WO2005023446A1 - 表面品質に優れたアルミニウム管及びその製造方法と製造装置並びに感光ドラム基体 - Google Patents
表面品質に優れたアルミニウム管及びその製造方法と製造装置並びに感光ドラム基体 Download PDFInfo
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- WO2005023446A1 WO2005023446A1 PCT/JP2003/011578 JP0311578W WO2005023446A1 WO 2005023446 A1 WO2005023446 A1 WO 2005023446A1 JP 0311578 W JP0311578 W JP 0311578W WO 2005023446 A1 WO2005023446 A1 WO 2005023446A1
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- Prior art keywords
- aluminum
- tube
- extruded
- pipe
- extrusion
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C25/00—Profiling tools for metal extruding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/04—Making uncoated products by direct extrusion
- B21C23/08—Making wire, bars, tubes
- B21C23/085—Making tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C35/00—Removing work or waste from extruding presses; Drawing-off extruded work; Cleaning dies, ducts, containers, or mandrels
- B21C35/02—Removing or drawing-off work
Definitions
- the present invention relates to an aluminum tube excellent in surface quality, which is preferably used as a photosensitive drum of an electrophotographic apparatus such as a copying machine, a printer, a facsimile machine, etc., a method of manufacturing the same, and a photosensitive drum substrate excellent in surface quality.
- Aluminum tubes used as photosensitive drums in electrophotographic devices such as copiers, printers, and facsimile machines are desired to have a relatively mirror-like surface due to their properties.
- mirror finishing was performed by cutting aluminum pipes.However, it is not easy to adjust and manage the cutting tools, and it is not suitable for mass production because it requires skill in work. there were.
- ED tubes which are obtained by drawing aluminum extruded raw tubes, have come into wide use as photosensitive drum bases.
- This ED tube is first extruded from an aluminum billet to obtain an extruded aluminum tube, cut into a predetermined length, and then subjected to a drawing process to improve the surface properties and then to a predetermined diameter.
- Example dimensions, internal dimensions, and wall thickness were obtained by obtaining an aluminum tube, followed by washing (see Japanese Patent Application Laid-Open No. 63-184842).
- the aluminum drawn tube manufactured as described above has very fine and elongated streak-like surface defects (hereinafter simply referred to as “white hair”) as shown in the optical micrograph of FIG. It was relatively common to occur almost along the pull-out direction. (In Fig. 14, white hairs extend diagonally upward from the center of the photographic image to the right. ing) .
- photosensitive drums for electrophotographic devices such as copiers, printers, and facsimile machines have been required to be capable of realizing excellent image quality.
- the rate of obtaining good quality products without surface defects such as white spots that is, the yield is about 70%, which means that the production efficiency is low. It was very bad. Therefore, there is an urgent need to develop a manufacturing method that does not cause such surface defects such as white spots.
- the present invention has been made in view of such a technical background, and a manufacturing method and a manufacturing apparatus capable of manufacturing an aluminum pipe having excellent surface quality without producing surface defects such as white spots with good production efficiency. It is another object of the present invention to provide an aluminum tube having excellent surface quality and a photosensitive drum substrate.
- the present inventor tried to investigate the cause of the occurrence of white spots (surface defects).
- the present inventor thought that the following factors might cause or influence the occurrence of white horn.
- the present invention provides the following means.
- [I] A method of producing an aluminum tube by extruding an aluminum billet to obtain an aluminum extruded raw tube, and then drawing the extruded raw tube, wherein the extruded aluminum extruded raw tube is extruded. Cutting at a position within 1 Om or less from the discharge position of the die to obtain an aluminum extruded raw tube having a length of 1 Om or less, and subjecting the extruded raw tube to the drawing process, excellent in surface quality. Manufacturing method of aluminum tube.
- a method for producing an aluminum pipe having excellent surface quality comprising: a cutting step of obtaining an aluminum extruded raw pipe; and a drawing step of drawing an aluminum extruded raw pipe after the cutting to obtain an aluminum pipe.
- the extruded aluminum extrusion tube is cut at a position within 10 m from a discharge position of an extrusion die to obtain an aluminum extrusion tube having a length of 1 to 6 m. Excellent aluminum pipe manufacturing method.
- the extruded aluminum extruded raw tube is cut at a position within 7 m from the discharge position of the extrusion die to obtain an aluminum extruded raw tube having a length of 2 to 5 m. Manufacturing method of aluminum tube.
- the length L in the extrusion direction of the die bearing portion forming the outer surface of the aluminum extrusion tube is 5 mm or less, and the center line average roughness Ra (Y) in the circumferential direction of the bearing portion and the extrusion direction
- the relationship with the center line average roughness Ra (X) is Ra (Y) ⁇ Ra 8.
- Extrusion is performed using an extrusion die whose bearing part is made of cemented carbide material and whose surface roughness is adjusted to Ry (maximum height) 5 to 30 mm.
- the extruded raw tube is used as a rod for supporting the drawn plug.
- a rod having a structure in which one or a plurality of cores abutting on the inner peripheral surface of the extruded raw tube is mounted over the entire length of the extruded raw tube, wherein A method for manufacturing an aluminum tube with excellent surface quality as described.
