JP3373245B2 - Method of manufacturing bent pipe - Google Patents
Method of manufacturing bent pipeInfo
- Publication number
- JP3373245B2 JP3373245B2 JP05560893A JP5560893A JP3373245B2 JP 3373245 B2 JP3373245 B2 JP 3373245B2 JP 05560893 A JP05560893 A JP 05560893A JP 5560893 A JP5560893 A JP 5560893A JP 3373245 B2 JP3373245 B2 JP 3373245B2
- Authority
- JP
- Japan
- Prior art keywords
- pipe
- straight pipe
- bent
- straight
- bent pipe
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Branch Pipes, Bends, And The Like (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
Description
【発明の詳細な説明】
【０００１】
【産業上の利用分野】本発明は、曲率半径が管直径以下
の曲管部を備えた曲げパイプの製造方法に関するもので
ある。
【０００２】
【従来の技術】一般に、液体又は気体を輸送するための
管路系において、管路の向きを変える部分には継手が配
設されるが、かかる継手としては、従来より両端部側に
夫々直管部が形成されるとともに両直管部間に曲管部が
形成された曲げパイプ(エルボ)が多用されている。そし
て、かかる曲げパイプは、普通、直管状のパイプに曲げ
加工を施すことによって製造される。しかしながら、か
かる曲げ加工では、曲管部の曲率半径をそれほどは小さ
くすることができない。けだし、曲率半径を小さくする
と、曲げ加工を施す際に折れ曲がりが生じるなどして曲
管部を一様な曲率にすることができず、また通路断面の
真円度が非常に悪くなるからである。
【０００３】しかしながら、一般に管路を急激に曲げざ
るを得ない場合も多い。例えば、自動車用エンジンのブ
ローバイガスを吸気系に案内するためのブローバイガス
通路においては、一端がシリンダヘッドカバー内に下向
きに差し込まれる一方、他端が横向きに開口する継手が
必要とされるが、シリンダヘッドカバーのすぐ上方には
ボンネットが配置されるので、ボンネットとの干渉を避
けるためにかかる継手は、シリンダヘッドカバー上端面
にできるだけ近い位置で９０°向きを変えるものである
こと、すなわち極めて急激に９０°向きを変えるもので
あることが要求される。したがって、このような継手と
して曲げパイプを用いる場合は、その曲率半径が極めて
小さいこと、例えば曲率半径が管直径以下であることが
要求される。しかしながら、曲げ加工によってこれほど
曲率半径の小さい曲げパイプを製造するのは極めてむず
かしい。
【０００４】このため、方向を急激に９０°変える必要
がある場合には、一般に次のような継手が用いられてい
る。
(１)夫々軸線に対して４５°をなす方向に斜めに切断さ
れた直管状の２つのパイプを、切断面同士が当接するよ
うに配置した上で当接部をろう付けしたもの。
(２)直管状の第１のパイプの側壁に穴をあけ、該穴まわ
りの側壁に直管状の第２のパイプを、第１のパイプと直
交するようにろう付けしたもの。
(３)互いに直交する２つの側壁を有する中空の接続部材
の上記両側壁に夫々穴をあけ、両穴まわりの側壁に夫々
直管状のパイプを側壁と直交するようにろう付けしたも
の。
【０００５】
【発明が解決しようとする課題】しかしながら、上記
(１)〜(３)に示すような従来の継手では、いずれも１つ
の継手を製造するのに複数の部品を必要とするので製造
コストが高くなるといった問題がある。また、各部品を
ろう付けしなければならないのでろう付け作業に手間が
かかり、このため製造コストがさらに高くなるといった
問題がある。本発明は、上記従来の問題点を解決するた
めになされたものであって、曲管部の曲率半径が極めて
小さく、曲管部の曲率が一様でかつ通路断面の真円度が
高い低コストの曲げパイプあるいはその製造方法を提供
することを目的とする。
【０００６】
【課題を解決するための手段】上記の目的を達するた
め、本発明は、両端部側に夫々直管部が形成されるとと
もに、両直管部間に曲率半径が管直径以下である曲管部
が形成され、かつ第１の直管部の所定の位置にパイプ圧
入のためのつば部が一体形成されている曲げパイプを製
造する方法であって、(１)最終的に得ようとする曲げパ
イプの曲管部の外周面に対応する形状をなす内周面によ
って画成される空洞部を備えた成形型を準備し、(２)直
管状の金属製パイプに曲げ加工を施して、両端部に夫々
直管部を残しつつ中間部に湾曲部が形成され、かつ成形
型の空洞部内に収容されうる形状をなす曲げパイプ中間
体を製作し、(３)曲げパイプ中間体を、第１の直管部が
所定の長さだけ成形型外に突出し、かつ第２の直管部の
先端部分が成形型外に突出するようにして、成形型の空
洞部内に配置し、(４)第１の直管部側から曲げパイプ中
間体の中空部に所定の形状を有する第１の挿入部材を圧
入し、これによって曲げパイプ中間体を径方向外向きに
拡大させて湾曲部の第１の直管部側の外周部を成形型内
周面に対応する形状に成形し、(５)第１の直管部の先端
部に、成形型との間に所定の間隙を残して第１の直管部
と嵌合する押圧部材を押し付け、これによって第１の直
管部の、押圧部材と成形型との間の間隙部に位置する部
分を径方向外向きに膨出させてつば部を形成し、(６)第
２の直管部側から曲げパイプ中間体の中空部に所定の形
状を有する第２の挿入部材を圧入し、これによって曲げ
パイプ中間体を径方向外向きに拡大させて湾曲部の第２
の直管部側の外周部を成形型内周面に対応する形状に成
形して曲げパイプを得るようにしたことを特徴とする曲
げパイプの製造方法を提供する。
【０００７】
【０００８】
【０００９】
【００１０】
【実施例】以下、図１(a)〜図１(g)を参照しつつ、本発
明にかかる曲げパイプの製造方法を具体的に説明する。
(１)第１工程(曲げ加工)
図１(a)に示すように、中空部１を有する所定の寸法の
直管状の金属製パイプ２に曲げ加工を施して、第１直管
部２aと第２直管部２bと湾曲部２cとを備えた曲げパイ
プ中間体２'を製作する。この曲げ加工においては、パ
イプ２の軸線方向のほぼ中央部に折れ曲げ方向の力が加
えられ、パイプ２が、第１直管部２aの軸線と第２直管
部２bの軸線とが直交するように曲げられた後、湾曲部
２cにリストライク(打ち直し加工)が施され、湾曲部２c
が、後で説明する成形型５の空洞部６に収容されうるよ
うな形状に好ましく変形させられる。なお、第１,第２
直管部２a,２bは、直管状のパイプ２が夫々対応する端
部側で変形されずに直管状のまま残されたものである。
【００１１】ここで、湾曲部２cは急激な曲げ状態とさ
れるので、該湾曲部２cの内側湾曲面３は、最終的に得
ようとする曲げパイプの曲管部の内側湾曲面よりも管中
心側にへこんでおり、また湾曲部２cの外側湾曲面４
も、最終的に得ようとする曲げパイプの曲管部の外側湾
曲面よりも管中心側にへこんでいる。なお、直管状のパ
イプ２の寸法は、例えば管長８０mm、外径１７.３mm、
内径１４.５mm、肉厚１.４mmとされる。また、パイプ２
の材質は、例えばＳＴＫＭ１１Ａとされる。
【００１２】(２)第２工程(スプール加工の第１段階)
図１(b)に示すように、曲げパイプ中間体２'を、成形型
５の空洞部６内に配置(クランプ)する。成形型５は、詳
しくは図示していないが、上型と下型とからなる割り型
(割りダイス)とされ、下型の空洞部内に曲げパイプ中間
体２'を入れた後、下型の上に上型を固定するようにし
ている。そして、空洞部６は、最終的に得ようとする曲
げパイプの外周面の所定の部分(第２直管部の大部分と
曲管部)に対応する形状をなす内周面によって画成され
ている。ここで、空洞部６(成形型内周面)の曲率半径
は、パイプ２の外径以下に設定されている。なお、成形
型５は、第１直管部２aのほぼ全部が該成形型５の外に
突出し、第２直管部２bの先端部が成形型５の外に少し
だけ突出するような形状とされている。
【００１３】そして、第１直管部２aの先端面と対向す
る位置に第１成形装置７を配置する。この第１成形装置
７には、円柱形空間部８aを備えた略円柱形の第１パン
チ８と、第１芯金９とが設けられている。そして、円柱
