WO2014065290A1 - プレス加工方法及び底付容器 - Google Patents
プレス加工方法及び底付容器 Download PDFInfo
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- WO2014065290A1 WO2014065290A1 PCT/JP2013/078611 JP2013078611W WO2014065290A1 WO 2014065290 A1 WO2014065290 A1 WO 2014065290A1 JP 2013078611 W JP2013078611 W JP 2013078611W WO 2014065290 A1 WO2014065290 A1 WO 2014065290A1
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- WIPO (PCT)
- Prior art keywords
- punch
- die
- bottomed container
- inclined portion
- thickness
- Prior art date
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/21—Deep-drawing without fixing the border of the blank
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
- B21D24/04—Blank holders; Mounting means therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/02—Making hollow objects characterised by the structure of the objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
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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
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/08—Upsetting
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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
- B21K21/00—Making hollow articles not covered by a single preceding sub-group
- B21K21/16—Remodelling hollow bodies with respect to the shape of the cross-section
Definitions
- the present invention relates to a press working method for increasing the thickness of an inclined part rising from the bottom part of a bottomed container, and a bottomed container manufactured thereby.
- a disk-shaped workpiece is formed into a bottomed container 11 by deep drawing, and a bottomed container bottom surface 11a is formed.
- a method of increasing the thickness of the vertical wall 11c of the bottomed container by pressing the end surface 11b of the bottomed container with the pressing punch 14 in a state where the die 12 and the presser punch 13 are sandwiched.
- the restraint of the vertical wall portion of the bottomed container is weak, it buckles during the thickening and the entrainment 11d occurs.
- Patent Document 1 has a pressing punch and an upsetting punch, which secures a gap between the pressing punch and the die between the upper part of the workpiece end and the inside of the bottom, and sets the upper surface of the workpiece end.
- a thickening press working method in which pressurization is performed with an embedded punch is disclosed.
- Patent Document 1 there is a possibility that buckling occurs during the increase in thickness in the gap and entrainment occurs.
- Non-Patent Document 1 a method for overcoming the above-described drawbacks of the thickening method in the manufacture of a pulley piston for a continuously variable transmission of an automobile has been proposed.
- corner portions are provided in the thickened portion, and the end of the cup is pushed in to increase the thickness in a state where the constraining surface of the material is increased, so that it is possible to prevent entrainment due to buckling.
- the gap of the thickened portion is geometrically determined by the restriction due to the mold shape and the movement of the mold, the maximum possible thickness increase ratio in one molding is about 1.5.
- Patent Document 2 a work material made of a press including an end wall, a bent portion bent to one side from the outer periphery of the end wall, and a cylindrical portion connected to the bent portion is used.
- a crank punch that fits the inner surface of the inner wall, a clamp die that fits the outer surface of the end wall, and a thickening guide die that fits the outer periphery of the clamp die so that it can swing in the axial direction and fits the outer periphery of the bent and cylindrical parts
- the workpiece is clamped, the thickening punch is inserted into the space formed between the clamp punch and the thickening guide die, and the axial direction compression load is applied to the cylindrical part to increase the thickness of the bent part.
- Patent Document 3 A method of retracting the meat guide die with respect to the clamp die has been proposed. Further, in Patent Document 3, a knockout for receiving a main body portion of a workpiece, a plate presser for pressing up to an intermediate position of a rising portion that rises obliquely outward from the main body portion, and a thickening punch that presses the tip of the rising portion. And a die for receiving the rising portion, and a configuration has been proposed in which the die is movable in the axial direction relative to the knockout and thickening punch.
- the present invention has been made in order to solve the above-described conventional drawbacks, and avoids entanglement due to buckling in press working and enables a thickness increase of 1.5 times or more.
- the main purpose It is another object of the present invention to produce a bottomed container having a gentle shape without a large step at the boundary between the thickened portion and the non-thickened portion. It is another object of the present invention to make it possible to manufacture a bottomed container having a thickened inclined portion from a disk-shaped workpiece by one-step pressing.
- the gist of the present invention to achieve the above-described object is as follows.
