Method for forming a through-hole through the circumferential wall of a metal pipe and a metal pipe worked by the said method

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for forming a through-hole through the circumferential wall of a metal pipe and a metal pipe worked by the said method. More specifically, the invention relates to metal pipes having many branch holes in the outside circumferential surface, such as a cooling oil jet pipe that mainly serves to cool the cylinder or the piston of an engine and a lubrication oil jet pipe that is used in, for example, a system for supplying (jetting) a lubricant to a sliding portion such as a crank shaft or a cam shaft.
2. Description of the Prior Art
In metal pipes such as a cooling oil jet pipe for cooling the cylinder or the piston of an engine and a lubrication oil jet pipe used in, for example, a system for supplying (jetting) a lubricant to a sliding portion such as a crank shaft or a cam shaft, oil jetting nozzles are attached to the circumferential wall of a pipe body. For example, in conventional metal pipes of the above kind, nozzle pipes or branch pipes are brazed to respective through-holes that are formed through the circumferential wall of a pipe body.
However, the manufacture of metal pipes of the above kind has the following problems.
Common methods of forming through-holes through the circumferential wall of a metal pipe include (1) a method of forming through-holes with a drill, (2) a method of forming through-holes with a punch without inserting a core bar into a pipe, (3) a method of forming through-holes by inserting a core bar into a pipe, and (4) a method of forming through-holes with a laser. In the drilling method (1), chips may go into the inside of a pipe or a burr may be formed at each inside opening portion and much time and labor are needed to remove those chips and burrs. In the punch method (2) without a core bar, a large recess (shear droop) that may be formed at each outside opening portion impairs the shape of a metal pipe. Further, as in the case of method (1), a burr may be formed at each inside opening portion and some operation is needed to remove such burrs. In addition,, depending on the material of a metal pipe itself, particularly when the metal pipe or through-holes to be formed are small in diameter, the punch may be broken and hence it is difficult to form through-holes. In the punch method (3) using a core bar, the hole forming operation requires much time and labor because time and labor are needed for positioning of the core bar and the core bar needs to be moved for each hole forming position. It is necessary to remove punching chips that have dropped inside the core bar. If a burr is formed even at only one inside opening portion, it becomes difficult to pull out the core bar. Further, the hole forming operation cannot be performed on a portion between bent portions formed by bending a metal pipe. The laser method (4) is costly and dangerous to a human body. When a metal pipe is small in diameter, there is a possibility that a portion on the inside surface that is opposed to a through-hole formed may be damaged. Further, a droop may occur around a through-hole formed, or sputters may splash onto the inside surface of a metal pipe.
Where nozzle pipes or branch pipes are brazed to respective through-holes formed by any of the above methods, the brazing area is small because of a short radial length of through-holes, which causes problems that sufficient brazing strength is not secured and that the attachment direction of the nozzle pipes or the branch pipes becomes erroneous.
SUMMARY OF THE INVENTION
The present invention has been made to solve the above problems in the art, and an object of the invention is therefore to provide a method capable of forming easily, without causing the above problems in the art, through-holes having a desired diameter, preferably a small diameter, through the circumferential wall of a metal even if the metal pipe has a small diameter.
Another object of the invention is to provide a metal pipe that uses through-holes formed by the above method as branch holes as oil jetting branch holes and that can be used as a cooling oil jet pipe or a lubrication oil jet pipe.
To attain the above objects, according to a first aspect of the invention, there is provided a method for forming a through-hole through a circumferential wall of a metal pipe, comprising the steps of forming at least a thin portion by removing an outside circumferential surface portion of a metal pipe; and forming a through-hole in the thin portion from outside or inside and, at the same time, forming a cylindrical burring wall on an inside or outside circumferential surface side of the metal pipe.
In the above method, the through-hole may be formed by pressing the thin portion from outside with a punch. Alternatively, a preparatory through-hole may be formed together with the thin portion by removing the outside circumferential surface portion of the metal pipe. As a further alternative, the through-hole may be formed from outside with a punch having a larger diameter than the preparatory through-hole, or may be formed by pressing the thin portion from outside or inside by means of fluid pressure or a sphere.
According to a second aspect of the invention, there is provided a method for forming a through-hole through a circumferential wall of a metal pipe, comprising the steps of forming a thin portion by removing an outside circumferential surface portion of a metal pipe; and forming a through-hole by pressing the thin portion from outside with a punch and, at the same time, forming a cylindrical burring wall on an inside circumferential surface side of the metal pipe.
According to a third aspect of the invention, there is provided a method for forming a through-hole through a circumferential wall of a metal pipe, comprising the steps of forming a thin portion and a preparatory through-hole by removing an outside circumferential surface portion of a metal pipe; forming a through-hole by pressing the thin portion from outside with a punch having a larger diameter than the preparatory through-hole; and forming a cylindrical burring wall on an inside circumferential surface side of the metal pipe.
