JP2010179320A - Base stock to be worked and device for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a material to be worked which is improved in durability, and quality and a device for manufacturing the same. <P>SOLUTION: In the device for manufacturing the material to be worked in which a first corrugated shape is formed along a first direction on a thin plate and a second corrugated shape is formed along a second direction which is orthogonally crossed with the first direction, the device includes one-side gear roller member 51 and the other-side gear roller member 52 for applying corrugating work and the arrangement of gears is determined so as to bring the one-side gear roller member into contact with the thin plate at early timing when putting the thin plate between the gear roller members. The dimension C0 of the bottom clearance related to both gear roller members is determined larger than the predetermined reference distance related to expansion displacement by which the thin plate in the vicinity of the tip of the other-side gear roller member moves toward a root of tooth corresponding to the one-side gear roller member when the thin plate is corrugated. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to, for example, a processing material for producing covers used for the purpose of heat insulation, sound insulation, and vibration suppression for an object that generates heat and vibration, and an apparatus for manufacturing the same.

  An example of an object that generates such vibration is an internal combustion engine. Heat, noise, vibration, and the like are dissipated to the outside from an exhaust system such as an internal combustion engine body and an exhaust manifold (hereinafter abbreviated as exhaust manifold) connected to the internal combustion engine. Conventionally, various covers such as a heat insulator have been used for the vibration source in order to prevent a situation in which vibration is radiated from the vibration source such as the internal combustion engine body or the exhaust system to the outside. .

  FIG. 31 is a plan view of the heat shield panel 1 as the cover of the typical prior art described in Patent Document 1 below, and FIG. 32 is a cross-sectional view taken along the section line XX of FIG. is there. Hereinafter, the heat shield panel 1 will be described with reference to FIGS. 31 and 32.

  The heat shield panel 1 is attached to the exhaust manifold of the internal combustion engine and covers the exhaust manifold. Each ridge 2 of the heat shield panel 1 has a relatively wide wave crest. The height of the wave crest varies along the ridge 2 and has a crest 2a and a recess 2b. The crest of the ridge 2 is dented downwardly in the middle and low sled at the top 2a, but the crest is substantially flat in the recess 2b.

  The wave crest varies regularly along the ridge 2 and has a maximum width at the recess 2b and a minimum width at the top 2a. The narrowest point of the ridge 2 is located away from each other along a line extending perpendicular to the longitudinal direction of the ridge 2.

  Each groove 3 has a relatively wide bottom corresponding to the shape of the crest of the ridge 2. Thus, each bottom has a wide top 3a that is substantially flat in the transverse direction with respect to the length of each groove 3, and a narrow recess 3b that is sleded in the middle. In the longitudinal section in FIG. 25, the height of the groove bottom on the lower side of the sheet 4 changes in a sinusoidal shape along the groove 3. The width of the groove bottom changes regularly along the groove 3.

  The groove 3 has a side wall 5 of the groove 3 that is also a side wall of the ridge 2. These side walls 5 are inwardly curved, so that the grooves 3 are narrower at the opening between the crests of the ridge 2 than at their bottom. Each side wall 5 follows the undulation of the groove 3 and is joined to the crest of one ridge 2 and the bottom of one groove 3 at an angle of less than 90 degrees. The heat shield panel 1 has a rib rigidity due to its shape, and is more easily bent around the line extending in the transverse direction than the line extending in the longitudinal direction of the ridge 2.

Japanese Patent No. 3233364

  With respect to such a conventional heat shield panel and the method or apparatus for manufacturing the heat shield panel suggested in the second page of the above-mentioned Patent Document 1, the present inventor is useful for the heat shield panel and the method for manufacturing the same. From the basic recognition that it is, from the description of Patent Document 1 and the like, a reproduction experiment was conducted on the heat shield panel and its manufacturing method. This inventor came to obtain the following various knowledge by this reproduction experiment.

  As shown in FIG. 26, the conventional heat shield panel 1 as described above is formed with a folded portion 6 that is folded and crushed with a large curvature of nearly 180 degrees over the entire surface. . A large stress is generated in the folded portion 6, and a large number of pinholes are generated in the heat shield panel 1 in the corrugating process, and the pinholes are enlarged during a vibration experiment using a shaker or the like. It became clear that there was a problem with the durability of the heat shield panel 1, such as cracks and damage to the heat shield panel 1.

  Further, in the above prior art, when the heat shield panel 1 is manufactured using the manufacturing method and the manufacturing apparatus suggested in Patent Document 1, the top of the ridge 2 and the bottom of the groove 3 of the heat shield panel 1 are scraped. It was confirmed that damage such as crushing occurred. Thereby, it was confirmed that there is a problem in the quality of the manufactured heat shield panel 1.

