JP4460197B2 - Production method and apparatus for both end closed hollow material and rear end uneven thickness / thickened hollow material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention provides a method for manufacturing a hollow material in which both ends are closed (solid) by combining a forging method and an extrusion method in a metal processing method for light metals such as an aluminum alloy and a magnesium alloy, and after the hollow portion. The present invention relates to a manufacturing method and an apparatus suitable for thickening or uneven plastic processing of an end portion.
[0002]
[Prior art]
Closed forging and extrusion methods are widely used as light metal processing methods for light metals such as aluminum alloys and magnesium alloys.
Closed forging is a method in which metal working material is punched and pressed into a metal mold having cavities similar to the outer shape of various deformed shapes, and the deformed shape of the product shape and high strength can be obtained. Although excellent, elongated metal shapes, especially metal processing of hollow materials have been very difficult.
On the other hand, for extruding, for example, in the case of direct extrusion, a substantially cylindrical metal processed material is put in the container part, an extrusion die is arranged in the front, and it is pressurized with ram pressure from the rear to make an elongated product with the same cross-sectional shape. (Shape) is a method for obtaining a cross-sectional shape with a high degree of freedom, and it is excellent for obtaining a hollow material, but it is a very difficult technique to change the shape of the product (shape) with respect to the extrusion direction. is there.
Therefore, if the forging method and the extrusion method can be integrated technically and facilityally, products having structures and shapes that take advantage of the respective features can be obtained integrally and at low cost.
That is, for example, in the case of automobile parts, flanges and hook-like connecting parts are provided at the ends of propeller shafts, steering shafts, etc., and parts made of hollow materials are generally made of steel, and flanges or hook-like parts are used. The terminal portion is forged and the shaft portion is formed using a pipe material, and those parts joined by welding or the like can be integrally formed with a light alloy.
[0003]
[Problems to be solved by the invention]
The present invention combines a forging technique and an extrusion technique to produce a product in which both ends have a closed shape (solid shape) and a hollow shape between them, or a product in which the rear end of the hollow shape is uneven and thickened And an apparatus for the same.
[0004]
As a first object of the manufacturing method of the hollow material in which both ends are closed, the invention according to claim 1 is arranged such that an extrusion die is arranged in front of the container part and a closed forging die is connected in front of the extrusion die. After fixing the metal processing material into the container part and punching the metal processing material with a flat punch with a pressing surface formed in a substantially flat shape from the rear, the tip of the metal processing material is closed and forged. For closed forging after a predetermined gap is formed between the opening of the female die and the tip of the mandrel by pressing and plastically deforming from behind the metal workpiece with a stepped punch with a mandrel. After the mold is released and the metal processing material is extruded to follow the tip of the metal processing material in a free state to obtain a hollow portion, the metal processing material is left in the container again with a flat punch. Pressurize from behind Off and allows the After closing the terminal after the hollow portion, unplug the inner punch having a punch shape corresponding to the hollow portion contour, the product in double-acting punch consisting of outer punch having a punch shape corresponding to the container inner diameter The remainder of the metal processed material is removed as a residual ring portion .
[0005]
In this way, as a first step, first, the extrusion die and the closed forging die are connected and fixed to form a forging cavity, and the metal working material is formed into a flat punch whose pressing surface is substantially flat from the rear. The tip of the metal workpiece is partially forged by pressurizing the punch.
Next, as a second step, the flat punch used in the first step is removed or raised and slid sideways. Instead, a stepped punch provided with a mandrel portion that protrudes from the pressure surface is mounted or the upper part of the container The metal working material remaining in the container is plastically deformed and filled between the pressing surface of the stepped punch and the mandrel portion.
As a third step, when the forging die is released and the pressurization is continued in a free state, the metal workpiece is extruded from the gap between the female die and the mandrel portion, and a hollow portion is formed.
At this time, the forging die moves following the forging part located at the tip of the metal workpiece.
