JP2006192448A - Method for manufacturing flat ring member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a flat ring member which is advantageous to the cost. <P>SOLUTION: Belt-shaped steel W1 which is formed having a taper-like unequal thickness so that one side is thick and the other side is thin between a receiving member 21 having a concave curved surface 23 and a hammer 22 which is arranged oppositely to the concave curved surface 23 is continuously fed so that the thick side is along the concave curved surface 23 and coiling formation is performed while flattening the belt-like steel W1 is flattened into equal thickness by continuously striking the thin thickness side of the belt-like steel W1 with the hammer 22. The flat ring member having an end shape is cut out by cutting the coiled belt-like steel W1 into every approximately one roll. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a flat ring member obtained in the process of manufacturing a flat ring member such as a drive plate or a ring gear of an automobile.

  Flat ring members such as drive plates and ring gears for automobiles can be rolled, for example, by punching steel plates into a ring shape with a press, or by rolling a strip of steel material for approximately one flat ring member so that the wide surfaces are on the same plane. It is manufactured by molding, and then cutting the overlapping parts and welding the cut ends.

  The method of punching a steel sheet into a ring shape by a press generates many offcuts, which is disadvantageous in terms of cost because of many material losses. Also, the method of roll forming approximately one strip of steel is also difficult because it is difficult to roll form both ends of the strip steel to a desired curvature, and it is necessary to cut both ends. Material is generated.

  In view of such circumstances, conventionally, a step of bending a steel wire with a circular cross section into a ring shape, a step of cutting the steel wire material for each winding unit length, and welding both ends of the ring-shaped steel wire material A step of obtaining a ring wire having a circular cross section, a step of pressing the ring wire in the winding axis direction to obtain a ring-shaped plate material having a predetermined thickness, and an inner diameter portion and / or an outer diameter of the ring-shaped plate material. And a step of obtaining a ring-shaped plate member having a predetermined shape (hereinafter referred to as a flat ring member) by punching a portion (see, for example, Patent Document 1).

Japanese Patent Laid-Open No. 2000-042647

  In the method described in Patent Document 1, a steel wire having a circular cross section is curved in a ring shape and cut for each winding unit length, so that the cut portion of the steel wire is roll-formed to a desired curvature. In this method, in order to obtain one ring-shaped material, only both ends of the steel wire become end material, and no end material is generated at the cut portion of the steel wire. However, in order to obtain a flat ring member from a ring material, a pressing process and a punching process are further required, and an end material is generated in the punching process.

  The present invention has been devised in view of such circumstances, and an object thereof is to provide a method of manufacturing a flat ring member that is advantageous in terms of cost by reducing the number of man-hours and end materials.

  In order to achieve the above object, a method for manufacturing a flat ring member according to the present invention is such that one side is thick and the other side is thin between a receiving member having a concave curved surface and a hammer arranged opposite to the concave curved surface. The strip-shaped steel material formed in such a taper-like unequal thickness is continuously supplied so that the thickness side is along the concave curved surface, and the thin-wall side of the strip-shaped steel material is continuously hit with the hammer to make the strip-shaped steel material the same thickness. It includes a step of coiling while flattening, and a step of cutting the coiled strip-shaped steel material approximately every turn to cut an end-shaped flat ring member.

  In the concave curved surface of the receiving member, the cross-sectional contour in the supply direction of the strip-shaped steel material is a concave curve, and the cross-sectional contour in the direction orthogonal to the supply direction of the strip-shaped steel material is straight. When a strip-shaped steel material having a tapered cross section is continuously supplied between the receiving member and the hammer so that the thick side of the steel strip is along the concave curved surface of the receiving member, and the thin side of the strip-shaped steel material is continuously hit with a hammer, The thick side is thinned by spreading, while the thin side is thickened by compression. Thus, the strip-shaped steel material having a tapered cross section is coiled while being flattened to an equal thickness. Moreover, the cross-sectional contour in the thickness direction is formed or maintained in a straight shape by pressing the thick side of the strip steel material against the concave curved surface of the receiving member and hitting the thin side with a hammer. Therefore, the strip-shaped steel material is formed from a tapered cross section into a substantially rectangular section or a substantially square section by the coiling. When the coiled steel strip is cut almost every turn, an end-shaped flat ring member is obtained. Since the end of the end-like flat ring member is formed to have a desired curvature by coiling, no end material is generated from the end-like flat ring member. Moreover, since the flat flat ring member with an end is already flattened by coiling molding, the flat ring member can be obtained by joining both ends thereof. Since this flat ring member is formed so that the thickness direction of the outer peripheral portion and the inner peripheral portion is straight when coiling the strip-shaped steel material, punching of the outer peripheral portion and / or the inner peripheral portion is unnecessary.

