WO2016117364A1 - 機械部品の製造方法及び機械部品 - Google Patents
機械部品の製造方法及び機械部品 Download PDFInfo
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- WO2016117364A1 WO2016117364A1 PCT/JP2016/050320 JP2016050320W WO2016117364A1 WO 2016117364 A1 WO2016117364 A1 WO 2016117364A1 JP 2016050320 W JP2016050320 W JP 2016050320W WO 2016117364 A1 WO2016117364 A1 WO 2016117364A1
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Classifications
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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
- B21K1/28—Making machine elements wheels; discs
- B21K1/30—Making machine elements wheels; discs with gear-teeth
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- 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
- B21D22/30—Deep-drawing to finish articles formed by deep-drawing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/26—Making other particular articles wheels or the like
- B21D53/28—Making other particular articles wheels or the like gear wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/12—Forming profiles on internal or external surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/002—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating specially adapted for particular articles or work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
-
- 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
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/17—Toothed wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/008—Gears
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P2700/00—Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
- B23P2700/50—Other automobile vehicle parts, i.e. manufactured in assembly lines
-
- 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
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/17—Toothed wheels
- F16H2055/176—Ring gears with inner teeth
-
- 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
- F16H—GEARING
- F16H41/00—Rotary fluid gearing of the hydrokinetic type
- F16H41/24—Details
Definitions
- the present invention relates to a method of manufacturing a machine part and a machine part.
- This application claims priority based on Japanese Patent Application No. 2015-7912 filed in Japan on January 19, 2015 and Japanese Patent Application No. 2015-124050 filed in Japan on June 19, 2015. The contents thereof are incorporated herein.
- a metal mechanical part for example, a drive plate and a ring gear, which are components of a vehicle automatic transmission
- the thickness of the ring gear is larger than the thickness of the drive plate in order to ensure the strength of the teeth of the ring gear. It has become. For this reason, it is common to manufacture a single tooth profile component having both structures by separately manufacturing a drive plate and a ring gear and then welding the ring gear to the drive plate.
- a method of manufacturing a single tooth profile component having both a drive plate and a ring gear structure from a single material is also known.
- a single material for example, a circular metal plate
- a tooth-shaped mold is formed to form a tooth profile (a part corresponding to the ring gear) along the circumferential direction of the wall while increasing the wall thickness.
- the target thickness differs greatly between the tooth profile part (ring gear part) and the other disk-shaped part (drive plate part).
- the thickness of the drive plate portion may be the same as the plate thickness of the material, but the thickness of the tooth profile portion is required to be several times the plate thickness of the material in order to ensure strength.
- the thickness of a tooth profile part refers to the length of the tooth profile part in the radial direction (direction orthogonal to the plate
- cold forging has attracted attention as a method of manufacturing a machine part that requires high dimensional accuracy and strength, such as a tooth profile part for an automatic transmission, from a single material.
- Cold forging has advantages such as high-precision and high-strength machine parts, lower manufacturing costs, and higher yield than hot forging. Therefore, if we can develop a technology that can produce a machine part with a target thickness that differs greatly depending on the part from a single material by forging, the combination of that technology and cold forging will provide a quality advantage for the machine part ( It is possible to provide an ideal technique that can maximize the advantages of high precision and high strength and advantages in the manufacturing process (low cost and high yield).
- the present invention has been made in view of the above circumstances, and a machine part manufacturing method capable of manufacturing machine parts having greatly different target thicknesses depending on the part from a single material by forging, and the manufacturing method thereof
- the object is to provide manufactured machine parts.
- the present invention employs the following means in order to solve the above problems and achieve the object.
- the method of manufacturing a mechanical component according to one aspect of the present invention has a structure in which a plurality of layers having a thickness corresponding to the plate thickness of the material are overlapped by performing bending on the end portion of the material.
- the processed part having a structure in which two or three layers overlap each other may be formed on the material.
- the first step performs the bending process on the end portion of the material, thereby increasing the thickness of the material.
- a pre-bending molding step for forming a pre-bending molded part in which parts having a corresponding thickness are continuously formed in a zigzag shape; and an external force applied to the pre-bending molded part so that the parts of the pre-bending molded part overlap each other.
- a bending process for forming the part to be processed having a structure in which a plurality of the portions overlap as the layer.
- the first step applies a pressing force to the workpiece from the thickness direction of the material.
- the length of the processed part in the thickness direction of the layer is defined as the thickness of the processed part, and the thickness before the thickness increasing step
- the thickness Tcl is obtained by dividing the thickness Tcl by the thickness T0 in the thickness increasing process.
- the thickness increase amount of the workpiece may be controlled so that the thickness increase rate Tra to be satisfied satisfies the following conditional expression (1). 1.0 ⁇ Tra ⁇ 1.5 (1)
- the material has a convex portion and a concave portion provided on a surface of the material, and the first step Then, the bending process may be performed so that the convex part and the concave part mesh with each other at the boundary surface between the layers of the processed part.
- the second step is to place the material on which the workpiece is formed on a die; A portion of the material excluding the processed portion is sandwiched between the lower surface of the first punch and the die in a state where the side surface is in contact with the outer end portion of the processed portion; By moving the second punch having the direction of the material along the thickness direction of the material toward the die, the shaft pushing protrusion is pushed into the inner end portion of the workpiece and the workpiece is pushed. Crushing and pressing the layers of the processed part together by the plastic deformation Reluctant, the shape of the portion to be processed may be changed to the target shape.
- a mechanical component according to an aspect of the present invention is a mechanical component manufactured by the method for manufacturing a mechanical component according to any one of (1) to (7).
- a mechanical component includes a flat first portion; provided at an end of the first portion, and protrudes from the surface of the first portion in the plate thickness direction of the first portion. And defining the length of the second part in the direction perpendicular to the thickness direction of the first part as the thickness of the second part, the thickness of the second part is: When the second part is viewed in a cross section that is larger than the thickness of the first part and includes the thickness direction of the first part and the thickness direction of the second part, an interlayer boundary line is formed in the second part. Exists.
- the thickness of the processed portion formed in the material in the manufacturing process (the length of the processed portion in the direction orthogonal to the plate thickness direction of the material) is determined as the material. Therefore, it is possible to manufacture a machine part having a target thickness greatly different depending on a part from a single material by forging.
- FIG. 13 is a cross-sectional view of the pressing apparatus shown in FIG. It is explanatory drawing of the tooth formation process in the manufacturing method of the machine component which concerns on 6th Embodiment. It is explanatory drawing of the tooth formation process in the manufacturing method of the machine component which concerns on 6th Embodiment. It is explanatory drawing of the tooth formation process in the manufacturing method of the machine component which concerns on 6th Embodiment.
- a tooth profile component for example, a tooth profile component having both a drive plate and a ring gear structure
- a method for manufacturing by forging will be exemplified.
- the tooth profile part for an automatic transmission as described above is one of mechanical parts whose target thickness varies greatly depending on the part.
- FIG. 1 is an explanatory view of a vertical wall portion forming step (double folding forming step).
- a metal disc for example, a steel plate having a circular shape
- 1, 2 and 4 to 9 show the cross-sectional shape of one side portion of the material 11 from the central axis 1 of the material 11.
- the outer peripheral portion of the disk-shaped material 11 shown in FIG. 1A is bent 90 degrees into an L shape by drawing, as shown in FIG.
- the molded product 11A having the cup bottom 15 and the annular vertical wall 12 is formed.
