WO2015170707A1 - せん断加工部品の製造方法及び製造装置 - Google Patents
せん断加工部品の製造方法及び製造装置 Download PDFInfo
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- WO2015170707A1 WO2015170707A1 PCT/JP2015/063215 JP2015063215W WO2015170707A1 WO 2015170707 A1 WO2015170707 A1 WO 2015170707A1 JP 2015063215 W JP2015063215 W JP 2015063215W WO 2015170707 A1 WO2015170707 A1 WO 2015170707A1
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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
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/14—Dies
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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
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
-
- 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
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/16—Shoulder or burr prevention, e.g. fine-blanking
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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
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
Definitions
- the present invention relates to a method and apparatus for manufacturing a sheared part, and more specifically, a method and apparatus for manufacturing a sheared part made of high-strength steel or ultra-high-strength steel used in automobiles, construction machines, various plants, and the like. Relates to the device.
- This application claims priority based on Japanese Patent Application No. 2014-097044 filed in Japan on May 08, 2014, the contents of which are incorporated herein by reference.
- FIG. 16A is a cross-sectional view schematically showing a drilling process in which a hole is formed by shearing the workpiece 1.
- FIG. 16B is a cross-sectional view schematically showing a cutting process in which the workpiece 1 is sheared to form an open cross section.
- a workpiece 2 is placed on a die 3 and then a punch 2 is shown in the drawing.
- the workpiece 1 is punched by pushing it in the direction of the white arrow, and the workpiece 1 is punched and sheared.
- FIG. 17 is a cross-sectional view showing the shearing surface 8 formed on the workpiece 1 that has been sheared.
- the shearing surface 8 of the workpiece 1 formed by the shearing process has a sagging 4 formed by pressing the workpiece 1 with the punch 2, and a clearance between the punch 2 and the die 3.
- a shear plane formed by the workpiece 1 being drawn and locally stretched inside hereinafter referred to as “clearance” unless otherwise specified in the present specification).
- a fracture surface 6 formed by breaking the workpiece 1 drawn into the clearance between the punch 2 and the die 3, and a burr 7 generated on the back surface of the workpiece 1.
- Shearing has the advantage that it can be processed at low cost.
- the hardness required for the workpiece 1 tends to increase, and it is difficult to simply apply the conventional shearing method.
- a high-tensile steel plate having a tensile strength exceeding 780 MPa is used as the work material 1
- excessive burrs 7 are generated due to chipping of the cutting edge, so the mold must be frequently replaced, and productivity is increased.
- a decline is inevitable.
- blade loss is a phenomenon different from “blade wear”. In other words, wear is a phenomenon in which the roundness of the cutting edge increases with an increase in the number of machining operations, whereas the defect is a phenomenon in which the cutting edge is lost due to cracking.
- Non-Patent Document 1 the wear of the tool blade edge is often suppressed by performing a coating process on the surface of the tool. Further, with respect to chipping of the tool edge, a method for absorbing and mitigating shock when the tool edge comes into contact with the tool fastening portion is made flexible, for example, as disclosed in Non-Patent Document 2, There are known methods for rounding or chamfering only the cutting edge.
- Non-Patent Document 1 improves the tool life by reducing the frictional resistance between the tool surface and the workpiece.
- this method when shearing a high-tensile steel plate having a maximum tensile strength of 780 MPa or more, it is impossible to prevent a sudden tool edge defect due to an impact on the tool edge.
- the method described in Non-Patent Document 2 described above in which the cutting edge is rounded only on the punch, cannot prevent the cutting edge of the die from being lost.
- the present inventors know empirically that the frequency of occurrence of tool damage increases when the ratio between the hardness of the workpiece and the hardness of the tool (die, punch, etc.) exceeds a certain value.
- Table 1 shows the results of experiments conducted by the inventors on the ratio. In the tool evaluation shown in Table 1, G indicates Good (good) and NG indicates Not Good (problem). According to the above experimental results, it has been found that the occurrence frequency of tool damage sharply increases in high-strength steel and ultra-high-strength steel in which the Vickers hardness of the workpiece is 0.3 times or more of the Vickers hardness of the tool. In the experiment of Table 1, the experiment was performed using a punch and a die each having an acute tool edge.
- the clearance between the punch and the die when the plate thickness of the workpiece is t is changed within the range of 0.1 ⁇ t to 0.2 ⁇ t, but the result is not affected. It was confirmed that the ratio between the hardness of the tool and the hardness of the tool was dominant.
- the present invention has been made in view of the above circumstances, and even if a workpiece made of high-tensile steel or ultra-high-strength steel having a Vickers hardness of 0.3 times or more of the Vickers hardness of the tool is used, It is an object of the present invention to provide a manufacturing method and a manufacturing apparatus for a sheared part, which can manufacture the sheared part at a low cost without causing a typical cutting edge defect.
- a method of manufacturing a sheared part according to one aspect of the present invention includes a workpiece having a Vickers hardness of 0.3 times to less than 1.0 times, whichever is lower of the Vickers hardness of a punch and the Vickers hardness of a die.
- a method of manufacturing a plurality of sheared parts by performing a plurality of shearing processes on the material using the punch and the die, the step of fixing the workpiece to the die, Punching the workpiece with the punch and the die relatively close to each other, and performing the shearing process a plurality of times, and facing the workpiece at the start of a series of shearing processes.
- a punch comprising: a first tip surface; and a first cutting edge including a first receding surface retracted from the first tip surface with reference to a direction of approach to the die; a second tip facing the workpiece Surface and said pad A second cutting edge comprising a second retraction surface recessed from said second distal end surface approaching direction with respect to the switch, and the die comprises a; with performing the shearing.
- the first receding surface when viewed in a cross section perpendicular to the first tip surface is equal to or higher than Rmin (mm) defined by the following equation 1 and the following equation 2
- Chamfering having a width dimension equal to or less than ⁇ max (mm) defined
- the second receding surface when viewed in a cross section perpendicular to the second tip surface is Rmin (mm) defined by the following formula 1
- either one or both of the first receding surface and the second receding surface is a curved surface having a curvature of 0.05 mm or more and 0.5 mm or less, or C0.05 mm or more and C0. It may be a chamfer of 5 mm or less.
- the first receding surface of the first tip surface, the first receding surface, and the outer surface of the punch At least a first condition having the highest frictional resistance and a second condition having the highest frictional resistance of the second receding surface among the second tip surface, the second receding surface, and the inner surface of the die. One may be satisfied.
- the workpiece may be subjected to any one of surface decarburization treatment, plating treatment, and solid lubrication treatment. Good.
- the apparatus for manufacturing a sheared part according to another aspect of the present invention has a Vickers hardness of not less than 0.3 times and less than 1.0 times of the lower one of the Vickers hardness of the punch and the Vickers hardness of the die.
- a punch for punching the workpiece, and the punch has a first tip surface facing the workpiece and a first receding surface retracted from the first tip surface with reference to the direction of approach to the die.
- the die includes a second tip surface facing the workpiece, and a second receding surface retracted from the second tip surface with reference to the approaching direction to the punch. 2 cutting edges.
- the first receding surface when viewed in a cross section perpendicular to the first tip surface is equal to or greater than Rmin (mm) defined by the following equation 1 and the following equation 2
- Chamfering having a width dimension equal to or less than ⁇ max (mm) defined
- the second receding surface when viewed in a cross section perpendicular to the second tip surface is Rmin (mm) defined by the following formula 1
- either one or both of the first receding surface and the second receding surface is a curved surface having a curvature of 0.05 mm or more and 0.5 mm or less, or C0.05 mm or more and C0. It may be a chamfer of 5 mm or less.
- the first receding surface of the first tip surface, the first receding surface, and the outer surface of the punch At least a first condition having the highest frictional resistance and a second condition having the highest frictional resistance of the second receding surface among the second tip surface, the second receding surface, and the inner surface of the die. One may be satisfied.
- each aspect of the present invention even when using a workpiece made of high-strength steel or ultra-high-strength steel having a Vickers hardness of 0.3 times or more of the tool's Vickers hardness, sudden chipping of the cutting edge can be achieved. It is possible to manufacture sheared parts at low cost without the occurrence.
- FIG. 4 is a diagram for explaining a detailed mechanism when a die blade edge and a punch blade edge are broken when a high-tensile steel plate is sheared as a workpiece, and is a cross-sectional view showing a continuation process of FIG. 3A It is.
- Sectional drawing which shows the detailed mechanism at the time of carrying out the shearing process using a high-tensile steel plate as a workpiece, and when the cutting edge of a die and the cutting edge of a punch are broken, and shows the process following FIG. 3B It is. It is a figure which shows the result of having calculated
- FIG. 1 the principal part of the shear processing apparatus which concerns on one Embodiment of this invention is shown.
