Flow forming equipment

Abstract

To provide a flow forming processing device which can prevent loss of a finished product by simple means in flow forming processing for molding a raw material by pressing the same against a molding surface.SOLUTION: A flow forming processing device comprises a metal mold with a molding surface, a raw material processed along the molding surface, and a processing jig for pressing the raw material against the molding surface, and has a build-up part on the molding surface for the raw material. The device can prevent loss of a finished product, and improve yielding percentage, production efficiency, and quality of the product.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a flow forming apparatus and a flow forming method, and more particularly to a flow forming apparatus and a flow forming method for forming a material such as a metal into a cylindrical or disc shape. [Background technology]

[0002] Currently, in the manufacturing method of cylindrical or disk-shaped products such as vehicle wheels, flow forming, in which a material such as metal is rolled and stretched along a die to form it, as shown in Patent Document 1, is widely used. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2006-1322 A Summary of the Invention [Problem to be solved by the invention]

[0004] Here, in order to mold a product having a complex shape by flow forming, it is necessary to press the material against the molding surface of a die having a corresponding shape. However, in the flow forming process, in which the material is pressed against the molding surface, the material may rise up from the molding surface due to elastic deformation, which can cause defects such as chipping in the finished product.

[0005] An object of the present invention is to provide a flow forming apparatus capable of preventing damage to a completed product by simple means in a flow forming process in which a material is pressed against a forming surface to form the material. [Means for solving the problem]

[0006] As a result of extensive research into the above-mentioned problems, the inventors discovered that by providing a build-up portion on the formed surface of a material, it is possible to prevent chipping of the finished product, and thus completed the present invention. That is, the present invention relates to the following flow forming apparatus, flow forming method, method for manufacturing a molded product by the flow forming apparatus, and control program used in the flow forming method.

[0007] In order to solve the above problems, the flow forming apparatus of the present invention includes a die having a forming surface, a material to be processed along the forming surface, and a processing tool that presses the material against the forming surface, and is characterized in that the forming surface of the material has a build-up portion. According to this flow forming device, since the forming surface of the material has a build-up portion, the material of the build-up portion is pushed into the space where the end of the material is raised during the flow forming process, which prevents damage to the finished product, improves the yield and production efficiency, and also improves the quality of the product. In addition, in a flow forming apparatus that presses a material along a die having a forming surface, repeated pressing reduces the lifting of the end of the material, and thus multiple pressing processes are performed to prevent damage to the product. According to the flow forming apparatus of the present invention, the buildup is pressed into the space of the lifting, so there is an effect that the number of pressing processes required until the lifting of the end of the material is reduced can be reduced.

[0008] In addition, the flow forming method of the present invention is a flow forming method in which a material is pressed along a die having a molding surface, and is characterized by including a build-up portion forming step of forming a build-up portion on the molding surface of the material. According to the above-mentioned flow forming method, since the forming surface of the material has a build-up portion, the material of the build-up portion is pushed into the space where the end of the material is raised during the flow forming process, so that it is possible to prevent damage to the finished product, improve the yield, increase production efficiency, and improve product quality. In addition, in a flow forming method in which a material is pressed along a die having a forming surface, repeated pressing reduces the lifting of the end of the material, and thus multiple pressing processes are performed to prevent damage to the product. According to the flow forming method of the present invention, the buildup is pressed into the space of the lift, so there is an effect that the number of pressing processes required until the lifting of the end of the material is reduced can be reduced.

[0009] In addition, in one embodiment of the flow forming method of the present invention, the buildup forming process is characterized by including a first processing step of moving a portion of the material toward the end side, and a second processing step of forming a buildup on the forming surface of the material. According to one embodiment of the flow forming method, the volume of the material near the end portion can be increased by performing a first processing step for moving a part of the material toward the end portion of the material as a preliminary step of a second processing step for forming the buildup portion, which makes it possible to easily form the buildup portion by the second processing step.

