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Manufacturing Method And Manufacturing Device For Sheared Article

Abstract: This manufacturing method for a sheared article performs multiple iterations of a shearing process which includes a step for fixing a member to be processed to a die and a step for punching the member to be processed by moving a punch (110) and the die towards each other and performing punching on the member to be processed. The shearing process is performed using the punch which has a first end surface (111) that faces the member to be processed and a first blade edge that includes a first receding surface (112) that recedes from the first end surface relative to the direction towards the die when the series of shearing processes start and the die that is provided with a second end surface that faces the member to be processed and a second blade edge that includes a second receding surface that recedes from the second end surface relative to the direction towards the punch when the series of shearing processes start.

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Patent Information

Application #
Filing Date
07 November 2016
Publication Number
06/2017
Publication Type
INA
Invention Field
MECHANICAL ENGINEERING
Status
Email
remfry-sagar@remfry.com
Parent Application
Patent Number
Legal Status
Grant Date
2022-09-14
Renewal Date

Applicants

NIPPON STEEL & SUMITOMO METAL CORPORATION
6 1 Marunouchi 2 chome Chiyoda ku Tokyo 1008071

Inventors

1. MATSUNO Takashi
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo 1008071
2. SATO Koichi
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo 1008071
3. YASUTOMI Takashi
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo 1008071

