1306416 九、發明說明： 【發明所屬之技術領域】 本發明係有關於一種以金屬胚料進行角隅整緣成 形方法，係針對金屬杯狀胚料外圓角部，或孔凸緣轴 之内圓角部進行整緣，其主要於杯形胚料或轴形孔凸 緣件之底部上貼抵壓料板，以可動模具抱持作用端側 牆，利用沖頭對作用端面施力擠壓，而於角隅部形成 直角。 【先前技術】 按，在進行金屬成形加工時，為了提升胚料的成 形限且降低成形負荷，模具的母模和沖頭肩部必須設 計為圓角，因此成形後會在工件上留下圓角。使用較 大的模具圓角雖較易於成形，且模具的應力集中現象 較少，但較大的模具圓角會增大工件的加工預留量， 而且影響工件後續組裝加工的配合裕度；而使用較小 的圓角雖然可以避免以上的缺點，但工件内的死金屬 產生區域較廣也較不利於塑性成形。 因此在金屬成形後再進行角隅整緣（edge s i z i ng)，可以使工件更接近「淨形」（net shape)， 自然可以減少加工預留量；並且使工件達到「一體形」 化的目的，可以直接以緊密配合或旋牙方式來接合其 他軸件，無需以鉚接或銲接等較困難的機械組裝法， 因此可避免由多件組成的零件較會有尺寸安定性低， 組裝後偏擺誤差大、鬆脫、撓性較差的問題點，以及 其所造成振動及噪音等缺點。 5 1306416 一般整緣成形雖然工件内的材料塑性流動量不 多，但由於加壓面積較大，因此負荷極易升高，尤其 在岔閉鍛造的情況下，胚料充填模穴後負荷急遽升高 的情形更明顯，往往使模具產生較多的彈性變形，= 而使工件喪失應有的平坦精度，或者需要較大^力的 成形設備，造成加工的經濟性降低。如是根據現有的 金屬角隅整緣成形加工法’可分為針對外圓角與内圓 角整緣，此二種製程概述如下： 、 (一） 外圓角整緣 請參閱第一圖所示，外圓角直化工法適用 於杯狀深引伸件的外圓角整緣，為了壤 的外圓角隅部，必須先將工件⑴的 起部（11)，再以沖頭下壓此杯狀深引伸工件（1) 的底部，而使材料離心流動至外圓角隅部充填 而形成直角，應用此加工法進行外圓角整緣 時，必須將工件（1)底部稍做隆起部（n)，因此 多了一道預成形工程；此外，隆起部（11)之位 置以及隆起部（11)必須經過精算，否則會造成 角隅充填不足的缺陷，或者過度充填而造成模 具過多的彈性變形，且影響模具壽命及成品之 平坦度。 (二） 内圓角整緣 内圓角直化工法〔如第二圖所示〕，此工 法類似後向擠伸法，主要是以沖頭（21)和可動 模具（22)合模後，將胚料（2)壓入固定成形模仁 6 1306416 (23)内，由於此成形模仁（23)設計為階梯推拔 狀，因此在沖頭（21)下壓時’凸緣前端肢料（2) 1^1者此行程下壓進入推拔模穴内，所受拘^束力 也逐漸變大，而使胚料（2)膨脹並回填至底角汐 並填滿為直角。此沖頭（21)内徑倒〜小圓角& 在下壓過程中除了提供模具内部潤滑油積蓄， 並可防止因過度充填，造成模具彈性變形，影 響模具壽命及成品之平坦度。而應用此工法加 工時，孔凸緣的如緣會有薄化的現象，若將階 梯推拔狀成形模仁（23)變更設計為階梯狀，^ 然可使端緣較平整，但必須特別注意胚料（2) 的尺寸管理，否則會造成角隅充填不足的缺 陷，或者因過度充填小圓角模穴，而造成上述 的模具產生過多彈性變形，且影響模具壽命及 成品之平坦度。 緣是，本發明人有鑑於此，秉持多年模具豐富專 業設計製造及實際研究開發之經驗，茲針對^見^二結 構及其缺失予以研究改良，因此，欲改善上述缺點， 模具的設計必須減少加壓面積外，亦即所謂的鈑金材 料流動控制（fl〇w control forming 〇fsheet 耐.） 觀念，另外便是以背壓裝置來有效抑制模穴充填後負 荷急遽升尚的現象，如此，才能完全改善現有之所有 缺失者。 【發明内容】 本發明係有關於一種以金屬胚料進行角隅整緣成 1306416 行角隅整緣成形方法，具有下列幾項優點，如下： 1. 本發明一種以金屬胚料進行角隅整緣成形方法，使 金屬胚料成形後再進行角隅整緣，可以使工件更接 近「淨形」，自然可以減少加工預留量；並且使工件 達到「一體形」化的目的，且可以大幅提升產品精 度和降低製造成本。 2. 於實施角隅整緣後，金屬胚料可以直接以緊密配合 或旋牙方式來接合其他轴件，無需以鉚接或銲接等 困難的機械組裝法，可避免由多重組件所造成之組 裝偏差、鬆脫、及撓性差的缺點，或日後運轉之振 動及噪音缺失。 3. 本發明一種以金屬胚料進行角隅整緣成形方法，利 用背壓可以有效防止密閉鍛造時，負荷急遽上升所 造成模具破裂的現象。 綜上所述，本發明實施例確能達到所預期之使用 功效，又其所揭露之具體構造，不僅未曾見諸於同類 產品中，亦未曾公開於申請前，誠已完全符合專利法 之規定與要求，爰依法提出發明專利之申請，懇請惠 予審查，並賜准專利，則實感德便。 1306416 【圖式簡單說明】 第一圖：現有之外圓角整緣技術示意圖 第二圖：現有之内圓角整緣技術示意圖 (左半部為成形前，右半部為成形後） 第三圖：本發明之之製造流程 第四圖：本發明之具外圓角胚料施工剖視示意圖 (左半部為成形前，右半部為成形後） 第五圖：本發明之具内圓角胚料施工剖視示意圖 (左半部為成形前，右半部為成形後） 第六圖：本發明之胚料態樣示意圖（一） 第七圖：本發明之胚料態樣示意圖（二） 第八圖··本發明之胚料態樣示意圖（三） 【主要元件符號說明】 <本發明> (10) 胚料入模 (20) 模具合模 (30) 角隅整緣成形 (3) 胚料 (31) 平板部 (32) 圓角 (33) 作用端 (34) 直角 (4) 模穴 (41) 固定模具 (42) 壓料塊 (43) 沖頭 (44) 可動模具 <現 有> (1) 工件 (11) 隆起部 (2) 胚料 (21) 沖頭 (22) 可動模具 (23) 模仁 12</ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> </ RTI> The whole edge is carried out, which is mainly attached to the bottom of the cup-shaped blank or the shaft-shaped flange member against the pressing plate, and the movable mold holds the side wall of the working end, and the punching force is applied to the working end surface by the punch, and the angle is applied The crotch forms a right angle. [Prior Art] According to the metal forming process, in order to increase the forming limit of the blank and reduce the forming load, the mold and the shoulder of the die must be designed to be rounded, so that a round is left on the workpiece after forming. angle. Although the use of larger mold fillets is easier to form, and the stress concentration of the mold is less, the larger mold fillet will increase the machining allowance of the workpiece, and affect the fit margin of the subsequent assembly processing of the workpiece; Although the use of smaller rounded corners can avoid the above disadvantages, the area of dead metal in the workpiece is wider and less favorable for plastic forming. Therefore, after the