JP4398897B2 - Ball valve ball manufacturing method - Google Patents

Description

  The present invention relates to a method of manufacturing a ball for forming a valve body of a ball valve, and mainly relates to a ball valve ball used in a pipe through which a metal corrosive liquid such as seawater, hydrochloric acid, sulfuric acid, and metal corrosive gas circulates. It relates to a manufacturing method.

  Although publicly known documents cannot be specifically mentioned as the prior art relating to the present invention, most of the balls of the ball valves that have been conventionally used are manufactured by casting or forging.

  For example, ball valve balls used in pipes where metal corrosive liquids such as seawater, hydrochloric acid and sulfuric acid circulate are nickel alloys as corrosion resistant metal materials that are strong against metal corrosive liquids such as seawater, hydrochloric acid and sulfuric acid. And titanium alloys are used, but these corrosion-resistant metal materials such as nickel alloys are very expensive, so when the production quantity is small, balls are manufactured by casting or forging. Since a small amount of melting furnace is required depending on the size of the balls, there is a problem that the unit price of balls is very high.

  In the present invention, when manufacturing a ball valve ball with an expensive corrosion-resistant metal material such as a nickel alloy or a titanium alloy, it is possible to reduce the manufacturing unit price even if the manufacturing quantity is small, and more necessary than the conventional method. An object of the present invention is to provide a ball manufacturing method that can reduce the product weight while reducing the amount of raw materials (materials).

Means for solving the above problems will be described with reference numerals in the embodiments described later. The ball valve ball manufacturing method according to the first aspect of the present invention provides a rectangular plate 1 made of a corrosion-resistant metal material. The cylindrical body 2 is formed by roll bending or press-type bending so that both end edges 1a and 1a are abutted, and after welding the butted edges 1a and 1a of the cylindrical body 2, Both ends of the cylindrical body 2 are subjected to press-type bending with a pair of upper and lower hemispherical molds 4 and 5, thereby forming a substantially spherical ball body 3 and inserting sleeves at positions corresponding to both ends of the cylindrical body 2. Opening portions 10 and 10 are formed, and an engaging member insertion opening portion 11 for inserting a concave engaging member 6 into which the engaging convex portion 13a of the ball rotation driving spindle 13 is engaged is formed in the ball main body 3. Opening , So as to weld the ball body 3 a through channel forming sleeve 30 and a concave engaging member 6 in the sleeve insertion opening 10, 10 and the engaging member insertion opening 11 each insert and, this time, the cylinder When the ball body 3 is formed by press-bending the body 2 with a pair of upper and lower hemispherical molds 4 and 5, the ball body 3 is formed at the entrances of the hemispherical recesses 4a and 5a of the upper and lower hemispherical molds 4 and 5, respectively. Half-ring-shaped guide members 26 and 27 having divergent tapered guide portions 26a and 27a for guiding and guiding the end portions of the cylindrical body 2 to the hemispherical concave portions 4a and 5a are detachably attached. No. 27 is characterized in that both end portions of the cylindrical body 2 are guided to the hemispherical concave portions 4a and 5a of both hemispherical molding dies 4 and 5 and then removed.

Claim 2 is the method for manufacturing a ball for ball valve according to claim 1, a through-flow path forming sleeve 30 and a concave engagement member 6 after welding to ball body 3, it has to perform the heat treatment It is characterized by.

  The effect of the invention by the above solution will be described with reference numerals in the embodiments described later. The manufacturing method of the invention according to claim 1 is a conventional ball manufacturing method by bending and welding. Compared to casting and forging, the equipment required for manufacturing can be made extremely simple and small-scale, so even if a small amount of balls are manufactured using extremely expensive corrosion-resistant metal sheets such as nickel alloys and titanium alloys, the unit price It is possible to reduce the weight of the product and to reduce the weight of the product. In particular, in this manufacturing method, since the metal plate material to be used has a rectangular shape, waste of material is very small when cutting, and the sleeve insertion opening 10 is not formed by drilling but by a pair of upper and lower pairs. Therefore, the material loss due to drilling is eliminated and the material loss can be extremely reduced. In addition, since the welding distance is very short compared with the conventional manufacturing method, the working time can be shortened, and the manufacturing cost of the ball can be further reduced.

