JP3397746B2 - Method of manufacturing metal product in which thick portion is integrally formed on the outer peripheral portion of thin metal disk, and apparatus for manufacturing such metal product - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing a metal product in which a thick wall portion is integrally formed on the outer peripheral portion of a thin metal disk and a manufacturing apparatus for such a metal product, and more particularly to a thin metal disk material. The present invention relates to a method capable of advantageously producing a target metal product by performing a rolling process on an outer peripheral portion, and a production apparatus preferably used for such a production method.

[0002]

BACKGROUND ART Conventionally, a metal product in which a thick portion is integrally formed on an outer peripheral portion of a thin metal disk has been generally used as a component part of various machines. The drive plate that connects the crankshaft and the torque converter of the automatic transmission is made of such a metal product. That is, this drive plate has a cylindrical thick portion integrally formed on the outer peripheral portion of a disc-shaped base portion, which is light-weight and flexible by being made thin. That is, a gear portion having a large number of teeth is provided on the outer peripheral surface of the thick portion.

By the way, various methods have heretofore been proposed as a method for producing a metal product, such as a drive plate or the like, in which a thick metal portion is integrally formed on the outer peripheral portion of a thin metal disk. As one of them, for example, a method disclosed in Japanese Patent Application Laid-Open No. 4-37432 is known.

That is, in the method of manufacturing a metal product described in the above publication, first, a thin metal disk material that gives a target metal product is clamped between two molds coaxially opposed to each other. While the two molds are integrally rotated with their shaft centers as rotation axes, the ridge formation on the outer peripheral surface is performed while rotating the slitting roller having the ridge having a V-shaped cross section formed on the outer peripheral surface. By pressing the portion against the outer peripheral surface of the metal disk material under the integral rotation, the outer peripheral portion of the metal disk material is slit and divided in the plate thickness direction to form a bifurcated shape. Next, a mold having two dies different from the above two dies, in which a cavity having a shape corresponding to the cylindrical thick portion of the intended metal product is formed in the outer peripheral portion of the die matching portions. A metal disc material having a bifurcated outer peripheral portion is sandwiched between two dies of this molding die, and the metal disc material is integrally rotated with the two dies. And then
While rotating the thickening roller having a cylindrical outer peripheral surface, the outer peripheral surface is pressed against the bifurcated outer peripheral portion of the metal disk material, so that the outer peripheral portion has a shape corresponding to the thick portion. In order to increase the thickness, the thick portion is formed. In addition, here, after forming such a thick portion, using a gear portion forming roller in which uneven portions for giving teeth and tooth grooves are continuously formed on the outer peripheral surface, the outer peripheral surface of the thick portion is rolled. By performing the above, the gear portion is formed on the outer peripheral surface.

In such a method, the outer peripheral portion of the metal disc material is subjected to a rolling process using a predetermined rolling roller, so that the outer peripheral portion is thickened to increase the thickness. Since the part is formed, the target metal product can be obtained with a comparatively small processing force, but as a pre-processing for thickening the outer peripheral part of the metal disc material Since the slitting is performed on the outer peripheral portion, there is a problem that the number of steps is increased by that much, and thereby the productivity is reduced.
Moreover, in the method as described above, since the molding die having the cavity having the shape corresponding to the thick portion is used, a plurality of types of metal products having different shapes and sizes of the thick portion are manufactured. In this case, it is necessary to prepare as many expensive molding dies as the number of intended metal products, which increases the manufacturing cost of the molding dies and thus increases the manufacturing cost of metal products. The problem of being lost was inherent.

As another method for manufacturing the metal product, for example, a method disclosed in Japanese Patent Laid-Open No. 9-66330 is also known.

In this method, a molding die made of two dies having a diameter smaller than that of the metal disc material is used. First, the outer peripheral portion of the metal disc material is positioned so as to project laterally from between the two dies. In this way, the metal disc material can be integrally rotated with the two molds with their axes being the rotation axis while being clamped between the two molds. A peripheral groove is provided on the outer peripheral surface, and two side surfaces of the peripheral groove are inclined surfaces that widen toward the opening side, and one side surface is configured to be higher than the other side surface. The thickened roller is used to rotate the thickened roller to bring the two molds close to each other, and the tip of the outer peripheral portion of the metal disk material that is integrally rotated with the two molds is connected to the one of the circumferential grooves Of the metal disk material while sliding the tip of the outer peripheral portion of the metal disk material against one side surface and the bottom surface of the circumferential groove while bringing the thickening roller closer to the two molds. Push into. As a result, the outer peripheral portion of the metal disc material is bent and deformed, and the cylindrical thick portion is formed by compressing between the both side surfaces of the peripheral groove to increase the thickness. At this time, since the metal disc material is thin, buckling is likely to occur at the outer peripheral portion of the metal disc material that cannot be pushed into the circumferential groove. Therefore, in this manufacturing method, the expansion angle of both side surfaces of the circumferential groove is set to an appropriate size to prevent such buckling. Also here, after the thick portion is formed, the gear portion is formed on the outer peripheral surface by performing the rolling process using the gear portion forming roller on the outer peripheral surface of the thick portion. Become.

In such a manufacturing method, unlike the method for manufacturing a metal product disclosed in the above-mentioned Japanese Patent Laid-Open No. 4-37432, the slotting process is performed before the thickening process on the metal disc material. Since it is not performed, the target metal product can be efficiently obtained with excellent productivity, and a cavity having a shape corresponding to the thick portion is provided in the thickening roller, so that the molding die is simply Since it is used only for clamping and rotating a metal disc material, one molding die can be used when manufacturing multiple types of metal products with different shapes and sizes of thick parts. Since it can be used for multiple purposes, it is only necessary to prepare multiple types of thickening rollers, which are cheaper and easier to manufacture than molding dies, which is extremely advantageous in manufacturing costs of these multiple types of metal products. It is the also becomes possible to suppress.

However, in the case of adopting such a manufacturing method, in the process of thickening the outer peripheral portion of the metal disk material to form the thick portion, the outer peripheral portion is prevented from buckling, When setting the expansion angle of both sides of the peripheral groove formed on the outer peripheral surface of the thickening roller to an appropriate size, it is not easy to determine the optimum value of the expansion angle, Since it is not easy to form a circumferential groove on the outer peripheral surface of the thickening roller so that the expansion angle exactly matches the determined optimum value, it prevents buckling when forming a thick part. Therefore, there was a big problem in that extremely difficult work was forced.

[0010]

The present invention has been made in view of the circumstances as described above, and a problem to be solved by the present invention is to form a thick metal portion integrally with an outer peripheral portion of a thin metal disk. When manufacturing a metal product made of a metal, it is possible to secure excellent productivity, and it is possible to obtain multiple types of metal products with different shapes and sizes of thick-walled parts at the lowest possible price. It is an object of the present invention to provide a method capable of reliably and extremely easily preventing the occurrence of buckling during the step of forming a meat portion. Further, in the present invention, it is also a problem to be solved to provide an apparatus capable of industrially producing such a metal product.

[0011]

According to the present invention, in order to solve such a problem, a rolling process is performed on an outer peripheral portion of a thin metal disc material, so that the outer peripheral portion of the thin metal disc is formed. A method for manufacturing a metal product having a thick portion integrally formed, comprising: (a) contacting one surface of the metal disc material;
A first die provided with a first clamp part having a first contact surface having a diameter smaller than that of the metal disk material, and the metal disk material, which contacts the other surface of the metal disk material. A second clamp portion having a second contact surface having a diameter equal to or larger than that of the first clamp portion is coaxial with the first contact surface of the first clamp portion. A second mold which is provided so as to face each other and is configured to be integrally rotatable with the first clamp part with the central axis of the first clamp part as the first rotation axis. Using a molding die, in a state where the metal disc material is brought into contact with the first and second contact surfaces of the first and second clamp portions, respectively, to the first and second clamp portions. Positioned concentrically with respect to each other, a clamp is provided between the first clamp part and the second clamp part. And (b) integrally rotating the first and second clamp portions around the first rotation axis while pushing down, and (b) the metal disc material of the metal disk material accompanying the integral rotation around the first rotation axis. Under the rotating condition, in the height direction intermediate portion of the outer peripheral portion facing the outer peripheral surface of the metal disc material,
A second clamp part having a small-diameter thick-walled part forming roller provided with a stepped surface that makes the second clamp side part of the outer peripheral part smaller in diameter than the first clamp part side part. The outer peripheral surface of the side portion is brought into contact with the outer peripheral surface of the metal disc material, and is rotated about a second rotation axis parallel to the first rotation axis, while having a diameter relative to the metal disc material. By pressing inward in the direction, the outer peripheral portion of the metal disc material is formed on the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller, the step surface, and the second clamp portion. Formed with the second contact surface,
An outer peripheral portion of a thin-walled metal disk, including a step of forming the thick-walled portion by pushing it into a cavity having a shape corresponding to the thick-walled portion of the metal product, compressing it, and increasing the thickness. The gist is a method of manufacturing a metal product in which a thick part is integrally formed.

