US20110016944A1 - Method of producing metallic member - Google Patents

Method of producing metallic member Download PDF

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Publication number
US20110016944A1
US20110016944A1 US12/840,170 US84017010A US2011016944A1 US 20110016944 A1 US20110016944 A1 US 20110016944A1 US 84017010 A US84017010 A US 84017010A US 2011016944 A1 US2011016944 A1 US 2011016944A1
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United States
Prior art keywords
cup
protrusions
forming
producing
metallic
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Abandoned
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US12/840,170
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English (en)
Inventor
Jun Tamai
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Canon Inc
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Canon Inc
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Assigned to CANON KABUSHIKI KAISHA reassignment CANON KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TAMAI, JUN
Publication of US20110016944A1 publication Critical patent/US20110016944A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00—Making other articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/38—Making other particular articles locksmith's goods, e.g. handles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/12—Forming profiles on internal or external surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/28—Making machine elements wheels; discs
    • B21K1/30—Making machine elements wheels; discs with gear-teeth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00—Making hollow articles not covered by a single preceding sub-group
    • B21K21/12—Shaping end portions of hollow articles

Definitions

  • the present invention relates to a method of producing a metallic member. More particularly, the present invention relates to a method of producing a metallic member having a plurality of protrusions of, for example, a gear member or a vibration member of a vibration wave driving apparatus.
  • a vibration member for a vibration wave driving apparatus discussed in Japanese Patent Laid-Open No. 07-135785 is available.
  • the vibration member is an annular or a disc-shaped member.
  • Many protrusions like the teeth of a comb are provided at one surface (upper surface) of the vibration member, and a base not having teeth of a comb are provided at the opposite surface (lower surface) of the vibration member.
  • a ring-like piezoelectric element is joined to the lower surface of the base.
  • the many protrusions are formed by a forging method or a method of cutting many radial grooves using a grinding tool or a milling cutter having the shape of a disc (a grinding method or a cutting method).
  • the role of the protrusions is to increase vibration displacement when rotating a moving member by transmitting vibration of the vibration member to the moving member by friction force.
  • a hole extending through an output shaft is provided in the center of the vibration member.
  • a gear such as that discussed in Japanese Patent Laid-Open No. 2001-205385 is available.
  • the gear (such as a bevel gear) having teeth as the plurality of protrusions has a hole portion that does hot have a core for passing a shaft therethrough.
  • the teeth of the gear may also be formed by the cutting method or the grinding method, or by the forging method using a pressing device.
  • the forging method is lower in cost than the cutting method and the grinding method because the forging method is a processing method that can be simplified.
  • FIGS. 6A and 6B schematically illustrate states in which protrusions are formed on a processing object 111 by the forging method.
  • FIG. 6A is a sectional view
  • FIG. 6B is a perspective view.
  • the circular processing object 111 is used, and is inserted into an inside diameter portion of a die ring 123 (serving as an outer frame of a stationary mold (female mold)) to directly form the protrusions.
  • this method has the following problems.
  • a punch 122 serving as a pressing mold (male mold)
  • stress applied to the female mold is instantaneously increased.
  • the female mold tends to break.
  • a force for reducing the thickness of the processing object 111 interposed between the punch 122 and the female mold is applied to the molds at the same time that pressure is applied. Therefore, a large total load is required for a molding operation. From this viewpoint also, the molds tend to break.
  • the stress concentrates at a thin-walled portion 124 a of a die 124 having recesses and protrusions.
  • the thin-walled portion 124 a is provided for forming grooves (between the protrusions) in an outer-peripheral lower surface of the disc-shaped processing object.
  • the present invention makes it possible to easily mold a plurality of protrusions to any width on a metallic processing object, and to reduce a load on a mold during the molding of the plurality of protrusions.
  • a method of producing a metallic member having a plurality of protrusions includes forming a cup-like member by applying a load to a metallic plate member, the load applied to the plate member having a component that is perpendicular to a surface of the plate member; and forming the plurality of protrusions at an opening end portion of the cup-like member with a mold by applying a load to the cup-like member, the load applied to the cup-like member having a component that is perpendicular to a surface of a bottom portion of the cup-like member.
  • a cutting operation or a grinding operation is not required, so that a load on a mold when forming the protrusions can be reduced.
  • FIGS. 1A to 1C are schematic views showing states in which a cup-like member is formed according to a first embodiment.
