WO2016152012A1

WO2016152012A1 - Member manufacturing method, method for manufacturing members of various types, member manufacturing device, and system for manufacturing members of various types

Info

Publication number: WO2016152012A1
Application number: PCT/JP2016/000849
Authority: WO
Inventors: 繁彦鬼頭; 井上　智紀
Original assignee: 株式会社デンソー
Priority date: 2015-03-25
Filing date: 2016-02-18
Publication date: 2016-09-29

Abstract

A method for manufacturing a member (96) having through-holes (94, 98, 99), said member manufacturing method including: a molding step wherein a powder (10) of a material or wire for forming the member is stacked inside a case (123, 223) in which a core (25, 35, 45) formed in the shape of the through-holes is placed, after which the stacked powder or wire is partially heated, or the material or powder for forming the member is heated while being stacked inside a case in which a core has been placed, thereby molding a core-equipped member (961), which is a member in which the core is inserted into the through-holes; and a removal step wherein the core is removed from the core-equipped member after the molding step.

Description

MANUFACTURING METHOD FOR MEMBER, MANUFACTURING METHOD FOR MULTI-TYPE MEMBER, EQUIPMENT MANUFACTURING APPARATUS, AND PRODUCT SYSTEM FOR MULTI-TYPE

Cross-reference of related applications

This application is based on Japanese Patent Application No. 2015-62711 filed on March 25, 2015 and Japanese Patent Application No. 2015-243935 filed on December 15, 2015. The description is incorporated.

The present disclosure relates to a method for manufacturing a member, a method for manufacturing a multi-product member having a common part that forms a common shape among multi-product members, and a feature part that has a different shape, a device manufacturing apparatus, and a system for manufacturing a multi-product member It is about.

In recent years, it has been required to control the fuel spray state in the combustion chamber of the internal combustion engine to improve the combustion efficiency of the internal combustion engine. For this reason, it is necessary to change the shape of the injection hole of the fuel injection valve according to the specifications of the internal combustion engine, and a manufacturing method capable of efficiently manufacturing a plurality of fuel injection valves having different injection hole shapes is required. Yes. For example, Patent Document 1 discloses a fuel injection in which a portion having a nozzle hole of a fuel injection valve is processed as a separate member by metal powder injection molding, and the portion having the nozzle hole and a substantially cylindrical valve body are diffusion bonded. A method for manufacturing the valve is described.

Japanese Patent Laid-Open No. 9-079114

In the method of manufacturing a fuel injection valve described in Patent Document 1, the injection hole is processed by perforating a green body processed by injection molding. However, in order to highly control the fuel spray state in the fuel injection valve, for example, the inner edge of the inner opening of the nozzle hole is curved or the cross-sectional area of the nozzle hole is changed. A nozzle hole is required. In the fuel injection valve manufacturing method described in Patent Document 1, such a complicated injection hole cannot be processed.

An object of the present disclosure is to provide a method for manufacturing a member that improves the degree of freedom of the shape of the member.

The method for manufacturing a member according to an aspect of the present disclosure is a method for manufacturing a member having a through hole, and includes a forming step for forming the member and a removing step for removing the core.

In the molding process, after the powder or wire of the material forming the member is laminated in the case where the core formed in the shape of the through hole is placed, the laminated powder or wire is partially heated, or the core is The powder or wire of the material forming the member is laminated while being heated in the placed case, and a cored member that is a member having the core inserted through the through hole is formed.

The removal step removes the core from the cored member after the molding step.

In the member manufacturing method of the present disclosure, first, powder or wire of the material forming the member is laminated and heated in the case where the core formed in the shape of the through hole is placed, and the inside of the through hole is inserted. A member with a core, which is a member through which the child is inserted, is formed. Thereafter, when the core is removed from the cored member, a through hole is formed at a portion where the core of the member has been removed. Since the through hole is formed so as to follow the shape of the core in the forming step, the injection hole can be formed into a shape that is difficult to achieve by conventional cutting. Therefore, in the member manufacturing method of the present disclosure, the degree of freedom of the shape of the through hole of the member can be improved.

Also, since the through hole is formed along the shape of the core, the shape of the through hole can be changed only by changing the shape of the core. Thereby, the freedom degree of the shape of a through-hole can further be improved.