形空間部８aの径は該円柱形空間部８aが第１直管部２a
と嵌合できるように好ましく設定され、また円柱形空間
部８aの深さは第１直管部２aの軸線方向の長さよりも若
干短く設定されている。他方、第１芯金９の径は該第１
芯金９が第１直管部２aの中空部１と嵌合できるように
好ましく設定され、また第１芯金９の先端部の形状は、
最終的に得ようとする曲げパイプの曲管部の第１直管部
側の部分の内周面に対応する形状とされている。ここ
で、第１パンチ８と第１芯金９とは矢印Ｘ1方向に、所
定の押圧力でもって移動できるようになっている。な
お、第１パンチ８と第１芯金９とは、夫々、特許請求の
範囲に記載された「押圧部材」と「第１の挿入部材」とに相
当する。
【００１４】(３)第３工程(スプール加工の第２段階)
図１(c)に示すように、第１パンチ８と第１芯金９とを
成形型側に向かって、すなわち図１(b)中の矢印Ｘ1方向
に移動させる。ここにおいて、第１パンチ８の円柱形空
間部８aは第１直管部２aと嵌合するが、第１パンチ８と
成形型５との間には所定の長さαのクリアランス部(間
隙)が残される。また、このとき第１芯金９は第１直管
部２a(曲げパイプ中間体２')の中空部１内に圧入され
る。
【００１５】(４)第４工程(スプール加工の第３段階)
図１(d)に示すように、第１パンチ８をさらに成形型側
に向かって強い押圧力でもって移動させ、第１パンチ８
を成形型５に当接させる。このとき、第１直管部２aが
その軸線方向に圧縮され、第１直管部２aの、第１パン
チ８と成形型５との間のクリアランス部に位置していた
部分は、径方向外向きに膨出し、これによってつば部１
１が形成される。ここで、互いに対向する成形型５の端
面と第１パンチ８の端面とには夫々切欠部が設けられ、
第１直管部２aの肉部がこの切欠部に塑性流動すること
によってつば部１１が形成される。なお、このつば部１
１は、第１直管部２aを他の部材(例えばシリンダヘッド
カバー)への差し込み深さを一定化するために設けられ
る。
【００１６】また、このとき第１芯金９が、さらに深く
中空部１内に圧入され、第１芯金９の先端部は、湾曲部
２cのほぼ中央部に達する。このとき、湾曲部２cの第１
直管部側の半部は第１芯金９によって拡管され、その外
周部が成形型５(空洞部６)の内周面に圧接させられ、こ
の部分は最終的に得ようとする曲げパイプの曲管部の外
周部と同一形状となる。また、前記したとおり、第１芯
金９の先端部は、最終的に得ようとする曲げパイプの曲
管部の第１直管部側の部分の内周面に対応する形状とさ
れているので、湾曲部２cの第１直管部側の半部の内周
部も、最終的に得ようとする曲げパイプの曲管部の内周
部と同一形状となる。つまり、所定の形状の外周面及び
内周面を備えた、したがって通路断面の真円度の高い曲
管部の半部(第１直管部側半部)が完成するわけである。
【００１７】(５)第５工程(バルジ加工の第１段階)
図１(e)に示すように、第２直管部２bの先端面と対向す
る位置に、第２成形装置１２を配置する。この第２成形
装置１２には、円い皿状の凹部１３aを備えた略円柱形
の第２パンチ１３と、第２芯金１４とが設けられてい
る。そして、第２パンチ１３の凹部１３aの径は第２直
管部２bの外径よりは若干大きく設定され、また凹部１
３aの深さは第２直管部２bの成形型５から突出した部分
の突出長さよりも若干短く設定されている。他方、第２
芯金１４の径は該第２芯金１４が第２直管部２bの中空
部１と嵌合できるように好ましく設定され、また第２芯
金１４の先端部の形状は、最終的に得ようとする曲げパ
イプの曲管部の第２直管部側の部分の内周面に対応する
形状とされている。ここで、第２パンチ１３と第２芯金
１４とは矢印Ｘ2方向に所定の押圧力でもって移動でき
るようになっている。なお、第２芯金１４は、特許請求
の範囲に記載された「第２の挿入部材」に相当する。
【００１８】(６)第６工程(バルジ加工の第２段階)
図１(f)に示すように、第２パンチ１３と第２芯金１４
とを成形型側に向かって、すなわち図１(e)中の矢印Ｘ2
方向に移動させる。このとき第２芯金１４は第２直管部
２b(曲げパイプ中間体２')の中空部１内に圧入される。
【００１９】(７)第７工程(バルジ加工の第３段階)
図１(g)に示すように、第２パンチ１３をさらに成形型
側に向かって強い押圧力で移動させ、第２パンチ１３を
成形型５に当接させる。ここにおいて、第２パンチ１３
によって第２直管部２bの成形型５から突出した部分が
圧縮され、この部分の肉部が塑性流動により第２パンチ
１３の凹部１３a内に満たされ、これによって第２直管
部２bの先端部にビード部１５が形成される。なお、こ
のビード部１５は、第２直管部２bにホースを接続した
ときにホースの抜けを防止するために設けられる。
【００２０】また、このとき第２芯金１４が、さらに深
く中空部１内に圧入され、第２芯金１４の先端部は、湾
曲部２cのほぼ中央部に達する。このとき、湾曲部２cの
第２直管部側の半部は第２芯金１４によって拡管され、
その外周部が成形型５(空洞部６)の内周面に圧接させら
れ、この部分は最終的に得ようとする曲げパイプの曲管
部の外周部と同一形状となる。また、前記したとおり、
第２芯金１４の先端部は、最終的に得ようとする曲げパ
イプの曲管部の第２直管部側の部分の内周面に対応する
形状とされているので、湾曲部２cの第２直管部側の半
部の内周部も、最終的に得ようとする曲げパイプの曲管
部の内周部と同一形状となる。この時点で、所定の形状
の外周面及び内周面を備えた、曲率半径が小さく(管直
径以下)、かつ通路断面の真円度の高い曲管部２dが完成
する。このようにして、図２(a)〜図２(d)に示すよう
な、第１直管部２aと第２直管部２bと曲管部２dとつば
部１１とビード部１５とを備えた曲げパイプＰが完成す
る。なお、第１直管部２aの先端部には後加工によりテ
ーパ部１６が形成される。なお、かかる曲げパイプＰの
製造において、第２工程〜第４工程(スプール加工)と、
第５〜第７工程(バルジ加工)とを並行して行ってもよい
のはもちろんである。このようにすれば、製造時間を短
縮することができる。
【００２１】かかる曲げパイプＰの製造方法によれば、
単一の部品(直管状パイプ)に曲げ加工とスプール加工と
バルジ加工とを施すだけで、したがって非常に低コスト
で、曲率半径が管直径以下であり、曲率がほぼ一様であ
り、かつ通路断面の真円度の高い曲げパイプＰを製造す
ることができる。
【００２２】以下、本発明にかかる製造方法により製造
された曲げパイプＰの形状特性について説明する。図３
に、外径１７.３mm、内径１４.５mm、肉厚１.４mm、材
質ＳＴＫＭ１１Ａの直管状の金属製パイプから実際に製
造された曲げパイプＰの一例を示す。図３から明らかな
ように、この曲げパイプＰにおいては、曲管部２dはほ
ぼ一様な曲率で湾曲している。そして、曲管部２dの曲
率半径Ｒ2は１２mm、すなわち管外径(１７.３mm)のほぼ
０.７倍となっている。このように、曲管部２dの曲率半
径が非常に小さいので、該曲げパイプＰを、例えば前記
の自動車用エンジンのブローバイガス通路の継手のよう
に、管路の向きを極めて急激に９０°変える必要がある
場面における継手として用いることができる。また、曲
管部２dの外側湾曲面もほぼ一様な曲率で湾曲しており
その半径Ｒ3は１８.４mmとなっている。このように外側
湾曲面がほぼ一様な曲率となっているので、曲管部２d
の通路断面の真円度が非常に高くなる。また、曲管部２
dの内側湾曲面は極めて急激に湾曲しており、その半径
Ｒ1(測定せず)は非常に小さく、内側湾曲面は実質的に
は直角に折れ曲がっていると考えても差し支えがない。
【００２３】曲げパイプＰのt1〜t12位置における肉厚
は次のとおりである。
t1 :１.１８mm t7 :１.０２mm
t2 :１.１２mm t8 :１.０６mm
t3 :１.１０mm t9 :１.０３mm
t4 :０.８７mm t10:１.２２mm
t5 :０.９２mm t11:１.２１mm
t6 :０.９０mm t12:１.３１mm
このように、曲げパイプＰの曲管部２d及び第２直管部
２bのどの部分でも十分な肉厚が確保されているので、
曲げパイプＰの強度が十分に確保される。
【００２４】図４、図５、図６に、夫々、曲げパイプＰ
の１つの試作品(Ｎo.１ワーク)の第１直管部２aのＡ、
Ｂ、Ｃ位置における通路断面の径方向の凹凸を１０００
倍に拡大して得られた断面形状特性を示す。また、図
７、図８、図９に、夫々、曲げパイプＰのもう１つの試
作品(Ｎo.２ワーク)の第１直管部２aのＡ、Ｂ、Ｃ位置
における通路断面の径方向の凹凸を１０００倍に拡大し
て得られた断面形状特性を示す。なお、図４〜図９に示
