JP2009061503A - Metal parts manufacturing method, core metal, and injection gear - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve a problem that the working man-hour is increased in the cold forging because the intermediate annealing, the lubrication or the like are necessary in the forming process, the works are intermittent, the production takes time, and the cost of a metal parts to be manufactured is increased. <P>SOLUTION: In a metal parts manufacturing method, a metal material is automatically transferred by an automatic-transfer type press machine so as to be subjected to various kinds of press workings such as drawing, burring and folding; and a worked portion of the metal material projected by the press working is squeezed by the pressure, or overlapped on other portion of the metal material by the folding, or shifted to other portion of the metal material by the compression to form a thickness-increased part. A resin-made locking part of various kinds of shapes such as a hole, a recess, a projection, an unevenness, a gear, a cutout and a rising piece can be formed in a resin-covered part in the metal material by the press working. In a case that the metal material is a blank, the metal material can be transferred to the press machine without any change, and subjected to the subsequent press working. In a case that metal material is a coil material wound in a roll, the metal material is blanked into a blank of a predetermined shape such as a disk and a plate, and the blank is transferred to the press machine for press working. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing metal parts having various uses and various shapes, for example, core metal for injection gears by press working with an automatic transfer press, and the core metal and injection gear manufactured by the manufacturing method. .

  An injection gear is incorporated in a pinion type electric power steering of an automobile. In the injection gear, a resin gear B is coated and formed on the outer periphery of a metal core metal A shown in FIGS. 9A and 9B as shown in FIGS. In the core metal A, both front and back surfaces of the peripheral edge portion D of the shaft hole C and the outer peripheral portion E are thick, and a large number of concave and convex protrusions F are formed on the entire outer periphery of the outer peripheral portion E. The uneven projection F is for preventing the resin gear B from slipping or misaligned by the resin gear B coated and molded by a molding method such as injection molding on the outside thereof. .

  Conventional core metal for injection gears is formed by cold forging. Cold forging requires intermediate annealing, lubrication, and the like in the forming process, which increases the number of work steps, interrupts the work, takes time for production, and increases the cost of manufactured metal parts.

The metal part manufacturing method of the present invention comprises a drawing process, a burring process, while a metal material is automatically transferred by a transfer processing type, robot processing type or other automatic transfer type press (hereinafter simply referred to as “pressing machine”). Various pressing processes such as bending are performed, and the processed part of the metal material protruding by pressing is crushed by pressure, overlapped with other parts of the metal material by bending, or other metal material by compression This is a manufacturing method in which thickened portions are formed on both front and back sides of a metal material . In this case, the metal material is drawn and protruded, the protruding portion is burring processed to open a pilot hole and the peripheral edge of the pilot hole protrudes into a cylindrical shape, and the protruding peripheral edge of the protrusion is crushed by pressure, Alternatively, the front and back both sides of the peripheral edge of the pilot hole can be increased in thickness by being overlapped with other portions of the metal material by bending or being brought together with other portions of the metal material by compression. The outer peripheral edge of the metal material is protruded by drawing or bending, and the protruded outer peripheral edge is crushed by pressure, overlapped with other parts of the metal material by bending, or other metal material by compression It is also possible to form thickened portions on both the front and back sides of the metal material by bringing them together. Various shapes of resin locking portions such as holes, dents, protrusions, irregularities, gears, notches, cut-and-raised pieces, etc. can be formed by pressing in resin-covered portions of the metal material. In these manufacturing methods, when the metal material supplied to the press machine is a blank material, it can be transferred to the press machine as it is for subsequent press processing, but in the case of a coil material wound in a roll, it is a disc. After blanking into a blank material having a predetermined shape such as a plate shape or a plate shape, the blank material can be transferred to a press machine and pressed.

