プレス成形の加工プロセスと型設計に関する研究 :
回転ノブおよびフライホイールの成形加工
著者
松田 豪彦, 中西 賢二, 上谷 俊平
雑誌名
鹿児島大学工学部研究報告
巻
48
ページ
1-8
別言語のタイトル
Experimental Study on Forming Process and Die
Design in Press Forming : Forming of a Knob
and a Flywheel
プレス成形の加工プロセスと型設計に関する研究 :
回転ノブおよびフライホイールの成形加工
著者
松田 豪彦, 中西 賢二, 上谷 俊平
雑誌名
鹿児島大学工学部研究報告
巻
48
ページ
1-8
別言語のタイトル
Experimental Study on Forming Process and Die
Design in Press Forming : Forming of a Knob
and a Flywheel
㣮ఽፉᄢቇᎿቇㇱ⎇ⓥႎ๔ ╙ 48 ภ㧔2006㧕
ࡊࠬᚑᒻߩടᎿࡊࡠࠬߣဳ⸳⸘ߦ㑐ߔࠆ⎇ⓥ
㧙࿁ォࡁࡉ߅ࠃ߮ࡈࠗࡎࠗ࡞ߩᚑᒻടᎿ㧙
᧻↰ ⽕ᒾ* ਛ ⾫ੑ**
⼱ ବᐔ**
Experimental Study on Forming Process and Die Design in Press Forming
㧙Forming of a Knob and a Flywheel㧙
Takehiko MATSUDA, Kenji NAKANISHI and Shunpei KAMITANI
The flywheel, roller and knob can be formed directly from the cylindrical work-piece by cold axisymmetric upsetting with lateral extrusion. Lack of material filling was observed at the rim part of an extruded product, when an ordinal die was used. Then, the forming process and die was designed to achieve effective material flow to fulfill the lack portion of an extruded product. The product formed by the proposed forming process and die has the circular concave plane at the disk surface. When that concave plane is related to the base plane of an ornament plate in a knob and to the lightweight design of a product in a flywheel, the net shape forming can be achieved in the proposed forming process and die. K eyw ords : flywheel, knob, closed die forging, tool/die design