Specification

The present invention relates to a manufacturing method and a manufacturing device of sheared components, and specifically, to a manufacturing method and a manufacturing device of sheared components which are used in a vehicle, a construction machine, and various plants, and are made of high-tension steel or ultra-high-tension steel. Priority is claimed on Japanese Patent Application No. 2014-097044, filed on May 8,2014, the content of which is incorporated herein by reference. [Related Art] [0002] FIG. 16Ais a sectional view schematically showing drilling for forming a hole by shearing a workpiece I. In addition, FIG. 16B is a sectional view schematically showing cutting for forming an open section by shearing the workpiece 1. When manufacturing sheared components which are used in a vehicle, a construction machine, and further, various plants, as shown in FIGS. 16A and 16B, after loading the workpiece 1 on a die 3, the workpiece 1 is punched by pushing a punch 2 in the outlined arrow direction in the drawing, and the sheared components are manufactured by shearing, in many cases. [0003] FIG. 17 is a sectional view showing a sheared surface 8 which is formed in the sheared workpiece 1. As shown in FIG. 17, the sheared surface 8 of the workpiece 1 formed by shearing includes: a sag 4 which is formed as the workpiece 1 is pushed by the punch 2; a shcarcd surface 5-which is formed as the workpiece 1 is drawn into a clearance (hereinafier, in a case where "clearance" is written without any particular remarks in the specification, the clearance means a clearance between thc punch and the die) between the punch 2 and the die 3, and is locally extended; a fracture surface 6 which is formed as the worlcpiece I is drawn into the clearance between the punch 2 and the die 3 is fractured; and a burr 7 which is generated on a rear surface of the worlcpiece 1. [0004] Shearing has an advantage that processing can be performed at a low cost. However, in recent years there has been a trend for the hardness required for the workpiece 1 to increase, and it is difficult to simply employ the shearing method used so far. For example, in a case where a high-tension steel sheet of which a tensile strength exceeds 780 MPa is used as the workpiece 1, since the burr 7 which is extremely large is generated due to a deficiency of a cutting edge, it is necessary to frequently exchange a die, and deterioration of productivity cannot he avoided. In addition, "deficiency of a cutting edge" mentioned here is a phenomenon different from "wear of a cutting edge". In other words, while the wear is a phenomenon in which roundness of the cutting edge increases as the number of processings increases, the deficiency is a phenomenon in which the cutting edge becomes chipped due to the presence of cracks. [0005] There are many cases where the wear of a tool cutting edge is suppressed by performing coating treatment on a surface of a tool, for example, as disclosed in Non-Patent Document 1. In addition, with respect to the deficiency of the tool cutting edge, a method of absorbing and nritigating shock when the tool cutting edge is in a contact state using a flcxible part as a fastening portion ofthe tool, or method for rounding or chamfering only the cutting edge of the punch, for example, as disclosed in Non-Patent Document 2, is Itnown. [Prior Art Documents] I , [Patent Document] [0006] [Non-Patent Document 11 Die and Mold Technology, Vol. 18, No. 8, pp. 8-9 [Non-Patent Document 21 Proceedings of the 2013 Japanese Spring Conference for the Technology of Plasticity, Japan Society for Technology of Plasticity, pp. 193-194 [Disclosure of the Invention] [Problems to be Solved by the Invention] [0007] A method of performing the coating treatment on the tool surface as described in the above-described Non-Patent Document 1 improves tool service life by reducing the frictional resistance between the tool surface and the workpiece. However, in the method, in a case of shearing a high-tension steel sheet of which the maximum tensile strength is equal to or greater than 480 MPa, it is not possible to prevent a sudden deficiency of the tool cutting edge which is caused by an impact on the tool cutting edge. In addition, in the method for rounding the cutting edge only in the punch described in the above Non-Patent Document 2, it is not possible to prevent the deficiency of the cutting edge of the die. In addition, when shearing mrld steel, in order to prevent generation of the burr in the workpiece, it is necessary to make the cutting edge of both of the punch and the die an acute angle, and even when rounding or chamfering the cutting edge as described in the above-described Non-Patent Document 2, a function as a shearing tool is not sufticiently achicved when not being limited to any one of the punch and thc die. [OOOS] Meanwhile, the inventors empirically understood that the frequency of generation of tool damage increases in a case where the ratio between the hardness of the workpiece and the hardness of the tool (die or punch) exceeds a certain value. The result of investigation of the ratio through experiment by the inventors is shown in the following Table 1. In addition, in the tool evaluation of Table 1, G indicates GOOD (excellent), and NG indicates NOT GOOD (there is a problem). According to the experiment results, it was ascertained that the frequency of generation of tool damage rapidly increases in high-tension steel or ultra-high-tension steel in which the Vicker's hardness of the workpiece becomes equal to or greater than 0.3 times the Viclcer's hardness of the tool. In addition, in the experiment of Table 1, an experiment in which the punch and the die which respectively had the tool cutting edge having an acute angle were used, was performed. In addition, the clearance between the punch and the die in a case where the sheet thickness of the workpiece was t, varied within a range of 0.1 x t to 0.2 x t, but this did not influence the results, and it was confirmed that the ratio between the hardness of the workpiece and the hardness of the tool is dominant. [0009] [Table I] [OO 1 01 From the above, it was confirmed