- the shearing component manufacturing apparatus 100 in this embodiment is relatively close to the die 120 and the plate presser 130 that sandwich and fix the workpiece 1 from above and below, and the die 120.
- the shear processing component manufacturing apparatus 100 uses, as a workpiece 1, a high-tensile steel plate having a Vickers hardness that is 0.3 times or more and less than 1.0 times the lower one of the Vickers hardness of the punch 110 and the Vickers hardness of the die 120. This is an apparatus for producing a plurality of sheared parts by performing a plurality of shearing processes.
- the punch 110 includes a first front end surface 111 that faces the workpiece 1 and a first cutting edge 113 that includes a first retreating surface 112 that retreats from the first front end surface 111 with reference to the approaching direction to the die 120.
- the die 120 includes a second tip surface 121 that faces the workpiece 1 and a second cutting edge 123 that includes a second receding surface 122 that recedes from the second tip surface 121 with reference to the approaching direction to the punch 110.
- the die 120 is a pedestal on which the workpiece 1 is placed, and is a through-hole that is an inner surface that forms a predetermined clearance c with respect to the outer surface 114 of the punch 110 in a cross section perpendicular to the axis of the punch 110.
- the plate retainer 130 is a tool for sandwiching and fixing the workpiece 1 placed on the die 120 between the die 120 and, like the die 120, a through hole 131 coaxial with the punch 110 is formed. ing.
- high-strength steel When shearing a workpiece made of high-strength steel or ultra-high-strength steel (hereinafter sometimes referred to as “high-strength steel”) whose Vickers hardness is 0.3 times or more of the Vickers hardness of the tool The mechanism for the resulting tool edge failure is not known in detail. Therefore, the present inventors have confirmed the mechanism by experiments. The present invention has been completed based on the knowledge obtained at that time.
- the present inventors performed a tool durability test when shearing was performed using a high-tensile steel plate having a tensile strength of 780 MPa as a workpiece. As a result of the tool durability test, it was found that even when the tool edge was not damaged, the edge was worn from a substantially acute angle to a radius of 0.05 mm or more by the first 1000 shots.
- FIGS. 2A and 2B are partial cross-sectional views showing the state of occurrence of burrs during shearing of a steel plate.
- 2A shows a case where a mild steel plate having a tensile strength of less than 780 MPa is used as the workpiece 1A
- FIG. 2B shows a case where a high strength steel plate having a tensile strength of 780 MPa or more is used as the workpiece 1.
- FIG. 3A is a partial cross-sectional view showing an initial process when punching a workpiece (high-tensile steel plate) 1 with a punch 300 and a die 310, and as shown by a white arrow, with respect to the die 310.
- the situation where the punch 300 is approached is shown.
- both the cutting edge 301 of the punch 300 and the cutting edge 311 of the die 310 have a cross-sectional shape having a right angle in the initial process.
- 3B is a partial cross-sectional view showing a state in which the punch 300 is closer to the die 310 than in FIG. 3A.
- a plastic flow is formed from one side of the workpiece 1 to the other side and from the other side to the other side with a straight line connecting the cutting edges 301 and 311 as a boundary.
- These plastic flows are particularly high in pressure between the cutting edges 301 and 311 where the flow path becomes narrow, and the cutting edges 301 and 311 are pressed and plastically deformed so as to push them along their own flow. As a result, the blade edges 301 and 311 become protrusions that protrude from the original position.
- the blade edge 301 receives a pressing force due to plastic flow and is punched. It moves to the outer surface of 300 and finally loses.
- the cutting edge 311 receives the pressing force due to plastic flow, moves to the inner surface of the die 310, and is lost.
- the workpiece 1 when the workpiece 1 is a high-strength steel plate, the workpiece 1 cannot move freely including the portions that contact the cutting edges 301 and 311 because of its hardness. Therefore, the portion of the workpiece 1 that hits the cutting edges 301 and 311 remains stopped while maintaining a high pressure, and continues to apply high stress to the cutting edges 301 and 311. It will be plastically deformed so as to push out from its original position. Subsequently, the cutting edge 301 pushed out to the outer surface of the punch 300 is lost due to a shearing force due to relative displacement with the workpiece 1 around the punch 300 this time. Similarly, the cutting edge 311 pushed out to the inner surface of the die 310 is also damaged due to a shearing force due to relative displacement with the workpiece 1 in the die 310.
- the present inventors tried detailed examination also about the roundness given to a tool blade edge, and the size of chamfering.
- the examination results are described below.
- the radius of curvature when rounding the tool edge was studied. Specifically, the Vickers hardness Hw of the workpiece, the Vickers hardness Ht of the tool, and the clearance c between the tools (between the punch and the die) were set, and the amount of plastic deformation generated at the tool edge was calculated by simulation. .
- An example of the simulation calculation result is shown in FIG. In the example of FIG. 4, the magnitude of the amount of plastic deformation is color-coded, and the amount of plastic deformation is the maximum value at the position indicated by the symbol H, which is the cutting edge.
- the curvature radius of the roundness at the tool edge is increased and recalculated, and the minimum curvature radius of the roundness satisfying the condition that the plastic deformation amount is within the allowable range is obtained. . Then, the obtained minimum curvature radius of roundness was set as the minimum value Rmin of roundness (R value) in the above setting.
- Rmin of roundness R value
- Rmin (0.9 + 0.2e -0.08c ) (0.3571x 2 -0.2595x + 0.0965) .
- Rmin (0.9 + 0.2e -0.08c ) (0.3571x 2 -0.2595x + 0.0965) .
- the unit of Rmin is (mm), and e is the base of natural logarithm.
- c (mm) is a clearance between tools, and in the case of a drilling tool, indicates a clearance between the inner surface of the die and the outer surface of the punch.
- x represents a dimensionless number obtained by dividing the Vickers hardness Hw (MPa) of the workpiece by the Vickers hardness Ht (MPa) of the tool, and 0.3 ⁇ 0.3 for reasons described later. The value satisfies x ⁇ 1.0.
- x is a hardness ratio obtained by dividing the Vickers hardness of the workpiece by the Vickers hardness of the punch, and for a die, the Vickers hardness of the workpiece by the Vickers hardness of the die. Is the hardness ratio divided by.
- the reason why the lower limit value of the hardness ratio x is 0.3 (0.3 ⁇ x) is that, as explained based on the experimental results in Table 1, the present invention has a ratio of 0.3 times or more as the ratio. This is because the material is the target of application.
- the reason why the upper limit of the hardness ratio x is less than 1.0 (x ⁇ 1.0) is that when the Vickers hardness Hw of the workpiece exceeds the Vickers hardness Ht of the tool, the hardness balance is reversed and the machining cannot be performed. Because. For the above reasons, the hardness ratio is a value satisfying 0.3 ⁇ x ⁇ 1.0.
- the inventors have determined the cutting edges of both the punch and the die.
- a mild steel plate having a tensile strength of 270 MPa As the work material, three steel types were used: a mild steel plate having a tensile strength of 270 MPa, a 590 MPa steel plate, and a 780 MPa high strength steel plate.
- the clearance between the punch and the die is 15% t (% t indicates the ratio of the clearance width to the plate thickness of the workpiece.
- the plate thickness of the workpiece is t (mm).
- the clearance 0.15 ⁇ t (mm)), and continuous drilling of 20,000 shots at the maximum was performed.
- FIG. 5 is a bar graph showing the number of shots until the tool edge is broken.
- a mild steel plate 270 MPa steel plate
- a 590 MPa steel plate was used as the work material
- the tool edge was not damaged under any of the round tool conditions (in FIG. 5).
- the arrow indicates that there was no damage after 20,000 shots (the same applies to the bar graphs in the other figures).
- the tool edge was damaged in the case where the tool edge was an acute angle, the case of R0.01 mm, and the case of R0.04 mm. In the case of R0.05 mm to R1.00 mm, the tool edge was not damaged.
- the Vickers hardness of the used tool was 653 Hv
- the Vickers hardness of the mild steel plate was 82 Hv
- the Vickers hardness of the 590 MPa steel plate was 184 Hv
- the Vickers hardness of the 780 MPa high strength steel plate was 245 Hv.
- the correspondence relationship between each steel plate and the Vickers hardness value is the same in other experiments described in this embodiment.
- the roundness is 0.05 mm or more as compared with the above cases (1) to (3) where the radius is 0.04 mm or less.
- cases (7) to (7) a significant increase in tool life was confirmed. Naturally, no excessive burrs due to sudden chipping of the tool edge occurred.
- the amount of plastic deformation can be suppressed by setting the radius of rounding to 0.05 mm or more. Therefore, it was confirmed that it is effective to estimate the lower limit value Rmin of the roundness imparted to the cutting edge based on the above formula 1.
- the upper limit value Rmax of the roundness of the tool edge was examined. If the roundness of the tool edge is too large as necessary, the height of the burr generated on the workpiece after shearing tends to be higher than allowable, so it is based on the roundness corresponding to the allowable burr height.
