JPH08164428A - Production of engine manifold flange - Google Patents

Abstract

PURPOSE: To provide a producing method of an engine manifold flange with good quality without causing punching dull or cracks, etc., by using a simple die in a common press machine. CONSTITUTION: When an upper die set 1 is lowered, a counter 3 is brought first into contact with a material 10. On one side, a stripper 6 to lift the material 10 to a prescribed height in a lower die set 5 is applied always with an upward pressure by a lower constant pressure pin 23. Because the pressure of a female die 2 is stronger than the material lift-up pressure of the stripper 6, the stripper 6 is pressed down. Then, the female die 2 presses the material 10 to the upper end of a punch 7 and punches.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an engine manifold flange.

[0002]

2. Description of the Related Art Conventionally, a method for manufacturing an engine manifold flange is based on a fine blanking press (hereinafter referred to as FB).
It is called a press machine. In many cases, the punching method is used. For fine blanking, a special FB press machine is used to drive a special wedge called a material retainer into the metal plate material, and a strong pressure is also applied to the counter, giving a special stress to the material during punching and punching and female die. This is a method of punching with a very small clearance. It is a processing method that finishes the cut surface by these operations in the same way as cutting. The FB press machine
This is a special press manufactured in Switzerland, West Germany, the United Kingdom, etc. It is a very expensive press machine including engineering. Is also expensive. However,
As a problem in processing of the FB press machine, a droop or crack is likely to occur in the convex portion of the product, and the problem has not yet been solved. Further, a draft taper is also generated, and it can be recognized that a punch taper having a product thickness of 4.5 to 6 mm and an outer diameter of 0.04 to 0.07 mm is produced.

[0003]

The problem to be solved by the present invention is to use an inexpensive general-purpose press machine to reduce the running cost due to a simple die structure, and to prevent sagging and cracks from the FB press machine. It is an object of the present invention to provide a method of manufacturing a high quality engine manifold flange that does not occur.

[0004]

According to the present invention, the punch 7 of the lower die has an inner diameter female die 9 having an upper chamfered portion 9a at the upper entrance thereof, and the plate-shaped material 10 is provided on the punch 7.
With the material 10 supported by the stripper 6 from below so that the material 10 floats from the punch 7, the taper portion 2a is provided at the lower entrance and the straight portion 2b, the reverse taper portion 2c and A material 10 is pressed against the punch 7 by a female die 2 of an upper die, which is provided with a die hole having a relief portion 2d and at the center of which an inner diameter punch 4 having chamfered portions 4a to 4c is arranged. The material 10 is passed through the die hole of the female die 2 to form a primary product with an inner diameter hole, and then the primary product is formed into a female die 2
Is pressed by a counter 3 from above to pass through the die hole below the female die 2 to obtain a product. Then, the object of the present invention is to provide a method for manufacturing a high-quality engine manifold flange that does not cause drooping, cracks, etc., by using an inexpensive general-purpose press machine.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a sectional view for explaining a mold of a general-purpose press according to an embodiment of the method of the present invention. The present invention attaches the punch 7 to the lower die, attaches the female die 2 to the upper die,
The primary product enters the upper female die 2, is pushed down by the counter 3 to the lower surface of the female die 2, and is discharged by air pressure or cylinder pressure.

The basic configuration of FIG. 1 will be described. A counter 3 is built in the female die 2, while an inner diameter punch 4 is prepared inside the counter 3. Through holes are prepared inside the punch 7. A slight round chamfer or taper chamfer, which will be described later, is applied to the inlet of the through hole to form an inner diameter female die 9. The bottom of the through hole is a slag hole 8. In the engine manifold flange product 24 shown in FIG. 3, the outer peripheral portion 24a and the inner diameter hole 24b are processed at the same time.

A counter knock disk 14 is arranged above the counter 3, and the counter knock disk 1 is provided.
4 is provided in the counter holder 16 so as to be vertically movable. The stripper 6 is fitted in the punch 7 in a vertically slidable relationship, and the lower normal pressure pin 23 causes the punch plate 21 to move.
And is supported by the lower die set 5. The punch 7 is fixed to the punch plate 21 by the punch holder 22.
The plate-shaped material 10 is placed on the stripper 6 and is automatically fed from the left side to the right side in FIG. It can be moved to the left or right, but it is determined by the factory layout and the post-process of the product. In FIG. 1, the material 10 moves from left to right.

Above the upper die set 1, a press slide knockout bar 11 of the press machine is provided with a knockout pin 1.
It acts on 2 and is provided as a means for pushing down the counter 3.
A knockout pin 12 penetrating through the center of the upper die set 1 and vertically movable is connected to a knockout disk 13 sandwiched between the upper die set 1 and the counter plate 17 at the lower end portion, and is vertically moved with respect to the upper die set 1 and the counter plate 17. It is movably provided. Counter push pin 15
However, the counter knock disk 14 and the knockout disk 13 are connected. When the counter push-down pin 15 receives pressure from above by the press slide knockout bar 11, the counter push-down pin 15 pushes down the counter 3.

