JP4923597B2 - Method for forming cylindrical shaft product and mold - Google Patents

Method for forming cylindrical shaft product and mold Download PDF

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JP4923597B2
JP4923597B2 JP2006026036A JP2006026036A JP4923597B2 JP 4923597 B2 JP4923597 B2 JP 4923597B2 JP 2006026036 A JP2006026036 A JP 2006026036A JP 2006026036 A JP2006026036 A JP 2006026036A JP 4923597 B2 JP4923597 B2 JP 4923597B2
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shaft
mold
metal plate
shape
longitudinal
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JP2007203343A (en
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至 矢野倉
昇一 赤羽
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セイコーエプソン株式会社
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本発明は、円筒軸に関する。より詳細には、金属板を曲げ加工して製造される円筒軸に関する。   The present invention relates to a cylindrical shaft. More specifically, the present invention relates to a cylindrical shaft manufactured by bending a metal plate.
金属板を曲げ加工して円筒状の製品を製造する技術は数多くある。下記の特許文献1には、そのうちでも比較的薄い金属板を曲げて小径の管を製造する技術が開示されている。即ち、特許文献1は、目的とする円筒状製品の内径に略等しい芯ロールと、芯ロールに押しつけられて連れ回る一対の押付ロールと、独特な経路で各ロールにかけ渡された案内ベルトによって、金属板を芯ロールに密着させながら成形することを提案している。また、これにより、樽型変形のない成形が行えると記載されている。
特開2003−245721号公報
There are many techniques for manufacturing cylindrical products by bending metal plates. Patent Document 1 below discloses a technique for manufacturing a small-diameter pipe by bending a relatively thin metal plate among them. That is, Patent Document 1 includes a core roll that is substantially equal to the inner diameter of a target cylindrical product, a pair of pressing rolls that are pressed against the core roll, and a guide belt that is passed over each roll through a unique path. It has been proposed that the metal plate be formed while being in close contact with the core roll. In addition, it is described that molding without barrel deformation can be performed.
JP 2003-245721 A
しかしながら、例えばコストダウンのために、切削加工により製造された細径の中実な金属製丸棒材に替えて円筒状の製品を使おうとすると、表面の真円度、軸方向の直線性等の点において満足な品質を有する製品は製造されていない。   However, for example, to reduce the cost, if you try to use a cylindrical product instead of a solid metal round bar material produced by cutting, roundness of the surface, linearity in the axial direction, etc. No product with satisfactory quality is produced.
上記課題を解決するために、本発明の第1の形態によると、金属板を曲げ加工して形成された円筒状の軸製品を成形して、その軸方向の直線性を高くする成形方法であって、長手方向に対して直交する断面の各々において軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、軸製品の長手方向と平行な断面の各々において直線状の内面形状を有する直線溝を備えた直金型と、長手方向に対して直交する断面の各々において軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、軸製品の長手方向と平行な断面の各々において、長手方向の中央に近づくほど軸製品に対する圧下率が高くなる凸曲線状の内面形状を有する曲溝を備えた曲金型とを用い、軸製品における金属板の接合部に対して曲金型の溝の最も深い部分が当接するように、曲溝および直線溝の間に軸製品を挟んで軸製品を成形する成形方法が提供される。これにより、円筒軸として略完成された製品を更に成形して、全長にわたって高い真円度を有する円筒軸を製造できる。 In order to solve the above problems, according to a first embodiment of the present invention, by shaping the cylindrical shaft products that are formed by bending a metal plate, a molding method of increasing the linearity of the axial Each of the cross-sections perpendicular to the longitudinal direction has a cross-sectional shape that forms an arc having the same inner diameter as the outer diameter of the shaft product, and is a linear inner surface in each of the cross-sections parallel to the longitudinal direction of the shaft product. A straight die having a straight groove having a shape, and a cross-sectional shape that forms an arc having the same inner diameter as the outer diameter of the shaft product in each of the cross sections orthogonal to the longitudinal direction, and the longitudinal direction of the shaft product; In each of the parallel cross sections, the metal plate joint in the shaft product using a curved die having a curved inner surface shape with a convex curve shape, the rolling reduction with respect to the shaft product increases as it approaches the center in the longitudinal direction. The deepest part of the groove of the curved mold abuts against Sea urchin, a molding method for molding a shaft product is provided across the axial products between Kyokumizo and straight grooves. Thereby, the substantially completed product as a cylindrical shaft can be further molded to produce a cylindrical shaft having high roundness over the entire length.
また、ひとつの実施形態においては、上記成形方法において、直金型を、溝を上方に開口させて配置し、接合部を上方に向けて軸製品を溝の内部に置き、曲金型を、溝を下に向けて、直金型に向かって降下させ、直線溝および曲溝の間で軸製品を成形する。これにより、円筒軸においてスプリングバックが最も顕著に作用する金属板の合わせ目における加工度を高くし、円筒軸の全長にわたって均一な真円度を有する円筒軸を形成できる。 Further, in one embodiment, in the above molding method, the direct mold is disposed with the groove opened upward, the shaft product is placed inside the groove with the joint portion facing upward, and the curved mold is With the groove facing down, it is lowered toward the straight mold, and a shaft product is formed between the straight groove and the curved groove. As a result, it is possible to increase the degree of processing at the joint of the metal plate on which the spring back acts most significantly on the cylindrical shaft, and to form a cylindrical shaft having a uniform roundness over the entire length of the cylindrical shaft.
