WO2024111215A1 - 中実部分を有する差厚パイプの押出成形方法及び押出成形装置 - Google Patents

中実部分を有する差厚パイプの押出成形方法及び押出成形装置 Download PDF

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Publication number
WO2024111215A1
WO2024111215A1 PCT/JP2023/032371 JP2023032371W WO2024111215A1 WO 2024111215 A1 WO2024111215 A1 WO 2024111215A1 JP 2023032371 W JP2023032371 W JP 2023032371W WO 2024111215 A1 WO2024111215 A1 WO 2024111215A1
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Prior art keywords
inner diameter
mandrel
hollow
tip
outer diameter
Prior art date
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Ceased
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PCT/JP2023/032371
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English (en)
French (fr)
Japanese (ja)
Inventor
喬志 木村
健太郎 野津
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sango Co Ltd
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Sango Co Ltd
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Filing date
Publication date
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Priority to CN202380080596.8A priority Critical patent/CN120239635A/zh
Priority to JP2024501508A priority patent/JP7603880B2/ja
Publication of WO2024111215A1 publication Critical patent/WO2024111215A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/14—Making other products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/21—Presses specially adapted for extruding metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/08—Dies or mandrels with section variable during extruding, e.g. for making tapered work; Controlling variation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00—Making hollow articles not covered by a single preceding sub-group
    • B21K21/08—Shaping hollow articles with different cross-section in longitudinal direction, e.g. nozzles, spark-plugs

Definitions

  • the present invention relates to an extrusion molding method and extrusion molding device for making pipes with different thicknesses and solid portions.
  • a differential thickness pipe also called a “butted pipe” or “butted tube” in which a thick-walled portion is formed in a portion of the axial direction of the pipe for the purpose of achieving a desired mechanical strength in the thick-walled portion while reducing the weight of the thin-walled portion (portion other than the thick-walled portion).
  • a differential thickness pipe that is hollow over its entire length can be integrally molded from a cylindrical blank tube by extrusion molding, as disclosed in Patent Document 1 (Patent Publication No. 6933762), for example.
  • differential thickness pipes in the field of shafts, for example, but rather than making them hollow over their entire length, it may be required to provide a solid portion having a certain length in the axial direction at one end.
  • differential thickness pipes with solid portions cannot be molded by the above-mentioned method.
  • Patent Document 2 JP Patent Publication 49-035497 discloses a method of manufacturing a bottomed hollow metal product by combining a piercing and compression process in which a punch is inserted into a roughly cylindrical, solid material to form a hollow hole, and a subsequent process in which a separate punch is used to press the bottom of the hollow hole while extruding the entire material to form a hollow portion (thickness difference portion) and a solid portion (bottom portion).
  • Patent Document 3 JP Patent Publication 58-048264 discloses a method in which a material having a flange and a hollow hole (and bottom) in a specified positional relationship is formed in advance in a forging process, and in the next process the tip of a center punch is used to press against the bottom of the hollow hole to form an intermediate material with corners, and in the next process the end of the intermediate material opposite the bottom is pressed with a sleeve punch to form a hollow portion (differential thickness portion) and a solid portion (bottom).
  • Patent No. 6933762 Japanese Patent Publication No. 49-035497 Japanese Patent Publication No. 58-048264
  • Patent Document 1 a material having a hollow portion and a solid portion was pressed into a container (die) with a small inner diameter at the tip side to reduce the diameter, in order to extrude a pipe with a different thickness and a solid portion.
  • a crack tended to occur around the entire circumference at the boundary between the bottom of the hollow hole and the side wall, as illustrated by the thick solid line in Figure 6(a).
  • the inventor conducted further research and discovered that the above problem can be solved by appropriately controlling the positional relationship between the tip of the mandrel and the bottom of the hollow hole in the material, as well as the movement of the sleeve and mandrel.
  • the extrusion molding method of the present invention for producing a pipe with a hollow portion having a different thickness is an extrusion molding method in which a material having a predetermined shape is extruded to produce a pipe with a hollow portion having a different thickness in an extrusion molding device.
  • the extrusion molding device includes a mandrel having a predetermined shape, a sleeve having a predetermined shape, a container having a container hole that is a through hole having a predetermined shape, and a drive mechanism configured to push the mandrel into the container hole.
  • the material is a member consisting of a first hollow portion and a first solid portion, and has a cylindrical outer shape with a first outer diameter that is a predetermined outer diameter overall.
  • the first hollow portion is a cylindrical portion having a first wall thickness that is a predetermined thickness, in which a first hollow hole is formed, which is a cylindrical space having a first inner diameter that is a predetermined inner diameter, and which opens to the end face on the base end side that is the upstream side in the extrusion direction.
  • the first solid portion is a cylindrical portion located between the end face on the tip end side that is the downstream side in the extrusion direction and the first hollow portion.
  • the differential thickness pipe is a member consisting of a second hollow portion, a third hollow portion, a fourth hollow portion, and a second solid portion.
  • the second hollow portion is a cylindrical portion having a first outer diameter and a first wall thickness.
  • the third hollow portion is a tubular portion adjacent to the tip side of the second hollow portion, in which the outer diameter changes from the first outer diameter to a second outer diameter, which is a predetermined outer diameter smaller than the first outer diameter, from the base end side toward the tip side, and the wall thickness changes from the first wall thickness to a second wall thickness, which is a predetermined wall thickness smaller than the first wall thickness.
  • the fourth hollow portion is a cylindrical portion adjacent to the tip side of the third hollow portion, having a second outer diameter and a second wall thickness.
