Method for manufacturing metal components for faucets and apparatus for manufacturing metal components for faucets

Abstract

This invention provides a method for manufacturing metal components for faucets and an apparatus for manufacturing metal components for faucets that can achieve sharp design while improving dimensional accuracy. [Solution] The manufacturing method for a metal member for a faucet according to the embodiment includes an installation step, a shaping step, and a forming step. In the installation step, a metal workpiece having a flat portion and a wall portion is placed in a first mold such that the inside of the flat portion and the inside of the wall portion are in contact. In the shaping step, with the second mold set in the direction in which the wall portion extends, a third mold set in a position opposite the second mold presses the workpiece, causing the second mold to shape the wall portion. In the forming step, the leading edge of the wall portion comes into contact with a pressure surface provided in the second mold by the pressing of the third mold, and the pressing of the third mold is continued after contact, so that the leading edge is pressed from the pressure surface, causing a part of the workpiece material to plastically flow to fill the gap formed between the second mold, the third mold and the workpiece, thereby forming the R portion.

Description

Technical Field

[0001] The disclosed embodiments relate to a method for manufacturing a metal member for a faucet and a manufacturing apparatus for a metal member for a faucet.

Background Art

[0002] Conventionally, various techniques related to a method for manufacturing a metal member have been proposed (see, for example, Patent Document 1). In the prior art, for a metal workpiece having a flange with a curved end, the flange is pressed to increase the thickness of the R portion of the flange for forming.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, with only the pressing of the flange as in the prior art, the dimensions of the formed parts are difficult to be stabilized, and there is room for improvement in terms of improving dimensional accuracy. In recent years, in a metal member for a faucet, a sharp design with a relatively small radius of curvature for the R portion has sometimes been required.

[0005] One aspect of the embodiment aims to provide a method for manufacturing a metal member for a faucet and a manufacturing apparatus for a metal member for a faucet that can obtain a sharp design while improving dimensional accuracy.

Means for Solving the Problems

[0006] A method for manufacturing a metal member for a faucet according to one embodiment includes an installation step, a shaping step, and a forming step. In the installation step, a metal workpiece having a flat portion and a wall portion extending vertically from the end of the flat portion is placed in a first mold such that the inside of the flat portion and the inside of the wall portion are in contact. In the shaping step, a second mold having a space through which the first mold is inserted, and the inner circumference of the space being smaller than the outer circumference of the workpiece placed in the first mold, is set in the direction in which the wall portion extends, and a third mold set opposite the second mold presses the workpiece placed in the first mold, thereby shaping the wall portion of the second mold. In the molding process, the tip surface of the wall portion comes into contact with a pressure surface provided on the second mold by pressing the third mold, and the pressing of the third mold is continued even after the tip surface comes into contact with the pressure surface, thereby pressing the tip surface against the pressure surface, causing a portion of the workpiece material to plastically flow to fill the gap formed between the second mold, the third mold and the workpiece, and forming an R portion that connects the flat portion and the wall portion.

[0007] In this way, the ironing process, which involves ironing the wall portion of the workpiece, and the forming process, which involves plastically flowing a portion of the workpiece material to form (increase the thickness of) the R portion, are performed in succession. This makes it possible to stabilize the dimensions in the width direction of the formed workpiece wall portion and improve dimensional accuracy, as well as to obtain a sharp design with a relatively small radius of curvature in the R portion.

[0008] Furthermore, the length of the inner wall portion of the second mold is longer than the length of the wall portion.

[0009] This ensures the formation of a gap between the second mold, the third mold, and the workpiece, where plastic flow can occur. In other words, if the length of the inner wall of the second mold is shorter than the length of the wall, there will be areas that are left open in the aforementioned gap, and there is a risk that the desired position (R section) cannot be properly thickened by plastic flow. In contrast, by configuring the length of the inner wall of the second mold to be longer than the length of the wall, the aforementioned gap can be reliably formed, and as a result, the desired position (R section) can be properly thickened by plastic flow.

[0010] Furthermore, in the third mold, the radius of curvature of the corner portion that forms the gap is smaller than the radius of curvature of the R portion of the workpiece.

[0011] Thus, since the radius of curvature of the corner of the third mold is smaller than the radius of curvature of the R portion of the workpiece, it becomes possible to make the corner of the third mold a right angle or a nearly right angle. As a result, in the gap where plastic flow occurs, it becomes less likely that extra gaps that do not constitute the R portion of the workpiece will be formed, that is, it becomes less likely that plastic flow will occur to fill the extra gaps, and thus the desired position (R portion) of the workpiece can be increased in thickness more appropriately.

