SLIDING FRICTIONAL FORCE GENERATION MECHANISM BY FITTING AND DIE CUSION FOR PRESS MACHINE

Abstract

A sliding frictional force generation mechanism includes a metal hole member having a hole, a metal shaft member fitted in the hole of the hole member in an axially slidable manner, and a lubrication mechanism configured to supply lubricating oil serving as a cooling medium between the holed ember and the shaft member. The shaft member is fitted in the hole in an interference fit state.

Claims

1. A sliding frictional force generation mechanism comprising: a metal hole member having a hole; a metal shaft member fitted in the hole of the hole member slidably in an axial direction; and a lubrication mechanism configured to supply lubricating oil serving as a cooling medium between the hole member and the shaft member, wherein the shaft member is fitted in the hole in an interference fit state.

2. The sliding frictional force generation mechanism as recited in claim 1, wherein a passage through which the lubricating oil or another cooling medium flows is formed in at least one of the hole member and the shaft member.

3. The sliding frictional force generation mechanism as recited in claim 1, wherein both the hole member and the shaft member are made of carbon steel, and wherein a surface hardening treatment is subjected to at least one of or both of sliding surfaces of the hole member and the shaft member.

4. The sliding frictional force generation mechanism as recited in claim 1, wherein surface roughness Ra of the hole and the shaft member is 0.01 to 0.2 m

5. The sliding frictional force generation mechanism as recited in claim 1, wherein the surface roughness Ra of the hole and the shaft member is 0.08 to 0.2 m.

6. A die cushion device for a press machine, comprising: the sliding frictional force generation mechanism as recited in claim 1; and a return mechanism configured to return the shaft member pushed in to a state before being pushed in, wherein the sliding frictional force generation mechanism is used for clamping a workpiece as a reaction force or resistance force generation source of press working.

7. A die for a press machine in which the sliding frictional force generation mechanism as recited in claim 1 is used as a reaction force or resistance force generation source of processing pressure to be applied to a die.

8. A die cushion device comprising: the sliding frictional force generation mechanisms as recited in claim 1; and a reversing mechanism configured to reverse the sliding frictional force generation mechanism, wherein the hole of the hole member of the sliding frictional force generation mechanism is a through-hole, a length of the shaft member is longer than the hole, the reversing mechanism is configured to reverse the sliding frictional force generation mechanism for each pressing motion of a press machine, so that the shaft member pushed in is returned to a state before being pushed in, and the sliding frictional force generation mechanism is used for clamping a workpiece as a reaction force or resistance force generation source of press working.

9. A relief type die cushion device comprising: a hydraulic cylinder composed of a cylinder and a piston, wherein a cushion force is exerted by resistance of hydraulic oil coming out of the hydraulic cylinder, and portions of an inner surface of the cylinder and an outer surface of the piston that are in sliding contact with each other near at a bottom dead center of a press machine constitute the sliding frictional force generation mechanism as recited in claim 1.

10. A method for producing the sliding frictional force generation mechanism as recited in claim 1, comprising: fitting a shaft member in a hole member by a cold-fit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Some embodiments of the present disclosure are shown by way of example, and not limitation, in the accompanying figures.

[0032] FIG. 1 is a configuration diagram showing one embodiment of a die cushion device of the present invention in a state in which the die cushion device is attached to a press machine.

[0033] FIG. 2A and FIG. 2B are a plan view and a schematic longitudinal cross-sectional view of a sliding frictional force generation mechanism coupled to a die, respectively.

[0034] FIG. 3 is a configuration diagram showing another embodiment of a die cushion device of the present invention.

[0035] FIG. 4A and FIG. 4B show still another embodiment of a die cushion device of the present invention, wherein FIG. 4A is a configuration diagram in a state in which the die cushion device is attached to a press machine, and FIG. 4B is a plan view of the die cushion device.

[0036] FIG. 5A and FIG. 5B show an application example in which the die cushion of the present invention is used for fine blanking, wherein FIG. 5A is a cross-sectional view of dies, and FIG. 5B is a front view of a punched product.

[0037] FIG. 6A and FIG. 6B show a still another embodiment of the die cushion device of the present invention, wherein FIG. 6A is a front view in a state in which the die cushion device is attached to a press, and FIG. 6B is a plan view thereof.

[0038] FIG. 7A and FIG. 7B show essential parts of the die cushion device of FIG. 6A, wherein FIG. 7A is a front cross-sectional view thereof, and FIG. 7B is a side cross-sectional view thereof.

[0039] FIG. 8 is a schematic process diagram showing the operating state of the die cushion device shown in FIG. 6A.

[0040] FIG. 9A and FIG. 9B show still another embodiment of a die cushion device using the frictional force generating mechanism of the present invention, wherein FIG. 9A shows a state in which a press machine is in the top dead center, and FIG. 9B shows a state in which the press machine is in the bottom dead center.

[0041] FIG. 10 is a graph showing the operation of the die cushion device of FIG. 9A.

[0042] FIGS. 11A and 11B are schematic configuration diagrams of a friction pin and a hub used for an element test of interference fit sliding, and FIG. 11C is a detailed view of the friction pin, and FIG. 11D is an enlarged view showing an oil groove.

[0043] FIGS. 12A and 12B are a plan view and a front view of the friction pin used for a durability sliding test.

[0044] FIG. 13A and FIG. 13B are a plan view and a longitudinal cross-sectional view of a main part of a hub used for the durability sliding test.

[0045] FIGS. 14A and 14B are photomicrographs each showing the roughness of the sliding portion and the non-sliding portion of the friction pin after the durable sliding test, and FIG. 14C is an enlarged view showing the oil groove of the friction pin.

[0046] FIG. 15A and FIG. 15B are photomicrographs showing the comparison of the state of the inner surface of the hub before and after the durable sliding test.

EMBODIMENTS FOR CARRYING OUT THE INVENTION

[0047] In the following paragraphs, some embodiments in the present disclosure will be described by way of example and not limitation. It should be understood based on this disclosure that various other modifications can be made by those in the art based on these illustrated embodiments.

