JP2008264821A

JP2008264821A - Method for manufacturing pulley for clutch

Info

Publication number: JP2008264821A
Application number: JP2007110584A
Authority: JP
Inventors: Kazuhiro Kimura; 和弘木村; Hitoshi Nakajima; 仁中島; Masaru Itoi; 優糸井
Original assignee: Asahi Sangyo Co Ltd
Current assignee: Asahi Sangyo Co Ltd
Priority date: 2007-04-19
Filing date: 2007-04-19
Publication date: 2008-11-06

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a pulley for a clutch, by which method, a pulley having a required shape can be easily worked, and a working time can be shortened, and further its manufacturing cost can be reduced. SOLUTION: In the method for manufacturing the pulley for the clutch, the pulley for the clutch is manufactured by working a circular flat steel plate. A cup shape body 10 is composed of an outer cylindrical portion 10A, an inner cylindrical portion 10B, and a bottom portion (a connecting portion) 10C connecting the outer cylindrical portion 10A and the inner cylindrical portion 10B, and is set between metallic dies 30A, 30B having required shapes. The outer cylindrical portion 10A and the inner cylindrical portion 10B are concentric, and have different diameters. A part 33 of the metallic die is gradually or stepwise pushed in toward the bottom portion 10C connecting the outer cylindrical portion 10A and the inner cylindrical portion 10B of the cup shape body 10 so as to thicken a part of the inner cylindrical portion 10B and the bottom portion 10C. COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、平板鋼板をプレス加工と転造成形を併用してクラッチ用プーリを形成するクラッチ用プーリの製造方法に関する。 The present invention relates to a clutch pulley manufacturing method for forming a clutch pulley by using a flat steel plate in combination with pressing and rolling.

従来、クラッチ用プーリとして、例えば外周にＶ溝を多数設けたポリＶプーリが自動車用オルタネータ等の部品の一部などに用いられている。ここで、従来のポリＶプーリの製造方法について、図面を参照しながら具体的に説明する。
このポリＶプーリの製造方法は、図２０において、一対の金型１０１、１０２でクランプされた円板状の鋼板１００の端面１００Ａに、図２１に示すローラダイス１０３を押し当てながら回転させることで、鋼板１００の端面１００Ａから、断面略凹状を呈する円弧状のリム部１００Ｂを形成する。さらに、図２２に示すように、このリム部１００ＢにＶ溝形成用のローラダイス１０４を押し当てながら回転させることで、リム部１００ＢにポリＶ溝１００Ｃを設けたポリＶプーリを形成していた(例えば、特許文献１参照)。 Conventionally, as a pulley for a clutch, for example, a poly V pulley having a large number of V grooves on its outer periphery is used as a part of a part such as an automobile alternator. Here, a conventional method for manufacturing a poly-V pulley will be specifically described with reference to the drawings.
The poly V pulley manufacturing method is shown in FIG. 20 by rotating the roller die 103 shown in FIG. 21 against the end face 100A of the disc-shaped steel plate 100 clamped by the pair of molds 101 and 102. From the end surface 100A of the steel plate 100, an arc-shaped rim portion 100B having a substantially concave cross section is formed. Further, as shown in FIG. 22, a poly V pulley having a poly V groove 100C provided on the rim portion 100B is formed by rotating the rim portion 100B while pressing the roller die 104 for forming the V groove. (For example, refer to Patent Document 1).

また、これ以外のポリＶプーリの製造方法としては、例えば図２４〜図２６に示すものが知られている(例えば、特許文献２参照)。即ち、この方法では、初めに、円板状の鋼板２００から絞り加工によって略椀状に形成した後、底部に孔あけ加工を行うことで、図２４に示す孔あきカップ体２１０を形成する(ここでは上下逆さまの状態を示す)。その後、胴壁２０１の一部を折り曲げるなどの各種加工を施すことで、図２５に示す増肉されたリム部２０２を有する成形体２２０を形成し、最後に図２６に示すリム部２０２にポリＶ溝２０３を形成することで、ポリＶプーリ２３０を形成していた。
特開昭６３−６３５４３号公報(図１〜図４) 特開平９−２９２００７号公報(図１２、１４、１６) As other poly V pulley manufacturing methods, for example, those shown in FIGS. 24 to 26 are known (see, for example, Patent Document 2). That is, in this method, first, a disk-shaped steel plate 200 is formed into a substantially bowl shape by drawing and then drilled at the bottom to form a perforated cup body 210 shown in FIG. Here, the upside down state is shown). Thereafter, by performing various processes such as bending a part of the body wall 201, the molded body 220 having the increased rim portion 202 shown in FIG. 25 is formed, and finally, the rim portion 202 shown in FIG. By forming the V groove 203, the poly V pulley 230 was formed.
Japanese Unexamined Patent Publication No. 63-63543 (FIGS. 1 to 4) JP-A-9-292007 (FIGS. 12, 14, and 16)

ところで、このようなポリＶプーリは、前者のような方法で製造すると、図２３に示すように、厚さがそれほど厚くない板状を呈する鋼板１００の端面１００Ａを、ローラダイス１０３の外周面１０３Ａの押し込み力で押し潰すことにより、円弧状のリム部１００Ｂを形成している。従って、鍛造加工に近い加工作業を行うことにより、板状部分の肉をこれに直交する厚さ方向に強引に移動させることで増肉させてリム部を形成することとなるので、その加工が難しい。 By the way, when such a poly-V pulley is manufactured by the former method, as shown in FIG. 23, the end surface 100A of the steel plate 100 having a plate shape that is not so thick is used as the outer peripheral surface 103A of the roller die 103. The arc-shaped rim portion 100B is formed by crushing with the pushing force. Therefore, by performing a processing operation close to forging, the rim portion is formed by forcibly moving the thickness of the plate-like portion in the thickness direction perpendicular to the thickness, so that the processing is performed. difficult.

本発明の目的は、所望形状のものを容易に加工することができるとともに、加工時間を短縮でき、延いては製造コストも削減することができるクラッチ用プーリの製造方法を提供することにある。 An object of the present invention is to provide a method of manufacturing a clutch pulley that can easily process a desired shape, reduce processing time, and reduce manufacturing cost.

本発明のクラッチ用プーリの製造方法は、金属平板鋼板を加工して径の異なる同心状の円筒部を連結部で連結したカップ体を形成し、このカップ体からクラッチ用プーリを製造するクラッチ用プーリの製造方法であって、前記カップ体を所定形状の金型間にセットして、前記カップ体の前記円筒部に前記金型の一部を徐々に若しくは段階的に押し込んで、前記円筒部若しくは前記連結部に増肉を行うことを特徴とする。これによれば、金型の一部を徐々に若しくは段階的に押し込ませるだけで、所望形状のものを容易に加工することができるとともに、加工時間を短縮でき、延いては製造コストを削減することが可能となる。 The method for manufacturing a clutch pulley according to the present invention includes a cup body in which concentric cylindrical portions having different diameters are formed by processing a metal flat steel plate and connected by a connecting portion, and the clutch pulley is manufactured from the cup body. A method of manufacturing a pulley, wherein the cup body is set between molds having a predetermined shape, and a part of the mold is pushed into the cylindrical part of the cup body gradually or stepwise to form the cylindrical part. Alternatively, the connecting portion is increased in thickness. According to this, it is possible to easily process a desired shape by simply pushing a part of the mold gradually or stepwise, reduce the processing time, and thus reduce the manufacturing cost. It becomes possible.

本発明のクラッチ用プーリの製造方法は、金属平板鋼板を加工して径の異なる同心状の円筒部を連結部で連結したカップ体を形成し、このカップ体からクラッチ用プーリを製造するクラッチ用プーリの製造方法であって、前記カップ体を所定形状の金型間にセットして、中央部に向けて窪んだ略円錐形状の凹部を有するとともに前記凹部の中央部に逃げ穴を有し、首振り運動を行なうことにより前記凹部表面を前記カップ体の連結部に部分的に、若しくは段階的に当接する、前記金型の一部を構成するこま部材により、前記カップ体の前記連結部を徐々に、かつ、部分的に押圧させるとともに、前記連結部の部分的な押圧部位を周方向に順次ずらして、前記カップ体の円筒部若しくは連結部に増肉を行うことを特徴とする。これによれば、こま部材などを用いて、所望形状のものを容易に加工することができるとともに、加工時間を短縮でき、延いては製造コストも削減することが可能となる。 The method for manufacturing a clutch pulley according to the present invention includes a cup body in which concentric cylindrical portions having different diameters are formed by processing a metal flat steel plate and connected by a connecting portion, and the clutch pulley is manufactured from the cup body. A method of manufacturing a pulley, wherein the cup body is set between molds having a predetermined shape, and has a substantially conical recess recessed toward the center and a relief hole in the center of the recess, The connecting portion of the cup body is formed by a member constituting a part of the mold, wherein the concave portion surface is brought into contact with the connecting portion of the cup body partially or stepwise by performing a swing motion. While gradually and partially pressing, the cylindrical portion or the connecting portion of the cup body is thickened by sequentially shifting the partial pressing portion of the connecting portion in the circumferential direction. According to this, a desired shape can be easily processed using a top member or the like, the processing time can be shortened, and the manufacturing cost can also be reduced.