- a molded product 11B having the portion 13 is molded.
- the two outer peripheral portions 13 are bent by 90 degrees in the direction opposite to the conventional bending direction, starting from the end 13a of the outer peripheral portion 13.
- a molded product 11C having the stacked vertical wall portions 14 is molded.
- the fact that the folding direction is the same direction means that the folding is the same in the clockwise direction or the counterclockwise direction with respect to the bending base point. Further, the fact that the folding direction is the reverse direction means that it is counterclockwise with respect to the clockwise direction or clockwise with respect to the counterclockwise direction.
- the vertical wall portion 14 rises from the outer periphery of the molded product 11C.
- two bent portions 141a and 141b obtained by bending the material 11 are overlapped in the radial direction of the molded product 11C.
- the bent portion 141a is positioned on the radially outer side of the molded product 11C
- the bent portion 141b is positioned on the radially inner side of the molded product 11C.
- two layers (folded portions 141a and 141b) having a thickness corresponding to the plate thickness of the material 11 are obtained by performing the bending process on the outer peripheral portion of the material 11.
- the vertical wall portion 14 (processed portion) having an overlapping structure is formed on the material 11 such that the plate thickness direction of the layer is orthogonal to the plate thickness direction of the material 11.
- the vertical wall forming process is completed.
- the bending process of the vertical wall part forming process described above if it is difficult to bend at 90 degrees by one bending process because of the requirement of ensuring the shape accuracy of the molded product, the bending process is performed multiple times, Can be bent at 90 degrees. For example, it is possible to perform the bending molding by dividing into 45 degrees twice.
- the vertical wall portion forming step a part of the initial material 11 shown in FIG. 1A is bent, so that the outer diameter of the molded product 11C shown in FIG. 1D is the initial value shown in FIG.
- the outer diameter of the material 11 becomes smaller.
- the thickness of each bending part 141a and 141b is substantially equal to the thickness of the initial raw material 11
- the thickness of the vertical wall part 14 which piled up the two bending parts 141a and 141b is more than the thickness of the initial raw material 11. Also thicken. That is, the vertical wall portion 14 is thickened.
- the height H11 is the length from the upper surface of the cup bottom 15 to the front end surface of the vertical wall portion 14, and the height H12 is the lower surface of the cup bottom 15 from the front end surface of the vertical wall portion 14. Is the length.
- the press forming apparatus used in the tooth forming step is formed as a die, a die 23 on which a molded product 11C is placed, a columnar plate presser 24 arranged to face the die 23, and an annular shape. It has an inner diameter tooth profile punch 21 disposed outside the outer peripheral surface of the presser 24 and an outer diameter tooth profile punch 22 formed in an annular shape and disposed outside the outer peripheral surface of the inner diameter tooth profile punch 21. A tooth profile portion 211 is formed on a part of the outer peripheral surface of the inner diameter tooth punch 21.
- the outer diameter tooth-shaped punch 22 has a main body portion 222 having a tooth shape portion 221 formed on the inner peripheral surface, and a pressing portion 223 that protrudes inward in the radial direction of the outer diameter tooth shape punch 22 from the upper end of the main body portion 222.
- the tooth profile portions 211 and 221 are opposed to each other in the radial direction of the inner diameter tooth profile punch 21 and the outer shape tooth profile punch 22.
- the lower surface of the pressing portion 223 is a pressing surface 224 that presses the upper end of the vertical wall portion 14.
- the front end surface of the pressing portion 223 is in contact with the upper part of the outer peripheral surface of the inner diameter tooth punch 21.
- the inner diameter tooth profile punch 21, the outer diameter tooth profile punch 22, and the plate retainer 24 are disposed rotationally symmetrically with respect to the central axis 1, and can move independently upward and downward along the central axis 1.
- 2A is a height from the lower surface of the main body 222 of the outer diameter tooth-shaped punch 22 to the pressing surface 224, and is substantially equal to the height H11 shown in FIG. 1D.
- a height H22 shown in FIG. 2A is a height from the lower surface of the inner toothed punch 21 to the pressing surface 224, and is substantially equal to the height H12 shown in FIG.
- the molded product 11C is placed on the die 23, and the plate holder 24 presses the cup bottom 15 against the die 23, whereby the molded product 11C is fixed on the die 23. Thereafter, the inner-diameter tooth profile punch 21 and the outer-diameter tooth profile punch 22 are pushed into the two stacked vertical wall portions 14. At this time, the vertical wall portion 14 is plastically deformed by being pushed by the tooth profile portion 211 of the inner diameter tooth profile punch 21 and the tooth profile portion 221 of the outer diameter tooth profile punch 22, and is formed into a tooth profile shape along the tooth profile portions 211 and 221 (forging pressure). Molded).
- the bent portion 141b of the vertical wall portion 14 is pressed toward the radially outer side of the molded product 11C by the tooth profile portion 211 of the inner diameter tooth profile punch 21 and plastically flows.
- the bent portion 141a of the vertical wall portion 14 is pressed inward in the radial direction of the molded product 11C by the tooth profile portion 221 of the outer diameter tooth profile punch 22, and plastically flows.
- the pressing surface 224 suppresses the vertical wall portion 14 from plastically flowing upward.
- a tooth profile 142 is formed on the inner peripheral surface of the vertical wall portion 14 along the tooth profile portion 211 of the inner diameter tooth profile punch 21, and the outer periphery of the vertical wall portion 14.
- a tooth profile 143 along the tooth profile 221 of the outer diameter tooth profile punch 22 is formed on the surface, and the tooth forming process is completed.
- the bent portions 141a and 141b are plastically deformed by receiving the pressing force from the tooth shape portion 211 of the inner diameter tooth profile punch 21 and the tooth shape portion 221 of the outer diameter tooth shape punch 22, thereby bending portions 141a and 141b.
- the tooth forming step forging is performed on the vertical wall portion 14 (worked portion), thereby fastening the layers of the vertical wall portion 14 (the bent portions 141a and 141b) by plastic deformation ( The shape of the vertical wall portion 14 is changed to a target shape (in this embodiment, a tooth shape).
- 3A and 3B are schematic views of the AA cut surface of FIG. 2B in the vertical wall portion 14.
- 3 (a) and 3 (b) show a part of the final molded product (tooth profile part) molded by the tooth forming process.
- a tooth profile component having both a drive plate and a ring gear structure can be obtained by the method of manufacturing a mechanical component according to the present embodiment. That is, the tooth profile component is provided at a flat first portion (a portion corresponding to the drive plate, that is, a portion other than the vertical wall portion 14) and an end portion of the first portion, and the first portion is formed from the surface of the first portion. And a second portion projecting in the thickness direction of one portion (a portion corresponding to the ring gear, that is, the vertical wall portion 14 including the tooth profile portions 142 and 143).
- the thickness of the first portion (the portion corresponding to the drive plate) is the same as the thickness of the material 11, but the thickness of the second portion (the vertical wall portion 14 corresponding to the ring gear) is 2 of the thickness of the material 11. It is about double.
- the thickness of the second portion refers to the length of the vertical wall portion 14 in the radial direction of the tooth profile component (the direction orthogonal to the plate thickness direction of the material 11).
- the second part when the second part is viewed in a cross section including the thickness direction of the first part and the thickness direction of the second part (cross section orthogonal to the circumferential direction of the material 11), the second part has an interlayer boundary line (that is, There is an overlay 18).
