WO2019039199A1 - 鍛造クランク軸の製造方法 - Google Patents
鍛造クランク軸の製造方法 Download PDFInfo
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- WO2019039199A1 WO2019039199A1 PCT/JP2018/028443 JP2018028443W WO2019039199A1 WO 2019039199 A1 WO2019039199 A1 WO 2019039199A1 JP 2018028443 W JP2018028443 W JP 2018028443W WO 2019039199 A1 WO2019039199 A1 WO 2019039199A1
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- mold
- pin
- journal
- forged crankshaft
- arm
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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
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
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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
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
- B21J5/025—Closed die forging
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- 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
- B21K1/06—Making machine elements axles or shafts
- B21K1/08—Making machine elements axles or shafts crankshafts
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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
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C3/00—Shafts; Axles; Cranks; Eccentrics
- F16C3/04—Crankshafts, eccentric-shafts; Cranks, eccentrics
- F16C3/06—Crankshafts
Definitions
- the present invention relates to a method of manufacturing a crankshaft by hot forging.
- crankshaft In reciprocating engines such as automobiles, motorcycles, agricultural machines or ships, a crankshaft is essential to convert the reciprocating motion of the piston into rotational motion and extract power.
- the crankshaft can be manufactured by die forging or casting.
- a crankshaft manufactured by die forging hereinafter, also referred to as "forged crankshaft" is often used.
- FIG. 1A and 1B are schematic views showing an example of the general shape of a general forged crankshaft.
- FIG. 1A is a general view
- FIG. 1B is a cross-sectional view taken along line IB-IB of FIG. 1A.
- the example shown in FIG. 1B representatively shows one crank arm A7, a counterweight W7 integral with the crank arm A7, and a pin P4 and a journal J4 connected to the crank arm A7.
- the forged crankshaft 11 shown in FIGS. 1A and 1B is a forged crankshaft of four-cylinder eight-piece counterweight mounted on a four-cylinder engine.
- the forged crankshaft 11 has five journal portions J1 to J5, four pin portions P1 to P4, a front portion Fr, a flange portion Fl, and eight crank arm portions (hereinafter also referred to as "arm portions").
- A1 to A8 are provided.
- the arm parts A1 to A8 respectively connect the journal parts J1 to J5 and the pin parts P1 to P4.
- the eight (all) arm portions A1 to A8 integrally include counterweight portions (hereinafter also referred to as "weight portions”) W1 to W8.
- a front portion Fr is provided at the front end in the axial direction of the forged crankshaft 11, and a flange portion Fl is provided at the rear end.
- the front part Fr is connected to the leading first journal part J1
- the flange part Fl is connected to the trailing fifth journal part J5.
- the reference numerals are “J” in the journal and “P” in the pins. Also described as “A” in the arm part and “W” in the weight part. Further, the arm portion A and the weight portion W integral with the arm portion A are collectively referred to as "web".
- the width Bw of the weight portion W is larger than the width Ba of the arm portion A. For this reason, the weight portion W protrudes largely from the arm central surface (a surface including the central axis of the pin portion P and the central axis of the journal portion J).
- a billet is generally used as a starting material.
- the cross section perpendicular to the longitudinal direction of the billet i.e. the cross section, is round or square.
- the area of the cross section is constant over the entire length of the billet.
- the “cross section” means a cross section perpendicular to the longitudinal direction of the billet or each of the rough surfaces described later or the forged crankshaft.
- Longitudinal section means a section parallel to its longitudinal direction or its axial direction.
- the area of the cross section is simply referred to as "cross-sectional area”.
- the forged crankshaft is manufactured by sequentially performing a preforming process, a die forging process and a deburring process. In addition, if necessary, a deburring process is followed by a shaping process.
- the preforming process includes the steps of roll forming and bending.
- the die forging process includes the steps of roughing and finishing.
- FIGS. 2A to 2F are schematic views for explaining a manufacturing process of a conventional general forged crankshaft.
- FIG. 2A shows a billet.
- FIG. 2B shows a roll wasteland.
- FIG. 2C shows a bending waste.
- FIG. 2D shows a rough forged material.
- FIG. 2E shows a finish forged material.
- FIG. 2F shows a forged crankshaft.
- 2A to 2F show a series of steps in the case of manufacturing the forged crankshaft 11 having the shape shown in FIGS. 1A and 1B.
- a method of manufacturing the forged crankshaft 11 will be described with reference to FIGS. 2A to 2F.
- roll forming and bending are performed in that order in a preliminary forming process.
- the billet 12 is rolled and squeezed using, for example, a hole type roll.
- the volume of the billet 12 is distributed in the axial direction to obtain a roll stock 13 as an intermediate material (see FIG. 2B).
- the roll stock 13 is partially pressed from a direction perpendicular to the axial direction.
- the volume of the roll waste 13 is distributed, and the bending waste 14 which is a further intermediate material is obtained (see FIG. 2C).
- a rough forged material 15 is obtained by forging the bending rough 14 up and down using a pair of molds (see FIG. 2D).
- the rough forging material 15 is shaped into an approximate shape of a forged crankshaft (final product).
- the forged material 16 is obtained by forging the rough forging material 15 up and down using a pair of molds (see FIG. 2E).
- the finish forging 16 is shaped to match the forged crankshaft of the final product.
- the excess material flows out from between the mold split surfaces of the molds facing each other, and the excess material becomes burrs B. For this reason, the rough forgings 15 and the finish forgings 16 both have a large amount of burrs B around.
- the burr B is punched out with a blade type in a state in which the finish forged material 16 with burrs is sandwiched and held by a pair of dies. Thereby, the burrs B are removed from the finish forged material 16, and a burrless forged material is obtained.
- the burrless forged material has substantially the same shape as the forged crankshaft 11 shown in FIG. 2F.
- the burr-free forging material In the shaping process, a key portion of the burr-free forging material is slightly pressed down from above and below by a mold, and the burr-free forging material is corrected to the dimensional shape and shape of the final product.