本発明のクラッチ用プーリの製造方法において、前記増肉部分は、前記カップ体の内方側の円筒部のベアリングとの嵌合部、前記連結部の内方側の円筒部寄りの周縁部、前記連結部の外方側の円筒部寄りの周縁部に対応するオーバハング部のいずれかであることが好ましい。 In the clutch pulley manufacturing method of the present invention, the increased thickness portion includes a fitting portion with a bearing of the cylindrical portion on the inner side of the cup body, a peripheral portion near the inner cylindrical portion of the connecting portion, It is preferable that it is one of the overhang parts corresponding to the peripheral part near the cylindrical part on the outer side of the connecting part.

本発明のクラッチ用プーリの製造方法において、前記金型の一部の間で前記カップ体が押圧される際に、前記連結部の前記外方側の円筒部寄りの部分が前記金型の後退した逃げ部分に進入することにより突出部を形成した後、前記上金型と下金型に徐々に接近させることにより、前記連結部の突出部の肉と前記外方側の円筒部の肉とを移動させて、前記外方側の円筒部の体積と前記突出部の体積との合計体積とほぼ等しくなるような体積を有するリム部を形成して、前記外周面に複数の溝を転造成形するのが好ましい。 In the clutch pulley manufacturing method of the present invention, when the cup body is pressed between a part of the molds, the portion of the coupling part near the outer cylindrical part is retracted from the mold. After forming the projecting part by entering the escape portion, the meat of the projecting part of the connecting part and the meat of the outer cylindrical part are gradually brought closer to the upper mold and the lower mold. To form a rim portion having a volume substantially equal to the total volume of the outer cylindrical portion and the protruding portion, and forming a plurality of grooves on the outer peripheral surface. Preferably it is shaped.

本発明のクラッチ用プーリの製造方法において、前記カップ体の内筒部の内周面を前記金型の下金型でしごき、しごかれた肉を前記金型の上金型と下金型でもって略直角の水平部を形成するのが好ましい。 In the clutch pulley manufacturing method of the present invention, the inner peripheral surface of the inner cylindrical portion of the cup body is squeezed with a lower mold of the mold, and the squeezed meat is squeezed into an upper mold and a lower mold of the mold. Therefore, it is preferable to form a substantially perpendicular horizontal portion.

本発明によれば、所定形状の金型間に径の異なる複数の円筒部を有するカップ体をセットして、カップ体の連結部に金型の一部を徐々に、若しくは段階的に押し込むだけで、所望部位の増肉を行うことができるので、所望形状のリム部などを容易に加工して形成することができるとともに、加工時間を短縮でき、延いては製造コストを削減可能なクラッチ用プーリの製造方法を提供できる。 According to the present invention, a cup body having a plurality of cylindrical parts with different diameters is set between molds of a predetermined shape, and a part of the mold is pushed into the connecting part of the cup body gradually or stepwise. Therefore, it is possible to increase the thickness of the desired part, so that the rim part having the desired shape can be easily processed and formed, the processing time can be shortened, and the manufacturing cost can be reduced. A method for manufacturing a pulley can be provided.

以下、本発明の実施形態について添付図面を参照しながら詳細に説明する。
（第１の実施形態）
図1は、本発明の第１の実施形態に係るクラッチ用プーリの製造方法によりクラッチ用プーリを製造するときの中間製造物であるカップ体の製造工程を示す断面図であり、図２〜図７は図１に示すカップ体１０からポリＶ溝を形成する前までの成形体２０の製造工程を示す断面図である。 Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
(First embodiment)
FIG. 1 is a cross-sectional view illustrating a manufacturing process of a cup body that is an intermediate product when a clutch pulley is manufactured by the clutch pulley manufacturing method according to the first embodiment of the present invention. 7 is a cross-sectional view showing a manufacturing process of the molded body 20 from the cup body 10 shown in FIG. 1 to before the poly V groove is formed.

このクラッチ用プーリの製造方法では、初めに図１に示すカップ体１０を形成し、次にこのカップ体１０から図７に示す成形体２０を形成し、次に、図８に示すベアリング２１及びコイル２２などを取付けることで、或いはさらにリム部の外周面に図示外のポリＶ溝を形成することで、クラッチ用プーリが完成する。 In this clutch pulley manufacturing method, the cup body 10 shown in FIG. 1 is first formed, then the molded body 20 shown in FIG. 7 is formed from the cup body 10, and then the bearing 21 shown in FIG. A clutch pulley is completed by attaching the coil 22 or the like or by forming a poly V groove (not shown) on the outer peripheral surface of the rim portion.

最初に、カップ体１０の製造方法について、図１を参照しながら説明する。
円板状の板状金属素材１１を用意し、この中央部をポンチなどにより丸く打ち抜いて中心孔１２を形成する（同図(Ａ)参照）。次に、同図(Ｂ)に示すように、所定の金型１３及びプレス機１４などを用いて、板状金属素材１１をプレス加工する。これにより、同図(Ｃ)に示すように、同心状に大小２つの円筒部（以下、これを外筒部１０Ａ、内筒部１０Ｂとよぶ）と、この外筒部１０Ａ及び内筒部１０Ｂを連結した部分の半断面（中心線を基準として片側部分での断面を「半断面」とよぶ）が略Ｕ字形状を呈する連結部（以下、第１の実施形態では底部とよぶ）１０Ｃとを有する、カップ体１０を形成する。なお、カップ体１０には、このカップ体１０を次に説明する成形体２０へ加工する前に、滑動可能な表面処理、例えば加工品と成形金型の摩擦抵抗をなくす為の潤滑被膜を付けるボンデ処理（リン酸亜鉛皮膜処理）などを施しておくようにしてもよい。 Initially, the manufacturing method of the cup body 10 is demonstrated, referring FIG.
A disk-shaped plate-shaped metal material 11 is prepared, and a central hole 12 is formed by punching the center part round by a punch or the like (see FIG. 1A). Next, as shown in FIG. 4B, the plate-shaped metal material 11 is pressed using a predetermined die 13 and a press 14. As a result, as shown in FIG. 6C, the two cylindrical portions (hereinafter referred to as the outer cylindrical portion 10A and the inner cylindrical portion 10B) are concentrically formed, and the outer cylindrical portion 10A and the inner cylindrical portion 10B. A connecting portion (hereinafter referred to as a bottom portion in the first embodiment) 10C having a substantially U-shaped half-section (a section at one side with respect to the center line is referred to as a “half-section”) A cup body 10 is formed. The cup body 10 is provided with a slidable surface treatment, for example, a lubricating film for eliminating the frictional resistance between the processed product and the molding die, before the cup body 10 is processed into a molded body 20 described below. Bonding (zinc phosphate coating) or the like may be performed.

次に、本発明のクラッチ用プーリの製造方法を用いて、成形体を製造する場合の製造方法について、図２〜図７を参照しながら説明する。
本実施形態では、初めに、製造する成形体２０の構造と、この成形体２０の製造の際に用いる金型について、説明する。 Next, the manufacturing method in the case of manufacturing a molded object using the manufacturing method of the pulley for clutches of this invention is demonstrated, referring FIGS.
In the present embodiment, first, a structure of a molded body 20 to be manufactured and a mold used for manufacturing the molded body 20 will be described.

この成形体２０は、本実施形態の場合、自動車のコンプレッサクラッチに使用するものであって、図７（Ａ）に示すように、同心状に内外に設けた円筒形状を有する外筒部２０Ａ及び内筒部２０Ｂと、この外筒部２０Ａ及び内筒部２０Ｂを連結する半断面略コ字型の連結部２０Ｃとを備えている。
このうち、外筒部２０Ａには、後述する第３の実施形態のような図示外のポリＶ溝をその後に形成してもよく、その場合にはポリＶ溝に図示外の無端ベルトを装着させることにより、無端ベルトの幅方向に横ずれすることなく、エンジンシャフトからの回転力を他へ確実に伝達させることができる。 In the case of this embodiment, this molded body 20 is used for a compressor clutch of an automobile, and as shown in FIG. 7A, an outer cylinder portion 20A having a cylindrical shape concentrically provided inside and outside, and An inner cylinder portion 20B and a connecting portion 20C having a substantially U-shaped half section for connecting the outer cylinder portion 20A and the inner cylinder portion 20B are provided.
Of these, a poly V groove (not shown) as shown in the third embodiment to be described later may be formed in the outer cylinder portion 20A after that. In that case, an endless belt (not shown) is attached to the poly V groove. By doing so, the rotational force from the engine shaft can be reliably transmitted to the other without causing lateral displacement in the width direction of the endless belt.

