JP2015157295A - Method of manufacturing component, and ring-shaped component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve a problem of material utilization inefficiency when a ring-shaped component is pressed and punched from a metal plate.SOLUTION: A method of manufacturing a component includes: a processing process of taking out a plate material from a metal plate-like member; a deformation process of three-dimensionally deforming the plate material from the processing process and manufacturing a three-dimensional member; an opening process of manufacturing an opening part on the three-dimensional member from the deformation process; and a flattening process of making the three-dimensional member after the opening process into a plane member. A ring-shaped metal component is formed of a single metal plate, and the ring-shaped component which is not subjected to surface treatment and addition of an element and compound and has hardness higher than that of the single metal plate by 30% or more. The plate-like component is formed of the metal plate, and has the opening part in a center. A periphery of the opening part is doubled by folding back the metal plate.

Description

  The present invention relates to a ring-shaped component and a manufacturing method thereof.

  Conventionally, ring-shaped parts have been used very often in the automotive field, electrical product field, mechanical field, and the like. For example, there is a ring-shaped component 9 called a ring plate (Patent Document 1). 8A is a plan view of the ring-shaped component 9, and FIG. 8B is a cross-sectional view. The ring-shaped part 9 has an opening 12 therethrough in the middle.

  As a manufacturing method of the ring-shaped part 9, there is a method of punching the ring-shaped part 9 from the metal plate 11 by pressing as shown in the plan view of FIG. That is, the ring-shaped component 9 is punched out from the metal plate 11 having a necessary thickness by a press device.

JP 2003-34106 A

  Here, in the conventional manufacturing method by punching a part from the metal plate 11 of FIG. 8C, the metal of the opening 12 inside the ring-shaped part 9 and the peripheral part 14 around the ring-shaped part 9 The material of the plate 11 was wasted. More than half was discarded (turned to recycling).

  In order to solve the above problems, a processing step of taking out a plate material from a metal plate member, a deformation step of three-dimensionally deforming the plate material of the processing step to produce a three-dimensional member, and the three-dimensional shape of the deformation step A method comprising an opening step of creating an opening in a member and a planarization step using the three-dimensional member after the opening step as a planar member is used.

  In the present invention, since a target part is produced by deforming and processing a necessary amount of metal plate material, the material utilization efficiency is high. Strength is improved by deforming the metal.

(A) A plan view showing a layout when the ring-shaped component of the present invention is punched from a metal plate, (b) a plan view of the ring-shaped component of the present invention. (A)-(f) The figure explaining the manufacturing method of Embodiment 1 (A)-(h) The figure explaining the manufacturing method of Embodiment 1 (A) The top view of the conventional components, (b)-(e) The figure explaining the manufacturing method of Embodiment 2 (A) Side view of a conventional component, (b) Plan view of a conventional component, (c) Plan view of one of the conventional components, (d) Plan view of one of the conventional components (A)-(g) The figure explaining the manufacturing method of Embodiment 3, (h) Sectional drawing of a prior art example (A)-(h) The figure explaining the manufacturing method of Embodiment 4 (A) Plan view of conventional ring-shaped component, (b) Cross-sectional view of (a), (c) Diagram showing layout when punching conventional ring-shaped component from metal plate

(Embodiment 1)
In the method of the first embodiment, as shown in the plan view of FIG. 1A, the punching member 20 is punched from the metal plate 11 by press working. Thereafter, the punching member 20 is deformed and processed so that the ring-shaped component 10 having the opening shown in FIG. Details will be described in FIG.

In FIG. 8 (c), only four pieces of metal plate 11 having the same size as in FIG. 1 (a) can be taken, but the same ring-shaped component 10 can be obtained by the method of the present invention. As shown in FIG. 1A, several times the number of parts can be taken.
The method according to the first embodiment will be described with reference to FIGS. 2 (a) to 2 (f).