[0048] The die cushion device 10 shown in FIG. 1, FIG. 2A and FIG. 2B is composed of a normal pressure type air cushion device 12 attached to a press machine 11 and arranged below a bolster 13, and a friction die cushion 15 coupled to the lower portion of a lower die 14 arranged above the bolster 13. The reference numeral 16 denotes a supply system configured to circularly supply lubricating oil which also serves as cooling medium to the friction die cushion 15. The left side of FIG. 1 shows a state of the press machine 11 in which a slide 19 is raised and the right side shows a state in which the slide 19 is lowered. This also applies to FIG. 3 and FIG. 4A. The press machine 11 is composed of a frame 18, the aforementioned bolster 13, the slide 19 that moves up and down, and a known slide drive mechanism (not illustrated) that drives the slide 19 up and down.

[0049] The air cushion device 12 is composed of a plural staged bellows 20, air (pressurized air) filled in the bellows 20, a base plate 21 for supporting the lower part of the bellows 20, bolts 22 and pipes 23 for fixedly hanging the base plate 21 from the bolster 13, and a cushion pad 24 fixed to the upper end of the bellows 20. The cushion pad 24 is vertically slidably guided by the pipes 23. The air duct for supplying air to the bellows 20 is not illustrated.

[0050] In this embodiment, a through-hole 26 is formed in the center of the bolster 13, and a cushion pin 27 is slidably passed through the through-hole 26. The through-hole 26 and the cushion pin 27 may be plural (see FIG. 4A and FIG. 4B). The cushion pin 27 is a component arranged so as to penetrate the bolster 13 for transmitting the cushion force, and is usually formed in a cylindrical shape. The cushion pin 27 is used for various dies (lower die 14), and is not connected to the die but is merely in contact with the die. The cushion pin 27 merely comes into contact with the cushion pad 24. However, the cushion pin 27 may be coupled to the die 14 and/or the cushion pad 24 if necessary.

[0051] As shown in the upper part of FIG. 2B, the lower die 14 is provided with a die 29 having a punching hole 28 of a predetermined shape and a counter (counter punch) 30 slidably accommodated in the punching hole 28 via a minute clearance. A friction die cushion 15 is arranged below the lower die 14, and the friction die cushion 15 is fixed to the bolster 13 by bolts or the like (see FIG. 1). The friction die cushion 15 is composed of a friction pin 31 arranged below the counter 30 and a holder 32 for supporting the friction pin 31 in an upwardly and downwardly movable manner. The friction pin 31 has a contour smaller than the counter 30 and is usually cylindrical (see FIG. 2A). The counter 30 is fastened to the upper end of the friction pin 31 with bolts or the like, and the die 29 is fixed to the holder 32 with bolts or the like. The upper portion 31a and the lower portion 31b of the friction pin 31 are formed to be somewhat smaller in diameter than the intermediate portion 31c. The holder 32 is composed of a hub (hub plate) 33 corresponding to the intermediate portion 31c of the friction pin 31 and spacers 34 and 35 arranged on the upper side and the lower side of the hub 33, respectively. For sealing lubricating oil, it is preferable to seal the abutting surfaces of the hub 33 and spacers 34 and 35 with a seal ring or a gasket and fix the spacers 34 and 35 to the hub 33 with bolts or the like.

[0052] The hub 33 is provided with a friction hole 36 which slidably fits to the intermediate portion 31c of the friction pin 31 in an interference fit manner. The intermediate portion 31c of the friction pin 31 and the friction hole 36 constitute the sliding frictional force generation mechanism of the present invention. An annular or helical oil groove 37 is formed on the outer peripheral surface of the intermediate portion 31c, the inner surface of the friction hole 36, or both thereof. In the upper spacer 34, a guide hole 34a which is slidably fitted to the upper portion 31a of the friction pin 31 and an enlarged diameter portion 34b which does not come into sliding contact with the intermediate portion 31c and forms an oil pocket 38 between the upper portion 31a of the friction pin 31 and the enlarged diameter portion 34b are formed. In the same manner, in the lower spacer 35, a guide hole 35a which slidably fits to the lower portion 31b of the friction pin 31 and an enlarged diameter portion 35b which does not come into sliding contact with the intermediate portion 31c of the friction pin 31 and forms an oil pocket 38 between the the lower portion 31b and the enlarged diameter portion 35b are formed. An O-ring groove is formed on the inner surface of each of the guide holes 34a and 35a, and an O-ring 39 is accommodated therein. Passages 40 and 41 communicating the oil pockets 38 and 38 with the outside are formed in the upper and lower spacers 34 and 35.

[0053] The intermediate portion 31c of the friction pin 31 and the friction hole 36 are fitted in an interference fit state. That is, in a natural state in which they are not fitted with each other, the diameter of the intermediate portion 31c of the friction pin 31 is larger than the diameter of the friction hole 36 by the tightening margin. Then, the intermediate portion 31c of the friction pin 31 contracts elastically due to the fit, and correspondingly the friction hole 36 elastically expands in diameter. That is a so-called minus tolerance fit. For example, when the diameter of the intermediate portion 31c and the diameter of the friction hole 36 are 30 to 50 mm, it is preferable that the tightening margin be about 0.02 to 0.04 mm, particularly about 0.03 mm. When fitting the friction pin 31 to the friction hole 36 of the hub 33, a cold-fit method is used. According to this method, the friction pin 31 is preliminary cooled so as to be thermally contracted until the friction pin 31 becomes smaller in diameter than the friction hole 36. In this state, the friction pin 31 is inserted into the friction hole 36, then the friction pin 31 is returned to normal temperature to thereby cause a strongly fit. This makes it possible to perform an interference fit without damaging the material of the hub 33. Note that the interference fit may be performed by a shrink fit or a press fit. For a press fit, a lubricant, particularly lubricating oil, is applied on the friction surface before the press fit.

