WO2016114212A1 - 打抜き加工方法、打抜き加工装置、および積層鉄心の製造方法 - Google Patents
打抜き加工方法、打抜き加工装置、および積層鉄心の製造方法 Download PDFInfo
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- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
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- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/22—Notching the peripheries of circular blanks, e.g. laminations for dynamo-electric machines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
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- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
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- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
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- H01F1/14716—Fe-Ni based alloys in the form of sheets
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/16—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of sheets
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/061—Winding flat conductive wires or sheets
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- 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
- B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
- B21D43/28—Associations of cutting devices therewith
- B21D43/287—Devices for handling sheet or strip material
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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Definitions
- the punching apparatus is a punching apparatus provided with a mold and punched in a state where a plurality of electromagnetic steel sheets are overlapped, wherein the thickness of the electromagnetic steel sheet is 0.35 mm or less, Vickers hardness (test Force 1 kg) is 150 to 400, the average crystal grain size is 50 to 250 ⁇ m, the mold clearance is 7% or more of the minimum thickness among the plurality of electromagnetic steel plates, and the plurality of electromagnetic It is 7% or less of the total thickness of the steel sheet, and the pressure exerted on the electromagnetic steel sheet by the plate pressing of the mold is 0.10 MPa or more.
- the plate retainer 8 In order for the plate retainer 8 to perform the above function, it is sufficient that the plate retainer pressure is exerted on a local portion of the base material in the vicinity of the punch 4 being punched. However, since the force with which the plate presser 8 presses the workpiece with the general mold 3 is uniform over the entire surface of the presser plate (stripper plate) of the plate presser 8, the total value of the force acting on the plate presser 8 is determined by the plate. It is obtained by dividing by the area of the presser 8.
- Crystal grain size of magnetic steel sheet-average grain size 50-250 ⁇ m The crystal grain size is an important factor governing the magnetic properties of the non-oriented electrical steel sheet, and it is generally known that the larger the crystal grain size, the better the iron loss. However, little is known about the effect of the crystal grain size of the magnetic steel sheet subjected to punching on the deterioration of the magnetic properties of the iron core after punching (see Patent Documents 6 and 7).
- the accumulated amount of strain due to elasto-plastic deformation increases as the non-uniformity of mechanical properties inside the base material increases.
- the grain boundary portion and the inside of the crystal grain are distributed roughly, so in the punching process in a state where a plurality of steel plates are overlapped, the deterioration of iron loss becomes significant. Conceivable.
- crystal grain boundaries are densely distributed, so that deformation in the steel plate occurs uniformly, and deterioration of iron loss is suppressed.
- Si is an element that contributes to the reduction of iron loss by reducing the eddy current loss by increasing the specific resistance of steel. If this added amount (content) is less than 0.5% by mass ratio, even if other components (Al, Cr, etc.) are added, the Vickers hardness is increased to 150 or more without deterioration of the iron loss of the material. It is difficult to increase. Therefore, the Si content is limited to 0.5% or more. Further, when the Si content exceeds 6.6% by mass ratio, it is difficult to perform punching in a state where two or more sheets are overlapped due to embrittlement of the base material. The content is limited to 0.5 to 6.6%.
- Mn increases the specific resistance of steel and has the effect of preventing red heat embrittlement during hot rolling. Moreover, Mn forms MnS in steel and contributes to the improvement of punching workability as will be described later. In order to obtain these effects, the Mn content needs to be 0.1% or more by mass ratio. Further, if the Mn content exceeds 3.0% by mass ratio, the magnetic flux density is significantly reduced. Therefore, the Mn content is limited to 0.1 to 3.0% by mass ratio.
- the particle size and number of inclusions were limited to the above ranges.
- a method for integrating a plurality of core pieces a method of caulking inside the mold 3 using the lowering by the punch 4 after the core pieces are cut from the base material after punching inside the mold 3 (So-called in-mold caulking).
- This method is excellent in terms of manufacturability.
- only a punching process is performed inside the mold 3, and a plurality of core pieces may be integrated by welding, fixing with bolts, applying an adhesive, or applying an adhesive coating outside the mold 3. .
- a method of applying an adhesive to the surface of the electromagnetic steel sheet and punching out while bonding the core pieces can also be applied to the present invention.
