JP2012086227A - Method for manufacturing washer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a washer, which can manufacture a washer having preferable mechanical property, and by which forging facilities can be used for a long time.SOLUTION: The method for manufacturing a washer includes the steps of: cutting a wire rod 4 at a required length dimension to form it into a blank 41; forming the blank into a raw-shape blank 42 having a larger diameter and smaller thickness than the blank 41 by a first forging device 31; forming the raw-shape blank into a proto-washer 43 having a larger diameter than the raw-shape blank 42 by a second forging device 32; and punching a hole 51 in the proto-washer 43 by a third forging device 33 to manufacture a product washer 5.

Description

  The present invention relates to a method for manufacturing a washer.

  FIG. 10 schematically shows a first example of a conventional manufacturing method for manufacturing a plurality of annular flat washers 11 by punching from a single metal plate 1. In this method, the original washer 11a is punched from the metal plate 1 having a predetermined thickness with a puncher (not shown) to make the washer 11. However, the entire metal plate 1 cannot be used, and a lot of wasted material is generated. There is a problem. Furthermore, there is a risk of burring on the periphery of the punched washer 11, and there is a risk of injury, and the mechanical strength of the washer 11 manufactured by this method is low, so the quality as a product is poor.

  In FIG. 11, the outline | summary of the 2nd manufacturing method of the prior art example which manufactures a washer is shown. This is a washer having a required thickness from the strip wire 22 through cold forging using a forging facility 21 having a hollow feeding device 211, a clamping device 212, a hollow female die 213, and a male die 215 with a punch 214. 23, the wire 22 is supplied by the feeding device 211, and the wire 22 sent from the feeding device 211 is clamped and transferred to the female mold 213 by the clamping device 212. The feeding step (a) in which the wire 22 is exposed to a required length from the female mold 213 and the clamping section 221 in the female mold 213, and the male 22 so as to be close to the female mold 213. The die 215 is moved, the forging step (b) for forming the original washer 223 having the required thickness and shape by forging the discharge part 222 of the wire rod 22, and the punch 214 to open the hole of the washer Punch out the center. Next, the punch 214 is further moved to press the clamping part 221 of the wire rod 22 to separate the original washer 223 from the clamping part 221, and the male mold 215 is moved away from the female mold 213. And taking out the washer 23 to return to the original position (d).

  In the second conventional manufacturing method example, a plurality of washers can be manufactured from one wire 22 by repeatedly performing steps (a) to (d) a plurality of times through cold forging. The discharge portion 222 is press-molded into an annular short column shape only from the steps (a) to (b) to produce the annular flat original washer 223. Therefore, the deformation amount of the wire rod is large, and the machine of the washer 23 to be molded is formed. There is a problem that deteriorates the characteristics. Further, since the clamping device 212 and the feeding device 211 directly perform cold forging and punching with respect to the discharge portion 222 and the clamping portion 221 of the wire 22 connected with the clamping portion 221 held therebetween, the clamping device 212 and the feeding device 211 has a problem that the force applied from the punch 214 is absorbed by the pinching portion 221 and receives friction from the pinching portion 221, so that the clamping device 212 and the feeding device 211 are worn and broken. Further, in the punching step (c), the punch 214 is punched into the discharge part 222 so as to manufacture the washer 23, and at the same time the clamping part 221 is pushed downward, so that a large pressing force The service life of the female mold 213, the male mold 215, and the clamp device 212 is shortened. For this reason, there is a problem in that the clamping accuracy is affected, a product with good quality cannot be obtained, and the manufacturing cost increases. In addition, stopping the forging facility 21 in order to perform repairs or replacement of parts so as to increase the accuracy causes a problem that manufacturing efficiency is lowered and productivity is poor.

  The present invention has been made in view of the above problems, and one object thereof is to provide a washer manufacturing method capable of manufacturing a washer having good mechanical properties.

  Another object of the present invention is to provide a method of manufacturing a washer that can use a forging facility for a long time.

  In order to achieve the above object, the present invention is a rough molding in which a blank is larger in diameter and thinner than a blank by a step of cutting a wire into a required length and molding it into a blank and a first forging means. A step of forming into a blank, a step of forming a rough formed blank into an original washer having a diameter larger than that of the rough formed blank by the second forging means, and a punched product washer by punching out the original washer by the third forging means. And a washer manufacturing method characterized by comprising the steps of:

  In the method of the present invention, it is preferable that alignment marks are respectively provided on both surfaces of the rough molding blank opposite to each other by the second forging means.