  In the member process (punching process) of FIG. 2A, a rectangular punching member 20 is punched by pressing the punching member 20 from a metal plate SPHC (hot rolled mild steel sheet: JIS G 3131) thickness of 2.6 mm. . Although thickness is not limited, 1 mm to 3 mm is preferable on the process demonstrated below. Within this range, the punching process, three-dimensional process, cutting process, burring process, and planarization process described below can be performed with higher accuracy.

  The size (volume) is a dimension having a volume slightly larger than the volume of the final ring-shaped part 10. The volume ratio is about 30% larger than the final shape. This is because a portion that is discarded due to the bottom opening 30 (FIG. 2D) is generated. A preferred range is 20% to 40%. It is stable and can be produced without waste. In the process described below, it is necessary to ensure a large volume to some extent because it is not punched once but is cut or deformed a plurality of times during the process.

In the deforming step (drawing step) in FIG. 2B, a convex mold is pressed against the punching member 20 to draw the hull-like member 21 shaped like the bottom of the ship. That is, it becomes three-dimensional.
2C, the ship-like member 21 is compressed into a box-like member 22 having corners. Furthermore, it is deformed in three dimensions. This forming step is not essential and is more preferable.

2D, the bottom of the box-shaped member 22 is cut, and the frame-shaped member 23 having the bottom opening 30 is produced. It is preferable to allow a margin in advance because it is difficult to make the place to cut constant.
In the burring step of FIG. 2 (e), the bottom opening 30 is widened so that the frame-like member 23 has a donut shape, and the donut-shaped component 24 is produced. The frame-shaped member 23 is spread with a conical jig. In this example, it is a donut, but it is expanded according to the shape of the final part.

In the planarization step (squeezing step) in FIG. 2 (f), the donut-shaped component 24 is compressed from above and below, and the ring-shaped component 10 is completed.
After the drawing process, the shape is finally finished by compressive deformation by forging. Cold working without increasing the temperature. By this forging process, a type (end ring component) in which a side wall is provided on the inner diameter portion of the ring-shaped component 10 can also be produced.

The above processes are roughly classified into a flat metal plate punching process, a three-dimensional process (deformation process, forming process), a cutting process, a burring process, and a flattening process. In this method, one feature is that the plane is once three-dimensionalized and then flattened again.
In addition, you may punch out a required shape with a press after it becomes planar shape of FIG.2 (f). In this case, however, the yield (material utilization efficiency) is slightly reduced.

  Here, the punching means punching a metal plate having a desired shape. The cutting is a process of removing or separating a part of the metal. Burring is a process in which the periphery of the through hole and opening of the metal plate is drawn to make an edge, or the metal plate is turned to the periphery of the through hole and opening without reaching the edge. It is a process of making the periphery of the opening three-dimensional, or making the three-dimensional object around the opening.

Drawing is a process in which a metal plate is bent and deformed into a shape such as a spherical surface. The forging process is not a cutting or punching process, but a process of compressing and deforming a metal plate with pressure, a mold or the like. The forming process is a process of deforming and compressing a metal plate to obtain a desired shape.

(Strength test)
The Vickers hardness (HV) hardness of the conventional ring-shaped part 9 and the ring-shaped part 10 of Embodiment 1 was measured. The Vickers hardness is a value obtained by dividing the load when a pyramid-shaped depression is formed on a test surface by using a diamond square cone indenter having a diagonal angle of 136 ° by the length of the diagonal line of the depression.
When the load is P (N) and the average length of the diagonal lines of the recess is d (mm), the Vickers hardness HV is as follows. Vickers hardness is calculated as HV = 0.188909 × (P / d ² ), and Vickers hardness is not expressed in units. The Vickers hardness HV is the most representative hardness test because, if the material is uniform, an almost constant value can be obtained regardless of the test load, and the range of hardness to be measured is relatively wide. In addition, the magnitude | size of the weight by this Vickers hardness measurement was 30 kg.

  The measurement results are shown in Table 1. Here, the initial product is a member (the material itself, the ring-shaped component 9) which is only punched as shown in FIG. 2 (a), FIG. 8 (a), or (b). This is produced by punching parts with a conventional press. The intermediate product is a product immediately after planarization in FIG. The final is a finished product that has been forged after FIG. For the ring-shaped parts 9 and 10, several tens of points were measured along the circumference. In the case of a plate-shaped material, measurement was performed at several tens of points in an even place.