また、他の実施形態においては、上記成形方法において、曲溝の内面が、曲溝の長手方向と平行な断面の各々において連続した滑らかな曲線を描く。これにより、全長にわたって等しい真円率が均一に得られる。 In another embodiment, in the above molding method, the inner surface of the curved groove draws a continuous smooth curve in each of the cross sections parallel to the longitudinal direction of the curved groove. Thereby, an equal roundness is obtained uniformly over the entire length.
また、本発明の第2の形態として、金属板を曲げ加工して形成された円筒状の軸製品を成形して、その軸方向の直線性を高くする成形金型であって、長手方向に対して直交する断面の各々において軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、軸製品の長手方向と平行な断面の各々において直線状の内面形状を有する直線溝を備えた直金型と、長手方向に対して直角な断面の各々において軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、軸製品の長手方向と平行な断面の各々において、長手方向の中央に近づくほど軸製品に対する圧下率が高くなる凸曲線状の内面形状を有する曲溝を備えた曲金型とを備え、軸製品における金属板の接合部に対して曲金型の溝の最も深い部分が当接するように、曲溝および直線溝の間に軸製品を挟んで軸製品を成形する成形金型が提供される。これにより、高い真円度を全長にわたって有する円筒軸を製造できる。
According to a second aspect of the present invention, there is provided a molding die for forming a cylindrical shaft product formed by bending a metal plate and increasing its linearity in the longitudinal direction. A straight groove having a cross-sectional shape that forms an arc having the same inner diameter as the outer diameter of the shaft product in each of the cross-sections orthogonal to the shaft product, and a linear inner surface shape in each of the cross-sections parallel to the longitudinal direction of the shaft product. In each of the cross-sections that form a circular arc having the same inner diameter as the outer diameter of the shaft product in each of the cross sections perpendicular to the longitudinal direction and the straight mold provided, and parallel to the longitudinal direction of the shaft product A curved mold having a curved groove having a convex curved inner surface shape, the rolling reduction with respect to the shaft product increases as it approaches the center in the longitudinal direction, and the curved mold with respect to the joint portion of the metal plate in the shaft product. Curved and straight grooves so that the deepest part of the groove touches Molding die for molding the shaft product is provided across the axis product in between. Thereby, the cylindrical shaft which has high roundness over the full length can be manufactured.
なお、上記の発明の概要は、本発明の必要な特徴の全てを列挙したものではなく、これらの特徴群のサブコンビネーションもまた、発明となりうる。   The above summary of the invention does not enumerate all the necessary features of the present invention, and sub-combinations of these feature groups can also be the invention.
以下、発明の実施の形態を通じて本発明を説明するが、以下の実施形態は特許請求の範囲に係る発明を限定するものではなく、また実施形態の中で説明されている特徴の組み合わせの全てが発明の解決手段に必須であるとは限らない。   Hereinafter, the present invention will be described through embodiments of the invention. However, the following embodiments do not limit the claimed invention, and all combinations of features described in the embodiments are included. It is not necessarily essential for the solution of the invention.
図1は、曲げ加工して円筒軸20にする前の金属板10の形状を示す図である。金属板10には、その端部から突出する凸部16が間隔をおいて複数形成されている。また、他方の端部にも、凹18が間隔をおいて複数形成されている。更に凸部16の各々は凹部18の各々と、金属板10の長手方向に対して直交方向の同じ位置に配置されている。   FIG. 1 is a diagram showing the shape of the metal plate 10 before bending into the cylindrical shaft 20. The metal plate 10 is formed with a plurality of convex portions 16 projecting from the end portions at intervals. A plurality of recesses 18 are also formed at the other end portion at intervals. Further, each of the convex portions 16 is disposed at the same position in the direction orthogonal to the longitudinal direction of each of the concave portions 18 and the metal plate 10.
図2は、上記のような金属板10を、後述する加工により円筒軸20としたものを部分的に拡大して示す図である。同図に示すように、円筒軸20に成形された状態では、これら凸部16および凹部18が嵌合して、接合部が開くことを防止している。従って、この円筒軸20は、溶接、接着等の工程なしに、そのまま軸製品として利用できる。   FIG. 2 is a partially enlarged view of the metal plate 10 having the cylindrical shaft 20 formed by processing described later. As shown in the figure, in a state where the cylindrical shaft 20 is molded, the convex portion 16 and the concave portion 18 are fitted to prevent the joint portion from being opened. Therefore, the cylindrical shaft 20 can be used as a shaft product as it is without any steps such as welding and bonding.
図3は、上記金属板10に対するはじめの曲げ加工に使用する金型30の形状を示す。同図に示すように、金型30は、互いに相補的な形状の加工面31、33を有するダイ32とパンチ34とを備えている。ダイ32およびパンチ34の加工面は、中央付近が平坦である一方、両端部は約90度の円弧状断面形状を有する。   FIG. 3 shows the shape of a mold 30 used for the first bending process on the metal plate 10. As shown in the figure, the mold 30 includes a die 32 having processing surfaces 31 and 33 having complementary shapes and a punch 34. The processed surfaces of the die 32 and the punch 34 are flat near the center, while both ends have an arcuate cross-sectional shape of approximately 90 degrees.