  • FIGS. 2A to 2D are schematic views showing states in which protrusions are formed according to the first embodiment.
  • FIG. 3 is a schematic view of a cup-like member according to a second embodiment.
  • FIGS. 4A to 4C are schematic views showing states in which a preliminary molded product is formed according to the second embodiment.
  • FIGS. 5A to 5C are schematic views showing states of a final molding operation according to the second embodiment.
  • FIGS. 6A and 6B are schematic views showing a related forging molding operation.
  • a vibration-wave-driving-apparatus vibration member having protrusions for increasing vibration displacement, or a gear having teeth for output transmission is used as an example.
  • a vibration-wave-driving-apparatus vibration member having protrusions for increasing vibration formed on a surface of the vibration member is used as an example, to describe a method of producing the vibration member.
  • the vibration wave driving apparatus includes the vibration member provided with a piezoelectric element (which is one type of electro-mechanical energy conversion element). In the vibration wave driving apparatus, an alternate signal is supplied to the piezoelectric element to generate a traveling wave at a surface of the vibration member, and the traveling wave is used to drive a moving member that contacts the vibration member.
  • a disc 11 - 1 formed of stainless steel (SUS420J2) and being a plate member that has been punched out by a pressing operation, is placed at an inside-diameter portion of a positioning plate 26 of a mold for a drawing operation.
  • the metallic member may be formed of, for example, SPC material, a low alloy steel, a high alloy steel, or a non-ferrous alloy.
  • the drawing mold comprises a punch 22 , which is a male mold, and a female mold.
  • the female mold comprises a die 24 having a recessed portion, a die ring 23 serving as an outer frame and being a holding portion of the die 24 , a knockout portion 25 for separating a molded product from the female mold, and a positioning plate 26 .
  • the cup-like member 11 - 2 is molded as shown in FIG. 1C .
  • the cup-like member has the form of a container having a bottom portion 52 and a side surface 53 formed along the outer periphery of the bottom portion 52 .
  • a hole or a recess may be formed in the bottom portion 52 .
  • the cup-like member is such that the width in a radial direction of an opening end portion 51 is smaller than the width in a radial direction of protrusions (represented by reference numeral 55 in FIG. 2D ) of a final molded product, and such that the height of the side surface 53 is greater than the height of the protrusions (that is, the length thereof in a direction perpendicular to the radial direction) of the final molded product.
  • a molding load is reduced when forming the protrusions in the post-processing process. Therefore, performing this is desirable. This is because, since, as shown in FIG. 2B , the cup-like member is deformed so as to extend outward in the molding process, a load that is applied to a thin-walled portion 34 a in a height direction is reduced.
  • an annealing heat treatment at a temperature of 750° C. is performed.
  • the heat treatment is performed to reduce molding load during a forging operation performed for forming the protrusions in the post-processing process, so that the cup-like member tend to undergo plastic deformation.
  • the annealing heat treatment may sometimes be omitted.
  • a lubricating treatment may be performed on the surface of the cup-like member 11 - 2 .
  • a lubricant whose main component is molybdenum disulfide is applied.
  • FIG. 2A shows a state in which the cup-like member 11 - 2 is placed in a mold (used for molding the protrusions) and is positioned in the mold.
  • the mold used for molding the protrusions includes a female mold (including a die ring 33 , a die 34 , and a knockout portion 35 ) and a punch 32 (serving as a male mold).
  • a groove in which the cup-like member is inserted is formed along the circumference of the die 34 .
  • the thin-walled portion 34 a disposed with an equal interval in a peripheral direction, is formed in the groove formed along the circumference.
  • An inner peripheral wall of the groove has a slope.
  • the cup-like member is positioned at an inside-diameter portion of the die ring 33 , and the opening end portion of the cup-like member is disposed so as to contact the upper end of the thin-walled portion 34 a (a portion of the die 34 ) for forming grooves between the protrusions.
  • FIG. 2B shows a state in which, as the punch 32 is moved downward, a load having a component that is perpendicular to the bottom portion of the cup-like member is applied, and the cup-like member is being deformed.
  • a load applied to the punch 32 and the thin-walled portion 34 a is small.
  • protrusions start to form at the opening end portion of the cup-like member 11 - 3 .
  • the punch 32 is moved downward, the load is gradually increased, and the whole molding operation ends at the bottom dead point as shown in FIG. 2C .
  • a final molded product 11 - 4 is obtained as shown in FIG. 2D .
  • the protrusions 55 are formed at the opening end portion 51 of the cup-like member, and the width in the radial direction of the protrusions 55 becomes greater than the width of the opening end portion of the cup-like member.
  • the thickness of the bottom portion 54 of the final molded product is less than the thickness of the bottom portion 52 of the cup-like member. Accordingly, in the embodiment, stress applied to each portion of the molds, in particular, to the thin-walled portion 34 a during the molding process is gradually increased, and a force applied to the thin-walled portion in the peripheral direction is small, so that the probability with which the thin-walled portion 34 a is broken is reduced.
