JP4537792B2 - Hydroforming mold with movable mold and metal branch pipe - Google Patents

Hydroforming mold with movable mold and metal branch pipe Download PDF

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JP4537792B2
JP4537792B2 JP2004223002A JP2004223002A JP4537792B2 JP 4537792 B2 JP4537792 B2 JP 4537792B2 JP 2004223002 A JP2004223002 A JP 2004223002A JP 2004223002 A JP2004223002 A JP 2004223002A JP 4537792 B2 JP4537792 B2 JP 4537792B2
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mold
branch pipe
hydroforming
pipe
movable
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JP2006035301A (en
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英幸 中村
修 本多
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Nippon Steel Corp
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本発明は自動車構造用部材などに用いられる金属分岐管を得るためのハイドロフォーミングの型および金属分岐管に関するものである。   The present invention relates to a hydroforming mold and a metal branch pipe for obtaining a metal branch pipe used for automobile structural members and the like.

近年、自動車部品の加工技術としてハイドロフォーミングが注目されている。図5は従来のハイドロフォーミングの例を示す図で、図5(a)は型構造の管長手断面の図である。固定された型21に金属管3がセットされ、さらに枝頂点の破断を防ぐためカウンター24が金属管3に接している。金属管3は軸押し型23によって管端を押し込まれながら内圧を作用され、さらにカウンター24が制御される。これによって、図5(b)に示すように、主管62と枝管61からなる成形品が得られる。しかしこの方法ではシワや割れの発生を抑制しつつ枝管の高さを高めることが難しく、主管、枝管ともに円管であり、枝管の張り出し高さも主管の直径の半分程度の排気管継ぎ手などに適用が限られていた。   In recent years, hydroforming has attracted attention as a processing technology for automobile parts. FIG. 5 is a diagram showing an example of conventional hydroforming, and FIG. 5 (a) is a diagram of a longitudinal section of a pipe of a mold structure. A metal tube 3 is set on the fixed mold 21, and a counter 24 is in contact with the metal tube 3 to prevent breakage of the branch vertex. The metal tube 3 is subjected to internal pressure while being pushed into the tube end by the shaft push die 23, and the counter 24 is further controlled. As a result, as shown in FIG. 5 (b), a molded product including the main pipe 62 and the branch pipe 61 is obtained. However, with this method, it is difficult to increase the height of the branch pipe while suppressing the occurrence of wrinkles and cracks. Both the main pipe and the branch pipe are circular pipes, and the height of the branch pipe is about half the diameter of the main pipe. Application was limited.

ハイドロフォーミングで枝管の高さを高めるために型の一部を移動させる方法が知られている。例えば非特許文献1には、枝管を張り出す方向や高さの自由度を増す方法が開示されている。また特許文献2では、予め曲げ加工した金属管を用いて枝管の張り出し高さを従来の数倍にする方法が開示されている。   A method of moving a part of a mold in order to increase the height of a branch pipe by hydroforming is known. For example, Non-Patent Document 1 discloses a method of increasing the degree of freedom in the direction and height of extending a branch pipe. Further, Patent Document 2 discloses a method of increasing the protruding height of a branch pipe several times that of the prior art by using a metal pipe bent in advance.

しかし、これらの手法を主管が多角形断面の分岐管に適用すると、シワや割れといった成形不良を生じやすいことがわかった。自動車のサスペンションメンバーなどの構造用部材は剛性を高めるために、主管、枝管ともに多角形断面であることが多いが、これまでの分岐管の検討は自転車用ラッグあるいは排気管などの円断面を主な対象としており、多角形断面での知見がない。   However, it has been found that when these methods are applied to a branch pipe having a polygonal cross section, it is likely to cause molding defects such as wrinkles and cracks. In order to increase rigidity, structural members such as automobile suspension members often have a polygonal cross section for both the main and branch pipes. It is the main target and there is no knowledge of polygonal cross sections.