- the upper limit was determined. Specifically, in each of the cases (1) to (7), shearing was performed, and the burr height was determined for each predetermined number of shots.
- FIGS. 6A to 6C are graphs showing how the burr height in the hole formed by continuous drilling changes with the number of shots.
- FIG. 6A is a graph when a mild steel plate is used as a workpiece.
- FIG. 6B is a graph when a 590 MPa steel plate is used as a workpiece.
- FIG. 6C is a graph when a 780 MPa high-tensile steel plate is used as a workpiece. Of these workpieces, the present invention targets the 780 MPa high-tensile steel plate shown in FIG. 6C, and FIGS. 6A and 6B are shown for reference.
- the burr height is obtained through all the shot numbers except for the case where the tool edge is rounded with an acute angle or R0.01 mm.
- R0.01 mm was 0.2 mm or more.
- the burr height when a 780 MPa high-tensile steel plate was used as the work material, the burr height could be suppressed to 0.2 mm or less when the roundness of the tool edge was R0.5 mm or less. It was confirmed that the burr height rapidly increased when the roundness of the cutting edge was R 0.6 mm or more. More specifically, as shown in FIG. 6C, in the cases (6) to (7) in which the radius of curvature of the roundness is 0.6 mm or more, the burr height cannot be suppressed within the allowable range. In the cases of (2) to (5) where the radius of curvature is 0.5 mm or less, it was confirmed that the burr height can be suppressed within an allowable range.
- a high-strength steel or super-high-strength steel of 780 MPa class or higher is used as a work material, the Vickers hardness Hw of the work material, the Vickers hardness Ht of the tool, and between tools (between the punch and die In the case where the combination of the clearance c) was changed, an experiment was performed to determine the tendency of the maximum value Rmax of the radius of curvature of the roundness of the tool edge that can suppress the burr height.
- Rmax was calculated
- Rmax (0.9 + 0.2e -0.08c ) (-9.1856x 4 + 25.17x 3 -24.95x 2 + 11.054x-1.5824) .
- the unit of Rmax is (mm), and the hardness ratio x, clearance c, and the like are the same as those described in (Equation 1) above.
- the generated burr height is so small as to be allowed, and the tool blade tip is not suddenly damaged. It was found that the radius of curvature of the tool edge needs to be 0.05 mm to 0.5 mm. Further, when the object of the workpiece is a wider range including the super high-strength steel, the generated burr is allowed by setting the radius of curvature of the tool edge within the range of Rmin to Rmax. It was found that the tool edge was minor and no sudden chipping of the tool edge occurred.
- a shearing component that includes the punch 110 and the die 120, and mass-produces the shearing component by continuously performing shearing on a plurality of high-tensile steel plates having a maximum tensile strength of 780 MPa, which is the workpiece 1.
- the tool cutting edges 113 and 123 of both the punch 110 and the die 120 are preferably rounded to a radius of 0.05 mm to 0.5 mm at the start of a series of shearing processes.
- the radii of the tool cutting edges 113 and 123 be in the range of Rmin to Rmax.
- the shearing component manufacturing apparatus 100 including the punch 110 and the die 120 having the above-described configuration, a large number of high-tensile steel sheets having a maximum tensile strength of 780 MPa class, or ultra-high-tensile steels having a maximum tensile strength higher than that.
- shearing is performed continuously on a single sheet, it is possible to mass-produce sheared parts without causing burrs to occur to an acceptable level and without sudden breakage of the tool cutting edges 113 and 123. become.
- the case of chamfering C on the tool edge was also examined. Specifically, assuming that the Vickers hardness Hw of the workpiece, the Vickers hardness Ht of the tool, and the clearance c between the tools (between the punch and the die) are assumed to be a certain value, Simulation calculation. The result of the simulation calculation was color-coded according to the amount of plastic deformation as in FIG. 4 described above (not shown because it is similar to FIG. 4). Then, if the maximum value of the plastic deformation amount exceeds the allowable range, the chamfer dimension C at the tool edge is increased and recalculated, and the chamfer dimension C that satisfies the condition that the plastic deformation amount is within the allowable range is obtained. . The obtained chamfer dimension C was set as the minimum value ⁇ min in the above setting.
- a white arrow a indicates the moving direction of the punch 110
- a symbol l indicates a tangent to the tip surface 111 (first tip surface) of the punch 110
- a symbol 112 indicates a chamfering that is a first receding surface
- a symbol 114 indicates a side surface (outer surface).
- the inclination angle ⁇ with respect to the tangent l of the front end surface 111 is set to 45 °.
- the ⁇ min was determined as the following (formula 3), which is a function of the hardness ratio x and the clearance c between the tools.
- ⁇ min 0.0222e 2.0833x (0.9 + 0.1e -0.07c ). . . (Formula 3)
- e is the base of the natural logarithm.
- C (mm) indicates a clearance between the inner surface 124 of the die 120 and the outer surface 114 of the punch 110.
- X represents a dimensionless number obtained by dividing the Vickers hardness Hw (MPa) of the workpiece 1 by the Vickers hardness Ht (MPa) of the tool, and 0.3 for the above-described reason.
- ⁇ x ⁇ 1.0.
- x is the hardness ratio obtained by dividing the Vickers hardness of the workpiece 1 by the Vickers hardness of the punch 110 in the case of the punch 110, and the Vickers hardness of the die 120 in the case of the die 120. It is a hardness ratio obtained by dividing the Vickers hardness of the workpiece 1.
- the work material three types of steel, a mild steel plate having a tensile strength of 270 MPa, a 590 MPa steel plate, and a 780 MPa high strength steel plate, are used, and the clearance between the punch and the die is 15% t (% t is the clearance relative to the plate thickness of the work material) In the case of this example, the clearance is 0.15 ⁇ t (mm) when the thickness of the workpiece is t (mm). Drilling was performed.
- FIG. 8 is a bar graph showing the number of shots until the tool edge is broken.
- a mild steel plate or a 590 MPa steel plate was used as the work material, the tool edge was not damaged under any of the chamfering conditions.
- a 780 MPa grade steel tensile steel plate was used as the work material, tool breakage occurred in the case where the tool edge was an acute angle, the case of C0.01 mm, and the case of C0.04 mm, whereas in the example of the present invention, In a case of C0.05 mm to C1.00 mm, the tool edge was not damaged.
- the upper limit value ⁇ max of the chamfer dimension of the tool edge was examined.
- the chamfer dimension of the tool edge is too large than necessary, the height dimension of the burr generated on the workpiece after shearing tends to be higher than allowable, so the chamfer dimension corresponding to the allowable burr height.
- the upper limit was determined. Specifically, in each of the cases (8) to (14), shearing was performed, and the burr height was determined for each predetermined number of shots.
- FIGS. 9A to 9C are graphs showing how the burr height at the hole formed by continuous drilling changes with the number of shots.
- FIG. 9A is a graph when a mild steel plate is used as a workpiece.
- FIG. 9B is a graph in the case of using a 590 MPa steel plate as a workpiece.
- FIG. 9C is a graph when a 780 MPa high-tensile steel plate is used as a workpiece. Of these workpieces, the present invention targets the case of the 780 MPa high-tensile steel plate shown in FIG. 9C, and FIGS. 9A and 9B are shown for reference.
- the burr height is 0 through all the shot numbers except for the case where the tool blade edge is an acute angle or C0.01 mm. .2 mm or more.
- the chamfer dimension of the tool blade edge was C0.50 mm or less, and the burr height was suppressed to 0.2 mm or less. It was confirmed that the burr height increased rapidly when the chamfering of the tool edge was C0.60 mm or more. More specifically, as shown in FIG. 9C, in the case of (13) to (14) where the chamfer dimension is C0.60 mm or more, the burr height cannot be suppressed within the allowable range, but the chamfer dimension is C0. In the cases of (9) to (12) which are .50 mm or less, it was confirmed that the burr height can be suppressed within an allowable range.
- ⁇ max was determined as the following (formula 4), which is a function of the hardness ratio x and the clearance c between the tools.
- ⁇ max (0.9 + 0.1e -0.07c ) (-0.3274x 2 + 0.9768x-0.1457) . .
- the unit of ⁇ max is (mm), and the hardness ratio x, clearance c, and the like are the same as those described in (Equation 3) above.
- the burrs that occur are minor enough to be allowed and sudden breakage of the tool edge. Therefore, the chamfer dimension of the tool edge to prevent the occurrence of C is required to be C0.05 mm to C0.5 mm.
- the chamfer dimension of the tool edge is within the range of the ⁇ min to the ⁇ max, and the generated burr is allowed. The tool edge is required to be as small as possible and not to cause a sudden chipping of the tool edge.
- a shearing component that includes the punch 110 and the die 120, and mass-produces the shearing component by continuously performing shearing on a plurality of high-tensile steel plates having a maximum tensile strength of 780 MPa, which is the workpiece 1.
