The present invention relates to a press-work method of thickening an inclined portion rising from a bottom surface portion of a bottomed container, and to a bottomed container manufactured by the same.
With reference to
For example, Patent Literature 1 discloses a thickening press-work method in which a pressing punch and an upsetting punch are provided, and between an upper end portion and a bottom inner portion of a workpiece, a gap is reserved between the pressing punch and a die, and an upper surface of the end portion of the workpiece is pressed by the upsetting punch. However, in the method of Patent Literature 1, folding may also occur because buckling occurs in the gap during the thickening.
Therefore, there has been proposed a method to overcome the drawbacks of the above-described thickening methods, in the manufacture of a pulley piston for continuously variable transmission of an automobile, as described in Non Patent Literature 1. This forming method is capable of preventing folding ascribable to buckling because a portion to be thickened is thickened by pushing an end portion of a cup in a state where a constraint surface of a material is increased by providing a corner portion in the portion to be thickened. However, since a gap of the portion to be thickened is geometrically decided by constraint by the shape of a mold and the movement of the mold, a maximum thickening ratio that can be achieved in one forming is about 1.5. Further, before this process, it is necessary to form a bottomed cylindrical container by deep drawing or the like, and totally two processes are required.
Further, Patent Literature 2 proposes a method in which a press-worked workpiece which has an end wall, a bent portion bent from an outer periphery of the end wall toward one side, and a cylindrical portion provided to continue from the bent portion is used, the workpiece is clamped by a clamp punch adapted to an inner surface of the workpiece, a clamp die adapted to an outer surface of the end wall, and a thickness-increase guide die fitted to an outer peripheral surface of the clamp die so as to be swingable in an axial direction and adapted to outer peripheral surfaces of the bent portion and the cylindrical portion, a thickness-increasing punch is inserted in space formed between the clamp punch and the thickness-increase guide die to apply an axial-direction compression load to the cylindrical portion, thereby thickening the bent portion, and the thickness-increase guide die is retracted from the clamp die according to the thickening.
Further, Patent Literature 3 proposes a structure in which a knockout for receiving a body portion of a workpiece, a plate presser for pressing an area up to the middle of a rising portion rising obliquely outward from the body portion, a thickness-increasing punch for pressing a tip of the rising portion, and a die for receiving the rising portion are provided, and the die is movable in an axial direction relatively to the knockout and the thickness-increasing punch. In the process of crushing the rising portion by pressing the tip of the rising portion by the thickness-increasing punch, the die is pressed by the rising portion which is in the course of being thickened without being pushed by the thickness-increasing punch, to move relatively to the knockout, so that a gap between the plate presser and the die which sandwich the rising portion widens.
However, the methods of Patent Literatures 2, 3 also require the forming of a bottomed cylindrical container by deep drawing or the like, and thus require totally two processes. Further, a cutting process is sometimes required because a large step occurs in a boundary between a thickened portion and a non-thickened portion. Further, an achievable thickening ratio is not mentioned.
Further, in the structure in which the die is divided and part thereof is moved, in Patent Literature 2, for example, a force in a direction perpendicular to an inclined portion (2b in Patent Literature 2) acts on the thickness-increase guide die at the time of the thickening. Since this force acts in such a direction as to make the thickness-increase guide die separate from the clamp die (outward in a diameter direction), a gap occurs in a boundary between the clamp die and the thickness-increase guide die, which may cause a burr.
Patent Literature 1: Japanese Laid-open Patent Publication No. 2001-47175
Patent Literature 2: Japanese Laid-open Patent Publication No. 2010-247199
Patent Literature 3: Japanese Laid-open Patent Publication No. 2009-248092
Non Patent Literature 1: “Automotive Engineering”, Automotive Engineers of Japan Inc., 1996, Vol. 50, No 12, p. 31-37
The present invention was made in order to solve the above-described conventional drawbacks and its main object is to make it possible to avoid folding due to buckling to achieve thickening with a thickening ratio of 1.5 times or more in a press-work. Its another object is to make it possible to manufacture a bottomed container having a smooth shape without a large step in a boundary between a thickened portion and a non-thickened portion. Its another object is to make it possible to manufacture a bottomed container whose inclined portion is thickened, from a disk-shaped workpiece by a press-work having one process.
The gist of the present invention that is to achieve the aforesaid objects is as follows.