- the important points of the burr-free forging material are, for example, shaft portions such as the journal portion J, the pin portion P, the front portion Fr, the flange portion Fl, etc., and further the arm portion A and the weight portion W.
- the forged crankshaft 11 is manufactured.
- FIGS. 2A to 2F can be applied to various forged crankshafts as well as the forged crankshafts of four-cylinder and eight-piece counterweights shown in FIGS. 1A and 1B. For example, it can be applied to forged crankshafts of four cylinders and four counterweights.
- some of the eight arm portions A1 to A8 have the weight portion W integrally.
- the remaining arm parts specifically, the second, third, sixth and seventh arm parts (A2, A3, A6 and A7) do not have weight parts, and the shape is an oval shape and the like. Become.
- the manufacturing process is the same even if it is a forged crankshaft mounted on a 3-cylinder engine, in-line 6-cylinder engine, V-type 6-cylinder engine, 8-cylinder engine or the like.
- a twisting process is added after a burr removal process.
- the main purpose of the preforming process is to distribute the billet volume.
- the material yield means the ratio (percentage) of the volume of the forged crankshaft (final product) to the volume of the billet.
- the wasteland obtained by the pre-forming is formed on the forged crankshaft in the die forging process of the post process.
- Patent Document 1 discloses a preforming method using a pair of upper mold and lower mold. In the preforming method, when a bar-like workpiece is pressed down by the upper and lower dies, a portion of the workpiece is extended and a portion continuous with the portion is offset with respect to the axial center. Thereby, in patent document 1, since extending and bending can be implemented simultaneously, it is supposed that equipment investment can be reduced.
- Patent Document 2 uses a 4-pass high-speed roll facility instead of the conventional 2-pass roll forming.
- the cross-sectional area of the roll stock is determined in accordance with the distribution of the cross-sectional area of the weight portion, the arm portion and the journal portion of the forged crankshaft (final product).
- the material yield can be improved.
- Patent Document 3 distributes the volume of a part of the billet in the axial direction and the radial direction of the billet by rolling. By forging the volume-allocated billet, a forged crankshaft is obtained. Thus, in Patent Document 3, the material yield can be improved.
- a billet is formed on a forged crankshaft by one-time die forging using a pair of upper die, lower die, and punch.
- the die forging step first, an area to be a journal portion and an area to be a pin portion of the billet are pressed down by punches that are operated separately. The pressure causes the billet volume to be distributed. Thereafter, die forging is performed by the upper die and the lower die. That is, preforming and die forging can be performed in one step.
- it is supposed that the forged crankshaft of complicated shape can be efficiently manufactured by single installation.
- Patent Document 3 requires equipment for performing rolling. As a result, the equipment cost is high, and it is difficult to improve the production efficiency.
- An object of the present invention is to provide a method of manufacturing a forged crankshaft capable of forming a forged crankshaft with a precise shape and improving the material yield.
- the manufacturing method of the forged crankshaft according to the present embodiment includes: a plurality of journals as a rotation center; a plurality of pins eccentric to the journals; and a plurality of crank arms connecting the journals and the pins. It is a manufacturing method of a forged crankshaft provided.
- a first preforming step of obtaining an initial wasteland from a billet a second preforming step of obtaining a final wasteland from the initial wasteland, and forging a final wasteland by at least one die forging And a finish forging step of forming the finished dimensions of the crankshaft.
- the cross-sectional area of each portion is reduced by pressing down the portion to be the pin portion of the billet and the portion to be the journal portion from the direction perpendicular to the axial direction of the billet. Form a flat part.
- the width direction of the flat portion is the pressure reduction direction to reduce the portions to be the plurality of journals, and after the start of the pressure reduction by the first mold, And (2) using a mold and making the width direction of the flat portion eccentrically to eccentrically move the portions to be a plurality of pin portions.
- the thickness of a portion to be a plurality of crank arms is the same as the thickness of the finished dimension.
- the manufacturing method of the forged crankshaft according to the embodiment of the present invention can obtain the final waste with the axial volume distribution promoted by the first preforming step and the second preforming step.
- the volume of the portion to be the journal, the volume of the portion to be the pin, and the volume of the portion to be the arm are properly distributed.
- the finish forging process can shape the shape of the forged crankshaft from the final waste area. From these, material yield can be improved.
- FIG. 1A is a schematic view showing an example of the general shape of a general forged crankshaft.
- FIG. 1B is a cross-sectional view taken along line IB-IB of FIG. 1A.
- FIG. 2A is a schematic view showing a billet in the conventional manufacturing process.
- FIG. 2B is a schematic view showing a roll waste in a conventional manufacturing process.
- FIG. 2C is a schematic view showing a bending waste in a conventional manufacturing process.
- FIG. 2D is a schematic view showing a rough forged material in the conventional manufacturing process.
- FIG. 2E is a schematic view showing a finish forged material in the conventional manufacturing process.
- FIG. 2F is a schematic view showing a forged crankshaft in a conventional manufacturing process.
- FIG. 1A is a schematic view showing an example of the general shape of a general forged crankshaft.
- FIG. 1B is a cross-sectional view taken along line IB-IB of FIG. 1A.
- FIG. 3A is a schematic view showing a billet in the example of the manufacturing process of the present embodiment.
- FIG. 3B is a schematic view showing an initial waste land in the example of the manufacturing process of the present embodiment.
- FIG. 3C is a schematic view showing the final waste land in the example of the manufacturing process of the present embodiment.
- FIG. 3D is a schematic view showing a finish forged material in the example of the manufacturing process of the present embodiment.
- FIG. 3E is a schematic view showing a forged crankshaft in the example of the manufacturing process of the present embodiment.
- FIG. 4A is a longitudinal cross-sectional view schematically showing a state before reduction in a processing flow example of the first preliminary forming step.