Further , according to the present invention , the upper and lower end portions of the cylindrical body 2 can be quickly and easily inserted into the upper and lower hemispherical molds 4 and 5 by the guide members 26 and 27, and the molding operation by the hemispherical molds 4 and 5 is possible. Efficiency can be improved.

According to the second aspect of the present invention, the distortion generated in the ball main body, the sleeve, and the concave engaging member can be removed, the machine finishing performed later becomes easy, and the processing accuracy can be improved.

  FIG. 1 to FIG. 5 show the manufacturing process of the ball of the ball valve according to the present invention. The manufacturing method will be described. First, a corrosion-resistant metal plate material is cut and processed as shown in FIG. Such a rectangular plate 1 is formed. Nickel alloy, titanium alloy, or stainless steel is used as the corrosion-resistant metal plate material for forming the rectangular plate material 1, but here, it has the trademark name “HASTELLOY”, which has excellent corrosion resistance and heat resistance. A known nickel alloy is used.

  As shown in FIGS. 1 (b) and 1 (c), the rectangular plate 1 thus formed is hung on a bending roll machine BM and rolled into a cylindrical shape so that both end edges 1a and 1a of the plate 1 are brought into contact with each other. The cylindrical body 2 is formed by processing. Then, the butted edges 1a and 1a of the cylindrical body 2 are welded. A welded portion of the butted edges 1a and 1a is indicated by W. The bending roll machine BM has a known structure including a pair of fixed rolls 22 and 22 and a presser roll 23 on a base 21.

  Next, both ends of the cylindrical body 2 are subjected to press bending using a pair of upper and lower hemispherical molds 4 and 5 as shown in FIGS. Form. The spherical ball main body forming step will be described in detail. The upper hemispherical molding die 4 has a substantially hemispherical recess 4a opened on the lower surface side of the mold main body 4o, and an upper portion of the substantially hemispherical recess 4a. A hole 4b having a circular cross section is formed at the center, and is fixed to a movable base frame 24 that is driven up and down. The lower hemispherical molding die 5 has a substantially hemispherical recess 5a opened on the upper surface side of the mold body 5o, and a circular hole 5b having a circular cross section is formed at the lower center of the substantially hemispherical recess 5a. It is fixed to the fixed base frame 25.

  Further, on the lower surface of the mold body 4o of the upper hemisphere molding die 4 and the upper surface of the mold body 5o of the lower hemisphere molding die 5, the end of the cylindrical body 2 is guided and guided to the hemispherical recesses 4a and 5a. Further, ring-shaped guide members 26 and 27 having divergent tapered guide portions 26a and 27a are detachably attached by bolts (not shown), and these insertion guide members 26 and 27 are provided at both end portions of the cylindrical body 2. Is guided to the hemispherical recesses 4a and 5a of both hemispherical molds 4 and 5, and then removed. Each of the ring-shaped guide members 26 and 27 is divided into two semicircular members.

  The guide members 26 and 27 have tapered tapered guide portions 26a and 27a that are formed in a tapered shape whose outer end diameter is larger than that of the inner end portion, and the inner ends of the guide members 26a and 27a. The diameter of the part is substantially the same as the diameter of the inlet part of the hemispherical recesses 4a and 5a. Moreover, the diameter of the entrance part of hemispherical recessed part 4a, 5a is formed so that it may become slightly larger than the outer diameter of the cylindrical body 2. FIG.

  Thus, in order to form the cylindrical body 2 into the ball body 3 with the pair of upper and lower hemispherical molds 4 and 5, after attaching the guide members 26 and 27 to the hemispherical molds 4 and 5, (a ), The lower end portion of the cylindrical body 2 is guided and guided by the guide member 27 to enter the hemispherical concave portion 5a of the lower hemispherical molding die 5, and is held upright as illustrated. Thereafter, the upper hemispherical mold 4 is lowered to a predetermined position, and the upper and lower hemispherical molds 4, 5 are guided by guide members 26, 27 at the upper and lower ends of the cylindrical body 2 as shown in FIG. The hemispherical concave portions 4a and 5a are guided and guided into the hemispherical concave portions 4a and 5a. The upper and lower ends of the cylindrical body 2 that have entered the hemispherical recesses 4a and 5a are molded and squeezed as shown. By using such guide members 26 and 27, the upper and lower end portions of the cylindrical body 2 can be quickly and easily inserted into the upper and lower hemispherical molds 4 and 5, and molding by the hemispherical molds 4 and 5 is performed. The work efficiency can be improved.