[1] A press-work method using a press mold which includes an inner punch, an intermediate punch disposed along an outer periphery of the inner punch and having an intermediate punch inclined portion at a leading end, an outer punch disposed along an outer periphery of the intermediate punch, and a die having a die inclined portion facing the intermediate punch inclined portion, central axes of all of which are disposed coaxially, the method including a thickening step of, while constraining a bottom portion of a bottomed container by the inner punch and the die, pressing an end portion of the bottomed container by the outer punch and moving the intermediate punch in a direction opposite a direction in which the outer punch is pressed, to thereby thicken a bottomed container inclined portion of the bottomed container sandwiched by the intermediate punch inclined portion and the die inclined portion.
[2] A press-work method using a press mold which includes an inner punch having an inner punch flat portion and an inner punch inclined portion at a leading end, an intermediate punch disposed along an outer periphery of the inner punch and having an intermediate punch inclined portion at a leading end, an outer punch disposed along an outer periphery of the intermediate punch, and a die having a die inclined portion disposed to face the intermediate punch inclined portion, central axes of all of which are disposed coaxially, the inner punch inclined portion being formed at an end portion, of the leading end of the inner punch, on a side adjacent to the intermediate punch inclined portion, the method including:
an outer punch pressing step of, while constraining a bottom portion of a bottomed container by the inner punch flat portion and the die, pressing an end portion of the bottomed container by the outer punch to thereby bring a bottomed container inclined portion, of the bottomed container, which extends along the inner punch inclined portion and the intermediate punch inclined portion, into contact with the die inclined portion;
an intermediate punch pressing step of pressing the intermediate punch in a direction of the die against the bottomed container which is brought into contact with the die inclined portion in the outer punch pressing step, to bring the intermediate punch inclined portion into contact with the bottomed container inclined portion; and
a thickening step of pressing the outer punch against the bottomed container which is brought into contact with the intermediate punch inclined portion in the intermediate punch pressing step, and moving the intermediate punch in a direction opposite a direction in which the outer punch is pressed, to thereby thicken the bottomed container inclined portion.
[3] The press-work method according to [1], including, before the thickening step, a forming step of pressing a disk-shaped workpiece into the die by the inner punch and the intermediate punch to form the bottomed container in which the bottomed container inclined portion is formed at a position sandwiched by the intermediate punch inclined portion and the die inclined portion.
[4] The press-work method according to [2], including, before the outer punch pressing step, a forming step of pressing a disk-shaped workpiece into the die by the inner punch and the intermediate punch to form the bottomed container in which the bottomed container inclined portion is formed at a position sandwiched by the inner punch inclined portion and the intermediate punch inclined portion, and the die inclined portion.
[5] The bottomed container manufactured by the press-work method according to [1], wherein a thickening ratio of a thickness of the bottomed container inclined portion is 1.5 times or more.
[6] The bottomed container manufactured by the press-work method according to [2], wherein a thickening ratio of a thickness of the bottomed container inclined portion is 1.5 times or more.
According to the present invention, it is possible to avoid folding due to buckling to achieve thickening with a thickening ratio of 1.5 times or more.
Further, it is possible to manufacture a bottomed container having a smooth shape without a large step in a boundary between a thickened portion and a non-thickened portion.
Furthermore, it is possible to manufacture a bottomed container whose inclined portion is thickened, from a disk-shaped workpiece by a press-work having one process.
Hereinafter, modes for carrying out the present invention will be described with reference to the attached drawings.
As a result of studious studies, the present inventor has found out that, by performing deep drawing by using an inner punch, an intermediate punch disposed along an outer periphery of the inner punch, and a die, central axes of all of which are coaxially disposed, to form a bottomed container, and subsequently, while constraining a workpiece, performing thickening by gradually increasing a gap between the intermediate punch and the die when an end surface of the bottomed container is pressed by the outer punch, it is possible to perform the thickening with a thickening ratio of 1.5 times or more by a press-work having one process while avoiding folding due to buckling.
(First Embodiment)
The inner punch 23 has a columnar shape, and is of a movable type capable of moving up and down by a not-illustrated drive source of a mechanical type (hydraulic or servo motor, or the like).
