WO2022039167A1 - 加工品及び加工品製造方法 - Google Patents
加工品及び加工品製造方法 Download PDFInfo
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- WO2022039167A1 WO2022039167A1 PCT/JP2021/030069 JP2021030069W WO2022039167A1 WO 2022039167 A1 WO2022039167 A1 WO 2022039167A1 JP 2021030069 W JP2021030069 W JP 2021030069W WO 2022039167 A1 WO2022039167 A1 WO 2022039167A1
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- die
- processed product
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- cut
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/16—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
- 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
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D51/00—Making hollow objects
- B21D51/16—Making hollow objects characterised by the use of the objects
- B21D51/18—Making hollow objects characterised by the use of the objects vessels, e.g. tubs, vats, tanks, sinks, or the like
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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
- B21D53/00—Making other particular articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D15/00—Shearing machines or shearing devices cutting by blades which move parallel to themselves
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
- C23C2/06—Zinc or cadmium or alloys based thereon
Definitions
- the present invention relates to a processed product having a cut end portion and a processed product manufacturing method for manufacturing the processed product, using a plated steel sheet having a plated layer on the surface as a material.
- processed products made of plated steel sheets having a plated layer on the surface are increasingly used as parts of equipment such as automobiles and home appliances.
- a plated steel sheet as a material, surface treatment after molding of the processed product can be omitted, and the manufacturing cost can be suppressed.
- Omitting the surface treatment after molding it is possible to avoid deterioration of the dimensional accuracy of the parts due to the surface treatment after molding. Omitting the surface treatment after molding is particularly considered for parts that require high dimensional accuracy, such as motor cases.
- the area where the steel sheet substrate is exposed appears at the cut end of the processed product.
- red rust may occur in the exposed area of the steel sheet substrate. Red rust deteriorates the appearance of processed products.
- the area where red rust is generated expands with the passage of time, there is a concern that the strength of the processed product may decrease due to red rust.
- electrical short circuit due to lack of rust.
- motor cases and the like have a shape that does not have a flange.
- a motor case is used by inserting a motor through the opening of the motor case and sealing the opening with another part called a bottom plate. If moisture enters the inside of the motor case, it may cause a failure of the motor or deterioration of performance, so that high airtightness is required between the opening and the bottom plate. In order to ensure high airtightness, a predetermined flat portion is required for the opening.
- the thickness of the Zn-based plated steel sheet is 0 on the shoulder of the punch or die.
- punching using a die having a radius of curvature of 1 to 0.5 times, the ratio of the sheared surface of the punched end surface after punching is 90% or more, and the zinc coverage of the sheared surface is increased.
- a method of increasing to 50% or more has been proposed.
- the punching clearance is set to 1 to 20% of the plate thickness regardless of the plate thickness of the Zn-based plated steel sheet, and the thickness of the Zn-based plated steel sheet is 0.12 on the shoulder of the punch or die.
- a Zn-based galvanized steel sheet is cut using a mold with a radius of curvature that is more than double, and processed products with a sagging Z of 0.10 x plate thickness or more and a sagging X of 0.45 x plate thickness or more on the cut end face are cut. How to get it has been proposed.
- Patent Document 3 a method of obtaining a product having corrosion resistance of an end face by half-cutting a plated steel sheet with a minus clearance to 60 to 95% of the plate thickness and shearing it by flat pressing from the opposite side of the half-cutting. Has been proposed.
- Patent Document 4 a first step of half punching a metal plate material by using a first punch and a first die and attaching a shaving allowance to the final processed surface of a punched portion of the metal plate material is described. Using a second punch and a second die, it has a second step of further performing shaving processing mainly on shearing on the half-punched portion, and 70% or more on the final processed surface of the punched portion. A method for pressing a metal plate material to secure a sheared surface is disclosed.
- Patent Document 1 targets a steel plate having a plate thickness of 2 mm or less, and when a steel plate having a plate thickness of more than 2 mm is used as a material, the zinc coverage of the sheared surface becomes insufficient and red rust occurs. It can be difficult to control. In addition, it is difficult to apply it to drawn products such as motor cases where the flange end is thickened.
- the plated steel sheet is half-cut with a minus clearance and sheared by flat pressing from the opposite side of the half-cut. For this reason, a fracture surface may be formed at an intermediate position in the plate thickness direction of the cut end portion of the plated steel sheet, and whiskers-like burrs may be generated when the plated steel sheet is pressed flat, resulting in deterioration of shape quality.
- Patent Document 4 is a technique related to shaving processing, and the final processed surface of the metal plate material is made good by forming a large sheared surface. Even if a metal plate having a plating layer on the surface is shaving by the method described in Patent Document 4, the plating layer on the surface hardly remains on the final processed surface, so that the corrosion resistance of the final processed surface is low.
- the present invention has been made in view of the above problems, and an object of the present invention is corrosion resistance and shape quality even when a plated steel sheet having a plate thickness of more than 2.0 mm is used as a material. It is an object of the present invention to provide a good processed product and a method for manufacturing the processed product.
- a processed product made of a plated steel sheet having a plating layer on the surface and having a cut end portion on a hollow tubular side wall, and the cut end portion is , It is flush with the outer surface of the side wall of the processed product, and has a sheared surface and a fracture surface in order in the plate thickness direction of the cut end, or has a sheared surface, and the sheared surface is due to the plating layer on the surface.
- a processed product is provided in which the ratio L / t1 of the residual length L of the plated component covered and the plate thickness t1 of the cut end portion of the processed product is 0.70 or more.
- the length W1 of the fracture surface in the plate thickness direction of the cut end portion may be more than 0 mm and 1.0 mm or less.
- the length W1 of the fracture surface in the plate thickness direction of the cut end portion may be 0.5 mm or less.
- the ratio Lt / t of the length Lt of the flat surface of the end face of the processed product orthogonal to the side wall and the plate thickness t of the side wall of the processed product may be 0.35 or more.
- the length of the burr at the cut end may be less than 0.2 mm.
- the cut end portion has a shear surface, a fracture surface and a coining surface in order in the plate thickness direction of the cut end portion, or a shear surface and a coining surface in order, and the shear surface of the cut end portion in the plate thickness direction.
- the length W2 of the fracture surface between the surface and the coining surface may be more than 0 mm and 0.5 mm or less.
- it is for manufacturing a processed product which uses a plated steel plate having a plating layer on the surface as a material and has a cut end portion on a hollow tubular side wall.
- the half-cut first element body is finished and cut from the same direction as the half-cutting, and the outer surface and surface of the side wall of the processed product are cut.
- the inner diameter D 32 of the second die is set to be equal to or larger than the inner diameter D 31 of the first die, and the plate thickness of the cut portion of the first element is t1.
- the clearance C 31-41 between the first die and the first punch satisfies the following formula (a1), where the remaining plate thickness of the cut portion after the half-cutting step is t2, and the cutting edge of the first die.
- the radius of curvature R1 of 1 satisfies the following formula (a2), and the pushing amount D of the first die or the first punch with respect to the cut portion of the first element body satisfies the following formula (a3) and is the first at the bottom dead point.
- the distance CPD between the die and the first punch satisfies the following formula (a4), and the clearance C 32-42 between the second die and the second punch satisfies the following formula (a5) in the finish cutting step.
- a method for manufacturing a processed product is provided, wherein the radius of curvature R2 of the cutting edge of the second die satisfies the following formula (a6). -0.35 x t1 ⁇ C 31-41 ⁇ -0.01 ...
- a processed product having a plated steel plate having a plating layer on the surface as a material and having a cut end portion on a hollow tubular side wall is manufactured.
- the first die and the first punch in which the clearance between the first die and the first punch is set to a negative clearance which is a method for manufacturing a processed product, the cut portion of the first prime field formed from the material is cut into a plate.
- the half-cut first prime field is finished and cut from the same direction as the half-cutting, and the outer surface and surface of the side wall of the processed product are cut.
- the inner diameter D 32 of the second die is set to be equal to or larger than the inner diameter D 31 of the first die, and the plate thickness of the cut portion of the first prime field is t1.
- the clearance C 31-41 between the first die and the first punch satisfies the following formula (b1), where the remaining plate thickness of the cut portion after the half-cutting step is t2, and the cutting edge of the first die.
- the radius of curvature R11 of the above satisfies the following equation (b2-1), and the radius of curvature R12 of the cutting edge of the first punch satisfies the following equation (b2-2), and the first die or the first die or the first die with respect to the cut portion of the first prime field.
- the pushing amount D of one punch satisfies the following formula (b3), and the distance CPD between the first die and the first punch at the bottom dead point satisfies the following formula (b4).
- a processed product manufacturing method in which the clearance C 32-42 between the second die and the second punch satisfies the following formula (b5), and the radius of curvature R2 of the cutting edge of the second die satisfies the following formula (b6).
- the processed product obtained in the finish cutting step is used as the second element, and the corners of the cut end of the second element are pressed against the pad to form a coining surface at the corners. It may further include a coining step to obtain the product.
- the difference D 32 -D 31 between the inner diameter D 31 of the first die and the inner diameter D 32 of the second die may be 1.00 mm or less.
- the above-mentioned processed product manufacturing method may further include a preparatory step of forming a first prime field having a hollow side wall and a flange portion from a flat plate-shaped plated steel plate before the semi-cutting step.
- the corrosion resistance and shape quality of the obtained processed product can be improved.
- FIG. 2 is a detailed view of a cross-sectional view on the left side. It is a schematic diagram explaining the airtightness by the size of the flat surface of a processed product end. It is explanatory drawing which shows the processed product manufacturing method which concerns on the same embodiment.
- the cut end portion of the processed product after the coining step is shown, the left side is a cross-sectional view on the ZX plane including the central axis of the processed product, and the right side is a side view from the X direction.
- it is a photograph showing a deformed squeezed product.
- As an example of the processed product of the present invention it is a photograph showing a square tube squeezed product.
- FIG. 1 is a perspective view showing an example of a processed product 1 manufactured by the processed product manufacturing method according to the first embodiment of the present invention.
- the processed product 1 shown in FIG. 1 is a motor case made of a plated steel plate having a plating layer on the surface.
- the motor case shown in FIG. 1 can be formed by subjecting a flat plate-shaped plated steel sheet to a forming process such as drawing.
- the processed product 1 has a body portion 10 and a protrusion portion 11.
- the body portion 10 has a hollow cylindrical side wall 101 and a top wall 103 formed so as to cover one end of the side wall 101.
- the top wall 103 may be called another way such as a bottom wall depending on the orientation in which the processed product 1 is used.
