JP6002547B2 - Metal part processing method and processing apparatus - Google Patents

Description

  The present invention relates to a metal part processing method and a processing apparatus.

  Examples of the metal component having a thickened end portion of a metal plate material include a brake pad and a support component that supports the brake pad (see, for example, Patent Documents 1 to 5). For example, if the portion of the brake pad pressure plate that receives a circumferential load from the support that supports the brake pad during braking of the vehicle is thick, the possibility of the brake pad falling off the support is reduced. The surface pressure of the part that transmits the load to the support is reduced.

JP 52-135969 A JP 2008-12579 A JP 2012-72848 A JP 2002-250375 A US Pat. No. 6,367,594

  As a method for thickening the end portion of the metal plate material, for example, there is a method of applying external pressure to the plate material from a direction perpendicular to the thickness direction of the plate material. In this case, the mold structure is likely to be complicated, and a great amount of external pressure is required at the time of thickening, and an excessive pressure is applied to the plate material, so that the mold and the plate material are greatly damaged. Moreover, since a great amount of external pressure is required at the time of increasing the thickness, it is difficult to increase the amount of increased thickness. In addition, when an external pressure is applied to the plate material from a direction perpendicular to the thickness direction of the plate material, the plate material is subjected to the external pressure, so that a twist or bending force is easily applied to the plate material.

  This invention is made in view of such a subject, and it is a subject to provide the processing method and processing apparatus of a metal component which can improve the workability at the time of thickening the edge part of metal board | plate materials. To do.

  In the present invention, in order to solve the above-described problem, the end portion of the plate member is bent and then the end portion is crushed.

  Specifically, a metal component processing method for thickening an end portion of a metal plate material, wherein the end portion of the plate material is bent toward one of the front surface and the back surface of the plate material; , Crushing the end portion of the plate material subjected to the bending treatment, the metal material constituting the end portion of the plate material of the other surface which is the surface opposite to the one surface of the front surface and the back surface of the plate material And a molding process that moves toward the side.

  Generally, the load required for bending a plate material is smaller than the load required for applying an external pressure to the plate material from the direction perpendicular to the thickness direction to make the end portion of the plate material thick. Further, by bending the end portion of the plate material, the amount of the metal material at the end portion can be made larger than the portion other than the end portion.

Therefore, the processing method performs a process of bending the end part to increase the amount of the metal material at the end part, and crushing and forming the end part in that state. Since the end portion is crushed in a state where the end portion is bent, it is possible to easily increase the thickness compared to the case where the bending processing is omitted. Also in this process, it is possible to increase the thickness of the end by simply applying a load smaller than the load required when the bending process is omitted to increase the thickness.

  In the forming process, the end of the plate material bent to the one surface side by the bending process is crushed toward the other surface side, and the metal material is moved to the other surface side. You may send. By subjecting the end portion subjected to the bending treatment to the forming treatment with the load applied from such a direction, the end portion having an increased thickness can be formed at an appropriate position.

  Further, in the forming process, the end of the plate material is pressed against the bottom surface of the recess of the mold that receives the end of the plate material bent in the bending process, and the end of the plate material is crushed, and the metal material is It may be raised to the other side. In such a molding process, the direction in which the load is applied during the bending process is the same as the direction in which the load is applied during the molding process. Therefore, the bending process and the molding process are continuously performed in a single operation. Can be realized.

  In addition, the said processing method is applicable to manufacture of a brake pad, for example. In other words, the processing method of the metal part includes a predetermined end portion of the pressure plate of the brake pad, to which a circumferential load that the brake pad receives from a support member that supports the brake pad during braking of the vehicle is applied. A method of processing a metal part to be thickened, wherein the bending process bends the predetermined end portion to either one of a front surface and a back surface of the pressure plate, and the forming process includes the bending process. Crushing the predetermined end portion applied, and bringing the metal material constituting the predetermined end portion toward the other surface, which is the surface opposite to the one surface, of the front and back surfaces of the pressure plate It may be.