  • the second solid portion is a cylindrical portion located between the end on the tip side and the fourth hollow portion, and has a second outer diameter. Furthermore, a second hollow hole, which is a cylindrical space having a first inner diameter and opens to the end face on the base end side, is continuously formed from the second hollow portion to the fourth hollow portion.
  • the mandrel is a cylindrical member that is fitted coaxially and axially slidably into the sleeve and has a third outer diameter that is a predetermined outer diameter corresponding to the first inner diameter.
  • the sleeve is a cylindrical member that is fitted coaxially and axially slidably into the mandrel and has a second inner diameter that is a predetermined inner diameter corresponding to the third outer diameter and a first outer diameter.
  • the container hole consists of a large inner diameter portion, a small inner diameter portion, and a reduced inner diameter portion.
  • the large inner diameter portion is formed on the base end side and has a third inner diameter, which is an inner diameter corresponding to the first outer diameter.
  • the small inner diameter portion is formed on the tip end side and has a fourth inner diameter, which is an inner diameter corresponding to the second outer diameter.
  • the reduced inner diameter portion is formed between the large inner diameter portion and the small inner diameter portion and has an inner diameter that decreases from the third inner diameter to the fourth inner diameter as it approaches the small inner diameter portion.
  • the method of the present invention includes the following first to third steps.
  • the first step is a step of inserting a raw material into the large inner diameter portion of the container hole, abutting the tip end of the raw material into the reduced inner diameter portion of the container hole, abutting the base end of the raw material with a sleeve, inserting a mandrel into a first hollow hole in the raw material, and fixing the tip-to-tip distance, which is the relative distance in the extrusion direction between the tip end of the sleeve and the tip end of the mandrel, to a predetermined first distance.
  • the second step is a step of advancing the sleeve and mandrel in the extrusion direction while maintaining the tip-to-tip distance at a first distance, thereby forcing the material through the reduced inner diameter portion of the container hole and into the smaller inner diameter portion, thereby performing an extrusion process, and continuing to advance the sleeve and mandrel until the first point in time at which the tip end of the mandrel reaches the base end of the reduced inner diameter portion of the container hole.
  • the third step is a step of advancing the sleeve and the mandrel in the extrusion direction while maintaining the tip-to-tip distance at the first distance after the first point in time.
  • the present invention also relates to an extrusion molding device for forming a pipe with a hollow portion having a different thickness by carrying out the above-mentioned method of the present invention (hereinafter, this may be referred to as the "device of the present invention").
  • a variable thickness pipe with a hollow portion can be precisely and easily formed from a material having a simple structure.
  • a manufacturing method and manufacturing device for a variable thickness pipe with a solid portion which can reduce the occurrence of defects such as cracks and/or material pockets without requiring a material with a complex shape.
  • FIG. 1 is a schematic cross-sectional view showing an example of the configuration of a raw material that is the source of the material used in an extrusion molding method (first method) for a differential thickness pipe having a solid portion according to a first embodiment of the present invention, the material, and a differential thickness pipe having a solid portion molded from the material.
  • FIG. 2 is a schematic cross-sectional view showing an example of the configuration of a mandrel, a sleeve, and a container used in the first method.
  • 4 is a flowchart illustrating a flow of first to third steps executed in a first method.
  • 1 is a schematic cross-sectional view illustrating a problem observed when attempting to extrude a pipe having a solid portion with a different thickness based on the prior art.
  • the first method is an extrusion molding method in which a material having a predetermined shape is extruded to form a hollow pipe having a different thickness.
  • the extrusion molding apparatus includes a mandrel having a predetermined shape, a sleeve having a predetermined shape, a container having a container hole which is a through hole having a predetermined shape, and a drive mechanism configured to push the mandrel into the container hole.
  • the basic configuration of such an extrusion molding apparatus is well known to those skilled in the art, and detailed description will be omitted.
  • the components including the mandrel, the sleeve, and the container are made of materials having properties (e.g., mechanical strength and durability) that can withstand processing conditions such as load acting on the components in the extrusion process described below.
  • the drive mechanism for pushing the mandrel into the container hole can be appropriately selected from various drive mechanisms well known in the art according to the properties (e.g., mechanical strength and hardness) of the material constituting the material to be subjected to the extrusion process.
  • a press machine such as a hydraulic press machine is used as the drive mechanism.
  • FIG. 1A, 1B, and 1C are schematic cross-sectional views showing an example of the configuration of an original material 11, a material 21, and a differential thickness pipe 31 having a solid portion formed from the material 21, which are used in the first method.
  • the material 21 is a member having a cylindrical outer shape consisting of a first hollow portion PH1 and a first solid portion PS1, and having a first outer diameter DO1, which is a predetermined outer diameter overall.
  • the first hollow portion PH1 is a cylindrical portion having a first wall thickness T1, in which a first hollow hole HH1, which is a cylindrical space having a first inner diameter DI1, is formed and opens to the end face on the base end side, which is the upstream side in the extrusion direction, and is a cylindrical space having a first inner diameter DI1, which is a predetermined inner diameter.
  • the first solid portion PS1 is a cylindrical portion located between the end face on the tip side, which is the downstream side in the extrusion direction, and the first hollow portion PH1.
  • the material 21 has a relatively simple structure, and therefore can be easily manufactured by forming a first hollow hole HH1 in the raw material 11, which is a cylindrical member having a first outer diameter DO1 as exemplified in FIG. 1(a).
  • the specific method for forming the first hollow hole HH1 in the raw material 11 is not particularly limited, but the first hollow hole HH1 can be easily formed in the raw material 11 by a method such as cutting, for example.
  • the material constituting the raw material 11 is not particularly limited as long as it can be formed into a desired shape by plastic deformation in the extrusion process.