- the body portion 10 of the processed product 1 shown in FIG. 1 has a perfect circular cross-sectional shape in an XY plane, but the present invention is not limited to this example.
- the cross-sectional shape of the body portion 10 on the XY plane may be another shape such as an ellipse or a polygon.
- the body portion 10 has an opening on the opposite side of the top wall 103. The motor is inserted through the opening.
- the protrusion 11 is a protrusion protruding from the top wall 103 to the outside in the central axial direction (Z direction) of the body 10.
- the protrusion 11 does not necessarily have to be formed, and the top wall 103 may have a flat plate shape.
- the body portion 10 has a cut end portion 13 on the outer surface of the end portion on the opening side.
- the cut end portion 13 is formed by cutting the prime field processed into the processed product 1.
- the cut end portion 13 is formed so as to be flush with the outer surface of the body portion 10.
- Cutting processing includes processing such as cutting, punching and drilling.
- Cutting is a process of cutting an object to be cut along a predetermined straight line or curve.
- Punching is the process of punching a product from the object to be cut.
- Drilling is a process of punching a non-product part from a cutting target to obtain a product having an opening.
- the body portion 10 having the cut end portion 13 shown in FIG. 1 can be obtained by punching from the prime field.
- the plated steel sheet it is preferable to use a plated steel sheet having various plating layers.
- various steel sheets can be used, but it is preferable to use a Zn-based plated steel sheet.
- Zn-based plating includes Zn plating, Zn-Al-based alloy plating, Zn-Al-Mg-based alloy plating, and Zn-Al-Mg-Si-based alloy plating.
- the plated steel sheet it is particularly preferable to use a steel sheet plated with a Zn—Al—Mg based alloy.
- the alloy plating preferably contains 80% by mass or more of Zn, and more preferably 90% by mass or more of Zn, based on the total number of moles of the plating.
- the base steel sheet of the plated steel sheet is arbitrary, but may be, for example, ultra-low carbon steel or the like.
- the lower limit of the amount of plating adhered to the plated steel sheet is preferably 30 g / m 2 , and more preferably 45 g / m 2 may be the lower limit.
- the plating adhesion amount on the plated steel sheet may be preferably 450 g / m 2 as the upper limit, and more preferably 190 g / m 2 as the upper limit.
- the plating adhesion amount is 45 g / m 2 or more, the plated metal easily wraps around the sheared surface of the cut end portion 13 (sheared surface 13c in FIG. 2), so that the corrosion resistance after the cutting process can be improved.
- the plate thickness of the plated steel plate is arbitrary, but may be 2.0 mm or less, or may be more than 2.0 mm.
- the thickness of the plated steel sheet may be, for example, 0.8 mm or more and 6.0 mm or less, more preferably 2.0 mm or more and 4.5 mm or less.
- FIG. 2 shows the cut end portion 13 in the region A of the processed product 1 of FIG. 1, the left side is a cross-sectional view on a ZX plane including the central axis of the processed product 1, and the right side is a side view from the X direction.
- FIG. 3 is a detailed cross-sectional view on the left side of FIG. In FIG. 2, the description of the plating layers 13f1 and 13f2 is omitted.
- the cut end portion 13 of the processed product 1 is formed so as to be flush with the outer surface of the processed product 1, for example, the outer surface 101a of the side wall 101 in the Z direction. Further, the cut end portion 13 is a direction parallel to the central axis of the processed product 1 and is orthogonal to the plate thickness direction (hereinafter, also referred to as “first direction”) T1 of the side wall 101 (hereinafter, “first direction”). Also referred to as "direction 2”) It is formed along T2.
- the cut end portion 13 has, in order, a shear surface 13c and a fracture surface 13d in the second direction T2, for example, as shown in FIGS. 2 and 3.
- the curved surface portion Rd is exaggerated so as to be slightly present at the boundary between the outer surface 101a and the cut end portion 13 of the processed product, but the curved surface portion Rd is shown between the outer surface 101a and the cut end portion.
- the outer surface 101a and the cut end portion 13 can be regarded as flush with each other without causing a large step at the boundary with 13.
- the step between the surface of the cut end portion 13 and the outer surface 101a of the side wall 101 is 0.5 mm or less, it is determined that there is no large step, and the outer surface 101a and the cut end portion 13 are regarded as flush with each other.
- the upper limit of this step may be 0.4 mm, 0.3 mm, 0.2 mm or 0.1 mm.
- the plate thickness t of the processed product 1 is the plate thickness at the lowermost portion of the side wall 101 of the processed product 1. That is, the plate thickness of the side wall 101 just above the curved surface portion Rd at the boundary between the outer surface 101a of the side wall 101 and the cut end portion 13 is defined as the plate thickness t of the processed product 1.
- the sheared surface 13c is a surface on which the element body of the processed product 1 is sheared by the cutting edge of the cutting die.
- the fracture surface 13d is a surface in which cracks generated in the element body from the cutting edge of the cutting die are associated and broken.
- the fracture surface 13d is adjacent to the shear plane 13c in the second direction T2. Burrs may occur on the lower side of the fracture surface 13d (that is, on the side opposite to the shear surface 13c).
- the burr is a portion where the prime field is stretched or torn off when the fracture surface 13d is formed.
- a part of the sheared surface 13c of the cut end portion 13 is covered with the plating layer 13f1.
- the plating layer 13f1 is stretched by the cutting die and wraps around the sheared surface 13c. Due to the wraparound of the plating layer 13f1, at least a part of the sheared surface 13c is covered with the plating layer 13f1. The occurrence of red rust can be suppressed in the portion of the sheared surface 13c covered with the plating layer 13f1.
- the plating layer 13f1 is a Zn-based plating layer
- the occurrence of red rust can be suppressed even in the vicinity of the portion covered by the plating layer 13f1 due to the sacrificial anticorrosion action of the Zn-based plating layer.
- the processed product 1 shown in FIG. 3 is a processed product 1 having almost no step at the boundary between the outer surface 101a and the cut end portion 13, the curved surface portion Rd is not shown in FIG.
- the length L of the plating layer 13f1 covering at least a part of the sheared surface 13c of the cut end portion 13 is the plate thickness t1 of the cut end portion 13 of the processed product 1 (hereinafter, “cut end portion”). It is 0.70 times or more the length t1 of 13.). That is, the ratio L / t1 of the residual length L of the plating component whose shear surface 13c is covered by the plating layer 13f1 and the plate thickness t1 of the cut end portion 13 of the processed product 1 is 0.70 or more. The larger the ratio L / t1, the more preferable. The lower limit of the ratio L / t1 may be 0.75, 0.78, 0.81, 0.83, 0.85 or 0.88.
- the upper limit of the ratio L / t1 is 1.00.
- the plate thickness t1 of the cut end portion 13 is the length in the second direction T2 from the lower end of the curved surface portion Rd to the end surface of the body portion 10 (end surface 14a in FIG. 3). ..
- the fracture surface 13d is generated as a result of the association of cracks generated in the element body, and is a rough new surface.
- the metal component of the steel substrate is exposed.
- the plating layer 13f1 covering the sheared surface 13c does not easily wrap around to the fracture surface 13d. Therefore, the fracture surface 13d is more likely to generate red rust ahead of the other surfaces of the cut end portion 13.
- the present inventors conducted experiments in which the plate thickness t1 of the cut end portion 13 of the processed product 1, the cutting processing conditions, the surface treatment conditions, and the like were changed in various ranges, and the occurrence of red rust was investigated.
- the plate thickness t1 of the cut end portion 13 of the processed product 1 was changed by changing the plate thickness of the flange portion 20 (that is, the plate thickness of the plated steel plate) shown on the left side of FIG. 5, which will be described later.
- the plating layer 13f1 was made to wrap around the sheared surface 13c, and it was conceived to obtain a processed product 1 having a ratio L / t1 of 0.70 or more.
- the occurrence of red rust at the cut end portion 13 can be suppressed with the passage of time after the cutting process.
- the length W1 of the fracture surface 13d in the plate thickness direction (that is, the second direction T2) of the cut end portion 13 of the processed product 1 (hereinafter, also referred to as “fracture surface length”) is more than 0 mm. It is preferably 1.0 mm or less. If the fracture surface length W1 of the processed product 1 is 1.0 mm or less, even if red rust occurs on the fracture surface 13d, it is not noticeable, so it can be judged that there is no practical problem.
- the fracture surface length W1 of the processed product 1 is preferably small, and may be 0.8 mm or less or 0.6 mm or less.
- the fracture surface length W1 of the processed product 1 is 0.5 mm or less, 0.3 mm or less, or 0.2 mm or less. Further, the ratio W1 / t1 of the fracture surface length W1 and the plate thickness t1 of the cut end portion 13 of the processed product 1 is less than 0.15, less than 0.10, less than 0.08, less than 0.06, or 0. It may be less than 04.
- the fracture surface length W1 of the processed product 1 may be 0 mm. That is, the cut end portion 13 of the processed product 1 does not have to have the fracture surface 13d. In this case, the cut end 13 has only the shear plane 13c in the second direction T2.
- the end surface 14a of the opening (opening 14 in FIG. 4) of the processed product 1 according to the present embodiment has a flat surface 13k.
- the end surface 14a of the body portion 10 is usually a mounting surface for other parts.
- the bottom plate 15 is fixed to the end surface 14a of the body portion 10 and the opening is sealed.
- the larger the length Lt of the flat surface 13k of the end surface 14a of the body portion 10 the larger the contact area of the bottom plate 15 with the mounting surface 15a, and the airtightness can be improved.
- the ratio Lt / t of the length Lt of the flat surface 13k and the plate thickness t of the side wall 101 of the processed product 1 is 0.35 or more, 0.40 or more, or 0.50.
- the above is preferable, and more preferably 0.60 or more, 0.70 or more, 0.80 or more, or 0.85 or more.
- the length of the burr generated on the lower side of the fracture surface 13d of the cut end portion 13 of the processed product 1 may be less than 0.2 mm. Burrs can cause dents, electrical short circuits, and the like. By setting the length of the burr to less than 0.2 mm and preventing the burr from remaining in the processed product 1 as much as possible, it is possible to suppress the occurrence of dents, electrical short circuits, and the like.
- the length of the burr is more preferably less than 0.1 mm.
- the processed product according to this embodiment is manufactured by cutting a plated steel sheet by two steps, a semi-cutting step and a finish cutting step, instead of cutting in one step. As a result, it is possible to obtain a processed product 1 in which a larger number of plating layers 13f1 are wrapped around the sheared surface 13c.
- the processed product manufacturing method according to the present embodiment will be described.