metal is formed, the edge sizi ng can be used to make the workpiece closer to the "net shape", which naturally reduces the processing allowance and makes the workpiece "integrated". The other shaft members can be directly joined by tight fitting or screwing, without the need of difficult mechanical assembly methods such as riveting or welding, so that parts with multiple parts can be prevented from having lower dimensional stability and yaw error after assembly. Big, loose, poorly flexible problems, and the shortcomings caused by vibration and noise. 5 1306416 Generally, although the plastic flow of the material in the workpiece is not much, the load is extremely easy to rise due to the large pressing area, especially in the case of forging and forging, the load is suddenly increased after the filling of the blank. The high case is more obvious, and the mold is often more elastically deformed, and the workpiece is lost to the flatness accuracy, or the forming equipment requiring a large force is required, resulting in a reduction in the economics of the processing. According to the existing metal corner rim forming method, it can be divided into the outer edge and the inner fillet. The two processes are summarized as follows: (1) The outer edge of the fillet is shown in the first figure. The rounded straight chemical method is applicable to the outer edge of the cup-shaped deep extension. For the outer corner of the soil, the starting part (11) of the workpiece (1) must be pressed first with the punch. The bottom of the workpiece (1) is extended deep, and the material is centrifugally flowed to fill the top of the fillet to form a right angle. When the rounding of the outer fillet is applied by this machining method, the bottom of the workpiece (1) must be slightly raised ( n), therefore, a pre-forming project; in addition, the position of the ridge (11) and the bulge (11) must be actuated, otherwise it will cause defects in insufficient filling of the corners, or excessive filling will cause excessive elastic deformation of the mold. And affect the life of the mold and the flatness of the finished product. (2) The rounded corner of the fillet is straight chemical method (as shown in the second figure). This method is similar to the backward extrusion method, mainly after the punch (21) and the movable mold (22) are clamped. Pressing the blank (2) into the fixed forming die 6 1306416 (23), since the forming die (23) is designed to be stepped up, when the punch (21) is pressed, the front end of the flange is (2) 1^1 This stroke is pressed into the push-pull cavity, and the restraint force is gradually increased, so that the blank (2) is expanded and backfilled to the bottom corner and filled to a right angle. The punch (21) inner diameter is inverted ~ small rounded & in addition to providing lubricant accumulation inside the mold during the pressing process, and preventing over-filling, causing elastic deformation of the mold, affecting the life of the mold and the flatness of the finished product. When applying this method, the edge of the hole flange may be thinned. If the stepped push-out forming die (23) is changed to a step shape, the edge may be flat, but special attention must be paid to the embryo. Dimensional management of material (2), otherwise it will cause defects in insufficient filling of corners, or excessive filling of small rounded mold holes, resulting in excessive elastic deformation of the above-mentioned mold, and affecting the life of the mold and the flatness of the