JP3319863B2 - Manufacturing method of clutch shaft - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a clutch shaft used for a rotary drive mechanism of a one-tub type electric washing machine.

[0002]

2. Description of the Related Art Conventionally, in a single-tub type electric washing machine in which washing and dehydration are continuously performed in a single tub, a rotary drive mechanism is used.
For example, a structure as shown in FIG. 10 is generally used. That is, the one-way spring clutch 14 is attached to the lower end of the main shaft 12 that rotates the dewatering tub 10 and the pulsator 11, and when the one-way spring clutch 14 is rotated through the pulley 20 in the direction in which the one-way spring clutch is tightened, the main The clutch shaft 13 externally fitted to the shaft 12 rotates at a high speed integrally with the main shaft 12. This high-speed rotation is transmitted to the gear case 15 containing the sun gear 5, the planetary gear group 17 and the outer ring gear 22 meshing therewith, and is transmitted to the dewatering tank 10 via the dewatering shaft 16 extending upward from the gear case 15. Thereby, a dehydration operation is performed. Reference numeral 18 denotes a holding guide that integrally holds the rotating shafts of the planetary gear group 17 from above and below. The clutch shaft 13 is rotatably supported by a lower bearing cover 25 fixed to the main body of the washing machine via a first bearing 26. In addition, the dehydrating shaft 16 is
It is rotatably supported by an upper bearing cover 27 also fixed to the main body of the washing machine via a second bearing 21. On the other hand, when the one-way spring clutch 14 is rotationally driven through the pulley 20 in a loosening direction, the clutch shaft 13 does not rotate, and only the main shaft 12 rotates. This rotation is performed by the sun gear 5 in the gear case 15.
, And the reduced rotation is transmitted to the pulsator shaft 19. Thereby, the pulsator 1 attached to the upper end of the pulsator shaft 19
1 rotates at a low speed, and a washing / rinsing operation is performed. In addition,
2 is a one-way bearing for preventing the clutch shaft 13 from rotating together with the main shaft 12;
Is the bearing.

[0003] The clutch shaft 13 used in the rotary drive mechanism is usually manufactured as follows. That is, first, as shown in FIG. 9, an iron wire 30 having a predetermined diameter and wound in a coil shape around a winding core 31 is prepared, and the wire 30 is unwound and supplied to a known continuous multi-stage forging machine. I do. In the continuous multi-stage forging machine, the supplied wire 30 is first cut into a predetermined length, and then the cut wire 30 is mounted on a different mold tool, and a plurality of compression moldings are performed stepwise to perform plastic deformation. Is continuously repeated, whereby a molded article can be obtained continuously.

[0004] The continuous multi-stage forging machine, the wire 30
As a result, as shown in FIG. 11A, a preformed body 34 is formed in which the upper part is formed in the thick large-diameter part 32 and the lower part is formed in the small-diameter cylindrical part 33. And this preform 3
4 is subjected to a cold forging press to plastically deform the thick large-diameter portion 32 in the radial direction to form a larger-diameter flat portion 35 and the cylindrical portion 33 as shown in FIG. Increase the length of. At the same time, a shallow hole 36 is formed downward from the center of the upper end face, and a center hole 37 is formed at the center of the lower end face. Next, FIG.
As shown in (1), a hole is drilled at the position of the center hole 33 to form a through hole 38. Next, FIG.
As shown in (a), the upper and lower portions of the inner wall of the through hole 38 are cut to form a step for fitting a bearing for mounting the main shaft 12 (see FIG. 10). Also, on the outer peripheral surface of the cylindrical portion 33 in which the through hole 38 is formed,
A step portion for fitting a bearing for attaching the lower bearing cover 25 (see FIG. 10) is formed. And the column part 3
After induction hardening was performed on the stepped portion on the outer peripheral surface of No. 3, FIG.
As shown in (b), by polishing and finishing the peripheral surface, the desired clutch shaft 13 can be obtained. In FIG. 12B, the cylindrical portion 33 in which the through hole 38 is formed is referred to as a substantially cylindrical main body 40. The collar 35 may be flat as shown in FIGS. 11 and 12, or the outer peripheral side of the collar 35 may be lifted slightly above the center via a tapered portion as shown in FIG. It can also be made into a shallow dish shape. Further, in a recent electric washing machine rotation drive mechanism, the clutch shaft 1
3 and the gear case 15 are not fixed by screws as shown in FIG.
The crimping portion 35 and the lower end portion of the gear case 15 are caulked and integrated. Therefore, when the clutch shaft 13 is to be swaged with the gear case 15, after the induction hardening of the clutch shaft 13 is completed, notches are formed at four peripheral portions of the collar portion 35 by press working. Polishing is performed as shown in FIG.