- FIG. 5 is an explanatory diagram showing a processed product manufacturing method according to the present embodiment.
- the processed product manufacturing method according to the present embodiment includes a preparation step, a semi-cutting step, and a finish cutting step.
- the preparation process is the process of preparing the first prime field 2.
- the first prime field 2 can be obtained by subjecting a flat plate-shaped plated steel sheet to a forming process such as drawing. That is, the first prime field 2 is made of a plated steel plate as the processed product 1.
- the first prime field 2 has a flange portion 20 at a position to be a cut end portion 13 shown in FIG.
- the flange portion 20 may have a circular outer shape or a non-circular outer shape in a plan view. With respect to the portion other than the flange portion 20, the first prime field 2 may have the same shape as the processed product 1.
- the preparation step is not an indispensable part for the implementation of the present invention. If the prime field processed by a third party can be obtained by some method, the preparation step can be omitted.
- the half-cutting step is a step of half-cutting the first prime field 2.
- the flange portion 20 is half-cut.
- the half-cutting is a process of cutting the flange portion 20 to an intermediate position in the cutting direction of the flange portion 20.
- the flange portion 20 is a removal portion 20a that is finally outside the product, and is cut at a boundary position with a portion that becomes a side wall 101 of the body portion 10 of the processed product 1.
- the cutting direction of the flange portion 20 is the plate thickness direction of the flange portion 20.
- the finish cutting process is a process of finishing cutting the first prime field 2.
- the finish cutting step the half-cut flange portion 20 is cut and separated from the portion serving as the side wall 101 of the body portion 10 of the processed product 1.
- a processed product 1 having a cut end portion 13 formed flush with the side wall 101 can be obtained.
- the end surface 14a of the opening 14 of the processed product 1 is covered with the plating layer 13f2 on the inner side surface 101b side of the body portion 10. Further, the end surface 14a of the opening 14 of the processed product 1 is formed so as to have a flat surface 13k.
- the first prime field 2 is processed by using a die and a punch.
- the details of the semi-cutting process and the finishing cutting process will be described in two forms according to the shapes of the cutting edges of the die and the punch used in the semi-cutting process.
- the cutting edge of the die and punch may be referred to as the "shoulder".
- the upper mold upper mold
- the lower mold lower mold
- the moving direction of the die and the punch is determined according to the installation state, and may move in the vertical direction or may move in the horizontal direction.
- FIG. 6 is an explanatory diagram showing a half-cutting process when the cutting edge of the die used in the half-cutting process has an R shape.
- FIG. 7 is an explanatory diagram showing a finish cutting step performed following the half-cutting step of FIG.
- the flange portion 20 of the first prime field 2 is half-cut using the first die 31 and the first punch 41.
- the flange portion 20 is half-pulled out from the first prime field 2 in which the portion to be the side wall 101 of the body portion 10 is sandwiched by the first punch 41 and the first guide 51.
- the first die 31 constitutes a cutting die that is pushed into the flange portion 20 in half-cutting.
- the mold for pressing the end surface (end surface 14a in FIG. 3) of the side wall 101 of the body portion 10 is the first punch 41
- the mold for pressing the flange portion 20 that is, the removed portion 20a
- the first. 1 die 31 is used.
- the clearance C 31-41 between the first die 31 and the first punch 41 is a negative clearance.
- the clearance C 31-41 represents a gap between the first die 31 and the first punch 41, and specifically, as shown in FIG. 6, the side surface 31a of the first die 31 and the side surface 41a of the first punch 41 It is expressed by the distance of.
- the clearance when the first punch 41 is separated from the first punch 41 is called a plus clearance
- the clearance when the first die 31 and the first punch 41 partially overlap is called a minus clearance.
- the clearance between the die and the punch the positive clearance is represented by a positive value and the negative clearance is represented by a negative value.
- the first die 31 and the first punch 41 are one when viewed from the pushing direction of the first die 31. They are arranged so that they overlap. Assuming that the clearance C 31-41 is a plus clearance, cracks generated from the cutting edges of the first die 31 and the first punch 41 are associated with each other as in the case of punching performed once, and the removed portion 20a from the flange portion 20 is completely removed. There is a possibility of being disconnected. Further, the cutting position of the flange portion 20 is separated from the side wall 101 of the body portion 10, the cut end portion 13 is not flush with the side wall 101, and a step is generated on the outer surface of the processed product 1.
- the clearance C 31-41 By setting the clearance C 31-41 to a negative clearance, it is possible to prevent the flange portion 20 (that is, the removed portion 20a) from being completely cut from the first prime field 2 in the semi-cutting step, and to make the cut end portion 13 a side wall. It can be flush with 101.
- the clearance C 31-41 [mm] between the first die 31 and the first punch 41 is ⁇ 0.01 mm or less and the cut portion of the first prime field 2 (that is, that is, as shown in the following formula (a1)).
- the plate thickness t1 [mm] of the flange portion 20) is set to ⁇ 0.35 times or more.
- the plate thickness t1 of the cut portion (that is, the flange portion 20) of the first prime field 2 is equal to the plate thickness (t1) of the cut end portion 13 of the processed product 1.
- the clearance C 31-41 When the clearance C 31-41 is ⁇ 0.01 mm or less, the negative clearance can be maintained without partially becoming a positive clearance due to the slide accuracy of the press machine, the misalignment of the die, and the like. As a result, cracks are generated during the half-cutting, complete cutting occurs, and a large fracture surface does not occur. On the other hand, if the clearance C 31-41 is ⁇ 0.35 times or more the plate thickness t1 of the flange portion 20, the forming load required for half-cutting does not increase and the pressing capacity is not exceeded. Therefore, the burden on the mold is small, and it is possible to suppress a decrease in the life of the mold.
- the clearance C 31-41 is ⁇ 0.30 times or more, ⁇ 0.25 times or more, or ⁇ 0.20 times or more the plate thickness t1 of the flange portion 20.
- the width Lt of the flat surface 13k can be 0.35 times or more the plate thickness t of the side wall 101 of the processed product 1.
- the upper limit of the clearance C 31-41 may be ⁇ 0.05 times, ⁇ 0.10 times, or ⁇ 0.15 times the plate thickness t1 of the flange portion 20.
- the cutting edge of the first die 31 has an R shape having a radius of curvature R1. As shown in FIG. 6, since the first die 31 is pushed into the flange portion 20, the cutting edge of the first die 31 has an R shape having a radius of curvature R1.
- the radius of curvature R1 is 0.10 times or more and 0.50 times or less the plate thickness t1 [mm] of the flange portion 20 of the first prime field 2.
- the radius of curvature R1 is 0.10 times or more the plate thickness t1
- a large hydrostatic pressure is generated under a negative clearance without scraping the plating layer 13f1
- the scrap material directly under the first die 31 is used as the first die 31. It can flow from the cutting edge of the first die 31 to the side surface 31a side of the first die 31. Due to this flow, in the stress generated when the first die 31 is pushed into the flange portion 20, between the material that becomes scrap (that is, the removed portion 20a) after the cutting process and the side wall material that becomes the side wall 101 of the body portion 10. The proportion of tensile stress generated in the scrap is reduced. As a result, it is possible to wrap around the sheared surface 13c plating layer 13f1.
- the radius of curvature R1 is 0.50 times or less the plate thickness t1
- the amount of material located at the cutting edge of the first die 31 is reduced during half-cutting, and a fracture surface 13d is generated in the subsequent finish cutting. Can be reduced.
- the cutting edge of the first punch 41 has a square shape without roundness as shown in FIG.
- the cutting edge of the first punch 41 may have a radius of curvature less than 0.1 times the plate thickness t1 of the flange portion 20 of the first prime field 2.
- the radius of curvature of the cutting edge of the first punch 41 may be less than 0.06 times, less than 0.04 times, or less than 0.02 times the plate thickness t1 of the flange portion 20 of the first prime field 2, if necessary. ..
- the pushing amount D [mm] of the first die 31 into the flange portion 20 of the first prime field 2 is the cut portion of the first prime field 2 (that is, the flange portion 20). It is set to 0.70 times or more of the plate thickness t1 [mm].
- the pushing amount D is a position where the pushing of the first die 31 is stopped from a position where the first die 31 comes into contact with the upper surface of the flange portion 20 of the first prime field 2 (hereinafter, this position is referred to as this position). It is the amount of movement of the first die 31 to the "bottom dead center").
- the distance CPD [mm] between the first die 31 and the first punch 41 at the bottom dead center is set to 0.20 mm or more as shown in the following formula (a4).
- the residual plate thickness t2 in which the flange portion 20 (that is, the removed portion 20a) remains in the first prime field 2 after half-cutting may be 0.30 times or less the plate thickness t1 [mm] of the flange portion 20.
- the residual plate thickness t2 is the residual plate thickness on the outer surface 101a of the side wall 101 of the processed product 1. If the indentation amount D is 0.70 times or more the plate thickness t1, it becomes difficult to generate a fracture surface 13d in the subsequent finish cutting.
- a distance CPD between the first die 31 and the first punch 41 at the bottom dead center of 0.20 mm or more cracks occur during half - cutting and partial complete cutting occurs. You can avoid it.
- the burden on the mold is small, and it is possible to suppress a decrease in the life of the mold.
- the interval CPD is the minimum value of the interval between the first die 31 and the first punch 41 at bottom dead center.
- the pushing amount D of the first die 31 into the flange portion 20 of the first prime field 2 is the plate thickness t1 [mm] of the flange portion 20 of the first prime field 2. It may be 0.70 times or more of, but may be set to 0.95 times or less (0.70 ⁇ t1 ⁇ D ⁇ 0.95 ⁇ t1).
- the pushing amount D is 0.95 times or less of the plate thickness t1
- cracks occur during half-cutting due to the slide accuracy of the press machine, misalignment of the die, and the like, resulting in complete cutting. No large fracture surface is generated.
- the burden on the mold is small, and it is possible to suppress a decrease in the life of the mold.
- the half-cut flange portion 20 is finish-cut using the second die 32 and the second punch 42.
- the portion to be the side wall 101 of the body portion 10 is sandwiched by the second punch 42 and the second guide 52, and the flange portion 20 (that is, the removed portion 20a) is sandwiched from the first prime field 2.
- the second die 32 constitutes a cutting die that is pushed into the flange portion 20 in finish cutting.
- the second punch 42 is the mold that presses the portion that becomes the end surface (end surface 14a in FIG.
- the second die 32 may be the same as the first die 31. That is, the first die 31 used in the half-cutting step may be used as the second die 32 in the finishing cutting step.
