Patent Publication Number: US-9849495-B2

Title: Spinning thickening forming method and spinning thickening forming apparatus

Description:
TECHNICAL FIELD 
     The present invention relates to a spinning thickening forming method of increasing a thickness of a peripheral portion of a plate while rotating the plate and a spinning thickening forming apparatus suitable for the spinning thickening forming method. 
     BACKGROUND ART 
     Spinning forming is typically utilized for ironing or drawing but is sometimes used as a method of increasing a thickness of a peripheral portion of a plate. For example, as shown in  FIG. 9 , PTL 1 discloses a method of sandwiching a plate  100  between a fixing base  110  and a pressing plate  120 ; and increasing the thickness of an overhanging portion  101  of the plate  100  while rotating the plate  100 , the overhanging portion  101  overhanging from the fixing base  110  and the pressing plate  120 . 
     According to the method disclosed in PTL 1, the fixing base  110  and the pressing plate  120  also serve as a die for a thickened shape. Specifically, the fixing base  110  and the pressing plate  120  are about the same in size as each other, and a tapered surface which decreases in diameter toward the plate  100  is formed at each of an upper portion of a side surface of the fixing base  110  and a lower portion of a side surface of the pressing plate  120 . 
     According to the method disclosed in PTL 1, first, the entire overhanging portion  101  of the plate  100  is heated by a high-frequency heater. Then, a swaging die  130  including a forming groove having a substantially triangular cross section compresses the overhanging portion  101  until the swaging die  130  contacts the fixing base  110  and the pressing plate  120 . With this, the overhanging portion  101  is formed to have an arrowhead-shaped cross section. According to the other drawings of PTL 1, the swaging die  130  is presumed to be a roller which rotates following the plate  100 . 
     CITATION LIST 
     Patent Literature 
     PTL 1: Japanese Laid-Open Patent Application Publication No. 7-290181 
     SUMMARY OF INVENTION 
     Technical Problem 
     However, to use the fixing base  110  and the pressing plate  120  as the die for the thickened shape, the fixing base  110  and the pressing plate  120  need to be the same in size as each other, and the fixing base  110  and the pressing plate  120  need to be produced with a high degree of accuracy. Therefore, the cost of the forming apparatus increases. 
     An object of the present invention is to provide a spinning thickening forming method capable of increasing the thickness of the peripheral portion of the plate at low cost and a spinning thickening forming apparatus suitable for the forming method. 
     Solution to Problem 
     To achieve the above object, a spinning thickening forming method according to the present invention is a spinning thickening forming method of, while rotating a plate including a center portion fixed to a fixing jig, increasing a thickness of a peripheral portion of the plate, the method including, while locally heating the peripheral portion of the plate such that at least a portion of the plate which is adjacent to the fixing jig maintains stiffness, pressing a forming roller against the peripheral portion of the plate to compress the peripheral portion in at least a direction perpendicular to a thickness direction of the peripheral portion. 
     According to the above configuration, when locally heating the peripheral portion of the plate, a portion of the plate which maintains the stiffness remains at least in the vicinity of the fixing jig. Therefore, while enduring the pressing force of the forming roller by this stiff portion, in other words, at a position away from the fixing jig, the thickness of the peripheral portion can be increased. Therefore, a component which just has a function of being able to fix the center portion of the plate can be used as the fixing jig. Therefore, the cost of the forming apparatus can be reduced. 
     For example, the peripheral portion of the plate may be heated by high-frequency induction heating. 
     The heating by the high-frequency induction heating may be performed by using a heater including: a doubled circular-arc coil portion extending along the peripheral portion of the plate; and a core including a groove in which the coil portion is fitted, and covering the coil portion from an opposite side of the peripheral portion of the plate. According to this configuration, the magnetic flux can be concentrated on the peripheral portion of the plate, so that the peripheral portion can be efficiently heated. 
