KR20110020275A - Method for producing rotor - Google Patents

Abstract

An object of the present invention is to efficiently manufacture a rotor. The present invention is directed to a method of manufacturing a rotor. The present invention is integrally formed so that the vane grooves 4 along the axial direction in the outer circumferential portion of the cylindrical rotor portion 2 are formed in plural at intervals in the circumferential direction, and bulge toward one end side of one end surface of the rotor portion 2. The forging step of obtaining the rotor material 1 having the excess thickness portion 6 which is formed of the vane groove 4 and closes the one end side of the vane groove 4, and the impact member strikes the excess thickness portion 6, and the excess thickness thereof. By removing the part 6 from the rotor part 2, the excess thickness part removal process of obtaining the rotor R by which the vane groove 4 was opened to the one end part side is included.

Description

Manufacturing method of rotor {METHOD FOR PRODUCING ROTOR}

The present invention relates to a method for manufacturing a rotor for producing a rotor having a vane groove on its outer circumference and a related art.

The rotor of a compressor and the rotor of a rotary vacuum pump for brake control generally have a plurality of vane grooves formed parallel to the axis in the circumferential direction at equal intervals in the circumferential direction. In addition, the rotor of the air conditioning rotary compressor and the brake control rotary vacuum pump rotor are mainly made of aluminum alloy for the purpose of weight reduction, and are generally manufactured using forging.

For example, in the rotor manufacturing method of the following patent document 1, the blade part for vane groove formation is formed in the shaping | molding hole of a lower metal mold | die, and the cylindrical forging material set on the shaping | molding hole is carried out below by an upper metal mold | die. By pressurizing, the forged material is filled into the molding holes. Thereby, the cylindrical rotor raw material in which the vane groove was formed from the lower end surface to the vicinity of an upper end surface is obtained. Then, the upper end portion (surplus thickness portion) of the rotor material is cut off by cutting along the plane orthogonal to the shaft center, and the one end side (upper end side) of the vane groove is opened, thereby opening both ends of the vane groove, It is configured as.

In the rotor manufacturing method described in Patent Literature 2, a punch having a groove for forming a vane groove is provided in a molding surface of an upper die, and a groove of an upper die is formed in a forging material set in a molding hole of a lower die. The punch with which it has is beaten and a vane groove is formed in the vicinity of a lower end surface from an upper end surface. Thereafter, punches having grooves are punched out to punch out and remove excess thickness portions that block the lower end sides of the vane grooves, thereby opening both ends of the vane grooves.

Japanese Patent Laid-Open No. 11-230068 Japanese Patent Laid-Open No. 2000-220588

Although the conventional rotor manufacturing method of the said patent document 1 cuts and removes the excess thickness part of the rotor raw material obtained by forging, but the machining, such as cutting, produces compared with the press working, such as forging. The efficiency is low. Therefore, it is difficult to improve the production efficiency as a whole as long as this low production efficiency machining is used.

Moreover, although the conventional rotor manufacturing method of the said patent document 2 punches and removes the excess thickness which blocks the lower end part of a vane groove with the punch which has a groove, generally, punching process controls precisely a breaking position. It is difficult, and there is a high possibility of unintentional cracking or missing, causing a problem that the excess thickness portion cannot be removed reliably.

The preferred embodiment of the present invention has been made in view of the above-described and / or other problems in the related art. Preferred embodiments of the present invention can significantly improve existing methods and / or devices.

This invention is made | formed in view of the said subject, Comprising: It aims at providing the manufacturing method of the rotor which can reliably remove the excess thickness part, and its related technique, ensuring high production efficiency.

Other objects and advantages of the present invention will become apparent from the following preferred embodiments.

In order to achieve the said objective, this invention is equipped with the following structures.

[1] A vane groove along the axial direction in the outer peripheral portion is formed integrally so as to swell to one end side of the cylindrical rotor portion formed in a plurality of spaced intervals in the circumferential direction, and to one end side of the rotor portion, and one end side of the vane groove. A forging step of obtaining a rotor material having an excess thickness to block the

And a surplus thickness part removing step of hitting the impact member against the excess thickness part and removing the excess thickness part from the rotor part to obtain a rotor with the vane groove open to one end side.

[2] The method of producing a rotor according to the above item 1, wherein the surplus thickness portion is formed at one end side than the end surface of the rotor portion, and the vane groove is formed to the inside of the excess thickness portion.

[3] The rotor according to the preceding item 2, wherein the excess thickness portion has a peripheral wall portion that closes the peripheral side surface of the vane groove, and in the removing of the excess thickness portion, the excess thickness portion is broken by the peripheral wall portion to remove it. Manufacturing method.

[4] The method of producing a rotor according to the above item 2 or 3, wherein the thickness of the closed portion is set to 3 to 10 mm when the dimension from the distal end portion to the one end surface of the vane groove is the thickness of the closed portion.

[5] In the forging step, a crack is formed between the excess thickness portion and the rotor portion,

The manufacturing method of the rotor in any one of Claims 1-4 which cut | disconnects the said rotor raw material along the said crack in the said excess thickness part removal process.

[6] In the excess thickness portion removing step, a punching punch as an impact member is punched into the vane groove of the rotor material from the other end side opening portion, and the excess thickness portion is punched to one end side by the punch. The manufacturing method of the rotor in any one of Claims 1-5.

[7] In the forging step, the vane groove forming die is relatively struck from the other end surface of the cylindrical forging material to form the vane groove from one end surface to the other end surface.

The rotor according to any one of items 1 to 6, wherein when the vane groove forming die is struck into the forged material, back pressure is applied to a region corresponding to the vane groove forming scheduled portion on one end surface of the forged material. Method of preparation.

[8] The excess thickness portion is the vane groove side excess thickness portion, and the impact member is the vane groove side impact member,

In the forging process, a shaft hole along the axial center direction is formed in the rotor portion of the rotor material, and one end of the shaft hole side excess thickness that closes one end of the shaft hole on one end surface of the rotor portion. Integrally formed to swell to the side,

In the excess thickness portion removing step, the shaft hole side impact member is struck by the shaft hole side excess thickness portion, and the excess thickness portion is removed from the rotor portion so that the shaft hole is opened to one end side. The manufacturing method of the rotor in any one of Claims.

[9] The above-mentioned item 8, wherein a punching punch as an impact member is punched into the shaft hole of the rotor material from the other end side opening portion and punched out of the shaft hole side excess thickness portion by one end thereof. Method of manufacturing the rotor.

[10] In the forging step, the shaft hole forming die is relatively struck from the other end face of the cylindrical forging material, and the shaft hole is formed from the other end face to one end face.

The method of manufacturing the rotor according to the preceding item 8 or 9, wherein the back pressure is applied to a region corresponding to the shaft hole forming scheduled portion on one end surface of the forged material when the shaft hole forming die is struck into the forged material.

[11] In the rotor material, the excess thickness portion is integrally formed on one end surface of the rotor portion to swell to one end side, while the one end surface of the vane groove does not reach the excess thickness portion. The manufacturing method of the rotor of Claim 1 arrange | positioned inside an end surface of the said rotor part.

[12] When the gap between the one end face of the rotor portion and the one end face of the vane groove in the rotor material is the end face difference on the vane groove side, the difference in the end face on the vane groove side is set to 0 to 2 mm. The manufacturing method of the described rotor.

[13] When the distance between the inner circumferential surface of the vane groove and the outer circumferential surface of the excess thickness portion in the rotor material is the diameter difference on the vane groove side, the difference in diameter on the vane groove side is set to 0.01 to 0.1 mm. The manufacturing method of the described rotor.

[14] The method for producing a rotor according to any one of items 11 to 13, wherein the vane groove side diameter difference is partially different.

[15] The method for producing a rotor according to the preceding item 13 or 14, wherein a diameter difference of at least one of the inner circumferential side end portion and the outer circumferential side end portion is largely set with respect to the diameter difference of the middle part among the diameter differences on the vane groove side.

[16] The excess thickness portion is the vane groove side excess thickness portion, and the impact member is the vane groove side impact member,

In the forging process, a shaft hole along the axial center direction is formed in the rotor portion of the rotor material, and one end of the shaft hole side excess thickness that closes one end of the shaft hole on one end surface of the rotor portion. Integrally formed to swell to the side,

In the excess thickness portion removing step, the shaft hole side impact member is struck by the shaft hole side excess thickness portion and the excess thickness portion is removed from the rotor portion so that the shaft hole is opened to one end side.

In the rotor raw material by the said forging process, the end surface of the said shaft hole does not reach the said shaft hole side excess thickness part, but is arrange | positioned inside the one end surface of the said rotor part, The description of any one of the preceding claims 11-15. Method of manufacturing the rotor.

[17] The foregoing paragraph wherein the end face difference on the shaft hole side is set to 0 to 2 mm when the distance between the one end face of the rotor portion and the end face of the shaft hole in the rotor material is the end face difference on the shaft hole side. The manufacturing method of the rotor of 16.

[18] When the distance between the inner circumferential surface of the shaft hole and the outer circumferential surface of the excess portion of the shaft hole side in the rotor material is the diameter difference on the shaft hole side, the diameter difference on the shaft hole side is set to 0.01 to 0.1 mm. The manufacturing method of the rotor of Claim 16 or 17.