また、この金型30は、上記の断面形状を保ったまま、紙面の奥行き方向に延在している。更に、このダイ32およびパンチ34の加工面は、金属板10の一方の端部12に形成された凸部16の先端から他方の端部14までの長さと同じ長さを有している。以上のような構造の金型30に対して、前記金属板10は、その長手方向が図面の奥行き方向と一致するように挿入される。   Further, the mold 30 extends in the depth direction of the paper surface while maintaining the above-described cross-sectional shape. Further, the processed surfaces of the die 32 and the punch 34 have the same length as the length from the tip end of the convex portion 16 formed at one end portion 12 of the metal plate 10 to the other end portion 14. The metal plate 10 is inserted into the mold 30 having the above structure so that the longitudinal direction thereof coincides with the depth direction of the drawing.
図4は、図3に示す金型30で曲げ加工された金属板10の断面形状を示す図である。同図に示すように、金属板10の短辺方向の両端は曲げ加工を受け、内角が約90°の円弧状断面を有する被曲げ加工部22、24を形成している。   FIG. 4 is a diagram showing a cross-sectional shape of the metal plate 10 bent by the mold 30 shown in FIG. As shown in the figure, both ends in the short side direction of the metal plate 10 are bent to form bent portions 22 and 24 having arc-shaped cross sections having an inner angle of about 90 °.
図5は、図4に示した金属板10に対する次の曲げ加工に使用する金型40の形状を示す図である。同図に示すように、この金型40は、ダイ42とパンチ44とを備えている。ここで、ダイ42は、円弧状の断面を有し、上方に向かって開いた加工面41を備えている。これに対して、パンチ44は、円弧状の断面を有する加工面43を下端に備えている。更に、加工面43の上方には、曲げ加工によって上昇した金属板10の端部14、12を避けるために、加工面43よりも幅の狭い逃げが形成されている。   FIG. 5 is a view showing the shape of a mold 40 used for the next bending process for the metal plate 10 shown in FIG. As shown in the figure, the mold 40 includes a die 42 and a punch 44. Here, the die 42 has a processing surface 41 having an arc-shaped cross section and opened upward. On the other hand, the punch 44 has a processed surface 43 having an arc-shaped cross section at the lower end. Furthermore, a clearance narrower than the processing surface 43 is formed above the processing surface 43 in order to avoid the end portions 14 and 12 of the metal plate 10 raised by bending.
図6は、図5に示した金型40で曲げ加工された金属板10の断面形状を示す図である。同図に示すように、金属板10は、その端部14から凸部16の先端までの中央が、金型40の加工面41、43の中心と一致するように装入されて曲げ加工されている。   FIG. 6 is a view showing a cross-sectional shape of the metal plate 10 bent by the mold 40 shown in FIG. As shown in the figure, the metal plate 10 is inserted and bent so that the center from the end portion 14 to the tip of the convex portion 16 coincides with the centers of the processing surfaces 41 and 43 of the mold 40. ing.
また、金型30により円弧状に曲げ加工された被曲げ加工部22、24に加え、やはり円弧状に曲げ加工された新規な被曲げ加工部26が形成されている。一方、被曲げ加工部22および被曲げ加工部26の間並びに被曲げ加工部24および被曲げ加工部26の間には、それぞれ、非曲げ加工部21、23が残っている。なお、ここまでの工程は、以下に記載する実施例1および実施例2において共通である。   Further, in addition to the bent portions 22 and 24 bent into an arc shape by the mold 30, a new bent portion 26 which is also bent into an arc shape is formed. On the other hand, unbent portions 21 and 23 remain between the bent portion 22 and the bent portion 26 and between the bent portion 24 and the bent portion 26, respectively. In addition, the process so far is common in Example 1 and Example 2 described below.
(実施例1)
図7は、図6に示した形状の金属板10に対する本実施例における仕上げ工程で使用する金型50に装着されたダイ52およびパンチ54の形状を示す断面図である。同図に示すように、この金型50は、ダイ52およびパンチ54に加えて、芯型56を含んで形成されている。ダイ52は、その上面から僅かに持ち上げられて形成された、円弧状断面形状を有する加工面51を備えている。これに対して、パンチ54は、その下端面から上方に退避した位置に、やはり円弧状断面形状を有する加工面53を備えている。
Example 1
FIG. 7 is a cross-sectional view showing the shapes of the die 52 and the punch 54 attached to the mold 50 used in the finishing process in the present embodiment for the metal plate 10 having the shape shown in FIG. As shown in the figure, the mold 50 includes a core mold 56 in addition to a die 52 and a punch 54. The die 52 includes a machining surface 51 having an arcuate cross-sectional shape formed by being slightly lifted from the upper surface thereof. On the other hand, the punch 54 includes a machining surface 53 having an arcuate cross-sectional shape at a position retracted upward from the lower end surface thereof.
