WO2012035663A1 - クランクシャフトの製造方法およびクランクシャフトの製造装置 - Google Patents
クランクシャフトの製造方法およびクランクシャフトの製造装置 Download PDFInfo
- Publication number
- WO2012035663A1 WO2012035663A1 PCT/JP2010/066243 JP2010066243W WO2012035663A1 WO 2012035663 A1 WO2012035663 A1 WO 2012035663A1 JP 2010066243 W JP2010066243 W JP 2010066243W WO 2012035663 A1 WO2012035663 A1 WO 2012035663A1
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- WIPO (PCT)
- Prior art keywords
- pin
- becomes
- web
- journal
- crankshaft
- Prior art date
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C3/00—Shafts; Axles; Cranks; Eccentrics
- F16C3/04—Crankshafts, eccentric-shafts; Cranks, eccentrics
- F16C3/06—Crankshafts
- F16C3/08—Crankshafts made in one piece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
- B21J13/025—Dies with parts moving along auxiliary lateral directions
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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
- B21K1/00—Making machine elements
- B21K1/06—Making machine elements axles or shafts
- B21K1/08—Making machine elements axles or shafts crankshafts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C3/00—Shafts; Axles; Cranks; Eccentrics
- F16C3/04—Crankshafts, eccentric-shafts; Cranks, eccentrics
- F16C3/06—Crankshafts
- F16C3/14—Features relating to lubrication
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C2220/00—Shaping
- F16C2220/40—Shaping by deformation without removing material
- F16C2220/46—Shaping by deformation without removing material by forging
Definitions
- the present invention relates to a crankshaft manufacturing method and a crankshaft manufacturing apparatus, and in particular, a journal part serving as a rotation center axis, a pin part eccentric from the journal part, and a web extending between the journal part and the pin part.
- the present invention relates to a crankshaft manufacturing method and a crankshaft manufacturing apparatus.
- Patent Document 1 is known as a conventional technique related to the manufacture of a crankshaft.
- a round bar made of a cold forging material is cut to form a billet material having a predetermined length (in the present invention, an example of the material), and the billet material is bent by a hydraulic bender.
- an offset material 10 ′ in which a portion j ′ serving as each journal portion and a portion p ′ serving as each pin portion are offset in the direction perpendicular to the axis is formed (bending step).
- FIG. 1 is known as a conventional technique related to the manufacture of a crankshaft.
- a round bar made of a cold forging material is cut to form a billet material having a predetermined length (in the present invention, an example of the material), and the billet material is bent by a hydraulic bender.
- an offset material 10 ′ in which a portion j ′ serving as each journal portion and a portion p ′ serving as each pin portion are offset in the direction perpendicular to the axis
- crank body 100 ′ is compression molded (upsetting process).
- each counterweight formed by cold forging separately from the crank body is pressed in a state where the counterweight is positioned with respect to each connecting wall of the crank body and temporarily pressed, and then each counterweight is compressed.
- a method is disclosed in which a crankshaft is manufactured by plastically fastening each connecting wall to integrate a crank body and a counterweight (0017).
- the portion j ′ serving as the journal portion and the portion p ′ serving as the pin portion of the offset material 10 ′ are respectively held on the template plates 30 ′ and 31 ′, and this is held in the case 32 ′.
- the portion w ′ serving as the continuous wall is formed so as to be crushed and extended in the radial direction, and from the eccentric amount of the journal portion of the offset material 10 ′ and the portions j ′ and p ′ serving as the pin portion.
- a template for holding the portion p ′ serving as the pin portion 31 ' may be comprised so that it can move to the direction extended within case 32' with the increase in eccentricity.
- the upsetting process finishing of the present invention is performed as shown in FIG.
- the amount of crushing the portion w ′ that becomes the web portion of the offset material 10 ′ was large.
- the present invention has been made in view of the above-described problems, and an object of the present invention is to provide a method and an apparatus for manufacturing a crankshaft easily and accurately with a simple configuration.
- the crankshaft manufacturing method of the present invention manufactures a crankshaft having a journal portion serving as a rotation center axis, a pin portion eccentric from the journal portion, and a web portion extending between the journal portion and the pin portion.
- the crankshaft manufacturing apparatus includes a crankshaft having a journal portion serving as a rotation center axis, a pin portion eccentric from the journal portion, and a web portion extending between the journal portion and the pin portion.
- An apparatus for manufacturing a preforming apparatus for forming a rough shape material in which a material is bent to form a pin portion and a web portion, and the web portion by pressing the rough shape material in an axial direction.
- a finish forming device that forms a portion to be a predetermined thickness, and the preforming device includes a punch that grips a portion that becomes a pin portion of a material, and a die that grips a portion that becomes a journal portion.
- the punch and the die have a protrusion for forming a thin portion at a portion to be a web portion of the material.
- the rough shape material is pressed in the axial direction in the finish forming step.
- the portion that becomes the web portion is molded to a predetermined thickness, the amount of crushing of the portion that becomes the web portion can be reduced, and as a result, the flow of the material can be reduced.
- a crankshaft can be manufactured well.
- a portion that becomes a pin portion of a material is gripped by a punch, and a portion that becomes a journal portion is gripped and bent by a die, and a protrusion between the punch and the die
- a thin portion is formed in the portion that becomes the web portion of the material.
- FIG. 3 is a partially enlarged view of a crankshaft formed by performing finish molding from the state of FIG. 2. It is the elements on larger scale shown in order to demonstrate the state (a) before starting preforming, and (b) immediately after starting preforming by one Embodiment of the preforming apparatus of this invention. It is the front view (a) and side view (b) which were shown in order to demonstrate one Embodiment of the punch and die
- FIG. 9 is a cross-sectional view taken along the line AA in FIG.
- FIG. 10 is a longitudinal front view (a) and a side view (b) shown for explaining an embodiment of a die or punch for manufacturing the crankshaft shown in FIGS. 8 and 9.
- Finishing molding apparatus having a central journal portion fixing means for fixing a journal portion located at the center of the rough shape member, and an axial direction pressing means for pressing both ends of the rough shape material in the axial direction toward the center.
- FIG. 1 An embodiment in which a portion to become the second pin portion is preformed is shown in FIG.
- FIG. 1 An embodiment in which a portion to become the second pin portion is preformed is shown in FIG.
- FIG. 1 One embodiment of preforming a portion that becomes the third pin portion eccentric in the same direction as the second pin portion shown in FIG.
- FIG. 23 is an enlarged cross-sectional view taken along the line BB of FIG.
- crankshaft manufacturing apparatus of the present invention will be described mainly based on the embodiment shown in FIGS.
- the crankshaft 100 having a plurality of pin portions is described, the journal portion J, the pin portion P, the web portion W of each portion, and the rough shape member 10
- the material 1 in order to specify the part j to be a journal part, the part p to be a pin part, and the part w to be a web part, a number is added after each alphabetic code.
- the crankshaft 100 which is not limited to having a plurality of pin portions, and the rough shape member 10 and the material 1, will be numbered after the alphabetical symbol. It shall be described without.
- the same reference numerals are given to similar or corresponding parts.
- the present invention extends between a journal part J serving as a rotation center axis, a pin part P eccentric from the journal part J, and the journal part J and the pin part P.
- a device for manufacturing a crankshaft 100 having a web portion W which is a preforming device 2 for bending a material 1 to form a rough shaped member 10 in which portions p and j to be a pin portion and a web portion are formed.
- a finish forming device 3 that presses the rough shape member 10 in the axial direction to form the web portion w to a predetermined thickness and forms the web portion W at a predetermined pitch.
- the preforming apparatus 2 includes a punch 20 that grips a portion p that becomes a pin portion of the material 1 and a die 21 that grips a portion j that becomes a journal portion. Thin part on part w And a projecting portion 22 for forming.
- the preforming apparatus 2 in this embodiment includes a punch 20 that holds a portion p that becomes a pin portion of the material 1, and a pair of dies 21 and 21 that hold a portion j that becomes a journal portion.
- Axis orthogonal direction drive means (described later) for driving the punch 20 in the axis orthogonal direction and an axial direction drive main stage 26 (described later) for driving the die 21 in the axial direction with respect to the punch 20 are provided.
- the punch 20 and the die 21 are provided with a protrusion 22 for forming the thin portion T by partially pressing the portion w that becomes the web portion of the rough shaped material 10 to the portion that forms the portion w that becomes the web portion.
- the finish molding apparatus 3 in this embodiment includes a template 30 that holds a portion j that becomes a journal portion of the rough material 10 and a template that holds a portion p that becomes a pin portion. 31, a case 32 that holds the mold plates 30, 31 in the axial direction while being constrained in the radial direction (axial orthogonal direction), and the mold plates 30, 31 are moved in the axial direction within the case 32.
- An axial pressurizing means 26 (to be described later) for applying pressure in the axial direction so as to crush the portion w which becomes the web portion of the rough shaped member 10 between the mold plates 30 and 31 to form the web W at a predetermined pitch is provided. ing.
