Abstract
A method of manufacturing a rectangular tube having a stepped portion includes: forming V-shaped grooves on a rectangular tube at surfaces of an end thereof in a direction parallel to a longitudinal direction thereof; and pressing each of the surfaces having the V-shaped grooves formed thereon from outside to inside, whereby the end of the rectangular tube is radially reduced.
Claims
1. A method of manufacturing a rectangular tube having a stepped portion comprising a series of sequential steps comprising: a first step of forming V-shaped grooves on the rectangular tube on a first pair of opposing surfaces and a second pair of opposing surfaces of an end thereof in a direction parallel to a longitudinal direction thereof; and a second step, after the first step, of successively pressing each of the surfaces having the V-shaped grooves formed thereon from outside to inside such that through contact of dies each having a flat planar surface corresponding to each of the first and second pair of opposing surfaces, the first pair of opposing surfaces are compressed, while the second pair of opposing surfaces are not being compressed, to thereby close the V-shaped grooves on the second pair of opposing surfaces, and thereafter the second pair of opposing surfaces are compressed, while the first pair of opposing surfaces are not being compressed, to thereby close the V-shaped grooves on the first pair of opposing surfaces, in a sequential manner, whereby the end of the rectangular tube is radially reduced as the stepped portion of a rectangular cross-sectional shape.
2. The method of manufacturing the rectangular tube having the stepped portion according to claim 1, wherein the first step of forming the V-shaped grooves on the rectangular tube at the surfaces of the end thereof comprises: placing a first die having a V-shaped concave portion formed thereon inside the end of the rectangular tube; placing a second die having a V-shaped convex portion formed thereon at a position that is opposite to the concave portion and is outside the end of the rectangular tube; and pressing the second die against the rectangular tube at each of the surfaces of the end thereof.
3. The method of manufacturing the rectangular tube having the stepped portion according to claim 2, wherein the second die has an inclined surface on a side opposite to a surface thereof contacting the rectangular tube, and a fixed base is arranged to be fixed at a position opposite to the rectangular tube across the second die, whereby the V-shaped grooves are formed by squeezing a wedge-shaped tool between the fixed base and the inclined surface of the second die so as to move the second die toward the rectangular tube.
4. The method of manufacturing the rectangular tube having the stepped portion according to claim 2, wherein a third die having an inclined surface on a side opposite to a surface thereof contacting the rectangular tube is placed, and a fixed base is arranged to be fixed at a position opposite to the rectangular tube across the third die, whereby the end of the rectangular tube is radially reduced by squeezing a wedge-shaped tool between the fixed base and the inclined surface of the third die so as to move the third die toward the rectangular tube and press the end of the rectangular tube.
5. The method of manufacturing the rectangular tube having the stepped portion according to claim 3, wherein a third die having an inclined surface on a side opposite to a surface thereof contacting the rectangular tube is placed, and the fixed base is arranged to be fixed at a position opposite to the rectangular tube across the third die, whereby the end of the rectangular tube is radially reduced by squeezing the wedge-shaped tool between the fixed base and the inclined surface of the third die so as to move the third die toward the rectangular tube and press the end of the rectangular tube.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For more thorough understanding of the present invention and advantages thereof, the following descriptions should be read in conjunction with the accompanying drawings, in which:
(2) FIG. 1 depicts a cross-sectional view showing an end of a rectangular tube having an internal die inserted therein, and V-shaped external dies.
(3) FIG. 2 depicts a cross-sectional view showing one step of forming V-shaped grooves on the rectangular tube at the end thereof.
(4) FIG. 3 depicts a cross-sectional view showing further step of forming further V-shaped grooves on the rectangular tube at the end thereof.
(5) FIG. 4 depicts a cross-sectional view showing one tube-radially reducing step of pressing the end of the rectangular tube having the V-shaped grooves formed thereon.
(6) FIG. 5 depicts a cross-sectional view showing further tube-radially reducing step of pressing the end of the rectangular tube having the V-shaped grooves formed thereon.
(7) FIG. 6 depicts a cross-sectional view showing still further tube-radially reducing step of pressing the end of the rectangular tube having the V-shaped grooves formed thereon.
(8) FIG. 7 depicts a cross-sectional view showing a radially reduced portion formed on the rectangular tube at the end thereof.
(9) FIG. 8 depicts a perspective view showing the rectangular tube having the radially reduced portion formed at the end thereof.
