JP2012183564A - Method for manufacturing metal parts - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce welding inferiority, when welding those parts, by coupling two metal parts in a bean-jam-filled wafers shape by providing the manufacture of the metal part of which the outside radius of a bending portion between a half cylindrical body and a flange has been lessened.SOLUTION: The method for manufacturing the metal parts 2, 3 having a plurality of the half cylindrical portions 4, the planar flange 5 provided between adjoining half cylindrical portions 4, 4, and the bending portion 6 for coupling the above half cylindrical portion 4 and the planar flange 5 includes: a process for forming an excess thickness portion for forming a curved surface-like excess thickness portion by squeezing the metal plate so that the deepest part may come to be deeper than the final position of the planar flange 5 in the portion for forming the planar flange 5; and a squeezing process for forming a planar portion located in the final position of the planar flange 5 and the bending portion 6 by plastically deforming the above excess thickness portion.

Description

  The present invention relates to a method of manufacturing a metal part, and more particularly, to a method of manufacturing a metal part that integrally manufactures a metal part having a plurality of half cylinder parts and a flange provided between adjacent half cylinder parts.

  An outer shell 1 of a metal exhaust manifold as shown in FIG. 1 is formed by joining a pair of metal parts 2 and 3 that are half halves in a monaca manner. The metal parts 2 and 3 which are the halves are provided between a plurality of half cylinder portions 4 and the adjacent half cylinder portions 4 and 4 and connect the adjacent half cylinder portions 4 and 4 to each other. (Plane connecting portion) 5, and the half cylinder portion 4 and the flange 5 are connected by a bent portion 6. Moreover, the half connection part 7 for fitting in the hole formed in the fastening member to the engine which is not shown in figure is formed in the front part of the half cylinder part 4. As shown in FIG.

The following manufacturing methods are known as methods for manufacturing the metal parts 2 and 3.
(A) First, a drawing process is performed to squeeze a metal flat plate to the depth of the shape of the metal part, thereby forming a half cylinder portion 4 and a flat flange portion that is the basis of the flange 5.
(B) Next, an end cutting step of cutting out the central portion of the flange portion so that the outer shape thereof has a predetermined shape is performed.
(C) Next, a part of the flange part is cut and a bending process is performed in which a bending part is formed by bending the flange part at a right angle to the flange part.
(D) Next, a cutting end cutting process is performed in which the cut and bent portion is cut out along the same plane as the attachment surface of the flange 5 (the side opposite to the protruding side of the half cylinder portion 4).
Thereby, the metal parts 2 and 3 are manufactured (for example, refer patent document 1).

Japanese Patent Publication No. 7-32944

  The two metal parts 2 and 3 manufactured by the above manufacturing method are welded with the flanges 5 and 5 being overlapped with each other, and the edges of the metal parts 2 and 3 are welded to each other. The outer shell 1 is formed.

  However, in the conventional metal parts 2 and 3, in order to form the bent portion 6 in one drawing process, the inner surface side of the outer shell 1 of the exhaust manifold in the bent portion 6 (hereinafter, the bent portion is referred to as the bent portion 6. If the radius R1 (refer to FIG. 16) of the outer side of 6 is made smaller, the thickness of the bent portion 6 becomes thinner or cracks occur in the bent portion 6, so that the half cylinder portion 4 and the flange 5 It was difficult to make the bent portion 6 close to a right angle by reducing the outer radius R1.

  Further, when the outer radius R1 of the bent cylinder portion 4 and the bent portion 6 of the flange 5 is increased, the flanges 5 and 5 of the metal parts 2 and 3 are overlapped with each other as shown in FIG. , 5, large triangular gaps 8 are formed at both ends. When the width W1 of the gap 8 is more than half of the diameter of the welding wire, there is a possibility that poor welding may occur when the metal parts 2 and 3 are welded together.

  Then, this invention aims at providing the manufacturing method of the metal component which can make small the radius of the outer side of a bending part and can suppress generation | occurrence | production of poor welding.

In order to solve the above-described problems, a metal part manufacturing method according to the present invention includes a plurality of half cylinders, a flat flange provided between adjacent half cylinders, and the half cylinders. In the method of manufacturing a metal part having a bent portion connecting the flange,
A surplus part forming step of forming the curved surplus part by narrowing the metal plate so that the deepest part in the flange forming part is deeper than the final position of the flange;
The surplus portion is plastically deformed to have a planar portion located at the final position of the flange and a drawing step for forming the bent portion.

In the metal part manufacturing method according to the present invention, the drawing step includes
A first squeezing step of squeezing the surplus portion deeper than the final position of the flange and shallower than the deepest squeezed position in the surplus portion forming step; ,
A second drawing step in which the preliminary flange is protruded to the final position of the flange, and the flesh of the preliminary flange is plastically flowed in the direction of the half cylinder portion to form the planar portion and the bent portion; It is good to consist of.

  The formation position of the preliminary flange may be deeper than the final position of the flange by a thickness equal to or less than the thickness of the metal plate.

In addition, before the second drawing step,
An end cutting step of cutting the preliminary flange into a predetermined shape;
A part of both sides of the preliminary flange is bent while being cut so as to be perpendicular to the preliminary flange to form a cut and bent part;
After the second drawing step,
It is good to have the near end cutting process which cuts out the said bending part in the same plane as the surface on the opposite side to the said half cylinder part in the said planar part.

  In the present invention, a curved surplus portion is formed by the above configuration, and the surplus portion (material) of the surplus portion is bent by forming the flat portion and the bent portion by pushing up the surplus portion. Since it can be plastically flowed in the direction and collected at the bent portion, the radius outside the bent portion can be reduced as compared with the bent portion formed by a single drawing process as in the prior art. it can. As a result, when the flanges of the metal parts are overlapped with each other, the triangular gaps at both ends of the flange can be made smaller than those of the prior art, and welding defects in welding between the bent portions can be reduced.

The perspective view which shows one example of the metal component to which the manufacturing method of the metal component of this invention is applied. The figure explaining the surplus part formation process in Example 1 of this invention. The figure after forming the surplus part by drawing from the state of FIG. The figure explaining the aperture_diaphragm | restriction process in Example 1 of this invention. The figure explaining the end cutting process in Example 1 of this invention. The figure explaining the cutting and bending process in Example 1 of this invention. The perspective view for demonstrating the cutting and bending process in Example 1 of this invention. The figure explaining the near end cutting process in Example 1 of this invention. The figure which shows the state which match | combined two metal parts manufactured with the manufacturing method of Example 1 of this invention with monaca. The figure explaining the 1st aperture_diaphragm | restriction process in Example 2 of this invention. The figure explaining the end cutting process in Example 2 of this invention. The figure explaining the cutting and bending process in Example 2 of this invention. The figure explaining the 2nd aperture_diaphragm | restriction process in Example 2 of this invention. The figure explaining the near end cutting process in Example 2 of this invention. The figure which shows the state which match | combined two metal parts manufactured with the manufacturing method of Example 2 of this invention with monaca. The figure which shows the state which match | combined two metal parts manufactured with the conventional manufacturing method.

A mode for carrying out the present invention will be described based on an embodiment shown in the drawings.
[Example 1]
1 to 9 show a first embodiment of the present invention.

  A joining portion of metal pipes such as an exhaust pipe of an engine, for example, an outer shell 1 of a metal exhaust manifold as shown in FIG. 1 is formed by combining two metal parts 2 and 3 together. In addition, since the outer shell 1 of the metal exhaust manifold has a complicated curved surface shape, in FIG. 1, in order to express the complicated curved surface shape, a boundary line between surfaces that does not actually appear is added. As shown.

  As shown in FIG. 1, the two metal parts 2, 3 have a plurality of half cylinder parts 4 and a flange 5 provided between adjacent half cylinder parts 4, 4. The flange 5 is connected by a bent portion 6. Further, as shown in FIG. 1, a connecting portion 7 that fits into a hole portion formed in a fastening member to an engine (not shown) is formed at the front portion of each of the half cylinder portions 4, and this adjacent connection is formed. The flange 5 and the bent portion 6 are not formed between the portions 7 and 7. In addition, the number of the half cylinder parts 4 may be set arbitrarily according to the number of cylinders of the engine, etc., and may be plural. The number of the flanges 5 is also arbitrarily set according to the number of the half cylinder portions 4.