- the average length in the drawing direction of the crystal grains on the surface of the aluminum extruded raw tube obtained by the cutting is 60 m or more, and the average length of the crystal grains in the drawing direction is 1.3 times.
- an aluminum pipe whose average length in the drawing direction of the crystal grains on the surface exceeds 300 m by drawing in such a manner as described above For manufacturing aluminum pipes with excellent surface quality.
- a photosensitive drum substrate comprising an aluminum tube manufactured by the manufacturing method according to any one of the above items 1 to 19.
- a cutting machine that is arranged at a position in front of the extruder in the extrusion direction, and performs cutting while moving in synchronization with the moving speed of the aluminum extruding element tube extruded from the extruder;
- An aluminum pipe manufacturing apparatus characterized in that an aluminum extrusion pipe is cut by a cutter at a position within 1 Om from a discharge position.
- a photosensitive drum base comprising an aluminum drawing tube substantially free of fine streak-like surface defects extending substantially in the drawing direction on the surface.
- the photosensitive layer is formed on the outer peripheral surface of the photosensitive drum substrate according to the above item 22 or 29.
- a photosensitive drum characterized in that:
- the extruded aluminum extruded tube is cut at a position within 1 Om from the discharge position of the extrusion die to obtain an aluminum extruded tube having a length of 1 Om or less. Since the drawing process is performed, an aluminum tube having no surface defects such as white spots can be manufactured, and an aluminum tube having excellent surface quality can be manufactured with high production efficiency.
- the reason that surface defects such as white spots can be prevented in this way is that the time required for the hot extruded tube immediately after extrusion to contact the felt layer on the surface of the support roller is shortened, and the fibers of the felt layer are exposed to the surface of the tube. This is presumed to be because it can be effectively prevented from sticking to the surface.
- the extruded aluminum extruded tube is cut at a position within 1 Om from the discharge position of the extrusion die to obtain an aluminum extruded tube having a length of 1 Om or less. Since the pipe is drawn, it is possible to manufacture an aluminum pipe free of surface defects such as white spots and the like, and thus to efficiently manufacture an aluminum pipe having excellent surface quality. In this way, surface defects such as white spots can be prevented because the time required for the hot extruded tube immediately after extrusion to contact the felt layer on the surface of the support roller is reduced, and the fibers of the felt layer are reduced. It is presumed that this is because it can be effectively prevented from sticking to the surface.
- the occurrence of surface defects such as white spots can be sufficiently prevented.
- the occurrence of surface defects such as white spots can be reliably prevented.
- the extruded raw tube since the extruded raw tube is conveyed in the extrusion direction while being supported by a supporting roller around which a synthetic fiber felt is circumferentially wound, the extruded raw tube can be favorably formed without damaging the surface of the extruded raw tube. It can be transported while maintaining the surface state.
- the main component of the fiber constituting the felt is the aramide fiber, so that the fiber of the felt layer is more sufficiently prevented from sticking and adhering to the surface of the extruded tube (high temperature state).
- the composition of the billet is specified within the above specific range, so that an aluminum tube suitable for a photosensitive drum can be manufactured.
- a thin film of the extruded material can be easily formed on the surface of the bearing portion of the extrusion die, whereby the affinity between the bearing portion and the extruded material is improved, and seizure during extrusion can be reduced.
- An aluminum pipe having better surface smoothness can be manufactured. .
- the number of steps is the same as that of the conventional drawing process, the occurrence of concave defects caused by oil pits is suppressed, and the die existing on the surface of the extruded raw tube is repaired to improve the surface smoothness. High drawn tubes can be manufactured.
- one or more cores that are in contact with the inner peripheral surface of the extruded raw tube are mounted on the rod over the entire length of the extruded raw tube.
- the axis of the tube can be maintained in alignment with the axis of the die from the beginning to the end of drawing regardless of the length of the tube.
- the positional relationship among the die, the plug, and the extruded raw tube during drawing can be stabilized throughout, and an aluminum tube (drawn tube) with less runout can be reliably manufactured.
- an aluminum tube with further improved surface smoothness can be manufactured.
- the aluminum pipe is bent and straightened by the roll straightening machine after cutting off the lip which is a source of foreign matter, so that the foreign matter is not brought into the roll straightening machine. It is possible to correct the bending of the aluminum tube without scratching due to the above. Further, since the lip is cut by the press cutting method, no chips are generated at the time of cutting, and therefore, the bending of the aluminum pipe can be corrected without scratching due to the chips.
- an aluminum tube suitable for a photosensitive drum of an electrophotographic apparatus such as a copying machine, a printer, and a facsimile can be manufactured.
- an aluminum tube having excellent surface quality can be provided.
- the invention according to [22] provides a photosensitive drum substrate excellent in surface quality, which is suitable for a photosensitive drum of an electrophotographic apparatus such as a copying machine, a printer, and a facsimile. 5
- the invention (manufacturing apparatus) of [23] it is possible to manufacture an aluminum pipe having no surface defects such as white spots, thereby producing an aluminum pipe having excellent surface quality. It can be manufactured efficiently.
- the extruded raw tube can be conveyed while being kept in a good surface state without being damaged.
- the fiber of the felt layer is more sufficiently prevented from sticking and sticking to the surface of the extruded tube (high temperature state). be able to.
- an aluminum extruded raw tube precisely defined to a desired length can be manufactured.