  Further, the present invention can also grasp the above processing method from the side of the processing apparatus. For example, the present invention is a processing apparatus for a metal part that thickens an end portion of a metal plate material, and bending the end portion of the plate material to one of the front surface and the back surface of the plate material. And crushing the end portion of the plate material bent by the bending means, and the other metal plate constituting the end portion of the plate material is a surface opposite to the one surface of the front surface and the back surface of the plate material Forming means that moves toward the side of the surface.

  If it is the said metal component processing method and processing apparatus, the workability at the time of thickening the edge part of metal board | plate materials will improve.

It is an example of the figure which showed the 1st processing apparatus. It is an example of the figure which showed the 2nd processing apparatus. It is an example of the figure which showed the state at the time of processing of metal parts. It is an example of the figure which showed the process of a metal component using the 1st processing apparatus. It is an example of the figure which showed the processing process of the metal components using the 2nd processing apparatus. It is the figure which showed the 1st modification of the 2nd processing apparatus. It is an example of the figure which showed the state at the time of the process of the metal component which concerns on a 1st modification. It is an example of the figure which showed the 2nd modification of the 2nd processing apparatus. It is an example of the figure which showed the state at the time of the process of the metal component which concerns on a 2nd modification. It is an example of the figure which showed the manufacturing process of the metal component which concerns on a 2nd modification. It is an example of the figure which showed the brake pad manufactured with the processing method of the metal component which concerns on embodiment. It is an example of the figure which showed the brake pad manufactured using the processing method of the metal component which concerns on a 1st modification. It is an example of the figure which showed the modification of the brake pad.

  Hereinafter, embodiments of the present invention will be described. The embodiment described below exemplifies one aspect of the present invention, and does not limit the technical scope of the present invention to the following aspect.

  Drawing 1 is an example of the figure showing the 1st processing device 1 for realizing the processing method of the metal parts concerning an embodiment. The 1st processing apparatus 1 is an apparatus attached to a press apparatus, and is provided with the upper die set 11 and the lower die set 12 as shown in FIG. The first processing device 1 presses a workpiece, which is a metal plate material, by moving the upper die set 11 up and down by a hydraulic drive device and control devices provided in the press device. The lower die set 12 includes a bending die 13 for bending the end portion of the workpiece, a lower cushion 14 disposed inside the bending die 13, and an expansion / contraction that supports the lower cushion 14 slidable inside the bending die 13. A possible lower elastic body (for example, a spring) 15 is attached. Further, the upper die set 11 is provided with a bending punch 16 for pushing the workpiece into the bending die 13.

  Drawing 2 is an example of the figure showing the 2nd processing device 2 for realizing the processing method of the metal parts concerning an embodiment. The 2nd processing apparatus 2 is an apparatus attached to a press apparatus similarly to the 1st processing apparatus 1, and is provided with the upper die set 21 and the lower die set 22, as shown in FIG. Similar to the first processing device 1, the second processing device 2 presses the workpiece by moving the upper die set 21 up and down by a hydraulic drive device and control devices provided in the press device. The lower die set 22 supports a forming die 23 for forming the end portion of the workpiece, a lower cushion 24 disposed inside the forming die 23, and a lower cushion 24 slidable inside the forming die 23. A stretchable lower elastic body 25 is attached. A cutout portion 29 is provided at the edge of the surface of the lower cushion 24 that contacts the workpiece. The upper die set 21 supports a molding punch 26 that crushes the end of the workpiece, an upper cushion 27 disposed inside the molding punch 26, and an upper cushion 27 that is slidable inside the molding punch 26. A stretchable upper elastic body 28 is attached.

  Note that one of the first processing device 1 and the second processing device 2 can be replaced by replacing the punch or cushion attached to the die set of the other processing device. You may also use this processing apparatus. Moreover, the 1st processing apparatus 1 and the 2nd processing apparatus 2 may be put together as one apparatus, or each may be an independent separate apparatus.

  Hereinafter, the processing method of the metal component which concerns on embodiment is demonstrated. FIG. 3 is an example of a diagram illustrating a state during processing of a metal part that can be realized by using the first processing apparatus 1 and the second processing apparatus 2. When using the 1st processing apparatus 1 and the 2nd processing apparatus 2, for example, as shown in FIG. 3, the bending process which bends the edge part of a workpiece | work to either the surface side of the surface of a workpiece | work and a back surface. It is possible to realize a forming process in which the end of the workpiece subjected to the bending process is crushed and the metal material constituting the end of the work is brought closer to the other surface side of the work. In order to realize this, the first processing apparatus 1 and the second processing apparatus 2 are used as follows.

