EP2306025B1 - Empreinte et procédé de forgeage d un matériau pour rotor - Google Patents

Empreinte et procédé de forgeage d un matériau pour rotor Download PDF

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Publication number
EP2306025B1
EP2306025B1 EP09770179.1A EP09770179A EP2306025B1 EP 2306025 B1 EP2306025 B1 EP 2306025B1 EP 09770179 A EP09770179 A EP 09770179A EP 2306025 B1 EP2306025 B1 EP 2306025B1
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EP
European Patent Office
Prior art keywords
load
hole
vane
die
sub
Prior art date
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Not-in-force
Application number
EP09770179.1A
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German (de)
English (en)
Other versions
EP2306025A4 (fr
EP2306025A1 (fr
Inventor
Hidemi Yamada
Daisuke Endo
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Resonac Holdings Corp
Original Assignee
Showa Denko KK
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Publication date
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Publication of EP2306025A1 publication Critical patent/EP2306025A1/fr
Publication of EP2306025A4 publication Critical patent/EP2306025A4/fr
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Publication of EP2306025B1 publication Critical patent/EP2306025B1/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2/00—Rotary-piston machines or pumps
    • F04C2/30—Rotary-piston machines or pumps having the characteristics covered by two or more groups F04C2/02, F04C2/08, F04C2/22, F04C2/24 or having the characteristics covered by one of these groups together with some other type of movement between co-operating members
    • F04C2/34—Rotary-piston machines or pumps having the characteristics covered by two or more groups F04C2/02, F04C2/08, F04C2/22, F04C2/24 or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in groups F04C2/08 or F04C2/22 and relative reciprocation between the co-operating members
    • F04C2/344—Rotary-piston machines or pumps having the characteristics covered by two or more groups F04C2/02, F04C2/08, F04C2/22, F04C2/24 or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in groups F04C2/08 or F04C2/22 and relative reciprocation between the co-operating members with vanes reciprocating with respect to the inner member
    • 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
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K3/00—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01C—ROTARY-PISTON OR OSCILLATING-PISTON MACHINES OR ENGINES
    • F01C21/00—Component parts, details or accessories not provided for in groups F01C1/00 - F01C20/00
    • F01C21/08—Rotary pistons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2230/00—Manufacture
    • F04C2230/10—Manufacture by removing material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2230/00—Manufacture
    • F04C2230/20—Manufacture essentially without removing material
    • F04C2230/25—Manufacture essentially without removing material by forging
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2240/00—Components
    • F04C2240/20—Rotors

Definitions

  • the present invention relates to a rotor material forging die assembly for producing a rotor material having vane grooves at its outer peripheral portion, and a method for forging the rotor material.
  • the invention relates to a die assembly according claim 1 and a method according to claim 10.
  • a die assembly and a method of the initially-mentioned type are known from, e.g. US 6,094,815 A ; JP10296382 A discloses a further die assembly.
  • a rotor for a compressor or a rotor for a rotary type vacuum pump for use in a brake controller is generally provided with a plurality of vane grooves parallel to an axial center formed in an outer peripheral portion at equal intervals in the circumferential direction. Further, most of rotors for an air-conditioning rotary compressor and for a rotary vacuum pump for used in a brake controller, which are to be mounted on a vehicle, are aluminum alloy products for the purpose of attaining the weight saving, and generally produced by forge processing.
  • the upper die with the groove forming punches are driven into a forging raw material set in the forming hole of the lower die, to thereby form vane grooves extending from the upper end face near to the lower end face.
  • a groove forming punch is driven therein to punch out and remove the excess thickness portion closing the lower end side of the vane groove to open both ends of the vane groove.
  • the preferred embodiments of the present invention have been developed in view of the above-mentioned and/or other problems in the related art.
  • the preferred embodiments of the present invention can significantly improve upon existing methods and/or apparatuses.
  • the present invention was made in view of the aforementioned problems, and aims to provide a die assembly for forging a rotor material and a method for forging a rotor material capable of accurately removing an excess thickness portion while securing high production efficiency.
  • the present invention is provided with the following structures.
  • the die assembly for forging a rotor material of the item 1 since a rotor material in which one end face of the vane groove is positioned inner than the end face of the rotor portion can be obtained, the radius difference between the inner periphery of the vane groove and the outer periphery of the excess thickness portion can be reduced. For this reason, the vane groove side excess thickness portion can be removed easily and appropriately, and therefore the productivity can be improved.
  • the die assembly for forging a rotor material of the item 4 it is possible to prevent improper dropping of the excess thickness portion.
  • the die assembly for forging a rotor material of the item 5 since a rotor material processed article in which one end face of the center hole is positioned inner than the end face of the rotor portion can be obtained, the radius difference between the inner periphery of the center hole and the outer periphery of the excess thickness portion can be reduced. For this reason, the center hole side excess thickness portion can be removed easily and appropriately, and therefore the productivity can be improved.
  • the flexural deformation and/or torsional deformation of the center pin and the vane portion can be restrained.
  • the first sub-load and the second sub-load can be set independently in accordance with the shape and dimension of the center pin and the vane portion, which can more assuredly maintain the balance between the metal flow toward the outer periphery and a force for causing an inward deformation of the vane portion at the time of forming the center hole.
  • an aluminum or aluminum alloy rotor material excellent in dimensional accuracy can be forged with a high material yield.
  • the rotor R is a generally cylindrical columnar member in which a center hole 3 as a shaft hole for inserting a shaft therein is formed at the center thereof and five vane grooves 4 with a groove bottom enlarged into a round in cross-section are formed in the outer peripheral surface.