- the punch 20 of the preforming apparatus 2 includes a main body 20a that presses the material 1 in the direction perpendicular to the axis, and a punch presser 20b that is provided below the main body 20a and grips a portion p that becomes a pin portion of the material 1. ing.
- the punch presser 20b can be detached from the main body 20a so as to be opened / closed or detachable.
- the material 1 is arranged in a state in which the punch presser 20b is opened or removed from the main body 20a, and then the punch presser 20b is closed or attached to the main body 20a, and the state is maintained by clamping or the like. A portion p to be a pin portion is gripped.
- the punch 20 is attached to the upper board 23.
- the upper board 23 is connected to, for example, a press ram that extends and retracts in the direction perpendicular to the axis of the material 1 as the axis perpendicular direction driving means.
- the main body 20a presses the portion p that becomes the pin portion of the material 1 gripped by lowering the upper board 23 in the axis orthogonal direction, and a portion w that becomes a web portion adjacent to the portion p that becomes the pin portion will be described later.
- a protrusion 22 is formed to form a recess that becomes a thin portion T by being partially pressed in the axial direction between the die 21 and the main body 21a.
- the die 21 includes a main body 21 a that is formed so as to crush a portion w that becomes a web portion between the die 20 and a portion that is provided above the main body 21 a and serves as a journal portion j of the material 1.
- the die presser 21b can be attached to the main body 21a so that it can be opened and closed or detached.
- the main body 21a has a protrusion 22 for forming a concave portion that becomes a thin portion T in a portion w that becomes a web portion.
- the die is provided so as to be movable in the axial direction.
- the axial driving means 26 can be constituted by a cam mechanism that moves so as to approach each other when the upper board 23 is lowered, as shown in FIG. 4 and FIGS.
- the cam mechanism 26 constituting the axial direction drive means is constituted by a drive cam 26a and a driven cam 26b.
- the cam surfaces of both cam mechanisms 26 for moving the pair of dies 21 and 21 in the axial direction are set at the same angle. By moving down, both dies 21 and 21 are moved in the axial direction so as to move in the same manner.
- the drive cam 26a and the driven cam 26b are disposed on the side of the material 1 (in the front and back of the paper in FIG.
- the drive cam 26a and the driven cam 26b are indicated by chain lines.
- the drive cam 26a is provided so as not to move in the axial direction
- the driven cam 26b is provided so as to be movable in the axial direction and connected to the die 21.
- the cam mechanism 26 in this embodiment is in a state where the drive cam 26a is not lowered and the driven cam 26b is not moved in the axial direction so as to approach each other (that is, the preforming of the material 1 is not started).
- the cam surfaces of the drive cam 26a and the driven cam 26b are set so as to contact each other. Therefore, in this embodiment, the structure is such that the pressing of the material in the direction perpendicular to the axis by the lowering of the upper board 23 and the pressing of the material in the axial direction by the cam mechanism 26 are started simultaneously.
- the axial direction driving means 26 is not limited to the cam mechanism, and can be constituted by other actuators such as a hydraulic cylinder that extends and retracts in the axial direction.
- the mold plates 30 and 31 of the finish forming apparatus 3 hold the part j to be a journal part and the part p to be a pin part, respectively, and are divided so that they can be removed detachably so that they can be removed.
- the case 32 is generally formed in a cylindrical shape, and can be opened and closed so that the coarse material 10 held by the mold plates 30 and 31 can be placed inside and removed after molding. It is divided and formed in a split shape, and the half-shaped case 32 is held so as not to be inadvertently opened when finish forming is performed. For example, as shown in FIGS.
- the axial pressurizing means 33 brings one end of the case 32 into contact with a floor surface or a wall surface, and a pressing member 37 connected from the other end to a press ram or the like. It can be configured by inserting, or by inserting a pressing member 37 connected to a press ram or the like from both ends of the case as shown in FIG.
- FIG. 1 shows a rough shape 10 formed by preforming the material 1 when manufacturing a crankshaft 100 used for an in-line four-cylinder internal combustion engine, for example.
- Portions w10, w12, w21, w23, w32, w34, w43, and w45 that are web portions that support both ends are formed.
- the present invention extends between a journal part J serving as a rotation center axis, a pin part P eccentric from the journal part J, and the journal part J and the pin part P.
- the method includes a finish forming step of pressing the rough shape member 10 in the axial direction to form the web portion w to a predetermined thickness and forming the web portion W at a predetermined pitch.
- the thin portion T is formed in the portion w that becomes the web portion of the rough shaped member 10.
- the material 1 is made of a rod-like or linear metal material having a circular cross section.
- the material 1 grips the portion p that becomes the pin portion of the material 1 by the punch 20, and grips the portion j that becomes the journal portion by the dies 21 and 21, respectively.
- the punch 20 is moved and pressurized in the direction orthogonal to the axis of the material 1, and the dies 21 and 21 are moved in the axial direction so as to approach the punch 20 and pressed.
- the portion p which becomes the pin portion of the material 1 is deviated from the portion j which becomes the journal portion, and accordingly, the portion p which becomes the pin portion and the journal portion are moved by moving the dies 21 and 21 toward each other.
- a portion w that becomes a web portion between the portions j is pressed between the main body 20a of the punch 20 and the main body 21a of the die 21 in the axial direction. Due to the resultant force of pressurization when the punch 20 moves in the direction perpendicular to the axis of the material 1 and pressurization when the dies 21 and 21 move in the axial direction so that they are close to each other, The protrusion 22 is partially pressurized in the direction perpendicular to the axis to form a recess, and as a result, a thin portion T is formed in the portion w that becomes the web portion.
- the thin portion T is compared with an offset material 10 ′ (see the chain line in FIG. 2) simply bending the material 1 ′ as in the prior art. It is thinner in the thickness direction a. Further, the thin portion T is thinner both in the axial direction (left-right direction in FIG. 2) b and in the radial direction (up-down direction in FIG. 2) c than in the conventional technique.
- the mold plates 30 and 31 are attached and held in the portion p that becomes the pin portion and the portion j that becomes the journal portion of the rough shaped member 10, and are placed in the case 32. And pressurize in the axial direction. Since the thin portion T is formed in the portion w that becomes the web portion of the rough shape member 10, as shown in FIG. 3, the portions j and p that become the journal portion and the pin portion in the finish forming process are formed as the template 30, When the portion w which becomes the web portion of the rough shape member 10 is crushed in the axial direction between the mold plates 30 and 31, the rough shape member 10 is pressed. The amount of crushing from the thickness w of the web portion to the predetermined thickness of the web portion W of the crankshaft 100 can be reduced, and the projected area in contact with the templates 30 and 31 can be reduced. The pressure will be small.
- the web portion W that is compression-molded so as to be crushed in the axial direction in the finish forming step is formed in the corner portion. Since the stealing shape is formed, the moment when the crankshaft 100 is rotated around the axis about the journal portion J can be reduced, so that the counterweight can be reduced in weight. The entire shaft 100 can be reduced in weight.
- the axial orthogonal direction driving means first starts to press the portion p that becomes the pin portion of the material 1 in the axial orthogonal direction.
- the pressure in the axial direction is started so that the position in the axial direction of the portion p that becomes and the portion j that becomes the journal portion adjacent thereto become close to each other.
- the cam mechanism 26 constituting the axial direction driving means shown in FIG. 4 is such that the punch 20 starts to press the portion p that becomes the pin portion of the material 1 in the direction perpendicular to the axis, and the upper surface of the driving cam 26a is raised.
- a predetermined gap S is set with respect to the board 23.
- the driven cam 26b is supported on the base board 25 of the lower board 24 so as to be movable in the axial direction.
- the drive cam 26a is provided so as not to move in the axial direction of the material 1 when it is suspended from the lower surface of the upper plate 23 and the upper plate 23 descends and comes into contact with the upper surface of the drive cam 26a.
- the cam surface of the cam 26a can be supported so as to slide with respect to the cam surface of the driven cam 26b, and the drive cam 26a can be biased upward.
- the drive cam 26a is attached to the lower surface of the upper board 23, and the drive cam 26a and the driven cam 26b are not moved in the axial direction so that the upper board 23 is not lowered and the driven cam 26b is close to each other. It is also possible to adopt a structure in which a vertical gap S is generated between the two cam surfaces.
- crankshaft manufacturing method of the present invention will be described together with the operation of the preforming apparatus 2 configured as shown in FIG.
- parts that are the same as or correspond to those in the above-described embodiment are denoted by the same reference numerals, description thereof is omitted, and only different parts are described.
- the preforming step first, the portion p that becomes the pin portion of the material is started to be pressed in the direction perpendicular to the axis, and then the portion p that becomes the pin portion is adjacent to the portion p. Pressurization in the axial direction is started so as to bring the position in the axial direction of the portion j to be the journal portion closer to each other.
