JPH0767595B2 - Washer manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a method for manufacturing a washer.

[0002]

2. Description of the Related Art Washers have a wide range of use, and the number used is considerably large. Generally, they are used by interposing screw parts such as bolts or nuts, and when tightening work with bolts or nuts, While increasing the force receiving area for tightening, it is expected that the effect of interference and slack prevention will be improved by increasing the number of the pressure contact portions, and that damage due to excessive tightening of the equipment on the bottom surface of the screwed component will be prevented. Since the washer belongs to a consumable item and has a large demand, a large amount of material is usually purchased and mass-produced.
Since it does not require a high degree of precision, is not a complicated part, and its size is in a certain range, it lacks the attractiveness of further research and development of its production technology, and even now, it relies mostly on the punching press manufacturing method. ing.

As shown in FIG. 7, the manufacture is carried out by feeding a sheet material A in the form of a ribbon coil into a press,
When the spacing distance T between the washers A1 produced by punching and shearing is set in the sheet material A and the punch of the press is driven to start the punching operation, each washer A1 is sequentially pushed to the sheet material A1. While being pushed out from A, the sheet material A in the circular through hole A2 at the center of each washer A1 is also
After punching out all the washers A1 set on the entire sheet material A by punching and discharging according to the punching operation of the punch, the sheet material becomes scrap and is sold as scrap iron if a certain amount is collected. It

At the time of punching, as shown in FIG. 7, in addition to the method of arranging the punching range of the washer A1 on the sheet material A in a single row, the dense staggered arrangement method as shown in FIG. 8 is most often used. As is the case with the method shown in FIG. 7, it is a principle that the washer A1 is arranged in the tightest arrangement and the interval between punching and punching is set to the same degree as the thickness of the sheet material. The rows are arranged in a hexagonal arrangement while interlacing the washer punching positions. Besides, if the width of the sheet material is expanded infinitely in the arrangement as shown in FIG. 8, it is considered that the washer punching arrangement can be increased infinitely. It is used for the theoretical estimation of and is difficult to implement.

Perhaps the most regrettable point in producing washers by punching shear at present is probably the material waste problem. Here, the actual situation of wasting materials will be described by taking as an example the washers used for bolts and nuts of three types such as M10, M20 and M30;

Washer size; Standard of threaded parts Washer inner diameter Washer outer diameter Washer thickness M10 11mm 21mm 2mm M20 22mm 37mm 3.2mm M30 33mm 56mm 4.5mm

Material utilization rate: Standard of screw parts Single row press Three row press Infinite row press M10 43.71% 50.56% 54.86% M20 39.84% 45.89% 49.66% M30 40.88 % 46.95% 50.72%

As can be clearly seen from the above data, when a washer is manufactured by punching forging, the material utilization rate is almost 50% or less. In other words, more than half of the materials purchased by the production factory are used. It is wasted, and this kind of waste is passed on to consumers.

[0009]

SUMMARY OF THE INVENTION In view of the above problems in the conventional washer manufacturing method, the present invention significantly increases the utilization rate of materials used, reduces production costs, and enhances mechanical strength. It is an object to provide a method for manufacturing a washer.

[0010]

According to the present invention, a wire is fed into a die hole formed of one member by a feeding means,
Further, after extending the front end of the wire rod by a predetermined length from the opening of the end face of the die provided opposite to the punch, the wire rod is clamped by the chuck means, and the punch is driven to face the die end face. A press forging operation is performed to press the wire rod extended from the end face of the die to a standard thickness of the washer, and further release the fixed state of the punch rod axially attached to the punch with the punch. The punching punching is actuated toward the central portion of the wire rod pressed to the thickness of the wire rod, and at this time, the chucking means and the feeding means simultaneously loosen the nipping of the wire rod to allow the wire rod to retreat. A washer is formed by punching a through hole in the central portion, and finally, the punch and the punch rod retract together, and the punch rod contracts and retracts into the punch shaft hole to form the washer. Punch rod Method of manufacturing a washer to be al detached is provided.

A chuck means for tightly gripping the wire rod and a feeding means for feeding the wire rod into the die hole are provided behind the die, and a punch for performing a pressing operation at a proper time toward the die is provided at the front end of the die. Installed relative to the surface,
Further, it is more preferable to use a structure in which a punch rod having the punch attached thereto is released from a fixed state with the punch at a proper time to perform a punching operation independently.

