JP3615674B2 - Manufacturing method of swash plate for swash plate compressor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a swash plate that is one of the components constituting a swash plate compressor.
[0002]
[Prior art]
Compressors generally used in vehicle air conditioning systems, etc., have a fixed capacity compressor with a fixed inclination angle of the swash plate with respect to the shaft, and a variable capacity with variable inclination angle of the swash plate with respect to the shaft. There is a compressor of the type. Each swash plate compressor has a shaft that rotates and a disk-like swash plate that rotates in synchronization with the shaft, and by rotating the shaft, the piston attached to slide on the swash plate has a predetermined reciprocating motion. I do. The piston is fitted in the cylinder, and when the piston reciprocates in the cylinder, the piston functions as a compressor by performing suction, compression, and exhaust.
[0003]
The swash plate used here generally has the shape shown in FIG. FIG. 1A shows a schematic shape of a swash plate used in a fixed capacity compressor. The swash plate 1 is not substantially disk-shaped, and a hole 1a is provided through which a shaft is inserted into a central boss portion 1c. It has a peripheral portion 1b that becomes a sliding surface near the outer periphery. The shaft hole 1a is provided obliquely with a predetermined angle with respect to the substantially disk-shaped portion, and the swash plate 1 has a constant inclination angle with respect to the shaft. FIG. 1 (b) shows a schematic shape of a swash plate used for a variable displacement compressor, and the swash plate 2 has a substantially disk shape and has a peripheral portion 2b serving as a sliding surface near the outer periphery. The shaft has a boss at the center, and a shaft hole 2a having a relatively large diameter through which the shaft can be inserted while changing its angle.
[0004]
Since the swash plate functions as a compressor component, various properties such as high static strength and fatigue strength, excellent wear resistance and impact resistance, and a low coefficient of thermal expansion are required. As materials satisfying this requirement, hypereutectic Al—Si alloys such as A390 are widely used. As a method for producing a swash plate using this hypereutectic Al-Si alloy, casting or forging is conceivable, but since casting has low strength and varies in various properties, forging is performed in consideration of reliability. It has become common to be manufactured by. However, hypereutectic Al-Si alloys have a structure containing primary crystal Si, and are relatively brittle and have a relatively low deformability. When forging with a large degree of processing is performed, defects such as cracks occur. It is easy.
[0005]
Conventionally, forging of a swash plate has been performed by a method schematically shown in FIG. FIG. 6 shows forging of a swash plate for a fixed displacement compressor, and upper and lower forging dies 10 and 20 forming a cavity 30 for forming a required outer shape are used. The swash plate 1 is obtained by forging the material to be filled in the cavity 30 by placing the material in 20 and applying pressure.
[0006]
[Problems to be solved by the invention]
However, in the above conventional forging method, the plastic flow of the material is not efficient, the material is not filled to every corner of the cavity, and the product is thinned, the material is covered on the outer periphery of the swash plate, Forging defects such as cracks occurring in each of these areas are likely to occur. In addition, the poor plastic flow efficiency during forging also causes wear of the mold and shortens the mold life. Furthermore, with the conventional method, precise forging is difficult due to variations in the amount of materials, and only products with a large machining allowance due to subsequent machining can be forged. In particular, if an excessive amount of materials is introduced, the product itself is inevitable. Troubles such as burrs or cracks in the mold occur.
[0007]
Furthermore, in the conventional forging method, when using a die attached with a punch (protrusion) to simultaneously forge a shaft hole to be processed in the central portion, the plastic flow becomes more complicated, and the forging defects described above, The load on the mold was further increased. Therefore, the simultaneous forging of the shaft hole has to be abandoned, and the shaft hole is drilled by performing cutting after the forging, resulting in a large burden on the subsequent process and material loss.
[0008]
The present invention has been made to solve the problems of the conventional forging method described above, and a space into which surplus material flows is provided in the cavity, and the plastic flow of the material during forging is made appropriate. A method for producing a swash plate compressor swash plate including an excellent forging process, which has the advantage that there are few forging defects, the burden on the mold is small, and the shaft hole provided in the central portion can be processed at the same time. It is intended to provide.
[0009]
[Means for Solving the Problems]
The method for manufacturing a swash plate for a swash plate compressor according to the present invention is a method for manufacturing a swash plate for a swash plate compressor having a shaft hole so that the shaft is inserted in the center and having a substantially disk shape. A first mold and a second mold forming a cavity, and either one of the first mold or the second mold has a shaft hole forming punch for forming the shaft hole; The other of the first die or the second die uses a forging die having a recess at a position facing the punch, and a forging material having a cylindrical outer shape is placed in the forging die and the first die is placed. The mold and the second mold are abutted against each other and pressurized, and the forging material is plastically flowed and filled in the cavity, and the product part having the required product shape and the outside of the product part are continuous. The surplus material that does not form the product portion of the forged material is attached to the recess. A forging step of forming integrally a supplementary portion which is formed by sexual flow, characterized in that the supplementary part comprises a supplementary portion removing step of removing from the product portion.
