201127518 六、發明說明： 【發明所屬之技術領域】 [0001] 本發明係有關一種在本體上一體具有凸缘部之凸缘構造 體的製造方法。 【先前技^标】 [0002] 例如，汽車的停車制動器用錨塊係在軸部的一端部的外 周具有大的橢圓狀突出之凸缘部的鉄鋼製零件。在這樣 的零件的製造中，由於素材的變形量大，故凸缘部之成 0 型以熱鍛方式進行者居多。 [0003] 但是，因熱鍛需要加熱用的大型裝置而有導致成本增大 、生產速度慢、需要熟練、不易獲得表面狀態良好的製 品，且針對要求高尺寸精度的零件又需切削、研磨等之 後工程等的不利點。 [0004] 為此，亦一直檢討以冷鍛進行所有的工程，但在進行具 有大突出的凸缘部之鋼鉄零件的成型的情乳，加工壓力 變太大並不實際。又，以凸缘部的突出形狀是橢圓形等 Ο 之非圓形者而言，在藉由頂鍛方式突出成圓形後，要配 合所求得之凸缘部的形狀進行切削或去毛邊，故有所謂 材料良率變差之問題點。 [0005] 【先前技術文獻】 【專利文獻】 【專利文獻1】 日本專利特開2008— 267481號公報 【發明内容】 100101546 表單編號A0101 第3頁/共35頁 1003050605-0 201127518 [0006] 本發明係有鑒於上述那樣的情況而完成者，目的在於提 供一種可有效率地製造具備從本體大大突出之凸缘部的 凸缘構造體之方法。 [0007] 本發明係一種凸缘構造體的製造方法，係將具備有自本 體朝外侧延伸的非圓形凸缘部之凸缘構造體予以成型的 方法，其中包含： 第一鍛造工程，採用冷鍛或溫鍛方式，以第一衝頭推壓 被裝設在凹設有具備突出部形成部的模具孔之第一模具 上的素材，藉由在由前述第一模具中的前述突出部形成 部内面和與前述第一衝頭中的前述第一模具之對向面所 包圍的閉鎖空間内，使前述素材的一部份朝前述本體的 外侧方向突出，形成一部份是朝與前述凸缘構造體中的 前述凸缘部之突出方向匹配的方向突出且該突出部是比 前述凸缘構造體中的前述凸缘部還厚壁的中間成型體； 第二鍛造工程，係採用冷鍛或溫鍛方式，藉由事先作成 在前述第二模具和第二衝頭之間壓塌前述中間成型體中 的突出部之際讓前述突出部的外周中之至少一部份不受 前述第二模具和前述第二衝頭所拘束，以形成具備比欲 獲得之前述凸缘構造體的前述凸缘部還大的大凸缘部之 大凸缘部形成體；及 衝壓工程，係透過對前述大凸缘部施以衝壓加工而形成 前述凸缘部的輪廓。 [0008] 此外，本發明中的「素材」係指作為原料的棒材或筒材 等、及因應需求而對此棒材或筒材等施作了前處理的金 屬材料。 100101546 表單編號A0101 第4頁/共35頁 1003050605-0 201127518 [〇〇〇9] 根據本發明’能有效率地製造具備大的突出之凸缘部的 凸缘構造體。 【實施方式】 [0010] 依據第1圖至第18圖來說明本發明的實施形態。 [0011] 在本實施形態製造的凸缘構造體係汽車的停車制動器用 錨塊1 (以下，記載為「錨塊丨」）。此錨塊具備在屬本 體之階差轴部2的一端部周圍大大地突出之略橢圓狀的凸 缘部3。 〇 [0012]起始材料的圓棒係鋼製且歷經數個階段的成型工程而成 型具有大徑部11、及與此大徑部1丨同軸且比大徑部^還 更小徑的小徑部12之階差棒觖鋼材1〇。 剛首先，透過對此階差棒狀_1()施予冷锻或溫锻而形成 中間成型體（第一鍛造工程）^ [0014]201127518 VI. Description of the Invention: [Technical Field of the Invention] [0001] The present invention relates to a method of manufacturing a flange structure integrally having a flange portion on a body. [Prior Art] For example, an anchor block for a parking brake of an automobile is a steel part having a large elliptical protruding flange portion on the outer periphery of one end portion of the shaft portion. In the manufacture of such a part, since the amount of deformation of the material is large, the type of the flange portion is mostly performed by hot forging. [0003] However, hot forging requires a large-scale apparatus for heating, which results in an increase in cost, a slow production speed, requires skill, and is difficult to obtain a product having a good surface condition, and requires cutting, grinding, etc. for parts requiring high dimensional accuracy. After the engineering and other disadvantages. [0004] For this reason, it has been reviewed that all the works are carried out by cold forging, but it is not practical to carry out the molding of the steel enamel parts having the flange portions having large protrusions. Further, in the non-circular shape in which the protruding portion of the flange portion is an elliptical shape or the like, after being rounded by the upsetting method, the shape of the obtained flange portion is cut or deburred in accordance with the shape of the obtained flange portion. Therefore, there is a problem of the so-called material yield deterioration. [Patent Document] [Patent Document 1] Japanese Patent Laid-Open Publication No. 2008-267481 [Draft of the Invention] 100101546 Form No. A0101 Page 3 / Total 35 Page 1003050605-0 201127518 [0006] In view of the above circumstances, it is an object of the invention to provide a method for efficiently manufacturing a flange structure having a flange portion that largely protrudes from a main body. [0007] The present invention relates to a method of manufacturing a flange structure, which is a method of molding a flange structure including a non-circular flange portion extending outward from a body, comprising: a first forging project, a cold forging or warm forging method of pressing a material attached to a first mold recessed with a die hole having a protrusion forming portion by a first punch, by the aforementioned protrusion in the first mold Forming a portion of the material toward the outer side of the body in a closed space surrounded by the inner surface of the forming portion and the opposing surface of the first die in the first punch, forming a portion facing the front The protruding portion of the flange structure protrudes in a direction in which the protruding direction matches, and the protruding portion is an intermediate molded body thicker than the flange portion of the flange structure; the second forging