The above and other objects, features, and advantages of the present disclosure will become more apparent from the following detailed description with reference to the accompanying drawings. The drawing
It is a schematic diagram of a fuel injection valve provided with a nozzle body manufactured by a nozzle body manufacturing system according to a first embodiment of the present disclosure, FIG. 3 is an enlarged cross-sectional view of a nozzle body manufactured by a nozzle body manufacturing system according to the first embodiment of the present disclosure; It is a sectional view of a nozzle body manufactured by a nozzle body manufacturing system according to the first embodiment of the present disclosure, It is a schematic diagram of a nozzle body manufacturing system according to the first embodiment of the present disclosure, It is a flowchart of the manufacturing method of the nozzle body according to the first embodiment of the present disclosure, FIG. 6 is a schematic diagram illustrating a molding process for manufacturing an injection unit in the nozzle body manufacturing method according to the first embodiment of the present disclosure; It is a perspective view of a core used in the manufacturing method of the nozzle body according to the first embodiment of the present disclosure, It is an expanded sectional view of a nozzle body manufactured in a manufacturing method of a nozzle body according to the second embodiment of the present disclosure, FIG. 5 is an enlarged cross-sectional view of a nozzle body manufactured in a nozzle body manufacturing method according to a third embodiment of the present disclosure; FIG. 9 is a schematic diagram illustrating a molding process for manufacturing an injection unit in a nozzle body manufacturing method according to a fourth embodiment of the present disclosure; It is a schematic diagram of a nozzle body manufacturing system as a reference example of the present disclosure, It is a flowchart of a manufacturing method of a nozzle body as a reference example of the present disclosure, It is a schematic diagram explaining the process process which processes the injection part in the manufacturing method of the nozzle body as a reference example of this indication.

A plurality of embodiments of the present disclosure will be described with reference to the drawings.

(First embodiment)
A member manufacturing method, a multi-product member manufacturing method, a member manufacturing apparatus, and a multi-product member manufacturing system according to a first embodiment of the present disclosure will be described with reference to FIGS.

First, the structure of the fuel injection valve 90 manufactured by the nozzle body manufacturing system 1 as a manufacturing system for multi-product members according to the first embodiment will be described. FIG. 1 shows a fuel injection valve 90 for diesel fuel. The fuel injection valve 90 includes a nozzle body 91 as a multi-product member, a needle 92 provided so as to be able to be separated and abutted on a valve seat 911 included in the nozzle body 91, and an electromagnetic drive capable of driving the needle 92 in the axial direction. The unit 93 is provided.

A suck chamber 910 is defined between the needle 92 and the nozzle body 91 that are in contact with the valve seat 911 (see FIG. 2). The nozzle body 91 has nozzle holes 94 as a plurality of through holes that communicate the outside of the nozzle body 91 and the sac chamber 910. In the first embodiment, the nozzle body 91 has six injection holes 94, and the inner edge portion 912 of the inner opening of each injection hole 94 is formed in a curved shape as shown in FIG. The fuel introduced into the nozzle body 91 is supplied to the sac chamber 910 when the needle 92 moves away from the valve seat 911 and is injected from the injection hole 94 into a combustion chamber of an internal combustion engine (not shown).

Here, two parts set in the nozzle body 91 manufactured by the nozzle body manufacturing system 1 will be described with reference to FIG.

The main body portion 95 as a common portion, which is one of the two portions, refers to a portion having a common shape that all of the plurality of types of nozzle bodies have when compared. In the first embodiment, as shown in FIG. 3, the main body portion 95 is a substantially cylindrical portion that is formed so that the outer diameter decreases from the first end portion 951 toward the second end portion 952.

The other part of the two parts, the injection part 96 as a member and a characteristic part, indicates a part having a different shape when a plurality of nozzle bodies are compared. That is, the injection part 96 is a part having a characteristic shape different from that of the other nozzle bodies in the nozzle body 91. In the first embodiment, the injection unit 96 is a lid-like portion provided to close the opening of the second end portion 952 of the main body portion 95 in each of the plurality of types of nozzle bodies. The injection part 96 is different from the other nozzle bodies except for the nozzle body 91 among a plurality of types of nozzle bodies in the number of injection holes 94 and, for example, the shape of the inner edge part 912 as shown in FIG. That is, a plurality of types of nozzle bodies 91 having different injection units 96 correspond to a variety of members. In FIG. 3, the boundary between the main body portion 95 and the injection portion 96 is indicated by a virtual line VL1.

Next, the configuration of the nozzle body manufacturing system 1 will be described with reference to FIG. The nozzle body manufacturing system 1 includes a first processing device 11 as a common portion processing device, a second processing device 12, a core processing device 13 as a core removing unit, a control unit 14 as a control device, and the like. ing. FIG. 4 shows the columnar member 15 before being processed into the nozzle body 91, and movement of the member to be processed in the nozzle body manufacturing system 1 is indicated by white arrows M11 to M18. The 2nd processing apparatus 12 and the core processing apparatus 13 are corresponded to the manufacturing apparatus of a member.

1st processing apparatus 11 is an apparatus which processes the columnar member 15 formed from the metal to the main-body part 95 by cutting, such as turning and drilling, for example.

The second processing device 12 directly forms the injection portion 96 at a predetermined position of the main body portion 95 processed by the first processing device 11. The 2nd processing apparatus 12 is an apparatus which manufactures a metal member by what is called a metal additive manufacturing method. In the first embodiment, the injection unit 96 is formed by selective laser sintering (SLS). The second processing apparatus 12 includes a laser oscillator 121 as a heating unit, a galvanometer 122, a case 123, a recoater 124, a core 25, and the like.

The laser oscillator 121 oscillates a laser capable of melting the metal material powder 10 forming the injection unit 96 toward the galvanometer 122. The galvanometer 122 scans so that the laser oscillated by the laser oscillator 121 can be applied to the entire region in the case 123. In the present embodiment, the powder of the material forming the member is referred to as the metal powder 10.

