JP4484976B2 - Manufacturing method of shift lever in wastegate valve of turbocharger - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a shift lever in a wastegate valve assembled in a turbocharger used in an automobile engine or the like, and more particularly, to a shift lever in a novel wastegate valve that eliminates cutting in the manufacture thereof. It relates to a manufacturing method.
[0002]
BACKGROUND OF THE INVENTION
A turbocharger is known as a supercharger used as a means for increasing the output and performance of an automobile engine. In this system, a turbine is driven by the exhaust energy of the engine, and a compressor is rotated by the output of the turbine so as to bring the engine to a supercharged state higher than natural intake air. Such a turbocharger may receive excessive exhaust gas energy depending on the engine rotation state. Therefore, when such excessive exhaust gas is supplied, that is, the engine is substantially rotated at high speed. In such a case, the exhaust gas is bypassed without being used for driving the turbine and exhausted as it is. A wastegate valve is used to open such a bypass path, but the equipment around the turbocharger, such as the wastegate valve or a shift lever that drives the wastegate valve, receives exhaust gas almost directly and is close to several hundred degrees Celsius. Therefore, extremely high heat resistance is required. However, such heat-resistant materials, for example, JIS standard and SUS310S materials are excellent in heat resistance, but are difficult to perform machining such as cutting. It took extremely careful work and time, and there was a certain limit to improving the production efficiency.
[0003]
[Technical problem to be solved]
The present invention has been made in consideration of such a background, and even if it is a heat-resistant metal material which is such a difficult-to-cut material, by eliminating the cutting process, the wastegate valve of the turbocharger is highly efficient. This is an attempt to develop a new technique that can machine shift levers in the factory.
[0004]
[Means for Solving the Problems]
That is, the manufacturing method of the shift lever in the wastegate valve of the turbocharger according to claim 1 includes a stem portion constituting the rotating shaft, an oscillating portion bent in a vent shape connected to one end of the stem portion, and the oscillating portion. Oite to a method of manufacturing a shift lever in the waste gate valve of the turbocharger comprising a resistant stainless material integral with the valve body supporting portion in part tip has a pin hole for mounting the valve,
First, in the header processing step, the starting material round bar unbent consisting Heat resistant stainless steel material, so that the flange portion to the intermediate portion is formed in the partition like a header machine, a small diameter of the predetermined shape in the circumferential surface of the starting material In this process, the plastic part is cold plastically deformed, and the stem part is completed by this process, and the rocking part is brought into an intermediate machining state that has not been bent. Then, in the bend press process, the rocking part in the intermediate processing state is almost bent. Jo bending processed, after forming the crushed part press vent is plastically deformed into a flat shape by press working range further extending from the pivot portion side surface portion on the valve body supporting portion, further crushing and valves swing tip A body support portion is formed, and then in the piercing process, the valve body support portion is perforated by piercing.
[0005]
According to a second aspect of the present invention, there is provided a method for manufacturing a shift lever in a waste gate valve of a turbocharger. This is a more depressed state, characterized in that the surface roughness is set to Ra 1.2 or less and the axial accuracy is set to 20 μm or less.
[0006]
Furthermore, the manufacturing method of the shift lever in the waste gate valve of the turbocharger according to claim 3 is characterized in that, in addition to the requirement of claim 1 or 2, the swinging portion is bent into a bent shape in the bend press processing step. In doing so, a rolling roller is provided at the contact portion between the bending die and the rocking portion in the intermediate processing state.
[0007]
According to the above invention, even a shift lever in a wastegate valve to which a heat resistant material that is a difficult-to-cut material is applied does not take any cutting work, and an extremely high performance product can be obtained with high efficiency.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be specifically described below based on the illustrated embodiments. First, the shift lever in the wastegate valve manufactured according to the present invention will be described, and then the manufacturing method will be described in order from the starting material to the completion of the product. 1 and 2, reference numeral 1 denotes a wastegate valve, which comprises a shift lever 10 manufactured according to the present invention, and is attached to a turbocharger 2. First, the peripheral equipment of the turbocharger 2 will be described. As is well known, this is one of the superchargers for improving the combustion efficiency of the engine E. From this, the exhaust pipe 3 and the air cleaner 4 are used. A silencer 7 is further connected to the exhaust side of the turbocharger 2 via a catalytic converter 6.
[0009]
The turbocharger 2 is provided with a turbine 21 for receiving the exhaust gas G from the exhaust pipe 3 with respect to the casing 20, and a compressor 22 driven by the turbine 21 is provided on the intake pipe 5 side. An exhaust inlet 23 formed on the turbine 21 side is connected to the exhaust pipe 3, and the exhaust inlet 23 is formed to branch into a main inlet 23A and a bypass inlet 23B. A wastegate port 25 is opened in the partition wall 24 between the main inlet 23A and the bypass inlet 23B, and the wastegate port 25 is controlled to be opened and closed by the wastegate valve 1 including the manufacturing object of the present invention. The turbine 21 is driven by the exhaust gas G from the main inlet 23A, and the exhaust gas G finally joins the path from the bypass inlet 23B and is exhausted from the exhaust outlet 26 to reach the catalytic converter 6. .