The core metal of the present invention performs various pressing processes such as drawing, burring, and bending while automatically transferring the metal material by a press machine, and pressurizing the processed portion of the metal material protruding by the pressing process. A shaft hole with a thick peripheral edge is formed by crushing and increasing the thickness on both sides of the metal material. In this case, the resin locking portion can be formed by press working on the resin-coated portion on the outer peripheral portion of the metal material. According to the metal part manufacturing method of the present invention, a part of the disk-shaped metal material (the central part and the outer peripheral part) is projected by drawing, and a pilot hole is made in the protruding part and a cylindrical shape is formed in the pilot hole peripheral part of the pilot hole. The flange is crushed by pressure , the front and back both sides of the metal material are thickened to form a thick peripheral shaft hole, and the outer peripheral portion is crushed by pressure, Alternatively, the upper end side of the outer peripheral portion is overlapped with the outer peripheral portion or the end side by bending to increase the thickness, and a resin locking portion is formed at the resin-coated portion of the metal material.

  In the injection gear of the present invention, the resin gear is coated on the resin coated portion and the outer peripheral edge of the core metal manufactured by the metal part manufacturing method of the present invention, and the resin gear is formed on the resin locking portion of the resin coated portion. It is locked and fixed.

The metal part manufacturing method of the present invention has the following effects.
(1) Unlike cold forging, there is no need for intermediate annealing or lubrication during production, and metal materials are automatically transferred by a press machine and can be continuously formed until completion of metal parts. The cost of manufactured metal parts is reduced.
(2) The part protruded by drawing or bending is crushed by pressing, overlapped with other parts of the metal material by bending, or brought together with other parts of the metal material by compression. Therefore, even a thin metal material can be partially thickened to form a metal part having a thick portion.
(3) Since the resin locking part is formed by press working, a resin locking part having a shape and structure in which the resin can be easily locked, such as holes, notches, and cut-and-raised pieces that could not be formed by cold forging, is formed. Therefore, it is suitable for manufacturing core metals for injection gears.
(4) Since the molding is performed by pressing, it is possible to reduce the weight of the metal part by making a hole in the metal material or cutting a part of the metal material.
(5) In order to mass-produce by cold forging, it is necessary to prepare a large number of molds with the same shape and structure, or to prepare a mold for taking a large number of molds. However, in the manufacturing method of the present invention by press working, such a variation is difficult to occur and the product dimensions are stabilized.

  The core metal of the present invention is inexpensive because it is manufactured by the metal part manufacturing method of the present invention, and includes a resin locking portion having a shape and structure that is difficult to form by cold forging.

  In the injection gear of the present invention, since the resin injection gear is coated on the core metal provided with the resin locking portion having a shape that is difficult to form by cold forging, the locking and fixing of the injection gear to the core metal is stable. In addition, rattling and displacement of the injection gear are prevented.

