A basic study on sheet metal forming method combined with joining process

为了通过金属板的常规深冲压来生产深杯，在一个或多个阶段中的再冲压和/或变薄拉深作为深冲压之后的后续操作是必要的。当这种多阶段成形应用于非常深的杯的小批量生产时，随着产品数量的减少，工具成本变得相对昂贵。为了便于小批量生产深杯形件，本研究开发了一种新的成形与连接工艺相结合的工艺。一个开发的空白，其周边切割就像花瓣，被用来代替传统的圆形坯料。这使得可以减小坯料的凸缘部分处的拉拔阻力。借助这种效应，可以在一次拉深操作中容易地生产出非常深的圆柱形、方形和锥形杯形件。然而，在所生产的杯子的侧壁处存在接缝，并且如何连接接缝是一个问题。为了连接接缝，采用了镶嵌金属制品和折叠或卷曲等机械缝合方法，并在杯的侧壁处同时进行拉深和接缝连接。重点考察了压边保持器和展开毛坯形状对连接部变形行为的影响，确定了合适的工作条件。还证实了板料成形工艺与连接工艺相结合可以用作便于小批量生产非常深的杯形件的方法。

In order to produce a deep cup by conventional deep drawing of sheet metal, redrawing and/or ironing in one or more stages are necessary as the subsequent operation after the deep drawing. When such multi-stage forming is applied to the small lot production of very deep cups, tool cost becomes relatively expensive as the number of product decreases. And also, the lead time to the production can not be shortened.To facilitate the small lot production of very deep cups, in this study, a new forming process combined with joining process has been developed. A developed blank, the periphery of which is cut just like petals, was used instead of a conventional circular blank. This makes it possible to reduce the drawing resistance at the flange portion of the blank. By the aid of this effect, very deep cylindrical, square and tapered cups were easily produced in one drawing operation. However, there exist seams at the side wall of the cup produced and how to join the seams is a problem. To join the seams, mechanical seaming methods such as inlaid metalwork and folding or curling were adopted, and deep drawing and joining of seams at the side wall of the cup was carried out simultaneously. The effect of shapes of blank holder and developed blank on deformation behavior of joining portions was mainly examined and suitable working conditions were clarified. It is also confirmed that the sheet metal forming process combined with joining process can be used as a method to facilitate small lot production of very deep cups.