According to a fourth aspect of the invention, there is provided a method for forming a through-hole through a circumferential wall of a metal pipe, comprising the steps of forming a thin portion by removing an outside circumferential surface portion of a metal pipe; and forming a through-hole by pressing the thin portion from outside or inside by means of fluid pressure or a sphere and, at the same time, forming a cylindrical burring wall on an inside or outside circumferential surface side of the metal pipe.
According to a fifth aspect of the invention, there is provided a metal pipe having at least one branch hole in a circumferential wall, the metal pipe being formed with a through-hole in a thin portion of the circumferential wall formed by removing an outside circumferential surface portion of the metal pipe, the through-hole having a burring wall projecting from an inside or outside circumferential surface of the metal pipe.
In the invention, the reasons why a thin portion (and a preparatory through-hole) is formed by removing an outside circumferential surface portion of a metal pipe are to facilitate formation of a through-hole by means of fluid pressure or a sphere without using a core bar and enable formation of a through-hole in such a manner that almost no recess (shearing droop) is formed at the outside opening portion, to form a burring wall, preferably a cylindrical one, on the pipe inside or outside circumferential surface side when a through-hole is formed by means of a punch, fluid pressure, or a sphere, to thereby secure a sufficient axial length of the through-hole, and to prevent formation of a shearing droop at the boundary between the pipe outside circumferential surface and a through-hole and preferably form an edge shape there.
For example, an outside circumferential surface portion of a metal pipe may be removed (and a preparatory through-hole may be formed when necessary) by forming a groove or a circular recess by cutting away an outside circumferential surface portion having a predetermined width or diameter of a metal pipe by a press-cutting method, a round-cutting method, or cutting or grinding with a tool. The groove may be formed so as to be perpendicular to, inclined from, or in a certain situation parallel with the center line of the metal pipe. The thickness of the thin portion that is formed on the pipe outside circumferential surface side is determined properly in consideration of the material, thickness, and strength of the metal pipe, the through-hole diameter, the burring wall height, and other factors.
A through-hole having a burring wall may be formed so as to be inclined from the center line of a metal pipe, or may be formed along a line that does not pass through the center line of a metal pipe.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of a thin portion formed by cutting away an outside circumferential surface portion of a metal pipe in a first embodiment of a method for forming a through-hole through the circumferential wall of a metal pipe according to a first aspect of the present invention;
FIG. 2 is a front sectional view taken along line II--II in FIG. 1;
FIG. 3 is a sectional view corresponding to FIG. 1 and shows a metal pipe having a through-hole formed by the method shown by FIGS. 1 and 2;
FIG. 4 is a front sectional view taken along line IV--IV in FIG. 3;
FIGS. 5(A) and 5(B) are sectional views showing metal pipes having an inclined through-hole according to another embodiment of the first aspect of the invention, in which FIG. 5(A) shows a case where a thin portion is formed by a groove having a rectangular cross-section and FIG. 5(B) shows a case where a thin portion is formed by a groove having an arc-shaped cross-section;
FIG. 6 is a sectional view corresponding to FIG. 4 and shows a metal pipe having an eccentric through-hole according to another embodiment of the first aspect of the invention;
FIG. 7 is a plan view of a metal pipe according to still another embodiment of the first aspect of the invention;
FIG. 8(A) is a side sectional view showing the main part of a metal pipe according to a further embodiment of the first aspect of the invention;
FIG. 8(B) is a sectional view taken along line VIII--VIII in FIG. 8(A);
FIG. 9(A) is a side sectional view showing the main part of a metal pipe according to another embodiment of the first aspect of the invention;
FIG. 9(B) is a sectional view taken along line IX--IX in FIG. 9(A);
FIG. 10 is a plan view of a through-hole portion formed by removing an outside circumferential surface portion of a metal pipe in a first embodiment of a method for forming a through-hole through the circumferential wall of a metal pipe according to a second aspect of the present invention;
FIG. 11(A) is a sectional view taken along line XI--XI in FIG. 10;
FIG. 11(B) is a sectional view taken along line XI'--XI' in FIG. 10;
FIG. 12 is a plan view showing a through-hole portion having a different shape than shown in FIG. 10;
FIG. 13 is a sectional view corresponding to FIG. 11(A) and shows a metal pipe having a through-hole with a burring wall that has been formed by the method shown by FIGS. 10 and 11(A)-11(B);
FIG. 14 is a sectional view corresponding to FIG. 13 and shows a metal pipe to which a nozzle pipe is brazed to a through-hole having a burring wall;
FIG. 15 is a sectional view corresponding to FIG. 13 and shows another metal pipe to which a nozzle pipe is brazed to a through hole having a burring wall;
FIG. 16 is a sectional view corresponding to FIG. 13 and shows a metal pipe having an inclined through-hole according to another embodiment of the second aspect of the invention;
FIG. 17 is a sectional view corresponding to FIG. 13 and shows a metal pipe having an eccentric through-hole according to another embodiment of the second aspect of the invention;