  Moreover, it is assumed that the thermal insulation panel 1 is arrange | positioned so that the location used as the heat source of a vehicle other than an engine, an exhaust manifold, and a vibration source other than an engine may be covered. At this time, in response to the shape of the heat source, vibration source, etc., or in response to the maximum temperature of the generated heat and the temporal change of temperature, or the state of vibration, in addition to examining the appropriate three-dimensional shape of the heat shield panel itself, Naturally, it is assumed that a study on the corrugated shape itself, such as the size and pitch of the corrugated shape provided in the heat shield panel, or a material such as the thickness of the thin plate material constituting the heat shield panel 1 is necessary. Patent Document 1 neither discloses nor suggests any knowledge for determining such an appropriate corrugated shape. Therefore, the problem that there was no versatility regarding the manufacture of the heat shield panel 1 including the manufacturing apparatus and the degree of freedom in design was low was confirmed.

  In view of these points, the inventor of the present invention has developed a corrugating mechanism, a heat shielding function, and a damping mechanism for the purpose of improving durability and quality in the corrugated plate corrugated in the two intersecting directions. As a result of earnest research on the present invention, the present invention has been reached.

  The present invention has been made in order to solve the above-mentioned problems, and the object thereof is to provide a processing material with greatly improved durability and quality, and the degree of freedom in design is remarkably increased. It is to provide an improved processing material manufacturing apparatus.

  In the manufacturing apparatus for a processing material according to the first aspect of the present invention, a first corrugated shape in which valleys and ridges are alternately connected to each other and formed alternately in a first direction is formed on an elastically deformable thin plate material. And a manufacturing apparatus for a processing material in which a second corrugated portion and a raised portion are alternately connected to each other along a second direction intersecting the first direction. A first gear roller member and a second gear roller member that perform corrugation processing with the corrugated shape sandwiched between the thin plate materials, and the other gear roller when the thin plate material is sandwiched between the one gear roller member and the other gear roller member. The gear arrangement of the one gear roller member and the other gear roller member is determined so that the gear of the one gear roller member comes into contact with the thin plate material at an earlier timing than the gear of the member. The top dimension C0 regarding the two gear roller members when each gear meshes with the member is such that when the thin plate material is sandwiched between the two gear roller members and corrugated, the thin plate material near the tooth tip of the other gear roller member is one gear roller. It is characterized in that it is determined to be larger than a predetermined reference distance Lt relating to the extension displacement toward the corresponding tooth base of the member.

  According to a second aspect of the present invention, there is provided an apparatus for manufacturing a processing material according to the first aspect of the invention, wherein the first corrugated shape in which the valleys and the ridges are alternately connected to the elastically deformable thin plate material is the first. Production of a processing material in which a second corrugated shape is formed that is formed along a direction and alternately repeats a valley portion and a raised portion along a second direction intersecting the first direction. The apparatus is characterized in that the tooth shape of each gear roller member is set based on the size of each part of the processing material having the predetermined waveform shape.

  According to a third aspect of the present invention, there is provided the processing material according to the first aspect, wherein the first corrugated shape in which the valleys and the ridges are alternately connected to each other is formed along the first direction on the elastically deformable thin plate material, A processing material in which a second waveform shape is formed in which valleys and ridges are alternately connected to each other along a second direction intersecting with the first direction, wherein the first waveform shape and In the second corrugated shape, the folding portion where the thin plate is folded at an acute angle is provided with a crush prevention means between the folded thin plates so that the thin plate is folded at an angle larger than a predetermined limit angle. It is characterized by that.

  The processing material of the invention according to claim 4 is a thin plate material, a first corrugated shape in which a plurality of corrugated shapes each extending in a first direction, and a trough portion and a raised portion, A processing material having a second corrugated shape in which a plurality of corrugated shapes that are continuous in a second direction intersecting the first direction is formed, and each raised portion in the second corrugated shape has an acute angle from the trough. It includes a pair of side walls that stand up, and a top portion that connects between the pair of side walls.

  As described above, according to the first aspect of the invention, when the thin plate material is sandwiched between the one gear roller member and the other gear roller member, the timing of the gear of the one gear roller member is earlier than that of the gear of the other gear roller member. In contact with the thin plate material. Accordingly, when the other gear roller member is disposed on the lower side in the vertical direction than the one gear roller member, the thin plate material is bent toward the other gear roller member by its own weight, and further bent from above by the teeth of the one gear roller member. Accordingly, the thin plate material is smoothly guided between the two gear roller members, and is conveyed while being corrugated by the two gear roller members. This eliminates the need for delicate position adjustment by manual operation when the thin plate material is introduced into the manufacturing apparatus, and the degree of freedom in design is greatly improved.

