JPH1133637A - Forming method by both normal/reverse drawing, equipment therefor and formed product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the manpower required for production/assembly/inspection of a part by reducing the number of parts by normal-drawing a thin sheet material previously as intermediate working, then reverse-drawing the material continuously, thereby integrally producing a complicatedly shaped container therefrom. SOLUTION: The thin sheet material 17 is formed to a two stepped cylindrical topped formed material 24 consisting of a wall 20/shoulder 21 at a first step and a wall 22/ceiling 23 at a second step. Part of the cylindrical wall 20 at the first step is pressed by a die to a flat face 25, a horizontal hole 27 is blanked to the flat face 25. The horizontal hole 27 is used for a connecting hole between a mounting seat of a sintered metal formed part and an fluid outlet/inlet formed part, a top part consisting of the wall 22 and the ceiling 23 at the second step is protruded toward an inner face by subjecting to reverse drawing in the opposite direction, an inner face protruding formed material 34 having the protruded part consisting of an annular edge part 29, a wall at the first step, a step 31, a wall 32 at the second step and a bottom 33 are formed. Successively, a wall 35, a step 36, a wall 37 and a bottom 38 are shaped by two step reverse drawing, a formed material 39 having shape protruded part is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technique for integrally molding a plurality of members having different shapes constituting a pressure regulator from a thin plate material mainly by press molding to produce a container having a small number of joints.

[0002]

2. Description of the Related Art When operating equipment, if the equipment involves a change in temperature or pressure, an automatic adjusting device comprising a detection unit and a control unit is provided in order to cope with the change. In many cases, a sensor that detects a change as an electrical or mechanical displacement and a mechanism that operates by an output based on the displacement of the sensor are built in the control unit, and the valve seat is opened and closed using such a mechanism. The control unit has a functional product called a pressure regulator or simply a regulator,
There are many types, from very large single items that require a crane in shape to mass-produced items that fit on the palm.

In a mass-produced pressure regulator as shown in FIG. 1, the number of components and the materials used for the components vary widely, but the structure is shown in FIG.
As shown in (A), the valve is constituted by a combination of an upper valve stem operating portion and a valve seat portion, and the operation is only to move the valve stem in one direction, and a diaphragm built in the valve stem operating portion (shown in FIG. The movement of the central shaft of (b) opens and closes the valve, and the actuation input to the diaphragm is small but enlarged by the diaphragm to a size sufficient to move the valve stem.

[0004] The components of the pressure regulator are mainly occupied by parts molded from powder raw materials by means of die casting or metal sintering, and molded articles made of sheet material by sheet metal working using a press. The material is assembled by joining means such as crimping, press-fitting and brazing, and then painted, and then subjected to a pressure test to produce a product. May be used, but such opportunities have been greatly reduced.

[0005]

The structure of the pressure regulator shown in FIG. 2 (A) has a large number of parts to be assembled around a thin plate container, and a press-formed part and a non-press-formed part or a combination of these parts. The number of joint surfaces caused by the press fitting, brazing and inspection increases the number of working steps, and the sealing surface is damaged by press fitting and brazing. Dents. These methods have reached the limit in answering the inevitable cost reduction demands of mass-produced products, as they raise problems such as drowning and affect the total manufacturing cost of the products.

[0006] Manufacturing industry. Regardless of the non-manufacturing industry, the ratio of labor costs to the total cost of all industries is only rising year by year, and for this reason manufacturers are investing in thorough unmanned operations, which is the limit of labor saving of equipment At present, the structure of the parts themselves has been sought to find shapes suitable for unmanned production, and it has been hard to reduce the ratio of labor costs to costs.

[0007]

SUMMARY OF THE INVENTION The present invention is directed to a thin container which is a main component of a pressure regulator. An object of the present invention is to provide a molding method, molding equipment, and a molded product for integrally producing a thin sheet material by a continuous processing step of a mixed press.