一方、内筒部２０Ｂは、図７（Ｂ）に示すように、図示外のクラッチ用の回転軸を回転自在に支持するベアリング２１（図８参照）を嵌合させるために増肉された肉厚形状（第１増肉部α）に形成されており、その第１増肉部αに、ベアリング嵌合用の切削代２０Ｄと位置決めストッパとなる段部２０Ｅなどが形成されている。これにより、内筒部２０Ｂには、図８に示すように、ベアリング２１を確実に嵌合させることができる。また、外筒部２０Ａ及び内筒部２０Ｂの間の略リング状の大きなスペースには、電磁クラッチを構成する円環状のコイル２２を装着させるようになっており、発生する電磁力で後述するアーマチュア２３を吸引可能とする。 On the other hand, as shown in FIG. 7 (B), the inner cylinder portion 20B has a thickness increased to fit a bearing 21 (see FIG. 8) that rotatably supports a rotating shaft for a clutch (not shown). A thick shape (first thickened portion α) is formed, and a cutting margin 20D for bearing fitting, a stepped portion 20E serving as a positioning stopper, and the like are formed in the first thickened portion α. Thereby, as shown in FIG. 8, the bearing 21 can be reliably fitted to the inner cylinder part 20B. An annular coil 22 constituting an electromagnetic clutch is attached to a large ring-shaped space between the outer cylinder portion 20A and the inner cylinder portion 20B, and an armature described later by the generated electromagnetic force. 23 can be sucked.

さらに、連結部２０Ｃには、アーマチュア２３が圧接可能に設置されており、コイル２２の磁力で吸着されて連結部２０Ｃの外面に当接すると、エンジン側の回転駆動力が伝達されてコンプレッサの回転軸が回転する。
なお、連結部２０Ｃには、図７（Ｂ）に示すように、底部１０Ｃの外周縁部に対応する部分に増肉されたオーバハング部となる第３増肉部γとが形成される。また、この連結部２０Ｃには、図７（Ｂ）には形成されていないが、後述する第２の実施形態の図１２に示すように、内筒部２０Ｂ寄りの内周縁部に対応する部分に肉厚形状の第２増肉部βを形成することもできる。 Further, an armature 23 is installed in the connecting portion 20C so as to be press-contactable. When the armature 23 is attracted by the magnetic force of the coil 22 and abuts against the outer surface of the connecting portion 20C, the rotational driving force on the engine side is transmitted to rotate the compressor. The shaft rotates.
In addition, as shown in FIG. 7B, the connecting portion 20C is formed with a third thickened portion γ that becomes an overhang portion thickened at a portion corresponding to the outer peripheral edge portion of the bottom portion 10C. Further, the connecting portion 20C is not formed in FIG. 7B, but as shown in FIG. 12 of the second embodiment to be described later, a portion corresponding to the inner peripheral edge near the inner cylinder portion 20B. It is also possible to form the thickened second thickened portion β.

次に、この成形体２０の製造に用いる金型について説明する。
本実施形態のクラッチ用プーリの製造方法では、図２に示す金型３０、即ち、不動状態に固定された下金型３０Ａ及び下方へスライドしてカップ体１０の内筒部１０Ｂと外筒部１０Ａとの間などに押し込ませる上金型３０Ｂで構成されたものが使用される。 Next, the metal mold | die used for manufacture of this molded object 20 is demonstrated.
In the clutch pulley manufacturing method of the present embodiment, the mold 30 shown in FIG. 2, that is, the lower mold 30 A fixed in a stationary state and the lower cylinder 30 A and the inner cylinder 10 B and the outer cylinder of the cup body 10 are slid downward. What was comprised with the upper metal mold | die 30B pushed between 10A etc. is used.

この上下一対の金型３０Ａ、３０Ｂのうち、下金型３０Ａは、各種サイズの異なるカップ体２０が製造できるようにするため、外型３１及び内型３２に分割可能になっている。換言すれば、外筒部１０Ａ及び内筒部１０Ｂの径サイズの変更に対応して、それに合わせた径を有する外型３１及び内型３２と交換可能に構成されている。 Of the pair of upper and lower molds 30A and 30B, the lower mold 30A can be divided into an outer mold 31 and an inner mold 32 so that cup bodies 20 of various sizes can be manufactured. In other words, the outer mold 31 and the inner mold 32 having a diameter corresponding to the change in the diameter size of the outer cylinder part 10A and the inner cylinder part 10B can be exchanged.

外型３１は、略円筒形状に形成されており、内周面にカップ体１０の外周面を当接させることで、カップ体１０を抱持しながら後述する増肉加工を行う際に、外筒部１０Ａが押し広がるのを阻止する。内型３２は、中心部分にカップ体１０の中心孔１０Ｄ（元の中心孔１２に対応する）とほぼ同じ外径寸法を有する円柱部材３２１と、この円柱部材３２１に外接するリング状の円筒部材３２２とで構成されている。この円筒部材３２２の上面外周縁部には、図２に示すように、成形体２０のオーバーハング部γ（リブ部）を形成するために外周縁部側が窪んだ凹部３２２Ａを設けている。なお、この円柱部材３２１と円筒部材３２２とは、前述したように、外円筒部１０Ａ及び内円筒部１０Ｂの径寸法に応じて各種サイズのものと交換或いは組み合わせ可能となっている。 The outer mold 31 is formed in a substantially cylindrical shape, and the outer peripheral surface of the cup body 10 is brought into contact with the inner peripheral surface, so that the outer mold 31 can be used when performing a thickening process to be described later while holding the cup body 10. The cylindrical portion 10A is prevented from spreading. The inner mold 32 includes a cylindrical member 321 having a substantially same outer diameter as the central hole 10D (corresponding to the original central hole 12) of the cup body 10 at the center portion, and a ring-shaped cylindrical member circumscribing the cylindrical member 321. 322. As shown in FIG. 2, a concave portion 322 A whose outer peripheral edge side is recessed is provided in the outer peripheral edge portion of the upper surface of the cylindrical member 322 in order to form an overhang portion γ (rib portion) of the molded body 20. As described above, the column member 321 and the cylindrical member 322 can be exchanged or combined with various sizes according to the diameter of the outer cylindrical portion 10A and the inner cylindrical portion 10B.

一方、上金型３０Ｂは、下金型３０Ａの内型３２と同様に２つの部材から構成されており、下金型３０Ａに向けて押し込んでいく。この上金型３０Ｂは、具体的には、カップ体１０の中心孔１２とほぼ同じ外径寸法を有する円柱部材３３１と、この円柱部材３３１に対してスライド可能に内接する円筒部材３３２とで構成されている。円柱部材３３１は、完成した成形体２０の内筒部２０Ｂの一部を肉厚構造として、先端部（下端部）側の一部の外径寸法を狭めた構造を有している。また、円筒部材３３２も、カップ体２０の厚さ分だけ先端部（下端部）側の外径寸法を狭めた構造を有している。 On the other hand, the upper mold 30B is composed of two members similarly to the inner mold 32 of the lower mold 30A, and is pushed toward the lower mold 30A. Specifically, the upper mold 30B includes a columnar member 331 having substantially the same outer diameter as the center hole 12 of the cup body 10, and a cylindrical member 332 slidably inscribed with respect to the columnar member 331. Has been. The columnar member 331 has a structure in which a part of the inner cylinder portion 20B of the completed molded body 20 has a thick structure, and a part of the outer diameter on the tip (lower end) side is narrowed. In addition, the cylindrical member 332 also has a structure in which the outer diameter dimension on the tip (lower end) side is narrowed by the thickness of the cup body 20.

この成形体２０の製造は、図１で製造したカップ体１０を用いて、初めに、図２に示すように、下金型３０Ａの外型（外枠）３１にカップ体１０を抱持させた状態にセットする。その際に、カップ体１０の底部１０Ｃを内型３２の内筒部材３２２上面に当接させる。
そして、図２に示すように、上金型３０Ｂをカップ体１０に押し込ませていく。つまり、カップ体１０の外筒部１０Ａと内筒部１０Ｂとの間に（あまり大きな力を作用せずに）挿入できるところまで円筒部材３３２を挿入していく。なお、この円筒部材３３２の挿入位置は、少なくとも、先端（下端）面が外型３１の上面よりも若干下方に位置するところである。
その後、カップ体１０の中心孔１０Ｄに円柱部材３３１を挿入させたならば、図３に示すように、円柱部材３３１の先端面（下面）が円柱部材３２１の上面に当接するまで押し込んでいく。 The molded body 20 is manufactured by first using the cup body 10 manufactured in FIG. 1 to hold the cup body 10 in the outer mold (outer frame) 31 of the lower mold 30A as shown in FIG. Set to the correct state. At that time, the bottom 10 C of the cup body 10 is brought into contact with the upper surface of the inner cylinder member 322 of the inner mold 32.
Then, as shown in FIG. 2, the upper mold 30 B is pushed into the cup body 10. That is, the cylindrical member 332 is inserted until it can be inserted between the outer cylinder portion 10A and the inner cylinder portion 10B of the cup body 10 (without applying a large force). The cylindrical member 332 is inserted at least at the tip (lower end) surface slightly below the upper surface of the outer mold 31.
Thereafter, when the cylindrical member 331 is inserted into the center hole 10 D of the cup body 10, the cylindrical member 331 is pushed in until the tip surface (lower surface) of the cylindrical member 331 contacts the upper surface of the cylindrical member 321 as shown in FIG. 3.

