Method and apparatus for forming an end portion of a cylindrical member

Abstract: The present invention is directed to a method and apparatus for forming an end portion of a cylindrical member or cylinder. At least one roller is supported on a main shaft to be radially moved to and from the main shaft. The cylinder is supported to position the central axis thereof on the plane including the main shaft. Then, at least one of the cylinder and the roller is driven to be rotated relative to each other about an oblique axis inclined against the central axis of the cylinder, while the roller is moved radially toward the oblique axis, with the roller being in substantial contact with the outer surface of the one end portion of the cylinder. As a result, the one end portion of the cylinder is formed into a reduced diameter portion such as a tapered portion having the oblique axis.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming an end portion of a cylindrical member such as a metal cylinder or shell, and an apparatus therefor, especially the method and apparatus for forming the end portion of the cylindrical metal member by spinning to form a reduced diameter end portion having an oblique axis inclined against the central axis of the cylindrical member. 2. Description of the Related Arts In document JP-A-03 226 327, disclosed is a method for forming an end portion of a cylindrical member (hereinafter, simply referred to as a cylinder) made of metal to form a reduced diameter portion on the end portion. According to the Publication, a spinning process is performed by supporting the cylinder with a chuck and rotating it about its axis, and moving a roller for forming toward the axis to reduce the diameter of the cylinder, thereby to form the reduced diameter portion having a neck portion and a tapered portion. In general, the spinning process is employed to form a plate into a shell. Likewise, a flange and neck portion can be formed by spin flow forming into a cylindrical can body, as disclosed in document US-A-4 563 887. Furthermore, a computerized spinning machine has been proposed in document JP-B-2 534 530. Recently, it has been requested to form a reduced diameter end portion having an oblique axis inclined against the central axis of the metal cylinder. When the metal cylinder is used for an outer shell of a muffler of an automotive vehicle, for example, the cylinder will be easily mounted in a vehicle. Also, when the metal cylinder is used for a housing of a catalytic converter, it will be easily located near an engine, to reduce increasing time of the temperature of catalyst. Furthermore, dual converters may be easily assembled, with their neck portions positioned close to each other. A method and an apparatus comprising the features summarized in the preambles of claims 1 and 9 are disclosed in document JP-A-62 167 956. According to the prior methods for forming the cylinder or shell by the spinning process, the reduced diameter portion was formed to be coaxial with the main body of the cylinder, but the reduced diameter end portion having the oblique axis could not be formed. In order to produce the cylinder like the shell or housing as described above, therefore, the portions corresponding to the main body and the reduced diameter portion were formed by press working, and then these components were connected together by welding or the like. According to these methods, however, the produced cylinder can not be expected to be so strong, comparing with that of the integral construction. Furthermore, they need the connecting process, different from the forming process, so that it is difficult to produce the cylinder by those methods, and it is almost impossible to produce the cylinder by the computerized forming process as described in the prior publication. As a result, the manufacturing cost of the cylinder shall be increased, comparing with the cylinder of the coaxial type formed by the spinning process. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a method for forming a reduced diameter end portion having an oblique axis inclined against a cylindrical member or cylinder, easily and properly by a spinning process. It is another object of the present invention to provide an apparatus for forming a reduced diameter end portion having an oblique axis inclined against a cylindrical member or cylinder, easily and properly by a spinning process. According to the invention, these objects are achieved by the method according to claim 1 and the apparatus according to claim 9. Further developments of the method and the apparatus according to the invention are defined in the dependent claims. According to the method and apparatus as described above, the reduced diameter portion may be formed to provide a tapered portion, with the diameter of the cylinder gradually reduced from a main body thereof toward the tip end thereof. The reduced diameter portion may be formed to provide the tapered portion and a neck portion of a tubular configuration extending from the tip end of said tapered portion. BRIEF DESCRIPTION OF THE DRAWINGS The above stated object and following description will become readily apparent with reference to the accompanying drawings, wherein like reference numerals denote like elements, and in which: FIG.1 is a schematic block diagram illustrating a spinning apparatus according to a first embodiment of the present invention; FIG.2 is a side view of the spinning apparatus with a portion thereof sectioned according to the first embodiment of the present invention; FIG.3 is a plan view of the spinning apparatus with a portion thereof sectioned according to the first embodiment of the present invention; FIG.4 is a perspective view showing a clamp section of the first embodiment of the present invention; FIG.5 is a perspective view of a finished cylinder formed according to an embodiment of the present invention; FIG.6 is a plan view of a cylinder showing a first spinning process applied thereto according to an embodiment of the method according to the present invention; FIG.7 is a plan view of a cylinder showing also the first spinning process applied thereto according to an embodiment of the method according to the present invention; FIG.8 is a plan view of a cylinder formed by the first spinning process according to an embodiment of the method according to present invention; FIG.9 is a plan view of a cylinder showing a second spinning process applied thereto according to an embodiment of method according to the present invention; Figs. 10 to 16 are plan views of a cylinder showing also the second spinning process applied thereto according to an embodiment of method according to the present invention; FIG.17 is a plan view of a cylinder formed by the second spinning process according to an embodiment of the method according to the present invention; FIG.18 is a flowchart showing the second spinning process according to an embodiment of the method according to the present invention; FIG.19 is a side view of a finished cylinder