WO2012086573A1 - 冷間後方押出鍛造用パンチ - Google Patents
冷間後方押出鍛造用パンチ Download PDFInfo
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- WO2012086573A1 WO2012086573A1 PCT/JP2011/079319 JP2011079319W WO2012086573A1 WO 2012086573 A1 WO2012086573 A1 WO 2012086573A1 JP 2011079319 W JP2011079319 W JP 2011079319W WO 2012086573 A1 WO2012086573 A1 WO 2012086573A1
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- WIPO (PCT)
- Prior art keywords
- molding
- punch
- land portion
- brake piston
- range
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/18—Making uncoated products by impact extrusion
- B21C23/186—Making uncoated products by impact extrusion by backward extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/18—Making machine elements pistons or plungers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K21/00—Making hollow articles not covered by a single preceding sub-group
- B21K21/06—Shaping thick-walled hollow articles, e.g. projectiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K21/00—Making hollow articles not covered by a single preceding sub-group
- B21K21/12—Shaping end portions of hollow articles
- B21K21/14—Shaping end portions of hollow articles closed or substantially-closed ends, e.g. cartridge bottoms
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2125/00—Components of actuators
- F16D2125/02—Fluid-pressure mechanisms
- F16D2125/06—Pistons
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2200/00—Materials; Production methods therefor
- F16D2200/0004—Materials; Production methods therefor metallic
- F16D2200/0026—Non-ferro
- F16D2200/003—Light metals, e.g. aluminium
Definitions
- the present invention relates to a cold rear extrusion forging punch, a cold rear extrusion forging device, a method for manufacturing a brake piston shaped material, a method for manufacturing a brake piston, and a method for manufacturing a bottomed cylindrical forged product.
- a cold backward extrusion forging method using a punch and a forming die is known (for example, see Non-Patent Document 1).
- a bottomed cylindrical forged product such as a brake piston shaped material can be formed.
- the punch 101 used at that time is formed to be continuous with the molding land portion 102 formed in parallel to the punch shaft 107 and the molding land portion 102 on the tip side of the molding land portion 102.
- a molding tip surface 104 formed in a flat surface perpendicular to the punch shaft 107 and connected to the molding land portion 102 on the tip side of the molding R portion 103.
- a relief portion 105 formed on the base end side.
- the escape portion 105 is smaller in diameter than the molding land portion 102 and is formed in parallel with the punch shaft 107.
- Reference numeral 106 denotes the center of curvature of the molded R portion 103.
- a metal material 120 is disposed in the molding cavity 109 of the molding die 108.
- the surface of the material 120 is subjected to a lubrication process such as a bond process. Then, when the material 120 is pressed by the punch 101 in the molding cavity 109, the material of the material 120 flows backward along the molding R portion 103 and the molding land portion 102 of the punch 101, and the cylindrical peripheral wall portion 121. Is formed.
- Non-Patent Document 1 On pages 86 to 87 of Non-Patent Document 1, as an explanation of FIG. 6.12 in Non-Patent Document 1, in cold backward extrusion forging using a punch having a spherical tip (so-called spherical punch), the cross-section of forging It describes that the processing load increases rapidly when the reduction rate increases, and that the spherical punch is more suitable for forming shallow holes. Therefore, it is difficult to form a forged product 125 having a thin peripheral wall 121 using a spherical punch.
- the punch 101 on the inner peripheral surface 121a of the material 120 (forged product 125) is formed when the material 120 is subjected to cold backward extrusion forging.
- seizure occurred when the radius of curvature R of the forming R portion 103 of the punch 101 is larger than the thickness L of the cylindrical peripheral wall 121 of the forged product 125 (material 120), in other words, the thickness of the peripheral wall 121 of the forged product 125.
- the present invention has been made in view of the above-described technical background, and the object thereof is to prevent the occurrence of seizure even when the radius of curvature of the molding R portion of the punch is large, and has high dimensional accuracy.
- Cold rear extrusion forging punch capable of forming a bottomed cylindrical forged product, a cold rear extrusion forging device equipped with the punch, a method for producing a brake piston shaped material using the punch, and the brake piston
- Another object of the present invention is to provide a method for manufacturing a brake piston using a base material, and a method for manufacturing a bottomed cylindrical forged product using the punch.
- the present invention provides the following means.
- a cold backward extrusion forging punch used when forming a bottomed cylindrical forged product by cold backward extrusion forging a metal material The material has a Rockwell hardness HRF in the range of 65 to 105, The radius of curvature of the molded R portion is set larger than the thickness of the cylindrical peripheral wall portion of the forged product, The length of the molding land is set within a range of 0.05 to 0.15 mm, A cold backward extrusion forging punch in which a relief width of the relief portion with respect to the forming land portion is set in a range of 0.15 to 1.0 mm.
- a cold backward extrusion forging device comprising the punch described in item 1 above.
- a method for manufacturing a shaped material for a brake piston which is formed by forming a bottomed cylindrical brake piston shaped material by cold backward extrusion forging, The material has a Rockwell hardness HRF in the range of 65 to 105, The radius of curvature of the molding R portion of the punch is set larger than the thickness of the cylindrical peripheral wall portion of the shaped material, The length of the molding land portion of the punch is set within a range of 0.05 to 0.15 mm, A method for manufacturing a brake piston shaped material, wherein a relief width of the relief portion of the punch with respect to a molding land portion is set within a range of 0.15 to
- the material is cold backward extrusion forged in a molding cavity of a molding die corresponding to the punch,
- the outer periphery of the bottom surface of the molding cavity of the molding die is connected to the peripheral surface of the molding cavity, and a recess is formed.
- the said recessed part is what suppresses that a material retains in the corner
- a method for manufacturing a brake piston wherein the brake piston shape material obtained by the method for manufacturing a brake piston shape material according to any one of items 3 to 8 is subjected to artificial aging treatment.