Compared to the initial one, the final product has an increase of about 1.5 times in hardness.

It is an intermediate product, which is about 30% better than the initial product. This is presumably because the metal was deformed and compressed by the member processing, deformation process, molding process, and planarization process, and the strength was improved. This is for work hardening.
In this method, the hardness can be improved only by processing from the original material without additional treatment such as surface treatment, addition of elements and compounds, and without special heat treatment. However, the above result is at the measurement location and is a local strength improvement. It seems that the strength of the deformed and compressed part was improved. In the conventional cutting process (punching process), the fiber (metal flow) of the material is cut and the strength does not increase, but decreases. On the other hand, since the metal flow is not interrupted in the processing (punching, burring, forging pressure) of the present application, the fatigue strength is improved as compared with the cutting processing.

  As a result, in this embodiment, the material utilization efficiency is improved and the hardness is locally improved by about 50%. Furthermore, as another example, an example of processing after FIG. 2 (f) will be described using FIG. 3 (a) to FIG. 3 (f). 3 (a) to 3 (c) are perspective views. 3D to 3F are cross-sectional views of FIGS. 3A to 3C, respectively.

The ring-shaped component 10 produced in FIG. 2 (f) corresponds to FIGS. 3 (a) and 3 (b).
Thereafter, as shown in FIG. 3B and FIG. 3E, the outer periphery is drawn to process the ring-shaped component 10 into a three-dimensional shape, and the three-dimensional ring component 26 is manufactured. A side wall 35 is formed.

Then, it is made into the roundish shape like FIG.3 (c) and FIG.3 (f) in a forge pressure process. That is, the corner portion is compressed and deformed. The effect of providing this side wall 35 improves the strength as a whole by making it three-dimensional. That is, the whole is formed from a thin metal plate, the metal usage fee is suppressed, and the strength is secured by three-dimensionalization instead. In addition, as described above, the strength is improved even by deformation such as bending.
In addition, only by the cutting method of the conventional construction method, the fiber (metal flow) of material will be parted and strength will fall. However, since the metal flow is not interrupted in the press working (burring, forging pressure) of this embodiment, the fatigue strength is improved as compared with the cutting work.

In this example, one shape is produced, and various desired shapes are processed.
Here, FIG. 3G and FIG. 3H are shown as one modification. 3 (g) is a perspective view corresponding to FIG. 3 (c), and FIG. 3 (h) is a cross-sectional view corresponding to FIG. 3 (f).
Unlike FIG.3 (c) and FIG.3 (f), it is the three-dimensional ring component 26 which provided the side wall 35 in the inner periphery. From the state of FIG. 3A and FIG. 3D, the central opening is burred and the side wall 35 is provided. Thereafter, the inner peripheral corner 29 is rounded (R-shaped) by forging or the like. Due to this roundness, it is easy to fit the solid ring part 26 into the shaft or the like.
In addition, the ring-shaped component 10 can also be manufactured by rounding one elongate metal rod and plate into a ring shape and welding. However, in this case, the joints are different in strength from the other parts, the whole bending method differs depending on the location, and the number of bendings is small. Furthermore, since another method called welding is required, it is complicated, and the number of steps increases, which is not good compared with the first embodiment.

(Embodiment 2)
FIG. 4A shows a plan view of a conventional component. Unlike Embodiment 1, the shape is different in the vertical direction and the horizontal direction.

  It is the plate component 39 which has a plate shape and has an opening. In Embodiment 1, since it was a circular component that is omnidirectional and point-symmetric, it could be manufactured by the method as in Embodiment 1. However, since the component in FIG. 4A is not point-symmetric in all directions, the method as in the first embodiment cannot be used. In this example, the component shown in FIG. 4A is manufactured by the following method.

  This method will be described with reference to FIGS. 4B to 4E. In the member process (punching process) of FIG. 4B, the punching member 40 is punched out with a press from a metal plate SPHC (hot rolled mild steel sheet: JIS G 3131) thickness of 2.6 mm.

