JP7167820B2 - Manufacturing method of circular material - Google Patents

Manufacturing method of circular material Download PDF

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JP7167820B2
JP7167820B2 JP2019067672A JP2019067672A JP7167820B2 JP 7167820 B2 JP7167820 B2 JP 7167820B2 JP 2019067672 A JP2019067672 A JP 2019067672A JP 2019067672 A JP2019067672 A JP 2019067672A JP 7167820 B2 JP7167820 B2 JP 7167820B2
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outer peripheral
mold
peripheral portion
lower mold
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JP2020163443A (en
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充弘 岡本
憲司 田村
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Nippon Steel Corp
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Description

本開示は、円形材の製造方法に関する。 FIELD OF THE DISCLOSURE The present disclosure relates to a method for manufacturing circular members.

鉄道用車輪、ギア、リング等といった円形材は、例えば、次のように製造される。初めに、ビレットを加熱する。加熱されたビレットに対して1回以上の鍛造を実施し、予成形材を成形する。予成形材に対して仕上げ圧延、仕上げ鍛造等を施し、予成形材を所定の外形及び寸法に成形する。その後、必要に応じて熱処理、機械加工等を実施して、円形材を得る。 Circular materials such as railway wheels, gears, rings, etc. are manufactured, for example, as follows. First, the billet is heated. One or more forgings are performed on the heated billet to form a preform. The preformed material is subjected to finish rolling, finish forging, and the like to form the preformed material into a predetermined outer shape and dimensions. Thereafter, heat treatment, machining, etc. are performed as necessary to obtain a circular material.

例えば、特許文献1は、エアコン用コンプレッサのスクロール部品である円形材の製造方法を開示する。この方法では、アルミニウム合金丸棒を据え込み加工して予成形材を成形し、パンチ及びダイスを用いてこの予成形材を鍛造する。予成形材は、パンチにより、スクロール部品の羽根部を成形するためのダイス空間に押し込まれる。予成形材において羽根部が成長している途中で、この羽根部に対し、成長方向と反対方向の背圧が付与される。 For example, Patent Literature 1 discloses a method of manufacturing a circular member that is a scroll component of an air conditioner compressor. In this method, a preformed material is formed by upsetting an aluminum alloy round bar, and this preformed material is forged using a punch and a die. The preformed material is forced by a punch into a die space for forming the vanes of the scroll component. Back pressure in the direction opposite to the growth direction is applied to the blade portion while the blade portion is growing in the preformed material.

国際公開第01/77398号WO 01/77398

ところで、円形材の一種として、薄肉の湾曲円板部と、厚肉の外周部とを有するものが知られている。このような円形材は、上型及び下型からなる金型を用い、予成形材に曲げ加工を施すことで成形される。具体的には、予成形材の平坦な円板部を下型で支持し、予成形材を上型で圧下することで、円板部を曲げる。 By the way, as one type of circular member, one having a thin curved disc portion and a thick outer peripheral portion is known. Such a circular member is formed by bending a preformed member using a mold consisting of an upper mold and a lower mold. Specifically, a flat disc portion of the preform is supported by a lower die, and the preform is pressed down by an upper die to bend the disc portion.

しかしながら、円板部を曲げる際、予成形材の外周部近傍の材料が半径方向外側かつ下方に向かって流動する。そのため、外周部が下型から半径方向外側に向かって離れやすく、外周部において欠肉が生じやすい。 However, when the disc portion is bent, the material near the outer periphery of the preform flows radially outward and downward. Therefore, the outer peripheral portion tends to separate radially outward from the lower mold, and the outer peripheral portion tends to be underfilled.

本開示は、欠肉を抑制することができる円形材の製造方法を提供することを課題とする。 An object of the present disclosure is to provide a method for manufacturing a circular material that can suppress underfill.

本開示に係る円形材の製造方法は、準備工程と、鍛造工程と、を備える。準備工程では、円板部と、円板部の外周縁に接続され、円板部よりも厚肉である外周部と、を含む予成形材を準備する。鍛造工程では、上型と、第1及び第2下型と、を含む金型によって予成形材を鍛造する。鍛造工程は、拘束工程と、曲げ工程と、を含む。拘束工程では、円板部を第1下型上に載置するとともに、外周部を第2下型に対向させた状態で上型を下降させ、外周部を第2下型及び上型で挟む。曲げ工程では、拘束工程後、上型をさらに下降させて下死点に到達させ、上型及び第1下型によって予成形材の円板部を曲げる。 A method for manufacturing a circular member according to the present disclosure includes a preparation process and a forging process. In the preparation step, a preform is prepared that includes a disk portion and an outer peripheral portion that is connected to the outer peripheral edge of the disk portion and is thicker than the disk portion. In the forging process, the preformed material is forged with a die including an upper die and first and second lower dies. The forging process includes a restraining process and a bending process. In the constraining step, the disk portion is placed on the first lower mold, and the upper mold is lowered with the outer peripheral portion facing the second lower mold, and the outer peripheral portion is sandwiched between the second lower mold and the upper mold. . In the bending step, after the restraining step, the upper die is further lowered to reach the bottom dead center, and the disk portion of the preform is bent by the upper die and the first lower die.