process is cold In the forging or warm forging method, at least a part of the outer circumference of the protruding portion is not affected by the foregoing when the protruding portion in the intermediate molded body is crushed between the second mold and the second punch Two mold The second punch is restrained to form a large flange portion forming body having a large flange portion larger than the flange portion of the flange structure to be obtained, and a punching process for transmitting the large convex portion The edge portion is subjected to press working to form the contour of the flange portion. Further, the term "material" in the present invention means a bar material, a cylindrical material, or the like as a raw material, and a metal material which is pretreated for the bar material or the cylindrical material or the like according to the demand. 100101546 Form No. A0101 Page 4 of 35 1003050605-0 201127518 [〇〇〇9] According to the present invention, a flange structure having a large protruding flange portion can be efficiently manufactured. [Embodiment] An embodiment of the present invention will be described with reference to Figs. 1 to 18 . [0011] The anchor block 1 for a parking brake of an automobile of the flange structure system manufactured in the present embodiment (hereinafter referred to as "anchor block"). This anchor block has a slightly elliptical flange portion 3 which is greatly protruded around one end portion of the stepped shaft portion 2 of the body. 〇[0012] The round material of the starting material is made of steel and has been molded in several stages to form a large diameter portion 11 and a small diameter coaxial with the large diameter portion 1 and smaller than the large diameter portion. The step of the diameter portion 12 is 1 觖 steel. First, an intermediate molded body (first forging work) is formed by applying cold forging or warm forging to this step bar_1 () [0014]
在第-锻造工程所使用的第—锻造裝置獅具備第一模 具41及第-衝頭42。第-模具41係仰金屬形成圓柱狀 在其上面（與第，衝頭42對向的面）凹設有模具孔Μ °該模具孔43係由上面側的突出部形成部44和底面側的 第-軸孔部45所構成。突出部形成邹砸上面看呈橫寬 的略橢圓狀，其長圓方向（紙面W右方向）及短圓方 向（對Λ面正交的方向）的長度係比最終成型物的錯塊上 中的凸缘部3之長度還短 。在該突出部形成部44的底面中央位 其深度比凸缘部3的厚度還大 置，用以收容階差 棒狀鋼材10中的大徑部丨丨的下部及 部45係縱向凹設。又，突出部形成 小徑部12的第一轴孔 邹44的底面被賦予傾 100101546 表單編號Α0101 第5頁/共35頁 1003050605-0 201127518 斜，越接近中心（第一轴孔部45的形成位置）變越深（ 與第杈具41的上面分離）。從正面方向（第1圖的紙面 正交方向）看傾斜的角度約為15。。 [0015] [0016] s亥第一模具41的外周固定了上面備有開口部的第一導引 構件46，藉由第—衝頭a嵌合於其開口部，第一模具ο 和第一衝頭42被校準成同一中心。 第衝頭4 2係由外衝頭4 7和内衝頭4 8二個零件所構成外 衝頭47係利用金屬形成圓柱狀，其中心位置形成有沿著 軸向貫通之斷面圓形的衝頭孔49 »此衝頭孔49的内徑作 ,、 成可收容階差棒狀鋼材10之大徑部Π的大小。利用金屬 形成圓棒狀的内衝頭48被大致賢密地插通於衝頭孔49的 内部。又，外衝頭47的下面（和第一模具41的上面對向 的面）設有凹坑部50。該凹坑部50的内壁係形成隨著接 近中心（衝頭孔49的開口部）而稍朝上方傾斜的傾斜面 。此外，該外衝頭47及内律頭48倒未詳細蜱圖示，係透 過彈性構件固定於加壓裝置。 [0017] 其次’針對使甫遠樣的第一鍛造裝置40的第— 作說明。第一鍛造工程係以冷鍛或溫鍛的方式進 溫鍛的情況，鍛造溫度是550X：〜98(TC者較佳， 者最好。 锻造工程The first forging device lion used in the first forging process has a first mold 41 and a first punch 42. The first mold 41 is formed of a cylindrical shape, and a mold hole is recessed on the upper surface (the surface facing the punch 42). The mold hole 43 is formed by the projection forming portion 44 on the upper surface side and the bottom surface side. The first-axis hole portion 45 is formed. The protrusion forms a slightly elliptical shape with a horizontal width as viewed from above, and the length in the direction of the long circle (the right direction of the paper surface W) and the direction of the short circle (the direction orthogonal to the plane of the jaw surface) are larger than those in the wrong block of the final molded product. The length of the flange portion 3 is also short. The depth of the center of the bottom surface of the protruding portion forming portion 44 is larger than the thickness of the flange portion 3, and the lower portion and the portion 45 for accommodating the large-diameter portion 阶 of the stepped steel material 10 are longitudinally recessed. Further, the bottom surface of the first axial hole of the small-diameter portion 12 is given a tilt 100101546. Form number Α0101 5th page/35 pages 1003050605-0 201127518 obliquely, closer to the center (formation of the first shaft hole portion 45) The position becomes deeper (separated from the top of the cookware 41). The angle of inclination is about 15 as seen from the front direction (the direction