     The forming roller may be pressed against the peripheral portion of the plate in a state where a rotation axis direction of the forming roller is in parallel with the thickness direction of the peripheral portion of the plate. According to this configuration, excessive load can be prevented from being applied to the bearings rotatably supporting the forming roller. 
     The forming roller may include: a cylindrical pressing surface extending in the rotation axis direction of the forming roller; and a guide surface rising from at least one of end portions of the pressing surface. According to this configuration, an end surface parallel to the thickness direction of the peripheral portion of the plate can be formed by the cylindrical pressing surface, and the expansion of the peripheral portion in the thickness direction by the compressing can be restricted by the guide surface. 
     The forming roller may be pressed against the peripheral portion of the plate in a pressing direction which is inclined relative to a direction perpendicular to the thickness direction of the peripheral portion of the plate, and the guide surface may be provided at one of the end portions of the pressing surface so as to form an obtuse angle together with the pressing surface, the one of the end portions being opposite to the other end portion located at a side toward which the pressing direction is inclined. This configuration is preferable when the peripheral portion of the plate is formed so as to expand toward one side along the thickness direction. 
     The plate may be made of a titanium alloy. In the case of the steel, the aluminum alloy, or the like, the yield strength (stress at which plastic deformation starts) gradually decreases as the temperature increases. However, in the case of the titanium alloy, the yield strength significantly decreases in a certain temperature range. Therefore, by heating the peripheral portion of the plate at a temperature higher than the above temperature range, only a narrow range of the plate which includes the peripheral portion can be deformed. 
     A spinning thickening forming apparatus according to the present invention includes: a fixing jig to which a center portion of a plate is fixed; a rotating shaft to which the fixing jig is attached; a heater configured to locally heat a peripheral portion of the plate; and a forming roller configured to be pressed against the heated peripheral portion of the plate in a pressing direction inclined relative to a direction perpendicular to a thickness direction of the peripheral portion, to compress the peripheral portion in at least a direction perpendicular to the thickness direction of the peripheral portion, wherein the forming roller includes: a cylindrical pressing surface extending in a rotation axis direction of the forming roller; and a guide surface rising from one of end portions of the pressing surface so as to form an obtuse angle together with the pressing surface, the one of the end portions being opposite to the other end portion located at a side toward which the pressing direction is inclined. 
     Advantageous Effects of Invention 
     According to the present invention, the thickness of the peripheral portion of the plate can be increased at low cost. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a schematic configuration diagram of a spinning thickening forming apparatus used for a spinning thickening forming method according to one embodiment of the present invention. 
         FIG. 2A  is a plan view of a heater.  FIG. 2B  is a cross-sectional view taken along line II-II of  FIG. 2A . 
         FIGS. 3A and 3B  are partial cross-sectional views of a forming roller.  FIG. 3A  shows a state before thickening forming.  FIG. 3B  shows a state after the thickening forming. 
         FIGS. 4A to 4D  are diagrams each showing the shape of a peripheral portion of a plate. 
         FIG. 5  is a graph showing a relation between a temperature and yield strength of Ti-6Al-4V that is a titanium alloy. 
         FIG. 6  is a cross-sectional view showing the forming roller and the plate according to Modification Example. 
         FIG. 7  is a configuration diagram of the spinning thickening forming apparatus including an auxiliary roller. 
         FIGS. 8A and 8B  are diagrams each showing the auxiliary roller according to Modification Example. 
         FIG. 9  is a partial cross-sectional view of a conventional spinning thickening forming apparatus. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
       FIG. 1  shows a spinning thickening forming apparatus  1  used for a spinning thickening forming method according to one embodiment of the present invention. The apparatus  1  executes a method of, while rotating a plate  8  including a center portion  83  fixed to a fixing jig  3 , increasing the thickness of a peripheral portion  81  of the plate  8 . More specifically, while locally heating the peripheral portion  81  of the plate  8  such that at least a portion of the plate  8  which is adjacent to the fixing jig  3  maintains stiffness, the apparatus  1  presses a forming roller  6  against the peripheral portion  81  of the plate to compress the peripheral portion  81  in at least a direction perpendicular to a thickness direction of the peripheral portion  81 . The plate  8  including the peripheral portion  81  which has been increased in thickness may be cut into a desired shape by machine work. 
