 12.
  • the upper outer punch 20 is inserted to this step forming hole 12a.
  • a step forming hole 20b is formed at the lower surface of the upper outer punch 20.
  • a heated forging material 80A is set on the step forming hole 12a on the lower die 12.
  • the upper die 19 is went down, and the lower surface of the upper outer punch 20 is contacted to the upper surface of the forging material 80A.
  • the lower surface of the upper die 19 is not contacted to the upper surface of the lower die 12.
  • a retaining force is applied to the die pin 13.
  • the upper outer punch 20 is subjected the forging material 13 to fluidization and deformation to form parts of the axis part 81, the upper small diameter part 82, the large diameter part 83, and the lower small diameter part 84.
  • the upper die 19 is went down, and the lower surface of the upper die 19 and the upper surface of the lower die 12 are contacted to each other and die-clamped.
  • an excessive forging material 3A moves the die pin 13 back against the retaining force of the die pin 13.
  • the excessive forging material 80A is flown into the pin inserting hole of the lower die 12 to form the lightening margin 80a. Also, it is flown into the axis part 81 to form the axis part 81 completely.
  • the upper die 19 is raised and the die pin 13 is raised to remove the formed product.
  • a retaining force which is larger than the load applied to the die pin 13 when the forging material 80A is filled in the forming hole, is applied.
  • the forging material 80A is surely filled into a fine portion of the forming hole and an excessive raw material is flown into the pin inserting hole so that defect unfilled material with in the forging die dose not occur.
  • the material of the moved back part is completely removed in the later step so that the excessive raw material does not cause any bad effect to accuracy.
  • the retaining force of the die pin 13 can be adjustable by a hydraulic cylinder so that the load applied to the die pin 13 when the forging material 80A is filled in the forming hole can be easily known. Accordingly, forging can be carried out with the minimum forming force.
  • the retaining force of the die pin 13 is so set as to relatively low, whereby the excessive forging material 80A is contacted to the die pin 13 and moves the die pin 13 back against the retaining force of the die pin 13. And it is flowing into the pin inserting hole while moving the die pin 13 so that a interruption of the forging caused by the high pressure closed state dose not occur and a load applied to the die can be reduced.
  • Fig. 57 is a drawing showing the structure of a lightening shaft formed by the die forging method according to the eighth example of the present invention, and Fig. 57(A) is a perspective view and Fig. 57(B) is a sectional view.
  • Fig. 58 is a drawing showing the structure of the semi-finished forged product of the lightening shaft of Fig. 57, and Fig. 58(A) is a perspective view and Fig. 58(B) is a sectional view.
  • the semi-finished forged product 90 had a edge part 91, a hole part 92 and an axis part 93.
  • a lightening margin 90a is projected from the axis part 93. This lightening margin 90a is removed by machining, etc., to obtain a final lightening axis 90.
  • Fig. 59 to Fig. 62 are sectional views schematically showing an apparatus and forging steps for forging the semi-finished forged product of the lightening shaft of Fig. 58.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a die pin 13 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19 and a punch 24 which slides in the punch inserting hole up and down.
  • a step forming hole 12a is provided at the upper surface of the lower die 12.
  • a step forming hole 19a is formed at a part of the lower surface of the upper die 19, which faces to the above-mentioned step forming hole 12a.
  • these step forming holes 19a and 12a are connected to each other.
  • a heated forging material 90A is set in the step forming hole 12a of the lower die 12.
  • the upper surface of the die pin 13 is positioned at the same plane as the surface of the step forming hole 12a.
  • the upper die 19 and the upper punch 24 are simultaneously went down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12, and die-clamped.
  • the upper punch 24 is went down to a first level.
  • the forging material is fluidized and deformed, and a part of the edge part 91, the hole part 92 and the axis part 93 are formed.
  • a load applied to the die pin 13 due to pressing of the forging material is equaled to the retaining force of the die pin 13 whereby the die pin 13 is not moved back.
  • the upper punch 24 is went down to a second level.
  • the load applied to the die pin 13 becomes larger than the retaining force, and the excessive forging material 90A moves the die pin 13 back against the retaining force of the die pin 13.
  • the edge part 91 is completely formed, and the excessive forging material 90A is flown into the pin inserting hole whereby a lightening margin 90a is formed.
  • the upper die set is returned to the upper limit position to remove the semi-finished forged product. Thereafter, the lightening margin 90a is removed by machining, etc., to obtain the final lightening shaft 90.
  • Fig. 63 is a drawing showing the structure of a hand shower supporting fitment formed by the die forging method according to the ninth example of the present invention, and Fig. 63(A) is a plane sectional view and Fig. 63(B) is a side surface sectional view.
  • the hand shower supporting fitment 100 of this example has a closed bottom cylindrical shape, and has two recessed parts of a deep recessed part (the first recessed part) 101 to insert the hand shower and a shallow recessed part (the second recessed part) 102 having larger diameter than the above.
  • a pushed out part 103 which is pushed out to outer peripheral is provided, and at the closed bottom part, a small projection 104 is provided.
  • Fig. 64 to Fig. 69 are sectional views schematically showing an apparatus and forging steps for forging the hand shower supporting fitment of Fig. 63.
  • This brass material forging machine has an lower die set and a upper set corresponding to the lower die set.
  • the lower die set has a lower die 12, and a die pin 13 which slides in a pin inserting hole of the lower die 12 up and down.
  • the upper die set has an upper die 19, an upper outer punch 20 and an upper inner punch 21.