FIG. 4 is an example of a diagram illustrating a metal part machining process using the first machining apparatus 1. In this machining step, the workpiece W is set in the first machining apparatus 1 (see FIG. 4A). Next, the upper die set 11 is lowered by moving the press device. When the upper die set 11 is lowered, the workpiece W is pushed down by the bending punch 16 and the end portion of the workpiece W in contact with the bending die 13 starts to bend. At this time, the workpiece W is sandwiched and restrained between the bending punch 16 and the lower cushion 14. When the end portion of the work W starts to bend, the lower cushion 14 supporting the work W from below is pushed downward. Since the lower cushion 14 is supported by the expandable lower elastic body 15, it slides downward inside the bending die 13 and stops when it contacts the lower die set 12 (FIG. 4B). reference). When the lower cushion 14 comes into contact with the lower die set 12, the operation direction of the upper die set 11 is reversed and the upper die set 11 is raised. When the upper die set 11 is raised, the lower cushion 14 is pushed up by the lower elastic body 15, and the workpiece W having a bent end comes out of the bending die 13 (FIG. 4C). Thereby, the metal component machining process using the first machining apparatus 1 is completed.

  FIG. 5 is an example of a diagram illustrating a metal part machining process using the second machining apparatus 2. In the present machining step, the workpiece W having its end bent using the first machining apparatus 1 is set in the second machining apparatus 2 (see FIG. 5A). Next, the upper die set 21 is lowered by moving the press device. When the upper die set 21 is lowered and the upper cushion 27 comes into contact with the workpiece W, the upper elastic body 28 contracts while the upper cushion 27 starts to slide inside the molding punch 26, and the lower elastic body 25 contracts and lowers. The cushion 24 begins to slide inside the molding die 23. If the lowering operation of the upper die set 21 is continued, the end portion of the workpiece W is formed into the molding punch 26 until the upper cushion 27 comes into contact with the upper die set 21 and the lower cushion 24 comes into contact with the lower die set 22. The metal material constituting the end portion of the workpiece W moves downward and enters the cutout portion 29 (see FIG. 5B). When the upper cushion 27 contacts the upper die set 21 and the lower cushion 24 contacts the lower die set 22, the operation direction of the upper die set 21 is reversed and the upper die set 21 is raised. When the upper die set 21 is raised, the lower cushion 24 is pushed up by the lower elastic body 25, and the work W whose end portion is crushed comes out of the forming die 23 (FIG. 5C). Thereby, the metal component machining process using the second machining apparatus 2 is completed. Thereby, the board | plate material which made the edge part thick is obtained.

  In the processing method according to the present embodiment, the end portion is bent in a state where the end portion is bent to increase the amount of the metal material at the end portion. In addition, the load required in the bending process and the molding process is smaller than in the prior art. For example, if you want to increase the thickness of the edge, increase the height of the edge that is vertical by bending, and if you want to reduce the thickness of the edge, reduce the height of the edge that is vertical by bending. By doing so, the thickness of the end portion can be easily increased or decreased. Moreover, since the processing method according to the present embodiment is basically press processing with a high processing speed, the productivity is high. If it is the processing method which concerns on this embodiment, the workability at the time of thickening the edge part of metal board | plate materials will improve in this way.

<First modification>
The second processing apparatus 2 may be modified as follows, for example. FIG. 6 is an example of a diagram illustrating a first modification of the second processing apparatus. A cutout portion 29 provided in the lower cushion 24 is omitted from the lower cushion 24 ′ of the second processing apparatus 2 ′ shown in FIG. About another structure, it is the same as that of the said 2nd processing apparatus 2. FIG.