㧝㧚✜⸒ ࿁ォࡁࡉޔࡈࠗࡎࠗ࡞ߥߤޔゲઃ߈᧼⁁ㇱ ຠ߇ࠞࡔޔࠕࡦࡊޔ࠴ࡘ࠽߅ࠃ߮⸘᷹ᯏེߥ ߤߩᄙߊߩ♖ኒዊဳᯏེߦࠊࠇߡࠆޕߔߥࠊߜޔ ࿁ォࡁࡉߪᯏེߩᯏ⢻ࠍ⺞ᢛߔࠆㇱຠߣߒߡޔࡈ ࠗࡎࠗ࡞ߪ࿁ォേࠍṖࠄ߆ߦߔࠆㇱຠߣߒߡ ࠊࠇࠆޕ࿁ォࡁࡉߣࡈࠗࡎࠗ࡞ࠍ࿑࿑㧙㧝ߦ␜ ߔޕ࿑㧔A㧕ߪゲࠍ࿁ォߔࠆ㓙ߩᜰߦࠃࠆࠣ࠶ࡊ
䋨A䋩 Rotating knob
䋨B䋩 longitudinal cross sections of the flywheel
a b c
a b
䋨A䋩 Rotating knob
䋨B䋩 longitudinal cross sections of the flywheel 䋨A䋩 Rotating knob
䋨B䋩 longitudinal cross sections of the flywheel
a b c a b ࿑㧙㧝 ࿁ォࡁࡉ߅ࠃ߮ࡈࠗࡎࠗ࡞ ᗵߣ࿁ߒᤃߐ߇ⷐ᳞ߐࠇࠆ࿁ォࡁࡉߩᄖᒻᒻ⁁ࠍ ߒߡߡޔࡁࡉߩ㕙ߪ a ߇ᐔ㕙ޔb ߇ḧᦛ㕙ޔ 2006ᐕ 8 31 ᣣฃℂ * ඳ჻ᓟᦼ⺖⒟‛⾰↢↥Ꮏቇኾ ** ᯏ᪾Ꮏቇ⑼ ― 1 ―
ߐࠄߦ㨏߇ࡠ࠶࠻ᮨ᭽ࠍߔޕ߹ߚޔ࿑㧔B㧕ߪ ᄖ㕙ㄭறߩ⾰㊂ࠍᄢ߈ߊߒゲਛᔃㄭறߩ⾰㊂ࠍ ዊߐߊ⸳⸘ 1)ߔࠆߎߣߢޔ㧔࿁ォᘠᕈജ㧛⾰㊂㧕Ყ ࠍᄢ߈ߊߔࠆߎߣ߇ⷐ᳞ߐࠇࠆࡈࠗࡎࠗ࡞ᢿ 㕙ᒻ⁁ࠍߔޕ⸥ߩゲઃ᧼⁁ㇱຠߪޔ಄㑆ᣇ ߒ㎊ㅧടᎿߦࠃߞߡᩇ⁁⚛᧚߆ࠄ⋥ធᚑᒻ ടᎿߢ߈ࠆޕ߹ߚޔࡁࡉ㕙ߩᒻ⁁߅ࠃ߮ゲਛᔃㄭ றߩ┄ߺᒻ⁁ߩᚑᒻടᎿߪ㊄ဳౝ㕙ߩᐞቇ⊛ᒻ ⁁ࠍຠ㕙ߣㅒߦߔࠆߎߣߦࠃࠅน⢻ߣߥࠆޕ ߚߛߒޔ಄㑆ᣇߒ㎊ㅧടᎿߩ႐วޔടᎿ⚳ ੌ೨ߩ႟ᕈᵹࠇ߇ဳౝㇱߢ㐽Ⴇ⁁ᘒߦ㒱ࠅޔ⚿ᨐߣ ߒߡടᎿຠᄖⷺㇱ㧔ᄖ✼ㇱ㧕ߦ⚛᧚ߩలႯਇ⿷㧔ᰳ ⡺㧕߇⊒↢ߒᤃޕᓥߞߡޔหടᎿᴺࠍታ↪ൻߔࠆ ߦߪ⸥㗴ὐࠍ⸃ߔࠆᔅⷐ߇ࠆޕ ߎߩߎߣߦ㑐ߒߡޔ╩⠪ࠄߪవߦᩰሶ✢⸃ᨆᴺ 2),3)ࠍㆡ↪ߒߚ৻ㅪߩ಄㑆ᐔ㕙߭ߕߺᣇߒ ㎊ㅧടᎿታ㛎ࠍⴕߞߡޔဳߩౝㇱߦᲑᏅⓨ㑆ࠍ⸳ߌ ࠆဳ᭴ㅧߣߔࠆߎߣߦࠃࠅૐࡄࡦ࠴⩄㊀ߢᄖ ⷺㇱ߳ߩ⚛᧚లႯࠍ⏕ታߦߔࠆ႟ᕈᵹࠇ߇ᓧࠄࠇ ࠆߎߣࠍߛߒߚ4)ޕ ゲኻ⒓ᣇߒ㎊ㅧടᎿߦޔㅀߩဳ᭴ㅧࠍㆡ ↪ߒߚ႐วޔᲑᏅⓨ㑆ߪဳᐩ㕙✼ㇱߩⅣ⁁Ḵߣߥࠆ ߎߣ߆ࠄᚑᒻຠᐩ㕙ਛᄩㇱߦᒻ┄ߺ㕙߇ᚑᒻߐ ࠇࠆߎߣߦߥࠆޕߎߩ┄ߺ㕙ߪ࿁ォࡁࡉߩ႐วߪࠝ ࠽ࡔࡦ࠻㧔ᢥሼߥߤࠍೞශߒߚ㘼ࠅ᧼㧕ߥߤߩข ࠅઃߌ㕙ߦ⋧ᔕߐߖޔࡈࠗࡎࠗ࡞ߩ႐วߪޔห ຠߩシ㊂ൻࠍ⋡⊛ߣߒߡゲਛᔃㇱߦ⸳ߌࠆ┄ߺ 㕙ߦ⋧ᔕߐߖࠆߎߣߢ㧔ᚑᒻຠߣဳߩㅪ៤⸳⸘ߦࠃ ࠆ㧕ࡀ࠶࠻ࠪࠚࠗࡊടᎿ㧔⸳⸘࿑ㅢࠅߩᚑᒻຠࠍᓧ ࠆടᎿ㧕߇ታߢ߈ࠆޕ એߩⷰὐߦၮߠߡޔᧄ⎇ⓥߢߪ৻ㅪߩᚑᒻട Ꮏታ㛎ࠪࡒࡘ㧙࡚ࠪࡦࠍⴕޔടᎿຠᄖ✼ㇱಽߩ ᒻ⁁ォ౮⢻ࠍะߐߖߚ಄㑆ゲኻ⒓ᣇߒ㎊ ㅧടᎿߩടᎿࡊࡠࠬߣหࡊࡠࠬࠍታߔࠆဳ ⸳⸘ࠍⴕߞߚޕ 㧞㧚ᚑᒻടᎿታ㛎ࠪࡒࡘ࡚ࠪࡦߩᚑᒻ ຠታ㛎ⵝ⟎ታ㛎᧦ઙታ㛎ᣇᴺ ᚑᒻຠ ࿑㧙㧞ߩ㧔A㧕ߦ⚛᧚ߣᚑᒻടᎿຠߩ 3 ᰴరᒻ⁁ ࠍߔޕᚑᒻടᎿຠߩኸᴺᒻ⁁ߩ⸵ኈ୯ߩ▸࿐ౝ ߢ࿁ォࡁࡉߣߒߡߩᦨㆡ୯ࠆߪࡈࠗࡎࠗ ࡞ߣߒߡߩᦨㆡ୯ࠍ⸳ቯߔࠆߣޔ೨ㅀߩࠃ߁ߦᚑᒻ ຠߣဳߩㅪ៤⸳⸘ߦࠃࠆࡀ࠶࠻ࠪࠚࠗࡊടᎿ߇ታ ߢ߈ࠆޕ ታ㛎ⵝ⟎ޔታ㛎᧦ઙ߅ࠃ߮ታ㛎ᣇᴺ ታ㛎ⵝ⟎ࠍ࿑㧙㧞ߩ㧔B㧕ߦ␜ߔޕᧄⵝ⟎ߩ․ᓽ ߣߒߡޔဳౝㇱᐩ㕙㧔ඨᓘ R㧕ߦߪޔຠᄖ✼ㇱ ߩᒻ⁁ォ౮⢻ࠍะߐߖࠆᯏ⢻ࠍᜬߟᲑᏅⓨ㑆㧔eޔ f㧕ࠍᒻᚑߔࠆ᧼ᒻ⁁ࡊ࠻㧔ඨᓘ Rbޔෘߐ Hb㧕ࠍ⸳⟎ߔࠆߎߣ߇ߢ߈ࠆޕߥ߅ޔߎߩᲑᏅⓨ 㑆ߪޔဳᐩ㕙✼ㇱߦ⸳ߌࠆⅣ⁁Ḵߦ⋧ᒰߔࠆޕ߹ߚޔ ᣇߒㇱⓨ㑆ߩ㜞ߐ H ߪ 10.4mmޔඨᓘ R ߪ 15mmߢࠆޕ࿑㧔C㧕ߦࡄࡦ࠴ߩߒㄟߺߦ߁ ⚛᧚ᚑᒻㆊ⒟ߩᮨᑼ࿑ࠍߔޕ ታ㛎᧦ઙߪޔᲑᏅⓨ㑆ߩᷓߐࠍᒻᚑߔࠆ᧼ᒻ⁁ࡊ ࠻ߩෘߐ Hb ࠍ Hb=3 mm ߦ࿕ቯߒߡޔหࡊ ࠻ ߩ ඨ ᓘ Rb ࠍ Rb=10.3 mm(0.667) ޔ 10.9 mm(0.586)ޔ11.5 mm (0.5)ޔ13.2mm(0.257)߅ࠃ߮ 15 mm( 0 : ᲑᏅⓨ㑆ήߒߣߥࠆ)ߩ㧡⒳㘃ߦᄌൻߐߖ ߚޕߎߎߢޔ( )ౝߩᢙ୯ߪᒛߒㇱಽߩඨᓘᣇะ 㐳ߐ 7 mm ߦኻߔࠆᲑᏅḴⓨ㑆ߩඨᓘᣇะ Rw ߩ ഀวࠍߔޕߐࠄߦޔታ㛎᧦ઙߦࡊ࠻ήߒ 㧔Hb=0 mm㧕ߩ᧦ઙࠍട߃ߚޕ ⸥ߩฦᲑᏅⓨ㑆⸳⟎᧦ઙ߅ࠃ߮ࡊ࠻ήߒ ߩ᧦ઙਅߢޔᩇ⚛᧚ࠍဳౝߦⵝႯߒࡄࡦ࠴㧔g㧕 ࠍ⸳⟎ᓟޔหታ㛎ⵝ⟎ࠍᴤࡊࠬ㧔30tf ⶄേᴤ ࡊࠬ㧕ߩᎿౕบߦ⒖ߒߡᚑᒻടᎿታ㛎ࠍⴕߞߚޕ ታ㛎ߦ↪ߚ⚛᧚ߪޔᏒ⽼Ꮏᬺ↪⚐ࠕ࡞ࡒ࠾࠙ࡓ A1050ߩ㊰᧚㧔㊰ᓟߩ⎬ߐ HV= 21㧕ߢࠆޕ ㎊ㅧടᎿㆊ⒟ߩࡄࡦ࠴⩄㊀ߪᎿౕบߦ⸳⟎ߒߚ⩄
Work-piece
40 mmc
a
b
d
e
g
Rb
R
f
Hb
H
Punch stroke
Product
㱂16 mm 10 .4 mm 㱢30mmRw
㱂16 mm䋨B䋩
䋨C䋩
䋨A䋩
a,b : Split dies c,d : Clamp
e,f : Stepwise cavity g : Punch
Work-piece
40 mmc
a
b
d
e
g
Rb
R
f
Hb
H
Punch stroke
Product
㱂16 mm 10 .4 mm 㱢30mmRw
㱂16 mm䋨B䋩
䋨C䋩
䋨A䋩
a,b : Split dies c,d : Clamp
e,f : Stepwise cavity g : Punch ࿑㧙㧞 ታ㛎ⵝ⟎ޔ⚛᧚߅ࠃ߮ᚑᒻടᎿຠߩ⇛࿑ ㊀ᄌ឵ེߦࠃࠅ⸘᷹ߒޔࡄࡦ࠴⒖േ㊂ߪࡊࠬࡓ ߩേ߈ߦㅪേߔࠆᄌᄌ឵ེߦࠃࠅ⸘᷹ߒߚޕࡄࡦ ࠴⩄㊀ߣࡄࡦ࠴⒖േ㊂ߩ⸘᷹୯ߪ࠺࠲ࠦ࠳ ࠍ↪ߡടᎿᤨ㑆ߩផ⒖ߦኻᔕߐߖߡㅪ⛯⊛ߦ⸥ ㍳ߒߚޕߥ߅ޔฦታ㛎᧦ઙਅߦ߅ߌࠆᦨᄢࡄࡦ࠴⩄ ㊀ࠍห৻ߦߒߚ႐วߩᚑᒻ⁁ᘒࠍ⋧ߦᲧセߔࠆ ߚޔ੍ታ㛎ࠍⴕߞߚߢᦨᄢࡄࡦ࠴⩄㊀ࠍ 105kNߦ⸳ቯߒߚޕࡄࡦ࠴⒖േ㊂ࠍᦨᄢࡄࡦ࠴⩄㊀ ୯߹ߢㅪ⛯ߒߡ⒖േߐߖߚታ㛎߅ࠃ߮ടᎿ㐿ᆎ ⟎߆ࠄ⚳ੌ⟎߹ߢߩ㑆ߢ 5 Ბ㓏ߦᄌ߃ߚታ㛎㧔ㅙ ᰴᄌᒻታ㛎㧕ߩਔᣇࠍⴕߞߚޕㅙᰴᄌᒻታ㛎ߢߪޔ ᚑᒻߩㅴⴕߦߞߚ⚛᧚ᄖᒻᒻ⁁ߩᄌൻࠍ᷹ቯߒ ߚޕ 㧟㧚ታ㛎⚿ᨐ߅ࠃ߮⠨ኤ ฦ⒳ᲑᏅⓨ㑆ࠍ⸳⟎ߒߚဳ߅ࠃ߮ᲑᏅⓨ㑆ࠍ⸳ ߌߥဳࠍ↪ߚ㎊ㅧടᎿㆊ⒟ߩࡄࡦ࠴⩄㊀ߣࡄ ࡦ࠴ࠬ࠻ࡠࠢߩ᷹ቯ⚿ᨐ߅ࠃ߮ᚑᒻຠᄖᒻࠍ࿑࿑ 㧙㧟ߦ␜ߔޕห࿑ਛߩဳߩᮨᑼ࿑ߪᚑᒻടᎿߦ↪ ߒߚဳߩౝㇱᒻ⁁ࠍߔޕ࿑㧔A㧕ߩࡄࡦ࠴⩄㊀㧙 ࡄࡦ࠴ࠬ࠻ࡠࠢᦛ✢ߪ⚛᧚߇ᣇߦߐࠇࠆ ㆊ⒟ߦ߅ߌࠆࡄࡦ࠴⩄㊀ߩߥߛࠄ߆ߥჇടㆊ⒟ߣޔ ⚛᧚ߩᣇߒㇱಽవ┵߇ဳოߦ㆐ߒߚᓟ ߦဳⓨ㑆߳లḩߔࠆㆊ⒟ߦ߅ߌࠆࡄࡦ࠴⩄㊀ߩ㗼 ⪺ߥჇടㆊ⒟ࠍߔޕ߹ߚޔဳⓨ㑆߳లḩߔࠆㆊ⒟ ߦ߅ߌࠆࡄࡦ࠴⩄㊀ߩࡄࡦ࠴ࠬࡠࠢߦኻߔࠆჇ ടഀวߪޔဳౝㇱᐩ㕙ߦ⸳ߌߚᲑᏅⓨ㑆ߩߩᓇ㗀 ࠍฃߌࠆߎߣ߇ࠊ߆ࠆޕ ᲑᏅⓨ㑆ࠍ⸳ߌߥဳ㧔Hb=0 mm㧕ࠍ↪ߚᚑ ᒻടᎿታ㛎ߢߪޔࡄࡦ࠴ࠬ࠻ࡠࠢ߇ 26mm ઃㄭ ߢ㐽Ⴇ⁁ᘒߣߥࠅޔߎߩߣ߈ߩࡄࡦ࠴⩄㊀ߪ 75kN ߢߞߚޕߐࠄߦടߒߡ߽႟ᕈᵹࠇߪᱛ߹ߞߚ߹ ߹ߢߞߚޕ࿑㧔B㧕ߦ߅ߡޔᚑᒻຠᄖᒻߣ ― 3 ―
0
50
100
150
0
5
