JP4422219B2 - Metal tube for hydrofoam and method for forming and processing the same - Google Patents
Metal tube for hydrofoam and method for forming and processing the same Download PDFInfo
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- JP4422219B2 JP4422219B2 JP09503598A JP9503598A JP4422219B2 JP 4422219 B2 JP4422219 B2 JP 4422219B2 JP 09503598 A JP09503598 A JP 09503598A JP 9503598 A JP9503598 A JP 9503598A JP 4422219 B2 JP4422219 B2 JP 4422219B2
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Description
【0001】
【発明の属する技術分野】
本発明は、鋼管などの金属管を金型内に装着し、管内に内圧をかけて管軸方向に押込みつつ所定の形状に加工するハイドロフォーム用金属管、およびハイドロフォーム加工成形方法に関するものである。
【0002】
【従来の技術】
自動車部品等において、鋼管等の金属管をハイドロフォーム加工により成形した製品が採用され始めている。その加工法は、図1のT字管成形試験の例に示すように、金属管1を金型4,5に入れ、液導入孔8から金属管1内に液を導入して内圧をかけ、両側から押し込み用のシリンダー6,7で管軸方向に圧縮荷重を負荷して押込みつつ所定の形状に加工する方法である。
得られた成形品3は軽量で、しかも複雑な形状のものまで高精度の成形が可能である。したがって、部品の軽量化と部品数削減によるコストダウンを目的として、自動車部品等への適用が進行しつつある。
【0003】
素材の金属管に関し、管軸方向に押込まず内圧のみで加工するバルジ加工については、軟質材料、n値の高い材料、r値の高い材料を選択すべきであることが知られているが、ハイドロフォーム加工については、軟質の材料がよいことが知られている程度であった。
【0004】
本発明者らは、ハイドロフォーム加工の変形様式を解析し、その加工成形性に及ぼす材料特性の影響について研究を進めている。そして、金属管の管軸方向のr値が管周方向のr値よりも大きいものが優れた加工性を有することを明らかにし、特願平8−336480号により特許出願している。
【0005】
【発明が解決しようとする課題】
ハイドロフォーム加工の良否は、金属管が破断や座屈を起こさずに成形できることのほか、加工部の肉厚分布や表面の擦り疵発生状況などにより評価される。したがって、素材の金属管が、上記出願のような優れた加工性を有することのほか、潤滑剤の適否が重要な課題である。しかし従来、ハイドロフォーム加工における潤滑特性の定量的影響については明らかにされていない。
【0006】
そこで本発明は、鋼管などの金属管を金型内に装着し、管内に内圧をかけて管軸方向に押込みつつ所定の形状に加工するハイドロフォーム加工用として、優れた潤滑特性を有する金属管、およびその成形加工方法を提供することを目的とする。
【0007】
【課題を解決するための手段】
上記目的を達成するための本発明金属管は、管内に内圧をかけて管軸方向に押込みつつ所定の形状に加工するハイドロフォーム用金属管であって、ビード部を有する凸金型と凹金型とで帯状の試験片を挟みつけて試験片を引抜く高面圧下での摺動試験において(1)式で定義される「傾きの摩擦係数」μを求め、μが0.07以下となる潤滑剤を選定し、前記選定した潤滑剤の層を管表面に有せしめたことを特徴とするハイドロフォーム用金属管である。
μ=ΔF/(2×ΔP) (1)
ΔFは試験片がビード部を通過する際の引抜き張力増分
ΔPは試験片がビード部を通過する際のビード成形方向荷重増分
そして前記潤滑剤層が、高分子合成ワックスと水性樹脂を成分とする固体潤滑剤からなることが好ましい。
【0008】
また本発明法は、金属管に、ビード部を有する凸金型と凹金型とで帯状の試験片を挟みつけて試験片を引抜く高面圧下での摺動試験において請求項1記載の(1)式で定義される「傾きの摩擦係数」μを求め、μが0.07以下となる潤滑剤を選定し、前記選定した潤滑剤の層を管表面に形成したのち、当該管を金型内に装着し、管内に内圧をかけて管軸方向に押込みつつ所定の形状に加工することを特徴とするハイドロフォーム加工成形方法である。
そして、高分子合成ワックスと水性樹脂を成分とする固体潤滑剤で、前記潤滑剤層を形成することが好ましい。
【0009】
【発明の実施の形態】
本発明におけるハイドロフォーム加工は、図1に示すT字管成形試験例のように、金属管1を金型4,5に入れ、液導入孔8から金属管1内に液を導入して内圧をかけ、両側から押し込み用のシリンダー6,7で管軸方向に圧縮荷重を負荷して押込みつつ加工して成形品3とするものである。対象とする金属管1は、金属板を管状に成形し、突合せ部を溶接して製造されるほか、シームレス管でもよい。
【0010】
本発明は、このようなハイドロフォーム加工用の金属管であって、高面圧下での摺動試験において、(1)式で定義される「傾きの摩擦係数」μが0.07以下となる潤滑剤層を有する。高面圧下での摺動試験は、図2および図3に示すように、ビード部10を有する凸金型9と凹金型11とで帯状の試験片2を挟みつけて試験片2を引抜く試験である。「傾きの摩擦係数」μは、試験片2がビード部10を通過する際の引抜き張力Pの増分ΔPと、ビード成形方向荷重Fの増分ΔFから、(1)式で求められる。
【0011】