  In the metal part manufacturing method of the present invention, as in the metal parts 2 and 3, a plurality of half cylinder parts 4 and a flange 5 provided between adjacent half cylinder parts 4 and 4 are integrally formed. It can be applied to any metal part as long as it is a metal part. In the following description, the mating surface side of the metal parts 2 and 3 in the manufacturing process of the metal parts 2 and 3 will be described as the lower side, and the opposite side thereof as the upper side. FIGS. Is shown in the lower side.

  Next, a method for manufacturing the metal parts 2 and 3 will be described. The half cylinder part 4, the flange 5, and the bent part 6 in the metal parts 2 and 3 can be manufactured by using the same manufacturing method although the shapes are different.

  At the time of manufacture, a metal plate 10 having a predetermined size and a predetermined thickness is prepared. As the metal plate 10, a metal plate of any material can be used as long as it is a metal. However, when manufacturing the metal parts 2 and 3 used for the outer shell 1 of the exhaust manifold, stainless steel, Inconel, Hastelloy, etc. It is preferable to use a metal having heat resistance. In this example, a flat metal plate made of stainless steel with a thickness of 2.5 mm was used.

(Remaining part forming process)
First, as shown in FIG. 2, after the metal plate 10 is interposed between the first punch 11 and the first die 12, as shown in FIG. Drawing is performed by using the punch 11 and the first die 12, and a plurality of half cylinder parts 4 and a curved surplus part 13 that is curved downward between the adjacent half cylinder parts 4 and 4 as a whole. And are integrally formed. As shown in FIG. 3, the lowermost surface 13a of the surplus portion 13 is deeper than the position (hereinafter referred to as the final position) P1 of the lower surface 5c (see FIG. 4) of the final (product) flange 5. In other words, it is formed so as to be located in a direction opposite to the half cylinder portion 4 from the final position P1 of the flange 5.

  The distance d1 between the final position P1 of the flange 5 and the lower surface 13a at the deepest squeezed position is arbitrarily set depending on the material of the metal plate 10, the plate thickness, the half cylinder portion 4, the shape of the flange 5, and the like.

(Drawing process)
Next, as shown in FIG. 4, drawing is performed using the second punch 15 and the second die 16, and the surplus portion 13 has the lower surface at the same position as the final position P <b> 1 of the flange 5. The flat flange portion 5a and the bent portion 6 are formed. The curvature of the bent portion 6 at this time is arbitrarily set depending on the material of the metal plate 10, the plate thickness, the shape of the half cylinder portion 4, the flange 5, and the like.

(End cutting process)
Next, as shown in FIG. 5, the intermediate product formed in the drawing step is placed on the fixed cutting blade 17, and the intermediate product is pressed by the pad 18 from above the movable cutting blade 20. Is lowered from above the intermediate product, and the center portion of the flange portion 5a is cut into a predetermined shape. 5d in FIG. 5 shows the cut-out scrap.

(Cutting and bending process)
Next, as shown in FIG. 6, the intermediate product formed in the end cutting process is placed on the fixed cutting blade 21, and the intermediate product is pressed by the pad 22 from the upper part of the intermediate product. The cutting and bending blade 23 is lowered and cut and bent. During this cutting and bending, as shown by the dotted line in FIG. 7, the flange portion 5b is located between the portions 7a and 7a, and the rear portion 5b. While cutting between the flange portion main body portion 5e 24, a portion 5b of the flange portion is bent downward at a right angle with respect to the main body portion 5e of the flange portion to form a cut bent portion 26, and the flange 5 is Form.

(Close-up process)
Next, as shown in FIG. 8, the intermediate product formed in the cutting and bending step is placed on the fixed cutting blade 28, and the movable cutting blade 29 is placed along the same plane as the lower surface 5 c of the flange 5. The cut and bent portion 26 is moved in the direction of the cut and bent portion 26, and the cut and bent portion 26 is cut out along the same plane as the lower surface 5 c of the flange 5. Thereby, the connection part 7 and its joining surface 7b are formed. 26a in FIG. 8 shows the cut and bent part.

