200822985 九、發明說明： 【發明所屬之技術領域】 ^發明係有關於-種以金屬胚料進行角隅整緣成 法，係針對金屬杯狀胚料外圓角部，或孔 7圓㈣進行整緣，其主要於杯形胚料或孔 ===料板’以可動模具抱持作用端側 1角利用相對作用端面施力擠壓，而㈣隅部形成 【先前技術】 按，在進行金屬成形加工時，為了提升胚料的成 言降低成形負荷，模具的母模和沖頭肩部必須設 大的二角’因此成形後會在工件上留下圓角。使用較 較/具圓角雖，易於成形，且模具的應力集中現象 夕，但較大的模具圓角會增大工件的加工預留量， =響工件後續組裝加工的配合裕度；而使用較小 產：？雖然可以避免以上的缺點’但工件内的死金屬 區域較廣也較不利於塑性成形。 • •因此在金屬成形後再進行角隅整緣（edge 白，、可以使工件更接近「淨形」（net shape)， #二可以減少加工預留量；並且使工件達到「一體形」 他也1的二可以直接以緊密配合或旋牙方式來接合其 s 以鉚接或銲接等較困難的機械組裝法， 由多件組成的零件較會有尺寸安定性低， =衣後私誤差大、鬆脫、撓性較差的_點，以及 其所造成振動及噪音等缺點。 5 200822985 一般整緣成形雖然工件内的材料塑性流動量不 多，但由於加歷面積較大，因此負荷極易升高，尤其 在密閉鍛造的情況下，胚料充填模穴後負荷急遽升高 的情形更明顯，往往使模具產生較多的彈性變形，反 而使工件喪失應有的平坦精度，或者需要較大出力的 成形設備，造成加工的經濟性降低。如是根據現有的 金屬角隅整緣成形加工法，可分為針對外圓角與内圓 角整緣，此二種製程概述如下： (一） 外圓角整緣 請參閱第一圖所示，外圓角直化工法適用 於杯狀深引伸件的外圓角整緣，為了填滿工件 的外圓角隅部，必須先將工件（1)的底部稍做隆 起部（11)，再以沖頭下壓此杯狀深引伸工件（1) 的底部，而使材料離心流動至外圓角隅部充填 而形成直角，應用此加工法進行外圓角整緣 時，必須將工件0)底部稍做隆起部（11)，因此 多了一道預成形工程；此外，隆起部（11)之位 置以及隆起部（11)必須經過精算，否則會造成 角隅充填不足的缺陷，或者過度充填而造成模 具過多的彈性變形，且影響模具壽命及成品之 平坦度。 (二） 内圓角整緣 内圓角直化工法〔如第二圖所示〕，此工 法類似後向擠伸法，主要是以沖頭（21)和可動 模具（22)合模後，將胚料（2)壓入固定成形模仁 6 200822985 ⑽内’由於此成形模仁（23)設計為階梯推拔 狀，因此在沖頭（21)下壓時，凸緣前端胚料⑵ 隨著此行程下壓進入推拔模穴内，所受拘束力 也逐漸變大，而使胚料（2)膨脹並回填至底角處 亚填滿為直角。此沖頭（21)内徑倒一小圓角^ 在下壓過程中除了提供模具内部潤滑油積蓄， 並可防止因過度充填，造成模具彈性變形，影 響，具壽命及成品之平坦度。而應用此工法加 工日守，孔凸緣的前緣會有薄化的現象，若將階 梯推拔狀成形模仁（23)變更設計為階梯狀，雖 然可使端緣較平整，但必須特別注意胚料（2) 的尺寸管理，否則會造成角隅充填不足的缺 陷’或者因過度充填小圓角模穴，而造成上述 的模具產生過多彈性變形，且影響模具壽命及 成品之平坦度。 緣是，本發明人有鑑於此，秉持多年模具豐富專 業没计製造及實際研究開發之經驗，兹針對現有之結 構及其缺失予以研究改良，因此，欲改善上述缺點， 模具的設計必須減少加壓面積外，亦即所謂的鈑金材 料流動控制（fl〇w control forming 〇f Sheet metals) 觀念，另外便是以背壓裝置來有效抑制模穴充填後負 荷急遽升高的現象，如此，才能完全改善現有之所有 缺失者。 ° 【發明内容】 本發明係有關於一種以金屬胚料進行角隅整緣成 7 200822985 =方法，其係利用因引伸而產生有圓角之金屬胚料進 打胚料入模、模具合模及角隅整緣成形步驟，而 角，趨近淨形，其巾係設-背壓來拘絲料平板部: 同日守於金屬胚料作用端面貼抵一沖頭，以沖頭與可動 杈具緊貼後，再對金屬胚料作用端緣進行擠壓，迫使 在作用的胚料充填形成角隅。此金屬角隅整緣成开4 疋一個全新的模具設計概念，可以廣泛地應用於軸對 稱件的生產，對於國内日益嚴重的產業外移問題，此 金屬角隅整緣成形法可提昇製品精度和降低製造成 本，提供電子、電機、機械、汽、機、腳踏車業，尤 其是沖壓、鍛造及模具等傳統基礎產業提昇競爭力之 契機。 【實施方式】 而為令本發明之技術手段能夠更完整且清楚的揭 露，茲請一併參閱所附圖式及圖號，並詳細說明如下： 首先，請參閱第三〜五圖所示，係為本發明以金 屬胚料進行角隅整緣成形方法之製造流程及施工剖視 示意圖’該金屬胚料（3)進行角隅整緣之步驟為： A胚料入模〇〇):設一具有平板部（31)及引伸有圓角 (32)之金屬胚料（3)，先將金屬胚 料（3)置於模穴（4)内； B模具合模（20):該金屬胚料（3)之平板部（31)一側 對應固定模具（41 )，另一側設有 壓料塊（42)，於壓料塊（42)上具 有一背壓來拘束胚料（3)平板部 8 200822985 (31) ’同時於欲進行整緣之圓角 (32) 所對應之作用端（33)面貼抵 沖頭（43)，及側面設一限位的 可動模具（44); C角隅整緣成形⑽··以沖頭（43)與可動模具（44) 緊貼後，再對金屬胚料（3)作 用端（33)緣進行擠壓，迫使 在作用端（33)的胚料（3)充 填此直角模穴（4)而形成直 β & 角（34)者。 4苓閱第四圖所示，為金屬胚料（3)〔杯狀引伸件〕 之外圓角（32)整緣的成形示意圖，其作動方式如下： 先將杯狀胚料（3)置於模穴（4)内，再以背壓來拘 束杯狀胚料（3)底部，隨後以沖頭（43)與可動模具（44) 緊貼後，再對胚料（3)作用端（33)緣進行擠壓，迫使在 外圓角（32)部位的胚料（3)充填此直角模穴（4)，達成 =圓角（32)整緣之目的。由於沖頭（43)的加壓面積較 少，可以降低模具的彈性變形量，胚料（3)所成形之工 件平坦精度提升，也可以使用較小出力的成形設備， 因此加工的經濟性提升；在整個實際成形加工過程 中’此背壓可以有效防止密閉鍛造時，負荷急遽上升 所造成模具破裂的現象。 請參閱第五圖所示，為金屬胚料（3)〔孔凸緣件〕 内圓角（32)整緣的成形示意圖，此乃將孔凸緣成形後 的工件胚料（3)反轉，再將凸緣軸作用端（33)稍許擠回 200822985 以充填内圓角（32)，其作動方式如下·· 先將金屬胚料（3)〔孔凸緣件〕置於模穴（4)内， 再以背壓來拘束胚料（3)平板部（31)，隨後以沖頭（43) 與可動模具（44)〔可動銷〕緊貼後，再對孔凸緣軸作 用端（33)端緣進行擠壓，迫使在内圓角（32)部位的胚 料（3)充填此直角模穴（4)，達成角隅整緣成直角（34) 之目的。 請再參閱第六〜八圖所示，利用本發明一種以金 屬胚料進行角隅整緣成形方法而成形直角（34)的胚料 (3)型悲’包含有如第六圖所示之前向孔凸緣的殼件胚 料（3)、後向孔凸緣的殼件胚料（3)〔如第七圖所示〕， 及單向孔凸緣的板件胚料（3)〔如第八圖所示〕。 由上述可知’由於沖頭（43)加壓的端面較小，因 此負何也較小’而凸緣内圓角（32)充填完後〔如第五 ，所不〕’材料轉而離心向外流出，所遭遇的流動阻力 =小於外圓角（32)充填後〔如第四圖所示〕，材料向心 流入所，，逐漸加大的流動阻力，因此，平板部（31) 僅產生微1膨脹現象；也因為此緣故，凸緣内圓角（32) m需使用少量的背壓’即可達到整緣之目的，且 可避免杯底材料膨脹的問題點。 、iI之Λ知例或圖示並非限定本發明之結構樣態 ，尺寸’任何所屬技術領域中具有通常知識者之適當 k化，修飾’皆應視為不脫離本發明之專利範疇。 藉由上述可知’本發明之組成與使用實施說明相 較於-般現有加卫技術，我們可以知道以金屬胚料進 10 200822985 行角隅整緣成形方法，具有下列幾項優點，如下： 1. 本發明一種以金屬胚料進行角隅整緣成形方法，使 金屬胚料成形後再進行角隅整緣，可以使工件更接 近「淨形」，自然可以減少加工預留量；並且使工件 達到「一體形」化的目的，且可以大幅提升產品精 度和降低製造成本。 2. 於實施角隅整緣後，金屬胚料可以直接以緊密配合 或旋牙方式來接合其他軸件，無需以鉚接或銲接等 困難的機械組裝法，可避免由多重組件所造成之組 裝偏差、鬆脫、及撓性差的缺點，或日後運轉之振 動及噪音缺失。 3. 本發明一種以金屬胚料進行角隅整緣成形方法，利 用背壓可以有效防止密閉鍛造時，負荷急遽上升所 造成模具破裂的現象。 綜上所述，本發明實施例確能達到所預期之使用 功效，又其所揭露之具體構造，不僅未曾見諸於同類 產品中，亦未曾公開於申請前，誠已完全符合專利法 之規定與要求，爰依法提出發明專利之申請，懇請惠 予審查，並賜准專利，則實感德便。 