[0010] In addition, in order to solve the above problems, the present invention provides a method for manufacturing a molded product by flow forming, which is characterized in that it includes a mold having a molding surface, a material to be processed along the molding surface, and a processing tool for pressing the material against the molding surface, and uses a flow forming device having a padding portion on the molding processing surface of the material. According to the above-mentioned manufacturing method for a molded product, since the forming surface of the material has a build-up portion, the material of the build-up portion is pushed into the space where the end of the material is raised during the flow forming process, which prevents damage to the finished product, improves the yield and production efficiency, and also improves the quality of the product. In addition, in a flow forming process in which a material is pressed along a die having a forming surface, repeated pressing reduces the lift of the end of the material, so that multiple pressing processes are performed to prevent damage to the product. According to the manufacturing method of the molded product of the present invention, the buildup is pressed into the space of the lift, so that it is possible to reduce the number of pressing processes required until the lift of the end of the material is reduced.

[0011] In one embodiment of the method for producing a molded product of the present invention, the molded product is a vehicle wheel. According to this method for manufacturing a molded product, it is possible to provide a method for manufacturing a vehicle wheel with less breakage and with a reduced number of pressing processes.

[0012] In addition, the control program used in the flow forming method of the molded product of the present invention is a control program used in a flow forming method in which a material is pressed along a die having a molding surface, and is characterized by including a padding formation step in which a padding portion is formed on the molding surface of the material. According to the above control program, since the control program includes a step of forming a build-up portion on the formed surface of the material, the build-up portion material is pushed into the space where the end of the material is raised during the flow forming process, which prevents damage to the finished product, improves the yield, increases production efficiency, and improves product quality. In addition, in a flow forming process in which a material is pressed along a die having a forming surface, repeated pressing reduces the lift of the end of the material, so that damage to the product is suppressed by performing multiple pressing processes. According to the control program of the present invention, the buildup is pressed into the space of the lift, so that it is possible to reduce the number of pressing processes required until the lift of the end of the material is reduced. Effect of the Invention

[0013] According to the present invention, a flow forming apparatus can be provided that can prevent damage to a completed product by simple means in a flow forming process in which a material is pressed against a forming surface to form the material. [Brief description of the drawings]

[0014] [Figure 1] 1 is a cross-sectional view of an existing flow forming apparatus seen from the side, and is a schematic explanatory diagram showing the structure and operation of the existing flow forming apparatus. (A) is a schematic explanatory diagram showing the state of a material before flow forming. (B) is a schematic explanatory diagram showing the state of a material during flow forming. (C) is a schematic explanatory diagram showing the state of a material after flow forming. [Diagram 2] FIG. 1 is a cross-sectional side view of a flow forming apparatus according to a first embodiment of the present invention, and is a schematic explanatory diagram of a flow forming apparatus 100 according to the first embodiment of the present invention. [Diagram 3] 1A and 1B are cross-sectional views of a flow forming apparatus according to a second embodiment of the present invention as viewed from the side, and are schematic explanatory diagrams of a flow forming apparatus 200 according to a second embodiment of the present invention. (A) is a schematic explanatory diagram showing the state of a material before a build-up portion forming process. (B) is a schematic explanatory diagram showing the state of a material after a build-up portion forming process. [Figure 4] 1 is a cross-sectional side view of a flow forming apparatus according to a third embodiment of the present invention, and is a schematic explanatory diagram of a flow forming apparatus 300 according to a third embodiment of the present invention. (A) is a schematic explanatory diagram showing the state of a material before a buildup portion forming process. (B) is a schematic explanatory diagram showing the state of a material after a first process in a buildup portion forming process. (C) is a schematic explanatory diagram showing the state of a material after a second process in a buildup portion forming process. [Diagram 5]5A and 5B are schematic explanatory diagrams showing a state in which the flow forming apparatus according to the present invention is used to form a vehicle wheel, (A) a schematic explanatory diagram showing a process for forming a wheel rim by the flow forming apparatus of the present invention, (B) a schematic explanatory diagram showing a process for forming a vehicle wheel rim by the flow forming apparatus of the present invention, as seen from the AA cross section of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, embodiments of a flow forming apparatus, a flow forming method, a method for manufacturing a molded product by the flow forming apparatus, and a control program used in the flow forming method according to the present invention will be described in detail. The flow forming method and the method for manufacturing a molded product by the flow forming apparatus according to the present invention will be replaced with the description of the flow forming apparatus according to the present invention. The flow forming method, the method for manufacturing a molded product by a flow forming apparatus, and the control program used in the flow forming method described in the embodiments are merely examples used to explain the flow forming method, the method for manufacturing a molded product by a flow forming apparatus, and the control program used in the flow forming method according to the present invention, and are not limited thereto.

