JP5376526B2 - Spinning method and apparatus - Google Patents

Description

  The present invention relates to a spinning processing method and apparatus.

  The spinning processing device is a processing device that rotates a plate-shaped or tubular metal blank with a motor and presses the blank with a roller tool to perform a forming process. Generally, a spindle for rotating the blank and a roller tool are used. A plurality of linear motion mechanisms intersecting each other for driving and pressing the blank.

  In a spinning processing device, processing is performed while rotating the blank. In general, the position of the processing roller in the radial direction is kept constant with respect to a certain feed amount of the processing roller in the main axis direction, and the cross-sectional shape orthogonal to the main shaft until now. However, it was only possible to process a product having an axially symmetric shape that is a coaxial circle.

In order to solve this, as a spinning processing device for forming a product having an irregular cross-sectional shape by spinning processing, for example, as seen in the following Patent Document 1, based on product shape data stored in advance, the main shaft direction There has been proposed one that includes means for pressing the material along the mold by moving the processing roller forward or backward in the radial direction in accordance with the displacement of the processing roller and the rotation angle of the main shaft.
Further, as seen in Patent Document 2 below, the pressing force of the processing roller is controlled by feedback from a force sensor attached to the processing roller, and the blank is formed following the forming die having an irregular cross-sectional shape. A device having means for forming a blank following the cross-sectional shape is proposed.

Patent Publication 2003-181555 WO2005 / 056210

  However, when molding is performed by one pass of the processing roller from the top to the bottom of the product, if the angle formed between the side surface of the product and the main shaft is too small, the thickness of the side surface becomes thin, and in the worst case, breakage occurs. In particular, there is a problem that such a breakage is likely to occur when a shape such as a prismatic shape in which the side surface of the product is parallel to the main axis is formed.

  Also, in the conventional axisymmetric spinning process, the processing roller is manually moved by the operating lever to perform molding, the path of the processing roller at that time is memorized, and then the path is regenerated to repeat the molding. Reproduction methods have been widely used for some time. However, in the prior art, the processing roller is precisely controlled so that the processing roller moves forward / backward in the radial direction according to the deformed cross-sectional shape of the product while the main shaft makes one rotation. It was impossible to memorize the route.

If a product with an irregular cross-sectional shape whose cross-sectional shape perpendicular to the main axis is not circular can be formed without causing such inconvenience, the use of spinning processing can be greatly expanded by diversifying the products that can be formed. it can.
Therefore, in order to solve the problems of the prior art, the present invention makes it possible to easily derive the position control of the processing roller that does not cause breakage from the final shape and the blank shape of the product, and by using a plurality of paths of the processing roller. Another object of the present invention is to provide a spinning method capable of forming a product having an irregular cross-sectional shape having a part in which the product side surface and the main axis are parallel, and a spinning device for efficiently carrying out the method.

  In addition, the present invention provides a spinning processing apparatus capable of forming a product with an irregular cross-sectional shape by a teaching reproduction method by changing the forward / backward movement of the processing roller synchronized with the rotation of the main shaft by manual operation of the operation lever. It aims to be realized.

  In order to achieve the above object, the spinning method of the present invention includes a main shaft driven by a motor with a rotation angle sensor, and a deformed cross section in which a blank is mounted and rotated by the main shaft, and a cross section orthogonal to the main shaft is not circular. The blank is shaped by following the molding die by a shaping die having a shape, a processing roller that contacts the blank to perform the molding processing, and an actuator that drives the processing roller in the main axis direction and the radial direction. In the spinning method, the step of storing the target shape data of the product in the first storage medium in the form of a plurality of cross-sectional shapes, and the step of storing the blank shape data in the form of the blank outer peripheral shape in the second storage medium And a plurality of transient path data of the processing roller from the blank shape data to the target shape data in a third storage medium. For storing the product shape data and the blank in a data format represented by a point coordinate sequence on a plane composed of a plurality of radial displacements and principal axis displacements based on the target shape data Corresponding to the shape data, based on the transient path data and the main shaft rotation angle, a step of performing interpolation calculation of the actual radial displacement and main shaft direction displacement of the processing roller, and the processing roller was obtained by the interpolation calculation. By performing position control so as to follow the displacement in the radial direction and the displacement in the main axis direction, the blank is pressed against the mold and molded.