formed by a spinning process according to an embodiment of the present invention; FIG.20 is a side view of dual converters for use in an exhaust purifying system employing cylinders formed by a spinning process according to an embodiment of the present invention; FIG.21 is a side view of a spinning apparatus with a portion thereof sectioned according to a second embodiment of the present invention; FIG.22 is a plan view of the spinning apparatus with a portion thereof sectioned according to the second embodiment of the present invention; FIG.23 is a diagram showing a basic concept for reducing the diameter of an end portion of a cylinder by means of the spinning apparatus according to the first or second embodiment; FIG. 24 shows front views and side views of an end portion of a cylinder formed according to the basic concept of Fig. 23; FIG.25 is a plan view of a cylinder showing a third spinning process applied thereto according to an embodiment of the method according to the present invention; Figs. 26 to 29 are plan views of a cylinder showing also the third spinning process applied thereto according to an embodiment of the method according to the present invention; FIG.30 is a side view of a spinning apparatus with a portion thereof sectioned according to a third embodiment of the present invention; FIG.31 is a plan view of the spinning apparatus with a portion thereof sectioned according to the third embodiment of the present invention; FIG.32 and 33 are plan views of a cylinder showing a bending process applied thereto; FIG.34 is a plan view of a cylinder bent and reduced by the bending process according to Figs. 32 and 33; FIG.35 is a plan view of a cylinder bent and reduced by a bending process and a spinning process according to a further embodiment of the method according to the present invention; FIG.36 is a plan view of a cylinder showing a bending process applied thereto; and FIG.37 is a plan view of a cylinder bent and reduced at its opposite ends by a bending process and spinning process according to a further embodiment of the method according to the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS.1-3, there is schematically illustrated a spinning apparatus according to an embodiment of the present invention, which is adapted to configure an end portion of a cylindrical member 4 (i.e., cylinder) having a central axis Xt and an oblique axis Xe inclined against the axis Xt, as shown in FIG.5, to be used for an outer shell (not shown) of a muffler for an automobile, a case (not shown) of a catalytic converter, or the like. The cylinder to be formed according to the present embodiment is the one made of stainless steel, while it is not limited to this, and may be selected from other metallic cylinders. In FIGS.1-3, the spinning apparatus according to the present embodiment includes a first driving mechanism 2 that serves as the first driving device according to the present invention, and a second driving mechanism 3 that serves as the second driving device according to the present invention, both of which are operatively mounted on a base 1. In the first driving mechanism 2, a central axis Xr of a main shaft 21 is employed as X-axis, in parallel with which a pair of X-axis guide rails 5 are fixedly secured to one side (right side in FIGS.2, 3) on the base 1. A case 20 is arranged to be movable along the X-axis guide rails 5. The case 20 has a ball socket 7 secured under its base, which is engaged with a spline shaft 8. This shaft 8 is mounted on the base 1 in parallel with the X-axis guide rails 5, to be rotated by a servo motor 9. Accordingly, when the spline shaft 8 is rotated by the servo motor 9, the case 20 is moved along the X-axis. On the other hand, a bed 1a is formed on the other side (left side in FIGS.2, 3) of the base 1. Fixedly secured to the bed 1a are a pair of Y-axis guide rails 10, on which a pair of sliders 11 for supporting a sliding table 6 and a clamp device 12 are movably mounted, respectively. The clamp device 12 includes a lower clamp 13 rotatably mounted on the table 6, and an upper clamp 17 arranged upward the lower clamp 13, to clamp the cylinder 4 between the lower clamp 13 and upper clamp 17. The table 6 has a ball socket 14 secured thereunder, which is engaged with a spline shaft 15. This shaft 15 is mounted on the base 1a in parallel with the Y-axis guide rails 10, to be rotated by a servo motor 16. When the spline shaft 15 is rotated by the motor 16, the table 6 and clamp device 12 are moved along the Y-axis relative to the case 20. A rotating device such as a motor 31 is embedded in the table 6, and an output shaft 31a of the motor 31 extends upward in FIG.2, or vertically to the base 1, to be engaged with the lower clamp 13, which is rotated about the shaft 31a. On the upper surface of the table 6, there is formed a guide groove 32 which has a circular configuration with its center located on the shaft 31a, and into which a guide roller 33 is fitted. The guide roller 33 is rotatably mounted on the lower clamp 13, so that the lower clamp 13 is guided by the groove 32 to be rotated about the shaft 31a. Above the clamp device 12, an actuator 18, which is activated by oil pressure, for example, and which serves as a driving device, is arranged to support the upper clamp 17 and drive it vertically. When the cylinder 4 is set to or removed from the clamp device 12, the upper clamp 17 is lifted by the actuator 18 upward. A clamp face 13a of a half cylinder configuration is formed on the upper surface of the lower clamp 13, and a clamp face 17a of a half cylinder configuration is formed on the lower surface of the upper clamp 17. Therefore, when the cylinder 4 is clamped between the clamp faces 13a and 17a, it is secured not to be rotated or moved. On the clamp device 12, a stopper 19 is disposed at the opposite side to the case 20, to abut on a one end portion of the cylinder 4. The stopper 19 is secured to the lower clamp 13, so as to be movable together with the clamp device 12. If the stopper 19 is connected to the lower clamp 13 to be adjustable along the central axis Xt of the cylinder 4, positioning of the cylinder 4 in its axial direction can be made properly and easily. Accordingly, when the cylinder 4 is set on the clamp face 13a of the lower clamp 13, with the one end portion of the cylinder 4 abutted on the stopper 19, and then the upper clamp 17 is actuated to move downward by the actuator 18, the cylinder 4 is clamped at a predetermined position between the lower clamp 13 and upper clamp 17. In this case, the cylinder 4 is positioned such that its axis Xt is located on the same plane as the plane where the longitudinal central axis Xr of the main shaft 21, which will be described later, is located in parallel with the base 1, i.e., on the same height from the base 1 as the height of the axis Xr from the base 1. With respect to the second driving mechanism 3, the main shaft 21 is positioned on the same plane as the plane, on which the axis Xt of the cylinder 4 is located, and which