- the method for manufacturing a machine part according to the present embodiment it is possible to manufacture a machine part having a target thickness greatly different depending on a part from a single material by forging. Therefore, by combining cold forging with the manufacturing method of the machine part according to the present embodiment, the quality advantage (higher accuracy and higher strength) of the machine part and the manufacturing process advantage (lower cost and higher yield). )) To the maximum.
- the tooth formation process which forge-forms the tooth profile parts 142 and 143 in the vertical wall part 14 is not restricted to 1 process as shown to this embodiment. Processes such as pre-molding to reduce the maximum load or re-striking to obtain dimensional accuracy are required based on the required characteristics such as press forming capacity, mold strength, and dimensional accuracy of tooth profile parts 142 and 143. You may provide according to.
- the tooth profile 143 only on the outer peripheral surface of the vertical wall portion 14 by using a cylindrical inner diameter punch without the tooth profile 211 instead of the inner diameter tooth profile punch 21. In this case, when the tooth profile 143 is formed, the overlapping portion 18 can be plastically fastened. It is also possible to form the tooth profile portion 142 only on the inner peripheral surface of the vertical wall portion 14 by using a cylindrical outer diameter punch without the tooth profile portion 221 instead of the outer diameter tooth profile punch 22. In this case, when the tooth profile 142 is formed, the overlapping portion 18 can be plastically fastened.
- the tooth profile 142 is formed on the inner peripheral surface of the vertical wall 14 and the outer periphery of the vertical wall 14 A tooth profile component having a tooth profile 143 formed on the surface is molded.
- a gap 212 is formed between the tooth profile 142 on the inner diameter side and the cup bottom 15. Therefore, the molded product 11E of FIG. 4C is suitable for molding a tooth profile component having a gap 212 between the tooth profile 142 on the inner diameter side and the cup bottom 15.
- the method for manufacturing a machine part (tooth profile part) according to the second embodiment also includes a vertical wall forming step (first step) and a tooth forming step (second step).
- first step a vertical wall forming step
- second step a vertical wall part shaping
- FIGS. 5A to 5C are explanatory views of a vertical wall portion forming step (triple bending forming step) in which the material 11 is bent and formed in triplicate. Since the process up to FIG. 5A for bending the material 11 in a double manner is the same as the process up to FIG. 1D of the first embodiment, the description thereof is omitted.
- the two stacked vertical wall portions 14 shown in FIG. 5A are further bent 90 degrees and overlapped with the cup bottom 15 to form a three-layered outer peripheral portion 16 as shown in FIG. 5B. Then, by bending the end 16a of the three-layered outer peripheral portion 16 by 90 degrees in the direction opposite to the bending direction of the previous step, the three-layered vertical wall portion 17 is formed as shown in FIG.
- the formed product 11F is formed.
- the three bent portions 171a, 171b, and 171c overlap in the radial direction of the molded product 11F.
- the material 11 may not be bent at 90 degrees at a time in bending, but may be bent at 45 degrees twice.
- a layer having a thickness corresponding to the plate thickness of the material 11 (the bent portion 171a, A vertical wall portion 17 (processed portion) having a structure in which three 171b and 171c) overlap each other is formed on the material 11.
- the outer peripheral portion of the material 11 is further bent inward in the radial direction of the material 11 as compared to the vertical wall portion forming step of the first embodiment. For this reason, the outer diameter of the molded product 11F is smaller than the outer diameter of the molded product 11C shown in FIG. Further, in the vertical wall portion 17, since the three bent portions 171a, 171b and 171c are overlapped, the thickness of the vertical wall portion 17 is the same as that in FIG. 1 (d) where the two bent portions 141a and 141b are overlapped. It becomes thicker than the thickness of the vertical wall portion 14 shown. That is, the vertical wall portion 17 of the present embodiment is further thickened than the vertical wall portion 14 of the first embodiment.
- the thickness of the portion corresponding to the drive plate (the portion other than the vertical wall portion 17) is the same as the thickness of the material 11, but the ring gear.
- the thickness of the portion corresponding to (the vertical wall portion 17 having the tooth shape) can be set to about three times the thickness of the material 11.
- the molded product 11C having the two stacked vertical wall portions 14 shown in FIG. 1 (d) is used, and the three stacked vertical shown in FIG. A molded product 11F having the wall portion 17 was molded.
- the molded product 11D having the two vertical wall portions 14 shown in FIG. 4B is used as in the first modification, and the bending direction is not changed.
- a molded product 11G having three vertical wall portions 17 may be formed.
- 6 (a) to 6 (c) are explanatory views of a vertical wall portion forming step (triple bending forming step) in which the material 11 is bent and formed into three layers.
- a vertical wall portion forming step triple bending forming step
- the two vertical wall portions 14 are folded 90 degrees from the radially inner end 14a in the same direction as the bending direction of the previous step, and overlapped with the cup bottom portion 15 as shown in FIG.
- a three-layer outer peripheral portion 16 is formed.
- the material 11 may not be bent at 90 degrees at one time in bending, but may be bent at 45 degrees twice, for example.
- FIGS. 7A and 7B are explanatory diagrams of a vertical wall portion forming step (triple folding forming step) in which the material 11 is bent and formed in triplicate. Since the process up to FIG. 7A for forming the three-layered outer peripheral portion 16 is the same as the process up to FIG. 6B of Modification 1 of the second embodiment, the description thereof is omitted. In the first modification of the second embodiment, the three-layered outer peripheral portion 16 is bent 90 degrees in the same direction as the bending direction of the previous step, thereby having the three-layered vertical wall portion 17 shown in FIG. Molded product 11G was molded.
- the three-layer vertical wall 16 is folded by 90 degrees in the direction opposite to the bending direction of the previous process, as shown in FIG. 7B.
- a molded product 11H having the portion 17 is molded.
- the three bent portions 171a, 171b, and 171c overlap in the radial direction of the molded product 11H.
- the material 11 may not be bent at 90 degrees at a time in bending, but may be bent at 45 degrees twice.
- the bending is not limited to three layers, and it is also possible to form a vertical wall portion by overlapping four or more bent portions by bending the material 11 while appropriately changing the bending direction.
- the method for manufacturing a machine part (tooth profile part) according to the third embodiment also includes a vertical wall forming process (first process) and a tooth forming process (second process).
- the third embodiment is the same as the first embodiment in that the vertical wall portion 14 (processed portion) having a two-layer structure is formed on the material 11 in the vertical wall portion forming step, but the formation process is the first. Different from the embodiment.
- the outer peripheral portion of the material 11 shown in FIG. By performing the pre-bending molding process of bending, the molded product 11I having the pre-bending molding portion 19 is molded as shown in FIG.
- the pre-bending part 19 has a tapered bent part 191 that rises obliquely outward in the radial direction from the cup bottom 15, and a tapered bent part 192 that inclines radially outward and downward from the upper end of the bent part 191.
- the bent outer surface 193 is an outer surface of a portion connecting the bent portions 191 and 192.
- a thickness corresponding to the plate thickness of the material 11 is obtained by performing a bending process on the outer peripheral portion of the material 11.
- the pre-bending part 19 is formed in which the parts (folded parts 191 and 192) having the zigzag shape are continuously formed.
- the press molding apparatus is formed in an annular shape, and a bending portion pushing punch 25 disposed outside the outer peripheral surface of the plate presser 24, and an annular shape And a drawing punch 26 disposed outside the outer peripheral surface of the bending portion pushing punch 25.