The intermediate punch 24 has a cylindrical shape, and on its surface that comes into contact with a portion to be thickened of a workpiece (that is, on a lower end portion (leading end) of the intermediate punch 24), an intermediate punch inclined portion 24a is formed. This intermediate punch inclined portion 24a is inclined in an obliquely upward direction from an inner punch 23 side toward an outer punch 25 side. The intermediate punch 24 is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
The outer punch 25 has a cylindrical shape and is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
The knockout 26 has a columnar shape, is intended to detach a formed product from the mold, and is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
The die 27 is of a fixed type, has a substantially concave shape, and has, at a center portion, a hole allowing the knockout 26 to be inserted therein. Further, in the die 27, a die inclined portion 27a is formed, and this die inclined portion 27a is disposed to face the intermediate punch inclined portion 24a.
In this embodiment, by executing the following forming step and thickening step, the workpiece 21 was press-worked. As the workpiece 21, a disk-shaped high-tensile steel sheet (SAPH590) having a 240 mm outside diameter and a 4 mm sheet thickness was used.
The workpiece 21 is placed on the die 27 and is subjected to the deep drawing by pressing the inner punch 23 and the intermediate punch 24, whereby a bottomed container 22 in which a bottomed container inclined portion 22a is formed at a position sandwiched by the intermediate punch inclined portion 24a and the die inclined portion 27a is formed as illustrated in
In the state illustrated in
Subsequently, as illustrated in
After the thickening step, the inner punch 23, the intermediate punch 24, the outer punch 25, and the knockout 26 are moved upward, and the bottomed container 22 is detached from the die 27. A sheet thickness of the bottomed container inclined portion 22a is 6.9 mm, and thus the thickness can be increased to 1.73 times an original sheet thickness of 4 mm without any occurrence of folding due to buckling.
Further, at the time of the thickening, a force in a direction perpendicular to the intermediate punch inclined portion 24a acts on the intermediate punch 24, but since this force acts in such a direction as to press the intermediate punch 24 against the inner punch 23 (inward in a diameter direction (center direction)), there occurs no gap in a boundary between the inner punch 23 and the intermediate punch 24 and a burr is not generated.
(Second Embodiment)
In a second embodiment, a bottomed container having a smooth shape without a large step in a boundary between a thickened portion and a non-thickened portion is manufactured.
The inner punch 33 has a columnar shape, and on its leading end, an inner punch inclined portion 33a and an inner punch flat portion 33b are formed. The inner punch inclined portion 33a is formed on a peripheral edge portion of the leading end, that is, on an end portion on a side adjacent to an intermediate punch inclined portion 34a, and the inner punch flat portion 33b is formed around the central axis 30. The inner punch inclined portion 33a is inclined in an obliquely upward direction from a central axis 30 side toward an intermediate punch 34 side. The inner punch flat portion 33b extends in a horizontal direction perpendicular to the central axis 30. The inner punch 33 is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
The intermediate punch 34 has a cylindrical shape, and on its surface that comes into contact with a portion to be thickened of a workpiece (that is, on a lower end portion (leading end) of the intermediate punch 34), the intermediate punch inclined portion 34a is formed. This intermediate punch inclined portion 34a is inclined in an obliquely upward direction from an inner punch 33 side toward an outer punch 35 side. The intermediate punch 34 is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
Here, when a height of an end portion of the inner punch inclined portion 33a on a side more distant from the central axis 30 and a height of an end portion of the intermediate punch inclined portion 34a on a side closer to the central axis 30 are equal, that is, in the state illustrate in
The outer punch 35 has a cylindrical shape and is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
The knockout 36 has a columnar shape, is intended to detach a formed product from the mold, and is of a movable type capable of moving up and down by a not-illustrated mechanical drive source.
The die 37 is of a fixed type, has a substantially concave shape, and has, at a center portion, a hole allowing the knockout 36 to be inserted therein. In the die 37, a die inclined portion 37a is formed, and this die inclined portion 37a is disposed to face the inner punch inclined portion 33a and the intermediate punch inclined portion 34a.
In this embodiment, by executing the following forming step, outer punch pressing step, intermediate punch pressing step, and thickening step, the workpiece 31 was press-worked. As the workpiece 31, a disk-shaped high-tensile steel sheet (SAPH590) having a 224 outside diameter and a 4 mm sheet thickness was used.