本開示に係る円形材の製造方法によれば、欠肉を抑制することができる。 According to the method for manufacturing a circular member according to the present disclosure, underfill can be suppressed.

図1は、実施形態に係る製造方法で製造される円形材の縦断面図である。FIG. 1 is a vertical cross-sectional view of a circular member manufactured by a manufacturing method according to an embodiment. 図2は、図1に示す円形材の素材となる予成形材の縦断面図である。FIG. 2 is a vertical cross-sectional view of a preform that is a raw material for the circular member shown in FIG. 図3は、実施形態に係る製造方法の鍛造工程で用いられる金型の1/2鉛直断面図である。FIG. 3 is a 1/2 vertical sectional view of a die used in the forging process of the manufacturing method according to the embodiment. 図4は、鍛造工程を説明するための模式図である。FIG. 4 is a schematic diagram for explaining the forging process. 図5は、鍛造工程を説明するための模式図である。FIG. 5 is a schematic diagram for explaining the forging process. 図6は、鍛造工程を説明するための模式図である。FIG. 6 is a schematic diagram for explaining the forging process. 図7は、鍛造工程を説明するための模式図である。FIG. 7 is a schematic diagram for explaining the forging process. 図8は、他の実施形態に係る製造方法の鍛造工程を説明するための模式図である。FIG. 8 is a schematic diagram for explaining a forging step of a manufacturing method according to another embodiment. 図9は、一般的な方法で円形材を製造する場合を説明するための模式図である。FIG. 9 is a schematic diagram for explaining a case of manufacturing a circular material by a general method.

実施形態に係る円形材の製造方法は、準備工程と、鍛造工程と、を備える。準備工程では、円板部と、円板部の外周縁に接続され、円板部よりも厚肉である外周部と、を含む予成形材を準備する。鍛造工程では、上型と、第1及び第2下型と、を含む金型によって予成形材を鍛造する。鍛造工程は、拘束工程と、曲げ工程と、を含む。拘束工程では、円板部を第1下型上に載置するとともに、外周部を第2下型に対向させた状態で上型を下降させ、外周部を第2下型及び上型で挟む。曲げ工程では、拘束工程後、上型をさらに下降させて下死点に到達させ、上型及び第1下型によって予成形材の円板部を曲げる(第1の構成)。 A method for manufacturing a circular member according to an embodiment includes a preparation step and a forging step. In the preparation step, a preform is prepared that includes a disk portion and an outer peripheral portion that is connected to the outer peripheral edge of the disk portion and is thicker than the disk portion. In the forging process, the preformed material is forged with a die including an upper die and first and second lower dies. The forging process includes a restraining process and a bending process. In the constraining step, the disk portion is placed on the first lower mold, and the upper mold is lowered with the outer peripheral portion facing the second lower mold, and the outer peripheral portion is sandwiched between the second lower mold and the upper mold. . In the bending step, after the restraining step, the upper die is further lowered to reach the bottom dead center, and the disk portion of the preform is bent by the upper die and the first lower die (first configuration).

第1の構成に係る円形材の製造方法では、上型及び第1下型によって予成形材の円板部が曲げられる間、予成形材の外周部が上型及び第2下型で挟まれて拘束されている。これにより、予成形材の鍛造中、半径方向外側への材料の流動が規制され、外周部を第1下型に沿わせることができる。よって、外周部における欠肉を抑制することができる。 In the method for manufacturing a circular member according to the first configuration, while the disk portion of the preformed member is bent by the upper die and the first lower die, the outer peripheral portion of the preformed member is sandwiched between the upper die and the second lower die. are constrained by As a result, the radially outward flow of the material is restricted during the forging of the preformed material, and the outer peripheral portion can be made to conform to the first lower die. Therefore, the lack of thickness in the outer peripheral portion can be suppressed.

上記の円形材の製造方法において、金型はさらに、第2下型を上方に向かって付勢する弾性部材を含んでいてもよい(第2の構成)。 In the above method for manufacturing a circular member, the mold may further include an elastic member that biases the second lower mold upward (second configuration).

第2の構成によれば、弾性部材の作用により、第2下型が外周部を下方から加圧するため、上型及び第2下型によって外周部をより強固に拘束することができる。よって、材料がより流動しにくくなり、外周部における欠肉をさらに抑制することができる。 According to the second configuration, due to the action of the elastic member, the second lower die presses the outer peripheral portion from below, so that the outer peripheral portion can be more firmly restrained by the upper die and the second lower die. Therefore, the material becomes more difficult to flow, and the lack of thickness in the outer peripheral portion can be further suppressed.

第1の構成において、金型はさらに、第2下型を上下方向に移動させる駆動装置を含んでいてもよい(第3の構成)。 In the first configuration, the mold may further include a driving device for vertically moving the second lower mold (third configuration).

第3の構成によれば、駆動装置を制御して第2下型を上下動させることで、上型及び第2下型によって外周部を拘束する力及びタイミングを任意に設定することができる。 According to the third configuration, by controlling the driving device to move the second lower mold up and down, it is possible to arbitrarily set the force and timing with which the outer peripheral portion is restrained by the upper mold and the second lower mold.

以下、図面を参照して本開示の実施の形態を詳しく説明する。図中同一又は相当部分には同一符号を付してその説明は繰り返さない。 Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. The same reference numerals are given to the same or corresponding parts in the drawings, and the description thereof will not be repeated.