is parallel with the base 1. The main shaft 21 is placed opposite to the cylinder 4, and mounted on the case 20 to be rotated about its axis Xr by a motor 22, which serves as the rotating device, through a connecting belt 23. A rotary member 24 is secured to one end portion of the main shaft 21 opposite to the cylinder 4, so that the rotary member 24 is rotated about the axis Xr in accordance with the rotation of the main shaft 21 about the axis Xr. The rotary member 24 is formed into a cylindrical case with a bottom, at the center of which the main shaft 21 is secured to the rotary member 24. In the case 20, a pair of actuators 25 of a pressure cylinder actuated by oil, air or the like are received and mounted on the case 20 through brackets 25b. Each actuator 25 has a rod 25a slidably received therein in parallel with the axis Xr of the main shaft 21, and moved back and forth in response to the pressurized oil or air fed into the actuator 25. A force transmitting member 26 of a circular ring plate configuration is secured to the tip ends of the rods 25a, and disposed within the rotary member 24 to be moved to and from the cylinder 4 in response to the sliding movement of the rods 25a. The transmitting member 26 has a tapered surface 26a formed on the inner surface of its open end portion, extending toward its tip end to enlarge its inner diameter gradually. As shown in FIGS.2 and 4, a plurality of support members 27 (three support members in the present embodiment) are disposed around the periphery of the rotary member 24 with an even space defined between them, and operatively mounted on the rotary member 24 to be movable in parallel with the main shaft 21, and movable in a radial direction to and from the central axis Xr of the main shaft 21. Each support member 27 has a tapered surface 27a formed on the inner side of the rotary member 24 to abut on the tapered surface 26a of the transmitting member 26. A roller 28 is mounted on the tip end of each support member 27 to be rotated about its axis. Also disposed in the rotary member 24 is a biasing device for urging each support member 27 toward the outer periphery of the rotary member 24, such as a compression spring 29 as shown in FIG.2. Accordingly, when the transmitting member 26 is activated by the actuators 25 to move forward (leftward in FIG.2), each support member 27 engaged with the transmitting member 26 through the tapered surfaces 26a, 27a, and each roller 28 mounted on the support member 27 are moved in a radial direction toward the axis Xr of the main shaft 21. Whereas, when the transmitting member 26 is retracted by the actuators 25 to move rearward (rightward in FIG.2), each support member 27 and roller 28 are moved outwardly in a radial direction. The roller 28 may be provided only one, but it is preferable to provide a plurality of rollers, so as to reduce intermittent impacts. The course traced by the roller 28 is not necessarily limited to a straight line in the radial direction, but any course may be selected as long as the roller 28 can be moved to and from the axis Xr of the main shaft 21. Instead of the actuator 25 of the pressure cylinder, other devices such as those of a screw type, lever type or the like may be employed as the device for actuating the roller 28. As a further embodiment of the device for actuating the roller 28 to be moved in a radial direction toward the axis Xr, may be employed a mechanism having a main shaft of dual tubes, which are connected to the roller 28 through differential gear units (e.g., planetary gear system, not shown herein), respectively, and wherein the rotation of the main shaft will produce a difference between the rotational speeds of the tubes, so as to cause the roller 28 to be moved in the radial direction. The motors 9, 16, 22, 31 and actuators 18, 25 are electrically connected to a controller CT as shown in FIG.1, from which control signals are output to the actuators to control them numerically. The controller CT includes a central processor MP, memory ME, input interface IT and output interface OT, which are connected with each other through a bus bar, as shown in FIG.1. The central processor MP is adapted to execute a program for spinning according to the present embodiment, and the memory ME is adapted to memorize the program and temporarily memorize variable data needed to execute the program. An input device IP is connected to the input interface IT to input initial conditions, operating conditions or the like of each actuator into the central processor MP, e.g., by operating a key board or the like manually. There are provided various sensors (not shown), if necessary, and signals detected by those sensors are fed to the controller CT, in which the signals are input from the input interface IT to the central processor MP through amplifying circuits AD or the like. The control signals are output from the output interface OT and fed into the motors 9, 16, 22, 31 and actuators 18, 25, through driving circuits AC1 to AC6. Instead of the controller CT, a control circuit may be provided for each device to perform a predetermined individual control, respectively. According to the spinning apparatus as constituted above, various methods can be contemplated for reducing the diameter of the end portion of the cylinder to form the reduced diameter end portion having the oblique axis. Referring to FIGS.6-8, will be explained an embodiment of the method for reducing the diameter of the end portion of the cylinder by the above-described spinning apparatus, to form the reduced diameter end portion having the oblique axis, by means of a single rotating process in setting the oblique axis. In FIG.6, "C0" indicates the center of rotating motion of the cylinder 4 held by the clamp device 12, and rotated about the shaft 31a of motor 31. "C1" indicates the center of the innermost end section of the oblique end portion of the cylinder 4 to be formed. "R1" is the distance between the centers (C0) and (C1). The axis Xr of the main shaft 21 is fixed on the plane in parallel with the base 1, while the cylinder 4 is rotated about the shaft 31a, i.e., center (C0), to produce an oblique angle () as shown in FIG.6. In this case, the oblique axis Xe in parallel with the axis Xr and including the center (C1) of the oblique end portion is apart from the axis Xr by a distance (S) in the direction perpendicular to the axis Xr, or parallel with the Y-axis. Therefore, the distance (S) is calculated as S=R1·sin . If each roller 28 is moved toward the axis Xr, it will trace each locus or path as indicated by two-dot chain lines in FIG.6, whereby the end portion of the cylinder 4 will not be formed properly. In order to form a proper end portion, the main shaft 21 should be set on the axis Xe. Accordingly, the axis Xe is used for a forming target axis in this embodiment, so that the cylinder 4 is moved perpendicularly to the axis Xr along the Y-axis guide rails 10, downward in FIG.6, by the distance (S). The geometric relationship between the main shaft 