  • the load on the die and the knockout portion is also reduced, thereby reducing the probability of deformation and breakage thereof.
  • the shape of the side surface of the cup-like member and the shape of the protrusions are not limited to the shapes discussed in the embodiment as long as they can be deformed so that the width in the radial direction of the protrusions, that is, the plate thickness is increased during the forging operation.
  • the protrusions may be inclined not only at the inner peripheral side, but also at the outer peripheral side, or may be formed with the same width.
  • a plate member serving as the processing object a plate member having a width that is smaller than the width in the radial direction of the groove of the die 34 (that is, the width in the radial direction of the protrusions of the molded product) may be used, thereby reducing costs. The reason will be given below.
  • a plate member whose diameter is larger than the diameter of the vibration member (which is the final molded product) as with the disc 11 - 1 shown in FIG. 1A and which is such that the thickness of the disc 11 - 1 is less than the thickness of the protrusions of the vibration member may be used. Accordingly, since a rolled plate that is lower in cost than, for example, a round bar may be used, it is possible to reduce material roughness and increase the parallelism of both surfaces, and to reduce costs. In addition, since the plate member is thin, little changes occur in the plate thickness when forming the bottom portion to a predetermined thickness (height), so that work hardening does not progress very much. As a result, the stress that is required for reducing the thickness of the bottom portion is reduced, so that deformation and breakage of the die and the knockout portion occur even less often.
  • the vibration member formed in accordance with the embodiment makes it possible for the mass of the protrusions of the vibration member to provide vibration energy, and to reduce the width of the thin-walled portion in the peripheral direction. Therefore, it is possible to cause the width of the grooves formed between the protrusions that are adjacent to each other to be as small as possible. That is, it is possible to increase the width in the peripheral direction of the protrusions, and to increase resistance to wear of the protrusions that contact the moving member.
  • the vibration wave driving apparatus if the width in the peripheral direction of the protrusions formed by the compression molding is increased, not only is the resistance to wear increased, but also undesired vibration is restricted. This is because, since natural vibration frequency of each protrusion itself is small, undesired vibration caused by the protrusions themselves infrequently occurs.
  • the method of molding the cup-like member by applying a load having a component that is perpendicular to the surface of the plate member to the plate member is not limited to drawing. As long as it is a method of three-dimensionally deforming the plate member, any other method, such as burring, stretch forming (embossing), or dish extrusion (bowl molding) may also be used.
  • the method of forming the protrusions by applying a load having a component that is perpendicular to the surface of the bottom portion of the cup-like member to the cup-like member is not limited to cold forging.
  • the plate member may also be molded by hot forging, warm forging, or cold pressing.
  • a vibration member formed of stainless steel (SUS420J2), having an outside diameter of 48 mm, whose bottom portion has a thickness of 2.5 mm, whose protrusions have a width of 5 mm in a radial direction, and whose protrusions have a height of 4.5 mm was produced.
  • a mold used for molding the protrusions had a height of 4.5 mm and a width of 0.6 mm (at a thinnest portion) in a peripheral direction of a thin-walled portion of a die.
  • a load of at least 3 t was required, and a large pressure instantaneously acted upon the thin-walled portion, as a result of which the probability of breakage of the thin-walled portion was high.
  • a load was not instantaneously applied to the thin-walled portion, or a total load was small, thereby reducing the burden on the mold during the molding.
  • the second embodiment differs from the first embodiment in that a hole is formed in the center of a bottom portion of a cup-like member and in that a preliminary molding operation is performed on the cup-like member between a step of forming the cup-like member and a step of forming a final molded product.
  • FIG. 3 is a cup-like member 41 - 1 after drawing.
  • the cup-like member is open by press-punching a circular hole 41 - 1 a in the center of a bottom portion 52 .
  • the other features of the cup-like member are the same as those of the cup-like member according to the first embodiment.
  • the circular hole may be formed when a plate member provided prior to molding the cup-like member is formed, or when the cup-like member is molded, or after the cup-like member is molded.
  • the circular hole is formed for determining the center position in a next molding step. Therefore, instead of such a through hole, a recess may be formed.
  • FIG. 4A shows a state in which protrusions are molded by applying a load having a component that is perpendicular to a surface of the bottom portion 52 of the cup-like member to the cup-like member.
  • the circular hole of the cup-like member is fitted to a positioning protrusion 42 a , provided at an end portion of a punch 42 , and the center of the cup-like member 41 - 1 and the center of a mold coincide with each other. This prevents the cup-like member from being decentered when it is being compressed.