  • the material constituting the raw material 11 is a metal such as lead, tin, aluminum, copper, zirconium, titanium, molybdenum, vanadium, niobium, and steel.
  • the differential thickness pipe 31 is a member consisting of a second hollow portion PH2, a third hollow portion PH3, a fourth hollow portion PH4, and a second solid portion PS2.
  • the second hollow portion PH2 is a cylindrical portion having a first outer diameter DO1 and a first wall thickness T1.
  • the third hollow portion PH3 is a cylindrical portion adjacent to the tip side of the second hollow portion PH2, the outer diameter of which changes from the first outer diameter DO1 to a second outer diameter DO2, which is a predetermined outer diameter smaller than the first outer diameter DO1, from the base end side to the tip side, and the wall thickness of which changes from the first wall thickness T1 to a second wall thickness T2, which is a predetermined wall thickness smaller than the first wall thickness T1.
  • the fourth hollow portion PH4 is a cylindrical portion adjacent to the tip side of the third hollow portion PH3, and has a second outer diameter DO2 and a second wall thickness T2.
  • the second solid portion PS2 is a cylindrical portion located between the tip end and the fourth hollow portion PH4 and has a second outer diameter DO2.
  • a second hollow hole HH2 which is a cylindrical space that opens to the end face on the base end side and has a first inner diameter DI1, is formed continuously from the second hollow portion PH2 to the fourth hollow portion PH4.
  • the rate of change in the outer diameter of the third hollow portion PH3 increases from the base end to the tip end, and the contour of the outer diameter of the third hollow portion PH3 is a curve that is convex outward in the radial direction.
  • the pattern of the change in the outer diameter of the third hollow portion PH3 from the first outer diameter DO1 to the second outer diameter DO2 is not limited to this.
  • the contour of the outer diameter of the third hollow portion PH3 may be a curve that is concave outward in the radial direction, or the rate of change in the outer diameter of the third hollow portion PH3 may be constant from the base end to the tip end, and the contour of the outer diameter of the third hollow portion PH3 may be a straight line.
  • the bottom (end portion on the tip side) of the second hollow hole HH2 has a conical shape.
  • the shape of the bottom of the second hollow hole HH2 is not limited to this, and can be various shapes depending on, for example, the use of the differential thickness pipe 31.
  • the shape of the bottom of the second hollow hole HH2 may be a plane perpendicular to the axial direction of the differential thickness pipe 31, or may be a convex curved surface (e.g., a spherical surface) on the tip side.
  • Such a shape of the bottom of the second hollow hole HH2 can be achieved, for example, by making the shape of the end portion on the tip side of the mandrel a shape corresponding to the shape of the bottom of the second hollow hole HH2.
  • the mandrel 41 is a cylindrical member that is coaxially and axially slidably fitted into the sleeve 51 and has a third outer diameter DO3 that is a predetermined outer diameter corresponding to the first inner diameter DI1 that is the inner diameter of the first hollow portion PH1 of the material 21.
  • the sleeve 51 is coaxially and axially slidably fitted into the mandrel 41 and has a cylindrical member that has a second inner diameter DI2 that is a predetermined inner diameter corresponding to the third outer diameter DO3 that is the outer diameter of the mandrel 41, and a first outer diameter DO1 that is the outer diameter of the material 21.
  • the base end portion of the mandrel 41 and the sleeve 51 can be provided with a structure and/or mechanism suitable for driving by a driving mechanism provided in the extrusion molding device and/or for attachment and detachment from the driving mechanism.
  • the container hole HC1 formed in the container 61 is composed of a large inner diameter portion PDIL, a small inner diameter portion PDIS, and an inner diameter decreasing portion PDIT.
  • the large inner diameter portion PDIL is a portion formed on the base end side and has a third inner diameter DI3, which is an inner diameter corresponding to the first outer diameter DO1, which is the outer diameter of the material 21.
  • the small inner diameter portion PDIS is a portion formed on the tip end side and has a fourth inner diameter DI4, which is an inner diameter corresponding to the second outer diameter DO2, which is the outer diameter of the fourth hollow portion PH2 and the second solid portion PS2 of the differential thickness pipe 31.
  • the inner diameter decreasing portion PDIT is a portion formed between the large inner diameter portion PDIL and the small inner diameter portion PDIS, and the inner diameter decreases from the third inner diameter DI3 to the fourth inner diameter DI4 as it approaches the small inner diameter portion PDIS from the large inner diameter portion PDIL.
  • the large inner diameter portion PDIL is made up of two members, the inner diameter reducing portion PDIT and the most proximal portion of the small inner diameter portion PDIS are integrally formed from one member, and the remaining portion of the small inner diameter portion PDIS is made up of two members. That is, the container 61 illustrated in FIG. 2(b) is made up of five members as a whole.
  • the configuration of the container 61 is not limited to this, and may be made up of one member as a whole, or the large inner diameter portion PDIL, the small inner diameter portion PDIS, and the inner diameter reducing portion PDIT may each be made up of one member, and the container 61 may be made up of three members as a whole.
  • the first method includes steps 1 to 3 listed below, as illustrated by the flowchart in FIG. 3.
  • the first process executed in step S01 is to insert a material into the large inner diameter portion of the container hole, abut the tip end of the material against the reduced inner diameter portion of the container hole, abut the base end of the material against a sleeve, insert a mandrel into the first hollow hole of the material, and fix the tip-to-tip distance, which is the relative distance in the extrusion direction between the tip end of the sleeve and the tip end of the mandrel, to a predetermined first distance. That is, in the first process, the material, mandrel, sleeve, and container are set in predetermined positions.