11 200822985 【圖式簡單說明】 第一圖：現有之外圓角整緣技術示意圖 第二圖：現有之内圓角整緣技術示意圖 (左半部為成形前，右半部為成形後） 第三圖：本發明之之製造流程 第四圖：本發明之具外圓角胚料施工剖視示意圖 (左半部為成形前，右半部為成形後） 第五圖：本發明之具内圓角胚料施工剖視示意圖 (左半部為成形前，右半部為成形後） 第六圖：本發明之胚料態樣示意圖（一） 第七圖：本發明之胚料態樣示意圖（二） 第八圖··本發明之胚料態樣示意圖（三） 【主要元件符號說明】 <本發明> (10) 胚料入板 (20) 模具合模 (30) 角隅整緣成形 (3) 胚料 (31) 平板部 (32) 圓角 (33) 作用端 (34) 直角 (4) 模穴 (41) 固定模具 (42) 壓料塊 (43) 沖頭 (44) 可動模具 <現 有> (1) 工件 (11) 隆起部 (2) 胚料 (21) 沖頭 (22) 可動模具 (23) 模仁 12200822985 IX. Description of the invention: [Technical field to which the invention pertains] ^The invention relates to a method for forming a corner burr by a metal blank, which is for a metal cup-shaped blank fillet portion, or a hole 7 circle (four) The whole edge, which is mainly in the cup-shaped blank or hole === the material plate' is pressed by the opposite end face with the movable mold holding end side angle, and (4) the crotch portion is formed. [Prior Art] Press, proceed In the metal forming process, in order to improve the forming of the blank, the forming load is reduced, and the mold and the shoulder of the die must be provided with large dimples, so that the workpiece will leave rounded corners after forming. Although it is easier to form with more rounded corners, and the stress concentration of the mold is concentrated, the larger mold rounding will increase the machining allowance of the workpiece, and the matching margin of the subsequent assembly processing of the workpiece; Smaller production:? Although the above disadvantages can be avoided, the wide area of dead metal in the workpiece is also disadvantageous for plastic forming. • • Therefore, after the metal is formed, the corner edge is trimmed (edge white, which can make the workpiece closer to the net shape, #2 can reduce the processing allowance; and make the workpiece "integral". Also, the second one can directly join the s in a tight fit or a screwing manner to a difficult mechanical assembly method such as riveting or welding. The parts composed of multiple pieces have a lower dimensional stability, and the private error after the clothing is large and loose. Disadvantages of detachment and poor flexibility, as well as the vibration and noise caused by it. 5 200822985 Generally, although the plastic flow of the material in the workpiece is not large, the load is extremely easy to rise due to the large area of the calendar. Especially in the case of closed forging, the situation that the load is suddenly increased after filling the cavity is more obvious, and the mold is often more elastically deformed, which causes the workpiece to lose the flatness accuracy, or requires a larger output. Forming equipment, resulting in reduced economics of processing. If it is based on the existing metal corner rim forming method, it can be divided into the outer edge of the fillet and the fillet. The two processes are summarized as follows. : (1) The outer corner of the fillet is shown in the first figure. The rounded straight chemical method is applicable to the outer edge of the cup-shaped deep extension. In order to fill the top of the workpiece, it must first The bottom of the workpiece (1) is slightly raised (11), and then the bottom of the cup-shaped deep extension workpiece (1) is pressed by a punch, and the material is centrifugally flowed to fill the top of the fillet to form a right angle. When the machining method performs the rounded edge, the bottom of the workpiece 0) must be slightly raised (11), so a pre-forming project is added; in addition, the position of the ridge (11) and the ridge (11) must pass. Actuarial, otherwise it will cause