JP2004351488A - Method for producing tubular member having partition plate by hydraulic forming - Google Patents
Method for producing tubular member having partition plate by hydraulic forming Download PDFInfo
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Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は仕切板付管状部材の液圧成形による製造方法に関する。
【０００２】
【従来の技術】
従来、管状部材の内部に仕切板を形成して該管状部材を流通する流路を分割した仕切板付管状部材が公知となっている。
【０００３】
例えば、前記仕切板付管状部材が自動車のエンジンの下流側に接続される仕切板付排気管に適用される場合、該仕切板付排気管の排気流路を分割することにより排気干渉を回避してエンジンの排気効率の向上を図っている（特許文献１、２参照）。
【０００４】
上記特許文献１、２における仕切板付管状部材の製造方法は、金属製の板材で仕切板を形成した後、該板材の一端側を券回して円筒形状に形成し、その端部を溶接固定するか、管の内部に仕切板を挿入してその両端部を溶接固定した後、プレス曲げ加工をして形成している。
【０００５】
【特許文献１】
特開２０００−１７０５３２号公報 （第１−３頁、第２図）
【特許文献２】
特開２００２−２０４９４７号公報 （第１−３頁、第４図）
【０００６】
【発明が解決しようとする課題】
しかしながら、従来の仕切板付管状部材の製造方法のうち、前者の金属製の板材で仕切板を形成した後、該板材の一端側を券回して円筒形状に形成し、その端部を溶接固定する場合、製造に多くの手間と時間がかかるため、結果、仕切板付管状部材の効率的な生産性を阻害する虞があるという問題点があった。
【０００７】
また、後者の管の内部に仕切板を挿入してその両端部を溶接固定した後、プレス曲げ加工を行う場合、プレス曲げ加工装置が複雑となってコスト高を招く上、プレス曲げ加工後の溶接に困難が生じる虞があるという問題点があった。
【０００８】
本発明は上記問題点に着目してなされたもので、その目的とするところは、液圧成形によって容易に仕切板付管状部材を得ることができ、従来の仕切板付管状部材に比べて製品精度と生産効率の向上の両立を図った仕切板付管状部材の液圧成形による製造方法を提供することにある。
【０００９】
【課題を解決するための手段】
請求項１記載の発明では、管内部が仕切板によって第１流路と第２流路に隔成された仕切板付管状部材の液圧成形による製造方法であって、金属製の三枚の板材を上下に重ね合わせて両端部同士を溶接固定すると共に、前記板材のうち、中央の板材と上下の板材との間に高圧の液状成形媒体を供給して該両側の板材を製造すべき仕切板付管状部材の外形状にそれぞれ膨出させることにより前記第１流路及び第２流路を形成したことを特徴とする。
【００１０】
請求項２記載の発明では、管内部が仕切板によって第１流路と第２流路に隔成された仕切板付管状部材の液圧成形による製造方法であって、製造すべき仕切板付管状部材の軸直方向における断面がＳ字形状に形成された金属製の仕切板と、前記仕切板の上下にそれぞれ重なった状態で該仕切板の両端部に溶接固定され、該仕切板との間に前記第１流路及び第２流路にそれぞれ対応する注入口を有する金属製の板材からなる予備成形品を形成する予備成形工程と、前記注入口に高圧の液状成形媒体を供給して前記板材を膨出させることにより第１流路及び第２流路を液圧成形する液圧成形工程と、を備えることを特徴とする。
【００１１】
請求項３記載の発明では、請求項２記載の仕切板付管状部材の液圧成形による製造方法において、予備成形工程が、金属製の三枚の板材を上下に重ね合わせて両端部同士を溶接固定する溶接工程と、前記重ねられた板材をプレス加工により製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となるように形成するプレス加工工程と、前記板材のうち、中央の板材に重ねられた上下の板材に第１流路及び第２流路にそれぞれ対応する注入口を形成する注入口加工工程と、を備えることを特徴とする。
【００１２】
請求項４記載の発明では、請求項２記載の仕切板付管状部材の液圧成形による製造方法において、予備成形工程が、プレス加工により製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となる仕切板と、該仕切板の上下にそれぞれ重なる形状の板材をそれぞれ形成するプレス加工工程と、前記仕切板の上下に前記板材を重ね合わせて両端部同士を溶接固定する溶接工程と、前記仕切板の両側の板材に第１流路及び第２流路に対応する注入口をそれぞれ形成する注入口加工工程と、を備えることを特徴とする。
【００１３】
請求項５記載の発明では、請求項２記載の仕切板付管状部材の液圧成形による製造方法において、予備成形工程が、製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となる仕切板と、第１流路及び第２流路に対応する注入口を有し、前記仕切板の上下にそれぞれ重なる形状の板材をそれぞれプレス加工により形成するプレス加工工程と、前記仕切板の上下に前記板材を重ね合わせて両端部同士を溶接固定する溶接工程と、を備えることを特徴とする。
【００１４】
【発明の作用及び効果】
請求項１記載の発明にあっては、金属製の三枚の板材を上下に重ね合わせて両端部同士を溶接固定すると共に、前記板材のうち、中央の板材と上下の板材との間に高圧の液状成形媒体を供給して該上下の板材を製造すべき仕切板付管状部材の外形状にそれぞれ膨出させることにより前記第１流路及び第２流路を形成したため、従来の発明に比べて複雑なプレス加工装置や多数の押し型を必要としない上、製造工程が少なくて済むため、液圧成形による製品精度の高い仕切板付管状部材を製造することができる。
【００１５】
請求項２記載の発明にあっては、予備成形工程において、製造すべき仕切板付管状部材の軸直方向における断面がＳ字形状に形成された金属製の仕切板と、前記仕切板の上下にそれぞれ重なった状態で該仕切板の両端部に溶接固定され、該仕切板との間に前記第１流路及び第２流路にそれぞれ対応する注入口を有する金属製の板材からなる予備成形品が形成される。
【００１６】