[0012] In short, according to the present invention, a method for producing a metal product in which a thick metal portion is integrally formed on the outer peripheral portion of a thin metal disc is a metal disc material which gives a target metal product,
While contacting the first and second contact surfaces of the first and second clamp portions on both sides thereof to clamp between the first clamp portion and the second clamp portion, And the second clamp part is rotated integrally with the second clamp part, and the step surface provided at the intermediate part in the height direction of the outer peripheral part has the second clamp part side part of the outer peripheral part at the first clamp part. The thick-walled portion forming roller having a smaller diameter than that of the side portion is pressed against the outer peripheral surface of the metal disc material at the outer peripheral surface of the second clamp portion side portion having the smaller diameter. The outer peripheral portion is formed by the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller, the step surface and the second contact surface of the second clamp portion, and the thickness of the target metal product. Push into the cavity of the shape corresponding to the meat Nde compressed and allowed thickening is a thing which is adapted to form a thick-walled portion.

As described above, according to the method of the present invention, the outer peripheral portion of the metal disc material is thickened by the combination of the rolling process using the slitting roller and the rolling process using the thickening roller. Unlike the conventional method of forming a thick wall portion by simply rolling the outer peripheral portion of the metal disc material using a thick wall portion forming roller, the outer peripheral portion can be easily formed without any trouble. Since it is possible to increase the thickness, the target metal product can be efficiently and excellently manufactured with a smaller number of steps as compared with the case where the conventional method of combining two different types of rolling processes is adopted. It can be advantageously manufactured with productivity.

Further, in the method of the present invention, the cavity corresponding to the thick portion is provided with the outer peripheral surface and the step surface of the second clamp portion side portion of the thick portion forming roller and the second clamp portion of the second clamp portion. When changing the shape and size of the thick part to be formed from the place where it is formed with the contact surface, the outer peripheral surface and the step surface of the second clamp part side part of the thick part forming roller It is only necessary to change the shape, size, etc. of the first clamp part, the second clamp part, and by extension, the shape and structure of the molding die including the first and second molds in which they are provided. Since there is no need to change anything, it is possible to use a single expensive molding die when manufacturing multiple types of metal products with different shapes and sizes of cylindrical parts. It is cheaper than the mold Work is be able to dispense with only preparing plural kinds easy thick portion forming roller.

Moreover, in the method of the present invention, one surface of the outer peripheral portion of the metal disk material is brought into contact with a second contact surface which is the same as or larger than that, and the first and second surfaces are contacted. In the state of being sandwiched between the clamp parts of, the outer peripheral part of the metal disk material is pushed into the cavity having a shape corresponding to the thick part and compressed to increase the outer peripheral part. Since the thick portion is formed, when the outer peripheral portion of the metal disk material is pushed into the cavity, the portion of the outer peripheral portion which is not yet pushed into the cavity makes the second contact. The surface can be stably held in contact with the surface, so that buckling of such a portion can be very effectively prevented.

Therefore, if such a method of the present invention is adopted, the outer peripheral portion of the metal disc material is positioned so as to project laterally from between the two molds and is clamped between the two molds. In order to prevent buckling at the time of forming the thick portion, unlike the case where the conventional method of pushing the outer peripheral portion into the cavity having a shape corresponding to the thick portion is adopted, It is not necessary to make the outer peripheral surface and the step surface of the second clamp portion side portion of the thick portion forming roller that gives the surface a special shape, and they can be configured in an arbitrary shape, whereby the cavity surface can be formed. It can be advantageously released from the tedious and difficult work of making a special shape.

Therefore, according to the method of manufacturing a metal product according to the present invention in which the thick part is integrally formed on the outer peripheral part of the thin metal disk, the desired metal product can be produced with excellent productivity. In addition to being able to be manufactured efficiently, multiple types of metal products with different shapes and sizes of thick parts can also be manufactured at the lowest possible price, and moreover, they can be manufactured during the process of forming thick parts. The occurrence of buckling can be reliably and extremely easily prevented.

According to one of the advantageous aspects of the method for producing a metal product according to the present invention, in which the thick-walled portion is integrally formed with the outer peripheral portion of the thin-walled metal disk, the thick-walled portion is provided. The stepped surface of the forming roller has a tapered surface shape whose diameter gradually increases from the second clamp portion side toward the first clamp portion side. When such a configuration is adopted, it is formed by the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller, the step surface and the second contact surface of the second clamp portion, When the outer peripheral portion of the metal disc material is pushed into the cavity having a shape corresponding to the thick portion, the metal material that gives the outer peripheral portion can be made to flow well, and the outer peripheral portion of the metal disc material becomes The thickness can be increased smoothly and surely.

According to another preferred embodiment of the method for producing a metal product according to the present invention, in which a thick-walled portion is integrally formed on the outer peripheral portion of a thin-walled metal disk, the thick-walled portion is formed. A corner portion between the outer peripheral surface of the roller on the side of the second clamp portion and the step surface has a concave curved surface shape. Also by this, when the outer peripheral portion of the metal disc material is pushed into the cavity to increase the thickness, the flow of the metal material that gives the outer peripheral portion becomes good, and thus the outer peripheral portion of the metal disc material is thickened. Can be implemented more smoothly and reliably.

Further, according to another preferred embodiment of the method for producing a metal product in which a thick portion is integrally formed on the outer peripheral portion of a thin metal disc according to the present invention, the metal disc material is , A tip end portion of the outer peripheral portion of the metal disc material, which has a tapered cylindrical bent portion that gradually increases in diameter toward the opening side. Between the clamp part and the clamped part, the tapered cylindrical bent part is positioned so as to be opened toward the first clamp part side and clamped by the first and second clamp parts. The adopted method is adopted. According to the method of the present invention as described above, when the outer peripheral portion of the metal disk material is pushed into the cavity, the outer corner portion of the bent portion provided on the outer peripheral portion is located at the outer peripheral portion of the thick portion forming roller. The outer peripheral surface of the second clamp portion side portion is slid against the outer peripheral surface, whereby the outer peripheral portion of the metal disc material can be pushed into the cavity more smoothly. The thickening process can be performed even more smoothly.

Furthermore, according to one of further advantageous embodiments of the method for producing a metal product according to the present invention, wherein a thick-walled portion is integrally formed on the outer peripheral portion of a thin-walled metal disk, Of the metal product has an outer peripheral surface having a shape corresponding to the inner peripheral surface shape of the thick-walled portion of the metal product, and the outer peripheral portion of the metal disc material is pressed into the cavity for compression. At the same time, the thickness of the thick portion is increased by being pinched between the outer peripheral surface of the first clamp portion and the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller. Part will be formed.

With such a structure, when a plurality of metal products are obtained, each metal product has a second clamp portion on the outer peripheral surface of the first clamp portion and the second clamp portion on the outer peripheral portion of the thick portion forming roller. A constant shape having inner and outer peripheral surfaces respectively corresponding to the outer peripheral surfaces of the side portions, and second end surfaces of the second contact surface of the second clamp portion and stepped surfaces of the thick-wall forming roller. The advantage is that a thick portion having a large size can always be stably manufactured.

Further, as described above, in the method of the present invention,
The outer peripheral portion of the metal disk material is pushed into the cavity to be compressed, and is clamped between the outer peripheral surface of the first clamp portion and the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller. Then, in the case of forming the thick portion by increasing the thickness, advantageously, the metal disk material having the thick portion formed, on the inner peripheral surface of the thick portion, While being brought into contact with the outer peripheral surface having a shape corresponding to the inner peripheral surface shape of the thick portion in the first clamp portion, the first clamp portion is rotated with the integral rotation about the first rotation axis, A gear portion forming roller in which concave portions and convex portions that provide teeth and tooth grooves of a predetermined gear are alternately and continuously provided on the outer peripheral surface of the metal disc material facing the outer peripheral portion of the thick portion, While rotating around a third rotation axis parallel to the first rotation axis, By pressing against the outer peripheral portion of the thick portion of the metal disc material, by sandwiching the thick portion between the outer peripheral surface of the tooth portion forming roller and the outer peripheral surface of the first clamp portion, The method further includes a step of forming a gear portion in which teeth and tooth grooves corresponding to the concave portions and the convex portions of the gear portion forming roller are alternately and continuously provided in an outer peripheral portion of the thick portion. Will be adopted.

According to the method of the present invention as described above, a metal product in which a thick portion is integrally formed on the outer peripheral portion of a thin metal disk and a gear portion is provided on the outer peripheral surface of the thick portion is manufactured. In doing so, the target metal product can be efficiently produced with excellent productivity, and a plurality of types of metal products having different shapes and sizes of the thick portion can be obtained at the lowest possible price, and Therefore, the occurrence of buckling during the step of forming the thick portion can be reliably and extremely easily prevented.