- the positional relationship between the second die 32 and the first prime field 2 is the same as the positional relationship between the first die 31 and the first prime field 2. If these positional relationships are not the same, for example, if the diameter of the second die 32 is larger than the diameter of the first die 31, a step is generated at the cut end portion 13. On the contrary, for example, when the diameter of the second die 32 is smaller than the diameter of the first die 31, the second die 32 comes into contact with the half-cut end portion generated in the half-cutting step and wraps around the sheared surface 13c. The second die 32 may scrape off the plating layer 13f.
- the finish cutting according to this embodiment is performed from the same direction as the half cutting. That is, when the first die 31 is pushed into the flange portion 20 from above the flange portion 20 in half-cutting as shown in FIG. 6, the flange portion 20 is pushed from above the flange portion 20 in finish cutting as shown in FIG. Push in the second die 32. As a result, the removed portion 20a is separated from the first prime field 2.
- the clearance C 32-42 between the second die 32 and the second punch 42 is a plus clearance.
- the clearance C 32-42 is represented by the distance between the side surface 32a of the second die 32 and the side surface 42a of the second punch 42.
- the clearance in a state where the second die 32 and the second punch 42 are separated is called a plus clearance, and a state in which the second die 32 and the second punch 42 partially overlap each other.
- the clearance at is called minus clearance.
- the clearance C 32-42 [mm] between the second die 32 and the second punch 42 is 0.01 mm or more, and the removed portion 20a is the first prime field 2 after half-cutting.
- the thickness is set to 0.2 times or less of the remaining plate thickness t2 remaining on the flange portion 20 of the above.
- the clearance C 32-42 is 0.01 mm or more, even if the slide accuracy of the press machine or the misalignment of the die occurs during finish cutting, the blade of the second die 32 and the blade of the second punch 42 Does not come into contact with. On the other hand, if the clearance C 32-42 is 0.2 times or less the remaining plate thickness t2, burrs are less likely to be generated at the tip of the fracture surface 13d.
- the lower limit of the clearance C 32-42 may be 0.05 times or 0.10 times the remaining plate thickness t2.
- the cutting edge of the second die 32 has an R shape having a radius of curvature R2. As shown in FIG. 7, since the second die 32 is pushed into the portion where the finish cutting of the flange portion 20 is performed, the cutting edge of the second die 32 has an R shape having a radius of curvature R2.
- the cutting edge of the second punch 42 has a square shape without roundness as shown in FIG. 7. At this time, the cutting edge of the second punch 42 may have a radius of curvature of less than 0.25 mm, less than 0.15 mm, less than 0.10 mm, or less than 0.05 mm.
- the radius of curvature of the cutting edge of the second punch 42 may be less than 0.1 times the plate thickness t1 of the flange portion 20 of the first prime field 2, and if necessary, less than 0.06 times, 0.04. It may be less than double or less than 0.02 times.
- the radius of curvature R2 [mm] is 0.25 mm or more and 1.50 times or less of the remaining plate thickness t2 of the half-cut portion, as shown in the following formula (6).
- the second die 32 does not scrape off the plating layer 13f1 that wraps around the sheared surface 13c.
- the radius of curvature R2 is 1.50 times or less the remaining plate thickness t2, burrs are less likely to be generated at the tip of the fracture surface 13d.
- the inner diameter D 32 of the second die 32 is the same as or slightly larger than the inner diameter D 31 of the first die 31. Specifically, it is desirable that the difference D 32 -D 31 between the inner diameter D 31 of the first die 31 and the inner diameter D 32 of the second die 32 is 1.00 mm or less. As a result, it is possible to reduce the step generated at the cut end portion 13 of the processed product 1 by the inner diameter difference D 32 -D 31 of the dies 31 and 32 in order to carry out the two steps of the semi-cutting step and the finishing cutting step. It is possible to obtain a good cut cross section. If the step of the cut end portion 13 is allowed as the quality of the processed product 1, the inner diameter difference D 32 -D 31 may be more than 1.00 mm.
- the upper limit of the inner diameter difference D 32 -D 31 is preferably as small as possible, and may be 0.75 mm, 0.50 mm, 0.35 mm or 0.20 mm.
- the lower limit of the inner diameter difference D 32 -D 31 is 0 mm.
- FIG. 8 is an explanatory diagram showing a half-cutting process when the cutting edge of the die and the punch used in the half-cutting process has an R shape.
- FIG. 9 is an explanatory diagram showing a finish cutting step performed following the half-cutting step of FIG.
- the flange portion 20 of the first prime field 2 is half-cut using the first die 31 and the first punch 41.
- the flange portion 20 is formed from the first prime field 2 in which the portion to be the side wall 101 of the body portion 10 is sandwiched by the first punch 41 and the first guide 51.
- the mode of half-punching is shown.
- the first die 31 constitutes a cutting die that is pushed into the flange portion 20 in half-cutting.
- the mold for pressing the end surface (end surface 14a in FIG. 3) of the side wall 101 of the body portion 10 is the first punch 41
- the mold for pressing the flange portion 20 that is, the removed portion 20a
- the first. 1 die 31 is used.
- the clearance C 31-41 between the first die 31 and the first punch 41 is a negative clearance. Therefore, as shown in FIG. 8, the first die 31 and the first punch 41 that half-cut the first prime field 2 are the first die 31 and the first punch 41 when viewed from the pushing direction of the first die 31. Are arranged so that they partially overlap.
- the clearance C 31-41 to a negative clearance, it is possible to prevent the flange portion 20 (that is, the removed portion 20a) from being completely cut from the first prime field 2 in the semi-cutting step, and to make the cut end portion 13 a side wall. It can be flush with 101.
- the meanings of the clearance C 31-41 , the negative clearance and the plastic clearance in the present embodiment b are the same as those in the above embodiment a.
- the clearance C 31-41 [mm] between the first die 31 and the first punch 41 is the plate thickness t1 of the cut portion (that is, the flange portion 20) of the first prime field 2 as shown in the following formula (b1). It is set to ⁇ 0.10 times or less and ⁇ 0.45 times or more of [mm].
- the clearance C 31-41 is ⁇ 0.10 times or less the plate thickness t1 of the flange portion 20, a large hydrostatic stress is generated in the region sandwiched by the first die 31 and the first punch 41, and the tensile stress is increased. The percentage decreases. As a result, cracks are generated during the half-cutting, complete cutting occurs, a large fracture surface is not generated, and the flange portion 20 (that is, the removed portion 20a) is the first prime field 2 in the half-cutting step. You can avoid being completely disconnected from.
- the clearance C 31-41 is ⁇ 0.45 times or more the plate thickness t1 of the flange portion 20, the forming load required for half-cutting does not increase and the pressing capacity is not exceeded. Therefore, the burden on the mold is small, and it is possible to suppress a decrease in the life of the mold.
- the clearance C 31-41 is ⁇ 0.15 times or less the plate thickness t1 of the flange portion 20.
- the clearance C 31-41 is ⁇ 0.15 times or less the plate thickness t1 of the flange portion 20.
- the lower limit of the clearance C 31-41 may be ⁇ 0.40 times, ⁇ 0.35 times, or ⁇ 0.30 times the plate thickness t1 of the flange portion 20.
- the cutting edges of the first die 31 and the first punch 41 have an R shape.
- the radius of curvature R11 [mm] of the cutting edge of the first die 31 and the radius of curvature R12 [mm] of the cutting edge of the first punch 41 are as shown in the following equations (b2-1) and (b2-2).
- the thickness of the cut portion (that is, the flange portion 20) of the first prime field 2 is 0.10 times or more and 0.65 times or less the plate thickness t1 [mm].
- the radius of curvature R11 of the cutting edge of the first die 31 and the radius of curvature R12 of the cutting edge of the first punch 41 may be the same or different.
- the scrap material directly under the first die 31 is used as the first material. It can flow from the cutting edge of the die 31 to the side surface 31a side of the first die 31. Due to this flow, in the stress generated when the first die 31 is pushed into the flange portion 20, between the material that becomes scrap (that is, the removed portion 20a) after the cutting process and the side wall material that becomes the side wall 101 of the body portion 10. The proportion of tensile stress generated in the scrap is reduced. As a result, it is possible to wrap around the sheared surface 13c plating layer 13f1.
- the radii of curvature R11 and R12 are 0.65 times or less of the plate thickness t1
- the amount of material located at the cutting edge of the first die 31 is reduced during half-cutting, and the fracture surface 13d in the subsequent finish cutting. Generation can be reduced.
- the pushing amount D [mm] of the first die 31 into the flange portion 20 of the first prime field 2 is the cut portion (that is, the flange portion 20) of the first prime field 2 as shown in the following formula (b3). It is set to 0.70 times or more of the plate thickness t1 [mm].
- the pushing amount D is a position where the pushing of the first die 31 is stopped from a position where the first die 31 comes into contact with the upper surface of the flange portion 20 of the first prime field 2 (hereinafter, this position is also referred to as "bottom dead center”. .) Is the amount of movement of the first die 31.
- the distance CPD [mm] between the first die 31 and the first punch 41 at the bottom dead center is set to 0.20 mm or more as shown in the following formula (b4).
- the residual plate thickness t2 in which the flange portion 20 (that is, the removed portion 20a) remains in the first prime field 2 after half-cutting may be 0.30 times or less the plate thickness t1 [mm] of the flange portion 20.
- the residual plate thickness t2 is the residual plate thickness on the outer surface 101a of the side wall 101 of the processed product 1, and is different from the interval CPD . If the pushing amount D is 0.70 times or more the plate thickness t1 of the flange portion 20, it becomes difficult to generate a fracture surface 13d in the subsequent finish cutting.
- the interval CPD is the minimum value of the interval between the first die 31 and the first punch 41 at bottom dead center.
- the cutting edge of only the first die 31 is R-shaped as in the above embodiment a
- the pushing amount D of the first die 31 is set to the plate thickness t1 or more of the cutting portion (that is, the flange portion 20)
- the first die 31 The cutting edge of the first punch 41 comes into contact with the cutting edge of the first punch 41. Therefore, in the above-mentioned embodiment a, the pushing amount D of the first die 31 cannot be set to the plate thickness t1 or more of the flange portion 20.
- the cutting edges of the first die 31 and the first punch 41 have an R shape, as shown in FIG. 8, the first die 31 until the cutting edge of the first die 31 comes into contact with the cutting edge of the first punch 41. The amount that can be pushed in is increased.
- the cutting amount of the flange portion 20 can be made larger than that of the form a, and the ratio of the sheared surface 13c in the cut end portion 13 can be made larger.