  Further, in the above processing method, a step of manually giving an operation command to the processing roller via an operation lever, and based on the operation command, a radial direction displacement and a main axis direction displacement in the transient path data are: And a step of designating as point coordinates on a plane.

  In order to efficiently realize the spinning method described above, the spinning device of the present invention has a main shaft driven by a motor with a rotation angle sensor, a blank mounted, and rotated by the main shaft, and a cross section orthogonal to the main shaft. In a spinning processing apparatus comprising: a non-circular shaped cross-sectional mold, a processing roller that performs a forming process in contact with the blank, and an actuator that drives the processing roller in the principal axis direction and the radial direction. From a first storage medium storing shape data in the form of a plurality of cross-sectional shapes, a second storage medium storing shape data of the metal plate blank in the form of a blank outer peripheral shape, and shape data of the metal plate blank , A plurality of transient path data of the processing roller until reaching the target shape data, a plurality of transition data based on the target shape data A third storage medium stored in a data format represented by a point coordinate sequence on a plane consisting of radial displacement and principal axis displacement, corresponding to the product shape data and blank shape data, Interpolation calculation means for performing interpolation calculation of the actual radial displacement and main shaft direction displacement of the processing roller based on the transient path data and the main shaft rotation angle, and the radial displacement and main shaft obtained by calculating the processing roller by the interpolation calculation means. Position control means for performing position control to follow the directional displacement is provided.

  Further, in the above spinning processing apparatus, an operation lever for manually giving an operation command to the processing roller is provided, and a radial displacement and a main shaft direction displacement in the transient path data are obtained by operating the operation lever. Specified as point coordinates on a plane.

According to the present invention, the following effects can be obtained by the above configuration.
That is, the target shape data of the product is stored in the first storage medium in the form of a plurality of cross-sectional shapes, the blank shape data is stored in the form of the blank outer peripheral shape in the second storage medium, and the third storage medium A plurality of transitional path data of the processing roller from the blank shape data to the target shape data is obtained on a plane composed of a plurality of radial displacements and principal axis displacements based on the target shape data. Based on the product shape data and blank shape data, it is stored as a point coordinate sequence, and the actual radial displacement and principal axis displacement of the machining roller are obtained by interpolation calculation corresponding to the machining roller path data and the spindle rotation angle. By following the processing roller, the blank is pressed against the mold, so it synchronizes with the rotation of the spindle from the processing roller path expressed as a curved line on the plane. The reciprocating motion of the processing roller can be derived, and the reciprocating motion can be continuously changed from the movement along the outer periphery of the blank to the movement along the irregular cross-sectional shape of the product. It is possible to simply design an optimum path of the processing roller when gradually approaching the product shape, and it is possible to realize highly accurate processing without causing breakage or the like in the blank.

  In addition, the operation lever for manually giving an operation command to the processing roller allows the radial displacement and the principal axis displacement in the transient path data to be designated as point coordinates on a plane. The movement in two directions is converted into a continuous change in the reciprocating motion of the processing roller synchronized with the spindle rotation, and the blank can be pressed against the mold having an irregular cross-sectional shape by manual operation of the operation lever. A product having an irregular cross-sectional shape can be formed by the teaching reproduction method similar to the spinning process of the axially symmetric shape.

It is a schematic plan view which shows an example of the spinning processing apparatus which concerns on this invention. It is a schematic diagram showing the expression method of the target shape data of an irregular cross-sectional shape, and the shape data of a blank. FIG. 6 is a schematic diagram showing a transient path of the processing roller 5. It is a schematic diagram which shows the process of calculating | requiring the radial direction displacement of the processing roller 5 by interpolation calculation. It is a schematic diagram showing the effect | action of transient radial direction displacement Syt. It is a figure which shows the structure of the teaching reproduction | regeneration system by an operation lever.

  Embodiments of a spinning method and apparatus according to the present invention will be described below with reference to the drawings based on examples.