[0016] The present invention relates to a flow forming process in which a material such as a metal is pressed to conform to the shape of a die. 1(A)-(C) are cross-sectional views of an existing flow forming apparatus as viewed from the side, and Fig. 1(A) and (B) show the flow forming process using the existing flow forming apparatus. Specifically, as shown in Fig. 1(A), a material A such as a metal to be processed is pressed along a forming surface B1 of a die B by a processing tool C such as a roller, thereby forming it into a shape that conforms to the forming surface B1 as shown in Fig. 1(B). Here, as shown in FIG. 1(C), in the case of existing flow forming equipment, a part of the material is elastically deformed after pressing by the flow forming process, and this causes the material to float up from the corner B2, which is the end of the forming surface B1, which may result in defective molding of the product.

[0017] Therefore, the flow forming apparatus, flow forming method, method for manufacturing a molded product using the flow forming apparatus, and control program used in the flow forming method of the present invention prevent defective molding of the product due to the material floating up after pressing by providing a padding portion in advance in a part of the material that corresponds to the part that will float up.

[0018] As shown in Figures 5(A) and (B), the product formed by the flow forming apparatus, the flow forming method, the method for manufacturing a molded product by the flow forming apparatus, and the control program used in the flow forming method according to the present invention is preferably a vehicle wheel. In the conventional manufacturing method for vehicle wheels, the material is repeatedly pressed to prevent damage caused by lifting of the "rim," which is the outer diameter end portion of the vehicle wheel. This results in poor production efficiency. The effect of the present invention is that it is possible to form the "rim" which is the outer diameter end part of a vehicle wheel by pressing a small number of times. This makes it possible to improve production efficiency and reduce manufacturing costs. In addition, it is possible to suppress the occurrence of chipping.

[0019] [First embodiment] A flow forming apparatus 100 according to a first embodiment of the present invention will be described with reference to Fig. 2. Fig. 2 is a cross-sectional view of the flow forming apparatus according to the first embodiment of the present invention as seen from the side, and is a schematic explanatory diagram of the flow forming apparatus 100 according to the first embodiment of the present invention.

[0020] As shown in FIG. 2, the flow forming apparatus 100 includes a material 1, a die 2, and a processing jig 3. Here, the blank 1 has a pressing surface 11 (shown by a solid line in the blank 1 in FIG. 2) which is a portion pressed by the processing tool 3, and a forming surface 12 (shown by a dashed line in the blank 1 in FIG. 2) which is a portion formed along a forming surface 21 of a die 2, which will be described later. The forming surface 12 has a build-up portion 13. Moreover, the die 2 has a molding surface 21 for molding the material 1 into a desired shape, and the molding surface 21 has corners 22 which are edge portions of the molding surface 21 . Each component will be described in detail below.

[0021] <Material> The blank 1 is pressed against the die 2 by a processing tool 3, which will be described later, and is molded into a shape that conforms to a molding surface 21 of the die 2. The material of the material 1 is not particularly limited, but a material that is easily deformed by pressing is preferable. Examples include metals such as iron and aluminum, and polymeric materials such as plastic. In particular, metals such as iron and aluminum that have been cast are preferable. Due to the characteristics of the casting process, the metal structure in the material 1 is coarse, making it relatively soft and easy to process by pressing. In addition, the metal structure in the material 1 becomes dense when pressed, so it is possible to maintain strength even when processed to be thin. This allows the molded product to be lightweight and strong. In addition, the material 1 is a metal that has been heated to 300 to 400° C. This makes the material 1 soft, making it easier to roll, and the formed product is less likely to suffer from defects after the flow forming process.