An inner diameter punch 4 is arranged at the center of the inner diameter of the female die 2, and the inner diameter punch 4 is fixed to an upper die counter plate 17 by an inner diameter punch holder 19. At the center of the punch 7, there is a slag hole 8 which is provided with an inner diameter female die 9 and communicates with the punch plate 21. Air hole 2 provided in the gap between the counter holder 16 and the female die holder 18
0 communicates with the outer circumference of the counter 3, the gap between the female die 2 and the inner diameter punch 4. A slag discharge air device 25 is provided below the slag hole 8.
Is prepared.

FIG. 2 is a half sectional view of the female die 2 of the method of the present invention. The internal structure of the female die 2 has a tapered portion 2a at the lower entrance. The taper portion 2a has an angle of 20 ° to 150 °, and an appropriate angle is determined by a trial experiment. Following the taper portion 2a, there are provided a straight portion 2b having a standard size, an inverse taper portion 2c having an angle of 20 ° to 150 °, and a relief portion 2d. The difference in size between the straight portion 2b and the relief portion 2d differs depending on the thickness of the product 24, but the thicker it is, the larger the outer peripheral portion 24a of the product 24 to be pressed expands. Therefore, it is necessary to increase the size of the relief portion 2d, so that the inner diameter of the relief portion 2d is expanded by 10 μm to 200 μm from the reference dimension of the straight portion 2b.

FIG. 4 is a side view showing the cutting edge surface of the inner diameter punch 4 of the method of the present invention. Depending on the size of the inner diameter hole 24b of the product 24, the size of the product 24, the thickness of the product 24, the hardness of the material, and the like, any one of FIGS. 4A, 4B, and 4C is selected. FIG. 4A shows an example in which the chamfered portion of the inner diameter punch 4 is provided with a round chamfer 4a having a radius of about 5% of the diameter of the inner diameter punch 4. FIG. 4B is an example in which a chamfered portion 4b of about 5 ° is provided as a chamfered portion of the inner diameter punch 4, and the circular diameter Y of the chamfered chamfered portion 4b is about 60% of the diameter φ of the inner diameter punch 4. Y = 0.6φ FIG. 4C shows a chamfered portion of the inner diameter punch 4 which is 2/100.
An example in which a taper chamfer 4c of mm is provided is shown. The diameter φ of the inner diameter punch 4 and the dimension X of the starting point of the taper chamfer 4c are equal, for example, X and φ are 10 mm. X≈φ Further, as shown in FIG. 4C, a rounded portion may be provided on the upper portion of the tapered chamfer 4c. The length of the inner diameter punch 4 is set such that the tip surface is at the same position as the height of the lower surface of the straight portion 2b of the female die 2. The punch 7 bites into the material 10 and an unreasonable pressure is generated at the taper portion 2a of the female die 2. Especially, the irregular pressure is concentrated on the center of the primary product 24 ', so that the inner diameter punch 4 is easily broken. , Is a measure to prevent this. Since the irregular pressure concentrated on the primary product 24 'is reduced at the straight portion 2b, it is possible to extend the life of the inner diameter punch 4 by starting the work for forming the inner diameter hole 24b from that point.

FIG. 5 is a sectional view showing the inner diameter female die 9 of the punch 7 of the method of the present invention. The inner diameter female die 9 formed in the center of the punch 7 has an upper chamfered portion 9a at the upper entrance as shown in FIG. The upper chamfer 9a has a corner chamfer of .alpha..degree. = 5.degree.-60.degree. Or has a small radius round chamfer. Whether the upper chamfer 9a is chamfered or rounded is determined by the plate thickness of the material 10. The inner diameter female die 9 has a straight portion 9b following the upper chamfered portion 9a. Further, the punch 7 is provided with a slag hole 8 together with the inner diameter female die 9 and is used for discharging the slag. The slag does not occur when the outer circumference is punched, but it occurs when the inner diameter hole is punched. This slag is discharged from inside the punch 7 to the punch plate 2
It can be easily discharged to the outside through the prepared side hole by the discharge air device 25.

Next, the operation will be described. Since the clearances of the female die 2 and the punch 7 and the inner diameter punch 4 and the inner diameter female die 9 are made small, the purpose is to prevent the blade portions of the dies from hitting each other and the outer peripheral portion 24 of the product 24.
The machining method that considers that the cut surface of a and the inner diameter hole 24b is cleanly finished is by providing chamfered portions 4a to 4c at the taper portion 2a at the inlet of the female die 2 and the tip of the inner diameter punch 4. Will be resolved.

When the upper die set 1 is lowered, the material 10 is first hit by the counter 3. The stripper 6 is constantly pressed upward by the lower normal pressure pin 23. Since the pressing pressure of the female die 2 is stronger than the material lifting pressure of the stripper 6, the stripper 6 is pushed down as the upper die set is lowered, and the punch 7 bites into the remaining material 10.
Reach the bottom surface of the female die 2. The punch 7 reaching the lower surface of the female die 2 enters into the female die 2. At the same time, the primary product 24 'that is about to be cut from the material 10
Enters deep into the female die 2 and pushes up together with the counter push-down pin 15 on the upper part of the counter 3, the inner diameter punch 4 starts to hit the primary product 24 '. The inner diameter punch 4 begins to hit the inner diameter female die 9 provided inside the lower punch 7, and the inner diameter hole 24b is formed in the primary product 24 '.
Punch out. The primary product 24 ′ that has entered the female die 2 enters the taper portion 2a, the straight portion 2b having the reference size, the reverse taper portion 2c, and the relief portion 2d in that order.