また、可動型を用いる場合、型の分割は重要である。特許文献3には可動型として円筒状の第2軸押し工具とする方法が開示されているが、本方法では成形初期の張出し用空洞内で金属管が同心円上に拡管されてしまうため、特定の方向に枝管を張り出す分岐管の場合、第2軸押し工具を移動させた際に噛み込みを生じて実質的に成形ができない。また、円筒状の第2軸押し工具は製作が困難であり、極めてコストがかかる。
塑性と加工 Vol.23, No.255, (1982-4), 303-306 特開2002−153917号公報 特開平10−296347号公報
In addition, when using a movable mold, the division of the mold is important. Patent Document 3 discloses a method of using a cylindrical second shaft pressing tool as a movable mold. However, in this method, a metal tube is expanded concentrically in an overhanging cavity at the initial stage of molding. In the case of the branch pipe that projects the branch pipe in the direction of, the biting occurs when the second axial pushing tool is moved, and the molding cannot be substantially performed. In addition, it is difficult to manufacture the cylindrical second shaft pressing tool, which is extremely expensive.
Plasticity and processing Vol.23, No.255, (1982-4), 303-306 Japanese Patent Laid-Open No. 2002-153917 JP-A-10-296347

本発明の課題は、金属分岐管を安定して成形できる、可動型を有するハイドロフォーミングの型を安価に提供する。   An object of the present invention is to provide a hydroforming mold having a movable mold that can stably mold a metal branch pipe at a low cost.

上記課題を解決するためになされた本発明は、
(1)1つまたは複数の可動型を用いて、主管から1箇所または複数箇所の枝管の張出し成形を行うハイドロフォーミングの型であって、可動型は枝管を成形するために主管軸方向に移動されるものであり、主管及び枝管がともに多角形断面を有し、枝管の張出し予定部と相対する型の主管軸に垂直な多角形断面の角部の曲率半径が張出し予定部の幅の0.2 倍以上であることを特徴とする、可動型を有するハイドロフォーミングの型、
(2)1つまたは複数の可動型を用いて1箇所または複数箇所の枝管の張出し成形を行うハイドロフォーミングの型であって、型が上型と下型に分離され、可動型が下型にのみ保持されることを特徴とする、(1)に記載の可動型を有するハイドロフォーミングの型、(3)主管軸に垂直な多角形断面の、張り出された枝管と相対する角部の曲率半径が枝管の幅の0.2 倍以上であることを特徴とする、(1)または(2)に記載のハイドロフォーミングの型で成形された金属分岐管、
である。
The present invention made to solve the above problems
(1) A hydroforming mold that uses one or a plurality of movable molds to project one or more branch pipes from a main pipe, and the movable mold is formed in the direction of the main pipe axis to form the branch pipes. The main pipe and the branch pipe both have a polygonal cross section, and the curvature radius of the corner of the polygonal cross section perpendicular to the main pipe axis of the mold is opposite to the planned extension of the branch pipe. Hydroforming mold having a movable mold, characterized in that it is at least 0.2 times the width of
(2) A hydroforming mold that uses one or a plurality of movable molds to project one or more branch pipes, the mold is separated into an upper mold and a lower mold, and the movable mold is a lower mold (1) A hydroforming mold having the movable mold according to (1), (3) a corner section of a polygonal cross section perpendicular to the main pipe axis and opposed to the overhanging branch pipe The metal branch pipe formed by the hydroforming mold according to (1) or (2), wherein the radius of curvature of the pipe is 0.2 times or more the width of the branch pipe,
It is.

本発明によれば型移動を有する型を用いてハイドロフォーミングで安定して主管及び枝管がともに多角形断面の分岐管を成形できるようになり、枝管分岐部の溶接が不要となるため、溶接削減によるコスト低減のみならず、溶接不良などの不安定要素を除外できるので、試作評価工数を削減できるなど、産業上の寄与は大きい。 According to the present invention, it becomes possible to form a branch pipe having a polygonal cross section for both the main pipe and the branch pipe stably by hydroforming using a mold having mold movement, and welding of the branch pipe branch portion is unnecessary. In addition to cost reduction due to welding reduction, unstable elements such as welding defects can be excluded, so the industrial contribution is significant, such as reducing the number of prototype evaluation man-hours.