10
15
20
25
30
Punch stroke䇭S䇭/mm
Lo
ad
䇭
P
䇭
/k
N
Rb=15mm Hb= 3mm Rb=13.2mm Hb= 3 mm Rb=11.5mm Hb= 3 mm Hb= 0 mm Rb=10.9mm Hb= 3 mm Rb=10.3mm Hb= 3 mm䋨A) Punch load-stroke curves
Die Die
Die Die Die
Die
Die configurations
0
50
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150
0
5
10
15
20
25
30
Punch stroke䇭S䇭/mm
Lo
ad
䇭
P
䇭
/k
N
Rb=15mm Hb= 3mm Rb=13.2mm Hb= 3 mm Rb=11.5mm Hb= 3 mm Hb= 0 mm Rb=10.9mm Hb= 3 mm Rb=10.3mm Hb= 3 mm䋨A) Punch load-stroke curves
Die Die
Die
Die DieDie DieDie
Die
Die configurations
䋨B䋩 Product photographs
1mm 5mm Hb= 0 mm Rb=10.3mm Hb= 3 mm Rb=10.9mm Hb= 3 mm Rb=11.5mm Hb= 3 mm Rb=13.2mm Hb= 3 mm Rb=15mm Hb= 3mm䋨B䋩 Product photographs
1mm 5mm Hb= 0 mm Rb=10.3mm Hb= 3 mm Rb=10.9mm Hb= 3 mm Rb=11.5mm Hb= 3 mm Rb=13.2mm Hb= 3 mm Rb=15mm Hb= 3mm 1mm 5mm Hb= 0 mm Rb=10.3mm Hb= 3 mm Rb=10.9mm Hb= 3 mm Rb=11.5mm Hb= 3 mm Rb=13.2mm Hb= 3 mm Rb=15mm Hb= 3mm ࿑㧙㧟 ࡄࡦ࠴⩄㊀㧙ࠬ࠻ࡠࠢᦛ✢߅ࠃ߮ᚑᒻടᎿຠᄖᒻᒻ⁁ߩ⋧Ყセ ߒᚑᒻㇱߩᄖ㕙ⷺㇱߦࠆ⚛᧚ᧂలႯ▎ᚲ ߩᄢ࿑ࠍ␜ߔޕⷺㇱߢߪޔ⚛᧚ߩలႯ⁁ᘒ߇Ბ Ꮕⓨ㑆ࠍ⸳ߌࠆߎߣߦࠃࠅᡷༀߐࠇޔ߹ߚޔలႯ⁁ ᘒ߇ᲑᏅⓨ㑆ߩߦ߽ଐሽߒߡᄌࠊࠆߎߣ߇ಽ߆ ࠆޕ৻ᣇޔਅⷺㇱߢߪޔᲑᏅⓨ㑆ࠍ⸳ߌߥ႐ว 㧔Hb=0 mm㧕ߦ⚛᧚ߩᧂలႯ߇ࠄࠇࠆ߇ޔᲑᏅ ⓨ㑆ࠍ⸳ߌߚ႐ว㧔Hb=3 mm㧕ߪޔᲑᏅⓨ㑆ߩߦ ߆߆ࠊࠄߕ⚛᧚߇ቢోߦలႯߒߡࠆޕᲑᏅⓨ㑆ߩ⸳⟎᧦ઙߣⷺㇱ߳ߩ⚛᧚లႯ⁁ᘒߩ㑐ଥࠍ࿑࿑㧙 㧠ߦ␜ߔޕ❑ゲߩలႯ₸Ș ߪޔⷺㇱࠍᐔ㕙ߦᛩᓇ ߒߚ࿑ߦ⸳ቯߒߚ৻ㄝ 3.5 mm ߩᱜᣇᒻⓨ㑆ᨒౝߦ ߅ߡޔలႯߐࠇߚ⚛᧚ߩභ㕙Ⓧ A ߇භࠆഀ วޔ㧔Ș= A㧛ⷺㇱⓨ㑆ᨒߩో㕙Ⓧ㧔3.52 㧕㧕ߩ⊖ಽ ₸␜ߢߒߚޕᮮゲߪᲑᏅⓨ㑆ࠍ⸳ߌࠆߚߦဳ ᐩㇱߦ⸳⟎ߔࠆ᧼ᒻ⁁ࡊ࠻ඨᓘ㧔Fig. 2 ߩ Rb㧕߅ࠃ߮ᲑᏅⓨ㑆ߩḴ㧔Fig. 2 ߩ Rw㧕ࠍߔޕ ห࿑߆ࠄဳౝߩᐩ㕙ߦ Rw=1.8 mm㧔Rb=13.2 mmޔ Hb=3 mm㧕ߩᲑᏅⓨ㑆ࠍ⸳ߌߚ႐วߦޔဳⓨ㑆߳ߩ ⚛᧚లႯ߇ᦨ߽⦟ᅢߣߥࠅޔలႯ₸Ș= 98㧑ߦ㆐ߔ ࠆߎߣ߇ಽ߆ࠆޕḴ Rw=1.5㨪3mm ⒟ᐲߩ▸࿐ߢ Ș= 97㧑એߩ㜞లႯ₸߇⛽ᜬߐࠇࠆߎߣ߇ಽ߆ࠆޕ ߐࠄߦḴ Rw ࠍ 4mm ߹ߢߍߡ߽ޔలႯ₸ Ș= 95㧑⒟ᐲߩలႯ₸߇ᓧࠄࠇࠆߎߣ߇ಽ߆ࠆޕ ᧂలႯ▎ᚲߩᐔ㕙ᛩᓇ࿑ߦ߅ߡޔߘߩᮮࠍ xޔ ❑ࠍ y ߣߒߚߣ߈ߩဳᐩ㕙ߩࡊ࠻ඨᓘ Rb ߣ 60 65 70 75 80 85 90 95 100 9 10 11 12 13 14 15 Rb /mm䇭䋨Hb=3mm䋩 F ill in g rate Ș / % 1 0 1 2 3 4 5 6 Rw䇭/mm 100 5 . 3 2u A K Rb 15 Rw