- the occurrence of surface defects such as white spots can be reliably prevented.
- an aluminum tube having excellent surface quality can be provided.
- a photosensitive drum substrate excellent in surface quality suitable for a photosensitive drum of an electrophotographic apparatus such as a copying machine, a printer, and a facsimile machine.
- a photosensitive drum suitable for an electrophotographic apparatus such as a copying machine, a printer, a facsimile machine, and capable of forming an excellent image.
- Fig. 1A is a partially enlarged view of the die bearing part of the extrusion die
- Fig. 1B is an enlarged cross-sectional view taken along the line Ib-Ib in Fig. 1A
- Fig. 1C is Ic in Fig. 1A).
- It is a cross-sectional enlarged view of the Ic line.
- FIG. 2 is a cross-sectional view showing an example of a porthole die for extruding an extruded raw tube.
- FIG. 3 is a schematic plan view of the manufacturing apparatus of the present invention.
- FIG. 4 is a sectional view taken along line IV-IV in FIG.
- FIG. 5 is a cross-sectional view of the support roller.
- FIG. 6 is a sectional view showing an example of a drawing apparatus.
- FIG. 7A, FIG. 7B, and FIG. 7C are perspective views of the core, respectively.
- FIG. 8 is a sectional view showing another example of the drawing apparatus.
- FIG. 9 is an explanatory diagram for explaining the definitions of the outer diameter reduction rate and the cross-sectional area reduction rate.
- FIG. 1OA is an enlarged vertical sectional view showing a main part of the extraction plug
- FIG. 10B is an enlarged vertical sectional view showing an essential part of the extraction die.
- FIG. 11 is a longitudinal sectional view of a drawing die in which the drawing plug and the drawing die shown in FIG. 10 are combined.
- FIG. 12A is a partial cross-sectional side view showing a step of cutting a lip
- FIG. 12B is a side view showing a correction step.
- FIG. 13A is a cross-sectional view showing an example of an ultrasonic cleaner
- FIG. 13B is a cross-sectional view showing another example
- FIG. 13C is a partially cutaway perspective view showing still another example. is there.
- Fig. 14 is an optical micrograph of the surface of an aluminum drawn tube manufactured by the conventional method.
- Fig. 14A is a 37.5 times enlarged photograph
- Fig. 14B is a 100 times magnified photograph. It is an enlarged photograph.
- the extrusion die having the following configuration. That is, the length L in the extrusion direction of the die bearing portion forming the outer surface of the aluminum extruded raw tube is 5 mm or less, and the center line average roughness R a (Y) in the circumferential direction of the bearing portion and the extrusion direction are different. It is preferable to extrude using an extrusion die whose relationship with the center line average roughness Ra (X) is set so that Ra (Y) ⁇ Ra (X).
- the extrusion method is not particularly limited, and may be a method using a porthole die or a mandrel extrusion. Fig.
- FIG. 2 shows an example of a porthole die used for porthole extrusion.
- (1) is a female die
- (2) is a die pressing die.
- a through-hole (11) is formed in the center part, and the peripheral surface on the inlet side of the extrusion hole is formed as a circular bearing (12).
- (13) is a relief portion.
- die press (
- the length of the bearing portion forming the outer surface of the aluminum extrusion tube that is, the length of the extrusion direction (indicated by the arrow X in FIG. 1) of the female bearing portion (12) in the die of FIG.
- a particularly preferred range of the length of the bearing portion (12) in the extrusion direction is 3 mm or less.
- the length of the bearing section (1 2) in the extrusion direction is too short, the strength of the bearing section is reduced and the bearing section is liable to be damaged, and the bearing section is radiused and the shape becomes unstable. Therefore, it is desirable to secure a length of 1 mm or more.
- Ra (Y) ⁇ Ra (X) is set, the A 1 scum that adheres to and accumulates on the bearing is likely to be trapped in the groove on the surface of the bearing, and A 1 Adhesion and migration of scum are suppressed.
- Set Ra (Y) ⁇ Ra (X) The method for this is not particularly limited, but it may be polished along the circumferential direction (Y direction) as shown in FIG. 1, for example, with a diamond file.
- an extrusion die that satisfies the following conditions. That is, in the extrusion die, it is preferable that the bearing portion (12) is formed of a super-hard material, and the surface roughness of the bearing portion (12) is adjusted to Ry (maximum height) 5 to 30 m. By defining the range of the surface roughness within the specific range, a thin film of the extruded material is easily formed on the surface of the bearing portion (12), and the bearing portion (12) is uniformly formed of a film having the same composition as the extruded material.
- the affinity between the bearing portion (12) and the extruded material is improved, seizure during extrusion can be eased, and the surface smoothness of the extruded raw tube can be improved.
- Ry is less than 5 m, the effect of forming a film is poor, and thus it is not preferable.
- Ry exceeds 30 m the surface smoothness is unfavorably reduced.
- the surface roughness of the bearing portion (12) is adjusted to Ry (maximum height) of 10 to 20 m.
- the cemented carbide material forming the bearing portion (12) is not particularly limited, as long as it can be used as a normal die material such as various cemented carbides and ceramics. Note that the Ry (maximum height) is specified in JIS B0601.