- the die 21 is used to hold the portion j, which is the journal portion of the material 1 molded to a predetermined length, with the upper board 23 raised.
- the part p to be a part is held by the punch 20 and the upper board 23 is lowered.
- the portion p that becomes the pin portion of the material 1 is pressurized in the direction perpendicular to the axis with the start of the lowering of the upper board 23, and accordingly, the portion w that becomes the web portion of the material 1 and the portion p that becomes the pin portion.
- the boundary portion and the boundary portion between the portion that becomes the web portion w and the portion that becomes the journal portion j are bent and deformed. Then, as shown in FIG.
- the die 21 and the journal portion of the material 1 can be easily and reliably gripped and pressed in the axial direction without slipping.
- FIGS. 5 to 7 show the case of the punch 20, and the reference numerals of the die 21 corresponding to the punch 20 are shown in parentheses. .
- parts that are the same as or correspond to those in the above-described embodiment are denoted by the same reference numerals, description thereof is omitted, and only different parts are described.
- FIG. 5A is a front view of the punch 20, and FIG. 5B is a side view of the punch 20.
- FIG. FIG. 6 shows the preforming apparatus 2 that employs the punch 20 and the die 21 in this embodiment.
- (A) of FIG. 7 is an explanatory view showing the flow of the material 1 by the punch 20 and the die 21 of the basic configuration described above by arrows in the preforming step, and (b) of FIG. It is explanatory drawing which showed the flow of the material of the raw material 1 by the punch 20 and die
- the portion of the basic structure punch 20 and the main body 20a, 21a of the die 20 that are in contact with the portion w that becomes the web portion of the material 1 is shown in FIG. It is indicated by a chain line in b).
- the punch 20 and the main bodies 20a, 21a of the die 21 are formed with a surface M inclined so that the portion abutting on the portion w that becomes the web portion of the material 1 flows the material of the material 1 in the radial direction.
- a ridge line N is formed above the portion that holds the material 1, and the inclined surfaces M on both sides of the ridge line N are laterally directed from the ridge line N to the paper surface. It is inclined so as to be lower and higher upward.
- the punch 20 and the die 21 configured as described above are provided on the upper board 23 and the base board 25 of the lower board 24, respectively, as shown in FIG. Then, when the predetermined position of the material 1 is gripped and the upper board 23 is lowered and the preforming is started, the material of the material 1 is formed on the surface M inclined from the ridge line N as shown by an arrow in FIG. It is pressed by the protrusion 22 so that it can escape not only in the axial direction but also in the radial direction of the material 1, so that the material flows directly in the axial direction as shown by the arrows in FIG.
- the length of the material 10 does not extend longer than that of the material 1, and the thickness of the web portion W that does not require relatively axial rigidity can be reduced to reduce the weight of the crankshaft 100.
- FIGS. 8 to 11 show the case of the die 21 and the reference numerals of the portions of the punch 20 corresponding to the die 21 are shown in parentheses. . Also in this embodiment, parts that are the same as or correspond to those in the above-described embodiment are denoted by the same reference numerals, description thereof is omitted, and only different parts are described. As shown in FIGS. 8 and 9, the crankshaft 100 is usually formed with an oil hole H for lubrication.
- the oil hole H includes an axial orthogonal direction oil hole H1 penetrating the journal portion J in the radial direction, and an inclined oil hole H2 communicating with the axial orthogonal direction oil hole H1 and opening in the pin portion P.
- Such oil holes H are generally formed by machining using a drill or the like after the crankshaft 100 is formed.
- a protrusion 27 capable of forming a pilot hole is formed on the inner peripheral surface of the portion of the punch 20 and the die 21 that holds the material 1.
- a pair of protrusions 27 are formed on the inner peripheral surface of the portion of the die 21 and the punch 20 that holds the material 1.
- the shape of the protrusion 27 can be a conical shape or a polygonal pyramid such as a triangular pyramid or a quadrangular pyramid.
- the angle ⁇ (FIG. 11B) of the bottom surface of the protrusion 27 is set to be substantially the same as the angle ⁇ (FIG. 11A) with respect to the direction perpendicular to the axis of the inclined oil hole H ⁇ b> 2.
- the diameter d (FIG. 11B) is set to be equal to or smaller than the diameter D of the oil hole H (FIG. 9).
- the manufacturing method of the present invention forms a pilot hole for machining at a portion where the oil hole H of the crankshaft 100 is opened in the preforming step.
- a punch 20 and a die 21 in which protrusions 27 are formed on the inner peripheral surface of the portion of the preforming apparatus 2 that holds the material 1 are prepared in advance, and main bodies 21a and 20a, a die presser 21b,
- a pilot hole for machining the oil hole H in the crankshaft 100 is formed in the material 1 in a later step.
- the step of forming a pilot hole for machining the oil hole H after molding the crankshaft 100 can be omitted.
- the protrusions 27 it is possible to prevent the material 1 held by the punch 20 and the die 21 from sliding relative to each other at the time of preforming. As a result, the material 1 is pressed in the direction perpendicular to the axis. At the same time, pressurization in the axial direction can be started.
- protrusions 27 formed on the punch 20 and the die 21 will be described with reference to FIGS. Also in this embodiment, the same or corresponding parts as those of the above-described embodiment are denoted by the same reference numerals, the description thereof will be omitted, and only different parts will be described.
- four protrusions 27 are formed at equal intervals in the circumferential direction on the inner peripheral surface of the portion of the punch 20 and the die 21 that holds the material 1.
- Each protrusion 27 is formed so as to protrude gradually inward in the circumferential direction from one protrusion 27 adjacent thereto to the other protrusion 27.
- the die 21 and the punch 21 in which the protrusions 27 are formed in this way are disposed at predetermined positions of the material 1 between the main bodies 21a and 20a and the die presser material 21b and the punch presser 20b, and held by the clamps.
- a groove-shaped pilot hole whose depth gradually increases in the circumferential direction is formed, a process of forming a pilot hole for machining the oil hole H after molding the crankshaft 100 is performed.
- the material 1 held by the punch 20 and the die 21 can be prevented from sliding relatively during pre-forming, so that the material is pressed in the axial direction simultaneously with the pressure in the direction perpendicular to the axis. Can be configured to start.
- the crankshaft 100 since the lower hole is formed in a groove shape that gradually becomes deeper in the circumferential direction, when used as the crankshaft 100, the crankshaft 100 rotates around the journal portion J around the axis. By doing so, the lubricant is rubbed into the groove-shaped lower hole and efficiently flows into the oil hole H1, and the contact area between the journal part J or the pin part P and the bearing part R supporting them is small. Therefore, the amount of lubricant supplied to the bearing portion R can be reduced. As a result, the capacity of the pump for pumping the lubricant is reduced, and the crankshaft 100 is used for an internal combustion engine. The fuel consumption can be kept low.
- FIGS. 14A and 14B are front views in which either one shows the basic configuration of the preforming device 2, and the other is perpendicular to either one (perpendicular to the paper surface). It is the plane or bottom view seen from.
- the die 21 that grips the portion j that becomes the journal portion by the cam mechanism 26 as the portion p that becomes the pin portion of the material 1 is gripped by the punch 20 and pressed in the direction perpendicular to the axis.
- the pre-forming apparatus 2 in this embodiment grips the portion p that becomes the pin portion of the material 1 with the punch 21
- the means 40 (FIG. 14B) for pressurizing in the direction perpendicular to the axis and the dies 21 and 21 holding the portion j to be the journal part are moved so as to approach each other in the axial direction to pressurize in the axial direction.
- the means 41 (FIG. 14 (a)) for this is comprised separately. More specifically, in this embodiment, means 40 for gripping the portion p that becomes the pin portion of the material 1 with the punch 20 and pressurizing it in the direction perpendicular to the axis is as shown in FIG.
- an actuator 40 such as a hydraulic cylinder connected to the punch 20, and is used for pressing in the axial direction so as to hold the portions j which become the journal portions of the material 1 with the dies 21 and bring them together in the axial direction.
- the means 41 moves the dies 21 and 21 in the axial direction so that the movable platen 42 approaches the fixed platen 43 as driven by the ram of the press machine.
- a cam mechanism is used. By adopting the cam mechanism 41 in this way, both the dies 21 and 21 can be evenly moved in the axial direction as in the above-described embodiment.
- the present invention is not limited to this embodiment.
- the means 41 for pressurizing the die 21 in the axial direction so as to move the dies 21 toward each other in the axial direction extends in the axial direction instead of the cam mechanism 41.
- An actuator such as a retracting cylinder may be connected to the die 21.
- the pressure in the direction perpendicular to the axis of the portion p that becomes the pin portion of the material and the axial position of the portion p that becomes the pin portion and the portion j that becomes the journal portion adjacent thereto are brought closer to each other.
- the axial pressurization is performed by individually controllable drive means 40 and 41, respectively.
- the means 40 for pressurizing in the direction perpendicular to the axis and the means 41 for pressurizing in the direction of the axis are individually configured, so that pressurization in the direction perpendicular to the axis and pressurization in the direction of the axis are performed as necessary.