The case 123 is a bottomed cylindrical member having a space 120 opened to the galvanometer 122 side. The case 123 can be filled with the metal powder 10. The case 123 has a hole 125 into which the main body 95 can be inserted at the bottom. In the present embodiment, the space 120 corresponds to the inside of the case 123.

The recoater 124 is provided so as to be movable relative to the case 123. The recoater 124 can level the surface of the metal powder layer supplied in the case 123 and spread the metal powder 10 in the case 123 while supplying the metal powder 10 in the case 123.

The core 25 is, for example, a linear member made of a metal that is relatively easy to melt. When the injection unit 96 is molded, the core 25 is set in the case 123. The core 25 defines the shape of the injection unit 96.

The core processing device 13 can heat or disassemble a member in which the main body 95, the injection unit 96, and the core 25 sent from the second processing device 12 are integrated.

The control unit 14 includes a microcomputer and the like, and includes a CPU, a ROM, an I / O, and a bus line for connecting them. The control unit 14 is electrically connected to the first processing device 11 and the second processing device 12. The control unit 14 controls the operations of the first processing apparatus 11 and the second processing apparatus 12 based on information regarding the shape of the nozzle body 91 input from the outside.

Next, a method for manufacturing a nozzle body as a method for manufacturing multi-product members according to the first embodiment will be described with reference to FIGS.

First, in 101, the main body 95 and the injection unit 96 are set in the nozzle body 91. Information regarding the shapes of the main body 95 and the injection unit 96 set as shown in FIG. 3 is input to the control unit 14. In subsequent 102 and 103, the control unit 14 controls the operations of the first processing device 11 and the second processing device 12 so as to form the nozzle body 91 based on the input information regarding the shape of the nozzle body 91.

Next, in 102 as a processing step for processing the common part, the main body part 95 is manufactured. Specifically, as shown in FIG. 4, in the first processing device 11, the primary processing member 16 is formed by processing the columnar member 15 so that the outer shape of the columnar member 15 becomes the outer shape of the nozzle body 91. Next, a through hole 161 is formed in the longitudinal direction of the primary processing member 16. Thereby, the substantially cylindrical main-body part 95 is manufactured.

Next, at 103 as a member manufacturing method, the injection unit 96 is manufactured. FIG. 6 shows how the injection unit 96 is manufactured in the second processing apparatus 12. In FIG. 6, in order to make the shape of the injection portion 96 in the case 123 easier to understand, a part of the metal powder 10 is omitted while making the size of the metal powder 10 filled in the case 123 larger than the actual size. ing. In the present embodiment, 103 corresponds to a molding process.

In 103, first, the main body 95 processed in 102 is inserted into the hole 125 of the case 123 whose relative position is fixed with respect to the main body 95. Specifically, as shown in FIG. 6, the main body portion 95 is inserted so that the second end portion 952 on the side where the injection portion 96 is provided is positioned in the case 123. After the second end portion 952 of the main body portion 95 is set in the case 123, the case 123 is positioned such that a specific portion of the core 25 is located in the injection hole 94 of the injection portion 96 manufactured directly on the main body portion 95. The core 25 is set inside.

FIG. 7 shows a perspective view of the core 25 set in the space 120. The core 25 is formed of a plurality of linear members extending in the radial direction from the approximate center of the core 25. In the first embodiment, the core 25 includes an inner support portion 251, an intermediate portion 252 as a plurality of through-hole corresponding portions, and an outer support portion 253 as a plurality of support portions. In the first embodiment, the core 25 has six intermediate portions 252 and six outer support portions 253 so as to correspond to the six injection holes 94 of the injection portion 96.

The inner support portion 251 is a portion where six linear portions are arranged radially. The inner support portion 251 is formed so as not to contact the inner wall of the injection portion 96 manufactured at 103. The inner support portion 251 supports the intermediate portion 252 so as to fix the relative position of the intermediate portion 252 with respect to the injection portion 96 inside the injection portion 96 processed in 103.

The six intermediate portions 252 are connected to respective end portions of the six linear portions of the inner support portion 251. The six intermediate portions 252 are each formed to have the shape of the nozzle hole 94. When the injection part 96 is manufactured at 103, the intermediate part 252 is located in the injection hole 94.

The six outer support portions 253 are provided at the ends of the six intermediate portions 252 opposite to the side connected to the inner support portion 251. The outer support part 253 is formed so as not to contact the outer wall of the injection part 96. The end of the outer support 253 opposite to the side connected to the intermediate part 252 is in contact with the bottom surface 126 of the case 123 as shown in FIG. Thereby, the outer side support part 253 supports the intermediate part 252 so that the relative position of the intermediate part 252 with respect to the case 123 is fixed outside the injection part 96 manufactured in 103.