  • the upper outer punch 20 slides between the lower stopping surface 19b and the upper stopping surface 19c of the upper die 19 up and down. Further, the upper outer punch 20 is biased upward by a spring 20c.
  • the upper inner punch 21 slides in the punch inserting hole of the upper outer punch 20 up and down.
  • a recessed part 13a is provided at the upper surface of the die pin 13. This recessed part 13a is to form a projection 104 of the hand shower supporting fitment 100.
  • a step forming hole 19a is provided at the lower surface of the upper die 19.
  • a heated forging material 100A is set on the die pin 13 in the lower die 12.
  • the lower surface of the upper outer punch 20 biased upward is positioned at the same plane as the lower surface of the upper die 19.
  • the upper die 19 and the upper inner punch 21 are gone down simultaneously, the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12 and die clamped.
  • the die pin 13 is raised.
  • the upper inner punch 21 is supported to locate at the position as shown in Fig. 65.
  • the forging material 100A is fluidized and deformed to form a pushed out part 103 and a projection 104 is formed at the end surface.
  • the upper inner punch 21 is gone down.
  • forming of a deep recessed part 101' is started.
  • the die pin 13 is moved back downward while applying a back pressure to the forging material 100A.
  • the die pin 13 goes down until a volume corresponding to the going down part thereof is equal to the volume corresponding to the forced part by the upper inner punch 21.
  • the upper inner punch further goes down.
  • the upper inner punch 21 is contacted to the upper outer punch 20 and the upper outer punch 20 also simultaneously goes down.
  • a shallow recessed part 102 is formed.
  • the die pin 13 is moved back under applying a back pressure.
  • a pressing force of the punch may be made substantially the same as the working force of the raw material so that buckling of the punch does not occur and the depth of the recessed part can be freely set.
  • Fig. 70 is a drawing showing the structure of a flush valve lid formed by the die forging method according to the tenth example of the present invention.
  • the flush valve lid 110 of this example has a recessed shape, and has a cylinder part 111 and a tip part 112. At the upper surface of the tip part 112, a knob 113 having an undercut is provided. Also, at the cylinder part 111, a shoulder art 114 is provided.
  • Fig. 71 to Fig. 77 are sectional views schematically showing an apparatus and forging steps for forging the hand shower supporting fitment of Fig. 70.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, and a lower punch 235 which slides in a punch inserting hole of the lower die 12 up and down.
  • a color 236 is attached and biased upward by a spring.
  • the upper die set has an upper die 19, and an upper punch 24 which slides in the punch inserting hole of the upper die 19 up and down.
  • a block 237 is provided at the outer peripheral of the upper punch 24, a block 237 is provided.
  • This block 237 comprises two parts 237a and 237b, which are symmetrical to the axis direction of the upper punch 24 and biased by a spring to the outer direction perpendicular to the axis.
  • a step forming hole 12a is provided at the upper surface of the lower die 12.
  • the lower surface of the block 237 is formed in a recessed shape. Also, at the parts thereof, which face to the divided parts 237a and 237b of the block 237, a recessed part 237c is provided. This recessed part 237c is to form the knob 113 of the flush valve lid 110.
  • a heated forging material 110A is set on the lower punch 235 of the lower die 12.
  • the lower end surface of the block 237 is positioned at lower than the lower surface of the upper die 12.
  • the upper die 19 and the upper punch 24 are simultaneously went down, and the lower surface of the block 237 is contacted to the upper surface of the lower die 12 and die-clamped.
  • the heated forging material 110A is fluidized and deformed whereby the tip part 112 and the shoulder part 114 are formed, and simultaneously a starting part 113' of the knob 113 is started to forming at the tip part.
  • the lower punch 235 is raised.
  • the forging material 110A is further fluidized and deformed, and the starting part 113' of the knob 113 further grows upward.
  • a force stronger than the retaining force of the spring is applied to the upper part of the color 236 of the lower punch 235 so that the cylinder part 111 is completely formed.
  • back pressure is applied to the color 236 by the spring, and by pressing the lower end of the cylinder part 111, crack of the forging material can be prevented.
  • the upper punch 24 is gone down.
  • the starting part of the knob 113 formed at the tip part 112 is pressed to be pushed out to the side direction, and the knob (a protruded part) 113 having an undercut is formed.
  • the knob (a protruded part) 113 having an undercut is formed.
  • the die forging method comprises a step B by firstly drawing out the lower punch 235 (punch) used for forming the cylinder part 111 (cylinder part) when the forging finished product 110 (formed product) is removed, and a step C by drawing out the formed product from the block 237 (die) used for forming the outer peripheral surface of the cylindrical part 111 (cylindrical part) after the step B.
  • a step B by firstly drawing out the lower punch 235 (punch) used for forming the cylinder part 111 (cylinder part) when the forging finished product 110 (formed product) is removed
  • a step C by drawing out the formed product from the block 237 (die) used for forming the outer peripheral surface of the cylindrical part 111 (cylindrical part) after the step B.
  • Fig. 78 is a side surface sectional view showing the structure of a H bushing formed by the die forging method according to the eleventh example of the present invention.
  • the H-shaped bushing 120 has an H-shaped sectional surface and has an upper recessed part 121 and a lower recessed part 122, and a flange 123 projected to the outer direction on the outer circumference is formed.
  • Fig. 79 and Fig. 80 are sectional views schematically showing an apparatus and forging steps for forging the H-shaped bushing of Fig. 78.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower set.
