JP2007283315A - Method for spinning tube end - Google Patents
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- JP2007283315A JP2007283315A JP2006110488A JP2006110488A JP2007283315A JP 2007283315 A JP2007283315 A JP 2007283315A JP 2006110488 A JP2006110488 A JP 2006110488A JP 2006110488 A JP2006110488 A JP 2006110488A JP 2007283315 A JP2007283315 A JP 2007283315A
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Abstract
Description
本発明は、自動車のコンバーターケースやマフラーに用いられる管端に縮径部を有する管体の成形方法に関する。 The present invention relates to a method for forming a tubular body having a reduced diameter portion at a pipe end used for a converter case or a muffler of an automobile.
自動車の排気系に装備される排気ガス浄化用触媒(コンバーター)のケース,あるいは消音器(マフラー)のケースには、大容量化の必要性から素材として大径の管が用いられている。そして、そのケース部材端部には、前後の部材との接続のためにテーパ部と、さらに必要に応じてテーパ部に連続した小径の平行部が備えられている。
図1は、このようなケース1が、素材である大径の管の部分(1a)、前後の部材と接続するために設けられるテーパ部(1b)及びテーパ部に連続した小径の平行部(1c)から構成されている例を示す。そして、テーパ部(1b)は素管部(1a)にショルダー部(2)を介して、また、テーパ部(1b)はネック部(3)を介して小径の平行部(1c)と接続されている。
このような形状品は、管端にスピニング加工法を適用することにより成形される場合が多くなっている。
Large-diameter pipes are used as materials in the case of exhaust gas purifying catalysts (converters) or silencers (mufflers) that are installed in the exhaust system of automobiles because of the need to increase the capacity. And the case member edge part is provided with the taper part for the connection with the member before and behind, and also the small diameter parallel part which continued to the taper part as needed.
FIG. 1 shows that such a
Such shaped products are often formed by applying a spinning method to the pipe end.
スピニング加工方法は、例えば特許文献1で紹介されているように、成形工具である加工ローラを被加工管の表面に接触させ、加工ローラを被加工管の周りで相対的に公転させながら、加工ローラを被加工管の半径方向及び軸方向に駆動させて、被加工管の端部に向けて次第に縮径するテーパ部と、必要に応じてそれに連続する小径の平行部を形成する方法である。
そして、例えば、特許文献2には、被加工管の外周に加工ローラを押し当ててスピニング加工することによりコンバーターケースを製造することが記載されている。
For example, as introduced in
For example,
このような形状の部材を成形する方法としてスピニング加工法が多用される背景としては、板材をプレス成形により複数の部分に分割して加工した後に別工程にて溶接接合する方法と比較して、1)材料歩留りが高い、2)一体成形であるために部材強度が高く、部品点数を減らせる、3)溶接を必要としないために溶接部による部材の信頼性低下がない、等の点が挙げられる。
しかしながら、プレス成形方法と比較して、スピニング加工法では加工ローラを被加工管の軸方向へ繰返し往復動させて成形を進めるため、塑性変形により材料が管端方向に移動しやすく、特にテーパ部の板厚が被加工管の素材板厚よりも局所的に減少する傾向がある。また、縮径された母材部の加工端、あるいは被加工管が電縫管の場合には管端の溶接部の加工端を起点とする破断が起こりやすい。さらに、加工速度を高速度化した場合には、スピニング加工中に加工部にしわが発生し、所定の加工部形状が得られない、といった成形不良が発生しやすくなる。
However, compared to the press forming method, the spinning method repetitively moves the processing roller in the axial direction of the tube to be processed to advance the forming, so that the material is easily moved in the tube end direction due to plastic deformation, particularly the tapered portion. There is a tendency that the thickness of the steel sheet locally decreases than the material thickness of the material to be processed. Further, when the processed end of the base material portion having a reduced diameter or the processed pipe is an electric resistance welded tube, breakage is likely to occur starting from the processed end of the welded portion of the pipe end. Furthermore, when the processing speed is increased, a forming defect such as a wrinkle is generated in the processed part during the spinning process and a predetermined processed part shape cannot be obtained.