(Embodiment 1 of metal part manufacturing method)
There are various embodiments of the metal part manufacturing method of the present invention. FIG. 1 shows an example of the case where the metal part to be manufactured is a core metal for an injection gear, and is an example in which a disk-shaped blank material is manufactured while being automatically transferred by a transfer press. . The processing steps will be described below.
(1) The blanked flat disk-shaped metal material 1 (FIG. 1 (1)) is supplied to the press machine, and in the first draw process (FIG. 1 (2)) of the press machine, The center part 2 is squeezed out to the surface side (upper side in the figure) of the metal material 1 and transferred to the next process when the squeezing is completed.
(2) In the second draw process (FIG. 1 (3)) of the press machine, the outer peripheral edge 3 of the metal material 1 is squeezed and protruded to the surface side (upper side in the figure) of the metal material 1. In this case, as shown in FIG. 3 (a), the lower portion 3a of the protruding outer peripheral edge 3 is slanted so that the upper portion 3b rises vertically, or the lower portion 3a to the upper portion 3b as shown in FIG. 3 (c). It can also be squeezed to stand up vertically.
(3) In the edge forming step (FIG. 1 (4)) of the press machine, the outer peripheral edge 3 in FIG. In this case, as shown in FIG. 3B, the thick edge 4 is arranged such that the inner lower end portion 4a that spreads at the bottom is aligned with the inner lower end portion 3c of the outer peripheral edge portion 3 (FIG. 3A). As shown in FIG. 3 (c), the protruding outer peripheral edge 3 can be bent at the upper part 3a inward to form a thick edge 4 that spreads at the bottom. In this case, the thick edge 4 has an inner lower end 4a (FIG. 3 (d)) that spreads out from the inner lower end 3a (FIG. 3 (c)) of the outer peripheral edge 3 before bending.
(4) In the piercing process of the press machine (FIG. 1 (5)), a small hole 5 is formed in the central portion 2 of the metal material 1 that has been squeezed out first.
(5) In the burring process of the press machine (FIG. 1 (6)), the small hole 5 of the metal material 1 is enlarged to open the pilot hole 6, and the peripheral edge of the pilot hole is extruded to the front side of the metal material 1 in a cylindrical shape. The flange 7 is formed.
(6) In the molding process of the press machine (FIG. 1 (7)), the flange 7 is crushed by pressurization to increase the peripheral edge 8 of the pilot hole 6, and the pilot hole 6 is turned into a shaft hole. The thickening process can be performed as shown in FIG. In FIG. 2, the pilot hole 6 of the metal material 1 subjected to burring is placed on a receiving base 10 by covering the die 9 with a round bar shape, and a ring-shaped regulation base 11 is arranged on the outer periphery of the metal material 1, and the punch 16 Thus, the flange 7 of the metal material 1 is pressed and crushed. Since the pressurized flange 7 is restricted from being laterally spread by the restriction table 11, the peripheral edge 8 of the prepared hole is increased in thickness. Reference numeral 17 in FIG. 2 denotes a clearance hole for the tip side of the die 9 to enter when the punch 16 is lowered.
(7) In the gear (resin locking portion) forming step (FIG. 1 (8)) of the press machine, the uneven gear (resin locking portion) 12 is formed on the entire outer periphery of the thick outer peripheral edge portion 4. This resin latching | locking part 12 is a shape shown to Fig.4 (a), (b), Fig.9 (a), (b). The resin latching portion 12 is not limited to this shape, and may have other shapes. Other shapes will be described later.
(8) In the trim processing step (FIG. 1 (9)) of the press machine, the outer side 13 of the outer peripheral edge 4 of the metal material 1 is cut and removed (bordered) into a ring shape to set the outer diameter of the inner metal part 14 to a predetermined value. Make dimensions.

  The disk-shaped metal part (core metal) 14 press-molded as described above is taken out of the press machine, and the upper edge 15 of the inner peripheral surface of the prepared hole is cut (chamfered) into a R surface by another machine. This chamfering process can also be performed by the press machine. This chamfering process can also be performed after resin molding described later.

  A resin gear 15 is formed by coating the outer peripheral portion of the disk-shaped core metal 14 processed as described above with resin as shown in FIGS. As a molding method of the resin gear 15, there is, for example, injection molding or other methods.

(Embodiment 2 of metal parts manufacturing method)
Another embodiment of the metal part manufacturing method of the present invention is shown in FIG. Although this embodiment is also a case where the core metal for injection gears is manufactured using a press machine, it is the case of Embodiment 1 in using the coil material wound in roll shape instead of the blank material as a metal material. And different. Details will be described below.
(1) A coil material wound in a roll shape (FIG. 5 (1)) is continuously supplied to the press machine by a coil material supply mechanism (not shown) provided at the front stage of the press machine.
(2) The supplied coil material is blanked by a blanking mechanism (not shown) to obtain a disk-shaped blank material (metal material) 1 (FIG. 5 (1)). The blank 1 is sequentially transferred to the next processing step by the transfer mechanism of the press.
(3) In the first draw process of the press machine (FIG. 5 (2)), the central portion 2 of the metal material 1 is squeezed out to the surface side of the metal material 1.
(4) The squeezed part is secondarily squeezed to increase the squeeze height in the second draw process (FIG. 5 (3)) of the press machine.
(5) The portion extracted in the second draw step is subjected to third drawing in the third draw step (FIG. 5 (4)) of the press machine to make the outer shape of the squeezed portion thinner.
(6) In the piercing step of the press machine (hole punching step: (FIG. 5 (5))), a small hole 5 is formed at the top of the previously narrowed portion.
(7) In the burring process (FIG. 5 (6)) of the press machine, burring is performed to enlarge the small hole 5 of the metal material 1 to form the pilot hole 6, and the cylindrical peripheral portion 8 of the pilot hole is projected The flange 7 is formed. At the same time, the outer peripheral portion 3 of the metal material 1 is drawn to squeeze the outer peripheral portion 3 in the same direction as the flange 7.
(8) In the molding process of the press machine (FIG. 5 (7)), the flange 7 is pressed and crushed to increase the thickness, and the peripheral edge 8 of the pilot hole is molded to have a thickened inner hem. Also in this case, it can be molded using a mold as shown in FIG. Simultaneously with the pressurization, the outer peripheral edge portion 3 is also crushed by the pressurization to increase the thickness, thereby forming a thick edge 4 that spreads at the bottom. Also in this case, the thick edge 4 can be bent inward to increase the thickness.
(9) In the gear forming step of the press machine (FIG. 5 (8)), the uneven gear 12 is formed on the entire outer periphery of the thick edge 4 as shown in FIG.
(10) In the trim processing step of the press machine (FIG. 5 (9)), the outer portion 13 of the outer peripheral edge 3 is cut (bordered) into a ring shape, and the outer diameter of the disk-shaped core metal 14 remaining inside is predetermined. Make dimensions.