[0022] The blank 1 has a pressing surface 11 and a forming surface 12 . The pressed surface 11 is a part of the raw material 1 and is a portion that is pressed by a processing tool 3 described later. The pressed surface 11 is a portion of the raw material 1 shown in FIG. 2, which is indicated by a solid line. The forming surface 12 is a portion that is formed along the shape of a forming surface 21 of a die 2, which will be described later, and is the portion of the blank 1 shown in FIG. The formed surface 12 also has a build-up portion 13 .

[0023] (Overlay part) The build-up portion 13 is a part of the raw material 1, and is a convex portion (colored gray) formed on the forming surface 12. The build-up portion 13 is pressed into the end side of the raw material by the flow forming process, and fills the space between the raw material 1 and the forming surface 21 caused by the lifting of the end. The build-up portion 13 is preferably provided in a portion of the forming surface 12 that is expected to rise due to elastic deformation after flow forming. Usually, the end side of the raw material 1 (the front side in the direction of travel of the processing tool) rises up, so it is preferable to provide the build-up portion 13 on the end side of the raw material 1. Although the build-up portion 13 is shown in one place in FIG. 2, multiple build-up portions may be provided.

[0024] [Determination of the shape of the build-up portion and the shape of the build-up portion] The shape of the build-up portion 13 is determined based on the reference line L1, the first parallel line L2, the second parallel line L3, the intersections P1 to P4, and the relative distance R1 shown in FIG.

[0025] 2, the reference line L1 is an imaginary line drawn along the forming surface 21, which is a portion where the material 1 is expected to rise after the flow forming process. In this embodiment, the reference line L1 is an imaginary line drawn in the left-right direction of FIG. 2 along the forming surface 21 near the corner 22 so as to pass through the corner 22.

[0026] The first parallel line L2 is an imaginary line drawn parallel to the reference line L1 in the upward direction of Figure 2, and is the imaginary line that is closest to the reference line L1 among the imaginary lines that intersect with the molding surface 12 at two points (intersection point P1 and intersection point P2). That is, the position of the first parallel line L2 is determined as follows. First, draw a first parallel line L2 so that it overlaps with the reference line L1. Next, starting from the position of the reference line L1, move the first parallel line L2 parallel to the reference line L1 upward in Fig. 2 until the intersection point between the first parallel line L2 and the forming surface 12 of the material 1 changes from one point to two points. This position is the position of the first parallel line L2. In addition, of the two intersections between the first parallel line L2 and the forming surface 12 of the raw material 1 at the position of the first parallel line L2, the intersection on the left side in FIG. 2 is designated as P1, and the intersection on the right side in FIG.

[0027] As shown in Fig. 2, the second parallel line L3 is an imaginary line drawn parallel to the first parallel line L2 in the upward direction of Fig. 2. The second parallel line L3 intersects with the forming surface 12 of the raw material 1 at intersections P3 and P4. The position of the second parallel line L3 is determined as follows. First, draw the second parallel line L3 so that it overlaps with the first parallel line L2. Next, starting from the position of the first parallel line L2, move the second parallel line L3 parallel to the first parallel line L2 upward in Fig. 2 until the intersection points between the second parallel line L3 and the forming surface 12 of the material 1 change from two to three, and then back to two points. This position is the position of the second parallel line L3. Of the two intersections between the second parallel line L3 and the forming surface 12 at the position of the second parallel line L3, the intersection on the left side in FIG. 2 is designated P3, and the intersection on the right side in FIG. 2 is designated P4.

[0028] The relative distance between the first parallel line L2 and the second parallel line L3 is a relative distance R1. The amount by which the build-up portion 13 protrudes toward the forming surface 21 is determined by the length of this relative distance R1. Moreover, the relative distance R1 is determined in advance according to the expected amount of lift of the material after the flow forming process.

