JP4328372B2 - Core metal manufacturing method, core metal and injection gear - Google Patents

Description

The present invention relates to a method for manufacturing core metals of various uses and various shapes, for example, core metals for injection gears, by press working with an automatic transfer press, and the core metal and injection gear manufactured by the manufacturing method.

  An injection gear is incorporated in a pinion type electric power steering of an automobile. In the injection gear, a resin gear B is coated and formed on the outer periphery of a metal core metal A shown in FIGS. 9A and 9B as shown in FIGS. In the core metal A, both front and back surfaces of the peripheral edge portion D of the shaft hole C and the outer peripheral portion E are thick, and a large number of concave and convex protrusions F are formed on the entire outer periphery of the outer peripheral portion E. The uneven projection F is for preventing the resin gear B from slipping or misaligned by the resin gear B coated and molded by a molding method such as injection molding on the outside thereof. .

Conventional core metal for injection gears is formed by cold forging. In cold forging, intermediate annealing, lubrication, and the like are required in the forming process, which increases the number of work steps, interrupts the work, takes time for production, and increases the cost of the core metal to be manufactured.

Method of manufacturing a core metal according to claim 1 is to transfer the flat metal material is a blank or coil material in a press, drawing, and press working such burring, flat by drawing in press some shaped for the metal material protrudes on one of its front and back surfaces, opening the pilot hole by burring in the press machine to the projecting portion, the flange projecting a peripheral edge of the prepared hole in a cylindrical shape Forming a shaft through hole having increased thickness peripheral edges projecting to both the front and back sides of the metal material by pressurizing the flange by pressing with a press to increase the thickness of the metal material from the original thickness. holes in the resin coating point of the outer peripheral portion of the metal material, indentations, projections, irregularities, gear, notch, characterized by molding the resin locking portion such as a lug.
Method of manufacturing a core metal according to claim 2 is to transfer the flat metal material is a blank or coil material in a press, drawing, and press working such burring, flat by drawing in press some shaped for the metal material protrudes on one of its front and back surfaces, opening the pilot hole by burring in the press machine to the projecting portion, the flange projecting a peripheral edge of the prepared hole in a cylindrical shape Forming a shaft through hole having increased thickness peripheral edges projecting to both the front and back sides of the metal material by pressurizing the flange by pressing with a press to increase the thickness of the metal material from the original thickness. The outer peripheral edge of the metal material is formed with an increased outer peripheral edge, and the outer peripheral edge of the increased thickness is projected to one of the front and back surfaces of the metal material by pressing with a press, and the outer peripheral edge is pressed. Bend by machine Superimposed on other portions of the genus material, or a press under pressure to fit closer to the other parts of the metal material, or and forming by compressing in a press.
Method of manufacturing a core metal according to claim 3 is to transfer the flat metal material is a blank or coil material in a press, drawing, and press working such burring, flat by drawing in press some shaped for the metal material protrudes on one of its front and back surfaces, opening the pilot hole by burring in the press machine to the projecting portion, the flange projecting a peripheral edge of the prepared hole in a cylindrical shape Forming a shaft through hole having increased thickness peripheral edges projecting to both the front and back sides of the metal material by pressurizing the flange by pressing with a press to increase the thickness of the metal material from the original thickness. , Resin locking parts such as holes, dents, protrusions, irregularities, gears, notches, cut-and-raised pieces, etc. are formed in the resin-coated part of the outer peripheral part of the metal material, and the thickened outer peripheral edge part on the outer peripheral part of the metal material Forming and increasing the outer peripheral edge of the press machine The outer peripheral edge of the metal material is projected to either one of the front and back surfaces of the metal material by pressing, and the outer peripheral edge of the metal material is folded onto another part of the metal material, or the other part of the metal material is pressed by the press. It is characterized in that it is formed by being brought together or compressed by a press .

The core metal according to claim 4 is a core metal formed by the core metal manufacturing method according to claim 1 , and a shaft having thickened peripheral edge portions protruding on both the front and back sides of the metal material on a part of the flat metal material. A through hole is provided , and a resin locking portion such as a hole, a dent, a protrusion, an unevenness, a gear, a notch, and a cut and raised piece is provided in a resin coating portion on the outer peripheral portion of the metal material.
The core metal according to claim 5 is a core metal formed by the core metal manufacturing method according to claim 2 , and a shaft having a thickened peripheral edge portion protruding from both sides of the metal material on a part of the flat metal material. A through hole is provided, and the outer peripheral edge of the metal material is protruded on either the front or back surface of the metal material by pressing with a press machine , and the outer peripheral edge is bent to form another metal material. It is characterized by having a thickened outer peripheral edge that is thickened by being overlapped with a part, or by being brought together with another part of a metal material, or by being crushed by compression.
The core metal according to claim 6 is a core metal formed by the core metal manufacturing method according to claim 3 , and a shaft having thickened peripheral edges protruding from both sides of the metal material on a part of the flat metal material. A through hole is provided, and a resin-covered portion such as a hole, a dent, a protrusion, an unevenness, a gear, a notch, and a cut-and-raised piece is provided at a resin-coated portion on the outer periphery of the metal material. The peripheral edge is projected on one of the front and back surfaces of the metal material by pressing with a press, and the outer peripheral edge is bent and overlapped with another part of the metal material, or on the other part of the metal material. It is characterized by having a thickened outer peripheral edge that is thickened by bringing together or by crushing by compression.