- An inner punch in which each central axis is coaxially disposed, an intermediate punch disposed along the outer periphery of the inner punch and having an intermediate punch inclined portion at a tip portion, and along the outer periphery of the intermediate punch A press working method using a press die comprising an outer punch arranged and a die having a die inclined portion facing the middle punch inclined portion, While the bottom of the bottomed container is constrained by the inner punch and the die, the end of the bottomed container is pushed by the outer punch, and the middle punch is pushed in a direction opposite to the direction of pushing the outer punch.
- a press working method comprising a step of increasing the thickness of the bottomed container inclined portion of the bottomed container sandwiched between the middle punch inclined portion and the die inclined portion by moving.
- Each central axis is coaxially arranged, an inner punch having an inner punch flat part and an inner punch inclined part at the tip part, and an inner punch inclined at the tip part, arranged along the outer periphery of the inner punch.
- a middle punch having a portion, an outer punch disposed along an outer periphery of the middle punch, and a die having a die slanted portion disposed opposite to the middle punch slanted portion, wherein the inner punch slanted portion is the inner punch
- a press working method using a press die formed at an end portion on the side close to the middle punch inclined portion at the tip portion of the punch By pressing the end of the bottomed container with the outer punch while the bottom of the bottomed container is constrained by the inner punch flat part and the die, the inner punch inclined part and the intermediate punch inclined part are An outer punch pushing step of bringing the bottomed container inclined part of the bottomed container extending along the die into contact with the die inclined part; An intermediate punch that presses the middle punch in the direction of the die with respect to the bottomed container that has contacted the die inclined part in the outer punch pressing step, and brings the intermediate punch inclined part into contact with the bottomed container inclined part.
- Indentation step By pushing the outer punch against the bottomed container in contact with the middle punch inclined portion in the middle punch pushing step, and moving the middle punch in a direction opposite to the direction of pushing the outer punch, A thickening step for increasing the thickness of the bottomed container inclined portion.
- a disk-shaped workpiece is pushed into the die by the inner punch and the middle punch, and a bottom is placed at a position sandwiched between the middle punch inclined portion and the die inclined portion.
- the pressing method according to [1] further including a forming step of forming a bottomed container in which the container inclined portion is formed.
- a disk-shaped workpiece is pressed into the die with the inner punch and the intermediate punch, and the inner punch inclined portion, the intermediate punch inclined portion, and the die inclined portion.
- Attached container [6] A bottomed container manufactured by the pressing method according to [2], wherein a thickness increase ratio of the thickness of the inclined part of the bottomed container is 1.5 times or more. Attached container.
- a bottomed container having a gentle shape can be manufactured.
- a bottomed container having a thickened inclined portion can be manufactured from a disk-shaped workpiece by one-step pressing.
- FIG. 1A is a cross-sectional view showing a conventional thickening process.
- FIG. 1B is a cross-sectional view showing a conventional thickening process.
- FIG. 2 is a cross-sectional view showing a state before deep drawing in the press working method according to the first embodiment.
- FIG. 3 is a cross-sectional view showing a state after deep drawing in the press working method according to the first embodiment.
- FIG. 4 is a cross-sectional view showing a state in the middle of thickening forming in the press working method according to the first embodiment.
- FIG. 5 is a cross-sectional view showing a state after thickening forming in the press working method according to the first embodiment.
- FIG. 6 is a cross-sectional view showing a state before deep drawing in the press working method according to the second embodiment.
- FIG. 7 is a cross-sectional view showing a state after deep drawing in the press working method according to the second embodiment.
- FIG. 8 is a cross-sectional view showing a state in which the inclined portion of the die is brought into contact with the inclined portion of the bottomed container in the press working method according to the second embodiment.
- FIG. 9 is a cross-sectional view showing a state in which the inclined portion of the middle punch is brought into contact with the inclined portion of the bottomed container in the press working method according to the second embodiment.
- FIG. 10 is a cross-sectional view showing a state in the middle of thickening forming in the press working method according to the second embodiment.
- FIG. 11 is a cross-sectional view showing a state after thickening forming in the press working method according to the second embodiment.
- FIG. 12 is a cross-sectional view showing a comparative example of the second
- FIG. 2 is a cross-sectional view showing a state before deep drawing is performed.
- the press die includes an inner punch 23 in which each central axis 20 is disposed coaxially, an intermediate punch 24 disposed along the outer periphery of the inner punch 23, and an intermediate punch 24.
- An outer punch 25 disposed along the outer periphery, a knockout 26, and a die 27 disposed along the outer periphery of the knockout 26 are provided.