orthogonal to the plane of the drawing in Fig. 1). . [0016] The first guiding member 46 having the opening portion is fixed to the outer circumference of the first mold 41, and the first punch ο and the first portion are fitted to the opening portion thereof by the first punch a The punches 42 are calibrated to the same center. The first punch 4 2 is composed of two parts, an outer punch 47 and an inner punch 48. The outer punch 47 is formed in a cylindrical shape by metal, and its central position is formed with a circular cross section which is penetrated in the axial direction. The punch hole 49 » the inner diameter of the punch hole 49 is formed to accommodate the large diameter portion 阶 of the stepped steel bar 10 . The inner punch 48 which is formed into a round bar shape by metal is inserted into the inside of the punch hole 49 substantially savvyly. Further, the lower surface of the outer punch 47 (the surface facing the upper surface of the first die 41) is provided with a recessed portion 50. The inner wall of the recessed portion 50 is formed as an inclined surface that is slightly inclined upward as it approaches the center (the opening of the punch hole 49). Further, the outer punch 47 and the inner head 48 are not shown in detail, and are fixed to the pressurizing device via the elastic member. [0017] Next, the description will be made with respect to the first forging device 40. The first forging engineering is carried out by cold forging or warm forging. The forging temperature is 550X: ~98 (TC is better, the best. Forging engineering
行。在 7〇〇°CRow. At 7 ° ° C
[0018] 首先’將階差棒狀鋼材10以小徑部12側朝向下側地播 第一軸孔部45而設定在第一模具41。其次，榀从 ^ 铞作加壓裝 置使第一衝頭42下降。在下降操作的初期狀態中 頭48的下端面是位在比外衝頭47的下端面還稍後退的衝 100101546 表單編號A0101 第6頁/共35頁 1〇〇3〇5〇6〇5-〇 201127518 置（上方位置）。第一衝頭42繼續下降時，首先外衝頭 47進入第—導引構件46的内部，外衝頭47的下面抵碰第 一模具41的上面。在此狀態中，階差棒狀鋼材1〇中的大 徑部11的上部成為進入衝頭孔49的内部之狀態。接著當 内衝頭48再繼續下降時，階差棒狀鋼材10中的大徑部11 之上部被内衝頭48壓塌而在由第一模具41的突出部形成 部44和第1衝頭42的凹坑部50所形成之閉鎖空間的内部擴 展。 Ο [0019] 如此一來’形成具備階差軸部2及形成於該階差轴部2的 上端之頭部21的中間成型體2〇 (參照第3圖及第4圖）。 頭部21的形狀係與目標之錨塊1的凸缘部3形狀同樣地， 從抽向看來呈略橢圓狀，其長方向:¾左右方向）及短 圓方向（前後方向）的突出長度係作成比凸缘部3的突出 長度還短，其厚度作成比凸缘部3的厚度還厚。 [0020] G [0021] 此外，第一模具41中的突出部甩成部44的底面、及外衝 頭47的凹坑部50之内面設置傾斜，材料的流動變順暢， 不容易在所形成之中間戍型艘2〇上產生破損等之缺陷。 所獲得之中間成型體20係經過除鏽、表面處理等的工程 而被供給至第二鍛造工程。在第二鍛造工程中，透過對 中間成型體20施以冷鍛或溫鍛而形成大凸缘部31。 [0022] 在第二鍛造工程所使用的第二鍛造裝置51，係如第6圖所 不’具備有第二模具52及第二衝頭53。第二模具52係利 用金屬形成圓柱狀’其上面（與第二衝頭53對向的面） 设置有模具側凹部55Α。該模具側凹部55Α係作成從上面 100101546 表單編號A0101 第7頁/共35頁 1003050605-0 201127518 方向所看到的外形是與從錨塊1中的凸缘部3之軸向所看 到的外形相等。又，模具側凹部55A的側壁面56A係由從 第二模具52的上面朝下方垂直延伸的筆直部57A、以及自 其筆直部57A的下端緣越朝下方越靠中心傾斜的傾斜部 58A所構成。又’在該模具側凹部55A的底面中心位置， 用以收容中間成型體2 0的階差軸部2的第二轴孔部5 9係縱 向凹設。 [0023] 一方面，第二衝頭53係利用金屬形成圓柱狀，其下面（ 與第二模具52對向的面）設置衝頭侧凹部55B。該衝頭側 凹部5 5B係作成從下方向所看到的外形是與從錨塊1中的 凸缘部3的轴向所看到的外形相等。又衝頦侧凹部55B 的側壁面56Β係由從第二衝頭53的下面朝上方垂直延伸的 筆直部57Β、以及自其筆直部57Β的上端緣越朝上方越靠 中心傾斜的傾斜部5 8 Β所構成。該第二衝.頭5 3係被固定於 加壓裝置（未圖示）。 .[0018] First, the stepped bar-shaped steel material 10 is set to the first mold hole 41 by sliding the first shaft hole portion 45 toward the lower side with the small diameter portion 12 side. Next, the first punch 42 is lowered from the pressing device. In the initial state of the lowering operation, the lower end surface of the head 48 is located at a lower end than the lower end surface of the outer punch 47. 100101546 Form No. A0101 Page 6 / Total 35 pages 1〇〇3〇5〇6〇5-〇 201127518 set (upper position). When the first punch 42 continues to descend, first, the outer punch 47 enters the inside of the first guiding member 46, and the lower surface of the outer punch 47 abuts against the upper surface of the first mold 41. In this state, the upper portion of the large-diameter portion 11 of the stepped bar-shaped steel material 1 is in a state of entering the inside of the punch hole 49. Then, when the inner punch 48 continues to descend again, the upper portion of the large-diameter portion 11 in the stepped steel bar 10 is crushed by the inner punch 48 at the projection forming portion 44 and the first punch by the first die 41. The interior of the closed space formed by the dimple portion 50 of 42 is expanded. [0019] Thus, the intermediate molded body 2A having the stepped shaft portion 2 and the head portion 21 formed at the upper end of the stepped shaft portion 2 is formed (see FIGS. 3 and 4). The shape of the head portion 