  As described above, the present invention eliminates the need for pressing or punching by flattening the strip-shaped steel material having a tapered cross-section, and eliminates the need for punching, and the end material generated at the time of punching. Will not occur. Therefore, the manufacturing cost of the flat ring member can be reduced by reducing the number of man-hours and the end material.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 shows a strip-shaped steel material W1 having a tapered cross section. This strip-shaped steel material W1 is a long wire having a trapezoidal cross section in which one side W1a in the width direction is thick and the opposite side W1b is thin. The strip-shaped steel material W1 is formed into a roll shape with the width direction being substantially the same as the axial direction of the roll shaft 1 as shown in the figure for the manufacturing reason of rolling and forming a wire having a circular cross section and the transportation reason. Provided in a wound state. Hereinafter, one side in the width direction of the strip-shaped steel material W1 is referred to as a thick side W1a, and the opposite side is referred to as a thin side W1b.

  FIG. 2 shows an example of a flat ring member manufacturing apparatus to which the method of the present invention is applied. In the figure, reference numeral 10 is a roller leveler, reference numeral 20 is a bending jig for the strip steel W1, and reference numeral 30 is a cutter.

  The roller leveler 10 is used in a process of pulling out the strip-shaped steel material W1 wound in a roll shape and correcting the bending strain. As shown in FIG. 2, the roller leveler 10 includes a plurality of rollers 11 and 12 arranged in a staggered manner. The distance between the roller 11 disposed on the upper surface side of the strip-shaped steel W1 and the roller 12 disposed on the lower surface side increases from the start end side (upper right end side in the drawing) of the roller leveler 10 toward the end side (upper left end side in the drawing). It is gradually spreading.

  When the strip-shaped steel material W1 wound in a roll shape is pulled out, the strip-shaped steel material W1 is bent due to residual strain. In the drawing, since the tension is applied to the drawn strip steel material W1, it is not bent, but when the tension is released, bending occurs due to residual strain. When the strip-shaped steel material W1 is continuously supplied between the rollers 11 and 12 constituting the roller leveler 10, the strip-shaped steel material W1 has a large undulation at the start end side of the roller leveler 10, and the undulation width gradually decreases toward the end side. It is discharged in a state of extending straight from, and the bending strain is corrected.

  The bending jig 20 includes a receiving member 21 and a hammer 22 as main components, and is used in a process of bending the strip-shaped steel material W1 in the width direction to form a spiral shape. As shown in FIG. 3, the receiving member 21 has a concave curved surface 23 that guides the thick side W <b> 1 a of the strip-shaped steel material W <b> 1 supplied from the roller leveler 10. In the concave curved surface 23, the cross-sectional contour which is a cross section in the supply direction of the strip-shaped steel material W1 has a concave curved shape, and the vertical sectional contour has a straight shape. In this embodiment, the concave curved surface 23 is a partial cylindrical surface. The hammer 22 strikes the thin side W1b of the strip-shaped steel material W1 fed from the roller leveler 10 and deforms the strip-shaped steel material W1 so that the thick-side W1a contacts the concave curved surface 23. In this embodiment, the hammer 22 is constituted by a cylindrical eccentric roller that can continuously rotate around the eccentric shaft at a position facing the concave curved surface 23 of the receiving member 21. The hammer 22 continuously rotates in the same direction as the flow direction of the strip steel material W1 by a motor (not shown), and the hammering portion 24 collides with the thin side W1b of the strip steel material W1 for each rotation. The steel material W1 is bent in the width direction.