図1は、本発明の可動型を有するハイドロフォーミングの型の例を示したもので、(a) は長手方向断面、(b) は図1(a)のA−A線断面図、(c) は図1(a)のB−B線断面図である。この型では図2に示すように枝管41、主管42ともに四角形断面の分岐管を成形できる。 図1で、可動型13は下型12に保持される。軸押し型14は金属管1の管端を押し込み、さらに突起15によって可動型13を押し込む。また突起16は成形終了時点での軸押し型14の移動量を一定にする位置決めである。wは枝管張り出し予定部の空隙12aの幅で、Rは枝管張り出し予定部と相対する上型の断面の角部の曲率半径であり、wの0.2 倍以上である。本発明では主管及び枝管がともに多角形断面を有するものとし、この例では枝管41、主管42ともに四角形断面であるが、断面が左右非対称でもよい。ただし、いずれの場合でも、枝管張り出し予定部と相対する上型の多角形断面の角部の曲率半径は張り出し予定部の空隙の幅wの0.2 倍以上でなければ、成形中にシワや割れといった成形不良を生じる。さらに好ましくはRはwの0.5 倍とする。なお、非特許文献1には、可動型13あるいは下型12の角部に相当する部位の曲率半径を小さくできることが示されている。本発明でもこれらは特に限定するものではないが、小さいと型が傷付きやすく、大きいと周辺部品の取り付けなどが困難になるため、板厚の2倍以上10倍以下が望ましい。 FIG. 1 shows an example of a hydroforming mold having a movable mold according to the present invention, where (a) is a longitudinal section, (b) is a sectional view taken along line AA in FIG. ) Is a cross-sectional view taken along line BB in FIG. In this mold, as shown in FIG. 2, a branch pipe having a square cross section can be formed for both the branch pipe 41 and the main pipe. In FIG. 1, the movable mold 13 is held by the lower mold 12. The shaft pushing die 14 pushes the tube end of the metal tube 1, and pushes the movable die 13 by the projection 15. The protrusion 16 is positioned so that the movement amount of the shaft pressing die 14 at the end of molding is constant. w is the width of the gap 12a in the planned branch tube overhanging portion, and R is the radius of curvature of the corner of the upper mold section facing the branch tube overhanging portion, which is 0.2 times or more of w. In the present invention, both the main pipe and the branch pipe have a polygonal cross section. In this example, both the branch pipe 41 and the main pipe 42 are square cross sections, but the cross section may be asymmetrical. However, in any case, if the radius of curvature of the corner of the polygonal section of the upper mold facing the branch tube overhanging portion is not more than 0.2 times the width w of the gap in the overhanging portion, wrinkles or cracks may occur during molding. This causes molding defects. More preferably, R is 0.5 times w. Non-Patent Document 1 shows that the radius of curvature of the portion corresponding to the corner of the movable mold 13 or the lower mold 12 can be reduced. In the present invention, these are not particularly limited, but if it is small, the mold is easily damaged, and if it is large, it is difficult to attach peripheral components.

図3は、本発明の型を用いたハイドロフォーミングの成形過程を示す図で、軸押し型14は金属管1の管端を押し込むと同時に、可動型13を介して金属管1の張り出した部位を圧縮する。金属管1はさらに内圧を受けて枝管を張り出していく。
図4は成形終了時の状態を示し、軸押し型14は位置決めの突起16が上型11に接触して停止する。さらに金属管1の内圧を上げて型に十分に密着させることもできる。
なお、図6は型の分割を変更した例で、図1(b)に相当する断面である。金属管2を挟み込むため、あるいは取り出すためには可動型を上可動型33と下可動型34に分割する必要がある。さらに上型31を開放する際に上可動型33も同時に引き上げるため、爪状のガイド33aによって上可動型33を上型31に吊り下げることが必要である。このように可動型の一部または全部を上型に取り付けることは型構造を複雑にしてコスト増を招く。
FIG. 3 is a diagram showing a forming process of hydroforming using the mold of the present invention. The axial push mold 14 pushes the pipe end of the metal pipe 1 and simultaneously projects the metal pipe 1 through the movable mold 13. Compress. The metal pipe 1 further receives the internal pressure and extends the branch pipe.
FIG. 4 shows a state at the end of molding, and the shaft pressing die 14 stops when the positioning projection 16 contacts the upper die 11. Further, the internal pressure of the metal tube 1 can be increased to sufficiently adhere to the mold.
FIG. 6 is an example in which the mold division is changed, and is a cross section corresponding to FIG. In order to sandwich or take out the metal tube 2, it is necessary to divide the movable mold into an upper movable mold 33 and a lower movable mold 34. Further, when the upper mold 31 is opened, the upper movable mold 33 is also lifted at the same time. Therefore, the upper movable mold 33 needs to be suspended from the upper mold 31 by a claw-shaped guide 33a. Thus, attaching a part or all of the movable mold to the upper mold complicates the mold structure and causes an increase in cost.