  • These vane grooves 4 are arranged in parallel with the axial line of the cylindrical columnar member and communicated with both end surfaces thereof, and also formed so as to inwardly cut into the columnar member eccentrically with respect to the center hole 3.
  • the offset amount U of the vane groove 4 is represented by the distance between the center line L1 extending in the groove width direction and the linear line L2 extending in parallel with the center line L1 and passing through the axial line of the rotor R.
  • aluminum or aluminum alloy As the material of the rotor R, aluminum or aluminum alloy is generally used.
  • aluminum alloy consisting of Si: 14 to 16 mass%, Cu: 4 to 5 mass%, Mg: 0.45 to 0.65 mass%, Fe: 0.5 mass% or less, Mn: 0.1 mass% or less, Ti: 0.2 mass% or less, and the balance being Al and inevitable impurities can be exemplified.
  • the production steps of the rotor typically include a cutting step, a mass selection step, a forging step, a punching step, a heat treatment step, and an inspection step. After these steps, a rotor product is shipped.
  • the cutting step and the mass selection step are steps for obtaining a forging raw material.
  • a continuously cast member is cut into a given length.
  • the cast members are selected in accordance with the mass (weight) to obtain a desired forging raw material.
  • the forging rawmaterial is subjected to forge processing to obtain a rotor material. Thereafter, in the punching step, the excess thickness portions are removed form the rotor material to obtain a rotor R.
  • the rotor R is subj ected to a heat treatment and a quenching treatment to improve the hardness and the abrasion resistance to thereby obtain a rotor product.
  • the inspection step the rotor product is subjected to a final inspection and then shipped when no defect is found.
  • Fig. 1 and Figs. 2A to 2D show a forging die assembly as a forging device for use in forge processing
  • Fig. 3 shows a rotor material 1 to be forged by the forging die assembly.
  • the forging die assembly includes a lower die 10 as a die and an upper die 30 as a punch for giving forming loads.
  • a lower die 10 as a die
  • an upper die 30 as a punch for giving forming loads.
  • well-known die steel is used as the material for these dies.
  • the lower die 10 is divided into a lower die body 11 having a forming hole 12, a base 15 to be disposed at the lower side of the lower die body 11, and a bush 19 to be disposed at the upper side of the lower die body 11.
  • the vane portion 13 is a thin plate-shaped member having one end circular in cross-section and has a cross-sectional shape corresponding to that of the vane groove 4.
  • the base 15 is formed into a plate-shape and has a center pin 16 for forming a center hole 3 of the rotor fixed at the center of the base and through-holes 18 for knockout pins 17 surrounding the center pin 16.
  • the bush 19 is an annular plate member provided with a loading hole 20 penetrated in the up-and-down direction and having the same diameter as that of the forming hole 12 of the lower die body 11.
  • the center pin 16 is inserted into the forming hole 12 of the lower die body 11, forming the inner portion of the forming hole 12 into an inversion cross-sectional shape of the rotor R. Further, in this state, the loading hole 20 of the bush 19 communicates with the forming hole 12. Further, in the forging preparation step shown in Fig. 2A , the knockout pins 17 are inserted into the through-holes 18 of the base 15, and the tip end faces thereof are being held at the same height as the upper surface of the base 15.
  • the upper die 30 is divided into an upper die body 31 for applying a main load F to the forging rawmaterial W, a cylindrical pin 40 for applying sub-loads F1 and F2, and a flat plate 41.
  • the cylindrical pin 40 constitutes a back-pressure pin
  • the flat plate 41 constitutes a back-pressure plate
  • the lower-half punch portion 32 is formed into a generally cylindrical columnar member having an outer diameter corresponding to the through-hole 20 of the bush 19, and the larger-diameter upper half portion 33 is provided with a concave portion 34 at the upper surface thereof.
  • a concave portion 34 Formed in this concave portion 34 is a single circular hole 35 having a cross-sect ion corresponding to the cross-section of the cylindrical pin 40 and configured to insert the cylindrical pin 40 in an advanceable and retractablemanner and five flat holes 36 each having a cross-section corresponding to the cross-section of the flat plate 41 and configured to insert the flat plate 41 in an advanceable and retractable manner.
  • the circular hole 35 and the flat holes 36 are penetrated up to the tip end face of the punch portion 32, respectively, and the flat holes 36 are opened to the outer peripheral surface of the punch portion 32.
  • the position of the circular hole 35 and the positions of the flat holes 35 correspond to the position of the center pin 16 and the positions of the vane portions 13 of the lower die body 11, respectively.
  • the circular hole 36 constitutes a center pin corresponding hole
  • each flat hole 35 constitutes a vane portion corresponding hole.
  • the cylindrical pin 40 is a cylindrical pin having a diameter larger than that of the center pin 16 in the lower die body 11, and is integrally provided with, at its upper end, a retaining portion 42 having a diameter larger than that of the circular hole 35.
  • the flat plate 41 is a thin-plate member having a round portion at its tip end in the same manner as in the vane portion 13 of the lower die body 11, but the flat plate 41 is one size larger than the vane portion 13 and integrally provided with, at its upper end, a retaining portion 43 enlarged in cross-sectional area than the flat hole 36.
  • the cylindrical pin 40 in a state in which the cylindrical pin 40 is fitted into the circular hole 35 from the concave portion 34 of the upper die body 31, and the flat plates 41 are fitted into the respective flat holes 36, the upper die body 31, the cylindrical pin 40, and the flat plates 41 form a single cylindrical columnar member having a continuous tip end face and a continuous peripheral surface.