  Further, the crest dimension C0 regarding the two gear roller members when the gears of the one gear roller member and the other gear roller member are engaged with each other is determined when the thin plate material is sandwiched between the two gear roller members and corrugated. The thin plate material in the vicinity of the tooth tip is set to be larger than a predetermined reference distance Lt relating to the extension displacement toward the corresponding tooth root of the one gear roller member.

  When processing is carried out with a thin plate material sandwiched between the one gear roller member and the other gear roller member, the contact point of the pair of teeth adjacent to the one gear roller member and the contact of the teeth of the other gear roller member between the pair of teeth When the thin plate material is bent at a point, the portion near the tooth tip of the other gear roller member of the thin plate material is extended and displaced toward the corresponding tooth base of the one gear roller member. And confirmed by measurement.

  If the extension displacement of the thin plate material is not sufficiently allowed between the one gear roller member and the other gear roller member, the extension displacement portion is crushed darkly between the two gear roller members, and the surface of the thin plate material is caused by the collapse. In addition, damage such as scratching and crushing occurs, causing problems in the quality of manufactured products.

  On the other hand, in the present invention, the crest dimension C0 relating to both gear roller members when the gears of the one gear roller member and the other gear roller member mesh with each other so that the extension part of the thin plate material can be sufficiently displaced is the extension. It is determined to be larger than a predetermined reference distance Lv related to the displacement. Thereby, it is allowed that the extension displacement part of the thin plate material which is extended and displaced is sufficiently extended and displaced toward the corresponding tooth base of the one gear roller member. Therefore, the occurrence of the damage to the thin plate material is prevented, and the quality of the manufactured product can be significantly improved.

  According to invention of Claim 2, in addition to the effect regarding said Claim 1, there exist the following effects. That is, when manufacturing various products using the processing material of the present invention, the corrugated shape adjustment is included in the conditions for adjusting the product characteristics corresponding to the various products. In the present invention, the tooth shape of each gear roller member is set based on the size of each part of the processed material to be manufactured.

  Therefore, when the shape and dimensions of each part of the processing material are determined according to the characteristics of the products corresponding to the various products, the tooth shape of each gear roller member is set according to the shape and size of each part of the processing material. Therefore, after all, the tooth shape of each gear roller member corresponding to the various products is set, and the degree of freedom in design is greatly improved.

  According to the third aspect of the invention, the crushing preventing means acts so that the thin plate material is folded at an angle larger than a predetermined limit angle at the folded portion. Therefore, it is possible to prevent the folded portion from being bent with a large curvature without darkness, that is, with a small radius of curvature without darkness, to prevent the occurrence of pinholes in the folded portion, and to suppress the occurrence of cracks and the like. The durability of the product can be significantly improved.

  According to invention of Claim 4, the boundary site | part between a trough part and a pair of side wall, and the boundary site | part between a pair of side wall and a top part comprise the said folding | turning part. In the present invention, by providing a crush prevention means at these boundary portions, it is possible to prevent the occurrence of pinholes at these boundary portions, and as described above, durability of a product manufactured from a processing material is improved. The sex can be greatly improved.

It is simplified sectional drawing which shows the structure of the manufacturing apparatus 50 in a present Example. FIG. 3 is a schematic diagram showing an entire manufacturing process using the manufacturing apparatus 50. It is sectional drawing which shows the process initial stage state of the manufacturing apparatus. It is a schematic diagram which shows the processing state of an initial stage of a process. It is a schematic diagram which shows the processing state of an initial stage of a process. It is sectional drawing explaining the 1st corrugation process of a present Example. It is a schematic diagram which shows the progress state of a 1st corrugation process. It is sectional drawing explaining a 2nd corrugate process. It is a front view of the state which mounted | wore the exhaust manifold 23 with the metal covers 21 of a present Example. It is sectional drawing seen from the cut surface line X10-X10 of FIG. 3 is an enlarged front view of a metal cover 21. FIG. It is sectional drawing seen from the cut surface line X12-X12 of FIG. It is sectional drawing seen from the cut surface line X13-X13 of FIG. It is sectional drawing seen from the cut surface line X14-X14 of FIG. FIG. 10 is a simplified cross-sectional view seen from the section line X15-X15 in FIG. 9; It is a figure explaining the characteristic of a present Example. It is a schematic diagram of the 1st angle state at the time of the 2nd corrugating process of a present Example. It is a schematic diagram of a 2nd angle state. It is a schematic diagram of a 3rd angle state. It is a graph of the experimental result based on a present Example. It is a graph which shows the detail of an experimental result. It is sectional drawing explaining the other characteristic of a present Example. It is a graph which shows the relationship between the bending angle and elongation rate of various board thickness of a present Example. It is a graph which shows the relationship between the plate | board thickness of a present Example, a bending angle, and elongation rate. It is a graph which shows the relationship between the bending angle at the time of the elongation rate of 40% in a present Example, and the thinnest part radius. It is a graph which shows the relationship between the elongation rate of a present Example, and a bending angle. It is a figure equivalent to FIG. 11 of 2nd Example of this invention. It is a figure equivalent to FIG. 12 of 2nd Example. It is a figure equivalent to FIG. 13 of 2nd Example. It is a figure equivalent to FIG. 14 of 2nd Example. It is a figure equivalent to FIG. 15 of 2nd Example. It is a figure equivalent to FIG. 16 of 2nd Example. This is the real example. It is sectional drawing of 3rd Example of this invention. It is sectional drawing of this 3rd Example. 1 is a plan view of a typical prior art heat shield panel 1. FIG. It is sectional drawing seen from the cut surface line X32-X32 of FIG.