21 is similar to the shape of the flange portion 3 of the anchor block 1 of the target, and is slightly elliptical in the direction of drawing, and its longitudinal direction is about 3⁄4 direction and the length of the short circle (front-rear direction). The thickness is shorter than the protruding length of the flange portion 3, and the thickness thereof is made thicker than the thickness of the flange portion 3. [0020] Further, the bottom surface of the protruding portion forming portion 44 in the first mold 41 and the inner surface of the concave portion 50 of the outer punch 47 are inclined, and the flow of the material becomes smooth and is not easily formed. In the middle of the stern type, there are defects such as damage on the raft. The obtained intermediate molded body 20 is supplied to a second forging work by a process such as rust removal, surface treatment, or the like. In the second forging work, the large flange portion 31 is formed by subjecting the intermediate molded body 20 to cold forging or warm forging. [0022] The second forging device 51 used in the second forging process is provided with a second die 52 and a second punch 53 as shown in Fig. 6. The second mold 52 is formed of a metal in a cylindrical shape. The upper surface (the surface facing the second punch 53) is provided with a mold side concave portion 55A. The mold side recessed portion 55 is formed to have an outer shape as seen from the direction of the upper surface of the flange portion 3 of the anchor block 1 as seen from the direction of the upper surface 100101546, the form number A0101, the seventh page/the total 35 page 1003050605-0 201127518. equal. Further, the side wall surface 56A of the mold side recessed portion 55A is composed of a straight portion 57A that vertically extends downward from the upper surface of the second mold 52, and an inclined portion 58A that is inclined downward toward the center from the lower end edge of the straight portion 57A. . Further, at the center of the bottom surface of the mold-side recessed portion 55A, the second shaft hole portion 59 for accommodating the stepped shaft portion 2 of the intermediate molded body 20 is longitudinally recessed. [0023] On the other hand, the second punch 53 is formed in a cylindrical shape by metal, and a punch side concave portion 55B is provided on the lower surface (the surface opposite to the second mold 52). The punch-side recessed portion 5 5B is formed such that the outer shape as seen from the lower direction is equal to the outer shape as seen from the axial direction of the flange portion 3 of the anchor block 1. Further, the side wall surface 56 of the punching side recessed portion 55B is a straight portion 57 that extends vertically upward from the lower surface of the second punch 53 and an inclined portion that is inclined toward the center from the upper end edge of the straight portion 57A. It is composed of Β. The second punch head 5 3 is fixed to a pressurizing device (not shown). .
[0024] 此外’模具侧凹部55:ii的深度和衝頭、侧,部55Β的深度之 合計係作成比欲獲得之凸缘部3的乘度還小。 [0025] 在第一模具52的外周配置有第二導引構件54，用以對合 第二模具52和第二衝頭53的軸之位置。 [0026] 其次’針對使用這樣的第二鍛造裝置51的第二鍛造工程 作說明。第二鍛造工程係與第一鍛造工程相同，採用冷 锻或溫鍛方式進行。在溫锻的情況，鍛造溫度是550°C〜 980°C者較佳，700°C者最好。 [0027] 首先，將中間成型體20以階差軸部2側朝向下側地插入第 100101546 表單編號A0101 第8頁/共35頁 1003050605-0 201127518 二軸孔部59而設定在第二模具52 ^其次，操作加壓裝置 使第二衝頭53下降。第二衝頭53係伴隨著下降動作而進 入第二導引構件54的内部而到達與中間成型體2〇的頭部 21接觸的位置。使第二衝頭53再繼續下降時，中間成型 體20的頭部21在第二模具52和第二衝頭53之間被壓塌並 在平面方向擴展，形成大凸缘部31。 [0028] Ο 接著，在第二衝頭53下降到從模具側凹部55Α的底面迄至 衝頭側凹部55Β的頂面為止的距離是和欲獲得之凸缘部3 的厚度大致相等的位置後，停止第二衝頭53的下降動作 。在该狀態下’由於模具側凹部55Α的;深度和衝頭側凹部 55Β的深度之合計係作成比目標之錨塊&中的凸缘部3厚度 還小’所以在第二模具52和第二衝頭53之間隙擴展的材 料的上下面及側面的一部份雖受到模具側凹部55Α及衝頭 側凹部55Β所拘束’但大凸缘部31的外掏面係面對朝其外 侧開放的空間，使材料成為可朝外側自由地壓延之非拘 束狀態。因此’材料的一部-份從模具侧凹部55Α及衝頭侧 * . , ο 凹部55Β伸出並朝沙綱方向自由地流動。如此一來，材料 之側面的一部份未受模具所&束下，藉由使剩餘的材料 在衝頭和模具之間成為毛邊伸出，可在無需過大的加工 壓力下進行鍛造。 [0029] 如此’可獲得具備階差軸部2及形成於該階差軸部2上端 之大凸缘部31的大凸缘部形成體3〇。從階差轴部2的軸向 看來’大凸缘部31係呈比目標之錨塊1的凸缘部3還大上 一圈的略擴圓形’在其上下面分別形成有外突部32Α、 32Β。下側的外突部“A的形狀係與模具側凹部55Α的凹 100101546 表單編號Α0101 第9頁/共35頁 1003050605-0 201127518 狀相匹配’其外周面具備朝下方垂直延伸的直壁部35八、 以及從該直壁部3 5 A的下端緣越朝下方越往内側傾斜的傾 斜部36A。一方面，上側的外突部32B的形狀與衝頭側凹 部55B的凹狀匹配’其外周面具備朝上方垂直立起的直壁 部35B、以及從該直壁部35B的上端緣越朝上方越往内侧 傾斜的傾斜部36B。 [0030]所獲得之大凸缘部形成體30係被供給到下個衝壓工程。 在該衝壓工程中，切掉大凸缘部31的剩餘部分33 (大凸 缘部31中比外突部32A、32B的直壁部35A、35B還外周側 的部分），做成凸缘部3的#靡形狀。