(10) FIG. 9 depicts a cross-sectional view showing the end of the rectangular tube having an internal die inserted therein, V-shaped external dies, fixed bases, and wedge-shaped tools.
(11) FIG. 10 depicts a cross-sectional view showing one step of forming V-shaped grooves on the rectangular tube at the end thereof.
(12) FIG. 11 depicts a cross-sectional view showing further step of forming further V-shaped grooves on the rectangular tube at the end thereof.
(13) FIG. 12 depicts a cross-sectional view showing one step of pressing the end of the rectangular tube having the V-shaped grooves formed thereon so as to radially reduce the end.
(14) FIG. 13 depicts a cross-sectional view showing further step of pressing the end of the rectangular tube having the V-shaped grooves formed thereon so as to radially reduce the end.
(15) FIG. 14 depicts a cross-sectional view showing still further step of pressing the end of the rectangular tube having the V-shaped grooves formed thereon so as to radially reduce the end.
(16) FIG. 15 depicts a cross-sectional view showing a radially reduced portion formed on the rectangular tube at the end thereof.
(17) FIG. 16 depicts a perspective view showing the rectangular tube having the radially reduced portion formed at the end thereof.
(18) FIG. 17 depicts a view showing an example of a V-shaped external die used in the present example.
(19) FIG. 18 depicts a view showing an example of a flat die used in the present example.
(20) FIG. 19 depicts a view showing an example of an internal die used in the present example.
DESCRIPTION OF EMBODIMENTS OF THE INVENTION
(21) The inventors have studied a forming method of forming a radially reduced portion formed on a rectangular tube at the end thereof with superior forming precision at low cost, and a connecting method of connecting two rectangular tube members by inserting one rectangular tube having a stepped portion, which is manufactured by the forming method, into the end (at which a radially reduced end is not formed) of another rectangular tube.
(22) When a rectangular tube is formed with a radially reduced portion at the end thereof, which is rectangular in cross section, there are many embodiments that two edges opposite to each other at the end of the rectangular tube are pressed from outside to inside. However, the other two edges (two non-pressed edges) adjacent to the two pressed edges are bent outward to the extent that a distance between the two pressed edges is shortened. Furthermore, the two initially pressed edges are bent outward by subsequently pressing the other two bent edges. For this reason, each edge of the radially reduced rectangular tube at the end thereof is bent, which makes it difficult to insert the radially reduced end of one rectangular tube into the non-radially reduced end of another rectangular tube when connecting two rectangular tubes.
(23) In the present invention, therefore, V-shaped grooves are formed on an outer surface of a rectangular tube in a direction parallel to a longitudinal direction of the rectangular tube before pressing two opposite edges of the rectangular tube from outside to inside. A processing method of processing the rectangular tube in such a fashion that the V-shaped grooves are formed thereon will be described with reference to FIGS. 1 to 6.
(24) Initially, an internal die (20) having V-shaped concave portions (20a, 20b, 20c, 20d) formed on an outer surface thereof is inserted into an end of a rectangular tube (10) (see FIG. 1). Subsequently, V-shaped external dies (30a, 30b) having V-shaped convex portions (35a, 35b) formed on their respective surfaces are arranged across the rectangular tube (10) such that the V-shaped convex portions (35a, 35b) are opposite to the concave portions (20a, 20b, 20c, 20d) of the internal die (20). In FIG. 1, the V-shaped external die (30a) having the V-shaped convex portion (35a) formed on a surface thereof is arranged such that the V-shaped convex portion (35a) is opposite to the concave portion (20a) of the internal die, and the V-shaped external die (30b) having the V-shaped convex portion (35b) formed on a surface thereof is arranged such that the V-shaped convex portion (35b) is opposite to the concave portion (20b) of the internal die.
(25) Subsequently, the end of the rectangular tube (10) having the internal die (20) inserted therein is pressed from outside to inside by one V-shaped external die (30a) and the other V-shaped external die (30b) while interposed therebetween. At this moment, the convex portion (35a) and the other convex portion (35b) are pressed against the concave portions (20a, 20b) of the internal die (20) such that the convex potions (35a, 35b) and the concave portions (20a, 20b) are aligned, respectively (see FIG. 2). After the step shown in FIG. 2, the rectangular tube (10) is rotated approximately 90 degrees around the center (O) of the cross-section across a longitudinal direction of the rectangular tube, which is regarded as substantially a center of rotation, and the two edges having no V-shaped grooves formed thereon are pressed by one V-shaped external die (30a) and the other V-shaped external die (30b) in a similar fashion (see FIG. 3). Through such steps, the V-shaped grooves are formed on their respective surfaces of the rectangular tube (10) at the end thereof.