- the inner punch 23 is disposed to face the knockout 26 and the die 27, and the middle punch 24 and the outer punch 25 are disposed to face the die 27.
- the inner punch 23 has a cylindrical shape, and is movable so that it can be moved up and down by a drive source (not shown) such as a mechanical type (hydraulic pressure, servo motor, etc.).
- the intermediate punch 24 has a cylindrical shape, and an intermediate punch inclined portion 24a is formed on a surface (that is, a lower end portion (front end portion)) of the intermediate punch 24 that comes into contact with the portion of the workpiece to be thickened. .
- the middle punch inclined portion 24a is inclined in the upward oblique direction from the inner punch 23 side toward the outer punch 25 side.
- the middle punch 24 is a movable type that can be raised and lowered by a mechanical drive source (not shown).
- the outer punch 25 has a cylindrical shape and is movable so as to be lifted and lowered by a mechanical drive source (not shown).
- the knockout 26 has a cylindrical shape, is for removing the molded product from the mold, and is movable so that it can be raised and lowered by a mechanical drive source (not shown).
- the die 27 is fixed, has a substantially concave shape, and is provided with a hole in the center for allowing the knockout 26 to pass through. Further, the die 27 is formed with a die inclined portion 27a, and the die inclined portion 27a is disposed opposite to the middle punch inclined portion 24a.
- the workpiece 21 was pressed by performing the following forming step and thickening step.
- a disc-shaped high-tensile steel plate SAPH590 having an outer diameter of 240 mm and a plate thickness of 4 mm was used.
- the workpiece 21 is placed on the die 27, the inner punch 23 and the middle punch 24 are pushed in, and deep drawing is performed. As shown in FIG. 3, the bottom is located between the middle punch inclined portion 24a and the die inclined portion 27a.
- the bottomed container 22 formed with the attached container inclined portion 22a is formed (molding step).
- the inner punch 23, the middle punch 24, the outer punch 25 and the knockout 26 are moved upward, and the bottomed container 22 is removed from the die 27.
- the plate thickness of the bottomed container inclined portion 22a is 6.9 mm, and there is no occurrence of winding due to buckling, and the thickness is increased to 1.73 times the original plate thickness of 4 mm.
- a force is applied to the middle punch 24 in a direction perpendicular to the middle punch inclined portion 24a. This force presses the middle punch 24 against the inner punch 23 (inner side in the radial direction (center direction)). ), There is no gap at the boundary between the inner punch 23 and the middle punch 24, and no burrs are generated.
- FIG. 6 is a cross-sectional view showing a state before deep drawing is performed.
- the press die includes an inner punch 33 in which each central axis 30 is coaxially disposed, an intermediate punch 34 disposed along the outer periphery of the inner punch 33, and the intermediate punch 34.
- An outer punch 35 disposed along the outer periphery, a knockout 36, and a die 37 disposed along the outer periphery of the knockout 36 are provided.
- the inner punch 33 is disposed to face the knockout 36 and the die 37, and the middle punch 34 and the outer punch 35 are disposed to face the die 37.
- the inner punch 33 has a cylindrical shape, and an inner punch inclined portion 33a and an inner punch flat portion 33b are formed at the tip thereof.
- the inner punch inclined portion 33 a is formed at the peripheral edge portion of the tip, that is, the end portion on the side close to the middle punch inclined portion 34 a, and the inner punch flat portion 33 b is formed around the central axis 30.
- the inner punch inclined portion 33a is inclined in the upward oblique direction from the central axis 30 side toward the middle punch 34 side.
- the inner punch flat portion 33 b extends in the horizontal direction perpendicular to the central axis 30.
- the inner punch 33 is a movable type that can be moved up and down by a mechanical drive source (not shown).
- the intermediate punch 34 has a cylindrical shape, and an intermediate punch inclined portion 34a is formed on a surface (that is, a lower end portion (tip portion) of the intermediate punch 34) that contacts a portion of the workpiece to be thickened. .
- the middle punch inclined portion 34a is inclined in an upward oblique direction from the inner punch 33 side toward the outer punch 35 side.
- the middle punch 34 is a movable type that can be raised and lowered by a mechanical drive source (not shown).