以下に本発明の実施例を示す。
図1に示す型と、外径(d)65mm 、肉厚(t)2mm、長さ300mm の金属管(STKM11A) を用いて次のような分岐管を製造した。枝管の張り出し高さ90mm、主管の軸と垂直な断面での枝管の幅(w)45mm 、枝管の管長手方向の幅65mm、枝管張り出し部と相対する主管の管軸に垂直な角の曲率半径(R)10mm 、枝管と主管の分岐部の曲率半径10mm、枝管頂点肩の曲率半径10mm。
Examples of the present invention are shown below.
Using the mold shown in FIG. 1 and a metal pipe (STKM11A) having an outer diameter (d) of 65 mm, a wall thickness (t) of 2 mm, and a length of 300 mm, the following branch pipe was manufactured. Branch pipe overhang height 90mm, branch pipe width (w) 45mm in cross section perpendicular to main pipe axis, branch pipe longitudinal width 65mm, perpendicular to main pipe pipe axis opposite to branch pipe overhang The corner radius of curvature (R) is 10mm, the radius of curvature of the branch and main pipe is 10mm, and the radius of curvature of the top of the branch is 10mm.

可動型13は空隙12a の管長手方向の長さが175mm となるようにセットした。また、突起15は軸押し型を25mm押し込んだときに可動型13に接触するようにして、位置決め用突起16は軸押し型14を110mm 押し込むと上型11に接触するようにした。この状態で金属管をセットして軸押し型14を押し込んでシールし、内圧を30MPa まで上昇させてから軸押し型14を移動させ、さらに内圧を50MPa まで上昇させながら可動型13とともに軸押し型14を押し込み、軸押し型が停止したところでさらに内圧を150MPaまで上昇させた。
この結果、シワや割れなどの成形不良のない良好な枝管を得た。枝管の最小肉厚は1.6mm 、主管の肉厚は1.8mm から2.4mm であり、元の肉厚の±20%程度の変動にできた。
The movable mold 13 was set so that the length of the gap 12a in the longitudinal direction of the tube was 175 mm. Further, the protrusion 15 is brought into contact with the movable mold 13 when the shaft pushing die is pushed by 25 mm, and the positioning protrusion 16 is brought into contact with the upper die 11 when the shaft pushing die 14 is pushed by 110 mm. In this state, set the metal tube, push in the shaft push die 14 and seal it, increase the internal pressure to 30 MPa, then move the shaft push die 14, and further raise the internal pressure to 50 MPa and the shaft push die together with the movable die 13 14 was pushed in, and when the shaft pushing die stopped, the internal pressure was further increased to 150 MPa.
As a result, a good branch pipe free from molding defects such as wrinkles and cracks was obtained. The minimum thickness of the branch pipe was 1.6mm, and the thickness of the main pipe was 1.8mm to 2.4mm, which was about ± 20% of the original thickness.