  • a gas cushion 45 for applying a load thereto is arranged above each of the cylindrical pin 40 and flat plates 41.
  • a piston rod 47 is inserted into the cylinder 46 in an advanceable and retractable manner.
  • the sealed compressed gas causes a force in the advancing direction equal to the force in the retracting direction.
  • the cylinder 46 is fixed to the mounting board 48.
  • the upper die body 31 and the mounting board 48 are assembled in a state in which the tip end of the piston rod 47 is in contact with the corresponding retaining portion 42 and 43 of the cylinder pin 40 and the flat plate 41 and an initial load by the advancing force of each piston rod 47 is applied to the corresponding cylindrical pin 40 and the flat plate 41.
  • the mounting board 48 is configured to move up and down together with the upper die 30, but the sub-loads F1 and F2 applied to the cylindrical pin 40 and the flat plate 41, respectively, are controlled by the gas cushions 45 independent from the main load F.
  • the value of the first sub-load F1 and that of the second sub-load F2 can be adjusted by setting the operating load of the gas cushion 45. Furthermore, the cylindrical pin 40 and the flat plates 41 are each provided with the gas cushion 45, and therefore can be controlled in load independently. In other words, the main load F applied to the upper die body 32, the first sub-load F1 applied to the cylindrical pin 40 and the five second sub-loads F2 applied to the five flat plates 41 can be set independently.
  • the lower die body 10 and the upper die body 30 are arranged such that the cylindrical pin 40 and the flat plates 41 are arranged at the respective positions corresponding to the center pin 16 and the vane portions 13. Therefore, as shown in Fig. 7 , the first sub-load F1 is applied to directly above the center pin 16, and the second sub-load F2 is applied to directly above the vane portion 13.
  • the main load F is applied to the portions other than the center pin 16 and the vane portions 13. Furthermore, in this invention, each of the first sub-load F1 and the second sub-load F2 is set to a value smaller than the main load F.
  • lubricant agent is applied to required portions of the lower die 10 and the upper die 30, and a cylindrical forging material 49 is loaded in the loading hole 20 of the bush 19.
  • the forging raw material W is a material produced by a method, such as, e.g., a method in which a continuous cast material is cut into a predetermined length, and heated to a predetermined temperature as needed.
  • aqueous graphite lubricant agent and oil-graphite lubricant agent can be exemplified.
  • the pre-heating temperature is preferably set to 400 to 450 °C.
  • the main load F is applied to the portions of the forging raw material W not corresponding to the cylindrical pin 40 and the flat plates 41, while the first sub-load F1 and the second sub-load F2 independent from the main load F are applied to the portions of the forging raw material W corresponding to the cylindrical pin 40 and the flat plates 41.
  • the optimum value of the first sub-load F1 and that of the second sub-load F2 are appropriately set depending on the volume of the center pin 16 and that of the vane portion 13. As these volumes increase, the escape amount of material increases. Therefore, provided that the volume of the vane portion 13 is constant, the balance can be maintained by increasing the inflow amount into the circular hole 35 by decreasing the first sub-load F1 as the volume of the center pin 16 increases.
  • the upper die 30 in a state in which the upper die 30 has reached the bottom dead point (in the die mated state), it is configured such that the level of the tip end face (upper end face) of the center pin 16 coincides with or distances from the level of the opening face (lower end face) of the circular hole 35.
  • the center hole side end face difference D3 is set to 0 to 2 mm (See Fig. 12 ).
  • the die mated state it is configured such that the level of the tip end face (upper end face) of the vane portion 13 coincides with or distances from the level of the opening face (lower end position) of the flat hole 36.
  • the vane groove side end face difference D4 is set to 0 to 2 mm (See Fig. 13A ).
  • the center hole side clearance D5 is set to 0.01 to 0.1 mm, more preferably 0.05 to 0.1 mm (see Fig. 12 ).
  • the vane side clearance D6 is set to 0.01 to 0.1 mm, more preferably 0.05 to 0.1 mm (see Fig. 13A ).
  • the adjustment is normally made by changing the inner diameter of the circular hole 35 and that of the flat hole 36.
  • the upper die 30 After completion of driving the upper die 30, as shown in Fig. 2D , the upper die 30 is raised and the knockout pins 17 are raised to push up the forged rotor material 1.
  • the piston rods 47 of the gas cushions 45 return to the respective original positions.
  • first sub-load F1 and the second sub-road F2 are set to be smaller than the main load F, the materials pushed back by the cylindrical pin 40 and the vane portions 13 easily flow. This enables the upper die 30 to move downward to the height where the cylindrical pin 40 and the vane portions 13 break into the circular hole 35 and the flat holes 36, respectively.
  • excess thickness portions 5 and 6 corresponding to the portions of the center hole 3 and the vane grooves 4 are formed on the upper end face (one end face 2a) of the rotor portion 2.
  • the first sub-load F1 and the second sub-load F2 are applied separately. Therefore, the excess thickness portion 5 above the center hole 3 and the excess thickness portion 6 above the vane groove 4 are formed separately.
  • the respective planner shapes of the excess thickness portions become corresponding cross-sectional shapes of the cylindrical pin 40 and the flat plates 41.
  • the back-pressures by the first and second sub-loads F1 and F2 are applied at the time of the forge processing, which can assuredly prevent such drawbacks that the excess thickness portions 5 and 6 are unintentionally ripped apart or torn off from the rotor portion 2.