- a punch for cold backward extrusion forging formed on the base end side and having a relief portion having a smaller diameter than the molding land portion A method for producing a bottomed cylindrical forged product in which a metal material is cold backward extrusion forged to form a bottomed cylindrical forged product, The material has a Rockwell hardness HRF in the range of 65 to 105, The radius of curvature of the molding R portion of the punch is set larger than the thickness of the cylindrical peripheral wall portion of the forged product, The length of the molding land portion of the punch is set within a range of 0.05 to 0.15 mm, A method for producing a bottomed cylindrical forged product, wherein a relief width of the relief portion of the punch with respect to a molding land portion is set within a range of 0.15 to
- the present invention has the following effects.
- the radius of curvature of the punched R portion is set to be larger than the thickness of the peripheral wall portion of the brake piston shaped material. Then, even when the thickness of the peripheral wall portion of the raw material is equal to or less than the radius of curvature of the molding R portion of the punch, for the material having the Rockwell hardness HRF in the range of 65 to 105, the punch on the inner peripheral surface of the material It is possible to prevent seizure of the brake piston and to obtain a brake piston shaped material having high dimensional accuracy.
- the retention state (dead metal state) of the material can be improved, and thus seizure can be reliably prevented, and the material It is possible to prevent the occurrence of skin pull-in scratches due to retention (dead metal). As a result, a high-quality brake piston material can be obtained.
- seizure can be prevented more reliably, and further, the occurrence of skin pull-in scratches caused by the retention of material can be reliably prevented. Can do.
- seizure can be more reliably prevented, and the occurrence of skin pull-in scratches due to material retention can be further reliably prevented. can do.
- seizure can be more reliably prevented.
- the material is an aluminum alloy that has been subjected to solution treatment without being subjected to O treatment, the following effects can be obtained.
- the brake piston shaped material in the conventional method for manufacturing a brake piston shaped material, it is necessary to perform O treatment on the material before forging in order to reduce the hardness of the material and improve the forgeability. Further, when the O material is subjected to O treatment in this way, the brake piston shaped material formed by cold backward extrusion forging the material has low hardness. Therefore, it has been necessary to subject the base material to a solution treatment after forging. That is, in the conventional manufacturing method, it is necessary to perform at least two heat treatment steps (O treatment and solution treatment). On the other hand, in the method for manufacturing a brake piston material according to the present invention, the brake piston material having high dimensional accuracy even when a hard material having a Rockwell hardness HRF in the range of 65 to 105 is forged.
- a brake piston adjusted to a hardness suitable for the brake piston can be obtained.
- the bottomed cylindrical forged product having high dimensional accuracy can be obtained and seizure with the punch on the inner peripheral surface of the material can be prevented. .
- FIG. 1 is a cross-sectional view of a state before a metal material is pressed with a punch of a cold backward extrusion forging device according to a first embodiment of the present invention.
- FIG. 2 is a cross-sectional view of a state in which the material is pressed with the punch.
- FIG. 3 is an enlarged view of FIG.
- FIG. 4 is a process diagram according to an embodiment of the present invention showing a process of manufacturing a brake piston from a material.
- FIG. 5 is sectional drawing of the state which pressed the metal raw material with the punch of the cold back extrusion forging apparatus which concerns on 2nd Embodiment of this invention.
- FIG. 5 is sectional drawing of the state which pressed the metal raw material with the punch of the cold back extrusion forging apparatus which concerns on 2nd Embodiment of this invention.
- FIG. 6 is sectional drawing of the state which pressed the metal raw material with the punch of the cold back extrusion forging apparatus which concerns on 3rd Embodiment of this invention.
- FIG. 7 is a view corresponding to FIG. 3 for explaining a punch forming R portion of the cold backward extrusion forging device of the first embodiment.
- FIG. 8 is a process diagram according to a reference example showing a process of manufacturing a brake piston from a material.
- FIG. 9 is a cross-sectional view of a state in which a metal material is pressed with a punch used for explaining the background art of the present invention.
- 15 is a cold backward extrusion forging device according to the first embodiment of the present invention.
- the forging device 15 is for forming, for example, a brake piston shaped material as a bottomed cylindrical forged product 25 from a metal material 20, and is a first embodiment of the present invention.
- a punch 1 for cold backward extrusion forging a forming die 8 corresponding to the punch 1, and the like.
- the molding die 8 has a molding cavity 9.
- the forged product 25 (the shape material for the brake piston) is made of metal, and as shown in FIG. 2, a cylindrical shape integrally formed on the disk-like bottom wall portion 22 and the outer peripheral edge portion of the bottom wall portion 22. And a peripheral wall portion 21.
- the bottom wall portion 22 corresponds to the crown portion of the brake piston
- the peripheral wall portion 21 corresponds to the skirt portion of the brake piston.
- the metal material 20 used for manufacturing the forged product 25 has a disk shape or a column shape, and is disposed in the molding cavity 9 of the molding die 8. Then, by pressing the material 20 with the punch 1 in the molding cavity 9, a bottomed cylindrical forged product 25 is molded as shown in FIG.
- the bottom surface 9b of the molding cavity 9 of the molding die 8 has a flat circular shape. The radius of the peripheral surface 9 a of the molding cavity 9 is constant in the central axis direction of the molding cavity 9.
- the material 20 has a Rockwell hardness HRF in the range of 65 to 105.
- the Rockwell hardness is a value measured according to “Rockwell hardness test-test method” of JIS (Japanese Industrial Standard) Z2245: 2005, and the scale used for the measurement is F, indenter.
- F, indenter Has a steel ball of 1.5875 mm and a test load of 588.4 N.
- the formal hardness symbol is HRFS.