[円形材の構成]
図1を参照して、まず、本実施形態に係る製造方法によって製造される円形材1について説明する。図1は、円形材1の縦断面図である。縦断面とは、円形材1の中心軸A1を含む平面で切断した断面をいう。円形材1において、中心軸A1が延びる方向は軸方向又は厚み方向であり、中心軸A1に垂直な方向は半径方向である。
[Configuration of circular material]
First, a circular member 1 manufactured by the manufacturing method according to the present embodiment will be described with reference to FIG. FIG. 1 is a longitudinal sectional view of a circular member 1. FIG. A vertical section refers to a section cut along a plane including the central axis A1 of the circular member 1 . In the circular member 1, the direction in which the central axis A1 extends is the axial direction or the thickness direction, and the direction perpendicular to the central axis A1 is the radial direction.

図1に示すように、円形材1は、湾曲円板部11と、外周部12と、を含む。 As shown in FIG. 1 , the circular member 1 includes a curved disc portion 11 and an outer peripheral portion 12 .

円形材1の軸方向視で、湾曲円板部11の外形は実質的に円形である。湾曲円板部11は、円環板状であってもよいし、孔なしの円板状であってもよい。本実施形態では、湾曲円板部11は、孔なしの円板状である。円形材1の縦断面視では、湾曲円板部11は、湾曲形状を有する。具体的には、湾曲円板部11のうち半径方向の中央部分が軸方向の一方側に隆起している。 When viewed in the axial direction of the circular member 1, the outer shape of the curved disc portion 11 is substantially circular. The curved disk portion 11 may be in the shape of an annular disk, or may be in the shape of a disk without holes. In this embodiment, the curved disk portion 11 is a disk-like shape without holes. In a vertical cross-sectional view of the circular member 1, the curved disc portion 11 has a curved shape. Specifically, the central portion in the radial direction of the curved disk portion 11 protrudes toward one side in the axial direction.

本実施形態において、湾曲円板部11は、全体にわたり、概ね一定の厚みを有する。ただし、湾曲円板部11では、他の部分と比較して厚みが大きい部分が存在してもよい。例えば、湾曲円板部11が円環板状の場合、湾曲円板部11の内周部分を他の部分よりも厚肉とすることができる。 In this embodiment, the curved disc portion 11 has a substantially constant thickness over its entirety. However, the curved disc portion 11 may have a portion that is thicker than other portions. For example, when the curved disc portion 11 is in the shape of an annular disc, the inner peripheral portion of the curved disc portion 11 can be made thicker than the other portions.

外周部12は、湾曲円板部11を取り囲む。外周部12は、湾曲円板部11の外周縁111に接続されている。外周部12は、湾曲円板部11よりも厚肉である。外周部12の厚みは、少なくとも、湾曲円板部11の外周縁111の厚みよりも大きい。そのため、円形材1において、外周部12は、湾曲円板部11の外周縁111から厚み方向の両側に突出している。 The outer peripheral portion 12 surrounds the curved disc portion 11 . The outer peripheral portion 12 is connected to the outer peripheral edge 111 of the curved disc portion 11 . The outer peripheral portion 12 is thicker than the curved disc portion 11 . The thickness of the outer peripheral portion 12 is at least greater than the thickness of the outer peripheral edge 111 of the curved disk portion 11 . Therefore, in the circular member 1 , the outer peripheral portion 12 protrudes from the outer peripheral edge 111 of the curved disk portion 11 to both sides in the thickness direction.

[円形材の製造方法]
次に、円形材1の製造方法について説明する。本実施形態に係る円形材1の製造方法は、準備工程と、鍛造工程と、を含む。
[Manufacturing method of circular material]
Next, a method for manufacturing the circular member 1 will be described. The manufacturing method of the circular member 1 according to this embodiment includes a preparation process and a forging process.

(準備工程)
図2を参照して、準備工程では、円形材1(図1)の素材となる予成形材2を準備する。図2は、予成形材2の縦断面図である。ここでの縦断面とは、予成形材2の中心軸A2を含む平面で切断した断面をいう。予成形材2において、中心軸A2が延びる方向は軸方向又は厚み方向であり、中心軸A2に垂直な方向は半径方向である。
(Preparation process)
With reference to FIG. 2, in the preparation step, a preformed material 2 as a material for circular material 1 (FIG. 1) is prepared. FIG. 2 is a longitudinal sectional view of the preform 2. As shown in FIG. The vertical section here refers to a section cut along a plane including the central axis A2 of the preform 2 . In the preformed material 2, the direction in which the central axis A2 extends is the axial direction or the thickness direction, and the direction perpendicular to the central axis A2 is the radial direction.

予成形材2は、例えば、鋼からなるビレットに対し、1回以上の鍛造を実施して得ることができる。予成形材2は、円板部21と、外周部22と、を含む。 The preformed material 2 can be obtained, for example, by forging a steel billet one or more times. The preformed material 2 includes a disc portion 21 and an outer peripheral portion 22 .