     Specifically, the apparatus  1  includes: a rotating shaft  2 ; the fixing jig  3  attached to the rotating shaft  2 ; and a pressing jig  4  sandwiching the plate  8  together with the fixing jig  3 . The center portion  83  of the plate  8  is fixed to the fixing jig  3 . The apparatus  1  further includes: a heater  7  configured to locally heat the peripheral portion  81  of the plate  8 ; and the forming roller  6  configured to be pressed against the heated peripheral portion  81 . 
     In the present embodiment, a rotation axis direction of the rotating shaft  2  corresponds to a vertical direction. However, the rotation axis direction of the rotating shaft  2  may correspond to a horizontal direction or an oblique direction. A lower portion of the rotating shaft  2  is supported by a base  11 , and a motor (not shown) configured to rotate the rotating shaft  2  is arranged inside the base  11 . 
     The shape of the plate  8  is not especially limited as long as the shape of the plate  8  is a circular shape when viewed from the rotation axis direction of the rotating shaft  2  (hereinafter simply referred to as “in a plan view”). In the present embodiment, the plate  8  has a dish shape which increases in diameter downward. However, the plate  8  may have a cup shape formed such that a peripheral wall vertically hangs down from a peripheral edge of a bottom wall. In a case where the plate  8  has the dish shape or the cup shape, the plate  8  may be fixed to the fixing jig  3  in a posture which is open upward. Or, the plate  8  may have a bowl shape which entirely curves or a flat plate shape (see  FIG. 6 ). 
     In the present embodiment, the plate  8  is made of a titanium alloy. Examples of the titanium alloy include an anticorrosion alloy (for example, Ti-0.15Pd), an α alloy (for example, Ti-5Al-2.5Sn), an α+β alloy (for example, Ti-6Al-4V), and a β alloy (Ti-15V-3Cr-3Sn-3Al). However, the material of the plate  8  is not limited to the titanium alloy and may be, for example, steel or an aluminum alloy. 
     The fixing jig  3  is, for example, a circular table which is smaller than the plate  8  in a plan view. The fixing jig  3  includes a supporting surface (in the present embodiment, an upper surface) having a shape spreading along the center portion  83  of the plate  8 . To be specific, a ring-shaped portion of the plate  8  which is located around the fixing jig  3  in a plan view is a proximal portion  82  adjacent to the fixing jig  3 , and the peripheral portion  81  is a distal end when viewed from the proximal portion  82 . A positioning pin may be provided at a center of the supporting surface of the fixing jig  3 . In this case, a through hole in which the positioning pin is fitted is provided at a center of the plate  8 . 
     The pressing jig  4  is attached to a pressurizing rod  51  which is lifted and lowered by a lifting/lowering mechanism  52 . The pressing jig  4  is pressed by the lifting/lowering mechanism  52  against the plate  8  placed on the fixing jig  3 . With this, the plate  8  is fixed to the fixing jig  3 . The lifting/lowering mechanism  52  is fixed to a frame  12  arranged above the rotating shaft  2 . A bearing rotatably supporting the pressurizing rod  51  is incorporated in the lifting/lowering mechanism  52 . The pressing jig  4  is not necessarily required, and the plate  8  may be fixed to the fixing jig  3  by screws. 