[0005]

However, the above-mentioned manufacturing method has a problem that the material cost and the processing cost are high due to the large cutting allowance. Further, since the distance for drilling by a drill (indicated by L in FIG. 11 << c >>) is long, there is also a problem that a long processing time is required in combination with a large number of other cutting allowances. Therefore, when manufacturing a clutch shaft, it is strongly desired to simplify these steps and to reduce the cost.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an excellent clutch shaft manufacturing method capable of reducing material costs and processing costs and greatly simplifying the processing steps. And

[0007]

In order to achieve the above object, the present invention relates to a method of manufacturing a clutch shaft in which a large-diameter flange is formed at an upper end portion of a substantially cylindrical main body, the method comprising: By compressing and plastically deforming the rod-shaped body in the first mold, the upper part is formed into a thick large-diameter part, and the lower part is formed into a small-diameter cylindrical part. From the center of the lower end surface of the small-diameter cylindrical part, A step of preparing a preformed body having a hole of a predetermined depth formed upward, a substantially cylindrical male upper mold, and in the center of the upper surface,
The lower mold body having a hole having the same diameter as the outer diameter of the small-diameter cylindrical portion of the preformed body is elastically held in the vertical direction, and the hole in the lower mold body is located below the small-diameter cylindrical portion of the preformed body. A shaft portion having the same diameter as the inner diameter of the hole formed in the end surface is coaxially inserted from the lower side of the main body, and the upper end portion is fixed so as to be lower than the hole opening on the upper surface of the main body held elastically. and providing a second mold comprising a combination of the female lower die, in a state where the large diameter portion of the preform is fitted to the small diameter cylinder portion of the preform into the bore of the female lower die protrudes upwardly Put on,
The male upper die is lowered from above, and the small-diameter cylindrical portion lower part of the preformed body is pushed into the annular gap formed by the female lower die hole portion and the shaft portion, thereby forming a deep hole at the small-diameter cylindrical portion lower portion. while, the body of the female lower mold, the top surface of the main body together with the push down to a position flush with the shaft body upper surface, is formed between said male upper die bottom surface and the female lower die upper surface Forming a flange portion by plastically deforming a large-diameter portion of the preform in the gap in the radial direction, and a hole having the same diameter as an inner diameter of a hole formed at the lower end surface of the small-diameter cylindrical portion of the preform at the lower center. A male upper die having a formed therein, a hole having the same diameter as the outer diameter of the small-diameter cylindrical portion of the preformed body is formed in the center of the upper surface, and in this hole, formed at the lower end surface of the small-diameter cylindrical portion of the preformed body. The shaft with the same diameter as the inside diameter of the hole In a state of protruding upward, preparing a female mold bottom that is coaxially inserted into said holes, said preform by fitting the small diameter cylindrical portion of the preform into the bore of the female lower die the flange portion is mounted in a floating state above the upper surface of the female mold bottom, the upper lower <br/> was subjected to the male upper die from fitting the male upper die lower surface the flange portion of the preform Press down on the preform in a state where the engagement, the flange lower surface with pressing the upper surface the female lower die, and a drilling process through the ceiling surface of the preform in the axial body of the female lower die Take the configuration.