された断面形状の真円度は次のとおりである。
(Ｎo.１ワーク) (Ｎo.２ワーク)
図４:１２.４μm 図７:１１.０μm
図５:１２.７μm 図８:１２.８μm
図６:１２.２μm 図９:１４.８μm
このように、曲げパイプＰの第１直管部２aでは、十分
な真円度が確保されている。
【００２５】以上、本発明によれば、曲管部２dの曲率
半径が管直径以下であり、曲管部２dの曲率がほぼ一様
であり、かつ通路断面の真円度の高い曲げパイプＰが低
コストで得られる。
【００２６】
【発明の作用・効果】本発明によれば、単一の直管状の
パイプに曲げ加工を施して曲げパイプ中間体を製作した
上で、該曲げパイプ中間体に第１,第２挿入部材と押圧
部材とを用いて簡単な加工(スプール加工、バルジ加工)
を施すだけで、したがって非常に低コストで、曲管部の
曲率半径が管直径以下であり、曲管部の曲率がほぼ一様
であり、かつ通路断面の真円度の高い曲げパイプを製造
することができる。
【００２７】
【００２８】
【００２９】Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a bent pipe having a curved pipe portion having a radius of curvature equal to or less than a pipe diameter. 2. Description of the Related Art Generally, in a pipeline system for transporting liquid or gas, a joint is provided at a portion where the direction of the pipeline is changed. A bent pipe (elbow) in which a straight pipe is formed and a curved pipe is formed between both straight pipes is often used. Such a bent pipe is usually manufactured by bending a straight pipe. However, such a bending process cannot make the radius of curvature of the curved tube portion so small. If the radius of curvature is reduced, the curved pipe portion cannot be made uniform in curvature due to, for example, bending when the bending process is performed, and the roundness of the passage cross section becomes extremely poor. . [0003] However, in many cases, it is generally necessary to sharply bend the pipeline. For example, in a blow-by gas passage for guiding blow-by gas of an automobile engine to an intake system, a joint having one end inserted downward into a cylinder head cover and the other end opened laterally is required. Since the bonnet is disposed immediately above the head cover, such a joint should be turned 90 ° at a position as close as possible to the upper end surface of the cylinder head cover in order to avoid interference with the bonnet, that is, 90 ° very sharply. It is required to change direction. Therefore, when a bent pipe is used as such a joint, it is required that the radius of curvature is extremely small, for example, the radius of curvature is equal to or less than the pipe diameter. However, it is extremely difficult to produce a bent pipe having such a small radius of curvature by bending. [0004] Therefore, when it is necessary to change the direction abruptly by 90 °, the following joint is generally used. (1) Two straight pipes cut obliquely in a direction at an angle of 45 ° with respect to the axis, and arranged such that the cut surfaces are in contact with each other, and then brazed the contact portions. (2) A hole is formed in the side wall of the first straight pipe, and a second straight pipe is brazed to the side wall around the hole so as to be orthogonal to the first pipe. (3) A hollow connecting member having two side walls orthogonal to each other, a hole is formed in each of the side walls, and straight pipes are brazed to the side walls around both holes so as to be orthogonal to the side walls. [0005] However, the above-mentioned problems
The conventional joints shown in (1) to (3) have a problem that the manufacturing cost is increased because a plurality of parts are required to manufacture one joint. In addition, since each component must be brazed, the brazing operation is troublesome, and thus there is a problem that the manufacturing cost is further increased. SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems, and has a very small radius of curvature of a curved tube portion, a uniform curvature of a curved tube portion, and a high circularity of a passage cross section. It is an object of the present invention to provide a bent pipe or a method for manufacturing the same. SUMMARY OF THE INVENTION In order to achieve the above object, the present invention has a straight pipe