- the extruded aluminum extruded raw tube is cut at a position within 10 m from the discharge position of the extrusion die to obtain an aluminum extruded raw tube (4) having a length of 1 Om or less (cutting step). That is, the distance (Q) from the extruding die discharge position (M) of the extruder (24) to the cutting position (N) by the cutting machine (25) is set within 10 m, and cutting by the cutting machine (25) is performed.
- the length (R) of the extruded aluminum pipe (4) obtained by the above process is cut so as to be 1 Om or less (see Fig. 3).
- FIG. 3 shows a schematic plan view of an apparatus involved in the extrusion step and the cutting step.
- (24) is an extruder
- (25) is a cutting machine
- (26) is a supporting roller
- (27) is a control device
- (28) is a speed sensor.
- the extruder (24) extrudes an aluminum extrusion tube (4) from the discharge port of the extrusion die at the right end after an aluminum billet is introduced from the left end.
- the cutting machine (25) is arranged at a position in front of the extruder (24) in the extrusion direction, and moves in synchronization with the moving speed of the aluminum extrusion tube (4) extruded from the extruder (24). While cutting the pipe (4). At this time, the extruder (4) is cut by the cutter (25) at a position within 1 Om from the discharge position (M) of the extrusion die of the extruder (24). I have.
- a plurality of pairs of support rollers (26) (26) are arranged between the extruder (24) and the cutting machine (25). As shown in FIG.
- the pair of support rollers (26) and (26) are arranged in such a manner that their axes are orthogonal to each other and open upward in a V-shape.
- the support roller (26) has a configuration in which a synthetic fiber felt (26b) is circumferentially attached to the outer peripheral surface of a tubular roller core (26a).
- the felt (26b) on the outer surface contacts and supports the extrusion tube (4).
- an aramide fiber is used as a main fiber of the fiber constituting the fault (26b).
- the control device (27) controls execution of the cutting operation of the cutting machine (25) based on information on the moving speed of the raw pipe (4). That is, cutting machine
- the extruded raw tube (4) is cut at a timing such that the length (R) of the aluminum extruded raw tube (4) obtained by the cutting in (25) becomes 1 Om or less.
- the extruded aluminum extruded pipe (4) is cut at a position within 1 Om from the discharge position of the extrusion die, (M), and the aluminum pipe having a length (R) of 1 Om or less is obtained.
- the aluminum extruded tube (4) is obtained and subjected to the next drawing process, whereby an aluminum drawn tube (5) free from white defects and other surface defects can be manufactured, and as a result, aluminum with excellent surface quality
- the pipe (5) can be manufactured with high production efficiency. In this way, the occurrence of surface defects such as white spots can be prevented by reducing the time for the hot extruded tube (4) in the hot state immediately after extrusion to contact the felt layer (26b) on the surface of the support roller (26).
- the extruded aluminum extruded pipe (4) is cut at a position within 10 m from the discharge position (M) of the extrusion die to obtain an aluminum extruded raw pipe (1) having a length of 1 to 6 m.
- the extruded aluminum extrusion tube (4) is cut at a position within 7 m from the discharge position (M) of the extrusion die, and the aluminum extrusion tube (2) having a length of 2 to 5 m is cut. It is particularly preferred to obtain. .
- the aluminum billet to be introduced into the extruder (24) is not particularly limited, but Mn: 1.1 to: L. 6% by mass, Si: 0.7% by mass or less, Fe: 0. 8% by mass or less, Cu: 0.04 to 0.21% by mass, Zn: 0.11% by mass or less, it is desirable to use a billet consisting of aluminum and unavoidable impurities. There is an advantage that an aluminum tube particularly suitable for a photosensitive drum can be manufactured.
- the surface roughness in the circumferential direction of the extruded aluminum pipe (4) obtained by the cutting is preferably in the range of Ry (maximum height) 0.5 to 1 Qm. If the surface roughness exceeds 10 m in Ry (maximum height), fine wrinkle-like defects are present on the surface of the aluminum pipe obtained by drawing. In this case, when the photosensitive layer is thin-film coated, it tends to cause a coating pool. On the other hand, when the surface roughness is less than 0.5 m in Ry, the extruded raw tube is too smooth, and the lubricating oil during drawing is pushed between the drawn die and the raw tube, and the surface of the obtained aluminum tube is reduced in thickness.
- Extrusion tube (4 ) The particularly preferred lower limit of the surface roughness in the circumferential direction is 1 m in Ry, and the upper limit is 7 m in Ry.
- the means for defining the surface roughness in the circumferential direction of the aluminum extrusion tube (4) in the range of Ry 0.5 to 10 m is not particularly limited.
- the means for the die bearing of the extrusion die may be used.
- Means include defining the length in the extrusion direction or suppressing the extrusion speed to a certain value or less.
- the aluminum extruded raw pipe (4) obtained by the cutting is drawn to obtain an 'aluminum pipe (aluminum drawn pipe) (5) (drawing step).
- the cut aluminum extruded raw tube (4) is passed between the drawing die (31) and the drawing plug (33), and the drawing die (31) and the aforementioned extruded raw tube (4) are passed through. While the lubricating oil having a viscosity of 200 cst or less is supplied, the extruded raw pipe (4) is pulled out, and the outer diameter reduction rate from the extruded raw pipe (4) to the aluminum pipe (5) is 30% or less. It is preferable to perform the drawing process so that the area reduction rate is 5% or more.
