JP2023029152A - Method for manufacturing extension part integrated cylindrical member, and the extension part integrated cylindrical member - Google Patents

Abstract

To provide an extension part integrated cylindrical member in which a noncylindrical extension part integrally formed in a hollow trunk has a three-dimensional shape, and a method for manufacturing the same.SOLUTION: A method for molding an extension part integrated cylindrical member in which a cylindrical trunk and a noncylindrical extension part are integrally formed comprises at least: a first step of forming a U groove roughly U-shaped in section on the center of a trunk forming scheduled part of a plate material and first flat plate parts on both sides thereof in a longitudinal direction, and forming a three-dimensionally shaped first extension part connected to the trunk forming scheduled part to provide a first intermediate member; a second step of additionally molding the first extension part of the first intermediate member to provide a second intermediate member having a second extension part; a third step of bending the end of a first flat plate part of the second intermediate member to form a bent part and a second flat plate part parallel to the U groove, thereby providing a third intermediate member; and a fourth step of rounding the second flat plate part and the bent part of the third intermediate member to form a trunk of a closed section. Each step is carried out through press-machining.SELECTED DRAWING: Figure 5

Description

発明の詳細な説明Detailed description of the invention

本発明は、延長部一体型筒状部材の製造方法に関し、特に、排気浄化装置のケーシングの製造方法に関する。 TECHNICAL FIELD The present invention relates to a method for manufacturing an extension-integrated tubular member, and more particularly to a method for manufacturing a casing of an exhaust purification device.

車両の構造部材のような湾曲した中空パイプを製造する方法として、所謂「Ｕ－Ｏ成形」と呼ばれる工法が多用される。特に３次元的に湾曲した中空パイプの製造方法として、特許文献１に記載の工法が用いられる。また、中空パイプの両端に平板上の取付け部を一体形成したい場合には、特許文献２に開示の工法が提案されている。 A so-called "UO molding" method is often used as a method of manufacturing a curved hollow pipe such as a structural member of a vehicle. In particular, the construction method described in Patent Document 1 is used as a method for manufacturing a three-dimensionally curved hollow pipe. Further, when it is desired to integrally form mounting portions on flat plates at both ends of a hollow pipe, a construction method disclosed in Patent Document 2 is proposed.

一方、車両の内燃機関に取付けられる排気浄化装置として、特許文献３に記載される排気マニホールド一体型の触媒コンバータ装置（以下、マニバータと称する）が最近では一般的になっている。このようなマニバータにおいては、触媒担体を内装し保持する中空パイプ部（胴部）と、それに隣接する排気マニホールドとしてのエルボ部とを、Ｕ－Ｏ工法を用いて一体的に形成すれば強度面やコスト面で有利であろうことが想定される。 On the other hand, as an exhaust purification device attached to an internal combustion engine of a vehicle, a catalytic converter device integrated with an exhaust manifold (hereinafter referred to as a maniverter) described in Patent Document 3 has recently become popular. In such a maniverter, if the hollow pipe portion (body portion) inside and holding the catalyst carrier and the adjacent elbow portion serving as the exhaust manifold are integrally formed using the UO construction method, the strength is improved. and is expected to be advantageous in terms of cost.

特公平７－６３７５８号公報Japanese Patent Publication No. 7-63758 特許第６００５５９９号公報Japanese Patent No. 6005599 特許第６６５３９７０号公報Japanese Patent No. 6653970

しかしながら、特許文献１は全体が中空パイプなのでマニバータ等の製法には適用できず、特許文献２は、中空胴部と一体形成されるのは平板状の取付部であるので、この製法も適用困難である。 However, since Patent Document 1 is a hollow pipe as a whole, it cannot be applied to a manufacturing method such as a maniverter, and Patent Document 2 is difficult to apply because it is a flat mounting portion that is integrally formed with the hollow body portion. is.

そこで本発明は、中空胴部から延出し一体形成される部分を任意の形状に成形できる製造方法を提供することを課題とする。 SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a manufacturing method capable of forming an integrally formed portion extending from a hollow body into an arbitrary shape.

