WO2017006830A1 - 突起部成形装置、突起部成形方法及び成形品 - Google Patents
突起部成形装置、突起部成形方法及び成形品 Download PDFInfo
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- WO2017006830A1 WO2017006830A1 PCT/JP2016/069332 JP2016069332W WO2017006830A1 WO 2017006830 A1 WO2017006830 A1 WO 2017006830A1 JP 2016069332 W JP2016069332 W JP 2016069332W WO 2017006830 A1 WO2017006830 A1 WO 2017006830A1
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- Prior art keywords
- punch
- die
- workpiece
- protrusion
- punch portion
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/24—Perforating, i.e. punching holes
- B21D28/34—Perforating tools; Die holders
- B21D28/343—Draw punches
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/16—Shoulder or burr prevention, e.g. fine-blanking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/24—Perforating, i.e. punching holes
- B21D28/26—Perforating, i.e. punching holes in sheets or flat parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
- B21D37/12—Particular guiding equipment, e.g. pliers; Special arrangements for interconnection or cooperation of dies
-
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
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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
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K23/00—Making other articles
Definitions
- the present invention relates to a projection forming apparatus, a projection forming method, and a molded product.
- the fine blanking method is a method of performing high-precision shearing by plastically deforming a workpiece by applying a compressive force.
- the fine blanking method is difficult to form when the height of the protrusion is equal to or greater than the plate thickness. This is because the punch diameter and the die hole diameter are generally the same, and therefore, if the height of the protrusion is greater than or equal to the plate thickness, the workpiece is cut by shearing force and cannot be processed.
- An object of the present invention is to provide a protruding portion forming apparatus, a protruding portion forming method, and a molded product that can be formed with a height equal to or greater than the plate thickness, have sharp edges, and prevent the occurrence of cracks.
- the present invention relates to a die portion provided with a die hole, a large punch portion that can advance and retreat in a first direction toward the die portion side, and cannot be inserted into the die hole, and the large punch portion.
- a projection forming apparatus that deforms the workpiece to form a projection by pressing the punch toward the die by the punch.
- the distance d1 between the side surface of the small punch portion and the side surface of the large punch portion and the distance d2 between the side surface of the small punch portion and the inner surface of the die hole satisfy the relationship d2 ⁇ d1. It is preferable that it exists in.
- the distance d2 between the side surface of the small punch portion and the inner surface of the die hole and the plate thickness T of the workpiece have a relationship of d2 ⁇ T.
- the lower surface of the small punch portion is provided with a slope inclined in a direction in which the thickness of the small punch portion becomes thinner toward the edge of the small punch portion.
- the present invention provides a placing step of placing a workpiece on a die portion provided with a die hole, a large punch portion that cannot be inserted into the die hole, and the die portion side from the large punch portion.
- the punch part having a small punch part of a size that can be inserted into the die hole is moved in the first direction toward the die part side, and is disposed between the die part and the punch part.
- the distance d1 between the side surface of the small punch portion and the side surface of the large punch portion and the distance d2 between the side surface of the small punch portion and the inner surface of the die hole satisfy the relationship of d2 ⁇ d1. It is preferable that it exists in.
- the distance d2 between the side surface of the small punch portion and the inner surface of the die hole and the plate thickness T of the workpiece have a relationship of d2 ⁇ T.
- the method in the punching step, a slope inclined in a direction in which the thickness of the small punch portion becomes thinner toward the edge of the small punch portion is provided on the lower surface of the small punch portion. It is preferable that the method includes a first step of forming a protruding portion by the punched portion and a second step of forming the protruding portion by a punched portion having a flat bottom surface of the small punch portion.
- the present invention is also a molded product including a flat portion having a thickness T and a protrusion protruding from one surface side of the flat portion, and the other surface side of the protrusion in the molded product includes a first portion.
- the thickness T of the flat portion is a molded product that satisfies the relationship d2 ⁇ T.
- the molded product can be molded such that H ⁇ T when the height H is from the one surface of the flat portion to the upper surface on the one surface side of the protrusion.
- the width S1 of the first recess, the width S2 of the second recess, and the width S3 of the protrusion on the one surface side satisfy a relationship of S2 ⁇ S3 ⁇ S1.
- FIG. 1A and 1B are schematic views of a projection forming apparatus, where FIG. 1A shows a state before processing the workpiece, and FIG. 1B shows a state after processing the workpiece.
- (A) is a photograph of the seat gear provided with the downward projection W1 as seen from below
- (b) is a photograph of the seat gear provided with the downward projection W1 as seen from above. It is the A section enlarged view of FIG.1 (b). It is a partial cross-sectional view of the molded product W01 after processing.