(Embodiment 1 of core metal)
The core metal of FIGS. 9A and 9B has a gear-shaped resin locking portion, but the resin locking portion of the core metal of the present invention may have other shapes. 6 (a) to 6 (d) as an example thereof, a round hole 20 and an elongated hole 21 are formed in the outer peripheral portion of the disk-shaped metal material 1 with a press machine, and the outer peripheral portion is drawn and processed. Protruding to the surface side of the raw material 1, crushing the outer peripheral part by pressurization to form the thick edge 4, forming the round hole 20 and the vertically long hole 21 as the resin locking part 12, and covering resin into these holes It flows in and is locked and fixed. The resin locking holes may be all round holes or vertically long holes. It may be a square hole or other shaped hole. Instead of a hole, it may be a depression, unevenness or notch, a cut-and-raised piece 23 as shown in FIGS.

(Embodiment 2 of core metal)
7 (c) and 7 (d), a raised piece 23 is formed on the outer periphery of a disk-shaped metal material 1 by forming a convex piece 24 (FIGS. 7 (a) and (b)). It can be formed by projecting slightly from the inside to the surface side of the metal material 1 by drawing or bending, and crushing the convex pieces 24 by pressing to form a thick wall. The cut-and-raised piece 23 becomes the resin locking portion 12, and the resin gear is locked and fixed thereto.

(Embodiment 3 of core metal)
7C and 7D are all protruded in the same direction (surface side of the metal material), but can also be protruded on both the front and back sides of the disk-shaped metal material 1. In any case, many of the cutting pieces 23 do not have to have the same shape, the same size, and the same protruding length, and can have different shapes, sizes, and protruding lengths.

  The metal parts and core metal of the present invention are not limited to disk-like ones, but may be other desired shapes. The size, structure, molding position, thickness, shape, length, etc. of the thickened portion are shown in the figure. It can be molded even if it is not.

(Embodiment of injection gear)
As an example of the injection gear of the present invention, the one shown in FIG. 8 is formed by coating the resin gear B from the outer periphery to the outside of the core metal shown in FIG. It is fixed to the resin locking part 12 by the vertically long hole 21. Gear grooves G are formed on the outer peripheral surface of the resin gear B at uniform intervals as shown in FIGS.

  The metal part manufacturing method of the present invention can manufacture metal parts of various shapes, structures, and sizes used in other fields.