前記の課題を解決するために本発明の延長部一体型筒状部材の製造方法は、板材の胴部形成予定部の中央に略Ｕ字断面のＵ溝とその両側に第１平板部とを形成し、併せて前記胴部形成予定部と連続して３次元形状から成る第１延長部とを形成して、第１中間部材を得る第１の工程と、前記第１中間部材の前記第１延長部に追加の成形を施し、第２延長部を有する第２中間部材を得る第２の工程と、前記第２中間部材の前記第１平板部の端部に曲げ加工を施して前記Ｕ溝と平行な折曲部と第２平板部とを形成して第３中間部材を得る第３の工程と、前記第３中間部材の前記第２平板部及び前記折曲部に丸め加工を施して閉断面の胴部を形成する第４の工程と、を少なくとも含みプレス加工にて形成されることを特徴とするものである。 In order to solve the above-mentioned problems, the method of manufacturing an extension-integrated tubular member according to the present invention includes forming a U-groove having a substantially U-shaped cross-section in the center of a portion of a plate member to be formed into a body portion, and first flat plate portions on both sides of the U-groove. a first step of obtaining a first intermediate member; a second step of additionally forming one extension portion to obtain a second intermediate member having a second extension portion; a third step of forming a bent portion parallel to the groove and a second flat plate portion to obtain a third intermediate member; and rounding the second flat plate portion and the bent portion of the third intermediate member. and at least a fourth step of forming a body portion with a closed cross section by pressing.

また、前記板材は、板厚が異なる複数の板状部材を溶接接続してなることが好ましい。 Moreover, it is preferable that the plate material is formed by welding and connecting a plurality of plate-like members having different plate thicknesses.

本発明によれば、延長部一体型筒状部材において、中空胴部に一体形成される延長部分を任意形状に成形できる。また、異なる板厚の板材を用いることで、部位によって板厚が異なる延長部一体型筒状部材を容易に得ることができる。 According to the present invention, in the extension part-integrated cylindrical member, the extension part integrally formed with the hollow body part can be formed into an arbitrary shape. In addition, by using plate materials with different plate thicknesses, it is possible to easily obtain extension portion-integrated tubular members with different plate thicknesses depending on the part.

本発明の第１の工程に係る第１中間素材の斜視図である。FIG. 4 is a perspective view of a first intermediate material according to the first step of the present invention; 本発明の第２の工程に係る第２中間素材の斜視図である。FIG. 4 is a perspective view of a second intermediate material according to a second step of the present invention; 本発明の第３の工程に係る第３中間素材の斜視図である。FIG. 10 is a perspective view of a third intermediate material according to a third step of the present invention; 本発明の第４の工程に係る中間過程の斜視図である。It is a perspective view of the intermediate process concerning the 4th process of this invention. 本発明の延長部一体型筒状部材の成形品の斜視図である。FIG. 4 is a perspective view of a molded product of the tubular member with integrated extension portion of the present invention; 本発明の延長部一体型筒状部材を排気浄化装置のケーシングに適用した事例の斜視図である。FIG. 10 is a perspective view of an example in which the extension-integrated tubular member of the present invention is applied to a casing of an exhaust purification device;

以下、本発明の望ましい実施形態について図を参照して説明する。なお、全図において、煩雑さを避けるべく板厚は省略して図示する。本発明によって規定される製造方法によって得られる延長部一体型筒状部材１は、図５に示すとおりである。延長部一体型筒状部材１は中空円筒状の胴部２と、非円筒形状かつ３次元的な形状である延長部３とが一体的に形成されている。胴部は所謂Ｕ－Ｏ成形によるもので、突合せの溶接部８と開口９、１０を有する。 Preferred embodiments of the present invention will now be described with reference to the drawings. In addition, in order to avoid complication, the plate thickness is omitted in all drawings. The extension-integrated tubular member 1 obtained by the manufacturing method defined by the present invention is as shown in FIG. The extension part-integrated tubular member 1 is integrally formed with a hollow cylindrical body part 2 and an extension part 3 having a non-cylindrical shape and a three-dimensional shape. The body is of so-called UO molding and has butt welds 8 and openings 9,10.

胴部２と延長部３との間は切込み状の境界部４で区画されているが、境界部は必須ではない。延長部３には、徐変部７とバーリング部６が一体的に形成されており、バーリング部６の中央には、開口５が穿設されている。すなわち、中空胴部と任意形状の延長部とが一体形成されているものである。このような最終形状である延長部一体型筒状部材１を得る製造方法を、以下に工程を追って説明する。 A notch-shaped boundary 4 separates the body 2 and the extension 3, but the boundary is not essential. A gradually changing portion 7 and a burring portion 6 are integrally formed in the extension portion 3 , and an opening 5 is formed in the center of the burring portion 6 . That is, the hollow body and the extension of any shape are integrally formed. A manufacturing method for obtaining the extension-integrated cylindrical member 1 having such a final shape will be described step by step below.