[0010]
In other words, the greatest feature of the manufacturing method of the present invention is that a recess is provided in the mold so that a space into which surplus material flows is present in the cavity, and the central portion is located at a position facing this space of the other mold. In the forging process, a punch for forming the shaft hole is attached and forging is performed by pressing the material so as to push the punch toward the space. In this forging process, the material can be filled in the cavity while efficiently plastically flowing.
[0011]
Due to the proper plastic flow of the forging material in the cavity and the presence of a space for surplus material to flow in, the forging process of the manufacturing method of the present invention produces a product with extremely few forging defects such as cracks and covering and good dimensional accuracy. Can be forged. In addition, the space into which surplus material flows is a space that can efficiently absorb excess surplus material among surplus materials, reducing the burden on the forging mold, minimizing the risk of mold cracking, and extending the mold life. It becomes possible to do. Furthermore, the manufacturing method of the present invention enables simultaneous forging of the outer shape of the swash plate and the central shaft hole, which could not be performed so far, and removes the incidental portion formed from the surplus material by a simple method that follows. This is an efficient manufacturing method with low manufacturing cost.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
The object to which the manufacturing method of the present invention is applied is a swash plate which is one of the components of a swash plate compressor. As described above, the swash plate compressor has a fixed capacity and a variable capacity, and can be applied to any swash plate used for the compressor. The swash plate of the fixed displacement compressor has a shape as shown in FIG. 1 (a), and the swash plate of the variable displacement compressor has a shape as shown in FIG. 1 (b). Each of the swash plates has a substantially disk-shaped peripheral portion serving as a sliding surface, and has a shaft hole through which the shaft is inserted in the central portion. The fixed swash plate is formed with a shaft hole having a predetermined angle with a disk constituting the peripheral part, and the periphery of the shaft hole is thicker than the peripheral part to form a boss part.
[0013]
The material of the swash plate is not particularly limited, but an aluminum alloy is generally used, and the manufacturing method of the present invention particularly exerts its effect on the aluminum alloy swash plate. Examples of the aluminum alloy that can be used include hypoeutectic Al—Si and hypereutectic Al—Si. Considering the balance of cost, mechanical characteristics, etc., for example, Al-Si aluminum alloys such as A390, A4032, and AC9 may be used.
[0014]
The forging die used in the forging step of the manufacturing method of the present invention includes a first die and a second die that form a cavity by abutting. For example, when a vertical forging machine is used, there are two molds, an upper mold and a lower mold. The cavity formed by the two molds abutting each other becomes a space where the material is plastically flowed and filled during forging. The cavity has a spatial shape in which a product part that matches the product shape composed of the peripheral part and the central part of the swash plate described above and an incidental part that will be described in detail later can be simultaneously formed.
[0015]
Either the first die or the second die constituting the forging die has a shaft hole forming punch for forming the shaft hole. The shaft hole forming punch is a protrusion having the same outer diameter as the inner diameter of the shaft hole provided in the product. The forging material is plastically flowed so as to be spread to the peripheral portion by the punch, or is plastically flowed toward the punch, thereby forming a shaft hole provided in the center portion of the product.
[0016]
The other of the first die or the second die constituting the forging die has a recess at a position facing the shaft hole forming punch. This recess forms a predetermined space in combination with the tip of the shaft hole forming punch. This space is a space that is continuous with the space for forming the required product part and exists outside the part required for the product. This space becomes a space for molding the incidental part by the material flowing in during plastic forging.
[0017]
Due to the presence of the space forming the incidental portion, the plastic flow of the material is activated, and the shaft hole provided in the center portion of the product can be easily formed. In addition, activation of plastic flow can also reduce friction between the material and the mold during forging, realize a forging process with less wear on the mold, and eliminate forging defects such as cracking and covering. It also leads to prevention. Furthermore, the space that forms the incidental part becomes a space that can absorb excess material that is excessive even among surplus materials, and not only prevents the occurrence of forging burrs and the like, but also prevents abnormal forging dies. The forging process can be realized without load and without trouble such as mold cracking.
[0018]
Forging uses the forging die described above, a forging material having a cylindrical outer shape is placed in the forging die, the first die and the second die are abutted and pressurized, and the forging material is placed in the cavity. The product part having the required product shape and the surplus material that is continuously attached to the outside of the product part and does not form the product part of the forging material plastically flow into the recess. The incidental part formed by the above is integrally formed. The forging machine should just use the existing forging machine with the capability according to a product, and does not specifically limit it. What is necessary is just to follow the conditions generally performed about forging conditions. In addition, when forging from the raw material of an aluminum alloy, it is good to carry out by hot forging, and it is desirable to forge the raw material heated in the range of 360-450 degreeC.