Explanatory drawing of an example of the manufacturing process of the metal component manufacturing method of this invention. Explanatory drawing which shows an example of the cylindrical part pressurization method in the metal component manufacturing method of this invention. (A)-(d) is explanatory drawing which shows two examples of the method of crushing the outer-periphery edge part by pressurization in the metal component manufacturing method of this invention. (A) is a top view which shows an example of the core metal manufactured with the metal component manufacturing method of this invention, (b) is sectional drawing of the core metal. Explanatory drawing of the other example of the manufacturing process of the metal component manufacturing method of this invention. (A)-(d) is explanatory drawing which shows an example of the processing method of the resin latching | locking part of the core metal shape | molded with the metal component manufacturing method of this invention. (A)-(d) is explanatory drawing which shows the other example of the processing method of the resin latching | locking part of the core metal shape | molded with the metal component manufacturing method of this invention. Sectional drawing which shows an example of the core metal for injection gears which coat | covered the resin-made gears with the core metal of this invention. (A) is the surface side perspective view which shows an example of the core metal for conventional injection gears, (b) is a back surface side perspective view of the core metal. (A) is the surface side perspective view which shows an example of the conventional injection gear, (b) is the back surface side perspective view of the gear.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Metal material 2 Center part of metal material 3 Outer peripheral edge part 3a Lower part of outer peripheral part 3b Upper part of outer peripheral part 3c Inner lower end part of outer peripheral part 4 Thick edge 4a Inner lower end part of thick edge 5 Small Hole 6 Pilot hole 7 Flange 8 Pilot hole peripheral part 9 Die 10 Receiving base 11 Restricting base 12 Uneven gear (resin locking part)
13 Outer peripheral portion of metal material 14 Metal part (core metal)
15 Punch 17 Escape hole 20 Round hole 21 Vertically long hole 23 Cut and raised piece 24 Convex piece A Core metal B Resin gear C Shaft hole D Peripheral part E Outer part F Convex protrusion G Gear groove

Claims (9)

Various pressing processes such as drawing, burring, and bending are performed while the metal material is automatically transferred by a press machine, and the processed part of the metal material protruding by pressing is crushed by pressure or bent. A method of manufacturing a metal part, characterized in that a thickened portion is formed on both the front and back sides of the metal material by overlapping with the other portion of the metal material or by bringing the metal material into contact with another portion of the metal material by compression. 2. The metal part manufacturing method according to claim 1, wherein the metal material is drawn and protruded, the protruding portion is burred to form a pilot hole, and the pilot hole periphery is protruded into a cylindrical shape, and the protruding pilot hole peripheral part is projected. Crushing by pressing, or by overlapping with other parts of the metal material by bending, or by bringing it together with other parts of the metal material by compression, forming thickened portions on both front and back sides of the peripheral edge of the pilot hole A metal part manufacturing method characterized by the above. 3. The metal part manufacturing method according to claim 1, wherein the outer peripheral edge of the metal material is protruded by drawing or bending, and the protruded outer peripheral edge is crushed by pressurization or bent. A method of manufacturing a metal part, characterized in that a thickened portion is formed on both the front and back sides of the metal material by being overlapped with other portions or brought together with other portions of the metal material by compression.   The metal part manufacturing method according to any one of claims 1 to 3, wherein a resin member such as a hole, a dent, a protrusion, an unevenness, a gear, a notch, and a cut-and-raised piece is formed by pressing a resin-coated portion of a metal material. A metal part manufacturing method comprising forming a stop.   5. The metal part manufacturing method according to claim 1, wherein the metal material supplied to the press machine is a blank material or a coil material wound in a roll shape. A metal part manufacturing method comprising: transferring, blanking a blank material having a predetermined shape in the case of a coil material, transferring the blank material to a press machine, and pressing the blank material. Various pressing processes such as drawing, burring, and bending are performed while the metal material is automatically transferred by a press, and the metal material projecting by pressing is crushed by pressurization. A core metal characterized by thickened shaft holes on the front and back sides and thick wall edges. 7. The metal part according to claim 6, wherein a resin locking portion is formed by press working at a resin-coated portion on the outer peripheral portion of the metal material. A metal part manufacturing method according to any one of claims 1 to 5, wherein a part of a disk-shaped metal material is squeezed out and protruded, a pilot hole is made in the protruding part, and the peripheral part of the pilot hole is cylindrical. The peripheral edge of the prepared hole is crushed by pressing to increase the thickness on both front and back sides of the metal material, forming a shaft hole with a thick peripheral edge, and pressing the resin-coated part on the outer periphery of the metal material A core metal characterized in that a resin locking part is formed by processing.   9. An injection gear comprising: a resin-coated portion of the core metal according to claim 8; and a resin gear which is formed by covering the outer peripheral edge of the core metal, and the resin gear is locked and fixed to a resin locking portion of the resin-coated portion. .

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