円板部21は、円形材1の湾曲円板部11(図1)に対応する部分であり、湾曲円板部11と同様、予成形材2の軸方向視で実質的に円形の外形を有する。ただし、円板部21は、湾曲しておらず、概ね平板状である。 The disc portion 21 is a portion corresponding to the curved disc portion 11 ( FIG. 1 ) of the circular member 1 , and, like the curved disc portion 11 , has a substantially circular outer shape when viewed in the axial direction of the preformed member 2 . have. However, the disc portion 21 is not curved and is generally flat.

円板部21の厚みは、円形材1の湾曲円板部11(図1)に対応して、全体にわたって概ね一定である。円形材1の湾曲円板部11が厚肉の内周部分を有する場合、予成形材2の円板部21の内周部分も円板部21の他の部分よりも厚肉となる。 The thickness of the disc portion 21 is generally constant throughout, corresponding to the curved disc portion 11 (FIG. 1) of the circular member 1 . When the curved disc portion 11 of the circular member 1 has a thick inner peripheral portion, the inner peripheral portion of the disc portion 21 of the preformed member 2 is also thicker than the other portions of the disc portion 21 .

円板部21は、外周縁211を有する。外周縁211には外周部22が接続される。外周部22は、円板部21を取り囲む。外周部22は、円形材1の外周部12(図1)に対応する部分である。 The disc portion 21 has an outer peripheral edge 211 . The outer peripheral portion 22 is connected to the outer peripheral edge 211 . The outer peripheral portion 22 surrounds the disk portion 21 . The outer peripheral portion 22 is a portion corresponding to the outer peripheral portion 12 ( FIG. 1 ) of the circular member 1 .

外周部22は、円板部21よりも厚肉である。外周部22は、予成形材2の縦断面視で、円板部21よりも厚み方向の一方側及び他方側に突出する。すなわち、予成形材2は概略H形状の縦断面を有している。 The outer peripheral portion 22 is thicker than the disc portion 21 . The outer peripheral portion 22 protrudes from the disk portion 21 to one side and the other side in the thickness direction in a vertical cross-sectional view of the preform member 2 . That is, the preform 2 has a substantially H-shaped longitudinal section.

(鍛造工程)
鍛造工程では、準備した予成形材2を鍛造する。
(Forging process)
In the forging process, the prepared preformed material 2 is forged.

鍛造工程では、図3に示す金型3が用いられる。図3は、金型3の1/2鉛直断面図を示す。まず、金型3について説明する。 A die 3 shown in FIG. 3 is used in the forging process. FIG. 3 shows a 1/2 vertical sectional view of the mold 3. FIG. First, the mold 3 will be explained.

図3を参照して、金型3は、公知のプレス機(図示略)に取り付けられる。金型3は、上型31と、第1下型32と、第2下型33と、を含む。金型3は、さらに、弾性部材34を含む。 Referring to FIG. 3, mold 3 is attached to a known press (not shown). The mold 3 includes an upper mold 31 , a first lower mold 32 and a second lower mold 33 . Mold 3 further includes an elastic member 34 .

上型31は、図示しないプレス機のラムに取り付けられ、鉛直方向に移動可能である。上型31は、予成形材2を上方から圧下する。上型31の下面には、凸部311と、平坦部312と、が設けられる。凸部311は、平坦部312よりも下方に突出している。凸部311は、円形材1の湾曲円板部11(図1)に対応する形状を有する。すなわち、凸部311は、湾曲円板部11の軸方向の一方面に相当する湾曲形状を有する。平坦部312は、凸部311の周囲に設けられる。平坦部312は、凸部311の外周縁に接続される。平坦部312は、凸部311の外周縁から概ね水平に延びている。 The upper die 31 is attached to a ram of a press (not shown) and is vertically movable. The upper die 31 presses down the preformed material 2 from above. A convex portion 311 and a flat portion 312 are provided on the lower surface of the upper mold 31 . The convex portion 311 protrudes downward from the flat portion 312 . The convex portion 311 has a shape corresponding to the curved disk portion 11 ( FIG. 1 ) of the circular member 1 . That is, the convex portion 311 has a curved shape corresponding to one surface of the curved disk portion 11 in the axial direction. The flat portion 312 is provided around the convex portion 311 . The flat portion 312 is connected to the outer peripheral edge of the convex portion 311 . The flat portion 312 extends substantially horizontally from the outer peripheral edge of the convex portion 311 .

第1下型32は、本体部321と、フランジ部322と、を含む。本体部321の上面321aは、上型31の凸部311に対向する。上面321aは、上型31の凸部311とともに円形材1の湾曲円板部11(図1)を成形する加工面であり、湾曲円板部11に対応する形状を有する。すなわち、上面321aは、湾曲円板部11の軸方向の他方面に相当する湾曲形状を有する。 The first lower mold 32 includes a body portion 321 and a flange portion 322 . An upper surface 321 a of the body portion 321 faces the convex portion 311 of the upper mold 31 . The upper surface 321 a is a processing surface for forming the curved disc portion 11 ( FIG. 1 ) of the circular member 1 together with the convex portion 311 of the upper mold 31 , and has a shape corresponding to the curved disc portion 11 . That is, the upper surface 321a has a curved shape corresponding to the other surface of the curved disk portion 11 in the axial direction.