  • the lower die set has a lower die 19, a lower inner die pin 238 and a lower outer die pin 239.
  • the lower outer die pin 239 slides in the pin inserting hole of the lower die 19 up and down
  • the lower inner die pin 238 slides in the pin inserting hole of the lower outer die pin 239 up and down.
  • the upper die set has an upper die 12, and an upper punch 24 which slides in the punch inserting hole of the upper die 12 up and down.
  • the lower inner die pin 239, the lower outer die pin 239 and the upper punch 24 slide along the identical axis.
  • a step forming hole 19a is provided at the upper surface of the lower die 19. This step forming hole 19a is to form the flange 123. At the part of the lower surface of the upper die 12, which faces to the above-mentioned step forming hole 19a, a step forming hole 12a is formed. This step forming hole 12a is to form the upper recessed part 121.
  • a heated forging material 120A is set on the upper surface of the inner die pin 238 and the outer die pin 239 of the lower die 12. At this time, the upper surfaces of the each die pins are positioned at the same plane position.
  • the upper die 19 and the upper punch 24 are simultaneously went down, and the lower surface of the upper die 19 and the upper surface of the lower die 12 are contacted to each other and die-clamped. At this time, the forging material 120A is fluidized and deformed whereby a part 121' of the upper recessed part 121' and the flange 123 are formed.
  • the upper punch 24 is gone down further, and simultaneously, the outer die pin 239 gone down.
  • the volume corresponding to the going down part of the upper punch 24 is equaled to the volume corresponding to the going down part of the outer die pin 239.
  • the inner die pin 238 is retained under applying a high retaining pressure thereto.
  • the lower recessed part 122 is formed.
  • Fig. 81 is a side surface sectional view showing the structure of a tee formed by the die forging method according to the twelfth example of the present invention.
  • the tee 130 has a T-shaped cylindrical sectional surface, and has passages 131 and 132 opened to left and right, and the lower passage 133 opened downward perpendicular to the passages.
  • a semi-finished forging product 130B (see Fig.86) firstly, the final product is produced by machining, etc.
  • the semi-finished forging product 3B has a shape having walls at the center of the left and right passages 131 and 132, and between, the left and right passages 131 and 132, and the lower passage 133.
  • Fig. 82 to Fig. 86 are sectional views showing schematically an apparatus and forging steps for forging the semi-finished forged product of the tee of Fig. 81.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, and a left side punch 226, a right side punch 227, a ring 252 and a lower fixed punch 253.
  • the left and right side punches 226 and 227 slide in the left and right punch inserting holes of the lower die 12 on the identical axis.
  • the ring 252 slides on the outer peripheral of the fixed punch 253 of the lower die 12 up and down.
  • the sliding direction of the ring 252 is perpendicular to the sliding direction of the left and right side punches.
  • a forming hole 12a is provided at the upper surface of the lower die 12.
  • a forming hole 19a is formed at the lower surface of the upper die 19.
  • a heated forging material 130A is set on the upper surface of the fixed punch 253 and the ring 252 of the lower die 12. At this time, the upper surfaces of the fixed punch 253 and the ring 252 are positioned at the same plane.
  • the upper die 19 is went down, and the lower surface of the upper die 19 and the upper surface of the lower die 12 are contacted to each other and die-clamped.
  • the left and right side punches 226 and 227 are simultaneously driven into until a first level. At this time, the forging raw material 130A is fluidized and deformed whereby parts of the left and right passages 131' and 132' are formed.
  • the ring 252 has been retained.
  • the left and right side punches 226 and 227 are driven into until the second level.
  • the ring 252 is moved back simultaneously.
  • the volume corresponding to the driven into right and left punches is equaled to the volume corresponding to the moved back ring 252.
  • the left and right passages 131 and 132 are further formed, and the lower passage 133 is formed.
  • the die forging method comprises hole forming step by forming a hole by driving the left and side punches 226 and 227 (punches) into the forging material while the ring 252 (die pin) is in touch with one end surface of the forging material and moving back under applying a back pressure thereto, the left and right side punches 226 and 227 (punches) are driven into the forging material, and the above mentioned left and right side punches 226 and 227 (punches) are driven from a direction other than the moving back direction of the above-mentioned ring 252 (die pin) or the opposite direction thereof.
  • forming is carried out by driving the left and right side punches 226 and 227 (a plural number of punches) from the different direction simultaneously and by moving the ring 252 (die pin) back under applying a back pressure thereto during the forging.
  • a product having a complicated and various shape can be formed.
  • Fig. 87 is a sectional view showing a side surface sectional view showing the structure of a multi header formed by the die forging method according to the thirteenth example of the present invention.
  • the multi header 140 of this example has a passage 141 penetrating along the left to right, and three top and bottom passages 142 which is arranged perpendicular to the passage and connected to the passage.
  • Fig. 88 to Fig. 90 are sectional views schematically showing an apparatus and forging steps for forging the multi header of Fig. 87.
  • This brass material forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, and a left side punch 226, a right side punch 227 and a right hollow pin 255.
  • the left side punch 226 slides in the pin inserting hole of the lower die 12.
  • the right hollow pin 227 slides in the inserting hole of the lower die 12.
  • the right side punch 227 slides in the right hollow pin 255.
  • three fixed punches 253 are provided perpendicular to the above-mentioned inserting hole, and a lower hollow die pin 252, which slides the outer peripheral of the fixed punch 253 up and down, is provided.
  • a heated forging material 140A is set at the left, than the most left hollow die pin 252a, on the lower die 12.
