JP5962529B2 - Molding method and molding apparatus - Google Patents

Description

  The present invention relates to a molding method and a molding apparatus, and in particular, by thinly deforming a thin disk-shaped blank, the thin annular ring-shaped spoke part is connected to the radially outer end of the spoke part and directed in the axial direction. Suitable for forming a workpiece having a cylindrical drum portion extending in the direction from the axial end offset from the axial position to which the spoke portion of the drum portion is connected, and extending radially outward. The present invention relates to a molding method and a molding apparatus.

  Conventionally, by thinly deforming a thin disk-shaped blank, a thin annular ring spoke portion, a cylindrical drum portion connected to the radially outer end of the spoke portion and extending in the axial direction, and the drum portion There is known a molding method and a molding apparatus for molding a workpiece having a flange portion that extends radially outward from the axial end thereof (for example, see Patent Document 1). In the method and apparatus described in Patent Document 1, first, a thin disc-shaped blank is gripped by a gripping member in a state in which the outer end of the blank protrudes radially outward from the outer peripheral surface of the gripping member. After the gripping, the outer end of the blank is increased in thickness by pressing the outer end of the blank toward the central axis by the concave portion of the tool having a concave cross section. Then, the thickened portion is divided into two by being pressed toward the central axis with a tool having a thickness in the axial direction from the outside in the radial direction leaving a part, and the drum portion and the flange portion are formed. .

WO 01/007181 pamphlet

  However, in the method and apparatus described in Patent Literature 1, the drum portion and the flange portion of the workpiece are displaced by a tool having a large width in the axial direction toward the central axis and pressed against the outer peripheral surface of the gripping member. Since it is molded, it is easy for a lack of thickness to occur near the base of the flange portion. In particular, the lack of thickness is more likely to occur as the amount of offset between the axial position where the spoke portion is connected to the drum portion and the axial position where the flange portion is connected to the drum portion is larger.

  Moreover, in the method and apparatus described in Patent Document 1, the gripping member that grips the blank is exchanged between the step of increasing the outer end of the blank and the step of forming the drum portion and the flange portion of the workpiece. As a result of the replacement of the gripping member, an increase in the work manufacturing time and cost increase due to an increase in the number of processes are caused, and the work forming accuracy is lowered.

  The present invention has been made in view of the above-described points, and a molding method and a molding capable of suppressing the occurrence of thinning in the vicinity of the root of the flange portion without replacing the gripping member that grips the blank. An object is to provide an apparatus.

  The above-mentioned purpose is to plastically deform the blank by pressing the tool arranged on the radially outer side of the thin disc-shaped blank against the blank while rotating following the rotation around the central axis of the blank. The thin-walled annular spoke portion, the cylindrical drum portion connected to the radially outer end of the spoke portion and extending in the axial direction, and the axial position where the spoke portion of the drum portion is connected A molding method for forming a workpiece having a flange portion extending radially outward from an offset axial end, wherein the outer end portion of the blank protrudes radially outward from the outer peripheral surface of the gripping member. While holding the blank with the gripping member, the outer end of the blank is pressed toward the central axis with the concave portion of the first tool whose surface is formed in a concave shape. A thickening step for increasing the thickness of the end portion, and a sharpened portion of the second tool formed so that the surface of the thickened portion formed at the outer end portion of the blank in the thickening step is sharpened in a V shape And the second tool and / or the radially outer end surface from the one side in the axial direction to the other side in the axial direction while being rounded by being pressed toward the central axis. Using a third tool formed to have a smaller outer diameter, a part on the other side in the axial direction of one of the divided parts divided in the split step and the whole of the other divided part are directed in the axial direction. A drum forming step for forming the drum portion by stretching, and after forming the drum portion in the drum forming step, an end surface on one axial side of the one divided portion is formed in a columnar shape or a conical shape. Shaft with the formed fourth tool By pressing toward the direction the other side, a flanging step of forming the flange portion is achieved by a molding method comprising.

  Further, the above-mentioned purpose is to plastically deform the blank by pressing the tool arranged on the radially outer side of the thin disc-shaped blank against the blank while rotating following the rotation around the central axis of the blank. A thin annular ring-shaped spoke part, a cylindrical drum part connected to the radially outer end of the spoke part and extending in the axial direction, and an axial position where the spoke part of the drum part is connected Is a molding device for molding a workpiece having a flange portion extending radially outward from an offset axial end, and projecting the outer end of the blank radially outward from the outer peripheral surface. A gripping member for gripping the blank on both sides in the axial direction in the state, and a concave portion having a concave surface formed on the radially outer side of the blank gripped by the gripping member. The outer end of the blank is pressed toward the central axis to increase the thickness of the outer end of the blank, and the blank is held on the radially outer side of the blank held by the holding member. A V-shaped tool which is formed so as to be sharpened in a V shape and is divided into two in the axial direction by pressing a thickened portion formed on the outer end portion of the blank toward the central axis by the thickening tool; A part on the other side in the axial direction of one of the divided parts and the whole of the other divided part in the axial direction are arranged on the outer side in the radial direction of the blank held by the holding member and divided into two by the V-shaped tool. A drum forming tool for forming the drum portion by being stretched toward the outside, and arranged on the radially outer side of the blank gripped by the gripping member, formed in a columnar shape or a conical shape, After the drum part is molded, a molding apparatus comprising: a flange molding tool that molds the flange part by pressing an end surface on one axial side of the one divided portion toward the other axial side. Is achieved.

  According to the present invention, it is possible to suppress the occurrence of thinning in the vicinity of the base of the flange portion without replacing the gripping member that grips the blank.

It is principal part sectional drawing of the apparatus with which the workpiece | work shape | molded by the shaping | molding apparatus which is one Example of this invention is mounted. It is a perspective view of the structure containing the workpiece | work shape | molded by the shaping | molding apparatus of a present Example. It is a figure showing the process of shape | molding a workpiece | work from a thin disk shaped blank with the shaping | molding apparatus of a present Example. It is a block diagram of the shaping | molding apparatus of a present Example. It is a figure showing the structure of the V-shaped roller with which the shaping | molding apparatus of a present Example is provided. It is a figure showing the structure of the roller for drum forming with which the shaping | molding apparatus of a present Example is provided. It is whole sectional drawing showing the process of shape | molding a workpiece | work from a thin disk shaped blank with the shaping | molding apparatus of a present Example. It is the principal part perspective view and principal part sectional drawing showing the process of shape | molding a workpiece | work from a thin disk shaped blank with the shaping | molding apparatus of a present Example. It is a figure for demonstrating that a difference arises in a shaping | molding shape by the difference in the angle of the sharp part of the V-shaped roller with which the shaping | molding apparatus of a present Example is provided. It is a figure for demonstrating the factor that the difference in a shaping | molding shape arises by the difference in the angle of the sharp part of the V-shaped roller with which the shaping | molding apparatus of a present Example is provided. It is a figure showing the structure of the roller for flange forming with which the shaping | molding apparatus which is a modification of this invention is provided. It is a figure showing the structure of the roller for flange forming with which the shaping | molding apparatus which is a modification of this invention is provided.

  Hereinafter, specific embodiments of a molding method and a molding apparatus according to the present invention will be described with reference to the drawings.

  FIG. 1 is a cross-sectional view of a main part of a motor device 14 on which a workpiece 12 formed by a forming apparatus according to an embodiment of the present invention is mounted. FIG. 2 is a perspective view of the structure 16 including the workpiece 12 formed by the forming apparatus of this embodiment. FIG. 2 shows a state in which a part of the structure 16 is cut.

  The forming apparatus of the present embodiment is an apparatus for forming / manufacturing a workpiece 12 as a post-forming member from a blank by changing the shape (deformation) of a thin disc-shaped steel plate blank. The workpiece 12 is a member that is mounted on a motor device 14 that is used, for example, in a so-called one-motor type hybrid vehicle drive device.