[0008]

According to the present invention, in manufacturing a clutch shaft, a metal rod is first compressed and plastically deformed in a first mold to form a thick large-diameter portion at an upper portion. The lower side is formed in a small-diameter cylindrical portion, and after obtaining a preformed body having a hole formed in the lower end surface of the small-diameter cylindrical portion,
Further, a flange is formed by compressing and plastically deforming with a special second mold, and finally, a hole is formed in a ceiling portion of the preformed body, that is, a non-penetrated portion of the collar portion by a mold, and Thus, a clutch shaft shape is obtained. According to this manufacturing method, a shape close to the final shape is accurately formed by plastic deformation, so that a final cutting allowance is minimized, and material costs and processing costs can be significantly reduced. . Moreover, in the preforming step, a hole having a predetermined depth is formed from the lower end side by plastic deformation in a portion which was conventionally formed into a cylindrical shape, and this hole is deeply plastically deformed. In addition, since a hole is formed by a die, the time conventionally required for drilling can be greatly reduced.
As a whole, there is an advantage that the process can be greatly simplified.

Next, the present invention will be described in detail based on embodiments.

[0010]

First, the desired shape of the clutch shaft 13 is basically the same as the shape shown in FIG. However, as shown in FIG. 10, the outer peripheral side of the collar portion 35 is lifted slightly above the center side via a tapered portion, so that the entire flange portion 35 has a shallow dish shape. The thickness T of the flange 35 is 4 mm, and the diameter M is 71 mm.
It is. The upper outer diameter N of the substantially cylindrical main body 40 is 2
6 mm, the outer diameter P under the paragraph is 25.4 m
m, the lower outer diameter Q of the paragraph is 25 mm. The total length R is 53 mm, and the hole diameter S of the through hole 33 is 1
6 mm.

Then, in order to form the clutch shaft 13, a wire made of S35C (diameter 30 mm) wound in a coil shape is prepared and supplied to a continuous multistage forging machine.
First, as shown in FIG. 1A, the piece was cut into a length of 46 mm. Then, by subjecting the cut product 41 to a first compression step, one end face was plastically deformed into a clean chamfered shape as shown in FIG. Next, by performing a second compression step, the chamfered portion was plastically deformed so as to become a larger curved portion 42 as shown in FIG. Then, by performing a third compression step, a small diameter portion 43 was formed by pressing the curved portion 42 upward and squeezing a portion below the curved portion 42 to a small diameter as shown in FIG. Next, by performing a fourth compression step, as shown in FIG. 2A, the large-diameter portion above the curved portion 42 is further crushed in the radial direction, and the peripheral surface is substantially semicircular in cross section. A thick large-diameter portion 44 bulged was formed. Then, by performing a fifth compression step, a hole 45 was formed upward from the center of the lower end surface of the small diameter portion 43 as shown in FIG. By repeating this series of steps, it was possible to obtain a preform having the special shape continuously from the continuous multistage forging machine.

Next, the preform 50 was mounted on a mold 51 as shown in FIG. 3 and pressed in the mold 51 to give plastic deformation. That is, the male upper mold 52 of the mold 51
Has a substantially cylindrical shape, and a gentle convex portion 53 capable of shaping the shape of the upper surface of the collar portion of the intended clutch shaft is formed in the center of the lower surface 52a. On the other hand, the female lower mold 54 of the mold 51 has a lower mold main body 55 in which a concave portion 56 capable of shaping the shape of a lower surface of a collar portion of a target clutch shaft is formed on an upper surface 55a. And a compression coil spring 57 for holding the pressure. A hole 58 having the same diameter as the outer diameter of the small-diameter cylindrical portion 46 of the preform 50 is formed in the center of the upper surface 55a of the lower die body 55. In the hole 58, the preform 50 is formed. A shaft portion 59 having the same diameter as the inside diameter of the hole 45 formed in the lower end surface of the small-diameter cylindrical portion 46 is coaxially inserted. In addition, the above "same diameter"
The term is not limited to the literal "same diameter", but also includes the diameter of a dimension having a tolerance that can be fitted with each other, and the following "same diameter" is also used for the same purpose. . The upper end of the push-up cylinder 60 enters the lower side of the hole 58 from below. The pushing cylinder 60
Is adapted to move up and down along the shaft portion 59 with the operation of the elevating pins 62 which perform elevating operations in a base 61 provided below the lower die body 55. And the base 61
The low friction member 63 is fitted into a portion where the lifting pin 62 moves up and down.