- FIG. 4A is a longitudinal cross-sectional view schematically showing a state before reduction in a processing flow example of the first preliminary forming step.
- FIG. 4B is a longitudinal cross-sectional view schematically showing the condition at the end of rolling in the example of the processing flow of the first preliminary forming step.
- FIG. 5A is a cross-sectional view showing a portion to be a journal portion before rolling in a processing flow example of the first preforming step.
- FIG. 5B is a cross-sectional view showing a portion to be a journal at the end of rolling in the example of the processing flow of the first preforming step.
- FIG. 6A is a cross-sectional view showing a portion to be a pin portion before rolling in a processing flow example of the first preforming step.
- FIG. 6B is a cross-sectional view showing a portion to be a pin portion at the end of rolling in the processing flow example of the first preliminary forming step.
- FIG. 7A is a cross-sectional view showing an arm equivalent portion before reduction in an example of a processing flow of the first preforming step.
- FIG. 7B is a cross-sectional view showing the arm equivalent portion at the end of rolling in the example of the processing flow of the first preforming step.
- FIG. 8 is a longitudinal cross-sectional view showing the case where the second preforming step is performed with one mold.
- FIG. 9 is a longitudinal sectional view showing a first mold and a second mold of the present embodiment.
- FIG. 10 is a longitudinal cross-sectional view showing the first mold and the second mold of the present embodiment different from FIG. 9.
- FIG. 11A is a longitudinal cross-sectional view showing the situation at the start of the pressing process in the processing flow example of the second preliminary forming process.
- FIG. 11B is a longitudinal cross-sectional view showing the condition at the end of the pressing process in the processing flow example of the second preliminary forming process.
- FIG. 11C is a longitudinal cross-sectional view showing the condition at the end of the eccentricity step in the processing flow example of the second preliminary forming step.
- FIG. 12A is a cross-sectional view showing a portion to be an arm at the start of the pressing process in the example of the processing flow of the second preforming process.
- FIG. 12B is a cross-sectional view showing a portion to be an arm at the end of the pressing process in the processing flow example of the second preliminary forming process.
- FIG. 12A is a cross-sectional view showing a portion to be an arm at the start of the pressing process in the example of the processing flow of the second preforming process.
- FIG. 12B is a cross-sectional view showing a portion to be an arm at the end of the pressing process in the processing flow example of the second preliminary forming process.
- FIG. 13A is a cross-sectional view showing a portion to be a journal at the start of the pressing process in the processing flow example of the second preliminary forming process.
- FIG. 13B is a cross-sectional view showing a portion to be a journal at the end of the pressing process in the processing flow example of the second preliminary forming process.
- FIG. 14A is a cross-sectional view showing a portion to be a pin portion at the start of the eccentricity process in the example of the processing flow of the second preliminary forming process.
- FIG. 14B is a cross-sectional view showing a portion to be a pin portion at the end of the eccentricity step in the example of the processing flow of the second preliminary forming step.
- the manufacturing method of the forged crankshaft according to the present embodiment includes: a plurality of journals as a rotation center; a plurality of pins eccentric to the journals; and a plurality of crank arms connecting the journals and the pins. It is a manufacturing method of a forged crankshaft provided.
- a first preforming step of obtaining an initial wasteland from a billet a second preforming step of obtaining a final wasteland from the initial wasteland, and forging a final wasteland by at least one die forging And a finish forging step of forming the finished dimensions of the crankshaft.
- the cross-sectional area of each portion is reduced by pressing down the portion to be the pin portion of the billet and the portion to be the journal portion from the direction perpendicular to the axial direction of the billet. Form a flat part.
- the width direction of the flat portion is the pressure reduction direction to reduce the portions to be the plurality of journals, and after the start of the pressure reduction by the first mold, And (2) using a mold and making the width direction of the flat portion eccentrically to eccentrically move the portions to be a plurality of pin portions.
- the thickness of a portion to be a plurality of crank arms is the same as the thickness of the finished dimension.
- the manufacturing method of the present embodiment it is possible to obtain the final waste land in which the distribution of the axial volume is promoted by the first preforming step and the second preforming step.
- the final waste land has a shape close to the shape of a forged crankshaft because the volume of the region to be the journal, the volume of the region to be the pin, and the volume of the region to be the arm are properly distributed. .
- the shape of the forged crankshaft can be formed from the final waste area by the finish forging process. From these, material yield can be improved.
- the portion to be the journal portion is pressed first, and the portion to be the pin portion can be decentered after the portion to be the journal portion is pressed. Therefore, it is difficult for the initial waste land to be curved during eccentricity of the portion to be the pin portion. Since the volume-distributed initial waste land is pressed down at a predetermined position of the first mold, it is difficult to cause scraps and the like in the final waste land after the pressing.
- the eccentricity of the portions to be the plurality of pin portions by the second mold is started.
- the amount of eccentricity of the portion to be the pin portion is equal to or smaller than the amount of eccentricity of the finished dimension.
- the forged crankshaft targeted by the manufacturing method of the present embodiment includes a plurality of journals J as rotation centers, a plurality of pins P eccentric with respect to the journals J, a journal J and pins And a plurality of arm parts A connecting P.
- a forged crankshaft of four cylinders and eight counterweights shown in FIGS. 1A and 1B is an object to be manufactured.
- all of the plurality of arm portions A integrally include the weight portion W.
- Forged crankshafts and the like of the aforementioned four-cylinder four-piece counterweight are also objects of manufacture.
- a part of the plurality of arm parts A integrally includes a weight part W. Further, not all the arm portions A may have the weight portion W.
- the shape of the arm portion not provided with the weight portion is oval.
- an arm part comprises a weight part "integrally" means that an arm part and a weight part are not separate components, but both are shape
- the manufacturing method of the present embodiment includes a first preforming step, a second preforming step, and a finish forging step.
- a deburring process may be added as a process after the finish forging process.
- a shaping process may be added after the deburring process.
- a twisting step may be added after the deburring step.