portion formed at both ends, and a radius of curvature between the straight pipe portions is smaller than the pipe diameter. A method for manufacturing a bent pipe in which a curved pipe portion is formed, and a flange portion for press-fitting the pipe is integrally formed at a predetermined position of the first straight pipe portion. A mold having a cavity defined by an inner peripheral surface having a shape corresponding to the outer peripheral surface of the curved pipe portion of the bent pipe to be prepared is prepared, and (2) a bending process is performed on a straight tubular metal pipe. To produce a bent pipe intermediate having a curved portion formed at an intermediate portion while leaving straight pipe portions at both ends, and having a shape that can be accommodated in a cavity of a molding die. (3) A bent pipe intermediate The first straight pipe portion projects outside the molding die by a predetermined length, and the tip portion of the second straight pipe portion (4) A first insertion member having a predetermined shape is disposed in the hollow portion of the bent pipe intermediate body from the first straight pipe portion side so as to protrude out of the forming die. Press-fitting, thereby expanding the bent pipe intermediate body radially outward to form an outer peripheral portion of the curved portion on the side of the first straight pipe portion into a shape corresponding to the inner peripheral surface of the forming die; A pressing member that fits with the first straight pipe portion is pressed against the tip of the straight pipe portion while leaving a predetermined gap between the straight die portion and the pressing member. A portion located in the gap between the mold and the mold is bulged radially outward to form a flange portion. (6) A predetermined shape is formed in the hollow portion of the bent pipe intermediate from the second straight pipe portion side. Press-fits a second insert member having the bent pipe intermediate body in a radially outward direction so that
A method of manufacturing a bent pipe, characterized in that an outer peripheral portion on the side of the straight pipe portion is formed into a shape corresponding to an inner peripheral surface of a forming die to obtain a bent pipe. [0010] Hereinafter, a method for manufacturing a bent pipe according to the present invention will be described in detail with reference to FIGS. 1A to 1 G. (1) First Step (Bending Process) As shown in FIG. 1 (a), a bending process is performed on a straight metal pipe 2 having a hollow portion 1 and having a predetermined dimension to form a first straight pipe portion 2a. A bent pipe intermediate body 2 'having the second straight pipe portion 2b and the curved portion 2c is manufactured. In this bending process, a force in the bending direction is applied to a substantially central portion of the pipe 2 in the axial direction, so that the pipe 2 is perpendicular to the axis of the first straight pipe 2a and the axis of the second straight pipe 2b. After being bent as described above, the bending portion 2c is subjected to restriking (reworking), and the bending portion 2c
Is preferably deformed into a shape that can be accommodated in the cavity 6 of the mold 5 described later. Note that the first and second
The straight pipe portions 2a and 2b are formed by leaving the straight pipes 2 in a straight tube shape without being deformed at the corresponding end portions. Here, since the curved portion 2c is in a sharply bent state, the inner curved surface 3 of the curved portion 2c has a smaller pipe than the inner curved surface of the curved pipe portion of the bent pipe to be finally obtained. It is depressed toward the center, and the outer curved surface 4 of the curved portion 2c.