A
3.5mm 3. 5m m Hb=0䋨Flat plane䋩 95% 97% 98% 60 65 70 75 80 85 90 95 100 9 10 11 12 13 14 15 Rb /mm䇭䋨Hb=3mm䋩 F ill in g rate Ș / % 1 0 1 2 3 4 5 6 Rw䇭/mm 100 5 . 3 2u A K Rb 15 RwA
3.5mm 3. 5m m 100 5 . 3 2u A K Rb 15 RwA
A
3.5mm 3. 5m m Hb=0䋨Flat plane䋩 95% 97% 98% ࿑㧙㧠 ㊄ဳߩⷺㇱ OO ᐔᣇⓨ㑆ߦᛩᓇߒߡ⸘▚ߒ ߚ࠳ࠗࠬⓨ㑆߳ߩ⚛᧚ߩలႯ₸ ߩ㑐ଥࠍ࿑࿑㧙㧡ߦ␜ߒޔxޔyߣలႯ₸Șߣߩ㑐ଥࠍ ࿑㧙㧢ߦ␜ߔޕߎߩ㑐ଥ߆ࠄᮮxߩᣇ߇❑yࠃࠅ ߽ᄢ߈ߎߣ߇ࠊ߆ࠆޕ߹ߚޔలႯ₸߆ࠄⷺㇱߩ㕙 ขࠅߦ឵▚ߒߚ㑐ଥࠍ࿑࿑㧙㧣ߦ␜ߔޕలႯ₸Ș=96% ߦ㆐ߔࠆߣޔⷺㇱࠍ⋥㕙ߢ␜ߒߚ႐วߩC= 㧝ߩ㕙ขࠅߦ⋧ᒰߔࠆ୯ߦߥࠆߎߣ߇ಽ߆ࠆޕలႯ ₸Ș= 98㧑ߩ႐วߪC= 0.7⒟ᐲߩ㕙ขࠅߦ⋧ᒰߔࠆޕ ߥ߅ޔታ㓙ߩⷺㇱᒻ⁁ߪޔ᧚ᢱߩ႟ᕈᵹࠇߦଐሽߒ ߚ⥄↱ᦛ㕙ߦߥߞߡࠆߚޔဳⷺㇱ߆ࠄߩ〒㔌ߢ ߺࠆߣߐࠄߦ㕙ขࠅኸᴺߪዊߐߊߥࠆޕలႯ₸Ș= 98㧑ߢߩဳⷺㇱ߆ࠄߩ〒㔌ߪ0.37mmߣߥࠅޔ㕙ข ࠅߦ⋧ᒰߐߖࠆߣC=0.5⒟ᐲߦߥࠆޕ 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 8 10 12 14 Rb /mm x䋬䌹 /m m 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 8 10 12 14 Rb=0 Rb=0 x y x y x y 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 8 10 12 14 Rb /mm x䋬䌹 /m m 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 8 10 12 14 Rb=0 Rb=0 x y x y x y ࿑㧙㧡 Z[㧙4D ߩ㑐ଥ 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 60.0 70.0 80.0 90.0 100.0 Filling rate Ș /% x 䋬䌹 /m m 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 60 70 80 90 100 x y x y x y 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 60.0 70.0 80.0 90.0 100.0 Filling rate Ș /% x 䋬䌹 /m m 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 60 70 80 90 100 x y