次に、図３に示すように、円筒部材３３２を円筒部材３２２に向けて押し込んでいき、図４に示すように、カップ体１０の外筒部１０Ａの上端面に円筒部材３３２の段部３３２Ａが当接するところまで押し込む。このとき、円筒部材３３２の先端面（下面）は、カップ体１０の外筒部１０Ａ、内筒部１０Ｂが、それぞれ、底部１０Ｃと接する半断面略Ｕ字型に湾曲を始めるＲ状部分にちょうど当接するところの位置となる。そして、さらに円筒部材３３２を徐々に押し込んでいくと、図５に示すように、カップ体１０の底部１０Ｃが徐々に押し潰されてフラットな状態となっていく。つまり、半断面略Ｕ字型の底部１０Ｃが押し広げられていく。 Next, as shown in FIG. 3, the cylindrical member 332 is pushed toward the cylindrical member 322, and as shown in FIG. 4, a step portion 332A of the cylindrical member 332 is formed on the upper end surface of the outer cylinder portion 10A of the cup body 10. Push until it comes into contact. At this time, the front end surface (lower surface) of the cylindrical member 332 is just an R-shaped portion in which the outer cylinder portion 10A and the inner cylinder portion 10B of the cup body 10 begin to bend into a substantially U-shaped half-section in contact with the bottom portion 10C. This is the position where it abuts. When the cylindrical member 332 is further pushed in gradually, the bottom 10C of the cup body 10 is gradually crushed and becomes flat as shown in FIG. That is, the bottom portion 10C having a substantially U-shaped half cross section is expanded.

このようにして、最終的には、図６のように底部１０Ｃの内外両縁部側の角隅部分が断面円弧状から断面Ｌ字状（半断面略コ字状）に加工され、前述したように、所定部位が増肉された形状に形成される。即ち、カップ体１０の内筒部１０Ｂでの内周面の底部１０Ｃ寄りには、第１増肉部αが形成されるとともに、カップ体１０の底部１０Ｃでの外側縁部には、円筒部材３２２の凹部３２２Ａに肉の一部が移動した第３増肉部γが形成される。
なお、ここで、第１肉厚部αは、図７に示すように、ベアリング嵌合用の切削代を確保するとともに位置決めストッパとなる段部を形成するために設けている。また、第２肉厚部γは、図８に示すように、後にポリＶ溝を形成して装着する無端ベルトのはずれ防止のための突起等を形成するたに利用することができる。 In this way, finally, as shown in FIG. 6, the corner portions on the inner and outer edges of the bottom portion 10C are processed from a circular arc shape to a cross-sectional L shape (half-cross-section substantially U-shape), as described above. In this way, the predetermined part is formed in a thickened shape. That is, the first thickened portion α is formed near the bottom portion 10C of the inner peripheral surface of the inner cylindrical portion 10B of the cup body 10 and the cylindrical member is formed on the outer edge portion of the bottom portion 10C of the cup body 10. A third thickened portion γ in which a part of the meat has moved is formed in the concave portion 322A of 322.
Here, as shown in FIG. 7, the first thick portion α is provided to secure a cutting margin for bearing fitting and to form a step portion that serves as a positioning stopper. Further, as shown in FIG. 8, the second thick portion γ can be used to form protrusions and the like for preventing the endless belt to be attached after forming a poly V groove.

以上、説明してきた本実施形態のクラッチ用プーリの製造方法によれば、従来の絞り加工ではなく、一部に体積を増肉させるための空間部分も含む上下の金型で閉じられた空間の中に、カップ体を押し込んでいく加工方法、換言すれば、絞り加工と鍛造加工の中間的な加工方法を行うようになっている。これにより、所望部位を増肉させた形状のものを容易に、かつ、精度良く加工できる。特に、円筒部材により、カップ体の内筒部及び底部を金型内部の空間へ徐々に（又は段階的に）押し込むだけで所望形状に加工できるので、加工の際の加工時間も短縮でき、延いては製造コストを削減できる。 As described above, according to the method for manufacturing the clutch pulley of the present embodiment described above, the space of the space closed by the upper and lower molds including the space portion for partially increasing the volume is not used in the conventional drawing process. A processing method in which the cup body is pushed in, in other words, an intermediate processing method between drawing and forging is performed. Thereby, the thing of the shape which increased the desired site | part can be processed easily and accurately. In particular, the cylindrical member can be processed into a desired shape simply by gradually (or stepwise) pushing the inner cylinder part and bottom part of the cup into the space inside the mold. Manufacturing costs can be reduced.

（第２の実施形態）
次に、本発明の第２の実施形態について図面を参照しながら詳細に説明する。なお、本実施形態において、第１の実施形態と同一部分には同一符号を付して重複説明を避ける。また、本実施形態のクラッチ用プーリの製造方法では、初めに、第１の実施形態で形成した図１(Ｃ)、（Ｄ）に示すカップ体１０と同じものを形成する。このカップ体１０は、第1の実施形態における製造方法と同じ方法を用いて製造しているので、この製造方法についての説明は省略する。 (Second Embodiment)
Next, a second embodiment of the present invention will be described in detail with reference to the drawings. In the present embodiment, the same parts as those in the first embodiment are denoted by the same reference numerals to avoid redundant description. In the clutch pulley manufacturing method of this embodiment, first, the same cup body 10 shown in FIGS. 1C and 1D formed in the first embodiment is formed. Since this cup body 10 is manufactured using the same method as the manufacturing method in 1st Embodiment, description about this manufacturing method is abbreviate | omitted.

本実施形態では、第１の実施形態の成形体２０と略同じ成形体２０を製造するものであるが、この成形体２０は、図１２（Ｂ）に示すように、連結部２０Ｃにおいて、第１の実施形態の成形体２０にはない内筒部２０Ｂ寄りに、第２増肉部βが形成される。従って、この成形体２０製造に用いる金型については、第１の実施形態での金型と一部異なるので、製造方法法に先立ってこの金型から説明する。 In the present embodiment, the molded body 20 that is substantially the same as the molded body 20 of the first embodiment is manufactured. As illustrated in FIG. The second thickened portion β is formed near the inner cylinder portion 20B that is not included in the molded body 20 of the first embodiment. Accordingly, the mold used for manufacturing the molded body 20 is partially different from the mold in the first embodiment, and will be described from the mold prior to the manufacturing method.

カップ体１０から成形体２０を製造するときに用いる金型４０は、図９に示すように、下金型４０Ａと上金型４０Ｂで構成されている。このうち、下金型４０Ａは、外型３１と内型３３とで構成されている。内型３３の方は、図２に示す第１の実施形態における上金型３０Ｂと略同じ構成、つまり円柱部材３３１と円筒部材３３２とを有するものであるが、円柱部材３３１は、最初から、図３及び図４の状態に示す場合と略同じ量だけ、円筒部材３３２の先端面（図９では上面）よりも突設している。また、外型３１の方は、特に上金型４０Ｂとの対向面（図９では上面）３１１が外側に向けて低くなるように、所定の角度θだけ傾斜している。 As shown in FIG. 9, the mold 40 used when manufacturing the molded body 20 from the cup body 10 is composed of a lower mold 40A and an upper mold 40B. Among these, the lower mold 40 A includes an outer mold 31 and an inner mold 33. The inner mold 33 has substantially the same configuration as that of the upper mold 30B in the first embodiment shown in FIG. 2, that is, a columnar member 331 and a cylindrical member 332. It protrudes from the front end surface (upper surface in FIG. 9) of the cylindrical member 332 by substantially the same amount as shown in the state of FIGS. Further, the outer mold 31 is inclined by a predetermined angle θ so that the surface 311 facing the upper mold 40B (upper surface in FIG. 9) becomes lower toward the outside.

一方、上金型４０Ｂは、固有形状を有するこま部材４１を備えている。このこま部材４１は、下金型４０Ａとの対向面（図９では下面）が、中央部に向けて傾斜して窪んだ略円錐形状の凹部４１１を有するとともに、中央部に逃げ穴４１２を有している。
このような構成のこま部材４１Ｂは、中心線Ｃを基準として角度δの首振り運動(こまの歳差運動のように首振り動作を行うが、自転（回転）動作は行わない。)を行ないながら、凹部４１１の表面を、カップ体１０の円筒部１０Ａ、１０Ｂ間をつなぐ連結部（図1では底部に相当していた部分）１０Ｃの外周面に順次、部分的に、若しくは段階的に当接する。即ち、こま部材４１は、カップ体１０のＵ字状の底部１０Ｃを、徐々に、かつ、部分的に押し込ませながら、換言すれば、カップ体１０の底部１０Ｃでの押圧部位を周方向に沿って順次ずらしていくように移動させながら、毎回、局部的に底部１０Ｃを押し込ませてゆき、所定の部位の増肉を行うようにする。そのため、こま部材４１は、対向面（下面）の凹部４１１を囲む面（これを「外周縁面」とよぶ）４１３も傾斜させており、増肉時に肉が凹部４１１内から外部へ飛び出すのを回避させる。 On the other hand, the upper mold 40B includes a top member 41 having a specific shape. The top member 41 has a substantially conical concave portion 411 in which the surface facing the lower mold 40A (the lower surface in FIG. 9) is inclined and recessed toward the central portion, and has a relief hole 412 in the central portion. is doing.
The top member 41B having such a configuration performs a swing motion at an angle δ with respect to the center line C (performs a swing motion like a top precession motion, but does not perform a rotation (rotation) motion). However, the surface of the concave portion 411 is applied to the outer peripheral surface of the connecting portion (the portion corresponding to the bottom in FIG. 1) 10C that connects between the cylindrical portions 10A and 10B of the cup body 10 sequentially or partially. Touch. That is, the top member 41 gradually and partially pushes the U-shaped bottom portion 10C of the cup body 10, in other words, the pressing portion at the bottom portion 10C of the cup body 10 along the circumferential direction. The bottom portion 10C is locally pushed in each time while being moved so as to be sequentially shifted to increase the thickness of a predetermined portion. Therefore, the top member 41 is also inclined on a surface (called an “outer peripheral surface”) 413 surrounding the concave portion 411 on the opposing surface (lower surface), so that the meat jumps out from the concave portion 411 to the outside when the thickness is increased. Avoid it.