As a fourth step, the stepped punch used for the extrusion process is removed or raised and slid sideways, and the metal processed material remaining in the container with the flat punch used for the first step is viewed from behind. When the pressure is applied, since there is no mandrel part that restrains the hollow part of the mandrel part formed in the third step, the rear end of the product becomes a solid shape in order to plastically deform so that the hollow part is closed.
Here, the product may be taken out by extruding to the end as it is, but in the case of direct forward extrusion, there is a high risk that the final part of the extrusion contains impurities and intermetallic inclusions. It is desirable to leave part of the processed material to finish this fourth step.
[0006]
Accordingly, inner punch having a fifth step when allowed to remain a part of the metal processing material as described above into the container, after occlude the terminal after the hollow portion, the punch shape corresponding to the hollow portion outer Then, the product was pulled out with a double-action punch composed of an outer punch having a punch shape corresponding to the container inner diameter, and the remainder of the metal processed material was removed as a residual ring portion.
[0007]
The invention according to claim 2 uses a double-action punch comprising an inner punch and an outer punch after the hollow portion is extruded so that the fourth and fifth steps can be carried out continuously.
[0008]
As a second object of the method for manufacturing a product in which the thickness and internal shape of the rear end of the hollow portion are changed, the invention according to claim 3 is arranged such that an extrusion die is arranged in front of the container portion, and the extrusion die A closed forging die is connected and fixed to the front of the metal, and a metal workpiece is placed in the container, and a punch is pressed from behind using a flat punch with a pressing surface formed in a substantially flat surface. Closed forging, then pressurized and plastically deformed from behind the metal workpiece with a stepped punch with a mandrel part protruding from the pressure surface, between the opening of the female die and the tip of the mandrel part After the predetermined gap is formed in the mold, the closed forging die is released and is continuously extruded in a free state following the tip of the metal processed material to obtain a hollow portion. The stepped punch used during machining A double-action punch that has a stepped inner punch with a mandrel portion that is smaller in diameter than the outer diameter of the dorel portion, the shape of the stepped inner punch corresponds to the hollow portion outer shape, and the shape of the outer punch corresponds to the inner diameter of the container portion Then, after the hollow end of the hollow part was increased in thickness or plastically deformed, the product was removed, and the remainder of the metal processed material was removed as a residual ring part.
[0009]
In the above-described method, the mandrel portion having a smaller shape than the hollow portion formed by the mandrel portion of the stepped punch in the third step is used instead of closing the hollow portion by using the flat punch in the fourth step. When the pressure is applied using the stepped punch having the shape, the rear end of the hollow portion is plastically deformed into the shape of the subsequent mandrel portion, so that a product having a partially uneven or thickened shape can be obtained. .
[0010]
The invention described in claim 4 is intended to provide a metal working apparatus suitable for manufacturing these products, and is provided so as to be slidable so that a plurality of punches having different shapes can be selectively used for the upper and lower movable upper die of the press. The container part for placing and setting the metal processed material is arranged in the vertical direction directly below it, and the extrusion die is fixedly arranged immediately below the container part located in front of the container part, and the closing forging gold is placed in front of the extrusion die. It was provided with a wedge device for detachably connecting the molds, fixing and releasing the closed forging die, and an elevator device for supporting the closed forging die while sliding downward during extrusion.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
An example of a processing apparatus used for metal processing according to the present invention is shown in FIG.
Various punches such as a flat punch 30, a stepped punch 31, a flat punch 32 with an inner punch, and the like are attached to and detached from a vertically movable upper die 1 of a press machine via a punch slide device (punch mounting device) 2. The punch can be selected and used according to the machining process simply by sliding it left and right.
Immediately below the punch, a container portion 4 is provided in the vertical direction, and a metal workpiece 9 is placed inside the container.
The container part is attached with a heating device as required, and temperature control is possible.
An extrusion die 5 is provided immediately below the container portion, and a closed forging die 6 is provided so as to form a cavity portion of the forging portion in connection with the extrusion die. Supported by a mold holder 61.
