Design of Half Blanking Process for Reducing Rollover and Stress Acting on Tools in Forming of Lower Tooth

DOI : 10.5228/KSTP.2011.20.3.214

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嵢檺眲枪汞 嵪欪憊 愕 匎笛 彺橛 洆儖汊 氊穢 穞稊挚岳疿 击洛 昪凊

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沫律滊

· 牢筓昣

· 決旇篎

· 卆壟朞

· 愶沲笾

· 処堆熦

· 卆懗愂

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Design of Half Blanking Process for Reducing Rollover and Stress Acting on Tools in Forming of Lower Tooth

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M. J. Jang, H. S. Choi, S. H. Lee, D. S. Kim, S. G. Lee, D. C. Ko, B. M. Kim (Received November 29, 2011 / Revised January 6, 2011 / Accepted April 7, 2011) G

Abstract

In recent years, automotive seat components have been manufactured by the fine blanking process, allowing an improvement of dimensional accuracy at sheared surface in series production. However, the rollover has increased and die failures have occurred more frequently when manufacturing gears by fine blanking. Consequently, important goals for manufacturing seat recliner parts with gears have been to decrease the rollover as well as to improve the tool life. In this study, the half blanking and shaving processes were introduced to improve aforementioned problems for the lower tooth, the main component of a seat recliner. For this purpose, the half blanking process was optimized using the finite element (FE) analysis and design of experiment (DOE). The optimized conditions resulting from this study were an offset of 0.2 mm, a clearance of 0.1 mm and a penetration depth of 4.5 mm. Fine blanking experiment conducted under the optimal condition resulted in a rollover depth decrease from 1.9 to 1.3 mm, and no die failure occurrence.

Key Words : Lower Tooth, Recliner, Fine Blanking, Half Blanking, Shaving, Design of Experiment, FE-analysis

41# ⇆# ᤊG G

㧦☯㹾 㔲䔎⓪ 䋂Ợ ❇⹱㧊 㡃䞶㦚 䞮⓪ ⺇ (Back), 㫢㍳㦚 㞴⛺⪲ 㫆㩫䞮⓪ 䔎⧯(Track) ⹥ Ⰲ 䋊⧒㧊⍞(Recliner)⪲ ⋮⒮㠊㰚┺[1,2]. ⁎ 㭧㠦㍲

Ⰲ䋊⧒㧊⍞⓪ 㔲䔎⺇ὒ 䔎⧯㦚 㡆ἆ䞶 ㈦Ⱒ 㞚┞

⧒ 㫢㍳㦮 ṗ☚⯒ 㫆㩞䞮⓪ ₆⓻㦚 Ṗ㰚 ⿖䛞㧊 Ⳇ, 㔏ṳ㦮 㞞㩚ὒ Ṧ㎇㠦 ⰺ㤆 㭧㣪䞲 㡃䞶㦚 䞲

┺[3]. Ⰲ䋊⧒㧊⍞⯒ ῂ㎇䞮⓪ ⿖䛞㦖 㭒⪲ 㩚┾

Ὃ㩫㠦 㦮䟊 㩲㧧♮ἶ 㧊✺㦖 㣪ῂ 䔏㎇ ⹥ ῂ☯

Ⲫ䄺┞㯮㠦 ➆⧒ 㠶⽊㕇, ₆㠊 ㎇䡫 ❇㧊 㧊⬾㠊 㰚┺[4]. 䞲䘎, 㩚┾♲ ⿖䛞㦮 ┾Ⳋ㦚 ㌊䘊⽊Ⳋ 䞚

㡆㩗㦒⪲ ⪺㡺⻚(Roll-over), 㥶䣾㩚┾Ⳋ(Effective sheared surface), 䕢┾Ⳋ(Fracture surface), ⻚(Burr)Ṗ

⹲㌳䞮⓪◆[5,6] 䕢┾Ⳋὒ ⻚Ṗ 㫊㨂䞶 ἓ㤆, 㧊✺

㦚 㩲Ệ䞮₆ 㥚䞲 䤚Ὃ㩫㧊 䞚㣪䞶 ㈦Ⱒ 㞚┞⧒

㔲䔎㠦 㧻㹿 㔲, ⹎⊚⩒ 㩧㽟⿖ ❇㠦㍲ ㏢㦢, 㰚

☯㦮 ⶎ㩲⯒ 㧒㦒䋺ἶ, ἓ㤆㠦 ➆⧒㍲⓪ Ⰲ䋊⧒㧊

⍞㦮 㑮ⳛ㦚 ┾㿫㔲䋺⓪ 㤦㧎㧊 ♮₆☚ 䞲┺. ➆

⧒㍲ ⏨㦖 㩫⹖☚⯒ 㣪ῂ䞮⓪ 㔲䔎 Ⰲ䋊⧒㧊⍞

⿖䛞 㩲㫆 ㌆㠛㠦㍲⓪ ゚ᾦ㩗 ㌳㌆㎇㧊 ⥆㠊⋮Ⳇ 100%㠦 Ṗ₢㤊 㥶䣾㩚┾Ⳋ㦚 䢫⽊䞶 㑮 㧞⓪ 䕢 㧎な⨃ 䌏(Fine blanking) Ὃ⻫㧊 Ⱔ㧊 㩗㣿 ♮㠊 㡺 ἶ 㧞┺[7,8].