that a mechanism of the tool damage changed greatly considering 0.3 times the ratio between the hardness of the worlcpiece and the hardness of the tool as a boundary. This was not disclosed or suggested in either of the above-described Non-Patent Document 1 or Non-Patent Document 2. Accordingly, in the related art, means for slicaring a high-strength workpiece which is made of high-tension steel or ultra-high-tension steel without a deficiency of a tool cutting edge was not established. Therefore, as described above, in order to prevent the generation of the burr 7 which is extremely large due to the deficiency of the tool cutting edge, it is necessary to frequently exchange the die. [OO 1 l] Considering the above-described situation, an object of the present invention is to provide a manufacturing method and a manufacturing device of sheared components which can manufacture the sheared components at a low cost without generation of a sudden deficiency of a cutting edge, even when a workpiece which is made of high-tension steel or ultra-high-tension steel in which the Vicker's hardness thereof becomes equal to or greater than 0.3 times the Vicker's hardness of a tool is used. [Means for Solving the Problem] [OO 121 In order to solve the above-described problem and achieve the related object, the present invention employs the following aspects. (1) A manufacturing method of sheared components according to an aspect of the present invention is a method for manufacturing a plurality of sheared con~ponentsb y performing a shearing a plurality of times by using a punch and a die with respect to a worlcpiece of which a Vicker's hardness is equal to or greater than 0.3 times and less than 1.0 times the lower one of the Vicker's hardness of the punch and the Viclter's hardness of the die, in which the shearing including a process of fixing the workpiece to the die, and a process of punching the worltpiece by bringing the punch and the die relatively close to each other, is performed a plurality of times, and in which, when a shearing sequence is started, the shearing is performed by using a punch including a first cutting edge having a first tip end surface which opposes the workpiece, and a first retracting surface which retracts from the first tip end surface considering an approaching direction to the die as a standard; and a die including a second cutting edge having a second tip end surface which opposes the workpiece, and a second retracting surface which retracts from the second tip end surface considering an approaching direction to the punch as a standard. I , [0013] (2) In the aspect described in the above-described (I), the first retracting surface in a case of being viewed on a section perpendicular to the first tip end surface, may be a curved surface having a curvature that is equal to or greater than Rmin (mm) defined by a following Equation 1 and that is equal to or less than Rmax (mm) defined by a following Equation 2, or a chamfer having an inclination angle of 45" with respect to a tangent of the first tip end surface, and having a width dimension that is equal to or greater than amin (mm) defined by a following Equation 3 and that is equal to or less than m a x (mm) defined by a following Equation 4, and the second retracting surface in a case of being viewed on a section perpendicular to the second tip end surface, may be a curved surface having a curvature that is equal to or greater than Rmin (mm) defined by the following Equation 1 and that is equal to or less than Rmax (mm) defined by the following Equation 2, or a chamfer having an inclination angle of 45" with respect to a tangent of the second tip end surface, and having a width dimension that is equal to or greater than amin (mm) defined by the following Equation 3 and that is equal to or less than amax (mm) defined by the following Equation 4. Rmin = (0.9 + 0.2e~"~~")(0.35701.2~5~9-5 ~+ 0.0965) . . . (Equation 1) Rmax = (0.9 + 0.2e-~~~~)(-9.185256.x17~x+3 2 4.95x2+ 11.054-~ 1.5824) . . . (Equation 2) amin = 0.0222e~~~'~"(+0 0.9. l e-007c.) . . (Equation 3) mnax = (0.9 + 0. I e-0.07c)(-0.3274+x2 0 .9768~ - 0.1457) . . . (Equation 4) here, c is a base of a natural logarithms, c (mm) indicates a clearance between an inner surface of the die and an outcr surface of the punch, and x ofthe punch is a hardness ratio obtained by dividing the Vicker's hardness of the workpiece by the Vicker's hardness of the punch, x of the die is a hardness ratio obtained by dividing the Vicker's hardness of I ' the workpiece by the Vicker's hardness of the die in the die, and satisfies 0.3 5 x < 1 .O. [0014] (3) In a case of the above-described (2), one or both of the first retracting surface and the second retracting surface may be a curved surhce having a curvature of 0.05 mm to 0.5 mm, or one or both of the first retracting surface and the second retracting surface may be a chamfer with a chamfer distance ofCO.05 mm to C0.5 mm. [00 151 (4) In the aspect described in any one of the above-described (1) to (3), at least one of a first condition in which a frictional resistance of the first retracting surface is the highest among the first tip end surface, the first retracting surface, and the outer surface of the punch, or a second condition in which a frictional resistance of the second retracting surface is the highest among the second tip end surface, the second retracting surface, and the inner surface of the die, may be satisfied. [00 161 (5) In the aspect described in any one of the above-described (1) to (4), any one of a surface decarbonizing treatment, a plating, and a specific lubricating treatment may be performed with respect to the workpiece. [00 171 (6) A manufacturiug device of sheared components according to another aspect of the present invention is a device for manufacturing a plurality of sheared components by performing a shearing a plurality of times with respect to a workp~eceo f which a Vicker's hardness is equal to or greatcr than 0.3 times and lcss than 1.0 times the lower one of the Viclier's hardness of a punch and the Vicker's hardness of a die, the device including: the die which fixes the worlipiece; and the punch