また、加工面51の外側の側部と、パンチ54の加工面53以外の先端部とは、互いに相補的な形状をしており、パンチ54を降下させたときに、両者が当接しないようになされている。なお、芯型56は、最終的に得られる円筒軸20の内径と同じ外径を有する丸棒であり、金型40において曲げ加工された金属板10の中に入れて用いられる。   Further, the outer side portion of the processing surface 51 and the tip portion other than the processing surface 53 of the punch 54 have complementary shapes so that they do not come into contact when the punch 54 is lowered. Has been made. The core die 56 is a round bar having the same outer diameter as the inner diameter of the finally obtained cylindrical shaft 20, and is used by being put in the metal plate 10 bent in the mold 40.
図8は、図7に示した金型50におけるパンチ54の形状を示す斜視図である。同図に示すように、パンチ54において、その長手方向に直交する各断面は、図7に示した通りの断面形状を有している。一方、このパンチ54を長手方向に直交する側面から見たときは、長手方向の中央において高さ方向の寸法が大きくなっている。   FIG. 8 is a perspective view showing the shape of the punch 54 in the mold 50 shown in FIG. As shown in the figure, in the punch 54, each cross section orthogonal to the longitudinal direction has a cross sectional shape as shown in FIG. On the other hand, when the punch 54 is viewed from a side surface orthogonal to the longitudinal direction, the dimension in the height direction is large at the center in the longitudinal direction.
図9は、図8に示したパンチ54を側方から見た様子を示す図である。同図に示すように、パンチ54は、上記の通り長手方向中央において高さ方向の寸法が最も大きく、その下面は全体に滑らかな曲線を描いている。このとき、長手方向に直交する各断面における加工面53の断面形状は一定である。従って、パンチ54の下面において加工面53が画成する溝も、全体に屈曲して曲溝を形成する。なお、図示は省略するが、ダイ52では、加工面51により画成される溝は曲がっておらず、直線溝を形成する。   FIG. 9 is a view showing a state in which the punch 54 shown in FIG. 8 is viewed from the side. As shown in the figure, the punch 54 has the largest dimension in the height direction at the center in the longitudinal direction as described above, and the lower surface of the punch 54 has a smooth curve as a whole. At this time, the cross-sectional shape of the processed surface 53 in each cross section orthogonal to the longitudinal direction is constant. Accordingly, the groove defined by the processed surface 53 on the lower surface of the punch 54 is also bent to form a curved groove. In addition, although illustration is abbreviate | omitted, in the die | dye 52, the groove | channel defined by the processed surface 51 is not bent, but forms a linear groove | channel.
上記のような金型50に対して、金型40ですでに曲げ加工された金属板10は、まず、被曲げ加工部26の外側が加工面51の内部に当接するように、ダイ52に装入される。次に、金属板10の内部に、芯型56が置かれる。   The metal plate 10 that has already been bent by the mold 40 with respect to the mold 50 as described above is first placed on the die 52 so that the outside of the bent portion 26 contacts the inside of the processing surface 51. It is inserted. Next, the core die 56 is placed inside the metal plate 10.
上記のような状態でパンチ54を降下させると、金属板10の端部14および凸部16を含む端部12が互いに近づき、やがて、凸部16が凹部18に嵌入する。更に、パンチ54を圧下すると、凸部16および凹部18を含む端部12、14の近傍は、パンチ54の加工面53と芯型56との間で、全体で円弧をなすように成形される。   When the punch 54 is lowered in the state as described above, the end portion 14 of the metal plate 10 and the end portion 12 including the convex portion 16 approach each other, and eventually the convex portion 16 fits into the concave portion 18. Further, when the punch 54 is squeezed, the vicinity of the end portions 12 and 14 including the convex portion 16 and the concave portion 18 is formed so as to form an arc as a whole between the processing surface 53 of the punch 54 and the core die 56. .
同時に、芯型56の下側では、芯型56とダイ52の加工面51との間で、非曲げ加工部21、23を含む金属板10が曲げ加工される。従って、金型50による曲げ加工で、金属板10は、全体で環状の断面を有する円筒となる。   At the same time, below the core die 56, the metal plate 10 including the non-bending portions 21 and 23 is bent between the core die 56 and the processing surface 51 of the die 52. Therefore, the metal plate 10 becomes a cylinder having an annular cross section as a whole by bending with the mold 50.
更に、この金型50では、パンチ54の加工面53が長手方向中央において、凸状に膨らんだ曲溝を形成している。従って、金属板10を加工した場合、その長手方向の中央付近において圧下率が大きくなる。このため、円筒軸20の長手方向中央におけるスプリングバックがより低減され、円筒軸20は全長にわたって均一な、より高い真円率で成形される。   Further, in this mold 50, the processed surface 53 of the punch 54 forms a curved groove that bulges in a convex shape at the center in the longitudinal direction. Therefore, when the metal plate 10 is processed, the rolling reduction increases near the center in the longitudinal direction. For this reason, the spring back in the longitudinal center of the cylindrical shaft 20 is further reduced, and the cylindrical shaft 20 is formed with a higher roundness that is uniform over the entire length.