  • the second process executed in step S02 is a process of advancing the sleeve and mandrel in the extrusion direction while maintaining the tip-to-tip distance at the first distance, thereby forcing the material into the small inner diameter portion through the reduced inner diameter portion of the container hole, and continuing to advance the sleeve and mandrel until the first time point, which is the time point when the tip end of the mandrel reaches the base end of the reduced inner diameter portion of the container hole.
  • the mandrel and sleeve are driven in cooperation to maintain the tip-to-tip distance at the first distance, and the sleeve and mandrel are advanced in the extrusion direction until the tip end of the mandrel reaches the base end of the reduced inner diameter portion of the container hole. This performs extrusion from the first solid portion of the material to the second solid portion of the differential thickness pipe.
  • the third process executed in step S03 is a process of advancing the sleeve and mandrel in the extrusion direction while maintaining the tip-to-tip distance at the first distance even after the first time point. That is, even in the third process, which is a process executed after the first time point, the tip-to-tip distance is maintained at the first distance by coordinated driving of the mandrel and sleeve, and the sleeve and mandrel are advanced in the extrusion direction, thereby performing extrusion processing from a part on the tip side of the first hollow portion of the material to the third hollow portion and the fourth hollow portion of the differential thickness pipe. The part of the first hollow portion of the material that was not subjected to extrusion processing in the third process becomes the second hollow portion of the differential thickness pipe.
  • FIG. 4 is a schematic cross-sectional view showing an example of the shape of the material 21 at the end of the first process and the positional relationship between the material 21 and the mandrel 41, sleeve 51, and container 61.
  • FIG. 4 in order to simplify the drawing, only some of the reference symbols given to the various parts shown in FIG. 1 and FIG. 2 are shown. However, in the following explanation of FIG. 4, the reference symbols shown in FIG. 1 and FIG. 2 will be used for accuracy, so please refer to FIG. 1 and FIG. 2 as necessary.
  • the blank 21 is inserted into the large inner diameter portion PDIL of the container hole HC1, and the tip end of the blank 21 abuts against the reduced inner diameter portion PDIT of the container hole HC1. This holds the blank 21 in a predetermined position inside the container hole HC1.
  • a sleeve 51 abuts against the base end of the blank 21, and a mandrel 41 is inserted into a first hollow hole HH1 formed in the blank 21.
  • the mandrel 51 and the sleeve 41 are driven in a coordinated manner to advance the sleeve 51 and the mandrel 41 in the extrusion direction (the downward direction in FIG. 4) while maintaining the tip-to-tip distance DT at the first distance D1.
  • the first solid portion PS1 of the material 21 is pushed from the tip side through the reduced inner diameter portion PDIT of the container hole HC1 into the small inner diameter portion PDIS, and the first solid portion PS1 of the material 21 is extruded into the second solid portion PS2 of the differential thickness pipe 31.
  • the second outer diameter DO2, which is the outer diameter of the second solid portion PS2 of the differential thickness pipe 31, is smaller than the first outer diameter DO1, which is the outer diameter of the first solid portion PS1 of the raw material 21 (DO2 ⁇ DO1).
  • the cross-sectional area of the second solid portion PS2 of the differential thickness pipe 31 is smaller than the cross-sectional area of the first solid portion PS1 of the raw material 21. Therefore, the length in the extrusion direction of the second solid portion PS2 of the differential thickness pipe 31 extruded from the first solid portion PS1 of the raw material 21 is greater than the length in the extrusion direction of the first solid portion PS1 of the raw material 21 (details will be described later).
  • the base end side end of the material 21 is pressed in the extrusion direction by the sleeve 51, but the bottom of the first hollow hole HH1 is not pressed by the mandrel 41.
  • This state can be achieved, for example, by not bringing the bottom of the first hollow hole HH1 of the material 21 into contact with the mandrel 41 at the second time point, or by providing a gap of a predetermined size between the bottom of the first hollow hole HH1 of the material 21 and the tip end of the mandrel 41 at the second time point (this will be described in detail later).
  • the so-called "upsetting phenomenon” may occur as the extrusion process proceeds.
  • the raw material expands radially outward and contracts axially due to the plastic flow of the material constituting the raw material and/or the elastic deformation of the container, and the bottom of the first hollow hole formed in the raw material is slightly displaced toward the base end. Therefore, even if there is a gap between the bottom of the first hollow hole in the raw material and the tip end of the mandrel at the second point in time, the gap may disappear or shrink due to the upsetting phenomenon.
  • the tip end of the mandrel 41 eventually reaches the base end of the reduced inner diameter portion PDIT of the container hole HC1.
  • the period up to the first point in time when the tip end of the mandrel 41 reaches the base end of the reduced inner diameter portion PDIT of the container hole HC1 corresponds to the second process, and the period after the first point in time corresponds to the third process.
  • FIG. 4 is a schematic cross-sectional view showing an example of the shape of the material 21 immediately after the end of the second step, i.e., immediately after the start of the third step, and the positional relationship between the material 21 and the mandrel 41, sleeve 51, and container 61.
  • the sleeve 51 and mandrel 41 continue to move in the extrusion direction while maintaining the tip-to-tip distance DT at the first distance D1 even after the first time point.
  • the first hollow portion PH1 of the material 21 is pushed from the tip side into the small inner diameter portion PDIS through the inner diameter reduction portion PDIT of the container hole HC1, and extrusion processing is performed from a part of the tip side of the first hollow portion PH1 of the material 21 to the fourth hollow portion PH4 and the third hollow portion PH3 of the differential thickness pipe 31. Also, as described above, the part of the first hollow portion PH1 of the material 21 that was not subjected to extrusion processing in the third step becomes the second hollow portion PH2 of the differential thickness pipe 31.