- the plating layer 13f1 can be made to wrap around the sheared surface 13c more, and the ratio of the cut end portion 13 covered by the plating layer 13f1 can be increased.
- the remaining plate thickness t2 becomes smaller, the cutting amount in the finish cutting step becomes smaller, and it is possible to avoid a state in which the plating layer does not remain in a part of the finish cut portion.
- the finish cutting step As shown in FIG. 9, the half-cut flange portion 20 is finish-cut using the second die 32 and the second punch 42.
- the finish cutting step may be performed in the same manner as the finish cutting step shown in FIG. 7, which is performed after half-cutting with the cutting edge of only one of the first die 31 or the first punch 41 having an R shape.
- the portion to be the side wall 101 of the body portion 10 is sandwiched by the second punch 42 and the second guide 52, and the flange portion 20 (that is, the removed portion 20a) is sandwiched from the first prime field 2. ) Is finished and punched out.
- the second die 32 constitutes a cutting die that is pushed into the flange portion 20 in finish cutting.
- the second punch 42 is the mold that presses the portion that becomes the end surface (end surface 14a in FIG. 3) of the side wall 101 of the body portion 10, and the mold that presses the flange portion 20 (that is, the removed portion 20a) is the first. 2 dies 32.
- the second die 32 may be the same as the first die 31. That is, the first die 31 used in the half-cutting step may be used as the second die 32 in the finishing cutting step.
- the positional relationship between the second die 32 and the first prime field 2 is the same as the positional relationship between the first die 31 and the first prime field 2. If these positional relationships are not the same, for example, if the diameter of the second die 32 is larger than the diameter of the first die 31, a step is generated at the cut end portion 13. On the contrary, for example, when the diameter of the second die 32 is smaller than the diameter of the first die 31, the second die 32 comes into contact with the half-cut end portion generated in the half-cutting step and wraps around the sheared surface 13c. The second die 32 may scrape off the plating layer 13f.
- the finish cutting according to this embodiment is performed from the same direction as the half cutting. That is, when the first die 31 is pushed into the flange portion 20 from above the flange portion 20 in half-cutting as shown in FIG. 8, the flange portion 20 is pushed from above the flange portion 20 in finish cutting as shown in FIG. Push in the second die 32. As a result, the removed portion 20a is separated from the first prime field 2.
- the clearance C 32-42 [mm] between the second die 32 and the second punch 42 is a positive clearance.
- the clearance C 32-42 between the second die 32 and the second punch 42 is 0.01 mm or more, and the removed portion 20a remains in the first prime field 2 after half-cutting. It is set to 0.2 times or less of the remaining plate thickness t2. If the clearance C 32-42 is 0.01 mm or more, even if the slide accuracy of the press machine or the misalignment of the die occurs during finish cutting, the blade of the second die 32 and the blade of the second punch 42 Does not come into contact with. On the other hand, if the clearance C 32-42 is 0.2 times or less the remaining plate thickness t2, burrs are less likely to be generated at the tip of the fracture surface 13d.
- the cutting edge of the second die 32 has an R shape having a radius of curvature R2. As shown in FIG. 9, since the second die 32 is pushed into the portion where the finish cutting of the flange portion 20 is performed, the cutting edge of the second die 32 has an R shape having a radius of curvature R2.
- the cutting edge of the second punch 42 may be a square shape without roundness as shown in FIG. 7, or may have a radius of curvature. If the cutting edge of the second punch 42 has a square shape without roundness, the burr generated at the tip of the fracture surface 13d can be made smaller.
- the radius of curvature of the cutting edge of the second punch 42 may be less than 1.00 mm, less than 0.50 mm, less than 0.20 mm, less than 0.10 mm, or less than 0.05 mm.
- the radius of curvature of the cutting edge of the second punch 42 may be less than 0.3 times the plate thickness t1 of the flange portion 20 of the first prime field 2, and if necessary, less than 0.1 times, 0.06. It may be less than double, less than 0.04 times, or less than 0.02 times.
- the radius of curvature R2 [mm] is 0.25 mm or more and 1.50 times or less of the remaining plate thickness t2 of the half-cut portion, as shown in the above formula (6).
- the radius of curvature R2 is 0.25 mm or more, the second die 32 does not scrape off the plating layer 13f1 that wraps around the sheared surface 13c.
- the radius of curvature R2 is 1.50 times or less the remaining plate thickness t2, burrs are less likely to be generated at the tip of the fracture surface 13d.
- the processed product manufacturing method according to the first embodiment of the present invention has been described above.
- the first die 2 formed of a plated steel plate and having a flange portion 20 is targeted for cutting, and the clearance between the first die 31 and the first punch 41 is set to a negative clearance.
- the cut end portion 13 of the processed product 1 cut by such two steps has a sheared surface 13c and a fracture surface 13d in order in the plate thickness direction of the cut portion. At least a part of the sheared surface 13c is covered with the plating layer 13f1. At this time, the ratio L / t1 of the residual length L of the plating component whose shear surface 13c is covered by the plating layer 13f1 and the plate thickness t1 of the cut end portion 13 of the processed product 1 is 0.70 or more. As described above, in the processed product 1, more plating layers 13f1 wrap around the sheared surface 13c. Even when a plated steel sheet having a plate thickness of more than 2.0 mm is used as a material, corrosion resistance and shape quality can be improved.
- At least the cutting edge of the die is R-shaped for the mold used in the half-cutting step and the finish cutting step. This eliminates the need to provide a gap between the body 10 of the processed product 1 and the die pushed into the cut portion. As a result, it is possible to obtain a processed product 1 having a cut end portion 13 flush with the body portion 10 without a step on the outer surface of the processed product 1.
- the cutting edge of the die is also sharp, it is installed away from the body 10 so that the die, which is a blade, does not come into contact with the body 10.
- the end face 14a of the opening 14 of the processed product 1 can be flattened.
- the clearance C 31-41 between the die and the punch in the half-cutting step is set to a negative clearance, so that a large static pressure is generated in the region sandwiched by the first die 31 and the first punch 41. Hydrostatic stress occurs.
- the portion of the opening 14 that becomes the end surface 14a after the cutting process is compressed, and a large flat surface 13k can be formed.
- the end surface 14a of the body portion 10 is usually a mounting surface for other parts. Since the large flat surface 13k can be formed, the contact area between the mounting surface of the other component and the end surface of the body portion 10 can be increased when the other component is attached, and the airtightness can be improved.
- more plating layers 13f can be made to wrap around the sheared surface 13c, so that red rust at the cut end portion 13 generated with the passage of time after the cutting process can be suppressed. Can be done.
- the clearance C 32-42 between the second die 32 and the second punch 42 is 0.01 mm or more, and is 0.2 times the remaining plate thickness t2 on the first prime field 2 of the portion where the half cut is performed. It is set to the following. As a result, it is possible to suppress the generation of burrs while preventing the blade of the second die 32 and the blade of the second punch 42 from coming into contact with each other and being damaged during finish cutting.
- the tip of the cutting edge of the second die 32 which is pushed into the portion of the first prime field 2 to be finished cut, has a residual plate thickness t2 of 0.25 mm or more and a half-cut portion.
- a curved shape having a radius of curvature R2 of 50 times or less is provided.
- FIG. 10 is an explanatory diagram showing a processed product manufacturing method according to the second embodiment of the present invention.
- the processed product manufacturing method according to the present embodiment includes a preparation step, a semi-cutting step, a finish cutting step, and a coining step.
- the processed product manufacturing method according to the present embodiment is a method in which a coining step is added to the processed product manufacturing method according to the first embodiment shown in FIG.
- the semi-cutting step and the finishing cutting step are performed on the first prime field 2 prepared in the preparatory step, as in the first embodiment. Therefore, detailed description of the preparation step, the semi-cutting step, and the finish cutting step will be omitted.
- the processed product obtained in the finish cutting process is used as the second prime field 6, and the second prime field 6 is subjected to the coining process.
- the corner portion 13 g of the cut end portion 13 on the fracture surface 13d side is pressed against the coining lower mold (coining lower mold 7 in FIG. 11), and the coining surface 13h is formed at the corner portion.
- the processed product 1 By the coining process, the region of the fracture surface 13d, which is a rough new surface, can be narrowed, and the region where red rust is generated can be suppressed. Further, the burrs can be crushed by the coining process, and the residual burrs in the processed product 1 can be suppressed more reliably.
- FIG. 11 is a schematic diagram showing an example of a mold used for coining processing.
- FIG. 12 is a partially enlarged view of the region B of FIG.
- FIG. 13 shows the cut end portion of the processed product 1 after the coining step, the left side is a cross-sectional view on a ZX plane including the central axis of the processed product 1, and the right side is a side view from the X direction.
- FIG. 14 is a photograph showing an example of the cut end portion of the processed product 1 after the coining step.
- the description of the plating layers 13f1 and 13f2 is omitted as in FIG.
- the curved surface portion Rd is exaggerated so as to be slightly present at the boundary between the outer surface 101a and the cut end portion 13 of the processed product, but the curved surface portion Rd is shown between the outer surface 101a and the cut end portion.
- the outer surface 101a and the cut end portion 13 can be regarded as flush with each other without causing a step at the boundary with 13.
- the processed product shown in FIG. 14 is different from the processed product 1 of the present embodiment, but the appearance of the sheared surface 13c, the fracture surface 13d and the coining surface 13h of the processed product 1 according to the present embodiment is the same as that of FIG. ..
- the second prime field 6 is processed by using the coining lower mold 7 and the coining upper mold 8.
- the lower coining mold 7 and the upper coining mold 8 are formed with recesses corresponding to the outer shape of the second prime field 6.
- the lower coining mold 7 accommodates the opening 14 side of the second prime field 6, and the upper coining mold 8 accommodates the protrusion 11 side of the second prime field 6.
- the second prime field 6 is sandwiched between the coining lower mold 7 and the coining upper mold 8, and the corner portion 13 g of the cut end portion 13 of the second prime field 6 is pressed against the coining lower mold 7 (pressing in FIG. 12).
- a coining surface is formed on the cut end portion 13.
- the cut end portion 13 of the processed product 1 after the coining step is in a state as shown in the photograph of FIG. 14, for example.
- the coining lower mold 7 has a vertical wall surface 70, a bottom wall surface 71, and a pressing surface 72.
- the vertical wall surface 70 faces the sheared surface 13c of the second prime field 6 and is substantially parallel to the sheared surface 13c of the second prime field 6 when the cut end portion 13 of the second prime field 6 is sandwiched between the lower coining mold 7 and the upper coining mold 8. Arranged to be.
