JP3442014B2 - Method and apparatus for corrugating a thin metal plate - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus for passing a thin metal plate between a pair of gears that mesh and rotate to corrugate the thin metal plate. The present invention relates to a method and a device for corrugating a metal foil for producing a corrugated foil used for the metal catalyst carrier honeycomb body.

[0002]

2. Description of the Related Art A catalyst carrier composed of a honeycomb body carrying a catalyst is installed in an exhaust gas passage for the purpose of removing harmful components contained in exhaust gas discharged from an internal combustion engine such as an automobile engine by a catalytic reaction. To be done. The catalyst carrier is composed of a honeycomb body having a large number of cells through which exhaust gas passes, and a ceramic or metal honeycomb body is used as the honeycomb body.

The metal honeycomb body is manufactured mainly by using a thin foil made of stainless steel, and is formed by spirally winding or laminating a metal flat foil and a metal corrugated foil. . The metal corrugated foil is a foil obtained by corrugating a metal flat foil, and is manufactured by passing a metal thin plate 13 between a pair of gears that mesh and rotate as shown in FIG. As a rotation driving method for a pair of gears, a rotation driving device is connected to one gear to form the driving side gear 2. The other gear is the non-driving side gear 3, meshes with the driving side gear, and rotates in synchronization with the rotation of the driving side gear.

As the gear that meshes and rotates, a general gear having a shape such as involute parallel teeth shown in FIG. 6 has been conventionally used. As a matter of course, the driving-side gear and the non-driving-side gear were gears having the same tooth profile.

[0005]

Conventional metal thin plate 13
In the corrugating process, the metal thin plate was broken during the process of passing the thin plate between the rotating gears to form the corrugated plate 1.

Similarly, in corrugation processing of the conventional metal thin plate 13, after the thin plate is passed between rotating gears to form a corrugated plate, the corrugated plate 1 is flattened as shown in FIG. However, the phenomenon of curling (curl 15) occurred. The curl 15 is generated by being wound around the drive-side gear 2 of the set of gears. Further, the thinner the metal thin plate 13 is, the more severe the curl 15 is. Therefore, in the case of a metal honeycomb body which is used by corrugating a thin metal foil, a particularly severe curl 15 is generated.

When an attempt is made to form a metal honeycomb body by using the curled corrugated foil as described above, when the flat foil and the corrugated foil are laminated to form a honeycomb body, the curled 15
Must be flattened by some means and the foils must be piled up while maintaining that state. If the flat holding means is opened during the stacking, the laminated corrugated foil returns to a curled state. Therefore, it is necessary to maintain the flat holding means until the honeycomb body is housed in the metal outer cylinder. Also, in the case of a shape in which a flat foil and a corrugated foil are spirally wound to form a honeycomb body, at the beginning of winding, it interferes with the work of engaging the curled corrugated foil between the flat foils, and at the end of winding. At the moment, the corrugated foil is curled into small pieces as soon as the corrugated foil is shear-cut, which hinders the formation of the winding end portion.

The present invention provides a method and apparatus for passing a thin metal plate between a pair of gears that mesh and rotate to corrugate the thin metal plate, and a method for preventing a trouble of breaking the thin metal plate. It is a first object to provide a method and a device, and a second object is to provide a method and a device for preventing the phenomenon that the corrugated sheet is curled after the corrugation process.

[0009]

That is, the gist of the present invention is as follows. ( 1 ) A method of passing a metal thin plate between a pair of gears that mesh and rotate to corrugate the metal thin plate, wherein one of the pair of gears is a drive-side gear 2 and the other is Non-driving
The side gear 3 and the tip corner portion 4 in the cross section of the gear
Shape of the curve of or contact the chamfered portion 9 at the tip corner
The shape of the curved line 10 is that the drive side gear 2 becomes the non-drive side gear 3
Characterized by a shape with a smaller curvature compared to
And corrugated metal thin plate processing method. ( 2 ) A corrugating device for a thin metal plate having a pair of gears that mesh and rotate, wherein one of the pair of gears is driven.
The drive side gear 2 is connected to the drive device and the other is not driven
The side gear 3 and the tip corner portion 4 in the cross section of the gear
Shape of the curve of or contact the chamfered portion 9 at the tip corner
The shape of the curved line 10 is that the drive side gear 2 becomes the non-drive side gear 3
Characterized by a shape with a smaller curvature compared to
A corrugating machine for thin metal plates.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION First, an embodiment of the present invention for preventing breakage of a thin metal plate during corrugation processing will be described.