  • the right side punch 227 and the tip end right hollow pin 255 are at the same surface, and the both tip ends are positioned at the left of the hollow die pin 252a.
  • the upper die 19 is gone down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die and die-clamped.
  • the left side punch 226 is driven into the right direction.
  • the right hollow pin 255 is moved back until near of the most left fixed punch 253a is exposed.
  • the most left lower hollow die pin 252a goes down.
  • the forging material is fluidized and deformed to form parts of the right and left passages and a part of the most left top and bottom passages are formed.
  • the left side punch 227 is driven into and the lower hollow die pin 252b is gone down to the stopping surface to form the second top and bottom passages.
  • the formed product has walls at end of the right and left passages, and between, the right and left passages, and, the top and bottom passages. Accordingly, these walls are machined to obtain a final formed product.
  • the die forging method comprises a forging step by driving the left side punch 227 (punch) into the forging material or by pressing a die to the forging material while the hollow die pin 252 (die pin) is in touch with one end surface of the forging material and moving back under applying a back pressure thereto, and a plural number of the above-mentioned hollow die pin 252 (die pin) are provided to form a plural number of deep holes.
  • a product having a complicated shape, such as a multiple header having a number of holes, can be formed.
  • a forged product having an outline shape is produced by using a bronze casting, etc., and the product is subjected to wide ranges of machining to make a final product shape.
  • This method is susceptible of defects such as pinhole, shrinkage, etc., which are specific to the casting material, and a ratio of non-defect products is bad.
  • a significant amount of machining is carried out and a machining time is long so that it is not suitable for mass production.
  • much amount of cutting swarf is generated whereby a yield of the material is poor.
  • a formed product having a shape near to the final product by forging forming it can be considered to prepare a formed product having a shape near to the final product by forging forming, but according to the conventional forging forming, a complicated shape, such as a hollow curve part, cannot be formed.
  • a product such as a water spouting apparatus having a hollow curve part which could never be forged by the conventional method, can be formed with a shape near to the final product shape.
  • a method comprising the following steps can be provided.
  • a die forging method in another embodiment comprises the following steps.
  • the above-mentioned second punch in the third step, can be inserted so that the separating wall positioned at the tip side of the above-mentioned second punch locates at the position near to the above-mentioned container side than the above-mentioned outlet. According to this, removal of the separating wall becomes easier in the above-mentioned fourth step.
  • a die forging method in still another embodiment contains the following steps.
  • forming is carried out while inserting the above-mentioned first punch into the above-mentioned raw material so that deflection of the material at the time of inserting the second punch can be reduced so that a product with high accuracy can be obtained.
  • an inner wall of the above-mentioned curved outlet is roughly formed by inserting the second punch into the above-mentioned raw material to form a hollow part, and when the above-mentioned second punch is to be inserted so that the separating wall positioned at the tip side of the above-mentioned second punch is near to the above-mentioned container side than the above-mentioned outlet, it may be carried out while the above-mentioned first punch is being inserted into the above-mentioned raw material. In this case, removal of the separating wall becomes further easier.
  • a die forging method in the still further embodiment contains the following steps.
  • the inner wall of the above-mentioned curved outlet is roughly formed by inserting the second punch into the above-mentioned raw material to form a hollow part, and at the time when the above-mentioned second punch is inserted so that the separating wall positioned at the tip side of the above-mentioned second punch is near to the above-mentioned container side than the above-mentioned outlet, it is carried out while inserting the above-mentioned first punch into the above-mentioned raw material, and the above-mentioned second punch may be inserted until the tip thereof is reached to the predetermined part of the above-mentioned first punch. In this case, removal of the separating wall becomes further easier.
  • the above-mentioned first step it has a gap between the outer peripheral of the above-mentioned raw material and the inner peripheral of the above-mentioned die
  • part of the above-mentioned raw material is swelled out to the above-mentioned gap by insertion of the above-mentioned first punch
  • the above-mentioned second punch may be inserted into the part of the above-mentioned raw material swelled out to the above-mentioned gap.
  • the above-mentioned outlet may form a curve along with the axis direction.
  • the above-mentioned container room and the above-mentioned outlet may be formed integrally.
  • dimensional accuracy of the product is improved and it is seamless so that a polishing step of the outer shape of the product can be simplified.
  • a water spouting apparatus which is one of the embodiments of the present invention comprises a water spouting apparatus having a container which has an opening for containing a flow amount or temperature adjusting part, as well as an inlet and an outlet, and a flow passage which is to connect the above-mentioned outlet formed at an inner wall of the above-mentioned container room and a water spouting port opened to outside, wherein it is formed by forging forming.
  • the die forging method of the present invention can be applied to production of a metal forming product having a first hole part and a curved shaped second hole part.
  • This die forging method contains the following steps.
  • the second hole part with a curved shape is formed by inserting the above-mentioned second punch, it is carried out while the first punch is still inserted into the above-mentioned raw material, deflection of the material when the second punch is inserted can be reduced and a product with a higher accuracy can be formed.
  • the die forging method in further another embodiment has the following steps.
  • the above-mentioned second punch has a circular arc shape with a constant curvature radius along with the axis direction, and the above-mentioned curved second hole part may be formed by a circumferential movement with the center of the circular arc as the center.
  • the die forging method of the present invention can be applied to a production of a metal formed product having a first hole part and a curved shaped second hole part, and being formed a connecting port at the inner wall of the above-mentioned first hole part, the port being connected to the above-mentioned second hole part.