[0019]
The shape of the recess provided in the mold is not particularly limited as long as it can ensure functions such as activation of plastic flow and absorption of excess material. However, in consideration of efficient plastic flow and the like, the shape of the concave portion is a shape including a weight portion that is recessed in a weight shape and a lead-out path portion that has a small cross-sectional area that communicates with the weight portion. It is desirable to form a shape having a weight body and a shaft body extending from the weight body.
[0020]
The weight portion recessed in the shape of a cone means a recess having a shape that is recessed in a so-called mortar shape. Such a concave portion is formed with a weight-shaped accessory portion whose cross-sectional area decreases as the distance from the product portion increases. In other words, the incidental part formed by the weight part is a weight body with the bottom face directed to the product part. When the material plastically flows toward the concave portion having such a shape, there is an advantage that the plastic flow of the material in the cavity becomes smoother and an excessively excessive material is not required. The weight surface constituting the weight portion may be either a conical surface or a truncated pyramid surface, but is preferably a conical surface in order to ensure a smoother plastic flow.
[0021]
The lead-out path portion that communicates with the weight portion is a passage for guiding excess material that protrudes from the weight portion. Since it is necessary to apply a certain amount of hydrostatic pressure to the entire material in order to fill the material in the cavity, it is desirable that the lead-out path is a passage having a small cross-sectional area. When using an Al—Si based alloy as a forging material, when a lead-out passage having a circular cross section is used, the diameter of the passage is preferably 1 to 10 mmφ, and more preferably 2 to 4 mmφ. The excess material flowing into the lead-out path part is formed as a shaft body in the accessory part of the product.
[0022]
In order to efficiently guide the material to the lead-out path, it is desirable that one end of the lead-out path portion communicates with the deepest portion of the weight portion, that is, the portion corresponding to the top of the weight surface constituting the weight portion. Further, since the shaft-like accessory portion is formed by the lead-out path portion, it is necessary that this shaft-like portion can be easily detached from the mold. Therefore, it is preferable that the lead-out path portion is provided straight in a direction parallel to the direction in which the forged product is detached from the mold.
[0023]
It is desirable that the other end of the lead-out path portion communicates with the outside of the mold. If the other end of the lead-out path portion is communicated to the outside of the mold, for example, two or more materials are placed, even if extremely excessive materials are placed in the mold, Since the excess material passes through this lead-out path and is discharged into the mold, the burden on the mold can be reduced, and there is a further prevention effect such as mold cracking.
[0024]
The forging material to be placed in the mold in the forging process has a shape having a cylindrical outer shape because the swash plate as a product has a substantially disk shape. In the forging process of this manufacturing method, the shaft hole at the center is also formed simultaneously. For example, when forging a swash plate that has a relatively thin product and a shaft hole diameter that is relatively large relative to the outer circumference of the disk, such as a variable capacity swash plate, a shaft hole forming punch is used as the forging material. By setting up, it is possible to perform forging by plastically flowing the material so as to spread it around the periphery. According to this form of forging, a cylindrical forging material having a small outer diameter can be used as compared with the case of forging in which a conventional shaft hole is not formed. The forging material is produced by cutting a long rod-shaped material into a predetermined length. In this case, a forging material can be produced from a rod-shaped material having a small outer diameter, and there is an advantage that variation in the amount of forging material per one due to variation in cutting accuracy is reduced.
[0025]
Again, for example, when forging a swash plate with a relatively thin product and a relatively large shaft hole diameter relative to the outer circumference of the disk, such as a variable capacity swash plate, a shaft hole forming punch is used. By being installed in the forging material, the material can be forged by plastic flow so that the material is pushed and spread to the periphery by this punch. In this case, it is desirable that the tip of the shaft hole forming punch has a convex shape. By making the tip convex, this convex part first comes into contact with the forging material, and the spreading of the material to the peripheral part can be made smoother. Further, it is desirable to match the shape of the convex portion at the tip of the shaft hole forming punch with the shape of the concave portion of the other mold that faces the other. The volume of the incidental part formed can be reduced, and efficient forging with less surplus material can be performed.
[0026]
In the manufacturing method of the present invention, the forging material is formed into a shape having a recess having a cross section larger than that of the shaft hole in one end surface of the columnar shape, and the forging is performed so that the shaft hole forming punch is inserted into the recess. The forging process can be performed by placing the material in a forging die. For example, it is effective in manufacturing a swash plate having a boss, a shaft hole with a relatively small diameter, and a long (depth) shaft hole (deep) shape, such as a fixed capacity swash plate. Embodiment.
[0027]
When forging a swash plate with a small shaft hole and a long shaft hole at the same time, a simple (solid) columnar material is used and the material is moved to the periphery by a shaft hole forming punch provided in the forging die. Forging so as to spread out, not only is the load applied to the shaft hole forming punch large, but the plastic flow of the material in the cavity may not be appropriate. Therefore, as in this embodiment, by using a forged material shaped like a pipe with a bottom, which is provided with a dent having a larger cross section than the shaft hole in the forged material, the burden on the shaft hole forming punch is reduced and the plastic flow of the material Can be optimized.