[0054] The friction pin 31 is preferably made of carbon steel, particularly cold die steel such as JIS standard DC53 steel. It is also preferable that the surface of the friction pin 31 be subjected to polishing and lapping into a very smooth surface with an arithmetic mean roughness Ra of 0.2 m or less except for oil grooves when there are oil grooves. As for the lower limit, for the purpose of, e.g., maintaining the oil film, it is preferable to set the arithmetic mean roughness Ra to 0.01 m or more, more preferably 0.08 m or more considering the ease of processing. Therefore, the arithmetic mean roughness Ra is preferably within the range of 0.01 to 0.2 m, particularly within the range of 0.08 to 0.2 m. Further, it is preferable to subject the surface of the friction pin 31 to a hardening treatment, such as, e.g., a low-temperature TiC treatment. The surface hardness is set to about 55 to 65 in Rockwell C scale (HRC). In the same manner, the hub 33 is preferably made of alloy tool steel such as JIS standard SKD61 steel. It is also preferable that the friction hole 36 of the hub 33 be subjected to polishing and lapping into a very smooth surface with an arithmetic mean roughness Ra of 0.01 to 0.2 m particularly 0.08 to 0.2 m. Further, it is preferable to subject the surface of the friction hole 36 to a hardening treatment, such as, e.g., a radical nitriding treatment. The surface hardness is set to about 45 to 49 in Rockwell C scale (HRC). The friction pin 31 and the hub 33 are preferably as close as possible in thermal expansion coefficient, particularly preferably the same in thermal expansion coefficient. In this case, even in cases where the friction pin 31 and the hub 33 expand thermally, the friction pin 31 and the hub 33 expand in the same manner, which can suppress the change of the sliding frictional force.

[0055] As shown in FIG. 1, a lubricating oil supply system 16 is connected to the passages 40 and 41 of the upper and lower spacers 34 and 35. The supply system 16 includes a supply pipe line 41a extending from an oil tank OT to the passage 41 of the lower spacer 35 and a return line 40a connecting the passage 40 of the upper spacer 34 to the oil tank OT. Note that the supply pipe line 41a may be connected to the passage 40 of the upper spacer 34. A suction filter SF, an oil pump OP, and an oil cooler OC are interposed in the middle of the supply pipe line 41a. The oil cooler OC cools the lubricating oil to remove/dissipate frictional heat.

[0056] To the slide 19 of the press machine 11, an upper die 45 for blanking a workpiece W in cooperation with the lower die 14 is attached. The upper die 45 is a known die including a punch 46 having a tip end to be inserted into the punching hole 28 of the die 29, a blank holder 47 slidably provided around the punch 46, a spring (upper cushion) 48 for urging the blank holder 47 downward, and a die holder 49 for regulating the lower limit of the vertical movement of the blank holder 47.

[0057] The die cushion device 10 configured as described above functions when blanking is performed by lowering the slide 19 after placing a workpiece W on the lower die 14. That is, when the slide 19 is lowered, the blank holder 47 presses periphery of the workpiece W, and the punch 46 presses the workpiece W downward. At that time, the force (F1+F2) obtained by adding the urging force F1 of the air cushion device 12 and the frictional resistance F2 of the friction die cushion 15 is applied to the counter 30 upward. For this reason, the workpiece W is pressed downward while being strongly clamped by the punch 46 and the counter 30. Furthermore, the periphery of the workpiece W is also clamped by the blank holder 47 and the die 29 strongly. As a result, the central portion Wa of the workpiece W is punched out from the surrounding portion Wb.

[0058] Since both the central portion Wa and the surrounding portion Wb of the workpiece W are clamped from above and below, the workpiece W is sheared in almost the entire area from the upper surface to the lower surface of the workpiece W (total shearing). Therefore, as shown in FIG. 5B, a clean shear plane 52 with fewer shear droops 50 in which the corner is rounded or fewer burrs 51 due to the small clearance between the die 29 and the punch 46 can be obtained. The punched portion and the remaining hole are high in dimensional accuracy. Further, the punched product is high in flatness since it did not receive a strong bending force. That is, a fine blanking or a fine punching was performed.

[0059] When the slide 19 is raised and therefore the punch 46 is raised, the counter 30 will be raised by the upward urging force F1 applied to the air cushion device 12 via the cushion pin 27 and the friction pin 31. On the other hand, the frictional resistance F of the friction die cushion 15 acts so as to prevent the upward movement of the friction pin 31. Therefore, the counter 30 is raised with the upward lifting force of F1-F. That is, in this embodiment, when the slide 19 is lowered, the air cushion device 12 and the friction die cushion 15 exert a cushioning effect, and when the slide 19 is raised, the air cushion device 12 acts as a return mechanism for returning the friction pin 31 to the original position.

[0060] The friction die cushion ability (frictional resistance) F is calculated by the product of the surface pressure p occurring between metals (sliding surfaces) by the interference fit, the area on which the surface pressure acts, and the friction coefficient The relationship between a tightening margin and generating surface pressure p in the fit is shown by Formula 1.

[00001]$\begin{array}{cc}p=\frac{}{D_1.Math.\left\{\frac{1}{E_1}+\frac{D_2^2+D_1^2}{E_2\left(D_2^2-D_1^2\right)}+\frac{v_2}{E_2}-\frac{v_1}{E_1}\right\}}& \left[\mathrm{Formula}.Math..Math.1\right]\end{array}$

[0061] The friction die cushion ability F is the product of the surface pressure p, the friction coefficient , and the sliding area S at the sliding surface. Since the sliding area S is D.sub.1L, the friction die cushion ability F is expressed by Formula 2.

[Formula 2]

F=p(D.sub.1L)

[0062] As the friction coefficient , a dynamic friction coefficient is adopted when the friction pin 31 is moving, and a static friction coefficient is adopted from the stationary state until it starts moving. Here, : tightening margin, v.sub.1: Poisson's ratio of the friction pin, v.sub.2: Poisson's ratio of the hub, E.sub.1: Young's modulus of the friction pin, D.sub.1: fit diameter of the friction pin, E.sub.2: Young's modulus of the hub, D.sub.2: outer diameter of the hub.

[0063] The friction coefficient varies in accordance with the viscous resistance of the lubricating oil, and the viscous resistance varies in accordance with temperature. Furthermore, the diameter of the friction hole and the diameter of the friction pin thermally expand in accordance with temperature. However, since the friction die cushion 15 in FIG. 1 is constantly cooled by the lubricating oil cooled by the oil cooler OC, there is little change, so the frictional resistance does not fluctuate greatly. Since smooth surfaces slide each other and are constantly lubricated with the lubricating oil, occurrence of seizure and/or galling of the friction surfaces can be prevented. It should be note that a passage for cooling oil as a cooling medium other than the lubricating oil may be formed in the hub 33 to cool the hub 33. In that case, since the passage cross-sectional area for the cooling oil can be increased, the hub 33 can be efficiently cooled. An inner passage of the hub 33 is preferably configured by a gap formed by concentrically arranging double cylinders configuring the hub 33. In this case, not only the passage cross-sectional area is large but also the contact area with the cooling medium is large, so the heat transfer efficiency is high.