- a punch shoulder R portion 261 formed of a curved surface is formed at the lower end of the inner peripheral surface of the aperture punch 26.
- the molded product 11I is placed on the die 23, and the plate holder 24 presses the cup bottom 15 of the molded product 11I against the die 23, whereby the molded product 11I is fixed on the die 23. Then, the drawing punch 26 is moved downward while pressing the bending outer surface 193 of the pre-bending molded portion 19 with the bending portion pushing punch 25, so that the bending is performed by the punch shoulder R portion 261 and the inner peripheral surface of the drawing punch 26. The molding part 19 is deformed. As a result, the bent portion 192 approaches the bent portion 191, and the bent portions 191 and 192 overlap between the outer peripheral surface of the plate retainer 24 and the inner peripheral surface of the drawing punch 26.
- the vertical wall portion 14 in which the two bent portions 191 and 192 are overlapped can be formed without causing a bending crack on the outer bending surface 193 of the pre-bending portion 19.
- an external force is applied to the pre-bending part 19 so that the bent parts 191 and 192 of the pre-bending part 19 overlap each other.
- the vertical wall portion 14 having a two-layer structure in which the bent portions 191 and 192 overlap as a layer is formed.
- the two bent portions 191 and 192 are formed by the pre-bending forming step.
- the present invention is not limited to this, and three or more bent portions can be formed.
- the vertical wall portion 14 is formed by overlapping the three or more bent portions with each other by using the press device described in this embodiment. Can do.
- the method for manufacturing a machine part (toothed part) according to the fourth embodiment also includes a vertical wall forming step (first step) and a tooth forming step (second step).
- the fourth embodiment is the same as the first embodiment in that the vertical wall portion 14 (processed portion) having a two-layer structure is formed on the material 11 in the vertical wall portion forming step, but the formation process is the first. Different from the embodiment. That is, in the first embodiment, the thickness of the vertical wall portion 14 is merely increased by folding the material 11. On the other hand, in the fourth embodiment, not only the material 11 is folded, but the thickness of the material 11 itself is increased.
- the vertical wall portion forming step of the fourth embodiment includes a step of increasing the thickness of the vertical wall portion 14 (thickening step).
- the press device used in the thickening step includes a thickening punch 27 that is formed in an annular shape and is arranged outside the outer peripheral surface of the plate presser 24.
- the thickening punch 27 has a pushing portion 271 that protrudes radially inward of the thickening punch 27.
- the lower surface of the pushing portion 271 is a thickening punch pushing surface 272.
- the front end surface of the pushing portion 271 is in contact with the outer peripheral surface of the plate retainer 24.
- the molded product 11C in which the vertical wall portion 14 is molded is placed on the die 23, and the plate holder 24 presses the cup bottom 15 against the die 23, whereby the molded product 11C is placed on the die 23.
- the radial clearance Tcl formed by the outer peripheral surface 241 of the plate presser 24 and the inner peripheral surface 273 of the thickening punch 27 is larger than the thickness T0 of the vertical wall portion 14 in the radial direction of the molded product 11C.
- the thickening punch 27 is moved downward, and the bending outer surface 144 of the vertical wall portion 14 is pressed using the thickening punch pushing surface 272 of the thickening punch 27.
- the vertical wall portion 14 is crushed in the vertical direction and spreads in the radial direction of the molded product 11C, and the inner peripheral surface of the vertical wall portion 14 is the outer peripheral surface of the plate presser 24 as shown in FIG. 241 is contacted. Therefore, the thickness of the vertical wall portion 14 is increased and the thickness is increased.
- the thickness increasing step included in the vertical wall portion forming step of the fourth embodiment by applying a pressing force to the vertical wall portion 14 from the thickness direction of the material 11, the thickness direction of the layers (in other words, the vertical wall portion 14 is increased in thickness in the radial direction of the material 11.
- the thickness Tcl is set to the thickness T0 in the above-described thickening step.
- the thickness increase amount of the vertical wall portion 14 is controlled so that the thickness increase rate Tra obtained by dividing by the above condition satisfies the following conditional expression (1). 1.0 ⁇ Tra ⁇ 1.5 (1)
- the wall increase rate Tra is preferably set within the range indicated by the conditional expression (1). .
- the number of bent portions constituting the vertical wall portion 14 is increased to increase the thickness T0 of the vertical wall portion 14 in the radial direction of the molded product 11C. It is preferable to reduce the meat ratio Tra.
- the vertical wall portion forming step of forming the vertical wall portion 14 of FIG. 9A on the outer peripheral portion of the material 11 and the tooth forming process for the increased vertical wall portion 14 of FIG. 9B are the first embodiment. Since it is the same as that of FIG.
- the method for manufacturing a machine part (toothed part) according to the fifth embodiment also includes a vertical wall forming step (first step) and a tooth forming step (second step).
- the fifth embodiment is the same as the first embodiment in that the vertical wall portion 14 (processed portion) having a two-layer structure is formed on the material 11 in the vertical wall portion forming step.
- protrusions and grooves 112 (concaves) are different from the first embodiment in that they are provided.
- a groove portion 112 on the outer peripheral portion of one surface (ie, upper surface) 11b of the material 11 is formed.
- a concave portion and a protruding portion 111 are provided.
- the concavo-convex shape is positioned at the portion (overlapping portion) 18 where the bent portions 141a and 141b are overlapped. Then, the outer peripheral portion of the material 11 is bent to form a double vertical wall portion 14.
- a plurality of annular grooves 112 and protrusions 111 are provided concentrically on the outer peripheral portion of the upper surface 11 b of the material 11. As shown in FIG. 10B, the uneven shape formed by the groove 112 and the protrusion 111 is point-symmetric about the reference point 12a.
- the protrusion 111, the groove 112, and the protrusion 111 are arranged in this order from the radially inner side to the radially outer side of the material 11. .
- the groove portion 112, the protruding portion 111, and the groove portion 112 are arranged in this order from the radially outer side of the material 11 toward the radially inner side.
- only the protrusion 111 may be arranged in the region 11c, and only the groove 112 may be arranged in the region 11d.
- groove part 112 may be arrange
- projection part 111 may be arrange
- the groove part 112 and the projection part 111 do not need to be annular as shown in FIG.
- the region 11c and the region 11d constitute a two-ply vertical wall portion 14 shown in FIG. That is, the region 11c constitutes a bent portion 141a, and the region 11d constitutes a bent portion 141b.
- the regions 11c and 11d to be the bent portions 141a and 141b have the concavo-convex shape (projection portion 111 and groove portion 112), the bent portions 141a and 141b are overlapped during the tooth formation shown in FIG.
- the surface area of the combined portion (overlapping portion) 18 increases. Therefore, in this embodiment, bending part 141a and 141b are fastened more firmly (plastic fastening).
- the concavo-convex shape of the bent portion 141a (the groove portion 112 and the protruding portion 111) and the concavo-convex shape of the bent portion 141b (the groove portion 112 and the protruding portion 111) that are overlapped with each other are fitted to each other. Since the concavo-convex shape is formed, the fastening force of the bent portions 141a and 141b can be further increased.
- the raw material 11 has the projection part 111 (convex part) and the groove part 112 (concave part) provided in the upper surface 11b of the raw material 11, and in a vertical wall part formation process, Bending is performed so that the protruding portion 111 and the groove portion 112 are engaged with each other at the boundary surface between the layers of the vertical wall portion 14 (the boundary surface between the bent portion 141a and the bent portion 141b: the overlapping portion 18).