[19] The method for producing a rotor according to any one of items 16 to 18, wherein the diameter difference on the shaft hole side is partially different.

[20] A vane groove along the axial direction along the axial direction is formed integrally so as to swell to the one end side of the cylindrical rotor portion formed in a plurality of spaced intervals in the circumferential direction and one end side of the rotor portion, and one end side of the vane groove. It is a method for removing the excess thickness of the rotor material having an excess thickness to block the

A method of removing excess thickness of a rotor material, wherein the impact member is caused to strike the excess thickness portion and the excess thickness portion is removed from the rotor portion to open the vane groove to one end side.

[21] A vane groove having a plurality of vane grooves along the axial direction at intervals in the circumferential direction and integrally formed so as to swell to one end side of one end surface of the rotor portion at an outer circumference thereof, and one end side of the vane groove. It is an apparatus for removing the excess thickness of the rotor material having an excess thickness to block the

The vane groove is punched into the vane groove of the rotor material from the other end side opening portion, and the excess thickness portion is punched out to one end side to remove the excess thickness portion from the rotor portion, thereby removing the excess thickness portion from the rotor portion. The apparatus for removing excess thickness of a rotor material, comprising a punching punch for opening the side toward one end.

In the present invention, it is also possible to replace the configuration corresponding to the vane grooves of the above-mentioned [2] to [7] with the configuration corresponding to the shaft hole and limit the configuration to the above-mentioned [8] [20] [21]. Do.

Moreover, in this invention, it is also possible to limit the structure of the preceding paragraph [11]-[19] to the structure of the preceding paragraph [20] [21].

According to the rotor manufacturing method of the invention [1], since the excess thickness portion is removed by the impact of the impact member, high production efficiency can be ensured. In addition, since the excess thickness is expanded, it can be reliably removed by the impact of the impact member.

According to the rotor manufacturing method of invention [2]-[6], the said effect can be acquired more reliably.

According to the manufacturing method of the rotor of invention [7], the excess thickness part of the said structure can be reliably formed.

According to the rotor manufacturing method of the invention [9], the excess thickness portion on the shaft side can be removed more reliably.

According to the rotor manufacturing method of the invention [10], the excess thickness portion can be reliably removed while ensuring high production efficiency as described above.

According to the rotor manufacturing method of the invention [11], since the diameter difference between the inner circumferential surface of the vane groove and the outer circumferential surface of the excess thickness portion can be made small, the excess thickness portion on the vane groove side can be easily and reliably removed, thereby improving production efficiency. Can be improved.

According to the manufacturing method of the rotor of invention [12] [13], the said effect can be acquired reliably.

According to the rotor manufacturing method of the invention [14] [15], the excess thickness portion can be prevented from inadvertently falling off.

According to the rotor manufacturing method of the invention [16], since the diameter difference between the inner circumferential surface of the shaft hole and the outer circumferential surface of the excess thickness portion can be made small, the excess thickness portion on the shaft hole side can be easily and reliably removed, resulting in increased production efficiency. I can improve it more.

According to the rotor manufacturing method of the invention [17] and [18], the excess thickness on the shaft side can be removed more reliably.

According to the rotor manufacturing method of the invention [19], the excess thickness on the shaft side can be prevented from inadvertently falling off.

According to the method of removing the excess thickness portion of the rotor material of the invention [20], the excess thickness portion on the shaft hole side can also be efficiently and reliably removed.

According to the apparatus for removing excess thickness of the rotor material of the invention [21], the excess thickness can be reliably removed while ensuring high production efficiency as described above.

BRIEF DESCRIPTION OF THE DRAWINGS The perspective view which disassembles and shows the forging metal mold | die used for the forging process in the manufacturing method of the rotor which is 1st Embodiment of this invention.
It is a schematic cross section in the forging preparation step in the forging process by the forging die of 1st Embodiment.
It is a schematic cross section in the upper metal mold | die dropping step in the forging process by the forging die of 1st Embodiment.
FIG. 2C is a schematic sectional view of the machining completed step in the forging process performed by the forging die of the first embodiment. FIG.
FIG. 2D is a schematic sectional view of a workpiece taken out in the forging process by the forging die of the first embodiment; FIG.
The perspective view which shows the rotor raw material obtained by the forging process of 1st Embodiment.
4 is a perspective view illustrating a rotor manufactured by the manufacturing method of the first embodiment.
FIG. 5 is a plan view showing an offset amount of a vane groove in the rotor material of FIG. 4. FIG.
FIG. 6 is a perspective view illustrating the upper die in the forging die of the first embodiment in an assembled state; FIG.
Fig. 7A is a partially cutaway perspective view showing a load applying state to the lower die in the forging die.
It is a figure for demonstrating the metal flow in the forging process in the forging metal mold | die.
8 is a plan view of a rotor material according to the first embodiment.
9 is a flowchart showing a process procedure in the manufacturing method of the first embodiment.
FIG. 10 is a cross-sectional view of the rotor material of the first embodiment cut away at the center hole; FIG.
11 is a cross-sectional view of the rotor material of the first embodiment cut away in the vane groove.
FIG. 12 is an enlarged cross-sectional view of a portion enclosed by a dashed-dotted line in FIG. 10. FIG.
It is sectional drawing which expands and shows the part enclosed with the dashed-dotted line of FIG.
Fig. 14 is a sectional view schematically showing the punching apparatus used in the excess thickness removing step in the manufacturing method of the first embodiment.
FIG. 15 is an enlarged cross-sectional view showing the periphery of the center hole in the rotor raw material of the first embodiment in a state where excess thickness is removed. FIG.
FIG. 16 is an enlarged cross-sectional view of the periphery of the vane groove in the rotor material of the first embodiment in a state where excess thickness is removed. FIG.
FIG. 17 is a cross-sectional view of the rotor material as a first modification of the present invention, cut out at the center hole; FIG.
Fig. 18 is a sectional view of the rotor material as a first modified example of the present invention cut away in the vane groove.
Fig. 19 is a sectional view of the rotor material as a second modified example of the present invention cut away at the center hole.
20 is a cross-sectional view of the rotor material as a second modified example of the present invention cut out in the vane groove.
The perspective view which shows the rotor raw material obtained by the forging process of 2nd Embodiment.
The top view of the rotor raw material in 2nd Embodiment.
It is a top view which expands and shows the vane groove part of the rotor raw material in 2nd Embodiment.
FIG. 23 is a cross-sectional view of the rotor material of the second embodiment cut away from the center hole; FIG.
24 is a cross-sectional view of the rotor raw material of the embodiment cut away in the vane groove.
FIG. 25 is an enlarged cross-sectional view of the periphery of the center hole side excess thickness portion in FIG. 23. FIG.
FIG. 26 is an enlarged cross-sectional view illustrating the periphery of the vane groove-side surplus thickness portion of FIG. 24. FIG.
Fig. 27A is a schematic sectional view of the upper die lowering step in the forging process by the forging die of the second embodiment.
FIG. 27B is a schematic sectional view at a machining completed step in forging processing with a forging die according to a second embodiment; FIG.

<Rotor>

First, the structure of the rotor R manufactured by 1st Embodiment of this invention is demonstrated. As shown in Fig. 4, the rotor R is a schematic cylindrical body having a center hole 3 as a shaft hole through which a shaft penetrates at the center thereof, and on the outer circumferential surface there are five vane grooves in which the groove bottom is enlarged in a circular cross section. 4) is formed. These vane grooves 4 are formed so as to be parallel to the axis of the cylinder and penetrate both end faces, and to be eccentrically into the center hole 3 and cut inward. In addition, as shown in FIG. 5, the offset amount U of the vane groove 4 is parallel to the center line L1 in the groove width direction and passes through the axis line of the rotor R in parallel with the center line L1. It is represented by the distance from the straight line L2.

As a material of the rotor R, aluminum or an aluminum alloy is generally used, and as an example thereof, 14 to 16 mass% of Si, 4 to 5 mass% of Cu, Mg: 0.45 to 0.65 mass%, Fe: 0.5 mass% or less, An aluminum alloy containing Mn: 0.1 mass% or less and Ti: 0.2 mass% or less, with the remainder being made of Al and inevitable impurities.

<Manufacturing process>

As shown in FIG. 9, the manufacturing method of a rotor in this embodiment mainly includes a cutting process, a mass sorting process, a forging process, a punching process, a heat treatment process, and an inspection process, and after passing through these processes as a rotor product, Shipped.

A cutting process and a mass sorting process are processes for obtaining a forging material, and in the cutting process, after cutting a continuous casting material to a predetermined length and obtaining a continuous casting material of a predetermined length, each casting material is mass (weight). Therefore, the desired forging material is obtained by screening.

Subsequently, in the forging process, the forging material is forged to obtain a rotor material, and then, in the punching step, excess thickness is removed from the rotor material to obtain a rotor.

Thereafter, in the heat treatment step, heat treatment and quenching treatment are performed on the rotor to improve hardness and wear resistance to obtain a rotor product. And final inspection is performed in the inspection process, and if there is no abnormality, it is shipped.

Hereinafter, the characteristic part of the manufacturing method of the rotor of this embodiment is demonstrated in detail.