The size is a dimension slightly larger than the volume of the final plate part 39. The same as in the first embodiment.
In the deformation step (drawing step) of FIG. 4C, a dumpling-like or crescent-shaped die is pressed against the punching member 40 to be folded in the longitudinal direction and drawn into the push-back member 31. It has a dumpling shape or a crescent shape. It is a circular shape of a donut that is shaped like a donut cut in half. There are an inner semicircular surface portion and an outer semicircular surface portion.

In the cutting step of FIG. 4D, the inner surface (inner semicircular surface) of the folding member 48 is cut and cut. The cut portion is the opening 42.
In the burring step (planarization step) in FIG. 4E, the folding member 48 is developed around the opening 43 that is the opening 42. Although it does not produce to the periphery around the opening 43, it is burring because it is deformed to be deflected. Thereafter, planarization (planarization process) is performed to complete the plate component 39. The opening 42 becomes the opening 43.

As in the first embodiment, it is roughly classified into a punching process, a three-dimensional process (deformation process, molding process), a cutting process, a burring process, and a planarization process.
Finally, it is forged and finished with compression deformation.

Similar to the first embodiment, the strength is partially improved and the material yield (utilization efficiency) is high.
In this example, the dumpling-like intermediate body or the crescent-shaped folding member 48 is used, but an intermediate body having a different shape may be used depending on the target part shape.

Items not described are the same as those in the first embodiment.
The features of the second embodiment are as follows. A flat plate material (square shape) close to the minimum amount is cut out from a flat metal plate. Bend it in two and cut a part of the folded part (back part). It is to make a flat surface and process it into the final shape. It is characterized by opening formation, three-dimensionalization, and planarization while deforming the plane.

(Embodiment 3)
Fig.5 (a) is a side view of the conventional components, FIG.5 (b) is a top view. This part is a cover plate for an automobile axle housing.
This part is produced by integrating the plate main body 52 as a plan view shown in FIG. 5C and the ring-like part 10 as a plan view shown in FIG. The ring-shaped component 10 having the opening 12 at the center is reinforced by attaching it to the plate body 52. The plate body 52 is made thin as a whole, and is partially reinforced by the ring-shaped component 10 to achieve weight reduction as a whole.

Since these two parts are separately manufactured and combined, the number of parts management and assembly processes is large. There was also a problem of dimensional deviation between the two parts. With only the methods of the first and second embodiments, this part cannot be produced only by processing one metal sheet.
In this embodiment, it is manufactured as one component by the following method.

FIGS. 6A to 6C are plan views, and FIGS. 6D to 6F are cross-sectional views. 6 (a) and 6 (d), FIG. 6 (b) and FIG. 6 (e), FIG. 6 (c) and FIG. 6 (f) correspond to each other. FIG. 6A and FIG. 6D are parts manufactured according to the second embodiment and whose omnidirectional is not point-symmetric.
It consists of a plate body 34 and an opening 33.

6 (a) and 6 (d) correspond to FIG. 4 (e). Thereafter, the plate body 34 is subjected to burring as shown in FIGS. 6 (b) and 6 (e). A side wall 35 is formed around the opening 33.
In FIG. 6C and FIG. 6F, the side wall 35 is folded over the plate body 34 and the ring portion 36 is provided.

After this, forging is performed and the shape is adjusted by compressive deformation to complete. The size of the opening 33 in FIG. 6A needs to be smaller than the size of the final product, for example, the opening 33 in FIG. That is, it is necessary to consider the provision of the side wall 35 as shown in FIG.
6 (g) and 6 (h) are schematic cross-sectional views showing a metal flow. FIG. 6G is a cross-sectional view of a part of the ring portion 36 and the plate body 34 of FIG. FIG. 6H is a view corresponding to one obtained by separately manufacturing and joining two conventional members (FIG. 5B). In FIG. 6G of the third embodiment, the metal flow is connected in the vertical direction compared to the conventional FIG. 6H, which is stronger in strength and more integrated.