  • This die forging method contains the following steps.
  • the above-mentioned third step it is preferred to insert the above-mentioned curved second punch so that the above-mentioned separating wall becomes at the above-mentioned first hole part side than the above-mentioned connecting port. According to this arrangement, removal of the separating wall becomes easier.
  • a first hole part and a curved second hole part are formed by driving a first punch and a curved second punch into a metal material.
  • a first hole part and a curved second hole part are formed by inserting a first punch, which has, along with the inserting direction, a first part having a first sectional shape and a second part having a second sectional shape in which a predetermined part of the above-mentioned first sectional shape being lacked, and a curved second punch which is so constituted that it is inserted until the tip of which is reached to the above-mentioned predetermined part, into a metal material.
  • a pinion is provided at the above-mentioned curved second punch, and the above-mentioned second punch preferably slides by sliding of a rod member to which a rack with the above-mentioned pinion is formed. Since the punch and the rod member are slid by the rack and the pinion, sliding of the punch and the rod member can be easily synchronized. Thus, it can be applied to forming accompanied by a heavy lord.
  • a linear moving passage having the same axis with the above-mentioned rod member which moves linear may be further provided. According to this, accuracy of a sliding track for the above-mentioned rod member is further improved.
  • a producing apparatus of a metal formed product in the other embodiment of the present invention has a first punch, a second punch having a circular arc shape with a constant curvature radius, and a driving means to move the second punch to circumferential movement with the center of said circular arc as a center, and the above-mentioned first punch and the above-mentioned second punch are inserted into a metal material to form a first hole part and a curved second hole part.
  • a producing apparatus of a metal formed product in the other embodiment of the present invention has a first punch, a second punch having a circular arc shape with a constant curvature radius, a driving means to move the second punch to circumferential movement with the center of said circular arc as a center, and a circular arc shape movement passage having the same axis with the above-mentioned second punch which moves said circumferential movement, and the above-mentioned first punch and the above-mentioned second punch are inserted into a metal material to form a first hole part and a curved second hole part.
  • a heater may be buried to the above-mentioned first punch and/or the second punch.
  • temperature control of the punches can be carried out so that setting of forming conditions in accordance with the material becomes easy.
  • a heater may be buried at the metal die at a part other than the above-mentioned first punch and the second punch. By providing a heater, temperature control of the punch can be carried out so that setting of forming conditions in accordance with the material becomes easy.
  • Fig. 91 is an assembly drawing showing a tap apparatus according to the fourteenth example of the present invention.
  • Fig. 92 is a drawing of parts of the tap apparatus of Fig. 1 in which machining has finished, and Fig. 92(A) is a plane view, Fig. 92(B) is a longitudinal sectional view and Fig. 92(C) is a side view.
  • This tap apparatus part 300 has a linear through passage (container) 301 opened to top and bottom, and a curved water spouting passage (curved outlet passage) 303 provided at the wall surface of the through hole 301.
  • the through hole 301 and the water spouting passage 303 are connected to each other.
  • Fig. 93 is a drawing showing an semi-finished forged product of a part of the tap apparatus of Fig. 92, and Fig. 93 (A) is a plane view, Fig. 93(B) is a longitudinal sectional view and Fig. 93(C) is a side view.
  • the semi-finished forging product 300B of this tap apparatus part 300 has a lower end flash part 301a at part of the lower end of the through passage 301. Also, it has a separating wall flash part (separating wall) 303a at the part into which the wall of the water spouting passage 303 is inserted in the through passage 301.
  • a final tap apparatus part 300 is obtained.
  • the curved outlet 303 of said part 300 is formed to a final product shape at forging step.
  • Fig. 94 is a plan view schematically showing an apparatus for forging the semi-finished forged product of the tap apparatus part and Fig. 95 is a side sectional view of said apparatus.
  • This forging machine has a lower die set and an upper die set corresponding to the lower die set.
  • the upper die set has an upper die 19.
  • the lower die set has a lower die 12, a side straight punch (a first punch) 460, a curved punch (a second punch) 461, a rotation bar (rod shaped member) 462 for rotating the curved punch 461, and an ejector pin 15 for sliding the pin inserting hole of the lower die 12 up and down.
  • the side straight punch 460 slides horizontally on the upper surface of the lower die 12.
  • a cut portion 460a is provided at the tip surface of the side straight punch 460.
  • the shape of this cut portion 460a is correspond with a shape of the semi-finished forging product 300B excluding the lower end flash part 301a and the separating wall flash part 303a of the through passage 301.
  • a step forming hole 12a having a straight part corresponding to the through passage 301 and a curved part corresponding to the water spouting passage 303 is provided.
  • a straight and curved step forming hole 19a is formed.
  • these step forming holes are connected to each other.
  • the curved punch 461 is so provided as to slide on a circular arc having a constant curvature radius along with the vertical axis of the upper surface of the lower die 12.
  • a pinion 461a is provided at a part of the outside of the curved punch 461.
  • the rotation bar 462 is a straight member and driven by a driving means (not shown in the drawing) to linearly slide on the upper surface of the lower die.
  • racks 462a are provided. These racks 462a are engaged with the pinion 461a of the curved punch 461.
  • the curved punch 461 rotates along with the vertical rotating axis on a circular arc.
  • the two are positioned not to reach the tip surface of the curved punch 461 to the cut portion 460a of the side straight punch 460. Also, at this time, the tip surface of the curved punch 461 has reached to the inside of the straight step forming hole 12a" over the curved step forming hole 12a'.