なお、上記のような加工の効果に鑑みて、金型50に円筒軸20をセットするときに、曲溝を有するパンチ54の加工面53に対して、円筒軸20の合わせ目28が正対するようにセットすることが好ましい。これにより、スプリングバックの分布と加工率の分布とが相殺しあって、円筒軸20の真円率、反り等が全長にわたって均一になる。また、前記のように、パンチ54の加工面53は全体に連続した滑らかな曲面を形成しているので、円筒軸20の特定の部位に加工が集中することがなく、局部的な変形も生じない。   In view of the processing effect as described above, when the cylindrical shaft 20 is set in the mold 50, the joint 28 of the cylindrical shaft 20 faces the processing surface 53 of the punch 54 having a curved groove. It is preferable to set as follows. As a result, the distribution of the spring back and the distribution of the processing rate cancel each other, and the roundness, warpage, and the like of the cylindrical shaft 20 are uniform over the entire length. Further, as described above, since the processed surface 53 of the punch 54 forms a continuous and smoothly curved surface, the processing does not concentrate on a specific part of the cylindrical shaft 20 and local deformation occurs. Absent.
図10は、図7に示す金型50で製造された円筒軸20の断面形状を示す図である。同図に示すように、金型30、金型40および金型50による一連の曲げ加工により、金属板10は、全体が同じ曲率で曲げられた円筒軸20となっている。ここで、金属板10は、その凸部16を含めて全体が同じ曲率に曲げ加工されているので、真円度の高い円筒軸20となっている。   FIG. 10 is a view showing a cross-sectional shape of the cylindrical shaft 20 manufactured by the mold 50 shown in FIG. As shown in the figure, the metal plate 10 is a cylindrical shaft 20 that is bent with the same curvature as a whole by a series of bending processes using the mold 30, the mold 40, and the mold 50. Here, since the whole metal plate 10 including the convex part 16 is bent to the same curvature, the cylindrical shaft 20 has a high roundness.
(作製例1)
厚さ0.5mmの亜鉛めっき鋼板を用いて、長さ300mm、外径5mmの円筒軸を作製した。また、比較のために、直線溝を有するパンチを用いて、同じ材料でやはり長さ300mm、外径5mmの円筒軸を作製した。ただし、曲溝を有するパンチ54に換えて、直線溝を有する通常のパンチを用い、圧下装置のバッキングとパンチとの間に厚さの異なるシクネステープを挟むことにより、パンチの長手方向中央における圧下率を上昇させた。
(Production Example 1)
A cylindrical shaft having a length of 300 mm and an outer diameter of 5 mm was produced using a galvanized steel sheet having a thickness of 0.5 mm. For comparison, a cylindrical shaft having a length of 300 mm and an outer diameter of 5 mm was made of the same material using a punch having a straight groove. However, instead of the punch 54 having a curved groove, a normal punch having a straight groove is used, and a thickness tape having a different thickness is sandwiched between the backing and the punch of the reduction device, so that the reduction ratio at the center in the longitudinal direction of the punch is reduced. Was raised.
具体的には、まず、長さが314mmの直線溝を有するパンチを用いて、パンチを全長にわたって均一に圧下して比較例1としての円筒軸を作製した。続いて、同じパンチを用いつつ、その長手方向中央を頂点とし、両端に向かって滑らかな円弧になるようにパンチを凸形状にし、作製例1としての円筒軸を作製した。   Specifically, first, using a punch having a straight groove having a length of 314 mm, the punch was uniformly crushed over the entire length to produce a cylindrical shaft as Comparative Example 1. Subsequently, while using the same punch, the center of the longitudinal direction was set as the apex, and the punch was formed in a convex shape so as to form a smooth arc toward both ends, and a cylindrical shaft as Production Example 1 was produced.
作製された比較例1および作製例1の円筒軸の寸法精度を、仕上げ工程における円筒軸に対する圧下方向の径の分布範囲の広さにより評価したところ、直線溝を有するパンチで仕上げた比較例1に係る試料に対し、実施例1の資料は真円度が70%向上された。   When the dimensional accuracy of the manufactured cylindrical shaft of Comparative Example 1 and Manufacturing Example 1 was evaluated based on the width of the diameter distribution range in the rolling direction with respect to the cylindrical shaft in the finishing process, Comparative Example 1 was finished with a punch having straight grooves. Compared to the sample, the circularity of the material of Example 1 was improved by 70%.
(実施例2)
この実施例に係る方法では、金型40による加工までは、実施例1と同じ工程を辿る。また、実施例1で仕上げ工程に使用した金型50も用いるが、後述の通りこの工程では仕上げ加工はせず、更に別の整形金型60を用いて円筒軸20を仕上げる。
(Example 2)
In the method according to this embodiment, the same steps as those in the first embodiment are followed until processing by the mold 40. Moreover, although the metal mold | die 50 used for the finishing process in Example 1 is also used, a finishing process is not carried out in this process as will be described later, and the cylindrical shaft 20 is finished using another shaping mold 60.
図11は、実施例2に係る円筒軸の製造において、仕上げ工程の前の工程として、金型50による金属板10の加工結果を示す図である。同図に示すように、本実施例では、金属板10の合わせ目28が完全に閉じ切る前に加工を止めて、後述する仕上げ工程における加工代を大きく残している。これにより、整形加工の効果をより高くすることができる。   FIG. 11 is a diagram illustrating a processing result of the metal plate 10 by the mold 50 as a step before the finishing step in manufacturing the cylindrical shaft according to the second embodiment. As shown in the figure, in the present embodiment, the machining is stopped before the joint 28 of the metal plate 10 is completely closed, leaving a large machining allowance in the finishing process described later. Thereby, the effect of a shaping process can be made higher.