- FIG. 4 is a graph showing the results of measuring the hardness of portions P1 to P4 in FIG. 3 of the protrusions formed in the present embodiment. It is the figure which showed 2nd Embodiment of this invention, and respond
- the projection forming apparatus 1 is an apparatus for forming a projection on a plate-like workpiece W such as a steel plate.
- FIG. 1A shows a projection W1 molding in which the workpiece W is arranged on the projection forming apparatus 1.
- FIG. 1B is a schematic view showing a state in which the protrusion W1 is formed on the workpiece W arranged in the protrusion forming apparatus 1 in the previous state.
- the projection forming apparatus 1 of the present embodiment is used when the projection W1 is formed on a sheet gear as shown in FIG. 2, for example.
- FIG. 2A is a photograph of the seat gear provided with the downward projection W1, as viewed from below
- FIG. 2B is a photograph of the seat gear provided with the downward projection W1, as viewed from above.
- the surface area of the protrusion W1 on the side in contact with the die hole 12a is large.
- molds in the state which the protrusion part W1 protruded below as shown in FIG.2 (b) is demonstrated.
- the projection forming apparatus 1 includes a fixed unit 10, a moving unit 30 that moves up and down with respect to the fixed unit 10, and a pressing unit 50 that is held by the moving unit 30 and moves further with respect to the moving unit 30.
- “upper and lower” is the direction of the arrow shown in FIG. 1, and hereinafter, in this specification, the direction in which the moving unit 30 approaches the fixed unit 10 is downward (first direction), and the moving unit 30 is separated from the fixed unit 10. The direction is called upward.
- the fixing part 10 includes a die holder 11, a die part 12, and a guide post 13.
- the die holder 11 is manufactured by a substantially rectangular thick plate member.
- the shape of the die holder 11 is not limited to a rectangle.
- a through hole 11 a is provided at the center of the die holder 11.
- the guide post 13 extends upward from the outer periphery of the die holder 11 in the figure. In this embodiment, for example, four guide posts 13 (only two are shown in the figure) are provided.
- the die portion 12 is disposed on the inner side of the guide post 13 on the upper surface of the die holder 11 and is fixed to the die holder 11.
- the die part 12 is a metal member having a constant thickness, and a die hole 12a corresponding to the shape of the protrusion part W1 formed by the protrusion part forming apparatus 1 is provided in the center part.
- a plurality of guide holes 12b are provided outside the die hole 12a in the die portion 12.
- a lower mold part 20 that is substantially the same shape and the same size as the die hole 12a and determines the height of the protrusion W1 is disposed inside the die hole 12a.
- An upper end of a rod-shaped knockout member 21 for discharging the workpiece W is attached to the lower surface of the lower mold part 20.
- the lower end of the knockout member 21 extends downward from the above-described through hole 11a provided in the die holder 11, and is connected to a drive mechanism (not shown). The drive mechanism presses the lower mold part 20 upward via the knockout member 21.
- the moving unit 30 includes a punch holder 31, a backing plate 32, a guide pin 36, and a punch unit 40.
- the punch holder 31 is made of a thick plate member having substantially the same size as the die holder 11.
- a first through hole 31 a is provided on the outer periphery of the punch holder 31 at a position corresponding to the above-described guide post 13.
- a guide bush 31c is inserted and fixed in the first through hole 31a.
- the guide bush 31 c is a cylindrical material and extends below the punch holder 31.
- the guide post 13 is inserted into the guide bush 31c, and when the guide bush 31c moves along the outer periphery of the guide post 13, a stable vertical movement of the moving part 30 relative to the fixed part 10 is ensured.
- a plurality of second through holes 31b are provided on the inner side of the punch holder 31 with respect to the guide bush 31c.
- the backing plate 32 is attached to the inner side of the lower surface of the punch holder 31 from the position where the guide bush 31c is provided.
- a two-stage hole 33 continuing from the second through hole 31 b is provided at a position corresponding to the second through hole 31 b described above.
- the second step hole 33 has the same axis as the second through hole 31b, is continuous with the second through hole 31b, and has the same diameter as the second through hole 31b, and the same as the second through hole 31b.
- the second hole 33b has an axis, is provided below the first hole 33a, and has a smaller diameter than the first hole 33a.
- the guide pin 36 is attached to the lower surface on the outer peripheral side of the two-step hole 33 of the backing plate 32 and extends downward from the backing plate 32.
- the punch portion 40 is fixed to the lower surface of the central portion of the backing plate 32.
- the punch section 40 includes a large punch section 41 on the backing plate 32 side and a small punch section 42 on the workpiece W side.
- the holding part 50 includes a bolt member 34, a holding plate 37, and a coil spring 35.
- the bolt member 34 has a head portion 34a smaller than the diameter of the second through hole 31b and the first hole 33a and larger than the diameter of the second hole 33b, and an extension having a diameter smaller than the diameter of the second hole 33b. Part 34b.