そして、液圧成形工程において、前記注入口に高圧の液状成形媒体を供給して前記板材を膨出させることにより第１流路及び第２流路を液圧成形する。
【００１７】
従って、予備成形品を形成した後、該予備成形品の注入口に高圧の液状成形媒体を供給して前記板材を膨出させることにより第１流路及び第２流路を液圧成形するという簡便な作業でもって、仕切板によって第１流路と第２流路に隔成された仕切板付管状部材を得ることができる。
【００１８】
また、従来の発明と比べて金属製の板材を券回したり、複雑なプレス曲げ加工をする必要がないため、製造にかかる時間・コスト・手間を短縮でき、この種の管状部材の生産性を大幅に向上できる。
【００１９】
請求項３記載の発明の発明にあっては、溶接工程において、金属製の三枚の板材を上下に重ね合わせて両端部同士を溶接固定する。
【００２０】
続いて、プレス加工工程において、前記重ねられた板材をプレス加工により製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となるように形成する。
【００２１】
最後に、注入口加工工程において、前記板材のうち、中央の板材に重ねられた上下の板材に第１流路及び第２流路にそれぞれ対応する注入口を形成することにより予備成形工程における予備成形品を得る。
【００２２】
従って、プレス加工工程、溶接工程、注入口加工工程を三枚の板材を重ねた状態で共に行うことができ、予備成形品を効率良く加工して得ることができる。
【００２３】
請求項４記載の発明にあっては、プレス加工工程において、プレス加工により製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となる仕切板と、該仕切板の上下にそれぞれ重なる形状の板材をそれぞれ形成する。
【００２４】
続いて、溶接工程において、前記仕切板の両側に前記板材を重ね合わせて両端部同士を溶接固定する。
【００２５】
最後に、注入口加工工程において、前記仕切板に重ねられた上下の板材に第１流路及び第２流路に対応する注入口をそれぞれ形成することにより予備成形工程における予備成形品を得る。
【００２６】
従って、仕切板と板材を予めそれぞれ精度良くプレス加工して形成することができ、仕切板と板材を重ね合わせた状態でプレス加工した場合に比べて、該仕切り部と板材の重なる部位の隙間なく重ねることができる上、両端部の溶接がプレス加工によって亀裂・破損する虞がなく、仕切板及び板材が堅固に固定された予備成形品を得ることができる。
【００２７】
また、前記予備成形品は仕切板及びその両側の板材の軸直方向の断面がＳ字形状に形成されているため、注入口に高圧の液状成形媒体を供給して板材を膨出させる際に、該板材の軸直方向の引っ張りによる薄肉化を防止できると共に、予備成形品の外形をコンパクトにできる。
【００２８】
さらに、液圧成形時における仕切板の負荷が軽減され、該仕切板を安定した形状に形成できる。
【００２９】
請求項５記載の発明にあっては、プレス加工工程において、プレス加工により製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となる仕切板と、第１流路及び第２流路に対応する注入口を有し、前記仕切板の上下にそれぞれ重なる形状の板材をそれぞれ形成する。
【００３０】
続いて、溶接工程において、前記仕切板の上下に板材を重ね合わせて両端部同士を溶接固定することにより予備成形工程における予備成形品を得る。
【００３１】
従って、三枚の板材を予め精度良くプレス加工して形成することができ、該三枚の板材の重なり合う部分を隙間無く形成することができる。
【００３２】
また、三枚の板材を重ね合わせて両端部同士を溶接固定した後に、注入口をそれぞれ形成する場合に比べて、注入口を予め所望の形状に精度良く形成することができ、液圧成形時の板材の膨出を安定して再現できる。
【００３３】
【発明の実施の形態】
以下、本発明の仕切板付管状部材の液圧成形による製造方法の実施の形態を説明する。
【００３４】
なお、本実施の形態では仕切板付管状部材を自動車の仕切板付排気管に適用した場合について説明する。
【００３５】
＜実施の形態１＞
以下、実施の形態１について説明する。
【００３６】
図１は本発明の実施の形態１の仕切板付排気管（仕切板付管状部材）を示す全体斜視図、図２は図１のＳ２−Ｓ２断面図、図３は仕切板付排気管の予備成形工程を説明する図、図４は仕切板付排気管の液圧成形工程を説明する図である。
【００３７】
本実施の形態の仕切板付管状部材の液圧成形による製造方法では、仕切板付管状部材をエンジンの下流側に配置される仕切板付排気管に適用した場合であって、図１、２に示すように、該仕切板付排気管Ａは半円筒形の板材１、２が仕切板４を挟んだ状態で全体が円筒形状に重ねられて両端部が溶接Ｘによって固定されている。
【００３８】
また、前記仕切板付排気管Ａの内部は、前記仕切板４によって第１流路４ａ及び第２流路４ｂに隔成されている。
【００３９】
このように構成された仕切板付排気管Ａは通常、エンジンの下流側に配置され、各気筒から流通したきた排気ガスを第１流路４ａ及び第２流路４ｂにそれぞれ流通させることにより排気干渉を回避して排気効率の向上を図っている。
【００４０】
そして、本実施の形態の仕切板付管状部材の液圧成形による製造方法にあっては、前記仕切板付排気管Ａを以下に詳述する予備成形工程と液圧成形工程を経て形成する。
【００４１】
（１）予備成形工程
以下、予備成形工程について説明する。
【００４２】
本実施の形態の予備成形工程は、溶接工程、プレス加工工程、注入口加工工程からなり、溶接工程においては、図３（ａ）に示すように、金属製の三枚の板材１〜３を上下に重ね合わせて両端部同士を溶接Ｘにて固定することにより該板材１〜３を一体的に形成する。
【００４３】
なお、前記溶接Ｘは製造すべき仕切板付排気管Ａの軸方向に亘って溶接される。
【００４４】
次に、プレス加工工程においては、図３（ｂ）に示すように、前記重ねられた板材１〜３を図外のプレス加工装置にて製造すべき仕切板付排気管１の軸直方向の断面がＳ字形状となるように同時にプレス加工する。
【００４５】
この際、板材２は仕切板４としての最終形状になる。
【００４６】
次に、注入口加工工程においては、図３（ｃ）に示すように、前記板材１，３の一方側端部に、前記第１流路４ａ及び第２流路４ｂにそれぞれ対応する注入口１ａ，３ａを形成することにより予備成形品８を得る。
【００４７】
なお、前記注入口１ａ，３ａの形成数、形成位置、形状などは製造すべき仕切板付排気管１の形状に応じて適宜設定される。
【００４８】