- the surface of the material 20 (that is, the upper surface 20a, the lower surface and the outer peripheral surface 20b of the material 20) is subjected to a lubricating process such as a bond process over the entire surface.
- the punch 1 advances into the molding cavity 9 of the molding die 8 along the punch shaft 7 by a punch driving means (eg, hydraulic cylinder) (not shown) and presses the material 20.
- a punch driving means eg, hydraulic cylinder
- the shape of the punch 1 is as follows.
- the punch 1 has a press-molded portion formed in a substantially hemispherical shape, that is, falls within the category of a so-called spherical punch. More specifically, the punch 1 has a forming land portion 2, a forming R portion 3 having an arcuate cross section, and a forming front end surface 4 as a press forming portion, and further has an escape portion 5.
- the escape portion 5 is also called a stem portion of the punch 1. 6 is the center of curvature of the molded R portion 3.
- the molding land 2 is formed in parallel with the punch shaft 7.
- the molded R portion 3 is formed on the tip side of the molded land portion 2 so as to be continuous with the molded land portion 2.
- the molding tip surface 4 is formed of a flat surface that is formed on the tip side of the molding R portion 3 so as to be continuous with the molding R portion 3 and is perpendicular to the punch shaft 7.
- the escape portion 5 has a smaller diameter than the molding land portion 2 and is formed in parallel with the punch shaft 7. Therefore, a step corresponding to the difference between the radius of the molding land 2 and the radius of the clearance 5 is generated between the molding land 2 and the clearance 5.
- the molded R portion 3 is formed smoothly and continuously with the molded land portion 2. Therefore, no corner is formed at the boundary between the molded R portion 3 and the molded land portion 2. Further, the molding tip surface 4 is formed so as to be smoothly connected to the molding R portion 3. Therefore, no corner is formed at the boundary between the molding tip surface 4 and the molding R portion 3.
- the radius of curvature of the molded R portion 3 is R
- the length of the molded land portion 2 is B
- C be the step between them.
- L is the thickness of the cylindrical peripheral wall portion 21 of the forged product 25 (material 20). L is the same size as the gap between the molding land 2 and the peripheral surface 9 a of the molding cavity 9 of the molding die 8.
- R, B, C and L are all greater than zero. That is, R> 0, B> 0, C> 0, L> 0.
- the radius of curvature R of the forming R portion 3 is set larger than the thickness L of the peripheral wall portion 21 of the forged product 25. That is, R> L, that is, R / L> 1.
- the hard material 20 having a Rockwell hardness HRF in the range of 65 to 105 is cold backward extrusion forged using the punch 1 having the curvature radius R of the molding R portion 3 larger than L as described above, 20 (forged product 25) is easily seized with the punch 1 on the inner peripheral surface 21a.
- the present inventor has set the length B of the molding land portion 2 within the range of 0.05 to 0.15 mm and has escaped. It has been found that the above-mentioned difficulties can be solved by setting the clearance width C of the portion 5 with respect to the molding land portion 2 within the range of 0.15 to 1.0 mm.
- the clearance width C is desirably 0.15 mm or more.
- C exceeds 1.0 mm, the rigidity of the relief portion 5 of the punch 1 is reduced, and the dimensional accuracy of the forged product 25 may be reduced.
- the temperature of the punch 1 at the time of forging is not particularly limited, but it is particularly desirable to set it within a range of 120 to 190 ° C.
- the material of the punch 1 is not limited, but is particularly preferably a cemented carbide.
- the hardness (Vickers hardness) of the punch 1 is not limited, but is particularly preferably HV1400 ⁇ 200.
- the manufacturing method of the first embodiment is particularly suitable for manufacturing a forged product 25 having the following shape.
- the forged product 25 having this shape is manufactured using a conventional punch, seizure is likely to occur, and the dimensional accuracy of the forged product 25 is low.
- the forged product 25 of this shape using the punch 1 of the first embodiment such a problem does not occur, that is, the occurrence of seizure can be prevented, The dimensional accuracy of the forged product 25 can be increased.
- FIG. 4 is a process diagram showing a preferred process of forming a brake piston shaped material from the material 20 as a bottomed cylindrical forged product 25 and subsequently manufacturing the brake piston from the shaped material.
- the material of the material 20 is an aluminum alloy.
- a material 20 having a predetermined shape that is, a disk shape or a columnar shape
- a predetermined size is obtained by cutting a rod-shaped continuous aluminum cast material, an aluminum alloy extruded material, an aluminum drawn material, or the like. obtain.
- the material 20 is subjected to a solution treatment in which the material 20 is heat-treated in a batch furnace or the like under conditions of 495 to 530 ° C. ⁇ 2.5 to 5.0 h and then cooled with water.
- the surface of the material 20 is bonded to the entire surface as a lubrication process.
- the surface of the material 20 is degreased, then a phosphate film (eg, zinc phosphate film) is formed on the surface of the material 20, and then a metal soap lubrication process using sodium stearate is performed.
- a phosphate film and sodium stearate are reacted to form a lubricating film (eg, zinc stearate film).
- the thickness of the lubricating film is, for example, 2 to 6 ⁇ m.
- the weight of the material 20 is selected, and the material 20 used for forging is selected. This step S4 is performed as necessary, and can be omitted.
- step S5 the raw material 20 is subjected to cold backward extrusion forging by the cold backward extrusion forging device 15 of the first embodiment to form a brake piston shaped material (forged product 25).
- step S6 the shaped material is artificially aged by a continuous furnace or the like as necessary. The preferable conditions for the aging treatment are 170 to 180 ° C. ⁇ 1.5 to 2.5 hours.
- step S7 the shaped material is cut into a desired brake piston shape.
- step S8 an alumite treatment is applied to the surface of the base material. The desired bottomed cylindrical brake piston is obtained through the above steps.