  • the excess thickness portions 5 and 6 structured as mentioned below can be integrally formed with the rotor material 1.
  • the rotor material 1 is constituted by the rotor portion 2 and the excess thickness portions 5 and 6, and the rotor portion 2 does not include the excess thickness portions 5 and 6.
  • the formed excess thickness portions 5 and 6 are, as shown in Figs. 10 and 11 , provided so that they protrude from one end face 2a of the rotor portion 2 toward the one end side.
  • each tip end face of the center pin 16 and the vane portions 13 coincides with or distances from each opening face of the circular hole 35 and the flat hole 36. Therefore, the one end faces 3a and 4a of the center hole 3 and the vane groove 4 of the rotor material 1 have not reached the inside of the excess thickness portion 5 and 6, and each one end face 3a and 4a is located inner than the one end face 2a of the rotor portion 2.
  • each end face difference (breaking length D3, D4) between one end face 2a of the rotor portion 2 of the rotor material 1 and one end face 3a and 4a of the center hole 3 and the vane groove 4 is also set to the same value.
  • center hole side clearance D5 and the vane groove side clearance D6 are set to 0.01 to 0.1 mm, preferably 0. 05 to 0.1 mm, respectively, and therefore the radius difference D5 andD6 between the outer periphery of the excess thickness portion 5 and 6 of the rotor material 1 and the inner periphery of the center hole 3 and the vane groove 4 is also set to the same value.
  • the radius difference D61 at the rotor portion outer peripheral side end portion and the radius difference D62 at the rotor portion inner peripheral side end portion are formed to be thicker than the radius difference D60 at the intermediate main portion.
  • the curvature radius r3 between the inner periphery of the center hole 3 of the rotor material 1 and one end face 2a of the center hole 3 is set to 0.2 to 1 mm.
  • the curvature radius r4 between the inner periphery of the vane groove 4 and one end face 4a thereof is also set to 0.2 to 1 mm.
  • the height B1 of the inner burr can be set to 1 mm or less. In cases where the height B1 of the inner burr exceeds 1 mm, the breaking position becomes unstable, resulting in difficult accuracy control of the inner side dimension of the center hole 3 and that of the vane groove 4.
  • the curvature radius r3a (r4a) between the excess thickness portion 5 (6) of the rotor material 1 and one end fade 2a of the rotor material 1 is set to be equal to or less than the inner periphery side curvature radius r3 (r4) of the excess thickness portion 5 (6).
  • the protruded burr height B2 can be set to 1 mm or less. Further, Lhe breaking position can also be stabilized, resulting in smaller variation of the protruded burr height B2, which makes it easy to control the cut portion control at the post-processing and therefore makes it easy to control the dimensional accuracy of the center hole 3 and the vane groove 4. In cases where the height B2 of the inner burr exceeds 1 mm, the breaking position becomes unstable, resulting in difficult accuracy control of the inner side dimension of the center hole 3 and that of the vane groove 4.
  • the die used in the present invention is a die for forming a rotor material having the aforementioned shape in which the curvature radius r3a is formed at the circular hole 35 of the upper die, an inversion shape of the curvature radius r4a is formed at the flat hole 36, an inversion shape of the curvature radius r3 is formed at the center pin 16 of the lower die, and an inversion shape of the curvature radius r4 is formed at the vane portion 13 .
  • the main load F, the first sub-load F1, and the second sub-load F2 are appropriately set depending on the shape, the dimension of each portion, the material composition, processing temperature, etc., of the rotor material 1.
  • a first sub-load F1 and second sub-load F2: 29 to 89 MPa can be exemplified.
  • the first sub-load F1 and the second sub-load F2 are set too small, there is a possibility that the excess thickness portion 5 and 6 will be torn off. To the contrary, if they are set too large, the effects of reducing the force to be applied to the center pin 16 and the force to be applied to the vane portion 13 reduce.
  • it is preferably set the first sub-load F1 and the second sub-load F2 so as to fall within the range of 29 to 89 MPa, more preferably 39 to 49 MPa, respectively.
  • a spring-type sub-load applying means such as a gas cushion 45
  • the first sub-load F1 and the second sub-load F2 increase as the upper die 30 goes downward.
  • the load within the aforementioned preferable range is an initial load.
  • a sub-load applying means for applying the first sub-load F1 and the second sub-load F2 is not specifically limited, but it is preferable to useameans which can apply a load in accordance with the raising and lowering operation of the upper die 30. From this aspect, a spring-type means such as a gas cushion is preferably used. As other sub-load applying means, a mechanical type spring, a hydraulic mechanism, and a shock absorber can be exemplified.
  • Fig. 14 is a cross-sectional view schematically showing a punching device (die set) as an excess thickness portion removing device used in the punching step (excess thickness portion removing step) .
  • this punching device is equipped with a lower die 8 and an upper die 9, and configured to punch out the excess thickness portions 5 and 6 from the rotor material 1 by punching processing.
  • the lower die 8 is equipped with a lower plate 81 and a lower die body 85 disposed on the upper surface of the lower plate 81.
  • the lower plate 81 has, at its center portion, an excess thickness portion discharging hole 82 penetrated in the up-and-down direction. Further, at both side portions of the lower plate 81, guide bars 83 are formed so as to extend in the vertical direction.
  • the lower die body 85 is fixed to the upper surface of the lower plate 81 so as to close the excess thickness discharging hole 82.
  • the lower die body 85 is provided with a work mounting portion 86 corresponding to the excess thickness discharging hole 82 of the lower plate 81.