[0028]
The dent of the forging material provided with the dent causes a pseudo space to exist around the shaft forming punch inserted at the time of forging. Then, by pressing the forging die and pressurizing the material, the material is not only expanded toward the periphery, but also plastically flows in the direction toward the center so as to fill the pseudo space. . By enabling such plastic flow, it becomes possible to forge-mold a relatively long shaft hole having a relatively small hole diameter.
[0029]
In order to make the plastic flow more appropriate, the present inventor has found that there is a relationship between the space volume of the recess provided in the forging material and the space volume of the shaft hole formed in the product. It was. The relationship is that the space volume of the recess provided in the forging material is V ₀ , V is the space volume of the shaft hole formed in the product _e The volume-to-space ratio (V ₀ / V _e ) Is preferably in the range of 1.1 to 2.5. V ₀ / V _e If the value is less than 1.1, there is a possibility that proper plastic flow cannot be achieved at the time of forging, and if it exceeds 2.5, forging defects such as buckling, covering, undercutting, etc. during forging. This is because it may cause
[0030]
In order to form a cylindrical forging material having a dent having a cross section larger than that of the shaft hole on one end face as described above, in the manufacturing method of the present invention, preliminary forging having a convex part for forming the dent on the end face. Implementation of a pre-forging process for forming a forged material by forging a material having a cylindrical shape having an outer diameter smaller than that of the forged material by using a mold so that the convex portion is placed on one end surface of the material. It can also be in the form.
[0031]
The preliminary forging die used in this preliminary forging step has a convex portion (punch) for forming a recess in one of two molds that form a cavity by abutting. A cylinder-shaped material having an outer diameter smaller than the outer diameter of the forged material formed by pre-forging is placed in a pre-forging die, and a pressure is applied by pressing the material by bringing a convex portion into contact with one end surface of the cylinder. Pre-forging is performed by plastically flowing to fill the cavity.
[0032]
The material to be filled in the cavity is hydrostatically, in other words, uniform throughout the material, by the action of the convex part that spreads the material outward in the radial direction by the convex part while forming the concave part. Upset forging is performed in a state where pressure is applied. Preliminary forging of such a method enables the use of a material with a smaller outer diameter, reduces variation in the amount per material due to variation in cutting accuracy, and increases processing accuracy in the subsequent forging process. It can also be increased. By the way, when using an Al-Si alloy, when performing pre-forging to increase the material diameter without forming a recess, only materials having a diameter of 80% or more of the forged material after pre-forging can be used. On the other hand, in the preliminary forging step, a material having a small outer diameter of 30 to 70% can be used. In addition, the smaller the material diameter, the smaller the man-hour for cutting, and the more the productivity is improved.
[0033]
The forging machine used in the preliminary forging process is not particularly limited, and a generally used forging machine can be used. The forging process which becomes the next process can also be carried out by being incorporated in the same forging machine as a separate stage. In addition, when pre-forging from the raw material of an aluminum alloy, it is good to carry out by hot forging, and it is desirable to perform pre-forging to the raw material heated in the range of 360-450 degreeC.
[0034]
Next, in the manufacturing method of the present invention, when manufacturing a swash plate having one or more through holes different from the shaft hole, one or more through holes are formed in either the first mold or the second mold. Forging dies having one or more through-hole forming punches, and the other of the first die or the second die further having one or more recesses at a position facing the punch, It can be set as embodiment which performs a forge process so that a plurality of incidental parts may be formed by carrying out plastic flow to a crevice.
[0035]
In addition to the shaft hole, the swash plate may have a shape having a through hole penetrating its peripheral portion and the like, such as an oil hole and a lightening hole for weight reduction. When manufacturing such a swash plate, it is sometimes desired to simultaneously form these through holes by forging. In this case, forging defects and the like are generated while maintaining the plastic flow at an appropriate level by providing the above-described concave portion at a position facing the through-hole forming punch and forming the number of incidental portions corresponding to the number of through-holes. It is possible to manufacture a swash plate with less.
[0036]
Furthermore, in the manufacturing method of the present invention, when a through hole is simultaneously forged, a forging material having a cylindrical shape with a recess having a cross section larger than the shaft hole and one or more recesses having a cross section larger than the through hole. In this embodiment, the forging material is placed in a forging die so that the shaft hole forming punch and the through hole forming punch are respectively inserted into the respective recesses.
[0037]
Generally, a through hole such as an oil hole has a small cross-sectional area. If forging is performed by pushing a through-hole having a small cross-sectional area into a material, it cannot be formed well due to a large load applied to the punch. Therefore, the presence of the above-mentioned pseudo space around the through-hole forming punch, and even if the through-hole has a small cross-sectional area, it is possible to easily perform simultaneous forging by making the plastic flow of the material appropriate. Become.