XUG ⿖㌆╖G 㩫⹖ṖὋ㔲㓺䎲㩚ὋG G YUG ൽG ┺㓺G ⁞䡫䕖G

ZUG ⿖㌆╖G ⿖䛞㏢㨂㌆䞯䡧⩻㡆ῂ㏢G

JG ᾦ㔶㩖㧦aG ⿖㌆╖G ₆ἚὋ䞯⿖SGlT”ˆ“aG‰”’”g—œšˆ•UˆŠU’™G

穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊V

YX\G

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㦮 ⿖䛞 㭧, 㣎䁷 ₆㠊 ⡦⓪ ⌊䁷 ₆㠊⯒ Ṗ㰚 ⿖ 䛞㧊 Ⱔ㧊 㩗㣿 ♮ἶ 㧞┺. ἆ䞿 ṫ☚⯒ 䟻㌗㔲䋺

₆ 㥚䟊㍲⓪ ₆㠊Ṛ㦮 㩧㽟 Ⳋ㩗㦚 㯳Ṗ 㔲䅲㟒 䞲┺. ⁎⩂⋮ 䕢㧎な⨃䌏 Ὃ㩫㠦㍲ ⹲㌳䞮⓪ ⪺㡺

⻚⪲ 㧎䟊㍲ ⿖䛞 ἆ䞿 㔲, 㥶䣾 㩧㽟 Ⳋ㩗㧊 ㌗

╏䧞 Ṧ㏢♮⓪ ἓ㤆Ṗ Ⱔ┺. 㧊⓪ 䔏䧞 90°⽊┺

䤾㞂 㧧㦖 ㌆⿖㦮 ṗ☚⯒ Ṗ㰚 ₆㠊⮮㠦㍲ ⶎ㩲 Ṗ ♲┺. Nakagawa ❇[9]㦖 䕢㧎な⨃䌏 Ὃ㩫㠦㍲

㩚┾㥺ὓ㦮 䡫㌗㧊 㩲䛞㦮 㩫⹖☚㠦 ⹎䂮⓪ 㡗䟻 㠦 ╖䟊㍲ 㔺䠮㩗㦒⪲ 㫆㌂䞮㡖⓪◆, 㧊 ⊳⿖⿚㦮 ṗ☚Ṗ 30°㧎 ἓ㤆 ⪺㡺⻚⓪ ㏢㨂 ⚦℮㦮 30% 㧊

㌗₢㰖 㯳Ṗ䞾㦚 ⽊㡖┺. ἆὒ㩗㦒⪲ ⪺㡺⻚⯒ Ṧ

㏢㔲䋺Ⳋ㍲ ☯⩻ 㩚╂ ⹥ ἆ䞿 ₆⓻㧊 Ṗ⓻䞲 ṗ☚

⯒ Ṗ㰚 ₆㠊⯒ 䕢㧎な⨃䌏㦒⪲ 㩲㫆䞮₆ 㥚䟊㍲⓪

₆㫊㦮 ㎇䡫 ⹿⻫ὒ⓪ ┺⯎ ⹿㔳㧊 㣪ῂ♲┺.

⽎ 㡆ῂ㠦㍲⓪ 㧦☯㹾 㔲䔎㦮 㭒㣪 ῂ㎇㣪㏢

㧎 㣎䂮䡫 Ⰲ䋊⧒㧊⍞㦮 㭒㣪 ⿖䛞㧎 ⪲㠊䒂㓺 (Lower tooth)㦮 ₆㠊⿖ ㎇䡫 㔲, ⪺㡺⻚⯒ 㩖Ṧ䞮

₆ 㥚䞮㡂 䞮䝚な⨃䌏(Half blanking, H/B) ⹥ ㏆㧊 ク(Shaving) Ὃ㩫㦚 ☚㧛䞮㡖┺[10,11]. ₆㫊㦮 䕢㧎 な⨃䌏㠦 㦮䞲 㩲䛞㦖 ⪺㡺⻚Ṗ ㏢㨂 ⚦℮㦮 40%

㧊㌗ ⹲㌳䞮㡖㦚 ㈦Ⱒ 㞚┞⧒ ㎇䡫 㔲, ὒ☚䞲 ⿖ 䞮⪲ 㧎䟊 ⁞䡫 䕢㏦㧊 ゞ⻞䞮㡖┺. ➆⧒㍲ ㏆㧊 ク 䤚, ⪺㡺⻚㦮 Ṧ㏢㢖 ⁞䡫 㑮ⳛ㦮 䟻㌗㦚 㥚䞲 㭒㣪 Ὃ㩫 ㍺Ἒ⼖㑮⪲㖾 䞮䝚な⨃䌏 ⁞䡫㦮 䡫㌗, 䋊Ⰲ㠊⩆㓺(Clearance), ㎇䡫 ⏨㧊 ❇㦚 ㍶㩫䞮㡖㦒 Ⳇ 㩗㩫Ṩ㦚 ἆ㩫䞮₆ 㥚䞮㡂 㥶䞲㣪㏢䟊㍳ ⹥ 㔺䠮Ἒ䣣⻫㦚 㩗㣿䞮㡖┺. ⡦䞲 㾲㩗䢪 ♲ Ὃ㩫 㫆Ị 䞮㠦㍲ 䞮䝚な⨃䌏 ⹥ ㏆㧊ク㦚 㑮䟟䞲 䤚,

⪺㡺⻚ 㩖Ṧ⨟㦚 䁷㩫䞮㡂 ⽎ 㡆ῂ㦮 䌖╏㎇㦚 㧛㯳䞮㡖┺.