  FIG. 1 is a schematic plan view showing an embodiment of a spinning processing apparatus according to the present invention. Here, the spinning processing apparatus 10 presses the blank 1 against the molding die 2 having an irregular cross-sectional shape and processes the blank 1 from the flat plate shape 1a, which is the initial shape of the blank 1, to the irregular sectional shape 1b. 2 and the main shaft 3 are fixed between the main shaft 3 and the main shaft 3 by a motor 4 provided with a rotation angle sensor such as an encoder for detecting the main shaft rotation angle θ.

  The processing roller 5 is advanced or retracted in the radial direction of the blank 1 by a linear motion table 6 driven by an actuator such as a ball screw or a hydraulic cylinder. The linear motion table 6 is parallel to the main shaft 3 by the linear motion table 7. Move forward or backward. The linear motion tables 6 and 7 are each provided with a displacement sensor such as an encoder for detecting a feed amount, and the position of the linear motion tables 6 and 7 is controlled by a control device 20 for controlling an actuator such as the ball screw or the hydraulic cylinder.

  That is, the control device 20 uses a computer, receives data such as a rotation angle sensor of the motor and displacement sensors of the linear motion tables 6 and 7, and generates a control signal according to control software installed in advance. This controls the drive of actuators such as the ball screw and hydraulic cylinder.

The control device 20 includes three storage media 21, 22, and 23. The first storage medium 21 stores the target shape data of the modified cross-sectional shape 1b, which is a product, in the form of a plurality of cross-sectional shapes, while the second storage medium 22 stores the shape data of the blank 1 in the blank outer periphery. Stored in shape format.
The third storage medium 23 stores a transient path of the processing roller 5 from the shape data of the blank 1 to the target shape data step by step as a transient path based on the target shape data. The data format is point coordinate data on a plane composed of a radial displacement and a displacement in the principal axis direction with respect to the target shape data for a cross section at a predetermined principal axis rotation angle θ. Details will be described later. .

  The control device 20 further includes a calculation unit 24, which obtains the target displacements Xt and Yt of the processing roller 5 by interpolation calculation from the data stored in the storage media 21, 22, and 23 and the spindle rotation angle θ. 7 is supplied to the controller 25 to cause the processing roller 5 to follow the target displacement by servo control.

  The characteristic configuration of the spinning process according to the present invention is that the target shape data of the irregular cross-sectional shape 1b, the shape data of the blank 1 stored in the storage media 21, 22, 23, and the processing roller 5 reach the final shape. The actual target displacement of the processing roller 5 is obtained by interpolation calculation from the transient path and the spindle rotation angle θ, and the processing roller 5 is made to follow the target displacement by the linear motion tables 6 and 7. Hereinafter, this characteristic configuration will be described through the operations of the spinning processing apparatus 10 and the control apparatus 20 configured as described above.

  FIG. 2 is a schematic diagram showing target shape data of the irregular cross-sectional shape 1b and shape data of the blank 1. As shown in FIG. The target shape data of the irregular cross-sectional shape 1b is represented by a plurality of cross-sectional shapes orthogonal to the main axis. For example, in the shape of a polygonal pyramid as shown in the figure, the kth cross-sectional shape data is a set of a radial displacement Yp (k, θ) and a displacement Xp (k) in the main axis direction with the main shaft rotation angle θ as an argument. It becomes.

  However, Yp (k, θ) is the radial displacement of the processing roller 5 when the processing roller 5 comes into contact with the deformed cross-sectional shape 1b when the main shaft direction displacement of the processing roller 5 is Xp (k) and the main shaft rotation angle is θ. Yp (k, θ) can be measured by making the roller follow the mold 2 while keeping Xp (k) constant. It can also be calculated as Yp (k, θ) data in a plane orthogonal to the main axis from CAD data of the target shape.