  The work 12 constitutes a rotor shaft (rotor hub) as the structure 16 and is a rotor support member that supports the motor rotor 18 from the radially inner side. The motor rotor 18 faces the motor stator 22 with a predetermined gap 20 in the radial direction. The workpiece 12 includes a thin annular spoke portion 24, a cylindrical drum portion 26 connected to the radially outer end of the spoke portion 24 in the axial direction of the inner peripheral surface, and a diameter from the axial end of the drum portion 26. And a flange portion 28 extending outward in the direction.

  The spoke portion 24 has a predetermined thickness in the axial direction, and is formed in a thin annular shape so as to extend radially inward from the vicinity of the center in the axial direction of the inner peripheral surface of the drum portion 26. The axial position where the spoke portion 24 is connected to the inner peripheral surface of the drum portion 26 and the axial position where the flange portion 28 is connected to the outer peripheral surface of the drum portion 26 are offset. The drum portion 26 holds the motor rotor 18 on the radially outer side. The motor rotor 18 is caulked and fixed while being supported by the flange portion 28 in the axial direction outside the drum portion 26 in the radial direction. The spoke part 24, the drum part 26, and the flange part 28 are integrally formed.

  The structure 16 includes the workpiece 12 and the support cylindrical portion 30. The supporting cylindrical portion 30 is connected to the radially inner end of the spoke portion 24 of the workpiece 12 in the middle of the outer peripheral surface in the axial direction, and extends to both sides in the axial direction with respect to the radially inner end of the spoke portion 24. It is formed in a cylindrical shape. That is, the spoke portion 24 of the workpiece 12 is formed to extend radially outward from the vicinity of the center in the axial direction of the outer peripheral surface of the support cylindrical portion 30. The workpiece 12 and the support cylindrical portion 30 are formed as separate bodies, and the structure 16 is formed by being attached and fixed after each molding.

  A cylindrical projecting portion 34 is inserted through a bearing 32 on the radially inner side of the support cylindrical portion 30. The cylindrical projecting portion 34 is a cylindrical member that is formed integrally with a case 36 that accommodates each component of the motor device 14 and projects in the axial direction. The structure 16 is supported by the case 36 and the cylindrical protrusion 34 so as to be rotatable about the axis via the bearing 32, and rotates about the axis while holding the motor rotor 18.

  Next, a method for forming the workpiece 12 using the forming apparatus 10 of the present embodiment will be described with reference to FIGS.

  FIG. 3 is a diagram showing a process of forming the workpiece 12 from the thin disc-shaped blank 40 by the forming apparatus 10 of the present embodiment. FIG. 4 shows a configuration diagram of the molding apparatus 10 of the present embodiment. FIG. 5 is a diagram showing the structure of the V-shaped roller provided in the molding apparatus 10 of the present embodiment. Moreover, FIG. 6 shows the figure showing the structure of the drum forming roller with which the shaping | molding apparatus 10 of a present Example is provided. 6A is an overall configuration diagram of the molding apparatus 10 including two types of drum molding rollers, and FIG. 6B is a diagram comparing the shapes of the two types of drum molding rollers. , Respectively.

  The workpiece 12 of the present embodiment is formed and manufactured by plastically deforming a steel plate blank 40 formed in a thin disk shape by the forming apparatus 10. The blank 40 before the start of molding has an outer diameter larger than the outer diameter of the workpiece 12 after the molding is completed. Further, a through hole 42 is provided at the axial center of the blank 40 so that the molding apparatus 10 supports the blank 40 during molding by the molding apparatus 10.

  The molding apparatus 10 includes a clamp 44 that holds the blank 40. The clamp 44 is a mandrel member that grips a thin disc-shaped blank 40 from both sides in the axial direction during molding, and has two mandrels 46 and 48 each formed in a columnar shape. ing. The two mandrels 46 and 48 are arranged such that the circular surfaces 46a and 48a face each other in the axial direction. The circular surfaces 46a and 48a have substantially the same outer diameter.

  The circular surfaces 46 a and 48 a are grip surfaces that can come into contact with both end surfaces of the blank 40 facing in the axial direction. The blank 40 is gripped in the axial direction by being sandwiched between the mandrels 46 and 48 while being in contact with the circular surfaces 46a and 48a. The mandrels 46 and 48 of the clamp 44 grip the blank 40 on both sides in the axial direction in a state where the outer end portion of the blank 40 protrudes radially outward from the outer peripheral surface before the start of molding. Hereinafter, the mandrel 46 on one side (left side in FIG. 4) is referred to as a main shaft side mandrel 46, and the mandrel 48 on the other side (right side in FIG. 4) is referred to as a mandrel side mandrel 48.

  The circular surface 46a of the main shaft side mandrel 46 is provided with a protrusion 50 protruding in the axial direction. Further, the circular surface 48a of the mandrel 48 is provided with a recessed hole 52 that is recessed in the axial direction. The protrusion 50 has an outer diameter that matches the diameter of the through hole 42 of the blank 40 and that matches the inner diameter of the recessed hole 52 of the mandrel 48 on the center pushing side, and can be inserted into the through hole 42 and the recessed hole 52. It is. The blank 40 is set so that the protrusion 50 of the spindle mandrel 46 is inserted into the through hole 42 before the start of molding.

  The main shaft side mandrel 46 and the tail pushing side mandrel 48 can be relatively moved (slid) in the axial direction. Specifically, in principle, the spindle mandrel 46 on which the blank 40 is set before the start of molding is fixedly installed (except for a sub-clamp described later in detail). On the other hand, the tail pushing side mandrel 48 is attached to the main slide device 54, and can be moved in the axial direction with respect to the main shaft side mandrel 46 by the main slide device 54.

  Hereinafter, the axial position of the mandrel side mandrel 48 when the spindle side mandrel 46 and the tailstock side mandrel 48 grip the blank 40 is the gripping position, and the spindle side mandrel 46 and the mandrel side mandrel 48 are blank. The axial position where the mandrel 48 on the tail pushing side waits when the hand 40 is not gripped is referred to as a standby position. The main slide device 54 can be displaced between the standby position and the gripping position by moving the mandrel side mandrel 48 relative to the main shaft side mandrel 46 in accordance with an instruction from the controller 56. The mandrel 48 on the tail pushing side can be displaced between the standby position and the gripping position by the main slide device 54.

  The main shaft side mandrel 46 is divided into two parts, an inner diameter side and an outer diameter side, a columnar main clamp (main shaft side main clamp) 60 located on the inner diameter side, and a cylindrical / annular shape located on the outer diameter side. Sub-clamp (main shaft side sub-clamp) 62. The main shaft side sub clamp 62 is disposed on the outer side in the radial direction of the main shaft side main clamp 60 so as to surround the outer peripheral surface of the main shaft side main clamp 60. The main shaft side main clamp 60 is formed in a columnar shape so as to have a predetermined outer diameter, and is a fixed member that is fixedly installed. Further, the main shaft side sub clamp 62 is formed in a cylindrical shape or an annular shape so as to have a predetermined radial thickness.

  The main shaft side sub clamp 62 is attached to the main shaft side sub slide device 64, and the main shaft side sub slide device 64 axially extends along the outer peripheral surface of the main shaft side main clamp 60 with respect to the main shaft side main clamp 60. It is possible to move. Hereinafter, the axial position positioned when the main spindle side sub clamp 62 grips the blank 40 is the operating position, and the axial position positioned when the main spindle side sub clamp 62 does not grip the blank 40 is the retracted position. Call each one. The spindle-side sub-slide device 64 can move the spindle-side sub clamp 62 with respect to the spindle-side main clamp 60 in accordance with an instruction from the controller 56 to displace between the retracted position and the operating position. For example, the main shaft side sub clamp 62 is displaced by hydraulic control. The main shaft side sub clamp 62 can be displaced between the retracted position and the operating position by the main shaft side sub slide device 64.