- the material 20 is an aluminum alloy that has been subjected to a solution treatment without being subjected to the O treatment. Play.
- a brake piston having high dimensional accuracy even if a hard material 20 having a Rockwell hardness HRF in the range of 65 to 105 is forged. It is possible to form a raw material, so that it is not necessary to perform O treatment on the material 20 before forging. In addition, since it is not necessary to subject the material 20 to O treatment before forging, it is not necessary to subject the base material to solution treatment after forging. Therefore, the manufacturing process of the brake piston can be simplified, and the manufacturing cost of the brake piston can be reduced.
- the material of the material 20 is preferably an aluminum alloy having the following composition. That is, the material of the material 20 is Si: 9.0 to 11.0% by mass, Fe: 0.50% by mass or less, Cu: 0.70 to 1.1% by mass, Mn: 0.15% by mass or less, It is desirable that the aluminum alloy be Mg: 0.3 to 0.7 mass%, Zn: 0.25 mass% or less, and the balance being Al and inevitable impurities. Since the aluminum alloy having this composition contains more Si than A6061, it contains more eutectic Si. Therefore, in step S8, the hard alumite treatment with no or almost no cracks can be applied to the surface of the base material (forged product 25).
- the aluminum alloy material 20 of this composition is hard (Rockwell hardness HRF: 65 to 105), so it is suitable for a brake piston, but it is difficult to produce a corner shape during cold backward extrusion forging and has low dimensional accuracy. There is a difficulty of becoming. However, if the material 20 is cold backward extrusion forged using the punch 1 of the first embodiment, a brake piston shaped material having high dimensional accuracy can be formed.
- the value obtained by dividing the surface roughness Ra of the upper surface 20a of the material 20 by the surface roughness Ra of the outer peripheral surface 20b of the material 20 and the surface roughness Rz of the upper surface 20a of the material 20 are as follows. Divided by the surface roughness Rz of the outer peripheral surface 20b of the material 20, the value obtained by dividing the undulation Wa of the upper surface 20a of the material 20 by the undulation Wa of the outer peripheral surface 20b of the material 20, and the undulation Wz of the upper surface 20a of the material 20. It is desirable that at least one of the value obtained by dividing by the swell Wz of the outer peripheral surface 20b of the material 20 is set within a range of 0.5 to 1.5. By setting in this way, seizing with the punch 1 of the inner peripheral surface 21a of the raw material 20 (forged product 25) can be reliably prevented.
- the upper surface 20 a of the material 20 is a contact surface with the punch 1 of the material 20.
- the surface roughness Ra, Rz, waviness Wa and Wz are all values measured according to JIS B0601: 2001. JIS B0601: 2001 is compliant with IS0 4287: 1997.
- the surface roughness Ra is the arithmetic average roughness of the roughness curve.
- the surface roughness Rz is the maximum height of the roughness curve.
- the waviness Wa is the arithmetic mean waviness of the waviness curve.
- the waviness Wz is the maximum height of the waviness curve.
- the above-described bond processing is performed on these surfaces 20a and 20b. Furthermore, it is particularly desirable that the lower surface of the material 20 is adjusted to the same surface properties as the upper surface 20a.
- the outer peripheral edge of the bottom surface 9 b of the molding cavity 9 of the molding die 8 extends over the entire circumference.
- An annular recess 10 is formed in connection with the peripheral surface 9 a of the molding cavity 9.
- the concave portion 10 has a structure in which the material 20 flows into the concave portion 10 during the forging of the raw material 20, so that the material stays in the vicinity of the corner portion 9 z between the bottom surface 9 b and the peripheral surface 9 a in the molding cavity 9. It has an inhibitory effect.
- the material 20 when the material 20 is forged, the material 20 tends to stay in the vicinity of the corner 9z between the bottom surface 9b and the peripheral surface 9a in the forming cavity 9 of the forming die 8.
- the retention of the material 20 is called “dead metal”. If material stagnation (dead metal) occurs near the corner 9z during the forging of the material 20, seizure of the inner peripheral surface 21a of the material 20 (forged product 25) with the punch 1 is likely to occur. No. 25 tends to cause a skin pull-in scratch. Therefore, in order to solve such a problem, in the molding die 8 of the second embodiment, the recess 10 is formed on the outer peripheral edge portion of the bottom surface 9b of the molding cavity 9.
- the material of the raw material 20 flows into the recess 10 from the front end side of the punch 1, and between the molding land portion 2 of the punch 1 and the peripheral surface 9 a of the molding cavity 9 of the molding die 8. It starts to flow toward the gap side. That is, the material flows smoothly in the vicinity of the corner 9z. As a result, the material retention state (dead metal state) in the vicinity of the corner portion 9z is improved. As a result, seizure can be reliably prevented, and the occurrence of skin pull-in scratches due to the retention of the material can be prevented. Thus, a high quality forged product 25 can be obtained.
- the opening width W of the recess 10 is set to be equal to or greater than the wall thickness L of the peripheral wall portion 21 of the forged product 25 (that is, W ⁇ L).
- the side surface 10 a disposed on the center side of the molding cavity 9 of the molding die 8 is inclined so that the opening width W of the recess 10 is widened.
- the side surface 10 a is inclined so that the opening width W of the recess 10 gradually increases from the bottom of the recess 10 toward the opening of the recess 10.
- the outer peripheral edge portion of the bottom surface 9b of the molding cavity 9 of the molding die 8 is An annular recess 10 extending over the entire circumference in the circumferential direction is formed in connection with the peripheral surface 9 a of the molding cavity 9.
- the concave portion 10 has the same effect as the concave portion of the second embodiment.
- the adjacent portion of the bottom surface 9 b of the molding cavity 9 adjacent to the side surface 10 a disposed on the center side of the molding cavity 9 of the molding die 8 is the molding cavity 9. Is raised to the inside. Even if the bottom surface 9b and the recess 10 of the molding cavity 9 have such a shape, the same effects as those of the second embodiment can be obtained.