21 (represented by the axis Xr) and the cylinder 4 will be as shown in FIG.7, wherein the axis Xr and the forming target axis Xe are overlapped. Thus, out of five paths shown by two-dot chain lines in FIG.7, the last path indicates the configuration to be formed, which has the central axis corresponding to the forming target axis Xe, i.e., the oblique axis of the reduced diameter portion to be formed. As a result, the one end portion of the cylinder 4 is formed into the tapered portion 4b and neck portion 4c having the oblique axis Xe inclined against the central axis Xt of the cylinder 4 as shown in FIG.8. In operation, referring to FIG.2, when the upper clamp 17 is lifted upward, the cylinder 4 to be formed is placed on the clamp face 13a of the lower clamp 13, and set at the predetermined position where the one end portion of the cylinder 4 is abutted on the stopper 19. Then, the actuator 18 is driven, so that the upper clamp 17 is moved downward, and the cylinder 4 is clamped between the lower clamp 13 and upper clamp 17, and held not to be rotated. In this case, the cylinder 4 is positioned such that the axis Xt of the cylinder 4 is aligned with the axis Xr of the main shaft 21. The transmitting member 26 is positioned at a retracted position, i.e., the right side to the position as shown in FIG.2, so that each roller 28 is retracted outside of the outer periphery of the cylinder 4. Next, the motor 31 is driven to rotate the lower clamp 13 about the its output shaft 31a by the predetermined oblique angle (). Since the guide roller 33 mounted on the lower clamp 13 is fitted into the guide groove 32 formed on the upper surface of the table 6, the lower clamp 13 can be rotated along the guide groove 32 about the shaft 31a (i.e., the center (C0)) to form the oblique angle () between the axis Xr and the axis Xt as shown in FIG.6. Therefore, an oblique reference axis extending through the center (C0) and overlapping with the axis Xr is set. Then, the spline shaft 15 is rotated by the motor 16 is driven, so that the clamp device 12 and the cylinder 4 are moved along the Y-axis guide rails 10 to position the forming target axis Xe in line with the axis Xr of the main shaft 21. Accordingly, the forming target axis Xe and the axis Xr are overlapped, as shown in FIG.7. Next, the spline shaft 8 is rotated by the motor 9, so that the case 20 is advanced along the X-axis guide rails 5 (moved leftward in FIGS.2, 3), and stopped at a position for starting the spinning process, which corresponds to the center (C1) in FIG.7, and which position is set as an origin. From the state as described above, the rotary member 24 is rotated by the motor 22, and the transmitting member 26 is advanced by the actuator 25, so that each roller 28 is moved toward the center of the rotary member 24, or the axis Xr. At the same time, the spline shaft 8 is rotated by the motor 9, the case 20 and the roller 28 are retracted a predetermined distance along the X-axis guide rails 5 (rightward in FIGS.2, 3). Consequently, each roller 28 is rotated about its axis and rotated about the axis Xr of the main shaft 21, which is overlapped with the forming target axis Xe in this case, simultaneously, and moved radially toward the axis Xe, being pressed to be in contact with the outer surface of the cylinder 4, thereby to perform the spinning process. Thus, each roller 28 is started to move from the starting position, until the end portion of the cylinder is deformed by spinning, to form the tapered portion for the first cycle. In the case where each roller 28 is retracted further, exceeding the predetermined distance, the roller 28 is held to be in its state, so that the end portion of the cylinder 4 is deformed in accordance with the retracting movement of each roller 28 to form the cylindrical neck portion for the first cycle, which has the oblique axis inclined against the axis Xt by the oblique angle (), and which is integrally connected to the smallest diameter side of the tapered portion 4b. Thereafter, the cylinder 4 and roller 28 are returned to the starting positions, thereby to provide a reciprocating motion together with the initial path for reducing the diameter of the cylinder 4, so that the spinning process in the first cycle is completed. For simplifying the explanation about the spinning process, the operation for reducing the diameter is performed only in a single path of the reciprocating motion according to the present embodiment. However, the operation for reducing the diameter of the cylinder 4 may be performed in another path of the reciprocating motion as well, to perform the spinning process in both of the paths in one cycle, thereby to improve the forming efficiency. Furthermore, in view of the energy efficiency and tact-time, each roller 28 is continuously rotated about the axis Xr, without being stopped every cycle. After the spinning process in the first cycle was completed and each roller 28 was returned to the starting position, the spinning process in the second cycle is performed. In practice, the spline shaft 8 is rotated by the motor 9, the case 20 and each roller 28 are advanced, and stopped in the state where each roller 28 is located in a second position retracted from the tip end of the cylinder 4 by a predetermined length. Then, the rotary member 24 is rotated, and the transmitting member 26 is advanced, so that each roller 28 is driven radially toward the axis Xr, and then each roller 28 is retracted along the X-axis guide rails 5, being pressed to be in contact with the outer surface of the cylinder 4 thereby to perform the spinning process. By repeating the process as described above three more times, in the present embodiment, the end portion of the cylinder 4 is formed into the reduced diameter portion 4d with the tapered portion 4b and neck portion 4c having the oblique axis as shown in FIG.8. According to the above-described embodiment, the diameter of the end portion of the cylinder is reduced along the oblique axis Xe, in accordance with a single relative rotating motion between the axis Xr and the axis Xt in setting the oblique reference axis. Therefore, if the distance between the oblique axis Xe and the axis Xr is large, the diameter of the rotating motion of the roller 28 about the cylinder 4 will be large and inertia moment of the roller will be large. As a result, the apparatus will have to be large in scale. Furthermore, each roller 28 abuts on only a part of the outer surface of the cylinder 4 for a long period of time, an impact will be applied to the cylinder 4 to cause a vibration and noise. In the case where those problems are to be solved, a plurality of relative rotating motions between the axis Xr and the axis Xt are performed in setting the oblique reference axis, in accordance with another embodiment as explained hereinafter with reference to FIGS.9-17. FIG.9 illustrates a state where the cylinder 4 (axis Xt) is rotated about the center (C0) relative to the main shaft 21 (axis Xr) by an angle (1). In this case, the forming