G
穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊V]XXG
氦壟昷笛汊 決殯穢 渗击笛 抆禎 洢浶击洛 儢愢
G
劒殯單#· 卆旇殶1 · 卆戏渆2· 愛汆朞2· 焮埲渆2 G
Development of Flow Forming Process for Hollow Shaped Parts from Seamless Steel Tube
G
Y. N. Kwon, S. W. Kim, B. J Kim, E. S. Park, D. J. Cha
(Received October 17, 2011 / Revised November 2, 2011 / Accepted November 8, 2011)G G
Abstract
Flow forming is an incremental forming process in which rollers are used to form cylindrical parts with repeated turning of both roller and starting material. Both sheet and tube can be used as the starting material. The process is highly useful for producing hollow shaped parts from a tube, with the benefit of the average strain in the final shape being significantly lower than that from a sheet material. In the present study, the flow forming process was studied and optimized for producing a hollow shaped part from seamless steel tube by both experiment and numerical analysis. Upon considering the difficulty of forming seamless steel sheet, the thickness reduction was distributed over several tool paths. In the end, an optimum process condition was attained, and the experiment verified the simulation results.
Key Words : Flow Forming, Finite Element Method, Roll Path Design
G
41# ⇆# ᤊG G
㥶☯㎇䡫(flow forming)㦖 䣢㩚䞮⓪ ㎇䡫 ⪺⩂
(roller)㦮 㤊☯ 㩲㠊⯒ 㧊㣿䞮㡂 䕦㨂㏢㨂⯒ 㩦㰚 㩗㦒⪲ ㎇䡫䞮⓪ ₆㑶㧊┺[1~3]. 㥶☯㎇䡫₆㑶㦚 䐋䟊 ⽋㧷䞲 䡫㌗㦚 㢚㩲䛞 䂮㑮㠦 㾲╖䞲 Ṗ₳
Ợ ῂ䡚䞶 㑮 㧞㦒Ⳇ ⁎ ὒ㩫㠦 䡫㎇♲ ㏢㨂ἆ (metal flow) 㩲㠊 ṖὋ ἓ䢪⯒ 㧊㣿䞮㡂 ₆Ἒ㩗 䔏㎇(㩫㩗 ṫ☚, 䞒⪲ ṫ☚, 䚲Ⳋ ἓ䢪) 䟻㌗㦚 ╂
㎇䞶 㑮 㧞⓪ 㧻㩦㦚 Ṗ㰚┺. 㥶☯㎇䡫Ὃ㩫㦖 㿫
╖䃃 㤦䡫㩲䛞㦮 ┺䛞㫛 㭧࡞㏢⨟㌳㌆㠦 䌗㤪䞲 ἓ㨗⩻㦚 Ṗ㰖ἶ 㧞┺. 㥶☯㎇䡫Ὃ㩫㦖 ₆㫊㦮 㿫
╖䃃 㤦䡫㩲䛞㦚 ╖⨟㌳㌆䞶 ➢ ㌂㣿♮⓪ 㓺䍂䞧 (stamping) Ὃ㩫 䢏㦖 ❻✲⪲㧟(deep drawing) Ὃ㩫
㠦 ゚䟊 ṖὋ 㡃䞯㩗㦒⪲ 㤆㑮㎇㦚 Ṗ㰖ἶ 㧞┺.
㯟 , 㓺 䍂 䞧 ❻ ✲ ⪲ 㧟 Ὃ 㩫 㦖 㭒 ⪲ 㑮 㰗 ⩻ (normal force)㦚 㧊㣿䞮㡂 ㏢㨂⯒ ⼖䡫㔲䋺㰖Ⱒ 㥶
☯㎇䡫Ὃ㩫㦖 㩚┾⩻(shear force)㦚 㭒⪲ 㧊㣿䞲┺.
㏢㎇⼖䡫㧊 ⁒⽎㩗㦒⪲ 䘎㹾㦧⩻㠦 㦮䟊 㥶♮
⸖⪲ 㑮㰗㦧⩻㦮 䘎㹾 ㎇ ⽊┺⓪ 㦧⩻Ṩ ⁎ 㧦 㼊Ṗ 䘎㹾㦧⩻㧎 㩚┾㦧⩻㧊 䤾㞂 䣾ὒ㩗㦒⪲ ㏢
㎇⼖䡫㦚 㥶䞶 㑮 㧞┺. ➆⧒㍲, 㥶☯㎇䡫㎇䡫 㧻䂮⓪ ṖὋ⩻㧊 ㌗╖㩗㦒⪲ 㧧㞚☚ ♮₆ ➢ⶎ㠦
㍺゚ 䒂㧦゚ ₆䌖 㰗Ṛ㩧 ゚㣿㦚 ╖䙃 㭚㧒 㑮 㧞 ┺ . 㥶 ☯ ㎇ 䡫 ₆ 㑶 㦖 ⁒ ⽎ 㩗 㦒 ⪲ 㓺 䞒 ┳ (spinning) Ὃ㩫ὒ 㥶㌂䞲 䣢㩚 㩦㰚 ㎇䡫 ₆㑶㧊 㰖Ⱒ, 㓺䞒┳㦖 䒂㧛㏢㨂㦮 ⚦℮⽊┺ 㟝㦖 䡫㌗㦚 ῂ䡚䞮⓪ ₆㑶㧎◆ ゚䟊 㥶☯㎇䡫₆㑶⪲⓪ 䒂㧛
XUG 䞲ῃ₆Ἒ㡆ῂ㤦G ㍺G 㨂⬢㡆ῂ㏢G 㦋䞿Ὃ㩫㡆ῂ⽎G ٻ
YUG ἓ㺓㌆㠛ൽG
JG ᾦ㔶㩖㧦aG 䞲ῃ₆Ἒ㡆ῂ㤦G ㍺G 㨂⬢㡆ῂ㏢G 㦋䞿Ὃ㩫㡆ῂ⽎SG lTaG X^[WgUUG
]
]XYGV穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊G
⊳┾㠦㍲ ⌊ 㰗ἓὒ ☯㧒䞲 㰗ἓ㦚 Ṗ㰖⓪ 䓲 ぢ ㏢㨂⯒ 㧊㣿䞮㡂 㭧㞯㥚⯒ 㿫ὖ ㎇䡫䞲 䤚 䓲ぢ㦮 㟧⊳ 㠦㍲ 㧎㧻 ㎇䡫䞮⓪ 㔳㦒⪲
㭧Ὃ 䡫㌗㦚 䣾ὒ㩗㦒⪲ ㎇䡫䞮⓪ 㞞㦚 Ṳ䞮 ἶ㧦 䞮㡖┺. 㧊⯒ 㥚䞮㡂 㥶䞲㣪㏢䟊㍳㦚 䐋䞮㡂
₆㽞㍺Ἒ⯒ 㑮䟟䞮㡖㦒Ⳇ 㩲 㥶☯㎇䡫 㔺䠮㦚 䐋 䞮㡂 䟊㍳ἆὒ⯒ Ỗ㯳䞮⓪ 㡆ῂ⯒ 㑮䟟䞮㡖┺.