[0012]

As described above, according to the present invention, the wire rod is fed into the die hole by the feeding means to extend the front end of the wire rod from the opening of the die front end surface by a predetermined length, and then the chuck means is used. The wire rod is sandwiched, a punch facing the die front end face is driven to perform a press forging operation toward the die, and the wire rod extended from the die end face is pressed to a thickness of a washer. The punch rod having the punch attached thereto is released from the punch, and the punching operation is performed toward the central portion of the wire rod pressed to the thickness of the washer,
At the same time, the chuck means loosens the holding of the wire rod and pushes out a through hole in the central portion of the wire, and the forged streamline of the washer that can be observed by a metallographic microscope on the front surface and the cross section of the wire from the central through hole. The punch and rod are retracted together, as well as the punch rod retracts into and retracts from the punch shaft hole, and the formed washer forms the punch. Since the washer is configured to be detached from the rod, the mechanical strength of the manufactured washer is increased, the used material is not wasted, and the production cost can be reduced.

A chuck means for tightly gripping the wire rod and a feeding means for feeding the wire rod into the die hole are provided at the rear of the die, and a punch which performs a pressing operation at a proper time toward the die is provided at the front end of the die. Installed relative to the surface,
Moreover, since the punch rod axially attached to the punch releases the fixed state with the punch to perform the punching operation independently, the press punching shearing work can be performed quickly and surely. Become.

The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the embodiments with reference to the drawings.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a schematic view showing a method for manufacturing a washer according to the present invention.
As shown in the figure, the material used in the present invention is a wire rod 1, a die 2 and a punch 3 corresponding to the die 2 are provided in the forging process, and the punch 3 is fixed to the punch 3 at a proper time. The punch rod 4 which is openable and retractable is axially attached, and is driven by the driving means 5 of the overall punch 3 and performs reciprocating press operation toward the die 2 and at an appropriate time and position. By operating the punch rod 4, the fixed state with the punch 3 is released so that the punch 3 can be expanded and contracted separately from the punch 3, and the outer diameter of the punch rod 4 is forged. Inner diameter and wire rod 1
The wire feeding means 6 and the chuck means 7 are provided behind the die 2 so as to have the same outer diameter.

The wire rod feeding means 6 feeds the wire rod 1 into the hole of the die 2. Before the wire rod 1 extends into the hole of the die 2, the wire rod 2 which has been coiled is first straightened. The chuck means 7 holds the wire rod 1 transported to a predetermined position, holds the wire rod 1 so that it is sufficiently fixed when the wire rod 1 is punched and sheared, and the wire rod 1 is held at an appropriate time.
To release (described later).

For example, FIG. 1 is a view showing a state in which the wire rod feeding means 6 of the present invention has already fed the wire rod 1 into the die hole and the tip of the wire rod is extended to a predetermined position outside the die hole. The length of the wire 1 extending from the die hole is converted from the volume of the washer 8 to be punch-molded in accordance with the outer diameter standard of the wire 1.
Since it has just been transported and fixed to a predetermined position, it is extremely firmly clamped and held by the chuck means 7 at this time.

As shown in FIG. 2, after the wire material 1 transported and fixed at a predetermined position is clamped by the chuck means 7,
The driving means 5 drives the punch 3 to perform punching toward the die 2, and the wire rod 1 extended from the hole of the die 2
Is press-molded until the end face of the punch 3 and the end face on the die side have a set distance (thickness of the washer to be manufactured), that is, at this time, the wire rod 1 is squeezed to have an outer diameter of the washer 8 to be formed. Outer diameter standard.

Further, as shown in FIG. 3, after the punch 3 presses the wire rod 1 to a predetermined thickness, the punch rod 4 axially attached to the punch 3 extends as a separate body from the punch 3, The wire rod 1 which has already been squeezed into a washer shape is punched toward the center of the head, and the tip of the punch rod 4 pushes out the washer 8 to form a through hole in the washer 8 so that the tip portion is in the die 2 hole. At this time, the central wire rod existing in the through hole of the washer 8 is pressed into the hole of the die 2, so that the punch rod 4 performs the push-out operation, and at the same time, the chuck means 7 and the feeding means 6 are pushed. Exhibiting an appropriate relaxation state to allow the punched wire to move backwards,
Then, the feeding means 6 tries to move backward to prepare for the next transportation of the wire rod 1.