target axis Xe is offset from the axis Xr of the main shaft 21, along the Y-axis by a distance (S1=R1·sin1). Also, the center (C1) is offset along the X-axis by a distance (γ=R1 · tan1 · sin1). According to the present embodiment, therefore, by moving the cylinder 4 relative to the main shaft 21 by the distance (S1) and distance (γ), (hereinafter omitted for simplicity), the axis Xr and the forming target axis Xe are overlapped, as shown in FIG.10. Accordingly, the cylinder 4 as shown in FIG.11 is formed with the tapered portion 4b1 and neck portion 4c1 having the oblique axis Xe overlapped with the axis Xr of the main shaft 21 and inclined against the central axis Xt of the cylinder 4 by the angle (1). FIG.12 illustrates a state where the cylinder 4 (axis Xt) is rotated about the center (C0) relative to the main shaft 21 (axis Xr) further, to provide an angle (2) added to the angle (1) by an angle (Δ), and the cylinder 4 is moved relative to the main shaft 21 by the distance (S2). Therefore, the axis Xr and the forming target axis Xe are overlapped, as shown in FIG.13, and then the cylinder 4 is produced to form the tapered portion 4b2 and neck portion 4c2 in addition to the tapered portion 4b1 and neck portion 4c1, having the oblique axis Xe overlapped with the axis Xr of the main shaft 21 and inclined against the central axis Xt of the cylinder 4 by the angle (2), as shown in FIG.14. Then, as shown in FIG.15, the cylinder 4 (axis Xt) is rotated further relative to the main shaft 21 (axis Xr) to provide an angle (3) added to the angle (2) by the angle (Δ), and the cylinder 4 is moved relative to the main shaft 21 by the distance (S3), so that the axis Xr and the forming target axis Xe are overlapped, as shown in FIG.16. Accordingly, the cylinder 4 is formed with the tapered portions 4b1, 4b2, 4b3 and neck portions 4c1, 4c2, 4c3 having the oblique axis Xe, as shown in FIG.17. Next, will be explained about the operation of the spinning process as explained above with reference to FIGS.9-17, which will be performed by the controller CT in accordance with a flowchart as shown in FIG.18. At the outset, various basic data are input by the input device IP at Step 101. The data input into the controller CT are the distance (R) between the center (C0) and the center (C1), target oblique angle () and the number of forming cycles (N). And, the oblique angle per one cycle (1) is calculated (1= /N) at Step 102. Then, the program proceeds to step 103 where a counter for forming the cylinder is incremented (k=k+1), and a rotating angle (n) is set to the angle per one cycle (1) at Step 104. The program proceeds to Step 105 where a position of the roller 28 to be located on the X-axis is calculated as X=R·sin( n). And, the program proceeds to Step 106 where each rollers 28 is moved along the X-axis to be located at the position set at Step 105. Then, the program proceeds to Step 107 where the position of the roller 28 to be located on the Y-, axis is calculated as Y=R-R·cos( n), and proceeds to Step 108 where each roller 28 is moved along the Y-axis to be located at the position set at Step 107. With each roller 28 and the cylinder 4 located as described above, the spinning process is performed at Step 109. When the counter has counted up the predetermined value (N) at Step 110, the program proceeds to Step 111 where the spinning process is terminated, so that each component will be returned to its starting position and the program will end. Whereas, when the counter has not counted up the predetermined value (N) at Step 110, Steps 103-109 are repeated. According to the above-described spinning apparatus, therefore, the cylinder 4 with the tapered portion 4b (including 4b1-4b3) and neck portion 4c (including 4c1-4c3) formed at its opposite end portions is produced, as shown in FIG.19, and may be used for the housing of catalytic converter. Furthermore, two cylinders 4x, 4y of similar configuration to the cylinder 4 may be combined to produce an exhaust purifying system having dual converters, as shown in FIG.20. FIGS.21, 22 illustrate the spinning apparatus according to another embodiment. In the embodiment as disclosed in FIGS.2, 3, the case 20 is moved along the X-axis and the cylinder 4 is moved along the Y-axis, so that they are moved relative to each other, whereas according to the present embodiment, the case 20 is secured to the base 1, while the cylinder 4 is moved along the X-axis and Y-axis, and rotated about the shaft 31a of the motor 31. That is, the first driving mechanism 2 that serves as the first driving device according to the present invention are gathered in the left side in FIGS.21, 22. The rest of the components such as the second driving mechanism 3 are the same as those in the aforementioned embodiment. Therefore, the components in FIGS.21, 22 having substantially the same function as those in FIGS.2, 3 are identified by the same reference numerals in FIGS.2, 3. In the first driving mechanism 2, a pair of X-axis guide rails 5 are fixedly secured to the base 1 at the left side thereof in FIGS.21, 22. A sliding base plate 30 is provided for mounting thereon the sliding table 6, the clamp device 12 and etc., and arranged to be movable along the X-axis guide rails 5. The ball socket 7 is secured to the base plate 30 thereunder, and the spline shaft 8 to be engaged with the ball socket 7 is mounted on the base 1 in parallel with the X-axis guide rails 5, to be rotated by the motor 9. Accordingly, when the spline shaft 8 is rotated by the motor 9, the base plate 30 is moved along the X-axis. Furthermore, a pair of Y-axis guide rails 10 are secured to the base plate 30 thereon, and a pair of sliders 11 are movably mounted on the Y-axis guide rails 10. The same clamp device 12 as that shown in FIGS.2, 3 is mounted on the sliders 11, so that when the spline shaft 15 is rotated by the motor 16, the clamp device 12 is moved along the Y-axis relative to the base plate 30. According to the present embodiment, when the shaft 31a is driven by the motor 31, the clamp device 12 is rotated about the shaft 31a. When the spline shaft 8 is rotated by the motor 9, the clamp device 12 is advanced along the X-axis guide rails 5 (i.e., moved rightward in FIGS.21, 22), and when the spline shaft 15 is rotated by the motor 16, the clamp device 12 is moved along the Y-axis guide rails 10 (i.e., moved downward in FIG.17). Accordingly, the clamp device 12 is stopped when the cylinder 4 is located at a position where it is moved to position the end portion of the cylinder 4 on the forming target axis. Then, the rotary member 24 is rotated by the motor 22, the transmitting member 26 is advanced by the actuator 25, and each roller 28 is moved toward the center of the rotary member 24 (i.e., the axis Xr). At the same time, the spline shaft 8 is rotated by the servo motor 9, so that the clamp device 12 and the cylinder 4 are retracted along the X-axis guide rails 5 (i.e., moved leftward in FIGS.21, 22). Consequently, each roller 28 is rotated about its axis and