  • the work mounting portion 86 is configured such that the rotor material 1 can be mounted with its one end face 2a facing downward.
  • a center hole side punch-out hole 87 is formed corresponding to the center hole side excess thickness portion 5 and a vane groove side punch-out hole 88 is formed corresponding to the vane groove side excess thickness portion 6.
  • This center hole side punch-out hole 87 is formed to have an inner peripheral shape corresponding to the outer peripheral shape of the center hole side excess thickness portion 5, so that the center hole side excess thickness portion 5 can be fitted therein in a closely fitted manner.
  • the vane groove side punch-out holes 88 are formed to have an inner peripheral shape corresponding to the outer peripheral shape of the vane groove side excess thickness portion 6, so that the vane groove excess thickness portion 6 can be fitted therein in a closely fitted manner. Further, each punch-out hole 87 and 88 is penetrated in the up-and-down direction, and the lower end side thereof is communicated with the excess thickness discharging hole 82.
  • the rotor material 1 can be set on the work mounting portion 86 in a positioned state by fitting the excess thickness portions 5 and 6 of the rotor material 1 in the punch-out holes 87 and 88 in a closely fitted manner, respectively, and disposing one end face 2a of the rotor portion 2 on the work mounting portion 86.
  • the upper die 9 is equipped with an upper plate 91 and an upper die body 95 disposed on the lower surface of the upper plate 91.
  • the upper plate 91 is configured to move upward and downward in the vertical direction by being driven upward and downward by a lifting and lowering driving means such as a hydraulic cylinder (not illustrated).
  • a lifting and lowering driving means such as a hydraulic cylinder (not illustrated).
  • guide holes 93 are formed corresponding to the guide bars 83 of the lower plate 81. As will be described later, when the upper plate 91 is moved downward, the guide bars 83 are inserted in the guide holes 93 to guide the descending movement of the upper plate 91.
  • the upper die body 95 is fixed to the lower surface of the upper plate 91 so as to face the lower die body 85.
  • a center hole side blanking punch 97 and vane groove side blanking punches 98 are attached to the upper die body 95 in a downwardly protruded manner, corresponding to the center hole side punch-out hole 87 and the vane groove side punch-out holes 88, respectively, i.e., corresponding to the center hole 3 and vane grooves 4 of the rotor material 1 set to the lower die 85.
  • the blanking punches 97 and 98 are structured as an impactor.
  • the rotor material 1 is mounted on the work mounting portion 86 of the lower die 8 of the punching device with the one end face 2a facing downward in a state in which each excess thickness portion 5 and 6 is fitted in the corresponding punch-out hole 87 and 88.
  • the center hole side blanking punch 97 and vane groove side blanking punch 98 of the upper die body 85 are arranged so as to face the other end side openings of the center hole 3 and vane grooves 4 of the rotor material 1.
  • the excess thickness portions 5 and 6 can be removed accurately at predetermined positions with a high degree of accuracy.
  • the excess thickness portion (5) (6) is formed to have a short breaking length (D3) (D4), the breaking area at the time of removing the excess thickness portion can be reduced, enabling easy removal of the excess thickness portion with a low load, which in turn can improve the production efficiency.
  • the processing can be performed with a low load, and therefore the abrasion of the punches 97 and 98 themselves can also be reduced, which can improve the durability of the punches 97 and 98. This in turn can further improve the durability of the punching device.
  • the fracture remain also becomes small.
  • the adverse effects by the fracture remain can be avoided. Therefore, for example, it is not required to perform finish processing for finishing the fracture remain at the post-step, resulting in reduced steps, which can further improve the productivity and reduce the production cost.
  • one ends 3a and 4a of the center hole 3 and the vane grooves 4 are positioned inner than one end face 2a of the rotor portion 2, and therefore the fraction remains after the removals of the excess thickness portions are positioned at the inner peripheries of the center hole 3 and vane groove 4. Also in this regard, adverse effects by the fracture remains can be prevented, making the post-finishing processing for the fracture remains unnecessary, which can further improve the productivity.
  • the radius difference D61 at the rotor portion outer peripheral side end portion and the radius difference D62 at the rotor portion inner peripheral side end portion are formed to be thicker than the radius difference D60 at the intermediate main portion. Therefore, after the forge processing but before the punching processing, improper dropping of the excess thickness portion 6 can be prevented. For example, such a problem that the excess thickness portion 6 remains in the forge processing die can be prevented assuredly, which can maintain the high productivity.
  • both end portions of the excess thickness portion 6 are formed to have large radius differences D61 and D62, improper breakage of these portions can be prevented assuredly, which can more assuredly prevent improper dropping of the excess thickness portion 6.
  • both end portions of the excess thickness portion 6 often become breakage starting points at the time of dropping. Therefore, by forming both end portions to be thick, it becomes hard to cause the breakage, which prevents improper dropping more assuredly.
  • the radius difference (clearanceD6) of the outer periphery of the excess thickness portion 6 at the side of the vane groove 4 is partially increased.
  • the present invention is not limited to the above, and allows partially increasing the radius difference D5 of the outer periphery of the excess thickness portion 5 at the side of the center hole 3.
  • the excess thickness portion 5 and 6 cannot be removed with a high degree of accuracy at the punching processing, which may cause adverse effects by the fracture remains. To the contrary, if the radius difference D5 and D6 is too small, the excess thickness portion 5 and 6 may improperly drop before the punching processing.