51# ⎎㚂᳓ᴿ# # ٻ
⽎ 㡆ῂ㠦㍲ ╖㌗㦒⪲ ㌒㦖 㭧Ὃ䛞㦖 Fig. 1 㠦 ⋮䌖⋲ ộὒ ṯ㦖 䡫㌗㦚 Ṗ㰖⓪ 㧦☯⼖㏣₆ 㣿 annulus gear 䛞㦒⪲ ⁎Ⱂ㠦㍲ ⽊㧊⓪ ⏨㧊 䟻㦒⪲ ㌗㧊䞲 㰗ἓὒ ⚦℮ 䙂⯒ Ṗ㰖⓪ 䛞 㧊┺. Fig. 2 㠦 ⋮䌖⌎ ộὒ ṯ㧊 ₆㫊㠦⓪ 㡊Ṛ┾
㫆⻫㦚 䐋䞮㡂 㩲㫆♮㠞₆ ➢ⶎ㠦 㤦㏢㨂 ₆㭖㦒
⪲ ㏢㨂㧊㣿㥾㧊 ⰺ㤆 ⌄㦖 㑮㭖㦒⪲ 㡊Ṛ┾㫆 㧊䤚㠦☚ ┺⨟㦮 ₆ἚṖὋ㧊 䞚㣪䞮㡖┺. ⡦䞲, 㡊Ṛ┾㫆㩲䛞㦖 ₆Ἒ㩗 䔏㎇㦚 䟻㌗㔲䌂 㑮 㧞⓪
㞞㧊 㠜⓪ Ⳋ㠦 㥶☯㎇䡫㩲䛞㦖 ㏢㎇⼖䡫㠦
ٻ ٻ ٻ ٻ ٻ
Fig. 1 Annulus gear sample having hollow geometry ٻ
㦮䞲 metal flowṖ 䡫㎇㧊 ♮㠊 㿪Ṗ㩗㧎 ₆Ἒ㩗 ⶒ㎇㦮 䟻㌗㦚 㠑㦚 㑮 㧞㦚 ộ㦒⪲ ₆╖♲┺.ٻ
Fig. 3㦖 Fig. 1㦮 Ṳ╖㌗ 㭧Ὃ䛞㦚 㥶☯㎇䡫 䞮₆ 㥚䞲 㞞㦒⪲ 㭧㕂㠦 㧧㦖 㰗ἓ㦮 ⰾ✲
⩦⪲ ㏢㨂⯒ ⹖㠊㧊ἶ ㌗䞮⪲ ⪺⩂⯒ 㧊㏷䞮㡂
㎇䡫㦚 䞮⓪ Ὃ⻫㧊┺ Fig. 2㦮 Ὃ㩫㦚 㥚䞮㡂 㤦
㏢㨂⓪ 䓲ぢ㏢㨂⯒ ㌂㣿䞮㡖┺. 㤦㏢㨂⓪ 550MPa 㦮 㧎㧻ṫ☚⯒ Ṗ㰖⓪ seamless 䓲ぢ⯒ ㌂㣿䞮 㡖┺. 㤦㏢㨂 䓲ぢ㦮 ⹎㎎㫆㰗 㧎㧻䔏㎇㦚 Fig.
4㢖 Table 1㠦 㩫Ⰲ䞮㡖┺. 㤦㏢㨂 㫆㰗㦖 䗮⧒㧊 䔎㢖 䗚⧒㧊䔎Ṗ 䢒䞿♲ 㧒ṫ㦒⪲ ㏢㎇ṖὋ
䟻㦒⪲ 㡆㔶♲ ἆ㩫Ⱃ ⺆㡊㦚 ⽊㡂㭒ἶ 㧞┺.