rotated about the axis Xr of the main shaft 21 simultaneously, to be moved radially toward the axis Xr, being biased to be in contact with the outer surface of the cylinder 4, thereby to perform the spinning process, in the same manner as in FIGS.2 and 3. In the embodiment as disclosed in FIGS.2, 3, the axis Xt of the cylinder 4 is fixed to a position of a predetermined height above the base 1, so as to be placed on the same plane as the axis Xr of the main shaft 21 in parallel with the base 1. The height of the axis Xt of the cylinder 4 to the base 1 may be adapted to be variable, and the axis Xt may be adjusted vertically relative to the axis Xr of the main shaft 21. In other words, the apparatus may be provided with a third driving mechanism (not shown) that drives the cylinder 4 vertically, in addition to the first driving mechanism 2 and second driving mechanism 3 as those shown in FIGS.2, 3. In this case, therefore, the axis Xt of the cylinder 4 can be adjusted to be located at a predetermined vertical position relative to the base 1, and the axis Xt can be adjusted vertically relative to the axis Xr of the main shaft 21, so that a fine adjustment will be made easily in the spinning process. Referring to FIGS.23, 24, will be explained a method for reducing the end portion of a cylinder 4bo by means of the aforementioned spinning apparatus to form a reduced diameter end portion having an eccentric axis offset from the central axis of the cylinder 4. A thick solid line in FIG.23 indicates an estimated configuration of the finished cylinder 4, which includes the main body 4a, and the tapered portion 4bo and neck portion 4co which form the reduced diameter portion 4do. At the outset, a starting position (O1) for starting the spinning process is set to a position retracted from the tip end of the cylinder 4 a forming distance (L1). When the tapered portion 4bo is formed, the offset amount (H) is divided by a predetermined number of forming cycles (N) (N=5, according to the embodiment in FIG.23), so that a moving distance toward the eccentric axis every cycle. i.e., moving distance (H1) along the Y-axis per one cycle, is set. In this embodiment, each moving distance (H1) is set to be equal, but a ratio for dividing the offset amount may be altered in accordance with the forming process to be required. For example, the moving distance between the cycles in an initial stage of the forming process may be made relatively long to reduce the forming time period, or the moving distance between the cycles in a terminating stage of the forming process may be made relatively short to improve the finished accuracy of the product. Likewise, with respect to the longitudinal length, a tapered length (LT) is divided by the predetermined forming cycles (N=5), so that a moving distance (X1) along the X-axis per one cycle, is set. In FIG.23, "D" indicates a diameter of the main body 4a of the cylinder 4, "RD" indicates the smallest diameter of the tapered portion 4bo which is equal to the diameter of the neck portion 4co. "V1" indicates a reduced amount of the diameter of a portion to be formed to a large extent, and "V2" indicates a reduced amount of the diameter of a portion to be formed to a small extent. "CY1" to "CY5" indicate the cycle of the forming process. The number of forming cycles (N) is selected properly in view of the limit for reducing the diameter of the cylinder 4. According to the present embodiment, the moving distance per one cycle is set to a value which does not exceed the limit for reducing the diameter of the cylinder. The limit for reducing the diameter of the cylinder is the limit at which plastic deformation working of the cylinder can not be made appropriately due to a material characteristic of the cylinder. In operation, referring to FIG.2, when the upper clamp 17 is lifted upward, the cylinder 4 to be formed is placed on the clamp face 13a of the lower clamp 13, and set at the predetermined position where the one end portion of the cylinder 4 is abutted on the stopper 19. Then, the actuator 18 is driven, so that the upper clamp 17 is moved downward, and the cylinder 4 is clamped between the lower clamp 13 and upper clamp 17, and held not to be rotated. In this case, the clamp device 12 is positioned such that the axis Xt of the cylinder 4 is aligned with the axis Xr of the main shaft 21. The transmitting member 26 is positioned at a retracted position, i.e., the right side to the position as shown in FIG.2, so that each roller 28 is retracted outside of the outer periphery of the cylinder 4. Next, the spline shaft 8 is rotated by the motor 9, so that the case 20 is advanced along the X-axis guide rails 5 (moved leftward in FIGS.2, 3), and stopped at a position where each roller 28 is retracted from the tip end of the cylinder 4 the forming length (L1 in FIG.23). In other words, each roller 28 is positioned at the position (O1) for starting the spinning process as shown in FIG.23, which position is set as the origin. Then, the spline shaft 15 is rotated by the motor 16, and the clamp device 12 is moved along the Y-axis guide rails 10 (moved downward in FIG.3), and stopped at a position where the cylinder 4 is moved along the Y-axis guide rails 10 by the offset moving distance (H1) moved toward the eccentric shaft per one cycle. The starting position of the cylinder 4 may be set to a position where the axis Xt of the cylinder 4 is moved toward the axis Xr of the main shaft 21 along the Y-axis by the moving distance (H1). From the state as described above, the rotary member 24 is rotated by the motor 22, and the transmitting member 26 is advanced by the actuator 25, so that each roller 28 is moved toward the center of the rotary member 24, or the axis Xr. At the same time, the spline shaft 8 is rotated by the motor 9, the case 20 and the roller 28 are retracted along the X-axis guide rails 5 (rightward in FIGS.2, 3). Consequently, each roller 28 is rotated about its axis and rotated about the axis Xr of the main shaft 21 simultaneously, and moved radially toward the axis Xr, being pressed to be in contact with the outer surface of the cylinder 4, thereby to perform the spinning process. Thus, each roller 28 is started to move from the starting position (O1), until each roller 28 moves the moving distance (X1), the end portion of the cylinder is deformed by spinning, to form a tapered portion 4bo1 with its axis offset from the axis Xt of the main body 4a by the moving distance (H1), as shown in (CY1) of FIG.24, because the axis Xr, about which the roller 28 is rotated, is offset relative to the axis Xt of the cylinder 4 by the moving distance (H1). In the case where each roller 28 is retracted further, exceeding the moving distance (X1), the roller 28 is held to be in its state (i.e., the position moved the predetermined distance (H1)). Therefore, the end portion of the cylinder 4 is deformed in accordance with the retracting movement of each roller 28 to form a cylindrical neck portion 4co1, which has the central axis offset relative