  Similarly to the spindle side mandrel 46, the mandrel side mandrel 48 is divided into two parts, an inner diameter side and an outer diameter side, and a cylindrical main clamp (a tail pushing side main clamp) 70 located on the inner diameter side. And a cylindrical / annular sub-clamp (center push side sub-clamp) 72 located on the outer diameter side. The tailstock side sub-clamp 72 is disposed on the radially outer side of the tailstock side main clamp 70 so as to surround the outer peripheral surface of the tailstock side main clamp 70. The center push side main clamp 70 is formed in a columnar shape so as to have substantially the same outer diameter as the outer diameter of the main spindle side main clamp 60. Further, the center push side sub-clamp 72 is formed in a cylindrical shape or an annular shape so as to have substantially the same radial thickness as that of the main shaft side sub-clamp 62.

  The tailstock side sub-clamp 72 is attached to the tailstock side sub-slide device 74, and is arranged on the outer peripheral surface of the tailstock-side main clamp 70 with respect to the tailstock-side main clamp 70. It is possible to move along the axial direction. Hereinafter, the axial position that is located when the tail-pushing side sub-clamp 72 grips the blank 40 is the operating position, and the axial position that is located when the tail-pushing-side sub clamp 72 does not grip the blank 40 is the retracted position. Respectively. The tailstock side sub-slide device 74 can move the tailstock side sub clamp 72 with respect to the tailstock side main clamp 70 in accordance with an instruction from the controller 56 to displace it between the retracted position and the operating position. Therefore, for example, the main shaft side sub clamp 62 is displaced by hydraulic control. The tail pushing side sub clamp 72 can be displaced between the retracted position and the operating position by the tail pushing side sub slide device 74.

  The controller 56 synchronizes the main shaft side sub-slide device 64 and the tail-pushing side sub-slide device 74 to synchronize the main shaft-side sub-clamp 62 and the tail-push side sub-clamp 72, thereby retracting and operating position. Displace between. For this reason, the main shaft side sub-clamp 62 and the tail pushing side sub-clamp 72 are synchronously displaced between the retracted position and the operating position. That is, when the main shaft side sub clamp 62 is in the retracted position, the tailstock side sub clamp 72 is also in the retracted position, and when the main shaft side sub clamp 62 is in the operating position, the tailstock side sub clamp 72 is also in the operating position. is there.

  Further, the forming apparatus 10 includes a roller 78 for plastically deforming the blank 40 held by the clamp 44. The roller 78 is disposed on the radially outer side of the clamp 44, that is, on the radially outer side of the blank 40 held by the clamp 44. A plurality of types of rollers 78 are provided in accordance with the process of forming the workpiece 12 from the blank 40 before the start of forming. The plurality of types of rollers 78 are annularly arranged on the radially outer side of the clamp 44.

  Each roller 78 can move in the radial direction, and can rotate (rotate) about its own axis, and can also rotate (revolve) about the axis of the clamp 44. The controller 56 is electrically connected to each roller 78. Each roller 78 is moved inward in the radial direction (center axis side) in accordance with the molding process in accordance with an instruction from the controller 56, and all the rollers 78 including the roller 78 moved inward in the radial direction. However, by revolving around the axis of the clamp 44, the blank 40 is plastically deformed and the blank 40 is formed.

  The forming process from the thin disk-shaped blank 40 to the workpiece 12 having the spoke part 24, the drum part 26, and the flange part 28 includes (1) a thickness increasing process for increasing the outer end of the blank 40, and (2) A split step of dividing the thickened portion of the blank 40 thickened in the thickening step into two in the axial direction, and (3) extending both of the divided portions divided into two in the split step while tilting outward in the axial direction ( However, about the division | segmentation site | part of the one side of an axial direction, the extension is complete | finished in the middle without extending to an edge part.) The drum formation process which shape | molds the drum part 26, (4) Drum part in a drum formation process 26, and a flange forming step of forming the flange portion 28 with the meat piece remaining at one end in the axial direction on the 26 side standing radially outward.

  The plurality of types of rollers 78 described above are adapted to the above steps (1) to (4), and are used mainly in the splitting step, with the thickening roller 78a and the supporting roller 78b used in the thickening step. It comprises a V-shaped roller 78c, a drum forming roller 78d used in the drum forming process, and a flange forming roller 78e used in the flange forming process.

  The thickening roller 78a and the support roller 78b are disposed at positions facing each other across the central axis on the radially outer side of the clamp 44. The thickening roller 78a is formed in a substantially columnar shape so as to have an axis extending in parallel with the axis of the clamp 44, and a groove 80 is provided in an annular shape around the axis at a substantially axial center of the outer peripheral surface. This is a roller formed in a concave shape when viewed from the direction of cross-section. The groove 80 of the thickening roller 78a is formed to have a predetermined depth and capacity corresponding to a desired thickening amount to be formed at the outer end portion of the blank 40. For example, the U-shaped cross section having a round bottom surface It is formed into a mold.

  The thickening roller 78a is configured separately from the first thickening roller 78a-1 for thickening the outer end of the thin disc-shaped blank 40 and the first thickening roller 78a-1. There are two types, a second thickening roller 78a-2 that further thickens the outer end of the blank 40 that has been thickened using the first thickening roller 78a-1. The first thickening roller 78a-1 and the second thickening roller 78a-2 are arranged side by side in the circumferential direction. The first thickening roller 78a-1 has a relatively small depth or capacity of the groove 80-1, and presses the outer end of the blank 40 to the first predetermined diameter position to increase the thickness of the outer end portion. Is a roller used for setting the first predetermined amount. Further, the second thickening roller 78a-2 has a relatively large depth or capacity of the groove 80-2, and the outer end of the blank 40 is a second inner diameter side of the first predetermined diameter position described above. It is a roller that is used for pressing to a predetermined diameter position and setting the amount of increase in thickness of the outer end to a second predetermined amount (final desired increase in thickness).

  The support roller 78b is formed in a substantially columnar shape so as to have an axis extending in parallel with the axis of the clamp 44, and a groove 82 is provided in an annular shape around the axis at a substantially axial center of the outer peripheral surface. This is a roller formed in a concave shape when viewed from the direction of cross-section. When the thickening roller 78a presses the outer end of the blank 40 toward the central axis to increase the thickness of the outer end, the support roller 78b is opposite to the thickening roller 78a across the central axis. It is a member that supports the clamp 44 that holds the blank 40 at a position and prevents the clamp 44 from being bent in the radial direction. The groove 82 of the support roller 78b is formed to have a predetermined depth and capacity that does not come into contact with the blank 40 until the workpiece 12 is formed from the thin disk-shaped blank 40 before being formed sandwiched by the clamp 44. It is formed in a U-shaped cross section.

  The support roller 78b includes a first support roller 78b-1 corresponding to the first thickness increase roller 78a-1, and a second thickness increase formed separately from the first support roller 78b-1. There are two types, the second support roller 78b-2 corresponding to the roller 78a-2. The first support roller 78b-1 and the second support roller 78b-2 are arranged side by side in the circumferential direction. The groove 82-1 of the first support roller 78b-1 and the groove 82-2 of the second support roller 78b-2 are formed to have substantially the same depth or capacity as long as the blank 40 does not contact. Alternatively, they may be formed at different depths or capacities.

  Two V-shaped rollers 78 c are provided on the outer side in the radial direction of the clamp 44 so as to face each other with the central axis in between. Each V-shaped roller 78c is formed in a disc shape so as to have an axis extending parallel to the axis of the clamp 44, and has a V-shaped point from the center axis thereof to the outside in the radial direction at a substantially axial center. This is a roller in which a pointed portion 84 is provided in an annular shape, and a tip portion on the outer side in the radial direction when viewed from a direction orthogonal to the axis is formed in a V shape. The two V-shaped rollers 78c facing each other across the central axis of the clamp 44 are formed in substantially the same shape.

