The present invention relates to a method of manufacturing a ring-shaped member.
A ring-shaped member 1 as shown in
However, in the conventional manufacturing method, the yield rate or the percentage of the weight of the ring-shaped member 1 with respect to the weight of the raw material 2 is bad, and tends to increase the cost of the ring-shaped member 1.
This is because the material is removed at high percentage of skeleton S1 and slug S2 with respect to the ring-shaped member 1. The “Skeleton” is a frame shaped scrap that remains after punching out a plurality of ring-shaped members 1, and the “slug” is a plurality of scraps punched out and removed with a punch when punching out the plurality of ring-shaped members 1.
A method of molding the ring-shaped member shown in
The method of molding the ring-shaped member described in Japanese Patent Application No. 62-2036331 includes a step of continuously bending the width of an elliptical ring-shaped raw material into a circular shape while preventing the deformation thereof, and a step of making the raw material formed into a circular shape into a perfect circle.
That is, as shown in
Thereafter, as shown in
However, in the method of molding the ring-shaped member described in Japanese Published Patent Application No. 62-203633, a curved part 107 having a small curvature radius remaining on the circular raw material 101 is pressed and widened from the inner side with a strong pressing force in the direction of an arrow K by the large diameter inner roller 106. When the curved part 107 of small curvature radius is pressed and widened from the inner side, a large “extension” is generated at the radial inner region of small curvature radius in the curved part 107 thereby thinning the relevant region and concentrating stress. Therefore, cracks may be generated at the radial inner region of the curved part 107 in the process of molding the circular shaped raw material 101 into a perfect circular shaped ring-shaped member 102, which degrades the yield rate or the percentage of the perfect circular shaped ring-shaped member 102 with respect to the elliptical ring-shaped raw material 100, and increases the cost.
The present invention, in view of solving the above problems, aims to provide a method of manufacturing a ring-shaped member that improves the yield rate or the percentage of the weight of the ring-shaped member with respect to the weight of the raw material, and improves the yield rate or the percentage of the ring-shaped member (correspond to ring-shaped part molded into a perfect circle described in the patent document 1) with respect to a longitudinal annular blank (correspond to elliptical ring-shaped raw material described in the patent document 1), even though the method can achieve a cost reduction.
A method of manufacturing a ring-shaped member according to the present invention is provided, where a longitudinal annular blank is molded into an annular shape by pressing curved parts at both ends in the longitudinal direction towards the opponent side from the outer side.
The “Blank” is a plate punched out for manufacturing the ring-shaped member.
In this manner, the material is removed such that the percentage of the skeleton and the slug with respect to the ring-shaped member is suppressed low, and the yield rate or the percentage of the weight of the ring-shaped member with respect to the weight of the raw material can be improved. Furthermore, “extension” of the radial inner region having a small curvature radius at the curved parts is suppressed as small as possible by pressing the curved parts at both ends in the longitudinal direction towards the opponent side from the outer side, thinning of the radial inner region can be avoided, and furthermore, flow of material that thickens the curved part is generated and alleviates stress concentration at the radial inner region. As a result, cracks are not generated at the curved part, and the yield rate or the percentage of the ring-shaped member with respect to the longitudinal annular blank can be improved.
The present invention desirably has the longitudinal annular blank molded to an annular shape by a shaping device including an inner die and an outer die. Accordingly, the high quality ring-shaped member can be efficiently manufactured, and cost can be reduced.
The present invention desirably has the longitudinal annular blank which includes linear parts that face each other on both sides in the width direction with a longitudinal hole on the inner side and curved parts for continuing both ends in the longitudinal direction of the linear parts; and the dimension in the width direction of the longitudinal annular blank is widened by pressing and energizing the linear parts by the inner die fitted into the longitudinal hole, the outer side of the curved parts are pressed and energized towards the curved parts of the opponent side by a molding outer die with a holding inner die fitted into the longitudinal hole whose dimension in the width direction is widened, and the curved parts are pressed and widened to a large cured part having a large curvature radius.
Therefore, if the outer side of the curved part is pressed and energized towards the curved part on the opponent side by the molding outer die with the holding inner die fitted into the longitudinal hole which dimension in the width direction has been widened after the dimension in the width direction of the longitudinal annular blank is widened by the inner die fitted into the longitudinal hole, such curved part is pressed inward from the outer side by the molding outer die while being positioned with the movement towards the curved part on the opponent side regulated by the holding inner die, whereby “extension” of the radial inner region having a small curvature radius at the curved parts is suppressed as small as possible, the thinning of the radial inner region is avoided, and furthermore, stress does not concentrate at the radial inner region and thus cracks are not generated at the curved part, and both curved parts are easily molded into a large curved part of large curvature radius.