<Forging process>

1, 2A to 2D show a forging die as a forging apparatus used for forging according to the first embodiment, and FIG. 3 shows a rotor material 1 forged by this forging die. to be.

As shown in these figures, the forging die includes a lower die 10 and an upper die 30 for applying a molding load. As these mold materials, well-known die steels are used.

The lower metal mold | die 10 is arrange | positioned above the lower metal mold body 11 which has the molding hole 12, the base 15 arrange | positioned under the lower metal mold body 11, and the lower metal mold body 11 upper side. It is divided into a bush 19.

In the shaping | molding hole 12 of the said lower metal mold | die main body 11, the five blade part 13 for shaping | molding the vane groove 4 from the inner peripheral wall surface of a hole protrudes. The blade portion 13 corresponds to the cross-sectional shape of the vane groove 4 and has a thin plate shape having a circular portion at its end. The base 15 has a plate shape, and a center pin 16 for forming the center hole 3 of the rotor R is fixed at the center thereof, and for the knockout pin 17 to surround the center pin 16. The through hole 18 of the hole is formed. The bush 19 is an annular body having a loading hole 20 penetrating up and down with the same diameter as the forming hole 12 of the lower mold body 11.

When the base 15, the lower mold main body 11 and the bush 19 are assembled and attached, the center pin 16 is inserted into the molding hole 12 of the lower mold main body 11 so that the inside of the molding hole 12 The rotor R is inverted and the loading hole 20 of the bush 19 communicates with the forming hole 12. In addition, in the forging preparation step shown in FIG. 2A, the knockout pin 17 is inserted into the through hole 18 of the base 15, and is waiting at a position where the distal end surface is flush with the base upper surface.

The upper mold 30 includes an upper mold body 31 for applying the main load F to the forging material W, a circular pin 40 and a flat plate for applying the sub loads F1 and F2. It is divided into 41.

The upper die body 31 has a lower cylindrical punch portion 32 formed as a rough cylindrical cylinder having an outer diameter corresponding to the through hole 20 of the bush 19, and has an upper surface on the upper half 33 having a large diameter. The recessed part 34 is formed. In the concave portion 34, one circular hole 35 into which the circular pin 40 can be inserted and retracted corresponding to the cross-sectional shape of the circular pin 40 and the cross-sectional shape of the flat plate 41 is provided. Correspondingly, five flat holes 36 for inserting the flat plate 41 forward and backward are formed. Both the circular hole 35 and the flat hole 36 penetrate the front end surface of the punch part 32, and the flat hole 36 is also open to the outer peripheral surface of the punch part 32. As shown in FIG. In addition, the position of the said circular hole 35 and the flat hole 35 corresponds to the position of the center pin 16 and the blade part 13 in the lower die main body 11.

The circular pin 40 is a circular pin having a diameter larger than that of the center pin 16 of the lower mold body 11, and an anti-falling part 42 having a diameter larger than the circular hole 35 is integrally formed at an upper end portion thereof. It is. The flat plate 41 is a thin plate shape having a circular portion at the distal end portion similar to the blade portion 13 of the lower mold body 11, but is larger than the blade portion 13 by one circumference and has a cross-sectional area greater than the flat hole 36 at the upper end portion thereof. The fall prevention part 43 which expanded this is integrally attached.

2A and 6, the circular pins 40 are fitted into the circular holes 35 from the recesses 34 of the upper mold body 31, and each of the flat holes 36 is fitted into the circular holes 35. When the flat plate 41 is inserted into the flat plate 41, the upper mold body 31, the circular pin 40, and the flat plate 41 are joined to each other so that the front end surface and the peripheral surface of the punch portion 32 are continuous. One cylinder is formed.

Above the circular pin 40 and the flat plate 41, a gas cushion 45 for applying a load applied thereto is disposed. When the piston rod 47 is retractably inserted into the cylinder 46 and the piston rod 47 is applied with a force in the retracting direction, the gas cushion 45 is formed in the retracting direction by the compressed gas enclosed therein. It generates the force in the forward direction to balance the force, and the greater the retraction distance, the greater the force in the forward direction. Each gas cushion 45 has a cylinder 46 fixed to the mounting plate 48, and the tip portion of the piston rod 47 is provided with the drop prevention portion 42 of the circular pin 40 and the flat plate 41 ( 43, the upper mold body 31 and the mounting plate 48 are assembled with the circular pin 40 and the flat plate 41 while the initial load by the forward force of the piston rod 47 is applied. It is. In addition, when the circular pin 40 and the flat plate 41 are raised and the piston rod 47 retreats, the load according to the retreat distance is applied to the circular pin 40 and the flat plate 41. Therefore, although the mounting board 48 raises and lowers with the upper metal mold | die 30, the sub load F1 (F2) applied to the circular pin 40 and the flat plate 41 is independent from the main load F. Controlled by the gas cushion 45.

The value of the first sub load F1 and the second sub load F2 can be adjusted by setting the operating load of the gas cushion 45, and also the gas is applied to the circular pin 40 and the flat plate 41, respectively. Since the cushion 45 is equipped, these can also control load independently. That is, the main load F applied to the upper mold body 32, the first sub load F1 applied to the circular pin 40, and the five second sub loads applied to the five flat plates 41. (F2) can be set to independent loads, respectively.

The lower mold 10 and the upper mold 30 have the circular pin 40 and the flat plate 41 at the corresponding positions of the center pin 16 and the blade portion 13 of the lower mold 10. It is arranged. Thus, as shown in FIGS. 7A and 7B, the first sub load F1 is applied directly above the center pin 16, and the second sub load F2 is applied directly above the blade portion 13. . The main load F is applied to portions other than the center pin 16 and the blade portion 13. In addition, in this invention, the said 1st sub load F1 and the 2nd sub load F2 are set to the value smaller than the main load F. As shown in FIG.

Next, referring to Figs. 2A to 2D, 7A, 7B, and 8 for a method of forging a forging material W to manufacture the rotor material 1 of Fig. 4 using the forging die. Explain while.

As shown in FIG. 2A, a lubricant is applied to the required portions of the lower mold 20 and the upper mold 30, and the cylindrical forging material 49 is loaded into the loading hole 20 of the bush 19. As mentioned above, the forging material W is produced by a method such as cutting the continuous cast material to a predetermined length, and is heated to a predetermined temperature as necessary. As the lubricant, an aqueous graphite lubricant, an oily graphite lubricant, and the like can be exemplified. In order to prevent scuffing from occurring between the forging material W and the molds 10 and 30, an aqueous graphite lubricant and an oily agent are used. It is preferable to use graphite lubricant together. The coating amount is about 2 to 10 g each. Moreover, as for the preheating temperature, when forging material W is an aluminum alloy, 400-450 degreeC is preferable.

From this state, as shown in FIG. 2B, when the upper die 30 is lowered to the main load F to forge the forged material W loaded in the lower die 10, the forged material W is formed into a molding hole. In the process of filling in (12), the circular pin 40 with the 1st sub load F1 smaller than the main load F, and the flat plate 41 with the 2nd sub load F2 pushed up. The material flows into the circular hole 35 and the flat hole 36. The first sub load applied to the circular pin 40 as the circular pin 40 and the flat plate 41 ascend with the lowering of the upper die 30 and the retracting distance of the piston rod 47 increases. The second sub load F2 applied to the F1 and the flat plate 41 is increased. In this manner, the main load F is applied to the portions other than the circular pin 40 and the flat plate 41 with respect to the forged material W, whereas the circular pin 40 and the flat plate 41 Corresponding portions are given a first sub load F1 and a second sub load F2 independent of the main load F.

As shown in FIG. 2B, the circular pin 40 and the flat plate 41 are provided with the first and second sub loads F1 and F2 smaller than the main load F, thereby providing a circular pin ( 40 and the flat plate 41 rise, and the material flows into the circular hole 35 and the flat hole 36. As the material flows into the circular hole 35 and the flat hole 36, the force applied to the center pin 16 and the blade portion 13 of the lower mold 10 is relaxed. As a result, as shown in FIG. 7B, the metal flow α1 between the wall surface of the forming hole 12 and the blade portion 13 and the metal portion α1 deform the blade portion 13 inward by the metal flow α1. Since the force α2 is relaxed and the metal flow α3 facing the outer circumference at the time of forming the center hole 3 acts in the opposite direction to the force α2 that deforms the blade portion 13 inward, these forces By maintaining the balance between (α2) and (α3), the bending deformation and the torsional deformation of the center pin 16 and the blade portion 13 can be suppressed.

Appropriate values of the first subload F1 and the second subload F2 are appropriately set in accordance with the volume of the center pin 16 and the blade portion 13. As the volume of these materials increases as the volume increases, the volume of the blade portion 13 is constant. As the volume of the center pin 16 increases, the first sub-load F1 decreases to the circular hole 35. The balance can be maintained by increasing the inflow of.

As shown in FIG. 2C through the above-described process, when the upper die 30 drops to the bottom dead center, the molding of the rotor material 1 is completed.

After that, as shown in FIG. 2D, the upper mold 30 is raised, the knockout pin 17 is raised, and the forged rotor material 1 is projected. When the circular pin 40 and the flat plate 41 are separated from the rotor 1 and the force from below is removed, the piston rod 47 of the gas cushion 45 is returned to the initial position.