- a mechanical drive source not shown
- the outer punch 35 has a cylindrical shape and can be moved up and down by a mechanical drive source (not shown).
- the knockout 36 has a cylindrical shape, is for removing the molded product from the mold, and is movable so that it can be raised and lowered by a mechanical drive source (not shown).
- the die 37 is fixed, has a substantially concave shape, and is provided with a hole in the center for passing the knockout 36.
- the die 37 is formed with a die inclined portion 37a, and the die inclined portion 37a is disposed so as to face the inner punch inclined portion 33a and the intermediate punch inclined portion 34a.
- the workpiece 31 was pressed by performing the following forming step, outer punch pressing step, intermediate punch pressing step, and thickening step.
- a disk-shaped high-tensile steel plate SAPH590 having an outer diameter of 224 mm and a plate thickness of 4 mm was used.
- the workpiece 31 is placed on the die 37 and the inner punch 33 and the intermediate punch 34 are pushed in to perform deep drawing, and as shown in FIG. 7, the inner punch inclined portion 33a, the intermediate punch inclined portion 34a, and the die inclined portion 37a.
- the bottomed container 32 in which the bottomed container inclined portion 32a is formed at a position sandwiched between the two is formed (molding step).
- the middle punch 34 is moved downward with respect to the bottomed container 32 that has come into contact with the die 37 in the outer punch pushing step (the middle punch 34 is pushed toward the die 37), and as shown in FIG.
- the punch inclined portion 34a is brought into contact with the bottomed container inclined portion 32a (medium punch pressing step).
- FIGS. 10 and 11 the end face of the bottomed container 32 is pushed by the outer punch 35 and the middle punch 34 is moved upward.
- the gap between the intermediate punch inclined portion 34a and the die inclined portion 37a gradually increases, and the bottomed container inclined portion 32a is sandwiched between the intermediate punch inclined portion 34a and the die inclined portion 37a to increase the thickness while suppressing buckling.
- Can (thickening step) The cross-sectional views of FIG. 10 and FIG. 11 show states during and after thickening molding, respectively.
- the inner punch 33, the middle punch 34, the outer punch 35 and the knockout 36 are moved upward, and the bottomed container 32 is removed from the die 37.
- the plate thickness of the bottomed container inclined portion 32a is 8 mm, there is no occurrence of winding due to buckling, and the thickness is increased to twice the original plate thickness of 4 mm.
- step difference in the boundary of a thickening part and a non-thickening part and it has a gentle shape.
- a force acts on the middle punch 34 in a direction perpendicular to the middle punch inclined portion 34a. This force presses the middle punch 34 against the inner punch 33 (inner side in the radial direction (center direction)). ), There is no gap at the boundary between the inner punch 33 and the middle punch 34, and no burrs are generated.
- the angle between the bottomed container inclined portions 22a and 32a and the horizontal direction is 45 °, but is preferably 20 ° or more and 70 ° or less. If the angle between the bottomed container inclined portions 22a and 32a and the horizontal direction is less than 20 °, the material flow from the bottomed container vertical wall portions 22b and 32b to the bottomed container inclined portions 22a and 32a becomes worse, and the load required for molding is increased. This is because it becomes larger. In addition, if the angle between the bottomed container inclined portions 22a and 32a and the horizontal direction exceeds 70 °, the contact length between the workpieces 21 and 31 and the mold becomes long, so that the frictional force becomes large and the load required for molding becomes large. It is to become.
- the bottomed container vertical wall portions 22b and 32b mean portions of the bottomed containers 22 and 32 that are closer to the outer punches 25 and 35 than the bottomed container inclined portions 22a and 32a.
- SAPH590 is used as a workpiece, but the material is not limited to an iron-based material, and can be used for metals such as aluminum and titanium.
- the present invention can be used to increase the thickness of the inclined portion that rises from the bottom surface of the bottomed container.