FIG. 6 shows a cross-sectional shape of an involute spur gear which has been conventionally used for corrugating a metal thin plate 13. The tooth surface 6 and the tooth bottom 8 of the involute spur gear are cut by a tool such as a hobbing machine, and the tooth surface 6 forms an involute tooth surface shape. On the other hand, the tip 7, which is the tip of the tooth, forms a tip circle 14 centered on the center of the gear. After the hobbing process is completed, the tip circle 14 is formed by a grindstone using a cylindrical grinder. Therefore, the tooth surface 6
A sharp bent surface is formed at an intersection 5 between the tooth tip circle 14 and the tooth tip circle 14. As a result of the study by the present inventors, the cause of the breakage of the metal thin plate in the conventional corrugation processing is the tooth surface 6 described above.
Since the metal thin plate is constrained and strong bending deformation is applied at the sharp bent surface of the intersection 5 of the tooth tip circle 14 with the tooth circle 14, smooth plastic deformation is hindered, and as a result, the metal thin plate is broken. It turned out to be

In the present invention, the cross-sectional shape of the tip portion of the gear is formed with a smooth curve, or the tip cross-sectional shape is chamfered so that the thin metal plate at the time of corrugation is processed. It is characterized by preventing breakage.

After the involute tooth flank 6 and the tip circle 14 at the tip are formed by the same gear manufacturing process as in the conventional case, the tip corner portion 4 where the tooth flank 6 and the tip circle 14 intersect is smoothed by means such as grinding. The gear shape of the present invention can be obtained by forming a curved shape or by forming the intersecting portion as the chamfered portion 9. Further, in the conventional hobbing machine for forming an involute gear, only the tooth flank 6 and the root 8 are machined by the hobbing machine, while the hobbing machine also grinds the tooth flank 6 and the root 8 together with the tooth tip 7. By cutting, the cutting tool has a rounded curve at the intersection of the tooth flank 6 and the tooth tip 7, or a chamfered shape at the intersection of the tooth flank 6 and the tooth tip 7. The gear shape of the present invention can be formed only by hobbing.

As for the shape of the tooth tip, it is basically formed by an involute tooth surface and a tooth tip circle as in the conventional case, and the intersection of both is rounded as shown in FIGS. 2 (a) and 2 (b). Not only the method of forming a curved line or the method of forming a chamfered shape as shown in FIG. 3A, but the entire tooth tip may be formed as a large semicircular shape as shown in FIGS. 3C and 3D. Of course, the tooth surface 6 may have an involute shape as shown in FIGS. 2 (a) and 2 (c), or FIG. 2 (b) (d) and FIG.
It may be a straight line or an arbitrary curve as shown in (b).

Next, an embodiment of the present invention for preventing the corrugated sheet 1 from curling after corrugation will be described.

As a result of the research conducted by the present inventors, when one of the pair of gears is used as the driving gear 2 and an ordinary gear is used for gear rotation, the waves formed by the teeth of the driving gear 2 ( (Hereinafter referred to as corrugated sheet mountain portion 11 as shown in FIG. 5)
When comparing the wave formed by the teeth of the non-drive side gear 3 (hereinafter referred to as the trough 12 of the corrugated plate), the crest portion 11 formed by the drive side gear 2 is formed by the non-drive side gear 3. It was found that the plastic working amount was larger than that of the valley portion 12. And, the mountain portion 11 and the valley portion 1
It was also found that the difference in the plastic working amount from that of No. 2 is the cause of the corrugated sheet 1 after the corrugation processing being curled on the driving side.

The present invention has been made on the basis of the above findings, and the curved shape of the tip corner portion 4 or the shape of the curve in contact with the tip corner chamfered portion 9 in the gear cross section is such that the drive side gear 2 is not driven side. It is characterized by having a shape having a smaller curvature than that of the gear 3. Here, when the tip corner portion 4 of the gear is an involute shape having a tip circle as shown in FIG. 2A or a substantially trapezoidal shape as shown in FIG. 2B, The two side corners 4 of the trapezoid are referred to, and when the tip of the tooth tip of the gear has a large semicircular shape as shown in FIGS. 2C and 2D, the semicircular shape is indicated as a whole.

When the metal thin plate 13 is corrugated by the meshing of a pair of gears, the metal thin plate 13 is plastically worked along the tooth profile of the meshed gears to form a corrugated shape. At this time, it is considered that the greater the curvature of the gear tip corner portion 4 is, the greater the restraining force with respect to the metal thin plate and the greater the degree of plastic working. When the same gear shape is originally used as the drive side and non-drive side gears, the crest portion 11 of the corrugated sheet formed by the drive side gear 2 as described above has a plastic working amount as compared with the opposite valley portion 12. Is getting bigger. If the plastic working amount is large, the springback amount is small, and if the plastic working amount is small, the springback amount is large. Since the springback angle at the crest of the wave is small and the springback angle at the trough is large, curling occurs on the drive-side gear side. Therefore,
By making the driving-side and non-driving-side gears different in shape, and making the shape of the curve at the tip corner part the driving-side gear 2 a curve with a smaller curvature than the non-driving-side gear 3,
It is possible to cancel the difference in the amount of plastic working between the peak portion 11 and the valley portion 12 of the wave. As a result, it is possible to prevent the occurrence of the curl 15 of the corrugated sheet 1 that has occurred after the corrugation process.