However, the bent portion of the bent pipe to be finally obtained is recessed toward the center of the pipe from the outer curved surface. The dimensions of the straight pipe 2 are, for example, a pipe length of 80 mm, an outer diameter of 17.3 mm,
The inner diameter is 14.5 mm and the wall thickness is 1.4 mm. Also, pipe 2
Is, for example, STKM11A. (2) Second Step (First Step of Spool Processing) As shown in FIG. 1B, the bent pipe intermediate body 2 ′ is arranged (clamped) in the cavity 6 of the forming die 5. Although not shown in detail, the mold 5 is a split mold composed of an upper mold and a lower mold.
(Split die), and after inserting the bent pipe intermediate 2 ′ into the cavity of the lower mold, the upper mold is fixed on the lower mold. The hollow portion 6 is defined by an inner peripheral surface having a shape corresponding to a predetermined portion (most of the second straight pipe portion and the curved pipe portion) on the outer peripheral surface of the bent pipe to be finally obtained. ing. Here, the radius of curvature of the cavity 6 (the inner peripheral surface of the mold) is set to be equal to or less than the outer diameter of the pipe 2. The molding die 5 has a shape such that substantially the entire first straight pipe portion 2a protrudes outside the molding die 5, and the tip of the second straight pipe portion 2b slightly protrudes outside the molding die 5. Have been. Then, the first molding device 7 is arranged at a position facing the distal end surface of the first straight pipe portion 2a. The first forming device 7 includes a substantially cylindrical first punch 8 having a cylindrical space 8a and a first metal core 9. The diameter of the cylindrical space 8a is such that the cylindrical space 8a is the first straight pipe 2a.
The depth of the cylindrical space portion 8a is set slightly shorter than the length of the first straight pipe portion 2a in the axial direction. On the other hand, the diameter of the first metal core 9 is
The core 9 is preferably set so as to be able to fit with the hollow portion 1 of the first straight pipe portion 2a, and the shape of the tip of the first core 9 is
The bent pipe has a shape corresponding to an inner peripheral surface of a portion on the side of the first straight pipe of the bent pipe to be finally obtained. Here, the first punch 8 and the first metal core 9 in the direction of arrow X 1, is adapted to be movable with a predetermined pressing force. Note that the first punch 8 and the first metal core 9 correspond to a “pressing member” and a “first insertion member” described in the claims, respectively. (3) Third Step (Second Stage of Spool Processing) As shown in FIG. 1 (c), the first punch 8 and the first metal core 9 are moved toward the molding die, ie, as shown in FIG. b) moving the direction of arrow X 1 in. Here, the cylindrical space portion 8a of the first punch 8 fits with the first straight pipe portion 2a, but a clearance portion (gap) having a predetermined length α is provided between the first punch 8 and the molding die 5. Is left. At this time, the first metal core 9 is pressed into the hollow portion 1 of the first straight pipe portion 2a (bent pipe intermediate body 2 '). (4) Fourth Step (Third Stage of Spool Processing) As shown in FIG. 1D, the first punch 8 is further moved toward the molding die with a strong pressing force, and the first punch 8 is moved. 8
Is brought into contact with the mold 5. At this time, the first straight pipe portion 2a is compressed in the axial direction, and the portion of the first straight pipe portion 2a located at the clearance between the first punch 8 and the molding die 5 is outside the radial direction. Bulges in the direction, so that the collar 1
1 is formed. Here, notches are respectively provided on the end face of the molding die 5 and the end face of the first punch 8 which face each other,
The collar portion 11 is formed by the plastic flow of the flesh portion of the first straight pipe portion 2a into the notch portion. In addition, this collar part 1
Reference numeral 1 is provided to stabilize the insertion depth of the first straight pipe portion 2a into another member (for example, a cylinder head cover). At this time, the first metal core 9 is further press-fitted into the hollow portion 1 so that the tip of the first metal core 9 reaches almost the center of the curved portion 2c. At this time, the first portion of the curved portion 2c
The half part on the side of the straight pipe part is expanded by the first metal core 9, and the outer peripheral part thereof is pressed against the inner peripheral surface of the mold 5 (hollow part 6), and this part is a bent pipe finally obtained. Has the same shape as the outer peripheral portion of the curved pipe portion. Further, as described above, the distal end of the first metal core 9 has a shape corresponding to the inner peripheral surface of the bent portion of the bent pipe to be finally obtained on the side of the first straight portion. Therefore, the inner peripheral portion of the half of the curved portion 2c on the first straight pipe portion side has the same shape as the inner peripheral portion of the curved pipe portion of the bent pipe to be finally obtained. In other words, the half of the curved pipe portion (the first straight pipe portion-side half portion) having the outer peripheral surface and the inner peripheral surface of a predetermined shape, and thus having a high roundness of the passage cross section is completed. (5) Fifth Step (First Step of Bulge Processing) As shown in FIG. 1 (e), the second molding device 12 is arranged at a position facing the distal end surface of the second straight pipe portion 2b. . The second molding device 12 is provided with a substantially cylindrical second punch 13 having a round dish-shaped concave portion 13a, and a second metal core 14. The diameter of the concave portion 13a of the second punch 13 is set slightly larger than the outer diameter of the second straight pipe portion 2b.