- the bolt member 34 has the head portion 34 a facing upward, and the extending portion 34 b is inserted into the second through hole 31 b, the first hole 33 a, and the second hole 33 b and is screwed to the pressing plate 37.
- the coil spring 35 is disposed at a portion protruding from the backing plate 32 of the bolt member 34 (the bolt member 34 is inserted into the coil spring 35).
- the pressing plate 37 is disposed on the outer peripheral side of the punch portion 40.
- the holding plate 37 is a thick plate member, and a first opening 37a is formed at the center.
- the first opening 37a is substantially the same diameter as the large punch 41 of the punch 40, and the large punch 41 is the first. It can slide in the one opening 37a.
- a bottomed bolt fixing screw portion 37 b is provided on the outer peripheral side of the first opening 37 a on the upper surface of the pressing plate 37.
- the threaded portion 37b is provided at a position corresponding to the extending portion 34b of the bolt member 34 described above, and the distal end of the extending portion 34b is inserted and fixed to the threaded portion 37b.
- the coil spring 35 is disposed between the backing plate 32 and the pressing plate 37 on the outer periphery of the extending portion 34b.
- a second opening 37 c is provided at a position corresponding to the above-described guide pin 36 on the outer peripheral side of the first opening 37 a of the pressing plate 37.
- a guide pin 36 is inserted into the second opening 37c. The lower end of the guide pin 36 is further inserted into the guide hole 12b of the die part 12, and the guide pin 36 is guided straight by the guide hole 12b of the die part 12 and the second opening part 37c.
- the workpiece W is disposed on the die portion 12.
- the workpiece W is, for example, a hot rolled steel plate (SPFH590) for automobiles.
- the workpiece W When forming a protrusion on the workpiece W, the workpiece W is disposed on the die portion 12. At this time, it positions so that the projection part formation location in the to-be-processed body W may be located on the die hole 12a.
- the moving unit 30 of the projection forming apparatus 1 is positioned above the state of FIG. Next, the moving unit 30 is lowered by a driving mechanism (not shown), and the pressing plate 37 is brought into contact with the workpiece W. Then, the moving part 30 is lowered, and the lower surface of the small punch part 42 of the punch part 40 is brought into contact with the workpiece W as shown in FIG.
- the moving unit 30 is further pressed downward by the driving mechanism.
- the punch 40 is further lowered, and the small punch 42 and the large punch 41 press the workpiece W.
- the workpiece W undergoes plastic deformation to form a projection W1 having a desired shape.
- the moving part 30 is raised to separate the workpiece W from the small punch part 42 and the large punch part 41, and the lower mold part 20 is pushed up by the knockout member 21.
- the protrusion W1 of the workpiece W is pushed out from the die hole 12a, and the workpiece W can be taken out.
- FIG. 3 is an enlarged view of a portion A in FIG. 1B after the projection W1 is formed.
- FIG. 4 is a partial cross-sectional view of the molded product W01 after the projection W1 is molded.
- the distance between the side surface of the small punch portion 42 and the side surface of the large punch portion 41 is d1
- the distance between the side surface of the small punch portion 42 and the inner surface of the die hole 12a is d2.
- d2 ⁇ d1 (1) There is a relationship.
- the width S1 of the large punch portion 41, the width S2 of the small punch portion 42, and the width S3 of the die hole 12a in a predetermined cross section are: S2 ⁇ S3 ⁇ S1 (2)
- the distance d2 between the side surface of the small punch portion 42 and the inner surface of the die hole 12a when inserted into the die hole 12a is less than the plate thickness T of the workpiece W. T> d2 (3)
- the molded product W01 when viewed as a molded product W01, has a flat portion W2 having a thickness T and a thickness protruding downward from the one surface A side of the flat portion W2 in FIG. A projection portion W1 of T, and a rising portion P2 rising from the flat portion W2 to the projection portion W1.
- the distance d2 between the side surface of the small punch portion 42 and the inner surface of the die hole 12a when inserted into the die hole 12a is the thickness d2 of the rising portion P2 in the direction orthogonal to the thickness T direction of the flat portion W2.
- the height H from one surface A of the flat portion W2 to one surface B of the protrusion W1 is relative to the plate thickness T of the workpiece W.
- the portion on the opposite side to the one surface B of the protruding portion W1 is pressed by the punch portion 40, so that it is a concave portion.
- the recess is formed by further recessing the first recess D1 having the first width S1 that is approximately the same as the width S1 of the large punch portion 41, and a second recess that is approximately the same as the width S2 of the small punch portion 42.
- the width of the protrusion W1 on the one surface B side is equal to the width S3 of the die hole 12a, and as described above, S2 ⁇ S3 ⁇ S1 (2) Satisfy the relationship.
- FIG. 5A and 5B are views showing a comparative form, in which FIG. 5A shows a state in which the workpiece W is arranged on the die portion 12A of the comparative form, and FIG. W shows a state in which the protrusion W1 is formed.