- the cross-sectional shape of the forming R portion 3 of the punch 1 is not a simple arc shape (for example, the cross-sectional shape of the forming R portion 3 is a composite R, a part of a parabola, or a part of an ellipse).
- the radius of curvature R of the forming R portion 3 is a circular approximation of the vicinity immediately before the forming R 2 contacting the forming land portion 2. For example, as shown in FIG.
- a line along the forming land portion 2 extends from the boundary X ⁇ b> 1 between the forming land portion 2 and the forming R portion 3.
- An intersection point of an extension line E1 extending to the tip end side of the punch 1 and a radius line E2 extending from the tip end of the punch 1 in a radially outward direction perpendicular to the punch axis 7 is defined as X0, and the extension line E1 centering on the intersection point X0.
- the curvature radius of the curve in the region X1 to X2 in the molding R portion 3 is preferably R.
- the punch 1 may not have the molding tip surface 4, that is, the entire portion on the tip side of the punch 1 from the molding land portion 2 is formed into a hemispherical shape only by the molding R portion 3. May be.
- the bottomed cylindrical forged product 25 is particularly preferably a brake piston shaped material, but may be a car compressor piston cup shaped material, for example, or a cup-shaped product. Etc.
- Tables 1 and 2 The five types of materials M1 to M5 shown in Tables 1 and 2 were prepared. These materials 20 are all used for manufacturing a brake piston shaped material, and the materials are all aluminum alloys. Table 1 shows the composition components of each material 20. Table 2 shows the heat treatment to the material 20 and the properties of the material 20.
- the materials M1, M2 and M4 are produced according to steps S1 to S4 in the process diagram shown in FIG. 4 as can be seen from the description of the “heat treatment to material” column in Table 2.
- the Rockwell hardness HRF is in the range of 65 to 105, that is, it is relatively hard.
- the materials 20 of types M3 and M5 are used as reference examples of the present invention, and have a Rockwell hardness HRF of less than 65, that is, a relatively soft material.
- the materials 20 of the types M3 and M5 are manufactured according to steps S11 to S14 in the process diagram shown in FIG.
- This process is a conventional process for manufacturing a shaped material for a brake piston.
- This process diagram will be described below.
- step S11 a raw material 20 having a predetermined shape and size is obtained by cutting a rod-like aluminum continuous cast material, an aluminum alloy extruded material, an aluminum drawn material, and the like.
- step S12 the material 20 is subjected to O treatment (annealing) in order to reduce the hardness of the material 20 and improve forgeability.
- step S13 the surface of the material 20 is bonded to the entire surface as a lubrication process.
- step S14 the weight of the material 20 is selected, and the material 20 used for forging is selected.
- step S15 the selected material 20 is subjected to cold backward extrusion forging to form a brake piston shaped material (forged product 25).
- step S16 in order to increase the hardness of the raw material 20, a solution treatment is performed on the base material.
- step S17 the raw material is subjected to artificial aging treatment.
- step S18 the shaped material is cut into a desired brake piston shape.
- step S19 an alumite treatment is performed on the surface of the base material.
- Such five types (M1 to M5) of the material 20 are subjected to cold backward extrusion forging using the cold backward extrusion forging device 15 of the first embodiment with various forging conditions changed, and thereby a bottomed cylinder.
- a shaped material for a brake piston was formed as a forged product 25.
- D is 28 mm
- F is 30 mm.
- the forged product 25 was evaluated for the accuracy of the inner diameter, seizure on the inner peripheral surface 21a, and the presence or absence of scratches. The results are shown in Table 3.
- the punch 1 used for this forging the molded R portion 3 is formed smoothly and continuously with the molded land portion 2.
- the material of the punch 1 is a cemented carbide, and the hardness of the punch 1 is HV1400.
- R, L, B, and C mean the following.
- R radius of curvature of the molded R portion 3 of the punch 1
- L thickness of the peripheral wall portion 21 of the forged product 25
- B length of the molded land portion 2 of the punch 1 C: relative to the molded land portion 2 of the relief portion 5 of the punch 1 Escape width.
- ⁇ The inner diameter dimensional accuracy is high
- ⁇ The inner diameter dimensional accuracy is low.
- A Seizure does not occur on the inner peripheral surface 21a and the gloss of the inner peripheral surface 21a is high.
- O Seizure does not occur on the inner peripheral surface 21a, and the gloss of the inner peripheral surface 21a.
- X Seizure occurred on the inner peripheral surface 21a.
- R of punch 1 used at that time should be smaller than L.
- a high-quality forged product could be obtained even when B and C were outside the predetermined range.
- a relatively soft material type: M3, M5
- high quality even if B and C are outside the predetermined range. A forged product could be obtained.
- Examples 21 to 24 A material 20 of type M2 shown in Tables 1 and 2 was prepared. And the shaping
- the blank 20 was subjected to cold backward extrusion forging to form a brake piston shaped material as a forged product 25. Subsequently, about the forged product 25, the incidence rate of the skin pull-in scratch and the seizure on the inner peripheral surface 21a were evaluated. The results are shown in Table 4.
- Example 21 is a case where the material 20 was cold backward extrusion forged using a molding die 8 in which the recess 10 was not formed, and Examples 22 to 24 were performed using the molding die 8 in which the recess 10 was formed.
- R applied in this forging is 10 mm, and L is 3 mm.
- D is 28 mm and F is 33 mm.
- the punch 1 used for this forging the molded R portion 3 is formed smoothly and continuously with the molded land portion 2.
- the material of the punch 1 is a cemented carbide, and the hardness of the punch 1 is HV1400.