- the vertical wall surface 70 is arranged so as to be parallel to the advancing / retreating direction (Z direction in FIG. 12) of the coining upper die 8.
- the bottom wall surface 71 is arranged so as to face the end surface 14a with the second prime field 6 interposed therebetween.
- the bottom wall surface 71 extends in a direction orthogonal to the vertical wall surface 70.
- the pressing surface 72 is a surface connecting the bottom wall surface 71 and the bottom wall surface 71.
- the pressing surface 72 is provided to form a coining surface (coining surface 13h in FIG. 13) on the second prime field 6.
- the pressing surface 72 is formed in a shape corresponding to the shape of the coining surface. For example, as shown in FIG. 13, when the coining surface 13h is a flat chamfered surface (hereinafter referred to as “C surface”), the pressing surface 72 is relative to the vertical wall surface 70 and the bottom wall surface 71. It may be an inclined plane. Further, for example, when the coining surface 13h is a curved surface (either a pressing surface or a compressed surface; hereinafter referred to as an “R surface”), the pressing surface 72 may be a curved surface.
- the coining upper mold 8 is pushed toward the coining lower mold 7 with the cut end portion 13 of the second prime field 6 facing the vertical wall surface 70 of the coining lower mold 7.
- the second prime field 6 is sandwiched between the coining upper mold 8 and the bottom wall surface 71 of the coining lower mold 7.
- the coining upper mold 8 is pushed toward the bottom wall surface 71, and the second prime field 6 is pushed down to a position where the end surface 14a of the second prime field 6 is in contact with the bottom wall surface 71.
- the corner portion 13g is pressed against the pressing surface 72.
- the coining upper mold 8 is further pushed in, and the end surface 14a of the second prime field 6 comes into contact with the bottom wall surface 71.
- the corner portion 13g is crushed by the pressing surface 72 to become the coining surface 13h.
- the coining surface 13h is a smooth surface to which the surface of the pressing surface 72 is transferred, and red rust is less likely to occur as compared with the rough surface fracture surface 13d. It is considered that the smooth surface roughness makes it difficult for water to stay on the coining surface 13h. Further, it is considered that red rust is less likely to occur because the plating layer 13f2 that continuously covers the end surface 14a from the inner surface side of the second prime field 6 is thinly extended to the coining surface 13h.
- the fracture surface length W2 (see FIG. 13) of the cut end portion 13 after the coining process is the fracture surface length W1 (see FIG. 13) of the cut end portion 13 before the coining process.
- the region of the fracture surface 13d which is a rough new surface, can be narrowed, and the region where red rust is generated can be suppressed.
- the burrs generated in the corner portion 13 g can be crushed by the coining process, the residual burrs in the processed product 1 are less than 0.2 mm, and the residual burrs can be suppressed more reliably.
- the length of the burr is preferably less than 0.1 mm, more preferably less than 0.05 mm or less than 0.01 mm.
- the length W2 of the fracture surface 13d between the sheared surface 13c and the coining surface 13h of the processed product 1 is pressed onto the corner portion 13g so as to be more than 0 mm and 0.5 mm or less. Press 72 for the time being.
- the second prime field 6 having a fracture surface length W1 of less than 1.0 mm it is preferable to obtain the second prime field 6 having a fracture surface length W1 of less than 1.0 mm.
- the fracture surface length W2 can be more reliably set to 0.5 mm or less in the coining step.
- the fracture surface length W2 of the processed product 1 is preferably small, and may be 0.4 mm or less or 0.3 mm or less. It is more preferable that the fracture surface length W2 of the processed product 1 is 0.2 mm or less or 0.1 mm or less.
- the ratio W2 / t1 of the fracture surface length W2 and the plate thickness t1 of the cut end portion 13 of the processed product 1 is less than 0.15, less than 0.10, less than 0.08, less than 0.06, or 0. It may be less than 04.
- the fracture surface length W2 of the processed product 1 may be 0 mm. That is, the cut end portion 13 of the processed product 1 does not have to have the fracture surface 13d. That is, as shown in FIG. 13, the cut end portion 13 may have a shear surface 13c, a fracture surface 13d, and a coining surface 13h in this order in the plate thickness direction of the cut end portion 13. Alternatively, the cut end portion 13 may have a shear surface 13c and a coining surface 13h in order in the plate thickness direction of the cut end portion 13.
- FIG. 15 is an explanatory view showing the volume of the corner portion 13 g crushed by the pressing surface 72 of the coining lower mold 7 of FIG.
- the corner portion 13 g comes into contact with the pressing surface 72 and is crushed.
- the material (base steel) of the crushed corner portion 13 g moves to the sheared surface 13c side along the pressing surface 72.
- the cut end portion 13 is pushed down to a position where the end surface 14a is in contact with the bottom wall surface 71, the volume V1 of the corner portion 13g of the second prime field 6 to be crushed by the pressing surface 72 according to the position and angle of the pressing surface 72. Changes.
- the volume V1 of the corner portion 13 g crushed by the pressing surface 72 is surrounded by the extension surface 13j of the shear surface 13c, the fracture surface 13d, and the pressing surface 72, and the volume V2 of the coining space.
- the fracture surface 13d of the cut end portion 13 of the second prime field 6 is inclined with respect to the vertical wall surface 70, and there is a gap between them.
- the volume V2 of the coining space created by this gap is a space into which the material of the corner portion 13 g crushed by the pressing surface 72 flows.
- the material of the corner portion 13 g crushed by the pressing surface 72 cannot be accommodated in the volume V2, and the coining. It will move toward the upper part of the lower mold 7.
- the volume V1 to the volume V2 or less, it is possible to prevent the material of the corner portion 13g crushed by the pressing surface 72 from protruding beyond the extension surface 13j of the shear surface 13c.
- the volume V1 exceeds the volume V2
- the material of the corner portion 13g crushed by the pressing surface 72 protrudes beyond the extension surface 13j of the shear surface 13c, and the upper part of the coining lower mold 7 is formed.
- An event such as moving toward is generated.
- the dimensional accuracy of the cut end portion 13 deteriorates. Therefore, it is preferable to process the corner portion 13g by the pressing surface 72 so that the volume V1 becomes the volume V2 or less.
- the processed product manufacturing method according to the second embodiment has been described above. According to the present embodiment, as in the first embodiment, it is possible to manufacture a processed product 1 having good corrosion resistance and shape quality even when a plated steel sheet having a plate thickness of more than 2.0 mm is used as a material. can. Further, in the semi-cutting step and the finish cutting step, it is not necessary to provide a gap between the body portion 10 of the processed product 1 and the die (or punch) pushed into the cut portion, so that the body portion 10 is cut flush with each other. The processed product 1 having the end portion 13 can be obtained, and the end surface 14a of the opening 14 of the processed product 1 can be flattened.
- more plating layers 13f can be made to wrap around the sheared surface 13c, so that red rust at the cut end portion 13 generated with the passage of time after the cutting process can be suppressed. Can be done.
- the region of the fracture surface 13d which is a rough new surface, can be narrowed, and the region where red rust is generated can be suppressed. Further, the burrs can be crushed by the coining process, and the residual burrs in the processed product 1 can be suppressed more reliably.
- Example a When only the cutting edge of the die used in the half-cutting process has an R shape, Samples of processed products were prepared by the methods shown in FIGS. 5 and 10 with the shoulder portion (that is, the cutting edge) of the die in the half-cutting step as an R shape having a predetermined radius of curvature.
- the plated steel sheet a Zn-6% Al-3% Mg (mass ratio) alloy plated steel sheet having a plate thickness t1 of 1.3 to 4.4 mm and a plating adhesion amount of 90 g / m 2 (one side) was used.
- the semi-cutting process was performed by using a die having an inner diameter D 31 of 68.00 mm and a punch whose inner diameter was changed according to the clearance C 31-41 between the die and the punch, and holding the plated steel sheet by a guide.
- the finish cutting process uses a die having an R shape whose shoulder (that is, the cutting edge) has a predetermined radius of curvature, and a punch in which the inner diameter D 32 is changed according to the clearance C 32-42 between the die and the punch.
- the plated steel sheet was held and carried out.
- the flat surface width Lt of the end face, the fracture surface length W1 after finish cutting, and the fracture surface length W2 after the coining process were measured. These were measured on the circumference of the end face of the processed product at intervals of 30 ° using a microscope, and the measured values of a total of 12 points were averaged. Further, for each sample, regarding the wraparound of the plating layer to the cut end portion, the length L of the plating layer wrapping around the sheared surface of the cut end portion from the cut position was measured. An electron probe microanalyzer (EPMA-WDS) was used to measure the length L of the plating layer at the cut end. It was determined that the plating layer was present in the portion where the detection level of the Zn component was 3 times or more the background.
- the measurement target is a processed product after finish cutting or a second prime field and a processed product after coining processing.
- the sheared surface, fracture surface and coining surface at the cut end of each sample are as shown in FIG. 14, and more specifically appear as follows.
- the sheared surface appears as a smooth surface at the cut end.
- the sheared surface is generated by rubbing against the side surface of the die by applying a compressive (pressurizing) force after the die comes into contact with the workpiece and biting into the workpiece.
- the sheared surface has a metallic luster because it is rubbed against the die. On the sheared surface, fine streaky sliding scratches are seen in the plate thickness direction.
- the fracture surface is a surface where cracks generated in the work material from the sheared surface side are associated and broken, and appears as a dull and rough surface.
- the die further bites into the work material after the sheared surface is formed on the work material, the work material is cracked by the cutting edge of the punch, and the work material is also cracked by the cutting edge of the die. Cracks generated from punches and dies meet and penetrate each other.
- the surface formed by the cracks is the fracture surface.
- the fracture surface is formed without contact between the punch and the die, resulting in a dull, rough surface.
- the fracture surface has an inclination according to the gap (clearance) between the punch and the die.
- the coining surface appears as a smooth surface in which the unevenness of the fracture surface is crushed.
- the coining surface is obtained by pressing an inclined or curved coining die from the lower surface side of the fracture surface end portion against the fracture surface corner portion.
- the coining surface becomes a smooth surface in which the unevenness of the fracture surface is crushed by transferring the surface roughness of the coining die.
- a method for specifying the sheared surface, fracture surface, and coining surface at the cut end for example, a method of observing and measuring the shape profile of the cut end with a microscope or a contracer from the appearance based on the above characteristics is used. be.
- the length Lt of the flat surface of the end face is 0.35 times or more the plate thickness t of the side wall of the processed product. ) ”, And those less than 0.35 times were evaluated as“ B (impossible) ”.
