Method of manufacturing a sub-muffler outer cylinder
10016801 ยท 2018-07-10
Assignee
Inventors
Cpc classification
B21D53/88
PERFORMING OPERATIONS; TRANSPORTING
F01N13/1894
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y10T29/49398
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T29/494
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F01N13/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A manufacturing method of a sub-muffler outer cylinder is provided. The manufacturing method includes pushing one push roll toward two receive rolls, and then bending a plate-shape workpiece to form the sub-muffler outer cylinder made of a cylindrical-shaped body. A push-in amount in a part of the workpiece corresponding to a corner part of the cylindrical-shaped body is made larger than a push-in amount in a part of the workpiece corresponding to a side part of the cylindrical-shaped body to form the cylindrical-shaped body having a polygonal cross-sectional shape.
Claims
1. A manufacturing method of a sub-muffler outer cylinder, the manufacturing method comprising: inserting a trapezoidal plate-shape workpiece having an upper base part and a lower base part between one push roll and two receive rolls; and pushing the one push roll toward the two receive rolls to bend the trapezoidal plate-shape workpiece, wherein a resistance is given to a part near the upper base part or a part near the lower base part of the workpiece by a roller or a weight to slide the workpiece and one of the push roll or the receive rolls to form the sub-muffler outer cylinder made of a cylindrical-shaped body having a tapered shape so as to be squeezed from a first end part to a second end part, wherein a push-in amount in a part of the workpiece corresponding to a corner part of the cylindrical-shaped body is made larger than a push-in amount in a part of the workpiece corresponding to a side part of the cylindrical-shaped body to form the cylindrical-shaped body having a polygonal cross-sectional shape, and wherein the push roll and the two receive rolls each have a truncated cone side surface.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
First Embodiment
(12) With reference to
(13) First, a manufacturing device used in the manufacturing method according to the first embodiment will be described. As shown in
(14) The push roll 10 is a truncated cone that is supported by the bearing housings 13 and 14 via an axial member 15 and can be rotated around an axis A10. The rotation direction of the push roll 10 is represented by -. One end part 10b of the push roll 10 has a diameter larger than that of the other end part 10a. The push roll 10 has a tapered shape so as to be squeezed from one end part 10b toward the other end part 10a. The side surface of the push roll 10 (may be referred to as a truncated cone side surface) is inclined to the axis at a predetermined taper angle. The push roll 10 can be moved along the -z direction by the hydraulic cylinders 16 and 17 via the bearing housings 13 and 14 and the axial member 15. The push roll 10 can be lowered, for example, toward the receive rolls 11 and 12.
(15) The receive rolls 11 and 12 are truncated cones that are supported by a supporting base (not shown) via an axial member (not shown) and can be respectively rotated around axes A11 and A12. The rotation directions of the receive rolls 11 and 12 are respectively represented by - and -. One end part 11b of the receive roll 11 has a diameter larger than that of the other end part 11a and one end part 12b of the receive roll 12 has a diameter larger than that of the other end part 12a. The receive roll 11 has a tapered shape so as to be squeezed from one end part 11b toward the other end part 11a. In a similar way, the receive roll 12 has a tapered shape so as to be squeezed from one end part 12b toward the other end part 12a. The side surfaces of the receive rolls 11 and 12 (may be referred to as truncated cone side surfaces) are inclined to the respective axes at a predetermined taper angle, which is similar to the side surface of the push roll 10. The receive rolls 11 and 12 are aligned with each other with a predetermined interval therebetween. The receive rolls 11 and 12 are fixed so that the axes of the receive rolls 11 and 12 are located in predetermined positions. Further, while the edge of the other end part 11a is shown to extend beyond the edge of one end part 11b on the ZX plane in
(16) The bearing housing 13 is arranged on one end part 10b of the push roll 10 and the bearing housing 14 is arranged on the other end part 10a of the push roll 10. Further, the bearing housings 13 and 14 are respectively supported by the hydraulic cylinders 16 and 17 so that the bearing housings 13 and 14 can be vertically moved.
(17) The hydraulic cylinders 16 and 17 are arranged below the bearing housings 13 and 14, respectively. The hydraulic cylinders 16 and 17 adjust a push-in amount by the push roll 10 via the bearing housings 13 and 14, respectively. The push-in amount means a distance from the lowermost part of the push roll 10 when the height of the lowermost part of the push roll 10 is equal to the height of the uppermost part of the receive roll 11 to the lowermost part of the push roll 10 when the push roll 10 is lowered (hereinafter, the push-in amount may be referred to as a push-in distance). The hydraulic cylinders 16 and 17 are able to change the push-in amount by the push roll 10 during a bending process so that the push-in distance of the push roll 10 changes according to the position of the workpiece. The hydraulic cylinders 16 and 17 may adjust the push-in amount by the push roll 10 by using, for example, a hydraulic controller 18 (may be referred to as a controller) that controls the amount of oil that flows through the hydraulic cylinders 16 and 17.