According to a seventh aspect of the present invention, there is provided an injection gear in which the resin gear is coated and formed from the resin coating portion of the core metal and the outer periphery of the core metal to the outer side of the core metal according to any one of the fourth to sixth aspects. It is characterized by being locked and fixed to the stopper.

The core metal manufacturing method of the present invention has the following effects.
(1) Unlike cold forging, there is no need for intermediate annealing or lubrication during production, and metal materials are automatically transferred by a press machine and can be continuously formed until the core metal is completed. The cost of the core metal that is produced is reduced.
(2) The part protruded by drawing or bending is crushed by pressing, overlapped with other parts of the metal material by bending, or brought together with other parts of the metal material by compression. Therefore, even a thin metal material can be thickened to form a core metal having a thick part.
(3) Since the resin locking part is formed by press working, a resin locking part having a shape and structure in which the resin can be easily locked, such as holes, notches, and cut-and-raised pieces that could not be formed by cold forging, is formed. Therefore, it is suitable for manufacturing core metals for injection gears.
(4) Since the molding is performed by pressing , it is possible to reduce the weight of the core metal by making a hole in the metal material or cutting a part of the metal material.
(5) In order to mass-produce by cold forging, it is necessary to prepare a large number of molds with the same shape and structure, or to prepare a mold for taking a large number of molds. variation is converted to products, but also the variation comes into dimensions of core metal that is manufactured, the manufacturing method of the present invention by pressing hardly out such variations, product dimensions are stabilized.

The core metal of the present invention is inexpensive because it is manufactured by the core metal manufacturing method of the present invention, and includes a resin locking portion having a shape and structure that is difficult to form by cold forging.

  In the injection gear of the present invention, since the resin injection gear is coated on the core metal provided with the resin locking portion having a shape that is difficult to form by cold forging, the locking and fixing of the injection gear to the core metal is stable. In addition, rattling and displacement of the injection gear are prevented.

(Embodiment 1 of the manufacturing method of a core metal )
There are various embodiments of the manufacturing method of the core metal of the present invention. FIG. 1 shows an example in which the core metal to be manufactured is a core metal for an injection gear, and is an example in which a disk-shaped blank material is manufactured while being automatically transferred by a transfer processing press. The processing steps will be described below.
(1) The blanked flat disk-shaped metal material 1 (FIG. 1 (1)) is supplied to the press machine, and in the first draw process (FIG. 1 (2)) of the press machine, The center part 2 is squeezed out to the surface side (upper side in the figure) of the metal material 1 and transferred to the next process when the squeezing is completed.
(2) In the second draw process (FIG. 1 (3)) of the press machine, the outer peripheral edge 3 of the metal material 1 is squeezed and protruded to the surface side (upper side in the figure) of the metal material 1. In this case, as shown in FIG. 3 (a), the lower portion 3a of the protruding outer peripheral edge 3 is slanted so that the upper portion 3b rises vertically, or the lower portion 3a to the upper portion 3b as shown in FIG. 3 (c). It can also be squeezed to stand up vertically.
(3) In the edge forming step (FIG. 1 (4)) of the press machine, the outer peripheral edge 3 in FIG. In this case, as shown in FIG. 3B, the thick edge 4 is arranged such that the inner lower end portion 4a that spreads at the bottom is aligned with the inner lower end portion 3c of the outer peripheral edge portion 3 (FIG. 3A). As shown in FIG. 3 (c), the protruding outer peripheral edge 3 can be bent at the upper part 3a inward to form a thick edge 4 that spreads at the bottom. In this case, the thick edge 4 has an inner lower end 4a (FIG. 3 (d)) that spreads out from the inner lower end 3a (FIG. 3 (c)) of the outer peripheral edge 3 before bending.
(4) In the piercing process of the press machine (FIG. 1 (5)), a small hole 5 is formed in the central portion 2 of the metal material 1 that has been squeezed out first.
(5) In the burring process of the press machine (FIG. 1 (6)), the small hole 5 of the metal material 1 is enlarged to open the pilot hole 6, and the peripheral edge of the pilot hole is extruded to the front side of the metal material 1 in a cylindrical shape. The flange 7 is formed.
(6) In the molding process of the press machine (FIG. 1 (7)), the flange 7 is crushed by pressurization to increase the peripheral edge 8 of the pilot hole 6, and the pilot hole 6 is turned into a shaft hole. The thickening process can be performed as shown in FIG. In FIG. 2, the pilot hole 6 of the metal material 1 subjected to burring is placed on a receiving base 10 by covering the die 9 with a round bar shape, and a ring-shaped regulation base 11 is arranged on the outer periphery of the metal material 1, and the punch 16 Thus, the flange 7 of the metal material 1 is pressed and crushed. Since the pressurized flange 7 is restricted from being laterally spread by the restriction table 11, the peripheral edge 8 of the prepared hole is increased in thickness. Reference numeral 17 in FIG. 2 denotes a clearance hole for the tip side of the die 9 to enter when the punch 16 is lowered.
(7) In the gear (resin locking portion) forming step (FIG. 1 (8)) of the press machine, the uneven gear (resin locking portion) 12 is formed on the entire outer periphery of the thick outer peripheral edge portion 4. This resin latching | locking part 12 is a shape shown to Fig.4 (a), (b), Fig.9 (a), (b). The resin latching portion 12 is not limited to this shape, and may have other shapes. Other shapes will be described later.
(8) In the trim processing step of the press machine (FIG. 1 (9)), the outer side 13 of the outer peripheral edge 4 of the metal material 1 is cut and removed (bordered) into a ring shape, and the outer diameter of the inner core metal 14 is set to a predetermined dimension. To.