- burrs that cause dents and electrical short circuits those with a size of less than 0.2 mm are "A (possible)", those with a size of 0.2 mm or more, or whiskers-like burrs are generated. The thing was evaluated as "B (impossible)”.
- the step on the end face caused by the inner diameter difference D 32 -D 31 between the inner diameter D 31 of the half-cutting die and the inner diameter D 32 of the finish-cutting die is not caused as much as possible in terms of appearance and product dimensional accuracy. .. Therefore, those having a step of 0.5 mm or less on the end face were evaluated as "A (possible)", and those having a step of more than 0.5 mm were evaluated as "B (impossible)".
- the sample was subjected to an air exposure test outdoors, and the number of days until conspicuous red rust was generated at the cut end was observed every 15 days.
- Table 1 also shows the plated steel sheet used for each sample, the conditions of the semi-cutting process and the finish cutting process, and the presence or absence of coing at the corners of the cut end.
- the plate thickness ratio (R1 / t1, R2 / t2) of the radius of curvature of the die is the roundness given to the shoulder portion of the die divided by the plate thickness. If the shoulder (blade edge) of the die is not intentionally rounded, " ⁇ 0.01" is written in this column.
- Example a19 the residual length L of the plating component with respect to the plate thickness t1 at the cut end was 0.70 times or more.
- the fracture surface length W1 of the cut end portion was 1.0 mm or less, and showed good corrosion resistance for 60 days until the occurrence of red rust.
- Examples a1 to a16 in which the fracture surface length of the cut end portion was 0.5 mm or less good corrosion resistance of 90 days or more until the occurrence of red rust was shown.
- Example a15 after finishing and punching, a coining process is performed to form an R-faced coining surface having a crushed side length (width of the coining surface) of 0.6 mm.
- Example a16 after finishing punching, a coining process is performed to form a C-faced coining surface chamfered at an angle of 45 ° with the length of the crushed side (width of the coining surface) set to 1.0 mm.
- the fracture surface length (W2) after the coining process was smaller than the fracture surface length W1 of the other examples.
- the inner diameter difference D 32 -D 31 between the inner diameter D 31 of the half-cut die and the inner diameter D 32 of the finish-cut die is 0.05 mm in Examples a1 to a17, and is zero in Example a18 (inner diameter D). 31 and the inner diameter D 32 are the same), and in Example a19, it was set to 1.00 mm, but in each case, the step on the end face was 0.5 mm or less.
- the cut ends of Examples a1 to a14, a18, and a19 have a sheared surface and a fracture surface in order in the plate thickness direction, and the cut ends of Examples a15 and a16 have a sheared surface in the plate thickness direction. It was confirmed from the appearance that the fracture surface and the coining surface were sequentially provided based on the above-mentioned characteristics.
- Comparative Examples a1 to a6, a8, and a10 to a13 the residual length L of the plating layer component with respect to the plate thickness t1 of the cut end portion of the processed product was less than 0.70, so that the cut end portion was The number of days until red rust occurred was less than 60 days, and the corrosion resistance was inferior to that of the examples.
- Comparative Example a9 a large negative clearance was adopted in the half-cutting process, but the load was exceeded in the half-punching process using a 750 kN mechanical press machine, and the press machine stopped.
- Comparative Examples a14 and a15 both showed good corrosion resistance for 90 days or more until the occurrence of red rust at the cut end, but large burrs of 0.2 mm or more were generated at the cut end.
- Comparative Example a7 the clearance between the die and the punch in the half-cutting step was set to zero, and the plated steel sheet was completely broken in the half-cutting step.
- Example b When the cutting edge of the die and punch used in the half-cutting process has an R shape, a sample of the processed product was prepared by the method shown in FIGS. 5 and 10 with the shoulder portion (that is, the cutting edge) of the die and the punch in the half-cutting step as an R shape having a predetermined radius of curvature.
- the plated steel sheet a Zn-6% Al-3% Mg (mass ratio) alloy plated steel sheet having a plate thickness of 1.3 to 4.4 mm and a plating adhesion amount of 90 g / m 2 (one side) was used.
- the semi-cutting process was performed by using a die having an inner diameter of 68.00 mm and a punch whose inner diameter was changed according to the clearance between the die and the punch, and holding the plated steel sheet by a guide.
- an R-shaped die whose shoulder (that is, the cutting edge) has a predetermined radius of curvature and a punch whose inner diameter is changed according to the clearance between the die and the punch are used, and the plated steel sheet is held by a guide. went.
- Example b For each sample, flatness evaluation, burr evaluation, and step evaluation were performed in the same manner as in Example a above, and the number of days of red rust occurrence by the air exposure test was investigated. The results of Example b are shown in Table 2.
- the residual length L of the plating component with respect to the plate thickness t1 of the cut end portion of the processed product was 0.70 times or more.
- the fracture surface length W1 of the cut end portion was 1.0 mm or less, and showed good corrosion resistance for 60 days until the occurrence of red rust.
- Examples b1 to b16 in which the fracture surface length W1 of the cut end portion was 0.5 mm or less good corrosion resistance of 90 days or more until the occurrence of red rust was shown.
- Example b15 after finishing and punching, a coining process is performed to form a coining surface of an R surface having a length of a side to be crushed (width of the coining surface) of 0.6 mm.
- Example b16 after finishing punching, a coining process is performed to form a C-faced coining surface chamfered at an angle of 45 ° with the length of the crushed side (width of the coining surface) set to 1.0 mm.
- the fracture surface length (W2) after the coining process was smaller than that of the other examples.
- the inner diameter difference D 32 -D 31 between the inner diameter D 31 of the half-cut die and the inner diameter D 32 of the finish-cut die is 0.05 mm in Examples b1 to b17 and zero in Example b18 (inner diameter D). 31 and the inner diameter D 32 are the same), and in Example b19, it was set to 1.00 mm, but in each case, the step on the end face was 0.5 mm or less.
- Examples b1 to b14, b18, and b19 have a sheared surface and a fracture surface in order in the plate thickness direction, and the cut ends of Examples b15 and b16 have a sheared surface in the plate thickness direction. It was confirmed from the appearance that the fracture surface and the coining surface were sequentially provided based on the above-mentioned characteristics.