In the above-described process, since the bending deformation and the torsional deformation of the center pin 16 and the blade portion 13 of the lower die 10 are suppressed, the rotor material 1 shown in FIG. 3 has the center hole 3. And the dimensional accuracy of the vane groove 4 is high, and mold life is lengthened by suppressing deformation. In addition, since it is not necessary to enlarge the outer diameter of the rotor material in order to prevent deformation of the blade portion 13, there is no part to be cut off in post-processing so that waste does not occur in the material.

In addition, the first sub load F1 and the second sub load F2 are set to a value smaller than the main load F, so that the material pushed out by the circular pin 16 and the blade portion 13 easily flows. Therefore, the upper die 30 can be lowered to a height at which the circular pin 16 and the blade portion 13 are fed into the circular hole 35 and the flat hole 36. For this reason, the rotor raw material 1 produced by the movement of the thickness part of the center hole 3 and the vane groove 4 has the center hole 3 in the upper end surface (one end surface 2a) of the rotor part 2. ) And the excess thickness portions 5, 6 are formed corresponding to the portions of the vane grooves 4.

In addition, since the first sub load F1 and the second sub load F2 are given separately, the excess thickness portion 5 on the center hole 3 and the excess thickness portion 6 on the vane groove 4 are separately. The planar shape of these excess thickness parts 5 and 6 corresponds to the cross-sectional shape of the circular pin 40 and the flat plate 41.

Here, in this embodiment, the rotor raw material 1 is comprised by the rotor part 2 and the excess thickness part 5, 6, and the rotor part 2 has the excess thickness part 5 (6). ) Is not included.

The excess thickness portions 5 and 6 formed in this manner are provided to swell from one end surface 2a of the rotor portion 2 to one end side, as shown in FIGS. The center hole 3 and the vane groove 4 are formed to the inside of (5) (6).

In addition, as shown in FIG. 12, the surplus thickness part 5 of the center hole side has the closed part 5a which closes the one end surface 3a of the center hole 3, and the circumferential side surface of the center hole 3. As shown in FIG. It has a peripheral wall part 5b which occludes the cross section, and the cross section is finished in substantially inverted U shape. Similarly, as shown in FIG. 13, the excess thickness part 6 of the vane groove side has the closed part 6a which occludes the one end surface 4a of the vane groove 4, and the peripheral side surface of the vane groove 4. As shown in FIG. It has the surrounding wall part 6b to block | close, and the cross section is finished in substantially inverted U shape. Further, the peripheral wall portions 5b and 6b in the excess thickness portion 5 are formed from the one end surface 2a of the rotor portion 2 and the one end surface 3a of the center hole 3 and the vane groove 4. It is a part arrange | positioned to the range up to (4a), and the closed part 5a, 6a is arrange | positioned at the one end side more than the one end surface 3a, 4a of the center hole 3 and the vane groove 4. Part.

In the present embodiment, at the time of forging, the peripheral wall portions 5b of the excess thickness portions 5 and 6 are adjusted by adjusting the main load F, the first and second sub loads F1 and F2. Cracks 7 and 7 are generated in 6b. The cracks 7 and 7 are formed in order to facilitate the removal of the excess thickness portions 5 and 6 in the punching step described later. In addition, in this embodiment, in order to remove the excess thickness part 5 and 6 easily and correctly, the excess thickness part 5 and 6 are formed in a specific structure, but the excess thickness part 5 The details of the configuration of (6) will be described later.

In addition, in this embodiment, since the back pressure by the 1st, 2nd sub-load F1 (F2) is given at the time of a forging process, the excess thickness part 5 and 6 are the rotor part 2; It is possible to reliably prevent the problem of being popped or torn from, and the excess thickness portions 5 and 6 having a desired configuration described later can be integrally formed on the rotor material 1.

Needless to say, both the center hole 3 and the vane groove 4 are opened on the other end surface (lower end surface 2b) of the rotor portion 2 in the rotor raw material 1.

In the forging process of this embodiment, the main load F, the 1st sub load F1, and the 2nd sub load F2 depend on the shape of the rotor material 1, the dimension of each part, material composition, processing temperature, etc. Set appropriately. For example, as a setting value in the case of manufacturing the rotor R of 40-70 mm in diameter and 30-60 mm in height made from aluminum or aluminum alloy, it is a main load F: 270-325 MPa, the 1st sub load F1, and 2nd sub load F2: 29-89 Mpa can be illustrated.

In addition, when the first sub load F1 and the second sub load F2 are set too small, the excess thickness portions 5 and 6 may be torn, whereas when the first sub load F1 and the second sub load F2 are set too small, the center pin 16 and the blade may be set too large. The effect of alleviating the force applied to the part 13 is small, and the effect of suppressing the collapse deformation and the torsional deformation becomes small. As mentioned above, when forging the aluminum alloy rotor R, 29-89 MPa is preferable and the range of 39-49 MPa is preferable. In addition, in the spring-type sub load applying means such as the gas cushion 45, the first sub load F1 and the second sub load F2 increase with the lowering of the upper mold 30, The load is the initial load.

In addition, although the sub load applying means for giving the 1st sub load F1 and the 2nd sub load F2 is not limited, It is preferable that a load can be provided following the lifting of the upper metal mold | die 30. As shown in FIG. From this point of view, a spring type such as a gas cushion is preferable, and a mechanical spring, a hydraulic mechanism, a shock absorber can be exemplified as another sub load applying means.

8, the planar shape of the excess thickness portions 5 and 6 in the rotor 1 has a width t of about 0.1 around the center pin 16 and the blade portion 13. The shape which added the expansion part of -3 mm is preferable. In other words, the gap t between the circular hole 35 and the center pin 16 of the upper mold body 31 and the gap t between the flat hole 36 and the blade portion 13 are 0.1 to 3 mm. It is preferable to set the circular hole 35 and the flat hole 36 so as to be. If the width t is less than 0.1 mm, the material flow may deteriorate at the time of forging, and the excessive thickness portions 5 and 6 may be broken, and the deformation preventing effect may be lowered by the breaking. When it exceeds 3 mm, the circular hole 35 and the flat hole 36 of the upper mold 30 may interfere with each other. Particularly preferred gap t is 1 to 2 mm.

<Punching process>

FIG. 14 is a cross-sectional view schematically showing a punching device (die set) as an excess removing device used in a punching machining step (an excess removing step). As shown in FIG. 14, this punching apparatus is provided with the lower metal mold | die 8 and the upper metal mold | die 9, As demonstrated in detail later, the excess thickness part from the rotor raw material 1 by the punching process ( 5) (6) can be punched out.

The lower metal mold | die 8 is equipped with the lower plate 81 and the lower metal mold main body 85 provided in the upper surface of the lower plate 81. As shown in FIG.

The lower plate 81 has an excess thickness portion discharge hole 82 penetrating in the vertical direction at the center thereof. In addition, guide bars 83 are provided on both sides of the lower plate 81 along the vertical direction.

The lower die main body 85 is fixed by closing the excess thickness portion discharge hole 82 on the upper surface of the lower plate 81.

The lower die main body 85 is provided with a workpiece mounting portion 86 corresponding to the excess thickness portion discharge hole 82 of the lower plate 81. The workpiece | work mounting part 86 is comprised so that the said rotor raw material 1 can be installed in the one end surface 2a side toward the lower side. That is, the center hole side demolding hole 87 is formed in this workpiece | work installation part 86 corresponding to the center hole side excess thickness part 5, and the vane groove side demolding hole corresponding to the vane groove side excess thickness part 6 is formed. 88 is formed. This center hole side demolding hole 87 is formed in the inner peripheral shape corresponding to the outer peripheral shape of the center hole side excess thickness part 5, and can fit the center hole side excess thickness part 5 in a suitable state. It is supposed to be. Moreover, the vane groove side demolding hole 88 is formed in the inner peripheral shape corresponding to the outer peripheral shape of the vane groove side excess thickness part 6, and can fit the vane groove side excess thickness part 6 in a suitable state. . In addition, each of the demolding holes 87 and 88 penetrates in the vertical direction, and the lower end portion communicates with the excess thickness portion discharge hole 82 of the lower plate 81.

Then, the excess thickness portions 5 and 6 of the rotor material 1 are fitted to the demolding holes 87 and 88 in a suitable state, respectively, and the one end surface 2a of the rotor portion 2 is fitted into the work attachment portion ( The rotor raw material 1 can be set in the positioning state on the workpiece | work mounting part 86 by loading on 86).

The upper mold 9 includes an upper plate 91 and an upper mold body 95 provided on the lower surface of the upper plate 91.

The upper plate 91 is configured to be capable of lifting up and down in a vertical direction, and can be driven up and down by lifting and lowering drive means such as a hydraulic cylinder (not shown).

In addition, the guide hole 93 is formed in the both side parts of the upper plate 91 corresponding to the guide bar 83 of the lower plate 83, and when the upper plate 91 falls as mentioned later, The bar 83 is inserted into the guide hole 93 so that the lowering movement of the upper plate 91 is guided.

The upper mold body 95 is fixed to the lower surface of the upper plate 91 so as to face the lower mold body 85.