上記している通り、スピニング加工法では塑性変形により材料が管端方向に移動しやすいため、テーパ部の板厚が被加工管の素材板厚よりも局所的に減少しやすくなる。特にテーパ角が大きいほどその傾向が強くなる。
このため、テーパ角を大きくして、触媒収容部が大きく、しかも排ガス導入・排出口が小さくて収容効率の高いコンバーターケースを製造しようとすると、テーパ部、特にネック部の板厚減少に起因した割れや変形が起こりやすくなる。場合によっては、外形のチェックや耐圧テストも必要になって、収容効率の高いコンバーターケースを安定的に低コストで供給することが困難となる。
本発明は、このような問題を解消するために案出されたものであり、管端に加工ローラを当接して縮径部を形成する際に、テーパ部に生じやすい板厚減少を極力抑制したスピニング加工方法を提供することを目的とする。
As described above, in the spinning method, the material is likely to move in the tube end direction due to plastic deformation, so the plate thickness of the tapered portion is likely to decrease locally than the material plate thickness of the tube to be processed. In particular, the tendency becomes stronger as the taper angle is larger.
For this reason, when trying to manufacture a converter case having a large taper angle, a large catalyst housing portion, and a small exhaust gas introduction / discharge port and a high housing efficiency, the taper portion, particularly the neck portion, is caused by a decrease in the plate thickness. Cracks and deformation are likely to occur. In some cases, an external shape check and a pressure resistance test are also required, making it difficult to stably supply a converter case with high accommodation efficiency at low cost.
The present invention has been devised to solve such problems, and suppresses plate thickness reduction that tends to occur at the taper portion as much as possible when the reduced diameter portion is formed by contacting the processing roller to the tube end. An object of the present invention is to provide a spinning method.
本発明の管端のスピニング加工方法は、その目的を達成するため、被加工管の外周に配置されてその周りを相対的に公転する加工ローラを用い、当該加工ローラを前記被加工管の半径方向へ移動させつつ軸方向に往復動させることにより被加工管の端部に向けて次第に縮径するテーパ部を形成する際、被加工管の被加工部に予め縮径処理を施して当該部分に予ひずみを付与した後に、前記テーパ部を形成することを特徴とする。
予め施す縮径処理としては、被加工部を金型内に挿入して全周に対して一様な縮径加工を付与する加工法を採用することが好ましい。
In order to achieve the object, the pipe end spinning method of the present invention uses a processing roller that is arranged on the outer periphery of the processing pipe and relatively revolves around the processing pipe, and the processing roller is used as a radius of the processing pipe. When forming a tapered portion that gradually decreases in diameter toward the end of the processed pipe by reciprocating in the axial direction while moving in the direction, the processed portion of the processed pipe is subjected to diameter reduction processing in advance. The taper portion is formed after prestraining is applied.
As the diameter reduction treatment to be performed in advance, it is preferable to employ a processing method in which a portion to be processed is inserted into a mold and uniform diameter reduction processing is applied to the entire circumference.
本発明では、加工ローラを被加工管の半径方向へ移動させつつ軸方向に往復動させて被加工管の端部に縮径部を形成する際に、被加工管の被加工部に予ひずみが付与されているため、当該部分は加工硬化しており、予ひずみなしの場合よりも変形に要する耐力(変形抵抗)が高くなっている。このため、管軸方向への材料の流動がテーパ部で起こる場合に板厚減少が特定の部位に集中しにくく、代わって、テーパ部の軸方向に広い領域に分散して変形が進行することになる。その結果、スピニング加工による縮径加工を行った場合に起こりやすい、被加工管の素材板厚よりもテーパ部の板厚が局所的に減少する問題を回避でき、良好な品質の縮径加工製品を得ることができる。 In the present invention, when the reduced diameter portion is formed at the end of the work tube by reciprocating in the axial direction while moving the work roller in the radial direction of the work tube, the pre-strain is applied to the work portion of the work tube. Therefore, the part is work-hardened, and the proof stress (deformation resistance) required for deformation is higher than that without pre-strain. For this reason, when the material flow in the tube axis direction occurs in the taper portion, the reduction in plate thickness is less likely to concentrate on a specific part, and instead, the deformation progresses by being distributed over a wide area in the axial direction of the taper portion. become. As a result, it is possible to avoid the problem that the plate thickness of the taper part decreases locally rather than the material plate thickness of the pipe to be processed, which is likely to occur when the diameter reduction processing is performed by spinning processing, and the diameter reduction processed product of good quality Can be obtained.