  • An opening end portion 51 of the cup-like member can be restrained at an inside-diameter portion of a die ring 43 , and the bottom portion 52 of the cup-like member, that is, a portion of the cup-like portion that contacts the punch 42 can be secured so as not to be shifted in a direction parallel to the surface of the bottom portion in FIG. 4A .
  • the reason that the circular hole is provided to restrain the center position in this way is related to the precision of the shape of the cup-like member 41 - 1 and uniformity in its plastic deformation.
  • the precision of the shape of a molded product is often influenced by the degree of its anisotropy.
  • Anisotropy occurs as a result of aggregate structures differing from each other in connection with, for example, crystal orientation according to material.
  • characteristics, such as stretching, processing hardening coefficient, an elastic limit value, and Young's modulus, in a rolling direction differ from those in a direction orthogonal to the rolling direction.
  • the opening end portion 51 of the cup-like member may be curled.
  • the opening end portion 51 of such a cup-like member infrequently has a high degree of circularity.
  • measures are taken to allow the use of a material having a high anisotropic property. That is, in the embodiment, as mentioned above, for example, a hole that restrains the center position is formed in the cup-like member. This causes deformation in a radial direction to be uniform during the deformation of the cup-like member. As a result, variations in the thickness in a peripheral direction of a molded product that is formed by compression are reduced.
  • FIG. 4B shows a state 41 - 2 in which the cup-like member has been compressed.
  • the molding step is a preliminary molding step.
  • the shape of a final molded product is not yet formed. Rather, the preliminary molded product 41 - 2 having low protrusions, that is, shallow grooves between the protrusions are formed as shown in FIG. 4C .
  • the preliminary molding is performed, when final protrusions are molded, almost no sideways force is generated at the thin-walled portion, thereby making it possible to reduce the probability of breakage. This is like forming a mortar-like recessed portion at a location where the hole is previously formed with a drill to make it possible to fix an end position of the drill and prevent breakage of the drill when the drill is bent.
  • shallow grooves are formed at positions where the grooves are previously formed, they function as guides to make it possible to easily mold final deep grooves, that is, high protrusions.
  • the preliminary molded product Prior to molding the final protrusions, it is desirable that the preliminary molded product be subjected to intermediate heat treatment (annealing).
  • annealing intermediate heat treatment
  • the preliminary molded product is softened, so that deformation resistance is reduced in a final step.
  • the heat treatment is also effective in reducing negative effects caused by the aforementioned anisotropy as recrystallization occurs.
  • a lubricating treatment also be performed on the preliminary molded product 41 - 2 whose protrusions have small volumes (grooves between the protrusions are shallow). This is because, stress on the molds in the final molding step, in particular, seizure of the thin-walled portion is reduced.
  • a lubricant whose main component is molybdenum disulfide is applied.
  • FIG. 5A shows a state in which the preliminary molded product is set in the mold used to mold the shape of the final vibration member.
  • the width in the peripheral direction of the grooves between the protrusions of the preliminary molded product be greater than the width in the peripheral direction of an end portion of a thin-walled portion 44 a corresponding thereto.
  • FIG. 5B shows a state in which the preliminary molded product 41 - 2 has been pressed until a molded product 41 - 3 having the final shape is formed.
  • the circular hole 41 - 2 a formed in the central portion of the preliminary molded product becomes a hole 41 - 3 a of the final molded product shown in FIG. 5C .
  • the diameter of the hole 41 - 3 a is smaller than the diameter of the circular hole 41 - 2 a.
  • the circular hole 41 - 2 a is formed in the center of the bottom portion of the cup-like member, and the preliminary molding step is provided prior to the step of forming the final protrusions.
  • Forming the circular hole makes it possible to restrain the center position and to reduce variations in the width of the molded product in the peripheral direction.
  • the circular hole makes it possible for excess metal to be used for the circular hole and to prevent excessive stress from being applied to the molds.
  • by providing the preliminary molding step when the final protrusions are being molded, almost no sideways force is generated at the thin-walled portion, thereby making it possible to further reduce the probability of breakage.
  • each of the embodiments is described taking as an example the case in which protrusions for increasing vibration in the vibration member are formed, the present invention is not limited thereto. That is, as long as a metallic processing object having a plurality of protrusions protruding in one direction is provided, the above-described molding method is applicable to parts having shapes similar to those of, for example, a bevel gear and a hypoid gear.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
US12/840,170 2009-07-24 2010-07-20 Method of producing metallic member Abandoned US20110016944A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2009-172920 2009-07-24
JP2009172920A JP5383362B2 (ja) 2009-07-24 2009-07-24 金属部材の製造方法