  The V-shaped roller 78c is used in a split process in which the thickened portion of the blank 40 that has been thickened in the thickening process is divided into two substantially equally in the axial direction. Each of them is stretched while being tilted outward in the axial direction (however, with respect to the divided portion on one axial side, the stretching is finished halfway without being stretched to the end), and the drum for forming the drum portion 26 of the workpiece 12 is formed. Also used in the molding process. That is, the V-shaped roller 78c is a member that divides the thickened portion of the blank 40 into two in the axial direction, and a member that extends both the divided portions outward in the axial direction to form the drum portion 26 of the workpiece 12 into a temporary shape. It is.

  The sharpened portion 84 of the V-shaped roller 78c is formed so that the angle formed by the left and right surfaces 86 and 88 in the axial direction with respect to the axis is a predetermined angle. In the following description, a surface 86 of the sharpened portion 84 facing the one side in the axial direction from which the flange portion 28 of the workpiece 12 is formed from the blank 40 is directed to one surface 86 of the sharpened portion 84 and the other axial direction of the sharpened portion 84. The surface 88 is referred to as the other surface 88 of the sharpened portion 84.

  The sharpened portion 84 is formed such that the angle formed by the one surface 86 with respect to the axis and the angle formed by the other surface 88 with respect to the axis substantially coincide with each other. Hereinafter, an angle formed by the surfaces 86 and 88 with respect to the axis is referred to as a roller attack angle α. The roller attack angle α is set to about 30 ° to 60 °, and is preferably set to around 45 °, for example. Further, the angle θ formed by the one surface 86 and the other surface 88 of the sharpened portion 84 is set to about 60 ° to 120 °, and is preferably set to, for example, around 90 °.

  Two drum forming rollers 78d are provided on the outer side in the radial direction of the clamp 44 so as to face each other across the central axis. Each of the drum forming rollers 78d has an axis extending parallel to the axis of the clamp 44, the end surface on one side in the axial direction is formed in a substantially flat shape, and the radial direction from one side in the axial direction to the other side in the axial direction. The outer end face (that is, the surface in contact with the blank 40) is rounded and formed into a trapezoidal shape or a conical shape as viewed from the direction orthogonal to the axis or in cross section so that the outer diameter becomes smaller around the axis. Is a roller. The drum forming roller 78d is a member for forming the drum portion 26 having a desired outer diameter by further extending the divided portion of the blank 40 extended outward in the axial direction by the V-shaped roller 78c further outward in the axial direction. It is.

  The drum-forming roller 78d is composed of two types of drum-forming rollers 78d-1 and 78d-2 having different degrees of sharpness in the vicinity of the connection portion (corner portion) between the end surface on one axial side and the end surface on the radially outer side. The first drum-forming roller 78d-1 and the second drum-forming roller 78d-2 are arranged at positions facing each other across the central axis on the radially outer side of the clamp 44. The drum portion 26 formed into a temporary shape by the V-shaped roller 78c is pressed in the order of the first drum forming roller 78d-1 → the second drum forming roller 78d-2 from the outer peripheral surface side toward the central axis side. To be formed.

  As shown in FIG. 6, the second drum forming roller 78d-2 has a kurtosis degree in the vicinity of the connecting portion between the end surface on one side in the axial direction and the end surface on the outer side in the radial direction, as compared with the first drum forming roller 78d-1. Is formed to be large. For example, the connecting portion of the first drum-forming roller 78d-1 is formed in a rounded shape, and is rounded with a radius of about 5 mm to about 15 mm (preferably R10). Further, the connecting portion of the second drum forming roller 78d-2 is formed in a rounded shape, and the R surface is processed with a radius of about 1 mm to about 3 mm (preferably, R2).

  The second drum molding roller 78d-2 is formed so that the maximum outer diameter is slightly larger (maximum outer diameter deviation Δr; for example, 1 mm to 3 mm) as compared to the first drum molding roller 78d-1. The axial position at the connecting portion is slightly (Δa; for example, 1 mm to 3 mm) so as to be closer to one side in the axial direction on the flange forming side, and the axial position at the maximum outer diameter portion is a predetermined distance ( Δb; for example, 5 mm to 15 mm).

  That is, in the first and second drum forming rollers 78d-1 and 78d-2, an angle β formed by a line connecting the vertices at the maximum outer diameter portions in the cross section with respect to the axial direction of the clamp 44 is, for example, 5 ° to 5 °. It is formed to be about 15 °. However, the first and second drum forming rollers 78d-1 and 78d-2 are formed in a line in which the radially outer surface of the second drum forming roller 78d-2 connects the vertices at the maximum outer diameter portion. On the other hand, it is carried out so as not to be located radially outside. Therefore, when the blank 40 is formed, the second drum forming roller 78d-2 has a radially outer end surface that is in contact with the blank 40 as compared with the first drum forming roller 78d-1. It is closer to the central axis side, and the connecting part is closer to one side in the axial direction.

  Further, the flange forming roller 78e is a roller formed in a columnar shape so as to have an axis extending parallel to a direction orthogonal to the axis of the clamp 44. The flange forming roller 78e is formed so that the end on the other side in the axial direction extends substantially linearly in a direction perpendicular to the axis of the clamp 44, that is, a direction extending in parallel with the cylindrical axis of the own roller 78e. The flange forming roller 78e presses a piece of meat remaining at one end in the axial direction of the drum portion 26 in the drum forming process from one axial side to the other axial side of the piece of meat. This is a member for forming the portion 28.

  FIG. 7 is an overall cross-sectional view showing a process of forming the workpiece 12 from the thin disc-shaped blank 40 by the forming apparatus 10 of the present embodiment. Moreover, FIG. 8 shows the principal part perspective view and principal part sectional drawing showing the process of shape | molding the workpiece | work 12 from the thin disk shaped blank 40 with the shaping | molding apparatus 10 of a present Example.

  In the above-described forming apparatus 10, when forming the workpiece 12 having the spoke portion 24, the drum portion 26, and the flange portion 28 from the thin disc-shaped blank 40, first, the thin disc-shaped blank 40 is formed in the through hole 42. Is set so that the protrusion 50 of the mandrel 46 on the main shaft side of the clamp 44 is inserted (FIGS. 7A and 8A).

  Then, the mandrel 48 of the center pushing side of the clamp 44 is moved from the standby position so as to approach the spindle side mandrel 46 in the axial direction by the main slide device 54 and reaches the gripping position. The mandrels 46 and 48 are held in contact with the circular surfaces 46a and 48a and are held by the clamp 44 (FIGS. 3A and 7B). At this time, both of the mandrels 46 and 48 have the sub-clamps 62 and 72 in the operating position, and the sub-clamps 62 and 72 are adjacent to each other by being inserted radially outside the main clamps 60 and 70. The outer diameters of 46a and 48a are set to be relatively large.

  When the thin disc-shaped blank 40 is gripped by the clamp 44 as described above, the first thickening roller 78 a-1 and the first support roller 78 b-1 of all the rollers 78 are next to the clamp 44. The first support roller 78b-1 is moved inward in the radial direction, and is moved to the side wall surfaces of the mandrels 46 and 48 of the clamp 44 (specifically, the outer peripheral surfaces of the sub clamps 62 and 72) until just before contact. At the same time, the bottom surface of the groove 80-1 of the first thickening roller 78a-1 is brought into contact with the outer end of the blank 40 (FIGS. 7C and 8B).