The upper mold main body 95 corresponds to the center hole side demolding hole 87 and the vane groove side demolding hole 88 in the lower mold main body 85, that is, the rotor material provided in the lower mold 85 ( Corresponding to the center hole 3 and the vane groove 4 of 1), the center hole side punching punch 97 and the vane groove side punching punch 98 are mounted so as to project downward, respectively.

In this embodiment, the punching punch 97 and 98 are comprised as an impact member.

Next, the method of removing the excess thickness part 5 and 6 of the rotor raw material 1 using the punching apparatus of the said structure is demonstrated.

First, the rotor material 1 is placed downward at the one end surface 2a side of the work attachment portion 86 in the lower die 8 of the punching device, and each surplus thickness portion 5, 6 is formed. It installs in the state suitable for the corresponding demolding hole 87 and 88. FIG. In this installation state, the center hole side punching punch 97 and the vane groove side punching punch 98 of the upper mold body 85 have the other ends of the center hole 3 and the vane groove 4 of the rotor material 1. It is arranged opposite the side opening.

When the upper die 85 is lowered in the state where the rotor material 1 is set in this manner, the punches 97 and 98 of the upper die body 85 become the upper end surface (the other end surface () of the rotor material 1). 2b)) is inserted into the center hole 3 and the vane groove 4 from each side, and each punch 97 and 98 collide with the excess thickness portions 5 and 6 in a pressurized state, and the excess thickness portion 5 (6) is punched out. As a result, the excess thickness portions 5 and 6 are removed from the rotor portion 2, and the removed excess thickness portions 5 and 6 are removed through the excess thickness portion discharge holes 82 of the lower plate 81. It is discharged downwards. In this way, as shown in FIGS. 15 and 16, the one end side of the center hole 3 and the vane groove 4 in the rotor material 1 is opened, whereby the center hole 3 and the vane groove 4. It is possible to obtain a rotor (R), both ends of which are open.

In the present embodiment, the excess thickness portions 5 and 6 are formed on the one end surface 2a of the rotor portion 2 so as to swell to one end side, so that the excess thickness portions 5 and 6 are punched out. When it does so, it can break correctly at the position of the peripheral wall parts 5b and 6b, and the excess thickness parts 5 and 6 can be removed reliably with high precision.

In particular, in the present embodiment, as shown in Figs. 12 and 13, since the cracks 7 and 7 are formed in the peripheral wall portions 5b and 6b of the excess thickness portions 5 and 6, The part of the cracks 7 and 7 can be reliably broken, and the excess thickness portions 5 and 6 can be removed from the rotor R with higher accuracy.

In addition, since the cracks 7 and 7 are formed at the fracture scheduled positions, the punching loads of the punches 97 and 98 can be concentrated at the positions of the cracks 7 and 7, so as to be sure at that position. It can break. For this reason, even if the load of the punch 97 and 98 is made small, the excess thickness part 5 and 6 can be reliably punched. Since press work can be carried out at such a low load in this way, high load becomes a factor, and it can effectively prevent that a crack and fracture generate | occur | produce in the rotor R, and a high-quality rotor product can be manufactured. As a specific example, the punch load can be reduced to about half as compared with the case where no cracks 7 and 7 are formed when the cracks 7 and 7 are formed.

In addition, since the processing can be performed in a low weight, wear of the punches 97 and 98 itself can be reduced, and the durability of the punches 97 and 98 and further, the durability of the punching device can be further improved. In addition, since it is being lowered, the strength of the punches 97 and 98 itself can also be lowered. For example, the punches 97 and 98 can be employed without problems even if they have a thin plate shape having a thickness of about 2.5 mm.

Moreover, in this embodiment, the excess thickness part 5 and 6 are formed only in the periphery of the center hole 3 and the vane groove 4 in the end surface of the rotor raw material 1 by a forging process. At the same time, since only a partial excess thickness portion 5 and 6 is removed by the punching process, the capacity of the excess thickness portions 5 and 6, that is, extra material, is reduced, so that the material yield can be improved. Therefore, cost can be reduced.

In addition, the punching process of this embodiment does not need to heat the rotor raw material 1 in particular, and is cold performed. In the present invention, however, the rotor material 1 may be heated immediately before the punching process, and the punching process may be performed hot.

However, when the excess thickness portions 5 and 6 are broken and removed from the peripheral wall portions 5b and 6b as in the present embodiment, as shown in Figs. 15 and 16, the burrs 5c ( Although 6c) generate | occur | produces, this bur 5c and 6c may be removed as needed. For example, the burr removing step may be provided between the punching step and the heat treatment step, and the burrs 5c and 6c may be removed therefrom or the burr removing step may be provided between the heat treatment step and the inspection step.

In the case where the end face is finished and cut at the shipping destination, the burrs 5c and 6c may be removed by the finishing cut, so that the burrs 5c and 6c are removed during the manufacturing process of the rotor R. There is no need.

Further, as will be described later, the burr 5c (by placing the fracture surface at the time of removing the excess thickness portions 5 and 6 at a position equivalent to or at an inner side of the one end surface 2a of the rotor portion 2) ( 6c) may be prevented from forming.

Next, an example of the rotor R in the present embodiment will be described, and a configuration that is optimal for reliably removing the excess thickness portions 5 and 6 in the rotor of this example will be described below.

First, the rotor R of the example to be produced has a length in the axial direction of 30 to 60 mm, an outer diameter (diameter) of 45 to 65 mm, a diameter of the center hole 3 of 10 to 15 mm, and a width of the vane groove 4. 2-4 mm and the depth from the outer peripheral surface of the vane groove 4 are set to 15-20 mm.

In the rotor raw material 1 used to produce the rotor R of such an example, as shown in FIG. 12, the thickness of the closed portion 5a on the center hole side, that is, the excess thickness portion 5. The dimension from the distal end to the one end face 3a of the center hole 3 is defined as "T5", the height of the peripheral wall part 5b, that is, the one end face of the center hole 5 in the excess thickness part 5. When the dimension from (5a) to the one end surface 2a of the rotor part 2 is set to "Z5", the swelling amount H5 of the excess thickness part 5 becomes equal to "T5 + Z5".

The optimal configuration in the center hole side excess thickness portion 5 at this time is 3.5 to 12 mm for the amount of swelling H5 of the excess thickness portion 5 and 3 to 10 mm for the thickness T5 of the closure portion 5a. It is preferable to set the height T5 of the peripheral wall portion 5b to 0.5 to 2 mm. In particular, when the obstruction portion thickness T5 is too small, the breaking position at the time of removing the excess thickness portion 5 becomes unstable, resulting in a short mold life and a low dimensional accuracy. On the contrary, when the obstruction portion thickness T5 is too large, the material yield deteriorates.

Furthermore, the curvature radius r5 of the vertical rising part (installation part) in the outer circumferential surface of the excess thickness part 5 is adjusted to 0 to 10 degrees for the demolding gradient θ5 of the excess thickness part 5 to 0.5 to 3 mm. It is good.

In addition, also in the vane groove side excess thickness part 6 as shown in FIG. 13, the swelling amount H6 of the excess thickness part 6 is the thickness T6 of the obstruction part 6a similarly to the peripheral wall part. It becomes equal to the value which added height Z5 of (6b).

In addition, the optimum structure in the vane groove side excess thickness part 6 at this time is also the same as the above. That is, from the same reason as above, the expansion amount H6 of the excess thickness part 6 is 3.5-12 mm, the thickness T6 of the obstruction part 6a is 3-10 mm, and the height Z6 of the peripheral wall part 6b. Is preferably set to 0.5 to 2 mm. In addition, similarly to the above, the demold gradient θ6 of the excess thickness portion 6 is 0 to 10 °, and the radius of curvature r6 of the vertical rise portion (installation portion) on the outer circumferential surface of the excess thickness portion 6 is from 0.5 to 10 degrees. It is good to adjust it to 3mm.

When the excess thickness portions 5 and 6 are configured as described above, the excess thickness portions 5 and 6 can be reliably punched by the punches 97 and 98, and the excess thickness portions 5 ( 6) can be removed with high accuracy. In particular, the adjustment of the radius of curvature r5 and r6 is important. In other words, if the radius of curvature r5 (r6) is reduced, the crack 7 is likely to occur, and the crack 7 can be enlarged. On the contrary, if the radius of curvature r5 (r6) is enlarged, the crack 7 is generated. It is difficult to do so, and the crack 7 becomes small. Therefore, according to adjustment of the radius of curvature r5 (r6), the magnitude | size, shape, a position, etc. of the crack 7 can be controlled suitably, and the excess thickness part 5 and 6 can be reliably made more precisely. Can be removed

Thus, in this embodiment, since the excess thickness part 5 and 6 are removed by punching process, compared with the case where the excess thickness part is cut off by mechanical processing with low efficiency, such as a cutting process, it is efficient. As a result, the excess thickness portions 5 and 6 can be removed, thereby improving production efficiency.

In addition, since the excess thickness portions 5 and 6 are formed in the bulging shape on one end surface 2a of the rotor material 1, the excess thickness portions 5 and 6 can be easily and precisely formed by punching. Can be removed.

On the other hand, the rotor R from which the excess thickness portions 5 and 6 are removed by the punching step is subjected to the heat treatment step and the inspection step after the burrs 5c and 6c are removed as necessary as described above. It is shipped (see FIG. 9).