フランジ部322は、本体部321の周囲に設けられる。フランジ部322は、本体部321から、その外周側に突出する。フランジ部322は、本体部321の下部に接続されている。 The flange portion 322 is provided around the body portion 321 . The flange portion 322 protrudes from the body portion 321 to the outer peripheral side thereof. The flange portion 322 is connected to the lower portion of the body portion 321 .

第2下型33は、第1下型32の本体部321の周囲に設けられ、上型31の平坦部312と対向する。第2下型33は、第1下型32のフランジ部322の上方に位置付けられる。第2下型33は、弾性部材34を介し、フランジ部322によって支持されている。 The second lower mold 33 is provided around the body portion 321 of the first lower mold 32 and faces the flat portion 312 of the upper mold 31 . The second lower mold 33 is positioned above the flange portion 322 of the first lower mold 32 . The second lower mold 33 is supported by the flange portion 322 via the elastic member 34 .

弾性部材34の下端部は、第1下型32のフランジ部322に接続される。弾性部材34の上端部は、第2下型33に接続されている。弾性部材34は、第2下型33を上方に向かって付勢する。弾性部材34の付勢力は、上型31の圧下力よりも弱くなるように設定される。弾性部材34は、例えば、ばね、油圧ダンパである。 A lower end portion of the elastic member 34 is connected to the flange portion 322 of the first lower mold 32 . An upper end portion of the elastic member 34 is connected to the second lower mold 33 . The elastic member 34 biases the second lower mold 33 upward. The biasing force of the elastic member 34 is set to be weaker than the pressing force of the upper die 31 . The elastic member 34 is, for example, a spring or a hydraulic damper.

次に、図4~図7を参照して、金型3によって予成形材2を鍛造する工程について説明する。図4~図7は、予成形材2の鍛造工程を説明するための模式図である。鍛造工程は、予成形材2の外周部22を拘束する拘束工程と、予成形材2の円板部21を曲げる曲げ工程と、を含む。 Next, the process of forging the preformed material 2 with the die 3 will be described with reference to FIGS. 4 to 7. FIG. 4 to 7 are schematic diagrams for explaining the forging process of the preformed material 2. FIG. The forging process includes a restraining process of restraining the outer peripheral portion 22 of the preformed material 2 and a bending process of bending the disc portion 21 of the preformed material 2 .

図4を参照して、拘束工程では、初めに予成形材2の円板部21を第1下型32上に載置する。より具体的には、円板部21の中央部分を第1下型32の本体部321上に載置する。この際、円板部21の外周部分は、本体部321の上面321aに接触しない。また、予成形材2の外周部22は、第2下型33と接触せずに対向している。 Referring to FIG. 4 , in the restraining step, first, disk portion 21 of preform 2 is placed on first lower mold 32 . More specifically, the central portion of the disc portion 21 is placed on the body portion 321 of the first lower mold 32 . At this time, the outer peripheral portion of the disc portion 21 does not come into contact with the upper surface 321a of the body portion 321 . In addition, the outer peripheral portion 22 of the preformed material 2 faces the second lower mold 33 without contacting it.

この状態から上型31を下降させると、図5に示すように、凸部311が予成形材2に接触する。より詳細には、予成形材2の円板部21のうち第1下型32に接触していない外周部分に、凸部311が上方から接触する。これにより、円板部21の外周部分が下方に移動するとともに、外周部22も下方に移動する。すなわち、円板部21及び外周部22が上型31によって圧下される。 When the upper die 31 is lowered from this state, the projections 311 come into contact with the preformed material 2 as shown in FIG. More specifically, the protruding portion 311 contacts the outer peripheral portion of the disk portion 21 of the preform 2 that is not in contact with the first lower mold 32 from above. As a result, the outer peripheral portion of the disk portion 21 moves downward, and the outer peripheral portion 22 also moves downward. That is, the disc portion 21 and the outer peripheral portion 22 are pushed down by the upper die 31 .

予成形材2の外周部22は、所定の距離下降した時点で第2下型33と接触する。第2下型33は弾性部材34により上方に向けて付勢されているため、外周部22が第2下型33に到達した後、外周部22の下降速度は低下する。外周部22の下降が第2下型33によって妨げられる一方、上型31は速度を緩めずに下降し続ける。その結果、図6に示すように、上型31の平坦部312が外周部22に接触し、外周部22が第2下型33及び平坦部312によって挟まれる。これにより、拘束工程が完了する。 The outer peripheral portion 22 of the preformed material 2 comes into contact with the second lower mold 33 when it descends by a predetermined distance. Since the second lower mold 33 is urged upward by the elastic member 34, after the outer peripheral part 22 reaches the second lower mold 33, the lowering speed of the outer peripheral part 22 decreases. While the lowering of the outer peripheral portion 22 is prevented by the second lower mold 33, the upper mold 31 continues to descend without slowing down. As a result, as shown in FIG. 6 , the flat portion 312 of the upper mold 31 contacts the outer peripheral portion 22 and the outer peripheral portion 22 is sandwiched between the second lower mold 33 and the flat portion 312 . This completes the restraining process.