[0038]
There are various shapes of the swash plate. For example, there is a case where it is desired to form the swash plate in a shape having a concavo-convex portion that functions as a reinforcing rib or the like instead of forming the peripheral portion of the swash plate into a flat plate shape. In such a case, the cavity formed by the two molds can be made into a shape that matches the required shape. As described above, various forging methods that have been conventionally performed can be adopted in the present manufacturing method, and embodiments of the forging process of the present manufacturing method are not limited to the above-described embodiments.
[0039]
The incidental part removal process performed after the forging process mentioned above does not specifically limit the method. For example, it can be performed by any method such as press cutting using a mold, fusing by plasma, or cutting by machining using a lathe. The same forging machine can be used to simplify the process by incorporating a press cutting die on a separate stage and linked to the forging process. In the case of cutting by machining, it is performed simultaneously with precision finishing. Therefore, the number of steps can be omitted.
[0040]
【Example】
Hereinafter, a method for producing a swash plate for a swash plate compressor according to the present invention, particularly a forging step therein, will be described with reference to the drawings. However, the following examples are only examples of the production method of the present invention, and the production methods of the present invention are not limited to the following embodiments.
[0041]
<First embodiment>
The present embodiment is a swash plate used in a variable capacity swash plate compressor, and as illustrated in FIG. 1B, a swash plate in which a shaft hole 2a formed at the center has a relatively large diameter. This embodiment is suitable for the above. FIG. 2 schematically shows the state of the forging process.
[0042]
The swash plate 2 to be manufactured has a disc-like shape having a peripheral portion 2b of 9.5 mm and a diameter of 97 mmφ, and has a shaft hole 2a having a diameter of 47 mmφ in the center. A forging material 3 for forging the swash plate 2 is A390 (Al-Si alloy, Al-17Si-4.5Cu-0.6Mg), and has a cylindrical shape with a diameter of 60 mmφ and a length (thickness) of 30 mm. It is what you did. Forging is performed by heating the forging material 3 to 420 ° C. and hot.
[0043]
The forging die to be used is composed of an upper die 10 and a lower die 20. When the upper mold 10 and the lower mold 20 are brought into contact with each other, the material is filled to form a cavity 30 for molding a product. The upper mold 10 is provided with a shaft hole forming punch 11 for forming the shaft hole 2a. The tip 11a of the punch 11 has a shape having a protruding convex portion, and the shape of the convex portion is a shape that fits (follows) a concave portion 21 of the lower mold 20 described later. . Further, the lower mold 20 has a concave portion 21 at a position facing the shaft hole forming punch 11, and the concave portion 21 includes a weight portion 21a formed by a conical surface and a cone top (deepest portion) of the weight portion 21a. A lead-out path portion 21b having a circular cross section extending straightly downward and leading to the outside of the lower mold 20 is formed. The conical bottom diameter of the weight portion 21a is 15 mmφ, the depth is 10 mm, and the diameter of the lead-out passage portion 21b is 3 mmφ.
[0044]
The forging material 3 is placed in the center of the lower mold 20, the upper mold 10 and the lower mold 20 are brought close to each other, and the forging material 3 is pressed with both molds. The tip 11a of the shaft hole forming punch 11 provided in the upper die 10 first comes into contact with the forging material 3, and then the material is pressed against the recess 21 provided in the lower die 20 by the pressure applied by the punch 11. , It will plastically flow as it is pushed out in the peripheral direction. Just before the end of forging, the material fills the cavity 30. Thereafter, the excess material flows into the lead-out path portion 21b constituting the recess 21 by continuing the pressurization, and the forging is finished.
[0045]
The forged product is a product part 4 required for the swash plate 2, that is, a part mainly composed of a peripheral part 2 b formed to a predetermined thickness, and an incidental part 5 continuous to the product part 4. Will be. In addition, the incidental part 5 is shape | molded by the weight part 21a and the derivation | leading-out path part 21b of the recessed part 21, respectively in the shape which has the weight body 5a and the shaft body 5b continuous with it.
[0046]
The feature of the present embodiment is that the shaft hole forming punch is placed in the material and plastically flows so as to spread the material to the peripheral part, and the plasticity is provided by a recess provided at a position facing the punch. It is to make the flow appropriate. According to the forging process of the present embodiment, the raw material is smoothly filled up to every corner in the cavity of the forging die by receiving hydrostatic pressure. Therefore, it is possible to forge-mold a product that is free of defects and has no defects such as cracking and covering. Furthermore, since the plastic flow is smooth, the wear of the mold is reduced and the forging process has a long mold life. Furthermore, it becomes a forging process which can prevent a mold crack etc., without having an excessive burden on a metal mold | die by having the space which absorbs an excess raw material.