- the present embodiment can be applied even when three or more vertical wall portions are formed.
- the molded product 11F shown in FIG. 5 (c) the molded product 11G shown in FIG. 6 (c), and the molded product 11H shown in FIG. 7 (b)
- the surface where the bent portions 171a and 171b are overlapped the surface where the bent portions 171a and 171b are overlapped.
- An uneven shape (projection 111 and groove 112) similar to that of the present embodiment may be formed on the surface on which the portions 171b and 171c are overlapped.
- the method for manufacturing a machine part (toothed part) according to the sixth embodiment also includes a vertical wall forming step (first step) and a tooth forming step (second step).
- the sixth embodiment is the same as the first embodiment in that the vertical wall portion 14 (processed portion) having a two-layer structure is formed on the material 11 in the vertical wall portion forming step, but the forging process in the tooth forming step. Is different from the first embodiment.
- FIG. 12 is a schematic configuration diagram of a press device used in the tooth forming process of the sixth embodiment.
- FIG. 13 is a cross-sectional view taken along the line BB of the pressing apparatus shown in FIG.
- the press device used in the tooth forming process of the sixth embodiment includes a die 300, a first punch 310, and a second punch 320.
- the die 300 is a cylindrical mold part that shares the drive axis D of the press apparatus as a central axis and has a bottom at one end.
- the die 300 has a bottom upper surface 301 that is a flat surface, an inner peripheral surface 302 (side surface) that is a curved surface having a radius R1 centered on the drive axis D, and a diameter that centers on the drive axis D from the inner peripheral surface 302.
- a plurality of protrusions 303 protruding inward in the direction. Each protrusion 303 is provided on the inner peripheral surface 302 so as to extend along the drive axis D.
- the protrusions 303 are provided on the inner peripheral surface 302 so as to be arranged at a predetermined interval along the circumferential direction with the drive axis D as the center.
- the lower end of each protrusion 303 is connected to the bottom upper surface 301.
- the inner peripheral surface 302 of the die 300 is a side surface having a shape corresponding to the target shape of the vertical wall portion 14 (that is, a tooth profile shape in the present embodiment).
- the protrusion 303 provided on the inner peripheral surface 302 of the die 300 is referred to as a tooth-shaped protrusion.
- the first punch 310 is a cylindrical mold part that shares the drive axis D of the press device as a central axis.
- the first punch 310 has a lower surface 311 which is a flat surface and an outer peripheral surface 312 which is a curved surface having a radius R2 with the drive axis D as the center.
- the radius R2 of the outer peripheral surface 312 of the first punch 310 (that is, the outer diameter R2 of the first punch 310) is smaller than the radius R1 of the inner peripheral surface 302 of the die 300 (that is, the inner diameter R1 of the die 300).
- the first punch 310 is installed movably along the drive axis D in the internal space of the die 300 (the upper space of the bottom upper surface 301).
- the second punch 320 is an annular mold part that shares the drive axis D of the press device as the central axis.
- the second punch 320 has an inner peripheral surface 321 that is a curved surface with a radius R3 centered on the drive axis D, and a lower portion that is provided below the second punch 320 and is a curved surface with a radius R4 centered on the drive axis D.
- An outer peripheral surface 322 (side surface), a plurality of axial push projections 323 projecting radially outward from the lower outer peripheral surface 322 about the drive axis D, and a diameter centered on the drive axis D from the lower outer peripheral surface 322
- a pressing portion 324 provided on the upper portion of the lower outer peripheral surface 322 so as to protrude outward in the direction and extend annularly along a circumferential direction centering on the drive axis D, and a pressing which is a flat bottom surface of the pressing portion 324 Surface 325.
- the radius R3 of the inner peripheral surface 321 of the second punch 320 (that is, the inner diameter R3 of the second punch 320) is equal to the outer diameter R2 of the first punch 310. That is, the first punch 310 can be accommodated in the internal space of the second punch 320.
- Each shaft pushing projection 323 is provided on the lower outer peripheral surface 322 so as to extend along the drive axis D. Further, the shaft pressing protrusions 323 are provided on the lower outer peripheral surface 322 so as to be arranged at a predetermined interval along the circumferential direction with the drive axis D as the center. The lower end of each shaft pushing projection 323 is inclined toward the lower outer peripheral surface 322. The upper end of each shaft pressing projection 323 is connected to the pressing surface 325.
- the shaft pressing protrusions 323 of the second punch 320 are disposed on the lower outer peripheral surface 322 so as to be positioned between adjacent tooth-shaped protrusions 303 provided on the inner peripheral surface 302 of the die 300.
- the lower outer peripheral surface 322 of the second punch 320 and the inner peripheral surface 302 of the die 300 are curved surfaces along the circumferential direction centering on the drive axis D, but in FIG.
- the outer peripheral surface 322 and the inner peripheral surface 302 of the die 300 are illustrated as flat surfaces.
- the planar shape of the pressing portion 324 of the second punch 320 is such that the space between the second punch 320 and the die 300 has no gap. It is set to be closed. Therefore, as shown in FIG. 12, when the maximum length from the drive axis D in the radial direction around the drive axis D to the end surface of the pressing portion 324 is defined as R5, the maximum length R5 is It is equal to the inner diameter R1.
- the second punch 320 configured as described above is movably installed along the drive axis D in the internal space of the die 300 (the upper space of the bottom upper surface 301). As shown in FIG. 12, the initial position of the second punch 320 on the drive axis D is set above the first punch 310.
- FIG. 14 and 15 are explanatory views of a tooth forming process in the method of manufacturing a machine part according to the sixth embodiment.
- the vertical wall portion forming step of the sixth embodiment is the same as that of the first embodiment, and thus the description thereof is omitted.
- the vertical wall portion having a two-layer structure as shown in FIG. 14 is obtained by the vertical wall portion forming step of the sixth embodiment.
- a material 11 having 14 is obtained.
- the end portion farthest from the center (center axis 1) of the material 11 is the outer end portion, and the other end portion.
- the end is defined as the inner end.
- the material 11 on which the vertical wall portion 14 is formed is placed at the bottom of the die 300 with the die 300 fixed at a predetermined position on the drive axis D. Place on top surface 301. At this time, the material 11 is placed on the die 300 so that the central axis 1 of the material 11 coincides with the drive axis D of the press device.
- the first punch 310 is moved (lowered) along the drive axis D (that is, the thickness direction of the material 11) toward the bottom upper surface 301 of the die 300. ) Then, in a state where the tooth profile protrusion 303 provided on the inner peripheral surface 302 of the die 300 is in contact with the outer end portion of the vertical wall portion 14, the vertical direction is formed between the lower surface 311 of the first punch 310 and the bottom upper surface 301 of the die 300. A portion of the material 11 excluding the wall portion 14 (that is, a portion corresponding to the drive plate) is sandwiched.
- the first punch 310 is interposed between the outer peripheral surface 312 of the first punch 310 and the inner end of the vertical wall portion 14.
- a gap having a length equal to the difference between the outer diameter R2 of 310 and the radius R4 of the lower outer peripheral surface 322 of the second punch 320 is formed.
- the second punch 320 is lowered along the drive axis D toward the bottom upper surface 301 of the die 300 until the lower end of the second punch 320 comes into contact with the material 11.