<Variation example>

In the said embodiment, the excess thickness part 5 and 6 are comprised by the bulging part which expands from the one end surface 2a of the rotor part 2, and the excess thickness part 5 and 6 of Although the case where the center hole 3 and the vane groove 4 are formed to the position outside the one end surface 2a in the inside was described as an example, in the present invention, the center hole 3 and the vane groove ( It is not necessary to form one end surface 3a, 4a of 4) to the outer side rather than the one end surface 2a of the rotor part 2. As shown in FIG.

For example, as shown in FIG. 17, FIG. 18, the center hole 3 and the vane groove 4 are made into the one end surface 3a, 4a, and the one end surface 2a of the rotor part 2 substantially. You may form so that it may be arrange | positioned at the same position.

In this case, corresponding to the position of the one end surface 2a in the rotor part 2, the cracks 7 and 7 are formed in the excess thickness portions 5 and 6, and are broken at the position, The excess thicknesses 5 and 6 are removed. Therefore, the burr after removal of the excess thickness portions 5 and 6 can be formed smaller than the burrs 5c and 6c of the above embodiment.

Further, as shown in FIGS. 19 and 20, the center hole 3 and the vane groove 4 have one end face 3a and 4a inside the one end face 2a of the rotor part 2 (the other end part). On the side).

In this case, the cracks 7 and 7 are formed from the vertically raised position on the outer circumferential surface of the excess thickness portions 5 and 6 from the end corner positions of the center hole 3 and the vane groove 4. , It is broken at that position, and the excess thickness portions 5 and 6 are removed. Thus, a chamfered cutout is formed at the periphery of the center hole and the periphery of the vane groove in the one end face 2a of the rotor material 1 at the removal mark of the excess thickness portions 5 and 6, thereby forming burrs. It can surely be prevented.

In addition, in the said embodiment, although the cracks 7 and 7 are formed in the excess thickness part 5 and 6, as demonstrated in detail in 2nd Embodiment of the following, in this invention, a crack ( It is not necessary to form 7) (7).

On the other hand, in the said embodiment, although the excess thickness part 5 and 6 are punched out by the punch 97 and 98 inserted from the other end side of the center hole 3 and the vane groove 4, it is made to punch. In the present invention, when the excess thickness is removed, the punching is not limited to punching.

That is, the impact member such as a hammer is hit from the outer side of the rotor material 1, for example, from a direction orthogonal to the axial center direction, and removed so as to slap the excess thickness portion by the impact, or an impact member such as a cutting tool. It is also possible to cut the excess thickness portions 5 and 6 by cutting the roots (base ends) of the excess thickness portions 5 and 6 along the surface perpendicular to the axial direction.

In the above embodiment, the center pin 16 and the vane groove forming blade portion 13 are provided in the lower mold 10 so that the center hole 3 is formed at the same time as the vane groove 4 is formed. However, the method of forming the center hole is not limited only to the above. For example, before forging, the center hole may be formed in the forging material in advance, and only the vane groove is formed by forging by a mold without a center pin, and the rotor material having the vane groove is post-processed. A center hole may be formed at

In addition, in the said embodiment, although forging process and excess thickness punching process are performed using a separate apparatus, it is not limited only to this, In this invention, forging process and excess thickness punching process are the same. It is also possible to carry out by an apparatus.

For example, in the forging apparatus shown in FIG. 1, FIG. 2, a long thing is used as the blade part 13 and the center pin 16 of the lower metal mold | die 10, and at the time of forging processing, The same forging is performed by lowering the upper die 30 at the same stroke amount. In the subsequent excess thickness punching, the thickness of the upper portion 30 is lowered by the blade portion 13 and the center pin 16 by following the above forging and lowering the upper die 30 to increase the stroke amount. 5) (6) may be punched out.

Moreover, in the said embodiment, it is used as a forging apparatus which is the type of providing the vane groove forming blade part 13 and the center hole forming pin 16 in the fixed side metal mold | die, such as the lower metal mold | die 10. However, the present invention is not limited thereto, and in the present invention, a vane groove forming blade portion (punch) and a center hole forming pin (punch) are provided in a movable side mold such as the upper die 30. You may make it use a forging apparatus. Also in this case, by using a long thing as a punch for forming a vane groove and a punch for forming a center hole, a forging process and an excess thickness punching process can be performed together by one apparatus (forging apparatus) similarly to the above.

<2nd embodiment>

21-26 is a figure which shows the rotor raw material 1 obtained by the forging process in 2nd Embodiment of this invention. As shown in these figures, in the second embodiment, the rotor material 1 is constituted by the rotor portion 2 and the excess thickness portions 5 and 6, and the rotor portion 2 Excess thickness portions 5 and 6 are not included.

The excess thickness portions 5 and 6 are provided so as to expand from one end surface 2a of the rotor portion 2 toward one end side.

In addition, in the rotor material 1 of this embodiment, the one end surface 3a of the center hole 3 does not reach the inside of the excess thickness part 5, and the one end surface 3a does not reach the inside of the rotor part 2; It is arrange | positioned inside one end surface 2a.

In addition, the one end surface 4a of the vane groove 4 does not reach the inside of the excess thickness part 6 similarly, and the one end surface 4a is arrange | positioned inside the one end surface 2a of the rotor part 2, and have.

Moreover, in the other end surface (lower end surface 2b) of the rotor part 2 in the rotor raw material 1, both the center hole 3 and the vane groove 4 are opened.

As shown in FIG. 25, FIG. 26, the end surface difference (breaking length D3) between the one end surface 2a of the rotor part 2 and the one end surface 3a of the center hole 3 is 0-2 mm. In addition, the end surface difference (breaking length D4) between the one end surface 2a of the rotor part 2 and the one end surface 4a of the vane groove 4 is similarly set to 0 to 2 mm.

The diameter difference D5 between the outer circumferential surface of the excess thickness portion 5 and the inner circumferential surface of the center hole 3 is set to 0.01 to 0.1 mm, preferably 0.05 to 0.1 mm. The diameter difference D6 between the outer circumferential surface of the excess thickness portion 6 and the inner circumferential surface of the vane groove 4 is similarly set to 0.01 to 0.1 mm, preferably 0.05 to 0.1 mm.

On the other hand, as shown in FIG. 22B, in the present embodiment, the diameter difference D61 and the inner circumferential side of the outer peripheral side end of the rotor portion among the diameter difference D6 between the excess thickness portion 6 and the vane groove 4. The diameter difference D62 of an edge part is formed thicker than the diameter difference D60 of an intermediate main part.

25 and 26, in the present embodiment, the radius of curvature r3 between the inner circumferential surface of the center hole 3 and the one end surface 3a in the rotor material 1 is set to 0.2 to 1 mm. It is. Moreover, it is preferable that the curvature radius r4 between the inner peripheral surface and the one end surface 4a of the vane groove 4 is also set to 0.2-1 mm similarly. By setting it to this range, when the excess thickness part 5 (6) is removed by punching, for example, as shown in FIG. 26, the inside which remain | survives inside the center hole 3 and the vane groove 4 is shown. The average value of the height B1 from the inner wall surface of the center hole 3 of the burr and the vane groove 4 can be adjusted to a preferable value. Specifically, the height B1 of the inner burr can be set to 1 mm or less. In addition, when the height B1 of this inner burr exceeds 1 mm, the breaking position becomes unstable, and it becomes difficult to precisely control the inner dimensions of the center hole 3 and the vane groove 4.

In addition, in this embodiment, the curvature radius r3a (r4a) between the outer peripheral surface and the one end surface 2a of the excess thickness part 5 and 6 in the rotor raw material 1 is the excess thickness part 5 ( It is good to adjust to below the radius of curvature r3 (r4) of the said inner peripheral surface side of 6). Specifically, it is preferable to satisfy the relationship of "r3a≤r3" and "r4a≤r4". By setting it to this range, when the excess thickness part 5 (6) is removed by punching, for example, as shown in FIG. 26, the average value of the height B2 of the convex burr remaining in the one end surface 2a is shown. Can be adjusted to a desired value. Specifically, the height B2 of the convex burr can be set to 1 mm or less. In addition, the break position can be stabilized, and as a result, the deviation of the height B2 of the convex burr is also reduced, so that the cutting value can be easily managed in a later step, and the dimensional accuracy management of the center hole 3 and the vane groove 4 can be performed. It becomes easy. In addition, when the height B2 of the inner burr exceeds 1 mm, the breaking position becomes unstable, and it becomes difficult to precisely control the inner dimensions of the center hole 3 and the vane groove 4.

The metal mold | die used by this invention is a molding die which forms the rotor raw material which has such a shape, The radius of curvature r3a is formed in the circular hole 35 of the upper mold, and the inversion shape of the radius of curvature r4a of the flat hole 36 is carried out. In addition to this, the inverted shape of the radius of curvature r3 of the center pin 16 of the lower die has the inverted shape of the radius of curvature r4 in the blade portion 13.

In this embodiment, the rotor raw material 1 of the said structure is manufactured using the forging process apparatus similar to the said 1st Embodiment.