  Similarly, the shape data of the flat plate shape 1a of the blank 1 is a radial displacement of the processing roller 5 when the processing roller 5 comes into contact with the outer periphery of the blank 1 when the main shaft rotation angle is θ, and the main shaft rotation angle θ is calculated as follows. Yb (θ) is expressed as an argument, and when the blank 1 is a disk, Yb (θ) is a constant value. The target shape data Yp (k, θ) and Xp (k) for the irregular cross-sectional shape 1b are stored in the first storage medium 21 and the shape data Yb (θ) for the blank 1 are stored in the second storage medium 22. Yes.

  FIG. 3 is a diagram showing stepwise deformation by the processing roller 5 when forming a hexagonal pyramid-shaped side surface extending leftward from the right end in the modified cross-sectional shape 1b of FIG. Is on the rightmost hexagonal side, and the Xt axis indicates the state in which the processing roller 5 has reached the deformed cross-sectional shape 1b, that is, the radial displacement of the processing roller 5 at each spindle rotation angle θ. It shows that it is equal to the value connecting the target shape data Yp (k, θ).

  In the first processing, the processing roller 5 starts from the origin O and moves to the outermost side until it reaches the outer periphery (Syt = 1) of the blank 1 while moving to the bottom surface side. Spinning process.

  After that, the processing roller 5 is reversed from the position corresponding to the outer periphery of the blank 1 to the right side toward the origin O while slightly narrowing to the center side, and the molding following the molding die 2 is completed by the first processing. Return to the location and start the second machining. In the second machining, the second stage spinning process is performed at a position closest to the bottom surface side. At this time, since the blank 1 has a shade shape and the outer periphery size is reduced, the maximum value of Syt is set accordingly.

  Thereafter, similarly, in the example of FIG. 3, the processing roller 5 reciprocates five times within the section from the right end to the left end of the hexagonal pyramid. During this time, the blank 1 is gradually copied from the right side to the mold 2. As a result, the spinning process is completed.

  Here, Xt is the displacement in the main shaft direction of the processing roller 5, and in the example shown in the figure, the processing roller 5 becomes the blank 1 on the hexagonal side at the right end from the processing start position to the processing end position in the main shaft direction. A simplified process is shown until contact is made to match the target shape data Yp (k, θ) of the irregular cross-sectional shape 1b in five stages of processing. The radial displacement is normalized by data based on the target shape data Yp (k, θ) with respect to the displacement Xt in the main axis direction, and reaches a final shape representing 0 on the center side and 1 on the outer peripheral side. It is represented by a transient displacement Syt until

  The processing roller 5 moves back and forth in the radial direction in synchronization with the rotation angle θ of the main shaft 3 during actual processing, but a transient path can be set as a curved line on the plane, so that the front and rear in synchronization with the rotation angle. Regardless of the motion, it can be designed in the same manner as the processing roller path in the conventional axial object shape.

Assuming that all the radial displacements of the processing roller corresponding to the rotation angle θ of the main shaft and the main shaft direction displacement Xt are set in advance as such processing roller paths, it is necessary to set a very large amount of three-dimensional data. Therefore, the amount of data handled can be significantly reduced by using interpolation calculation. Therefore, when a point (Xt, Syt) on the transition path until the final shape of the processing roller 5 in the third storage medium 23 and the main shaft rotation angle θ are given, the following interpolation calculation is performed. The actual displacement of the processing roller 5 in the main axis direction and the radial direction is calculated.
Here, referring to the target shape data of the deformed cross-sectional shape 1b stored in the first storage medium 21, with respect to the displacement in the main axis direction,
(Formula 1) Xp (k) <Xt <Xp (k + 1)
The number k of the cross-sectional shape that holds is obtained.
Then
(Expression 2) Yp (Xt, θ) = {Xt−Xp (k)} · Yp (k + 1, θ) / {Xp (k + 1) −Xp (k)} + {Xp (k + 1) −Xt} · Yp ( k, θ) / {Xp (k + 1) −Xp (k)}
Thus, the radial displacement Yp (Xt, θ) with respect to the deformed cross-sectional shape 1b when the main shaft direction displacement is Xt and the main shaft rotation angle is θ is obtained.