- the clearance (one side) a at the time of punching was changed in the range of 2 to 15% with respect to the total thickness of 0.50 mm of the two electromagnetic steel sheets. Further, the pressure (plate pressing pressure) applied by the plate presser 8 to the electromagnetic steel plate in the mold 3 was changed in the range of 0.05 to 1.0 MPa.
- the Vickers hardness (test force 1 kg) of the used magnetic steel sheet was 195, the average crystal grain size was 80 ⁇ m, the coefficient of static friction between the steel sheets was 0.2, and the distance between the steel sheet and the mold 3 (plate retainer 8, die plate 7). The static friction coefficient was 0.25.
- a primary coil b1 for excitation and a secondary coil b2 for magnetic flux measurement are wound around the core back portion to form a magnetic circuit. Then, magnetic core measurement was performed to evaluate core iron loss. Table 1 shows the above conditions and the evaluation results of the core iron loss.
- FIG. 4 is a diagram showing the relationship between the clearance a of the die 3 for punching and the iron loss deterioration rate represented by the above formula (1).
- the iron loss deterioration rate is suppressed as the clearance a decreases.
- the iron loss deterioration rate is remarkably reduced when the clearance a is set to 3.5 to 7% of the total thickness of the two electromagnetic steel sheets.
- the iron loss deterioration rate was higher than in the case of single punching, and problems remained in the future.
- FIG. 5 is a diagram showing the relationship between the plate pressing pressure and the iron loss deterioration rate.
- the iron loss deterioration rate hardly depends on the plate pressing pressure.
- the iron loss deterioration rate is reduced when the plate pressing pressure is controlled to be in the range of 0.10 MPa or more (preferably 0.30 to 0.80 MPa).
- Example 2 As a base steel sheet, electromagnetic steel sheet coils having thicknesses of 0.35 mm, 0.25 mm, 0.20 mm, and 0.15 mm with different crystal grain sizes by changing the contents of Si, Al, Mn, and P in the steel are 160 mm. A steel strip coil for punching with slits in the width was prepared. Among them, the two steel strip coils (C1, C2) with different combinations were simultaneously punched using the punching apparatus 10 shown in FIG. The outer peripheral part of the punched iron core piece was welded to manufacture a stator core (motor core) for a brushless DC motor. The clearance (one side) a at the time of punching was 25 ⁇ m (5% of the total thickness of the two sheets), and the pressure (plate pressing pressure) applied to the material in the mold 3 by the plate pressing 8 was 0.35 MPa.
- a motor core having the same dimensions as the present example (invention example) was produced by wire cutting (processing method: wire cutting).
- the iron loss (core iron loss) of the manufactured motor core was evaluated by simple magnetic measurement using the magnetic circuit shown in FIG. Table 2 shows the above conditions and the evaluation results of the core iron loss.
- FIG. 6 is a diagram showing the relationship between the hardness of the electrical steel sheet and the iron loss deterioration rate of the motor core.
- FIG. 7 is a figure which shows the relationship between the crystal grain diameter of an electromagnetic steel plate, and the iron loss deterioration rate of a motor core.
- the iron loss deterioration rate in FIGS. 6 and 7 is an increase rate of the iron loss (core iron loss) of the motor core of the present embodiment with respect to the iron loss (wire cut core iron loss) of the motor core manufactured by wire cutting. means.
- the plate thickness is 0.25 mm, 0.20 mm,. It was found that the iron loss deterioration rate when punching two sheets was reduced when the thickness was 15 mm. From this, it can be said that it is advantageous to use a magnetic steel sheet having a thickness of 0.25 mm or less in applying the technique of the present invention.
- the clearance a is set to 7% or more of the minimum thickness and 7% or less of the total thickness. It was found that the increase in iron loss due to the is suppressed.
- the static friction coefficient of the surface of the electromagnetic steel sheet coil having a thickness of 0.10 mm was changed.
- the static friction coefficient was changed by changing the composition of the chromic acid-resin coating (resin blending ratio, amount of added wax).
- Three steel strip coils (C1 to C3) having a width of 160 mm were prepared from such electromagnetic steel sheet coils. Using the punching apparatus 10 shown in FIG. 1, three sheets were punched simultaneously (processing method: punching).
- the punched iron core piece was caulked in the mold 3 to produce a stator core (motor core) for a brushless DC motor.
- the clearance (one side) a during punching was 15 ⁇ m (4.3% of the total plate thickness of 0.35 mm), and the plate pressing pressure was 0.06 to 0.5 MPa.