Further, in the method of the present invention further including such a gear portion forming step, it is preferable that the first contact surface contacting one surface of the metal disk blank has the first contact surface. Of the first die provided with the clamp portion and a second contact surface contacting the other surface of the metal disc material and having a diameter equal to or smaller than the first contact surface of the first clamp portion. A third clamp portion having three contact surfaces is provided on the third contact surface so as to be coaxially opposed to the first contact surface of the first clamp portion, and the first clamp portion is provided. Using a molding die including a third die configured so as to rotate integrally with the first clamp portion around the rotation axis of the metal disc material in which the thick portion is formed. To the first and third contact surfaces of the first and third clamp parts. The first and third clamp portions in a state of being in contact with each other and being concentrically positioned with respect to the first and third clamp portions, while clamping between the first clamp portion and the third clamp portion. The step of forming the gear part on the outer peripheral portion of the thick part of the metal disc material is performed in a state in which the third clamp part and the third clamp part are integrally rotated about the first rotation axis.

If such a method of the present invention is adopted, both end faces of the thick portion formed on the outer peripheral portion of the metal disc material are contacted with the first contact surface and the third contact surface, respectively. Since the metal disc material is clamped between the first clamp part and the third clamp part without being restrained, the outer peripheral surface of the thick part of the metal disc material is When the gear part forming roller is pressed against the thick part, the metal material forming the part which is depressed corresponding to the convex part of the gear part forming roller can be well flowed, whereby the thick part The gear part can be more reliably formed with a desired shape on the outer peripheral surface of the part.

Further, according to the present invention, there is also provided an apparatus for producing a metal product in which a thick-walled portion is integrally formed on the outer peripheral portion of a thin-walled metal disk, and (a) relatively A metal mold having a first mold and a second mold that are opposed to each other so that they can approach / separate, and the first mold is in contact with one surface of the metal disc material. A first clamp portion having a first contact surface having a diameter smaller than that of the plate material is provided, while the second die is in contact with the other surface of the metal disk material, A second clamp portion having a second contact surface having the same diameter or a larger diameter is coaxially opposed to the first contact surface of the first clamp portion at the second contact surface. The metal disc material is provided so as to be located at the first and second clamp portions of the first and second clamp portions. With contacting each Sawamen,
The first and second clamp parts are clamped between the first clamp part and the second clamp part so that they are located concentrically with respect to the first and second clamp parts. Is a molding die configured to rotate integrally with those axes as a first rotation axis, and (b) rotatably around a second rotation axis parallel to the first rotation axis, Further, it is arranged so as to be able to move toward and away from the molding die in a direction perpendicular to the first rotation axis, and at an intermediate portion in the height direction of the outer peripheral portion facing the molding die. A roller provided with a step surface for making the portion of the outer peripheral portion on the side of the second clamp portion smaller than the portion on the side of the first clamp portion, the second clamp side having the smaller diameter Rotate the outer peripheral surface of the part along with the integral rotation around the first rotation axis. The metal disk material is pressed against the outer peripheral surface of the metal disk material inward in the radial direction, and the outer peripheral portion of the metal disk material is made to have a small diameter. It is pressed into a cavity formed by the outer peripheral surface of the second clamp portion side portion, the step surface and the second contact surface of the second clamp portion, the cavity having a shape corresponding to the thick portion of the metal product. By compressing and thickening,
A thick metal portion forming roller for forming the thick wall portion is also included, and a metal product manufacturing apparatus in which a thick wall portion is integrally formed on an outer peripheral portion of a thin metal disk is also provided. To do.

In the apparatus for manufacturing a metal product according to the present invention in which the thick portion is integrally formed on the outer peripheral portion of the thin metal disk, only one type of thick portion forming roller is used. The outer peripheral portion is thickened to form a thicker portion only by performing a rolling process on the outer peripheral portion of the metal disc material, and a cavity for giving such a thicker portion is It is formed by the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller, the step surface and the second contact surface of the second clamp portion, and one of the outer peripheral portions of the metal disc material. The surface of the metal disk is brought into contact with a second contact surface which is the same as or larger than that, and is clamped between the first and second clamp parts. It can be compressed by pushing it into the cavity that has a shape corresponding to the thick part. Due to the fact that the outer peripheral portion is made thicker to form a thicker portion, a plurality of different types of the target metal product or different shapes and sizes of the thickened portion are formed. The above can be manufactured extremely advantageously with excellent productivity, at a relatively low cost, and without causing processing defects such as buckling.

[0029]

BEST MODE FOR CARRYING OUT THE INVENTION In order to more specifically clarify the constitution of the present invention, a metal product according to the present invention, in which a thick-walled portion is integrally formed on the outer peripheral portion of a thin-walled metal disk, is described. The manufacturing method will be described in detail with reference to the drawings showing an example of a device having a structure according to the present invention.

First, referring to FIG. 1, as an example of a metal product manufactured according to the method of the present invention by using the manufacturing apparatus according to the present invention, a drive connecting a crankshaft of an automobile engine and a torque converter of an automatic transmission. The plate is shown schematically in its cross-sectional form. As is clear from FIG. 1, the drive plate 1
Like the conventional one, 0 is a cylindrical thick portion 12 extending upward with a predetermined length on the outer peripheral portion of a base portion 11 having a thin disk shape. Is configured to have a bottomed cylindrical shape. The drive plate 10 has a base 11
A shaft hole 14 into which a crankshaft (not shown) is inserted is formed at the center of the shaft hole 14. Around the shaft hole 14, the drive plate 10 is connected to a crankshaft and a torque converter (not shown). A plurality of bolt holes 16 into which mounting bolts (not shown) for mounting are inserted are formed. On the other hand, a large number of teeth 17 and tooth grooves 18 are formed on the outer peripheral surface of the thick portion 12.
A gear unit 20 composed of and is provided.

By the way, such a drive plate 1
For example, 0 is manufactured according to the following method.

That is, first, a metal disc material 22 having a shape as shown in FIG. 2 is prepared. This metal disc material 22
Is a relatively thin-walled metal flat plate having flat upper and lower surfaces. While one is provided, the central hole 24
A plurality of through holes 26 for forming the bolt holes 16 of the drive plate 10 are formed in the periphery of the. In addition, in such a metal disc material 22, at the outer peripheral edge portion,
Bending part 2 in the shape of a taper that gradually increases in diameter upward
8 is formed so as to extend integrally.

The metal disc material 22 as described above may be a ready-made one or a specially formed one. However, when the metal disc material 22 is formed, For example, a circular metal plate having a large diameter is used, and the circular metal plate 22 is punched to form the center hole 24 and the through hole 26 and is drawn using a known press molding machine. Or other known press bending work, or a rolling work using a general rolling work machine or the like, the bent portion 28 is formed and obtained. The material of the circular metal plate that provides the metal disk material 22 is appropriately selected from those conventionally used as the constituent material of the target drive plate 10.

The bent portion 2 of the metal disk material 22 is
The target drive plate 10 is obtained by rolling the outer peripheral portion including 8 and, at that time, the manufacturing apparatus 30 as shown in FIG. 3 is advantageously used.

As is clear from FIG. 3, the manufacturing apparatus 30 has a molding die 34 arranged on a base 32 and is constructed. Further, the molding die 34 is an upper die 36 as a first die that is coaxially opposed to each other.
And a lower mold 38 as a second mold.

As shown in FIGS. 4 and 5, the lower die 38 of the molding die 34 includes a lower die side holder 40, a lower die side pad 42, and a center block 44, respectively. It is fixed by bolts in a state of being positioned coaxially with the central shaft 46, and is integrally assembled and configured. A centering projection 47 is integrally provided upright on the center of the upper surface of the center block 44.

On the other hand, the upper die 36 has an upper die side holder 48, an upper die side pad 50, and a center payout pin 52 which are coaxially arranged with respect to the central axis 46. 50 is bolted to the upper die side holder 48, and a center payout pin 52 is placed in an insertion hole 54 formed at a central portion of the upper die side pad 50 so as to axially penetrate therethrough. The mold 36 is inserted and arranged so as to be vertically movable in the axial direction. In addition, this center payout pin 52
The compression coil spring 56 arranged between the upper mold holder 48 and the upper mold holder 48 is adapted to urge it downward while it is moved upward. The downward movement of the center payout pin 52 is achieved by the engagement protrusion formed around the outer peripheral surface in a flange shape on the inner peripheral surface of the insertion hole 54 of the upper mold side pad 50. By being engaged with the portion, it can be regulated at a predetermined moving position. Further, in FIG. 4 and FIG. 5, 58 is, as will be described later.
When the upper die 36 is moved closer to the lower die 38, the centering projection 47 of the center block 44 in the lower die 38
Is a hole for centering through which is inserted to perform centering.