- FIG. 3A to 3E are schematic views for explaining an example of a manufacturing process of the forged crankshaft according to the present embodiment.
- FIG. 3A shows a billet.
- FIG. 3B shows the initial wasteland.
- FIG. 3C shows the final wasteland.
- FIG. 3D shows a finish forged material.
- FIG. 3E shows a forged crankshaft.
- 3A to 3E show a series of steps in the case of manufacturing the forged crankshaft 11 having the shape shown in FIG. 1A.
- a plurality of portions (hereinafter, also referred to as "pin equivalent portions”) to be a pin portion and a plurality of portions to be a journal portion (hereinafter, “journal equivalents”)
- the cross-sectional area is reduced in each of
- a plurality of flat portions 23 a are formed in the billet.
- the flat portion 23a is formed at the position of the pin equivalent portion and the journal equivalent portion.
- the flat portion 23a has a width Bf in the direction perpendicular to the rolling direction larger than the thickness ta in the rolling direction, as shown in FIGS. 5B and 6B described later.
- a reduce roll or a cross roll can be used in the first preforming step.
- the first pre-forming step can also be performed in accordance with an example of a processing flow using a third mold described later.
- the second preforming step includes a pressing step and an eccentric step.
- the pressing process the journal equivalent portion of the initial waste land 23 is pressed using a pair of first molds.
- the eccentric step after starting the pressure reduction by the first mold, the pin equivalent portion is eccentric using the second mold.
- the pressing direction and the eccentric direction are the width direction of the flat portion 23a. That is, in the second preforming step, the initial waste 23 obtained in the first preforming step is rotated by 90 ° and then pressed down. This provides a final waste area 24 in which the approximate shape of the forged crankshaft is shaped.
- the axial thickness t1 (see FIG. 3C) of the arm equivalent is the same as the thickness t0 (see FIG.
- the thickness t0 of the finished dimension means the axial thickness of the arm portion of the forged crankshaft (final product). Further, the eccentricity of the pin equivalent portion of the final waste area 24 is equal to or smaller than the eccentricity of the finished dimension.
- the eccentricity of the finishing dimension means the eccentricity of the pin portion of the forged crankshaft. Details of the second preforming step will be described later.
- a final forged area 24 is formed into a finished size of a forged crankshaft by die forging. Specifically, a pair of molds are used at the top and the bottom. The final waste land 24 is disposed above the lower mold in a posture in which the pin portions are aligned in the horizontal plane. Then, forging is performed by lowering the upper die. As a result, burrs B are formed as the excess material flows out, and a finished forged material 25 with burrs is obtained (see FIG. 3D). The finish forging 25 is shaped to match the forged crankshaft of the final product.
- the rough shape of the forged crankshaft is formed in the final waste area 24, so that the formation of burrs B can be minimized when the final waste area 24 is forged in the finish forging process.
- the finish forging process may be performed once or may be divided into multiple times.
- the burr B is punched out with a blade type in a state in which the finish forged material 25 with a burr is sandwiched and held by a pair of dies. Thereby, the burrs B are removed from the finish forged material 25. As a result, a forged crankshaft 11 (final product) is obtained.
- FIGS. 4A to 7B are schematic views showing an example of a processing flow of the first preforming step.
- FIG. 4A is a longitudinal cross-sectional view showing the situation before reduction
- FIG. 4B is a longitudinal cross-sectional view showing the situation at the end of reduction.
- FIG. 5A and 5B are cross sectional views showing the journal equivalent. Of these figures, FIG. 5A shows the situation before reduction, and FIG. 5B shows the situation at the end of reduction. 5A is a cross-sectional view taken along the line VA-VA of FIG. 4A, and FIG. 5B is a cross-sectional view taken along the line VB-VB of FIG. 4B.
- FIG. 6A and 6B are cross-sectional views showing the corresponding parts of the pins. Of these figures, FIG. 6A shows the situation before reduction and FIG. 6B shows the situation at the end of reduction. 6A is a cross-sectional view taken along line VIA-VIA in FIG. 4A, and FIG. 6B is a cross-sectional view taken along line VIB-VIB in FIG. 4B.
- FIG. 7A and 7B are cross-sectional views showing the arm equivalent. Of these figures, FIG. 7A shows the situation before reduction and FIG. 7B shows the situation at the end of reduction. 7A is a cross-sectional view taken along the line VIIA-VIIA in FIG. 4A, and FIG. 7B is a cross-sectional view taken along the line VIIB-VIIB in FIG. 4B.
- the third mold 30 includes a third upper die 31 and a third lower die 32.
- the third upper mold 31, the third lower mold 32, and the billet 22 before reduction are indicated by two-dot chain lines, and
- the axial center position C is indicated by a black circle.
- the pair of third molds 30 includes a pin processing portion that abuts on the pin equivalent portion and a journal processing portion that abuts on the journal equivalent portion.
- the journal processing unit is composed of an upper mold journal processing unit 31a and a lower mold journal processing unit 32a as shown by thick lines in FIG. 5A.
- the upper die journal processing unit 31 a is provided in the third upper die 31.
- the lower die journal processing unit 32 a is provided to the third lower die 32.
- the upper die journaling portion 31a is concave and can accommodate a billet.
- the lower die journal processing portion 32 a is provided on the tip end surface of the convex portion.
- type journal process part 32a is made into concave shape. That is, the lower die journalized portion 32a may be concave capable of accommodating the billet.
- the pin processing portion is composed of an upper mold pin processing portion 31b and a lower mold pin processing portion 32b, as shown by thick lines in FIG. 6A.
- the upper mold pin processing portion 31 b is provided to the third upper mold 31.
- the lower mold pin processing portion 32 b is provided to the third lower mold 32.
- the upper mold pin processing portion 31 b is concave and can accommodate a billet.
- the lower mold pin processing portion 32 b is provided on the tip end surface of the convex portion.