  The present invention is described below with reference to examples. 1 to 26 show a first embodiment of the present invention. FIG. 1 is a simplified cross-sectional view showing a configuration of a manufacturing apparatus 50 in the present embodiment, FIG. 2 is a schematic view showing a manufacturing process using the manufacturing apparatus 50, and FIG. 3 shows a first corrugating process of the present embodiment. 4 is a schematic view showing the progress of the first corrugating process, FIG. 5 is a cross-sectional view showing the initial state of processing of the manufacturing apparatus 50, and FIG. FIG. 7 is a schematic view for explaining the features of the working action of this embodiment, FIG. 8 is a sectional view for explaining the second corrugating work, and FIG. 9 is a drawing for explaining the working action. 10 is a front view of the state in which the metal cover 21 is attached to the exhaust manifold 23, FIG. 10 is a cross-sectional view taken along the section line X10-X10 of FIG. 9, and FIG. 11 is an enlarged front view of the metal cover 21. Yes, FIG. 12 is a sectional view taken along the section line X12-X12 in FIG. 13 is a cross-sectional view taken along section line X13-X13 in FIG. 11, FIG. 14 is a cross-sectional view taken along section line X14-X14 in FIG. 11, and FIG. FIG. 16 is a simplified cross-sectional view seen from the cutting plane line X15-X15, FIG. 16 is a diagram for explaining the characteristics of the present embodiment, and FIG. 17 is a diagram illustrating a first angle state during the second corrugating process of the present embodiment. FIG. 18 is a schematic diagram of the second angle state, FIG. 19 is a schematic diagram of the third angle state, FIG. 20 is a graph of experimental results based on this example, and FIG. FIG. 22 is a cross-sectional view illustrating other characteristics of the present example, and FIG. 23 is a graph illustrating the relationship between the bending angle and elongation rate of various plate thicknesses of the present example. FIG. 24 is a graph showing the relationship between the plate thickness, bending angle, and elongation rate of this example. Is a graph showing the relationship between put elongation of 40% when the bending angle and the thinnest part radius to this embodiment, FIG. 26 is a graph showing the relationship between elongation and bending angle of the embodiment.

  Hereinafter, the outline of the metal cover 21 will be described with reference to FIGS. 9 and 10. An exhaust manifold (hereinafter referred to as an exhaust manifold) 23 of an internal combustion engine such as an automobile engine 22 passes, for example, combustion exhaust gas pulsating at a frequency of several thousand cycles per minute at a high temperature of 600 to 700 ° C. from the combustion chamber of the internal combustion engine. Therefore, the exhaust manifold 23 itself becomes a high-temperature heat source that generates high-temperature heat radiation, and vibration that dissipates noise caused by the explosion of fuel in the engine 22 and the movement of combustion exhaust gas in the exhaust manifold 23 to the outside. The source.

  In the present embodiment, in order to suppress such vibration from the exhaust manifold 23 as much as possible, a metal cover 21 having a configuration to be described later is installed in a manner covering the exhaust manifold 23. As shown in FIG. 10, the metal cover 21 of this embodiment is composed of a thin plate material 24 made of aluminum having a specific gravity of about 2.7 with a plate thickness of about 0.3 mm, and FIGS. 9, 10, and 15. As shown in FIG. 3, the three-dimensional shape is formed along the external shape of the exhaust manifold 23. The metal cover 21 includes a side wall T1 and a top T2 that connects the entire circumference of the end of the side wall T1. The side wall T1 and the top part T2 are connected at an obtuse angle θ.

  In the present embodiment, the thin plate member 24 is not limited in its kind as long as it is a material that can be elastically deformed. Aluminum foil or aluminum alloy foil, further aluminum plate or alloy thereof, further stainless steel, A thin plate material made of synthetic resins such as engineering plastics is included as a modification. However, considering the weight reduction of the metal cover 21 as described later, a thin plate material made of synthetic resin such as aluminum, its alloy, or engineering plastic is suitable.