Next, referring to the shape data of the blank 1 stored in the second storage medium 22, using the transient radial displacement Syt of the processing roller 5,
(Expression 3) Yt = Syt · Yb (θ) + (1−Syt) · Yp (Xt, θ)
From the above calculation, the actual radial displacement Yt of the processing roller 5 is obtained.

FIG. 4 is a schematic diagram showing the process of the interpolation calculation. First, the cross-sectional shape data Yp (Xt, θ) corresponding to Xt is interpolated from the two cross-sectional shape data Yp (k, θ) and Yp (k + 1, θ) of the deformed cross-sectional shape 1b sandwiching the displacement Xt in the main axis direction. To do. Next, the actual radial displacement Yt of the processing roller 5 is interpolated from Yp (Xt, θ) and the outer peripheral shape data Yb (θ) of the blank 1 using the transient radial displacement Syt as a weighting factor.
In addition, the above interpolation calculation is implement | achieved by the program mounted in the control apparatus 20 of the spinning processing apparatus 10. FIG.

  FIG. 5 is a schematic diagram showing the action of the transient radial displacement Syt in the cross section at the specific principal axis direction displacement Xt. Each closed curve represents the actual radial displacement Yt of the processing roller 5 as a trajectory relative to the blank. In Syt = 1, the trajectory of Yt coincides with the outer peripheral shape Yb (θ) of the blank 1. When Syt = 0, the trajectory of Yt becomes equal to the target cross-sectional shape Yp (Xt, θ) of the irregular cross-sectional shape 1b, and the processing roller 5 can press the blank 1 against the mold 3. When 0 <Syt <1, the trajectory of Yt takes an intermediate shape according to the value of Syt. Therefore, if the value of Syt is gradually increased or decreased to 0 while increasing or decreasing between 0 and 1 as shown in FIG. 3, the blank 1 gradually approaches the target irregular cross-sectional shape 1b from the flat plate shape 1a, and finally. Is completed by being pressed against the mold 3. Since it is possible to easily specify the reciprocating multiple times as described above only by the transitional path to the final shape of the processing roller represented by the curve on the plane, for example, like a prism Even a product with an irregular cross-sectional shape having a part in which the product side surface and the main axis are parallel can be easily formed.

  In order to perform processing with higher accuracy, the cross-sectional shape data Yp (k, θ) and (Xt, Syt) may be input with a finer mesh, and the material such as deformation followability to the stress of the blank 1 may be used. It may be automatically determined based on a map obtained experimentally in advance according to the characteristics, thickness, deformation amount required to reach the final shape, or required processing quality.

In the above description, it is assumed that the transitional path to the final shape of the processing roller 5 is pre-programmed and stored in the third storage medium 23. However, the processing is performed manually by the operation lever. It is also possible to perform processing by the teaching reproduction method in which the route is stored while performing the processing, and thereafter the processing is repeated using the route.
FIG. 6 is a diagram showing the configuration of the teaching reproduction method. By operating the operation lever 23, a transient radial displacement Syt and a principal axis displacement Xt of the processing roller 5 are designated, and the target shape data of the irregular cross-sectional shape 1b stored in the first storage medium 21, the second It is given to the calculation unit 24 together with the shape data of the blank 1 stored in the storage medium 22, and the actual radial displacement Yt of the processing roller 5 is calculated by interpolation. If Xt is increased or decreased by the operation lever 23, the displacement Xt in the main shaft direction of the processing roller 5 is also increased or decreased accordingly. Further, when the Syt is increased or decreased by the operation lever 23, if the value of Syt approaches 1, the trajectory of the processing roller 5 approaches the outer peripheral shape of the blank 1; It approaches the cross-sectional shape of shape 1b.

  On the other hand, Xt and Syt are stored in the third storage medium 23 as a transient path of the processing roller 5 while performing processing by manually operating the operation lever 23 in this way. After that, if the switch SW is switched and Xt and Syt are given from the third storage medium 23 to the calculation unit 24, the same configuration as in FIG. 1 is obtained, so that the transition of the processing roller 5 stored in the third storage medium 23 is achieved. Based on a typical path, it is possible to reproduce the same machining as the manual machining.