[0008] The present invention uses a thin sheet material of a required thickness and narrow width made of metal, and uses a material which has been subjected to a distortion correcting process. Punching the material into a disk-shaped thin sheet material of a required size by a punching process; (B). A part of the inside of the circumference of the disk-shaped sheet material is held in a ring shape, the remaining inner part is projected in two steps, and the first wall and step and the second step wall and ceiling are formed and a top part is attached. (C). Forming a part of the cylindrical surface of the first-stage wall of the processed material with a top into a flat surface to obtain a processed material with a flat surface; (D). (C) forming a horizontal hole in a flat portion of the flat surface processed material to form a horizontal hole processed material; The second-stage ceiling of the processed material with lateral holes is squeezed in the direction opposite to the protruding direction, and is formed into an annular edge, a first-stage wall and a step, and a second-stage wall and a bottom to form a processed material with an internal protruding portion, (F). The first step wall and the step and the second step wall and the bottom of the protruding part including the annular edge part of the processing part with the inner protruding part are shaped to obtain a shaping part with a required fitting accuracy, ). (H). A punched hole is formed by punching out the bottom end of the processed material with a shaping projection to form a holed processed material. The end face of the hole of the perforated material is enlarged or shaped into a thread surface to obtain an end face processed material, (I). The circumferential part of the end face processed material is processed into a required flange to obtain a flanged processed material, (J). This is a molding method using a mixture of forward and reverse drawing, characterized by continuously bending each outer shape of the flange of the flanged work material inwardly over the entire circumference to form a bent flanged work material, Based on the method: (A). A punching step of converting the material into a disk-shaped thin sheet material of a required size by a punching step; (B). A part of the inside of the circumference of the disk-shaped sheet material is held in a ring shape, the remaining inner part is projected in two steps, and the first wall and step and the second step wall and ceiling are formed and a top part is attached. (C) a normal drawing process as a processing material; (D) a flattening step in which a part of the cylindrical surface of the first-stage wall of the processed material with a top portion is formed into a flat surface to obtain a processed material with a flat surface; (E) an opening process in which a hole is made in a flat portion of the work material having a flat surface to form a work material having a lateral hole; Squeeze the second ceiling of the processed material with side holes in the direction opposite to the protruding direction and form it into the annular edge, the first wall and the step, and the second wall and the bottom to obtain the processed material with the internal protrusion A reverse drawing step; (F). Shaping of the first-stage wall and step and the second-stage wall and bottom of the protruding part, including the annular edge of the processing material with an internal protruding part, to obtain the required mating accuracy. (G). (H) an opening process in which a hole is formed in the punching of the bottom end portion of the processed material with a shaping projection to form a processed material with holes; An end surface processing step of enlarging or shaping the end surface of the hole of the holed material into a thread surface to obtain an end surface processed material; (I). A cutting step of processing the circumferential portion of the end face processed material into a required flange to obtain a flanged processed material; (J). Forward and reverse, characterized in that a die and a pressing device for each step of a bending process in which the outer edge of the flange of the flanged material is bent inward over the entire circumference to form a bent flanged material are connected. It is a molding equipment by mixing both drawers, using equipment configured by the present method, having a bending flange which is turned inward of a flange or an outer edge of the flange,
A small-sized integrated structure having a cylindrical protrusion rising from the inner edge of the flange and a flat surface with a horizontal hole on the cylindrical surface, and two-stage cylindrical protrusions arranged concentrically so as to be folded inward from the tip of the cylindrical surface. The container is made of a thin metal plate and is a molded product obtained by mixing forward and reverse drawing.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, the material of the main part is steel. stainless steel. It is intended for mass-produced pressure regulators composed of metals such as copper-based alloys. The main components of the regulators are conventionally integrated with a plurality of components by combining and bonding means. Since a thin plate material was processed by a continuous process called processing, the bonding area was minimized, and the molding technology that maintained the required accuracy was established. Inspection and management related to the soldering point of brazing were reduced, and the production cost of this part was reduced.

According to the present invention, when the final shape of the thin plate container needs to have a protrusion on the inner surface and have a flat surface or a hole on the outer surface of the cylinder, the shape of the protrusion on the inner surface and the processing of the outer surface interfere with each other. One of the features of this method is to first squeeze out the surface area corresponding to the part protruding to the inner surface in the same direction as the outer surface molding before forming the outer surface. The second characteristic is that, after finishing processing such as flat surface and perforation while maintaining the same shape, the first portion of the normal aperture is squeezed in the opposite direction (for convenience, the reverse aperture is referred to as a reverse aperture). In this case, the surface area of the molded portion at that time is substantially close to the surface area of the first molded portion.