  • the breaking length D3 (or D4) is minus, i.e., one end face 3a (or 4a) of the center hole 3 (or the vane groove 4) is positioned outer than one end face 2a of the rotor portion 2 and inside the excess thickness portion 5 (or 6), even if the thickness portion 5 (or 6) is removed by punching processing, a part of the peripheral wall of the excess thickness portion 5 (or 6) remains and the remainedportion (fracture remain) will be positioned so as to protrude outward of the rotor R. For this reason, it is required to remove the protruded fracture remain at the post-processing, increasing the number of steps, which may cause deterioration of the productivity, and therefore it is not preferable.
  • the punching processing is performed as cold working since it is not especially required to heat the rotor material 1.
  • the punching processing can be performed as hot processing by heating the rotor material 1 immediately before performing the punching processing.
  • the excess thickness portions 5 and 6 are punched out by the punches 97 and 98 inserted from the other end side of the center hole 3 and vane grooves 4.
  • the removal processing of the excess thickness portions is not limited to the blanking processing by a punch.
  • it can be configured such that an impact member such as a hammer is hit against the excess thickness portion from the outside of the rotor material 1, for example, in a direction perpendicular to the axis direction to remove the excess thickness portion by the impacts, or the basal end (base end portion) of the excess thickness portions 5 and 6 is cut (sheared) along the plane perpendicular to the axial direction using an impact member such as a cutting tool.
  • an impact member such as a hammer is hit against the excess thickness portion from the outside of the rotor material 1, for example, in a direction perpendicular to the axis direction to remove the excess thickness portion by the impacts, or the basal end (base end portion) of the excess thickness portions 5 and 6 is cut (sheared) along the plane perpendicular to the axial direction using an impact member such as a cutting tool.
  • a rotor material 1 shown in Fig. 3 was forged using a forging dies 10 and 30 shown in Figs. 1 and 2 .
  • the rotor material 1 was a material for producing an aluminum alloy rotor R shown in Fig. 4 .
  • the rotor R had an outer diameter: 52 mm, a height: 50 mm, a diameter of the center hole 3: 10 mm, the number of vane grooves 4: 5, a groove width: 3 mm, a groove depth: 15 mm, an offset dimension U: 10 mm.
  • the material alloy was A390 aluminum alloy.
  • the clearance D5 between the center pin 16 of the lower die 10 and the circular hole 35 of the upper die 35 was set to 0.1 mm
  • the clearance D6 between the vane portion 13 of the lower die 10 and the flat hole 36 of the upper die 30 was also set to 0.1 mm in the same manner as mentioned above.
  • the distance (breaking length D3) between the center pin 16 of the lower die 10 and the opening face of the circular hole 35 of the upper die 30 was set to 1.5 mm
  • the distance (breaking length D4) between the vane portion 13 of the lower die 10 and the opening face of the flat hole 36 of the upper die 30 was also set to 1.5 mm in the same manner as mentioned above.
  • a forging raw material W heated to 400 °C was mounted in the lower die 10 and formed into a rotor material 1 by applying the following forming loads .
  • the first sub-load F1 and the second sub-load F2 increased.
  • Each of the final loads was 1.5 times of each initial load.
  • the material yielding percentage of the rotor R with respect to the forging raw material W was 82.9 %.
  • D3, D4 D5, D6 Fracture during forging Fracture position Fracture area Example 1 1.5 mm 0.1 mm Nil Inner periphery Small Example 2 0 0.1 mm Nil Inner periphery Small Comparative Example 1 -2 mm 0.1 mm Yes Outer periphery Small Comparative Example 2 -2 mm 2 mm Nil Outer periphery Large
  • a rotor R was produced in the same manner as in the aforementioned Example 1 except that the breaking lengths D3 and D4 of the excess thickness portions 5 and 6 were set to "0 (zero)," respectively.
  • a rotor R was produced in the same manner as in the aforementioned Example except that the breaking lengths D3 and D4 of the excess thickness portions 5 and 6 were set to "-2 mm,” respectively.
  • a rotor R was produced in the same manner as in the aforementioned Example except that the breaking lengths D3 and D4 of the excess thickness portions 5 and 6 were set to "-2 mm,” respectively, and that the clearances D5 and D6 of the outer periphery of the excess thickness portions 5 and 6 were set to "2 mm,” respectively.
  • Rotors R were produced in the same conditions as in the aforementioned Example 1 except that the curvature radiuses r3 and r3a of the center hole 3 were adjusted to the values as shown in Table 2. Then, the inner burrs, and protruded burrs (see Fig. 13B ) were evaluated. The results are also shown in Table 2.