[0010]
Further, a shift linkage 27 for driving the waste gate valve 1 and an actuator 28 for driving the shift linkage 27 are provided on the side of the turbocharger 2. The actuator 28 is operated by detecting the intake pressure of the engine with a diaphragm or the like, for example, as shown in a skeleton form in FIG.
[0011]
The wastegate valve 1 attached to the turbocharger 2 having such a structure will be described in more detail. As an example, the wastegate valve 1 has a valve body 11 attached to one end thereof via a pin 12 relatively loosely with respect to a shift lever 10 having a substantially L shape as a whole as shown in FIG. This shift lever 10 has a stem portion 13 constituting a rotating shaft and a swinging portion 14 bent in a vent shape with respect to the stem portion 13, and a flange portion 15 is formed therebetween. . The end portion of the stem portion 13 is provided with a linkage receiving end 16 having a smaller diameter.
[0012]
Further, the swinging portion 14 has a vent portion 17 bent approximately 90 ° almost gently, and a valve body support portion 18 formed continuously at the tip thereof. The vent portion 17 and the valve body support portion 18 are in a state of being flattened, and the vent portion 17 is a vent crushing portion 17A in which the side surface of the circular section is further pushed in somewhat. On the other hand, the valve body support portion 18 has a state in which the surface shape seen from the side surface is widened with further crushing. The valve body support portion 18 has a pin hole 19 for receiving the pin 12 and attaching the valve body 11. The shift lever 10 is most preferably made of a heat-resistant stainless steel material, for example, a material such as JIS standard or SUS310S. The stem portion 13 preferably has a surface roughness Ra of 1.2 or less and an axial accuracy of 20 μm or less as shown in an enlarged view in FIG.
[0013]
The shift lever 10 in the waste gate valve 1 produced by the present invention, above mentioned such shapes are those having, while sequentially takes the step of carrying out the production method of the present invention as described below FIGS Manufactured.
(1) Supply of starting material Since the shift lever 10 is required to have sufficient heat resistance as the starting material W, for example, a heat-resistant stainless steel material such as SUS310S is applied as described above. This starting material W is selected in consideration of the dimensional specifications of the product and the state of plastic deformation of the material, and a round bar-shaped material is applied as shown in FIG.
[0014]
(2) Header processing step The round bar-shaped material is cold plastically deformed by header processing to obtain an intermediate product. In the following description, the intermediate material in the middle of processing will be described as reference W1.
[0015]
(2) -i. Oscillating part forming step First, using a predetermined header processing die, a part that will constitute the oscillating part 14 is processed on one end side of the starting material W as shown in FIG. In practice, the header processing is performed so as to reduce the diameter of the starting material W to some extent, and a step is formed between the portion where the flange portion 15 is formed by post-processing.
[0016]
(2) -ii. Processing of stem portion Subsequently, processing is performed so as to narrow the portion constituting the stem portion 13 to a small diameter by header processing. At that time, in the embodiment shown in FIG. 5C and FIG. 5D, narrowing is performed in two stages, but the number of header processing steps is determined from the relationship between the diameter of the starting material W and the diameter required for the product. . At this stage, the diameter of the stem portion 13 is almost set, and a desired diameter is obtained. Further, the flange portion 15 is formed by this step.
[0017]
(2) -iii. Processing of linkage receiving end In this state, as shown in FIG. 5 (e), a smaller-diameter linkage receiving end 16 is formed on the distal end side of the stem portion 13 by header processing.
[0018]
(3) Bending and pressing process
(3) -i. Bent forming step First, as shown in FIG. 6A, the straight round bar portion that becomes the vent portion 17 is bent so as to bend at a certain angle. This is processed by a bending die, but it is possible to arrange a rolling roller or the like at the contact portion of the bending die and the intermediate material W1 so that the bending process can be performed smoothly. preferable. In the case this Bend processing is not sufficient in one bending needed, or the like when the force is generated in the processing in a single bending, for example, the dimensional specifications Repeat this bending again restriking Get the flexing situation that suits you.
[0019]
(3) -ii. Next, as shown in FIG. 6B, a pressing process is performed so as to crush the entire side surface of the oscillating part 14. Thereafter, as shown in FIG. 6C, the tip of the swinging portion 14 is further flattened to form a space for forming the pin hole 19.