defects in insufficient filling of the corners, or excessive filling will cause excessive elastic deformation of the mold, and affect the life of the mold and the flatness of the finished product. (2) The rounded corner of the fillet is straight chemical method (as shown in the second figure). This method is similar to the backward extrusion method, mainly after the punch (21) and the movable mold (22) are clamped. Pressing the blank (2) into the fixed forming die 6 200822985 (10) 'Because the forming die (23) is designed to be stepped up, when the punch (21) is pressed, the flange front end material (2) When this stroke is pressed into the push-pull cavity, the restraining force is gradually increased, and the blank (2) is expanded and backfilled to the bottom corner to fill the right angle. The inner diameter of the punch (21) is inverted and rounded. In addition, the lubricant is accumulated in the mold during the pressing process, and the mold is prevented from being elastically deformed, affected, and has a long life and flatness of the finished product due to overfilling. However, the application of this method to process the day-to-day, the leading edge of the hole flange will be thinned. If the step-pushing forming die (23) is changed into a step shape, although the edge can be flat, special attention must be paid to the embryo. The size management of the material (2), otherwise it will cause the defect of insufficient filling of the corners or the overfilling of the small rounded cavity, resulting in excessive elastic deformation of the above-mentioned mold, and affecting the life of the mold and the flatness of the finished product. Therefore, the present inventors have in view of this, and for many years, the experience of the mold-rich professional and the actual research and development experience, the existing structure and its lack of research and improvement, therefore, in order to improve the above shortcomings, the mold design must be reduced In addition to the pressure area, that is, the so-called "float control" 流动f Sheet metals concept, the back pressure device is used to effectively suppress the sudden increase in load after cavity filling, so that it can be completely Improve all existing missing ones. [Description of the Invention] The present invention relates to a method for forming a corner of a metal billet into a 7200822985= method, which uses a metal billet having rounded corners due to the extension to enter the mold and mold clamping. And the angle of the whole edge forming step, and the angle, approaching the net shape, the towel is set - back pressure to tie the silk flat part: the same day, the metal blank is applied to the end face to a punch, with a punch and a movable jaw After being closely attached, the edge of the metal billet is pressed to force the filling of the active material to form a corner. The metal corner is formed into a new mold design concept, which can be widely applied to the production of axisymmetric parts. For the increasingly serious industrial migration problem in China, this metal corner gusset forming method can improve Accuracy and lower manufacturing costs, providing opportunities for electronics, motors, machinery, steam, machinery, bicycles, especially traditional infrastructure industries such as stamping, forging and molds to enhance competitiveness. [Embodiment] In order to make the technical means of the present invention more complete and clear, please refer to the drawings and drawings, and explain in detail as follows: First, please refer to the third to fifth figures, The manufacturing process and