The disk-shaped core metal 14 press-molded as described above is taken out from the press, and the upper edge 15 of the inner peripheral surface of the prepared hole is cut (chamfered) into another R surface by another machine. This chamfering process can also be performed by the press machine. This chamfering process can also be performed after resin molding described later.

  A resin gear 15 is formed by coating the outer peripheral portion of the disk-shaped core metal 14 processed as described above with resin as shown in FIGS. As a molding method of the resin gear 15, there is, for example, injection molding or other methods.

(Embodiment 2 of the manufacturing method of a core metal )
Another embodiment of the core metal manufacturing method of the present invention is shown in FIG. Although this embodiment is also a case where the core metal for injection gears is manufactured using a press machine, it is the case of Embodiment 1 in using the coil material wound in roll shape instead of the blank material as a metal material. And different. Details will be described below.
(1) A coil material wound in a roll shape (FIG. 5 (1)) is continuously supplied to the press machine by a coil material supply mechanism (not shown) provided at the front stage of the press machine.
(2) The supplied coil material is blanked by a blanking mechanism (not shown) to obtain a disk-shaped blank material (metal material) 1 (FIG. 5 (1)). The blank 1 is sequentially transferred to the next processing step by the transfer mechanism of the press.
(3) In the first draw process of the press machine (FIG. 5 (2)), the central portion 2 of the metal material 1 is squeezed out to the surface side of the metal material 1.
(4) The squeezed part is secondarily squeezed to increase the squeeze height in the second draw process (FIG. 5 (3)) of the press machine.
(5) The portion extracted in the second draw step is subjected to third drawing in the third draw step (FIG. 5 (4)) of the press machine to make the outer shape of the squeezed portion thinner.
(6) In the piercing step of the press machine (hole punching step: (FIG. 5 (5))), a small hole 5 is formed at the top of the previously narrowed portion.
(7) In the burring process (FIG. 5 (6)) of the press machine, burring is performed to enlarge the small hole 5 of the metal material 1 to form the pilot hole 6, and the cylindrical peripheral portion 8 of the pilot hole is projected The flange 7 is formed. At the same time, the outer peripheral portion 3 of the metal material 1 is drawn to squeeze the outer peripheral portion 3 in the same direction as the flange 7.
(8) In the molding process of the press machine (FIG. 5 (7)), the flange 7 is pressed and crushed to increase the thickness, and the peripheral edge 8 of the pilot hole is molded to have a thickened inner hem. Also in this case, it can be molded using a mold as shown in FIG. Simultaneously with the pressurization, the outer peripheral edge portion 3 is also crushed by the pressurization to increase the thickness, thereby forming a thick edge 4 that spreads at the bottom. Also in this case, the thick edge 4 can be bent inward to increase the thickness.
(9) In the gear forming step of the press machine (FIG. 5 (8)), the uneven gear 12 is formed on the entire outer periphery of the thick edge 4 as shown in FIG.
(10) In the trim processing step of the press machine (FIG. 5 (9)), the outer portion 13 of the outer peripheral edge 3 is cut (bordered) into a ring shape, and the outer diameter of the disk-shaped core metal 14 remaining inside is predetermined. Make dimensions.