  • the method for forging a rotor material according to the present invention can be applied in producing a rotor, for example for a compressor.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Forging (AREA)
  • Rotary Pumps (AREA)

Claims (14)

  1. Ensemble matrice comprenant une matrice inférieure (10) et une matrice supérieure (30), destiné à appliquer des charges de formage, et configuré de façon à forger un matériau de rotor columnaire en général cylindrique (1) qui présente un trou central (3) et une rainure d'ailette (4) qui s'étend parallèle à une ligne axiale, et qui est formée dans une partie périphérique extérieure ;
    dans lequel la matrice inférieure (10) présente une partie ailette de formage de rainure (13) qui fait saillie dans un trou de formage (12), et une broche centrale de formage de trou central (16) destinée à être agencée au centre du trou de formage (12) ;
    caractérisé en ce que :
    la matrice supérieure (30) présente un corps de matrice supérieure (31) destiné à appliquer une charge principale (F) à des parties situées sur une extrémité supérieure d'une matière première de pièce de forge (W) qui ne correspond ni à la broche centrale (16) ni à la partie ailette (13) de la matrice inférieure (10), une broche de contre-pression (40) adaptée dans un trou correspondant de la broche centrale (35), formé dans le corps de matrice supérieure (31) d'une façon à pouvoir s'avancer et se rétracter, la broche de contre-pression (40) étant configurée de façon à appliquer une première charge secondaire (F1) sur une partie située sur une extrémité supérieure d'une matière première de pièce de forge (W) qui correspond à la broche centrale (16), et une plaque de contre-pression (41) adaptée dans un trou correspondant de la partie ailette (36), formé dans le corps de matrice supérieure (31) d'une façon à pouvoir s'avancer et se rétracter, la plaque de contre-pression (41) étant configurée de façon à appliquer une seconde charge secondaire (F2) sur une partie située sur une extrémité supérieure d'une matière première de pièce de forge (W) correspondant de la partie ailette (13), dans lequel la charge principale (F), la première charge secondaire (F1) et la seconde charge secondaire (F2) peuvent être déterminées de manière indépendante ; et
    dans lequel une face d'extrémité supérieure de la partie ailette (13) est agencée de façon à coïncider avec une face d'extrémité inférieure du trou correspondant de la partie ailette (36), ou à se situer à une distance de celle-ci, au moment du montage de la matrice.
  2. Ensemble matrice destiné à former le matériau de rotor (1) selon la revendication 1, dans lequel, lorsque la distance entre la face d'extrémité supérieure de la partie ailette (13) et la face d'extrémité inférieure du trou correspondant de la partie ailette (36) au moment du montage de la matrice, est définie en tant que distance de face d'extrémité latérale de rainure d'ailette (D4), la distance de face d'extrémité latérale de rainure d'ailette (D4) est fixée à une valeur comprise entre 0 mm et 2 mm.
  3. Ensemble matrice destiné à former le matériau de rotor (1) selon la revendication 1 ou la revendication 2, dans lequel, lorsque la distance entre une périphérie extérieure de la partie ailette (13) et une périphérie intérieure du trou correspondant de la partie ailette (36), est définie en tant que jeu latéral de rainure d'ailette (D6), le jeu latéral de rainure d'ailette (D6) est fixé à une valeur comprise entre 0,01 mm et 0,1 mm.
  4. Ensemble matrice destiné à former le matériau de rotor (1) selon la revendication 3, dans lequel, dans le jeu latéral de rainure d'ailette, l'un au moins d'un jeu de partie d'extrémité latérale périphérique intérieure, et d'un jeu de partie d'extrémité latérale périphérique extérieure, est fixé de façon à être plus grand qu'un jeu de partie intermédiaire.
  5. Ensemble matrice destiné à former le matériau de rotor (1) selon l'une quelconque des revendications 1 à 4, dans lequel une face d'extrémité supérieure de la broche centrale (16), est agencée de façon à coïncider avec une face d'extrémité inférieure du trou correspondant de la broche centrale (35), ou à se situer à une distance de celle-ci, au moment du montage de la matrice.
  6. Ensemble matrice destiné à former le matériau de rotor (1) selon la revendication 5, dans lequel, lorsque la distance entre la face d'extrémité supérieure de la broche centrale (16) et la face d'extrémité inférieure du trou correspondant de la broche centrale (35) au moment du montage de la matrice, est définie en tant que distance de face d'extrémité latérale de trou central (D3), la distance de face d'extrémité latérale de trou central (D3) est fixée à une valeur comprise entre 0 mm et 2 mm.
  7. Ensemble matrice destiné à former le matériau de rotor (1) selon la revendication 5 ou la revendication 6, dans lequel, lorsque la distance entre une périphérie extérieure de la broche centrale (16) et une périphérie intérieure du trou correspondant de la broche centrale (35), est définie en tant que jeu latéral de trou central (D5), le jeu latéral de trou central (D5) est fixé à une valeur comprise entre 0,01 mm et 0,1 mm.
  8. Ensemble matrice destiné à former le matériau de rotor (1) selon l'une quelconque des revendications 1 à 7, comprenant en outre des moyens d'application d'une charge secondaire disposés au-dessus de la broche de contre-pression (40), destinés à appliquer une première charge secondaire sur la broche de contre-pression (40), et des moyens d'application d'une charge secondaire disposés au-dessus de la plaque de contre-pression (41) destinés à appliquer une seconde charge secondaire sur la plaque de contre-pression (41).
  9. Ensemble matrice destiné à former le matériau de rotor (1) selon la revendication 8, dans lequel les moyens d'application d'une charge secondaire sont un coussin de gaz (45).