上記潤滑剤層は、金属管にあらかじめ形成しておくほか、加工の前工程で形成することもできる。形成手段としては、潤滑剤液中に浸漬する方法、潤滑剤液をスプレーする方法、ロールやバーあるいは刷毛等により塗布する方法、静電塗布法などで行うことができる。
そして、固体潤滑剤からなる潤滑剤層をあらかじめ形成した金属管とするのが好ましく、特に、高分子合成ワックスと水性樹脂からなる固体潤滑剤を採用するのが好ましい。
【0012】
ここで高分子合成ワックスとしては、粒径が3μm以下のポリオレフィンワックスで、軟化点が120℃以下のものと120℃超のものとを固形分重量比で9/1〜1/9に混合したエチレン系不飽和カルボン酸もしくはその無水物、またはカルボキシル基含有誘導体を結合成分として極性基を有する分子量が1000〜4000、酸価1〜20の球形ポリオレフィンワックスを、水または水溶液に分散させたディスパージョンをトータル固形分とするものなどがある。
【0013】
水性樹脂としては、揮発性溶剤を含まないオレフィンアクリル樹脂、アクリル樹脂、酢酸ビニール樹脂などがある。
また、必要に応じてシリカ(直径5〜50nmの球形シリカゾル)を配合することもできる。
【0014】
傾きの摩擦係数μが0.07以下であることにより、同じ材料の金属管でも、たとえば図1のT字管成形試験における成形高さhが高く、より高加工度の加工成形を、破断や座屈を起こさずに行うことができる。そして加工部の肉厚減少の程度が小さく、かつ表面の擦り疵やかじりの発生が抑えられる。
特に上記のような固体潤滑剤からなる潤滑剤層とした場合は、加工成形において優れた特性が安定して得られるほか、金属管を加工工程に移送するとき、あるいは加工工程で金型にセットするとき、潤滑剤層が安定で取扱いが容易である。
つぎに本発明法は、金属管に上記傾きの摩擦係数μが0.07以下となる潤滑剤層を形成したのち、金型内に装着してハイドロフォームにより加工成形する。潤滑剤層は金属管にあらかじめ形成しておくほか、加工の前工程で形成することもできる。形成手段としては、上記のように潤滑剤液中に浸漬する方法、潤滑剤液をスプレーする方法、ロールやバーあるいは刷毛等により塗布する方法、静電塗布法などで行うことができる。
潤滑剤としては、高分子合成ワックスと水性樹脂を成分とする固体潤滑剤を採用するのが好ましい。
このような本発明法により、上記のような優れた効果が得られる。
【0015】
【実施例】
板厚1.6mmの鋼板(JIS G3141 に規定されるSPCC)を管状に成形し、突合せ溶接して製造した外径60.5mmφ、長さ300mmの鋼管を素材とし、その外面に潤滑剤層を形成した金属管1について、図1に示すようなT成形試験を行った。T成形試験は、T張出し部のダイス穴直径を60.5mm、肩アールを20mmとした割り金型4,5を使用し、最大内圧値Pmを20〜40MPa の範囲で変化させ、シリンダーストローク片側50mmで行った。
金属管1の潤滑剤層としては、表1に示す6種類のものを形成した。AおよびCは固体潤滑剤であり、刷毛で塗布後2時間乾燥してT成形試験を行った。B,D,E,Fは液体潤滑剤であり、刷毛で塗布後ただちにT成形試験を行った。
【0016】
試験結果、成形高さhは、図4に示すように、最大内圧値Pmを高めると高くなり、Pmを高くしすぎると成形途中で破断を起こし、hが小さくなる。傾きの摩擦係数μが小さい程、成形高さhが高くなり、破断に至る最大内圧値Pmが高く、特にμ≦0.07で顕著である。破断せずに加工できる最大の成形高さ(限界成形高さhmax )も、図5に示すように、μ≦0.07で顕著に向上している。
【0017】
さらに、表2に示すように、μ≦0.07のものは、加工部の肉厚最小部位における肉厚減少率(t0 −t)/t0 ×100(%)が小さく、また、加工部の表面性状も良好であった。t0 は加工前の肉厚、tは加工後の肉厚である。なお表2においてFは破断した。表面性状の○は擦り疵もかじりもないもの、△は軽度の擦り疵およびかじりが発生したもの、×は重度の擦り疵およびかじりが発生したものである。
【0018】
【表1】
【0019】
【表2】
【0020】
【発明の効果】
金属管の表面に潤滑剤層を形成し、傾きの摩擦係数μが0.07以下であることにより、ハイドロフォーム加工において、同じ材料の金属管でも、より高加工度の加工成形を破断や座屈を起こさずに行うことができる。そして加工部の肉厚減少の程度が小さく、かつ表面の擦り疵やかじりの発生が抑えられる。
【0021】
特に、高分子合成ワックスと水性樹脂を成分とする固体潤滑剤を採用した場合は、加工成形において優れた特性が安定して得られるほか、金属管を加工工程に移送するとき、あるいは加工工程で金型にセットするとき、潤滑剤層が安定で取扱いが容易である。
【図面の簡単な説明】
【図1】本発明の対象とするハイドロフォーム加工法の例を示す断面図である。
【図2】本発明における高面圧下での摺動試験を行うための工具の例を示す斜視図である。
【図3】本発明における高面圧下での摺動試験の例を示す側面図である。
【図4】実施例のT成形試験における成形高さを示すグラフである。
【図5】実施例のT成形試験における限界成形高さを示すグラフである。
【符号の説明】
1…金属管 2…試験片
3…成形品 4,5…金型
6,7…シリンダー 8…液導入孔
9…凸金型 10…ビード部
11…凹金型[0001]
BACKGROUND OF THE INVENTION
TECHNICAL FIELD The present invention relates to a metal pipe for hydrofoam, in which a metal pipe such as a steel pipe is mounted in a mold, and is processed into a predetermined shape while being pushed in the pipe axis direction by applying internal pressure in the pipe, and a hydrofoam processing and molding method. is there.