Furthermore, the present invention may have both end faces in the width direction of the longitudinal annular blank which are formed by both end faces in the width direction of the raw material, and the curved parts for continuing the linear parts to each other which are formed at both ends in the longitudinal direction by cutting the raw material. Accordingly, the material can be removed such that the percentage of scrap with respect to the longitudinal annular blank is suppressed to a minimum, and in consequence, the yield rate or the percentage of the weight of the ring-shaped member with respect to the weight of the raw material can be improved.
According to the present invention, the ring-shaped member is manufactured by molding the longitudinal annular blank into an annular shape by pressing the curved parts at both ends in the longitudinal direction towards the opponent side from the outer side, and thus the yield rate or the percentage of the weight of the ring-shaped member with respect to the weight of the raw material improves and the cost of the ring-shaped member reduces by removing the material such that the percentage of the skeleton and the slug with respect to the ring-shaped member is suppressed low, and furthermore, “extension” of the radial inner region having a small curvature radius at the curved parts at both ends in the longitudinal direction is suppressed as small as possible, thinning of the radial inner region is avoided, and furthermore, flow of material that thickens the curved part is generated so that stress does not concentrate at the radial inner region. As a result, cracks are not generated at the curved part, and the yield rate or the percentage of the ring-shaped member with respect to the longitudinal annular blank can be improved.
A preferred embodiment of the method of manufacturing the ring-shaped member according to the present invention will now be described based on the drawings.
As shown in
The first shaping device 4 includes a moving plate 5 and a pair of front and back guide plates 6, where the moving plate 5 is guided by the guide plates 6 to move forward and backward in the left and right direction (direction of arrow X1, X2) by a forward/backward movement mechanism (not shown). The moving plate 5 includes a main body part 5a, and collar parts 5b, 5b formed on both ends in the front and back direction of the main body part 5a, where the collar parts 5b, 5b slidably go under the lower side of the edges 6a, 6a at the side facing the opponent in the guide plate 6, and a vertical step difference surface 5c formed at the boundary of the main body part 5a and the collar parts 5b, 5b is arranged so as to slidably contact the end surface 6b at the side facing the opponent in the guide plate 6. An inner die 8-1 having a boat shape in a projected plane is projected upward at the central part of the main body part 5a in the moving plate 5 on the line Y orthogonal to line X. The width dimension w2 of the inner die 8-1 is set to a size slightly smaller than the width dimension w1 of the longitudinal hole 3a so as to fit into the longitudinal hole 3a of the blank 3.
A pair of front and back positioning projections 8-2, and two pairs of front and back positioning/deformation tolerating projections 9 are arranged on the guide plate 6 in the first shaping device 4. As mentioned below, the pair of positioning projections 8-2 is provided to prevent the longitudinal annular blank 3 from moving in the direction of the arrow Y1, Y2 and to position the longitudinal annular blank 3 at an appropriate position when the longitudinal annular blank 3 is set in the first shaping device 4, and furthermore, is arranged at symmetrical positions with the line X in between so as to face each other on the line Y orthogonal to the line X, where the distance in between is set to a value slightly larger than the dimension in the longitudinal direction of the longitudinal annular blank 3 to enable the setting of the longitudinal annular blank 3.
As mentioned below, the two pairs of front and back positioning/deformation tolerating projections 9 are provided to prevent the longitudinal annular blank 3 from moving in the direction of the arrows X1, X2 and to position the longitudinal annular blank 3 at an appropriate position as well as to tolerate the deformation of the longitudinal annular blank 3 by an inner die 7 when the longitudinal annular blank 3 is set in the first shaping device 4, and is further arranged at symmetrical positions with the line X and the line Y passing through the center of the moving plate 5 in between, where the distance in between in the direction of the line X is set at a value slightly larger than the dimension in the width direction of the longitudinal annular blank 3 to enable the setting of the longitudinal annular blank 3. Each positioning/deformation tolerating projection 9 has a circular arc shaped deformation tolerating surface 9b formed in continuation to the positioning surface 9a that is parallel to the line Y.
As shown in
The moving plate 5 is moved in the direction of the arrow X2 in this state. The inner die 7 presses and energizes the linear part 3c on the right side of the longitudinal annular blank 3 in the direction of the arrow X2 from the inner side to bend in the direction of the arrow X2 as shown in
In the next step, the deformed longitudinal annular blank 3A shown in
The second shaping device 11 includes a pair of left and right molding outer dies 12, and a pair of front and back regulating dies 13, where the molding outer die 12 is guided by a guide groove 14 and is moved forward and backward in the left and right direction (direction of arrows X1, X2) on the base 15 by a forward/backward movement mechanism (not shown).