The metal parts 2 and 3 can be obtained through the manufacturing process.
In the manufacturing method of the present invention, the surplus part 13 having a curved surface is formed, and the surplus part 13 is pushed up to form the flange part 5a and the bent part 6, whereby the surplus part (material) of the surplus part 13 is obtained. In the squeezing step, plastic flow can be made in the direction of the bent portion 6 and collected in the bent portion 6. Therefore, the bending portion 6 of the present invention can increase the thickness of the bending portion 6 as compared with the bending portion formed by a single drawing process of the flat plate of the prior art, and the radius outside the bending portion 6 can be increased. R2 can be smaller than that of the outer radius R1 of the prior art. Thus, as shown in FIG. 9, when the flanges 5, 5 of the metal parts 2, 3 are overlapped with each other, the triangular gaps 8 formed at both ends of the flanges 5, 5 are changed from those of the prior art. The welding failure at the time of welding the metal parts 2 and 3 can be reduced.

[Example 2]
In the first embodiment, after the bent portion 6 is formed, a part of the flange portion 5a is cut and bent by a cutting and bending process, so that the radius R2 outside the bent portion 6 is reduced in order to reduce the gap 8. There is a possibility that a shock line may be generated outside the bent portion by the cutting and bending process.

  Therefore, in the second embodiment, after the surplus portion forming step of the first embodiment, the surplus portion 13 is first shallower than the deepest position and deeper than the final position P1 of the flange 5. After forming the preliminary flange by performing the drawing process, similarly to the first embodiment, the end cutting process and the cutting and bending process are performed, and then, the second drawing process of pushing up the preliminary flange to the final position P1 of the flange 5. Is performed to suppress the occurrence of the shock line.

Next, a method for manufacturing a metal part in the second embodiment will be described in detail with reference to FIGS.
The same metal plate 10 as in Example 1 was used, and in this example, a stainless steel plate having a thickness t of 2.5 mm was used.

(Remaining part forming process)
First, as shown in FIGS. 2 and 3, the metal plate 10 is drawn using a first punch 11 and a first die 12 in the same manner as in the first embodiment, so that a plurality of half cylinder portions are obtained. 4 and a curved surplus portion 13 that is curved downward as a whole is integrally formed between the adjacent half cylinder portions 4 and 4. As shown in FIG. 3, the lower surface 13 a of the surplus portion 13 is formed so as to be deeper than the final position P <b> 1 of the flange 5.

  The distance d1 between the final position P1 of the flange 5 and the lower surface 13a at the deepest squeezed position is arbitrarily set depending on the material of the metal plate 10, the plate thickness t, the half cylinder portion 4, the shape of the flange 5, and the like. In this embodiment, the distance d1 is set to 6 mm.

(First drawing process)
Next, as shown in FIG. 10, drawing is performed using a third die 31 and a third punch 32, and the surplus portion 13 has a lower surface 35 b that is more than the final position P <b> 1 of the flange 5. Drawing is performed so that the flat spare flange 35 is located deeper and shallower than the deepest squeezed position, so that the spare flange 35 and the spare flange 35 and the half cylinder portion 4 are separated. The preliminary bend portion 36 is formed.

  The distance d2 between the position P2 of the lower surface 35b of the preliminary flange 35 and the final position P1 of the flange 5 may be set as long as it is smaller than the distance d1, but the distance d2 is determined from the thickness t of the metal plate 10. Is preferably smaller and larger than 0. If this distance d2 is larger than the plate thickness t of the metal plate 10, there is a risk that the flatness of the flange 5 will be deteriorated due to excess flesh when the preliminary flange 35 is pushed up in the second drawing step. In this embodiment, the distance d2 is set to 1.5 mm.

  Further, the outer radius R3 of the preliminary bent portion 36 is set to be larger than the outer radius R4 (see FIG. 15) of the final bent portion 6, and in this embodiment, R3 is set to 5.5 mm.