  FIG. 7 is an example of a diagram illustrating a state at the time of processing a metal part according to the first modification that can be realized by using the first processing apparatus 1 and the second processing apparatus 2 ′ according to the present modification. is there. When using 1st processing apparatus 1 and 2nd processing apparatus 2 ', as shown in FIG. 7, for example, the bending which bends the edge part of a workpiece | work to the side of either one of the surface of a workpiece | work and a back surface. Processing, crushing the end of the workpiece subjected to the bending treatment, and bringing the metal material that constitutes the end of the workpiece toward the other surface of the workpiece makes a thick structure with one surface raised It is possible.

<Second modification>
The second processing device 2 may be modified as follows, for example. FIG. 8 is a view showing a second modification of the second processing apparatus. 8 includes an upper die set 30 and a lower die 31. The upper die set 30 includes a forming punch 32 that crushes the end of the workpiece, and an inside of the forming punch 26. An upper elastic body 34 is attached to the upper cushion 33, and the upper elastic body 34 that can expand and contract to support the upper cushion 33 slidable inside the molding punch 32. The corner portion of the surface of the upper cushion 33 on which the workpiece comes into contact. Is provided with a recess 35 for receiving the end of the workpiece bent by the forming punch 32. Further, the portion of the forming punch 32 that contacts the workpiece is cut away, and the pressing surface presses the end of the workpiece. In addition, a concave portion 37 that receives an end portion of the workpiece bent by the molding punch 32 is provided at a corner portion of the surface of the lower die 31 on which the workpiece abuts. In addition, a recessed part is the concept which shows the part recessed rather than the circumference | surroundings, and the recessed part like the notch part 29 is not completely surrounded by the circumference | surroundings, but a part of side is open | released. It is a concept including the aspect which exists.

  FIG. 9 is an example of a diagram illustrating a state at the time of processing a metal part according to the second modification that can be realized by using the second processing apparatus 2 ″ according to the present modification. 9, for example, as shown in FIG. 9, the end of the work subjected to the bending process is performed while bending the end part of the work to one of the front and back surfaces of the work. The forming process of crushing the part and bringing the metal material constituting the end of the work toward the other surface of the work can be realized with one stroke (it can also be expressed as “one-shot”). After performing the forming process, an unnecessary part is cut by a cutting process or a shaving process, and a finishing process for finishing the end face is performed.

  FIG. 10 is an example of a diagram illustrating a metal part machining process according to the second modification using the second machining apparatus 2 ″ according to this modification. In this machining process, the second machining apparatus is illustrated. The workpiece W is set at 2 ″ (see FIG. 10A). Next, the upper die 30 is lowered by moving the press device. When the upper die 30 is lowered, both end portions of the work W come into contact with the pressing surface 36 and are pushed down by the upper die 30, and both end portions of the work W supported from the lower side by the lower die 31 begin to bend to the lower surface side. When the end of the work W is bent and eventually the end of the work W comes into contact with the bottom surface of the recess 37, the end of the work W starts to be crushed. When the upper die 30 is further lowered and the end portion of the workpiece W is further crushed, the metal material constituting the end portion of the workpiece W moves into the recess 35 that is not pressed by the upper die 30 or the lower die 31. As a result, the end of the workpiece W rises not only on the lower surface side but also on the upper surface side of the workpiece W (see FIG. 10B).

  In this way, by performing the operation of lowering the upper die 30 unilaterally, after the workpiece W is continuously subjected to the bending process and the forming process in one stroke, the operation direction of the upper mold 30 is reversed. The mold 30 is raised and the workpiece W is taken out from the lower mold 31 (see FIG. 10C). And the board | plate material which thickened the edge part is obtained by cutting the edge part of the workpiece | work W picked out from the lower mold | type 31. FIG. Thus, if the second machining apparatus 2 ″ according to this modification is used, the first machining apparatus 1 can be omitted.

<Application example>
The metal part processing method according to the above-described embodiment and each modification can be applied when processing various metal parts. Examples of applicable objects include, for example, the end of a pressure plate of a brake pad of a disc brake, the end of a plate material such as a thin metal plate that needs reinforcement during use, and the end of a structural material of a building or various equipment. Etc.