- the roughness of the portion of the die plate 7 that contacts the electromagnetic steel plate (mold surface 1) and the portion of the plate retainer 8 that contacts the electromagnetic steel plate (mold surface 2) is changed.
- the coefficient of static friction between the mold 3 and the electromagnetic steel sheet was changed.
- a motor core having the same dimensions as this example (invention example) was produced by wire cutting (processing method: wire cutting).
- the iron loss (core iron loss) of the manufactured motor core was evaluated by simple magnetic measurement using the magnetic circuit shown in FIG. Table 3 shows the above conditions and the evaluation results of the core iron loss.
- FIG. 8 is a graph showing the relationship between the coefficient of static friction between steel plates and the iron core deterioration rate of the motor core.
- Table 3 and FIG. 8 in this example, because three steel sheets are punched simultaneously, the iron loss deterioration rate is larger than when punching two steel sheets at the same time, but by satisfying the requirements of the present invention, It was found that the iron loss deterioration rate for iron cores made by wire cutting was suppressed.
- iron loss is reduced by setting the coefficient of static friction between steel sheets to 0.3 or more and the coefficient of static friction between the steel sheet and the mold 3 in the range of 0.3 to 0.8. It was found that the rate was stably suppressed to 21% or less.
- Example 4 In manufacturing the steel slab, the size and number of inclusions in the steel were adjusted by adjusting the degassing time and molten steel reflux rate. Next, after adjusting the content of Si, Al, Mn and other elements by adjusting the components in the degassing process, continuous casting, hot rolling, hot-rolled sheet annealing / pickling, and cold rolling are performed. The plate thickness was 0.15 mm. Thereafter, a magnetic steel sheet coil was manufactured by finish annealing and coating application. Two steel strip coils (C1, C2) having a width of 160 mm were prepared from such electromagnetic steel sheet coils.
- the coating conditions were the same for all steel strip coils, the coefficient of static friction between the steel sheets was 0.4, and the coefficient of static friction between the steel sheet and the mold 3 (the surface in contact with the steel sheet) was 0.4.
- the coefficient of static friction between the steel sheet and the mold 3 was 0.4.
- the crystal grain size, hardness and the number of inclusions in the steel were investigated.
- the punched iron core piece was caulked in the mold 3 to produce a stator core (motor core) for a brushless DC motor.
- the clearance (one side) a at the time of punching was 12 ⁇ m (4% of the total thickness of the two steel plates), and the plate pressing pressure was 0.40 MPa.
- the ratio of the clearance a to the steel sheet having the minimum thickness is 8%, and the ratio of the clearance a to the total thickness is 4%.
- the iron loss (core iron loss) of the manufactured motor core was evaluated by simple magnetic measurement using the magnetic circuit shown in FIG. Table 4 shows the above conditions and the evaluation results of the core iron loss.
- the punching process of the present embodiment it is possible to minimize the iron loss deterioration of the iron core when performing the punching process by stacking a plurality of steel plates. Therefore, a laminated core for a high-efficiency rotating machine of a motor or a generator can be manufactured with high efficiency from a thin steel sheet.
- the punching method, the punching apparatus, and the method for manufacturing a laminated core according to the present invention are useful for punching a steel sheet used for an iron core and manufacturing a laminated core
- the magnetic steel sheet is suitable for a punching method, a punching apparatus, and a method for manufacturing a laminated core that can simultaneously punch a steel sheet with minimal deterioration of iron loss.