[0012] The manufacturing apparatus for metal components for faucets also comprises a first mold, a second mold, and a third mold. The first mold is fitted with a metal workpiece having a flat portion and a wall portion extending vertically from the end of the flat portion, such that the inside of the flat portion and the inside of the wall portion are in contact. The second mold has a space through which the first mold is inserted, and the inner circumference of the space is smaller than the outer circumference of the workpiece fitted with the first mold. The third mold is set in a position opposite to the second mold. The manufacturing apparatus also performs ironing of the wall portion of the second mold by pressing the workpiece fitted with the first mold using the third mold while the second mold is set in the direction in which the wall portion extends. Furthermore, the manufacturing apparatus causes the tip surface of the wall portion to come into contact with a pressure surface provided on the second mold by the pressing of the third mold, and continues pressing of the third mold even after the tip surface has come into contact with the pressure surface, thereby causing a portion of the workpiece material to plastically flow to fill the gap formed between the second mold, the third mold and the workpiece, and forming an R portion that connects the flat portion and the wall portion.

[0013] In this way, the process of ironing the wall of the workpiece and then using plastic flow to form the R-shaped section (increase the thickness) by partially moving the workpiece material is carried out in a continuous manner. This makes it possible to stabilize the dimensions in the width direction of the formed workpiece wall and improve dimensional accuracy, as well as to obtain a sharp design with a relatively small radius of curvature in the R-shaped section. [Effects of the Invention]

[0014] According to one embodiment, a metal component for a faucet can be made to have a sharp design while improving dimensional accuracy. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is a side view showing a faucet device in which a metal component for a faucet according to the embodiment is used. [Figure 2]FIG. 2 is a bottom view of a faucet device in which the metal member for a faucet according to the embodiment is used. [Figure 3] FIG. 3 is a cross-sectional view taken along line III-III of FIG. 2. [Figure 4] FIG. 4 is a cross-sectional view showing a workpiece before the manufacturing method according to the embodiment is applied. [Figure 5] FIG. 5 is a flowchart for explaining the manufacturing process of the metal member for a faucet according to the embodiment. [Figure 6] FIG. 6 is a cross-sectional view for explaining the manufacturing apparatus of the metal member for a faucet according to the embodiment. [Figure 7] FIG. 7 is a cross-sectional view for explaining the manufacturing method by the manufacturing apparatus of the metal member for a faucet. [Figure 8] FIG. 8 is a cross-sectional view for explaining the manufacturing method by the manufacturing apparatus of the metal member for a faucet. [Figure 9] FIG. 9 is a cross-sectional view showing an enlarged view of the vicinity of the void.

Embodiments for Carrying Out the Invention

[0016] Hereinafter, embodiments of a method for manufacturing a metal member for a faucet and a manufacturing apparatus for a metal member for a faucet disclosed in the present application will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited by the embodiments shown below.

[0017] First, a faucet device in which the metal member for a faucet according to the embodiment is used will be described with reference to FIGS. 1 and 2. FIG. 1 is a side view showing a faucet device 100 in which the metal member for a faucet according to the embodiment is used. FIG. 2 is a bottom view of a faucet device in which the metal member for a faucet according to the embodiment is used. Note that FIGS. 1, 2, and FIGS. 3 and later are all schematic diagrams.

[0018] As shown in FIGS. 1 and 2, the faucet device 100 is a shower device, specifically an overhead shower device. The faucet device 100 is arranged above a bathroom (not shown) and discharges water. Note that the faucet device 100 is not limited to a shower device, and may be other types of faucet devices such as a washbasin faucet or a kitchen faucet. Also, in this specification, "water" is described to include heated hot water.

[0019] Specifically, the faucet device 100 includes a water supply part 110, a mounting part 120, and a water spraying part (water spraying plate) 200. The water supply part 110 is connected to a water supply source (not shown) and is a flow path through which water from the water supply source is supplied. Note that the water supply source includes, but is not limited to, a water pipe, a water heater, etc.

[0020] The mounting part 120 is connected to the water supply part 110 and is a member to which the water spraying part 200 is attached. The mounting part 120 is formed, for example, in a disc shape, and a hole 121 through which water from the water supply part 110 passes is formed near the center.