此外，衝壓工程宜 在大凸缘部开>成體30形成後隨即進行。因為過了時間再 做處理時，因加工硬化惡化.，在衝壓時容易「在製品上產 生破損之緣故。 _]在衝壓卫顏使用的衝壓裝㈣係具備聽模㈣及衝 壓頭62。衝壓模具61係利用金屬形成矩形板狀，於其中 心位置設有貫通上下方向的衝壓孔63。衝壓孔63從上下 ..... ...： 方向（板厚方向)所看到的外形係作成和從錨塊丨中的凸 缘部3之轴向所看到的外形相等…方面，衝壓頭62係利 用金屬形成可大致緊密插通衝壓孔63的形狀。此第2衝頭 53被固定於加壓裝置（未圖示）。 [0032] 100101546Further, the total of the depth of the mold side recessed portion 55: ii and the depth of the punch, the side, and the portion 55 is made smaller than the degree of the flange portion 3 to be obtained. [0025] A second guiding member 54 is disposed on the outer circumference of the first mold 52 for aligning the positions of the axes of the second mold 52 and the second punch 53. Next, the second forging work using such a second forging device 51 will be described. The second forging engineering department is the same as the first forging project and is carried out by cold forging or warm forging. In the case of warm forging, the forging temperature is preferably 550 ° C to 980 ° C, and the best is 700 ° C. [0027] First, the intermediate molded body 20 is inserted into the second mold 52 with the stepped shaft portion 2 side facing downward to the 100th 101546 form number A0101, page 8/35 pages 1003050605-0 201127518, the two-axis hole portion 59. ^ Next, the pressing device is operated to lower the second punch 53. The second punch 53 enters the inside of the second guiding member 54 along with the lowering operation, and reaches a position in contact with the head portion 21 of the intermediate molded body 2〇. When the second punch 53 is further lowered, the head portion 21 of the intermediate molded body 20 is collapsed between the second mold 52 and the second punch 53, and expands in the planar direction to form the large flange portion 31. [0028] Next, after the second punch 53 is lowered to a position from the bottom surface of the mold-side concave portion 55Α to the top surface of the punch-side concave portion 55Β, the distance is substantially equal to the thickness of the flange portion 3 to be obtained. The lowering action of the second punch 53 is stopped. In this state, the total of the depth of the mold-side recess 55 ; and the depth of the punch-side recess 55 作 is made smaller than the thickness of the flange portion 3 in the target anchor block & The upper and lower surfaces of the material of the gap expansion of the second punch 53 and the side surface portion are restrained by the mold side concave portion 55Α and the punch side concave portion 55Β, but the outer surface of the large flange portion 31 faces the outer side thereof. The space makes the material an unconstrained state that can be freely calendered toward the outside. Therefore, a part of the material is extended from the mold side concave portion 55 and the punch side, and the concave portion 55 is freely flowing in the direction of the sand. In this way, a portion of the side of the material is unwound from the mold and can be forged without excessive processing pressure by allowing the remaining material to protrude between the punch and the die. [0029] Thus, the large flange portion forming body 3 having the stepped shaft portion 2 and the large flange portion 31 formed at the upper end of the stepped shaft portion 2 can be obtained. From the axial direction of the stepped shaft portion 2, the large flange portion 31 is slightly enlarged by a circle larger than the flange portion 3 of the target anchor block 1, and an outer protrusion is formed on the upper and lower sides thereof, respectively. Department 32Α, 32Β. The shape of the outer protrusion "A" on the lower side is concave 100100546 of the mold side recess 55 Form No. 101 0101 Page 9 / 35 pages 1003050605-0 201127518 The outer peripheral surface has a straight wall portion 35 extending vertically downward. And an inclined portion 36A which is inclined toward the inner side from the lower end edge of the straight wall portion 3 5 A. On the one hand, the shape of the upper outer protruding portion 32B matches the concave shape of the punch side concave portion 55B. The surface has a straight wall portion 35B that rises vertically upward, and an inclined portion 36B that is inclined upward toward the upper side from the upper end edge of the straight wall portion 35B. [0030] The obtained large flange portion