- a high-viscosity lubricating oil is used, if the lubricating oil is pushed between the drawing die (31) and the extruded pipe (4), an oil pit tends to be formed, which tends to cause a concave defect. If lubricating oil having a viscosity of 200 cst or less is used, the formation of oil pits can be suppressed, and the occurrence of concave defects in the aluminum pipe (drawing pipe) (5) can be sufficiently suppressed. Particularly preferred viscosity of the lubricating oil is 100 cst or less. Examples of lubricating oils having a viscosity of 200 cst or less include mineral oils and oils and fats.
- the outer diameter reduction rate and the cross-sectional area reduction rate are defined by the following equations, respectively (see FIG. 9).
- Outer diameter reduction rate (%) (D.-D) ZD. X 100
- the outer diameter reduction rate exceeds 30%, the die of the extruded raw pipe (4) is crushed, and This is not preferable because the portion protrudes and burrs or eaves-like defects easily occur on the surface of the drawn pipe (5).
- the cross-sectional area reduction rate is less than 5%, the dice are not sufficiently closed by drawing and may remain as concave defects, which is not preferable.
- a particularly preferable reduction rate of the outer diameter is 10% or less, and a particularly preferable reduction rate of the cross-sectional area is 20% or more.
- the cut aluminum extruded raw tube (4) is drawn between the drawing die (31) and the drawn plug (33) to be drawn, and the extruded raw tube (4) is drawn.
- one or a plurality of cores (6) abutting on the inner peripheral surface of the extruded raw tube (4) are used as rods (32) for supporting the extraction plug (33). It is preferable to use a rod (32) (see FIGS. 6 to 8) which is mounted over the entire length of the rod.
- the core (6) attached to the rod (32) prevents the radius of the raw tube (4) by its own weight by abutting against the inner peripheral surface of the extruded raw tube (4).
- the core (6) is mounted over the entire length of the tube (4) so that the axis of the tube (4) coincides with the axis of the die (31) from the beginning to the end of drawing. Can be held.
- the holding of the base tube (4) prevents the die (31), the plug (33), and the base tube (4) from being changed in the positional relationship during the drawing. : Deflection of the rubber extraction tube (5) can be sufficiently suppressed.
- the core (6) may have any shape as long as it can prevent the extruded raw tube (4) from bending and maintain the coaxiality between the drawing die (31) and the raw tube (4), as shown in FIG.
- a simple columnar shape (6a) (6b) (6c) can be exemplified.
- the cores (6a), (6b), and (6c) of such a shape can be inserted through the rod (32) at the center, and attached to the core (6a) (6b) (6
- a stable holding force can be obtained by inscribed in the pipe (4) all around c).
- the outer peripheral surface is formed with a metal (7) parallel to the axis as shown in FIGS. 7B and 7C.
- the core (6b) shown in Fig. 7B has a continuous groove (7>) on the entire outer peripheral surface, and the lubricating oil can be efficiently removed.
- the circumferential width of the contact surface (8) that comes into contact with the inner peripheral surface of the tube becomes narrower, and the holding force of the raw tube (4) is smaller.
- the groove (7) is provided at an interval, and the contact surface (8) that comes into contact with the inner peripheral surface of the raw tube (4) has a wider circumferential width so that the holding force of the raw tube (4) is also increased. Therefore, when the groove (7) is provided in the core (6), the shape shown in Fig. 7C is preferable, and the shape shown in Fig. 7A, Fig. 7B, In Fig. 7C, the cores (6a), (6b) and (6c) are shown as short cores, but the cross-sectional shape is the same for the long core (6e). is there.
- the material of the core (6) is not particularly limited as long as it is a soft material that does not damage the extruded raw tube (4), and is preferably made of a resin such as nylon, vinyl chloride, polyethylene, or polypropylene.
- the core (6) is provided with a rod (32) and a pipe (32) in order to secure a stable positional relationship among the drawing die (31), the drawing plug (33), and the pipe (4) during drawing. 4) It is good to install over the entire length of.
- a plurality of short cores (6d) may be mounted at appropriate intervals as shown in FIG. 6, or as shown in FIG.
- One long core (6e) may be used. In either case, it is possible to prevent the extruded raw pipe (4) from bending, and to sufficiently suppress the deflection of the aluminum pipe (drawn pipe) (5).
- the cut aluminum extruded raw tube (4) is drawn between the drawing die (31) and the drawn plug (33) to be drawn, and the extruded raw tube (4) is drawn.
- a die having an approach angle of 10 to 40 ° and a bearing length of 8 to 25 mm is used as the drawing die (31), while an approach angle of 6 to 40 is used as the drawing plug (33). 10 °, It is preferable to use a plug with a bearing length of 1.5 to 3 mm (see Figs. 10 and 11).
- Figures 10 and 11 show a drawing die (31) and a drawing plug (33) for the ball drawing method.
- the drawing die (31) includes a die case (41) and a die body (42) integrally fitted to the die case (41) and made of a material such as die steel, cemented carbide, or ceramics. It has a die hole (43) in the center, and around the die hole (43), an approach part (44), followed by a bearing part (45) and a relief part (46). ing . Therefore, it is preferable that the approach angle (i) of the approach section (44) is set in the range of 10 to 40 °.