- the punch part 40A of the comparative form does not have a large punch part as shown, but has only a small punch 42A.
- the distance d2 between the side surface of the small punch portion 42 and the inner surface of the die hole 12a is equal to or less than the plate thickness T of the workpiece W.
- the punch unit 40A when the punch unit 40A is lowered from the state of FIG. 5A, the punch unit 40A (small punch 42A) presses the workpiece W as shown in FIG. 5B.
- the indentation depth is increased, the workpiece W is plastically deformed.
- the edge of the protrusion becomes sharp.
- cracks are generated because tensile stress acts on the rising portion (P2 in the drawing) of the protrusion.
- the punch part 40 of this embodiment has a two-stage structure of a large punch part 41 and a small punch part 42 as shown in FIG.
- symbol B in FIG. 3 of the to-be-processed body W is pressed below by the large punch part 41, when shape
- the material of this B part flows to another part as shown by the arrow in FIG. That is, the material is pressed and flows, and the material is supplied to the portion where the tensile stress acts, so that the tensile stress is relaxed.
- the pressed portion 41 is forged and the hardness is increased.
- FIG. 6 is a graph showing the results of measuring the hardness of the P1 to P4 portions in FIG. 3 of the workpiece W formed in the present embodiment.
- the position indicated by the dotted line is the hardness 197HV of the workpiece W itself. According to this embodiment, any part of P1 to P4 is hard, and the product strength can be improved.
- the protrusion W1 since the protrusion W1 also has a deformed form due to shearing, the corner portion R of the workpiece W after molding becomes sharp (angle drift hardly occurs). Therefore, fine irregularities can be formed. Further, the material that has flowed from the portion B not only increases the hardness, but also flows to other portions of the workpiece W. By this flow, a predetermined thickness can be secured at the portions P2 and P3 that are the rising portions of the protrusion W1. Further, the fluidized material is applied to the corner portion C1 between the large punch portion 41 and the small punch portion 42 in the workpiece W and the corner portion C2 between the lower mold portion 20 and the side surface of the die hole 12a. Since it is pushed in, the corner portion R of the workpiece W after molding becomes sharper (an angle drift is less likely to occur). Therefore, finer irregularities can be formed.
- the edge of the protrusion W1 becomes sharp in this way, the surface area of the portion in contact with the die hole 12a of the protrusion W1 increases. For this reason, when rotating the to-be-processed body W by making the projection part W1 contact other members, a big rotational torque can be taken out. Therefore, for example, it is suitable for manufacturing a projection such as a seat gear.
- FIG. 7 is a diagram showing a second embodiment of the present invention, and corresponds to FIG. 3 of the first embodiment.
- FIG. 8 is a partial cross-sectional view of the molded product W02 after processing in the second embodiment.
- the difference between the present embodiment and the first embodiment is that the lower surface of the small punch portion 42 is provided with a slope 42a that is inclined in a direction in which the thickness of the small punch portion 42 decreases as it goes toward the edge of the small punch portion 42. This is the point.
- the molded product W02 of the second embodiment is different from the molded product W01 of the first embodiment in that a slope W1a is formed on the bottom surface of the second recess D2 by the slope 42a of the small punch portion 42. .
- the other parts are the same and will not be described.
- the punch portion 40 when the punch portion 40 is pressed against the surface of the workpiece W, since the inclined surface 42a is provided, the material present in the D portion of the workpiece W where the inclined surface 42a is located is shown in the drawing. It tends to flow in the direction indicated by the arrow. Therefore, the flow of the material to the portion P2 between the small punch portion 42 that is liable to crack and the inner surface of the die hole 12a is further promoted. Thereby, the protrusion part W1 which is hard to produce a crack (crack) still more than 1st Embodiment can be formed.
- the fluidized material flows to the other part of the workpiece W.
- This fluidized material is pushed into the corner C1 between the large punch 41 and the small punch 42 in the workpiece W and the corner C2 between the lower die 20 and the side surface of the die hole 12a.
- the corner portion R of the workpiece W (molded product W02) after molding becomes sharper. Therefore, finer irregularities can be formed.
- the protrusion forming apparatus 1 of the first embodiment shown in FIG. After forming the protrusion W1 on the workpiece W by the protrusion forming apparatus 1 of the second embodiment shown in FIG. 7, the protrusion forming apparatus 1 of the first embodiment shown in FIG. Thus, the workpiece W is further pressed to form the protrusion W1 more sharply.
- the punch portion 40 when the punch portion 40 is pressed against the surface of the workpiece W by the projection forming apparatus 1 shown in FIG. 7, the material of the surface of the workpiece W is transferred to the small punch portion 42 by the inclined surface 42 a. Flow outward.