- the ram and the stroke of the hydraulic cylinder 40 can be controlled to be adjusted individually. Therefore, the rough shape member 10 can be preformed with high accuracy.
- the finishing molding apparatus 3 in this embodiment includes a central journal part fixing means (to be described later) for fixing a portion j to be a journal part located at the center of the rough shape member 10 and both ends of the rough shape member 10 toward the center. And an axial pressurizing means 36 for pressurizing in the axial direction.
- FIG. 15A shows a state before the rough profile 10 is pressed in the axial direction
- FIG. 15B shows the crankshaft 100 by pressing the rough profile 10 in the axial direction.
- molded was shown.
- the finish forming apparatus 3 in this embodiment is for manufacturing a crankshaft 100 having a plurality of pin portions P (four in FIG. 15), and as described above, the journal portion of the rough shape member 10 and
- the mold plates 30 and 31 for holding part or all of the portions j and p to be the pin portions, and the mold plates 30 and 31 are held so as to be movable in the axial direction while being constrained in the radial direction (axial orthogonal direction).
- the case 32 and the stencils 30 and 31 are moved in the axial direction in the case 32 to crush the portion w which becomes the web portion of the rough shaped member 10 and apply pressure in the axial direction so as to form a gap between the webs W at a predetermined pitch.
- an axial pressurizing means 36 is constituted by cam mechanisms 36 and 36 that pressurize from both ends toward a portion j that becomes a journal portion located at the center of the rough shape member 10.
- both ends of the rough profile 10 are axially pressurized toward the center in a state in which the portion j23 serving as a journal portion located at the center of the rough profile 10 is fixed. Is.
- a pin (referred to as the first pin) located at the left end of the rough shape member 10 in the figure and a pin (as the fourth pin) located at the right end.
- the portions p1 and p4 that are to be referred to are eccentric in the same direction from the journal portion, and two pins between the portions p1 and p4 that become the first pin and the fourth pin (the second pin on the left side and the third pin on the right side)
- the portions p2 and p3 that are to be called are eccentric in the same direction from the portion j that is to be the journal portion.
- the portions j12 and j34 which are journal portions between the portions p1 and p2 which are the first pin and the second pin and between the portions p3 and p4 which are the third pin and the fourth pin.
- the finish forming apparatus 3 includes the second pin 3 and the portions p2 and p3 that are eccentric in the same direction of the rough shape member 10, and the portions p1 and p2 that are the first pin and the second pin.
- movable mold plates 31 and 30 for holding portions j12 and j34 which are journal portions between the portions p3 and p4 which are the third pin and the fourth pin. These movable mold plates 30 and 31 are movable in the axial direction within the case 32.
- the movable mold plate 30 that holds the portions j12 and j34 that are journal portions between the portions p1 and p2 that are the first pin and the second pin and between the portions p3 and p4 that are the third pin and the fourth pin is provided in the case 32.
- the parts j12 and j34 to be journal parts are shaped so as to be held without moving in the radial direction, and further extend toward the end of the case 32, respectively.
- the movable mold plate 31 that holds the portions p2 and p3 to be the 2nd pin and the 3rd pin has the web portion W formed at a predetermined pitch by crushing the portion w to be the web portion by pressing in the axial direction.
- the pin portion P is shaped so as to be movable in the radial direction within the case 32 so as to allow the pin portion P to have a predetermined eccentric amount with respect to the journal portion J.
- the fixed mold plate 35 that holds the portion j23 serving as a journal portion located at the center of the rough shape member 10 is formed to be longer or larger than the inner diameter of the case 32.
- a concave portion 32a held by the plate 35 is formed.
- the fixed template 35 and the recess 32a of the case 32 that holds the fixed template 35 constitute a central journal portion fixing means.
- the case 32 is formed in a substantially cylindrical shape as a whole, and the rough shape member 10 held by the fixed mold plate 35 and the movable mold plates 30 and 31 is disposed inside and can be taken out after molding. It is divided and molded in a halved shape that can be opened and closed.
- the axial pressurizing means 36 in this embodiment is constituted by a cam mechanism.
- the cam mechanism 36 includes a drive cam 36a and a driven cam 36b, and is provided as a pair.
- Each drive cam 36a is attached to an upper board 53 supported by a ram or the like of a press machine, and each driven cam 36b is slidably provided on a base board 55 on a lower board 54.
- Portions j12 and j34 serving as journal portions between the portions p1 and p2 serving as the first pin and the second pin and between the portions p3 and p4 serving as the third pin and the fourth pin are formed on the vertical surfaces of the driven cams 36b facing each other.
- a pressing member 37 that presses the end surface of the portion of the movable mold 30 to be held extending toward the end of the case 32 is provided.
- both ends of the rough profile 10 are axially pressurized toward the center in a state in which the portion j23 serving as a journal portion located at the center of the rough profile 10 is fixed. Is.
- the finish forming process in this embodiment is performed between the portions p1 and p2 which become the first pin and the second pin of the rough shape member 10, and the portion p3 which becomes the third pin and the fourth pin.
- Portions j12 and j34 that become journal portions between p4 are held by the movable plate 30, and portions p2 and p3 that become the second and third pins are held by the movable plate 31, and the second and third pins are further held.
- a portion j23 serving as a journal portion between the portions p2 and p3 serving as pins is held by a fixed mold plate 35 and arranged in a case 32 formed in a split shape, and the fixed mold plate 35 is disposed in a recess 32a on the inner surface of the case 32. And the case 32 is closed and held in a cylindrical shape. And the driven cam of the end portion of the movable mold plate 30 holding the portions j12 and j34 which become the journal portions between the portions p1 and p2 which become the first pin and the second pin and between the portions p3 and p4 which become the third pin and the fourth pin.
- the driven cam 36b is disposed between the pair of drive cams 36a provided on the upper board 53 in a state where the pressing member 37 of 36b is brought into contact therewith.
- the cam surfaces of the drive cam 36a and the driven cam 36b slide so that the driven cams 36b move toward each other. It becomes. Therefore, a portion j12 that becomes a journal portion between the portions p1 and p2 that become the first pin and the second pin of the rough shape member 10, and a portion j34 that becomes a journal portion between the portions p3 and p4 that become the third pin and the fourth pin.
- the template 30 that holds the portion j that becomes the journal portion is held in a state in which the portion j that becomes the journal portion is held in a constrained state so as not to move in the radial direction in the case 32.
- it In order to move in the axial direction, it is formed slightly smaller than the inner peripheral surface of the case 32, and the outer peripheral end surface of the template 30 slides on the inner peripheral surface of the case 32.
- the fixed mold plate 35 in this embodiment is particularly affected by the flow of the material. It is conceivable that the template 30 holding the portion j23 serving as the journal portion located in the center corresponding to the above will be broken due to mold cracking or bending. However, in this embodiment, since the fixed mold plate 35 that holds the portion j23 serving as the journal portion located in the center is uniformly pressed from both sides in the axial direction, the fixed mold plate 35 is placed in the case 32. Therefore, the fixed mold plate 35, which does not need to be slid in the case 32, is not subjected to excessive force due to sliding in the case 32, so that it is difficult to increase the strength. Can do.
- the preforming device 2 in this embodiment is for manufacturing a crankshaft having a plurality of pin portions (four in this embodiment, P1 to P4), and is eccentric from the journal portion J in the same direction.
- the finish forming device 3 in this embodiment is formed by finishing the second pin portion and the portions p2 and p3 that are the third pin portions that are eccentric in the same direction from the portion j that is the journal portion of the rough shaped member 10.
- Each finish molding is performed separately in the finish molding of the portions p1 and p4 that become the first pin portion and the fourth pin portion.
- FIG. 16 shows the portion p2 that becomes the second pin portion
- FIG. 17 shows the portion p3 that becomes the third pin portion
- FIG. 18 shows the portion p1 that becomes the first pin portion
- FIG. 19 shows the portion p4 that becomes the fourth pin portion.
- 20 shows the second pin portion and the portions p2 and p3 that become the third pin portion that are eccentric in the same direction from the portion j that becomes the journal portion of the rough shape member 10
- FIG. 21 shows the first pin portion and the fourth pin.
- FIG. 2 shows a state before (a) performing finish molding of the parts p1 and p4 to be parts and (b) after performing finish molding.
- the preforming apparatus 2 includes a punch 20 that holds a portion p that becomes each pin portion of the material 1 and dies 21 that respectively hold portions j that become journal portions located on both sides of the punch 20. Has a number corresponding to the journal portion J of the crankshaft 100 so as to be able to hold the portion j to be each journal portion.
- the preforming device 2 can be configured as a dedicated device for preforming each of the portions p1 to p4 to be the pin portions, and whether the position of the material 1 is shifted relative to the punch 20 and the die 21. Alternatively, the positions of the punch 20 and the die 21 may be relatively shifted with respect to the material 1 so that the portions p1 to p4 to be the pin portions are preliminarily formed in common.