  • the second outer diameter DO2, which is the outer diameter of the fourth hollow portion PH4 of the differential thickness pipe 31, is smaller than the first outer diameter DO1, which is the outer diameter of the first hollow portion PH1 of the material 21 (DO2 ⁇ DO1).
  • the inner diameter of the second hollow hole HH2 of the differential thickness pipe 31 is maintained at the first inner diameter DI1, which is the inner diameter of the first hollow portion PH1 of the material 21, by the mandrel 41. That is, the cross-sectional area of the fourth hollow portion PH4 of the differential thickness pipe 31 is smaller than the cross-sectional area of the first hollow portion PH1 of the material 21.
  • the outer diameter of the third hollow portion PH3 of the differential thickness pipe 31 changes from the first outer diameter DO1 to the second outer diameter DO2, which is smaller than the first outer diameter DO1, from the base end side to the tip end side as described above, the inner diameter of the third hollow portion PH3 of the differential thickness pipe 31 is also maintained at the first inner diameter DI1 by the mandrel 41. That is, the cross-sectional area of the third hollow portion PH3 of the differential thickness pipe 31 is also smaller than the cross-sectional area of the first hollow portion PH1 of the raw material 21.
  • the length in the extrusion direction of the fourth hollow portion PH4 and the third hollow portion PH3 of the differential thickness pipe 31 extruded from the first hollow portion PH1 of the raw material 21 is greater than the length in the extrusion direction of the portion of the first hollow portion PH1 of the raw material 21 that is subjected to the extrusion process (details will be described later).
  • FIG. 4 is a schematic cross-sectional view showing an example of the shape of the differential thickness pipe 31 at the end of the third step, and the positional relationship between the mandrel 41, sleeve 51, and container 61 and the differential thickness pipe 31.
  • a differential thickness pipe 31 having a desired shape and consisting of the second hollow portion PH2, the third hollow portion PH3, the fourth hollow portion PH4, and the second solid portion PS2 can be easily formed from a material 21 having a simple shape.
  • the tip-to-tip distance DT which is the relative distance in the extrusion direction between the tip end of the sleeve and the tip end of the mandrel, is maintained at a predetermined first distance D1 while the sleeve 51 and the mandrel 41 are advanced in the extrusion direction, so that the first solid portion PS1 of the material 21 is pushed through the reduced inner diameter portion PDIT of the container hole HC1 into the small inner diameter portion PDIS, thereby performing extrusion processing from the first solid portion PS1 of the material 21 to the second solid portion PS2 of the differential thickness pipe 31.
  • the mandrel 41 does not contribute to the extrusion process, but rather serves the function of maintaining the cross-sectional shape of the second hollow hole HH2 formed in the differential thickness pipe 31 identical to that of the first hollow hole HH1 formed in the material 21 during the process in which a portion of the tip side of the first hollow portion PH1 of the material 21 changes into the fourth hollow portion PH4 and third hollow portion PH3 of the differential thickness pipe 31.
  • the second hollow portion PH2, the third hollow portion PH3, and the fourth hollow portion PH4 of the differential thickness pipe 31 are formed from the first hollow portion PH1 of the material 21, and the second solid portion PS2 of the differential thickness pipe 31 is formed from the first solid portion PS1 of the material 21. Therefore, the following relationships are established between the axial length of each portion of the material 21 (hereinafter, may be simply referred to as "length") and the axial length of each portion of the differential thickness pipe 31.
  • the length (LPH2) of the second hollow portion PH2 of the differential thickness pipe 31 is the length of the portion that has not been subjected to extrusion processing and remains in an unprocessed state as the raw material 21 at the time the third process is completed. Therefore, as long as it is smaller than the length (LPH1) of the first hollow portion PH1 of the raw material 21, LPH2 can be set to any size depending on the timing of completing the third process.
  • the length (LPH3) of the third hollow portion PH3 of the differential thickness pipe 31 is automatically determined by the length (LPDIT) of the reduced inner diameter portion PDIT of the container hole HC1 formed in the container 61. Therefore, LPH3 can be set to any size by adjusting the LPDIT in the container hole HC1 formed in the container 61.
  • the length (LPH4) of the fourth hollow portion PH4 of the differential thickness pipe 31 can be calculated by subtracting the volume (VPH2+VPH3) of the material constituting the second hollow portion PH2 and the third hollow portion PH3 of the differential thickness pipe 31 from the volume (VPH1) of the material constituting the first hollow portion PH1 of the blank 21, and dividing the remaining volume by the area (APH4) of the annular cross section of the fourth hollow portion PH4. Therefore, in order to obtain the desired LPH4, it is necessary to configure the container hole HC1 formed in the blank 21, the differential thickness pipe 31, and the third container 61 so that the following formula (1) is established.
  • VPH1, VPH2, and APH4 can be expressed by the following formulas (2) to (4).
  • VPH3 changes depending on the pattern of change in the outer diameter of the third hollow portion PH3 (i.e., the shape of the outline), so it is necessary to calculate it according to the shape of the third hollow portion PH3.
  • the relationship between the length (LPS1) of the first solid portion PS1 of the material 21 and the length (LPS2) of the solid portion PS2 of the differential thickness pipe 31 can be expressed by the following formula (5).
  • the first method is a manufacturing method for a differential thickness pipe having a solid portion, which can reduce the occurrence of defects such as cracks and/or material pools without requiring a material having a complex shape.
  • Such a differential thickness pipe with a solid portion is useful as a part that is required to achieve the desired mechanical strength in the thick portion while reducing the weight in the thin portion (portion other than the thick portion).