- the length (li) of the bearing portion (45) for defining the outer diameter of the aluminum pipe (5) is preferably set in the range of 8 to 25 mm. If the length of the bearing portion (45) is less than 8 mm, the roundness and wall thickness of the aluminum tube (5) will vary and the dimensions will be unstable, which is not preferable. On the other hand, if the length of the bearing portion (45) exceeds 25 mm, seizure may occur and the surface smoothness of the aluminum pipe (5) may be impaired, which is not preferable.
- the extraction plug (33) also has an approach part (51), followed by a bearing part (52) and a relief part (53). Therefore, it is preferable that the approach angle ( 2 ) of the approach portion (51) of the plug (33) is set in the range of 6 to: I0 °. When the approach angle is less than 6 °, the roundness of the aluminum tube (5) is hardly obtained, which is not preferable. On the other hand, if the approach angle exceeds 10 °, the roundness, wall thickness, etc. of the aluminum pipe (5) will vary and dimensions will be unstable, which is not preferable.
- the bearing (52) of the plug (33) The length (1 2 ) is preferably set in the range of 1.5 to 3 mm.
- the length of the bearing part (52) is less than 1.5 mm, the roundness of the aluminum pipe (5) is not easily obtained, which is not preferable.
- the length of the bearing portion (52) exceeds 3 mm, it is not preferable because seizure occurs and the surface smoothness of the aluminum tube (5) may be impaired.
- the outer diameter of the bearing (52) of the plug (33) and the inner diameter of the bearing (45) of the die (31) are determined by the inner and outer diameter and wall thickness of the aluminum pipe (5) to be manufactured. Needless to say, it is determined by the relationship.
- the bearing (52) of the plug (33) has a peripheral surface in the die (31).
- the bearing part (45) is combined with the aluminum tube (5) so that it faces the center part of the aluminum pipe (5) in the longitudinal direction at the center in the longitudinal direction through a gap corresponding to the intended thickness. Construct the mold (54). Then, the extruded raw tube (4) extruded by the extruder is pulled out by this mold (54) as shown by a chain line in FIG. 11 to reduce the diameter.
- the drawing may be performed only once to obtain the aluminum pipe (5).
- the drawing is repeated several times to reduce the diameter sequentially, thereby obtaining the aluminum pipe (5). Is preferred. Above all, it is particularly preferable to perform the drawing twice to reduce the diameter to obtain the aluminum tube (5).
- the drawing is performed by the ball drawing method.
- the present invention is not particularly limited to this, and the plug may be pulled out by a floating plug pulling method without fixing the plug.
- the drawing step it is preferable to perform drawing or the like so as to satisfy the following conditions. That is, the average length in the drawing direction of the crystal grains on the surface of the aluminum extruded raw tube (4) obtained by the cutting is 60 m or more, and the average length of the crystal grains in the drawing direction is 1.3 times. In order to draw it so that it becomes Therefore, it is preferable to obtain an aluminum tube (5) whose average length in the drawing direction of the crystal grains on the surface exceeds 300 m.
- the use of an aluminum extruded pipe (4) with an average length in the drawing direction of the crystal grains on the surface of not less than 60 m is less than 60 m. This is because it is difficult to make the length exceed 300 m.
- the stretching ratio in the drawing process is such that the average length in the drawing direction of the crystal grains on the surface is 1.3 times or more. 1.
- a particularly preferred stretching ratio is 1.5 to 2.5 times.
- the average length of the crystal grains on the surface of the aluminum extruded tube (4) is adjusted by cold-drawing the extruded tube (4), annealing at a temperature higher than the recrystallization temperature, and then performing the cold drawing at that time. Or by adjusting the annealing temperature.
- the aluminum tube (5) obtained through the drawing step is straightened.
- This straightening is preferably performed as follows. That is, it is preferable to cut the butt portion (57) of the aluminum tube obtained by the drawing process by a press cutting method and then straighten the aluminum tube using a roll straightening machine (61). Good.
- the mouth part (57) of the extruded raw pipe (4) is passed through the die hole (43) from the rear of the drawing die (31), and the mouth part (57) is inserted with the chuck part of the carriage (58).
- the carriage (58) is moved forward to pull out (see FIGS. 6 and 8). Dirt concentrates on the lip (57) after the pull-out, and burrs are formed due to the penetration by the chuck.
- the kiss (57) is cut off before performing the straightening. That is, as shown in FIG. Insert the end of the rubber drawing tube (5) on the side of the mouth (57) into the mold (59) (59) and lower the cutting blade (60) to lower the mouth (57). Cut and remove. Since cutting is performed by the parting blade (60), no chips are generated.
- this aluminum drawn tube (5) is put into the roll straightening machine (61) from one end, and straightened by the action of the internal straightening roll (62) ... (See Fig. 12B) .
- the aluminum drawn tube (5) is fed into the roll straightening machine (61) after the lip (57) is cut off without generating chips, so that foreign matter such as dirt, A1 debris, and chips are removed. It is not carried into the roll straightener (61), so the aluminum drawing tube (5) is not scratched during straightening.
- the bent aluminum tube (5) is cleaned.
- This washing removes the lubricating oil.