さらに、枝管張り出し部と相対する主管の管軸に垂直な角の曲率半径(R) のみを変えるため、上型を変更した試験を行った。Rを32.5mmとした場合、ほぼ同条件で成形可能であった。しかし、Rを5mmとした場合、枝管張り出し部の裏側になる主管に、管内面に向けて深い折れ込みが生じ、亀裂を生じて成形途中で内圧が低下したため、成形を中止した。試験を繰り返したところ、可動型を10mm程度押し込んだところで枝管張り出し部の裏側にシワが発生しており、さらに成形を進めるとシワが管内側に折り込まれて、周囲に亀裂を生じることを確認した。そこでシワを回避すべく内圧を高めたが、枝管頂点で割れが生じたため、成形完了品は得られなかった。   Furthermore, in order to change only the radius of curvature (R) of the angle perpendicular to the tube axis of the main pipe facing the branch pipe overhanging portion, a test was performed with the upper mold changed. When R was 32.5 mm, molding was possible under almost the same conditions. However, when R was 5 mm, the main pipe on the back side of the branch pipe projecting portion was deeply bent toward the inner surface of the pipe, causing cracks and lowering the internal pressure during molding, so the molding was stopped. When the test was repeated, it was confirmed that when the movable mold was pushed in about 10 mm, wrinkles occurred on the back side of the branch tube overhang, and as the molding progressed further, the wrinkles were folded inside the tube and cracked around it. did. Therefore, although the internal pressure was increased to avoid wrinkles, a molded product was not obtained because a crack occurred at the top of the branch pipe.

表1にそれぞれの成形状況と枝管の最小肉厚および主管の最大肉厚を示す。本発明によれば、偏肉の少ない成形品を安定して得ることができることが確認された。   Table 1 shows the respective molding conditions, the minimum thickness of the branch pipe, and the maximum thickness of the main pipe. According to the present invention, it was confirmed that a molded product with less uneven thickness can be obtained stably.

Figure 0004537792
Figure 0004537792

本発明のハイドロフォーミングの型の図で、(a) は長手方向断面図、(b) は(a) のA−A断面図、(c) は(a) のB−B断面図である。FIG. 4 is a diagram of the hydroforming mold of the present invention, in which (a) is a longitudinal sectional view, (b) is an AA sectional view of (a), and (c) is a BB sectional view of (a). 本発明のハイドロフォーミングにより成形された枝管の一部である。It is a part of branch pipe shape | molded by the hydroforming of this invention. 本発明のハイドロフォーミングの成形過程で可動型が押し込まれている状態を示す長手方向断面図である。It is a longitudinal direction sectional view showing the state where the movable mold is pushed in the forming process of the hydroforming of the present invention. 本発明のハイドロフォーミングの成形完了時の状態を示す長手方向断面図である。It is longitudinal direction sectional drawing which shows the state at the time of completion of shaping | molding of the hydroforming of this invention. 枝管を成形する従来のハイドロフォーミングの例で、(a) は長手方向断面図、(b) は成形品である。In the example of conventional hydroforming for forming a branch pipe, (a) is a longitudinal sectional view and (b) is a molded product. 可動型を有するハイドロフォーミングの型の分割例である。It is an example of the division | segmentation of the hydroforming type | mold which has a movable type | mold.

符号の説明Explanation of symbols

1 金属管
2 金属管
3 金属管
11 上型
11a 主管の断面形状と金属管との間に生じる上型の空隙
12 下型
12a 枝管張り出し予定部
13 可動型
14 軸押し型
15 可動型を押し込むための突起
16 軸押し型の位置決め用突起
21 従来技術における分岐管成型用の型
23 軸押し型
24 カウンター
31 可動型が分割される型割の上型
32 可動型が分割される型割の下型
33 分割された上可動型
33a 分割された上可動型を上型に吊るための爪状のガイド
34 分割された下可動型
41 多角形断面の枝管
42 多角形断面の主管
61 円形断面の枝管
62 円形断面の主管
1 Metal tube 2 Metal tube 3 Metal tube
11 Upper mold
11a Upper mold gap created between the cross-sectional shape of the main pipe and the metal pipe
12 Lower mold
12a Branch pipe projecting part
13 Movable type
14 axis push type
15 Protrusions for pushing the movable mold
16 Axial push type positioning protrusion
21 Conventional mold for branch pipe molding
23 Axial push type
24 counter
31 Upper mold of mold division where movable mold is divided
32 Lower mold of mold division where movable mold is divided
33 Divided upper movable type
33a Claw-shaped guide for hanging the divided upper movable mold on the upper mold
34 Divided lower movable type
41 Branch pipe with polygonal cross section
42 Main pipe with polygonal cross section
61 Branch pipe with circular section
62 Main pipe with circular section