（２）液圧成形工程
【００４９】
液圧成形工程においては、図４（ａ）に示すように、製造すべき仕切板付管状部材１の外径に一致する当接面Ｏを有する凹状の型１０ａ，１０ｂの間に予備成形品８の両端部８ａ，８ａを挟み込み、前記注入口１ａ，３ａに高圧の液状成形媒体を供給すると、図４（ｂ）に示すように、板材１，３が型１０ａ，１０ｂに合致する形状にそれぞれ膨出して所望の仕切板付排気管Ａを得る。
【００５０】
この際、前記予備成形品８の仕切板４及び板材１，３がＳ字形状に形成されているため、注入口１ａ，３ａに高圧の液状成形媒体を供給して板材を膨出させる際に、該板材の軸直方向の引っ張りによる薄肉化を防止できると共に、予備成形品の外形をコンパクトにできる。
【００５１】
さらに、液圧成形時における仕切板４の負荷が軽減され、該仕切板４を安定した形状に形成できる。
【００５２】
なお、注入口１ａ，３ａ等の不要な部分は適宜切断される。
【００５３】
従って、本実施の形態の仕切板付管状部材の液圧成形による製造方法にあっては、予備成形品８を形成した後、注入口１ａ，３ｂに高圧の液状成形媒体を供給して板材１，３を型１０ａ，１０ｂに合致する形状に膨出させるという簡便な作業でもって仕切板付排気管１を得ることができる。
【００５４】
また、予備成形工程においては、板材１〜３を重ねた状態で溶接工程、プレス加工工程、注入口加工工程を共に行うため、従来の発明に比べて製造工程の削減と作業の効率化が図れる。
【００５５】
＜実施の形態２＞
以下、実施の形態２について説明する。
【００５６】
本実施の形態の仕切板付管状部材の液圧成形による製造方法は、前記実施の形態１で説明した予備成形工程（１）の別の例であり、前記実施の形態１と同一の構成部材については同じ符号を付してその説明は省略する。
【００５７】
図５は仕切板付排気管の予備成形工程を説明する図である。
【００５８】
（３）予備成形工程
【００５９】
本実施の形態における液圧成形による仕切板付管状部材の予備成形工程は、プレス加工工程、溶接工程、注入口加工工程からなり、プレス加工工程においては、図５（ａ）に示すように、板材１〜３を図外のプレス加工装置にて製造すべき仕切板付排気管Ａの軸直方向の断面がＳ字形状となるようにそれぞれプレス加工する。
【００６０】
この際、板材２は仕切板４としての最終形状になる。
【００６１】
続いて、溶接工程においては、図５（ｂ）に示すように、前記板材１〜３を上下に重ね合わせて両端部同士を溶接Ｘにて固定することにより該板材１〜３を一体的に形成する。
【００６２】
次に、注入口加工工程においては、図５（ｃ）に示すように、前記板材１，３に第１流路及び第２流路にそれぞれ対応する注入口１ａ，３ａを形成することにより、予備成形品８を得る。
【００６３】
なお、液圧成形工程については前記実施の形態１の（２）で説明した工程と同一であるためその説明は省略する。
【００６４】
従って、本実施の形態の仕切板付管状部材の液圧成形による製造方法にあっては、プレス加工工程にて板材１〜３をそれぞれ単体で形成するため、該板材１〜３の単体精度を向上させることができ、結果、板材１〜３同士を重ね合わせた際の隙間をなくしたり、溶接Ｘの溶着を確実にでき、結果、製品精度の高い仕切板付管状排気管Ａを得ることができ、ひいてはこの種の仕切板付管状部材の製品精度の向上に貢献する。
【００６５】
＜実施の形態３＞
以下、実施の形態３について説明する。
【００６６】
本実施の形態の仕切板付管状部材の液圧成形による製造方法は、前記実施の形態１で説明した予備成形工程（１）の別の例であり、前記実施の形態１と同一の構成部材については同じ符号を付してその説明は省略する。
【００６７】
図６は仕切板付排気管の予備成形工程を説明する図である。
【００６８】
（４）予備成形工程
【００６９】
本実施の形態における液圧成形による仕切板付管状部材の予備成形工程は、プレス加工工程、溶接工程からなり、プレス加工工程においては、図６（ａ）に示すように、板材１〜３を図外のプレス加工装置にて製造すべき仕切板付排気管１の軸直方向の断面がＳ字形状となるようにそれぞれプレス加工して形成すると共に、板材１，３に第１流路及び第２流路に対応する注入口をそれぞれ形成する。
【００７０】
この際、板材２は仕切板４としての最終形状になる。
【００７１】
続いて、溶接工程においては、図６（ｂ）に示すように、前記仕切板４の上下に板材１，３を重ね合わせて両端部同士を溶接Ｘにて固定することにより予備成形品８を得る。
【００７２】
なお、液圧成形工程については前記実施の形態１の（２）で説明した工程と同一であるためその説明は省略する。
【００７３】
従って、本実施の形態の仕切板付管状部材の液圧成形による製造方法にあっては、板材１〜３をそれぞれ予め精度良くプレス加工して形成することができ、該板材１〜３の重なり合う部分を隙間無く形成することができる。
【００７４】
また、注入口１ａ，３ａの形状を予め所望の形状に精度良く形成することができ、液圧成形時の板材１，３の膨出を安定して再現できる。
【００７５】
以上、本発明の実施の形態を説明してきたが、本発明の具体的構成は本実施の形態に限定されるものではなく、発明の要旨を逸脱しない範囲の設計変更などがあっても本発明に含まれる。
【００７６】
例えば、仕切板付排気管Ａを曲折した形状に形成する場合は従来の技術で開示されたプレス曲げ加工方法によって加工できる。
【００７７】
また、本実施の形態では板材１、３を凹部状の型１０ａの当接面Ｏに当接するように膨出させて仕切付排気管１を円筒形状にしたものついて説明したが、凹部状の型１０ａの当接面Ｏの形状を変更することにより、仕切付排気管１を楕円形状または矩形形状等に形成できることはいうまでもない。
【図面の簡単な説明】
【図１】本発明の実施の形態１の仕切板付排気管（仕切板付管状部材）を示す全体斜視図である。
【図２】図１のＳ２−Ｓ２断面図である。
【図３】本実施の形態の仕切板付排気管の予備成形工程を説明する図である。
【図４】本実施の形態の仕切板付排気管の液圧成形工程を説明する図である。
【図５】本発明の実施の形態２の仕切板付排気管の予備成形工程を説明する図である。
【図６】本発明の実施の形態３の仕切板付排気管の予備成形工程を説明する図である。
【符号の説明】
Ａ 仕切板付排気管
Ｘ 溶接
１、２、３ 板材
１ａ、３ａ 注入口
４ 仕切板
４ａ 第１流路
４ｂ 第２流路
８ 予備成形品
８ａ 両端部