  • thermocouple 464 is provided at the each dies. The temperature data measured by the thermocouple 464 are sent to a temperature controller, and the temperature of the heater 463 is controlled by the controller.
  • an heat insulating material 465 and an stainless steel cover 466 are wound to maintain the temperature.
  • a sheet shaped heat insulating material 467, an stainless steel plate 468 and a sheet shaped heat insulating material 469 are held between the lower die 12 and a body flame, and between the upper die 19 and the upper slider, heat conductions to the body flame and the upper slider are prevented.
  • Fig. 96 to Fig. 100 are sectional views schematically showing a step for forging the semi-finished forged product of the parts of the tap apparatus of Fig. 93.
  • each punch 460 and 461 are moved back, and a heated forging material 300A is set to the step forming hole 12a of the lower die 12.
  • the upper die 19 goes down and contacts with the lower die 12 to die-clamp.
  • the side straight punch 460 is driven into a forming hole 12".
  • a part of the forging material 300B is fluidized and deformed, and an upper opening and a hollow part of the semi-finished forging product are formed. Also, a part of the material is swelled out in the curved step forming hole 12a'.
  • the hollow part is formed by the curved punch 351 while swelling out the material, forming of the hollow shape becomes easy. Also, since the curved punch 461 is driven into while driving the side straight punch 460 into, deflection of the material can be reduced.
  • the side straight punch 460 is moved back to the left direction of the drawing. Also, the rotation bar 462 is moved back to the lower direction of the drawing, and the curved punch 461 is rotated to the outside direction (clock direction of the drawing) and moved back. Thereafter, the upper die 19 is returned to the upper limit position.
  • This semi-finished formed product is treated by the above-mentioned machining, etc., and unnecessary portions are removed to obtain a final formed product.
  • the separating wall flash part 303a is present in the cylindrical shaped through passage 301 so that it can be easily removed with the lower edge surface flash part 301a.
  • Fig. 101 is a drawing showing the structure of a shower hanger according to the fifteenth example of the present invention, and (A) is a perspective view, (B) is a side view, (C) is a front view and (D) is a plane view.
  • the shower hanger 310 is a member substantially rectangular shape, having a hook part 311 for hooking the shower at one edge surface and a fixing part 313 to be fixed to the wall at the other edge surface.
  • the hook part 311 comprises a key hole shaped groove 311a penetrating from the front surface to the back surface.
  • the groove 311a is opened to the edge surface.
  • the key hole shaped groove 311a is also slightly inclined to the upper direction from the front surface toward the back surface.
  • the fixing part 313 comprises a hole having a predetermined depth cut from the edge surface of the opposed side.
  • This hole is constituted by a box shaped part 313a wherein a sectional surface from the edge surface to a certain height is rectangle, and a H-shaped part 313b wherein a sectional surface from the bottom of the box shaped part to the bottom is H-shaped.
  • Fig. 102 to Fig. 108 are sectional views schematically showing an apparatus and forging steps for forging the shower hanger of Fig. 101.
  • This forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a side punch 470 and an ejector pin 15.
  • the side punch 470 is so provided as to slide the lower die 12 to the diagonally upper direction.
  • the sectional surface shape of the side punch 470 is the same as the shape of the key hole shaped groove 311a of the hook part 311 of the hanger 310. Also, the sliding direction of the side punch 470 is accorded with the inclined direction of the key hole shaped groove 311a of the hook part 311.
  • a step forming hole 12a corresponding to the outer shape of the end surface of the hook part 311 is provided.
  • the upper die set has an upper die 19 and an upper punch 471 which slides in the upper die up and down.
  • a cut portion 471a corresponding to the shape of the box shape part 313a and the H-shaped part 313b of the fixing part 313 of the hanger 310 is provided.
  • a heated forging material 310A is set to the step forming hole 12a of the lower die 12.
  • the upper die 19 goes down and the lower surface of the upper punch 471 is contacted to the forging material 310A. Incidentally, it is not necessarily contacted to each other.
  • the forging material 310A is fluidized and deformed and a pressed part is flowed into the gap between the side punch 470 of the lower die 12 and the step forming hole 12a to form a hook part 311 at which the key hole state groove is provided. Also, the part fluidized upward is flowed into the cut portion 471a of the upper punch 471 so that the fixing part 313 is formed.
  • the upper punch 471 is raised.
  • the upper die 19 is raised.
  • the side punch 470 is moved back and as shown in Fig. 108, the ejector pin 15 is raised to remove the formed product.
  • Fig. 109 is a longitudinal sectional view showing the structure of a part X according to the sixteenth example of the present invention.
  • the part X 320 has a closed bottom cylindrical shape as a whole. At the center of the part X, an axis hole 321 with a constant inner diameter is provided.
  • the outer surface thereof comprises an upper small diameter part 322, a flange part 323, a large diameter part 324 and a lower small diameter part 325 from the top.
  • Fig. 110 to Fig. 119 are sectional views schematically showing an apparatus and forging steps for forging the part X of Fig. 1.
  • This forging machine has a lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a lower outer punch 480 which slides in the lower die 12 up and down, and a lower inner punch 481 which slides in the lower outer punch 480 up and down.
  • the lower inner punch 481 is connected to an actuator (now shown in the drawing) but the lower outer punch 480 is not connected to the actuator.