  • a differential thickness pipe with a solid portion as described above is used as a shaft-type part that requires an oil stopper, a plug for the oil stopper is not required, which increases design freedom and reduces manufacturing costs.
  • the tip-to-tip distance which is the relative distance in the extrusion direction between the tip end of the sleeve and the tip end of the mandrel, is maintained at a predetermined first distance while the sleeve and mandrel are advanced in the extrusion direction, forcing the material into the small inner diameter portion through the reduced inner diameter portion of the container hole to perform the extrusion process.
  • the third step in which a part of the tip side of the first hollow portion PH1 of the material 21 is extruded into the fourth hollow portion PH4 and the third hollow portion PH3 of the differential thickness pipe 31, the bottom of the first hollow hole of the material and the tip end of the mandrel are separated from each other.
  • the mandrel does not contribute to the extrusion process, but rather has the function of maintaining the cross-sectional shape of the hollow hole in the process in which the first hollow hole formed in the material changes into the second hollow hole formed in the differential thickness pipe 31.
  • a pipe with a hollow portion can be precisely and easily formed from a material with a simple structure.
  • the first method makes it possible to easily manufacture a pipe with a hollow portion while reducing the occurrence of defects such as cracks and/or solid portions, without the need for a material with a complex shape.
  • the so-called "upsetting phenomenon” may occur at the time when the blank starts to be pushed into the small inner diameter portion through the reduced inner diameter portion of the container hole formed in the container (i.e., at the start of the extrusion processing).
  • the blank expands radially outward and contracts axially, causing the bottom of the first hollow hole formed in the blank to be slightly displaced toward the base end.
  • the tip end of the mandrel is pressed toward the base end by the bottom of the first hollow hole, and the reaction to this applies stress to the bottom of the first hollow hole, which may cause a crack to form at the boundary between the bottom of the first hollow hole and the side wall portion.
  • the second method is the above-mentioned first method, which is an extrusion molding method for a differential thickness pipe having a hollow portion, characterized in that at least at the second point in time, which is the start point of the extrusion processing in the second step, the bottom of the first hollow hole in the material is not in contact with the mandrel.
  • FIG. 5 is a schematic cross-sectional view showing an example of the positional relationship between the bottom of the first hollow hole in the material near the bottom of the first hollow hole and the mandrel at the start of the second step included in the second method, and is an enlarged view of the area surrounded by the thick dashed line in FIG. 4(a).
  • the bottom of the first hollow hole HH1 in the material 21 and the mandrel 41 are not in contact.
  • a gap G is provided between the bottom of the first hollow hole HH1 in the material 21 and the mandrel 41.
  • the bottom (end on the tip side) of the first hollow hole HH1 has a conical shape. Therefore, in the example shown in FIG. 5, the gap G between the bottom of the first hollow hole HH1 of the material 21 and the mandrel 41 is determined by the distance between the average position in the axial direction of the bottom surface of the first hollow hole HH1 of the material 21 and the tip surface of the mandrel 41.
  • the shape of the bottom of the first hollow hole HH1 is not limited to this, and can be various shapes depending on, for example, the use of the differential thickness pipe 31 and/or the shape of the end on the tip side of the mandrel.
  • the shape of the bottom of the first hollow hole HH1 may be a plane perpendicular to the axial direction of the material 21, or a curved surface (e.g., a spherical surface) that is convex toward the tip side.
  • the bottom of the first hollow hole in the material is not in contact with the mandrel. Therefore, according to the second method, even if the upsetting phenomenon occurs at the start of the extrusion process in the second step and the bottom of the first hollow hole formed in the material is displaced toward the base end, it is possible to reduce the possibility that the bottom of the hollow hole will press against the tip of the mandrel. As a result, it is possible to reduce the risk of cracks occurring at the boundary between the bottom of the first hollow hole and the side wall portion due to the reaction of the bottom of the first hollow hole pressing against the tip of the mandrel.
  • the gap G initial gap
  • the gap G (initial gap) between the bottom of the first hollow hole of the material and the mandrel at the second time point
  • the third method is the above-mentioned second method, which is a method for extrusion molding a pipe having a hollow portion with a different thickness, characterized in that the initial length, which is the length of the initial gap in the extrusion direction, is equal to or greater than a first predetermined length and is less than a second predetermined length longer than the first length.
  • the initial gap is a gap between the bottom of the first hollow hole of the material at the second point in time and the end of the mandrel on the tip side.
  • the first length can be determined based on the magnitude of the dimensional change of the material during the period from the second time point to the third time point, which is the time point when the tip end of the material starts to enter the portion of the container hole that has a reduced inner diameter.
  • the first length can be determined based on the magnitude of the displacement of the bottom of the first hollow hole toward the base end during the period from the second time point to the third time point.
  • the magnitude of the dimensional change of the material such as the displacement of the bottom of the first hollow hole toward the base end, can be determined, for example, by verification through a preliminary experiment and/or a computer simulation such as a flow analysis.
  • the second length can be set to a predetermined length that is equal to or less than the maximum length at which the material constituting the blank does not flow into the first gap during the period from the second point in time (which is a predetermined point in time after the tip end of the mandrel passes through the part of the container hole that reduces the inner diameter).
  • a second length can also be determined, for example, by verification through preliminary experiments and/or computer simulations such as flow analysis.
  • the initial gap is set in a suitable range to sufficiently reduce the risk of cracks occurring at the boundary between the bottom and sidewall of the first hollow hole at the time when the sleeve and mandrel start to move in the extrusion direction (the second time point).