Further, in such a molding die 34, the lower center portion of the upper die pad 50 of the upper die 36 has a columnar shape and is protruded by a predetermined height. The upper die side clamp portion 60 is used as one clamp portion. The outer peripheral surface of the upper mold side clamp portion 60 is an inner peripheral surface forming surface 62 having a shape corresponding to the inner peripheral surface of the target thick portion 12 of the drive plate 10. As a first contact surface to be brought into contact with the upper surface of the metal disk blank 22 by the lower surface of the side clamp portion 60 and the lower surface of the center payout pin 52 inserted and arranged in the insertion hole 54 of the upper die pad 50. That is, the upper mold side contact surface 64 is formed. In addition,
The upper die side contact surface 64 is formed of a flat horizontal surface and has the same diameter as the base portion 11 of the drive plate 10, in other words,
It has a diameter sufficiently smaller than that of the metal disc material 22 (see FIG. 8).

In the molding die 34, the lower die side pad 42 of the lower die 38 and the center block 4 are formed.
4, a lower die side clamp portion 66 as a second clamp portion is configured, and further, the lower die side clamp portion 6 is provided.
6, the lower die side pad 42 and the center block 44
The upper surface of each of the above forms a lower die side contact surface 68 formed of a flat horizontal surface as a second contact surface to be brought into contact with the lower surface of the metal disc material 22.
In addition, here, the lower die side contact surface 68 has a diameter sufficiently larger than the diameter of the target drive plate 10 and one diameter larger than the diameter of the metal disc material 22 which provides the drive plate 10. (See FIG. 8).

As shown in FIG. 3, the lower mold 38 having the above-described structure is fixedly mounted on the lower mold mounting plate 70 arranged on the base 32. . The lower die mounting plate 70 to which the lower die 38 is attached is rotatably supported on the base 32, and the rotation shaft of the motor 74 in the motor housing hole 72 formed in the base 32. The lower die 38 is coaxially attached to the motor 76 so that the lower die 38 rotates around the rotation shaft 76 of the motor 74, in other words, the central axis 46 of the molding die 34 as the motor 74 rotates. It is designed to be rotated.

On the other hand, the upper die 36 is fixedly mounted on an upper die mounting plate 80 which is rotatably supported by an upper die moving plate 78 which is arranged to face the base 32.
The upper die moving plate 78 is slidably supported in the vertical direction with respect to a plurality of guide posts 82 that are erected on the base 32. Further, a fixed plate 84 is fixedly attached to the upper ends of the plurality of guide posts 82, and the piston rod 86 is mounted at the center of the fixed plate 84 by a hydraulic mechanism (not shown). An upper die moving plate pressurizing cylinder 88 for causing the protrusion operation is attached to the 32 side. Then, the upper die moving plate pressing cylinder 8
The tip portion of the piston rod 86 inside 8 is fixed to the upper die moving plate 78. As a result, the upper die 36 can rotate integrally with the upper die mounting plate 80 about the central axis 46 of the molding die 34.
The upper die mounting plate 80 and the upper die 36 are moved downward and upward as the piston rod 86 in the upper die moving plate pressurizing cylinder 88 projects and retracts.

Thus, in the molding die 34, the upper die 36 approaches the lower die 38 as the piston rod 86 in the upper die moving plate pressing cylinder 88 projects and retracts. It can be moved away from one another. By moving the upper die 36 closer to the lower die 38, the metal disc material 22 can be clamped between the upper die 36 and the lower die 38, and Such upper mold 36 lower mold 38
The upper mold 36 and the lower mold 38 are configured to rotate integrally around their central axes 46 while clamping the metal disk blank 22 by driving the motor 74 to rotate in a state of approaching. It has been done.

Further, in the manufacturing apparatus 30 in which such a molding die 34 is arranged, a roller pressure is applied to the outer peripheral portion of the base 32 so as to face each other with the molding die 34 interposed therebetween. Cylinders 90a and 90b are respectively arranged. The roller pressing cylinders 90a and 90b are provided with clamps 92a and 92b, respectively, each having a substantially U-shaped cross section at its tip.
The piston rods 94a and 94b fixed to the upper and lower clamp parts 60 of the molding die 34, more specifically, the upper die 36 of the molding die 34 in a relatively close state.
It is configured so as to be capable of projecting and retracting in a direction perpendicular to the central axis 46 of the mold 34. And
With respect to the clamps 92a and 92b of the piston rods 94a and 94b, the thick portion forming roller 96 and the gear portion forming roller 98 rotate about the rotating shafts 100 and 102 parallel to the central shaft 46 of the molding die 34. , Each of which is rotatably attached.

In the manufacturing apparatus 30 of the present embodiment, as the thick portion forming roller 96, the first thick portion forming roller 96a and the second thick portion forming roller 96b as shown in FIGS. 6 and 7 are used. 2 are used, and they are alternately attached to the clamp 92a. Further, as is apparent from FIGS. 6 and 7, the first and second thick portion forming rollers 96a and 96b are both provided with the step surface 10 at the intermediate portion in the height direction of the outer peripheral portion.
Due to the provision of 4, 106, the step surface 1
The region below 04 and 106 has a diameter smaller than that of the region above, and the upper and lower end faces are flat horizontal surfaces, and is configured as a stepped columnar shape as a whole. The step surface 104 of the first thick portion forming roller 96a has a tapered surface shape whose diameter gradually increases upward, while the step surface 106 of the second thick portion forming roller 96b has The roller 96b has a flat surface shape that spreads in a direction perpendicular to the rotation axis (central axis) 100 of the roller 96b. Further, in such first and second thick portion forming rollers 96a and 96b, the entire height and the step surface 1
04, 106 above each large diameter portion 107,
Although the diameters of 109 are substantially the same, the diameter and height of the small diameter portion 108 below the step surface 104 of the first thick portion forming roller 96a (h in FIG. 6).
_The dimension indicated by ₁ ) is the second thick portion forming roller 96.
In comparison with the diameter and height (the dimension indicated by h _{2 in} FIG. 7) of the small diameter portion 110 below the step surface 106 of b,
It is made smaller by a predetermined size.

In this case, in particular, the total height of the first and second thick portion forming rollers 96a and 96b is below the upper die side clamp portion 60 of the upper die 36 and the lower die 38. The size is set to be slightly smaller than the distance between the upper mold side clamp part 60 and the lower mold side clamp part 66 while the metal disc material 22 is clamped between the mold side clamp part 66 and the mold side clamp part 66. Further, the small-diameter portion 110 of the second thick portion forming roller 96b has the same height as the target thick portion 12 of the drive plate 10, and the step surface 106 thereof has the same thickness. It has the same width as the portion 12. Further, in the first thick portion forming roller 96a,
Corner 1 between the outer peripheral surface of the small diameter portion 108 and the step surface 104
11 is a concave curved surface shape.

On the other hand, the gear portion forming roller 98, as shown in FIG. 8, has a concave portion 1 having a shape corresponding to the teeth 17 formed on the gear portion 20 of the target drive plate 10.
12 and convex portions 114 having a shape corresponding to the tooth gap 18 between the teeth 17 and the teeth 17 are alternately and continuously provided on the outer peripheral surface.

Thus, in the manufacturing apparatus 30, the thick portion forming rollers 96a and 96b and the gear portion forming roller 98 having the above-described structure are provided with the central shaft 46 of the molding die 34.
While being rotatable about rotating shafts 100 and 102 that are parallel to each other, the respective outer peripheral surfaces of the upper mold 36 face the inner peripheral surface forming surface 62 formed of the outer peripheral surface of the upper mold side clamp portion 60. , As the piston rods 94a, 94b in the roller pressure cylinders 90a, 90b project and retract,
The upper die 36 can be moved toward and away from the upper die side clamp portion 60.

Therefore, when the target drive plate 10 is manufactured using the manufacturing apparatus 30 having such a structure, for example, first, as shown in FIG. After being set in the molding die 34, the molding die 34 and the molding die 34 are integrally rotated around the central axis 46 thereof. That is, in the mold open state of the molding die 34, the central hole 24 is formed in the metal disc material 22 with the tapered tubular bent portion 28 opening upward.
The centering projection 47 of the center block 44 of the lower mold 38 is inserted thereinto, and the lower mold side clamp portion 66 of the lower mold 38 is inserted.
The upper die 36 is concentrically placed on the upper die moving plate pressing cylinder 88, and the piston rod 86 in the upper die moving plate pressing cylinder 88 is caused to project. The metal disc material 22 is concentrically clamped between the upper die side clamp portion 36 of the metal plate 36. After that, the motor 74 attached to the base 32 is rotationally driven to rotate the entire lower mold 38, whereby the upper mold 36 and the lower mold 38 are rotated.
And the metal disc material 22 clamped between them are integrally rotated around the central axis 46 of the molding die 34.