- the edge portion can be made sharper by further flowing the material of the portion shown in FIG. 7 by the protruding portion forming apparatus 1 shown in FIG.
- FIG. 9 shows the fourth embodiment of the present invention and corresponds to FIG. 3 of the first embodiment.
- FIG. 10 is a partial cross-sectional view of a molded product W04 after processing in the fourth embodiment.
- the punch portion 40 of the projection forming apparatus 1 of the present embodiment is different from the first embodiment in that the projection 43 along the outer periphery of the small punch portion 42 is formed at the end of the surface of the small punch portion 42 on the workpiece W side. Is a point provided.
- the molded product W04 of the fourth embodiment is different from the molded product W01 of the first embodiment, as shown in FIG. 10, by the protrusion 43, a recess W1b is further formed at the corner of the bottom surface of the second recess D2. It is a point that has been.
- the other parts are the same and will not be described.
- the pressing load can be reduced as compared with the case where the entire lower surface of the punch portion 40 is pressed during molding.
- the protrusion 43 is provided when the punch portion 40 is pressed against the surface of the workpiece W, the material existing in the E portion of the workpiece W where the protrusion 43 is located is used. It tends to flow in the direction indicated by the arrow in the figure. Therefore, the flow of the material to the portion P2 between the small punch portion 42 that is liable to crack and the inner surface of the die hole 12a is further promoted. Thereby, the protrusion part W1 which is hard to produce a crack (crack) still more than 1st Embodiment can be formed. Moreover, the fluidized material not only increases the hardness but also flows to other parts of the workpiece W.
- This fluidized material is pushed into the corner C1 between the large punch 41 and the small punch 42 in the workpiece W and the corner C2 between the lower die 20 and the side surface of the die hole 12a.
- the corner portion R of the workpiece W after molding becomes sharper. Therefore, finer irregularities can be formed.
- the workpiece W is a hot rolled steel plate SPFH590.
- the mechanical properties are YS (yield stress) 522 MPa, TS (tensile strength) 604 MPa, EL (elongation) 26%, and the plate thickness is 2.9 mm. Two types of 5 mm were used. Table 1 shows measured values of the protrusion W1 of the workpiece W formed using the protrusion forming apparatus 1 of each embodiment.
- FIG. 3 shows which portion of each of the remaining direction thickness and (5) corner portion is.