- the tool cutting edges 113 and 123 of both the punch 110 and the die 120 are preferably chamfered to C0.05 mm to C0.5 mm at the start of a series of shearing processes.
- the chamfer dimensions of the tool cutting edges 113 and 123 are in the range of ⁇ min to ⁇ max.
- a high-tensile steel plate having a maximum tensile strength of 780 MPa, which is the workpiece 1, or a super-high-strength steel having a maximum tensile strength higher than that is continuously sheared.
- the shear processing component manufacturing method and manufacturing apparatus has a Vickers hardness of 0.3 times or more and less than 1.0 times, whichever is lower of the Vickers hardness of the punch 110 and the Vickers hardness of the die 120.
- a method of manufacturing a plurality of sheared parts by performing a plurality of shearing processes on the workpiece 1 using the punch 110 and the die 120, wherein the workpiece 120 is provided on the die 120. 1 is fixed, and the punching process of the workpiece 1 is performed by relatively bringing the punch 110 and the die 120 close to each other.
- the shearing process is performed using the die 120 including the second cutting edge 123 including the receding surface 122.
- the first receding surface 112 when viewed in a cross section perpendicular to the first tip surface 111 is equal to or greater than Rmin (mm) defined by the following equation 1 and defined by the following equation 2.
- Rmin (mm) defined by the following equation 1
- ⁇ min (mm) defined by the following equation 2.
- Chamfering having a width dimension equal to or less than ⁇ max (mm) as defined;
- the second receding surface 122 when viewed in a cross section perpendicular to the second tip surface 121 is Rmin ( mm) and a curved surface having a curvature equal to or less than Rmax (mm) defined by the following formula 2, or an inclination angle of 45 ° with respect to the tangent to the second tip surface 121 and ⁇ min ( mm) and a chamfer having a width dimension not more than ⁇ max (mm
- one or both of the first receding surface 112 and the second receding surface 122 is a curved surface having a curvature of 0.05 mm or more and 0.5 mm or less; Either one or both of the receding surface 112 and the second receding surface 122 may be chamfered with C0.05 mm or more and C0.5 mm or less.
- the workpiece 1 is made of high-strength steel or ultra-high-strength steel having a Vickers hardness of 0.3 times or more of the Vickers hardness of the tool, It is possible to manufacture a sheared part at low cost without causing a sudden chipping of the cutting edge.
- the surface decarburization process, the plating process, and the solid lubrication process are performed on the surface of the workpiece 1 before the shearing process, regardless of whether the tool edge is rounded or chamfered. Any one of the above is preferably applied.
- the inventors also investigated steel sheets with different surface treatments. The experimental results are shown in FIG. FIG. 10 shows the transition of the burr height in the workpiece for each number of shots when a continuous drilling process is performed on the workpiece using a tool with a radius of curvature of 0.05 mm at the tool edge. It is a graph. And the case where the work material which gave hot-dip galvanization is used as a work material, and the case where an unprocessed work material is used are compared.
- the burr height can be halved when hot dip galvanizing is applied to the workpiece as compared with the case of no treatment.
- the hot dip galvanized layer relaxes the impact force applied to the tool edge, and as a result, the wear of the tool edge (increasing the radius of curvature of the roundness) can be suppressed. It was thought that the increase in burr height was suppressed.
- the surface treatment is not limited to hot dip galvanization.
- the plastic flow of the material in contact with the other parts can be further suppressed when the workpiece is sheared. Thereby, the burr height can be further reduced.
- FIG. 11 is an enlarged cross-sectional view of the tool cutting edges of the punch 110 and the die 120 in the sheared component manufacturing apparatus according to the present embodiment.
- the tool is polished only by the outer surface 114 and the through hole 124 (hereinafter also referred to as the inner surface 124) of the punch 110 and the die 120, respectively.
- the friction coefficient of the portions 119 and 129 excluding the outer side surface 114 and the inner side surface 124 is set to about 0.2
- the friction coefficient of the outer side surface 114 and the inner side surface 124 is set to about 0.1. it can. As a result, the burr height can be further reduced.
- the punch 110 and the die 120 are manufactured in advance with soft tool steel
- a method of performing nitriding treatment or coating treatment only on the side surface 114 can also be used.
- the friction coefficient of the portions 119 and 129 other than the outer side surface 114 and the inner side surface 124 can be relatively increased by a surface treatment that provides a coating that increases the friction coefficient and fine irregularities.
- the friction coefficient is measured by a test (a test generally used as a method for measuring the friction coefficient) in which a tool is pressed against and slides on the steel plate to be processed 1.
- the value is defined as a value obtained by dividing the sliding resistance by the pressing pressure.
- a test material for the sliding test in order to simulate the sliding at the time of shearing, the tool itself or a part of the tool is cut out and used so that the area of the contact portion is 1.0 mm 2 or more. be able to. It is desirable that the pressing pressure in the sliding test is about 50 MPa to 300 MPa, and the sliding speed is about 10 mm / second to 400 mm / second.
- a well-known and conventional tool steel can be used as this type of tool steel.
- high speed steel such as SKH51, die steel such as SKD11, or super steel of about V40.
- a tool durability test was conducted for drilling with a diameter of 10 mm.
- a 780 MPa high-tensile steel plate is used as the workpiece, and the clearance c between the punch 110 and the die 120 is 15% t (% t indicates the ratio of the clearance width to the plate thickness of the workpiece.
- the clearance is 0.15 ⁇ t (mm).
- the cutting edge shape of both the punch 110 and the die 120 was made into three cases of acute angle, R0.5 mm, and C0.5 mm, and the entire tool was polished for R0.5 mm and C0.5 mm.
- Two types of tools were prepared: conditions and conditions where only the tool side was polished. At this time, the coefficient of friction measured by the sliding test was about 0.1 in the portion where polishing was applied, and 0.25 in the portion where polishing was not applied.
- FIG. 12 is a bar graph showing the number of shots until the tool breaks. As shown in FIG. 12, tool breakage occurred when the tool edge was an acute angle. However, under the conditions of R0.05 mm and C0.05 mm according to the present invention, the tool breakage occurred regardless of the polished state of the tool. There wasn't.
- FIG. 13 shows, as a graph, the transition of the burr height in the hole after drilling according to the number of shots.
- the burr height was 0.2 mm or less for any tool, but in the case of a tool that was polished to polish only the side surface, the tool was polished on the entire surface. The burr height was clearly lower than that.
- the tool is divided into the side portion and the other portion of the tool.
- the punch 110 includes the first tip surface 111 facing the workpiece 1 and the tool cutting edge 113.
- the first retreating surface 112 (rounded R portion) and the outer surface 114 the first condition in which the first retreating surface 112 has the highest frictional resistance;
- the second of the die 120 facing the workpiece 1 Of the tip surface 121, the second receding surface 122 (the rounded R portion) including the tool cutting edge 123, and the inner surface 124, at least one of the second condition in which the second receding surface 122 has the highest frictional resistance; It is desirable to satisfy. More preferably, both the first condition and the second condition are satisfied.
- the frictional resistance is higher in the order of the first receding surface 112 (rounded R portion), followed by the first tip surface 111, and then the outer surface 114; and the second receding surface 122 (rounded). It is most preferable that the frictional resistance is high in the order of the attached R portion), the second tip surface 121, and then the inner surface 124.
- the burr height is suppressed to 0.04 mm in the case where the tool edge R portion, the tip surface, and the side surface are in order. It was confirmed that
- Table 6 shows the experimental results showing the case where the tool edge is rounded, but the same can be said for the case where the tool edge is chamfered. That is, among the first tip surface 111 of the punch 110 facing the workpiece 1, the first receding surface 112 having a chamfered portion, and the outer surface 114, the third receding surface 112 has the highest frictional resistance.
- the second tip surface 121 of the die 120 facing the workpiece 1, the second receding surface 122 having a chamfered portion, and the inner side surface 124, the fourth receding surface 122 has the highest frictional resistance. It is desirable to satisfy at least one of the conditions; More preferably, both the third condition and the fourth condition are satisfied.
- the frictional resistance increases in the order of the first receding surface 112, then the first tip surface 111, and then the outer surface 114; and the second receding surface 122, then the second tip surface 121, and further. It is most preferable that the friction resistance is higher in the order of the inner side surface 124.
- the burr height can be suppressed to 0.04 mm in the case of the order of the chamfered portion, the tip surface, and the side surface. was confirmed.
- the following (D) may be further adopted.
- (D) In the aspect described in any one of (A) to (C) above, among the first tip surface 111, the first receding surface 112, and the outer surface 114 of the punch 110, the first The first condition that the frictional resistance of the first receding surface 112 is the highest, and the frictional resistance of the second receding surface 122 among the second tip surface 121, the second receding surface 122, and the inner side surface 124 of the die 120. Satisfies at least one of the second condition with the highest value.