FIG. 18 is a plan view of a metal pipe according to still another embodiment of the second aspect of the invention in which a through-hole portion is formed in a direction inclined from the axial line of the metal pipe by removing an outside circumferential surface portion of the metal pipe;
FIG. 19 is a side sectional view showing a first embodiment of a method for forming a through-hole through the circumferential wall of a metal pipe according to a third aspect of the invention, more specifically, showing a thin portion formed by a method in which a through-hole is formed in the thin portion that has been formed by removing an outside circumferential surface portion of a metal pipe, by applying fluid pressure to the thin portion from outside and a cylindrical burring wall is thereby formed on the inside circumferential surface side of the metal pipe;
FIG. 20 is a sectional view taken along line XX--XX in FIG. 19;
FIG. 21 is a sectional view corresponding to FIG. 20 and shows another embodiment of the third aspect of the invention, more specifically, a method in which a through-hole is formed in a thin portion that has been formed by removing an outside circumferential surface portion of a metal pipe, by applying fluid pressure to the thin portion from inside and a cylindrical burring wall is thereby formed on the outside circumferential surface side of the metal pipe;
FIG. 22 is a sectional view showing a metal pipe having a through-hole formed by the method of FIG. 21;
FIG. 23 is a sectional view corresponding to FIG. 20 and shows another embodiment of the third aspect of the invention, more specifically, a method in which a through-hole is formed in a thin portion that has been formed by removing an outside circumferential surface portion of a metal pipe, by pressing the thin portion from outside with a sphere and a cylindrical burring wall is thereby formed on the inside circumferential surface side of the metal pipe;
FIG. 24 is a sectional view corresponding to FIG. 22 and shows a metal pipe having a through-hole formed by the method of FIG. 23;
FIG. 25 is a sectional view corresponding to FIG. 19 and shows still another embodiment of the third aspect of the invention, more specifically, a method in which a through-hole is formed in a thin portion that has been formed by removing an outside circumferential surface portion of a metal pipe, by pressing the thin portion from inside with a sphere and a cylindrical burring wall is thereby formed on the outside circumferential surface side of the metal pipe;
FIG. 26 is a sectional view corresponding to FIG. 22 and shows a metal pipe having a through-hole formed by the method of FIG. 25;
FIGS. 27(A) and 27(B) are sectional views corresponding to FIG. 19 and showing metal pipes having an inclined through-hole, in which FIG. 27 (A) shows a case where a thin portion is formed by a groove having a rectangular cross-section and FIG. 27(B) shows a case where a thin portion is formed by a groove having an arc-shaped cross-section;
FIGS. 28(A) and 28(B) are sectional views corresponding to FIG. 22 and showing metal pipes having an eccentric through-hole according to a further embodiment of the third aspect of the invention, in which FIG. 28(A) shows a metal pipe having a cylindrical burring wall on the pipe inside circumferential surface side and FIG. 28(B) shows a metal pipe having a cylindrical burring wall on the pipe outside circumferential surface side; and
FIG. 29 is a plan view of a metal pipe according to another embodiment of the third aspect of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First, in a first aspect of the present invention shown by FIG. 1 to FIGS. 9(A)-9(B), reference symbols 1 and 1a-1d denote metal pipes; 2 and 2a-2d, grooves or recesses formed by removing an outside circumferential surface portion of a metal pipe; 3, a thin portion; 4 and 4a-4d, through-holes; 5 and 5a-5c, burring walls; 6, an opening edge; and 7, a punch.
Metal pipes such as a cooling jet pipe for cooling the cylinder or the piston of an engine and a lubrication oil jetting pipe used in, for example, a system for supplying (jetting) a lubricant for a crank shaft or a cam shaft and metal pipes that can be produced by working by the method of the invention are steel pipes that are, for example, 4.0-20 mm in diameter and 0.5-3 mm in thickness (relatively thin) and are made of, for example, STKM. Branch holes of about 0.6-1.0 mm in diameter for, for example, oil jetting nozzles are formed so as to be spaced from each other in the pipe axis direction. When necessary, nozzle pipes or branch pipes are brazed to the inside surfaces of the respective branch holes or are brazed to a metal pipe so as to include the respective branch holes.
In a method according to a first embodiment of the first aspect of the invention shown by FIGS. 1 and 2, a thin portion 3 is formed by forming a groove 2 whose bottom surface is a flat surface, an arc surface, or an arc surface having a large radius of curvature by removing an outside circumferential surface portion having a predetermined width of a metal pipe 1 by, for example, a press-cutting method in which a blade is moved straightly or a round-cutting method in which a blade performs arc motion. Alternatively, a thin portion 3 is formed by forming a recess 2 having a flat or arc bottom surface by removing an outside circumferential surface portion by a cutting or grinding method in which a small-diameter blade or grindstone is rotated.
It is preferable that the width of the groove 2 or the diameter of the recess 2 be made approximately equal to the diameter of a through-hole 4 to be formed there. The depth of the groove or recess 2 is so set as to avoid formation of a recess (shearing droop) at the opening portion on the pipe outside circumferential surface side when a through-hole 4 is formed by a punch method.