  • the risk of cracks occurring at the boundary between the bottom and sidewall of the first hollow hole in the material can be more reliably reduced.
  • the present invention relates not only to the extrusion molding method of a pipe having a different thickness and a solid portion, including the above-mentioned first to third methods, but also to an extrusion molding device of a pipe having a different thickness and a solid portion. Therefore, the extrusion molding device of a pipe having a different thickness and a solid portion according to various embodiments of the present invention will be described below.
  • an extrusion molding device for differential thickness pipes (hereinafter, sometimes referred to as the "fourth device").
  • the fourth apparatus is an extrusion molding apparatus for a differential thickness pipe having a solid portion, the extrusion molding apparatus comprising a mandrel having a predetermined shape, a sleeve having a predetermined shape, a container having a container hole which is a through hole having a predetermined shape, and a drive mechanism configured to push the mandrel into the container hole.
  • the basic configuration of such an extrusion molding apparatus is well known to those skilled in the art, and the components including the mandrel, sleeve, and container are made of materials having properties (e.g., mechanical strength, durability, etc.) that can withstand processing conditions such as the load acting on the components in the above-mentioned extrusion processing.
  • the fourth device is configured to perform the first to third steps listed below to form a pipe of different thicknesses having a hollow portion from a material having a predetermined shape by extrusion processing.
  • the first step is a step of inserting a raw material into the large inner diameter portion of the container hole, abutting the tip end of the raw material into the reduced inner diameter portion of the container hole, abutting the base end of the raw material with a sleeve, inserting a mandrel into a first hollow hole in the raw material, and fixing the tip-to-tip distance, which is the relative distance in the extrusion direction between the tip end of the sleeve and the tip end of the mandrel, to a predetermined first distance.
  • the second step is a step of advancing the sleeve and mandrel in the extrusion direction while maintaining the tip-to-tip distance at a first distance, thereby forcing the material through the reduced inner diameter portion of the container hole and into the smaller inner diameter portion, thereby performing an extrusion process, and continuing to advance the sleeve and mandrel until the first point in time at which the tip end of the mandrel reaches the base end of the reduced inner diameter portion of the container hole.
  • the third step is a step of advancing the sleeve and the mandrel in the extrusion direction while maintaining the tip-to-tip distance at the first distance after the first point in time.
  • the material 21 is a member consisting of a first hollow portion PH1 and a first solid portion PS1, and has a cylindrical outer shape with a first outer diameter DO1, which is a predetermined outer diameter overall.
  • the first hollow portion PH1 is a cylindrical portion having a first thickness T1, in which a first hollow hole HH1, which is a cylindrical space with a first inner diameter DI1, which is a predetermined inner diameter, is formed and opens to the end face on the base end side, which is the upstream side in the extrusion direction.
  • the first solid portion PS1 is a cylindrical portion located between the end face on the tip side, which is the downstream side in the extrusion direction, and the first hollow portion PH1.
  • the differential thickness pipe 31 is a member consisting of a second hollow portion PH2, a third hollow portion PH3, a fourth hollow portion PH4, and a second solid portion PS2.
  • the second hollow portion PH2 is a cylindrical portion having a first outer diameter DO1 and a first wall thickness T1.
  • the third hollow portion PH3 is a cylindrical portion adjacent to the tip side of the second hollow portion PH2, and the outer diameter changes from the first outer diameter DO1 to a second outer diameter DO2, which is a predetermined outer diameter smaller than the first outer diameter DO1, from the base end side to the tip side, and the wall thickness changes from the first wall thickness T1 to a second wall thickness T2, which is a predetermined wall thickness smaller than the first wall thickness T1.
  • the fourth hollow portion PH4 is a cylindrical portion adjacent to the tip side of the third hollow portion PH3, and has a second outer diameter DO2 and a second wall thickness T2.
  • the second solid portion PS2 is a cylindrical portion located between the tip end and the fourth hollow portion PH4 and has a second outer diameter DO2.
  • a second hollow hole HH2 which is a cylindrical space that opens to the end face on the base end side and has a first inner diameter DI1, is formed continuously from the second hollow portion PH2 to the fourth hollow portion PH4.
  • the mandrel 41 is fitted coaxially and axially slidably into the sleeve 51, and is a cylindrical member having a third outer diameter DO3 which is a predetermined outer diameter corresponding to the first inner diameter DI1 which is the inner diameter of the first hollow portion PH1 of the material 21.
  • the sleeve 51 is fitted coaxially and axially slidably into the mandrel 41, and is a cylindrical member having a second inner diameter DI2 which is a predetermined inner diameter corresponding to the third outer diameter DO3 which is the outer diameter of the mandrel 41, and a first outer diameter DO1 which is the outer diameter of the material 21.
  • the container hole HC1 formed in the container 61 is composed of a large inner diameter portion PDIL, a small inner diameter portion PDIS, and an inner diameter decreasing portion PDIT.
  • the large inner diameter portion PDIL is a portion formed on the base end side and has a third inner diameter DI3, which is an inner diameter corresponding to the first outer diameter DO1, which is the outer diameter of the material 21.
  • the small inner diameter portion PDIS is a portion formed on the tip end side and has a fourth inner diameter DI4, which is an inner diameter corresponding to the second outer diameter DO2, which is the outer diameter of the fourth hollow portion PH2 and the second solid portion PS2 of the differential thickness pipe 31.
  • the inner diameter decreasing portion PDIT is a portion formed between the large inner diameter portion PDIL and the small inner diameter portion PDIS, and the inner diameter decreases from the third inner diameter DI3 to the fourth inner diameter DI4 as it approaches the small inner diameter portion PDIS from the large inner diameter portion PDIL.