[0064] A die cushion device 55 shown in FIG. 3 is equipped with a friction die cushion 56 substantially similar to the friction die cushion 15 shown in FIG. 2B and a knockout mechanism 57 for pushing up the friction pin 31. No air cushion device is equipped. The illustration of an oil supply circuit for supplying lubricating oil to the friction die cushion 56 is omitted.

[0065] In the friction die cushion 56 of this embodiment, the upper portion 31a of the friction pin 31 also serves as a counter, and a die 58 serving as a spacer is arranged on the hub 33. Other points, especially the configuration of the intermediate portion 31c of the friction pin 31 and the configuration of the friction hole 36 of the hub 33 are the same as those of the friction die cushion 15 shown in FIG. 2B. The upper die 45 is similar to the upper die of FIG. 1. The contour of the punch 46 of the upper die 45 and the contour of the upper portion 31a of the friction pin 31 which also serves as a counter are both circular, and the guide hole 58a formed in the die 58 is also circular. Therefore, it can be configured such that an O-ring groove is formed on the inner circumferential surface of the guide hole 58a and an O-ring is fitted therein to seal the gap between the inner circumferential surface of the guide hole 58a and the upper portion 31a of the friction pin 31.

[0066] The knockout mechanism 57 is composed of a cam 59 rotatably provided below the bolster 13, a cam drive mechanism (not illustrated) for rotating the cam 59 synchronously with the up-and-down motion of the slide 19, a cam follower 60 that moves up and down in contact with the outer peripheral surface of the cam 59, and a knockout pin 61 for transmitting the up-and-down motion of the cam follower 60 to the friction pin 31. As the cam 59, a plate cam with a protrusion 62 protruding smoothly on a part of a disk is adopted. Note that the cam 59 may be a cam of other forms such as a groove cam. The knockout pin 61 is slidably provided in the through-hole 26 formed in the bolster 13. The cam 59 can be rotationally driven by, for example, transmitting the rotational motion of a crankshaft driving the slide 19 of the press machine 11 via a connecting shaft.

[0067] Further, the cam 59 can also be rotationally driven independently by a motor provided separately from a crankshaft. In this case, a control device for controlling the motor by detecting the operating state of the press machine 11 is provided. As the motor, a servomotor is preferably adopted since the timing of the up-and-down motion of the knockout pin 61 can be freely set. Instead of the cam mechanism, other mechanisms that convert a rotational motion into a linear reciprocating motion, such as, e.g., a screw mechanism and a rack-pinion mechanism, can also be adopted. The mechanism for returning these friction pins 31 to their original positions can also be applied to the friction die cushion 15 independent from the dies as shown in FIG. 1 and FIG. 2B, the friction die cushion 56 integrated with the dies of FIG. 3, and the friction die cushion used for a drawing die of FIG. 4A and FIG. 4B.

[0068] The die cushion device 55 shown in FIG. 3 is not equipped with an air cushion device. Therefore, when the slide 19 is lowered, the force of clamping the workpiece W between the punch 46 and the counter punch (here, the upper portion 31a of the friction pin 31 in this embodiment) is provided only by the friction die cushion 56. Further, even in cases where the frictional force is not strong, there is no upward urging force, so it can be used as a cushion equipped with a so-called locking mechanism. For this reason, the timing to take out the punched product from the die can be set freely.

[0069] The die cushion device 63 shown in FIG. 4A and FIG. 4B is equipped with an air cushion device 12 and a friction die cushion 64. As a die, a die of a drawing type (deep drawing type) is adopted, and the upward urging force of the die cushion device 12 is used for a blank holder of a workpiece. The lower die 65 is composed of a base 66, a punch 67 arranged in a manner such that its upper portion protrudes at the center of the base 66, a cushion ring 68 provided in a manner as to be movable up and down with respect to the base 66 so as to surround the punch 67, four spacer pins 69 disposed below the cushion ring 68 to support the cushion ring 68. The upper die 70 that works with the lower die 65 is equipped with a die 71 that fits on the punch 67 in a manner as to clamp the workpiece W, and a die plate 72 for holding the die 71.

[0070] The cushion ring 68 of the lower die 65 is accommodated slidably up and down in an annular groove 73 provided in the upper surface of the base 66, and the spacer pins 69 are slidably accommodated in corresponding four holes 66a penetrating from the bottom of the annular groove 73 to the lower surface of the base 66. As shown in FIG. 4B, four spacer pins 69 are arranged at equal intervals in the circumferential direction.

[0071] The friction die cushion 64 is composed of four friction pins 31 arranged concentrically below respective spacer pins 69, a hub 33 for slidably holding the friction pins 31 in an interference fit state, and spacers 34 and 35 arranged on and under the hub 33. The friction pin 31, the hub 33, and the upper and lower spacers 34 and 35 are the same as those of the friction die cushion 15 shown in FIG. 1 and FIG. 2B except that the number of the friction pins 31 and friction holes 36 is four, respectively.

[0072] The friction die cushion 64 is also the same as the friction die cushion 15 shown in FIG. 2B in that the upper portion 31a and the lower portion 31b of the friction pin 31 are small in diameter and frictional resistance is caused by sliding friction between the outer peripheral surface of the intermediate portion 31c and the inner surface of the friction hole 36 of the hub 33. In the bolster 13, through-holes 26 are formed at four positions in the front, rear, left, and right of the center, and cushion pins 27 are accommodated in respective through-holes 26 in an upwardly and downwardly movable manner. In consideration of general versatility of the positions of the cushion pins 27, in some cases, a large number of through-holes 26 are formed in the bolster 13 in a grid pattern or a large rectangular opening is formed in place of through-holes.

[0073] FIG. 5A shows the operating state of the blanking die 75, which is almost the same as that shown in FIG. 1, especially at the time of starting blanking of a workpiece W. In this state, the workpiece W is clamped between the blank holder 47 and the upper surface of the die 29, and the lower end of the punch 46 is somewhat biting into the upper surface of the workpiece W. Similarly, the upper peripheral edge of the punching hole 28 of the die 29 is biting into the lower surface of the workpiece W. The clearance between the punching hole 28 and the punch 46 is as narrow as about 0.01 mm to about 0.03 mm. When the punch 46 is further lowered from this state, the workpiece W is sheared substantially at a right angle with respect to the workpiece W at a position between a portion corresponding to the lower surface periphery of the punch 46 and a portion corresponding to the peripheral edge of the die punching hole 28. For this reason, fine shearing (fine blanking) causing less shear droop and burr is performed (see FIG. 5B).