１０ａ、１０ｂ 型[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing a tubular member with a partition plate by hydroforming.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a tubular member with a partition plate is known in which a partition plate is formed inside a tubular member and a flow path through which the tubular member flows is divided.
[0003]
For example, when the tubular member with a partition plate is applied to an exhaust pipe with a partition plate connected to the downstream side of an engine of an automobile, the exhaust flow path of the exhaust pipe with the partition plate is divided to avoid exhaust interference and prevent engine interference. The exhaust efficiency is improved (see Patent Documents 1 and 2).
[0004]
In the method of manufacturing a tubular member with a partition plate in
[0005]
[Patent Document 1]
JP 2000-170532 A (Pages 1-3, FIG. 2)
[Patent Document 2]
JP-A-2002-204947 (Pages 1-3, FIG. 4)
[0006]
[Problems to be solved by the invention]
However, in the conventional method of manufacturing a tubular member with a partition plate, after forming the partition plate with the former metal plate material, one end side of the plate material is turned into a cylindrical shape, and the end portion is welded and fixed. In this case, a lot of trouble and time are required for manufacturing, and as a result, there is a problem that the efficient productivity of the tubular member with a partition plate may be impaired.
[0007]
In addition, when press bending is performed after inserting a partition plate into the inside of the latter tube and fixing both ends thereof by welding, the press bending device becomes complicated and causes an increase in cost. There has been a problem that welding may be difficult.
[0008]
The present invention has been made in view of the above problems, and its object is to easily obtain a tubular member with a partition plate by hydraulic forming, and to provide a product with higher precision and accuracy than a conventional tubular member with a partition plate. An object of the present invention is to provide a method of manufacturing a tubular member with a partition plate by hydraulic forming, which achieves both improvement in production efficiency.
[0009]
[Means for Solving the Problems]
According to the first aspect of the present invention, there is provided a method for producing a tubular member with a partition plate in which the inside of a pipe is separated into a first flow path and a second flow path by a partition plate by hydraulic forming, wherein three metal plate members are provided. The upper and lower sides are overlapped with each other, and both ends are welded and fixed, and a high-pressure liquid forming medium is supplied between the center plate and the upper and lower plates to produce the plates on both sides. The first flow path and the second flow path are formed by swelling to the outer shape of the tubular member.