Claims (3)

1つまたは複数の可動型を用いて、主管から1箇所または複数箇所の枝管の張出し成形を行うハイドロフォーミングの型であって、可動型は枝管を成形するために主管軸方向に移動されるものであり、主管及び枝管がともに多角形断面を有し、枝管の張出し予定部と相対する型の主管軸に垂直な多角形断面の角部の曲率半径が張出し予定部の幅の0.2 倍以上であることを特徴とする、可動型を有するハイドロフォーミングの型。 A hydroforming mold that uses one or more movable molds to form one or more branch pipes from a main pipe, and the movable mold is moved in the axial direction of the main pipe to form the branch pipes. Both the main pipe and the branch pipe have a polygonal cross section, and the radius of curvature of the corner of the polygonal section perpendicular to the main pipe axis of the mold opposite to the planned extension of the branch pipe is the width of the planned extension. A hydroforming mold with a movable mold, characterized by being 0.2 times or more. 1つまたは複数の可動型を用いて1箇所または複数箇所の枝管の張出し成形を行うハイドロフォーミングの型であって、型が上型と下型に分離され、可動型が下型にのみ保持されることを特徴とする、請求項1に記載の可動型を有するハイドロフォーミングの型。   Hydroforming mold that uses one or more movable molds to stretch out one or more branch pipes, the mold is separated into an upper mold and a lower mold, and the movable mold is held only by the lower mold The hydroforming mold having a movable mold according to claim 1, wherein the mold is a hydroforming mold. 主管軸に垂直な多角形断面の、張り出された枝管と相対する角部の曲率半径が枝管の幅の0.2 倍以上であることを特徴とする、請求項1または2に記載のハイドロフォーミングの型で成形された金属分岐管。 3. The hydroelectric device according to claim 1, wherein a radius of curvature of a corner portion of the polygonal cross section perpendicular to the main pipe axis and facing the protruding branch pipe is 0.2 times or more the width of the branch pipe. A metal branch pipe formed with a forming mold.
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CN103962408A (en) * 2014-05-29 2014-08-06 河北宏润重工股份有限公司 Extrusion forming mould for branch pipes of main nuclear pipeline
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CN105921588B (en) * 2016-06-03 2018-10-19 广东工业大学 A kind of unilateral feeding manifold inside high-pressure forming method and device

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JPS58167033A (en) * 1982-03-29 1983-10-03 Agency Of Ind Science & Technol Formation of tube side projection by liquid pressure bulging
JPS63260632A (en) * 1987-04-16 1988-10-27 Katsuteru Araki Liquid pressure bulging method
JPH01255792A (en) * 1988-04-01 1989-10-12 Matsushita Refrig Co Ltd Flow divider
JP2000015356A (en) * 1998-07-03 2000-01-18 Mitsubishi Alum Co Ltd Formation of cylindrical member having branch pipe
JP2002210521A (en) * 2001-01-17 2002-07-30 Toyota Motor Corp Branch pipe, and its manufacturing device and method

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS58167033A (en) * 1982-03-29 1983-10-03 Agency Of Ind Science & Technol Formation of tube side projection by liquid pressure bulging
JPS63260632A (en) * 1987-04-16 1988-10-27 Katsuteru Araki Liquid pressure bulging method
JPH01255792A (en) * 1988-04-01 1989-10-12 Matsushita Refrig Co Ltd Flow divider
JP2000015356A (en) * 1998-07-03 2000-01-18 Mitsubishi Alum Co Ltd Formation of cylindrical member having branch pipe
JP2002210521A (en) * 2001-01-17 2002-07-30 Toyota Motor Corp Branch pipe, and its manufacturing device and method

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