- the height of the protruding portion is obtained when the thickness of the workpiece W is 2.9 mm or 2.5 mm.
- a protrusion W1 having a thickness H equal to or greater than the plate thickness T shown in Formula (4) (H ⁇ T) could be formed.
- the second embodiment, the third embodiment, and the fourth embodiment (2) remaining in the width direction when the thickness of the workpiece W is 2.9 mm or 2.5 mm.
- Plate thickness d2 (2) Plate thickness direction remaining plate thickness (4) 45 ° direction remaining plate thickness In a state where a predetermined thickness is secured within a range equal to or less than plate thickness T of workpiece W, protrusion W1 could be molded.
- the third embodiment in which the protrusion W1 is further formed based on the first embodiment has a smaller corner droop and a sharper protrusion.
- W1 could be molded.
- the corner droop is smaller than that in the first embodiment and the second embodiment, and sharp.
- a projection W1 could be formed.
Abstract
Description
しかし、絞り加工は、パンチの側面とダイス孔の内面との間の距離が板厚以上であることが必要である。また、絞り加工の場合、パンチとダイスの角部のR(丸み)が大きい。このため、エッジがシャープな突起部を成形することができない。
ファインブランキング法とは、被加工体に圧縮力を作用させることで塑性変形させて高精度にせん断加工を行う方法である。
しかし、ファインブランキング法は、突起部の高さが板厚以上の場合、成形が困難である。それは、一般にパンチ径とダイス孔径とが略同一であるため、突起部の高さが板厚以上になると、被加工体がせん断力により切断されて加工することができないからである。
本発明の目的は、板厚以上の高さが形成でき、エッジがシャープで、さらに亀裂の発生が防止される突起部成形装置、突起部成形方法及び成形品を提供することである。
以下、図面に基づいて本発明の実施形態の突起部成形装置1の全体構成について説明する。突起部成形装置1は、鋼板等の板状の被加工体Wに突起部を成形する装置であり、図1(a)は突起部成形装置1に被加工体Wを配置した突起部W1成形前の状態、図1(b)は突起部成形装置1に配置した被加工体Wに突起部W1を成形した状態を示した概略図である。
なお、以下の説明において、図2(b)に示すように突起部W1が下に突き出した状態に成形する場合について説明する。
ダイスホルダ11は、略矩形の厚板部材で製造されている。なお、ダイスホルダ11の形状は矩形に限定されない。ダイスホルダ11の中央部には貫通孔11aが設けられている。
ガイドポスト13は、ダイスホルダ11の外周部から図中上方に向かって延びている。本実施形態でガイドポスト13は、例えば4本(図では2本のみ示す)設けられている。
ダイス部12は、一定の厚みの金属部材で、中央部には、突起部成形装置1により成形する突起部W1の形状に対応したダイス孔12aが設けられている。
また、ダイス部12におけるダイス孔12aの外側には、複数のガイド孔12bが設けられている。
下型部20の下面には、被加工体W排出用の棒状のノックアウト部材21の上端が取り付けられている。ノックアウト部材21の下端はダイスホルダ11に設けられた上述の貫通孔11aより下方に延び、図示しない駆動機構に連結されている。駆動機構は、ノックアウト部材21を介して下型部20を上方に押圧する。
パンチホルダ31の外周部には、上述のガイドポスト13に対応する位置に第1貫通孔31aが設けられている。第1貫通孔31aにはガイドブッシュ31cが挿入されて固定されている。ガイドブッシュ31cは筒状材で、パンチホルダ31の下方に延びている。ガイドポスト13はガイドブッシュ31cの内部に挿入され、ガイドブッシュ31cがガイドポスト13の外周に沿って移動することにより、移動部30の固定部10に対する安定した上下動が確保される。
バッキングプレート32における、上述の第2貫通孔31bに対応する位置には、第2貫通孔31bから連続する、2段孔33が設けられている。
2段孔33は、第2貫通孔31bと同一軸線を有し、第2貫通孔31bから連続し、且つ第2貫通孔31bと同径の第1孔33aと、第2貫通孔31bと同一軸線を有し、第1孔33aよりも下方に設けられ、第1孔33aよりも小径の第2孔33bとを備える。
パンチ部40は、後に詳述するがバッキングプレート32側の大パンチ部41と、被加工体W側の小パンチ部42とを備える。
ボルト部材34は、第2貫通孔31b及び第1孔33aの径よりも小さく、且つ第2孔33bの径よりも大きなヘッド部34aと、第2孔33bの径よりも小さい径を有する延在部34bとを有する。