(26) After the V-shaped grooves are formed on their respective outer surfaces of the rectangular tube (10) at the end thereof through the use of the internal die (20) as well as one V-shaped external die (30a) and the other V-shaped external die (30b) as shown in FIGS. 1 to 3, the internal die (20) is pulled out from the rectangular tube (10). Subsequently, as shown in FIGS. 4 to 7, the end of the rectangular tube (10) is pressed from outside to inside by flat external dies (40a, 40b) while interposed therebetween so that the end of the rectangular tube (10) can be radially reduced by the application of pressure thereto. Surfaces (401a, 401b) of the flat external dies (40a, 40b) facing the rectangular tube (10) are planar and substantially parallel to the facing surfaces of the rectangular tube (10). By pressing the end of the rectangular tube (10) with the flat external dies (40a, 40b), the V-shaped grooves formed on the two surfaces, which do not face the surfaces (401a, 401b) of the flat external dies (40a, 40b), out of the surfaces of the end of the rectangular tube (10) are pressed so as to be deformed along the V-shaped grooves to the extent that the V-shaped grooves are closed (see FIG. 5). In such a fashion, only a portion having the V-shaped grooves formed thereon out of a whole portion of the rectangular tube (10) along a longitudinal direction can be radially reduced. After the step shown in FIG. 5, the rectangular tube (10) is rotated approximately 90 degrees around the center (O), which is regarded as substantially a center of rotation, and the two surfaces having the closed V-shaped grooves are arranged to face their respective surfaces (401a, 401b) of the flat external dies (40a, 40b). When the end of the rectangular tube (10) is pressed from outside to inside with the flat external dies (40a, 40b) (see FIG. 6), the V-shaped grooves are closed so that the radially reducing process can be completed. As a result, the rectangular tube (10) having the stepped portion for connection formed at the end thereof can be obtained as shown in FIGS. 7 and 8.
(27) The surfaces (401a, 401b) of the flat external dies (40a, 40b) facing the rectangular tube (10) are not entirely limited to be in a planar shape. It is sufficient at least if portions of the surfaces contacting the rectangular tube (10) whose end is pressed are in a planar shape.
(28) In such a fashion, by virtue of forming the V-shaped grooves in advance on the outer surfaces of the end of the rectangular tube (10), the V-shaped grooves formed on the two surfaces not facing the surfaces (401a, 401b) of the flat external dies (40a, 40b) are deformed so as to be closed therealong, when the two surfaces of the rectangular tube (10) facing the surfaces (401a, 401b) of the flat external dies (40a, 40b) are pressed. There can be suppressed, therefore, the bending of the radially reduced end of the rectangular tube (10), and the concavo-convex crimp likely to be generated on the radially reduced end. As a result, a rectangular tube having a stepped portion with favorable dimensional accuracy can be obtained.
(29) Pressing means for pressing external dies used in radially reducing the end of a rectangular tube does not need to be limited in particular. It is sufficient if such pressing means is capable of processing a rectangular tube to predetermined dimensions. In other words, it is sufficient if the external dies can be pressed by a pressing machine or other equipment from both sides as the pressing means.
(30) In the present invention, as will be described hereinafter, the two opposite surfaces of the rectangular tube (10) are processed simultaneously.
(31) Inclined surfaces (521a, 521b) are formed on the V-shaped external dies (52a, 52b) at sides opposite to the surfaces contacting the rectangular tube (10) (see FIG. 9). Further, fixed bases (56a, 56b) are arranged to be fixed at positions opposite to the rectangular tube (10) with respect to the V-shaped external dies (52a, 52b), respectively, such that the fixed bases (56a, 56b) face their respective inclined surfaces (521a, 521b). Still further, the V-shaped external dies (52a, 52b) are configured to be moved toward the rectangular tube (10) by squeezing wedge-shaped tools (58a, 58b) having their respective inclined surfaces (581a, 581b) along the inclined surfaces (521a, 521b) of their respective V-shaped external dies (52a, 52b) between the V-shaped external dies (52a, 52b) and the fixed bases (56a, 56b), respectively (see FIGS. 9 and 10). By this means, through the movement in one direction from the upper side to the lower side in FIG. 9 i.e. squeezing the wedge-shaped tools (58a, 58b) between the V-shaped external dies (52a, 52b) and the fixed bases (56a, 56b), respectively, the two opposite surfaces of the rectangular tube (10) can be simultaneously pressed (V-shaped groove processing). Assuming that the V-shaped external dies (30a, 30b) are used for processing V-shaped grooves by simultaneously pressing the two surfaces at the end of a tube, the simultaneous movement of two dies in opposite directions would be required. On the other hand, according to the present invention, one action i.e. squeezing two wedge-shaped tools (58a, 58b) simultaneously from the upper side to the lower side in FIG. 9 through the use of e.g. a general-purpose pressing machine is sufficient.