Fig. 2 Benefit comparison of two fabrication methods for hollow geometry part
穢穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊V]XZG Fig. 3 Flow forming concept for hollow shape partٻ
Fig. 4 Microstructure of tube used in the present study
Table 1 Tensile properties of tube material YS(MPa) UTS(MPa) Elong.(%)
372.5 546.2 46.5 ٻ
61# ⟊ᒃ⇛㚿# ඟ⢿⇎൮#
⽎ 㡆ῂ㠦㍲⓪ 㧦☯㹾 ⼖㏣₆㣿 annulus gear 䛞㦮 㥶☯㎇䡫 Ὃ㩫₆㑶 Ṳ㦚 㥚䟊 Fig. 5 㠦 ⋮ 䌖⌎ ộὒ ṯ㧊 annulus gear 䛞㦮 㟧 ⊳┾㦮 ⌊
㰗ἓὒ ☯㧒䞲 ⌊㰗ἓ㦚 Ṭ⓪ 䓲ぢ㏢㨂⯒ 㧊 㣿䞮㡂 㥶☯㎇䡫㦚 䐋䟊 㭧㞯㥚⯒ 㿫ὖ ㎇䡫䞲 䤚 㟧 ⊳┾㦚 㧎㧻 ㎇䡫䞾㦒⪲㖾 2 Ṳ㦮 annulus gear 䛞㦚 㩲㫆䞲 䤚 㭧Ṛ㦚 㩞┾䞮⓪ ⻫
㦚 ἶ㞞䞮㡖┺. 㧊 㩲㫆 㞞㦖 1 䣢 ㎇䡫㦒⪲ ╖ 䃃䡫㌗㦚 ㎇䡫䞮㡂 㩞┾㦚 䐋䟊 2 Ṳ㦮 㩲䛞㦚 㩲 㫆䞶 㑮 㧞⓪ ⻫㦒⪲ 㩲㫆Ὃ㩫 㔲Ṛ㦚 ┾㿫㔲 䌂 㑮 㧞⓪ 䣾ὒ㩗㧎 ⻫㦒⪲ 䕦┾♲┺.
㡞゚㔺䠮㦖 ㏢㨂⯒ ⌟Ṛ㌗䌲㠦㍲ 㑮䟟䞮㡖㦒Ⳇ 1 㹾 ㎇䡫㔲 㥶☯㎇䡫㧻゚㦮 㾲╖ Ṗ 㞫⩻㧎 200bar 㦮 㞫⩻㦚 Ṗ䞮㡂☚ 㿫ὖ㧊 㧊⬾㠊 㰖㰖 㞠㞮┺. ㏢㨂㦮 ⚦℮ ṫ☚㠦 ゚䟊 㧻゚㦮 䠞㣿 㞫⩻㧊 ⌄㦢㠦 ₆㧎䞲 ộ㦒⪲ 䕦┾♲┺. 㧊㠦 ➆
⧒ ㏢㨂⯒ ἶ㡾㦒⪲ Ṗ㡊䞮㡂 ㎇䡫㎇㦚 䟻㌗㔲䋾
Fig. 5 Flow forming process design for annulus gear ٻ
Fig. 6 Roll path design for annulus gear forming
䤚 㥶☯㎇䡫 Ὃ㩫㦚 㩗㣿䞮⓪ Ὃ㩫㞞㦚 Ỗ䏶䞮㡖
┺. 㧊㌗㦮 ⻫㠦 ╖䞲 㥶䞲㣪㏢䟊㍳㦚 䐋䟊 㩗 㣿 Ṗ⓻㎇㦚 Ỗ䏶䞮ἶ, 㧊⯒ 䌫㦒⪲ annulus gear
䛞㦮 㔲㩲䛞㩲㧧㦚 㥚䞲 㔺䠮㦚 㑮䟟䞮㡖┺.
Fig. 5 㠦 ⋮䌖⌎ 㥶☯㎇䡫 Ὃ㩫㠦㍲ 㔺㩲 ⪺⩂
㠦 ὒ♮⓪ 䞮㭧㧊 ⌟Ṛ㌗䌲㠦㍲⓪ ⰺ㤆 ⏨㦖 ộ㦒⪲ 1 㹾㩗㦒⪲ 䢫㧎䞮㡖┺. 㧊㠦 ➆⧒ 㿫ὖ㎇
䡫 㔲 ⪺⩂㠦 ὒ♮⓪ 䞮㭧㦚 㾲㏢䢪䞮ἶ, ㏢㨂 㦮 ㎇䡫㎇㦚 䟻㌗㔲䋺₆ 㥚䟊 600ଇ㠦㍲ 㥶☯㎇
䡫 Ὃ㩫䟊㍳㦚 㰚䟟䞮㡖┺. Fig. 6 㦖 Ṳ⨋㩗㧎 Ὃ ῂ ἓ⪲⯒ ⽊㡂㭒ἶ 㧞⓪◆ 㩲䛞㦮 㿫ὖ ⌊䁷 ὒ ☯㧒䞲 䡫㌗㦮 ⪺⩂⪲ 㿫ὖ䞶 ἓ㤆, ⪺⩂㦮 䆪
⍞ 㥚㠦㍲ ὒ☚䞲 㦧⩻㰧㭧㧊 ㌳䞾㠦 ➆⧒
㏢㨂㦮 䕢┾㌳㧊 㤆⩺♲┺. ➆⧒㍲, 㧊⯒ 㰖 䞮₆ 㥚䟊 㤆㍶, ⚦℮Ṗ 㟝ἶ ἷⳊ㦒⪲ 㧊⬾㠊㰚
㎇䡫㣿 ⪺⩂ #1 㦚 㧊㣿䞮㡂 Ṳ⨋㩗㧎 䡫㌗㦒⪲
䣢㩚䞮⓪ 䓲ぢ⯒ 㿫ὖ ㎇䡫䞲 䤚, ⋶䃊⪲㤊 䆪⍞
ṗ㦚 Ṗ㰚 ⚦ ⻞㱎 ㎇䡫 ⪺⩂ #2 ⯒ 㧊㣿䞮㡂 㩲 䛞㦮 㭧㞯 㿫ὖ ⳾㍲Ⰲ㦮 ṗ☚⯒ 䡫㎇䞶 㑮 㧞
☚⪳ Ὃῂἓ⪲⯒ ㍺Ἒ䞮㡖┺. 㺎㡂₆㠛㠦㍲ ⽊㥶 䞮ἶ 㧞⓪ 㥶☯㎇䡫 ㎇䡫㧻゚⓪ ☯㔲㠦 2 Ṳ㦮 ⪺
⩂㦮 㧧☯㦚 㰖㤦䞮ἶ 㧞㦒⸖⪲, 㧊 Ὃ㩫㦖 䞲 ⻞ 㠦 㧻㹿♲ ⚦ Ṳ㦮 ⪺⩂⯒ 㑲㹾㩗㦒⪲ 㧊㏷㔲䌊 㦒⪲㖾 㡆㏣㩗㧎 ㎇䡫㧊 㧊⬾㠊 㰞 㑮 㧞┺.