The metal powder 10 is supplied to the space 120 in the case 123. After the metal powder 10 is supplied, when the surface of the metal powder layer in the case 123 is smoothed by the reciprocating movement of the recoater 124 (outlined arrow F12 in FIG. 6), the injection previously input to the control unit 14 Laser is irradiated based on the shape of the portion 96. At this time, the position where the laser is irradiated is controlled based on the shape of the injection unit 96 input in advance to the control unit 14. The metal powder 10 irradiated with the laser is melted and sintered with the adjacent metal powder 10. Thereby, the injection part 96 in a state where the core 25 is inserted into the injection hole 94 is manufactured on the second end part 952. The injection part 96 in a state where the core 25 is inserted through the injection hole 94 is referred to as a core-injection part 961 as a core-attached member.

103, when the core injection unit 961 is manufactured on the main body 95, the main body 95 and the core injection unit 961 are integrated using the core processing device 13 in 104 as a member manufacturing method. The core 25 is removed from the bottomed cylindrical member 97. Examples of a method for removing the core 25 from the bottomed cylindrical member 97 include a method for heating the core 25 and a method for disassembling the core 25. In the case where the heat treatment for heating the core 25 is performed, in the core processing apparatus 13, the bottomed cylindrical member 97 is at a temperature that can improve the hardness of the injection portion 96 and the core 25 can be melted. The bottomed tubular member 97 is heated to a temperature. Moreover, when performing the decomposition | disassembly process which decomposes | disassembles the core 25, in the core processing apparatus 13, it is the gas or liquid which does not damage the main-body part 95 or the injection part 96, and can decompose | disassemble the core 25 by chemical reaction. The bottomed cylindrical member 97 is placed in gas or liquid, and the core 25 is disassembled. The core 25 is removed from the injection unit 96 by these methods. In the present embodiment, 104 corresponds to a removal process.

Finally, in 105, the finish grinding is performed, and the nozzle body 91 is completed.

In the conventional cutting process, it is difficult to process a complicated shape inside a bottomed cylindrical member such as the inner edge 912 of the nozzle hole 94 of the nozzle body 91 of the first embodiment. In addition, even in a method in which the metal powder deposited in the case is sintered by a selective laser sintering method or the like, a step due to the sintered metal powder is likely to occur on the inner wall surface forming the nozzle hole, and the nozzle hole of a desired shape It was difficult to form.

In the nozzle body manufacturing method according to the first embodiment, the metal powder 10 laminated in the case 123 in which the core 25 is placed in 103 is heated based on the shape of the injection unit 96. Of the heated and melted metal powder 10, the metal powder 10 in contact with the intermediate portion 252 of the core 25 is melted along the outer peripheral wall surface 254 of the intermediate portion 252 and then sintered. Thereafter, in 104, when the cored injection section 961 that is the injection section 96 with the core 25 inserted through the nozzle hole 94 is heated, only the core 25 is melted. The child 25 is removed. As a result, the metal powder 10 that has been sintered after being melted along the outer peripheral wall surface 254 of the intermediate portion 252 is a jet having an inner edge portion 912 formed in a curved surface and a smooth inner wall surface 913 (see FIG. 2) having no step. Hole 94 is formed.

As described above, in the method of manufacturing the nozzle body, the metal powder 10 that forms the nozzle hole 94 is disposed in the intermediate portion 252 while the core 25 is used so that the metal powder 10 is not filled in the position corresponding to the nozzle hole 94. Are melted and sintered along the outer peripheral wall surface 254 of the steel plate. Thereby, the nozzle hole which has a shape difficult by cutting can be formed with high precision. Therefore, in the nozzle body manufacturing method according to the first embodiment, the degree of freedom of the shape of the injection hole 94 of the injection unit 96 can be improved.

Moreover, since the nozzle hole 94 is formed along the shape of the core 25, the shape of the nozzle hole 94 can be changed only by changing the shape of the core 25. Thereby, the freedom degree of the shape of the nozzle hole 94 can further be improved.

In the nozzle body manufacturing method according to the first embodiment, the injection unit 96 is directly processed on the second end portion 952 of the main body unit 95 provided in the case 123. Thereby, the process of joining the main-body part 95 and the injection part 96 can be made unnecessary.

Further, in the nozzle body manufacturing method according to the first embodiment, the main body portion 95 and the injection portion 96 are processed in separate steps.

Since the main body 95 is a part having a common shape that all of the plurality of types of nozzle bodies have when compared with a plurality of types of nozzle bodies, one type of first processing is performed even when processing a plurality of types of nozzle bodies. The apparatus 11 can process all the main body portions of a plurality of types of nozzle bodies.

The injection unit 96 performs processing according to the shape of the injection unit 96 by the selective laser sintering method in the second processing apparatus 12. In the selective laser sintering method, the metal powder 10 in the case 123 is partially heated and sintered based on information regarding the shape of the nozzle body 91 input to the control unit 14. Thereby, even if the shape of a nozzle body is changed, the injection part 96 can be processed, without changing the specification of a processing apparatus.

As described above, in the method of manufacturing the nozzle body, the setup change due to the difference in the shape of the nozzle body becomes unnecessary, and therefore, the man-hours required for manufacturing the nozzle body can be reduced.