     For example, the heater  7  and the forming roller  6  are arranged so as to be opposed to each other across the rotating shaft  2 . For example, the heater  7  is moved by a first horizontal movement mechanism  13  in a radial direction around a rotation axis of the rotating shaft  2 , and the first horizontal movement mechanism  13  is moved by a first vertical movement mechanism  14  in the vertical direction. Similarly, for example, the forming roller  6  is moved by a second horizontal movement mechanism  15  in the radial direction around the rotation axis of the rotating shaft  2 , and the second horizontal movement mechanism  15  is moved by a second vertical movement mechanism  16  in the vertical direction. Each of the first vertical movement mechanism  14  and the second vertical movement mechanism  16  extends so as to couple the base  11  and the frame  12 . 
     In the present embodiment, used as the heater  7  is a heater which heats the peripheral portion  81  of the plate  8  by high-frequency induction heating. The “high-frequency induction heating” denotes induction heating whose frequency is 5 to 400 kHz. It should be noted that, for example, a gas burner may be used as the heater  7 . 
     Specifically, as shown in  FIGS. 2A and 2B , the heater  7  includes: a conducting wire  71  including a coil portion  72 ; and a core  75  configured to collect magnetic flux generated around the coil portion  72 . In the present embodiment in which the material of the plate  8  is the titanium alloy, for example, the heater  7  heats the peripheral portion  81  of the plate  8  to about 500 to 1,000° C. by a skin effect in the induction heating. The conducting wire  71  is a hollow tube in which a cooling liquid flows. For example, the temperature of the peripheral portion  81  of the plate  8  is measured, and an alternating voltage applied to the conducting wire  71  is controlled such that the measured temperature becomes a target temperature. 
     In the present embodiment, as shown in  FIG. 4A , the peripheral portion  81  of the plate  8  has such a shape as to be cut in the horizontal direction. However, the peripheral portion  81  of the plate  8  may have such a shape as to be cut in the vertical direction as shown in  FIG. 4B , may have such a shape that a tip end thereof is rounded as shown in  FIG. 4C , or may have such a shape as to be cut in the thickness direction as shown in  FIG. 4D . 
     The coil portion  72  has a doubled circular-arc shape extending along the peripheral portion  81  of the plate  8 . In the present embodiment, since the heater  7  is arranged immediately under the peripheral portion  81  (the heater  7  heats the peripheral portion  81  from below), a direction in which two circular-arc portions of the coil portion  72  are lined up corresponds to the horizontal direction. In a case where the heater  7  is arranged immediately at a side of the peripheral portion  81  (the heater  7  heats the peripheral portion  81  from a radially outer side), the direction in which the two circular-arc portions of the coil portion  72  are lined up may correspond to the vertical direction. 
     The core  75  is a circular-arc member which covers the coil portion  72  from an opposite side of the peripheral portion  81  of the plate  8 . A groove in which the coil portion  72  is fitted is formed on a surface (in the present embodiment, an upper surface) of the core  75 , the surface facing the peripheral portion  81  of the plate  8 . In the present embodiment, the core  75  is constituted by one inner peripheral piece  76  and two outer peripheral pieces  77 . The inner peripheral piece  76  is provided with a groove  76   a  in which an inner circular-arc portion of the coil portion  72  is fitted. Each of the outer peripheral pieces  77  is provided with a groove  77   a  in which an outer circular-arc portion of the coil portion  72  is fitted. However, the core  75  may be configured such that the inner peripheral piece  76  and the outer peripheral pieces  77  are integrally formed via an insulator. 
     In the present embodiment in which the material of the plate  8  is the titanium alloy, in order to locally heat the peripheral portion  81  of the plate  8  such that at least the proximal portion  82  of the plate  8  maintains the stiffness, a distance from the fixing jig  3  to the peripheral portion  81  is only required to be secured to some extent. This is because heat conductivity of the titanium alloy is extremely low. With this, since the proximal portion  82  is maintained at a comparatively low temperature, at least the proximal portion  82  maintains the stiffness. 
     In a case where the material of the plate  8  is the steel or the aluminum alloy, in order to locally heat the peripheral portion  81  of the plate  8  such that at least the proximal portion  82  of the plate  8  maintains the stiffness, for example, the fixing jig  3  may be provided with a cooling means, or the other countermeasure may be taken. 