- the axial pushing protrusion 323 of the two punch 320 is pushed into the inner end portion of the vertical wall portion 14, and the vertical wall portion 14 is crushed by the pressing surface 325 of the second punch 320 so that the layers of the vertical wall portion 14 are plastically deformed.
- fastening (pressing) the shape of the vertical wall portion 14 is changed to a tooth shape (target shape) defined by the tooth profile protrusion 303.
- the first punch 310 is housed in the inner space of the second punch 320, while the gap between the outer peripheral surface 312 of the first punch 310 and the inner end of the vertical wall portion 14 is A wall between the lower outer peripheral surface 322 and the inner peripheral surface 321 of the second punch 320 is inserted. Therefore, the second punch 320 can be smoothly lowered until the lower end of the second punch 320 contacts the material 11.
- the thickness increase of the vertical wall portion 14 is the length between the lower end of the second punch 320 and the pressing surface 325, that is, the lower outer peripheral surface 322 of the second punch 320. It depends on the length in the drive axis D direction. Therefore, the length of the lower outer peripheral surface 322 in the direction of the drive axis D may be appropriately set according to the target value of the increase in thickness.
- the tooth profile part 400 shown in FIG. 16 is obtained. That is, the tooth-shaped part 400 is provided at a flat first portion 410 (a portion corresponding to the drive plate) and an end portion of the first portion 410, and the thickness of the first portion 410 from the surface of the first portion 410. And a second portion 420 (a portion corresponding to the ring gear) protruding in the direction.
- a tooth profile portion 421 having a tooth profile defined by the tooth profile protrusion 303 of the die 300 is formed along the circumferential direction of the tooth profile component 400 at the outer end portion.
- a recess 422 generated by the axial pushing protrusion 323 of the second punch 320 being pushed into the vertical wall portion 14 of the material 11 extends along the circumferential direction of the tooth profile component 400. Is formed.
- part 420 becomes the shape which curved three-dimensionally intricately. . Therefore, according to the manufacturing method of the machine part according to the sixth embodiment, the interlayer coupling force in the second part 420 can be increased, and as a result, the second part 420 of the tooth profile part 400 (that is, corresponding to the ring gear). The strength of the part to be performed) can be increased.
- the tooth forming process of the sixth embodiment may be employed as the tooth forming process of the first to fifth embodiments.
- the present invention has been described together with various embodiments, but the present invention is not limited to these embodiments, and can be modified within the scope of the present invention.
- the die 23 and the plate holder 24 are fixed, and the punches 21, 22, 25, 26, and 27 are moved downward with respect to the die 23.
- the punches 21, 22, 25, 26, and 27 are What is necessary is just to move relatively with respect to 23.
- the raw material 11 illustrated the case where it was a metal disk (for example, steel plate which has circular shape).
- the material of the material 11 is not limited to this, and various known materials that can be plastically processed, such as metals such as iron, steel, aluminum, titanium, stainless steel, and copper, or alloys thereof, can be used. Further, a composite material of metal and resin, or a composite material of dissimilar metals may be employed as the material 11.
- the method of manufacturing a machine part according to the present invention is not limited to the tooth profile part that is a constituent element of the automatic transmission for a vehicle, but to the manufacture of a tooth profile part that is a constituent element of a driving force transmission mechanism of a general machine or a ship. Can be applied.
- the shape of the material 11 is not limited to a circular shape.
- the method of manufacturing a machine part according to the present invention can be applied to a method of manufacturing a machine part having a target thickness greatly different depending on a part from a long plate-shaped material.