As described above, the diameter of the upper mold side contact surface 64 including the lower surface of the upper mold side clamp portion 60 in the molding die 34 used here is the diameter of the target base portion 11 of the drive plate 10. And the diameter of the lower die side contact surface 68 of the lower die side clamp portion 66 is sufficiently smaller than the diameter of the drive plate 10. Large and metal disc material 2
Since the metal disc material 22 is clamped between the upper die side and the lower die side clamp portions 60, 66 as described above, since the diameter is made larger than the diameter of 2 by one turn,
The upper surface of the metal disc material 22 is only in the inner peripheral portion,
While being brought into contact with the upper mold side contact surface 64, the lower surface thereof is brought into contact with the lower mold side contact surface 68 over the entire surface excluding the lower surface of the bent portion 28 having the tapered tubular shape. As a result, when the metal disc material 22 is set in the molding die 34, the inner peripheral portion of the metal disc material 22 has the upper and lower contact surfaces 6 on the upper and lower sides thereof.
While being held in contact with Nos. 4 and 68, the outer peripheral portion is held in contact with only the lower surface at the lower mold side contact surface 68. Further, at this time, the center payout pin 52 that gives the central portion of the upper die side contact surface 64 is pushed up by the contact with the metal disc material 22, and based on the urging force generated by the compression of the compression coil spring 56, It is in a state of being urged downward.

After that, the outer peripheral portion of the metal disc material 22 set in the molding die 34 is increased in two steps by using the first and second thick portion forming rollers 96a and 96b. However, first of all, the piston rod 94 in the roller pressure cylinder 90a attached to the base 32 is
A first thick portion forming roller 96a having a small diameter portion 108 and a small height is rotatably attached to the tip of a, and the piston rod 94a is caused to project so that the first thick portion is formed. The roller 96a is moved toward the upper mold side clamp portion 60 of the upper mold 36. Thus, as shown in the right half of FIG.
The first thick-walled portion forming roller 96a is rotated around the rotating shaft 100 by bringing the first thick-walled portion forming roller 96a into contact with the outer corner portion of the bent portion 28 provided at the outer peripheral edge portion of the metal disc material 22 that is integrally rotated around. The plate material 22 is rotated in the opposite direction to the rotation direction. Then, in this state, the first thick portion forming roller 9
6a is moved closer to the upper mold side clamp portion 60, so that the outer peripheral portion of the metal disk blank 22 is reduced in diameter by the outer peripheral surface of the small diameter portion 108 of the first thick portion forming roller 96a. Press inward in the direction.

At this time, the first thick portion forming roller 96a
The outer corner of the bent portion 28 of the metal disc material 22 slides on the outer peripheral surface of the small-diameter portion 108 of the first thick-walled portion forming roller 96a as the upper die-side clamp portion 60 approaches and moves. While the outer peripheral portion of the metal disc material 22 is gradually bent and deformed, the end surface of the bent portion 28 abuts on the step surface 104 of the first thick portion forming roller 96a and is engaged with the step portion 104. In addition, under such a state, the outer peripheral portion of the metal disc material 22 has the step surface 104 of the first thick portion forming roller 96a.
And a first cavity 116 formed of an annular groove formed by the outer peripheral surface of the small-diameter portion 108 and the lower die side contact surface 68 of the lower die side clamp portion 66 on which the metal disc material 22 is placed. It is gradually pushed in.

Then, as shown in the left half of FIG.
The upper and lower end surfaces of the first thick portion forming roller 96a are formed on the lower surface of the outer die of the upper die side pad 50 of the upper die 36 and the lower die 3.
8, while the outer peripheral surface of the large diameter portion 107 of the first thick portion forming roller 96a slides on the lower die side contact surface 68 of the upper die 36.
By moving the first thick portion forming roller 96a close to the upper mold side clamp portion 60 until it comes into contact with the inner peripheral surface forming surface 62 of the upper mold side clamp portion 60, the first thick wall portion forming roller 96a is moved into the first cavity 116. The outer peripheral portion of the pressed metal disk blank 22 is compressed in the first cavity 116 to increase the thickness by a certain amount, and increase the thickness of the target drive plate 10 to be thinner than the target thick portion 12. The meat portion 118 is formed.

In the present step, in which the first step of increasing the thickness of the outer peripheral portion of the metal disk blank 22 is performed, the thick portion forming roller 96a moves closer to the upper mold side clamping portion 60. The bent portion 28 provided on the outer peripheral edge portion of the metal disc material 22 is adapted to be slidable on the outer peripheral surface of the small diameter portion 108 of the thick portion forming roller 96a at the outer corner portion thereof. Depending on the metal disc material 22
The outer peripheral portion of can be more smoothly pushed into the first cavity 116. Further, as described above, here, the corner portion 111 between the outer peripheral surface of the small diameter portion 108 of the first thick portion forming roller 96a providing the first cavity 116 and the step surface 104 has a concave curved surface shape. In addition, the stepped surface 104 of the first thick portion forming roller 96a with which the end surface of the bent portion 28 is brought into contact when the outer peripheral portion of the metal disc material 22 is pushed into the first cavity 116, The first cavity 116 has a tapered surface shape that gradually increases in diameter upward.
The metal material forming the outer peripheral portion of the metal disc material 22 to be pushed in can be made to flow better in the first cavity 116. In addition, the first thick portion forming roller 9 having a concave curved shape
6a, the radius of curvature of the corner portion 111 between the outer peripheral surface of the small-diameter portion 108 and the step surface 104, and the inclination angle of the step surface 104 having a tapered surface shape (the central axis of the first thick portion forming roller 96a ( Angle of inclination with respect to a plane perpendicular to the axis of rotation 100))
In order to allow the metal material to flow better in the first cavity 116, the radius of curvature is preferably 0. It is desirable that it is set within a range of about 5 to 3 mm and that the tilt angle is about 30 ° or less.

Moreover, in this process, the metal disc material 22
However, since the lower surface of the outer peripheral portion is set in the molding die 34 while being held in contact with the lower mold side contact surface 68, the outer peripheral portion of the metal disc material 22 is The first cavity 11 is pressed radially inward by the outer peripheral surface of the small diameter portion 108 of the thick portion forming roller 96a.
It is also possible to advantageously prevent such buckling deformation from occurring in the outer peripheral portion when being pushed into 6. In addition, the first thick portion forming roller 96
Since a is slid on the lower surface of the outer peripheral portion of the upper die side pad 50 at the upper end surface thereof, it can be moved closer to the upper die side clamp portion 60, so that such a first thick wall When the outer peripheral part of the metal disc material 22 is pushed into the first cavity 116 as the part forming roller 96a moves closer to the upper mold side clamp part 60, the first thick part forming roller 96a is pressed. It is also possible to effectively prevent the first thick-walled portion forming roller 96a from floating due to the upward pressing force from the outer peripheral portion of the metal disc material 22 that acts on the step surface 104. It is like this.

After that, the height of the small diameter portion 110 and the step surface 1
The second thick portion forming roller 96b having the width 06 of the same dimension as the height and width of the target thick portion 12 of the drive plate 10 is replaced with the first thick portion forming roller 96a. After the piston rod 94a is attached to the front end of the piston rod 94a, the second thick-walled portion forming roller 96b is moved closer to the upper die side clamp portion 60 of the upper die 36 by performing the same operation as described above. As a result, as shown in the right half of FIG. 7, the outer peripheral surface of the small diameter portion 110 of the second thick portion forming roller 96b is formed on the outer peripheral portion of the metal disk blank 22 which is integrally rotated about the central axis 46. The second thick-walled portion forming roller 96b is rotated around the rotation axis 100 in a direction opposite to the rotation direction of the metal disk blank 22 by contacting the outer peripheral surface of the thickened portion 118 thus formed. Then, in this state, the second thick portion forming roller 96b is moved closer to the upper die side clamping portion 60, whereby the metal disc material 22
The outer peripheral portion of is pressed radially inward by the outer peripheral surface of the small diameter portion 110 of the second thick portion forming roller 96b. Thus, as the second thick portion forming roller 96b moves closer to the upper mold side clamp portion 60, the outer peripheral portion of the metal disk material 22 including the thickened portion 118 is formed into the second thick portion forming portion. Laura 9
In the second cavity 120 formed of an annular groove different from the first cavity 116, which is formed by three surfaces of the step surface 106 of 6b and the outer peripheral surface of the small diameter portion 110 and the lower mold side contact surface 68. Then, push in gradually.

Then, as shown in the left half of FIG.
The upper and lower end surfaces of the second thick portion forming roller 96b are formed on the lower surface of the outer die of the upper die pad 50 of the upper die 36 and the lower die 3.
8, while the outer peripheral surface of the large diameter portion 109 of the second thick portion forming roller 96b slides on the lower die side contact surface 68 of the upper die 36.
The second thick part forming roller 96b is moved closer to the upper mold side clamp part 60 until it comes into contact with the inner peripheral surface forming surface 62 of the upper mold side clamp part 60, and the metal disk including the thickened part 118 is formed. The outer peripheral portion of the material 22 is pushed into the second cavity 120 to be compressed, and the outer peripheral surface of the small diameter portion 110 and the inner peripheral surface of the upper mold side clamp portion 60 of the second thick portion forming roller 96b are formed. By sandwiching it with the surface 62, the outer peripheral portion is thickened so as to have the same dimension as the width of the step surface 106 of the second thick portion forming roller 96b. The thick portion 12 is formed in the portion.