That is, the forging raw material 49 is loaded into the loading hole 20 of the lower mold 10 (see FIG. 2A as the first embodiment), and from this state, the upper mold 30 is opened as shown in FIG. 27A. Lower In this way, by lowering the upper die 30 to the bottom dead center, the upper die 30 is molded into the shape of the rotor material 1 as shown in FIG. 27B.

Thereafter, after the upper die 30 rises, the rotor raw material 1 as a forged product is taken out as described above.

In this embodiment, when the upper mold 30 falls to the bottom dead center (at the time of mold fitting), the front end face (upper end face) of the center pin 16 is the opening face (lower end position) of the circular hole 35. ) Or to be spaced apart. Thereby, as mentioned above, the one end surface 3a of the center hole 3 in the rotor raw material 1 does not reach the inside of the excess thickness part 5, but the one end surface of the rotor part 2 ( While disposed inside 2a), one end surface 4a of the vane groove 4 does not reach the inside of the excess thickness portion 6, but is disposed inside the one end surface 2a of the rotor portion 2 inside. do.

Here, the distal end surface of the center pin 16 and the opening surface of the circular hole 35 and the spacing (end surface difference D3) at the time of mold-fitting are equal to the above-described fracture length D3 on the center hole side. Is set to 0 to 2 mm, and the interval (end face difference D4) between the tip end face of the blade portion 13 and the opening face of the flat hole 36 is equal to the breaking length at the vane groove side described above. To 2 mm (see Figs. 25 and 26).

The clearance (diameter difference D5) between the outer circumferential surface of the center pin 16 and the inner circumferential surface of the circular hole 35 is the inner circumferential surface of the center hole 3 in the rotor material 1 and the excess thickness portion 5. Is equal to the diameter difference D5 from the inner circumferential surface thereof, and is set to 0.01 to 0.1 mm, preferably 0.05 to 0.1 mm, and the clearance between the outer circumferential surface of the blade portion 13 and the outer circumferential surface of the flat hole 36 The difference D6 is equivalent to the diameter difference D6 between the inner circumferential surface of the flat hole 36 in the rotor material 1 and the inner circumferential surface of the excess thickness portion 5, and is preferably 0.01 to 0.1 mm. It is set to 0.05 to 0.1 mm (see FIG. 25, FIG. 26).

In addition, when the diameter difference (D5) (D6) of the excess thickness part outer periphery or the break length (D3) (D4) is too large, the excess thickness part 5 (6) can be removed with high precision in a punching process. There is no fear that adverse effects due to the break marks will occur. On the contrary, when diameter difference D5 (D6) is too small, there exists a possibility that the excess thickness part 5 and 6 may inadvertently fall out before a punching process.

In the rotor material 1 of the second embodiment thus obtained, the excess thickness portions 5 and 6 are removed by using the punching apparatus shown in FIG. 14 as described above, for example, and the rotor ( R).

In the rotor manufacturing method of this 2nd Embodiment, in addition to the effect of the said 1st Embodiment, it has the following effects.

First, in the rotor raw material 1 as the forged workpiece in the second embodiment, the diameter difference D5 (D6) between the excess thickness portion 5, 6, the center hole 3, and the vane groove 4 is shown. ), The excess thickness portions 5 and 6 can be reliably removed at a predetermined position.

In particular, in the present embodiment, since the fracture lengths D3 and D4 of the excess thickness portions 5 and 6 are formed thin, the fracture area at the time of removing the excess thickness portion can be reduced, and the bottom load is simple. Can be removed, it is possible to improve the production efficiency.

In addition, when the excess thickness portions 5 and 6 are removed, the excess thickness portions 5 and 6 can be punched by the punch 97 and 98 under the floor load, so that high load is a factor. The generation of harmful cracks and breaks in the rotor R can be effectively prevented and a high quality rotor product can be manufactured.

In addition, since the processing can be performed at a lowered weight, wear of the punches 97 and 98 itself can be reduced, and the durability of the punches 97 and 98 and further, the durability of the punching device can be further improved.

In addition, since the fracture area at the time of removing the excess thickness is small, the fracture mark (rupture surface) is also reduced, so that adverse effects due to the fracture mark can be avoided, for example, a finishing process for finishing the fracture mark in a post process can be performed. There is no need, and by reducing the number of steps, the productivity can be further improved and the cost can be reduced.

Furthermore, in this embodiment, since the one end surface 3a, 4a of the center hole 3 and the vane groove 4 is arrange | positioned inside the one end surface 2a of the rotor part 2, the excess thickness Since the fracture marks after the removal of the portions are disposed inside the inner circumferential surfaces of the center hole 3 and the vane groove 4, that is, inside the rotor R, the adverse effects due to the fracture marks can also be prevented in this regard, and the fracture It is possible to reliably omit the post-treatment of the marks, and further improve the productivity.

In the present embodiment, the diameter difference D61 on the outer peripheral end side of the rotor portion and the diameter difference D62 on the inner peripheral end side of the diameter difference D6 between the surplus thickness portion 6 and the vane groove 4, Since it forms thicker than the diameter difference D60 of an intermediate principal part, it can prevent that the excess thickness part 6 inadvertently falls off after a forging process and before punching, for example, the excess thickness part 6 is forged. Problems, such as remain | surviving in a metal mold | die for a process, can be prevented reliably, and high productivity can be maintained.

Furthermore, in this embodiment, since the diameter difference D61 (D61) (D62) of the both ends of the excess thickness part 6 is formed thick, it can reliably prevent inadvertent rupture in this part, and the excess thickness The department 6 can more reliably prevent inadvertent fallout. In other words, both ends of the excess thickness portion 6 tend to be the break start points at the time of dropping, and by forming the both ends thickly, breakage is less likely to occur, and inadvertent fallout can be more reliably prevented.

In addition, in this embodiment, although the diameter difference D6 in the outer periphery of the excess thickness part 6 by the side of the vane groove 4 is made thick, it is not limited only to this, In this invention, the center The diameter difference D5 at the outer circumference of the excess thickness portion 5 on the side of the hole 3 may be partially thickened.

Example

EXAMPLE 1

The rotor material 1 shown in FIG. 3 was forged using the forging dies 10 and 30 shown in FIGS. 1 and 2. The rotor material 1 is a material for producing the aluminum alloy rotor R shown in FIG. 4.

In the rotor R, the outer diameter is 52 mm, the height is 50 mm, the diameter of the center hole 3 is 10 mm, the number of vane grooves 4 is 5, the groove width is 3 mm, the depth of the groove is 15 mm, and the offset dimension ( U): 10 mm. In addition, the material alloy used A390.

In addition, as shown in Table 1 below, in the forging die, the clearance D5 between the center pin 16 of the lower die 10 and the circular hole 35 of the upper die 30 is 0.1 mm. The clearance D6 between the blade portion 13 of the lower mold 10 and the flat hole 36 of the upper mold 30 was also 0.1 mm in the same manner as above.

The blade of the lower mold 10 has a spacing (break length D3) between the center pin 16 of the lower mold 10 and the opening face of the circular hole 35 in the upper mold 30. The space | interval (breaking length D4) of the part 13 and the opening surface of the flat hole 36 in the upper metal mold | die 30 was set to 1.5 mm similarly to the above.

And the forging raw material W heated at 400 degreeC was loaded to the lower metal mold | die 10, the following molding load was applied, and the rotor raw material 1 was formed. During this forging, the first sub load F1 and the second sub load F2 were increased, and the final load was 1.5 times the respective initial load.

Main load (F) = 325 MPa

Initial load of the first sub load F1: 32.9 MPa (4.0 kg / mm2)

Initial load of part 2 load (F2): 44.1 MPa (4.5 kg / mm2)

The rotor raw material 1 thus obtained was removed using the punching device shown in FIG. 14 to remove the excess thickness portions 5 and 6 to obtain the rotor R. As shown in FIG.

The material yield of the rotor R with respect to the forging raw material W (weight of the rotor R / weight x100 of the forging raw material W) was 82.9%.

EXAMPLE 2

As shown in Table 1, the rotor R was produced similarly to the said Example 1 except having set the breaking length D3 (D4) of the excess thickness part 5 (6) to "0".

[Comparative Example 1]

As shown in Table 1, the rotor R was produced similarly to the said Example except having set the breaking length D3 (D4) of the excess thickness part 5 (6) to "-2mm."

[Comparative Example 2]

As shown in Table 1, the fracture lengths D3 and D4 of the excess thickness portions 5 and 6 are set to "-2 mm", and the clearance thickness D5 (D6) of the excess thickness portion outer periphery is "2 mm". The rotor R was produced similarly to the said Example except having set to.

〔evaluation〕

As shown in Table 1, in the manufacturing method of Example 1, 2, at the time of a forging process, the excess thickness part 5 and 6 did not inadvertently break or fall off, and it could process without stagnation.

In addition, in the manufacturing method of Example 1, 2, the fracture surface after a punching process (after removing the excess thickness part) is small, and the fracture mark (rupture surface) is the inside of the center hole 3 and the vane groove 4 Was formed on. Therefore, it is considered that there is no problem even if the fracture mark is not finished.

On the other hand, in the manufacturing method of the comparative example 1, the excess thickness part 5 (6) was inadvertently broken at the time of forging, and it could not process smoothly.