The depth of 3a is set slightly shorter than the protruding length of the portion of the second straight pipe portion 2b protruding from the molding die 5. On the other hand, the second
The diameter of the mandrel 14 is preferably set so that the second mandrel 14 can be fitted into the hollow portion 1 of the second straight pipe portion 2b, and the shape of the tip of the second mandrel 14 is finally obtained. The bent pipe has a shape corresponding to the inner peripheral surface of the portion of the bent pipe on the side of the second straight pipe. Here, the second punch 13 and the second metal core 14 is made to move with a predetermined pressing force to the direction of arrow X 2. The second metal core 14 corresponds to a “second insertion member” described in the claims. (6) Sixth Step (Second Stage of Bulging) As shown in FIG. 1 (f), the second punch 13 and the second metal core 14 are used.
Toward the mold, that is, the arrow X 2 in FIG.
Move in the direction. At this time, the second metal core 14 is pressed into the hollow portion 1 of the second straight pipe portion 2b (bent pipe intermediate 2 '). (7) Seventh step (third stage of bulging) As shown in FIG. 1 (g), the second punch 13 is further moved toward the molding die with a strong pressing force, Is brought into contact with the mold 5. Here, the second punch 13
As a result, the portion of the second straight pipe portion 2b protruding from the molding die 5 is compressed, and the flesh of this portion is filled in the recess 13a of the second punch 13 by plastic flow. A bead portion 15 is formed in the portion. The bead portion 15 is provided to prevent the hose from coming off when the hose is connected to the second straight pipe portion 2b. At this time, the second metal core 14 is further press-fitted into the hollow portion 1, and the tip of the second metal core 14 reaches almost the center of the curved portion 2c. At this time, the half of the curved portion 2c on the side of the second straight pipe portion is expanded by the second metal core 14, and
The outer peripheral portion is pressed against the inner peripheral surface of the molding die 5 (hollow portion 6), and this portion has the same shape as the outer peripheral portion of the curved pipe portion of the bending pipe to be finally obtained. Also, as mentioned above,
The distal end of the second cored bar 14 has a shape corresponding to the inner peripheral surface of the curved portion of the bent pipe to be finally obtained, which is on the side of the second straight portion. The inner peripheral part of the half on the second straight pipe part side also has the same shape as the inner peripheral part of the curved pipe part of the bent pipe to be finally obtained. At this point, a curved pipe portion 2d having a predetermined radius of curvature (less than or equal to the pipe diameter) and an outer peripheral surface and an inner peripheral surface having a predetermined shape and a high circularity of the passage cross section is completed. In this manner, as shown in FIGS. 2A to 2D, the first straight pipe portion 2a, the second straight pipe portion 2b, the curved pipe portion 2d, the collar portion 11, and the bead portion 15 are provided. The bent pipe P is completed. Note that a tapered portion 16 is formed at the tip of the first straight pipe portion 2a by post-processing. In the manufacture of the bent pipe P, a second step to a fourth step (spool processing)
It goes without saying that the fifth to seventh steps (bulge processing) may be performed in parallel. In this way, the manufacturing time can be reduced. According to the method of manufacturing the bent pipe P,
It only requires bending, spooling and bulging on a single part (straight tubular pipe), so it is very low cost, the radius of curvature is less than the pipe diameter, the curvature is almost uniform and the passage is A bent pipe P having a high roundness in cross section can be manufactured. Hereinafter, the shape characteristics of the bent pipe P manufactured by the manufacturing method according to the present invention will be described. FIG.
An example of a bent pipe P actually manufactured from a straight tubular metal pipe made of STKM11A with an outer diameter of 17.3 mm, an inner diameter of 14.5 mm, a wall thickness of 1.4 mm, and a material of STKM11A is shown in FIG. As is clear from FIG. 3, in the bent pipe P, the curved pipe portion 2d is curved with a substantially uniform curvature. Then, the radius of curvature R 2 of the curved pipe portion 2d is made 12 mm, i.e. approximately 0.7 times the outer diameter (17.3 mm). As described above, since the radius of curvature of the curved pipe portion 2d is very small, the direction of the bent pipe P is extremely rapidly changed by 90 ° like the joint of the blow-by gas passage of the automobile engine. It can be used as a joint when necessary. Further, the radius R 3 outer curved surface of the curved pipe portion 2d also is curved in a substantially uniform curvature and has a 18.4 mm. Since the outer curved surface has a substantially uniform curvature as described above, the curved pipe portion 2d
The roundness of the passage cross section becomes extremely high. In addition, curved pipe section 2
The inner curved surface of d is extremely sharply curved, its radius R 1 (not measured) is very small, and it can be safely assumed that the inner curved surface is bent substantially at a right angle. The thickness of the bent pipe P at the positions t 1 to t 12 is as follows. t 1 : 1.18 mm t 7 : 1.02 mm t 2 : 1.12 mm t 8 : 1.06 mm t 3 : 1.10 mm t 9 : 1.03 mm t 4 : 0.87 mm t 10 : 1.22 mm t 5 : 0.92 mm t 11 : 1.21 mm t 6 : 0.90 mm t 12 : 1.31 mm As described above, a sufficient wall thickness can be obtained in any of the curved pipe portion 2 d and the second straight pipe portion 2 b of the bent pipe P. Since it is secured,
The strength of the bent pipe P is sufficiently ensured. 4, 5, and 6 show bent pipes P, respectively.