  10. Procédé destiné à forger un matériau de rotor columnaire en général cylindrique (1) qui présente un trou central (3) et une rainure d'ailette (4) qui s'étend parallèle à une ligne axiale, et qui est formé dans une partie périphérique extérieure, comprenant les étapes consistant à :
    préparer une matrice inférieure (10) qui présente une partie ailette de formage de rainure (13) qui fait saillie dans un trou de formage (12), et une broche centrale de formage de trou central (16) destinée à être agencée au centre du trou de formage (12) ; et
    préparer une matrice supérieure (30) ;
    caractérisé par une étape consistant à :
    préparer une telle matrice supérieure (30) qui comprend un corps de matrice supérieure (31) destiné à appliquer une charge principale (F) à des parties sur une extrémité supérieure d'une matière première de pièce de forge (W) qui ne correspond ni à la broche centrale (16) ni à la partie ailette (13) de la matrice inférieure (10), une broche de contre-pression (40) adaptée dans un trou correspondant de la broche centrale (35), formé dans le corps de matrice supérieure (31) d'une façon à pouvoir s'avancer et se rétracter, la broche de contre-pression (40) étant configurée de façon à appliquer une première charge secondaire (F1) sur une partie située sur une extrémité supérieure d'une matière première de pièce de forge (W) qui correspond à la broche centrale (16), et une plaque de contre-pression (41) adaptée dans un trou correspondant de la partie ailette (36), formé dans le corps de matrice supérieure (31) d'une façon à pouvoir s'avancer et se rétracter, la plaque de contre-pression (41) étant configurée de façon à appliquer une seconde charge secondaire (F2) sur une partie située sur une extrémité supérieure d'une matière première de pièce de forge (W) correspondant de la partie ailette (13) ;
    dans lequel la charge principale (F), la première charge secondaire (F1) et la seconde charge secondaire (F2) peuvent être déterminées de manière indépendante ; et
    dans lequel une face d'extrémité supérieure de la partie ailette (13) est agencée de façon à coïncider avec une face d'extrémité inférieure du trou correspondant de la partie ailette (36), ou à se situer à une distance de celle-ci, au moment du montage de la matrice.
  11. Procédé destiné à forger le matériau de rotor (1) selon la revendication 10, dans lequel une face d'extrémité supérieure de la broche centrale (16), est agencée de façon à coïncider avec une face d'extrémité inférieure du trou correspondant de la broche centrale (35), ou à se situer à une distance de celle-ci, au moment du montage de la matrice.
  12. Procédé destiné à forger le matériau de rotor (1) selon la revendication 10 ou la revendication 11, dans lequel la première charge secondaire (F1) et la seconde charge secondaire (F2) sont fixées à une valeur comprise entre 29 MPa et 89 MPa, respectivement.
  13. Procédé destiné à forger le matériau de rotor (1) selon l'une quelconque des revendications 10 à 12, dans lequel la première charge secondaire (F1) est réduite lorsque la section en coupe transversale de la broche centrale (16) augmente.
  14. Procédé destiné à forger le matériau de rotor (1) selon l'une quelconque des revendications 10 à 13, dans lequel le matériau de rotor (1) est constitué d'aluminium ou d'un alliage d'aluminium.
EP09770179.1A 2008-06-24 2009-06-24 Empreinte et procédé de forgeage d un matériau pour rotor Not-in-force EP2306025B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2008164327 2008-06-24
JP2009044372 2009-02-26
PCT/JP2009/061467 WO2009157469A1 (fr) 2008-06-24 2009-06-24 Empreinte et procédé de forgeage d’un matériau pour rotor

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EP2306025A1 EP2306025A1 (fr) 2011-04-06
EP2306025A4 EP2306025A4 (fr) 2012-11-21
EP2306025B1 true EP2306025B1 (fr) 2018-08-08

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EP (1) EP2306025B1 (fr)
JP (1) JP5468541B2 (fr)
KR (1) KR101627878B1 (fr)
CN (1) CN102076964B (fr)
MY (1) MY153554A (fr)
PT (1) PT2306025T (fr)
WO (1) WO2009157469A1 (fr)

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MY154651A (en) * 2008-06-24 2015-07-15 Showa Denko Kk Method for producing rotor
KR101224401B1 (ko) * 2011-12-01 2013-01-21 한국기계연구원 금형 형상 변화를 이용한 알루미늄 또는 마그네슘 합금 스크롤 로터의 열간단조 성형방법
CN102728760B (zh) * 2012-07-03 2014-08-13 北京有色金属研究总院 铝合金转子成形模具及方法
KR20150145821A (ko) 2014-06-19 2015-12-31 희성정밀 주식회사 로터 성형용 금형 및 그 금형을 이용한 로터 성형방법
KR101678459B1 (ko) 2015-02-17 2016-11-23 희성정밀 주식회사 센터홀과 베인홀이 형성된 압축기용 로터 성형 장치 및 성형 방법
DE102015206684B4 (de) * 2015-04-14 2024-03-14 Hanon Systems Efp Deutschland Gmbh Pumpenvorrichtung
KR101692937B1 (ko) * 2015-05-22 2017-01-04 주식회사 성원정밀 로터 다이캐스팅용 몰드
CN106001341A (zh) * 2016-06-17 2016-10-12 宾科汽车紧固件（昆山）有限公司 一种转子的冷锻工艺以及一种反挤孔模具
KR20160084828A (ko) 2016-07-01 2016-07-14 희성정밀 주식회사 로터 성형용 금형 및 그 금형을 이용한 로터 성형방법
CN106180535B (zh) * 2016-07-08 2018-07-06 杭州汽轮铸锻有限公司 一种提高转子锻件质量的自由锻造方法
KR20160101883A (ko) 2016-08-01 2016-08-26 희성정밀 주식회사 센터홀과 베인홀이 형성된 압축기용 로터 성형 장치 및 성형 방법

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EP2306025A4 (fr) 2012-11-21
JPWO2009157469A1 (ja) 2011-12-15
KR20110027709A (ko) 2011-03-16
JP5468541B2 (ja) 2014-04-09
CN102076964B (zh) 2014-02-26
KR101627878B1 (ko) 2016-06-07
EP2306025A1 (fr) 2011-04-06
WO2009157469A1 (fr) 2009-12-30
PT2306025T (pt) 2018-11-15
MY153554A (en) 2015-02-27
CN102076964A (zh) 2011-05-25

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