which punches the workpiece by bringing the workpiece relatively close to the die, in which the punch includes a first cutting edge having a first tip end surface which opposes the worlipiece, and a first retracting surface which retracts from the first tip end surface considering an approaching direction to the die as a standard, and in which the die includes a second cutting edge having a second tip end surface which opposes the worlcpiece, and a second retracting surface which retracts from the second tip end surface considering an approaching direction to the punch as a standard. [00 181 (7) In the aspect described in the above-described (6), the first retracting surface in a case of being viewed on a section perpendicular to the first tip end surface, may be a curved surface having a curvature that is equal to or greater than Rmin (mm) defined by a following Equation 1 and that is equal to or less than Rrnax (mm) defined by a following Equation 2, or a chamfer having an inclination angle of 45" with respect to a tangent of the first tip end surface, and having a width dimension that is equal to or greater than amin (mm) defined by a following Equation 3 and that is equal to or less than amax (mm) defined by a following Equation 4, and the second retracting surface in a case of being viewed on a section perpendicular to the second tip end surface, may be a curved surface having a curvature that is equal to or greater than Rmln (mm) defined by the following Equation I and that is equal to or less than Rmax (mm) defined by the following Equation 2, or a chamfer having an inclination angle of 45" with respect to a tangent of the second tip end surface, and having a width dimension that is equal to or greater than arnin (mm) defined by the following Equation 3 and that is equal to or less than atnax (mm) defined by the following Equation 4. Rmin = (0.9 + 0 . 2 e ~ ~ ~ ~ ~ " ) ( 0 .03.5257915~~+~ 0-. 0965) . .. (Equation 1) Rmax = (0.9 + 0.2e-'.~~")(-98.15 6x4+ 25.17x3 - 24.95x2 + 11.054-~ 1.5824) . . . (Equation 2) I , 2,08331 nmin = 0.0222e (0.9 + 0. le-0.07c.) . . (Equation 3) max = (0.9 + 0.le-~~'")(-0.32740~.~9+7 68~- 0.1457) . . . (Equation 4) here, e is a base of a natural logarithms, c (mm) indicates a clearance between an inner surface of the die and an outer surface of the punch, and x of the punch is a hardness ratio obtained by dividing the Vicker's hardness of the workpiece by the Vicker's hardness of the punch, x of the die is a hardness ratio obtained by dividing the Vicker's hardness of the workpiece by the Vicker's hardness ofthe die in the die, and satisfies 0.3 5 x < 1.0. [0019] (8) In a case of the above-described (7), one or both of the first retracting surface and the second retracting surface may be a curved surface having a curvature of 0.05 mm to 0.5 mm, or a chamfer distance of CO.05 mm to C0.5 mm. [0020] (9) In the aspect described in any one of the above-described (6) to (8), at least one of a first condition in which a frictional resistance of the first retracting surface is the highest among the first tip end surface, the first retracting surface, and the outer surface of the punch, or a second condition in which a frictional resistance of the second retracting surface is the highest among the second tip end surface, the second retracting surface, and the inner surface ofthe die, may be satisfied. [EiTects of the Invention] [0021] According to each of the above-described aspects of the present invention, it is possible to manufacture sheared components at a low cost without generation of a sudden deficiency of a cutting edge, even when a workpiece which is made of high-tension steel or ultra-high-tension steel in which the Vicker's hardness thereof becomes equal to or greater than 0.3 times the Vicker's hardness of a tool is used. [Brief Description of the Drawings] LO0221 FIG. 1 is a view showing main portions of a shearing device according to an embodiment of the present invention, and is a longitudinal sectional view showing a state where a workpiece is nipped between a die, and a punch and a blank holder. FIG 2Ais a sectional view showing a situation of generation of a burr in a case ' where shearing is performed on a workpiece consisting of a mild steel sheet of which a tensile strcngth is less than 780 MPa. FIG. 29 is a sectional view showing a situation of generation of the burr in a case where the shearing is performed on a workpiece consisting of a high-tension steel sheet of which the tensile strength is equal to or greater than 780 MPa. FIG. 3A is a view explaining a detailed mechanism when the shearing is performed on a workpiece consisting of the high-tenqion steel sheet, and when a cutting edge of the die and a cutting edge of the punch are defic~enta, nd is a sectional view when the shearing is started. FIG. 39 is a view explaining a detailed mechanism when the shearing is perfornied on a workpiece consisting of the high-tension steel sheet, and when the cutting edge ofthe die and the cutting edge of the punch are deficient, and is a sectional view showing a process following FIG. 3A. FIG. 3C is a view explaining a detailed mechanism when the shearing is perforrncd on a workpiece consisting of the high-tension stecl sheet, and when the cutting edge of the die and the cutting edge of the punch are delicient, and is a sectional view showing a process following FIG. 3B. FIG. 4 is a view showing a result of size distribution of plastic deformation amounts in a tool cutling edge obtained by simulation calculation. FIG. 5 is a bar graph showing the number of shots when drilling is continuously performed on workpieces consisting of three types of steel until the tool cutting edge is damaged. The horizontal axis indicates the radius of curvature of a roundness of the tool cutting edge, and the vertical axis indicates the number of shots. FIG. 6A is a graph showing transition of the height of the burr when the drilling is continuously performed on a workpiece consisting of the mild steel sheet according to the number of shots. FIG. 6B is a graph showing transition of the height of the burr when the drilling is continuously performed on a workpiece consisting