[0020]
(4) Piercing Step After that, pin holes 19 are formed by piercing punches P as shown in FIG. In such a formed state, the stem portion 13 has a surface roughness of approximately Ra 1.2 or less and an axial accuracy of approximately 20 μm or less. Incidentally, even in this case, since the rough surface formed on the stem portion 13 is in a state of being recessed from the reference surface as shown in an enlarged view in FIG. It will not be an obstacle. In the case of cutting, for example, in the case of this kind of difficult-to-cut material, the shaft accuracy varies within the range of ± 5/100 mm to ± 6/100 mm, and the variation is on the standard surface as shown in FIG. On the other hand, since the convex portion and the concave portion are formed in a repeated shape, the convex portion has to take sufficient clearance particularly in relation to the bearing portion that receives the stem portion 13, and as a result, it is loose. In some cases, this may lead to problems in improving the performance of the product as a whole.
[0021]
(5) Assembling process of valve body Incidentally, it is preferable that the valve body 11 is formed in a shade shape by pressing and blanking by a fine blanking technique. Since the pin 12 is set so as to penetrate the pin hole 19 in the valve body 11 and the pin hole 19 in the shift lever 10, both ends thereof are caulked to attach the valve body 11 to the valve body support portion 18 in the shift lever 10. is there. In this attachment, it is preferable that the valve body 11 is assembled in a relatively loose state so that the valve body 11 can be in close contact with the wastegate port 25 in the partition wall 24.
[0022]
【The invention's effect】
The present invention has a configuration as described above, and even a shift lever in a wastegate valve to which a heat-resistant material that is a difficult-to-cut material is applied does not take any cutting process in the manufacturing process, and has extremely high performance. The product can be obtained with high efficiency.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a wastegate bubble and a turbocharger incorporating a shift lever manufactured by the manufacturing method of the present invention.
FIG. 2 is an explanatory diagram skeletally showing peripheral equipment of a turbocharger.
FIG. 3 is a front view (a) and a side view (b) showing a partially cutaway view of a wastegate valve incorporating a shift lever manufactured by the manufacturing method of the present invention.
FIG. 4 is an enlarged view showing a difference in surface roughness of a stem portion processed by two different methods.
FIG. 5 is an explanatory view showing step by step how the stem portion and the swinging portion of the shift lever are narrowed down.
FIG. 6 is an explanatory view showing step by step how vent portions and pin holes are formed in the shift lever.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Wastegate valve 2 Turbocharger 3 Exhaust pipe 4 Air cleaner 5 Intake pipe 6 Catalytic converter 7 Silencer 10 Shift lever 11 Valve body 12 Pin 13 Stem part 14 Oscillating part 15 Flange part 16 Linkage receiving end 17 Vent part 17A Vent crushing Part 18 Valve body support part 19 Pin hole 20 Casing 21 Turbine 22 Compressor 23 Exhaust inlet 23A Main inlet 23B Bypass inlet 24 Partition 25 Westgate port 26 Exhaust outlet 27 Shift linkage 28 Actuator E Engine G Exhaust gas P Piercing punch W Starting material W1 Intermediate material

Claims (3)

Integral having a stem portion constituting a rotating shaft, a swinging portion bent in a vent shape connected to one end of the stem portion, and a valve body support portion having a pin hole for attaching a valve to the tip of the swinging portion Oite to a method of manufacturing a shift lever in the waste gate valve of the turbocharger consisting of heat-resistant stainless steel,
First, in the header processing step, the starting material of the round rod-shaped material made of heat-resistant stainless steel is bent into a small diameter with a predetermined shape so that the flange part is formed in the middle part by the header machine. This process is cold plastically deformed so that the stem is completed by this process, and the rocking part is brought into an intermediate machining state that has not yet been bent. Then, in the bending and pressing process, the rocking part in the intermediate processing state is almost vented. Jo bending processed, after forming the crushed part press vent is plastically deformed into a flat shape by press working range further extending from the pivot portion side surface portion on the valve body supporting portion, further crushing and valves swing tip forming a body supporting portion, and then the piercing process, weather turbocharger, characterized in that the drilled hole machining by piercing to the valve body supporting portion Method of manufacturing a shift lever in the preparative gate valve.   The processing of the stem portion in the header processing is a state in which the rough surface formed here is recessed from the reference surface, the surface roughness is Ra 1.2 or less, and the axial accuracy is set to 20 μm or less. The manufacturing method of the shift lever in the wastegate valve of the turbocharger according to claim 1.   In the bending and pressing process, when bending the swinging portion into a bent shape, a rolling roller is disposed at the contact portion between the bending die and the swinging portion in the intermediate processing state. 3. A method for manufacturing a shift lever in a wastegate valve of a turbocharger according to claim 1 or 2.

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