- the following (E) may be adopted.
- the tool life can be further extended as compared with the case of no treatment.
- the workpiece 1 is preliminarily subjected to any one of surface decarburization treatment, plating treatment, and solid lubrication treatment. deep.
- the present invention is not limited to the configuration in which both the tool cutting edge 113 of the punch 110 and the tool cutting edge 123 of the die 120 are rounded, and the configuration in which chamfering is applied to both the tool cutting edge 113 of the punch 110 and the tool cutting edge 123 of the die 120.
- the tool edge of the punch 110 may be rounded and the tool edge of the die 120 may be chamfered, or the tool edge of the punch 110 may be chamfered and the tool edge of the die 120 may be rounded.
- the shapes of the tool cutting edge of the punch 110 and the tool cutting edge of the die 120 are not limited to the above-described forms, and for example, modifications illustrated in FIGS. 14 and 15 can also be employed. That is, in the modified example of FIG. 14, a chamfer C is formed on the tool cutting edge 113 (123), and between the chamfer C and the tool tip surface 111 (121), and between the chamfer C and the tool side surface 114 (124). ) Are provided with roundness R ′. Therefore, there is no corner from the tool tip surface 111 (121) through the chamfer C to the tool side surface 114 (124), and it is smoothly formed. Note that the curvatures of the two rounds R ′ may be the same or different from each other. Further, as the chamfer width dimension ⁇ ′, it is preferable that ⁇ min ⁇ ′ ⁇ max is satisfied based on the above (Expression 3) and (Expression 4).
- roundness R ′ is provided on both sides of the chamfer C.
- a roundness R ′ may be provided.
- a chamfer C is formed on the tool cutting edge 113 (123), and there is an angle E between the chamfer C and the tool tip surface 111 (121), and the chamfer C and the tool side surface 111 (121) It is preferable to provide a roundness R ′ between them.
- the chamfer width dimension ⁇ ′ it is preferable that ⁇ min ⁇ ′ ⁇ max is satisfied based on the above (Expression 3) and (Expression 4).
- a roundness R ′ may be provided only between the chamfer C and the tool tip surface 111 (121) (not shown).
- a chamfer C is formed on the tool cutting edge 113 (123)
- a roundness R ′ is provided between the chamfer C and the tool tip surface 111 (121)
- the chamfer C and the tool side surface 111 (121) are provided.
- An angle E is preferably provided between the two.
- the workpiece is made of high-strength steel or ultra-high-strength steel having a Vickers hardness of 0.3 times or more of the Vickers hardness of the tool, it is low without causing sudden chipping of the cutting edge. It is possible to manufacture sheared parts at a low cost.
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Abstract
Description
本願は、2014年05月08日に、日本国に出願された特願2014-097044号に基づき優先権を主張し、その内容をここに援用する。
自動車や建設機械、さらには各種プラント等で用いられるせん断加工部品の製造に際しては、図16A及び図16Bに示すように、ダイ3上に被加工材1を載置した後に、パンチ2を図中の白抜き矢印の方向に押し込むことによって被加工材1を打ち抜く、せん断加工で製造されることが多い。
図17に示すように、せん断加工により形成された被加工材1のせん断加工面8は、被加工材1がパンチ2により押し込まれて形成されるダレ4と、パンチ2及びダイ3間のクリアランス内(以下、本明細書において特に断りなく「クリアランス」と表記した場合は、パンチ及びダイ間のクリアランスを意味する)に被加工材1が引き込まれて局所的に引き伸ばされて形成されるせん断面5と、パンチ2及びダイ3間のクリアランス内に引き込まれた被加工材1が破断して形成された破断面6と、被加工材1の裏面に生じるバリ7と、を含む。
なお、ここで言う「刃先の欠損」は、「刃先の摩耗」とは異なる現象である。すなわち、摩耗は、刃先の丸みが加工回数の増加とともに増していく現象であるのに対し、欠損は、刃先が割れにより欠けて無くなる現象である。
また、工具刃先の欠損に対しては、工具の締結部を柔軟なものとして、工具刃先が接触する際のショックを吸収及び緩和する方法や、例えば非特許文献2に開示されるようにパンチの刃先のみを丸めたり、面取りしたりする方法が知られている。
また、上記非特許文献2に記載されている、パンチのみに刃先の丸みを付ける方法では、ダイの刃先欠損を防止することができない。なお、軟鋼のせん断加工に際しては、被加工材でバリが発生するのを防ぐために、パンチ及びダイの双方の刃先を鋭角にする必要が有り、上記非特許文献2に記載のような丸みや面取りを刃先に付けるとしても、パンチ及びダイの何れか一方のみに限定しないとせん断工具としての機能を十分に果たせない。
上記実験結果よれば、被加工材のビッカース硬度が工具のビッカース硬度の0.3倍以上となる、高張力鋼や超高張力鋼において、工具損傷の発生頻度が急激に高まることがわかった。なお、表1の実験では、それぞれ鋭角の工具刃先を持つパンチ及びダイを用いて実験を行った。また、被加工材の板厚をtとした場合におけるパンチ及びダイ間のクリアランスを0.1×t~0.2×tの範囲で変更させたが結果に影響はなく、やはり、被加工材の硬度と工具の硬度との比率が支配的であることが確認された。
よって、従来では、高張力鋼や超高張力鋼からなる高強度の被加工材を工具刃先の欠損なしにせん断加工する手段が確立されていなかった。そのため、上述したような、工具刃先の欠損による過大なバリ7の発生を防ぐためには、金型を頻繁に交換せざるを得なかった。
(1)本発明の一態様に係るせん断加工部品の製造方法は、パンチのビッカース硬度及びダイのビッカース硬度の何れか低い方の0.3倍以上1.0倍未満のビッカース硬度を持つ被加工材に対して、前記パンチ及び前記ダイを用いて複数回のせん断加工を行うことにより、複数のせん断加工部品を製造する方法であって、前記ダイに前記被加工材を固定する工程と、前記パンチと前記ダイとを相対的に接近させて前記被加工材の打ち抜き加工を行う工程と、を含む前記せん断加工を複数回行い、これら一連のせん断加工の開始時に、前記被加工材に対向する第1先端面と、前記ダイへの接近方向を基準として前記第1先端面より後退した第1後退面を含む第1刃先と、を備える前記パンチと;前記被加工材に対向する第2先端面と、前記パンチへの接近方向を基準として前記第2先端面より後退した第2後退面を含む第2刃先と、を備える前記ダイと;を用いて前記せん断加工を行う。