図12は、本実施例の仕上げ工程において使用する整形金型60の構造を示す断面図であり、軸製品の長手方向に直交する断面における、パンチ64、ダイ62および芯型56の形状を示す。同図に示すように、ここで用いるパンチ64およびダイ62は、相互に密着したときに、円筒軸20の仕上がり形状と相補的な形状の加工面63、61を内側に形成する。   FIG. 12 is a cross-sectional view showing the structure of the shaping die 60 used in the finishing process of this embodiment, and shows the shapes of the punch 64, the die 62, and the core die 56 in a cross section orthogonal to the longitudinal direction of the shaft product. . As shown in the figure, when the punch 64 and the die 62 used here are in close contact with each other, processed surfaces 63 and 61 having a shape complementary to the finished shape of the cylindrical shaft 20 are formed inside.
図13は、図12に示した整形金型60におけるパンチ64の形状を示す斜視図である。同図に示すように、パンチ64において、半円径の断面形状を有する加工面63が形成された下面は、中央の寸法がより大きくなっている。即ち、パンチ64は、幅長手方向中央において高さ方向の寸法が最も大きく、その下面は全体に滑らかな曲線を描いている。これにより、加工面63も円滑な曲面を形成する。   FIG. 13 is a perspective view showing the shape of the punch 64 in the shaping die 60 shown in FIG. As shown in the figure, the lower surface of the punch 64 on which the processed surface 63 having a semicircular sectional shape is formed has a larger central dimension. That is, the punch 64 has the largest dimension in the height direction at the center in the width-longitudinal direction, and the lower surface of the punch 64 forms a smooth curve as a whole. Thereby, the processing surface 63 also forms a smooth curved surface.
ただし、このパンチ64において、各断面における加工面63の形状は相互に等しく、加工面63が形成する曲溝の深さは全体に一定である。なお、図示は省略するが、このようなパンチ64に対して、ダイ62は、加工面61の断面形状はパンチ64の加工面63と同じであるが、全体に屈曲することなく、直線溝を形成している。   However, in this punch 64, the shape of the processed surface 63 in each cross section is equal to each other, and the depth of the curved groove formed by the processed surface 63 is constant throughout. Although not shown, the die 62 has the same cross-sectional shape as the processed surface 63 of the punch 64 with respect to such a punch 64, but the straight groove is not bent entirely. Forming.
上記のように、直線溝を有するダイ62と曲溝を有するパンチ64を用いて円筒軸20を加工した場合、その長手方向の中央において、円筒軸20に対する圧下率が大きくなり、円筒軸20の加工度が高くなる。このため、円筒軸20の長手方向中央におけるスプリングバックがより低減され、円筒軸20はその全長にわたって均一な真円率で整形される。   As described above, when the cylindrical shaft 20 is processed using the die 62 having the linear groove and the punch 64 having the curved groove, the rolling reduction with respect to the cylindrical shaft 20 is increased at the center in the longitudinal direction, and The degree of processing increases. For this reason, the spring back in the longitudinal center of the cylindrical shaft 20 is further reduced, and the cylindrical shaft 20 is shaped with a uniform roundness over the entire length thereof.
なお、上記のような加工の効果に鑑みて、整形金型60に円筒軸20をセットするときに、曲溝を有するパンチ64の加工面63に対して、円筒軸20の合わせ目28が正対するようにセットすることが好ましい。これにより、スプリングバックの分布と加工率の分布とが相殺しあって、円筒軸20の真円率、反り等が全長にわたって均一になる。また、前記のように、パンチ64の加工面63は全体に連続した滑らかな曲面を形成しているので、円筒軸20の特定の部位に加工が集中することがなく、局部的な変形も生じない。   In view of the processing effect as described above, when the cylindrical shaft 20 is set in the shaping die 60, the joint 28 of the cylindrical shaft 20 is correctly aligned with the processing surface 63 of the punch 64 having a curved groove. It is preferable to set it in the opposite direction. As a result, the distribution of the spring back and the distribution of the processing rate cancel each other, and the roundness, warpage, and the like of the cylindrical shaft 20 are uniform over the entire length. Further, as described above, since the machining surface 63 of the punch 64 forms a continuous and smoothly curved surface, the machining does not concentrate on a specific part of the cylindrical shaft 20 and local deformation occurs. Absent.
作製例2
厚さ0.5mmの亜鉛めっき鋼板を用いて、長さ300mm、外径5mmの円筒軸を作製した。ただし、曲溝を有するパンチ64に換えて、直線溝を有する通常のパンチを用い、圧下装置のバッキングとパンチとの間に厚さの異なるシクネステープを挟むことにより、パンチの長手方向中央における圧下率を上昇させた。
Production Example 2
A cylindrical shaft having a length of 300 mm and an outer diameter of 5 mm was produced using a galvanized steel sheet having a thickness of 0.5 mm. However, instead of the punch 64 having a curved groove, a normal punch having a linear groove is used, and a thickness tape having a different thickness is sandwiched between the backing and the punch of the reduction device, so that the reduction ratio at the center in the longitudinal direction of the punch is reduced. Was raised.