  In the method of the present invention, the rough molding blank has the first large diameter portion, the first small diameter portion having a smaller diameter than the first large diameter portion, and the first large diameter portion between the first large diameter portion and the first small diameter portion. And an inclined neck portion having a small diameter from the portion to the first small diameter portion.

  In the method of the present invention, it is preferable that the prototype washer has a thin central portion and an outer peripheral portion thicker than the central portion, and alignment marks are provided on both sides of the central portion opposite to each other. .

  In the method of the present invention, it is preferable that a recessed central portion is formed on both surfaces of the original washer.

  In the method of the present invention, it is preferable that the original washer is further formed by protruding an intermediate protruding portion from the central portion.

  In the method of the present invention, it is preferable that the method further includes a step of turning over the rough blank before forging by the second forging means.

  In the method of the present invention, the blank cut from the wire rod before forging by the first forging means is not shaped by the trim device into a rounded portion rounded around one side of the square and the other side 2. It is preferable to further include a trimming step of trimming a trim blank having a certain shape with two ridges.

  In the method of the present invention, it is preferable that the method further includes a step of turning over a blank having a predetermined shape before forging by the first forging means.

  According to the method for producing a washer of the present invention, the blank 41 is first roughened before the original washer is obtained by performing the step of forging the rough formed blank between the step of obtaining the blank and the step of forging the original washer. Since it is formed into a molding blank, the deformation rate of the product can be greatly reduced. Therefore, the mechanical characteristics and product quality of the washer can be greatly improved. Further, according to the method of the present invention, it is possible to easily control the roundness and thickness dimension of the washer in an even manner as compared with the conventional method using only one forging. Furthermore, since the washer is manufactured by each of the first to third forging means independently of the blank cut to the required size, it is based on forging as compared with the conventional method using only one forging. The impact force can be reduced by dispersing two or more times. Therefore, damage and wear of the mold and the crank device can be greatly reduced, and the forging equipment can be used for a long time.

It is a figure which shows a series of processes in Example 1 of the manufacturing method of the washer which concerns on this invention. It is a figure which shows the process in which a washer is manufactured from a blank in a series of processes. It is a figure which shows the process of shape | molding a rough molding blank from a blank by the 1st forging means. It is a figure which shows the process of shape | molding an original washer from a rough-formed blank by a 2nd forging means. It is a figure which shows the process of shape | molding a product washer from a prototype washer by the 3rd forging means. It is a figure which shows that a washer is manufactured from a blank in a series of processes in Example 2 of the manufacturing method of a washer according to the present invention. It is a figure which shows the trim process which arranges the blank cut | disconnected from the wire to the blank with a predetermined shape with a trim apparatus, before forging with a 1st forging means. It is a figure which shows the process of shape | molding a rough shaping | molding blank from the blank arranged in the predetermined shape by the 1st forging means. It is a figure which shows that a washer is manufactured from a blank in a series of processes in Example 3 of the manufacturing method of a washer according to the present invention. It is a figure which shows roughly an example of the method of manufacturing the conventional washer. It is a figure which shows the other example of the method of manufacturing the conventional washer.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, about the component which has the same structure and function, the same number is attached | subjected and the overlapping description is abbreviate | omitted.

  1-5 shows Example 1 of the manufacturing method of the washer based on this invention. In this method, the washer 5 is manufactured by pressing from the wire 4 by using the forging equipment 3. The forging facility 3 includes first forging means 31, second forging means 32, and third forging means 33. The first forging means 31 has a female die 312 in which a molding cavity 311 is formed and a male die 314 in which a punch rod 313 is provided. The second forging means 32 has a female die 322 provided with a molding cavity 321 and a male die 324 provided with a punch rod 323. The third forging means 33 has a female die 332 provided with a through hole 331 and a male die 334 provided with a punch rod 333. The method for manufacturing the washer 5 includes the following steps.

  In a 1st process, the wire 4 is selected according to the required material and dimension of a product washer, and the wire rod roll which wound the wire 4 in coil shape beforehand is prepared.

  In the second step, the wire 4 is linearly drawn by a feeding device (not shown) and fed to the forging facility 3 side. When the wire rod 4 is sent to a cutting device (not shown), the wire rod 4 is cut into a required length by the cutting device, and the cut wire rod 4 is sent to the forging facility 3 and formed into a cylindrical blank 41. As shown in FIG. 2, the thickness of the blank 41 is determined according to the required dimensions of the washer 5 as a product.