拘束工程の完了後、曲げ工程を実施する。曲げ工程では、上型31をさらに下降させ、円板部21を曲げる。この際、外周部22は、第2下型33及び上型31で挟まれて拘束された状態となっている。この状態のまま、図7に示すように、上型31を下降させて下死点まで到達させると、円板部21の外周部分が第1下型32の本体部321に接触し、上型31及び第1下型32によって円板部21が狙いの湾曲形状に成形される。これにより、図7に示すように、曲げ工程が完了し、円形材1が得られる。 After completion of the restraining process, a bending process is performed. In the bending step, the upper die 31 is further lowered to bend the disc portion 21 . At this time, the outer peripheral portion 22 is sandwiched and restrained between the second lower mold 33 and the upper mold 31 . In this state, as shown in FIG. 7, when the upper die 31 is lowered to reach the bottom dead center, the outer peripheral portion of the disc portion 21 contacts the main body portion 321 of the first lower die 32, and the upper die 31 and the first lower mold 32 form the disk portion 21 into a desired curved shape. Thereby, as shown in FIG. 7, the bending process is completed and the circular material 1 is obtained.

[効果]
一般的な方法で円形材1を製造する場合、例えば図9に示すように、上型31と、下型92と、を含む金型9で予成形材2の円板部21に曲げ加工を施す。このとき、外周部22が下型92に未達の状態で円板部21の曲げ加工が開始されるため、外周部22の材料が予成形材2の半径方向外側かつ下方に向かって流動する。そのため、外周部22の内径が拡大し、半径方向において外周部22と下型92との間に隙間Sが生じる。その結果、製造された円形材1の外周部12に欠肉が生じやすい。これに対し、本実施形態の円形材1の製造方法では、外周部22を上型31及び第2下型33で拘束した状態で円板部21を曲げる。そのため、材料の半径方向外側への流動が抑制され、半径方向において外周部22と第1下型32との間に隙間が生じにくい。よって、製造された円形材1の外周部12における欠肉を抑制することができる。
[effect]
When manufacturing the circular material 1 by a general method, for example, as shown in FIG. Apply. At this time, since the bending of the disk portion 21 is started before the outer peripheral portion 22 reaches the lower mold 92, the material of the outer peripheral portion 22 flows radially outward and downward of the preformed material 2. . Therefore, the inner diameter of the outer peripheral portion 22 is enlarged, and a gap S is generated between the outer peripheral portion 22 and the lower die 92 in the radial direction. As a result, the outer peripheral portion 12 of the manufactured circular member 1 tends to be underfilled. In contrast, in the method of manufacturing the circular member 1 of the present embodiment, the disc portion 21 is bent while the outer peripheral portion 22 is constrained by the upper mold 31 and the second lower mold 33 . Therefore, the radially outward flow of the material is suppressed, and a gap is less likely to occur between the outer peripheral portion 22 and the first lower mold 32 in the radial direction. Therefore, it is possible to suppress the lack of thickness in the outer peripheral portion 12 of the manufactured circular member 1 .

円形材1の外周部12に欠肉が生じる可能性がある場合、一般に、この欠肉を補うことが可能な程度の余肉を、素材である予成形材2の外周部22に設けておく必要がある。そのため、予成形材2に投入する材料の重量が増加し、歩留りが低下する。また、予成形材2から製造された円形材1において、機械加工等によって除去すべき余剰な材料が増えるため、加工負荷が増大する。さらに、予成形材2の円板部21を金型9で圧下すると外周部22が半径方向外側に押し出されるため、外周部22では半径方向内側又は厚み方向に余肉を持たせる必要がある。予成形材2の外周部22において半径方向内側に余肉を持たせた場合、加工中に外周部22が金型9とこすれて円形材1に疵が生じる可能性がある。外周部22において厚み方向に余肉を持たせた場合も、上型31が下死点に到達した際に外周部22が座屈し、やはり円形材1に疵が発生する可能性がある。 When there is a possibility that the outer peripheral portion 12 of the circular member 1 may be insufficiently thick, generally, the outer peripheral portion 22 of the preformed member 2, which is the raw material, is provided with excess thickness to compensate for the insufficient thickness. There is a need. Therefore, the weight of the material put into the preformed material 2 increases, and the yield decreases. Moreover, in the circular member 1 manufactured from the preformed member 2, the excess material to be removed by machining or the like increases, so the processing load increases. Furthermore, when the disk portion 21 of the preformed material 2 is pressed down by the die 9, the outer peripheral portion 22 is pushed out radially outward, so the outer peripheral portion 22 needs to have excess thickness radially inward or in the thickness direction. If the outer peripheral portion 22 of the preformed material 2 has excess thickness on the inner side in the radial direction, the outer peripheral portion 22 may rub against the mold 9 during processing, and the circular material 1 may be damaged. Even if the outer peripheral portion 22 has extra thickness in the thickness direction, the outer peripheral portion 22 may buckle when the upper die 31 reaches the bottom dead center, and the circular material 1 may be damaged.