     As shown in  FIG. 3A , the forming roller  6  pressed against the heated peripheral portion  81  of the plate  8  includes a through hole at its center, and a shaft  65  is inserted through the through hole. A pair of bearings rotatably supporting the forming roller  6  are arranged between the shaft  65  and the through hole. In  FIG. 3A , for simplicity, the forming roller  6  fits the shaft  65 , and the bearings are omitted. As shown in  FIG. 1 , both end portions of the shaft  65  are supported by a bracket  67  (not shown in  FIG. 3A ) attached to the second horizontal movement mechanism  15 . 
     A plurality of forming rollers  6  may be provided. For example, two forming rollers  6  may be arranged so as to be opposed to each other across the rotating shaft  2 . In this case, the heater  7  may be arranged at a position which forms 90° together with each of the forming rollers  6  around the rotation axis of the rotating shaft  2 . 
     Referring again to  FIG. 3A , it is desirable that the forming roller  6  be pressed against the peripheral portion  81  in a state where a rotation axis direction Y of the forming roller  6  is in parallel with a thickness direction T of the peripheral portion  81 . This is to prevent excessive load from being applied to the bearings rotatably supporting the forming roller  6 . The rotation axis direction Y is not necessarily, completely in parallel with the thickness direction T. The rotation axis direction Y is only required to be substantially in parallel with the thickness direction T. For example, an angle of the rotation axis direction Y relative to the thickness direction T may be not more than 5°. 
     A pressing direction P in which the forming roller  6  is pressed against the peripheral portion  81  of the plate  8  may be in parallel with a perpendicular direction X perpendicular to the thickness direction T of the peripheral portion  81  or may be inclined relative to the perpendicular direction X. The former is preferable when the peripheral portion  81  is formed so as to expand toward both sides along the thickness direction T. The latter is preferable when the peripheral portion  81  is formed so as to expand toward one side along the thickness direction T. In the present embodiment, in order to expand the peripheral portion  81  inward, the pressing direction P is closer to a horizontal direction than the perpendicular direction X is. Since the forming roller  6  is pressed against the peripheral portion  81  in this pressing direction P, the peripheral portion  81  can be formed in a thickened shape which expands inward as shown in  FIG. 3B . Of course, the peripheral portion  81  can be expanded outward. 
     In a case where the pressing direction P is inclined relative to the perpendicular direction X, it is desirable that an angle θ formed between the pressing direction P and the perpendicular direction X be not more than 20°. This is because if this angle θ is more than 20°, bending deformation of the peripheral portion  81  requires much force, so that large force is required to press the forming roller  6 . 
     More specifically, the forming roller  6  includes a cylindrical pressing surface  61  and a guide surface  62 . The pressing surface  61  extends in the rotation axis direction Y of the forming roller  6 . The guide surface  62  rises from one of end portions of the pressing surface  61 , the one of the end portions being opposite to the other end portion located at a side toward which the pressing direction P is inclined relative to the perpendicular direction X. In the present embodiment, the guide surface  62  forms an obtuse angle together with the pressing surface  61 . The angle of the guide surface  62  is set such that when the forming roller  6  is pressed as shown in  FIG. 3B , a radially outer end portion of the guide surface  62  is prevented from interfering with the plate  8 . 
     A round portion  63  is formed between the pressing surface  61  and the guide surface  62 . The round portion  63  smoothly couples the pressing surface  61  and the guide surface  62  to each other. In a case where the peripheral portion  81  having such a shape as to be cut in the horizontal direction is expanded inward as in the present embodiment, it is desirable that an initial contact position of a tip end of the peripheral portion  81  be within a range from a center of the round portion  63  to an end of the round portion  63 , the end being located at the guide surface  62  side. 