[0002]
[Prior art]
Products such as steel pipes that have been formed by hydroforming are being used in automotive parts. As shown in the example of the T-shaped tube forming test in FIG. 1, the metal tube 1 is placed in the
The obtained molded
[0003]
It is known that for bulge processing that is processed only with internal pressure without being pushed in the direction of the tube axis with respect to the material metal tube, a soft material, a material with a high n value, and a material with a high r value should be selected. For hydroforming, it was known that soft materials were good.
[0004]
The present inventors have analyzed the deformation mode of hydroforming, and are studying the influence of material properties on its workability. It has been clarified that a metal tube whose r value in the tube axis direction is larger than the r value in the tube circumferential direction has excellent workability, and a patent application has been filed in Japanese Patent Application No. 8-336480.
[0005]
[Problems to be solved by the invention]
The quality of the hydroforming process is evaluated based on the fact that the metal tube can be formed without causing breakage or buckling, and the thickness distribution of the processed part and the state of occurrence of scratches on the surface. Therefore, the suitability of the lubricant is an important issue in addition to the excellent workability of the material metal tube as in the above application. However, the quantitative influence of lubrication characteristics in hydroforming has not been clarified so far.
[0006]
Therefore, the present invention provides a metal tube having excellent lubrication characteristics for hydroforming, in which a metal tube such as a steel tube is mounted in a mold and processed into a predetermined shape while being pushed in the tube axis direction by applying internal pressure in the tube. And a method for forming the same.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, a metal tube of the present invention is a metal tube for hydrofoam that is processed into a predetermined shape while applying an internal pressure to the tube and pushing it in the tube axis direction. In a sliding test under high surface pressure, with a strip-shaped test piece sandwiched between the mold and the test piece, the “friction coefficient of inclination” μ defined by the equation (1) is obtained, and μ is 0.07 or less. A metal pipe for hydrofoam, characterized in that a lubricant is selected and a layer of the selected lubricant is provided on the pipe surface .