本発明者等は、被加工管と、当該被加工管の外周に配置されてその周りを相対的に公転する加工ローラを用い、前記加工ローラを前記被加工管の半径方向へ移動させつつ軸方向に往復動させることにより被加工管の端部に向けて次第に縮径するテーパ部と、それに連続する小径の平行部を形成する際に、テーパ部に生じやすい板厚減少の発生原因とその対策について種々検討を重ねてきた。
その結果、加工ローラを押し当てて縮径の加工を施すときの加工硬化がその後の変形態様に微妙な影響を与えると推測し、局部的な板厚減少の抑制には、被加工部を予め加工硬化させておくことが有効であることを見出した。
以下に、本発明に至った経緯から説明する。
The inventors use a processing tube and a processing roller that is disposed on the outer periphery of the processing tube and relatively revolves around the processing tube, and moves the processing roller in the radial direction of the processing tube while rotating the shaft. When the taper part that gradually reduces the diameter toward the end of the pipe to be processed by reciprocating in the direction and the parallel part of the small diameter that continues to the taper part, the cause of the reduction in the plate thickness that is likely to occur in the taper part and its cause Various studies have been made on countermeasures.
As a result, it is presumed that work hardening when pressing the processing roller to reduce the diameter has a subtle effect on the subsequent deformation mode. It was found that work hardening is effective.
Hereinafter, the background to the present invention will be described.
まず、スピニング加工時にテーパ部に生じやすい板厚減少の発生メカニズムから検討した。
図2は、降伏強さ251MPa,引張強さ428MPa,伸び36%の機械的特性を有する板厚1.2mmのフェライト系ステンレス鋼板を素材とし、プラズマ溶接により直径89.1mmとなるように造管した素管を被加工管として、テーパ角を種々変更して縮径加工したときの、加工部の板厚減少状況を見たものである。なお、この予備試験では、送り速度:3000mm/min一定で全13パスの加工を施し、最終的に外径38.1mmまで縮径率57%で縮径している。また、小径の平行部の目標長さは30mmとした。
図2(a)は、同図(b)に示すように、ショルダー部の変形が開始した点を起点とし、5mmピッチで板厚変化を測定した結果を示している。
図2に見られるように、テーパ部で局所的に素管板厚よりも板厚が減少した部分が発生しており、テーパ角が増大するほど局所的な板厚減少も顕著となる。
First, the mechanism of the reduction in plate thickness that tends to occur at the taper during spinning processing was examined.
FIG. 2 shows a ferritic stainless steel plate having a thickness of 1.2 mm having mechanical properties of yield strength 251 MPa, tensile strength 428 MPa, and elongation 36%, and is piped to have a diameter of 89.1 mm by plasma welding. The thickness of the processed part when the diameter of the processed pipe is reduced by variously changing the taper angle by using the processed pipe as a processed pipe is shown. In this preliminary test, all 13 passes were processed at a constant feed rate of 3000 mm / min, and finally the diameter was reduced to an outer diameter of 38.1 mm with a reduction ratio of 57%. The target length of the small-diameter parallel part was 30 mm.
FIG. 2A shows the result of measuring the plate thickness change at a pitch of 5 mm, starting from the point where the deformation of the shoulder portion started, as shown in FIG.