- the finish molding apparatus 3 includes the template plates 30, 31, and 38 that hold the portions j 12, j 23, and j 34 that are the journal portion and the pin portion of the rough profile 10, and p 2 and p 3, and the template plates 30 and 31. , 38 are held in the axial direction while being constrained in the radial direction (axial orthogonal direction), and the web portion of the rough shape member 10 is moved by moving the templates 30 and 31 in the axial direction within the case 32.
- Axial pressurizing means 33 is provided to apply pressure in the axial direction so as to crush the parts w21 and 23 and w34 and w43 to form the webs W21, W23, W34 and W43 at a predetermined pitch.
- the template 30 holds the portions p2 and p3 that are the second pin portion and the third pin portion, or the portions p1 and p4 that are the first pin portion and the fourth pin portion.
- the template 31 includes portions j12 and j23 that become journal portions between the first pin portion and the second pin portion, between the second pin portion and the third pin portion, and between the third pin portion and the fourth pin portion. , J34, or the parts j01 and j45 which are journal parts on the end side of the first pin part and the fourth pin part, and the parts j12, j34 and j01 and j45 which are journal parts are held
- the plate 31 extends in the direction of the end of the case.
- the template 38 holds the journal portion J12 between the first pin and the second pin and the journal portion J34 between the third pin and the fourth pin that have been finished and formed.
- the case 32 includes a template 30 for holding the second and third pin portions p2 and p3, and the second and third pin portions between the first and second pin portions. And a dedicated one that accommodates the template 31 for holding the portions j12, j23, and j34 that are journal portions between the third pin portion and the fourth pin portion, and the first and fourth pin portions.
- the template 30 for holding the parts p1 and p4, the template 31 for holding the parts j01 and j45 which become the journal parts on the end side of the first pin part and the fourth pin part, and finishing first A dedicated one for accommodating the molded journal portion J12 between the first pin and the second pin to the journal portion J34 between the third pin and the fourth pin is prepared.
- the case 32 includes a template 30 for holding portions 2 and 3 that are the second pin portion and the third pin portion, and between the first pin portion and the second pin portion, the second pin portion and the third pin.
- the thing which can be used in can also be prepared.
- the crankshaft generally has a plurality of pin portions (four in this embodiment, P1 to P4), and the plurality of pin portions P are in the same direction from the journal portion J.
- the portions p2 and p3 that become the second pin portion and the third pin portion that are eccentric in the same direction from the journal portion J and the portions w21, w23, w34, and w34 that become the web portions thereof. are divided into pre-molding and pre-molding of parts p1 and p4 to be the first pin part and the fourth pin part and parts to be the web parts w10, w12, w43, and w45, and each preforming is performed sequentially It is.
- the finish forming step in this embodiment includes finish forming of the second pin portion P2 and the third pin portion P3 and their web portions W21, W23, W34, and W34 that are eccentric in the same direction from the journal portion J, and 1
- Each finish molding is performed by dividing into the finish molding of the number pin part P1 and the number 4 pin part P4 and their web parts W10, W12, W43, and W45.
- a portion p2 to be the second pin portion of the rod-shaped material 1 is held by the punch 20,
- the journal portions j12 and j23 adjacent to the second pin portion are held by the dies 21 and 21, respectively, and the upper board 23 is lowered as shown in FIG.
- the parts p2, w21, and w23 to be the web parts to be positioned are preformed.
- the portions w21 and w23 to be the web portions are pressed in the axial direction to form the thin portion T, and the amounts of movement in the axial direction so that the dies 21 and 21 are brought closer to the punch 20 are the same. Is set.
- a portion p3 that becomes the third pin portion of the material 1 in which the second pin portion and the portions p2, w12, and w23 that are the web portions located on both sides thereof are preformed are formed. While being held by the punch 20, the parts j 23 and j 34 that become journal portions adjacent to the third pin portion are held by the dies 21 and 21. At this time, it is not necessary to rotate the raw material 1 around the axis from the state where the second pin portion and the portions p2, w12, and w23 which are the web portions located on both sides thereof are preformed. Subsequently, as shown in FIG.
- the upper board 23 is lowered, and the third pin portion and portions p3, w23, and w34 that become the web portions located on both sides thereof are preformed.
- the amount of movement in the axial direction so that the dies 21 and 21 are brought closer to the punch 20 for pressurizing the web portions w23 and w34 in the axial direction to form the thin portion T is set to be the same. Yes.
- the material 1 in which the second and third pin portions and the portions p2, w12, w23, p3, w23, and w34 that are the web portions located on both sides thereof are preformed.
- the portion p1 that becomes the first pin portion is held by the punch 21, and the portions j01 and j12 that become the journal portions adjacent to the first pin portion are held by the dies 21 and 21, respectively.
- the material 1 is rotated around the axis from the state where the second pin portion and the third pin portion and the portions p2, w12, w23, p3, w23, and w34 which are the web portions located on both sides thereof are preformed.
- FIG. 18 (a) the material 1 in which the second and third pin portions and the portions p2, w12, w23, p3, w23, and w34 which are the web portions located on both sides thereof are preformed.
- the upper board is lowered by 23, and the first pin portion and the portions p1, w01, and w12 that become the web portions located on both sides thereof are preformed.
- the amount of movement in the axial direction so that the dies 21 and 21 are brought closer to the punch 20 to press the portions w01 and w12 to be the web portions in the axial direction to form the thin portion T is set to be the same. Yes.
- the second pin portion, the third pin portion, and the first pin portion and the portions p2, w12, w23, p3, w23, w34, p1, w01, w12 which are the web portions located on both sides thereof were preformed. It is not necessary to rotate the material 1 around the axis from the state. Subsequently, as shown in FIG. 19 (b), the upper board 23 is lowered, and the fourth pin portion and the portions p4, w43, and w45 that become the web portions located on both sides thereof are preformed.
- the formed rough shaped member 10 has thin portions T formed in portions that become the web portions w10, w12, w21, w23, w34, w34, w43, and w45.
- the templates 30 and 31 are respectively attached to the portions j12, j23, and j34 that are the journal portions between the third pin and the fourth pin, arranged in the case 32, and pressed as shown in FIG. 20 (b).
- the member 37 is pressurized in the axial direction.
- the portions that become the web portions w21, w23, w34, and w34 adjacent to the second pin portion and the third pin portion of the rough shape member 10 are finish-molded so as to be crushed to a predetermined thickness as shown in FIG.
- the web portions W21, W23, W34, and W34 have a predetermined pitch.
- the semi-rough shaped material 10 / half crankshaft 100 state is taken out from the case 32, and as shown in FIG. 21 (a), the journal between the finished first pin and the second pin is obtained.
- the portion from the portion J12 to the journal portion J34 between the third and fourth pins is held by the template 38, and the portions p1 and p4 that become the first and fourth pins are adjacent to the first and fourth pins, respectively.
- the parts j01 and j45 that are the journal portions located at both ends are held by the template plates 30 and 31, and are arranged in the case 32 to press in the axial direction.
- the portions w10, w12, w43, and w45 that become the web portions adjacent to the first pin portion and the fourth pin portion of the rough shape member 10 are finish-molded so as to be crushed to a predetermined thickness as shown in FIG.
- the web portions W10, W12, W43, and W45 have a predetermined pitch.
- the preforming device 2 in the above-described embodiment includes the preforming of the portions p2 and p3 that become the second pin portion and the third pin portion that are eccentric in the same direction from the journal portion J, and the first pin portion and the fourth pin portion.
- the preliminary molding apparatus 2 in this embodiment is generally located at one end portion, whereas the preliminary molding is performed sequentially by dividing into the preliminary molding of the portions p1 and p4.
- the preforming device 2 in this embodiment includes an end portion restraining member 60 that restrains an end portion of the material 1, and portions p2, w21, w23 or p3, w32, w34 that become one pin portion and a web portion.
- a portion w12 or w23 that becomes the web portion on the other end side of the portions that become the web portions w10, w12 or w21, w23 that have already been formed adjacent to each other, and a portion j12 that becomes the journal portion that continues to this web portion or web portion-journal portion restraining member 61 for restraining j23, and the axial direction driving means 28 of the pre-forming apparatus 2 includes portions w10, w12, w21, w23, w32, w34, w43, which become web portions.
- portions w21, w32, and w43 that are web portions on one end side are replaced by web portions w23, w34, and w45 that are web portions on the other end side. Is the axial direction in a number (L1> L2) gather as pressurizing configuration.
- the portions p2 and p3 that become the second pin portion and the third pin portion that are eccentric in the same direction from the journal portion J, and the first pin portion and 4 in the preforming step are sequentially performed by dividing into parts p1 and p4 to be the number pin portions, and at this time, both dies 21 and 21 are moved in the axial direction so as to approach each other by the same amount with respect to the punch 20, and further, a finish forming step
- each finish molding was performed separately for the second pin portion and the third pin portions P2 and P3 that are eccentric in the same direction from the journal portion, and the first and fourth pin portions P1 and P4. .