(32) As shown in FIGS. 12 to 14, in a similar fashion, inclined surfaces (621a, 621b) may be formed on the flat external dies (62a, 62b), which are used for radially reducing the end of the rectangular tube (10) having the V-shaped grooves formed thereon, at sides opposite to the surfaces contacting the rectangular tube (10). Also in such a case, the two opposite surfaces of the rectangular tube (10) can be simultaneously processed (i.e. radially reduced) by the movement in only one direction from the upper side to the lower side in FIG. 12 i.e. squeezing the wedge-shaped tools (58a, 58b) between the flat external dies (62a, 62b) and the fixed bases (56a, 56b).
(33) The V-shaped groove processing and the rectangular tube (10) radially reducing through the use of dies provided with the wedge-shaped tools (58a, 58b) will be specifically described with reference to FIGS. 9 to 16. Initially, the internal die (20) having the V-shaped concave portions (20a, 20b, 20c, 20d) formed thereon is inserted into the end of the rectangular tube (10) (see FIG. 9). Subsequently, the V-shaped external dies (52a, 52b) having the V-shaped convex portions (54a, 54b) formed on the surfaces thereof are arranged such that the V-shaped convex portions (54a, 54b) are opposite to the concave portions (20a, 20b) of the internal die (20) across the rectangular tube (10) (see FIG. 9).
(34) Subsequently, by pressing the wedge-shaped tool (58a) from the upper side to the lower side in FIG. 9 through the use of e.g. a general-purpose pressing machine, the wedge-shaped tool (58a) is inserted between the fixed base (56a) and the V-shaped external die (52a) so that the convex portion (54a) can be pressed against the rectangular tube (10) (see FIG. 10). When the wedge-shaped tool (58a) and the wedge-shaped tool (58b) are simultaneously pressed by the general-purpose pressing machine, the wedge-shaped tool (58a) is squeezed between the fixed base (56a) and the V-shaped external die (52a), and at the same time, the wedge-shaped tool (58b) is squeezed between the fixed base (56b) and the V-shaped external die (52b) so that the convex portion (54b) can be pressed against the rectangular tube (10) (see FIG. 10). It is possible to simultaneously form the V-shaped grooves on the two opposite surfaces of the rectangular tube (10) at the end thereof by simultaneously carrying out a pressing step through the use of the wedge-shaped tools (58a, 58b). After the step shown in FIG. 10, the rectangular tube (10) is rotated approximately 90 degrees around the center (O) as substantially a center of rotation. For the two surfaces having no V-shaped grooves formed thereon, the wedge-shaped tools (58a, 58b) are inserted between the V-shaped external dies (52a, 52b) and the fixed bases (56a, 56b), respectively, in a similar fashion (see FIG. 11). Through such one-direction movement from the upper side to the lower side in FIG. 9, the rectangular tube (10) can be formed with the V-shaped grooves on the surfaces of the end thereof.
(35) Subsequently, the internal die (20) is pulled out from the rectangular tube (10). As shown in FIGS. 12 to 14, the flat external dies (62a, 62b) are arranged such that the end of the rectangular tube (10) having V-shaped grooves formed thereon is interposed therebetween. By pressing the wedge-shaped tools (58a, 58b) from the upper side to the lower side as shown in FIG. 12 through the use of a general-purpose pressing machine, the wedge-shaped tools (58a, 58b) are squeezed along the inclined surfaces (621a, 621b) of the flat external dies (62a, 62b), and the flat external dies (62a, 62b) are pressed against the rectangular tube (10) (see FIGS. 12 and 13). Accordingly, only a portion having the V-shaped grooves formed thereon out of a whole portion of the rectangular tube (10) along a longitudinal direction can be radially reduced.