Rmin=(0.9+0.2e-0.08c)(0.3571x2-0.2595x+0.0965) ...(式1)
Rmax=(0.9+0.2e-0.08c)(-9.1856x4+25.17x3-24.95x2+11.054x-1.5824) ...(式2)
αmin=0.0222e2.0833x (0.9+0.1e-0.07c) ...(式3)
αmax=(0.9+0.1e-0.07c)(-0.3274x2+0.9768x-0.1457) ...(式4)
ここで、eは自然対数の底であり、c(mm)は、前記ダイの内側面と前記パンチの外側面との間のクリアランスを示し、xは、前記パンチにあっては前記パンチのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であり、前記ダイにあっては前記ダイのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であって、なおかつ、0.3≦x<1.0を満たす。
Rmin=(0.9+0.2e-0.08c)(0.3571x2-0.2595x+0.0965) ...(式1)
Rmax=(0.9+0.2e-0.08c)(-9.1856x4+25.17x3-24.95x2+11.054x-1.5824) ...(式2)
αmin=0.0222e2.0833x (0.9+0.1e-0.07c) ...(式3)
αmax=(0.9+0.1e-0.07c)(-0.3274x2+0.9768x-0.1457) ...(式4)
ここで、eは自然対数の底であり、c(mm)は、前記ダイの内側面と前記パンチの外側面との間のクリアランスを示し、xは、前記パンチにあっては前記パンチのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であり、前記ダイにあっては前記ダイのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であって、なおかつ、0.3≦x<1.0を満たす。
図1に、本発明の一実施形態に係るせん断加工装置の要部を示す。同図に示すように、本実施形態におけるせん断加工部品の製造装置100は、被加工材1を上下より挟み込んで固定するダイ120及び板押え130と、ダイ120に対して相対的に接近して被加工材1を打ち抜くパンチ110と、を備えている。
せん断加工部品の製造装置100は、パンチ110のビッカース硬度及びダイ120のビッカース硬度の何れか低い方の0.3倍以上1.0倍未満のビッカース硬度を持つ高張力鋼板を被加工材1として、複数回のせん断加工を行うことにより、複数のせん断加工部品を製造する装置である。
ダイ120は、被加工材1が載置される台座であり、パンチ110の、同パンチ110の軸線に垂直な断面における外側面114に対して所定のクリアランスcを形成する内側面である貫通孔124が、前記パンチ110と同軸に形成されている。
板押え130は、ダイ120上に載置された被加工材1をダイ120との間に挟み込んで固定する工具であり、ダイ120と同様に、前記パンチ110と同軸の貫通孔131が形成されている。
図2A及び図2Bは、鋼板のせん断加工時におけるバリの発生状況を示す部分断面図である。図2Aは、引張強度が780MPa未満の軟鋼板を被加工材1Aとして用いる場合を示し、図2Bは、引張強度が780MPa以上の高張力鋼板を被加工材1として用いる場合を示している。
以上の試験結果より、せん断加工部のバリ高さが鋼板の硬度(又は引張強度)に応じて異なるのは、鋼板の延性が異なるためであることが推察された。
その結果について図3A~図3Cを用いて説明する。本実験では、引張強度780MPa以上の高張力鋼板からなる被加工材1を、それぞれが鋭角な工具刃先を持つパンチ300及びダイ310によりせん断加工した。
その結果、刃先301,311は、本来の位置よりも突出した突起となるが、さらにパンチ300をダイ310に近づけて図3Cの過程に至ると、刃先301は塑性流動による押圧力を受けてパンチ300の外側面にまで移動し、ついには欠損する。同様に、刃先311も塑性流動による押圧力を受けてダイ310の内側面まで移動し、そして欠損する。
続いて、パンチ300の外側面に押し出された刃先301は、今度は、パンチ300周囲の被加工材1との相対変移によるせん断力を受けて欠損する。同様に、ダイ310の内側面に押し出された刃先311も、ダイ310内の被加工材1との相対変移によるせん断力を受けて欠損する。
まず、工具刃先に丸みを付ける場合の曲率半径について検討した。具体的には、被加工材のビッカース硬度Hw、工具のビッカース硬度Ht、そして工具間(パンチ及びダイ間)のクリアランスcのそれぞれを設定した上で、工具刃先に生じる塑性変形量をシミュレーション計算した。シミュレーション計算結果の一例を、図4に示す。この図4の例では、塑性変形量の大きさを色分けしており、刃先最先端である符合Hの箇所において、塑性変形量が最大値になっている。この塑性変形量が許容範囲を超えるものであれば、工具刃先における丸みの曲率半径を大きくして再計算し、塑性変形量が前記許容範囲内となる条件を満たす丸みの最小曲率半径を求めた。そして、求まった丸みの最小曲率半径を、上記設定における丸み(R値)の最小値Rminとした。
上記のようなシミュレーション計算を、被加工材のビッカース硬度Hw、工具のビッカース硬度Ht、そして工具間のクリアランスcそれぞれの組み合わせを変えながら行った。その結果を下表2に示す。
Rmin=(0.9+0.2e-0.08c)(0.3571x2-0.2595x+0.0965) ..(式1)
ここで、Rminの単位は(mm)であり、eは自然対数の底である。
また、c(mm)は、工具間のクリアランスであり、穴空け工具の場合には、ダイの内側面とパンチの外側面との間のクリアランスを示す。
また、xは、被加工材のビッカース硬度Hw(MPa)を工具のビッカース硬度Ht(MPa)で除算した無次元数であるx=Hw/Htを示し、なおかつ、後述の理由により0.3≦x<1.0を満たす値となっている。例えば穴空け工具の場合、xは、パンチにあってはパンチのビッカース硬度で被加工材のビッカース硬度を除算した硬度比であり、ダイにあってはダイのビッカース硬度で被加工材のビッカース硬度を除算した硬度比である。
(1)鋭角とした場合と、
(2)半径0.01mmの丸みを付けた場合と、
(3)半径0.04mmの丸みを付けた場合と、
(4)半径0.05mmの丸みを付けた場合と、
(5)半径0.50mmの丸みを付けた場合と、
(6)半径0.60mmの丸みを付けた場合と、
(7)半径1.00mmの丸みを付けた場合と、
のそれぞれについて、直径10mmの穴空け加工を繰り返す工具耐久試験を行った。
図5に示すように、軟鋼板(270MPa鋼板)や590MPa鋼板を被加工材とした場合には、いずれの丸み寸法の工具条件であっても、工具刃先は破損しなかった(図5中の矢印は、2万ショット後でも破損がなかったことを示す。以下、他の図の棒グラフも同様である)。一方、780MPa高張力鋼板を被加工材とした場合には、工具刃先が鋭角のケースとR0.01mmのケースとR0.04mmのケースとにおいて工具刃先の破損が生じたのに対し、本発明例であるR0.05mm~R1.00mmのケースでは工具刃先の破損が生じなかった。なお、使用した工具のビッカース硬度は653Hv、軟鋼板のビッカース硬度は82Hv、590MPa鋼板のビッカース硬度は184Hv、780MPa高張力鋼板のビッカース硬度は245Hvであった。なお、各鋼板とビッカース硬度値との対応関係は、本実施形態に記載の他の実験においても同様である。
先に示した上記式1を求めたシミュレーション計算結果においても、丸みの半径を0.05mm以上にすることで塑性変形量が抑えられることが確認されている。したがって、上記式1に基づいて、刃先に付与する丸みの下限値Rminを推定することが有効であることが確認された。
工具刃先の丸み寸法が必要上に大きすぎると、せん断加工後の被加工材に生じるバリの高さ寸法が許容以上に高くなる傾向にあるので、許容できるバリ高さに対応する丸み寸法に基づいて上限値を定めることとした。具体的には、上記(1)~(7)それぞれのケースにおいて、せん断加工を行い、所定のショット数毎にバリ高さを求めた。
より具体的に言うと、図6Cに示すように、丸みの曲率半径が0.6mm以上である(6)~(7)の場合ではバリ高さを許容範囲内に抑えられないものの、丸みの曲率半径が0.5mm以下である(2)~(5)の場合においてはバリ高さを許容範囲内に抑えられることが確認された。
すなわち、高張力鋼や超高張力鋼を被加工材として、同被加工材のビッカース硬度Hw、工具のビッカース硬度Ht、そして工具間(パンチ及びダイ間)のクリアランスc、の組み合わせを複数設定した上で、それぞれのケースについて、連続穴空け加工を上限2万ショットとして行った。そして、各設定条件の下、バリ高さを0.2mm以下に抑えられた工具刃先の丸みの曲率半径の最大値を、前記Rmaxとして求めた。その結果を下表3に示す。
Rmax=(0.9+0.2e-0.08c)(-9.1856x4+25.17x3-24.95x2+11.054x-1.5824) ..(式2)
ここで、Rmaxの単位は(mm)であり、硬度比xやクリアランスc等については、上記(式1)において説明したものと同じである。
なお、パンチ及びダイ双方の工具刃先を、一連のせん断加工の開始時に、半径0.05mm~0.5mm、又は前記Rmin以上前記Rmax以下に丸めるための手段としては、NC加工機による研削等が例示される。