Abstract
Description
例えば特許文献1には、押さえパンチ及び据え込パンチを有し、ワークの端部上方部及び底部内方との間において押さえパンチとダイスとの間に間隙を確保し、ワーク端部上面を据え込パンチで加圧する増肉プレス加工法が開示されている。しかし、特許文献1の方法でも、間隙において増肉中に座屈し、巻き込みが発生するおそれがある。
また、特許文献3にて、加工対象物の本体部を受けるノックアウトと、本体部から斜め外方に立ち上がる立上り部の途中位置までを押える板押えと、立上り部の先端を押圧する増肉用ポンチと、立上り部を受けるダイスとを備え、ダイスが、ノックアウトおよび増肉用ポンチに対して相対的に軸心方向に移動可能となっている構成が提案されている。増肉用ポンチにより、立上り部の先端を押圧して、その立上り部を押し潰す過程で、ダイスが、増肉用ポンチに押されることなく増肉されつつある立上り部に押されて、ノックアウトに対して相対的に移動することで、立上り部を挟む板押えとダイスとの間が広がる。
しかし、特許文献2、3の方法でも、深絞り等により底付円筒容器を成形する必要があり、都合2工程を要する。更に、増肉部と非増肉部の境界に大きな段差が発生し、切削工程が必要な場合がある。また、可能な増肉比が言及されていない。
また、ダイを分割してその一部を移動させる構成とすると、特許文献2の例でいえば、増肉成形時に、増肉案内ダイには傾斜部(特許文献2における2b)に垂直な方向に力が作用する。この力は、増肉案内ダイをクランプダイから離間させる方向(径方向の外側)に作用するため、クランプダイと増肉案内ダイの境界部に隙間が生じ、バリが発生する可能性がある。
[1] 各々の中心軸が同軸上に配置された、内パンチと、前記内パンチの外周に沿って配置され、先端部に中パンチ傾斜部を有する中パンチと、前記中パンチの外周に沿って配置された外パンチと、前記中パンチ傾斜部に対向するダイ傾斜部を有するダイとを備えるプレス金型を用いたプレス加工方法であって、
底付容器の底部を前記内パンチ及び前記ダイにて拘束した状態で、前記外パンチにより前記底付容器の端部を押込むとともに、前記中パンチを前記外パンチを押込む方向と逆方向に移動させることにより、前記中パンチ傾斜部及び前記ダイ傾斜部によって挟まれた前記底付容器の底付容器傾斜部を増肉する増肉ステップを有することを特徴とするプレス加工方法。
[2] 各々の中心軸が同軸上に配置された、先端部に内パンチフラット部及び内パンチ傾斜部を有する内パンチと、前記内パンチの外周に沿って配置され、先端部に中パンチ傾斜部を有する中パンチと、前記中パンチの外周に沿って配置された外パンチと、前記中パンチ傾斜部に対向配置されるダイ傾斜部を有するダイとを備え、前記内パンチ傾斜部が前記内パンチの先端部における前記中パンチ傾斜部に近接する側の端部に形成されたプレス金型を用いたプレス加工方法であって、
底付容器の底部を前記内パンチフラット部及び前記ダイにて拘束した状態で、前記外パンチにより前記底付容器の端部を押込むことにより、前記内パンチ傾斜部及び前記中パンチ傾斜部に沿って延びる前記底付容器の底付容器傾斜部を前記ダイ傾斜部に接触させる外パンチ押込みステップと、
前記外パンチ押込みステップで前記ダイ傾斜部に接触した前記底付容器に対して、前記中パンチを前記ダイの方向に押込んで、前記中パンチ傾斜部を前記底付容器傾斜部に接触させる中パンチ押込みステップと、
前記中パンチ押込みステップで前記中パンチ傾斜部に接触した前記底付容器に対して、前記外パンチを押込むとともに、前記中パンチを前記外パンチを押込む方向と逆方向に移動させることにより、前記底付容器傾斜部を増肉する増肉ステップと、を有することを特徴とするプレス加工方法。
[3] 前記増肉ステップの前に、前記内パンチ及び前記中パンチで前記ダイに円板状の被加工材を押込んで、前記中パンチ傾斜部と前記ダイ傾斜部によって挟まれる位置に底付容器傾斜部が形成された底付容器を成形する成形ステップを有することを特徴とする[1]に記載のプレス加工方法。
[4] 前記外パンチ押込みステップの前に、前記内パンチ及び前記中パンチで前記ダイに円板状の被加工材を押込んで、前記内パンチ傾斜部及び前記中パンチ傾斜部と前記ダイ傾斜部によって挟まれる位置に底付容器傾斜部が形成された底付容器を成形する成形ステップを有することを特徴とする[2]に記載のプレス加工方法。