- preliminary molding is sequentially performed from the portion p1 serving as the first pin portion toward the portion p4 serving as the fourth pin portion, and at this time, the first pin portion is formed.
- the part p1 is preliminarily formed, one end of the material 1 is constrained, and then the web parts w10 and w12 adjacent to the part p1 that is already formed as the first pin part, In a state where the portion w12 that becomes the web portion on the second pin portion side and the portion j12 that becomes the journal portion continuous with the portion that becomes the web portion are restrained, this restrained side (the portion p1 side that becomes the first pin portion)
- the axial length L1 approaching the portion p2 that becomes the second pin portion for forming the portion w21 that becomes the web portion of the web portion is equal to that of the portion w23 that becomes the web portion on the opposite side (the portion p3 side that becomes the third pin portion).
- the portion w43 that becomes the web portion on the already formed side (the portion p3 side that becomes the third pin portion) is moved to the portion p4 that becomes the fourth pin portion.
- the axial length L1 is larger than the axial length L2 approaching the portion p4 serving as the fourth pin portion for forming the portion w45 serving as the web portion on the opposite side (other end portion side) (L1> L2) Move and shape the fourth pin portion and the portions p4, w43, and w45 that become the web portion adjacent thereto.
- the preforming device 2 in this embodiment is different from the cam mechanism 26 in the above-described embodiment in that one cam mechanism 28 constituting the axial direction driving means. That is, in this embodiment, the pre-forming apparatus 2 for forming the second pin portion to the fourth pin portion and the portions p2 to p4 that become the web portion, and w21, w23, w32, w34, w43, and w45 is shown in FIG. As shown in FIGS. 25 to 27, the amount of axial movement of the die 21 that accompanies the lowering of the upper board 23 is such that the die 21 located on the left side of the figure is located on the right side of the figure. It is set differently so that there are more than the die 21. In the embodiment shown in FIGS.
- the angle of the cam surfaces of the drive cam 28a and the driven cam 28b of the left cam mechanism 28 in each figure is the drive of the right cam mechanism 26 in each figure.
- the cam surfaces approach the horizontal, and the left and right cam mechanisms 28 and 26 have different settings.
- the portion p that becomes the pin portion of the material 1 is pressed in the direction orthogonal to the axis, and the portion j that becomes the journal portion adjacent thereto is pressed so as to move toward each other in the axial direction, and the thin portion T is formed on the portion w that becomes the web portion.
- the material of the portion w that becomes the web portion flows to the portion j that becomes the adjacent journal portion, and as a result, the material 1 extends in the axial direction as shown by the arrows in FIGS. It will be.
- the material flow may cause a shrinkage K particularly near the boundary between the web portion w and the journal portion j.
- the shrinkage K generated by the material flowing in the preforming of the portion p that becomes the one pin portion is reversed, and the material flows in the reverse direction in the preforming of the portion p that becomes the next pin portion.
- it is configured to replenish and repair the generated shrinkage K.
- the rough shaped member 10 is formed using the preforming device in this embodiment configured as described above, first, as shown in FIG.
- the portion p1 that becomes the portion is held by the punch 20, and one end portion is inserted into the end portion restraining member 60 so as not to extend or expand in the axial direction and is adjacent to the portion p1 that becomes the first pin portion.
- the portions that become the journal portions j01 and j12 are held by the dies 21 and 21, and the upper board 23 is lowered as shown in FIG. 24 (b), and the first pin portion and the portion p1 that becomes the web portion located on both sides thereof. , W10, w12 are preformed.
- the cam mechanisms 26 and 28 move in the axial direction so that the dies 21 and 21 are brought closer to the punch 20
- the amount to be set is set to be the same.
- the material of the portion w12 that becomes the web portion located on the other end side of the portion p1 that becomes the molded first pin portion flows in the axial direction, and the shrinkage K is generated.
- the material 1 is rotated around the axis from the state in which the first pin portion and the portions p1, w10, and w12 to be the web portions located on both sides thereof are preformed to rotate the second pin.
- the portion p2 that becomes the pin portion is held by the punch 20, and the portions j12 and j23 that become the journal portions adjacent to the second pin portion are held by the dies 21 and 21, respectively.
- a portion w12 that becomes the web portion on the second pin portion side of the portion that becomes the web portions w10 and w12 adjacent to the first pin portion and the web portion are continuous.
- a web portion-journal portion restraining member 61 for restraining the portion j12 to be the journal portion to be formed is integrally formed.
- the die 21 on the left side (one side) in the drawing is arranged farther from the extension line of the punch 20 than the die 21 on the right side (the other side) (L1> L2). ).
- the upper board 23 is lowered
- the dies 21 and 21 are moved in the axial direction until the dies 21 and 21 are at the same distance from the punch 20.
- the axial movement amount L1 of the left die 21 is larger than the axial movement amount L2 of the right die 21 (L1> L2). Therefore, as shown in FIG. 25 (c), the material of the portion w21 that becomes the web portion on the first pin portion side is the first pin portion of the portions w21 and w23 that become the web portion adjacent to the second pin portion.
- the shrinkage K generated in the portion w12 that flows to the portion p1 side and becomes the web portion located on the other end side of the first pin is repaired.
- the material of the portion w23 that becomes the web portion on the other end side flows to the other end portion side, and the other end of the second pin
- the shrinkage K is generated in the portion w23 that becomes the web portion located on the side.
- the first pin portion and the second pin portion and the parts 1, w10, w12, p2, w21, and w23 that are the web portions located on both sides thereof are preformed 1
- the portion p3 to be the third pin portion is held by the punch 20 and the portions j23 and j34 to be the journal portions adjacent to the third pin portion are held by the dies 21 and 21.
- the die 21 located on the left side of the drawing is continuous with the web portion and the portion w23 that becomes the web portion on the third pin portion side of the portions w21 and w23 that become the web portion adjacent to the second pin portion.
- a web portion-journal portion restraining member 61 that restrains the journal portion j23 is integrally formed.
- the die 21 on the left side (one side) in the drawing is arranged farther from the extension line of the punch 20 than the die 21 on the right side (the other side) (L1> L2). ).
- the upper board 23 is lowered
- the dies 21 and 21 are moved in the axial direction until the dies 21 and 21 become the same distance from the punch 20. That is, the axial movement amount L1 of the left die 21 is larger than the axial movement amount L2 of the right die 21 (L1> L2). Therefore, as shown in FIG.
- the material of the portion w32 that becomes the web portion on the second pin portion side is the second pin portion of the portions w32 and w34 that become the web portion adjacent to the third pin portion.
- the shrinkage K generated in the portion w23 that flows to the portion p2 side and becomes the web portion located on the other end side of the second pin is repaired.
- the material of the portion w34 that becomes the web portion on the other end side flows to the other end side, and the other end of the third pin
- the shrinkage K occurs in the portion w34 that is the web portion located on the side.
- the die 21 on the left side (one side) in the drawing is arranged farther from the extension line of the punch 20 than the die 21 on the right side (the other side) (L1> L2). ).
- the upper board 23 is lowered
- the dies 21 and 21 are moved in the axial direction until the dies 21 and 21 are at the same distance from the punch 20. That is, the axial movement amount L1 of the left die 21 is larger than the axial movement amount L2 of the right die 21 (L1> L2). Therefore, as shown in FIG.
- the material of the portion w43 that becomes the web portion on the side of the 3rd pin portion of the portions w43 and w45 that become the web portion adjacent to the 4th pin portion becomes the 3rd pin portion.
- the shrinkage K generated in the portion w34 which flows to the portion p3 side and becomes the web portion located on the other end side of the third pin is repaired.
- the material of the portion w45 that becomes the web portion on the other end side of the portions w43 and w45 that become the web portion adjacent to the 4th pin portion is changed by the end portion restraining member 60 on the other end side. Since the material is constrained, the material does not flow to the other end side, so that the shrinkage K does not occur.
- the present invention is not limited to the above, and an internal combustion engine having a plurality of cylinders other than a single cylinder or four cylinders, an internal combustion engine having a plurality of cylinders other than in-line, or other than an internal combustion engine
- the present invention can also be applied when manufacturing a crankshaft for use in an engine. Further, the preliminary molding step and the finish molding step can be performed hot or cold at a predetermined temperature as required.