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- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Power Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Dispersion Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
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- Iron Core Of Rotating Electric Machines (AREA)
- Punching Or Piercing (AREA)
Abstract
Description
まず、図1を参照して本実施の形態の打抜き加工装置の構成および打抜き加工処理の概要について説明する。図1に示すように、打抜き加工装置10は、プレス機1とピンチロール2とを備える。プレス機1に設置される打抜き加工用の金型3は、パンチ4とダイ5とを備える。ダイ5には、成形すべき鉄心素片の形状に対応した形状の貫通孔であるダイホール6と、鋼板に接するダイプレート7とが形成されている。パンチ4は、図示しない制御装置により、ダイ5に対して昇降可能に構成される。ダイホール6に対応する位置に配置されたパンチ4がダイホール6に挿入されると、金型3に挟み込まれた鋼板がダイホール6の形状に従って剪断され打ち抜かれる。なお、パンチ4とダイ5との間には所定間隔の隙間(クリアランスa)が設定される。また、金型3は、板押さえ8を備え、打抜き加工の際に鋼板の端部付近をパンチ4側から押さえることにより、鋼板をダイプレート7に押しつけて拘束する。この板押さえ8には、例えば、ばね等の付勢手段9が設けられている。
本発明は、このように重ね合わせた複数の電磁鋼板(以下、鋼板とも記す)の打抜き加工に際して、積層鉄心(以下、鉄心とも記す)の磁気特性(鉄損)の劣化を抑止するものである。そのために、発明者らは、まず、打抜き加工の際、重ね合わせた(積層した)鋼板間の拘束力の影響に着目した。そして、発明者らは、金型3と被加工材料(鋼板)の両方の条件を同時に制御することで鋼板間の拘束力を高め、重ね合わせた状態での打抜き加工における磁気特性(鉄損)の劣化を最小限に抑制することが可能であると考え、本発明に至った。すなわち、複数枚重ね合わせた状態での剪断加工では、個々の鋼板同士は表面の摩擦を介して影響を及ぼし合っているが、通常の条件ではこのような摩擦力は打抜き加工による鉄損の劣化を防止するには不十分である。発明者らは、金型3と母材との条件を従来よりも厳密に制御することで、鋼板面間の摩擦力を適正に制御することが可能であると考えた。そこで、発明者らは、このような鋼板面間の摩擦力を利用した拘束力の向上のために、まず打抜き加工時の板押さえ8が鋼板に及ぼす力に着目し、さらに、鋼板面間の摩擦係数および鋼板と接する金型3の面との摩擦係数を適正な範囲に制御しようと考えた。
本実施の形態の打抜き加工処理は、上記の知見に基づいて規定された以下の要件を満たすものである。なお、本実施の形態では、上記式(1)におけるW0の加工方法にワイヤカット方式を採用した。
本実施の形態では、積層鉄心の母材として板厚0.35mm以下の電磁鋼板を使用する。板厚が0.35mmを超えて厚くなると、鉄心の生産効率向上のために複数枚同時に打抜き加工を行うメリットが小さくなる。また、2枚以上の鋼板の合計の板厚が過大となり、積層状態の鉄心の寸法精度を保つことが困難となるとともに、後述する他の要件で打ち抜くことによっても、必ずしも良好な磁気特性が得られなくなる。
一般に、打抜き加工においてクリアランスaが打抜き端部の形状に影響を及ぼすことが知られている。そのため、板厚に応じてクリアランスaを変更する必要がある。複数の鋼板を重ねて打ち抜く場合、クリアランスaの適正値に影響を与えうる因子として、重ね合わされた鋼板それぞれの板厚と複数の鋼板の板厚の合計値とがある。クリアランスaの適正値は、それぞれの寄与を考慮して規定する必要がある。
一般に、打抜き加工用の金型3の板押さえ8は、主として打抜き加工の際の被加工材の跳ね上がりを防止するために使用される。これに対し、本実施の形態では、板押さえ8は、鋼板を重ね合わせて打抜き加工を行う場合に、重ね合わされた鋼板の剪断加工が行われる端部付近の拘束力を増加させるために使用される。そのため、板押さえ8が鋼板に及ぼす圧力を十分確保することで、打抜き加工中の鋼板間の位置のずれや鋼板のダイホール6へ引き込まれる量が軽減され、鋼板の端部の変形量が低減される。その結果、鋼板の磁気特性の劣化が軽減される。そのためには、板押さえ8が鋼板に及ぼす圧力(板押さえ圧力)を少なくとも0.10MPaとする。板押さえ圧力が0.10MPaを下回ると、打抜き加工中に複数の鋼板同士の拘束力が低下し、打抜き加工中の端部の局所的なずれ量が増加して磁気特性が劣化する。