  In this state, the first support roller 78b-1 supports the mandrels 46 and 48 from the radially outer side toward the central axis while the roller 78 rotates around the axis of the clamp 44, and the first increase. The meat roller 78a-1 is further moved radially inward with respect to the clamp 44, and presses the outer end of the blank 40 toward the first predetermined radial position toward the central axis at the bottom surface of the groove 80-1. The first thickening roller 78a-1 moves radially inward with respect to the clamp 44 until immediately before the outer peripheral surface thereof contacts the outer peripheral surfaces of the sub-clamps 62 and 72 of the mandrels 46 and 48 of the clamp 44. Then, the outer end of the blank 40 is pressed to the first predetermined diameter position, and the thickness increase at the outer end becomes the first predetermined amount (FIG. 3B, FIG. 7D and FIG. 8 (C)).

  When the outer end of the blank 40 is pressed to the first predetermined diameter position as described above, the main shaft side sub clamp 62 of the main shaft side mandrel 46 is then displaced from the operating position to the retracted position by the main shaft side sub slide device 64. Then, the holding of the blank 40 is released, and the center pushing side sub-clamp 72 of the tail pushing side mandrel 48 is displaced from the operating position to the retracted position by the tail pushing side sub slide device 74 to release the holding of the blank 40. On the other hand, the main shaft side main clamp 60 of the main shaft side mandrel 46 and the center pushing side main clamp 70 of the tail pushing side mandrel 48 continue to hold the blank 40 at this time. For this reason, when the sub clamps 62 and 72 of both mandrels 46 and 48 are retracted to the retracted position, the sub clamps 62 and 72 are pulled out from the radially outer side of the main clamps 60 and 70 to the radially outer side of the main clamps 60 and 70. Since the sub clamps 62 and 72 are not adjacent to each other, the outer diameters of the circular surfaces 46a and 48a are relatively small.

  Further, a job change of the roller 78 is performed simultaneously with or after the sub-clamps 62 and 72 are retracted to the retracted position, specifically, the first thickening roller 78a-1 and the first support roller 78b. -1 is moved radially outward with respect to the clamp 44, and the second thickening roller 78a-2 and the second support roller 78b-2 are moved radially inward with respect to the clamp 44. In this case, the second support roller 78b-2 is moved to the side wall surface of the mandrels 46, 48 of the clamp 44 (specifically, the outer peripheral surface of the main clamps 60, 70) until just before contact, and the second The bottom surface of the groove 80-2 of the thickening roller 78a-2 is in contact with the outer end of the blank 40.

  In this state, the second support roller 78b-2 supports the mandrels 46 and 48 from the radially outer side toward the central axis while the roller 78 rotates around the axis of the clamp 44, and the second increase The meat roller 78a-2 is further moved radially inward with respect to the clamp 44, and presses the outer end of the blank 40 toward the second predetermined diameter position toward the central axis on the bottom surface of the groove 80-2. The second thickening roller 78a-2 moves radially inward with respect to the clamp 44 until immediately before its outer peripheral surface comes into contact with the outer peripheral surfaces of the sub-clamps 62 and 72 of the mandrels 46 and 48 of the clamp 44. Then, the outer end of the blank 40 is pressed to the second predetermined diameter position, and the thickness increase at the outer end becomes the second predetermined amount (desired thickness increase) (FIG. 3 (C), FIG. 7 (E) and FIG. 8 (D)).

  Therefore, by performing the switching between the thickening roller 78a and the support roller 78b in the molding apparatus 10 as described above, a thickening process for increasing the thickness of the outer end portion of the thin disc-shaped blank 40 to a desired thickening amount is realized. be able to.

  When the outer end of the thin disc-shaped blank 40 is pressed to the second predetermined diameter position and the outer end of the blank 40 is increased in the thickness increasing process as described above, the job change of the roller 78 is then performed. Specifically, the second thickening roller 78a-2 and the second support roller 78b-2 are moved radially outward with respect to the clamp 44, and the V-shaped roller 78c is moved to the clamp 44. On the other hand, it is moved radially inward (FIG. 7F). Further, even after the V-shaped roller 78c comes into contact with the outer end of the blank 40 at the pointed portion 84 (specifically, approximately the center in the axial direction of the thickened portion), the V-shaped roller 78c is further radially inward with respect to the clamp 44. By moving the thickened portion of the outer end of the blank 40, the thickened portion is plastically deformed by pressing the thickened portion toward the center axis at the sharpened portion 84, thereby axially moving the thickened portion. Are divided into two substantially equally divided into Y shapes (FIGS. 3D, 7G, and 8E). Thereby, the split process described above is realized.

  As described above, when the thickened portion of the outer end portion of the blank 40 is divided into two in the axial direction by using the V-shaped roller 78c in the splitting process, the V-shaped roller 78c then moves to the radial position. First, it is moved to one side in the axial direction (left side in each of FIG. 3, FIG. 7, FIG. 8, etc.) while maintaining the thickness of the blank 40 at the tip of the sharp portion 84 of the V-shaped roller 78c. The divided part on one side in the axial direction, which is divided into two parts, is extended by being tilted to one side in the axial direction, the movement is stopped halfway (predetermined axial position), and the extension ends (FIG. 3 (E), FIG. 7 (H) and FIG. 8 (F)).

  Then, the V-shaped roller 78c is moved to the other side in the axial direction (right side in each of FIGS. 3, 7, 8, etc.) with the movement in the axial direction reversed while maintaining the radial position. Then, the divided portion on the other side in the axial direction where the thickened portion of the blank 40 is divided into two at the tip of the sharp portion 84 of the V-shaped roller 78c is tilted to the other side in the axial direction and extended to the end (FIG. 3F). FIG. 7 (I) and FIG. 8 (G)). In this case, the drum part 26 of the workpiece 12 is molded to a temporary shape by plastic deformation of both divided parts obtained by dividing the thickened part of the outer end portion of the blank 40 into two parts (temporary molding). Thereby, the above-described drum forming process (specifically, the drum temporary forming process) for temporarily forming the drum portion 26 is realized.

  When the drum portion 26 is temporarily formed as described above, a job change of the roller 78 is performed. Specifically, the V-shaped roller 78c is moved radially outward with respect to the clamp 44, and The drum forming roller 78d is moved radially inward with respect to the clamp 44. Note that the portion of the blank 40 where the radially outer end surface of the drum forming roller 78d first contacts with the movement of the drum forming roller 78d toward the clamp 44 is the axial direction of the portion formed in a cylindrical shape. One end.

  Then, after the drum forming roller 78d comes into contact with the cylindrical portion of the blank 40 as it moves in the radial direction (FIGS. 7J and 8H), the cylindrical portion is pressed to a predetermined position. Moving to the other side in the axial direction, the cylindrical portion is further extended in the axial direction (FIGS. 3G, 7K, and 8I). The first and second drum forming rollers 78d-1 and 78d-2 are moved in synchronization with each other. In this case, the blank 40 is further plastically deformed to form the drum portion 26 having a desired outer diameter. Thereby, the above-described drum forming step (specifically, the drum main forming step) for forming the drum portion 26 into a desired shape is realized.

  When the drum portion 26 is formed into a desired shape in the drum forming process as described above, a job change of the roller 78 is then performed. Specifically, the drum forming roller 78d is moved with respect to the clamp 44. The flange forming roller 78e is moved radially inward with respect to the clamp 44 while being moved radially outward. The axial position where the flange forming roller 78e is moved radially inward with respect to the clamp 44 is the position on the one axial side of the piece of meat remaining at the end on the one axial side of the blank 40. .

  Thereafter, the flange forming roller 78e is moved in the radial direction until the tip thereof contacts the surface of the clamp 44 (FIG. 8 (J)), and then moved to the other side in the axial direction. The meat piece remaining at the end is pressed from one axial side to the other axial side to stand the meat radially outward (FIGS. 3H, 7L, and 8K). )). In this case, the flange portion 28 is formed such that the end surface on one side in the axial direction faces the axial direction. Thereby, the above-described flange forming step is realized.