Further, the nozzle body manufacturing system 1 can process nozzle bodies having different shapes by one type of first processing device 11 and one type of second processing device 12. Thereby, since the change of the specification of the processing apparatus by the difference in the shape of a nozzle body becomes unnecessary, the installation cost of a nozzle body manufacturing system can be reduced.

(Second embodiment)
Next, a member manufacturing apparatus according to the second embodiment of the present disclosure will be described with reference to FIG. The second embodiment is different from the first embodiment in the shape of the core. In addition, the same code | symbol is attached | subjected to the site | part substantially the same as 1st embodiment, and description is abbreviate | omitted.

FIG. 8 shows an enlarged cross-sectional view of the injection unit 96 manufactured in the second processing apparatus according to the second embodiment. In FIG. 8, the core 35 inserted through the injection hole 98 of the injection unit 96 is indicated by a dotted line.

The core 35 includes an inner support portion 251, a plurality of intermediate portions 352 as a plurality of through hole corresponding portions, and a plurality of outer support portions 253. In FIG. 8, for convenience, virtual lines VL21 and VL22 that indicate boundaries between the inner support portion 251, the intermediate portion 352, and the outer support portion 253 that form the core 35 are shown.

The intermediate part 352 is formed to have the shape of the nozzle hole 98. Specifically, the intermediate portion 352 has a reduced diameter portion 354 formed on the side connected to the inner support portion 251 so as to follow the curved shape of the inner edge portion 982 of the injection hole 98. The intermediate portion 352 is formed so that the outer diameter increases from the reduced diameter portion 354 toward the end portion 355 on the side connected to the outer support portion 253.

The injection hole 98 is formed so that the inner diameter increases from the inner side to the outer side of the injection unit 96. In the second embodiment, the injection hole 98 is formed such that the inner diameter D98 on the inner side of the injection unit 96 is smaller than 0.4 mm, for example, and the length L98 is longer than 2.0 mm, for example.

In the second processing apparatus according to the second embodiment, the core 35 is formed so that the cross-sectional area of the intermediate portion 352 inserted through the nozzle hole 98 changes. Thereby, the injection hole 98 can be made into the desired shape from which the cross-sectional area becomes large toward the downstream from the upstream of a fuel. Therefore, the second embodiment has the same effect as the first embodiment.

(Third embodiment)
Next, a member manufacturing apparatus according to a third embodiment of the present disclosure will be described with reference to FIG. The third embodiment is different from the first embodiment in the shape of the core. In addition, the same code | symbol is attached | subjected to the site | part substantially the same as 1st embodiment, and description is abbreviate | omitted.

FIG. 9 shows an enlarged cross-sectional view of the injection unit 96 manufactured in the second processing apparatus according to the third embodiment. In FIG. 9, the core 45 inserted through the injection hole 99 of the injection unit 96 is indicated by a dotted line.

The core 45 includes an inner support portion 251, intermediate portions 452 as a plurality of through hole corresponding portions, and a plurality of outer support portions 253. In FIG. 9, virtual lines VL <b> 31 and VL <b> 32 that indicate boundaries between the inner support portion 251, the intermediate portion 452, and the outer support portion 253 that form the core 45 are shown.

The intermediate part 452 is formed to have the shape of the injection hole 99. Specifically, the intermediate portion 452 has a reduced diameter portion 454 formed on the side connected to the inner support portion 251 so as to follow the curved shape of the inner edge portion 992 of the injection hole 98. The intermediate portion 452 is formed so that the outer diameter is substantially constant from the reduced diameter portion 454 to the central portion 455, while moving toward the end portion 456 on the side connected to the outer support portion 253 from the central portion 455. The outer diameter is formed to be large.

The injection hole 99 is formed so that the inner diameter increases from the approximate center of the injection hole 99 toward the outside of the injection part 96. In the third embodiment, the injection hole 99 is formed so that the inner diameter D99 on the inner side of the injection unit 96 is smaller than 0.4 mm, for example. Further, the injection hole 99 is formed so that the length L991 of the portion having a constant inner diameter from the inner side of the injection unit 96 is longer than, for example, 0.5 mm, and the inner diameter increases toward the outer side of the injection unit 96. The length L992 of the part is formed to be longer than 0.5 mm, for example.

In the second processing apparatus according to the third embodiment, the core 45 is formed such that the cross-sectional area of the intermediate portion 352 inserted through the nozzle hole 99 changes. Thereby, the injection hole 99 can be made into the desired shape from which the cross-sectional area changes toward the downstream from the upstream of a fuel. Therefore, the third embodiment has the same effect as the first embodiment.

(Fourth embodiment)
Next, a member manufacturing apparatus according to the fourth embodiment of the present disclosure will be described with reference to FIG. The fourth embodiment is different from the first embodiment in the configuration of the second processing apparatus. In addition, the same code | symbol is attached | subjected to the site | part substantially the same as 1st embodiment, and description is abbreviate | omitted.

FIG. 10 shows a state of processing of the injection unit 96 in the second processing apparatus 22. The second processing device 22 directly forms the injection portion 96 at a predetermined position of the main body portion 95 processed by the first processing device 11. The second processing apparatus 22 includes a laser oscillator 121, a galvanometer 122, a case 223, a recoater 124, a core 25, and the like.