(36) After the step shown in FIGS. 12 and 13, the rectangular tube (10) is rotated approximately 90 degrees around the center (◯) as substantially a center of rotation, and arranged such that the two surfaces having the not-yet-closed V-shaped grooves do not face the surfaces (622a, 622b) of the flat external dies (62a, 62b), respectively (see FIG. 14). In other words, the rectangular tube (10) is arranged such that the two surfaces having the closed V-shaped grooves face the two surfaces (622a, 622b) of the flat external dies (62a, 62b), respectively. Subsequently, the wedge-shaped tools (58a, 58b) are squeezed along the inclined surfaces (621a, 621b) of the flat external dies (62a, 62b), and the flat external dies (62a, 62b) are pressed against the rectangular tube (10) by pressing the wedge-shaped tools (58a, 58b) in an arrow direction from the upper side to the lower side in FIG. 14 through the use of e.g. a general-purpose pressing machine. In such a fashion, each surface having each V-shaped groove formed thereon can be radially reduced. By such a rational method using only a general-purpose pressing machine and equipment for rotating and moving a rectangular tube, the rectangular tube (10) having a stepped portion with favorable dimensional accuracy, as shown in FIGS. 15 and 16, can be obtained. In other words, merely through the use of a general-purpose pressing machine instead of any dedicated equipment, the bending of the radially reduced end when a rectangular tube is radially reduced can be suppressed, and the concavo-convex crimp likely to be generated on the radially reduced end can also be suppressed. As a result, the rectangular tube (10) having a stepped portion with favorable dimensional accuracy can be obtained while a capital-investment being suppressed.
EXAMPLES
(37) In the radially reducing process according to the present invention, the rectangular tube, which is 45 mm in length and is rectangular in cross-section, was used. Material for the rectangular tube is a high-strength steel plate that is 3.2 mm in thickness and 400 MPa in tensile strength. As shown in FIG. 17, for the V-shaped external die, the angle (θ) of a V-shaped tip of the convex portion is 45 degrees, the length of an inclined part (a) of the V-shaped tip of the convex portion is 20 mm, and the length of a flat part (b) of the convex portion protruding from the main body was 40 mm, the length (c) of a main body is 100 mm. As shown in FIG. 18, a flat die in substantially a cubic shape, which is 100 mm in height (d), 100 mm in width (e), and 100 mm in length (f), was used. As shown in FIG. 19, the internal die having formed thereon the V-shaped grooves of 10 mm in width (g), 5 mm in depth (h), and 120 mm in length (i) was used.
(38) Initially, the internal die was inserted into one end of the rectangular tube. The V-shaped groove of 5 mm in depth, 10 mm in width, and 100 mm in total length in a longitudinal direction of the rectangular tube was formed on each surface of the rectangular tube by pressing the V-shaped external dies through the use of a hydraulic cylinder. The V-shaped grooves were formed simultaneously on the two laterally opposite surfaces of the rectangular tube, respectively. Subsequently, the rectangular tube was rotated 90 degrees, and the V-shaped grooves were formed on the other two surfaces of the rectangular tube.
(39) Subsequently, the flat external dies were attached after the V-shaped external dies had been detached, and the flat external dies were pressed with a hydraulic cylinder. In a similar fashion to the above, the two surfaces of the rectangular tube having the V-shaped grooves formed thereon were simultaneously radially reduced to the extent that one side of the tube reaches 38 mm in width over 100 mm in length of the tube. As a comparison example, a tube end was radially reduced from 100 mm to 38 mm in width by pressing only with the flat external dies for the same rectangular tube and flat external dies as the above example without forming the V-shaped grooves.
(40) As a result of comparison between the radially reducing method according to the present invention and the radially reducing method in the comparison example, the radially reduced end having specified dimensions could be readily formed when the radially reducing method according to the present invention was adopted, while some parts could not be radially reduced to the specified dimensions due to the generation of a concavo-convex crimp on each surface of the radially reduced end when the radially reducing method in the comparison example was adopted.
REFERENCE NUMERALS
(41) 10 rectangular tube 20 internal die 30a, 30b, 52a, 52b V-shaped external die 35a, 35b convex portion 40a, 40b, 62a, 62b flat external die 54a, 54b convex portion 56a, 56b fixed base 58a, 58b wedge-shaped tool