As shown in FIGS. 2 (c) and 2 (d), when the tip of the tooth tip of the gear has a large semicircular shape, the curvature of the curve of the tip corner portion 4 inevitably becomes substantially equal to the curvature of the semicircle, Since it is a large semicircle, the curvature is naturally small. On the other hand, when the tip of the gear has a substantially trapezoidal shape as shown in FIGS. 2A and 2B and the tip corner portion 4 is a rounded curve, the curve of the tip corner portion 4 is inevitable. The curvature of is larger than that of the large semicircle.
Therefore, the tip of the drive-side gear 2 has a large semicircular shape as shown in FIGS. 2 (c) and 2 (d), and the tip of the non-drive-side gear 3 has a tip corner portion as shown in FIGS. 2 (a) and 2 (b). If 4 has a rounded trapezoidal shape, the curvature of the tip corner curve of the driving gear 2 and the non-driving gear 3 is configured as in the present invention to prevent the curl 15 from occurring. Can be done (Fig. 1).

The shape of the corner portion 4 at the tip of the gear is most preferably a smooth curve, but as shown in FIGS. 3 (a) and 3 (b).
It is also possible to chamfer the tip corner as shown in. By setting the angle θ of the chamfered portion 9 in FIG. 4 to be 120 ° or more, it is possible to obtain an effect substantially equal to that of the case of a smooth curve. When the chamfered shape is used, the curvature of the curve in contact with the chamfered portion 9 can be treated in the same manner as the curvature of the smooth curve, and thus even when one or both of the pair of gears has the chamfered tip corners 4. If the relationship between the shapes of the tip corners of the drive-side gear 2 and the non-drive-side gear 3 is configured as in the present invention, the curl 15 can be prevented from occurring.

The degree of the curl 15 of the corrugated sheet after the corrugation process decreases as the difference in the curvatures of the tip corner portions of the drive-side gear 2 and the non-drive-side gear 3 increases. If the difference in the curvatures is too large, the non-driving side gear 3 will be curled. Therefore, the curvatures of the tip corner portions of the driving-side gear 2 and the non-driving-side gear 3 can be determined so as to eliminate the curl of the corrugated sheet after the corrugation processing by making an optimal combination through experiments or the like.

The degree of curling of the corrugated sheet 1 after corrugation is
The thinner the metal thin plate 13 is, the larger it is. That is, even when the proper gear shape that does not cause curl is determined based on the present invention, the optimum gear shape may differ depending on the plate thickness of the metal thin plate 13 used for corrugation.

Curling after corrugation can also be prevented by driving both of the pair of gears. However, in order to apply an equal driving force to both gears and rotate both gears in synchronization, it is necessary to use a precise rotation control system, which leads to an increase in cost of the device. Therefore, as in the present invention, the drive gear is only one,
A method in which the driving-side gear 2 and the non-driving-side gear 3 have different gear shapes is more preferable as a curl prevention measure.

[0024]

EXAMPLE The present invention was applied in the manufacture of a metal honeycomb body used as a catalyst carrier for exhaust gas purification. Foil thickness 20
Corrugated processing is applied to the stainless steel foil of μm, wave height 1.2
A corrugated foil having a wave pitch of 5 mm and a wave pitch of 2.5 mm is formed, and the corrugated foil and a stainless flat foil having the same foil thickness of 20 μm are alternately wound to form a honeycomb body to obtain a metal honeycomb body.

In the comparative example, the involute spur gear shown in FIG. 6 is used, one gear is the driving gear 2 and the other is the non-driving gear 3 as shown in FIG. 5, and between the pair of gears. Corrugation was performed by passing through a stainless steel foil.
When corrugating, the distance between the cores of both gears was gradually reduced to make the wave height dimension a predetermined 1.25 mm. When the wave height reached 1.0 mm, foil breakage occurred and operation was continued. lost. Further, in the corrugated foil that could be formed by the time immediately before breaking, curl 15 was observed on the drive-side gear 2 side.

In the reference example 1, both the drive-side gear 2 and the non-drive-side gear 3 have two tip corners 4 each having a radius of curvature (reciprocal of curvature) as shown in FIG. 2 (a).
Was a smooth curve of 0.2 mm. In the corrugation process, breakage of the corrugated foil as seen in the comparative example did not occur at all. On the other hand, the corrugated foil is curled 15 on the side of the drive side gear 2.
Was observed.