これに対し、本実施形態の円形材1の製造方法では、円形材1の外周部12の欠肉が抑制されるため、予成形材2の外周部22に不必要に余肉を設ける必要がない。よって、予成形材2に投入する材料の重量を低減させることができ、歩留りを向上させることができる。また、円形材1の余剰な材料を除去するための機械加工等を不要又は最小限とすることができるため、加工負荷を低減させることができる。さらに、予成形材2の余肉に起因して発生する円形材1の疵を抑制することができる。 On the other hand, in the method for manufacturing the circular member 1 of the present embodiment, the outer peripheral portion 12 of the circular member 1 is suppressed from being underfilled, so it is unnecessary to provide excess thickness to the outer peripheral portion 22 of the preformed member 2. do not have. Therefore, it is possible to reduce the weight of the material put into the preformed material 2 and improve the yield. In addition, since machining or the like for removing excess material from the circular member 1 can be eliminated or minimized, the processing load can be reduced. Furthermore, scratches on the circular member 1 caused by excess thickness of the preformed member 2 can be suppressed.

本実施形態の円形材1の製造方法では、弾性部材34が第2下型33を上方に向かって付勢する。そのため、第2下型33及び上型31によって外周部22を強固に挟むことができ、円板部21の曲げ加工中における材料の流動がさらに抑制される。よって、外周部22における欠肉をさらに抑制することができる。 In the method of manufacturing the circular member 1 of this embodiment, the elastic member 34 urges the second lower mold 33 upward. Therefore, the outer peripheral portion 22 can be firmly sandwiched between the second lower mold 33 and the upper mold 31, and the flow of the material during the bending of the disc portion 21 is further suppressed. Therefore, the lack of thickness in the outer peripheral portion 22 can be further suppressed.

また、上型31の凸部311が円板部21を圧下する場合、外周部22の下面が外周側に向かって反りやすい。弾性部材34によって第2下型33を上方に付勢することで、外周部22が第2下型33から受ける垂直抗力が増大し、外周部22の下面と第2下型33との間の摩擦力が大きくなる。この摩擦力により、外周部22の下面が外側に向かって反りにくくなる。よって、外周部22の内径が拡大しにくくなり、外周部22における欠肉をさらに抑制することができる。 Further, when the convex portion 311 of the upper die 31 presses down the disk portion 21, the lower surface of the outer peripheral portion 22 tends to warp toward the outer peripheral side. By urging the second lower mold 33 upward by the elastic member 34 , the normal force that the outer peripheral portion 22 receives from the second lower mold 33 increases, and the force between the lower surface of the outer peripheral portion 22 and the second lower mold 33 increases. Friction increases. This frictional force prevents the lower surface of the outer peripheral portion 22 from warping outward. Therefore, it becomes difficult for the inner diameter of the outer peripheral portion 22 to expand, and the lack of thickness in the outer peripheral portion 22 can be further suppressed.

以上、本実施形態の円形材の製造方法について説明した。その他、本開示は上記の実施形態に限定されず、本開示の趣旨を逸脱しない範囲で、種々の変更が可能であることは言うまでもない。 The method for manufacturing the circular member according to the present embodiment has been described above. In addition, the present disclosure is not limited to the above embodiments, and it goes without saying that various modifications are possible without departing from the scope of the present disclosure.

例えば、上記の実施形態では、拘束工程において、第2下型33が上型31よりも先に予成形材2の外周部22と接触する場合について説明した。しかしながら、上型31が第2下型33よりも先に外周部22と接触してもよい。要するに、上型31が下死点に到達する前に外周部22が上型31及び第2下型33によって挟まれればよく、上型31及び第2下型33が外周部22と接触する順序は問わない。 For example, in the embodiment described above, the second lower mold 33 contacts the outer peripheral portion 22 of the preform 2 before the upper mold 31 in the restraining step. However, the upper die 31 may contact the outer peripheral portion 22 before the second lower die 33 . In short, it is sufficient that the outer peripheral portion 22 is sandwiched between the upper die 31 and the second lower die 33 before the upper die 31 reaches the bottom dead center. does not matter.

上記の実施形態では、金型3が弾性部材34を含む場合について説明した。しかしながら、金型3は、図8に示すように、弾性部材34に代えて駆動装置35を含んでいてもよい。駆動装置35の上端部は、第2下型33に接続される。駆動装置35の下端部は、第1下型32のフランジ部322に接続されていてもよいし、ボルスタプレート(図示略)に接続されていてもよい。駆動装置35は、油圧制御により伸縮可能に構成されている。駆動装置35は、例えば、油圧シリンダである。 In the above embodiment, the case where the mold 3 includes the elastic member 34 has been described. However, the mold 3 may include a driving device 35 instead of the elastic member 34, as shown in FIG. The upper end of the driving device 35 is connected to the second lower mold 33 . A lower end portion of the driving device 35 may be connected to the flange portion 322 of the first lower mold 32 or may be connected to a bolster plate (not shown). The driving device 35 is configured to be extendable and retractable by hydraulic control. The drive device 35 is, for example, a hydraulic cylinder.

このような構成の金型3により、駆動装置35は第2下型33を上下方向に自在に移動させることができる。よって、鍛造中に上型31及び第2下型33によって外周部22を拘束する力を任意に設定することができ、かつ、第2下型33を任意のタイミングで予成形材2の外周部22に接触させることができる。 With the mold 3 having such a configuration, the driving device 35 can freely move the second lower mold 33 in the vertical direction. Therefore, the force for restraining the outer peripheral portion 22 by the upper die 31 and the second lower die 33 can be arbitrarily set during forging, and the second lower die 33 can be applied to the outer peripheral portion of the preformed material 2 at an arbitrary timing. 22 can be contacted.