┾Ἒ ㎇䡫䟊㍳ ἆὒ(⪺⩂ #1)
⪺⩂ #1 㦖 ⰾ✲Ⰺ㠦 㦮䟊 䣢㩚䞮⓪ ㏢㨂㠦 㩧 㽟䞮㡂 3 㹾㤦 䡫㌗㦚 ㎇䡫䞮⸖⪲ Fig. 6 㦮 X-Z
]
]X[GV穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊G Fig. 7 Roll path for roller #1
䘟Ⳋ ⌊㠦㍲ 2 㹾㤦 㤊☯㦚 䞮Ợ ♮Ⳇ, 㧊㠦 ╖䞲
㌗㎎䞲 ἓ⪲⓪ Fig. 7 㠦 ☚㔲䞮㡖┺. Fig. 8 㠦㍲ ☚ 㔲♲ P1~P4 ⓪ ⪺⩂ #1 㧊 䣢㩚㿫㦮 㭧㕂㦒⪲ 㧊
☯䞮Ⳋ㍲ ㏢㨂㠦 㩧㽟♮⓪ 㥚䂮⯒ ⋮䌖⌊ἶ 㧞┺.
⪺⩂ #1 㦖 ㏢㨂㦮 㫢䁷䞮┾㠦㍲ 㧊☯㦚 㔲㧧䞮㡂
㌗䞮㫢㤆㤊☯㦚 ⽋䞮Ⳋ㍲ 䓲ぢ㦮 㭧㞯⯒ Ṳ
⨋㩗㧎 䡫㌗㦒⪲ 㿫ὖ䞮Ợ ♲┺.
Fig. 8㦖 Fig. 7 㦮 Ὃῂἓ⪲ 㥚䂮⼚ ⼖䡫䡫㌗, 㥶 䣾⼖䡫⮶, 㥶䣾㦧⩻ 䙂⯒ ⽊㡂㭒ἶ 㧞┺. P1 㠦
㍲⓪ ⪺⩂ #1 㧊 䓲ぢ㏢㨂㦮 㫢䁷䞮┾㠦㍲ 㿲䞮 㡂 X 䟻㦒⪲ 㧊☯䞲 䤚 ㏢㨂㢖 㩧㽟䞮Ⳋ㍲ 㟓Ṛ 㦮 ㏢㎇⼖䡫㦚 㥶☚䞮ἶ 䓲ぢ㏢㨂㦮 㭧Ṛ㡗㡃₢
㰖 Z 䟻㦒⪲ 㧊☯䞾㦒⪲㖾 䓲ぢ㏢㨂㦮 䞮䁷 ⊳
┾㦮 ⚦℮⯒ Ṧ㏢䞮₆ 㥚䞲 Ὃ㩫㧊Ⳇ P2 ⓪ ⪺⩂
Ṗ 䓲ぢ㏢㨂㦮 㫢䁷㌗┾㠦㍲ 㿲䞮㡂 X 䟻㦒⪲
㧊☯䞲 䤚 ㏢㨂㢖 㩧㽟䞮Ⳋ㍲ 㟓Ṛ㦮 ㏢㎇⼖䡫㦚 㥶☚䞮ἶ 䓲ぢ㏢㨂㦮 㭧Ṛ㡗㡃₢㰖 Z 䟻㦒⪲
㧊☯䞾㦒⪲㖾 䓲ぢ㏢㨂㦮 ㌗䁷 ⊳┾㦮 ⚦℮⯒ Ṧ
㏢䞮₆ 㥚䞲 Ὃ㩫㧊┺. P3 ⓪ ⪺⩂Ṗ 㿫ὖ⯒ ㎇ 䡫䞮₆ 㥚䞮㡂 㿫ὖ㦮 㭧㞯㠦㍲ 㿲䞮㡂 X 䟻㦒⪲ 㧊☯䞮㡂 䓲ぢ㏢㨂⯒ 㿫ὖ䞮ἶ, 䞮┾⪲
㧊☯䞮㡂 㿫ὖ㡗㡃㦚 ⍩䧞⓪ Ὃ㩫㧊Ⳇ, P4 㠦㍲⓪ P3 㠦㍲㢖 ☯㧒䞮⋮, 㭧㠦㍲ 㿲䞮㡂 ㌗┾
⪲ 㧊☯䞾㦒⪲㖾 ㌗┾⯒ 㿫ὖ䞮⓪ Ὃ㩫㧊┺. ⪺
⩂⯒ 䐋䟊㍲ 䓲ぢ㏢㨂㦮 㭧㞯㥚⯒ ἷⳊ㦒⪲ 㿫 ὖ䞶 㑮 㧞㠞㦒⋮, ⪺⩂⓪ 㿫ὖ㦮 Ṳ⨋㩗㧎 䡫
㌗㦚 ㎇䡫䞮₆ 㥚䞲 Ὃ㩫㦒⪲ 㾲㫛 ㎇䡫䤚 Fig.