[0047]
Moreover, it is advantageous that the forged material can be made to have a small diameter by placing the shaft hole forming punch in the material and plastically flowing the material so as to push the material to the peripheral part. By the way, using the A390 cylindrical material, the limit processing rate when forging so that it is simply crushed in the column height direction (the processing rate at which the cylinder starts to forge cracks, that is, the maximum processing rate at which sound processing is possible) The processing rate is the cylinder height of the forging material. ₀ When the product height after forging is H, (H ₀ -H) ÷ H ₀ X means 100%) is only 42%. However, in this embodiment, the spread forging having a processing rate of 68% is possible.
[0048]
<Second embodiment>
The present embodiment is a swash plate used in a fixed displacement swash plate compressor, and as illustrated in FIG. 1A, a shaft hole 1a formed in the center has a relatively large diameter, This is an embodiment suitable for a swash plate in which a boss 1c is formed around a shaft hole. FIG. 3 schematically shows the state of the forging process.
[0049]
The swash plate 1 to be manufactured has a substantially disc shape with a peripheral portion 1b having a thickness of 13 mm and a diameter of 80 mm as viewed from the shaft direction. The swash plate 1 has a shaft hole 1 a with a diameter of 15 mm and a boss portion 1 c. The swash plate has a diameter of 40 mmφ and a thickness of 30 mm. The forging material 3 for forging the swash plate 1 is A390 as in the case of the first embodiment, has a cylindrical shape with a diameter of 60 mmφ and a length (thickness) of 33 mm, and has a diameter of 33 mmφ at the center and a depth of It has a recess 3a with a thickness of 23 mm. Incidentally, the volume V of the shaft hole of the molded product _e And the volume V of the recess 3a ₀ Space volume ratio (V ₀ / V _e ) Is 2.4. Forging is performed hot by heating the forging material 3 to 420 ° C. as in the case of the first embodiment.
[0050]
The forging die to be used is composed of an upper die 10 and a lower die 20. When the upper mold 10 and the lower mold 20 are brought into contact with each other, the material is filled to form a cavity 30 for molding a product. The upper mold 10 is provided with a shaft hole forming punch 11 for forming the shaft hole 1a. Further, the lower mold 20 has a concave portion 21 at a position facing the shaft hole forming punch 11, and the concave portion 21 has a weight portion 21a formed with a conical surface, and a lower portion from the cone portion (the deepest portion) of the weight portion 21a. And a lead-out path portion 21b having a circular cross section that extends straight toward the outside and communicates with the outside of the lower mold 20. The conical bottom diameter of the weight portion 21a is 17 mmφ, the depth is 12 mm, and the diameter of the lead-out passage portion 21b is 2.5 mmφ.
[0051]
The forging material 3 is placed at a position where the shaft hole forming punch 11 provided in the upper die 10 is inserted into the recess 3a at the center of the lower die 20, and the upper die 10 and the lower die 20 are brought into contact with each other. The forging material 3 is pressed with both molds so as to be close together. Unlike the case of the first embodiment, the pressurized material not only plastically flows toward the peripheral part, but also plastically flows so as to fill the pseudo space existing around the recess 3a. The material also plastically flows so as to rise to form the boss 1c. Immediately before the forging is completed, the material fills the cavity 30, and then the excess material continues to pressurize to flow into the lead-out path portion 21 b constituting the recess 21, and the forging ends.
[0052]
As in the case of the first embodiment, the forged product is divided into a product part 4 required for the swash plate 1, that is, a part mainly composed of a peripheral part 1 b formed to a predetermined thickness, and a product part 4. The continuous incidental portion 5 is integrally formed. In addition, the incidental part 5 is shape | molded by the weight part 21a and the derivation | leading-out path part 21b of the recessed part 21, respectively in the shape which has the weight body 5a and the shaft body 5b continuous with it.
[0053]
The feature of the forging process of the present embodiment is that, in addition to the function of the concave portion of the mold in the case of the first embodiment, a forged material is previously provided with a recess having a diameter larger than the shaft hole, and the pseudo space formed by this recess is filled. This is to make the material plastic flow. Even in a swash plate having a relatively small hole diameter and a deep shaft hole, the plastic flow of the material can be made appropriate. As a result, the forging process of the present embodiment is a smooth forging process that does not cause forging defects such as cracking and covering, forging that does not apply an excessive load to the shaft hole forming punch and prevents damage to the mold. It becomes a process.
[0054]
Next, a pre-forging process for manufacturing the forging material 3 to be used in the forging process will be described. FIG. 4 schematically shows the pre-forging process. The preliminary forging process is also performed hot by heating the material to 420 ° C. as in the forging process.