- This cleaning is preferably performed as follows. That is, it is preferable to wash the aluminum pipe (5) with a solvent having a KB (kauributanol) value of 20 or more within 3 days after drawing. Washing with a solvent within 3 days after drawing is difficult because the volatile components contained in the oil-based lubricant used at the time of drawing are volatilized and solidified over time after drawing. If the number of days exceeds, it becomes difficult to remove the solvent even if a solvent having a high degreasing power is used. The earlier it is, the better the cleaning time is after the drawing, and the earlier it is, the more the solvent with low degreasing power can be completely removed.
- the KB (kauributanol) value of the solvent indicates the solvent's dissolving ability, that is, degreasing power, and the test solvent is dropped at 25 ° C to 20 g of a solution of 100 g of natural kauri gum dissolved in 500 g of butanol. It is expressed in mL of the test solvent added until turbidity or precipitation occurs. The higher the KB value, the higher the solubility. In this washing step, it is preferable to wash with a solvent having a KB value of 20 or more. This is because a solvent with a low dissolving power with a KB value of less than 20 cannot sufficiently remove oily lubricating oil even if it is washed as early as 3 days after drawing.
- Examples of the solvent having a KB value of 20 or more include kerosene (30), cyclohexane (60), toluene (100), and aromatic naphtha ( 50-80) and dearomatic naphtha (20-30). Among them, it is particularly preferable to use a solvent having a KB value of 25 or more.
- the specific method of washing is not particularly limited, and examples thereof include an immersion method and a shower method.
- finish cleaning is further performed.
- the finish cleaning it is preferable to perform the following ultrasonic cleaning. That is, the relationship between the frequency f (kHz) of ultrasonic waves in the ultrasonic oscillator and the ultrasonic cleaning time T (minutes) was set to fXT ⁇ 120 (kHz * minutes) for the aluminum tube (5). It is preferable to carry out ultrasonic cleaning. By performing cleaning under these conditions, it is possible to prevent the occurrence of convex defects on the surface of the aluminum pipe (5). The reason is presumed as follows. In other words, the product f T of the ultrasonic frequency f (kHz) and the ultrasonic cleaning time T (min) seems to be related to the cleaning energy.
- f XT 120, the energy is too large and the convex defect Is presumed to be hit in the rising direction. Above all, it is particularly preferable to set f xT ⁇ 100 (kHz-min). On the other hand, if fT is too small, the cleaning effect will be poor, so the lower limit is preferably set to fxT ⁇ 2 (kHz ⁇ min). More preferably, the relationship between the output P (W) of the ultrasonic oscillator and the ultrasonic oscillation area, that is, the area S (cm 2 ) of the vibrator, is 0.1 ⁇ PZS ⁇ 1.0 (W / cm It is better to perform the above ultrasonic cleaning with setting to 2 ).
- the ultrasonic cleaning is for cleaning an aluminum pipe as an object to be cleaned by sending ultrasonic waves into a cleaning liquid, but the method of irradiating ultrasonic waves in the cleaning tank is not particularly limited.
- a throw-in type shown in FIG. 13A an adhesive type shown in FIG. 13B, a vibration transmitter type shown in FIG. In FIG.
- washing liquid (75) is a cleaning liquid. It is.
- white kerosene, light oil, alkali, surfactant, trichloroethylene, or the like is generally used, but is not limited thereto, and water-based, hydrocarbon-based, chlorine-based organic solvents, and the like are used. May be used as appropriate.
- the distance between the vibrator or the vibration transmitter and the aluminum tube is not particularly limited, but is preferably set to 2 to 50 cm.
- the aluminum pipe (5) obtained through the extrusion process, cutting process, drawing process, straightening process, washing process, and finishing washing process described above has a fine streak-like surface that extends almost in the drawing direction. It has no defects (white spots) and has excellent surface quality. Therefore, it is suitable as a photosensitive drum substrate for electrophotographic devices such as copiers, printers, and facsimile machines. .
- extruded aluminum tube (outer diameter 32 mm, wall thickness 1.5 mm). Obtained.
- the surface roughness in the circumferential direction of the aluminum extruded raw tube was Ry 2.5 2.m.
- the average length in the drawing direction of the crystal grains on the surface of the extruded element tube is 200 im, and the average length is 7 mm.
- Extrusion dies The porthole dies shown in Figs. 1 and 2 were used.
- the length L in the extrusion direction of the die bearing was 3 mm.
- the relationship between the center line average roughness Ra (Y) in the circumferential direction of the bearing and the center line average roughness Ra (X) in the extrusion direction is set as Ra (Y) ⁇ Ra (X).
- the bearing part is made of super hard material,
- the surface roughness of the ring was Ry 5.5 m.
- the fiber constituting the felt (26b) on the surface of the support roller (26) was composed of 35% by mass of oxidized fiber and 65% by mass of p-aramid fiber.
- Drawing device The structure shown in Fig. 6 (The shape of the core adopts Fig. 7B.)
- Drawing die The structure shown in Figs.
- the aluminum pipe (5) is bent using a roll straightening machine (61). (See Figure 12). Furthermore, the aluminum tube after straightening was washed with toluene (KB 'value: 100) within one day, and then ultrasonically washed under the following conditions to obtain an aluminum tube for a photosensitive drum (5).