- the “dimension of the recess” in Table 4 indicates the size relationship between the dimension of the opening width W of the recess 10 and R and L.
- the “skin pulling incidence” indicates the number of times the skin pulling scratches have occurred in the forged product 25 when forging is performed 20 times.
- the meanings of the symbols in the “burn-in” column are as follows.
- A Seizure does not occur on the inner peripheral surface 21a and the gloss of the inner peripheral surface 21a is high.
- O Seizure does not occur on the inner peripheral surface 21a, and the gloss of the inner peripheral surface 21a. Is low.
- Examples 31 to 35 A material 20 of type M2 shown in Tables 1 and 2 was prepared. Then, using the cold back extrusion forging device 15 of the first embodiment, the surface roughness Ra, Rz and the undulations Wa, Wz of the upper surface 20a and the outer peripheral surface 20b of the material 20 are variously changed, and the material 20 is cold Back extrusion forging was performed to form a brake piston shaped material as a forged product 25.
- R applied in this forging is 10 mm, and L is 3 mm.
- D is 28 mm and F is 30 mm.
- the punch 1 used for this forging the molded R portion 3 is formed smoothly and continuously with the molded land portion 2.
- the material of the punch 1 is a cemented carbide, and the hardness of the punch 1 is HV1400.
- seizure of the forged product 25 on the inner peripheral surface 21a was evaluated. The results are shown in Table 5.
- upper surface means the upper surface 20a of the material
- outer peripheral surface means the outer peripheral surface 20b of the material
- ratio means the material.
- 20 shows a value obtained by dividing each measured value (Ra, Rz, Wa, Wz) of the upper surface 20a of 20 by each measured value (Ra, Rz, Wa, Wz) of the outer peripheral surface 20b of the material 20.
- Ra, Rz, Wa and Wz are all values measured in accordance with JIS B0601: 2001.
- the lower surface of the material 20 is adjusted to the same surface properties as the upper surface 20a.
- the meanings of the symbols in the “burn-in” column are as follows.
- A Seizure does not occur on the inner peripheral surface 21a and the gloss of the inner peripheral surface 21a is high.
- O Seizure does not occur on the inner peripheral surface 21a, and the gloss of the inner peripheral surface 21a. Slightly high ⁇ : No seizure occurs on the inner peripheral surface 21a, and the gloss of the inner peripheral surface 21a is slightly low.
- the value obtained by dividing the surface roughness Ra of the upper surface 20a of the material 20 by the surface roughness Ra of the outer peripheral surface 20b of the material 20, and the surface roughness Rz of the upper surface 20a of the material 20 is the outer periphery of the material 20.
- the value obtained by dividing the surface roughness of the surface 20b by the surface roughness Rz, the value obtained by dividing the waviness Wa of the upper surface 20a of the material 20 by the waviness Wa of the outer peripheral surface 20b of the material 20, and the waviness Wz of the upper surface 20a of the material 20 When at least one of the value divided by the waviness Wz of the surface 20b is set within the range of 0.5 to 1.5 (more preferably 0.85 to 1.2) (Examples 33 to 35) ), The seizure of the inner peripheral surface 21a of the material 20 (forged product 25) with the punch 1 could be reliably prevented. In particular, when these values are all set within the range of 0.5 to 1.5 (more preferably 0.85 to 1.2), seizure could be prevented more reliably. .
- the surface roughness Ra of the outer peripheral surface 20b of the material 20 is in the range of 0.6 to 1.5 ⁇ m, and the surface roughness Rz of the outer peripheral surface 20b of the material 20 is in the range of 5 to 15 ⁇ m.
- the seizure is that the undulation Wa of the outer peripheral surface 20b of the material 20 is in the range of 0.7 to 1.5 ⁇ m and the undulation Wz of the outer peripheral surface 20b of the material 20 is in the range of 5 to 15 ⁇ m. It has been found particularly desirable to prevent the occurrence of Therefore, in order to prevent the occurrence of seizure, it has been found that it is desirable to set the surface roughness of the material 20 to an appropriate roughness instead of reducing the surface roughness.
- the term present invention or inventory should not be construed inappropriately as identifying criticality, nor should it be construed as inappropriately applied across all aspects or all embodiments ( That is, it should be understood that the present invention has numerous aspects and embodiments) and should not be construed inappropriately to limit the scope of the present application or the claims.
- the term “embodiment” is also used to describe any aspect, feature, process or step, any combination thereof, and / or any part thereof. It is done. In some examples, various embodiments may include overlapping features.
- the abbreviations “e.g.,” and “NB” may be used, meaning “for example” and “careful”, respectively.
- the present invention can be used for a cold backward extrusion forging punch, a cold backward extrusion forging device, a method for producing a brake piston shaped material, a method for producing a brake piston, and a method for producing a bottomed cylindrical forged product. is there.