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Abstract
Description
また、本発明のクランクシャフトの製造装置は、回転中心軸となるジャーナル部と、該ジャーナル部から偏心するピン部と、前記ジャーナル部とピン部との間に延びるウエブ部とを有するクランクシャフトを製造する装置であって、素材を曲げ加工してピン部およびウエブ部となる部分が形成された粗形材を成形する予備成形装置と、該粗形材を軸方向に加圧してそのウエブ部となる部分を所定の厚さに成形する仕上成形装置とを備え、前記予備成形装置は、素材のピン部となる部分を把持するパンチと、ジャーナル部となる部分を把持するダイとを備えており、前記パンチとダイは、素材のウエブ部となる部分に肉薄部を形成するための突部を有することを特徴とするものである。
また、本願のクランクシャフトの製造装置に係る発明によれば、素材のピン部となる部分をパンチで把持するとともにジャーナル部となる部分をダイに把持して曲げ加工し、パンチとダイの突部によって素材のウエブ部となる部分に肉薄部を形成する。これにより、仕上成形装置で粗形材を軸方向に加圧してそのウエブ部となる部分を所定の厚さに成形するときに、かかるウエブ部となる部分の潰し量が低減され、その結果、材料の流動を低減させることができることから、容易に精度よくクランクシャフトを製造することができる。
この実施の形態における予備成形装置2は、軸直交方向駆動手段が最初に素材1のピン部となる部分pを軸直交方向に加圧するのを開始し、その後、軸方向駆動手段26がピン部となる部分pとこれに隣接するジャーナル部となる部分jとの軸方向の位置を互いに寄せるよう軸方向に加圧するのを開始するよう構成されている。
この実施の形態における製造方法は、予備成形工程で、最初に素材のピン部となる部分pを軸直交方向に加圧するのを開始し、その後、該ピン部となる部分pとこれに隣接するジャーナル部となる部分jとの軸方向の位置を互いに寄せるよう軸方向に加圧するのを開始するものである。
図8および図9に示すように、クランクシャフト100には、通常、潤滑を目的とした油孔Hが形成されている。油孔Hは、ジャーナル部Jを径方向に貫通する軸直交方向油孔H1と、この軸直交方向油孔H1と連通しピン部Pに開口する傾斜油孔H2とを備えている。このような油孔Hは、一般に、クランクシャフト100を成形した後にドリルなどを用いる機械加工によって形成される。このような油孔Hを成形するための機械加工、特に傾斜油孔H2を成形するための機械加工を行う際には、予め下孔を形成する必要がある。そこで、この実施の形態では、パンチ20とダイ21の素材1を把持する部分の内周面に下孔を形成することが可能な突起27が形成されている。
本発明の製造方法は、予備成形工程で、クランクシャフト100の油孔Hが開口する部分に機械加工のための下孔を成形するものである。そして、より具体的には、予備成形装置2の素材1を把持する部分の内周面に突起27が形成されたパンチ20とダイ21を予め用意し、本体21a,20aと、ダイ押え21bおよびパンチ押え20bとの間にそれぞれ素材1の所定位置を配置してクランプなどで保持することにより、後の工程でクランクシャフト100に油孔Hを機械加工するための下孔を素材1に形成する。この実施の形態では、クランクシャフト100を成形した後に油孔Hを機械加工するための下孔を形成する工程を省略することができる。また、突起27を形成することにより、パンチ20とダイ21に把持された素材1が予備成形時に相対的に滑るのを防止することができ、その結果、素材1に対する軸直交方向への加圧と同時に軸方向への加圧を開始するよう構成することができる。
図14の(a)と(b)は、いずれか一方が予備成形装置2の基本的な構成を示す正面図であり、いずれか他方がいずれか一方と直交する方向(紙面に対して垂直方向)から見た平面または底面図である。上述した実施の形態では、素材1のピン部となる部分pをパンチ20で把持して軸直交方向に加圧するのに伴って、カム機構26により、ジャーナル部となる部分jを把持したダイ21,21を、軸方向に互いに寄せるよう移動させて軸方向に加圧していたのに対して、この実施の形態における予備成形装置2は、素材1のピン部となる部分pをパンチ21で把持して軸直交方向に加圧するための手段40(図14(b))と、ジャーナル部となる部分jを把持したダイ21,21を、軸方向に互いに寄せるよう移動させて軸方向に加圧するための手段41(図14(a))とを個別に構成している。より具体的に説明すると、この実施の形態では、素材1のピン部となる部分pをパンチ20で把持して軸直交方向に加圧するための手段40は、図14の(b)に示すように、パンチ20に接続された油圧シリンダなどのアクチュエータ40により構成されており、素材1のジャーナル部となる部分jをダイ21でそれぞれ把持して軸方向に互いに寄せるよう軸方向に加圧するための手段41は、図14の(a)に示すように、プレス機のラムなどによる駆動によって可動盤42が固定盤43に近付くのに伴ってダイ21,21を互いに寄せるように軸方向に移動させるカム機構により構成されている。このようにカム機構41を採用することにより、上述した実施の形態と同様に、両ダイ21,21を軸方向に均等に移動させることができる。しかしながら、本発明はこの実施の形態に限定されることはなく、例えば、ダイ21を軸方向に互いに寄せるよう軸方向に加圧するための手段41は、カム機構41に代えて、軸方向に伸長・退縮するシリンダなどのアクチュエータをダイ21にそれぞれ接続してもよい。
予備成形工程において、素材のピン部となる部分pに対する軸直交方向への加圧と、このピン部となる部分pとこれに隣接するジャーナル部となる部分jとの軸方向の位置を互いに寄せるよう軸方向への加圧とを、それぞれ個別の制御可能な駆動手段40,41によって行うものである。
この実施の形態における仕上成形装置3は、粗形材10の中央に位置するジャーナル部となる部分jを固定する中央ジャーナル部固定手段(後述する)と、粗形材10の両端を中央に向かって軸方向に加圧する軸方向加圧手段36とを備えている。
この実施の形態における製造方法は、仕上工程で、粗形材10の中央に位置するジャーナル部となる部分j23を固定した状態で、粗形材10の両端を中央に向かって軸方向に加圧するものである。
この実施の形態における製造方法は、仕上工程で、粗形材10の中央に位置するジャーナル部となる部分j23を固定した状態で、粗形材10の両端を中央に向かって軸方向に加圧するものである。
この実施の形態における予備成形装置2は、複数のピン部(この実施の形態ではP1~P4の4つ)を有するクランクシャフトを製造するためのものであって、ジャーナル部Jから同じ方向に偏心する2番ピン部および3番ピン部P2,P3となる部分p2,p3の予備成形と、1番ピン部および4番ピン部P1、P4となる部分p1,p4の予備成形とに分けて、各予備成形を順次行うものである。また、この実施の形態における仕上成形装置3は、粗形材10のジャーナル部となる部分jから同じ方向に偏心する2番ピン部および3番ピン部となる部分p2,p3の仕上成形と、1番ピン部および4番ピン部となる部分p1,p4の仕上成形とに分けて、各仕上成形を行うものである。
この実施の形態における予備成形工程は、概略、クランクシャフトが複数(この実施の形態ではP1~P4の4つ)のピン部を有しており、ジャーナル部Jから複数のピン部Pが同じ方向に偏心したクランクシャフトを製造する場合において、ジャーナル部Jから同じ方向に偏心する2番ピン部および3番ピン部となる部分p2,p3ならびにそれらのウエブ部となる部分w21、w23、w34、w34の予備成形と、1番ピン部および4番ピン部となる部分p1,p4ならびにそれらのウエブ部w10,w12,w43,w45となる部分の予備成形とに分けて、各予備成形を順次行うものである。そして、この実施の形態における仕上成形工程は、ジャーナル部Jから同じ方向に偏心する2番ピン部P2および3番ピン部P3ならびにそれらのウエブ部W21,W23,W34,W34の仕上成形と、1番ピン部P1および4番ピン部P4ならびにそれらのウエブ部W10,W12,W43,W45の仕上成形とに分けて、各仕上成形を行うものである。
上述した実施の形態における予備成形装置2は、ジャーナル部Jから同じ方向に偏心する2番ピン部および3番ピン部となる部分p2,p3の予備成形と、1番ピン部および4番ピン部となる部分p1、p4の予備成形とに分けて、各予備成形を順次行うものであったのに対して、この実施の形態における予備成形装置2は、概略、一方の端部に位置する1番ピン部となる部分p1から他方の端部に位置する4番ピン部となる部分p4に向かって、順次予備成形するものである。また、この実施の形態における予備成形装置2は、素材1の端部を拘束する端部拘束部材60と、一のピン部およびウエブ部となる部分p2,w21,w23またはp3,w32,w34と隣接して既に形成されたウエブ部w10,w12またはw21,w23となる部分のうちの他方の端部側のウエブ部となる部分w12またはw23とこのウエブ部に連続するジャーナル部となる部分j12またはj23を拘束するウエブ部-ジャーナル部拘束部材61とを有しており、予備成形装置2の軸方向駆動手段28は、ウエブ部となる部分w10,w12、w21,w23、w32,w34、w43,w45のうちの一方の端部側のウエブ部となる部分w21、w32、w43を他方の端部側のウエブ部となる部分w23、w34、w45よりも軸方向に多く(L1>L2)寄せるように加圧する構成とされている。