[0074] A die cushion device 76 shown in FIG. 6A is equipped with a friction die cushion 77 and a reversing mechanism 78 or turn-over mechanism which reverses the entire friction die cushion 77 every time processing is performed. The friction die cushion 77 is composed of a housing 79, a cylindrical hub 80 arranged in the housing 79 so as to extend in the left-right direction and rotatably supported about its own axis, and a friction pin 82 slidably fitted in a friction hole 81 formed in the hub 80 in the diameter direction in an interference fit state. In order to avoid interference with the portion of the friction pin 82 protruding from the hub 80, the housing 79 is provided with a cylindrical or semicircular or fan-shaped space 83 (see FIG. 7A and FIG. 7B). The materials of the hub 80 and the friction pin 82 and the dimensional relationship between the friction hole 81 and the friction pin 82 are the same as those of the friction die cushion 15 in FIG. 2A.

[0075] At the center of the hub 80, a passage and an oil pocket 84 for circulating lubricating oil serving as a cooling medium or refrigerant is formed. The oil pocket 84 opens at both ends of the hub 80 and both the ends are closed with caps 85. The oil pocket 84 is further connected to a supply pipe line 41a and a return line 40a of an oil feeding system of lubricating oil via rotary joints 86 attached to the caps 85. One end (right side in FIG. 6A) of the hub 80 is protruded largely from the housing 79, and the reversing mechanism 78 is provided around the hub 80. In this embodiment, a gear or pinion 87 is fixed around the hub 80, so that the hub 80 is reciprocally and rotatably driven by a motor and a reduction gear (not illustrated). The hub 80 may be rotated by one half revolution in the same direction. The hub 80 may be reciprocally and rotatably driven by a rack in which an air cylinder or a slide drive mechanism of a press machine is used as a driving source.

[0076] The die cushion device 76 shown in FIG. 6A can be used for a drawing die which is similar to the die of the embodiment shown in FIG. 4A. A lower die 65 is placed on the housing 79, and an upper die 70 is attached to a slide of the press machine. A hole 74 extending upward from the space 83 is formed in the housing 79. The lower die 65 includes a base 66, a punch 67, and a cushion ring 68, and the cushion ring 68 is supported by four cushion pins 68a. The cushion pin 68a is constantly urged upward by a lift spring 68b (see FIG. 7A). The cushion pin 68a is accommodated in a hole 66a formed in the base 66 of the lower die 65 so as to freely move up and down. These holes 66a are formed at portions corresponding to the holes 74 of the housing 79, and are normally arranged equally in the circumferential direction. The upper die 70 is similar to the upper die shown in FIG. 5A and is equipped with a die 71.

[0077] As shown in FIG. 6B, two hubs 80 are provided in front and rear so as to extend in the left-right direction in parallel with each other. The friction pins 82 supported by respective hubs 80 and the aforementioned cushion pins 68a are concentrically arranged up and down. Both ends of the friction pin 82 are each formed in a substantially convex spherical shape, and the lower end of the cushion pin 68a is formed into a substantially concave spherical surface corresponding to the spherical surface. With this, the relief of the cushion pin 68a can be minimized, and the position of the cushion pin 68a can be stabilized.

[0078] In the die cushion device 76 configured as described above, the friction pin 82 is driven by the die (see the reference numeral 71 in FIG. 6A) via a workpiece and the cushion pin 68a in a state in which its upper end is protruded from the hub 80 (see S1 in FIG. 8, upper left) and therefore displaced downward (S2 in FIG. 8, see the upper right). With this, the lower end of the friction pin 82 is protruded downward from the lower surface of the hub 80. Next, after the slide of the press machine is raised and therefore the die 71 is raised (S3), the hub 80 is rotated by 180 degrees (S4 and S5). With this, the friction pin 82 returns to the state in which the end portion of the friction pin 82 is protruded from the upper surface of the hub 80. As a result, it becomes possible to process a workpiece again while receiving a cushion force with the die 71.

[0079] When reversing from this state, the hubs 80 may be rotated in the same direction or may be rotated in opposite directions. By rotating the hubs 80 in opposite directions so that the protruded end portion of the friction pin 82 turns outside area of the space 83, it becomes possible to narrow the core-to-core distance of the hubs 80. As the driving source of the hub 80, other than the aforementioned motor, a gas/liquid cylinder, or a vertical movement of a slide, or a rotation of a crankshaft, etc., may be used. In the gap between the friction pin 82 and the hub 80, lubricating oil is supplied from the oil pocket 84 provided at the center of the hub 80. The lubricating oil is supplied to the oil pocket 84 from the supply pipe line 41a and flows out of the return line 40a. The supply pipe line 41a is filled with low temperature lubricating oil, and therefore lubrication and cooling can be performed simultaneously by the lubricating oil.

[0080] In the embodiments shown in FIG. 1 to FIG. 5, in preparation for the next processing, the friction pin is returned to its original position using the urging force of the air cushion device (FIG. 1 and FIG. 4A) or the knockout mechanism (FIG. 3). In contrast, in the die cushion device 76 shown in FIG. 6A, by reversing the entire friction die cushion 77, the friction pin 82 can be returned to its original state without changing the relative positional relationship between the friction pin 82 and the hub 80. Therefore, the energy efficiency is high. In FIG. 6A, a die cushion device using a friction die cushion used for a drawing die is described, but the die cushion device can also be used for a fine cutting die similar to that shown in FIG. 1. In that case, it is enough to use one cushion pin.

[0081] A die cushion device 90 shown in FIG. 9A is a so-called relief type die cushioning device equipped with a cylinder 91 arranged below the press machine 11, a piston 92 accommodated in the cylinder 91 in an upwardly and downwardly movable manner, a communication path 93 for applying pressure to the hydraulic oil in the cylinder 91 and guiding the hydraulic oil to the outside when the piston 92 is lowered, and a hydraulic circuit 94 for exerting a cushion force by applying back pressure to the hydraulic oil to be discharged to the outside. The communication path 93 includes an annular space 93a formed on the lower outer periphery of the cylinder 91, a plurality of communication holes 93b communicating the inside of the cylinder 91 and the annular space 93a, and a communication passage 93c formed in the frame 18 or bolster 13 of the press machine 11. The hydraulic circuit 94 is provided with an oil pump OP for supplying hydraulic oil to the cylinder 91 and a relief valve LV for releasing the hydraulic oil when the inner pressure of the cylinder 91 exceeds a predetermined value.

