JPH0199735A - Method for forming flange by rolling roller - Google Patents

Abstract

PURPOSE:To obtain a product free from reduction of sheet thickness based on shrink mark and excellent in quality by advancing a rolling roller inclined at a fixed angle, roll-forming a flange inclined at a fixed angle, converting an inclined roller to a horizontal position and lowering an upper mandrel. CONSTITUTION:A work A which eas flanged up to a bending angle 45 deg. at the previous stage is set on a lower mandrel 1 and an upper mandrel 2 is lowered and rotated with the work A. The rolling roller 6 inclined by alpha (45 deg.) is advanced to complete a roller-forming. The rolling roller converts its position to a horizontal position, at the same time the mandrel 2 is lowered further, a flange forming die 5 is dropped to work the flange inclined at a gradient alpha to a horizontal flange and to complete the forming stage. Hereby, it is possible to obtain a product free from reduction of sheet thickness (or rapture) based on shrink mark and excellent in quality.

Description

[Detailed Description of the Invention] [Object of the Invention] (Industrial Application Field) The present invention relates to a method for forming an axisymmetric line-shaped flange made of a disc of thin steel plate using a rolling roller device. It is used for forming flanges of body boosters.

(Prior art) Regarding rolling roller forming of the flange of the side plate body shown in (b) of the automobile brake booster shown in FIG. It is formed by (a) processing start step → (b) processing step → (c) processing completion step, as shown in FIG. That is, the bending angle is approximately 4
The workpiece 10 with a flange raised at 56 is rotated while being sandwiched between an upper mandrel and a lower mandrel, and the rolling roller 6 advances horizontally to bend and form the flange as shown in (c).

(Problems to be solved by the invention) However, as shown in FIG. 11(d), the above-mentioned molding method
The workpiece 10 is axially symmetrical, and when the rolling roller comes into contact with the workpiece 10 and processing progresses, there is no movement of material at A above the rolling roller 6 because no processing is applied to it (part A is at that position). ), the upper part A of the rolling roller
There is tension between the upper and lower parts B, elongation occurs at the 0 part as shown in (e), and as the processing progresses, a "sink mark" 11 occurs at the end of processing as shown in (c), resulting in a uniform board thickness. There is a problem that the flange cannot be formed.

The present invention solves the technical problem of developing a forming method that can form a flange with a uniform thickness without causing "sink marks" when forming an axisymmetrically shaped flange such as a flange of an automobile brake booster. That is.

[Structure of the invention]

(Means for solving the problems) The technical measures taken to solve the above technical problems are as follows. That is, in the method of forming the side plate body of a brake booster having a flange from a disc material, when forming with a rolling roller device consisting of an upper mandrel, a lower mandrel, and a rolling roller, the upper mandrel is fitted with a spring. This device is equipped with a workpiece holder that can move up and down, a flange forming die for forming a flange around the outer periphery of the workpiece holder, and a rolling roller whose rotating shaft can rotate by α-45° during flange processing. ) α Mi 4
Set the workpiece flanged up at 5 degrees on the lower mandrel, (2) the upper mandrel descends and hold the workpiece with the work holder, rotate the lower and upper mandrels, (3) tilt α=45”. The rolling roller is moved forward to form the inclined flange, (4) the inclined forming roller is moved horizontally, and at the same time the upper mandrel is further lowered, (5) the flange forming die is lowered and the inclined flange is formed. Finished machining the flange horizontally.

The uniformity of the flange using the above device is a method of forming the plate thickness.

(Operation) The technical means operates as follows. That is, the workpiece is fixed on the lower mandrel, and (1) setting process → (
2) Upper mandrel lowering process → (3) Lower mandrel rotating process = (4) Roller advancing process → (5) Rolling roller forming process = (6) Roller horizontal lowering forming process = (7) Forming completion process A flange is formed, and the roller bends α0 in the above-mentioned (5) rolling roller forming process and (6) roller horizontal downward forming process, so that a flange of uniform plate thickness without 'sink' can be formed. It is.

(Example) Examples will be described below.

P in Fig. 1 is a rolling machine for forming a flange, which bends an axisymmetric flange made of a circular thin steel plate;
is the workpiece and l is the lower mandrel.

2 is an upper mandrel, 3 is a spring that presses down the workpiece holder 4, and 5 is a flange forming die.

6 is a rolling roller for bending the flange, 7 is the flange bending portion of the work A, and α is the inclination angle of the rolling roller 6.

In the rolling roller device for flange forming shown in Fig. 1,
The workpiece, which has been flanged up to a 45° flange bending angle in the previous process, is formed into a flange of uniform thickness using this machine through each process shown in Figures 2 to 8.T1) Setting process (Figure 2) Workpiece A, which has been flanged up to α (45°) or more, is set on the lower mandrel 1.

(2) Upper mandrel lowering step (Fig. 3) The upper mandrel 2 is lowered.

(3) Lower mandrel rotation step (Fig. 4) The upper mandrel 2 further descends and holds the work A by the work holder 4 with the spring 3 attached. Next, the lower mandrel 1 rotates, and the workpiece A and the upper mandrel 2 rotate simultaneously.

(4) Roller advancement process (FIG. 5) The rolling roller 6 tilted by α (45”) moves forward and hits the flange bent portion 7 of the workpiece A, and at the same time the rolling roller 6 rotates.

(5) Roller forming process (Fig. 6) Forming with the rolling roller 6 completes the forming with the α (45°) inclined roller.

(6) Rolling roller horizontal processing forming process (Fig. 7) α (45
°) The tilted rolling roller 6 changes its position horizontally, and at the same time, the upper mandrel 2 further descends, the flange forming die 5 descends, and the flange formed by α (45"Hl) is lowered horizontally to complete forming.

(7) Molding completion process (Figure 8) The rolling roller 6 retreats and the upper mandrel 2 rises.

By the above steps, it is possible to form a flange of workpiece A with a uniform thickness without "sink marks" as shown in 8 of FIG. 9.

〔Effect of the invention〕

The present invention has the following effects. In other words, with the conventional method using rolling roller forming, it was not possible to suppress the reduction in plate thickness (or breakage) due to "sink marks", but with this forming method, "sink marks" do not occur and the quality is improved. It is possible to form a good product.

[Brief explanation of the drawing]

Fig. 1 is an omitted cross-sectional view of the rolling roller device, Figs. 2 to 9 are explanatory cross-sectional views of each process in this embodiment, and Fig. 10 (a) is a partially broken cross-sectional view of the booster. , (b) is (
A) is an enlarged view of the flange, and FIGS. 11A to 11F are explanatory views of the conventional example. A...Work, 1...Lower mandrel. 2... Upper mandrel, 3... Spring. 4... Work holder. 5...Flange forming die. 6... Rolling roller. 7...Flange of workpiece.

Claims (1)

[Claims] In a method of forming a side plate body of a brake booster having a flange from a disc material using a rolling roller device comprising an upper mandrel, a lower mandrel, and a rolling roller,
The upper mandrel has a work holder that can be moved up and down by a spring,
A flange forming die is installed on the outer periphery of the work holder, (1) the workpiece flanged up at a certain angle is set on the lower mandrel, (2) the upper mandrel descends and the work holder holds the workpiece between the lower mandrel and the upper mandrel. The mandrel is rotated, (3) the rolling roller inclined at a certain angle is advanced to form a flange inclined at a certain angle, (4) the inclined forming roller is moved horizontally, and the upper mandrel is further lowered. (5) A method of forming a flange of uniform thickness using a rolling roller device, in which the flange forming die descends and completes the horizontal descent of the inclined flange.