Therefore, as shown in FIG. 3, the small-diameter cylindrical portion 46 of the preform 50 is fitted into the hole 58 of the lower die body 55, and the large-diameter portion 44 is mounted so as to protrude upward. Then, as shown in FIG.
2 to lower the preformed body 50 so that the lower part of the small-diameter cylindrical part 46 is formed in the hole 58 of the female lower mold 54.
And into the annular gap formed by the shaft portion 59. Then, the male upper mold 52 continues to descend while the lower surface of the large diameter portion 44 of the preform 50 is in contact with the upper surface 55a of the lower mold body 55, and the upper surface 55a of the lower mold body 55 is
9 to a position at which the height of the lower mold body 55 substantially coincides with the upper surface of the lower mold body 9.
a in the gap formed between the lower surface 52a of the male upper die 52 and the upper surface 55a of the lower die body 55,
The large-diameter portion 44 of the preform 50 is plastically deformed in the radial direction, and the small-diameter cylindrical portion 46 is pushed downward to form the hole 4.
5 is extended to a predetermined length while being formed deeply. Then, the male upper mold 52 is further lowered to narrow the gap, so that the flange 35 having a predetermined thickness and the small-diameter cylindrical portion 46 (the hole 45 is deepened and the entire cylindrical portion is formed) as shown in FIG. (Formed into a cylindrical shape), and formed into a shape approximating the shape of the intended clutch shaft. Therefore, as shown in FIG. 6, the male upper mold 52 is raised and the push-up cylinder 60 is raised from below the lower mold body 55 via the elevating pins 62 to obtain the obtained preformed body 5 with a flange.
0 was demolded.

Next, the preformed body 50 with a brim thus obtained is mounted on a mold 71 as shown in FIG. That is, a hole was made in the center of the brim portion 35 and penetrated. More specifically, the male upper mold 7 of the mold 71 will be described.
2, a convex portion 73 is formed on the lower surface 72a so as to fit with the upper surface of the brim portion 35 of the preformed body 50, and a hole having the same diameter as the inner diameter of the hole 45 of the preformed body 50 is formed at the center thereof. A part 74 is formed. On the other hand, the female lower die 75 of the die 71 is provided on the upper surface 75a with the preformed body 5
A concave portion 76 that can be fitted to the lower surface of the flange portion 35 is formed at the center thereof.
A hole 77 having the same diameter as the outside diameter is formed. And
A shaft portion 78 having the same diameter as the inside diameter of the hole 45 of the preform 50 is inserted into the hole portion 77 with its tip protruding above the opening of the hole portion 77. It is inserted coaxially.

Therefore, as shown in FIG. 7, the small-diameter cylindrical portion 46 of the preform 50 is fitted into the gap formed by the hole 77 and the shaft 78 of the knife lower die 75, and The collar 35 of the body 50 is the upper surface 75a of the female lower die 75.
After being mounted so as to rise from above, as shown in FIG. 8, the male upper die 72 is lowered from above, and the lower surface 72a of the male upper die 72 is fitted to the upper surface of the flange 35 of the preform 50. By pressing down the preformed body 50 in this state, the center of the flange 35 of the preformed body 50 can be penetrated by the shaft 78 of the female lower die 75 to make a hole.