Moreover, in the manufacturing method of the comparative example 2, the fracture surface after a punching process was large, and also the fracture mark (rupture surface) was arrange | positioned so that it might protrude outside. Therefore, in actual use, it is considered that this breaking mark needs to be removed by finishing.

[Test Examples 1 to 7]

The rotor was produced on the same conditions as the said Example 1 except having adjusted so that the curvature radius r3 (r3a) of the center hole 3 side might be set to the value shown in Table 2. And the inner burr and convex burr (refer FIG. 26) were evaluated. The results are shown in Table 2 together.

As apparent from the above table, adjusting the curvature radius r3 (r3a) to a specific value stabilized the states of the inner burrs and the convex burrs.

Moreover, similar test was also obtained about the curvature radius r4 (r4a) by the side of the vane groove 4, and the same evaluation was obtained.

This application is accompanied by priority claims of Japanese Patent Application No. 2008-164327 of Japanese Patent Application, filed June 24, 2008, and Japanese Patent Application No. 2009-47963 of Japanese Patent Application, filed March 2, 2009 The disclosure is constituting a part of this application as it is.

The terms and phrases used herein are for the purpose of description and not of limitation, and do not exclude any equivalents of the features disclosed and described herein, but are intended to be within the scope of the claimed subject matter. It should be recognized that various modifications in the same are also allowed.

While the present invention can be embodied in many different forms, this disclosure should be considered to provide an embodiment of the principles of the invention, which examples illustrate and / or illustrate the invention herein. Many illustrative embodiments are described herein with the understanding that they are not intended to be limited to the preferred embodiments.

While several illustrative embodiments of the invention have been described herein, the invention is not limited to the various preferred embodiments described herein, and equivalent elements that can be recognized by those skilled in the art based on this disclosure, It also includes all embodiments having modifications, deletions, combinations (for example, combinations of features relating to various embodiments), improvements, and / or changes. The limitations of the claims should be interpreted broadly based on the terminology used in the claims, and should not be construed as limited to the embodiments set forth herein or in the sections herein, and such embodiments should be construed as non-exclusive.

The manufacturing method of the rotor of this invention can be applied when manufacturing rotors, such as a compressor.

1: rotor material
2: rotor part
2a: one side
3: center hole (shaft hole)
3a: one side
4: vane groove
4a: one side
5, 6: excess thickness
5a: obstruction
5b: surrounding wall
7: no crack
13: Blade part (vane groove forming type)
97, 98: punching punch
D3, D4: End face difference
D5, D6: diameter difference
R: rotor
T5: occlusion thickness
W: forged material

Claims (21)

A vane groove along the axial direction of the outer peripheral portion is formed integrally so as to swell to the one end side of the cylindrical rotor portion formed in plural at intervals in the circumferential direction and one end surface of the rotor portion, and further closes one end side of the vane groove. A forging step of obtaining a rotor material having excess thickness;
And a surplus thickness part removing step of hitting the impact member against the excess thickness part and removing the excess thickness part from the rotor part to obtain a rotor with the vane groove open to one end side. The rotor manufacturing method according to claim 1, wherein in the rotor material, the excess thickness portion is formed at one end side of the rotor portion from one end surface, and the vane groove is formed to the inside of the excess thickness portion. The rotor according to claim 2, wherein the surplus thickness portion has a peripheral wall portion that closes the circumferential side surface of the vane groove, and in the removing of the excess thickness portion, the excess thickness portion is manufactured by breaking the excess thickness portion at the peripheral wall portion. Way. The method of manufacturing a rotor according to claim 2 or 3, wherein, when the dimension from the distal end portion to the one end surface of the vane groove is the thickness of the closed portion, the thickness of the closed portion is set to 3 to 10 mm. . The said forging process WHEREIN: The crack is formed between the said excess thickness part and the said rotor part in the said forging process,
The manufacturing method of the rotor which cut | disconnected the said rotor raw material along the said crack in the said excess thickness part removal process. The said excess thickness part removal process WHEREIN: The punching punch as an impact member is struck in the said vane groove of the said rotor raw material from the other end side opening part, The said punch in any one of Claims 1-5. The manufacturing method of the rotor which punched and removed the said excess thickness part to the one end part side. The said forging process WHEREIN: The said forging process WHEREIN: The vane groove formation die is relatively beaten from the other end surface of the forging material of a cylindrical shape, and the said vane is spread from one end surface to the other end surface. While forming a groove,
A method for manufacturing a rotor in which a back pressure is applied to a region corresponding to a vane groove forming scheduled portion on one end surface of the forged material when the vane groove forming die is struck into the forged material. The said excess thickness part is a vane groove side excess thickness part, The said impact member is made into the vane groove side impact member, The said any one of Claims 1-7.
In the forging process, a shaft hole along the axial center direction is formed in the rotor portion of the rotor material, and one end of the shaft hole side excess thickness that closes one end of the shaft hole on one end surface of the rotor portion. Integrally formed to swell to the side,
In the excess thickness portion removing step, the shaft hole side impact member is struck by the shaft hole side excess thickness portion and the excess thickness portion is removed from the rotor portion so that the shaft hole is opened to one end side. . The rotor according to claim 8, wherein a punching punch as an impact member is punched into the shaft hole of the rotor raw material from the other end side opening portion, and the shaft hole excess thickness portion is punched to one end side and removed by the punch. Method of preparation. The said forging process WHEREIN: The said forging process WHEREIN: The shaft hole formation mold is relatively beaten from the other end surface of a forging material of a cylindrical shape, and the said shaft hole is formed from one end surface to the other end surface. Meanwhile,
And a back pressure is applied to a region corresponding to a shaft hole formation scheduled portion on one end surface of the forged material when the shaft hole forming mold is struck into the forged material. The said rotor raw material WHEREIN: The said excess thickness part is integrally formed in one end surface in the said rotor part so that it may expand to one end side, The one end surface of the said vane groove reaches the said excess thickness part of Claim 1, Comprising: And the rotor is disposed inside the one end surface of the rotor portion. The end surface difference of the vane groove side is set to 0 to 2 mm when the distance between the one end surface of the rotor portion and the one end surface of the vane groove in the rotor material is the end surface difference of the vane groove side. Method of manufacturing the rotor. The diameter difference of the vane groove side is 0.01-0.1 mm when the space | interval between the inner peripheral surface of the said vane groove in the said rotor raw material, and the outer peripheral surface of the said excess thickness part is made into the diameter difference of the vane groove side. The manufacturing method of the rotor set. The manufacturing method of a rotor according to any one of claims 11 to 13, wherein the vane groove side diameter difference is partially different. The manufacturing method of the rotor of Claim 13 or 14 in which the diameter difference of at least any one of an inner peripheral side edge part and an outer peripheral side edge part among the diameter difference of the said vane groove side is set large with respect to the diameter difference of an intermediate part. The said excess thickness part is a vane groove side excess thickness part, The said impact member is made into the vane groove side impact member, The said any one of Claims 11-15,
In the forging process, a shaft hole along the axial center direction is formed in the rotor portion of the rotor material, and one end of the shaft hole side excess thickness that closes one end of the shaft hole on one end surface of the rotor portion. Integrally formed to swell to the side,
In the excess thickness portion removing step, the shaft hole side impact member is struck by the shaft hole side excess thickness portion and the excess thickness portion is removed from the rotor portion so that the shaft hole is opened to one end side.
The rotor raw material by the said forging process WHEREIN: The manufacturing method of the rotor in which the one end surface of the said shaft hole is arrange | positioned inside the one end surface of the said rotor part, without reaching the said shaft hole side excess thickness part. 17. The end face difference of the shaft hole side is 0 to 2 mm when the distance between the one end face of the rotor portion and the one end face of the shaft hole in the rotor material is the end face difference on the shaft hole side. The manufacturing method of the rotor set. 18. The diameter difference on the shaft hole side according to claim 16 or 17, wherein when the distance between the inner circumferential surface of the shaft hole and the outer circumferential surface of the shaft hole side excess thickness part in the rotor material is the diameter difference on the shaft hole side, The manufacturing method of the rotor set to 0.01 to 0.1 mm. The manufacturing method of a rotor according to any one of claims 16 to 18, wherein the diameter difference on the shaft hole side is partially different. A vane groove along the axial direction of the outer peripheral portion is formed integrally so as to swell to the one end side of the cylindrical rotor portion formed in plural at intervals in the circumferential direction and one end surface of the rotor portion, and further closes one end side of the vane groove. A method for removing the excess thickness of the rotor material having an excess thickness,
A method of removing excess thickness of a rotor material, wherein the impact member is caused to strike the excess thickness portion and the excess thickness portion is removed from the rotor portion to open the vane groove to one end side. A vane groove along the axial direction of the outer peripheral portion is formed integrally so as to swell to the one end side of the cylindrical rotor portion formed in plural at intervals in the circumferential direction and one end surface of the rotor portion, and further closes one end side of the vane groove. An apparatus for removing the excess thickness of the rotor material having an excess thickness,
The vane groove is punched into the vane groove of the rotor material from the other end side opening portion, and the excess thickness portion is punched out to one end side to remove the excess thickness portion from the rotor portion, thereby removing the excess thickness portion from the rotor portion. The apparatus for removing excess thickness of a rotor material, comprising a punching punch for opening the side toward one end.

Images