[5] [1]に記載のプレス加工方法によって製造される底付容器であって、前記底付容器傾斜部の厚さの増肉比が1.5倍以上であることを特徴とする底付容器。
[6] [2]に記載のプレス加工方法によって製造される底付容器であって、前記底付容器傾斜部の厚さの増肉比が1.5倍以上であることを特徴とする底付容器。
更に、請求項2に記載の発明によれば、増肉部と非増肉部の境界に大きな段差がなく、なだらか形状を有する底付容器を製造することができる。
更にまた、請求項3、4に記載の発明によれば、一工程のプレス加工により、円板状の被加工材から、傾斜部を増肉させた底付容器を製造することができる。
本発明者は、鋭意検討を行った結果、各々の中心軸が同軸上に配置された、内パンチと、内パンチの外周に沿って配置した中パンチと、ダイとを用いて深絞りを行い、底付容器を成形し、続いて、外パンチにより底付容器の端面を押込む際に、中パンチとダイの隙間を徐々に大きくし、被加工材を拘束した状態で増肉することにより、一工程のプレス加工により、座屈による巻き込みを回避し、増肉比1.5倍以上の増肉が可能なことを見出した。
図2は深絞りを実施する前の状態を示す断面図である。図2に示すように、プレス金型は、各々の中心軸20が同軸上に配置された、内パンチ23と、内パンチ23の外周に沿って配置された中パンチ24と、中パンチ24の外周に沿って配置された外パンチ25と、ノックアウト26と、ノックアウト26の外周に沿って配置されたダイ27とを備える。内パンチ23はノックアウト26及びダイ27に対向配置されており、中パンチ24及び外パンチ25はダイ27に対向配置されている。
中パンチ24は円筒状の形状であり、被加工材の増肉される部分に接触する面(つまり、中パンチ24の下端部(先端部))には中パンチ傾斜部24aが形成されている。この中パンチ傾斜部24aは内パンチ23側から外パンチ25側に向かって上斜方向に傾斜している。中パンチ24は図略の機械式の駆動源により昇降可能な可動式である。
外パンチ25は円筒状の形状であり、図略の機械式の駆動源により昇降可能な可動式である。
ダイ27は固定式であり、概略凹状の形状であり、ノックアウト26を通すために中央部に穴が設けられている。また、ダイ27には、ダイ傾斜部27aが形成されており、このダイ傾斜部27aは中パンチ傾斜部24aに対向配置されている。
続いて、図4及び図5に示すように、成形ステップで成形された底付容器22の端面を外パンチ25で押込むとともに中パンチ24を上方に移動させる。これにより、中パンチ傾斜部24aとダイ傾斜部27aの隙間が徐々に大きくなり、底付容器傾斜部22aを中パンチ傾斜部24a及びダイ傾斜部27aで挟んで座屈を抑制しながら増肉することができる(増肉ステップ)。図4及び図5の断面図はそれぞれ増肉成形途中及び増肉成形後の状態を示している。
また、増肉成形時に、中パンチ24には中パンチ傾斜部24aに垂直な方向に力が作用するが、この力は中パンチ24を内パンチ23に押し付ける方向(径方向の内側(中心方向))に作用するため、内パンチ23と中パンチ24の境界部に隙間は生じず、バリが発生しない。
第二の実施形態は、増肉部と非増肉部の境界に大きな段差がなく、なだらか形状を有する底付容器を製造するものである。
図6は深絞りを実施する前の状態を示す断面図である。図6に示すように、プレス金型は、各々の中心軸30が同軸上に配置された、内パンチ33と、内パンチ33の外周に沿って配置された中パンチ34と、中パンチ34の外周に沿って配置された外パンチ35と、ノックアウト36と、ノックアウト36の外周に沿って配置されたダイ37とを備える。内パンチ33はノックアウト36及びダイ37に対向配置されており、中パンチ34及び外パンチ35はダイ37に対向配置されている。
ここで、内パンチ傾斜部33aの中心軸30から離隔した側の端部の高さと、中パンチ傾斜部34aの中心軸30に近接した側の端部の高さとが同じであるとき、つまり、図6に図示する状態において、内パンチ傾斜部33a及び中パンチ傾斜部34aはなだらかな曲線を形成する。