  In the third step, as shown in FIGS. 2 and 3, the blank 41 is sent out to the first forging means 31 by a feeding device (not shown) and installed in the molding cavity 311 of the female die 312. Next, the male die 314 is driven to move toward the female die 312, and the punch rod 313 protrudes to perform initial forging on the blank 41 in the molding cavity 311. As a result, a rough molding blank 42 having a diameter larger than that of the blank 41 and a small thickness is obtained. In this embodiment, the rough molding blank 42 includes a first large diameter portion 421, a first small diameter portion 423 having a smaller diameter than the first large diameter portion 421, and between the first large diameter portion 421 and the first small diameter portion 423. And an inclined neck portion 422 having a small diameter from the first large diameter portion 421 to the first small diameter portion 423. In order to facilitate alignment in the next step, alignment marks 424 and 425 that are recessed at the centers of the surface of the first large diameter portion 421 and the surface of the first small diameter portion 423 are provided concentrically. These alignment marks 424 and 425 can be provided on the rough molding blank 42 by previously providing small projections on the male mold 314 and the female mold 312 in advance. Then, the male mold 314 is driven to move away from the female mold 312, and the rough molding blank 42 is taken out from the female mold 312.

  In the fourth step, as shown in FIGS. 2 and 4, the rough molding blank 42 taken out from the female die 312 is turned over by a feeding device (not shown) and sent to the second forging means 32. The rough molding blank 42 turned over is placed in the molding cavity 321 so that a part thereof protrudes from the female mold 321. The male die 324 is driven so as to move to the female die 322 side, the punch rod 323 is protruded, and the rough forming blank 42 is punched and forged. As a result, a disc-shaped original washer 43 having a larger diameter and a smaller thickness than the rough molding blank 42 is formed. This prototype washer 43 has a thin central part 433 and an outer peripheral part 431 thicker than the central part 433, and alignment marks 424 and 425 are provided on both sides of the central part 433 opposite to each other. Yes. This facilitates alignment in the next step. Then, when the second male mold 324 is driven to move away from the second female mold 322, the original washer 43 is taken out from the second female mold 322.

  In the fifth step, as shown in FIGS. 2 and 5, after the fourth step, the original washer 43 is fed to the third forging means 33 by a feeding device (not shown), and the through hole 331 of the third female die 332 is sent. The original washer 43 is disposed on the surface of the male die 334 so that the central portion 433 of the original washer 43 corresponds to the through hole 331. When the third male mold 334 is driven and moved to the third female mold 332 side, the punch rod 333 is protruded and the central portion 433 of the original washer 43 is punched out. At this time, the central portion 433 is dropped into the through-hole 331, and the washer 5 having the hole 51 is formed. In this form, it is manufactured as a flat, annular flat washer. When the male mold 334 is driven and moved away from the female mold 332, the washer 5 is taken out from the third forging means 33.

  A plurality of washers 5 can be continuously manufactured by repeating the first to fifth steps a plurality of times.

  FIGS. 6-8 shows Example 2 of the manufacturing method of the washer based on this invention. This method is similar to the method of the first embodiment, but before the forging by the first forging means 31, the blank 41 cut from the wire rod is shaped into a predetermined shape by a trimming device 34. A trim step for trimming the trim blank 41A. The trim device 34 includes a female die 342 provided with a molding cavity 341 and a male die 344 provided with a punch rod 343.

  In the trimming process, the blank 41 is sent to the trim device 34 and installed in the molding cavity 341 of the female die 342. When the male die 344 is driven and moves closer to the female die 342 side, the punch rod 343 is protruded to punch the blank 41, and at the same time, the burr is removed by adjusting to a predetermined shape in the molding cavity 341. The trim blank 41 </ b> A has a rounded portion 411 rounded around the corner of one surface (the lower surface in FIG. 6) and two ridge corner portions 412 that are not shaped on the other surface (the upper surface in FIG. 6).

  When the male mold 344 is driven and moves away from the female mold 342, the trim blank 41A is taken out from the female mold 342. Next, an initial forging process is performed by the first forging means 31.

  In the initial forging step, the trim blank 41 </ b> A is turned over by a feeding device (not shown) and sent to the first forging means 31. A rough blank 42 is formed by the first forging means 31 in the same manner as in the first embodiment. In the same manner as in the first embodiment, the rough molding blank 42 is formed on the original washer 43, and finally the product washer 5 is manufactured.

  In this embodiment, when a trim blank 41A having a predetermined shape is obtained by performing a process of adjusting the blank 41 cut into a predetermined dimension into a predetermined shape, the product is ready in a subsequent forging process. There is an advantage that the outer shape can be maintained. Further, by performing the trimming process between the process of obtaining the blank 41 and the initial forging process, the deformation rate of the material can be reduced, so that the mechanical characteristics of the washer 5 can be improved.