The closed forging die 6 is provided with a wedge device 7 so that it can be fixed or released.
The container unit 4, the extrusion die 5, the closed forging die 6 (die holder 61) and the wedge device are housed in the die set 100 so that the positioning can be facilitated. It is not limited to the above.
[0012]
In addition, wedge-shaped wedges 71a and 71b are attached to the wedge device 7 so as to be movable to the left and right, so that the forging die 6 can be fixed or released. An elevator device 8 is provided so as to be slidably supported downward.
The elevator device 8 is provided with a guide 81 and is movable up and down by an ejector 82. A knockout guide 83 is provided directly below the elevator device 8. After the product is extruded, the sub wedge 84 is moved from the side of the knock guide 83. By inserting, the product can be knocked out from the mold by pressurizing the repel rod 62 upward as shown in FIG.
In addition, although the example of the metal processing apparatus shown in FIG. 1 has provided the elevator apparatus in the lower part of the floor level and has kept the height of the press machine comparatively low, if the length of extrusion of a metal processing material can be maintained, All of the devices may be provided at the upper part of the floor level, or may be arranged in the horizontal direction without the need to arrange in the vertical direction as shown in FIG.
[0013]
An example of a method of metal processing using such a metal processing apparatus will be described below with reference to the drawings.
(First step)
As shown in FIG. 2 (a), an extrusion die 5 and a closed forging die 6 are connected and fixed immediately below the container part 4, and a metal workpiece 9 is put into the container part.
The processing conditions such as the container temperature and the preheating temperature of the mold processing material can be arbitrarily selected depending on the pressurizing capacity of the press, the product shape, etc. In the case of an aluminum alloy, the processing conditions are 300 to 600 ° C. It is desirable to heat to the extent.
Moreover, the enlarged view of the positional relationship of the container part 4, the extrusion die 5, and the metal mold | die 6 for closed forging is shown in FIG.
An upper part of the extrusion die 5 is provided with a female die opening 51. A closed forging die 6 is formed so as to be fitted in this portion, and a cavity 6a approximating the shape of the forged part of the product is provided. It has been.
Needless to say, the cavity shape is formed in accordance with the required product shape.
As shown in FIG. 2 (a), after the metal workpiece 9 is put into the container part, when the pressing surface 30a as shown in FIG. As shown in FIG. 3, a forging portion 91 is obtained in accordance with the cavity shape, and a part of the processed material remains in the container portion.
[0014]
(Second step)
When replaced with a stepped punch 31 as shown in FIG. 8 and pressurized as shown in FIG. 3 (c), the metal working material in the container part is deformed as shown in FIG. 3 (d).
At this time, the mandrel portion 31 b provided so as to protrude from the pressing surface 31 a of the stepped punch 31 shown in FIG. 8 is deformed until it is positioned at the opening of the female die of the extrusion die 5.
(Third step)
As shown in FIG. 3 (e), when the wedges 71a and 71b are moved backward to release and press the forging die, the metal working material is extruded from the gap formed by the die 5 and the mandrel portion 31b. An extruded portion 92 is formed.
[0015]
(4th process)
As shown in FIG. 4 (f), when the extrusion is continued instead of the flat punch 30, the hollow portion 92a of the metal processing material remaining in the container (the portion where the mandrel portion 31b of the stepped punch 31 has been inserted) ) Is crushed so that a solid portion 93 is formed in which the rear end of the hollow portion is closed as shown in FIG.
(5th process)
The product can be taken out as it is, but a flat punch 32 with an inner punch having an outer punch 32A and an inner punch 32B as shown in FIG. 9 is a perspective view of a double-action punch and FIG. Instead of the double-action punch, the product can be cut off with the inner punch 32B as shown in FIG.
In this way, it is possible to remove from the product a rear end portion where impurities such as intermetallic inclusions are likely to remain.
At this time, as shown in FIG. 10, if a recess 132C is provided on the side portion of the inner punch, a part of the material goes around the recess when the product is cut off, and the residual ring portion 94 left in the container raises the double-action punch. Therefore, it can be discharged out of the container as it is.