例えば、予成形材2を第1下型32に載置し、駆動装置35を伸長させれば、上型31よりも先に第2下型33を外周部22に接触させることができる。あるいは、第2下型33が上型31と同時に外周部22に接触するように駆動装置35を伸長制御してもよい。また、上記の実施形態と同様、第2下型33が上型31よりも後に外周部22に接触するように駆動装置35を伸長制御することもできる。第2下型33が外周部22に接触した後、この第2下型33と上型31とで外周部22を拘束した状態で、上型31の下降速度に応じて駆動装置35を縮退させながら、上型31を下死点に到達させる。これにより、上型31及び第1下型32によって予成形材2の円板部21を曲げることができる。 For example, by placing the preform 2 on the first lower mold 32 and extending the driving device 35 , the second lower mold 33 can be brought into contact with the outer peripheral portion 22 before the upper mold 31 . Alternatively, the driving device 35 may be controlled to extend so that the second lower mold 33 contacts the outer peripheral portion 22 at the same time as the upper mold 31 . Further, as in the above embodiment, the drive device 35 can be controlled to extend so that the second lower mold 33 comes into contact with the outer peripheral portion 22 after the upper mold 31 does. After the second lower mold 33 contacts the outer peripheral portion 22, the driving device 35 is retracted according to the lowering speed of the upper mold 31 while the outer peripheral portion 22 is constrained by the second lower mold 33 and the upper mold 31. while the upper die 31 reaches the bottom dead center. Thereby, the disc portion 21 of the preform 2 can be bent by the upper mold 31 and the first lower mold 32 .

上記の実施形態に係る製造方法において、鍛造工程で得られる円形材は、仕上げ鍛造品であってもよいし、鍛造荒地であってもよい。円形材が鍛造荒地である場合、この円形材は、仕上げ鍛造、機械加工等を経て最終製品となる。 In the manufacturing method according to the above embodiment, the circular material obtained in the forging process may be a finish forged product or a rough forged product. If the circular material is a rough forged material, this circular material becomes the final product through finish forging, machining, and the like.

円形材を成形する鍛造工程は、熱間で実施されてもよいし、冷間で実施されてもよい。鍛造工程を熱間で実施する場合、鍛造工程の前に予成形材を所定の温度に加熱すればよい。 The forging process for forming the circular material may be performed hot or cold. When the forging process is performed hot, the preformed material may be heated to a predetermined temperature before the forging process.

1:円形材
11:湾曲円板部
111:外周縁
12:外周部
2:予成形材
21:円板部
211:円板部の外周縁
22:外周部
3:金型
31:上型
32:第1下型
33:第2下型
34:弾性部材
35:駆動装置
1: Circular Material 11: Curved Disk Part 111: Peripheral Edge 12: Peripheral Part 2: Preformed Material 21: Disk Part 211: Peripheral Edge of Disk Part 22: Peripheral Part 3: Mold 31: Upper Mold 32: First lower mold 33: Second lower mold 34: Elastic member 35: Driving device

Claims (3)

円形材の製造方法であって、
円板部と、
前記円板部の外周縁に接続され、前記円板部よりも厚肉である外周部と、を含む予成形材を準備する準備工程と、
上型と、第1及び第2下型と、を含む金型によって前記予成形材を鍛造する鍛造工程と、を備え、
前記鍛造工程は、
前記円板部を前記第1下型上に載置するとともに、前記外周部を前記第2下型に対向させた状態で前記上型を下降させ、前記外周部を第2下型及び前記上型で挟む拘束工程と、
前記拘束工程後、前記上型をさらに下降させて下死点に到達させ、前記上型及び前記第1下型によって前記予成形材の前記円板部を曲げる曲げ工程と、を含む、円形材の製造方法。
A method for manufacturing a circular member, comprising:
a disk portion;
A preparation step of preparing a preformed material including an outer peripheral portion connected to the outer peripheral edge of the disc portion and having a thickness greater than that of the disc portion;
a forging step of forging the preformed material with a mold including an upper mold and first and second lower molds,
The forging process includes
The disk portion is placed on the first lower mold, and the upper mold is lowered while the outer peripheral portion is opposed to the second lower mold, and the outer peripheral portion is separated from the second lower mold and the upper mold. a restraining step of sandwiching between molds;
a bending step of further lowering the upper die to reach a bottom dead center after the restraining step, and bending the disc portion of the preformed member by the upper die and the first lower die. manufacturing method.
請求項1に記載の円形材の製造方法であって、
前記金型はさらに、
前記第2下型を上方に向かって付勢する弾性部材を含む、円形材の製造方法。
A method for manufacturing a circular member according to claim 1,
The mold further includes:
A method for manufacturing a circular member, including an elastic member that biases the second lower mold upward.
請求項1に記載の円形材の製造方法であって、
前記金型はさらに、
前記第2下型を上下方向に移動させる駆動装置を含む、円形材の製造方法。
A method for manufacturing a circular member according to claim 1,
The mold further includes:
A method for manufacturing a circular workpiece, including a driving device for vertically moving the second lower mold.
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JP2019063846A (en) 2017-10-04 2019-04-25 株式会社丸順 Metal mold for press working

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