具体的には、長さが314mmの直線溝を有するパンチを用いて、その長手方向中央を頂点とし、両端に向かって滑らかな円弧になるようにパンチを製作例1より更に30%凸形状にし、作製例2としての円筒軸を作製した。   Specifically, using a punch having a straight groove with a length of 314 mm, the punch is made 30% more convex than Production Example 1 so that the center in the longitudinal direction is the apex and becomes a smooth arc toward both ends. Then, a cylindrical shaft as Production Example 2 was produced.
作製された比較例2および作製例2の円筒軸の寸法精度を、仕上げ工程における円筒軸に対する圧下方向の径の分布範囲の広さにより評価したところ、実施例1に係る試料に対し、実施例2の資料は真円度が更に30%向上された。   When the dimensional accuracy of the manufactured cylindrical shafts of Comparative Example 2 and Manufacturing Example 2 was evaluated based on the wide distribution range of the diameter in the rolling direction with respect to the cylindrical shaft in the finishing process, The roundness of Material 2 was further improved by 30%.
以上詳細に説明した通り、圧下率に分布を形成して仕上げ加工することにより、金属板10を曲げ加工して製造した中空の円筒軸でありながら、高い真円度と直線性を有するものが製造できる。この円筒軸は、中実な金属製丸棒材に代替して使用することができる。従って、部品精度の限界から削り出しの丸棒材を使用せざるを得なかった多くの用途において材料コストを低減させることができる。また、この円筒軸は中実材よりも軽量なので、これを用いることにより、機器の重量はもちろん、動作時のフリクションロスも低減させることができる。   As described in detail above, a hollow cylindrical shaft manufactured by bending the metal plate 10 by forming a distribution in the rolling reduction and finishing, but having a high roundness and linearity Can be manufactured. This cylindrical shaft can be used in place of a solid metal round bar. Therefore, the material cost can be reduced in many applications in which a machined round bar has to be used due to the limit of component accuracy. Further, since this cylindrical shaft is lighter than the solid material, it is possible to reduce the friction loss during operation as well as the weight of the device by using this cylindrical shaft.
以上、本発明を実施の形態を用いて説明したが、本発明の技術的範囲は上記実施の形態に記載の範囲には限定されない。上記実施の形態に、多様な変更または改良を加え得ることが当業者に明らかである。その様な変更または改良を加えた形態も本発明の技術的範囲に含まれ得ることが、特許請求の範囲の記載から明らかである。   As mentioned above, although this invention was demonstrated using embodiment, the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above embodiment. It is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.
この発明に係る円筒軸20の材料となる金属板10の形状を示す図。The figure which shows the shape of the metal plate 10 used as the material of the cylindrical shaft 20 concerning this invention. 金属板10により形成された円筒軸20の形状を部分的に示す図。The figure which shows partially the shape of the cylindrical axis | shaft 20 formed with the metal plate 10. FIG. 金属板10に対するはじめの曲げ加工で使用する金型30を示す断面図。FIG. 3 is a cross-sectional view showing a mold 30 used in the first bending process for the metal plate 10. 図2に示す金型30で曲げ加工された金属板10の断面形状を示す図。The figure which shows the cross-sectional shape of the metal plate 10 bent by the metal mold | die 30 shown in FIG. 金属板10に対する次の曲げ加工に使用する金型40を示す断面図。Sectional drawing which shows the metal mold | die 40 used for the next bending process with respect to the metal plate 10. FIG. 図5に示す金型40で曲げ加工された金属板10の断面形状を示す図。The figure which shows the cross-sectional shape of the metal plate 10 bent by the metal mold | die 40 shown in FIG. 金属板10に対する最後の曲げ加工に使用する金型50を示す断面図。FIG. 3 is a cross-sectional view showing a mold 50 used for the final bending process on the metal plate 10. 実施例1において仕上げ工程で用いたパンチ54の形状を示す斜視図。FIG. 3 is a perspective view showing a shape of a punch 54 used in a finishing process in Example 1. 実施例1において仕上げ工程で用いたパンチ54の形状を示す側面図。The side view which shows the shape of the punch 54 used in the finishing process in Example 1. FIG. 上記仕上げ工程により作製された円筒軸20の断面形状を示す図。The figure which shows the cross-sectional shape of the cylindrical axis | shaft 20 produced by the said finishing process. 実施例2において、金型50で加工した後の金属板10の形状を示す断面図。Sectional drawing which shows the shape of the metal plate 10 after processing with the metal mold | die 50 in Example 2. FIG. 実施例2の仕上げ工程において使用した整形金型60のダイ62およびパンチ64の形状を示す断面図。Sectional drawing which shows the shape of the die | dye 62 and the punch 64 of the shaping die 60 used in the finishing process of Example 2. FIG. 整形金型60に装着されるパンチ64の形状を示す斜視図。The perspective view which shows the shape of the punch 64 with which the shaping die 60 is mounted | worn.