In this embodiment, after using the flat punch 30 in the rear end closing process shown in FIGS. 4F and 4G, as shown in FIG. Although the product was cut off by replacing with 132, the fourth step shown in FIGS. 4 (F) and 4 (G) and the fifth step shown in FIGS. 5 (H), (L), and (N) were performed with this flat punch with an inner punch. 32, 132 can also be carried out continuously.
A perspective view of an example of the product 90 manufactured in this way is shown in FIG. 11 and includes a forged portion 91, a hollow portion 92 by extrusion, and a solid portion (rear end closing portion) by extrusion.
[0016]
Next, an embodiment of a method for manufacturing a product in which the thickness and the inner shape of the rear end of the hollow portion are changed will be described.
(First step)
FIG. 12 shows an example of a female die 250 when the outer shape is an irregular shape. In the extrusion die for forming the outer shape of the extruded portion, a female die opening 251 that forms a bearing portion at the time of extrusion processing is shown. It has an irregular shape that forms the outer shape of the product.
The female die and the closed forging die are connected to form a cavity, and a metal working material is pressed with a flat punch from behind the container part to form a forged part.
As a result, a forged portion 291 is obtained as shown in FIG.
(Second step)
As shown in FIG. 13, the stepped punch 231 having the mandrel part 231b inserted into the female die opening is plastically deformed so that the metal processing material remaining in the container part is filled around the mandrel part.
(Third step)
Next, when the mold for closing forging is released and the extrusion is made in a free state so that the die can be moved following the forging portion, a hollow portion 292 is formed by extrusion as shown in FIG.
(4th process)
After the extrusion process, the punch is replaced with a double-action punch 232 composed of an inner punch 232B and an outer punch 232A as shown in FIG.
The pressure surface 232Ba of the inner punch 232B of this punch has a mandrel portion 232c provided so as to protrude. First, the height of the pressure surface 232Aa of the outer punch 232A and the pressure surface 232Ba of the inner punch is matched to perform metal processing. When the material is pressed from the rear, the shape of the mandrel part 232c provided in the inner punch is smaller than the shape of the mandrel part 231b of the stepped punch used in the third step, so that the metal processing material becomes the outer shape of the mandrel part. The hollow portion is plastically deformed so as to fit, and an uneven thickness and increased thickness portion 293 are formed by extrusion shown in FIG.
The following steps are the same as the method for manufacturing the both-end-closed hollow material described above, and therefore description thereof is omitted.
[0017]
Next, an application example of the metal processing method according to the present invention will be described.
FIG. 16 shows a structural example of a mold for forming serrations on the outer shape of the closed portion, and an extrusion die 350 having a forging die 360 having a serration-shaped cavity 360a and an opening 351 for forming an outer shape of the extruded portion. Consists of.
A product 390 molded using this mold structure is shown in FIG.
An extruded portion is formed behind the forged portion 391. If the flat punch used in the forging process is used as it is and then extruded, the extruded portion 392A becomes a solid extruded material. After forming, the flat punch is replaced with a stepped punch having a mandrel, and then extruded, then when the flat punch is replaced and pressurized, a product having a hollow portion and a solid closed end can be obtained. .
[0018]
Further, as shown in FIG. 18, when a forging die 460 is provided with a cavity 460a provided with serrations and an extrusion die 450 is provided with a serrated opening 451, a product 490 as shown in FIG. 19 is obtained. It is done.
[0019]
As a modified example of the die structure of the forging portion, as shown in FIG. 20, the core 561a and 561b are mounted in the cavity portion 560a of the forging die 560 and connected to an extrusion die 550 having an extrusion opening 551. 24, after the closed forging as shown in FIG. 24, extrusion is performed as shown in FIG. 25, the cores 561a and 561b are retracted as shown in FIG. 26, and the product 590 is taken out as shown in FIG. A lateral through hole 591a using a core can also be provided in the forging portion 591 as shown.