The primary product 24 'passes through the taper portion 2a of the female die 2 and reaches the straight portion 2b, the reverse taper portion 2c and the relief portion 2d, and the press machine reaches the bottom dead center. At this time, the primary product 24 'has a taper forcibly formed on the primary product 24' when passing through the tapered portion 2a, and further expands by 0.03 to 0.15 mm at the outer circumference. Since the primary product 24 'is pushed out by the counter 3 to the lower surface of the female die 2 as it is, a product 24 with a punch taper and with drooping is produced. The primary product 24 'is pushed by the counter 3 from the relief portion 2d to the reverse taper portion 2c, the straight portion 2b and the female die 2 inlet lower surface. The slide knockout bar 11 of the press machine produces a great effect by simultaneously performing two processes with one stroke.

The punching slag does not occur at the outer peripheral punching, but does occur at the inner diameter punching. The slag is discharged from the inside of the punch 7 to the inside of the punch plate 21 by its own weight, and discharged from the prepared lateral hole to the outside of the die by the discharging air device 25. On the other hand, the product 24 is discharged from the female die 2 to the outside by the knockout pin 12 and the slide knockout bar 11 when the press reaches the top dead center. At the time of discharging the product 24 by the counter 3 from the inside of the female die 2 through the escape portion 2d at the back, a slight amount of slag is generated at the time of the punching taper and the drooping removal processing, so that the removing work is required. Since it is very difficult to mechanically perform the work of removing this slag, an air hole 20 is installed by penetrating the lateral hole into the gap between the inside of the counter holder 16 and the outer periphery of the counter 3, and the high pressure air is placed there. It is necessary to constantly keep the inside of the female die 2 clean by spraying.

[0017]

As described above, the method of manufacturing the engine manifold flange of the present invention is a method of forming a simple die on an inexpensive general-purpose press machine and performing press working. The material that is pressed into the female die by the pressing pressure is punched in the straight part with a small irregular pressure, and then punched into the relief part once. Next, the taper portion is forcibly formed in the taper portion in the previous step, and the primary product whose outer shape has expanded is passed from the escape portion through the reverse taper portion and pushed back to the female die inlet to perform punch taper and punch sag removal processing. This manufacturing method has an effect of manufacturing an engine manifold flange of higher quality that does not cause sagging or cracks, as compared with the FB press machine. Further, in the present invention, providing a lower die of a general-purpose press with a female die for inner diameter and a punch for punching a slag hole has an effect that the punch slag can be easily discharged because the slag falls by its own weight.

[Brief description of drawings]

FIG. 1 is a sectional view illustrating a die of a general-purpose press according to an embodiment of the method of the present invention.

FIG. 2 is a half sectional view of a female die of the method of the present invention.

FIG. 3 is a plan view and a sectional view showing a product manufactured by the method of the present invention.

FIG. 4 is a side view showing a cutting edge surface of an inner diameter punch according to the method of the present invention.

FIG. 5 is a sectional view showing an inner diameter female die of a punch according to the method of the present invention.

[Explanation of symbols]

1 ... Upper die set, 2 ... Female die, 2a ... Tapered portion, 2
b ... Straight portion, 2c ... Reverse taper portion, 2d ... Relief portion,
3 ... Counter, 4 ... Inner diameter punch, 4a ... R chamfer,
4b ... Square chamfer, 4c ... Tapered chamfer, 5 ... Lower die set, 6 ... Stripper, 7 ... Punch, 9 ... Inner diameter female die,
9a ... Upper chamfered portion, 9b ... Straight portion, 10 ... Plate-shaped material, 23 ... Lower normal pressure pin, 24 ... Product, 24 '... 1
Next product, 24a ... Outer peripheral portion, 24b ... Inner diameter hole.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B21D 28/16 F01N 7/08 E F02M 35/104

Claims (1)

[Claims] 1. A manufacturing method for press-molding an engine manifold flange, wherein a punch of a lower die has an inner diameter female die having an upper chamfered portion at an upper entrance and is punched in the center, and a plate-shaped material is formed on the punch. With the material placed above and supported by a stripper from below so that the material floats from the punch, a die hole having a taper portion at the lower entrance and a straight portion, a reverse taper portion and a relief portion is formed following the taper portion. By setting the inner die having a chamfered portion at the bottom and arranging it in the center, the material is pressed against the punch by the female die of the upper die, and the material is raised through the die hole of the female die. After molding a primary product with an inner diameter hole, press the primary product from above the female die by a counter to pass the die hole below the female die into a product. A method for manufacturing engine manifold flanges by press working.