  • a flange 480a is provided at the lower end part of the lower outer punch 480. Rising of the punch 480 is stopped by contacting the flange 480a to an upper stopping surface 12b in the lower die. Descending of the punch 480 is stopped by contacting the flange 480a to a lower stopping surface 12c of the lower die 12.
  • the upper die set has an upper die 12 and an upper punch 482 which slides in the upper die up and down. At the upper tip part of said punch 482, a flange 482a is provided. Descending of the punch 482 is stopped by contacting the flange 482a to a lower stopping surface 19c of the upper die 19.
  • a step forming hole 12a is formed.
  • a step forming hole 19a is provided. This step forming hole is to form the upper small diameter part and the flange part of the part X. At the die-clamping state, these step forming holes are connected to each other.
  • a heated forging material 320A is set at the step forming hole 12a of the lower die 12.
  • the upper die 19 and the upper punch 482 are simultaneously gone down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12 to die-clamp.
  • the lower inner punch 481 and the lower outer punch 480 are raised. At this time, the forging material is pressed from downward, and fluidized and deformed. And the upper small diameter part 322 and the flange part 323 are formed, and a part of the axis hole 321 is starting to be formed.
  • the upper punch 482 goes down. According to the pressure difference between the pressing force of the upper punch 482 and the back pressure to the lower inner punch 481 and the lower outer punch 480, the lower inner punch 481 and the lower outer punch 480 go down. At this time, the axis hole 321 is further formed.
  • the lower outer punch 480 goes down, as shown in Fig. 114, until the flange 480a of said punch 480 contacts with the lower stopping surface 12c of the lower die 12.
  • the upper punch 482 goes down until the flange 482a contacts with the lower stopping surface 19c, and simultaneously the lower inner punch 481 goes down. At this time, the lower small diameter part 325 is formed and the axis hole 321 is further deeply formed. At the lower inner punch 481, the back pressure is still applied.
  • the upper punch 482 is raised.
  • the upper die 19 is raised.
  • the lower inner punch 481 is raised.
  • the lower outer punch 480 is raised with the lower inner punch 481 to remove the formed product.
  • Fig. 120 is a longitudinal sectional view showing the structure of a part Y according to the sixteenth example of the present invention.
  • the part Y 330 is a conical shaped solid part as a whole.
  • the part Y 330 has a flange part 331 and under the flange part 331, a large diameter part 332, a small diameter part 333 and an axis part 334 are continuously provided.
  • Fig. 121 to Fig. 130 are sectional views schematically showing an apparatus and forging steps for forging the part Y of Fig. 120.
  • This forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a lower inner punch 490 which slides in the lower die 12 up and down, and a double lower outer punch.
  • the lower inner punch 490 is connected to an actuator (now shown in the drawing), but the lower outer punch is not connected to the actuator.
  • the lower outer punch comprises an inside outer punch 491 and an outside outer punch 492.
  • a flange 492a is provided at the lower end part of the outside outer punch 492. Rising of said punch 492 is stopped by contacting the flange 492a to an upper stopping surface 12c of the lower die 12. Descending of the punch 492 is stopped by contacting the flange 492a to a lower outer stopping surface 12d of the lower die 12.
  • a flange 491a is provided at the lower end part of the inside outer punch 491. Rising of said punch 491 is stopped by contacting the flange 491a to the flange 492a of the outside outer punch 492. Descending of the punch 492 is stopped by contacting the flange 492a to a lower inner stopping surface 12e of the lower die 12.
  • a step forming hole 12a is provided.
  • the upper die set has an upper die 19 and an upper punch 493 which slides in the upper die 19 up and down. At the upper end part of the upper punch 493, a flange 493a is provided. Descending of the punch 493 is stopped by contacting the flange 493a to a lower stopping surface 19c of the upper die 19.
  • a heated forging material 330A is set at the step forming hole 12a of the lower die 12.
  • the upper die 19 and the upper punch 493 simultaneously go down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12 to die-clamp.
  • the upper punch 493 goes down.
  • the upper punch 493 continuously goes down. According to the pressure difference between the pressing force of the upper punch 493 and the back pressure to the lower inner punch 490 and the lower outer punch, the lower inner punch 490 and the lower outer punch simultaneously go down.
  • the outside outer punch 492 goes down until the flange 492a contacts with the outer stopping surface 12d. At this time, parts of the flange part 331 and the large diameter part 332 are starting to be formed.
  • the upper punch 493 goes down, and the lower inner punch 490 and the inside outer punch 491 simultaneously go down.
  • the outside outer punch 492 is stopped at a lower stopping surface 12d of the lower die 12.
  • the inside outer punch 491 goes down until it contacts with an inner stopping surface 12e. At this time, the flange part 331 and the large diameter part 332 are further formed, and the small diameter part 333 is starting to be formed.
  • the upper punch 493 goes down until the flange 493a of said punch 493 contacts with a lower stopping surface 19c of the upper die 19.
  • the lower inner punch 490 continuously goes down.
  • the flange part 331, the large diameter part 332, the small diameter 333 and the axis part 334 are formed.
  • the back pressure is continuously applied to the lower inner punch 490.
  • the upper punch 493 is raised.
  • the upper die 19 is raised.
  • the lower inner punch 490 is raised.
  • the lower outer punches 491 and 492 are further raised with the lower inner punch 490 to remove the formed product.
  • Fig. 131 is a longitudinal sectional view showing the structure of a part Z according to the seventeenth example of the present invention.
  • the part Z 340 has a cylindrical shape as a whole and a longitudinal sectional surface is H-shaped.