- Molding cavity 10 Concavity 15: Cold backward extrusion forging device 20: Material 20a: Material upper surface 20b: Material outer peripheral surface 25: Forged product (brake piston shaped material)
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Abstract
Description
金属素材を冷間後方押出鍛造して有底円筒状鍛造品を成形する際に用いられる冷間後方押出鍛造用パンチであって、
前記素材は、ロックウェル硬さHRFが65~105の範囲内のものであり、
前記成形R部の曲率半径は、前記鍛造品の円筒状周壁部の肉厚よりも大きく設定されており、
前記成形ランド部の長さは、0.05~0.15mmの範囲内に設定され、
前記逃げ部の前記成形ランド部に対する逃げ幅は、0.15~1.0mmの範囲内に設定されている冷間後方押出鍛造用パンチ。
金属素材を冷間後方押出鍛造して有底円筒状ブレーキピストン用素形材を成形するブレーキピストン用素形材の製造方法であって、
前記素材は、ロックウェル硬さHRFが65~105の範囲内のものであり、
前記パンチの成形R部の曲率半径は、前記素形材の円筒状周壁部の肉厚よりも大きく設定されており、
前記パンチの成形ランド部の長さは、0.05~0.15mmの範囲内に設定され、
前記パンチの逃げ部の成形ランド部に対する逃げ幅は、0.15~1.0mmの範囲内に設定されているブレーキピストン用素形材の製造方法。
前記成形ダイの成形キャビティの底面の外周縁部に成形キャビティの周面と連接して凹部が形成されており、
前記凹部は、その内部に素材の鍛造時に素材の材料が流れ込むことにより、前記成形キャビティ内におけるその底面とその周面との間の角部近傍で材料が滞留するのを抑制するものである前項3記載のブレーキピストン用素形材の製造方法。
金属素材を冷間後方押出鍛造して有底円筒状鍛造品を成形する有底円筒状鍛造品の製造方法であって、
前記素材は、ロックウェル硬さHRFが65~105の範囲内のものであり、
前記パンチの成形R部の曲率半径は、前記鍛造品の円筒状周壁部の肉厚よりも大きく設定されており、
前記パンチの成形ランド部の長さは、0.05~0.15mmの範囲内に設定され、
前記パンチの逃げ部の成形ランド部に対する逃げ幅は、0.15~1.0mmの範囲内に設定されている有底円筒状鍛造品の製造方法。
L:鍛造品25の周壁部21の肉厚
B:パンチ1の成形ランド部2の長さ
C:パンチ1の逃げ部5の成形ランド部2に対する逃げ幅。
×:内径寸法精度が低い。
○:内周面21aに焼付きは発生しておらす、且つ内周面21aの光沢性が低い
×:内周面21aに焼付きが発生した。
×:内周面21aに傷がある。
上記表1及び2に示した種類M2の素材20を準備した。そして、上記第1実施形態の冷間後方押出鍛造装置15の成形ダイ8のように成形キャビティ9の底面9bの外周縁部に凹部10が形成されていない成形ダイ8と、上記第2実施形態の冷間後方押出鍛造装置15の成形ダイ8のように成形キャビティ9の底面9bの外周縁部に凹部10が形成された成形ダイ8と、を用い、更に、凹部10の開口幅Wを様々に変えて、素材20を冷間後方押出鍛造して鍛造品25としてブレーキピストン用素形材を成形した。次いで、鍛造品25について表皮引込み傷の発生率と内周面21aでの焼付きとを評価した。その結果を表4に示す。
○:内周面21aに焼付きは発生しておらす、且つ内周面21aの光沢性が低い。
上記表1及び2に示した種類M2の素材20を準備した。そして、上記第1実施形態の冷間後方押出鍛造装置15を用い、素材20の上面20a及び外周面20bの表面粗さRa、Rz及びうねりWa、Wzを様々に変えて、素材20を冷間後方押出鍛造して鍛造品25としてブレーキピストン用素形材を成形した。この鍛造で適用したRは10mmであり、Lは3mmである。鍛造品25の形状において、Dは28mmであり、Fは30mmである。なお、この鍛造の際に使用したパンチ1では、成形R部3は成形ランド部2と滑らかに連なって形成されている。パンチ1の材質は超硬合金であり、パンチ1の硬さはHV1400である。次いで、鍛造品25について内周面21aでの焼付きを評価した。その結果を表5に示す。
○:内周面21aに焼付きは発生しておらす、且つ内周面21aの光沢性がやや高い
△:内周面21aに焼付きは発生しておらず、且つ内周面21aの光沢性がやや低い。
2:成形ランド部
3:成形R部
4:成形先端面
5:逃げ部
7:パンチ軸
8:成形ダイ
9:成形キャビティ
10:凹部
15:冷間後方押出鍛造装置
20:素材
20a:素材の上面
20b:素材の外周面
25:鍛造品(ブレーキピストン用素形材)
Claims (10)
- パンチ軸と平行に形成された成形ランド部と、前記成形ランド部よりも先端側に前記成形ランド部と連なって形成された断面円弧状の成形R部と、前記成形ランド部よりも基端側に形成され且つ前記成形ランド部よりも小径の逃げ部と、を有し、
金属素材を冷間後方押出鍛造して有底円筒状鍛造品を成形する際に用いられる冷間後方押出鍛造用パンチであって、
前記素材は、ロックウェル硬さHRFが65~105の範囲内のものであり、
前記成形R部の曲率半径は、前記鍛造品の円筒状周壁部の肉厚よりも大きく設定されており、
前記成形ランド部の長さは、0.05~0.15mmの範囲内に設定され、
前記逃げ部の前記成形ランド部に対する逃げ幅は、0.15~1.0mmの範囲内に設定されている冷間後方押出鍛造用パンチ。 - 請求項1記載のパンチを具備する冷間後方押出鍛造装置。
- パンチ軸と平行に形成された成形ランド部と、前記成形ランド部よりも先端側に前記成形ランド部と連なって形成された断面円弧状の成形R部と、前記成形ランド部よりも基端側に形成され且つ前記成形ランド部よりも小径の逃げ部と、を有する冷間後方押出鍛造用パンチを用い、
金属素材を冷間後方押出鍛造して有底円筒状ブレーキピストン用素形材を成形するブレーキピストン用素形材の製造方法であって、
前記素材は、ロックウェル硬さHRFが65~105の範囲内のものであり、
前記パンチの成形R部の曲率半径は、前記素形材の円筒状周壁部の肉厚よりも大きく設定されており、
前記パンチの成形ランド部の長さは、0.05~0.15mmの範囲内に設定され、
前記パンチの逃げ部の成形ランド部に対する逃げ幅は、0.15~1.0mmの範囲内に設定されているブレーキピストン用素形材の製造方法。 - 前記素材は、前記パンチに対応する成形ダイの成形キャビティ内で冷間後方押出鍛造されるものであり、
前記成形ダイの成形キャビティの底面の外周縁部に成形キャビティの周面と連接して凹部が形成されており、