符号の説明Explanation of symbols
10 金属板、12、14 端部、16 凸部、18 凹部、20 円筒軸、21、23 非曲げ加工部、22、24、26 被曲げ加工部、28 合わせ目、30、40、50 金型、60 整形金型、32、42、52、62 ダイ、31、33、41、43、51、53、61、63 加工面、34、44、54、64 パンチ、56 芯型 10 Metal plate, 12, 14 End, 16 Convex part, 18 Concave part, 20 Cylindrical shaft, 21, 23 Unbending part, 22, 24, 26 Bending part, 28 Joint, 30, 40, 50 Mold , 60 Shaping mold, 32, 42, 52, 62 Die, 31, 33, 41, 43, 51, 53, 61, 63 Machining surface, 34, 44, 54, 64 Punch, 56 cores

Claims (4)

  1. 曲げ加工して形成された円弧状の金属板を成形して円筒状の軸製品に成形する成形方法であって、
    長手方向に対して直交する断面の各々において前記軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、前記軸製品の長手方向と平行な断面の各々において直線状の内面形状を有する直線溝を備えた直金型と、
    前記長手方向に対して直角な断面の各々において前記軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、前記軸製品の長手方向と平行な断面の各々において、長手方向の中央に向かって前記軸製品に対する圧下率が高くなる凸曲線状の内面形状を有する曲溝を備えた曲金型とを用い、
    前記軸製品における前記金属板の対向される一対の端部が前記曲金型の前記曲溝に対して正対するように、前記曲溝および前記直線溝の間に前記円弧状の金属板を挟んで前記円筒状の軸製品に成形する成形方法。
    A forming method of forming an arc-shaped metal plate formed by bending into a cylindrical shaft product,
    Each of the cross-sections orthogonal to the longitudinal direction has a cross-sectional shape forming an arc having the same inner diameter as the outer diameter of the shaft product, and a linear inner surface shape in each of the cross-sections parallel to the longitudinal direction of the shaft product A direct mold with a linear groove having
    Each of the cross sections perpendicular to the longitudinal direction has a cross-sectional shape that forms an arc having the same inner diameter as the outer diameter of the shaft product, and in each of the cross sections parallel to the longitudinal direction of the shaft product, Using a curved mold having a curved groove having a convex curve-shaped inner surface shape in which the rolling reduction with respect to the shaft product increases toward the center,
    The arc-shaped metal plate is sandwiched between the curved groove and the linear groove so that a pair of opposed ends of the metal plate in the shaft product face the curved groove of the curved mold. A forming method for forming the cylindrical shaft product by:
  2. 前記直金型を、前記直線溝を上方に開口させて配置し、前記一対の端部を上方に向けて前記円弧状の金属板を前記直線溝の内部に置き、前記曲金型を、前記曲溝を下に向けて、前記直金型に向かって降下させ、前記直線溝および前記曲溝の間で前記円筒状の軸製品に成形する請求項1に記載の成形方法。 The straight mold is arranged with the linear groove opened upward, the arcuate metal plate is placed inside the linear groove with the pair of ends facing upward, and the curved mold is The molding method according to claim 1, wherein a curved groove is directed downward and lowered toward the straight mold, and the cylindrical shaft product is molded between the linear groove and the curved groove.
  3. 前記曲金型の前記曲溝の内面が、前記曲溝の長手方向と平行な断面の各々において連続した滑らかな曲線を描く請求項1に記載の成形方法。   The molding method according to claim 1, wherein the inner surface of the curved groove of the curved mold draws a continuous smooth curve in each of the cross sections parallel to the longitudinal direction of the curved groove.
  4. 曲げ加工して形成された円弧状の金属板を成形して円筒状の軸製品に成形する成形金型であって、
    長手方向に対して直交する断面の各々において前記軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、前記軸製品の長手方向と平行な断面の各々において直線状の内面形状を有する直線溝を備えた直金型と、
    前記長手方向に対して直交する断面の各々において前記軸製品の外径と同じ内径の円弧をなす断面形状を有し、且つ、前記軸製品の長手方向と平行な断面の各々において、長手方向の中央に向かって前記軸製品に対する圧下率が高くなる凸曲線状の内面形状を有する曲溝を備えた曲金型とを備え、
    前記軸製品における前記金属板の対向される一対の端部が前記曲金型の前記曲溝に対して正対するように、前記曲溝および前記直線溝の間に前記円弧状の金属板を挟んで前記円筒状の軸製品に成形する成形金型。
    A molding die for forming an arc-shaped metal plate formed by bending into a cylindrical shaft product,
    Each of the cross-sections orthogonal to the longitudinal direction has a cross-sectional shape forming an arc having the same inner diameter as the outer diameter of the shaft product, and a linear inner surface shape in each of the cross-sections parallel to the longitudinal direction of the shaft product A direct mold with a linear groove having
    Each of the cross-sections orthogonal to the longitudinal direction has a cross-sectional shape forming an arc having the same inner diameter as the outer diameter of the shaft product, and in each of the cross-sections parallel to the longitudinal direction of the shaft product, A curved mold having a curved groove having a convex curve-shaped inner surface shape in which the rolling reduction with respect to the shaft product increases toward the center;
    The arc-shaped metal plate is sandwiched between the curved groove and the linear groove so that a pair of opposed ends of the metal plate in the shaft product face the curved groove of the curved mold. A mold for forming the cylindrical shaft product with the above.
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