51# ⠺ᒃⳒ# ⎆㍢# ᩖㄞᠦ⠞ᆲG

514# ᩖㄞᠦ⠞ᆲ# ถ⤚#

Fig. 1 㔲䔎 Ⰲ䋊⧒㧊⍞㦮 ῂ㫆⯒ ⋮䌖⌊㠞┺. Ⰲ 䋊⧒㧊⍞⓪ 㔲䔎⺇ὒ 㔲䔎 䔎⧯㦚 㡆ἆ䞮⓪ ⿖䛞㦒

⪲ 㔲䔎⺇㦮 ṗ☚ ἶ㩫 ⹥ 㫆㩫㡃䞶㦚 䞮Ⳇ 㔲䔎 Ⰲ䋊⧒㧊⍞⓪ 㠊䗒䒂㓺(Upper tooth), ⪲㠊䒂㓺, 䃶 (Cam) ⹥ ぢ⧒䅩(Bracket) ❇㦒⪲ ῂ㎇♮㠊 㧞┺.

⪲㠊䒂㓺⓪ Ⰲ䋊⧒㧊⍞ ₆⓻㠦 㞚㭒 㭧㣪䞲 㡃 䞶㦚 䞮⓪ ⿖䛞㦒⪲㖾 11Ṳ㦮 䂮䡫㦚 Ṗ㰖ἶ 㧞 㦒Ⳇ ⚦℮⓪ 5mm 㧊┺. Fig. 2㠦 ⪲㠊䒂㓺㦮 䡫㌗

⹥ 㭒㣪䂮㑮⯒ ⋮䌖⌊㠞┺.

Fig. 1 Components of an automotive seat recliner

Fig. 2 Shape and dimensions of the lower tooth

515# ᤆ♞㋖⍎⠂# ⣆⤚# ඟ⢿#

51514# ㎶⠢Ếᡗㅣ# Ჹ# Ặᤆ⼗# ⢫❓

Fig. 3㠦 ₆㫊㦮 ⪲㠊䒂㓺 㩲㫆 Ὃ㩫㦚 ⋮䌖⌊㠞

┺. 䂮䡫⿖⯒ 㩲㣎䞲 㣎ὓ ⿖⿚㦚 䕢㧎な⨃䌏㦒⪲

㎇䡫䞮ἶ ⻚⯒ 㩲Ệ䞮₆ 㥚䞲 ⹪⩦(Barrel) 㡆Ⱎ⯒

㑮䟟䞲┺. 䂮䡫㦖 ぢ⪲䃃(Broaching)㠦 㦮䟊 㩞㌃

♮㠊 㾲㫛 㩲䛞㦒⪲ ♲┺. ⁎⩂⋮ 䕢㧎な⨃䌏 ⹥ ぢ⪲䃃 Ὃ㩫㠦 ╖䞲 ṗṗ㦮 䂮㑮 ὖⰂṖ 䞚㣪䞮 Ⳇ ⶊ㠝⽊┺ Ὃ㩫㑮 㯳Ṗ㠦 ➆⯎ 㤦Ṗ ㌗㔏㧊 ⶎ 㩲Ṗ ♲┺. 㧊⯒ Ṳ㍶䞮₆ 㥚䞮㡂 䂮䡫⿖⯒ 䙂䞾 䞲 ⪲㠊䒂㓺㦮 㣎ὓ⿖⯒ 1䣢㦮 䕢㧎な⨃䌏㦒⪲

㩲㫆䞮⓪ ộ㧊 䞚㣪䞮┺.

Fig. 3 Previous manufacturing process for the lower tooth by fine blanking and broaching

#

51515# ㎶⠢Ếᡗㅣ♺# ⠂㘆# ᤆ♞㋖⍎# ⣆⠻#

Fig. 4㠦 䕢㧎な⨃䌏㠦 㦮䟊 㩲㧧♲ ⪲㠊䒂㓺⯒

⋮䌖⌊㠞┺. ⁎⩂⋮ 䂮䡫⿖㠦㍲ ㏢㨂 ⚦℮㦮 㟓 40% Ṗ⨟㦮 ⪺㡺⻚Ṗ ⹲㌳䞮㡖┺. ὒ☚䞮Ợ ⹲㌳

YX]

Fig. 4 Lower tooth manufactured by fine blanking process and its cross section

Fig. 5 Lower tooth assembled with the upper tooth

Fig. 6 Fine blanking tools which occurs chipping

Fig. 7 Half blanking and shaving lay-out for the lower tooth

䞲 ⪺㡺⻚⓪ Fig. 5 㠦 ⋮䌖⌎ ⹪㢖 ṯ㧊 㠊䗒䒂㓺 㢖㦮 ἆ䞿 㔲, 㔺㩧㽟Ⳋ㩗㦚 Ṧ㏢㔲䅲 䂮䡫⿖㦮 Ⳋ㞫㦚 㯳Ṗ㔲䋺ἶ ἆὒ㩗㦒⪲ Ⰲ䋊⧒㧊⍞㦮 㑮 ⳛ㦚 ┾㿫㔲䌂 㑮 㧞┺.

Fig. 6 㠦 䂮䞧(Chipping)㧊 ⹲㌳䞲 ⁞䡫 ㌂㰚㦚

⋮䌖⌊㠞┺. 㧊⩂䞲 㤦㧎㦒⪲⓪ ㎇䡫 㔲, 㩲䛞㦮

䡫㌗㠦 ➆⧒ ῂ㫆㩗㦒⪲ 䀾㟓䞲 䂮䡫⿖㠦 ⏨㦖 Ⳋ㞫㧊 㧧㣿䞮₆ ➢ⶎ㦒⪲ 䕦┾♲┺.