Even in the present step of performing the second step of increasing the thickness of the outer peripheral portion of the metal disk material 22, as in the preceding step of performing the first step of increasing the thickness of the metal disk material 22, Is set in the molding die 34 in a state of being held in contact with the lower die side contact surface 68 on the lower surface of the outer peripheral portion thereof, and at the same time, the second thick portion forming roller 96
While b is slid on the lower surface of the outer peripheral portion of the upper die side pad 50 at the upper end surface thereof and is moved closer to the upper die side clamp portion 60, during the course of this step, Buckling deformation occurs in the outer peripheral portion of the metal disc material 22 and upward pressing force applied from the outer peripheral portion of the metal disc material 22 to the step surface 106 of the second thick portion forming roller 96b causes The fact that the second thick portion forming roller 96b floats can be advantageously prevented.

Next, the piston rod 94a, to which the thick portion forming roller 96b is attached, is retracted and actuated, while the piston rod 94b, to which the gear portion forming roller 98 is attached, is projected and actuated to form the gear portion forming roller 9
8 is moved closer to the upper mold side clamp portion 60 of the upper mold 36. As a result, as shown in FIG. 8, the outer periphery of the gear portion forming roller 98 is the outer periphery of the thick portion 12 formed on the metal disc material 22 that is integrally rotated around the central axis 46 of the molding die 34. The central axis 4 by contacting the surface
While rotating in the direction opposite to the metal disc material 22 about the rotation shaft 102 parallel to the direction 6, the thick portion 12 of the metal disc material 22 is formed in the radial direction on the outer peripheral surface of the gear portion forming roller 98. Press inward. As the gear portion forming roller 98 moves closer to the upper mold side clamp portion 60, the thick portion 12 of the metal disc material 22 is gradually strengthened on the outer peripheral surface of the gear portion forming roller 98. By pressing the gear portion forming roller 9 on the outer peripheral surface of the thick portion 12,
A large number of recesses 11 formed alternately and continuously on the outer peripheral surface of 8
A large number of teeth 17 and tooth grooves 18 corresponding to 2 and the convex portion 114 are formed alternately and continuously.

Thus, the shaft hole 14 and the bolt hole 16 which are constituted by the inner peripheral portion of the metal disc material 22 and which are provided in the inner peripheral portion and which are composed of the central hole 24 and the through hole 26 are formed. A thin disk-shaped base portion 11 and a cylindrical thick portion 12 extending upward from an outer peripheral edge portion of the base portion 11 by a predetermined length, and further, the thick portion A target drive plate 10 in which a gear portion 20 including a large number of teeth 17 and tooth grooves 18 is formed on the outer peripheral surface of the drive plate 10.
To get.

After that, by retracting and moving the piston rod 86 in the upper die moving plate pressing cylinder 88, the upper die 36 is moved upward as shown in FIG. The drive plate 10 obtained as described above is ejected from the upper mold 36 by opening and opening the center ejecting pin 52 so as to project downward by the urging force of the compression coil spring 56.
It is released from the molding die 34.

As described above, the present embodiment aims to increase the thickness of the outer peripheral portion of the metal disk material 22 by the first and second thick portion forming rollers 96a and 96b. The outer periphery of the metal disc material 22 is formed by increasing the thickness of the outer periphery of the metal disc material 22 by forming the thick portion 12 on the outer periphery of the metal disc material 22 only by rolling. The target drive plate 10 is manufactured with a smaller number of steps as compared with the case where the conventional method of performing the slotting process on the outer peripheral portion is adopted as a pre-process for increasing the thickness of the portion. You can
As a result, work efficiency and productivity at the time of manufacturing the drive plate 10 can be improved very effectively.

Further, in this embodiment, the outer peripheral surfaces of the small-diameter portions 108 and 110 of the first and second thick portion forming rollers 96a and 96b and their step surfaces 104,
106 and the lower mold side contact surface 68 of the lower mold 38, the outer peripheral portion of the metal disc material 22 is pushed into the first and second cavities 116 and 120, so that the thick portion 12
Therefore, when the shape and size of the thick portion 12 are changed, the shape and size of the upper mold 36 and the lower mold 38 are simply changed without changing the shape. It is only necessary to change the shapes and sizes of the outer peripheral surfaces of the small-diameter portions 108 and 110 and the step surfaces 104 and 106 thereof in the first and second thick portion forming rollers 96a and 96b.

Therefore, according to the present embodiment as described above, when the plural kinds of drive plates 10 having different shapes and sizes of the thick portion 12 are obtained, the expensive molding die 3 is used.
It is possible to use 4 as one, and it suffices to prepare a plurality of types of first and second thick portion forming rollers that are cheaper and easier to manufacture than the molding die 34.
As a result, the plurality of types of drive plates 10 as described above can be manufactured more easily and cheaply.

Further, in the present embodiment, the tapered cylindrical bent portion 28 is provided at the outer peripheral edge portion of the metal disc material 22, so that the outer periphery of the metal disc material 22 is Of the first thick-walled portion forming roller 96a forming the first cavity 116, and the step surface 104 of the first thick-walled portion forming roller 96a has a larger diameter toward the upper side. In addition to having a surface shape, the corner portion 111 between the outer peripheral surface of the small diameter portion 108 and the step surface 104 of the first thick portion forming roller 96a has a concave curved surface shape.
Since the metal material that gives the outer peripheral portion of the metal disk blank 22 pressed into the first cavity 116 can be made to flow better in the first cavity 116, The outer peripheral portion of the plate material 22 can be thickened more smoothly and reliably.

Moreover, in the present embodiment, the outer peripheral portion of the metal disc material 22 is held in contact with the lower die side contact surface 68 on the lower surface thereof, so that the outer peripheral portion is And second thick portion forming rollers 96a, 9
Since it is possible to prevent the occurrence of buckling at the outer peripheral portion when pushing the inside of the first and second cavities 116, 120 by 6b to increase the thickness, such buckling is prevented. In doing so, the outer peripheral surfaces of the small-diameter portions 108 and 110 of the first and second thick portion forming rollers 96a and 96b and the step surfaces 104 and 106, which give the first and second cavities 116 and 120, are made special. Since there is no need to perform a troublesome and difficult work for forming the shape, it is possible to reliably and extremely easily prevent buckling during the formation process of the thick portion 12. Of.

Further, in the present embodiment, the outer peripheral portion of the metal disc material 22 is pressed by the first thick portion forming roller 96a to form the thickened portion 118 on the outer peripheral portion, and thereafter, this thickened portion 118 is formed. The outer peripheral portion of the metal disc material 22 on which the meat portion 118 is formed,
The second thick portion forming roller 96b presses the second thick portion forming roller 96b into the second cavity 120 for compression, and the outer peripheral portion of the second thick portion forming roller 96b has a small diameter portion 11
0 outer peripheral surface and the inner peripheral surface forming surface 62 of the upper mold side clamp portion 60.
Since the thick portion 12 is formed by being sandwiched between the drive plate 1 and the drive plate 1, even if a plurality of drive plates 10 are manufactured,
0 indicates an inner peripheral surface forming surface 62 of the upper mold side clamp portion 60 and an inner peripheral surface having a shape corresponding to the outer peripheral surface of the small diameter portion 110 of the second thick portion forming roller 96b, and the lower mold side contact surface 68. It is possible to always stably manufacture the thick portion 12 having a constant shape and size, which has both end faces of the shape corresponding to the step surface 106 of the second thick portion forming roller 96b. Of.

Further, in the present embodiment, when the thickness increasing process for the outer peripheral portion of the metal disc material 22 using the first and second thick portion forming rollers 96a and 96b is performed, the metal disc material is advanced. The first and second thick portion forming rollers 96a and 96b are pressed by the upward pressing force exerted on the step surfaces 104 and 106 of the first and second thick portion forming rollers 96b from the outer peripheral portion of 22. Can be prevented from being floated up, so that the thick portion 12 having a desired shape and size can be stably obtained.

Further, as described above, in the present embodiment, the first and second thick portion forming rollers 96 which provide the first and second cavities 116 and 120 of different sizes, respectively.
Since the thickening process is performed in two steps on the outer peripheral portion of the metal disc material 22 using a and 96b, the thick portion 12 having a sufficiently large thickness is It can be smoothly formed without difficulty.

The specific construction of the present invention has been described in detail above, but this is merely an example, and the present invention is not restricted by the above description.

For example, in the above-described embodiment, the metal disk material 22 having the bent portion 28 provided at the outer peripheral edge portion is used, but the metal disk material 22 does not have any bent portion 28. Those having a simple disk shape, or those having a shape in which a recess or a protrusion is formed in the inner peripheral portion according to the shape of the intended metal product, etc., are appropriately used.

Further, in the above embodiment, the lower mold side contact surface 68 as the second contact surface has a diameter slightly larger than the diameter of the metal disc material 22. The die-side contact surface 68 may have the same diameter as the metal disc material 22.