x y x y ࿑㧙㧢 Z[㧙ǯ ߩ㑐ଥ ― 5 ―ဳߦ⸳ߌࠆᲑᏅⓨ㑆ߩᐞቇ⊛․ᓽߪߒㇱ ಽᚑᒻຠᮮᢿ㕙ⓍSc (࿑㧙㧞ߦ߅ߡޔSc=ǸR2)ߣ 0.0 0.5 1.0 1.5 2.0 2.5 3.0 60 65 70 75 80 85 90 95 100 Filling rate Ș /% C o rn er cu t 䇭C / m m 0.0 0.5 1.0 1.5 2.0 2.5 3.0 60 65 70 75 80 85 90 95 100 96% 98%
Corner cut C evaluated form unfilled area 㱓䋽Filled aria / corner aria 3.52 㬍100
0.0 0.5 1.0 1.5 2.0 2.5 3.0 60 65 70 75 80 85 90 95 100 Filling rate Ș /% C o rn er cu t 䇭C / m m 0.0 0.5 1.0 1.5 2.0 2.5 3.0 60 65 70 75 80 85 90 95 100 96% 98%
Corner cut C evaluated form unfilled area 㱓䋽Filled aria / corner aria 3.52 㬍100
࿑㧙㧣 లႯ₸ ǯ ߦ㑐ㅪઃߌߚ㕙ขࠅ㧯ߩ୯ ᲑᏅⓨ㑆㐿ญㇱ㕙ⓍSb (࿑㧙㧞ߦ߅ߡޔSb=Ǹ(R2 –Rh2)ߩᲧ㧔ߔߥࠊߜᲑᏅⓨ㑆ߩߒᲧ㧕Sc/Sbߢ ߔߎߣ߇ߢ߈ࠆޕᦨ߽⦟ᅢߥဳߩᒻ⁁ォ౮⢻߇ᓧ ࠄࠇߚᲑᏅⓨ㑆ߩߒᲧߪޔ㧔R=15 mm߅ࠃ߮ Rb=13.2 mmࠃࠅ㧕Sc/Sb=4.43ߣߥࠆޕߥ߅ޔ⸥Ბ Ꮕⓨ㑆ߩߒᲧSc/Sbߩ୯ߪޔᐔ㕙߭ߕߺᣇ ߒ㎊ㅧടᎿ4)ߦ߅ߡᦨ߽⦟ᅢߥဳߩᒻ⁁ォ౮⢻ ߇ᓧࠄࠇࠆSc/Sbߩ୯ߣ߶ߣࠎߤห৻୯ߢࠆޕ ᦨ߽⦟ᅢߥᒻ⁁ォ౮⢻ࠍᓧߚᲑᏅⓨ㑆ࠍဳᐩ㕙 ߦ⸳ߌߚ႐ว߅ࠃ߮ᲑᏅⓨ㑆ߩή႐วߩᣇߦ ߟߡޔᣇߒ㎊ㅧടᎿㆊ⒟ߦ߅ߌࠆࡄࡦ࠴ࠬ ࠻ࡠࠢߩផ⒖ߦ߁ဳౝㇱ⚛᧚ߩᒻ⁁ᄌൻ߅ࠃ ߮ࡄࡦ࠴⩄㊀ߣࡄࡦ࠴ࠬ࠻ࡠࠢߩ㑐ଥࠍ࿑࿑㧙㧤 ߦ␜ߔޕဳᐩ㕙ߦᲑᏅⓨ㑆ࠍ⸳ߌߚဳߩ႐ว㧔࿑
(A) Die䋺Hb=3mm, Rb=13.2mm
(B) Die䋺Hb=0mm
(Ref. to Fig.1)
(Ref. to Fig.1)
s
1 2 3 4 5 5 4 3mms
1 2 3 4 5 4 5 3mm E Position 25 4.7 0.75 20 2.5 0.3 35 9.6 1.8 0 0 0 Load /kN Punch stroke /mm Time /s 5.6 4.6 125 61 26 23s
1 3 4 5 2 Position 37 8.8 1.9 30 5 1.1 39 10 2.15 0 0 0 Load /kN Punch stroke /mm Time /s 5.2 3.8 105 67 23 17s
1 2 3 4 5(A) Die䋺Hb=3mm, Rb=13.2mm
(B) Die䋺Hb=0mm
(Ref. to Fig.1)
(Ref. to Fig.1)
s
1 2 3 4 5 5 4 3mms
1 2 3 4 5 4 5 3mm E(A) Die䋺Hb=3mm, Rb=13.2mm
(B) Die䋺Hb=0mm
(Ref. to Fig.1)
(Ref. to Fig.1)
s
1 2 3 4 5 5 4 3mm 3mms