[0011] Such a mixture of the forward and reverse drawing is less necessary when the working space is large enough to insert a mold or the like. There is not enough mold insertion space for forming a flat surface or drilling holes, so if drilling precedes it, a large effect can be obtained if it is applied to a case where the preceding part is deformed by the subsequent process. The reason is that by considering the surface area equivalent to the protrusion of the inner surface at the stage of pre-processing,
This is because deformation can be prevented without being affected by post-processing even if intermediate processing of flat surface or drilling precedes.

The series of processing steps are as shown in Table 1.
The difference in the processing shape of the flange in the final stage is determined by whether the mating side to be connected has connecting means such as caulking or the part side has connecting means. 4 and 5 correspond to the reference numerals described in [Claims 1 and 3] in the column of [Claim 1] and [0008] in the column of [Detailed Description of the Invention]. It also corresponds to the sign.

[0013]

[Table 1]

When the individual processes such as punching and drawing are taken out of the continuous machining processes shown in Table 1, the molding devices constituting the processes and the transfer devices placed between the processes are sufficient. Although it can be dealt with by a known technique, if the continuation of the process is intended to reduce the manufacturing cost, [0
[010] As described in the paragraph [10], in the course of the shape change, interference occurs in which the contents of the preceding processing are affected by the post-processing, and it often happens that the post-processing cannot be performed. Although the production is divided into individual products, it is natural that the production cannot avoid a plurality of methods and an increase in incidental work.

In the present invention, the roles of both the normal drawing and the reverse drawing shown in Table 1 are as follows. First, the part which is obstructed by the next processing is once removed outside the processing area by the normal drawing, and the processing of the necessary part is completed. Later, the normal drawing portion was made into the final shape by reverse drawing, and the ratio of the processing surface area of the normal drawing and the reverse drawing was the same or the former was made larger so that interference did not occur before and after processing, so processing Even if the target material is no longer divided and the process itself increases, there are many advantages due to continuous processing,
The production cost was significantly reduced as compared with the method of dividing the work material.

The object of application of the molding method according to the present invention is not limited to mass-produced pressure regulators when there is no increase or decrease in the material to be processed throughout the entire process. As long as it is a molded product, a remarkable effect can be obtained when it is incorporated in a continuous process facility called progressive processing or transfer press processing. I do.

[0017]

The function of the molding method, the molding equipment and the molded product by the combination of the forward and reverse drawing according to the present invention is as follows. Is difficult or is affected by post-processing,
By performing the two-stage processing in which the processing of the specific portion is performed in advance by the normal drawing and the intermediate processing, and then the reverse drawing is performed, a thin sheet container having a final shape can be obtained without affecting the pre-processed portion.

[0018]

[Comparative example] Fig. 1 shows a mass-produced pressure regulator 1
The regulator 1 comprises an operating part 2 and a valve seat part 3, and both of them crimp a flange 6 of the valve seat part 3 using a bent flange 5 on the operating part 2 side at a connection part 4. With an integrated structure, a diaphragm is built into the operating part,
The diaphragm is operated by the control fluid supplied from the connection pipe 7, and FIG.
As shown in (A), the regulator outer shell 8 is composed of an inlet / outlet molded article 9 for a fluid entering and exiting the inside, an attachment seat 10 and an entrance / exit molded article 12 with another connecting pipe 13 for a fluid forming the valve seat 11, The valve seat 10 is in contact with a valve 14 that is directly connected to the diaphragm of the operating section 2.

The regulator outer shell 8 shown in FIG. 2A is a thin steel plate molded product, a molded product 9 for a fluid to be connected to the regulator shell, a mounting seat 10, and a molded product 12 for another fluid port. Are sintered metal molded products, and both are subjected to brazing after fitting by press-fitting to seal and connect them. Wounds. Dents. It raises problems such as blinding and raises manufacturing costs including inspection.