ボルト部材34は、ヘッド部34aを上にして、延在部34bが、第2貫通孔31b、第1孔33a及び第2孔33b内に挿入され、押さえ板37にねじ留めされている。
押さえ板37の上面の第1開口部37aの外周側には、有底のボルト固定用ねじ部37bが設けられている。ねじ部37bは上述のボルト部材34の延在部34bに対応する位置に設けられ、このねじ部37bに延在部34bの先端が挿入されて固定されている。
コイルスプリング35は、延在部34bの外周の、バッキングプレート32と押さえ板37との間に配置されている。
また、押さえ板37の第1開口部37aの外周側の、上述のガイドピン36と対応する位置には、第2開口部37cが設けられている。第2開口部37c内にはガイドピン36が挿入されている。ガイドピン36の下端は、さらにダイス部12のガイド孔12bに挿入され、ガイドピン36は、ダイス部12のガイド孔12b、及び第2開口部37cによって直進案内される。
なお、この時点で突起部成形装置1の移動部30は、図1(a)の状態よりも上方に位置する。
次いで、図示しない駆動機構により、移動部30を下降させ、押さえ板37を、被加工体Wに当接させる。
そして、移動部30を下降させ、そして、図1(a)に示すようにパンチ部40の小パンチ部42の下面を、被加工体Wに当接させる。
図1(b)に示すように被加工体Wには塑性変形が発生して所望の形の突起部W1が形成される。
その後、移動部30を上昇させて、被加工体Wと小パンチ部42及び大パンチ部41とを離間させ、下型部20をノックアウト部材21によって押し上げる。
そうすると、被加工体Wの突起部W1がダイス孔12aから押し出され、被加工体Wの取り出しが可能となる。
本実施形態においては、図3に示すように、小パンチ部42の側面と大パンチ部41の側面との間隔をd1、小パンチ部42の側面とダイス孔12aの内面との間隔をd2とすると、
d2<d1・・・・・(1)
の関係がある。
S2<S3<S1・・・・・(2)
の関係がある。
(S1-S2)/2=d1,(S3-S2)/2=d2であり、式(2)よりS3<S1であるので、上記(1)式のd2<d1となる。
T>d2・・・・・(3)
ダイス孔12aに挿入されたときの小パンチ部42の側面とダイス孔12aの内面との間隔d2は、立ち上がり部P2の、平坦部W2の厚さT方向と直交する方向の厚さd2であるとも言え、上述のように
T>d2・・・・・(3)
の関係を満たす。
H≧T・・・・・(4)
の関係を満たすことが可能である。
S2<S3<S1・・・・・(2)
の関係を満たす。
なお、比較形態においても小パンチ部42の側面とダイス孔12aの内面との間隔d2は被加工体Wの板厚T以下である。
押し込み深さが深くなると、被加工体Wが塑性変形する。ここで、被加工体Wはせん断加工により変形するため、突起部のエッジはシャープになる。しかし突起部の立ち上がり部(図示するP2の部分)に引張応力が作用するためクラックが発生する。
本実施形態によると、被加工体Wの図3に符号Bで示す部分に存在していた部分が、突起部W1を成形する際に大パンチ部41により下方に押圧される。そうすると、このB部の材料は図3に矢印で示すように他の部分に流動する。すなわち、材料が押圧されて流動し、引張応力が作用する部分に材料供給が行われ、引張応力が緩和される。また、大パンチ部41に押圧されることにより、この押圧された部分が鍛造され硬さが上昇する。
図6中、点線で示した位置は、被加工体W自体の固さ197HVである。本実施形態によると、P1からP4のいずれの部分でも硬くなっており、製品強度の向上も可能となる。
また、部分Bから流動した材料は、硬度を上昇させるだけでなく、被加工体Wの他の部分に流動する。この流動により、突起部W1の立ち上がり部であるP2及びP3の部分で、所定の厚みを確保することができる。また、この流動された材料は、被加工体Wにおける大パンチ部41と小パンチ部42との間の角部C1や、下型部20とダイス孔12aの側面との間の角部C2に押し込まれるので成形後の被加工体Wの角部のRがよりシャープになる(角度だれが生じにくい)。ゆえに、さらに微細な凹凸を形成することができる。
図7は、本発明の第2実施形態を示した図で、第1実施形態の図3に対応している。図8は、第2実施形態における加工後の成形品W02の一部断面図である。
本実施形態が第1実施形態と異なる点は、小パンチ部42の下面には、小パンチ部42の縁部に向かうに従って、小パンチ部42の厚みが薄くなる方向に傾いた斜面42aが設けられている点である。
また、第2実施形態の成型品W02が第1実施形態の成型品W01と異なるのは、小パンチ部42の斜面42aにより、第2凹部D2の底面に斜面W1aが形成されている点である。他の部分については同様であるので説明を省略する。
したがって、亀裂が生じやすい小パンチ部42とダイス孔12aの内面との間のP2の部分への材料の流動がさらに促進される。これにより、第1実施形態よりもさらにクラック(亀裂)が生じにくい突起部W1を形成することができる。
第3実施形態は、図7に示す第2実施形態の突起部成形装置1により、被加工体Wに突起部W1を形成したのち、さらに図3に示す第1実施形態の突起部成形装置1により、被加工体Wをさらに押圧して突起部W1をさらにシャープに成形する方法である。
本実施形態によると、まず、図7の突起部成形装置1により、パンチ部40を被加工体W表面に押し付ける際に、斜面42aによって、被加工体Wの表面の材料を小パンチ部42の外側に流動させる。
次いで、図3の突起部成形装置1により、図7の部分の材料をさらに流動させることにより、よりエッジ部をシャープにすることができる。
図9は、本発明の第4実施形態を示した図で、第1実施形態の図3に対応している。図10は第4実施形態における加工後の成形品W04の一部断面図である。
本実施形態の突起部成形装置1のパンチ部40が第1実施形態と異なる点は、小パンチ部42の被加工体W側の面の端部に、小パンチ部42外周に沿った突起43が設けられている点である。