具体的には、図１２に示すように、このこま部材４１が毎回一方向に首振り動作を行い、外周縁面４１３の一部が外型３１の対向面（上面）３１１に接触する部分では、こま部材４１の外周縁面４１３が対向面（上面）３１１と密着するようになっている。しかも、これら双方の面が密着する状態のときには、外周縁面４１３の最内縁（つまり、凹部４１１の最外縁）と円筒部材３３２の溝部の最外縁とが、一致するように構成されている。 Specifically, as shown in FIG. 12, the top member 41 swings in one direction each time, and a part of the outer peripheral surface 413 is in contact with the opposing surface (upper surface) 311 of the outer mold 31. The outer peripheral surface 413 of the top member 41 is in close contact with the opposing surface (upper surface) 311. In addition, when these two surfaces are in close contact with each other, the innermost edge of the outer peripheral surface 413 (that is, the outermost edge of the recess 411) and the outermost edge of the groove portion of the cylindrical member 332 are configured to coincide with each other.

次に、この成形体２０の製造方法について説明する。
初めに、図１(Ｃ)、（Ｄ）に示すカップ体１０と同じものをプレス加工などで形成したならば、図９に示すように、カップ体１０を第１の実施形態とは逆向きの上下逆さまの状態にして、カップ体１０の外筒部１０Ａ、内筒部１０Ｂが、下金型４０Ａの円筒部材３３２の溝部の最奥部まで挿入するように、しっかりと押し込ませておく。 Next, the manufacturing method of this molded object 20 is demonstrated.
First, if the same cup body 10 as shown in FIGS. 1C and 1D is formed by press working or the like, the cup body 10 is reverse to the first embodiment as shown in FIG. In an upside down state, the outer cylinder portion 10A and the inner cylinder portion 10B of the cup body 10 are firmly pushed so as to be inserted to the innermost part of the groove portion of the cylindrical member 332 of the lower mold 40A.

その後、同図に示すように、そのカップ体１０をセットした下金型４０Ａを上昇移動させるとともに、この直上の上金型４０Ｂを構成するこま部材４１に首振り運動を行わせる。これにより、初めは、カップ体１０のＵ字状の連結部１０Ｃのうち内筒部１０Ｂ寄りの部位から、順次段階的に、こま部材４１の凹部４１１に押し当てられながら押し込まれていく。これにより、連結部１０Ｃが、徐々に、かつ、部分的にこま部材４１の凹部４１１に押し込まれていく。その結果、連結部１０Ｃは、図１０、図１１に示すように、徐々に押し曲げられて押し潰されていくので、半断面がコ字型の形状に加工される。 Thereafter, as shown in the figure, the lower mold 40A on which the cup body 10 is set is moved up and moved, and the swinging motion is performed by the member 41 constituting the upper mold 40B immediately above. As a result, the U-shaped connecting portion 10C of the cup body 10 is initially pushed from the portion near the inner cylinder portion 10B while being pressed against the concave portion 411 of the top member 41 in a stepwise manner. Accordingly, the connecting portion 10C is gradually and partially pushed into the concave portion 411 of the top member 41. As a result, as shown in FIGS. 10 and 11, the connecting portion 10C is gradually pushed and bent and crushed, so that the half section is processed into a U-shaped shape.

そして、最後には、図１２（Ａ）に示すように、下金型４０Ａと上金型４０Ｂとの間の空間を埋めるような形状に加工される。特に、これにより、カップ体１０の内筒部１０Ｂの内周面のベアリングの嵌合部である第１増肉部α、内筒部１０Ｂ寄りの連結部１０Ｃの内周縁部に臨む第２増肉部βが増肉される。なお、第１の実施形態のような金型（凹部３２２Ａを設けた円筒部材３２２など）を用いて、連結部１０Ｃの外周縁部に対応するオーバハング部γを形成してもよい。 And finally, as shown to FIG. 12 (A), it processes to the shape which fills the space between 40 A of lower molds, and the upper mold 40B. In particular, this increases the first thickening portion α, which is a fitting portion of the bearing on the inner peripheral surface of the inner cylinder portion 10B of the cup body 10, and the second increase facing the inner peripheral edge portion of the connecting portion 10C near the inner cylinder portion 10B. The meat part β is increased. Note that the overhang portion γ corresponding to the outer peripheral edge of the connecting portion 10C may be formed using a mold (such as the cylindrical member 322 provided with the recess 322A) as in the first embodiment.

従って、本実施形態によれば、図９に示す半断面が略Ｕ字型のカップ体１０の、下金型４０Ａから突出した主に連結部１０Ａの体積（肉）部分が押し潰されて変形し、その体積部分から、図１２（Ｂ）に示す半断面が略コ字型の成形体２０が形成される。換言すれば、連結部１０Ｃの突出部の体積と内筒部１０Ｂの一部の体積とを移動させて、外筒部２０Ａの体積と突出部の体積との合計体積とほぼ等しくなるような体積を有する成形体２０を形成して、内筒部の内周面にベアリングを嵌合させる溝を切削する切削代を確保することができる。 Therefore, according to the present embodiment, the volume (meat) portion of the coupling portion 10A that protrudes from the lower mold 40A of the cup body 10 having a substantially U-shaped half section shown in FIG. 9 is crushed and deformed. Then, a molded body 20 having a substantially U-shaped half section shown in FIG. In other words, the volume of the protruding portion of the connecting portion 10C and the partial volume of the inner cylindrical portion 10B are moved so that the total volume of the outer cylindrical portion 20A and the protruding portion is substantially equal to the volume. It is possible to secure a cutting allowance for cutting a groove for fitting a bearing to the inner peripheral surface of the inner cylinder portion.

（第３の実施形態）
次に、本発明の第３の実施形態について図面を参照しながら詳細に説明する。なお、本実施形態において、第１、第２の実施形態と同一部分には同一符号を付して重複説明を避ける。
本実施形態のクラッチ用プーリの製造方法では、成形体２０を製造した後に、図１７に示す両側にベルト脱落防止用の突起とポリＶ溝（複数の溝）を設けたリム部Ｒを形成する。 (Third embodiment)
Next, a third embodiment of the present invention will be described in detail with reference to the drawings. In the present embodiment, the same parts as those in the first and second embodiments are denoted by the same reference numerals to avoid redundant description.
In the clutch pulley manufacturing method of this embodiment, after the molded body 20 is manufactured, the rim portion R provided with the belt drop prevention protrusions and the poly V grooves (plural grooves) on both sides shown in FIG. 17 is formed. .

ここで、最初に、本実施形態のクラッチ用プーリを製造する際に、特にカップ体１０を用いて成形体２０を製造するときに用いる金型について、説明する。
本実施形態の成形体２０を製造するときに用いる金型は、下型４０Ｃと上型４０Ｄからなる。下型４０Ｃは、図９に示す第２の実施形態の成形体２０を製造するときに用いた下型４０Ａの替わりに用いるものであり、上型４０Ｄには、同じく上型４０Ｂのこま部材４１の替わりに図１３に示すこま部材４２を用いる点が、第２の実施形態とは異なる。 Here, when manufacturing the clutch pulley of this embodiment, the metal mold | die used when manufacturing the molded object 20 especially using the cup body 10 is demonstrated.
A mold used when manufacturing the molded body 20 of the present embodiment includes a lower mold 40C and an upper mold 40D. The lower mold 40C is used in place of the lower mold 40A used when manufacturing the molded body 20 of the second embodiment shown in FIG. 9, and the upper mold 40D has a top member 41 of the upper mold 40B. The point which uses the top member 42 shown in FIG. 13 instead of is different from 2nd Embodiment.

このうち、本実施形態の下型４０Ａの外型３５には、第２の実施形態の外型３１と同様のものを用いているが、第２の実施形態の外型３１と異なり、上型４０Ｂに対向する対向面(上面)部分は傾斜した形状にする必要はない。また、本実施形態の内型３４は、第２の実施形態の内型３３を構成する円柱部材３３１と円筒部材３３２のような分割可能な構造であってもよいが、図１３に示すように一体構造でもよい。 Of these, the outer mold 35 of the lower mold 40A of the present embodiment is the same as the outer mold 31 of the second embodiment, but unlike the outer mold 31 of the second embodiment, the upper mold The facing surface (upper surface) portion facing 40B need not be inclined. Further, the inner mold 34 of the present embodiment may be a separable structure such as a columnar member 331 and a cylindrical member 332 constituting the inner mold 33 of the second embodiment, but as shown in FIG. A monolithic structure may be used.