結晶粒径は無方向性電磁鋼板の磁気特性を支配する重要な因子であり、一般的に結晶粒径が大きいほど鉄損に優れることが知られている。しかしながら、打抜き加工が施される電磁鋼板の結晶粒径が打抜き後の鉄心の磁気特性の劣化に及ぼす影響についてはあまり知られていない(特許文献6,7参照)。
材料の硬度が上昇すると、伸びが小さくなり、剪断加工過程で被加工材の破断が早期に起こる。すると、ダイホール6に被加工材が引き込まれる量が小さくなり、加工端部付近の歪みの蓄積量が小さくなるため、鉄損の劣化が抑止されると考えられる。前述のように、複数の鋼板を重ね合わせた状態での打抜き加工では、ダイホール6へ被加工材(鋼板)が引き込まれる量が増加しやすいため、被加工材の破断を適正に制御することの重要度が、通常の打抜き加工の際と比べて格段に高くなる。
前述のように、本発明では、重ね合わされた複数の鋼板を同時に打ち抜く際に、鋼板間の拘束力を高めることにより得られる効果を利用する。このような効果は、鋼板表面の静摩擦係数を高めることにより得られる。すなわち、重ね合わされて打抜き加工が行われる電磁鋼板の面同士の静摩擦係数を制御する必要がある。異なる電磁鋼板を用いる場合には、電磁鋼板の重ね合わされる面同士で静摩擦係数を評価するのがよい。
本実施の形態では、後述する実施例4に基づいて、鉄心の母材である電磁鋼板の鋼成分として、Si,Al,Mnの含有量を、質量比率でそれぞれ0.5~6.6%、2.5%以下、0.1~3.0%とする。これにより、材料のビッカース硬度150以上を満足する素地がつくられるとともに、鋼中の介在物の形成が促進される。ここで、ビッカース硬度による効果については上記のとおりである。また、鋼中介在物の効果については後述する。
本実施の形態では、複数の鋼板を重ね合わせた状態で打抜き加工を行う場合に、上記の要件に加え、後述する実施例4に基づいて、鋼中の粒径0.1~3.0μmの介在物の個数を1000~8000個/mm2とする。これにより、打抜き加工後の鉄心の鉄損が低減される。これは、上記の鋼板の硬度についての考察と同様に、打抜き加工中に鋼板がダイホール6中に引き込まれつつ破断する際、介在物が亀裂発生の基点となって鋼板の破断が打抜き加工過程の早期に起こり、打抜き加工後の鉄心に残留する歪みの量が低下するからである。
以上の要件を満たす打抜き加工処理により得られた鉄心素片を積層し、一体化させることで、モータ・発電機用の積層鉄心を製造する。
以下、本発明の実施例について説明する。なお、以下に示す実施例のうち、本発明の要件を満足するものは本発明例であり、満足しないものは比較例である。
母材鋼板として、鋼中に質量比でSi:3.0%、Al:0.8%、Mn:0.7%、P:0.03%を含有する板厚が0.25mmの電磁鋼板コイルを160mm幅にスリット加工した打抜き加工用の鋼帯コイル2本を用意した。図1に示した打抜き加工装置10を用いて、この2枚の鋼帯コイル(C1,C2)に対して同時に打抜き加工を行った(加工方法:2枚重ね打抜き)。打抜かれた鉄心素片に金型3内でカシメを施して、図2に示すブラシレスDCモータ用固定子鉄心(モータコア)を製造した。
母材鋼板として、鋼中のSi,Al,Mn,Pの含有量を変えて結晶粒径が異なる板厚0.35mm、0.25mm、0.20mm、0.15mmの電磁鋼板コイルを、160mm幅にスリット加工した打抜き加工用の鋼帯コイルを用意した。そのうち、組み合わせを変えた2枚の鋼帯コイル(C1,C2)に対して、図1に示した打抜き加工装置10を用いて、同時に打抜き加工を行った。打ち抜かれた鉄心素片の外周部を溶接して、ブラシレスDCモータ用固定子鉄心(モータコア)を製造した。打抜き加工の際のクリアランス(片側)aは25μm(2枚合計の板厚の5%)、板押さえ8が金型3内の材料に与える圧力(板押さえ圧力)は0.35MPaとした。