The molded article obtained in this way is shown in FIG.
As shown in (a) and (b), after cutting and induction hardening, if necessary, a notch of a detent is formed in the peripheral portion of the brim portion 35 by pressing, and finally polishing is performed. By performing the processing, the intended clutch shaft was obtained.

According to the above-described manufacturing method, at the stage of molding the preform 50, a hole 45 is formed from below into a small-diameter cylindrical portion 46 on the lower side of the large-diameter portion 44 conventionally formed into a simple columnar shape. Then, the hole 45 is deepened by the next plastic deformation to deform the small-diameter cylindrical portion 46 into a cylindrical shape, and the flange portion 35 is formed. Further, a hole is formed in the center of the flange portion 35 by a mold 71. As a result, the time conventionally required for drilling can be greatly reduced. As a whole, there is an advantage that the process can be greatly simplified. In addition, since a shape close to the final shape is precisely formed by plastic deformation, a cutting allowance for final cutting is minimized, and material costs and processing costs can be significantly reduced.

In the above embodiment, the wire 30 of S35C was used in order to obtain the preform 50.
Various iron materials and stainless steel materials can be used from the viewpoint of rigidity, toughness and the like. Further, various high-strength metals and alloys may be used.

Further, in the above embodiment, the wire 30 is wound into a coil shape, and the preform 50 is continuously obtained by passing the wire 30 through a continuous multistage forging machine. There is no need to use it, wire 30,
Alternatively, the rod material is cut into a predetermined size in advance, and the cut material is sequentially passed through forging machines having different mold shapes to obtain a preform 50.
May be obtained. According to this method, the number of steps is increased and the cost is slightly higher as compared with the case of using the continuous multistage forging machine, but it is more advantageous in terms of steps and cost than the conventional method.

Further, in the above embodiment, the cut product 41 obtained by cutting the wire 30 is deformed by the five steps shown in FIGS. 1 (b) to 1 (d) and FIGS. 2 (a) and 2 (b). The number of steps is not necessarily limited to these five steps, and the step can be performed with an appropriate number of steps.

In the above embodiment, the flange portion 35 of the clutch shaft is formed into a shallow dish shape in which the outer peripheral side of the flange portion 35 is slightly raised from the center side via the tapered portion as shown in FIG. However, it is not always necessary to form the above-mentioned shallow dish shape, and as shown in FIG.
There is no problem if the flange 35 is formed flat. In addition,
In this case, the pressing surfaces of the upper and lower dies of the dies 51 and 71 are flat.

[0022]

As described above, according to the method of manufacturing a clutch shaft of the present invention, a metal rod is compressed and plastically deformed in a first mold to form a thick large-diameter portion at an upper portion. Then, after obtaining a preformed body having a lower side formed into a small-diameter cylindrical portion having a hole, the hole is further deepened by compressing and plastically deforming the small-diameter cylindrical portion with a special second mold, and the flange portion is formed. Finally, a hole is formed in the unpenetrated portion of the collar portion by a mold to obtain a desired clutch shaft shape. According to this manufacturing method, a shape close to the final shape is accurately formed by plastic deformation, so that a final cutting allowance is minimized, and material costs and processing costs can be significantly reduced. . In addition, in the preforming step, a hole is formed from the lower side by plastic deformation in the part which was conventionally formed into a cylindrical shape, the hole is deepened by the next plastic deformation, and a collar portion is formed. Since a hole is formed in the center of the through-hole by using a metal mold, the time conventionally required for drilling can be greatly reduced. As a whole, there is an advantage that the process can be greatly simplified.

[Brief description of the drawings]

1 (a), 1 (b), 1 (c) and 1 (d) are explanatory views of a forming step of a preform in one embodiment of the present invention.

FIGS. 2 (a) and 2 (b) are explanatory views of a forming step of a preform in the above embodiment.