The die structure in this case is shown in FIG. 21, the forging die structure is shown in FIG. 22, and the core shape is shown in FIG.
By combining the cores in this way, the shape of the blocking portion can be freely selected.
[0020]
【The invention's effect】
In the present invention, an extrusion die and a closed forging die are connected and arranged in front of a container portion into which a metal workpiece is placed and set, so that the forging die can be fixed or released. Since the processing technology is integrated, it becomes a metal processing device with a simple structure, the processing tip is forged, the middle part is a hollow material having a hollow part, and the rear end part is solidly closed. It is possible to integrally manufacture a product having a terminal-blocking hollow material or a product in which the inner wall of the hollow portion at the rear end of processing is unevenly thickened.
Therefore, the forging part can be manufactured using various forging techniques to produce a product shape using a core, and the extruded part can also be used to produce a product having an irregularly shaped hollow part utilizing the degree of freedom of the cross-sectional shape. Furthermore, since the rear end of the extruded portion can be closed, and plastic deformation such as uneven thickness and thickening can be easily performed, the strength of the terminal portion can be freely adjusted.
In addition, in the case of a product that has been conventionally manufactured by being partly molded and welded together without being able to be integrally formed, it is inevitable that a partial strength decrease due to the heat effect of the welded part. Thus, the joint portion can be eliminated or reduced, and the weight and size can be further reduced in terms of the strength and durability reliability of the product.
In the present invention, when a double-action punch consisting of an inner punch and an outer punch is used when the product is removed from the mold, impurities such as intermetallic inclusions approaching the rear end of the metal workpiece are removed from the product as a residual ring portion. I can do it.
[Brief description of the drawings]
FIG. 1 shows an example of a metal processing apparatus applied to the present invention.
FIG. 2 shows a forging process.
FIG. 3 shows a process for forming a hollow part by extrusion.
FIG. 4 shows a process for forming a solid part by extrusion.
FIG. 5 shows a product cutting process.
FIG. 6 shows the positional relationship among a container part, an extrusion die, and a forging die.
FIG. 7 shows a flat punch.
FIG. 8 shows a stepped punch.
FIG. 9 shows a double-action punch.
FIG. 10 shows an example in which a residual ring locking recess is provided on the side of the inner punch.
FIG. 11 shows an example of a product of both end closed hollow materials, and shows an extruding part in a half-section shape.
FIG. 12 shows an example of an extrusion die (female die) in the case where an extruded portion is formed into an irregular cross section.
FIG. 13 shows a stepped punch having a deformed mandrel part shape.
FIG. 14 shows an example in which a mandrel portion is provided on the pressure surface of the inner punch.
FIG. 15 shows an example of a deformed product having an extruded shape.
FIG. 16 shows an example of a die structure in the case where serrations are provided on the outer shape of a forged part.
17 is an external view of a product molded with the mold structure of FIG. 16;
FIG. 18 shows an example of a mold structure in the case where serrations are provided in a forging portion and an extrusion portion.
FIG. 19 is an external view of a product molded with the mold structure of FIG.
FIG. 20 shows an example of a die structure when a through hole is formed in a forged part in a direction different from the forming direction.
21 shows the extrusion die portion of FIG.
22 shows a portion of the forging die in FIG. 20;
FIG. 23 is an external view of the core shown in FIG.
24 shows a cross-sectional view of a state in which a product is molded with the mold structure of FIG.
FIG. 25 is a cross-sectional view of a state where a product is lowered by an elevator apparatus after being molded using the mold structure of FIG.
FIG. 26 shows a state where the core is retracted.
FIG. 27 is a cross-sectional view showing a state where a product is removed.
28 shows a product molded with the mold structure of FIG.