A of the first straight pipe part 2a of one prototype (No. 1 work)
The unevenness in the radial direction of the passage cross section at the positions B and C is 1000
The cross-sectional shape characteristics obtained by magnifying twice are shown. 7, 8, and 9 show the radial cross section of the passage section at the positions A, B, and C of the first straight pipe portion 2 a of another prototype (No. 2 work) of the bent pipe P, respectively. The cross-sectional shape characteristics obtained by enlarging the unevenness by 1000 times are shown. The roundness of the cross-sectional shapes shown in FIGS. 4 to 9 is as follows. (No.1 work) (No.2 work) Figure 4: 12.4μm Figure 7: 11.0μm Figure 5: 12.7μm Figure 8: 12.8μm Figure 6: 12.2μm Figure 9: 14.8μm In the first straight pipe portion 2a of the bent pipe P, sufficient roundness is ensured. As described above, according to the present invention, the radius of curvature of the curved pipe portion 2d is equal to or less than the pipe diameter, the curvature of the curved pipe portion 2d is substantially uniform, and the bent pipe P having a high circularity in the cross section of the passage. Can be obtained at low cost. According to the present invention, a single straight tubular pipe is bent to produce a bent pipe intermediate, and then the first and second bent pipe intermediates are formed. Simple processing using the insertion member and pressing member (spool processing, bulge processing)
Therefore, it is possible to produce a bent pipe with a very low cost, a radius of curvature of the curved pipe portion equal to or less than the pipe diameter, a substantially uniform curvature of the curved pipe section, and a high roundness of the passage cross section. can do. [0029]
【図面の簡単な説明】
【図１】 (a)〜(g)は本発明にかかる曲げパイプの製造
工程を示す図であり、夫々第１〜第７工程を示してい
る。
【図２】 (a)〜(d)は夫々、本発明にかかる曲げパイプ
の上面平面図と立面図と側面図と下面平面図とである。
【図３】 本発明にかかる曲げパイプの立面図である。
【図４】 本発明にかかる曲げパイプの１つの試作品
(Ｎo.１ワーク)の図３中のＡ位置における通路断面の径
方向の凹凸を１０００倍に拡大して得られた断面形状特
性を示す図である。
【図５】 Ｎo.１ワークの図３中のＢ位置における通路
断面の径方向の凹凸を１０００倍に拡大して得られた断
面形状特性を示す図である。
【図６】 Ｎo.１ワークの図３中のＣ位置における通路
断面の径方向の凹凸を１０００倍に拡大して得られた断
面形状特性を示す図である。
【図７】 本発明にかかる曲げパイプのもう１つの試作
品(Ｎo.２ワーク)の図３中のＡ位置における通路断面の
径方向の凹凸を１０００倍に拡大して得られた断面形状
特性を示す図である。
【図８】 Ｎo.２ワークの図３中のＢ位置における通路
断面の径方向の凹凸を１０００倍に拡大して得られた断
面形状特性を示す図である。
【図９】 Ｎo.２ワークの図３中のＣ位置における通路
断面の径方向の凹凸を１０００倍に拡大して得られた断
面形状特性を示す図である。
【符号の説明】
Ｐ…曲げパイプ
１…中空部
２…パイプ
２'…曲げパイプ中間体
２a…第１直管部
２b…第２直管部
２c…湾曲部
２d…曲管部
５…成形型
６…空洞部
８…第１パンチ
９…第１芯金
１１…つば部
１４…第２芯金BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1 (a) to 1 (g) are diagrams showing a manufacturing process of a bent pipe according to the present invention, showing first to seventh processes, respectively. FIGS. 2A to 2D are a top plan view, an elevation view, a side view, and a bottom plan view of a bent pipe according to the present invention, respectively. FIG. 3 is an elevation view of a bent pipe according to the present invention. FIG. 4 shows one prototype of a bent pipe according to the present invention.
FIG. 4 is a diagram showing a cross-sectional shape characteristic obtained by enlarging the unevenness in the radial direction of the passage cross section at the position A in FIG. 3 (No. 1 work) by 1000 times. 5 is a view showing a cross-sectional shape characteristic obtained by enlarging the unevenness in the radial direction of the passage cross section at a position B in FIG. 3 of the No. 1 work by 1000 times. 6 is a view showing a cross-sectional shape characteristic obtained by enlarging the unevenness in the radial direction of the passage cross section at the position C in FIG. 3 of the No. 1 work by 1000 times. 7 is a cross-sectional shape characteristic obtained by enlarging the unevenness in the radial direction of the passage cross section at the position A in FIG. 3 of another prototype of the bent pipe according to the present invention (No. 2 work) by 1000 times. FIG. 8 is a diagram showing a cross-sectional shape characteristic obtained by enlarging the unevenness in the radial direction of the passage cross section at a position B in FIG. 3 of the No. 2 work by 1000 times. 9 is a diagram showing a cross-sectional shape characteristic obtained by enlarging the unevenness in the radial direction of the passage cross section at the position C in FIG. 3 of the No. 2 work by 1000 times. [Description of Signs] P: bent pipe 1 ... hollow part 2 ... pipe 2 '... bent pipe intermediate 2a ... first straight pipe part 2b ... second straight pipe part 2c ... curved part 2d ... curved pipe part 5 ... molding die 6 hollow part 8 first punch 9 first core metal 11 flange 14 second metal core
───────────────────────────────────────────────────── フロントページの続き (56)参考文献 特開 平２−253088（ＪＰ，Ａ) 特開 昭54−157181（ＪＰ，Ａ) 実開 昭56−133192（ＪＰ，Ｕ) 実開 平１−21892（ＪＰ，Ｕ) (58)調査した分野(Int.Cl.7，ＤＢ名) B21D 51/10 B21D 51/16 - 51/18 B21D 3/00 B21D 3/14 B21D 5/00 - 9/18 F16L 43/00 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-2-253088 (JP, A) JP-A-54-157181 (JP, A) JP-A-56-133192 (JP, U) JP-A-1 21892 (JP, U) (58) Fields investigated (Int. Cl. 7 , DB name) B21D 51/10 B21D 51/16-51/18 B21D 3/00 B21D 3/14 B21D 5/00-9/18 F16L 43/00