- Comparative Examples b12 and b13 both showed good corrosion resistance for 90 days or more until the occurrence of red rust at the cut end, but large burrs of 0.2 mm or more were generated at the cut end.
- Comparative Examples b6 and b15 the negative clearance between the die and the punch in the half-cutting step was not sufficient, so that the plated steel sheet was completely broken in the half-cutting step.
- the residual length L of the plating component is 0.70 times the shape of the cut end portion with respect to the plate thickness t1 of the cut end portion of the processed product. From the above, it was confirmed that a cut end portion having good corrosion resistance can be obtained.
- the processed product of the present invention may be a drawn product as long as it is a drawn product, and may be, for example, a deformed drawn product as shown in FIG. 16 or a square tube drawn product as shown in FIG.
- FIG. 17 shows the state of the element body before the half-cutting step is carried out, and the half-cutting step and the finishing cutting step are performed along the trim line shown by the broken line.
- the processed product may have a cut end portion flush with the outer surface of the side wall only on a part of the side wall of the processed product.
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Abstract
Description
-0.35×t1≦C31-41≦-0.01 ・・・(a1)
0.10×t1≦R1≦0.50×t1 ・・・(a2)
D≧0.70×t1 ・・・(a3)
CP-D≧0.20 ・・・(a4)
0.01≦C32-42≦0.2×t2 ・・・(a5)
0.25≦R2≦1.50×t2 ・・・(a6)
ここで、C31-41、CP-D、C32-42及びR2の単位はmmとする。
-0.45×t1≦C31-41≦-0.10×t1 ・・・(b1)
0.10×t1≦R11≦0.65×t1 ・・・(b2-1)
0.10×t1≦R12≦0.65×t1 ・・・(b2-2)
D≧0.70×t1 ・・・(b3)
CP-D≧0.20 ・・・(b4)
0.01≦C32-42≦0.2×t2 ・・・(b5)
0.25≦R2≦1.50×t2 ・・・(b6)
ここで、C31-41、CP-D、C32-42及びR2の単位はmmとする。
[1-1.加工品]
まず、図1に基づいて、本発明の第1の実施形態に係る加工品製造方法によって製造される加工品1について説明する。図1は、本発明の第1の実施形態に係る加工品製造方法によって製造される加工品1の一例を示す斜視図である。図1に示す加工品1は、表面にめっき層を有するめっき鋼板を素材とするモータケースである。図1に示すモータケースは、平板状のめっき鋼板に対して例えば絞り加工等の成形加工を施すことにより成形することができる。
次に、図2及び図3に基づいて、本実施形態に係る加工品1の切断端部13について説明する。図2は、図1の加工品1の領域Aにおける切断端部13を示し、左側は加工品1の中心軸を含むZX平面での断面図、右側はX方向から側面視した図である。図3は、図2左側の断面図の詳細図である。なお、図2では、めっき層13f1、13f2の記載を省略している。
まず、図5に基づいて、本実施形態に係る加工品製造方法について説明する。図5は、本実施形態に係る加工品製造方法を示す説明図である。本実施形態に係る加工品製造方法は、図5に示すように、準備工程、半切断工程及び仕上げ切断工程を含む。
まず、図6及び図7に基づいて、半切断工程で使用されるダイの刃先のみをR形状とする場合の半切断工程及び仕上げ切断工程について説明する。図6は、半切断工程で使用されるダイの刃先をR形状とする場合の半切断工程を示す説明図である。図7は、図6の半切断工程に続いて行われる仕上げ切断工程を示す説明図である。
半切断工程では、図6に示すように、第1素体2のフランジ部20が、第1ダイ31及び第1パンチ41を用いて半切断される。図6では、半切断の一態様として、第1パンチ41及び第1ガイド51によって胴部10の側壁101となる部分が挟持された第1素体2から、フランジ部20を半抜きする態様を示している。第1ダイ31は、半切断においてフランジ部20に押し込まれる切断金型を構成する。本実施形態では、胴部10の側壁101の端面(図3の端面14a)となる部分を押さえる金型を第1パンチ41とし、フランジ部20(すなわち、除去部分20a)を押さえる金型を第1ダイ31とする。
CP-D≧0.20 ・・・(a4)
仕上げ切断工程では、図7に示すように、半切断されたフランジ部20が、第2ダイ32及び第2パンチ42を用いて仕上げ切断される。図7では、仕上げ切断の一態様として、第2パンチ42及び第2ガイド52によって胴部10の側壁101となる部分を挟持して、第1素体2からフランジ部20(すなわち、除去部分20a)を仕上げ打ち抜きする態様を示している。第2ダイ32は、仕上げ切断においてフランジ部20に押し込まれる切断金型を構成する。本実施形態では、胴部10の側壁101の端面(図3の端面14a)となる部分を押さえる金型を第2パンチ42とし、フランジ部20(すなわち、除去部分20a)を押さえる金型を第2ダイ32とする。第2ダイ32は、第1ダイ31と同一であってもよい。つまり、半切断工程で使用した第1ダイ31を、仕上げ切断工程で第2ダイ32として使用してもよい。
次に、図8及び図9に基づいて、半切断工程で使用されるダイ及びパンチの刃先をR形状とする場合の半切断工程及び仕上げ切断工程について説明する。図8は、半切断工程で使用されるダイ及びパンチの刃先をR形状とする場合の半切断工程を示す説明図である。図9は、図8の半切断工程に続いて行われる仕上げ切断工程を示す説明図である。
半切断工程では、図8に示すように、第1素体2のフランジ部20が、第1ダイ31及び第1パンチ41を用いて半切断される。図8では、図6と同様、半切断の一態様として、第1パンチ41及び第1ガイド51によって胴部10の側壁101となる部分が挟持された第1素体2から、フランジ部20を半抜きする態様を示している。第1ダイ31は、半切断においてフランジ部20に押し込まれる切断金型を構成する。本実施形態では、胴部10の側壁101の端面(図3の端面14a)となる部分を押さえる金型を第1パンチ41とし、フランジ部20(すなわち、除去部分20a)を押さえる金型を第1ダイ31とする。
0.10×t1≦R12≦0.65×t1 ・・・(b2-2)
CP-D≧0.20 ・・・(b4)
仕上げ切断工程では、図9に示すように、半切断されたフランジ部20が、第2ダイ32及び第2パンチ42を用いて仕上げ切断される。仕上げ切断工程は、図7に示した、第1ダイ31または第1パンチ41の一方のみ刃先をR形状として半切断を行った後に実施される仕上げ切断工程と同様に行えばよい。
次に、図10に基づいて、本発明の第2の実施形態に係る加工品製造方法について説明する。図10は、本発明の第2の実施形態に係る加工品製造方法を示す説明図である。本実施形態に係る加工品製造方法は、図10に示すように、準備工程、半切断工程、仕上げ切断工程及びコイニング工程を含む。
半切断工程でのダイの肩部(すなわち、刃先)を所定の曲率半径を有するR形状として、図5及び図10に示す方法により加工品のサンプルを作成した。めっき鋼板として、板厚t1が1.3~4.4mmで、めっき付着量が90g/m2(片面)のZn-6%Al-3%Mg(質量比)合金めっき鋼板を用いた。半切断加工は、内径D31が68.00mmのダイと、ダイとパンチとのクリアランスC31-41に応じて内径さを変更したパンチを用い、ガイドによりめっき鋼板を保持して行った。仕上げ切断加工は、肩部(すなわち、刃先)が所定の曲率半径を有するR形状としたダイと、ダイとパンチとのクリアランスC32-42に応じて内径D32を変更したパンチを用い、ガイドによりめっき鋼板を保持して行った。
次に、半切断工程でのダイ及びパンチの肩部(すなわち、刃先)を所定の曲率半径を有するR形状として、図5及び図10に示す方法により加工品のサンプルを作成した。めっき鋼板として、板厚が1.3~4.4mmで、めっき付着量が90g/m2(片面)のZn-6%Al-3%Mg(質量比)合金めっき鋼板を用いた。半切断加工は、内径68.00mmのダイと、ダイとパンチとのクリアランスに応じて内径を変更したパンチを用い、ガイドによりめっき鋼板を保持して行った。仕上げ切断加工は、肩部(すなわち、刃先)が所定の曲率半径を有するR形状のダイと、ダイとパンチとのクリアランスに応じて内径を変更したパンチを用い、ガイドによりめっき鋼板を保持して行った。
2 第1素体
6 第2素体
7 コイニング下型
8 コイニング上型
10 胴部
11 突部
12、20 フランジ部
13 切断端部
13c せん断面
13d 破断面
13f、13f1、13f2 めっき層
13g 角部
13h コイニング面
13k 平坦面
14 開口部
14a 端面
20a 除去部分
31 第1ダイ
32 第2ダイ
41 第1パンチ
42 第2パンチ
70 縦壁面
71 底壁面
72 押当面
101 側壁
101a 外側面
101b 内側面
103 頂壁
Claims (11)
- 表面にめっき層を有するめっき鋼板を素材とし、中空筒状の側壁に切断端部を有する加工品であって、
前記切断端部は、
当該加工品の側壁の外面と面一であり、
当該切断端部の板厚方向に、せん断面及び破断面を順に、または、せん断面を有しており、
前記せん断面が前記表面のめっき層により覆われているめっき成分残存長さLと、前記加工品の切断端部の板厚t1との比L/t1は、0.70以上である、加工品。 - 前記切断端部の板厚方向における前記破断面の長さW1は、0mm超かつ1.0mm以下である、請求項1に記載の加工品。
- 前記切断端部の板厚方向における前記破断面の長さW1は、0.5mm以下である、請求項2に記載の加工品。
- 前記側壁に対して直交する前記加工品の端面の平坦面の長さLtと、前記加工品の側壁の板厚tとの比Lt/tは、0.35以上である、請求項1~3のいずれか1項に記載の加工品。
- 前記切断端部のバリの長さは0.2mm未満である、請求項1~4のいずれか1項に記載の加工品。
- 前記切断端部は、当該切断端部の板厚方向に、前記せん断面、前記破断面及びコイニング面を順に、または、前記せん断面及びコイニング面を順に有しており、
前記切断端部の板厚方向における前記せん断面と前記コイニング面との間の前記破断面の長さW2は、0mm超かつ0.5mm以下である、請求項1~5のいずれか1項に記載の加工品。 - 表面にめっき層を有するめっき鋼板を素材とし、中空筒状の側壁に切断端部を有する加工品を製造するための加工品製造方法であって、
第1ダイと第1パンチとのクリアランスがマイナスクリアランスに設定された前記第1ダイ及び前記第1パンチを用いて、前記素材から形成された第1素体の切断部分を板厚方向に半切断する半切断工程と、
第2ダイ及び第2パンチを用いて、半切断された前記第1素体を前記半切断と同一方向から仕上げ切断して、加工品の側壁の外面と面一な切断端部を有する加工品を得る仕上げ切断工程と、
を含み、
前記第2ダイの内径D32は、前記第1ダイの内径D31以上とし、
前記第1素体の切断部分の板厚をt1、前記半切断工程後の前記切断部分の残存板厚をt2として、
前記半切断工程において、
前記第1ダイ及び前記第1パンチとのクリアランスC31-41は、下記式(a1)を満たし、
前記第1ダイの刃先の曲率半径R1は、下記式(a2)を満たし、
前記第1素体の切断部分に対する前記第1ダイまたは前記第1パンチの押込み量Dは、下記式(a3)を満たし、
下死点での前記第1ダイと前記第1パンチとの間隔CP-Dは、下記式(a4)を満たし、
前記仕上げ切断工程において、
前記第2ダイと前記第2パンチとのクリアランスC32-42は、下記式(a5)を満たし、
前記第2ダイの刃先の曲率半径R2は、下記式(a6)を満たす、加工品製造方法。
-0.35×t1≦C31-41≦-0.01 ・・・(a1)
0.10×t1≦R1≦0.50×t1 ・・・(a2)
D≧0.70×t1 ・・・(a3)
CP-D≧0.20 ・・・(a4)
0.01≦C32-42≦0.2×t2 ・・・(a5)
0.25≦R2≦1.50×t2 ・・・(a6)
ここで、C31-41、CP-D、C32-42及びR2の単位はmmとする。 - 表面にめっき層を有するめっき鋼板を素材とし、中空筒状の側壁に切断端部を有する加工品を製造するための加工品製造方法であって、
第1ダイと第1パンチとのクリアランスがマイナスクリアランスに設定された前記第1ダイ及び前記第1パンチを用いて、前記素材から形成された第1素体の切断部分を板厚方向に半切断する半切断工程と、
第2ダイ及び第2パンチを用いて、半切断された前記第1素体を前記半切断と同一方向から仕上げ切断して、加工品の側壁の外面と面一な切断端部を有する加工品を得る仕上げ切断工程と、
を含み、
前記第2ダイの内径D32は、前記第1ダイの内径D31以上とし、
前記第1素体の切断部分の板厚をt1、前記半切断工程後の前記切断部分の残存板厚をt2として、
前記半切断工程において、
前記第1ダイ及び前記第1パンチとのクリアランスC31-41は、下記式(b1)を満たし、
前記第1ダイの刃先の曲率半径R11は、下記式(b2-1)を満たし、
前記第1パンチの刃先の曲率半径R12は、下記式(b2-2)を満たし、
前記第1素体の切断部分に対する前記第1ダイまたは前記第1パンチの押込み量Dは、下記式(b3)を満たし、
下死点での前記第1ダイと前記第1パンチとの間隔CP-Dは、下記式(b4)を満たし、
前記仕上げ切断工程において、
前記第2ダイと前記第2パンチとのクリアランスC32-42は、下記式(b5)を満たし、
前記第2ダイの刃先の曲率半径R2は、下記式(b6)を満たす、加工品製造方法。
-0.45×t1≦C31-41≦-0.10×t1
・・・(b1)
0.10×t1≦R11≦0.65×t1 ・・・(b2-1)
0.10×t1≦R12≦0.65×t1 ・・・(b2-2)
D≧0.70×t1 ・・・(b3)
CP-D≧0.20 ・・・(b4)
0.01≦C32-42≦0.2×t2 ・・・(b5)
0.25≦R2≦1.50×t2 ・・・(b6)
ここで、C31-41、CP-D、C32-42及びR2の単位はmmとする。 - 前記仕上げ切断工程で得られた加工品を第2素体として、
前記第2素体の前記切断端部の角部をパッドに押し当て、前記角部にコイニング面が形成された加工品を得るコイニング工程をさらに含む、請求項7または8に記載の加工品製造方法。 - 前記第1ダイの内径D31と前記第2ダイの内径D32との差D32-D31は、1.00mm以下である、請求項7~9のいずれか1項に記載の加工品製造方法。
- 前記半切断工程の前に、平板状のめっき鋼板から、中空の側壁とフランジ部とを有する第1素体を成形加工する準備工程をさらに含む、請求項7~10のいずれか1項に記載の加工品製造方法。
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