一方、本実施形態のこま部材４２は、第２の実施形態のこま部材４１の中央部に向けて傾斜して窪んだ略円錐形状の凹部４１１の替わりに、中央部に向けて傾斜して突出する略円錐形状の凸部４２１を下型４０Ａに対向する対向面（下面）に設けるとともに、下型４０Ａに対向する対向面（下面）の外縁部に沿って、第２の実施形態のこま部材４１の外周縁面４１３の替わりに段部４２３を設けている。なお、下型４０Ａに対向する対向面（下面）の中央部に逃げ穴４２２を設ける点は、第２の実施形態のこま部材４１と同様である。 On the other hand, the top member 42 of the present embodiment is inclined and protrudes toward the center instead of the substantially conical recess 411 that is inclined and recessed toward the center of the top member 41 of the second embodiment. The substantially cone-shaped convex portion 421 is provided on the facing surface (lower surface) facing the lower mold 40A, and the top member of the second embodiment is formed along the outer edge portion of the facing surface (lower surface) facing the lower mold 40A. A step portion 423 is provided in place of the outer peripheral surface 413 of the 41. In addition, the point provided with the escape hole 422 in the center part of the opposing surface (lower surface) which opposes the lower mold | type 40A is the same as the top member 41 of 2nd Embodiment.

次に、この成形体２０の製造方法について説明する。
初めに、第１、第２の実施形態と同様にして、図１(Ｃ)、（Ｄ）に示すカップ体１０と同様のものをプレス加工などで形成する。次に、図１３に示すように、第２の実施形態と同様に、そのカップ体１０を上下逆さまの状態にして、カップ体１０の外筒部１０Ａ、内筒部１０Ｂが、下金型４０Ａの内型３４の溝部の最奥部まで挿入するように、確実に押し込む。 Next, the manufacturing method of this molded object 20 is demonstrated.
First, in the same manner as in the first and second embodiments, the same cup body 10 as shown in FIGS. 1C and 1D is formed by press working or the like. Next, as shown in FIG. 13, as in the second embodiment, the cup body 10 is turned upside down, and the outer cylinder portion 10A and the inner cylinder portion 10B of the cup body 10 are connected to the lower mold 40A. The inner mold 34 is surely pushed so as to be inserted to the innermost part of the groove.

その後、同図に示すように、そのカップ体１０をセットした下金型４０Ａを上方に移動させるとともに、その直上のこま部材４１に首振り運動を行わせるようにする。そして、第２の実施形態と同様にして、カップ体１０のＵ字状の連結部１０Ｃを、徐々に、かつ、部分的に押し込ませていくが、本実施形態の場合、連結部１０Ｃの外筒部１０Ａ寄りからではなく連結部１０Ｃの略全体が同時に押し曲げられ、押し潰されていく。 Thereafter, as shown in the figure, the lower mold 40A on which the cup body 10 is set is moved upward and the top member 41 just above is caused to swing. In the same manner as in the second embodiment, the U-shaped connecting portion 10C of the cup body 10 is gradually and partially pushed. In the present embodiment, the outer portion of the connecting portion 10C is removed. Nearly the entire connecting portion 10C is pressed and bent at the same time, not from the tube portion 10A.

これにより、連結部１０Ｃは、最終的には、図１４に示すように、連結部１０Ｃが半断面略コ字型に押し潰され、下金型４０Ａと上金型４０Ｂとの間の空間を埋める状態に加工される。その結果、特に、カップ体１０の内筒部１０Ｂの内周面のベアリングの嵌合部となる第１増肉部α、及び連結部１０Ｃの外周縁部に対応するオーバハング部γが増肉される。なお、本実施形態では、内筒部１０Ｂ寄りの連結部１０Ｃの内周縁部の第２増肉部βは形成されていないが、金型を変更することでこれも形成することが可能である。 As a result, the connecting portion 10C is finally crushed into a substantially U-shaped half section as shown in FIG. 14, and the space between the lower die 40A and the upper die 40B is formed. Processed to fill. As a result, in particular, the first thickened portion α serving as the bearing fitting portion on the inner peripheral surface of the inner cylinder portion 10B of the cup body 10 and the overhang portion γ corresponding to the outer peripheral edge portion of the connecting portion 10C are increased. The In the present embodiment, the second thickened portion β at the inner peripheral edge of the connecting portion 10C near the inner cylinder portion 10B is not formed, but it can be formed by changing the mold. .

次に、完成した成形体２０を金型４０から取り出し、両側にベルト脱落防止用の突起を設けたリム部（これを、「予備リム部」とよぶ）を形成し、その後、さらに、この予備リム部にポリＶ溝を形成したリム部を形成する。なお、本実施形態のクラッチ用プーリを製造する場合、成形体２０から予備リム部を製造する際に金型５０及び押圧ローラ６０を用い、予備リム部からリム部を形成する際に同じ金型５０と押圧ローラ７０を用いる。 Next, the completed molded body 20 is taken out from the mold 40 to form a rim portion (hereinafter referred to as a “preliminary rim portion”) provided with protrusions for preventing the belt from dropping off on both sides. A rim portion having a poly V groove formed in the rim portion is formed. When the clutch pulley of the present embodiment is manufactured, the mold 50 and the pressing roller 60 are used when the spare rim portion is manufactured from the molded body 20, and the same die is used when the rim portion is formed from the preliminary rim portion. 50 and a pressing roller 70 are used.

そこで、成形体２０からリム部の製造方法を説明するのに先立ち、予備リム部の製造に用いる金型５０及び押圧ローラ６０、７０について説明する。
金型５０は、図１５に示すように、外金型５１と、内金型５２と、中金型５３と、側金型５４で構成されており、回転軸Ｌ１を中心として回転する。この金型５０では、一旦、中金型５３と側金型５４とを取り外した後に、成形体２０の内筒部２０Ｂを内金型５２との間の外金型５１の溝部に奥部まで押し込んでセットし、再度、中金型５３と側金型５４を組み付けたならば、図示外の型締め手段で一体に固定させるようにしている。なお、この金型５０には、押圧ローラ６０での押圧動作により押し潰された肉の部分が逃げ込むための逃げ部分となる窪み（５１Ａ、５４Ａ）が外金型５１、側金型５４に形成されている。 Therefore, prior to describing the method for manufacturing the rim portion from the molded body 20, the mold 50 and the pressure rollers 60 and 70 used for manufacturing the preliminary rim portion will be described.
As shown in FIG. 15, the mold 50 includes an outer mold 51, an inner mold 52, an intermediate mold 53, and a side mold 54, and rotates about the rotation axis L1. In this mold 50, once the middle mold 53 and the side mold 54 are removed, the inner cylinder part 20 B of the molded body 20 is inserted into the groove part of the outer mold 51 between the inner mold 52 and the inner part. When the middle mold 53 and the side mold 54 are assembled again after being pushed in and set, they are fixed together by mold clamping means (not shown). In this mold 50, recesses (51 A, 54 A) are formed in the outer mold 51 and the side mold 54 that serve as escape parts for the meat parts crushed by the pressing operation of the pressing roller 60 to escape. Has been.

押圧ローラ６０は、第１金型６１〜第３金型６３で構成されており、これらを緊締させた状態で、回転軸Ｌ２を中心に回転させることによって、外筒部２０Ａから両側にベルト脱落防止用の突起を設けた予備リム部Ｐ（図１６参照）を形成するようになっている。なお、第１金型６１〜第３金型６３にも、同様の逃げ部分となる窪み（６１Ａ、６２Ａ、６３Ａ）が形成されている。そのため、成形体２０の外筒部２０Ａは、第１金型６１〜第３金型６３と、外金型５１、中金型５３及び側金型５４との間で形成される空間で押し潰されながら空間内部を移動することで、予備リム部Ｐが形成される。なお、押圧ローラ６０は、回転軸Ｌ２が金型５０の回転軸Ｌ１と平行な状態に設置されており、双方が同一の回転方向に沿って回転する。 The pressing roller 60 is composed of a first mold 61 to a third mold 63, and the belt is dropped from the outer cylinder portion 20A to both sides by rotating around the rotation axis L2 in a state in which these are tightened. A preliminary rim portion P (see FIG. 16) provided with a protrusion for prevention is formed. The first mold 61 to the third mold 63 are also formed with depressions (61A, 62A, 63A) that are similar relief portions. Therefore, the outer cylinder portion 20A of the molded body 20 is crushed in a space formed between the first mold 61 to the third mold 63, the outer mold 51, the middle mold 53, and the side mold 54. The spare rim portion P is formed by moving inside the space while being done. Note that the pressing roller 60 is installed in a state in which the rotation axis L2 is parallel to the rotation axis L1 of the mold 50, and both rotate along the same rotation direction.

押圧ローラ７０は、図１７に示すように、第１金型７１〜第３金型７３で構成されており、これらを緊締させた状態で、回転軸Ｌ３を中心に回転させることによって、予備リム部Ｐの外周面にポリＶ溝を設けたリム部Ｒを形成するようになっている。 As shown in FIG. 17, the pressing roller 70 is composed of a first mold 71 to a third mold 73, and is rotated around the rotation axis L 3 in a state in which these are tightened, thereby preparing a spare rim. A rim portion R provided with a poly V groove on the outer peripheral surface of the portion P is formed.