[0021] The water spraying part 200 is attached to the mounting part 120 and is a member that discharges water. Specifically, the water spraying part 200 is, for example, a bottomed cylindrical member. More specifically, it includes a flat part 210, a wall part 220, and an R part 230.

[0022] The flat part 210 is, for example, a flat plate-like member and is formed in a circular shape in plan view. In other words, the flat part 210 is formed in a disc shape. Water spraying holes 211 penetrating in a direction perpendicular to the flat surface are formed in the flat part 210. The wall part 220 is formed to extend along the vertical direction from the end part 210a of the flat part. The R part 230 is a part connecting the flat part 210 and the wall part 220. Specifically, the R part 230 connects the end part 210a of the flat part 210 and the wall part 220 and is a part that becomes the corner part of the water spraying part 200.

[0023] The water supply section 110, the mounting section 120, and the watering section 200 are made of metal such as stainless steel or brass. In other words, the water supply section 110, the mounting section 120, and the watering section 200 are metal components for a faucet. The types of metals listed above as materials for the watering section 200, etc., are merely examples and not limiting.

[0024] In the faucet device 100, the spraying unit 200 is attached to the mounting unit 120, thereby forming an internal space 240 between the spraying unit 200 and the mounting unit 120. A rectifier plate (not shown), for example, is placed in the internal space 240. As a result, in the faucet device 100, water supplied from the water supply unit 110 flows into the internal space 240 through the hole 121 in the mounting unit 120, and the water that flows in is discharged from the spraying holes 211 of the spraying unit 200.

[0025] In the manufacturing method according to this embodiment, the manufacturing method of the water spraying section (water spraying plate) 200, which is one of the metal components for the faucet that constitutes the faucet device 100 described above, will be explained as an example.Hereinafter, the manufactured water spraying section 200 may be referred to as "workpiece 200".In this example, the workpiece 200 is assumed to be circular in plan view, but the shape is not limited to this, and may be other shapes such as square or elliptical.

[0026] Figure 3 is a cross-sectional view taken along line III-III in Figure 2, showing only the workpiece (spraying section) 200. Note that in Figure 3, the watering holes 211 and other elements are omitted from the illustration. Figure 4 is a cross-sectional view showing the workpiece 200 before the manufacturing method according to this embodiment is applied.

[0027] In this embodiment, the workpiece 200 is formed by drawing a disc-shaped flat plate, for example, to create a bottomed cylindrical member as shown in Figure 4. That is, the drawing process gives the workpiece 200 a flat portion 210, a wall portion 220, and a rounded portion 230.

[0028] Here, the R-section 230 after the drawing process has a relatively large radius of curvature and a rounded shape. In this embodiment, the radius of curvature of the R-section 230 is made relatively small to achieve a sharper design. Also, after the drawing process, the outer circumference dimension X1a on the opening side of the workpiece 200 tends to be larger than the outer diameter dimension X2a on the flat section 210 side (X1a > X2a), which can lead to a decrease in dimensional accuracy. In this embodiment, as shown in Figure 3, the difference between the outer circumference dimension X1 on the opening side and the outer diameter dimension X2 on the flat section 210 side is made as small as possible to improve dimensional accuracy. Furthermore, when the wall section 220 is pressurized and a portion of the material of the workpiece 200 is plastically flowed to form the R-section 230, pressurization alone can make it difficult to stabilize the width dimension Y1 of the wall section 220 of the formed workpiece 200, which can lead to a decrease in dimensional accuracy. In this embodiment, the width dimension Y1 of the wall section 220 of the formed workpiece 200 is stabilized to improve dimensional accuracy.

[0029] Next, the manufacturing process of the metal component for the faucet (workpiece 200) according to the embodiment will be explained with reference to the flowchart in Figure 5. Figure 5 is a flowchart illustrating the manufacturing process of the metal component for the faucet (workpiece 200) according to the embodiment.

[0030] Before describing Figure 5, let's first explain the configuration of the manufacturing apparatus for the metal component (workpiece 200) for the faucet according to this embodiment. Figure 6 is a cross-sectional view illustrating the manufacturing apparatus for the metal component for the faucet according to this embodiment.

[0031] As shown in Figure 6, the manufacturing apparatus 1 comprises a first mold 10, a second mold 20, a third mold 30, a base 40, and a support part 50.