(18) Next, the manufacturing method according to the first embodiment will be described. As shown in
(19) Typically, roll bending is performed so that the lower base part W2 passes through the side of one end part 10b while allowing the upper base part W1 of the workpiece W0 to pass through the side of the other end part 10a. The push roll 10 pushes the workpiece W0 at a predetermined push-in amount P1 while the workpiece W0 passes between the push roll 10 and the receive rolls 11 and 12. A side part 20a (see
(20) Subsequently, as shown in
(21) Next, the side part forming process S1 and the corner part forming process S2 are alternated until the time that the leg part W3 and the leg part W4 face each other or come in contact with each other. As shown in
(22) Now, a relation among the dimension of the formed product, the roll diameter, and the push-in amount will be described. As shown in
(rf+r12)2=(r12+c/2)2+{(rf+r12)b}2(Expression 1)
(23) Solving Expression 1 for rf obtains Expression 2.
(rf+r12)2=r122+r12c+c2/4+(rf+r12)22b(rf+r12)+b2
0=r122+r12c+c2/42b(rf+r12)+b2
2brf=r122+r12c+c2/42r12b+b2
rf={(r12b)2+r12c+c2/4}/2b(Expression 2)
(24) The radius rf of the formed product can be approximated by Expression 2. According to Expression 2, the radius rf of the formed product is influenced by the radius r12 of the receive roll 12, the push-in amount b, and the distance c. In a similar way, the radius rf of the formed product is also influenced by the radius of the receive roll 11. Accordingly, in order to adjust the radius rf of the formed product, the receive rolls 11 and 12 may be respectively moved in the -x direction (see
(25) Next, the end part 23 of the cylindrical-shaped body 20 and the end part 24 of the cylindrical-shaped body 20 may be welded together (welding process S3). By welding together the end part 23 and the end part 24, it is possible to form the cylindrical-shaped body which has no seam in the circumferential direction.
(26) By changing the push-in amount in each of the side part forming process S1 and the corner part forming process S2 and the number of times that these processes are repeated, the plate-shape workpiece W0 can be formed into cylindrical bodies having various cross-sectional shapes.
(27) From the above description, according to the manufacturing method of the first embodiment, the cylindrical-shaped body having a polygonal cross-sectional shape can be formed. Further, in the manufacturing method according to the first embodiment, a roll bending device having a general configuration that includes a push roll and receive rolls is used, and the necessary equipment cost is low. Further, it is possible to change the push-in amount according to the position of the workpiece by the hydraulic cylinder or the hydraulic controller, for example. According to this configuration, it is possible to manufacture cylindrical-shaped bodies having various polygonal cross-sectional shapes with a low equipment cost using a device having a general configuration without using equipment such as a plurality of press dies to form various cross-sectional shapes.
(28) Incidentally, by performing processing such as a diameter reducing process to reduce the end part of the cylindrical-shaped body obtained by the manufacturing method according to the first embodiment or arranging a duct which is a flow path of exhaust gas in the cylindrical-shaped body obtained by the manufacturing method according to the first embodiment, it is possible to obtain, for example, a sub-muffler. One example of such a sub-muffler is a sub-muffler 1 shown in
(29) As shown in
Second Embodiment
(30) With reference to
(31) First, a manufacturing device used in the manufacturing method according to the second embodiment will be described. The manufacturing device used in the manufacturing method according to the second embodiment includes the same configurations as those of the roll bending device 100 except for the configurations of the push roll and the receive rolls. Elements of this embodiment which are the same as those of the first embodiment are denoted by the same reference symbols as those of the first embodiment and the descriptions thereof will be omitted.
(32) As shown in
(33) The push roll 210 is a columnar body that is supported by the bearing housings 13 and 14 via the axial member 15 and can be rotated around the axis. The side surface of the push roll 210 (may be referred to as a column side surface) is substantially parallel to the axis. That is, the push roll 210 has a straight shape, not a tapered shape, and has a taper angle of about 0. The push roll 210 is vertically moved by the hydraulic cylinders 16 and 17 via the bearing housings 13 and 14 and the axial member 15. The push roll 210 can be lowered, for example, toward the receive rolls 211 and 212.
(34) The receive rolls 211 and 212 are columnar bodies that are supported by a supporting base (not shown) via an axial member (not shown) and can be rotated around an axis. The side surfaces of the receive rolls 211 and 212 (may be referred to as column side surfaces) are parallel to the axis, which is similar to the side surface of the push roll 210. In summary, the receive rolls 211 and 212 do not have a tapered shape and the taper angle is substantially 0. The receive rolls 211 and 212 are aligned with each other with a predetermined interval therebetween. The receive rolls 211 and 212 are fixed so that the axes of the receive rolls 211 and 212 are located in predetermined positions.