μ = ΔF / (2 × ΔP) (1)
ΔF is the pulling tension increment when the test piece passes through the bead part ΔP is the load increment in the bead molding direction when the test piece passes through the bead part and the lubricant layer is composed of a polymer synthetic wax and an aqueous resin It is preferable to consist of a solid lubricant.
[0008]
The method according to claim 1 is a sliding test under high surface pressure in which a strip-shaped test piece is sandwiched between a convex mold having a bead portion and a concave mold on a metal tube and the test piece is pulled out. (1) “Friction coefficient of inclination” defined by the equation μ is obtained, a lubricant with μ of 0.07 or less is selected, the layer of the selected lubricant is formed on the tube surface, It is a hydroforming process forming method characterized in that it is mounted in a mold and processed into a predetermined shape while being pushed in the tube axis direction by applying internal pressure in the tube.
The lubricant layer is preferably formed of a solid lubricant composed of a polymer synthetic wax and an aqueous resin.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
In the hydroforming process according to the present invention, as in the T-shaped tube forming test example shown in FIG. The molded
[0010]
The present invention is such a metal tube for hydroforming, and in a sliding test under high surface pressure, the “friction coefficient of inclination” μ defined by the equation (1) is 0.07 or less. It has a lubricant layer. As shown in FIGS. 2 and 3, the sliding test under high surface pressure is performed by holding the strip-
[0011]
The lubricant layer can be formed on the metal tube in advance, or can be formed in a pre-process. As the forming means, a method of immersing in a lubricant solution, a method of spraying a lubricant solution, a method of applying with a roll, a bar, a brush or the like, an electrostatic coating method, or the like can be used.
It is preferable to use a metal tube in which a lubricant layer made of a solid lubricant is formed in advance, and it is particularly preferable to employ a solid lubricant made of a polymer synthetic wax and an aqueous resin.
[0012]
Here, as the polymer synthetic wax, a polyolefin wax having a particle size of 3 μm or less and a softening point of 120 ° C. or less and a mixture of more than 120 ° C. were mixed in a weight ratio of 9/1 to 1/9. Dispersion in which a spherical polyolefin wax having a polar group and a molecular weight of 1000 to 4000 and an acid value of 1 to 20 is dispersed in water or an aqueous solution using an ethylenically unsaturated carboxylic acid or its anhydride or a carboxyl group-containing derivative as a binding component In the total solid content.
[0013]
Examples of the aqueous resin include olefin acrylic resin, acrylic resin, and vinyl acetate resin that do not contain a volatile solvent.
Further, if necessary, silica (spherical silica sol having a diameter of 5 to 50 nm) can be blended.
[0014]
When the friction coefficient μ of the inclination is 0.07 or less, even with a metal tube made of the same material, for example, the forming height h in the T-shaped tube forming test of FIG. It can be done without buckling. And the degree of thickness reduction of the processed part is small, and the generation of scratches and galling on the surface is suppressed.
In particular, when a lubricant layer made of a solid lubricant as described above is used, excellent properties can be stably obtained in processing and molding, and when a metal tube is transferred to the processing process or set in a mold in the processing process. The lubricant layer is stable and easy to handle.
Next, in the method of the present invention, a lubricant layer having a friction coefficient μ of 0.07 or less is formed on a metal tube, and then mounted in a mold and processed by hydroforming. The lubricant layer can be formed on the metal tube in advance, or can be formed in a pre-processing step. The forming means can be performed by a method of immersing in a lubricant solution as described above, a method of spraying a lubricant solution, a method of applying with a roll, a bar or a brush, an electrostatic coating method, or the like.
As the lubricant, it is preferable to employ a solid lubricant composed of a polymer synthetic wax and an aqueous resin.
Such an excellent effect as described above can be obtained by the method of the present invention.
[0015]
【Example】
A steel pipe with an outer diameter of 60.5mmφ and a length of 300mm manufactured by forming a steel plate with 1.6mm thickness (SPCC specified in JIS G3141) into a tubular shape and butt-welding is used, and a lubricant layer is applied to the outer surface. The formed metal tube 1 was subjected to a T forming test as shown in FIG. The T-molding test uses split
As the lubricant layer of the metal tube 1, six types shown in Table 1 were formed. A and C are solid lubricants, which were applied with a brush and dried for 2 hours to perform a T molding test. B, D, E, and F are liquid lubricants, and a T molding test was performed immediately after application with a brush.