図１は、本実施形態の最初の工程である第１の工程を経て成形された、第１中間部材を示す斜視図である。成形は周知のプレス金型による絞りプレス加工にて行われるもので、詳細は割愛する。所定の形状に切断した金属製の板材にプレス加工を施して、略半円断面のＵ溝１１と、その先端に第１の延長部１６を連続形成する。Ｕ溝が形成される範囲は、後に胴部となる胴部形成予定部αに亘る範囲であり、Ｕ溝ではない残部は第１平板部１２及び１３となる。 FIG. 1 is a perspective view showing the first intermediate member molded through the first step, which is the first step of this embodiment. The molding is performed by drawing press working using a well-known press die, and the details are omitted. A metal plate cut into a predetermined shape is pressed to continuously form a U-groove 11 having a substantially semicircular cross section and a first extension 16 at the tip thereof. The range in which the U-groove is formed is a range that extends over the portion to be formed into the trunk portion α that will later become the trunk portion.

延長部形成予定部βに亘る第１の延長部は、胴部形成予定部αに連続する徐変部１４と、それに連続する先端部１５とから成り、先端部１５の中央には開口１７が穿設されている。徐変部１４は必須の部位ではなく、所望形状によって適宜設定すれば良い。胴部形成予定部αと延長部形成予定部βとは、一つの（上下一組の）金型によるプレス絞り成形によって同時形成される。ここにおいて、前述の特許文献２における平板的な（プレス成形されない）取付部とは異なるものである。 The first extension extending over the extension portion forming portion β is composed of a gradually changing portion 14 continuing to the body portion forming portion α and a distal end portion 15 continuing therefrom, and an opening 17 is formed in the center of the distal end portion 15. perforated. The gradually changing portion 14 is not an essential part, and may be appropriately set depending on the desired shape. The portion to be formed in the body portion α and the portion to be formed in the extended portion β are simultaneously formed by press draw forming using one (a pair of upper and lower) dies. Here, it is different from the flat (not press-molded) mounting portion in the aforementioned Patent Document 2.

図２は、本実施形態の２番目の工程である第２の工程を経て成形された、第２中間部材２０を示す斜視図である。第２の工程も、第１の工程と同様にプレス金型による絞り成形を施すのであるが、その成形対象は第１の延長部１６だけである。すなわち、第１の延長部１６に対してプレス絞り成形を施して、更に３次元的な形状の第２の延長部２１を得る工程である。 FIG. 2 is a perspective view showing the second intermediate member 20 molded through the second step, which is the second step of this embodiment. In the second step, draw forming is performed using a press die in the same manner as in the first step, but only the first extension portion 16 is to be formed. That is, it is a step of press-drawing the first extension portion 16 to obtain the second extension portion 21 having a three-dimensional shape.

具体的には、第１の延長部１６に対して、周縁部の切除（トリム）、周縁に壁部２４の形成、開口１７周縁にバーリング部２２の形成及び開口２３の再成形、を実施するものである。そのような成形は１つのプレス型で成形しても良いし、数個のプレス型で順次成形しても良く、それらの工程を包含して第２の工程とする。このようにして、第２中間部材２０を得る。 Specifically, the first extension 16 is trimmed around the periphery, forming a wall 24 around the periphery, forming a burring portion 22 around the periphery of the opening 17, and reshaping the opening 23. It is a thing. Such molding may be carried out with one press die, or may be carried out with several press dies in succession, and these steps are included in the second step. Thus, the second intermediate member 20 is obtained.

図３は、本実施形態の３番目の工程である第３の工程を経て成形された、第３中間部材３０を示す斜視図である。第２中間部材２０の平板部１２および１３に対して、その縁部を折曲げ加工にて折曲げて、折曲部３１および３２を形成する。それ以外の部位には特に成形を施さない。折曲げ加工は、金型の押し付けによる成形でも、何らかの把持工具による挟み曲げでも、工法は任意に選択すれば良い。 FIG. 3 is a perspective view showing the third intermediate member 30 molded through the third step, which is the third step of this embodiment. Edges of the flat plate portions 12 and 13 of the second intermediate member 20 are bent by bending to form bent portions 31 and 32 . Other parts are not specially molded. For the bending process, any method may be selected, such as molding by pressing with a mold, or pinching and bending with some kind of gripping tool.