Then, a through-hole 4 is formed by pressing the thin portion 3 of the metal pipe 1 inward in the radial direction by a press method using a punch 7 having approximately the same diameter as the width of the groove 2 or the diameter of the recess 2. By pressing the thin portion 3 inward in the radial direction by the press method using the punch 7, as shown in FIGS. 3 and 4, a through-hole 4 is formed in the thin-portion 3 without causing a shearing droop at the opening portion on the pipe outside circumferential surface side and, at the same time, a cylindrical burring wall 5 is formed on the inside circumferential surface of the metal pipe 1 so as to extend in the radial direction. The through-hole 4 thus formed is preferably longer than the thickness of the metal pipe 1 because of the formation of the cylindrical burring wall 5 extending in the radial direction of the metal pipe 1, and an edge 6 is formed at the opening portion on the pipe outside circumferential surface side.
FIGS. 5(A) and 5(B) show a metal pipe according to another embodiment in which a through-hole is formed so as to be inclined from the center line of the metal pipe. Specifically, FIG. 5(A) shows a metal pipe 1a in which a through-hole 4a having a cylindrical burring wall 5a that projects from the pipe inside circumferential surface has been formed by forming a groove or recess 2a having a rectangular cross-section in a direction inclined from the center line of the metal pipe 1a by removing an outside circumferential surface portion having a predetermined width or diameter of the metal pipe 1a, and then pressing a thin portion of the metal pipe 1a inward at the same inclination angle as that of the groove or recess 2a by a press method using a punch 7 having approximately the same diameter as the groove or recess 2a. Similarly, FIG. 5(B) shows a metal pipe 1b in which a through-hole 4b having a cylindrical burring wall 5b that projects from the pipe inside circumferential surface has been formed by forming a groove 2b having an arc-shaped cross-section by removing an outside circumferential surface portion having a predetermined width of the metal pipe 1b, and then pressing a thin portion formed by the groove 2b inward in a direction inclined from the center line of the metal pipe 1b by a press method using a punch 7. As in the case of FIGS. 4 and 5, the through-holes 4a and 4b of the respective metal pipes 1a and 1b shown in FIGS. 5(A) and 5(B) are preferably longer than the thickness of the respective metal pipes 1a and 1b because of the formation of the cylindrical burring walls 5a and 5b extending from the inside surfaces of the respective metal pipes 1a and 1b, and edges 6 are formed at the opening portions on the pipe outside circumferential surface side.
FIG. 6 shows a metal pipe according to another embodiment in which an eccentric through-hole is formed. Specifically, FIG. 6 shows a metal pipe 1c in which a through-hole 4c having a cylindrical burring wall 5c that projects from the pipe inside circumferential surface has been formed by forming a groove or recess 2c having a flat bottom surface along a line that is deviated from the center line of the metal pipe 1c by a predetermined distance by removing an outside circumferential surface portion of the metal pipe 1c, and then pressing a thin portion of the metal pipe 1c inward along a line that does not pass through the center line of the metal pipe 1c by a press method using a punch 7 having approximately the same diameter as the groove or recess 2c. As in the above embodiments, the eccentric through-hole 4c of the metal pipe 1c is preferably longer than the thickness of the metal pipe 1c because of the formation of the cylindrical burring wall 5c extending from the inside circumferential surface of the metal pipe 1c, and an edge 6 is formed at the opening portion on the pipe outside circumferential surface side.
In the above embodiments, when the thin portion is formed by a groove, each of the grooves 2 and 2a-2c is formed by removing an outside circumferential surface portion in the direction perpendicular to the center line of each of the metal pipes 1 and 1a-1c. FIG. 7 shows an alternative structure in which a groove 2d is formed so as to be inclined from, or in a certain situation parallel with, the center line of a metal pipe 1d. Then, as in the above embodiments, a through-hole 4d having a cylindrical burring wall that extends from the pipe inside circumferential surface is formed by pressing the thin portion inward by a press method using a punch having approximately the same diameter as the width of the groove 2d. As in the above embodiments, the through-hole 4d thus formed is preferably longer than the thickness of the metal pipe 1d because of the formation of the cylindrical burring wall extending from the pipe inside circumferential surface of the metal pipe 1d, and an edge 6 is formed at the opening portion on the pipe outside circumferential surface side.
By using the through-holes 4 and 4a-4d as branch holes for nozzles, the metal pipes 1 and 1a-1d formed with the through-holes 4 and 4a -4d can be used as they are as, for example, a cooling oil jet pipe for cooling the cylinder or the piston of an engine or a lubrication oil jet pipe that is used in a system for supplying (jetting) a lubricant to a sliding portion such as a crank shaft or a cam shaft. If necessary, nozzle pipes may be connected to the through-holes to change the oil jetting direction or make the jetting outlets closer to an object or branch pipes for general piping may be connected to the through-holes.
That is, as shown in FIGS. 8(A) and 8(B), an end portion 8a of a nozzle pipe 8 that is enlarged to assume a funnel shape so that the diameter becomes larger than the length or diameter of the groove or recess 2 is brazed to the outside circumferential surface of the metal pipe 1 so as to include the groove or recess 2. As a result, in addition to the advantage of the burring wall 5, an advantage is obtained that high brazing strength can be secured because the area of brazing between the funnel-shaped end portion 8a and the outside circumferential surface of the metal pipe 1 is increased.