As can be seen in FIG. 2, there is a portion where the thickness of the taper portion is locally smaller than the raw tube thickness, and the local reduction in the plate thickness becomes more significant as the taper angle increases.
一般に管端を縮径するスピニング加工では、曲げ加工等により板状の素材を略管状に成形し、続いて板端同士を突き合わせて溶接することで製造した溶接管を被加工管として用いる。管状に成形するための加工ひずみは縮径加工によって受けるひずみよりもはるかに小さい。そのため、被加工部は一様に殆ど加工硬化を受けていない状態で縮径加工に供される。すなわち、加工硬化を受けていないから、塑性変形を起こすために必要な変形抵抗が小さい。 In general, in a spinning process for reducing the diameter of the pipe end, a welded pipe manufactured by forming a plate-shaped material into a substantially tubular shape by bending or the like and then welding the plate ends together is used as a pipe to be processed. The processing strain for forming into a tubular shape is much smaller than the strain experienced by the diameter reduction processing. Therefore, the processed portion is subjected to diameter reduction processing in a state where it is hardly subjected to work hardening uniformly. That is, since it is not subjected to work hardening, the deformation resistance necessary for causing plastic deformation is small.
スピニング加工で被加工管の端部に向けて次第に縮径するテーパ部を形成すると、加工部は、加工度合いに応じた加工硬化を受ける。未加工部の素管に近い部分ほど、縮径加工度が小さいため材料が受けた加工硬化も小さく、逆に加工端に近い部分ほど縮径加工度が大きいから大きな加工硬化を受けている。大きな加工硬化を受けた部分ほど変形抵抗も増大しているから、未加工部の素管に近い部分ほど変形抵抗が小さく、加工端に近い部分ほど変形抵抗が大きい部分が分布することになる。 If the taper part which diameter-reduces gradually toward the edge part of a to-be-processed pipe is formed by spinning process, a process part will receive work hardening according to the process degree. The portion closer to the raw tube of the unprocessed portion has a smaller diameter reduction processing degree, so the work hardening received by the material is also smaller. Conversely, the portion closer to the processing end has a larger diameter reduction processing degree and thus receives a larger work hardening. Since the deformation resistance increases as the portion has undergone a large work hardening, the deformation resistance decreases as the portion closer to the raw tube of the unprocessed portion, and the portion where the deformation resistance increases as the portion closer to the processing end.
ところで、スピニング加工による管端の縮径加工では、加工ローラを材料に当接させつつ軸方向に往復動させるため、被加工管の端部に向けて材料の流動が起こりやすい。このとき、材料の流動(塑性変形)は、変形抵抗の小さい部分に集中しやすい。すなわち、テーパ部の未加工部(素管)に近い部分に材料の軸方向への流動が集中しやすく、この部分で板厚の減少が起こることになる。
ここで、素管部は加工硬化を受けていないから変形抵抗は小さいが、管径が大きく断面積が大きい。そのため、加工ローラの管軸方向の往復動による材料の軸方向への流動は、断面積の効果により素管部に及ぶ応力としては小さくなり、塑性変形とならないから素管部は板厚減少を起こさない。
一方、テーパ部は、素管部から離れ平行部に近づくほど管径が小さくなるので、加工ローラの管軸方向の往復動による材料の流動がテーパ部では素管部よりも大きい応力として作用する。このとき、塑性変形を起こす変形抵抗を上回った部分に材料の流動が集中し、この部分で板厚の局部的な減少が進行することになる。
By the way, in the diameter reduction processing of the tube end by spinning processing, the material flows easily toward the end of the tube to be processed because the processing roller is reciprocated in the axial direction while contacting the material. At this time, the flow (plastic deformation) of the material tends to concentrate on a portion having a small deformation resistance. That is, the flow of the material in the axial direction tends to concentrate on a portion near the unprocessed portion (element tube) of the taper portion, and the plate thickness is reduced at this portion.