  After the upper and lower end portions of the cylindrical body 2 have been inserted into the hemispherical concave portions 4a and 5a of the upper and lower hemispherical molding dies 4 and 5 as described above, the guide members 26 and 27 are removed, and FIG. State as shown. From this state, as shown in FIGS. 3B and 3C, the upper hemispherical mold 4 is lowered, and the lower surface of the mold body 4o is brought into contact with the upper surface of the mold body 5o of the lower hemispherical mold 5. By making the contact state, the cylindrical body 2 is subjected to a press-type bending process to form a substantially spherical ball body 3 and sleeve insertion openings 10 and 10 are formed at positions corresponding to both ends of the cylindrical body 2. To do. In this case, the inner diameter of each sleeve insertion opening 10 is substantially the same as the inner diameter of the punched holes 5a, 5b of the hemispherical molds 4, 5.

  Thereafter, the upper hemispherical mold 4 is raised and the formed ball body 3 is taken out from the lower hemispherical mold 5. At this time, the ball body 3 is machined as shown in FIG. 4 (a) because the inner peripheral surfaces of the sleeve insertion openings 10 and 10 are not parallel surfaces. As shown, the inner peripheral surfaces of the sleeve insertion openings 10 and 10 on both sides are finished so as to be parallel to each other along the axis G. A through-flow passage forming sleeve 30 is inserted into the sleeve insertion opening 10.

  Then, the engagement member insertion for inserting the concave engagement member 6 engaged with the engagement convex portion 13a of the ball rotation driving spindle 13 in the ball valve 12 as shown in FIGS. 7 (a) and (b). The opening 11 is formed in a direction orthogonal to the direction of the axis G of the sleeve insertion hole 10 by machining.

  The through-flow passage forming sleeve 30 is a circular tube that penetrates the ball body 3 in the diameter direction and forms an open passage when the ball valve 12 is opened, and is formed of the same metal material as the ball body 3. . The inner diameter of the sleeve insertion hole 10 into which the sleeve 30 is inserted is slightly larger than the outer diameter of the sleeve 30. The engaging member insertion opening 11 is formed in a rectangular shape as shown in FIG. The concave engaging member 6 inserted into the opening 11 is also made of the same metal material as that of the ball main body 3, and has a rectangular shape corresponding to the opening 11 in plan view as shown in FIG. In addition to being formed, the vertical cross-sectional shape is an arc shape as shown in (a) of the figure, and the horizontal cross-sectional shape is a U-shape as shown in (b) of the figure. An air vent hole 14 is provided at the bottom of the concave engaging member 6.

  After the sleeve insertion hole 10 and the engaging member insertion opening 11 are formed in the spherical ball body 3 as described above, as shown in FIGS. 4 (b) and 4 (c), these sleeve insertion hole 10 and The through-flow passage forming sleeve 30 and the concave engaging member 6 are inserted into the engaging member inserting opening 11 and welded to the ball body 3.

  That is, the through-flow passage forming sleeve 30 is inserted into the sleeve insertion holes 10 and 10 of the ball body 3, and both end portions of the sleeve 30 are welded to the peripheral portions of the sleeve insertion holes 10 and 10 of the ball body 3, respectively. The concave engaging member 6 is inserted into the engaging member insertion opening 11 as shown in FIG. 5C, and the upper end surface of the concave engaging member 6 is flush with the outer peripheral surface of the ball body 3. Then, the opening end of the concave engaging member 6 is welded to the opening 11 of the ball body 3. As a result, the ball body 3, the through-flow passage forming sleeve 30, and the concave engaging member 6 are assembled together as shown in FIG. 4 (c) and further as shown in FIGS. 5 (a) and 5 (b). A simple ball 31 is formed.

  After assembling the ball body 3, the through-flow passage forming sleeve 30, and the concave engaging member 6 as described above, heat treatment for removing internal stress caused by the welding, for example, annealing (annealing) )I do. By this heat treatment, distortion generated in the ball main body 3, the sleeve 30, and the concave engaging member 6 is removed, and subsequent machining processing and polishing processing are facilitated, and processing accuracy is improved.