[0029] As shown in the gray area of ​​the raw material 1 in FIG. 2, the build-up portion 13 is a portion of the formed surface 12 that is surrounded by intersections P1, P3, and P4. Therefore, the shape of the buildup portion 13 is determined by finding the reference line L1, the first parallel line L2, the second parallel line L3, and the intersection points P1 to P4 from the shapes of the material 1 and the mold 2 so that a predetermined arbitrary relative distance R1 is established.

[0030] <Mold> The die 2 is for forming the material 1 into a predetermined shape by pressing it with a processing tool 3 described later. The die 2 has a forming surface 21. Note that the shape, material, etc. of the die 2 are not limited. 2, the forming surface 21 is a portion that comes into contact with a forming surface 12 of the raw material 1 when the raw material 1 is pressed against a die 2 by a processing tool 3 described later. It is also a portion that forms the raw material 1 into a predetermined shape. Although the molding surface 21 in this embodiment has corners 22, it may be a flat molding surface without corners.

[0031] 2, the corner portion 22 is an end portion of the forming surface 21, and is a portion that comes into contact with the buildup portion 13 after the raw material 1 is pressed by the flow forming process. Moreover, the corner portion 22 is a portion where the raw material 1 is expected to rise up after the flow forming process.

[0032] <Processing jigs and tools> The processing tool 3 is used to press the material 1 and form it along the forming surface 21 . Furthermore, the shape, structure, etc. of the processing tool 3 may be any as long as it can press the material 1 and form it along the forming surface 21 . For example, as shown in Fig. 2, it may have a roller-like structure. This allows the material 1 to be rolled efficiently along the forming surface 21.

[0033] [Movement of the flow forming apparatus 100] First, the blank 1 having the buildup portion 13 formed based on the reference line L1, the first parallel line L2, the second parallel line L3, and the intersection points P1 to P4 determined from the shapes of the blank 1 and the die 2 is placed at a predetermined position in the die 2. Next, the processing tool 3 moves from the right to the left in Fig. 2 along the pressing processing surface 11, thereby pressing the raw material 1 against the forming surface 21. As a result, the raw material 1 is rolled from the right to the left in Fig. 2 in accordance with the movement of the processing tool 3, and is formed into a shape that conforms to the forming surface 21. This process of pressing the raw material 1 against the forming surface 21 may be repeated multiple times. In the process of pressing the blank 1 against the forming surface 21, the corners 22 of the die 2 and the buildup portion 13 are tightly attached to each other, so that a part of the blank is pressed into the corners 22. This makes it possible to prevent damage to the product caused by the blank 1 floating up due to elastic deformation after the flow forming process.

[0034] Furthermore, the operation of the processing tool 3 in the flow forming process may include a step of stretching the raw material 1 before the step of pressing the raw material 1 against the molding surface 21. The step of stretching the raw material 1 is a step of moving the processing tool 3 along the pressing surface 11 of the raw material 1 while the molding surface 12 of the raw material 1 and the molding surface 21 of the die 2 are separated, and is a step of stretching the raw material 1. This makes it easier for the raw material 1 to be stretched because no friction occurs between the molding surface 21 of the die 2 and the molding surface 12 of the raw material 1, and it is possible to reduce the number of times flow forming is performed by the processing tool 3. This makes it possible to reduce the energy required for processing, thereby improving manufacturing efficiency.

[0035] [Second embodiment] 3(A) and (B), a flow forming apparatus 200 according to a second embodiment of the present invention will be described. This is a cross-sectional view of the flow forming apparatus 200 according to the second embodiment of the present invention as seen from the side, and is a schematic explanatory view of the flow forming apparatus 200 according to the second embodiment of the present invention. Moreover, FIG. 3(A) shows the state of the material before the build-up portion forming step, and FIG. 3(B) shows the state of the material after the build-up portion forming step.