forming body 30 is In the press working, the remaining portion 33 of the large flange portion 31 is cut out (the portion of the large flange portion 31 which is on the outer peripheral side of the straight wall portions 35A and 35B of the outer protruding portions 32A and 32B) The shape of the flange portion 3 is made into a shape of the flange portion 3. In addition, the stamping process is preferably performed after the formation of the large flange portion, and the formation of the body 30 is performed immediately, because the work hardening is deteriorated after the time has elapsed. It is easy to "break in the product when stamping. _] in the stamping The stamping device (4) used has a hearing die (4) and a punching head 62. The stamping die 61 is formed into a rectangular plate shape by metal, and has a punching hole 63 penetrating in the vertical direction at a center position thereof. The punching hole 63 is up and down. The shape seen in the direction (the thickness direction) is equal to the outer shape seen from the axial direction of the flange portion 3 in the anchor block 3, and the punching head 62 is formed substantially by metal. The shape of the punching hole 63 is inserted. The second punch 53 is fixed to a pressurizing device (not shown). [0032] 100101546
使用這樣的衝壓裝置60進行衝壓工程時首先，將大凸 缘部形成體30以階差輪部2側朝向下側地裝設於衝壓孔63 。大凸缘部形成體3〇為，大凸缘部31的下面侧之外突部 32A進入衝壓孔63的内部，外周的剩餘部分33成為被載置 於衝壓頭62的上面之狀態。此時，藉由下侧的外突部32A 表單編號A0101 第10頁/共35頁 ,〇〇〇 201127518 [0033] Ο [0034] [0035] ❹ 100101546 中的直壁部35Α的壁面與衝壓孔63的内周面接觸’可謀求 大凸缘部形成體3〇對衝壓頭62定位。 其次，操作加歷裝置使衝壓頭62下降。使衝壓頭62下降 到與大凸缘部形成體30的上面接觸之位置，若再繼續朝 下方擠進，則Λ凸缘部31中比衝壓孔63的開口緣還内側 部分係被衝壓。接著被衝壓的製品部分（衝壓體34)係 通過衝壓孔63J·朝下掉落，剩餘部分33殘留在衝壓模具 61上。如此，形成凸缘部3的輪廓形狀《此時，由於在大 凸缘部31中的上面侧之外突部32Β的外周亦形成有直壁部 35Β，所以在衝塵時，四緣部3的外周變得難以產生毛邊 。藉此，可簡化後工程。- 如此所獲得的衝塵體34係歷經車床加工、鑽孔加工等必 要之後處理而成為錨塊1。 如以上那樣，本實施形態之凸缘構造體的製造方法，係 所謂歷經第一锻造工程及第二锻造工程之兩階段的鍛造 工程。在第一鍛造工程中，係以第一衝頭42推壓被裝設 在凹設有具備突出部形成部44的模.具孔43之第一模具4 j 上的素材’藉由在由第-模具41中的突出部形成部44内 面和與第__42巾㈣―模具41之對向賴包圍的閉 鎖工門内使階差棒狀鋼材10的一部份朝外周方向突出 ，而形成朝與錯塊1中的凸缘部3之突出方向匹配的方向 犬出且比凸缘部3還厚壁的中間成型體2〇。接著在第二鍛 泣工程中’係藉由事先作成在第二模具52和第二衝頭53 之間壓羽中間成型體2〇的頭部21之際讓該頭部的外周 中的至V 不受第二模具52和第二衝頭53所拘束’ 表單編號A0101 « 弟 11 頁/共 35 頁 1003050605-0 201127518 以形成具備比凸缘部3在外周方向還大上一圈的大凸缘部 31之大凸缘部形成體30。 [0036] 如此，藉由兩階段進行鍛造，於第二鍛造工程中可將大 凸缘部31形成接近凸缘部3的最終形狀之形狀，所以應切 掉的剩餘部分33不需要很大，材料良率變好。 [0037] 又，在第一锻造工程中，事先形成朝和欲獲得之凸缘部3 的突出方向匹配之方向突出的厚壁的頭部21，再者，在 第二鍛造工程將該頭部21壓塌之際，侧面的一部份未被 模具所拘束，使剩餘的材料在第二衝頭53和第二模具52 之間成為毛邊伸出。藉此，由於可在各工程中縮小成型 所需的壓縮荷重，所以就算不採用熱鍛方式亦可形成突 出面積大的凸缘部。 [0038] 由此等得知，所有工程成為可藉由冷鍛或溫鍛來形成， 變得不需要大型的熱鍛裝置。且可活用易獲得表面狀態 良好的製品及能進行精密的加工等之冷鍛‘溫鍛的特性 ，得以減少切削、研磨等之後工程。藉此可謀求降低成 本。而且，以冷鍛、溫鍛而言，生產速度高且有關溫度 管理等之熟練度並未要求需像熱鍛那樣的程度，故能謀 求生產性之提升。 [0039] <其他實施形態> 本發明未受限於藉上述記述及圖面所說明的實施形態， 例如以下那樣的實施形態亦被本發明的技術範圍所涵蓋 〇 (1)上述實施形態中雖已針對凸缘部3是橢圓形者作了 100101546 表單編號A0101 第12頁/共35頁 1003050605-0 201127518 例示，但是凸缘部的形狀沒有必要一定是搞圓形，例如 十字型、矩形等、非圓形者都可適合本發明。而在該情 況時，中間成型體中的突出部形狀亦與凸缘部的形狀相 匹配地成型。 (2)要獲得從原料的棒材供給到中間形成體形成工程之 階差棒狀鋼材10的工程並未侷限於上述實施形態，只要 是為獲得這樣的構件而進行的一般工程，都可在無特別 制限下採用。 Ο [0040] ❹ 100101546 【圖式簡單說明】 第1圖係顯示在實施形態中的第一鍛造工程中利用第一鍛 造裝置推壓階差棒狀鋼材前的樣態之側剖視圖； 第2圖係顯示在第一鍛造工程利用第一鍛造裝置利用階差 棒狀鋼材後的樣態之側剖視圖； 第3圖係中間形成體的前視圖。 第4圖係中間形成體的俯視圖； 第5圖係中間形成體的仰視圖； 第6圖係顯示第二鍛造工程中利用第二鍛造裝置推壓中間 成型體前的樣態之剖視圖； 第7圖係第二鍛造裝置中的模具侧凹部及衝頭側凹部之部 分放大剖視圖； 第8圖係顯示第二鍛造工程中利用第二鍛造裝置推壓中間 成型體後的樣態之剖視圖； 第9圖係大凸缘部形成體的前視圖； 第10圖係大凸缘部形成體的仰視圖； 第11圖係顯示衝壓工程中利用衝壓裝置推壓大凸缘部形 成體前的樣態之侧剖視圖； 表單編號Α0101 第13頁/共35頁 1003050605-0 201127518 第12圖係衝壓工程中載置於衝壓模具上的大凸缘部形成 體之部分放大側剖視圖； 第13圖係顯示衝壓工程中利用衝壓裝置推壓大凸缘部形 成體後的樣態之侧剖視圖； 第14圖係顯示衝壓工程結束後的衝壓體及剩餘部分之斜 視圖， 第15圖係衝壓體之前視圖； 第16圖係衝壓體之仰視圖； 第1 7圖係錯塊之斜視圖，以及 . 第18圖係錨塊之仰視圖。 【主要元件符號說明】 [0041] 100101546 1:停車制動器用錨塊（凸缘構造體）； 2 :階差軸部（軸構件）； 3:凸缘部； 10 :階差棒狀鋼材（素材）； 11 :大徑部； 12 :小徑部； , 20 :中間成型體； 21 :頭部（突出部）； 30 :大凸缘部形成體； 31 :大凸缘部； 32A、32B :外突部； 33 :剩餘部分； 34 :衝壓體； 35A、35B :直壁部； 36A ' 36B、58A、58B :傾斜部； 表單編號A0101 第14頁/共35頁 1003050605-0 201127518 40 :第一鍛造裝置； 41 :第一模具； 42 :第一衝頭； 43 :模具孔； 44 :突出部形成部； 45 :第一軸孔部； 46 :第一導引構件； 47 :外衝頭； Ο 48 :内衝頭； 49 :衝頭孔； 50 :凹坑部； 51 :第二模具； 52 :第二衝頭； 53 :第二衝頭； 54 :第二導引構件； 55A :模具側凹部（凹部） 55Β :衝頭側凹部（凹部： 57Α、57Β :筆直部； 5 6 A、5 6 Β :側壁面； 59 :第二軸孔部； 60 :衝壓裝置； 61 :衝壓模具； 62 :衝壓頭；以及 6 3 :衝壓孔。 