  When the above heat treatment is completed, the surface of the ball main body 3 and the welded portion between the ball main body 3, the sleeve 30, and the concave engaging member 6 are machine-finished. That is, the surface of the spherical ball body 3 and the welded portion are cut by, for example, an NC lathe so that the ball 31 becomes a complete sphere, and then the entire surface of the cut ball body 4 is polished by a polishing apparatus. To do. Thereby, the manufacture of the ball 31 is completed.

  5A is an enlarged longitudinal sectional view of the ball 31 that has been manufactured, and FIG. 5B is an enlarged transverse sectional view of the ball 31. FIG. In these (a) and (b), W is a welded portion between the ball body 3 and the through-flow passage forming sleeve 30, and indicates a welded portion between the ball body 3 and the concave engaging member 6. In (a) and (b), reference numeral 16 denotes an air vent hole provided on the opposite side of the ball main body 3 from the concave engaging member 6.

  In the ball valve ball manufacturing method described above, the bending roll machine BM is used to form the cylindrical body 2 from the rectangular plate material 1, but FIG. 6 shows a mold instead of the roll bending process by the bending roll machine BM. The process of forming the cylindrical body 2 is shown by press-type bending the rectangular plate 1 using the bending machine PM. The mold bending machine PM includes a punch 33 that is suspended and connected to an elevating ram 32, and a die 34 having a recess 34a having a semicircular cross section.

  In the press die bending process by the die bending machine PM, a rectangular plate 1 made of a corrosion-resistant metal material as shown in FIG. 6 (a) is formed by the punch 33 and the die 34 of the die bending machine PM (b). As shown in (d), the cylindrical body 2 is formed by gradually bending. Thereafter, as shown in (e), the both ends 1a and 1a of the plate member 1 are pressed by the vice apparatus DM so as to abut each other, and the abutting portions are welded as shown in (f). Thereafter, as shown in (g), the vice apparatus DM is used again to finish the cylindrical body 2 in a correct circular shape, and finally, as shown in (h), the circular cylindrical body 2 is finally formed. The vise device DM includes a pair of upper and lower vice members 35 and 36 that hold the cylindrical body 2 from both upper and lower sides.

  FIG. 7A is an external perspective view showing the ball valve 12 including the ball 31 manufactured as described above, and FIG. 7B is a longitudinal sectional view of the ball valve 12. In these (a) and (b), 17 is a body main body that forms one fluid conduit 17a, and 18 is a socket that forms the other fluid conduit 18a and is flange-joined to the body main body 17. 17 and the socket 18 form a body 19. Ball seats 20 and 20 are provided on both sides of the central portion in the body 19, and the ball 2 is rotatably held by the ball seats 20 and 20.

  In addition, a ball rotation driving spindle 13 is rotatably supported at the center of the body 19, and a prismatic engagement protrusion 13 a formed at the tip of the spindle 13 is a concave engagement member of the ball 2. 6 is engaged. The spindle 13 is rotated by a handle 15 (see FIG. 7A) attached to the spindle 13 to rotationally drive the ball 2, whereby the flow path is opened and closed between the fluid lines 17a and 18b. It will be. FIG. 7B shows a state where the through-flow passage forming sleeve 30 of the ball 31 is positioned coaxially with both the fluid conduits 17 a and 18 b of the body 19 and opened.

  According to the manufacturing method of the present invention as described above, the cylindrical body 2 is formed by roll-bending or press-bending a rectangular plate 1 made of a corrosion-resistant metal material into a cylindrical shape, and its butt edge 1a. , 1a are welded, and both ends of the cylindrical body 2 are subjected to press die bending with upper and lower hemispherical molds 4 and 5, thereby forming a substantially spherical ball body 3 and corresponding to both ends of the cylindrical body 2. The sleeve insertion openings 10 and 10 are formed at positions, and the engagement member insertion openings for inserting the concave engagement members 6 engaged with the engagement protrusions 13a of the ball rotation driving spindle 13 into the ball body 3. After the portion 11 is opened, the through-flow passage forming sleeve 30 and the concave engaging member 6 are respectively inserted into the sleeve insertion openings 10 and 10 and the engagement member insertion opening 11 and welded to the ball body 3. , Ball body The surface and the welded portion W from a method of mechanically finished, compared with a manufacturing method casting or forging of a conventional ball, can be small and significantly simplified equipment required for production.