- the billet 22 is moved to the third upper die 31 with the third upper die 31 raised and the third upper die 31 and the third lower die 32 separated. Arranged between the third lower mold 32.
- the third upper die 31 is lowered from this state, the pin equivalent portion of the billet 22 is accommodated in the concave upper die pin processing portion 31b (refer to FIG. 6A), and the journal equivalent portion is the concave upper die journal processing portion 31a (see FIG. 5A).
- the billet is pressed down by the upper die pin processing portion 31b and the lower die pin processing portion 32b, and the upper die journal processing portion 31a and the lower die journal processing portion 32a. Cross sectional area decreases.
- the width Bf is larger than the thickness ta (see FIGS. 5B and 6B).
- the dimensions of the width Bf and the thickness ta of the flat portion 23a may be different between the journal equivalent part and the pin equivalent part.
- the material moves in the axial direction of the billet as the pin equivalent portion and the journal equivalent portion are pressed down. Thereby, the material flows into the arm equivalent between the pin equivalent and the journal equivalent. As a result, it is possible to obtain an initial waste area in which the volume is distributed in the axial direction.
- the opening of the concave upper mold pin processing portion 31b is closed by the lower mold pin processing portion 32b.
- a closed cross section is formed by the upper die pin processing portion 31 b and the lower die pin processing portion 32 b.
- the opening of the concave upper die journalizing portion 31a is closed by the lower die journaling portion 32a, and a closed cross section is formed by the upper die journaling portion 31a and the lower die journal milling portion 32a.
- the arm equivalent When a pair of third molds is used in the first pre-forming step, the arm equivalent may not be pressed by the third mold in order to promote the axial distribution of the volume (see FIGS. 7A and 7B). . Further, in order to adjust the shape (dimension) of the arm equivalent portion, the arm equivalent portion may be partially pressed by the third mold.
- FIG. 8 is a longitudinal cross-sectional view showing the case where the second preforming step is performed with one mold.
- the initial waste land 23 is disposed on the first lower die 42.
- the pin equivalent portion is decentered.
- the lower mold pin processing portion 42b of the first lower mold 42 for processing the pin equivalent portion of the initial waste land 23 protrudes more than the lower mold journal processing portion 42a. Therefore, when the initial rough surface 23 is arranged in the first lower mold 42, the initial rough surface 23 is supported at two points by the two lower mold pin processing portions 42b.
- the upper mold pin processing portion 41b of the first upper mold 41 is disposed closer to the end portion side of the initial rough surface 23 than the lower mold pin processing portion 42b.
- FIG. 9 is a longitudinal sectional view showing a first mold and a second mold of the present embodiment.
- the manufacturing apparatus of the present embodiment includes a first mold 40 and a second mold 50.
- the second mold 50 includes a second upper mold 51 and a second lower mold 52.
- the second mold 50 includes two second upper dies 51 and two second lower dies 52.
- the second upper mold 51 and the second lower mold 52 can move up and down independently of the first mold 40.
- the second lower mold 52 is disposed at the same height or lower than the lower mold journal processing portion 42a, and the second upper mold 51 is disposed at the same height or upper than the upper mold journal processing portion 41a. It is done.
- the second lower die 52 and the second upper die 51 do not project beyond the lower die journal processing portion 42a and the upper die journal processing portion 41a. Therefore, even if the initial rough surface 23 is arranged in the first lower mold 42 before the start of the reduction, the initial rough area 23 is not supported by the second lower mold 52.
- the initial wasteland 23 is supported by a plurality of lower die journaling portions 42a.
- the area in which the plurality of lower die journal processing portions 42a support the initial waste land 23 is larger than the area in which the second lower mold 52 supports the initial waste land.
- the eccentricity of the pin corresponding portion of the initial waste area 23 by the second lower die 52 of the second mold 50 is started.
- the eccentricity of the pin corresponding portion of the initial waste area 23 by the second upper mold 51 of the second mold 50 is started. Therefore, during eccentricity of the pin equivalent portion, the journal equivalent portion of the initial waste land 23 is pressed down by the upper die journal processing portion 41a and the lower die journal processing portion 42a.
- journal equivalent portion of the initial rough area 23 is restrained by the upper die journal processing unit 41a and the lower die journal processing unit 42a. Therefore, during the eccentricity of the pin equivalent portion, the initial rough surface 23 is difficult to move and is pressed at a predetermined position.
- the second upper die 51 and the second lower die 52 move up and down independently, and the journal equivalent portion of the initial wasteland 23 is pushed down prior to the pin equivalent portion, so that the eccentricity of the pin equivalent portion is being performed.
- the land 23 is hard to bend. Since the volume-distributed initial waste 23 is pressed at a predetermined position of the first mold 40, it is difficult to cause a defect or the like in the final waste after pressing.
- the configuration of the first mold 40 and the second mold 50 will be described.
- the second mold 50 includes a control mechanism to raise and lower the second upper mold 51 and the second lower mold 52 independently.
- the control mechanism is, for example, a die cushion or a hydraulic cylinder.
- the first lower mold 42 is supported by the bolster base 82 via the die cushion 81.
- the die cushion 81 has a buffer function.
- the second lower mold 52 is supported by the bolster base 82 via the pin base 83.
- the die cushion 81 is set such that the second lower die 52 contacts the pin equivalent portion of the initial wasteland 23 after the upper die journal processing portion 41a and the lower die journal processing portion 42a contact the journal equivalent portion of the initial wasteland 23 Be done.
- the pin equivalent portion of the initial waste land 23 is decentered after the start of rolling of the journal equivalent portion.
- FIG. 10 is a longitudinal cross-sectional view showing the first mold and the second mold of the present embodiment different from FIG. 9.
- the hydraulic cylinder 84 can raise and lower the second lower mold 52.
- the second lower die 52 is supported by the bolster base 82 via a hydraulic cylinder 84.