8(d)㠦㍲㢖 ṯ㧊 㿫ὖ 㟧 ⊳┾㦮 ㏢㨂 ⹎㿿㰚 䡚㌗㧊 ㌳䞮㡖┺. 㧊⓪ 2 ⻞㱎 ┾Ἒ㠦㍲ ⋶䃊⪲
㤊 䆪⍞ṗ㦚 Ṗ㰚 ⪺⩂㠦 㦮䟊 㾲㏢䢪♶ 㑮 㧞㦚 ộ㦒⪲ 䕦┾♲┺.
Fig. 9 ⓪ ⪺⩂ #1 㧊 㧊☯䞮⓪ Ὃ㩫㭧 㣪ῂ♮⓪ 䞮㭧㦚 ⽊㡂㭒ἶ 㧞⓪◆, 㽞₆ 䓲ぢ㦮 㟧⊳┾㦮
⚦℮⯒ Ṧ㏢䞮₆ 㥚䞲 P1, P2 㥚䂮㠦㍲㦮 ⪺⩂ #1 㦮 䞮㭧㧊 㟓 18~22ton 㦒⪲ ゚ᾦ㩗 䋂Ợ ⋮䌖⌂
㦒Ⳇ, 㿫ὖ㦚 㥚䞲 P3, P4 㥚䂮㠦㍲㦮 ⪺⩂ #1 㦮
(a)
(b)
(c)
(d)
Fig. 8 Step-wise simulation results for roller #1, (a) P1, (b) P2, (c) P3, (d) P4
穢穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊V]X\G Fig. 9 Roll force prediction for roller #1
Fig.10 Roll path for roller #2
(a)
(b)
Fig.11 Step-wise simulation results for roller #2, (a) P1, (b) P2
Fig.12 Roll force prediction for roller #2
䞮㭧㦖 㟓 3ton 㩫☚Ṗ 㣪ῂ♲┺.
⪺⩂ #1 㠦 㦮䟊 Ṳ⨋㩗㦒⪲ ㎇䡫♲ 㿫ὖ㦮 䡫㌗㦚 ⽊┺ 㩫䢫䞲 䡫㌗㦚 㡂䞮₆ 㥚䞲 2 ㎇䡫
┾Ἒ⓪ 㿫ὖ㦮 䆪⍞㦮 䡫㌗ὒ ☯㧒䞲 䡫㌗㦚 Ṗ㰚 ⪺⩂ #2 ⯒ 㧊㣿䞮㡂 㥶☯㎇䡫 䟊㍳㦚 㰚䟟 䞮㡖㦒Ⳇ, Fig. 10 㦖 ⪺⩂ #2 㦮 Ὃῂἓ⪲⯒ ⽊㡂㭒 ἶ 㧞┺.ٻ
⪺⩂ #2 ⓪ 㿫ὖ 㭧㞯㠦㍲ 㿲䞮㡂 X 䟻㦒
⪲ 㰚䟟䞾㦒⪲㖾 ㏢㨂㦮 㿫ὖ⯒ 䘟䌚䢪䞮ἶ ㌗ 䞮䁷㦒⪲ 㧊☯䞾㦒⪲㖾 㿫ὖ㦮 㟧 ⊳┾㦚 㩫⹖
㎇䡫䞮⓪ Ὃ㩫㦒⪲ ṗ 㥚䂮⼚ 䟊㍳ἆὒ⯒ Fig. 11 㠦 ☚㔲䞮㡖┺. ⁎ ἆὒ Fig. 11 㠦 ⽊㡂㰖⓪ 㢖 ṯ㧊 䓲ぢ㦮 㣎䁷䡫㌗㦖 䘟䌚䞮Ợ ㎇䡫㧊 Ṗ⓻䞮 㡖㦒Ⳇ, ⌊䁷 䆪⍞㦮 ἓ㤆 1 ┾Ἒ㠦㍲㦮 ⹎㿿㰚
㦚 Ⱔ㧊 㩲Ệ䞮㡖㦒⋮, 䆪⍞㦮 ㏢㨂 ⚦℮
Ṧ㏢⪲ 㧎䟊 㧒 ⹎㿿㰚 㦖 㡂㩚䧞 ㌳䞮
⓪ ộ㦒⪲ ⋮䌖⌂┺.
Fig. 12⓪ ⪺⩂ #2 㦮 㧊☯㥚䂮⼚ 䞮㭧㡞䁷 ἆὒ
⯒ ⽊㡂㭒ἶ 㧞⓪◆ 㽞₆ ㏢㨂㢖 㩧㽟䞮㡂 㿫ὖ
䘟䌚䢪Ṗ 㧊⬾㠊㰖⓪ P1 㠦㍲⓪ 㟓 12ton 㦮 䞮 㭧㧊 㣪ῂ♮㠞㦒Ⳇ, 䆪⍞⯒ 䡫㎇䞮⓪ P2 㠦㍲⓪ 㟓 7ton 㦮 ⪺⩂ 䞮㭧㧊 㣪ῂ♮⓪ ộ㦒⪲ 㡞䁷♮
㠞┺.