     If a curvature radius R of the round portion  63  is too large, a force of pressing the forming roller  6  becomes large. If the curvature radius R of the round portion  63  is too small, the peripheral portion  81  tends to crack, wrinkle, or the like. Therefore, it is desirable that the curvature radius R of the round portion  63  be not less than t/20 and not more than t/2 where t denotes the thickness of the peripheral portion  81 . For example, in a case where the thickness t is 30 mm, the curvature radius R is not less than 1.5 mm and not more than 15 mm. 
     As explained above, in the present embodiment, when locally heating the peripheral portion  81  of the plate  8 , a portion of the plate  8  which maintains the stiffness remains at least in the vicinity of the fixing jig  3 . Therefore, while enduring the pressing force of the forming roller  6  by this stiff portion, in other words, at a position away from the fixing jig  3 , the thickness of the peripheral portion  81  can be increased. Therefore, a component which just has a function of being able to fix the center portion  83  of the plate  8  can be used as the fixing jig  3 . Therefore, the cost of the forming apparatus  1  can be reduced. 
     In the present embodiment, used is the heater  7  including the core  75  which covers the coil portion  72  from the opposite side of the peripheral portion  81  of the plate  8 . Therefore, the magnetic flux can be concentrated on the peripheral portion  81  of the plate  8 , so that the peripheral portion  81  can be efficiently heated. 
     Further, in the present embodiment, an end surface parallel to the thickness direction T of the peripheral portion  81  of the plate  8  can be formed by the cylindrical pressing surface  61  of the forming roller  6 , and the expansion of the peripheral portion  81  in the thickness direction T by the pressing can be restricted by the guide surface  62 . 
     In the case of the steel, the aluminum alloy, or the like, yield strength (stress at which plastic deformation starts) gradually decreases as the temperature increases. However, in the case of the titanium alloy, as shown in  FIG. 5 , the yield strength significantly decreases in a certain temperature range (about 320 to 400° C.). Therefore, by heating the peripheral portion  81  of the plate  8  at a temperature higher than the above temperature range, only a narrow range including the peripheral portion  81  can be deformed. 
     Other Embodiments 
     The present invention is not limited to the above embodiment, and various modifications may be made within the scope of the present invention. 
     For example, the guide surface  62  is only required to rise from at least one end portion of the pressing surface  61 . The angle formed between the guide surface  62  and the pressing surface  61  is not limited to the obtuse angle. For example, as shown in  FIG. 6 , the guide surfaces  62  may be respectively provided at both end portions of the pressing surface  61  so as to be perpendicular to the pressing surface  61 . 
     For example, as shown in  FIG. 7 , in order to prevent the peripheral portion  81  of the plate  8  from moving in a radially outward direction by the pressing of the forming roller  6 , an auxiliary roller  9  may be auxiliarily pressed against the peripheral portion  81  of the plate  8 . As shown in  FIG. 7 , the auxiliary roller  9  may have such a shape that: the rotation axis direction thereof is in parallel with the vertical direction; and the cross-sectional shape of a side surface thereof is substantially an isosceles triangle. Or, as shown in  FIG. 8A , the auxiliary roller  9  may have such a disc shape that the rotation axis direction thereof is perpendicular to the thickness direction of the peripheral portion  81  of the plate  8 , or as shown in  FIG. 8B , the auxiliary roller  9  may have a trapezoidal cross-sectional shape, and the rotation axis direction thereof is in parallel with the thickness direction of the peripheral portion  81 . 
     INDUSTRIAL APPLICABILITY 
     According to the present invention, a plate having small thickness can be formed into a shape close to an actual product (near net shape), and this is useful for material cost reduction. 
     REFERENCE SIGNS LIST 
     
         
         
           
               1  spinning thickening forming apparatus 
               2  rotating shaft 
               3  fixing jig 
               6  forming roller 
               61  pressing surface 
               62  guide surface 
               7  heater 
               72  coil portion 
               75  core 
               75   a ,  75   b  groove 
               8  plate 
               81  peripheral portion 
               82  proximal portion 
               83  center portion