- the hydraulic cylinder 84 is set so that the second lower die 52 contacts the pin equivalent portion of the initial wasteland 23 after the upper die journal processing portion 41a and the lower die journaling portion 42a contact the journal equivalent portion of the initial wasteland 23 Be done.
- the pin equivalent portion of the initial waste land 23 is decentered after the start of rolling of the journal equivalent portion.
- the timing at which the second lower die 52 protrudes from the first lower die 42 is appropriately set.
- the pin equivalent portion may be decentered between the start of the pressure reduction of the journal equivalent portion and the completion of the pressure reduction.
- the pin portion may be decentered after the reduction of the journal portion.
- eccentricity of the pin equivalent portion in the second preforming step instead of the first preforming step has the following advantages.
- the first preforming step the cross-sectional area of the pin portion of the billet is reduced. That is, the cross-sectional area of the pin equivalent portion of the initial waste land 23 is smaller than the cross-sectional area of the pin equivalent portion of the billet. Therefore, the cross-sectional area of the pin equivalent portion after eccentricity is smaller and the amount of remaining material is smaller when the pin equivalent portion of the initial waste 23 is eccentric than when the pin equivalent portion of the billet is eccentric. If the amount of remaining material is small, the amount of burrs after the finish forging step in the post process can be small, and the yield is good. Therefore, in the manufacturing method of the present embodiment, the eccentricity of the pin equivalent portion is performed in the second preforming step in order to improve the yield.
- FIGS. 11A to 14B are schematic views showing an example of a processing flow of the second pre-forming step.
- FIG. 11A is a longitudinal cross-sectional view showing the situation at the start of the reduction process
- FIG. 11B is a longitudinal cross-sectional view showing the situation at the end of the reduction process
- FIG. It is a longitudinal cross-sectional view which shows.
- FIG. 12A and 12B are cross sectional views showing the arm equivalent. Of these figures, FIG. 12A shows the situation at the start of the reduction step, and FIG. 12B shows the situation at the end of the reduction step. 12A is a cross-sectional view taken along the line XIIA-XIIA of FIG. 11A, and FIG. 12B is a cross-sectional view taken along the line XIIB-XIIB shown in FIG. 11C.
- FIG. 13A and 13B are cross-sectional views showing the journal equivalent. Of these figures, FIG. 13A shows the situation at the start of the reduction step, and FIG. 13B shows the situation at the end of the reduction step. 13A is a cross-sectional view taken along line XIIIA-XIIIA of FIG. 11A, and FIG. 13B is a cross-sectional view taken along line XIIIB-XIIIB shown in FIG. 11C.
- FIG. 14A and FIG. 14B are cross-sectional views showing the pin equivalent.
- FIG. 14A shows the situation at the start of the eccentric process
- FIG. 14B shows the situation at the end of the eccentric process.
- 14A is a cross-sectional view taken along line XIVA-XIVA of FIG. 11A
- FIG. 14B is a cross-sectional view taken along line XIVB-XIVB of FIG. 11C.
- FIGS. 11A to 13B show the initial waste land 23 obtained in the above-mentioned first pre-forming step and a pair of first molds 40 at the top and bottom.
- 14A and 14B show an initial wasteland 23 and a second mold 50.
- FIG. The first mold 40 includes a first upper die 41 and a first lower die 42.
- the first upper mold 41, the first lower mold 42, and the initial waste area 23 at the start of the reduction are indicated by the two-dot chain line.
- the heart position C is indicated by a black circle.
- the second mold 50 includes a second upper mold 51 and a second lower mold 52.
- One second upper mold 51 is in contact with a portion (first pin equivalent portion) to be a first pin portion
- another second upper die 51 is a fourth pin portion (a fourth pin equivalent portion) Abut.
- One second lower die 52 is in contact with a portion (second pin equivalent portion) to be a second pin portion
- another second lower die 52 is a portion (third pin equivalent portion) to be a third pin portion Abut.
- the lower mold arm processed portion 42c is concave.
- the upper mold arm processed portion 41c is planar.
- which of the upper mold arm processed portion and the lower mold arm processed portion is to be concave can be appropriately set according to the shape of the forged crankshaft.
- the lower mold arm processed portion 42c has a weight processed portion 42e that abuts a portion (weight equivalent portion) to be the weight portion.
- the weight processing unit 42e is located on the opening side of the concave lower mold arm processing unit 42c.
- the opening width Bp of the weight processing part 42e becomes wider as it goes away from the bottom surface of the concave lower mold arm processing part 42c.
- the weight process part 42e as for the both sides, all are inclined surfaces.
- the thickness of the arm equivalent portion is made the same as the thickness of the finished dimension. Therefore, the axial length of the upper mold arm processed portion 41c and the lower mold arm processed portion 42c is the same as the thickness of the finished dimension of the arm portion.
- the journal processing unit includes an upper mold journal processing unit 41a and a lower mold journal processing unit 42a, as shown by thick lines in FIG. 13A.
- the upper die journal processing unit 41 a is provided on the first upper die 41.
- the lower die journal processing unit 42 a is provided on the first lower die 42.
- the upper die journal processing portion 41 a is concave and can accommodate the entire flat portion of the initial waste land 23.
- the lower die journal processing portion 42 a is provided on the tip end surface of the convex portion.
- type journal process part 42a is made into concave shape. That is, the lower die journal processing portion may be concave so as to be able to accommodate the entire flat portion of the initial rough area.
- the second upper mold 51 of the second mold 50 is concave as shown by a thick line in FIG. 14A, and can accommodate the entire flat portion of the initial waste land 23.
- the second lower mold has a configuration in which the upper and lower sides of the second upper mold 51 are inverted.
- the initial waste 23 is processed as the first upper mold 41. And the first lower mold 42.
- the initial rough surface 23 was rotated 90 ° around the axis from the state at the end of the first preforming step so that the width direction (long axis direction in the case of an ellipse) of the flat portion becomes the pressure reduction direction and the eccentric direction. It is arranged by posture.