Such a problem of press-fitting and brazing is raised because it is necessary to divide a complicated shape in order to proceed with processing, and a mold is inserted into an outer shell of a product to be processed. Forming a protruding portion in the outer shell is a conventional technique, as long as it has sufficient space to meet the requirements or does not require any additional processing on the outer surface formed by the initial drawing. It is not difficult at all, but if this condition is not satisfied, continuous forming without deformation of the preceding part cannot be performed even if the processing order is changed, such as prior to drilling the outer shell and then performing protruding processing.

[0021]

FIG. 2B is a mass-production type pressure regulator using a regulator shell 16 made of a thin steel plate formed by integrating the regulator shell 8 and the inlet / outlet molded product 12 shown in FIG. 2A. At 15, the brazing process was performed after the fitting of the regulator shell 16, the fluid inlet / outlet molded article 9 and the mounting seat 10 to form a sealed connection and integrated, so that the press-fitting and brazing work was reduced and the work was reduced. Damage on the seal surface. Dents. Reduced drowning problems and made inspection easier.

In order to easily understand the difference in the manufacturing method, FIG.
FIG. 3 (C) is a cross-sectional view of a regulator shell 8 having different connecting pipes 13 and 13A according to a conventional product, and FIG. 3 (B, D) is a cross-sectional view of a regulator shell 16 formed based on the present invention. 3 (A, C), the regulator shell 8 which is a thin plate molded product and another inlet / outlet molded product 12 of a fluid which is a sintered metal molded product are integrally formed from the thin plate material in FIG. 3 (B, D). Since it is formed into the regulator outer shell 16, it is possible to reduce one point of the sintered metal molded product and the mounting work of the product.

The processing steps will be described in detail after this section.
FIGS. 4 (A to F) and FIGS. 5 (G to J) show changes in the shape of each process from the sheet material of the present invention to a sheet container having a projection in the outer shell. Correspondence is made between the appended alphabetic codes, [Claims 1 and 3] in the "Claims" column, and [0008] in the "Detailed description of the invention" column, and the alphabetical codes described in the flow sheet of Table 1. .

FIG. 4A is a side view of a thin sheet material 17 formed into a disc shape by a blanking process by using a strip-shaped material obtained by flattening a narrow, roll-shaped thin plate through a rewinding process. FIG. 4B shows the edge 1 of the sheet material in the normal drawing process.
8, an annular portion is secured as a flange in the inward direction, and the remaining inner portion is extruded in one direction and formed into a two-stage cylindrical shape, and the first-stage walls 20 and 21 and the second-stage walls 22 and the ceiling 23 are formed. In the cross-sectional view of the processed material 24 with the top portion, the total surface area of the top portion due to the forward drawing is equal to or slightly larger than the total surface area of the protrusion to the inner surface due to the reverse drawing in the subsequent process.

FIG. 4 (C) shows one of the molds inserted into the inner surface and the mold from the outer surface in order to make a part of the surface of the first-stage cylindrical wall 20 of the cylindrical material 20 flat. On the other hand, FIG. 4D is a cross-sectional view of a flat surface 25 of a processed material 26 having a flat surface with a horizontal hole 27 punched out by a die. It is used as a connection hole between the mounting seat 10 of the sintered metal molded product and the fluid inlet / outlet molded product 9, in which case the mounting seat 10 and the flat surface 25. The connecting surfaces of the molded article 9 and the mounting seat 10 were sealed by brazing.

FIG. 4 (E) shows, for the first time at the stage where the working material 28 has been worked up to the side hole-formed workpiece 28, the top formed by the second stage wall 22 and the ceiling 23 formed by the positive drawing machined in the first stage is turned upside down. In the opposite direction to project inward, the annular edge 29, the first wall 30, the step 31, and the second wall 32, the bottom 33
In this stage, a curved surface is left at a step or a corner of the protruding portion such as the bottom 33 at this stage.

FIG. 4 (F) shows a two-stage reverse drawing portion of the workpiece 34 with an inner surface protruding portion formed by a wall 35 and a step 36 and a wall 37 and a bottom 38.
FIG. 5 (G) is a cross-sectional view of a shape obtained by forming a hole 40 in the bottom portion of the processed material 39 with a shaping protrusion, and FIG. 5 (H) is a cross-sectional view of the processed material 41 with a hole. FIG. 3 is a cross-sectional view of a hole end surface 42 having a shape obtained by enlarging the end surface of the hole 40 into a conical shape and having a thread surface subjected to end surface processing.