71# ⎆⣆㔲# ⣆⠻#
㥶䞲㣪㏢䟊㍳ ἆὒ⯒ ₆㽞⪲ annulus gear㦮 㥶
☯㎇䡫 㔺䠮㦚 㑮䟟䞮㡖┺. 䟊㍳㦒⪲ Ỗ㯳䞲 ㍺Ἒ 㞞ὒ ☯㧒䞮Ợ 䓲ぢ㏢㨂㦮 㭧㞯 㿫ὖ㦚 㥚䟊 Ṗ 㡊Ὃ㩫㦚 㿪Ṗ 䞮㡖┺. Ṗ㡊Ὃ㩫㦖 Fig. 13ὒ ṯ㧊
]
]X]GV穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊G Fig.13 Flow forming experiment for annulus gear ٻ
䣢㩚䞮⓪ 䘟䕦㥚㠦 ὖ㨂⯒ 㞞㹿䞮ἶ, 䣢㩚㔲䋾⛺, Ṗ㓺䏶䂮⯒ 㧊㣿䞮㡂 ἓ䟻㦒⪲ ‶㧒䞮Ợ Ṗ 㡊♮☚⪳ 䞮㡖㦒Ⳇ, 㩧㽟㔳 㡾☚Ἒ⯒ 㧊㣿䞮㡂 600ଇ₢㰖 Ṗ㡊䞮㡖┺.
1 㹾 ㎇䡫㦖 㧊䡫㨂Ṗ ☚䙂♲ ⰾ✲⩦㠦 Ṗ㡊♲
㏢㨂⯒ 㞞㹿䞮㡂 ㌗ ⰾ✲⩦㦚 䞮(谨)䟻㦒⪲
Ṗ㞫䞾ὒ ☯㔲㠦 ⪺⩂ #1 㦚 㧊㣿䞮㡂 㿫ὖ⯒
3~4 䣢 ⽋䞮㡂 ㌗䞮䟻㦒⪲ 㧊☯䞾㦒⪲㖾 㿫ὖ
㦮 ╖⨋㩗㧎 䡫㌗㦚 ㌳㎇䞮㡖┺. 㧊䤚 䆪⍞ἓ 㧊 㧧㦖 ⪺⩂ #2 ⯒ 㧊㣿䞮㡂 㿫ὖ㦮 㟧 䆪⍞
㦮 䡫㌗㦚 ㌳㎇䞮㡖┺. 㣿☚㠦 ➆⧒ ⪺⩂ #1, #2
⓪ ṗ₆ ┺⯎䡫㌗㦒⪲ 㩲㧧♮㠞㦒Ⳇ. ⰾ✲⩦㦮 䣢 㩚㏣☚⓪ 500~600rpm 㦒⪲ 㥶㰖䞮㡖┺.
2 㹾 ㎇䡫㦖 1 㹾 ㎇䡫㦒⪲ 㿫ὖṖ 䡫㎇♲ ┾ 㹾⯒ Ṗ㰚 ὖ㨂㦮 㟧 ⊳┾㦮 ⚦℮Ṧ㏢ 䡫㌗
ῂ䡚㦚 㥚䞮㡂, 1 㹾 Ὃ㩫㠦㍲㢖 Ⱎ㺂Ṗ㰖⪲ ☯㧒 䞲 䡫㌗㦮 ⰾ✲⩦㠦 㧊䡫㩲⯒ ☚䙂䞮ἶ ⪺⩂ #3,
#4 ⯒ 㧊㣿䞮㡂 㥶☯㎇䡫 Ὃ㩫㦚 㰚䟟䞮㡖┺. ⪺
⩂ #3 㦖 㭧㞯㠦㍲ ㌗⪲ 㧊☯䞮Ⳋ㍲ 1/2 䡫㌗
㦚 ㎇䡫䞮⓪ 㡃䞶㦚 䞮㡖㦒Ⳇ, Ⱎ㺂Ṗ㰖⪲ ☯㧒䞲 䡫㌗㦮 ⪺⩂ #4 ⓪ 㭧㞯㠦㍲ 䞮⪲ 㧊☯䞮Ⳋ㍲
⋮Ⲏ㰖 1/2 䡫㌗㦚 ㎇䡫䞮⓪ 㡃䞶㦚 䞮㡖┺.