The workpiece 31 is placed on the die 37, and is subjected to the deep drawing by pressing the inner punch 33 and the intermediate punch 34, whereby a bottomed container 32 in which a bottomed container inclined portion 32a is formed at a position sandwiched by the inner punch inclined portion 33a and the intermediate punch inclined portion 34a, and the die inclined portion 37a is formed as illustrated in
In the state illustrated in
Subsequently, an end surface of the bottomed container 32 formed in the forming step is pressed by the outer punch 35, whereby the bottomed container inclined portion 32a extending along the inner punch inclined portion 33a and the intermediate punch inclined portion 34a is brought into contact with the die inclined portion 37a as illustrated in
Subsequently, the intermediate punch 34 is moved downward toward the bottomed container 32 which is brought into contact with the die 37 in the outer punch pressing step (the intermediate punch 34 is pressed toward the die 37), whereby the intermediate punch inclined portion 34a is brought into contact with the bottomed container inclined portion 32a as illustrated in
Subsequently, as illustrated in
After the thickening step, the inner punch 33, the intermediate punch 34, the outer punch 35, and the knockout 36 are moved upward, and the bottomed container 32 is detached from the die 37. A sheet thickness of the bottomed container inclined portion 32a is 8 mm, and thus the thickness can be increased to twice an original sheet thickness of 4 mm without any occurrence of folding due to buckling. Further, a smooth shape is achieved without any large step in a boundary between a thickened portion and a non-thickened portion.
Further, at the time of the thickening, a force in a direction perpendicular to the intermediate punch inclined portion 34a acts on the intermediate punch 34, but since this force acts in such a direction as to press the intermediate punch 34 against the inner punch 33 (inward in a diameter direction (center direction)), there occurs no gap in a boundary between the inner punch 33 and the intermediate punch 34 and a burr is not generated.
Here, in the state illustrated in
In the above-described examples, an angle made by the bottomed container inclined portions 22a, 32a and the horizontal direction is 45°, but it is desirably not less than 20° nor more than 70°. This is because, if the angle made by the bottomed container inclined portion 22a, 32a and the horizontal direction is less than 20°, a flow of a material from bottomed container vertical wall portions 22b, 32b to the bottomed container inclined portions 22a, 32a becomes worse, and a load required for the forming becomes large. Further, this is because, if the angle made by the bottomed container inclined portions 22a, 32a and the horizontal direction is over 70°, a contact length of the workpieces 21, 31 and the mold becomes long, and accordingly a frictional force becomes large, so that a load required for the forming becomes large. Note that the bottomed container vertical wall portions 22b, 32b mean portions of the bottomed containers 22, 32 on a side closer to the outer punches 25, 35 than the bottomed container inclined portions 22a, 32a.
Hitherto, the present invention has been described together with various embodiments, but the present invention is not limited only to these embodiments, and changes and so on can be made within the scope of the present invention.
In the above-described examples, SAPH590 is used as the workpiece, but it is not limited to an iron-based material, but an aluminum-based metal, a titanium-based metal, or the like is usable.
Further, in the above-described embodiments, the examples where the bottomed container whose inclined portion is thickened is manufactured from the disk-shaped workpiece by the press-work having one process, but the present invention is also applicable to a press-work whose thickening target is a bottomed container having an inclined portion which is formed in a separate process, that is, to a press-work whose starting state is
The present invention is usable for thickening an inclined portion rising from a bottom surface portion of a bottomed container.
Number | Date | Country | Kind |
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2012-233707 | Oct 2012 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2013/078611 | 10/22/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2014/065290 | 5/1/2014 | WO | A |
Number | Date | Country |
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2000024745 | Jan 2000 | JP |
2001-47175 | Feb 2001 | JP |
2005-349433 | Dec 2005 | JP |
2009-248092 | Oct 2009 | JP |
2010-120058 | Jun 2010 | JP |
2010-214381 | Sep 2010 | JP |
2010-247199 | Nov 2010 | JP |
Entry |
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“Automotive Engineering”, Automotive Engineers of Japan Inc., 1996, vol. 50, No. 12, pp. 31-37. |
International Search Report, issued in PCT/JP2013/078611, dated Jan. 21, 2014. |
Written Opinion of the International Searching Authority, issued in PCT/JP2013/078611, dated Jan. 21, 2014. |
International Preliminary Report on Patentability and English translation of the Written Opinion of the International Searching Authority (Forms PCT/IB/338, PCT/IB/373 and PCT/ISA/237), dated May 7, 2015, for International Application No. PCT/JP2013/078611. |
Number | Date | Country | |
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20150239029 A1 | Aug 2015 | US |