1 2 3 4 5 4 5 3mm 3mm E Position 25 4.7 0.75 20 2.5 0.3 35 9.6 1.8 0 0 0 Load /kN Punch stroke /mm Time /s 5.6 4.6 125 61 26 23s
1 3 4 5 2 Position 25 4.7 0.75 20 2.5 0.3 35 9.6 1.8 0 0 0 Load /kN Punch stroke /mm Time /s 5.6 4.6 125 61 26 23s
1 3 4 5 2 Position 37 8.8 1.9 30 5 1.1 39 10 2.15 0 0 0 Load /kN Punch stroke /mm Time /s 5.2 3.8 105 67 23 17s
1 2 3 4 5 Position 37 8.8 1.9 30 5 1.1 39 10 2.15 0 0 0 Load /kN Punch stroke /mm Time /s 5.2 3.8 105 67 23 17s
1 2 3 4 5 ࿑㧙㧤 ᚑᒻടᎿㆊ⒟ߦ߅ߌࠆ⚛᧚ߩᄖᒻᒻ⁁ߩㅪ⛯ᄌൻ㧔ታ᷹࠺࠲㧕7.0 9.0 11.0 13.0 15.0 17.0 19.0 0 5 10 15 20 25 Punch stroke S /mm Rq /m m 40° 50° 60° 70° 80° 䋨A䋩 Hb=3䋬Rb=13.2 40㫦 60㫦 80㫦 7.0 9.0 11.0 13.0 15.0 17.0 19.0 0 5 10 15 20 25 Punch stroke S /mm Rq /m m 40° 50° 60° 70° 80° 䋨A䋩 Hb=3䋬Rb=13.2 40㫦 60㫦 80㫦 40㫦 60㫦 40㫦 60㫦 80㫦 7.0 9.0 11.0 13.0 15.0 17.0 19.0 0 5 10 15 20 25 30 Punch stroke䇭S /mm Rq 䇭/m m 40° 50° 60° 70° 80° 䋨B) Hb=0 40㫦 80㫦 60㫦 7.0 9.0 11.0 13.0 15.0 17.0 19.0 0 5 10 15 20 25 30 Punch stroke䇭S /mm Rq 䇭/m m 40° 50° 60° 70° 80° 䋨B) Hb=0 40㫦 80㫦 60㫦 40㫦 80㫦 60㫦 40㫦 80㫦 60㫦 ࿑㧙㧥 ࡄࡦ࠴ࠬ࠻ࡠࠢߦ㑐ㅪઃߌߚ⚛᧚ߩᄖᒻᒻ⁁ߩᄌൻ 㧔A㧕㧕ޔࡄࡦ࠴ࠬ࠻ࡠࠢ߇٤4߆ࠄ٤5ߦ⒖േߔࠆ Ბ㓏ߢ⚛᧚ߪᲑᏅⓨ㑆ߣⷺㇱⓨ㑆ߦ߶ߣࠎߤหᤨ ߦቢోߦ႟ᕈᵹߔࠆߎߣ߇ಽ߆ࠆޕ߹ߚޔᲑᏅⓨ 㑆߳ߩ⚛᧚ߩ႟ᕈᵹേߪ⚛᧚߇ဳოߦ㆐ᓟߦ 㐿ᆎߔࠆ߇ޔ⚛᧚ߪဳო㕙ߦ㆐ߒߡ߆ࠄਅ2ᣇ ะ߳ߣᵹࠇ߇ಽ߆ࠇߡలḩߔࠆߎߣ߇ಽ߆ࠆޕᲑᏅ ⓨ㑆ߦ⚛᧚߇లḩߔࠆᲑ㓏ߢޔᲑᏅⓨ㑆ߩౝო㕙ߣ ⚛᧚ߩ㑆ߦᱷࠆࠊߕ߆ߥⓨ㓗㧔࿑㧔A㧕ߦ␜ߔ٤E㧕 ߇႟ᕈᵹࠇߩ㐽Ⴇ⁁ᘒࠍ㒐ߋᓎഀࠍᨐߚߔߣ⸒߃ ࠆޕߎߩㇱಽߩᚑᒻຠᄖᒻߪޔဳߦࠃࠆ᜔᧤ࠍฃߌ ߥ⥄↱ߥ႟ᕈᵹࠇߢᒻᚑߐࠇࠆᭂዊᦛ㕙ߣߥࠆޕ หᦛ㕙ߪ᧼ਛᄩㇱߩ┄ߺ㕙ߣ᧼ᄖㇱᐩ㕙ࠍ ⚿߱ᦛ㕙ߢࠅޔ․ߦᓟടᎿߦࠃࠆ࠻ࡒࡦࠣߪਇ ⷐߣ⠨߃ࠆޕ ߥ߅ޔᲑᏅⓨ㑆ߩᷓߐHbߪᧄታ㛎ߢߪ3mmߦ⸳ቯ ߒߚ߇ޔߒᲧSc/Sb=4.43ߩᲑᏅⓨ㑆ࠍ⸳ߌߚဳ 㧔Rb=13.2mmޔḴRw=1.8mm㧕ࠍ↪ߚታ㛎⚿ᨐ ߆ࠄޔ⚛᧚߇ᲑᏅⓨ㑆ౝ߳2 mm႟ᕈᵹേߒߚ⁁ᘒߢ ຠⷺㇱߪ㕙ขࠅC=1.0ߦ⋧ᒰߔࠆ⦟ᅢߥᒻ⁁ߣ ߥࠆ߇ಽ߆ߞߚޕ ৻ᣇޔဳᐩ㕙ߦᲑᏅⓨ㑆ࠍ⸳ߌߥဳߩ႐ว㧔࿑ 