  FIG. 9 shows a third embodiment of the method for manufacturing a washer according to the present invention. This method is similar to the method of the first embodiment, except that the structure of the female die of the second forging means (not shown in FIG. 9) is changed.

  When the rough molding blank 42 is sent to the second forging means, the original washer 43 is formed. In this embodiment, an intermediate protrusion 435 is further formed on the lower surface portion of the central portion 433 of the prototype washer 43 in FIG. The alignment marks 424 and 425 are formed on the upper surface portion of the central portion 433 and the intermediate protrusion portion 435, respectively. Next, when the original washer 43 is sent to the third forging means (not shown in FIG. 9), the central washer 433 and the intermediate protrusion 435 of the original washer 43 are punched out by the third forging means, and the washer 5 with the hole 51 opened. Is manufactured.

  In this embodiment, the intermediate protrusion 435 is formed below the central portion 433 of the original washer 43, so that the clamping device (not shown) can stably hold and transfer the original washer 43. It is like that.

  From the above description, by performing the process of forging the rough molding blank 42 between the process of obtaining the blank 41 and the process of forging the original washer 43, the blank 41 is firstly rough-formed blank before the original washer 43 is obtained. 42, the deformation rate of the product can be greatly reduced. Therefore, the mechanical characteristics of the washer 5 and the quality as a product can be improved. Further, according to the method of the present invention, it is easy to uniformly control the roundness and thickness of the washer 5 as compared with the conventional method using only one forging. Further, the blank 41 cut to a required size is passed through the first to third forging means 31, 32, 33, or the washer 5 through the trim device 34 and the first to third forging means 31, 32, 33. Can be forged. In the forging facility 3, the washer 5 is manufactured through two or more forging steps after the initial forging step, so that the impact force due to forging is twice as compared with the conventional method using only one forging. This can be reduced by dispersing. Therefore, damage and wear of the mold and the crank device can be greatly reduced, and the forging equipment 3 can be used for a long time.

3 Forging Equipment 31 First Forging Means 311 Molding Cavity 312 Female Mold 313 Punch Rod 314 Male Mold 314
32 Second forging means 321 Molding cavity 322 Female mold 323 Punch rod 324 Male mold 33 Third forging means 331 Through hole 332 Female mold 333 Punch rod 334 Male mold 34 Trim device 341 Molding cavity 342 Female mold 343 Punch rod 344 Male mold 4 Wire material 41 Blank 411 Round portion 412 Edge corner portion 41A Trim blank 42 Rough molding blank 421 First large diameter portion 422 Inclined neck portion 423 First small diameter portion 424, 425 Alignment mark 43 Prototype washer 431 Outer portion 433 Central portion 435 Intermediate projection portion 5 Washer 51 hole

Claims (9)

Cutting the wire into the required length and forming it into a blank;
A step of forming the blank into a rough molding blank having a diameter larger than that of the blank and having a small thickness by the first forging means;
Forming the rough molding blank into a prototype washer having a larger diameter than the rough molding blank by a second forging means;
Punching out the original washer by a third forging means to produce a perforated product washer;
A washer manufacturing method characterized by comprising:   The washer manufacturing method according to claim 1, wherein the second forging means is provided with alignment marks on opposite surfaces of the rough molding blank.   The coarse molding blank includes a first large diameter portion, a first small diameter portion having a smaller diameter than the first large diameter portion, and the first large diameter portion between the first large diameter portion and the first small diameter portion. The washer manufacturing method according to claim 2, further comprising an inclined neck portion having a small diameter from the first small diameter portion to the first small diameter portion.   The prototype washer has a thin central part and an outer peripheral part thicker than the central part, and alignment marks are respectively provided on both sides of the central part opposite to each other. Item 4. A washer manufacturing method according to Item 3.   The washer manufacturing method according to claim 4, wherein a recessed central portion is formed on each side of the original washer.   The washer manufacturing method according to claim 4, wherein the original washer is further formed by protruding an intermediate protrusion from the central portion.   4. The washer manufacturing method according to claim 3, further comprising a step of turning the rough molding blank over before forging by the second forging means.   Prior to forging by the first forging means, the blank cut from the wire is further rounded by a trim device with a rounded corner around one side, and two ridges that are not shaped on the other side. 4. The washer manufacturing method according to claim 3, further comprising a trimming step of trimming a trim blank having a predetermined shape.   The washer manufacturing method according to claim 7, further comprising a step of turning over the blank arranged in a predetermined shape before forging by the first forging means.

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