  • the part Z 340 has an upper recessed part 341 and a lower recessed part 342. Near to the upper end of the upper recessed part 341, a flange 343 is provided. At said flange 343, a circular projection part 344 extending upward is provided.
  • Fig. 132 to Fig. 141 are sectional views schematically showing an apparatus and forging steps for forging the part Z of Fig. 131.
  • This forging machine has an lower die set and a upper die set corresponding to the lower die set.
  • the lower die set has a lower die 12, a lower inner punch 500 which slides in the lower die 12 up and down, and a lower outer punch 501.
  • the lower outer punch 501 is connected to an actuator (not shown in the drawing) but the lower inner punch 500 is not connected to the actuator.
  • an upper flange 501a is provided at the lower end part thereof.
  • a rod 501b is so provided to extend downward.
  • a lower flange 501c is attached to the lower end part of said rod 501b.
  • a flange 500a is provided at the lower end part of the lower inner punch 500.
  • the rod 501b of the lower outer punch 501 is slidably penetrated in the flange 500a of the lower inner punch 500. Accordingly, the lower inner punch 500 slides between the upper flange 501a and the lower flange 501c of the lower outer punch 501 along with the rod 501b. Descending of the lower inner punch 500 is stopped by contacting the flange 500a to a lower stopping surface 12b of the lower die 12.
  • the upper die set has an upper die 19 and an upper punch 502 which slides in the upper die 19 up and down. At the upper end part of the upper punch 502, a flange 502 is provided. The punch 502 is stopped by contacting the flange 502a to a lower stopping surface 19c of the upper die 19.
  • a forming hole 12a is provided at the upper surface of the lower die 21 .
  • a step forming hole 19a is provided at the part of the lower surface of the upper die 19, which faces to the above-mentioned forming hole.
  • a heated forging material 340A is set at the forming hole 12a of the lower die 12.
  • the upper die 19 and the upper punch 502 simultaneously go down, and the lower surface of the upper die 19 is contacted to the upper surface of the lower die 12 to die-clamp.
  • the lower outer punch 501 is raised with the lower inner punch 500.
  • the forging material is fluidized and deformed, and the circular projection 344 and the flange 343 are formed by the portion pressed upward.
  • the upper punch 502 goes down.
  • the lower outer punch 501 and the lower inner punch 500 simultaneously go down.
  • the upper recessed part 341 is starting to be formed.
  • the upper punch 502 continuously goes down, and the lower inner punch 500 simultaneously goes down.
  • the lower inner punch 500 goes down until the flange 500a of said punch 500 is contacted to a lower stopping surface 12b of the lower die 12. At this time, the upper recessed part 341 is further deeply formed.
  • the upper punch 502 further goes down until the flange 502a of said punch 502 is contacted to a lower stopping surface 19c of the upper die 19.
  • the lower outer punch 501 further goes down along with the rod 500b of the lower inner punch 500.
  • the lower outer punch 501 goes down until the upper flange 501a of said punch 501 is contacted to the flange 500a of the lower inner punch 500. Incidentally, it is not necessarily contacted to each other.
  • the upper punch 502 by the upper punch 502, the upper recessed part 341 is completely formed. Further, by going the lower outer punch 501 down, the lower recessed part 342 is formed.
  • the upper punch 502 is raised.
  • the upper die 19 is raised.
  • the lower outer punch 501 is raised.
  • the lower inner punch 500 is raised with the lower outer punch 501 to remove the formed product.
EP99931517A 1998-07-24 1999-07-23 Procede de forgeage par matrices Withdrawn EP1123764A1 (fr)

Applications Claiming Priority (21)

Application Number Priority Date Filing Date Title
JP20917398 1998-07-24
JP10209173A JP2000042674A (ja) 1998-07-24 1998-07-24 黄銅材の鍛造方法、黄銅材用鍛造装置及び黄銅製吐水機器
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JP10275792A JP2000102834A (ja) 1998-09-29 1998-09-29 管状台座及びその製造方法
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JP34556298A JP2000176596A (ja) 1998-10-06 1998-12-04 黄銅製羽根車及びその製造方法
JP34556298 1998-12-04
JP36814998A JP2000193501A (ja) 1998-12-24 1998-12-24 流量計、金属成形品の製造方法および金属成形品の製造装置
JP36814998 1998-12-24
JP11070156A JP2000263179A (ja) 1999-03-16 1999-03-16 型鍛造方法及び型鍛造装置
JP7015699 1999-03-16
JP11070155A JP2000263178A (ja) 1999-03-16 1999-03-16 型鍛造方法及び型鍛造装置
JP7015599 1999-03-16
JP7667299 1999-03-19
JP7667299 1999-03-19
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JP11122856A JP2000314157A (ja) 1999-04-28 1999-04-28 吐水装置及びその製造方法
JP15729799 1999-06-04
JP15729799 1999-06-04
PCT/JP1999/003964 WO2000005008A1 (fr) 1998-07-24 1999-07-23 Procede de forgeage par matrices

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CN102989955B (zh) * 2012-12-06 2014-12-03 无锡透平叶片有限公司 一种飞机黑匣子的精密模锻成型工艺
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US10557505B2 (en) 2015-07-13 2020-02-11 Nsk Ltd. Method and device for manufacturing bearing unit
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AU4800399A (en) 2000-02-14
CN1309592A (zh) 2001-08-22
WO2000005008A1 (fr) 2000-02-03
CA2338376A1 (fr) 2000-02-03

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