to the axis Xt of the main body 4a by the distance (H1), and which is integrally connected to the smallest diameter side of the tapered portion 4bo1. Thereafter, the cylinder 4 and roller 28 are returned to the starting positions, thereby to provide a reciprocating motion together with the initial path for reducing the diameter of the cylinder 4, so that the spinning process in the first cycle (CY1) is completed. The operation for reducing the diameter of the cylinder 4 may be performed in another path of the reciprocating motion as well. After the spinning process in the first cycle (CY1) was completed and each roller 28 was returned to the starting position, the spinning process in the second cycle (CY2) is performed in the same manner as described above. By repeating the process as described five times, in the present embodiment, the reduced diameter portion 4do with the tapered portion 4bo and neck portion 4co having the eccentric axis is formed. FIGS.25-29 relate to a further embodiment of the spinning method, wherein the end portion of the cylinder 4 is formed into the reduced diameter end portion having the eccentric axis and the oblique axis, by means of the apparatus as shown in FIGS.2, 3. At the outset, according to the method as explained with reference to FIGS.23, 24, the end portion of the cylinder 4 is formed into the tapered portion 4bo and neck portion 4co having the eccentric axis, as shown in FIG.25, wherein the two-dot chain line indicates the configuration to be formed, which has the oblique axis and the eccentric axis. Next, the axis Xr of the main shaft 21 is fixed on the plane in parallel with the base 1, while the cylinder 4 is rotated about the center (C0), to produce the oblique angle () as shown in FIG.26. In this case, the oblique axis, or forming target axis Xe is positioned to be in parallel with the axis Xr and to include the center (C1) of the oblique end portion, which center is apart from the axis Xr by the distance (S=R1·sin) in the direction parallel with the Y-axis. Therefore, the cylinder 4 is moved perpendicularly to the axis Xr along the Y-axis guide rails 10, downward in FIG.26, by the distance (S), so that the axis Xr and the forming target axis Xe are overlapped. Then, as shown by two-dot chain line in FIG.27, each roller 28 is rotated about its axis and rotated about the axis Xr (the forming target axis Xe) simultaneously, and moved radially toward the axis Xr, being pressed to be in contact with the outer surface of the cylinder 4, thereby to perform the spinning process. As a result, the one end portion of the cylinder 4 is formed into the tapered portion 4bp and neck portion 4cp having the oblique axis inclined against the axis Xt of the cylinder 4, as shown in FIG.28, then its tip end portion is cut out to form the tapered portion 4bp and neck portion 4cp, as shown in FIG.29. FIGS.30 and 31 illustrate the spinning apparatus according to a further embodiment, wherein a mandrel 40 of a columnar configuration, with its tip end 41 configured to correspond to the inner surface of the end portion of the cylinder to be formed, is supported above the base 1 in parallel therewith. The mandrel 40 is arranged to penetrate the main shaft 21 longitudinally, and movably supported in a coaxial relationship therewith by an actuator 42 activated by oil pressure for example, which is mounted on a bracket 1c secured to the base 1. Instead of the motor 31 in FIGS.2, 3, a motor 50 and gear box 51 engaged therewith are mounted on the sliding table 6, so as to rotate a rotating table 52, on which the clamp device 12 is mounted, about a vertical axis (not shown) at the center (C0) in FIG.6. The rest of the components in FIGS.30, 31 have substantially the same function as those in FIGS.2, 3. Therefore, the components in FIGS.30, 31 having substantially the same function as those in FIGS.2, 3 are identified by the same reference numerals in FIGS.2, 3. Referring to FIGS.32-37, will be explained a further embodiment of the method for forming the end portion of the cylinder, wherein a bending device for bending the one end portion of the cylinder is used to form a bent portion at its end, in advance to the spinning process. Referring to FIG.32, a lower die 80 and upper die (not shown) are provided to form a bore 81 having the same configuration as that of the cylinder to be bent and reduced at its end portion, as shown in FIG.34. Then, a cylinder 4z having slant open ends 4ze at its opposite ends is pushed into the bore 81 of the die 80, as shown in FIG.33, and then removed from the die 81. Through this process, the end portion of the cylinder 4z is formed into a bent and reduced portion 4zf having a substantially oblique axis Xf inclined against the central axis Xt of the cylinder 4z, as shown in FIG.34. At the same time, the slant open end 4ze of the cylinder 4z pushed into the bore 81 is formed into such an open end face of the bent and reduced portion 4zf that is perpendicular to the axis Xf. Thus, it will be unnecessary to cut out the open end of the cylinder 4z after the spinning process. As for the bending and reducing process, other processes may be employed, such as a combination of known bending process and reducing process, hydraulic forming or bulging process, high-frequency heating process, or the like. If anything is to be inserted in the cylinder 4z, like a catalyst CA as shown by broken lines in FIGS.32-37, it is preferable to insert it into the cylinder 4z at the stage as shown in FIG.32, or before pushing the cylinder 4z into the bore 81. Next, the cylinder 4z having the bent and reduced portion 4zf is set on the clamp device 12 of the spinning apparatus as shown in FIGS.30, 31. In this case, the cylinder 4z is positioned so as to align its axis Xf with the axis Xr of the main shaft 21. Then, by spinning the end portion 4zf of the cylinder 4 along the axis Xf (and, the axis Xr), the cylinder 4z with a tapered end portion 4zb and a neck portion 4zc having the oblique axis Xf is formed as shown in FIG.35, with the catalyst CA held therein. The spinning process may be performed in accordance with the same manner as described with reference to FIGS.6-17. The opposite end of the cylinder 4z may be formed in the same manner as shown in FIG.36, to produce the cylinder 4z with the tapered end portion 4zb and the neck portion 4zc formed at its opposite ends, and the catalyst CA held therein, as shown in FIG.37. According to the method as shown in FIGS.32-37, therefore, it is easy to form the cylinder 4z provided with the tapered end portion 4zb and the neck portion 4zc having the oblique axis Xf, so that its manufacturing cost and time can be reduced, comparing with the aforementioned methods. It should be apparent to one skilled in the art that the above-described embodiments are merely illustrative of but a few of the many possible specific embodiments of the present invention. Numerous and various other arrangements can be readily devised by those skilled in the art within the scope of the following claims.