The case 223 is formed integrally with the main body portion 95. Specifically, the case 223 includes a bottom portion 224 formed on the outer peripheral wall surface 953 of the second end portion 952 of the main body portion 95 so as to extend radially outward, and an outer edge portion of the bottom portion 224 on the side opposite to the main body portion 95. It has the cylinder part 225 formed so that it may stand up. A space 220 opened to the galvanometer 122 side is formed by the bottom portion 224 and the cylindrical portion 225. In the present embodiment, the space 220 corresponds to the inside of the case 223.

In the nozzle body manufacturing method according to the fourth embodiment, when the injection unit 96 is manufactured as 103 after the nozzle body manufacturing method 101, 102 according to the first embodiment, the outer surface of the core 25 is formed on the inner bottom surface 226 of the bottom portion 224. The core 25 is set so that the support portion 253 contacts. Thereby, the core 25 is set so that the intermediate part 252 is positioned in the injection hole 94 of the injection part 96.

Next, the metal powder 10 is supplied to the space 220. At this time, the amount of the metal powder 10 to be supplied is smaller than that in the first embodiment, as shown in FIG. Specifically, the case 223 is filled with a metal powder 10 in such an amount that a part of the injection unit 96 can be molded. After the metal powder 10 is filled, the surface of the metal powder layer in the case 223 is smoothed by the reciprocating movement of the recoater 124 (open arrow F22 in FIG. 10), and the injection unit 96 input in advance to the control unit 14. The laser is irradiated based on the shape. At this time, the position where the laser is irradiated is controlled based on the shape of the injection unit 96 input in advance to the control unit 14.

In the selective laser sintering method used in the fourth embodiment, the length of the laser irradiation direction (direction of solid line arrow L22 shown in FIG. 10) that can be processed by one laser irradiation is shorter than that in the first embodiment. And it manufactures so that a part of injection part 96 may be stacked in order from the main-body part 95 side. Specifically, after a part of the injection part 96 is processed on the second end part 952, the main body part 95 and the case 223 move away from the recoater 124. At this time, the main body part 95 moves to such an extent that a part of the jet part 96 to be processed next to a part of the jet part 96 that has already been processed comes to a position where laser irradiation is possible. After the main body part 95 moves, the metal powder 10 is supplied again onto a part of the injection part 96 already formed by the recoater 124, and the laser is irradiated. In this way, the injection unit 96 is processed in a plurality of times from the main body unit 95 side, and the injection unit 961 with the core, which is the injection unit 96 in a state where the core 25 is inserted into the injection hole 94, is the second. Manufactured on end 952.

Next, similarly to 104 of the manufacturing method of the nozzle body 91 according to the first embodiment, the bottomed cylindrical member in which the main body portion 95 and the core-injecting portion 961 are integrated using the core processing device 13. The core 25 is removed from 97.

Finally, finish grinding is performed at 105. At this time, the case 223 integrated with the main body 95 is also removed from the main body 95 by cutting, and the nozzle body 91 is completed.

In the fourth embodiment, the main body part 95 and the case 223 are moved a plurality of times in the direction away from the recoater 124, and the injection part 96 is formed on the main body part 95. At this time, since the outer support portion 253 of the core 25 is in contact with the case 223 integrated with the main body portion 95, the relative position of the intermediate portion 252 with respect to the main body portion 95 is unlikely to change. Thereby, while exhibiting the effect of 1st embodiment, 4th embodiment can shape | mold the position and shape of the nozzle hole 94 in the injection part 96 further with high precision.

(Reference example)
Next, a multi-product member manufacturing system as a reference example of the present disclosure will be described with reference to FIGS. The reference example differs from the first embodiment in the configuration of the second processing apparatus. In addition, the same code | symbol is attached | subjected to the site | part substantially the same as 1st embodiment, and description is abbreviate | omitted.

The nozzle body manufacturing system 5 of the reference example includes a first processing device 11, a second processing device 72, a control unit 14, and the like as shown in FIG. In FIG. 11, movement of members to be processed in the nozzle body manufacturing system 5 is indicated by white arrows M51 to M56.

The second processing device 72 processes the injection unit 96 at a predetermined position of the main body portion 95 processed by the first processing device 11. The 2nd processing apparatus 72 is an apparatus which shape | molds a metal member with a metal additive manufacturing method. As shown in FIG. 11, the second processing device 72 includes a laser oscillator 121, a galvanometer 122, a case 123, a recoater 124, and the like. That is, unlike the first embodiment, the second processing device 72 does not include a core.

Next, a method for manufacturing the nozzle body 91 of the reference example will be described with reference to FIGS. In FIG. 12, the flowchart of the manufacturing method of the nozzle body 91 of a reference example is shown.

First, in 501, the main body portion 95 and the injection portion 96 are set in the nozzle body 91 as in 101 of the first embodiment.

Next, in 502 as a processing step for processing the common portion, the main body portion 95 is manufactured in the same manner as 502 in the first embodiment.