  As an example, the thin plate member 24 used for the cover 21 of the present embodiment is formed from a single aluminum thin plate. As shown in FIGS. 9 to 16, the thin plate member 24 has a plurality of first corrugated shapes in which the ridges 27 and the valleys 28 are alternately connected to each other along the first direction A <b> 1. The corrugated portion 29 and the raised portion 31 are connected to each other along the second direction A2 that intersects the first direction A1, preferably in the direction orthogonal to the first direction A1, and has the second corrugated shape. A simple waveform shape 32 is formed. As shown in FIGS. 11 to 13, the raised portions 27 are alternately arranged with valleys 30 and raised portions 31 rising from the valleys 28 along the vertical direction of FIG. 11. Moreover, as for the said trough part 28, the flat part 33a and the recessed part 33b are alternately arranged as FIG.

  The trough 30 includes a pair of side walls 34 and 35 that rise from the trough 28 in a substantially trapezoidal shape, and a relatively flat top 38 that is formed by connecting the tips of the side walls 34 and 35 to each other. A one-cycle shape of the flat portion 33a is formed. The flat portion 33a is inwardly curved, and the top length L2 of the top portion 38 along the first direction A1 is longer than the opening length L10 along the first direction A1 of the base end portion of the flat portion 33a. It is done.

  On the other hand, the raised portion 31 is formed by a substantially rectangular thin plate member 24 being crushed by a predetermined amount in the width direction, and a pair of side walls 39 and 40 respectively rising from the flat portion 31a, and the side walls 39 and 40. The distal ends are connected to each other, and a concave recess 43 is formed on the lower side of FIG. Each of the raised portions 31 and the flat portions 31 a is formed so as to be intermittently connected along the first direction A <b> 1 in which the plurality of waveform shapes 29 extend.

  Further, the raised portion 31 is inwardly curved, and the apex length L12 along the first direction A1 of the raised portion 31 is longer than the opening length L11 along the first direction A1 of the proximal end portion of the raised portion 31. It is determined as follows. Further, the side walls 34 and 35 and the side walls 39 and 40 have a corrugated shape 29 along at least one of the first direction A1 and the second direction A2, and the thin plate member 24 is folded over the thin plate member 4 itself. A folded stack 55 is configured.

  In the metal cover 21 of the present embodiment, as an example of the dimensions of each part, as shown in FIGS. 12 and 13, the length L1 of one cycle of the waveform 29 along the first direction A1, the top of the flat portion 33a The length L2 of 38 and the length L3 of the top 43 of the raised portion 31 are selected to be 11 mm, 7 mm, and 5 mm, respectively. Accordingly, the opening length L10 is selected to be smaller than 7 mm, and the opening length L11 is selected to be smaller than 5 mm.

  Of course, the technical scope of the present invention is not limited to such dimension examples, and the dimensions and the like are appropriately selected according to the required specifications of the metal cover 21 in which the invention is implemented. . The metal cover 21 has such a shape, and is formed by pressing the thin plate material 24 into a three-dimensional shape along the outer shape of the exhaust manifold 23.

  Hereinafter, with reference to FIG. 16, one of the features of the metal cover 21 of the present embodiment will be described. Since the metal cover 21 of the present embodiment is formed into a three-dimensional shape along the three-dimensional appearance of the exhaust manifold 23 as described above, the metal cover 21 is thin as shown in FIGS. One or a plurality of ridge line corresponding portions 46 which are bent portions and ridge portions of the plate material 24 are formed. In the present embodiment, the thin plate member 24 is arranged such that the first direction A1 which is the longitudinal direction of the corrugated shape 29 is a direction intersecting a main ridge line equivalent portion 46 described later among the plurality of ridge line equivalent portions 46. Is pressed into a three-dimensional shape.

  Here, the main ridge line equivalent portion 46 is a bent portion where a relatively large curvature characterizing the overall shape of the metal cover 21 continues. That is, among the various large and small bent portions formed on the metal cover 21, the bent portion extending over a relatively long length that substantially determines the external shape of the metal cover 21 is indicated.

  When the metal cover 21 is attached to the exhaust manifold 23, the metal cover 21 is also vibrated by transmission of vibration from the exhaust manifold 23. When the metal cover 21 vibrates due to this vibration, the metal cover 21 vibrates so that the portions of the metal cover 21 on both sides of the main ridge line corresponding portion 46 flutter. If such vibration is left unattended, a portion near the ridge line corresponding portion 46 of the metal cover 21 is likely to be cracked due to metal fatigue due to repeated bending.