Further, in the above embodiment, the thick portion 12 is formed by using the two thick portion forming rollers 96 to perform the thickening process on the outer peripheral portion of the metal disc material 22 in two steps. However, the outer peripheral portion of the metal disc material 22 is subjected to a single thickening process using one thick portion forming roller 96, or a plurality of thick portions are formed. It is also possible to form the thick portion 12 by performing the thickening process using the forming roller 96 three times or more.

Furthermore, in the above embodiment, the base 32
And a molding die 34 rotatably arranged on the base 32 about a central axis 46, and the molding die 3 on the base 32.
4 at a position facing each other with the central axis 4 of the molding die 34
Two types of rolls, a thick portion forming roller 96 and a gear portion forming roller 98, which are arranged so as to be rotatable about rotating shafts 100 and 102 parallel to 6 and movable toward and away from the molding die 34. By using the manufacturing apparatus 30 having a manufacturing roller to form the thick portion 12 on the outer peripheral portion of the metal disc material 22 and to form the gear portion 20 on the outer peripheral surface of the thick portion 12, the purpose The drive plate 10 to be obtained was designed to be obtained from the metal disc material 22 at once, but without using the manufacturing apparatus 30 having such a structure,
The metal disc material 22 is formed by separately using a device for forming only the thick portion 12 on the outer peripheral portion of the metal disc material 22 and a device for forming the gear portion 20 on the outer peripheral surface of the thick portion 12. It is also possible to manufacture the target drive plate 10 step by step.

When the gear portion 20 is formed on the outer peripheral surface of the thick-walled portion 12 by using a device different from the device for forming the thick-walled portion 12 on the outer peripheral portion of the metal disc material 22 as described above. For example, as shown in FIG. 10, the upper mold side clamp portion 124 of the upper mold 122 and the lower mold side clamp portion 128 of the lower mold 126 are substantially the same as the base portion 11 of the target metal product, respectively. Upper mold side contact surface 130 and lower mold side contact surface 1
An apparatus having a molding die 134 provided with 32 will be used. Then, with the metal disk material 22 having the thick portion 12 formed in contact with the upper die side and lower die side contact surfaces 130, 132 at the inner peripheral portion thereof, the upper die side and lower die side clamp portions are formed. After clamping between 124 and 128, as shown in the right half of FIG. 10, the gear portion forming roller 98 is pressed against the outer peripheral surface of the thick portion 12 of the metal disc material 22 as in the above embodiment. The gear portion 20 is formed. By doing so, the metal disk blank is formed such that both end surfaces of the thick portion 12 do not come into contact with the upper die side and lower die side contact surfaces 130, 132 and are not restricted by them. 22 is upper mold side and lower mold side clamp parts 124, 1
Will be clamped between 28, which
When the gear portion forming roller 98 is pressed against the outer peripheral surface of the thick portion 12 of the metal disc material 22, a portion of the thick portion 12 that is recessed corresponding to the protrusion 114 of the gear portion forming roller 98 is formed. The metal material to be flowed can be satisfactorily fluidized, so that the gear portion 20 can be formed more reliably on the outer peripheral surface of the thick portion 12 with a desired shape.

Further, as described above, the thick portion 12 and the gear portion 2 are
When a device for forming 0 is used, for example, as shown in the left half of FIG. 10, the teeth 17 and the tooth grooves 18 of the gear portion 20 are provided on the outer peripheral surface of the height direction intermediate portion of the outer peripheral portion. The concave portions 112 and the convex portions 114 for forming are alternately and continuously provided, and the upper and lower sides thereof project radially outwardly by a predetermined height and continuously extend in the circumferential direction at the upper end portion and the lower end portion thereof. The gear portion forming roller 140 in which the flange portions 136 and 138 are integrally formed is used, and the lower surface of the upper flange portion 136 and the upper surface of the lower flange portion 138 of the gear portion forming roller 140 are respectively formed in the molding die 134.
The gear portion forming roller 14 is slidably in contact with the upper and lower end surfaces of the thick portion 12 of the metal disc material 22 set inside the gear portion forming roller 14.
The gear portion 20 may be formed on the outer peripheral surface of the thick portion 12 by pressing the outer peripheral surface of the middle portion in the height direction 0 against the outer peripheral surface of the thick portion 12. As a result, when the gear portion 20 is formed, excess thickness generated by pressing the gear portion forming roller 140 against the outer peripheral surface of the thick portion 12 may be added to both upper and lower end surfaces of the thick portion 12. It can be advantageously prevented.

When the gear portion 20 is formed on the outer peripheral surface of the thick portion 12 by using the manufacturing apparatus 30 having the structure shown in FIG. 3, the lower end surface of the thick portion 12 is a lower mold. Since it is brought into contact with the side contact surface 68, instead of the gear section forming roller 98 shown in FIG. A forming roller may be used. With this, the same effect as described above can be obtained.

Of course, the gear portion 20 is not provided on the outer peripheral surface of the thick wall portion 12, and the base portion 1 is made of a thin metal disk.
In order to obtain a metal product in which the thick portion 12 having a flat outer peripheral surface is integrally formed on the outer peripheral portion of No. 1, the gear portion forming roller 98 (140) is used to roll the thick portion 12. It goes without saying that the step of forming the gear portion 20 by means of is omitted.

Further, the thick portion forming roller 96a (96b)
The shape of is not limited to that shown in the above-described embodiment, and is clamped at least between the upper and lower clamp parts 60 and 66 as the first and second clamp parts. At the intermediate portion in the height direction of the outer peripheral portion facing the outer peripheral surface of the metal disc material 22, the step surface 104 (10
6) is provided, and the portion below the step surface 104 (106) may be formed into a small diameter portion 108 (110) having a smaller diameter than the above portion. Therefore, for example, the large-diameter portion 107 (109) above the stepped surface 104 (106) does not necessarily have to be in the shape of a cylinder, and is configured in an arbitrary shape, and the small-diameter portion 108 ( The shape of 110) is also
It can be changed as appropriate according to the shape of the outer peripheral surface of the thick portion.

Furthermore, the arrangement structure and the number of the thick portion forming rollers 96 and the gear portion forming rollers 98 are not limited to those shown in the above embodiment.
Of course.

In addition, in the above-described embodiment, a specific example of the method for manufacturing a drive plate mounted on an automobile and the device for manufacturing the drive plate to which the present invention is applied has been described. , A method for manufacturing a metal product in which a thick part is integrally formed on the outer peripheral part of a thin metal disk, and any of the manufacturing devices for such a metal product can be advantageously applied. Of course.

Although not listed one by one, the present invention
It can be carried out in an embodiment in which various changes, modifications, improvements, etc. are added based on the knowledge of those skilled in the art, and such an embodiment does not depart from the gist of the present invention.
Both are included within the scope of the present invention,
Needless to say.

[0082]

As is apparent from the above description, according to the method of manufacturing a metal product according to the present invention, in which a thick metal portion is integrally formed on the outer peripheral portion of a thin metal disk, It is possible to efficiently manufacture products with excellent productivity, and it is also possible to manufacture multiple types of metal products with different shapes and sizes of thick-walled parts at the lowest possible price. Buckling can be reliably and extremely easily prevented during the step of forming the portion.

In addition, according to the present invention, in the apparatus for manufacturing a metal product in which the thick part is integrally formed on the outer peripheral part of the thin metal disk, the individual metal product of interest and the thick part are manufactured. It is possible to manufacture a plurality of types of parts having different shapes and sizes with excellent productivity, at a relatively low cost, and extremely advantageously without causing processing defects such as buckling. .

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional explanatory view showing an example of a drive plate manufactured according to the method of the present invention.

FIG. 2 is a vertical cross-sectional explanatory view of a metal disc material used to manufacture the drive plate shown in FIG.

FIG. 3 is an explanatory diagram showing an example of a process for manufacturing a drive plate according to the method of the present invention, showing a state in which a metal disk material is set in an apparatus for manufacturing the drive plate.

FIG. 4 is an explanatory longitudinal sectional view showing an example of a molding die used when manufacturing a drive plate according to the method of the present invention.

FIG. 5 is an explanatory view showing another example of steps in manufacturing a drive plate according to the method of the present invention, in which a metal disc material is clamped between an upper die and a lower die which constitute a molding die. And shows a state in which they are integrally rotated around the central axis.

FIG. 6 is an explanatory view showing still another example of steps for manufacturing a drive plate according to the method of the present invention, in which the right half is formed with a thick portion in a bent portion provided on the outer peripheral portion of the metal disc material. The state where the rollers are in contact with each other is shown, and the left half shows a state where the outer peripheral portion of such a metal disc material is pressed by the thick portion forming roller to form the thickened portion on the outer peripheral portion.

FIG. 7 is an explanatory diagram showing another example of the process of manufacturing the drive plate according to the method of the present invention, in which the right half is
The thickened portion formed on the outer peripheral portion of the metal disc material is shown in contact with a thick portion forming roller different from that shown in FIG. 6, and the left half is the outer peripheral portion of the metal disc material. It shows a state in which a thick portion is formed on the outer peripheral portion by pressing with the thick portion forming roller.