  The strip steel W1 is coiled by being continuously supplied to the bending jig 20 while rotating the hammer 22. At the time of coiling, the thick side W1a of the strip-shaped steel material W1 extends in the circumferential direction and becomes thin, and the thin side W1b becomes compressed and thick in the circumferential direction. Further, the thick side W1a of the strip-shaped steel material W1 is pressed against the concave curved surface 23 of the receiving member 21, and the thin side W1b is hit by the cylindrical surface of the hammer 22, so that the cross-sectional profile in the thickness direction is maintained in a straight shape. . By this coiling forming, as shown in FIG. 4, the strip-shaped steel material W1 is flattened from a taper-shaped cross section to a substantially rectangular cross-section with a reduced thickness difference between the thick side W1a and the thin side W1b.

  The cutter 30 is used in a step of cutting the strip-shaped steel material W1 coiled by the bending jig 20 for each turn to cut an end-shaped flat ring member. In this embodiment, the lower surface side of the strip steel material W1 is supported by the pedestal 31, and the cutter 30 is lowered from above the strip steel material W1 to cut the strip steel material W1. The cutter 30 detects at least one rotation number of the plurality of rollers 11 and 12 constituting the roller leveler 10 with the encoder 32, and operates when the rotation number of the roller reaches a predetermined number. Specifically, from the detection result of the encoder 32, whether or not the feed length of the strip steel material W1 has reached the length of one turn is determined by a control device (not shown), and at the stage where the length of one turn has been reached. The cutter 30 is operated. In addition, since the cutter 30 should just be arrange | positioned in the downstream position rather than the hammer 22 in the flow path of the strip | belt-shaped steel materials W1, in this embodiment, it is arrange | positioned in the terminal position vicinity of the concave curved surface 23 of the receiving member 21. When the coiled strip-shaped steel material W1 is cut for every turn, an end-shaped flat ring member W2 is obtained as shown in FIG.

  When both end portions of the end-like flat ring member W2 are joined as shown in FIG. 5, an endless flat ring member W3 processed into a drive plate, a ring gear or the like of an automobile is obtained. For example, a flash butt welding apparatus 40 as shown in FIG. 6 is used in the step of joining both end portions of the end-shaped flat ring member W2. The flash butt welding apparatus 40 includes a pair of chucks 41 and 42 disposed to face each other with a gap between both ends of the end-shaped ring member W2, and an end-like shape attached to the pair of chucks 41 and 42. A voltage applying means 43 for applying a voltage to the flat ring member W2 and one chuck 41 (hereinafter referred to as a movable chuck 41) with respect to the other chuck 42 (hereinafter referred to as a fixed chuck 42) placed at a predetermined position. And a driving means 44 for approaching and moving away as a main component.

  While applying a voltage to the end-like flat ring member W2 attached to the pair of chucks 41, 42, the end portions of the end-like flat ring member W2 facing each other are brought into contact with each other and then pulled apart. Flash (arc discharge) occurs between the ends of the flat end ring member W2. In order to maintain the flash, the movable chuck 41 is stroked by the driving means 44, and the ends of the flat ring member W2 having an end shape are moved closer to and away from each other. After the both ends of the end-shaped flat ring member W2 are heated and melted by flash, the ends of the end-shaped flat ring member W2 are brought into pressure contact with each other so that the ends of the end-shaped flat ring member W2 are brought into contact with each other. By joining, a flat ring member W3 as shown in FIG. 5 is obtained.

  According to the said embodiment, when carrying out roll forming of the strip | belt-shaped steel material W1 with a cross-section taper shape, it is flattened by equal thickness, and it is cut for every turn, The end-shaped flat ring member W2 is obtained, and end-shaped Since the flat ring member W3 is obtained by welding the ends of the flat ring member W2, no pressing or punching is required. Further, by eliminating the need for punching, the end material generated at the time of punching is not generated.