Here, since the raw tube portion is not subjected to work hardening, the deformation resistance is small, but the tube diameter is large and the cross-sectional area is large. For this reason, the axial flow of the material due to the reciprocating motion of the processing roller in the tube axial direction is reduced as a stress on the raw tube due to the effect of the cross-sectional area and does not cause plastic deformation. Do not wake up.
On the other hand, since the diameter of the taper portion becomes smaller as the distance from the raw tube portion is closer to the parallel portion, the material flow due to reciprocation in the tube axis direction of the processing roller acts as a larger stress in the taper portion than in the raw tube portion. . At this time, the flow of the material concentrates on a portion exceeding the deformation resistance causing the plastic deformation, and the local reduction of the plate thickness proceeds at this portion.
予ひずみの付与手段としては、コスト面を考慮して、被加工管の被加工部である管端に縮径加工を施す手段を採用する。
縮径加工を施す態様としては、一例として被加工部を金型内に挿入して、全周に対して一様に縮径加工を付与する加工法が挙げられる。この加工により、縮径度合いに応じた円周方向の圧縮ひずみと軸方向の引張ひずみを付与できる。このように管端を金型内に挿入して全周に対して一度に縮径加工を行う場合、管の座屈を防ぐため、必要に応じて管の内部にも金型を用いるなどの手段を用いてもよい。このように、予ひずみの付与手段は、本来のスピニング加工とは別工程になるので、時間がかかる逐次的な加工ではなく、全周に対していちどに加工できる方法を採用する。
なお、スピニング加工は、加工ローラの動きにより積極的に軸方向に材料を流動させる加工法であり、板厚減少が起こりやすい加工方法であるため、この際の予ひずみ付与手段としては適当でない。
As the means for applying the pre-strain, a means for reducing the diameter of the pipe end, which is a processed part of the processed pipe, is adopted in consideration of cost.
As an example of a mode for performing the diameter reduction processing, a processing method in which a portion to be processed is inserted into a mold and the diameter reduction processing is uniformly applied to the entire circumference can be cited. By this processing, circumferential compressive strain and axial tensile strain according to the degree of diameter reduction can be applied. In this way, when the pipe end is inserted into the mold and diameter reduction processing is performed at once on the entire circumference, a mold is also used inside the pipe as necessary to prevent buckling of the pipe. Means may be used. Thus, since the pre-strain imparting means is a separate process from the original spinning process, a method that can process the entire circumference at once is adopted instead of the time-consuming sequential process.
Spinning is a processing method in which a material is actively flowed in the axial direction by the movement of a processing roller, and is a processing method that tends to cause a reduction in plate thickness.
降伏強さ251MPa,引張強さ428MPa,伸び36%の機械的特性を有する板厚1.2mmのフェライト系ステンレス鋼板を素材として用い、プラズマ溶接により直径120mmとなるように造管した素管を被加工管とした。
まず、比較例として、前記のように製造した素管に対して、予ひずみ付与加工を施さずに図3に示した目標形状に同軸スピニング加工を実施した。
また、実施例として、図4に示す予ひずみ付与加工を行ったのちに、比較例と同様に図3の目標形状に同軸スピニング加工を実施した。
A ferritic stainless steel plate having a thickness of 1.2 mm having mechanical properties of yield strength 251 MPa, tensile strength 428 MPa, elongation 36% is used as a material, and a blank pipe is formed by plasma welding to have a diameter of 120 mm. A processed tube was used.
First, as a comparative example, coaxial spinning was performed to the target shape shown in FIG. 3 without performing pre-straining processing on the raw tube manufactured as described above.
Further, as an example, after performing the pre-straining process shown in FIG. 4, the coaxial spinning process was performed on the target shape of FIG. 3 in the same manner as in the comparative example.