- the first upper mold 41 of the first mold 40 is lowered. Then, as shown to FIG. 13A and FIG. 14A, the flat part of the initial stage wasteland 23 is accommodated in concave upper mold
- the second upper mold 51 and the second lower mold 52 of the second mold 50 eccentricize the pin corresponding portion.
- the center of gravity of the pin equivalent portion moves in the eccentric direction of the pin portion (see the hatched arrow in FIG. 1B).
- the amount of eccentricity of the portion corresponding to the pin is equal to the amount of eccentricity of the finish dimension.
- the amount of eccentricity of the pin equivalent portion is not limited to this.
- the eccentricity of the pin equivalent portion may be smaller than the eccentricity of the finished dimension. In this case, in the finish forging step, the eccentricity of the portion corresponding to the pin is taken as the eccentricity of the finish dimension.
- the first upper mold 41 and the second upper mold 51 are raised, and the processed initial waste land 23 (final waste land 24) is taken out.
- the thickness of the arm equivalent is the same as the thickness of the finished dimension.
- the material flows from the pin equivalent portion and the journal equivalent portion to the arm equivalent portion.
- This allows the volume to be distributed in the axial direction.
- the material corresponding to the arm flows in the inside of the arm processed portions 41c and 42c, narrows on the concave bottom side, and widens on the concave opening side. Therefore, the volume is properly distributed within the arm equivalent portion.
- the finish forging step of the post process it is possible to suppress the occurrence of chipping in the arm portion.
- an arm part contains a weight part, it can suppress that a missing part arises in a weight part.
- the second upper mold 51 and the second lower mold 52 of the second mold 50 move up and down independently, and the journal equivalent portion of the initial waste land 23 is pushed down prior to the pin equivalent portion, During the eccentricity of the portion corresponding to the pin, the initial land 23 is difficult to bend. As a result, since the volume-distributed initial waste 23 is pressed at a predetermined position of the first mold 40, it is difficult to cause a defect or the like in the final waste after pressing, and a final waste having a precise shape can be obtained.
- the final waste land can be obtained by the first and second preforming steps described above. Therefore, the material yield can be improved.
- the distribution of axial volume can be promoted by the first preforming step and the second preforming step. That is, the cross-sectional areas of the pin equivalent part and the journal equivalent part can be reduced, and the cross-sectional area of the arm equivalent part can be increased. Since the rough shape of this forged crankshaft is used to form the final wasteland, even in the finish forging process, the formation of burrs can be minimized. These can improve the material yield.
- volume distribution in the arm equivalent portion is adjusted by appropriately changing the shape of the arm processed portions 41c and 42c according to the shape of the forged crankshaft (final product) Can.
- the opening width of the arm processing portion may be changed, or the arm processing portion may be an inclined surface.
- the upper portion of the upper mold journalized portion 41a acts as a partition that restricts the axial flow of the material.
- the opening width Bj of the concave upper die journaled portion is too narrow, the load becomes large in the later step.
- the opening width Bj (mm) of the concave upper die journaling portion is 0.5 to 1.5 in ratio to the diameter Dj (mm) of the journal portion of the forged crankshaft (final product) preferable.
- the third die 30 is used to press down the entire circumference of the billet.
- the closed cross section is formed by the upper die journal processing part 31a and the lower die journal processing part 32a during the reduction
- the closed cross section is formed by the upper die pin processing part 31b and the lower die pin processing part 32b I assume.
- This can prevent the formation of burrs.