[0036] The flow forming apparatus 200 is characterized in that, in addition to the main features of the flow forming apparatus 100 in the first embodiment, it also includes a build-up portion forming step, which will be described later. Specifically, in the case of the flow forming apparatus 100 in the first embodiment, a buildup portion is provided in advance on the material, whereas the flow forming apparatus 200 in the second embodiment is characterized in that a buildup portion is newly formed on a material that does not have a buildup portion by a buildup portion forming process described below.

[0037] The build-up forming process forms build-up on the forming surface of the material, and the build-up material is pushed into the space that arises at the end of the material during the flow forming process. This prevents damage to the finished product, improves yield and production efficiency, and improves product quality.

[0038] As shown in FIGS. 3(A) and 3(B), the flow forming apparatus 200 is made up of a material 4, a die 5, and a processing jig 6. Here, the raw material 4 is referred to as a raw material 4A in a state before a build-up portion forming step described later, and a raw material 4B in a state after a build-up portion has been formed in the build-up portion forming step.

[0039] Furthermore, the blank 4A or blank 4B has a pressing surface 41A or 41B which is a portion pressed by the processing tool 6, and a forming surface 42A or 42B which is a portion formed along the forming surface 51 of the die 5. Then, a buildup portion 43 is formed on the forming surface 42B by a buildup portion forming step which will be described later.

[0040] In addition, the pressing surface 41A or 41B, the forming surface 42A or 42B, the buildup portion 43, the die 5, the molding surface 51, the corner portion 52, the processing tool 6, the reference line L4, the first parallel line L5, the second parallel line L6, the intersection points P5 to P8, and the relative distance R2 are the same as the pressing surface 11, the forming surface 12, the buildup portion 13, the die 2, the molding surface 21, the corner portion 22, the processing tool 3, the reference line L1, the first parallel line L2, the second parallel line L3, the intersection points P1 to P4, and the relative distance R1 of the flow forming processing apparatus 100 in the first embodiment, so their explanations are omitted.

[0041] [Build-up part forming process] The build-up portion forming step is not particularly limited as long as it is a step of forming a build-up portion using a processing tool 6, and for example, proceeds in the order of a build-up portion shape determining step and a build-up portion forming step. First, in the build-up portion shape determination step, the shape of the build-up portion 43 shown in FIG. 3(B) is determined in advance based on the reference line L4, the first parallel line L5, the second parallel line L6, the intersection points P5 to P8, and the relative distance R2 obtained from the shapes of the raw material 4 and the mold 5, as in the first embodiment. Next, in the build-up portion forming step, as shown in Fig. 3(A), an end portion of the raw material 4A is pressed in the direction of the arrow along the pressing surface 41A by the processing jig 6. As a result, the end portion on the left side of the forming surface 42A in Fig. 3 is tilted toward the forming surface 51. As a result, the raw material 4 is deformed into the shape of the raw material 4B shown in Fig. 3(B), and the build-up portion 43 is formed.

[0042] [Movement of the flow forming apparatus 200] The movement of the flow forming apparatus 200 after the build-up portion forming step is the same as the movement of the flow forming apparatus 100 in the first embodiment.

[0043] [Third embodiment] A flow forming apparatus 300 according to a third embodiment of the present invention will be described with reference to FIGS. 4(A) to 4(C). 4(A) to (C) are cross-sectional views of a flow forming apparatus 300 in a third embodiment of the present invention as viewed from the side, and are schematic explanatory views of the flow forming apparatus 300 in the third embodiment of the present invention. Fig. 4(A) shows the state of the material before the build-up forming process, Fig. 4(B) shows the state of the material after the first processing step in the build-up forming process, and Fig. 4(C) shows the state of the material after the second processing step in the build-up forming process.