[Explanation of symbols]
1 Upper die 2 Punch slide device (Punch mounting device)
21 Punch holder 30 Flat punch 30a, 31a, 231a Pressurizing surface 31, 231, Stepped punch 31b, 231b, Mandrel part 32, 132 Flat punch 32A with inner punch, 132A Outer punch 32B, 132B Inner punch 232 Mandrel part on inner punch Double acting punch 232A Outer punch 232Aa Outer punch pressure surface 232B Inner punch 232Ba Inner punch pressure surface 232c Mandrel portion 4 of inner punch Container portion 5, 250, 350, 450, 550 Extrusion dies 51, 251, 551 Female die opening 351, 451 Die openings 6, 360, 460, 560 Closing forging dies 6a, 360a, 460a, 560a Cavities 561a, 561b Core 61 Mold holder 62 Ripel 7 Wedge device 71a, 71b Wedge 8 Elevator device 81 Guide 82 Ejector 83 Knockout guide 84 Sub wedge 9 Metal workpiece 90, 290, 390, 490, 590 Product shape 91, 291, 391, 491, 591 Forging part 392A Extrusion parts 92, 292, 592 Hollow parts 93, 293, 593 by extrusion process Solid parts (blocking part) by extrusion process
94 Residual ring 100 Die set

Claims (4)

A flat punch in which an extrusion die is arranged in front of the container part, a closed forging die is connected and fixed in front of the extrusion die, a metal workpiece is introduced into the container part, and a pressure surface is formed in a substantially flat surface from the rear. Forcibly forging the tip of the metal workpiece using a punch press, and then pressing and plastically deforming from the rear of the metal workpiece with a stepped punch with a mandrel protruding from the pressure surface, After a predetermined gap is formed between the opening of the female die and the tip of the mandrel, the closed forging die is released and the extrusion is continued in a free state following the tip of the metal workpiece. After the hollow portion is obtained, the metal processing material left in the container portion is again pressed from behind by using a flat punch to close the rear end of the hollow portion, and then the punch corresponding to the outer shape of the hollow portion. Has shape That the inner punch, dropped disconnect the product at double acting punching consisting outer punch having a punch shape corresponding to the container inner diameter, both ends closed hollow member, characterized in that the removal of the remainder of the metal processing material as the remainder ring portion Manufacturing method. The method for producing a hollow material with closed ends according to claim 1, wherein the flat punch that pressurizes the hollow portion again after extrusion is a double-action punch comprising an inner punch and an outer punch. A flat punch in which an extrusion die is arranged in front of the container part, a closed forging die is connected and fixed in front of the extrusion die, a metal workpiece is introduced into the container part, and a pressure surface is formed in a substantially flat surface from the rear. Forcibly forging the tip of the metal workpiece using a punch press, and then pressurizing and plastically deforming from the rear of the metal workpiece with a stepped punch with a mandrel part protruding from the pressing surface, After a predetermined gap is formed between the opening of the female die and the tip of the mandrel, the closed forging die is released and the extrusion is continued in a free state following the tip of the metal workpiece. After obtaining the hollow portion, the stepped inner punch has a mandrel portion having a diameter smaller than the outer diameter of the mandrel portion of the stepped punch used at the time of extrusion of the hollow portion, and the shape of the stepped inner punch is Corresponds to the outer shape of the hollow part, and the double-action punch whose outer punch shape corresponds to the inner diameter of the container part is used to remove the product after the hollow part's rear end has been subjected to uneven or increased plastic deformation, and the remainder of the metal workpiece is removed. A method for producing a rear end uneven thickness / increased hollow material, which is removed as a residual ring portion. The upper and lower movable upper die of the press is slidably equipped so that a plurality of punches of different shapes can be selected and used, and a container part for placing and setting metal processing material is arranged vertically below this container part. An extrusion die is fixedly arranged immediately below the container portion located in the front, a closed forging die is detachably connected to the front of the extrusion die, and a wedge device for fixing and releasing the closed forging die is provided. The metal working apparatus used for the manufacturing method in any one of Claim 1 to 3 provided with the elevator apparatus which supports a metal mold | die for closed forging while sliding to a downward direction at the time of an extrusion process.

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