- the formation of burrs may be prevented by partially pressing the portion corresponding to the journal by the journal processing portion. Further, formation of burrs may be prevented by partially pressing the portion corresponding to the pin by the pin processing portion.
- the present invention is not limited to the above embodiment, and various modifications can be made without departing from the scope of the present invention.
- a forged crankshaft for example, a forged crankshaft with four cylinders and four counterweights
- the first embodiment of the above-described embodiment can be used.
- the preforming process, the second preforming process, and the finish forging process can be applied.
- the present invention can be effectively used for the manufacture of forged crankshafts mounted on reciprocating engines.
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Abstract
Description
第1予備成形工程では、ビレットのうちのピン部となる部位、およびジャーナル部となる部位を、ビレットの軸方向と垂直な方向から圧下することにより、各部位の断面積を減少させて複数の扁平部を形成する。
第2予備成形工程では、一対の第1金型を用い、扁平部の幅方向を圧下方向にして複数のジャーナル部となる部位を圧下する工程と、第1金型による圧下を開始後、第2金型を用い、扁平部の幅方向を偏心方向にして複数のピン部となる部位を偏心させる工程とを含む。
最終荒地は、複数のクランクアーム部となる部位の厚みが仕上げ寸法の厚みと同じである。
第1予備成形工程では、ビレットのうちのピン部となる部位、およびジャーナル部となる部位を、ビレットの軸方向と垂直な方向から圧下することにより、各部位の断面積を減少させて複数の扁平部を形成する。
第2予備成形工程では、一対の第1金型を用い、扁平部の幅方向を圧下方向にして複数のジャーナル部となる部位を圧下する工程と、第1金型による圧下を開始後、第2金型を用い、扁平部の幅方向を偏心方向にして複数のピン部となる部位を偏心させる工程とを含む。
最終荒地は、複数のクランクアーム部となる部位の厚みが仕上げ寸法の厚みと同じである。
本実施形態の製造方法が対象とする鍛造クランク軸は、回転中心となる複数のジャーナル部Jと、ジャーナル部Jに対して偏心した複数のピン部Pと、ジャーナル部Jとピン部Pをつなぐ複数のアーム部Aと、を備える。例えば、前記図1Aおよび図1Bに示す4気筒-8枚カウンターウエイトの鍛造クランク軸が製造対象である。4気筒-8枚カウンターウエイトの鍛造クランク軸の場合、複数のアーム部Aのうちの全部がウエイト部Wを一体で備える。前述の4気筒-4枚カウンターウエイトの鍛造クランク軸等も製造対象である。4気筒-4枚カウンターウエイトの鍛造クランク軸の場合、複数のアーム部Aのうちの一部がウエイト部Wを一体で備える。また、全てのアーム部Aがウエイト部Wを備えていなくてもよい。ウエイト部を備えないアーム部の形状は長円状である。なお、アーム部がウエイト部を「一体」で備えるとは、アーム部とウエイト部とが別部品ではなく、1つのビレットから両者が成形されていることを意味する。
図4A~図7Bは、第1予備成形工程の加工フロー例を示す模式図である。これらの図のうち、図4Aは、圧下前の状況を示す縦断面図であり、図4Bは圧下終了時の状況を示す縦断面図である。
本実施形態の第2予備成形工程では、ジャーナル相当部の圧下と、ピン相当部の偏心とを実施する。ジャーナル相当部の圧下と、ピン相当部の偏心とは別個の金型によって実施される。
図11A~図14Bは、第2予備成形工程の加工フロー例を示す模式図である。これらの図のうち、図11Aは、圧下工程開始時の状況を示す縦断面図であり、図11Bは圧下工程終了時の状況を示す縦断面図であり、図11Cは偏心工程終了時の状況を示す縦断面図である。
第2予備成形工程によるアーム相当部内の体積配分は、鍛造クランク軸(最終製品)の形状に応じてアーム加工部41c、42cの形状を適宜変更することにより、調整することができる。例えば、アーム加工部の開口幅を変更したり、アーム加工部を傾斜面としたりすればよい。
前述の通り、第2予備成形工程では、アーム相当部を形成する際に、上型ジャーナル加工部41aの上側の部位が材料の軸方向の流動を制限する仕切りとして作用する。この作用を増大させるには、凹状の上型ジャーナル加工部41aにおいて、開口幅(Bj:図13A参照)を狭くすることが重要となる。一方で、凹状の上型ジャーナル加工部の開口幅Bjが狭すぎると、後工程で負荷が大きくなる。
22 ビレット
23 初期荒地
23a 扁平部
24 最終荒地
25 仕上げ鍛造材
30 第3金型
31 第3上型
31a 第3金型の上型ジャーナル加工部
31b 第3金型の上型ピン加工部
32 第3下型
32a 第3金型の下型ジャーナル加工部
32b 第3金型の下型ピン加工部
40 第1金型
41 第1上型
41a 第1金型の上型ジャーナル加工部
41b 第1金型の上型ピン加工部
41c 第1金型の上型アーム加工部
42 第1下型
42a 第1金型の下型ジャーナル加工部
42b 第1金型の下型ピン加工部
42c 第1金型の下型アーム加工部
42e ウエイト加工部
50 第2金型
51 第2上型
52 第2下型
A、A1~A8 クランクアーム部
J、J1~J5 ジャーナル部
P、P1~P4 ピン部
W、W1~W8 カウンターウエイト部
B バリ
Claims (3)
- 回転中心となる複数のジャーナル部と、前記ジャーナル部に対して偏心した複数のピン部と、前記ジャーナル部と前記ピン部をつなぐ複数のクランクアーム部と、を備える鍛造クランク軸の製造方法であって、
当該製造方法は、
ビレットから初期荒地を得る第1予備成形工程と、
前記初期荒地から最終荒地を得る第2予備成形工程と、
少なくとも1回の型鍛造によって前記最終荒地を前記鍛造クランク軸の仕上げ寸法に成形する仕上げ鍛造工程と、を含み、
前記第1予備成形工程では、前記ビレットのうちの前記ピン部となる部位、および前記ジャーナル部となる部位を、前記ビレットの軸方向と垂直な方向から圧下することにより、前記各部位の断面積を減少させて複数の扁平部を形成し、
前記第2予備成形工程では、一対の第1金型を用い、前記扁平部の幅方向を圧下方向にして前記複数のジャーナル部となる部位を圧下する工程と、前記第1金型による圧下を開始後、第2金型を用い、前記扁平部の幅方向を偏心方向にして前記複数のピン部となる部位を偏心させる工程とを含み、
前記最終荒地は、前記複数のクランクアーム部となる部位の厚みが仕上げ寸法の厚みと同じである、鍛造クランク軸の製造方法。 - 請求項1に記載の鍛造クランク軸の製造方法であって、
前記第2予備成形工程では、前記一対の第1金型による圧下が完了した後、前記第2金型による前記複数のピン部となる部位の偏心を開始する、鍛造クランク軸の製造方法。 - 請求項1または請求項2に記載の鍛造クランク軸の製造方法であって、
前記ピン部となる部位の偏心量は、仕上げ寸法の偏心量と同じかまたはそれよりも小さい、鍛造クランク軸の製造方法。
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MX2020001946A MX2020001946A (es) | 2017-08-21 | 2018-07-30 | Metodo para producir un cigue?al forjado. |
US16/640,131 US11253910B2 (en) | 2017-08-21 | 2018-07-30 | Method for producing forged crankshaft |
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JP2001105087A (ja) | 1999-09-30 | 2001-04-17 | Toyota Motor Corp | 予備成形方法と型構造 |
JP2016107273A (ja) * | 2014-12-02 | 2016-06-20 | 本田技研工業株式会社 | クランクシャフトの製造方法 |
WO2016147674A1 (ja) * | 2015-03-18 | 2016-09-22 | 新日鐵住金株式会社 | 鍛造クランク軸の製造方法 |
WO2016152933A1 (ja) * | 2015-03-24 | 2016-09-29 | 新日鐵住金株式会社 | 鍛造クランク軸の製造方法 |
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WO2019155847A1 (ja) * | 2018-02-07 | 2019-08-15 | 日本製鉄株式会社 | 鍛造クランク軸の製造方法 |
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JP6822574B2 (ja) | 2021-01-27 |
BR112020001910A2 (pt) | 2020-07-28 |
CN110997178A (zh) | 2020-04-10 |
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