Claims: A method for forming an end portion of a cylindrical member (4) by spinning, said method comprising the steps of: supporting at least one roller (28) to be radially moved to and from a main shaft (21); and supporting said cylindrical member (4) to position the central axis (Xt) thereof on a plane including the central axis (Xr) of said main shaft (21); and driving at least one of said cylindrical member (4) and said at least one roller (28) to be rotated relative to each other about a forming target axis (Xe) with said at least one roller (28) radially moved to be in contact with the outer side of one end portion of said cylindrical member (4), to form the one end portion into a reduced diameter portion (4d), characterized in that said forming target axis is an oblique axis (Xe) inclined against the central axis (Xt) of said cylindrical member (4), so that said reduced diameter portion (4d) according to has the oblique axis (Xe) as its axis. The method claim 1, wherein said driving step includes the step of moving said at least one roller (28) radially toward the oblique axis (Xe) inclined against the central axis (Xt) of said cylindrical member (4), in accordance with a plurality of spinning cycles. The method according to claim 1 or 2, further comprising the step of driving at least one of said cylindrical member (4) and said at least one roller (28) to be rotated relative to each other about an eccentric axis offset from the central axis (Xt) of said cylindrical member (4), with said at least one roller (28) radially moved to be in contact with the outer side of one end portion of said cylindrical member (4), to form the one end portion into a reduced diameter portion (4d) having the oblique axis (Xe) and the eccentric axis. The method according to one of claims 1 to 3, further comprising the step of bending the one end portion of said cylindrical member (4) to form a bent portion, before spinning said cylindrical member (4) to form the bent portion into the reduced diameter portion (4d) having the oblique axis (Xe). The method according to one of claims 1 to 4, wherein said driving step includes the steps of: moving at least one of said cylindrical member (4) and said at least one roller (28) relative to each other, with the central axis (Xt) of said cylindrical member (4) held on the plane including the central axis (Xr) of said main shaft (21); rotating at least one of said cylindrical member (4) and said main shaft (21) relative to each other about a vertical axis to the plane including the central axes (Xt, Xr) of said cylindrical member (4) and of said main shaft (21), to produce an oblique angle () between the central axis (Xt, Xr) of said cylindrical member (4) and said main shaft (21), and set an oblique reference axis extending from said vertical axis against the central axis (Xt) of said cylindrical member (4), with the oblique angle  formed therewith; moving at least one of said cylindrical member (4) and said main shaft (21) relative to each other to position said main shaft (21) in line with the forming target axis set in parallel with the oblique reference axis; moving said at least one roller (28) radially toward the forming target axis, with said at least one roller (28) being in substantial contact with the outer surface of the one end portion of said cylindrical member (4); and driving at least one of said cylindrical member (4) and said at least one roller (28) to be rotated relative to each other about the forming target axis. The method of claim 5, wherein said step of moving said at least one roller (28) radially toward the forming target axis includes the step of moving said at least one roller (28) gradually close to the forming target axis, in accordance with a plurality of spinning cycles. The method according to one of claims 1 to 6, wherein said reduced diameter portion (4d) is formed to provide a tapered portion (4b), with the diameter of said cylindrical member (4) gradually reduced from a main body (4a) thereof toward the tip end thereof. The method according to claim 7, wherein said reduced diameter portion (4d) is formed to provide said tapered portion (4b) and a neck (4c) portion of a tubular configuration extending from the tip end of said tapered portion (4b). An apparatus for forming an end portion of a cylindrical member (4) by spinning, comprising: a main shaft (21) positioned on a plane including the central axis (Xt) of said cylindrical member (4); at least one roller (28) operatively mounted on said main shaft (21) to be radially movable to and from said main shaft (21), and in contact with the end portion of said cylindrical member; first driving means (2) for moving at least one of said cylindrical member (4) and said at least one roller (28) relative to each other, in parallel with said plane including the central axes (Xt, Xr) of said cylindrical member (4) and said main shaft (41), second driving means (3) for moving said at least one roller (28) radially toward a forming target axis, with said at least one roller (28) being in substantial contact with the outer surface of the one end portion of said cylindrical member (4) and rotating said at least one roller (28) about said main shaft (21) relative to said cylindrical member (4); and control means (CT) for controlling said first and second driving means (2, 3) to form the one end portion of said cylindrical member (4) into a reduced diameter portion (4d) characterized in that said first driving means (2) is additionally adapted to rotate at least one of said cylindrical member (4) and said main shaft (21) relative to each other about a vertical axis to the plane including the central axes (Xt, Xr) of said cylindrical member (4) and said main shaft (21), to produce an oblique angle () between the central axes (Xt, Xr) of said cylindrical member (4) and said main shaft (21), and set an oblique reference axis extending from said vertical axis against the central axis (Xt) of said cylindrical member (4), with the oblique angle () formed therewith, said first driving means (2) moving at least one of said cylindrical member (4) and said main shaft (21) relative to each other to position said main shaft (21) in line with the forming target axis set in parallel with the oblique reference axis, so that said reduced diameter portion (4a) is formed with an oblique axis (Xe). The apparatus according to claim 9, wherein said first driving means (2) is adapted to move said at least one roller (28) gradually close to the forming target axis, in accordance with a plurality of spinning cycles, and wherein said second driving means (3) is adapted to rotate said at least one roller (28) about said main shaft relative to said cylindrical member (4) every spinning cycle. The apparatus according to claim 10, wherein said first driving means (2) is adapted to move at least one of said cylindrical member (4) and said at least one roller (28) relative to each other, to move said at least one roller (28) radially toward an eccentric axis offset from the central axis (Xt) of said cylindrical member (21) with said at least one roller (28) being in substantial contact with the outer surface of the one end portion of said cylindrical member (4), and wherein said second driving means (3) is adapted to rotate at least one of said cylindrical member (4) and said at least one roller (28) to be rotated relative to each other about the eccentric axis of said cylindrical member (4), to form the one end portion of said cylindrical member (4), into a reduced diameter portion (4d) having the oblique axis (Xr) and the eccentric axis. The apparatus according to claim 11, wherein said first driving means (2) is adapted to move at least one of said cylindrical member (4) and said at least one roller (28) relative to each other, to move the central axis (Xt) of said cylindrical member (4) and the eccentric axis thereof gradually close to each other in accordance with a plurality of spinning cycles, and wherein said second driving means (3) is adapted to rotate said at least one roller (28) about said main shaft (21) relative to said cylindrical member (4) every spinning cycle. The apparatus according to one of claims 9 to 12, wherein said second driving means (3) includes a plurality of rollers (28) moved radially toward said main shaft (21), and rotated about said main shaft (21). The apparatus according to one of claims 9 to 13, further comprising third driving means for moving at least one of said cylindrical member (4) and said at least one roller (28) relative to each other, along the vertical axis to the plane including the central axis (Xt, Xr) of said cylindrical member (4) and said main shaft (21). The apparatus according to one of claims 9 to 14, further comprising bending means (80) for bending the one end portion of said cylindrical member (4) to form a bent portion, before spinning said cylindrical member (4) to form the bent portion into the reduced diameter portion (4d) having the oblique axis (Xr). The apparatus according to one of claims 9 to 15, wherein said reduced diameter portion (4d) is formed to provide a tapered portion (4b) with the diameter of said cylindrical member (4) gradually reduced from a main body (4d) thereof toward the tip end thereof. The apparatus according to claim 16, wherein said reduced diameter portion (4d) is formed to provide said tapered portion (4b) and a neck portion (4d) of a tubular configuration extending from the tip end of said tapered portion (4b).

Inventors: IRIE TOHRU, IRIE, TOHRU, IRIE, TOHRU, C/O SANGO CO., LTD.
Applicants: SANGO CO LTD, SANGO CO., LTD.
Application year: 1998
Main classification: B21D41
IPC codes: B21D41, B21D22, F01N3, F01N13