➆⧒㍲ ⪲㠊䒂㓺 ⪺㡺⻚⯒ Ṧ㏢㔲䋺Ⳋ㍲ ⁞䡫 㑮ⳛ₢㰖 䢫⽊䞶 㑮 㧞⓪ ㎇䡫 Ὃ⻫㧊 㣪ῂ♮Ⳇ

⽎ 㡆ῂ㠦㍲⓪ 䞮䝚な⨃䌏 ⹥ ㏆㧊ク Ὃ㩫㦚 ☚ 㧛䞮㡖┺.

61# 㘂㖮Ếᡗㅣ# Ჹ# √⠞ἃ# ඟ⢿⠂# ⢫❓#

#

614# 㘂㖮Ếᡗㅣ# Ჹ# √⠞ἃ# ඟ⢿# ᢲ⠞◮❭#

Fig. 7㠦 ⪲㠊䒂㓺 㩲㫆⯒ 㥚䞲 Ὃ㩫 ⩞㧊㞚㤙 (Lay-out)㦚 ⋮䌖⌊㠞┺. ₆㫊㠦⓪ 䞒㠊㕇 ⹥ 䕢㧎 な⨃䌏㦒⪲ 㩲㧧♮㠞㦒⋮ 䞮䝚な⨃䌏 ⹥ ㏆㧊ク Ὃ㩫㦒⪲ ⿚䞶䞾㦒⪲㖾 ⪺㡺⻚ ⹥ ⁞䡫㠦 㧧㣿䞮

⓪ 㦧⩻㦚 㩖Ṧ㔲䌂 㑮 㧞㦚 ộ㦒⪲ 㡞㌗♲┺. ㏆ 㧊ク ⁞䡫 䡫㌗㦖 ⪲㠊䒂㓺㦮 䡫㌗ὒ ☯㧒䞮⸖⪲

⽎ 㡆ῂ㠦㍲⓪ 䞮䝚な⨃䌏 ⁞䡫㦮 䡫㌗ ⹥ ⼖㑮 㾲㩗䢪㠦 㭧㩦㦚 ⚦㠞㦒Ⳇ 㧊⯒ 㥚䞮㡂 㥶䞲㣪㏢

䟊㍳ ⹥ 㔺䠮Ἒ䣣⻫㦚 㩗㣿䞮㡖┺.

#

615# 㘂㖮Ếᡗㅣ# ඟ⢿# ⇎൮#

61514# ⟊㘆✾∶㘞⇇# ᭒ᐢ#

Fig. 8 FE-model of half blanking for lower tooth

Fig. 8㠦 㥶䞲㣪㏢䟊㍳ ⳾◎㦚 ⋮䌖⌊㠞┺. 䟊㍳

㦖 䂮䡫⿖㦮 ⪺㡺⻚⯒ 㭧㩦㩗㦒⪲ 䕢㞛䞮₆ 㥚䞮 㡂 㩲䛞 ⌊⿖㦮 䞒㠊㕇⿖⯒ ₆㭖㦒⪲ 1/4 ⳾◎㠦

╖䟊 㑮䟟♮㠞┺. 䞲䘎, 䞮䝚な⨃䌏 䟊㍳㦖 ゚Ⱇ (Vee-ring)㧊 ㏢㨂⯒ 䋊⧾䞧䞮⓪ 1 ┾Ἒ ⹥ 㓺䔎Ⰲ 䗒, 䃊㤊䎆 䗖䂮Ṗ 䞮㭧㦚 Ṗ䞮Ⳋ㍲ ㎇䡫䞮⓪ 2

┾Ἒ⪲ ⋮⑚㠊 㰚䟟䞮㡖┺.

㥶䞲㣪㏢䟊㍳㦖 ṫ㏢㎇ 㥶䞲㣪㏢䟊㍳ 䆪✲㧎 DEFORM 3D(ver. 10.1)㠦 㦮䟊 㑮䟟♮㠞┺. ⡦䞲

⪲㠊䒂㓺㦮 ㏢㨂㧎 SNCM220 㦮 㥶☯㦧⩻㔳㦖 㧎 㧻㔲䠮㦚 䐋䞮㡂 ┺㦢ὒ ṯ㧊 㠑㠞㦒Ⳇ ㏢㨂 ⚦

℮Ṗ 5mm ⪲ ゚ᾦ㩗 ⚦ℒ㤆⸖⪲ 㞫㡆㠦 㦮䞲 㧊

⹿㎇㦖 ἶ⩺♮㰖 㞠㞮┺.

穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊V

YX^G

G ]

[ 727 H

MPa V

h L T F

8 0 . u

u u

Fig. 9 The relationship between compressive yield strength and hardness of the tool material [12]

(1)

㓺䔎Ⰲ䗒 䞮㭧 ⹥ 䃊㤊䎆 䞮㭧㦚 ㍶㩫䞮₆ 㥚 䞮㡂 ⪲㠊䒂㓺㦮 䕢㧎な⨃䌏 㔲 㧧㣿䞮⓪ ㎇䡫 䞮㭧㦚 Ἒ㌆䞮㡖┺. 㧒⹮㩗㦒⪲ 㩚┾ Ὃ㩫 㔲 㧧 㣿䞮⓪ 䞮㭧㦖 㔳(2)㠦 㦮䟊 Ἒ㌆♲┺.