[0055]
The pre-forging die to be used is composed of an upper die 40 and a lower die 50 as in the forging die in the forging process. When the upper mold 40 and the lower mold 50 abut each other, the material is filled to form a cavity 60 for molding a product. The upper die 40 is provided with a convex portion (dent forming punch) 41 for forming the dent 3 a of the forged material 3.
[0056]
The material 6 has a cylindrical shape with a diameter of 55 mmφ and a length of 35 mm. The material 6 is placed in the center of the lower mold 50 with its end face down, and the upper mold 40 and the lower mold 50 are brought close to each other so as to press the material 6 with both molds. . A dent molding punch 41 provided in the upper mold 40 first comes into contact with the material 6, and then the material is plastically flowed by the pressure applied by the punch 41 so as to be pushed and expanded in the peripheral direction. Then, by continuing the pressurization, the material fills the cavity 60, and the forged material 3 is formed.
[0057]
The pre-forging process is characterized in that a convex portion (concave punch) is placed in the material and plastically flows so as to spread the material to the peripheral portion. Similar to the forging process of the first embodiment, according to the preliminary forging process of the present embodiment, the material is filled smoothly to every corner in the cavity of the forging mold while being subjected to hydrostatic pressure, The plastic flow is appropriate. Therefore, a forging material having a dent can be formed without causing defects such as undercutting, cracking, and covering. Furthermore, since the plastic flow is smooth, the wear of the mold is reduced, and the preliminary forging process has a long mold life.
[0058]
Further, as in the forging process of the first embodiment, the plastic flow so as to spread the material to the peripheral portion has the merit that the material that can be used can have a small diameter. The ability to use a material with a small diameter can reduce the variation in the amount of material per forging material due to variations in the cutting accuracy of the material, and further reduces the man-hours for cutting the material. In this preliminary forging step, forging forging having a processing rate of 56% is performed.
[0059]
<Third embodiment>
This embodiment, like the second embodiment, is an embodiment of a swash plate used in a fixed displacement swash plate compressor, but unlike the second embodiment, two penetrating oil holes are provided in the peripheral portion. It is an Example about the swash plate which has. FIG. 5 schematically shows the forging process. Forging is performed hot by heating the forging material to 420 ° C., as in the case of the other examples.
[0060]
The swash plate 1 to be manufactured has the same outer shape as that of the second embodiment, and has two oil holes having a diameter of 5 mmφ in the vicinity of the boss portion 1c of the peripheral portion 1b. The forging material 3 for forging the swash plate 1 is A390, as in the case of the second embodiment, has a cylindrical shape with a diameter of 60 mmφ and a length (thickness) of 26 mm, a diameter of 35 mmφ at the center, and a depth of It has a recess 3a with a thickness of 20 mm, and further has two recesses 3b with a diameter of 10 mmφ and a depth of 15 mm on the outside in the radial direction.
[0061]
The forging die to be used is composed of an upper die 10 and a lower die 20. When the upper mold 10 and the lower mold 20 are brought into contact with each other, the material is filled to form a cavity 30 for molding a product. The upper mold 10 is provided with a shaft hole forming punch 11 for forming the shaft hole 1a and two oil hole forming punches (through hole forming punch) 12 for forming an oil hole (through hole) 1d. Yes. Further, the lower mold 20 has a recess 21 at a position facing the shaft hole forming punch 11 and further has a respective recess 21 at a position facing each oil hole forming punch 12. Each recess 21 has a conical surface. And a lead-out path portion 21b having a circular cross section that extends straight downward from the cone top (deepest portion) of the weight portion 21a and communicates with the outside of the lower mold 20. Note that the conical bottom surface diameter of the weight portion 21a of the concave portion 21 provided at a position facing the shaft hole forming punch 11 is 17 mmφ, the depth is 8 mm, and the diameter of the lead-out passage portion 21b is 2.5 mmφ. Further, the conical bottom surface diameter of the weight portion 21a of the concave portion 21 provided at the position facing the oil hole forming punch 12 is 6 mmφ, the depth is 4 mm, and the diameter of the lead-out passage portion 21b is 1.5 mmφ.
[0062]
The forged material 3 is inserted into the recess 3a in the center portion of the lower die 20 and the shaft hole forming punch 11 provided in the upper die 10 is inserted into the recess 3b. The upper die 10 and the lower die 20 are brought close to each other so as to collide with each other, and the forging material 3 is pressurized with both dies. As in the case of the second embodiment, the pressurized material not only plastically flows toward the peripheral portion, but also plastically flows so as to fill the pseudo space existing around the recess 3a, and further the recess 3b. It also plastically flows to fill the pseudo-space that exists around.
[0063]
The forged product is obtained by integrally forming a product part 4 required for the swash plate 1 and three accessory parts 5 continuous to the product part 4. As in the case of the other embodiments, each auxiliary portion 5 is formed into a shape having a weight body 5a and a shaft body 5b continuous therewith by the weight portion 21a and the lead-out path portion 21b of the recess 21. The
[0064]
The feature of the forging process of the present embodiment is that a through hole other than the shaft hole is simultaneously forged. In this embodiment, it is possible to further simplify the manufacturing process of the swash plate by enabling smooth forging without applying excessive load to each punch and generating forging defects such as cracking and covering. It becomes.