FIGS. 9(A) and 9(B) show another embodiment in which one end portion of a nozzle pipe 8' having approximately the same outer diameter as the inner diameter of the through-hole 4 is inserted through the through-hole 4 and brazed to the inside surface of the burring wall 5. This structure can not only secure sufficient brazing strength by increasing the brazing area but also improve the jetting directivity.
Next, a method for forming a through-hole through the circumferential wall of a metal pipe according to a second aspect of the invention will be described with reference to FIGS. 10-18.
In FIGS. 10-18, reference symbols 11 and 11a-11c denote metal pipes; 12, an elliptical, circular, or rectangular preparatory hole formed by removing an outside circumferential surface portion of a metal pipe with an arc-shaped blade, a round blade, or a flat blade; 13 and 13a-13c, through-holes; 14 and 14a -14b, burring walls; 15, a punch; and 16, an edge.
Metal pipes used in this aspect of the invention have basically the same shape and structure and are made of basically the same material as the metal pipes described in the first aspect of the invention.
In a method according to a first embodiment of the second aspect of the invention, first, as shown in FIG. 10 and FIGS. 11(A) and 11(B), an elliptical preparatory hole 12 is formed by removing an outside circumferential surface portion of a metal pipe 11 by, for example, a press-cutting method in which an arc-shaped blade is moved straightly or a cutting or grinding method in which a grindstone is rotated. Alternatively, as shown in FIG. 12, a rectangular preparatory hole 12 is formed by, for example, a press-cutting method in which a flat blade is moved straightly or a cutting or grinding method. The preparatory hole 12 can be given a desired shape by using a proper blade and a proper removing method. A slight thin portion is formed around the thus-formed preparatory hole 12. The size of the preparatory hole 12 is set in accordance with the diameter of the metal pipe 11 so as to avoid formation of a recess (shearing droop) at the opening portion on the pipe outside surface side.
Then, the preparatory hole 12 portion of the metal pipe 11 is pressed inward in the radial direction by a press method using a punch 15 having a larger diameter than the size of the preparatory hole 12 that is formed on the outside circumferential surface side of the metal pipe 11. By pressing the preparatory hole 12 portion inward in the radial direction by the press method using the punch 15, a cylindrical burring wall 14 is formed so as to extend in the radial direction from the inside circumferential surface of the metal pipe 11 as shown in FIG. 13. A through-hole 13 thus formed does not cause a shearing droop at the opening portion on the pipe outside circumferential surface side, and is preferably longer than the thickness of the metal pipe 11 because of the formation of the cylindrical burring wall 15 extending in the radial direction of the metal pipe 1. Further, an edge 16 is formed at the opening portion on the pipe outside circumferential surface side.
The thus-formed through-hole 13 having the cylindrical burring wall 14 can be used, as it is, as a branch hole for a nozzle. However, the through-hole 13 has a relatively large diameter because it is formed by removing an outside circumferential surface portion of the metal pipe 11.
Therefore, if necessary, as shown in FIG. 14, an end portion 13' of a nozzle pipe 13 that is enlarged to assume a funnel-like and saddle-like shape so that the diameter becomes larger than the length or diameter of the through-hole 13 is brazed to the outside circumferential surface of the metal pipe 11 so as to include the outside end of the through-hole 13. As a result, in addition to the advantage of the burring wall 14, an advantage is obtained that high brazing strength can be secured because the area of brazing between the funnel-shaped end portion 13' and the outside circumferential surface of the metal pipe 11 is increased.
Alternatively, as shown in FIG. 15, one end portion of a nozzle pipe 13' having approximately the same outer diameter as the inner diameter of the through-hole 13 may be inserted through the through-hole 13 and brazed thereto as well as to the inside surface of the burring wall 14. This structure can not only secure sufficient brazing strength because the brazing area is increased by the cylindrical burring wall 14, but also improve the jetting directivity.
FIG. 16 shows a metal pipe according to another embodiment in which a through-hole is formed so as to be inclined from the center line of the metal pipe. Specifically, FIG. 16 shows a metal pipe 11a in which a through-hole 13a having a cylindrical burring wall 14a that projects from the pipe inside circumferential surface has been formed by forming a preparatory hole 12 in a direction inclined from the center line of the metal pipe that by removing an outside circumferential surface portion of the metal pipe 11a, and then pressing the preparatory hole 12 portion of the metal pipe 11a inward at a predetermined inclination angle by a press method using a punch 7 having a larger diameter than the preparatory hole 12. As in the case of the above embodiments, the inclined through-hole 13a is preferably longer than the thickness of the metal pipe 11a because of the formation of the cylindrical burring wall 14a extending from the inside surface of the metal pipe 11a, and an edge 16 is formed at the opening portion on the pipe outside circumferential surface side.