前記凹部は、その内部に素材の鍛造時に素材の材料が流れ込むことにより、前記成形キャビティ内におけるその底面とその周面との間の角部近傍で材料が滞留するのを抑制するものである請求項3記載のブレーキピストン用素形材の製造方法。 - 前記凹部の開口幅は、前記素形材の周壁部の肉厚以上に設定されている請求項4記載のブレーキピストン用素形材の製造方法。
- 前記成形キャビティの中心側に配置された前記凹部の側面は、前記凹部の開口幅が広くなるように傾斜している請求項4又は5記載のブレーキピストン用素形材の製造方法。
- 前記素材の上面の表面粗さRaを前記素材の外周面の表面粗さRaで割った値と、前記素材の上面の表面粗さRzを前記素材の外周面の表面粗さRzで割った値と、前記素材の上面のうねりWaを前記素材の外周面のうねりWzで割った値と、前記素材の上面のうねりWzを前記素材の外周面のうねりWzで割った値と、のうち少なくとも一つが0.5~1.5の範囲内に設定されている請求項3~6のいずれかに記載のブレーキピストン用素形材の製造方法。
- 前記素材の材質は、O処理が施されないで溶体化処理が施されたアルミニウム合金である請求項3~7のいずれかに記載のブレーキピストン用素形材の製造方法。
- 請求項3~8のいずれかに記載のブレーキピストン用素形材の製造方法により得られたブレーキピストン用素形材を人工時効処理するブレーキピストンの製造方法。
- パンチ軸と平行に形成された成形ランド部と、前記成形ランド部よりも先端側に前記成形ランド部と連なって形成された断面円弧状の成形R部と、前記成形ランド部よりも基端側に形成され且つ前記成形ランド部よりも小径の逃げ部と、を有する冷間後方押出鍛造用パンチを用い、
金属素材を冷間後方押出鍛造して有底円筒状鍛造品を成形する有底円筒状鍛造品の製造方法であって、
前記素材は、ロックウェル硬さHRFが65~105の範囲内のものであり、
前記パンチの成形R部の曲率半径は、前記鍛造品の円筒状周壁部の肉厚よりも大きく設定されており、
前記パンチの成形ランド部の長さは、0.05~0.15mmの範囲内に設定され、
前記パンチの逃げ部の成形ランド部に対する逃げ幅は、0.15~1.0mmの範囲内に設定されている有底円筒状鍛造品の製造方法。
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EP11851026.2A EP2656942A4 (en) | 2010-12-20 | 2011-12-19 | Punch for cold backward extrusion forging |
KR1020137015831A KR101511884B1 (ko) | 2010-12-20 | 2011-12-19 | 냉간 후방 압출 단조용 펀치, 냉간 후방 압출 단조 장치, 브레이크 피스톤용 소형재의 제조 방법, 브레이크 피스톤의 제조 방법 및 바닥이 있는 원통 형상 단조품의 제조 방법 |
SG2013047642A SG191747A1 (en) | 2010-12-20 | 2011-12-19 | Punch for cold backward extrusion forging |
CN201180061443.6A CN103415360B (zh) | 2010-12-20 | 2011-12-19 | 向后冷挤压锻造用冲头和锻造装置 |
JP2012549791A JP5808341B2 (ja) | 2010-12-20 | 2011-12-19 | 冷間後方押出鍛造用パンチ |
US13/995,546 US20130333813A1 (en) | 2010-12-20 | 2011-12-19 | Punch for cold backward extrusion forging |
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- 2011-12-19 SG SG2013047642A patent/SG191747A1/en unknown
- 2011-12-19 MY MYPI2013701041A patent/MY159001A/en unknown
- 2011-12-19 US US13/995,546 patent/US20130333813A1/en not_active Abandoned
- 2011-12-19 WO PCT/JP2011/079319 patent/WO2012086573A1/ja active Application Filing
- 2011-12-19 JP JP2012549791A patent/JP5808341B2/ja not_active Expired - Fee Related
- 2011-12-19 KR KR1020137015831A patent/KR101511884B1/ko active IP Right Grant
- 2011-12-19 EP EP11851026.2A patent/EP2656942A4/en not_active Withdrawn
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2020001084A (ja) * | 2018-06-29 | 2020-01-09 | 富士ゼロックス株式会社 | インパクトプレス装置、製造装置、及び製造方法 |
JP7159648B2 (ja) | 2018-06-29 | 2022-10-25 | 富士フイルムビジネスイノベーション株式会社 | インパクトプレス装置、製造装置、及び製造方法 |
CN113976809A (zh) * | 2021-10-27 | 2022-01-28 | 通裕重工股份有限公司 | 确定风机主轴冲孔位置的装置、方法及风机主轴制作方法 |
CN115106396A (zh) * | 2022-07-20 | 2022-09-27 | 陕西长羽航空装备股份有限公司 | 一种钛合金深筒体的制坯装置及使用该装置的挤轧成型方法 |
Also Published As
Publication number | Publication date |
---|---|
CN103415360A (zh) | 2013-11-27 |
MY159001A (en) | 2016-11-30 |
EP2656942A1 (en) | 2013-10-30 |
JP5808341B2 (ja) | 2015-11-10 |
EP2656942A4 (en) | 2017-07-26 |
CN103415360B (zh) | 2015-11-25 |
JPWO2012086573A1 (ja) | 2014-05-22 |
SG191747A1 (en) | 2013-08-30 |
KR101511884B1 (ko) | 2015-04-13 |
US20130333813A1 (en) | 2013-12-19 |
KR20130087573A (ko) | 2013-08-06 |
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