ここで、予ひずみ付与方法としては、図4に示すように、金型を用いて素管の全周に対して一様に縮径加工を行った。このとき、予ひずみ付与加工の対象長さは、予ひずみ付与加工なしで比較例の加工を行う場合に必要な被加工部長さが105mmであるため、この領域全体を含む長さとするために、この予ひずみ付与は、管端から115mmまでの部分を対象とした。予ひずみ付与加工のテーパ角は15°、縮径部の径はφ100mmとした。
図3に示すように、同軸型スピニング加工の目標形状は、テーパ角θを30°、縮径した平行部の直径(外径)を54mm(縮径率55%),平行部の目標長さを30mmとした。また、スピニング加工は、予ひずみ付与加工の有無に関わらず加工パス数は13パス、送り速度は3000mm/min一定とした。
Here, as a prestrain imparting method, as shown in FIG. 4, diameter reduction processing was uniformly performed on the entire circumference of the raw pipe using a mold. At this time, the target length of the prestraining process is 105 mm because the workpiece length required when performing the processing of the comparative example without the prestraining process is set to a length including the entire region. This pre-strain was applied to a portion from the tube end to 115 mm. The taper angle in the prestraining process was 15 °, and the diameter of the reduced diameter portion was φ100 mm.
As shown in FIG. 3, the target shape of the coaxial spinning process is that the taper angle θ is 30 °, the diameter (outer diameter) of the reduced parallel portion is 54 mm (reduction ratio 55%), and the target length of the parallel portion. Was 30 mm. In the spinning process, the number of machining passes was 13 and the feed rate was constant 3000 mm / min regardless of the presence or absence of the prestraining process.
両者のスピニング加工後の板厚分布を図5に示す。予ひずみを付与しないものは、局所的な板厚減少が最大で14%に及んでいるが、予ひずみを付与したものについては10%である。テーパ部における局所的な板厚分布が軽減されていることから、予ひずみ付与によるテーパ部の局所的な板厚減少の抑制効果が確認できる。 FIG. 5 shows the plate thickness distribution after both spinning processes. In the case where the pre-strain is not applied, the local thickness reduction is 14% at the maximum, but in the case where the pre-strain is applied, it is 10%. Since the local plate thickness distribution in the taper portion is reduced, it is possible to confirm the effect of suppressing the local plate thickness decrease in the taper portion due to prestraining.
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR101079975B1 (en) | 2011-08-23 | 2011-11-04 | 박선용 | Upset forging device of tube with different inner thickness |
CN102896470A (en) * | 2012-10-11 | 2013-01-30 | 合肥实华管件有限责任公司 | Production technology for pipe cap with hole |
CN110814169A (en) * | 2019-11-20 | 2020-02-21 | 江西江铃底盘股份有限公司 | Necking and bulging multi-station combined die and technology for elastic spacer bush of automobile driving rear axle |
WO2020213108A1 (en) * | 2019-04-17 | 2020-10-22 | 江崎工業株式会社 | Method of arranging functional member |
WO2024117435A1 (en) * | 2022-12-01 | 2024-06-06 | 주식회사 에테르씨티 | Pipe for forming high-pressure fluid storage container |
-
2006
- 2006-04-13 JP JP2006110488A patent/JP2007283315A/en not_active Withdrawn
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR101079975B1 (en) | 2011-08-23 | 2011-11-04 | 박선용 | Upset forging device of tube with different inner thickness |
CN102896470A (en) * | 2012-10-11 | 2013-01-30 | 合肥实华管件有限责任公司 | Production technology for pipe cap with hole |
WO2020213108A1 (en) * | 2019-04-17 | 2020-10-22 | 江崎工業株式会社 | Method of arranging functional member |
JPWO2020213108A1 (en) * | 2019-04-17 | 2021-05-06 | 江崎工業株式会社 | How to arrange functional members |
CN110814169A (en) * | 2019-11-20 | 2020-02-21 | 江西江铃底盘股份有限公司 | Necking and bulging multi-station combined die and technology for elastic spacer bush of automobile driving rear axle |
WO2024117435A1 (en) * | 2022-12-01 | 2024-06-06 | 주식회사 에테르씨티 | Pipe for forming high-pressure fluid storage container |
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