折曲部３１および３２は、特許文献２における段付け工程に該当し、次工程である大曲げ工程に備えたきっかけ部を形成するものである。折曲部３１および３２以外の部分は平板部３３および３４となるが、折曲部と平板部の割合は任意である。このようにして、第３中間部材３０を得る。 The bent portions 31 and 32 correspond to the stepped step in Patent Document 2, and form trigger portions for the large bending step which is the next step. Portions other than the bent portions 31 and 32 are flat plate portions 33 and 34, but the ratio of the bent portion to the flat plate portion is arbitrary. Thus, the third intermediate member 30 is obtained.

図４は、本実施形態の４番目の工程である第４の工程における成形途中の形状を現す斜視図である。第４の工程は、特許文献２における大曲げ工程に該当し、金型の曲面形状を折曲部３１、３２および平板部３３、３４へ押し付けて行くことで順次曲面化して中間部４１を形成しつつ、最終的に端部同士が突合わさった円断面の筒状体である胴部２を形成する。この大曲げ工程の過程で第２の延長部２１の根元も徐変形状へと成形され、最終的な延長部３となる。 FIG. 4 is a perspective view showing a shape during molding in the fourth step, which is the fourth step of this embodiment. The fourth step corresponds to the large bending step in Patent Document 2, and the intermediate portion 41 is formed by pressing the curved surface shape of the mold against the bent portions 31 and 32 and the flat plate portions 33 and 34 to sequentially curve. While doing so, finally, the body portion 2, which is a cylindrical body with a circular cross section, is formed with the ends abutting each other. In the course of this large bending process, the base of the second extension 21 is also shaped into a gradually deformed shape to form the final extension 3 .

そして、端縁同士が突合わされた部分にアーク溶接等が施され、溶接部８によって気密かつ一体的に接合されることにより、目的とする胴部２が形成される。このようにして、図５に示す、３次元形状の延長部３が胴部２と連続的に形成された延長部一体型筒状部材１を得る。 Then, arc welding or the like is applied to the portions where the edges are butted together, and the target body portion 2 is formed by joining them airtightly and integrally by the welding portion 8 . In this way, the extension part-integrated cylindrical member 1 shown in FIG. 5 is obtained in which the three-dimensional extension part 3 is formed continuously with the body part 2 .

本実施形態によれば、第１の工程と第２の工程において延長部が胴部と同時に３次元的に成形されるので、中空パイプに連続して任意の３次元形状の延長部を一体形成することが可能となる。而して、延長部一体型筒状部材において、中空胴部に一体形成される延長部分を追加工なく任意形状に成形できる。また、異なる板厚の板材（テーラードブランク材）を用いることで、部位によって板厚が異なる延長部一体型筒状部材１を容易に得ることができる。 According to this embodiment, since the extension part is three-dimensionally formed at the same time as the body part in the first step and the second step, an arbitrary three-dimensional shape extension part is integrally formed continuously with the hollow pipe. It becomes possible to Therefore, in the extension part-integrated cylindrical member, the extension part integrally formed with the hollow body part can be formed into an arbitrary shape without additional work. Further, by using plate materials (tailored blank materials) having different thicknesses, it is possible to easily obtain the extension portion-integrated cylindrical member 1 having different thicknesses depending on the part.

参考として図６に、本実施形態の延長部一体型筒状部材１を用いた、触媒装置一体型排気マニホールド（マニバータ）５０を示す。本品は、排気上流側の延長部３にプレス製のハーフシェル５１を溶接固定してマニホールド部（エルボ部）を形成するとともに、開口９に下流側コーン部５２を外嵌し溶接固定したものである。このように、本来は胴部２と別体で溶接固定されるべきマニホールド部（エルボ部）の半分が一体形成されるので溶接長を削減でき、高温強度が向上するとともに溶接コストも低減できる。 As a reference, FIG. 6 shows a catalytic device-integrated exhaust manifold (maniverter) 50 using the extension portion-integrated tubular member 1 of the present embodiment. In this product, a pressed half shell 51 is welded and fixed to the extension 3 on the exhaust upstream side to form a manifold (elbow), and a downstream cone 52 is externally fitted to the opening 9 and welded and fixed. is. In this way, the half of the manifold portion (elbow portion), which should be welded separately from the trunk portion 2, is integrally formed, so that the welding length can be reduced, the high-temperature strength can be improved, and the welding cost can be reduced.