- toluene KB 'value: 100
- the distance (Q) from the extrusion die discharge position (M) of the extruder (24) to the cutting position (N) by the cutting machine (25), and the length (R) of the extruded raw tube (4) obtained by cutting ) was set to the values shown in Table 1 in the same manner as in Example 1 to obtain an aluminum tube for a photosensitive drum.
- An aluminum tube for a photosensitive drum was obtained by a conventional manufacturing method. That is, the above Q was set to 50 m, and R was set to 50 m, to obtain an aluminum tube for a photosensitive drum.
- the aluminum pipes of Examples 1 to 7 manufactured by the manufacturing method of the present invention have a low occurrence frequency of white spots (fine streaky surface defects) on the surface.
- the defect rate was extremely small, and the defective rate due to the occurrence of white spots was remarkably reduced.
- the product yield was remarkably improved in the comprehensive evaluation including the presence / absence of other surface defects, straightness, uneven thickness, and roundness.
- the aluminum pipe of Comparative Example 1 manufactured by the conventional manufacturing method has a high frequency of white spots (fine streak-like surface defects) on its surface, and the defect rate due to white spots is high.
- the frequency of occurrence of white spots is high, the product yield is low in the comprehensive evaluation.
- An aluminum tube according to the present invention and an aluminum tube manufactured by the manufacturing method of the present invention Since the rubber tube has excellent surface quality, it is suitably used as a photosensitive drum of an electrophotographic device such as a copying machine, a printer, and a facsimile.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Photoreceptors In Electrophotography (AREA)
- Extrusion Of Metal (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2003266506A AU2003266506A1 (en) | 2003-08-27 | 2003-09-10 | Aluminum pipe having excellent surface quality, method and apparatus for manufacturing the aluminum pipe, and photosenstive drum base body |
US10/569,803 US20070039369A1 (en) | 2003-08-27 | 2003-09-10 | Aluminum pipe having excellent surface quality, method and apparatus for manufacturing the aluminum pipe, and photosensitive drum base body |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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JP2003-303334 | 2003-08-27 | ||
JP2003303334 | 2003-08-27 | ||
US49933503P | 2003-09-03 | 2003-09-03 | |
US60/499,335 | 2003-09-03 |
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WO2005023446A1 true WO2005023446A1 (ja) | 2005-03-17 |
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PCT/JP2003/011578 WO2005023446A1 (ja) | 2003-08-27 | 2003-09-10 | 表面品質に優れたアルミニウム管及びその製造方法と製造装置並びに感光ドラム基体 |
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AU (1) | AU2003266506A1 (ja) |
WO (1) | WO2005023446A1 (ja) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN103031469A (zh) * | 2012-11-11 | 2013-04-10 | 马鞍山市新马精密铝业有限公司 | 表面品质优良的感光鼓用铝管及其制造方法 |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS61159544A (ja) * | 1984-12-29 | 1986-07-19 | Canon Inc | 精密加工用アルミニウム合金、これを用いた管材及び光導電部材 |
JPS6445615U (ja) * | 1987-09-14 | 1989-03-20 | ||
JPH05220589A (ja) * | 1992-02-13 | 1993-08-31 | Honda Motor Co Ltd | 金属製中空材の切断方法 |
JPH0985331A (ja) * | 1995-09-21 | 1997-03-31 | Showa Alum Corp | 引抜管の製造方法 |
JPH0999314A (ja) * | 1995-10-05 | 1997-04-15 | Showa Alum Corp | 引抜管の製造方法 |
JPH10109107A (ja) * | 1996-10-02 | 1998-04-28 | Showa Alum Corp | 引抜加工方法 |
JP2000075531A (ja) * | 1998-08-27 | 2000-03-14 | Furukawa Electric Co Ltd:The | 感光ドラム用アルミニウム引抜管とその製造方法 |
-
2003
- 2003-09-10 WO PCT/JP2003/011578 patent/WO2005023446A1/ja active Application Filing
- 2003-09-10 AU AU2003266506A patent/AU2003266506A1/en not_active Abandoned
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS61159544A (ja) * | 1984-12-29 | 1986-07-19 | Canon Inc | 精密加工用アルミニウム合金、これを用いた管材及び光導電部材 |
JPS6445615U (ja) * | 1987-09-14 | 1989-03-20 | ||
JPH05220589A (ja) * | 1992-02-13 | 1993-08-31 | Honda Motor Co Ltd | 金属製中空材の切断方法 |
JPH0985331A (ja) * | 1995-09-21 | 1997-03-31 | Showa Alum Corp | 引抜管の製造方法 |
JPH0999314A (ja) * | 1995-10-05 | 1997-04-15 | Showa Alum Corp | 引抜管の製造方法 |
JPH10109107A (ja) * | 1996-10-02 | 1998-04-28 | Showa Alum Corp | 引抜加工方法 |
JP2000075531A (ja) * | 1998-08-27 | 2000-03-14 | Furukawa Electric Co Ltd:The | 感光ドラム用アルミニウム引抜管とその製造方法 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN103031469A (zh) * | 2012-11-11 | 2013-04-10 | 马鞍山市新马精密铝业有限公司 | 表面品质优良的感光鼓用铝管及其制造方法 |
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