[0010]
According to the second aspect of the present invention, there is provided a method of manufacturing a tubular member with a partition plate in which the inside of a pipe is separated into a first flow path and a second flow path by a partition plate by hydraulic forming, wherein the tubular member with a partition plate to be manufactured is provided. The cross section in the direction perpendicular to the axis is a metal partition plate formed in an S-shape, and is welded and fixed to both ends of the partition plate in a state where the partition plate overlaps above and below the partition plate, respectively, between the partition plate A preforming step of forming a preform formed of a metal plate having an inlet corresponding to each of the first flow path and the second flow path; and supplying a high-pressure liquid molding medium to the inlet to form the plate. And a hydraulic forming step of hydraulically forming the first flow path and the second flow path by swelling.
[0011]
According to a third aspect of the present invention, in the method for manufacturing a tubular member with a partition plate according to the second aspect of the present invention, the preforming step includes welding three metal plates one above the other and welding both ends thereof. Welding step, a pressing step of forming the tubular member with a partition plate to be manufactured by pressing the stacked plate material so that the cross section in the direction perpendicular to the axis has an S shape, and a central plate material among the plate materials. And an inlet processing step of forming inlets respectively corresponding to the first flow path and the second flow path in the upper and lower plate members superimposed on each other.
[0012]
According to a fourth aspect of the present invention, in the method for manufacturing a tubular member with a partition plate according to the second aspect of the present invention, the preforming step includes forming an S-shaped cross section in a direction perpendicular to the axis of the tubular member with the partition plate to be manufactured by press working. A partition plate having a shape, a press working step of forming a plate material having a shape respectively overlapping above and below the partition plate, and a welding step of welding and fixing both ends by overlapping the plate material above and below the partition plate, An injection port processing step of forming injection ports corresponding to the first flow path and the second flow path in plate materials on both sides of the partition plate, respectively.
[0013]
According to a fifth aspect of the present invention, in the method of manufacturing a tubular member with a partition plate according to the second aspect of the present invention, the preforming step is such that the section of the tubular member with a partition plate to be manufactured has an S-shape in a direction perpendicular to the axis. A pressing step of forming, by press working, plate members having a partition plate, an inlet corresponding to the first flow path and the second flow path, and having a shape overlapping the upper and lower sides of the partition plate, respectively; And a welding step in which the plate members are overlapped and both ends are welded and fixed to each other.
[0014]
Function and effect of the present invention
According to the first aspect of the present invention, three metal plates are vertically stacked and both ends are welded and fixed, and a high pressure is applied between the center plate and the upper and lower plates of the plate. The first flow path and the second flow path were formed by supplying the liquid forming medium and expanding the upper and lower plate members to the outer shape of the tubular member with a partition plate to be manufactured. Since a complicated press working device and a large number of press dies are not required and the number of manufacturing steps is small, it is possible to manufacture a tubular member with a partition plate having high product accuracy by hydraulic forming.
[0015]
In the invention according to
[0016]
Then, in the hydraulic forming step, the first flow path and the second flow path are hydraulic-formed by supplying a high-pressure liquid forming medium to the inlet and expanding the plate material.
[0017]
Therefore, after the preform is formed, the first flow path and the second flow path are hydraulically formed by supplying a high-pressure liquid forming medium to the injection port of the preform and expanding the plate material. With a simple operation, it is possible to obtain a tubular member with a partition plate separated into the first flow path and the second flow path by the partition plate.
[0018]
Also, compared to the conventional invention, there is no need to twist a metal plate or perform complicated press bending, so that the time, cost and labor required for manufacturing can be reduced, and the productivity of this type of tubular member can be reduced. Can be greatly improved.
[0019]
According to the third aspect of the present invention, in the welding step, three metal plates are vertically overlapped and both ends are welded and fixed.
[0020]
Subsequently, in a press working step, the stacked plate members are formed such that the cross section in the direction perpendicular to the axis of the tubular member with a partition plate to be manufactured by press working has an S-shape.
[0021]
Finally, in the injection port processing step, the injection ports corresponding to the first flow path and the second flow path are respectively formed in the upper and lower plate materials superimposed on the central plate material among the plate materials, so that the preliminary processing in the preforming step is performed. Obtain molded articles.
[0022]
Therefore, the pressing step, the welding step, and the injection port processing step can be performed together in a state where three sheets are stacked, and the preform can be efficiently processed and obtained.
[0023]
According to the invention as set forth in
[0024]
Subsequently, in a welding step, the plate material is overlapped on both sides of the partition plate, and both ends are fixed by welding.
[0025]
Finally, in the injection port processing step, the injection ports corresponding to the first flow path and the second flow path are respectively formed in the upper and lower plate members superposed on the partition plate to obtain a preform in the preforming step.
[0026]
Therefore, the partition plate and the plate material can be formed by press working each with high precision in advance, and compared to the case where the partition plate and the plate material are pressed in a state of being overlapped, there is no gap between the part where the partition portion and the plate material overlap. In addition to being able to be overlapped, there is no possibility that the welding at both ends is cracked or damaged by press working, and a preform in which the partition plate and the plate material are firmly fixed can be obtained.
[0027]
Further, in the preformed product, since the cross section in the direction perpendicular to the axis of the partition plate and the plate material on both sides thereof is formed in an S-shape, when the high-pressure liquid forming medium is supplied to the injection port to expand the plate material. In addition, it is possible to prevent the thickness of the plate material from being reduced by pulling in the direction perpendicular to the axis, and to make the outer shape of the preformed product compact.