[0016]
As a result of the test, as shown in FIG. 4, the molding height h increases as the maximum internal pressure value Pm is increased, and if Pm is increased too much, fracture occurs during the molding and h decreases. The smaller the friction coefficient μ of the inclination is, the higher the molding height h is, and the maximum internal pressure value Pm leading to the fracture is higher, particularly when μ ≦ 0.07. The maximum molding height (limit molding height h max ) that can be processed without breaking is also significantly improved when μ ≦ 0.07, as shown in FIG.
[0017]
Further, as shown in Table 2, when μ ≦ 0.07, the thickness reduction rate (t 0 −t) / t 0 × 100 (%) at the minimum thickness portion of the processed portion is small, and the processing The surface properties of the part were also good. t 0 is the thickness before processing, and t is the thickness after processing. In Table 2, F broke. The surface texture ○ indicates that there is no scuffing or scuffing, Δ indicates that mild scuffing or scoring has occurred, and × indicates that severe scuffing or scoring has occurred.
[0018]
[Table 1]
[0019]
[Table 2]
[0020]
【The invention's effect】
By forming a lubricant layer on the surface of the metal tube and having a coefficient of friction μ of inclination of 0.07 or less, even in the metal foam of the same material in hydroforming, it is possible to break and form a higher degree of work forming. It can be done without bending. And the degree of thickness reduction of the processed part is small, and the generation of scratches and galling on the surface is suppressed.
[0021]
In particular, when a solid lubricant composed of a polymer synthetic wax and a water-based resin is used, excellent properties can be stably obtained in processing and molding, and when a metal tube is transferred to the processing step or in the processing step. When set in the mold, the lubricant layer is stable and easy to handle.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a hydroforming method targeted by the present invention.
FIG. 2 is a perspective view showing an example of a tool for performing a sliding test under high surface pressure in the present invention.
FIG. 3 is a side view showing an example of a sliding test under high surface pressure in the present invention.
FIG. 4 is a graph showing a molding height in a T molding test of an example.
FIG. 5 is a graph showing a limit molding height in a T molding test of an example.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ...
Claims (4)
μ=ΔF/(2×ΔP) (1)
ΔFは試験片がビード部を通過する際の引抜き張力増分
ΔPは試験片がビード部を通過する際のビード成形方向荷重増分A metal tube for hydroforming that is processed into a predetermined shape while being pushed in the axial direction of the tube by applying internal pressure to the tube. The test piece is formed by sandwiching a strip-shaped test piece between a convex mold having a bead portion and a concave mold. In the sliding test under high surface pressure, the “friction coefficient of inclination” μ defined by the equation (1) is obtained, a lubricant having μ of 0.07 or less is selected, and the lubricant of the selected lubricant is selected. A metal pipe for hydrofoam characterized by having a layer on the pipe surface .
μ = ΔF / (2 × ΔP) (1)
ΔF is the pulling tension increment when the test piece passes through the bead portion. ΔP is the load increment in the bead forming direction when the test piece passes through the bead portion.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP09503598A JP4422219B2 (en) | 1998-04-07 | 1998-04-07 | Metal tube for hydrofoam and method for forming and processing the same |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP09503598A JP4422219B2 (en) | 1998-04-07 | 1998-04-07 | Metal tube for hydrofoam and method for forming and processing the same |
Publications (2)
Publication Number | Publication Date |
---|---|
JPH11290963A JPH11290963A (en) | 1999-10-26 |
JP4422219B2 true JP4422219B2 (en) | 2010-02-24 |
Family
ID=14126838
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP09503598A Expired - Fee Related JP4422219B2 (en) | 1998-04-07 | 1998-04-07 | Metal tube for hydrofoam and method for forming and processing the same |
Country Status (1)
Country | Link |
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JP (1) | JP4422219B2 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP4966457B2 (en) * | 2001-06-11 | 2012-07-04 | 新日本製鐵株式会社 | Solid tube for hydrofoam and metal tube having solid lubricant layer |
JP5270133B2 (en) * | 2007-10-29 | 2013-08-21 | 住友軽金属工業株式会社 | Hydroform lubricant, hydroform metal tube using the same, and hydroform molding method |
-
1998
- 1998-04-07 JP JP09503598A patent/JP4422219B2/en not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
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JPH11290963A (en) | 1999-10-26 |
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