  As described above, when the flange portion 28 of the blank 40 (that is, the workpiece 12) is formed using the flange forming roller 78e in the flange forming step, the flange forming roller 78e is then radially moved with respect to the clamp 44. When the mandrel 48 of the clamp 44 is moved from the gripping position to the standby position by the main slide device 54 after the movement, both the mandrels 46, 48 (specifically, the main clamp 60, 70), the gripping of the workpiece 12 is released.

  Here, even when the molding of the blank 40 is completed and the gripping of the mandrels 46 and 48 by the main clamps 60 and 70 is released, as shown in FIG. The main clamps 60 and 70 (particularly, the center pushing side main clamp 70 occupying most of the drum portion 26) are inserted, that is, the drum portion 26 is maintained in a state of being fitted to the outer peripheral surfaces of the main clamps 760 and 70. Sometimes.

  On the other hand, in the present embodiment, after the grip of the blank 40 by the main clamps 60 and 70 of both mandrels 46 and 48 is released as described above, the sub-clamps 62 and 72 (particularly, the tail pushing side sub-clamp 72). ) Is reciprocated once in the axial direction by the sub-slide devices 64 and 74 in the order of retracted position → actuated position → retracted position. In this case, the sub-clamps 62 and 72 are inserted outside the main clamps 60 and 70 in the radial direction to form an adjacent state. When such a state is formed, even if the main clamps 60 and 70 are inserted on the inner peripheral side of the drum portion 26 of the blank 40, the shaft of the drum portion 26 is driven by the force that the sub clamps 62 and 72 move in the axial direction. The other end in the direction is pressed toward the one side in the axial direction with respect to the main clamps 60 and 70 (FIG. 7N). Thereby, the payout process in which the blank 40 is paid out from the main clamps 60 and 70 is realized.

  Thus, according to the present embodiment, by using the molding apparatus 10, the spoke portion is formed from the thin disc-shaped blank 40 by sequentially performing the thickness increasing step, the splitting step, the drum molding step, and the flange molding step. The workpiece 12 having 24, the drum portion 26, and the flange portion 28 can be formed. In addition, the workpiece | work 12 mounted in the motor apparatus 14 is formed in a desired shape by being cut | disconnected so that the periphery of the center axis | shaft of the blank 40 paid out in said discharge | payout process may have a desired internal diameter.

  In the present embodiment, the thickening process for increasing the outer end of the thin disc-shaped blank 40, which is a process necessary for forming the workpiece 12, is performed while changing the outer diameter of the clamp 44 in two stages. The Specifically, in the thickening process, initially, the sub-clamps 62 and 72 are inserted radially outside the main clamps 60 and 70 of both the mandrels 46 and 48 of the clamp 44 so that the outer diameter of the clamp 44 is increased. While holding the thin disc-shaped blank 40 between the mandrels 46 and 48 in a relatively large state, the first thickening roller 78a-1 having a relatively shallow groove 80-1 is used to remove the blank 40 from the blank 40. By pressing the end toward the first predetermined diameter position toward the central axis, the outer end portion of the blank 40 is increased in thickness to a first predetermined amount smaller than the desired thickness increase amount. Thereafter, the sub-clamps 62 and 72 are pulled out from the outer side in the radial direction of the main clamps 60 and 70, and the outer diameter of the clamp 44 is relatively small without making the sub-clamps 62 and 72 adjacent to the outer side in the radial direction. The second blanking roller 78a-2 having a relatively deep groove 80-2 is used to hold the blank 40 between the mandrels 46 and 48, and the second end of the blank 40 is directed toward the central axis. By pressing to the predetermined diameter position, the outer end portion of the blank 40 is increased to the desired thickness increase.

  According to this process, in the thickness increasing process, the outer diameter of the mandrels 46 and 48 is adjusted to match the outer diameter of the blank 40 that is gripped by both mandrels 46 and 48 of the clamp 44 and whose outer end is thickened. Can be varied. Specifically, until the outer diameter of the blank 40 reaches the first predetermined diameter position from the start of molding, the outer diameters of the mandrels 46 and 48 are made relatively large, while the outer diameter of the blank 40 is the first predetermined diameter. The outer diameters of the mandrels 46 and 48 can be made relatively small from reaching the position until reaching the second predetermined diameter position on the inner diameter side of the first predetermined diameter position.

  In this regard, in the thickening process, while the outer diameter of the blank 40 is relatively large, the blank 40 is held by the clamp 44 having a relatively large outer diameter, while after the outer diameter of the blank 40 becomes relatively small, The blank can be gripped by a relatively small outer diameter clamp 44. Therefore, according to the molding apparatus 10 of the present embodiment, by changing the outer diameter of the clamp 44 that holds the blank 40 in the thickness increasing process, the blank 40 is directed radially outward from the outer peripheral surface of the mandrels 46 and 48. Thus, the radial length (protrusion length) L of the outer end portion that protrudes can be always shortened. For this reason, according to the present embodiment, when the outer end of the blank 40 is increased in thickness by a large amount, even when the outer diameter of the thin disk-shaped blank 40 before the start of molding is relatively large, the blank 44 is gripped by the clamp 44. The blank 40 is buckled in the thickening process in which the outer end of the blank 40 is thickened by pressing the outer end of the blank 40 toward the central axis by the groove 80 of the thickening roller 78a. It can be surely prevented.

  On the other hand, in order to prevent buckling of the blank 40, it is conceivable to increase the axial thickness of the thin disc-shaped blank 40 before the start of molding, but in this structure, the weight of the blank 40 is increased. . On the other hand, in this embodiment, since the buckling of the blank 40 can be prevented even if the axial thickness of the thin disc-shaped blank 40 before the start of molding is small, the thickness of the blank 40 The buckling can be prevented while avoiding an increase in weight due to the increase. Even if the thickness of the thin disk-shaped blank 40 before the start of molding is small, if the outer diameter is increased, a large amount of thickening to the outer end portion is possible. Therefore, according to the present embodiment, even if the axial thickness of the thin disc-shaped blank 40 before the start of molding is relatively small and the outer diameter is relatively large, the blank 40 is not buckled. A large amount of thickening to the outer end can be realized.

  In this embodiment, the thin disk-shaped blank 40 is gripped by the clamp 44 and the outer end thereof is increased in thickness, and then the workpiece 12 having the spoke part 24, the drum part 26, and the flange part 28 is formed. The blank 40 can be gripped using the same clamp 44 until it is dispensed. For this reason, it is unnecessary to replace the member that holds the blank 40 until the workpiece 12 having the spoke part 24, the drum part 26, and the flange part 28 is formed from the thin disk-shaped blank 40. Therefore, according to the present embodiment, there is no increase in the number of processes due to the replacement of the gripping member of the blank 40, so that it is possible to prevent an increase in work manufacturing time or an increase in cost. Further, since the accuracy of the replacement position due to the replacement of the gripping member of the blank 40 does not occur, it is possible to prevent the molding accuracy of the workpiece 12 from decreasing.

  In this embodiment, the thickened portion formed at the outer end portion of the blank 40 is divided into two Y-shaped portions in the axial direction using the V-shaped roller 78c, and the two divided portions are respectively divided. By forming the drum portion 26 of the workpiece 12 by extending it while being tilted outward in the axial direction, the meat piece remaining at the end portion on the one axial side of the divided portion on the one axial side is caused to stand outward in the axial direction. Then, the flange portion 28 is formed. In this regard, in forming both the drum portion 26 and the flange portion 28 of the workpiece 12, a tool having a large axial width is displaced from the radially outer side toward the central axis, and the blank 40 is moved to the outer peripheral surface of the clamp 44. It is not necessary to press it against.