ダイ37は固定式であり、概略凹状の形状であり、ノックアウト36を通すために中央部に穴が設けられている。また、ダイ37には、ダイ傾斜部37aが形成されており、このダイ傾斜部37aは内パンチ傾斜部33a及び中パンチ傾斜部34aに対向配置されている。
続いて、成形ステップで成形された底付容器32の端面を外パンチ35で押込み、内パンチ傾斜部33a及び中パンチ傾斜部34aに沿って延びる底付容器傾斜部32aを、図8に示すようにダイ傾斜部37aに接触させる(外パンチ押込みステップ)。
また、増肉成形時に、中パンチ34には中パンチ傾斜部34aに垂直な方向に力が作用するが、この力は中パンチ34を内パンチ33に押し付ける方向(径方向の内側(中心方向))に作用するため、内パンチ33と中パンチ34の境界部に隙間は生じず、バリが発生しない。
上記実施例では、被加工材としてSAPH590を用いたが、鉄系の材料に限定するものではなく、アルミ系、チタン系等の金属に使用できる。
Claims (6)
- 各々の中心軸が同軸上に配置された、内パンチと、前記内パンチの外周に沿って配置され、先端部に中パンチ傾斜部を有する中パンチと、前記中パンチの外周に沿って配置された外パンチと、前記中パンチ傾斜部に対向するダイ傾斜部を有するダイとを備えるプレス金型を用いたプレス加工方法であって、
底付容器の底部を前記内パンチ及び前記ダイにて拘束した状態で、前記外パンチにより前記底付容器の端部を押込むとともに、前記中パンチを前記外パンチを押込む方向と逆方向に移動させることにより、前記中パンチ傾斜部及び前記ダイ傾斜部によって挟まれた前記底付容器の底付容器傾斜部を増肉する増肉ステップを有することを特徴とするプレス加工方法。 - 各々の中心軸が同軸上に配置された、先端部に内パンチフラット部及び内パンチ傾斜部を有する内パンチと、前記内パンチの外周に沿って配置され、先端部に中パンチ傾斜部を有する中パンチと、前記中パンチの外周に沿って配置された外パンチと、前記中パンチ傾斜部に対向配置されるダイ傾斜部を有するダイとを備え、前記内パンチ傾斜部が前記内パンチの先端部における前記中パンチ傾斜部に近接する側の端部に形成されたプレス金型を用いたプレス加工方法であって、
底付容器の底部を前記内パンチフラット部及び前記ダイにて拘束した状態で、前記外パンチにより前記底付容器の端部を押込むことにより、前記内パンチ傾斜部及び前記中パンチ傾斜部に沿って延びる前記底付容器の底付容器傾斜部を前記ダイ傾斜部に接触させる外パンチ押込みステップと、
前記外パンチ押込みステップで前記ダイ傾斜部に接触した前記底付容器に対して、前記中パンチを前記ダイの方向に押込んで、前記中パンチ傾斜部を前記底付容器傾斜部に接触させる中パンチ押込みステップと、
前記中パンチ押込みステップで前記中パンチ傾斜部に接触した前記底付容器に対して、前記外パンチを押込むとともに、前記中パンチを前記外パンチを押込む方向と逆方向に移動させることにより、前記底付容器傾斜部を増肉する増肉ステップと、を有することを特徴とするプレス加工方法。 - 前記増肉ステップの前に、前記内パンチ及び前記中パンチで前記ダイに円板状の被加工材を押込んで、前記中パンチ傾斜部と前記ダイ傾斜部によって挟まれる位置に底付容器傾斜部が形成された底付容器を成形する成形ステップを有することを特徴とする請求項1に記載のプレス加工方法。
- 前記外パンチ押込みステップの前に、前記内パンチ及び前記中パンチで前記ダイに円板状の被加工材を押込んで、前記内パンチ傾斜部及び前記中パンチ傾斜部と前記ダイ傾斜部によって挟まれる位置に底付容器傾斜部が形成された底付容器を成形する成形ステップを有することを特徴とする請求項2に記載のプレス加工方法。
- 請求項1に記載のプレス加工方法によって製造される底付容器であって、前記底付容器傾斜部の厚さの増肉比が1.5倍以上であることを特徴とする底付容器。
- 請求項2に記載のプレス加工方法によって製造される底付容器であって、前記底付容器傾斜部の厚さの増肉比が1.5倍以上であることを特徴とする底付容器。
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