FIG. 3 is an explanatory diagram of a mold used in the embodiment.

FIG. 4 is a diagram illustrating the operation of the mold.

FIG. 5 is an explanatory view of the operation of the mold.

FIG. 6 is a diagram illustrating the operation of the mold.

FIG. 7 is an explanatory diagram of another mold used in the above embodiment.

FIG. 8 is an explanatory diagram of the operation of the mold.

FIG. 9 is an explanatory diagram of a wire used for manufacturing a clutch shaft.

FIG. 10 is a general explanatory view of a rotation drive mechanism of the electric washing machine.

FIGS. 11 (a), (b) and (c) are explanatory views of a conventional clutch shaft manufacturing method.

12 (a) and (b) are explanatory diagrams of a conventional method for manufacturing a clutch shaft.

[Explanation of symbols]

 35 collar part 44 large diameter part 45 hole 46 small diameter cylindrical part 50 preformed body 51,71 die 52,72 male upper die 52a, 72a lower surface 54,75 female lower die 55 lower die body 55a, 75a upper surface 58,77 hole Part 59,78 Shaft part

────────────────────────────────────────────────── ─── Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) D06F 17/08 F16C 3/00-9/06 B21J 1/00-13/14 B21J 17/00-19 / 04 B21K 1/00-31/00

Claims (1)

(57) [Claims] 1. A method of manufacturing a clutch shaft in which a large-diameter flange portion is formed at an upper end portion of a substantially cylindrical main body, wherein a metal rod body having a predetermined length is compressed in a first mold and plastically deformed. As a result, a preformed body having an upper portion formed in a thick large-diameter portion, a lower portion formed in a small-diameter cylindrical portion, and a hole having a predetermined depth formed upward from the center of the lower end surface of the small-diameter cylindrical portion is prepared. Step, a male upper mold having a substantially cylindrical shape, and a lower mold body in which a hole having the same diameter as the outer diameter of the small-diameter cylindrical portion of the preformed body is formed at the center of the upper surface is elastically held in a vertical direction, A shaft having the same diameter as the inside diameter of the hole formed in the lower end of the small-diameter cylindrical portion of the preformed body is coaxially inserted from the lower side of the main body into the hole of the lower mold body, and the upper end thereof holds the elasticity. Combined with a female lower mold fixed so that it is lower than the hole opening on the top of the main body A second mold is prepared, and the small-diameter cylindrical portion of the preform is fitted into the hole of the lower knife, and the large-diameter portion of the preform is mounted in a state of protruding upward. Lowering the male upper mold, while pressing the small-diameter cylindrical portion lower part of the preformed body into the annular gap formed by the female lower mold hole and the shaft, deeply forming the small-diameter cylindrical portion lower hole, the female lower die body, the body upper surface with depress to a position flush with the shaft body top surface, preliminary in the gap formed between said male upper die bottom surface and the female lower die upper surface Forming a flange portion by plastically deforming the large-diameter portion of the molded body in the radial direction, and forming a hole having the same diameter as the inner diameter of the hole formed on the lower end surface of the small-diameter cylindrical portion of the preformed body at the lower center. male upper mold and, with the same diameter as that of the small-diameter cylindrical outer diameter of the preform center of the upper surface Parts are formed,
In the hole, the shaft having the same diameter as the inner diameter of the hole formed in the lower end of the small-diameter cylindrical portion of the preformed body has its tip projected above the hole opening. coaxially to prepare the female mold bottom that is inserted in under the knife
The small-diameter cylindrical portion of the preform is fitted into the hole of the mold, and the flange of the preform is mounted in a state of being raised above the upper surface of the female lower mold, and the male upper mold is lowered from above, Press down on the preform to said male upper die bottom surface when the mated to the flange portion of the preform, the flange lower surface with pressing the upper surface the female lower mold, the female the ceiling surface of the preform preparation of the clutch shaft, characterized in that a drilling process through under-type shaft of.