100101546 表單編號A0101 第15頁/共35頁 1003050605-0When the press working is performed using such a press device 60, first, the large flange portion forming body 30 is attached to the punching hole 63 with the step wheel portion 2 side facing downward. The large flange portion forming body 3 is such that the projection 32A of the large flange portion 31 enters the inside of the punching hole 63, and the remaining portion 33 of the outer periphery is placed on the upper surface of the punching head 62. At this time, the wall surface and the punched hole of the straight wall portion 35Α in the lower side outer portion 32A form number A0101 page 10/35 pages, 〇〇〇201127518 [0033] 00 [0034] ❹ 100101546 The inner peripheral surface contact of 63 can be positioned to position the punching head 62 by the large flange portion forming body 3 . Next, the urging means is operated to lower the ram 62. When the punching head 62 is lowered to a position in contact with the upper surface of the large flange portion forming body 30, if it is further pushed downward, the inner side portion of the flange portion 31 is punched toward the inner edge of the punching hole 63. Then, the portion (the punching body 34) to be stamped is dropped downward through the punching hole 63J. The remaining portion 33 remains on the press die 61. In this manner, the contour shape of the flange portion 3 is formed. In this case, since the straight portion 35Β is formed on the outer periphery of the projection 32Β on the upper surface side of the large flange portion 31, the four edge portion 3 is formed during dusting. The outer circumference becomes difficult to produce burrs. This simplifies the post-engineering. - The dust-absorbent body 34 thus obtained is subjected to lathe processing, drilling processing, and the like, and is then processed to become the anchor block 1. As described above, the method of manufacturing the flange structure of the present embodiment is a so-called forging process that has undergone two stages of the first forging process and the second forging process. In the first forging process, the material that is mounted on the first mold 4 j that is recessed with the mold hole 43 having the protrusion forming portion 44 is pressed by the first punch 42. - the inner surface of the protruding portion forming portion 44 in the mold 41 and the locking door surrounded by the __42 towel (four) - the mold 41 are protruded in the outer circumferential direction to form a portion toward the outer circumferential direction. The intermediate portion 2 of the flange portion 3 in which the protruding direction of the wrong block 1 matches is in the direction of the intermediate molded body 2 which is thicker than the flange portion 3. Then, in the second forging project, the front end of the head is made to V by the pre-forming of the head portion 21 of the intermediate molded body 2 between the second mold 52 and the second punch 53. Not limited by the second mold 52 and the second punch 53 'Form No. A0101 « Brother 11 pages / Total 35 pages 1003050605-0 201127518 to form a large flange having a larger circumference than the flange portion 3 in the outer circumferential direction The large flange portion of the portion 31 forms the body 30. [0036] Thus, by forging in two stages, the large flange portion 31 can be formed in a shape close to the final shape of the flange portion 3 in the second forging process, so the remaining portion 33 to be cut does not need to be large. The material yield is getting better. [0037] Further, in the first forging process, a thick head portion 21 protruding in a direction matching the protruding direction of the flange portion 3 to be obtained is formed in advance, and the head is further formed in the second forging work. At the time of the collapse of 21, a part of the side surface is not restrained by the mold, so that the remaining material is burred between the second punch 53 and the second mold 52. Thereby, since the compression load required for molding can be reduced in each project, the flange portion having a large protruding area can be formed without using the hot forging method. [0038] It is thus known that all the works can be formed by cold forging or warm forging, and it becomes unnecessary to require a large hot forging device. Moreover, it is possible to use a product that is easy to obtain a surface condition and a cold forging that can be subjected to precision machining, such as warm forging, to reduce the number of processes such as cutting and grinding. This