[0044] The flow forming apparatus 300 is characterized in that the build-up portion forming step of the flow forming apparatus 200 in the second embodiment is divided into a first processing step and a second processing step. Specifically, in the case of the flow forming processing apparatus 200 in the second embodiment, a new build-up portion is formed by processing a material that does not have a build-up portion, whereas in the flow forming processing apparatus 300 in the third embodiment, the processing for forming the build-up portion is performed in a first processing step of moving a part of the material toward the end side, and after the first processing step, a second processing step of actually forming the build-up portion on the formed surface of the material.

[0045] According to the flow forming apparatus 300 of this embodiment, the volume of the material near its end can be increased by the first processing step, so that the buildup can be easily formed by the second processing step.

[0046] As shown in FIGS. 4(A) to 4(C), the flow forming apparatus 300 is made up of a material 7, a die 8, and a processing jig 9. Here, the raw material 7 is divided into raw material 7A, which is in a state before the build-up portion forming process described below, raw material 7B, which is in a state in which a part of the raw material has been moved toward the end side by the first processing process, and raw material 7C, which is in a state in which a build-up portion has been formed on the molded surface of the raw material.

[0047] Furthermore, the blanks 7A-7C each have press surfaces 71A-71C which are portions pressed by the processing tool 9, and forming surfaces 72A-72C which are portions formed along the forming surface 81 of the die 8. Then, a buildup portion 73 is formed on the forming surface 72C by a second processing step, which will be described later, of the buildup portion forming step.

[0048] The pressing surfaces 71A to 71C, the forming surfaces 72A to 72C, the build-up portion 73, the die 8, the forming surface 81, the corner portion 82, the processing tool 9, the reference line L7, the first parallel line L8, the second parallel line L9, the intersections P9 to P12, and the relative distance R3 correspond to the pressing surfaces 11, the forming surfaces 12, the build-up portion 13, the die 2, the forming surface 21, the corner portion 22, the processing tool 3, the base 4, and the relative distance R3 of the flow forming apparatus 100 in the first embodiment. The directrix L1, the first parallel line L2, the second parallel line L3, the intersections P1 to P4, the relative distance R1, and the pressing surfaces 41A, 41B, the forming surfaces 42A, 42B, the buildup portion 43, the die 5, the forming surface 51, the corner portion 52, the processing tool 6, the reference line L4, the first parallel line L5, the second parallel line L6, the intersections P5 to P8, and the relative distance R2 of the flow forming apparatus 200 in the second embodiment are the same, so their explanation will be omitted.

[0049] [Build-up part forming process] The build-up portion forming process in this embodiment is not particularly limited as long as it is a process of forming the build-up portion using a processing tool 9, but for example, it may involve determining the shape of the build-up portion to be formed in a build-up portion shape determination step, then performing a first processing step (process), and then performing a second processing step (process). First, in the buildup portion shape determination step, the shape of the buildup portion 73 shown in Figure 4(C) is determined in advance based on the reference line L7, the first parallel line L8, the second parallel line L9, the intersection points P9 to P12, and the relative distance R3, similar to the first and second embodiments. Next, in the first processing step (process), the material 7A is pressed while being moved leftward in Fig. 4(A) along the pressing surface 71A. As a result, as shown in Fig. 4(B), the end portion of the forming surface 72B of the material 7B after the first processing step (process) is extended leftward in Fig. 4(B) more than the forming surface 72A of the material 7A before the first processing step (process). Next, in the second processing step (process), as shown in Fig. 4(C), the pressing surface 71C is pressed in the direction of the arrow (left-right direction) by the processing jig 9. As a result, the end portion of the forming surface 72C on the left side in Fig. 4 is tilted toward the forming surface 81. As a result, the material 7B is deformed into the shape of the material 7C shown in Fig. 4(C), and the build-up portion 73 is formed. In this embodiment, by providing the first processing step, the pressed surface 71A of the raw material 7A can be pressed over the entire area, so that the number of buildup portions can be increased compared to the buildup portion 43 of the second embodiment. In addition, since the raw material 7A can be elongated together with the formation of the buildup portion 73, the number of times of flow forming after the buildup portion forming step can be reduced.