Next, at 503, the injection unit 96 is manufactured. FIG. 13 shows how the injection unit 96 is manufactured in the second processing apparatus 72. In FIG. 13, a part of the metal powder 10 filled in the case 123 is omitted for easy understanding of the shape of the injection unit 96 in the case 123.

In 503, first, the second end portion 952 of the main body portion 95 processed in 502 is inserted into the hole 125 included in the case 123 of the second processing apparatus 12. After the second end 952 of the main body 95 is set in the case 123, the metal powder 10 is supplied to the space 120 in the case 123. After the metal powder 10 is supplied to the space 120, when the surface of the metal powder layer in the case 123 is smoothed by the reciprocating movement of the recoater 124 (the white arrow F52 in FIG. 13), the laser oscillator 121 is moved into the case 123. The metal powder 10 is irradiated with a laser. At this time, the position where the laser is irradiated is controlled based on the shape of the injection unit 96 input in advance to the control unit 14. The metal powder 10 irradiated with the laser is melted and sintered. Thereby, the injection unit 96 is processed on the second end portion 952.

In the selective laser sintering method used in the reference example, the length of the laser irradiation direction (in the direction of the solid line arrow L52 shown in FIG. 13) that can be processed by one laser irradiation is the length of the laser irradiation direction L52 of the injection unit 96. Short compared to the length. For this reason, in the reference example, the injection part 96 is processed so that a part of the injection part 96 is stacked in order from the main body part 95 side. Specifically, after a part of the injection portion 96 is processed on the second end portion 952, the main body portion 95 moves in a direction to be extracted from the case 123. At this time, the main body part 95 moves to such an extent that a part of the jet part 96 to be processed next to a part of the jet part 96 that has already been processed comes to a position where laser irradiation is possible. After the main body portion 95 moves, the metal powder 10 is again supplied to the space 120 by the recoater 124 and irradiated with a laser. In 503, in this way, the injection unit 96 is processed in multiple steps from the main body unit 95 side.

In 503, when all of the injection portions 96 are processed, finally, in 504, finishing grinding is performed, and the nozzle body 91 is completed.

In the manufacturing method of the nozzle body 91 of the reference example, the injection unit 96 is manufactured by a selective laser sintering method. Thereby, even a bottomed cylindrical member having a complicated shape on the inner side and difficult to cut can be manufactured. Therefore, the degree of freedom of the shape of the nozzle body 91 can be improved. Moreover, since the injection part 96 is directly processed on the 2nd end part 952 of the main-body part 95 provided in the case 123, the process of joining the main-body part 95 and the injection part 96 may become unnecessary. it can.

(Other embodiments)
In the above-described embodiment, the nozzle body manufacturing method as a method for manufacturing a variety of members including a member manufacturing method has been described. However, the manufacturing method to which the member manufacturing method is applied is not limited to this. You may manufacture the member which has a through-hole only with the manufacturing method of a member. Further, the multi-product member to which the manufacturing method of the multi-product member is applied is not limited to the nozzle body. What is necessary is just a member which has the common part which makes a common shape between multiple types of members, and the characteristic part which makes a different shape between multiple types of members.

In the above-described embodiment, the core inserted through the nozzle hole is removed from the injection unit by melting by heating or decomposition by chemical reaction. However, the method of removing the core from the injection unit is not limited to this.

In the above-described embodiment, the core has the intermediate portion formed to have the shape of the nozzle hole, and the inner support portion and the outer support portion that support the intermediate portion. However, the part which comprises a core is not limited to this. What is necessary is just to be formed so that it may become a shape of a nozzle hole.

In the above-described embodiment, the second processing apparatus processes the injection portion by the selective laser sintering method (SLS) of the metal additive manufacturing method. However, the method by which the second processing apparatus processes the injection portion is not limited to this. Laser direct laminating method (LENS) in which metal powder is directly sprayed and sintered in the molten pool on the surface of the main body or the jet section on the main body heated by a laser, or the wire of the metal material forming the jet section You may process an injection part by the melt deposition method (FDM) etc. which fuse | melt by arc discharge, sending out to the surface of the injection part on a main-body part.

In the above-described embodiment, the nozzle body manufacturing system as a manufacturing system for a wide variety of members including a member manufacturing apparatus processes the bottomed cylindrical nozzle body of the fuel injection valve. However, the members manufactured by the manufacturing system for multi-product members are not limited to this. What is necessary is just the member formed from the characteristic part which makes a different shape between the common part which makes the common shape which several members have, and several members. Further, the member manufacturing apparatus may be configured to be able to manufacture a member having a through hole alone, and a case in which powder or wire of a material forming the member can be laminated inside, a through hole placed inside the case A core formed in the shape of the material, a material supply part capable of supplying powder or wire of the material forming the member in the case, a heating part capable of heating the powder or wire of the material forming the member, and a through hole It is only necessary to have a core removing portion that can remove the core from the core-attached member that is a member into which the core is inserted.

In the second and third embodiments, the injection unit is manufactured by the second processing apparatus of the first embodiment. However, you may manufacture an injection part with the 2nd processing apparatus of 4th embodiment.

