METHOD OF MANUFACTURING INDUSTRIAL COMPONENT HAVING THROUGH HOLES WITH HIGH ASPECT RATIO

Abstract

A method of manufacturing an industrial component is provided which can highly accurately form through holes in a target object even with a narrow bar width and a long bar length. The method is for manufacturing an industrial component having through holes with a high aspect ratio by using a punch and a die. The punch has leading ends formed into punching cutters and serving as stacking axes of plural sheets of punch materials. The plural sheets of punch materials are punched by the punch and thereafter kept held by a side surface of the punch. When a given punch material is held by the side surface of the punch, a next punch material is punched and stacked, with the leading ends of the punch projecting farther than the lowest surface of the given punch material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overview diagram illustrating an example of a manufacturing method according to the present invention;

FIGS. 2( a) to 2(e) are step explanatory diagrams illustrating an example of the method according to the present invention of manufacturing an industrial component having through holes with a high aspect ratio by using a punch and a die, with FIG. 2(a) illustrating a first sheet preparation step of placing the first sheet of thin plate materials on the die, FIG. 2(b) illustrating a first sheet punching step of punching the first sheet with the punch, FIG. 2(c) illustrating a second sheet preparation step, FIG. 2(d) illustrating a second sheet punching step, and FIG. 2(e) illustrating a sheet punching completion step of separating stacked plate materials with a stripper after completion of punching and stacking of all sheets;

FIGS. 3( a) and 3(b) are diagrams illustrating an opening of a through hole formed by a punching mold according to a conventional method, with FIG. 3(a) being a pattern diagram illustrating a situation in which cracks occur, and FIG. 3(b) being an explanatory diagram illustrating a cross-sectional shape of the through hole formed in a plate material after punching;

FIGS. 4( a) and 4(b) are diagrams illustrating an opening of a through hole formed by laser processing according to a conventional method, with FIG. 4(a) being a pattern diagram illustrating a processing state using laser beam, and FIG. 4(b) being an explanatory diagram illustrating a cross-sectional shape of the through hole formed after the laser processing;

FIGS. 5( a) and 5(b) are diagrams illustrating an industrial component having through holes with a high aspect ratio according to the present invention, with FIG. 5(a) being an explanatory diagram illustrating an example of the shortest distance of a through hole, and FIG. 5(b) being an explanatory diagram illustrating another example of the shortest distance of the through hole;

FIGS. 6( a) and 6(b) are diagrams illustrating examples of cross-sectional shapes of the through holes with a high aspect ratio according to the present invention, with FIG. 6(a) illustrating an example of through holes of a typical elongated punched shape, and FIG. 6(b) illustrating an example in which a punched shape (i.e., bar shape) is a plurality of circles connected to one another;

FIG. 7 is an explanatory diagram illustrating an example of a conventional punching method using a punch and a die;

FIG. 8 is an explanatory diagram illustrating an example of the method according to the present invention of manufacturing an industrial component having through holes with a high aspect ratio by using a punch and a die; and

FIG. 9 is a side view illustrating an embodiment of the punch used in the method according to the present invention of manufacturing an industrial component having through holes with a high aspect ratio.

Claims

1. A method of manufacturing an industrial component having through holes with a high aspect ratio by using a punch and a die, comprising: using the punch which has leading ends formed into punching cutters and serving as stacking axes of plural sheets of punch materials,punching the plural sheets of punch materials by the punch and thereafter keeping held the plural sheets of punch materials by a side surface of the punch, andwhen a given punch material is held by the side surface of the punch, punching and stacking next punch material with the leading ends of the punch projecting farther than the lowest surface of the given punch material.

2. The method of manufacturing an industrial component according to claim 1, wherein a punched shape of the punch material has a ratio L/W of greater than 17 between a bar width W and a bar length L, the bar width W corresponding to a through hole interval.

3. The method of manufacturing an industrial component according to claim 1, wherein a punched shape of the punch material has a bar width of equal to or less than 0.07 mm, a bar length of equal to or greater than 0.6 mm, and a thickness of equal to or less than 0.11 mm, the bar width corresponding to a through hole interval.

4. The method of manufacturing an industrial component according to claim 2, wherein a punched shape of the punch material has a bar width of equal to or less than 0.07 mm, a bar length of equal to or greater than 0.6 mm, and a thickness of equal to or less than 0.11 mm, the bar width corresponding to a through hole interval.