[0082] The die cushion device 90 further includes a frictional force cushion area 95 formed on the inner surface of the cylinder 91 circularly in a band shape in a manner as to slidably fit on the outer surface of the lower end of the piston 92 and its vicinity in an interference fit state. The frictional force cushion area 95 is smaller in inner diameter than the other area by the tightening margin. The frictional force cushion area 95 and the piston 92 serves as a friction die cushion which exerts a cushion force only at a specific position near the bottom dead center of the press machine.

[0083] In this relief type die cushion device 90, when a counter and a cushion ring are pressed downward by an upper die to process a workpiece, the hydraulic oil in the cylinder 91 is led to the hydraulic circuit 94 side via the communication path 93 (see FIG. 9B). At that time, the pipeline resistance of the hydraulic oil passing through the communication path 93 and the resistance generated when the hydraulic oil passes through the relief valve LV become the cushion force. The hydraulic cushion force can be preset by the relief valve LV of the hydraulic circuit 94. Before the piston 92 reaches the frictional force cushion area 95, the cushion function is performed only by the aforementioned hydraulic pressure force. When the piston 92 reaches the frictional force cushion area 95, the cushion function caused by the combination of the hydraulic cushion force and the frictional force combined is exerted.

[0084] When the slide is raised (see the dot-dash line in FIG. 10), the hydraulic oil is supplied from the hydraulic circuit 94 into the cylinder 91 to raise the piston 92. At this time, the frictional force becomes resistance to hinder the piston 92 from rising up. However, once the piston 92 passes the frictional force cushion area 95, unnecessary frictional resistance disappears.

[0085] By the way, in the relief type die cushion device 90, as the flow velocity increases, the viscous resistance increases and as the flow velocity increases, the viscous resistance decreases. Therefore, the cushion ability has a speed dependence. For this reason, as shown by the solid line and the dot-dash line in FIG. 10, there is a pressure override characteristic in which the cushion ability decreases near at the bottom dead center where the stroke speed decreases. Further, although the override characteristic is reduced if the flow passage area of the relief valve is reduced with a servo valve or the like, a phenomenon occurs in which the product is pushed back by the cushion residual pressure after passing the bottom dead center.

[0086] In the die cushion device 90 of FIG. 9A and FIG. 9B, in order to cope with these phenomena, the friction die cushion is also used for a hydraulic cylinder device including the cylinder 91 and the piston 92. Therefore, the decrease in cushion force due to the override characteristic near at the bottom dead center can be compensated, and the stable cushion ability can be maintained to the bottom dead center (see the broken line in FIG. 10).

[0087] In the aforementioned embodiments, all of the frictional force generating mechanisms are used for a die cushion of a press machine. However, the frictional force generating mechanism of the present invention is not limited thereto but can be applied to various devices, such as, e.g., a friction damper which attenuates vibrations by sliding frictional resistance, a knockout overload prevention device, and a press overload protector device. In the aforementioned embodiments, a case in which the hub is cooled by lubricating oil or cooling oil is described, but the hub can be cooled with other cooling medium or refrigerant, such as, e.g., water and air.

[0088] [Test 1: Interference Fit Sliding: Element Test]

[0089] Next, the element test of the interference fit sliding performed to verify the practicality and effect of the sliding frictional force generation mechanism of the present invention will be described. The friction pin (shaft member) 96 of Example 1 used for this test had the general shape shown in FIG. 11A and FIG. 11B. Specifically, the friction pin 96 had the shape and dimensions shown in FIG. 11C. The unit of the numeral is mm (millimeter). The mark (o+/) in the figure denotes a diameter. The material of the friction pin 96 was S45C (JIS), and was set to Hs 353 by refining of quenching and tempering. On the other hand, the material of the hub 97 was a S45C raw material (basically no heat treatment was subjected). The inner diameter D1 of the hub (hole member) 97 was slightly smaller (by about 0.03 mm) than the outer diameter D1 of the friction pin 96. The outer diameter D2 of the hub was 64 mm and the height L was 51 mm. No oil groove was formed in the hub 97.

[0090] The friction pin 96 was immersed in liquid nitrogen to be cooled and inserted into the hole 97a of the hub 97 after the boiling of the liquid nitrogen is ceased. Thereafter, the friction pin 96 was returned to normal temperature to make an interference fit state. Next, the friction pin 96 was pressed in the axial direction by a press machine and pulled out of the hub 97, and the state of the surface was observed. Five samples were prepared, and the aforementioned interference fit and pulling-out were repeated six times respectively. In the first test, a friction pin 96 to which the oil groove shown in FIG. 11A was not formed was used. In the second and subsequent tests, as shown in FIG. 11B, a friction pin 98 to which an oil groove 98a was formed was used.

[0091] As shown in FIG. 11D, the oil groove 98a had an arc shape with a width of 0.21 mm and a depth of 0.03 mm. As shown in FIG. 11C, the oil groove 98a was spirally formed at intervals of 1.2 mm (Lead) in the axial direction. A plurality of annular oil grooves may be arranged and connected by an oil groove extending in a direction parallel to the axis. In either case, the cylindrical surface between the oil grooves 98a served as a sliding surface 98b.

[0092] The number of test samples was five, Sample No. 1 to No. 5. Among them, in Sample No. 1, No. 3, and No. 5, friction pins 96 and 98 were cooled to about 180 C. with liquid nitrogen and then inserted into a hub 97 to thereby perform a cold-fit. In Sample No. 2 and No. 4, a shrink fit method in which a hub 97 was heated to 150 C. and then inserted into a friction pin 96 of normal temperature was inserted was adopted.

[0093] In the test, six cold-fit/extraction (pulling-out) tests were conducted and the surface roughness Ra before and after the test was measured. Furthermore, an applied load at each cold-fit/extraction was measured. The surface roughness Ra of each of the friction pins 96 and 98 and the hub 97 before and after the test is shown in Table 1. In Table 1, the static friction coefficients obtained by inversely calculating the generating surface pressure from the applied load and tightening margin at the time of the first to sixth pulling-out are also shown. As a surface roughness measuring instrument, a roughness measuring instrument Surftest SJ-301 manufactured by Mitsutoyo Corporation was used. The unit of the surface roughness Ra is m.