FIG. 11 is an example of a diagram illustrating a brake pad manufactured by the metal part processing method according to the embodiment. FIG. 11A is a top view, and FIG. 11B is a cross-sectional view when the brake pad is cut along an alternate long and short dash line AA shown in FIG. By applying the metal part processing method according to the above embodiment to the production of the pressure plate of the brake pad, it is possible to produce a highly accurate pressure plate with thick edges and no twisting or bending force. It is. In addition, when the vehicle is braked, the brake pad receives a load from the support that supports the brake pad, which increases the thickness of the portion where the brake pad is dropped. It can be expected to reduce the surface pressure of the receiving part, improve the hardness of the end due to plastic deformation, improve the strength of the pressure plate and prevent wear due to the change in fiber flow.

  FIG. 12 is an example of a diagram illustrating a brake pad manufactured using the metal part machining method according to the first modification. 12A is a top view, and FIG. 12B is a cross-sectional view when the brake pad is cut along a dashed line BB shown in FIG. 12A. By applying the metal part processing method according to the first modification to the production of the pressure plate of the brake pad, no twisting or bending force is applied as in the pressure plate shown in FIG. It is possible to manufacture a pressure plate whose end portion is thicker than the pressure plate. In addition, when the vehicle is braked, the brake pad receives a load in the circumferential direction from the support that supports the brake pad, which further increases the thickness of the brake pad. A further decrease in the surface pressure of the part that receives the load from can be expected.

  In manufacturing the brake pad, the present invention is not limited to the above-described embodiment and the first modification. For example, the metal part machining method according to the second modification can be applied.

  FIG. 13 is an example of a diagram showing a modified example of the brake pad. FIG. 13A is a top view, and FIG. 13B is a cross-sectional view when the brake pad is cut along an alternate long and short dash line CC shown in FIG. 11 and 12 exemplify the pressure plate in which the portion receiving the load from the support protrudes on both sides. However, the metal part processing method according to the above-described embodiment and each modified example has such a brake pad. It does not apply only to the production of pressure plates. That is, for example, as shown in FIG. 13, even if the pressure plate has a depressed portion that receives a load from the support, the metal part processing method according to the embodiment or each modification is applied, and the load is applied from the support. It is possible to make the receiving part thick.

W ··· Work: 1 ·· First processing equipment: 11, 21, 30 ·· Upper die set: 12, 22 ·· Lower die set: 13 ·· Bending dies: 14, 24, 24 '·· Lower cushion Lower elastic body: 16, Bending punch: 2, 2 ', 2 ", Second processing device: 23, Molding die: 26, 32, Molding punch: 27, 33 Upper cushion: 28, 34, upper elastic body: 29, notched portion: 31, lower mold: 35, 37, concave portion: 36, pressing surface:

Claims (3)

A metal part processing method for thickening the end of a metal plate,
Bending process for bending the end of the plate material to either one of the front surface and the back surface of the plate material;
The side of the other surface that is the surface opposite to the one surface of the front surface and the back surface of the plate material is crushed by crushing the end portion of the plate material subjected to the bending treatment. and a molding process of lapping to,
In the molding process, the end of the plate is pressed against the bottom surface of the concave portion of the mold that is depressed so that the bent portion of the end of the plate that is bent in the bending process enters. , Raising the metal material to the other surface side,
Processing method of metal parts. In the processing method of the metal part, a predetermined end portion of the pressure plate of the brake pad is thickened where a circumferential load received by the brake pad from a support member supporting the brake pad is applied during braking of the vehicle. It is a processing method of metal parts,
In the bending process, the predetermined end is bent to one of the front and back surfaces of the pressure plate,
In the forming process, the predetermined end subjected to the bending process is crushed, and the metal material constituting the predetermined end is formed on the surface opposite to the one of the front and back surfaces of the pressure plate. To the other side,
The metal part processing method according to claim 1. A metal part processing apparatus for thickening the end of a metal plate,
Bending means for bending the end of the plate material to either one of the front surface and the back surface of the plate material;
The end portion of the plate member bent by the bending means is crushed, and the metal material constituting the end portion of the plate member is formed on the other surface which is the surface opposite to the one surface among the front surface and the back surface of the plate member. Forming means that moves toward the side ,
In the molding process, the end of the plate is pressed against the bottom surface of the concave portion of the mold that is depressed so that the bent portion of the end of the plate that is bent in the bending process enters. , Raising the metal material to the other surface side,
Metal parts processing equipment.

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