finished product. Therefore, the inventor of the present invention has been studying and improving the professional design and manufacture of the mold and the actual research and development experience for many years, and has studied and improved the structure and the absence of the mold. Therefore, in order to improve the above disadvantages, the design of the mold must be reduced. In addition to the pressurized area, the so-called sheet metal flow control (fl〇w control forming 〇fsheet resistance) concept, in addition to the back pressure device to effectively suppress the phenomenon of sudden increase in load after cavity filling, so Completely improve all existing missing. SUMMARY OF THE INVENTION The present invention relates to a method for forming a corner of a corner of a metal billet into a 1304,416 corner corner, which has the following advantages, as follows: 1. The present invention performs corner trimming with a metal blank. The edge forming method allows the metal blank to be formed and then the corners of the corners to make the workpiece closer to the "net shape", which naturally reduces the processing allowance; and the workpiece is "integrated" and can be greatly Improve product accuracy and reduce manufacturing costs. 2. After the corners are finished, the metal blanks can be directly joined to other shaft parts by tight fit or screwing, without the need for difficult mechanical assembly such as riveting or welding, which avoids assembly variations caused by multiple components. Disadvantages of looseness and poor flexibility, or lack of vibration and noise during future operation. 3. The present invention relates to a method for forming a corner burr by a metal blank, and the back pressure can effectively prevent the rupture of the mold caused by a sudden increase in load during the closed forging. In summary, the embodiments of the present invention can achieve the expected use efficiency, and the specific structure disclosed therein has not been seen in similar products, nor has it been disclosed before the application, and has completely complied with the provisions of the Patent Law. And the request, the application for the invention of a patent in accordance with the law, please forgive the review, and grant the patent, it is really sensible. 1306416 [Simple description of the diagram] The first picture: the schematic diagram of the existing outer rounded edge technology. The second picture shows the existing rounded edge technology (the left half is before forming and the right half is formed) Fig.: The fourth process of the manufacturing process of the present invention: a schematic cross-sectional view of the blanked blank material of the present invention (the left half is before forming and the right half is formed). The fifth figure: the inner circle of the present invention Schematic diagram of corner billet construction (front part is formed before forming, right part is formed). Fig. 6: Schematic diagram of the billet of the present invention (1). Fig. 7: Schematic diagram of the billet of the present invention ( 2) Fig. 8: Schematic diagram of the blank material of the present invention (3) [Explanation of main component symbols] <The present invention> (10) Blank material feeding mold (20) Mold clamping (30) Corner rim Forming (3) Blank (31) Flat (32) Rounded corner (33) Active end (34) Right angle (4) Cavity (41) Fixed mold (42) Press block (43) Punch (44) Movable Mold <Existing > (1) Workpiece (11) Uplift (2) Blank (21) Punch (22) Movable Mold (23) Mold 12