TABLE-US-00001 TABLE 1 Sample No. 1 2 3 4 5 Pin: Initial surface roughness Ra 0.12 * 0.13 ** 0.19 (measured value) Hub: Initial surface roughness Ra 0.18 0.21 0.20 (measured value) 1.sup.st time ( inverse calculation value) 0.217 0.175 0.25 2.sup.nd time ( inverse calculation value) 0.304 0.223 0.467 3.sup.rd time ( inverse calculation value) 0.321 0.336 0.342 4.sup.th time ( inverse calculation value) 0.246 *** 0.253 5.sup.th time ( inverse calculation value) 0.21 0.23 6.sup.th time ( inverse calculation value) 0.17 0.21 Pin: Surface roughness Ra after the test 0.11 0.18 (measured value) Hub: Surface roughness Ra after the test 0.15 0.18 (measured value)

[0094] As can be seen from Table 1, In Sample No. 1: Surface roughness Ra (pin: 0.12 m, hub: 018 m) and Sample No. 5: Surface roughness Ra (pin: 0.19 m, hub: 0.20 m), the friction coefficient decreases as the number of tests increases, and after the 6.sup.th tests, the surface roughness was lower than that before the test. That is, the surface was smoothed by the sliding test.

[0095] On the other hand, in Sample No. 3 in which the surface roughness Ra of the friction pins 96, 98 was 0.13 m and the surface roughness Ra of the hole 97a of the hub 97 was 0.21 m, as the number of sliding increases, the friction coefficient increased and galling occurred at the friction pin 98 during the 4.sup.th sliding test, so the test was terminated (***). Although the reason is not clear, when the surface roughness is large, there is a portion that partially and strongly hits, and therefore there is a possibility that the lubricating oil was not supplied sufficiently. In Sample No. 2 (*) and Sample No 4 (**) in which a shrink fit was performed, seizure occurred immediately after the start of the test, so it was substantially impossible to conduct a test. In the case of a shrink fit, there is a possibility that a uniform interference fit could not be made or the lubrication film on the surface was destroyed.

[0096] [Test 2: Diameter Measurement, Surface Roughness Measurement]

[0097] Next, a friction pin 99 and a hub 100 of Example 2 shown in FIG. 12 and FIG. 13 were prepared, and the surface roughness and the outer diameter at the time of preparation and after the test were measured. The outer diameter of the sliding portion of the friction pin 99 was about 35.035 mm and the length was 64 mm. On the sliding portion, an oil groove 99a of a semicircular cross-section having a radius of 0.4 mm shown in FIG. 14C was spirally formed. The portion between the adjacent grooves 99a was served as a sliding surface 99b. In the region near the oil groove 99a of the sliding surface 99b, a loose tapered flank face 99c was formed.

[0098] The surface hardness of the inner surface of hole 100a of the hub 100 is lower than the surface hardness of the friction pin 99. Specifically, the friction pin 99 has an outer diameter of 35.035 (see Table 2, the material is DC53 (die steel manufactured by Daido Steel Co., Ltd., equivalent to SKD11 (JIS)). The surface hardness HRC (Rockwell hardness C scale) was set to 602 by quenching and high temperature tempering. Further, a low temperature TIC treatment (titanium carbide film treatment) was carried out.

[0099] In the hub 100, the inner diameter of the hole 100a was about 34.998 mm, the material was SKD61, and the hardness HRC was set to 472 by quenching and high temperature tempering. Further, a radical nitriding treatment was performed. The hole 100a of the hub 100 had the shape and dimensions shown in FIG. 13A and FIG. 13B. No oil groove was formed.

[0100] The measured values of the surface roughness and the outer diameter at the time of creating a friction pin are shown in Table 2. The measurement positions of the surface roughness were set at the positions A and B in the circumferential direction of FIG. 12A and in the positions I, II, and III in the axial direction of FIG. 12B, i.e., 6 positions in total. As the measuring instrument, a surface roughness measuring instrument Surftest SJ-301 manufactured by Mitsutoyo Corporation was used. The measurement points of the outer diameter were set to the positions I, II, and III in the axial direction of FIG. 13B between A-C and between B-D in FIG. 13A, which is 6 in total. As the measuring instrument, a micro gauge manufactured by Mitsutoyo Corporation, and the unit was m.

TABLE-US-00002 TABLE 2 Pin: Initial State Surface Roughness Ra (m) Outer Diameter (mm) A B A-C B-D I 0.08 0.08 35.033 35.033 II 0.09 0.08 35.034 35.034 III 0.09 0.10 35.033 35.033

[0101] The measurement results of the surface roughness of the inner surface of the hole 100a at the time of creating the hub 100 are shown on the left side of Table 3. The measurement positions were set at the positions A and B in the circumferential direction of FIG. 13A and in the positions I, II, and III in the axial direction of FIG. 13B, i.e., 6 positions in total. Also, the measured results of the inner diameter at the time of creating the hub 100 are shown on the right side in Table 3. The measurement positions were set at the positions A-C and B-D in the circumferential direction and the positions I, II, and III in the axial direction, i.e., 6 positions in total. The inner surface of the hole 100a was rough as shown by the photomicrograph in FIG. 15A.

TABLE-US-00003 TABLE 3 Hub: Initial State Surface Roughness Ra (m) Inner Diameter (mm) A B A-C B-D I 0.04 0.03 34.998 34.999 II 0.03 0.03 34.998 34.998 III 0.04 0.04 34.997 34.998

[0102] The aforementioned friction pin 99 was immersed in liquid nitrogen to be cooled at 180 C. and then inserted into the hole 100a of the hub 100 to return to normal temperature. Thus, a cold-fit was performed. Thereafter, while supplying lubricating oil, the friction pin 99 was reciprocally slid by applying an axial pressing force and a pulling-out force. The temperature of the lubricating oil was maintained at 20 C. and lubricated at a flow rate of 100 cc/min and a pressure of 0.5 MPa. Galling and seizure did not occur even when the number of sliding exceeded 600,000 times. The sliding frictional resistance at this dimension was 62 kN to 64 kN and the average was 63 kN, and it was found that the variation was small.