Claims (21)
- 回転中心軸となるジャーナル部と、該ジャーナル部から偏心するピン部と、前記ジャーナル部とピン部との間に延びるウエブ部とを有するクランクシャフトを製造する方法であって、
素材を曲げ加工してピン部およびウエブ部となる部分が形成された粗形材を成形する予備成形工程と、
該粗形材を軸方向に加圧してそのウエブ部となる部分を所定の厚さに成形する仕上成形工程とを含み、
前記予備成形工程で、粗形材のウエブ部となる部分に肉薄部を形成することを特徴とするクランクシャフトの製造方法。 - 前記予備成形工程でウエブとなる部分をその軸直交方向に加圧することにより前記肉薄部を形成することを特徴とする請求項1に記載のクランクシャフトの製造方法。
- 前記予備成形工程で、素材のピン部となる部分を軸直交方向に加圧するとともに、該ピン部となる部分とこれに隣接するジャーナル部となる部分との軸方向の位置を互いに寄せるよう軸方向に加圧することを特徴とする請求項1または2に記載のクランクシャフトの製造方法。
- 前記予備成形工程で、最初に素材のピン部となる部分を軸直交方向に加圧するのを開始し、その後、該ピン部となる部分とこれに隣接するジャーナル部となる部分との軸方向の位置を互いに寄せるよう軸方向に加圧するのを開始することを特徴とする請求項3に記載のクランクシャフトの製造方法。
- 前記予備成形工程で、素材のピン部となる部分を軸直交方向に加圧するのに伴って、該ピン部となる部分とこれに隣接するジャーナル部となる部分との軸方向の位置を互いに寄せるよう軸方向に加圧することを特徴とする請求項3または4に記載のクランクシャフトの製造方法。
- 予備成形工程において、素材のピン部となる部分に対する軸直交方向への加圧と、該ピン部となる部分とこれに隣接するジャーナル部となる部分との軸方向の位置を互いに寄せるよう軸方向への加圧とを、それぞれ個別の制御可能な駆動手段によって行うことを特徴とする請求項3または4に記載のクランクシャフトの製造方法。
- クランクシャフトに油孔を機械加工によって成形する場合において、
前記予備成形工程で、油孔が開口する部分に前記機械加工のための下孔を成形することを特徴とする請求項1~6のいずれか1項に記載のクランクシャフトの製造方法。 - クランクシャフトが複数のピン部を有しており、ジャーナル部から複数のピン部が同じ方向に偏心したクランクシャフトを製造する場合において、
前記予備成形工程で、ジャーナル部に対して偏心する方向が同じピン部およびウエブ部となる部分毎に順次曲げ加工して粗形材を成形し、
その後、前記仕上成形工程で、ジャーナル部に対して偏心する方向が同じピン部およびウエブ部となる部分毎に粗形材を軸方向に加圧してそのウエブ部となる部分を所定の厚さに成形することを特徴とする請求項1~7のいずれか1項に記載のクランクシャフトの製造方法。 - クランクシャフトが複数のピン部を有するクランクシャフトを製造する場合において、
前記予備成形工程で、素材の一方の端部から他方の端部に向かって順次曲げ加工してそれぞれのピン部およびウエブ部となる部分を形成し、
一方の端部のピン部およびウエブ部となる部分を形成するときに素材の一方の端部を拘束し、
中間部の一のピン部およびウエブ部となる部分を形成するときに、一のピン部およびウエブ部となる部分と隣接して既に形成されたウエブ部となる部分のうちの他方の端部側のウエブ部となる部分と該ウエブ部に連続するジャーナル部とを拘束して、一のウエブ部となる部分のうちの一方の端部側のウエブ部となる部分を他方の端部側のウエブ部となる部分よりも軸方向に多くの長さを寄せるように加圧し、
他方の端部のピン部およびウエブ部となる部分を形成するときに、素材の他方の端部と、該端部のピン部およびウエブ部となる部分と隣接して既に形成されたウエブ部となる部分のうちの他方の端部側のウエブ部となる部分と該ウエブ部に連続するジャーナル部となる部分とを拘束して、端部のウエブ部となる部分のうちの一方の端部側のウエブ部となる部分を他方の端部側のウエブ部となる部分よりも軸方向に多くの長さを寄せるように加圧することを特徴とする請求項3~8のいずれか1項に記載のクランクシャフトの製造方法。 - 前記仕上工程で、粗形材の中央に位置するジャーナル部となる部分を固定した状態で、粗形材の両端を中央に向かって軸方向に加圧することを特徴とする請求項8または9に記載のクランクシャフトの製造方法。
- 回転中心軸となるジャーナル部と、該ジャーナル部から偏心するピン部と、前記ジャーナル部とピン部との間に延びるウエブ部とを有するクランクシャフトを製造する装置であって、
素材を曲げ加工してピン部およびウエブ部となる部分が形成された粗形材を成形する予備成形装置と、
該粗形材を軸方向に加圧してそのウエブ部となる部分を所定の厚さに成形する仕上成形装置とを備え、
前記予備成形装置は、素材のピン部となる部分を把持するパンチと、ジャーナル部となる部分を把持するダイとを備えており、
前記パンチとダイは、素材のウエブ部となる部分に肉薄部を形成するための突部を有することを特徴とするクランクシャフトの製造装置。 - 前記突部は、ウエブとなる部分をその軸直交方向に加圧することにより前記肉薄部を形成するものであることを特徴とする請求項11に記載のクランクシャフトの製造装置。
- 前記予備成形装置は、前記パンチを素材の軸直交方向に移動させる軸直交方向駆動手段と前記ダイを前記パンチに寄せるよう軸方向に加圧する軸方向駆動手段とを備えていることを特徴とする請求項11または12に記載のクランクシャフトの製造装置。
- 前記予備成形装置は、軸直交方向駆動手段が最初に素材のピン部となる部分を軸直交方向に加圧するのを開始し、その後、軸方向駆動手段がピン部となる部分とこれに隣接するジャーナル部となる部分との軸方向の位置を互いに寄せるよう軸方向に加圧するのを開始するよう構成されていることを特徴とする請求項13に記載のクランクシャフトの製造装置。
- 前記ダイとパンチの、素材のウエブ部となる部分に当接する部位を、素材の材料をその径方向に流動させるよう傾斜させたことを特徴とする請求項13または14に記載のクランクシャフトの製造装置。
- 前記予備成形装置は、前記軸方向駆動手段が、前記軸直交方向駆動手段により前記パンチを素材の軸直交方向に移動させるのに伴って、前記ダイを前記パンチに寄せるよう軸方向に加圧するよう構成されていることを特徴とする請求項13~15のいずれか1項に記載のクランクシャフトの製造装置。
- 前記予備成形装置は、個別の制御可能な前記軸直交方向駆動手段と軸方向駆動手段によって構成されていることを特徴とする請求項13~15のいずれか1項に記載のクランクシャフトの製造装置。
- クランクシャフトが機械加工によって成形される油孔を有する場合において、
前記予備成形装置のパンチとダイスが、油孔の開口する部分と対応する位置に前記機械加工のための下孔を成形するための突起を有することを特徴とする請求項11~17のいずれか1項に記載のクランクシャフトの製造装置。 - クランクシャフトが複数のピン部を有しており、ジャーナル部から複数のピン部が同じ方向に偏心したクランクシャフトを製造する場合において、
前記予備成形装置は、ジャーナル部に対して偏心する方向が同じピン部およびウエブ部となる部分毎に順次曲げ加工して粗形材を成形するものであり、
前記仕上成形装置は、ジャーナル部に対して偏心する方向が同じピン部およびウエブ部毎に粗形材を軸方向に加圧してそのウエブ部となる部分を所定の厚さに成形するものであることを特徴とする請求項11~18のいずれか1項に記載のクランクシャフトの製造装置。 - クランクシャフトが複数のピン部を有するクランクシャフトを製造する場合において、
前記予備成形装置は、素材の一方の端部から他方の端部に向かって順次曲げ加工してそれぞれのピン部およびウエブ部となる部分を形成するものであって、
一方または他方の端部のピン部およびウエブ部となる部分を形成するときに素材の一方の端部を拘束する端部拘束部材と、
一のピン部およびウエブ部となる部分と隣接して既に形成されたウエブ部となる部分のうちの他方の端部側のウエブ部となる部分と該ウエブ部に連続するジャーナル部となる部分とを拘束するウエブ部-ジャーナル部拘束部材とを有しており、
前記軸方向駆動手段は、ウエブ部となる部分のうちの一方の端部側のウエブ部となる部分を他方の端部側のウエブ部となる部分よりも軸方向に多くの長さを寄せるように加圧するよう構成されていることを特徴とする請求項13~18のいずれか1項に記載のクランクシャフトの製造装置。 - 前記仕上装置は、粗形材の中央に位置するジャーナル部となる部分を固定する中央ジャーナル部固定手段と、粗形材の両端を中央に向かって軸方向に加圧する軸方向加圧手段とを備えていることを特徴とする請求項19または20に記載のクランクシャフトの製造装置。
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