  On the other hand, in the present embodiment, the direction in which the first direction A1 of the plurality of corrugated shapes 29 formed on the metal cover 21 intersects the main ridge line equivalent portion 46, preferably the direction orthogonal to each other. Therefore, the corrugated shape 29 realizes the action of the rib against the vibration centered on the ridge line corresponding portion 46. Thereby, the vibration of the metal cover 21 can be suppressed, the occurrence of cracks in the metal cover 21 can be prevented, and the quality of the metal cover 21 can be significantly improved.

  Furthermore, with respect to the vibration generated along the extending direction of the ridge line corresponding portion 46 described above, it is shown in FIGS. 11 to 13 that intermittently extend along the second direction A2 and continue along the first direction A1. The raised portion 27 also realizes the function of a rib and suppresses vibration.

  Further, in this embodiment, as shown in FIG. 15, a flange 47 is formed on at least a part of the outer peripheral portion of the metal cover 21. As a result, when the metal cover 21 vibrates, the flange 47 realizes the function of a rib, the amplitude of vibration of the metal cover 21 can be reduced, and the occurrence of cracks in the metal cover 21 is suppressed. be able to.

  As described above, according to the present embodiment, the metal cover 21 is formed by forming the thin plate material 24 into a three-dimensional shape, and the plurality of corrugated shapes 29 formed on the thin plate material 24 are raised. A portion 27 and a valley portion 28 are formed continuously along the first direction A1, and the height of each raised portion 7 is periodically changed along the longitudinal direction, that is, the first direction A1. Further, the first direction A1 is defined in a direction orthogonal to the main ridge line corresponding portion 30 of the metal cover 21 forming a three-dimensional shape.

  Therefore, the corrugated shape 9 realizes the action of the ribs against the vibrations on both sides of the main ridge line equivalent part 30. As a result, the vibration from the exhaust manifold 3 prevents the metal cover 21 from vibrating such that the portions of the metal cover 21 on both sides of the main ridge line corresponding portion 30 flutter, and the metal cover 21. This prevents a situation in which the portion near the ridge line corresponding portion 30 is prone to metal fatigue due to repeated bending and is likely to generate cracks.

  Thereby, the vibration of the metal cover 21 of this embodiment can be suppressed, the occurrence of cracks in the metal cover 21 can be prevented, and the quality of the metal cover 21 can be significantly improved.

  Hereinafter, the configuration of the manufacturing apparatus 50 of the present embodiment and the manufacturing method using the manufacturing apparatus 50 will be described with reference to FIGS. As shown in FIGS. 11 to 14, the manufacturing apparatus 50 performs corrugation processing along the directions A <b> 1 and A <b> 2 that intersect each other in the metal cover 21 described above. That is, in this embodiment, the manufacturing apparatus 50 manufactures a corrugated plate 24a that is a processing material from a thin plate material 24 such as a flat aluminum plate or aluminum foil. At this time, the plate thickness t0 of the thin plate material 24 takes into consideration the shape of the metal cover 21 and the required sound absorption characteristics from a plurality of options such as 0.125 mm, 0.3 mm, and 0.5 mm as an example. As will be described later.

  The manufacturing apparatus 50 includes gear rollers 51 and 52 as a basic configuration. As an example, the shape of each tooth part 51a, 52a and valley part 51b, 52b of each gear roller 51, 52 may be an involute gear shape, but is not limited thereto.

  In the drawings of the present embodiment, only the gear rollers 51 and 52 which are the main points of the present invention are shown for the sake of simplification. However, in an actual apparatus, the frames supporting the gear rollers 51 and 52 and the gaps between the gear rollers 51 and 52 are described. Naturally, parts such as a pressure adjustment mechanism including a spring for adjusting the elastic pressure on the thin plate member 24 by adjusting the interval of the thin plate member 24 and a drive mechanism including a motor, a power transmission gear train and the like are equipped. Is.

  As shown in FIGS. 1 to 5, in the manufacturing apparatus 50, when the thin plate member 24 is sandwiched between the gear roller 51 and the gear roller 52, the teeth 52 a of the gear roller 52 are more than the teeth 51 a of the gear roller 51. The arrangement of the gear rollers 51 and 52 is determined so as to contact the thin plate material 24 at an early timing. Specifically, the manufacturing apparatus 50 is configured as described below with reference to FIGS.

  In this embodiment, as shown in FIGS. 1 to 5, the thin plate member 24 is substantially perpendicular to an imaginary line connecting the rotation centers of the gear rollers 51 and 52 and is intermediate between the rotation centers of the gear rollers 51 and 52. The manufacturing apparatus 50 of the present embodiment is configured to be guided toward the position and proceed along the traveling direction B3.

  At this time, the thin plate member 24 bends a little toward the gear roller 52 by its own weight, and as shown in FIGS. 3 and 4, the positions of the gear rollers 51 and 52 and the teeth 51 a and 52 a of the gear rollers 51 and 52. A phase is defined. Thereby, the thin plate material 24 advances along the traveling direction B <b> 3 while being in contact with the teeth 52 a of the gear roller 52.