[0028]
Further, the load on the partition plate during the hydroforming is reduced, and the partition plate can be formed in a stable shape.
[0029]
According to the invention as set forth in claim 5, in the pressing step, the partition member having the S-shaped cross section in the direction perpendicular to the axis of the tubular member with the partition plate to be manufactured by the pressing, the first channel and the second channel. A plate material having an inlet corresponding to the passage and having a shape overlapping with the upper and lower portions of the partition plate is formed.
[0030]
Subsequently, in a welding step, a preform in the preforming step is obtained by laminating plate members on the upper and lower sides of the partition plate and fixing both ends by welding.
[0031]
Therefore, the three plate members can be formed by press working with high precision in advance, and the overlapping portions of the three plate members can be formed without gaps.
[0032]
In addition, the injection port can be formed in a desired shape with high precision in advance as compared with the case where the injection port is formed after three plate materials are overlapped and both ends are welded and fixed. Swelling of the plate material can be reproduced stably.
[0033]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of a method of manufacturing a tubular member with a partition plate by hydroforming according to the present invention will be described.
[0034]
In this embodiment, a case where the tubular member with a partition plate is applied to an exhaust pipe with a partition plate of an automobile will be described.
[0035]
<Embodiment 1>
Hereinafter, Embodiment 1 will be described.
[0036]
1 is an overall perspective view showing an exhaust pipe with a partition plate (a tubular member with a partition plate) according to Embodiment 1 of the present invention, FIG. 2 is a cross-sectional view taken along line S2-S2 of FIG. 1, and FIG. FIG. 4 is a diagram illustrating a hydraulic forming step of the exhaust pipe with the partition plate.
[0037]
In the method of manufacturing a tubular member with a partition plate according to the present embodiment by hydraulic forming, a case where the tubular member with a partition plate is applied to an exhaust pipe with a partition plate arranged downstream of the engine, as shown in FIGS. The exhaust pipe A with a partition plate is entirely cylindrically stacked with the
[0038]
Further, the inside of the exhaust pipe A with a partition plate is divided into a
[0039]
The exhaust pipe A with the partition plate configured as described above is usually arranged on the downstream side of the engine, and the exhaust gas flowing from each cylinder flows through the
[0040]
Then, in the manufacturing method of the tubular member with a partition plate according to the present embodiment by hydraulic forming, the exhaust pipe A with the partition plate is formed through a preforming step and a hydraulic forming step described in detail below.
[0041]
(1) Preforming Step Hereinafter, the preforming step will be described.
[0042]
The preforming step of the present embodiment includes a welding step, a pressing step, and an injection port processing step. In the welding step, as shown in FIG. The plate materials 1 to 3 are integrally formed by vertically overlapping and fixing both ends by welding X.
[0043]
The weld X is welded in the axial direction of the exhaust pipe A with a partition plate to be manufactured.
[0044]
Next, in the pressing step, as shown in FIG. 3B, a cross section in the direction perpendicular to the axis of the exhaust pipe 1 with the partitioning plate to be manufactured by using a pressing device (not shown). Are simultaneously pressed so as to have an S-shape.
[0045]
At this time, the
[0046]
Next, in the injection port processing step, as shown in FIG. 3 (c), the injection ports corresponding to the
[0047]
The number, position and shape of the
[0048]
(2) Hydraulic molding process
In the hydraulic forming step, as shown in FIG. 4 (a), a preform 8 is formed between
[0050]
At this time, since the
[0051]
Further, the load on the
[0052]
Unnecessary portions such as the
[0053]
Therefore, in the method of manufacturing a tubular member with a partition plate according to the present embodiment by hydraulic forming, after forming the preform 8, a high-pressure liquid forming medium is supplied to the
[0054]
Further, in the preforming step, since the welding step, the pressing step, and the injection port processing step are performed together in a state where the plate materials 1 to 3 are overlapped, the number of manufacturing steps can be reduced and the work efficiency can be improved as compared with the conventional invention. .
[0055]
<
Hereinafter,
[0056]
The manufacturing method of the tubular member with a partition plate according to the present embodiment by hydraulic forming is another example of the preforming step (1) described in the first embodiment, and the same components as those in the first embodiment are used. Are denoted by the same reference numerals, and description thereof is omitted.
[0057]
FIG. 5 is a diagram illustrating a preforming step of the exhaust pipe with the partition plate.
[0058]
(3) Preforming step
The preforming step of the tubular member with a partition plate by hydroforming according to the present embodiment includes a pressing step, a welding step, and an injection port processing step. In the pressing step, as shown in FIG. Each of Nos. 1 to 3 is pressed so that the cross section in the direction perpendicular to the axis of the exhaust pipe A with a partition plate to be manufactured by a press working device not shown has an S-shape.
[0060]
At this time, the
[0061]
Subsequently, in the welding step, as shown in FIG. 5 (b), the plates 1 to 3 are vertically overlapped and both ends are fixed to each other by welding X, whereby the plates 1 to 3 are integrally formed. Form.
[0062]
Next, in the injection port processing step, as shown in FIG. 5C, the injection holes 1a and 3a corresponding to the first flow path and the second flow path are formed in the
[0063]
The hydraulic forming process is the same as the process described in (2) of the first embodiment, and the description thereof will not be repeated.