FIG. 5 (I) is a cross-sectional view of a shape in which the edge of the end face processing material 43 is formed into a flange 44 having a shape necessary for joining with the counterpart, and FIG. FIG. 6 is a cross-sectional view showing the final shape of a bent flanged material 46 which is formed by bending the outer edge of the flange 44 inward according to the mating shape of the mating member to form a bent flange 45. FIG. In a view taken in the direction of the arrow, a series of processes are all continuously operated by a press and an automatic transfer device between processes.

This molding is characterized by a forward drawing step for obtaining the shape shown in FIG. 4B and a reverse drawing step for obtaining the shape shown in FIG. And that the total surface area of the effective forming portion of the mold used for both drawing is determined to be substantially equal. Even if another processing step is incorporated between the two by this treatment, The part processed by the process is no longer affected by the subsequent process.

The regulator outer shell 16 of the molded product manufactured by the molding equipment based on the molding method of the present invention is, as apparent from the comparison between FIGS. 3A and 3B and FIGS.
This effort reduces the number of peripheral parts and the labor of processing and inspection, and the continuous forming equipment required for this processing also requires only adding a reverse drawing process to the conventional equipment to correspond to the normal drawing process. As a result, the manufacturing cost of the regulator shell 16 has been reduced by a factor of about 30 percent compared to the method before the present invention.

[0031]

According to the present invention, the following effects can be obtained by the molding method, the molding equipment, and the molded product by mixing the forward and reverse drawing. It has become possible to integrally produce a container having a complicated shape from a sheet material. The integration has reduced the number of parts and the time required for manufacturing, assembling and inspecting the parts has also been reduced. Using a conventional progressive press or transfer press,
Continuous processing of containers with complicated shapes was made possible only by opening both the forward and reverse drawing steps and incorporating a separate step between them. The manufacturing cost of the molded article by this molding method and molding equipment has been greatly reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view of a pressure regulator.

2A is a cross-sectional view of a conventional product, and FIG.
(B) shows a cross-sectional view of the product of the present invention.

FIG. 3 (A) around the outer shell of a regulator based on the conventional method, (B) around the outer shell of the regulator according to the present invention, (C) around another outer shell of the regulator based on the conventional method, (D) is each sectional drawing around another outer shell of the regulator based on this invention.

FIGS. 4A to 4F show changes in the shape change of a processed material in a continuous forming step.

FIGS. 5A to 5J show changes in the shape change of a processed material in a continuous forming step.

FIG. 6 is a top view of a regulator shell.

[Explanation of symbols]

 Reference Signs List 1,15 Pressure regulator 2 Actuator 3 Valve seat 4 Joint 5.6 Flange 8,16 Regulator shell 17 Thin plate material 18 Edge 20 First wall 21 First shoulder 22 Second wall 23 Second stage Of the ceiling 24 Work material with a top part 25 Flat surface 26 Work material with a flat surface 27 Side hole 28 Work material with a side hole 30, 37 First stage wall 31, 38 First stage stage 32, 39 Second stage wall 33, 40 Bottom of the second step 34 Workpiece with inner projection 39 Workpiece with shaping projection 40 Hole 41 Holeworker 43 Workpiece with end face 44 Flange 45 Workpiece with flange 47 Workpiece with bent flange

Claims (5)