(2)

㡂₆㍲ Ts⓪ ㏢㨂㦮 㧎㧻ṫ☚, L 㦖 㩚┾ 㥺ὓ

₎㧊, h ⓪ ㎇䡫 ₠㧊⯒ 㦮⹎䞲┺. 㔳 (2)⯒ 䐋䟊 Ἒ㌆♲ ⪲㠊䒂㓺㦮 ㎇䡫 䞮㭧㦖 㟓 30ton 㧊┺. 䞲 䘎, 䕢㧎な⨃䌏 Ὃ㩫㠦㍲㦮 㓺䔎Ⰲ䗒 䞮㭧 ⹥ 䃊 㤊䎆 䞮㭧㦖 ṗṗ ㎇䡫䞮㭧㦮 50% ⹥ 15%⯒ 㩗 㣿䞮⓪ ộ㧊 㧒⹮㩗㧊┺. ➆⧒㍲ ⽎ 㡆ῂ㠦㍲⓪ 䞮䝚な⨃䌏 㔲 㓺䔎Ⰲ䗒 䞮㭧 ⹥ 䃊㤊䎆 䞮㭧㦚 ṗṗ 15ton, 5ton 㦒⪲ 㩗㣿䞮㡖┺. ⡦䞲 ㏢㨂㢖 ⁞ 䡫 Ṛ㦮 Ⱎ㺆㌗㑮(m)㦖 0.1 ⪲ ㍶㩫䞮㡖┺.

䞲䘎, ⁞䡫㦮 䟃⽋ 㡂⿖⯒ 䕢㞛䞮₆ 㥚䟊 Fig.

9㠦 ⋮䌖⌎ ⹪㢖 ṯ㧊 ⁞䡫㨂㦮 ἓ☚㢖 㞫㿫䟃⽋

ṫ☚㢖㦮 ὖἚ⯒ 㧊㣿䞮㡖┺[12]. ⽎ 㡆ῂ㠦㍲ ㌂ 㣿♲ ⁞䡫㨂⓪ 㡊㻮Ⰲ♲ STD11㫛㦒⪲ HRc 60~61

㦚 Ṗ㰚┺. ➆⧒㍲ 㞫㿫䟃⽋ṫ☚㦮 ⻪㥚⓪ 2,000~

2,800MPa㦮 Ṩ㦚 Ṗ㰖㰖Ⱒ 㞞㩚⮶㦚 ἶ⩺䞮㡂 2,000MPa 㧊㌗㦮 㦧⩻㧊 ⁞䡫㠦 㧧㣿䞶 㔲, 䟃⽋

♮㠊 䕢㏦㠦 㧊⯊⓪ ộ㦒⪲ 䕦┾䞮㡖┺.

#

61515# 㘂㖮Ếᡗㅣ# ඟ⢿⇎൮#

Fig. 10(a), (b)㠦 䞮䝚な⨃䌏 Ὃ㩫㦮 Ṳ⨋☚ ⹥ ἶ⩺♲ ㍺Ἒ ⼖㑮⯒ ṗṗ ⋮䌖⌊㠞┺. ㍺Ἒ ⼖㑮

⓪ 㡺䝚㎡(Offset)⨟, 䋊Ⰲ㠊⩆㓺 ⹥ 䗖䂮 㓺䔎⪲䋂

⪲ ㍶㩫䞮㡖㦒Ⳇ 䗖䂮 ⹥ ┺㧊㦮 ㍶┾⿖ ⹮ἓ㦖 0.1mm ⪲ ἶ㩫䞮㡖┺. 㡺䝚㎡㦮 㯳Ṗ㠦 ➆⧒ 䞮䝚 な⨃䌏 䤚 㧊 ⊳ ⹮ἓ(R1)㧊 㩲䛞㦮 㧊 ⊳ ⹮ἓ (R₂)⽊┺ 㯳Ṗ䞮₆ ➢ⶎ㠦 ⪺㡺⻚Ṗ Ṧ㏢♮⓪ 䣾 ὒṖ 㧞┺[9]. ⁎⩂⋮ 㡺䝚㎡㧊 ὒ☚䞶 ἓ㤆㠦⓪

㏆㧊ク Ὃ㩫㠦㍲㦮 ㎇䡫⨟㧊 㯳Ṗ䞮㡂 ⁞䡫㦮 ṫ

☚㩗 䁷Ⳋ㠦㍲ 䀾㟓䞮┺⓪ ┾㩦㧊 㧞┺. 䞲䘎, 䋊 Ⰲ㠊⩆㓺Ṗ 㦢(-)㧎 ἓ㤆㠦⓪ ⁞䡫㦮 Ὃ☯⿖⪲ 㥶 㧛♮⓪ 㨂⬢㦮 㟧㧊 㯳Ṗ䞶 ㈦Ⱒ 㞚┞⧒ 㩫㑮㞫 㦧⩻㧊 䡫㎇♮㠊 ₆㠊⿖㦮 ⪺㡺⻚Ṗ Ṧ㏢䞮ἶ 㩚

┾Ⳋ㦮 䛞㰞 ⡦䞲 䟻㌗♮⓪ 䣾ὒṖ 㧞┺[13]. ⁎⩂

⋮ ὒ☚䞲 㦢㦮 䋊Ⰲ㠊⩆㓺㦮 㫆Ị㠦㍲ ㎇䡫䞶 ἓ㤆, ⁞䡫㠦 ⏨㦖 Ⳋ㞫㧊 㧧㣿䞮⓪ ⶎ㩲Ṗ 㧞┺.