[0032] The first mold 10 is a mold on which the workpiece 200 is placed. The first mold 10 is formed, for example, in the shape of a disc, and the workpiece 200 is placed on its upper surface 10a. A support section 50 is connected to the first mold 10. The support section 50 includes a support column 50a, which supports the first mold 10 from below. The support column 50a is configured to be vertically movable, and therefore the first mold 10 is also vertically movable, as indicated by arrow A. The first mold 10 can also be called a core mold on which the workpiece 200 is placed.

[0033] The second mold 20 is formed, for example, in a cylindrical shape. That is, the second mold 20 has a wall portion 21 formed in a circumferential shape, and a space 22 is formed inside it. This space 22 is the space through which the first mold 10 is inserted. In the second mold 20, the inner circumference dimension C2 of the space 22 is set to be smaller than the outer circumference dimension C1 of the workpiece 200 placed in the first mold 10 (C1 > C2). The inner circumference dimension C2 of the space 22 can also be said to be the inner circumference dimension on the inner side of the wall portion 21 of the second mold 20, or in other words, the inner circumference dimension of the inner wall portion 21a. Furthermore, the second mold 20 is set in the direction (up and down direction) in which the wall portion 220 of the workpiece 200 placed in the first mold 10 extends.

[0034] Furthermore, the second mold 20 is equipped with a pressure surface 23. The pressure surface 23 is formed near the bottom of the second mold 20. Specifically, the pressure surface 23 is formed at a position corresponding to the wall portion 220 of the workpiece 200 installed in the first mold 10 (more precisely, at a position below the wall portion 220). During the molding process, the leading edge surface 220a of the wall portion 220 comes into contact with this pressure surface 23, applying pressure to the leading edge surface 220a, which will be described later.

[0035] The second mold 20 is fixed to the base 40. The base 40 is a non-movable part. Therefore, the second mold 20 is also non-movable, i.e., fixed. Furthermore, as will be described later, the second mold 20 is subjected to ironing and pressing processes, so it can also be called an ironing and pressing mold.

[0036] The third mold 30 is formed, for example, in a cylindrical shape. The third mold 30 is set in a position opposite to the second mold 20. Specifically, the third mold 30 is set in an upper position opposite to the space 22 of the second mold 20, and also in an upper position opposite to the flat surface 210 of the workpiece 200 installed in the first mold 10. The third mold 30 is connected to a vertical movement drive device (not shown) and is capable of vertical movement as indicated by arrow B. The third mold 30 can also be called a pressing mold because it presses the workpiece 200, as will be described later.

[0037] Continuing the explanation of Figure 5, the manufacturing apparatus 1 performs the workpiece 200 installation process (step S10). Specifically, as shown in Figure 6, the workpiece 200 is placed on the first mold 10. More specifically, the first mold 10 is installed such that the inside 210b of the flat portion 210 of the workpiece 200 and the inside 220b of the wall portion 220 of the workpiece 200 are in contact. More specifically, the workpiece 200 is installed on the first mold 10 such that the inside 210b of the flat portion 210 of the workpiece 200 is in contact with the top surface 10a of the first mold 10, and the inside 220b of the wall portion 220 of the workpiece 200 is in contact with the side surface 10b of the first mold 10.

[0038] Next, the manufacturing apparatus 1 performs a stripping process to strip the wall portion 220 of the workpiece 200 (step S11). The stripping process will be explained with reference to Figure 7. Figure 7 is a cross-sectional view illustrating the manufacturing method (stripping process) of a metal component for a faucet using the manufacturing apparatus 1.

[0039] As shown in Figure 7, in the ironing process, with the second die 20 set in the direction (up and down) of the extension of the wall portion 220 of the workpiece 200 placed in the first die 10, the third die 30 is moved downward (see arrow D). After the third die 30 comes into contact with the flat portion 210 of the workpiece 200, the third die 30 is moved further downward to press the workpiece 200 placed in the first die 10. As a result of this pressing, the first die 10 and the workpiece 200 move downward (see arrow E). Here, since the inner circumference dimension C2 of the space 22 of the second die 20 is smaller than the outer circumference dimension C1 of the workpiece 200 (see Figure 6), the workpiece 200 that has moved downward is pressed downward while the outer surface 220c of the wall portion 220 slides against the inner side of the wall portion 21 of the second die 20, i.e., the inner wall portion 21a, and the ironing process of the wall portion 220 is performed. In more detail, the wall portion 220 is pressed from the third mold 30 while sandwiched between the inner wall portion 21a of the second mold 20 and the side surface 10b of the first mold 10, thereby performing ironing from the tip surface 220a towards the R portion 230. In this way, during the ironing process, the third mold 30 presses the workpiece 200 placed in the first mold 10, causing the second mold 20 to perform ironing of the wall portion 220.