㧔B㧕㧕ޔࡄࡦ࠴ࠬ࠻ࡠࠢ߇ਃⷺࡑࠢ5ߩ⟎ߢ ⚛᧚ߩ႟ᕈᵹࠇ߇߶ߣࠎߤᱛߒߡޔᣇߒㇱ ဳოߩਅⷺㇱ߇ᰳ⡺⁁ᘒߩ߹߹㐽Ⴇ⁁ᘒߣߥ ࠅޔࡄࡦ࠴⩄㊀ߛߌ߇Ⴧടߒ⛯ߌࠆߎߣ߇ಽ߆ࠆޕ ဳᐩ㕙ߦᲑᏅⓨ㑆ࠍ⸳ߌߚ႐วߣ⸳ߌߥ႐ว ߦ߅ߌࠆᚑᒻຠߩᄖᒻᒻ⁁ߩ⋧㆑ὐࠍቯ㊂⊛ߦ ␜ߔࠆߚߦޔဳᐩ㕙ߩਛᔃ⟎ߢ߈ⷺࠍ10°ߕ ߟᄌ߃ߚ⋥✢ࠍ↪ߡหਛᔃὐ߆ࠄ᷹ߞߚ⚛᧚ 㕙ߩὐ߹ߢߩ〒㔌Rqߣࡄࡦ࠴ࠬ࠻ࡠࠢߩ㑐ଥ ࠍ᳞ߚޕ⚿ᨐࠍ࿑࿑㧙㧥ߦ␜ߔޕ࿑ਛ㧔A㧕ߩᲑᏅ ⓨ㑆ࠍ⸳ߌߚ႐วߩᣇ߇ޔ࿑ਛ㧔B㧕ߩᲑᏅⓨ㑆ࠍ ⸳ߌߥ႐วߦᲧߴߡRqߩ୯߇ᄢ߈ߊߥࠆߎߣ߇ ࠊ߆ࠆޕߔߥࠊߜޔᣇㇱᣇะ߳ߩ᧚ᢱߩᵹࠇ߇ ᄢ߈ߎߣ߇ࠊ߆ࠆޕ 㧠㧚⚿⸒ ᧄ⎇ⓥߢߪ಄㑆ゲኻ⒓ᣇߒ㎊ㅧടᎿߦ߅ ߡޔဳߦࠃࠆടᎿຠᄖ✼ㇱߩᒻ⁁ォ౮⢻ࠍ⪺ߒߊ ะߐߖࠆߎߣ߇ߢ߈ࠆဳౝㇱᐩ㕙ߦ⸳ߌࠆᲑᏅ ⓨ㑆㧔Ⅳ⁁Ḵ㧕ߩ⸳⟎ⷐઙࠍታ㛎ࠪࡒࡘ㧙࡚ࠪࡦ ߦࠃࠅࠄ߆ߦߒߚޕ⎇ⓥᚑᨐࠍએਅߦߔࠆޕ (1) ဳౝㇱᐩ㕙✼ㇱಽߦㆡಾߥᲑᏅⓨ㑆㧔ታ㛎ߦ↪ ߚဳߩ႐วޔᲑᏅⓨ㑆ߩḴ Rw=1.5㨪4 mmޔḴ ᷓߐ Hb=3mm ߩⅣ⁁ᲑᏅⓨ㑆㧕ࠍ⸳ߌߚဳࠍ↪ ߚᚑᒻടᎿߢߪޔ⚛᧚ߩలႯ⁁ᘒ߇⪺ߒߊะߒޔ ࡄࡦ࠴⩄㊀߇ 105kN ߢဳ߳ߩలႯ߇߶ߣࠎߤቢੌ ߔࠆޕ․ߦḴ Rw=1.8mm ߢߪޔဳⓨ㑆߳ߩ⚛᧚ లႯ߇ᦨ߽⦟ᅢߣߥࠆޕᐔ㕙ᛩᓇ࿑ߢߺࠆߣޔဳ ― 7 ―
ⷺㇱ߆ࠄߩ〒㔌ߪ 0.37mm ߣߥࠅ C=0.5 ߩ㕙ขࠅߦ ⋧ᒰߔࠆఝࠇߚలႯ⁁ᘒ߇ᓧࠄࠇߚޕ৻ᣇޔᲑᏅ ⓨ㑆ࠍ⸳ߌߥဳࠍ↪ߚᚑᒻടᎿߢߪޔࡄࡦ࠴ ࠬ࠻ࡠࠢ߇ 26mm ઃㄭߢ㐽Ⴇ⁁ᘒߣߥࠅޔࡄࡦ ࠴⩄㊀㧔ᦨᄢ୯㧕ࠍ⚂ 125 kN ߹ߢჇߒߡ߽႟ᕈᵹ ࠇߪᱛ⁁ᘒߢߞߚޕ (2)ᦨ߽⦟ᅢߥᄖ✼ㇱᒻ⁁ォ౮߇ᓧࠄࠇߚᲑᏅⓨ㑆 㧔Rw=1.8mm㧕ࠍ⸳ߌߚဳࠍ↪ߚᚑᒻടᎿߦ߅ ߡޔߎߩᲑᏅⓨ㑆ᒻ⁁ߩ․ᓽࠍᣇߒㇱᮮᢿ 㕙Ⓧ Sc ߣᲑᏅⓨ㑆ㇱᮮᢿ㕙Ⓧ Sb ߩᲧ㧔Sc/Sb㧕ߢ ⸥ߔࠆߣޔSc/Sb=4.43 ߣߥࠆޕߎߩ୯ߪޔᐔ㕙 ߭ߕߺᣇߒ㎊ㅧടᎿߦ߅ߌࠆᦨఝ⦟ᒻ⁁ォ ౮ ⢻ ࠍ ᓧ ߚ Ბ Ꮕ ⓨ 㑆 ᒻ ⁁ ࠍ ห ᭽ ߦ ⸥ ߒ ߚ Sc/Sb=4.43ߣ৻⥌ߒߚޕ (3) ဳⷺㇱ߳ߩ⚛᧚ߩ႟ᕈᵹേߪޔ⚛᧚߇ဳ㕙ߦ ㆐ߒߡ߆ࠄ㐿ᆎߒޔਅᣇะ߳ᵹࠇ߇ಽ߆ࠇߡ లḩߔࠆޕᲑᏅⓨ㑆ࠍ⸳ߌߚ႐วޔᣇㇱᣇะ ߳ߩ᧚ᢱᵹࠇ߇ᄢ߈ߊߥࠆޕ߹ߚޔᧂలႯㇱಽߩ ߪ❑ࠃࠅඨᓘᣇะ߇ᄢ߈ޕ (4) ᲑᏅⓨ㑆ߩḴࠍ Rw=1.8mm㧔Sc/Sb=4.43㧕ߦ⸳ ቯߒߡޔḴᷓߐࠍ Hb=2mm ߣߒߚ႐วߢ߽ޔဳߩ ᒻ⁁ォ౮⢻߇⪺ߒߊะߔࠆߎߣ߇ࠊ߆ߞߚޕ (5) ဳᐩ㕙✼ㇱߦᲑᏅⓨ㑆ࠍ⸳ߌߚဳࠍㆡ↪ߒߚ႐ วޔᚑᒻຠᐩ㕙ਛᄩㇱߦ┄ߺ㕙߇ᚑᒻߐࠇࠆߎߣ ߦߥࠆޕߎߩ┄ߺ㕙ࠍ࿁ォࡁࡉ߿ࡈࠗࡎࠗ࡞ ߩ⸳⸘ᒻ⁁ߦ⋧ᔕߐߖࠆߣޔ㧔ᚑᒻຠߣဳߩㅪ៤⸳ ⸘ߦࠃࠆ㧕ࡀ࠶࠻ࠪࠚࠗࡊടᎿ߇ታߢ߈ࠆޕ ⻢ㄉ ᧄ⎇ⓥߩㆀⴕߦ߅ߡޔᧄቇਛᄩታ㛎Ꮏ႐ߩᛛⴚ ⡯ຬߩᣇޘߦဳߩᲑ㓏ߢ⒳ޘߩߏදജࠍ㗂߈ ߹ߒߚޕ⎇ⓥᚑᨐߩ߹ߣߦ㓙ߒߡෘߊ߅␞↳ߒ ߍ߹ߔޕ ෳ⠨ᢥ₂ 1㧕Ỉኪ㧦ᯏ᪾ⷐ⚛ߩ⸳⸘⸃ᨆޔጊᶏၴޔp.265(1967) 2㧕ਛ⾫ੑޔ—⑥㓶ੑ㧦႟ᕈߣടᎿޔ36-418, pp.1300-1306(1995) 3㧕ਛ⾫ੑޔᄢ㊀Ⓜੑޔ⼱ବᐔ㧦ᣣᧄᯏ᪾ቇળ ⺰ᢥ㓸 A ✬ޔ63-616, pp.203-208(1997) 4㧕ᬀ⋿৻㇢ޔਛ⾫ੑޔ⼱ବᐔޔጊਅᐽᐔ㧦 ႟ᕈߣടᎿޔ46-532, pp. 402-406 (2005)