[0050] [Movement of the flow forming apparatus 300] The movement of the flow forming apparatus 300 after the build-up portion forming step is the same as the movement of the flow forming apparatuses 100, 200 in the first and second embodiments.

[0051] [Fourth embodiment] The flow forming apparatus 400 (not shown) in the fourth embodiment is characterized in that the build-up portion forming process of the flow forming apparatus 200 in the second embodiment or the flow forming apparatus 300 in the third embodiment is performed by computer control. Moreover, a flow forming apparatus 400 (not shown) in the fourth embodiment is characterized in that it is provided with a program for performing the build-up portion forming process of the flow forming apparatus 200 in the second embodiment or the flow forming apparatus 300 in the third embodiment by computer control. The other configurations are similar to those of the flow forming apparatus 200 in the second embodiment or the flow forming apparatus 300 in the third embodiment.

[0052] The above-mentioned embodiments show examples of the flow forming apparatus, the flow forming method, the method for manufacturing a molded product by the flow forming apparatus, and the control program used in the flow forming method. The flow forming apparatus, the flow forming method, the method for manufacturing a molded product by the flow forming apparatus, and the control program used in the flow forming method according to the present invention are not limited to the above-mentioned embodiments, and the flow forming method, the method for manufacturing a molded product by the flow forming apparatus, and the control program used in the flow forming method according to the above-mentioned embodiments may be changed within the scope of the gist of the claims.

[0053] For example, multiple padding sections may be provided in accordance with the locations where the material is expected to rise. This makes it possible to prevent defects due to the material rising, without increasing the amount of material and thickness, even for products with more complex shapes, and to mold them thin and lightweight. [Industrial Applicability]

[0054] The flow forming apparatus, flow forming method, method for manufacturing a molded product using the flow forming apparatus, and control program used in the flow forming method of the present invention can be suitably used for manufacturing disc-shaped molded products such as vehicle wheels. [Explanation of symbols]

[0055] A,1,4A,4B,7A,7B,7C...Material, B,2,5,8...Mold, C,3,6,9...Processing jig, A1,11,41A,41B,71A,71B,71C...Press processing surface, A2,12,42A,42B,72A,72B,72C...Forming surface, B1 ,21,51,81...molding surface, B2,22,52,82...corner, L1,L4,L7...reference line, L2,L5,L8...first parallel line, L3,L6,L9...second parallel line, P1,P2,P3,P4,P5,P6,P7,P8,P9,P10,P11,P12...intersection.

Claims

1. The method includes the steps of: forming a mold having a molding surface; and pressing a material against the molding surface. The processing tool is a flow forming device characterized in that it performs a process in which the processing tool presses the molding surface of the material to form a build-up portion at a location where lift-up is expected, and a process in which the material is pressed against the molding surface to bring a corner of the die into close contact with the build-up portion, thereby forcing a portion of the material into the corner.

2. A flow forming method in which a material is pressed along a die having a forming surface, A process for forming a cladding portion at a portion where the forming surface of the material is expected to rise is provided. The build-up portion forming step includes a first processing step of moving a part of the material to an end side, A second processing step of forming a build-up portion on the shaping surface of the material is provided; A flow forming method, characterized in that in a process of pressing a material against a molding surface, a processing process is carried out in which a corner of the die and the padding portion are brought into close contact with each other, thereby forcing a part of the material into the corner.

3. A method for manufacturing a molded product, comprising the steps of: Construction method.

4. The flow sheet according to claim 3, wherein the molded product is a vehicle wheel. A manufacturing method for molded products using a forming device.

5. A control program for use in a flow forming method in which a material is pressed along a die having a forming surface, A cladding forming step is provided for forming a cladding portion at a portion where the forming surface of the material is expected to rise, The cladding portion forming step includes a first processing step of moving a part of the material toward the end portion, and then a second processing step of forming a cladding portion on the processed surface of the material, A control program comprising a processing step in which, in a step of pressing a material against a molding surface, a corner of the die and the padding portion come into close contact with each other, thereby forcing a portion of the material into the corner.

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