FIG. 17 shows a metal pipe according to another embodiment in which an eccentric through-hole is formed. Specifically, FIG. 17 shows a metal pipe 11b in which a through-hole 13b having a cylindrical burring wall 14b that projects from the pipe inside circumferential surface has been formed by forming a preparatory hole 12 along a line that is deviated from the center line of the metal pipe 11b by a predetermined distance by removing an outside circumferential surface portion of the metal pipe 11b, and then pressing the preparatory hole 12 portion of the metal pipe 11b inward along a line that does not pass through the center line of the metal pipe 11b by a press method using a punch 15 having a larger diameter than the preparatory hole 12. One end portion of a nozzle pipe 13" is inserted through the through-hole 13b and brazed thereto as well as to the inside surface of the burring wall 14b. As in the above embodiments, the eccentric through-hole 13b of the metal pipe 11b is preferably longer than the thickness of the metal pipe 11b because of the formation of the cylindrical burring wall 14b extending from the inside circumferential surface of the metal pipe 11b, and an edge 16 is formed at the opening portion on the pipe outside circumferential surface side.
In the above embodiments of the second aspect of the invention, when the through-hole is formed removing an outside circumferential surface portion of the metal pipe, the preparatory hole 12 is formed by removing the outside circumferential surface portion in the direction perpendicular to the center line of the metal pipe. FIG. 18 shows an alternative structure in which a preparatory hole 12 is formed so as to be inclined from, or in a certain situation parallel with, the center line of a metal pipe 11c. Then, as in the above embodiments, a through-hole 13c having a cylindrical burring wall that extends from the pipe inside circumferential surface is formed by pressing the preparatory hole 12 portion inward by a press method using a punch 15 having a larger diameter than the preparatory hole 12. As in the above embodiments, the through-hole 13c of the metal pipe 11c thus formed is preferably longer than the thickness of the metal pipe 13c because of the formation of the cylindrical burring wall extending from the inside circumferential surface of the metal pipe 11c, and an edge 16 is formed at the opening portion on the pipe outside circumferential surface side.
By using the through-holes 13 and 13a-13c as branch holes for nozzles, the metal pipes 11 and 11a-11c formed with the through-holes 13 and 13a-13c can be used as they are as, for example, a cooling oil jet pipe for cooling the cylinder or the piston of an engine or a lubrication oil jet pipe that is used in a system for supplying (jetting) a lubricant to a sliding portion such as a crank shaft or a cam shaft. If necessary, nozzle pipes may be connected to the through-holes to change the oil jetting direction or make the jetting outlets closer to an object or branch pipes for general piping may be connected to the through-holes.
Next, a method for forming a through-hole through the circumferential wall of a metal pipe according to a third aspect of the invention will be described with reference to FIGS. 19-29. In FIGS. 19-29, reference symbols 21 and 12a-21h denote metal pipes; 22 and 22a-22h, grooves or recesses formed by removing an outside circumferential surface portion of a metal pipe; 23, a thin portion; 24 and 24a-24h, through-holes; 25 and 25a-25f, burring walls; 26, an opening edge; 27, an outside cylinder jig; 28, a liquid; 29 and 31, hole-forming jigs; and 30, a sphere.
Metal pipes used in this aspect of the invention have basically the same shape and structure and are made of basically the same material as the metal pipes described in the first and second aspects of the invention.
In a method according to an embodiment of the third aspect of the invention shown by FIGS. 19 and 20, a thin portion 23 is formed by forming a groove 22 whose bottom surface is a flat surface, an arc surface, or an arc surface having a large radius of curvature by removing an outside circumferential surface portion having a predetermined width of a metal pipe 21 by, for example, a press-cutting method in which a blade is moved straightly or a round-cutting method in which a blade performs arc motion. Alternatively, a thin-portion 23 is formed by forming a recess 22 having a flat or arc bottom surface by removing an outside circumferential surface portion by a cutting or grinding method in which a small-diameter blade or grindstone is rotated.
It is preferable that the width of the groove 22 or the diameter of recess 22 be made approximately equal to the diameter of a through-hole 24 to be formed there. The depth of the groove or recess 22 is so set as to avoid formation of a recess (shearing droop) at the opening portion on the pipe outside circumferential surface side when a through-hole 24 is formed by fluid pressure.
Then, after an outside cylinder jig 27 is fitted to the outside circumferential surface of the metal pipe 21 so as to establish a sealing condition, a liquid 28 is introduced into the space between the metal pipe 21 and the outside cylinder jig 27 to impart fluid pressure. The fluid pressure causes pressing force that is directed inward in the radial direction and hence acts on the thin portion 23. As a result, a through-hole 24 is formed in the thin portion 23 without causing a large shearing droop at the opening portion on the pipe outside circumferential surface side and, at the same time, a cylindrical burring wall 25 is formed so as to extend radially from the inside circumferential surface of the metal pipe 21. The metal pipe 21 assumes basically the same shape as the metal pipe 1 according to the first aspect of the invention shown in FIGS. 3 and 4. The through-hole 24 thus formed is preferably longer than the thickness of the metal pipe 21 because of the formation of the cylindrical burring wall 25 extending in the radial direction of the metal pipe 21, and an edge 26 is formed at the opening portion on the pipe outside circumferential surface side.