(End cutting process)
Next, as shown in FIG. 11, the intermediate product formed in the drawing step is placed on the fixed cutting blade 37 in substantially the same manner as in the first embodiment, and the intermediate product is placed on the pad 38 from above. In a pressed state, the movable cutting edge 40 is lowered from above the intermediate product, and the central portion of the spare flange 35 is cut out into a predetermined shape. In FIG. 11, 35 d represents the cut scrap.

(Cutting and bending process)
Next, as shown in FIG. 12, the intermediate product formed in the end cutting step is placed on the fixed cutting blade 41 in substantially the same manner as in the first embodiment, and the intermediate product is placed on the pad 42 from above. In a state where is held, the movable cutting and bending blade 43 is lowered and bent. At the time of this cutting and bending, between the part of the spare flange 35 located on both sides of the spare flange 35 and located between the portions 7a and 7a to be the connection portion 7 and the main body part of the spare flange 35 behind it. A portion of the preliminary flange 35 is bent at a right angle downward with respect to the main body portion of the preliminary flange 35 to form a cut bent portion 46.

(Second drawing process)
Next, as shown in FIG. 13, the intermediate product formed in the cutting and bending step is placed on the fourth die 47, and the spare flange 35 is used by using the fourth die 47 and the fourth punch 48. Are protruded (pushed up) until the lower surface 35b is located at the same position as the final position P1 of the flange 5, and the flange 5 and the bent portion 6 are formed.

  By this process, the flesh of the preliminary flange 35 plastically flows toward the preliminary bent portions 36, 36 to form the bent portion 6. Therefore, the radius R4 outside the bent portion 6 is set to the radius outside the preliminary bent portion 36. It becomes smaller than R3. The outer radius R4 of the bent portion 6 may be arbitrarily set as long as it is smaller than the outer radius R3 of the preliminary bent portion. In the second embodiment, the metal parts 2 and 3 can be formed satisfactorily even when the outer radius R4 of the bent portion 6 is set to 3.0 mm and the inner radius R5 of the bent portion 6 is set to 1.5 mm. Thus, in the second embodiment, the radius R4 (= 3.0 mm) outside the bent portion 6 is set to the radius R5 (1.5 mm) inside the bent portion 6 + the thickness t (= 2.5 mm), and the outer radius R4 of the bent portion 6 of the second embodiment can be made smaller than the outer radius R2 of the bent portion of the first embodiment.

(Close-up process)
Next, as shown in FIG. 14, the intermediate product formed in the cutting and bending process is placed on the fixed cutting blade 28 as in the first embodiment, and the movable cutting blade 29 is attached to the flange 5. The cut portion 46 is moved along the same plane as the lower surface 5 c in the direction of the cut and bent portion 46, and the cut and bent portion 46 is cut out along the same plane as the lower surface 5 c of the flange 5. Thereby, the connection part 7 and its joining surface 7b are formed. 14a in FIG. 14 shows the cut and bent part.

The metal parts 2 and 3 can be obtained through the manufacturing process.
Also in the second embodiment, the same operations and effects as the first embodiment can be achieved.

  Furthermore, in the second embodiment, a curved surplus portion 13 is formed, and the surplus portion 13 is squeezed deeper than the final position P1 of the flange 5 and shallower than the surplus portion 13 to form a planar shape. After forming the preliminary flange 35, the preliminary flange 35 is pushed up to form the bent portion 6, so that the surplus wall is more likely to plastically flow toward the bent portion 6 than in the first embodiment, and the final bent. Since the outer radius R4 of the portion 6 can be made smaller than the outer radius R2 of the first embodiment, the bent portion 6 can be brought close to a right angle. Thereby, as shown in FIG. 15, the triangular space | gap 8 formed in the both ends of the flanges 5 and 5 can be made smaller than the thing of the said Example 1, and in the case of the welding of the metal components 2 and 3 each other Welding defects can be further reduced.