- the machine parts that can be manufactured by the method of manufacturing a machine part according to the present invention are not limited to tooth profile parts.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Forging (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Gears, Cams (AREA)
Abstract
Description
本願は、2015年1月19日に日本に出願された特願2015-7912号と、2015年6月19日に日本に出願された特願2015-124050号とに基づき優先権を主張し、それらの内容をここに援用する。
ドライブプレートとリングギヤとを溶接することにより一個の歯形部品を製造する方法は、製造工数が多いため製造コストが高くなるという問題、及び溶接時の組付け精度を確保することが難しいという問題などを有する。特許文献1及び2に開示されているように、鍛造加工によって単一の素材からドライブプレート及びリングギヤの両方の構造を有する歯形部品を製造する方法では、歯形部(リングギヤ部)の増肉量(厚さ)が素材の板厚によって制約を受けるので、歯形部の厚さを大きくするのにも限界がある。また、歯形部の強度を確保するためには、歯形部の増肉率を高くする必要があるが、増肉率を高くしようとすると、歯形部の根元に折込み不良が生じる可能性がある。
(1)本発明の一態様に係る機械部品の製造方法は、素材の端部に対して折り曲げ加工を実施することにより、前記素材の板厚に相当する厚さを有する層が複数重なり合う構造を有する被加工部を、前記層の板厚方向が前記素材の板厚方向に直交するように前記素材に形成する第1工程と;前記被加工部に対して鍛造加工を実施することにより、前記被加工部の前記層同士を塑性変形によって圧接させながら、前記被加工部の形状を目標形状に変化させる第2工程と;を有する。
1.0<Tra≦1.5 ・・・(1)
まず、本発明の第1実施形態について説明する。
第1実施形態に係る機械部品(歯形部品)の製造方法は、縦壁部成形工程(第1工程)と歯形成形工程(第2工程)とを有する。図1は、縦壁部成形工程(2重折り曲げ成形工程)の説明図である。本実施形態では、素材11として金属製の円板(例えば円形状を有する鋼板)を用いる。図1、2及び4~9では、素材11のうち、素材11の中心軸1から片側部分の断面形状を示している。
このように、縦壁部成形工程では、素材11の外周部に対して折り曲げ加工を実施することにより、素材11の板厚に相当する厚さを有する層(折り曲げ部141a及び141b)が2つ重なり合う構造を有する縦壁部14(被加工部)を、層の板厚方向が素材11の板厚方向に直交するように素材11に形成する。
以上により、縦壁部成形工程が終了する。上述した縦壁部成形工程の曲げ成形において、1回の曲げ成形で90度に折り曲げることが成形品の形状精度を確保するなどの要求から難しい場合は、複数回の曲げ成形を行って、最終的に90度に折り曲げることができる。例えば、45度ずつ2回に分けて折り曲げ成形を行うことができる。
以上のように、歯形成形工程では、縦壁部14(被加工部)に対して鍛造加工を実施することにより、縦壁部14の層同士(折り曲げ部141a及び141b)を塑性変形によって締結(圧接)させながら、縦壁部14の形状を目標形状(本実施形態では歯形形状)に変化させる。
図3に示すように、本実施形態に係る機械部品の製造方法によって、ドライブプレート及びリングギヤの両方の構造を有する歯形部品を得られる。すなわち、この歯形部品は、平坦な第1部位(ドライブプレートに対応する部位、つまり縦壁部14以外の部位)と、第1部位の端部に設けられ、前記第1部位の表面から前記第1部位の板厚方向に突出する第2部位(リングギヤに対応する部位、つまり歯形部142及び143を含む縦壁部14)とを備える。
縦壁部成形工程において、図1(c)に示した成形品11Bの2枚重ねの外周部13を、該外周部13の端13bを起点にして、図4(a)に示すように、図1(b)までの曲げ方向と同一方向へ90度折り曲げることで、図4(b)に示すように、2枚重ねの縦壁部14を有する成形品11Dを成形してもよい。
図4(a)に示した2枚重ねの外周部13を有する成形品11Bにおいて、2枚重ねの外周部13を、外周部13の端13bよりさらに中心軸1に近い地点11aを起点にして、図1(b)までの曲げ方向と同一方向へ90度折り曲げることで、図4(c)に示すように、2枚重ねの縦壁部14を有する成形品11Eを成形することも可能である。成形品11Eでは、縦壁部14の内径側の部分と、カップ底部15との間に隙間212が形成される。変形例1,2の成形品11D,11Eに対して上述と同様の歯形成形工程を行うことで、縦壁部14の内周面に歯形部142が成形されるとともに、縦壁部14の外周面に歯形部143が成形された歯形部品が成形される。成形品11Eから得られる歯形部品では、内径側の歯形部142とカップ底部15との間に隙間212が形成される。従って、図4(c)の成形品11Eは、内径側の歯形部142とカップ底部15との間に隙間212を有する歯形部品を成形するのに好適である。
次に、本発明の第2実施形態について説明する。
上記第1実施形態と同様に、第2実施形態に係る機械部品(歯形部品)の製造方法も、縦壁部成形工程(第1工程)と歯形成形工程(第2工程)とを有する。上記第1実施形態では、縦壁部成形工程にて2層構造の縦壁部14(被加工部)を素材11に形成する場合を例示したが、第2実施形態では、縦壁部成形工程にて3層構造の縦壁部17(被加工部)を素材11に形成する点で第1実施形態と相違する。
このように、第2実施形態の縦壁部成形工程では、素材11の外周部に対して折り曲げ加工を実施することにより、素材11の板厚に相当する厚さを有する層(折り曲げ部171a、171b及び171c)が3つ重なり合う構造を有する縦壁部17(被加工部)を素材11に形成する。
従って、第2実施形態では、歯形成形工程終了後に得られる歯形部品において、ドライブプレートに対応する部位(縦壁部17以外の部位)の厚さは、素材11の厚さと同じであるが、リングギヤに対応する部位(歯形形状を有する縦壁部17)の厚さを素材11の厚さの3倍程度とすることができる。
上述の第2実施形態では、図1(d)に示す2枚重ねの縦壁部14を有する成形品11Cを用い、折り曲げる方向を逆転させながら、図5(c)に示す3枚重ねの縦壁部17を有する成形品11Fを成形した。これに対し、本変形例1のように、図4(b)に示す2枚重ねの縦壁部14を有する成形品11Dを用い、折り曲げる方向を変えずに、図6(c)に示すように、3枚重ねの縦壁部17を有する成形品11Gを成形してもよい。
図7(a)及び(b)は、素材11を3重に折り曲げ成形する縦壁部成形工程(3重折り曲げ成形工程)の説明図である。3枚重ねの外周部16を成形する図7(a)の工程までは、第2実施形態の変形例1の図6(b)までの工程と同一であるため、説明を省略する。第2実施形態の変形例1では、3枚重ねの外周部16を前工程の曲げ方向と同一方向へ90度折り曲げることで、図6(c)に示す3枚重ねの縦壁部17を有する成形品11Gを成形した。これに対し、本変形例2では、3枚重ねの外周部16を、前工程の曲げ方向と逆方向へ90度折り曲げることで、図7(b)に示すように、3枚重ねの縦壁部17を有する成形品11Hを成形する。このようにして成形された縦壁部17では、3つの折り曲げ部171a、171b及び171cが成形品11Hの径方向に重なっている。第1実施形態と同様に、折り曲げ成形において素材11を1回で90度に折り曲げず、例えば、45度ずつ2回に分けて折り曲げ成形を行っても構わない。
次に、本発明の第3実施形態について説明する。
上記第1実施形態と同様に、第3実施形態に係る機械部品(歯形部品)の製造方法も、縦壁部成形工程(第1工程)と歯形成形工程(第2工程)とを有する。第3実施形態では、縦壁部成形工程にて2層構造の縦壁部14(被加工部)を素材11に形成する点で第1実施形態と同様であるが、その形成プロセスが第1実施形態と異なる。
このように、第3実施形態の縦壁部成形工程に含まれる予曲げ成形工程では、素材11の外周部に対して折り曲げ加工を実施することにより、素材11の板厚に相当する厚さを有する部位(折り曲げ部191及び192)がジグザグ状に連続して成る予曲げ成形部19を形成する。
このように、第3実施形態の縦壁部成形工程に含まれる曲げ成形工程では、予曲げ成形部19の折り曲げ部191及び192が互いに重なり合うように予曲げ成形部19に対して外力を加えることにより、折り曲げ部191及び192が層として重なり合う2層構造を有する縦壁部14を形成する。
次に、本発明の第4実施形態について説明する。
上記第1実施形態と同様に、第4実施形態に係る機械部品(歯形部品)の製造方法も、縦壁部成形工程(第1工程)と歯形成形工程(第2工程)とを有する。第4実施形態では、縦壁部成形工程にて2層構造の縦壁部14(被加工部)を素材11に形成する点で第1実施形態と同様であるが、その形成プロセスが第1実施形態と異なる。
すなわち、第1実施形態では、素材11を折り重ねることにより、縦壁部14の増肉を行っているだけである。これに対し、第4実施形態では、素材11を折り重ねるだけでなく、素材11の厚さ自体を増加させる。
ここで、増肉工程前の縦壁部14の厚さをT0、増肉工程終了後の縦壁部14の厚さをTclと定義すると、上記増肉工程では、厚さTclを厚さT0で除算して得られる増肉率Traが下記条件式(1)を満足するように縦壁部14の増肉量を制御する。
1.0<Tra≦1.5 …(1)