can reduce costs. Further, in terms of cold forging and warm forging, the production speed is high and the proficiency in temperature management does not require the degree of hot forging, so that productivity can be improved. <Other Embodiments> The present invention is not limited to the embodiments described above with reference to the drawings and drawings. For example, the following embodiments are also covered by the technical scope of the present invention. (1) The above embodiment Although the case where the flange portion 3 is elliptical has been made 100101546, the form number A0101, the 12th page, the total 35 pages, 1003050605-0, 201127518 is exemplified, but the shape of the flange portion does not necessarily have to be circular, such as a cross shape or a rectangle. Equal, non-circular shapes are suitable for the present invention. In this case, the shape of the projection in the intermediate molded body is also shaped to match the shape of the flange portion. (2) The process of obtaining the stepped bar-shaped steel material 10 from the supply of the raw material bar to the intermediate formation forming process is not limited to the above embodiment, and any general work performed to obtain such a member may be It is used without special restrictions. ❹ [101] ❹ 100101546 [Brief Description of the Drawings] Fig. 1 is a side cross-sectional view showing a state before the stepped steel bar is pressed by the first forging device in the first forging process in the embodiment; A side cross-sectional view showing a state in which the first forging project utilizes a stepped bar-shaped steel material by the first forging device; and FIG. 3 is a front view of the intermediate formed body. 4 is a plan view of the intermediate formed body; FIG. 5 is a bottom view of the intermediate formed body; FIG. 6 is a cross-sectional view showing a state before the intermediate formed body is pressed by the second forging device in the second forging work; FIG. 8 is a cross-sectional view showing a portion of a second side forging device in which a mold side concave portion and a punch side concave portion are formed; FIG. 8 is a cross-sectional view showing a state in which a second forging device presses an intermediate molded body in a second forging process; Fig. 10 is a front view of a large flange portion forming body; Fig. 11 is a view showing a state before a large flange portion forming body is pressed by a press device in a press working process; Side sectional view; Form No. 1010101 Page 13 of 35 1003050605-0 201127518 Figure 12 is a partial enlarged side cross-sectional view of the large flange portion forming body placed on the stamping die in the stamping project; Figure 13 shows the stamping project A side cross-sectional view of a state in which a large flange portion is formed by a press device; FIG. 14 is a perspective view showing a stamp body and a remaining portion after the press working, and FIG. 15 is a front view of the stamp body; Figure 16 is a bottom view of the stamping body; Figure 17 is a perspective view of the block, and Figure 18 is a bottom view of the anchor block. [Description of main component symbols] [0041] 100101546 1: Anchor block for parking brake (flange structure); 2: Stepped shaft portion (shaft member); 3: Flange portion; 10: Stepped bar steel material 11: large diameter section; 12: small diameter section; 20: intermediate molding body; 21: head (protrusion); 30: large flange portion forming body; 31: large flange portion; 32A, 32B: Outer protrusion; 33: Remaining part; 34: Stamping body; 35A, 35B: Straight wall portion; 36A '36B, 58A, 58B: Inclined portion; Form number A0101 Page 14/35 pages 1003050605-0 201127518 40: a forging device; 41: first mold; 42: first punch; 43: mold hole; 44: protrusion forming portion; 45: first shaft hole portion; 46: first guiding member; 47: outer punch Ο 48: inner punch; 49: punch hole; 50: dimple; 51: second die; 52: second punch; 53: second punch; 54: second guiding member; 55A: Mold side recess (recess) 55Β: punch side recess (recess: 57Α, 57Β: straight; 5 6 A, 5 6 Β: side wall surface; 59: second shaft hole; 60: stamping device; 61: stamping die 62: punch; and 63: punched holes Form Number A0101 100 101 546 Page 15 / Total 35 1003050605-0