FIG. 21 shows another method in which a thin portion 23 is formed by forming a groove 22a or a recess that is the same as in the above embodiment by removing an outside circumferential surface portion of a metal pipe 21a, and then a through-hole having a cylindrical burring wall on the outside circumferential surface side of the metal pipe 21a is formed by applying fluid pressure to the thin portion 23 from inside, that is, in the direction opposite to the direction in the method of FIGS. 19 and 20. Specifically, a through-hole 24a having a cylindrical burring wall 25a on the outside circumferential surface side of the metal pipe 21a is formed in the thin portion 23 of the metal pipe 21a (see FIG. 22) by applying desired liquid pressure to the thin portion 23 by introducing a liquid 28 into the metal pipe 21a from its one end in a state that both end portions of the metal pipe 21a are sealed. As in the above embodiment, the through-hole 24a thus formed is preferably longer than the thickness of the metal pipe 21a because of the formation of the cylindrical burring wall 25a extending in the radial direction of the metal pipe 21.
FIG. 19-21 exemplify the method in which a through-hole having a cylindrical burring wall is formed by applying fluid pressure to a thin portion that has been formed by removing an outside circumferential surface portion of a metal pipe. Another method will be described below in which a through-hole having a cylindrical burring wall is formed by using a sphere rather than fluid pressure.
FIGS. 23 and 24 show an embodiment of such a method. Specifically, a through-hole 24b having a cylindrical burring wall 25b that extends radially from the pipe inside circumferential surface is formed by applying desired pressure to a sphere 30 by supplying pressurized fluid such as compressed air or pressurized oil or water to a hole-forming jig 29 in a state that the hole-forming jig 29 in which the sphere 30 is inserted is attached, from outside, to a thin portion 23 that has been formed by forming a groove 22b or recess that is the same as in the above embodiment by removing an outside circumferential surface portion of a metal pipe 21b. As in the case of the metal pipe 1 shown in FIGS. 3 and 4, the through-hole 24b thus formed is preferably longer than the thickness of the metal pipe 21b because of the formation of the cylindrical burring wall 25b extending in the radial direction of the metal pipe 21b, and an edge 26 is formed at the opening portion on the pipe outside circumferential surface side.
FIGS. 25 and 26 show a method in which a through-hole having a cylindrical burring wall on the outside circumferential surface side of a metal pipe is formed by pressing, from inside (i.e., in the direction opposite to the direction in the method of FIGS. 23 and 24), with a sphere, a thin portion that has been formed by removing an outside circumferential surface portion of the metal pipe. Specifically, a hole-forming jig 31 that is composed of a disc 31-1 being slidable in the internal space of a metal pipe 21c and a liquid supply pipe 31-2 and that is so configured as to apply pressing force to a sphere 30 that is inserted in a guide cylinder 31-3 of the disc 31-1 in the radial direction via pressurized fluid that is supplied from the fluid supply pipe 31-2 is inserted into the metal pipe 21c and fixed at a position where the guide cylinder 31-3 is opposed to the thin portion 23 from inside. In this state, a through-hole 24c having a cylindrical burring wall 25c that extends radially from the outside circumferential surface of the metal pipe 21c is formed by applying radial pressing force to the sphere 30 by supplying pressurized fluid to the disc 31-1 from the fluid supply pipe 31-2. As in the case of the metal pipe 21a shown in FIG. 22, the through-hole 24c thus formed is preferably longer than the thickness of the metal pipe 21c because of the formation of the cylindrical burring wall 25c extending in the radial direction of the metal pipe 21b.
FIGS. 27(A) and 27(B) show a metal pipe according to a further embodiment in which a through-hole is formed so as to be inclined from the center line of the metal pipe. Specifically, FIG. 27(A) shows a metal pipe 21d in which a through-hole 24a having a cylindrical burring wall 25d that projects from the pipe inside circumferential surface has been formed by forming a groove or recess 22d having a rectangular cross-section in a direction inclined from the center line of the metal pipe 21d by removing an outside circumferential surface portion having a predetermined width or diameter of the metal pipe 21d, and then pressing a thin portion of the metal pipe 21d formed by the groove or recess 22d inward at the same inclination angle as that of the groove or recess 22d by, for example, the method of FIG. 23. Similarly, FIG. 27(B) shows a metal pipe 21e in which a through-hole 24e having a cylindrical burring wall 25e that projects from the pipe inside circumferential surface has been formed by forming a groove 22e having an arc-shaped cross-section by removing an outside circumferential surface portion having a predetermined width of the metal pipe 21e, and then pressing a thin portion formed by the groove 21e inward in a direction inclined from the center line of the metal pipe 1b by, for example, the same method as in the case of FIG. 27(A). As in the above embodiments, the through-holes 24d and 24e of the respective metal pipes 21d and 21e shown in FIGS. 27(A) and 27(B) are preferably longer than the thickness of the respective metal pipes 21d and 21e because of the formation of the cylindrical burring walls 25d and 25e extending from the inside surfaces of the respective metal pipes 21d and 21e, and edges 26 are formed at the opening portions on the pipe outside circumferential surface side.