Fig. 15㠦 ⋮䌖⌎ ộὒ ṯ㧊 1, 2 㹾 Ὃ㩫 䤚 㩲 䛞䡫㌗㦖 ゚ᾦ㩗 ㍺Ἒ䟞▮ 㢖 㥶㌂䞲 䡫㌗㦒⪲
㩲㧧♮㠞㦒⋮, 䟊㍳㌗ ἶ⩺♮㰖 㞠㞮▮ 䓲ぢ 㟧
⊳┾㦮 ┾㹾 䡫㎇㔲 ┺㦢ὒ ṯ㦖 ⶎ㩲㩦㧊 ㌳
♮㠞┺. 1 㹾 ㎇䡫 Ὃ㩫䤚 㿫ὖ♲ 䆪⍞㥚Ṗ 㰗ṗ 㦒⪲ ㎇䡫♾㠦 ➆⧒ 2 㹾 ㎇䡫㔲 ㏢㨂Ṗ 䙊❿♮⓪ 䡚㌗ ㌳䞮㡖┺. 1 㹾 Ὃ㩫 䤚 䆪⍞㥚⯒ ₆Ἒ ṖὋ䞮㡂, ἓ㌂ṗ㦚 Ⱒ✺㠊㭢㦒⪲㖾 㧊⯒ 㰖䞮 㡖㦒⋮, ㎇䡫 Ὃ㩫㭧 ṖὋὋ㩫㧊 㿪Ṗ♾㠦 ➆⧒
㌳㌆㎇㠦 ⶎ㩲㩦㦚 㟒₆䞾㠦 ➆⧒, 1 㹾 ㎇䡫Ὃ㩫 㦮 Ὃῂἓ⪲ ⁞䡫 䡫㌗ 㑮㩫㧊 㣪ῂ♲┺. 2 㹾
Fig.14 Rollers set-up for annulus gear forming
(a)
(b)
Fig.15 (a) forming samples (b) forming result compared to designed geometry
㎇䡫 Ὃ㩫 䤚 䓲ぢ㦮 㣎䁷㦖 ₆ἚṖὋ㡂㥶⯒ 㩲 㣎䞮ἶ ゚ᾦ㩗 㩫䢫䞲 䡫㌗㦒⪲ ㎇䡫♮㠞㦒⋮ 㿫 ὖ♲ 䆪⍞㥚㦮 ⌊䁷㧊 ㏢㨂Ṗ ⹎㿿㰚 ♮⓪ 䡚㌗㧊 ㌳䞮㡖┺. 㧊⓪ 㞴㍲ 㑮䟟♮㠞▮ 䟊㍳㠦
㍲㢖 ☯㧒䞲 䡚㌗㦒⪲ 䆪⍞ 㦮 ⚦℮ Ṧ㏢⪲ 㧎 䞲 䡚㌗㦒⪲ 䕦┾♲┺. ➆⧒㍲ 㿫ὖ 㦮 ₎㧊⯒
䢫㧻䞮㡂 ₆ἚṖὋ㡂㥶Ṗ ▪ 䄺㰖☚⪳ Ὃῂἓ⪲
㠦 ╖䞲 㑮㩫㧊 㣪ῂ♲┺.
Fig. 16⓪ 㥶☯㎇䡫 ┾Ἒ⼚ metal flow ⯒ ⋮䌖⌊
⓪ ⁎Ⱂ㦒⪲ 㩲䛞㦮 ₎㧊 䟻㦒⪲ metal flow Ṗ 䡫㎇♮ἶ 㧞㦢㦚 䢫㧎䞶 㑮 㧞┺. ⡦䞲, 㥚⼚⪲
⚦℮ 䙂Ṗ ⼖䢪䞮Ⳇ Ṗ㧻 㟝㦖 㥚㠦㍲ Ṗ㧻 㫆⹖䞲 metal flow Ṗ 䡫㎇♮㠊 㧞㦢㦚 㞢 㑮 㧞┺.
Ὃ㩫⼚⪲ ゚ᾦ㩗 ⚦℮Ṗ ‶㧒䞮Ợ 䡫㎇♮㠞㦒⋮
㔲䠮㠦 ㌂㣿䞲 ⪺⩂㦮 㰗ἓ㧊 ἶ㩫♮㠊 㧞₆ ➢ ⶎ㠦 2 㹾 ㎇䡫䛞㠦㍲⓪ ㎇䡫䛞㠦 ⪺⩂ 㰗ἓ㦮 㡗 䟻㧊 㡗♮㠊 㧞┺. 㥶☯㎇䡫㠦 㦮䞲 ṖὋἓ䢪㠦
➆⯎ ἓ☚⼖䢪⯒ 䁷㩫䞮₆ 㥚䞮㡂 ⁎Ⱂ㠦 䚲㔲䞲
穢穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊V]X^G Fig.16 Metal flow and microstructure at several
different sections for flow formed annulus gear
Fig.17 Hardness distribution for flow formed annulus gear
Table 2 Tensile properties for for flow formed annulus gear
G YS(MPa) UTS(MPa) Elong.(%) 1ststep 639.6 665.3 23.8 2ndstep 389.8 566.5 35.0 G
ộὒ ṯ㧊 ῂṚ㦚 䞶䞮㡂 ἓ☚⯒ 䁷㩫䞮㡖┺.
Fig. 17㠦 䚲㔲♲ 㥚䂮⻞䢎Ṗ 1, 2 㹾 ㎇䡫㠦 Ỏ㼦 㩫䢫䞮Ợ ☯㧒䞮㰖⓪ 㞠㰖Ⱒ ㎇䡫㠦 ➆⯎ ἓ☚⼖
䢪⯒ 㿪㩫䞶 㑮 㧞┺. 1 㹾 ㎇䡫㔲㠦⓪ Ṗ㧻 㟝㦖
⚦℮⯒ Ṗ㰖⓪ 1, 2 ⻞ ῂ㡃㧊 Ṗ㧻 ⏨㦖 ἓ☚⯒
Ṗ㰖Ⳇ 2 㹾 ㎇䡫䛞㠦㍲⓪ 5~7 ⻞ ῂ㡃㧊 Ṗ㧻 㟝 㦖 ⚦℮⯒ Ṗ㰖₆ ➢ⶎ㠦 Ṗ㧻 ⏨㦖 ἓ☚⯒ Ṗ㰚
┺. 䞮㰖Ⱒ, 2 㹾 ㎇䡫䛞㦮 1~3 ⻞ ῂ㡃㦖 1 㹾 ㎇ 䡫㔲㦮 ἓ☚⽊┺ ⌄㦖 Ṩ㦚 Ṗ㰖⓪◆ 㧊⓪ 㔲䠮 㠦 ㌂㣿䞲 㧻゚㦮 䞮㭧㧊 㫇䞮㡂 ㎇䡫 㩚䤚㠦 Ṗ㡊㦚 䐋䟊 ㏢㨂㦮 ἓ☚⯒ 㧎㥚㩗㦒⪲ ⌄㿮 ộ 㠦 ₆㧎䞲┺. 㯟, ㎇䡫㧻゚㦮 䞮㭧㧊 㿿䧞 䋊 ἓ