In the first example of the present invention, the driving side gear 2 has a large semicircular tooth tip as shown in FIG.
The radius of curvature of the semicircular shape was 0.26 mm. In addition, the non-driving side gear 3 has a shape shown in FIG. 2A, the shape of the two tip corners 4 is a smooth curve with a radius of curvature of 0.1 mm, and the shape of the tooth tip 7 is a tooth circle 14. Based on the shape. Regarding the shape of the tooth flank 6, both the drive side gear 2 and the non-driving side gear 3 are involute tooth flanks. When corrugating the stainless foil as shown in FIG. 1 using these gears, not only the breakage of the corrugated foil as seen in the comparative example did not occur but also the curl of the corrugated foil 15
Was not seen. Therefore, in producing a metal honeycomb body by spirally winding the corrugated foil and the flat foil produced in this manner, it is possible to produce a honeycomb body without any hindrance to the forming at both the winding start and the winding end. I was able to.

As Example 2 of the present invention, the non-driving side gear 3 is shown in FIG.
As shown in (a), the tip corner portion was chamfered. The angle θ of the chamfered portion in FIG. 4 was 135 °, and the length L of the chamfered portion was 0.1 mm. Other conditions are the same as those of the second example of the present invention. When corrugating of the stainless foil was performed using these gears, no breakage of the corrugated foil occurred and no curl 15 of the corrugated foil was observed, as in Example 1 of the present invention.

[0029]

EFFECTS OF THE INVENTION A method and an apparatus for passing a thin metal plate between a pair of gears that mesh and rotate to corrugate the thin metal plate, particularly a wave used for a metal catalyst carrier honeycomb body for purifying exhaust gas. A method and apparatus for corrugating a metal foil for producing a foil, wherein one of a pair of gears has a drive side tooth.
Car, if the other is a non-drive side gear, disconnect the gear
The shape of the curve at the tip corner of the surface, or the tip
The shape of the curve that touches the corner chamfer is
With a shape with a smaller curvature than the non-drive side gear
If so, the corrugated sheet will be curled after the corrugation process.
It has become possible to prevent such a phenomenon. This allows
To manufacture a catalyst metal carrier honeycomb body for exhaust gas purification
When using a curl-free corrugated foil,
It has become possible to manufacture cam bodies.

[0030]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a state where corrugation is performed using a pair of gears of the present invention.

FIG. 2 is a partial cross-sectional view showing the shape of the gear of the present invention,
(A) and (b) are formed by forming smooth curves at the two tip corners of the gear, and are used as non-drive side gears. In (c) and (d), the tip of the tooth tip of the gear has a large semicircular shape and is used as a drive-side gear.

FIG. 3 is a partial cross-sectional view showing the shape of the gear of the present invention,
The gear has two chamfered tip corners and is used as a non-drive side gear.

FIG. 4 is a partial view showing details of a tip end portion of the gear of FIG.

FIG. 5 is a cross-sectional view showing a state where corrugation processing is performed using a conventional involute spur gear.

FIG. 6 is a partial cross-sectional view showing the shape of a conventional involute spur gear.

FIG. 7 is a diagram showing a state in which a corrugated sheet is curled in a conventional corrugating process.

[Explanation of symbols]

1 corrugated board 2 Drive side gear 3 Non-drive side gear 4 Tip Corner (Invention) 5 Tip corner (conventional example) 6 Tooth surface 7 addendum 8 roots 9 chamfer 11 Mountains of corrugated sheet 12 Valley part of corrugated sheet 13 Metal thin plate 14 Tip circle 15 curls

─────────────────────────────────────────────────── --- Continuation of the front page (56) References JP-A-9-187660 (JP, A) JP-A-8-229615 (JP, A) JP-A-7-80558 (JP, A) JP-A-50- 116361 (JP, A) JP 2000-193388 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) B21D 33/00 B21D 13/04

Claims (2)

(57) [Claims] 1. Gold between a pair of gears that mesh and rotate.
A method of passing a metal thin plate and corrugating the metal thin plate
In the method, one of the pair of gears is a drive-side gear and the other is a non-drive-side gear, and the curved shape of the tip corner portion in the gear cross section or the shape of the curve in contact with the tip corner chamfer is The method for corrugating a metal thin plate, wherein the driving-side gear has a shape having a smaller curvature than that of the non-driving-side gear. 2. A pair of gears that mesh with each other and rotate.
A corrugating device for a thin metal plate, wherein one of the pair of gears is a driving gear and is connected to the driving device, and the other is a non-driving gear, and a curve of a tip corner portion in the gear cross section Or the curved shape in contact with the tip corner chamfer is a drive-side gear having a smaller curvature than a non-drive-side gear, the corrugating apparatus for a thin metal plate.