FIGS. 28(A) and 28(B) show metal pipes according to another embodiment in which an eccentric through-hole is formed. Specifically, FIG. 28(A) shows a metal pipe 21f in which a through-hole 24f having a cylindrical burring wall 25f that projects from the pipe inside circumferential surface has been formed by forming a groove or recess 22f having a flat bottom surface along a line that is deviated from the center line of the metal pipe 21f by a predetermined distance by removing an outside circumferential surface portion of the metal pipe 21f, and then pressing a thin portion formed by the groove or recess 22f inward along a line that does not pass through the center line of the metal pipe 21f by, for example, the method of FIG. 23. Similarly, FIG. 28(B) shows a metal pipe 21g in which a through-hole 24g having a cylindrical burring wall 25g that projects from the pipe outside circumferential surface has been formed by forming a groove or recess 22g having a flat bottom surface along a line that is deviated from the center line of the metal pipe 21g by a predetermined distance by removing an outside circumferential surface portion of the metal pipe 21g, and then pressing a thin portion formed by the groove or recess 22g outward along a line that does not pass through the center line of the metal pipe 21g by, for example, the method of FIG. 25. As in the above embodiments, the through-holes 24f and 24g of the respective metal pipes 21f and 21g are preferably longer than the thickness of the respective metal pipes 21f and 21g because of the formation of the cylindrical burring walls 25f and 25g extending from the inside circumferential surface of the metal pipe 1c, and an edge 26 is formed at the opening portion of the metal pipe 21f on the outside circumferential surface side.
In the above embodiments of the third aspect of the invention, when the thin portion is formed by a groove, each of the grooves 22 and 22a-22g is formed by removing an outside circumferential surface portion in the direction perpendicular to the center line of each of the metal pipes 21 and 21a-21g. FIG. 29 shows an alternative structure in which a groove 22h is formed so as to be inclined from, or in a certain situation parallel with, the center line of a metal pipe 21h. Then, as in the above embodiments, a through-hole 24h having a cylindrical burring wall that extends from the pipe inside circumferential surface is formed by pressing the thin portion, for example, inward by means of fluid pressure or a sphere. As in the above embodiments, the through-hole 24h of the metal pipe 21h thus formed is preferably longer than the thickness of the metal pipe 21h because of the formation of the cylindrical burring wall extending from the pipe inside circumferential surface of the metal pipe 21h, and an edge 26 is formed at the opening portion on the pipe outside circumferential surface side.
By using the through-holes 24 and 24h as branch holes for nozzles, the metal pipes 21 and 21a-21h formed with the through-holes 24 and 24a-24h can be used as they are as, for example, a cooling oil jet pipe for cooling the cylinder or the piston of an engine or a lubrication oil jet pipe that is used in a system for supplying (jetting) a lubricant to a sliding portion such as a crank shaft or a cam shaft. If necessary, nozzle pipes may be connected to the through-holes in the manner as shown in FIGS. 8(A) and 8(B) or FIGS. 9(A) and 9(B) to change the oil jetting direction or make the jetting outlets closer to an object, or branch pipes for general piping may be connected to the through-holes,.
As described above, the invention provides the following advantages:
(1) Since a through-hole is formed by a press method using a punch or by means of fluid pressure or a sphere, chips or sputters are not generated.
(2) A cylindrical burring wall can easily be formed on the pipe inside or outside circumferential surface side, and a sufficient through-hole length for, for example, brazing to nozzle pipes or branch pipes can be secured.
(3) The thickness of a hole-forming portion is decreased in advance, no recess (shearing droop) occurs at the opening portion of a through-hole on the pipe outside surface side and an edge shape can be formed there.
(4) A through-hole having a cylindrical burring wall can be formed so as to be inclined from the center line of a metal pipe by an arbitrary angle, or can be formed along a line that does not pass through the center line of a metal pipe.
(5) When a nozzle pipe or a branch pipe is brazed to a through-hole having a burring wall that projects from the inside or outside circumferential surface of a metal pipe, the brazing strength and the stability of the jetting direction can be increased because the brazing area is increased by the burring wall.
(6) A very fine through-hole of 0.6-1.0 mm in diameter can be formed by a press method using a punch.
(7) Having a constant diameter, a through-hole enables a constant flow rate when it is used as an oil jetting hole. Since the boundary between the pipe outside circumferential surface and the through-hole assumes an edge shape, the shape of an oil jet as output is stabilized and divergence of an oil jet can be prevented. Further, the jetting direction of an oil jet can be stabilized by virtue of the action of the burring wall.
(8) Because a core bar is not needed to form a through-hole, a through-hole can be formed quickly and properly at an arbitrary position of a metal pipe. A through-hole can be formed even in a portion between bent portions formed by bending a metal pipe.

Number	Date	Country
9-330918	Nov 1997	JPX
10-112791	Apr 1998	JPX
10-112793	Apr 1998	JPX

Number	Name	Date
4161873	Mabery	Jul 1979
4457200	Borzym	Jul 1984
5544514	Maier et al.	Aug 1996

Method for forming a through-hole through the circumferential wall of a metal pipe and a metal pipe worked by the said method

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