In the above embodiment, the inner edge of the nozzle hole of the nozzle body is formed in a curved surface. However, the shape of the inner edge is not limited to this. Any shape may be used as long as the fuel spray state in the fuel injection valve is highly controlled. Further, the shape of the nozzle hole is not limited to the above embodiment. The central axis may have a curved shape, or a shape that decreases after the cross-sectional area increases.

Suppose that the first processing device as the above-mentioned common part processing device processes the main body by cutting such as turning or drilling. However, the processing method of the main body is not limited to this.

In the above-described embodiment, the second processing apparatus as the member manufacturing apparatus includes a laser oscillator, a galvanometer, a case, a recoater, a core, a heat treatment unit, and the like. However, the structure of the member manufacturing apparatus is not limited to this.

In the above-described embodiment, the material filled in the case of the second processing apparatus is metal. However, the material filled in the case is not limited to metal. When the member is formed of a resin, it may be a resin.

In the above-described embodiment, the second processing apparatus has a laser oscillator as a heating unit for heating the metal powder. However, the heating unit is not limited to this. Arc discharge may be used.

As described above, the present disclosure is not limited to the above embodiment, and can be implemented in various forms without departing from the gist thereof.

Although the present disclosure has been described with reference to the embodiments, it is understood that the present disclosure is not limited to the embodiments and structures. The present disclosure includes various modifications and modifications within the equivalent range. In addition, various combinations and forms, as well as other combinations and forms including only one element, more or less, are within the scope and spirit of the present disclosure.

Claims

A method for producing a member (96) having through holes (94, 98, 99),
After the powder (10) or wire of the material forming the member is laminated in the case (123, 223) where the core (25, 35, 45) formed in the shape of the through hole is placed The powder or wire is partially heated or laminated while heating the powder or wire of the material forming the member in the case where the core is placed, and the core is inserted into the through hole. A molding step of molding the cored member (961) which is the member;
After the molding step, a removing step of removing the core from the cored member;
The manufacturing method of the member containing this.
The member manufacturing method according to claim 1, wherein in the removing step, the core is heated to a temperature at which the core can be melted.
The method for manufacturing a member according to claim 1, wherein in the removing step, the core is chemically decomposed.
The method for manufacturing a member according to any one of claims 1 to 3, wherein a nozzle body of a fuel injection valve as the member having the injection hole as the through hole is manufactured.
Multi-variety capable of manufacturing the multi-variety member having the common part (95) having a common shape among the multi-variety members (91) and the characteristic part (96) as the member having a different shape between the multi-variety members. A method for manufacturing a member, comprising:
A processing step of processing the common part;
The member according to any one of claims 1 to 4, wherein after the processing step, the core is changed in accordance with a shape of the through hole of the feature portion, and the feature portion is formed on the common portion. A manufacturing method of
A method for producing a variety of products including
The core includes a through hole corresponding portion (252, 352, 452) formed in the shape of the through hole, and a support portion (253) capable of fixing a relative position of the through hole corresponding portion with respect to the common portion. Have
The method for manufacturing a multi-product member according to claim 5, wherein, in the molding step, the core is provided so that the through hole corresponding portion is positioned at a position corresponding to the through hole.
An apparatus for producing a member (96) having through holes (94, 98, 99),
A case (123, 223) capable of laminating powder (10) or wire of the material forming the member inside (120, 220);
A core (25, 35, 45) placed inside the case and formed in the shape of the through hole;
A material supply part (124) capable of supplying powder or wire of the material forming the member in the case;
A heating section (121) capable of heating powder or wire of the material forming the member;
A core removing portion (13) capable of removing the core from the cored member (961) which is the member through which the core is inserted into the through hole;
A device manufacturing apparatus comprising:
The member manufacturing apparatus according to claim 7, wherein the core removing unit is capable of heating the cored member to a temperature at which the core can be melted.
The member manufacturing apparatus according to claim 7, wherein the core removing unit is capable of chemically decomposing the core included in the core-attached member.
The member manufacturing method according to any one of claims 7 to 9, wherein the core has a through hole corresponding portion (352, 452) formed so that a cross-sectional area changes along a shape of the through hole. apparatus.
The member manufacturing apparatus according to any one of claims 7 to 10, wherein a nozzle body of a fuel injection valve as the member having an injection hole as the through hole is manufactured.
A multi-product member for manufacturing the multi-product member having a common part (95) having a common shape among the multi-product members (91) and a characteristic part (96) as the member having a different shape between the multi-product members A manufacturing system of
A common part processing device (11) for processing the common part;
The member manufacturing apparatus (12, 13) according to any one of claims 7 to 11, wherein the core is provided so as to be changeable according to a shape of the feature portion, and the feature portion is formed on the common portion. 22)
A control device (14) for controlling the operation of the common part processing apparatus and the member manufacturing apparatus based on the shapes of the common part and the characteristic part of the multi-product member;
A system for manufacturing various types of components.
The core includes a through hole corresponding portion (252, 352, 452) formed in the shape of the through hole, and a support portion (253) capable of fixing a relative position of the through hole corresponding portion with respect to the common portion. The manufacturing system of the multi-product member according to claim 12.