上記構成を持つパンチ110及びダイ120を備える、せん断加工部品の製造装置100によれば、最大引張強度が780MPa級である高張力鋼板、またはそれ以上の最大引張強度を持つ超高張力鋼を多数枚、連続してせん断加工を行った場合、発生するバリが許容される程度に軽微であってかつ工具刃先113,123の突発的な欠損を生じることなく、せん断加工部品を量産することが可能になる。
そして、塑性変形量の最大値が許容範囲を超えるものであれば、工具刃先における面取り寸法C大きくして再計算し、塑性変形量が前記許容範囲内となる条件を満たす面取り寸法Cを求めた。そして、求まった面取り寸法Cを、上記設定における最小値αminとした。
先端面111の接線lに対する傾斜角度θとしては45°を設定している。このθについても別途検討したところ、10°<θ<60°の範囲内であれば前記αminへの影響が少ないことが確認されている。したがって、変数を減らしてデータを取り扱いやすくするためにθ=45°に固定の下、被加工材のビッカース硬度Hw、工具のビッカース硬度Ht、そして工具間のクリアランスcそれぞれの組み合わせを変えながら上記シミュレーション計算を行った。その結果を下表4に示す。
ここで、eは自然対数の底である。
また、c(mm)は、前記ダイ120の内側面124と前記パンチ110の外側面114との間のクリアランスを示す。
また、xは、被加工材1のビッカース硬度Hw(MPa)を工具のビッカース硬度Ht(MPa)で除算した無次元数であるx=Hw/Htを示し、なおかつ、前述の理由により0.3≦x<1.0を満たす値となっている。例えば、穴空け工具の場合、xは、パンチ110にあってはパンチ110のビッカース硬度で被加工材1のビッカース硬度を除算した硬度比であり、ダイ120にあってはダイ120のビッカース硬度で被加工材1のビッカース硬度を除算した硬度比である。
(8)鋭角とした場合と、
(9)C0.01mmの面取りを付けた場合と、
(10)C0.04mmの面取りを付けた場合と、
(11)C0.05mmの面取りを付けた場合と、
(12)C0.50mmの面取りを付けた場合と、
(13)C0.60mmの面取りを付けた場合と、
(14)C1.00mmの面取りを付けた場合と、
のそれぞれについて、直径10mmの連続穴空け加工を対象として工具耐久試験を行った。
図8に示すように、軟鋼板や590MPa鋼板を被加工材とした場合には、いずれの面取り条件であっても工具刃先は破損しなかった。一方、780MPa級鋼張力鋼板を被加工材とした場合には、工具刃先が鋭角のケースとC0.01mmのケースとC0.04mmのケースとにおいて工具破損が生じたのに対し、本発明例であるC0.05mm~C1.00mmのケースでは、工具刃先の破損が生じなかった。
先に示した上記式3を求めたシミュレーション計算結果においても、面取りをC0.05mm以上にすることで塑性変形量が抑えられることが確認されている。したがって、上記式3に基づいて、工具刃先に付与する面取り寸法の下限値αminを推定することが有効であることが確認された。
すなわち、工具刃先の面取り寸法が必要以上に大きすぎると、せん断加工後の被加工材に生じるバリの高さ寸法が許容以上に高くなる傾向にあるので、許容できるバリ高さに対応する面取り寸法に基づいて上限値を定めることとした。具体的には、上記(8)~(14)それぞれのケースにおいて、せん断加工を行い、所定のショット数毎にバリ高さを求めた。
より具体的に言うと、図9Cに示すように、面取り寸法がC0.60mm以上である(13)~(14)の場合ではバリ高さを許容範囲内に抑えられないものの、面取り寸法がC0.50mm以下である(9)~(12)の場合においてはバリ高さを許容範囲内に抑えられることが確認された。
すなわち、高張力鋼や超高張力鋼を被加工材として、同被加工材のビッカース硬度Hw、工具のビッカース硬度Ht、そして工具間(パンチ及びダイ間)のクリアランスc、の組み合わせを複数設定した上で、それぞれのケースについて、連続穴空け加工を上限2万ショットとして行った。そして、各設定条件の下、バリ高さを0.2mm以下に抑えられた工具刃先の面取り寸法の最大値を、前記αmaxとして求めた。その結果を下表5に示す。
αmax=(0.9+0.1e-0.07c)(-0.3274x2+0.9768x-0.1457) ...(式4)
ここで、αmaxの単位は(mm)であり、硬度比xやクリアランスc等については、上記(式3)において説明したものと同じである。
なお、パンチ及びダイ双方の工具刃先を、一連のせん断加工の開始時に、C0.05mm~C0.5mm、又は前記αmin以上前記αmax以下に面取りするための手段としては、NC加工機による研削等が例示される。
このせん断加工部品の製造装置によれば、被加工材1である最大引張強度が780MPa級である高張力鋼板、またはそれ以上の最大引張強度を持つ超高張力鋼を多数枚、連続してせん断加工を行うことにより、発生するバリが許容される程度に軽微であってかつ工具刃先の突発的な欠損を生じることなく、せん断加工部品を量産することが可能になる。
(A)本実施形態に係るせん断加工部品の製造方法及び製造装置は、パンチ110のビッカース硬度及びダイ120のビッカース硬度の何れか低い方の0.3倍以上1.0倍未満のビッカース硬度を持つ被加工材1に対して、前記パンチ110及び前記ダイ120を用いて複数回のせん断加工を行うことにより、複数のせん断加工部品を製造する方法であって、前記ダイ120に前記被加工材1を固定する工程と、前記パンチ110と前記ダイ120とを相対的に接近させて前記被加工材1の打ち抜き加工を行う工程と、を含む前記せん断加工を複数回行い、これら一連のせん断加工の開始時に、前記被加工材1に対向する第1先端面111と、前記ダイ120への接近方向を基準として前記第1先端面111より後退した第1後退面112を含む第1刃先113と、を備える前記パンチ110と;前記被加工材1に対向する第2先端面121と、前記パンチ110への接近方向を基準として前記第2先端面121より後退した第2後退面122を含む第2刃先123と、を備える前記ダイ120と;を用いて前記せん断加工を行う。
Rmin=(0.9+0.2e-0.08c)(0.3571x2-0.2595x+0.0965) ...(式1)
Rmax=(0.9+0.2e-0.08c)(-9.1856x4+25.17x3-24.95x2+11.054x-1.5824) ...(式2)
αmin=0.0222e2.0833x (0.9+0.1e-0.07c) ...(式3)
αmax=(0.9+0.1e-0.07c)(-0.3274x2+0.9768x-0.1457) ...(式4)
ここで、eは自然対数の底であり、c(mm)は、前記ダイ120の内側面と前記パンチ110の外側面との間のクリアランスを示し、xは、前記パンチ110にあっては前記パンチ110のビッカース硬度で前記被加工材1のビッカース硬度を除算した硬度比であり、前記ダイ130にあっては前記ダイ130のビッカース硬度で前記被加工材1のビッカース硬度を除算した硬度比であって、なおかつ、0.3≦x<1.0を満たす。
本発明者らは、表面処理が異なる鋼板においても調査を行った。その実験結果を図10に示す。図10は、工具刃先に曲率半径0.05mmの丸みを設けた工具を用いて被加工材に連続穴空け加工を行った際の、被加工材におけるバリ高さの推移をショット数毎に示したグラフである。そして、被加工材として、溶融亜鉛メッキを施した被加工材を用いた場合と、無処理の被加工材を用いた場合とを比較している。この比較結果より明らかなように、被加工材に溶融亜鉛メッキを施した場合は無処理の場合に比べてバリ高さを半減できることが確認された。被加工材に溶融亜鉛メッキを施した場合、工具刃先に加わる衝撃力を溶融亜鉛メッキ層が緩和し、その結果、工具刃先の摩耗(丸みの曲率の大径化)を押えることができるので、バリ高さの増加を抑えられていると考えられた。
以上に示したように、例えば被加工材の表面に溶融亜鉛メッキを施していれば、無処理の場合に比べてさらにバリ高さを抑えられるとの結果が得られた。なお、表面処理としては溶融亜鉛メッキのみに限定されるものではない。
工具側面以外の部位の摩擦係数を相対的に高める手段としては、例えば、工具の磨きを、パンチ110及びダイ120それぞれの外側面114,貫通孔124(以下、内側面124とも言う)のみとすること(以下、「磨き分け」という)が例示される。磨き分けを用いた場合、例えば、外側面114,内側面124を除く部位119,129の摩擦係数を0.2程度、外側面114,内側面124の摩擦係数を0.1程度とすることができる。その結果、バリ高さをさらに低減することができる。
この際、摺動試験により測定した摩擦係数は、磨きをかけた部位において0.1程度となり、磨きをかけない部分においては0.25となった。
図12に示すように、工具刃先が鋭角である場合には工具破損が生じたが、本発明例であるR0.05mmとC0.05mmの条件では、工具の磨き状態に関わらず工具破損は生じなかった。
図13に示すように、いずれの工具であってもバリ高さは0.2mm以下であったが、側面のみに磨きをかける磨き分けを行った工具の場合は、全面を磨いた工具の場合よりも明らかにバリ高さが低くなった。
また、上記第1条件と上記第2条件との双方を満たすことがより好ましい。さらに言えば、第1後退面112(丸みを付けたR部)、続いて第1先端面111、さらに続いて外側面114、の順に摩擦抵抗が高く;なおかつ、第2後退面122(丸みを付けたR部)、続いて第2先端面121、さらに続いて内側面124、の順に摩擦抵抗が高いことが最も好ましい。
すなわち、パンチ110の、被加工材1に対向する第1先端面111、面取り部を有する第1後退面112、及び外側面114のうち、前記第1後退面112の摩擦抵抗が最も高い第3条件と;ダイ120の、被加工材1に対向する第2先端面121、面取り部を有する第2後退面122、及び内側面124のうち、第2後退面122の摩擦抵抗が最も高い第4条件と;の少なくとも一方を満たすことが望ましい。