  Therefore, according to the present embodiment, it is possible to suppress the occurrence of a lack of thickness near the root of the flange portion 28 of the workpiece 12 (that is, near the connection portion with the drum portion 26), and the flange portion 28. Molding can be performed with low load and high accuracy. For this reason, it is possible to increase the axial force when the caulking is fixed while the motor rotor 18 is supported on the flange portion 28 outside the drum portion 26 of the work 12.

  FIG. 9 is a diagram for explaining that a difference occurs in the molding shape due to a difference in the angle of the sharpened portion 84 of the V-shaped roller 78c included in the molding apparatus 10 of the present embodiment. FIG. 10 is a diagram for explaining a factor that causes a difference in molding shape due to a difference in the angle of the sharpened portion 84 of the V-shaped roller 78c provided in the molding apparatus 10 of the present embodiment.

  In the present embodiment, the angle (roller reception) formed by the surfaces 86 and 88 of the sharpened portion 84 of the V-shaped roller 78c (particularly, the one surface 86 on one axial side that is the side forming the flange portion 28) with respect to the shaft. (Angle) α is about 30 ° to 60 °, and is set, for example, in the vicinity of 45 °. On the other hand, the roller attack angle α is set to about 75 °, and the sharpened portion 84 of the V-shaped roller 78c is formed at a relatively acute angle (contrast structure shown in FIGS. 9B and 10B). Then, when the thickened portion of the outer end portion of the blank 40 is divided into two Y-shaped in the axial direction, the two divided portions stand radially outward, and the angle formed by the divided portions with respect to the axis And the Y-shaped branch does not spread at a very large angle. In this respect, in such a contrast structure, when the V-shaped roller 78c moves to the left and right in the axial direction with the branch portion of the blank 40 as a base point, the divided portion of the blank 40 (specifically, the flange portion 28 is formed). Since the axially divided portion on the one side in the axial direction is greatly pulled in the axial direction, a lack of thickness is likely to occur near the base of the flange portion 28.

  On the other hand, in the present embodiment, the above-mentioned roller attack angle is about 30 ° to 60 °, and is set, for example, in the vicinity of 45 °, and the sharpened portion 84 of the V-shaped roller 78c is formed at a relatively obtuse angle. Is done. For this reason, when the V-shaped roller 78c moves to the left and right in the axial direction from the branching portion of the blank 40 in the drum forming process, the two divided portions of the blank 40 are not pulled greatly in the axial direction. In addition, it is possible to suppress the occurrence of thinning in the vicinity of the root of the flange portion 28.

  Further, in this embodiment, the drum forming roller 78d used in the drum forming step is, as described above, formed between the end surface on one side in the axial direction and the end surface on the outer side in the radial direction, which are opposed to each other with the central axis of the clamp 44 interposed therebetween. It consists of two types of drum forming rollers 78d-1 and 78d-2 with different sharpness in the vicinity of the connection site (corner). The degree of corner sharpness is greater for the second drum molding roller 78d-2 than for the first drum molding roller 78d-1. In addition, when the blank 40 is formed, the second drum forming roller 78d-2 has a radially outer end surface that is in contact with the blank 40 at the center of the clamp 44 as compared to the first drum forming roller 78d-1. It is closer to the axial side, and the connecting part is closer to one side in the axial direction.

  Therefore, according to the present embodiment, the drum portion 26 of the blank 40 temporarily formed by the V-shaped roller 78c at the time of drum formation by the drum forming roller 78d before forming the flange portion 28 by the blank 40 Because the two types of drum forming rollers 78d-1 and 78d-2 having different sharpness in the vicinity of the portion can be pressed more greatly in the direction of the central axis of the clamp 44, a piece of meat can be filled in the vicinity of the root of the flange portion 28. , It can reduce the lack of near the root. Further, since the drum forming by the drum forming roller 78d can be performed in stages using the two types of drum forming rollers 78d-1, 78d-2, the two types of drum forming rollers 78d-1, 78d- By moving 2 in the axial direction of the clamp 44, the drum portion 26 can be extended in the axial direction without difficulty, and the drum portion 26 can be accurately thinned to a desired radial thickness.

  In the present embodiment, the roller 78 (specifically, the V-shaped roller 78c and the drum-forming roller 78d) is moved in the axial direction after the V-shaped roller 78c divides the thickened portion of the blank 40 into two parts. As a result, the two divided parts of the blank 40 are extended while being tilted outward in the axial direction, so that the axial position where the spoke part 24 is connected to the drum part 26 and the axial direction where the flange part 28 is connected. Even if the offset amount with respect to the position is large, the drum portion 26 and the flange portion 28 can be appropriately formed without causing a lack of thickness near the base of the flange portion 28.

  Further, in this embodiment, after the outer end portion of the blank 40 is increased in thickness, the sharpened portion 84 of the V-shaped roller 78c is substantially centered in the axial direction of the increased thickness portion formed at the outer end portion of the blank 40. , The increased thickness portion is divided into two substantially equally in the axial direction. For this reason, in the work 12, it is possible to make the volume of each site | part of the axial direction both sides across the spoke part 24 substantially the same. In addition, in the workpiece 12, when the ratio of the volume of each part on both sides in the axial direction is predetermined with the spoke part 24 being sandwiched, the axial position where the above-mentioned thickened part is divided into two in the axial direction is What is necessary is just to set according to the ratio.

  Further, in this embodiment, after the forming of the workpiece 12 having the spoke portion 24, the drum portion 26, and the flange portion 28 is completed, the sub clamps 62, 72 are replaced with the main clamps 60, 70 by using the sub slide devices 64, 74. On the other hand, by moving in the axial direction, the sub-clamps 62 and 72 are inserted adjacent to each other on the radially outer side of the main clamps 60 and 70, thereby forming a state in which the workpiece 12 having been formed is completed. 70 can be paid out. Therefore, according to this embodiment, even when the drum portion 26 is fitted to the outer peripheral surface of the main clamps 60 and 70 when the work 12 is completely formed, the work 12 is automatically discharged from the main clamps 60 and 70. Therefore, the work by the operator can be made unnecessary to eliminate the fitted state, and the manufacturing time and the manufacturing cost can be reduced.

  In the above embodiment, the clamp 44 is in the “gripping member” described in the claims, and the thickening roller 78a is in the “first tool” and “thickening tool” in the claims. The groove 80 of the thickening roller 78a is in the “recessed portion” described in the claims, and the V-shaped roller 78c is “second tool”, “V-shaped tool”, and “drum forming” in the claims. In the “tool”, the drum forming roller 78d is described in the claims “third tool”, “drum forming tool”, and “finishing tool”, and in the claims, the flange forming roller 78e is described in the claims. It corresponds to a “fourth tool” and a “flange forming tool”, respectively.

  By the way, in the above-described embodiment, the change of the outer diameter of the clamp 44 according to the outer diameter of the blank 40 is performed by using the sub-slide devices 64 and 74 on the outer side in the radial direction of the main clamps 60 and 70. However, the present invention is not limited to this and may be performed in three or more stages.

  Further, in the above embodiment, the flange forming roller 78e is formed in a columnar shape having an axis extending in parallel to the direction orthogonal to the axis of the clamp 44, and the end on the other side in the axial direction is the axis of the clamp 44. The flange portion 28 is formed so as to extend substantially linearly in a direction orthogonal to each other, and the flange portion 28 after forming the workpiece 12 is formed such that the surface on one side in the axial direction faces the axial direction of the clamp 44. However, the present invention is not limited to this, and the flange-forming roller 78e is formed in a conical shape, and the end on the other side in the axial direction extends obliquely with respect to the axis of the clamp 44 (specifically, Is so that the end on the other side in the axial direction is located on the one side in the axial direction from the base side to the tip side of the flange portion 28 or the other side in the axial direction on the other side, that is, the outer diameter is from the base side of the flange portion 28. The flange portion 28 after forming the workpiece 12 is formed such that the surface on one side in the axial direction is inclined with respect to the axial direction of the clamp 44. It is good to do.