FIG. 8 is an explanatory view showing still another example of the process of manufacturing the drive plate according to the method of the present invention, in which the thick portion formed on the outer peripheral portion of the metal disc material is pressed by the gear portion forming roller. The gear portion is formed on the outer peripheral surface of the thick portion.

FIG. 9 is an explanatory diagram showing another example of the process of manufacturing a drive plate according to the method of the present invention, showing a state in which the manufactured drive plate is released from the mold.

FIG. 10 is an explanatory view showing another example of the step of forming a gear portion on the outer peripheral surface of the thick portion formed on the outer peripheral portion of the metal disc material when manufacturing the drive plate according to the method of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Drive plate 12 Thick part 20 Gear part 22 Metal disk material 28 Bending part 30 Manufacturing equipment 34 Mold 60 Upper mold side clamp part 64 Upper mold side contact surface 66 Lower mold side clamp part 68 Lower mold side contact surface 96 Thick part forming roller 98 Gear part forming rollers 104, 106
Step surfaces 108, 110 Small-diameter portion 116 First cavity 120 Second cavity

─────────────────────────────────────────────────── ─── Continuation of the front page (56) Reference JP-A-9-300036 (JP, A) JP-A-62-282734 (JP, A) JP-A-3-20154 (JP, A) JP-A-5- 76982 (JP, A) JP-A-4-37432 (JP, A) JP-A-9-66330 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) B21H 1/00 B21H 1 / 04 B21H 5/00

Claims (8)

(57) [Claims] 1. A method for producing a metal product in which a thick-walled portion is integrally formed on the outer peripheral portion of a thin metal disk by rolling the outer peripheral portion of the thin metal disk material. A first mold provided with a first clamp portion having a first contact surface having a diameter smaller than that of the metal disk material, the first mold being in contact with one surface of the metal disk material; A second clamp portion having a second contact surface having a diameter equal to or larger than that of the metal disk material, which comes into contact with the other surface of the disk material, has a second contact surface at the second contact surface. The first clamp portion is coaxially opposed to the first contact surface of the first clamp portion, and rotates integrally with the first clamp portion with the central axis of the first clamp portion as the first rotation axis. Using a molding die including a second die configured so that The first and second clamp portions are in contact with the first and second contact surfaces, respectively, and are concentrically positioned with respect to the first and second clamp portions, A step of integrally rotating the first and second clamp parts around the first rotation axis while clamping between the clamp part and the second clamp part; Under the rotating state of the metal disc material due to the integral rotation of, the intermediate portion in the height direction of the outer peripheral portion facing the outer peripheral surface of the metal disc material, the second clamp portion side of the outer peripheral portion. A thick-walled portion forming roller provided with a stepped surface having a smaller diameter than that of the first clamp portion side portion is provided on the outer peripheral surface of the second clamp portion side portion having the smaller diameter with the metal disc. Place it in contact with the outer peripheral surface of the material, parallel to the first axis of rotation. By pressing the metal disc material inward in the radial direction while rotating it about the second rotation axis, the outer peripheral portion of the metal disc material is moved to the second portion of the thick portion forming roller. It is compressed by being pushed into a cavity having a shape corresponding to the thick portion of the metal product, which is formed by the outer peripheral surface of the clamp portion side portion, the step surface and the second contact surface of the second clamp portion. And a step of increasing the thickness to form the thick portion, the method for producing a metal product, wherein the thick portion is integrally formed on the outer peripheral portion of the thin metal disk. 2. The stepped surface of the thick portion forming roller,
The thick-walled portion is formed on the outer peripheral portion of the thin-walled metal disk according to claim 1, which has a tapered surface shape whose diameter gradually increases from the second clamp portion side toward the first clamp portion side. A method for manufacturing a metal product integrally formed. 3. The corner portion between the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller and the step surface has a concave curved surface shape.
The method for manufacturing a metal product, wherein the thick metal part is integrally formed on the outer peripheral part of the thin metal disk. 4. The metal disc material is configured such that a tip end portion of an outer peripheral portion of the metal disc material has a tapered cylindrical bent portion whose diameter gradually increases toward the opening side. Between the first clamp part and the second clamp part, the tapered tubular bent part is opened toward the first clamp part side and positioned so that the first and the second clamp parts are opened. The method for manufacturing a metal product according to any one of claims 1 to 3, wherein the second clamp portion clamps the thick metal disk integrally with a thick wall portion on an outer peripheral portion thereof. 5. The first clamp portion is configured to have an outer peripheral surface having a shape corresponding to the inner peripheral surface shape of the thick portion of the metal product, and the outer peripheral portion of the metal disc material is It is pushed into the cavity and compressed, and is clamped between the outer peripheral surface of the first clamp portion and the outer peripheral surface of the second clamp portion side portion of the thick portion forming roller to increase the thickness. The thick portion is formed by being squeezed, according to any one of claims 1 to 4,
A method of manufacturing a metal product, wherein a thick-walled portion is integrally formed on the outer peripheral portion of a thin-walled metal disk. 6. A shape of the metal disk material having the thick portion formed on the inner circumferential surface of the thick portion corresponding to the inner circumferential surface shape of the thick portion of the first clamp portion. While being in contact with the outer peripheral surface of the metal disc, the outer peripheral surface facing the outer peripheral portion of the thick-walled portion of the metal disc material is provided with a predetermined While rotating a gear portion forming roller, in which concave portions and convex portions that provide teeth and tooth grooves of the gear are alternately and continuously provided, while rotating about a third rotation axis parallel to the first rotation axis, On the outer peripheral surface, press against the outer peripheral portion of the thick portion of the metal disc material,
By pinching the thick portion between the outer peripheral surface of the tooth portion forming roller and the outer peripheral surface of the first clamp portion, the concave portion of the gear portion forming roller is formed at the outer peripheral portion of the thick portion. The thick-walled outer peripheral portion of the thin metal disk according to claim 5, further comprising a step of forming a gear portion in which teeth and tooth grooves corresponding to the convex portions are alternately and continuously provided. A method for manufacturing a metal product in which parts are integrally formed. 7. The first die provided with the first clamp portion having the first contact surface, which contacts one surface of the metal disk material, and the other of the metal disk materials. A third clamp portion having a third contact surface having a diameter equal to or smaller than that of the first contact surface of the first clamp portion contacting the surface of
The first clamp portion is provided so as to be coaxially opposed to the first contact surface, and is configured to rotate integrally with the first clamp portion around the first rotation axis. Using a molding die including a third die, the metal disc material having the thick portion formed, the first and third contact surfaces of the first and third clamp portions. Are placed concentrically with respect to the first and third clamp parts in a state of being in contact with the first clamp part and the third clamp part, respectively. A step of forming the gear portion with respect to an outer peripheral portion of a thick portion of the metal disc material under a state in which the first and third clamp portions are integrally rotated about the first rotation axis. Item 7. A thick metal part is integrally formed on the outer peripheral part of the thin metal disk. Method of manufacturing a metal product that. 8. A device for manufacturing a metal product, wherein a thick-walled portion is integrally formed on an outer peripheral portion of a thin-walled metal disk, the first device being opposed to each other so as to be relatively approachable / separable. A molding die having a mold and a second mold, the first mold being in contact with one surface of the metal disc material, and a first contact surface having a smaller diameter than the metal disc material. While the first clamp portion having the second metal plate is provided with a second clamp having a diameter equal to or larger than that of the metal disc material, the second die is in contact with the other surface of the metal disc material. A second clamp portion having a contact surface is provided on the second contact surface so as to be coaxially opposed to the first contact surface of the first clamp portion. The material is brought into contact with the first and second contact surfaces of the first and second clamp portions, respectively, and The first and second clamp parts are clamped between the first clamp part and the second clamp part so that they are located concentrically with respect to the first and second clamp parts. Is a molding die configured to integrally rotate with their axes as a first rotation axis, and rotatable about a second rotation axis parallel to the first rotation axis, and the molding It is arranged so as to be able to move toward and away from the mold in a direction perpendicular to the first rotation axis, and the outer periphery is located at a middle position in the height direction of the outer periphery facing the molding die. Is a roller provided with a stepped surface that makes the portion on the side of the second clamp portion smaller than the portion on the side of the first clamp portion, and the outer circumference of the portion on the second clamp side having the smaller diameter. The surface is rotated along with the integral rotation around the first rotation axis. In the state of being brought into contact with the outer peripheral surface of the metal disc material, the metal disc material is pressed inward in the radial direction so that the outer peripheral portion of the metal disc material has the second diameter which is set to the small diameter. Of the outer peripheral surface of the clamp portion side portion, the step surface and the second contact surface of the second clamp portion, and is pushed into a cavity having a shape corresponding to the thick portion of the metal product. A thick portion forming roller that forms the thick portion by compressing and increasing the thickness;
An apparatus for manufacturing a metal product, comprising a thick metal portion integrally formed on an outer peripheral portion of a thin metal disc.