[0065]
【The invention's effect】
In the method for manufacturing a swash plate for a swash plate compressor according to the present invention, the forging step is provided with a recess in the mold so that a space into which surplus material flows is present in the cavity, and is opposed to this space of the other mold. A punch for forming a central shaft hole is attached at a position, and the forging is performed by pressing the material so as to push the punch toward the space. By adopting the forging process configured in this way, the plastic flow of the material in the forging process is optimized, and excess material is efficiently absorbed. This is an extremely excellent manufacturing method in which the forging is small, the forging defects are small, the burden on the mold is small, and the shaft hole provided in the central portion can be simultaneously forged.
[Brief description of the drawings]
FIG. 1 shows a schematic shape of a swash plate compressor swash plate to which the manufacturing method of the present invention is applied.
FIG. 2 schematically shows a forging process according to a first embodiment, which is an example of manufacturing a variable capacity compressor swash plate.
FIG. 3 schematically shows a forging process according to a second embodiment, which is an example of manufacturing a fixed displacement compressor swash plate.
FIG. 4 schematically shows a preliminary forging step of a second embodiment which is an example of manufacturing a fixed capacity compressor swash plate.
FIG. 5 schematically shows a forging process of a third embodiment, which is an example of manufacturing a fixed displacement compressor swash plate having an oil hole.
FIG. 6 schematically shows a forging process of a conventional manufacturing method.
[Explanation of symbols]
1: Swash plate for fixed capacity compressor
1a: Shaft hole 1b: Peripheral part 1c: Boss part
1d: Oil hole (through hole)
2: Swash plate for variable capacity compressor
2a: Shaft hole 2b: Peripheral part
3: Forging material
3a: dent 3b: dent
4: Product Department
5: incidental part
5a: weight 5b: shaft
6: Material (in preliminary forging)
10: Upper die (forging process)
11: Shaft hole forming punch 11a: Tip portion
12: Oil hole forming punch (through hole forming punch)
20: Lower mold (forging process)
21: Recessed part 21a: Weight part 21b: Deriving path part
30: Cavity
40: Upper die (pre-forging process)
41: Convex part (dent forming punch)
50: Lower die (pre-forging process)
60: cavity

Claims (6)

A method of manufacturing a swash plate for a swash plate compressor having a shaft hole so that a shaft is inserted into a central portion and having a substantially disk shape,
The first die and the second die that form a cavity by abutting each other, and either the first die or the second die is a shaft hole forming punch for forming the shaft hole And the other of the first die or the second die uses a forging die having a recess at a position facing the punch, and a forging material having a cylindrical outer shape is placed in the forging die. The first die and the second die are abutted and pressurized, and the forging material is plastically flowed and filled in the cavity, and a product part having the required product shape and the product part A forging step of integrally forming an additional portion formed by plastic flow of the surplus material that is continuously attached to the outside and does not form the product portion of the forged material;
The manufacturing method of the swash plate for compressors which includes the incidental part removal process which removes the said incidental part from the said product part. The concave portion of the forging die includes a weight portion that is recessed in a weight shape and a lead-out passage portion that has a small cross-sectional area that communicates with the weight portion. The manufacturing method of the swash plate for compressors of Claim 1 shape | molded in the shape which has a shaft body extended. The forging material has a recess having a larger cross section than the shaft hole in one end surface of the columnar shape, and the forging material is placed in the forging die so that the shaft hole forming punch is inserted into the recess. The manufacturing method of the swash plate for compressors of Claim 1 or Claim 2 which performs a forge process by this. Using a preliminary forging die having a convex portion for forming the dent on the end face, forging a material having a cylindrical shape having an outer diameter smaller than that of the forging material so that the convex portion is installed on one end surface of the raw material. The method for manufacturing a swash plate for a swash plate compressor according to claim 3, further comprising a preliminary forging step of forming the forged material. The swash plate has one or more through holes different from the shaft hole,
Either the first mold or the second mold has one or more through hole forming punches for forming the one or more through holes, and the first mold or the second mold 3. The oblique line according to claim 1, wherein the other has one or more recesses at a position facing the punch, and a plurality of incidental portions are formed by plastic flow of the surplus material into the respective recesses. Manufacturing method of swash plate for plate type compressor. The forging material has a recess having a cross section larger than the shaft hole and one or more recesses having a cross section larger than the through hole on one end surface of the columnar shape, and the shaft hole forming punch and the through hole forming are formed in each recess. The method for producing a swash plate for a swash plate compressor according to claim 5, wherein the forging material is placed in the forging die so as to insert the punches, and the forging process is performed.

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