(35) The hydraulic cylinders 16 and 17 adjust the push-in amount by the push roll 210 via the bearing housings 13 and 14, respectively. The hydraulic cylinders 16 and 17 can change the push-in amount by the push roll 10 during the forming process so that the push-in distance of the push roll 210 changes depending on the position of the workpiece.
(36) Next, the manufacturing method according to the second embodiment will be described. First, similar to the manufacturing method according to the first embodiment, roll bending is performed by pushing the push roll 210 toward the receive rolls 211 and 212 while allowing a trapezoidal plate shape workpiece W20 to pass between the push roll 210 and the receive rolls 211 and 212 (side part forming process S21). The workpiece W20 is a rectangular plate made of a material which can be roll-bended. The workpiece W20 includes short-side parts W23 and W24 corresponding to the short sides of the rectangle and long-side parts W21 and W22 corresponding to the long sides of the rectangle. When the workpiece W20 passes between the push roll 210 and the receive rolls 211 and 212, the push roll 210 pushes the workpiece W20 at a predetermined push-in amount P1. A side part 220a (see
(37) Next, the push roll 210 pushes the workpiece W20 at a push-in amount P2 which is larger than the push-in amount P1 while allowing the workpiece W20 to pass between the push roll 210 and the receive rolls 211 and 212 (corner part forming process S22). A corner part 220f (see
(38) Next, the side part forming process S21 and the corner part forming process S22 are alternated until the time that the short-side parts W23 and W24 face each other or come in contact with each other. As shown in
(39) Further, while the side part forming process S21 and the corner part forming process S22 are alternated in the manufacturing method according to the second embodiment, the push-in amount P1 in the side part forming process S21 may be 0 (zero). When the push-in amount P1 in the side part forming process S21 is 0 (zero), the curvature R of the side parts 220a, 220b, 220c, 220d, and 220e becomes 0 and the shape of the side parts 220a, 220b, 220c, 220d, and 220e becomes flat.
(40) As seen from the above description, according to the manufacturing method of the second embodiment, the cylindrical body having a polygonal cross-sectional shape can be formed. Further, in the manufacturing method according to the second embodiment, the push-in amount can be changed depending on the position of the workpiece using a roll bending device having a general configuration that includes a push roll and receive rolls. Accordingly, it is possible to manufacture cylindrical-shaped bodies having polygonal cross-sectional shapes by only using a device having a general configuration without using equipment such as a plurality of press dies to form various cross-sectional shapes.
(41) Incidentally, by performing processing such as a diameter reducing process to reduce the end part of the cylindrical-shaped body 220 obtained by the manufacturing method according to the second embodiment or arranging a duct which is a flow path of exhaust gas in the cylindrical-shaped body 220 obtained by the manufacturing method according to the second embodiment, it is possible to obtain, for example, a sub-muffler. One example of such a sub-muffler is a sub-muffler 201 shown in
(42) Note that the present invention is not limited to the above first and second embodiments and may be changed as appropriate without departing from the spirit of the present invention. For example, while the push roll 10 is pushed toward the two receive rolls 11 and 12 in the manufacturing method according to the first and second embodiments, the two receive rolls 11 and 12 may instead be pushed toward the push roll 10. Further, the order of the side part forming process S1 or S21 and the corner part forming process S2 or S22 or the number of times that these processes are repeated can be changed as appropriate. Further, the roll bending device used in the manufacturing method according to the first and second embodiments may further include a roll opposed to the push roll 10 on the side of the two receive rolls 11 and 12. Further, while the roll bending device according to the first embodiment uses the hydraulic cylinders 16 and 17 to push the push roll, an actuator (or it may be referred to as a drive part) may be used in place of the hydraulic cylinders. Such an actuator may include, for example, a hydraulic motor. Further, while the trapezoidal plate shape workpiece W0 is used in the manufacturing method according to the first embodiment, a fan plate shape workpiece may be used instead. Further, while the workpiece is passed between the push roll and the receive rolls once in the manufacturing method according to the first and second embodiments, the workpiece may be passed between them a plurality of times.
(43) Further, in the manufacturing method according to the first embodiment, by changing the combination of the push-in amount by the push roll 10 (see
(44) Further, while the taper angle of the formed product is determined by the taper angle of the push roll 10 or the receive rolls 11 and 12 in the manufacturing method according to the first embodiment, a resistance may be given to a part near the upper base part W1 or a part near the lower base part W2 of the workpiece W0 by a roller or a weight to slide the workpiece and the push roll or the receive roll to change the speed at which the workpiece W0 passes in one end part 10b or the other end part 10a having a diameter smaller than that of one end part 10b. It is therefore possible to change the taper angle of the cylindrical-shaped body obtained by forming the workpiece.
(45) From the invention thus described, it will be obvious that the embodiments of the invention may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended for inclusion within the scope of the following claims.