(Embodiment 1 of core metal)
The core metal of FIGS. 9A and 9B has a gear-shaped resin locking portion, but the resin locking portion of the core metal of the present invention may have other shapes. 6 (a) to 6 (d) as an example thereof, a round hole 20 and an elongated hole 21 are formed in the outer peripheral portion of the disk-shaped metal material 1 with a press machine, and the outer peripheral portion is drawn and processed. Protruding to the surface side of the raw material 1, crushing the outer peripheral part by pressurization to form the thick edge 4, forming the round hole 20 and the vertically long hole 21 as the resin locking part 12, and covering resin into these holes It flows in and is locked and fixed. The resin locking holes may be all round holes or vertically long holes. It may be a square hole or other shaped hole. Instead of a hole, it may be a depression, unevenness or notch, a cut-and-raised piece 23 as shown in FIGS.

(Embodiment 2 of core metal)
7 (c) and 7 (d), a raised piece 23 is formed on the outer periphery of a disk-shaped metal material 1 by forming a convex piece 24 (FIGS. 7 (a) and (b)). It can be formed by projecting slightly from the inside to the surface side of the metal material 1 by drawing or bending, and crushing the convex pieces 24 by pressing to form a thick wall. The cut-and-raised piece 23 becomes the resin locking portion 12, and the resin gear is locked and fixed thereto.

(Embodiment 3 of core metal)
7C and 7D are all protruded in the same direction (surface side of the metal material), but can also be protruded on both the front and back sides of the disk-shaped metal material 1. In any case, many of the cutting pieces 23 do not have to have the same shape, the same size, and the same protruding length, and can have different shapes, sizes, and protruding lengths.

The core metal of the present invention is not limited to the disc shape, and may be other desired shapes. The size, structure, molding position, thickness, shape, length, etc. of the thickened portion are other than those shown in the figure. Even molding is possible.

(Embodiment of injection gear)
As an example of the injection gear of the present invention, the one shown in FIG. 8 is formed by coating the resin gear B from the outer periphery to the outside of the core metal shown in FIG. It is fixed to the resin locking part 12 by the vertically long hole 21. Gear grooves G are formed on the outer peripheral surface of the resin gear B at uniform intervals as shown in FIGS.

The core metal manufacturing method of the present invention can also manufacture core metals having various shapes, structures, and sizes used in other fields.

Explanatory drawing of an example of the manufacturing process of the manufacturing method of the core metal of this invention. Explanatory drawing which shows an example of the cylinder part pressurization method in the manufacturing method of the core metal of this invention. (A)-(d) is explanatory drawing which shows two examples of the method of crushing the outer periphery part by pressurization in the manufacturing method of the core metal of this invention. (A) is a top view which shows an example of the core metal manufactured with the manufacturing method of the core metal of this invention, (b) is sectional drawing of the core metal. Explanatory drawing of the other example of the manufacturing process of the manufacturing method of the core metal of this invention. (A)-(d) is explanatory drawing which shows an example of the processing method of the resin latching | locking part of the core metal shape | molded with the manufacturing method of the core metal of this invention. (A)-(d) is explanatory drawing which shows the other example of the processing method of the resin latching | locking part of the core metal shape | molded with the manufacturing method of the core metal of this invention. Sectional drawing which shows an example of the core metal for injection gears which coat | covered the resin-made gears with the core metal of this invention. (A) is the surface side perspective view which shows an example of the core metal for conventional injection gears, (b) is a back surface side perspective view of the core metal. (A) is the surface side perspective view which shows an example of the conventional injection gear, (b) is the back surface side perspective view of the gear.