[0103] After the test, the friction pin 99 was removed from the hub 100 and the surface roughness and the fit diameter of the surface of the friction pin 99 and the inner surface of the hole 100a of the hub were measured. The measurement results are shown in Tables 4 and 5.

TABLE-US-00004 TABLE 4 Pin: After 600,000 Times Sliding Test Surface Roughness Ra (m) Outer Diameter (mm) A B A-C B-D I 0.08 0.08 35.033 35.033 II 0.09 0.08 35.034 35.033 III 0.09 0.10 35.033 35.034

TABLE-US-00005 TABLE 5 Hub: After 600,000 times Sliding Test Surface Roughness Ra (m) Inner Diameter (mm) A B A-C B-D I 0.03 0.03 34.999 34.999 II 0.03 0.03 34.998 34.998 III 0.04 0.04 34.998 34.998

[0104] As can be seen by comparing Table 2 with Table 4 and by comparing Table 3 with Table 5, the surface roughness and the sliding portion diameter of the friction pin 99 and the hub 100 both before and after the sliding test of 600,000 times were almost unchanged. That is, the surface roughness Ra of the friction pin 99 before and after the test had no change except for the increase of 0.01 m at the measurement points B and III, and it can be judged that substantially no abrasion occurred. In addition, there was no change except that the outer diameter was decreased by 0.001 mm between B and D at II and increased by 0.001 mm between B and D at III, and therefore it can be judged that substantially no abrasion occurred.

[0105] In the case of the hub 100, there was no change except that the surface roughness Ra was decreased by 0.01 m at the measurement points A and I and the inner diameter was increased by 0.001 mm at the positions I and III between A and C respectively. This indicates that durability is sufficiently high and practical when the initial surface roughness and the sliding portion diameter finishing accuracy is sufficiently high even if sliding is repeated with a high surface pressure.

[0106] [Observation of Pin Surface Condition]

[0107] FIG. 14A and FIG. 14B show photomicrographs of the sliding surface 99b and the flank face 99c of the friction pin 99 of Example 2 after 600,000 times sliding tests, respectively. The magnification was 3,000 times. Similarly, photomicrographs of the initial and after 600,000 (six hundred thousand) times sliding tests of the hub 100 of Example 2 are shown in FIG. 15A and FIG. 15B, respectively. The magnification was 5,000 times. As can be seen from these photomicrographs, the friction pin 99 and the hub 100 had no galling on the surface after 600,000 sliding tests.

[0108] As can be seen by comparing FIG. 14A with FIG. 14B, the sliding surface 99b of the friction pin 99 was decreased in roughness and irregularities as compared with the flank face 99c. Similarly, as can be seen by comparing FIG. 15A with FIG. 15B, it is understood that the surface state (surface roughness) after the sliding test of the hub 100 was equal to or higher than the initial state (smoothing by sliding). It is thought that the surface was made smooth by lapping processing by repeating sliding under sufficient lubrication.

[0109] It should be understood that the terms and expressions used herein are used for explanation and have no intention to be used to construe in a limited manner, do not eliminate any equivalents of features shown and mentioned herein, and allow various modifications falling within the claimed scope of the present invention.

[0110] While the present invention may be embodied in many different forms, a number of illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein.

DESCRIPTION OF REFERENCE SYMBOLS

[0111] 10 die cushion device [0112] 11 press machine [0113] 12 air cushion device [0114] 13 bolster [0115] 14 lower die [0116] 15 friction die cushion [0117] 16 lubricating oil supply system [0118] 18 frame [0119] 19 slide [0120] 20 bellows [0121] 21 base plate [0122] 22 bolt [0123] 23 pipe [0124] 24 cushion pad [0125] 26 through-hole (of bolster) [0126] 27 cushion pin [0127] 28 punching hole [0128] 29 die [0129] 30 counter [0130] 31 friction pin [0131] 31a upper portion [0132] 31b lower portion [0133] 31c intermediate portion [0134] 32 holder [0135] 33 hub [0136] 34, 35 spacer [0137] 34a, 35a guide hole (of the spacer) [0138] 34b, 35b enlarged diameter portion [0139] 36 friction hole [0140] 37 oil groove [0141] 38 oil pocket [0142] 39 O-ring [0143] 40, 41 passage [0144] 41a supply pipe line [0145] 40a return line [0146] OT oil tank [0147] SF suction filter [0148] OP oil pump [0149] OC oil cooler [0150] 45 upper die [0151] W workpiece [0152] 46 punch [0153] 47 blank holder [0154] 48 spring [0155] 49 die holder [0156] F1 urging force of the air cushion device [0157] F2 frictional resistance of the friction die cushion [0158] 50 shear droop [0159] 51 burrs [0160] 52 shear plane [0161] 55 die cushion device [0162] 56 friction die cushion [0163] 57 knockout mechanism [0164] 58 die [0165] 58a guide hole (of a die) [0166] 59 cam [0167] 60 cam follower [0168] 61 knockout pin [0169] 63 die cushion device [0170] 64 friction die cushion [0171] 65 lower die [0172] 66 base [0173] 66a hole (of a base) [0174] 67 punch [0175] 68 cushion ring [0176] 68a cushion pin [0177] 69 spacer pin [0178] 70 upper die [0179] 71 die [0180] 72 die plate [0181] 73 annular groove [0182] 74 hole (of a housing) [0183] 75 blanking die [0184] 76 die cushion device [0185] 77 friction die cushion [0186] 78 reversing mechanism (turn-over mechanism) [0187] 79 housing [0188] 80 hub [0189] 81 friction hole [0190] 82 friction pin [0191] 83 space [0192] 84 oil pocket [0193] 85 cap [0194] 86 rotary joint [0195] 87 pinion [0196] 68a cushion pin [0197] 68b lift spring [0198] 90 die cushion device [0199] 91 cylinder [0200] 92 piston [0201] 93 communication path [0202] 93a annular space [0203] 93b communication hole [0204] 93c communication passage [0205] 94 hydraulic circuit [0206] 95 frictional force cushion area [0207] 96 friction pin (Example 1) [0208] 97 hub [0209] 97a hole [0210] 98 friction pin (after oil groove processing) [0211] 98a oil groove [0212] 98b sliding surface [0213] 99 friction pin (Example 2) [0214] 99a oil groove [0215] 99b sliding surface [0216] 99c flank face [0217] 100 hub [0218] 100a hole [0219] A, B, C, D circumferential position [0220] I, II, III axial position