㤆 ㏢㨂㦮 ἓ☚⯒ ㏢㨂㦮 ἶ㥶䞲 ṫ䢪⓻⩻₢㰖 㯳 Ṗ㔲䌂 㑮 㧞㦚 ộ㦒⪲ 㡞㌗♲┺. Table 2 ⓪ annulus gear ㎇䡫 䤚 㭧㕂(1, 2 㹾 ㎇䡫䛞㦮 1~3 ⻞ 㥚) 㠦㍲ 㔲䘎㦚 ⠒㠊⌊㠊 ṖὋ䞲 䤚 㧎㧻㔲䠮䞲 ἆ ὒ㧊┺. 㾲㫛 2 㹾 ㎇䡫䛞 ₆㭖㦒⪲ 㤦㏢㨂㠦 ゚ 䟊 䟃⽋ṫ☚⓪ 㥶㌂䞲 㑮㭖㧊⋮ 㧎㧻ṫ☚⓪ 㫆⁞
㯳Ṗ䞲 ἓ䟻㦚 ⽊㡂㭒ἶ 㧞┺. 1 㹾 ㎇䡫䛞㦖 㾲㫛 2 㹾 ㎇䡫䛞㠦 ゚䟊 ㌗╖㩗㦒⪲ ⏨㦖 ṫ☚⯒ Ṗ㰚
┺. 㞴㍲ ㍺ⳛ䞲 ộὒ ṯ㧊 ┾Ἒ⼚ ㎇䡫㩚䤚㠦 Ṗ 㡊㦚 䞮㰖 㞠㦚 ἓ㤆 㽞₆ 550MPa 㩫☚㦮 㧎㧻ṫ
☚⯒ Ṗ㰖⓪ ㏢㨂⪲☚ 700MPa 㩫☚㦮 㧎㧻ṫ☚⯒
Ṗ㰖⓪ 㩲䛞㦚 㩲㫆䞶 㑮 㧞⓪ Ṗ⓻㎇㦚 䢫㧎䞮 㡖┺. ṫ☚㦮 㯳Ṗ㠦 䟊 㡆㔶㥾㦖 Ṧ㏢䞮⓪ ἓ 䟻㦚 ⽊㡂㭒ἶ 㧞┺. 㯟, 㥶☯㎇䡫 㩲䛞 ㍺Ἒ㔲 ṫ㫛㦚 ㍶䌳䞮⓪ ₆㭖㦒⪲ 㩲䛞㧊 㣪ῂ䞮⓪ ṫ☚
㢖 㡆㔶㥾㦮 ⺎⩆㓺㠦 ╖䞲 ₆㭖㧊 䞚㣪䞶 ộ㦒
⪲ ㌳ṗ♲┺.ٻ
81# ൚# ᤊ#
ٻ
⽎ 㡆ῂ㠦㍲⓪ 㿫╖䃃 㤦䐋䡫㌗㦚 Ṗ㰖⓪ 㩲䛞 㦮 㩫䡫㎇䡫㠦 䣾ὒ㩗㦒⪲ 㩗㣿䞶 㑮 㧞⓪ 㥶☯
㎇䡫㠦 ὖ䞲 ₆㽞㡆ῂ⯒ 㑮䟟䞲 ἆὒ⯒ 㩫Ⰲ䞮㡖
┺. 㥶☯㎇䡫㦚 㧊㣿䞮㡂 㭧Ὃ䛞㦚 䣾ὒ㩗㦒⪲
㌳㌆䞶 㑮 㧞⓪ Ṗ⓻㎇㦚 䢫㧎䞮㡖㦒Ⳇ Ὃῂἓ⪲
㦮 㿪Ṗ㩗㧎 㾲㩗䢪⯒ 䐋䟊 㟧㌆㠦 㩗㣿䞶 㑮 㧞
⓪ 㑮㭖㦮 㩲䛞㦚 㩲㧧䞶 㑮 㧞㦢㦚 䢫㧎䞮㡖┺.
㝮
⽎ 㡆ῂ⓪ ㌆㠛㤦㻲₆㑶Ṳ㌂㠛(ὒ㩲ⳛ: Flow forming Roll die forming 㠦 㦮䞲 䂮䡫 䛞㦮 ἓ
⨟ಷ㧒㼊䢪 ㎇䡫 ₆ ₆㑶 - ὒ㩲⻞䢎: 10033529)㦮 㰖㤦㦚 㞚 㑮䟟♮㠞㦒Ⳇ 㧊㠦 Ṧ㌂ ✲Ⱃ┞┺.
Ⳣ ඊ ᯢ 㙶
[1] H. N. Nagarajana, H. Kotrappaa, C. Mallannaa, V. C.
Venkatesha, 1981, Mechanics of Flow Forming, CIRP Ann., Vol. 30, No. 1 pp. 159~162.
[2] C. C. Wong, J. Lin, T. A. Dean, 2005 Effects of Roller Path and Geometry on the Flow Forming of Solid Cylindrical Components, J. Mater. Process.
Technol., Vol. 167, No. 2-3, pp. 344~353.
]
]X_GV穢剳暒昷儆击穟箒滆V洢YW劒G 洢_笾SGYWXX噊G Mechanical Properties of Flow Formed AISI 4130 Steel Tubes-a theoretical and experimental assessment, J. Mater. Process. Technol., Vol. 125-126, pp. 503~
511.
Materials, Vol. 4, No. 4, pp. 895~898
[7] J. N. Park, D. H. Kim, B. M. Kim, 2002, Experiemental Investigation on the Flow Control of Hub Clutch for Automotive, Trans. Mater. Process., Vol. 11, No. 5, pp. 430~438.