(Embodiment 4)
In the third embodiment, the ring portion 36 has the same shape as the outer periphery of the opening 33, but may have a polygonal shape. An example of this case will be described with reference to FIGS. 7A to 7H.

FIGS. 7A to 7D are top views, and FIGS. 7E to 7H are cross sections of FIGS. 7A to 7D, respectively.
In advance, the metal plate main body 34 is punched from the metal plate (punching step).

Next, as shown to Fig.7 (a), the convex part 37 is provided in the plate main body 34 which is a metal plate. A mold is pressed against the plate body 34 and bent to form a convex portion 37 (three-dimensional process (deformation process, molding process). FIG. 7 (e) is a cross section thereof.
Next, as shown in FIG. 7B, a cross opening 33 is provided in the convex portion 37 (cutting step).

After that, as shown in FIG. 7C, the opening 33 is set up vertically to the folded plate body 34 by burring, and the side wall 35 is provided (burring process).
As shown in FIG. 7D, the side wall 35 is folded on the plate body 34 to form the ring portion 36 (planarization step).

As in the first and second embodiments, it can be roughly classified into a punching process, a three-dimensional process (a deformation process, a molding process), a cutting process, a burring process, and a planarization process.
By this method, even when the opening 33 is not circular, the ring part can be formed as a final product by folding. One component made of one metal sheet and a component having a two-layer structure can be produced. As in the first and second embodiments, the hardness increases. High material utilization efficiency. Moreover, since it is turned up, the strength is further improved. It is not a joint of two members but has high unity.

  Items not described are the same as those in the first and second embodiments. The ring-shaped component means a component having an opening inside the component, and the illustrated component is a ring-shaped component.

  Various parts can be produced by the production method of the present invention.

9, 10 Ring-shaped component 11 Metal plate 12 Opening 14 Peripheral portion 20, 40 Punching member 21 Ship-shaped member 22 Box-shaped member 23 Frame-shaped member 24 Donut-shaped component 26, 27 Three-dimensional ring component 29 Inner peripheral corner 30 Bottom opening 31 Pushing back Member 33, 43 Opening 34, 44 Plate body 35 Side wall 36 Ring part 37 Convex part 39 Plate component 42 Opening port 51 Cover plate 52 Plate body 41, 48 Folding member 105 Initial product 130 Intermediate product 150 Final product

Claims (12)

A punching process for removing the plate material from the metal plate member;
A three-dimensional process for producing a three-dimensional member by three-dimensionally deforming the plate material in the punching process;
A cutting step for producing an opening in the three-dimensional member;
A first burring step of burring the three-dimensional member after the cutting step;
A flattening step of flattening the three-dimensional member after the first burring step. In the three-dimensional process, the plate is folded,
The method for manufacturing a component according to claim 1, wherein in the cutting step, a part of the folded portion is cut. 3. The method for manufacturing a component according to claim 1, wherein in the three-dimensionalization step, the plate material is further formed into a dumpling shape or a crescent shape. Furthermore, the manufacturing method of the components of any one of Claim 1 to 3 which performs a 2nd burring process after the said planarization process. The method of manufacturing a component according to claim 4, wherein a processed portion of the second burring is bent after the second burring step. The method for manufacturing a part according to claim 1, wherein the part has a circular opening at a center. The method for manufacturing a component according to any one of claims 1 to 6, further comprising a notch step of providing a notch in the deformed portion after the three-dimensionalization step. The method for manufacturing a component according to claim 7, further comprising a step of turning back the planar member by the notch after the notch step. A ring-shaped component produced by the manufacturing method according to claim 1 and having a hardness improved by 30% or more than the metal plate member. A ring-shaped metal part made of a single metal plate, which has a hardness of 30% or more higher than the hardness of the single metal sheet by being deformed without adding surface treatment, compound or element. . Parts made of metal plates,
A ring-shaped component having an opening at the center and a metal plate folded around the opening. The ring-shaped component according to claim 11, wherein the metal flow of the folded and doubled portion is continuous with other portions.