Subsequently, as shown in FIG. 4, the punch rod 4
After the punching work is finished, the punch 3 shrinks into the punch 3 until its front end surface becomes substantially flat with the end surface on the punch 3 side.
Then, the washer 8 formed by punching is returned to its original position where it is not punched, and the washer 8 formed by punching is dropped by its own gravity to be collected, and the feeding means 6 is chucked by the chuck means. Prepare to feed in the wire 1 sandwiched between.

That is, the forging equipment according to the present invention repeats the operations shown in FIGS. 1 to 4 to forge the washer 8 and is manufactured by the manufacturing method of the present invention comprising the above forging steps. The washer has the following advantages:

1. The material utilization rate is close to 100%,
The scrap generation rate is almost zero (there are only a small amount of wear at the front end and the end of each wire roll, and this wear is less than 1 kg when each wire roll is about 1.5 Ton (conventional). In the manufacturing method of 7 for every 1.5 Ton of sheet material
Since 50 kg of scrap is generated), the material cost can be significantly reduced by completely utilizing the entire material, and this merit can be passed on to the consumer.

2. The material used in the present invention is a wire, and the prices of steel plates (conventional washer manufacturing materials) produced by the China Steel Corporation of Taiwan are compared as follows. Wire material; material Quality of wire material Diameter (Ton) 1008 11mm NT $ 10490 1008 22mm NT $ 10490 1008 33mm NT $ 10490 1045 11mm NT $ 10500 1045 22mm NT $ 10500 1045 33mm NT $ 10500 Steel plate thickness Steel plate (Ton) 1002 2mm NT $ 11330 1008 3.2mm NT $ 11290 1008 4.5mm NT $ 11260 1045 2mm NT $ 12090 1045 3.2mm NT $ 12050 1045 4.5mm NT $ 12020

From the above price analysis, it is found that the wire rod price is lower than the steel plate price, and when the washer is forged with a general steel plate, the material utilization rate is only about 50%, and the washer forging method of the present invention is used. When applied, the material can be used almost completely, and thus the present invention is a washer manufacturing method that provides a considerable economic return in terms of production costs.

3. Moreover, even if it says from the physical properties of the manufactured washer, as can be seen by referring to FIGS. 5 and 6, the washer manufactured by the conventional forging method has a forged streamline display diagram (generally, a front view and a cross section). The forged streamlines are so dense that they can be seen for the first time with a metallographic microscope, and this figure is an enlarged view of this.) As shown in FIG. 5, the steel sheet material has undergone rolling punching. Therefore, the forged streamline A ₉ is in a parallel state both in the front and in the cross section. Therefore, when the threaded component is fastened to the front, the threaded component will be in contact with each forged streamline A ₉ . It is difficult to evenly distribute the tightening force, and when a bending test is carried out, the washer clearly breaks easily from the center of the forged streamline A _{9 in} the parallel arrangement, and the bending occurs at a point perpendicular to the forged streamline A ₉ (not shown). ) Does not easily rupture in the center There is observed, can be seen how the force received by the each of its sides is not uniform.

On the other hand, as shown in FIG. 6, the washer manufactured by the manufacturing method of the present invention has a forged streamline 9 on its front surface.
Are formed radially from the central portion through hole 10 toward the peripheral edge 11, and the cross-section forged streamline 9 also flows from the central portion through hole 10 toward the peripheral edge 11 and is further curved at the peripheral edge 11 to form the central portion through hole 10. Since the forged streamline 9 of the washer is uniformly subjected to the force when the threaded component is screwed, the same result is obtained on each side surface when the bending test is performed. , The physical properties of washers made in accordance with the present invention are more ideal than washers made by conventional methods.

4. As can be seen from the cross-sectional views in FIGS. 5 and 6, since the washer manufactured by the conventional method is based on the cutting punching, the upper edge of the outer peripheral wall forms an arcuate edge that curves downward, The lower edge of the inner peripheral wall forms an arcuate edge that curves upward, and the cut peripheral wall of the outer periphery usually has cracks, which is not ideal because the external appearance of the product is affected. , There is an arcuate space at the lower edge of the inner peripheral wall, and when screwing a screwed component from above, the upper edge of the inner peripheral wall is dented downward (it may not be obvious to the naked eye, but it certainly exists). The pressing force is largely applied to the outer peripheral edge of the washer, which affects the fastening stability. On the other hand, as shown in FIG. 6, since the outer peripheral wall surface of the washer manufactured according to the present invention has an arcuate shape, the appearance is not unsightly, and the punch rod has a punch and a die holding the wire firmly. Since the push-out operation is performed, the inner peripheral wall surface of the washer becomes smooth in the vertical direction, and when the screwed component is fastened from above, there is no tail fin in which the upper end edge of the inner peripheral wall falls downward.