of a steel sheet having a tensile strength of 590 MPa according lo the number of shots. FIG. 6C is a graph showing transition of the height ofthe burr when the drilling is continuously performed on a workpiece consisting of a high-tension steel sheet having 780 MPa according to the number of shots. FIG. 7 is a view showing a sectional shape in a case where the tool culling edge is chamfered, and is a sectional view of main portions of the punch. FIG. 8 is a bar graph showing the number of shots when the drilling is continuously performed on workpieces consisting of three types of steel until the tool cutting cdge is damaged, the horizontal axis indicates the chamfering dimens~ono f the tool cutting edge, and the vertical axis indicates the number of shots. FIG. 9A is a graph showing transition of the height of the burr when the drilling is co~itinuouslyp erfonned on a workpiece consisting of the mild stccl sheet according to the number of shots. FIG. 9B is a graph showing transition of the height of the burr when the drilling is continuously performed on a workpiece consisting of a steel sheet having a tensile strength of 590 MPa according to the number of shots. FIG. 9C is a graph showing transition of the height of the burr when the drilling is continuousiy performed on a workpiece consisting of a h~gh-tensions teel sheet having a tensile strength of 780 MPa according to the number of shots. FIG 10 is a graph showing an effect of reducing the height of the burr in a case where hot-dip galvanizing is performed as surface treatment with respect to the workpiece. FIG. 11 is a view showing a modification example of the embodiment, and is a sectional view in which a tool cutting edge part is enlarged in a case where divisional polishing is performed with respect to each of the punch and the die. FIG. 12 is a bar graph showing the number of shots when the drilling is continuously performed until the tool cutting edge is damaged. The horizontal axis indicates a radius of curvature of the roundness of the tool cutting edge or a chamfering dimension of the tool cutting edge, and the vertical axis indicates the number of shots until the tool is damaged. FIG. 13 is a graph showing transition of the height of the burr when the drilling is continuously performed according to the number of shots. FIG. 14 is a view showing another modification example of the tool, and is a sectional view of the tool cutting edge part in a case of being viewed on the section perpendicular to a tip end surface of the tool. FIG. 15 is a view showing still another modification example of the tool, and is a sectional view of the tool cutting edge part in a case of being viewed on the section perpendicular to the tip end surface ofthe tool. FIG. 16A is a view scliematically showing the drilling for forming a hole by shearing the workpicce, and is a longitudinal sectional view in a case of being viewed on the section including an axial line of the punch. FIG. 16B is a view schematically showing cutting for forming an open section by I ' shearing the workpiece, and is a longitudinal sectional view in a case of being viewed on the section of the workpiece in the thickness direction. FIG. 17 is a view showing a sheared surface of the workpiece formed by the shearing, and is a sectional view in a case of being viewed on the section perpendicular to a surface of the workpiece. [Embodiments of the Invention] LO0231 Embodiments and modification examples regarding a manufacturing method and a manufacturing device of sheared components of the present invention will be described hereinafter. FIG. 1 shows main portions of a shearing device according to an embodiment of the present invention. As shown in FIG. 1, a manufacturing device of sheared components 100 in the embodiment includes: a die 120 which fix a workpiece 1 by nipping the workpiece 1 vertically and a blank holder 130; and a punch 110 which punches the workpiece 1 relatively approaching the die 120. The manufacturing device of sheared compo~ients 100 is a device which manufactures the plurality of sheared components by performing a shearing a plurality of times on the workpiece 1 consisting of a high-tension steel sheet of which the Vicker's hardness is equal to or greater than 0.3 times and less than 1.0 times the lower one of the Vicker's hardness of the punch 110 and the Vicker's hardness of the die 120. [0024] 'The punch 11 0 includes a first cutting edge 113 having a first tip end surface 11 I which opposes the workpiece 1 and a first retracting surface 112 which retracts from the first tip end surface 11 1 considering the approaching direction to the die 120 as a standard. Meanwhile, the die 120 includes a second culting edge 123 having a second tip end surface 121 which opposes the workpiece 1, and a second retracting surface 122 which retracts from the second tip end surface 121 considering the approaching direction to the punch 110 as a standard. The die 120 is a pedestal on which the workpiece 1 is loaded, and a through hole 124 which is an inner surface that forms a predetermined clearance c with respect to an outer surface 114 on the section perpendicular to the axial line of the punch 110, in the punch 110, is formed coaxially to the punch 110. The blank holder 130 is a tool which fixes the workpiece 1 by nipping the workpiece 1 loaded on the die 120 between the blank holder 130 and the die 120, and similar to the die 120, forms a through hole 13 1 which is coaxial to the punch 110. LO0251 A mechanism regarding a deficiency of the tool cutting edge generated when the workpiece of which the Vicker's hardness becomes equal to or greater than 0.3 times the Viclcer's hardness of the tool, and which is made of high-tension steel or ultra-high-tension steel (hereinafter, high-tension steel or ultra-high-tension steel is generally called "high-strength steel" in some cases) is sheared, is not known in detail. Here, the mechanism is confirmed by experiment of the inventors. The present invention is completed based on knowledge obtained during the experiment. [0026] First, the inventors pcrforrned a tool durability test in a case where the shearing is performed on the worl