  As shown in FIGS. 1 to 5, in this embodiment, the top dimension C <b> 0 of the gear rollers 51 and 52 is determined to be larger than a predetermined reference distance Lt related to the extension displacement of the thin plate member 24. The reference distance Lt is set so that the thin plate material 24 near the tooth tip of the gear roller 52 has a corresponding tooth root of the gear roller 51 when the thin plate material 24 is sandwiched between the gear rollers 51 and 52 and corrugated as will be described later. It is chosen to be about the maximum value of the extensional displacement.

  Various dimensions such as the corrugated period and the folding length of the corrugated shape attached to the metal cover 21 described in FIG. 9 and subsequent figures can be appropriately set by setting the tooth dimensions in the gear rollers 51 and 52. This is because the desired design value is determined by appropriately setting the tooth dimensions in the gear rollers 51 and 52 with respect to the desired design values such as the shape, damping characteristics, and sound absorption characteristics of the metal cover 21. The metal cover 21 having this can be realized.

  In the present embodiment, as shown in FIGS. 3 and 4, the period of the corrugated shape first applied to the flat sheet material 24 is equal to the period of the teeth 51 a and 52 a of the gear rollers 51 and 52. Further, the height H1 of the corrugated shape 9 shown in FIG. 8 is about the tooth height of the gear rollers 51 and 52.

  Accordingly, when the gear roller 52 is disposed on the lower side in the vertical direction than the gear roller 51, the thin plate material 24 is bent toward the gear roller 52 by its own weight, and is further bent by the teeth of the gear roller 51 from above. Further, the thin plate member 24 is smoothly guided between the two gear rollers 51 and 52 and is conveyed while being corrugated by the two gear rollers 51 and 52. This eliminates the need for delicate position adjustment by manual work when the thin plate member 24 is introduced into the manufacturing apparatus 50, and the degree of freedom in design is greatly improved.

  In addition, the top dimension of the gear rollers 51 and 52 when the gears of the gear roller 51 and the gear roller 52 mesh with each other is determined to be larger than a predetermined reference distance.

  In the present embodiment, one of the most important technical matters is that the top dimension of the gear rollers 51 and 52 is selected to be larger than a predetermined reference distance. That is, the top dimension when the gears of the gear roller 51 and the gear roller 52 mesh with each other is determined to be larger than a predetermined reference distance.

The inventor has conducted many experiments and numerical analyzes on the meshing phenomenon and the behavior of the metal plate at that time. One example will be described below. The present inventor approximated the position of each part of the corrugated shape in one cycle at the time of the first corrugating process shown in FIGS. 3 and 4 with the function of the first formula with respect to the side surface portion and the top portion of the corrugated shape. The shape of the half cycle at this time was approximated by the second equation.

Moreover, the shape in case the bending angle with respect to the top part of the corrugated side part at the time of the second corrugating process shown in FIG. 8 is an obtuse angle and is not greatly bent is approximated by the third to fifth expressions.

The shape in the case where the bending angle with respect to the top of the corrugated side surface portion in the second corrugating process shown in FIG. 8 is a right angle is approximated by the sixth to eighth equations.

Moreover, the shape in case the bending angle with respect to the top part of the corrugated side surface part at the time of the second corrugating process shown in FIG.

  The approximation results by these equations are shown in FIGS. 17 to 19, respectively, and it was confirmed that there is a good approximation relationship with the actual corrugated shape and the change of the metal plate in the manufacturing process.

  When the thin plate member 24 is sandwiched between the gear roller 51 and the gear roller 52, the contact of the pair of teeth 51a adjacent to the gear roller 51 and the contact of the teeth 52a of the gear roller 52 between the pair of teeth 51a are performed. It is confirmed that when the thin plate member 24 is bent, a portion of the thin plate member 24 between the pair of teeth 52a of the gear roller 52 is extended and extended toward the gear roller 51 side. ing.

  When the extension displacement of the thin plate member 24 is not allowed between the gear roller 51 and the gear roller 52, the portion where the extension is displaced is crushed darkly between the gear rollers 51 and 52, and the surface of the thin plate member 24 is caused by the collapse. In addition, damage such as scratching and crushing occurs, causing problems in the quality of manufactured products.

  On the other hand, in the present invention, the crest dimensions of the gear roller 51 and the gear roller 52 are determined to be larger than a predetermined reference distance so that the elongated portion of the thin plate member 24 can be sufficiently displaced. Thereby, generation | occurrence | production of the said damage with respect to the thin board | plate material 24 is prevented, and the quality of the product manufactured can be improved markedly.