[0040] Continuing the explanation of Figure 5, the manufacturing apparatus 1 performs a molding process by plastic flow (step S12). The molding process will be explained with reference to Figures 8 and 9. Figure 8 is a cross-sectional view illustrating the manufacturing method (molding process) of a metal component for a faucet using the manufacturing apparatus 1. Figure 9 is a cross-sectional view showing an enlarged view of the area around the void formed in the molding process.

[0041] As shown in Figure 8, in the molding process, the third mold 30 is moved further downward to continue pressing (see arrow F), thereby moving the workpiece 200 further downward. As the workpiece 200 moves downward, the leading edge surface 220a of the wall portion 220 comes into contact with the pressing surface 23 of the second mold 20. Even after the leading edge surface 220a of the workpiece 200 comes into contact with the pressing surface 23 of the second mold 20, the pressing of the third mold 30 continues, thereby applying pressure to the leading edge surface 220a from the pressing surface 23 (see arrow G in Figure 9). This pressure causes plastic flow in the wall portion 220, increasing the thickness of the R portion 230 of the workpiece 200 as it is molded.

[0042] More specifically, when the third die 30 is moved downward and the leading edge surface 220a of the workpiece 200 is in contact with the pressing surface 23 of the second die 20, a gap H is formed between the second die 20, the third die 30, and the workpiece 200, as clearly shown in Figure 9. As the pressing of the third die 30 continues, the leading edge surface 220a of the workpiece 200 is pressed against the pressing surface 23 of the second die 20, causing a portion of the material of the workpiece 200 to undergo plastic flow to fill the gap H (see arrow J), thereby forming the R portion 230 of the workpiece 200. Specifically, the R portion 230, which had a relatively large radius of curvature and a rounded shape, becomes a R portion 230 with a relatively small radius of curvature and a sharper shape due to the plastic flow. In Figure 8, the R portion 230 before plastic flow is shown with a solid line, and the R portion 230 after plastic flow is shown with a dashed line. As an example, the R-section 230 formed by plastic flow has a relatively small radius of curvature, approximately R1, and preferably approximately R0.8. Note that the specific numerical values ​​for the R-section 230 described above are merely examples and not limiting.

[0043] To elaborate on the configuration of the second mold 20, as shown in Figure 8, the length K1 of the inner wall portion 21a of the second mold 20 is set to be longer than the length K2 of the wall portion 220 of the workpiece 200 (K1 > K2).

[0044] This ensures the formation of a gap H between the second mold 20, the third mold 30, and the workpiece 200, where plastic flow can occur. Specifically, if the length K1 of the inner wall portion 21a of the second mold 20 is shorter than the length K2 of the wall portion 220, there may be areas that are left open in the gap H, and the desired position (R portion 230) may not be properly thickened by plastic flow. In contrast, by configuring the length K1 of the inner wall portion 21a of the second mold 20 to be longer than the length K2 of the wall portion 220, the gap H can be reliably formed, and as a result, the desired position (R portion 230) can be properly thickened by plastic flow.

[0045] Next, to elaborate on the configuration of the third mold 30, as clearly shown in Figure 9, the radius of curvature of the corner portion 31 that forms the gap H in the third mold 30 is set to be smaller than the radius of curvature of the R portion 230 of the workpiece 200.

[0046] Thus, since the radius of curvature of the corner portion 31 of the third mold 30 is smaller than the radius of curvature of the R portion 230 of the workpiece 200, it becomes possible to make the corner portion 31 of the third mold 30 a right angle or a nearly right angle. As a result, in the gap H where plastic flow occurs, it becomes less likely that extra gaps that do not constitute the R portion 230 of the workpiece 200 will be formed, that is, it becomes less likely that plastic flow that fills extra gaps will occur, and thus the desired position (R portion 230) of the workpiece 200 can be thickened more appropriately.

[0047] Continuing the explanation of Figure 5, the manufacturing apparatus 1 performs a process of removing the molded workpiece 200 (step S13). In the removal process, the workpiece 200 is removed from the manufacturing apparatus 1 by, for example, a knockout device (not shown).