[Claims] 1. A thin metal material having a required thickness and a narrow width, which is made of a metal and subjected to a distortion correcting process, is used. The material is punched into a disk-shaped thin plate material (17) of a required size by a punching process (B). A part of the inside of the circumference of the disk-shaped thin plate material (17) is held in a ring shape, and the remaining inner part is projected in two steps, and the first step wall (20) and the step (21) and the second step wall ( 22) and a ceiling (23) are formed into a processed material (24) with a top, (C). (D) forming a part of the cylindrical surface of the first wall (20) with the top part (24) into a flat surface (25) to form a flat surfaced work material (26); A horizontal hole (2) is formed in the flat surface of the processing material (26) with a flat surface.
7) Open to make a processed material with side holes (28); (E). Second-stage ceiling (23) of processed material with side holes (28)
Is squeezed in the direction opposite to the first projecting direction, and the annular edge (29), the first wall (30), the step (31) and the second wall (3)
2) and formed into the bottom (33) and processed material (3
4) and (F). The first step of the projection is formed into a wall (35) and a step (36), and the second step is formed into a wall (37) and a bottom (38), including shaping of the annular edge of the work piece with an internal protrusion (34). (G). (H). A punched hole (40) is formed by punching out the tip of the bottom (38) of the shaped material (39). The end face (4) of the hole (40) of the perforated material (41)
2) is enlarged or shaped into a yarn surface to obtain an end surface processing material (43); (I). Processing the circumferential portion of the end face processing material (43) into a required flange (44) to obtain a flanged processing material (45); (J). Flange (44) of flanged material (45)
Characterized in that the outer edge of the material is turned inward over the entire circumference to continuously change the shape of each of the bent flanged workpieces (47) to form a workpiece with a bent flange (47). 2. A processing material having an inner projection and a surface area of a projection forming a second stage of the processing material having a top portion.
The ratio of the sum of the surface areas of the first-stage wall (30) and the step (31) and the second-stage wall (32) and the bottom (33), including the formation of the annular edge constituting 2. The molding method according to claim 1, wherein the former is substantially the same or the former is slightly larger. 3. A thin sheet material having a required thickness and a narrow width, which is made of metal, and a material which has been subjected to a distortion correction processing step is used. A punching step of converting the material into a disc-shaped thin sheet material (17) having a required size by a punching step; (B). A part of the circumference of the disk-shaped thin plate material (17) is held in an annular shape, and the remaining inner portion is projected in two steps, and the first-stage walls (19) and (20) and the second-stage wall ( (C) forming a ceiling (22) and a ceiling (22) to form a processed material (24) with a top; A flattening step of forming a part of the cylindrical surface of the first-stage wall (19) with the top-side processed material (24) into a flat surface (25) to obtain a flat-surfaced processed material (26); A horizontal hole (2) is formed in the flat surface of the processing material (26) with a flat surface.
7) opening a hole to form a working material with side holes (28); Second-stage ceiling (23) of processed material with side holes (28)
Squeezed in the direction opposite to the first projection direction, and the annular edge (29)
A reverse drawing step of forming a first step wall (30) and a step (31) and a second step wall (32) and a bottom (33) into a work material (34) with an inner surface projection; ). The first step of the projection is formed into a wall (35) and a step (36), and the second step is formed into a wall (37) and a bottom (38), including shaping of the annular edge of the work piece with an inner projection (34). (G) a shaping step of forming a shaping material with a shaping protrusion (39) having a required fitting accuracy. A hole forming step of punching a hole (40) by punching a tip of a bottom (38) of the shaping material with a protruding portion (39) to form a working material with a hole (41); (H). The end face (4) of the hole (40) of the perforated material (41)
2) Enlarging or shaping the yarn surface into an end surface processing material (43), and (I). A cutting process in which a circumferential portion of the end face processed material (43) is processed into a required flange (44) to obtain a flanged processed material (45); (J). Flange (44) of flanged material (45)
In the bending process in which the outer edge of is bent inward over the entire circumference to form a bent flanged work material (47), a mold and a pressing device provided for each process are continuous, and both forward and reverse drawing. Molding equipment with mixed use. 4. A processing material (3) provided with a mold for projecting and molding the second step of the top-side processed material (24).
The first-stage wall (3) including the shaping of the annular edge in (4)
0) and step (31) and second step wall (32) and bottom (3
4. The molding equipment according to claim 3, wherein the ratio to the total surface area of the mold to be molded in (3) is substantially the same or the former is slightly larger. 5. A cylindrical wall (20) having a flange (44) or a bent flange (45) with the outer edge of the flange folded inward, rising from the inner edge (19) of the flange.
And a flat surface (25) and a lateral hole (27) on the cylindrical surface,
A forward / reverse throttle, wherein an outer shell (16) having an integral structure in which two cylindrical projections are concentrically arranged inward from the front end of the cylindrical surface is made of a thin metal material (17). Molded product by mixed use.