Claims (1)
もに、両直管部間に曲率半径が管直径以下である曲管部
が形成され、かつ第１の直管部の所定の位置にパイプ圧
入のためのつば部が一体形成されている曲げパイプを製
造する方法であって、 最終的に得ようとする曲げパイプの曲管部の外周面に対
応する形状をなす内周面によって画成される空洞部を備
えた成形型を準備し、 直管状の金属製パイプに曲げ加工を施して、両端部に夫
々直管部を残しつつ中間部に湾曲部が形成され、かつ成
形型の空洞部内に収容されうる形状をなす曲げパイプ中
間体を製作し、 曲げパイプ中間体を、第１の直管部が所定の長さだけ成
形型外に突出し、かつ第２の直管部の先端部分が成形型
外に突出するようにして、成形型の空洞部内に配置し、 第１の直管部側から曲げパイプ中間体の中空部に所定の
形状を有する第１の挿入部材を圧入し、これによって曲
げパイプ中間体を径方向外向きに拡大させて湾曲部の第
１の直管部側の外周部を成形型内周面に対応する形状に
成形し、 第１の直管部の先端部に、成形型との間に所定の間隙を
残して第１の直管部と嵌合する押圧部材を押し付け、こ
れによって第１の直管部の、押圧部材と成形型との間の
間隙部に位置する部分を径方向外向きに膨出させてつば
部を形成し、 第２の直管部側から曲げパイプ中間体の中空部に所定の
形状を有する第２の挿入部材を圧入し、これによって曲
げパイプ中間体を径方向外向きに拡大させて湾曲部の第
２の直管部側の外周部を成形型内周面に対応する形状に
成形して曲げパイプを得るようにしたことを特徴とする
曲げパイプの製造方法。(57) [Claims 1] A straight pipe portion is formed on each of both end portions, and a curved pipe portion having a radius of curvature equal to or less than the pipe diameter is formed between both straight pipe portions, and A method of manufacturing a bent pipe in which a flange portion for press-fitting a pipe is integrally formed at a predetermined position of a first straight pipe portion, wherein an outer peripheral surface of a bent pipe portion of a bent pipe to be finally obtained Prepare a forming die with a cavity defined by the inner peripheral surface having a shape corresponding to, and bend a straight tubular metal pipe, leaving a straight pipe part at both ends, and an intermediate part A bent pipe intermediate body having a curved portion formed therein and having a shape that can be accommodated in the cavity of the molding die is manufactured, and the bent pipe intermediate body is removed from the molding die by a first straight pipe portion by a predetermined length. The inside of the cavity of the molding die is protruded and the tip portion of the second straight pipe portion projects outside the molding die. A first insertion member having a predetermined shape is press-fitted into the hollow portion of the bent pipe intermediate body from the first straight pipe portion side, thereby expanding the bent pipe intermediate body radially outward and bending the bent pipe intermediate body. The outer peripheral portion of the first straight pipe portion is formed into a shape corresponding to the inner peripheral surface of the forming die, and a first gap is formed at the tip of the first straight pipe portion while leaving a predetermined gap between the first straight pipe portion and the forming die. Pressing a pressing member that fits into the straight pipe portion of the first straight pipe portion, thereby bulging the portion of the first straight pipe portion located in the gap between the pressing member and the molding die outward in the radial direction, thereby forming a flange portion. Is formed, and a second insertion member having a predetermined shape is press-fitted into the hollow portion of the bent pipe intermediate body from the second straight pipe portion side, whereby the bent pipe intermediate body is expanded radially outward and bent. The outer peripheral part of the part on the side of the second straight pipe part is formed into a shape corresponding to the inner peripheral surface of the forming die to obtain a bent pipe. Method for producing a bent pipe, characterized and.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP05560893A JP3373245B2 (en) | 1993-03-16 | 1993-03-16 | Method of manufacturing bent pipe |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP05560893A JP3373245B2 (en) | 1993-03-16 | 1993-03-16 | Method of manufacturing bent pipe |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH06262282A JPH06262282A (en) | 1994-09-20 |
| JP3373245B2 true JP3373245B2 (en) | 2003-02-04 |
Family
ID=13003488
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP05560893A Expired - Fee Related JP3373245B2 (en) | 1993-03-16 | 1993-03-16 | Method of manufacturing bent pipe |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3373245B2 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19614196B4 (en) * | 1995-04-14 | 2007-12-06 | Denso Corp., Kariya | Method and device for producing a pipe |
| JP2006263750A (en) * | 2005-03-22 | 2006-10-05 | Calsonic Kansei Corp | Pipe manufacturing method |
| JP5019181B2 (en) * | 2008-03-21 | 2012-09-05 | 株式会社昭和螺旋管製作所 | Method of manufacturing bent pipe having bellows and bent pipe having bellows |
| CN103672272A (en) * | 2012-09-11 | 2014-03-26 | 北京首宏钢重型装备技术有限公司 | Pipe blank |
| JP6546684B1 (en) * | 2018-10-19 | 2019-07-17 | サンライズ工業株式会社 | Method of manufacturing bent pipe |
| CN111531051A (en) * | 2020-03-30 | 2020-08-14 | 江苏统联科技股份有限公司 | Method for processing pipe orifice convex diameter of waste gas recirculation water inlet and outlet pipe |
-
1993
- 1993-03-16 JP JP05560893A patent/JP3373245B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH06262282A (en) | 1994-09-20 |
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