the cross-sectional view of the construction method of the corner blank forming method for the metal blank of the present invention are as follows: 'The step of the metal blank (3) for cornering the whole edge is: A blank material into the mold): a metal blank (3) having a flat plate portion (31) and a rounded corner (32), first placing the metal blank (3) in the cavity (4); B mold clamping (20): the metal The flat portion (31) of the blank (3) corresponds to the fixed mold (41), the other side is provided with a pressing block (42), and the pressing block (42) has a back pressure to restrain the blank (3) ) flat plate portion 8 200822985 (31) 'At the same time, the working end (33) corresponding to the rounded corner (32) of the full edge is attached to the punch (43), and the movable mold (44) with a limit on the side is provided. C corner 隅 integral edge forming (10)·· After the punch (43) and the movable mold (44) are in close contact, the edge of the working end (33) of the metal blank (3) is pressed, forcing at the active end 33) of the billet (3) at right angles to this charge filled cavity (4) to form a linear β & angle (34) persons. 4 See the fourth figure, which is a schematic diagram of the forming of the outer edge of the rounded corner (32) of the metal blank (3) [cup extension]. The operation is as follows: First, the cup blank (3) is placed. In the cavity (4), the back of the cup-shaped blank (3) is restrained by back pressure, and then the punch (43) is pressed against the movable mold (44), and then the end of the blank (3) is applied ( 33) The edge is pressed to force the billet (3) at the outer rounded corner (32) to fill the right-angled cavity (4) to achieve the purpose of the rounded corner (32). Since the pressing area of the punch (43) is small, the amount of elastic deformation of the mold can be reduced, the flatness of the workpiece formed by the blank (3) can be improved, and the forming device with a smaller output can be used, so that the economical efficiency of the processing is improved. In the actual forming process, this back pressure can effectively prevent the mold from rupturing due to the sudden increase in load during the closed forging. Please refer to the fifth figure for the forming of the inner edge of the fillet (32) of the metal blank (3) [hole flange]. This is to reverse the workpiece blank (3) after forming the hole flange, and then convex The edge end (33) is slightly pushed back to 200822985 to fill the fillet (32). The action is as follows: · Place the metal blank (3) [hole flange] in the cavity (4), then back Pressing the blank (3) flat portion (31), and then pressing the punch (43) against the movable mold (44) (movable pin), and then pressing the end edge of the hole flange end (33). The billet (3) at the inner rounded corner (32) is forced to fill the right-angled cavity (4) to achieve a right angle (34). Referring to the sixth to eighth figures, the blank (3) type of the right angle (34) formed by the method of forming the corners by the metal blank is used to include the forward direction as shown in the sixth figure. Shell blank (3) of the hole flange, shell blank (3) of the rear hole flange (as shown in the seventh figure), and the blank of the unidirectional hole flange (3) [as shown in the eighth figure] . It can be seen from the above that 'the end face which is pressed by the punch (43) is small, so the weight is smaller. 