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