次に、上述した金型５０及び押圧ローラ６０、７０を用いて、図１４に示す成形体２０の外筒部２０ＡからポリＶ溝を設けたリム部を製造するまでの製造方法を説明する。
前述したように、図１５において、金型５０を用いて、これから中金型５３と側金型５４とを取り外した後に、成形体２０の内筒部２０Ｂを内金型５２との間の外金型５１の溝部に奥部まで押し込んでセットし、再度、中金型５３と側金型５４を組み付けた後、図示外の型締め手段で一体に固定させる。 Next, a manufacturing method until manufacturing a rim portion provided with a poly V groove from the outer cylindrical portion 20A of the molded body 20 shown in FIG. 14 using the mold 50 and the pressing rollers 60 and 70 described above will be described.
As described above, in FIG. 15, after the middle mold 53 and the side mold 54 are removed from the mold 50, the inner cylinder portion 20 B of the molded body 20 is placed between the inner mold 52 and the outer mold 52. The inner mold 53 and the side mold 54 are assembled again after being pushed into the groove of the mold 51 to the back, and then fixed together by a mold clamping means (not shown).

次に、金型５０を回転させるとともに押圧ローラ６０を回転させ、この回転する押圧ローラ６０を成形体２０の外筒部２０Ａに徐々に押し付ける。これにより、金型５０と押圧ローラ６０との間の空間内で成形体２０の外筒部２０Ａが徐々に押し潰され、最終的には、図１６に示すように、両側にベルト脱落防止用の突起Ｐ１、Ｐ２を設けた予備リム部Ｐが形成される。 Next, the mold 50 is rotated and the pressing roller 60 is rotated, and the rotating pressing roller 60 is gradually pressed against the outer cylinder portion 20 A of the molded body 20. As a result, the outer cylindrical portion 20A of the molded body 20 is gradually crushed in the space between the mold 50 and the pressing roller 60, and finally, as shown in FIG. The preliminary rim portion P provided with the projections P1, P2 is formed.

次に、成形体２０を金型５０に装着させた状態のまま、押圧ローラ６０に替えて、図１７に示す押圧ローラ７０を用い、これを回転させ、この回転する押圧ローラ７０を成形体２０の予備リム部Ｐに徐々に押し付ける。これにより、図１７に示すように、金型５０と押圧ローラ７０との間の空間内で成形体２０の予備リム部Ｐが徐々に押し潰され、最終的には、同図に示すように、外周面にポリＶ溝を設けたリム部Ｒが形成される。 Next, in the state in which the molded body 20 is mounted on the mold 50, the pressure roller 70 shown in FIG. 17 is used instead of the pressure roller 60, and this is rotated. Gradually press against the spare rim P. As a result, as shown in FIG. 17, the preliminary rim portion P of the molded body 20 is gradually crushed in the space between the mold 50 and the pressing roller 70, and finally, as shown in FIG. A rim portion R having a poly V groove on the outer peripheral surface is formed.

従って、本実施形態によれば、図１５に示す金型５０から突出した部分が押し潰されて変形し、外筒部２０Ａの体積（肉）部分と、連結部２０Ｃの一部の体積と、オーバハング部βの体積との合計の体積部分から、図１７に示すリム部Ｒが形成される。換言すれば、連結部２０Ｃの一部と、オーバハング部βと、外筒部２０Ａとを移動させて、これらの体積との合計体積とほぼ等しくなるような体積を有するリム部Ｒを形成して、外周面にポリＶ溝を転造成形することができる。 Therefore, according to the present embodiment, the portion protruding from the mold 50 shown in FIG. 15 is crushed and deformed, the volume (meat) portion of the outer cylindrical portion 20A, the partial volume of the connecting portion 20C, A rim portion R shown in FIG. 17 is formed from the total volume portion including the volume of the overhang portion β. In other words, a part of the connecting portion 20C, the overhang portion β, and the outer cylinder portion 20A are moved to form a rim portion R having a volume that is substantially equal to the total volume of these volumes. Poly V grooves can be formed by rolling on the outer peripheral surface.

（第４の実施形態）
次に、本発明の第４の実施形態について、説明する。第４の実施形態は、上述した第１の実施形態や第２の実施形態と同様に、最初に、半断面が略Ｕ字型のカップ体から断面が略コ字状の成形体を形成しておく。そして、図１８に示すように、金型８０の上金型８１と下金型８２との間に成形体８３をセットする。上金型８１は外型８４を備え、外型８４の間に中型８６が設けられ、同様に、下金型８２も外型８７と中型８９が備えられている。従って、上下の外型８４、８７により成形体８３の連結部９０を固定した状態でセットされている。この状態から、図１８（ａ）に示すように、下金型８２の中型８９を図でみて上方向に移動させていく。 (Fourth embodiment)
Next, a fourth embodiment of the present invention will be described. In the fourth embodiment, similarly to the first embodiment and the second embodiment described above, first, a molded body having a substantially U-shaped cross section is formed from a cup body having a substantially U-shaped half section. Keep it. Then, as shown in FIG. 18, a molded body 83 is set between the upper mold 81 and the lower mold 82 of the mold 80. The upper mold 81 includes an outer mold 84, and an intermediate mold 86 is provided between the outer molds 84. Similarly, the lower mold 82 includes an outer mold 87 and an intermediate mold 89. Therefore, the upper and lower outer molds 84 and 87 are set in a state where the connecting portion 90 of the molded body 83 is fixed. From this state, as shown in FIG. 18A, the middle mold 89 of the lower mold 82 is moved upward as viewed in the figure.

中型８９の直径Ｄは成形体８３の内筒体９１により形成される内径ｄよりも大きく、直径Ｄ−内径ｄの差がしごき量（内筒体８３の肉の移動量）となる。従って、図１８（ｂ）に示すように、中型８９により内筒体９１がしごかれ、しごかれた肉は上方向に移動させられる。所望量しごいた後、下金型８２の中型８９を内筒体９１と密着固定し、上金型８１の中型８６を下方向に移動させていく。すると、図１８（ｃ）に示すように、しごかれた肉が上金型８１の中型８６と下金型８２の中型８９により形成された空間に移動させられる結果、内筒体９１の上部から水平方向に肉が移動される。このとき、上金型８１の外型８４と中型８６との間では略直角の角度が形成されており、この角度が肉の移動時に転写され、内筒部９１の上部では略直角となっている。 The diameter D of the middle mold 89 is larger than the inner diameter d formed by the inner cylinder 91 of the molded body 83, and the difference between the diameter D and the inner diameter d is the amount of ironing (the amount of movement of the meat of the inner cylinder 83). Therefore, as shown in FIG. 18B, the inner cylinder 91 is squeezed by the middle die 89, and the squeezed meat is moved upward. After the desired amount has been squeezed, the middle mold 89 of the lower mold 82 is fixed in close contact with the inner cylinder 91, and the middle mold 86 of the upper mold 81 is moved downward. Then, as shown in FIG. 18 (c), the squeezed meat is moved to the space formed by the middle mold 86 of the upper mold 81 and the middle mold 89 of the lower mold 82, and as a result, the upper part of the inner cylindrical body 91. The meat is moved horizontally. At this time, a substantially right angle is formed between the outer mold 84 and the middle mold 86 of the upper mold 81, and this angle is transferred when the meat moves, and becomes substantially right at the upper part of the inner cylinder portion 91. Yes.

図１９には、第４の実施形態により製造された成形体にベアリングを装着した例が示されている。ベアリング９２は内筒体９１に、図で見て下方向から圧入固定され、水平部９３によりベアリング９２の抜け落ちが防止できるようになっている。また、内筒体９１と水平部９２とにより直角部９４が形成され、この直角部９４により、隙間の極小化ができ、防水機能を果たすことができ、防水カバーが不要となり、製品コストが低減できる。 FIG. 19 shows an example in which a bearing is mounted on a molded body manufactured according to the fourth embodiment. The bearing 92 is press-fitted and fixed to the inner cylinder 91 from below as seen in the figure, and the horizontal portion 93 can prevent the bearing 92 from falling off. In addition, the inner cylinder 91 and the horizontal portion 92 form a right angle portion 94. The right angle portion 94 can minimize the gap, perform a waterproof function, eliminate the need for a waterproof cover, and reduce the product cost. it can.

なお、本発明は上述した実施形態に何ら限定されるものではなく、その要旨を逸脱しない範囲において種々の形態で実施し得るものである。 The present invention is not limited to the embodiment described above, and can be implemented in various forms without departing from the gist of the present invention.