[0048] As described above, the manufacturing method for a metal component for a faucet includes an installation step, a shaping step, and a forming step. In the installation step, a metal workpiece 200 having a flat portion 210 and a wall portion 220 extending vertically from the end 210a of the flat portion 210 is installed in the first mold 10 such that the inside 210b of the flat portion 210 and the inside 220b of the wall portion 220 are in contact. In the shaping step, a second mold 20 having a space 22 through which the first mold 10 is inserted, and the inner circumference dimension C2 of the space 22 being smaller than the outer circumference dimension C1 of the workpiece 200 installed in the first mold 10, is set in the direction in which the wall portion 220 extends, and the second mold 20, set in a position opposite the second mold 20, presses the workpiece installed in the first mold 10, thereby shaping the wall portion 220. In the molding process, the tip surface 220a of the wall portion 220 comes into contact with the pressure surface 23 provided on the second mold 20 by pressing with the second mold 20. After the tip surface 220a comes into contact with the pressure surface 23, the pressing with the third mold 30 is continued, and the tip surface 220a is pressed against the pressure surface 23, causing a portion of the material of the workpiece 200 to plastically flow to fill the gap H formed between the second mold 20, the third mold 30 and the workpiece 200, thereby forming the R portion 230 that connects the flat portion 210 and the wall portion 220.

[0049] In this way, the ironing process, which involves ironing the wall portion 220 of the workpiece 200, and the forming process, which involves plastically flowing a portion of the material of the workpiece 200 to form (increase the thickness of) the R portion 230, are performed in succession. As a result, for example, the dimensions of the wall portion 220 of the formed workpiece 200 can be stabilized in the width direction, thereby improving dimensional accuracy, and a sharp design with a relatively small radius of curvature can be obtained in the R portion 230.

[0050] In other words, by performing ironing and forming processes on the wall portion 220, it becomes possible to shape the wall portion 220 in a vertical direction. As a result, as shown in Figure 3, the difference between the outer circumference dimension X1 on the opening side of the workpiece 200 and the outer diameter dimension X2 on the flat portion 210 side can be minimized, thereby improving dimensional accuracy. Furthermore, by ironing the wall portion 220, the width dimension Y1 of the wall portion 220 of the formed workpiece 200 can be stabilized, further improving dimensional accuracy. In addition, forming by plastic flow allows for a sharp design with a relatively small radius of curvature in the R portion 230.

[0051] Furthermore, after the ironing process, the outer surface 220c of the wall portion 220 of the workpiece 200 and the inner wall portion 21a of the second mold 20 come into close contact, and the inner surface 220b of the wall portion 220 and the side surface 10b of the first mold 10 come into close contact, eliminating any gaps between the workpiece 200 and the first and second molds 10 and 20. This prevents the wall portion 220 from buckling when the tip surface 220a is pressed.

[0052] Furthermore, since the wall portion 220 of the workpiece 200 is in close contact with the inner wall portion 21a of the second mold 20 and the side surface 10b of the first mold 10 during ironing, there is no increase in plate thickness due to pressure on the tip surface 220a, and the pressing force mainly acts on the plastic flow to the R portion 230. In addition, because the wall portion 220 is in close contact with the inner wall portion 21a of the second mold 20, etc., it becomes possible to generate plastic flow with a smaller pressing force compared to, for example, when there is a gap between the wall portion 220 and the inner wall portion 21a of the second mold 20, etc.

[0053] Furthermore, the portion that contacts the tip surface 220a of the workpiece 200 (pressure surface 23) and the portion that contacts the wall portion 220 (inner wall portion 21a) are integrated in the second mold 20. Therefore, the relative velocity between the movement of the material due to the pressure on the tip surface 220a (in the direction of trying to move upward, although it is not actually moving) and the second mold 20 in contact with the wall portion 220 is zero. As a result, for example, friction due to sliding does not occur, and the molding load can be reduced.