  Although one embodiment of the present invention has been described above, the present invention is not limited to the above-described embodiment, and various modifications are possible. For example, the strip-shaped steel material W1, which is a raw material, has a thick side W1a and a thin thickness. The cross-sectional outline of the side W1b in the thickness direction may not be a trapezoidal cross-section with a straight shape. Even if the cross-sectional contours in the thickness direction of the thick side W1a and the thin side W1b are curved, the hammer 22 whose outer diameter surface is a cylindrical surface while keeping the thick side W1a along the concave curved surface 23 such as a partial cylindrical surface. Thus, by hitting the thin side W1b, the cross-sectional contour in the thickness direction is formed into a straight shape.

  Moreover, the structure of the processing apparatus used at each process of the said embodiment can be changed suitably. For example, the receiving member 21 constituting the bending jig 20 may be provided with a horizontal groove (not shown) as a guide path for the strip-shaped steel material W1, and a concave curved surface 23 may be formed at the back of the horizontal groove. The groove depth is shallower than the width dimension of the strip-shaped steel material W1, and the groove width is about the thickness of the thick side W1a of the strip-shaped steel material W1.

  Moreover, in the said embodiment, although the hammer 22 of the bending jig 20 is comprised with the eccentric roller which can be rotated continuously, the hammer 22 strikes the thin side W1b of the strip | belt-shaped steel material W1 by rocking | fluctuating or moving back and forth. It is good also as a structure. When the hammer 22 is configured to swing or move back and forth, the frictional force generated when the strip steel W1 is struck is greater than that of the eccentric roller that continuously rotates in the supply direction of the strip steel W1, and the processing of the strip steel W1 is increased. Accuracy is reduced.

  Moreover, in the said embodiment, although each process for obtaining many endless flat ring members W3 from the strip | belt-shaped steel material W1 provided in the state wound by roll shape is demonstrated, it is extended straightly. When a large number of flat ring members W3 are obtained from the strip-shaped steel material W1 provided in a state of being removed, the step of correcting the bending strain of the strip-shaped steel material W1 by the roller leveler 10 is not necessary.

It is a figure which shows the strip | belt-shaped steel material of the cross-section taper shape wound by roll shape. It is a front view which shows an example of the apparatus used at the process of correcting the bending distortion of a strip-shaped steel material, the process of coiling a strip-shaped steel material, and the process of cutting a strip-shaped steel material. It is a top view which shows the apparatus used at the process of correcting the bending distortion of a strip-shaped steel material, the process of coiling a strip-shaped steel material, and the process of cutting a strip-shaped steel material. It is a figure which shows the cross section of the strip shaped steel material before coiling shaping | molding, and the cross section of the strip shaped steel material after coiling shaping | molding. It is a figure which shows an endless flat ring member and the endless flat ring member obtained by joining the both ends. It is a figure which shows an example of the apparatus used for the process of joining the both ends of a flat ring member with ends.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Roll axis | shaft 10 Roller levelers 11, 12 Roller 20 Bending jig 21 Receiving member 22 Hammer 23 Concave surface 24 Strike part 30 Cutter 31 Base 32 Encoder 40 Flash butt welding apparatus 41 Movable chuck 42 Fixed chuck 43 Voltage application means 44 Drive means W1 Band shape Steel material W1a Thick side W1b Thin side W2 Ended flat ring member W3 Flat ring member

Claims (3)

  Between the receiving member having a concave curved surface and a hammer arranged opposite to the concave curved surface, a strip-shaped steel material formed with a taper unequal thickness so that one side is thick and the opposite side is thin, Continuously feeding along the concave curved surface, continuously striking the thin side of the strip steel material with the hammer and coiling while making the strip steel material flattened to an equal thickness, and almost one roll of the coiled strip steel material A method for producing a flat ring member, including a step of cutting every minute to cut out an end-shaped flat ring member.   The hammer formed of a cylindrical eccentric roller that can rotate about an eccentric shaft at a position facing the concave curved surface is continuously rotated to continuously hit the thin side of the strip-shaped steel material. Manufacturing method of flat ring member.   The method for producing a flat ring member according to claim 1, wherein the strip-shaped steel material is cut at a stage where it is coiled by approximately one turn.