⡦䞲 䞮䝚な⨃䌏 Ὃ㩫㠦㍲㦮 㓺䔎⪲䋂⓪ 㭒⪲ 䞮 䝚な⨃䌏 ⹥ ㏆㧊ク ⁞䡫㠦 㧧㣿䞮⓪ 㦧⩻㦚 㩗 㩞䞮Ợ ⿚㌆㔲䋺⓪ 䣾ὒṖ 㧞㦒⸖⪲ 㧊㠦 ╖䞲 㩗㩫Ṩ㦚 ㍶㩫䞮⓪ ộ㧊 㭧㣪䞮┺. ➆⧒㍲ 㧊⩂䞲 Ὃ㩫⼖㑮⯒ 㾲㩗䢪㔲䋺₆ 㥚䞮㡂 㔺䠮Ἒ䣣⻫ ⹥ 㥶䞲㣪㏢䟊㍳㧊 㩗㣿♮㠞┺. Table 2 㠦 ㍺Ἒ ⼖㑮

⹥ ⁎ 㑮㭖Ṩ㦚 ⋮䌖⌊㠞┺. 㥶䞲㣪㏢䟊㍳㦖 Table 2 㦮 ㍺Ἒ⼖㑮⯒ ⹪䌫㦒⪲ L9(3⁴)㦮 㰗ᾦ⺆㡊䚲⯒

㧧㎇䞮㡂 ṗ 㑮㭖 㫆䞿㠦 ➆⧒ 㑮䟟♮㠞┺.

䞲䘎, ⳿㩗䞾㑮(O.F)⓪ ⪺㡺⻚, 䞮䝚な⨃䌏 ⹥

㏆㧊ク ⁞䡫㦮 ṫ☚⯒ ἶ⩺䞶 㑮 㧞☚⪳ 㔳(3)㠦 㦒⪲ 㩫㦮䞮㡖┺.

G

Fig.10 Schematic drawing of half blanking process and considered design parameters

YX_

material die , Y max .

material , die Y max Y

max , Y max , .



V V

V V V

V V V

if L

if L

R F O

S R H

F O

3

 u

u 3

Table 2 Design parameters and their levels of half blanking process

Level

Factor 1 2 3

A Offset (mm) 0.1 0.2 0.3 B Clearance (mm) -0.1 -0.2 -0.3 C Punch stroke(mm) 4.2 4.5 4.8

(3)

㡂₆㍲ LR,





⁞䡫㠦 㧧㣿䞮⓪ 㾲╖ 㥶䣾 㦧⩻㦚 㦮⹎䞲┺. ⳿ 㩗䞾㑮⓪ ⰳ㏢䔏㎇㧊Ⳇ, 㔳(3)㦚 㧊㣿䞶 ἓ㤆 ⪺㡺

⻚ ㈦Ⱒ 㞚┞⧒ ⁞䡫㠦 㧧㣿䞮⓪ 㦧⩻ ⡦䞲 㧧㦖 Ṩ㦚 Ṗ㰖⓪ ㍺Ἒ⼖㑮㦮 㫆䞿㦚 ㍶㩫䞶 㑮 㧞┺.

#

616# ⟊㘆✾∶㘞⇇# ൚ඦ# Ჹ# ඊⳚ

Table 3㠦 㥶䞲㣪㏢ 䟊㍳㦚 䐋䟊 㡞䁷♲ ⪺㡺⻚

䋂₆, ⁞䡫㦮 ṫ☚ ⹥ 㧊㠦 ➆⧒ Ἒ㌆♲ ⳿㩗䞾㑮 Ṩ㦚 ⋮䌖⌊㠞㦒Ⳇ Fig. 11㠦⓪ ⳿㩗䞾㑮㠦 ╖䞲

㍺Ἒ⼖㑮㦮 㡗䟻☚⯒ ⁎⧮䝚⪲ ⋮䌖⌊㠞┺.

Fig. 11(a)㠦㍲ 㞢 㑮 㧞❅㧊 䞮䝚な⨃䌏 ⁞䡫 㑮 ⳛ㠦 㡗䟻㦚 ⹎䂮⓪ 㧎㧦⓪ 㡺䝚㎡⨟, 䋊Ⰲ㠊⩆㓺 㧊Ⳇ, 㧊 Ṩ✺㧊 䋊㑮⪳ ⁞䡫㠦 㧧㣿䞮⓪ 㦧⩻㧊 㯳Ṗ䞮㡖┺. 㧊⓪ 㡺䝚㎡⨟㧊 䋂Ⳋ 㩚┾㥺ὓ₎㧊 Ṗ ₎㠊㰖Ⳇ 䋊Ⰲ㠊⩆㓺Ṗ 㦢㦒⪲ 䄺㰞㑮⪳ ㏢㨂 㦮 㞫㿫㦧⩻㧊 㯳Ṗ䞮㡂 ⁞䡫㠦 䋆 㦧⩻㦚 ⹲㌳

㔲䋺₆ ➢ⶎ㧊┺. Fig. 11(b)㠦㍲ ㏆㧊ク ⁞䡫 㑮ⳛ 㠦 Ṗ㧻 㡗䟻㦚 㭒⓪ 㧎㧦⓪ 㡺䝚㎡⨟㧚㦚 㞢 㑮 㧞⓪◆ 㡺䝚㎡⨟㧊 䋊㑮⪳ ㏆㧊ク Ὃ㩫㠦㍲㦮 Ṗ Ὃ⨟㧊 㯳Ṗ䞮₆ ➢ⶎ㧎 ộ㦒⪲ ㌂⬢♲┺. ⡦䞲 Fig. 11(c)㠦㍲ 㞢 㑮 㧞❅㧊 ⪲㠊䒂㓺 䂮䡫⿖㦮 ⪺ 㡺⻚ 䋂₆㠦 㡗䟻㦚 ⹎䂮⓪ ㍺Ἒ⼖㑮⓪ 㡺䝚㎡⨟