[0054] <Note> (1) A method for manufacturing metal components for faucets, Installation step: A metal workpiece having a flat portion and a wall portion extending vertically from the end of the flat portion is placed in a first mold such that the inside of the flat portion and the inside of the wall portion are in contact. A second die, having a space through which the first die is inserted, and having an inner circumference dimension of the space smaller than the outer circumference dimension of the workpiece placed in the first die, is set in the direction in which the wall portion extends. A third die, set opposite the second die, presses the workpiece placed in the first die, thereby performing a wiping process in which the second die wisps the wall portion. A molding process in which the tip surface of the wall portion comes into contact with a pressure surface provided on the second mold by pressing the third mold, and the pressing of the third mold is continued even after the tip surface comes into contact with the pressure surface, thereby causing a portion of the workpiece material to plastically flow to fill the gap formed by the second mold, the third mold and the workpiece, thereby forming an R portion that connects the flat portion and the wall portion. A method for manufacturing metal components for faucets, including the method described above. (2) The length of the inner wall portion of the second mold is longer than the length of the wall portion. (1) A method for manufacturing a metal component for a faucet as described in (1). (3) In the third mold, the radius of curvature of the corner forming the gap is smaller than the radius of curvature of the R portion of the workpiece. A method for manufacturing a metal component for a faucet as described in (1) or (2). (4) A metal workpiece having a flat portion and a wall portion extending vertically from the end of the flat portion is installed in a first mold such that the inside of the flat portion and the inside of the wall portion are in contact. A second mold having a space through which the first mold is inserted, wherein the inner circumference of the space is smaller than the outer circumference of the workpiece installed in the first mold, A third mold is set in a position opposite to the second mold. Equipped with, With the second mold set in the direction in which the wall portion extends, the third mold presses the workpiece placed in the first mold, thereby causing the second mold to iron the wall portion. The pressing of the third mold causes the leading edge of the wall portion to come into contact with a pressure surface provided on the second mold, and the pressing of the third mold is continued even after the leading edge comes into contact with the pressure surface, thereby causing a portion of the workpiece material to plastically flow to fill the gap formed between the second mold, the third mold and the workpiece, and forming an R-shaped portion that connects the flat portion and the wall portion. Manufacturing equipment for metal components used in faucets.

[0055] Further effects and modifications can be readily derived by those skilled in the art. Therefore, broader aspects of the present invention are not limited to the specific details and representative embodiments expressed and described above. Accordingly, various modifications are possible without departing from the spirit or scope of the overall concept of the invention as defined by the appended claims and their equivalents. [Explanation of Symbols]

[0056] 1 Manufacturing equipment 10. First mold 20. Second mold 30. Third mold 200 work 210 Plane section 220 Wall section 230 R section

Claims

1. A method for manufacturing metal components for faucets, Installation step: A metal workpiece having a flat portion and a wall portion extending vertically from the end of the flat portion is placed in a first mold such that the inside of the flat portion and the inside of the wall portion are in contact. A second mold, having a space through which the first mold is inserted, and having an inner circumference dimension of the space smaller than the outer circumference dimension of the workpiece placed in the first mold, is set in the direction in which the wall portion extends. A third mold, set opposite the second mold, presses the workpiece placed in the first mold, thereby performing a wiping process in which the second mold wipes the wall portion. A molding process in which the tip surface of the wall portion comes into contact with a pressure surface provided on the second mold by pressing the third mold, and the pressing of the third mold is continued even after the tip surface comes into contact with the pressure surface, thereby causing a portion of the workpiece material to plastically flow to fill the gap formed between the second mold, the third mold and the workpiece, thereby forming an R portion that connects the flat portion and the wall portion. A method for manufacturing metal components for faucets, including the method described above.

2. The length of the inner wall portion of the second mold is longer than the length of the wall portion. A method for manufacturing a metal member for a faucet according to claim 1.

3. In the third mold, the radius of curvature of the corner forming the gap is smaller than the radius of curvature of the R portion of the workpiece. A method for manufacturing a metal member for a faucet according to claim 1.

4. A metal workpiece having a flat portion and a wall portion extending vertically from the end of the flat portion is installed in a first mold such that the inside of the flat portion and the inside of the wall portion are in contact. A second mold having a space through which the first mold is inserted, wherein the inner circumference of the space is smaller than the outer circumference of the workpiece installed in the first mold, A third mold is set in a position opposite to the second mold. Equipped with, With the second mold set in the direction in which the wall portion extends, the third mold presses the workpiece placed in the first mold, thereby causing the second mold to iron the wall portion. The pressing of the third mold causes the leading edge of the wall portion to come into contact with a pressure surface provided on the second mold, and the pressing of the third mold is continued even after the leading edge comes into contact with the pressure surface, thereby causing a portion of the workpiece material to plastically flow to fill the gap formed between the second mold, the third mold and the workpiece, and forming an R-shaped portion that connects the flat portion and the wall portion. Manufacturing equipment for metal components used in faucets.

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