  In particular, in this manufacturing method, since the metal plate 1 to be used has a rectangular shape, waste of material is extremely small when cutting, and the sleeve insertion opening 10 is not formed by punching, Since the press-type bending process is performed with the hemispherical molding dies 4 and 5, no material loss due to drilling is eliminated, so that the material loss can be suppressed to several percent. Since material loss can be extremely reduced in this way, even when a small amount of balls 31 are manufactured using a very expensive corrosion-resistant metal plate such as a nickel alloy or a titanium alloy, the manufacturing unit price can be reduced. Is possible. In addition, according to this manufacturing method, it is possible to reduce the raw material (material) necessary for manufacturing the ball 2 to about 1/3 that of the conventional method, and the product weight is a ball manufactured by the conventional method. It is also possible to reduce to about 1/3 of the above.

  Further, in this manufacturing method, after the ball main body 3, the through-flow passage forming sleeve 30, and the concave engaging member 6 are assembled by welding, the internal stress generated by welding is removed before mechanical finishing. Since the heat treatment is performed, the distortion generated in the ball main body 3, the sleeve 30, and the concave engaging member 6 can be removed, and the subsequent mechanical finishing can be facilitated, and the processing accuracy can be improved.

(a)-(c) is explanatory drawing explaining the cylindrical body formation process in the manufacturing process of the ball | bowl of the ball valve which concerns on this invention. (a) And (b) is explanatory drawing explaining the positioning step of the metal mold | die in the process of shape | molding a cylindrical body to a spherical ball | bowl main body with a pair of upper and lower hemispherical metal molds. (a)-(c) is explanatory drawing explaining the state which shape | molds the cylindrical body in the ball | bowl body with a pair of upper and lower hemispherical molds. (a)-(c) is explanatory drawing explaining the process of finishing a ball | bowl by inserting the sleeve for penetration flow path formation in a ball | bowl main body. (a) is an enlarged vertical cross-sectional view of the completed ball, (b) is an enlarged cross-sectional view of the ball, and (c) is a state where a concave engaging member is inserted into the engaging member inserting opening of the ball body. FIG. (a)-(h) is explanatory drawing explaining the process of forming a cylindrical body by carrying out the press-type bending process of the rectangular-shaped board | plate material using a mold bending machine. (a) is an external perspective view showing a ball valve provided with a ball manufactured by the method of the present invention, and (b) is a longitudinal sectional view of the ball valve.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Rectangular plate 1a Edge 2 of rectangular plate 2 Cylindrical body 3 Ball | bowl main body 4,5 Hemispherical metal mold | die 4a, 5a Hemispherical recessed part 6 Concave engagement member 10 Sleeve insertion opening 11 Engagement member insertion opening 26 27 Guide member 30 Sleeve for forming through-flow passage

Claims (2)

A rectangular plate made of a corrosion-resistant metal material is formed into a cylindrical body by roll bending or press-type bending so that both end edges of the rectangular plate material are joined, and after welding the butt end edge of this cylindrical body, Both ends of this cylindrical body are subjected to press-type bending with a pair of upper and lower hemispherical molds, thereby forming a substantially spherical ball body and forming sleeve insertion openings at positions corresponding to both ends of the cylindrical body. An opening for engaging member insertion for inserting a concave engaging member to be engaged with an engaging convex portion of the ball rotation driving spindle is opened in the ball body, and the sleeve inserting opening and the engaging member are inserted. a method of manufacturing a ball of the ball valve so as to penetration flow path forming sleeve and a concave engagement member in use opening each insert and welded to the ball body, this time, the cylinder upper and lower pair of When forming a ball body by press-bending with a spherical mold, the upper and lower hemispherical molds are respectively spread at the entrance of the hemispherical recess, and the end of the cylindrical body is guided and guided to the hemispherical recess. A ball valve in which a half ring-shaped guide member having a tapered guide portion is detachably attached, and both guide members are removed after guiding both end portions of the cylindrical body to the hemispherical recesses of both hemispherical molding dies. Ball manufacturing method. The ball valve ball manufacturing method according to claim 1 , wherein the through-flow passage forming sleeve and the concave engaging member are welded to the ball body, and then heat treatment is performed.

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