以上、本発明の実施形態を説明してきたが、本発明は上記の実施形態に限られるものではなく、本発明の趣旨を逸脱し範囲の変更があっても本発明に包含される。また、成果品である延長部一体型筒状部材の用途及び使用形態も、上記マニバータに限らず任意である。 Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and the present invention encompasses any modifications that deviate from the gist of the present invention. In addition, the use and usage pattern of the tubular member with integrated extension portion, which is the product, is not limited to the maniverter described above, and is arbitrary.

１ 延長部一体型筒状部材
２ 胴部
３ 延長部
４ 境界部
５、９、１７，２３ 開口
６ バーリング部
７、１４ 徐変部
８ 溶接部
１０ 第１中間部材
１１ Ｕ溝
１２、１３ 第１平板部
１５ 先端部
１６ 第１の延長部
２０ 第２中間部材
２１ 第２の延長部
２２ バーリング部
２４ 壁部
３０ 第３中間部材
３１、３２ 折曲部
３３、３４ 第２平板部
５０ 触媒装置一体型排気マニホールド
５１ ハーフシェル
５２ 下流側コーン部1 Extension Integrated Cylindrical Member 2 Trunk 3 Extension 4 Boundaries 5, 9, 17, 23 Opening 6 Burrings 7, 14 Gradual change 8 Welding 10 First intermediate member 11 U grooves 12, 13 First Flat plate portion 15 Tip portion 16 First extension portion 20 Second intermediate member 21 Second extension portion 22 Burring portion 24 Wall portion 30 Third intermediate members 31, 32 Bent portions 33, 34 Second flat plate portion 50 Catalyst device Body type exhaust manifold 51 Half shell 52 Downstream cone

Claims (3)

筒状の胴部と非筒状の延長部を一体的に形成した延長部一体型筒状部材の製造方法であって、
板材の胴部形成予定部の中央に略Ｕ字断面のＵ溝とその両側に第１平板部とを形成し、併せて前記胴部形成予定部と連続して３次元形状から成る第１延長部とを形成して、第１中間部材を得る第１の工程と、
前記第１中間部材の前記第１延長部に追加の成形を施し、第２延長部を有する第２中間部材を得る第２の工程と、
前記第２中間部材の前記第１平板部の端部に曲げ加工を施して前記Ｕ溝と平行な折曲部と第２平板部とを形成して第３中間部材を得る第３の工程と、
前記第３中間部材の前記第２平板部及び前記折曲部に丸め加工を施して閉断面の胴部を形成する第４の工程と、
を少なくとも含み各工程はプレス加工にて成形されることを特徴とする延長部一体型筒状部材の製造方法。A method for manufacturing an extension-integrated tubular member in which a tubular body and a non-tubular extension are integrally formed,
A U groove having a substantially U-shaped cross section and first flat plate portions are formed on both sides of the U-groove formed in the center of the portion to be formed of the body portion of the plate material, and a first extension having a three-dimensional shape continuous with the portion to be formed of the body portion. a first step of forming a part to obtain a first intermediate member;
a second step of additionally forming the first extension of the first intermediate member to obtain a second intermediate member having a second extension;
a third step of bending an end portion of the first flat plate portion of the second intermediate member to form a bent portion parallel to the U groove and a second flat plate portion to obtain a third intermediate member; ,
a fourth step of rounding the second flat plate portion and the bent portion of the third intermediate member to form a body portion with a closed cross section;
A method of manufacturing an extension-integrated tubular member, wherein each step is formed by press working. 前記板材は、板厚が異なる複数の板状部材を溶接接続してなる
ことを特徴とする請求項１に記載の延長部一体型筒状部材の製造方法。2. The method of manufacturing an extension part-integrated cylindrical member according to claim 1, wherein the plate member is formed by welding a plurality of plate members having different plate thicknesses. 丸め加工にて形成された筒状の胴部と、
該胴部に隣接し板材に絞り加工を施して３次元的に形成された非筒状の延長部とが、共通の板材から一体形成されたことを特徴とする延長部一体型筒状部材。a cylindrical trunk formed by rounding;
An extension part-integrated cylindrical member characterized in that a non-cylindrical extension part adjacent to the body part and three-dimensionally formed by drawing a plate material is integrally formed from a common plate material.

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