  Further, when the flange forming roller 78e is formed in a conical shape whose outer diameter increases from the root side to the tip side of the flange portion 28 as shown in FIG. 11, the flange portion of the workpiece 12 during molding of the workpiece 12 is formed. Since the difference in speed in the contact surface between the roller 28 and the flange forming roller 78e can be absorbed, relative slip on the contact surface can be suppressed.

  Further, when the flange forming roller 78e is formed in a conical shape whose outer diameter increases from the root side to the tip side of the flange portion 28, the flange forming roller 78e is clamped at the end on the other side in the axial direction. For forming the flange portion 28 so as to extend substantially linearly in a direction perpendicular to the axis of the workpiece 12, that is, forming the flange portion 28 after the molding of the workpiece 12 so that the surface on one side in the axial direction faces the axial direction of the clamp 44. In order to achieve this, the flange-forming roller 78e may be arranged so that the conical axis obliquely intersects with the axis of the clamp 44, as shown in FIG. According to such a modified example, the surface on the one axial side of the flange portion 28 after the completion of the work forming is suppressed while suppressing relative sliding on the contact surface between the flange portion 28 of the work 12 and the flange forming roller 78e during the work forming. It is possible to mold the clamp 44 so as to face the axial direction.

  In the above-described embodiment, the roller 78 disposed radially outside the clamp 44 is revolved around the axis of the clamp 44, so that the roller 78 and the clamp 44 are relatively rotated around the center axis of the clamp 44. However, the workpiece 40 is formed by plastically deforming the blank 40 held by the clamp 44 while rotating the roller 78 following the relative rotation, but the present invention is not limited to this. The roller 78 and the clamp 44 are rotated by rotating the clamp 44 holding the blank 40 around the axis without revolving the roller 78 around the axis of the clamp 44, that is, while fixing the position of the roller 78 around the clamp 44 axis. Are rotated about the central axis of the clamp 44, and the roller 78 is rotated by rotating the roller 78 to rotate. The blank 40 is plastically deformed may perform the shaping of the workpiece 12.

  Further, the above embodiment is applied to the molding of the workpiece 12 constituting the rotor shaft. However, the present invention is not limited to this, and the invention is not limited to the workpiece 12 constituting the rotor shaft. It is good also as applying, and it is good also as applying to things other than the motor apparatus 14. FIG.

DESCRIPTION OF SYMBOLS 10 Forming device 12 Work piece 18 Motor rotor 40 Blank 44 Clamp 46 Main shaft side mandrel 48 Mandrel side mandrel 54 Main slide device 56 Controller 78 Roller 78a Thickening roller 78b Support roller 78c V-shaped roller 78d Drum forming roller 78e Flange forming roller 80 groove 84 pointed portion 86,88 pointed surface

Claims (8)

A thin circular ring is formed by plastically deforming the blank by pressing it against the blank while rotating the tool arranged on the outer side in the radial direction of the thin disk-shaped blank following the rotation around the central axis of the blank. An axial end that is offset from the spoke portion, a cylindrical drum portion that is connected to the radially outer end of the spoke portion and extends in the axial direction, and an axial position where the spoke portion of the drum portion is connected A molding method for molding a workpiece having a flange portion extending radially outward from
The concave portion of the first tool whose surface is formed in a concave shape in a state where the blank member is gripped by the gripping member while protruding the outer end portion of the blank radially outward from the outer peripheral surface of the gripping member. A thickening step for increasing the thickness of the outer end of the blank by pressing the outer end of the blank toward the central axis;
By pressing the thickened portion formed at the outer end portion of the blank in the thickening step toward the central axis with the sharpened portion of the second tool formed so that the surface is sharpened in a V shape, A splitting step that divides it into two in the axial direction;
In the splitting step, the second tool and / or the third tool formed so that the outer diameter is reduced while the end surface on the radially outer side is rounded from one axial side to the other axial side. A drum forming step of forming the drum portion by extending a part of the other divided part in one of the two divided parts and the whole of the other divided part in the axial direction;
After forming the drum portion in the drum forming step, the end surface on one side in the axial direction of the one divided portion is directed toward the other side in the axial direction using a fourth tool formed in a columnar shape or a conical shape. A flange forming step for forming the flange portion by pressing; and
A molding method comprising:   In the drum forming step, at least the second tool is used to extend a part of the other divided portion in the axial direction of the one divided portion divided in the split step and the whole of the other divided portion in the axial direction. The molding method according to claim 1, wherein the drum portion is molded. The drum molding process includes
Using the second tool, a part of the other divided part on the other side in the axial direction is extended toward one side in the axial direction, and the whole of the other divided part is extended toward the other side in the axial direction. A temporary forming step of temporarily forming the drum part;
After the drum portion is temporarily formed in the temporary forming step, the third tool is used to direct a part on the other axial side of the one divided part and the whole of the other divided part in the axial direction. A main forming step of main forming the drum portion by stretching;
The molding method according to claim 2, comprising: A thin circular ring is formed by plastically deforming the blank by pressing it against the blank while rotating the tool arranged on the outer side in the radial direction of the thin disk-shaped blank following the rotation around the central axis of the blank. An axial end that is offset from the spoke portion, a cylindrical drum portion that is connected to the radially outer end of the spoke portion and extends in the axial direction, and an axial position where the spoke portion of the drum portion is connected A molding device for molding a workpiece having a flange portion extending radially outward from the workpiece,
A gripping member for gripping the blank on both sides in the axial direction in a state in which the outer end portion of the blank is protruded radially outward from the outer peripheral surface;
The blank is disposed on the radially outer side of the blank gripped by the gripping member, and has a concave portion whose surface is formed in a concave shape. By pressing the outer end of the blank toward the central axis with the concave portion, the blank A tool to increase the thickness of the outer end of the
It is arranged on the outer side in the radial direction of the blank held by the holding member, the surface is formed so as to be pointed in a V shape, and the thickened portion formed at the outer end portion of the blank by the thickening tool is a central axis. A V-shaped tool that is split in the axial direction by pressing toward
A part on the other side in the axial direction of one of the divided parts and the whole of the other divided part arranged in the axial direction are arranged on the radially outer side of the blank held by the holding member and divided into two by the V-shaped tool. A drum forming tool for forming the drum portion by extending the drum portion;
Arranged on the radially outer side of the blank to be gripped by the gripping member, formed in a columnar shape or a conical shape, and after the drum portion is molded by the drum forming tool, one axial direction side of the one divided portion A flange forming tool for forming the flange portion by pressing the end surface of the flange portion toward the other side in the axial direction;
A molding apparatus comprising:   The molding apparatus according to claim 4, wherein the drum forming tool includes at least the V-shaped tool. The drum forming tool is disposed on the radially outer side of the V-shaped tool and the blank gripped by the gripping member, and the end surface on the radially outer side is rounded from one axial side to the other axial side. A finishing tool formed to have a small outer diameter,
The V-shaped tool also divides the thickened portion into two in the axial direction, and then extends a part on the other side in the axial direction of the one divided portion toward the one side in the axial direction. And extending the whole of the divided portion toward the other side in the axial direction, thereby temporarily forming the drum portion,
In the finishing tool, after the drum portion is temporarily formed by the V-shaped tool, a part on the other axial side of the one divided part and the whole of the other divided part are extended in the axial direction. 6. The molding apparatus according to claim 5, wherein the drum portion is subjected to main molding.   The finishing tool is composed of two tools that are arranged to face each other across a central axis and have different sharpnesses in the vicinity of a connecting portion between an end surface on one axial side and an end surface on the radially outer side. 6. The molding apparatus according to 6. The forming apparatus according to any one of claims 4 to 6, wherein a tip surface of the sharp portion of the V-shaped tool forms an angle of 30 ° to 60 ° with respect to the axial direction.

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