  In the first embodiment, the outer radius R2 of the bent portion 6 = the inner radius of the bent portion 6 + the thickness t of the metal plate 10, and the inner radius of the bent portion 6 is the thickness t of the metal plate 10. Therefore, when the plate thickness t of the metal plate 10 is 2.5 mm, the outer radius R2 of the bent portion 6 is 5.0 mm or more.

  On the other hand, when the manufacturing method according to the second embodiment is used, the radius R4 outside the bent portion 6 can be set to 3.0 mm as described above, and the radius R4 outside the bent portion 6 (= 3.0 mm). ) <Radius R5 (1.5 mm) inside the bent portion 6 + plate thickness t (= 2.5 mm) of the metal plate 10. Therefore, as shown in FIG. 15, when the flanges 5, 5 of the metal parts 2, 3 are overlapped, the triangular gaps 8 formed at both ends of the flanges 5, 5 are those of the first embodiment. It is possible to further reduce the welding failure during the welding of the metal parts 2 and 3.

  Further, the outer radius R3 of the preliminary bent portion 36 is formed to be larger than the radius R4 of the bent portion 6, and a portion of the preliminary flange 35 is cut and formed to form a cut bent portion 46. Since the bending portion 6 is formed by performing the two-drawing process, it is possible to suppress the occurrence of a shock line caused by strong processing outside the boundary portion of the cut and bent portion, and suppress the reduction in strength of the metal parts 2 and 3. it can.

  In the second embodiment, in the second drawing step, drawing is performed without restricting the end portion 35a of the preliminary flange 35. However, the preliminary flange 35 is extended by extending a part of the fourth die 47. The drawing may be performed by restraining the end portion 35a. As a result, the flesh of the spare flange 35 can be plastically flowed toward the pre-curved portions 36, 36, and surplus material can be collected at the pre-curved portion 36.

[Example 3]
In the first and second embodiments, an end cutting process, a cutting and bending process, and a close end cutting process were performed in order to form the connection portion 7. However, the exhaust manifold described in JP-A-2005-36724 is disclosed. As described above, the metal parts 2 and 3 in which the leading edge portion of the half cylinder portion 4 and the leading edge portion of the flange 5 are aligned without using the connection portion 7, and other metals are contained in the half cylinder portions 4 and 4. When the pipes are fitted and joined, the metal parts 2 and 3 may be manufactured without performing the end cutting step, the cutting and bending step, and the close end cutting step in the first and second embodiments.

  Also in the third embodiment, the same operations and effects as the first and second embodiments can be achieved.

2, 3 Metal parts 4 Half cylinder part 5 Flange 6 Bent part 10 Metal plate 13 Extra part 35 Preliminary flange 26, 46 Cut and bent part P1 Final position of flange

Claims (4)

In the method of manufacturing a metal part having a plurality of half cylinder parts, a planar flange provided between adjacent half cylinder parts, and a bent part connecting the half cylinder part and the flange,
A surplus part forming step of forming the curved surplus part by narrowing the metal plate so that the deepest part in the flange forming part is deeper than the final position of the flange;
A method of manufacturing a metal part, comprising: a step of plastically deforming the surplus portion to form a planar portion located at a final position of the flange and forming the bent portion. The drawing step includes
A first squeezing step of squeezing the surplus portion deeper than the final position of the flange and shallower than the deepest squeezed position in the surplus portion forming step; ,
A second drawing step in which the preliminary flange is protruded to the final position of the flange, and the flesh of the preliminary flange is plastically flowed in the direction of the half cylinder portion to form the planar portion and the bent portion; The method of manufacturing a metal part according to claim 1, comprising:   3. The method for manufacturing a metal part according to claim 2, wherein the formation position of the preliminary flange is deeper than the final position of the flange by a thickness equal to or less than the thickness of the metal plate. Before the second drawing step,
An end cutting step of cutting the preliminary flange into a predetermined shape;
A part of both sides of the preliminary flange is bent while being cut so as to be perpendicular to the preliminary flange to form a cut and bent part;
After the second drawing step,
The method of manufacturing a metal part according to claim 2 or 3, further comprising a near-end cutting step of cutting the cut and bent portion into the same plane as a surface of the planar portion opposite to the half cylinder portion. .

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