5. The conventional washer is manufactured by directly punching a steel sheet by roll forming, and the washer according to the present invention is manufactured through each forming step such as pressing and punching, so that it has an advantage of work hardening, especially in a general fastening state. There is a screw hole below the washer that has a relatively larger diameter than the threaded part (that is, a hole with a larger diameter than the through hole in the center of the washer). Therefore, when the washer is fastened by the threaded part, Although the peripheral edge of the through hole receives a force and is slightly recessed downward, the washer manufactured according to the present invention has the advantage of work hardening,
The degree of lower depression due to this phenomenon is reduced.

[0029]

As described above, according to the present invention, since the relatively inexpensive material is used, and the utilization rate of the material is greatly improved so that there is almost no waste, the production cost of the washer can be considerably reduced. The manufactured washer has ideal mechanical properties, and has an excellent effect on the fastening strength of threaded parts such as bolts, thereby increasing industrial profit. In addition, since the die is made of one member, unlike the conventional method using a die made of a pair of members, a part of the wire rod does not escape into the gap between the pair of members to generate a burr, which results in the wire rod. It is not necessary to open the pair of die members in order to pass them through. Further, when the wire is forged, a part of the acting force is received by the radial inner peripheral surface of the die, so the chuck means on the rear side of the die only needs to hold the wire with a small force, which reduces the load. It does not matter if a minute gap is generated between the chuck means and the wire.

[Brief description of drawings]

FIG. 1 is a diagram showing a first stage of a manufacturing apparatus and a manufacturing process in an embodiment of the present invention.

FIG. 2 is a diagram showing a second stage of the manufacturing process.

FIG. 3 is a diagram showing a third stage of the manufacturing process.

FIG. 4 is a diagram showing a final stage of the manufacturing process.

FIG. 5 is a view showing a forged streamline of a washer by a conventional manufacturing method.

FIG. 6 is a forging streamline display diagram of the washer according to the manufacturing method of the present invention.

FIG. 7 is a single row arrangement display view of washers in a conventional sheet material.

FIG. 8 is a three-row layout display diagram of a conventional sheet material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Wire rod 2 ... Die 3 ... Punch 4 ... Punch rod 6 ... Feeding means 7 ... Chucking means 8 ... Washer 9 ... Forging stream line 10 ... Washer central hole

Claims (2)

[Claims] 1. A part of a wire (1) is fed by a feeding means (6).
After the wire (1) is fed into the hole of the die (2) and the front end of the wire (1) is extended by a predetermined length from the end face opening of the die (2) provided facing the punch (3), The wire rod (1) is sandwiched by chuck means (7), the punch (3) is driven to perform a press forging operation toward the end face of the die (2), and the wire is extended from the end face of the die (2). A punch rod (4) in which the wire (1) is pressed to a standard thickness of a washer (8), and the punch (3) is axially attached.
Of the punch (3) is released, and the punching punching is operated toward the center of the wire (1) pressed to the thickness of the washer (8). 7) and the feeding means (6) simultaneously loosen the clamping of the wire rod (1) to allow the wire rod to retreat, and push out a through hole in the central portion of the wire rod (1) to form a washer (8). And finally, the punch (3) and the punch rod (4) retract together, and the punch rod (4) contracts and retracts into the punch (3) axial hole to form a washer (8). ) Is disengaged from the punch rod (4). 2. A chuck means (7) for tightly gripping the wire (1) and a feeding means (6) for feeding the wire (1) into the hole of the die (2) are provided behind the die (2). A punch rod (4) having a punch (3) for performing a pressing operation toward the die (2) in a timely manner so as to face the front end face of the die (2), and the punch (3) being axially attached to the punch rod (4). 2. The method for manufacturing a washer according to claim 1, wherein the punching operation is performed independently by appropriately releasing the fixed state with the punch (3).