また、上記第3条件と上記第4条件との双方を満たすことがより好ましい。さらに言えば、第1後退面112、続いて第1先端面111、さらに続いて外側面114、の順に摩擦抵抗が高く;なおかつ、第2後退面122、続いて第2先端面121、さらに続いて内側面124、の順に摩擦抵抗が高いことが最も好ましい。
(D)上記(A)~(C)の何れか一項に記載の態様において、前記パンチ110の、前記第1先端面111、前記第1後退面112、及び外側面114のうち、前記第1後退面112の摩擦抵抗が最も高い第1条件と、前記ダイ120の、前記第2先端面121、前記第2後退面122、及び内側面124のうち、前記第2後退面122の摩擦抵抗が最も高い第2条件と、の少なくとも一方を満たす。
(E)上記(A)~(D)の何れか一項に記載の態様において、前記被加工材1に、表面脱炭処理、メッキ処理、及び個体潤滑処理の何れか一つを予め施しておく。
すなわち、図14の変形例においては、工具刃先113(123)に面取りCが形成されるとともに、この面取りCと工具先端面111(121)との間、及び前記面取りCと工具側面114(124)との間、の双方に、丸みR’が設けられている。よって、工具先端面111(121)から面取りCを経て工具側面114(124)に至るまで角部が無く滑らかに形成されている。なお、上記2つの丸みR’の曲率は、互いに同じであっても良いし、または互いに異なってもよい。
また、面取りの幅寸法α’としては、上記(式3)及び(式4)に基づいて、αmin<α’<αmaxを満たすことが好ましい。
また、面取りの幅寸法α’としては、上記(式3)及び(式4)に基づいて、αmin<α’<αmaxを満たすことが好ましい。
さらに言えば、図15の変形例とは逆に、面取りCと工具先端面111(121)との間のみに丸みR’を設けてもよい(図示略)。この場合、工具刃先113(123)に面取りCが形成されるとともに、この面取りCと工具先端面111(121)との間に丸みR’を設けるとともに、前記面取りCと工具側面111(121)との間には角Eを設けることが好ましい。
110 パンチ
111 第1先端面
112 第1後退面
113 第1刃先
120 ダイ
121 第2先端面
122 第2後退面
123 第2刃先
Claims (9)
- パンチのビッカース硬度及びダイのビッカース硬度の何れか低い方の0.3倍以上1.0倍未満のビッカース硬度を持つ被加工材に対して、前記パンチ及び前記ダイを用いて複数回のせん断加工を行うことにより、複数のせん断加工部品を製造する方法であって、
前記ダイに前記被加工材を固定する工程と、
前記パンチと前記ダイとを相対的に接近させて前記被加工材の打ち抜き加工を行う工程と、
を含む前記せん断加工を複数回行い、
これら一連のせん断加工の開始時に、
前記被加工材に対向する第1先端面と、前記ダイへの接近方向を基準として前記第1先端面より後退した第1後退面を含む第1刃先と、を備える前記パンチと;
前記被加工材に対向する第2先端面と、前記パンチへの接近方向を基準として前記第2先端面より後退した第2後退面を含む第2刃先と、を備える前記ダイと;
を用いて前記せん断加工を行う
ことを特徴とするせん断加工部品の製造方法。 - 前記第1先端面に垂直な断面で見た場合の前記第1後退面が、
下式1で規定されるRmin(mm)以上かつ下式2で規定されるRmax(mm)以下の曲率を持つ曲面、
又は、前記第1先端面の接線に対して45°の傾斜角度と下式3で規定されるαmin(mm)以上かつ下式4で規定されるαmax(mm)以下の幅寸法とを有する面取りであり;
前記第2先端面に垂直な断面で見た場合の前記第2後退面が、
下式1で規定されるRmin(mm)以上かつ下式2で規定されるRmax(mm)以下の曲率を持つ曲面、
又は、前記第2先端面の接線に対して45°の傾斜角度と下式3で規定されるαmin(mm)以上かつ下式4で規定されるαmax(mm)以下の幅寸法とを有する面取りである;
ことを特徴とする請求項1に記載のせん断加工部品の製造方法。
Rmin=(0.9+0.2e-0.08c)(0.3571x2-0.2595x+0.0965) ...(式1)
Rmax=(0.9+0.2e-0.08c)(-9.1856x4+25.17x3-24.95x2+11.054x-1.5824) ...(式2)
αmin=0.0222e2.0833x (0.9+0.1e-0.07c) ...(式3)
αmax=(0.9+0.1e-0.07c)(-0.3274x2+0.9768x-0.1457) ...(式4)
ここで、
eは自然対数の底であり、
c(mm)は、前記ダイの内側面と前記パンチの外側面との間のクリアランスを示し、
xは、前記パンチにあっては前記パンチのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であり、前記ダイにあっては前記ダイのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であって、なおかつ、0.3≦x<1.0を満たす。 - 前記第1後退面及び前記第2後退面の何れか一方もしくは両方が、
0.05mm以上0.5mm以下の曲率を持つ曲面、または、
C0.05mm以上C0.5mm以下の面取りである
ことを特徴とする請求項2に記載のせん断加工部品の製造方法。 - 前記パンチの、前記第1先端面、前記第1後退面、及び外側面のうち、前記第1後退面の摩擦抵抗が最も高い第1条件と、
前記ダイの、前記第2先端面、前記第2後退面、及び内側面のうち、前記第2後退面の摩擦抵抗が最も高い第2条件と、
の少なくとも一方を満たすことを特徴とする請求項1~3の何れか一項に記載のせん断加工部品の製造方法。 - 前記被加工材に、表面脱炭処理、メッキ処理、及び個体潤滑処理の何れか一つが施されていることを特徴とする請求項1~4の何れか一項に記載のせん断加工部品の製造方法。
- パンチのビッカース硬度及びダイのビッカース硬度の何れか低い方の0.3倍以上1.0倍未満のビッカース硬度を持つ被加工材に対して、複数回のせん断加工を行うことにより、複数のせん断加工部品を製造する装置であって、
前記被加工材を固定するダイと、
前記ダイに対して相対的に接近させて前記被加工材を打ち抜くパンチと、
を備え、
前記パンチが、前記被加工材に対向する第1先端面と、前記ダイへの接近方向を基準として前記第1先端面より後退した第1後退面を含む第1刃先とを備え、
前記ダイが、前記被加工材に対向する第2先端面と、前記パンチへの接近方向を基準として前記第2先端面より後退した第2後退面を含む第2刃先とを備える
ことを特徴とするせん断加工部品の製造装置。 - 前記第1先端面に垂直な断面で見た場合の前記第1後退面が、
下式1で規定されるRmin(mm)以上かつ下式2で規定されるRmax(mm)以下の曲率を持つ曲面、
又は、前記第1先端面の接線に対して45°の傾斜角度と下式3で規定されるαmin(mm)以上かつ下式4で規定されるαmax(mm)以下の幅寸法とを有する面取りであり;
前記第2先端面に垂直な断面で見た場合の前記第2後退面が、
下式1で規定されるRmin(mm)以上かつ下式2で規定されるRmax(mm)以下の曲率を持つ曲面、
又は、前記第2先端面の接線に対して45°の傾斜角度と下式3で規定されるαmin(mm)以上かつ下式4で規定されるαmax(mm)以下の幅寸法とを有する面取りである;
ことを特徴とする請求項6に記載のせん断加工部品の製造装置。
Rmin=(0.9+0.2e-0.08c)(0.3571x2-0.2595x+0.0965) ...(式1)
Rmax=(0.9+0.2e-0.08c)(-9.1856x4+25.17x3-24.95x2+11.054x-1.5824) ...(式2)
αmin=0.0222e2.0833x (0.9+0.1e-0.07c) ...(式3)
αmax=(0.9+0.1e-0.07c)(-0.3274x2+0.9768x-0.1457) ...(式4)
ここで、
eは自然対数の底であり、
c(mm)は、前記ダイの内側面と前記パンチの外側面との間のクリアランスを示し、
xは、前記パンチにあっては前記パンチのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であり、前記ダイにあっては前記ダイのビッカース硬度で前記被加工材のビッカース硬度を除算した硬度比であって、なおかつ、0.3≦x<1.0を満たす。 - 前記第1後退面及び前記第2後退面の何れか一方もしくは両方が、
0.05mm以上0.5mm以下の曲率を持つ曲面、または、
C0.05mm以上C0.5mm以下の面取りである
ことを特徴とする請求項7に記載のせん断加工部品の製造装置。 - 前記パンチの、前記第1先端面、前記第1後退面、及び外側面のうち、前記第1後退面の摩擦抵抗が最も高い第1条件と、
前記ダイの、前記第2先端面、前記第2後退面、及び内側面のうち、前記第2後退面の摩擦抵抗が最も高い第2条件と、
の少なくとも一方を満たすことを特徴とする請求項6~8の何れか一項に記載のせん断加工部品の製造装置。
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WO2020196701A1 (ja) | 2019-03-26 | 2020-10-01 | 日本製鉄株式会社 | 鋼板及び部材 |
JP2021006353A (ja) * | 2019-06-28 | 2021-01-21 | 本田技研工業株式会社 | 部材の打ち抜き加工方法およびダイのチャンファの形状設定方法 |
JP7129048B1 (ja) | 2022-01-28 | 2022-09-01 | 株式会社小松精機工作所 | アモルファス合金箔のせん断加工法 |
WO2023148899A1 (ja) * | 2022-02-03 | 2023-08-10 | 日本製鉄株式会社 | 鋼材、自動車部品、せん断加工装置及び鋼材の製造方法 |
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