  The spinning processing apparatus according to the present invention has been described based on the embodiments. However, the present invention is not limited to such embodiments, and various implementations can be made within the scope of the technical matters described in the claims. Needless to say, there is a mode of.

  Since the present invention is configured as described above, it is possible to easily derive the motion of the processing roller from the target product shape and blank shape, and, for example, like a prism by a plurality of paths of the processing roller. Molding of products with irregular cross-sections with parts parallel to the product side and the main axis can be performed with high accuracy without causing breakage etc. in the blank, and diversification of products that can be molded and expansion of applications, It can be widely used for manufacturing automobile parts, aircraft parts, energy-related and other various parts.

  Further, according to the present invention, since the blank can be pressed against the mold having an irregular cross-sectional shape by manual operation of the operation lever, the odd-shaped cross-section is obtained by a teaching reproduction system similar to that of the conventional spinning process that is widely used. A product having a shape can be formed, and can be easily introduced even in a manufacturing site such as a press sheet metal field having know-how for operating a conventional spinning machine.

1 Blank 1a Flat plate (material)
1b Deformed cross-sectional shape of target product 2 Mold 3 Spindle 4 Motor 5 Processing roller 6 Linear motion table 7 Linear motion table 10 Spinning processing device 20 Control device 21 First storage medium 22 Second storage medium 23 Third storage Storage medium 24 Arithmetic unit 25 Controller

Claims (4)

A main shaft driven by a motor with a rotation angle sensor, a blank is mounted and rotated by the main shaft, and a cross-section perpendicular to the main shaft is not circular, and a mold having a deformed cross-sectional shape is brought into contact with the blank to perform molding processing In a spinning process method in which a forming process is performed by causing the blank to follow the forming die by a processing roller and an actuator that drives the processing roller in the main axis direction and the radial direction.
Storing the target shape data of the product in the first storage medium in the form of a plurality of cross-sectional shapes;
Storing the shape data of the blank in a second storage medium in the form of a blank outer peripheral shape;
A plurality of transient path data of the processing roller from the shape data of the blank to the target shape data in a third storage medium, a plurality of radial displacements based on the target shape data Storing in a data format represented by a point coordinate sequence on a plane consisting of displacement in the main axis direction,
Corresponding to the product shape data and blank shape data, interpolating the actual radial displacement and the main shaft direction displacement of the processing roller based on the transient path data and the main shaft rotation angle;
A spinning processing method comprising a step of pressing the blank against the forming die by performing position control so that the processing roller follows a radial displacement and a principal axis displacement obtained by the interpolation calculation.   A step of manually giving an operation command to the processing roller via an operation lever, and based on the operation command, a radial displacement and a principal axis displacement in the transient path data are designated as point coordinates on a plane. The spinning method according to claim 1, further comprising a step. A main shaft driven by a motor with a rotation angle sensor, a blank is mounted and rotated by the main shaft, and a cross-section perpendicular to the main shaft is not circular, and a mold having a deformed cross-sectional shape is brought into contact with the blank to perform molding processing In a spinning processing apparatus comprising a processing roller and an actuator for driving the processing roller in the main axis direction and the radial direction,
From the first storage medium that stores the target shape data of the product in the form of a plurality of cross-sectional shapes, the second storage medium that stores the shape data of the blank in the form of the blank outer peripheral shape, and the shape data of the blank, A plurality of transient path data of the processing roller until reaching the target shape data, a point coordinate sequence on a plane consisting of a plurality of radial displacements and principal axis displacements based on the target shape data A third storage medium stored in a data format represented by
In response to the product shape data and blank shape data, an interpolation calculation means for performing an interpolation calculation of an actual radial displacement and a main shaft direction displacement of the processing roller based on the transient path data and the main shaft rotation angle, and the processing A spinning processing apparatus comprising: a position control means for causing a roller to follow a radial displacement and a principal axis displacement obtained by the interpolation computing means.   Equipped with an operation lever for manually giving an operation command to the processing roller, and the radial displacement and the principal axis displacement in the transient path data can be designated as point coordinates on a plane by operating the operation lever. The spinning processing apparatus according to claim 3, wherein