そして、第4実施形態の成型品W04が第1実施形態の成型品W01と異なるのは、図10に示すように、突起43により、第2凹部D2の底面の角部にさらに凹部W1bが形成されている点である。他の部分については同様であるので説明を省略する。
したがって、亀裂が生じやすい小パンチ部42とダイス孔12aの内面との間のP2の部分への材料の流動がさらに促進される。これにより、第1実施形態よりもさらにクラック(亀裂)が生じにくい突起部W1を形成することができる。
また、流動した材料は、硬度を上昇させるだけでなく、被加工体Wの他の部分に流動する。この流動された材料は、被加工体Wにおける大パンチ部41と小パンチ部42との間の角部C1や、下型部20とダイス孔12aの側面との間の角部C2に押し込まれ、成形後の被加工体Wの角部のRがさらにシャープになる。ゆえに、より微細な凹凸を形成することができる。
突起部成形装置1に、最大荷重400トンの荷重を加えることが可能なナックルプレス機を用いて荷重を加えた。
被加工体Wは熱間圧延鋼板のSPFH590であり、機械的特性は、YS(降伏応力)522MPa、TS(引張強さ)604MPa、EL(伸び)26%、板厚は2.9mmと2.5mmとの2種類を用いた。
以下、それぞれの実施形態の突起部成形装置1を用いて成形された被加工体Wの突起部W1の測定値を表1に示す。
(1)突起部高さ(H)、(2)幅方向残存板厚(小パンチ部の側面とダイス孔の内面との間隔d2)、(3)板厚方向残存板厚(4)45°方向残存板厚、(5)角部だれ、のそれぞれがどの部分であるかは図3に示す。
また、第1実施形態、第2実施形態、第3実施形態及び第4実施形態において、被加工体Wの板厚が2.9mmと2.5mmのいずれの場合も、(2)幅方向残存板厚d2、(3)板厚方向残存板厚(4)45°方向残存板厚において、被加工体Wの板厚T以下の範囲内で所定の厚みが確保された状態で、突起部W1を成形することができた。
さらに、第2実施形態に基づいて突起部W1を成形した後、さらに第1実施形態に基づいて突起部W1を成形した第3実施形態は、角部だれが、小さくなり、よりシャープな突起部W1を成形することができた。
また、小パンチ部42の被加工体W側の面の端部に突起43を設けた第4実施形態においても、第1実施形態及び第2実施形態よりも角部だれが、小さくなり、シャープな突起部W1を成形することができた。
10 固定部
11 ダイスホルダ
12 ダイス部
12a ダイス孔
30 移動部
31 パンチホルダ
32 バッキングプレート
36 ガイドピン
37 押さえ板
40 パンチ部
41 大パンチ部
42 小パンチ部
42a 斜面
43 突起
Claims (11)
- ダイス孔が設けられたダイス部と、
前記ダイス部側に向かう第1方向に進退可能であって、前記ダイス孔に挿入不能な大きさの大パンチ部、及び、該大パンチ部から前記ダイス部側に突出し、前記ダイス孔に挿入可能な大きさの小パンチ部を有するパンチ部と、を備え、
前記ダイス部と前記パンチ部との間に配置された被加工体の一部を、前記パンチ部により前記ダイス部側に押圧することにより、前記被加工体を変形させて突起部を形成する、
突起部成形装置。 - 前記小パンチ部の側面と前記大パンチ部の側面との間隔d1と、
前記小パンチ部の側面と前記ダイス孔の内面との間隔d2とが、
d2<d1
の関係にある、
請求項1に記載の突起部成形装置。 - 前記小パンチ部の側面と前記ダイス孔の内面との間隔d2と、
前記被加工体の板厚Tとが、
d2<T
の関係にある、
請求項1または2に記載の突起部成形装置。 - 前記小パンチ部の下面には、前記小パンチ部の縁部に向かうに従い、前記小パンチ部の厚さが薄くなる方向に傾いた斜面が設けられている、
請求項1から3のいずれか1項に記載の突起部成形装置。 - ダイス孔が設けられたダイス部に被加工体を載置する載置工程と、
前記ダイス孔に挿入不能な大きさの大パンチ部、及び、該大パンチ部から前記ダイス部側に突出し、前記ダイス孔に挿入可能な大きさの小パンチ部を有するパンチ部を、前記ダイス部側に向かう第1方向に移動させ前記ダイス部と前記パンチ部との間に配置された被加工体の一部を、前記パンチ部により前記ダイス部側に押圧し、前記被加工体を変形させて突起部を形成するパンチ工程と、
を含む、
突起部成形方法。 - 前記小パンチ部の側面と前記大パンチ部の側面との間隔d1と、
前記小パンチ部の側面と前記ダイス孔の内面との間隔d2とが、
d2<d1
の関係にある、
請求項5に記載の突起部成形方法。 - 前記小パンチ部の側面と前記ダイス孔の内面との間隔d2と、
前記被加工体の板厚Tとが、
d2<T
の関係にある、
請求項5または6に記載の突起部成形方法。 - 前記パンチ工程は、
前記小パンチ部の下面には、前記小パンチ部の縁部に向かうに従い前記小パンチ部の厚さが薄くなる方向に傾いた斜面が設けられているパンチ部により、突起部を形成する第1工程と、
前記小パンチ部の下面が平面であるパンチ部により、突起部を形成する第2工程と、
を含む、
請求項5から7のいずれか1項に記載の突起部成形方法。 - 厚さTの平坦部と、前記平坦部の一面側より突出した突起部とを備える成形品であって、
前記成形品における前記突起部の他面側には、
第1の幅S1を有する第1凹部と、
前記第1凹部から更に凹んで形成され、第2の幅S2を有する第2凹部と、が形成され、
前記第2凹部における側壁部の厚さd2と、前記平坦部の厚さTとは、d2<Tの関係を満たす成形品。 - 前記平坦部の前記一面から、前記突起部の前記一面側の上面までの高さHとしたときに、
H≧T
である請求項9に記載の成形品。 - 前記第1凹部の幅S1と、前記第2凹部の幅S2と、前記一面側における前記突起部の幅S3とは、S2<S3<S1の関係を満たす請求項9または10に記載の成形品。
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US11224909B2 (en) | 2022-01-18 |
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