[0064]
Therefore, in the manufacturing method of the present embodiment by the hydraulic forming of the tubular member with a partition plate, since the plate members 1 to 3 are formed individually in the press working step, the accuracy of the plate members 1 to 3 is improved. As a result, it is possible to eliminate a gap when the plate materials 1 to 3 are overlapped with each other or to reliably weld the weld X, and as a result, it is possible to obtain a tubular exhaust pipe A with a partition plate having high product accuracy. Consequently, this kind of tubular member with a partition plate contributes to the improvement of the product accuracy.
[0065]
<
Hereinafter,
[0066]
The manufacturing method of the tubular member with a partition plate according to the present embodiment by hydraulic forming is another example of the preforming step (1) described in the first embodiment, and the same components as those in the first embodiment are used. Are denoted by the same reference numerals, and description thereof is omitted.
[0067]
FIG. 6 is a diagram illustrating a preforming step of the exhaust pipe with the partition plate.
[0068]
(4) Preforming step
The preforming step of the tubular member with a partition plate by hydroforming in the present embodiment includes a pressing step and a welding step. In the pressing step, as shown in FIG. The exhaust pipe 1 with a partition plate to be manufactured by an external press working device is formed by press working so that the cross section in the direction perpendicular to the axis becomes S-shaped, and the first flow path and the second An inlet corresponding to the flow path is formed.
[0070]
At this time, the
[0071]
Subsequently, in the welding step, as shown in FIG. 6B, the preform 8 is formed by superimposing the
[0072]
The hydraulic forming process is the same as the process described in (2) of the first embodiment, and the description thereof will not be repeated.
[0073]
Therefore, in the manufacturing method of the tubular member with a partition plate according to the present embodiment by hydraulic forming, the plate members 1 to 3 can be formed by press working with high precision in advance, and the overlapping portions of the plate members 1 to 3 can be formed. Can be formed without gaps.
[0074]
In addition, the shapes of the
[0075]
The embodiment of the present invention has been described above. However, the specific configuration of the present invention is not limited to the present embodiment, and the present invention is applicable even if there is a design change without departing from the gist of the invention. include.
[0076]
For example, when the exhaust pipe A with a partition plate is formed in a bent shape, it can be processed by the press bending method disclosed in the related art.
[0077]
In the present embodiment, the plate-shaped exhaust pipe 1 is formed into a cylindrical shape by expanding the
[Brief description of the drawings]
FIG. 1 is an overall perspective view showing an exhaust pipe with a partition plate (a tubular member with a partition plate) according to a first embodiment of the present invention.
FIG. 2 is a sectional view taken along line S2-S2 of FIG.
FIG. 3 is a diagram illustrating a preforming step of the exhaust pipe with a partition plate according to the present embodiment.
FIG. 4 is a diagram illustrating a hydraulic forming step of the exhaust pipe with a partition plate according to the present embodiment.
FIG. 5 is a diagram illustrating a preforming step of an exhaust pipe with a partition plate according to a second embodiment of the present invention.
FIG. 6 is a diagram illustrating a preforming step of an exhaust pipe with a partition plate according to a third embodiment of the present invention.
[Explanation of symbols]
A Exhaust pipe X with partition plate Welded 1, 2, 3
Claims (5)
金属製の三枚の板材を上下に重ね合わせて両端部同士を溶接固定すると共に、前記板材のうち、中央の板材と上下の板材との間に高圧の液状成形媒体を供給して該両側の板材を製造すべき仕切板付管状部材の外形状にそれぞれ膨出させることにより前記第１流路及び第２流路を形成したことを特徴とする仕切板付管状部材の液圧成形による製造方法。A method for manufacturing a tubular member with a partition plate in which the inside of a pipe is separated into a first flow path and a second flow path by a partition plate by hydraulic forming,
While three metal plates are vertically stacked and both ends are welded and fixed, a high-pressure liquid forming medium is supplied between the center plate and the upper and lower plates, and A method for producing a tubular member with a partition plate by hydraulic forming, wherein the first flow passage and the second flow passage are formed by bulging each of the tubular members with a partition plate to be manufactured into an outer shape.
製造すべき仕切板付管状部材の軸直方向における断面がＳ字形状に形成された金属製の仕切板と、
前記仕切板の上下にそれぞれ重なった状態で該仕切板の両端部に溶接固定され、該仕切板との間に前記第１流路及び第２流路にそれぞれ対応する注入口を有する金属製の板材からなる予備成形品を形成する予備成形工程と、
前記注入口に高圧の液状成形媒体を供給して前記板材を膨出させることにより第１流路及び第２流路を液圧成形する液圧成形工程と、
を備えることを特徴とする仕切板付管状部材の液圧成形による製造方法。A method for manufacturing a tubular member with a partition plate in which the inside of a pipe is separated into a first flow path and a second flow path by a partition plate by hydraulic forming,
A metal partition plate in which the section in the direction perpendicular to the axis of the tubular member with a partition plate to be manufactured is formed in an S-shape,
A metal made of a metal which is welded and fixed to both ends of the partition plate in a state of being overlapped on the upper and lower sides of the partition plate, respectively, and having inlets respectively corresponding to the first flow path and the second flow path with the partition plate. A preforming step of forming a preformed product made of a plate material;
A hydraulic forming step of hydraulically forming the first flow path and the second flow path by supplying a high-pressure liquid forming medium to the inlet and expanding the plate material;
A method for producing a tubular member with a partition plate by hydroforming.