増肉率Traが大きくなるに従い、縦壁部14に座屈や折れ込み等の成形不良が発生しやすくなる為、増肉率Traは上記条件式(1)に示す範囲で設定するのが好ましい。
次に、本発明の第5実施形態について説明する。
上記第1実施形態と同様に、第5実施形態に係る機械部品(歯形部品)の製造方法も、縦壁部成形工程(第1工程)と歯形成形工程(第2工程)とを有する。第5実施形態では、縦壁部成形工程にて2層構造の縦壁部14(被加工部)を素材11に形成する点で第1実施形態と同様であるが、素材11に突起部111(凸部)及び溝部112(凹部)が設けられている点で第1実施形態と異なる。
次に、本発明の第6実施形態について説明する。
上記第1実施形態と同様に、第6実施形態に係る機械部品(歯形部品)の製造方法も、縦壁部成形工程(第1工程)と歯形成形工程(第2工程)とを有する。第6実施形態では、縦壁部成形工程にて2層構造の縦壁部14(被加工部)を素材11に形成する点で第1実施形態と同様であるが、歯形成形工程における鍛造プロセスが第1実施形態と異なる。
このように、ダイ300の内周面302は、縦壁部14の目標形状(つまり本実施形態では歯形形状)に対応する形状を有する側面である。以下では、ダイ300の内周面302に設けられた突起303を歯形突起と呼称する。
上記のように構成された第2パンチ320は、ダイ300の内部空間(底部上面301の上部空間)を駆動軸線Dに沿って移動自在に設置されている。図12に示すように、駆動軸線D上における第2パンチ320の初期位置は、第1パンチ310の上部に設定されている。
このように、素材11が第1パンチ310とダイ300との間に挟まれた状態において、第1パンチ310の外周面312と縦壁部14の内側端部との間には、第1パンチ310の外径R2と第2パンチ320の下部外周面322の半径R4との差分に等しい長さを有する隙間が形成される。
第2パンチ320の下降中において、第2パンチ320の内部空間に第1パンチ310が収容されながら、第1パンチ310の外周面312と縦壁部14の内側端部との間の隙間に、第2パンチ320の下部外周面322と内周面321との間の肉壁が挿入される。そのため、第2パンチ320の下端が素材11に接触するまで、第2パンチ320をスムーズに下降させることができる。
また、図15から理解されるように、縦壁部14の増肉量は、第2パンチ320の下端と押圧面325との間の長さ、すなわち、第2パンチ320の下部外周面322の駆動軸線D方向の長さに依存する。従って、増肉量の目標値に応じて、下部外周面322の駆動軸線D方向の長さを適切に設定すればよい。
なお、上記第6実施形態の歯形成形工程を第1~第5実施形態の歯形成形工程として採用してもよい。
さらに、素材11の形状も円形状に限定されない。例えば、長い板状の素材から部位によって目標とする厚さが大きく異なる機械部品を製造する方法としても、本発明に係る機械部品の製造方法を適用することができる。言い換えれば、本発明に係る機械部品の製造方法によって製造可能な機械部品は歯形部品に限定されない。
11 被加工材
11A~11I 成形品
11a 地点
11b 上面
11c 領域
11d 領域
111 突起部
112 溝部
12 縦壁部
12a 基準点
13 2枚重ね外周部
13a 端
13b 端
14 2枚重ねの縦壁部
14a 端
141a、141b 折り曲げ部
142、143 歯形部
15 カップ底部
16 3枚重ねの外周部
16a 端
16b 端
16c 端
17 3枚重ねの縦壁部
171a~171c 折り曲げ部
19 予曲げ成形部
191、192 折り曲げ部
193 曲げ外表面
21 内径歯形パンチ
211 歯形部
212 隙間
22 外径歯形パンチ
221 歯形部
222 本体
223 押さえ部
224 押さえ面
23 ダイ
24 板押さえ
241 外周面
25 曲げ部押込みパンチ
26 絞りパンチ
261 パンチ肩R部
27 増肉パンチ
271 押込み部
272 増肉パンチ押込み面
273 内周面
300 ダイ
310 第1パンチ
320 第2パンチ
400 歯形部品
410 第1部位
420 第2部位
Claims (9)
- 素材の端部に対して折り曲げ加工を実施することにより、前記素材の板厚に相当する厚さを有する層が複数重なり合う構造を有する被加工部を、前記層の板厚方向が前記素材の板厚方向に直交するように前記素材に形成する第1工程と;
前記被加工部に対して鍛造加工を実施することにより、前記被加工部の前記層同士を塑性変形によって圧接させながら、前記被加工部の形状を目標形状に変化させる第2工程と;
を有することを特徴とする機械部品の製造方法。 - 前記第1工程では、前記層が2つ又は3つ重なり合う構造を有する前記被加工部を前記素材に形成することを特徴とする請求項1に記載の機械部品の製造方法。
- 前記第1工程は、
前記素材の端部に対して前記折り曲げ加工を実施することにより、前記素材の板厚に相当する厚さを有する部位がジグザグ状に連続して成る予曲げ成形部を形成する予曲げ成形工程と;
前記予曲げ成形部の前記部位が互いに重なり合うように前記予曲げ成形部に対して外力を加えることにより、前記部位が前記層として複数重なり合う構造を有する前記被加工部を形成する曲げ成形工程と;
を有することを特徴とする請求項1または2に記載の機械部品の製造方法。 - 前記第1工程は、前記素材の板厚方向から前記被加工部に対して押圧力を加えることにより、前記層の板厚方向に前記被加工部を増肉させる増肉工程を有することを特徴とする請求項1~3のいずれか一項に記載の機械部品の製造方法。
- 前記層の板厚方向における前記被加工部の長さを前記被加工部の厚さと定義すると共に、前記増肉工程前の前記被加工部の厚さをT0、前記増肉工程終了後の前記被加工部の厚さをTclと定義したとき、前記増肉工程では、前記厚さTclを前記厚さT0で除算して得られる増肉率Traが下記条件式(1)を満足するように前記被加工部の増肉量を制御することを特徴とする請求項4に記載の機械部品の製造方法。
1.0<Tra≦1.5 ・・・(1) - 前記素材は、前記素材の表面に設けられた凸部及び凹部を有し、
前記第1工程では、前記被加工部の前記層間の境界面で前記凸部と前記凹部とが互いに噛み合うように前記折り曲げ加工を実施することを特徴とする請求項1~5のいずれか一項に記載の機械部品の製造方法。 - 前記層の前記板厚方向における前記被加工部の両端部のうち、前記素材の中心から最も離れた端部を外側端部、他方の端部を内側端部と定義したとき、
前記第2工程では、
前記被加工部が形成された前記素材をダイの上に載置し;
前記ダイの側面が前記被加工部の前記外側端部に接した状態で、第1パンチの下面と前記ダイとの間に前記被加工部を除く前記素材の部位を挟み;
軸押し突起が設けられた側面を有する第2パンチを前記素材の板厚方向に沿って前記ダイへ向けて移動させることにより、前記軸押し突起を前記被加工部の前記内側端部に押し込ませるとともに、前記被加工部を押し潰して前記被加工部の前記層同士を前記塑性変形によって圧接させながら、前記被加工部の形状を前記目標形状に変化させる;
ことを特徴とする請求項1~6のいずれか一項に記載の機械部品の製造方法。 - 請求項1~7のいずれか一項に記載の機械部品の製造方法により製造されたことを特徴とする機械部品。
- 平坦な第1部位と;
前記第1部位の端部に設けられ、前記第1部位の表面から前記第1部位の板厚方向に突出する第2部位と;
を備え、
前記第1部位の板厚方向に直交する方向における前記第2部位の長さを前記第2部位の厚さと定義したとき、前記第2部位の厚さは、前記第1部位の板厚より大きく、
前記第1部位の板厚方向及び前記第2部位の厚さ方向を含む断面で前記第2部位を見たとき、前記第2部位には層間境界線が存在する、
ことを特徴とする機械部品。
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JPH0788582A (ja) * | 1993-09-20 | 1995-04-04 | Mitsubishi Motors Corp | 板金プレートのリングギア成形方法 |
JPH07256377A (ja) * | 1994-03-23 | 1995-10-09 | Mitsubishi Motors Corp | 板金製歯形部品の成形方法 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN113787306A (zh) * | 2021-09-02 | 2021-12-14 | 北京航空航天大学江西研究院 | 一种燃烧室帽罩流动控制精准热成形方法 |
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BR112017012576A2 (pt) | 2017-12-26 |
CN107107164A (zh) | 2017-08-29 |
CA2969640C (en) | 2020-03-10 |
KR102024219B1 (ko) | 2019-09-24 |
JPWO2016117364A1 (ja) | 2017-09-28 |
CA2969640A1 (en) | 2016-07-28 |
EP3248708B1 (en) | 2021-03-03 |
JP6493418B2 (ja) | 2019-04-03 |
MX2017009124A (es) | 2017-11-22 |
US10675673B2 (en) | 2020-06-09 |
US20170348763A1 (en) | 2017-12-07 |
EP3248708A4 (en) | 2018-10-17 |
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KR20170093937A (ko) | 2017-08-16 |
RU2676361C1 (ru) | 2018-12-28 |
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