鋼中に質量比率でSi:3.0%,Al:0.8%,Mn:0.7%,P:0.03%を含有するビッカース硬度(1kg加重測定)195、結晶粒径100μm、板厚0.10mmの電磁鋼板コイルの表面の静摩擦係数を変化させた。静摩擦係数は、クロム酸-樹脂系コーティングの組成(樹脂配合率、ワックス添加量)を変化させることにより変化させた。このような電磁鋼板コイルから160mm幅の鋼帯コイル3本(C1~C3)を用意した。図1に示した打抜き加工装置10を用いて、3枚同時に打抜き加工を行った(加工方法:打抜き)。打抜かれた鉄心素片に金型3内でカシメを施して、ブラシレスDCモータ用固定子鉄心(モータコア)を製造した。打抜き加工の際のクリアランス(片側)aは15μm(合計の板厚0.35mmの4.3%)、板押さえ圧力は0.06~0.5MPaとした。
鋼スラブを製造するにあたり脱ガス処理の時間および溶鋼還流速度の調整により鋼中の介在物の大きさと個数とを調整した。ついで、脱ガス処理工程での成分調整により、Si,Al,Mn,その他の元素の含有量を調整した後、連続鋳造、熱間圧延、熱延板焼鈍・酸洗、冷間圧延を行って、板厚を0.15mmとした。その後、仕上げ焼鈍、コーティング塗布により電磁鋼板コイルを製造した。このような電磁鋼板コイルから160mm幅の鋼帯コイル2本(C1,C2)を用意した。
2 ピンチロール
3 金型
4 パンチ
5 ダイ
6 ダイホール
7 ダイプレート
8 板押さえ
9 付勢手段
10 打抜き加工装置
a クリアランス
C 鋼帯コイル(電磁鋼板)
Claims (6)
- 複数の電磁鋼板を重ね合わせた状態で、金型で打ち抜く打抜き加工方法であって、
前記電磁鋼板の板厚を0.35mm以下、ビッカース硬度(試験力1kg)を150~400、平均結晶粒径を50~250μmとし、
前記金型のクリアランスを、前記複数の電磁鋼板の板厚のうち最小の板厚の7%以上、かつ前記複数の電磁鋼板の板厚の合計の7%以下とし、
前記金型の板押さえが前記電磁鋼板に及ぼす圧力を0.10MPa以上とすることを特徴とする打抜き加工方法。 - 前記電磁鋼板の板厚を0.25mm以下とすることを特徴とする請求項1に記載の打抜き加工方法。
- 重ね合わせた前記電磁鋼板の面間の静摩擦係数を0.3以上とし、前記電磁鋼板と該電磁鋼板と接する前記金型のダイプレートの表面、および前記電磁鋼板と前記金型の板押さえの表面との間の静摩擦係数を0.3~0.8とすることを特徴とする請求項1または2に記載の打抜き加工方法。
- 前記電磁鋼板に、質量比率で、Si:0.5~6.6%、Al:2.5%以下、Mn:0.1~3.0%を含有させ、結晶粒径0.1~3.0μmの鋼中の介在物の個数を1000~8000個/mm2の範囲とすることを特徴とする請求項1~3のうちいずれか1項に記載の打抜き加工方法。
- 金型を備え、複数の電磁鋼板を重ね合わせた状態で打ち抜く打抜き加工装置であって、
前記電磁鋼板の板厚が0.35mm以下、ビッカース硬度(試験力1kg)が150~400、平均結晶粒径が50~250μmであり、
前記金型のクリアランスが、前記複数の電磁鋼板の板厚のうち最小の板厚の7%以上、かつ前記複数の電磁鋼板の板厚の合計の7%以下であり、
前記金型の板押さえが前記電磁鋼板に及ぼす圧力が0.10MPa以上であることを特徴とする打抜き加工装置。 - 請求項1~4のうちいずれか1項に記載の打抜き加工方法を用いて打ち抜かれた鉄心素片を積層し一体化させることにより積層鉄心を製造することを特徴とする積層鉄心の製造方法。
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JP5958565B2 (ja) | 2016-08-02 |
CA2973670A1 (en) | 2016-07-21 |
US20180001369A1 (en) | 2018-01-04 |
TW201637805A (zh) | 2016-11-01 |
EP3246105B1 (en) | 2020-11-18 |
TWI574809B (zh) | 2017-03-21 |
KR20170094287A (ko) | 2017-08-17 |
EP3246105A4 (en) | 2017-11-22 |
JP2016129902A (ja) | 2016-07-21 |
RU2678622C1 (ru) | 2019-01-30 |
CA2973670C (en) | 2019-06-04 |
EP3246105A1 (en) | 2017-11-22 |
US10919081B2 (en) | 2021-02-16 |
CN107206457B (zh) | 2019-11-05 |
MX2017009202A (es) | 2017-11-17 |
KR101996158B1 (ko) | 2019-07-03 |
CN107206457A (zh) | 2017-09-26 |
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