'When the flange fillet (32) is filled (such as the fifth, no), the material is turned to the centrifugal direction. Outflow, the flow resistance encountered = less than the fillet (32) after filling [as shown in the fourth figure], the material flows into the center of the heart, and gradually increases the flow resistance, therefore, the flat portion (31) only produces Micro 1 expansion phenomenon; also for this reason, the flange fillet (32) m needs to use a small amount of back pressure 'to achieve the purpose of the whole edge, and can avoid the problem of the expansion of the cup bottom material. The exemplification or illustration of iI does not limit the structural form of the present invention, and any size or modification of the size of any one of ordinary skill in the art should be considered as not departing from the scope of the invention. From the above, it can be seen that the composition of the present invention and the implementation description are compared with the conventional reinforcement technology, and we can know that the metal billet into the 10 200822985 line corner rim forming method has the following advantages, as follows: The invention relates to a method for forming a corner burr by a metal blank, which is formed by forming a metal blank and then performing a corner gusset to make the workpiece closer to a "net shape", thereby naturally reducing the processing allowance; Achieve "integral shape", and can greatly improve product accuracy and reduce manufacturing costs. 2. After the corners are finished, the metal blanks can be directly joined to other shaft parts by tight fit or screwing, without the need for difficult mechanical assembly such as riveting or welding, which avoids assembly variations caused by multiple components. Disadvantages of looseness and poor flexibility, or lack of vibration and noise during future operation. 3. The present invention relates to a method for forming a corner burr by a metal blank, and the back pressure can effectively prevent the rupture of the mold caused by a sudden increase in load during the closed forging. In summary, the embodiments of the present invention can achieve the expected use efficiency, and the specific structure disclosed therein has not been seen in similar products, nor has it been disclosed before the application, and has completely complied with the provisions of the Patent Law. And the request, the application for the invention of a patent in accordance with the law, please forgive the review, and grant the patent, it is really sensible. 11 200822985 [Simple description of the diagram] The first picture: the schematic diagram of the existing outer rounded edge technology. The second picture shows the existing rounded edge technology (the left half is before forming and the right half is formed) Figure 3: Manufacturing Process of the Invention Figure 4: Schematic diagram of the construction of the rounded blank material of the present invention (the left half is before forming and the right half is formed). Figure 5: Inside the tool of the present invention Schematic diagram of the fillet blank material construction (the left half is before forming and the right half is formed). Figure 6: Schematic diagram of the billet of the present invention (I) Seventh: Schematic diagram of the billet of the present invention (2) Fig. 8: Schematic diagram of the blank material of the present invention (3) [Explanation of main component symbols] <Invention> (10) Blank material into the plate (20) Mold clamping (30) Angle adjustment Edge forming (3) Blank (31) Flat (32) Rounded corner (33) Active end (34) Right angle (4) Cavity (41) Fixed mold (42) Press block (43) Punch (44) Movable mold <existing > (1) workpiece (11) bulge (2) blank (21) punch (22) movable mold (23) mold core 12