DESCRIPTION OF SYMBOLS 1 Metal material 2 Center part of metal material 3 Outer peripheral edge part 3a Lower part of outer peripheral part 3b Upper part of outer peripheral part 3c Inner lower end part of outer peripheral part 4 Thick edge 4a Inner lower end part of thick edge 5 Small Hole 6 Pilot hole 7 Flange 8 Pilot hole peripheral part 9 Die 10 Receiving base 11 Restricting base 12 Uneven gear (resin locking part)
13 Outer part of outer peripheral edge of metal material 14 Core metal 15 Upper edge of inner surface of pilot hole 16 Punch 17 Escape hole 20 Round hole 21 Long hole 23 Cut and raised piece 24 Convex piece A Core metal B Plastic gear C Shaft hole D Edge E Outer periphery F Concavity and convexity projection G Gear groove

Claims (7)

A flat metal material that is a blank material or a coil material is transferred with a press machine, and press processing such as drawing and burring is performed.
A part of the flat metal material protrudes to either the front or back by drawing with a press machine .
It drilled pilot hole by burring in the press machine to the projecting portion to form the flange so as to protrude the periphery of the prepared hole in a cylindrical shape,
Pressurizing the flange by pressing with a press machine to increase the thickness of the original thickness of the metal material to form a shaft through hole having a thickened peripheral edge projecting on both the front and back sides of the metal material ,
A method for producing a core metal, comprising molding resin locking portions such as holes, dents, protrusions, irregularities, gears, notches, cut-and-raised pieces, etc. in resin-coated portions on the outer periphery of a metal material. A flat metal material that is a blank material or a coil material is transferred with a press machine, and press processing such as drawing and burring is performed.
A part of the flat metal material protrudes to either the front or back by drawing with a press machine .
It drilled pilot hole by burring in the press machine to the projecting portion to form the flange so as to protrude the periphery of the prepared hole in a cylindrical shape,
Pressurizing the flange by pressing with a press machine to increase the thickness of the original thickness of the metal material to form a shaft through hole having a thickened peripheral edge projecting on both the front and back sides of the metal material,
A thickened outer peripheral edge is formed on the outer peripheral edge of the metal material, and the increased outer peripheral edge protrudes to either the front or back surface of the metal material by pressing with a press machine, and the outer peripheral edge is pressed by the press machine. A method for producing a core metal, characterized in that the core metal is formed by being folded by being overlapped with another part of the metal material, or pressed with a press machine and brought together with another part of the metal material, or compressed with a press machine . A flat metal material that is a blank material or a coil material is transferred with a press machine, and press processing such as drawing and burring is performed.
A part of the flat metal material protrudes to either the front or back by drawing with a press machine .
It drilled pilot hole by burring in the press machine to the projecting portion to form the flange so as to protrude the periphery of the prepared hole in a cylindrical shape,
Pressurizing the flange by pressing with a press machine to increase the thickness of the original thickness of the metal material to form a shaft through hole having a thickened peripheral edge projecting on both the front and back sides of the metal material,
Molding resin locking parts such as holes, dents, protrusions, irregularities, gears, notches, cut-and-raised pieces, etc. on the resin-coated parts on the outer periphery of the metal material,
A thickened outer peripheral edge is formed on the outer peripheral edge of the metal material, and the increased outer peripheral edge protrudes to either the front or back surface of the metal material by pressing with a press machine, and the outer peripheral edge is pressed by the press machine. A method for producing a core metal, characterized in that the core metal is formed by being folded by being overlapped with another part of the metal material, or pressed with a press machine and brought together with another part of the metal material, or compressed with a press machine . A core metal manufactured by the core metal manufacturing method according to claim 1 ,
A part of a flat metal material is provided with a shaft through hole with thickened peripheral edges protruding on both the front and back sides of the metal material, and holes, dents, protrusions, irregularities, gears, notches, core metal, characterized in that with a resin locking portion such as a lug. A core metal formed by the core metal manufacturing method according to claim 2 ,
Provided with a shaft through hole with a thickened peripheral edge protruding on both the front and back sides of the metal material in a part of the flat metal material ,
The outer peripheral edge of the metal material is projected on one of the front and back surfaces of the metal material by pressing with a press, and the outer peripheral edge is bent and overlapped with the other part of the metal material. A core metal comprising a thickened outer peripheral edge which is thickened by bringing it together with other parts of a metal material or by crushing by compression. A core metal formed by the core metal manufacturing method according to claim 3 ,
Provided with a shaft through hole with a thickened peripheral edge protruding on both the front and back sides of the metal material in a part of the flat metal material ,
Hole in the resin-coated portion of the outer peripheral portion of the metal material, indentations, with projections, irregularities, gear, notch, the resin locking portion such as a lug,
The outer peripheral edge of the metal material is projected on one of the front and back surfaces of the metal material by pressing with a press, and the outer peripheral edge is bent and overlapped with the other part of the metal material. A core metal comprising a thickened outer peripheral edge which is thickened by bringing it together with other parts of a metal material or by crushing by compression. A resin gear is coated and formed from the outer periphery of the core metal to the resin coating portion of the core metal according to any one of claims 4 to 6, and the resin gear is locked and fixed to the resin locking portion of the core metal. Injection gear characterized by

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