  • the fourth device is an extrusion molding device for differential thickness pipes having solid portions, which corresponds to the first method described above. Therefore, the differential thickness pipes formed by the fourth device, the raw materials from which the differential thickness pipes are formed and the raw materials from which the raw materials are derived, as well as the mandrel, sleeve, and container that constitute the fourth device, are clear from the explanation of the first method described above, so a description thereof will be omitted here.
  • the fourth apparatus is an apparatus for manufacturing a pipe with a hollow portion and a different thickness, which can reduce the occurrence of defects such as cracks and/or solid portions without requiring a material with a complex shape.
  • an extrusion molding apparatus for a variable thickness pipe having a solid portion according to a fifth embodiment of the present invention (hereinafter, sometimes referred to as the "fifth apparatus") will be described.
  • the fifth apparatus is the fourth apparatus described above, which is an extrusion molding apparatus for a differential thickness pipe having a hollow portion, characterized in that at least at the second point in time, which is the start point of the extrusion processing in the second step, the bottom of the first hollow hole in the material is not in contact with the mandrel.
  • the fifth device is an extrusion molding device for a pipe with a solid portion and a different thickness, which corresponds to the second method described above. Therefore, the details of the configuration and operation of the fifth device are clear from the explanation of the second method, so a detailed explanation will be omitted here.
  • the fifth device even if the upsetting phenomenon occurs at the start of the extrusion process in the second step and the bottom of the first hollow hole formed in the material is displaced toward the base end, the possibility of the bottom of the hollow hole pressing against the tip of the mandrel can be reduced, thereby reducing the risk of cracks occurring at the boundary between the bottom of the first hollow hole and the side wall portion due to the reaction of the pressing of the bottom of the first hollow hole against the tip of the mandrel.
  • an extrusion molding apparatus for a variable thickness pipe having a solid portion according to a sixth embodiment of the present invention (hereinafter, sometimes referred to as the "sixth apparatus") will be described.
  • a sixth device is the fifth device described above, which is an extrusion molding method for a differential thickness pipe having a hollow portion, characterized in that an initial length, which is the length of the initial gap in the extrusion direction, is equal to or greater than a predetermined first length and less than a predetermined second length longer than the first length.
  • the initial gap is a gap between a bottom of the first hollow hole in the raw material at a second time point and the tip end of the mandrel.
  • the first length can be determined based on the magnitude of dimensional change of the raw material during the period from the second time point to a third time point at which the tip end of the raw material begins to enter the reduced inner diameter portion of the container hole.
  • the second length can be determined to a predetermined length equal to or less than a maximum length at which the material constituting the raw material does not flow into the first gap during the period from the second time point to the first time point (which is a predetermined time point after the tip end of the mandrel has passed through the reduced inner diameter portion of the container hole).
  • the sixth device is an extrusion molding device for a pipe with a solid portion and a different thickness, which corresponds to the third method described above. Therefore, the details of the configuration and operation of the sixth device are clear from the explanation of the third method, so a detailed explanation will be omitted here.
  • the initial gap is set in a suitable range to sufficiently reduce the risk of cracks occurring at the boundary between the bottom and the side wall of the first hollow hole at the time (second time point) when the sleeve and mandrel start to move in the extrusion direction, and as a result, the sixth device can more reliably reduce the risk of cracks occurring at the boundary between the bottom and the side wall of the first hollow hole in the material.

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  • Mechanical Engineering (AREA)
  • Extrusion Of Metal (AREA)
PCT/JP2023/032371 2022-11-22 2023-09-05 中実部分を有する差厚パイプの押出成形方法及び押出成形装置 Ceased WO2024111215A1 (ja)

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JP2024501508A JP7603880B2 (ja) 2022-11-22 2023-09-05 中実部分を有する差厚パイプの押出成形方法及び押出成形装置

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Citations (5)

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JP2003266139A (ja) * 2002-03-14 2003-09-24 Toto Ltd 金属部品の鍛造方法
WO2013038526A1 (ja) * 2011-09-14 2013-03-21 荻野工業株式会社 パイプ製造方法
JP2013230494A (ja) * 2012-05-01 2013-11-14 Sango Co Ltd 中空品の製造方法
JP2014205187A (ja) * 2013-04-16 2014-10-30 トヨタ自動車株式会社 中空押出成形装置及び中空押出成形方法
JP2021041461A (ja) * 2019-09-06 2021-03-18 株式会社三五 差厚パイプの押出成形方法及び差厚パイプの押出成形装置

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US3213664A (en) * 1961-03-24 1965-10-26 Textron Inc Apparatus for forming articles
US3165199A (en) * 1962-04-05 1965-01-12 Fellows Gear Shaper Co Method of forming shouldered articles
US3261196A (en) * 1964-05-08 1966-07-19 Textron Inc Method for making hollow articles
JP2003010940A (ja) 2001-06-26 2003-01-15 Toto Ltd 鍛造装置及び鍛造方法

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Publication number Priority date Publication date Assignee Title
JP2003266139A (ja) * 2002-03-14 2003-09-24 Toto Ltd 金属部品の鍛造方法
WO2013038526A1 (ja) * 2011-09-14 2013-03-21 荻野工業株式会社 パイプ製造方法
JP2013230494A (ja) * 2012-05-01 2013-11-14 Sango Co Ltd 中空品の製造方法
JP2014205187A (ja) * 2013-04-16 2014-10-30 トヨタ自動車株式会社 中空押出成形装置及び中空押出成形方法
JP2021041461A (ja) * 2019-09-06 2021-03-18 株式会社三五 差厚パイプの押出成形方法及び差厚パイプの押出成形装置

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