The molding outer die 12 includes a mounting surface 12a and a pressing surface 12b projecting vertically upward from the mounting surface 12a and having the projected plane depressed into a circular arc shape, where the curvature radius of the pressing surface 12b is set to a value larger than the curvature radius of the outer peripheral surface of the curved part 3d in the deformed longitudinal annular blank 3A. The regulating die 13 is formed at the end face on the side facing the opponent with a regulating surface 13a having the projected plane depressed into a circular arc shape. Furthermore, a holding inner die 16 projecting upward from the upper surface at the central part of the base 15 and having a boat shape in projected plane view is arranged extending in the direction of the line X, where the width dimension of the holding inner die 16 is set to a dimension slightly smaller than the width dimension of the longitudinal hole 3e so as to be fitted to the longitudinal hole 3e of the deformed longitudinal annular blank 3A. A circular arc shaped holding surface 16a is arranged vertically at both ends on the line X of the holding inner die 16, and a cut-out part 16b is formed on the lower side of the holding surface 16a and the vicinity thereof.
As shown in
The molding outer dies 12 are moved in the direction of the arrows X1, X2 in this state. The pressing surface 12b of the molding outer die 12 thereby presses and energizes the outer side of the curved part 3d of the deformed longitudinal annular blank 3A towards the curved part 3d on the opponent side. In this case, the mounting surface 12a of the molding outer die 12 enters the cut-out part 16b of the holding inner die 16. Therefore, as shown in
In the process of molding both curved parts 3d to the large curved part 3D having a large curvature radius, the linear parts 3b, 3c in the deformed longitudinal annular blank 3A shown in
The half-finished article 18 shown in
The third shaping device 19 includes a base 20, and an upper plate 21 for blocking the upper surface of the base 20 by way of a spacing in the height direction, where a guide groove 22 is formed in the base 20 on the line X passing through the center, and a moving plate 23 that freely moves forward and backward in the direction of the arrows X1, X2 is fitted into the guide groove 22. The moving plate 23 moves forward and backward in the direction of the arrows X1, X2 by a forward/backward moving mechanism (not shown). The upper surface of the moving plate 23 is in plane with the upper surface of the base 20, and a finishing inner die 24 having an elliptical shape in a projected plane view is arranged at the central part so as to project upward on a line Y passing through the center of the base 20 and being orthogonal to the line X. The finishing inner die 24 faces a window part 25 of a substantially perfect circle formed on the upper plate 21, and the inner peripheral surface of the window part 25 functions as an outer die.
As shown in
The moving plate 23 is moved in the direction of the arrow X2 in such state. The finishing inner die 24 presses and energizes the right half portion of the half-finished article 17 in the direction of the arrow X2 from the inner side and presses the outer peripheral surface of the right half portion against the inner peripheral surface of the right half portion in the window part 25 of a substantially perfect circle, as shown in
Therefore, according to the present invention, the ring-shaped member 1 shown in
Furthermore, each curved part 3d is deformed along the pressing surface 12b when the radial outer surface of large curvature radius is pressed inward from the outer side by the pressing surface 12b depressed into a circular arc shape of the molding outer die 12 with the radial inner surface slightly pressed and widened by the circular arc shaped holding surface 16a of the holding inner die 16 and positioned with the movement in the directions of the arrows X1, X2 regulated by pressing and energizing the outer side of the pair of curved parts 3d of the deformed longitudinal annular blank 3A towards the curved part 3d on the opponent side by the pressing surface 12b depressed to a circular arc shape of the molding outer die 12 by the second shaping device 11, and thus “extension” in the radial outer region having large curvature radius is suppressed as much as possible, thinning of the radial inner region is avoided, and furthermore, flow of material that thickens the curved part 3d is generated so as to alleviate stress concentration at the radial inner region. As a result, both curved parts 3d can be molded to a large curved part 3D having a large curvature radius and being advantageous in manufacturing the ring-shaped member 1 without generating cracks at the curved part 3d, and thus the yield rate or the percentage of the ring-shaped member 1 with respect to the longitudinal annular blank 3A can be improved and the cost of the ring-shaped member 1 can be reduced.
In the above embodiment, the longitudinal annular blank 3 having a small width dimension w1 of the longitudinal hole 3a is punched out, and such blank 3 is pressed and widened to manufacture the ring-shaped member 1, as shown in
Moreover, as shown in
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2005/018840 | 10/13/2005 | WO | 00 | 4/8/2008 |
Publishing Document | Publishing Date | Country | Kind |
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WO2007/043176 | 4/19/2007 | WO | A |
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Number | Date | Country | |
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20090255318 A1 | Oct 2009 | US |