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US20120318035A1 (en) * 2011-06-20 2012-12-20 Shih-Ming Chen Pressing-shaping method for manufacturing circular cooling base for being embedded with fins and mold used in the method
US20130025340A1 (en) * 2010-04-23 2013-01-31 Topre Corporation Method of hot-press forming enabling hardness control
US20130228001A1 (en) * 2010-08-27 2013-09-05 Yoshiharu Nakamura Method for forming an undercut and method for manufacturing a formed article having an undercut
US9302318B2 (en) * 2014-12-14 2016-04-05 Griffin Tactical Incorporated Device and method for construction of baffles from engine block freeze plugs
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US11148186B2 (en) * 2017-04-03 2021-10-19 Matec Co., Ltd. Method of manufacturing cup structure

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CN109550802A (zh) * 2018-12-14 2019-04-02 江西福格新能源传动技术有限公司 一种差速器齿轮轴向分流冷挤压成形装置与方法

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US20070006628A1 (en) * 2004-04-16 2007-01-11 Youichi Tabei Molding method by forging and molding method for case
US7624611B2 (en) * 2004-12-13 2009-12-01 Jatco Ltd Method and apparatus for forming a cup-shaped member
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US20130025340A1 (en) * 2010-04-23 2013-01-31 Topre Corporation Method of hot-press forming enabling hardness control
US9409221B2 (en) * 2010-04-23 2016-08-09 Topre Corporation Method of hot-press forming enabling hardness control
US20130228001A1 (en) * 2010-08-27 2013-09-05 Yoshiharu Nakamura Method for forming an undercut and method for manufacturing a formed article having an undercut
US9266160B2 (en) * 2010-08-27 2016-02-23 Kabushiki Kaisha F.C.C. Method for forming an undercut and method for manufacturing a formed article having an undercut
US20120318035A1 (en) * 2011-06-20 2012-12-20 Shih-Ming Chen Pressing-shaping method for manufacturing circular cooling base for being embedded with fins and mold used in the method
US9302318B2 (en) * 2014-12-14 2016-04-05 Griffin Tactical Incorporated Device and method for construction of baffles from engine block freeze plugs
US20180297480A1 (en) * 2016-10-05 2018-10-18 Voltu Motor, Inc. Electric vehicle
US11148186B2 (en) * 2017-04-03 2021-10-19 Matec Co., Ltd. Method of manufacturing cup structure
US20180339330A1 (en) * 2017-05-26 2018-11-29 Toyota Boshoku Kabushiki Kaisha Manufacturing method for cylindrical portion
US10974302B2 (en) * 2017-05-26 2021-04-13 Toyota Boshoku Kabushiki Kaisha Manufacturing method for cylindrical portion
EP3550379A1 (en) * 2018-03-13 2019-10-09 Ricoh Company Ltd. Embossed component and housing and image forming apparatus including same
US11156244B2 (en) 2018-03-13 2021-10-26 Ricoh Company, Ltd. Embossed component and housing and image forming apparatus including same

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CN101961764B (zh) 2013-10-30

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