Documents

Application Documents

# Name Date
1 Priority Document [07-11-2016(online)].pdf 2016-11-07
2 Power of Attorney [07-11-2016(online)].pdf 2016-11-07
3 Form 5 [07-11-2016(online)].pdf 2016-11-07
4 Form 3 [07-11-2016(online)].pdf 2016-11-07
5 Form 18 [07-11-2016(online)].pdf_50.pdf 2016-11-07
6 Form 18 [07-11-2016(online)].pdf 2016-11-07
7 Form 1 [07-11-2016(online)].pdf 2016-11-07
8 Drawing [07-11-2016(online)].pdf 2016-11-07
9 Description(Complete) [07-11-2016(online)].pdf 2016-11-07
10 201617037957.pdf 2016-11-11
11 Other Patent Document [03-12-2016(online)].pdf 2016-12-03
12 201617037957-OTHERS-051216.pdf 2016-12-07
13 201617037957-Correspondence-051216.pdf 2016-12-07
14 abstract.jpg 2017-01-11
15 Other Patent Document [03-05-2017(online)].pdf 2017-05-03
16 Form 3 [03-05-2017(online)].pdf 2017-05-03
17 201617037957-RELEVANT DOCUMENTS [12-06-2019(online)].pdf 2019-06-12
18 201617037957-FORM 13 [12-06-2019(online)].pdf 2019-06-12
19 201617037957-Power of Attorney-140619.pdf 2019-06-25
20 201617037957-OTHERS-140619.pdf 2019-06-25
21 201617037957-Correspondence-140619.pdf 2019-06-25
22 201617037957-FER.pdf 2019-10-16
23 201617037957-OTHERS [06-04-2020(online)].pdf 2020-04-06
24 201617037957-FER_SER_REPLY [06-04-2020(online)].pdf 2020-04-06
25 201617037957-DRAWING [06-04-2020(online)].pdf 2020-04-06
26 201617037957-CORRESPONDENCE [06-04-2020(online)].pdf 2020-04-06
27 201617037957-COMPLETE SPECIFICATION [06-04-2020(online)].pdf 2020-04-06
28 201617037957-CLAIMS [06-04-2020(online)].pdf 2020-04-06
29 201617037957-ABSTRACT [06-04-2020(online)].pdf 2020-04-06
30 201617037957-PatentCertificate14-09-2022.pdf 2022-09-14
31 201617037957-IntimationOfGrant14-09-2022.pdf 2022-09-14

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1 201617037957searchstrategy_08-01-2019.pdf

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