Furthermore, the manufacturing apparatus 50 of the present embodiment, as shown in the measurement data of each table of FIGS. 20 to 26 and each table of Tables 1 to 13, of the processing material 24 having the predetermined waveform shape. Based on each part dimension, the tooth shape of each gear roller part 51 and 52 material is set.

  Thereby, when manufacturing various products using the thin plate material 24 of the present embodiment, adjustment of the corrugated shape is included in the conditions for adjusting the characteristics of the products corresponding to the various products. In the present invention, the tooth shape of each gear roller 51, 52 is set based on the size of each part of the processing material to be manufactured.

  Accordingly, when the shape and dimensions of each part of the thin plate material 24 are determined in accordance with the characteristics of the products corresponding to the various products, the tooth shapes of the gear rollers 51 and 52 corresponding to the shape and size of each part of the thin plate material 24. As a result, the tooth shape of each of the gear rollers 51 and 52 corresponding to the various products is set, and the degree of freedom in design is greatly improved.

  Moreover, according to each figure of FIGS. 17-21 mentioned above and each table | surface of Table 1-Table 13, when manufacturing the thin plate material 24 of a present Example, it synthesize | combines to the site | part equivalent to the said laminated part 55 at least. A crushing prevention means such as a resin film or a metal thin film is provided.

  Thereby, the crushing prevention means causes the thin plate member 24 to be folded back at an angle larger than a predetermined limit angle in the laminated portion 55. Accordingly, it is possible to prevent the laminated portion 55 from being bent with a large curvature without darkness, to prevent the occurrence of pinholes in the laminated portion 55, to suppress the occurrence of cracks, etc. Durability can be significantly improved.

  Further, the present invention is not limited to the above-described embodiment, and can also be implemented in a configuration in which the side wall of the corrugate as shown in FIGS. Further, as shown in FIGS. 34 and 35, the double structure of the embodiment may be adopted.

DESCRIPTION OF SYMBOLS 1 Metal cover 3 Exhaust manifold 4, 5 Metal plate 7, 7a Raised part 8, 8a Valley part 9, 9a, 9b Corrugated shape 10 1st standing part 11 2nd standing part 13 Recessed part 21 Metal cover 23 Exhaust manifold 24 Thin plate material 28 Flange 30 Major ridge line equivalent part 31 Bolt A1 1st direction A2 2nd direction

Claims (4)

In the thin plate material that can be elastically deformed, a first corrugated shape in which valleys and ridges are alternately connected to each other is formed along the first direction, and along the second direction intersecting the first direction. , A manufacturing apparatus for a processing material in which a second corrugated shape in which valleys and ridges are alternately connected to each other is formed,
Including one gear roller member and the other gear roller member that perform corrugation processing with the corrugated shape sandwiched between thin plate materials,
When the thin plate material is sandwiched between the one gear roller member and the other gear roller member, the one gear roller member and the other gear member are brought into contact with the thin plate material at an earlier timing than the gear of the other gear roller member. The arrangement of the gear with the gear roller member is determined,
The crest dimension C0 relating to the two gear roller members when the gears of the one gear roller member and the other gear roller member are engaged with each other is such that when the thin plate material is sandwiched between the two gear roller members and corrugated, An apparatus for manufacturing a processing material, wherein a nearby thin plate material is set to be larger than a predetermined reference distance Lt related to an extension displacement toward a corresponding tooth base of a one-gear roller member. In the thin plate material that can be elastically deformed, a first corrugated shape in which valleys and ridges are alternately connected to each other is formed along the first direction, and along the second direction intersecting the first direction. , A manufacturing apparatus for a processing material in which a second corrugated shape in which valleys and ridges are alternately connected to each other is formed,
2. The processing material manufacturing apparatus according to claim 1, wherein a tooth shape of each gear roller member is set based on each dimension of the processing material having the predetermined waveform shape. In the thin plate material that can be elastically deformed, a first corrugated shape in which valleys and ridges are alternately connected to each other is formed along the first direction, and along the second direction intersecting the first direction. The processing material is formed with a second corrugated shape in which valleys and ridges are alternately connected to each other,
In the first corrugated shape and the second corrugated shape, the folded portion where the thin plate material is folded at an acute angle is provided with a crush prevention means between the folded thin plate materials, and the thin plate material has an angle larger than a predetermined limit angle. A processing material characterized by being folded at A first corrugated shape in which a plurality of corrugated shapes each having a valley portion and a raised portion extending in a first direction are connected to the thin plate material, and a second direction in which the valley portion and the raised portion intersect the first direction. A processing material having a second waveform shape including a plurality of waveform shapes connected to
Each raised portion in the second corrugated shape includes a pair of side walls rising at an acute angle from the valley, and a top portion connecting the pair of side walls.

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