ὒ 䋊Ⰲ㠊⩆㓺㧊┺. 㡺䝚㎡⨟㦮 㯳Ṗ㠦 ➆⯎ 䂮䡫

⊳⿖㦮 ἷ⮶⹮ἓ 㯳Ṗ⪲ 㧎䟊 ⪺㡺⻚Ṗ Ṧ㏢䞮⓪ ộ㦒⪲ 䕦┾♮Ⳇ, 㦢㦮 䋊Ⰲ㠊⩆㓺㦮 㯳Ṗ⪲ 㧎䟊

㏢㨂Ṗ ⪺㡺⻚ 䁷㦒⪲ 㥶☯䞮⓪ ộ㧊 ἆὒ㩗㦒⪲

⪺㡺⻚㦮 㩖Ṧ㦚 Ṗ㪎 㡺⓪ ộ㦒⪲ ㌳ṗ♲┺.

䞲䘎, 㔳 (3)㠦 㦮䟊 Ἒ㌆♲ ⳿㩗䞾㑮㠦 ╖䞲 㡗 䟻☚ 䘟Ṗ⯒ Fig. 11(d)㠦 ⋮䌖⌊㠞┺. 㡂₆㍲ ⳿㩗 䞾㑮⯒ 㾲㏢䢪䞶 㑮 㧞⓪ ㍺Ἒ⼖㑮㦮 㫆䞿㦖 A2

Table 3 L

(3

) OA table and FE-analysis results of roll over, effective stress acting on the tools and objective function

max (MPa) No. A B C LR

(mm) H/B Shaving O.F

1 1 1 1 1.38 1,440 1,890 0.943 2 1 2 2 1.37 1,640 1,800 1.013 3 1 3 3 1.33 2,050 1,770 1.300 4 2 1 2 1.32 1,640 1,850 1.003 5 2 2 3 1.31 1,860 1,810 1.109 6 2 3 1 1.10 1,860 2,010 1.100 7 3 1 3 1.38 1,850 1,940 1.243 8 3 2 1 1.21 1,950 2,150 1.200 9 3 3 2 1.11 2,100 2,050 1.100

B₁C₂, 㯟 㡺䝚㎡⨟ 0.2mm, 䋊Ⰲ㠊⩆㓺 -0.1mm, 䗖 䂮 㓺䔎⪲䋂 4.5mm 㧊┺. 㧊 㫆Ị㦖 No. 4 㦮 㫆Ị ὒ ☯㧒䞮┺. 㧊 ➢㦮 ⁞䡫ṫ☚⓪ 䞮䝚な⨃䌏,

㏆㧊ク ṗṗ 1,640MPa, 1,850MPa ⪲ ⁞䡫㦮 䕢㏦

㠜㧊 ⪲㠊䒂㓺 ㌳㌆㧊 Ṗ⓻䞶 ộ㦒⪲ 䕦┾♲┺.

Fig. 12 㠦 A2B1C2㫆Ị 䞮㠦㍲㦮 ⁞䡫ṫ☚䟊㍳ ἆ ὒ⯒ ⋮䌖⌊㠞┺.

G

71# ᤆ♞㋖⍎# ⣆⠻# ⎎㚂#

㞴㠦㍲ 㩲㔲䞲 㾲㩗㫆Ị㦮 䟊㍳㦚 䐋䞮㡂 ⪺㡺

⻚ 㩖Ṧ ⹥ ⁞䡫䕢㏦㦮 㔶⬆㎇㦚 䢫⽊䞮₆ 㥚䞮 㡂 㔺䠮㦚 㑮䟟䞮㡖┺. Fig. 13㠦 䞮䝚な⨃䌏 ⹥ ㏆ 㧊ク 㔺䠮㦚 㥚䞲 ⁞䡫 ㎎䔎⯒ ⋮䌖⌊㠞┺.

Fig. 14㠦 㾲㩗㫆Ị 䞮㠦㍲㦮 㥶䞲㣪㏢䟊㍳ ἆὒ

⹥ 㧊㠦 ➆⧒ 㩲㧧♲ ⪲㠊䒂㓺⯒ ⋮䌖⌊㠞┺. ⁎ ἆὒ 㾲㩗㫆Ị㠦㍲㦮 ⪲㠊䒂㓺 䂮䡫⿖㠦㍲ ⹲㌳

䞲 ⪺㡺⻚⓪ 1.3mm⪲ ₆㫊㦮 䕢㧎な⨃䌏 Ὃ㩫㠦

㍲㦮 ⪺㡺⻚㧎 1.9mm㠦 ゚䟊 30% 㧊㌗ 㩖Ṧ䣾ὒ Ṗ 㧞⓪ ộ㦚 㞢 㑮 㧞┺. 㧊⓪ 䞮䝚な⨃䌏㠦㍲

⹲㌳䞲 ⪺㡺⻚㦮 ⊳┾⿖⯒ ㏆㧊ク ⁞䡫㠦 㦮䟊 㩞㌃䞶 㑮 㧞₆ ➢ⶎ㧊┺. 䞲䘎, 㥶䞲㣪㏢䟊㍳ ἆ ὒ㠦㍲☚ 㡞㌗♮❅㧊 Ὃ㩫 ⿚䞶㠦 ➆⯎ ⁞䡫 㦧

⩻ ⡦䞲 Ṧ㏢♮⸖⪲ 䕢㧎な⨃䌏 Ὃ㩫㠦 ゚ᾦ䞮㡂 䂮䞧 ⹲㌳㠦 ╖䞲 䞲Ἒ 㑮ⳛ㦚 ⓮Ⰺ 㑮 㧞㦚 ộ 㦒⪲ 䕦┾♲┺.

穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊V

YX`G

G (a) Effect on Max. effective stress acting on H/B tool (b) Effect on Max. effective stress acting on Shaving tool

(c) Effect on roll over (d) Effect on objective function Fig.11 Main effect plots of parameters level

Fig. 12 Effective stress distribution acting on the die

Fig.13 Experimental apparatus for half blanking and shaving of the lower tooth

Fig.14 FE-analysis result(a) and manufactured

lower tooth(b) under the determined process

condition

YYW

81# ൚# ᤊG

⽎ 㡆ῂ㠦㍲⓪ 䂮䡫㦚 Ṗ㰚 Ⰲ䋊⧒㧊⍞ ⿖䛞㧎

⪲㠊䒂㓺㦮 䕢㧎な⨃䌏 ㎇䡫 㔲, ⪺㡺⻚ 㩖Ṧὒ

☯㔲㠦 ⁞䡫 㑮ⳛ 䟻㌗㦚 㥚䞮㡂 䞮䝚な⨃䌏 ⹥

㏆㧊ク Ὃ㩫㦚 ☚㧛䞮㡖┺. 㥶䞲㣪㏢䟊㍳ ⹥ 䕢㧎 な⨃䌏 㔺䠮㦚 䐋䟊 ⪲㠊䒂㓺⯒ 㩲㫆䞲 ἆὒ, ┺ 㦢ὒ ṯ㦖 ἆ⪶㦚 㠑㠞┺.

(1) ぢ⪲䃃 Ὃ㩫㦚 ㌳⨋䞮₆ 㥚䟊 ⪲㠊䒂㓺㦮 㩚㼊 㥺ὓ㦚 1䣢 䕢㧎な⨃䌏Ⱒ㦒⪲ 㩲㫆䞮㡖㦚 ἓ㤆, 䂮䡫⿖㠦 1.9mm㦮 ὒ☚䞲 ⪺㡺⻚Ṗ ⹲㌳䞮 㡖㦒Ⳇ ⁞䡫㠦 䋆 㦧⩻㧊 㧧㣿䞮㡂 䂮䞧㧊 㓓Ợ 㧒㠊⌂┺.

(2) 䂮䡫⿖ ⪺㡺⻚ Ṧ㏢㢖 ⁞䡫㠦 㧧㣿䞮⓪ 㦧

⩻㦚 ⿚㌆㔲䋺₆ 㥚䞮㡂 䞮䝚な⨃䌏 ⹥ ㏆㧊ク Ὃ㩫㦚 ☚㧛䞮㡖┺. 㧊 ➢, 䞮䝚な⨃䌏 Ὃ㩫㦮 㭒 㣪 ㍺Ἒ⼖㑮⓪ 㡺䝚㎡⨟, 䋊Ⰲ㠊⩆㓺 ⹥ 䗖䂮 㓺 䔎⪲䋂⪲ ㍶㩫䞮㡖㦒Ⳇ, ⳿㩗䞾㑮⓪ ⪺㡺⻚㢖 䞮 䝚な⨃䌏 ⹥ ㎎㧊ク ⁞䡫㦮 ṫ☚⯒ ἶ⩺䞶 㑮 㧞

☚⪳ 㩫㦮䞮㡖┺.

(3) 䞮䝚な⨃䌏 Ὃ㩫 㾲㩗䢪⯒ 㥚䞮㡂 㔺䠮Ἒ䣣

⻫ ⹥ 㥶䞲㣪㏢䟊㍳㦚 㩗㣿䞮㡖㦒Ⳇ ⁞䡫㨂㦮 䟃

⽋ṫ☚ ⻪㥚 ⌊㠦㍲ Ṗ㧻 㧧㦖 ⪺㡺⻚⨟㦚 ⋮䌖

⌎ 䞮䝚な⨃䌏 Ὃ㩫 ⼖㑮⓪ 㡺䝚㎡ 0.2mm, 䋊Ⰲ 㠊⩆㓺 -0.1mm, 䗖䂮 㓺䔎⪲䋂 4.5mm㧊┺.

(4) ㍶㩫♲ 㫆Ị㠦 㦮䟊 ⪲㠊䒂㓺⯒ 㩲㫆䞲 ἆ ὒ, ⪺㡺⻚Ṗ ₆㫊㦮 1.9mm㠦㍲ 1.3mm⪲ 30% 㩖 Ṧ♮㠞㦒Ⳇ ⁞䡫 ṫ☚㩗㧎 䁷Ⳋ㠦㍲☚ 㤆㑮䞮┺

⓪ ộ㦚 㞢 㑮 㧞㠞┺.

㝮 ໚ G

⽎ 㡆ῂ⓪ 㰖㔳ἓ㩲⿖㢖 䞲ῃ㌆㠛₆㑶㨂┾㦮 㩚⨋₆㑶㧎⩻㟧㎇㌂㠛 ⹥ 2010⎚ 㩫⿖(ᾦ㥷ὒ䞯

₆㑶⿖)㦮 㨂㤦㦒⪲ 䞲ῃ㡆ῂ㨂┾㦮 㰖㤦㦚 ⹱㞚 㑮䟟♲ 㡆ῂ㧚(NRF-2009⎚-K20601000004-09E0100- 00410).

Ⳣ ඊ ᯢ 㙶

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穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊V

YYXG

G

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