前記予備成形工程が、金属製の三枚の板材を上下に重ね合わせて両端部同士を溶接固定する溶接工程と、
前記重ねられた板材をプレス加工により製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となるように形成するプレス加工工程と、
前記板材のうち、中央の板材に重ねられた上下の板材に第１流路及び第２流路にそれぞれ対応する注入口を形成する注入口加工工程と、
を備えることを特徴とする仕切板付管状部材の液圧成形による製造方法。A manufacturing method of the tubular member with a partition plate according to claim 2 by hydroforming.
The preforming step is a welding step in which three metal plates are vertically stacked and both ends are welded and fixed,
A press working step of forming the stacked plate material so that a cross section in the direction perpendicular to the axis of the tubular member with a partition plate to be manufactured by press working has an S-shape;
An injection port processing step of forming injection ports corresponding to the first flow path and the second flow path in upper and lower plate materials stacked on the center plate material among the plate materials,
A method for producing a tubular member with a partition plate by hydroforming.
前記予備成形工程が、製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となる仕切板と、該仕切板の上下にそれぞれ重なる形状の板材をそれぞれプレス加工により形成するプレス加工工程と、
前記仕切板の上下に前記板材を重ね合わせて両端部同士を溶接固定する溶接工程と、
前記仕切板に重ねられた上下の板材に第１流路及び第２流路に対応する注入口をそれぞれ形成する注入口加工工程と、
を備えることを特徴とする仕切板付管状部材の液圧成形による製造方法。A manufacturing method of the tubular member with a partition plate according to claim 2 by hydroforming.
The preforming step is a pressing step of forming a partition plate having an S-shaped cross section in a direction perpendicular to the axis of the tubular member with a partition plate to be manufactured, and a plate material having a shape that overlaps above and below the partition plate by press working, respectively. When,
A welding step of laminating the plate members above and below the partition plate and welding and fixing both end portions thereof,
An inlet processing step of forming inlets corresponding to the first flow path and the second flow path in upper and lower plate members stacked on the partition plate, respectively;
A method for producing a tubular member with a partition plate by hydroforming.
前記予備成形工程が、製造すべき仕切板付管状部材の軸直方向の断面がＳ字形状となる仕切板と、第１流路及び第２流路に対応する注入口を有し、前記仕切板の上下にそれぞれ重なる形状の板材をそれぞれプレス加工により形成するプレス加工工程と、
前記仕切板の上下に前記板材を重ね合わせて両端部同士を溶接固定する溶接工程と、
を備えることを特徴とする仕切板付管状部材の液圧成形による製造方法。A manufacturing method of the tubular member with a partition plate according to claim 2 by hydroforming.
The preforming step includes a partition plate having a S-shaped cross section in a direction perpendicular to the axis of the tubular member with a partition plate to be manufactured, and an inlet corresponding to a first flow path and a second flow path. A press working step of forming a plate material having a shape overlapping each other above and below by press working,
A welding step of laminating the plate members above and below the partition plate and welding and fixing both end portions thereof,
A method for producing a tubular member with a partition plate by hydroforming.
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| Application Number | Priority Date | Filing Date | Title |
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| JP2003153311A JP2004351488A (en) | 2003-05-29 | 2003-05-29 | Method for producing tubular member having partition plate by hydraulic forming |
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| Application Number | Priority Date | Filing Date | Title |
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| JP2003153311A JP2004351488A (en) | 2003-05-29 | 2003-05-29 | Method for producing tubular member having partition plate by hydraulic forming |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006248328A (en) * | 2005-03-09 | 2006-09-21 | Nissan Motor Co Ltd | Vehicle body structure member and its manufacturing method |
| JP2007061829A (en) * | 2005-08-29 | 2007-03-15 | Sumitomo Metal Ind Ltd | Sheet hydroforming product, method for hydroforming sheet and apparatus for hydroforming sheet using the same |
| JP2008119723A (en) * | 2006-11-13 | 2008-05-29 | Sumitomo Metal Ind Ltd | Hydroforming apparatus for metallic plate, hydroforming method, and product manufactured using the same apparatus |
| CN102284587A (en) * | 2011-04-21 | 2011-12-21 | 上海板换机械设备有限公司 | Heat radiating plate pair expansion forming process |
| CN103551472A (en) * | 2013-10-25 | 2014-02-05 | 南京航空航天大学 | Push-bending forming process for hollow blade |
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2003
- 2003-05-29 JP JP2003153311A patent/JP2004351488A/en active Pending
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006248328A (en) * | 2005-03-09 | 2006-09-21 | Nissan Motor Co Ltd | Vehicle body structure member and its manufacturing method |
| JP2007061829A (en) * | 2005-08-29 | 2007-03-15 | Sumitomo Metal Ind Ltd | Sheet hydroforming product, method for hydroforming sheet and apparatus for hydroforming sheet using the same |
| JP2008119723A (en) * | 2006-11-13 | 2008-05-29 | Sumitomo Metal Ind Ltd | Hydroforming apparatus for metallic plate, hydroforming method, and product manufactured using the same apparatus |
| CN102284587A (en) * | 2011-04-21 | 2011-12-21 | 上海板换机械设备有限公司 | Heat radiating plate pair expansion forming process |
| CN103551472A (en) * | 2013-10-25 | 2014-02-05 | 南京航空航天大学 | Push-bending forming process for hollow blade |
| CN103551472B (en) * | 2013-10-25 | 2015-09-09 | 南京航空航天大学 | A kind of hollow blade pushes away o ing technique |
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