本発明のクラッチ用プーリの製造方法は、所定形状の金型間にセットしたカップ体の径の異なる同心状の円筒部の周面若しくは双方の円筒部をつなぐ連結部に金型の一部を徐々に若しくは段階的に押し込んで増肉を行うので、所望形状を容易に加工することができる。従って、カップ体の円筒部の内部に、ベアリングなどの部材を嵌合させるための溝などを切削する切削代を確保できるようになったり、両側にベルト脱落防止用の突起やポリＶ溝を設けたリム部が形成できるなどという効果を有し、オルタネータ用のプーリなどの製造方法などとして有用である。 According to the clutch pulley manufacturing method of the present invention, a part of a mold is attached to a concentric cylindrical part with different diameters of a cup body set between molds having a predetermined shape or a connecting part that connects both cylindrical parts. Since the thickening is performed by pushing in gradually or stepwise, the desired shape can be easily processed. Therefore, it becomes possible to secure a cutting allowance for cutting a groove or the like for fitting a member such as a bearing inside the cylindrical portion of the cup body, and a belt drop-off preventing projection or a poly V groove is provided on both sides. This has the effect that a rim portion can be formed, and is useful as a method for producing a pulley for an alternator.

（Ａ）〜（Ｃ）は本発明の第１の実施形態に係るクラッチ用プーリを製造するためのカップ体を製造する方法を示す工程図、（Ｄ）は製造したカップ体を示す斜視図である。(A)-(C) are process drawings which show the method of manufacturing the cup body for manufacturing the pulley for clutches concerning the 1st Embodiment of this invention, (D) is a perspective view which shows the manufactured cup body. is there. そのカップ体から第１の実施形態に係る成形体を製造するための工程図である。It is process drawing for manufacturing the molded object which concerns on 1st Embodiment from the cup body. そのカップ体かその成形体を製造するための工程図である。It is process drawing for manufacturing the cup body or the molded object. そのカップ体からその成形体を製造するための工程図である。It is process drawing for manufacturing the molded object from the cup body. そのカップ体からその成形体を製造するための工程図である。It is process drawing for manufacturing the molded object from the cup body. そのカップ体からその成形体を製造するための工程図である。It is process drawing for manufacturing the molded object from the cup body. （Ａ）は本発明の第１の実施形態に係る成形体を示す断面図、（Ｂ）はそのＡ部拡大断面図である。(A) is sectional drawing which shows the molded object which concerns on the 1st Embodiment of this invention, (B) is the A section expanded sectional view. 本発明の第１の実施形態に係る成形体を用いて製造したクラッチ用プーリを示す断面図である。It is sectional drawing which shows the pulley for clutch manufactured using the molded object which concerns on the 1st Embodiment of this invention. 本発明の第２の実施形態に係るクラッチ用プーリを製造するための成形体の製造方法を示す工程図である。It is process drawing which shows the manufacturing method of the molded object for manufacturing the pulley for clutches concerning the 2nd Embodiment of this invention. その成形体の製造方法を示す工程図である。It is process drawing which shows the manufacturing method of the molded object. その成形体の製造方法を示す工程図である。It is process drawing which shows the manufacturing method of the molded object. （Ａ）はその成形体の製造方法で製造した成形体を示す断面図、（Ｂ）はその斜視図である。(A) is sectional drawing which shows the molded object manufactured with the manufacturing method of the molded object, (B) is the perspective view. 本発明の第２の実施形態に係るクラッチ用プーリを製造するための成形体の製造方法を示す工程図である。It is process drawing which shows the manufacturing method of the molded object for manufacturing the pulley for clutches concerning the 2nd Embodiment of this invention. その成形体の製造方法を示す工程図である。It is process drawing which shows the manufacturing method of the molded object. その成形体から本発明の第３の実施形態に係るポリＶプーリを製造するための工程図である。It is process drawing for manufacturing the poly V pulley which concerns on the 3rd Embodiment of this invention from the molded object. そのポリＶプーリを製造するための工程図である。It is process drawing for manufacturing the poly V pulley. そのポリＶプーリを製造するための工程図である。It is process drawing for manufacturing the poly V pulley. 本発明の第４の実施形態に係るベアリング挿入部分の加工工程図である。It is a processing-process figure of the bearing insertion part which concerns on the 4th Embodiment of this invention. 本発明の第４の実施形態により成形された成形体にベアリングを圧入した状態を示す図である。It is a figure which shows the state which press-fit the bearing to the molded object shape | molded by the 4th Embodiment of this invention. 従来の成形法であって、円板からの成形を示した図である。It is the conventional forming method, Comprising: It is the figure which showed shaping | molding from a disc. 従来の成形法であって、リムの成形を示した図である。It is the conventional shaping | molding method, Comprising: It is the figure which showed shaping | molding of the rim | limb. 従来の成形法であって、ポリＶプーリを製造するための工程図である。It is a conventional forming method, and is a process diagram for manufacturing a poly V pulley. （Ａ）から（Ｄ）は、そのポリＶプーリのリムを製造するための工程図である。(A) to (D) are process diagrams for manufacturing the rim of the poly V pulley. 従来の他のポリＶプーリを製造するための工程図である。It is process drawing for manufacturing another conventional poly V pulley. そのポリＶプーリを製造するための工程図である。It is process drawing for manufacturing the poly V pulley. そのポリＶプーリを製造するための工程図である。It is process drawing for manufacturing the poly V pulley.

Explanation of symbols

１０カップ体
１０Ａ、２０Ａ外筒部（外方側の円筒部）
１０Ｂ、２０Ｂ内筒部（内方側の円筒部）
１０Ｃ、２０Ｃ連結部（底部）
１１板状金属素材
２０成形体
２１ベアリング
２２コイル
２３アーマチュア
３０、４０、５０金型
３０Ａ下金型
３０Ｂ上金型
３１、３５外型
３２、３３、３４内型
３２１、３３１円柱部材
３２２、３３２円筒部材
３２２Ａ凹部
３３２Ａ段部
４０Ａ、４０Ｃ下型
４０Ｂ、４０Ｄ上型
４１、４２こま部材
４１１凹部
４２１凸部
４１３外周縁面
４２２逃げ穴
４２３段部
５１Ａ、５４Ａ、６１Ａ、６３Ａ、６３Ｂ窪み
６０、７０押圧ローラ
Ｃ中心線
Ｐ予備リム部
Ｒリム部
α 第１増肉部
β 第２増肉部
γ 第３増肉部（オーバハング部） 10 cup body 10A, 20A outer cylinder part (outer cylindrical part)
10B, 20B Inner tube (inner cylinder)
10C, 20C connecting part (bottom part)
DESCRIPTION OF SYMBOLS 11 Plate-shaped metal material 20 Molded body 21 Bearing 22 Coil 23 Armature 30, 40, 50 Mold 30A Lower mold 30B Upper mold 31, 35 Outer mold 32, 33, 34 Inner mold 321, 331 Cylindrical member 322, 332 Cylinder Member 322A Concave part 332A Step part 40A, 40C Lower mold 40B, 40D Upper mold 41, 42 Top member 411 Concave part 421 Convex part 413 Outer peripheral surface 422 Relief hole 423 Step part 51A, 54A, 61A, 63A, 63B Depression 60, 70 Press Roller C Center line P Preliminary rim part R Rim part α First thickened part β Second thickened part γ Third thickened part (overhang part)

Claims

A manufacturing method of a clutch pulley for processing a metal flat steel plate to form a cup body in which concentric cylindrical portions having different diameters are connected by a connecting portion, and manufacturing a clutch pulley from the cup body,
The cup body is set between molds of a predetermined shape, and a part of the mold is pushed into the cylindrical part of the cup body gradually or stepwise to increase the thickness of the cylindrical part or the connecting part. A method for producing a clutch pulley, comprising:

A manufacturing method of a clutch pulley for processing a metal flat steel plate to form a cup body in which concentric cylindrical portions having different diameters are connected by a connecting portion, and manufacturing a clutch pulley from the cup body,
Set the cup body between molds of a predetermined shape,
A concave portion having a substantially conical shape recessed toward the central portion and a relief hole in the central portion of the concave portion, and the surface of the concave portion is partly connected to the coupling portion of the cup body by performing a swing motion, or The connecting member of the cup body is gradually and partially pressed by a member that constitutes a part of the mold that abuts in a stepwise manner, and the partial pressing portion of the connecting member is surrounded by the periphery. A method of manufacturing a clutch pulley, wherein the cylindrical portion or the connecting portion of the cup body is thickened by sequentially shifting in the direction.

The thickened portion includes a fitting portion with a bearing of an inner cylindrical portion of the cup body, a peripheral portion near the inner cylindrical portion of the connecting portion, and an outer cylindrical portion near the connecting portion. The method for manufacturing a clutch pulley according to claim 1, wherein the clutch pulley is any one of overhang portions corresponding to a peripheral edge portion of the clutch.

When the cup body is pressed between a part of the molds, a portion near the cylindrical part on the outer side of the connecting part enters a retreating part where the mold is retracted, so that a protrusion is formed. After forming
By gradually approaching the upper mold and the lower mold, the flesh of the protruding part of the connecting part and the flesh of the cylindrical part on the outer side are moved, and the volume of the cylindrical part on the outer side is Forming a rim having a volume that is substantially equal to the total volume of the protrusions;
The manufacturing method of the pulley for clutches of any one of Claims 1-3 which roll-molds a some groove | channel on the said outer peripheral surface.

The inner peripheral surface of the inner cylindrical portion of the cup body is squeezed with a lower mold of the mold, and the squeezed meat is formed with a top mold and a lower mold of the mold to form a substantially perpendicular horizontal portion. Item 5. A method for producing a clutch pulley according to any one of Items 1 to 4.